c5 c10 c12 c14 c15 c16 c17 c18 c20 c25 c35 c40 c90 c100 c110 c120 c130 c140 c150 c152 c160 c170 c180 c190 c192 c200 c210 c220 c230 c240 c250 c260 c270 c280 c290 c300 c310a c310b c310c c310d c314a c314b c314c c314d c320a c320b c320c c324a c324b c324c c330 c332 c340 c350 c360 c370 c380 c390 c400 c410 c420 c430 c440 c450 c460 c490 c510a c510b c510c c510d c510e c510f c602 c604 c606 c608 c610 c612 c614 c616 c620 c640 c652 c654 c660 eof 1997020600181 19970206 00181 EU 1997 2 6 19735 1 19970115 G 2510 Z00N6068707220 BELT FITTING SOCATA TB10 TB10TOBAGO 8680696 EU CREW SEATS CORRODED B A VDNR K NONE O OTHER IN INSP/MAINT 1 SW 09 113J 900 606 FOUND BOTH CREW SEAT BELTS' ALUMINUM FITTINGS (ATTACHED TO SEAT BELT WEB) COMPLETELY CORRODED THROUGH. FITTINGS ARE MAD E OF ALUMINUM, AND ARE ATTACHED TO AIRFRAME. (X) 1 L 7 1 30 NT A51EU 2001041700092 20010417 00092 CE 2001 4 17 20010417AP001 1 19970525 G 3411 KNOB CESSNA 182 182Q 2072732 CE COCKPIT BACKED OUT C O OTHER J WARNING INDICATION CL CLIMB 1 SW 99 4673N 1100 18266848 CLIMBING VFR OUT OF KLAS, NOTED VVI AND AIRSPEED INDICATING ZERO, AND ALTIMITER FROZEN. PULLED ALTERNATE STATIC KNOB AN D INDICATIONS RETURNED TO NORMAL. AFTER LANDING, FOUND RUBBER TRIM PIECE AROUND ALTERNATE STATIC KNOB HAD COME UNGLUED FROM METAL MOUNTING BRACKET. THIS TRIM HUNG ON THE KNOB UNTIL IT VIBRATED THE KNOB OUT TO AN INTERMEDIATE POSITION THAT BLOCKED BOTH STATIC SOURCES. THE LOOSE TRIM DID NOT INTERFERE WITH ALTERNATE STATIC USE, BUT IF THE KNOB WAS PUSHED BA CK IN, THE TRIM WOULD VIBRATE THE KNOB BACK OUT. HAD MECHANIC SECURE TRIM PIECE. 1 H 7 1 3O NT 3A13 2001103100122 20011031 00122 GL 2001 10 31 2001FA0000435 3 19971024 G 6114 1A103 HUB MCAULY 1A103 1A103TCM GL PROPELLER ASSY CRACKED B ME4D K NONE O OTHER IN INSP/MAINT 1 SO 19 R774521 UPON INSPECTION PROPELLER HUB WAS FOUND TO BE CRACKED AT MOUNTING BOLT HOLD. PROPELLER HAS BEEN SCRAPPED. 5 N P50GL 2001103100123 20011031 00123 GL 2001 10 31 2001FA0000436 3 19970909 G 6114 D6603C88 HUB MCAULY 3A32C D3A32C88 GL PROPELLER ASSY CRACKED B ME4D K NONE O OTHER IN INSP/MAINT 1 SO 19 772394 UPON INSPECTION HUB WAS FOUND TO BE CRACKED IN BLADE SOCKET NR 2. HUB HAS BEEN SCRAPPED. 5 C P21EA 1997061900459 19970619 00459 GL 1997 6 19 97031300148 1 19970221 G 6100 BLADE AMTR LONGEZ LONGEZ 05690Z8 GL PROPELLER SEPARATION H A UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 SW 11 29TM 729 WHILE IN STABLE FLIGHT AT 7,500 FEET MSL IN SMOOTH AIR, PART OF THE WOODEN PROPELLER CAME APART. THE SEPARATION OCCURRE D LENGTHWISE DOWN ONE BLADE OF THE TWO-BLADED PROPELLER. THERE WERE NO SIGNS OF BIRDS PRIOR TO THE SEPARATION NOR WERE THERE ANY SIGNS OF AN OBJECT STRIKING THE PROPELLER. THE BREAKAGE OCCURRED LENGTHWISE DOWN THE BLADE MIDWAY BETWEEN THE LEADING AND TRAILING EDGES. THE BREAK DID NOT FOLLOW ALONG ANY LAMINATED PIECES OF WOOD. (X) 1 M 7 1 3O RT EXPA1M71 1997061900460 19970619 00460 SO 1997 6 19 97031300233 2 19970219 G 8550 CH48109 FILTER CHAMPION AMTR STRDST STARDUSTR300 GL CONT E225 E225* 17015 SO ENGINE OIL BURST H K NONE O K OTHER FLUID LOSS IN INSP/MAINT 1 WP 27 7989 476 2582D OIL FILTER BURST AT START-UP. GASKET FORCED FROM GROOVE. ENGINE LOST ALL OIL. FILTER 'DOMED OUT' AT BOTH ENDS. ALL O IL PASSAGEWAYS IN ENGINE AND OIL COOLER OK. PRESSURE RELIEF VALVE IN ENGINE OK. SUSPECT FILTER BYPASS. 1 Q 7 1 3O 3 O EXPA1Q71 E267 1997041000432 19970410 00432 NE 1997 4 10 970326 2 19970313 G 7230 384347 AIR SEAL PWA JFTD12 JFTD12A5A 52047 NE 7TH STAGE REAR CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 1537 677775 ON MARCH 13, 1997, COMPRESSOR ASSY S/N 677775 WAS SCHEDULED FOR AN OVERHAUL, W.O. NR 25419. TEAR DOWN WAS COMPLETED ON MARCH 14, 1997, WITH NO PROBLEMS. THE AIR SEAL ON THE REAR OF THE 7TH STAGE DISK WAS NOTED TO HAVE A CRACK COMPLETELY THROUGH IT AND ANOTHER CRACK HALF-WAY THROUGH APPROXIMATELY 130 DEGREES FROM THE FIRST CRACK. SIGNS OF AIR SEAL RUBBING WERE NOTED OVER A 2 INCH LONG AREA ON THE ADJACENT PART. THE AIR SEAL EXHIBITED OVERHEAT DAMAGE FROM RUBBING 360 DEGRE ES AROUND ITS EDGE. (X) 4 U E15EA 1997042400898 19970424 00898 NE 1997 4 24 970401 2 19970414 G 7230 536210 TAB LOCK PWA JFTD12 JFTD12A4A 52047 NE COMP BLADE MISSING B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 2FOR 2998 672538 TAB LOCK FOUND MISSING WHEN ENGINE DISASSEMBLED. NO CONTACT NOTED BETWEEN BLADE AND 3RD STAGE STATOR. BROKEN PIECES OF THE TAB LOCK CONTACTED BLADES AND STATORS AFT OF THE 3RD STAGE CAUSING IMPACT DAMAGE. ENGINE WAS LAST OVERHAULED BY PR ATT AND WHITNEY. (X) 4 U E15EA 1998040800080 19980408 00080 NM 1998 4 8 97UAL900850 1 19971202 G 2820 343T00123 TUBE ASSY BOEING 767 767222 1385122 NM PWA JT9 JT9D7R4D 52054 NE RIB 3 DAMAGED A O OTHER O OTHER CR CRUISE 1 WP 29 610UA 21871 CENTER TANK WENT FROM 300 INDICATED TO 1200 IN IST 1.5 HOURS OF FLIGHT. WHEN MAINS BELOW HALF, SCAVENGED BACK TO ZERO. *S/D* THIS PROBLEM WAS CAUSED BY TWO MINOR LEAKS TO THE CENTER FUEL TANKS. ONE WAS A LEAKY COUPLING ON THE FUEL SCAV ENGE PLUMBING IN THE CENTER TANK. THE O-RING WAS REPLACED AND THE COUPLING WAS RESECURED AND SAFETIED. THE SECOND WAS CAUSED BY A DAMAGED RT SURGE TANK DRAIN LINE. THE DAMAGE WAS LOCATED ON TUBE ASSY PN 343T0012-3 LOCATED JUST OUTBOARD O F RIB 3. THE DAMAGE TO THE TUBE WAS CAUSED FROM CONTACT WITH A HI-LOK COLLAR ON AN ADJACENT STRINGER. THE TUBE WAS REP AIRED PER GN/MM7-0-4-9. 2 L 7 2 4F 4 F RT A1NM E3NE 1997092500423 19970925 00423 NE 1997 9 25 97ZZZM968 2 19970809 G 7250 3040911 TURBINE BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE RT ENGINE FAILED A A AMWA J E DUMP FUEL ENGINE SHUTDOWN O OTHER TX TAXI/GRND HDL 1 CE 07 182YV UE182 114401 IN MCI, THE RIGHT ENGINE HAD A CONTAINED ENGINE FAILURE DURING START. REMOVED AND REPLACED RIGHT ENGINE GAS GENERATOR A ND POWER SECTION. TEAR DOWN INSP REVEALED THE COMPRESSOR TURBINE CENTER BOLT AND KEY WASHER WAS NOT SUFFICIENTLY LUBRIC ATED AT INSTALLATION. AS A RESULT, WHEN THE CT BOLT WAS TORQUED A FALSE TORQUE READING WAS INDICATED. THIS ALLOWED THE COMPRESSOR TURBINE TO COME LOOSE AND PULL FORWARD INTO THE POWER TURBINE VANE RING. 2 L 7 2 4T 4 T RT A24CE E26NE 1997092500432 19970925 00432 CE 1997 9 25 97ZZZM977 1 19970628 G 5753 3516505030 BRACKET BEECH 1900 1900D 1154162 CE LT TE FLAP WORN A AMWA K NONE O OTHER IN INSP/MAINT 1 CE 07 182YV 4100 UE182 AT ICT OVERNIGHT MAINTENANCE INSPECTION PER BEECH TEMP REV 5-6, FOUND LHOB FLAP. INBOARD ATTACH BRACKET WORN. REMOVED AND REPLACED ATTACH BRACKET IAW SRM 57-00 AND 51-40. 2 L 7 2 4T RT A24CE 1997031300147 19970313 00147 1997 3 13 97ZZZX1009 1 19970219 G 3411 1J47 FILTER PNEU AIR BLOCKED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 11 PRIOR TO INSTALLATION ON AIRCRAFT, BLEW THROUGH FILTER TO CHECK FOR OBSTRUCTIONS AND FREEDOM OF AIR MOVEMENT. FILTER AP PEARED TO BE BLOCKED. DISASSEMBLED FILTER AND FOUND MATERIAL THAT IS USED TO GLUE ELEMENT IN FILTER BLOCKING HOLE. 1997031300148 19970313 00148 GL 1997 3 13 97ZZZX1010 1 19970221 G 6100 BLADE AMTR LONGEZ LONGEZ 05690Z8 GL PROPELLER SPLIT H A UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 SW 11 29TM 729 WHILE IN STABLE FLIGHT AT 7,500 FEET MSL IN SMOOTH AIR, PART OF THE WOODEN PROPELLER CAME APART. THE SEPARATION OCCURRE D LENGTHWISE DOWN ONE BLADE OF THE TWO-BLADED PROPELLER. THERE WERE NO SIGNS OF BIRDS PRIOR TO THE SEPARATION NOR WERE THERE ANY SIGNS OF AN OBJECT STRIKING THE PROPELLER. THE BREAKAGE OCCURRED LENGTHWISE DOWN THE BLADE MIDWAY BETWEEN THE LEADING AND TRAILING EDGES. THE BREAK DID NOT FOLLOW ALONG ANY LAMINATED PIECES OF WOOD. 1 M 7 1 3O RT EXPA1M71 1997031300149 19970313 00149 SO 1997 3 13 97ZZZX1011 1 19970215 G 3234 SELECTOR PIPER PA31 PA31310 7103103 SO GEAR HANDLE MISRIGGED D A O OTHER W INADEQUATE Q C LD LANDING 1 NM 11 27518 317812038 UPON LANDING, NOSE GEAR COLLAPSED DOING SUBSTANTIAL DAMAGE TO THE AIRCRAFT. INSPECTION OF THE GEAR SELECTOR HANDLE FOUN D INSTRUMENT PANEL SHOCK MOUNT SCREW HITTING GEAR SELECTOR HANDLE WHEN SELECTING GEAR DOWN POSITION. ALSO, FOUND CABLE HAD BEEN MISRIGGED. AFTER REMOVING SCREW FROM PANEL AND RE-RIGGING CABLE GEAR, SELECTOR OPERATED FLAWLESSLY. 1 L 7 1 3O RT A20SO 1997031300150 19970313 00150 CE 1997 3 13 97ZZZX1012 1 19970126 G 3260 16936002547 BRACKET M24R BEECH 23 B24R 1151253 CE NLG LIMIT SWITCH DEFECTIVE G A O OTHER O OTHER TX TAXI/GRND HDL 1 EA 03 6570R 1302 MC298 DURING TAXI AFTER LANDING, THE NOSE GEAR COLLAPSED. INVESTIGATION DISCLOSED THE BRACKET WHICH HOLDS THE NOSE GEAR DOWN, LIMIT SWITCH WAS ELONGATED AT THE POINT WHERE THE BRACKET MOUNTS TO THE NOSE GEAR ASSEMBLY. THIS CONDITION ALLOWED THE LIMIT SWITCH TO GIVE A FALSE DOWN AND LOCKED INDICATION. IT IS RECOMMENDED A SECURITY CHECK IN ADDITION TO A VISUAL AN D OPERATIONAL CHECK BE MADE OF ALL LIMIT SWITCHES. 1 L 7 1 3O A1CE 1997031300151 19970313 00151 SO 1997 3 13 97ZZZX1013 1 19970217 G 3230 454656 BREAKER PIPER PA31 PA31350 7103110 SO GEAR SAFETY INTERMITTENT B IGXR O OTHER O OTHER AP APPROACH 1 NE 05 771A 317852027 LANDNG GEAR HANDLE DID NOT RETURN TO 'DOWN NEUTRAL' AFTER GEAR EXTENSION. TROUBLE WAS TRACED TO A CIRCUIT BREAKER LABEL ED 'GEAR SAFETY SOLENOID'. THIS BREAKER SUPPLIES THE SAFETY SYSTEM AS WELL AS THE INDICATION LIGHTS AND THE DOOR SOLENO ID ON THE POWER PACK. THE BREAKER WAS FOUND WITH INTERNAL RESISTANCE CAUSING IT TO BE INTERMITTENT. AIRFRAME TT 5,662. 00 HOURS. PART TT UNKNOWN. 1 L 7 2 3O A20SO 1997031300153 19970313 00153 NE 1997 3 13 97ZZZX1015 2 19970207 G 7200 ENGINE AMD FALC20 FALCON20F5 2730105 EU GE CF700 CF7002D2 30010 NE NR 2 POWER LOSS B A YL1R A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 SW 11 108BG 2730 403 E304495B PILOT NOTES: AFTER RE-FUEL, THE ACFT LOST PWR ON T/O APPROX 200 FEET AGL. NR 2 ENG EGT WENT RED LINE APPROX 780 DEGREE S FAHRENHEIT AND RPM HAD ROLL BACK. A POP WAS HEARD IN THE CABIN BY PASSENGERS. (POSSIBLE COMPRESSOR STALL). PILOT WE NT TO FLT IDLE WITH NR 2 THROTTLE. THE ENG CONTINUED TO TURN AND PARAMETERS FOR ENGINE READINGS RETURNED TO NORMAL FOR FLT IDLE. THE AIRCRAFT RETURNED TO AIRPORT FOR SAFE LDG. EXTERIOR VISUAL AND INTERIOR BORESCOPE ON THE ENG DID NOT SHO W ANY MAJOR DAMAGE THAT WOULD CAUSE LOSS OF PWR, ADDITIONAL GROUND RUNS, LOW PWR, HIGH PWR, AND RAPID ACC TEST WERE NORM AL. CAUSE FOR PWR LOSS UNK. FUEL FILTERS CK OK. PART TOTAL CYCLES, 6518. 2 L 7 2 4F 4 F RT A7EU E7EA 1997031300159 19970313 00159 CE 1997 3 13 97ZZZX1021 1 19970201 G 5240 DOOR LEAR 60 60LEAR 5170707 CE FUEL SERVICE WATER LEAK B A TR1R K NONE O OTHER IN INSP/MAINT 1 SW 05 5003X 039 THE DESIGN OF THE FUEL SERVICE PANEL AND DOOR DOES NOT PREVENT WATER FROM ENTERING THE DOOR AND COLLECTING AT THE BOTTOM OF THE PANEL. THERE IS NO DRAIN HOLE. THIS IS A POTENTIAL CORROSION PROBLEM. THREE MODEL 60'S WERE LOOKED AT. ALL TH REE ARE THE SAME DESIGN. 2 L 7 2 4F RT A10CE 1997031300160 19970313 00160 CE 1997 3 13 97ZZZX1022 1 19970220 G 2840 INDICATOR ASSY BEECH 100 B100 1152919 CE FUEL QUANTITY BRACKET CORRODED D K NONE O OTHER IN INSP/MAINT 1 EA 17 4004C 9007 BE12 PILOTS STATED FUEL INDICATION WAS SOME TIMES UNRELIABLE. REMOVED FUEL INDICATOR PANEL AND FOUND CORROSION ON BRACKET TH AT SERVES AS MOUNT FOR FUEL INDICATOR DIODES. SUSPECT THAT CORROSION ALLOWED A GROUND TO DIODES. (DIODES ARE NORMALLY INSULATED FROM BRACKET). THIS BRACKET IS DIRECTLY UNDER THE PILOTS VENT WINDOW. SUSPECT MOISTURE FROM LEAKING WINDOW SE AL CAUSED CORROSION. CORROSION WAS CLEANED FROM BRACKET. NEW INSULATORS INSTALLED. SYSTEM FUNCTIONS NORMALLY. 1 L 7 2 4T A14CE 1997031300161 19970313 00161 NM 1997 3 13 97ZZZX1023 1 19970129 G 5753 69207737 FITTING 65216329 BOEING 727 72730C 1384009 NM WS 144-204 TE CRACKED B IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 374 FOUR EACH FITTINGS, P/N 69-20773-7, LOCATED BETWEEN THE CENTER TWO AFT FLAP TRACKS ARE CRACKED AT THE LOWER FLANGE OF TH E FITTINGS. CRACKS RANGE FROM 1 INCH TO 6 INCHES DOWN THE LOWER FLANGE. SUSPECT CAUSE WOULD BE EXCESSIVE BOWING OF THE MID-FLAP. 2 L 7 3 4F A3WE 1997031300162 19970313 00162 GL 1997 3 13 97ZZZX1024 2 19970217 G 7261 6871311 TUBE ALLSN 250C 250C20 03013 GL BEARING OIL CRACKED B YKER K NONE O OTHER IN INSP/MAINT 1 EA 17 DURING OVERHAUL OF THE TURBINE, FOUND THE BEARING OIL TUBE TO HAVE A CRACK IN THE FLARE. 3 U E4CE 1997031300163 19970313 00163 EU 1997 3 13 97ZZZX1025 1 19970212 G 2520 PANEL SOCATA TB10 TB10TOBAGO 8680696 EU INTERIOR CORRODED B A VDNR K NONE O OTHER IN INSP/MAINT 1 SW 09 113J 898 606 DURING ROUTINE INSPECTION, FOUND INTERIOR ALUMINUM TRIM PANELS CORRODED AT ALL AREAS WHERE ANY STEEL PARTS, I.E., SCREWS , BOLTS, ETC., OR ADJACENT ALUMINUM STRUCTURE WAS MAKING CONTACT WITH THE TRIM PANELS. SUSPECT THAT THE FABRIC ATTACHED TO THE TRIM PANELS HAD BEEN FIREPROOFED WITH 'SALT BRINE SOLUTION' OR EQUIVALENT; CAUSING THE REPEATED HEAVY CORROSION FOUND ON ALL TRIM PANELS. 1 L 7 1 30 NT A51EU 1997031300164 19970313 00164 CE 1997 3 13 97ZZZX1026 1 19970211 G 2133 VALVE BEECH 200 200BEECH 1152920 CE OUTFLOW SAFETY CLAMP DEFECTIVE B VDNR K NONE O OTHER IN INSP/MAINT 1 SW 09 122RF 3406 BB122 PILOT REPORTED THAT CABIN PRESSURIZED ON GROUND. FOUND VACUUM HOSES TO OUTFLOW AND SAFETY VALVES HAD DEFECTIVE HOSE CLA MPS. REPLACED CLAMPS, OPS CHECK SATISFACTORY. 1 L 7 2 4T A24CE 1997031300165 19970313 00165 CE 1997 3 13 97ZZZX1027 1 19970224 G 7830 45122704 BEAM 660828110 LEAR 55 55LEAR 5170702 CE THRUST REV LT CORRODED B JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 2FOR 4437 0518 022 DURING 600-HOUR INSPECTION, FOUND INTERGRANULAR CORROSION OF BEAM AROUND NAS1154C5 ATTACH SCREW. BOTH OUTBOARD BEAMS OF THRUST REVERSERS HAD THIS CORROSION. BEAM IS EXTRUDED ALUMINUM. LEARJET RECOMMENDS BEAM REPLACEMENT. PART TOTAL CYCL ES, 2,933. 2 L 7 2 4F A10CE 1997031300166 19970313 00166 CE 1997 3 13 97ZZZX1028 1 19970224 G 7830 45122703 BEAM 660828119 LEAR 55 55LEAR 5170702 CE THRUST REV RT CORRODED B JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 VRBOL 4437 0519 022 DURING 600-HOUR INSPECTION, FOUND INTERGRANULAR CORRROSION OF BEAM AROUND NAS1154C5 ATTACH SCREW. BOTH OUTBOARD BEAMS O F THRUST REVERSERS HAD THIS CORROSION. BEAM IS EXTRUDED ALUMINUM. LEARJET RECOMMENDS BEAM REPLACEMENT. PART TOTAL CYC LES, 2,933. 2 L 7 2 4F A10CE 1997031300167 19970313 00167 CE 1997 3 13 97ZZZX1029 1 19970211 G 3233 1153800025 MOTOR BEECH 200 200BEECH 1152920 CE MLG GEARBOX DEFECTIVE B VDNR O OTHER J WARNING INDICATION NR NOT REPORTED 1 SW 09 122RF 3406 200 2073 BB122 PILOT REPORTED HE HAD GEAR UNSAFE LIGHT AND GEAR WOULD NOT RETRACT OR EXTEND. FOUND GEAR GEARBOX MOTOR DEFECTIVE. REPL ACED WITH NEW, RETRACT CHECKED SEVERAL TIMES IN NORMAL AND EMERGENCY MODES, SATISFACTORY. 1 L 7 2 4T A24CE 1997031300168 19970313 00168 EA 1997 3 13 97ZZZX1030 1 19970211 G 3234 600509677 CONTROL CNDAIR CL600 CL6002B16 1900305 EA MLG BINDING D O OTHER J WARNING INDICATION NR NOT REPORTED 1 EA 25 1812C 4494 206 5010 IN-FLIGHT EXPERIENCED: UNABLE TO RAISE LANDING GEAR HANDLE TO UP POSITION. TELESCOPING FUNCTION BINDING. 2 L 7 2 4F RT A21EA 1997031300169 19970313 00169 CE 1997 3 13 97ZZZX1031 1 19970220 G 3340 90033 BEACON WHELEN BEECH B300 B300 1159232 CE STROBE NOISY B MGOR K NONE O OTHER IN INSP/MAINT 1 CE 09 202PV FL50 THE FLASHING BEACON INSTALLATION IS CAUSING ELECTRONIC 'NOISE' IN THE STORMSCOPE EVEN AFTER FOLLOWING 3M INSTRUCTIONS FO R INSTALLATION. BEACON NEEDS A SB FOR AN APROVED ALTERATION TO ELIMINATE THE 'NOISE'. 2 L 7 2 4T RT A24CE 1997031300170 19970313 00170 CE 1997 3 13 97ZZZX1032 1 19970220 G 3340 90033 BEACON WHELEN BEECH 90 C90A 1152911 CE STROBE NOISY B MGOR K NONE O OTHER IN INSP/MAINT 1 CE 09 3242L LJ1413 THE FLASHING BEACON INSTALLATION IS CAUSING ELECTRONIC 'NOISE' IN THE STORMSCOPE EVEN AFTER FOLLOWING 3M INSTRUCTIONS FO R INSTALLATION. BEACON NEEDS A SB FOR AN APPROVED ALTERATION TO ELIMINATE THE 'NOISE'. 1 L 7 2 3T RT 3A20 1997031300171 19970313 00171 CE 1997 3 13 97ZZZX1033 1 19970225 G 5751 AILERON CESSNA 500 560CESSNA 2076750 CE WING TO AILERON CHAFING B A CNQR K NONE O OTHER IN INSP/MAINT 1 CE 07 344QS 5600344 AFTER A CONTINUOUS INSPECTION PHASE 1-5 WAS C/W, THE AIRCRAFT WAS RELEASED FOR A MAINTENANCE CHECK FLIGHT. A POST-FLIGH T SQUAWK WAS WRITTEN 'ON TEST FLIGHT, AILERONS FEEL LIKE THEY HAVE A CATCH GOING FROM LEFT BANK TO RIGHT BANK'. ON POST INSPECTION FOUND A MS27039-807 SCREW WAS CHAFING BETWEEN AILERON AND THE WING. SUBMITTER SUGGESTS ADDING TO MAINTENANC E RELEASE SHEET TO CHECK AILERON AIR CAP SEALS FOR FOREIGN OBJECTS PRIOR TO RELEASE. 2 L 7 2 4F RT A22CE 1997031300172 19970313 00172 SO 1997 3 13 97ZZZX1034 1 19970211 G 2434 1159SCAV373103 ALTERNATOR GULSTM G1159 GIV 3980115 SO LT ENGINE FAILED D A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CR CRUISE 1 EA 25 399CC 366 456 1051 IN-FLIGHT EXPERIENCED LT AD/DC POWER FAILURE AND RETURNED TO KEWR. REMOVED AND REPLACED DEFECTIVE LT ALTERNATOR. 2 L 7 2 4F RT A12EA 1997031300173 19970313 00173 SO 1997 3 13 97ZZZX1035 1 19970211 G 2420 1159SCAV373509 CONVERTER GULSTM G1159 GIV 3980115 SO LT AC/DC FAILED D K NONE O OTHER IN INSP/MAINT 1 EA 25 399CC 209 269 1051 IN-FLIGHT EXPERIENCED LT AC/DC POWER FAILURE AND RETURNED TO KEWR. REMOVED AND REPLACED DEFECTIVE LT CONVERTER. 2 L 7 2 4F RT A12EA 1997031300174 19970313 00174 EA 1997 3 13 97ZZZX1036 1 19970224 G 2820 6006286151 LINE CNDAIR CL600 CL6002B16 1900305 EA AUX TANK XSFER LEAK D A K NONE K FLUID LOSS IN INSP/MAINT 1 EA 25 733CF 2134 5057 DRY ROTTING OF FUEL TRANSFER LINE FROM FORWARD FUSELAGE FUEL TANK TO WING AUXILIARY TANK. FUEL LEAK INTO THE SHROUDS AN D INTO AIRSPACE OF DOUBLE WALL TANK IN CABIN. (LOWER FUSELAGE). 2 L 7 2 4F RT A21EA 1997031300175 19970313 00175 CE 1997 3 13 97ZZZX1037 1 19970205 G 3234 1013841379 SELECTOR BEECH 200 B200 1152922 CE MLG INTERMITTENT B HBKR O OTHER J WARNING INDICATION NR NOT REPORTED 1 SW 11 77HD BB1397 LANDING GEAR DID NOT EXTEND WHEN GEAR HANDLE WAS SELECTED DOWN. FOUND GEAR SELECTOR ASSEMBLY INTERMITTENT. INSTALLED N EW GEAR SELECTOR ASSEMBLY; GEAR SYSTEM OPERATIONAL CHECK OK. 1 L 7 2 4T A24CE 1997031300176 19970313 00176 NE 1997 3 13 97ZZZX1038 2 19970219 G 7230 817401 HUB PWA JT8 JT8D9A 52048 NE FRONT COMPRESSOR DAMAGED B VF5R K NONE O OTHER IN INSP/MAINT 1 NE 03 10797 P243242 FRONT COMPRESSOR FRONT HUBS WERE RECEIVED FOR SCHEDULED OVERHAUL. HUBS WERE INSPECTED PER INSP 01, JT8D ENGINE MANUAL 4 81672, SECTION 72-33-31. MINOR DAMAGE OBSERVED ON BLADE SLOT PRESSURE FACES. NO DAMAGE OR BLENDING ALLOWED IN THIS ARE A. 4 F E2EA 1997031300177 19970313 00177 NE 1997 3 13 97ZZZX1039 2 19970219 G 7230 817401 HUB PWA JT8 JT8D9A 52048 NE FRONT COMPRESSOR DAMAGED B VF5R K NONE O OTHER IN INSP/MAINT 1 NE 03 9991 R12135 FRONT COMPRESSOR FRONT HUBS WERE RECEIVED FOR SCHEDULED OVERHAUL. HUBS WERE INSPECTED PER INSP 01, JT8D ENGINE MANUAL 4 81672, SECTION 72-33-31. MINOR DAMAGE OBSERVED ON BLADE SLOT PRESSURE FACES. NO DAMAGE OR BLENDING ALLOWED IN THIS ARE A. 4 F E2EA 1997031300178 19970313 00178 NE 1997 3 13 97ZZZX1040 2 19970219 G 7230 817401 HUB PWA JT8 JT8D9A 52048 NE FRONT COMPRESSOR DAMAGED B VF5R K NONE O OTHER IN INSP/MAINT 1 NE 03 17861 M07042 FRONT COMPRESSOR FRONT HUBS WERE RECEIVED FOR SCHEDULED OVERHAUL. HUBS WERE INSPECTED PER INSP 01, JT8D ENGINE MANUAL 4 81672, SECTION 72-33-31. MINOR DAMAGE OBSERVED ON BLADE SLOT PRESSURE FACES. NO DAMAGE OR BLENDING ALLOWED IN THIS ARE A. 4 F E2EA 1997031300179 19970313 00179 NE 1997 3 13 97ZZZX1041 2 19970219 G 7230 817401 HUB PWA JT8 JT8D9A 52048 NE FRONT COMPRESSOR DAMAGED B VF5R K NONE O OTHER IN INSP/MAINT 1 NE 03 10878 P24455 FRONT COMPRESSOR FRONT HUBS WERE RECEIVED FOR SCHEDULED OVERHAUL. HUBS WERE INSPECTED PER INSP 01, JT8D ENGINE MANUAL 4 81672, SECTION 72-33-31. MINOR DAMAGE OBSERVED ON BLADE SLOT PRESSURE FACES. NO DAMAGE OR BLENDING ALLOWED IN THIS ARE A. 4 F E2EA 1997031300180 19970313 00180 NE 1997 3 13 97ZZZX1042 2 19970219 G 7230 817401 HUB PWA JT8 JT8D9A 52048 NE FRONT COMPRESSOR DAMAGED B VF5R K NONE O OTHER IN INSP/MAINT 1 NE 03 6382 S13547 FRONT COMPRESSOR FRONT HUBS WERE RECEIVED FOR SCHEDULED OVERHAUL. HUBS WERE INSPECTED PER INSP 01, JT8D ENGINE MANUAL 4 81672, SECTION 72-33-31. MINOR DAMAGE OBSERVED ON BLADE SLOT PRESSURE FACES. NO DAMAGE OR BLENDING ALLOWED IN THIS ARE A. 4 F E2EA 1997031300181 19970313 00181 NE 1997 3 13 97ZZZX1043 2 19970219 G 7230 817401 HUB PWA JT8 JT8D9A 52048 NE FRONT COMPRESSOR DAMAGED B VF5R K NONE O OTHER IN INSP/MAINT 1 NE 03 22446 M98582 FRONT COMPRESSOR FRONT HUBS WERE RECEIVED FOR SCHEDULED OVERHAUL. HUBS WERE INSPECTED PER INSP 01, JT8D ENGINE MANUAL 4 81672, SECTION 72-33-31. MINOR DAMAGE OBSERVED ON BLADE SLOT PRESSURE FACES. NO DAMAGE OR BLENDING ALLOWED IN THIS ARE A. 4 F E2EA 1997031300182 19970313 00182 NM 1997 3 13 97ZZZX1044 1 19970211 G 2720 591005017 PCU PARKER 591005017 BOEING 727 727222 1384073 NM RUDDER CONTAMINATED D K NONE O OTHER IN INSP/MAINT 1 NM 01 3408 PLASTIC BLAST MEDIA WAS FOUND THROUGHOUT THE UNIT. THE MAJORITY WAS FOUND IN THE PRESSURE AND RETURN FILTERS AND THE HY DRAULIC SOLENOID VALVE, P/N 59600-5003, S/N G194. 2 L 7 3 4F A3WE 1997031300227 19970313 00227 CE 1997 3 13 97ZZZX1047 1 19970225 G 3246 4040A WHEEL PARKERHANFIN CESSNA 335 335 2075601 CE RT MLG BROKEN H K NONE O OTHER LD LANDING 1 CE 09 2704N 4630 3350003 ON LANDING ROLL OUT, PILOT NOTICED JERKING ACTION ON THE RT MLG. AFTER PARKING AND FURTHER INVESTIGATION, REVEALED A 5 TO 6 INCH CHUNK OF WHEEL GONE, AND TIRE RUBBING ON BRAKE ASSEMBLY. SUSPECT HEAT FROM BRAKES HAS TRANSFERRED ENOUGH HEAT TO WEAKEN WHEEL TO POINT OF FAILURE. SUBMITTER RECOMMENDED RUNNING WHEELS UNDER TIME LIMITS OF SOME SORT. 1 L 7 2 3O 3A25 1997031300229 19970313 00229 SO 1997 3 13 97ZZZX1049 2 19970127 G 8540 653583A STARTER DRIVE 646209TMD CESSNA 421 421C 2076016 CE CONT O520 GTSIO520* 17032 SO RT ENGINE WORN D K NONE O OTHER IN INSP/MAINT 1 WP 07 411MZ 700 421C1002 277166R STARTER DRIVE GEAR WEAR UNACCEPTABLE IAW TELEDYNE CONTINENTAL CSB 94-4 EVEN THOUGH THE SERVICE KIT REQUIRED BY TCM CSB 9 4-4 HAD BEEN PREVIOUSLY INSTALLED AT ENGINE OVERHAUL. SUBMITTER SUGGESTED CSB 94-4 MAY NOT BE SUFFICIENT. RECOMMENDED FLEET DATA BE EXAMINATED TO DETERMINE NUMBER AND FREQUENCY OF OCCURRENCES. 1 L 7 2 3O 3 O A7CE E7CE 1997031300230 19970313 00230 CE 1997 3 13 97ZZZX1050 1 19970127 G 2750 500000862 CONTROL CABLE CESSNA 414 414A 2075907 CE FLAP EXTEND WORN D A K NONE O OTHER IN INSP/MAINT 1 WP 07 58H 5000 414A0314 EXTREME CABLE WEAR (FLAP EXTEND) AT PULLEY ASSY JUST OUTBOARD OF THE FLAP MOTOR AND TRANSMISSION ASSY. PULLEYS MUST BE REMOVED IN ORDER TO SEE THIS TYPE OF WEAR. SUBMITTER RECOMMENDED 100 PERCENT INSPECTION OF FLAP CABLES (BY REMOVAL AND REPLACEMENT) AT 4,000 HOURS ACTT, AND 100 PERCENT INSPECTION AT EVERY 600 HOUR/1 YEAR THEREAFTER. 1 L 7 2 3O A7CE 1997031300231 19970313 00231 SO 1997 3 13 97ZZZX1051 1 19970217 G 2824 4600 VALVE FITTING PIPER PA23 PA23250 7102308 SO FUEL CROSSFEED CRACKED D A K NONE K FLUID LOSS IN INSP/MAINT 1 CE 01 63851 2700 277854003 DURING ROUTINE MAINTENANCE, FOUND FUEL STAINS ON BELLY PAN. REMOVED, FOUND FUEL CROSSFEED FITTING CRACKED AND LEAKING. REMOVED AND DISASSEMBLED VALVE AND REDUCER, CRACKED AT CORNER OF HEX ALL THE WAY THROUGH AND OTHER CRACKS JUST ON INSID E OF THREADS NOT ON OUTSIDE OF HEX. THIS IS THE SAME ONE AS DESCRIBED IN AL43-16, ALERT 222, JANUARY, 1997. 1 L 7 2 3O 1A10 1997031300232 19970313 00232 CE 1997 3 13 97ZZZX1052 1 19970127 G 2750 500000862 CONTROL CABLE CESSNA 421 421C 2076016 CE FLAP EXTEND WORN D A K NONE O OTHER IN INSP/MAINT 1 WP 07 746CA 4000 421C1049 EXTREME CABLE WEAR (FLAP EXTEND) AT PULLEY JUST OUTBOARD OF THE FLAP MOTOR AND TRANSMISSION ASSY. PULLEYS MUST BE REMOV ED IN ORDER TO SEE THIS TYPE OF WEAR. SUBMITTER RECOMMENDED 100 PERCENT INSPECTION OF FLAP CABLES (BY REMOVAL AND REPLA CEMENT) AT 4,000 HOURS PLUS TT, AND 100 PERCENT INSPECTION AT 600-HOUR/1-YEAR CESSNA SPECIAL INSPECTION INTERVALS. 1 L 7 2 3O A7CE 1997031300233 19970313 00233 SO 1997 3 13 97ZZZX1053 2 19970219 G 8550 CH48109 FILTER CHAMPION AMTR STRDST STARDUSTR300 GL CONT E225 E225* 17015 SO ENGINE OIL BURST H K NONE K FLUID LOSS IN INSP/MAINT 1 WP 27 7989 476 2582D OIL FILTER BURST AT START-UP. GASKET FORCED FROM GROOVE. ENGINE LOST ALL OIL. FILTER 'DOMED OUT' AT BOTH ENDS. ALL O IL PASSAGEWAYS IN ENGINE AND OIL COOLER OK. PRESSURE RELIEF VALVE IN ENGINE OK. SUSPECT FILTER BYPASS. 1 Q 7 1 3O 3 O EXPA1Q71 E267 1997031300234 19970313 00234 NM 1997 3 13 97ZZZX1054 1 19970214 G 6230 A2035 YOKE ROBSIN R22 R22BETA NM SWASHPLATE CRACKED B WG3R K NONE O OTHER IN INSP/MAINT 1 WP 27 8066U 1804 1273 ON PRE-FLIGHT, ONE-HALF OF YOKE WAS FOUND CRACKED THROUGH. LOW TIME, PILOT DID NOT REPORT ANY SUBSTANTIAL VIBRATION DUR ING PREVIOUS FLIGHT. SURROUNDING AREA HAS CORROSION. DAMAGE DID NOT APPEAR TO HAVE BEEN CAUSED BY CORROSION. 1 G 7 1 3O H10WE 1997031300237 19970313 00237 CE 1997 3 13 97ZZZX1057 1 19970227 G 3230 3581512545 RETRACT ROD BEECH 58 58TC 1152746 CE LT RETRACT FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 23 97R 2331 TK45 DURING ANNUAL INSPECTION PERFORMING EMERGENCY EXTENSION, LOUD BANG HEARD. UPON FURTHER INVESTIGATION, FOUND LEFT RETRAC T ROD ASSY CRACKED ABOUT 8 INCHES OUTBOARD OF ACTUATOR. ROD ASSY COMPLETELY FAILED ON NEXT RETRACTION NOT ALLOWING LEFT GEAR TO EXTEND OR RETRACT. FAILURE PROBABLY DUE TO IMPROPER GEAR UPLOCK TENSION. 1 L 7 2 3O A23CE 1997031300238 19970313 00238 SW 1997 3 13 97ZZZX1058 1 19970224 G 2822 14990019 PUMP DUKES MOONEY M20 M20F 5870214 SW FUEL BOOST FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 01 9339M 5280 670253 OPERATOR REPORTED THAT EMERGENCY ELECTRIC FUEL PUMP NO LONGER WORKED. UPON REMOVAL AND REPLACMENT OF PUMP, DISCOVERED T HE FAILED PUMP HAD BEEN IN SERVICE ON THE AIRCRAFT FOR 23 YEARS. THESE PUMPS ARE STAMPED ON THE PUMP HOUSING TO REPLACE EVERY TEN YEARS. TOTAL TIME ON THE PUMP IS UNKNOWN, HOWEVER, ACFT TT IS 2,665.0 HOURS. SUBMITTER RECOMMENDED THIS SHO ULD BE AN ITEM OF PARTICULAR ATTENTION DURING ANNUAL INSPECTIONS. 1 L 7 1 3O 2A3 1997031300239 19970313 00239 NE 1997 3 13 97ZZZX1059 2 19970218 G 7230 1B4790 STATOR VANE BOEING 757 757* NM PWA 2037 PW2040 NE HPC MODULE FAILED B WA2D K NONE O OTHER IN INSP/MAINT 1 NE 03 16952 P726634 ENGINE WAS IN-FLIGHT, SHUT DOWN. DISASSEMBLY INSPECTION REVEALED ONE LIBERATED 10TH STAGE STATOR VANE AT THE CONVEX END OF ONE QUADRANT AT 9:00. THREE ADDITIONAL VANES IN THE SAME CLUSTER OF FIVE ARE FRACTURED THROUGH AT THE OUTSIDE DIAME TER SHROUD VANE BRAZE FILLET. METALLURIGCAL ANALYSIS OF THE 10TH STATOR AND 11TH BLADES IS BEING CONDUCTED BY PRATT AND WHITNEY MERL TO VERIFY FAILURE. 2 L 7 2 4F 4 F RT A2NM E17NE 1997031300240 19970313 00240 NE 1997 3 13 97ZZZX1060 2 19970213 G 7230 AS3209011 O-RING PWA 2037 PW2037 NE HPC MODULE MISSING B WA2D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 03 3992 3992 P727149 DISASSEMBLY INSPECTION OF HPC MODULE REVEALED O-RINGS, P/N AS3209-011, TO BE MISSING FROM THE 9TH STAGE VARI-VANE TRUNNI ONS (ALL VANES). THIS CONDITION WAS AN ORIGINAL MANUFACTURING ERROR. MANUFACTURING ADVISED OF CONDITION. NOTE: THE A BOVE CONDITION HAD NO BEARING ON ENGINE REMOVAL CAUSE. 4 F E17NE 1997031300242 19970313 00242 CE 1997 3 13 97ZZZX1061 1 19970130 G 3260 SWITCH LEAR 24 24A 5170304 CE MLG SQUAT ICE PACKED D O OTHER J WARNING INDICATION CL CLIMB 1 SW 99 63CK 119 LANDING GEAR WOULD NOT RETRACT AFTER DEPARTURE. FOUND GEAR SQUAT SWITCHES FROZEN AND PACKED WITH ICE. CLEANED GEAR OF ALL SNOW AND ICE, LUBED, AND PERFORMED SATISFACTORY OPERATIONAL CHECK. 2 L 7 2 4J A10CE 1997031300244 19970313 00244 CE 1997 3 13 97ZZZX1062 1 19970220 G 5712 57222061 RIB CESSNA 441 441 2076020 CE RT WING CRACKED B A WTXR K NONE O OTHER IN INSP/MAINT 1 NM 07 835MA 2963 4410343 DURING A PHASE INSPECTION, FOUND A CRACK IN THE RT WING CANTED RIB TOP CAP. CRACK STARTS AT AFT SIDE OF FORWARD WING SP AR AND RUNS AFT PARALLEL TO THE BEND RADIUS, APPROXIMATELY 1 INCH IN LENGTH. STOP-DRILLED ENDS OF CRACK PER CESSNA INST RUCTIONS. 1 L 7 2 3T RT A28CE 1997031300245 19970313 00245 EA 1997 3 13 97ZZZX1063 2 19970224 G 8530 05K21103 CYLINDER CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA EXHAUST VALVES DETERIORATED B RH6R K NONE O OTHER IN INSP/MAINT 1 NE 01 4635L 50 15284201 INSTALLED 4 NEW CYLINDERS ON OVERHAULED ENGINE. COMPRESSION LOSS STARTED AT ABOUT 300 HOURS THROUGH RINGS AND EXHAUST V ALVE SEAT. PULLED CYLINDERS, FOUND BADLY HEATED EXHAUST STEM AND EXHAUST SEAT. EXHAUST VALVES ERODED AND BADLY PITTED. INSTALLED ADDITIONAL 4 NEW CYLINDERS ON 1-20-97 APPRXOIMATELY ONE MONTH AND 50 HOURS AND SAME PROBLEM. OIL TEMP OK AN D BAFFLES INSTALLED. SUBMITTER STATED EXHAUST VALVE FAILURE IMMINENT. 1 H 7 1 3O 3 O NT 3A19 E223 1997031300247 19970313 00247 EA 1997 3 13 97ZZZX1065 2 19970204 G 7414 ES103827901 COIL CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA ENGINE MAGNETO CRACKED D L K NONE O OTHER IN INSP/MAINT 1 NM 03 1401E 489 17270986 L597976T BENDIX MAGNETO OVERHAULED BY ELECTRO SYSTEMS, REPAIR STATION UT2R22GL. MAGNETO WAS FURNISHED WITH LYCOMING FACTORY OVER HAULED ENGINE IN 1995. MAGNETO WAS REMOVED FOR 500-HOUR INSPECTION AND C/W AD 96-12-07 AT 489.3 SMOH FOR THE FIRST TIME . FOUND ONE EACH COIL P/N ES 10-382790-1 WITH MFG DATE 2/01/95 CRACKED IN 10 PLACES WITH CRACKS RADIATING OUTWARD FROM CENTER SUPPORTS AND BRUSH CONTACT TANG. 1 H 7 1 3O 3 O NT 3A12 E274 1997031300248 19970313 00248 EA 1997 3 13 97ZZZX1066 2 19970130 G 7414 D4RN2021 MAGNETO CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA DISTRIBUTOR GEAR TEETH MISSING D L K NONE O OTHER IN INSP/MAINT 1 NM 03 1401E 489 17270986 L597976T BENDIX/TCM DUAL MAGNETO REMOVEDF FROM LYCOMING. FACTORY OVERHAULED ENGINE AT SMOH 489.3 FOR 500-HOUR INSPECTION AND C/W AD 96-12-07. FOUND MAGENTO DISTRIBUTOR GEARS WITH THREE TEETH MISSING FROM ONE GEAR AND ONE-HALF TOOTH MISSING FROM OT HER GEAR. CONTINUED OPERATION WOULD HAVE CAUSED CATASTROPHIC FAILURE. THIS MAGNETO WAS OVERHAULED BY ELECTRO SYSTEMS I N 1995 AND HAD AN ELECTRO SYSTEMS DATA PLATE AFFIXED TO MAGNETO. THIS MAGNETO WAS INSTALLED AT LYCOMING OVERHAUL AND NE VER REMOVED UNTIL SMOH 489.3. RECOMMEND ALL MAGNETOS OVERHAULED BY ELECTRO SYSTEMS BE REMOVED AND INSPECTED IAW BENDIX OVERHAUL MANUAL. 1 H 7 1 3O 3 O NT 3A12 E274 1997031300328 19970313 00328 GL 1997 3 13 97ZZZX1078 3 19970206 G 6114 HUB MCAULY D3A34 D3A34C403 GL PROPELLER CORRODED B TX2R K NONE O OTHER IN INSP/MAINT 1 SW 05 398 890579 PROPELLER WAS DUE RESEAL. FOUND FACE OF HUB TO BE SEVERELY CORRODED OVER 60 PERCENT AT A DEPTH OF .008 INCH DEEP AND DE EPER. LAST OVERHAUL WAS 9-16-96 BY PRESCISION PROPELLER OUT OF TUSCALOOSA, AL. DURING OVERHAUL, CORROSION WAS PROBABLY NOT REWORKED ALL THE WAY. 5 C P47GL 1997031300329 19970313 00329 CE 1997 3 13 97ZZZX1079 1 19970129 G 2810 B1001421 CAP VENT CESSNA 150 152 2071835 CE FUEL TANK FROZE G A A UNSCHED LANDING Y ENGINE STOPPAGE NR NOT REPORTED 1 NE 03 67898 15282084 PREVIOUS DAY, ACCIDENT AIRCRAFT TIED DOWN ON OUTSIDE RAMP. RAIN AND SNOW WITH ABOVE FREEZING TEMPS. ICE NOT REMOVED FR OM CAPS DURING FREEZING CONDITION THE NEXT DAY. ICE FORMED IN VENT HOLES. FUEL STARVATION DUE TO VACUUM AS FUEL CONSUM ED CAUSED ENGINE FAILURE. NEED BETTER METHOD TO KEEP STANDING WATER FROM FREEZING CLOGGING VENTS. 1 H 7 1 3O NT 3A19 1997031300330 19970313 00330 SO 1997 3 13 97ZZZX1080 1 19970224 G 2910 AE7007422 LINE GULSTM G1159 G1159A 3970109 SO LT ENG COWL CHAFED B P A RO3R K NONE O OTHER IN INSP/MAINT 1 CE 03 7906G 497 AFTER THE LT ENGINE WAS REMOVED A VISUAL INSPECTION OF THE FIXED COWLING AREA, IT WAS NOTICED THAT A FIRE EXTINGUISHING DISCHARGE TUBE P/N 1159P20438-15 HAD A .75 INCH BY .25 INCH HOLE CHAFED INTO IT BY THE LT ENGINE HYDRAULIC LINE P/N AE70 0742-2. THE LINE WAS ALSO CHAFED AND HAD FRAYED BRAIDS. LOOKED AT A 2ND AIRCRAFT (S/N 389) AND FOUND SIMILAR CHAFE MAR KS ON THE FIRE EXTINGUISHING TUBE AND ON THE SAME HYDRAULIC LINE, BUT, ALSO, FOUND SIMILAR CHAFE MARKS ON THE RETURN HYD RAULIC AND BYPASS LINES THAT GO TO THE ENGINE HYDRAULIC PUMP. THESE LINES WERE MISSING CLAMPS OR WERE IMPROPERLY CLAMPE D TO PREVENT CHAFING ON THE EXTINGUISHER LINE. REMOVED AND REPLACED LINES AND PROPERLY CLAMPED TO PREVENT CHAFING. 2 L 7 2 4F A12EA 1997031300331 19970313 00331 SO 1997 3 13 97ZZZX1081 1 19970224 G 2620 1159P2043815 TUBE GULSTM G1159 G1159A 3970109 SO LT ENG FIRE EXT CHAFED B P A RO3R K NONE O OTHER IN INSP/MAINT 1 CE 03 7906G 497 AFTER THE LT ENGINE WAS REMOVED A VISUAL INSPECTION OF THE FIXED COWLING AREA, IT WAS NOTICED THAT A FIRE EXTINGUISHING DISCHARGE TUBE P/N 1159P20438-15 HAD A .75 INCH BY .25 INCH HOLE CHAFED INTO IT BY THE LT ENGINE HYDRAULIC LINE P/N AE70 0742-2. THE LINE WAS ALSO CHAFED AND HAD FRAYED BRAIDS. LOOKED AT A 2ND AIRCRAFT (S/N 389) AND FOUND SIMILAR CHAFE MAR KS ON THE FIRE EXTINGUISHING TUBE AND ON THE SAME HYDRAULIC LINE, BUT, ALSO, FOUND SIMILAR CHAFE MARKS ON THE RETURN HYD RAULIC AND BYPASS LINES THAT GO TO THE ENGINE HYDRAULIC PUMP. THESE LINES WERE MISSING CLAMPS OR WERE IMPROPERLY CLAMPE D TO PREVENT CHAFING ON THE EXTINGUISHER LINE. REMOVED AND REPLACED LINES AND PROPERLY CLAMPED TO PREVENT CHAFING. 2 L 7 2 4F A12EA 1997031300332 19970313 00332 CE 1997 3 13 97ZZZX1082 1 19970226 G 7820 075016161 MUFFLER CESSNA 185 A185F 2072821 CE BAFFLE CONE BROKEN D K NONE O OTHER IN INSP/MAINT 1 WP 07 7239E 2900 18502642 MUFFLER REMOVED TO FACILITATE OTHER MAINTENANCE. UPON REMOVAL, A VISUAL INSPECTION REVEALED A BAFFLE CONE WAS BROKEN AN D A LARGE PORTION OF THE BAFFLE WAS MISSING. SUBMITTER RECOMMENDED 100-HOUR INSPECTION INCLUDE THE USE OF A STRONG FLAS HLIGHT AND A MIRROR BE USED IN THE LARGE EXHAUST STACK TO EXAMINE BAFFLE INTEGRITY. 1 H 7 1 3O 3A24 1997031300333 19970313 00333 CE 1997 3 13 97ZZZX1083 1 19970227 G 5553 04311489 FITTING CESSNA 150 152 2071835 CE VERT STAB CRACKED D S K NONE O OTHER IN INSP/MAINT 1 SW 15 89301 5158 15282706 INSPECTION FOUND VERTICAL STABILIZER ATTACH FITTING CRACKED ON LEFT SIDE OF ROOT AREA. POSSIBLE CAUSE: ATTEMPTING SNAP ROLLS IN A C-152. 1 H 7 1 3O NT 3A19 1997031300334 19970313 00334 NM 1997 3 13 97ZZZX1084 1 19970225 G 5320 50534511 FITTING BOEING 707 7073D3C NM BS 600K CRACKED B S UGMR K NONE O OTHER IN INSP/MAINT 1 SW 03 2FOR 20495 SEVEN INCH LONG CRACK LT TERMINAL FITTING LOWER FORWARD CARGO AREA BS 600K, WL 170, LBL 50, INTERIOR P/N 50-5345-11. RE F DWG. 50-2529 5H.3A ZNC2. THE FOLLOWING A/C HAS THE SAME CRACKS IN THE SAME AREA FROM 3.8 INCHES LONG TO 8 INCHES LONG . BOEING 707-338C S/N 19296 N6546L 65,300 HRS. BOEING 707-338C S/N 19293 N2178F 59,473 HRS. BOEING 707-321C S/N 20016 N870PA 52,582.24 HRS. 2 L 7 4 4F 4A26 1997031300335 19970313 00335 NM 1997 3 13 97ZZZX1085 1 19970225 G 5320 50534511 FITTING BOEING 707 707338C 138367N NM BS 600K CRACKED B S UGMR K NONE O OTHER IN INSP/MAINT 1 SW 03 2178F 19293 3.8 INCH LONG CRACK LT TERMINAL FITTING, 8 INCH LONG CRACK, RT TERMINAL FITTING. LOWER FWD CARGO AREA BS 600K, WL 170, LBL 50, RBL 50, INTERIOR P/N 50-5345-11. REF DWG 50-2529 5H.3A ZNC2. THE FOLLOWING A/C HAS THE SAME CRACKS IN THE SAME AREA FROM 3.8 INCHES LONG TO 8 INCHES LONG. BOEING 707-338C S/N 19296 N6546L 65,300 HRS. BOEING 707-3D3C S/N 20495 JY -ADP 45,498.6 HRS. BOEING 707-321C S/N 20016 N870PA 52,582.24 HRS. 2 L 7 4 4F 4A26 1997031300336 19970313 00336 NM 1997 3 13 97ZZZX1086 1 19970225 G 5320 50534511 FITTING BOEING 707 707338C 138367N NM BS 600K CRACKED B S UGMR K NONE O OTHER IN INSP/MAINT 1 SW 03 6546L EIGHT INCH LONG CRACK LT TERMINAL FITTING LOWER FWD CARGO AREA BS 600K, WL 170, LBL 50, INTERIOR P/N 50-5345-11. REF DW G 50-2529 SH.3A ZNC2. THE FOLLOWING A/C HAS THE SAME CRACKS IN THE SAME AREA. FROM 3.8 INCHES LONG TO 8 INCHES LONG. B OEING 707-338C S/N 19293 N2178F 59,473 HRS. BOEING 707-3D3C S/N 20495 JY-ADP 45,498.6 HRS. BOEING 707-321C S/N 20016 N 870PA 52,582.24. 2 L 7 4 4F 4A26 1997031300337 19970313 00337 NM 1997 3 13 97ZZZX1087 1 19970225 G 5320 50534511 FITTING BOEING 707 707321C 138367B NM BS 600K CRACKED B S UGMR K NONE O OTHER IN INSP/MAINT 1 SW 03 870PA 20016 4.5 INCH LONG CRACK LT TERMINAL FITTING LOWER FWD CARGO AREA BS 600K, WL 170, LBL 50, INTERIOR P/N 50-5345-11. REF DWG 50-2529 SH.3A ZNC2. THE FOLLIWNG A/C HAS THE SAME CRACKS IN THE SAME AREA FROM 3.8 INCHES LONG TO 8 INCHES LONG. BOEIN G 707-338C S/N 19296 N6546L 65,300 HRS. BOEING 707-338C S/N 19293 N2178F 59,473 HRS. BOEING 707-3D3C S/N 20495 JY-ADP 45,498.6 HRS. 2 L 7 4 4F 4A26 1997031300338 19970313 00338 GL 1997 3 13 97ZZZX1088 3 19970226 G 6111 V8433N4 BLADE GULSTM 500 500B 0141106 SW HARTZL HCA3V HCA3VK2 GL SHANK CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 15 444CA 10026 1946 1458162 BJ165 INSPECTION FOUND RPOPELLER BLADE SHANK CRACKED. 1 H 7 2 3O 6A1 5 C P6EA 1997031300339 19970313 00339 CE 1997 3 13 97ZZZX1089 1 19970127 G 3231 12838002141 RELEASE CABLE MTSBSI MU300 MU300 5780602 CE MLG DOOR EMRG BROKEN B L A RO3R K NONE O OTHER IN INSP/MAINT 1 CE 03 482DM 1655 A088SA DURING A POST-FLIGHT INSP DAMAGE WAS NOTICED ON THE LT FUSELAGE MLG DOOR, THE AFT SIDE COVER ASSEMBLY, AND THE MIDDLE FU SELAGE SKIN ASSY. AFTER FURTHER INSP THE LT EMERG MLG DOOR UPLOCK RELEASE CABLE WS FOUND BROKEN AT THE ROD END ADJACENT TO THE DOOR UPLOCK RELEASE. AFTER LOWERING THE DOOR MANUALLY IT WAS DETERMINED THAT THE ROD END FROM THE BROKEN CABLE HAD JAMMED THE MLG DOOR UPLOCK RELEASE DURING A GEAR EXT. THIS ALLOWED THE UPLOCK RELEASE HOOK TO ONLY OPEN SLIGHTLY BU T NOT ENOUGH TO RELEASE THE MLG DOOR. AT THIS POINT THE LEFT MLG DOOR ACTUATOR BEGAN TO EXTEND THE UNRELEASED DOOR. AT THIS POINT THE LEFT MLG DOOR ACTUATOR BEGAN TO EXTEND THE UNRELEASED DAMAGE TO THE LT FUSELAGE MLG DOOR. 2 H 7 2 4F RT A14SW 1997032000267 19970320 00267 NE 1997 3 20 97ZZZX1091 3 19970130 G 6111 ABRASION STRIP DIAMON DA20A1 DA20A1 05626UX GL HOFMAN HOV352 HOV352F NE PROPELLER CRACKED B OG5R K NONE O OTHER IN INSP/MAINT 1 GL 21 179DA 124 10179 H493 INSPECTION FOUND ABRASION STRIP CRACKED FROM TIP OF PROPELLER TO APPROXIMATELY 5 INCHES FROM TIP. PROPELLER WAS NOT KNO WN TO HAVE HAD ANY STRIKES. CRACK WAS FOUND DURING PRE-FLIGHT INSPECTION. 1 L 7 1 3O NT TA4CH 5 C TP5BO 1997032000268 19970320 00268 GL 1997 3 20 97ZZZX1092 2 19970303 G 7230 23057142 CASE BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL COMPRESSOR LINER LOOSE H K NONE O OTHER IN INSP/MAINT 1 SW 09 18FH 1612 13642 2599 CAE833451 COMPRESSOR CASE PLASTIC LINER CAME LOOSE IN THE BLEED VALVE AIR FLOW BAND OF COMPRESSOR CASE. ONE PIECE APPROXIMATELY 2 SQUARE INCHES IN SIZE LODGED IN BLEED VALVE. 1 G 7 1 3U 3 U H2SW E4CE 1997032000269 19970320 00269 SW 1997 3 20 97ZZZX1093 1 19970225 G 3340 1402R LENS WHELEN HUGHES 500N 500N 3027374 SW STROBE CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 521FB 250 LN001 BASE OF LENS CRACKED FROM MOUNT RING CLAMP DUE TO VIBRATION. FOUND ON INSPECTION, APPROXIMATELY 250 HOURS. 1 G 7 1 3U NC H3WE 1997032000270 19970320 00270 SW 1997 3 20 97ZZZX1094 1 19970227 G 3340 LENS WHELEN HUGHES 500N 500N 3027374 SW STROBE CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 527FB 35 LN007 BASE OF LENS CRACKED WOULD HAVE FALLEN OFF. FOUND ON INSPECTION. TT: 35 HOURS. 1 G 7 1 3U NC H3WE 1997032000271 19970320 00271 CE 1997 3 20 97ZZZX1095 1 19970221 G 3340 MS25306222 SWITCH CESSNA 208 208B 2073701 CE LANDING LIGHT FAILED B BJFR K NONE O OTHER IN INSP/MAINT 1 EA 23 1293E 422 208B0537 AIRCRAFT LEFT LANDING LIGHT WOULD NOT SHUT OFF. PILOT REPORTED FAINT SMOKE SMELL IN COCKPIT. IINVESTIGATION REVEALED L ANDING LIGHT SWITCH HAD SHORTED AND SHOWED SIGNS OF OVERHEATING. THE SWITCH WAS REPLACED AND SYSTEM OPERATED NORMALLY. 1 H 7 1 3T A37CE 1997032000272 19970320 00272 SO 1997 3 20 97ZZZX1096 1 19970210 G 3260 SWITCH PIPER PA31 PA31350 7103110 SO LT MLG FAULTY D O OTHER N FALSE WARNING AP APPROACH 1 EA 23 161SA 531 318082029 PILOT REPORTS LEFT GEAR WILL NOT COME DOWN. C/W GEAR SWINGS WITH HYDRAULIC CART, COULD NOT DUPLICATE PROBLEM. LUBED GE AR, CHECKED RIGGING, REPLACED UPLOCK ROLLERS. FLEW AGAIN, SAME PROBLEM EXISTS. CHANGED LEFT GEAR ACTUATOR AND HYDRAULI C PACK, GEAR CHECK GOOD AGAIN IN HANGAR. FLEW AGAIN, SAME PROBLEMS. LAST RESORT, CHANGED DOWNLOCK SWITCH, FIXED PROBLE M. 1 L 7 2 3O A20SO 1997032000273 19970320 00273 1997 3 20 97ZZZX1097 4 19970213 G 6122 F848L GOVERNOR HARTZL PIPER PA31 PA31350 7103110 SO PROPELLER FAILED E A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 NE 05 344T 1088 B9590 317952013 GOVERNOR FAILED ON CLIMB-OUT CAUSING ENGINE TO FEATHER PROP NECESSITATING AN EMERGENCY LANDING. OIL PLUG WITHIN GOVERNO R CAME LOOSE CAUSING IT TO JAM OIL PUMP GEARS AND SHEAR SHAFT ON GOVERNOR. 1,088 HRS SMOH OF GOVERNOR. 1 L 7 2 3O A20SO 1997032000274 19970320 00274 CE 1997 3 20 97ZZZX1098 1 19970110 G 3260 1SE18 SWITCH CESSNA 310 310R 2074245 CE NLG FAILED D O OTHER J WARNING INDICATION AP APPROACH 1 GL 07 3700G 310R0899 DSM - TOOK SEVERAL CYCLES TO GET NOSE GEAR DOWN LIGHT. REMOVED AND REPAIRED NOSE GEAR DOWN AND LOCK SWITCH ASSY. CHECK ED GEAR SEVERAL TIMES, OPS CHECK GOOD. 1 L 7 2 3O 3A10 1997032000275 19970320 00275 SO 1997 3 20 97ZZZX1099 1 19970113 G 2140 461731 VALVE JANITROL PIPER PA31 PA31350 7103110 SO FUEL PRESS REG FAILS G K NONE K FLUID LOSS IN INSP/MAINT 1 NM 04 4091D 318152154 SUBMITTER STATED HAVE HAD 5 FAILURES OF THIS VALVE OVER 24 MONTH PERIOD. DIAPHRAGM FAILS AND FUEL LEAKS OVERBOARD. TIM E RANGES FROM 101 HOURS TO 600 HOURS. PIPER P/N 461-731. ELECTRO SYSTEMS, P/N A 23 D0407.5, NEW VALVES OR OVERHAULED V ALVES, MAKES NO DIFFERENCE. 1 L 7 2 3O A20SO 1997032000276 19970320 00276 CE 1997 3 20 97ZZZX1100 1 19970205 G 5730 SKIN CESSNA 441 441 2076020 CE RT WING LE CORRODED B DJFR K NONE O OTHER IN INSP/MAINT 1 EA 23 410MA 4960 4410254 RIGHT WING DEICE BOOT WAS REMOVED FOR REPLACEMENT. WING SKIN WAS FOUND TO HAVE EXCESSIVE CORROSION PITS ON MUCH OF THE SKIN. DAMAGE ALLOWANCE IS ONLY 15 PERCENT OF .032 INCH SKIN THICKNESS. LEADING EDGE ASSEMBLY HAS TO BE REPAIRED. THIS COULD POSSIBLY BE FOUND BY FEELING SURFACE OF DEICE BOOTS FOR LUMPS UNDERNEATH. DEICE BOOT INSTALLATION DATE AND TIME UNKNOWN. 1 L 7 2 3T RT A28CE 1997032000277 19970320 00277 SO 1997 3 20 97ZZZX1101 2 19970122 G 8550 12509225 ADAPTER CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO OIL FILTER LEAK D K NONE J K WARNING INDICATION FLUID LOSS NR NOT REPORTED 1 EA 23 4853N 18267420 PILOT REPORTED LOW OIL PRESSURE IN-FLIGHT. UPON INSPECTION, FOUND OIL LEAKING FROM OIL FILTER ADAPTER. REMOVED ADAPTER , INSTALLED NEW O-RING AND REINSTALLED. NO FURTHER LEAKS FOUND. 1 H 7 1 3O 3 O NT 3A13 E273 1997032000278 19970320 00278 SO 1997 3 20 97ZZZX1102 2 19970303 G 8530 A50222 CYLINDER CESSNA 150 150J 2071820 CE CONT O200 O200A 17020 SO NR 4 CYL ROCKER FAILED D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 EA 05 150J 1694 305 15069500 2045149A ENGINE RAN ROUGH ON START. REMOVED COWLING. RESTARTED ENGINE. SHAKING VIOLENTLY. REMOVED ROCKER COVER. ENTIRE ROCK ER ARMS, PINS, AND BOSSES FELL IN COVER. SUSPECT VALVE STUCK. 1 H 7 1 3O 3 O 3A19 E252 1997032000279 19970320 00279 CE 1997 3 20 97ZZZX1103 1 19970226 G 3230 50452112 FORK BOLT 08421043 CESSNA 402 402B 207590P CE NLG BROKEN D S A O OTHER J WARNING INDICATION AP APPROACH 1 NM 09 7162K 9243 402B1208 DURING APPROACH TO LAND, PILOT SELECTED GEAR DOWN. NOSE GEAR SHOWED UNSAFE. A FLY-BY WAS DONE AND PERSONNEL ON THE GRO UND VERIFIED THE NOSE LANDING GEAR WAS TRAILING AT 45 DEGREES. THE AIRCRAFT RETURNED TO HOME BASE AND A NOSE GEAR UP LA NDING WAS MADE. INSPECTION REVEALED THE NOSE LANDING GEAR FORK BOLT HAD BROKEN. METAL FATIGUE IS SUSPECTED DUE TO THE HIGH TIME ON PART. 1 L 7 2 3O A7CE 1997032000280 19970320 00280 CE 1997 3 20 97ZZZX1104 1 19970129 G 2750 500000862 CONTROL CABLE CESSNA 414 414A 2075907 CE FLAP FRAYED D K NONE O OTHER IN INSP/MAINT 1 EA 03 717BD 4992 414A0337 BASED ON PREVIOUS INSPECTIONS, REMOVED FLAP CABLES FOR CLOSE INSPECTION BY TWISTING AND BENDING. FOUND MANY INTERNAL ST RANDS BROKEN. SUBMITTER STATED MAY NEED TO HAVE LIFE LIMIT. THIS IS THE THIRD OCCURRENCE OUT OF FOUR, 400 SERIES INSPE CTED IN PAST SIX MONTHS. 1 L 7 2 3O A7CE 1997032000281 19970320 00281 CE 1997 3 20 97ZZZX1105 1 19970128 G 3230 MAIN GEAR BEECH 58 58 1152740 CE LT MLG FAILED D O OTHER J WARNING INDICATION AP APPROACH 1 GL 07 9044V TH216 LEFT LANDING GEAR FROZEN IN WHEELWELL, GEAR SELECTED DOWN, ROD BENT, AND GEAR STAYED IN WELL. REMOVED AND REPLACED BENT ROD AND MOTOR AND GEARBOX ASSY, LEFT PROPELLER AND LEFT ENGINE FOR PROPELLER STRIKE INSPECTION. 1 L 7 2 3O 3A16 1997032000282 19970320 00282 SW 1997 3 20 97ZZZX1106 1 19970203 G 7603 660226007 CABLE SWAGE MOONEY M20 M20K 5870220 SW THROTTLE LOOSE B S DYTR K NONE O OTHER IN INSP/MAINT 1 SO 15 98968 250542 WHILE ATTEMPTING TO ADJUST THROTTLE WARNING HORN, SOME MAJOR INCONSISTENT SETTINGS WOULD OCCUR. INVESTIGATION REVEALED A DEFECTIVE OR FAILED SWAGE JOINT WHERE FLEXIBLE CABLE TRANSITIONS AND CONNECTS AT AFT HOUSING ASSEMBLY. DEFECT LOCATED ONLY INCHES FORWARD OF WARNING HORN MICROSWITCH ATTACH. OPERATING THROTTLE WOULD MOVE HOUSING IN AND OUT INSTEAD OF CO NTROLLING ENGINE. 1 L 7 1 3O 2A3 1997032000283 19970320 00283 CE 1997 3 20 97ZZZX1107 1 19970228 G 3234 98810202 SELECTOR CESSNA 182 R182 2072734 CE GEAR LEAKING D O OTHER K FLUID LOSS AP APPROACH 1 CE 09 6122S 7800 R18201619 AFTER GEAR 'DOWN' SELECTION PRIOR TO LANDING, PILOT NOTICED HYD FLUID DRIPPING ONTO THE FLOOR. ACFT LANDED WITHOUT INCI DENT. LANDING GEAR POSITION SELECTOR V ALVE WAS REMOVED AND CHECKED. IT WAS DETERMINED THAT THE LEAK WAS CAUSED BY A D ETERIORATED 'PACKING' FOR THE 'DOWN' LINE UNION FITTING. THE REMAINING 3 LINE UNION FITTINGS WERE REMOVED AND IT WAS FO UND THAT THE UNION PACKINGS WERE ALSO DETERIORATED. THE AGE OF THESE PACKINGS CAUSED THEM TO BECOME HARD AND BRITTLE AN D HAD TAKEN A PERMANENT SET. NEW MS PACKINGS WERE INSTALLED UNDER THE UNION NUT FITTINGS AND SELECTOR VALVE. OPS CHECK ED GOOD. 1 H 7 1 3O RT 3A13 1997032000284 19970320 00284 SO 1997 3 20 97ZZZX1108 1 19970228 G 2820 484297 REDUCER PIPER PA31 PA31310 7103103 SO CROSSFEED CRACKED B BXSR K NONE K FLUID LOSS IN INSP/MAINT 1 EA 09 272HJ 317712055 PILOT REPORTED FUEL SMELL IN THE CABIN. FOUND THE CROSSFEED LINE DRAIN REDUCER FLARE CRACKED AND SEEPING FUEL. 1 L 7 1 3O RT A20SO 1997032000285 19970320 00285 SO 1997 3 20 97ZZZX1109 1 19970228 G 2820 601 HOSE PIPER PA31 PA31310 7103103 SO LT WING ROOT LEAK B BXSR K NONE O OTHER IN INSP/MAINT 1 EA 09 272HJ 317712055 PILOT REPORTED FUEL SMELL IN THE CABIN. FOUND AEROQUIP TYPE 601 HOSE INSTALLED IN THE LT WING ROOT DRIPPING FUEL. THES E HOSES ARE AFFECTED BY AEROQUIP BULLETIN NR AA135 WHICH LIMITED THEIR LIFE TO TWO YEARS. 1 L 7 1 3O RT A20SO 1997032000288 19970320 00288 1997 3 20 97ZZZX1112 4 19970228 G 3418 4219F010301 SWITCH AMD FALC50 FALCON50MYST 2730106 EU STALL VANE FAILED B UO2R K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 19 4350M 142 AIRCRAFT FAILED CAMP CARD CHECK OF NR 2 STALL VANE. FOUND AIRSPEED SWITCH 66F FAILED TO THE PLUS 270 KNOT POSITION. OR DERED AND INSTALLED REPLACEMENT AIRSPEED SWITCH. AIRCRAFT AGAIN FAILED CHECK, BUT A DIFFERENT PART OF THE CHECK. FOUND REPLACEMENT AIRSPEED SWITCH FAILED TO THE BELOW 270 KNOT POSITION. SWITCH HAD BEEN OVERHAULED TO ZERO TIME ON 1-16-97. 2 L 7 3 4F A46EU 1997032000289 19970320 00289 EU 1997 3 20 97ZZZX1113 1 19970228 G 2820 D97C00215 ACTUATOR AMD FALC50 FALCON50MYST 2730106 EU TRANSFER MALFUNCTIONED B A UO2R K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 19 4350M 763 142 TRANSFER INTERCONNECT VALVES WERE REMOVED AND SENT TO MIDWAY TO C/W DASSAULT SB F50-186. VALVES WERE RETURNED TO US, OV ERHAULED TO ZERO TIME. AFTER INSTALLATION AND TEST IN THE AIRCRAFT, THE TEST SHOWED ONE VALVE WORKING BACKWARDS (CLOSED WHEN SELECTED OPEN AND OPEN WHEN SELECTED CLOSED). REMOVED AND BENCH CHECKED VALVE PER CMM 28-15-28. VALVE FAILED FUN CTIONAL TEST. REPAIR TAG SAYS IT WAS TESTED PER CMM 28-15-28 AND PASSED. 2 L 7 3 4F A46EU 1997032000290 19970320 00290 CE 1997 3 20 97ZZZX1114 1 19970224 G 2910 2407003467 LINE LEAR 25 25D 5170514 CE HELL HOLE CRACKED D O OTHER K J FLUID LOSS WARNING INDICATION AP APPROACH 1 GL 23 900WA 10616 248 AIRCRAFT LOST HYDRAULIC PRESSURE DURING LANDING GEAR EXTENSION CYCLES. REPLACED CRACKED HYDRAULIC LINE IN HELL HOLE. S ERVICED RESERVOIR, BLED SYSTEM, LEAK AND FUNCTIONALLY CHECKED GOOD. 2 L 7 2 4J A10CE 1997032000386 19970320 00386 WP 1997 3 20 97ZZZX1117 1 19970122 G 6320 369D2512711 RING GEAR 369D25100 HUGHES 369 369D 4470706 WP M/R XMSN SPALLED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 5074R 447 1810 1151D OPENED TRANSMISSION TO INSPECT FOR WEAR AND FOUND M/R OUTPUT SHAFT RING GEAR 369D25127-11, S/N 005570-1089, AND PINION 3 69D25125-13, S/N 005570-0437, SPALLED IN SEVERAL PLACES. REPLACED TRANSMISSION. SENT THIS ONE IN FOR OVERHAUL. 1 G 7 1 3U H3WE 1997032000387 19970320 00387 GL 1997 3 20 97ZZZX1118 2 19970307 G 7250 6898735 TURBINE HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL EXH COLLECTOR SMOKING B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 5074R 7015 543 1151D CAE832750 19.4 HOURS AFTER A REPAIR TO THE TURBINE PT SUPPORT, THE TURBINE STARTED SMOKING HEAVILY ON SHUT DOWN. AFTER THE ENGINE COOLED, A VISUAL INSPECTION FOUND OIL PUDDLING IN THE TURBINE EXHAUST COLLECTOR. UNIT SENT BACK FOR REPAIR. 1 G 7 1 3U 3 U H3WE E4CE 1997032000388 19970320 00388 WP 1997 3 20 97ZZZX1119 1 19970303 G 5347 15080811 SEAT TRACK DOUG DC9 DC981 3022081 WP BS 200-237 CORRODED B S5WR K NONE O OTHER IN INSP/MAINT 1 SW 01 818SJ 48058 CORRODED SEAT TRACKS UNDER GALLEYS. FOUND DURING CPCP INSPECTION. SEAT TRACK SECTION REPLACED. SUBMITTER STATED SPECI AL ATTENTION TO SEALING AREA, UNDER GALLEY AND MAINTAINING ENVIRONMENTAL SEAL BETWEEN C-CHECKS. 2 L 7 2 4F A6WE 1997032000389 19970320 00389 WP 1997 3 20 97ZZZX1120 1 19970303 G 5347 15080721 SEAT TRACK DOUG DC9 DC981 3022081 WP BS 200-237 CORRODED B S5WR K NONE O OTHER IN INSP/MAINT 1 SW 01 818SJ 48058 CORRODED SEAT TRACKS UNDER GALLEYS. FOUND DURING CPCP INSPECTION. SEAT TRACK SECTION REPLACED. SUBMITTER STATED SPECI AL ATTENTION TO SEALING AREA, UNDER GALLEY AND MAINTAINING ENVIRONMENTAL SEAL BETWEEN C-CHECKS. 2 L 7 2 4F A6WE 1997032000696 19970320 00696 WP 1997 3 20 97ZZZX1124 2 19970212 G 7200 ENGINE BEECH 18 C45H 1151018 CE GARRTT TPE331 TPE331101B 01514 WP RT ENGINE FAILED D K NONE Y ENGINE STOPPAGE AP APPROACH 1 GL 23 4209V 7782 6310 AF884 P93010 RIGHT ENGINE QUIT RUNNING ON APPROACH TO YIP. UNEVENTFUL LANDING CARRIED OUT. ENGINE EXPERIENCED INTERNAL FAILURE, CAU SE AT THIS TIME UNKNOWN. ENGINE REPLACED WITH SERVICEABLE UNIT. AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 3R 3 T A765 E3WE 1997032000697 19970320 00697 CE 1997 3 20 97ZZZX1125 1 19970221 G 3020 10091000239 LINE BEECH 100 B100 1152919 CE ENG ANTI ICE FAILED B L A CW7R A UNSCHED LANDING X ENGINE FLAMEOUT CL CLIMB 1 GL 25 771CW BE52 CREW WAS PERFORMING A MISSED APPROACH PROCEDURE. DURING CLIMB-OUT, THE RT ENG WAS RETARDED TO FLIGHT IDLE TO SIMULATE E NG OUT CONDITION. DURING THIS ENTIRE TIME THE ACFT WAS IN LIGHT ICING CONDITIONS WITH ALL ANTI-ICE SYSTEMS OPERATING NO RMALLY. AFTER COMPLETION OF THE ENG OUT EXERCISE THE RT ENG THROTTLE WAS ADVANCED TO NORMAL CRUISE SETTING. THE PILOT NOTICED VERY LITTLE TO NO RESPONSE IN PERFORMANCE AND THEN SHORTLY AFTER THE RT ENG FLAMED OUT. THE ACFT RETURNED TO TH E AIRPORT WITHOUT FURTHER INCIDENT. DURING MAINT TROUBLESHOOTING, THE MECH FOUND THAT THE RT ENG INLET ANTI-ICE LINE 'B ' NUT HAD BACKED OFF AND SUBSEQUENT VIBRATION CAUSED THE LINE TO FATIGUE CRACK AND FAIL. AIRCRAFT TT 4,118.8 HOURS. 1 L 7 2 4T A14CE 1997032000698 19970320 00698 EU 1997 3 20 97ZZZX1126 1 19970228 G 2750 FLAP AIRBUS 320 A320321 3930325 EU WING LOCK OUT C A O OTHER F FLT CONT AFFECTED AP APPROACH 1 GL 03 E1TLH 247 ORD - FLT 4326 - FLAPS HAD ISOMETRIC FAULT AND LOCK-OUT ON APPROACH. AN EMERGENCY WAS DECLARED AND A NO-FLAP LANDING WA S MADE. AIRCRAFT LANDED AND TAXIED TO GATE WITH NO INCIDENT. WING TIP BRAKES RESET ON GROUND. BITE TEST WAS PERFORMED ON LGCIU IAW MM 32-69-00, 740-001. NO FAULT DETECTED. FLAPS OPERATE NORMALLY ON GROUND. 2 L 7 2 RT 4T A28NM 1997032000699 19970320 00699 SO 1997 3 20 97ZZZX1127 1 19970303 G 7120 6711949 MOUNT PIPER PA28 PA28R180 7102809 SO ENGINE CRACKED B BCBR K NONE O OTHER IN INSP/MAINT 1 EA 03 3811T 2001 28R30126 FOUND UPPER RT ENGINE MOUNT TUBE BROKEN. REF: PIPER S/L 568 PERTAINS TO THIS SUBJECT AND HAS A FACTORY APPROVED REPAIR PROCEDURE. TACH WAS AT 2001. LOGS NOT AVAILABLE TO CHECK IF THIS IS TOTAL TIME. 1 L 7 1 3O 2A13 1997032000700 19970320 00700 CE 1997 3 20 97ZZZX1128 1 19970226 G 8010 J4A18N GROUND WIRE BEECH 23 23 1151202 CE MAG SWITCH BURNED D P A K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 GL 13 2368L 2350 M209 THIS GROUND WIRE GROUNDS THE STARTER/VIBRATOR CIRCUIT. IT WAS GROUNDED VIA A COPPER CLAMP TO THE MAG. P-LEAD SHIELDING . THE P-LEAD SHIELDING WAS GROUNDED ONLY AT THE MAGNETO. THE GROUND WIRE, J4A18N, COULD NOT HANDLE THE LOAD DURING STA RT, AND, OVER TIME, DETERIORATED TO THE POINT WHERE THE WIRE J4A18N BURNED THROUGH CAUSING SMOKE IN THE COCKPIT AND DURI NG START. NEW WIRE WAS FABRICATED AND GROUNDED ELSEWHERE AS WERE THE P-LEAD SHIELDINGS. 1 L 7 1 3O A1CE 1997032000702 19970320 00702 NM 1997 3 20 97ZZZX1130 1 19970304 G 5320 50534511 FITTING BOEING 707 707338C 138367N NM LT 600K BLKHEAD CRACKED B VGMR K NONE O OTHER IN INSP/MAINT 1 SO 17 VHEBU 47677 19294 3 INCH LONG CRACK LT AND RT TERMINAL FITTING LOWER FWD CARGO AREA BS 600K WL 170 LBL 50 RBL 50 INTERIOR P/N 50-5345-11. REF DWG 50-2529 SH 3A ZN02. 2 L 7 4 4F 4A26 1997032000703 19970320 00703 CE 1997 3 20 97ZZZX1131 1 19970201 G 3250 MISLSH19C CONNECTOR LEAR 35 36A 5170603 CE NLG STEERING CORRODED B L4JD K NONE O OTHER IN INSP/MAINT 1 NM 03 978E 024 INTERMITTENT CONNECTION OF PLUG CAUSES INTERMITTENT AVAILABILITY OF VARIABLE AUTHORITY OF NOSE WHEEL STEERING. THE PLUG IS TOO SUSCEPTIBLE TO MOISTURE AND CORROSION. THIS SITUATION THE PLUG OPERATED INTERMITTENTLY CAUSING LOSS OF CONTROL OF NOSE WHEEL STEERING AND CONTROL OF THE AIRCRAFT WHICH WENT OFF THE RUNWAY. 2 L 7 2 4F A10CE 1997032000704 19970320 00704 NM 1997 3 20 97ZZZX1132 1 19970303 G 2730 59118 SPRING 680005003 BOEING 727 727225 1384077 NM ELEV PCU MISSING B DM4R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 19 UPON DISASSEMBLY OF ELEVATOR POWER CONTROL UNIT, IT WAS NOTED THAT THE CENTERING SPRING WAS MISSING. (NOT INSTALLED AT LAST REPAIR.) CUSTOMER REPORTED 'AIRPLANE PORPOISES IN A AND B MODE". 2 L 7 3 4F A3WE 1997032000705 19970320 00705 EA 1997 3 20 97ZZZX1133 2 19970225 G 8530 CYLINDER HILLER UH12 UH12E 4360122 WP LYC O540 VO540C2A 41532 EA FLANGE NOT TO SPEC D K NONE O OTHER IN INSP/MAINT 1 NM 09 36MV 5060 L254243 DURING ASSEMBLY OF ENGINE, MEASURED DRY TAPPET CLEARANCE FROM .107 INCH TO .187 INCH. LYC OHM REQUIRES .028 INCH TO .08 0 INCH. RETURNED 6 CYLINDERS TO EC/SW WHERE THEY CUT/REMOVED MATERIAL FROM THE CYL FLANGE. CYLINDERS WERE RE-INSTALLED . THESE CYLINDERS JUST MADE THE .080 INCH DTC USING THE LONGEST PUSH ROD AND NEW ROCKER ARMS. 1 G 7 1 3O 3 O 4H11 E304 1997032000706 19970320 00706 GL 1997 3 20 97ZZZX1134 2 19970305 G 7260 6854857A GEARSHAFT ALLSN 250C 250C20B 03013 GL TACH DRIVE WORN D K NONE O OTHER IN INSP/MAINT 1 NM 11 4889 UPI342 CAG37227 TACH DRIVE END WORN ABOUT .040 INCH. SUBMITTER STATED FOUND ABOUT 50 PERCENT OF ALL THE GEARS ARE FOUND WORN WHEN INSPE CTED. 3 U E4CE 1997032000707 19970320 00707 SW 1997 3 20 97ZZZX1135 1 19970217 G 5260 212075418105 ACTUATOR BELL 412 412EP 1182205 SW STEP FAILED B GS1R K NONE O OTHER IN INSP/MAINT 1 EA 03 1207W 17 P86908 36149 STEP ACTUATOR FAILED. REPLACED WITH NEW LINEAR ACTUATOR. 1 G 7 2 4U H4SW 1997032000708 19970320 00708 1997 3 20 97ZZZX1136 4 19970212 G 3425 1113034 INDICATOR BELL 412 412EP 1182205 SW ROLL COMMAND STICKS B GS1R K NONE O OTHER IN INSP/MAINT 1 EA 03 12070 16 93041 36147 INDICATOR ROLL COMMAND BAR STICKS. REPLACED WITH NEW INDICATOR. 1 G 7 2 4U H4SW 1997032000709 19970320 00709 EU 1997 3 20 97ZZZX1137 1 19970306 G 6310 FREEWHEEL SHAFT SNIAS 350 AS350B 8680801 EU ENG POWER SHAFT EXTRA O RING B RC0R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 17 4035W 199 2912 DURING REPLACEMENT OF MODULE I MAG ASSEMBLY, DISCOVERED AN O-RING ON POWER SHAFT BETWEEN FREEWHEEL UNIT AND MAG SEALING RING HOLDER. THIS PARTICULAR MODEL ENGINE DOES NOT USE AN O-RING IN THIS LOCATION. THE PRESENCE OF THIS O-RING COULD R ESTRICT SOME FLOW OF OIL TO THE FREEWHEEL UNIT. THIS COMPONENT WAS NEVER WORKED ON BEFORE THIS SEAL REPLACEMENT. DEFEC T WAS PROBABLY DONE DURING ASSEMBLY BY MANUFACTURER. 1 G 7 1 3U H9EU 1997032000710 19970320 00710 SW 1997 3 20 97ZZZX1138 1 19970220 G 6320 206040272101 SEAL ASSY 206040015015 BELL 206 206L1 1182107 SW MAIN DRIVE FAILED D K NONE O OTHER IN INSP/MAINT 1 EA 23 531KH 5441 45581 DURING PRE-FLIGHT INSPECTION, MAIN DRIVESHAFT GREASE WAS FOUND ON FORWARD FIREWALL. AFTER FURTHER INVESTIGATION WHEN TH E DRIVESHAFT WAS REMOVED, THE AFT SEAL ASSEMBLY HAD BECOME DEBONDED FROM THE ALUMINUM CUP. THE ROTOR BRAKE HAD ALSO STA YED ENGAGED WITH A VERY SLIGHT CLEARANCE BETWEEN THE PUCKS AND DISC. IT APPEARS THAT THE ROTOR DISC HAD GOTTEN HOT ENOU GH TO MELT THE SEAL; THUS, ALLOWING GREASE TO SLING OUT. 1 G 7 1 3U H2SW 1997032000711 19970320 00711 GL 1997 3 20 97ZZZX1139 2 19970225 G 7210 6875776 NOZZLE 6894171 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL GEARBOX GOUGED B S EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 8639F 6734 CAG36146 1280431D CAE832846 DURING DISASSEMBLY OF ENGINE GEARBOX, NR 4 BEARING WAS FOUND NOT TO BE SEATED ALL THE WAY ON THE JOURNAL ON THE HELICAL GEAR DUE TO IMPROPER INSTALLATION. SUBSEQUENT INSPECTION FOUND THE 6875776 OIL NOZZLE GOUGED ON THE BOTTOM FLANGE BY TH E BEARING. REPLACED NOZZLE. 1 G 7 1 3U 3 U H3WE E4CE 1997032000712 19970320 00712 GL 1997 3 20 97ZZZX1140 2 19970226 G 7210 6876925 OIL TUBE 6894171 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL GEARBOX TOO SHORT B EOOR K NONE W INADEQUATE Q C IN INSP/MAINT 1 AL 03 8639F 6734 3420 CAG36146 1280431D CAE832846 INSPECTED OIL TUBE PER CEB1307 AND IS TOO SHORT PER REQUIREMENTS OF THE BULLETIN. PART WAS REPLACED. 1 G 7 1 3U 3 U H3WE E4CE 1997032000713 19970320 00713 NE 1997 3 20 97ZZZX1141 1 19970213 G 2435 230321586 V BAND CLAMP LUCAS 23081042 SKRSKY S76 S76C 8143008 NE START GEN CRACKED B P KS4R K NONE O OTHER IN INSP/MAINT 1 SO 17 986AH 223 94039 760438 DURING ENGINE CHANGE, DISCOVERED STARTER/GENERATOR V-BAND CLAMP T-BOLT CRACKED AT WELD. REPLACED CLAMP ASSEMBLY. 1 G 7 2 3U NC H1NE 1997032700061 19970327 00061 EU 1997 3 27 97ZZZX1143 1 19970218 G 6510 350A34015003 SHAFT SNIAS 350 AS350B2 8680813 EU T/R DRIVE CHAFED D P A K NONE O OTHER IN INSP/MAINT 1 WP 07 6095U 1103 M2869 2699 DURING AN ANNUAL INSPECTION, A RUB SPOT WAS FOUND ON THE SHORT SHAFT JUST AFT OF THE ENGINE. THIS IS A HARD AREA TO INS PECT WITH BOTH PIECES OF DRIVE SHAFT COVER IN PLACE. A CLOSE LOOK AT THIS AREA AT ANNUAL SHOULD BE DONE AS IT IS HARD T O SEE. THE REAR ENGINE MOUNTS WERE CHANGED AND THE PROBLEM WAS CORRECTED. 1 G 7 1 3U H9EU 1997032700062 19970327 00062 WP 1997 3 27 97ZZZX1144 1 19970304 G 7820 A1698 MUFFLER ROBSIN R22 R22ALPHA 7640104 WP FLAME TUBE BROKEN D A K NONE O OTHER IN INSP/MAINT 1 CE 07 8561V 831 0484 FOUND ON ANNUAL INSPECTION, FLAME TUBES BROKEN LOOSE INSIDE OF THE MUFFLER AND SEVERAL PIECES BLOCKING SOME OF THE EXHAU ST STACK OPENING. 1 G 7 1 3O H10WE 1997032700063 19970327 00063 1997 3 27 97ZZZX1145 1 19970114 G 3510 80321301 REGULATOR SCOTTAVATION OXY SYS MISOVERHAULED H L K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 99 1964 INVESTIGATION FOR AN OXYGEN REGULATOR MALFUNCTION, FOUND SOMEONE ATTEMPTED TO REMOVE THE VALVE FROM THE ASSEMBLY. THE U PPER HOUSING BROKE OFF LEAVING THE BROKEN SCREWS EMBEDDED IN THE LOWER HOUSING. SOMEONE REMOVED THE LOWER HOUSING, HYDR OSTATIC TESTED THE CYLINDER AND INSTALLED THE UPPER HOUSING INTO THE LOWER HOUSING WITHOUT REMOVING THE BROKEN SCREWS. T HE UPPER HOUSING WAS INSTALLED INTO THE LOWER HOUSING 60 DEGREES OUT OF ALIGNMENT BY USING THE REMAINING THREE MACHINED SCREW HOLES IN THE LOWER HOUSING. ASSEMBLING THE REGULATOR 60 DEGREES OUT OF ALIGNMENT WILL CAUSE A PROBLEM ON THE AIRC RAFT DURING INSTALLATION AND IN THE ACTIVATION OF THE CYLINDER ASSEMBLY. 1997032700064 19970327 00064 EA 1997 3 27 97ZZZX1146 2 19970210 G 8530 SL14995 SPRING CESSNA 172 172K 2072430 CE LYC O320 O320E2D 41508 EA ENG CYL BROKEN D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 25 100PD 17257902 L7598927A RECEIVING INSPECTION OF A NEWLY OVERHAULED ENGINE FOUND PUSH ROD HOUSING COULD BE POPPED OUT OF SEAT. REMOVED ROCKER CO VER AND FOUND HOLD-DOWN SPRING BROKEN. FURTHER INVESTIGATION FOUND 3 OF 4 PUSH ROD SPRINGS BROKEN. SUBMITTER SUSPECTS SPRINGS MISMANUFACTURED AND ARE BRITTLE. 1 H 7 1 3O 3 O NT 3A12 E274 1997032700065 19970327 00065 GL 1997 3 27 97ZZZX1147 1 19970206 G 3230 5533525 LOCK PIN NAMER T6 SNJ5 6400418 GL LT MLG DEFECTIVE C L A K NONE O OTHER TX TAXI/GRND HDL 1 NM 11 6900C 84867 AFTER A ROUTINE FLIGHT AFTER LANDING, STOPPED ON THE TAXIWAY AND RETRACTED THE FLAPS THEN TAXIED ON WHILE S-TURNING. AC FT WAS APPROXIMATELY TWO-THIRDS THE WAY DOWN THE TAXIWAY WHEN THE LEFT GEAR COLLAPSED PUTTING THE WING TIP AND PROPELLER INTO THE GROUND. INSPECTED THE LOCK-PIN ON THE LEFT SIDE, IT WAS RETRACTED, THEN INSP THE RIGHT GEAR AND FOUND THE LOC K-PIN OUT AND LOCKED. WHILE LOOKING AT THE LEFT GEAR LOCK-PIN NOTICED IT WAS SLOWLY WORKING ITS WAY OUT INTO THE LOCKED POSITION. ON LATER INSPECTION, PUTTING THE AIRCRAFT ON JACKS THE GEAR-LOCK MECHANISM FUNCTIONED PROPERLY. UPON REMOVI NG THE LOCK-PIN AND SPRING, SMALL FLAKES OF HARD CHROME WERE DETECTED FROM AROUND THE AFT OF HOUSING-BORE AND LOCK-PIN. 1 L 7 1 3R A2575 1997032700066 19970327 00066 SO 1997 3 27 97ZZZX1148 1 19970226 G 5720 CH20391 RIB REINFORCMENT 7400906 PIPER PA31 PA31350 7103110 SO LT MLG HANGS GEAR G L A O OTHER J WARNING INDICATION AP APPROACH 1 AL 01 792FC 1 1 317552108 UPON RETRACTION OF THE GEAR, THE BRAKE CALIPER FITTING P/N 754-857 OVERCENTERED INTO THE RIB CUT OUT AND THE GEAR WOULD NOT COME DOWN UPON EXTENSION. THE PILOT HAD TO 'G' LOAD THE AIRCRAFT AND EXTEND THE GEAR SIMULTANEOUSLY TO GET THE LEFT GEAR TO EXTEND. BOUNDRY LAYER RESEARCH ENGINEERING HAS APPROVED A CLEARANCE MODIFICATION TO PRECLUDE ANY FURTHER PROBL EMS WITH THE SUPER CHIEF II WING RIB REINFORCEMENT. STC SA002025E. 1 L 7 2 3O A20SO 1997032700067 19970327 00067 SO 1997 3 27 97ZZZX1149 1 19970228 G 3230 4027909 DRAG BRACE PIPER PA31 PA31310 7103103 SO RT MLG BROKEN B B2ER O OTHER J WARNING INDICATION CL CLIMB 1 EA 23 100RT 5029 31808 AD 96-10-14 APPLIES TO THIS SUBJECT DRAG BRACE. AIRCRAFT TOOK OFF ON GUSTY/WINDY DAY, GEAR WAS SEEN TO BEGIN TO RETRACT , RT MAIN DROPPED BACK OUT. FWD SIDE BRACE IN AREA SUBJECT TO PENETRANT INSP. PART WAS INSPECTED 84.0 HOURS EARLIER. S UBMITTER RECOMMENDED 5000 HOUR TIME RETIREMENT ALONG WITH 1200 HOUR IN SERVICE AFTER DATE OF AD. 1 L 7 1 3O RT A20SO 1997032700068 19970327 00068 SO 1997 3 27 97ZZZX1150 2 19970207 G 7414 DISTRIBUTOR GEAR BENDIX BEECH 58 58TC 1152746 CE CONT O520 TSIO520L 17040 SO MAG BROKE B BIOR A E UNSCHED LANDING ENGINE SHUTDOWN J WARNING INDICATION NR NOT REPORTED 1 EA 23 117HS 3695 A156805 TK21 508213 DISTRIBUTION GEAR BROKE AND CONTACT STUCK ON NR 2 CYL LEAD. MAG CONTINUED TO ROTATE CAUSING ONLY NR 2 CYL TO FIRE EACH TIME POINTS OPENED. THIS CAUSED SEVERE DETONATION IN NR 2 CYL BURNING A HOLE THROUGH PISTON. THIS RESULTED IN AN INFLI GHT SHUT DOWN. ENGINE INSP, AND FOUND TO BE CONTAMINATED WITH METAL. ENGINE REPLACED. SUBMITTER STATED IMPROPER MAINT AND OVERHAUL TIME OF MAG NOT C/W. 1 L 7 2 3O 3 O A23CE E8CE 1997032700072 19970327 00072 CE 1997 3 27 97ZZZX1154 1 19970225 G 3230 08421211 TUBE ASSY CESSNA 310 310L 2074230 CE NLG LINKAGE BROKEN G A K NONE O OTHER IN INSP/MAINT 1 CE 05 3285X 310L0135 TUBE MAY BECOME BENT DUE TO HIGH AIR SPEED WHEN GEAR IS EXTENDED. AFTER INITIAL BENDING, TUBE WILL FLEX WITH EACH CYCLE EVENTUALLY BREAKING. THIS TUBE IS HARD TO INSPECT DUE TO THE LOCATION IN THE A/C. SUBMITTER SUGGESTED TUBE BE REMOVED AND INSPECTED EACH 2000 HOURS. 1 L 7 2 3O 3A10 1997032700073 19970327 00073 CE 1997 3 27 97ZZZX1155 1 19970303 G 2823 13341511 VALVE WHITTAKER MTSBSI MU2 MU2B60 5780460 CE MAIN FUEL SOV STUCK D K NONE O OTHER IN INSP/MAINT 1 GL 25 350RG 2946 773SA FOUND LEFT MAIN FUEL SHUT-OFF VALVE STUCK IN CLOSED POSITION. MANUALLY OPERATED VALVE AFTER REMOVAL AND VALVE BEGAN TO WORK PROPERLY. REINSTALLED AND VALVE OPERATED GOOD. SUGGEST OPERATION OF VALVE PERIODICALLY TO PREVENT STICKING. 1 H 7 2 3T RT A10SW 1997032700074 19970327 00074 CE 1997 3 27 97ZZZX1156 1 19970217 G 7120 50980002521 PLATE BEECH 90 E90 1152914 CE ENG MT CORRODED B AKGR K NONE O OTHER IN INSP/MAINT 1 CE 05 50EB 7946 LW128 ENGINE MOUNT PLATE AND SHIM WERE FOUND CORRODED UNDER THE AREA OF THE LEFT AND RIGHT ENGINE MOUNT TO FIREWALL ATTACHMENT . THE SHIMS WERE FLAKING AWAY SEVERELY AND IF LEFT UNREPAIRED, WOULD CAUSE THE MOUNT TO FIREWALL BOLT TORQUE TO DROP. T HESE PARTS SHOULD BE MADE OF STAINLESS STEEL. 1 L 7 2 3T 3A20 1997032700075 19970327 00075 CE 1997 3 27 97ZZZX1157 1 19970217 G 7120 50980002523 SHIM BEECH 90 E90 1152914 CE ENG MT CORRODED B AKGR K NONE O OTHER IN INSP/MAINT 1 CE 05 50EB 7946 LW128 ENGINE MOUNT PLATE AND SHIM WERE FOUND CORRODED UNDER THE AREA OF THE LEFT AND RIGHT ENGINE MOUNT TO FIREWALL ATTACHMENT . THE SHIMS WERE FLAKING AWAY SEVERELY AND IF LEFT UNREPAIRED, WOULD CAUSE THE MOUNT TO FIREWALL BOLT TORQUE TO DROP. T HESE PARTS SHOULD BE MADE OF STAINLESS STEEL. 1 L 7 2 3T 3A20 1997032700076 19970327 00076 SO 1997 3 27 97ZZZX1158 1 19970303 G 2810 48603 TANK LUSCOM 8 8A 8190104 SO FUSELAGE WELD WORN D S A K NONE O OTHER IN INSP/MAINT 1 EA 23 71231 1838 2678 TANK WORN FROM INTERIOR UPHOLSTERY PANEL VIBRATING AGAINST WELD. COULD BE CATASTROPHIC, DUMPING 14 GALS FUEL INTO CABIN AND AFT FUSELAGE. SUBMITTER STATED HAVE FOUND THIS IN NUMEROUS LUSCOMBES WITH FUS TANKS. RECOMMEND INSPECTING FOR DAM AGE TO EDGE WELD. IF STILL AIRWORTHY PUT FELT SPACERS ON PANEL TO KEEP PANEL AWAY FROM TANK. OTHERWISE, PURGE TANK AND RE-WELD OR REPLACE WITH AIRWORTHY TANK. 1 H 7 1 3O A694 1997032700077 19970327 00077 SO 1997 3 27 97ZZZX1159 2 19970227 G 8530 631475 PISTON BEECH 33 35C33A 1151410 CE CONT O520 IO520BA 17032 SO 1ST-2ND RING BROKEN B IQ4R K NONE O OTHER IN INSP/MAINT 1 SO 09 9480S CE6 1208025B INSTALL NEW TCM CYLINDER AND VALVE ASSY USED SA 631475 PISTON DUE TO WEIGHT DIFFERENCE (TO BALANCE PISTON SET). INSTALL TCM RING SET. FLEW 228.1 HOURS. REMOVE CYL DUE TO ENG MISSING. FOUND TOP OF PISTON AND 1ST RING GLAND BROKEN. TOP 2 RINGS BROKEN. REASON UNKNOWN. 1 L 7 1 3O 3 O 3A15 E5CE 1997032700078 19970327 00078 SW 1997 3 27 97ZZZX1160 1 19970214 G 2410 646655 HUB 649304 MOONEY M20 M20R 5870225 SW ALT DRIVE FAILED D O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 NM 09 97ST 62 L1595020 290101 ALTERNATOR FAILURE IN-FLIGHT. INVESTIGATION REVEALED ALT DRIVE HUB HAD FAILED. 1 L 7 1 3O RT 2A3 1997032700079 19970327 00079 CE 1997 3 27 97ZZZX1161 1 19970221 G 2612 FIRE LOOP CESSNA 500 500CESSNA 2076602 CE LT ENGINE CHAFED B FJTR K NONE N FALSE WARNING NR NOT REPORTED 1 SO 03 38MH 5000265 LEFT ENGINE FIRE LIGHT. INVESTIGATION FOUND LEFT FIRE LOOP WAS CHAFING ON ENGINE CASE. REPOSTIONED FIRE LOOP. 1 L 7 2 4F A22CE 1997032700080 19970327 00080 CE 1997 3 27 97ZZZX1162 1 19970312 G 2150 1179100609 PIVOT BEECH B300 B300 1159232 CE AIR COND MOUNT BROKEN D A E ENGINE SHUTDOWN E VIBRATION/BUFFET NR NOT REPORTED 1 SO 05 507EB 1505 FL81 THIS PIVOT P/N 117-910060-9, (I.P.B. KINGAIR 350 MODEL B300 AND B300C) BOOK P/N 130-590031-9A7 CHAPTER 21-50-20, PAGE 4, FIG 50-20, HAS BEEN FOUND BROKEN ON THE LAST TWO KINGAIR 350'S THAT INSPECTIONS WERE PERFORMED ON. BOTH AIRCRAFT HAD L ESS THAN 2,000 HOURS OPERATING TIME. WHEN THE PIVOT BREAKS AT ONE END, IT ALLOWS THE AIR CONDITIONING COMPRESSOR TO MOV E AND STARTS A VIBRATION THAT CAN BE MISTAKEN FOR AN ENGINE VIBRATION, RESULTING IN AN ENGINE SHUT DOWN. IT APPEARS THI S PIVOT IS NOT MADE TO WITHSTAND THE STRESS FROM THE AIR CONDITIONER COMPRESSOR WHEN ENGAGED AND SHUT DOWN. RECOMMEND A LL THESE PIVOTS BE REMOVED FROM AIRCRAFT AND NEW DESIGNED STRONGER PIVOTS INSTALLED. 2 L 7 2 4T RT A24CE 1997032700081 19970327 00081 1997 3 27 97ZZZX1163 4 19970210 G 2562 E01 ELT BEECH 23 C23 1151242 CE FUSEAGE FAILED D K NONE O OTHER IN INSP/MAINT 1 GL 25 9793L 014104 M1398 AKC EMERGENCY LOCATOR TRANSMITTER INSTALLED 12-05-94 WITH DURACELL MN 1300 BATTERIES WITH AN EXPIRATION DATE OF JANUARY 1999. WHILE INSPECTING IAW FAR 91.207(D), FOUND ONE OF THE BATTERIES HAD BEEN LEAKING. SOME OF THE FLUID LEAKED OUT OF THE CASE AND CAUSED A SMALL AMOUNT OF CORROSION ON THE MOUNTING TRAY. THERE WAS SOME CORROSION ON THE BOTTOM SPRING IN THE CASE. REPLACED THE BATTERIES WITH NEW MN 1300 BATTERIES AND FOUND THE ELT DID NOT OPERATE PROPERLY. RETURNED THE ELT TO THE MANUFACTURER FOR REPAIR. 1 L 7 1 3O A1CE 1997032700234 19970327 00234 WP 1997 3 27 97ZZZX1164 1 19970310 G 2921 4365082 DIAPHRAGM DOUG DC8 DC8* WP AUX HYD ACCUM TORN B DM4R K NONE O OTHER IN INSP/MAINT 1 SO 19 JW2897 AUXILIARY HYD POWER SURGE DAMPER ACCUMULATOR TANK HAD NEW DIAPHRAGM INSTALLED AT OVERHAUL. DIAPHRAGM FAILED (TORN) AFTE R 5 MONTHS TIME IN SERVICE. 2ND REPORT. THIS PART WAS OBTAINED FROM THE MANUFACTURER. 2 L 7 4 4J F 4A25 1997032700235 19970327 00235 WP 1997 3 27 97ZZZX1165 1 19970310 G 2921 4365082 DIAPHRAGM 43442795002 DOUG DC8 DC8* WP AUX HYD ACCUM TORN B DM4R K NONE O OTHER IN INSP/MAINT 1 SO 19 1620 AUXILIARY HYD POWER SURGE DAMPER ACCUMULATOR TANK HAD NEW DIAPHRAGM INSTALLED AT OVERHAUL. DIAPHRAGM FAILED (TORN) AFTE R 2 MONTHS TIME IN SERVICE. DIAPHRAGM SEPARATES HYD FLUID AND AIR. THIS PART WAS OBTAINED FROM THE MANUFACTURER. 2 L 7 4 4J F 4A25 1997032700236 19970327 00236 NE 1997 3 27 97ZZZX1166 3 19970305 G 6111 8022581 BLADE SAAB SF340 SF340A 7850100 EU HAMSTD 14RF 14RF19 NE SHANK FILLET CRACKED B H2SR K NONE O OTHER IN INSP/MAINT 1 SO 13 4770 DURING DYE CHECK OF THE BLADE SHANK, CRACK INDICATION IN THE BEARING RACE FILLET RADIUS WAS OBSERVED. THE INDICATION IS LOCATED APPROXIMATELY 170 DEGREES FROM THE BLADE PIN, CLOCKWISE, AS VIEWED FROM THE BUTT END. THE INDICATION IS APPROX IMATELY .300 INCH LONG, AND IS ORIENTED CIRCUMFERENTIALLY IN THE RADIUS. 2 L 7 2 4T RT A52EU 6 C P11NE 1997032700240 19970327 00240 CE 1997 3 27 97ZZZX1170 1 19970305 G 2435 23085001 ALTERNATOR LUCAS BEECH 300 300BEECH 1152930 CE LT START/GEN SEIZED D K NONE H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 SO 13 3237S 92 96055 FA163 THE PILOT REPORTED THE LEFT GENERATOR INOPERATIVE. UPON INVESTIGATION, THE GENERATOR WAS FOUND TO BE MECHANICALLY SEIZE D DUE TO APPARENT FAILURE OF THE ARMATURE RETAINING RING. 2 L 7 2 4T A24CE 1997032700241 19970327 00241 CE 1997 3 27 97ZZZX1171 1 19970211 G 3340 900336 LIGHT WHELEN BEECH MU300 400BEECH CE ANTI COLL HARDWARE LOOSE B A JEMR K NONE G MULTIPLE FAILURE NR NOT REPORTED 1 CE 01 402FB 594 10600122 RJ2 FOUND CAPACITOR IN UNIT LOOSE, AND SIDE COVER MOUNTING HARDWARE LOOSE AND ARCING TO DC BUSS OF AIRCRAFT. CAUSED BULB FI LAMENT TO BECOME FUSED TO UPRIGHTS OF FILAMENT. THIS WAS PRODUCING A 5 VAC PULSE AT 50 MICROSEC ON THE DC BUSS OF AIRCR AFT WHICH SHUT DOWN BOTH AC INVERTERS. CAUSED TAIL DE-ICE CONTROL BOX TO LOCK UP IN A STATE OF FAILURE AND LANDING FLAP DELAY. FIRST FAILURE, 216 TT 7-2-95, 2ND FAILURE 2-11-97. RECOMMEND DIFFERENT STYLE OF SIDE COVERS ON ANTI-COLLISION LIGHT. 2 H 7 2 4F RT A16SW 1997032700243 19970327 00243 CE 1997 3 27 97ZZZX1173 1 19970115 G 3710 442CW4 PUMP BEECH 58 58P 1152744 CE LT-RT VAC INOPERATIVE G A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 GL 03 6371V TJ417 PILOT REPORTED GYRO WAS OUT. (IFR) A/C DIVERTED TO RFD. BOTH INSTRUMENT VACUUM PUMPS FAILED, LT AND RT. NO FAULT COUL D BE FOUND THAT WOULD CAUSE BOTH PUMPS TO FAIL SIMULTANEOUSLY. TOTAL TIME OF PUMPS UNKNOWN. RECOMMEND LOG BOOK ENTRIES BE MADE WHEN VACUUM ADJUSTMENTS ARE MADE. LOGS SHOULD BE EXAMINED DURING INSPECTIONS TO DETERMINE IF REGULATORS HAVE B EEN ADJUSTED TO COMPENSATE FOR FAILING PUMPS. 1 L 7 2 3O A23CE 1997032700244 19970327 00244 EA 1997 3 27 97ZZZX1174 2 19970218 G 7261 3034393A FILTER BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA ENG OIL SCREEN FAILED B DX4R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 03 711MB 665 BB437 80969 THE INNER CONE SHAPED SCREEN HAD SEPARATED ON OIL FILTER. SEPARATION APPEARED TO BE AT A SEAM ON THE SCREEN. 1 L 7 2 4T 4 T A24CE E4EA 1997032700245 19970327 00245 CE 1997 3 27 97ZZZX1175 1 19970225 G 3243 45AS38401012 CYLINDER ASSY BEECH MU300 400A 1155402 CE RT BRAKE NUT DETACHED B L A UJDR A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 EA 05 10J 2545 RK31 CLIMBING OUT AT FL 300 AT APPROX 120 MILES FROM THE AIRPORT, THE HYD FLUID LOW ANNUNCIATOR ILLUMINATED. THE PILOTS DECI DED TO RETURN TO THE AIRPORT TO HAVE THE ACFT CHECKED. THE EMER GEAR EXT SYS WAS EMPLOYED TO LOWER THE GEAR AND THE EME R BRAKING WAS USED AFTER LANDING. UPON INSP OF THE ACFT, IT WAS NOTED THAT HYD FLUID WAS DRIPPING FROM THE FUSELAGE AND THAT THE HYD FLUID RESERVOIR WAS EMPTY. FURTHER INSP DISCLOSED THAT THE CAUSE OF THE HYD LEAK WAS A FAILED PILOT'S RT BRAKE MASTER. THE PISTON ROD HAD BECOME DISCONNECTED FROM THE CYL BARREL ASSEMBLY. UPON DISASSEMBLY OF THE CYL, IT WAS DISCOVERED THAT THE PISTON RETAINING NUT P/N NAS 679C08W HAD BECOME UNTHREADED FROM THE PISTON ROD. 2 H 7 2 4F RT A16SW 1997032700246 19970327 00246 EU 1997 3 27 97ZZZX1176 1 19970210 G 5610 7256100502 WINDSHIELD SAAB SF340 SF340A 7850100 EU COCKPIT DEFECTIVE B P9AR K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 05 THIS WINDOW WAS RECENTLY OVERHAULED FOR COMAIR. COMAIR SENT THE WINDOW FOR EVALUATION DUE TO VARIOUS DEFECTS. WINDSHI ELD HAS MAJOR DISTORTION. PHOTO REVEALS DISTORTION OF 1:3 IN CRITICAL OPTICAL AREAS. ACCEPTABLE DISTORTION IS 1:10. O UTSIDE WEATHER SEAL SHOWS SEAL TO BE .860 INCH TO 1.10 INCH; SEAL SHOULD BE .820 INCH PLUS OR MINUS .030 INCH. VARIOUS FRACTURES. 2 L 7 2 4T RT A52EU 1997032700247 19970327 00247 CE 1997 3 27 97ZZZX1177 1 19970219 G 2720 040010749 CONTROL CABLE CESSNA 150 152 2071835 CE RUDDER FRAYED C K NONE O OTHER IN INSP/MAINT 1 EA 21 47962 5025 15283264 RUDDER CABLES ARE FRAYING IN AFT BULKHEAD ON TOP OF PULLEYS. YOU MUST MOVE RUDDER IN OPPOSITE DIRECTION AND FEEL FWD AN D AFT OF PULLEY TO DETERMINE IF CABLE IS FRAYED. IN SOME CASES, THIS IS NOT A GUARANTEE THAT IT IS NOT FRAYED. 1 H 7 1 3O NT 3A19 1997032700248 19970327 00248 CE 1997 3 27 97ZZZX1178 1 19970219 G 2710 040010758 CONTROL CABLE CESSNA 150 152 2071835 CE RT WING FRAYED C K NONE O OTHER IN INSP/MAINT 1 EA 21 47962 5025 15283264 REMOVED PANEL AT FLAP OUTBOARD HINGE AREA. INSPECTED AFT CABLE FOR WEAR WHERE IT GOES OVER ANTI-CHAFE BOX. THIS IS SEC OND AIRCRAFT THAT AILERON CABLE WAS FOUND FRAYED AT THIS POINT. 1 H 7 1 3O NT 3A19 1997032700249 19970327 00249 CE 1997 3 27 97ZZZX1179 1 19970117 G 2434 ALV8402 ALTERNATOR CESSNA 310 310Q 2074242 CE DC SYSTEM FAILED G A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CR CRUISE 1 GL 03 6248Q 310Q0746 PILOT LOST RADIO CONTACT AND DIVERTED TO ALTERNATE AIRPORT. INVESTIGATION REVEALED ELECTRICAL POWER LOSS DUE TO ALTERNA TOR, ALTERNATOR SENSOR, AND ALTERNATOR BELT FAILURE. 1 L 7 2 3O 3A10 1997032700250 19970327 00250 CE 1997 3 27 97ZZZX1180 1 19970117 G 2430 99100943 SENSOR CESSNA 310 310Q 2074242 CE ALTERNATOR FAILED G A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CR CRUISE 1 GL 03 6248Q 310Q0746 PILOT LOST RADIO CONTACT AND DIVERTED TO ALTERNATE AIRPORT. INVESTIGATION REVEALED ELECTRICAL POWER LOSS DUE TO ALTERNA TOR, ALTERNATOR SENSOR, AND ALTERNATOR BELT FAILURE. 1 L 7 2 3O 3A10 1997032700251 19970327 00251 CE 1997 3 27 97ZZZX1181 1 19970117 G 2410 5395473500 BELT CESSNA 310 310Q 2074242 CE ALT DRIVE FAILED G A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CR CRUISE 1 GL 03 6248Q 310Q0746 PILOT LOST RADIO CONTACT AND DIVERTED TO ALTERNATE AIRPORT. INVESTIGATION REVEALED ELECTRICAL POWER LOSS DUE TO ALTERNA TOR, ALTERNATOR SENSOR, AND ALTERNATOR BELT FAILURE. 1 L 7 2 3O 3A10 1997032700252 19970327 00252 CE 1997 3 27 97ZZZX1182 1 19970219 G 2720 040010750 CONTROL CABLE CESSNA 150 152 2071835 CE RUDDER FRAYED C K NONE O OTHER IN INSP/MAINT 1 EA 21 67376 3060 15281792 RUDDER CABLES ARE FRAYING IN AFT REAR BULKHEAD ON TOP OF PULLEYS. SUBMITTER STATED YOU MUST MOVE RUDDER IN OPPOSITE DIR ECTION AND FEEL FWD AND AFT OF PULLEYS TO DETERMINE IF CABLE IS FRAYED. 1 H 7 1 3O NT 3A19 1997032700253 19970327 00253 CE 1997 3 27 97ZZZX1183 1 19970303 G 7160 646020 HOSE ELBOW CESSNA 414 414A 2075907 CE ENG INDUCTION BLOWN D K NONE R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 NM 10 6624C 414A0034 ENG INDUCTION HOSE BLOWN OUT CAUSING INDUCTION LEAKAGE AND ENG PERFORMANCE DEGRADATION IN ALL PWR MODES. RECOMMEND CHAN GING THE MATERIAL HOSES ARE MADE FROM. THIS IS THE THIRD OCCURENCE IN LESS THAN 600 HRS. 1 L 7 2 3O A7CE 1997032700254 19970327 00254 SO 1997 3 27 97ZZZX1184 1 19970202 G 2434 ALTERNATOR PIPER PA23 PA23250 7102308 SO DC SYS FAILED G O OTHER H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 GL 03 6943A 277954117 BOTH ELECTRICAL SYSTEMS FAILED IN-FLIGHT. RIGHT ALTERNATOR FAILED IN-FLIGHT. LEFT ALTERNATOR INOP LIGHT WAS NOT ILLUMI NATED DUE TO A BROKEN WIRE ON THE LIGHT CONCEALING A FAILED LEFT ALTERNATOR. SUBMITTER RECOMMENDATION: ADD INSPECTION OF ALTERNATOR INOP INDICATORS TO NORMAL INSPECTION PROGRAM. 1 L 7 2 3O 1A10 1997032700255 19970327 00255 CE 1997 3 27 97ZZZX1185 1 19970303 G 3230 574122218 HOOK ASSY CESSNA 414 414A 2075907 CE RT MLG MALFUNCTION D A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 WP 13 4686N 414A0075 PILOT REPORTED THAT AFTER GEAR RETRACTION ON TAKEOFF, THE GEAR UNLOCK RED LIGHT AND THE HYDRAULIC PRESSURE MASTER CAUTIO N LIGHT REMAINED ILLUMINATED. ACFT LANDED WITHOUT INCIDENT. AIRCRAFT PLACED ON JACKS AND GEAR OPERATIONAL CHECK ACCOMP LISHED. DISCREPANCY DUPLICATED. IT WAS DISCOVERED THAT THE RT MLG UPLOCK HOOK ASSEMBLY WAS NOT ENGAGING THE UPLOCK ROL LER P/N 5141206-1. THE HOOK ASSEMBLY, ATTACHING BOLT P/N NAS464P6-8, BUSHING P/N NAS75-6-117 AND BEARING BLOCK P/N 5T14 1203-3 WERE REMOVED, CLEANED, LUBRICATED AND REINSTALLED. GEAR CYCLED SIX (6) TIMES WITH NO DISCREPANCIES. SUBMITTER S TATED THESE AREAS BE LUBRICATED AFTER WASHING. ACFT RETURNED TO SERVICE. 1 L 7 2 3O A7CE 1997032700256 19970327 00256 GL 1997 3 27 97ZZZX1186 2 19970225 G 7210 6875035 BEARING 6894171 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL GRBOX PITTED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 8639F 6734 3420 CAG36146 1280431D CAE832846 DURING INSPECTION OF ENGINE GEARBOX, BEARING WAS FOUND TO BE PITTED ON SEVE RAL ROLLERS. 1 G 7 1 3U 3 U H3WE E4CE 1997032700257 19970327 00257 GL 1997 3 27 97ZZZX1187 2 19970225 G 7210 6851505 PICOLLO TUBE 6894171 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL GRBOX BURRS B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 8639F 6734 3420 CAG36146 1280431D CAE832846 INSPECTED PICOLLO TUBE PER CEB 1177 (S/N BN16959) AND FOUND BURRS - SCRAPPED PER CEB. 1 G 7 1 3U 3 U H3WE E4CE 1997032700258 19970327 00258 CE 1997 3 27 97ZZZX1188 1 19970227 G 7160 11111 ELBOW CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO NR 2 INDUCTION TORN D A O OTHER R PARTIAL RPM/PWR LOSS CR CRUISE 1 WP 13 6604C 414A0030 519399 PILOT REPORTED THAT THE RIGHT ENGINE WOULD NOT MAINTAIN POWER. MANIFOLD PRESSURE DECREASED DURING FLIGHT. TAKEOFF POWE R OKAY ON BOTH ENGINES. DURING CLIMB, THE RIGHT ENGINE ONLY DEVELOPED 27 IN HG. IT WAS DISCOVERED THAT THE INBOARD IND UCTION ELBOW RAM P/N 1111-1, LOCATED BETWEEN THE INTERCOOLER ASSEMBLY P/N 635921 AND NR 2 INTAKE MANIFOLD ELBOW P/N 6425 90 HAD TORN. INDUCTION ELBOW REPLACED. ENGINE RUN UP OKAY. AIRCRAFT RETURNED TO SERVICE. SUBMITTER STATED IT IS NOT UNCOMMON FOR THE RAM P/N 1111-1 OR TCM P/N 646020 INDUCTION TO TEAR. 1 L 7 2 3O 3 O A7CE E8CE 1997032700259 19970327 00259 GL 1997 3 27 97ZZZX1189 3 19970226 G 6111 A971 BEARING GULSTM 500 500A 0141104 SW HARTZL HCA3V HCA3VK2 GL PROP BLADE CRACKED B CBCR K NONE O OTHER IN INSP/MAINT 1 NM 03 9382R 131 500A8998 BJ146 BLADE BEARING RACE, P/N A971, FOUND CRACKED. PROP CAME IN FOR TBO (135 OP.). HAD NO PROBLEMS ON AIRCRAFT. 1 H 7 2 3O 6A1 5 C P6EA 1997032700260 19970327 00260 GL 1997 3 27 97ZZZX1190 3 19970226 G 6111 A971 BEARING GULSTM 500 500A 0141104 SW HARTZL HCA3V HCA3VK2 GL PROP BLADE CRACKED B S CBCR K NONE O OTHER IN INSP/MAINT 1 NM 03 9382R 141 500A8998 BJ146 BLADE BEARING RACE, P/N A971, FOUND CRACKED. CAME IN FOR TBO (135 OP.). HAD NO PROBLEMS ON AIRCRAFT. 1 H 7 2 3O 6A1 5 C P6EA 1997032700261 19970327 00261 CE 1997 3 27 97ZZZX1191 1 19970201 G 3211 23221971 BUSHING LEAR 60 60LEAR 5170707 CE MLG AFT TRUNNION MISALIGNED H K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 227N 049 AFT MAIN GEAR TRUNNION BUSHING NOT LINED UP WITH FORWARD BEARING. CORRECTED BY FOLLOWING PROCEDURES IN SRM 51-71-05. I NSTALLED NEW BUSHING, THEN LINE REAMED TO FORWARD BEARING LOCATION. 2 L 7 2 4F RT A10CE 1997032700262 19970327 00262 CE 1997 3 27 97ZZZX1192 1 19970201 G 3211 23221981 BUSHING LEAR 60 60LEAR 5170707 CE MLG AFT TRUNNION MISALIGNED H K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 227N 049 AFT MAIN GEAR TRUNNION BUSHING NOT LINED UP WITH FORWARD BEARING. CORRECTED BY FOLLOWING PROCEDURES IN SRM 51-71-05. I NSTALLED NEW BUSHING, THEN LINE REAMED TO FORWARD BEARING LOCATION. 2 L 7 2 4F RT A10CE 1997032700277 19970327 00277 CE 1997 3 27 97ZZZX1193 1 19970101 G 8120 4810B49001 WASTEGATE CESSNA 421 421 2076010 CE CONT O520 GTSIO520H 17032 SO ENG TURBO CRACKED D P K NONE O OTHER IN INSP/MAINT 1 SW 99 1361 DURING AN OIL AND FILTER CHANGE, THE WASTEGATE CRACK DEFECT WAS FOUND. DEFECT NOT PRESENT AT 50 HOUR CHECK 50 HOURS PRE VIOUS. 1 L 7 2 3O 3 O RT A7CE E7CE 1997032700278 19970327 00278 EA 1997 3 27 97ZZZX1194 2 19970304 G 8550 LINE SOCATA TB20 TB21 8680697 EU LYC O540 TIO540AB1A 41533 EA TURBO OIL FAILED D P A A UNSCHED LANDING K FLUID LOSS NR NOT REPORTED 1 WP 23 20NB 1738 557 INFLIGHT FAILURE OF THE TURBOCHARGER OIL RETURN LINE BETWEEN THE TURBOCHARGER HOUSING AND A SMALL RESERVOIR CAN LOCATED UNDER THE ENGINE. THE AIRCRAFT LOST 9 QUARTS OF OIL INFLIGHT AND WAS LANDED WITHOUT INCIDENT. THE OIL RETURN LINE WAS FOUND WITH A CRACK RUNNING AROUND 300 DEGREES OF THE TUBE'S CIRCUMFERENCE WHERE IT MADE A SWEEPING 90 DEGREE BEND BELOW THE MOUNTING FLANGE. MATERIAL FATIGUE FAILURE IN THE 90 DEGREE RADIUS BEND OF THE OIL RETURN LINE TUBE BETWEEN THE 2 BO LT MOUNTING FLANGE TO THE TURBOCHARGER HOUSING AND OIL RESERVOIR CAN. VISUAL INSPECTION INDICATES THAT THE OUTER RADIUS WALL THICKNESS WAS MUCH THINNER THAN THE INNER RADIUS WALL THICKNESS WHERE THE CRACK OCCURRED. 1 L 7 1 3O 3 O RT A51EU E14EA 1997032700279 19970327 00279 EA 1997 3 27 97ZZZX1195 2 19970217 G 8530 S14995 SPRING CESSNA 182 T182 2072736 CE LYC O540 O540L3C5 41532 EA CYL SHROUD TUBE BROKEN B L A WTXR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 07 201SP 18268313 L2385040A AFTER AN INITIAL TEST FLIGHT OF 1.1 HOURS, IT WAS NOTED THAT A LARGE AMOUNT OF OIL HAD COLLECTED ON THE RT SIDE OF THE E NG. FURTHER INSP REVEALED THAT THE PUSHROD HOUSING ON THE INTAKE SIDE OF THE NR 1 CYL RETAINING SPRING WAS FOUND TO BE BROKEN. WHEN THE REMAINING ROCKER COVERS WERE REMOVED, THE PUSHROD RETAINING SPRING FROM THE NR 5 CYLINDER WAS FOUND TO BE CRACKED. THESE PARTS WERE INSTALLED FROM A SUPERIOR AIR PARTS GASKET SET SL 13377 PURCHASED FROM SUPERIOR JAN. 1997 . SUPERIOR SL 94-002 AND LYCOMING SB 519 ADDRESSED THE PROBLEM OF CERTAIN SHROUD TUBE RETAINING SPRINGS THAT WERE BREAK ING IN SERVICE. HOWEVER, THOSE SPRINGS WERE MADE AND SOLD IN 1994. THESE SPRINGS WERE SOLD IN 1997. 1 L 7 1 3O 3 O 3A13 E295 1997032700280 19970327 00280 CE 1997 3 27 97ZZZX1196 1 19970301 G 3340 S21604 SWITCH CESSNA 172 172M 2072418 CE LANDING LIGHT CORRODED D K NONE M OVER TEMP IN INSP/MAINT 1 NM 01 9730H 17266338 DURING ANNUAL INSPECTION, DISCOVERED WIRE TERMINAL AT LANDING LIGHT SWITCH PARTIALLY MELTED CAUSED BY INCREASED RESISTAN CE DUE TO CORRODED WIRES AT TERMINAL. REPLACED TERMINALS. FOUND SIMILAR CONDITION ON 1 OTHER TYPE A/C. 1 H 7 1 3O NT 3A12 1997032700281 19970327 00281 CE 1997 3 27 97ZZZX1197 1 19970311 G 3246 HUB CESSNA 172 172M 2072418 CE WHEEL HALF WORN D K NONE O OTHER IN INSP/MAINT 1 NM 01 9730H 17266338 WHEN NOSE WHEEL WAS REMOVED TO GREASE BEARINGS, DISCOVERED THAT BEARING CUP (KOYO MFG) WAS LOOSE IN WHEEL HUB. WHEEL HUB WAS WORN WHERE CUP HAD BEEN SPINNING IN HUB. THE CUP IS NORMALLY A PRESS FIT INTO THE WHEEL. A/C HAD NOSE WHEEL SHIMM Y COMPLAINT PRIOR TO DISCOVERY. REPLACED RACE AND WHEEL HALF. 1 H 7 1 3O NT 3A12 1997032700282 19970327 00282 CE 1997 3 27 97ZZZX1198 1 19970223 G 3222 1243009201 FORK CESSNA 210 P210N 2073454 CE NLG FAILED G S K NONE O OTHER LD LANDING 1 WP 27 323DC P21000384 ON PROBABLE HARD LANDING, THE NOSE LANDING GEAR BROKE, WHERE THE FORKS ATTACH TO THE PISTON. NO RECOMMENDATIONS. 1 H 7 1 3O 3A21 1997032700283 19970327 00283 CE 1997 3 27 97ZZZX1199 1 19970304 G 2140 75D80 MOTOR JANITROL B4050 BEECH 58 58 1152740 CE COMBUSTION AIR RUNS BACKWARD E A K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 05 401SB 163 3751454 TH641 FOUND HEATER RUNS RICH, AFTER A LONG TROUBLESHOOTING TIME DISCOVERED COMBUSTION AIR FAN MOTOR RAN BACKWARDS. 1 L 7 2 3O 3A16 1997032700284 19970327 00284 CE 1997 3 27 97ZZZX1200 1 19970305 G 3710 4502003 SHUTTLE VALVE BEECH 33 35C33 1151408 CE VAC PUMP FAILED D S A K NONE O OTHER IN INSP/MAINT 1 NM 09 4887J 1000 68888233 CD1076 CHECK VALVE FAILED ON ENGINE DRIVEN VACUUM PUMP. SIDE RIVET HEAD SEPARATED FROM VALVE ASSEMBLY. RENDERED VALVE INOP. 1 L 7 1 3O 3A15 1997032700285 19970327 00285 CE 1997 3 27 97ZZZX1201 1 19970310 G 3211 LANDING GEAR CESSNA 150 150 2071802 CE MLG BOX RIVET SHEARED D K NONE O OTHER IN INSP/MAINT 1 SW 07 5960E 17460 BOX THAT HOLDS SPRING STEEL LANDING GEAR HAD TWO RIVETS WITH THE FACTORY HEADS SHEARED OFF. SKIN ON THE OUTSIDE AFT OF LANDING GEAR WAS WRINKLED. SUSPECT CAUSED BY A HARD LANDING. AIRFRAME TOTAL TIME 4580 HRS. 1 H 7 1 3O NT 3A19 1997032700286 19970327 00286 EU 1997 3 27 97ZZZX1202 1 19970306 G 2820 190620 COUPLING HOACAU DV20 DV20 4170001 EU FUEL LINE DISCONNECTED D K NONE K FLUID LOSS NR NOT REPORTED 1 SW 99 194DV 916 20094 AIRCRAFT MAIN FUEL LINE BECAME DISCONNECTED AT INLINE ELECTRIC FUEL PUMP QUICK DISCONNECT FITTING. QUICK DISCONNECT IS INSTALLED TO FACILITATE FUEL PUMP FILTER MAINTENANCE. FUEL SYSTEM SHOULD BE MODIFIED TO SYSTEM INSTALLED ON LATE MODEL DA-20 KATANAS. 1 L 7 1 3O A74EU 1997032700288 19970327 00288 1997 3 27 97ZZZX1204 1 19970310 G 2434 649093 HUB ASSY CONT O550 IO550* SO ALTERNATOR FAILED G K NONE O OTHER IN INSP/MAINT 1 SW 11 281690P ALTERNATOR KEY (633342-10) FAILED CAUSING HUB ASSY TO SPIN ON ALTERNATOR SHAFT. THE RESULTS WERE EXCESSIVE WEAR TO ALTE RNATOR SHAFT AND HUB ASSEMBLY. THERE WAS ALSO WEAR ON THE TEETH OF THE ALTERNATOR FACE GEAR. 3 O E3SO 1997032700289 19970327 00289 1997 3 27 97ZZZX1205 1 19970313 G 3350 EMSE299A BATTERY PACK GULTON EMBS1392 FWD GALLEY MELTED B DM4R K NONE O OTHER IN INSP/MAINT 1 SO 19 1297TM BATTERY PACK MELTED AND DETERIORATED. BATTERY PACK WAS REPLACED NEW FROM MANUFACTURER 1-29-97. APPROXIMATELY 30 DAYS IN SERVICE. 1997032700291 19970327 00291 EU 1997 3 27 97ZZZX1206 1 19970307 G 5240 F50B281043 DOOR AMD FALC50 FALCON50MYST 2730106 EU DOOR 170A MISSING B A JZBR K NONE E VIBRATION/BUFFET CL CLIMB 1 EA 25 134AP 048 DURING CLIMB, CREW NOTED A VIBRATION FOR APPROXIMATELY 5 SECONDS. DURING PRE-FLIGHT THE NEXT DAY, DOOR 170A WAS DISCOVE RED TO BE MISSING. TEMPORARY REPAIRS WERE MADE AND THE A/C WAS FLOWN TO A REPAIR FACILITY FOR REPLACEMENT OF DOOR 170A. 2 L 7 3 4F A46EU 1997032700292 19970327 00292 SO 1997 3 27 97ZZZX1207 1 19970228 G 2740 688237 SWITCH PIPER PA42 PA42720 7104212 SO TRIM MASTER FAILED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 AL 03 2247R 425501005 FOUND TRIM MASTER SWITCH PREVIOUSLY REPAIRED WITH GLUE. REPLACED SWITCH, NEW SWITCH FELL APART AT FWD SEAM AT FIRST OPS CHECK. SECOND NEW SWITCH DID THE SAME. BACK PART OF SWITCH FELL INTO CENTER CONSOLE, SHORTED OUT ON A/F STRUCTURE AND COULD NOT BE RETRIEVED TO SELECT TRIM OFF. POOR DESIGN OF SWITCH ASSEMBLY AND POOR CONSTRUCTION OF SWITCH. REPLACED S WITCH WITH ONE OF HIGHER QUALITY AND MADE BY A DIFFERENT MANUFACTURER. FAA FORM 337 AND FIELD APPROVAL GRANTED FOR CHAN GE. 1 L 7 2 4T A23SO 1997032700294 19970327 00294 SO 1997 3 27 97ZZZX1208 1 19970214 G 2822 RR12040F PUMP LKHEED 1329 1329 5263102 SO GARRTT TFE731 TFE7313 01518 WP NR 2 FAILED D K NONE O OTHER IN INSP/MAINT 1 AL 03 817BD 466 5083 FUEL PUMP WAS OVERHAULED BY CRS NR ZK3R027M ON 10-5-93. OVERHAUL REQUIREMENT IS 2000 HOURS. TIME SINCE OVERHAUL ON PART WAS 466 HOURS. PUMP WOULD NOT MAINTAIN PRESSURE WITH COLD FUEL. SUBMITTER STATED SEVERAL OPERATORS HAVE COMPLAINED AB OUT SIMILAR PROBLEMS WITH PUMPS FROM THE SAME CRS. 2 L 7 4 4J 4 F 2A15 E6WE 1997032700295 19970327 00295 CE 1997 3 27 97ZZZX1209 1 19970310 G 3610 10138417313 VALVE BEECH 90 C90 1152913 CE BLEED SYSTEM FAILED D A K NONE O OTHER IN INSP/MAINT 1 GL 15 6280E 7471 LJ1015 DURING ROUTINE PRIMARY INSPECTION, FLAPPER VALVE TEST WAS PERFORMED IAW BEECH MODEL 90 MM. VALVE FAILED TEST AND WHEN R EMOVED, IT WAS DISCOVERED THAT THE RUBBER DIAPHRAGM INSIDE THE VALVE HAD SEPARATED FROM ITS HINGE AND WAS CARRIED INTO T HE BLEED AIR DISTRIBUTION SYSTEM. PART WAS REPLACED AND SYSTEM RETURNED TO NORMAL OPERATION. RECOMMEND VISUAL INSPECTI ON AT 600 HOURS RATHER THAN A FUNCTIONAL CHECK. 1 L 7 2 3T 3A20 1997032700296 19970327 00296 CE 1997 3 27 97ZZZX1210 1 19970307 G 3210 10581002369 A FRAME BEECH 76 76 1153005 CE RT MLG CRACKED B UC2R K NONE O OTHER IN INSP/MAINT 1 GL 19 6002C 4864 ME120 WHEN INSPECTING LANDING GEAR A-FRAMES PER AD 91-14-14 AND BEECH SB 2361, THE RIGHT AND LEFT A-FRAMES WERE REMOVED FROM T HE AIRCRAFT FOR FURTHER INSPECTION. A MAGNAFLUX INSPECTION OF THESE PARTS WAS PERFORMED AND THE A-FRAMES WERE FOUND CRA CKED. THE MAGNAFLUX INSPECTION IS NOT CALLED OUT FOR IN SB 2361, BUT THE CRACKS THAT WERE FOUND DID NOT SHOW UP WITH TH E DYE PENETRANT INSPECTION AS REQUIRED BY SB 2361. RECOMMEND REPLACING THE OLD STYLE A-FRAMES WITH THE NEW STYLE A-FRAM ES LISTED IN SB 2361 REV 111. 1 L 7 2 3O A29CE 1997032700297 19970327 00297 CE 1997 3 27 97ZZZX1211 1 19970307 G 3210 10581002370 A FRAME BEECH 76 76 1153005 CE LT MLG CRACKED B A UC2R K NONE O OTHER IN INSP/MAINT 1 GL 19 6002C 4864 ME120 WHEN INSPECTING LANDING GEAR A-FRAMES PER AD 91-14-14 AND BEECH SB 2361, THE RIGHT AND LEFT A-FRAMES WERE REMOVED FROM T HE AIRCRAFT FOR FURTHER INSPECTION. A MAGNAFLUX INSPECTION OF THESE PARTS WAS PERFORMED AND THE A-FRAMES WERE FOUND CRA CKED. THE MAGNAFLUX INSPECTION IS NOT CALLED OUT FOR IN SB 2361, BUT THE CRACKS THAT WERE FOUND DID NOT SHOW UP WITH TH E DYE PENETRANT INSPECTION AS REQUIRED BY SB 2361. RECOMMEND REPLACING THE OLD STYLE A-FRAMES WITH THE NEW STYLE A-FRAM ES LISTED IN SB 2361 REV 111. 1 L 7 2 3O A29CE 1997040300001 19970403 00001 SO 1997 4 3 97ZZZX1217 1 19970312 G 8011 MHB4005 STARTER PRESTOLITE PIPER PA31 PA31P 7103120 SO ENGINE SHORTED B EKIR K NONE O OTHER IN INSP/MAINT 1 WP 07 18MC 341 A105041 31P7300143 STARTER INOPERABLE. FOUND SHORTED OUT. TIME 341.1 HOURS SMOH. ONE YEAR IN SERVICE. 1 L 7 2 3O A8EA 1997040300002 19970403 00002 SO 1997 4 3 97ZZZX1218 1 19970312 G 2434 ALV9510 ALTERNATOR PIPER PA31 PA31P 7103120 SO ROTOR SHAFT FAILED B A EKIR K NONE H ELECT. POWER LOSS-50 PC IN INSP/MAINT 1 WP 07 18MC 10 31P7300143 ALTERNATOR QUIT WORKING. REMOVED, FOUND SHAFT THROUGH ROTOR ASSY WOULD TURN WITHOUT TURNING ROTOR. UNIT OVERHAULED 1-1 3-97. 1 L 7 2 3O A8EA 1997040300003 19970403 00003 CE 1997 4 3 97ZZZX1219 1 19970319 G 3230 51001116 LINE CESSNA 414 414A 2075907 CE GEAR BOTTLE CORRODED B A NT2R K NONE O OTHER IN INSP/MAINT 1 CE 07 442CC 5086 414A0483 ALUMINUM LINE THAT ATTACHES TO GEAR BLOW-DOWN BOTTLE HAS A HOLE CORRODED IN TUBE 7.5 INCHES DOWN FROM BLOW-DOWN BOTTLE W HERE IT LAYED AGAINST THE CROSS-OVER HEAT DUCT INSULATION. SUBMITTER SUGGESTED LINE BE BENT OUT ENOUGH TO RELIEVE PRESS URE AND CHAFING PROBLEM. 1 L 7 2 3O A7CE 1997040300004 19970403 00004 CE 1997 4 3 97ZZZX1220 1 19970314 G 5553 04320049 BRACKET CESSNA 150 152 2071835 CE V FIN ATTACH CRACKED B A AJ4R K NONE O OTHER IN INSP/MAINT 1 WP 21 49169 7700 15281177 FOUND VERTICAL/HORIZONTAL STABILIZER REAR ATTACH FITTING CRACKED DURING ROUTINE MAINTENANCE. REMOVED FIN AND RUDDER. R EMOVED ELEVATORS TO REMOVE BRACKET ASSY, P/N 0432004-9. FOUND REINFORCEMENT, P/N 0432001-15, AND SPARS, P/N 0432001-56, ALSO CRACKED IN SAME LOCATION STARTING AT CENTERLINE OF FUSELAGE PROPAGATING TO THE RIGHT SIDE OF STABILIZER APPROXIMAT ELY 3.0 INCHES. MOST OF THIS AIRPLANE'S TIME HAS BEEN SPENT IN A FLIGHT SCHOOL. 1 H 7 1 3O NT 3A19 1997040300005 19970403 00005 CE 1997 4 3 97ZZZX1221 1 19970314 G 5511 043200115 REINFORCEMENT CESSNA 150 152 2071835 CE HORIZ STAB CRACKED B AJ4R K NONE O OTHER IN INSP/MAINT 1 WP 21 49169 7700 15281177 FOUND VERTICAL/HORIZONTAL STABILIZER REAR ATTACH FITTING CRACKED DURING ROUTINE MAINTENANCE. REMOVED FIN AND RUDDER. R EMOVED ELEVATORS TO REMOVE BRACKET ASSY, P/N 0432004-9. FOUND REINFORCEMENT, P/N 0432001-15, AND SPARS, P/N 0432001-56, ALSO CRACKED IN SAME LOCATION STARTING AT CENTERLINE OF FUSELAGE PROPAGATING TO THE RIGHT SIDE OF STABILIZER APPROXIMAT ELY 3.0 INCHES. MOST OF THIS AIRPLANE'S TIME HAS BEEN SPENT IN A FLIGHT SCHOOL. 1 H 7 1 3O NT 3A19 1997040300006 19970403 00006 CE 1997 4 3 97ZZZX1222 1 19970314 G 5511 043200156 SPAR CESSNA 150 152 2071835 CE HORIZ STAB CRACKED B AJ4R K NONE O OTHER IN INSP/MAINT 1 WP 21 49169 7700 15281177 FOUND VERTICAL/HORIZONTAL STABILIZER REAR ATTACH FITTING CRACKED DURING ROUTINE MAINTENANCE. REMOVED FIN AND RUDDER. R EMOVED ELEVATORS TO REMOVE BRACKET ASSY, P/N 0432004-9. FOUND REINFORCEMENT, P/N 0432001-15, AND SPARS, P/N 0432001-56, ALSO CRACKED IN SAME LOCATION STARTING AT CENTERLINE OF FUSELAGE PROPAGATING TO THE RIGHT SIDE OF STABILIZER APPROXIMAT ELY 3.0 INCHES. MOST OF THIS AIRPLANE'S TIME HAS BEEN SPENT IN A FLIGHT SCHOOL. 1 H 7 1 3O NT 3A19 1997040300007 19970403 00007 CE 1997 4 3 97ZZZX1223 1 19970226 G 7810 075016167 STACK CESSNA 185 A185F 2072821 CE EXHAUST RISER CRACKED B A ILIR K NONE O OTHER IN INSP/MAINT 1 WP 07 7239E 105 18502642 THREE INTERSECTING CRACKS, EACH ABOUT AN INCH LONG, RADIATING ON THE AFT SIDE OF THE CENTER EXHAUST TUBE (BOTH STACKS). FOUND DURING 100-HOUR INSPECTION. RECOMMEND THAT THE EXHAUST SYSTEM BE INSPECTED DURING THE 50-HOUR INSPECTION. 1 H 7 1 3O 3A24 1997040300008 19970403 00008 EA 1997 4 3 97ZZZX1224 2 19970318 G 8520 CRANKSHAFT SOCATA TB9 TB9 8680694 EU LYC O320 O320D2A 41508 EA FLANGE CRACKED B P A NI1R K NONE O OTHER IN INSP/MAINT 1 CE 03 508PC 1477 L1754339A THIS AIRCRAFT IS USED EXCLUSIVELY FOR FLIGHT TRAINING. ON PRE-FLIGHT, STUDENT AND INSTRUCTOR FOUND OIL ON THE COWLING. UPON INSPECTION, TWO CRACKS WERE FOUND ON THE CRANKSHAFT COVERGING AT THE RADIUS OF THE CRANKSHAFT AND CRANKSHAFT FLANG E. THIS ENGINE AND PROPELLER HAVE NO HISTORY OF PROPELLER STRIKE OR SUDDEN STOPPAGE. IN SERVICE DATE FOR THIS ENGINE A ND PROPELLER 4/92. TOTAL TIME SINCE NEW, ENGINE AND PROPELLER, 1,809 HOURS. 1 L 7 1 3O 3 O NT AS1EU E274 1997040300009 19970403 00009 1997 4 3 97ZZZX1225 2 19970204 G 7414 CAM ASSY BENDIX D4LH2021 IMPULSE COUPLING WORN D K NONE O OTHER IN INSP/MAINT 1 NM 08 779 R14992K INSPECTION IAW AD 96-12-7 FOUND NEW SNAP RING STYLE CAM ASSY WORN BEYOND LIMITS. THIS IS ONE OF SEVERAL THAT DID NOT MA KE 1,000 HOURS. FIRST INSPECTION AT 500 HOURS SHOWED WEAR, BUT WITHIN ACCEPTABLE LIMITS. WEAR WAS WELL BEYOND LIMITS B EFORE SECOND 500-HOUR INSPECTION WAS DUE. THESE CAM ASSEMBLIES SEEM TO BE MORE PRONE TO WEAR THAN THE OLD STYLE RIVETED ASSEMBLIES. 1997040300010 19970403 00010 CE 1997 4 3 97ZZZX1226 1 19970217 G 2430 C5930010101 SWITCH CESSNA 172 172M 2072418 CE OVERVOLTAGE FAILED D A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 NE 03 13593 3662 17262866 PILOT OBSERVED HIGH DISCHARGE RATE ON AMMETER APPROXIMATELY 45 MINUTES INTO FLIGHT. NO HIGH VOLTAGE LIGHT INDICATION. P ILOT MADE PRECAUTIONARY LANDING. REPLACED OVERVOLTAGE LIGHT ASSEMBLY AND OVERVOLTAGE SWITCH. ALL OTHER COMPONENTS BENC H CHECKED WITH NO DISCREPANCIES. OPERATIONAL CHECK WAS SATISFACTORY AND AIRCRAFT WAS RETURNED TO SERVICE. SUBMITTER SU GGESTED INSPECTION CHECKLIST REVISION TO INCLUDE TEST OF HIGH VOLTAGE INDICATING SYSTEM. 1 H 7 1 3O NT 3A12 1997040300011 19970403 00011 CE 1997 4 3 97ZZZX1227 1 19970304 G 3040 T2513 DIODE 99102222 CESSNA 402 402C 207590R CE WINDSHIELD HEAT BURNT D S K NONE B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 NE 01 1376G 402C0271 PILOT REPORTED ARCING AND SMOKE FROM ELECTRIC HEATED WINDSHIELD. ELECTRICAL CONNECTION OR LEFT SIDE OF HEATED WINDSHIEL D HAS DIODE THAT MELTED AND ARCED. 1 L 7 2 3O A7CE 1997040300012 19970403 00012 EA 1997 4 3 97ZZZX1228 2 19970311 G 7414 1038256013 DISTRIBUTOR GEAR ELECTROSYS PIPER PA32 PA32R300 7103213 SO LYC O540 IO540K1A5 41532 EA ENGINE MAGNETO TEETH BROKE D K NONE O OTHER IN INSP/MAINT 1 AL 01 1392H 655 6021788R 32R7780156 L1642048A MAGNETO DISTRIBUTOR TEETH BROKE DURING RUN-UP. RECOMMEND BETTER QC DURING MANUFACTURE. 1 L 7 1 3O 3 O A3SO 1E4 1997040300013 19970403 00013 CE 1997 4 3 97ZZZX1229 1 19970225 G 5751 512400075 AILERON CESSNA 402 402C 207590R CE BALANCE WEIGHT WEIGHT BROKEN D A K NONE O OTHER IN INSP/MAINT 1 EA 01 258PB 12000 119 402C0336 AILERON HAS A 4 FOOT LEAD WEIGHT INSTALLED FOR BALANCING. LEAD WEIGHT HAD BROKEN AWAY FROM MOUNT AND WAS LOOSE IN LEADI NG EDGE OF AILERON. LEADING EDGE WAS REMOVED AND BALANCE WEIGHT WAS RE-ATTACHED TO AILERON. FLIGHT CONTROL WAS RE-BALA NCED AND RETURNED TO SERVICE. 1 L 7 2 3O A7CE 1997040300014 19970403 00014 SO 1997 4 3 97ZZZX1230 1 19970219 G 3213 6531904 CYLINDER 3564405 PIPER PA28 PA28181 7102807 SO GEAR LEG EARS BROKEN B QWLR K NONE O OTHER IN INSP/MAINT 1 EA 25 8198P 3703 288090295 TORQUE LINK MOUNTING GEARS BROKE ON LANDING GEAR. ONE LINK MOUNT HAD EVIDENCE OF PRIOR CRACKS. BROKEN TAB HAD A DARK A REA. 1 L 7 1 3O 2A13 1997040300015 19970403 00015 CE 1997 4 3 97ZZZX1231 1 19970311 G 5511 053200198 SPAR 0532001202 CESSNA 172 172N 2072434 CE HORIZONTAL STAB CRACKED D S A K NONE O OTHER IN INSP/MAINT 1 CE 07 737YY 9200 17269789 CRACKS FROM FORWARD CENTER LIGHTNING HOLE UP AND DOWN THROUGH SPAR, DOUBLER, UPPER AND LOWER ANGLES AND UPPER-LOWER HORI ZONTAL SKINS RUNNING AFT. SUBMITTER SUGGESTED CAUSE AS MOVING AIRCRAFT USING HORIZONTAL AND, ALSO, FATIGUE DUE TO NUMBE R OF HOURS. PRIOR TO REMOVAL, HORIZONTAL TIP DEFLECTION 2 INCHES UP - 2 INCHES DOWN. 1 H 7 1 3O NT 3A12 1997040300016 19970403 00016 SO 1997 4 3 97ZZZX1232 2 19970306 G 8530 653446A5 CYLINDER CESSNA 210 210R 2073458 CE CONT O520 IO520L 17032 SO NR 3 CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 23 962CC 1101 21064986 294563R NR 3 CYLINDER WAS REMOVED DUE TO LOW COMPRESSION. THE CYLINDER WAS SENT FOR INSPECTION. THE CYLINDER INSPECTION REVEAL ED A CRACK WHICH BEGAN AT THE SPARK PLUG HOLE AND TERMINATED AT THE INTAKE VALVE SEAT. 1 H 7 1 3O 3 O RT 3A21 E5CE 1997040300017 19970403 00017 SO 1997 4 3 97ZZZX1233 2 19970306 G 8530 653446A5 CYLINDER CESSNA 210 210R 2073458 CE CONT O520 IO520L 17032 SO NR 2 CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 23 962CC 1297 21064986 294563R WHILE PERFORMING TCM SB 96-12, CONTINUED AIRWORTHINESS INSTRUCTIONS FOR TCM CYLINDERS, BUBBLES WERE FOUND ACCUMULATING A ROUND THE NR 2 CYLINDER UPPER SPARK PLUG HOLE. INSPECTION REVEALED A CRACK AT THE SPARK PLUG HOLE. THE CRACK ORIGINATE D AT THE 3 O'CLOCK POSITION AND EXTENDED AFT TOWARD THE FUEL NOZZLE HOLE. 1 H 7 1 3O 3 O RT 3A21 E5CE 1997040300018 19970403 00018 SO 1997 4 3 97ZZZX1234 2 19970312 G 8520 641931075 THROUGH BOLT BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO NR 2 CYLINDER FAILED D O OTHER O OTHER CR CRUISE 1 SW 17 977GF 781 TH175 287057R UPON INSPECTION OF LT ENGINE, FOUND NR 2 CYLINDER SEPARATED FROM CASE BY 2-3 INCHES. UPPER THROUGH-BOLT APPEARS TO BE B ROKEN INTERNALLY AS WELL AS LOWER THROUGH-BOLT, ALL UPPER AND LOWER CASE STUDS TO CYLINDER HOLD-DOWN APPEAR TO BE BROKEN AT THREAD AREA OR AFT OF THREAD AREA. PISTON STILL CONNECTED TO CONNECTING ROD TO CRANKSHAFT. EVIDENCE OF PISTON SKIR T AND RING MATERIAL IN CASE. AIRCRAFT IN NORMAL CRUISE SETTING WITH TEMPS AND PRESSURES NORMAL. 1 L 7 2 3O 3 O 3A16 E5CE 1997040300019 19970403 00019 CE 1997 4 3 97ZZZX1235 1 19970315 G 2436 GCSG5023 CONTROL UNIT CESSNA 210 P210N 2073454 CE GENERATOR FAILED D A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CR CRUISE 1 CE 07 93LC 24 1030B P21000741 THE GENERATOR CONTROL UNIT FAILED DURING FLIGHT (IFR). PLANE MADE AN EMERGENCY LANDING. NEW GENERATOR CONTROL UNIT INS TALLED. CHECKED OK. 1 H 7 1 3O 3A21 1997040300020 19970403 00020 SO 1997 4 3 97ZZZX1236 1 19970201 G 3030 9937726 SWITCH PIPER PA34 PA34200T 7103406 SO PITOT HEAT FAILED B F3NR O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 NM 04 633TC 348070314 PILOT REPORTED STRONG ELECTRICAL SMELL FROM LEFT SIDEWALL ELECTRIC SWITCH PANEL WITH ALL ANTI-ICE PROTECTION ON. INVEST IGATION REVEALED PITOT HEAT SWITCH HAD ARCED AND BURNED INTERNALLY. TOTAL TIME ON SWITCH 3,109.7 HOURS SINCE INSTALLED. 1 L 7 2 3O A7SO 1997040300294 19970403 00294 EA 1997 4 3 97ZZZX1237 2 19970307 G 8530 LW12987C2 CYLINDER HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA NR 1 DEFECTIVE B FW7R K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 EA 07 2044F 162 S1722 L2674451A AFTER THIS CYLINDER WAS INSTALLED, THE ENGINE OIL CONSUMPTION INCREASED. EVEN AFTER A SUFFICIENT BREAK-IN PERIOD, THE C ONSUMPTION DID NOT DROP. AFTER APPROXIMATELY 162 HOURS, THE ENGINE RAN EXTREMELY ROUGH EVEN WITHOUT THE MAIN ROTOR ENGA GED. THE SPARK PLUGS WERE REMOVED, AND THE LOWER NR 1 PLUG WAS FOUND COMPLETELY OIL FOULED. THE CYLINDER WAS REPLACED WITH A FACTORY NEW UNIT. 1 G 7 1 3O 3 O 4H12 1E10 1997040300295 19970403 00295 NE 1997 4 3 97ZZZX1238 1 19970227 G 6310 7636104008103 COUPLING SKRSKY S76 S76A 8143006 NE ENGINE DRIVE CRACKED D S A K NONE O OTHER IN INSP/MAINT 1 EA 25 22BF 760216 INSPECTION FOUND ENGINE DRIVE COUPLING CRACKED. 1 G 7 2 3U H1NE 1997040300296 19970403 00296 GL 1997 4 3 97ZZZX1239 2 19970317 G 7230 23052270 COMPRESSOR BELL 206 206L1 1182107 SW ALLSN 250C 250C30P 03013 GL SCROLL CRACKED H K NONE O OTHER IN INSP/MAINT 1 SW 09 5748H 8342 6506 CAC90373 45490 CAC890611 DURING DAILY INSPECTION OF ENGINE ASSY, A CRACK WAS DISCOVERED ON THE RIGHT UPPER SIDE OF THE SCROLL, 1.50 INCHES IN LEN GTH. 1 G 7 1 3U 3 U H2SW E1GL 1997040300297 19970403 00297 CE 1997 4 3 97ZZZX1240 1 19970214 G 2823 VALVE CESSNA 177 177 2073704 CE FUEL SELECTOR LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 GL 23 29530 1975 17700944 DURING ANNUAL INSPECTION IT WAS DETECTED THAT WHEN TESTING OR OPS CHECKING, THE FUEL SELECTOR VALVE TO DETERMINE DETENT OPERATION, MOVEMENT OF THE VALVE CAUSED FUEL TO LEAK OUT THE TOP OF VALVE AROUND THE SHAFT. THIS HAD BEEN IN PROCESS F OR SOME TIME BECAUSE THE BELLY WAS FUEL STAINED ALSO. 1 H 7 1 3O NT A13CE 1997040300298 19970403 00298 CE 1997 4 3 97ZZZX1241 1 19970301 G 3230 0840125 PUSH PULL ROD CESSNA 320 320E 2074514 CE NLG BENT D P O OTHER J WARNING INDICATION AP APPROACH 1 NM 11 3425Q 320E0025 AIRCRAFT WAS ON A PART 91 CROSS-COUNTRY FLIGHT. ON RETURN, THE NOSE GEAR FAILED TO EXTEND. THE AIRCRAFT WAS LANDED AND THE NOSE GEAR COLLAPSED DAMAGING BOTH PROPELLERS, THE NOSE GEAR DOORS, THE NOSE CONE, AND THE PITOT TUBE. THE AIRCRAFT WAS RAISED UP ON THE RUNWAY AND NOSE GEAR WAS LOWERED BY HAND AND TOWED TO THE HANGAR. ON INSPECTION, FOUND NOSE GEAR PUSH-PULL ROD BENT, CRACKED, AND JAMMING ON THE BULKHEAD AT FS 0.00. THIS IS USUALLY CAUSED BY THE LANDING GEAR BEING E XTENDED AT TOO HIGH AN AIR SPEED. RECOMMEND THAT ALL PILOTS BE MADE AWARE OF THIS PROBLEM. TOTAL TIME ON PART IS 1,556 HOURS. 1 L 7 2 3O 3A25 1997040300299 19970403 00299 SW 1997 4 3 97ZZZX1242 1 19970201 G 5753 21005000X BRACKET MOONEY M20 M20G 5870316 SW FLAP HINGE CORRODED D K NONE O OTHER IN INSP/MAINT 1 GL 11 3862N 2900 680056 FOUND AIRFRAME SIDE OF FLAP HINGE UNAIRWORTHY DUE TO SEVERE INTERGRANULAR EXFOLIATION. DEFECT WAS FOUND DURING AN ANNUA L INSPECTION. AIRCRAFT WAS EQUIPPED WITH A 'SPEED KIT' STC NR SA4023WE, WHICH INCLUDED FLAP HINGE FAIRINGS WITH THE FLA P HINGE FAIRINGS INSTALLED. INSPECTION OF THE HINGES IS LIMITED. THE FAIRINGS ON THIS AIRCRAFT WERE ATTACHED WITH BLIN D RIVETS. RECOMMEND REMOVING FAIRINGS AT EACH INSPECTION. 1 L 7 1 3O 2A3 1997040300300 19970403 00300 SW 1997 4 3 97ZZZX1243 1 19970201 G 5753 21004800X BRACKET MOONEY M20 M20G 5870316 SW FLAP HINGE CORRODED D K NONE O OTHER IN INSP/MAINT 1 GL 11 3862N 2900 680056 FOUND AIRFRAME SIDE OF FLAP HINGE UNAIRWORTHY DUE TO SEVERE INTERGRANULAR EXFOLIATION. DEFECT WAS FOUND DURING AN ANNUA L INSPECTION. AIRCRAFT WAS EQUIPPED WITH A 'SPEED KIT' STC NR SA4023WE, WHICH INCLUDED FLAP HINGE FAIRINGS WITH THE FLA P HINGE FAIRINGS INSTALLED. INSPECTION OF THE HINGES IS LIMITED. THE FAIRINGS ON THIS AIRCRAFT WERE ATTACHED WITH BLIN D RIVETS. RECOMMEND REMOVING FAIRINGS AT EACH INSPECTION. 1 L 7 1 3O 2A3 1997040300301 19970403 00301 SO 1997 4 3 97ZZZX1244 2 19970311 G 7314 6462123A1 PUMP CESSNA 310 310Q 2074242 CE CONT O470 IO470V 17026 SO RT ENG FUEL SHAFT SHEARED B L CSLR A UNSCHED LANDING Y ENGINE STOPPAGE NR NOT REPORTED 1 CE 01 7872Q 1230 1230 310Q0653 170980R RIGHT ENGINE FUEL PUMP FAILED DURING FLIGHT. BOOST PUMP WOULD NOT RUN AND ENGINE STOPPED, UNEVENTFUL LANDING WAS MADE. FOUND FUEL PUMP DRIVESHAFT SHEARED. FOUND BOOST PUMPS WOLD PRIME ENGINE AND ALLOW ENGINE TO RUN, BUT WOULD NOT RUN IN HIGH OR LOW BOOST PUMP POSITION. FOUND OIL PRESSURE SWITCHES IN NACELLE TO BE DIRTY AND NOT ALLOWING BOOST PUMP TO RUN. CLEAN AND ADJUST SWITCHES PER CESSNA 3100 MM, CHAPTER 11. NOTE: MEB 88-3 WAS C/W. 1 L 7 2 3O 3 O 3A10 3E1 1997040300302 19970403 00302 CE 1997 4 3 97ZZZX1245 1 19970311 G 2822 SWITCH CESSNA 310 310Q 2074242 CE CONT O470 IO470V 17026 SO BOOST PUMP DIRTY B CSLR K NONE O OTHER IN INSP/MAINT 1 CE 01 7872Q 1230 310Q0653 170980R RIGHT ENGINE FUEL PUMP FAILED DURING FLIGHT. BOOST PUMP WOULD NOT RUN AND ENGINE STOPPED, UNEVENTFUL LANDING WAS MADE. FOUND FUEL PUMP DRIVESHAFT SHEARED. FOUND BOOST PUMPS WOLD PRIME ENGINE AND ALLOW ENGINE TO RUN, BUT WOULD NOT RUN IN HIGH OR LOW BOOST PUMP POSITION. FOUND OIL PRESSURE SWITCHES IN NACELLE TO BE DIRTY AND NOT ALLOWING BOOST PUMP TO RUN. CLEAN AND ADJUST SWITCHES PER CESSNA 3100 MM, CHAPTER 11. NOTE: MEB 88-3 WAS C/W. 1 L 7 2 3O 3 O 3A10 3E1 1997040300303 19970403 00303 CE 1997 4 3 97ZZZX1246 1 19970201 G 3221 BRACKET CESSNA 170 170A 2072304 CE TAIL WHEEL BOLT BROKE D L A K NONE O OTHER NR NOT REPORTED 1 EA 13 9032A 5714 18787 TAIL WHEEL SEPARATED FROM AIRCRAFT. INVESTIGATION FOUND ASSY HAD SEPARATED DUE TO BROKEN BOLT. BOLT HAD BEEN DYE CHECK ED AT LAST ANNUAL DUE TO REPORT OF ANOTHER AIRCRAFT WITH BROKEN BOLT. THE BOLT CRACK DID NOT SHOW UP ON A DYE CHECK. S UBMITTER RECOMMENDED TO NDT X-RAY OR EDDY CURRENT CHECK. 1 H 7 1 3O A799 1997040300304 19970403 00304 CE 1997 4 3 97ZZZX1247 1 19970321 G 5700 STRUT CESSNA 140 140 2071602 CE WING LIFT STRUT CORRODED D S A K NONE O OTHER IN INSP/MAINT 1 SO 03 3728V 2300 15005 REMOVED WING LIFT STRUT VERTICAL BRACES TO FACILITATE REPAINT OF STRUTS AND BRACES. FOUND CORROSION ON STRUT AT BRACE C LAMP AREA. PTTING HAD OCCURRED CIRCUMFERENTIALLY AROUND THE LIFT STRUT. ALTHOUGH PITTING WAS NOT EXCESSIVE IN THIS CAS E, FURTHER DAMAGE COULD SERIOUSLY COMPROMISE STRUT INTEGRITY WHICH COULD RESULT IN A 'WING FOLD' IN-FLIGHT. PITTING OCC URRED IN A STRAIGHT LINE AROUND THE STRUT REDUCING WALL THICKNESS OF THE TUBING. NON-HYDROSCOPIC TAPE HAD BEEN USED AS A CHAFE STRIP UNDER BRACE CLAMP. RECOMMEND REMOVAL OF VERTICAL BRACE DURING REFINISHING OR WHENEVER CORROSION IS DETECT ED. 1 H 7 1 3O NC A768 1997040300305 19970403 00305 SO 1997 4 3 97ZZZX1248 2 19970320 G 8520 CRANKCASE BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO NR 6 CYL STUD CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 05 999AN TH924 561912 DURING OIL CHANGE, FOUND 1 INCH CRACK EXTENDING FROM CYLINDER NR 6 UPPER REAR STUD. AD 77-13-22 PARA(A) ADDRESSES THIS SUBJECT, BUT IS NOT INCLUDED IN THE SERIAL NUMBER REQUIREMENT LIST. 1 L 7 2 3O 3 O 3A16 E5CE 1997040300307 19970403 00307 CE 1997 4 3 97ZZZX1250 1 19970307 G 3233 ACTUATOR BEECH 200 200BEECH 1152920 CE NLG SLIPPING B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 42TD 600 BB968 ACTUATOR WAS INSTALLED NEW 14 MONTHS AGO. HAD TO MAKE ADJUSTMENTS TWICE SI NCE INSTALLED FOR RED INSTRANSIT LIGHT STAYI NG ON . ON THIRD TIME, FOUND END PLAY EXCESSIVE AND SPRING TENSION TOO TIGHT, NOSE GEAR NOT UP ALL THE WAY. CONSULTED BEECH REP AND WAS TOLD PINION GEAR IS SLIPPING IN ACTUATOR. ALSO, FOUND R12ZZ BEARING BAD TO NOSE GEAR ACTUATOR DRIVE A SSY, P/N 90820014-1. 1 L 7 2 4T A24CE 1997040300309 19970403 00309 NE 1997 4 3 97ZZZX1251 2 19970305 G 7313 NOZZLE LEAR 25 25B 5170511 CE GE CJ610 CJ6106 30006 NE STAGE 1 REQUIRED ADJ D K NONE X ENGINE FLAMEOUT NR NOT REPORTED 1 GL 23 50CK 10399 7232 157 241033 LEFT ENGINE FLAMED OUT. ADJUSTED STAGE 1 AIR NOZZLE. GROUND RUN AND PERFORMANCE CHECK GOOD. C/W ALTITUDE ACCELERATION TEST FLIGHT. OPS CHECK GOOD. 2 L 7 2 4J 4 J A10CE 1E16 1997040300310 19970403 00310 NE 1997 4 3 97ZZZX1252 2 19970309 G 7200 ENGINE LEAR 25 25B 5170511 CE GE CJ610 CJ6106 30006 NE LEFT ENGINE FAIL CHECK E K NONE L NO TEST IN INSP/MAINT 1 GL 23 50CK 10405 7233 157 241033 LEFT ENGINE FLAME OUT. RE-ADJUSTED STAGE 1 AIR NOZZLE. INSPECTED COMBUSTION LINER AND INSTALLED OVERHAULED FUEL CONTRO L UNIT. GROUND RUN LEAK AND PERFORMANCE CHECK GOOD. LEFT ENGINE FAILED ACCELERATION CHECK AT FL 410. REPLACED ENGINE WITH S/N 251-095A. GROUND RUN AND LEAK CHECK GOOD. 2 L 7 2 4J 4 J A10CE 1E16 1997040300311 19970403 00311 NE 1997 4 3 97ZZZX1253 2 19970312 G 7320 C2995150202 CONTROL CABLE CESSNA 208 208B 2073701 CE PWA PT6 PT6A114 52043 NE EMERGENCY POWER WORN D K NONE O OTHER IN INSP/MAINT 1 WP 17 762FE 2774 208B0255 19131 EMERGENCY POWER CABLE AND ATTACH BRACKETS WORN. THE BRACKETS WORN WITHIN .0625 INCH OF BEING COMPLETELY THROUGH MATERIA L. EMERGENCY POWER CABLE WORN THROUGH ATTACH POINT ON CABLE. SUGGEST WEAR IS NORMAL, CABLE AND ATTACH BRACKETS NEED TO BE OF HEAVIER MATERIAL. 1 H 7 1 3T 3 T A37CE E4EA 1997040300312 19970403 00312 NE 1997 4 3 97ZZZX1254 2 19970312 G 7320 24510022 BRACKET CESSNA 208 208B 2073701 CE PWA PT6 PT6A114 52043 NE EMERGENCY POWER WORN D K NONE O OTHER IN INSP/MAINT 1 WP 17 762FE 2774 208B0255 19131 EMERGENCY POWER CABLE AND ATTACH BRACKETS WORN. THE BRACKETS WORN WITHIN .0625 INCH OF BEING COMPLETELY THROUGH MATERIA L. EMERGENCY POWER CABLE WORN THROUGH ATTACH POINT ON CABLE. SUGGEST WEAR IS NORMAL, CABLE AND ATTACH BRACKETS NEED TO BE OF HEAVIER MATERIAL. 1 H 7 1 3T 3 T A37CE E4EA 1997040300313 19970403 00313 NE 1997 4 3 97ZZZX1255 2 19970312 G 7320 24510021 BRACKET CESSNA 208 208B 2073701 CE PWA PT6 PT6A114 52043 NE EMERGENCY POWER WORN D A K NONE O OTHER IN INSP/MAINT 1 WP 17 762FE 2774 208B0255 19131 EMERGENCY POWER CABLE AND ATTACH BRACKETS WORN. THE BRACKETS WORN WITHIN .0625 INCH OF BEING COMPLETELY THROUGH MATERIA L. EMERGENCY POWER CABLE WORN THROUGH ATTACH POINT ON CABLE. SUGGEST WEAR IS NORMAL, CABLE AND ATTACH BRACKETS NEED TO BE OF HEAVIER MATERIAL. 1 H 7 1 3T 3 T A37CE E4EA 1997040300314 19970403 00314 GL 1997 4 3 97ZZZX1256 2 19970312 G 7260 6854857 GEARSHAFT ALLSN 250C 250C20B 03013 GL TACH DRIVE WORN D K NONE O OTHER IN INSP/MAINT 1 NM 11 UPI314 TACHOMETER DRIVE END WORN ABOUT .040 INCH. 3 U E4CE 1997040300315 19970403 00315 CE 1997 4 3 97ZZZX1257 1 19970303 G 3244 184F102 TIRE GOODYEARAERO LEAR 55 55LEAR 5170702 CE BALANCE PATCH DEFECTIVE H O OTHER E VIBRATION/BUFFET TX TAXI/GRND HDL 1 GL 17 1125M 662 065 THE BALANCE PATCH THAT IS GLUED TO THE INSIDE OF NOSE TIRE, CAME OFF. THIS CAUSED THE NOSE WHEEL TO BECOME OUT OF BALAN CE CREATING A SHIMMY DURING GROUND OPERATION. LANDINGS, 135. 2 L 7 2 4F A10CE 1997040300318 19970403 00318 SO 1997 4 3 97ZZZX1260 1 19970315 G 7600 452557 ROD END PIPER PA34 PA34* SO ENGINE CONTROL BEARING FROZE D A K NONE O OTHER IN INSP/MAINT 1 NM 01 DURING INSTALLATION OF PIPER ENGINE CONTROL MODIFICATION KIT NR 79509, NOTICED THAT KIT ROD END BEARINGS WERE UNUSUALLY STIFF. AFTER 100 HOURS TIS, CONTROL ROD END BEARINGS, 4 EACH, WERE ALL FROZEN. SUBMITTER STATED THAT THE BEARINGS, P/N 452 557 (PS 10020-4-1R) ARE DEFECTIVE. 1 L 7 2 3O RT A7SO 1997040300638 19970403 00638 WP 1997 4 3 97ZZZX1262 1 19970220 G 5751 FINGER DOUBLER DOUG DC10 DC1010 3022110 WP RT OTBD AIL SKIN DISBONDED B MZAR K NONE O OTHER IN INSP/MAINT 1 SO 09 1813U 46612 DURING C-CHECK INSPECTION, FOUND RIB CAP FINGER DOUBLER DISBONDED ON RIGHT OTBD AILERON, TWO AREAS, LOWER SKIN, 1 EACH A T INBD END, AND 1 EACH AT CENTER HINGE. 2 L 7 3 4F A22WE 1997040300639 19970403 00639 WP 1997 4 3 97ZZZX1263 1 19970220 G 5751 FINGER DOUBLER DOUG DC10 DC1010 3022110 WP RT AIL OTBD DISBONDED B MZAR K NONE O OTHER IN INSP/MAINT 1 SO 09 1849U 46939 DURING C-CHECK INSPECTION, FOUND RIB CAP FINGER DOUBLER DISBONDED, RT OTBD AILERON, LOWER SKIN. 2 L 7 3 4F A22WE 1997040300640 19970403 00640 WP 1997 4 3 97ZZZX1264 1 19970219 G 5751 FINGER DOUBLER DOUG DC10 DC1010 3022110 WP RT AIL XORS 1013 CORRODED B MZAR K NONE O OTHER IN INSP/MAINT 1 SO 09 1849U 46939 DURING C-CHECK INSPECTION, FOUND RIB CAP FINGER DOUBLER DISBONDED RT OTBD AILERON UPPER SKIN. SUSPECT CAUSE, UNKNOWN. 2 L 7 3 4F A22WE 1997040300651 19970403 00651 SW 1997 4 3 97ZZZX1270 1 19970213 G 6210 206015001107 BLADE BELL 206 206L1 1182107 SW M/R CORRODED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 3185P 1664 A1666 45775 DURING DAILY INSPECTION FOUND SKIN CORRODED AND SEPARATED AT TIP. CORROSION AT WEAR PADS OR ROOT END. 1 G 7 1 3U H2SW 1997040300652 19970403 00652 SW 1997 4 3 97ZZZX1271 1 19970206 G 6320 2040401321 INNER RACE 206040004111 BELL 206 206L1 1182107 SW TRANSMISSION MAKING METAL B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 3186P 2842 BMC00271 45776 METAL CHIPPING AWAY FROM THE INNER RACE OF ONE BEARING SET FROM PLANETARY GEAR SET OF THE MAIN ROTOR TRANSMISSION. DETE CTED BY THE CHIP DETECTOR. 1 G 7 1 3U H2SW 1997040300653 19970403 00653 SW 1997 4 3 97ZZZX1272 1 19970218 G 6210 206015001107 BLADE BELL 206 206L1 1182107 SW M/R CORRODED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 3195P 828 A1311 45789 DISCOVERED DURING DAILY INSPECTION, CORROSION AND SKIN SEPARATION AT SPAR TIP. CORROSION AT ROOT END WEAR PADS. 1 G 7 1 3U H2SW 1997040300654 19970403 00654 SW 1997 4 3 97ZZZX1273 1 19970121 G 6320 206040030003 BEARING 206040004107 BELL 206 206L3 1182108 SW TRANSMISSION FAILED B ALGR K NONE J WARNING INDICATION IN INSP/MAINT 1 SW 03 351AL 1442 J0358 51431 TRANSMISSION MADE CHIP LIGHTS, FOUND BEARING BALLS BREAKING DOWN. 1 G 7 1 3U H2SW 1997040300655 19970403 00655 SW 1997 4 3 97ZZZX1274 1 19970128 G 5530 206023126101 VERTICAL FIN BELL 206 206L3 1182108 SW LT AUXILIARY CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 355AL 4975 BP00002190C0 51444 DAILY INSPECTION FOUND CRACK ON LEFT AUXILIARY VERTICAL FIN AT ATTACH POINT (4 INCH) SPIDER. THIS IS A PROBLEM THAT WAS CORRECTED MANY YEARS AGO ON 206L-1 SERIES. 1 G 7 1 3U H2SW 1997040300656 19970403 00656 SW 1997 4 3 97ZZZX1275 1 19970213 G 6210 206015001107 BLADE BELL 206 206L3 1182108 SW M/R SEPARATED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 366AL 1693 A1673 51470 DURING DAILY INSPECTION, FOUND UPPER SKIN SEPARATED AT SPAR TIP. CORROSION OR ROOT END AT WEAR PADS. 1 G 7 1 3U H2SW 1997040300658 19970403 00658 SW 1997 4 3 97ZZZX1277 1 19970206 G 6510 406090340101 DISC PACK 407040302101 BELL 407 407 SW NR 6 T/R SHAFT CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 407AL 309 309 53044 DURING A 50-HOUR INSPECTION, FOUND T/R COUPLING DISC PACK, P/N 406-090-340-101, TO HAVE A CRACK ON ONE OUTER LAMINATE EX TENDING THREE-FOURTHS OF THE WAY THROUGH THE LAMINATE. THE DESIGN OF THIS AIRCRAFT DOES NOT ALLOW THE NR 4 THROUGH THE NR 7 (ALL OF THEM ON THE TAILBOOM) T/R DRIVESHAFTS TO FLOAT. IT IS GOING TO BE HARDER ON DISC PACS THAN A 206L. THIS I S THE THIRD OCCURRENCE OF THIS PROBLEM ON A FLEET OF TWO A/C WITH 550 HOURS FLIGHT TIME COMBINED. 1 G 7 1 3U O H2SW 1997040300659 19970403 00659 SW 1997 4 3 97ZZZX1278 1 19970106 G 6510 HANGER SUPPORT 407040302101 BELL 407 407 SW NR 4 T/R BRG LOOSE B ALGR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 407AL 53044 DURING A 50-HOUR INSPECTION, THE NR 4 T/R BEARING HANGER SUPPORT WAS FOUND LOOSE FLOATING UP AND DOWN ON THE ATTACH BOLT . NR 7 HANGER SUPPORT WAS FOUND TO BE MAKING MUD AT CONTACT AREA WITH TAILBOOM BRACKET. FOUND ATTACH BOLT P/N NAS6604D 65 WORN AND STEPPED ON NR 4 SHAFT AND ONLY SLIGHTLY WORN ON NR 7 SHAFT. THE 407 MM REQUIRES TORQUE OF 50-70 INCHES/POUN DS. NEITHER CHAPTER 65 OR PARAGRAPHS 1-13 TORQUES STATE WHETHER OR NOT NUT DRAG SHOULD BE FACTORED IN. ALSO, DRAWING I N THE TAILBOOM BRACKET WILL EFFECT THE FINAL TORQUE. 1 G 7 1 3U O H2SW 1997040300660 19970403 00660 SW 1997 4 3 97ZZZX1279 1 19970114 G 6220 407010111101 CENTER CONE SET BELL 407 407 SW M/R DAMAGED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 407AL 263 53044 AFTER SITTING OFFSHORE IN MODERATE WINDS, THE PILOT NOTICED AN INCREASE IN VIBRATION LEVEL OF THE MAIN ROTOR ON THE NEXT FLIGHT. THE MAIN ROTOR CENTER CONE SET P/N 407-010-111-101 HAS A THICK TEFLON COATING ON THE INSIDE OF CONES. THIS CO ATING WAS DAMAGED ALLOWING THE HUB TO SHIFT. NOTE: BEFORE THE MAIN ROTOR HEAD WAS REMOVED, A MAST NUT RE-TORQUE WAS PE RFORMED. NO LOSS OF TORQUE WAS FOUND. 1 G 7 1 3U O H2SW 1997040300661 19970403 00661 SW 1997 4 3 97ZZZX1280 1 19970224 G 6510 406040340101 DISC PACK BELL 407 407 SW T/R SHAFT CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 407AL 394 394 53044 DURING ROUTINE INSPECTION, FOUND ONE DISC OF DISC PAC CRACKED IN THREE PLACES. TWO CRACKS WERE RUNNING PARALLEL WITH TH E GRAIN METAL EXTENDING APPROXIMATELY 75 PERCENT OF THE WIDTH OF THE DISC. THE THIRD CRACK RUNNING PERPENDICULAR TO THE GRAIN APPROXIMATELY 75 PERCENT OF THE WIDTH OF THE DISC. 1 G 7 1 3U O H2SW 1997040300662 19970403 00662 GL 1997 4 3 97ZZZX1281 2 19970109 G 7320 G851430 REAR SUPPORT G890550 BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ENGINE COMP CRACKED B ALGR K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SW 03 4572V 37119 770 ER38066 S665 CAE836143 COMPRESSOR WAS REMOVED FOR LOW POWER AND UPON PRELIMINARY INSPECTION, FOUND CRACKING OF REAR SUPPORT. AT APPROXIMATELY 1-5 INCHES OUT FROM BEARING BORE, FOUND CRACKING FROM 220 DEGREES - 260 DEGREES AROUND ON REAR SUPPORT. 1 G 7 2 3U 3 U H3EU E4CE 1997040300664 19970403 00664 SW 1997 4 3 97ZZZX1283 1 19970115 G 6210 206015001107 BLADE BELL 206 206L1 1182107 SW M/R SEPARATED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 5750Y 3303 A1242 45517 DISCOVERED DURING ROUTINE MAINTENANCE, SKIN SEPARATED FORM SPAR AT BLADE TIP. 1 G 7 1 3U H2SW 1997040300665 19970403 00665 SW 1997 4 3 97ZZZX1284 1 19970213 G 6210 206015001107 BLADE BELL 206 206L1 1182107 SW M/R SEPARATION B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 5760A 1876 A1358 45538 DURING DAILY INSPECTION FOUND SKIN SEPARATED OVER SPAR AND BLADE TIP. 1 G 7 1 3U H2SW 1997040300666 19970403 00666 SW 1997 4 3 97ZZZX1285 1 19970213 G 6210 206015001107 BLADE BELL 206 206L1 1182107 SW M/R SEPARATION B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 5760A 1876 A1361 45538 DURING DAILY INSPECTION FOUND SKIN SEPARATED AND CORRODED OVER SPAR AT TIP. 1 G 7 1 3U H2SW 1997040300667 19970403 00667 NE 1997 4 3 97ZZZX1286 1 19970120 G 6210 7615009100050 BLADE RIB SKRSKY S76 S76 8143010 NE M/R DEDBONDED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 702AL 6257 A08600880 760243 DISCOVERED DURING 500 HOUR INSPECTION THAT BLADE TIP RIB WAS DEBONDED. 1 G 7 2 3U H1NE 1997040300668 19970403 00668 SW 1997 4 3 97ZZZX1287 1 19970212 G 6230 206010443001 DUPLEX BEARING BELL 206 206L1 1182107 SW SWASHPLATE PITTED B ZV1R K NONE O OTHER IN INSP/MAINT 1 SW 03 2618 244 45503 SWASHPLATE REMOVED DUE TO BEARING ROUGHNESS. FOUND DUPLEX BEARING RACE PITTED DURING DISASSEMBLY AND INSPECTION. 1 G 7 1 3U H2SW 1997040300826 19970403 00826 NM 1997 4 3 97ZZZX1307 1 19970311 G 2720 69356021 LEVER ASSY 65C370527 BOEING 737 7373G7 1384595 NM RUDDER PCU BEARING DEFECT B A IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 43783 1026ASP TESTING, RUDDER PCU WAS WORKING FOR ABOUT 5 COMPLETE CYCLES SECONDARY STROKE/FLOW TEST PASSED IN BOTH RETRACT AND EXTEND POSITION. IN NEUTRAL TO FULL EXTEND, UNIT WAS BYPASSING AND WANTING TO GO IN THE RETRACT POSITION. IT REQUIRED AN EXC ESSIVE AMOUNT OF FORCE TO KEEP IN NEUTRAL OR EXTEND. UNIT WAS PUT IN THE ELECTRICAL POSITION MODE, UNIT WOULD NOT RESPO ND. IT WOULD HAVE A 5 TO 10 SECOND DELAY AND THEN WOULD OSCILLATE. COULD NOT CONTROL UNIT WITH THE POSITION KNOB. UNI T WAS OUT IN THE TOGGLE POSITION. IT WAS SHUDDERING IN BOTH DIRECTIONS. BEARING ON LEVER ASSY (18-1106) WAS NOT PROPER LY SECURED CAUSING BEARING TO POP UP ENOUGH TO CAUSE THE PRIMARY SLIDE TO BIND UP CAUSING AN UNWANTED RUDDER INPUT. 2 L 7 2 4F RT A16WE 1997040300829 19970403 00829 SO 1997 4 3 97ZZZX1310 1 19970319 G 2750 454657 BREAKER PIPER PA31 PA31350 7103110 SO FLAP FAILED B DINR K NONE O OTHER IN INSP/MAINT 1 EA 17 23TL 3295 318152172 DURING OUTGOING RUN-UP AFTER ANNUAL INSPECTION, FOUND BOTH COWL FLAPS INOPERABLE. TROUBLESHOT AND FOUND 10-AMP CIRCUIT BREAKER, P/N 454-657, FAILED TO OPEN. REPLACED BREAKER WITH NEW AND OPERATIONAL CHECKED GOOD. CUT OPEN OLD BREAKER AND FOUND CORROSION ON CONTACTS AND ALL INTERNAL PARTS. 1 L 7 2 3O A20SO 1997040300830 19970403 00830 CE 1997 4 3 97ZZZX1311 1 19970315 G 2432 RG35 BATTERY CONCORDEBATT CESSNA 182 182K 2072724 CE NEG POST POST MELTED D A K NONE O OTHER NR NOT REPORTED 1 GL 13 2624R 29 CBC293615 18258324 THE AIRPLANE HAS A CONCORDE RG35 (RECOMBINANT GAS) SEALED BATTERY INSTALLED. THE NEGATIVE BATTERY POST-POTTING SOLDER M ELTED (TWO TIMES, TWO DIFFERENT BATTERIES) JUST ENOUGH TO LEAVE THE TERMINAL GROUND STRAP CONNECTION LOOSE. I BELIEVE I T HAPPENS ON CHARGE-UP AFTER A LOW BATTERY. BOTH OF THE DAMAGED BATTERIES WERE REPLACED UNDER WARRANTY. CONCORDE SAYS THAT THEY ARE AWARE OF THE PROBLEM AND ARE WORKING ON A FIX. THIS ARIPLANE WAS USED IN FREQUENT IFR CONDITIONS AND WAS JUST A MOMENT AWAY FROM TOTAL ELECTRICAL FAILURE ON TWO SEPARATE OCCASIONS. 1 H 7 1 3O NT 3A13 1997040300831 19970403 00831 CE 1997 4 3 97ZZZX1312 1 19970219 G 5210 354104565 LATCH BEECH 58 58 1152740 CE FORWARD COCKPIT REQUIRED ADJ C S A A UNSCHED LANDING O OTHER CL CLIMB 1 SW 03 3012W TH364 SHORTLY AFTER TAKEOFF, COPILOT'S DOOR POPPED OPEN. AIRCRAFT RETURNED TO AIRPORT AND LANDED SAFELY. READJUSTED UPPER LA TCH. SUBMITTER SUGGESTION: EXTRA CARE BE TAKEN DURING 100-HOUR INSPECTION TO ENSURE PROPER LATCH RIGGING. 1 L 7 2 3O 3A16 1997040300832 19970403 00832 SO 1997 4 3 97ZZZX1313 2 19970226 G 8550 ENGINE CONT O470 IO470C 17026 SO ENGINE OIL LOW PRESSURE D K NONE O OTHER IN INSP/MAINT 1 SO 05 2842 7 711617C AT ANNUAL INSPECTION, ENGINE OIL PRESSURE WAS BELOW SPECIFIED LIMITS. CAUSE UNKNOWN. 3 O E273 1997040300834 19970403 00834 SO 1997 4 3 97ZZZX1315 1 19970318 G 5730 SKIN PIPER PA46 PA46350P SO LT WING MLG DOOR CRACKED B AIHR K NONE O OTHER IN INSP/MAINT 1 GL 11 61FL 1294 4622037 DURING THE ANNUAL INSPECTION, A CRACK WAS FOUND IN THE BOTTOM SKIN OF THE LEFT WING. THE CRACK WAS .75 INCH LONG AND ST ARTED AT THE FRONT CORNER OF THE LEFT MAIN GEAR DOOR. THE CRACK WAS LOCATED .1250 INCH AFT OF THE S.B. REINFORCEMENT KI T. THE CRACK RAN PARALLEL TO THE SPAR REINFORCEMENT PATCH. 1 L 7 1 3O RT A25SO 1997040300836 19970403 00836 SO 1997 4 3 97ZZZX1317 1 19970307 G 5510 452394 BEARING PIPER PA28 PA28161 7102803 SO STABILATOR WORN H K NONE O OTHER IN INSP/MAINT 1 SW 03 PA281 288016285 PIVOT BEARINGS WERE WORN TO POINT WHERE OUTBOARD END OF STABILATOR HAD 2 INCHES PLAY UP AND DOWN. 1 L 7 1 3O 2A13 1997040300837 19970403 00837 SO 1997 4 3 97ZZZX1318 1 19970304 G 2840 55000092 FUEL LINE GULSTM AA5 AA5B 3960105 SO COCKPIT BROKEN G A A UNSCHED LANDING K FLUID LOSS CR CRUISE 1 GL 03 81182 AA5B0450 REPORTED FUEL IN COCKPIT AND LANDED WITHOUT INCIDENT. INVESTIGATION REVEALED BROKEN FUEL LINE. 1 L 7 1 3O A16EA 1997040300838 19970403 00838 EA 1997 4 3 97ZZZX1319 2 19970307 G 8530 SL14995 SPRING PIPER PA25 PA25235 7102504 SO LYC O540 O540B2C5 41532 EA SHROUD TUBE BROKE D A K NONE O OTHER IN INSP/MAINT 1 GL 21 8677L 255427 L1480540 DURING ASSEMBLY OF THIS ENGINE, 6 SHROUD TUBE SPRINGS WERE INSTALLED, 3 BROKE WHEN THE NUT WAS TIGHTENED. THESE SPRINGS WERE SUPPLIED AS PART OF A PACKET SET FROM SUPERIOR AIR PARTS. 1 L 7 1 3O 3 O 2A10 E295 1997040300839 19970403 00839 EA 1997 4 3 97ZZZX1320 1 19970301 G 7713 GAUGE SCWZER G164 G164A 3952704 EA MANIFOLD PRESS READS LOW D K NONE O OTHER IN INSP/MAINT 1 SW 07 84PG 1536 INVESTIGATION FOR CONTINUING CYLINDER PROBLEMS, CRACKS, ETC., FOUND MANIFOLD PRESSURE GAUGE READING LOW. VERIFIED INCOR RECT READING PER BARO PRESSURE. SUSPECT OVERBOOST OF CYLINDERS DUE TO INCORRECT MP GAUGE READING. 1 Q 7 1 3R 1A16 1997040300840 19970403 00840 EU 1997 4 3 97ZZZX1321 1 19970305 G 2730 LEVER ARM BRAERO 1000 BAE1251000 1500287 EU ELEVATOR GOUGED B L A LEGR K NONE O OTHER IN INSP/MAINT 1 NE 03 514QS 3312 NAS1005 DURING A ROUTINE INSPECTION, FOUND ELEVATOR LEVER ARM (IPC 55-20-05-01, ITEM 370) GOUGED ON THE OUTBOARD SIDE APPROXIMAT ELY .5 INCH ABOVE ELEVATOR ROD ATTACHEMENT BOLT. DURING REMOVAL AND INSTALLATION OF THE TAIL ASSEMBLY BULLET FAIRING, ( IPC 55-30-10-01, PAGE 0) SCREWS (ITEM 10) FOR THE LEFT AND RIGHT INSPECTION PANELS (ITEMS 25 AND 30) CAN CONTACT THE ELE VATOR ACTUATING LEVER ESPECIALLY IF LONGER SCREWS ARE INSTALLED. FOUND LONGER SCREWS HAD BEEN INSTALLED IN SEVERAL LOCA TIONS ON THIS PANEL. 2 L 7 2 4F RT A3EU 1997040300841 19970403 00841 CE 1997 4 3 97ZZZX1322 1 19970319 G 7333 3035737 LINE BEECH 2000 2000 1152000 CE FUEL FLOW XDUCER CHAFED B A ERYR K NONE O OTHER IN INSP/MAINT 1 SO 11 999RF 1194 NC9 DURING ROUTINE INSPECTION, FOUND THE STAINLESS STEEL FUEL LINE FROM THE FUEL FLOW TRANSDUCER TO FLOW DIVIDER IN CONTACT WITH AND CHAFED INTO BY POWER LEVER BRACKET, P/N 122-940028-1. CHAFE AREA IS AT THE APEX OF THE FIRST BEND OF THIS LINE AS IT LEAVES THE FUEL FLOW TRANSDUCER. INSPECTED TWO OTHER AIRCRAFT AND FOUND SIMILAR CONTACT IN 4 OUT OF 6 POSSIBLE L OCATIONS. 1 L 7 2 4T RT A38ACE 1997040300842 19970403 00842 GL 1997 4 3 97ZZZX1323 2 19970321 G 7210 6889700 PINION GEAR 6886442 ALLSN 250C 250C20B 03013 GL GEARBOX WORN D K NONE O OTHER IN INSP/MAINT 1 NM 11 4889 2229076 INTERNAL SPLINES WORN OR AT LEAST BEYOND MAXIMUM LIMITS. NO WEAR STEP. BOTH BEARINGS JOURNALS .0002 INCH BELOW MINIMUM DIAMETER. 3 U E4CE 1997040300843 19970403 00843 1997 4 3 97ZZZX1324 1 19970321 G 3350 EMSE299A BATTERY PACK GULTON EMBS1392 GALLEY SHORTED B DM4R K NONE O OTHER IN INSP/MAINT 1 SO 19 1155TM BATTERY PACK HAS SEVERAL SHORTED CELLS. BATTERY PACK WAS REPLACED NEW FROM MANUFACTURER ON 1-30-97. EMERGENCY LIGHTS C AME ON WITH SWITCH OFF. 1997040300844 19970403 00844 CE 1997 4 3 97ZZZX1325 1 19970320 G 3010 260106712 LINE CESSNA 208 208B 2073701 CE DEICE HOLED B A P3NR K NONE O OTHER IN INSP/MAINT 1 EA 13 7580B 5013 208B0051 DURING A SCHEDULED INSPECTION, NOTED THE SECOND CYCLE OF THREE WAS NOT HOLDING ENOUGH PRESSURE IN THE SURFACE DEICE SYST EM. INSPECTION REVEALED A HOLE IN AN ALUMINUM LINE CAUSED BY A SCREW IN AN INSPECTION COVER MAKING CONTACT. SUGGEST MA KING SURE ADEQUATE CLEARANCE EXISTS AROUND INSPECTION COVERS AND PLUMBING. 1 H 7 1 3T A37CE 1997040300845 19970403 00845 CE 1997 4 3 97ZZZX1326 1 19970312 G 8010 2T4687 RELAY 241804331 LEAR 35 35A 5170602 CE START CUTOUT DEFECTIVE B DINR K NONE O OTHER IN INSP/MAINT 1 EA 17 258G 3929 443 HAD INTERMITTENT STARTER OPERATION ON NR 2 ENGINE. 'DELAYED' OR NO ROTATION WHEN STARTER SWITCH WAS MOVED TO THE START POSITION. FOUND POOR ELECTRICAL CONNECTION THROUGH THE CONTACTS OF THE K68 START CUT-OUT RELAY, P/N 2T-4687, LOCATED IN THE FUEL CONTROL RELAY PANEL, P/N 2418043-31. REPLACED RELAYS K68, K7A, K7B, AND K5. ALL LIKE PART NUMBERS WITH NEW STYLE RELAYS P/N E210-1655 AND OPERATIONAL CHCKED GOOD. 2 L 7 2 4F A10CE 1997040300846 19970403 00846 EU 1997 4 3 97ZZZX1327 1 19970318 G 5522 54630122 ELEVATOR ISRAEL 1123 1123 4500101 EU LT-RT ELEV CORRODED H GQFG K NONE O OTHER IN INSP/MAINT 1 SW 09 44PR 169 MAJOR CORROSION ON TRAILING EDGE RIVET LINE. MISSING AND WORKING RIVETS AS A RESULT. 2 M 7 2 4J A2SW 1997040300847 19970403 00847 EA 1997 4 3 97ZZZX1328 2 19970310 G 7314 02532330003 PUMP PESCO BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA LT ENGINE FUEL SEIZED D O OTHER X ENGINE FLAMEOUT CR CRUISE 1 GL 23 942CE 6295 3459 BB494 PCE81782 LEFT ENGINE ROLLED BACK TO IDLE CUT-OFF IN FLIGHT. (FLAME OUT.) MAIN ENGINE FUEL PUMP SEIZED CAUSING ROUNDING OFF OF S PLINE ON PUMP AND DRIVE COUPLING. SUBMITTER SUGGESTED TO INCREASE FREQUENCY OF INSPECTION FOR THIS COMPONENT. 1 L 7 2 4T 4 T A24CE E4EA 1997041000036 19970410 00036 CE 1997 4 10 97ZZZX1329 1 19970127 G 3710 3H647 REGULATOR CESSNA 500 S550 2076607 CE GYRO AIR DEFECTIVE B CWQR K NONE O OTHER IN INSP/MAINT 1 GL 05 211QS 8128 S5500011 DURING POST-INSPECTION RUN UP, NOTICED CO-PILOT'S ATTITUDE GYRO AIR PRESSURE LOW AND GYRO UNSTABLE. FOUND FIRST STAGE A IR PRESSURE REGULATOR LOWER THAN NORMAL AND UNADJUSTABLE. REPLACED REGULATOR. FOUND CORROSION, DIRT, AND WATER INSIDE R EGULATOR. AIR FILTER AND WATER SEPARATOR NOT REMOVING WATER. 1 L 7 2 4F RT A22CE 1997041000037 19970410 00037 CE 1997 4 10 97ZZZX1330 1 19970113 G 7720 TERMINAL LUG CESSNA 500 S550 2076607 CE T1 PROBE WRONG PART B CWQR K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 05 93QS S5500093 DURING ENGINE INSPECTION, FOUND IMPROPER TERMINAL LUG ON RIGHT ENGINE T1 PROBE. THE TERMINAL APPEARS TO BE THE PROPER M ATERIAL (AL), BUT IS NOT A 1-322338-0 TERMINAL. IT APPEARS THAT THIS TERMINAL LUG WAS INSTALLED WHEN THE PROPER ONE WAS UNAVAILABLE. 1 L 7 2 4F RT A22CE 1997041000038 19970410 00038 NE 1997 4 10 97ZZZX1331 3 19970220 G 6111 A2202 BEARING RACE BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE INBD BLADE SPLIT G P K NONE O OTHER IN INSP/MAINT 1 CE 01 94UX 6635 2882 6 UE94 HJ211 BLADE, S/N 930, PROPELLER WAS REMOVED FOR LOOSE BLADES AND SLINGING GREASE. WHEN DISASSEMBLED FOUND BLADE BEARING (SPLI T BEARING). ONE-HALF OF IT SPLIT IN TWO, OTHER ONE-HALF HAS ONE SIDE SPLIT AND BROKEN OFF, 2 INCH PIECE, AND OTHER SIDE SPLIT .50 INCH. 2 L 7 2 4T RT A24CE 5 C P10NE 1997041000039 19970410 00039 NE 1997 4 10 97ZZZX1332 3 19970220 G 6111 A2202 BEARING RACE BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE INBD BLADE SPLIT G K NONE O OTHER IN INSP/MAINT 1 CE 01 94UX 6635 2882 34 UE94 HJ211 BLADE, S/N 982, PROPELLER WAS REMOVED FOR LOOSE BLADES AND SLINGING GREASE. WHEN DISASSEMBLED, FOUND ONE-HALF OF SPLIT BEARING TO BE CRACKED UP CENTER APPROXIMATELY 2 INCHES. 2 L 7 2 4T RT A24CE 5 C P10NE 1997041000040 19970410 00040 NM 1997 4 10 97ZZZX1333 1 19970304 G 2731 600035507 CONTROL CABLE 600014503 PIPER PA60 PA60600 7106001 NM ELEVATOR TRIM BROKEN D K NONE O OTHER IN INSP/MAINT 1 GL 09 8234J 8600 600638796120 DURING INSPECTION, MAINTENANCE NOTICED THAT THERE WAS 'SPRING' IN THE ELEVATOR TRIM CABLE ASSY. MECHANIC APPLIED SLIGHT PRESSURE TO TRIM TABS AT WHICH POINT THE CABLE SNAPPED. INVESTIGATION REVEALED THE CABLE WAS BROKEN .25 INCH FROM THE SWAGED END. SUGGEST PERIODIC REPLACEMENT OF CABLE AS IT IS NOT POSSIBLE TO INSPECT IT. 1 M 7 2 3O RT A17WE 1997041000046 19970410 00046 1997 4 10 97ZZZX1339 4 19970123 G 2211 7008138903 COMPUTER FZ710 BOLKMS BK117 BK117C1 5626025 EU NR 1 AUTOPILOT FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 89080110 7505 NR 1 AUTOPILOT WOULD NOT COME ON LINE. 1 G 7 2 3U NC H13EU 1997041000047 19970410 00047 1997 4 10 97ZZZX1340 4 19970102 G 3421 4021541671 GYRO HORIZON BOLKMS 117 BK117A3 5626015 EU COCKPIT FAILED B TI1R O OTHER J WARNING INDICATION CR CRUISE 1 SW 05 911MZ 1 88071674 7098 HORIZON STARTED SPINNING AND TUMBLING IN-FLIGHT. 1 G 7 2 3U H13EU 1997041000049 19970410 00049 1997 4 10 97ZZZX1342 4 19970117 G 3421 4021541671 GYRO HORIZON BOLKMS 117 BK117A3 5626015 EU CSAS PITCH ROLL INOPERABLE B TI1R K NONE I FLT. ATTITUDE INST. IN INSP/MAINT 1 SW 05 911MZ 86081357 7098 GYRO HORIZ PITCH AND ROLL CSAS INOPERABLE. 1 G 7 2 3U H13EU 1997041000050 19970410 00050 1997 4 10 97ZZZX1343 4 19970104 G 2211 117884141 COMPUTER BOLKMS 117 BK117A3 5626015 EU YAW CSAS FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 911MZ 7098 YAW COMPUTER HAD EHA FAILED IN FULL RETRACT POSITION. 1 G 7 2 3U H13EU 1997041000055 19970410 00055 EU 1997 4 10 97ZZZX1348 1 19970120 G 2822 1176415103 PUMP BOLKMS 117 BK117A3 5626015 EU FUEL TRANSFER LEAKING B TI1R K NONE K FLUID LOSS IN INSP/MAINT 1 SW 05 1140H 169726 7078 LEAKING AT CASE DRAIN WHEN PUMP IS SHUT OFF. NEW PUMP, LASTED ONLY 15 MINUTES IN OPERATION. 1 G 7 2 3U H13EU 1997041000057 19970410 00057 EU 1997 4 10 97ZZZX1350 1 19970209 G 3411 PR6123 PITOT TUBE BOLKMS 117 BK117B1 5626012 EU PITOT SYSTEM CRACKED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117LU 5030057 7144 PITOT TUBE DEFORMED AND CRACKED. PREMATURE FAILURE ONLY INSTALLED FOR 205.8 HOURS. 1 G 7 2 3U H13EU 1997041000063 19970410 00063 1997 4 10 97ZZZX1356 4 19970102 G 2211 117884141 COMPUTER BOLKMS 117 BK117A4 5626017 EU YAW CSAS MALFUNCTION B TI1R K NONE O OTHER NR NOT REPORTED 1 SW 05 313LF 107 5034 7138 YAW CSAS OSCILLATES IN-FLIGHT. SAME DISCREPANCY WAS REPAIRED ON LAST REPAIR. (COMPUTER MALFUNCTION.) 1 G 7 2 3U H13EU 1997041000064 19970410 00064 EU 1997 4 10 97ZZZX1357 1 19970111 G 2822 1176415103 BOOST PUMP BOLKMS 117 BK117A4 5626017 EU FUEL SYSTEM LEAKING B TI1R K NONE K FLUID LOSS IN INSP/MAINT 1 SW 05 313LF 6 140485 7138 PUMP LEAKING FROM DRAIN. ONLY 5.6 HOURS IN A/C BEFORE FAILURE. 1 G 7 2 3U H13EU 1997041000065 19970410 00065 WP 1997 4 10 97ZZZX1358 2 19970310 G 7210 31016051 TRANSFER TUBE STBROS SC7 SC7SERIES3 8100512 EU GARRTT TPE331 TPE3312201A WP GEARBOX OIL FRACTURED B ILIR E ENGINE SHUTDOWN R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 WP 07 101UV 467 SH1842 P90255 PILOT REPORTED A LOSS OF POWER AND GEARBOX NOISE AND SHUT THE ENGINE DOWN. AFTER DISASSEMBLY OF THE GEARBOX, DISCOVERED THE OIL TUBE 3101605-1 HAD FRACTURED AND A 3 INCH PIECE OF THE TUBE WAS FOUND IN THE GEARBOX NEXT TO THE OIL SCAVENGE P UMP PICK-UP TUBE. THIS TUBE FEEDS OIL PRESSURE TO THE HIGH SPEED PINION WHICH FAILED AFTER OIL PRESSURE WAS LOST. AD 7 6-16-01 COVERS THIS PROBLEM, BUT AFTER CHECKING THE AD AND ITS MANUFACTURER'S SB, IT WAS DETERMINED THAT TUBE 3101605-1 IS THE TUBE CALLED FOR DURING C/W THE AD AND SB. C/W THE AD WAS PERFORMED 19 YEARS PRIOR TO THE TUBE FAILURE. 1 H 7 2 3T 4 T NT A15EU E3WE 1997041000066 19970410 00066 NE 1997 4 10 97ZZZX1359 1 19970220 G 5530 WEB SKRSKY S76 S76 8143010 NE AFT PYLON MISMANUFACTURED B ALGR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 UPON RECEIVING PART (NEW) FROM SIKORSKY, FOUND PYLON WEB MADE OF WRONG ALLOY OR NOT HEAT TREATED CORRECTLY. METAL TOO S OFT. 1 G 7 2 3U H1NE 1997041000067 19970410 00067 SW 1997 4 10 97ZZZX1360 1 19970214 G 6230 206010336005 LINK ASSY BELL 206 206L 1181522 SW PYLON WORN B ZV1R K NONE O OTHER IN INSP/MAINT 1 SW 03 DRIVE LINK ASSY HAS EXCESS PLAY AT TWO PLACES. SEE BELL MM L-3 FIG 62.21. AT TEAR DOWN, FOUND BEARINGS AND SPACERS WOR N BEYOND LIMITS. TOTAL TIME OF PARTS LESS THAN 1,000 HOURS AND 1 YEAR SINCE REPLACEMENT. REPLACED 4 EACH. 1 G 7 1 3U H2SW 1997041000068 19970410 00068 SW 1997 4 10 97ZZZX1361 1 19970317 G 7603 660190003 CONTROL CABLE MOONEY M20 M20C 5870208 SW THROTTLE DEFECTIVE B FC6R K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 11 101T 2887 CABLE WAS MANUFACTURED AND DELIVERED WITHOUT THE FRICTION LOCK COLLAR. 1 L 7 1 3O 2A3 1997041000069 19970410 00069 CE 1997 4 10 97ZZZX1362 1 19970105 G 5270 P18M30 SWITCH CESSNA 500 560CESSNA 2076750 CE CABIN DOOR FAILED B CWQR K NONE O OTHER IN INSP/MAINT 1 GL 05 350RD 1797 341 5600026 CREW REPORTED THAT DOOR SEAL CAUTION LIGHT DOES NOT COME ON WHEN SEAL DEFLATED. FOUND DOOR SEAL PRESSURE SWITCH STUCK O PEN. SUSPECT CAUSE IS CORROSION/CONTAMINATION, AND/OR POSITION OF SWITCH. SUBMITTER SUGGESTS A MORE RESISTENT SWITCH O R A BETTER POSITION TO MINIMIZE CONTAMINATION. 2 L 7 2 4F RT A22CE 1997041000070 19970410 00070 CE 1997 4 10 97ZZZX1363 1 19970318 G 3610 NAS130413 BOLT LEAR 55 55LEAR 5170702 CE NR 2 ENG BLEED FAILED B S A DINR K NONE O OTHER IN INSP/MAINT 1 EA 17 127GT 4006 067 FOUND EVIDENCE OF A BLEED AIR LEAK ON THE INBOARD UPPER COWL OF THE NR 2 ENGINE. REMOVED COWL AND FOUND BLEED AIR FLANG E (ITEM NR 159C REF PAGE 2) SEPARATED APPROXIMATELY .1250 INCH. BOTH BOLTS (ITEM NR 160) HAD THEIR HEADS SHEARED OR POP PED OFF. THE GASKET (ITEM NR 163P) WAS COMPLETELY MISSING. REPLACED ALL GASKETS AND HARDWARE WITH NEW. 2 L 7 2 4F A10CE 1997041000071 19970410 00071 CE 1997 4 10 97ZZZX1364 1 19970301 G 5540 65310181 BRACKET CESSNA 172 172P 2072436 CE RUDDER ATTACH LOOSE RIVETS B S AHVR K NONE O OTHER IN INSP/MAINT 1 GL 11 92SP 6500 17268830 INSPECTTION FOUND BOTTOM ATTACHMENT BRACKET FOR RUDDER BOLT TO HAVE LOOSE RIVETS. SUBMITTER STATES THIS WAS SECOND ONE FOUND THIS YEAR. 1 H 7 1 3O NT 3A12 1997041000072 19970410 00072 CE 1997 4 10 97ZZZX1365 1 19970301 G 5540 05310181 BRACKET CESSNA 172 172D 2072410 CE RUDDER ATTACH LOOSE RIVETS B A AHVR K NONE O OTHER IN INSP/MAINT 1 GL 11 2061Y 4250 17249561 INSPECTION FOUND BOTTOM ATTACHMENT BRACKET FOR RUDDER BOLTS TO HAVE LOOSE RIVETS. SUBMITTER STATED THIS WAS THIRD ONE T HIS YEAR. 1 H 7 1 3O NT 3A12 1997041000073 19970410 00073 CE 1997 4 10 97ZZZX1366 1 19970301 G 5540 05310181 BRACKET CESSNA 172 172I 2072426 CE BOT RUD ATTACH LOOSE RIVETS B AHVR K NONE O OTHER IN INSP/MAINT 1 GL 11 44BL 17256854 DURING SHOP INSPECTION FOUND ATTACH BRACKET FOR RUDDER BOLT TO HAVE LOOSE RIVETS. PART NUMBER FOR BRACKET BOTTOM ATTACH IS 0531018-1 AND FOR TOP ATTACH 0531018-2. 1 H 7 1 3O NT 3A12 1997041000075 19970410 00075 NM 1997 4 10 97ZZZX1368 1 19970119 G 5311 65B01709 FRAME BOEING 747 747228F 1384895 NM BS 300-320 CRACKED B CISY K NONE O OTHER IN INSP/MAINT 1 EA 31 809MC 79993 17434 20887 AD 96-26-04. INSPECTION OF LEFT FRAME BS 300 AND BS 320. BS 300, STR 39 - STR 40, LEFT, CRACKED. BS 320, STR 41 - STR 42, LEFT, CRACKED. REPAIRED IAW ATLAS E.O. 4753A031. 2 L 7 4 4F A20WE 1997041000076 19970410 00076 NM 1997 4 10 97ZZZX1369 1 19970224 G 5311 65B01709 FRAME BOEING 747 747228F 1384895 NM BS 320 STR 39 CRACKED B CISY K NONE O OTHER IN INSP/MAINT 1 EA 31 809MC 20887 AD 96-26-04. INSPECTION OF FRAME, RIGHT BS 320, STR 39R, CRACK FOUND. INTERIM REPAIR CARRIED OUT IAW SRM 53-10-04, FIG URE 85. 2 L 7 4 4F A20WE 1997041000077 19970410 00077 CE 1997 4 10 97ZZZX1370 1 19970301 G 3246 C30482 HUB CESSNA 177 177RG 2073709 CE NLG WHEEL CRACKED H S K NONE O OTHER IN INSP/MAINT 1 GL 03 1571H 177RG0745 CIRCUMSTANCE UNKNOWN. FOUND DURING ANNUAL INSPECTION. HUB THREAD CRACKS LOOK LIKE OVERTORQUE ON A VERY THIN BOSS. 1,0 70 HOURS ON AIRCRAFT AND DEFECTIVE PART. 1 H 7 1 3O A20CE 1997041000079 19970410 00079 EU 1997 4 10 97ZZZX1372 2 19970331 G 7210 837280 SHAFT SPLINES DIAMON DA20A1 DA20A1 05626UX GL ROTAX 912 ROTAX912 55555 EU PROP GEARBOX MISSING D A K NONE O OTHER IN INSP/MAINT 1 WP 23 608F 1161 10033 4380627 FOUND METAL IN CHIP DETECTORS. PULLED GEARBOX FOUND MISSING SPLINES ON PROPELLER SHAFT, P/N 837-280. 1 L 7 1 3O 3 I NT TA4CH EXPE3I 1997041000080 19970410 00080 EU 1997 4 10 97ZZZX1373 2 19970331 G 7210 837280 SHAFT SPLINE DIAMON DA20A1 DA20A1 05626UX GL ROTAX 912 ROTAX912 55555 EU PROP GEARBOX MISSING D A K NONE O OTHER IN INSP/MAINT 1 WP 23 607F 1024 10027 4380622 FOUND METAL IN CHIP DETECTOR. PULLED GEARBOX, FOUND MISSING SPLINES. 1 L 7 1 3O 3 I NT TA4CH EXPE3I 1997041000085 19970410 00085 GL 1997 4 10 97ZZZX1378 2 19970217 G 7250 6875491 MATING RING ALLSN 250C 250C28B 03013 GL TURBINE LEAKING B TI1R K NONE K FLUID LOSS IN INSP/MAINT 1 SW 05 24 QL61430 MATING RING LEAKING AFTER ONLY 23.5 HOURS. 3 U E1GL 1997041000086 19970410 00086 1997 4 10 97ZZZX1379 4 19970213 G 2562 ELT10 ELT NARCO COCKPIT FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 C48466 NO AUDIO DURING FUNCTIONAL CHECK BEFORE INSTALLATION. 1997041000087 19970410 00087 EU 1997 4 10 97ZZZX1380 1 19970212 G 6520 4639310012 BEARING BOLKMS BK117 BK117C1 5626025 EU T/R GEARBOX DAMAGED B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 1982 SCORING ON BEARING ROLLERS, BEARING WAS RECEIVED NEW FROM AEC. 1 G 7 2 3U NC H13EU 1997041000088 19970410 00088 EU 1997 4 10 97ZZZX1381 1 19970204 G 6520 4639310012 BEARING BOLKMS BK117 BK117C1 5626025 EU T/R GEARBOX DAMAGED B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 1793 DAMAGE ON ROLLERS. RECEIVED AS NEW PART FROM AMERICAN EUROCOPTER. 1 G 7 2 3U NC H13EU 1997041000089 19970410 00089 1997 4 10 97ZZZX1382 1 19970203 G 6520 469310012 BEARING T/R GEARBOX DAMAGED B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 1913 DAMAGE ON ROLLERS. BEARING WAS RECEIVED AS NEW, SERVICEABLE FROM AMERICAN EUROCOPTER. 1997041000090 19970410 00090 EU 1997 4 10 97ZZZX1383 1 19970203 G 6520 4639306006 BEARING BOLKMS BK117 BK117C1 5626025 EU T/R GEARBOX DAMAGED B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 2046 FOUND DAMAGE ON ROLLER. BEARING WAS RECEIVED NEW, SERVICEABLE FROM AMERICAN EUROCOPTER. 1 G 7 2 3U NC H13EU 1997041000091 19970410 00091 GL 1997 4 10 97ZZZX1384 2 19970217 G 7250 6898764 BELLOWS SEAL ALLSN 250C 250C20B 03013 GL ENGINE LEAKING B TI1R K NONE K FLUID LOSS IN INSP/MAINT 1 SW 05 24 95859 CARBON BELLOWS SEAL LEAKING AFTER ONLY 23.5 HOURS. 3 U E4CE 1997041000092 19970410 00092 EU 1997 4 10 97ZZZX1385 1 19970219 G 6520 4639311001 BEVEL GEAR BOLKMS 117 BK117A1 5626010 EU T/R GEARBOX DEFECTIVE B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 949 COULD NOT GET A GOOD BACKLASH AND CONTACT PATTERN TOGETHER AS REQUIRED BY CURRENT BK117REM305 MANUAL. PART CAME WITHOUT MANUFACTURER'S CONTACT PRINTS MADE AT MANUFACTURING. 1 G 7 2 3U H13EU 1997041000093 19970410 00093 EU 1997 4 10 97ZZZX1386 1 19970219 G 6520 4639311043 BEVEL GEARSHAFT BOLKMS BK117 BK117C1 5626025 EU T/R GEARBOX DEFECTIVE B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 893 COULD NOT GET A GOOD BACKLASH ON CONTACT PATTERN TOGETHER AS REQUIRED BY CURRENT BK117REM305 MANUAL. PART CAME WITHOUT MANUFACTURER'S CONTACT PRINTS MADE AT MANUFACTURING. 1 G 7 2 3U NC H13EU 1997041000094 19970410 00094 EU 1997 4 10 97ZZZX1387 1 19970219 G 6520 4639310012 BEARING BOLKMS BK117 BK117C1 5626025 EU T/R GEARBOX DAMAGED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 1824 BEARING WAS INSTALLED ON GEARSHAFT, P/N 4639311043 MMIR FORM NR 78853B, AND GEAR WAS FOUND BAD. BEARING WAS DAMAGED DUR ING REMOVING IAW BK117REM305 AND MUST BE REPLACED. 1 G 7 2 3U NC H13EU 1997041000095 19970410 00095 1997 4 10 97ZZZX1388 4 19970217 G 3424 9551BN541 INDICATOR BOLKMS 117 BK117B1 5626012 EU TURN SLIP INOPERATIVE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4 4760 INOPERABLE TURN AND SLIP INDICATOR. 1 G 7 2 3U H13EU 1997041000097 19970410 00097 EU 1997 4 10 97ZZZX1390 1 19970108 G 6330 1171282101 SUPPORT ASSY BOLKMS BK117 BK117C1 5626025 EU TRANSMISSION MISMANUFACTURED B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 13 TRANSMISSION SUPPORT WITH MFG DEFECT. TOP PAD TOO THIN. 1 G 7 2 3U NC H13EU 1997041000103 19970410 00103 SW 1997 4 10 97ZZZX1396 1 19970109 G 2432 RG222 BATTERY BELL 206 206L1 1182107 SW DC SYSTEM FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 721SP 362 CBC261759 45486 BATTERY WOULD NOT HOLD CHARGE. 1 G 7 1 3U H2SW 1997041000116 19970410 00116 CE 1997 4 10 97ZZZX1406 1 19970304 G 3010 621441323 SUPPLY TUBE CESSNA 650 650 2076802 CE WING LE CRACKED B BQVR K NONE O OTHER IN INSP/MAINT 1 EA 01 900FL 1016 6507049 DURING AN INSPECTION REQUIRING WING LEADING EDGE PANEL REMOVAL, THE OUTBOARD CENTER LEADING EDGE SECTION ANTI-ICING SUPP LY TUBE WAS FOUND CRACKED AND NOT CONNECTED. THIS WAS DUE TO MISALIGNMENT WHEN INSTALLED NEW AT THE FACTORY. 2 L 7 2 4F A9NM 1997041000118 19970410 00118 SW 1997 4 10 97ZZZX1407 1 19970120 G 6510 406040340101 COUPLING BELL 407 407 SW SHAFT DISC CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 417AL 131 53054 INSPECTION FOUND TWO OUTER DISCS CRACKED. ONE CRACKED INTO 2 PIECES, ONE CRACKED FROM MIDDLE OF DISC TO INNER EDGE. 1 G 7 1 3U O H2SW 1997041000119 19970410 00119 EU 1997 4 10 97ZZZX1408 1 19970121 G 6210 355A11002009 BLADE AEROSP AS355 AS355E 8680805 EU M/R CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 372E 3615 3841 5208 DURING DAILY INSPECTION, FOUND SKIN CRACKED AT STA 1000 MM. 1 G 7 2 3U H11EU 1997041000317 19970410 00317 GL 1997 4 10 97ZZZX1409 2 19970317 G 7210 6899402 PTO GEAR SPLINE HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL GEARBOX WORN B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 8639F 6734 3420 CG80352 1280431D CAE832846 DURING INSPECTION OF GEARBOX GEARS, FOUND THE PTO GEAR INTERNAL DRIVE SPLINES WORN BEYOND LIMITS. 1 G 7 1 3U 3 U H3WE E4CE 1997041000318 19970410 00318 GL 1997 4 10 97ZZZX1410 2 19970317 G 7210 6896437 SPUR GEAR 6894171 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL GEARBOX SPALLED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 8639F 6734 3420 60509 1280431D CAE832846 DURING INSPECTION OF GEARBOX GEARS, THE TEETH WERE FOUND SPALLED. 1 G 7 1 3U 3 U H3WE E4CE 1997041000319 19970410 00319 GL 1997 4 10 97ZZZX1411 2 19970317 G 7210 6876529 SPUR GEAR 6894171 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL GEARBOX SPALLED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 8639F UP1341 1280431D CAE832846 INSPECTION FOUND GEAR TEETH SPALLED. 1 G 7 1 3U 3 U H3WE E4CE 1997041000320 19970410 00320 GL 1997 4 10 97ZZZX1412 2 19970317 G 7260 6854857 GEARSHAFT 6894171 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL TACH DRIVE WORN B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 8639F 3420 UP1341 1280431D CAE832846 INSPECTION FOUND TACHOMETER DRIVE WORN BEYOND LIMITS. 1 G 7 1 3U 3 U H3WE E4CE 1997041000321 19970410 00321 GL 1997 4 10 97ZZZX1413 2 19970317 G 7260 689701 GEAR 6894171 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL TORQUE METER WORN B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 8639F 6734 3420 NN60045 1280431D CAE832846 DURING INSPECTION OF GEARBOX GEARS, FOUND THE TORQUE METER GEAR DAMPER RING GROOVE WORN BEYOND LIMITS. 1 G 7 1 3U 3 U H3WE E4CE 1997041000322 19970410 00322 NM 1997 4 10 97ZZZX1414 1 19970320 G 5330 6545775 SKIN BOEING 737 737242 1384477 NM BS 822-908 WRINKLED B S5WR K NONE O OTHER IN INSP/MAINT 1 SW 01 159PL 52863 21186 DURING C-CHECK INSPECTION, FOUND SKIN AFT OF AFT CARGO DOOR WRINKLED. CONDITION OF SKIN AN PREVIOUS REPAIRS NECESSITATE REPLACEMENT OF SKIN SECTION IAW BOEING TELEXES SOHR970319 AND SOHR970314. 2 L 7 2 4F A16WE 1997041000323 19970410 00323 GL 1997 4 10 97ZZZX1415 2 19970324 G 7261 6840532 FILTER ASSY ALLSN 250C 250C20B 03013 GL GEARBOX CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 11 4889 UPI342 GEARBOX FILTER ASSY EPOXY IS CRACKED. 3 U E4CE 1997041000427 19970410 00427 1997 4 10 97ZZZX1449 1 19970227 G 2121 1143800287 BLOWER VENT MALFUNCTION D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 03 428 MOTOR TURNS OPPOSITE DIRECTION WHEN POWER IS APPLIED WITH CORRECT POLARITY. RAYTHEON P/N 114-380028-7. ADVANCED IND P/ N BC80A-3. 1997041000428 19970410 00428 NM 1997 4 10 97ZZZX1450 1 19970112 G 3221 162N11427 SUPPORT PLATE BOEING 757 757* NM NLG SHOCK STRUT WRONG COATING B OBJY K NONE K FLUID LOSS IN INSP/MAINT 1 EA 35 SUPPORT PLATE SUB-CONTRACTED FOR APPLICATION OF 'KARON' COATING IAW BOEING 757 CMM 32-21-49. PART RETURNED WITH C OF C AS HAVING C/W ORDER, HOWEVER, PROCESS APPLIED IS NOT KARON COATING. BOEING ADVISED NO OTHER APPROVED PROCESS AND THAT O NLY APPROVED VENDOR IS KAMATICS. 2 L 7 2 4F RT A2NM 1997041000429 19970410 00429 SO 1997 4 10 97ZZZX1451 2 19970317 G 8510 634503 BEARING CONT O520 GTSIO520* 17032 SO PROP DRV GEAR MISPACKAGED B VA1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 19 P/N 630571 (BEARING FOR PROP DRIVER GEAR IN ENGINE CRANKCASE) MARKED ON PACKAGING AS P/N 630571. BEARING ITSELF MARKED AS P/N 634503. P/N 634503 IS CRANKSHAFT MAIN BEARING. PURCHASED NEW FROM TELEDYNE CONTINENTAL MOTORS. BEARINGS WILL F IT IN CRANKCASE SADDLES WHEN SWITCHED, BUT OIL HOLES DO NOT LINE UP AND BEARING OIL GROOVES ARE DIFFERENT WIDTHS. COULD CAUSE BEARING FAILURE/OIL STARVATION. 3 O E7CE 1997041000430 19970410 00430 1997 4 10 97ZZZX1452 4 19970325 G 2564 SAFETY VALVE EAAEROMARINE INFLATE CYLINDER MISASSEMBLED B RC0R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 17 DURING ANNUAL INSPECTION SERVICE OF A 6-MAN LIFE RAFT, THE CYLINDER SAFETY VALVE DISK WAS INSPECTED. AN EXTRA SAFETY DI SK RO508-RA AND AN EXTRA O-RING 514-05B WERE FOUND INSTALLED ON TOP OF THE ORIGINAL O-RING AND DISK. THESE WERE REMOVED AND THE SYSTEM RE-ASSEMBLED. THESE EXTRA COMPONENTS COULD HAVE CAUSED THE SAFETY VALVE NOT TO FUNCTION. 1997041000431 19970410 00431 CE 1997 4 10 97ZZZX1453 1 19970325 G 2701 169420028129 COVER BEECH 23 B24R 1151253 CE CONTROL COLUMN CORRODED B S CS3R K NONE O OTHER IN INSP/MAINT 1 WP 17 104DB 3216 MC309 DURING ANNUAL INSPECTION, DISCOVERED SEVERE CORROSION ALONG SEAMS OF CONTROL COLUMN COVER. 1 L 7 1 3O A1CE 1997041000433 19970410 00433 CE 1997 4 10 97ZZZX1454 1 19970301 G 3240 45226 ADJUSTER TUBE BFGOODRICH CESSNA 500 560CESSNA 2076750 CE BRAKE LOOSE B DXTR K NONE O OTHER IN INSP/MAINT 1 GL 07 348QS 429 215297 5600348 DURING PRE-FLIGHT INSPECTION, THE BRAKE ASSEMBLY ADJUSTER GUIDE TUBE WAS FOUND PROTRUDING ON S/N 2314 AND S/N 2362. THE ADJUSTER ASSEMBLY WAS LOOSE. REMOVED BOTH ASSEMBLIES AND SENT OUT FOR OVERHAUL. 2 L 7 2 4F RT A22CE 1997041000447 19970410 00447 CE 1997 4 10 97ZZZX1468 1 19970318 G 3244 650T661 TIRE GOODYEARAERO BEECH 90 C90 1152913 CE NLG DEFECTIVE B DFKR K NONE O OTHER IN INSP/MAINT 1 CE 05 4774M 41200939 LJ771 GOODYEAR FLIGHT CUSTOM 6.50X10-6PR TUBELESS. REMOVED TIRE FROM NOSE OF AIRCRAFT. TIRE WAS BULGING IN TREAD AREA NEAR S IDEWALL. AFTER TIRE REMOVAL FROM WHEEL, FOUND 'SOFT' AREA INSIDE TIRE AT BULGED AREA. 1 L 7 2 3T 3A20 1997041000450 19970410 00450 EU 1997 4 10 97ZZZX1471 2 19970401 G 7314 996592 PUMP DIAMON DA20A1 DA20A1 05626UX GL ROTAX 912 ROTAX912 55555 EU OUTPUT TUBE CRACKED D A O OTHER K FLUID LOSS CR CRUISE 1 WP 07 671DA 164 960157 10180 4412507 DURING FLIGHT, THE FUEL PUMP HOUSING CRACKED AT THE OUTPUT TUBE CAUSING THE AVAILABLE FUEL TO BE PUMPED INTO THE ENGINE COMPARTMENT. ONE-QUARTER TO ONE-HALF OF THE FUEL TANK WAS LOST IN APPROX 15 MINUTES. CAUSE OF THE FAILURE IS BELIEVED TO BE RELATIVE MOVEMENT OF THE RIDGED FUEL LINE OF ITS ATTACH POINT ON THE BALANCE TUBE. THE BALANCE TUBE WAS FOUND CHA FED. THIS IS THE SECOND OCCURRENCE OF THIS PROBLEM ON THIS AIRCRAFT. SUBMITTER RECOMMENDS AIRCRAFT INSPECTION AND RETU RN TO AN EARLIER DESIGN USING SOFT LINES. 1 L 7 1 3O 3 I NT TA4CH EXPE3I 1997041000451 19970410 00451 GL 1997 4 10 97ZZZX1472 3 19970314 G 6114 7015C87 HUB CESSNA 402 402B 207590P CE MCAULY 3AF32C 3AF32C87 GL NR 3 HOLE CRACKED B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 69374 7979 946 788094 402B0520 788094 INSPECTION FOUND HUB CRACK LOCATED IN NR 3 HOLE, 2ND THREAD FROM OUTSIDE EDGE. 1 L 7 2 3O A7CE 5 C P22EA 1997041000452 19970410 00452 GL 1997 4 10 97ZZZX1473 3 19970314 G 6111 7636D BLADE PIPER PA23 PA23160 7102304 SO HARTZL HC82 HC82VL2 GL V GROOVE CRACKED B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 3403P A8600 231367 K3045 INSPECTION FOUND PROPELLER BLADE CRACKED IN RETENTION V-GROOVE OF BLADE. 1 L 7 2 3O 1A10 5 C P23EA 1997041000453 19970410 00453 NM 1997 4 10 97ZZZX1474 1 19970327 G 2722 680105005 SERVO VALVE 65C370529 BOEING 737 7373G7 1384595 NM RUDDER PCU FAIL TEST B L A AU4R K NONE O OTHER IN INSP/MAINT 1 WP 05 20624 524X BRAZILIAN AIR LINES SENT RUDDER PCU TO REPAIR STATION AU4R FOR EVALUATION FOLLOWING FAILURE ON PRE-FLIGHT TEST PER BAC S B 7371202. FOUND UNIT FAIL TEST 12C SECONDARY STROKE/FLOW OF BAC CMM 27-20-01 AND CAUSE WAS IMPROPER ASSY OF SERVO CONT ROL VALVE AD 94-01-07 AND 95-06-53 APPLICABLE. 2 L 7 2 4F RT A16WE 1997041000458 19970410 00458 SW 1997 4 10 97ZZZX1479 1 19970327 G 3230 ACTUATOR GULSTM 690TP 690B 7630516 SW EMERGENCY EXT LEAK D K NONE O OTHER NR NOT REPORTED 1 SW 11 22CK 11524 N2 SYSTEM SHOWED HIGH PRESSURE. FOUND HYDRAULIC FLUID IN N2 SYSTEM. DRAINED SYSTEM AND RESERVICED WITH N2. SUSPECT CA USE IS MAIN LANDING GEAR EMERGENCY EXTEND ACTUATOR HAS LEAKING SEAL. 1 H 7 2 3T 2A4 1997041000459 19970410 00459 SW 1997 4 10 97ZZZX1480 1 19970309 G 2841 INDICATOR GULSTM 560 560A 0141404 SW FUEL QUANTITY FAILED G A A UNSCHED LANDING O OTHER NR NOT REPORTED 1 GL 15 2751B 251 DURING INVESTIGATION OF OFF-AIRPORT LANDING, IT WAS FOUND THAT THE FUEL QUANTITY INDICATOR WAS SHOWING 45 GALLONS OF FUE L ON BOARD. IN REALITY, ALL TANKS WERE EMPTY. 1 H 7 2 3O 6A1 1997041000460 19970410 00460 NM 1997 4 10 97ZZZX1481 1 19970301 G 5753 SPAR BOEING 727 727276 138408R NM MID FLAP CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 908PG 20951 DURING C-CHECK INSPECTION, INTERGRANULAR CORROSION WAS NOTED IN THE RIGHT WING OUTBOARD MID-FLAP LOWER FRONT SPAR. 2 L 7 3 4F RT A3WE 1997041000461 19970410 00461 CE 1997 4 10 97ZZZX1482 1 19970327 G 3244 301361311 TIRE BEECH B300 B300 1159232 CE SIDEWALL LEAKS B EKGR K NONE O OTHER IN INSP/MAINT 1 WP 07 96KA FL36 BOTH TIRES WERE PUT ON THE SAME DAY. BOTH LEAKED DOWN AND WERE FOUND TO HAVE PIN HOLES IN THE SIDEWALLS. SERIAL NUMBER S ON THE TIRES WERE 60691499 AND 60691500. 2 L 7 2 4T RT A24CE 1997041000462 19970410 00462 SW 1997 4 10 97ZZZX1483 1 19970301 G 5753 FLAP GULSTM 690TP 695A 7630519 SW INBD LT FLAPL MISINSTALLED B XMJR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 19 2267U 96007 WHILE AIRCRAFT WAS UNDERGOING MAINTENANCE, THE INBOARD LEFT FLAP WAS REMOVED. UPON INSTALLATION OF THE FLAP THE ATTACH BOLT MISSED THE ROD END THAT WAS COMING FROM THE PULLEY; THUS, WEDGING THE ROD END BETWEEN BOLT AND THE FLAP SKIN. THIS GAVE THE FALSE APPEARANCE THAT THE ROD END WAS INSTALLED CORRECTELY. IN THIS CONFIGURATION THE FLAP OPERATED NORMALLY. THE AREA OF THE CUT-OUT TOP OF THE FLAP IS NOT ENOUGH TO SEE THE ROD END TO BOLT ATTACHMENT CLEARLY. SUBMITTER STATE D THAT WHENEVER THE FLAPS ARE REMOVED, THAT THE TOP CUT-OUT BE EXTENDED BY .50 INCHES. THIS WOULD PROVIDE POSITIVE VISU AL CONFORMATION OF THE BOLT INSTALLATION. 1 H 7 2 4T 2A4 1997041000463 19970410 00463 CE 1997 4 10 97ZZZX1484 1 19970312 G 5610 1014200811 WINDOW BEECH 90 C90 1152913 CE PILOT SIDE D CRACKED D A I UNSCHED LANDING CABIN DEPRESSURIZATION O OTHER CR CRUISE 1 GL 15 851KA LJ851 WHILE IN CRUISE FLIGHT, PILOT HEARD A LOUD BANG. WHEN HE TURNED TO LOOK, THE 'D' WINDOW ON HIS SIDE HAD CRACKED FROM FO RWARD END TO AFT END. PILOT DE-PRESSURIZED CABIN AND RETURNED TO HOME BASE WITH NO INCIDENT. 1 L 7 2 3T 3A20 1997041000464 19970410 00464 1997 4 10 97ZZZX1485 4 19970317 G 2215 06500760012 PITCH SERVO ALIDSIGNAL KSA470 LEAR 35 31A 5170531 CE AUTOPILOT DEFECTIVE B L NVIR K NONE O OTHER IN INSP/MAINT 1 SW 05 293SA 2547 101 AUTOPILOT PORPOISES DEFECT. FOUND WEAK SERVO, REPLACED SWITCH REPAIRED UNIT. CONTINUED MALFUNCTION WITH AUTOPILOT. LE NGTHY TROUBLESHOOTING FOUND REPAIRED SERVO FAULT HAD BLOWN FUSE IN MODE SELECTOR DUE TO AP ELECTRICAL BOX FEEDBACK TO AP . ALL DEFECTIVE COMPONENTS REPLACED WHICH CORRECTED PROBLEM. 2 L 7 2 4F RT A10CE 1997041000465 19970410 00465 CE 1997 4 10 97ZZZX1486 1 19970301 G 3246 101800145 WHEEL BEECH 200 B200 1152922 CE NR 3 MLG BEARING FAILED G A O OTHER O OTHER TO TAKEOFF 1 EA 17 992TJ 125 BB992 NR 3 MAIN OUTER WHEEL BEARING FAILED. WHEEL DEPARTED AIRCRAFT ON TAKEOFF. WHEEL SLID OVER AXLE NUT AND COTTER PIN. BE ARING CONE SEIZED ON AXLE. AXLE WAS GALLED. BRAKE LINE FITTING SNAPPED OFF. 1 L 7 2 4T A24CE 1997041000466 19970410 00466 CE 1997 4 10 97ZZZX1487 1 19970301 G 3246 13600LA BEARING BFGOODRICH 101800145 BEECH 200 B200 1152922 CE NR 2 MLG WHEEL FAILED C L K NONE O OTHER IN INSP/MAINT 1 EA 17 6812A 350 1267 BB1484 FAILURE OF THE NR 2 MAIN GEAR OUTER WHEEL BEARING WAS FOUND DURING A GEAR LUBRICATION FOLLOWING A GEAR WASH. PREVIOUS T AXIING AND TOWING OF ACFT APPEARED NORMAL. BEARING CAGE ASSY APPEARS TO HAVE FAILED, AND RACE WAS SCORED AS A RESULT OF CAGE DISINTEGRATION. THE SEAL WAS TORN. THE FAILURE DOES NOT APPEAR TO BE LUBRICATION RELATED AND NO SIGNS OF HEAT DA MAGE. THE AXLE SHOWED NO SIGNS OF DAMAGE OR TEMPERATURE. THE FAILED WHEEL BEARING (TIMKEN P/N 13600-LA BEECH P/N 13600 LA3685) WAS CLEANED AND REPLACED 60 HRS PRIOR TO FAILURE. THE FAILED BEARING HAD 350 HOURS TIME IN USE. 1 L 7 2 4T A24CE 1997041000516 19970410 00516 SW 1997 4 10 97ZZZX1488 1 19970331 G 2730 530534501 ARM GULSTM 690TP 695B 3970610 SW ELEV WEIGHT CRACKED B S XMJR K NONE O OTHER IN INSP/MAINT 1 SW 19 81432 3407 96206 DURING THE 100-HOUR INSPECTION, BOTH ARMS ON THE ELEVATOR CONTROL BOBWEIGHT ASSEMBLY WERE FOUND CRACKED AT THE WEIGHT AT TACH POINTS. SUBMITTER RECOMMENDS BEEFING-UP THE AREA OF THE WEIGHT ATTACH POINTS. 1 H 7 2 4T RT 2A4 1997041700006 19970417 00006 WP 1997 4 17 97ZZZX1533 1 19970127 G 5512 SKIN CVAC 440 440 2422902 WP LT HORIZ STAB CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 LEFT HORIZONTAL STABILIZER LEADING SKIN CRACKED. 2 L 7 2 4R 6A6 1997041700007 19970417 00007 WP 1997 4 17 97ZZZX1534 1 19970127 G 5330 SKIN CVAC 440 440 2422902 WP BS 76 STR 10R TORN B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 FUSELAGE UPPER SKIN STA 76, STR 10R, TORN. 2 L 7 2 4R 6A6 1997041700008 19970417 00008 WP 1997 4 17 97ZZZX1535 1 19970127 G 5313 STRINGER CVAC 440 440 2422902 WP BS 413.3 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 STR 24R LAP SEAM CORRODED AFT OF BELT FRAME STA 413.30. 2 L 7 2 4R 6A6 1997041700009 19970417 00009 WP 1997 4 17 97ZZZX1536 1 19970127 G 5330 SKIN CVAC 440 440 2422902 WP FWD FUSELAGE CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 FORWARD LOWER FUSELAGE SKIN CRACKED. 2 L 7 2 4R 6A6 1997041700010 19970417 00010 WP 1997 4 17 97ZZZX1537 1 19970127 G 5320 INTERCOSTAL CVAC 440 440 2422902 WP BS 140 R1 DOOR CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 INTERCOSTAL AND STRINGER AT R1 DOOR LOWER SECTION STA 140 CORRODED. 2 L 7 2 4R 6A6 1997041700011 19970417 00011 WP 1997 4 17 97ZZZX1538 1 19970127 G 5313 STRINGER CVAC 440 440 2422902 WP BS 730-760 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 STRINGERS 4, 5, AND 6, STA 730 - STA 760, CORRODED. LAP SEAM STR 6L STA 681 - STA 730 CORRODED. 2 L 7 2 4R 6A6 1997041700012 19970417 00012 WP 1997 4 17 97ZZZX1539 1 19970127 G 5320 ANGLE CVAC 440 440 2422902 WP AFT BULKHEAD CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 AFT BULKHEAD L-ANGLE CORRODED AT FLOOR LEVEL. 2 L 7 2 4R 6A6 1997041700013 19970417 00013 WP 1997 4 17 97ZZZX1540 1 19970127 G 5330 SKIN CVAC 440 440 2422902 WP BS 730-745 CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 CROWN SKIN CRACKED STA 730 TO STR 745. 2 L 7 2 4R 6A6 1997041700014 19970417 00014 WP 1997 4 17 97ZZZX1541 1 19970127 G 5330 SKIN CVAC 440 440 2422902 WP BS 760 CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 CROWN SKIN CRACKED STA 760. 2 L 7 2 4R 6A6 1997041700015 19970417 00015 WP 1997 4 17 97ZZZX1542 1 19970127 G 5330 SKIN CVAC 440 440 2422902 WP BS 509 STR 21R CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 LAP SEAM CORRODED AT 21R STA 509 TO STA 526. 2 L 7 2 4R 6A6 1997041700016 19970417 00016 WP 1997 4 17 97ZZZX1543 1 19970127 G 5330 SKIN CVAC 440 440 2422902 WP BS 435.23 S21R CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 LAP SEAM CORRODED AT STA 435.23, STR 21R. 2 L 7 2 4R 6A6 1997041700017 19970417 00017 WP 1997 4 17 97ZZZX1544 1 19970127 G 5330 SKIN CVAC 440 440 2422902 WP BS 413-435 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 STR 21L LAP SEAM CORRODED STA 413 TO STA 435. 2 L 7 2 4R 6A6 1997041700018 19970417 00018 WP 1997 4 17 97ZZZX1545 1 19970127 G 5330 SKIN CVAC 440 440 2422902 WP BS 836 STR 4L DENTED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 SKIN DENTED STA 937 STR 4L. 2 L 7 2 4R 6A6 1997041700019 19970417 00019 WP 1997 4 17 97ZZZX1546 1 19970127 G 5320 INTERCOSTAL CVAC 440 440 2422902 WP BS 210-227 GOUGED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 INTERCOSTAL GOUGED AT BELT FRAME FLANGE STA 210 TO STA 227. 2 L 7 2 4R 6A6 1997041700020 19970417 00020 WP 1997 4 17 97ZZZX1547 1 19970127 G 5320 ANGLE CVAC 440 440 2422902 WP COCKPIT CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 ANGLE FORWARD OF CAPTAIN'S INSTRUMENT PANEL CORRODED 2 L 7 2 4R 6A6 1997041700021 19970417 00021 WP 1997 4 17 97ZZZX1548 1 19970127 G 5313 STRINGER CVAC 440 440 2422902 WP BS 92 STR 13R CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 STR 13R CRACKED AND DISTORTED STA 92. 2 L 7 2 4R 6A6 1997041700022 19970417 00022 WP 1997 4 17 97ZZZX1549 1 19970127 G 5320 INTERCOSTAL CVAC 440 440 2422902 WP BS 210 GOUGED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 INTERCOSTAL AT STA 210 GOUGED. 2 L 7 2 4R 6A6 1997041700023 19970417 00023 WP 1997 4 17 97ZZZX1550 1 19970127 G 5330 SKIN CVAC 440 440 2422902 WP BS 730 STR 29R CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 SKIN AT STR 29R CRACKED BETWEEN STA 730 TO STA 745. 2 L 7 2 4R 6A6 1997041700024 19970417 00024 WP 1997 4 17 97ZZZX1551 1 19970127 G 5330 SKIN CVAC 440 440 2422902 WP BS 420 STR 13R CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 FUSELAGE INNER SKIN CRACKED STA 420 STR'S 13 AND 14R 2 L 7 2 4R 6A6 1997041700025 19970417 00025 WP 1997 4 17 97ZZZX1552 1 19970127 G 5330 SKIN CVAC 440 440 2422902 WP BS 420 STR 13L CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 FUSELAGE SKIN INNER SURFACE CRACKED STA 420, STR'S 13, 14L. 2 L 7 2 4R 6A6 1997041700026 19970417 00026 WP 1997 4 17 97ZZZX1553 1 19970127 G 5330 SKIN CVAC 440 440 2422902 WP BS 344 STR 13 CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 FUSELAGE INNER SKIN CRACKED STA 344 BETWEEN STR 13 AND 14R. 2 L 7 2 4R 6A6 1997041700027 19970417 00027 WP 1997 4 17 97ZZZX1554 1 19970127 G 5330 SKIN CVAC 440 440 2422902 WP BS 798 STR 29R CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 SKIN CRACKED STR 29R, STA 798. 2 L 7 2 4R 6A6 1997041700028 19970417 00028 WP 1997 4 17 97ZZZX1555 1 19970127 G 5313 STRINGER CVAC 440 440 2422902 WP BS 760 STR 29R CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 STRINGER 29R CRACKED STA 760. 2 L 7 2 4R 6A6 1997041700029 19970417 00029 WP 1997 4 17 97ZZZX1556 1 19970127 G 5311 BELT FRAME CVAC 440 440 2422902 WP BS 698 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 BELT FRAME AT STA 698 CORRODED RT SIDE. 2 L 7 2 4R 6A6 1997041700030 19970417 00030 WP 1997 4 17 97ZZZX1557 1 19970127 G 5311 FRAME CVAC 440 440 2422902 WP BS 641 S25L CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 FRAME FLANGE CRACKED STA 641 OUTBOARD AT STR 25L. 2 L 7 2 4R 6A6 1997041700031 19970417 00031 WP 1997 4 17 97ZZZX1558 1 19970128 G 3211 FITTING CVAC 440 440 2422902 WP LT MLG TRUNNION CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 LEFT MLG INBOARD TRUNNION FITTING CRACKED. 2 L 7 2 4R 6A6 1997041700032 19970417 00032 WP 1997 4 17 97ZZZX1559 1 19970128 G 5551 FITTING CVAC 440 440 2422902 WP H. STAB ATTACH CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 RIGHT UPPER FORWARD HORIZONTAL STABILIZER ATTACH FITTING ATTACHED. 2 L 7 2 4R 6A6 1997041700033 19970417 00033 WP 1997 4 17 97ZZZX1560 1 19970127 G 5330 SKIN CVAC 440 440 2422902 WP BS 140 STR 11R CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 SKIN CRACKED STA 140 STR 11R. 2 L 7 2 4R 6A6 1997041700034 19970417 00034 WP 1997 4 17 97ZZZX1561 1 19970128 G 5315 FLOOR BEAM CVAC 440 440 2422902 WP BS 681 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 FLOOR BEAM STA 681 CORRODED 2 L 7 2 4R 6A6 1997041700035 19970417 00035 WP 1997 4 17 97ZZZX1562 1 19970128 G 5730 SKIN CVAC 440 440 2422902 WP LT WING CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 WING SKIN, STRINGERS (4 EACH), FORWARD SPAR WEB, AND AFT SPAR WEB CORRODED FROM WET BAY TO WING TIP. 2 L 7 2 4R 6A6 1997041700036 19970417 00036 WP 1997 4 17 97ZZZX1563 1 19970128 G 5730 SKIN CVAC 440 440 2422902 WP WS 23 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 SURFACE CORROSION RIGHT WING BAY WING PLANK STA 23 TO STA 29. 2 L 7 2 4R 6A6 1997041700037 19970417 00037 WP 1997 4 17 97ZZZX1564 1 19970128 G 5330 SKIN CVAC 440 440 2422902 WP ADF ANT CUT-OUT CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 AFT ADF ANTENNA SKIN CUT-OUT CRACKED. 2 L 7 2 4R 6A6 1997041700038 19970417 00038 WP 1997 4 17 97ZZZX1565 1 19970128 G 5720 SHROUD CVAC 440 440 2422902 WP LE WS 290 CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 CRACK IN INNER SHROUD RT OTBD L/E STA 290. 2 L 7 2 4R 6A6 1997041700039 19970417 00039 WP 1997 4 17 97ZZZX1566 1 19970128 G 5330 SKIN CVAC 440 440 2422902 WP BS 193 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 SKIN CORRODED IN FORWARD CARGO BAY AROUND BELT FRAME 193/210. 2 L 7 2 4R 6A6 1997041700040 19970417 00040 WP 1997 4 17 97ZZZX1567 1 19970128 G 5330 SKIN CVAC 440 440 2422902 WP FS 344 STR 13L CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 FUSELAGE INNER SKIN SURFACE CRACKED STA 344, STR'S 13L-14L. 2 L 7 2 4R 6A6 1997041700041 19970417 00041 WP 1997 4 17 97ZZZX1568 1 19970128 G 5730 SKIN CVAC 440 440 2422902 WP WS 23.5 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 LEFT WING UPPER SURFACE HAS CORROSION ON PLANK AND STRINGER BULKHEAD, STA 235 TO 28.5 2 L 7 2 4R 6A6 1997041700042 19970417 00042 WP 1997 4 17 97ZZZX1569 1 19970128 G 5753 BEAVER TAIL RIB CVAC 440 440 2422902 WP RT WING CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 RIGHT WING BEAVER TAIL, NUMEROUS RIBS HAVE EXFOLIATION. 2 L 7 2 4R 6A6 1997041700043 19970417 00043 WP 1997 4 17 97ZZZX1570 1 19970128 G 5720 FRAME CVAC 440 440 2422902 WP LT WING STA 25 CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 LEFT WING STA 25 FRAME CRACKED UPPER 'Z'. 2 L 7 2 4R 6A6 1997041700044 19970417 00044 WP 1997 4 17 97ZZZX1571 1 19970127 G 5313 STRINGER CVAC 440 440 2422902 WP BS 712 S10R CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 FUSELAGE STRINGER 10 RIGHT, CORRODED STA 712. 2 L 7 2 4R 6A6 1997041700045 19970417 00045 WP 1997 4 17 97ZZZX1572 1 19970127 G 5313 STRINGER CVAC 440 440 2422902 WP BS 698 S9R CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 FUSELAGE STRINGER CORRODED, STA 698 RT. 2 L 7 2 4R 6A6 1997041700046 19970417 00046 WP 1997 4 17 97ZZZX1573 1 19970127 G 5320 HAT SECTION CVAC 440 440 2422902 WP BS 681 RT CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 FUSELAGE HAT SECTION CORRODED STA 681, RT SIDE. 2 L 7 2 4R 6A6 1997041700047 19970417 00047 WP 1997 4 17 97ZZZX1574 1 19970127 G 5320 FLOOR SUPPORT CVAC 440 440 2422902 WP BS 681 RT CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 FLOOR SUPPORT CORRODED BETWEEN STA 681-712 RT. 2 L 7 2 4R 6A6 1997041700048 19970417 00048 WP 1997 4 17 97ZZZX1575 1 19970127 G 5315 FLOOR BEAM CVAC 440 440 2422902 WP BS 712 RT CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 FLOOR BEAM CORRODED AT STA 712 RT. 2 L 7 2 4R 6A6 1997041700049 19970417 00049 WP 1997 4 17 97ZZZX1576 1 19970127 G 5321 STRUCTURE CVAC 440 440 2422902 WP COCKPIT FLOOR CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 COCKPIT FLOOR STRUCTURE CORRODED STA 109 CENTER AREA. 2 L 7 2 4R 6A6 1997041700050 19970417 00050 WP 1997 4 17 97ZZZX1577 1 19970127 G 5730 SKIN CVAC 440 440 2422902 WP LT MLG WELL CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 LEFT MLG WHEELWELL AFT LOWER SKIN CRACKED. 2 L 7 2 4R 6A6 1997041700051 19970417 00051 WP 1997 4 17 97ZZZX1578 1 19970127 G 5400 DOUBLER CVAC 440 440 2422902 WP RT PIPE ACCESS CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 DOUBLER CRACKED RT INBD NR 2 ENGINE TAILPIPE ACCESS. 2 L 7 2 4R 6A6 1997041700052 19970417 00052 WP 1997 4 17 97ZZZX1579 1 19970127 G 5315 FLOOR BEAM CVAC 440 440 2422902 WP BS 718 RBL 8 CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 FLOOR BEAM CRACKED STA 718 RBL 8 AND 12. 2 L 7 2 4R 6A6 1997041700053 19970417 00053 WP 1997 4 17 97ZZZX1580 1 19970127 G 5551 FITTING CVAC 440 440 2422902 WP HORIZ STAB CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 582P 475 RT UPPER FORWARD HORIZ STAB FITTING CRACKED. 2 L 7 2 4R 6A6 1997041700054 19970417 00054 CE 1997 4 17 97ZZZX1581 1 19970303 G 2823 13341511 VALVE WHITTAKER MTSBSI MU2 MU2B60 5780460 CE MAIN FUEL SOV FAILED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 25 1297 THE SHUT-OFF VALVE FAILED IN CLOSED POSITION. ORDERED AN OVERHAULED VALVE AND IT TRIPPED THE CIRCUIT BREAKER. THIS WAS A NEWLY OVERHAULED VALVE WITH ZERO TIME. VALVE WAS RETURNED TO VENDOR. 1 H 7 2 3T RT A10SW 1997041700055 19970417 00055 SO 1997 4 17 97ZZZX1582 2 19970310 G 8530 637836 SPRING CONT O520 GTSIO520M 17032 SO VALVE BROKEN B L A WTXR K NONE O OTHER IN INSP/MAINT 1 NM 07 1014 276111R ENGINE WAS RECEIVED AT FACILITY FOR INSPECTION DUE TO METAL CONTAMINATION. UPON DISASSEMBLY OF THE CYLINDERS, NOTED THE RE WAS ONE BROKEN VALVE SPRING ON EACH CYLINDER IN THE INTAKE POSITION. CYLINDERS NR 1, NR 3, AND NR 4 HAD BROKEN INNER VALVE SPRINGS AND CYLINDERS NR 2, NR 5, AND NR 6 HAD BROKEN OUTER VALVE SPRINGS. THE SPRING ON NR 3 CYLINDER APPEARED TO HAVE BEEN BROKEN FOR SOME TIME AND WAS THE SOURCE OF THE METAL CONTAMINATION IN THE ENGINE. 3 O E7CE 1997041700056 19970417 00056 SO 1997 4 17 97ZZZX1583 2 19970310 G 8530 637837 SPRING CONT O520 GTSIO520M 17032 SO VALVE BROKEN B L A WTXR K NONE O OTHER IN INSP/MAINT 1 NM 07 1014 276111R ENGINE WAS RECEIVED AT FACILITY FOR INSPECTION DUE TO METAL CONTAMINATION. UPON DISASSEMBLY OF THE CYLINDERS, NOTED THE RE WAS ONE BROKEN VALVE SPRING ON EACH CYLINDER IN THE INTAKE POSITION. CYLINDERS NR 1, NR 3, AND NR 4 HAD BROKEN INNER VALVE SPRINGS AND CYLINDERS NR 2, NR 5, AND NR 6 HAD BROKEN OUTER VALVE SPRINGS. THE SPRING ON NR 3 CYLINDER APPEARED TO HAVE BEEN BROKEN FOR SOME TIME AND WAS THE SOURCE OF THE METAL CONTAMINATION IN THE ENGINE. 3 O E7CE 1997041700057 19970417 00057 SO 1997 4 17 97ZZZX1584 1 19970301 G 5711 SPAR GULSTM AA5 AA5 0631410 SO LT WING ROOT CORRODED D S A K NONE O OTHER IN INSP/MAINT 1 NM 02 5507L AA50627 AIRCRAFT WAS BEING DISASSEMBLED FOR PAINTING. UPON REMOVAL OF LEFT WING ROOT, AN AREA OF INTERGRANULAR CORROSION WAS FO UND ON THE TOP SURFACE OF THE INBOARD SPAR. EXFOLIATION HAD PENETRATED TO A DEPTH OF .0625 INCH OVER AN AREA APPROXIMAT ELY 3 INCHES BY 1.50 INCHES. THIS PORTION OF SPAR IS TOTALLY INACCESSIBLE UNLESS WING AND WING ROOT ARE REMOVED. SUSPE CT MOISTURE IS TRAPPED BETWEEN SPAR AND INSIDE SURFACE OF WING ROOT. 1 L 7 1 3O A16EA 1997041700058 19970417 00058 CE 1997 4 17 97ZZZX1585 1 19970327 G 3710 RAIJ47 FILTER RAPCO BEECH 33 F33A 1151425 CE AUX AIR SYSTEM MELTED D A K NONE O OTHER IN INSP/MAINT 1 WP 07 5530A 50 CE1342 IN-LINE AIR FILTER FOR AUXILIARY AIR SYSTEM MOUNTED SIX INCHES FROM LEFT EXHAUST STACK. THIS ITEM WAS MOUNTED FOR 50 HO URS IN WHICH TIME PART OF THE HOUSING MELTED, AND THE REST BROKE APART FROM HEAT DAMAGE. HOUSING IS MADE OF PLASTIC. M ANUFACTURER NEEDS TO RETURN TO USE OF METAL HOUSING. 1 L 7 1 3O 3A15 1997041700059 19970417 00059 SO 1997 4 17 97ZZZX1586 1 19970131 G 3230 3807802 HOOK PIPER PA32 PA32R301T 7103220 SO NLG DOWNLOCK WORN D L O OTHER N FALSE WARNING TX TAXI/GRND HDL 1 SW 09 8292G 32R8129004 PILOT REPORTED THE NOSE GEAR DOWN INDICATOR LIGHT WOULD 'FLICKER' AND THE GEAR PUMP RUN INTERMITTENTLY DURING TAXI. INV ESTIGATION REVEALED THE NOSE GEAR DOWNLOCK HOOK WAS SEVERELY WORN WHERE THE ARM OF THE DOWNLOCK SWITCH CONTACTED IT. TH IS ALLOWED THE SWITCH TO CLOSE AS THE DRAG LINK/DOWNLOCK ASSY FLEXED UNDER TAXI LOADS. 1 L 7 1 3O A3SO 1997041700060 19970417 00060 1997 4 17 97ZZZX1587 4 19970313 G 2562 AK450 ELT AMERIKING G SWITCH FAILED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 05 4504652 OUT OF BOX FAILURE: G-SWITCH. NEW ELT FUNCTION CHECKS NORMALLY ON TEST CIRCUIT, BUT WHEN G-SWITCH IS ACTIVATED THE TON E DOES NOT SWEEP. SUSPECT DEFECTIVE (HIGH RESISTANCE) G-SWITCH. 1997041700061 19970417 00061 CE 1997 4 17 97ZZZX1588 1 19970319 G 5751 0523816 HINGE CESSNA 172 172G 2072420 CE AILERON DAMAGED D S K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 15 HINGE AS DELIVERED FROM MFG SHOWS WHAT APPEARS TO BE A TOOL MARK. SUBMITTER STATED MAKE SURE PART IS INSPECTED BEFORE U SE. 1 H 7 1 3O NT 3A12 1997041700062 19970417 00062 SO 1997 4 17 97ZZZX1589 2 19970321 G 8530 TM641370 CYLINDER CONT O360 TSIO360F 17025 SO NR 2 HEAD SEPARATED D K NONE O OTHER IN INSP/MAINT 1 SW 15 305385 DURING ANNUAL INSPECTION, FOUND NR 2 CYLINDER HEAD SEPARATING FROM BARREL. THE HEAD WAS TURNED COUNTERCLOCKWISE 4 DEGRE ES AND WAS .0625 INCH FARTHER FROM FIRST CYLINDER FIN THAN OTHER CYLINDERS. LEAK CHECK (PARAGRAPH C TCM SB 96-12) REVEA LED LEAK. COMPRESSION WAS 69/80. 3 O E9CE 1997041700063 19970417 00063 1997 4 17 97ZZZX1590 1 19970320 G 2432 G35 BATTERY GILLBATT VENT CAP DEFECTIVE D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 WHEN SERVICING NEW BATTERY PRIOR TO INSTALLATION, FOUND VENT CAPS DEFECTIVE. LUG ON INSIDE OF CAP FELL OUT OF 4 OF 6 CA PS. 1997041700064 19970417 00064 1997 4 17 97ZZZX1591 4 19970321 G 3197 WIRE PIPER PA31T PA31T1 7103126 SO GLARESHIELD CHAFED D A O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 SW 11 WIRE BUNDLE FROM GLARESHIELD CHAFED THROUGH 'A+' WIRE FOR ANNUNCIATORS CAUSING ARCING AND SMOKE FROM UNDER GLARESHIELD. FOUND WIRES UNPROTECTED AT FEED-THROUGHS. ALSO, NO GROMMETS INSTALLED IN INSTRUMENT PANEL. THE SHORT ALSO CAUSED THE ANNUNCIATOR CONTROL BOX TO SMOKE AND BECOME INOPERATIVE LOSING ALL THE WARNING SYSTEMS. NOTE: NO CURRENT PROTECTION IS BETWEEN THE BOX AND PANEL. 1 L 7 2 3T A8EA 1997041700065 19970417 00065 CE 1997 4 17 97ZZZX1592 1 19970313 G 7160 125083920 HINGE PIN CESSNA 207 T207A 2073614 CE ALT AIR DOOR FAILED D A A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 WP 11 1783U 9400 20700383 PILOT REPORTED LOSS OF MANIFOLD PRESSURE AFTER TAKEOFF. MADE OFF-AIRPORT LANDING. NO INJURY, NO DAMAGE TO AIRCRAFT. M AINTENANCE INSPECTION FOUND ALTERNATE AIR DOOR HINGE PIN MISSING WHICH ALLOWED THE DOOR TO FALL INTO THE CONNECTING ELBO W TO THE TURBOCHARGER RESTRICTING AIR FLOW. 1 H 7 1 3O A16CE 1997041700066 19970417 00066 SO 1997 4 17 97ZZZX1593 1 19970320 G 3246 4086B WHEEL PIPER PA28 PA28161 7102803 SO LT MLG AXLE BEARING FROZE D A K NONE O OTHER IN INSP/MAINT 1 SW 03 2115P 287916274 WHEN REMOVING WHEEL TO REPLACE BRAKE DISK (DUE TO NORMAL WEAR), WHEEL BEARINGS WERE FOUND FROZEN ON AXLE. WHEN WHEEL WA S FINALLY FREED FROM AXLE INSIDE, FOUND WHEEL FILLED WITH CORROSION RESIDUE. AXLE HAD SOME MINOR PITTING, BUT WAS DETER MINED TO BE IN SERVICEABLE CONDITION. 1 L 7 1 3O 2A13 1997041700067 19970417 00067 SO 1997 4 17 97ZZZX1594 1 19970320 G 7160 37328802 AIR BOX PIPER PA28 PA28161 7102803 SO CARBURETOR AIR CRACKED D A K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SW 03 2115P 287916274 WHEN TROUBLESHOOTING POWER LOSS, FOUND CARBURETOR AIR BOX CRACKED IN SEVERAL PLACES, 1 OF 2 GROMMETS FOR FLAP PIVOT MISS ING, BOTH SCAT HOSE ATTACHMENT FLANGES LOOSE. THIS CONDITION ALLOWED HEAT TO CARBURETOR AT ALL TIMES. 1 L 7 1 3O 2A13 1997041700068 19970417 00068 SO 1997 4 17 97ZZZX1595 1 19970301 G 3030 464357 ELEMENT PIPER PA34 PA34200T 7103406 SO REAR PITOT HEAT OPEN D K NONE O OTHER IN INSP/MAINT 1 NM 05 24CT 347670248 LOSS OF AIRSPEED - TRACED TO OPEN ELEMENT IN PITOT HEAT. REPLACED REAR ELEMENT. 1 L 7 2 3O A7SO 1997041700214 19970417 00214 SW 1997 4 17 97ZZZX1620 1 19970319 G 2430 HARNESS SWRNGN SA226 SA226TC 8780404 SW LT GCU CHAFED B ATZR K NONE O OTHER NR NOT REPORTED 1 CE 09 62Z TC237 LEFT GCU WIRE HARNESS CHAFED IN NACELLE THROUGH LIGHTNING HOLE. CAUSED CIRCUIT BREAKER FOR GENERATOR TO TRIP. SUSPECT WIRE BUNDLE BROKE LOOSE FROM CLAMP DURING PROPELLER STRIKE 9.5 HRS BEFORE. ENGINES AND PROPELLERS CHANGED OUT 9.5 HRS B EFORE THIS PROBLEM. 2 L 7 2 4T RT A8SW 1997041700215 19970417 00215 CE 1997 4 17 97ZZZX1621 1 19970131 G 5610 991206415 WINDSHEILD CESSNA 500 550 2076604 CE COCKPIT DEFECTIVE B EBVR K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 09 801JP 4097 5500043 OWNER REQUESTED INSTALLATION OF A SET OF WINDSHEILDS DELIVERED BY THE CUSTOMER. INQUIRIES WERE MADE FROM THE SUPPLIER A S TO THE TRACEABILITY OF THE WINDSHIELDS. NO TRACABILITY COULD BE PROVIDED AND NEW WINDSHIELDS WERE ORDERED FROM CESSNA AND INSTALLED. THIS MATTER WAS TURNED OVER TO CESSNA QUALITY AND ENGINEERING FOR FINAL DISPOSITION WITH THEIR SUPPLIER AND HAS BEEN RESOLVED. 1 L 7 2 4F A22CE 1997041700216 19970417 00216 CE 1997 4 17 97ZZZX1622 1 19970131 G 5610 991206416 WINDSHEILD CESSNA 500 550 2076604 CE COCKPIT DEFECTIVE B EBVR K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 09 801JP 3720 5500043 OWNER REQUESTED INSTALLATION OF A SET OF WINDSHEILDS DELIVERED BY THE CUSTOMER. INQUIRIES WERE MADE FROM THE SUPPLIER A S TO THE TRACEABILITY OF THE WINDSHIELDS. NO TRACABILITY COULD BE PROVIDED AND NEW WINDSHIELDS WERE ORDERED FROM CESSNA AND INSTALLED. THIS MATTER WAS TURNED OVER TO CESSNA QUALITY AND ENGINEERING FOR FINAL DISPOSITION WITH THEIR SUPPLIER AND HAS BEEN RESOLVED. 1 L 7 2 4F A22CE 1997041700217 19970417 00217 CE 1997 4 17 97ZZZX1623 1 19970321 G 2460 99143871 OVERLAY CESSNA 650 650 2076802 CE PILOT CB PANEL SHORTED B S A JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 805GT 2988 6500212 UPON REINSTALLATION OF THE PILOT'S SIDE MAIN CIRCUIT BREAKER PANEL OVERLAY, THE ATTACHING SCREW INSTALLED IN THE AFT CEN TER MOUNT HOLE CONTACTED THE VERTICAL LEG OF A BUSS BAR. THE BUSS BAR IS LOCATED DIRECTLY BEHIND (OUTBOARD OF THE MOUNT ING NUTPLATE. THE SCREW BEING INSTALLED WAS ONLY SLIGHTLY LONGER, APROXIMATELY .0625 INCH, THAN THE ONE ORIGINALLY INST ALLED. WHEN THE AIRCRAFT WAS POWERED UP, AN ELECTRICAL SHORT CIRCUIT TO GROUND OCCURRED RESULTING IN DAMAGE TO THE CIRC UIT BREAKER PANEL, PANEL OVERLAY, SCREW, NUTPLATE, AND WIRING. 2 L 7 2 4F A9NM 1997041700219 19970417 00219 NM 1997 4 17 97ZZZX1625 1 19970323 G 2752 MS9391130ZE MOTOR BOEING 737 737222 1384473 NM FLAP DRIVE LEAKING B JR2R K NONE K FLUID LOSS IN INSP/MAINT 1 SW 15 9066U MX190398D 19947 DURING FUNCTIONAL CHECK FLIGHT, A-SYSTEM HYDRAULICS WAS LOST. UPON LANDING, FOUND THE FLAP DRIVE MOTOR LEAKING AT MOUNT SURFACE. UPON REMOVAL OF FLAP DRIVE MOTOR, FOUND THE SEAL PLATE P/N 176002 S/N 569341 SHEARED AWAY FROM MOTOR DUE TO C ORROSION OF INTERNAL WRENCHING RETAINING BOLTS P/N MS24-667-8L. THIS HYDRAULIC MOTOR MANUFACTURED BY MICKERS. 2 L 7 2 4F A16WE 1997041700221 19970417 00221 NE 1997 4 17 97ZZZX1627 3 19970319 G 6111 213E BEARING RACE ROTOL R389 R3894123F25 NE BALL TRACK BROKEN B S MS1R K NONE O OTHER IN INSP/MAINT 1 EA 27 19721 7380 DRG151286 DURING TEAR DOWN FOR OVERHAUL OF PROPELLER, NOTED THAT 2 EACH SMALL BEARING RACES WERE BROKEN IN BALL TRACK. ALSO, ALL 4 BLADE BEARING ASSEMBLIES OF PROPELLER HAVE HEAVY/SEVERE CORROSION. PROPELLER HAD BEEN REMOVED FOR ROUTINE OVERHAUL. A /C REG NR UNKNOWN. 6 C P30NE 1997041700222 19970417 00222 SO 1997 4 17 97ZZZX1628 1 19970320 G 7810 3563100 SHROUD ASSY PIPER PA28 PA28161 7102803 SO EXHAUST SYSTEM DAMAGED D A K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SW 03 2115P 287916274 WHEN TROUBLESHOOTING POWER LOSS, FOUND PIECE OF FOREIGN MATTER (PROBABLY PIECE OF SPIRAL WRAP) IN CARBUREATOR THROAT. A LSO, FOUND MUFFLER TAKEOFF SHROUD ASSEMBLY BADLY DAMAGED AND SCREEN MISSING. PRESUMABLY PIECE OF SPIRAL WRAP FELL OFF O F STARTER CABLE AND INTO CARB HEAT DUCT (DUE TO MISSING SCREEN) AND WAS INJESTED INTO CARBURETOR. 1 L 7 1 3O 2A13 1997041700223 19970417 00223 SO 1997 4 17 97ZZZX1629 1 19970301 G 3030 464356 ELEMENT PIPER PA34 PA34200T 7103406 SO FWD PITOT HEAT OPEN D K NONE O OTHER IN INSP/MAINT 1 NM 05 24CT 347670248 LOSS OF AIRSPEED TRACED TO OPEN PITOT TUBE ELEMENTS. 1 L 7 2 3O A7SO 1997041700224 19970417 00224 SO 1997 4 17 97ZZZX1630 1 19970301 G 3030 464357 ELEMENT PIPER PA34 PA34200T 7103406 SO REAR PITOT HEAT OPEN D K NONE O OTHER IN INSP/MAINT 1 NM 05 24CT 347670248 LOSS OF AIRSPEED TRACED TO OPEN PITOT TUBE ELEMENTS. 1 L 7 2 3O A7SO 1997041700225 19970417 00225 CE 1997 4 17 97ZZZX1631 1 19970207 G 3231 DOOR CESSNA 210 210L 2073448 CE NLG JAMMED D L O OTHER O OTHER CL CLIMB 1 NM 03 29209 21059832 AIRCRAFT TOOK OFF FOLLOWING RUN-UP AND TAXI IN 4-5 INCHES OF SNOW. GEAR RETRACT OK. RETURNED FOR LANDING AND GEAR DOOR WOULD NOT OPEN. GEAR UP LANDING WITH DAMAGE. RAISED NOSE, PRIED DOORS OPEN, GEAR FELL OUT. APPARENTLY, ICE CAUSED DO ORS TO RETRACT PAST SEAL AND JAM AFTER CLOSURE. 1 H 7 1 3O 3A21 1997041700226 19970417 00226 CE 1997 4 17 97ZZZX1632 1 19970402 G 3231 08411065 BELLCRANK CESSNA 310 310R 2074245 CE LT MLG DOOR BROKEN D A K NONE O OTHER IN INSP/MAINT 1 EA 21 310FH 310R1887 LEFT INBOARD GEAR DOOR WOULD NOT CLOSE. FOUND BROKEN BELLCRANK. DOOR ACTUATOR ARM FOUND BROKEN FROM CASTING. DOOR FOU ND TO BE RIGGED PER CESSNA MANUAL. 1 L 7 2 3O 3A10 1997041700227 19970417 00227 SO 1997 4 17 97ZZZX1633 1 19970301 G 3030 464356 ELEMENT PIPER PA34 PA34200T 7103406 SO FWD PITOT HEAT OPEN D K NONE O OTHER IN INSP/MAINT 1 NM 05 47537 347770413 LOSS OF AIRSPEED TRACED TO OPEN PITOT HEAT ELEMENTS. 1 L 7 2 3O A7SO 1997041700228 19970417 00228 SO 1997 4 17 97ZZZX1634 1 19970301 G 3030 464357 ELEMENT PIPER PA34 PA34200T 7103406 SO REAR PITOT HEAT OPEN D K NONE O OTHER IN INSP/MAINT 1 NM 05 47537 347770413 LOSS OF AIRSPEED TRACED TO OPEN PITOT HEAT ELEMENTS. 1 L 7 2 3O A7SO 1997041700229 19970417 00229 CE 1997 4 17 97ZZZX1635 1 19970311 G 7714 D11125025 TACHOMETER MITCH CESSNA 150 152 2071835 CE ENGINE DEFECTIVE H K NONE O OTHER IN INSP/MAINT 1 SW 15 68792 57 6446 15285338 TACHOMETER NEEDLE MOVEMENT HESITATES WITH CHANGES IN THROTTLE MOVEMENT. THIRD TACHOMETER OF SAME MAKE AND MODEL INSTALL ED IN SAME AIRCRAFT. 1 H 7 1 3O NT 3A19 1997041700230 19970417 00230 CE 1997 4 17 97ZZZX1636 1 19970318 G 3230 50410012 BELLCRANK CESSNA 310 310Q 2074242 CE RT MLG BROKEN D S A O OTHER O OTHER LD LANDING 1 AL 01 7598Q 4135 310Q0098 DISCOVERED BELLCRANK BROKEN AFTER RIGHT MAIN LANDING GEAR COLLAPSED ON LANDING ROLL OUT. 1 L 7 2 3O 3A10 1997041700231 19970417 00231 CE 1997 4 17 97ZZZX1637 1 19970317 G 2700 CONTROL CABLE CESSNA 206 TU206F 2073353 CE FLIGHT CONT CORRODED D A K NONE O OTHER IN INSP/MAINT 1 NM 09 7485Q U20602220 AIRCRAFT TOTAL TIME 3,075 HRS. AIRCRAFT BUILT AS LAND PLANE AND MODIFIED FOR FLOATS INSTALLATION IAW WIPAIRE STL SA1483 GL. POH SUPPLEMENT REQUIRES 'OPERATION IN FRESH WATER ONLY' PLACARD DUE TO NO STAINLES STEEL CONTROL CABLES OR FUSELAGE INTERIOR PRIMER. CONTROL CABLES FOUND BADLY RUSTED IN BELLY UNDER BAGGAGE DECK AREA. BAGGAGE DECK STRUCTURE BADLY COR RODED. 'FRESH WATER ONLY' PLACARD MISSING. AIRCRAFT HAD BEEN OPERATED IN SALT WATER FOR THREE YEARS. 1 H 7 1 3O A4CE 1997041700232 19970417 00232 CE 1997 4 17 97ZZZX1638 1 19970317 G 5320 STRUCTURE CESSNA 206 TU206F 2073353 CE BAG DECK CORRODED D A K NONE O OTHER IN INSP/MAINT 1 NM 09 7485Q U20602220 AIRCRAFT TOTAL TIME 3,075 HRS. AIRCRAFT BUILT AS LAND PLANE AND MODIFIED FOR FLOATS INSTALLATION IAW WIPAIRE STL SA1483 GL. POH SUPPLEMENT REQUIRES 'OPERATION IN FRESH WATER ONLY' PLACARD DUE TO NO STAINLES STEEL CONTROL CABLES OR FUSELAGE INTERIOR PRIMER. CONTROL CABLES FOUND BADLY RUSTED IN BELLY UNDER BAGGAGE DECK AREA. BAGGAGE DECK STRUCTURE BADLY COR RODED. 'FRESH WATER ONLY' PLACARD MISSING. AIRCRAFT HAD BEEN OPERATED IN SALT WATER FOR THREE YEARS. 1 H 7 1 3O A4CE 1997041700233 19970417 00233 CE 1997 4 17 97ZZZX1639 1 19970321 G 7120 J151981 MOUNT LORD CESSNA 188 A188B 2073005 CE ENGINE MISINSTALLED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 07 9086R 18802107T WHILE REMOVING ENGINE FOR MAJOR OVERHAUL, FOUND BOLTS OF THE REAR LORD MOUNTS NOT INSTALLED THROUGH THE INTERNAL SPACERS . APPARENTLY, BOLTS HAD BEEN REMOVED AND THE SPACERS FELL OUT OF POSITION AND THEN THE BOLTS WERE REINSTALLED. 1 L 7 1 3O A9CE 1997041700234 19970417 00234 SO 1997 4 17 97ZZZX1640 1 19970308 G 5711 SP17 SPAR LUSCOM 8 8A 8190104 SO WING REAR CORRODED D K NONE O OTHER IN INSP/MAINT 1 SW 05 1057K 3784 INTERGRANULAR CORROSION FOUND ON LEFT WING REAR SPAR WHILE INSPECTING AS REQUIRED BY AD 96-24-17. REPLACED WITH NEW SPA R. 1 H 7 1 3O A694 1997041700235 19970417 00235 SO 1997 4 17 97ZZZX1641 2 19970228 G 8530 635448CN CYLINDER BEECH 36 36BEECH 1151602 CE CONT O520 IO520B 17032 SO NR 2 FAILED D O OTHER O OTHER NR NOT REPORTED 1 SW 05 1194A 1400 E159 CYLINDER HEAD CAME OFF IN-FLIGHT 2-28-97. NO DAMAGE OR OIL LEAK OCCURRED. REPLACED CYLINDER. 1 L 7 1 3O 3 O 3A15 E5CE 1997041700236 19970417 00236 EA 1997 4 17 97ZZZX1642 2 19970325 G 7320 3030523 SUPPORT BRACKET PIPER PA31T PA31T 7103124 SO PWA PT6 PT6A28 EA P3 FILTER CRACKED D L A K NONE O OTHER IN INSP/MAINT 1 GL 09 23407 4021 31T7920055 51979 INSPECTION FOUND P3 FILTER HOUSING SUPPORT BRACKET CRACKED. IF UNIT FAILED COULD AFFECT FCU. 1 L 7 2 3T 4 T A8EA E4EA 1997041700237 19970417 00237 CE 1997 4 17 97ZZZX1643 1 19970314 G 2750 051015259 CONTROL CABLE CESSNA 206 U206F 2073333 CE LT FLAP DIRECT FRAYED D A K NONE O OTHER IN INSP/MAINT 1 EA 05 1523U 6558 U20602234 DURING A 200-HOUR INSPECTION, LEFT FLAP DIRECT CABLE WAS FOUND FRAYED WHERE IT PASSES OVER PULLEY NEXT TO BELLCRANK. FR AYED AREA COULD NOT BE SEEN WITH FLAPS DOWN. SUBMITTER STATED AGE AND INACCESSABILITY WERE PROBABLY THE CAUSES OF THIS PART FAILURE. RECOMMEND AREA BE INSPECTED WITH BOTH FLAPS UP AND DOWN. 1 H 7 1 3O A4CE 1997041700238 19970417 00238 CE 1997 4 17 97ZZZX1644 1 19970314 G 7120 075100331 MOUNT CESSNA 185 A185F 2072821 CE ENG RT FRONT CRACKED B CF4R K NONE O OTHER IN INSP/MAINT 1 AL 03 6705H 3362 18503337 DURING ENGINE CHANGE, BEADBLASTED AND MAGNAFLUX INSPECTED ENGINE MOUNT. FOUND CRACK AT WELD OF RIGHT FRONT CROSS MEMBER TO HORIZONTAL TUBE. THIS AREA HAD BEEN PREVIOUSLY WELDED AND THIS CRACK WAS AT THIS WELD AREA. THIS IS UNDER THE RIGH T FRONT MOUNT BED. 1 H 7 1 3O 3A24 1997041700239 19970417 00239 NE 1997 4 17 97ZZZX1645 2 19970228 G 7250 3029241 GAS GENERATOR CESSNA 501 501 2076603 CE PWA JT15 JT15D1 52060 NE DIFFUSER TUBE CORROSION HOLE B EBVR K NONE O OTHER IN INSP/MAINT 1 GL 09 1AT 4730 1533 5010159 77405 WHILE TROUBLESHOOTING AN EXISTING PROBLEM WITH ONE ENGINE, THE DIFFUSER TUBES WERE FOUND TO HAVE HEAVY CORROSION WITH SE VERAL HOLES CORRODED THROUGH. SUBSEQUENT INSPECTION OF THE OTHER ENGINE RESULTED IN FINDING THE SAME PROBLEM. BOTH ENG INES WERE REMOVED AND SENT TO THE MANUFACTURER. 1 L 7 2 4F 4 F A27CE E1NE 1997041700240 19970417 00240 NE 1997 4 17 97ZZZX1646 2 19970228 G 7250 3029241 GAS GENERATOR CESSNA 501 501 2076603 CE PWA JT15 JT15D1 52060 NE DIFFUSER TUBE CORROSION HOLE B EBVR K NONE O OTHER IN INSP/MAINT 1 GL 09 1AT 4730 1533 5010159 77402 WHILE TROUBLESHOOTING AN EXISTING PROBLEM WITH ONE ENGINE, THE DIFFUSER TUBES WERE FOUND TO HAVE HEAVY CORROSION WITH SE VERAL HOLES CORRODED THROUGH. SUBSEQUENT INSPECTION OF THE OTHER ENGINE RESULTED IN FINDING THE SAME PROBLEM. BOTH ENG INES WERE REMOVED AND SENT TO THE MANUFACTURER. 1 L 7 2 4F 4 F A27CE E1NE 1997041700241 19970417 00241 NE 1997 4 17 97ZZZX1647 3 19970325 G 6111 SK112315 PIN ASSY HAMSTD 7922221 HAMSTD 14SF 14SF7 NE BLADE CRACKED B H2SR K NONE O OTHER IN INSP/MAINT 1 SO 13 7052 DURING DYE CHECK OF BLADE SHANK, AN INDICATION IN THE BEARING RACE FILLET RADIUS WAS OBSERVED. THE INDICATION IS LOCATE D APPROXIMATELY 90 DEGREES FROM THE BLADE PIN, CLOCKWISE, AS VIEWED FROM THE BUTT END. THE INDICATION IS APPROXIMATELY .600 INCH LONG, AND IS ORIENTED CIRCUMFERENTIALLY IN THE RADIUS. 6 C P7NE 1997041700242 19970417 00242 CE 1997 4 17 97ZZZX1648 1 19970327 G 2121 591224 MOTOR 725652B CESSNA 650 650 2076802 CE HYD FAN ASSY LEAKAGE C K NONE K FLUID LOSS IN INSP/MAINT 1 EA 23 67SF 2498 166 6500045 ACFT PARKING BRAKE WAS SET AND BOTH ENGINES WERE STARTED, ACFT STARTED DRIFTING FWD. THE PILOT RESET PARKING BRAKE, THE N NOTICED BOTH HYD FLUID LEVEL AND HYD PRESSURE GAUGES FALLING RAPIDLY. ENG WERE SHUT DOWN IMMEIDATELY. HYD FLUID WAS FOUND RUNNING DOWN THE RT SIDE AND OUT OF THE BELLY DRAINS OF THE FUSELAGE. THE LOCATION OF LEAK WAS FOUND TO BE THE EN VIRONMENTAL CONTROL UNIT RAM AIR HYD FAN. THE FAN ASSEMBLY WAS REPLACED AND SYSTEM BLED. JUST PRIOR TO THIS OCCURRENCE , PILOTS HAD NOTICED A SLIGHTLY MORE THAN NORMAL PRESSURE DROP WHEN THE FAN WAS RUNNING AND THE ENGINES WERE AT IDLE. T HE FAN IS ONLY RUNNING WITH THE AIRCRAFT IS ON THE GROUND AND THE ECU'S ARE TURNED ON. 2 L 7 2 4F A9NM 1997041700502 19970417 00502 SW 1997 4 17 97ZZZX1654 1 19970212 G 2430 1820300150 SHUNT BELL 230 230 1182149 SW DC SYSTEM DEFECTIVE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 706 23019 SHUNT DISCOLORED, CAUSING INTERMITTENT LOAD BREAKDOWN. REPLACED 2 EACH. 1 G 7 2 3U NC H9SW 1997041700504 19970417 00504 SW 1997 4 17 97ZZZX1656 1 19970122 G 6720 230312001101 PITCH LINK BELL 230 230 1182149 SW BEARING WORN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 674 23019 BEARINGS WORN. REPLACED 2 EACH PITCH LINKS. 1 G 7 2 3U NC H9SW 1997041700549 19970417 00549 EA 1997 4 17 97ZZZX1666 2 19970331 G 8520 CRANKCASE ENSTRM F28 280F 3300550 GL LYC O360 HIO360F1AD 41514 EA CRANKCASE MISALIGNED D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 01 199TV 1510 L2313251A A FACTORY OVERHAULED ENGINE WAS INSTALLED. ENGINE STARTED TO MAKE METAL. WHEN OIL WAS DRAINED, IT LOOKED LIKE ALUMINUM PAINT. AN OIL SAMPLE AND FILTER ELEMENT WERE SENT TO FACTORY. FACTORY REQUESTED THAT ENGINE BE REMOVED AND SENT IN FO R REPAIR. TIME ON ENGINE 63.5 HRS SMOH. SUSPECT CAUSE WAS MISALIGNED CRANKCASE. THIS CAUSED PISTON PINS TO SHIFT. 1 G 7 1 3O 3 O H1CE 1E10 1997042200005 19970422 00005 WP 1997 4 22 97ZZZX1669 1 19970324 G 6720 369A18079 BEARING HUGHES 369 369HS 4470728 WP T/R PITCH LINK FAILED D A A UNSCHED LANDING F FLT CONT AFFECTED NR NOT REPORTED 1 SO 09 8388F 132 760838S TAIL ROTOR PITCH CHANGE LINKS WERE INSTALLED AT 13,300.8 AIRCRAFT HOURS. AT 13,432 AIRCRAFT HOURS, ONE PITCH CHANGE LIN K FAILED AT ONE END. THE BEARING APPEARS TO HAVE BEEN EXCESSIVELY OVER ROLL STAKED UPON INSTALLATION INTO THE LINK BEAR ING HOUSING. FAILURE OF THE LINK ASSY CAUSED LOSS OF TAIL ROTOR CONTROL OF THE AIRCRAFT. PILOT LANDED SAFELY WITHOUT F URTHER DAMAGE. RECOMMEND MANDATORY NDI INSPECTION AFTER A BEARING IS INSTALLED IN THESE LINKS. 1 G 7 1 3U H3WE 1997041700552 19970417 00552 SW 1997 4 17 97ZZZX1670 1 19970321 G 6320 206040076009 SCREEN BELL 206 206B 1181511 SW XMSN SUMP UNBONDED D K NONE O OTHER IN INSP/MAINT 1 SO 09 67960 598 5232 TRANSMISSION SUMP INBOARD SLEEVE UNBONDED FROM SCREEN ASSY, 2 EACH REPLACED IN LAST 4 MONTHS FOR SAME REASON. 1 G 7 1 3U H2SW 1997041700553 19970417 00553 NE 1997 4 17 97ZZZX1671 1 19970319 G 5320 7620103501101 SUPPORT BEAM SKRSKY S76 S76B 8143007 NE CABIN OVERHEAD CRACKED B EGRR K NONE O OTHER IN INSP/MAINT 1 EA 17 388GS 1608 760410 WHILE DOING CABIN INSPECTION, THE OVERHEAD LATERAL VIBRATION SUPPORT BEAM WAS FOUND CRACKED IN THE LOWER LEFT AND RIGHT CORNERS. THE SUPPORT BEAM WAS REPLACED WITH A NEW SUPPORT BEAM AND WAS MODIFIED IAW SIKORSKY INSTRUCTIONS AND 8110 INFO RMATION. 1 G 7 2 4U H1NE 1997041700554 19970417 00554 NE 1997 4 17 97ZZZX1672 1 19970319 G 5320 7620103501103 ANGLE SKRSKY S76 S76B 8143007 NE CABIN OVERHEAD CRACKED B EGRR K NONE O OTHER IN INSP/MAINT 1 EA 17 388GS 1608 760410 WHILE DOING CABIN INSPECTION, ANGLE WAS FOUND CRACKED. THE ANGLE WAS REPLACED WITH A NEW ANGLE AND REINFORCED IAW SIKOR SY SRM. 1 G 7 2 4U H1NE 1997041700555 19970417 00555 NE 1997 4 17 97ZZZX1673 1 19970319 G 5320 7620103501115 ANGLE SKRSKY S76 S76B 8143007 NE CABIN OVERHEAD CRACKED B EGRR K NONE O OTHER IN INSP/MAINT 1 EA 17 388GS 1608 760410 WHILE DOING CABIN INSPECTION, ANGLE WAS FOUND CRACKED IN THE RIGHT CORNER. THE ANGLE WAS REPLACED WITH A NEW ANGLE FROM SIKORSKY. 1 G 7 2 4U H1NE 1997041700558 19970417 00558 SW 1997 4 17 97ZZZX1675 1 19970312 G 3213 206324004 SKID TUBE BELL 206 206L1 1182107 SW SKID PLATE CRACKED B A HEER K NONE O OTHER IN INSP/MAINT 1 SW 03 5007Y AUG1495 45192 FOUND 8 CRACKS ON RT SKID TUBE RADIATING FROM SKIP-PLATE MOUNTING HOLES. THIS TUBE WAS MFG 8-14-95. HAVE FOUND 3 SKID TUBES CRACKED IN THIS MANNER. ALL TUBES WERE MFG IN AUG '95. REPLACED TUBES WITH SERVICEABLE TUBES. 1 G 7 1 3U H2SW 1997041700559 19970417 00559 SW 1997 4 17 97ZZZX1676 1 19970312 G 3213 206324003 SKID TUBE BELL 206 206L1 1182107 SW SKID PLATE CRACKED B HEER K NONE O OTHER IN INSP/MAINT 1 SW 03 5007Y AUG95 45192 FOUND 3 CRACKS ON RT SKID TUBE RADIATING FROM SKID PLATE AND FRONT MOUNTING HOLES. HAVE FOUND 3 SKID TUBES CRACKED IN T HIS MANNER. ALL MFG AUG '95. REPLACED TUBES WITH SERVICEABLE TUBES. 1 G 7 1 3U H2SW 1997041700561 19970417 00561 EU 1997 4 17 97ZZZX1678 1 19970301 G 6240 350A08386100 WARN HORN SNIAS 350 AS350B2 8680813 EU ROTOR RPM FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 09 6098U 2718 THERE ARE TWO TYPES OF WARNING HORNS. ONE MANUFACTURER IS KLAXON, THE OTHER IS VOXBELL. BOTH OF THE HORNS ARE FAILING DUE TO POOR WORKMANSHIP. ITEMS CAUSING FAILURE ARE POOR SOLDERING POINTS AND RIVETS NOT FULLY SQUEEZED WHICH SHOULD MAK E CONTACT TO ACTIVATE THE HORN WHEN ROTOR RPM FALLS BELOW MINIMUM. HAVE HAD TO ORDER FOUR HORNS IN SIXTY-DAY PERIOD. 1 G 7 1 3U H9EU 1997041700562 19970417 00562 WP 1997 4 17 97ZZZX1679 1 19970326 G 6410 36124 CUFF 3612319 HILLER UH12 UH12E 4360122 WP CONTROL BLADE CRACKED B OUGR K NONE O OTHER IN INSP/MAINT 1 WP 17 62392 3806 381 6526 1591 IAW AD 77-07-05(S) AND HILLER SB 36-1 REV 3, PARA 2(G). FOUND CRACK AT CONTROL BLADE CUFF INBOARD BOLT HOLE DURING 100- HOUR REPETATIVE DYE-PENETRANT INSPECTION. NOTE: 6,860 HOUR LIFE-LIMIT. 1 G 7 1 3O 4H11 1997041700563 19970417 00563 WP 1997 4 17 97ZZZX1680 1 19970326 G 6410 36124 CUFF 3612319 HILLER UH12 UH12E 4360122 WP CONTROL BLADE CRACKED B OUGR K NONE O OTHER IN INSP/MAINT 1 WP 17 62392 4402 381 5599 1591 IAW AD 77-07-05(S) AND HILLER SB 36-1 REV 3, PARA 2(G). FOUND CRACK AT CONTROL BLADE CUFF INBOARD BOLT HOLE DURING 100- HOUR REPETATIVE DYE-PENETRANT INSPECTION. NOTE: 6,860 HOUR LIFE-LIMIT. 1 G 7 1 3O 4H11 1997041700565 19970417 00565 GL 1997 4 17 97ZZZX1682 2 19970318 G 7210 6871064 DAMPER RING 6894171 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL GEARBOX CRACKED D K NONE O OTHER IN INSP/MAINT 1 AL 03 8639F 6734 3420 CAG36146 1280431D CAE832846 FOUND DAMPER RING CRACKED AND A SMALL CHIP MISSING ON THE OUTSIDE DIAMETER OF THE RING. THIS DEFECT BEING ON THE GEAR S IDE OF THE RING, FITS ALL THE WAY IN THE GROOVE, AND WAS ONLY FOUND AFTER REMOVAL. CRACK WAS 2 INCHES FROM THE END OF T HE RING. 1 G 7 1 3U 3 U H3WE E4CE 1997041700566 19970417 00566 SW 1997 4 17 97ZZZX1683 1 19970306 G 6410 206010765001 BEARING BELL 206 206L3 1182108 SW T/R FEATHER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 728H 51553 CRACKED FEATHERING BEARING ON TAIL ROTOR BLADE P/N 206-016-201-127. OCCURRED DURING NORMAL OPERATION, FOUND DURING ROUT INE INSPECTION. SUSPECTED GAP BETWEEN BEARING AND BLADE. RECOMMENDED AD OR ASB BE ISSUED TO REPLACE FEATHERING BEARING INSTEAD OF T.B. 206L-984-172. SUBMITTER STATEDTHIS PROBLEM HAS OCCURRED MANY TIMES. 1 G 7 1 3U H2SW 1997041700567 19970417 00567 SW 1997 4 17 97ZZZX1684 1 19970306 G 6410 206010765001 BEARING BELL 206 206L3 1182108 SW T/R FEATHER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 727H 51550 CRACKED FEATHERING BEARING ON TAIL ROTOR BLADE P/N 206-016-201-127. OCCURRED DURING NORMAL OEPRATION, FOUND DURING ROUT INE INSPECTION. SUSPECTED GAP BETWEEN BEARING AND BLADE. RECOMMENDED AD OR ASB BE ISSUED TO REPLACE FEATHERING BEARING INSTEAD OF T.B. 206L-94-172. SUBMITTER STATED PROBLEM HAS OCCURRED MANY TIMES. 1 G 7 1 3U H2SW 1997041700568 19970417 00568 SW 1997 4 17 97ZZZX1685 1 19970306 G 6410 206010765001 BEARING BELL 206 206L3 1182108 SW T/R FEATHER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 722H 51452 CRACKED FEATHERING BEARING ON TAIL ROTOR BLADE P/N 206-016-201-127. OCCURRED DURING NORMAL OEPRATION, FOUND DURING ROUT INE INSPECTION. SUSPECTED GAP BETWEEN BEARING AND BLADE. RECOMMENDED AD OR ASB BE ISSUED TO REPLACE FEATHERING BEARING INSTEAD OF T.B. 206L-94-172. SUBMITTER STATED PROBLEM HAS OCCURRED MANY TIMES. 1 G 7 1 3U H2SW 1997041700570 19970417 00570 NE 1997 4 17 97ZZZX1687 1 19970319 G 5313 7620204001146 LONGERON SKRSKY S76 S76B 8143007 NE TAIL BOOM CRACKED B EGRR K NONE O OTHER IN INSP/MAINT 1 EA 17 5NJ 2855 760346 WHILE REPAIRING CRACK IN AFT SHEAR DECK WEB, FOUND A CRACK IN THE RIGHT TAIL BOOM LONGERON. THE LONGERON WAS REPAIRED I AW SIKORSKY SRM. THE NESTED ANGLE, P/N 76202-04001-106, WAS REPLACED WITH NEW STYLE NESTED ANGLE P/N 76202-24001-104 IA W SRM AT THE SAME TIME. 1 G 7 2 4U H1NE 1997042400001 19970424 00001 WP 1997 4 24 97ZZZX1690 1 19970304 G 6310 234005 SHAFT HILLER UH12 H23B 4360114 WP INTERMED DRIVE SHEARED D A R AUTOROTATION J WARNING INDICATION HO HOVERING 1 NM 01 6055 262 2776 598 WHILE PERFORMING HOVER TRACK AND BALANCE OF THE M/R BLADE ASSEMBLIES, A LOUD BANG WAS HEARD AND ROTOR RPM DECAYED. A HO VERING AUTOROTATION WAS SUCCESSFULLY COMPLETED. UPON TEAR-DOWN, EXCESSIVE WEAR WAS FOUND ON THE INTERMEDIATE SHAFT LOWE R GEAR TEETH OF .030 INCH. THIS SHAFT HAD SHEARED IN TWO CAUSING THE DISENGAGEMENT OF THE ENGINE AND ROTOR DRIVE TRAIN. THE MATING GEAR LOCATED INSIDE OF THE MERCURY CLUTCH HOUSING HAD A WEAR OF APPROXIMATELY .037 INCH. 1 G 7 1 3O 6H2 1997042400002 19970424 00002 EU 1997 4 24 97ZZZX1691 1 19970327 G 6320 4638001004 TRANSMISSION BOLKMS 105 BO105S 5626006 EU SWASH PLATE PIN MISSING D K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 19 70EG 1234 S458 OPERATOR PURCHASED AN 'EXCHANGE' MAIN ROTOR TRANSMISSION FROM AMERICAN EUROCOPTER. UNIT RECEIVED WITH HISTORICAL RECORD CARDS, A 'SERVICABLE' TAG, AND A FAA FORM ONE CERTIFICATE. TRANSMISISON WAS OVERHAULED 2-4-97, FAA REPAIR STATION ZF6Y 043N. AFTER INSTALLATION AND DURING GROUND MAINTENANCE RUNS AND PREPARATION FOR MAIN ROTOR SYSTEM TRACK AND BALANCE CHE CKS, DISCOVERED THE TRANSMISSION HAD BEEN ASSEMBLED WITHOUT THE INSTALLATION OF P/N 105-41901.19, BALANCING SYSTEM MAGNE TIC PICK-UP 'TARGET'/INTERRUPTOR. SUBMITTER STATED ALTHOUGH NOT A HAZARDOUS SITUATION IN ITSELF, 'WHAT ELSE WAS NOT INS TALLED OR INSTALLED INCORRECTLY?' 1 G 7 2 3U H3EU 1997042400003 19970424 00003 NM 1997 4 24 97ZZZX1692 1 19970327 G 6320 A0061 GEARBOX ROBSIN R22 R22BETA NM M/R GEARBOX SLUDGED B GJOR K NONE O OTHER IN INSP/MAINT 1 NM 01 222YP 3799 726 1135 1057 WHILE PERFORMING A 100-HR INSPECTION, MAIN GEARBOX CHIP DETECTOR WAS REMOVED. CHIP DETECTOR FOUND WITH EXCESSIVE AMOUNT S OF SLUDGE BUILD-UP. A FUNCTIONAL CHECK VERIFIED A CHIP WOULD NOT COMPLETE THE CIRCUIT. AFTER CLEANING CHIP DETECTOR, NO FURTHER DISCREPANCIES NOTED. TT 190.0 HRS SINCE LAST CLEANING AND FUNCTIONAL CHECK ON CHIP DETECTOR. SUBMITTER REC OMMENDS A 100-HR CLEANING AND FUNCTIONAL CHECK ON CHIP DETECTOR ALONG WITH ANNUAL GEARBOX OIL CHANGE. THE ROBINSON R22 MAIN TRANSMISSION CHIP DETECTOR IS NOT EASILY ACCESSED. MOST AIRCRAFT AND ROTORCRAFT CHIP DETECTORS ARE OF A QUICK DISC ONNECT TYPE. SUBMITTER WOULD REQUEST A CHANGE IN DESIGN TO THE R22 TO INSTALL THE QUICK DISCONNECT TYPE CHIP DETECTOR. 1 G 7 1 3O H10WE 1997042400006 19970424 00006 1997 4 24 97ZZZX1695 1 19970318 G 3242 16430388 BRAKE DISC PARKERHANFIN WHEEL FLANGE MISMANUFACTURED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 07 INSPECTION FOUND BRAKE DISC MISMANUFACTURED. UNIT MEASURES 2.375 INCH OVERALL. CORRECT DIMENSION IS 2.335 INCHES TO 2.3 45 INCHES OVERALL. NUMBER STAMPED ON FLANGE IS 30388624. 1997042400007 19970424 00007 1997 4 24 97ZZZX1696 4 19970328 G 2562 BP1025 BATTERY PACK MERL CESSNA 170 170A 2072304 CE ELT CORRODED D K NONE O OTHER IN INSP/MAINT 1 WP 09 1314D 19890 DURING ANNUAL INSPECTION FOUND HEAVY RUST ON ENDS OF BATTERY PACK WHERE TERMINALS AND CONNECTING BUSS BARS ARE SOLDERED. CORROSION WAS NOT VISIBLE UNTIL PACK WAS DISASSEMBLED (RENDERING IT NOT USABLE) BECAUSE CARDBOARD WAS GLUED OVER ENDS THEN WHOLE BATTERY PACK WAS SHRINK WRAPPED IN PLASTIC. THIS PACK WAS CHANGED 6 MONTHS BEFORE DUE DATE FOR CONVENIENCE. BATTERY DID MAKE NORMAL VOLTAGE. 1 H 7 1 3O A799 1997042400008 19970424 00008 SO 1997 4 24 97ZZZX1697 1 19970327 G 5741 6244802 FITTING PIPER PA28 PA28R200 7102811 SO LT WING AFT CORRODED B A BXSR K NONE O OTHER IN INSP/MAINT 1 EA 09 15597 3251 28R7335072 DURING ANNUAL INSPECTION, FOUND AFT WING FITTINGS AND ADJACENT STRUCTURE CORRODED. PIPER SB977 ADDRESSES THIS PROBLEM. CAUSE DUE TO WINDOW SEALS FAILING AND MOISTURE REMAINING IN THE INSULATION. 1 L 7 1 3O 2A13 1997042400009 19970424 00009 SO 1997 4 24 97ZZZX1698 1 19970327 G 5741 6244803 FITTING PIPER PA28 PA28R200 7102811 SO RT WING AFT CORRODED B BXSR K NONE O OTHER IN INSP/MAINT 1 EA 09 15597 3251 28R7335072 DURING ANNUAL INSPECTION, FOUND AFT WING FITTINGS AND ADJACENT STRUCTURE CORRODED. PIPER SB977 ADDRESSES THIS PROBLEM. CAUSE DUE TO WINDOW SEALS FAILING AND MOISTURE REMAINING IN THE INSULATION. 1 L 7 1 3O 2A13 1997042400010 19970424 00010 SO 1997 4 24 97ZZZX1699 1 19970327 G 2810 6358500 FILLER NECK PIPER PA28 PA28R200 7102811 SO FUEL TANK CORRODED B BXSR K NONE O OTHER IN INSP/MAINT 1 EA 09 15597 3251 28R7335072 DURING ANNUAL INSPECTION, FOUND AFT WING FITTINGS AND ADJACENT STRUCTURE CORRODED. PIPER SB977 ADDRESSES THIS PROBLEM. CAUSE DUE TO WINDOW SEALS FAILING AND MOISTURE REMAINING IN THE INSULATION. FOUND THE FUEL TANK FILLER NECK CORRODED TH ROUGH INTO THE FUEL STORAGE AREA. THE PILOT REMARKED, 'AH! I WAS WONDERING WHY MY FUEL ALWAYS HAD WATER IN IT!'. THE CORROSION WAS PLAINLY VISIBLE, BUT COULD ONLY SEE THE PENETRATION WHEN THE RUST BUILD-UP WAS CLEANED AWAY. SUBMITTER ST ATED LACK OF SEAL MAINT AND BASED IN A CORROSIVE ENVIRONMENT CAUSED THIS PROBLEM. 1 L 7 1 3O 2A13 1997042400011 19970424 00011 SO 1997 4 24 97ZZZX1700 1 19970326 G 2410 452541 BELT PIPER PA28 PA28R200 7102811 SO ALT DRIVE FAILED B BXSR K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 09 15597 3251 28R7335072 A COMMON PROBLEM THAT SUBMITTER HAS FOUND OVER THE YEARS, WITH PIPER PRODUCTS ESPECIALLY, IS THE USE OF AUTOMOTIVE OR UN APPROVED ALTERNATOR DRIVE BELTS. IN THIS CASE, A NAPA AUTOMOTIVE BELT WAS INSTALLED. 1 L 7 1 3O 2A13 1997042400012 19970424 00012 SO 1997 4 24 97ZZZX1701 1 19970326 G 3411 69041005 PITOT HEAD PIPER PA28 PA28R200 7102811 SO AIR INLET CORRODED B BXSR K NONE O OTHER IN INSP/MAINT 1 EA 09 15597 3251 28R7335072 THE PITOT MAST WAS SO CORRODED THE AIR INLET HOLES WERE CLOSED APPROXIMATELY ONE-FOURTH DUE TO THE BUILD-UP OF THE CORRO SION. SUBMITTER STATED THE AIRCRAFT HAD BEEN BASED IN A CORROSIVE ENVIRONMENT (FLORIDA). 1 L 7 1 3O 2A13 1997042400013 19970424 00013 SO 1997 4 24 97ZZZX1702 1 19970326 G 7120 6711949 MOUNT PIPER PA28 PA28R200 7102811 SO ENG/MLG MT CRACKED B BXSR K NONE O OTHER IN INSP/MAINT 1 EA 09 15597 3251 F2079 28R7335072 MOST OF THE TUBES ON THIS ENGINE/LANDING GEAR MOUNT HAD TO BE REPLACED DUE TO CORROSION, CRACKS, OR CHAFING. THE CHAFIN G WAS FROM OLD LOOP-TYPE (ADEL) CLAMPS THAT HAD NOT BEEN REPLACED WHEN THE RUBBER CUSHIONS DRIED OUT. THE AIRCRAFT HAD BEEN IN AN ACCIDENT WHERE ONE GEAR COLLAPSED WHICH MAY ACCOUNT FOR THE TWO CRACKED TUBES. THE CORROSION WAS JUST FROM L ACK OF PREVENTATIVE MAINTENANCE IN A CORROSIVE ENVIRONMENT (FLORIDA). 1 L 7 1 3O 2A13 1997042400014 19970424 00014 CE 1997 4 24 97ZZZX1703 1 19970226 G 7120 07516001 MOUNT CESSNA 182 182P 2075816 CE ENG LT SIDE CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 07 344K 1750 K2772 18263709 THE ENGINE MOUNT WAS FOUND CRACKED ON THE LEFT HAND SIDE. THE LEFT HAND HORIZONTAL TUBE WAS FOUND CRACKED ABOUT THREE-F OURTHS OF THE WAY AROUND WITH THE CRACK STARTING AT THE AFT GUSSET WELD AND WORKING ITS WAY AROUND THE CIRCUMFERENCE OF THE TUBE. 1 H 7 1 3O NT TA13 1997042400015 19970424 00015 CE 1997 4 24 97ZZZX1704 1 19970321 G 5320 0024100113 COVER BEECH 33 F33A 1151425 CE NLG WELL CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 07 856KS 303 CE1753 AT 100-HOUR INSPECTION, CRACK ABOUT 3 INCHES LONG WAS FOUND IN NOSE GEAR WHEELWELL COVER JUST BEHIND NOSE GEAR STRUT. C AUSE OF CRACK IS UNKNOWN. PATCHED CRACK WITH SECTION OF A NEW COVER IAW 43.13. 1 L 7 1 3O 3A15 1997042400016 19970424 00016 CE 1997 4 24 97ZZZX1705 1 19970321 G 5320 0024100113 COVER BEECH 33 F33A 1151425 CE NLG WELL CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 07 854KS CE1764 AT 100-HOUR INSPECTION, CRACK ABOUT 5 INCES LONG WAS FOUND IN NOSE GEAR WHEELWELL COVER JUST BEHIND NOSE GEAR STRUT. CA USE OF CRACK IS UNKNOWN. SPLICED IN NEW SECTION OF A NEW COVER IAW 43.13. SUBITTER SUGGESTS KEEPING CLOSE INSPECTION O F THIS AREA FOR CRACKS. 1 L 7 1 3O 3A15 1997042400017 19970424 00017 SO 1997 4 24 97ZZZX1706 1 19970325 G 5347 MOUNT BRACKET PIPER PA42 PA42 7104202 SO PAX SEAT FRAME BROKEN B CS3R K NONE O OTHER IN INSP/MAINT 1 WP 17 158TJ 3090 428001057 DURING SCHEDULED MAINTENANCE, PASSENGER SEAT AFT FACING BEHIND COPILOT, WRITTEN UP AS 'LOOSE IN TRACK'. DISCOVERED FRON T FLOOR MOUNTED BRACKET CRACKED AND TORN FROM SEAT FRAME. SUSPECT CAUSE, SEAT BACK USED AS LEVERAGE INTO COCKPIT: ALSO , AIRCRAFT TYPE CERTIFICATE DOES NOT ALLOW FOR VARIATIONS IN CONFIGURATION OF SEATS. AIRCRAFT IS AOG. 1 L 7 2 4T A23SO 1997042400018 19970424 00018 1997 4 24 97ZZZX1707 4 19970401 G 6113 04500401 BULKHEAD CESSNA 150 150G 2071816 CE SPINNER REAR CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 25 4044J 15065344 SPINNER BULKHEAD CRACKED. SUSPECT FROM PUSHING ON SPINNER WHEN MOVING A/C AND OR PUTTING TOO MANY SHIMS ON FORWARD BULK HEAD; THUS, HAVING TO PUSH TOO HARD TO GET SCREW IN. SECOND TIME THIS BULKHEAD WAS REPLACED. 1 H 7 1 3O 3A19 1997042400019 19970424 00019 SO 1997 4 24 97ZZZX1708 1 19970324 G 7922 75944 VALVE PIPER PA32 PA32R301T 7103220 SO THERMO BYPASS DEFECTIVE B G9CR K NONE O OTHER IN INSP/MAINT 1 CE 01 4386B 32R85269001 AT ENGINE OVERHAUL, THE THERMOSTATIC VALVE WAS REMOVED AND FOUND WITH AN EXTREMELY ROUGH SEAT. THE SPRING WAS ALSO FOUN D COMING LOOSE. THE VALVE IS SUSPECT TO LYC SI 1423, BUT WAS NOT A FACTOR BECAUSE THE RETAINING NUT IS OK. 1 L 7 1 3O A3SO 1997042400020 19970424 00020 CE 1997 4 24 97ZZZX1709 1 19970319 G 5553 04311481 FITTING CESSNA 150 152 2071835 CE V FIN AFT ATTACH BROKEN B AJ4R K NONE O OTHER IN INSP/MAINT 1 WP 21 49169 7660 15281177 FOUND LEFT, REAR, VERTICAL FIN ATTACH FITTING BROKEN ON OUTBOARD LEG. THIS MDR IS RELATED TO AN EARLIER MDR REPORT ON A BROKEN HORIZONTAL/VERTICAL FIN ATTACH FITTING AND CRACKED SPAR/REINFORCEMENT STRUCTURE. AIRPLANE IS USED IN A FLIGHT S CHOOL 1 H 7 1 3O NT 3A19 1997042400021 19970424 00021 SO 1997 4 24 97ZZZX1710 1 19970402 G 8120 RETAIN RING PIPER PA23 PA23250 7102308 SO LYC O540 TIO540C1A 41532 EA TURBO SCAV PUMP DISLODGED D O OTHER O OTHER NR NOT REPORTED 1 WP 07 54830 3440 277554128 EXTERNAL RETAINING RING THAT HOLDS THE TURBO SCAVENGE PUMP DRIVEN GEAR IN PLACE DISLODGED ALLOWING GEAR TO DISENGAGE WIT H SUBSEQUENT PUMP FAILURE. WITH SCAVENGE PUMP INOPERABLE, OIL WAS FORCED BY TURBO SEAL AT A RAPID RATE AND BURNED IN TH E EXHAUST UNNOTICED BY PILOT UNTIL TAXIING IN. MINUTES MORE IN FLIGHT COULD HAVE RESULTED IN IMMINENT ENGINE FAILURE. S UBMITTER SUSPECT CAUSE WAS FAILURE TO C/W LYC SI NR 1338 DATED 7-2-76, AT ENGINE OVERHAUL WHICH WOULD HAVE REPLACED RETA INING RING WITH A ROLL PIN. POTENTIAL CONSEQUENCES OF THIS MALFUNCTION SHOULD HAVE WARRANTED MORE ATTENTION THAN JUST A SERVICE INSTRUCTION. 1 L 7 2 3O 3 O 1A10 E14EA 1997042400022 19970424 00022 GL 1997 4 24 97ZZZX1711 3 19970402 G 6114 D4883C55 HUB BEECH 55 95C55 1152708 CE MCAULY 2AF34C 2AF34C55 GL SOCKET NR 2 CRACKED B ME4R K NONE O OTHER IN INSP/MAINT 1 SO 19 9313Y 694015 TC9 694015 DURING INSPECTION, HUB FOUND CRACKED IN BLADE SOCKET NR 2. HUB HAS BEEN SCRAPPED. 1 L 7 2 3O 3A16 5 C P5EA 1997042400023 19970424 00023 SO 1997 4 24 97ZZZX1712 2 19970404 G 8540 635050A1 ADAPTER GEAR CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO STARTER FAILED B UG1R K NONE O OTHER IN INSP/MAINT 1 SW 03 999VE 1067 421C0629 272357R ENGINE FAILED TO START. INSPECTION REVEALED FAILED STARTER ADAPTER. REMOVED ADAPTER AND FOUND DRIVE GEAR AND CRANKSHAF T GEAR DEFECTIVE. INSPECTION OF OIL FILTER REVEALED METAL CONTAMINATION OF ENGINE OIL SYSTEM. ENGINE TSOH: 1,067 HOUR S. SUBMITTER RECOMMENDS C/W MANUFACTURER'S SB CSB94-4. 1 L 7 2 3O 3 O A7CE E7CE 1997042400025 19970424 00025 SO 1997 4 24 97ZZZX1713 1 19970331 G 3230 7642603 LINK ASSY PIPER PA28 PA28R201 7102816 SO NLG ASSY CRACKED B S UC2R K NONE O OTHER IN INSP/MAINT 1 GL 19 47227 5611 28R7737158 FOUND THE LINK ASSY CRACKED IN RADIUS JUST FORWARD OF THE ATTACH POINT FOR THE DOWNLOCK ASSY. THIS IS THE SECOND ONE FO UND IN FLEET. THE AREA WHERE THE CRACK OCCURRED IS ONE OF THE ITEMS CALLED OUT FOR IN SB 724A, PART II, ITEM NR 3, SKET CH 3, TO BE CHECKED FOR CRACKING. SUBMITTER SUGGESTS CHECKING THIS AREA FOR CRACKS EVERY 10 HOURS BY USING DYE PENETRAN T METHODS. 1 L 7 1 3O 2A13 1997042400026 19970424 00026 SO 1997 4 24 97ZZZX1714 1 19970403 G 3222 4533303 FORK ASSY PIPER PA31T PA31T2 7103127 SO NLG CRACKED B S LF1R K NONE O OTHER IN INSP/MAINT 1 EA 07 107PC 3831 31T8166046 DURING A COMBINATION EVENT 1 AND 2 INSPECTION, NOTED THE LEFT SIDE OF THE NLG FORK ASSY WAS CRACKED AT THE LOWER SURFACE OF THE AXLE OPENING. PILOT REPORTED NO HARD LANDINGS. NO OTHER DAMAGE NOTED. 1 L 7 2 3T RT A8EA 1997042400027 19970424 00027 CE 1997 4 24 97ZZZX1715 1 19970301 G 3710 RAIJ47 AIR FILTER RAPCO BEECH 33 F33A 1151425 CE INLINE AIR MELTED D A K NONE O OTHER IN INSP/MAINT 1 WP 07 5530A 26 02797 CE1342 DURING A ROUTINE INSP OF THE AIRCRAFT, FOUND THE IN-LINE AIR FILTER TO THE SECONDARY PRESSURE SYSTEM HAD BEEN HEATED BY THE EXHAUST SYSTEM ON THE LEFT EXHAUST. THE CLEAR PLASTIC MELTED THEN SHATTERED IN PIECES. SUBMITTER STATED THIS COULD CAUSE SMALL PIECES TO GET INTO THE INSTRUMENT AIR SYSTEM. AIRBORNE PRODUCTS MAKES AN IN-LINE AIR FILTER MADE OUT OF A METAL CANISTER. THIS FILTER WAS USED PREVIOUSLY ON THE AIRCRAFT WITHOUT HAVING ANY DISCREPANCIES. 1 L 7 1 3O 3A15 1997042400028 19970424 00028 NE 1997 4 24 97ZZZX1716 2 19970327 G 7230 745704 C4 DISK PWA JT8 JT8D1 52044 NE WINDAGE TAB CORRODED B VF5R K NONE O OTHER IN INSP/MAINT 1 NE 03 25321 K52635 C4 DISK WAS RETURNED DUE TO CORROSION. DISK WAS RECEIVED WITH 3 BROKEN AND 6 BENT WINDAGE TABS. PER ENGINE MANUAL 481 672 SECTION 72-33-35, INSP 01. THIS PART IS SCRAP. PART WAS TAGGED SCRAP AND RETURNED. 4 F E2EA 1997042400029 19970424 00029 SO 1997 4 24 97ZZZX1717 1 19970404 G 3230 1742001 DRAG LINK PIPER PA23 PA23250 7102308 SO MLG FITTING CRACKED B A HEWR K NONE O OTHER IN INSP/MAINT 1 SW 03 405MC 4122 277405314 DURING AN ANNUAL INSPECTION, CRACKS WERE FOUND ON THE MLG DRAG LINK FITTING SUPPORT TUBE ASSEMBLIES LOCATED ON THE RT IN BD P/N 17420-01, RT OTBD, P/N 17420-02, AND LT OTBD P/N 17420-03 AFT MOUNTING BOLT HOLES. TWO TUBE ASSEMBLIES REQUIRED REPLACEMENT AND ONE WAS REPAIRABLE. SUBMITTER SPECULATED THAT THE AFT MOUNTING BOLTS WERE NOT CHECKED FOR TORQUE DURING INSPECTIONS. 1 L 7 2 3O 1A10 1997042400030 19970424 00030 SO 1997 4 24 97ZZZX1718 1 19970404 G 3230 1742002 DRAG LINK PIPER PA23 PA23250 7102308 SO MLG FITTING CRACKED B A HEWR K NONE O OTHER IN INSP/MAINT 1 SW 03 405MC 4122 277405314 DURING AN ANNUAL INSPECTION, CRACKS WERE FOUND ON THE MLG DRAG LINK FITTING SUPPORT TUBE ASSEMBLIES LOCATED ON THE RT IN BD P/N 17420-01, RT OTBD, P/N 17420-02, AND LT OTBD P/N 17420-03 AFT MOUNTING BOLT HOLES. TWO TUBE ASSEMBLIES REQUIRED REPLACEMENT AND ONE WAS REPAIRABLE. SUBMITTER SPECULATED THAT THE AFT MOUNTING BOLTS WERE NOT CHECKED FOR TORQUE DURING INSPECTIONS. 1 L 7 2 3O 1A10 1997042400031 19970424 00031 SO 1997 4 24 97ZZZX1719 1 19970404 G 3230 1742003 DRAG LINK PIPER PA23 PA23250 7102308 SO MLG FITTING CRACKED B A HEWR K NONE O OTHER IN INSP/MAINT 1 SW 03 405MC 4122 277405314 DURING AN ANNUAL INSPECTION, CRACKS WERE FOUND ON THE MLG DRAG LINK FITTING SUPPORT TUBE ASSEMBLIES LOCATED ON THE RT IN BD P/N 17420-01, RT OTBD, P/N 17420-02, AND LT OTBD P/N 17420-03 AFT MOUNTING BOLT HOLES. TWO TUBE ASSEMBLIES REQUIRED REPLACEMENT AND ONE WAS REPAIRABLE. SUBMITTER SPECULATED THAT THE AFT MOUNTING BOLTS WERE NOT CHECKED FOR TORQUE DURING INSPECTIONS. 1 L 7 2 3O 1A10 1997042400032 19970424 00032 GL 1997 4 24 97ZZZX1720 3 19970401 G 6111 A14966 PILOT TUBE HARTZL HCA2V HCA2VK2 GL HUB CRACKED B LU4R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 17 NEW PILOT TUBE NEVER INSTALLED. HAD RELEVANT INDICATION FROM MAG PARTICLE TESTING APPROXIMATELY 2.5 INCHES RUNNING APPR OXIMATELY 15 DEGREES OF THE CENTERLINE OF THE PILOT TUBE. 5 C P24EA 1997042400033 19970424 00033 GL 1997 4 24 97ZZZX1721 1 19970325 G 2720 HORN AMTR SKYBLT SKYBOLT GL RUDDER BROKEN WELDS D A K NONE O OTHER IN INSP/MAINT 1 WP 07 420 THE WELDS ATTACHING THE RUDDER HORN TO THE RUDDER VERTICAL POST BROKE CAUSING AN IN-FLIGHT LOSS OF RUDDER CONTROL. ONLY ONE TAC WELD EXISTED AROUND THE VERTICAL TUBE. THIS FAILURE CAUSED BY INSUFFICIENT WELD AREA AROUND THE VERTICAL RUDDE R POST. THIS AREA IS COVERED WITH FABRIC AND IMPOSSIBLE TO INSPECT. WELDS APPEAR TO HAVE FAILED OVER A LONG PERIOD OF TIME. (SOME RUST FOUND IN BROKEN WELD AREA.) THE AIRCRAFT WAS LANDED WITHOUT FURTHER DAMAGE USING BRAKES FOR DIRECTION AL CONTROL ON GROUND. 1 Q 7 1 3O EXPA1Q71 1997042400034 19970424 00034 SW 1997 4 24 97ZZZX1722 1 19970204 G 3340 A402A LENS WHELEN HUGHES 500N 500N 3027374 SW LOWER AFT CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 N NR 521FB THROUGH N NR 527FB. P/N A402A 'R AND R/N' STROBE LENS, APPROXIMATELY 60 LENS COVERS HAVE BROKEN OR CRACKED O N OUR HELICOPTERS. DIFFERENT DESIGNS HAVE BEEN TRIED. SAME RESULTS. MOST BREAKAGE IS ON LOWER AFT STROBE. 1 G 7 1 3U NC H3WE 1997042400035 19970424 00035 SW 1997 4 24 97ZZZX1723 1 19970204 G 3340 7052101 LIGHT HUGHES 500N 500N 3027374 SW UPPER AFT FAIL G K NONE O OTHER IN INSP/MAINT 1 WP 07 N NR 521FB THROUGH N NR 527FB. P/N 70521-01. APPROXIMATELY 30 UNITS HAVE GONE BAD IN THE A996 SEASON. ALMOST ALL HAV E LESS THAN 500 HOURS ON THEM. MOST OF THE TIME IT IS THE UPPER AFT LOCATION. 1 G 7 1 3U NC H3WE 1997042400036 19970424 00036 SW 1997 4 24 97ZZZX1724 1 19970318 G 3340 A402ARN LENS WHELEN HUGHES 500N 500N 3027374 SW LOWER AFT CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 07 526FB 8 LN006 NEW LENS FROM WHELEN. FAILED BY CRACKING IN HALF AT SEAM. PARTS FOUND ON 100 HOUR INSPECTION . ALL 3 PIECES AT SHOP F OR INSPECTION. 1 G 7 1 3U NC H3WE 1997042400037 19970424 00037 SW 1997 4 24 97ZZZX1725 1 19970327 G 3340 LENS WHELEN HUGHES 500N 500N 3027374 SW LOWER STROBE SEAM CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 524FB 6 LN004 LOWER STROBE LENS SEAM CRACKED. FOUND ON PRE-FLIGHT. PART SENT TO WHELEN. 1 G 7 1 3U NC H3WE 1997042400038 19970424 00038 SW 1997 4 24 97ZZZX1726 1 19970317 G 3340 A402ARN LENS WHELEN HUGHES 500N 500N 3027374 SW LOWER AFT CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 524FB 21 LN004 LENS CRACKED RADIALLY .50 INCH - 1 INCH FROM TOP OR BOTTOM. NEW CLAMP WORKS GOOD. LENS IS NEW STYLE FROM WHELEN. PART SENT TO WHELEN. 1 G 7 1 3U NC H3WE 1997042400039 19970424 00039 SW 1997 4 24 97ZZZX1727 1 19970327 G 3340 LENS WHELEN HUGHES 500N 500N 3027374 SW LOWER AFT CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 525FB 31 LN005 LOWER AFT LENS CRACKED ON SEAM. ALSO, STAR CRACK ON FWD LIP. PART SENT TO WHELEN. 1 G 7 1 3U NC H3WE 1997042400040 19970424 00040 SW 1997 4 24 97ZZZX1728 1 19970204 G 3340 A470DRSU LIGHT WHELEN HUGHES 500N 500N 3027374 SW UPPER TAIL FAILED G K NONE O OTHER IN INSP/MAINT 1 WP 07 521FB 205 LN001 P/N 70521-01. STROBE GOES INTO 'GLOW' SELF-IONIZATION. PART CAUSES STROBES TO STOP OPERATION. SUBMITTER STATED MAY CA USE HAZARD DURING NIGHT OPERATION. 1 G 7 1 3U NC H3WE 1997042400041 19970424 00041 SW 1997 4 24 97ZZZX1729 1 19970204 G 3340 A470DRSU LIGHT WHELEN HUGHES 500N 500N 3027374 SW UPPER TAIL FAILED G K NONE O OTHER IN INSP/MAINT 1 WP 07 527FB 165 LN007 STOBE ASSY GOES INTO 'GLOW' SELF-IONIZATION. PART CAUSES STROBES TO STOP OPERATION. SUBMITTER STATED CAN CAUSE HAZARD WHEN FLYING AT NIGHT. P/N 70521-01. 1 G 7 1 3U NC H3WE 1997042400042 19970424 00042 SW 1997 4 24 97ZZZX1730 1 19970207 G 3340 A470DRSU LIGHT HUGHES 500N 500N 3027374 SW LOWER TAIL AFT FAILED G K NONE O OTHER IN INSP/MAINT 1 WP 07 527FB 165 LN007 STROBE LIGHT GOES INTO 'GLOW' SELF-IONIZATION. PART CAUSES STROBES TO STOP OPERATION. MAY CAUSE HAZARD DURING NIGHT FL IGHT. P/N 70521-01. 1 G 7 1 3U NC H3WE 1997042400043 19970424 00043 SW 1997 4 24 97ZZZX1731 1 19970328 G 3340 LENS WHELEN HUGHES 500N 500N 3027374 SW LOWER AFT CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 526FB 24 LN006 LENS CRACKED ALONG SEAM. FOUND ON MORNING WALK-AROUND. PART SENT TO WHELEN. 1 G 7 1 3U NC H3WE 1997042400044 19970424 00044 SW 1997 4 24 97ZZZX1732 1 19970402 G 3340 LENS WHELEN HUGHES 500N 500N 3027374 SW LOWER STOBE CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 524FB 45 LN004 LOWER AFT STROBE LENS FAILED BY CRACKING ALONG SEAM OF LENS. FOUND ON MORNING WALK-AROUND. PART SENT TO WHELEN. 1 G 7 1 3U NC H3WE 1997042400045 19970424 00045 SW 1997 4 24 97ZZZX1733 1 19970328 G 3340 LENS HUGHES 500N 500N 3027374 SW STROBE LIGHT CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 521FB 7 LN001 LOWER AFT LENSE CRACKED. NEW STYLE, AND NEW STYLE PLASTIC CLAMP. LENS SENT TO WHELEN. 1 G 7 1 3U NC H3WE 1997042400277 19970424 00277 NM 1997 4 24 97ZZZX1734 1 19970301 G 5320 STIFFENER BOEING 727 7272J4 1384006 NM NLG BOX BS 312 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 2FOR 20764 DURING C-CHECK INSPECTION, LEVEL 2 CORROSION WAS NOTED ON TOP NOSE GEARBOX HORIZONTAL STIFFENER AT STA 312 (AS VIEWED FR OM THE E/E BAY). 2 L 7 3 4F RT A3WE 1997042400278 19970424 00278 NM 1997 4 24 97ZZZX1735 1 19970301 G 5320 STIFFENER BOEING 727 7272J4 1384006 NM NLG BOX HORIZ CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 2FOR 20764 DURING C-CHECK INSPECTION, LEVEL 2 CORROSION WAS NOTED ON TOP NOSE GEARBOX HORIZONTAL SITFFENER, FROM END TO END, AT STA 294.5 (AS VIEW FROMT HE E/E BAY). 2 L 7 3 4F RT A3WE 1997042400279 19970424 00279 NM 1997 4 24 97ZZZX1736 1 19970328 G 5311 FRAME BOEING 727 7272J4 1384006 NM FR 950A S19L CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 2FOR 20764 DURING C-CHECK INSPECTION, LEVEL 2 CORROSION WAS FOUND ON FUSELAGE FRAME 950A BETWEEN S19L AND S20L. 2 L 7 3 4F RT A3WE 1997042400280 19970424 00280 NM 1997 4 24 97ZZZX1737 1 19970301 G 5711 SPAR CAP BOEING 727 7272J4 1384006 NM RT WS 560 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 2FOR 20764 DURING C-CHECK INSPECTION, LEVEL 2 CORROSION WAS NOTED ON LOWER FWD SPAR CAP AT RT WING STA 560 AT ATTACH POINT FOR LOWE R LEADING EDGE ACCESS PANEL. APPARENTLY CAUSED BY INADEQUATE PREVENTIVE TREATMENT. 2 L 7 3 4F RT A3WE 1997042400281 19970424 00281 NM 1997 4 24 97ZZZX1738 1 19970301 G 5313 STRINGER BOEING 727 7272J4 1384006 NM BS 277 S33L CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 2FOR 20764 DURING C-CHECK INSPECTION, LEVEL 2 CORROSION WAS NOTED ON S23L FROM STA 277 TO STA 294.5. 2 L 7 3 4F RT A3WE 1997042400282 19970424 00282 WP 1997 4 24 97ZZZX1739 2 19970328 G 7210 ENGINE GULSTM 690TP 695 7630518 SW GARRTT TPE331 TPE33110 01514 WP GEARBOX FAILED D E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 WP 23 3U 3451 17 95041 P38096 LEFT ENGINE SHUT DOWN IN-FLIGHT DUE TORQUE PRESSURE DROP (40 PSI). SPEED INCREASE TO 103+ . ON INSPECTION, NO OUTWARD SIGN OF DAMAGE, BUT COULD NOT ROTATE PROPELLER. ENGINE OIL FILTER REMOVED, METAL IN FILTER. METAL ON CHIP DETECTOR (NO LIGHT). OIL BLACK AND MILKEY. S.O.A.P. OBTAINED. SUSPECT GEARBOX PROBLEM. ENGINE REMOVED AND SHIPPED TO REPAIR AGEN T FOR INVESTIGATION. 1 H 7 2 3T 4 T 2A4 E4WE 1997042400284 19970424 00284 WP 1997 4 24 97ZZZX1741 1 19970401 G 5753 5614374503 FITTING DOUG DC8 DC8F54 3021926 WP LT FLAP STA 20 CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 56FA 45663 TAT: 66,105:12 HOURS. TAC: 23,119. DURING ROUTINE MAINTENANCE, FOUND A 2 INCH CRACK ON LEFT WING FLAP FITTING STA 22 0, INBOARD SIDE. REMOVED AND REPLACED FLAP SUPPORT FITTING IAW DOUGLAS MM CHAP 27-27-7 AND ACCOMPLISHED FLAP RIG CHECK IAW CHAP 27-30-0. 2 L 7 4 4F 4A25 1997042400285 19970424 00285 WP 1997 4 24 97ZZZX1742 1 19970331 G 5751 NRC60411K AILERON DOUG DC10 DC1010 3022110 WP WING RT OTBD DEBONDED B MZAR K NONE O OTHER IN INSP/MAINT 1 SO 09 1837U 47969 DURING ROUTINE C-CHECK, FOUND RT OTBD AILERON DISBONDED FROM INTERNAL DOUBLER. REPLACED BOTH LOWER SKINS. 2 L 7 3 4F A22WE 1997042400286 19970424 00286 WP 1997 4 24 97ZZZX1743 1 19970327 G 5751 NRC6041502 AILERON DOUG DC10 DC1010 3022110 WP STA XRS 885 DEBONDED B MZAR K NONE O OTHER IN INSP/MAINT 1 SO 09 1816U 46615 DURING ROUTINE C-CHECK, RT OTBD AILERON LOWER SKIN WAS FOUND BULGED IN SEVERAL AREAS STA XRS 885 TO XRS 1013. LOWER SKI N REMOVED AND FOUND DISBONDED FROM INTERNAL DOUBLER. FABRICATED NEW SKIN AND INSTALLED IAW UAL GN/MM1-0-8-2. A/C TOTA L TIME: 67,314.55 HOURS. A/C TOTAL CYCLES, 26,462. 2 L 7 3 4F A22WE 1997042400287 19970424 00287 WP 1997 4 24 97ZZZX1744 1 19970327 G 5751 NRC6041502L AILERON DOUG DC10 DC1010 3022110 WP STA XRS 1013 DISBONDED B MZAR K NONE O OTHER IN INSP/MAINT 1 SO 09 1830U MAC213 46629 DURING ROUTINE C-CHECK, RT OTBD AILERON LOWER SKIN WAS FOUND BULGED IN SEVERAL PLACES STA XRS 1013 TO SRX 1042. LOWER S KIN REMOVED AND FOUND DISBONDED WITH INTERNAL DOUBLER. FABRICATED NEW SKIN AND INSTALLED IAW UAL GN/MM 1-9-8-2. A/C TO TAL TIME: 60,225.58 HOURS. A/C TOTAL CYCLES, 24,014. 2 L 7 3 4F A22WE 1997042400288 19970424 00288 EA 1997 4 24 97ZZZX1745 2 19970408 G 7314 02532330003 PUMP PESCO BEECH 200 B200 1152922 CE PWA PT6 PT6A41 52043 EA LT ENG FUEL SHAFT FAILED D O OTHER X ENGINE FLAMEOUT CR CRUISE 1 GL 23 942CE 7476 BB494 PCE817782 ENGINE WENT TO IDLE CUT OFF IN-FLIGHT. (FLAME OUT.) MAIN ENGINE PUMP SEIZED. ENGINE SHAFT BECAME WORN AND ROUNDED OFF SPLINES. 1 L 7 2 4T 4 T A24CE E4EA 1997042400289 19970424 00289 SW 1997 4 24 97ZZZX1746 1 19970328 G 2434 CLAMP SWRNGN SA227 SA227AT 8780610 SW GENERATOR BROKEN D E ENGINE SHUTDOWN N A FALSE WARNING FLAME/FIRE TX TAXI/GRND HDL 1 WP 23 9UA AT495 ENGINE SHUT DOWN BY CREW (RT) DUE FIRE WARNING AND FLAME FROM JET PIPE. CREW ON TRAINING/CHK RIDE. A/C TAXI. ENG INSP NIL DAMAGE OBSERVED. BROKEN CLAMP NOTICED ON GENERATOR. THIS CLAMP SECURES FIRE THERMAL S/W AT FWD RT POSITION. S/W P/N 17343-61-350F. SUSPECT S/W HAD 'SHORTED' AGAINST GENERATOR CLAMP CAUSING FIRE LIGHT TO COME ON. S/W SECURED. FIRE EXT RE-CHARGED. GROUND RUNS CHK GOOD. SUSPECT FLAME CAUSED BY REMAINING FUEL AFTER SHUT DOWN AND HOT ENGINE. 2 L 7 2 4T RT A5SW 1997042400290 19970424 00290 CE 1997 4 24 97ZZZX1747 3 19970324 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 5543 919 FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF TWO PITCH PIN ENGAGEMENT SLOTS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997042400291 19970424 00291 CE 1997 4 24 97ZZZX1748 3 19970326 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 3568 2790NR FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997042400292 19970424 00292 CE 1997 4 24 97ZZZX1749 3 19970321 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 12310 4556 FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF ONE PITCH PIN ENGAGEMENT SLOT. PART SENT TO HARTZELL FOR EVALUATION. 2 L 7 2 4T RT A24CE 5 C P10NE 1997042400293 19970424 00293 CE 1997 4 24 97ZZZX1750 1 19970129 G 3260 840508 SWITCH RKWELL NA265 NA26565 7630107 CE LT MLG UPLOCK FAILED D A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 GL 03 2N 46563 ON 1-29-97, PILOT REPORTED RED FLASHING LIGHT IN GEAR HANDLE WITH HYDRAULIC PUMP RUN LIGHT. LANDING GEAR SEEMED TO RETR ACT OR TRY TO AFTER IT WAS RAISED. AFTER RETURN TO MDW, JACKED AIRCRAFT AND FUNCTIONAL CHECKED. LANDING GEAR CHECKED N ORMAL. AFTER 2 HOURS ON JACKS, A/C DUPLICATED ORIGINAL PROBLEM. TROUBLESHOT FAULT TO LT MLG UPLOCK SWITCH. REPLACED A ND RETURNED TO SERVICE. 2 L 7 2 4J A2WE 1997042400294 19970424 00294 1997 4 24 97ZZZX1751 4 19970127 G 2312 686804 CONTROL HEAD GABLES BRAERO DH125 BAE125800A 1500285 EU NR 1 COMM DIODE BURNED D A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 GL 05 8186 1596 57 258186 AFTER TAKEOFF, THE COCKPIT BEGAN TO FILL WITH SMOKE. THE AIRCRAFT WAS RETURNED TO THE DEPARTURE AIRPORT WITH NO DAMAGE TO THE AIRCRAFT. THE CAUSE OF THE SMOKE WAS DETERMINED TO BE THE NR 1 COMM. RADIO HEAD, PC BOARD, P/N 701-314-01, REV 3 , WAS FOUND WITH 9 BURNED DIODES. 2 L 7 2 4F RT A3EU 1997042400295 19970424 00295 CE 1997 4 24 97ZZZX1752 1 19970401 G 3610 45AA0304001 DUCT BEECH MU300 400A 1155402 CE BLEED AIR DUCT RUPTURED B BUER K NONE O OTHER IN INSP/MAINT 1 GL 23 80KM 2354 RK50 FOUND ENGINE BLEED AIR LINE STAINLESS STEEL OUTER BRAIDING AND BELLOWS ASSEMBLY RUPTURED NEAR NACELLE CONNECTION. 2 H 7 2 4F RT A16SW 1997042400296 19970424 00296 WP 1997 4 24 97ZZZX1753 1 19970314 G 5751 NRC60411K AILERON DOUG DC10 DC1010 3022110 WP LT WS XORS 855 DELAMINATED B MZAR K NONE O OTHER IN INSP/MAINT 1 SO 09 1812U MAC38 46611 LEFT WING OUTBOARD AILERON HAS DELAMINATION. REMOVED AND REPLACED DAMAGED SKIN IAW UNITED AIRLINES GN/MM 1-0-8-2. ACFT TT: 69,132.00 HOURS. ACFT TOTAL CYCLES: 27,585. ACFT TSO: 13,720.39 HOURS. ACFT CYCLES SINCE OVERHAUL: 5,698. 2 L 7 3 4F A22WE 1997042400297 19970424 00297 CE 1997 4 24 97ZZZX1754 1 19970301 G 5230 CARGO DOOR BEECH 200 B200 1152922 CE SUPPORT MISMODIFIED B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 3258P BB1526 AFT CARGO DOOR MOD/INSTALLATION PERFORMED ON ACFT IS UNAIRWORTHY. E.M.S. MODIFICATIONS WERE BEING DONE WHEN PROBLEMS IN THE DOOR AND ADDED STRUCTURE WAS NOTICED. AN UNBUCKED RIVET, DRILLED HOLES NOT FILLED WITH RIVETS, AND OVER BUCKED RIV ETS IN ADDED FORMER FOR CARGO DOOR SUPPORT. METAL SHAVINGS AND LOOSE RIVETS WERE FOUND UNDER FLOOR PANEL LYING ON AND C LOSE TO PULLEYS. FLIGHT TRIM CONTROL CABLES TOUCHING FORMER IN TWO PLACES OF NEW SUPPORT INSTALL. STRINGERS TOUCHING S UPPORTS IN FLOOR OF AIRCRAFT. 1 L 7 2 4T A24CE 1997042400298 19970424 00298 SO 1997 4 24 97ZZZX1755 1 19970310 G 2121 X702278A FAN LKHEED 188 188C 5262604 SO BEARING FAILED B FF3R K NONE O OTHER IN INSP/MAINT 1 WP 27 AA57871 DURING OVERHAUL, UNAPPROVED BEARINGS WERE INSTALLED CAUSING PREMATURE FAILURE. BEARING, P/N 377416-5, REPLACED WITH P/N 60042ZJ, BEARING P/N 377416-6, REPLACED WITH P/N 77200. 2 L 7 4 4T 4A22 1997042400301 19970424 00301 CE 1997 4 24 97ZZZX1758 1 19970404 G 7810 1019500191 EXHAUST BEECH 200 200BEECH 1152920 CE EXHAUST FLANGE CRACKED C A K NONE O OTHER IN INSP/MAINT 1 WP 23 30XY 356 BB305 STACK CRACKED AT FLANGE APPROXIMATELY 6 INCHES IN LENGTH. DEFECT FOUND ON PRE-FLIGHT INSPECTION. SUBMITTER SUGGESTS EN GINE EXHAUST STACKS BE LOOKED AT CLOSELY ON POST-FLIGHT INSPECTIONS. NEW EXHAUST STACKS P/N 101-950022-1 SEEM TO HOLD U P BETTER BECAUSE OF REINFORCEMENTS INSTALLED DURING MANUFACTURE. 1 L 7 2 4T A24CE 1997042400303 19970424 00303 NE 1997 4 24 97ZZZX1760 2 19970219 G 7240 LINER CESSNA 501 501 2076603 CE PWA JT15 JT15D1 52060 NE ENGINE COMB BURNED D O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 WP 25 501AF 6024 2522 500139 79128 PILOT REPORTED TEMP SPLIT BETWEEN ENGINES. MECHANIC PERFORMED GROUND PERFORMANCE RUN AND NOTED THE RIGHT ENGINE'S OUTPU T LOW. A BORESCOPE INSPECTION OF ENGINE HOT SECTION THROUGH THE INBD IGNITER HOLE WAS MADE AND FOUND THE COMBUSTION LIN ER BURNED AT THE OTBD IGNITER HOLE BY THE IGNITER. THE ENGINE HOT SECTION WAS REMOVED AND ALL COMPONENTS SENT TO P&WC F OR INSPECTION AND REPAIR. 1 L 7 2 4F 4 F A27CE E1NE 1997042400329 19970424 00329 GL 1997 4 24 97ZZZX1786 2 19970318 G 7260 6889094 GEAR 6894171 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL GEARBOX TEETH PITTED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 8639F UPI341 1280431D CAE832846 FOUND PTTING AND NICKS ON TEETH OF AIR OIL SEPARATOR GEAR. 1 G 7 1 3U 3 U H3WE E4CE 1997042400814 19970424 00814 SO 1997 4 24 97ZZZX1818 1 19970224 G 2434 BRUSH BENDIX 30E20111B GULSTM G1159 G1159 3953505 SO DC GENERATOR WORN B BQVR K NONE O OTHER IN INSP/MAINT 1 EA 01 900DH 15 1280 111 BLACK STREAKS WERE NOTICED ON THE ENGINE COWLING BY MAINTENANCE PERSONNEL. FOUND THE DC GENERATOR TO HAVE PREMATURE BRU SH WEAR, WORN BEYOND LIMITS (NO WEAR MARK REMAINING - 100 PERCENT WORN). 2 L 7 2 4F RT A12EA 1997042400816 19970424 00816 EU 1997 4 24 97ZZZX1819 1 19970123 G 4930 25VF3627 FUEL HOSE DUNLOP FLEXIMET BRAERO DH125 BAE125800A 1500285 EU APU FAILED B S COZR H DEACTIVATE SYST/CIRCUITS K FLUID LOSS IN INSP/MAINT 1 WP 27 415PT 2471 258016 DURING TROUBLESHOOTING IN THE TAIL COMPARTMENT, THE FUEL LINE SUPPLY HOSE FOR THE GARRETT 30-92 APU STARTED SPRAYING FUE L. THERE WAS ENOUGH FUEL COMING FROM THE LINE THAT THE TECHNICIAN'S CLOTHES WERE SOAKED. THE LINE THAT FAILED WAS A PR EMOD 253141B (THIS MOD INTRODUCES AN ALTERNATE HIGH PRESSURE HOSE). SEE HAWKER IPC 49-10-05-05, ITEM 255. 2 L 7 2 4F RT A3EU 1997042400869 19970424 00869 SO 1997 4 24 97ZZZX1820 1 19970328 G 3242 755950 SNAP RING 6335300 PIPER PA28 PA28140 7102802 SO HAND BRAKE CYL DISLODGED D A K NONE K FLUID LOSS IN INSP/MAINT 1 NM 01 5926U 3900 2826739 ON 2 OUT OF 15 LAST PRE-FLIGHTS, FOUND BRAKE RESERVOIR EMPTY. REFILLED AND LEVEL STAYED UP FOR 6 FLIGHTS, THEN WENT TOT ALLY EMPTY ON NEXT FLIGHT. DISCOVERED HAND BRAKE ACTUATING CYLINDER (PIPER P/N 63353-00/CLEVELAND 10-22) HAD DISLODGED ITS SNAP RING (P/N 755 950); THUS, CAUSING SHAFT AND INNER PISTON TO EXIT CYLINDER ANYTIME HAND BRAKE HANDLE WAS PUSHED FORWARD. THIS, IN TURN, WOULD 'QUICK' DUMP ALL RESERVOIR FLUID OUT THROUGH ACTUATOR END AND DIRECTLY DOWN CONTROL COLUM N OPENING IN CONSOLE. 1 L 7 1 3O 2A13 1997042400870 19970424 00870 SO 1997 4 24 97ZZZX1821 2 19970404 G 8550 653491 FILTER ADAPTER BEECH 36 A36 1151604 CE CONT O550 IO550B SO ENGINE OIL PLUG LOOSE D A K NONE O OTHER IN INSP/MAINT 1 WP 27 8294M 239 E2761 296844R WHEN THE OIL FILTER WAS REMOVED DURING AN ENGINE INSPECTION, DISCOVERED A PLUG THAT WAS PRESSED INTO AN UNUSED OIL PASSA GE IN THE OIL FILTER ADAPTER HAD COME LOOSE. THIS ALLOWED THE OIL FILTER TO BE BYPASSED AND FOR UNFILTERED OIL TO BE PU MPED IN THE OIL SYSTEM. THIS WAS A FACTORY REBUILT ENGINE WITH 239 HRS SINCE INSTALL. IT IS RECOMMENDED THE OIL FILTER ADAPTERS THAT HAVE THIS FEATURE BE INSPECTED TO CONFIRM THE SECURITY OF THE BLOCK-OFF PLUG INSTALLATION. 1 L 7 1 3O 3 O 3A15 E3SO 1997042400871 19970424 00871 CE 1997 4 24 97ZZZX1822 1 19970314 G 3213 05430181 CAP CESSNA 172 172F 2072414 CE NLG STRUT CRACKED D K NONE O OTHER IN INSP/MAINT 1 NE 03 8484U 1986 17252384 DURING ANNUAL INSPECTION, FOUND LOWER NOSE GEAR STRUT SECURING CAP CRACKED IN HALF AT RT ATTACH POINT. SUSPECT CAUSE IG NORING NOSE GEAR SHIMMY PROBLEMS/LOOSE TORQUE LINKS, AND NOT SERVICING DAMPENER AT SPECIFIED INTERVALS. SUBMITTER STATE D ADDRESS SHIMMY PROBLEMS ASAP AND FOLLOW MFG RECOMMENDED SERVICING INTERVALS AND PAY CLOSE ATTENTION TO SECURING POINTS DURING CORRECTION. 1 H 7 1 3O NT 3A12 1997042400874 19970424 00874 EA 1997 4 24 97ZZZX1825 2 19970407 G 8530 AEL12949 VALVE 75137CN HILLER UH12 UH12E 4360122 WP LYC O540 VO540C2A 41532 EA NR 2 CYLINDER FAILED D L K NONE O OTHER IN INSP/MAINT 1 NM 09 36MV 167 06 5060 L256043 THE HELICOPTER WAS RUNNING ROUGH SO A COMPRESSION CHECK WAS RUN. THE NR 2 CYLINDER HELD NO COMPRESSION AND WAS REMOVED FOR INSPECTION. NOTED A .1250 INCH BY .25 INCH SECTION OF THE VALVE FACE WAS MISSING. THE MISSING SECTION WAS IRREGULA R IN SHAPE AND APPEARED TO HAVE MANUFACTURING VOIDS WITHIN THE BASE METAL. SMALL CRATER LIKE HOLES WERE FOUND ALONG TH E EDGE OF THE BROKEN SECTION. THE VALVE STEM SHOWED HIGH WEAR ADJACENT TO THE VALVE KEEPERS UNDER THE HAT SECTION AT TH E TOP OF THE VALVE. IT APPEARED AS THOUGH THE VALVE WAS MANUFACTURED WITH SOFT MATERIAL. 1 G 7 1 3O 3 O 4H11 E304 1997042400875 19970424 00875 SO 1997 4 24 97ZZZX1826 2 19970206 G 8540 631871 CRANK GEAR CESSNA 421 421 2076010 CE CONT O520 GTSIO520H 17032 SO CRANKSHAFT SCREWS LOOSE B L CY4R K NONE W INADEQUATE Q C IN INSP/MAINT 1 AL 03 4584L 4210784 21015370H UPON ENGINE DISASSEMBLY FOUND ALL 6 CRANK GEAR RETAINING SCREWS 'GANG WIRED'. IN ADDITION TO NOT BEING LOCK WIRED CORR ECTLY, THE CRANK GEAR SCREWS WERE ALL LOOSE. SEE TELEDYNE CONTINENTAL MOTORS SIL 93-15 FOR CORRECT USE OF SAFETY WIRE, KEYS, AND LOCK TABS. FURTHER INSP REVEALED THE STARTER SHAFT NEEDLE BEARING, P/N 537721 (SEE GTSIO-520 PARTS BOOK NR X3 0046A, FIG 1, ITEM NR 3), WAS MISSING AND APPEARED THAT IT WAS NEVER RE-INSTALLED AT OVERHAUL, DATED 7-20-95. ALSO, LOG ENTRIES OF 2-16-96, TSO NOT NOTED, REVEALED CONTINUAL REPORTS OF STARTER/STARTER DRIVE SEAL LEAKS AND REPAIR WHICH IN ' HINDSIGHT' ARE UNDERSTANDABLE KNOWING STARTER DRIVE WAS NOT PROPERLY SUPPORTED ON THE LOWER OF 'CRANKCASE END' OF THE SH 1 L 7 2 3O 3 O RT A7CE E7CE 1997042400876 19970424 00876 CE 1997 4 24 97ZZZX1827 1 19970206 G 2410 GEAR 976J4171 CESSNA 421 421 2076010 CE ALTERNATOR DRIVE DETACHED B L CY4R O OTHER H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 AL 03 4584L A5990179 4210184 PILOT LOST POWER FROM THE ALTERNATOR. UPON INVESTIGATING THE PROBLEM, DISCOVERED THE ALTERNATOR DRIVE GEAR HAD FALLEN O FF THE ALTERNATOR, INSIDE THE ENGINE, CAUSING SUBSTANTIAL DAMAGE IN THE FORWARD RIGHT-HAND HALF OF THE CRANKCASE. UPON DISASSEMBLY OF THE ENGINE, THE CAMSHAFT CLUSTER GEARS, P/N 537432 AND P/N 535662, WERE FOUND LOOSE. THE CAMSHAFT GEAR R ETAINING SCREWS WERE 'FINGER LOOSE', BUT LOCK WIRED. THE ALTERNATOR HAD APPROXIMATELY 130 HOURS SINCE OVERHAUL, BUT THE ENGINE LOG IS UNCLEAR AS TO THE ACTUAL INSTALLMENT DATE. THE ENGINE HAS APPROXIMATELY 150 HOURS SINCE MAJOR OVERHAUL A ND APPROXIMATELY 43.5 HOURS SINCE A COMPLETE DISASSEMBLY AND REASSEMBLY. 1 L 7 2 3O RT A7CE 1997042400878 19970424 00878 EU 1997 4 24 97ZZZX1828 1 19970408 G 7810 LW14004 EXHAUST PARTEN P68 P68TCOBS 6780108 EU NR 4 CYLINDER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 01 737 132 40004OTC FOUND EXHAUST SYSTEM DEFORMED AND CRACKED ALONG WELDS WITH ONLY 132.1 HOURS ON NEW EXHAUST. SLIP JOINTS NOT ALLOWING EX HAUST TO MOVE PROPERLY. 1 H 7 2 30 A31EU 1997042400879 19970424 00879 EU 1997 4 24 97ZZZX1829 1 19970408 G 7810 LW14001 EXHAUST PARTEN P68 P68TCOBS 6780108 EU NR 1 CYLINDER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 01 737 275 40004OTC FOUND EXHAUST SYSTEM DEFORMED AND CRACKED ALONG WELDS WITH ONLY 275.1 HOURS ON NEW EXHAUST. 1 H 7 2 30 A31EU 1997042400880 19970424 00880 EU 1997 4 24 97ZZZX1830 1 19970408 G 7810 LW14002 EXHAUST PARTEN P68 P68TCOBS 6780108 EU NR 2 CYLINDER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 01 737 132 40004OTC FOUND EXHAUST SYSTEM DEFORMED AND CRACKED ALONG WELDS WITH ONLY 132.1 HOURS ON NEW EXHAUST. 1 H 7 2 30 A31EU 1997042400881 19970424 00881 EU 1997 4 24 97ZZZX1831 1 19970408 G 7810 LW15689 EXHAUST PARTEN P68 P68TCOBS 6780108 EU NR 3 CYLINDER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 01 737 275 40004OTC FOUND EXHAUST SYSTEM DEFORMED AND CRACKED ALONG WELDS WITH ONLY 275.1 HOURS ON NEW EXHAUST. 1 H 7 2 30 A31EU 1997042400882 19970424 00882 GL 1997 4 24 97ZZZX1832 3 19970402 G 6114 D6097C30 HUB MCAULY 2A34C D2AF34C30 GL NR 2 SOCKET CRACKED B ME4R K NONE O OTHER IN INSP/MAINT 1 SO 19 701309 701309 DURING INSPECTION, HUB FOUND CRACKED IN BLADE SOCKET NR 2. HUB HAS BEEN SCRAPPED. 5 C P5EA 1997042400883 19970424 00883 GL 1997 4 24 97ZZZX1833 3 19970416 G 6111 C52702 BEARING MCAULY 2A34C 2A34C201 GL BLADE DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 SW 99 739671 UPON DISASSEMBLY, FOUND BLADE BUTT HAD SMALL SCRATCHES THAT CAUSED THE PROPELLER TO LEAK. APPARENTLY CAUSED BY SHARP ED GES ON OUTER BEARING INNER RADIUS. 5 C P3EA 1997042400884 19970424 00884 EA 1997 4 24 97ZZZX1834 2 19970401 G 7414 M3548 ROTOR SHAFT SLICK 4370 CESSNA 172 172P 2072436 CE LYC O360 O360A4M 41514 EA MAGNETO BROKEN B EBVR K NONE O OTHER IN INSP/MAINT 1 GL 09 5361K 260 94100187 74080 L3350536A MAGNETO ROTOR SHAFT SHEARED .25 INCH BELOW CAM. SUBMITTER RECOMMENDS VISUAL INSPECTION OF SHAFT AT DISASSEMBLY. 1 H 7 1 3O 3 O NT 3A12 E286 1997042400885 19970424 00885 CE 1997 4 24 97ZZZX1835 1 19970413 G 3230 08421022 BELLCRANK CESSNA 320 320F 2074516 CE NLG IDLER FAILED G A O OTHER J WARNING INDICATION CL CLIMB 1 SW 01 6173Q 665 320F0023 BELLCRANK FAILED ON TAKEOFF DURING RETRACTION. NOSE GEAR WOULD NOT EXTEND TO LOCKED POSITION. ACCORDING TO AIRCRAFT RE CORDS, THE NOSE GEAR FAILED IN THE SAME MANNER IN DECEMBER, 1988. 1 L 7 2 3O 3A25 1997042400886 19970424 00886 SO 1997 4 24 97ZZZX1836 1 19970327 G 5513 6358701 RIB 6358600 PIPER PA32 PA32300 7103212 SO RT STAB TRIM TAB CRACKED G K NONE O OTHER IN INSP/MAINT 1 EA 05 681AT 4500 327740038 FIGHT TRIM TAB SKIN AND INBOARD SUPPORT RIB CRACKED AT ACTUATOR ATTACHMENT UNDER FLANGE FOOTPRINT. 1 L 7 1 3O A3SO 1997042400887 19970424 00887 1997 4 24 97ZZZX1837 4 19970331 G 2312 KX165 TRANSCEIVER PIPER PA60 PA60601P 7106012 NM NAV COMM EXCESS INTERF B LN7R K NONE O OTHER IN INSP/MAINT 1 EA 13 66CG P10800 61P0277061 UPON IFR CERTIFICATION UPGRADE OF APOLLO 2001GPS, C/W RFI TESTS. FOUND NAV COMM RADIO TO INDUCE EXCESSIVE RFI INTO GPS SYSTEM. CAUSE BEING NAV RADIO; OTHER NAV/COMM OF SAME TYPE OK IN EITHER NR 1 OR NR 2 SLOT. APPLICATION OF 'NOTCH' FILT ERS HAD NO AFFECT ON SITUATION. RADIO SENT TO FACTORY FOR REPAIR. 1 M 7 2 3O RT A17WE 1997042400888 19970424 00888 SO 1997 4 24 97ZZZX1838 2 19970301 G 8530 CYLINDER BEECH 36 A36 1151604 CE CONT O550 IO550B SO ALL CYLS EXCESS WORN H K NONE O OTHER IN INSP/MAINT 1 GL 11 72291 850 E2247 REMOVED ALL CYLINDERS FROM AN 850-HOUR FACTORY REMANUFACTURED (ZERO TIME) ENGINE DUE TO LOW COMPRESSION. FOUND ALL CYLI NDERS WORN .009 INCH - .011 INCH OVER NEW SPECS. OPERATOR KEEPS OIL SAMPLES WITH NO INDICATIONS. NORMAL OIL CHANGES AN D GOOD PILOT OPERATION. 1 L 7 1 3O 3 O 3A15 E3SO 1997042400890 19970424 00890 SO 1997 4 24 97ZZZX1840 1 19970301 G 3230 4546600 BREAKER PIPER PA24 PA24250 7102404 SO MLG FAILED D K NONE O OTHER NR NOT REPORTED 1 NM 05 8236P 2404 243490 LANDING GEAR FAILED TO RETRACT DUE TO INOPERATIVE CIRCUIT BREAKER. 1 L 7 1 3O 1A15 1997042400891 19970424 00891 SO 1997 4 24 97ZZZX1841 2 19970408 G 8550 OIL PAN CESSNA 172 172A 2072404 CE CONT O300 O300A 17022 SO PLUG BOSS CORRODED D K NONE O OTHER IN INSP/MAINT 1 EA 21 8591B 36291 16036 CORROSION FOUND INSIDE OF THE BOTTOM OF THE OIL PAN AROUND THE PLUG BOSS. THIS WAS DUE TO MOISTURE CONDENSING AND COLLE CTING AT THE BOTTOM OF PAN. IF THE AIRCRAFT IS GOING TO SIT FOR WEEKS ON END;SUBMITTER SUGGESTS ONE-QUARTER OF THE OIL BE DRAINED AS THIS WILL FACILITATE REMOVAL OF THE COLLECTED MOISTURE. 1 H 7 1 3O 3 O 3A12 E253 1997042400893 19970424 00893 CE 1997 4 24 97ZZZX1843 1 19970405 G 7110 075205712 STIFFENER CESSNA 182 182Q 2072732 CE COWL CRACKED D A K NONE O OTHER IN INSP/MAINT 1 WP 07 97852 18267222 STIFFENER HAS BEEN REPLACED 4 TIMES IN APPROXIMATELY 90 HOURS. EACH TIME IT CRACKS IN THE SAME AREA IN THE SAME WAY. A LL OTHER ATTACHING PARTS ARE NEW. IT APPEARS METAL IS TOO LIGHT OF A GAUGE OR IT IS BEING IMPROPERLY HEAT TREATED OR BO TH. CESSNA OFFERS CREDIT ON TWO OF THESE BUT HAS NOT IMPROVED PART OR OFFERRED A SOLUTION. ALL COWL MOUNTS ARE NEW AND ENGINE SHOWS NO SIGN OF VIBRATION TO CAUSE THIS CRACKING OF PART. THE ONE ON THE LEFT HAS OVER 90 HRS WITH NO SIGN OF CRACKING. 1 H 7 1 3O NT 3A13 1997042400895 19970424 00895 SO 1997 4 24 97ZZZX1845 1 19970403 G 2421 1159SCAV373105 GENERATOR GARRTT GTCP36100G GULSTM G1159 GIV 3980115 SO APU SHAFT DECOUPLED D L K NONE O OTHER IN INSP/MAINT 1 EA 25 2WL 1825 857 1118 DURING APU MAINTENANCE, THE AC GENERATOR WAS REMOVED. THE INPUT DRIVESHAFT WAS FOUND DECOUPLED FROM AC GENERATOR. THIS SHAFT IS HELD IN PLACE BY A SINGLE SCREW. IF THE SCREW SHEARS OFF OR BACKS OUT, IT CAN CAUSE INTERNAL DAMAGE OR FAILUR E TO THE AC GENERATOR. 2 L 7 2 4F RT A12EA 1997042400897 19970424 00897 NM 1997 4 24 97ZZZX1847 1 19970317 G 2710 25W530014509 CONTROL ROD ISRAEL 1125 1125 NM AILERON DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 GL 11 500AJ 074 FOUND PART TO HAVE A LOT OF PLAY SIDEWAYS TO ROD MOVEMENT. ALSO, PART DID NOT PASS THE AILERON LINEAR BALL BEARING INSP ECTION/CHECK PER ASTRA MM 2710-02, PAGE 601. MEASURED OUTSIDE DIAMETER OF ROD OF REJECTED PART .618 INCH. MEASURED AGA INST ANOTHER KNOWN NEW ROD .625 INCH. NO CHROME NOTED ON REJECTED ROD ASSY. 2 L 7 2 4F RT A16NM 1997050100103 19970501 00103 GL 1997 5 1 97ZZZX1848 3 19970328 G 6114 D32612 HUB PIPER PA31 PA31350 7103110 SO HARTZL HCE3Y HCE3YR2 GL MT FLANGE CRACKED B FG6R K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 NM 11 256 DJ9234A DJ9234A PILOT NOTED VIBRATION IN LEFT ENGINE WHEN POWER REDUCED FOR LANDING. FOUND 3 OF 6 MOUNTING STUDS ON PROPELLER FRACTURED . REMOVAL OF PROPELLER REVEALED O-RING PINCHED BETWEEN PROPELLER HUB AND STARTER RING GEAR. PROPER LOCATION OF O-RING IS INSIDE PROPELLER FLANGE. AS O-RING EXTRUDED OUT, BOLT TORQUE REDUCED ALLOWING PROPELLER TO WORK AND MOVE FRACTURING BOLTS. PROPELLER HAD RECENTLY BEEN REMOVED AND REPLACED FOR SPINNER ASSEMBLY REPLACEMENT. FURTHER INVESTIGATION REVEAL ED STARTER RING GEAR CRACKED AND HUB CRACKED AT ONE MOUNTING STUD HOLE. RING GEAR AND HUB REPLACED. SUSPECT CAUSE: FA ILURE TO FOLLOW MANUFACTURER'S INSTALLATION INSTRUCTIONS. 1 L 7 2 3O A20SO 5 C P33EA 1997050100104 19970501 00104 SW 1997 5 1 97ZZZX1849 1 19970201 G 3230 B10006 COUPLING DUKES 950158503 MOONEY M20 M20C 5870208 SW MLG ACTUATOR FAILED D A O OTHER J WARNING INDICATION AP APPROACH 1 EA 25 111JP 500 690078 DUKES LANDING GEAR ACTUATOR RUBBER DRIVE COUPLING CONNECTS TRANSMISSION TO ACTUATOR. COUPLING SPLIT IT IN TWO PLACES D ISCONNECTING TRANSMISSION TO ACTUATOR; THUS, PREVENTING ELECTRICAL OR MECHANICAL GEAR EXTENSION, A GEAR UP LANDING FOLLO WED. 1 L 7 1 3O 2A3 1997050100105 19970501 00105 SO 1997 5 1 97ZZZX1850 1 19970318 G 2140 10E212 HEATER JANITROL PIPER PA31T PA31T 7103124 SO FUEL DRAIN MALFUNCTION D A K NONE A FLAME/FIRE NR NOT REPORTED 1 WP 19 111KV 23 7920035 HEATER VENTING FUEL OVERBOARD FROM COMBUSTION CHAMBER DRAIN CAUSING FLAME STREAK THE LENGTH OF THE LOWER FUSELAGE. FUEL DRAIN IS LOCATED IN LINE AND 3 INCHES AHEAD OF HEATER EXHAUST. RECOMMEND AIR CREWS LOOK FOR THIS CONDITION DURING PRE- FLIGHT. 1 L 7 2 3T A8EA 1997050100106 19970501 00106 SO 1997 5 1 97ZZZX1851 1 19970415 G 5743 486291 SCREW 9564306 PIPER PA32 PA32RT300T 7103216 SO MLG TRUSS BKT LOOSE G K NONE O OTHER IN INSP/MAINT 1 GL 25 3034A 1600 32R7987020 INSPECTION FOUND ONE OF THE COUNTERSINK SCREWS ATTACHING MAIN GEAR TRUSS BRACKET TO WING SPAR IS LOOSE. NUT IS TIGHT ON SCREW, BUT SCREW CAN BE EASILY TURNED WITH FINGERS. 1 L 7 1 3O A3SO 1997050100107 19970501 00107 SO 1997 5 1 97ZZZX1852 1 19970410 G 5542 7892802 SKIN PIPER PA32 PA32RT300T 7103216 SO RUD LT SIDE CRACKED G K NONE O OTHER IN INSP/MAINT 1 GL 25 3034A 1600 32R7987020 INSPECTION FOUND RUDDER SKIN LT SIDE AT TRAILING EDGE, APPROXIMATELY 18 INCHES FROM TOP AT AFT END OF STIFFENING DIMPLE, TO HAVE ABOUT 6 SPIDER WEB CRACKS ALL ABOUT 1 INCH IN LENGTH. PIPER SL 882A WAS INCORPORATED. 1 L 7 1 3O A3SO 1997050100108 19970501 00108 SO 1997 5 1 97ZZZX1853 1 19970319 G 7160 DUCT PIPER PA28 PA28140 7102802 SO ENGINE INTAKE ICE DEBRIS D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 NE 01 3DP 287325252 PILOT PERFORMED PRE-FLIGHT INSPECTION OF AIRCRAFT. FOUND NO DISCREPANCIES, STARTED AIRCRAFT AND TAXIED TO RUN-UP AREA. PERFORMED GROUND RUN-UP, NO DISCREPANCIES NOTED. RECEIVED CLEARANCE FOR TAKEOFF, SHORTLY AFTER TAKEOFF, THE PILOT EXPE RIENCED POWER LOSS AND NOTIFIED ATC OF HIS SITUATION. PILOT LANDED UNEVENTFULLY AND ROLLED OFF THE RUNWAY WHERE THE ENG INE STOPPED. ON INSPECTION, WATER WAS SEEN DRIPPING OUT OF CARBURETOR HEAT BOX. INSPECTED DUCTING BETWEEN INDUCTION FI LTER AND CARBURETOR HEAT BOX AND FOUND A CHUNK OF ICE (APPROXIMATELY 1.5 INCHES BY 2 INCHES) LOOSE IN THE DUCTING. GROU ND RUN-UP PROVED ALL FUNCTIONS SATISFACTORY AFTER CLEARING DUCTING OF DEBRIS. 1 L 7 1 3O 2A13 1997050100112 19970501 00112 CE 1997 5 1 97ZZZX1857 1 19970328 G 2720 0024100341 TUBE BEECH 58 58 1152740 CE RUDDER PEDAL SCORED H A K NONE O OTHER IN INSP/MAINT 1 WP 25 3270J 265 TH1770 THE RUDDER PEDAL BELLCRANK INTERCONNECT TUBE WAS SCORED ENTIRELY THROUGH THE TUBE WALL BY A 1 INCH LONG PK TYPE UPHOLSTE RY SCREW USED TO SECURE THE PILOT'S KICKPLATE TO THE FLOOR BOARD. REPLACED TUBE. NEW SCREW INSTALLED NO LONGER THAN .7 5 INCH. SUBMITTER STATED BE SURE TO USE SCREWS .75 INCH LONG OR SHORTER. 1 L 7 2 3O 3A16 1997050100113 19970501 00113 SO 1997 5 1 97ZZZX1858 1 19970403 G 5711 6207400 SPAR PIPER PA28 PA28140 7102802 SO WING CORRODED D K NONE O OTHER IN INSP/MAINT 1 SO 14 3713K 2823702 DURING MAINTENANCE TO CHANGE THE WING FUEL TANK FLEXIBLE HOSES, FOUND INTERGRANULAR CORROSION IN THE AREA WHERE THE HOSE S PASS THROUGH THE SPARS, AND THE TOP AND BOTTOM OF THE RIGHT SPAR STRUCTURE. 1 L 7 1 3O 2A13 1997050100114 19970501 00114 SO 1997 5 1 97ZZZX1859 1 19970403 G 5711 6207401 SPAR PIPER PA28 PA28140 7102802 SO WING CORRODED D K NONE O OTHER IN INSP/MAINT 1 SO 14 3713K 2823702 DURING MAINTENANCE TO CHANGE THE WING FUEL TANK FLEXIBLE HOSES, FOUND INTERGRANULAR CORROSION IN THE AREA WHERE THE HOSE S PASS THROUGH THE SPARS, AND THE TOP AND BOTTOM OF THE RIGHT SPAR STRUCTURE. 1 L 7 1 3O 2A13 1997050100115 19970501 00115 CE 1997 5 1 97ZZZX1860 1 19970301 G 3213 07416011 GEAR LEG CESSNA 182 182G 2072716 CE LT MLG RUSTED D K NONE O OTHER IN INSP/MAINT 1 SO 25 3791U 18255191 DURING ANNUAL INSPECTION, RUST WAS NOTICED ON THE LANDING GEAR LEGS (MAIN GEAR) MOST SEVERE RUST WAS FOUND UNDER STOP. M ETAL WAS RUSTED TO THE POINT OF 'DELAMINATION'. THE RUST APPEARED TO HAVE BEEN CAUSED BY THE GLUE THAT WAS USED BY CESS NA TO HELP ATTACH THE STEP TO THE LANDING GEAR. SUBMITTER SUGGESTS THESE AIRCRAFT IN THIS SERIAL NUMBER RANGE BE CLEANE D AND INSPECTED IN THIS AREA. THE AIRCRAFT LISTED IN THIS REPORT REQUIRED REPLACEMENT OF BOTH GEAR LEGS. 1 H 7 1 3O NT 3A13 1997050100116 19970501 00116 CE 1997 5 1 97ZZZX1861 1 19970301 G 3213 07416012 GEAR LEG CESSNA 182 182G 2072716 CE RT MLG RUSTED D A K NONE O OTHER IN INSP/MAINT 1 SO 25 3791U 18255191 DURING ANNUAL INSPECTION, RUST WAS NOTICED ON THE LANDING GEAR LEGS (MAIN GEAR) MOST SEVERE RUST WAS FOUND UNDER STOP. M ETAL WAS RUSTED TO THE POINT OF 'DELAMINATION'. THE RUST APPEARED TO HAVE BEEN CAUSED BY THE GLUE THAT WAS USED BY CESS NA TO HELP ATTACH THE STEP TO THE LANDING GEAR. SUBMITTER SUGGESTS THESE AIRCRAFT IN THIS SERIAL NUMBER RANGE BE CLEANE D AND INSPECTED IN THIS AREA. THE AIRCRAFT LISTED IN THIS REPORT REQUIRED REPLACEMENT OF BOTH GEAR LEGS. 1 H 7 1 3O NT 3A13 1997050100117 19970501 00117 SO 1997 5 1 97ZZZX1862 1 19970306 G 5741 66762000 STRAP PIPER PA28 PA28R201T 7102813 SO AFT WING STRAP CORRODED G P A K NONE O OTHER IN INSP/MAINT 1 NE 05 38557 3276 28R7703242 REAR WING ATTACH STRAP FOUND CORRODED BEHIND FLAP. STRAP DIFFICULT TO SEE THROUGH SPAR CAP. SUBMITTER SUGGESTED LOWERI NG FLAP AND LOOK ABOVE FLAP UNDER TRAILING EDGE OF WING WHERE IT ATTACHED TO FUSELAGE FOR STRAP CORROSION. 1 L 7 1 3O 2A13 1997050100118 19970501 00118 CE 1997 5 1 97ZZZX1863 1 19970403 G 2434 ALV9510 ALTERNATOR PRESTOLITE CESSNA 421 421B 2076014 CE DC SYSTEM FAILED B EKIR O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 WP 07 4050Q 252 6010789 421B0274 LEFT ALTERNATOR BECAME INTERMITTENT THEN DROPPED OFF LINE. RETURNED FLIGHT TO YUMA. UNIT HAD BEEN OVERHAULED 1-25-96. 1 L 7 2 3O A7CE 1997050100122 19970501 00122 EA 1997 5 1 97ZZZX1867 2 19970225 G 8500 ENGINE PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA ENGINE REAR FIRE B KG4R K NONE A FLAME/FIRE NR NOT REPORTED 1 SO 19 43733 4154 667 288416122 L1131939A ENGINE COMPARTMENT ON FIRE AT REAR OF ENGINE. INSPECTION OF ENGINE REVEALS NO APPARENT CAUSE FOR START-UP OF FIRE. CAR BURETOR SENT TO SOUTHEAST FUEL SYSTEM, CRS TW4R559M FOR INSPECTION. REFER TO CEU INV NR 27646/2878 FOR DETAILS. 1 L 7 1 3O 3 O 2A13 E274 1997050100123 19970501 00123 EA 1997 5 1 97ZZZX1868 2 19970404 G 7414 M3975 COIL SLICK 4371 CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA MAG SHORTED B EEAR K NONE O OTHER IN INSP/MAINT 1 WP 21 65875 218 17275910 RL1835339A RIGHT MAGNETO ON ENGINE INOPERATIVE. NO ELECTRICAL OUTPUT. FOUND COIL AND SECONDARY COIL OHMS READING TO BE OUT OF TOL ERANCE. REMOVED COIL FOUND BURNED OUT SPOT ON BOTTOM OF COIL SHORTED OUT TO CASE. INSTALL NEW COIL. 1 H 7 1 3O 3 O NT 3A12 E274 1997050100125 19970501 00125 NE 1997 5 1 97ZZZX1870 1 19970301 G 7120 MOUNT CONAER LA4 LA4 5110302 NE ENGINE CRACKED D S A K NONE O OTHER IN INSP/MAINT 1 NM 13 6653L 712 416 ENGINE MOUNT CRACKS WERE DISCOVERED DURING REMOVAL OF BRACKETT AIR FILTER COWLING. CRACKED SUPPORT IS APPROXIMATELY 4 I NCHES LONG, 2 INCHES HIGH, .1250 INCH THICK AND MADE OF STEEL, AND IS WELDED HORIZONTALLY TO THE ENGINE MOUNT STRUCTURE. THE SUPPORT ACTS AS A RIVETED CONNECTION FOR THE FORWARD RIB, P/N 2-5250, 2-5200, AND AFT RIBS 2-5253-27 AND 28. 1 H 7 1 3O 1A13 1997050100126 19970501 00126 CE 1997 5 1 97ZZZX1871 1 19970317 G 3213 AXLE CESSNA 206 TU206F 2073353 CE MLG CORRODED D K NONE O OTHER IN INSP/MAINT 1 NM 09 7485Q U20602220 AIRCRAFT TOTAL TIME 3,075.0 HOURS. AIRCRAFT HAD BEEN CONVERTED TO SEAPLANE BY STC 1483GL IN 1991 AND OPERATED IN SALT W ATER FOR 3 YEARS PRIOR TO ANNUAL INSPECTION IN 1997. ON DISASSEMBLY FOR MAINTENANCE AND INSPECTION, THE MLG AXLES WERE REMOVED FROM THE GEAR SWING-ARMS. AFTER ACCUMULATED GREASE WAS REMOVED, NOTED ALL FOUR AXLES HAD SEVERE INTERGRANULAR C ORROSION AT THE UPPER MOUNTING BOSS LOCATION. AXLES WERE REPLACED WITH NEW PARTS. SUBMITTER SUGGESTED CLEANING GREASE FROM AXLES AND INSPECTING EACH ANNUAL. PARTS TOTAL TIME: APPROX 1,500 HOURS. 1 H 7 1 3O A4CE 1997050100127 19970501 00127 SO 1997 5 1 97ZZZX1872 2 19970401 G 8550 12509221 ADAPTER CESSNA 206 U206G 2073356 CE CONT O520 IO520L 17032 SO OIL FILTER DAMAGED D K NONE O OTHER IN INSP/MAINT 1 NM 09 756HK 4271 U20604102 567375 DURING ENGINE CHANGE, THE OIL FILTER ADAPTER WAS REMOVED AND THE THREADS WERE FOUND DAMAGED AS DEPICTED IN AD 96-12-22. THERE WERE NO SIGNS OF LEAKAGE, BUT THE BREAKAWAY TORQUE APPEARED TO BE LOW. SUBMITTER STATED THIS IS THE THIRD ADAPTE R OF THIS TYPE FOUND WITH THREAD DAMAGE. DIFFICULTY IN TORQUING WHILE MAINTAINING PROPER ALIGNMENT MAY BE A POSSIBLE CA USE. 1 H 7 1 3O 3 O A4CE E5CE 1997050100128 19970501 00128 SO 1997 5 1 97ZZZX1873 1 19970105 G 3230 TRANSMISSION PIPER PA30 PA30 7103002 SO MLG BOLTS BACKED OUT G O OTHER O OTHER LD LANDING 1 SO 15 7745Y 4300 30836 LANDING GEAR COLLAPSE DUE TO MOUNTING BOLTS ON GEAR TRANSMISSION AND MOTOR BACKING OUT (NO SAFETY WIRE). GEAR LINKAGE D ISRUPTED AND BECAME MISALIGNED. THIS PREVENTED NOSE GEAR FROM LOCKING. GEAR ALSO FAILED TO RETRACT. NOSE GEAR FAILED COMPLETELY DUE TO GEAR MOTOR SHEARING RIVETS AND RIPPING THE GEAR MOTOR FROM THE BULKHEAD. GEAR MOTOR MOUNTING BRACKET IS .1250 INCH T6 ALUMINUM MOUNTING BRACKET IS ATTACHED TO .32 INCH BULKHEAD AND SUPPORTS (FLIMSY). THIS AREA MUST BE BU TTRESSED BY .1250 INCH T6 SO THAT EVEN IF THE NOSE GEAR FAILS TO DESCEND OVER CENTER THE GEAR MOTOR ASSEMBLY WILL STILL SUPPORT THE GEAR. GEAR MOUNT BOLTS AT GEAR MOTOR BACKED OUT. NO SAFETY WIRE. DATE OF INCIDENT 1-5-97. 1 L 7 2 3O A1EA 1997050100129 19970501 00129 SO 1997 5 1 97ZZZX1874 1 19970105 G 3230 2176000 ATTACHMENT PIPER PA30 PA30 7103002 SO XMSN ATTACH FAILED G O OTHER O OTHER LD LANDING 1 SO 15 7745Y 4300 30836 LANDING GEAR COLLAPSE DUE TO MOUNTING BOLTS ON GEAR TRANSMISSION AND MOTOR BACKING OUT (NO SAFETY WIRE). GEAR LINKAGE D ISRUPTED AND BECAME MISALIGNED. THIS PREVENTED NOSE GEAR FROM LOCKING. GEAR ALSO FAILED TO RETRACT. NOSE GEAR FAILED COMPLETELY DUE TO GEAR MOTOR SHEARING RIVETS AND RIPPING THE GEAR MOTOR FROM THE BULKHEAD. GEAR MOTOR MOUNTING BRACKET IS .1250 INCH T6 ALUMINUM MOUNTING BRACKET IS ATTACHED TO .32 INCH BULKHEAD AND SUPPORTS (FLIMSY). THIS AREA MUST BE BU TTRESSED BY .1250 INCH T6 SO THAT EVEN IF THE NOSE GEAR FAILS TO DESCEND OVER CENTER THE GEAR MOTOR ASSEMBLY WILL STILL SUPPORT THE GEAR. GEAR MOUNT BOLTS AT GEAR MOTOR BACKED OUT. NO SAFETY WIRE. DATE OF INCIDENT 1-5-97. 1 L 7 2 3O A1EA 1997050100130 19970501 00130 SO 1997 5 1 97ZZZX1875 1 19970105 G 5320 2095400 CHANNEL ASSY PIPER PA30 PA30 7103002 SO BS 87 FAILED G A O OTHER O OTHER LD LANDING 1 SO 15 7745Y 4300 30836 LANDING GEAR COLLAPSE DUE TO MOUNTING BOLTS ON GEAR TRANSMISSION AND MOTOR BACKING OUT (NO SAFETY WIRE). GEAR LINKAGE D ISRUPTED AND BECAME MISALIGNED. THIS PREVENTED NOSE GEAR FROM LOCKING. GEAR ALSO FAILED TO RETRACT. NOSE GEAR FAILED COMPLETELY DUE TO GEAR MOTOR SHEARING RIVETS AND RIPPING THE GEAR MOTOR FROM THE BULKHEAD. GEAR MOTOR MOUNTING BRACKET IS .1250 INCH T6 ALUMINUM MOUNTING BRACKET IS ATTACHED TO .32 INCH BULKHEAD AND SUPPORTS (FLIMSY). THIS AREA MUST BE BU TTRESSED BY .1250 INCH T6 SO THAT EVEN IF THE NOSE GEAR FAILS TO DESCEND OVER CENTER THE GEAR MOTOR ASSEMBLY WILL STILL SUPPORT THE GEAR. GEAR MOUNT BOLTS AT GEAR MOTOR BACKED OUT. NO SAFETY WIRE. DATE OF INCIDENT 1-5-97. 1 L 7 2 3O A1EA 1997050100131 19970501 00131 SO 1997 5 1 97ZZZX1876 1 19970404 G 3250 9539400 CHANNEL PIPER PA34 PA34200 7103405 SO NLG STEERING DAMAGED G A O OTHER J WARNING INDICATION CL CLIMB 1 GL 15 94PG 347450064 NOSE LANDING GEAR TURN LIMITS EXCEEDED DURING GROUND HANDLING OF THE AIRCRAFT WITH TOW VEHICLE. THE NLG STRUT, UPPER TI LLER ROLLER (PN 78535-00) WAS DISPLACED OUTSIDE OF STEERING TRACK CHANNEL (PN 95394-00). PILOT DID NOT EXPERIENCE ANY A BNORMAL STEERING DURING TAXI/TAKEOFF. WHEN GEAR WAS RETRACTED, UNSAFE NLG LIGHT WAS EXPERIENCED. PILOT EXTENDED GEAR, LANDED AND NLG COLLAPSED DURING ROLL-OUT! 1 L 7 2 3O A7SO 1997050100132 19970501 00132 CE 1997 5 1 97ZZZX1877 1 19970401 G 3246 10322300 BOLT CESSNA 208 208B 2073701 CE MLG WHEEL BROKEN D S K NONE O OTHER IN INSP/MAINT 1 SW 99 A NEW OPERATOR HAS FOUND ONE OR TWO BOLTS BROKEN APART AND MISSING FROM MAIN WHEELS DURING INTRANSIT INSPECTION OF AIRCR AFT. THIS HAPPENED QUITE OFTEN ON FLEET AIRCRAFT. THEY WERE USING 53-57 PSI TIRE PRESSURE IAW CESSNA PHASE CHECK TACK C ARD 321004. PROBLEM STARTED AT APPROX 150 TSN AIRCRAFT TIME. CHAPTER 12 OF MM SHOWS A TABLE WITH THE REQUIRED PRESSURE FOR THIS OPERATOR'S TIRES WAS 35-45 PSI. TIRE PRESSURE WAS ADJUSTED IAW MM AND PROBLEM DISAPPEARED. SUBMITTER STATED MECHANICS SHOULD BE ADVISED TO FOLLOW THE MM INSTRUCTIONS OVER ANY OTHER DOCUMENT. 1 H 7 1 3T A37CE 1997050100133 19970501 00133 SO 1997 5 1 97ZZZX1878 1 19970331 G 2460 475109 SHOCK MOUNT PIPER PA31T PA31T1 7103126 SO RELAY PANEL BROKEN B L CPNR K NONE O OTHER IN INSP/MAINT 1 SW 17 114JR 31T8004037 PILOT REPORTED WHEN DEICE TURNED ON, PANEL LIGHTS WOULD FLICKER OR GO OUT. VARIOUS OTHER CKTS ENERGIZED (HEATER FUEL, B OOT DEICE, ETC). FOUND RELAY PANEL SHOCK MOUNT BROKEN CAUSING PANEL TO BE HOT WITH 24V DC, WHICH TURNED CIRCUITS ON. 1 L 7 2 3T A8EA 1997050100134 19970501 00134 EA 1997 5 1 97ZZZX1879 2 19970403 G 8520 SL13521 ROD BEARING BEECH 23 C23 1151242 CE LYC O360 O360A4K 41514 EA NR 3 FAILED B UC2R K NONE O OTHER IN INSP/MAINT 1 GL 19 13FC 661 M2017 L2620936A METAL WAS FOUND IN THE SCREEN AND OIL FILTER AT THE 100-HOUR INSPECTION. THE CYLINDERS WERE REMOVED AND NO EVIDENCE OF METAL WEAR COULD BE FOUND. THE AIRCRAFT WAS PUT BACK INTO SERVICE AND FLOWN FOR APPROXIMATELY 50 HOURS. THE SCREENS AN D FILTERS WERE AGAIN CHECKED FOR METAL. MORE METAL WAS FOUND AND THE ENGINE WAS REMOVED AND DISASSEMBLED FOR FURTHER IN SPECTION. THE NR 3 ROD BEARING WAS FOUND TO HAVE THE TOP LAYER OF MATERIAL (BABBIT) STARTING TO SEPARATE AND FLAKE OFF. 1 L 7 1 3O 3 O A1CE E286 1997050100136 19970501 00136 CE 1997 5 1 97ZZZX1881 1 19970409 G 2510 071402539 SEAT FRAME CESSNA 210 210N 2073453 CE PILOT SEAT BROKEN D S K NONE O OTHER IN INSP/MAINT 1 WP 23 9309Y 21064469 PILOT SEAT FRAME BROKEN WHERE BELLCRANK ATTACHES. SEAT P/N 0714025-39. 1 H 7 1 3O 3A21 1997050100137 19970501 00137 CE 1997 5 1 97ZZZX1882 1 19970409 G 2510 071402539 SEAT FRAME CESSNA 185 A185F 2072821 CE PILOT SEAT BROKEN D K NONE O OTHER IN INSP/MAINT 1 WP 17 9434N 2625 18504355 PILOT SEAT FRAME BROKEN WHERE BELLCRANK ATTACHES. 1 H 7 1 3O 3A24 1997050100138 19970501 00138 SO 1997 5 1 97ZZZX1883 2 19970317 G 8540 536421 CRANK GEAR CESSNA 180 180 2072602 CE CONT O470 O470J 17026 SO ASSY CASE TEETH BROKEN OFF D K NONE O OTHER IN INSP/MAINT 1 NM 09 3129D 1656 31927 469748JR NOISE HEARD AT IDLE POWER AFTER LANDING THAT SOUNDED LIKE A ROD KNOCK (OR A WELL RUNNING RADIAL ENG). DECIDED TO DISASS EMBLE ENGINE FOR OVERHAUL. FOUND TWO TEETH MISSING FROM CRANK GEAR P/N 536421 AND ONE TOOTH MISSING AND ANOTHER TOOTH C RACKED ON CAM GEAR P/N 535660. TEETH WERE FOUND IN OIL PAN. SUSPECT GEARS WERE STRESSED FROM SUDDEN STOPPAGE IN 1972. ENG TT SINCE CONT REMAN: 2,615 HRS. 1 H 7 1 3O 3 O NC 5A6 E273 1997050100139 19970501 00139 SO 1997 5 1 97ZZZX1884 2 19970317 G 8540 535660 CAM GEAR CESSNA 180 180 2072602 CE CONT O470 O470J 17026 SO ASSY CASE TEETH BROKEN OFF D K NONE O OTHER IN INSP/MAINT 1 NM 09 3129D 1656 31927 469748JR NOISE HEARD AT IDLE POWER AFTER LANDING THAT SOUNDED LIKE A ROD KNOCK (OR A WELL RUNNING RADIAL ENG). DECIDED TO DISASS EMBLE ENGINE FOR OVERHAUL. FOUND TWO TEETH MISSING FROM CRANK GEAR P/N 536421 AND ONE TOOTH MISSING AND ANOTHER TOOTH C RACKED ON CAM GEAR P/N 535660. TEETH WERE FOUND IN OIL PAN. SUSPECT GEARS WERE STRESSED FROM SUDDEN STOPPAGE IN 1972. ENG TT SINCE CONT REMAN: 2,615 HRS. 1 H 7 1 3O 3 O NC 5A6 E273 1997050100140 19970501 00140 CE 1997 5 1 97ZZZX1885 1 19970409 G 2434 ALT9422R ALTERNATOR BEECH 58 58 1152740 CE DC SYSTEM FAILED D O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 SO 11 6671X 552 TH1077 AFTER AN IN-FLIGHT ALTERNATOR FAILURE, FOUND THAT THE SHAFT HAD NO SUPPORT AND WOBBLED FREELY, THAT THE ALT GEAR P/N 640 932 WAS CHEWED UP AND SO WAS THE DRIVE GEAR FROM THE CRANKSHAFT P/N 632018. ALSO, ONE EACH LOCKPLATE P/N 641909 WAS MIS SING AS WELL AS THE TWO EACH P/N 634080 BOLTS THAT RETAIN IT. CUT OPEN THE OIL FILTER AND DISCOVERED LARGE AMOUNTS OF M ETAL. THE ENGINE WAS REMOVED FOR INSPECTION. 1 L 7 2 3O 3A16 1997050100141 19970501 00141 CE 1997 5 1 97ZZZX1886 1 19970403 G 3040 66001413 THERMOSTAT LEAR 35 35A 5170602 CE WINDSHIELD SW FAILED B JKIR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 17 2FOR 161 REMOVED FAILED SWITCHES, PURCHASED NEW FROM LEAR, TESTED AND FOUND FAILED, HAD SWITCHES TESTED BY LAB AND FAILED. REPLA CEMENTS FROM LEAR FAILED, ONE OUT OF TWO, 2 TIMES. RECOMMEND LEAR RE-INITIATE TEST PROGRAM ON THEIR SWITCHES LIKE THEY USED TO DO. 2 L 7 2 4F A10CE 1997050100142 19970501 00142 CE 1997 5 1 97ZZZX1887 1 19970408 G 3020 101910026 SHAFT BEECH 200 B200 1152922 CE RT ICE DOOR SHEARED C K NONE O OTHER IN INSP/MAINT 1 EA 17 6182A 905 BB1484 CREW REPORTED RIGHT ICE DEFLECTION DOOR IS INOPERATIVE. FOUND RIGHT ICE DOOR SHAFT ASSY SHEARED AT BOLT HOLE FOR ACTUAT OR ATTACHMENT ARM. NO BINDING NOTED ON DOOR ASSY. REMOVED AND REPLACED SHAFT ASSY WITH A NEW UNIT. GROUND OPS CHECKED OK. REFERENCE BEECHCRAFT MM CHAPTER 30-20-00 AND BEECHCRAFT PARTS CATALOG CHAPTER 30-22-01, PAGE 6 ITEM NR 53. 1 L 7 2 4T A24CE 1997050100144 19970501 00144 NE 1997 5 1 97ZZZX1889 2 19970109 G 7260 3013883H IDLER GEAR BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE ACCESSORY CASE FAILED G P A K NONE O OTHER IN INSP/MAINT 1 SW 03 6606R 2368 BB1122 PILOT REPORTED AIR COND INOP. MAINT SUSPECTED 'QUILL SHAFT' HAD SHEARED. REMOVED AND FOUND SHAFT IN SERVICEABLE CONDIT ION. REMOVAL OF ACCESSORY CASE FOUND IDLER GEAR HAD FAILED RESULTING IN LOSS OF DRIVE FOR AIR/COND COMP. NO REASON FOR FAILURE HAS BEEN DETERMINED AT THIS TIME. PART HAS BEEN SENT TO PRATT AND WHITNEY FOR EVAL. 1 L 7 2 4T 4 T A24CE E4EA 1997050100145 19970501 00145 CE 1997 5 1 97ZZZX1890 1 19970401 G 3240 07308500 PRESSURE PLATE PARKERHANFIN 30182 CESSNA 208 208B 2073701 CE RT BRAKE MISINSTALLED D S K NONE O OTHER IN INSP/MAINT 1 SW 99 DURING INSP, RT BRAKE PRESSURE PLATE FOUND INSTALLED IN WRONG POSITION. LINING SIDE WAS FACING THE PISTON HOUSING. ACF T BRAKING METAL-TO-METAL CAUSING VERY HIGH BRAKE TEMPERATURES AND SUSPECTED SPARKS CAME OUT ON EVERY BRAKE APPLICATION. PRESSURE PLATE AND LININGS DAMAGED BEYOND LIMITS. ACFT TT: 525 HRS. 1 H 7 1 3T A37CE 1997050100146 19970501 00146 SO 1997 5 1 97ZZZX1891 1 19970328 G 5320 1022914 WEB GULSTM AA5 AA5A 3960106 SO FUSELAGE CRACKED D S K NONE O OTHER IN INSP/MAINT 1 SW 99 9920U AA50320 INSPECTION FOUND FUSELAGE COMPONENT P/N 102291-4 CRACKED BOTH SIDES IN THE 90 DEGREE ANGLE UNDER RIVETS THAT ATTACH TO B ULKHEAD. ACTION DRILLED STOP HOLES AND INSTALLED REINFORCEMENT WITH NEW. 1 L 7 1 3O A16EA 1997050100147 19970501 00147 CE 1997 5 1 97ZZZX1892 1 19970408 G 5341 2050411129 BLOCK CESSNA 172 172 2072402 CE LT/RT WING SPAR CORRODED D K NONE O OTHER IN INSP/MAINT 1 EA 21 8591B 2363 36291 FRONT AND AFT BLOCKS (RIGHT AND LEFT SIDES) FOR WING SPAR ATTACHMENT SHOW HEAVY EXFOLIATION BETWEEN MAIN BOLT SPAR ATTA CHMENT AND HOLD-DOWN BOLTS FOR BLOCK, MAY BE UNDETECTABLE WITH WINGS ATTACHED, EVEN WITH SKIRTING REMOVED. MIGHT POSSIB LY DO A MIRROR INSPECTION; IF NOT, WOULD NEED TO MAKE SOME FORM OF PERIODIC INSPECTION SCHEUDLE TO PULL WINGS TO INSPECT INNER BLOCK AREA AND BOLTS FOR CORROSION AND/OR WHEN APPROPRIATE, PULL BLOCK TO INSPECT BACK PORTION AND BOLTS. SHOULD BE NOTED THAT AIRCRAFT SAT IN AN OPEN FIELD FOR APPROXIMATELY TEN YEARS. 1 H 7 1 3O NT 3A12 1997050100148 19970501 00148 CE 1997 5 1 97ZZZX1893 1 19970408 G 5341 2870512122 BEARING ATTACH CESSNA 172 172 2072402 CE LT/RT WING SPAR CORRODED D S A K NONE O OTHER IN INSP/MAINT 1 EA 21 8591B 2363 36291 FRONT AND AFT BLOCKS (RIGHT AND LEFT SIDES) FOR WING SPAR ATTACHMENT SHOW HEAVY EXFOLIATION BETWEEN MAIN BOLT SPAR ATTA CHMENT AND HOLD-DOWN BOLTS FOR BLOCK, MAY BE UNDETECTABLE WITH WINGS ATTACHED, EVEN WITH SKIRTING REMOVED. MIGHT POSSIB LY DO A MIRROR INSPECTION; IF NOT, WOULD NEED TO MAKE SOME FORM OF PERIODIC INSPECTION SCHEUDLE TO PULL WINGS TO INSPECT INNER BLOCK AREA AND BOLTS FOR CORROSION AND/OR WHEN APPROPRIATE, PULL BLOCK TO INSPECT BACK PORTION AND BOLTS. SHOULD BE NOTED THAT AIRCRAFT SAT IN AN OPEN FIELD FOR APPROXIMATELY TEN YEARS. 1 H 7 1 3O NT 3A12 1997050100342 19970501 00342 NM 1997 5 1 97ZZZX1899 1 19970221 G 2710 69356881 PCU FILTER CAP BOEING 737 737* NM AILERON SYSTEM BURST B IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 1800 3064SS THE FILTER CAP BURST UNDER WORKING CONDITIONS FOR THE AILERON PCU. THE ALUMINUM FILTER CAPS ARE WEAKER THAN THE STEEL O NES. IT IS RECOMMENDED THAT ALUMINUM CAPS BE REPLACED COMPLETELY BY STEEL FILTER CAPS. 2 L 7 2 4F RT A16WE 1997050100343 19970501 00343 EU 1997 5 1 97ZZZX1900 1 19970327 G 3610 HTE460009009 NON RETURN VALVE AIRBUS 320 A320321 3930325 EU APU AIR CRACKED B A F5HR K NONE O OTHER IN INSP/MAINT 1 NM 03 M174VNR274 VALVE FLAPPERS DEVELOP CRACKS. FLAPPER TO BODY HINGE HAS PREMATURE WEAR CAUSING HINGE TO SEPARATE FROM BODY. SUBMITTER STATED COMPONENT CONSTRUCTION IS ALUMINUM ALLOY. TIME CONTROL OF COMPONENT MAY ELIMINATE EXCESSIVE WEAR CONDITIONS ELI MINATING OPERATOR DIFFICULTY REPORTS AND DISCREPANCIES. 2 L 7 2 RT 4T A28NM 1997050100344 19970501 00344 EA 1997 5 1 97ZZZX1901 2 19970325 G 7414 1068291018 MAGNETO ELECTROSYS D6RN3200 PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA BASE FLANGE LOOSE B V0AR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 01 2QC 400 4052388 317752124 INSPECTION FOUND MAG COULD BE MOVED DUE TO BASE METAL FROM FLANGE MISSING TOP AND BOTTOM ABOUT .0625 INCH. MAG P/N 10-6 8291018, TYPE D6RN3200. SUBMITTER STATED THIS IS 2ND MAG 2000/3000 SERIES FOUND LOOSE WITH FLANGE METAL MISSING. 1 L 7 2 3O 3 O A20SO E14EA 1997050100345 19970501 00345 CE 1997 5 1 97ZZZX1902 1 19970324 G 3246 50300010109 WHEEL BEECH 90 65A90 1152908 CE LT MLG FAILED B P A EFAR K NONE O OTHER LD LANDING 1 WP 21 88SP 8291 B1884 LJ116 THE LEFT MLG OUTER WHEEL HALF FAILED AFTER LANDING ROLL-OUT AT THE RUNWAY TURN OFF. THE WHEEL HALF BLEW OFF, HIT THE AS PHALT AND BOUNCED UP INTO THE RT NACELLE CAUSING MINOR DAMAGE. CAUSE OF FAILURE SEEMS TO BE CRACKS STARTING AT THE VALV E STEM HOLE, BOTH SIDES, ABOUT THE CIRCUMFERENCE OF THE WHEEL OR POSSIBLY FROM A DENT ON THE OUTSIDE RIM. THE MFG DATE IS 1-68. SUBMMITTER RECOMMENDED STRIPPING PAINT AND DYE CHECK FOR EDDY CURRENT CHECK FOR CRACKS. CYCLES, 8,394. 1 L 7 2 3T 3A20 1997050100346 19970501 00346 NE 1997 5 1 97ZZZX1903 2 19970301 G 7323 1412654 BEARING WOODWARD 8210 PWA PT6 PT6A25 52043 NE GOVERNOR MISASSEMBLY H K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 03 NEW WOODWARD BEARING P/N 1412-654. RECEIVING IN INSPECTION REVEALED THAT INNER BEARING RACE, ROLLER BALLS, AND BALL CAG E WERE NOT SEATED CORRECTLY INTO THE OUTER RACE. BEARING WOULD SPIN, HOWEVER, THE OUTER RACE WOULD 'WOBBLE' WHEN ROTATE D. 3 T E4EA 1997050100347 19970501 00347 SO 1997 5 1 97ZZZX1904 1 19970312 G 7120 8936102 MOUNT PIPER PA44 PA44180 7104402 SO RT ENGINE CRACKED B S OG5R K NONE O OTHER IN INSP/MAINT 1 GL 21 192ND 4422 4495004 FOUND RIGHT ENGINE MOUNT CRACKED. CRACK WAS ON TOP RIGHT MOUNT RING WHERE MOUNT RING AND TUBE FROM FIREWALL ARE WELDED TOGETHER. CRACK RUNS ALONG EDGE OF WELD. INSPECTION FREQUENCY INCREASED BY OPERATION. 1 L 7 2 3O A19S0 1997050100348 19970501 00348 GL 1997 5 1 97ZZZX1905 3 19970324 G 6114 C93 HUB CESSNA 340 340A 2076405 CE MCAULY 3AF32C 3AF32C93 GL NR 2 SOCKET CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 03 2666J 1689 340A0718 791048 DURING PROPELLER INSPECTION A CRACK WAS FOUND IN THE THREADS OF BLADE SOCKET NR 2 ON THE ENGINE SIDE. 1 L 7 2 3O 3A25 5 C P22EA 1997050100349 19970501 00349 CE 1997 5 1 97ZZZX1906 1 19970403 G 5412 051310929 DOUBLER CESSNA 172 172P 2072436 CE FIREWALL LT CORRODED B P R2JR K NONE O OTHER IN INSP/MAINT 1 EA 21 62258 7458 17275236 DURING ANNUAL INSPECTION, CORROSION NOTED AT UPPER LT ENG MOUNT TO FIREWALL ATTACH POINT. FIREWALL DOUBLER BADLY CORROD ED. DOUBLER REMOVED AND SEVERE CORROSION FOUND ON REVERSE SIDE. FIREWALL WAS SALVAGED AND NEW DOUBLER WAS INSTALLED. D OUBLER WAS INSTALLED AT FACTORY WITH STEEL TUBULAR MS 20450C8 RIVETS AND CANNOT BE SUBSTITUTED PER CESSNA FACTORY REP. INFORMATION ON REPLACING DOUBLER NOT IN CESSNA MM. CESSNA FIELD SERVICE MUST BE CONTACTED. AREA OF CORROSION ADJACENT TO LEAD ACID BATTERY. SUBMITTER SUGGESTED INSPECTION OF THIS AREA AND REMOVE DOUBLER IF ANY EXTERNAL CORROSION FOUND. 1 H 7 1 3O NT 3A12 1997050100350 19970501 00350 SO 1997 5 1 97ZZZX1907 1 19970307 G 7120 8936102 MOUNT PIPER PA44 PA44180 7104402 SO LT ENGINE CRACKED B OG5R K NONE O OTHER IN INSP/MAINT 1 GL 21 851ND 4290 4495005 DURING SCHEUDLED INSPECTION, FOUND LEFT ENGINE MOUNT BROKEN. CRACK/BREAK IS AT 5 O'CLOCK LOWER DIAGONAL TUBE ON TOP RIG HT MOUNT. CRACK/BREAK IS ALONG WELD WHERE DIAGONAL TUBE IS WELDED TO MOUNT RING. NEW PART ON ORDER. 1 L 7 2 3O A19S0 1997050100351 19970501 00351 SO 1997 5 1 97ZZZX1908 1 19970312 G 7120 8936102 MOUNT PIPER PA44 PA44180 7104402 SO LT ENGINE CRACKED B S OG5R K NONE O OTHER IN INSP/MAINT 1 GL 21 854ND 4099 4495008 LEFT ENGINE MOUNT WAS FOUND CRACKED. CRACK WAS ON TOP RIGHT MOUNT RING AT WELD WHERE TUBE FROM FIREWALL MEETS MOUNT RIN G. C/W PIPER SB 937 PREVIOUSLY. CRACK WAS DETECTED WITHOUT REMOVING PAINT FROM MOUNT. INSPECTION FREQUENCY INCREASED BY OPERATOR. 1 L 7 2 3O A19S0 1997050100352 19970501 00352 SO 1997 5 1 97ZZZX1909 1 19970312 G 7120 8936102 MOUNT PIPER PA44 PA44180 7104402 SO LT/RT ENGINES CRACKED B S OG5R K NONE O OTHER IN INSP/MAINT 1 GL 21 855ND 3951 4495009 FOUND LEFT AND RIGHT ENGINE MOUNTS CRACKED. CRACKS WERE LOCATED ON TOP RIGHT MOUNT WHERE MOUNT RING AND TUBE FROM FIREW ALL ARE WELDED. CRACK WAS ALONG EDGE OF WELD. CRACKS WERE NOT DETECTABLE UNTIL PAINT WAS REMOVED AND INSPECTION AIDS W ERE USED. OPERATOR HAS INCREASED INSPECTION FREQUENCY. 1 L 7 2 3O A19S0 1997050100353 19970501 00353 SO 1997 5 1 97ZZZX1910 1 19970310 G 7120 8936102 MOUNT PIPER PA44 PA44180 7104402 SO LT ENGINE CRACKED B OG5R K NONE O OTHER IN INSP/MAINT 1 GL 21 852ND 4714 4495006 FOUND LEFT ENGINE UPPER RIGHT MOUNT CRACKED WHERE TUBE WELDS TO MOUNT RING AT 5 O'CLOCK POSITION. CRACK RUNS ALONG EDGE OF WELD. MOUNT WAS PREVIOUSLY MODIFIED PER PIPER SB 937. 1 L 7 2 3O A19S0 1997050100401 19970501 00401 GL 1997 5 1 97ZZZX1911 1 19970301 G 5610 28011302212 WINDSHIELD ENSTRM F28 280C 3300505 GL RT COCKPIT CRACKED G K NONE O OTHER IN INSP/MAINT 1 EA 17 122TV 1049 OUTSIDE AIR TEMP (27 DEGREES FAHRENHEIT). ON ENGI\EEN START-UP, WINDHSIELD CRACKED HORIZONTALLY APROXIMATELY 14 INCHES ONE-THIRD OF THE WAY UP FROM BOTTOM. CRACK ORIGINATED AT CENTER WINDSHIELD ATTACH RIVET. 1 G 7 1 3O H1CE 1997050100402 19970501 00402 CE 1997 5 1 97ZZZX1912 1 19970411 G 7830 2250012511 THRUST REVERSER BEECH MU300 400A 1155402 CE FORMER RING CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 23 200BL 2512 2465 RK23 AFT FAN DUCT FORMER RING CRACKED IN VICINITY OF SUPPORT BEAM MOUNT. SUSPECT CAUSE FATIGUE. 2 H 7 2 4F RT A16SW 1997050100403 19970501 00403 1997 5 1 97ZZZX1913 2 19970410 G 7414 M3827 ROTOR GEAR SLICK 4371 MAGNETO LOOSE B KC2R K NONE O OTHER NR NOT REPORTED 1 GL 03 91100139 THE ROTOR GEAR LOOSENED ON ROTOR SHAFT DUE TO NORMAL WEAR AND THERMAL CYCLING. THE GEAR THEN RUBBED THE DISTRIBUTOR BLO CK GENERATING NYLON PARTICLES THAT CONTAMINATED THE CONTACTS. THIS RENDERED THE MAGNETO INOPERATIVE. THIS ROTOR GEAR I S A PRESS FIT ON THE ROTOR AND NO MECHANICAL RETENSION IS USED. 1997050100404 19970501 00404 1997 5 1 97ZZZX1914 2 19970407 G 7414 N3525 COIL SLICK 4271 MAGNETO FAILED B KC2R K NONE O OTHER IN INSP/MAINT 1 GL 03 382 88100154 FOUND COIL IN MAGNETO HAS OPEN SECONDARY CIRCUIT. THIS PART NUMBER COIL IS USED IN MANY MAGNETO MODELS. SUBMITTER STA TED SEEING THIS PROBLEM IN MANY COILS MANUFACTURED IN THIS SAME TIME FRAME. 1997050100405 19970501 00405 1997 5 1 97ZZZX1915 4 19970411 G 3416 3431 CASTING 5934P1 CESSNA 177 177B 2073708 CE ALTIMETER CREEP B EI4R K NONE O OTHER IN INSP/MAINT 1 SO 15 17142 G4042 17702507 INCOMING INSPECTION CHECKS ON ALTIMETER REVEALED JUMPS IN THE OPERATION OF 100 FEET TO 200 FEET. THE END-SHAKES ON THE M ECHANISM SHAFTS WERE MEASURED. ONE END-SHAKE MEASURED ZERO. THE OH MANUAL CALLS OUT A MINIMUM END-SHAKE OF .0020 INCH ON ALL THREE CRITICAL ROTATING SHAFTS. BECAUSE OF THIS ZERO END-SHAKE CONDITION, FOUND THE JUMPY CONDITION AT ROOM TEMP , AND THE INSTRUMENT WOULD HANG UP THE POINTERS WHEN OPERATED IN A COLD ENVIRONMENT. THE MANUFACTURER INDICATED THAT A SHAFT END-SHAKE OF .0004 INCH OR LESS WILL CAUSE AN INSTRUMENT HANG-UP UNDER COLD OPERATING CONDITIONS ACCORDING TO THE IR TESTING. 1 H 7 1 3O A13CE 1997050100407 19970501 00407 EA 1997 5 1 97ZZZX1917 2 19970417 G 8520 LW18639 LOCKPLATE CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA CRANKSHAFT GEAR FAILED D K NONE O OTHER IN INSP/MAINT 1 CE 07 4863H 1551 15283989 L2045515 SEE LYCOMING O-235 SERIES PARTS CATALOG PC-302, FIGURE 3, INDEX 9. WHILE TROUBLESHOOTING EXCESSIVE MAGNETO DROP AND INS UFFICIENT STATIC RPM, DISCOVERED SCREW (STD 2213) HAD BACKED OUT OF CRANKSHAFT. THE LOCKPLATE EARS WERE FOUND IN THE OIL SUMP; THE CRANKSHAFT GEAR (13S19646) AND DOWEL (STD 1065) WERE WORN BEYOND LIMITS. THE ENGINE HAD BEEN OVERHAULED SEVE N YEARS PRIOR TO THIS EVENT; THE LOGBOOK ENTRY STATES, 'ASSEMBLED CRANKSHAFT GEAR ON CRANKSHAFT IAW LYCOMING SB NR 475. USED A NEW BOLT AND LOCKPLATE, FINAL TORQUES TO 204 INCH/POUND.....'. 1 H 7 1 3O 3 O NT 3A19 E223 1997050100408 19970501 00408 1997 5 1 97ZZZX1918 4 19970411 G 3416 3431 CASTING 5934P1 CESSNA 172 172L 2072432 CE ALTIMETER CREEP B EI4R K NONE O OTHER IN INSP/MAINT 1 SO 15 59PG H4059 17260347 THE END-SHAKES, (BACK AND FORTH MOVEMENT) OF THE THREE CRITICAL ROTATING SHAFTS OF THE MECHANISM OF THIS ALTIMETER WERE CHECKED. THE OH MANUAL CALLS OUT .0020 INCH MINIMUM END-SHAKE. ONE END-SHAKE MEASURED .00020 INCH. THIS IS TEN TIMES SMALLER THAN THE SPECIFICATION. WITH THIS CONDITION, THE INSTRUMENT COULD HANG UP THE POINTERS OF THE ALTIMETER UNDER A COLD TEMPERATURE OPERATING CONDITION. THE MANUFACTURER HAS INDICATED THAT AN END-SHAKE OF .0004 INCH OR LESS COULD CAU SE A POINTER HANG UP UNDER COLD OPERATING CONDITIONS. 1 H 7 1 3O NT 3A12 1997050100409 19970501 00409 SO 1997 5 1 97ZZZX1919 2 19970422 G 8520 653580 GEAR CESSNA 421 421C 2076016 CE CONT O520 GTSIO520N 17032 SO CRANKSHAFT FAILED B VA1R K NONE O OTHER IN INSP/MAINT 1 SW 19 6867L 400 421C1087 608068 NEW CRANKSHAFT GEAR P/N 653580 INSTALLED AT TIME OF ENGINE OVERHAUL IN CONJUNCTION WITH TCM SB CSB 94-4 IN KIT EQ6642. E NGINE FAILED APROXIMATELY 400.0 HOURS LATER. ENGINE DISASSEMBLY REVEALED THE POSSIBILITY THE GEAR BROKE FIRST CAUSING D AMAGE TO VALVE TRAIN, STARTER ADAPTER GEAR, AND IDLER GEAR. 1 L 7 2 3O 3 O A7CE E7CE 1997050100410 19970501 00410 SO 1997 5 1 97ZZZX1920 2 19970415 G 8520 CRANKCASE BEECH 35 S35 1151532 CE CONT O520 IO520B 17032 SO NR 2 CYL BASE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 13 8604Q 2078 940 D7635 1219368B DURING ANNUAL INSPECTION, CRANKCASE AT NR 2 CYLINDER BASE STUD FOUND CRACKED FOUR INCHES LONG. THIS IS A LIGHT CASE ENG INE. 1 L 7 1 3O 3 O 3A15 E5CE 1997050100411 19970501 00411 SO 1997 5 1 97ZZZX1921 1 19970409 G 2721 419938 SCREW PIPER PA46 PA46350P SO RUD TRIM WHEEL DETACHED B S A LF1R K NONE F FLT CONT AFFECTED NR NOT REPORTED 1 EA 07 88846 308 4622150 PILOT REPORTED COMPLETE CONTROL LOSS OF RUDDER TRIM SYSTEM: AN INSPECTION, REVEALED THE THREE MOUNTING SCREWS HOLDING T HE TRIM WHEEL TO THE SPROCKET HAD FALLEN OUT ALLOWING THE TRIM WHEEL TO SPIN FREE. THE SCREWS WERE LOCATED ON THE FLOOR PANELS UNDER THE CONTROL QUADRANT. SUBMITTER SUGGESTED TO ISSUE SB FOR INSPECTION. ALSO, NEED TO CHANGE SCREW TYPE TO MACHINE SCREW. ACFT TT: 308.1 HOURS. 1 L 7 1 3O RT A25SO 1997050800001 19970508 00001 EU 1997 5 8 97ZZZX1923 1 19970401 G 5310 STRUCTURE SOCATA TB10 TB10TOBAGO 8680696 EU INTERIOR CORRODED B FG5R K NONE O OTHER IN INSP/MAINT 1 GL 03 REPORT RECEIVED WHICH INDICATES THE EXTENSIVE USE OF FIRE RETARDANT CHEMICALS (BROMIDES AND SALINES) ON ACFT FABRICS, IS A MAJOR CAUSE OF STRUCTURAL CORROSION. 1 L 7 1 30 NT A51EU 1997050800002 19970508 00002 SO 1997 5 8 97ZZZX1924 1 19970402 G 3230 6720000 SPRING PIPER PA34 PA34200T 7103406 SO LT MLG WEAK E K NONE O OTHER IN INSP/MAINT 1 EA 17 19TP 4000 347870383 LANDING GEAR DOWN LIGHT SLOW COMING ON. LEFT GEAR FELT LOOSE ON LANDING. WEAK SPRINGS ON BOTH GEAR. SUBMITTER STATED DOWNLOCK SPRINGS SHOULD BE REPLACED EVERY 2,000 HOURS OR 2,000 CYCLES. 1 L 7 2 3O A7SO 1997050800003 19970508 00003 CE 1997 5 8 97ZZZX1925 1 19970408 G 7921 8406J COOLER CESSNA 177 177RG 2073709 CE ENGINE OIL FAILED D K NONE K FLUID LOSS AP APPROACH 1 NM 01 1958Q 99 177RG0358 AIRCRAFT WAS IN DOWN WIND FOR LANDING WHEN STUDENT NOTICED 'WET' GEAR LEG AND WHEEL. UPON EXAMINATION, FOUND OIL COOLER SUFFERED INTERNAL FAILURE, LOSS OF SUBSTANTIAL OIL. SUBMITTER STATED ENGINE FAILURE WOULD HAVE BEEN IMMINANT. OUTSIDE TEMP 58 DEGREES. 1 H 7 1 3O A20CE 1997050800004 19970508 00004 SO 1997 5 8 97ZZZX1926 1 19970217 G 7160 3551506 HEAT VALVE PIPER PA28 PA28161 7102803 SO CARBURETOR HEAT LOOSE D K NONE O OTHER IN INSP/MAINT 1 NE 05 3858M 1650 287816628 DURING ANNUAL INSPECTION, FOUND CARBURETOR HEAT VALVE MISSING SEAL MATERIAL. ALSO, WHERE ASSY ATTACHED TO ALUMINUM PLAT E, RIVETS WERE LOOSE AND WORKING. REPLACED WITH NEW SEAL AND LARGER RIVETS. SUBMITTER RECOMMENDED TO WATCH CLOSELY DUR ING INSPECTIONS. SUSPECT CAUSE IS HEAVY STEEL VALVE ASSEMBLY ATTACHED TO ALUMINUM PLATE WITH AN470-3 RIVETS. NOT SUFFI CIENT TO PREVENT VIBRATION AND LOOSENING OF RIVETS. 1 L 7 1 3O 2A13 1997050800005 19970508 00005 CE 1997 5 8 97ZZZX1927 1 19970310 G 2510 1414115 CAM CESSNA 185 A185F 2072821 CE SEAT BACK CRACKED D S K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 05 3868Q 18502205 ORDERED NEW SEAT BACK CAM FROM FACTORY. UNIT RECEIVED HAD CRACK ON ONE-HALF OF ASSY NEXT TO ATTACH RIVET. RETURNED TO FACTORY. 1 H 7 1 3O 3A24 1997050800007 19970508 00007 1997 5 8 97ZZZX1929 4 19970228 G 6113 C22831 BULKHEAD PIPER PA34 PA34200T 7103406 SO PROP SPINNER CRACKED D S K NONE O OTHER IN INSP/MAINT 1 NE 05 4516F 347670340 RECEIVED PROPELLER AND BULKHEAD FROM OVERHAUL FACILITY. DURING INSTALLATION, DISCOVERED BULKHEAD CRACKED FROM ANCHOR NU T ON FLANGE TO BULKHEAD DOUBLER. IT HAD BEEN PREVIOUSLY STOP DRILLED. REPLACED BULKHEAD WITH SERVICABLE UNIT. OVERHAU L FACILITY STATED THEY WERE AWARE OF IT, BUT DID NOTHING. 1 L 7 2 3O A7SO 1997050800008 19970508 00008 CE 1997 5 8 97ZZZX1930 1 19970405 G 3230 35815109 UPLOCK CABLE BEECH 35 V35 1151538 CE LT MLG FRAYED D K NONE O OTHER IN INSP/MAINT 1 WP 01 7586L D8289 DURING INSTALLATION OF OXYGEN SYSTEM, OBSERVED INBD END OF LEFT LANDING GEAR UPLOCK CABLE SEVERELY FRAYED AT THE TERMINA L END WHERE IT EXITS THE HOUSING: SUBMITTER SUSPECTS OLD AGE AND LACK OF LUBRICATION. SUBMITTER RECOMMENDS FREQUENT IN SPECTION OF BOTH MLG UPLOCK CABLES AND PREVENTATIVE LUBRICATION EACH 100 HOURS. 1 L 7 1 3O 3A15 1997050800010 19970508 00010 CE 1997 5 8 97ZZZX1932 1 19970402 G 2750 500000862 CONTROL CABLE CESSNA 425 425 2076018 CE RT FLAP EXTEND FAILED B A PRIR O OTHER F FLT CONT AFFECTED AP APPROACH 1 GL 03 67726 3049 0030 PILOT REPORATED WHILE ON APPROACH, FULL FLAPS WERE SELECTED. AT THAT TIME, A LOUD NOISE WAS HEARD AND THE A/C VIOLENTLY ROLLED TO THE RIGHT. THE PILOT REGAINED CONTROL OF THE A/C BY RAISING THE FLAPS AND MADE A SAFE LANDING. UPON INSP FO UND RT FLAP HANGING DOWN AND LOOSE. FURTHER INVESTIGATION DISCLOSED RT FLAP EXT CABLE BROKE AT PRESELECT CABLE ATTACH P OINT. THE FLAP GEARBOX WAS SEVERELY DAMAGED AND LIMIT SWITCH ARM SHAFT WAS BROKEN OFF. ALL FLAP PUSH RODS WERE FOUND B ENT FROM THE RETRACTION. IT IS BELIEVED THE EXTEND CABLE BROKE AT THE PRESELECT CABLE LEAVING FLAPS UNCONTROLLABLE. GE ARBOX REPLACED AND ALL PUSH RODS REPLACED AND ALL CABLES RERIGGED. 1 L 7 2 3T RT A7CE 1997050800012 19970508 00012 EA 1997 5 8 97ZZZX1934 2 19970401 G 8530 75838 VALVE GUIDE ENSTRM F28 F28C 3300407 GL LYC O360 HIO360E1BD 41514 EA NR 4 CYLINDER FAILED D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 EA 17 5691Y 566 4792 L1981551A EXHAUST VALVE GUIDE BROKE UP LETTING THE EXHAUST VALVE LOOSEN IN THE CYLINDER. EXHAUST VALVE DID NOT FAIL. PIECES FROM THE GUIDE JAMMED THE TURBOCHARGER TURBINE WHEEL DESTROYING THE TURBOCHARGER AND CAUSING LOSS OF POWER. 1 G 7 1 3O 3 O H1CE 1E10 1997050800013 19970508 00013 1997 5 8 97ZZZX1935 1 19970401 G 5741 6862102 ATTACH FITTING AFT WING ATTACH CORRODED D K NONE O OTHER IN INSP/MAINT 1 GL 05 A COMMON WATER CORROSION PROBLEM HAS BEEN FOUND WITH THESE SERIES OF AIRCAFT. ALMOST WITHOUT EXCEPTION, WATER HAS BEEN ENTERING THE INTERIOR OF THE CABIN AT FS 187.84 AND FS 138.63. THEN WATER IS ABSORBED BY THE INSULATION AND CARPET. TH IS CREATES A POTENTIALLY SERIOUS CORROSION PROBLEM WITH THE REAR WING ATTACH FITTINGS AND THE ANGLE AT STA 128. IT APPE ARS THAT WATER IS ABLE TO ENTER THROUGH THE OUTER SKIN LAP JOINTS. SEALING OF THESE JOINTS MAY HELP PREVENT FUTURE WATE R INTRUSION. 1997050800014 19970508 00014 1997 5 8 97ZZZX1936 1 19970401 G 5741 6862103 ATTACH FITTING AFT WING ATTACH CORRODED D K NONE O OTHER IN INSP/MAINT 1 GL 05 A COMMON WATER CORROSION PROBLEM HAS BEEN FOUND WITH THESE SERIES OF AIRCAFT. ALMOST WITHOUT EXCEPTION, WATER HAS BEEN ENTERING THE INTERIOR OF THE CABIN AT FS 187.84 AND FS 138.63. THEN WATER IS ABSORBED BY THE INSULATION AND CARPET. TH IS CREATES A POTENTIALLY SERIOUS CORROSION PROBLEM WITH THE REAR WING ATTACH FITTINGS AND THE ANGLE AT STA 128. IT APPE ARS THAT WATER IS ABLE TO ENTER THROUGH THE OUTER SKIN LAP JOINTS. SEALING OF THESE JOINTS MAY HELP PREVENT FUTURE WATE R INTRUSION. 1997050800015 19970508 00015 1997 5 8 97ZZZX1937 1 19970401 G 5320 6864400 ANGLE BS 128 CORRODED D A K NONE O OTHER IN INSP/MAINT 1 GL 05 A COMMON WATER CORROSION PROBLEM HAS BEEN FOUND WITH THESE SERIES OF AIRCAFT. ALMOST WITHOUT EXCEPTION, WATER HAS BEEN ENTERING THE INTERIOR OF THE CABIN AT FS 187.84 AND FS 138.63. THEN WATER IS ABSORBED BY THE INSULATION AND CARPET. TH IS CREATES A POTENTIALLY SERIOUS CORROSION PROBLEM WITH THE REAR WING ATTACH FITTINGS AND THE ANGLE AT STA 128. IT APPE ARS THAT WATER IS ABLE TO ENTER THROUGH THE OUTER SKIN LAP JOINTS. SEALING OF THESE JOINTS MAY HELP PREVENT FUTURE WATE R INTRUSION. 1997050800402 19970508 00402 NE 1997 5 8 97ZZZX1938 2 19970416 G 7250 657803 T3 DISK BELL 206 206B 1181511 SW PWA JT3D JT3D3B 52039 NE TIE ROD HOLES CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 19 30VA 12935 3229 P645748 DURING ROUTINE DISASSEMBLY AND ENGINE BUILD-UP, AD 82-14-02 WAS C/W ON T-3 DISK. DURING EDDY CURRENT INSPECTION, FOUND 2 TIE ROD HOLES HAD CRACKS RADIATING FROM HOLES INTO DISK. DISK WAS REMOVED FROM SERVICE AND SCRAPPED. CYCLES, 6,623. 1 G 7 1 3U 4 F H2SW 1E8 1997050800403 19970508 00403 SW 1997 5 8 97ZZZX1939 1 19970313 G 6320 2040401431 BEARING 204040016005 BELL 204 UH1B 1181410 SW TRANSMISSION SPALLED B QJ5R K NONE O OTHER IN INSP/MAINT 1 NM 05 600MA 976 2202A 6413970 SPALLING ON BALLS AND OUTER RACE OF BEARING. THIS BEARING IS USED IN SEVERAL DIFFERENT APPLICATIONS IN THE DRIVE TRAIN OF BELL HELICOPTERS. 1 G 7 1 4U EXPA1G71 1997050800404 19970508 00404 SW 1997 5 8 97ZZZX1940 1 19970212 G 6310 214040841101 SEAL 406040500113 BELL 206 206L4 1182110 SW FREEWHEEL LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 GL 03 696BA 130 A2944 52166 REPLACED FREEWHEELING UNIT TAIL ROTOR OUTPUT DRIVE SEAL DUE TO LEAKING OIL. ACFT TT: 317.6 HOURS. 1 G 7 1 3U NC H2SW 1997050800405 19970508 00405 SW 1997 5 8 97ZZZX1941 1 19970412 G 6310 214040841101 SEAL 406040500113 BELL 206 206L4 1182110 SW FREEWHEEL LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 GL 03 696BA 67 A2944 52166 REPLACED FREEWHEELING UNIT TAIL ROTOR OUTPUT DRIVE SEAL DUE TO LEAKING OIL. ACFT TT: 384.2 HOURS. 1 G 7 1 3U NC H2SW 1997050800406 19970508 00406 1997 5 8 97ZZZX1942 4 19970418 G 2561 KS9 LIFE VEST EAAEROMARINE INFLATE SEC FAIL TEST B GP4R K NONE L NO TEST IN INSP/MAINT 1 WP 13 C21391 LIFE VEST FAILED MANUFACTURER'S 2 PSI INFLATION TEST. 1997050800407 19970508 00407 NE 1997 5 8 97ZZZX1943 3 19970113 G 6111 792221 BLADE SFA13M10A HAMSTD 14SF 14SF7 NE SHANK CRACKED B H2SR K NONE O OTHER IN INSP/MAINT 1 SO 13 14911 8935 855906 DURING A MAJOR INSPECTION DYE CHECK, AN INDICATION WAS DETECTED IN THE BLADE SHANK FILLET RADIUS. THE INDICATION IS CIR CUMFERENTIALLY LOCATED APPROXIMATELY 135 DEGREES FROM THE BLADE PIN, ON THE FACE SIDE. THE SHAPE OF THE INDICATION IS R ECTANGULAR, WITH HALF OF IT LOCATED IN THE FILLET RADIUS, AND HALF ON THE SHANK OUTSIDE DIAMETERS, WITH BOTH HALVES CONN ECTED AT EACH END. 6 C P7NE 1997050800408 19970508 00408 GL 1997 5 8 97ZZZX1944 3 19970324 G 6111 FC84686R BLADE PIPER PA31 PA31350 7103110 SO HARTZL HCE3Y HCE3YR2A GL BLADE SHANK CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 01 4029 935 C20315 UPON INSPECTION OF PROPELLER BLADE DURING OVERHAUL, FOUND 1 INCH LONG CRACK IN BLADE SHANK FILLET. 1 L 7 2 3O A20SO 5 C P33EA 1997050800409 19970508 00409 SO 1997 5 8 97ZZZX1945 1 19970422 G 2434 ALU9510 ALTERNATOR PRESTOLITE PIPER PA31 PA31P 7103120 SO DC SYSTEM FAILED B EKIR K NONE O OTHER IN INSP/MAINT 1 WP 07 26556 185 A113559 31P7400184 ALTERNATOR FAILED AT 5-1/2 MONTHS AND 185.3 HRS TT. WAS OVERHAULED 9-19-96. CONTINUE TO HAVE VERY SHORT SERVICE LIFE O F THESE UNITS. 1 L 7 2 3O A8EA 1997050800410 19970508 00410 EA 1997 5 8 97ZZZX1946 2 19970402 G 7314 RG17980J PUMP ROMEC PIPER PA23 PA23250 7102308 SO LYC O540 TIO540C1A 41532 EA ENGINE FUEL LEAK D A O OTHER K A FLUID LOSS FLAME/FIRE TO TAKEOFF 1 SO 03 27FM 1100 1100 B8608 277654087 L416961A PUMP LEAKAGE AT SEAM CASE TO PUMP. PUMP LEAKAGE OCCURRED AT TAKEOFF. SPRAYED FUEL DIRECTLY ON HOT TURBOCHARGER CAUSING FIRE IN ENGINE COMPARTMENT. APPEARED TO LEAK AT GASKET FLANGE. 1 L 7 2 3O 3 O 1A10 E14EA 1997050800413 19970508 00413 EA 1997 5 8 97ZZZX1949 2 19970324 G 8530 CYLINDER PIPER PA34 PA34200 7103405 SO LYC O360 LIO360C1E6 41515 EA NR 2 CYLINDER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 13 55777 3993 1762 347350244 L71467A NR 2 CYLINDER FOUND CRACKED AT THE MOLD LINE THROUGH THE SPARKPLUG HOLE OUT ONTO THE TOP OF THE CYLINDER, THE INTAKE SID E, RIGHT ENGINE. 1 L 7 2 3O 3 O A7SO 1E10 1997050800414 19970508 00414 EA 1997 5 8 97ZZZX1950 2 19970414 G 8520 SL13212M03 BEARING BEECH B80 B80 1153010 CE LYC O540 IGSO540A1D 41532 EA CONNECT ROD DETERIORATED D K NONE O OTHER IN INSP/MAINT 1 GL 19 65RW 775 LD404 L240950 SECTIONS FROM THE CENTER OF THE BEARING APPEARED TO DETERIORATE OR DISSOLVE WITH NO APPARENT REASON. QUALITY OF BEARING IS IN QUESTION. 1 L 7 2 3O 3 O RT 3A20 1E7 1997050800415 19970508 00415 CE 1997 5 8 97ZZZX1951 1 19970429 G 3230 50120202143 ANGLE BEECH 90 F90 1152909 CE MLG SUPPORT CRACKED D A K NONE O OTHER IN INSP/MAINT 1 SO 03 66BS 500 LA40 LANDING GEAR SUPPORT BRACKET PART CRACKED VARIOUS PLACES. PART REPLACED AT INSPECTION AND PROBLEM OCCURRED SAME PART 50 0 HOURS LATER IN SAME LOCATION. EXACT PART LOCATION, LEFT AND RIGHT GEAR ANGLES. 1 L 7 2 4T A31CE 1997050800416 19970508 00416 CE 1997 5 8 97ZZZX1952 1 19970416 G 2720 51152604 TORQUE TUBE CESSNA 401 401A 207590D CE LT RUDDER PEDAL FAILED D A K NONE O OTHER NR NOT REPORTED 1 SW 09 671AW 401A0080 RUDDER SYSTEM CEASED TO OPERATE. FOUND LEFT RUDDER TORQUE TUBE ASSY ARM BROKEN FREE OF TORQUE TUBE. THIS ARM IS CONNEC TED TO RUDDER CABLE. REPLACED TORQUE TUBE WITH NEW PART. 1 L 7 2 3O A7CE 1997050800417 19970508 00417 EA 1997 5 8 97ZZZX1953 2 19970304 G 8520 LW15949 GEAR TOOTH CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA CRANKSHAFT FAILED D A UNSCHED LANDING D INFLIGHT SEPARATION CR CRUISE 1 NM 01 734JD 3050 350 17268882 RL323376T ENGINE STARTED TO MAKE A KNOCKING NOISE WHILE IN-FLIGHT. AS THE ENGINE WAS THROTTLED, BACK NOISE BECAME MORE PRONOUNCED . AIRCRAFT WAS LANDED AT NEAREST AIRPORT. INVESTIGATION OF KNOCKING NOISE REVEALED THAT ONE TOOTH WAS MISSING FROM THE CRANKSHAFT GEAR. ENGINE TIME SINCE FACTORY REMANUFACTURE APPROXIMATELY 3,050 HOURS. TIME SINCE MAJOR OVERHAUL, APPROX IMATELY 350 HOURS. CRANKSHAFT GEAR WAS MAGNAFLUXED AT MAJOR OVERHAUL. 1 H 7 1 3O 3 O NT 3A12 E274 1997050800418 19970508 00418 EA 1997 5 8 97ZZZX1954 2 19970401 G 7322 MA3 CARBURETOR FACET CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA POWER JET FOD PLUG D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SW 99 68148 15282150 L1511415 AIRCRAFT LOST POWER DURING LOCAL FLIGHT. STUDENT PILOT COULD ONLY GET 1200/1400 RPM'S, BUT MADE IT BACK TO AIRPORT. AF TER CHECKING FUEL STRAINERS, PROBLEM APPEARED TO BE IN CARBURETOR. DISASSEMBLY REVEALED A SMALL INSECT IN THE NOZZLE PO WER JET ASSEMBLY. THE INSECT THE SIZE OF A PENCIL POINT COULD NOT HAVE PASSED THROUGH THE FUEL STRAINERS. SUSPECT IT E NTERED WHILE ACFT WAS PARKED , THROUGH AIR BOX, AND INTO NOZZLE. TOTAL TIME ON CARBURETOR SINCE OVERHAUL, 836.0 HOURS. 1 H 7 1 3O 3 O NT 3A19 E223 1997050800420 19970508 00420 CE 1997 5 8 97ZZZX1956 1 19970328 G 3230 CB2320A BREAKER BEECH 36 A36 1151604 CE MLG MOTOR FAILED B DC1R O OTHER J WARNING INDICATION AP APPROACH 1 EA 07 88ES 6219 E758 LANDING GEAR MOTOR CIRCUIT BREAKER, WHEN RESET, NO LOAD WILL GO THROUGH BREAKER TO OPERATE MOTOR. PILOT MANUALLY CRANKE D LANDING GEAR DOWN. 1 L 7 1 3O 3A15 1997050800421 19970508 00421 SW 1997 5 8 97ZZZX1957 1 19970331 G 2430 PA10A06 WIRE MOONEY M20 M20J 5870219 SW FIREWALL SHORTED B A DYTR K NONE O OTHER IN INSP/MAINT 1 SO 15 195ER 5769 243256 WHILE TROUBLESHOOTING AN INTERMITTENT/UNCOMMANDED, ON OR OFF, OF THE AVIONICS MASTER RELAY - ELECTRICAL ARCING WAS HEARD . INVESTIGATION REVEALED ALTERNATOR OUTPUT 'A+' SHIELDED WIRE NR PA10A06 (BETWEEN FIRE WALL AND FORWARD END OF RF FILTE R) HAD RUBBED THROUGH INSULATION OF WIRE NR PB11A06 (AT UNSHIELDED WIRE BETWEEN AMPMETER SHUNT AND HOT SIDE OF START REL AY). THIS SHORT CIRCUIT BYPASSES ALL CIRCUIT BREAKER PROTECTION. 1 L 7 1 3O 2A3 1997050800422 19970508 00422 SO 1997 5 8 97ZZZX1958 1 19970221 G 7920 111F4176S0120 HOSE STRATOFLEX 1116 AMRGEN AG5B AG5B 3990100 SO OIL COOLER OBSTRUCTED B S PF2R K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 11 128VU 10067 HOSE PURCHASED NEW FROM AVIALL, NOVEMBER, 1996. DURING TEST FLIGHT, OIL TEMP NOTED EXCESSIVE. RESULTS OF INVESTIGATION , OIL COOLER RETURN FLOW LINE FOUND OBSTRUCTED. APPEARS LINE MAY HAVE MFG DEFECT. 1 L 7 1 3O NT 1L71 1997050800423 19970508 00423 GL 1997 5 8 97ZZZX1959 3 19970421 G 6114 HUB CESSNA 206 U206G 2073356 CE MCAULY 3A32C D3A32C90 GL NR 2 SOCKET CRACKED B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 2FOR U2063807 773447 DURING EDDY CURRENT INSPECTION, TWO CRACKS FOUND IN NR 2 HOLE, 3RD AND 4TH THREADS IN AT 6 O'CLOCK. 1 H 7 1 3O A4CE 5 C P21EA 1997050800424 19970508 00424 CE 1997 5 8 97ZZZX1960 1 19970412 G 3230 353800943 MOTOR BEECH 35 H35 1151520 CE MLG BRUSHES WORN D O OTHER P NO WARNING INDICATION AP APPROACH 1 EA 21 5414D 1668 D4921 THE LANDING GEAR WAS EXTENDED DURING AN APPROACH INTO THE LYH AIRPORT. PILOT REPORTED AN UNSAFE INDICATION (NO GREEN DO WN/LOCKED LIGHT). IT IS UNCLEAR IF THE EMERGENCY EXTENSION CYCLE WAS COMPLETED. THE PILOT STATES HE NEVER GOT A GREEN, GEAR DOWN INDICATION. UPON THE LANDING ROLL-OUT, LANDING GEAR COLLAPSED PARTIALLY. DAMAGE WAS MINIMAL DUE TO THE INNE R GEAR DOORS AND NOSE GEAR DOORS SUPPORTING MOST OF THE AIRCRAFT'S WEIGHT. SUBMITTER RECOMMENDS GEAR MOTOR BRUSHES AND EMERGENCY EXTENSION SYSTEM BE CHECKED AND OPERATED EVERY ANNUAL OR 100 HOURS. 1 L 7 1 3O 3A15 1997050800425 19970508 00425 CE 1997 5 8 97ZZZX1961 1 19970401 G 3110 S2501 HOSE CESSNA 172 172P 2072436 CE INSTRUMENTS DETERIORATED D A K NONE O OTHER IN INSP/MAINT 1 EA 21 62258 7458 17275236 DURING ANNUAL INSPECTION, INSTRUMENT HOSE UNDER INSTRUMENT PANEL CRUMBLED WHEN TOUCHED. HOSE IDENTIFIED AS THE SAME TYP E HOSE MENTIONED IN CESSNA BULLETIN SEB 96-10. THE REST OF THE SYSTEM INSPECTED AND ALL S2501 HOSES REPLACED. HOSE COM ING APART COULD CAUSE DEBRIS THAT CAUSES EARLY INSTRUMENT FAILURE. HOSE FAILURES COULD CAUSE COMPLETE SYSTEM FAILURE. S UBMITTER SUGGESTS MANDATORY COMPLIANCE OF CESSNA BULLETIN SEB 96-10, DATED 6-7-96. 1 H 7 1 3O NT 3A12 1997050800426 19970508 00426 EU 1997 5 8 97ZZZX1962 2 19970215 G 7230 EU58621A BLADE GULSTM G1159 G1159 3953505 SO RROYCE SPEY SPEY5118 54523 EU 5TH STG COMP BROKEN E K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 SW 99 17ND 3041 63 8552 CREW REPORTED HIGH ENGINE VIBRATION ON THE RIGHT ENGINE. A BORESCOPE INSPECTION OF THE L.P. COMPRESSOR REVEALED A FIFTH STAGE L.P. COMPRESSOR BLADE DAMAGED (APPROXIMATELY THREE INCHES OF THE BLADE WAS BROKEN OFF). 2 L 7 2 4F 4 F RT A12EA E2EU 1997050800427 19970508 00427 CE 1997 5 8 97ZZZX1963 1 19970401 G 7110 40S459B CAMLOC CESSNA 425 425 2076018 CE ENGINE COWL FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 99 5PP 4250198 DURING REMOVAL OF ENGINE COWL, ONE CAMLOC DIFFICULT TO REMOVE. CAMLOC FINALLY CAME OUT WHEN CROSS PIN FELL OUT. THE C ROSS PIN FELL INTO ENGINE INTAKE AIR PLENUM. THE PIN WAS RECOVERED. CAMLOC RECEPTACLE IS OF AN OPEN BACK TYPE AND LOCA TED INSIDE INTAKE AIR PLENUM OF THE ENGINE. IF PIN CAME OUT OR THE CAMLOC BROKE, THE PIECE WOULD LIKELY BE INGESTED BY ENGINE. THIS CAMLOC ALSO SHOWED EVIDENCE OF POST MANUFACTURE STAKING TO RETAIN PIN. CHANGE CAMLOC RECEPTACLES IN ENG I NTAKE AIR PLENUM TO CLOSE BACK TYPE. DO NOT TRY TO 'REPAIR' LOOSE PINS IN CAMLOCS, CHANGE CAMLOC INSTEAD. 1 L 7 2 3T RT A7CE 1997050800428 19970508 00428 WP 1997 5 8 97ZZZX1964 2 19970401 G 7250 8965841 SUPPORT ASSY GARRTT TPE331 TPE3316252B 01514 WP STG 1 TURBINE MISOVERHAULED D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 99 AFTER INSTALLATION OF SUPPORT ASSY, ENGINE MADE CHATTERING NOISE WHEN ROTATED. DISASSEMBLY SHOWED IMPROPER MACHINING OF SUPPORT ALLOWING SEGMENTS TO CONTACT TURBINE WHEEL BLADES. CAUSE: IMPROPER REPAIR. SUBMITTER SUGGESTS BETTER QUALITY CONTROL DURING REPAIR. 4 T E2WE 1997051500001 19970515 00001 NM 1997 5 15 97ZZZX1970 1 19970428 G 3240 MIL5606 HYD FLUID UNIVAC GC1 GC1B 9230104 NM BRAKE SYSTEM CONGEALED D L O OTHER O OTHER LD LANDING 1 WP 03 3312K 1305 INVESTIGATION FOR GROUND HANDLING DIRECTIONAL CONTROL (GROUND LOOP) FOUND BRAKES AT FAULT. WHEN THE BRAKE LINE WAS DISC ONNECTED AT THE WHEEL CYLINDER AND BRAKE PRESSURE WAS APPLIED, A GOOEY SUBSTANCE WAS EXCRETED FROM THE BRAKE LINE. THIS WAS ORIGINALLY 5606 'RED JUICE' THAT HAD CONGEALED. ACFT HAS A RETRACTABLE, NON-STEERABLE TAIL WHEEL THAT REQUIRES SOM E BRAKING FOR DIRECTIONAL CONTROL. THE CONGEALED FLUID CAUSED A DELAY IN THE ACTION OF THE BRAKES, AND ANOTHER DELAY IN THE REMOVAL OF BRAKE APPLICATION. NOT A GOOD SITUATION. 1 L 7 1 3O A766 1997051500002 19970515 00002 NM 1997 5 15 97ZZZX1971 1 19970428 G 3240 MIL5606 HYD FLUID UNIVAC GC1 GC1B 9230104 NM BRAKE SYSTEM CONGEALED D K NONE O OTHER IN INSP/MAINT 1 WP 03 80772 172 MECH STARTED OVERHAUL ON AIRCRAFT HYDRAULICS. FLAP ACTUATOR LOOKED GOOD, NO LEAKS. ALL O-RINGS LOOKED GOOD, THAT IS NO T SQUARED OFF, AND STILL PLIABLE. FLUID CLEAN WITH A SLIGHT FILM RESIDUE ON THE BOTTOM OF ACTUATOR END PIECES. REMOVAL OF THE BRAKE LINES AT THE WHEEL CYL INDICATED THE SAME CONGEALED PROBLEM THAT N NR 3312K HAD, BUT PROBABLY NOT QUITE AS CONGEALED. THE 5606 BRAKE FLUID TOOK ABOUT TEN MINUTES FOR THE FIRST DROP TO COME OUT. A COUPLE OF TABLESPOONS OF THI S 'GOO' SLOWLY DRIPPED OUT BEFORE NORMAL FLUID FLOW STARTED. THE LINE WAS A 601 AEROQUIP AND IS SUPPLYING FLUID TO CLEV ELAND 30-79B BRAKE ASSEMBLIES, AND HAD BEEN INSTALLED FOR MORE THAN 10 YEARS WITHOUT THE NEED TO BLEED THE SYSTEM. 1 L 7 1 3O A766 1997051500003 19970515 00003 CE 1997 5 15 97ZZZX1972 1 19970416 G 2140 719843 COIL CESSNA 310 310R 2074245 CE HEATER EXPLODED B A BXSR K NONE O OTHER IN INSP/MAINT 1 EA 09 123RA 526 8259HR2 310R0221 HEATER FOUND INOPERABLE. FOUND THE IGNITION COIL HAD EXPLODED. THE END CAP HAD COME OFF WITH ENOUGH FORCE THAT IT BENT THE IGNITER OVER; THE OPPOSITE REACTION CAUSED THE COIL CAN TO GO AFT AND BREAK WIRES OFF MISCELLANEOUS PARTS IN THE CO IL COVER. THE MOST SIGNIFICANT POINT WAS THAT FUEL WAS STILL BEING PUMPED INTO THE HEATER, BUT NOT BEING IGNITED. 1 L 7 2 3O 3A10 1997051500004 19970515 00004 SW 1997 5 15 97ZZZX1973 1 19970331 G 2497 WIRE MOONEY M20 M20J 5870219 SW FIREWALL BURNED B DYTR K NONE O OTHER IN INSP/MAINT 1 SO 15 195ER 5769 243256 WHILE TROUBLESHOOTING AND REPAIRING INOPERABLE PANEL LIGHTS, DISCOVERED NUMEROUS ELECTRICAL WIRES BURNED AND SHORTED. T HE PANEL LIGHTS FAULT WAS WORN THROUGH INSULATION BY ADJACENT LIKE TYPE WIRES IN MID-HARNESS, WORN AND BURNED SEVERAL PL ACES WITHIN THE HARNESS. ALSO DISCOVERED WORN, CUT, AND BURNED WIRES IN SAME HARNESS TO OTHER SYSTEMS CONTAINED IN THE BUNDLE. 1 L 7 1 3O 2A3 1997051500005 19970515 00005 EA 1997 5 15 97ZZZX1974 2 19970417 G 7414 LW68504611085 MAGNETO ELECTROSYS D6RN320 PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA RT ENGINE GEAR FAILED E K NONE O OTHER NR NOT REPORTED 1 AL 03 3536B 660 6080503 317952205 RL191768A INTERNAL DRIVE GEARS FAILED ON BOTH THE LEFT AND RIGHT SIDES OF THIS 'DUAL STYLE' MAGNETO ASSEMBLY, MODEL NR D6RN-3200. AIR CREW WAS TAXIING AIRCRAFT WHEN RIGHT POWERPLANT STOPPED RUNNING. 1 L 7 2 3O 3 O A20SO E14EA 1997051500007 19970515 00007 CE 1997 5 15 97ZZZX1976 1 19970417 G 5311 FRAME CESSNA 172 172M 2072418 CE DOOR POST CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 13 4574V 5338 17266358 FOUND BOTH AFT LOWER DOOR POST FRAMES CRACKED WHILE C/W SEB 97-1. INSTALLED SK172-149-1 AND SK172-149-2 TO REPAIR. INS TRUCTIONS CALL FOR THIS TO BE A 1,000 HOUR REPETITION INSPECTION. SUBMITTER STATED THAT IS MUCH TOO LONG. SHOULD BE IN CLUDED ON EACH ANNUAL AT LEAST. 1 H 7 1 3O NT 3A12 1997051500008 19970515 00008 CE 1997 5 15 97ZZZX1977 1 19970401 G 2810 F39172 VALVE CESSNA 172 172N 2072434 CE FUEL TANK LEAK G K NONE K FLUID LOSS IN INSP/MAINT 1 EA 17 6317F 17273189 NEW FUEL TANK DRAIN VALVES START DRIPPING APPROXIMATELY TWO AND THREE DAYS AFTER INSTALLATION. NO DEBRIS OR PARTICLES D RAIN FROM FUEL TANK. HOLDING VALVE UNSEATED. O-RINGS LOOKED GOOD. EACH PART HAD 8130-3 FORM ATTACHED. ALL MANUFACTUR ED 1993 OR LATER. SUBMITTER STATES HAVE REPLACED ABOUT SIX VALVES IN 18 MONTHS. 1 H 7 1 3O NT 3A12 1997051500009 19970515 00009 CE 1997 5 15 97ZZZX1978 1 19970401 G 2810 S21062 VALVE CESSNA 172 172N 2072434 CE FUEL TANK LEAK G K NONE K FLUID LOSS IN INSP/MAINT 1 EA 17 6317F 17273189 NEW FUEL TANK DRAIN VALVES START DRIPPING APPROXIMATELY TWO AND THREE DAYS AFTER INSTALLATION. NO DEBRIS OR PARTICLES D RAIN FROM FUEL TANK. HOLDING VALVE UNSEATED. O-RINGS LOOKED GOOD. EACH PART HAD 8130-3 FORM ATTACHED. ALL MANUFACTUR ED 1993 OR LATER. SUBMITTER STATES HAVE REPLACED ABOUT SIX VALVES IN 18 MONTHS. 1 H 7 1 3O NT 3A12 1997051500010 19970515 00010 EA 1997 5 15 97ZZZX1979 2 19970227 G 7322 105135 CARBURETOR SCREW CESSNA 172 172L 2072432 CE LYC O320 O320E2A 41508 EA ENGINE LOOSE D O OTHER J R WARNING INDICATION PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 05 7729G 199 CK13350 17259429 L1753927A IDLE ADJUSTMENT SCREW BACKED OUT OF CARBURETOR IN-FLIGHT. ENGINE FAILED TO RUN WITH POWER SETTING BELOW 2300 RPM'S. IN STALLED NEW SPRING AND SCREW. CARBURETOR THREADS APPEAR TO BE LOOSE. 1 H 7 1 3O 3 O NT 3A12 E274 1997051500011 19970515 00011 SO 1997 5 15 97ZZZX1980 1 19970325 G 2720 6342008 BAR ASSY PIPER PA28 PA28181 7102807 SO LT RUDDER CRACKED D P A O OTHER F FLT CONT AFFECTED LD LANDING 1 SW 09 8367T 3445 28190209 WHILE MAKING A RIGHT CROSS-WIND LANDING, RUDDER FELT MUSHY AND WOULD ONLY MOVE THE 5 DEGREES LEFT. INSPECTION REVEALED THE LEFT RUDDER BAR HAD CRACKED ALMOST COMPLETELY AT THE POINT WHERE THE STRAIGHT TUBING IS WELDED TO THE CURVED TUBING AND REINFORCED WITH A WELDED BRACE. THREE CRACKS EMANATED FROM AN OILING HOLE, RADIALLY, THEN LONGITUDINALLY TO THE LEF T .3750 INCH, THEN CRACKED AROUND THE CIRCUMFERENCE OF THE TUBE. TO PREVENT RECURRENCE IF EVIDENCE OF HARD LANDING DAMA GE EXISTS, THE RUDDER BARS SHOULD BE REMOVED AND CHECKED FOR BENDS. 1 L 7 1 3O 2A13 1997051500012 19970515 00012 SO 1997 5 15 97ZZZX1981 1 19970415 G 3230 6718900 SPRING PIPER PA28 PA28RT201T 7102817 SO NLG DOWNLOCK FAILED B S CS3R K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 17 NEW SPRING WITHDRAWN FROM STOCK. INSTALLED ON NOSE LANDING GEAR DOWNLOCK ASSY. SPRING SNAPPED FIRST CYCLE OF RETRACTIO N CHECK. 1 L 7 1 3O 2A13 1997051500013 19970515 00013 CE 1997 5 15 97ZZZX1982 1 19970422 G 2913 99101372 PUMP CESSNA 414 414A 2075907 CE RT ENGINE HYD LEAKING H O OTHER J WARNING INDICATION NR NOT REPORTED 1 WP 13 5614C 277 831 414A0203 PILOT REPORTED BOTH LEFT AND RIGHT HYDRAULIC FLOW LIGHTS ON THE CAUTION PANEL WERE ILLUMINATED. LANDING GEAR WAS EXTEND ED USING THE EMERGENCY EXTENSION PROCEDURE. AIRPLANE LANDING WITHOUT INCIDENT. FLUID DISCOVERED LEAKING FROM RIGHT ENG INE NACELLE DRAIN. DISCOVERED THE RIGHT HYDRAULIC PUMP SHAFT SEAL HAD FAILED ALLOWING HYDRAULIC FLUID TO BE PUMPED OVER BOARD. HYDRAULIC PUMP WAS REPLACED. LANDING GEAR EMERGENCY BLOW-DOWN SYSTEM SERVICED AND THE LANDING GEAR OPERATIONAL CHECK C/W IAW CESSNA SM. AIRPLANE RETURNED TO SERVICE. PUMP P/N 9910137-2, S/N 831, HAD 227.1 HOURS TOTAL TIME SINCE N EW. 1 L 7 2 3O A7CE 1997051500014 19970515 00014 EA 1997 5 15 97ZZZX1983 2 19970415 G 7322 30628 FLOAT PRECISION MA3A CESSNA 120 120 2071402 CE LYC O235 O235C1 41505 EA CARBURETOR FAILED D S A K NONE O OTHER IN INSP/MAINT 1 SW 01 76381 1100 Y7FG2092 10802 L868215 AFTER OPENING UP CARBURETOR TO REPLACE TWO-PIECE VENTURI, NOTICED FLOAT WAS BRO KEN, ONE-HALF OF IT LAYING IN BOWL. REP LACED WITH NEW METAL TYPE. 1 H 7 1 3O 3 O A768 E223 1997051500015 19970515 00015 SO 1997 5 15 97ZZZX1984 1 19970401 G 2410 635796 COUPLING PIPER PA28 PA28RT201T 7102817 SO ALTERNATOR DRIVE FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 05 83047 268 28R8131038 ALTERNATOR DRIVE COUPLING IS VIBRATION DAMPED BY RUBBER BONDED TO SHAFT AND OUTER HOUSING. RUBBER SEPARATED FROM OUTER HOUSING. SECOND FAILURE ON THIS TYPE AIRCRAFT SERVICED BY THIS AGENCY IN LAST 12 MONTHS. PART IS ALSO VERY EXPENSIVE. SUGGEST GOING BACK TO PREVIOUS DESIGN USING DRIVE BLOCKS LIKE MAGNETO DRIVES. 1 L 7 1 3O 2A13 1997051500016 19970515 00016 1997 5 15 97ZZZX1985 4 19970423 G 3421 500E1 GYRO SIGMATEK PIPER PA34 PA34200 7103405 SO COCKPIT ATTITUDE MISOVERHAULED B IP6R K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 01 56730 50 21712H 347450027 POOR OPERATION OF AUTOPILOT GYRO. FOUND LAST OVERHAUL WAS NOT PROPER. ROTOR BEARINGS HAVE EXCESSIVE PRELOAD. PENDULUM S HAVE BEEN ALTERED. ADDITIONAL CERAMIC PENDULUM STOPS ADDED BY ALTERING BOTTOM PLATE. HORIZON ARM RUBBING AT LEVEL FL IGHT POSITION AGAINST PIN CASTING. 1 L 7 2 3O A7SO 1997051500017 19970515 00017 NM 1997 5 15 97ZZZX1986 1 19970221 G 2700 126344171 PNEU DRIVE UNIT ALIDSIGNAL BOEING 747 747* NM DIAPHRAGM ASSY FAIL TEST B UN7R K NONE L NO TEST IN INSP/MAINT 1 SW 19 10P928 UNIT FAILED FUNCTIONAL TEST. FOUND DIAPHRAGM ASSY 886083-5 MISSING SPACER/SLEEVE P/N 113842-146. SPRING RETAINER P/N 3 166820-1 MISSING. WRONG SPRING IN VALVE, SPRING P/N 3160871-1 IS NOT USED WITH VALVE 3290402-1. SB 27-1014 NOT C/W. S B 27-1042 PARTIALLY C/W. 2 L 7 4 4F RT A20WE 1997051500018 19970515 00018 CE 1997 5 15 97ZZZX1987 1 19970113 G 2140 0800400239 FUEL LINE STWARNER 8259JR2 CESSNA 310 310R 2074245 CE HEATER LEAK G L A O OTHER A FLAME/FIRE NR NOT REPORTED 1 SO 15 6107X 2665 310R1276 FUEL LINE ON HEATER FAILED DUE TO CORROSION ALLOWING AVGAS TO SPRAY INTO NOSE BAGGAGE COMPARTMENT AND IGNITE. HEATER AS SY ITSELF IS IN GOOD CONDITION. AD 81-09-09 PROVIDES FOR INSPECTION OF THAT AREA BY HEATER OPERATION TIME, BUT, NO CALE NDAR TIME. PART HAD 19 HRS SINCE AD, HOWEVER, SEVERAL YEARS HAD PASSED. ACFT LOCATED IN FLORIDA WHICH HAS A CORROSIVE ENVIRONMENT. SUBMMITTER RECOMMENDATION - ADD CALENDAR TIME TO AD. 1 L 7 2 3O 3A10 1997051500019 19970515 00019 EA 1997 5 15 97ZZZX1988 2 19970401 G 8530 73806P PUSH ROD CESSNA 150 152 2071835 CE LYC O235 O235N2C 41505 EA ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 95693 15285959 L2454815 PUSH ROD CRACKED BOTH ENDS. CRACKS APPROXIMATELY .50 INCH LONG. AD'S 80-25-02K2 AND 95-03-10 DO NOT APPLY. ENGINE FAC TORY REMANUFACTURED APPROXIMATELY 3300 HOURS AGO. FIELD OVERHAUL APPROXIMATELY 900 HOURS AGO. RECORDS WOULD INDICATE 3 300 HOURS ON PUSH ROD! 1 H 7 1 3O 3 O NT 3A19 E223 1997051500020 19970515 00020 EU 1997 5 15 97ZZZX1989 1 19970408 G 2710 BELLCRANK RHNFLU EA300 EA300S 1130864 EU RT WING AILERON MOUNT DEBONDED D A O OTHER F FLT CONT AFFECTED AB AEROBATIC 1 CE 03 9K 664 022 ACFT HAD UNDERGONE A 50 HOUR INSP. NO DISCREPANCIES WERE NOTED IN THE AIL SYS WHEN THE BELLCRANKS WERE INSP NOR WAS ANY SLACK NOTED IN THE AIL SYS AT THE CONTROL STICK OR THE PUSH/PULL TUBES AT EACH AIL. DURING THE FIRST FLIGHT AFTER THE INSP WHILE PRACTICING SNAP ROLLS TO THE RT, THE AIL CONT STARTED TO BIND NEAR THE NEUTRAL POSITION. INITIAL INSP FOUND THE RT AIL PUSH/PULL TUBE WAS BINDING AGAINST THE OTBD EDGE OF THE BOTTOM SKIN CUT-OUT JUST FORWARD OF THE AIL. FURTHER INSP REVEALED OTBD AIL BELLCRANK ASSEMBLY WAS LOOSE IN THE WING. THE BOND JOINT ON THE MOUNT BLOCK TO BOTH THE UPPER A ND LOWER WING SKIN HAD FAILED. ALL OF THE BONDING MATERIAL WAS STILL ADHERED TO THE MOUNT BLOCK. 1 M 7 1 3O NC A67EU 1997051500021 19970515 00021 SO 1997 5 15 97ZZZX1990 1 19970415 G 3230 ROD PIPER PA44 PA44180 7104402 SO NLG FOLLOW UP FAILED H O OTHER J WARNING INDICATION LD LANDING 1 WP 03 PA44-180 PIPER SEMINOLE MADE A LANDING WITH THE NOSE GEAR RETRACTED. THE INSTRUCTOR-PILOT CLAIMED THAT, AFTER EXTENDING THE LANDING GEAR HANDLE, HAD A 'NOSE GEAR UNSAFE' INDICATION....'. AFTER SEVERAL ATTEMPTS TO NORMALLY AND MANUALLY EXT END THE NOSE GEAR, THE AIRCRAFT LANDED WITH THE NOSE GEAR RETRACTED. THE STUDENT/PILOT STATED THAT THE '..GEAR DOOR LIN KAGE FELL OUT WHEN (THE) NOSE WAS LIFTED'. THE OWNER/OPERATOR STATED THAT THE NOSE GEAR FOLLOW-UP ROD FAILED JAMMING TH E NOSE GEAR IN THE WHEELWELL. REPORTEDLY, THE PART HAD OVER 5,000 HOURS OF TIME IN SERVICE, AND THERE IS NO LIMITING TI ME PUBLISHED FOR THE PART. 1 L 7 2 3O A19S0 1997051500022 19970515 00022 SW 1997 5 15 97ZZZX1991 1 19970313 G 6720 205011711101 GRIP 20401180117 BELL 204 UH1B 1181410 SW T/R DEFECTIVE B P A QJ5R K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 05 22753 1143 IMPT4654 6413985 BUSHING FOR PITCH LINK DOES NOT PROTRUDE FLUSH ON BACK SIDE OF GRIP EAR. THEREFORE, SINGLE STEEL WASHER UNDER NUT OF PC LINK BOLT SITS OVER RECESS AND CAN 'DISH' INTO RECESS CAUSING BOLT TO LOOSE TORQUE. PC LINK CONTACTED GRIP EAR AS LOOS E BOLT MOVED. 1 G 7 1 4U EXPA1G71 1997051500023 19970515 00023 NE 1997 5 15 97ZZZX1992 1 19970408 G 5280 7620902019045 FITTING SKRSKY S76 S76B 8143007 NE LT MLG DOOR FAILED D A K NONE O OTHER IN INSP/MAINT 1 EA 17 22CP 1313 760425 LEFT MAIN LANDING GEAR DOOR FITTING FOUND FAILED ON DAILY POST-FLIGHT INSPECTION. FITTING WAS REPLACED BY A SUPERSEDED (-048) PART NUMBERED FITTING WHICH IS DIMENSIONALLY LARGER IN SUPPORT AREA. NOTE: SEE ALERT NR 217, AUGUST 1996, PAGE 12, FOR SAME PROBLEM. DOOR P/N 76207-02002-011. 1 G 7 2 4U H1NE 1997051500024 19970515 00024 SW 1997 5 15 97ZZZX1993 1 19970326 G 6510 AN1746A BOLT BELL 206 206L1 1182107 SW T/R DRIVE WORN B QEVR K NONE O OTHER IN INSP/MAINT 1 CE 03 400EA 45544 DURING PHASE INSPECTION, FOUND THOMAS COUPLING BOLTS ON SEGMENTED DRIVE SHAFTS FOR TAIL ROTOR TO HAVE WORN THREADS CAUSI NG NEW MS21042-L4 NUTS TO NOT HAVE PROPER LOCKING FRICTON AT THESE LOCATIONS, FORWARD SHORT SHAFT TO ENGINE, NR 3 SHORT SHAFT AND SHORT SHAFT AT TAIL ROTOR GEARBOX AREAS WHICH ARE REMOVED FREQUENTLY. SUBMITTER RECOMMENDS CHANGING BOLTS AT 600 OR 1200 HOUR INTERVALS OR EVEN MORE FREQUENTLY, IF WEAR IS NOTICED. 1 G 7 1 3U H2SW 1997051500025 19970515 00025 SW 1997 5 15 97ZZZX1994 1 19970326 G 6510 AN1747A BOLT BELL 206 206L1 1182107 SW T/R DRIVE WORN B A QEVR K NONE O OTHER IN INSP/MAINT 1 CE 03 400EA 45544 DURING PHASE INSPECTION, FOUND THOMAS COUPLING BOLTS ON SEGMENTED DRIVE SHAFTS FOR TAIL ROTOR TO HAVE WORN THREADS CAUSI NG NEW MS21042-L4 NUTS TO NOT HAVE PROPER LOCKING FRICTON AT THESE LOCATIONS, FORWARD SHORT SHAFT TO ENGINE, NR 3 SHORT SHAFT AND SHORT SHAFT AT TAIL ROTOR GEARBOX AREAS WHICH ARE REMOVED FREQUENTLY. SUBMITTER RECOMMENDS CHANGING BOLTS AT 600 OR 1200 HOUR INTERVALS OR EVEN MORE FREQUENTLY, IF WEAR IS NOTICED. 1 G 7 1 3U H2SW 1997051500028 19970515 00028 CE 1997 5 15 97ZZZX1997 1 19970127 G 3150 ANNUNCIATOR BEECH B300 B300 1159232 CE AUTOFEATHER MISWIRED H K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 3269W 18 FL147 PERFORMED AUTOFEATHER SYSTEM TEST AND ARM PROCEDURE PER B300 MM 61-20-00 AND CONFIRMED CONFLICTING LEFT/RIGHT ANNUNCIATI ON. VERIFIED WIRING PER B300 WIRING DIAGRAM 61-21-02 PAGE 4 AND SUBSEQUENT SECTIONS. CORRECTED MIS-WIRING AT ANNUNCIATO R LIGHT CONNECTORS TO CONFORM TO WIRING DIAGRAGM AND ANNUNCIATE CORRECTLY. PEFORMED AUTOFEATHER SYSTEM TEST AND ARM PRO CEDURE PER B300 MM 61-20-00 AND PASSED. 2 L 7 2 4T RT A24CE 1997051500029 19970515 00029 SW 1997 5 15 97ZZZX1998 1 19970429 G 5330 2730018023 SKIN SWRNGN SA226 SA226TB 8780406 SW BS 228.0 CRACKED B VH2R K NONE O OTHER IN INSP/MAINT 1 SW 17 626PS TB329 FUSELAGE SKIN WAS FOUND TO BE CRACKED IN PRESSURIZED, STRUCTURAL CLOSE OUT SKIN AREA. CRACK LOCATIONS WERE FS 228.0 AT BL 6.0 LT AND RT SIDES. BASED ON PREVIOUS EXPERIENCE WITH MODELS SA226-T, AT, AND TC, THE MOST PROBABLE CAUSE APPEARS T O BE THE BELLY FAIRING STRINGERS CHAFING AGAINST THE FUSELAGE SKIN. FAIRCHILD AIRCRAFT HAS ISSUED SB 226-53-006 WHICH A DDRESSES THIS PROBLEM FOR MODELS SA 226 T, AT, AND TC. SUBMITTER WOULD RECOMMEND FAIRCHILD SB 226-53-006 BE INCLUSIVE O F MODEL SA 226T(B). 2 L 7 2 4T RT A5SW 1997051500030 19970515 00030 CE 1997 5 15 97ZZZX1999 1 19970422 G 3241 302EX MOTOR ASSY ELECTROMECH CESSNA 500 550 2076604 CE ANTISKID MALFUNCTION B R8RR K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 2663Y 1833 5500602 AFTER REPLACING THE ANTI-SKID BRAKE MOTOR ASSY WITH THE GREEN AND BLACK WIRES CONNECTED PROPERLY, THE MOTOR ASSY RUNS IN A COUNTER CLOCKWISE DIRECTION, OPPOSITE OF THE NORM. REMOVED AND REPLACED ANTI-SKID MOTOR ASSY. SUBMITTER SUSPECTS IM PROPER WIRING WITHIN MOTOR AND IMPROPER BENCH TESTS PERFORMED. 1 L 7 2 4F A22CE 1997051500031 19970515 00031 CE 1997 5 15 97ZZZX2000 1 19970422 G 3241 302EX MOTOR ASSY CESSNA 500 550 2076604 CE ANTI SKID INTERMITTENT B R8RR K NONE O OTHER IN INSP/MAINT 1 WP 07 2663Y 00341 5500602 REMOVED AND REPLACED ANTI-SKID HYDRAULIC POWER PACK ASSY. AFTER 29.8 HRS OF USAGE, THE MOTOR BECAME INTERMITTENT. SUSP ECT A LOOSE CONNECTION WITHIN THE MOTOR ASSY. THIS WAS A REPAIRED ANTI-SKID HYDRAULIC POWER PACK PROVIDED BY THE MANUFA CTURER. REMOVED AND REPLACED THE ANTI-SKID MOTOR P/N 30-2. 1 L 7 2 4F A22CE 1997051500033 19970515 00033 NE 1997 5 15 97ZZZX2001 2 19970421 G 8530 CYLINDER AIRTRC AT300 AT301 0390103 SW PWA R1340 R1340AN1 52016 NE NR 9 HEAD SEPARATED D L A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 NM 08 4397S 3010057 51132 AIRCRAFT EXPERIENCED A SUDDEN LOSS OF POWER. EMERGENCY LANDING MADE AT MOUNTAIN HOME AIR FORCE BASE. NR 9 CYLINDER HEA D HAD SEPARATED JUST ABOVE THE TOP OF PISTON TRAVEL. FATIGUE FRACTURE APPEARS TO ORIGINATE AT THE EXHAUST VALVE SEAT. 6 75 SMOH. 1 L 7 1 3R 3 R A9SW 5E2 1997051500035 19970515 00035 SW 1997 5 15 97ZZZX2002 1 19970414 G 3222 SNAP RING GULSTM 690TP 690B 7630516 SW NLG STRUT FAILED B A WD4R O OTHER J WARNING INDICATION AP APPROACH 1 SO 17 137BW 11446 WHILE ATTEMPTING TO LAND, THE PILOT PUT THE GEAR HANDLE DOWN AND CONFIRMED THE NOSE GEAR DID NOT GO DOWN AND LOCKED. TH IS AIRCRAFT WAS LANDED WITH THE NOSE GEAR UP WITH DAMAGE TO THE FUSELAGE STRUCTURE. UPON INSPECTION, IT WAS FOUND THE N OSE GEAR LOWER STRUT SNAP RING CAME OUT OF THE STRUT WHICH ALLOW THE NOSE STRUT TO EXTEND WHILE STILL IN THE WHEELWELL. THE SNAP RING AND STRUT GROOVE WERE NOT DAMAGED. SUBMITTER STATED IT APPEARS THE SNAP RING WAS NEVER PROPERLY INSTALLE D. 1 H 7 2 3T 2A4 1997051500036 19970515 00036 WP 1997 5 15 97ZZZX2003 2 19970409 G 7314 8974001 PUMP STBROS SC7 SC73 8100512 EU GARRTT TPE331 TPE3312201A WP DRIVESHAFT LEAKAGE B L A ILIR K NONE O OTHER IN INSP/MAINT 1 WP 07 1846 4060 SH1846 P90094 INVESIGATION FOR EXCESS OIL USAGE, FOUND THE OIL WAS ENTERING THE FUEL SYS VIA THE OIL WET SPLINE MOD TO THE DRIVESHAFT THAT DRIVES THE FUEL PUMP ON THE ENG GEARBOX. ALLIED SIGNAL SB TPE 331-72-0104 IS THE WET SPLINE MOD. 1 H 7 2 3T 4 T A15EU E3WE 1997051500037 19970515 00037 EA 1997 5 15 97ZZZX2004 1 19970418 G 6123 8190026 SWITCH DHAV DHC6 DHC6300 EA AUTOFEATHER FAILED D A E ENGINE SHUTDOWN O OTHER NR NOT REPORTED 1 SW 99 235SA 105 3703 772 TORQUE PRESS SWITCH IN AUTOFEATHER SYSTEM FAILED CAUSING PROP TO FEATHER IN-FLIGHT. 1 H 7 2 3T A9EA 1997051500039 19970515 00039 EA 1997 5 15 97ZZZX2005 2 19970425 G 7250 PCE84114 GAS GENERATOR STBROS SD3 SD330 8100602 EU PWA PT6 PT6A45 52043 EA RT ENGINE SEAL FAILED D E A H ENGINE SHUTDOWN UNSCHED LANDING DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 GL 13 936MA SH3036 84114 PILOTS REPORTED SMOKE IN COCKPIT AND CLOSED PRSOV VALVE STOPPING THE SMOKE. SEVERAL MINUTES LATER, THE PILOTS NOTICED T ORQUE AND OIL PRESSURE FLUCTUATING. FEATHERED AND SHUT DOWN ENGINE AND LANDED WITHOUT INCIDENCE. ENGINE WAS LEAKING OI L FROM THE COMPRESSOR SEAL. 2 H 7 2 4T 4 T A41EU E4EA 1997051500040 19970515 00040 WP 1997 5 15 97ZZZX2006 1 19970425 G 5312 BULKHEAD WEB DOUG DC8 DC861F 3021953 WP AFT PRESSURE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 27UA 45942 DURING 'C' CK INSPECTION ACCOMPLISHED VISUAL AND DYE PENETRANT INSPECTION OF THE AFT PRESS BULKHEAD WEB IAW SB 53-73 REV 1. FOUND A CRACK AT RT FWD SIDE OF THE APB WEB AT I/B SIDE OF VERTICAL STIFFENER ABOVE FASTENER ROW. ACCOMPLISHED TER MINATING ACTION BY REMOVING CRACK SECTION AND INSTALLED A DOUBLER IAW DOUGLAS DWG SR08530007. ALSO DURING INSPECTION FO UND A CRACK AT LT FWD SIDE OF THE APB WEB AT BOTH SIDES OF THE STIFFENERS ABOVE FASTENERS. ACCOMPLISHED TERM. ACTION BY REMOVING CRACK SECTIONS AND INSTALLED DOUBLER IAW DACO DWG SR08530007. 2 L 7 4 4F 4A25 1997051500387 19970515 00387 CE 1997 5 15 97ZZZX2015 1 19970428 G 2435 230890002 GENERATOR LEARSIEGLER RKWELL NA265 NA26565 7630107 CE LT START/GEN BEARING FAILED D A UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 EA 13 265A 540 695 46547 ON 4-28-97, THE AIRCRAFT EXPERIENCED A VERY NOTICEABLE VIBRATION AND NOISE AFTER DEPARTURE. CREW WAS ABLE TO DETERMINE THAT IT CHANGED WITH THROTTLE MOVEMENT. ACFT RETURNED TO BASE, THE LEFT STARTER/GENERATOR WAS PULLED AND CHECKED. UPON INSPECTION IT WAS NOTED THERE WAS A LOT OF PLAY IN THE AFT BEARING. THE STARTER/GENERATOR WAS REPLACED. 2 L 7 2 4J A2WE 1997051500388 19970515 00388 CE 1997 5 15 97ZZZX2016 1 19970428 G 2820 57001133 FUEL LINE CESSNA 441 441 2076020 CE RT WING CWS 88.0 CHAFED D A K NONE O OTHER IN INSP/MAINT 1 WP 11 40FJ 3141 4410359 MAIN FUEL LINE FROM BOOST PUMP TEE TO FUEL CROSSFEED SHUTOFF VALVE WAS CHAFED BEYOND LIMITS BY WING RIB ASSY, AT WS 88.0 INCH, RIB P/N 572225-33. SUBMITTER RECOMMEND ALL CONQUEST II SHOULD BE INSPECTED IN THIS AREA - SHOULD THIS LINE OPEN UP DUE TO CHAFING, COULD RESULT IN COMPLETE LOSS OF AIRCRAFT. THIS IS A HIGH PRESSURE LINE THAT IS BEHIND FUEL SHUTOFF VALVE, SO WITH BOOST PUMPS IN, CANNOT SHUT FUEL OFF. FUEL COULD THEN BE IGNITED BY BLEED AIR LINE THAT RUNS IN SAME LEA DING EDGE COMPARTMENT. SUBMITTER RECOMMENDS LINE BE RESHAPED OVER THIS AREA AND SOME SORT OF CHAFING PREVENTION LIKE SP IRAL WRAP INSTALLED ON FUEL LINE. SUBMITTER STATED NOTE: THIS IS NOT THE FIRST TIME HAVE SEEN THIS PROBLEM IN THIS ARE 1 L 7 2 3T RT A28CE 1997051500389 19970515 00389 CE 1997 5 15 97ZZZX2017 1 19970429 G 2711 NAS35860900 TUBE LEAR 35 35A 5170602 CE AIL TAB PUSH ROD RUSTED B L A DINR K NONE O OTHER IN INSP/MAINT 1 EA 17 258G 3951 443 DURING POST FLIGHT INSP A SMALL PAINT BLISTER NOTED ON ONE OF THE LT HAND AIL BALANCE TAB PUSH RODS AT BOTTOM DEAD CENTE R APPROXIMATELY 3.50 INCHES FWD OF THE AFT ROD END BOLT CENTER. WHEN PROBED THE BLISTER OPENED UP TO A HOLE APPROXIMATE LY .25 INCH LONG BY .1250 INCH WIDE. FLAKED RUST WAS NOTED INSIDE THE TUBE AND COULD BE SHAKEN OUT THROUGH THE HOLE. B OTH DRIVE-IN RIVETS, USED FOR CORROSION TREATMENT, ARE STILL IN PLACE AND SECURE. IT SEEMS OBVIOUS MOISTURE ENTERED THE TUBE BY SOME MEANS AND OVER TIME RUSTED A HOLE THROUGH IT. 2 L 7 2 4F A10CE 1997051500390 19970515 00390 CE 1997 5 15 97ZZZX2018 1 19970422 G 3221 NAS464P61A BOLT CESSNA 182 R182 2072734 CE NLG ATTACH FAILED D A O OTHER J WARNING INDICATION CL CLIMB 1 SW 07 202CT 3935 24 R18200060 PILOT REPORTED NOSE GEAR NOT RETRACTING ALL THE WAY INTO GEAR WELL. INSPECTION FOUND LT NOSE GEAR MAIN ATTACH BOLT MISS ING. NOSE GEAR WAS HELD IN PLACE BY REMAINING BOLT (RT). BOLT WAS FOUND BELOW LT EXHAUST PIPE WITH THREAD END SHEARED OFF, NUT AND PART OF BOLT WAS NOT FOUND, REPLACED BOTH ATTACH BOLTS AND NUTS/WASHERS. 1 H 7 1 3O RT 3A13 1997051500391 19970515 00391 CE 1997 5 15 97ZZZX2019 1 19970416 G 7160 BA5710 AIR FILTER BRACKETT CESSNA 177 177RG 2073709 CE INDUCT AIR DETERIORATED H K NONE O OTHER IN INSP/MAINT 1 WP 09 217AF 777 177RG1011 AIR FILTER GASKET HAS TURNED TO MUSH FROM THE OIL THEY USE IN THE AIR FILTER, MAYBE A NEW TYPE OF GASKET IS CALLED FOR. PART HAS BEEN REPLACED. 1 H 7 1 3O A20CE 1997051500392 19970515 00392 SO 1997 5 15 97ZZZX2020 2 19970401 G 7414 CAM ASSY BEECH 35 K35 1151524 CE CONT O470 IO470C 17026 SO SNAP RING RIVET FAILED H K NONE O OTHER IN INSP/MAINT 1 WP 15 5008 D5865 DURING ACCOMPLISHING SB MSB645, NR 639, AND AD 96-12-07, FOUND MAG SNAP RING CAM ASSY HAD RIVET FAILURE. 1 L 7 1 3O 3 O 3A15 E273 1997051500393 19970515 00393 SO 1997 5 15 97ZZZX2021 2 19970428 G 7414 M3006 BEARING SLICK 6310 BEECH 58 58 1152740 CE CONT O550 IO550C SO MAG DRIVE FAILED H K NONE O OTHER IN INSP/MAINT 1 WP 23 877CA 1385 94020912 TH1727 676761 PILOT REPORTED LEFT ENGINE LEFT MAGNETO WAS 'DEAD' ON RUN-UP. REMOVED MAGNETO AND OPENED UP FOR INSPECTION. FOUND INTE RNAL DAMAGE - MATERIAL BEING WORN AWAY BY ROTATING MAGNET. FURTHER DISASSEMBLY REVEALED DRIVE END BEARING P/N M3006 BAL L RETAINER CAGE AND GREASE SEAL GONE - BEARING WAS DRY WHICH MAY HAVE LEAD TO FAILURE. NEW MAGNETO INSTALLED ON AIRCRAF T AND RETURNED TO SERVICE. 1 L 7 2 3O 3 O 3A16 E3SO 1997051500394 19970515 00394 SO 1997 5 15 97ZZZX2022 1 19970428 G 5512 SKIN PIPER PA24 PA24250 7102404 SO RT STAB DAMAGED D K NONE O OTHER IN INSP/MAINT 1 NE 05 8200P 2200 243452 ANNUAL INSP FOUND RT STAB SKIN WRINKLED AND BENT AT THE END OF TORQUE FITTING P/N 16809-03. 1 L 7 1 3O 1A15 1997051500395 19970515 00395 SO 1997 5 15 97ZZZX2023 1 19970428 G 5510 452363 BEARING PIPER PA24 PA24250 7102404 SO STAB WORN D K NONE O OTHER IN INSP/MAINT 1 NE 05 8200P 2200 243452 ANNUAL INSP FOUND STAB BEARING WAS WORN. INSP IN AREA COVERED IN AD 97-13-10 NOTE 1 PARA (A2) AND SB 411A INST PARA (1- 4). 1 L 7 1 3O 1A15 1997051500396 19970515 00396 SO 1997 5 15 97ZZZX2024 1 19970401 G 3211 39486803 TRUNNION ASSY PIPER PA34 PA34220T 7103420 SO RT MLG CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 07 8287U 348333027 DURING INSPECTION NOTICED PART CRACKED ON AFT WEBBING OF RT MAIN GEAR TRUNNION. STRIPPED PAINT, DYE PENETRANT INSPECTI ON REVEALED A CRACK LOCATED 4.5 INCHES FROM BASE STRETCHING HORIZONTALLY ACROSS SEAM APPROXIMATELY .50 INCH IN LENGTH. T HIS AREA HAD A FEW MANUFACTURING GRIND MARKS. 1 L 7 2 3O A7SO 1997051500397 19970515 00397 SO 1997 5 15 97ZZZX2025 1 19970422 G 5311 1056236 TUBE PIPER PA18 PA18 7101802 SO FUSELAGE FRAME CORRODED B L A QK5R K NONE O OTHER IN INSP/MAINT 1 NM 05 FAA APPROVED REPAIR STATION, THAT REBUILDS AND REPAIRS PA-18 FUSELAGE FRAMES, HAS EXPERIENCED A PROBLEM, IN FINDING SEVE RE CORROSION ON APPROX 35 PERCENT OF THE FUSELAGES IN WORK. ONE PROBLEM CENTERS ON THE .6250 INCH VERTICAL TUBE, P/N 10 562-36, FROM THE TOP LONGERON, UP TO THE REAR WING ATTACH FITTING, ON THE RT SIDE AND LOCATED AT THE AFT UPPER DOOR. TH E CHANNEL, P/N 12205-5, THAT IS TACK WELDED TO THIS TUBE, IS SET TO PROVIDE PROPER CLEARANCE TO THE REAR UPPER DOOR. FI NDING TRAPPED MOISTURE IS RETAINED BEHIND THE CHANNEL AND RUSTS OUT THE .6250 INCH TUBE. IMPOSSIBLE AREA TO INSPECT, UN LESS THE CHANNEL IS REMOVED. THE AREA, NOT COVERED BY THE CHANNEL, IS RELATIVELY FREE OF CORROSION. 1 H 7 1 3O 1A2 1997051500398 19970515 00398 EA 1997 5 15 97ZZZX2026 2 19970501 G 7322 105217 CARBURETOR MA4SPA PIPER PA28 PA28180 7102808 SO LYC O320 O320D3G 41508 EA BOWL DRAIN LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 07 15050 287225569 L2262227A TWO BOWL SCREWS LEAKING. FUEL BOWL DRAIN LEAKING. BOTTOM OF CARBURETOR SMALL HOUSING OF ACCELERATOR PUMP LEAKING. VER Y POOR QUALITY ASSURANCE. SUBMITTER STATED ALSO SAME PROBLEM ON AN OVERHAULED MODEL - SAME P/N, 10-5217. 1 L 7 1 3O 3 O 2A13 E274 1997051500400 19970515 00400 CE 1997 5 15 97ZZZX2028 1 19970317 G 2130 HOSE CESSNA 501 501 2076603 CE CABIN PRESS FAILED C L A B G EMER. DESCENT O2 MASK DEPLOYED J WARNING INDICATION CR CRUISE 1 EU 01 501CF 5010128 DURING CRUISE AT FL 370, PRESSURIZATION SET FOR FL 380 WITH CABIN AT APPROX 7,000 FEET. CREW HEARD A DULL NOISE, CABIN OXY MASK DEPLOYED, MASTER WARN RED LIGHTS AND CABIN ALTITUDE INCREASING. ACFT DIVERTED FOR REPAIR. FOUND FAILED BLEED SYS HOSE AND A NON-RETURN VALVE OUT OF LIMITS AT .75 INCH OPEN. 1 L 7 2 4F A27CE 1997051500402 19970515 00402 SO 1997 5 15 97ZZZX2030 2 19970401 G 8540 643110 SPRING 643259A28 CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO START ADAPTER BROKEN D K NONE O OTHER IN INSP/MAINT 1 WP 03 234CN 342 421C0404 292152R RIGHT ENGINE WOULD NOT TURN OVER TO START. FOUND CLUTCH SPRING INSIDE THE STARTER ADAPTER BROKEN. REPLACED STARTER ADA PTER. NOTE: THIS ENGINE AND STARTER ADAPTER IS NOT REQUIRED TO BE INSPECTED BY TCM BULLETIN CSB94-4A. 1 L 7 2 3O 3 O A7CE E7CE 1997051500403 19970515 00403 EU 1997 5 15 97ZZZX2031 1 19970312 G 3230 TB2061032003 SWITCH TB204207200 SOCATA TB20 TB20TRINIDAD 8680695 EU NLG LEG WIRE BROKEN D A O OTHER O OTHER AP APPROACH 1 EA 25 72BM 466 NOSE GEAR DID NOT FULLY EXTEND AND LOCK DUE TO A NOSE GEAR END OF TRAVEL LIMIT SWITCH. THE SWITCH IS MOUNTED ON THE FOR WARD LEG OF THE OVER-CENTER LINK AND DOWNLOCK. THE WIRE IS TY-WRAPPED TO THE LINK. THE SWITCH HAD 1736.08 HOURS TOTAL TIME. THE SWITCH SHOULD BE REPLACED ANY TIME THE OUTER COVER SHOWS SIGNS OF DETERIORATION OR CRACKING. 1 L 7 1 3O RT A51EU 1997051500404 19970515 00404 EA 1997 5 15 97ZZZX2032 2 19970416 G 7322 MA3A CARBURETOR FACET PIPER PA38 PA38112 7103812 SO LYC O235 O235L2C 41505 EA CARBURETOR MAIN JET BLOCKED D O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SO 15 2585B 3195 CR15849 3879A0132 L1768215 AIRCRAFT ENGINE LOST POWER FROM PARTIAL OBSTRUCTION OF MAIN JET WHICH FEEDS DISCHARGE NOZZLE. MATERIAL APPEARS TO HAVE BUILD-UP OF SEDIMENT SCALE. RECOMMEND INTERNAL BOWL INSPECTION OF CONDITION AT EACH 2,000-HOUR OPERATION. 1 L 7 1 3O 3 O A18SO E223 1997051500405 19970515 00405 1997 5 15 97ZZZX2033 3 19970228 G 6112 RA19833 CLAMP PIPER PA31T PA31T 7103124 SO PROP BLADE FAILED B L EBTR K NONE O OTHER IN INSP/MAINT 1 GL 09 23407 31T7920055 RAPCO P/N RA1983-3 CLAMP (DE-ICE BOOT AND HARNESS LEADS ATTACH AT THIS POINT ON PART) FAILED (CRACKED INTO PIECES) ALLOW ING WEIGHT OF PIECES TO PULL LEAD WIRES FROM SPINNER BULKHEAD TERMINAL STRIP. TERMINAL STRIP ON SPINNER BULKHEAD THEN F AILED AND PULLED WIRES FROM PROP DE-ICE SLIP RING. PILOT FOUND WIRES HANGING OUT OF SPINNER ON PRE-FLIGHT. 1 L 7 2 3T A8EA 1997051500406 19970515 00406 SW 1997 5 15 97ZZZX2034 1 19970421 G 6510 206040365001 SHAFT BELL 206 206L3 1182108 SW T/R DRIVE PITTED D K NONE O OTHER IN INSP/MAINT 1 NM 11 937S 1237 51258 DURING INSPECTION OF THE TAILBOOM, MECHANIC NOTICED A VERY FAINT DISCOLORED LINE ADJACENT TO THE GLUE LINE OF ONE FLANGE ON THE TAIL ROTOR DRIVESHAFT. FURTHER INSPECTION WITH 10X MAG GLASS REVEALED PITTING INTO THE ALUMINUM SHAFT APPROXIMA TELY 30 DEGREES OF THE CIRCUMFERENCE WITH EVIDENCE OF MORE BEGINNING THE REMAINDER OF THE WAY AROUND THE SHAFT. SUSPECT A CORROSIVE REACTION TO THE GLUE OR PREPARATION FOR GLUE AT MANUFACTURE AS THIS HELICOPTER HAS NEVER BEEN OPERATED IN A HIGH CORROSIVE ENVIRONMENT. THE PART WAS INSTALLED NEW 3 YEARS EARLIER AND HAS ACCUMULATED 1237.1 HOURS. 1 G 7 1 3U H2SW 1997051500407 19970515 00407 NE 1997 5 15 97ZZZX2035 2 19970409 G 7230 204322017 VANE ASSY LYC LF507 LF5071F NE 3RD STAGE COMP FOD DAMAGE B SW5R K NONE O OTHER IN INSP/MAINT 1 NE 03 LF07338 SEVERE FOD DAMAGE TO 1ST, 2ND, AND EXIT VANE ROWS. TRAMP MATERIAL LODGED BETWEEN VANES. OUTER SHROUD DAMAGED FROM FOD IMPACTS. 4 F E6NE 1997051500408 19970515 00408 NM 1997 5 15 97ZZZX2036 2 19970429 G 7261 ENGINE GULSTM 690TP 690C 7630517 SW GARRTT TPE331 TPE3315251K NM LT ENGINE LOW OIL PRESS D E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 NM 04 3XY 1970 11638 P40341 UPON REACHING FL 26,000 FEET, PILOT OBSERVED OIL PRESSURE DECREASING SLOWLY. THE OIL PRESSURE HAD REACHED A LOW END RED LINE. THE PILOT ELECTED TO SHUT DOWN NR 1 ENGINE AND RETURN TO THE AIRPORT. AFTER LANDING, INVESTIGATION WAS MADE INT O OIL PRESSURE. PRESSURES WERE ALL GOOD ON THE GROUND. SOAP SAMPLES PROVED GOOD. PREVIOUS ENGINE WORK SUGGESTS SOME P OSSIBLE NICKED O-RINGS ON OIL TRANSFER TUBES INTERNALLY IN ENGINE. THE ENGINE WAS REMOVED AND SENT BACK TO ALLIED SIGNA L FOR INSPECTION. 1 H 7 2 3T 4 T 2A4 E2WE 1997051500409 19970515 00409 EA 1997 5 15 97ZZZX2037 2 19970424 G 8530 LW14077 PISTON PIN HILLER UH12 UH12E 4360122 WP LYC O540 VO540C2A 41532 EA ENGINE DEFECTIVE H K NONE O OTHER IN INSP/MAINT 1 WP 17 62392 161 1591 L150943 AD 97-01-03 AND LYC SB 527B DO NOT REFERENCE VO540 ENGINES IN MODELS AFFECTED, BUT 4 OF 6 PISTON PINS IN ENGINE HAD TO B E REPLACED IN C/W THE SB REQUIRED ACTION. NOTE: 6-CYLINDER HELICOPTER ENGINES ARE LISTED IN WARRANTY LABOR ALLOWANCE A ND A VO540 ENGINE IS LISTED IN MODEL AND S/N ATTACHMENT TO THE SB. 1 G 7 1 3O 3 O 4H11 E304 1997051500410 19970515 00410 WP 1997 5 15 97ZZZX2038 1 19970305 G 6710 A21810064603 SWITCH HUGHES 369 369E 4470707 WP CYCLIC TRIM FAILED D A A UNSCHED LANDING F FLT CONT AFFECTED CR CRUISE 1 WP 07 504MP 381 O523E DURING NORMAL OPERATIONS, THE TRIM SYSTEM CONTINUED TO DRIVE TO THE LEFT LATERAL CYCLIC STOP. ATTEMPTS TO BRING THE TRI M BACK TO THE NEUTRAL POSITION WERE UNSUCCESSFUL FROM BOTH THE PILOTS AND COPILOTS POSITION (STICK). TRIM SYSTEM CIRCUI T BREAKER WAS PULLED TO PREVENT ANY FURTHER PROBLEMS, AND THE AIRCRAFT WAS FLOWN BACK TO FACILITY WHILE GREAT FORCE WAS EXERTED TO OVERCOME THE TRIM-SPRING CAPSULE. AFTER SHUT DOWN, THE STICK WAS RELAXED. AFTER REPLACING PILOT'S TRIM SWIT CH AND RESETTING CIRCUIT BREAKER, ALL GROUND AND FLIGHT TESTS CHECKED GOOD. 1 G 7 1 3U H3WE 1997051500411 19970515 00411 EU 1997 5 15 97ZZZX2039 1 19970418 G 2435 150SG122Q GENERATOR SNIAS 350 AS350B2 8680813 EU START/GEN FAILED B A R8RR K NONE O OTHER IN INSP/MAINT 1 WP 07 9084W 2672 AFTER INSTALLATION OF OVERHAULED STARTER/GENERATOR ON INITIAL START-OPERATIONAL CHECK, THE STARTER/GENERATOR DID NOT COM E ON-LINE, IT WAS RESET WITH NO RESULTS. IT WAS AGAIN RESET AND FUNCTIONED PROPERLY. LATER, ACFT WAS DISPATCHED WITH N O DISCREPANCIES. THE NEXT DAY, A MAINTENANCE RUN WAS PERFORMED TO VERIFY AN OIL SEEP ON THE TAIL GEARBOX. ACFT STARTED NORMAL, BUT GENERATOR DID NOT COME ON-LINE. AFTER SEVERAL ATTEMPTS TO RESET FAILED, STARTER/GENERATOR WAS REMOVED AND REPLACED. SUBMITTER SUSPECTS INTERNAL FAILURE, INADEQUATE OVERHAUL, OR BENCH TESTING PROCEDURES. 1 G 7 1 3U H9EU 1997051500413 19970515 00413 SO 1997 5 15 97ZZZX2041 2 19970401 G 8530 625393 RETAINER CONT O520 GTSIO520H 17032 SO NR 5 CYL INT VLV CRACKED D K NONE O OTHER IN INSP/MAINT 1 NE 03 267116R NR 5 CYLINDER VALVE RETAINER DEFECT. CHECKED TWO CYLINDERS ON THIS RUN-OUT CORE. ONE GOOD AND NR 5 WAS NOT DUE TO INTA KE VALVE SPRING RETAINER CRACKED. 3 O E7CE 1997051500414 19970515 00414 EA 1997 5 15 97ZZZX2042 2 19970401 G 8530 SL798606 PUSHROD CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA CYLINDER LOOSE END D K NONE O OTHER IN INSP/MAINT 1 NE 03 2400 L1453615 RUN-OUT CORE ENGINE THAT WAS DISASSEMBLED FOR PUSHRODS FOR C/W AD 95-3-10. THIS ENGINE HAD ONE SUPERIOR AIR PARTS PUSHR OD WITH LOOSE END. 1 H 7 1 3O 3 O NT 3A19 E223 1997051500415 19970515 00415 SO 1997 5 15 97ZZZX2043 2 19970401 G 8530 625393 RETAINER CESSNA 421 421B 2076014 CE CONT O520 GTSIO520H 17032 SO NR 3/4 EXH VLV CRACKED D K NONE O OTHER IN INSP/MAINT 1 NE 03 1562G 673 421B0801 267147R NR 3 AND NR 4 CYLINDER EXHAUST VALVE RETAINER CRACKED. 1 EACH CYLINDER. INSPECTED ALL OTHER CYLINDERS. NONE FOUND DEF ECTIVE. 1 L 7 2 3O 3 O A7CE E7CE 1997051500416 19970515 00416 SO 1997 5 15 97ZZZX2044 2 19970422 G 8530 542343CN CYLINDER CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO LT NR 5 SEPARATED D A UNSCHED LANDING E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CR CRUISE 1 SW 11 421FC 618 421C0442 604119 ACFT LOST NR 5 CYLINDER IN CRUISE FLIGHT TO JBR. CYLINDER SEPARATED ABOUT 1 INCH INBOARD OF THREADED AREA IN STEEL SLEE VE. AREA CRACKED IS 360 DEGREES AND EXPOSED TOP RINGS ON PISTON CAUSING METAL CONTAMINATION IN ENGINE. OIL PRESSURE WA S LOST 4 MINUTES BEFORE LANDING AT BVX. THE NR 5 CYLINDER THAT FAILED IS LOCATED ON THE LEFT ENGINE. CAUSE FOR THE CYL INDER FALURE HAS NOT BEEN DETERMINED. THE STEEL PORTION OF THIS CYLINDER HAD NO SIGN OF CRACKING OR LEAKING AT THE LAST INSPECTION WHICH WAS 15.9 HOURS AGO AT SCHEDULED OIL CHANGE ON 2-6-97. 1 L 7 2 3O 3 O A7CE E7CE 1997051500417 19970515 00417 SO 1997 5 15 97ZZZX2045 2 19970326 G 8520 530196A1 CRANKSHAFT PIPER PA17 PA17 7101702 SO CONT A65 A658 17003 SO NR 2 THROW FRACTURED G K NONE Y ENGINE STOPPAGE NR NOT REPORTED 1 SW 11 4820H 109 4F98 17118 T024483 CRANKSHAFT FRACTURED IN AFT CHEEK OF NR 2 THROW CAUSING ENGINE TO STOP. THE CRANKSHAFT WAS IN THE 0.010 INCH UNDER COND ITION. THE ORIGIN OF THE FRACTURE MAY HAVE BEEN THE AFT RADIUS OF THE NR 2 CRANK PIN. THE CRANKSHAFT WAS MAGNAFLUXED A T OVERHAUL. SUBMITTER RECOMMENDS MAKING ULTRASONIC INSPECTION AN OVERHAUL REQUIREMENT ON AGING ENGINES. 1 H 7 1 3O 3 O A805 E205 1997051500418 19970515 00418 1997 5 15 97ZZZX2046 4 19970505 G 3416 D120P2T ENCODER CESSNA 172 172P 2072436 CE INST PANEL ERRORS D K NONE O OTHER IN INSP/MAINT 1 WP 11 5394K 66694 17274093 ON STATIC TEST, ENCODER FOUND INOPERATIVE AT 4600 FEET. BETWEEN 5050 TO 5500 UNIT INDICATED 5200, AT 6050 TO 6500, UNIT INDICATED 6200. SAME AT 7050, 8050, TESTS TERMINATED AND UNIT WAS REPLACED. 1 H 7 1 3O NT 3A12 1997051500419 19970515 00419 SO 1997 5 15 97ZZZX2047 2 19970401 G 8550 625393 RETAINER CESSNA 421 421B 2076014 CE CONT O520 GTSIO520H 17032 SO NR 4 CYL INT VLV FAILED D K NONE O OTHER NR NOT REPORTED 1 NE 03 5451J 280 421B0909 267346R NR 4 CYLINDER INTAKE VALVE RETAINER FAILED. INSPECTED ALL OTHER CYLINDERS, FOUND NO OTHER DEFECTS. 1 L 7 2 3O 3 O A7CE E7CE 1997051500420 19970515 00420 1997 5 15 97ZZZX2048 4 19970408 G 2562 ELT10 ELT NARCO PIPER PA28 PA28140 7102802 SO ANTENNA DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 NM 07 6475W 1000 53461 2820549 INSPECTION REVEALED POSSIBLE SHORTING OF PORTABLE ANTENNA. ANTENNA MAY BECOME DISLODGED FROM ITS HOLD AND SHORTING TO T HE BASE THROUGH THE LATCH. SUBMITTER STATED REMOVE PLASTIC PULL AND INSULATOR FROM THE OUTSIDE OF ANTENNA AND PLACE ON INSIDE TO INSULATE THE ANTENNA FROM THE CLIP. 1 L 7 1 3O 2A13 1997051500421 19970515 00421 SO 1997 5 15 97ZZZX2049 2 19970421 G 8530 648045 PISTON 646657C CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE WRONG PART D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 07 6480N 21063054 245650R UPON DISASSEMBLY OF ENGINE, FOUND WRONG PISTONS INSTALLED. RECORDS INDICATE PISTONS SOLD AS PART OF A TOP OVERHAUL KIT WITH CHROME CYLINDERS (4/1994). CYLINDERS REMOVED FOR GLAZING AND 3 PISTONS WERE SCORED ENOUGH TO REQUIRE REPLACEMENT. REPLACED ALL 6 WITH CORRECT SET OF BALANCED PISTONS. 1 H 7 1 3O 3 O 3A21 E8CE 1997051500422 19970515 00422 EA 1997 5 15 97ZZZX2050 2 19970422 G 8530 LW13561 CYLINDER PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA INTAKE PORT CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 01 82606 81 31P7730011 L55762 DURING MAINTENANCE WITH INTAKE PIPE REMOVED, INTAKE GUIDE WAS FOUND MOVING WITH THE VALVE. CYLINDER REPLACED, TEAR DOWN REPORT REQUESTED FROM ENGINE OVERHAULER. REPORT STATED A CRACK HAD CAUSED THE PROBLEM. OUT OF 4 ENGINES OF THIS TYPE MAINTAINED BY THIS FACILITY, THIS WAS THE 6TH CYLINDER WITH CRACKS IN INTAKE PORT AREA. ALL CYLINDERS WERE OVERHAULED A ND CHROMED. TIMES VARIED 81 AND 900 HOURS. 1 L 7 2 3O 3 O A8EA E19EA 1997051500423 19970515 00423 EA 1997 5 15 97ZZZX2051 2 19970422 G 8530 LW13561 CYLINDER PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA NR 1 CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 01 82606 81 31P7730011 RL36662 DURING ROUTINE MAINTENANCE, NR 1 AND NR 3 CYLINDERS WERE FOUND CRACKED IN THE INTAKE PORT AREA. CRACKS WERE BETWEEN FIR ST AND SECOND COOLING FINS FROM THE TOP AND PROGRESSED TO THE THINNER AREA OF THE PORT. CRACKS NOTED BY A GREENISH TO B LACK STAIN LOOKING FROM THE BOTTOM OF THE ENGINE. OF FOUR ENGINES OF THIS TYPE MAINTAINED BY THIS FACILITY, THESE ARE T HE 4TH AND 5TH WITH SIMILAR CRACKS. ALL CYLINDERS WERE OVERHAULED AND CHROMED. TIMES WERE 80 HRS AND APPROX 900 HRS SI NCE OVERHAUL. 1 L 7 2 3O 3 O A8EA E19EA 1997051500424 19970515 00424 EA 1997 5 15 97ZZZX2052 2 19970422 G 8530 LW13561 CYLINDER PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA NR 3 CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 01 82606 81 31P7730011 RL36662 DURING ROUTINE MAINTENANCE, NR 1 AND NR 3 CYLINDERS WERE FOUND CRACKED IN THE INTAKE PORT AREA. CRACKS WERE BETWEEN FIR ST AND SECOND COOLING FINS FROM THE TOP AND PROGRESSED TO THE THINNER AREA OF THE PORT. CRACKS NOTED BY A GREENISH TO B LACK STAIN LOOKING FROM THE BOTTOM OF THE ENGINE. OF FOUR ENGINES OF THIS TYPE MAINTAINED BY THIS FACILITY, THESE ARE T HE 4TH AND 5TH WITH SIMILAR CRACKS. ALL CYLINDERS WERE OVERHAULED AND CHROMED. TIMES WERE 80 HRS AND APPROX 900 HRS SI NCE OVERHAUL. 1 L 7 2 3O 3 O A8EA E19EA 1997051500425 19970515 00425 SO 1997 5 15 97ZZZX2053 2 19970428 G 7414 1051324 SPRING BLANCA 1419 14193 1220406 GL CONT O470 IO470F 17026 SO LT MAG BROKEN B QKKR K NONE O OTHER IN INSP/MAINT 1 CE 01 8838R 26 446018 4192 BOTH MAGNETOS OVERHAULED APRIL 1995. NEW SPRINGS INSTALLED. BOTH SPRINGS FOUND BROKEN INTO 3 PARTS. CAUSE APPEARED TO BE FROM CORROSION PITS LEADING TO STRESS POINTS. THE REPORT WAS THAT MOST HOURS WERE FLOWN SHORTLY AFTER OVERHAUL AND THEN AIRCRAFT SAT. THE SPRINGS WERE PURCHASED BY THIS CRS DURING JANUARY 10 TO MARCH 21, 1995 RECORDS. 1 L 7 1 3O 3 O 1A3 3E1 1997051500426 19970515 00426 SO 1997 5 15 97ZZZX2054 2 19970428 G 7414 1051324 SPRING BLANCA 1419 14193 1220406 GL CONT O470 IO470F 17026 SO RT MAG BROKEN B QKKR K NONE O OTHER IN INSP/MAINT 1 CE 01 8838R 26 441258 4192 BOTH MAGNETOS OVERHAULED APRIL 1995. NEW SPRINGS INSTALLED. BOTH SPRINGS FOUND BROKEN INTO 3 PARTS. CAUSE APPEARED TO BE FROM CORROSION PITS LEADING TO STRESS POINTS. THE REPORT WAS THAT MOST HOURS WERE FLOWN SHORTLY AFTER OVERHAUL AND THEN AIRCRAFT SAT. THE SPRINGS WERE PURCHASED BY THIS CRS DURING JANUARY 10 TO MARCH 21, 1995 RECORDS. 1 L 7 1 3O 3 O 1A3 3E1 1997052200056 19970522 00056 CE 1997 5 22 97ZZZX2059 1 19970414 G 5751 21992 BRACKET 5180 BBAVIA 8 8KCAB 2110612 CE LT/RT AILERON CRACKED D A K NONE O OTHER IN INSP/MAINT 1 GL 19 1126E 1169 30677 UPON INSPECTION FOR RECOVER PROCESS, FOUND BRACKET P/N 2-1992 AND RIB P/N 3-446 WERE CRACKED AT SPAR ATTACH. SL 404 COV ERS THIS SUBJECT FOR '7' SERIES AIRCRAFT WITH 1,000 'PLUS' HOURS, BUT DOES NOT INCLUDE '8' SERIES AIRPLANES. THIS CONDI TION FOUND ON BOTH AILERONS. AIRCRAFT HAS AILERON SPADES INSTALLED. 1 H 7 1 3O A21CE 1997052200057 19970522 00057 NE 1997 5 22 97ZZZX2060 2 19970415 G 8500 ENGINE BEECH 18 H18 1151012 CE PWA R985 R985AN14B 52008 NE MAIN BEARING SEIZED G E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 SW 11 117ME 420 BA638 16729 WHILE IN CRUSE FLIGHT, PILOT NOTICED OIL PRESSURE STARTING TO DECREASE AND OIL TEMP STARTING TO RISE. ENGINE WAS SECURE D, PROP WAS FEATHERED, AND A PRECAUTIONARY LANDING MADE. UPON LANDING, PILOT FOUND HE COULD NOT TURN PROP BY HAND. SUS PECT THAT THE MAIN BEARING FAILED. ENGINE HAD APPROXIMATELY 420 HOURS SINCE OVERHAUL. 1 L 7 2 3R 3 R A765 5E1 1997052200058 19970522 00058 EA 1997 5 22 97ZZZX2061 2 19970320 G 7314 154739506 FUEL PUMP BEECH 23 B19 1151215 CE LYC O320 O320E3D 41508 EA PART NUMBER MISIDENTIFIED D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 02 2048A MB904 L4828827A NEW FUEL PUMP INSTALLED ON OVERHAULED ENGINE. DURING INITIAL RUN-UP, FUEL STREAMED OUT OF CARBURETOR. CARB RPLD WITH R E-MFG'D ONE AND PERFORMED IN LIKE MANNER. WHILE T/S, FOUND FUEL PUMP ONE OF A WRONG P/N, AND CAME FROM 'A' SUPPLIER IN ORIG TEXTRON LYC CONTAINER MARKED FUEL PUMP P/N LW-15472 WHICH IS NUMBER ENGINE REQUIRES (4-6 PSI). ACTUAL PART INSTAL LED SHOWED P/N 154739506 (25-35 PSI). FOUND FLOAT CRUSHED ON BOTH REMFG'D CARBS INSTALLED. CHECKING STOCK REVEALED ON E P/N 154739506 INSTALLED IN ORIG SEALED CONTAINER MARKED LW15472. SUBMITTER SUSPECTED HIGHER PRESSURE FUEL PUMPS CAUSE D FLOAT TO BE CRUSHED. RECOMMEND WHEN RECEIVING PARTS FOR STOCK, ENSURE EXTERIOR MARKED P/N IS SAME AS INTERIOR PART. 1 L 7 1 3O 3 O A1CE E274 1997052200059 19970522 00059 CE 1997 5 22 97ZZZX2062 1 19970501 G 5700 STRUCTURE BEECH 18 H18 1151012 CE WS 111-102 CRACKED B NI2R K NONE O OTHER IN INSP/MAINT 1 CE 03 26035 BA754 AD 75-27-09 PERFORMED ON OUTBOARD WING AT WS 111 AND WS 102. X-RAYS REVEALED LINEAR INDICATIONS AT WS 111 AND CORROSION AT WS 102. FILMS SENT TO BEECHCRAFT FOR FURTHER EVALUATION. THIS WING NOT YET ATTACHED TO AN AIRCRAFT. IT WAS PURCHA SED AS A SERVICEABLE SPARE. THE ACFT IDENTIFICATION ON THIS FORM IS FOR THE ACFT THE WING MAY BE USED ON. 1 L 7 2 3R A765 1997052200060 19970522 00060 SO 1997 5 22 97ZZZX2063 1 19970429 G 3240 A8504 VALVE GERDES PIPER PA22 PA22 7102202 SO PARKING BRAKE CABLE MISRIG D A K NONE O OTHER IN INSP/MAINT 1 NM 11 3461A 221735 AFTER REPAIRS TO BELLY, LANDING GEAR, AND ENGINE, THE FIRST GROUND RUN WAS PERFORMED. THE LEFT BRAKE LOCKED UP AND WOUL D NOT RELEASE. THE INVESTIGATION REVEALED THE PARK BRAKE RELEASED THE RIGHT BRAKE, BUT WOULD NOT FULLY RELEASE THE LEFT BRAKE. THE REMEDY WAS TO SECURE THE PARK BRAKE CABLE END CLOSER TO THE BRAKE VALVE CONTROL ARM MAKING THE ACTUATION OF THE PARK BRAKE VALVE MUCH MORE POSITIVE ALL THE WAY TO THE STOPS. 1 H 7 1 3O 1A6 1997052200061 19970522 00061 1997 5 22 97ZZZX2064 4 19970419 G 2210 0655011 ACCELEROMETER KING KFC200 PIPER PA31 PA31350 7103110 SO AUTOPILOT MALFUNCTION H K NONE O OTHER IN INSP/MAINT 1 AL 03 4082T 593 1109 318152089 AUTOPILOT WOULD KICK OFF IN STRAIGHT AND LEVEL FLIGHT WITH NO TURBULENCE. ALSO, THE ACCELEROMETER WOULD NOT TEST PROPER LY IN THE UP POSITION. 1 L 7 2 3O A20SO 1997052200062 19970522 00062 CE 1997 5 22 97ZZZX2065 1 19970429 G 3213 25410835 METERING TUBE 25411001 CESSNA 303 T303 2073820 CE LT STRUT BROKEN D A O OTHER J WARNING INDICATION CL CLIMB 1 NM 04 4095V 10142 T30300275 AFTER TAKEOFF, PILOT ELECTED GEAR UP. GEAR CYCLED UP NORMALLY . AT END OF CYCLE, AUDIBLE 'BANG' HEARD. PILOT SELECTE D DOWN AND GEAR EXTENDED WITH ONLY RT MAIN AND NOSE GEAR GREEN LIGHTS . LT MAIN GEAR STUCK UP IN WHEELWELL. NUMEROUS ATTEMPTS MADE TO EXTEND LT MLG. PILOT RETRACTED LANDING GEAR, FEATHERED, AND CAGED BOTH ENGINES, BELLIED ACFT ON NORMAL RUNWAY. INVESTIGATION REVEALED METERING TUBE INSIDE LT STRUT BROKE AT A MACHINED HOLE IN SHAFT. THIS ALLOWED LOWER PO RTION OF SHOCK STRUT BARREL TO OVEREXTEND AND COME OUT OF UPPER BARREL DUE TO CHARGE INSIDE STRUT. RECOMMENDATION: NDT OF METERING TUBE INSIDE SHOCK STRUT AT SOME GIVEN INTERVAL UPON ACCUMULATION OF 'X' AMOUNT OF HOURS. 1 L 7 2 3O A34CE 1997052200063 19970522 00063 CE 1997 5 22 97ZZZX2066 1 19970411 G 2710 05117862 CABLE CLAMP CESSNA 185 A185F 2072821 CE AILERON BOLT DETACHED D A K NONE F FLT CONT AFFECTED NR NOT REPORTED 1 NM 11 61423 2180 18504180 BOLT AND NUT WHICH HOLD CLAMP ON AILERON CABLE SWEGE TO PULLEY FELL OUT ON COCKPIT FLOOR ALLOWING AILERON CONTROL CABLE TO SLIP AROUND CONTROL COLUMN CENTER PULLEY. THIS CAUSED PARTIAL LOSS OF AILERON CONTROL. 1 H 7 1 3O 3A24 1997052200064 19970522 00064 CE 1997 5 22 97ZZZX2067 1 19970401 G 3211 24411001 PIVOT ASSY CESSNA 172 172RG 2072438 CE MAIN GEAR CRACKED D A K NONE K FLUID LOSS IN INSP/MAINT 1 NE 03 64332 4263 172RG0694 PIVOT ASSY CRACKED BETWEEN THE SPLINED END AND THE INTERNAL PASSAGE WAY THAT SUPPLIES THE BRAKE WITH FLUID. PART WOULD ONLY LEAK DURING GEAR EXTENSION AND WHEN APPLYING BRAKES ON ROLL-OUT. 1 H 7 1 3O 3A17 1997052200066 19970522 00066 CE 1997 5 22 97ZZZX2069 1 19970507 G 3230 12700341 SWITCH CESSNA 210 T210F 2073422 CE NLG SAFETY INTERMITTENT G A K NONE O OTHER NR NOT REPORTED 1 SW 99 10GM 4600 T2100151 WIRES TO SAFETY SWITCH CHAFED AND WORN INTERNALLY; ALLOWED GEAR TO RETRACT WITHOUT SWITCH BEING OPERATED. CAUSED NOSE G EAR TO RETRACT WITH INSUFFICIENT STRUT CHARGE. GEAR WOULD NOT EXTEND FOR LANDING. 1 H 7 1 3O 3A21 1997052200067 19970522 00067 CE 1997 5 22 97ZZZX2070 1 19970414 G 5712 3446 RIB 5180L BBAVIA 8 8KCAB 2110612 CE LT/RT AILERON CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 19 1126E 1169 30677 UPON INSPECTION FOR RECOVER PROCESS, FOUND BRACKET P/N 2-1992 AND RIB P/N 3-446 CRACKED AT SPAR ATTACH. SL 404 COVERS T HIS SUBJECT FOR '7' SERIES AIRCRAFT WITH 1,000 'PLUS' HOURS, BUT DOES NOT INCLUDE '8' SERIES AIRCRAFT, THIS CONDITION FO UND ON BOTH AILERONS. AIRCRAFT HAS AILERON SPADES INSTALLED. 1 H 7 1 3O A21CE 1997052200069 19970522 00069 CE 1997 5 22 97ZZZX2072 1 19970422 G 5311 1054200111 FRAME BEECH 76 76 1153005 CE BS 94 RT CRACKED B BF8R K NONE O OTHER IN INSP/MAINT 1 WP 07 3812C 6835 ME390 FORWARD SPAR ATTACH BRACKET AT STA 94.0 LEFT AND RIGHT SIDES. DURING ROUTINE INSPECTION, A CRACK WAS FOUND IN THE LOWER PORTION OF THE UPPER RADIUS FOR THE FORWARD SPAR SLOT CUT-OUT. LEFT FRAME WAS CRACKED .3750 INCH LONG, RT FRAME FOUND CRACKED .0625 INCH LONG. CAUSE: APPEARED TO BE STRESS RELEASE CRACK. ACT: 6,835.2 HOURS. 1 L 7 2 3O A29CE 1997052200070 19970522 00070 CE 1997 5 22 97ZZZX2073 1 19970422 G 5311 1054200111 FRAME BEECH 76 76 1153005 CE BS 94 LT CRACKED B S BF8R K NONE O OTHER IN INSP/MAINT 1 WP 07 3812C 6835 ME390 FORWARD SPAR ATTACH BRACKET AT STA 94.0 LEFT AND RIGHT SIDES. DURING ROUTINE INSPECTION, A CRACK WAS FOUND IN THE LOWER PORTION OF THE UPPER RADIUS FOR THE FORWARD SPAR SLOT CUT-OUT. LEFT FRAME WAS CRACKED .3750 INCH LONG, RT FRAME FOUND CRACKED .0625 INCH LONG. CAUSE: APPEARED TO BE STRESS RELEASE CRACK. ACT: 6,835.2 HOURS. 1 L 7 2 3O A29CE 1997052200072 19970522 00072 SO 1997 5 22 97ZZZX2075 1 19970502 G 8120 LW31S444 BOLT PIPER PA31 PA31350 7103110 SO TURBO MOUNT SHEARED D A K NONE O OTHER IN INSP/MAINT 1 AL 03 59829 317685081 TURBO MOUNT BOLT LOWER INBOARD AND OUTBOARD AND GETS LOOSE USUALLY AFTER 100 HOURS FLYING TIME. SUBMITTER RECOMMENDS TH E BOLT BE CHANGED FROM COURSE THREAD TO FINE THREAD WITH LOCKNUT. 1 L 7 2 3O A20SO 1997052200074 19970522 00074 CE 1997 5 22 97ZZZX2077 1 19970422 G 5311 1054200111 FRAME BEECH 76 76 1153005 CE BS 94 RT CRACKED B S BF8R K NONE O OTHER IN INSP/MAINT 1 WP 07 6636Z ME253 FORWARD SPAR ATTACH BRACKET AT STA 94.0, RT SIDE. DURING A ROUTINE INSPECTION, A CRACK WAS FOUND IN THE LOWER PORTION O F THE UPPER RADIUS FOR THE FORWARD SPAR SLOT CUT-OUT (APPROXIMATELY .25 INCH LONG). CAUSE: APPEARED TO BE STRESS RELEA SE CRACK. ACT: 7,538 HOURS. 1 L 7 2 3O A29CE 1997052200075 19970522 00075 CE 1997 5 22 97ZZZX2078 1 19970421 G 5730 SKIN CESSNA 340 340A 2076405 CE LT WING LE CORRODED B A DJFR K NONE O OTHER IN INSP/MAINT 1 EA 23 6826Y 340A1216 LUMPS OBSERVED UNDER WING DE-ICE BOOT AND BOOT COMING UNGLUED. DE-ICE BOOT WAS REMOVED AND SEVERE CORROSION FOUND. COR ROSION WAS REMOVED AND TREATED. WING SKIN REPAIRED WITH AN EXTERNAL DOUBLER BONDED INTO PLACE. SUGGEST BOOT REMOVAL FO R INSPECTION ANY TIME LUMPS ARE FOUND UNDER DE-ICE BOOT OR WHEN BOOT HAS COME UNGLUED AND MOISTURE HAS ENTERED BETWEEN W ING AND BOOT. 1 L 7 2 3O 3A25 1997052200077 19970522 00077 CE 1997 5 22 97ZZZX2080 1 19970401 G 5311 1054200111 FRAME BEECH 76 76 1153005 CE BS 94 LT CRACKED B BF8R K NONE O OTHER IN INSP/MAINT 1 WP 07 92ER ME425 FORWARD SPAR ATTACH BRACKET AT STA 94.0, LEFT SIDE. DURING A ROUTINE INSPECTION, A CRACK WAS FOUND IN THE LOWER PORTION OF THE UPPER RADIUS FOR THE FORWARD SPAR SLOT CUT-OUT (APPROXIMATELY .1250 INCH LONG). CAUSE: APPEARED TO BE STRESS R ELEASE CRACK. ACTT: 4,396.0 HOURS. 1 L 7 2 3O A29CE 1997052200078 19970522 00078 CE 1997 5 22 97ZZZX2081 1 19970408 G 2720 50150068 TORQUE TUBE CESSNA 401 401A 207590D CE RUDDER BROKEN G L A O OTHER O OTHER LD LANDING 1 SW 09 671AW 401A0080 PILOT EXPERIENCED LANDING DIFFICULTIES. UPON INSPECTION OF FLIGHT CONTROLS, TECHNICIAN DISCOVERED RUDDER CABLE ATTACH F ITTING BROKEN OFF OF THE LT CONTROL TORQUE TUBE ASSY. MAGNAFLUX INSPECTION OF THE RT TORQUE TUBE ASSY REVEALED IT CRACK ED AT THE EDGE OF THE WELD IN SAME LOCATION. PROBLEM BELIEVED TO BE CAUSED BY USE OF THE INSIDE RUDDER LOCK ASSY, P/N S Z15027-1-11 OR DASH 13, PUTTING UNDUE STRESS ON TORQUE TUBE ASSY. RECOMMEND USE OF AN OUTSIDE RUDDER LOCK AND A ONE-TIM E INSPECTION OF TORQUE TUBE ASSY. ACFT REF: PAGE 2-406, FIG 116, INDEX -3 RT, -13 LT. 1 L 7 2 3O A7CE 1997052200079 19970522 00079 CE 1997 5 22 97ZZZX2082 1 19970409 G 2710 35524664 BUNGEE SPRING BEECH 33 F33A 1151425 CE AILERON BROKEN D K NONE O OTHER IN INSP/MAINT 1 WP 07 8268T CE1547 PILOT REPORTED A LOUD POPPING SOUND AND A BIND IN THE RUDDER PEDALS. A MECHANIC PERFORMED ROUTINE INSPECTION AND FOUND UPPER FORWARD RUDDER AILERON BUNGEE SPRING HAD BROKEN IN HALF ON THE CLIP END SIDE. SUBMITTER SUGGESTED DURING ROUTINE 100-HOUR ANNUAL PROGRESSIVE INSPECTION, TO PAY CLOSE ATTENTION TO THIS AREA. 1 L 7 1 3O 3A15 1997052200471 19970522 00471 CE 1997 5 22 97ZZZX2085 1 19970430 G 5280 508201837 HINGE BEECH 200 B200 1152922 CE NLG DOOR CRACKED H A K NONE O OTHER IN INSP/MAINT 1 AL 03 575T BB1384 NOSE GEAR DOOR HINGE CRACKED AT RIVET HOLE ON INBOARD SIDE. SUSPECT CAUSE IS THAT THE HINGE IS .75 INCH THICK WITH AN O VERSIZE -4 CHERRY MAX RIVET HOLDING IT TOGETHER. ALL THE RIVET HOLES ON THE HINGE DECREASE THE AMOUNT OF METAL LEFT ON THE HINGE AT THE RIVET HOLES. THE HINGE NEEDS TO BE REDESIGNED WITH THICKER EARS. 1 L 7 2 4T A24CE 1997052200474 19970522 00474 CE 1997 5 22 97ZZZX2088 1 19970422 G 3240 1206P27 SWITCH CESSNA 500 550 2076604 CE PWR BRAKE PUMP FAILED D A K NONE O OTHER IN INSP/MAINT 1 SW 03 2737K 2430 5500595 THIS SWITCH IS THE CONTROL FOR THE POWER BRAKE PUMP. IT FAILS IN THE ELECTRICALLY 'OPEN' POSITION AND THE PUMP FAILS TO RUN CREATING A NO BRAKES CONDITION. SUBMITTER STATED IN LOOKING AT PAST RECORDS FOR THE LAST 5 YEARS, HAVE CHANGED THI S P/N SWITCH 5 TIMES IN FLEET OF 4 C-550'S. (CESSNA P/N 38-581-501). 1 L 7 2 4F A22CE 1997052200479 19970522 00479 NE 1997 5 22 97ZZZX2093 2 19970429 G 7314 GB3173CE FUEL PUMP FOKKER F27 F27MK500 4990629 EU RROYCE DART DART5327R 54509 NE LEFT ENGINE SHAFT SHEARED C A A UNSCHED LANDING Y ENGINE STOPPAGE CL CLIMB 1 SO 33 709FE 4839 10375 14206 ON CLIMB-OUT OF LCK, THE LEFT ENGINE AUTOFEATHERED. THE CREW DECLARED AN EMERGENCY AND RETURNED TO LCK WITH NO FURTHER PROBLEMS. THE MECHANIC FOUND A SHEARED SHAFT ON THE FUEL PUMP. THE ENGINE CHECKED GOOD IAW THE FOKKER MM AFTER THE FUE L PUMP WAS REPLACED. 2 H 7 2 4T 4 T A817 E297 1997052200480 19970522 00480 NE 1997 5 22 97ZZZX2094 2 19970206 G 7250 ENGINE FOKKER F27 F27MK500 4990629 EU RROYCE DART DART5327R 54509 NE LT ENG TURB DAMAGED C A E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 SO 33 721FE 18430 3054 10460 14727 EWR/YMX - EN ROUTE, THE LEFT ENGINE STARTED TO AUTOFEATHER. THE LEFT ENGINE TEMP STARTED TO RISE, THE FLIGHT CREW THEN MANUALLY FEATHERED THE PROP. THE CREW DECLARED AN EMERGENCY AND WAS CLEARED TO LAND IN ALB. THE PILOT TRIED TO RESTART THE ENGINE, BUT IT WOULD NOT START. THE AIRCRAFT LANDED WITHOUT ANY OTHER PROBLEMS. A MAINTENANCE CREW WAS DISPATCHED TO ALB FOR THE ENGINE CHANGE. 2 H 7 2 4T 4 T A817 E297 1997052200482 19970522 00482 1997 5 22 97ZZZX2096 4 19970429 G 3422 1426200314 GYRO SIGMATEK 46981E DIRECTIONAL GYRO SHORTED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 01 EXCITATION WIRE SHORTED TO CHASIS GROUND CAUSING THE HEADING OUTPUT TO BE INOPERABLE. SUBMITTER SUGGESTS TO INSULATE WI RE BUNDLE FROM CHASIS DURING THE ROUTING OF THE BUNDLE. 1997052200483 19970522 00483 EA 1997 5 22 97ZZZX2097 2 19970502 G 8530 SL139973 RETAINER KEY LYC O360 O360* 41514 EA CYLINDER KIT MISMANUFACTURED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 15 KEY NOT CUT ON ONE SIDE. PART IS IN A COMPLETE POWER SECTION. NEW CYLINDER KIT S/N 97-2806. 3 O E286 1997052200485 19970522 00485 SO 1997 5 22 97ZZZX2098 2 19970401 G 7322 63255424 LEVER 649052A2 BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO FUEL CONTROL MISINSTALLED D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 DURING ROUTINE MAINTENANCE, FUEL INJECTION ASSY FOUND LOOSE. OF THE 3 BOLTS THAT ATTACH THIS TO THE THROTTLE CONTROL AS SY, 2 BOLTS MISSING, 1 LOOSE. ASSY ABOUT TO BREAK LOOSE. ALSO, SHROUD P/N 646673 BROKEN AND LOOSE, AND CHAFING ON FUEL LINE FITTINGS. FITTINGS WERE CHAFED OVER 50 PERCENT THROUGH SIDE WALL THICKNESS. APPEARS TO BE CAUSED BY THROTTLE LE VER BEING INSTALLED INCORRECTLY AND HITTING ASSY AND SHROUD CAUSING PRESSURE AND SHEARING OF THE BOLTS. ALSO, FULL TRAV EL OF THE THROTTLE WAS IMPAIRED. 1 L 7 2 3O 3 O 3A16 E5CE 1997052200486 19970522 00486 CE 1997 5 22 97ZZZX2099 1 19970430 G 5312 05121593 BULKHEAD CESSNA 172 172M 2072418 CE V FIN ATTACH MISINSTALLED D S K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 25 29501 8042 17264117 VERTICAL FIN AFT SPAR TO BULKHEAD CLEARANCE EXCESSIVE. MAXIMUM CLEARANCE .070 INCH PER CESSNA 172 SM. P/N 0512159-3 IN STALLED INCORRECTLY OR MACHINED INCORRECTLY BY FACTORY AT LOWER HOLE MACHINE FACE. MISSING .090 INCH OF MATERIAL. FIXE D BY INSTALLING .090 INCH 204T3 SHIM ON BULKHEAD 0512159-3 AFT FACE. 1 H 7 1 3O NT 3A12 1997052200487 19970522 00487 SO 1997 5 22 97ZZZX2100 1 19970429 G 7160 VALVE MAULE MX7 MX7180 5460185 SO CARBURETOR HEAT SCREWS SHEARED D S A K NONE O OTHER IN INSP/MAINT 1 NM 10 3110Y 423 20024C DURING AN ANNUAL INSPECTION, THE CARBURETOR HEAT DIVERTER VALVE WAS FOUND SHEARED FROM THE CONTROL SHAFT. TWO 8-32 SCRE WS WITH SELF-LOCKING NUTS SECURE THE VALVE TO THE CONTROL SHAFT IN THE CARB AIR INTAKE BOX. 1 H 7 1 3O NC 3A23 1997052200488 19970522 00488 SW 1997 5 22 97ZZZX2101 1 19970429 G 2810 DRAIN BBAVIA 8 8GCBC 1220803 SW FUEL TANK LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 NE 01 106EB 36 38497 ALL FOUR FUEL TANK QUICK DRAINS WERE FOUND LEAKING. INVESTIGATION REVEALED ALL OF THE DRAIN SEALS HAD BECOME CLOGGED WI TH ALUMINUM SHAVINGS BELIEVED TO BE FROM THE TANK MANUFACTURING PROCESS. ALSO NOTED THE ALUMINUM DEBRIS HAD BEGUN TO BU ILD UP IN THE MAIN FUEL STRAINER. SUBMITTER RECOMMENDS DRAIN AND FLUSH OF FUEL SYSTEM AND REVIEW OF MANUFACTURING PROCE SS QUALITY CONTROL. 1 H 7 1 3O A21CE 1997052200489 19970522 00489 CE 1997 5 22 97ZZZX2102 1 19970427 G 3230 42104 CONTROL CABLE 5972730 CESSNA 185 185D 2072812 CE GEAR RETRACT BROKEN D K NONE O OTHER IN INSP/MAINT 1 SO 09 285BG 120 1850798 BROKEN CABLE P/N 42104 ON GEAR RETRACT. CABLE BROKE AT AFT END. SUSPECT CAUSE FROM RUST. 1 H 7 1 3O 3A24 1997052200490 19970522 00490 CE 1997 5 22 97ZZZX2103 1 19970428 G 7110 J74444 MOUNT LORD CESSNA 172 172N 2072434 CE COWL MOUNT SEPARATION D A K NONE O OTHER NR NOT REPORTED 1 SW 07 3056E 12 17271423 AIRCRAFT WAS TEST FLOWN AFTER ANNUAL INSPECTION. DURING FLIGHT AT AIRSPEED 10 KNOTS LESS THAN REDLINE, THE 6 LOWER COWL MOUNTS FAILED AT THE BONDED AREA TO THEIR BACKING PLATE. THE COWL CONTACTED THE SPINNER BULKHEAD WITH MINOR DAMAGE. S TILL HAVE 2 NEW MOUNTS PURCHASED AT THE SAME TIME AS THE ONES THAT FAILED. THEY ARE STAMPED WITH THE PROPER NUMBERS AND CURE DATE, HOWEVER, THE LAST 2 DIGITS OF P/N ARE OF A LARGER SIZE NUMBER THAN THE REST OF THE P/N'S. 1 H 7 1 3O NT 3A12 1997052200496 19970522 00496 CE 1997 5 22 97ZZZX2109 1 19970422 G 2730 0510105350 CONTROL CABLE CESSNA 182 R182 2072734 CE ELEVATOR UP WORN D K NONE O OTHER IN INSP/MAINT 1 NM 01 5131T 3314 R18201821 DURING ANNUAL INSPECTION, 'UP' ELEVATOR CABLE, P/N 0510105-350, FOUND SEVERELY WORN, MANY STRANDS WORN THROUGH AT PULLEY , FS 156.00. CABLE 'BUZZES' ON THIS PULLEY DURING FLIGHT. PULLEY ACTS AS FAIRLEAD; CABLE DEFLECTION ONLY A FEW DEGREES . PULLEY COULD BE DELETED, CABLE WOULD RUN STRAIGHT AND TRUE WITHOUT BEING DAMAGED. 1 H 7 1 3O RT 3A13 1997052200497 19970522 00497 EA 1997 5 22 97ZZZX2110 2 19970428 G 8520 CONNECTING ROD CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA NR 3 CYLINDER DETACHED D A UNSCHED LANDING E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CR CRUISE 1 SW 07 757CH 700 15279629 L1736815 PILOT EXPERIENCED RPM DROP, LOSS OF OIL PRESSURE, AND ROUGHNESS. LANDED ON CITY STREET. NO AIRCRAFT DAMAGE. FOUND OIL APPARENTLY EXHAUSTED THROUGH CRANKCASE BREATHER. NR 4 CYLINDER PISTON BURNED THROUGH AFT SIDE UNDER RINGS .3750 INCH H OLE. NR 3 CYLINDER CONNECTING ROD BROKEN LOOSE AT END CAP. PUNCTURED BOTTOM OF CRANKCASE. NOTE: APPROX 8 FLIGHT HOUR S PREVIOUSLY, CYLINDER COMPRESSION CHECKS WERE ALL IN THE MID 70'S, OVER 80. 1 H 7 1 3O 3 O NT 3A19 E223 1997052200498 19970522 00498 EA 1997 5 22 97ZZZX2111 2 19970428 G 8530 PISTON CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA NR 4 CYLINDER BURNED D A UNSCHED LANDING E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CR CRUISE 1 SW 07 757CH 700 15279629 L1736815 PILOT EXPERIENCED RPM DROP, LOSS OF OIL PRESSURE, AND ROUGHNESS. LANDED ON CITY STREET. NO AIRCRAFT DAMAGE. FOUND OIL APPARENTLY EXHAUSTED THROUGH CRANKCASE BREATHER. NR 4 CYLINDER PISTON BURNED THROUGH AFT SIDE UNDER RINGS .3750 INCH H OLE. NR 3 CYLINDER CONNECTING ROD BROKEN LOOSE AT END CAP. PUNCTURED BOTTOM OF CRANKCASE. NOTE: APPROX 8 FLIGHT HOUR S PREVIOUSLY, CYLINDER COMPRESSION CHECKS WERE ALL IN THE MID 70'S, OVER 80. 1 H 7 1 3O 3 O NT 3A19 E223 1997052200505 19970522 00505 CE 1997 5 22 97ZZZX2118 1 19970428 G 2730 MD4615M ROD END HEIM BEECH 35 S35 1151532 CE RUDDERVATOR WORN D K NONE O OTHER IN INSP/MAINT 1 SO 13 8604Q 2100 D7635 WHILE PERFORMING AD 97-06-11, ALL 4 RUDDERVATOR ROD ENDS WERE FOUND WORN AND ONE WITH CORROSION. SB NR 2668 PERTAINS TO THIS SUBJECT. 1 L 7 1 3O 3A15 1997052200506 19970522 00506 CE 1997 5 22 97ZZZX2119 1 19970430 G 5312 07125281 BULKHEAD CESSNA 182 182N 2072730 CE BS 230.187 CRACKED D K NONE O OTHER IN INSP/MAINT 1 NE 01 92391 3993 18260184 DURING ROUTINE INSPECTION, CRACKS DETECTED IN UPPER LEFT BULKHEAD FLANGE RADIUS ABOVE RUDDER STOP. SUBJECT IS COVERED B Y CESSNA SL 72-3 AND AD 72-07-09. SUSPECT CAUSE IS YEARS OF RUDDER STOP CONTACT. SUBMITTER STATED THIS TYPE OF CRACK M AY BE ELIMINATED BY THE USE OF EXTERNAL CONTROL LOCKS. 1 H 7 1 3O NT 3A13 1997052200507 19970522 00507 SO 1997 5 22 97ZZZX2120 2 19970423 G 7414 M917 SPRING SLICK 662 CESSNA 210 T210L 2073449 CE CONT O520 TSIO520H 17040 SO IMPULSE COUPLING BROKEN D K NONE O OTHER IN INSP/MAINT 1 NM 01 93377 7110441 21060381 TROUBLESHOOTING OF 400 RPM MAG DROP FOUND LEFT MAGNETO TIMING AT 7 DEGREES BTC. REMOVED MAG AND FOUND IMPULSE COUPLING SPRING BROKEN TWO INCHES FROM OUTER END. 1 H 7 1 3O 3 O 3A21 E8CE 1997052200527 19970522 00527 GL 1997 5 22 97ZZZX2123 2 19970401 G 7230 23005250 COMPRESSOR BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL SCROLL CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 09 255EV 6506 51488 89550 DURING ROUTINE VISUAL INSPECTION FOUND COMPRESSOR SCROLL CRACKED AT 7:00 O'CLOCK POSITION LOOKING FORWARD. 1 G 7 1 3U 3 U H2SW E1GL 1997052900186 19970529 00186 SW 1997 5 29 97ZZZX2293 1 19970416 G 6310 206050222005 SHAFT BELL 206 206B 1181511 SW FREEWHEEL. WORN B GS1R K NONE O OTHER IN INSP/MAINT 1 EA 03 206SB 442 4214 INSPECTION FOUND FREEWHEEL SHAFT INNER RACE SEAL AREA WORN. REPLACED WITH NEW SHAFT. 1 G 7 1 3U H2SW 1997052900187 19970529 00187 SW 1997 5 29 97ZZZX2294 1 19970304 G 6720 206010795101 PITCH LINK BELL 206 206L1 1182107 SW T/R CRACKED D A K NONE O OTHER IN INSP/MAINT 1 WP 23 73MM 45180 DURING PRE-FLIGHT INSPECTION, A CRACK WAS FOUND ON THE TAIL ROTOR PITCH CHANGE LINK ADJACENT TO THE BEARING. SUSPECT CA USE MAY HAVE BEEN DUE TO OUT OF BALANCE TAIL ROTOR ASSEMBLY. 1 G 7 1 3U H2SW 1997052900188 19970529 00188 EU 1997 5 29 97ZZZX2295 1 19970425 G 3233 1090500103 ACTUATOR AGUSTA A109 A109A 0260109 EU NLG DEFECTIVE D K NONE J WARNING INDICATION NR NOT REPORTED 1 WP 03 613AC 2458 7205 PILOT NOTICED UTILITY HYDRAULIC POWER CYCLING EXCESSIVELY. GROUND RETRACT TEST SHOWED PROBLEM ONLY ON UPSIDE, ISOLATING THE PROBLEM TO NOSE GEAR ACTUATOR. RESEALED THE PISTON O-RING. SUBSEQUENT RETRACTION TESTS AND FLIGHT, OK. SUBMITTER NOTE: A60STA TB 109.62 - LUBRICATION OF NOSE GEAR ACTUATOR C/W EVERY 900 HRS OR 3 YEARS DOES NOT ADDRESS THIS AREA. I T WOULD BE ADVISEABLE TO RESEAL THIS PISTON SEAL AT THIS TIME. 1 G 7 2 3U H7EU 1997052900189 19970529 00189 SW 1997 5 29 97ZZZX2296 1 19970402 G 6720 500N71123 LINK HUGHES 500N 500N 3027374 SW PEDAL CONTROL BEARING LOCK UP G K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 WP 07 OPERATOR REPORTS LINK BEARING ASSY HAS LIMITED LIFE DUE TO LOCKING UP OF BEARINGS CAUSES PILOT TO HAVE ERRATIC PEDAL CON TROL HARD PEDALS, CAM, OVERSCARRING OF CLEVIS AT GEARING. AT PRESENT, NO GREASING PER MDHC. S/N'S NOTED LN001 THROUGH LN007. 1 G 7 1 3U NC H3WE 1997052900190 19970529 00190 SW 1997 5 29 97ZZZX2297 1 19970506 G 3340 A402A LENS HUGHES 500N 500N 3027374 SW STROBE CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 OPERATOR HAS EXPERIENCED 5 EACH STROBE LENSES CRACKED AT SEAM LINE. ALL OCCURRED ON S/N'S LN001 THROUGH LN007. 1 G 7 1 3U NC H3WE 1997052900191 19970529 00191 SW 1997 5 29 97ZZZX2298 1 19970423 G 5312 369H2532 RING ASSY HUGHES 500N 500N 3027374 SW FS 137.50 CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 521FB 5700 LN001 RIGHT LOWER 137.50 BULKHEAD RING ASSY CRACKED 1 INCH UP AND COMPLETELY THROUGH SKIN ATTACH TURN-BACK. THIS CRACK IS REL ATED TO FLOAT LIGHT INSTALLATION. 1 G 7 1 3U NC H3WE 1997052900192 19970529 00192 SW 1997 5 29 97ZZZX2299 1 19970423 G 5313 369A250015 STRINGER HUGHES 500N 500N 3027374 SW AFT ENG BAY CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 521FB 5700 LN001 FIRST STRINGER LEFT OF CENTER KEEL CRACKED AT AFT END 1.50 INCHES. THIS CRACKING APPEARS TO BE RELATED TO FLOAT LIGHT M OUNTING PROCEDURES. 1 G 7 1 3U NC H3WE 1997052900193 19970529 00193 SW 1997 5 29 97ZZZX2300 1 19970423 G 5313 369A250016 STRINGER HUGHES 500N 500N 3027374 SW AFT END ENG BAY CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 521FB 5700 LN001 STRINGER CRACKED APPROXIMATELY 1.50 INCHES LONG AT AFT END. FIRST STRINGER TO RIGHT OF KEEL AT CENTER. THIS CRACKING A PPEARS TO BE RELATED TO FLOAT LIGHT MOUNTING PROCEDURE. 1 G 7 1 3U NC H3WE 1997052900194 19970529 00194 SW 1997 5 29 97ZZZX2301 1 19970407 G 5302 500N31307 BRACE HUGHES 500N 500N 3027374 SW NOTAR STA 137 LOOSE G K NONE O OTHER IN INSP/MAINT 1 WP 07 522FB 5252 LN002 UPON CHANGING FAN DRIVESHAFT, FOUND NOTAR DIAGONAL BRACE LOOSE. WORKING RIVETS BETWEEN FITTING 500N3130-3 AND TUBE 500N 3122 AT STA 137.5. 1 G 7 1 3U NC H3WE 1997052900195 19970529 00195 SW 1997 5 29 97ZZZX2302 1 19970402 G 7810 369A8230519 EXHAUST HUGHES 500N 500N 3027374 SW RT EXHAUST STACK CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 522FB 400 LN002 LOWER END AFT OF RT STACK CRACKED APPROXIMATELY 2 INCHES ON BOTTOM STARTING AT END TRAVELING THROUGH REINFORCEMENT RIDGE THEN CURVING TOWARD OUTBOARD SIDE OF MAIN BODY OF STACK. 1 G 7 1 3U NC H3WE 1997060300001 19970603 00001 SW 1997 6 3 97ZZZX2303 1 19970423 G 3340 A402A LENS WHELEN HUGHES 500N 500N 3027374 SW LOWER STROBE CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 524FB 73 LN004 LOWER AFT STROBE LENS CRACKED AND SEPARATED AT SEAM. 1 G 7 1 3U NC H3WE 1997052900196 19970529 00196 SW 1997 5 29 97ZZZX2304 1 19970423 G 3340 A402A LENS WHELEN HUGHES 500N 500N 3027374 SW STROBE CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 525FB 18 LN005 LOWER STROBE LENS CRACKED ON SEAM. FOUND ON MORNING WALK-AROUND POST-FLIGHT INSPECTION. ACFT HRS 4,727.6. 1 G 7 1 3U NC H3WE 1997052900197 19970529 00197 SW 1997 5 29 97ZZZX2305 1 19970414 G 6322 500N711311 TUBE ASSY HUGHES 500N 500N 3027374 SW FAN TRANSMISSION BINDING G K NONE O OTHER IN INSP/MAINT 1 WP 07 526FB 7347 LN006 INSPECTION FOUND SPLINES WORN AT SPIDER END. ROD BENT AT SPLINES. 1 G 7 1 3U NC H3WE 1997052900198 19970529 00198 SW 1997 5 29 97ZZZX2306 1 19970414 G 3340 A402A LENS WHELEN HUGHES 500N 500N 3027374 SW STROBE CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 525FB 85 LN005 FOUND LOWER AFT STROBE LENS CRACKED AT SEAM. 1 G 7 1 3U NC H3WE 1997052900199 19970529 00199 SW 1997 5 29 97ZZZX2307 1 19970411 G 6322 500N71163 SUPPORT HUGHES 500N 500N 3027374 SW FAN TRANSMISSION WORN G K NONE O OTHER IN INSP/MAINT 1 WP 07 526FB 4748 LN006 FOUND FAN TUBE SUPPORT WORN BY FAN POSITION PUSH ROD. SPLINED TEETH IN SUPPORT GUIDE WORN EXCESSIVELY. 1 G 7 1 3U NC H3WE 1997052900200 19970529 00200 SW 1997 5 29 97ZZZX2308 1 19970506 G 6710 A21810064603 SWITCH HUGHES 500N 500N 3027374 SW PILOT TRIM FAILURE G A O OTHER F FLT CONT AFFECTED CR CRUISE 1 WP 07 526FB 216 LN006 RUNAWAY TRIM TO THE RIGHT FOUND DURING FLIGHT. 1 G 7 1 3U NC H3WE 1997052900201 19970529 00201 SW 1997 5 29 97ZZZX2309 1 19970410 G 6230 206010336005 BEARING BELL 206 206L1 1182107 SW M/R WORN B ZV1R K NONE O OTHER IN INSP/MAINT 1 SW 03 FOUND EXCESSIVE PLAY AT TWO PLACES, SEE BELL MM L-3 FIG 62.21. AT TEAR DOWN FOUND BEARINGS AND SPACERS WORN BEYOND LIMI TS. TOTAL TIME OF PARTS LESS THAN 1,000 HRS/1 YEAR SINCE REPLACEMENT. REPLACED 5 EACH. 1 G 7 1 3U H2SW 1997052900249 19970529 00249 SW 1997 5 29 97ZZZX2310 1 19970414 G 2140 20608516 SILENCER ASSY BELL 206 206L3 1182108 SW HEATER CORRODED B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 17592 4689 51535 HEATER SILENCER HAS CORROSION AT INLET AREA AND OUTER SHIELD WHERE BLEED AIR TUBE SUPPORT PLATE IS ATTACHED. 1 G 7 1 3U H2SW 1997052900250 19970529 00250 SW 1997 5 29 97ZZZX2311 1 19970422 G 5302 2060313291035 FITTING BELL 206 206L3 1182108 SW TAIL BOOM LT CRACKED B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 17592 4689 51535 TAIL BOOM LT ATTACH FITTING FOUND CRACKED ON PHASE B (320 HR) INSPECTION. REPLACED FITTING. 1 G 7 1 3U H2SW 1997052900251 19970529 00251 SW 1997 5 29 97ZZZX2312 1 19970401 G 6220 206310005101 BOLT BELL 206 206L3 1182108 SW M/R HEAD MISSING B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 53702 8117 51249 ROTOR HEAD BOLT THAT HOLDS THE PILLOW BLOCK IN PLACE FOUND MISSING. FOUND DURING PMI ON 3-22-97. REPLACED BOLT AND TOR QUED ON MAIN ROTOR PILLOW BLOCK. 1 G 7 1 3U H2SW 1997052900252 19970529 00252 NE 1997 5 29 97ZZZX2313 1 19970416 G 6210 761509100043A BLADE SKRSKY S76 S76 8143010 NE M/R DISBONDED B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 5402T 11432 760140 MAIN ROTOR BLADE S/N AC86-00479 HAS AREAS OF DISBOND ON LOWER SIDE SKIN JUST AFT OF TITANIUM LEADING EDGE. FIRST AREA I S 47.50 INCHES OUTBOARD OF ROOT END AND IS APPROXIMATELY 13 INCHES BY 1 INCH. SECOND AREA IS 201 INCHES OUTBOARD OF ROO T END AND APPROXIMATELY 8 INCHES BY 1 INCH. 1 G 7 2 3U H1NE 1997052900253 19970529 00253 NE 1997 5 29 97ZZZX2314 1 19970416 G 6210 7615009100042A BLADE SKRSKY S76 S76 8143010 NE M/R DISBONDED B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 5402T 10584 A08600655 760140 MAIN ROTOR BLADE S/N A086-00655 HAS AREA OF DISBOND ON UPPER SIDE SKIN JUST OUTBOARD OF THE ROOT END LAMINATE APPROXIMAT ELY 6 INCHES BY 6 INCHES AT A PREVIOUS REPAIR C/W BY SIKORSKEY 20.50 INCHES OUTBOARD FROM ROOT END APPROXIMATELY 2 INCHE S FORWARD OF TRAILING EDGE. 1 G 7 2 3U H1NE 1997052900270 19970529 00270 SW 1997 5 29 97ZZZX2331 1 19970414 G 6220 369A10053 DAMPER PIN HUGHES 500N 500N 3027374 SW M/R HEAD FAILED G K NONE O OTHER IN INSP/MAINT 1 WP 07 523FB 5100 LN003 M/R DAMPER PINS LOST EXPANSION CLAMP UP. WILL NOT ADJUST TO HOLD DURING FLIGHT. 1 G 7 1 3U NC H3WE 1997052900271 19970529 00271 SW 1997 5 29 97ZZZX2332 1 19970411 G 6322 500N71163 SUPPORT HUGHES 500N 500N 3027374 SW FAN TRANSMISSION WORN G K NONE O OTHER IN INSP/MAINT 1 WP 07 523FB LN003 FOUND FAN TUBE SUPPORT WORN. GUIDE TEETH WORN FROM FAN PUSH ROD. 1 G 7 1 3U NC H3WE 1997052900296 19970529 00296 SO 1997 5 29 97ZZZX2333 2 19970429 G 7322 104894 CARBURETOR CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO MIX NEEDLE DEFECTIVE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 03 1413Q 4021425 15072713 INSTALLED OVERHAULED CARBURETOR. WOULD NOT MEET MINIMUM STATIC RPM OF 2,500 RPM. ANOTHER NEW CARBURETOR MET RPM. OLD UNIT OBSERVED IDLE MIXTURE NEEDLE AS TOO SHORT. VENTURI NUT CENTERED. SAFETY WIRE SLOPPY. 1 H 7 1 3O 3 O 3A19 E252 1997052900297 19970529 00297 SO 1997 5 29 97ZZZX2334 2 19970510 G 8520 CRANKSHAFT BEECH 33 F33A 1151425 CE CONT O520 IO520BA 17032 SO JOURNAL 3-4 BROKE D A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 SW 05 1890W 4500 1421 CE447 122913R CRANKSHAFT FAILED IN FLIGHT. BROKE THROUGH SHORT CHECK AREA BETWEEN ROD JOURNALS 3 AND 4. ENGINE FROZE IN FLIGHT. 1 L 7 1 3O 3 O 3A15 E5CE 1997052900298 19970529 00298 CE 1997 5 29 97ZZZX2335 1 19970502 G 5553 04310082 FITTING CESSNA 150 150H 2071818 CE V FIN ATTACH CORRODED D K NONE O OTHER IN INSP/MAINT 1 GL 03 22172 3802 15068115 INSPECTION FOUND VERTICAL FIN ATTACH FITTING WITH INTERGRANULAR CORROSION. SUBMITTER STATED SINCE THIS DEFECT IS CAUSED BY IMPROPER QUENCHING, THERE MAY BE MORE IN SERVICE THAT WERE HEAT TREATED IN THAT BATCH. 1 H 7 1 3O 3A19 1997052900299 19970529 00299 CE 1997 5 29 97ZZZX2336 1 19970502 G 5553 04310081 FITTING CESSNA 150 150H 2071818 CE V FIN ATTACH CORRODED D K NONE O OTHER IN INSP/MAINT 1 GL 03 22172 3802 15068115 INSPECTION FOUND VERTICAL FIN ATTACH FITTING WITH INTERGRANULAR CORROSION. SUBMITTER STATED SINCE THIS DEFECT IS CAUSED BY IMPROPER QUENCHING, THERE MAY BE MORE IN SERVICE THAT WERE HEAT TREATED IN THAT BATCH. 1 H 7 1 3O 3A19 1997052900300 19970529 00300 EA 1997 5 29 97ZZZX2337 2 19970429 G 7310 76292 DIAPHRAGM VALVE LW13889 PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA FUEL PRESS LOOSE B A EKIR K NONE Y ENGINE STOPPAGE NR NOT REPORTED 1 WP 07 252MA 3433 297 31P33 RL48862 SCREW THAT SECURES NEEDLE VALVE TO DIAPHRAGM IN FUEL PRESSURIZATION VALVE CAME LOOSE ALLOWING NEEDLE VALVE TO COME LOOSE WHICH SHUT ENGINE DOWN. SCREW STILL HAD EVIDENCE OF LOC-TITE ON THREADS. SUSPECT THAT FUEL MAY HAVE SOFTENED LOC-TITE WHICH ALLOWED SCREW TO BACK OUT. 1 L 7 2 3O 3 O A8EA E19EA 1997052900301 19970529 00301 SO 1997 5 29 97ZZZX2338 1 19970401 G 7120 MOUNT PIPER PA46 PA46310P 7104605 SO ENGINE CRACKED B S MZER K NONE O OTHER IN INSP/MAINT 1 GL 15 286CM 1626 468608043 FOUND ENGINE MOUNT CRACKED IN 3 SPOTS. NOTE: SL 1001 HAD BEEN C/W PREVIOUSLY. 1 L 7 1 3O A25SO 1997052900302 19970529 00302 EA 1997 5 29 97ZZZX2339 2 19970429 G 7322 MA4SPA CARBURETOR FACET PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA THROTTLE SHAFT FROZE G K NONE O OTHER IN INSP/MAINT 1 SW 99 47717 287816126 L3589927A THROTTLE SHAFT FROZE IN BUSHINGS. POSSIBLE RESULT OF PREVIOUS INSTALLATION OF THROTTLE SHAFT KIT. UNABLE TO DETERMINE EXACT CAUSE. 1 L 7 1 3O 3 O 2A13 E274 1997052900303 19970529 00303 CE 1997 5 29 97ZZZX2340 1 19970505 G 3222 12430097 TRUNNION CESSNA 210 T210N 2073456 CE NLG STRUT CRACKED D S K NONE O OTHER IN INSP/MAINT 1 EA 23 5154A 3894 21063289 DURING ANNUAL INSPECTION, THE NOSE GEAR STRUT LOWER TRUNNION WAS FOUND CRACKED AT BOTH EARS WHERE THE VERTICAL BRACES AR E ATTACHED. THE CRACKS STARTED AT THE FWD END AND TRAVELED AFT .250 INCH ON THE RIGHT AND .125 INCH ON THE LEFT EAR. N OSE STEERING TURN LIMIT DOWEL PIN WAS ALSO FOUND BROKEN OFF. CESSNA SINGLE ENGINE SB SEB 94-19 DETAILS INSPECTION REQUI REMENTS AND REPLACEMENT PROCEDURES FOR THE LOWER TRUNNION WITH A NEW (PN 1243402-15) STRENGTHENED TRUNNION. AS IS NOTED IN THE SB, AGGRESSIVE TOWING AND THE NOSE WHEEL BEING TURNED BEYOND ITS LIMITS CAN BE THE CAUSES OF THIS DAMAGE. THE L OWER TRUNNION WAS REPLACED AND TOW LIMIT INDICATORS APPLIED PER SEB 94-19 INSTRUCTIONS. 1 H 7 1 3O 3A21 1997052900304 19970529 00304 EA 1997 5 29 97ZZZX2341 2 19970501 G 8520 LW13885 BEARING PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA FRONT MAIN DETERIORATED B PAWR K NONE O OTHER IN INSP/MAINT 1 EA 17 521WA 86 317752103 L227268A AT INSPECTION, AN OIL CHANGE WAS BEING STARTED AND FOUND METAL SHAVINGS IN SUMP SCREEN AND FILTER. ENGINE WAS REMOVED A ND SENT TO OVERHAUL FACILITY FOR TEAR DOWN AND INSPECTION. PRELIMINARY INSPECTION REPORT REVEALED FRONT MAIN CRANKSHAFT BEARING FAILURE. 1 L 7 2 3O 3 O A20SO E14EA 1997052900305 19970529 00305 SO 1997 5 29 97ZZZX2342 1 19970430 G 5347 62557004 SEAT RAIL PIPER PA28 PA28140 7102802 SO RT OUTBOARD CORRODED D A K NONE O OTHER IN INSP/MAINT 1 NM 01 6072W 3298 2820085 RIGHT OUTBOARD SEAT TRACK SEVERELY CORRODED UNDER LIP OF TRACK. SUSPECT CAUSE OF CORROSION WAS TRAPPED WATER IN THE CAR PET FROM ENTRY INTO AIRCRAFT. ALSO, CARPET WAS NOT OF AIRCRAFT QUALITY OR TYPE (HOME SHAG CARPET). TO PREVENT RECURREN CE OF CORROSION, INSPECT CARPET AND REPLACE IF NOT AIRCRAFT QUALITY AND CAREFULLY INSPECT SEAT RAIL MORE FREQUENTLY AND REMOVE AND TARGET ANY CORROSION FOUND. 1 L 7 1 3O 2A13 1997052900306 19970529 00306 SO 1997 5 29 97ZZZX2343 2 19970511 G 8530 639222 CYLINDER CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO NR 1 CYLINDER HEAD SEPARATED D A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 GL 05 727NE 511 U20605152 570521 CYLINDER HEAD SEPARATED FROM BARREL IN FLIGHT. PILOT NOTICED ROUGH ENGINE AND MADE PRECAUTIONARY LANDING. FAILED CYLIN DER WAS 'LIGHT' CASTING WHILE OTHER FIVE WERE 'HEAVY' CASTING. HEAD SEPARATION ALSO CAUSED FUEL LINE SEPARATION AND EXH AUST Y-PIPE DAMAGE. ENGINE HAD 511 HOURS SINCE OVERHAUL BY SHOP IN CANADA. POSSIBLE CAUSE OF FAILURE, INTERNAL CORROSIO N BETWEEN BARREL AND HEAD THREADS. 1 H 7 1 3O 3 O A4CE E5CE 1997052900307 19970529 00307 SO 1997 5 29 97ZZZX2344 1 19970419 G 2821 2245800 STRAINER GASKET PIPER PA24 PA24250 7102404 SO FUEL STRAINER LEAK D K NONE K FLUID LOSS IN INSP/MAINT 1 GL 25 8209P 46 243461 REPLACED FUEL STRAINER SCREEN/GASKET IN MARCH, 1996 WITH PN 22458-00 PURCHASED FROM PIPER. DURING ANUAL INSPECTION, FOU ND FUEL STRAINER SEEPING AROUND CLAMP. UNABLE TO STOP SEEP WITH NEW CLAMP. THE DISTANCE BETWEEN BOWL ASSY AND COVER IN THE GASKET AREA IS .040 INCH. THE 22458-00 SCREEN/GASKET ALSO MEASURED .040 INCH. THIS DID NOT LET THE CLAMP PULL THE COVER AND BOWL TOGETHER ON THE GASKET TIGHT ENOUGH TO PREVENT LEAKING. A NEW FAA/PMA SCREEN/GASKET FROM WEBCO AIRCRAFT , PN W22458-000, MEASURED .068 INCH AND SEALED THE FUEL STRAINER WITH NO LEAKS. PIPER AIRCRAFT REP STATED REQUIRED DIME NSIONS FOR THIS GASKET WERE NOT AVAILABLE FROM PIPER AS IT IS PROPRIETARY. 1 L 7 1 3O 1A15 1997052900308 19970529 00308 CE 1997 5 29 97ZZZX2345 1 19970205 G 3260 GEAR WARN CESSNA 340 340A 2076405 CE RT MLG MALFUNCTION D K NONE P NO WARNING INDICATION NR NOT REPORTED 1 SW 99 8618G 340A0708 RIGHT GEAR LIGHT MALFUNCTION DUE TO SUSPECTED MICROSWITCH STICKING ON RIGHT GEAR (GEAR WAS FULLY DOWN AND LOCKED WHEN RT GEAR LIGHT STILL NOT OPERATING). ACFT WAS JACKED UP/GEAR CYCLED. FAULT COULD NOT BE REPLICATED, BUT MICROSWITCH AND G EAR RE-OILED AND LUBRICATED. 1 L 7 2 3O 3A25 1997052900309 19970529 00309 CE 1997 5 29 97ZZZX2346 1 19970509 G 2730 081400010 BRACKET CESSNA 310 310R 2074245 CE ELEV BELLCRANK ELONGATED HOLES D K NONE O OTHER IN INSP/MAINT 1 SO 19 98870 5640 310R0626 DURING 100 HOUR INSPECTION, NOTED EXCESSIVE PLAY/SLOPE OF ELEVATOR, FURTHER INSPECTION REVEALED ELONGATED BOLT HOLES AT LOCATION WHERE ELEVATOR BELLCRANK PIVOT BOLT IS SECURED AT THE BELLCRANK SUPPORT BRACKETS, BOLT HOLES LOCATED ON SUPPOR T BRACKETS WERE ELONGATED APPROX .75 INCH. THESE SUPPORT BRACKETS ARE LOCATED AT THE MOST AFT BULKHEAD OF TAIL ASSY. S USPECT CAUSE MAY BE IMPROPER RIGGING OF ELEVATOR CONTROL CABLES (TOO TIGHT). MAYBE THESE BRACKETS CAN BE REINFORCED AT BOLT HOLES BY CESSNA. 1 L 7 2 3O 3A10 1997052900310 19970529 00310 CE 1997 5 29 97ZZZX2347 1 19970509 G 2730 081400011 BRACKET CESSNA 310 310R 2074245 CE ELEV BELLCRANK ELONGATED HOLES D A K NONE O OTHER IN INSP/MAINT 1 SO 19 98870 5640 310R0626 DURING 100 HOUR INSPECTION, NOTED EXCESSIVE PLAY/SLOP OF ELEVATOR, FURTHER INS PECTION REVEALED ELONGATED BOLT HOLES AT LOCATION WHERE ELEVATOR BELLCRANK PIVOT BOLT IS SECURED AT THE BELLCRANK SUPPORT BRACKETS, BOLT HOLES LOCATED ON SUPPORT BRACKETS WERE ELONGATED APPROX .75 INCH. THESE SUPPORT BRACKETS ARE LOCATED AT THE MOST AFT BULKHEAD OF TAIL ASSY. SU SPECT CAUSE MAY BE IMPROPER RIGGING OF ELEVATOR CONTROL CABLES (TOO TIGHT). MAYBE THESE BRACKETS CAN BE REINFORCED AT B OLT HOLES BY CESSNA. 1 L 7 2 3O 3A10 1997052900312 19970529 00312 CE 1997 5 29 97ZZZX2349 1 19970328 G 5711 SPAR BEECH 18 AT11 1150202 CE RT WING CORRODED B UF7R K NONE O OTHER IN INSP/MAINT 1 WP 05 1214 HEAVY CORROSION FOUND DURING ROUTINE INSPECTION OF MAIN SPAR. ALSO, 2 CRACKS .1250 INCH LONG IN THE WELD AT RIGHT WS 64 . 1 L 7 2 3R A2582 1997052900317 19970529 00317 CE 1997 5 29 97ZZZX2353 1 19970523 G 3230 TRANSMISSION PIPER PA24 PA24180 7102402 CE MLG COVER FAILED G K NONE O OTHER NR NOT REPORTED 1 EA 07 7678P 2315 242889 TRANSMISSION COVER (AS REFERENCED IN PIPER PA-24-180 SM SECTION 6, FIG 6-13, ITEM 7), FAILED BY CRACKING AROUND ATTACHME NT LUG. LUG BECAME LIBERATED FROM REMAINING PORTION OF COVER. FAILURE CAUSED LANDING GEAR TO NOT LOCK IN DOWN POSITION . SUBMITTER RECOMMENDS PAYING PARTICULAR ATTENTION TO THIS AREA DURING INSPECTION OR REPAIR. FAILURE COULD BE INDUCED BY HARD LANDING OR IMPROPER GEAR RIGGING. 1 L 7 1 3O NT 1A15 1997052900318 19970529 00318 1997 5 29 97ZZZX2354 1 19970207 G 2410 696233B CSD GOVERNOR SUPPORT WRONG BOLT H K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 17 FOUND INCORRECT HARDWARE INSTALLED IN GOVERNOR BEARING SUPPORT. BOLTS INSTALLED ARE P/N MS 948925. THIS IS CONTRARY TO THE OEM MANUAL. OEM APPROVED HARDWARE FOR THIS INSTALLATION IS P/N 0645-1024-28UDK. 1997052900319 19970529 00319 1997 5 29 97ZZZX2355 1 19970506 G 3241 1400252 TRANSDUCER WHEEL SPEED DEFECTIVE D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 EU 01 15494 08688 DEFECTIVE CRIMPING FOUND ON WHEEL SPEED TRANSDUCER DURING WORKSHOP INVESTIGATION. UNIT REMOVED FROM AIRCRAFT G-CIVC ON MAY 6 1997. FOR AN 'ANTI-SKID ADVISORY', MESSAGE ON AIRCRAFT'S CENTRAL MAINTENANCE COMPUTER. FIRST VISIT OF UNIT TO W ORKSHOPS DEFECTIVE CRIMP POSSIBLY OCCURRED DURING MANUFACTURE. ADDITIONAL CHECK ADDED TO CHECK CRIMP INTEGRITY. 1997052900272 19970529 00272 CE 1997 5 29 97ZZZX2356 1 19970502 G 3222 10180211P STRUT BEECH 100 B100 1152919 CE NLG CRACKED D A K NONE O OTHER IN INSP/MAINT 1 GL 25 187J BE24 NOSE LANDING GEAR STRUT UPPER BODY CASTING HAS A CRACK FROM THE LEFT LOWER GREASE FITTING TO THE BOTTOM OF THE BODY CAST ING. A DISTANCE OF .3125 INCH LONG. SUBMITTER ADVISES OTHERS TO CHECK THIS AREA. 1 L 7 2 4T A14CE 1997052900273 19970529 00273 NE 1997 5 29 97ZZZX2357 2 19970520 G 7260 R1309P140 O RING 2CM82JIB GE CF700 CF7002D 30010 NE START/GEN DRIVE LEAK G A UNSCHED LANDING K FLUID LOSS NR NOT REPORTED 1 GL 05 304220B THE PILOT RETURNED AFTER 30 MINUTES DUE TO OIL PRESSURE AND OIL QUANTITY LOSS ON NR 2 ENGINE. AN INVESTIGATION REVEALE D THE O-RING SEAL (ACCESS 'C') ON THE DRIVE END OF THE STARTER/GENERATOR HAD APPARENTLY BECOME DAMAGED DURING INSTALLATI ON 3 HOURS PREVIOUSLY. SPECIAL CARE SHOULD BE TAKEN DURING INSTALLATION OF THE SEAL AND A THOROUGH LEAK CHECK (ENGINE R UN) AFTER INSTALLATION OF THE STARTER/GENERATOR. 4 F E7EA 1997052900275 19970529 00275 SO 1997 5 29 97ZZZX2359 1 19970305 G 5414 1159P20504 FAIRING GULSTM G1159 G1159 3953505 SO LT PYLON DELAMINATED D K NONE D INFLIGHT SEPARATION CR CRUISE 1 WP 01 21AM 110 LOWER LEFT PYLON SKIN MISSING. SKIN DELAMINATED FROM HONEYCOMB AND APPARENTLY CAME OFF IN FLIGHT. APPROXIMATE SIZE OF SKIN IS 12 INCHES BY 36 INCHES. LOWER RIGHT PYLON SKIN INSPECTED AND FOUND PARTIALLY DELAMINATED. LEFT SKIN REPLACED, RIGHT SKIN REPAIRED. IF THIS IS NOT AN ISOLATED INCIDENT, THE MANUFACTRER NEEDS TO IMPROVE LAMINATING PROCESS CONTROL A ND REQUIRE MORE FREQUENT INSPECTIONS OF THIS AREA. 2 L 7 2 4F RT A12EA 1997052900277 19970529 00277 EU 1997 5 29 97ZZZX2360 1 19970404 G 3213 200463301 UPPER MEMBER FOKKER F27 F27MK500 4990629 EU MLG CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 33 724FE 10677 INSPECTION FOUND MLG UPPER MEMBER CRACKED. PART TOTAL CYCLES, 56,096. PART TSO CYCLES, 6,712. (X) 2 H 7 2 4T A817 1997052900279 19970529 00279 CE 1997 5 29 97ZZZX2361 1 19970501 G 5210 511151515 HINGE CESSNA 441 441 2076020 CE CABIN DOOR CRACKED B S A WTXR K NONE O OTHER IN INSP/MAINT 1 NM 07 800YM 4781 4410266 WHILE AIRCRAFT WAS IN HANGAR FOR MAINTENANCE, LOWER CABIN DOOR, AFT HINGE BROKE IN TWO. BREAK WAS ALIGNED WITH THREE RI VETS THAT WERE ADDED TO C/W SB PJ 81-21. EVIDENCE OF PREVIOUS CRACKING WAS VISIBLE. NEW HINGE WAS INSTALLED. 1 L 7 2 3T RT A28CE 1997052900280 19970529 00280 CE 1997 5 29 97ZZZX2362 1 19970502 G 2120 651532627 VALVE ASSY CESSNA 500 S550 2076607 CE PRESS DUCT WORN H A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 GL 07 92QS 9435 S5500092 WHEN CLIMBING OUT OF 31,000 FEET, A LOUD BOOM WAS HEARD IN THE REAR OF AIRCRAFT. CABIN ALTITUDE ROSE AT 5,000 FPM. EME RGENCY DESCENT INITIATED AND AIRCRAFT LANDED AT PIT. TAIL CONE PRESSURIZATION DUCT BLOWN OFF AT CONNECTOR TO WATER SEPA RATOR. BEADING ON FLOOD COOLING VALVE WORN. CONNECTOR P/N SS4-300 AND SLEEVE P/N U50-300SS ALSO WORN. RECOMMEND PERIO DIC CHECKS FOR SECURITY AND SERVICEABILITY OF VALVE AND CLAMP/CONNECTOR SLEEVE ASSEMBLY. 1 L 7 2 4F RT A22CE 1997052900281 19970529 00281 EU 1997 5 29 97ZZZX2363 1 19970418 G 2150 12501605BSC COMPRESSOR BRAERO DH125 BAE125800A 1500285 EU AUX AIR COND SYS EXPLODED B A UA2R K NONE O OTHER IN INSP/MAINT 1 SW 15 98 4026 258156 DURING INITIAL START-UP OF AIR CONDITIONER TO ACCOMPLISH SERVICING THE COMPRESSOR EXPLODED. THIS DESTROYED THE HONEYCOM B COVER, DAMAGED THREE STRINGERS AND PUNCTURED HOLE IN FUSELAGE. 2 L 7 2 4F RT A3EU 1997052900282 19970529 00282 SW 1997 5 29 97ZZZX2364 1 19970501 G 5730 SKIN SWRNGN SA227 SA227TT SW LT WING CHAFED B W6NR K NONE O OTHER IN INSP/MAINT 1 GL 25 99JW 4836 TT450 DURING AN ENGINE EXHAUST PIPE FAIRING CHANGE, DISCOVERED A STEEL BRAIDED FUEL VENT LINE HAD CHAFED INTO THE TOP SKIN OF THE LEFT WING NEAR THE EXHAUST PIPE. THE CHAFED AREA WAS 1.25 INCHES LONG, .4375 INCH WIDE BY .017 INCH DEEP. FAIRCHIL D ENGINEERING DETERMINED THIS WAS STILL SERVICEABLE. RECOMMEND THIS AREA BE INSPECTED ASAP. 2 L 7 2 4T RT A5SW 1997052900283 19970529 00283 NM 1997 5 29 97ZZZX2365 1 19970507 G 2150 758073102 HOUSING R72EC53A DHAV DHC8 DHC8* NM ACM TURBINE MISMODIFIED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 05 880416 REF. FR26481. AIR LEAKING AROUND FORWARD CASE. AFTER EVALUATION AND ANALYSIS, DETERMINED ACM HOUSING HAD UNAUTHORIZED MODIFICATION DONE OUTSIDE OF HAMILTON STANDARD. IT WAS MODIFIED FROM A R72/EC53A HOUSING (MILITARY APPLICATION ONLY) T O ACCOMODATE R80/EC35A PARTS AND COMPONENTS. 2 H 7 2 4T RT A13NM 1997052900284 19970529 00284 CE 1997 5 29 97ZZZX2366 1 19970502 G 7120 909100141 MOUNT BEECH 100 B100 1152919 CE ENGINE TRUSS CHAFED D K NONE O OTHER IN INSP/MAINT 1 GL 25 187J 3894 BE24 DURING ROUTINE INSPECTION, DISCOVERED THE RIGHT ENGINE MOUNT TRUSS HAD BEEN CHAFED BEYOND ALLOWABLE LIMITS IN TWO PLACES BY A NR 8 STAINLESS STEEL HARD OIL SCAVAGE RETURN LINE. SUBMITTER ADVISES OTHERS WITH KA-B-100'S TO CHECK THIS AREA OF MOUNT TRUSS. THE CHAFED AREA WAS IN THE FORWARD BOTTOM AND OUTBOARD PORTION OF THE U-SHAPED PART. 1 L 7 2 4T A14CE 1997052900285 19970529 00285 SW 1997 5 29 97ZZZX2367 1 19970501 G 5620 WINDOW GULSTM 690TP 690A 0141722 SW CABIN DAMAGED B W6NR K NONE O OTHER IN INSP/MAINT 1 GL 25 80TB 5676 11300 DURING A ROUTINE 100-HOUR INSPECTION, DISCOVERED FIVE OF THE CABIN AND COCKPIT PLASTIC SIDE OUTER WINDOW PANELS HAD MELT ED AND DETERIORATED DEPRESSIONS ALONG THE BOTTOM HORIZONTAL EDGES WHERE THE WINDOW MEETS THE AIRFRAME. THE SUSPECTED CA USE IS FROM PAINT STRIPPER CONTACTING THE PLASTIC WINDOWS. 1 H 7 2 3T 2A4 1997052900286 19970529 00286 CE 1997 5 29 97ZZZX2368 1 19970502 G 2612 FIRE LOOP BEECH 200 200BEECH 1152920 CE ENGINE CONTAMINATED B L ABOR K NONE N FALSE WARNING IN INSP/MAINT 1 GL 15 83GA BB518 INTERMITTENT FIRE WARNING ON START-UP. TROUBLESHOOTING REVEALED THAT SUSPECT CAUSE IS MOISTURE CONTAMINATION OF FIRE LO OP DETECTORS. 1 L 7 2 4T A24CE 1997052900287 19970529 00287 1997 5 29 97ZZZX2369 4 19970501 G 2210 SWITCH SWRNGN SA227 SA227TT SW YAW DAMPENER MISWIRED B A W6NR K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 25 99JW 4836 TT450 DURING THE PROCESS OF TROUBLESHOOTING A YAW DAMPENER PROBLEM, DISCOVERED THE POSITION OF THE SWITCH (RIGHT OR LEFT),INDI CATING FROM WHICH BUS IT RECEIVED POWER, WAS REVERSED. CORRECTED THIS CONDITION AND ASSUMED THE AIRCAFT HAS BEEN WIRED THIS WAY SINCE IT WAS MANUFACTURED. 2 L 7 2 4T RT A5SW 1997052900288 19970529 00288 SW 1997 5 29 97ZZZX2370 1 19970501 G 5414 2735166905 FAIRING SWRNGN SA227 SA227TT SW RT EXHAUST CHAFED B W6NR K NONE O OTHER IN INSP/MAINT 1 GL 25 99JW 4836 TT450 BOTH LEFT AND RIGHT ENGINE EXHAUST PIPE FAIRINGS WERE FOUND CHAFED COMPLETELY THROUGH THE LOWER PORTION OF THE SEAL AND INNER FLANGE OF THE FAIRINGS. THIS WAS DISCOVERED DURING THE NORMAL A AND B LETTER CHECK INSPECTION. 2 L 7 2 4T RT A5SW 1997052900289 19970529 00289 SW 1997 5 29 97ZZZX2371 1 19970501 G 5414 2735166906 FAIRING SWRNGN SA227 SA227TT SW LT EXHAUST CHAFED B W6NR K NONE O OTHER IN INSP/MAINT 1 GL 25 99JW 4836 TT450 BOTH LEFT AND RIGHT ENGINE EXHAUST PIPE FAIRINGS WERE FOUND CHAFED COMPLETELY THROUGH THE LOWER PORTION OF THE SEAL AND INNER FLANGE OF THE FAIRINGS. THIS WAS DISCOVERED DURING THE NORMAL A AND B LETTER CHECK INSPECTION. 2 L 7 2 4T RT A5SW 1997052900290 19970529 00290 SW 1997 5 29 97ZZZX2372 1 19970501 G 3243 VI151125 MASTER CYLINDER SWRNGN SA227 SA227TT SW BRAKE LEAKING B W6NR K NONE K FLUID LOSS IN INSP/MAINT 1 GL 25 99JW TT450 DURING A ROUTINE AND B LETTER CHECK, FOUND BOTH PILOTS' LEFT AND RIGHT MASTER CYLINDERS LEAKING. BOTH CYLINDERS WERE RE PLACED. 2 L 7 2 4T RT A5SW 1997052900291 19970529 00291 GL 1997 5 29 97ZZZX2373 3 19970420 G 6114 HUB CESSNA 150 152 2071835 CE MCAULY 1A103 1A103TCM GL BOLT HOLE CRACKED H CB9T K NONE O OTHER IN INSP/MAINT 1 SW 15 6199Q 9361 5106 15288191 R775205 WHEN C/W AD 95-21-01, VISUAL INSPECTION OF PROPELLER HUB, A CRACK WAS FOUND FROM BOLT HOLE TO THE EDGE OF THE HUB APPROX IMATELY 1 INCH IN DEPTH. 1 H 7 1 3O NT 3A19 5 N P50GL 1997052900294 19970529 00294 SW 1997 5 29 97ZZZX2376 1 19970312 G 6310 212040687001 COUPLING BELL 412 412 1182202 SW MAIN DRIVE PITTED B VE3D K NONE O OTHER IN INSP/MAINT 1 WP 01 412WP 91 A4136 33170 ACFT TT 2,225.8 HOURS. ON A 6-MONTH (180 DAY) INSPECTION, M/D/SHAFT WAS REMOVED FOR INSPECTION AND REPACK OF GREASE COU PLINGS. BOTH INNER GEARS AND BOTH OUTER COUPLINGS WERE FOUND WITH CORROSION AND PITTING. TOTAL TIME ON M/D/SHAFT WAS 9 1.3 HOURS SINCE NEW AND 6 MONTHS SINCE INSTALLATION. BELL HELICOPTER WAS NOTIFIED AND NEW PARTS INSTALLED. 1 G 7 2 4U H4SW 1997060300003 19970603 00003 SW 1997 6 3 97ZZZX2377 1 19970503 G 2810 369A81205 CAP HUGHES 500N 500N 3027374 SW RT SIDE FUEL NO LOCK G A K NONE O OTHER IN INSP/MAINT 1 WP 07 521FB LN001 ACFT S/N LN001 THROUGH LN007 REPORTED 30 EACH FUEL CAPS HAVE WORN LOCK TABS AND REQUIRED REPLACEMENT. FUEL CAP WILL NOT LOCK PROPERLY. NO REPAIR CAP HAS TO BE CHANGED. 1 G 7 1 3U NC H3WE 1997052900295 19970529 00295 SW 1997 5 29 97ZZZX2378 1 19970503 G 2810 369A81205 CAP HUGHES 500N 500N 3027374 SW FUEL TANK FAILED G K NONE O OTHER IN INSP/MAINT 1 WP 07 521FB LN001 LOCK TAB ON FUEL CAP WORN AT CAM END. FUEL CAP WILL NOT LOCK PROPERLY. NO REPAIR. CAP MUST BE REPLACED. 1 G 7 1 3U NC H3WE 1997060500001 19970605 00001 NM 1997 6 5 97ZZZX2379 1 19970401 G 5311 FRAME BOEING 727 727230 1384080 NM BS 1090 S22L CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 357KP 20675 DURING C-CHECK INSPECTION, LEVEL 2 CORROSION WAS NOTED ON FORWARD FACE OF FRAME 1090 AND ON TOP OF THE FRAME EXTENDING F ROM S21L TO S22L. 2 L 7 3 4F A3WE 1997060500002 19970605 00002 NM 1997 6 5 97ZZZX2380 1 19970401 G 5311 FRAME BOEING 727 727230 1384080 NM BS 990 S22L CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 357KP 20675 DURING C-CHECK INSPECTION, LEVEL 2 CORROSION NOTED ON TOP CAP OF FRAME STA 990 AT S22L. 2 L 7 3 4F A3WE 1997060500003 19970605 00003 NM 1997 6 5 97ZZZX2381 1 19970401 G 5313 SRINGER BOEING 727 727230 1384080 NM BS 1030 S29R CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 357KP 20675 DURING C-CHECK INSPECTION, CORROSION NOTED ON S29R EXTENDING FROM STA 1030 TO STA 1050. 2 L 7 3 4F A3WE 1997060500004 19970605 00004 NM 1997 6 5 97ZZZX2382 1 19970401 G 5330 SKIN BOEING 727 727230 1384080 NM BS 950B-950C CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 357KP 20675 DURING C-CHECK INSPECTION, LEVEL 2 CORROSION NOTED ON INNER SKIN BETWEEN FS 950B AND STA 950C, AND BETWEEN S22L AND S23L . 2 L 7 3 4F A3WE 1997060500005 19970605 00005 NM 1997 6 5 97ZZZX2383 1 19970401 G 5313 STRINGER BOEING 727 727230 1384080 NM BS 950D S22L CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 357KP 20675 DURING C-CHECK INSPECTION, CORROSION NOTED ON S22L AT STA 950D. 2 L 7 3 4F A3WE 1997060500006 19970605 00006 NM 1997 6 5 97ZZZX2384 1 19970401 G 5311 FRAME BOEING 727 727230 1384080 NM BS 1010 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 357KP 20675 DURING C-CHECK INSPECTION, CORROSION NOTED ON FRAME 1010 BETWEEN S27R TO S26R. 2 L 7 3 4F A3WE 1997060500007 19970605 00007 NM 1997 6 5 97ZZZX2385 1 19970401 G 5311 FRAME BOEING 727 727230 1384080 NM BS 1166 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 357KP 20675 DURING C-CHECK INSPECTION, CORROSION NOTED ON FRAME 1166 BETWEEN S23L AND S22L. 2 L 7 3 4F A3WE 1997060500008 19970605 00008 NM 1997 6 5 97ZZZX2386 1 19970401 G 5311 FRAME BOEING 727 727230 1384080 NM BS 1130 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 357KP 20675 DURING C-CHECK INSPECTION, CORROSION NOTED ON FRAME 1130 EXTENDING FROM S21L TO S22L. 2 L 7 3 4F A3WE 1997060500009 19970605 00009 SW 1997 6 5 97ZZZX2387 1 19970502 G 6220 206011118001 BEARING 206011100147 BELL 206 206L3 1182108 SW M/R HUB FAILED B A LX5R K NONE O OTHER IN INSP/MAINT 1 GL 19 721LL 1168 A499 51164 AT DISASSEMBLY, FOUND BEARING BREAKING UP. ROLLERS WERE BROKEN AND GRINDING UP. THIS BEARING IS ONE OF TWO BETWEEN YOK E AND GRIP. 1 G 7 1 3U H2SW 1997060500294 19970605 00294 NE 1997 6 5 97ZZZX2476 1 19970209 G 6320 643520536101 MAIN SHAFT 643520500048 SKRSKY S64 S64F NE MGB SPLINES CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 158AC 2969 2199 55 64081 DURING O/H OF MGB, THE MAIN SHAFT WAS SUBJECTED TO A FMPI. ONE SPLINE FOUND CRACKED ACROSS THE SPLINE WIDTH ON UPPER EN D OF LOWER SPLINE. THE CRACK DID NOT APPEAR TO ORIGINATE WHERE THE LOWER PLANETARY SPLINE CONTACTS THE SHAFT, BUT WAS L OCATED APPROX 0.100 INCH ABOVE PLANETARY PLATE SPLINE CONTACT ZONE. THE CRACK EXTENDED FROM ROOF OF ONE SPLINE TOOTH TO THE ROOT OF ADJACENT SPLINE. APPROX 30 ADDITIONAL SPLINES HAD UNUSUAL CRACK-LIKE INDICATIONS IN ROOT RADIUS OF THE SPL INES. THESE INDICATIONS COULD NOT BE VERIFIED TO BE THE START OF CRACK. THE S HAFT IS BEING SENT TO A LAB FOR DESTRUCT IVE ANALYSIS OF THE CRACK AND ALL INDIC ATIONS. NOTE: THIS MDR PREVIOUSLY SUBMITTED, BUT INFO HAS BEEN CORRECTED. 2 G 7 2 4U H6EA 1997060500295 19970605 00295 NE 1997 6 5 97ZZZX2477 1 19970304 G 6320 643520536101 MAIN SHAFT 643520500048 SKRSKY S64 S64F NE MGB SPLINES CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 159AC 3428 2436 01 64084 MGB MAIN SHAFT INSPECTION. TWO SPLINES FOUND CONTAINING ONE INDICATION EACH. INDICATIONS LOCATED ON THE LOAD SIDE OF T HE SPLINE AND IN THE ROOT AREA. LENGTH OF INDICATIONS WERE APPROXIMATELY 0.100 INCH LONG. INDICATION DID NOT EXTEND ON TO THE TOOTH FACE OF SPLINE. INDICATIONS WERE FOUND DURING MPI INSPECTION. 2 G 7 2 4U H6EA 1997060500296 19970605 00296 NE 1997 6 5 97ZZZX2478 1 19970317 G 6320 643520536101 MAIN SHAFT 643520500048 SKRSKY S64 S64F NE MGB SPLINES CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 163AC 3473 338 65 64093 MGB MAIN SHAFT INSPECTION, CRACKS FOUND IN LOWER SPLINES. CRACKS APPEAR TO START IN SPLINE RADIUS AND TRAVEL AT 45 DEGR EES TOWARD THE SPLINE TOOTH. INDICATIONS ARE ON THE LOAD SIDE JUST AT OR BELOW ENGAGEMENT AREA. ELEVEN SPLINES WITH IN DICATIONS. LONGEST INDICATION IS 0.150 INCH LONG AND IS APPROXIMATELY 0.6 INCH BELOW THE TOP OF THE LOWER SPLINE. NOTE : THIS MDR PREVIOUSLY SUBMITTED, BUT INFORMATION HAS BEEN CORRECTED. 2 G 7 2 4U H6EA 1997060500298 19970605 00298 SW 1997 6 5 97ZZZX2480 1 19970430 G 6310 214040841101 SEAL BELL 206 206L4 1182110 SW FREEWHEEL LEAK D K NONE K FLUID LOSS IN INSP/MAINT 1 GL 03 696BA 23 52166 REPLACED FREEWHEELING UNIT TAIL ROTOR OUTPUT DRIVE SEAL DUE TO LEAKING OIL. ACFT TT, 407.4 HOURS. 1 G 7 1 3U NC H2SW 1997060500300 19970605 00300 SW 1997 6 5 97ZZZX2481 1 19970416 G 6520 99199 SLEEVE BELL 206 206B 1181511 SW T/R GRBOX SHAFT LEAKING B GS1R K NONE K FLUID LOSS IN INSP/MAINT 1 EA 03 206SB 442 4214 INSPECTION FOUND T/R GEARBOX INPUT SHAFT SLEEVE LEAKING. REPLACED WITH NEW SLEEVE. 1 G 7 1 3U H2SW 1997060500302 19970605 00302 EU 1997 6 5 97ZZZX2483 1 19970307 G 5240 F50B281043 DOOR AMD FALC50 FALCON50MYST 2730106 EU DOOR 170A DEPARTED B A JZBR O OTHER D INFLIGHT SEPARATION CL CLIMB 1 EA 25 96UH 55 REPORTED BELLY DOOR 170A P/N F50B281043 DEPARTED AIRCRAFT DURING CLIMB AND DAMAGED RT MLG DOOR. SUBMITTER BELIEVES THE LAV SERVICE DOOR MOUNTED IN DOOR 170A IS LIFTING INTO AIR STREAM AND CAUSING DOOR 170A TO DEPART ACFT. SUBMITTER STATES MFG'R BELIEVES LAV SERVICE DOOR LIFTS INTO AIR STREAM DUE TO WEAR OR OTHER REASONS. 2 L 7 3 4F A46EU 1997060500303 19970605 00303 EU 1997 6 5 97ZZZX2484 1 19970307 G 5240 F50B281043 DOOR AMD FALC50 FALCON50MYST 2730106 EU DOOR 170A DEPARTED B A JZBR O OTHER D INFLIGHT SEPARATION CL CLIMB 1 EA 25 99JD 129 REPORTED BELLY DOOR 170A P/N F50B281043 DEPARTED AIRCRAFT DURING CLIMB AND DAMAGED RT MLG DOOR. SUBMITTER BELIEVES THE LAV SERVICE DOOR MOUNTED IN DOOR 170A IS LIFTING INTO AIR STREAM AND CAUSING DOOR 170A TO DEPART ACFT. SUBMITTER STATES MFG'R BELIEVES LAV SERVICE DOOR LIFTS INTO AIR STREAM DUE TO WEAR OR OTHER REASONS. 2 L 7 3 4F A46EU 1997060500304 19970605 00304 NE 1997 6 5 97ZZZX2485 2 19970501 G 7310 F2MA521501100AZ LINE AMD FALC50 FALCON2000 2730170 NM CFE CFE73811B NE FUEL DIST CRACKED B CW1R K NONE K FLUID LOSS IN INSP/MAINT 1 EA 25 790M 766 019 MAINTENANCE PERSONNEL NOTICED FUEL ON BOTTOM OF ENGINE COWL. FURTHER INVESTIGATION REVEALED A CRACKED WELD IN THE MAIN FUEL SUPPLY LINE WHERE THE FUEL PRESSURE SENDER IS LOCATED. LOCATION OF THE SENDER MAY IMPOSE UNDUE STRESS ON THE WELD. 2 K 7 3 4F 4 F RT A50NM E44NE 1997060500305 19970605 00305 NM 1997 6 5 97ZZZX2486 1 19970422 G 2620 1032894 SELECTOR VALVE BOEING 707 707153B NM NR 1 ENGINE FAILED H A E F ENGINE SHUTDOWN ACTIVATE FIRE EXT. N FALSE WARNING NR NOT REPORTED 1 SW 15 2MIL 17926 IN FLT FIRE WARNING LIGHT INDICATING A FIRE ON NR 1 ENG. CREW C/W EMERG PROCEDURES, SECURED ENG AND FIRED EXT. ACFT LA NDED OK. FOUND FALSE FIRE WARN CAUSED BY OIL SOAKED HARNESS. DURING REPLACEMENT OF DISCHARGED FIRE BOTTLE, FOUND SHUTO FF VALVE FAILED AND PLUMBING UNDER PRESSURE. BOTTLE HAD FIRED, BUT VALVE FAILURE CAUSED AGENT TO NOT REACH ENG. THE EV ENT CAUSED USAF TO CK ALL C-137B/C ACFT FOR PROPER OPER OF FIRE SELECTOR VALVE P/N 10-3289-4 (MFG MAROTTA P/N 215343-4). SB 3326 ISSUED IN 1977 REF: FIRE EXT VALVES P/N 10-3289-1 AND -3. SUBMITTER STATED AFTER INSPECTING 77 ACFT, 10 SELE CTOR VALVES HAVE BEEN FOUND THAT DID NOT PASS THE FUNCTIONAL TEST. 2 L 7 4 4J F 4A21 1997060500306 19970605 00306 NM 1997 6 5 97ZZZX2487 1 19970508 G 5330 SKIN BOEING 727 7272J4 1384006 NM BS 277L STR 17L GOUGED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC GOUGE IN SKIN STA 277L STR 17L. GOUGE IS BEYOND LIMITS. REPAIR IAW SRM 53-30-3 FIG 1. 2 L 7 3 4F RT A3WE 1997060500307 19970605 00307 NM 1997 6 5 97ZZZX2488 1 19970508 G 5330 PANEL BOEING 727 7272J4 1384006 NM BS 1070-1130 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION ON TRANSITION PANEL FS 1070 - FS 1130. FABBED NEW PANEL IAW 727 SRM 51-20-1 AND SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500308 19970605 00308 NM 1997 6 5 97ZZZX2489 1 19970508 G 5315 FLOOR BEAM BOEING 727 7272J4 1384006 NM BS 1166 LBL 3 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION ON FLOOR BEAM FS 1166 AND LBL 3. REMOVED AND REPLACED DAMAGED SECTION IAW 727 SRM 53-10-5 FIG 6 AND SRM 51-30 -2. 2 L 7 3 4F RT A3WE 1997060500309 19970605 00309 NM 1997 6 5 97ZZZX2490 1 19970508 G 5315 FLOOR BEAM BOEING 727 7272J4 1384006 NM BS 1166 LBL 6 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION ON FLOOR BEAM FS 1166 AND LBL 6. REMOVED AND REPLACED DAMAGED SECTION FS 1166 - IAW 727 SRM 53-10-5 FIG 6 AND SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500310 19970605 00310 NM 1997 6 5 97ZZZX2491 1 19970508 G 5347 TRACK BOEING 727 7272J4 1384006 NM FWD GALLEY CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 FWD GALLEY NR 1 INBD SEAT TRACK CORRODED. INSTALLED SEAT TRACK IAW 727 SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500311 19970605 00311 NM 1997 6 5 97ZZZX2492 1 19970508 G 5315 FLOOR BEAM BOEING 727 7272J4 1384006 NM BS 1166 RBL 12 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION ON FLOOR BEAM FS 1166 RBL 12. REPLACED FLOOR BEAM SECTION IAW SRM 51-30-2 AND SRM 53-10-5 FIG 6. 2 L 7 3 4F RT A3WE 1997060500312 19970605 00312 NM 1997 6 5 97ZZZX2493 1 19970508 G 5320 DOUBLER BOEING 727 7272J4 1384006 NM SERVICE DOOR CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 DOUBLER AT SERVICE DOOR PAN FOUND CORRODED OUT OF LIMITS IAW 727 SRM 53-30-01. REPAIRED IAW 727 SRM 51-20-1 AND SRM 51- 30-2. 2 L 7 3 4F RT A3WE 1997060500313 19970605 00313 NM 1997 6 5 97ZZZX2494 1 19970508 G 5320 ANGLE BOEING 727 7272J4 1384006 NM L2 DOOR FLOOR CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 FLOOR ANGLE CORRODED AT L-2 DOOR. REPAIRED ANGLE IAW BAE 727 SRM 51-20-1. 2 L 7 3 4F RT A3WE 1997060500314 19970605 00314 NM 1997 6 5 97ZZZX2495 1 19970508 G 5320 ANGLE BOEING 727 7272J4 1384006 NM AFT GALLEY FLOOR CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 AFT GALLEY FLOOR 'L' ANGLE CORRODED. REPAIRED IAW BAC 727 SRM 51-10-6 AND SRM 51-10-1. 2 L 7 3 4F RT A3WE 1997060500315 19970605 00315 NM 1997 6 5 97ZZZX2496 1 19970508 G 5313 STRINGER BOEING 727 7272J4 1384006 NM BS 700-720 26L CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION ON STR 26L BETWEEN FS 700 - FS 720. REPAIRED IAW BAC727 SRM 53-10-3 DETAIL I. 2 L 7 3 4F RT A3WE 1997060500316 19970605 00316 NM 1997 6 5 97ZZZX2497 1 19970508 G 5330 PANEL BOEING 727 7272J4 1384006 NM FWD PIT FS 620 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 FORWARD PIT, CORROSION UNDER TRANSITION PANEL AT FS 620 RBL 18. REPAIRED IAW BAC 727 SRM'S 53-10-1, 53-10-2, 51-20-1, 51-30-2. 2 L 7 3 4F RT A3WE 1997060500317 19970605 00317 NM 1997 6 5 97ZZZX2498 1 19970508 G 5330 PANEL BOEING 727 7272J4 1384006 NM BS 560 RBL 18 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 FWD PIT CORROSION UNDER TRANSITION PANEL AT FS 650 RBL 18. REPAIRED IAW BAC 727 SRM'S 51-10-6, 51-20-1, 51-10-2, AND 51 -30-2. 2 L 7 3 4F RT A3WE 1997060500318 19970605 00318 NM 1997 6 5 97ZZZX2499 1 19970508 G 5313 STRINGER BOEING 727 7272J4 1384006 NM BS 481 STR 8L CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CRACK IN STRINGER AT BS 481 STR 8L. REPAIRED IAW BAC 727 SRM'S 53-30-3, 51-30-2. 2 L 7 3 4F RT A3WE 1997060500319 19970605 00319 NM 1997 6 5 97ZZZX2500 1 19970508 G 5347 SEAT TRACK BOEING 727 7272J4 1384006 NM BS 1090 RBL 24 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 SEAT TRACK CORRODED BS 1090 - BS 1140 RBL 24. REPLACED SEAT TRACK IAW BAC 727 SRM 53-10-5. 2 L 7 3 4F RT A3WE 1997060500320 19970605 00320 NM 1997 6 5 97ZZZX2501 1 19970508 G 5320 SUPPORT BOEING 727 7272J4 1384006 NM FWD LAVATORY CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 FWD LAVATORY SUPPORT CORRODED. REPLACED SUPPORT IAW BAC 727 SRM'S 51-30-5, 51-30-2. 2 L 7 3 4F RT A3WE 1997060500321 19970605 00321 NM 1997 6 5 97ZZZX2502 1 19970508 G 5347 SEAT TRACK BOEING 727 7272J4 1384006 NM FWD GALLEY CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 FWD GALLEY SEAT TRACK CORRODED. REPLACED SEAT TRACK IAW BAC 727 SRM'S 51-40-4, 51-30-2. 2 L 7 3 4F RT A3WE 1997060500322 19970605 00322 NM 1997 6 5 97ZZZX2503 1 19970508 G 5330 PANEL BOEING 727 7272J4 1384006 NM PNL 9501 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 PANEL 9501 CORRODED BEYOND LIMITS AT FASTENER HOLES. FABBED AND INSTALLED NEW REPAIR PARTS PER 727 SRM'S 55-30-7 AND 51 -30-02. 2 L 7 3 4F RT A3WE 1997060500323 19970605 00323 NM 1997 6 5 97ZZZX2504 1 19970508 G 5320 Z CHANNEL BOEING 727 7272J4 1384006 NM RT BS 320 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION ON Z-CHANNEL AT FS 320 RT NOSE GEARBOX. REAPAIRED EXTRUSION IAW BAC 727 SRM 51-40-4 PG 5. 2 L 7 3 4F RT A3WE 1997060500324 19970605 00324 NM 1997 6 5 97ZZZX2505 1 19970508 G 5330 PANEL BOEING 727 7272J4 1384006 NM PNL 3458 CORROSION B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 BLOW OUT PANEL 3458 HAS CORROSION AT BONDING WIRE ATTACH. FABBED AND INSTALLED NEW PANEL 3458 IAW 727 SRM'S 51-40-3 AND 51-30-2. 2 L 7 3 4F RT A3WE 1997060500325 19970605 00325 NM 1997 6 5 97ZZZX2506 1 19970508 G 5320 ANGLE BOEING 727 7272J4 1384006 NM BS 351.2 RT SIDE CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION AT FS 351.2 RIGHT SIDE OF NOSE GEARBOX ON ANGLE BELOW FLOOR LEVEL. REPAIRED ANGLE IAW BAC SRM 727-51-40-03. 2 L 7 3 4F RT A3WE 1997060500326 19970605 00326 NM 1997 6 5 97ZZZX2507 1 19970508 G 2730 PCU BOEING 727 7272J4 1384006 NM LT ELEVATOR LEAKING B KT3R K NONE K FLUID LOSS IN INSP/MAINT 1 WP 07 290SC 20764 LEFT ELEVATOR PCU LEAKING. REMOVED AND REPLACED PCU IAW BAC 727 MM 27-30-81. 2 L 7 3 4F RT A3WE 1997060500327 19970605 00327 NM 1997 6 5 97ZZZX2508 1 19970508 G 5755 SUPPORT STRUT BOEING 727 7272J4 1384006 NM NR 6 SPOILER DENTED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 DENT IN SUPPORT STRUT FOR NR 6 SPOILER. REPLACED SUPPORT STRUT WITH NEW BAC PART. 2 L 7 3 4F RT A3WE 1997060500328 19970605 00328 NM 1997 6 5 97ZZZX2509 1 19970508 G 5523 TAB BOEING 727 7272J4 1384006 NM LT ELEVATOR DELAMINATED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 ELEVATOR TAB DELAMINATED. REPAIRED IAW BAC 727 SRM 51-40-6 PARA 3 AND FIG 13. 2 L 7 3 4F RT A3WE 1997060500329 19970605 00329 NM 1997 6 5 97ZZZX2510 1 19970508 G 5330 SKIN BOEING 727 7272J4 1384006 NM BS 351.2 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION AT FS 351.2 BELOW FLOOR. REPAIRED IAW BAC 727 SRM 51-40-03 AND SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500330 19970605 00330 NM 1997 6 5 97ZZZX2511 1 19970508 G 5730 PANEL BOEING 727 7272J4 1384006 NM RT WING 8612 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 RIGHT WING ACCESS PANEL 8612 CORRODED. REPAIRED IAW BAC SRM 727 51-40-6 PAR 3 E, F, 2C, J, AND K. 2 L 7 3 4F RT A3WE 1997060500331 19970605 00331 NM 1997 6 5 97ZZZX2512 1 19970508 G 5320 SUPPORT BOEING 727 7272J4 1384006 NM L2 SERVICE DOOR CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 GALLEY FLOOR AND SUPPORT CORRODED AT L-2 SERVICE DOOR. REPAIRED IAW BAC 727 SRM 51-20-1 AND SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500332 19970605 00332 NM 1997 6 5 97ZZZX2513 1 19970508 G 5520 FITTING BOEING 727 7272J4 1384006 NM NR 4 ELEV HINGE CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 NR 4 ELEVATOR HINGE FITTING CRACKED AT T-E BEAM. REPAIRED IAW BAC 727 SRM 55-10-4 FIG 5. 2 L 7 3 4F RT A3WE 1997060500333 19970605 00333 NM 1997 6 5 97ZZZX2514 1 19970508 G 7110 NOSE COWL BOEING 727 7272J4 1384006 NM NR 3 ENGINE DENTED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 NR 3 ENGINE NOSE COWL DENTED. REPAIRED NOSE COWL IAW DAC SRM 54-04A PAGE 3. NOTE: VALSAN MOD. 2 L 7 3 4F RT A3WE 1997060500334 19970605 00334 NM 1997 6 5 97ZZZX2515 1 19970508 G 5520 FITTING BOEING 727 7272J4 1384006 NM RT ELEV NR 4 CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 RIGHT NR 4 ELEVATOR HINGE ATTACH FITTING CRACKED. REPAIRED IAW BAC SRM 727-5T5-10-04 FIG 5. 2 L 7 3 4F RT A3WE 1997060500335 19970605 00335 NM 1997 6 5 97ZZZX2516 1 19970508 G 5520 FITTING BOEING 727 7272J4 1384006 NM RT ELEV NR 5 CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 RIGHT NR 5 ELEVATOR HINGE ATTACH FITTING CRACKED. REPAIRED IAW BAC 727 SRM 55-10-04 FIG 6. 2 L 7 3 4F RT A3WE 1997060500336 19970605 00336 NM 1997 6 5 97ZZZX2517 1 19970508 G 5315 FLOOR BEAM BOEING 727 7272J4 1384006 NM BS 1166 RBL 15 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION ON FLOOR BEAM FS 1166 AND RBL 15. FABBED AND INSTALLED REPAIR PARTS IAW 727 SRM'S 51-30-2, 53-10-5 FIG 6. 2 L 7 3 4F RT A3WE 1997060500337 19970605 00337 NM 1997 6 5 97ZZZX2518 1 19970508 G 5520 FITTING BOEING 727 7272J4 1384006 NM LT ELEV NR 5 CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 LEFT NR 5 ELEVATOR HINGE ATTACH FITTING CRACKED. REPAIRED IAW BAC 727 SRM 55-10-04 FIG 6. 2 L 7 3 4F RT A3WE 1997060500338 19970605 00338 NM 1997 6 5 97ZZZX2519 1 19970508 G 5730 SKIN BOEING 727 7272J4 1384006 NM RT WS 825 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 WING LOWER SURFACE AT FS 825 RBL 15 HAS CORROSION. REMOVED CORROSION IAW SRM 51-10-6. THICKNESS CHECKED WITHIN LIMITS IAW BAC 727 SRM 57-30-01 FIG 4. 2 L 7 3 4F RT A3WE 1997060500339 19970605 00339 NM 1997 6 5 97ZZZX2520 1 19970508 G 2560 MOUNT BRACKET BOEING 727 7272J4 1384006 NM L2 DOOR SLIDE CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION ON L-2 DOOR SLIDE MOUNT BRACKET. REPAIRED IAW BAC 727 SRM 51-20-1. 2 L 7 3 4F RT A3WE 1997060500340 19970605 00340 NM 1997 6 5 97ZZZX2521 1 19970508 G 5315 FLOOR BEAM BOEING 727 7272J4 1384006 NM BS 540 RBL 8 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 FWD PIT CORROSION UNDER NUTPLATES ON FLOOR BEAM AT FS 540 RBL 8. REPAIRED IAW BAC 727 SRM 53-10-5 AND SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500341 19970605 00341 NM 1997 6 5 97ZZZX2522 1 19970508 G 2530 ANGLE BOEING 727 7272J4 1384006 NM NR 4 GALLEY CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 GALLEY SERVING CART COMPT ANGLE CORRODED. REMOVED AND REPLACED ANGLE IAW BAC 727 SRM 51-10-6 AND SRM 51-20-04. 2 L 7 3 4F RT A3WE 1997060500342 19970605 00342 NM 1997 6 5 97ZZZX2523 1 19970508 G 5312 ANGLE BOEING 727 7272J4 1384006 NM BS 178 BLKHEAD CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 L-ANGLE CRACKED FORWARD BULKHEAD FS 178. INSTALLED NEW ANGLE IAW 727 SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500343 19970605 00343 NM 1997 6 5 97ZZZX2524 1 19970508 G 5315 FLOOR BEAM BOEING 727 7272J4 1384006 NM BS 1166 RBL 9 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION ON FLOOR BEAM FS 1166 AND RBL 9 REMOVED AND REPLACED BEAM SECTION IAW 727 SRM 53-10-5 FIG 6 AND SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500344 19970605 00344 NM 1997 6 5 97ZZZX2525 1 19970508 G 5320 SUPPORT BOEING 727 7272J4 1384006 NM BS 1130 RBL 3 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION ON SUPPORT FOR CARGO NET FRAME 1130 RBL 3. FABBED NEW TOP PLATE IAW SRM 51-30-02. 2 L 7 3 4F RT A3WE 1997060500345 19970605 00345 NM 1997 6 5 97ZZZX2526 1 19970508 G 5330 PANEL BOEING 727 7272J4 1384006 NM C3 DOOR FR 1090 CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 PANEL FWD OF C3 DOOR AND FRAME 1090 IS CRACKED. REPAIRED PANEL IAW 727 SRM 51-90-2 AND SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500346 19970605 00346 NM 1997 6 5 97ZZZX2527 1 19970508 G 5315 FLOOR BEAM BOEING 727 7272J4 1384006 NM BS 1030 STR 29R CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION FLOOR BEAM AT FLOOR BOARD SUPPORT FS 1030 AND S29R. FABBED AND INSTALLED NEW BEAM SECTION IAW 727 SRM 51-40-3 AND SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500347 19970605 00347 NM 1997 6 5 97ZZZX2528 1 19970508 G 5320 ATTACH ANGLE BOEING 727 7272J4 1384006 NM BS 219.8 STR 25R CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION ON ATTACH ANGLE FS 219.8 APPROXIMATELY S25R. FABBED NEW PART PER 51-10-01 AND INSTALLED PER 51-30-2. 2 L 7 3 4F RT A3WE 1997060500348 19970605 00348 NM 1997 6 5 97ZZZX2529 1 19970508 G 5330 PANEL BOEING 727 7272J4 1384006 NM BS 1030-1166 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION ON LEFT TRANSITION PANEL FROM BS 1030 TO BS 1166. FABBED AND INSTALLED NEW TRANSITION PANEL IAW 727 SRM 51-20 -1 AND SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500349 19970605 00349 NM 1997 6 5 97ZZZX2530 1 19970508 G 5320 FLOOR SUPPORT BOEING 727 7272J4 1384006 NM BS 360 RBL 12 CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CABIN FLOOR BOARD SUPPORT CRACKED STA 370 RBL 12. FABBED AND INSTALLED NEW SUPPORT IAW 727 SRM 51-20-1 AND SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500350 19970605 00350 NM 1997 6 5 97ZZZX2531 1 19970508 G 5320 SUPPORT ANGLE BOEING 727 7272J4 1384006 NM COCKPIT STA 243 CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 TWO EACH COCKPIT SUPPORT ANGLES CRACKED APPROXIMATELY STA 243. FABBLED AND INSTALLED TWO NEW SUPPORT ANGLES IAW 727 SRM 51-20-1 AND SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500351 19970605 00351 NM 1997 6 5 97ZZZX2532 1 19970508 G 5347 SEAT TRACK BOEING 727 7272J4 1384006 NM RT OTBD BS 420 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 RIGHT OUTBOARD SEAT TRACK CORRODED STA 420 TO STA 460. FABBED NEW SEAT TRACK AND INSTALLED IAW 727 SRM 53-10-5 AND SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500352 19970605 00352 NM 1997 6 5 97ZZZX2533 1 19970508 G 5320 651841713 STIFFENER BOEING 727 7272J4 1384006 NM BS 294.5 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 INTERGRANULAR CORROSION ON NOSE GEARBOX HORIZONTAL STIFFENER STA 294.5. INSTALLED NEW STIFFENER IAW 727 SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500353 19970605 00353 NM 1997 6 5 97ZZZX2534 1 19970508 G 5330 SKIN BOEING 727 7272J4 1384006 NM BS 312L STR 17L DENTED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 DENTS IN SKIN STA 312L STR 17L - STR 18L. INSTALLED REPAIR DOUBLER IAW SRM 50-30-3. 2 L 7 3 4F RT A3WE 1997060500354 19970605 00354 NM 1997 6 5 97ZZZX2535 1 19970508 G 5320 65184175 STIFFENER BOEING 727 7272J4 1384006 NM BS 312 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION ON NOSE GEARBOX HORIZONTAL STIFFENER STA 312. INSTALLED NEW STIFFENER IAW 727 SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500355 19970605 00355 NM 1997 6 5 97ZZZX2536 1 19970508 G 5320 BRACE BOEING 727 7272J4 1384006 NM FR 420 STR 27L CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION ON BRACE BACK SIDE FRAME 420 S27L. FABBED AND INSTALLED NEW PART IAW 51-20-1 AND 51-30-2. 2 L 7 3 4F RT A3WE 1997060500356 19970605 00356 NM 1997 6 5 97ZZZX2537 1 19970508 G 5320 ANGLE BOEING 727 7272J4 1384006 NM BS 760 BL 7R-7L CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION ON ANGLE BETWEEN FS 760 AND PANEL 3217 BL 7R-7L. FABBED AND INSTALLED ANGLE IAW 51-20-1 AND SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500357 19970605 00357 NM 1997 6 5 97ZZZX2538 1 19970508 G 5320 T ANGLE BOEING 727 7272J4 1384006 NM ADF ANT RT CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION ON T-ANGLE TO RIGHT OF ADF ANT AFT OF PNEUMATIC GROUND CONNECTION. REPLACED T-ANGLE IAW 727 SRM 51-30-2. 2 L 7 3 4F RT A3WE 1997060500358 19970605 00358 NM 1997 6 5 97ZZZX2539 1 19970508 G 5315 FLOOR BEAM BOEING 727 7272J4 1384006 NM BS 342 RBL 12 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 FLOOR BEAM STA 342 APPROXIMATELY RBL 12 CORRODED. INSTALLED REPAIR IAW 727 SRM 53-10-8 FIG 9. 2 L 7 3 4F RT A3WE 1997060500359 19970605 00359 NM 1997 6 5 97ZZZX2540 1 19970508 G 5311 FRAME BOEING 727 7272J4 1384006 NM PNL 3217 LBL 5 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION AFT OF PANEL 3217 ON FRAME ABOVE IT APPROXIMATELY LBL 5 A/C BAY. INSTALLED NEW PART 69-46628-4. 2 L 7 3 4F RT A3WE 1997060500360 19970605 00360 NM 1997 6 5 97ZZZX2541 1 19970508 G 2730 PCU BOEING 727 7272J4 1384006 NM RT ELEVATOR LEAKING B KT3R K NONE K FLUID LOSS IN INSP/MAINT 1 WP 07 290SC 20764 RIGHT ELEVATOR PCU LEAKING. REMOVED AND REPLACED PCU IAW BAC 727 MM 27-30-81. 2 L 7 3 4F RT A3WE 1997060500361 19970605 00361 NM 1997 6 5 97ZZZX2542 1 19970508 G 5320 SHEAR TIE BOEING 727 7272J4 1384006 NM BS 350 STR 26L CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 CORROSION ON SHEAR TIE AT STA 350 STR 26L. REPAIRED IAW BAC 727 SRM'S 53-10-2, 51-40-3, 51-30-2. 2 L 7 3 4F RT A3WE 1997060500362 19970605 00362 NM 1997 6 5 97ZZZX2543 1 19970508 G 5730 PANEL BOEING 727 7272J4 1384006 NM RT WING 8613 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 290SC 20764 RIGHT WING PANEL 8613 CORRODED. REPAIRED IAW BAC 727 SRM 51-40-6 PAR 3(E)(I). 2 L 7 3 4F RT A3WE 1997060500363 19970605 00363 CE 1997 6 5 97ZZZX2544 1 19970429 G 2121 591224 HYDRAULIC MOTOR SUNDSTRANDEM 725652B CESSNA 650 650 2076802 CE RAM HYD FAN DEFECTIVE C K NONE O OTHER IN INSP/MAINT 1 EA 23 67SF 57 143 6500045 PILOT REPORTED LOW HYDRAULIC PRESSURE WITH ONE ENGINE RUNNING AND AT IDLE. DISCOVERED THE HYDRAULIC FLUID FLOW RATE THR OUGH THE RAM AIR HYDRAULIC FAN TO BE EXCESSIVE. REPLACED ASSEMBLY WITH REPAIRED UNIT AND RETESTED FLOW RATE AND FOUND T O BE WITHIN TOLERANCE LEVELS. DUE TO THE NORMALLY HIGH FLOW RATE OF THE FAN MOTOR AND THE SUBSEQUENT LOSS OF PRESSURE W HEN THIS UNIT BEGINS TO FAIL, IT IS SUGGESTED THAT AN ELECTRIC MOTOR/FAN ASSEMBLY BE DESIGNED AS A REPLACEMENT TO THIS E XISTING ASSEMBLY. 2 L 7 2 4F A9NM 1997060500365 19970605 00365 1997 6 5 97ZZZX2546 4 19970308 G 2562 PARACHUTE TANDEM MAIN MALFUNCTION H L A O OTHER O OTHER NR NOT REPORTED 1 WP 25 TANDEM RESERVE CHUTE DEPLOYMENT OCCURRED DUE TO MAIN CHUTE CLOSING LOOP BROKE JUST BELOW FINGER TRAP ENTRY POINT FOLLOWI NG EXIT FROM AIRCRAFT. 1997060500366 19970605 00366 NM 1997 6 5 97ZZZX2547 1 19970501 G 2720 664483621 MANIFOLD 654486121 BOEING 737 737* NM FILTER BOWL CRACKED B IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 6609A RUDDER PCU MANIFOLD IS CRACKED INSIDE FILTER BOWL AT PRESSURE PORT PASSAGEWAY. 2 L 7 2 4F RT A16WE 1997060500367 19970605 00367 NM 1997 6 5 97ZZZX2548 1 19970501 G 2720 664483617 MANIFOLD 654486121 BOEING 737 737* NM FILTER BOWL CRACKED B IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 6603A RUDDER PCU MANIFOLD IS CRACKED INSIDE FILTER BOWL AT PRESSURE PORT PASSAGEWAY. 2 L 7 2 4F RT A16WE 1997060500368 19970605 00368 NM 1997 6 5 97ZZZX2549 1 19970501 G 2720 664483615 MANIFOLD 654486114 BOEING 737 737* NM FILTER BOWL CRACKED B IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 4008 RUDDER PCU MANIFOLD IS CRACKED INSIDE FILTER BOWL AT PRESSURE PORT PASSAGEWAY. 2 L 7 2 4F RT A16WE 1997060500369 19970605 00369 1997 6 5 97ZZZX2550 4 19970519 G 6122 210738 GOVERNOR WOODWARD BEECH 100 B100 1152919 CE LT PROP WRONG PART B W6NR K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 25 500KD 1998547E BE79 UPON INSPECTING AIRCRAFT FOR PART 135 OPERATION, THE LEFT PROP GOV WAS FOUND TO BE A PART NUMBER NOT AUTHORIZED FOR B-10 0'S. THIS WAS CONFIRMED THROUGH WOODWARD GOVERNOR. THERE WERE NO OPERATING PROBLEMS AT THE TIME. GOVERNOR WAS REPLACE D WITH PROPER PART NUMBER OF 210939. THE GOVERNOR WAS BEING REPLACED ALSO DUE TO 6-YEAR OVERHAUL REQUIREMENT PER WOODWA RD SB 33580E. 1 L 7 2 4T A14CE 1997060500370 19970605 00370 SW 1997 6 5 97ZZZX2551 1 19970425 G 5610 407030114125 WINDSHIELD BELL 407 407 SW COCKPIT DISTORTED B GS1R K NONE O OTHER IN INSP/MAINT 1 EA 03 6932Z 8 53124 INSPECTION FOUND WINDSHIELD DISTORTED. REPLACED WITH NEW WINDSHIELD. 1 G 7 1 3U O H2SW 1997060500457 19970605 00457 EU 1997 6 5 97ZZZX2552 1 19970510 G 6520 GEARBOX SNIAS 350 AS350B 8680801 EU T/R GEARBOX CHIP LIGHT D K NONE J WARNING INDICATION AP APPROACH 1 WP 07 91GT 3140 102 M1916 1289 ON FINAL APPROACH, T/R CHIP LIGHT ILLUMINATED. FOUND EXCESSIVE CHIPS IN OIL. REMOVED GEARBOX FROM SERVICE. 1 G 7 1 3U H9EU 1997060500458 19970605 00458 EU 1997 6 5 97ZZZX2553 1 19970512 G 6520 HUB SNIAS 350 AS350B 8680801 EU T/R GEARBOX BOLT SEIZED D K NONE W INADEQUATE Q C AP APPROACH 1 WP 07 91GT 3140 102 M1916 1289 DURING REMOVAL OF T/R HUB, HUB RETAINING BOLT WAS VERY HARD TO REMOVE. UPON INSPECTION OF BOLT, FOUND SIGNS THAT BOLT W AS INSTALLED WITH (RED) LOCTITE INSTEAD OF LOCTITE 242 (BLUE). MWC 65.20.00.401 PARA 4 STATES TO APPLY LOCTITE 242 (BLU E) TO THREADS. AFTER TALKING TO ANOTHER REPAIR STATION ABOUT THIS PROBLEM, THEY STATED THAT 80 PERCENT OF THE GEARBOXES THEY OVERHAUL/REPAIR GET RED LOCTITE; THUS, GOING AGAINST THE AIRCRAFT MANUFACTURER'S OVERHAUL/REPAIR PROCEDURES. 1 G 7 1 3U H9EU 1997060500461 19970605 00461 GL 1997 6 5 97ZZZX2556 1 19970513 G 6230 28161191 UNIVERSAL HSNG ENSTRM F28 F28F 3300412 GL SWASHPLATE CRACKED C PP0M K NONE O OTHER AP APPROACH 1 WP 01 8624B 641 13100991H 752 MOUNTING WEBS FOR CONTORL ROD BEARINGS AND UNIVERSAL JOINT OF LOWER SWASHPLATE FOUND CRACKED AT INSPECTION. THIS IS A P RIMARY FLIGHT CONTROL PART. THIS PART HAS A RETIREMENT LIFE OF 17,700 HOURS. PART NON-REPAIRABLE. REPLACED WITH NEW P ART 28-16119-1. 1 G 7 1 3O H1CE 1997060500462 19970605 00462 GL 1997 6 5 97ZZZX2557 1 19970514 G 6230 28161191 UNIVERSAL HSNG ENSTRM F28 F28F 3300412 GL SWASHPLATE CRACKED C PP0M K NONE O OTHER AP APPROACH 1 WP 01 8626S 6672 1085185H 786 MOUNTING WEBS FOR CONTORL ROD BEARINGS AND UNIVERSAL JOINT OF LOWER SWASHPLATE FOUND CRACKED AT INSPECTION. THIS IS A P RIMARY FLIGHT CONTROL PART. THIS PART HAS A RETIREMENT LIFE OF 17,700 HOURS. PART NON-REPAIRABLE. REPLACED WITH NEW P ART 28-16119-1. 1 G 7 1 3O H1CE 1997060500479 19970605 00479 NE 1997 6 5 97ZZZX2575 1 19970207 G 6320 643520500048 SHAFT 643520536101 SKRSKY S64 S64F NE MGB CRACKED B JYDR K NONE O OTHER AP APPROACH 1 NM 09 179AC 2725 61 64091 MAIN GEARBOX INSPECTION. TWO INDICATIONS FOUND IN THE RADIUS OF ONE SPLINE DURING MPI INSPECTION. BOTH INDICATIONS WER E APPROXIMATELY 0.050 INCH IN LENGTH AND EXTENDING TOWARDS THE TOOTH FACE. NO OTHER INDICATIONS WERE FOUND. 2 G 7 2 4U H6EA 1997060500480 19970605 00480 CE 1997 6 5 97ZZZX2576 1 19970510 G 3230 08421201 DRIVE TUBE CESSNA 320 320D 2074512 CE NLG BENT D S A K NONE O OTHER IN INSP/MAINT 1 SO 15 15DS 4150 320D0079 ROUTINE INSPECTION FOUND FWD END OF PUSHROD BENT. REMOVED AND DETERMINED SPACERS (ITEM 7) WERE NOT INSTALLED ABOVE AND BELOW END BEARING WHICH ALLOWED ACTUATOR ROD TO WORK UP AND DOWN. FURTHER INSP REVEALED IDLER BELLCRANK (ITEM 11) WAS I NSTALLED WITHOUT THE MAIN .25 INCH TO .4375 INCH BUSHING (ITEM 14) INSTALLED WHICH CAUSED BELLCRANK TO FLOAT ON THE .25 INCH BOLT (ALLOW .200 INCH PLAY). THIS AREA WAS REPAIRED AFTER A NOSE GEAR COLLAPSE APPROX 350 HRS EARLIER AT WHICH TIM E THE IDLER BELLCRANK APPEARED TO HAVE BEEN REPLACED. THERE WAS NO LOG ENTRY OF ANY OF THIS REPAIR. 1 L 7 2 3O 3A25 1997060500481 19970605 00481 SO 1997 6 5 97ZZZX2577 1 19970501 G 2701 62716 SHAFT PIPER PA32 PA32300 7103212 SO CONTROL COLUMN MISDRILLED D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 AL 05 2884M 6000 327840058 YOKE CONTROL SHAFT FITTED AND DRILLED IMPROPERLY. WAS CHANGING OUT CONTROL U-JOINT, FOUND THIS DEFECTIVE CONTROL SHAFT. HAVE HAD ACFT FOR 4,500 HOURS AND PRIOR TO THAT, NO RECORD OF CONTROL COLUMN BEING APART. ASSUME IT WAS DRILLED IMPRO PERLY AT FACTORY. SUBMITTER STATED TO PREVENT BY CHECKING WORK. FIND BY FEEL: SHAFT SHOULD BE FLUSH IN SPROCKET HOLE. 1 L 7 1 3O A3SO 1997060500482 19970605 00482 SO 1997 6 5 97ZZZX2578 2 19970501 G 8520 CRANKCASE UNIVAC GC1 GC1B 9230104 NM CONT O360 IO360C 17025 SO OVER NR 2 CYL CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 09 2403B 3703 R55320SD THIRTY HOURS AFTER REPAIR AND OVERHAUL OF ENGINE, CRANKCASE WAS FOUND TO HAVE A CRACK ON UPPER AREA ABOVE NR 2 CYLINDER (NOT A STUD HOLE CRACK) EXTENDING 1 INCH FORE AND AFT APPROX 1 INCH INBOARD OF CYLINDER MOUNT AREA. CYLINDERS ALSO FOUN D NOT TO HAVE BEEN OVERHAULED. ENGINE DISASSEMBLED AND FOUND NUMEROUS OTHER DISCREPANCIES. ( NO COTTER PIN, ETC.). SB 96-13 NOT SIGNED OFF. AD 92-04-09 NOT C/W. 1 L 7 1 3O 3 O A766 E1CE 1997060500483 19970605 00483 NM 1997 6 5 97ZZZX2579 1 19970501 G 3230 1153230542 CONTROL CABLE UNIVAC GC1 GC1* NM GEAR EXTENSION JAMMED D K NONE O OTHER IN INSP/MAINT 1 EA 09 2403B 3703 DURING ANNUAL GEAR RETRACTION TEST, SHORT EXTENSION CABLE KINKED AND JAMMED LT GEAR 1/2 TRAVEL BETWEEN UP AND DOWN POSIT ION. CABLE WAS FOUND RUSTED AND STIFF. REMOVED CABLE AND INSTALLED NEW CABLE AND ADJUSTED TENSION. SUBMITTER SUGGESTE D OLDER AIRCRAFT BE LOOKED AT CLOSER DURING ANNUAL INSPECTIONS. PART IS APPROXIMATELY 50 YEARS OLD. 1 L 7 1 3O A766 1997060500484 19970605 00484 SO 1997 6 5 97ZZZX2580 1 19970501 G 2430 9937713 SWITCH PIPER PA34 PA34200T 7103406 SO MASTER SWITCH CORRODED D K NONE O OTHER IN INSP/MAINT 1 SO 09 36345 347870321 INTERNAL CORROSION ON ALL CONTACTS OF SWITCH. POSSIBLE WATER ENTRAPMENT, SOURCE MOST LIKELY PILOT SIDE WINDOW. REPLACE D SWITCH ASSY WITH OEM REPLACEMENT. SEALED SWITCH WITH FUEL TANK SEALANT. 1 L 7 2 3O A7SO 1997060500485 19970605 00485 CE 1997 6 5 97ZZZX2581 1 19970515 G 5542 553300054 SKIN CESSNA 500 560CESSNA 2076750 CE RUDDER RT SIDE CRACKED B DXTR K NONE O OTHER IN INSP/MAINT 1 GL 07 393QS 649 5600393 FOUND 3 INCH CRACK ON RIGHT SIDE OF RUDDER ALONG AFT RIB - WL 158.00. CRACK IS THROUGH 3 EACH RIVETS. SUBMITTER STATED THIS IS THE 8TH OCCURRENCE ON FLEET. 2 L 7 2 4F RT A22CE 1997060500487 19970605 00487 EA 1997 6 5 97ZZZX2583 2 19970422 G 7414 ROTOR BENDIX S4LN203 PIPER PA28 PA28180 7102808 SO LYC O360 O360A4A 41514 EA RT MAG SHAFT SHEARED D K NONE O OTHER IN INSP/MAINT 1 GL 09 5224T 1857 A39663 287205248 L1661236A ROTOR SHAFT SHEARED OFF JUST AFT OF SEAL RUNNER BUSHING. THE BREAK IN THE SHAFT APPEARS TO HAVE BEEN CRACKED FOR SOME T IME. THIS ENGINE HAD MAJOR OVERHAUL 441 HOURS AGO FOR PROP STRIKE. THE RIGHT MAGNETO IS DIRECT DRIVE (NO IMPULSE), AND SUSPECT THE SHAFT FAILURE WAS DUE TO SUDDEN STOP OR TORSIONAL SHOCK TO MAGNETO ROTORSHAFT. THE ENGINE HAD SUDDEN STOPP AGE PREVIOUSLY, AND PROP WAS SEVERELY CURLED THE FIRST STRIKE. LOGS SHOW LEFT MAG TO BE ORIGINAL EQUIPMENT. 1 L 7 1 3O 3 O 2A13 E286 1997060500488 19970605 00488 GL 1997 6 5 97ZZZX2584 3 19970514 G 6114 HUB CESSNA 150 152 2071835 CE MCAULY 1A103 1A103TCM GL NR 1 BLADE CRACKED B EK2D K NONE O OTHER IN INSP/MAINT 1 SW 09 5238H 15284071 R776219 PROPELLER INSPECTION FOUND CRACK APPROXIMATELY .820 INCH LONG, .040 INCH DEEP, TRAILING EDGE SIDE OF HUB OF NR 1 BLADE. AD 97-21-01 AND MCAULEY SB 221B ADDRESSES THE HUB FRONT FACE AND BOLT HOLES. NO RE-WORK IS ALLOWED ON SIDE OF HUB. 1 H 7 1 3O NT 3A19 5 N P50GL 1997060500489 19970605 00489 SO 1997 6 5 97ZZZX2585 1 19970520 G 7810 K3342005 PIPE PIPER PA23 PA23250 7102308 SO RT ENG EXH HOLED D K NONE O OTHER IN INSP/MAINT 1 SO 01 6776A 277954088 EXHAUST PIPE HAD LARGE HOLE IN PIPE INSIDE HEAT MUFFLER. THIS ALLOWED RAW EXHAUST GAS TO ENTER ENGINE THROUGH FUEL SERV O. P/N RSA-5AD1. 1 L 7 2 3O 1A10 1997060500492 19970605 00492 SO 1997 6 5 97ZZZX2588 1 19970505 G 2913 ESQ12S BRUSH PRESTOLITE 9667102 PIPER PA32 PA32R300 7103213 SO HYD PUMP ASSY WORN B EKIR K NONE O OTHER IN INSP/MAINT 1 WP 07 6925J 2268 32R7680388 INSPECTED HYDRAULIC PUMP MOTOR FOLLOWING ACFT LANDING WITH NOSE GEAR UNLOCKED. FOUND BRUSHES WORN OUT AND COMMUTATOR UN DERCUT. COMMUTATOR WAS TURNED AND NEW BRUSHES INSTALLED 368 HRS PREVIOUSLY, 1-3-95. BRUSHES WERE REMOVED AND INSPECTED 296 HRS PRIOR TO FAILURE AND FOUND NO EVIDENCE OF WEAR SINCE INSTALLED 72 HRS PREVIOUSLY. BRUSHES AND COMMUTATOR LOOK AS IF MOTOR RAN FOR MANY HOURS. 1 L 7 1 3O A3SO 1997060500494 19970605 00494 CE 1997 6 5 97ZZZX2590 1 19970501 G 7160 96919100609 INDUCT AIR BOX BEECH 95 95B55 1152729 CE AIR DOOR MISMANUFACTURED D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 11 NEW AIR BOX ASSEMBLIES LISTED WERE RECEIVED DEFECTIVE. 'NEW PARTS FROM BEECH'. THE AIR FILTER SLOT IS NOT WIDE ENOUGH TO ACCOMODATE THE SUPPLIED AIR FILTER. SECOND, THE ALTERNATE AIR DOOR DOES NOT CLOSE COMPLETELY. SUBMITTER STATED POOR QC ON BOTH ASSEMBLIES. 1 L 7 2 3O RT 3A16 1997060500495 19970605 00495 CE 1997 6 5 97ZZZX2591 1 19970501 G 7160 96919100615 AIR BOX BEECH 95 95B55 1152729 CE AIR FILTER MISMANUFACTURED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 11 NEW AIR BOX ASSEMBLIES LISTED WERE RECEIVED DEFECTIVE. 'NEW PARTS FROM BEECH'. THE AIR FILTER SLOT IS NOT WIDE ENOUGH TO ACCOMODATE THE SUPPLIED AIR FILTER. SECOND, THE ALTERNATE AIR DOOR DOES NOT CLOSE COMPLETELY. SUBMITTER STATED POOR QC ON BOTH ASSEMBLIES. 1 L 7 2 3O RT 3A16 1997060500497 19970605 00497 SO 1997 6 5 97ZZZX2593 2 19970520 G 7414 S6RN1225 MAGNETO BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO IMPULSE COUPLING CRACKED D P K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SW 05 2038X 860 H21595 CE819 569620 WHEN CHECKING MAGNETOS DURING ENGINE RUN-UP PRIOR TO TAKEOFF, RIGHT MAGNETO GAVE A 350 FOOT RPM DROP ACCOMPANIED BY A VE RY ROUGH RUNNING ENGINE. AFTER RIGHT MAGNETO WAS REMOVED FOR TROUBLESHOOTING, CRACKS WERE DISCOVERED ON THE TOP AND BOT TOM OF THE HOUSING EXTENDING FORWARD APPROXIMATELY 1.50 INCHES FROM THE FLANGE OF THE IMPULSE COUPLING. 1 L 7 1 3O 3 O 3A15 E5CE 1997060500498 19970605 00498 NE 1997 6 5 97ZZZX2594 1 19970520 G 3230 18000045 HOSE ASSY CONAER LA4 LA4200 5110310 NE GEAR RETRACT MISASSEMBLY D K NONE W K INADEQUATE Q C FLUID LOSS IN INSP/MAINT 1 NM 08 3060P 6 971 HYDRAULIC HOSE KIT ORDERED FROM LAKE FACTORY INSTALLED ON AIRCRAFT. TWO OUT OF SIX LANDING GEAR RETRACT HOSES LEAKED AT THE FITTINGS. UPON DISASSEMBLY OF HOSES, FOUND THE ENDS WERE IMPROPERLY INSTALLED. THE FERRULES WERE SCREWED ONTO THE HOSE ONLY ONE THREAD, SHOULD BE THREE THREADS. THE INSIDE PART OF THE FITTING WAS APPARENTLY INSTALLED WITHOUT THE PRO PER TOOL CAUSING IT TO CUT THE INSIDE OF THE HOSE. HOSE IS AEROQUIP 303-4. FITTINGS ARE MS24590-4. 1 H 7 1 3O 1A13 1997060500500 19970605 00500 EA 1997 6 5 97ZZZX2595 2 19970522 G 8530 73806 PUSHROD CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA NR 2 EXH VLV MUSHROOMED D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 NE 01 69232 1897 15282575 L1709915 PILOT REPORTED ENGINE RUNS ROUGH. CHECKED VALVE CLEARANCE AND FOUND NR 2 EXHAUST TO BE .083 INCH. REMOVED NR 2 EXHAUST PUSHROD. PUSHROD FOUND MUSHROOMED AND BALL END WAS LOOSE. SUBMITTER SUGGESTS INSPECTING PUSHRODS FOR LOOSE BALL ENDS ANYTIME THE 100-HOUR VALVE TAPPET CLEARANCE INSPECTION DISCLOSES A LARGER THAN ACCEPTABLE VALUE OR WHEN LOW POWER IS NOT ED. REFERENCE LYCOMING SI 1388C AND SI 1068A. 1 H 7 1 3O 3 O NT 3A19 E223 1997060500501 19970605 00501 EA 1997 6 5 97ZZZX2596 3 19970518 G 6111 BLADE PIPER PA28 PA28180 7102808 SO SNSNCH 76E 76EM8S5 EA PROPELLER TIP SEPARATED D A UNSCHED LANDING E D VIBRATION/BUFFET INFLIGHT SEPARATION CR CRUISE 1 EA 13 7863W 3271 281884 8697K FOUR INCHES OF BLADE TIP SEPARATED IN-FLIGHT. AIRCRAFT RETURNED TO BASE IN REDUCED POWER SETTING. NO DAMAGE OR INJURIE S. 1 L 7 1 3O 2A13 5 N P4EA 1997060500502 19970605 00502 CE 1997 6 5 97ZZZX2597 1 19970429 G 2821 HE15262 GASKET BEECH 33 F33A 1151425 CE FUEL SELECT MISINSTALLED B AW4R K NONE O OTHER IN INSP/MAINT 1 WP 11 99MK HE763 CE742 PILOT REPORTED LOW FUEL FLOW AND HIGH EGT'S. AFTER EXTENSIVE T/S AND BENCH CHECK OF ENGINE FUEL INJECTION SYSTEM COMPON ENTS, DISCOVERED THE AIRFRAME FUEL SELECTOR VALVE SCREEN ASSY IMPROPERLY ASSEMBLED. ACFT EQUIPPED WITH STC'D TIP TANKS WHICH UTILIZED A NON-STANDARD FUEL SELECTOR VALVE. DUE TO DATE OF ISSUANCE OF STC, INSTRUCTIONS FOR CONTINUED AIRWORTHI NESS (MANDATED BY PAR 21.50) WERE NOT ISSUED BY THE STC HOLDER. BY NOT HAVING INSTRUCTIONS AVAILABE, IT IS POSSIBLE TO INCORRECTLY ASSEMBLE THE FUEL SCREEN WHICH CAN RESULT IN RESTRICTED FUEL FLOW AT HIGH POWER SETTINGS. THIS CAN RESULT I N EXCESSIVELY LEAN MIXTURES WITH EXCESSIVELY HIGH EGT'S WHICH CAN CAUSE CYLINDER DAMAGE AND POSSIBLE ENGINE FAILURE. 1 L 7 1 3O 3A15 1997060500503 19970605 00503 SO 1997 6 5 97ZZZX2598 2 19970519 G 8530 535666 SCREW 654761A1 BEECH 35 E35 1151512 CE CONT E225 E2258 17015 SO ROCKER SHAFT STRIPPED D K NONE O OTHER IN INSP/MAINT 1 WP 17 3251C D3916 30350D48 DURING CYLINDER INSTALLATION ATTEMPTING TO TORQUE ROCKER SHAFT HOLD-DOWN SCREWS RESULTED IN 2 SCREWS STRIPPING BEFORE TH E MINIMUM TORQUE OF 180 INCH/POUND WAS REACHED. THIS IS THE 2ND OCCURRENCE ON THIS ENGINE. BOTH TIMES THE CORRECTIVE A CTION WAS REPLACING SCREWS AND CLEANING THREADS IN ROCKER SHAFT. COULD NOT DETERMINE IF THREADS IN SHAFT ARE STRIPPING O R IF SCREWS ARE DEFECTIVE. 1 L 7 1 3O 3 O A777 E267 1997060500724 19970605 00724 1997 6 5 97ZZZX2606 1 19970506 G 7920 3038 HOSE AEROQUIP PLUGGED D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 15 AFTER INSTALLING FITTINGS ON A PIECE OF AEROQUIP 303-8 HOSE, FOUND HOSE CLOGGED. INVESTIGATION REVEALED APPROX 1 FOOT O F THE HOSE WAS SOLID RUBBER INSIDE. HOSE PURCHASED FROM AVSCO ON 4-28-97. BATCH NR MIL-H-8794-8-3096-248-06827. IF HOS E HAD NOT BEEN CHECKED AFTER INSTALLING FITTINGS, ENGINE OIL FLOW WOULD HAVE STOPPED AT OIL COOLER WITH DISASTROUS RESUL TS. HOSE SENT TO NTSB, MIA. 1997060500725 19970605 00725 SO 1997 6 5 97ZZZX2607 2 19970514 G 8530 SA10200A20P CYLINDER CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO BARREL FAILED D A UNSCHED LANDING E Y B VIBRATION/BUFFET ENGINE STOPPAGE SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 SW 17 148EL 1024 15077412 253635A48 ON A TRAINING FLIGHT, THE ENGINE STARTED RUNNING ROUGH. INSTRUCTOR REQUESTED DIRECT RETURN. WHITE SMOKE CAME FROM ENGI NE, A LOUD BANG, FOLLOWED BY VERY ROUGH ENGINE AND PARTIAL POWER LOSS. ENGINE STOPPED, SAFE LANDING, CYLINDER HEAD AND TOP ONE-THIRD OF BARREL SEPARATED FROM LOWER ONE-THIRD OF CYLINDER. PISTON DESTROYED, PUSH ROD BENT, SUBMITTER STATED CAUSE WAS DEFECTIVE CYLINDER BARREL, PREVENT BY USING NEW CONTINENTAL CYLINDERS. 1 H 7 1 3O 3 O 3A19 E252 1997060500726 19970605 00726 CE 1997 6 5 97ZZZX2608 1 19970324 G 3240 BRAKE LINE ZINAIR CH2000 CH2000 9950100 CE RT MLG FAILED G K NONE O OTHER IN INSP/MAINT 1 WP 09 25ZA 86 200025 DURING TAXI INSTRUCTION, RT MLG BRAKE ASSY FAILED. INSPECTION OF BRAKE PRESSURE DETERMINED THE .25 INCH NYLON TUBING (C LEAR) HAD A BUBBLE FORMED IN THE LINE AND HAD RUPTURED AT THAT POINT. DURING TAXI INST, IT IS BELIEVED THE STUDENT MAIN TAINED PRESSURE ON THE RT BRAKE CAUSING BRAKE DISK TO BUILD UP EXCESSIVE HEAT WHICH WAS TRANSFERRED TO THE NYLON LINE WH ICH IS ROUTED CLOSE TO THE DISK. ACFT HAS WHEEL FAIRINGS INSTALLED MAKING PRE-FLIGHT INSPECTION OF THIS AREA VERY DIFFI CULT. 1 L 7 1 3O NT TA5CH 1997060500727 19970605 00727 SO 1997 6 5 97ZZZX2609 1 19970428 G 7603 472606 ROD END 455359 PIPER PA32 PA32300 7103212 SO THROTTLE FAILED D K NONE O OTHER IN INSP/MAINT 1 EA 21 32641 327540054 LOST THROTTLE CONTROL. INSPECTION FOUND BALL AND BEARING HAD COME OUT OF ROD END, P/N 472-606. CAN REPLACE WITH P/N 317 47-00, JOINT ASSY. IF NEW PART FOR ROD END USED, P/N 472-606, USE AN 'AN' 970-3 WASHER UNDER BOLT HEAD SO HOUSING CANNO T SLIP OFF. 1 L 7 1 3O A3SO 1997060500728 19970605 00728 CE 1997 6 5 97ZZZX2610 1 19970515 G 3230 NAS505SJ BEARING BEECH 36 A36 1151604 CE RT MLG UPLOCK FROZEN D A K NONE O OTHER IN INSP/MAINT 1 SO 15 37CH E1460 RIGHT LANDING GEAR UPLOCK ROLLER BEARING FROZEN CAUSING RT LANDING GEAR NOT TO RELEASE FROM ROLLER. SUBMITTER SUGGESTS MAY HAVE BEEN CAUSED BY NOT LUBING AT LAST INSPECTION. 1 L 7 1 3O 3A15 1997060500732 19970605 00732 CE 1997 6 5 97ZZZX2614 1 19970514 G 5730 SKIN CESSNA 402 402B 207590P CE RT WING CRACKED C K NONE O OTHER IN INSP/MAINT 1 SW 01 5040Q 402B0347 DURING A 50-HOUR INSPECTION, MECHANIC NOTICED CRACK IN WING SKIN IN THE MOST AFT OTBD SECTION OF RT WING. ALSO, TWO RIV ETS WERE SHEARED THAT ATTACH THE OTBD HINGE BRACKET ASSY (CESSNA PN 5021002-13) WHICH ARE THE SAME RIVETS THAT ATTACH TI P TANK SUPPORT BRACKETS (CESSNA PN 0822600-29 AND 30) TO THE WING. THE MOST OTBD WING RIB CRACKED IN MOST AFT LOWER SEC TION (CESSNA PN 0822040-18). SUSPECT CAUSES: TIP TANK STRINGER (MOST AFT POINT) HAS SLIGHT DAMAGE AS THOUGH IT HAS STR UCK A SOLID OBJECT. AMOUNT OF WEIGHT WITH A FULL TANK OF FUEL BOUNCING ON THE TIP OF THE WING COULD ALSO BE A CONTRIBUT ING FACTOR. 1 L 7 2 3O A7CE 1997060500733 19970605 00733 CE 1997 6 5 97ZZZX2615 1 19970514 G 5720 502100213 SUPPORT BRACKET CESSNA 402 402B 207590P CE RT WING RIVETS SHEARED C K NONE O OTHER IN INSP/MAINT 1 SW 01 5040Q 402B0347 DURING A 50-HOUR INSPECTION, MECHANIC NOTICED CRACK IN WING SKIN IN THE MOST AFT OTBD SECTION OF RT WING. ALSO, TWO RIV ETS WERE SHEARED THAT ATTACH THE OTBD HINGE BRACKET ASSY (CESSNA PN 5021002-13) WHICH ARE THE SAME RIVETS THAT ATTACH TI P TANK SUPPORT BRACKETS (CESSNA PN 0822600-29 AND 30) TO THE WING. THE MOST OTBD WING RIB CRACKED IN MOST AFT LOWER SEC TION (CESSNA PN 0822040-18). SUSPECT CAUSES: TIP TANK STRINGER (MOST AFT POINT) HAS SLIGHT DAMAGE AS THOUGH IT HAS STR UCK A SOLID OBJECT. AMOUNT OF WEIGHT WITH A FULL TANK OF FUEL BOUNCING ON THE TIP OF THE WING COULD ALSO BE A CONTRIBUT ING FACTOR. 1 L 7 2 3O A7CE 1997060500734 19970605 00734 CE 1997 6 5 97ZZZX2616 1 19970514 G 5712 082204018 RIB CESSNA 402 402B 207590P CE RT WING OTBD CRACKED C K NONE O OTHER IN INSP/MAINT 1 SW 01 5040Q 402B0347 DURING A 50-HOUR INSPECTION, MECHANIC NOTICED CRACK IN WING SKIN IN THE MOST AFT OTBD SECTION OF RT WING. ALSO, TWO RIV ETS WERE SHEARED THAT ATTACH THE OTBD HINGE BRACKET ASSY (CESSNA PN 5021002-13) WHICH ARE THE SAME RIVETS THAT ATTACH TI P TANK SUPPORT BRACKETS (CESSNA PN 0822600-29 AND 30) TO THE WING. THE MOST OTBD WING RIB CRACKED IN MOST AFT LOWER SEC TION (CESSNA PN 0822040-18). SUSPECT CAUSES: TIP TANK STRINGER (MOST AFT POINT) HAS SLIGHT DAMAGE AS THOUGH IT HAS STR UCK A SOLID OBJECT. AMOUNT OF WEIGHT WITH A FULL TANK OF FUEL BOUNCING ON THE TIP OF THE WING COULD ALSO BE A CONTRIBUT ING FACTOR. 1 L 7 2 3O A7CE 1997060500735 19970605 00735 CE 1997 6 5 97ZZZX2617 1 19970520 G 5330 SKIN CESSNA 210 T210N 2073456 CE SERVO MT BS 166 CRACKED D A K NONE O OTHER IN INSP/MAINT 1 WP 23 5144U 2230 21064851 UPON INVESTIGATION OF SKIN CRACK AT FS 166.4 IN THE TOP AREA OF EMPENNAGE, DETERMINED CESSNA FACTORY INSTALLED AUTOPILOT PITCH SERVO ATTACHED TO STA 166.4 BULKHEAD AND AREA SKIN FAILED. A TEAR-LIKE CRACK OCCURRED ON SKIN AND TWO CRACKS FOU ND ON LOCATION BULKHEAD IN AREA OF SERVO MOUNT ATTACH. INVESTIGATION DISCLOSED SERVO MOUNT DID NOT INCLUDE ANY DOUBLER OR STIFFENER TO SKIN OR BULKHEAD. CESSNA AUTOPILOT SM ALSO DID NOT INCLUDE DOUBLER OR STIFFENER TO SUPPORT SERVO MOUNT . 1 H 7 1 3O 3A21 1997060500736 19970605 00736 CE 1997 6 5 97ZZZX2618 1 19970421 G 5313 2611201 LONGERON CESSNA 208 208B 2073701 CE BELLY SKIN CORRODED D K NONE O OTHER IN INSP/MAINT 1 SW 05 5187B 3828 208B0270 ON INSPECTION, CORROSION WAS FOUND ON LONGERONS BETWEEN FS 188.70 AND FS 214.40 AND ON THE BELLY SKIN FLANGE WHERE THE N UTPLATES ARE INSTALLED FOR THE MLG FORWARD STRAPS TO BOLT ONTO. THIS ACFT CAME FROM A SALT WATER CLIMATE. WATER RUNS I NTO WING ATTACH AREA DOWN TO FUEL RESERVOIR TANK AREA. THE TANK AREA IS SEALED. CESSNA DID HAVE A DRAIN IN THE BAY JUS T OUTBOARD OF THE AREA OF CORROSION, HOWEVER, DRAIN WAS PLUGGED UP WHEN POD INSTALLED WHICH GAVE NO MEANS TO DRAIN THIS AREA. CESSNA HAS BEEN CONTACTED FOR A SOLUTION. 1 H 7 1 3T A37CE 1997060500737 19970605 00737 CE 1997 6 5 97ZZZX2619 1 19970421 G 5313 2611202 LONGERON CESSNA 208 208B 2073701 CE BELLY SKIN CORRODED D A K NONE O OTHER IN INSP/MAINT 1 SW 05 5187B 3828 208B0270 ON INSPECTION, CORROSION WAS FOUND ON LONGERONS BETWEEN FS 188.70 AND FS 214.40 AND ON THE BELLY SKIN FLANGE WHERE THE N UTPLATES ARE INSTALLED FOR THE MLG FORWARD STRAPS TO BOLT ONTO. THIS ACFT CAME FROM A SALT WATER CLIMATE. WATER RUNS I NTO WING ATTACH AREA DOWN TO FUEL RESERVOIR TANK AREA. THE TANK AREA IS SEALED. CESSNA DID HAVE A DRAIN IN THE BAY JUS T OUTBOARD OF THE AREA OF CORROSION, HOWEVER, DRAIN WAS PLUGGED UP WHEN POD INSTALLED WHICH GAVE NO MEANS TO DRAIN THIS AREA. CESSNA HAS BEEN CONTACTED FOR A SOLUTION. 1 H 7 1 3T A37CE 1997060500738 19970605 00738 SO 1997 6 5 97ZZZX2620 2 19970501 G 8530 CYLINDER CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO NR 4 STUDS FAIL D A UNSCHED LANDING O OTHER CR CRUISE 1 AL 05 5246E 779 18503943 281256R PILOT HEARD AND FELT ABRUPT CHANGE IN ENGINE 10 MINUTES INTO FLIGHT. UNEVENTFUL RETURN TO BASE WITH ENGINE INSTRUMENTS NORMAL. NR 4 CYLINDER HAD SHEARED ALL 8 STUDS AND HAD SEPARATED .50 INCH FROM CASE. ENGINE HAD HISTORY OF PROP STRIKE TEAR-DOWN 460 HRS PRIOR TO FAILURE. 1 H 7 1 3O 3 O 3A24 E5CE 1997060500741 19970605 00741 CE 1997 6 5 97ZZZX2623 1 19970517 G 7160 BA5110A AIR FILTER CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA AIR INDUCT WRONG PART D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 17 64154 7 17265049 L4166627A DURING ANNUAL INSPECTION, BRACKETT AIR FILTER ASSY WAS FOUND LOOSE ON THE AIRBOX. UPON REMOVAL, IT WAS FOUND TO BE THE INCORRECT ASSEMBLY FOR THE AIRCRAFT MODEL. THE MODEL 172M USES ASSEMBLY NR BA 5110, A BA 5710A WAS INSTALLED. THE CAML OCK STUDS ON THE BA 5110A ARE TOO LONG. THE BASE GASKET WOULD NOT CONTACT THE AIRBOX LEAVING IT LOOSE AND FLOPPING. 1 H 7 1 3O 3 O NT 3A12 E274 1997060500742 19970605 00742 EA 1997 6 5 97ZZZX2624 2 19970521 G 7310 HOSE AEROQUIP PIPER PA24 PA24250 7102404 SO LYC O540 O540A1A5 41532 EA ENGINE COMPT DETERIORATED D K NONE O OTHER IN INSP/MAINT 1 GL 07 8174P 2884 243430 FUEL HOSES IN ENGINE COMPARTMENT. ORIGNAL HOSES DATED 1962. HOSES WERE VERY STIFF, BUT NOT LEAKING. SHOULD HAVE BEEN CHANGED BEFORE THEY LOSE FLEXABILITY. 1 L 7 1 3O 3 O 1A15 E295 1997060500743 19970605 00743 SO 1997 6 5 97ZZZX2625 1 19970516 G 7922 75944 VALVE PIPER PA32 PA32R301T 7103220 SO THERMO BYPASS LOOSE CRIMP NUT D K NONE O OTHER IN INSP/MAINT 1 NM 01 8387D 63736 32R8129072 VERNATHERM VALVE INSPECTED PER LYCOMING SB 518C. NUT LOOSE. SUBMITTER STATED VALVES CONTINUE TO BE A PROBLEM. THIS BU LLETIN SHOULD BE MADE INTO AN AIRWORTHINESS DIRECTIVE. 1 L 7 1 3O A3SO 1997060500744 19970605 00744 SO 1997 6 5 97ZZZX2626 1 19970428 G 7922 53E19600 VALVE PIPER PA31 PA31350 7103110 SO THERMO BYPASS NUT LOOSE D K NONE O OTHER IN INSP/MAINT 1 EA 21 89PA 872 317952110 FOUND NUT LOOSE. LYC SB 518C DOES NOT APPLY. THIS VALVE ABOVE S/N LIST IN SB 518C. USE VALVE MADE BY SUPERIOR. IT HA S ROLL PIN TO HOLD NUT ON VALVE. 1 L 7 2 3O A20SO 1997060500745 19970605 00745 CE 1997 6 5 97ZZZX2627 1 19970501 G 3222 BRACE BEECH 35 K35 1151524 CE UPPER NLG CORRODED G A K NONE O OTHER IN INSP/MAINT 1 EA 21 9520R D6154 ABOVE THE LOWER BEARING IN THIS CASTING, THERE IS CORROSION ALL THE WAY THROUGH THE NOSE WHEEL BRACE ASSY. THE CORROSIO N IS ON THE INSIDE AND HARD TO SEE WITHOUT DISASSEMBLING. TOTAL TIME ON THIS AIRCRAFT IS 3,315 HRS. 1 L 7 1 3O 3A15 1997060500746 19970605 00746 WP 1997 6 5 97ZZZX2628 2 19970227 G 7320 APR SYSTEM LEAR 55 55LEAR 5170702 CE GARRTT TFE731 TFE7313A 01518 WP ENGINE MALFUNCTION D K NONE O OTHER NR NOT REPORTED 1 SW 99 646G 763 108291 016 AUXILIARY PERFORMANCE RESERVE (APR). WHEN SYSTEM IS 'ARMED' SYSTEM GOES STRAIGHT TO 'ON' WHEN N2'S ARE MATCHED. 2 L 7 2 4F 4 F A10CE E6WE 1997060500747 19970605 00747 NM 1997 6 5 97ZZZX2629 1 19970512 G 2782 654476015 ACTUATOR BOEING 737 737* NM LE SLAT MISMODIFIED H L A K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 03 SLAT ACTUATOR FAILED TO OPERATE PROPERLY UPON INSTALLATION. INITIAL INSPECTION AND TESTING REVEALED COMPONENT TO BE THE DASH 12 CONFIGURATION RATHER THAN DASH 15 CONFIGURATION. THE CURRENT CONFIGURATION WAS DETERMINED BY THE LENGTH OF STR OKE AND A BEARING PART NUMBER. CUSTOMER STATES THIS UNIT HAS NOT BEEN OPERATED SINCE OVERHAUL. 2 L 7 2 4F RT A16WE 1997060500748 19970605 00748 1997 6 5 97ZZZX2630 4 19970508 G 6122 1355780REVA PACKING WOODWARD 8210212D BEECH 300 300BEECH 1152930 CE BETA VLV SHAFT DEFECTIVE C W0VM O OTHER J WARNING INDICATION LD LANDING 1 EA 09 1WV 63 2137236 FA62 WHEN POWER WAS REDUCED DURING LANDING FLARE, RT PROP WENT TO A FLATTER PITCH THAN LEFT. BELIEVE O-RING TO BE TIGHT IN B ORE OF BETA VALVE. REPLACED O-RING. MADE NO CHANGES IN RIGGING. NEW O-RING PERFORMED SATISFACTORY. 2 L 7 2 4T A24CE 1997060500749 19970605 00749 WP 1997 6 5 97ZZZX2631 2 19970513 G 7261 31081381 GASKET SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP TURB SCAV PUMP FAILED B ATZR K NONE E VIBRATION/BUFFET NR NOT REPORTED 1 CE 09 19WP 3154 TC390 P54286 SCAVENGE PUMP GASKET WENT BAD CAUSING SLOW LOSS OF ENGINE OIL. ALSO, THIS CAUSED VIBRATION TO BREAK OIL JET AT PUMP ASS Y. NEW STYLE GASKET NOW INSTALLED. 2 L 7 2 4T 4 T RT A8SW E4WE 1997060500750 19970605 00750 WP 1997 6 5 97ZZZX2632 2 19970407 G 7250 8682721 ROTOR SWRNGN SA226 SA226T 8780122 SW GARRTT TPE331 TPE3313U 01514 WP 2ND STAGE TURB CRACKED B S2WR K NONE O OTHER IN INSP/MAINT 1 WP 07 264B 2842 80134510069 T221 P03074C SECOND STAGE TURBINE ROTOR EXHIBITS RIVET HOLE CRACKS 0.020 INCH TO 0.050 INCH DEEP. DEFECT DISCOVERED 200 HOURS AFTER HOT SECTION INSPECTION AT UNSCHEDULED ENGINE REMOVAL. 2 L 7 2 4T 4 T RT A5SW E4WE 1997060500751 19970605 00751 EU 1997 6 5 97ZZZX2633 1 19970522 G 2130 25VF3323309 CONTROL LINE BRAERO DH125 BAE125800A 1500285 EU PRESS VENTURI CHAFED B P JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 300GN 3315 258057 REMOVED CABIN FLOOR PANEL F61A AT FRAME 9 RT SIDE FOR UNRELATED MAINTENANCE WORK. FOUND PRESSURIZATION VENTURI CONTROL LINE CUT APPROXIMATELY ONE-HALF WAY THROUGH FROM LOWER AILERON CABLE CONTACTING LINE WHENEVER AILERON CONTROL WHEEL MOVE D. AFTER FURTHER INSPECTION, IT APPEARS LINE WAS NOT INSTALLED WITH SUFFICIENT CLEARANCE FROM CABLE. INSPECTED CABLE, F OUND NOT TO BE WORN. INSTALLED NEW LINE AND PROVIDED PROPER CLEARANCE. 2 L 7 2 4F RT A3EU 1997060500752 19970605 00752 SW 1997 6 5 97ZZZX2634 1 19970404 G 3240 111672BD090S0000 BRAKE LINE SWRNGN SA226 SA226T 8780122 SW OTBD BRAKE ASSY BROKEN D K NONE O OTHER IN INSP/MAINT 1 GL 23 39MS T257 WHILE REMOVING BRAKE ASSY, NORMAL FLEXING OF OTBD BRAKE LINE CAUSED LINE TO BREAK OFF AT METAL FERRULE. FURTHER INVESTIG ATION REVEALED LINE WAS SO BRITTLE, IT LITERALLY SNAPPED OFF RIGHT THROUGH THE FABRIC AND METAL BRAIDING. RESEARCH OF L OG BOOKS SHOWED THE BRAKE LINES ARE ORIGINAL AND ALL HAVE A MANUFACTURE DATE OF 1974. NO TIME LIFE REQUIREMENTS, SB'S, SL'S, OR AD'S WERE FOUND THAT ADDRESSES THE CHANGE OF THESE BRAKE LINES. SUBMITTER RECOMMENDED OPERATOR OF THESE AIRCRA FT CHECK MANUFACTURE DATE AND INSPECT BRAKE LINES AND REPLACE, AS NEEDED, BEFORE A FAILURE OCCURS. 2 L 7 2 4T RT A5SW 1997061200124 19970612 00124 CE 1997 6 12 97ZZZX2636 1 19970402 G 3244 850T061 TIRE GOODYEARAERO MTSBSI MU2 MU2B36 5780412 CE RT MLG SEPARATION D K NONE O OTHER LD LANDING 1 NM 09 500PJ 284 51710805 668 RIGHT HAND MAIN GEAR TIRE TREAD SEPARATED FROM CASING ALONG INBOARD EDGE COMPLETELY AROUND CIRCUMFERENCE. OCCURRED ON L ANDING. TIRE REMAINED INFLATED. TREAD STAYED ATTACHED AROUND OUTBOARD EDGE CIRCUMFERENCE. THIS WAS ONE OF THREE SIMIL AR OCCURRENCES WITHIN 30 DAYS ON TWO DIFFERENT AIRCRAFT (BOTH MU-2'S). TIRE RETURNED TO MFG FOR EVALUATION. 1 H 7 2 3T RT A10SW 1997061200125 19970612 00125 CE 1997 6 12 97ZZZX2637 1 19970430 G 3244 850T061 TIRE GOODYEARAERO MTSBSI MU2 MU2B36 5780412 CE LT MLG SEPARATION D K NONE O OTHER IN INSP/MAINT 1 NM 09 500PJ 228 51582304 668 LEFT HAND MAIN GEAR TIRE TREAD SEPARATED FROM CASING ALONG INBOARD EDGE FOR APPROXIMATELY 10 INCHES. OCCURRED ON LANDIN G. TIRE REMAINED INFLATED. THIS WAS ONE OF 3 SIMILAR OCCURRENCES WITHIN 30 DAYS ON TWO DIFFERENT MU-2'S. TIRE WAS RET URNED TO MFG FOR EVALUATION. 1 H 7 2 3T RT A10SW 1997061200126 19970612 00126 CE 1997 6 12 97ZZZX2638 1 19970421 G 3260 1CH16 SWITCH LEAR 35 35A 5170602 CE NLG ACTUATOR INTERMITTENT B DJFR K NONE O OTHER IN INSP/MAINT 1 EA 23 425AS 281 DURING LANDING GEAR RETRACTION FOR MAINTENANCE, NOSE GEAR DOWNLOCK LIGHT BECAME INTERMITTENT. TROUBLESHOT TO NOSE GEAR ACTUATOR DOWNLOCK SWITCH. REMOVED SWITCH AND FOUND WIRE POTTING COMPOUND CRACKED AT SWITCH CASE. WHEN WIRES WERE FLEXE D AT CRACK, CONNECTION WAS INTERMITTENT. THE NEW SWITCH HAD A MUCH MORE FLEXIBLE POTTING COMPOUND. SUGGEST CLOSE ATTEN TION TO POTTING COMPOUND AREA OF SWITCH WHERE WIRES FLEX. 2 L 7 2 4F A10CE 1997061200127 19970612 00127 EU 1997 6 12 97ZZZX2639 1 19970430 G 2752 1181 MOTOR AVIAC60144 AMD FALC10 FALCON10 2730101 EU FLAP GEARBOX SCREW LOOSE D S A K NONE O OTHER IN INSP/MAINT 1 GL 09 654PC 1107 190 131 PILOTS REPORTED FLAP CIRCUIT BREAKER TRIPPED ON SELECTION, RESET AND WORKED FINE. OPS CHECKED ON GROUND, COULD NOT DUPL ICATE. APPROXIMATELY 20 DAYS LATER, HAPPENED AGAIN. REMOVED FLAP REDUCTION GEAR MOTOR, DISASSEMBLED, FOUND SET SCREW, PN ATQ1ED040005UL, AND NUT, PN 936-003, LAYING LOOSE IN HOUSING. THERE WAS DAMAGE TO CLUTCH SPRINGS AND OTHER SIGNS OF CONTACT IN GEARBOX. 2 L 7 2 4F A33EU 1997061200128 19970612 00128 CE 1997 6 12 97ZZZX2640 1 19970506 G 2430 60884082 GCU LEAR 60 60LEAR 5170707 CE NR 2 BATTERY STUD LOOSE D P K NONE M OVER TEMP IN INSP/MAINT 1 EA 25 660AH 1356 017 STUD THAT CONNECTS NR 2 BATTERY TO BATTERY BUSS IS LOOSE. DISCREPANCY FOUND DURING 300-HOUR INSPECTION. STUD LOCATED IN THE GENERATOR CONTROL PANEL. EVIDENCE OF OVERHEAT CONDITION. 2 L 7 2 4F RT A10CE 1997061200129 19970612 00129 EU 1997 6 12 97ZZZX2641 1 19970513 G 5610 WINDSHIELD AMD FALC50 FALCON50MYST 2730106 EU COPILOT OUTER CRACKED B JGVR O OTHER O OTHER CR CRUISE 1 CE 09 747Y 50 OUTER WINDSHIELD CRACKED WHILE AIRCRAFT WAS IN CRUISE FLIGHT. AIRCRAFT WAS VISUALLY INSPECTED AND DETERMINED IN AIRWORT HY CONDITION. SUSPECT CAUSE OF CRACK WAS A DEFECT IN THE OUTER PANEL OF THE WINDSHIELD. 2 L 7 3 4F A46EU 1997061200130 19970612 00130 1997 6 12 97ZZZX2642 4 19970514 G 3425 727421 CIRCUIT BREAKER BRAERO DH125 BAE125800A 1500285 EU EFIS PWR SUPPLY SHORTED B S JGVR K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CE 09 800N 6739 258003 WHILE PERFORMING 1,200 HOUR CHECK (CODE 340009 ON PAGE 4 OF CHAPTER 5) OF EFIS POWER SUPPLIES, FOUND EFIS TUBES TO BLANK OUT WITH RT GENERATOR OFF AND BUS TIE OPEN. FURTHER INVESTIGATION FOUND 35 AMP CIRCUIT BREAKER B5 (TO FEED PS1B BUS FR OM PS1 BUS) ON PANEL ZK TRIPPED. THIS C/B WAS CHANGED. ANOTHER ENGINE RUN TO FUNCTION TEST THIS SYSTEM SHOWED (WITH RT GENERATOR OFF AND BUS TIE OPEN) EFIS TUBES TO REMAIN ON FOR ABOUT 10 SECONDS AND THEN 35 AMP B5 BREAKER WOULD TRIP WITH 22 VOLTS SHOWING ON PS2 BUS (SHOULD READ ZERO). WHILE ISOLATING VOLTAGE SOURCE, FOUND SMOKE COMING FROM SUBPANEL 'C' O F DA PANEL. FOUND LOWER TERMINAL OF 1 AMP BREAKER (PN 7274-2-1) FOR 'EFIS EQUIP NR 1' ABRADED INTO A WIRE BUNDLE. 2 L 7 2 4F RT A3EU 1997061200131 19970612 00131 CE 1997 6 12 97ZZZX2643 1 19970417 G 3244 850T061 TIRE GOODYEARAERO MTSBSI MU2 MU2B36 5780412 CE RT MLG SEPARATION D K NONE O OTHER IN INSP/MAINT 1 NM 09 869P 300 51701608 692 RIGHT HAND MAIN GEAR TIRE TREAD SEPARATED FROM CASING ALONG INBOARD EDGE FOR APPROXIMATELY 1 INCH. SEPARATION NOTICED D URING A POST-FLIGHT WALK AROUND INSPECTION. THIS WAS ONE OF THREE SIMILAR OCCURRENCES WITHIN 30 DAYS ON TWO DIFFERENT M U-2'S. TIRE WAS RETURNED TO MFG FOR EVALUATION. 1 H 7 2 3T RT A10SW 1997061200132 19970612 00132 1997 6 12 97ZZZX2644 4 19970426 G 2563 400 PARACHUTE RELATIVE 3253 STEERING LINES MALFUNCTION H O OTHER O OTHER NR NOT REPORTED 1 SW 15 RESERVE PARACHUTE ACTIVATED DUE TO MAIN CHUTE MALFUNCTION FOLLOWING DROGUE RELEASE. THE SLIDE HUNG UP THREE-FOURTHS OF THE WAY BY TENSION KNOTS ON BOTH STEERING LINES. RESERVE EMERGENCY PROCEDURES EXECUTED NORMALLY. 1997061200133 19970612 00133 1997 6 12 97ZZZX2645 4 19970414 G 2561 KS9 LIFE VEST EAAEROMARINE CELL FAIL TEST B KQ1R K NONE L NO TEST IN INSP/MAINT 1 EA 07 BB1482 LIFE VEST FAILED THE MANUFACTURER'S 2 PSI INFLATION TEST. 1997061200134 19970612 00134 1997 6 12 97ZZZX2646 4 19970417 G 2561 KS9 LIFE VEST EAAEROMARINE CELL FAIL TEST B KQ1R K NONE L NO TEST IN INSP/MAINT 1 EA 07 B18664 LIFE VEST FAILED THE MANUFACTURER'S 2 PSI INFLATION TEST. 1997061200135 19970612 00135 1997 6 12 97ZZZX2647 4 19970528 G 2561 KS9 LIFE VEST EAAEROMARINE CELL FAIL TEST B KQ1R K NONE L NO TEST IN INSP/MAINT 1 EA 07 C77644 LIFE VEST FAILED 2 PSI TEST. 1997061200136 19970612 00136 1997 6 12 97ZZZX2648 4 19970414 G 2561 GA12 LIFE VEST EAAEROMARINE CELL FAIL TEST B KQ1R K NONE L NO TEST IN INSP/MAINT 1 EA 07 A76108 LIFE VEST FAILED THE MANUFACTURER'S 2 PSI INFLATION TEST. 1997061200137 19970612 00137 1997 6 12 97ZZZX2649 4 19970414 G 2561 KS9 LIFE VEST EAAEROMARINE CELL FAIL TEST B KQ1R K NONE L NO TEST IN INSP/MAINT 1 EA 07 B18454 LIFE VEST FAILED THE MANUFACTURER'S 2 PSI INFLATION TEST. 1997061200138 19970612 00138 SO 1997 6 12 97ZZZX2650 1 19970524 G 2750 451813 TRANSMISSION PIPER PA31T PA31T 7103124 SO FLAP EXCESS WEAR D K NONE O OTHER IN INSP/MAINT 1 WP 11 111KV 97020016 31T7920035 FLAP TRANSMISSION INSTALLED ON PIPER PA31T. EXCESSIVE JACK SCREW WEAR EXCEEDED LIMITS IN 60-DAY PERIOD. PART WAS ORIGI NALLY REBUILT BY MANUFACTURER. PART RETURNED TO MANUFACTURER FOR EVALUATION. TOTAL TIME ON PART, 99.6 HOURS, APPROXIMA TELY 70 CYCLES. 1 L 7 2 3T A8EA 1997061200139 19970612 00139 EU 1997 6 12 97ZZZX2651 1 19970514 G 3221 TB1042010005 MOUNT SOCATA TB9 TB9 8680694 EU NLG CORRODED D A K NONE O OTHER IN INSP/MAINT 1 SO 15 142ER 4304 1337 NOSE GEAR MOUNT TUBE RUSTED FROM INSIDE OUT. SUBMITTER STATED RUSTED AREA 2ND ONE FOUND IN FLEET. 1 L 7 1 3O NT AS1EU 1997061200140 19970612 00140 EA 1997 6 12 97ZZZX2652 2 19970520 G 8500 ENGINE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA POWER SECTION FAILED D O OTHER J WARNING INDICATION DE DESCENT 1 AL 01 3582P 7799 1391 318052103 L655361A DURING DESCENT TO LANDING, PILOT NOTICED MANIFOLD PRESSURE STARTING TO DECREASE, FUEL FLOW INCREASE AND CYLINDER HEAD TE MP DECREASE AND THE EXHAUST GAS TEMP DECREASE. AFTER LANDING AND ON THE GROUND, THE ENGINE WOULD ONLY PRODUCE 2,200 RPM AND 28 INCHES OF MANIFOLD PRESSURE. THE OIL SCREENS WERE CHECKED WITH AN EXCESIVE AMOUNT OF STEEL AND ALUMINUM SHAVING S FOUND. THE ENGINE WAS REMOVED FROM SERVICE FOR A TEAR DOWN INSPECTION. 1 L 7 2 3O 3 O A20SO E14EA 1997061200141 19970612 00141 SO 1997 6 12 97ZZZX2653 1 19970501 G 5711 6707002 SPAR PIPER PA28 PA28R180 7102809 SO LT WING CORRODED D K NONE O OTHER IN INSP/MAINT 1 NE 05 3760T 4500 28R30069 DURING ANNUAL INSPECTION, FOUND LT WING MAIN SPAR UPPER CAP SEVERELY CORRODED ON FWD FLANGE. ONLY WAY TO DETECT IS WITH A MIRROR THROUGH FWD WHEELWELL INSPECTION PANEL. WING REMOVED AND SPAR REPLACED. SUBMITTER STATED INTERGRANULAR CORROS ION IS THE CAUSE. 1 L 7 1 3O 2A13 1997061200142 19970612 00142 SO 1997 6 12 97ZZZX2654 1 19970501 G 5753 6232840 RIB 6232000 PIPER PA28 PA28R180 7102809 SO LT FLAP CORRODED D K NONE O OTHER IN INSP/MAINT 1 NE 05 3760T 4500 28R30069 DURING ANNUAL INSPECTION, FOUND BOTH LT AND RT FLAP OTBD HINGE BRACKETS ATTACHED TO FLAPS WORKING WERE FREE DUE TO CORRO SION ON END CAPS. REMOVED AND REPLACED CAPS AND REATTACHED BRACKETS. CAUSE OF FAILURE APPEARS TO BE DISSIMILAR METAL C ORROSION. 1 L 7 1 3O 2A13 1997061200143 19970612 00143 SO 1997 6 12 97ZZZX2655 1 19970501 G 5753 6232901 RIB 6232002 PIPER PA28 PA28R180 7102809 SO RT FLAP CORRODED D K NONE O OTHER IN INSP/MAINT 1 NE 05 3760T 4500 28R30069 DURING ANNUAL INSPECTION, FOUND BOTH LT AND RT FLAP OTBD HINGE BRACKETS ATTACHED TO FLAPS WERE WORKING FREE DUE TO CORRO SION ON END CAPS. REMOVED AND REPLACED CAPS AND REATTACHED BRACKETS. CAUSE OF FAILURE APPEARS TO BE DISSIMILAR METAL C ORROSION. 1 L 7 1 3O 2A13 1997061200144 19970612 00144 SO 1997 6 12 97ZZZX2656 2 19970404 G 8530 J92KBW CYLINDER CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO SLEEVE CRACKED B BUPR K NONE O OTHER IN INSP/MAINT 1 EA 23 45511 653426 15076955 1994529A WHILE CHANGING PUSHROD SEALS, A CRACK WAS FOUND IN THE CYLINDER SLEEVE, THE CRACK IS ABOUT 1.5 INCHES LONG AND TRAVELED RADIALLY. THE CRACK IS ABOUT 2 INCHES UP FROM THE BASE FLANGE. 1 H 7 1 3O 3 O 3A19 E252 1997061200146 19970612 00146 CE 1997 6 12 97ZZZX2658 1 19970506 G 5753 052323113 FLAP TRACK CESSNA 172 172M 2072418 CE LT FLAP WELL CORRODED D K NONE O OTHER IN INSP/MAINT 1 SO 05 64134 7052 17265039 SEVERE CORROSION AND WEAR FOUND ON TRACK DURING ANNUAL INSPECTION. TRACK AND ROLLERS SHOWED NO SIGNS OF RECENT LUBRICAT ION. TRACK IS AVAILABLE FOR INSPECTION. 1 H 7 1 3O NT 3A12 1997061200147 19970612 00147 EA 1997 6 12 97ZZZX2659 2 19970514 G 8530 SL15345 PUSHROD CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA ENGINE CYLINDER FAILED B QX2R K NONE O OTHER IN INSP/MAINT 1 EA 11 738QZ 312 17270167 L577876T BALL END OF PUSHROD BROKEN OFF. SUBITTER STATED A POSSIBLE MANUFACTURE MACHINING DEFECT. 1 H 7 1 3O 3 O NT 3A12 E274 1997061200148 19970612 00148 SO 1997 6 12 97ZZZX2660 2 19970505 G 8530 641916 CYLINDER CESSNA 172 172B 2072406 CE CONT O300 O300D 17022 SO HEAD CRACKED H K NONE O OTHER IN INSP/MAINT 1 EA 13 8220X 3518 705 17248720 24677010 DURING AN INSPECTION, CYLINDER WAS FOUND WITH LOW COMPRESSION/EXHAUST VALVE LEAKAGE. CYLINDER WAS REMOVED FOR REPAIR AN D SENT TO ENGINE SHOP. AFTER CLEANING, NOTED THE HEAD WAS CRACKED FROM THE ROCKER COVER FLANGE THROUGH THE EXHAUST PORT AND ACROSS TO THE UPPER SPARKPLUG HOLE. CYLINDER WAS REPLACED WITH A NEW ASSEMBLY. 1 H 7 1 3O 3 O NT 3A12 E253 1997061200149 19970612 00149 SO 1997 6 12 97ZZZX2661 2 19970331 G 8530 SA10200A20P CYLINDER CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO NR 3 FAILED B BUPR A UNSCHED LANDING R PARTIAL RPM/PWR LOSS DE DESCENT 1 EA 23 8898U 145 15078019 264405A48 WHILE PERFORMING A POWER OFF STALL TO FULL POWER RECOVERY, PILOT FELT ENGINE BEGIN TO RUN ROUGH. WHILE RETURNING TO AIR PORT, IT STARTED TO GET WORSE. PILOT SUCCESSFULLY LANDED AIRCRAFT. UPON INSPECTION, FOUND NR 3 CYLINDER SPLIT IN HALF ABOUT 2 INCHES UP FROM BASE FLANGE. VISUAL INSPECTION OF BREAK SHOWED 90 PERCENT SMOOTH AND 10 PERCENT JAGGED EDGE. PI STON AND CONNECTING ROD WERE BOTH DESTROYED. 1 H 7 1 3O 3 O 3A19 E252 1997061200150 19970612 00150 EA 1997 6 12 97ZZZX2662 2 19970526 G 7322 RSA5AD1 SERVO PIPER PA24 PA24260 7102406 SO LYC O540 IO540D4A5 41532 EA FUEL INJ SEAL LEAK D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SO 16 991K 6543 244055 L138248 ENGINE ROUGHNESS DUE TO EXCESS RIGH MIXTURE. FOUND RECENT OVERHAULED SERVO TO BE AT FAULT DUE TO SEAL LEAKING FUEL INTO AIR CHAMBER. SERVO TSO SERVICE 30 HOURS. SEAL, S/N 2539561. 1 L 7 1 3O 3 O 1A15 1E4 1997061200151 19970612 00151 SO 1997 6 12 97ZZZX2663 1 19970501 G 3211 6704013 TRUNNION PLATE PIPER PA34 PA34200T 7103406 SO MLG BOLTS LOOSE D L A K NONE O OTHER IN INSP/MAINT 1 SW 99 2855U 4090 347970294 RIGHT SIDE FORWARD LANDING GEAR TRUNNION PLATE BOLTS WERE BACKED OUT AND HOLES IN PLATE HAD ELONGATED AS A RESULT. THIS PLATE HAD BEEN PREVIOUSLY MODIFIED IAW PIPER SB 956, PART TWO, WHICH HAD ENLARGED BOLT HOLES AS OUTLINED IN SB. LARGER BOLTS AN5-10A5 ARE INSTALLED AT TIME OF PERFORMANCE OF SB ALONG WITH NUTPLATES OR NUTS AS REQUIRED. 1 L 7 2 3O A7SO 1997061200152 19970612 00152 CE 1997 6 12 97ZZZX2664 1 19970429 G 5711 052340014 SPAR CESSNA 172 172B 2072406 CE STIFFENER CORRODED B A5OR K NONE O OTHER IN INSP/MAINT 1 SO 09 6978X 3344 17247878 DURING HIDDEN DAMAGE INSPECTION OF WINGS AFTER HAIL AND WIND DAMAGE, FORWARD LEFT WING SPAR, EXTRUDED STIFFENER WAS FOUN D TO HAVE SEVERAL SPOTS OF INTERGRANULAR CORROSION. SUBMITTER STATED THIS IS A COMMON PROBLEM ON CESSNAS THAT DID NOT H AVE ANY WING PARTS PRIMERED PREVIOUSLY AT THE FACTORY. 1 H 7 1 3O NT 3A12 1997061200153 19970612 00153 CE 1997 6 12 97ZZZX2665 1 19970429 G 5311 05230201 ANGLE CAP CESSNA 172 172B 2072406 CE LT WING SPAR CORRODED B A5OR K NONE O OTHER IN INSP/MAINT 1 SO 09 6978X 3344 17247878 DURING HIDDEN DAMAGE INSPECTION OF WINGS AFTER HAIL AND WIND DAMAGE, THE FORWARD LT WING SPAR CAP WAS FOUND TO HAVE EXTE NSIVE INTERGRANULAR CORROSION. SUBMITTER STATED THIS IS A COMMON PROBLEM ON CESSNAS THAT DID NOT HAVE WING PARTS PRIMED AT THE FACTORY. 1 H 7 1 3O NT 3A12 1997061200154 19970612 00154 CE 1997 6 12 97ZZZX2666 1 19970501 G 5320 521304011 TRUNNION TEE CESSNA 404 404CESSNA 2075901 CE NLG BROKEN D K NONE E VIBRATION/BUFFET LD LANDING 1 NM 01 41SA 4040023 PILOT REPORTED SEVERE NOSE SHIMMY ON LANDING. AIRCRAFT NOSE GEAR WAS JACKED UP AND FOUND BOTH TEE EXTRUSIONS BROKEN WHI CH ARE PART OF THE PRIMARY STRUCTURAL SUPPORT FOR THE NOSE LANDING GEAR TRUNNION. 1 L 7 2 3O A25CE 1997061200155 19970612 00155 CE 1997 6 12 97ZZZX2667 1 19970501 G 5343 521304012 TRUNNION TEE CESSNA 404 404CESSNA 2075901 CE NLG BROKEN D S A K NONE E VIBRATION/BUFFET LD LANDING 1 NM 01 41SA 4040023 PILOT REPORTED SEVERE NOSE SHIMMY ON LANDING. AIRCRAFT NOSE GEAR WAS JACKED UP AND FOUND BOTH TEE EXTRUSIONS BROKEN WHI CH ARE PART OF THE PRIMARY STRUCTURAL SUPPORT FOR THE NOSE LANDING GEAR TRUNNION. 1 L 7 2 3O A25CE 1997061200156 19970612 00156 CE 1997 6 12 97ZZZX2668 1 19970501 G 5320 HILOKS CESSNA 404 404CESSNA 2075901 CE NLG STRUCTURE LOOSE D S K NONE O OTHER IN INSP/MAINT 1 NM 01 48SA 4040417 DURING A RECENT MDL 404 GEAR INSPECTION, NOTED THE NOSE GEAR ACTUATOR ATTACH STRUCTURE HAD NUMEROUS LOOSE HI-LOKS. 1 L 7 2 3O A25CE 1997061200157 19970612 00157 CE 1997 6 12 97ZZZX2669 1 19970527 G 3230 5741100203 GEAR PIN CESSNA 404 404CESSNA 2075901 CE MLG LINK PIVOT WORN D K NONE O OTHER IN INSP/MAINT 1 NM 01 48SA 4040417 DURING A RECENT 404 TITAN GEAR INSPECTION ON THE MAIN LANDING GEAR, FOUND TRAILING LINK PIVOT PINS WORN EXCESSIVELY. TH E PHENOLIC-LINED BUSHINGS WERE WITHIN MANUFACTUER'S SPECS. NEW PINS WERE INSTALLED. 1 L 7 2 3O A25CE 1997061200158 19970612 00158 CE 1997 6 12 97ZZZX2670 1 19970527 G 3230 5741100204 GEAR PIN CESSNA 404 404CESSNA 2075901 CE MLG LINK PIVOT WORN D K NONE O OTHER IN INSP/MAINT 1 NM 01 48SA 4040417 DURING A RECENT 404 TITAN GEAR INSPECTION ON THE MAIN LANDING GEAR, FOUND TRAILING LINK PIVOT PINS WORN EXCESSIVELY. TH E PHENOLIC-LINED BUSHINGS WERE SITHIN MANUFACTUER'S SPECS. NEW PINS WERE INSTALLED. 1 L 7 2 3O A25CE 1997061200161 19970612 00161 CE 1997 6 12 97ZZZX2673 3 19970418 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PROPELLER PITCH CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 4643 2446NR FORWARD EAR OF PROPELLER PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOT. 2 L 7 2 4T RT A24CE 5 C P10NE 1997061200162 19970612 00162 CE 1997 6 12 97ZZZX2674 3 19970521 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PROPELLER PITCH CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 1791NR FORWARD EAR OF PROPELLER PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997061200163 19970612 00163 CE 1997 6 12 97ZZZX2675 3 19970418 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PROPELLER PITCH CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 4541 2313NR FORWARD EAR OF PROPELLER PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOT. 2 L 7 2 4T RT A24CE 5 C P10NE 1997061200164 19970612 00164 NE 1997 6 12 97ZZZX2676 3 19970429 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PROPELLER PITCH CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 2996 2740NP FORWARD EAR OF PROPELLER PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997061200166 19970612 00166 NM 1997 6 12 97ZZZX2677 1 19970527 G 3230 35210400000 SWITCH HOUSING D25W252004 ISRAEL 1125 1125 NM DWNLOCK ACTUATOR LEAKING B AN3R O OTHER K FLUID LOSS AP APPROACH 1 WP 23 49MW 019 019 AIRCRAFT LOST NORMAL HYDRAULIC SYSTEM PRESSURE. AUXILIARY PUMP AND LANDING GEAR BLOW DOWN BOTTLE WERE USED FOR LANDING. FOUND LEFT MAIN LANDING GEAR ACTUATOR DOWNLOCK SWITCH HOUSING ALLOWING FLUID TO BYPASS PLUNGER SEALS, TRAVEL AROUND AN D THROUGH DOWNLOCK SWITCH, AND LEAK FROM SWITCH HARNESS BEFORE SPRAYING INTO WHEELWELL. 2 L 7 2 4F RT A16NM 1997061200167 19970612 00167 CE 1997 6 12 97ZZZX2678 1 19970506 G 5610 10138402517 WINDSHIELD BEECH 300 300BEECH 1152930 CE HEAT TERMINAL SMOKED D O OTHER B SMOKE/FUMES/ODORS/SPARKS DE DESCENT 1 GL 03 6PW 3670 95271H5974 FA32 PILOT REPORTED SMOKE IN COCKPIT DURING DESCENT. RAN AIRCRAFT AND FOUND PILOT'S WINDSHIELD SMOKING AT LOW HEAT TERMINAL. 2 L 7 2 4T A24CE 1997061200168 19970612 00168 CE 1997 6 12 97ZZZX2679 1 19970501 G 3213 66413301 STRUT ASSY CESSNA 500 560CESSNA 2076750 CE SCISSOR PIN BOSS WORN B P A HAXR K NONE O OTHER IN INSP/MAINT 1 SW 11 615AT 5600245 LOWER SCISSOR PIN AND BOSS ASSEMBLY WORN EXCESSIVELY. TOTAL TIME 1,071 HOURS. TOTAL CYCLES, 839. THIS WAS FOUND DURING A ROUTINE INSPECTION. THERE WAS A SMALL AMOUNT OF UP AND DOWN PLAY IN THE ASSEMBLY. 2 L 7 2 4F RT A22CE 1997061200170 19970612 00170 NE 1997 6 12 97ZZZX2681 2 19970520 G 7220 F2MA581100801 INLET AMD FALC50 FALCON2000 2730170 NM CFE CFE73811B NE ENGINE BOLTS LOOSE B A CW1R K NONE O OTHER IN INSP/MAINT 1 EA 25 790M 798 FA037LN40 P105134 P105134 AFTER ENGINE FAILURE, MORE THAN HALF THE BOLTS SECURING THE ENGINE INLET HA D UNSCREWED THEMSELVES. THE REMAINING WERE LOOSE. SUBMITTER SUSPECTS UNUSUAL ENGINE VIBRATION CAUSED THE BOLTS TO BACK OUT. THE INLET COULD POSSIBLY FALL OFF THE AIRCRAFT IN-FLIGHT. 2 K 7 3 4F 4 F RT A50NM E44NE 1997061200171 19970612 00171 NE 1997 6 12 97ZZZX2682 2 19970520 G 7250 ENGINE AMD FALC50 FALCON2000 2730170 NM CFE CFE73811B NE TURBINE FAILED B A CW1R A UNSCHED LANDING Y ENGINE STOPPAGE CL CLIMB 1 EA 25 790M 19 P105134 RIGHT ENGINE COMPLETELY FAILED AFTER TAKEOFF AT APPROXIMATELY 200 FEET AGL. AFTER A SUCCESSFUL LANDING, ENGINE WAS EXAM INED AND FOUND THE FAN SEIZED; THE TURBINE BADLY DAMAGED. NO EVIDENCE OF FOD WAS FOUND. AWAITING EVALUATION FROM THE M ANUFACTURER TO DETERMINE CAUSE. 2 K 7 3 4F 4 F RT A50NM E44NE 1997061200172 19970612 00172 CE 1997 6 12 97ZZZX2683 1 19970523 G 3240 MS252531 SWITCH CESSNA 500 560CESSNA 2076750 CE GEAR CONTROL FAILED D O OTHER P NO WARNING INDICATION LD LANDING 1 EA 03 81SH 560 5600357 FAILURE OF SWITCH RESULTED IN BRAKE PEDAL GOING TO FLOOR AND NO ANNUNCIATOR WARNING. THIS SWITCH SUPPLIES A GROUND FOR THE POWER BRAKE PUMP AND THE LOW BRAKE PRESSURE ANNUNCIATOR LIGHT. EXTENDED TR USE STOPPED AIRCRAFT WITHOUT INCIDENT. 2 L 7 2 4F RT A22CE 1997061200173 19970612 00173 EU 1997 6 12 97ZZZX2684 1 19970320 G 2620 CONNECTOR BRAERO DH125 BAE125800A 1500285 EU FIRE EXT SYSTEM MISINSTALLED D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 23 935H NA0475 DURING FUNCTIONAL TEST OF ENGINE FIRE EXTINGUISHER SYSTEM CIRCUIT CAMP CODE 262085, FOUND AFT FIRE BOTTLE CONNECTORS GH HEAD 'A' AND HEAD 'B' WERE INSTALLED REVERSED. THE LABELING ON THE CONNECTORS READ 'AFT FIRE BOTTLE, AFT SQUIB' WHICH S HOULD HAVE BEEN INSTALLED ON FWD SQUIB HAD THE ENGINE FIRE EXTINGUISHER NR 2 ENGINE SHOT 1 BEEN ACTIVATED, THE BOTTLE WO ULD HAVE BEEN DISCHARGED TO THE NR 1 ENGINE. 2 L 7 2 4F RT A3EU 1997061200174 19970612 00174 EU 1997 6 12 97ZZZX2685 1 19970320 G 2150 20388022 COOLING TURBINE BRAERO DH125 BAE125800A 1500285 EU BEARINGS MAKING METAL D A K NONE O OTHER IN INSP/MAINT 1 GL 23 935H 1273 79939 NA0475 AFTER ROTATION, CREW SELECTED MAIN AIR VALVES ON. A RUMBLE AND VIBRATION WERE NOTED BY CREW LASTING APPROX 2 MINS INTO FLT. REMAINDER OF TRIP WAS UNEVENTFUL. AIRCRAFT TURNED OVER TO MAINTENANCE. WITH APPLICATION OF BLEED AIR FROM THE AP U, MAINTENANCE FOUND RUMBLE TO INCREASE WHEN SELECTING COOLER TEMPS. A CHECK OF THE COOLING TURBINE OIL LEVEL WAS SATIS FACTORY. UPON REMOVAL OF THE MAG CHIP DETECTOR, EXCESSIVE AMOUNTS OF METAL AND BEARING PARTS WERE FOUND. UNIT WAS REMO VED AND REPLACED WITH THE UPGRADED/MODIFIED 203880-30-1 UNIT. PART TT 1272.3 HOURS, 48 MONTHS FROM BUILD. 2 L 7 2 4F RT A3EU 1997061200175 19970612 00175 1997 6 12 97ZZZX2686 4 19970412 G 3445 CAS67A TCAS UNIT CESSNA 500 550 2076604 CE COCKPIT MALFUNCTION G A B EMER. DESCENT N FALSE WARNING CR CRUISE 1 WP 17 960CP 5500313 PILOT DEVIATED FROM ASSIGNED ALTITUDE OF FL 330 AFTER HE APPARENTLY RECEIVED A SECOND RA VERBAL ALERT TO DESCEND WHILE A PPROACHING ANOTHER AIRCRAFT AT ASSIGNED ALTITUDE OF FL 310. PILOT SAID HE HAD TCAS II UNIT CHECKED AT A REPAIR STATION AND UNIT CHECKED GOOD. AN ALLIED SIGNAL REPRESENTATIVE COULD FIND NO DEFECTS AFTER INSPECTING THE AIRCRAFT AND TCAS II UNIT. PILOT OF THE OTHER AIRCRAFT DID NOT HAVE A TCAS RA ALERT. ALLIED SIGNAL REPRESENTATIVE AT OLATHE, KS AND RESPECT IVE FAA MIDO OFFICE HAS BEEN CONTACTED ABOUT THIS INCIDENT. ATC DOCUMENTATION IS BEING FORWARDED TO THE RESPONSIBLE MID O OFFICE. 1 L 7 2 4F A22CE 1997061200780 19970612 00780 EA 1997 6 12 97ZZZX2708 2 19970514 G 8530 SL134441 PISTON PIN CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA ENGINE CYLINDER FAILED G A UNSCHED LANDING Y ENGINE STOPPAGE CL CLIMB 1 WP 11 739ZL 700 17270936 L473076 CATASTROPHIC FAILURE AFTER TAKEOFF FROM CLEAR LAKE, CA ON 5-14-97. PILOT TURNED BACK AND MADE UNPOWERED LANDING AT AIRP ORT. FOUND CYLINDER BROKEN OFF ENGINE. PISTON BROKEN, CRANKSHAFT BROKEN. PISTON PIN BROKEN IN HALF. 1 H 7 1 3O 3 O NT 3A12 E274 1997061200781 19970612 00781 CE 1997 6 12 97ZZZX2709 1 19970522 G 3240 20701900 HOSE PARKERHANFIN 199101 MTSBSI MU2 MU2B36A 5780413 CE GARRTT TPE331 TPE3315 01514 WP BRAKE KIT WRONG PART B RG4R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 03 105WM 109 709SA FOUND, CLEVELAND BRAKE KIT 199-101 STC SA648GL BRAKE HOSES U/A HOSE LISTED SAE DOAS SAE DOT 3000 PSI AIR BRAKE HOSE, FIT TING CONNECTORS WERE 45 DEGREE ANGLE AND HOSE FITTINGS WERE 45 DEGREES. CONICAL SEAL WAS FOUND IN ONE HOSE FOR SEALINGS . 1 H 7 2 3T 4 T A10SW E4WE 1997061200782 19970612 00782 CE 1997 6 12 97ZZZX2710 1 19970522 G 3240 20701900 HOSE PARKERHANFIN 19901 MTSBSI MU2 MU2B60 5780460 CE GARRTT TPE331 TPE33110 01514 WP BRAKE KIT WRONG PART B RG4R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 03 223JS 770 1544SA FOUND CLEVELAND BRAKE KIT 199-101 STC 648GL BRAKE HOSES WERE SAE DOT 3000 PSI AIR BRAKE HOSES. FITTINGS WERE 45 DEGREES . 1 H 7 2 3T 4 T RT A10SW E4WE 1997061200783 19970612 00783 NE 1997 6 12 97ZZZX2711 3 19970516 G 6114 7943021 BEARING RACE HAMSTD 7827014 HAMSTD 14SF 14SF7 NE NR 1 BORE CRACKED B A BN4R K NONE O OTHER IN INSP/MAINT 1 WP 05 804 REFERENCE: FR28191 AND FW0508. PROPELLER REMOVED DUE TO BURNED ELEMENT ON BLADE HEATER. UPON BLADE REMOVAL, NR 1 BORE OUTER BEARING RACE FOUND CRACKED. SUBMITTER'S RECOMMENDATIONS: HUB ASSEMBLY AND NR 1 BLADE RETURNED TO HAMILTON STAND ARD FOR INVESTIGATION. 6 C P7NE 1997061200784 19970612 00784 NM 1997 6 12 97ZZZX2712 1 19970508 G 3250 1692R1 PRESSURE PORTS 1692RA12 BOEING 737 737* NM STEERING VALVE PITTED B IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 334 STEERING VALVE PRESSURE PORTS ARE CONTINUOUSLY FOUND PITTED AND SCORED FROM CONTAMINATION. RECOMMEND SEALING ALL MATING POINTS WITH RTV SEALANT. 2 L 7 2 4F RT A16WE 1997061200785 19970612 00785 NM 1997 6 12 97ZZZX2713 1 19970521 G 2782 108010 ACTUATOR 1U1110 BOEING 727 727 1384001 NM LE FLAP CRACKED B IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 296 DURING NDI, THE FLAP ACTUATOR BODY ASSEMBLIES WERE FOUND CRACKED IN THE EXTENSION TRUNNION PORT. 2 L 7 3 4F A3WE 1997061200788 19970612 00788 CE 1997 6 12 97ZZZX2716 1 19970529 G 5711 5262 SPAR BBAVIA 7 7KCAB 21101P3 CE STRUT ATTACH CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 09 2606G 2158 51 INSPECTED SPAR IAW SL 406. FOUND RIGHT FORWARD SPAR CRACKED OUTBOARD, AFT SIDE OF STRUT ATTACH DOUBLER. CRACK VERY DIF FICULT TO SEE WITHOUT BENDING LEADING EDGE ALUMINUM UP TO GET A CLEAR VIEW OF TOP OF SPAR. THIS CRACK COULD NOT BE SEEN FROM BOTTOM OF WING USING MIRRORS AND LIGHTS. WING HAD BEEN DAMAGED IN A GROUND LOOP PREVIOUSLY. 1 H 7 1 3O A759 1997061200789 19970612 00789 CE 1997 6 12 97ZZZX2717 1 19970526 G 4940 15700431 DIODE BOARD CESSNA 210 T210L 2073449 CE APU FAILED D K NONE O OTHER IN INSP/MAINT 1 NM 11 732AJ 4220 21061360 HOOKED UP APU AND STARTER IMMEDIATELY CRANKED ENGINE. INVESTIGATION FOUND BOARD CONTAINING DIODES IN CABIN NEXT TO POW ER RELAY TO HAVE BOTH DIODES INOPERATIVE. PART IS IN DIFFICULT LOCATION TO TEST INDIVIDUAL DIODES. REPLACED DIODE BOAR D P/N 1570043-1 AND TESTED GOOD. RECOMMEND TESTING APU AT EACH ANNUAL. NOTE: PARTS MANUAL DOES NOT SHOW PART ON THIS SERIAL NUMBERED ACFT; HOWEVER, MAINTENANCE SCHEMATIC IS NOT SERIAL SPECIFIC. 1 H 7 1 3O 3A21 1997061200790 19970612 00790 GL 1997 6 12 97ZZZX2718 1 19970503 G 6310 CLUTCH AMTR 500 MINI500 13015HW GL ENGINE VIBRATION D K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 WP 07 5455K 0090 THIS IS AN AMATEUR-BUILT AIRCRAFT FROM REVOLUTION HELICOPTERS. AT 100 PERCENT ENGINE RPM, PILOT REPORTED A VERY HIGH VI BRATION IN THE AIRFRAME. TROUBLESHOOTING REVEALED AN 8.0 IPS VIBRATION AT 6,500 RPM AT THE ENGINE CLUTCH ASSY. THE CLU TCH WAS SENT BACK TO REVOLUTION WHO RE-BALANCED THE ASSEMBLY. AFTER RE-BALANCING AND RE-INSTALLATION, THE VIBRATION WAS STILL PRESENT. 1 G 7 1 3I NC EXPA1G71 1997061200791 19970612 00791 NM 1997 6 12 97ZZZX2719 1 19970227 G 7921 20008A OIL COOLER ROBSIN R22 R22BETA NM ENGINE OIL DAMAGED G K NONE O OTHER IN INSP/MAINT 1 SO 17 444PH 1492 1578 ALTERNATOR BELT P/N 3VX375 BROKE DAMAGING THE OIL COOLER P/N 20008A CAUSING A LOSS IN OIL PRESSURE. 1 G 7 1 3O H10WE 1997061200792 19970612 00792 NM 1997 6 12 97ZZZX2720 1 19970227 G 2410 3VX375 BELT ROBSIN R22 R22BETA NM ALTERNATOR BROKE G K NONE O OTHER IN INSP/MAINT 1 SO 17 444PH 1492 1578 ALTERNATOR BELT P/N 3VX375 BROKE DAMAGING THE OIL COOLER P/N 20008A CAUSING A LOSS IN OIL PRESSURE. 1 G 7 1 3O H10WE 1997061200793 19970612 00793 SW 1997 6 12 97ZZZX2721 1 19970512 G 5512 222035250109 SKIN BELL 222 222U 1182140 SW HORIZ STABILIZER TORN B BUBR K NONE O OTHER IN INSP/MAINT 1 GL 23 911EC 1371 47505 A TEAR IN THE HORIZONTAL STABILIZER SKIN WAS FOUND DURING INSPECTION. THE DAMAGE WAS LOCATED ON THE RT INBOARD LEADING EDGE. THE DAMAGE MAY HAVE BEEN CAUSED DURING IMPROPER OR ROUGH INSTALLATION. THE DAMAGE WAS REPAIRED UNDER MANUFACTURER 'S INSTRUCTIONS AND FAA FORM 337 FOR THIS AIRCRAFT DATED 5-12-97 HAS BEEN SUBMITTED. A 'NOTE' IN THE INSTALLATION INST RUCTIONS OF THE MM COULD HELP OTHERS FROM DAMAGING THIS PART. 1 G 7 2 3U H9SW 1997061200794 19970612 00794 SW 1997 6 12 97ZZZX2722 1 19970522 G 5302 222035150105 TAILBOOM BELL 222 222U 1182140 SW T/B RT SIDE CRACKED B BUBR K NONE O OTHER IN INSP/MAINT 1 GL 23 911EC 1371 47505 A CRACK OF OVER 2 INCHES WAS FOUND ON RT SIDE OF TAILBOOM DURING PILOT POST-FLIGHT CHECK. OTHER OPERATORS HAVE EXPERIEN CED CRACKS IN THE SAME AREA. BELL HAS ISSUED A TECHNICAL BULLETIN (TB 222U-94-65) TO ADDRESS THE PROBLEM. SUBMITTER RE COMMENDATION, HAVE BELL CHANGE THE TB TO AN ASB. 1 G 7 2 3U H9SW 1997061200795 19970612 00795 NE 1997 6 12 97ZZZX2723 2 19970527 G 7230 COMPRESSOR SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1D NE ENGINE DAMAGE D O OTHER E C VIBRATION/BUFFET F.O.D. HO HOVERING 1 WP 07 91GT 3497 500 1289 4078 PICKED UP HIGH FREQUENCY VIBRATION WHILE HOVERING TO MAINTENANCE HANGAR. UPON INSPECTION, FOUND FOD DAMAGE TO COMPRESSO R. SUSPECTED CAUSE IS ROTOR WASH KICKED UP FOD. 1 G 7 1 3U 3 U NC H9EU E19EU 1997061200796 19970612 00796 SW 1997 6 12 97ZZZX2724 1 19970514 G 6710 A21810064603 SWITCH HUGHES 500N 500N 3027374 SW PILOT CYCLIC STICKS G A K NONE F FLT CONT AFFECTED NR NOT REPORTED 1 SW 99 524FB 336 LN004 TRIM SWITCH STICKS TO RIGHT MAKING MOTOR RUN UNTIL BREAKING. 1 G 7 1 3U NC H3WE 1997061200827 19970612 00827 GL 1997 6 12 97ZZZX2753 2 19970506 G 7323 23057869 GOVERNOR BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ENGINE DEFECTIVE B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 50588 194 86220668 S780 NR 1 ENGINE WOULD NOT BEEP PAST 95 PERCENT N2. REPLACED GOVERNOR, CURED PROBLEM. 1 G 7 2 3U 3 U H3EU E4CE 1997061200828 19970612 00828 GL 1997 6 12 97ZZZX2754 2 19970502 G 7323 23057869 GOVERNOR BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ENGINE DEFECTIVE B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 5352Y 814 85590222 S781 18 PERCENT TORQUE SPLIT. REPLACED GOVERNOR CURED PROBLEM. 1 G 7 2 3U 3 U H3EU E4CE 1997061200829 19970612 00829 NE 1997 6 12 97ZZZX2755 1 19970508 G 5210 7620902019043 HINGE SKRSKY S76 S76 8143010 NE DOOR CORRODED B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 5401G 13674 760137 CORROSION WHERE BUSHINGS GO THROUGH HINGE. REPLACED DOOR HINGE. 1 G 7 2 3U H1NE 1997061200830 19970612 00830 GL 1997 6 12 97ZZZX2756 2 19970507 G 7323 23004836 GOVERNOR SKRSKY S76 S76 8143010 NE ALLSN 250C 250C30 03013 GL ENGINE MALFUNCTION B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 5402T 1331 25705 760140 UNRESPONSIVE AT HIGH TORQUE RANGES. SHAFT RATCHETY AND STIFF. REPLACED GOVERNOR. 1 G 7 2 3U 3 U H1NE E1GL 1997061200831 19970612 00831 NE 1997 6 12 97ZZZX2757 2 19970312 G 7320 2525013 AFCU 324473513 BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE DIAPHRAGM TORN B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 2071S 833 33046 DURING REPAIR OF AFCU, FOUND DIAPHRAGM TORN AND ABOUT TO RUPTURE. 1 G 7 2 4U 4 U H4SW E22EA 1997061900379 19970619 00379 SW 1997 6 19 97ZZZX2758 1 19970402 G 6320 206040032011 BEARING 206040004107 BELL 206 206L3 1182108 SW TRANSMISSION FAILED B ALGR K NONE J WARNING INDICATION NR NOT REPORTED 1 SW 03 350AL J0972 51429 FIELD CHIP LIGHT. FOUND BEARING BALLS, INNER AND OUTER RACE, PITTED (BREAKING DOWN). 1 G 7 1 3U H2SW 1997061900380 19970619 00380 SW 1997 6 19 97ZZZX2761 1 19970327 G 6510 406040340101 DISC PACK BELL 407 407 SW T/R DRIVE CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 407AL 309 53044 DURING 50-HOUR PREVENTIVE MAINTENANCE INSPECTION, FOUND T/R DRIVE SHAFT DISC PACK CRACKED. 1 G 7 1 3U O H2SW 1997061200834 19970612 00834 SW 1997 6 12 97ZZZX2762 1 19970327 G 6510 406040340101 DISC PACK BELL 407 407 SW T/R DRIVE CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 407AL 394 53044 DURING A 50-HOUR PREVENTIVE MAINTENANCE INSPECTION, FOUND DISC PACK CRACKED. 1 G 7 1 3U O H2SW 1997061200835 19970612 00835 SW 1997 6 12 97ZZZX2763 1 19970327 G 6510 406040340101 DISC PACK BELL 407 407 SW T/R CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 417AL 305 53054 DURING 50-HOUR PREVENTIVE MAINTENANCE INSPECTION, FOUND T/R DRIVE SHAFT DISC PACK CRACKED. 1 G 7 1 3U O H2SW 1997061200836 19970612 00836 SW 1997 6 12 97ZZZX2764 1 19970327 G 6510 406040340101 DISC PACK BELL 407 407 SW T/R DRIVE CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 417AL 351 RNFS4667 53054 DURING 50-HOUR PREVENTIVE MAINTENANCE INSPECTION, FOUND T/R DRIVE SHAFT DISC PACK CRACKED. 1 G 7 1 3U O H2SW 1997061200837 19970612 00837 SW 1997 6 12 97ZZZX2765 1 19970327 G 6510 406040340101 DISC PACK BELL 407 407 SW T/R DRIVE CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 417AL 131 53054 DURING 50-HOUR PREVENTIVE MAINTENANCE INSPECTION, FOUND T/R DRIVE SHAFT DISC PACK CRACKED. 1 G 7 1 3U O H2SW 1997061200838 19970612 00838 SW 1997 6 12 97ZZZX2766 1 19970304 G 6510 406040340101 DISC PACK BELL 407 407 SW FWD END CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 417AL RNFS4887 53054 DURING 50-HOUR PMI, FOUND FORWARD DISC PACK CRACKED ON NR 7 T/R DRIVESHAFT. 1 G 7 1 3U O H2SW 1997061200842 19970612 00842 GL 1997 6 12 97ZZZX2769 1 19970518 G 6230 28161191 UNIVERSAL HSNG ENSTRM F28 F28F 3300412 GL SWASHPALTE CRACKED C A PP0M K NONE O OTHER TO TAKEOFF 1 WP 01 8624B 641 13100991H 752 MOUNTING WEBS FOR CONTROL ROD BEARINGS AND UNIVERSAL JOINT OF LOWER SWASHPLATE FOUND CRACKED AT INSPECTION. THIS IS A P RIMARY FLIGHT CONTROL PART. THIS PART HAS A RETIREMENT LIFE OF 17,700 HOURS. PART NON-REPAIRABLE. REPLACED WITH NEW PA RT 28-16119-1. 1 G 7 1 3O H1CE 1997061200844 19970612 00844 GL 1997 6 12 97ZZZX2771 1 19970514 G 6230 28161191 UNIVERSAL HSNG ENSTRM F28 F28F 3300412 GL SWASHPLATE CRACKED C A PP0M K NONE O OTHER IN INSP/MAINT 1 WP 01 8626S 6672 1085185H 786 MOUNTING WEBS FOR CONTROL ROD BEARINGS AND UNIVERSAL JOINT OF LOWER SWASHPLATE FOUND CRACKED AT INSPECTION. THIS IS A P RIMARY FLIGHT CONTROL PART. THIS PART HAS A RETIREMENT LIFE OF 17,700 HOURS. PART NON-REPAIRABLE. REPLACED WITH NEW PA RT 28-16119-1. 1 G 7 1 3O H1CE 1997061200846 19970612 00846 GL 1997 6 12 97ZZZX2773 1 19970519 G 6720 0169104 ROD END BEARING ENSTRM F28 F28F 3300412 GL T/R CONTROL WORN C A PP0M K NONE O OTHER IN INSP/MAINT 1 WP 01 890JR 6387 764 ACCELERATED LATERAL BEARING WEAR. EXCEEDED LIMITS WITHIN 304 HOURS. THIS ROD END NORMALLY LASTS UP TO 1,000 HOURS IN S ERVICE. INSTALLED 2 NEW 01-691-04 BEARINGS. 1 G 7 1 3O H1CE 1997061200876 19970612 00876 EA 1997 6 12 97ZZZX2775 2 19970303 G 7320 2525013 DIAPHRAGM BENDIX 32447218 BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA AFCU RUPTURED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 2FOR A20325 30932 61073 DURING DISASSEMBLY OF AFCU, FOUND DIAPHRAGM RUPTURED, P/N 2525013. 1 G 7 1 4U 4 U H4SW E22EA 1997061200877 19970612 00877 SW 1997 6 12 97ZZZX2776 1 19970527 G 5531 2050308465 FIN SPAR UH1514471 BELL 204 UH1B 1181410 SW TAILBOOM CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 99478 BBBE0596 638636 DURING ROUTINE VISUAL INSPECTION WHILE REFUELING, CRACK IN TAILBOOM SPAR CAP WAS DETECTED. MECHANIC STATED NO CRACK WAS NOTED DURING PRE-FLIGHT INDICATING IT FORMED WITHIN AN HOUR OF OPERATION. NO FRETTING NOTED TO SUPPORT THIS. GARLICK HELICOPTERS ALERT SB NR UH1-96-04 WAS C/W BY REMOVAL OF RIVET AT FIN STA 70.3. THIS TAILBOOM HAD ACCUMULATED APPROXIMAT ELY 2,500 HRS OF CIVILIAN SERVICE PERFORMING LOGGING OPERATIONS UNDER PART 133. 1 G 7 1 4U EXPA1G71 1997061900202 19970619 00202 EU 1997 6 19 97ZZZX2780 3 19970529 G 6114 601022294 HUB ROTOL R4304 R2124304 EU DRIVE SNOUT CRACKED B S MS1R K NONE O OTHER IN INSP/MAINT 1 EA 27 24811 5993 R212 SE4582 UPON DISASSEMBLY OF PROPELLER FOR ROUTINE OVERHAUL, NOTED FRONT FACE OF HUB ASSEMBLY WAS CRACKED ALL THE WAY AROUND HUB CENTER DRIVE SNOUT RADIUS. HUB ASSY REJECTED FROM FURTHER SERVICE. REFERENCE AD 75-15-04. 6 C P899 1997061900203 19970619 00203 EA 1997 6 19 97ZZZX2781 2 19970522 G 7322 MA4SPA CARBURETOR PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA THROTTLE BODY LOOSE D K NONE O OTHER IN INSP/MAINT 1 EA 03 900 THROTTLE BODY LOOSE AT PARTING SURFACE TO FUEL BOWL DUE TO LOOSENING OF LOCKING TABS ' NOT THE RETAINING BOLTS'. SUBMIT TER RECOMMENDS SAFETY WIRE IN PLACE OF TABS. THIRD INCIDENT NOTED WITH LOCKING TABS. 1 L 7 1 3O 3 O 2A13 E274 1997061900204 19970619 00204 SO 1997 6 19 97ZZZX2782 1 19970501 G 2710 40092 BELLCRANK PIPER PA14 PA14 7101402 SO LT AILERON CRACKED D K NONE O OTHER IN INSP/MAINT 1 AL 03 INSPECTION FOUND LT AILERON BELLCRANK CRACKED. REF: PIPER SB 109. 1 H 7 1 3O A797 1997061900205 19970619 00205 SO 1997 6 19 97ZZZX2783 1 19970501 G 2750 4009210 BELLCRANK PIPER PA12 PA12 7101202 SO LT FLAP CRACKED D K NONE O OTHER IN INSP/MAINT 1 AL 03 INSPECTION FOUND LT FLAP BELLCRANK CRACKED. REF: PIPER SB 109. 1 H 7 1 3O A780 1997061900206 19970619 00206 SO 1997 6 19 97ZZZX2784 1 19970501 G 2450 4009210 BELLCRANK PIPER PA14 PA14 7101402 SO LT FLAP CRACKED D K NONE O OTHER IN INSP/MAINT 1 AL 03 INSPECTION FOUND LT FLAP BELLCRANK CRACKED. REF: PIPER SB 109. 1 H 7 1 3O A797 1997061900207 19970619 00207 SO 1997 6 19 97ZZZX2785 1 19970501 G 2750 4009210 BELLCRANK PIPER PA18 PA18 7101802 SO RT FLAP CRACKED D K NONE O OTHER IN INSP/MAINT 1 AL 03 INSPECTION FOUND RT FLAP BELLCRANK CRACKED. REF: PIPER SB 109. 1 H 7 1 3O 1A2 1997061900208 19970619 00208 SO 1997 6 19 97ZZZX2786 1 19970501 G 2750 400929 BELLCRANK PIPER PA22 PA22 7102202 SO RT FLAP CRACKED D K NONE O OTHER IN INSP/MAINT 1 AL 03 INSPECTION FOUND RT FLAP BELLCRANK CRACKED. REF: PIPER SB 109. 1 H 7 1 3O 1A6 1997061900209 19970619 00209 SO 1997 6 19 97ZZZX2787 1 19970501 G 2750 4009210 BELLCRANK PIPER PA20 PA20 7102002 SO LT FLAP CRACKED D K NONE O OTHER IN INSP/MAINT 1 AL 03 INSPECTION FOUND LT FLAP BELLCRANK CRACKED. REF: PIPER SB 109. 1 H 7 1 3O 1A4 1997061900210 19970619 00210 SO 1997 6 19 97ZZZX2788 1 19970501 G 2710 40092 BELLCRANK PIPER PA12 PA12 7101202 SO LT AILERON CRACKED D A K NONE O OTHER IN INSP/MAINT 1 AL 03 INSPECTION FOUND LT AILERON BELLCRANK CRACKED. REF: PIPER SB 109. 1 H 7 1 3O A780 1997061900211 19970619 00211 SO 1997 6 19 97ZZZX2789 2 19970516 G 8550 12504221 ADAPTER CONT O520 IO520A 17032 SO OIL FILTER THREADS BROKEN D S K NONE O OTHER IN INSP/MAINT 1 SW 01 775 1116706A CESSNA OIL FILTER TOWER INSPECTED IAW AD 96-12-22. FOUND ONE THREAD BROKEN AWAY .6250 INCH LONG. NO DAMAGE TO INTERNAL THREADS OF OIL PUMP HOUSING. 3 O E5CE 1997061900212 19970619 00212 SO 1997 6 19 97ZZZX2790 1 19970603 G 2730 1374500 CONTROL CABLE PIPER PA18 PA18125 7101812 SO ELEVATOR CONTROL BROKEN G S A O OTHER F FLT CONT AFFECTED CR CRUISE 1 AL 03 1169A 18767 LOWER ELEVATOR CABLE SEPARATED IN-FLIGHT. CAUSE OF SEPARATION WAS USE OF NON-FLEXIBLE CABLE IN A REPAIR SPLICE. CABLE WORK HARDENED AND BROKE WHERE IT WENT AROUND THE PULLEY. THIS IS A KNOWN HIGH WEAR POINT ON PA-18-150. AN INSPECTION H OLE SHOULD BE INSTALLED OVER THIS POSITION FOR EASE OF INSPECTION. 1 H 7 1 3O 1A2 1997061900213 19970619 00213 EA 1997 6 19 97ZZZX2791 2 19970527 G 8530 LW15322 CYLINDER PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA ROCKER ARM LOOSE STUD B R2JR O OTHER R PARTIAL RPM/PWR LOSS CR CRUISE 1 EA 21 142CK 1269 447995252 RL20677T ENGINE LOST POWER DURING FLIGHT. SAFE LANDING C/W. MAINT FOUND NR 2 CYLINDER PUSH ROD BENT. FURTHER INSPECTION REVEAL ED ROCKER ARMS ON THAT CYLINDER VERY LOOSE, ALMOST FELL OFF WHEN ROCKER COVER REMOVED. ROCKER SHAFT STUDS FOUND BACKED OUT. THERE ARE NO SAFTIES TO PREVENT THIS FROM HAPPENING. DAMAGED CYLINDER HAD TO BE CHANGED. SUBMITTER SUGGESTS C/W F ACTORY RECOMMENDED 400-HOUR VALVE TRAIN INSPECTION PROCEDURES. ALSO, SUGGESTS MANUFACTURER RE-DESIGN ROCKER ARM ATTACHM ENT OR INSTALL SAFETY ON STUDS. 1 L 7 2 3O 3 O A19S0 E286 1997061900214 19970619 00214 EU 1997 6 19 97ZZZX2792 1 19970507 G 3221 MOUNT SOCATA TB9 TB9 8680694 EU NLG CORRODED B S A DYTR K NONE O OTHER IN INSP/MAINT 1 SO 15 144ER 4933 1339 NOSE GEAR MOUNT CORRODED COMPLETELY THROUGH FROM INSIDE OUT. SMALL CRACK IN PAINT FOUND DURING INSPECTION. TUBE BROKE OFF DURING REMOVAL. CRACKED AREA. 1 L 7 1 3O NT AS1EU 1997061900215 19970619 00215 CE 1997 6 19 97ZZZX2793 1 19970524 G 2822 BREAKER BEECH 80 65B80 1152812 CE LT BOOST PUMP SMOKED D K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 GL 15 138BA 7467 LD361 SMOKE COMING FROM CIRCUIT BREAKER PANEL. LEFT BOOST PUMP DID NOT WORK. PILOT TURNED MASTER OFF. SUBMITTER STATED CYCL E CIRCUIT BREAKER ONCE EACH YEAR. 1 L 7 2 3O 3A20 1997061900216 19970619 00216 SW 1997 6 19 97ZZZX2794 1 19970528 G 8011 MZ4222R STARTER ELECTROSYS MOONEY M20 M20J 5870219 SW MOTOR BODY BOLTS LOOSE B DY1R K NONE O OTHER IN INSP/MAINT 1 EA 13 201YE 6061149 240513 THE .3125 INCH HEAD MACHINE HARDWARE HOLDING THE STARTER MOTOR FORWARD CASE TO THE BODY HAS COME LOOSE LEAVING THE MOTOR ARMATURE IN FAILURE. THE LOC-TITE APPLIED TO THE THREADED HARDWARE SEEMS INAPPROPRIATE. SUBMITTER STATED SAFETY WIRE THE STARTER BODY HARDWARE. FACTORY TO PROVIDE THE IMPROVED DRILLED MACHINE HARDWARE. 1 L 7 1 3O 2A3 1997061900217 19970619 00217 CE 1997 6 19 97ZZZX2795 1 19970515 G 5347 05112435 SEAT RAIL CESSNA 172 172M 2072418 CE COCKPIT WORN D K NONE O OTHER IN INSP/MAINT 1 NM 01 20582 529 17261414 REPLACED ALL SEAT RAILS AND ROLLERS ON SEATS. 529.4 HOURS LATER OF OPERATION, THE FOURTH HOLE AFT WAS FOUND OUT OF LIMI TS PER AD 87-20-03R2. AD 87-20-03R2 STATES FIRST INSPECTION DUE 1,000 HOURS AFTER NEW RAILS INSTALLED. RECOMMEND REDUC ING FIRST INSPECTION TO 500 HOURS FOR FAR 135 OPERATORS DOING SHORT HAUL. 1 H 7 1 3O NT 3A12 1997062400001 19970624 00001 EA 1997 6 24 97ZZZX2797 2 19970528 G 8520 CRANKCASE PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA ALT MT LUG BROKEN D A O OTHER K FLUID LOSS CR CRUISE 1 CE 07 2885D 1969 287990520 L2678036A RIGHT CRANKCASE LOWER FRONT ALTLERNATOR SUPPORT MOUNT LUG BROKE OUT OF CRANKCASE AND LEFT A HOLE 1.50 INCHES IN DIAMETER . CAUSE UNKNOWN. CREATED OIL LEAK WITH OIL ON WINDSHIELD DURING FLIGHT. REMOVED ENGINE AND INSTALLED LYCOMING REBUILT . 1 L 7 1 3O 3 O 2A13 E286 1997061900219 19970619 00219 EA 1997 6 19 97ZZZX2798 2 19970530 G 7414 1051659 BUSHING S4LN1227 CESSNA 177 177A 2073706 CE LYC O360 O360A2F 41514 EA ENG LT MAG WRONG PART D L K NONE O OTHER IN INSP/MAINT 1 GL 07 30567 85020127 17701332 ROUGH ENGINE, LEFT MAG DEAD ON RUN-UP. REMOVED LEFT MAG AND FOUND SHOULDERED MAGNETO DRIVESHAFT BUSHING WITH SHOULDER M ISSING. UPON EXAMINATION OF BUSHING, DETERMINED IT WAS THE OLD STYLE, SINTERED IRON PN 10-51659. IT SHOULD HAVE HAD A MACHINED STEEL BUSHING PN 10-163049 INSTALLED. REF: TCM SB 556C OR AD 74-26-09. 1 H 7 1 3O 3 O A13CE E286 1997061900220 19970619 00220 CE 1997 6 19 97ZZZX2799 1 19970603 G 7931 LINE CESSNA 150 150J 2071820 CE OIL PRESS IND CHAFED G K NONE K FLUID LOSS IN INSP/MAINT 1 AL 03 3829J 15065129 OIL PRESSURE INDICATOR LINE (COPPER) BETWEEN FIREWALL AND INDICATOR WORE THROUGH AND LEAKED DUE TO IMPROPER SECURING OF LINE BY PLASTIC TY-RAP BANDS. PLASIC TY-RAP IS HARDER THAN COPPER .1250 INCH LINE. LINES SHOULD BE SECURED BY PROPER S IZE ADEL CLAMPS. 1 H 7 1 3O 3A19 1997061900221 19970619 00221 GL 1997 6 19 97ZZZX2800 1 19970402 G 5340 ATTACH ANGLE NAMER T6 AT6C 6400412 GL TAILCONE ATTACH EXCESS WORN D K NONE O OTHER IN INSP/MAINT 1 EA 17 417AS 7000 847648 LOWER RT TAILCONE TO STEEL TUBE FUSELAGE ATTACH BOLTS WORN SEVERELY IN ALUM ATTACH ANGLES. INSTALLED AN5 BOLTS GROOVED. WASHER NEXT TO NUT CHAFED AROUND COUNTERBORE APPROXIMATELY .060 INCH INTO A .090 INCH THICK ALUM ANGLE. .3125 INCH BO LT HOLES ELONGATED APPROX .250 INCH BY .4375 INCH. REPLACED ALUM ANGLES. SUSPECT CAUSE, TOO LONG OF LENGTH HARDWARE IN STALLED. NUT BOTTOMED ON THREADS. 1 L 7 1 3R A2575 1997061900222 19970619 00222 SO 1997 6 19 97ZZZX2801 1 19970527 G 5551 FITTING PIPER PA28 PA28236 7102815 SO STAB ATTACH CORRODED B S R2JR K NONE O OTHER IN INSP/MAINT 1 EA 21 43595 2436 288411018 WHILE COMPLETING ANNUAL/100 HR INSPECTION, STABILATOR ATTACH BRACKETS WERE INSPECTED PER PIPER SB 856. CORROSION FOUND UNDER TWO ATTACHMENTS. BRACKETS ARE STEEL AND ATTACHED TO ALUMINUM SKIN. REMOVED, CLEANED, AND PAINTED. EPOXY PRIMER INSTALLED ON SKIN. SB 856 CALLS FOR INSPECTION EACH 12 MOS. THIS AIRCRAFT WAS INSPECTED 8 MOS EARLIER. NO CORROSION. ALSO, SUGGEST PIPER COME UP WITH A PERMANENT FIX. 1 L 7 1 3O 2A13 1997061900223 19970619 00223 1997 6 19 97ZZZX2802 4 19970501 G 6113 D3586 BULKHEAD BEECH 36 A36 1151604 CE PROP SPINNER CRACKED D S K NONE O OTHER IN INSP/MAINT 1 NM 01 4612M 500 E1244 INSPECTION FOUND AFT SIDE PROPELLER SPINNER REAR BULKHEAD CRACKED. 1 L 7 1 3O 3A15 1997061900224 19970619 00224 EA 1997 6 19 97ZZZX2803 2 19970508 G 8530 LW12427 CYLINDER PIPER PA28 PA28180 7102808 SO LYC O360 O360A4A 41514 EA EXH PORT CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 01 4749L 298 284077 L1118436A DURING AN ANNUAL INSPECTION OF ENGINE, CRACKS WERE FOUND IN THE TWO REAR CYLINDERS IN EXHAUST PORTS. ONE HAD CRACKS IN THE INNER (TOWARD CENTER OF HEAD) AND AFT. OTHER IN INNER ONLY. BOTH WERE INSTALLED DEC, '91 AND HAD ACCUMULATED APPRO XIMATELY 300 HOURS. 1 L 7 1 3O 3 O 2A13 E286 1997061900225 19970619 00225 EA 1997 6 19 97ZZZX2804 2 19970507 G 7322 CARBURETOR PRECISION PIPER PA28 PA28180 7102808 SO LYC O360 O360A4A 41514 EA BOWL CRACKED D K NONE W K INADEQUATE Q C FLUID LOSS IN INSP/MAINT 1 CE 01 4749L K105073 284077 L1118436A DURING ANNUAL INSPECTION, FUEL FOUND SEEPING FROM LOWER AREA OF CARBURETOR. FURTHER INVESTIGATION FOUND A BOLT USED TO MOUNT THE AIRBOX TO THE CARBURETOR WAS TOO LONG AND HAD BROKEN THE CARBURETOR BOWL. SUBMITTER STATED MAINTENANCE PERSON NEL SHOULD BE REMINDED TO CHECK, IN THIS CASE, BOLTS TO ASSURE THEY ARE THE CORRECT LENGTH/PART NUMBER. 1 L 7 1 3O 3 O 2A13 E286 1997061900226 19970619 00226 SO 1997 6 19 97ZZZX2805 2 19970519 G 8540 643259A ADAPTER CESSNA 310 310N 2074234 CE CONT O520 IO520E 17032 SO STARTER BINDING D K NONE O OTHER IN INSP/MAINT 1 EA 05 488SP 90 310N0029 215853R WHILE PERFORMING COMPRESSION TEST, DISCOVERED ENGINE WOULD LOCK-UP WHEN ROTATED BACKWARDS. TROUBLESHOOTING REVEALED STA RTER ADAPTER WAS CAUSE OF PROBLEM. FURTHER INSPECTION OF ADAPTER SHOWED ACCUMULATION OF RUST AT STARTER MOUNTING PAD. T HIS WAS SECOND NEWLY OVERHAULED ENGINE FOUND WITH THIS PROBLEM. ADAPTER WAS REPLACED WITH NO FURTHER PROBLEMS. 1 L 7 2 3O 3 O 3A10 E5CE 1997061900228 19970619 00228 CE 1997 6 19 97ZZZX2807 1 19970530 G 3231 ROD END S2321L3 CESSNA 210 P210R 2073455 CE NLG DOOR STUD DEFECTIVE B S A FC6R K NONE O OTHER IN INSP/MAINT 1 NM 11 5293A 1178 P21000845 THREADED STUD STAKED IN ROD END PULLS THROUGH WHICH WOULD ALLOW NOSE GEAR DOOR TO JAM OR FLAP IN THE AIRFLOW. THIS WAS FOUND DURING AN INSPECTION. 1 H 7 1 3O RT 3A21 1997061900229 19970619 00229 CE 1997 6 19 97ZZZX2808 1 19970602 G 7160 INLET TUBE CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA CARB HEAT BOX DETACHED D A K NONE O OTHER IN INSP/MAINT 1 WP 03 5550L 15284352 L2275715 FOUND THAT WARM AIR INLET TUBE ROLLER FLANGE ON LT SIDE OF CARBURETOR AIRBOX BECOMES WORN AND DISCONNECTED. THIS RENDE RS CARBURETOR HEAT AIR SUPPLY INEFFECTIVE. SUBMITTER SUGGESTS ATTACHING TUBE WITH SPOT WELDS. 1 H 7 1 3O 3 O NT 3A19 E223 1997061900230 19970619 00230 CE 1997 6 19 97ZZZX2809 1 19970317 G 3530 1780001 BRACKET BEECH 100 B100 1152919 CE OXYGEN BOTTLE CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 09 55FR 2322 BE123 FOUND OXYGEN BOTTLE RT SUPPORT BRACKET CRACKED. CRACK LOCATED AT THE CORNER OF THE CUT-OUT FOR THE BAND CLAMP. 1 L 7 2 4T A14CE 1997061900231 19970619 00231 EA 1997 6 19 97ZZZX2810 2 19970505 G 8500 ENGINE PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA OIL SYSTEM MAKING METAL E K NONE O OTHER IN INSP/MAINT 1 WP 07 600EE 715 317952158 L21468A DURING SCHEDULED INSPECTION, ENGINE OIL FILTER WAS CUT OPEN AND INSPECTED. FILTER WAS FOUND CONTAMINATED WITH METAL PAR TICLES. INSPECTION OF PROPELLER AND ALL OTHER ENGINE ACCESSORIES WAS SATISFACTORY. ENGINE WAS REMOVED FROM SERVICE. 1 L 7 2 3O 3 O A20SO E14EA 1997061900232 19970619 00232 EA 1997 6 19 97ZZZX2811 2 19970607 G 8500 ENGINE PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA POWER SECTION FAILED E K NONE Y ENGINE STOPPAGE IN INSP/MAINT 1 WP 07 600EE 317952158 L150268A DURING COMPLIANCE OF LYCOMING SI 1427B, 'GROUND TEST PROCEDURES', ENGINE STOPPED RUNNING DURING 3 TO 5 SECONDS OF 'FULL STATIC POWER CHECK'. ALL ENGINE OPERATING PARAMETERS WERE NORMAL BEFORE FAILURE. PROPELLER COULD NOT BE MOVED BY HAND AFTER FAILURE. PROPELLER AND ALL ACCESSORIES WERE REMOVED AND INSPECTED. NO DEFECTS IN ACCESSORIES OR PROP WERE FOUND. 1 L 7 2 3O 3 O A20SO E14EA 1997061900233 19970619 00233 GL 1997 6 19 97ZZZX2812 3 19970417 G 6114 HUB CESSNA 150 152 2071835 CE MCAULY 1A103 1A103TCM GL NR 2 BLADE CRACKED B EK2R K NONE O OTHER IN INSP/MAINT 1 SW 17 6155Q 15285175 RBF183 FOUND CRACK APPROXIMATELY .626 INCH LONG, .025 INCH DEEP, TRAILING EDGE SIDE OF HUB OF NR 2 BLADE. AD 95-21-01 AND MCCA ULEY SB 221B ADDRESSES THE HUB FRONT FACE AND BOLT HOLES. NO RE-WORK IS ALLOWED ON SIDE OF HUB. 1 H 7 1 3O NT 3A19 5 N P50GL 1997061900234 19970619 00234 CE 1997 6 19 97ZZZX2813 1 19970606 G 5711 SPAR CESSNA 150 150M 2071830 CE RT WING ERODED H S A CZ9T K NONE O OTHER IN INSP/MAINT 1 WP 01 66667 4988 15076195 AFTER DISASSEMBLING AIRCRAFT FOR REFURBISHMENT, RT WING MAIN SPAR ATTACH FITTING WAS FOUND ERODED. ADDITIONAL SIGNS OF FRETTING AND EROSION WERE DETECTED AT THE LOWER END OF THE LIFT STRUT. ALL WEAR WAS INDICATIVE OF A LIMITED FORE AND AF T 'SWING' OF THE ENTIRE WING STRUCTURE, AS OPPOSED TO GENERAL FRETTING IN THE CONTACT AREAS. 1 H 7 1 3O 3A19 1997061900235 19970619 00235 CE 1997 6 19 97ZZZX2814 1 19970605 G 2510 S22373 RETAINER BUSHING CESSNA 150 152 2071835 CE LAP BELT MISSING G A K NONE O OTHER IN INSP/MAINT 1 GL 19 68473 3851 15282309 BOTH SHOULDER HARNESS RETAINERS PN S2237-3 MISSING. CONDITION NOTICE ISSUED. ALERT NR 210 DATED JAN 96 PAGE 11 COVERS THIS SUBJECT. 1 H 7 1 3O NT 3A19 1997061900236 19970619 00236 CE 1997 6 19 97ZZZX2815 1 19970521 G 2520 12005041 HANDLE CESSNA 172 172K 2072430 CE PAX SEAT LATCH BROKEN D A K NONE O OTHER IN INSP/MAINT 1 CE 09 7203G 4999 17258903 HANDLE BROKE AT PIVOT POINT. ALLOWED THE ARM TO FALL FROM PIVOT POINT CAUSING THE SEAT LATCH DROP PIN TO NOT ENGAGE THE SEAT RAIL ALLOWING THE PASSENGER SEAT TO SLIDE BACK WHEN POWER TO THE AIRCRAFT IS APPLIED. INDIVIDUALS SHOULD LOOK AT THIS AREA ON 100 HOUR AND ANNUAL INSPECTIONS. 1 H 7 1 3O NT 3A12 1997061900237 19970619 00237 SO 1997 6 19 97ZZZX2816 2 19970517 G 8530 646612 EXHAUST VALVE 653426A13 CESSNA 140 140 2071602 CE CONT C85 C8512 17008 SO ENGINE LEAK D K NONE O OTHER IN INSP/MAINT 1 CE 01 72742 40 9921 22960612 FORTY HOURS AFTER CYLINDER ASSY REPLACED, ALLL EXHAUST VALVES WERE LEAKING ON COMPRESSION CHECK ON ALL 4 CYLINDERS. 1 H 7 1 3O 3 O NC A768 E233 1997061900238 19970619 00238 CE 1997 6 19 97ZZZX2817 1 19970605 G 3710 131823H12A0030 LINE BEECH 33 F33A 1151425 CE AUXILIARY VAC DETERIORATED B A JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 8004V 1055 CE1649 THE AUXILIARY INSTRUMENT VACUUM SYSTEM LINE PASSES CLOSE TO THE LT EXHAUST STACK. COMING OUT OF THE AFT SIDE OF THE IN- LINE FILTER IS A PLASTIC HOSE THAT CONNECTS THE FILTER TO THE HARD LINE. THIS HARD PLASTIC HOSE CANNOT TAKE THE HEAT FR OM THE EXHAUST AND HAS A TENDENCY TO GET BRITTLE AND SPLIT OR BREAK. SOLUTION TO THIS PROBLEM WAS TO INSTALL A HIGH QU ALITY, HIGH TEMPERATURE SILICONE HOSE IN PLACE OF THE CHEAPER FACTORY HOSE. 1 L 7 1 3O 3A15 1997061900239 19970619 00239 CE 1997 6 19 97ZZZX2818 1 19970526 G 3230 2VA20 SWITCH CESSNA 402 402B 207590P CE GEAR SAFETY MALFUNCTION E A K NONE O OTHER IN INSP/MAINT 1 SO 21 814CF 2644 402B0335 LANDING GEAR SWITCH FOUND TO BE INTERMITTENT. FLIGHT CREW TOOK AIRCRAFT FOR A FLIGHT JUST AFTER WASHING. GEARS WOULD N OT RETRACT. ON INSPECTION, FOUND MOISTURE IN SIDE OF MLG SAFETY SWITCH. 1 L 7 2 3O A7CE 1997061900240 19970619 00240 SO 1997 6 19 97ZZZX2819 1 19970605 G 2510 RETAINER BUSHING PIPER PA34 PA34220T 7103420 SO LAP BELT MISSING G K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 19 8393Y 1984 348133108 PILOT'S NYLON SHOULDER HARNESS RETAINER MISSING. THIS SUBJECT WAS COVERED IN ALERT NR 210, JAN '96. SUBMITTER STATED H AVE FOUND SEVERAL AIRCRAFT WITHOUT TY-RAPS, BUT WITH THE NYLON SHOULDER HARNESS RETAINER MISSING. MAINTENANCE PERSONNEL NEED TO INSPECT THIS AREA CLOSER. SEVERAL OTHER AIRCRAFT FOUND MISSING NYLON: CESSNA AND PIPER. NOTE: UNABLE TO FIN D PIPER PART NUMBER. 1 L 7 2 3O A7SO 1997061900241 19970619 00241 SO 1997 6 19 97ZZZX2820 2 19970524 G 8530 639614 ROCKER ARM UNIVAR 415 415G 0420310 NM CONT O200 O200A 17020 SO NR 2 CYL EXHAUST FAILED G S K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 19 94415 3600 1225 5050 2045979A NR 2 CYLINDER HAD INTAKE AND EXHAUST ROCKER ARM ASSEMBLIES SWITCHED. NR 2 EXHAUST VALVE MIGHT HAVE STUCK DUE TO NO LUBR ICATION OR COOLING FROM THE DRILLED PASSAGEWAY BECAUSE THE EXHAUST ROCKER ARM WAS IN THE INTAKE VALVE POSITION. INTAKE ROCKER FAILED. 1 L 7 1 3O 3 O A787 E252 1997061900242 19970619 00242 GL 1997 6 19 97ZZZX2821 1 19970501 G 3230 LANDING GEAR AMTR GAIR GLASAIRIII 05691HK GL MLG-NLG MALFUNCTION H K NONE O OTHER LD LANDING 1 SW 99 957DJ 3084 PILOT REPORTED LANDING GEAR WOULD NOT RETRACT AFTER HE DEPARTED AIRPORT EN ROUTE TO TORRANCE AIRPORT, CA. HE STATED HE HAD THREE GREEN LIGHTS DURING THE FLIGHT TO COMPTON. PILOT DECIDED TO LAND AT COMPTON AIRPORT TO CHECK OUT GEAR PROBLEM . WHILE LANDING AT COMPTON, THE LEFT GEAR COLLAPSED, THEN THE RIGHT, THEN THE NOSE GEAR, IN THAT ORDER. CAUSE NOT KNOW N. LANDING GEAR CHECK FOUND NO DISCREPANCIES. 1 L 7 1 3O RT EXPA1L71 1997061900243 19970619 00243 SO 1997 6 19 97ZZZX2822 1 19970605 G 5330 99470 SKIN PIPER PA34 PA34200T 7103406 SO FUSELAGE CRACKED D S K NONE O OTHER IN INSP/MAINT 1 GL 21 9798C 347870222 FUSELAGE SKIN CRACKED AT REAR BULKHEAD HORIZONTAL STABILIZER ATTACH BRACKETS. CRACK IS LOCATED IN FORMED FUSELAGE SKIN. 1 L 7 2 3O A7SO 1997061900244 19970619 00244 SO 1997 6 19 97ZZZX2823 1 19970605 G 5330 99471 SKIN PIPER PA34 PA34200T 7103406 SO FUSELAGE CRACKED D S K NONE O OTHER IN INSP/MAINT 1 GL 21 9798C 347870222 FUSELAGE SKIN CRACKED AT REAR BULKHEAD HORIZONTAL STABILIZER ATTACH BRACKETS. CRACK IS LOCATED IN FORMED FUSELAGE SKIN. 1 L 7 2 3O A7SO 1997061900381 19970619 00381 GL 1997 6 19 97ZZZX2824 2 19970429 G 7323 23057870 GOVERNOR BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ENGINE FAILED B A AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 5059C 1031 BR32500 S779 GOVERNOR FAILED TO MAINTAIN N2 ROTOR SPEED. HAVING ALOT OF PROBLEMS WITH THESE GOVERNORS FAILING AT ABOUT THIS TIME. TH E COUPLINGS ON THESE GOVERNORS DO NOT HOLD UP. REPLACED GOVERNOR WITH SERVICEABLE ITEM. 1 G 7 2 3U 3 U H3EU E4CE 1997061900382 19970619 00382 NE 1997 6 19 97ZZZX2825 1 19970501 G 6210 7615009100041 BLADE SKRSKY S76 S76A 8143006 NE M/R BLUE SKIN MISSING B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 7266F 9754 A08600648 760273 BLUE M/R BLADE MISSING A SECTION OF OUTER SKIN ON BOTTOM OF BLADE. MISSING SECTION STARTS JUST AFT OF LEADING EDGE STRI P EXTENDING TO TRAILING EDGE BETWEEN APPROXIMATELY BLADE STA 204 THROUGH STA 216 (APPROX 12 INCHES LONG). REMOVED AND R EPLACED BLUE M/R BLADE, BALANCED AND TRACKED M/R SYSTEM. 1 G 7 2 3U H1NE 1997061900384 19970619 00384 EU 1997 6 19 97ZZZX2827 1 19970515 G 6520 350A33215300 LAMINATE HINGE SNIAS 350 AS350B 8680801 EU T/R CRACKED B FF6R K NONE O OTHER IN INSP/MAINT 1 NM 11 911NT 62 1556 RUBBER LAMINATE IS CRACKED 180 DEGREES AROUND PART. 1 G 7 1 3U H9EU 1997061900454 19970619 00454 CE 1997 6 19 97ZZZX2828 1 19970514 G 5542 553300054 SKIN CESSNA 500 560CESSNA 2076750 CE RUD RT LOWER CRACKED B DXTR K NONE O OTHER IN INSP/MAINT 1 GL 07 315QS 1343 5600315 FOUND CRACK ON RIGHT SIDE LOWER RUDDER SKIN. THIS IS THE 2ND TIME A CRACK HAS BEEN FOUND IN THIS AREA ON THIS PARTICULA R RUDDER. THE FIRST WAS AT 718.2 HOURS TOTAL TIME. THE SKIN WAS REPLACED AT THAT TIME AND WAS CHANGED AGAIN THIS TIME. SUBMITTER STATED IT SEEMS THERE MAY BE AN ENGINEERING AND/OR A PRODUCTION DEFECT. NINTH OCCURRENCE IN FLEET. 2 L 7 2 4F RT A22CE 1997061900455 19970619 00455 CE 1997 6 19 97ZZZX2829 1 19970516 G 3510 1780001 BRACKET BEECH 100 B100 1152919 CE OXYGEN BOTTLE CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 09 55FR 3000 BE123 FOUND OXYGEN BOTTLE LEFT SUPPORT BRACKET CRACKED. CRACK LOCATED AT THE CORNER OF THE CUT OUT FOR THE BAND CLAMP. BRACK ET MANUFACTURED BY PURITAN BENNETT. 1 L 7 2 4T A14CE 1997061900456 19970619 00456 CE 1997 6 19 97ZZZX2830 1 19970530 G 5320 251127162 FRAME LEAR 35 35A 5170602 CE ENTRY DOOR FWD CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 03 58MM 261 THE LOWER ENTRY DOOR FORWARD STEP FRAME WAS CRACKED IN THE RADIUS OF THE EXTERNAL SKIN FLANGE AT THE HINGE. CAUSE OF CR ACK WAS DUE TO IMPROPER RIGGING OF THE ASSEMBLY. 2 L 7 2 4F A10CE 1997061900457 19970619 00457 EU 1997 6 19 97ZZZX2831 1 19970528 G 3310 RH00252350JBS DIMMER SWITCH AMD FALC50 FALCON900 2700160 EU CREW LIGHT SHORTED D A K NONE O OTHER NR NOT REPORTED 1 WP 23 730SA 322 9550 155 THE THIRD CREW MEMBER'S READING LIGHT RHEOSTAT ELECTRICALLY SHORTED TO THE ADJACENT OXYGEN MASK CONTAINER. THE READING LIGHT CIRCUIT BREAKER TRIPPED. THIS COULD HAVE BEEN A POTENTIAL SERIOUS INCIDENT. THE OPERATOR SUGGESTED TO DASSAULT N OT TO USE RHEOSTATS WITH OPEN CONTACTS. AIRCRAFT TOTAL TIME: 322.4 HOURS. LANDINGS, 215. 2 L 7 3 4F RT A46EU 1997061900458 19970619 00458 EA 1997 6 19 97ZZZX2832 1 19970527 G 5320 60035031201 SUPPORT ANGLE CNDAIR CL600 CL6002A12 1900304 EA FLOOR SUPPORT CRACKED B S R2JR K NONE O OTHER IN INSP/MAINT 1 EA 21 999JR 4627 3061 WHILE PERFORMING 4,800 HOUR/120 MONTH INSPECTION, FOUND FLOOR SUPPORT ANGLE CRACKED AT FS 621 (AFT PRESSURE BULKHEAD). A REA INSPECTED WAS UNDER THE FLOOR IN AFT BAGGAGE COMPARTMENT. SUBMITTER SUGGESTS CLOSE INSPECTION OF THIS AREA. SRM AT A 53-15-08 HAS A RIVETED ANGLE DOUBLER REPAIR FOR THIS CRACKING. THIS AREA PRONE TO CRACKING IS MAJOR STRUCTURE FOR PRE SSURE BULKHEAD AND BAGGAGE FLOOR. 2 L 7 2 4F RT A21EA 1997061900462 19970619 00462 SO 1997 6 19 97ZZZX2834 1 19970522 G 3320 BR9800005 LAMP GULSTM G1159 GIV 3980115 SO RT CABIN AFT BURNED D A K NONE O OTHER IN INSP/MAINT 1 EA 17 401JL 527 1283 RIGHT SIDE AFT CABIN LOWER FLUORESCENT LAMP WAS FOUND INOPERABLE. THE ACCESS COVER WAS REMOVED TO CHECK THE LAMP AND FO UND TO BE BURNED COMPLETELY IN HALF .50 INCH FROM END OF TUBE. EVIDENCE OF A SMALL FIRE IN THAT AREA WAS FOUND. SMOKE AND FIRE STAINS ON WALL BEHIND BULB WERE 4 INCHES HIGH TOWARD THE CEILING. PARTS WERE SENT TO GULFSTREAM IMMEDIATELY FO R EVALUATION. BRUCE INDUSTRIES INC, PN BR 98000-005; SYLVANIA, P/N 5108WW. 2 L 7 2 4F RT A12EA 1997061900463 19970619 00463 WP 1997 6 19 97ZZZX2835 1 19970502 G 6310 369A532 BEARING HUGHES 369 369HS 4470728 WP OVERRUN CLUTCH CRACKED B QH5R K NONE O OTHER IN INSP/MAINT 1 NM 07 OVERRUNNING CLUTCH BEARING OUTER RACE IS CRACKED. 1 G 7 1 3U H3WE 1997061900464 19970619 00464 GL 1997 6 19 97ZZZX2836 1 19970501 G 5610 28011302212 WINDSHIELD ENSTRM F28 280C 3300505 GL COCKPIT CRACKED G K NONE O OTHER IN INSP/MAINT 1 EA 17 122TV 1049 DURING ENGINE START ON A COLD MORNING, RT WINDSHIELD CRACKED APPROXIMATELY 14 INCHES FROM CENTER WINDSHIELD ANCHORING ST RIP TOWARD OUTBOARD OF AIRCRAFT. POSSIBLY HAD A PREVIOUS CRACK AT RIVET LOCATION THAT WAS HIDDEN UNDER CENTER STRIP. 1 G 7 1 3O H1CE 1997061900465 19970619 00465 GL 1997 6 19 97ZZZX2837 2 19970508 G 7320 6893073 AIR LINE SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL GOV PC TO FCU BROKEN B A ZV1R E A ENGINE SHUTDOWN UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 03 202SR 760236 CAE890251S IN CRUISE FLIGHT, NR 2 ENGINE SPOOLED DOWN TO 30 PERCENT AND THEN DOWN TO 10 PERCENT. ENGINE WAS SECURED AND AIRCRAFT W AS FLOWN TO AIRPORT FOR LANDING. FOUND PC AIR LINE, PN 6893073, BROKEN AT FERRULE ON FUEL CONTROL. THIS LINE COMES FRO M GOVERNOR TO FUEL CONTROL. REPLACED LINE. OPS CHECK AND FLIGHT OK. RAN VIB CHECK ON ENGINE. FOUND 1.25 IPS. REPLAC ED ENGINE ASSY DUE TO HIGH VIB LEVEL. RECOMMEND VIB CHECK AT LEAST EVERY 300 HOURS. 1 G 7 2 3U 3 U H1NE E1GL 1997061900466 19970619 00466 EA 1997 6 19 97ZZZX2838 2 19970407 G 8530 AEL12949 INTAKE VALVE HILLER UH12 UH12E 4360122 WP LYC O540 VO540C2A 41532 EA STEM AND FACE WORN D K NONE O OTHER IN INSP/MAINT 1 NM 09 36MV 160 75137CN 5060 L256043 THE VALVE STEM UNDER THE KEEPER'S WAS HEAVILY WORN. THIS CONDITION WAS ALSO FOUND ON 4 OTHER VALVES (INTAKE) ALL HAVING THE SAME TOTAL TIME AND PART NUMBER. THE 6TH VALVE WAS A LYCOMING WITH THE SAME TIME AND INSTALLATION DATE. NO PROBLE M FOUND. 1 G 7 1 3O 3 O 4H11 E304 1997061900467 19970619 00467 SW 1997 6 19 97ZZZX2839 1 19970512 G 6330 222031605109 FLEXTURE BELL 222 222B 1182124 SW M/R XMSN MT DELAMINATED B GS1R K NONE O OTHER IN INSP/MAINT 1 EA 03 510W 838 LK00131 47133 INSPECTION FOUND FLEXTURES DELAMINATED. REPLACED WITH NEW FLEXTURES. 1 G 7 2 3U H9SW 1997061900468 19970619 00468 SW 1997 6 19 97ZZZX2840 1 19970512 G 6330 222031605109 FLEXTURE BELL 222 222B 1182124 SW M/R XMSN MT DELAMINATED B GS1R K NONE O OTHER IN INSP/MAINT 1 EA 03 510W 1016 LK0124 47133 INSPECTION FOUND FLEXTURES DELAMINATED. REPLACED WITH NEW FLEXTURES. 1 G 7 2 3U H9SW 1997061900469 19970619 00469 1997 6 19 97ZZZX2841 4 19970512 G 2210 412074030101 AMPLIFIER BELL 412 412 1182202 SW AUTOFLIGHT BURNT B GS1R K NONE O OTHER IN INSP/MAINT 1 EA 03 82628 510 36106 INSPECTION FOUND AMPLIFIER BURNT. REPLACED WITH NEW AMPLIFIER. 1 G 7 2 4U H4SW 1997061900470 19970619 00470 WP 1997 6 19 97ZZZX2842 1 19970528 G 6710 B2923 ROD END ROBSIN R22 R22HP WP COLLECTIVE BROKEN D A K NONE O OTHER IN INSP/MAINT 1 NE 01 9077Q 1200 A0387 0273 DURING PRE-FLIGHT FOR A TRAINING FLIGHT WHILE LIFTING COLLECTIVE STICK, A LOUD BANG WAS HEARD. CYCLING COLLECTIVE STICK UP AND DOWN, TWO MORE SOFTER BANGS AND RATCHETING FEELING IN STICK. MAINTENANCE WAS CALLED AND COLLECTIVE STICK WAS SM OOTH AND NO NOISE WAS HEARD. FURTHER INVESTIGATION REVEALED SPRING ASSY A429-8 WAS LAYING FREE UNDER COPILOT'S COLLECTI VE STICK, UPPER ROD END, LT THREAD, BENT AND BROKE OFF AT BASE OF PLATE CAUSING UNIT TO COCK TO ONE SIDE RESULTING IN TH E BREAKAGE OF THREE A28-1 RODS AND COMPLETE SEPARATION OF SPRING ASSY. FLIGHT IN THIS CONDITION WOULD BE VERY DIFFICULT BECAUSE OF NO SPRING HELP, HEAVY COLLECTIVE CONTROLS. SUBMITTER STATED INSPECTION AT 100 HRS FOR BENT ROD ENDS. 1 G 7 1 3O O H10WE 1997061900471 19970619 00471 NM 1997 6 19 97ZZZX2843 1 19970523 G 2761 656952210 HOUSING 65449616 BOEING 737 7372M8 1384483 NM SPOILER CRACKED B IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 149AW80BD SPOILER ACTUATOR HAS A HOLE IN HOUSING. FOUND DURING PROOF PRESSURE TESTING FOR REPAIR. 2 L 7 2 4F A16WE 1997061900472 19970619 00472 1997 6 19 97ZZZX2844 4 19970203 G 6113 AN526C1032R8 SCREW BEECH 36 36BEECH 1151602 CE SPINNER CRACKED B S A OYSR K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 09 RECEIVED SHIPMENT OF 400 EACH AN526C-1032R8 SPINNER SCREWS. UPON RECEIVING, INSPECTED, NOTED ALL SCREWS HAD CRACKS OR F ISSURES ALL THE WAY THROUGH SCREW HEAD RADIATING FROM PHILLIPS RECESS. THIS COULD RESULT IN PROPELLER SPINNER DEPARTING AIRCRAFT IN-FLIGHT. SUBMITTER RECOMMENDS TRACING TO MANUFACTURER (NOT LISTED ON PARTS BAG) AND RECALL ALL SCREWS ON TH IS LOT NUMBER. 1 L 7 1 3O 3A15 1997061900473 19970619 00473 NE 1997 6 19 97ZZZX2845 2 19970602 G 8500 ENGINE BEECH 18 H18 1151012 CE PWA R985 R985AN14B 52008 NE LT ENGINE MAKING METAL G E ENGINE SHUTDOWN K FLUID LOSS CR CRUISE 1 SW 11 117ME 1266 BA638 P225009 WHILE IN CRUISE FLIGHT, PILOT NOTICED OIL LEAK ON LEFT ENGINE. ENGINE WAS SECURED, PROPELLER FEATHERED, AND AN UNEVENTF UL LANDING MADE. MAINTENANCE FOUND PROPELLER TO BE LEAKING, BUT THE ENGINE OIL SCREEN WAS FULL OF METAL. SUSPECT INTER NAL FAILURE. ENGINE TO BE REMOVED AND REPLACED. 1 L 7 2 3R 3 R A765 5E1 1997061900474 19970619 00474 SO 1997 6 19 97ZZZX2846 1 19970527 G 2910 TUBE PIPER PA28 PA28RT201T 7102817 SO NLG ACTUATOR LEAK B SL5R O OTHER K FLUID LOSS AP APPROACH 1 NE 03 3071N 28R7931060 LANDING GEAR WOULD NOT EXTEND. EMERGENCY EXTENSION PERFORMED AND AIRCRAFT LANDED SAFELY. FOUND HYDRAULIC POWER PACK RE SERVOIR VERY LOW ON FLUID. SERVICED RESERVOIR AND GEAR RETRACTION AND EXTENSION OPS CHECKED GOOD WHILE AIRCRAFT WAS ON JACKS. FOUND INSULATION WAS SOAKED WITH HYDRAULIC LEAK FROM PIN HOLE IN NOSE LANDING GEAR ACTUATOR LOWER HYD TUBE. FAB RICATED NEW TUBE, NO FURTHER LEAKS NOTED. 1 L 7 1 3O 2A13 1997061900475 19970619 00475 GL 1997 6 19 97ZZZX2847 1 19970501 G 5311 FRAME DHAV DHC1 DHC1B2S3 2801738 GL BS 190 CRACKED D L A K NONE O OTHER IN INSP/MAINT 1 WP 07 33BR 166 THE FUSELAGE FRAMES AT STA 190 ARE CRACKED. THE CRACKS FOUND DURING INSPECTIONS ARE LOCATED AT THE POINT WHERE THE LOWE R SPAR CAP IS SANDWICHED. THE CRACKS RUN VERTICALLY FROM TOP TO BOTTOM AND THE DEPTH IS COMPLETELY THROUGH FRAME MATERI AL. THE CRACKS ARE LOCATED 6 INCHES INBD FROM FUSELAGE SIDES WHERE THE STEEL DOUBLERS END ON LOWER SPAR CAP. BOTH FRAM ES FRONT AND REAR SHOULD BE INSPECTED. IF ANY CRACKS ARE FOUND, ADVISE SUSPENDING ANY AEROBATIC FLYING AND HAVING REPAI RS ACCOMPLISHED AS SOON AS POSSIBLE. 1 L 7 1 3O EXPA1L71 1997061900476 19970619 00476 CE 1997 6 19 97ZZZX2848 1 19970121 G 3213 MS9048180 PIN 16981001215 BEECH 23 C24R 1151254 CE NLG COMPRESSOR SHEARED D L A O OTHER O OTHER AP APPROACH 1 EA 11 3343L MC466 ACFT WAS NOT ABLE TO LOWER NOSE GEAR IN-FLIGHT. MADE A NOSE GEAR UP LANDING WITH DAMAGE TO THE PROPELLER AND ENGINE COW LING. NOSE GEAR FOUND STUCK IN THE UP POSITION WITH DOWN MOVEMENT BEING PREVENTED BY THE TIRE HITTING THE ACFT SKIN IN NOSE WHEELWELL. FURTHER INSPECTION REVEALED ROLL PIN P/N MS9048-180 HAD SHEARED IN THE COMPRESSOR ASSY, P/N 169-810012- 15. THIS ROLL PIN HOLDS THE ROD, P/N 169-810000-111, IN THE COMPRESSOR ASSY. 1 L 7 1 3O A1CE 1997061900477 19970619 00477 CE 1997 6 19 97ZZZX2849 1 19970501 G 3230 504501019 TORQUE TUBE CESSNA 402 402B 207590P CE LT MLG CRACKED D P A O OTHER O OTHER CL CLIMB 1 SW 99 403PA 8 402B0917 PILOT REPORTED 'AFTER DEPARTURE, ADVISED BY ANOTHER AIRCRAFT THAT THE LEFT GEAR WAS DOWN AND LOCKED'. AFTER VERIFYING T HIS IN MIRROR, HE CONTINUED TO DESTINATION AND EXTENDED GEARS AND A SAFE LANDING WAS MADE. THE PART WAS SUPERCEDED TO A DIFFERENT NUMBER WHEN ORDERED. 1 L 7 2 3O A7CE 1997061900478 19970619 00478 CE 1997 6 19 97ZZZX2850 1 19970528 G 8120 4066109005 TURBOCHARGER GARRTT CESSNA 210 T210G 2073432 CE CONT O520 TSIO520C 17040 SO EXH HOUSING CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 01 6843R FDR0152 T2100243 1408179C TURBOCHARGER EXHAUST HOUSING CRACKED AROUND AUXILIARY MOUNTING LUG. 1 H 7 1 3O 3 O 3A21 E8CE 1997061900479 19970619 00479 CE 1997 6 19 97ZZZX2851 1 19970526 G 3230 12806005 ACTUATOR 12805147 CESSNA 210 T210L 2073449 CE NLG DOWNLOCK CRACKED D A K NONE O OTHER IN INSP/MAINT 1 NM 03 732AJ T21061360 DURING ANNUAL INSPECTION, FOUND A CRACK IN THE BEARING END OF THE NOSE GEAR ACTUATOR. THE CRACK ORIGINATES AT THE DOWNL OCK PIN LOCATION AND EXTENDS FORWARD LONGITUDINALLY AROUND THE CASTING. (NO PLAY WAS NOTED IN PIN WHEN C/W SEB 95-20). POTENTIAL OF NOSE GEAR DOWNLOCK FAILURE IN NEAR FUTURE. 1 H 7 1 3O 3A21 1997061900480 19970619 00480 SO 1997 6 19 97ZZZX2852 1 19970605 G 3222 6705408 TRUNNION ASSY PIPER PA32 PA32R301 7103218 SO NLG SPRING ARM BROKEN D S A K NONE O OTHER NR NOT REPORTED 1 EA 13 9274Q 156 3246038 NLG TRUNNION ASSY CRACKED AT THE AREA THAT THE SPRING ATTACHES. P/N 6716800. 1 L 7 1 3O A3SO 1997061900481 19970619 00481 SO 1997 6 19 97ZZZX2853 1 19970530 G 5553 STABILIZER PIPER PA34 PA34200T 7103406 SO V STAB ATTACH RIVETS POPPED B A APCR K NONE O OTHER IN INSP/MAINT 1 NM 01 4377X 347670035 INSPECTION OF RUDDER AND VERTICAL STABILZIER AREA REVEALED RIVETS WITH POPPED HEADS ON ATTACHMENT FITTING FOR AFT SPAR O N VERTICAL STABILIZER-TO-EMPENNAGE ATTACH POINT. (SIX OUT OF EIGHT RIVETS WERE SHEARED). THOROUGH INSPECTION OF EMPENN AGE REVEALED NO OTHER PROBLEMS. 1 L 7 2 3O A7SO 1997061900482 19970619 00482 EA 1997 6 19 97ZZZX2854 2 19970412 G 8530 75068 VALVE GULSTM AA5 AA5B 3960105 SO LYC O360 O360A4K 41514 EA NR 1 CYL EXHAUST FAILED G S O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TO TAKEOFF 1 NM 03 38X 2011 AA5B0889 L2699236A VALVE MALFUNCTION OCCURRED DURING TAKEOFF AT APPROXIMATELY 2,450 RPM. (AIRPORT AT 5,100 FEET). OAT 20 DEGREES FAHRENHEI T. 1 L 7 1 3O 3 O A16EA E286 1997061900661 19970619 00661 NE 1997 6 19 97ZZZX2855 1 19970508 G 5210 7620902019043 HINGE SKRSKY S76 S76 8143010 NE DOOR BROKE B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 5414X 760152 DOOR HINGE BROKE WHILE MECHANIC WAS STANDING ON DOOR. REPLACED HINGE. 1 G 7 2 3U H1NE 1997061900662 19970619 00662 NE 1997 6 19 97ZZZX2856 1 19970501 G 3212 7625101110106 EXPLOSIVE LINK SKRSKY S76 S76 8143010 NE FLOATS FAILED B AC2R K NONE O OTHER NR NOT REPORTED 1 SW 03 5447C 12925 0517 760180 EXPLOSIVE LINK DID NOT ACTIVATE WHEN FLOATS WERE DEPLOYED. HARNESS TEST OK. REPLACED LINK. 1 G 7 2 3U H1NE 1997061900664 19970619 00664 SW 1997 6 19 97ZZZX2857 1 19970310 G 3212 8226003 FUSIBLE PLUG 206073847103 BELL 407 407 SW RT FLOAT BOTTLE FAILED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 427AL 15 53107 WHILE AIRCRAFT WAS SITTING ON MAINTENANCE RAMP, NITROGEN CAME OUT OF FUSIBLE PLUG. THE INTERNAL PLUNGER CAME LOOSE OR S HEARED. 1 G 7 1 3U O H2SW 1997061900665 19970619 00665 NE 1997 6 19 97ZZZX2858 1 19970430 G 6210 7615009100051 BLADE RIB SKRSKY S76 S76A 8143006 NE M/R DEBONDED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 164AG 6245 446 A08601424 760290 DISCOVERED DURING 500-HOUR INSPECTION, MAIN ROTOR BLADE TIP RIB DEBONDED. 1 G 7 2 3U H1NE 1997061900668 19970619 00668 NE 1997 6 19 97ZZZX2859 1 19970501 G 3212 PM225681 SWITCH SKRSKY S76 S76 8143010 NE FLOAT SHORTED B AC2R K NONE O OTHER NR NOT REPORTED 1 SW 03 5447C 12925 760180 FLOAT INFLATED PREMATURELY. FOUND SWITCH ROTATING IN CYCLIC, LOOSE INSTALLATION, WIRE FRAYED. NO SHIELDING OVER SOLDER JOINT, CAUSING SHORT. UNSOLDERED CONNECTION, INSTALLED SHIELDING OVER WIRES, RESOLDERED, AND INSTALLED SWITCH SECURELY TO PREVENT TURNING. 1 G 7 2 3U H1NE 1997062600098 19970626 00098 NE 1997 6 26 97ZZZX2861 3 19970603 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 8863 4615 2761NR HJ473 FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997062600099 19970626 00099 NE 1997 6 26 97ZZZX2862 3 19970606 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 4621 4621 2488NR HJ380 FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997062600100 19970626 00100 CE 1997 6 26 97ZZZX2863 1 19970528 G 2121 99123232 BLOWER CESSNA 500 550 2076604 CE AFT CABIN FAILED D K NONE O OTHER NR NOT REPORTED 1 WP 11 10EG 344 1250 5500055 INSTALLED A CESSNA CITATION FACTORY SUPPLIED 'NEWLY OVERHAULED' EXCHANGE OVERHEAD BLOWER ASSEMBLY PN 9912323-2, MANUFACT URER'S PN BC61A901-2EX ON 5-7-96. NORMAL USE IS FOR THIS BLOWER TO BE TURNED 'ON' TO SUPPLY AIR TO THE OVERHEAD WEMAC V ENT SYSTEM. APPARENTLY, THE CENTRIFUGAL FAN END BEARINGS HAVE FAILED IN SERVICE AFTER ONLY 343.8 HOURS OF INSTALLED TIM E. THIS IS A TBO PART AS LISTED IN THE CITATION MM CHAPTER 5-11-00 WITH A TIME BETWEEN OVERHAUL OR REPLACEMENT OF 1,200 HOURS. THE 'SQUIRREL CAGE' CENTRIFUGAL BLOWER WAS NOT DAMAGED OR SEVERELY DIRTY. THE MOTOR COOLING VENT TUBE AND ADAPT ER WERE ATTACHED AND UN-RESTRICTED. CAUSE OF BEARING FAILURE IS NOT OBVIOUS OR KNOWN AT THIS TIME. 1 L 7 2 4F A22CE 1997062600102 19970626 00102 SW 1997 6 26 97ZZZX2864 1 19970610 G 6123 57B4026 PITCH CHANGE ROD 573083150 AIRTRC AT802 AT802 0390305 SW PROPELLER FAILED B EK2R K NONE O OTHER IN INSP/MAINT 1 SW 17 1546H 2257 802A0003 AIRCRAFT PARKED IN FIELD. DURING RUN-UP, LOUD BANG WHEN PROPELLER WAS REVERSED. ENGINE WAS SHUT DOWN AND PROPELLER WAS REMOVED FOR INSPECTION. ALL DAMAGE WAS CONTAINED TO THE FEATHER SPRING ASSEMBLY. 1 L 7 1 3T NC A19SW 1997062600103 19970626 00103 CE 1997 6 26 97ZZZX2865 1 19970501 G 2720 265313461013 SUPPORT WEB RKWELL NA265 NA26565 7630107 CE RUD TORQ TUBE CRACKED D S K NONE O OTHER IN INSP/MAINT 1 NE 05 58HT 5980 46570 WHILE VISUALLY INSPECTING THE RUDDER SUPPORT ASSY DURING A 150-HOUR INSPECTION, TWO CRACKS WERE FOUND ON THE RUDDER TORQ UE TUBE LOWER SUPPORT WEB. THE CRACKS WERE DEVELOPED AS A RESULT OF PART STRESS DURING MANUFACTURE. 2 L 7 2 4J A2WE 1997062600105 19970626 00105 CE 1997 6 26 97ZZZX2866 1 19970528 G 2612 473275 DETECTOR BEECH 200 200BEECH 1152920 CE ENGINE FAILED B BXSR K NONE N FALSE WARNING NR NOT REPORTED 1 EA 09 200BE 1265 BB832 FLAME DETECTOR FAILED WITHIN 71 HOURS AND WOULD INTERMITTENTLY CAUSE THE ENGINE FIRE ANNUNCIATOR TO ILLUMINATE. 1 L 7 2 4T A24CE 1997062600106 19970626 00106 EU 1997 6 26 97ZZZX2867 1 19970502 G 2710 10306233 SERVO AMD AMD FALC20 FALCON20F5 2730105 EU LT AILERON LEAKS C K NONE K FLUID LOSS NR NOT REPORTED 1 SW 09 347HS 497 347 LEFT AILERON SERVO LEAKING EXCESSIVELY WITH NO SYSTEM PRESSURE APPLIED OTHER THAN 21 PSI ON HYDRAULIC TANK (HEAD PRESSUR E). BELIEVE PISTON O-RING SEALS SPLIT OR ROLLED. NOT SURE UNTIL AERO PRECISION REPAIR AND OVERHAUL, INC., FL, HAS HAD AN OPPORTUNITY TO INVESTIGATE CAUSE. 2 L 7 2 4F RT A7EU 1997062600107 19970626 00107 EU 1997 6 26 97ZZZX2868 1 19970609 G 2710 10306233 SERVO AMD AMD FALC20 FALCON20F5 2730105 EU LT AILERON SYST LEAKS D O OTHER K FLUID LOSS NR NOT REPORTED 1 EA 25 347HS 1913 347 LEFT AILERON SERVO LEAKED EXCESSIVELY IN-FLIGHT, CAUSED LOSS OF NR 1 HYDRAULIC SYSTEM. SUBMITTER BELIEVES PISTON O-RING SEALS RUPTURED OR ROLLED. NOT SURE UNTIL INVESTIGATED. 2 L 7 2 4F RT A7EU 1997062600108 19970626 00108 CE 1997 6 26 97ZZZX2869 1 19970603 G 3244 265F864 TIRE GOODYEARAERO BEECH 200 B200 1152922 CE NLG DEFECTIVE B FGQR K NONE O OTHER IN INSP/MAINT 1 SO 01 700WR 51171106 BB1313 TWO INCH KNOT RAISED ON EDGE OF TIRE TREAD ADJACENT TO SIDEWALL. NO OTHER APPARENT TIRE DAMAGE. .2187 TREAD DEPTH. TI RE TIME IN SERVICE, 348.4 HOURS. TOTAL LANDINGS, 404. 1 L 7 2 4T A24CE 1997062600109 19970626 00109 CE 1997 6 26 97ZZZX2870 1 19970506 G 2121 239 FAN CESSNA 500 500CESSNA 2076602 CE CABIN FAILED G K NONE O OTHER NR NOT REPORTED 1 SW 11 96FB 7708 926 5000094 THE CABIN BLOWER MOTOR FAN CAME APART CAUSING THE MOTOR TO OVERHEAT AND ULTIMATELY BURN THE BLOWER MOTOR UP. INSTALL SB 500-21-20. 1 L 7 2 4F A22CE 1997062600275 19970626 00275 SO 1997 6 26 97ZZZX2871 2 19970528 G 7414 1052948 BEARING S6RSC25 CONT O360 LTSIO360EB 17025 SO DRIVE END LOOSE H K NONE K FLUID LOSS IN INSP/MAINT 1 GL 21 361 D099634DR 807336R DRIVE END BEARING INNER RACE BECAME LOOSE ON SHAFT CAUSING OIL TO LEAK THOUGH SEAL. MAG HAD AN EXTREME AMOUNT OF OIL IN TERNALLY AND STILL RAN NORMALLY. 3 O E9CE 1997062600277 19970626 00277 1997 6 26 97ZZZX2872 1 19970602 G 2460 1648009060 BREAKER CESSNA ELECTRIC SYSTEM MISMARKED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 15 CIRCUIT BREAKER FROM CESSNA IMPROPERLY MARKED. THE BODY OF THE CIRCUIT BREAKER IS MARKED 60A AND THE RESET BUTTON IS MA RKED 20. 1997062600278 19970626 00278 SO 1997 6 26 97ZZZX2873 1 19970530 G 5720 4042313 STIFFENER PIPER PA31 PA31350 7103110 SO WS 49 RT CRACKED D K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 SO 25 124AG 317852103 FOUND .50 INCH CRACK IN STIFFENER ON RIB, PIPER PN 40423-13. REPAIRED IAW AC43.13. CRACK IS LOCATED ADJACENT TO WHEEL BUMPER IN UPPER WHEELWELL AND SUSPECT WAS CAUSED BY FATIGUE FROM GEAR RETRACTION. 1 L 7 2 3O A20SO 1997062600279 19970626 00279 EA 1997 6 26 97ZZZX2874 2 19970605 G 7314 RG9080J4A FUEL PUMP ROMEC PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA VALVE BODY LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 AL 01 300ED 510 317852008 RL267268A UPON PULLING AIRCRAFT IN HANGAR FOR A SCHEDULED INSPECTION, FOUND THE ENGINE DRIVEN FUEL PUMP LEAKING FUEL FROM THE VALV E BODY PARTING FLANGES. PUMP WAS REMOVED FROM SERVICE. SUSPECT CAUSE, THE PARTING HALF FLANGE SCREWS FOR THE VALVE BOD Y MAY BE IMPROPERLY TORQUED. GASKET MAY BE PINCHED. THIS HAS BEEN A PROBLEM WITH OTHER PUMPS IN THE PAST. 1 L 7 2 3O 3 O A20SO E14EA 1997062600280 19970626 00280 SO 1997 6 26 97ZZZX2875 1 19970606 G 5521 4007514 SPAR PIPER PA31 PA31350 7103110 SO LT ELEVATOR CRACKED D A K NONE O OTHER IN INSP/MAINT 1 AL 01 3527U 14480 317952141 AIRCRAFT ELEVATORS WERE OPENED UP IN C/W PIPER MANDATORY SB 998. THE LEFT ELEVATOR SPAR WAS FOUND CRACKED AT THE TIP AN D FOUND CRACKED HALF WAY THROUGH THE SPAR JUST INBOARD OF THE VERY OUTBOARD ATTACH POINT. ELEVATOR SPARS NEED TO BE STR ENGTHENED UP AT THESE POINTS AND THE ELEVATOR LEADING EDGE ABRASION (RUBBER BOOT) NEEDS TO BE CHANGED TO SOMETHING SOLID THAT DOESN'T VIBRATE IN THE AIRFLOW. 1 L 7 2 3O A20SO 1997062600281 19970626 00281 SO 1997 6 26 97ZZZX2876 1 19970503 G 5412 337505 FIREWALL PIPER PA28 PA28R201T 7102813 SO TURBOCHARGER CORRODED D K NONE O OTHER IN INSP/MAINT 1 EA 17 48427 28R7803056 UPON ENGINE REMOVAL, FOUND GALVANIZED PORTION OF FIREWALL DETERIORATED AND CORROSION SET IN FROM THE OUTSIDE IN. SUSPEC T HIGH HEAT AREA DIRECTLY BEHIND TURBOCHARGER. RECOMMEND HEAT SHIELD MADE OF STAINLESS STEEL - BEHIND TURBOCHARGER (INS ULATING COVER WAS IN PLACE AROUND THE TURBOCHARGER). 1 L 7 1 3O 2A13 1997062600282 19970626 00282 SO 1997 6 26 97ZZZX2877 2 19970602 G 7322 P16160 FULCRUM PIN BENDIX NAS3A1 CESSNA 140 140 2071602 CE CONT C85 C8512 17008 SO CARBURETOR FLOAT SPALLED D A UNSCHED LANDING Y ENGINE STOPPAGE CL CLIMB 1 CE 05 76122 10519 24177612 ENGINE QUIT ON TAKEOFF JUST AFTER ROTATION RESULTING IN DAMAGE TO THE AIRCRAFT. ENGINE WAS CHECKED FOR FUEL, COMPRESSIO N, AND IGNITION. ENGINE WAS STARTED AND RUN-UP. OPERATION APPEARED TO BE NORMAL. DISASSEMBLED CARBURETOR AND BENCH CH ECKED. FLOAT LEVEL WAS WITHIN SPECS. ALL PASSAGES CLEAN AND OPEN. DID FIND THE FLOAT FULCRUM PIN SPALLED. EXPERIENCE HAS SHOWN ANY WEAR ON THIS PIN CAN CAUSE THIS TYPE OF PROBLEM. BECAUSE OF THE VERY LIMITED MOVEMENT OF THE FLOAT LEVEL , IT IS HARD TO SAY WHAT THE FIX SHOULD BE. PERHAPS IT NEEDS SOME ENGINEERING STUDY. NTSB ACCIDENT NR CHI-97LA143. 1 H 7 1 3O 3 O NC A768 E233 1997062600283 19970626 00283 SO 1997 6 26 97ZZZX2878 1 19970604 G 3222 6705408 TRUNNION PIPER PA32 PA32R301 7103218 SO NLG EAR BROKEN B LF1R K NONE O OTHER IN INSP/MAINT 1 EA 07 9274Q 158 3246038 AFTER LANIDNG AIRCRAFT, PILOT NOTICED SPRING HANGING FROM NOSE GEAR ARM. UPON INVESTIGATING, FOUND EAR ON RT FORWARD UP PER SIDE OF TRUNNION BROKEN. GEAR OPERATIONS ARE NORMAL, NO BINDING OR INTERFERENCE WAS NOTED WITH AIRCRAFT ON JACKS. S USPECT A DEFECT IN MANUFACTURING THAT EXISTED SINCE NEW. AIRCRAFT 6 MONTHS OLD. REPLACED TRUNNION WITH NEW UNIT. 1 L 7 1 3O A3SO 1997062600284 19970626 00284 GL 1997 6 26 97ZZZX2879 1 19970529 G 3230 KHP1CAL RELAY BLANCA 17 1730A 1220433 GL GEAR SYSTEM DETACHED B A IU2R K NONE O OTHER NR NOT REPORTED 1 SW 15 93603 1332 7330610 RELAY CAME LOOSE FROM SOCKET. RELAY IS MOUNTED UPSIDE DOWN IN AIRCRAFT. NO WAY TO ATTACH IN HOLDER. NEEDS SOME TYPE O F POSITIVE LOCKING. IF SWITCH COMES LOOSE ON ONE SIDE, GEAR WILL NOT GO UP. IF SWITCH COMES LOOSE ON THE OTHER SIDE, G EAR WILL NOT GO DOWN. FACTORY ADVISED TO INSTALL AND WRAP TAPE AROUND IT. NEEDS A BETTER POSITIVE LOCKING DEVICE. 1 L 7 1 3O A18CE 1997062600285 19970626 00285 SO 1997 6 26 97ZZZX2880 1 19970609 G 2510 FD56673 BUSHING FDC59001205 PIPER PA28 PA28RT201T 7102817 SO SEAT BOLT MISSING G S K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 19 8392T 2267 28R8131140 NYLON SHOULDER HARNESS RETAINING BUSHING WAS FOUND MISSING FROM BOTH FRONT SEAT LAP BELTS. MANUFACTURER INDICATED NO FI ELD REPAIRS. MANUFACTURER STATED THEY ARE DOING A N/C REPLACEMENT. SUBMITTER STATED LIKE CONDITION FOUND ON VARIOUS OT HER SEAT BELTS. 1 L 7 1 3O 2A13 1997062600286 19970626 00286 CE 1997 6 26 97ZZZX2881 1 19970523 G 7120 085112132 MOUNT BEAM CESSNA 340 340A 2076405 CE RT OTBD NACELLE CORRODED E K NONE O OTHER IN INSP/MAINT 1 CE 01 111SC 5031 340A0335 DURING 100-HOUR INSPECTION, SEVERE CORROSION WAS FOUND ON RIGHT OUTBOARD ENGINE MOUNT BEAM ASSY, AFT CANTED BULKHEAD, AN D RT AND LT DOUBLERS. FOUND PARTS TO BE EXTREMELY SCARCE FOR THIS TYPE OF REPAIR. CORROSION CAUSED BY HEAT FROM EXHAUS T TAILPIPE AND EXHAUST ELBOW. SUBMITTER SUGGESTS HEAT SHIELD. 1 L 7 2 3O 3A25 1997062600287 19970626 00287 CE 1997 6 26 97ZZZX2882 1 19970604 G 2430 GROUND WIRE CESSNA 425 425 2076018 CE RT GENERATOR LOOSE D K NONE O OTHER IN INSP/MAINT 1 SO 13 12214 1650 4250194 RIGHT GENERATOR CONTINUOUSLY DROPPED OFF-LINE, BUT WOULD RESET. FOUND GENERATOR GROUNDING ATTACHED TO SPAR WEB JUST AFT OF ENGINE. THE GROUND WIRE WAS LOOSE AND HAD BEEN ARCING TO SPAR WEB. ORIGINAL HOLE IS ORIGINALLY .375 INCH DIAMETER A ND HAD BEEN ARCED OUT TO ALMOST 1 INCH IN DIAMETER. 1 L 7 2 3T RT A7CE 1997062600288 19970626 00288 CE 1997 6 26 97ZZZX2883 1 19970529 G 2140 719843 COIL 8259HR2 CESSNA 310 310R 2074245 CE HEATER IGNITOR SHORTED B A BXSR K NONE K FLUID LOSS IN INSP/MAINT 1 EA 09 123RA 5 310R0221 THE FIRST COIL EXPLODED BREAKING OFF THE TOP OF THE IGNITOR AND BREAKING WIRES IN THE IGNITION UNIT SPEWING 'OIL' FROM I NSIDE THE COIL THROUGHOUT THE HEATER BAY. THE REPLACEMENT COIL SHORTED OUT, LEAKED OIL, AND THE COVER CAME LOOSE. 1 L 7 2 3O 3A10 1997062600289 19970626 00289 SO 1997 6 26 97ZZZX2884 1 19970611 G 2720 2151 CONNECTOR SPRING LUSCOM 8 8E 8190112 SO RUD TAIL WHEEL BROKEN D C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 SW 17 2070B 6497 PILOT AT TAKEOFF NOTICED AIRCRAFT FELT STRANGE IN THE TAIL SECTION/TAIL WHEEL. TAIL WAS OFF THE GROUND, PILOT SET TAIL BACK ON GROUND, AIRCRAFT TOOK HARD SHARP TURN TO THE LEFT AND ENDED UP IN A FENCE. AFTER INVESTIGATION, NOTED THE CONNE CTOR SPRING AND CHAIN WAS BROKEN ON THE RIGHT SIDE OF AIRCRAFT. PART NR 2151. RECOMMEND THAT CONNECTOR SPRING AND CHAI N BE REINFORCED OR UPGRADED TO A STRONGER CHAIN SYSTEM. 1 H 7 1 3O A694 1997062600290 19970626 00290 EA 1997 6 26 97ZZZX2885 2 19970613 G 8550 LW13901 SUMP SLNSBY T67 T67M260 8323006 EU LYC O540 AEIO540D4A5 41532 EA ENGINE OIL CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 SW 17 3188R 538 2205 L2551348A AFTER A PHASE INSPECTION AND AFTER ENGINE RUN-UP, THE ENGINE WAS CHECKED FOR OIL LEAKS BEFORE COWLING INSTALLED. A LEAK WAS NOTED BEHIND THE RIGHT REAR ENGINE MOUNT BRACKET. A CLOSER LOOK WAS MADE AND A CRACK WAS FOUND (ABOUT 2.50 INCHES LONG). OIL SUMP WAS REMOVED AND REPLACED WITH A SERVICEABLE PART. CAUSE UNKNOWN. 1 L 7 1 3O 3 O NT A73EU 1E4 1997062600291 19970626 00291 EA 1997 6 26 97ZZZX2886 2 19970529 G 8520 LW13831 CRANKCASE PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA LT CASE HALF CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 27 46SD 1656 278054040 RL1583748A FOUND A CRACK IN THE LEFT CASE HALF BETWEEN NR 4 AND NR 6 CYLINDERS. 1 L 7 2 3O 3 O 1A10 1E4 1997062600292 19970626 00292 CE 1997 6 26 97ZZZX2887 1 19970529 G 5510 07321014 REINFORCEMENT 123260031 CESSNA 182 R182 2072734 CE LT HORZ STAB CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 27 52442 9561 R18201646 THE LEFT HAND REINFORCEMENT ON THE HORIZONTAL STABILIZER WAS FOUND CRACKED. THIS REINFORCEMENT IS ONE OF THE AFT ATTACH POINTS OF THE HORIZONTAL STABILIZER. 1 H 7 1 3O RT 3A13 1997062600293 19970626 00293 EA 1997 6 26 97ZZZX2888 2 19970606 G 7310 HOSE PIPER PA24 PA24250 7102404 SO LYC O540 O540A1A5 41532 EA ENGINE FUEL DETERIORATED D K NONE O OTHER IN INSP/MAINT 1 EA 03 6159P 5170 24412 HOSES HAVE NO IDENTIFICATION MARKINGS BECAUSE THEY ARE SO OLD. SEVERELY CHAFED, HARDENED WITH FOSSILIZED EMBRITTLEMENT. OUTER COVERING ON ONE HOSE HAS DISSENTEGRATED TO THE INNER CORE. SUBMITTER RECOMMENDED THAT ALL GENERAL AVIATION FLEX IBLE HOSES LOCATED IN THE ENGINE COMPARMENT HAVE A MANDATORY LIFE LIMIT ESTABLISHED BY AN AIRWORTHINESS DIRECTIVE. 1 L 7 1 3O 3 O 1A15 E295 1997062600294 19970626 00294 EA 1997 6 26 97ZZZX2889 2 19970605 G 8530 74925 CYLINDER PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA NR 2 FAILED D O OTHER E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NR NOT REPORTED 1 GL 15 6881Y 274230 L99348 PILOT NOTICED LEFT ENGINE COWLING BECOMING COVERED WITH OIL. ENGINE WAS UNCOWLED FOR INVESTIGATION AND FOUND NR 2 CYLI NDER HEAD CRACKED COMPLETELY OFF THE CYLINDER BARREL. THE ONLY THING HOLDING THE CYLINDER HEAD IN PLACE WAS THE EXHAUST , INDUCTION TUBE, AND ENGINE BAFFLING. TOTAL TIME ON CYLINDER UNKNOWN. TIME ON CYLINDER SMOH, 1,905 HOURS. CAUSE UNKN OWN. 1 L 7 2 3O 3 O 1A10 1E4 1997062600295 19970626 00295 CE 1997 6 26 97ZZZX2890 1 19970523 G 7120 085112132 MOUNT BEAM CESSNA 340 340CESSNA 2076404 CE RT OTBD NACELLE CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 01 69558 5163 3400504 DURING ANNUAL INSPECTION, SEVERE CORROSION FOUND ON RT OUTBOARD ENGINE MOUNT BEAM ASSY, AFT CANTED BULKHEAD AND RT AND L T DOUBLERS. PROBE WAS USED TO TEST CORROSION AND PUSHED COMPLETELY THROUGH MOUNT BEAM. PARTS ARE EXTREMELY SCARCE FOR THIS REPAIR. CORROSION WAS CAUSED BY HEAT EXHAUST TAILPIPE AND ELBOW. SUGGEST HEAT SHIELD. 1 L 7 2 3O 3A25 1997062600296 19970626 00296 1997 6 26 97ZZZX2891 4 19970528 G 2562 12630423 G SWITCH DORNEMARGLN SLNSBY T67 T67M260 8323006 EU ELT FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 17 7020D 1067 2109 WHILE PERFORMING AN ANNUAL ELT INSPECTION, ELT SENSOR DID NOT COME ON. DORNE AND MARGOLIN, ELT NR TSOC91. 1 L 7 1 3O NT A73EU 1997062600360 19970626 00360 EU 1997 6 26 97ZZZX2893 2 19970509 G 7321 1310526 SOLENOID WOODWARD 8063215 CFMINT CFM56 CFM563C 13802 EU FUEL CONTROL MALFUNCTION B L UU2R K NONE O OTHER IN INSP/MAINT 1 GL 03 94318 WOODWARD RECENTLY BECAME AWARE OF A POTENTIAL NON-CONFORMANCE OF THE CFM56-3 IDLE RESET SOLENOID. THE NON-CONFORMANCE I S DIRECTLY RELATED TO A SPECIFICATION CHANGE FOR THE SOLENOID. SPECIFICALLY, THE SPEC WAS ALTERED TO REQUIRE DROP-OUT A T EXTREME RATHER THAN NORMAL PRESSURIZATION CONDITIONS. THE PRESSURIZATION CHARACTERISTICS AFFECT BOTH PULL-IN AND DROP -OUT OF THE SOLENOID, SO THE SUPPLIER ALTERED THE CALIBRATION OF THE UNIT ACCORDINGLY. AS A RESULT OF THE ALTERED CALIB RATION, IT HAS BEEN DETERMINED THAT IN SOME CASES THE SOLENOID WILL NOT DROP OUT WITH NORMAL PRESSURIZATION. 4 F E21EU 1997062600362 19970626 00362 CE 1997 6 26 97ZZZX2894 1 19970514 G 2497 WIRE CESSNA 206 U206F 2073333 CE FIREWALL SHORTED D O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 EA 27 1523U 6662 U20602234 THE PILOT NOTED SMOKE COMING FROM UNDER THE INSTRUMENT PANEL UPON ACTIVATING THE MASTER ELECTRICAL SWITCH. UPON INVESTI GATION, FOUND THE WIRING COMING THROUGH THE UPPER LEFT FIREWALL WAS BURNED AT THE FIREWALL ONLY. IT APPEARS THAT DUE TO AGE, THE INSULATOR GROMMET HAD WORN THROUGH ALLOWING ONE WIRE TO CONTACT GROUND AND BURN THROUGH WHICH STARTED THE OTHE RS IN THE BUNDLE ALLOWING THEM TO SHORT TO THE SHIELDING. THE AREA WAS COVERED BY A THICK GLOB OF SEALANT MAKING IT IMP OSSIBLE TO INSPECT. AFTER REPLACING OR REPAIRING THE WIRES AS NECESSARY, A FUNCTIONAL CHECK OF THE CIRCUIT PROTECTORS W AS DONE AND FOUND NORMAL. 1 H 7 1 3O A4CE 1997062600363 19970626 00363 SO 1997 6 26 97ZZZX2895 1 19970618 G 3213 58383 GEAR LEG 08311 LUSCOM 8 8E 8190112 SO LT MLG FAILED G S K NONE O OTHER LD LANDING 1 EA 21 1750K 2840 4477 PRIVATE PILOT REPORTED DURING LANDING ROLL, 20 TO 25 KNOTS, APPLIED LIGHT BRAKING. ACFT THEN VEERED TO THE RT INTO A GROUND LOOP. LT MAIN GEAR COLLAPSED. EXAMINATION OF MLG REVEALED HEAVY CORROSION WITHIN THE INNER BORE OF LOWER LEG ST RUT WHERE IT JOINS THE AXLE. SUBMITTER STATED CORROSION MAY HAVE REDUCED STRENGTH OF THE MLG STRUT BY 70 PERCENT. MOIS TURE INTRODUCED INTO THE INNER CORE OF THE STRUT THROUGH THE MLG FAIRING ATTACH POINT BOLT HOLES. AREA DIFFICULT TO INS PECT DUE TO POSITION OF THE GEAR FAIRING AND ROD CLEVIS. RECOMMENDATION: STRIP AREA AND PERFORM DYE PENETRANT INSP CH ECK FOR CRACKS AND PITTING, FILLING STRUT WITH LINSEED OIL, DRAIN, AND PROVIDE SEAL FOR MLG FAIRING TO STRUT BOLT HOLES. 1 H 7 1 3O A694 1997062600364 19970626 00364 EA 1997 6 26 97ZZZX2896 1 19970602 G 2622 892480 EXTINGUISHER KIDDE CNDAIR CL600 CL6002A12 1900304 EA AGENT DEFECTIVE B A JG1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 25 1824T 18380 3029 FIRE EXTINGUISHER RECEIVED FOR OVERHAUL. WHEN A FUNCTIONAL TEST WAS PERFORMED PRIOR TO OVERHAUL, A STRANGE VIBRATION OR THUMP WAS FELT WHEN THE CO2 CARTRIDGE WAS DISCARDED INTO THE EXTINGUISHER. WHEN THE DISCHARGE LEVER WAS PUSHED, NO EXT INGUISHING AGENT WAS DISCHARGED, ONLY CO2. UPON EXAMINATION, THE EXTINGUISHER WAS FOUND CONTAMINATED WITH WHAT SMELLED LIKE LACQUER THINNER. THE SIPHON TUBE WAS FOUND COILED INSIDE THE CYLINDER. THIS PROBABLY WAS THE NOISE HEARD ON DISCH ARGING THE CO2. THE BOTTOM OF THE CYLINDER ALSO IS CORRODED AND THE PLATING IS FLAKING. THE EXTINGUISHER FLUID WAS POU RED INTO A CONTAINER AND THERE WAS A LAYER OF FLAMMABLE LIQUID ON TOP OF THE ANTIFREEZE. 2 L 7 2 4F RT A21EA 1997062600365 19970626 00365 CE 1997 6 26 97ZZZX2897 1 19970609 G 5510 3541050416 STAB CUFF BEECH 35 C35BEECH 1151508 CE RT HORIZ STAB MISINSTALLED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 21 656D 71 D2924 DURING ANNUAL INSPECTION AND AD 94-20-04 PARA (B) COMPLIANCE FOUND BEECH KIT 35-4016-3 (STAB REINFORCEMENT) LEADING EDGE CUFF ATTACH RIVETS FAULTY. FOUND LT CUFF ON THE RT SIDE AND RT CUFF ON LT SIDE. REVERSAL CAUSED A MISFIT OF CONTOUR A ND INADQUATE RIVETING. 1 L 7 1 3O A777 1997062600366 19970626 00366 CE 1997 6 26 97ZZZX2898 1 19970609 G 5510 3541050415 STAB CUFF BEECH 35 C35BEECH 1151508 CE LT HORIZ STAB MISINSTALLED D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 21 656D 71 D2924 DURING ANNUAL INSPECTION AND AD 94-20-04 PARA (B) COMPLIANCE FOUND BEECH KIT 35-4016-3 (STAB REINFORCEMENT) LEADING EDGE CUFF ATTACH RIVETS FAULTY. FOUND LT CUFF ON THE RT SIDE AND RT CUFF ON LT SIDE. REVERSAL CAUSED A MISFIT OF CONTOUR A ND INADQUATE RIVETING. 1 L 7 1 3O A777 1997062600367 19970626 00367 EA 1997 6 26 97ZZZX2899 2 19970517 G 8530 SEAL PIPER PA31 PA31310 7103103 SO LYC O540 TIO540A2C 41532 EA NR 3 CYL PUSHROD LEAK D A UNSCHED LANDING K FLUID LOSS CL CLIMB 1 GL 13 666AW 317312061 L415661A AFTER TAKEOFF DURING CLIMB-OUT, PILOT NOTICED FINE SPRAY OF OIL MIST FROM RT ENGINE OUTBOARD SIDE AND TRACE OF OIL LEAK BEGIN TO FORM. PILOT MADE AN UNEVENTFUL LANDING AND ENGINEERING INVESTIGATION WAS CARRIED OUT. NR 3 CYLINDER EXHAUST P USHROD LOCKING CLIP HAD UNLOCKED ALLOWING SEAL TO LEAK OIL DUE TO A LOOSE SHROUD TUBE. SUBMITTER RECOMMENDATION: TO WI RE LOCK WITH SAFETY WIRE IN PAIRS THE LOCKING CLIPS OF THE INDIVIDUAL SHROUD TUBES FOR EVERY CYLINDER. 1 L 7 1 3O 3 O RT A20SO E14EA 1997062600368 19970626 00368 EA 1997 6 26 97ZZZX2900 2 19970425 G 7322 14190 THROTTLE VALVE MA4SPA CESSNA 172 172K 2072430 CE LYC O320 O320E2D 41508 EA CARBURETOR OUT OF ADJUST D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 03 78512 CK815294 17257646 L4478727A OVERHAULED CARBURETOR FURNISHED WITH LYCOMING OVERHAULED ENGINE WOULD NOT IDLE BELOW 1,000 RPM AFTER BUILD-UP AND INSTAL LATION. CARUBURETOR WAS NEWLY OVERHAULED. REMOVAL AND INSPECTION REVEALED THE THROTTLE PLATE WAS NOT ALIGNED CORRECTLY AND WAS BINDING ON THROAT OF CARBURETOR WHEN CLOSED AND WOULD NOT HIT IDLE STOP WITH SCREW FULLY BACKED OUT. 1 H 7 1 3O 3 O NT 3A12 E274 1997062600369 19970626 00369 SW 1997 6 26 97ZZZX2901 1 19970612 G 5711 SPAR BBAVIA 7 7GCBC 1220601 SW RT WING CRACKED G S A K NONE O OTHER IN INSP/MAINT 1 WP 11 88083 700 71974 WHILE C/W AMERICAN CHAMPION SL 406 RE: CRACKED SPARS. BOTH MAIN SPARS FOUND TO HAVE HAIRLINE CRACKS OPPOSITE THE UPPER INBOARD ATTACH BOLT FOLLOWING THE SPAR GRAIN. BOTH WINGS TO BE REPLACED WITH FACTORY NEW WINGS. 1974 CITABRIA 7GCBC 7 00 HRS TTSN. NEVER USED FOR AEROBATIC TRAINING. WAS USED BRIEFLY WHEN NEW FOR GLIDER TOWING. 1 H 7 1 3O NC A759 1997062600370 19970626 00370 SW 1997 6 26 97ZZZX2902 1 19970612 G 5711 SPAR BBAVIA 7 7GCBC 1220601 SW LT WING CRACKED G S K NONE O OTHER IN INSP/MAINT 1 WP 11 88083 700 71974 WHILE C/W AMERICAN CHAMPION SL 406 RE: CRACKED SPARS. BOTH MAIN SPARS FOUND TO HAVE HAIRLINE CRACKS OPPOSITE THE UPPER INBOARD ATTACH BOLT FOLLOWING THE SPAR GRAIN. BOTH WINGS TO BE REPLACED WITH FACTORY NEW WINGS. 1974 CITABRIA 7GCBC 7 00 HRS TTSN. NEVER USED FOR AEROBATIC TRAINING. WAS USED BRIEFLY WHEN NEW FOR GLIDER TOWING. 1 H 7 1 3O NC A759 1997062600371 19970626 00371 CE 1997 6 26 97ZZZX2903 1 19970602 G 2750 BELLCRANK CESSNA 500 S550 2076607 CE LT WING FLAP CORRODED B A CWQR K NONE O OTHER IN INSP/MAINT 1 GL 05 134QS 8994 S5500134 DURING INSPECTION, FOUND LT INBOARD FLAP OUTBOARD BELLCRANK WITH EXCESSVIE SIDE-TO-SIDE PLAY. UPON REMOVAL, FOUND UPPER AND LOWER BEARINGS FROZEN AND/OR CORRODED. A LARGE QUANTITY OF RUSTY WATER FLOWED OUT OF THE BELLCRANK TUBE. IT APPEA RS THE TUBE WAS FILLED WITH WATER AS THE BEARINGS, SPACER, AND MOUNTING BOLTS WERE FOUND CORRODED. SUBMITTER STATED PER HAPS A DRAIN HOLE IN BELLCRANK TUBE WOULD HELP. 1 L 7 2 4F RT A22CE 1997062600372 19970626 00372 GL 1997 6 26 97ZZZX2904 2 19970602 G 7210 6894171 GEARBOX BELL 206 206B3 1181506 SW ALLSN 250C 250C20B 03013 GL ENGINE CRACKED H K NONE O OTHER IN INSP/MAINT 1 GL 03 16917 7850 834952 2303 834952 FOUND ENGINE GEARBOX CRACKED AT TOP MOUNTING LOCATION FOR COMPRESSOR. NO ABNORMAL VIBRATIONS OR CIRCUMSTANCES LED TO FI NDING CRACK. 1 G 7 1 3U 3 U H2SW E4CE 1997062600373 19970626 00373 SO 1997 6 26 97ZZZX2905 1 19970608 G 7333 3006614 CLAMP PIPER PA42 PA42 7104202 SO PWA PT6 PT6A41 52043 EA FUEL FLOW XMIT MISSING H K NONE K FLUID LOSS IN INSP/MAINT 1 GL 25 242RA 428001003 PCE80883 FUEL FLOW TRANSMITTER IS MOUNTED TO ENGINE WITH 2 STAINLESS LINES PN 3032010 AND PN 3026779 B1; AND, IF SUPPORT CLAMP PN 30006614 IS NOT INSTALLED, LINES WILL CRACK AT WELDS CREATING A HEAVY FUEL LEAKING ENGINE COMPARTMENT AND ONTO WING. 1 L 7 2 4T 4 T A23SO E4EA 1997062600374 19970626 00374 CE 1997 6 26 97ZZZX2906 1 19970602 G 2435 300SG1064 ARMATURE 300SG118Q CESSNA 441 441 2076020 CE START/GENERATOR DAMAGED E E F ENGINE SHUTDOWN ACTIVATE FIRE EXT. H J ELECT. POWER LOSS-50 PC WARNING INDICATION AP APPROACH 1 WP 07 445AE 982 1682 4410043 WHILE APPROACHING TO LAND AT 'LAS', PILOT LOST LT GENERATOR INDICATION. TWO MINUTES LATER PILOT GOT A FIRE WARNING INDI CATION AND SECURED THE ENGINE AND FIRED THE LT FIRE BOTTLE. LANDED WITH NO FURTHER PROBLEMS. EXAMINATION FOUND THE GEN ERATOR SHAFT SHEARED AND ARMATURE DAMAGED. BEARINGS WERE INTACT AND CASE OF GENERATOR SHOWED SIGNS OF OVERHEATING. NO OTHER DAMAGE FOUND. INSTALLED SERVICEABLE GENERATOR AND FIRE BOTTLE. SYSTEMS CHECKED GOOD. 1 L 7 2 3T RT A28CE 1997062600375 19970626 00375 CE 1997 6 26 97ZZZX2907 1 19970523 G 5720 65220516 CAP ANGLE CESSNA 500 560CESSNA 2076750 CE RT WHEELWELL CRACKED B CWQR K NONE O OTHER IN INSP/MAINT 1 GL 05 561EJ 3400 5600035 DURING PHASE 1-4 INSPECTION, FOUND RT WHEELWELL CAP ANGLE CRACKED AT AFT END. HARD TO TELL WHAT CAUSED CRACK OTHER THAN INSTALLATION OR NORMAL USE. 2 L 7 2 4F RT A22CE 1997062600376 19970626 00376 CE 1997 6 26 97ZZZX2908 1 19970523 G 5542 553300053 SKIN CESSNA 500 560CESSNA 2076750 CE RUDDER LT LOWER CRACKED B CWQR K NONE O OTHER IN INSP/MAINT 1 GL 05 561EJ 3460 5600035 DURING PHASE 1-4 INSPECTION, FOUND LT LOWER RUDDER SKIN CRACKED ALONG A ROW OF RIVETS. LIKELY CAUSE IS VIBRATION. THIS IS A COMMON PROBLEM ON S550 AND 560 AIRCRAFT. HEAVIER SKIN AND/OR INTERNAL BEEF-UP NEEDED. 2 L 7 2 4F RT A22CE 1997062600377 19970626 00377 EA 1997 6 26 97ZZZX2909 3 19970515 G 6111 BLADE LUSCOM 8 8A 8190104 SO SNSNCH W72 W72GK EA TIP SEPARATED G A UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 WP 07 5896X 55 2553 TIP AND CENTER SECTION (LAMINATE) SEPARATED IN-FLIGHT UNBALANCING ENGINE. MADE UNSCHEDULED STOP AT NEARBY AIRPORT AFTER SHUT DOWN. 1 H 7 1 3O A694 5 N P170 1997062600717 19970626 00717 CE 1997 6 26 97ZZZX2910 1 19970501 G 5511 0530015 SPAR CESSNA 172 172 2072402 CE HORIZ STABILIZER CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 27 3853 INSPECTION FOUND HORIZONTAL STABILIZER FRONT SPAR CRACKED. 1 H 7 1 3O NT 3A12 1997062600718 19970626 00718 CE 1997 6 26 97ZZZX2911 1 19970611 G 3411 LINE CESSNA 320 320 2074502 CE PITOT CORRODED D K NONE O OTHER IN INSP/MAINT 1 SW 11 FOUND PITOT LINE FROM PITOT TUBE TO FORWARD BULKHEAD CORRODED THROUGH IN NUMEROUS LOCATIONS. 1 L 7 2 3O 3A25 1997062600719 19970626 00719 CE 1997 6 26 97ZZZX2912 1 19970606 G 2510 HARNESS CESSNA 150 152 2071835 CE COCKPIT UNLATCHES C A K NONE O OTHER IN INSP/MAINT 1 SO 13 THE SHOULDER HARNESS CLIP THAT ATTACHES THE SHOULDER STRAP TO THE LAP (SEAT) BELT IS DEFECTIVE. THE SHOULDER STRAP WILL DISCONNECT FROM THE LAP BELT UNLESS TENSION IS KEPT ON THE SHOULDER STRAP. 1 H 7 1 3O NT 3A19 1997062600720 19970626 00720 CE 1997 6 26 97ZZZX2913 1 19970528 G 3230 AHM6NMB ROD END BEECH 36 A36 1151604 CE NLG RETRACT FAILED D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 03 1849W 5343 E428 THIS ROD END IS PART OF THE AFT EXTENSION/RETRACTION TUBE FOR THE NOSE GEAR RETRACT SYSTEM. THE TUBE WAS FOUND INSTALLE D BACKWARDS RESULTING IN THE INCORRECT ROD END STYLE BEING ATTACHED TO THE GEARBOX ARM. THIS ROD END SHOULD HAVE BEEN A TTACHED TO THE IDLER ARM. THE DESIGN OF THIS ROD END IS FOR FORE AND AFT MOVEMENT (IDLER ARM) NOT ROTATIONAL MOVEMENT ( GEARBOX). THE RESULT WAS THAT SIDE PRESSURE CRACKED THE ROD END BEARING CASE, STRETCHED THE CASE TO A 'C' SHAPE DURING GEAR OPERATION, AND, FINALLY, ALLOWED THE BEARING TO SEPARATE FROM THE CASE RESULTING IN THE NOSE GEAR FAILING TO EXTEND . SUBMITTER BELIEVES THIS TO BE AN ORIGINAL FACTORY INSTALLATION. 1 L 7 1 3O 3A15 1997062600722 19970626 00722 CE 1997 6 26 97ZZZX2915 1 19970616 G 7810 82269 EXHAUST WYE CESSNA 340 340A 2076405 CE TURBOCHARGER CRACKED D S K NONE O OTHER IN INSP/MAINT 1 CE 07 5174J 2000 340A0009 THE EXHAUST TO TURBOCHARGER WYE AND BYPASS ELBOW PN 8226-9 AND PN K9910299-5 WERE FOUND CRACKED AT THEIR COUPLING FLANGE S. 1 L 7 2 3O 3A25 1997062600723 19970626 00723 EU 1997 6 26 97ZZZX2916 1 19970212 G 2432 RG390E BATTERY BRAERO DH125 HS125700A 4230170 EU DC SYSTEM SPLIT D P K NONE O OTHER IN INSP/MAINT 1 GL 05 571CH 503 CBC273171 NA0256 NR 1 BATTERY SHOWS CRACK. CRACK IS ON A SEAM. NR 2 BATTERY SHOWS RETAINER SLEEVE VIBRATED DOWN TO BOTTOM OF BATTERY. P ART TOTAL CYCLES, 436. 2 L 7 2 4F A3EU 1997062600724 19970626 00724 EA 1997 6 26 97ZZZX2917 2 19970616 G 7322 12856 LEVER MA45 PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA THROTTLE SEPARATED G A UNSCHED LANDING R PARTIAL RPM/PWR LOSS AP APPROACH 1 GL 25 5955V 53 G519232 287790516 L2727336A WHILE ON APPROACH TO CAK, PILOT LOST THROTTLE CONTROL, AND , SUBSEQUENTLY, LANDED IN AN OPEN FARM FIELD. INVESTIGATION REVEALED THAT THE THROTTLE CONTROL LEVER WAS LOOSE EVEN THOUGH THE CASTLE NUT AND COTTER PIN WERE FAIRLY TIGHT AND INTAC T. SUSPECT IMPROPER INSTALLATION PROCEDURE AND IMPROPER TORQUE OF NUT SECURING ARM. 1 L 7 1 3O 3 O 2A13 E286 1997062600725 19970626 00725 CE 1997 6 26 97ZZZX2918 1 19970609 G 5741 05233091 ANGLE CESSNA 150 150M 2071830 CE RT WING SPAR CORRODED D K NONE O OTHER IN INSP/MAINT 1 EA 21 66221 15075929 DURING ANNUAL INSPECTION, INTERGRANULAR CORROSION WAS FOUND IN ANGLE REINFORCEMENT AT RT WING SPAR BUTT WHERE SPAR BOLTS TO FUSELAGE SPAR CARRY-THROUGH. DIFFICULT AREA TO INSPECT WITHOUT REMOVAL OF COCKPIT HEADLINER. SUBMITTER STATED IMPR OPER HEAT TREATMENT WHEN MANUFACTURED. RECOMMENDATION: AGING AIRCRAFT REQUIRE MORE DETAILED INSPECTION IN DIFFICULT TO SEE AREAS. SIDE NOTE: A PAIR OF PLIERS WERE FOUND INSIDE A VOID IN THE RIGHT WING. RUST OF PLIERS INDICATE IT HAD BE EN THERE A LONG TIME. 1 H 7 1 3O 3A19 1997062600726 19970626 00726 CE 1997 6 26 97ZZZX2919 1 19970423 G 3230 12802091 PIN CESSNA 210 T210M 2073451 CE NLG DOWNLOCK SHEARED B S CM2R K NONE O OTHER IN INSP/MAINT 1 SW 15 6798M 2314 21061992 SEE FIGURE 126A OF PART MANUAL 1970 TO 1980 CESSNA 210. PIN PN 1280209-1 IS PRESSED INTO BEARING END PN 1280600-5 AND L OCKED IN PLACE WITH A ROLL PIN. THIS PIN IS USED FOR NOSE GEAR DOWNLOCK. PINS WERE BEING REPLACED AS PART OF REPAIR TO REMOVE PLAY IN NLG. DOWNLOCK ASSY PINS DID NOT SHOW EXCESSIVE WEAR AND WERE TIGHT IN BEARING END. UPON REMOVAL, FOUND BOTH PINS SHEARED AT GROOVE FOR ROLL PIN. 1 H 7 1 3O 3A21 1997062600727 19970626 00727 CE 1997 6 26 97ZZZX2920 1 19970612 G 2434 ALT9422 ALTERNATOR CESSNA 401 401A 207590D CE RT ENGINE LUG CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 WP 25 711SN 197 512260 401A0054 ALTERNATOR MOUNT LUG FOUND CRACKED, AND OIL LEAKING AT GASKET. ALTERNATOR HAS ONLY 197 HRS SINCE OVERHAUL. ON DISASSEM BLY, ONE LUG FOUND CRACKED AND ONE LUG FELL OFF COMPLETELY. 1 L 7 2 3O A7CE 1997062600728 19970626 00728 EA 1997 6 26 97ZZZX2921 2 19970524 G 8530 LYC16T19468 VALVE SEAT 05K21108CKP PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA RT ENG EXHAUST LOOSE E D RETURN TO BLOCK E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TX TAXI/GRND HDL 1 AL 03 493SC 1585 317652048 L184368A DURING TAXI FOR TAKEOFF, PILOT REPORTED ENGINE RUNNING ROUGH. RIGHT ENGINE MANIFOLD PRESSURE HIGHER THAN NORMAL. COMPR ESSION CHECK FOUND NR 1 CYLINDER LOW, 10/80. DISASSEMBLY OF CYLINDER FOUND LOOSE EXHAUST VALVE SEAT. 1 L 7 2 3O 3 O A20SO E14EA 1997062600729 19970626 00729 GL 1997 6 26 97ZZZX2922 3 19970612 G 6114 HUB CESSNA 150 152 2071835 CE MCAULY 1A103 1A103TCM GL PROP BOLTS CRACKED B PI4R K NONE O OTHER IN INSP/MAINT 1 SO 07 49951 5451 15281411 R772521 PROPELLER HAS 2 CRACKS APPROXIMATELY .4375 INCH LONG AT BOLT HOLES. FOUND DURING INSPECTION REQUIRED BY AD 97-06-18 AND SB 221B. 1 H 7 1 3O NT 3A19 5 N P50GL 1997062600730 19970626 00730 CE 1997 6 26 97ZZZX2923 1 19970508 G 5412 FIREWALL CESSNA 172 172P 2072436 CE COWL MOUNT CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 27 53051 3407 17274673 FOUND FIREWALL CRACKED AT COWL MOUNT NEXT TO BATTERY BOX BRACKET AND EXTERNAL POWER RECEPTACLE. AFTER REMOVING COWL MOU NT AND STIFFENER, FOUND CRACK UNDER STIFFENER WHICH COULD NOT BE SEEN WITH STIFFENER INSTALLED ON AIRCRAFT. SUSPECT CAU SE OF CRACK IS COMBINATION OF NORMAL ENGINE MOUNT VIBRATION AND WEIGHT OF BATTERY BOX AND EXT POWER RELAY MOUNTED ON FIR EWALL. RECOMMENDATION TO PREVENT RECURRENCE IS TO FABRICATE STIFFENER TO EXTEND FROM COWL MOUNT TO UNDER BATTERY BOX BR ACKET. 1 H 7 1 3O NT 3A12 1997062600731 19970626 00731 CE 1997 6 26 97ZZZX2924 1 19970617 G 5541 04310043 RUDDER CESSNA 150 150M 2071830 CE FORWARD RIB CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 11 6122K 4900 15077536 AT ANNUAL INSPECTION, CRACKS WERE FOUND IN THE FORWARD RIB OF THE RUDDER AROUND THE TOP LIGHTNING HOLE. PART WAS REMOVE D AND REPLACED. ANNUAL INSPECTIONS OF THIS AREA ARE RECOMMENDED. 1 H 7 1 3O 3A19 1997062600732 19970626 00732 GL 1997 6 26 97ZZZX2925 3 19970612 G 6114 HUB CESSNA 150 152 2071835 CE MCAULY 1A103 1A103TCM GL PROPELLER BOLTS CRACKED B PI4R K NONE O OTHER IN INSP/MAINT 1 SO 07 6529M 5646 1750 15284763 R77918 PROPELLER HAS CRACK APPROXIMATELY .50 INCH LONG AT BOLT HOLE. FOUND DURING INSPECTION REQUIRED BY AD 97-06-16 AND SB 22 1B. 1 H 7 1 3O NT 3A19 5 N P50GL 1997062600733 19970626 00733 SW 1997 6 26 97ZZZX2926 1 19970520 G 2434 ALU8421 ALTERNATOR MOONEY M20 M20J 5870219 SW CONT O360 IO360A 17025 SO HOUSING CRACKED D A K NONE O OTHER IN INSP/MAINT 1 SO 15 658FT 190 5081285 243270 L1170451A FOUND ALTERNATOR HOUSING CRACKED AT THE FRONT MOUNTING ARM. AFTER INSPECTING LIKE AIRCRAFT, FOUND A SECOND ALTERNATOR C RACKED IN THE SAME LOCATION. THE SUSPECT CAUSE FOR THE CRACK IS INCORRECT SHIMMING OF THE ALTERNATOR TO THE MOUNT. SUB MITTER STATED CLOSE ATTENTION NEEDS TO BE GIVEN TO THE CORRECT SHIMMING OF THE ALTERNATOR WHEN IT IS INSTALLED. 1 L 7 1 3O 3 O 2A3 E1CE 1997062600734 19970626 00734 CE 1997 6 26 97ZZZX2927 1 19970618 G 3260 SWITCH CESSNA 340 340CESSNA 2076404 CE RT MLG DOWNLOCK WIRE BROKEN B NVIR L ABORTED APPROACH N FALSE WARNING AP APPROACH 1 SW 05 69507 3400344 UPON GEAR EXTENSION, RT MAIN GEAR UNSAFE DOWN AND LOCK INDICATION WAS SHOWN. GEAR APPEARED TO BE DOWN AND LOCKED AFTER A LOW FLY-BY OVER THE CONTROL TOWER. AIRCRAFT LANDED WITH NO FURTHER INCIDENT. FOUND BAD WIRE CONNECTIONS AT RT DOWN A ND LOCK SWITCH. RE-SOLDERED CONNECTIONS. GEAR INDICATION AND OPERATIONAL CHECKS WERE GOOD. 1 L 7 2 3O 3A25 1997062600735 19970626 00735 CE 1997 6 26 97ZZZX2928 1 19970612 G 8120 085071239 HEADER ASSY GARRTT 4066109025 CESSNA 310 T310R 2074246 CE TURBO HOLE BURNED D P K NONE O OTHER IN INSP/MAINT 1 SO 03 777V 1200 310R0267 SPECIAL INSPECTION OF EXHAUST SYSTEMS IAW AD 75-23-08-R5 AND CESSNA PILOTS ASSOCIATION LETTER 4-28-97 (URGENT LETTER TO OWNERS OF TURBOCHARGED TWIN CESSNAS). THE HEADER HAD A HOLE BLOWN IN V-BAND CLAMP AREA. THE BAFFLE IN HEADER WAS WARPE D FROM HEAT AND CRACKED APPROXIMATELY 1 INCH AT THE BOTTOM. THE TURBO WAS ALSO UNSERVICEABLE DUE TO MATING FLANGE BETWE EN EXHAUST AND AIR SIDE BEING BLOWN. SUBMITTER STATED SIMPLIFY OR MAKE CLEAR THE REQUIREMENTS. 1 L 7 2 3O 3A10 1997062600736 19970626 00736 CE 1997 6 26 97ZZZX2929 1 19970601 G 5540 12310349 RUDDER CESSNA 206 U206F 2073333 CE EMPENNAGE MISRIGGED D L A K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 02 8146Q 1665 U20603097 DURING AN ANNUAL INSPECTION, NOTICED THE SEAPLANE-TYPE RUDDER WOULD CONTACT THE ELEVATOR ASSEMBLY WHEN BOTH SURFACES WER E POSITIONED APPROXIMATELY HALF THEIR TRAVEL. ELEVATOR TRAVEL WAS DETERMINED TO BE CORRECT. BECAUSE A SEAPLANE-TYPE RU DDER WAS INSTALLED, RIGGING OF THE RUDDER WAS REFERENCED THROUGH THE CESSNA 206 SM. THE SM MAKES ABSOLUTELY NO DISTINCT ION BETWEEN RIGGING A STANDARD RUDDER AS OPPOSED TO A SEAPLANE RUDDER. 1 H 7 1 3O A4CE 1997062600737 19970626 00737 SO 1997 6 26 97ZZZX2930 2 19970608 G 8530 CYLINDER CESSNA 188 A188B 2073005 CE CONT O520 IO520D 17032 SO NR 5 AND NR 2 DEFECTIVE D L K NONE O OTHER IN INSP/MAINT 1 SW 17 4915R 1250 18802432T FOLLOWING TOP OVERHAUL, NOTED A KNOCK FROM CYLINDERS 5 AND 2. FOUND NEW PISTONS WERE HITTING ON THE CYLINDER HEADS. FO UND THE CYLINDER HEAD TO BARREL DISTANCE IS SMALLER THAN OTHER CYLINDERS. 1 L 7 1 3O 3 O A9CE E5CE 1997062600738 19970626 00738 CE 1997 6 26 97ZZZX2931 1 19970501 G 3246 D3C259 HUB CESSNA 185 A185F 2072821 CE MLG WHEEL CRACKED D S K NONE O OTHER IN INSP/MAINT 1 WP 23 1708R 2117 18502430 AT TIRE CHANGE, WHEEL COMPONENTS WERE INSPECTED. FOUND CENTER HUB CRACKED IN THREE PLACES. RECOMMEND CAREFUL INSPECTIO N. MECHANIC/PILOT MADE NO HARD LANDINGS OR ROUGH FIELDS. 1 H 7 1 3O 3A24 1997062600739 19970626 00739 EA 1997 6 26 97ZZZX2932 1 19970601 G 3211 MS20009138 BOLT SCWZER G164 G164B 3952802 EA LT MLG ATTACH FAILED D K NONE O OTHER IN INSP/MAINT 1 SO 25 8097K 1016 562B PILOT WAS MAKING A TURN FOR TAKEOFF WITH A LOAD OF FERTILIZER WHEN LEFT GEAR COLLAPSED CAUSING DAMAGE TO PROPELLER AND L ANDING GEAR BEAM, BRACKET ASSY, PN A1322-001, AND STUD ASSY, PN A1518-111. CAUSE WAS SUSPECT DUE TO THE HEAD OF THE REA R BOLT, PN MS20009-138 HAD BROKEN OFF CAUSING THE UPPER ATTACH POINT OF THE GEAR LEG TO FAIL. 1 Q 7 1 3R 1A16 1997070300132 19970703 00132 NE 1997 7 3 97ZZZX2936 1 19970609 G 2150 451400016 DRIVE BELT SKRSKY S76 S76 8143010 NE AIR COND COMP FAILED E O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 NE 03 176SH 1851 760182 BELT SPLIT CAUSING LOSS OF TENSION AND ALLOWING BELT TO JUMP OFF PULLEY DRIVE AND WEDGING BETWEEN MOTOR AND PULLEY; THUS , CAUSING RUBBER SMELL AND SMOKE IN CABIN. BELT WAS LAST INSPECTED FOR CONDITION 33.2 HRS AGO. DATE OF LAST REPLACEMEN T 8-11-92. ITEM IS ON CONDITION. 1 G 7 2 3U H1NE 1997070300134 19970703 00134 SW 1997 7 3 97ZZZX2938 1 19970515 G 2841 407375006101 INDICATOR BELL 407 407 SW FUEL QUANTITY MALFUNCTION B GS1R K NONE O OTHER IN INSP/MAINT 1 EA 03 407FC 0054 53050 FUEL QUANTITY INDICATOR STAYS IN TEST MODE FOR LONG PERIODS OF TIME. REPLACED WITH NEW INDICATOR. 1 G 7 1 3U O H2SW 1997070300136 19970703 00136 CE 1997 7 3 97ZZZX2939 1 19970605 G 2910 306588003039 LINE ASSY RKWELL NA265 NA26540 6402608 CE FS 367 CHAFED B S JV2R K NONE O OTHER IN INSP/MAINT 1 CE 03 316NT 11055 28260 DURING PYLON MATCHING ANGLES AND FUSELAGE SKIN INSPECTION, NOTED AN ADEL CLAMP, PN MS21919DG6, WAS BROKEN ON THE RIGHT H AND SIDE FS 367. FURTHER INSPECTION REVEALED THE THRUST REVERSER STOW HYDRAULIC PRESSURE LINE ASSY, PN 306-588003-039, HAD WORN THROUGH APPROXIMATELY HALF OF THE .035 INCH WALL THICKNESS CAUSED BY THE BROKEN ADEL CLAMP AND RUBBING AGAINST THE ATTACH BRACKET. RECOMMEND A ONE-TIME INSPECTION OF CLAMPS AND LINE ASSEMBLIES AND REINSPECTION EVERY 150 HOURS MAI NTENANCE CHECK. 2 L 7 2 4J A2WE 1997070300137 19970703 00137 SO 1997 7 3 97ZZZX2940 1 19970604 G 2820 3999710 HOSE ASSY PIPER PA31 PA31350 7103110 SO FUEL SYSTEM LEAKS B WWKR K NONE K FLUID LOSS IN INSP/MAINT 1 AL 03 4105D 5750 318252027 HOSE ASSY LEAKS. NOT AT FITTINGS, BUT IN MIDDLE OF HOSE. HOSE HAS STAINLESS BRAID ON OUTSIDE WHICH LOOKS FINE, BUT RUB BER IS DETERIORATED. 1 L 7 2 3O A20SO 1997070300138 19970703 00138 EA 1997 7 3 97ZZZX2941 2 19970428 G 8530 VALVE MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA NR2 CYL EXH DEFORMED B BJFR K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 EA 23 4182H 240656 L1938951A AT 308 HRS SMOH, ANNUAL INSPECTION REVEALED NR 2 CYLINDER HAD NO COMPRESSION. CYLINDERS WERE ECI CERMINIL CYLINDERS. U PON REMOVAL, FOUND EXHAUST VALVE AND SEAT DEFORMED. NEW CYLINDER INSTALLED ALL OPS CHECK GOOD. 314 HRS SMOH, PILOT REP ORTS AIRCRAFT SEEMS TO BE LOSING POWER. COMPRESSION TEST REVEALED NR 3 CYLINDER COMPRESSON FAILING. REMOVED NR 3 CYLIN DER AND FOUND DAMAGE SIMILAR TO NR 2. REMOVED NR 4 CYLINDER AND FOUND IRREGULAR WEAR MARKS. LOG BOOK RESEARCH REVEALED NR 1 CYLINDER REMOVED AT 208 HRS DUE TO EXHAUST VALVE FAILURE. 1 L 7 1 3O 3 O 2A3 1E10 1997070300140 19970703 00140 EU 1997 7 3 97ZZZX2943 2 19970601 G 8520 ENGINE AMTR KITFOX KITFOX 05613LZ GL ROTAX 582 ROTAX582 55555 EU REAR CYLINDER SEIZED G A UNSCHED LANDING Y ENGINE STOPPAGE NR NOT REPORTED 1 NM 03 950AW 950 3971294 ENGINE SEIZED AFTER 2 HOURS OF FLIGHT OPERATION ON INITIAL FLIGHT. ENGINE WAS STORED FOR 4 YEARS AND UNCRATED FOR 2 YEA RS. ENIGNE SHOWED SIGNS OF CORROSION ON OUTPUT SHAFT OF GEARBOX. MANUFACTURER OF THE KIT SUPPLIED NO INFORMATION FOR L ONG TERM STORAGE OF THE ENGINE. THE REAR CYLINDER ROD LOST LUBRICATION, MADE METAL, AND SEIZED THE ENGINE. LOWER ROD B EARING COMPLETELY GONE AND ROD WAS HEAT DISCOLORED. SUBMITTER SUGGESTED KIT MANUFACTURER BE REQUIRED TO SUPPLY ENGINE S TORAGE AND PREPARATION INFORMATION. 1 H 7 1 3I 3 I NC EXPA1H71 EXPE3I 1997070300195 19970703 00195 NM 1997 7 3 97ZZZX2944 1 19970606 G 5751 65464542 SKIN BOEING 737 737* NM RT AILERON DISBONDED B HN6R K NONE O OTHER IN INSP/MAINT 1 NM 01 26300 BN206 AILERON SKIN DISBOND, 3-4 YEARS AFTER BOND REPAIR PERFORMED. SUSPECT CAUSE: BREAKDOWN OF BOND DUE TO REPORTED ENTRANCE OF WATER FROM LEADING AND TRAILING EDGES. BOND FAILURE POSSIBLY DUE TO IMPROPER CLEANING PRIOR TO LAY-UP AND INSTALLAT ION OF FIBERGLASS REPAIRS. SUBMITTER RECOMMENDATIONS TO PREVENT RECURRENCE: PERFORM REMEDIAL AND RECURRENT TRAINING OF TECHNICIANS ON PROPER/CORRECT FIBERGLASS BOND PRACTICES. OPERATOR: SOUTH AFRICAN AIRWAYS. 2 L 7 2 4F RT A16WE 1997070300196 19970703 00196 EU 1997 7 3 97ZZZX2945 1 19970609 G 5751 258WG2 AILERON BRAERO DH125 BAE125800A 1500285 EU LEADING EDGE WATER CONTAM B JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 354WG NA0436 FOUND STAINS ON THE LT AND RT AILERON LEADING EDGES. INVESTIGATED AND FOUND WATER SEEPING FROM AILERON LEADING EDGE FAS TENER HOLES. REMOVED NECESSARY FASTENERS TO DRAIN AND PURGED THE AILERON LEADING EDGE. RE-INSTALLED BLIND FASTENERS WI TH SEALANT PER FAA FROM J37 DATED 5-18-97. SUBMITTER STATED IT IS VERY DIFFICULT TO DO A THOROUGH INSPECTION OF THE INT ERNAL STRUCTURE OF THE LEADING EDGE TO LOOK FOR EVIDENCE OF CORROSION. SUBMITTER STATED TO PREVENT THIS FROM HAPPENING, THOROUGHLY INSPECT THE AILERON LEADING EDGE GAP SEAL TO LOOK FOR VOIDS IN THE SEALANT AND ALSO TO INSPECT FASTENER HEAD CONDITION. 2 L 7 2 4F RT A3EU 1997070300197 19970703 00197 EU 1997 7 3 97ZZZX2946 1 19970609 G 5751 258WG1 AILERON BRAERO DH125 BAE125800A 1500285 EU LEADING EDGE WATER CONTAM B A JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 354WG NA0436 FOUND STAINS ON THE LT AND RT AILERON LEADING EDGES. INVESTIGATED AND FOUND WATER SEEPING FROM AILERON LEADING EDGE FAS TENER HOLES. REMOVED NECESSARY FASTENERS TO DRAIN AND PURGED THE AILERON LEADING EDGE. RE-INSTALLED BLIND FASTENERS WI TH SEALANT PER FAA FROM J37 DATED 5-18-97. SUBMITTER STATED IT IS VERY DIFFICULT TO DO A THOROUGH INSPECTION OF THE INT ERNAL STRUCTURE OF THE LEADING EDGE TO LOOK FOR EVIDENCE OF CORROSION. SUBMITTER STATED TO PREVENT THIS FROM HAPPENING, THOROUGHLY INSPECT THE AILERON LEADING EDGE GAP SEAL TO LOOK FOR VOIDS IN THE SEALANT AND ALSO TO INSPECT FASTENER HEAD CONDITION. 2 L 7 2 4F RT A3EU 1997070300198 19970703 00198 NM 1997 7 3 97ZZZX2947 1 19970601 G 5330 SKIN BOEING 727 727287 1384020 NM BS 1030 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 920PG 21688 DURING C-CHECK INSPECTION, LEVEL 2 CORROSION WAS NOTED ON INTERIOR SKIN AT STA 1030 (L-2 DOOR CUT-OUT) AT S10L. 2 L 7 3 4F RT A3WE 1997070300199 19970703 00199 NM 1997 7 3 97ZZZX2948 1 19970601 G 5311 FRAME CAP BOEING 727 727287 1384020 NM BS 1183 RT CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 920PG 21688 DURING C-CHECK INSPECTION, LEVEL 2 CORROSION WAS NOTED ON 1183 BULKHEAD FRAME CAP RT SIDE AT S17R. 2 L 7 3 4F RT A3WE 1997070300200 19970703 00200 NM 1997 7 3 97ZZZX2949 1 19970601 G 5210 HINGE CAVITY BOEING 727 727287 1384020 NM R2 DOOR CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 920PG 21688 DURING C-CHECK INSPECTION, LEVEL 2 CORROSION WAS NOTED ON INSIDE OF UPPER HINGE CAVITY. 2 L 7 3 4F RT A3WE 1997070300201 19970703 00201 NM 1997 7 3 97ZZZX2950 1 19970616 G 2761 656952212 HOUSING 65449617 BOEING 737 7372B7 1384560 NM ACTUATOR CRACKED B S IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 1054 13315 CRACK WAS FOUND DURING INCOMING INSPECTION OF DRAG CONTROL ACTUATOR. 2 L 7 2 4F A16WE 1997070300202 19970703 00202 CE 1997 7 3 97ZZZX2951 1 19970515 G 7722 8972052 RESISTOR CESSNA 441 441 2076020 CE NR 1 ENG EGT FAULT D A E ENGINE SHUTDOWN R PARTIAL RPM/PWR LOSS CR CRUISE 1 NM 01 711GE 1487 1510N 4410209 DURING ROUTINE CLIMB THROUGH 12,000 FEET, LOST POWER IN LT ENG, OBSERVED TORQUE AT 300 POUNDS AND EGT OVER RED LINE. SH UT DOWN NR 1 ENG AND SECURED. DURING TROUBLESHOOTING, ISOLATED PROBLEM TO INTERMITTENT FAULT IN EGT COMPENSATING RESIST OR. A FAULT IN THIS SYS CAUSED ENG COMPUTER TO SENSE AN ERRONEOUS OVERTEMP CONDITION AND THE AUTOTEMP AND TORQUE FUNCTI ON OF COMPUTER TAKES CONTROL OVER THE POWER LEVER. HAD THIS OCCURRED AT TAKEOFF DURING ROTATION, CONTROL OF ACFT WOULD BE DIFFICULT AS NTS SYS WILL NOT SENSE A FAILURE WITH 300 POUNDS TORQUE AND THE ENG IS PRODUCING MORE DRAG THAN THRUST A ND WILL NOT AUTOFEATHER. THIS SITUATION CAN BE ISOLATED BY TURNING OFF AUTO TORQUE AND EGT FUNCTIONS OF THE COMPUTER. 1 L 7 2 3T RT A28CE 1997070300389 19970703 00389 NM 1997 7 3 97ZZZX2952 1 19970525 G 5730 SKIN BOEING 727 72722 1384002 NM BS 259.5-295 CORROSION B ERKR K NONE O OTHER IN INSP/MAINT 1 WP 07 400RG 38277 19149 DURING C-CHECK INSPECTION, DISCOVERED CORROSION COMMON TO THE LAP SEAM BETWEEN STA 259.5 AND STA 295 AND STR 24R. REPAI RED BY CLEANING OUT CORROSION PER SB 53-0072. DUE TO EXTENT OF DAMAGE, THE LAP SEAM WAS REPAIRED USING REPAIR DOUBLERS AND FILLERS. REPAIRED IAW EVERGREEN AIR CENTER - ENGINEERING CHANGE/REPAIR AUTHORIZATION NR N400RG-53-04-EAC. 2 L 7 3 4F A3WE 1997070300644 19970703 00644 CE 1997 7 3 97ZZZX2955 1 19970611 G 3710 PUMP SIGMATEK CESSNA 210 P210N 2073454 CE VAC SYSTEM FAILED G O OTHER J WARNING INDICATION CR CRUISE 1 NM 11 40RP 1700 P21000041 DURING VFR FLIGHT, LOST AIR OPERATED INSTRUMENTS. LANDED WITHOUT INCIDENT. ENGINE TT, 1,700 HRS. 1 H 7 1 3O 3A21 1997070300645 19970703 00645 SO 1997 7 3 97ZZZX2956 1 19970605 G 3340 8517402 SUPPORT PIPER PA28 PA28140 7102802 SO LANDING LIGHT MISINSTALLED H K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 11 6072W 2820085 DURING A 100-HOUR INSPECTION, THE LANDING LIGHT SUPPORT WAS FOUND INSTALLED UPSIDE-DOWN PREVENTING THE CASE FROM DRAININ G. SUBMITTER SUGGESTS INATTENTION DURING RE-ASSEMBLY. PLACARD THE PART 'THIS SIDE UP'. ALIGN PROPERLY AND RIVET TO A IR FILTER RETAINER. 1 L 7 1 3O 2A13 1997070300647 19970703 00647 CE 1997 7 3 97ZZZX2958 1 19970623 G 2820 FITTING BBAVIA 8 8KCAB 2110612 CE HEADER TANK SEEP D L A K NONE K FLUID LOSS IN INSP/MAINT 1 GL 03 8SC 1720 58480 OWNER COMPLAINED OF FUEL SMELL IN THE COCKPIT. FOUND A SEEP ON THE EXIT FITTING, TOP OF HEADER TANK, UNDER DASH GOING TO THE FIREWALL SOV. THIS TANK IS SUPPLIED BY BOTH WING TANKS. FITTING IS A COMPRESSION TYPE, NOT AN AN-FLARE. MECHA NIC WENT TO SNUG IT UP AND FOUND THAT FUEL HAD SATURATED CARPET AND WAS DRIPPING OUT THE TAIL. WHEN MECHANIC PUT A WREN CH ON THE FITTING, LINE BROKE CLEAN OFF SPRAYING FUEL AND FURTHER SOAKING COCKPIT. WITH THE HEAD PRESSURE AT THIS POIN T, IT SPRAYED UP AND BEHIND THE INSTR PANEL WHERE SEVERAL ELECTRICAL SWITCHES AND RADIOS ARE LOCATED. SUBMITTER BELIEVE S IF THE FLIGHT HAD STARTED, A FIRE WAS IMMINENT, EITHER AT START-UP OR DURING AEROBATICS, BOTH WITH THE SAME OUTCOME. 1 H 7 1 3O A21CE 1997071000248 19970710 00248 NE 1997 7 10 97ZZZX3013 1 19970613 G 6210 641520601045 BLADE SKRSKY S64 S64F NE MAIN ROTOR CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 159AC 1153 64M65385921 64084 BLADE OPERATED BY ERICKSON FOR APPROXIMATELY 350.0 HOURS AND WAS REMOVED FOR A BLACK BIM INDICATION. A NITROGEN LEAK WA S DETECTED BETWEEN BLADE POCKETS NR 24 AND NR 25 ON THE LOWER SPAR SURFACE. IT APPEARED TO ORIGINATE UNDER AN APPROVED MILITARY APPLIED PATCH. THE PATCH WAS REMOVED AND ALSO POCKETS NR 24 AND NR 25. A SEVERE GOUGE WAS NOTED AT THE AREA B ETWEEN THE POCKETS. IT APPEARS TO BE THE RESULT OF POOR WORKMANSHIP WHEN THE BLADE WAS REWORKED TO APPLY THE PATCH. A CHORDWISE CRACK WAS FOUND AT THE BOTTOM OF THE GOUGED AREA APPROXIMATELY 1.75 INCHES IN LENGTH IN THE SPAR. PART HAS BE EN SCRAPPED. 2 G 7 2 4U H6EA 1997071000249 19970710 00249 1997 7 10 97ZZZX3014 4 19970130 G 6122 592444 IOC DHAV DHC4 DHC4A 2800304 EA RT ENG PROP GOV FAILED G L A E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 AL 03 702SC 538 126 INVESIGATION FOR PROPELLER OVERSPEED AND ENGINE FEATHER WHICH LED TO TERRAIN COLLISION, FOUND THE INDEPENDENT OIL CONTRO L FAILURE. RT ENGINE COWL COVERED WITH H-5606 FLUID. LAST OVERHAUL 6-10-96. 2 H 7 2 4R 1A19 1997071000250 19970710 00250 NE 1997 7 10 97ZZZX3015 3 19970625 G 6111 SFA13M10A BLADE HAMSTD 14SF 14SF7 NE ZONE 3 STA 45 CRACKED B A PAIR K NONE O OTHER IN INSP/MAINT 1 SO 05 21112 2746 853671 RECEIVED PROPELLER BLADE ONLY. REMOVED DEICER BOOT, FOUND FIBERGLASS CRACKED IN THE DEICER AREA ON THE LEADING EDGE NEX T TO NICKEL SHEATH. THE CRACK EXTENDED 2.50 INCHES FROM THE LEADING EDGE TOWARD THE TRAILING EDGE. THE BLADE IS SHOWIN G SIGNS OF TWISTING IN THIS AREA. 6 C P7NE 1997071000251 19970710 00251 1997 7 10 97ZZZX3016 2 19970625 G 7421 RHB32S SPARK PLUG CHAMPION ELECTRODE SPLIT B S CS3R K NONE O OTHER IN INSP/MAINT 1 WP 17 CHAMPION SPARK PLUG RHB325S SIDE ELECTRODE HAS APPEARANCE OF DELAMINATION, USAGE IN LYCOMING OR CONTINENTAL NO DIFFERENC E: 30 PLUS PLUGS THIS YEAR. 1997071000252 19970710 00252 SO 1997 7 10 97ZZZX3017 2 19970624 G 7414 1051324 SPRING CESSNA 337 337G 2075730 CE CONT O360 IO360G 17025 SO MAG IMPULSE BROKEN D K NONE O OTHER IN INSP/MAINT 1 SW 07 CUSTOMER COMPLAINED THAT UPON PERFORMING REAR ENGINE MAGNETO CHECK, ONE MAGNETO PRODUCED NO DROP, THE OTHER MAGNETO WOUL D CAUSE ENGINE DECELERATE TO THE POINT OF STOPPING. MAGNETO'S WERE REMOVED AND INSPECTED. FOUND IMPULSE COUPLING SPRIN G BROKEN. THIS IS THE THIRD SUCH SPRING FOUND BROKEN IN ONE MONTH. 1 H 7 2 3O 3 O A6CE E1CE 1997071600004 19970716 00004 CE 1997 7 16 97ZZZX3018 1 19970619 G 3230 57412026 HOOK CESSNA 414 414A 2075907 CE LT MLG UPLOCK CRACKED E K NONE O OTHER IN INSP/MAINT 1 CE 01 135BG 5749 414A0419 OLD UPLOCK HOOK CRACKED IN HOOK AREA. NEW UNPLOCK HOOK ASSY PN 5141312-10 IS MUCH HEAVIER. SUSPECT CAUSE WAS TIME AND NUMBER OF GEAR CYCLES. 1 L 7 2 3O A7CE 1997071000253 19970710 00253 SO 1997 7 10 97ZZZX3019 1 19970520 G 3230 400111 BOLT PIPER PA23 PA23250 7102308 SO RT MLG DOWNLOCK FAILED D A O OTHER O OTHER LD LANDING 1 EA 25 333FS 274456 RIGHT LANDING GEAR COLLAPSED ON LANDING. FOUND A BROKEN DOWNLOCK DRAG LINK BOLT. 1 L 7 2 3O 1A10 1997071000254 19970710 00254 CE 1997 7 10 97ZZZX3020 1 19970530 G 3231 08411066 BELLCRANK CESSNA 340 340A 2076405 CE RT INBD DOOR BROKE D P A K NONE O OTHER LD LANDING 1 SO 05 391DJ 2187 340A1250 RIGHT INBOARD DOOR BELLCRANK BROKE ON LANDING. FURTHER INSPECTION FOR CAUSE FOUND RT MLG ROD PN 5045009-16 HAD A LOOSE JAMNUT AT INBOARD IDLER BELLCRANK. POSSIBLE STRETCHING OF ROD END THREAD AND LENGTHENING OF ROD PLACED EXCESS TENSION O N BELLCRANK. 1 L 7 2 3O 3A25 1997071000255 19970710 00255 CE 1997 7 10 97ZZZX3021 1 19970422 G 7931 070009937 LINE ASSY CESSNA 182 TR182 2072735 CE OIL PRESS GAUGE LEAK D L K NONE K FLUID LOSS IN INSP/MAINT 1 SW 99 4700S 1325 R18201388 OIL LINE BETWEEN FIREWALL AND OIL PRESSURE GAUGE LEAKING OIL THROUGH TWO CORRODED PIN HOLES ONTO CARPET ON COPILOT SIDE. LOST APPROXIMATELY 3-4 QUARTS OF OIL. 1 H 7 1 3O 3A13 1997071000256 19970710 00256 EA 1997 7 10 97ZZZX3022 2 19970624 G 7322 30800 FLOAT HA6 CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA CARBURETOR DEFECTIVE D A K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 WP 07 6303V 19 DL0198 172RG0615 PILOTS REPORT EXCESS MAGNETO DROPS OF GREATER THAN 300 RPM'S AND SEVERE ENGINE ROUGHNESS. THE FLOAT IN THE CARBURETOR W AS REMOVED AND FOUND THAT THE REAR-MOST CHAMBER WAS FILLED WITH FUEL. FLOAT IS A PLASTIC DESIGN WITH 3 VISABLE CHAMBERS . THE CHAMBER THAT WAS FULL OF FUEL WAS THE ONE CLOSEST TO THE NEEDLE VALVE. UPON INSTALLING A SERVICEABLE FLOAT, ENGI NE OPERATED NORMALLY. 1 H 7 1 3O 3 O 3A17 E286 1997071000257 19970710 00257 SO 1997 7 10 97ZZZX3023 1 19970606 G 3250 3945902 MOUNT ASSY PIPER PA34 PA34220T 7103420 SO NLG STEERING BROKEN D K NONE O OTHER IN INSP/MAINT 1 WP 07 8287U 7325 348333027 LOWER TAB OF MOUNT BRACKET PN 39459-02 FOR STEERING ARM ASSY OF NOSE GEAR WAS FOUND BROKEN AWAY FROM BRACKET ASSY. THIS DEFECT WAS DISCOVERED DURING AN INSPECTION AS A RESULT OF NOSE STEERING PROBLEM. THIS DEFECT IS A RESULT OF AGE/METAL FATIGUE AND/OR OVERSTEERING USING TUG FROM ANOTHER AIRPORT LOCATION. SUBMITTER SUGGESTS CLOSE LOOK AT EVERY OPPORTUNITY IF ANY NOTABLE STEERING PROBLEM. 1 L 7 2 3O A7SO 1997071000258 19970710 00258 SO 1997 7 10 97ZZZX3024 1 19970527 G 3710 212CW PUMP AIRBORNE PIPER PA34 PA34220T 7103420 SO VACUUM SYSTEM SHAFT FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 07 8404X 98 9AM2818 348133146 INSTALLED NEW VACUUM PUMP: WITHIN 98 HOURS, PUMP WAS INOPERABLE. CAUSE WAS BROKEN PUMP TO GEAR DRIVESHAFT TWISTED OFF. CHECKED AND FOUND NO ENGINE STOPPAGE OR INTERNAL PROBLEM WITH ENGINE TO CAUSE BROKEN SHAFT. SUSPECT CAUSE - VANE IN PU MP STOPPED PUMP ROTATION. 1 L 7 2 3O A7SO 1997071000259 19970710 00259 SO 1997 7 10 97ZZZX3025 2 19970407 G 8520 CRANKSHAFT PIPER PA34 PA34220T 7103420 SO CONT O360 LTSIO360KB 17025 SO NR 1 ROD CHEEK BROKE B MW2R K NONE O OTHER NR NOT REPORTED 1 GL 17 83878 348133097 233941H CRANKSHAFT BROKE AT NR 1 ROD CHEEK RESULTING IN ENGINE FAILURE. ENGINE HAD A VAR CRANKSHAFT INSTALLED SN J159203. TT 3 ,295 HOURS. 1 L 7 2 3O 3 O A7SO E9CE 1997071000260 19970710 00260 SO 1997 7 10 97ZZZX3026 1 19970606 G 3250 3945902 MOUNT ASSY PIPER PA34 PA34220T 7103420 SO NLG STEERING FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 07 8449T 5863 348133272 THE LOWER MOUNTING TAB FOR PN 95061-28 BUSHING AND PN 95395-00 STEERING ARM ASSY WAS FOUND COMPLETELY CRACKED AND HAD SE PARATED FROM THE ENTIRE ASSY (PN 39459-02) CAUSING LOSS OF NOSE WHEEL STEERING. SUBMITTER SUGGESTED CAUSE DUE TO METAL FATIGUE. RECOMMENDATION FOR PREVENTION WOULD BE CLOSE INSPECTION OF THE ENTIRE MOUNT ASSY AND DYE PENETRANT TEST AT REG ULAR INSPECTIONS OR STRENGTHEN STRUCTURE. 1 L 7 2 3O A7SO 1997071000261 19970710 00261 NM 1997 7 10 97ZZZX3027 1 19970619 G 3213 65221125 STRUT BOEING 707 707320C 1383668 NM MLG CRACKED B VQ4R K NONE O OTHER IN INSP/MAINT 1 SO 19 1871 THE TWO 707 MLG INNER CYLINDERS WERE RECEIVED FOR EVALUATION IN SERVICEABLE CONDITION. DURING MAGNETIC PARTICLE INSPECT ION, NUMEROUS REGIONS OF UNTEMPERED AND OVERTEMPERED MARTENSITE WITH LADDER CRACKS WERE FOUND UNDER THE CHROME PLATING. PN 65-22112-1, SN 1871. PN 65-22112-5, SN 2624. NORTHROP RUMM AN W/O: 314848 AND W/O 314847. 2 L 7 4 4F 4A26 1997071000262 19970710 00262 NM 1997 7 10 97ZZZX3028 1 19970619 G 3213 65221125 STRUT BOEING 707 707320C 1383668 NM MLG CRACKED B VQ4R K NONE O OTHER IN INSP/MAINT 1 SO 19 2624 THE TWO 707 MLG INNER CYLINDERS WERE RECEIVED FOR EVALUATION IN SERVICEABLE CONDITION. DURING MAGNETIC PARTICLE INSPECT ION, NUMEROUS REGIONS OF UNTEMPERED AND OVERTEMPERED MARTENSITE WITH LADDER CRACKS WERE FOUND UNDER THE CHROME PLATING. PN 65-22112-1, SN 1871. PN 65-22112-5, SN 2624. NORTHROP RUMM AN W/O: 314848 AND W/O 314847. 2 L 7 4 4F 4A26 1997071000263 19970710 00263 NM 1997 7 10 97ZZZX3029 1 19970619 G 3230 65588324 BEAM BOEING 707 707320C 1383668 NM MLG ACTUATOR CRACKED B VQ4R K NONE O OTHER IN INSP/MAINT 1 SO 19 THE 707 MLG ACTUATOR BEAM WAS RECEIVED FOR OVERHAUL. VISUAL INSPECTION REVEALED A LARGE CRACK AT THE SUPPORT LINK ATTAC H LUG. THE CRACK WAS DETECTED THROUGH THE PAINT. NORTHROP GRUMMAN W/O: 314846 2 L 7 4 4F 4A26 1997071000264 19970710 00264 NM 1997 7 10 97ZZZX3030 1 19970619 G 3230 6552361 SUPPORT LINK BOEING 707 707320C 1383668 NM ACTUATOR BEAM CRACKED B VQ4R K NONE O OTHER IN INSP/MAINT 1 SO 19 THE 707 SUPPORT LINK WAS RECEIVED FOR OVERHAUL WITH 2 CRACKS AT THE HANGER ATTA CH REGION. THE CRACKS WERE FOUND DURING PENETRANT INSPECTION AFTER THE REMOVAL OF THE BUSHINGS AND PAINT. NORTHOP GRUMMAN W/O: 314847. 2 L 7 4 4F 4A26 1997071000265 19970710 00265 NM 1997 7 10 97ZZZX3031 1 19970619 G 3213 6532855 SIDE STRUT BOEING 707 707320C 1383668 NM MLG CRACKED B VQ4R K NONE O OTHER IN INSP/MAINT 1 SO 19 THE 707 MLG SIDE STRUT WAS RECEIVED FOR OVERHAUL. AFTER BUSHING REMOVAL AND PAINT REMOVAL, PEENTRANT INSPECTION DETECTE D TWO 3-INCH CRACKS AT THE CENTER SECTION (WEB REGION). 2 L 7 4 4F 4A26 1997071000266 19970710 00266 NE 1997 7 10 97ZZZX3032 2 19970620 G 7322 7923801 FLAPPER NOZZLE 7863927 PWA 120 PW120 NE FCU CLOGGED B BN4R O OTHER Y ENGINE STOPPAGE CR CRUISE 1 WP 05 139 F21454 REFERENCE: FW05670. ENGINE SHUT-DOWN IN FLIGHT. SUSPECT TBD - SCREEN ON POSITIVE FLAPPER NOZZLE BECAME CLOGGED WITH C ONTAMINATION. SUBMITTER RECOMMENDS FUEL CONTROL BE OVERHAULED. OPERATOR OF AIRCRAFT HAS BEEN NOTIFIED OF FUEL SYSTEM C ONTAMINATION. CUSTOMER: MAYA AIRLINES THROUGH PWC SERVICE CENTER (MONTREAL). 4 T E20NE 1997071000267 19970710 00267 EU 1997 7 10 97ZZZX3033 1 19970620 G 3250 632010 SWITCH EA18D12 ISRAEL 1124 1124 4500102 EU STEERING VALVE FAILED B W6NR K NONE O OTHER IN INSP/MAINT 1 GL 25 1124F 20 IL153 281 INSTALLED OVERHAULED STEERING VALVE ASSY. 20 HOURS LATER, STEERING VALVE FAILED. TROUBLESHOT, FOUND BAD PRESSURE SWITC H. INSTALLED NEW PRESSURE SWITCH AND STEERING WAS STILL INOPERABLE. FOUND SWITCH WAS LOOSING CONTACT WHEN SWITCH WAS D EPRESSED ALL THE WAY. INSTALLED ANOTHER PRESSURE SWITCH FOR STEERING VALVE ASSY. PERFORMED OPERATIONAL AND CHECKED SAT ISFACTORY. 2 M 7 2 4F A2SW 1997071000269 19970710 00269 EA 1997 7 10 97ZZZX3035 2 19970605 G 7200 ENGINE DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043 EA RT ENGINE FAILED D O OTHER Y ENGINE STOPPAGE NR NOT REPORTED 1 SW 01 35062 2750 429 PCE40881 RIGHT ENGINE QUIT WHEN POWER WAS REDUCED TO IDLE. ENGINE WAS REMOVED AND REPLACED, AIRCRAFT RETURNED TO SERVICE. AWAIT ING TEAR-DOWN REPORT. 1 H 7 2 3T 4 T A9EA E4EA 1997071000270 19970710 00270 CE 1997 7 10 97ZZZX3036 1 19970623 G 3213 508102903 STRUT BEECH 90 B90 1152912 CE MLG CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 21 48A 629 LJ381 A CRACK WAS FOUND IN THE FILLET AREA ABOVE THE PIVOT OF THE TOP SCISSOR ARM. 1 L 7 2 3T 3A20 1997071000271 19970710 00271 CE 1997 7 10 97ZZZX3037 1 19970601 G 5260 551124411 BRACKET CESSNA 500 500CESSNA 2076602 CE STEP STOP BENT D S K NONE O OTHER IN INSP/MAINT 1 SW 99 58TC 5000261 THE BRACKET WAS BENT DOWN FROM STEP BEING PUSHED UP TOO FAR AND ANCHOR NUTPLATES HAVE CRACKS IN SKIN BETWEEN RIVETS. 1 L 7 2 4F A22CE 1997071000272 19970710 00272 CE 1997 7 10 97ZZZX3038 1 19970623 G 2150 11791006013 BRACKET BEECH B300 B300 1159232 CE AIR CONDITIONER CRACKED B S KI2R K NONE O OTHER IN INSP/MAINT 1 CE 01 65CR FL60 AIR CONDITIONER BRACKET CRACKED. THIS IS THE UPDATED BRACKET MADE OUT OF STEEL. WHEN BRACKET WAS MADE OUT OF ALUMINUM, HAD ALOT OF FAILURES ALL IN THE SAME AREA. 2 L 7 2 4T RT A24CE 1997071000273 19970710 00273 EU 1997 7 10 97ZZZX3039 1 19970425 G 3241 9542653 DETECTOR AMD FALC10 FALCON10 2730101 EU ANTI SKID SHORTED G A O OTHER O OTHER LD LANDING 1 GL 15 908RF 2500 46 UPON LANDING, ACFT PULLED RIGHT AND DEPARTED RUNWAY. MAINTENANCE FOUND NR 2 DETECTOR (TACH GEN) FOR THE ANTI-SKID SYSTE M HAD 'SHORTED OUT' WHERE THE WIRES ENTER THE CONNECTOR. THE DEAD SHORT APPARENTLY CAUSED THE CONTROL BOX TO READ A SK ID SITUATION AND PREVENTED BRAKE PRESSURE FROM BEING APPLIED TO THE LEFT BRAKE. SUBMITTER RECOMMENDS THAT SPECIAL ATTEN TION BE GIVEN TO THIS AREA DURING INSP DUE TO THE ENVIRONMENT, ETC. SUBMITTER ALSO SUSPECTED THE PROBLEM WAS LIKELY DUE TO POOR MAINTENANCE PRACTICES WHEN THIS CONNECTOR WAS PREVIOUSLY REPAIRED. APPARENTLY THE WIRE INSULATION WAS STRIPPED BACK TOO FAR EXPOSING WIRES. 2 L 7 2 4F A33EU 1997071000276 19970710 00276 WP 1997 7 10 97ZZZX3040 2 19970611 G 7230 8945283 STATOR VANE GARRTT TPE331 TPE331* 01514 WP 2ND STAGE CLOGGED B S XWMR K NONE O OTHER IN INSP/MAINT 1 SW 15 INSPECTION FOUND 1 EACH VANE AIR PASSAGE CLOGGED. CLOGGED VANE AIR PASSAGES CAN RESTRICT COOLING AIR TO CENTER SHEET ME TAL SEAL SUPPORT. THIS COULD BE A CONTRIBUTING FACTOR IN THE FAILURE OF THE SEAL SUPPORT. IF THE SEAL SUPPORT FAILS, I T IS LIKELY THAT A CATASTROPHIC FAILURE WILL OCCUR. SUBMITTER RECOMMENDATION: MODIFICATION TO -10. 3 T E2WE 1997071000277 19970710 00277 WP 1997 7 10 97ZZZX3041 2 19970612 G 7230 8945286 STATOR VANE GARRTT TPE331 TPE331* 01514 WP 2ND STAGE CLOGGED B S XWMR K NONE O OTHER IN INSP/MAINT 1 SW 15 7E081 INSPECTION FOUND 2 EACH VANE AIR PASSAGES CLOGGED. CLOGGED VANE AIR PASSAGES CAN RESTRICT COOLING AIR TO CENTER SHEET M ETAL SEAL SUPPORT. THIS COULD BE A CONTRIBUTING FACTOR IN THE FAILURE OF THE SEAL SUPPORT. IF THE SEAL SUPPORT FAILS I T IS LIKELY THAT A CATASTROPHIC FAILURE WILL OCCUR. SUBMITTER RECOMMENDATION: MODIFICATION TO -10. 3 T E2WE 1997071000278 19970710 00278 WP 1997 7 10 97ZZZX3042 2 19970616 G 7230 89452810 STATOR VANE GARRTT TPE331 TPE331* 01514 WP 2ND STAGE CLOGGED B S XWMR K NONE O OTHER IN INSP/MAINT 1 SW 15 INSPECTION FOUND 14 EACH VANE AIR PASSAGES CLOGGED. CLOGGED VANE AIR PASSAGES CAN RESTRICT COOLING AIR TO CENTER SHEET METAL SEAL SUPPORT. THIS COULD BE A CONTRIBUTING FACTOR IN THE FAILURE OF THE SEAL SUPPORT. IF THE SEAL SUPPORT FAILS, IT IS LIKELY THAT A CATASTROPHIC FAILURE WILL OCCUR. SUBMITTER RECOMMENDATION: REJECT. 3 T E2WE 1997071000279 19970710 00279 WP 1997 7 10 97ZZZX3043 2 19970611 G 7230 8945286 STATOR VANE GARRTT TPE331 TPE331* 01514 WP 2ND STAGE CLOGGED B S XWMR K NONE O OTHER IN INSP/MAINT 1 SW 15 7E048 INSPECTION FOUND 2 EACH VANE AIR PASSAGES CLOGGED. CLOGGED VANE AIR PASSAGES CAN RESTRICT COOLING AIR TO CENTER SHEET M ETAL SEAL SUPPORT. THIS COULD BE A CONTRIBUTING FACTOR IN THE FAILURE OF THE SEAL SUPPORT. IF THE SEAL SUPPORT FAILS, IT IS LIKELY THAT A CATASTROPHIC FAILURE WILL OCCUR. SUBMITTER RECOMMENDATION: MODIFICATION TO -10. 3 T E2WE 1997071000280 19970710 00280 WP 1997 7 10 97ZZZX3044 2 19970611 G 7230 8945286 STATOR VANE GARRTT TPE331 TPE331* 01514 WP 2ND STAGE CLOGGED B S XWMR K NONE O OTHER IN INSP/MAINT 1 SW 15 4083782597 INSPECTION FOUND 1 EACH VANE AIR PASSAGE CLOGGED. CLOGGED VANE AIR PASSAGES CAN RESTRICT COOLING AIR TO CENTER SHEET ME TAL SEAL SUPPORT. THIS COULD BE A CONTRIBUTING FACTOR IN THE FAILURE OF THE SEAL SUPPORT. IF THE SEAL SUPPORT FAILS, I T IS LIKELY THAT A CATASTROPHIC FAILURE WILL OCCUR. SUBMITTER RECOMMENDATION: MODIFICATION TO -10. 3 T E2WE 1997071000281 19970710 00281 WP 1997 7 10 97ZZZX3045 2 19970611 G 7230 8945286 STATOR VANE GARRTT TPE331 TPE331* 01514 WP 2ND STAGE CLOGGED B S XWMR K NONE O OTHER IN INSP/MAINT 1 SW 15 6C090 INSPECTION FOUND 1 EACH VANE AIR PASSAGE CLOGGED. CLOGGED VANE AIR PASSAGES CAN RESTRICT COOLING AIR TO CENTER SHEET ME TAL SEAL SUPPORT. THIS COULD BE A CONTRIBUTING FACTOR IN THE FAILURE OF THE SEAL SUPPORT. IF THE SEAL SUPPORT FAILS, I T IS LIKELY THAT A CATASTROPHIC FAILURE WILL OCCUR. SUBMITTER RECOMMENDATION: MODIFICATION TO -10. 3 T E2WE 1997071000282 19970710 00282 WP 1997 7 10 97ZZZX3046 2 19970611 G 7230 8945286 STATOR VANE GARRTT TPE331 TPE331* 01514 WP 2ND STAGE CLOGGED B S XWMR K NONE O OTHER IN INSP/MAINT 1 SW 15 7C098 INSPECTION FOUND 5 EACH VANE AIR PASSAGES CLOGGED. CLOGGED VANE AIR PASSAGES CAN RESTRICT COOLING AIR TO CENTER SHEET M ETAL SEAL SUPPORT. THIS COULD BE A CONTRIBUTING FACTOR IN THE FAILURE OF THE SEAL SUPPORT. IF THE SEAL SUPPORT FAILS, IT IS LIKELY THAT A CATASTROPHIC FAILURE WILL OCCUR. SUBMITTER RECOMMENDATION: MODIFICATION TO -10. 3 T E2WE 1997071000283 19970710 00283 WP 1997 7 10 97ZZZX3047 2 19970616 G 7230 8945286 STATOR VANE GARRTT TPE331 TPE331* 01514 WP 2ND STAGE CLOGGED B S XWMR K NONE O OTHER IN INSP/MAINT 1 SW 15 4083782083 INSPECTION FOUND 12 EACH VANE AIR PASSAGES CLOGGED. CLOGGED VANE AIR PASSAGES CAN RESTRICT COOLING AIR TO CENTER SHEET METAL SEAL SUPPORT. THIS COULD BE A CONTRIBUTING FACTOR IN THE FAILURE OF THE SEAL SUPPORT. IF THE SEAL SUPPORT FAILS, IT IS LIKELY THAT A CATASTROPHIC FAILURE WILL OCCUR. SUBMITTER RECOMMENDATION: REJECT. 3 T E2WE 1997071000284 19970710 00284 WP 1997 7 10 97ZZZX3048 2 19970611 G 7230 8945286 STATOR VANE GARRTT TPE331 TPE331* 01514 WP 2ND STAGE CLOGGED B S XWMR K NONE O OTHER IN INSP/MAINT 1 SW 15 7D084 INSPECTION FOUND 5 EACH VANE AIR PASSAGES CLOGGED. CLOGGED VANE AIR PASSAGES CAN RESTRICT COOLING AIR TO CENTER SHEET M ETAL SEAL SUPPORT. THIS COULD BE A CONTRIBUTING FACTOR IN THE FAILURE OF THE SEAL SUPPORT. IF THE SEAL SUPPORT FAILS, IT IS LIKELY THAT A CATASTROPHIC FAILURE WILL OCCUR. SUBMITTER RECOMMENDATION: MODIFICATION TO -10. 3 T E2WE 1997071000285 19970710 00285 NE 1997 7 10 97ZZZX3049 2 19970624 G 7261 30722311 HOUSING CESSNA 650 650 2076802 CE GARRTT TFE731 TFE7313B 01518 NE OIL FILTER CRACKED D S A K NONE K FLUID LOSS IN INSP/MAINT 1 EA 21 2606 2885 650194 P87488 AFTER LANDING DURING THE CREWS TRANSIENT WALK-AROUND, FOUND THE LT ENGINE OIL QUANTITY ONE AND ONE-HALF QUARTS LOW. THE OIL WAS FULL BEFORE THE 2-1/2 HOUR FLIGHT. FURTHER INVESTIGATION REVEALED A CRACKED OIL FILTER HOUSING PN 3072231-1. A LSO, FOUND A CRACKED ATTACH BRACKET PN 3071943-1. MPI'S WERE JUST COMPLETED 87 HOURS AGO. THE CREW NOTED NO ABNORMAL O IL RPESSURE OR VIBRATION INDICATIONS. THE OIL FILTER HOUSING WAS REPLACED AND A VIBRATION SURVEY WAS COMPLETED WITH NO ABNORMAL FINDINGS. 2 L 7 2 4F 4 F A9NM E6WE 1997071700103 19970717 00103 NM 1997 7 17 97ZZZX3066 1 19970601 G 5320 65198618 T CHORD BOEING 727 72730 1384008 NM BS 320 S26R CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 357KP 20675 DURING C-CHECK INSPECTION, CORROSION NOTED ON T-CHORD BETWEEN STA 320 AND STA 350 AT S26R. 2 L 7 3 4F A3WE 1997071700104 19970717 00104 NM 1997 7 17 97ZZZX3067 1 19970616 G 2913 42086 PUMP ABEX DORNER DO32 DO328100 2996000 NM HYDRA SYSTEM FAILED D O OTHER J WARNING INDICATION AP APPROACH 1 GL 09 653PC 1570 4476 3027 INBOUND, MAIN HYDRA PUMP FAILED. MADE NORMAL LANDING WITH BACK-UP AUXILIARY PUMP. INSPECTED MOTOR PUMP ASSY, FOUND POW ER BREAKERS TRIPPED. RESET AND OPS CHECKED SYSTEM, BREAKERS TRIPPED, UNIT REMOVED. INSTALLED REPAIRED UNIT. OPS CHECK WAS GOOD. AIRCRAFT RETURNED TO SERVICE. NOTE: MAIN HYDRA SYSTEM IS 115 VAC MOTOR PUMP ASSY DRIVEN BY ENGINE ALTERNAT ORS. 2 H 7 2 4T RT A45NM 1997071700107 19970717 00107 1997 7 17 97ZZZX3070 4 19970106 G 6122 C290D3KT12 PROP GOVERNOR CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA ENGINE MISINSTALLED D S A UNSCHED LANDING K FLUID LOSS NR NOT REPORTED 1 CE 07 52945 840366 177RG1316 L185651A THE CESSNA SM AND LYC ENGINE OVERHAUL DO NOT CONTAIN THE REQUIREMENT TO USE A PROPELLER GOV PAD PLATE, PN LW-12347, WHEN INSTALLING A MCCAULEY GOVERNOR ON LYC 4 OR 6 CYLINDER ENGINE WITH REAR MOUNTED DUEL MAG INSTALLATIONS. THIS PLATE WAS L EFT OUT DURING REINSTALLATION OF THE ENGINE AND THE ACFT MADE A FORCED LANDING DUE TO LOSS OF ENGINE OIL THROUGH THE GOV ERNOR ADAPTER PLATE SCREW. 1 H 7 1 3O 3 O A20CE 1E10 1997071700108 19970717 00108 SO 1997 7 17 97ZZZX3071 2 19970609 G 8520 CONNECT ROD CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO 2 AFT CYLINDERS FAILED G A UNSCHED LANDING E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NR NOT REPORTED 1 GL 23 30AW 18502369 559733 THE TWO REAR OPPOSING CYLINDERS FAILED; THUS, PUNCHING HOLES INTO THE ENGINE BLOCK. THIS CAUSED SMOKE IN COCKPIT (CASE) FOLLOWED BY EMERGENCY LANDING. 1 H 7 1 3O 3 O 3A24 E5CE 1997071700109 19970717 00109 CE 1997 7 17 97ZZZX3072 1 19970625 G 7921 629116 GASKET CESSNA 421 421C 2076016 CE OIL COOLER TORN D S K NONE K FLUID LOSS IN INSP/MAINT 1 SW 99 321FL 242 421C0207 AIRCRAFT CAME IN WITH RIGHT ENGINE LEAKING OIL. FOUND LEAK BETWEEN OIL COOLER AND CASE. WHEN COOLER PULLED AWAY FROM C ASE, GASKET HAD A STRAIGHT LINE TEAR AND PART 'OF 1 SIDE OF GASKET ON CASE, OTHER ON COOLER. THE REST OF THE GASKET HAD UNEVEN MARKS LIKE BEING TORN' WHEN COOLER WAS REMOVED. 1 L 7 2 3O A7CE 1997071700110 19970717 00110 NM 1997 7 17 97ZZZX3073 1 19970618 G 7120 300022501AF MOUNT PIPER PA60 PA60600 7106001 NM LYC O540 IO540K1J5 41532 EA ENG MOUNT 'V' CHAFED THROUGH D A K NONE O OTHER IN INSP/MAINT 1 EA 13 6894G 34488 600905816125 L2097248A LOWER MOTOR MOUNT 'V' AT MIDDLE ATTACH FITTING WAS FOUND CHAFED COMPLETELY THROUGH THE WALL OF TUBING (APPROXIMATELY 20 PERCENT OF DIAMETER OF TUBE) BY P/N 920029-01 FLEX DUCT. SUBMITTER STATED THIS PROBLEM IS REPEATEDLY SEEN ON ALL MODEL AEROSTAR. RECOMMEND THOROUGH INSPECTION OF AREA. 1 M 7 2 3O 3 O RT A17WE 1E4 1997071700111 19970717 00111 SO 1997 7 17 97ZZZX3074 1 19970618 G 7112 BAFFLE PIPER PA32 PA32R300 7103213 SO ENG FWD LT CHAFED B LF1R K NONE O OTHER IN INSP/MAINT 1 EA 07 9253N 272 3213100 DURING ANNUAL INSPECTION, FOUND PROPELLER CONTROL ATTACH BOLT AT GOVERNOR RUBBING ON ENGINE BAFFLE. IF LEFT ALONE, BAFF LE COULD WEAR THROUGH CAUSING PROPELLER CONTROL TO JAM AT A SELECTION OTHER THAN FULL RPM. A BRACKET WAS MANUFACTURED T O KEEP BAFFLE CLEAR. SUBMITTER STATED PIPER SHOULD RE-DESIGN OR PUT OUT SB TO RECTIFY PROBLEM. SUBMITTER STATED THIS I S 4TH AIRCRAFT WITH THIS CONDITION. 1 L 7 1 3O A3SO 1997071700112 19970717 00112 SO 1997 7 17 97ZZZX3075 1 19970607 G 2750 6270600 BRACKET PIPER PA28 PA28140 7102802 SO FLAP LEVER CRACKED D A K NONE O OTHER IN INSP/MAINT 1 SO 14 9500W 5848 PA2822921 WHILE C/W WITH PIPER SB NR 965, FOUND FLAP HANDLE MOUNTING BRACKET CRACKED IN 4 PLACES. NOTE: THERE WAS NO MECHANICAL REASON FOUND FOR SB NR 965. 1 L 7 1 3O 2A13 1997071700113 19970717 00113 SO 1997 7 17 97ZZZX3076 1 19970625 G 5521 4007516 SPAR PIPER PA31 PA31325 7103105 SO ELEVATOR CRACKED D L K NONE O OTHER IN INSP/MAINT 1 SW 99 979SD 4089 317812015 WHILE DOING REPETATIVE INSPECTION OF PIPER SB 998 WITH BORESCOPE, FOUND .75 INCH LONG CRACK IN TOP OUTBOARD SPAR. CRACK WAS NOT THERE 100 HRS AGO. 100 HOURS AGO HOLES WERE CUT PER SB 998. 1 L 7 2 3O A20SO 1997071700114 19970717 00114 SO 1997 7 17 97ZZZX3077 1 19970619 G 7920 6240008D0290 HOSE PIPER PA36 PA36285 7103610 SO ENGINE OIL LEAK B CKYR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 03 9986P 367560101 FOUND MASSIVE OIL LEAK REAR OF ENGINE. RAN ENGINE AFTER CLEANING AND OIL SPRAYING OUT OF HOSE. HOSE HAD A FIRE SLEEVE INSTALLED OR A FIRE WOULD HAVE STARTED IN THE ENGINE COMPARTMENT. AD 95-26-13 SHOULD BE REVISED TO INCLUDE PA-36 IN ITS APPLICATION, ALSO, PA-25. HOSE REPLACED. 1 L 7 1 3O A10SO 1997071700116 19970717 00116 1997 7 17 97ZZZX3078 4 19970502 G 3418 66082639 STALL COMPUTER LEAR 35 35A 5170602 CE STALL WARNING INTERMITTENT D K NONE O OTHER IN INSP/MAINT 1 SW 05 152TJ 01520 243 RECEIVED REPAIRED STALL WARNING COMPUTER PN 6608263-9 FROM LEARJET PARTS. INSTALLED IN AIRCRAFT, UNIT WAS INTERMITTENT ON SEVERAL SETTINGS. UNABLE TO CALIBRATE SYSTEM, REMOVED, REPLACED WITH SECOND REPAIRED UNIT SAME PART NUMBER. SECOND UNIT FUNCTIONED PROPERLY. RETURNED FIRST UNIT FOR WARRANTY. 2 L 7 2 4F A10CE 1997071700117 19970717 00117 CE 1997 7 17 97ZZZX3079 1 19970624 G 2722 4006719 SERVO HONEYWELL CESSNA 650 650 2076802 CE RUDDER FAILED D A O OTHER F FLT CONT AFFECTED AP APPROACH 1 EA 21 2605 1597 87103491 6500144 DURING APPROACH, CREW NOTICED RUDDER OPERATION WAS EXTREMELY STIFF IN BOTH DIRECTIONS. MAINT INVESTIGATION VERIFIED RUD DER TRAVEL WAS FULL, BUT VERY STIFF WITH OR WITHOUT ELECTRIC POWER. OCCASIONALLY, STIFFNESS WOULD BREAK FREE, THEN RE-E NGAGE. THE RUDDER SERVO WAS DISCONNECTED AND FREE MOVEMENT RESTORED. THE RUDDER SERVO DRIVE OUTPUT CLUTCH WAS FULLY EN GAGED. THE RUDDER SERVO DRIVE WAS REPLACED. SUBMITTER STATED THIS CONDITION COULD HAVE BEEN A DANGEROUS SITUATION HAD THERE BEEN A CROSSWIND OR WHERE RUDDER INPUT WAS REQUIRED. 2 L 7 2 4F A9NM 1997071700118 19970717 00118 NE 1997 7 17 97ZZZX3080 2 19970618 G 7200 ENGINE LEAR 24 24D 5170311 CE GE CJ610 CJ6106 30006 NE POWER SECTION FLAME OUT G O B OTHER EMER. DESCENT X ENGINE FLAMEOUT CR CRUISE 1 GL 15 295NW 295 251712A IN-FLIGHT FLAME OUT AT 45,000 FEET. DESCENDED TO 23,000 FEET, RESTARTED, CLIMBED TO 43,000 FEET. SUBMITTER STATED THIS OCCURRENCE IS COMMON TO LEAR 24 DXR'S. NO DEFECT NOTED. 2 L 7 2 4J 4 J A10CE 1E16 1997071700119 19970717 00119 CE 1997 7 17 97ZZZX3081 1 19970627 G 5320 551124914 FRAME CESSNA 500 500CESSNA 2076602 CE THRESHOLD OTBD CRACKED G P A K NONE O OTHER IN INSP/MAINT 1 GL 15 58TC 6319 5000261 DURING INSPECTION, A REPAIR STATION DISCOVERED A CRACK IN THE LOWER DOOR FRAME. CLOSER INSP NOTED CRACK EMANATED FROM THE HOLES DRILLED FOR INSTALLATION OF A NUTPLATE (FOR THE DOOR STEP INSTALLATION, AFT ATTACH POINT). NOTED NUMEROUS CR ACKS THROUGHOUT THIS AND SEVERAL OTHER PIECES OF THE LOWER DOOR FRAME ASSY. THERE WERE A NUMBER OF HOLES DRILLED THAT D ID NOT HAVE PROPER EDGE DISTANCE SOME OF WHICH WERE AROUND THE 2 HOLES FOR THE MAIN CABIN DOOR BOTTOM RETAINING PINS. S UBMITTER STATED IT APPEARS THESE DEFICIENCIES WERE CAUSED DURING ORIG MANUFACTURE AS THERE IS NO EVIDENCE THIS AREA HAS BEEN REWORKED. THESE AREAS ARE NOW MANIFESTING THEMSELVES AS CRACKS. ACFT HAS 6,319 HRS TIME IN SERVICE AS OF 6-24-97 1 L 7 2 4F A22CE 1997071700120 19970717 00120 CE 1997 7 17 97ZZZX3082 1 19970627 G 5320 55112493 FRAME CESSNA 500 500CESSNA 2076602 CE THRESHOLD INBD CRACKED G K NONE O OTHER IN INSP/MAINT 1 GL 15 58TC 6319 5000261 DURING INSPECTION, A REPAIR STATION DISCOVERED A CRACK IN THE LOWER DOOR FRAME. CLOSER INSP NOTED CRACK EMANATED FROM THE HOLES DRILLED FOR INSTALLATION OF A NUTPLATE (FOR THE DOOR STEP INSTALLATION, AFT ATTACH POINT). NOTED NUMEROUS CR ACKS THROUGHOUT THIS AND SEVERAL OTHER PIECES OF THE LOWER DOOR FRAME ASSY. THERE WERE A NUMBER OF HOLES DRILLED THAT D ID NOT HAVE PROPER EDGE DISTANCE SOME OF WHICH WERE AROUND THE 2 HOLES FOR THE MAIN CABIN DOOR BOTTOM RETAINING PINS. S UBMITTER STATED IT APPEARS THESE DEFICIENCIES WERE CAUSED DURING ORIG MANUFACTURE AS THERE IS NO EVIDENCE THIS AREA HAS BEEN REWORKED. THESE AREAS ARE NOW MANIFESTING THEMSELVES AS CRACKS. ACFT HAS 6,319 HRS TIME IN SERVICE AS OF 6-24-97. 1 L 7 2 4F A22CE 1997071700121 19970717 00121 CE 1997 7 17 97ZZZX3083 1 19970627 G 5320 551123937 CHANNEL CESSNA 500 500CESSNA 2076602 CE LOWER FRAME CRACKED G K NONE O OTHER IN INSP/MAINT 1 GL 15 58TC 6319 5000261 DURING INSPECTION, A REPAIR STATION DISCOVERED A CRACK IN THE LOWER DOOR FRAME. CLOSER INSP NOTED CRACK EMANATED FROM THE HOLES DRILLED FOR INSTALLATION OF A NUTPLATE (FOR THE DOOR STEP INSTALLATION, AFT ATTACH POINT). NOTED NUMEROUS CR ACKS THROUGHOUT THIS AND SEVERAL OTHER PIECES OF THE LOWER DOOR FRAME ASSY. THERE WERE A NUMBER OF HOLES DRILLED THAT D ID NOT HAVE PROPER EDGE DISTANCE SOME OF WHICH WERE AROUND THE 2 HOLES FOR THE MAIN CABIN DOOR BOTTOM RETAINING PINS. S UBMITTER STATED IT APPEARS THESE DEFICIENCIES WERE CAUSED DURING ORIG MANUFACTURE AS THERE IS NO EVIDENCE THIS AREA HAS BEEN REWORKED. THESE AREAS ARE NOW MANIFESTING THEMSELVES AS CRACKS. ACFT HAS 6,319 HRS TIME IN SERVICE AS OF 6-24-97. 1 L 7 2 4F A22CE 1997071700122 19970717 00122 CE 1997 7 17 97ZZZX3084 1 19970627 G 5320 551124913 STIFFENER CESSNA 500 500CESSNA 2076602 CE DOOR CRACKED G K NONE O OTHER IN INSP/MAINT 1 GL 15 58TC 6319 5000261 DURING INSPECTION, A REPAIR STATION DISCOVERED A CRACK IN THE LOWER DOOR FRAME. CLOSER INSP NOTED CRACK EMANATED FROM THE HOLES DRILLED FOR INSTALLATION OF A NUTPLATE (FOR THE DOOR STEP INSTALLATION, AFT ATTACH POINT). NOTED NUMEROUS CR ACKS THROUGHOUT THIS AND SEVERAL OTHER PIECES OF THE LOWER DOOR FRAME ASSY. THERE WERE A NUMBER OF HOLES DRILLED THAT D ID NOT HAVE PROPER EDGE DISTANCE SOME OF WHICH WERE AROUND THE 2 HOLES FOR THE MAIN CABIN DOOR BOTTOM RETAINING PINS. S UBMITTER STATED IT APPEARS THESE DEFICIENCIES WERE CAUSED DURING ORIG MANUFACTURE AS THERE IS NO EVIDENCE THIS AREA HAS BEEN REWORKED. THESE AREAS ARE NOW MANIFESTING THEMSELVES AS CRACKS. ACFT HAS 6,319 HRS TIME IN SERVICE AS OF 6-24-97. 1 L 7 2 4F A22CE 1997071700123 19970717 00123 CE 1997 7 17 97ZZZX3085 1 19970604 G 2810 TUBE LEAR 35 35A 5170602 CE TIP TANK MISINSTALLED B A NVIR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 71E 7598 306 WHILE PERFORMING INSPECTION OF TIP TANK FLAPPER VALVES PER AD 95-25-03, FOUND AFT INTERCONNECT TUBE SCARFED AT AN ANGLE NOT ALLOWING FLAPPER VALVE TO BE MOUNTED IN REQUIRED PERPENDICULAR POSITION. REMOVED TIP TANK, RE-PROFILED TUBE END TO ALLOW FOR PROPER ALIGNMENT OF FLAPPER. RE-INSTALLED TIP TANK, LEAK CHECKED, OPS CHECKED FLAPPER. RECORDS RESEARCHED BA CK TO THE 12-YEAR INSPECTION. NO RECORD FOUND OF TIP TANK REPAIR. SUBMITTER STATED POSSIBLY THIS SITUATION HAD EXISTED SINCE AIRCRAFT WAS NEW. 2 L 7 2 4F A10CE 1997071700124 19970717 00124 WP 1997 7 17 97ZZZX3086 2 19970224 G 7210 FITTING SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE3313U 01514 WP ENGINE GEARBOX STRIPPED E E ENGINE SHUTDOWN K FLUID LOSS CR CRUISE 1 SW 11 509SS 4021 TC206 P03297 WHILE IN CRUISE FLIGHT, PILOT NOTICED OIL LEAK ON RIGHT ENGINE. ENGINE SECURED AND UNEVENTFUL LANDING MADE. FURTHER IN VESTIGATION FOUND SCAVANGE OIL PUMP FITTING THREADS STRIPPED. ENGINE REMOVED AND SENT TO OUTSIDE MAINTENANCE FACILITY F OR REPAIR. 2 L 7 2 4T 4 T RT A8SW E4WE 1997071700126 19970717 00126 CE 1997 7 17 97ZZZX3088 2 19970521 G 7414 104001676 IMPULSE CAM MOONEY M20 M20K 5870220 SW CONT O360 TSIO360MB 17025 CE MAG CRACKED H S K NONE O OTHER IN INSP/MAINT 1 CE 07 252ZA 328 251072 279241R HEARD LOUD POP WHEN INSTALLING IMPULSE ASSEMBLY WHEN 15 POUNDS/FOOT OF TORQUE WAS REACHED. REMOVED AND FOUND INNER HUB OF IMPULSE CRACKED IN THREE PLACES. 1 L 7 1 3O 3 O 2A3 E9CE 1997071700127 19970717 00127 EA 1997 7 17 97ZZZX3089 2 19970603 G 7322 THROTLE BODY GULSTM AA5 AA5B 3960105 SO LYC O360 O360A4K 41514 EA ENGINE STUCK OPEN B NVIR K NONE O OTHER IN INSP/MAINT 1 SW 05 28339 AA5B0870 THROTTLE STUCK OPEN. GAINED ACCESS TO AIRCRAFT ENGINE THROTTLE BODY BY REMOVING RT AND LT TOP ENGINE COWLINGS AND LOWER ENGINE COWL. RAN THROTTLE THROUGH AND SAW THROTTLE ARM LOOSE AND SLIPPING ON CARBURETOR. REMOVED AND INSPECTED ARM SER RATIONS AND CARBURETOR SERRATIONS, NOTED NO DEFECTS. RE-INSTALLED ARM. DISCONNECTED THROTTLE CABLE ROD END AND LUBED T HROTTLE CABLE. RE-INSTALLED ROD END ON CABLE. 1 L 7 1 3O 3 O A16EA E286 1997071700128 19970717 00128 CE 1997 7 17 97ZZZX3090 1 19970617 G 2760 20544470 FILTER CESSNA 650 650 2076802 CE SPOILER VALVE FAILED B A GJQR K NONE O OTHER IN INSP/MAINT 1 NM 01 39WP 6024 650039 DURING SMIP INSPECTION OPERATION 10, ITEM 27-20, INSPECTION REVEALED FILTER SEPARATED FROM MOUNTING FLANGE IN THE END OF THE ELBOW FITTING PERMITTING FILTER TO SLIDE BACK AND FORTH WITHIN THE FITTING. SUBMITTER STATED THIS NEGATES FILTERIN G CAPABILITY. REPLACED ELBOW FILTER FITTING. THIS IS 3RD FITTING FOUND BROKEN OR FAILED DURING THE 1200-HOUR REMOVAL IN SPECTION. SUBMITTER RECOMMENDS IMPROVED FILTER ASSY OR A REPLACEMENT INTERVAL. 2 L 7 2 4F A9NM 1997071700129 19970717 00129 CE 1997 7 17 97ZZZX3091 1 19970625 G 2150 73838416 ACM CESSNA 441 441 2076020 CE FAN BLADES DAMAGED B HUNR K NONE O OTHER IN INSP/MAINT 1 NM 01 477B 4410055 ACTT 4,328.25 HOURS. BLADES FOUND DAMAGED, SOURCE UNKNOWN. APPLIANCE TTSN UNKNOWN. REPLACED ACM. 1 L 7 2 3T RT A28CE 1997071700130 19970717 00130 EA 1997 7 17 97ZZZX3092 2 19970625 G 7322 25244405 FUEL CONTROL BENDIX PIPER PA31T PA31T 7103124 SO PWA PT6 PT6A28 EA LT ENGINE FAILED D A E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 EA 21 707ML 2048 A41149 7520017 PS0761 ON THE 23RD OF JUNE, 1997 IN CRUISE FLIGHT, LEFT ENGINE WENT TO MAX POWER EXCEEDING TORQUE, TEMP, AND SPEED LIMITS. ENG INE WAS SHUT DOWN WITH THE FIREWALL SHUT OFF, PROPELLER FEATHERED, AND A DECLARED EMERGENCY LANDING MADE AT PHF WITHOUT ANY FURTHER PROBLEMS. UPON FURTHER INVESTIGATION, FOUND BEARINGS IN FUEL CONTROLLER INPUT SHAFT DETERIORATED CAUSING TH E SHAFT TO DISENGAGE CAUSING AN OUT OF CONTROL ENGINE RUNAWAY. 1 L 7 2 3T 4 T A8EA E4EA 1997071700131 19970717 00131 SO 1997 7 17 97ZZZX3093 2 19970613 G 7310 11141745032D HOSE STRATOFLEX AYRES S2 600S2DRESTD 0143012 SO CONT O520 IO520A 17032 SO ENGINE FUEL DEFECTIVE G A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SW 11 898LF 323 1113886A DURING A POST-ACCIDENT INSPECTION/DISASSEMBLY, A TSO'D HOSE ASSY FROM 'STRATOFLEX' WAS REMOVED FROM THE FUEL CONTROL TO THE FUEL INJECTION MANIFOLD. THIS HOSE WAS FOUND TO HAVE A SLIVER OF THE INNER WALL PROTRUDING BETWEEN THE INNER FERRUL E AND THE NUT AT THE MANIFOLD ORIFICE. THIS IS STRONGLY SUSPECTED AS THE CAUSE FOR LOSS OF ENGINE POWER IN-FLIGHT. THI S SEEMED TO BE AN INTERMITTENT PROBLEM IN THAT THE PILOT REPORTED THAT FUEL PRESSURE WAS ERRATIC DURING FLIGHT. HOSE IN FO: CD3Q92, OP3000 PSI, TSO C532, A1193, OT 250 DEGREES FAHRENHEIT. 1 L 7 1 3R 3 O A4SW E5CE 1997071700132 19970717 00132 CE 1997 7 17 97ZZZX3094 1 19970614 G 2120 DUCT CESSNA 182 TR182 2072735 CE AVIONICS COOLING DETERIORATED D K NONE O OTHER IN INSP/MAINT 1 NM 11 5153R R18200637 DURING AVIONICS INSTALLATION, AVIONICS COOLING DUCT FROM AIR INLET ON SIDE OF AIRCRAFT TO COOLING PANS ON LEFT AND RIGHT SIDE OF RADIOS WAS FOUND COMPLETELY DETERIORATED. THE BLACK FABRIC OF THE HOSE HAD ROTTED LEAVING STRIPS OF FABRIC HANG ING BEHIND PANEL. IT APPEARS THE AIRCRAFT WAS OPERATED NEAR SALT WATER CAUSING THE INTERIOR WIRE SUPPORTING THE HOSE TO RUST COMPLETELY THROUGH IN SEVERAL PLACES. THE RUSTED SPRING WIRE WAS FOUND RUBBING ON ELECTRICAL WIRES AND HOSES CAUS ING A HAZARD. 1 H 7 1 3O 3A13 1997071700133 19970717 00133 SO 1997 7 17 97ZZZX3095 2 19970612 G 8530 CYLINDER BEECH 36 A36 1151604 CE CONT O520 IO520BB 17032 SO NR 4 CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 05 361BC 1466 5498388 E1331 282253R INSPECTION FOUND NR 4 CYLINDER CRACKED. CRACK RUNS FROM EXHAUST. 1 L 7 1 3O 3 O 3A15 E5CE 1997071700134 19970717 00134 SO 1997 7 17 97ZZZX3096 1 19970625 G 8120 301E10 TURBOCHARGER ROTOMASTER PIPER PA34 PA34200 7103405 SO ENGINE BEARING FAILED D K NONE K FLUID LOSS IN INSP/MAINT 1 NM 11 42752 2950 129 347450172 A MINOR OIL LEAK WAS DISCOVERED COMING FROM THE TURBOCHARGER HOUSING. UPON INSPECTION, FOUND THE TURBO'S MAIN BEARINGS HAD GONE OUT CAUSING SLIGHT DAMAGE TO THE OIL SEAL. TURBO HAS BEEN REMOVED AND IS BEING REPLACED WITH A SERVICEABLE PAR T. 1 L 7 2 3O A7SO 1997071700135 19970717 00135 CE 1997 7 17 97ZZZX3097 1 19970622 G 2436 DGR3 CONTROL UNIT CESSNA 150 152 2071835 CE ALTERNATOR DEFECTIVE D K NONE P NO WARNING INDICATION IN INSP/MAINT 1 WP 23 5447P 15284948 CESSNA/LAMAR PN DGR3 IS SUPPOSED TO BE A SUITABLE SUBSTITUTE FOR C611005-0101. HOWEVER, WHEN INSTALLED, ENGINE OFF, BAT TERY/ALT SWITCH ON - LOW VOLTAGE LIGHT DOES NOT COME ON. SUSPECT DGR3 IS A SUBSTITUTE FOR ANOTHER CESSNA PN, NOT C61100 5-0101. 1 H 7 1 3O NT 3A19 1997071700136 19970717 00136 SO 1997 7 17 97ZZZX3098 1 19970624 G 2823 5226303 FUEL SELECTOR PIPER PA31 PA31350 7103110 SO CONTROL PANEL SHAFT BROKE D P A E ENGINE SHUTDOWN Y ENGINE STOPPAGE NR NOT REPORTED 1 AL 01 59829 14956 317652081 TOP END OF FUEL CONTROL ARM BROKE OFF WHERE HANDLE ATTACHES WITH ROLL PIN. HANDLE BROKE OFF DURING TANK SELECTION IN TH E OFF POSITION. RIGHT ENGINE QUIT AND WAS FEATHERED. TOP OF CONTROL ARM SHAFT HAD BEEN REPAIRED AND RE-DRILLED FOR ROL L PIN. FUEL CONTROL ARM SHOULD BE REPLACED ANY TIME THERE IS PLAY BETWEEN OPERATING HANDLE AND SHAFT. STEEL ROLL PIN W HICH ATTACHES HANDLE TO SHAFT WILL ELONGATE HOLE IN SHAFT. 1 L 7 2 3O A20SO 1997071700137 19970717 00137 EA 1997 7 17 97ZZZX3099 2 19970625 G 7322 THROTTLE ARM CESSNA 172 172L 2072432 CE LYC O360 O360A4M 41514 EA CARBURETOR JAMMED G K NONE O OTHER NR NOT REPORTED 1 GL 23 7031Q 17260331 MISALIGNMENT OF THE RIGGING OF THE THROTTLE ARM TO THE CARBURETOR (IN 1994) CAUSED THE THROTTLE ARM TO JAM PREVENTING TH E ENGINE FROM ACCELERATING. 1 H 7 1 3O 3 O NT 3A12 E286 1997071700138 19970717 00138 CE 1997 7 17 97ZZZX3100 1 19970625 G 3246 201302561 WHEEL CESSNA 172 172N 2072434 CE RT MLG CRACKED B CBCR K NONE O OTHER IN INSP/MAINT 1 NM 03 73764 3231 17267661 DURING A 100-HOUR INSPECTION, THE RT MAIN TIRE WAS BEING ROTATED. DURING INSPECTION OF MAIN WHEEL CENTER HUB, CRACKS WE RE DISCOVERED AT EACH BOLT HOLE (6) ON THE OUTBOARD SIDE OF WHEEL. ALSO, ON THE INBOARD SIDE 3 OF THE 6 HOLES SHOWED CR ACKS TOO. THIS AIRCRAFT IS USED FOR TRAINING PURPOSES. POSSIBLE CAUSE, REPEATED HARD LANDINGS. 1 H 7 1 3O NT 3A12 1997071700139 19970717 00139 CE 1997 7 17 97ZZZX3101 1 19970610 G 5210 05170194 HINGE CESSNA 172 172N 2072434 CE RT CABIN DOOR MISMANUFACTURED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 03 739NY 17270685 CABIN DOOR HINGE MANUFACTURED WITH DEFECT IN PIN BOSS. LOOKS AS IF WHEN DRILLING HOLE, BIT WAS ON A SLANT AND DID NOT D RILL THROUGH CENTER OF MATERIAL. DEFECT WAS NOT CAUGHT BY INSPECTION PERSONNEL. 1 H 7 1 3O NT 3A12 1997071700140 19970717 00140 NE 1997 7 17 97ZZZX3102 2 19970612 G 8520 CONNECT ROD DHAV DHC4 DHC4A 2800304 EA PWA R2000 R20007M2 52023 NE ENGINE FAILED H A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SW 99 800NC 96 98 P106788 ENGINE BROKE A CONNECTING ROD IN-FLIGHT. RETURNED TO BASE WITH 25 INCHES MANIFOLD PRESSURE. LANDED WITHOUT INCIDENT. E NGINE STILL RAN WITH BROKEN ROD AND DID NOT DESTROY ITSELF. 2 H 7 2 4R 4 R 1A19 5E5 1997071700141 19970717 00141 SW 1997 7 17 97ZZZX3103 1 19970625 G 5280 DOOR HINGE MOONEY M20 M20M 5870222 SW MLG RIVET SHEARED D A K NONE O OTHER NR NOT REPORTED 1 SW 99 72FG 270118 THE RIVETS HOLDING THE INNER STBD MAIN LANDING GEAR DOOR HINGE SHEARED CAUSING THE DOOR TO JAM AND PREVENTING FULL GEAR RETRACTION. GEAR EXTENSION WAS NOT AFFECTED. THE RIVETS WERE REPLACED AND THE BENT OPERATING RODS AND BELLCRANK. GEAR RETRACTION TESTS WERE CARRIED OUT. SUBMITTER RECOMMENDS CLOSE INSPECTION OF GEAR DOOR HINGE RIVETS AT ROUTINE MAINTENAN CE CHECKS. AIRCRAFT TOTAL TIME 714.6 HOURS. 1 L 7 1 30 RT 2A3 1997071700142 19970717 00142 WP 1997 7 17 97ZZZX3104 1 19970624 G 7922 53E19600 VALVE ROBSIN R22 R22ALPHA 7640104 WP THERMO BYPASS CRIMP NUT LOOSE D K NONE O OTHER IN INSP/MAINT 1 SW 13 8497Y 520 5998A 0408 DURING A00-HOUR INSPECTION OF OIL SCREEN, FOUND NUT ON END OF VERNATHERM THERMOSTATIC VALVE WAS LOOSE. ACCORDING TO LYC OMING SB 518C, THIS PART NUMBER AND SERIAL NUMBER ARE NOT REQUIRED TO HAVE THE INSPECTIONS LISTED TO DETERMINE IF THE NU T IS LOOSE. VALVE WAS RE-WORKED IAW LYC SI NR 1423 AND RE-INSTALLED IN ENGINE ON 6-24-97. 1 G 7 1 3O H10WE 1997071700631 19970717 00631 CE 1997 7 17 97ZZZX3148 1 19970626 G 2150 12502327 SWITCH CESSNA 208 208B 2073701 CE AIR CONDITIONER MISMANUFACTURED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 01 171 AIR CONDITIONER PRESSURE SWITCH NOT MACHINED ADEQUATELY TO ACCEPT THE SEALING O-RING. 1 H 7 1 3T A37CE 1997071700632 19970717 00632 GL 1997 7 17 97ZZZX3149 3 19970607 G 6114 D4035C30 HUB MCAULY 2A34C D2AF34C30 GL NR 2 SOCKET CRACKED B ME4R K NONE O OTHER IN INSP/MAINT 1 SO 19 1314 701310 PROPELLER WAS RECEIVED FOR ROUTINE OVERHAUL. AFTER DISASSEMBLY, HUB WAS FOUND CRACKED IN NR 2 BLADE SOCKET, 2 THREADS I N AT THE 6 O'CLOCK POSITION ABOUT 1.5 INCHES LONG. CRACK DISCOVERED USING A 10X POWER MICROSCOPE. 5 C P5EA 1997071700633 19970717 00633 CE 1997 7 17 97ZZZX3150 1 19970703 G 2822 1016 PUMP AIRBORNE BEECH 58 58P 1152744 CE BOOST LT ENGINE LEAK D K NONE K FLUID LOSS IN INSP/MAINT 1 SW 01 133Z 12E360 TJ367 INSPECTION OF LEFT FUEL BOOST PUMP REVEALED FUEL LEAKING FROM B PLUS INSULATOR. REF: BSL 1255 R1. PUMP WAS OVERHAULE D 3-91. 1 L 7 2 3O A23CE 1997071700636 19970717 00636 CE 1997 7 17 97ZZZX3153 1 19970613 G 2434 ALV9510 ALTERNATOR PRESTOLITE CESSNA 421 421 2076010 CE DC SYSTEM FAILED B EKIR K NONE O OTHER NR NOT REPORTED 1 WP 07 421Z 137 A11378L 4210077 ALTERNATOR FAILED AFTER 136.6 HOURS OF OPERATION. OVERHAULED 10-3-96. SUBMITTER STATED CONTINUE TO HAVE SHORT SERVICE LIFE ON THESE UNITS. 1 L 7 2 3O RT A7CE 1997071700637 19970717 00637 GL 1997 7 17 97ZZZX3154 3 19970702 G 6114 C6447C23 HUB BEECH 33 35C33 1151408 CE MCAULY 2A36C 2A36C23 GL NR 2 SOCKET CRACKED B ME4R K NONE K FLUID LOSS IN INSP/MAINT 1 SO 19 5908S 238 CD1026 7710546 PROPELLER RECEIVED FOR INSPECTION OF RED DYE OIL LEAK (SMALL). DISASSEMBLED PROPELLER, INSPECTED HUB WITH 10X POWER MIC ROSCOPE, FOUND CRACK IN NR 2 BLADE SOCKET, LAST THREAD IN 8 O'CLOCK POSITION, 1.50 INCHES TO 2 INCHES LONG. NOTE: THIS PROPELLER HAS TTSN UNKNOWN. TSO: 238.1 HOURS WITH 32 MONTHS SINCE LAST OVERHAUL. AD NOTE 89-26-08, OIL FILLING THIS PROPELLER PREVENTED A CATASTROPHIC FAILURE. 1 L 7 1 3O 3A15 5 C P880 1997071700638 19970717 00638 SO 1997 7 17 97ZZZX3155 1 19970630 G 5347 62557004 SEAT TRACK PIPER PA28 PA28150 7102804 SO CABIN CORRODED D K NONE O OTHER IN INSP/MAINT 1 NM 09 5071W 2880 ON AN ANNUAL INSPECTION, POWDER CORROSION WAS NOTED ON PASSENGER SIDE INBOARD SEAT TRACK, ON PEELING CARPET OFF, FOUND T HE SEAT TRACK WAS CORRODED TO REPLACEMENT. THREE OTHER SEAT TRACKS WERE ALSO BADLY CORRODED. IT WOULD BE WELL TO PEEL THE CARPET OFF SEAT TRACKS AND TREAT. 1 L 7 1 3O 2A13 1997071700639 19970717 00639 SO 1997 7 17 97ZZZX3156 1 19970419 G 3230 17SF41014 SPRING STOLAM RC3 RC3 3080202 SO GEAR DOWNLOCK DETACHED D O OTHER O OTHER LD LANDING 1 WP 21 6505K 771 OVERCENTER LOCKING SPRINGS, 2 EACH, ON INTERNAL LANDING GEAR CAME OFF ALLOWING OR CAUSING OVERCENTER LOCKING MECHANISM T O RELEASE ALLOWING LANDING GEAR TO ROTATE REARWARD TO UP POSITION. THIS OCCURRED DURING ROLLOUT FOLLOWING NORMAL LANDIN G. NO APPRECIABLE DAMAGE TO AIRCRAFT. SPRINGS SLIGHTLY DEFORMED. NEW SPRINGS INSTALLED, TESTED, AND ALL OK NOW. 1 H 7 1 3O A769 1997071700642 19970717 00642 SO 1997 7 17 97ZZZX3159 1 19970424 G 7820 66894003 MUFFLER PIPER PA28 PA28161 7102803 SO BAFFLES FAILED D L A K NONE O OTHER IN INSP/MAINT 1 NE 01 8234D 1017 288216027 FOLLOWING A REPORT THAT AIRCRAFT SOUNDED 'FUNNY' DURING APPROACH, INSPECTION FOUND EXHAUST FLAME TUBE FAILED AND WAS BLO CKING MUFFLER OUTLET. AIRCRAFT USED FOR FLIGHT SCHOOL RENTAL. 1 L 7 1 3O 2A13 1997071700643 19970717 00643 SW 1997 7 17 97ZZZX3160 1 19970617 G 7920 AN626410D16 OIL LINE TMPSON NAVION NAVION* 6150130 SW ENGINE OIL FAILED G K NONE O OTHER IN INSP/MAINT 1 SW 99 8551H NAV4535 OIL LINE FAILED AFTER ENGINE CHANGE. THE OIL COOLER LINES WERE NOT CHANGED. THE LINE APPEARED TO BE ORIGINAL, 50 YEARS OLD. 1 L 7 1 3O A782 1997071700644 19970717 00644 CE 1997 7 17 97ZZZX3161 1 19970703 G 2720 0025240205 PEDAL BEECH 95 95B55 1152729 CE PILOT LEFT WORN D S A K NONE O OTHER IN INSP/MAINT 1 SO 06 213CH 4378 TC2298 WHILE INSPECTING THE PILOT'S RUDDER PEDALS AT THE ANNUAL INSPECTION, THE PILOT'S PEDAL ARMS WERE FOUND WORN AT THE PEDAL TO ARM ATTACH PIVOT HOLES; .0625 INCH OF ARM WAS LEFT IN THE AREA AROUND THE BUSHING AT THE PIVOT POINT. SUBMITTER STA TED TIME ON AIRCRAFT, AND BOLTS NOT TIGHT ENOUGH, CONTRIBUTED TO THIS PROBLEM. CHECK FOR PLAY AT INSPECTIONS. 1 L 7 2 3O RT 3A16 1997071700645 19970717 00645 CE 1997 7 17 97ZZZX3162 1 19970703 G 2720 0025240206 PEDAL BEECH 95 95B55 1152729 CE PILOT RIGHT WORN D K NONE O OTHER IN INSP/MAINT 1 SO 06 213CH 4378 TC2298 WHILE INSPECTING THE PILOT'S RUDDER PEDALS AT THE ANNUAL INSPECTION, THE PILOT'S PEDAL ARMS WERE FOUND WORN AT THE PEDAL TO ARM ATTACH PIVOT HOLES; .0625 INCH OF ARM WAS LEFT IN THE AREA AROUND THE BUSHING AT THE PIVOT POINT. SUBMITTER STA TED TIME ON AIRCRAFT, AND BOLTS NOT TIGHT ENOUGH CONTRIBUTED TO THIS PROBLEM. CHECK FOR PLAY AT INSPECTIONS. 1 L 7 2 3O RT 3A16 1997071700646 19970717 00646 EA 1997 7 17 97ZZZX3163 2 19970630 G 8520 STUD PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA NR 3 CYLINDER FAILED B EKIR K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 WP 07 252MA 697 31P33 RL12762 FOUR CYLINDER ATTACH STUDS ON NR 3 CYLINDER FOUND BROKEN FOLLOWING ENGINE RUNNING ROUGH. FOUND NO EVIDENCE OF DETONATIO N ON TEAR DOWN. 1 L 7 2 3O 3 O A8EA E19EA 1997072200007 19970722 00007 SO 1997 7 22 97ZZZX3165 1 19970424 G 2913 PUMP PIPER PA31 PA31325 7103105 SO HYDRAULICS FAILED D L A K NONE O OTHER NR NOT REPORTED 1 NE 01 4039L 318112013 INVESTIGATION FOR DUAL HYDRAULIC PUMP FAILURE FOUND PUMPS RAN DRY DUE TO NO HYDRAULIC FLUID. SIGHT GAUGE USED FOR FLUID CHECK. IT IS BELIEVED FLUID CHECK WAS ERRONEOUS DUE TO STAIN ON GAUGE. GAVE INDICATION OF ADEQUATE FLUID WHEN ACTUALL Y FLUID WAS DEPLETED. 150 FLIGHT HOURS SINCE RESERVOIR SERVICED. 1 L 7 2 3O A20SO 1997071700649 19970717 00649 CE 1997 7 17 97ZZZX3166 1 19970708 G 7120 MOUNT BEECH 55 E55 1152732 CE ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 08 48CM TE985 THIS REPORT INVOLVES METAL FATIGUE AND SEVERE CRACKING ON BOTH ENGINE MOUNTS ON AN E-55 BEECHCRAFT BARON. LEFT ENGINE W AS REMOVED FOR REPLACEMENT WITH A FACTORY REMANUFACTURED IO520. LEFT MOUNT WAS FOUND CRACKED IN FOUR PLACES. SAME COND ITION EXPERIENCED ON RIGHT ENGINE EXCEPT CRACKS WERE MORE EXTENSIVE. BOTH MOUNTS WERE OVERHAULED WITH AN APPROVED KIT W ELDING PROCEDURE. THIS ACFT WAS INSPECTED BY THREE DIFFERENT INSPECTORS DURING THE PRE-PURCHASE INSPECTION AND WAS SUBS EQUENTLY INSPECTED DURING TWO ANNUAL INSPECTIONS AND NONE OF THE CRACKS WERE FOUND UNTIL THE ENGINES WERE REMOVED. TT A CFT AND ENGINES, 1,675 HOURS. 1 L 7 2 3O 3A16 1997071700650 19970717 00650 SO 1997 7 17 97ZZZX3167 1 19970627 G 8120 646396 TURBOCHARGER PIPER PA34 PA34200T 7103406 SO LT ENGINE SEAL FAILED B RG4R K NONE B K SMOKE/FUMES/ODORS/SPARKS FLUID LOSS IN INSP/MAINT 1 SO 03 5423F 33 347770018 TURBOCHARGER OIL SEAL FAILED BETWEEN FLIGHTS. ACFT PARKED, AND WAS RESTARTED 15 MINUTES AFTER SHUT DOWN. LEFT ENGINE W AS BLOWING BLUE SMOKE AND OIL WAS RUNNING OUT OF COWL. TURBOCHARGER SEAL FAILURE OCCURRED DURING START ON THE GROUND. 1 L 7 2 3O A7SO 1997071700651 19970717 00651 CE 1997 7 17 97ZZZX3168 1 19970326 G 3230 0842107497 DRAG BRACE CESSNA 310 310I 2074224 CE NLG FAILED D O OTHER J WARNING INDICATION LD LANDING 1 WP 21 8133M 310I0133 NOSE GEAR DRAG BRACE FAILED ON LANDING ROLL OUT. 1 L 7 2 3O 3A10 1997071700652 19970717 00652 SO 1997 7 17 97ZZZX3169 1 19970626 G 2434 ALX9425ECH ALTERNATOR PRESTOLITE PIPER PA34 PA34200T 7103406 SO SLIP RING DEFECTIVE E K NONE O OTHER IN INSP/MAINT 1 NM 01 8407C 109 A119339 347670137 AFTER ONLY 109 HOURS ON THE OVERHAULED ALTERNATOR, IT WOULD NOT FUNCTION PROPERLY (I.E., PARALLEL, SHARE THE LOAD, REMAI N ON-LINE). UPON REMOVAL OF THE BRUSHES, FOUND BURNED SLIP RINGS. UNIT REMOVED FOR WARRANTY CONSIDERATION AND 'NEW' EX HANGE UNIT INSTALLED. 1 L 7 2 3O A7SO 1997071700653 19970717 00653 EA 1997 7 17 97ZZZX3170 2 19970601 G 8550 S19515 DRAIN PLUG PIPER PA44 PA44180 7104402 SO LYC O360 O360A1H 41514 EA SEAL DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 SO 16 924ER 4496011 FOUND SEAL ON OIL SIDE OF DRAIN SWOLLEN CAUSING THE QUICK DRAIN TO OOZE AND NOT DRAIN PROPERLY. 1 L 7 2 3O 3 O A19S0 E286 1997071700654 19970717 00654 EA 1997 7 17 97ZZZX3171 2 19970601 G 8550 BJ1000AH4 DRAIN PLUG PIPER PA44 PA44180 7104402 SO LYC O360 O360A1H 41514 EA ENGINE OIL DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 SO 16 923ER 4496010 L3504136A DURING ROUTINE INSPECTION, FOUND OIL DRAIN O-RING NOT SEATED PROPERLY. 1 L 7 2 3O 3 O A19S0 E286 1997071700655 19970717 00655 CE 1997 7 17 97ZZZX3172 1 19970624 G 2913 73303 PUMP ADAPTER BEECH 80 65A80 1152808 CE HYDRAULIC PUMP CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 15 95LL LD235 THE HYDRAULIC PUMP ADAPTER CRACKS AND EVENTUALLY BREAKS AT THE ATTACH POINT TO ACCESSORY CASE. 1 L 7 2 3O 3A20 1997071700624 19970717 00624 1997 7 17 97ZZZX3173 2 19970618 G 7200 9125M65G07 LEVER ASSY BOEING 747 74745E 1384947 NM VSV STATOR STG 5 FAILED C A O OTHER J WARNING INDICATION CL CLIMB 1 SW 99 407EV 17865 27899 CAPTAIN REPORTED NR 3 ENGINE FAILURE ON INITIAL CLIMB AT 1,500 FEET AGL. POWER HAD JUST GONE FROM TAKEOFF THRUST TO CLI MB THRUST. LOUD EXPLOSIVE NOISE HEARD ACCOMPANIED BY HEAVY VIOLENT 'JOLT'. NO FURTHER VIBRATION AFTER ENGINE FAILURE. METAL CHIPS ARE NOTICED AT TAIL PIPE AREA. SEVERAL STAGE 5 VSV LEVER ARMS BROKEN. NO OBVIOUS SIGN OF FOD NOTICED. SU SPECT CAUSE MAY BE THE STAGE 5 LEVER ARMS. A FLEET WIDE ONE TIME INSPECTION WILL BE CARRIED OUT AS A RECOMMENDATION, AN D NOTICE AND REQUEST G.E. DOES FORMAL INVESTIGATION. ENGINE CYCLES: 1,202 (SINCE INSTALLED), 2,666 (TOTAL). 2 L 7 4 4F RT A20WE 1997071700627 19970717 00627 CE 1997 7 17 97ZZZX3174 1 19970624 G 3230 SUPPORT BRACKET CESSNA 650 650 2076802 CE NLG ACTUATOR FAILED D A O OTHER J WARNING INDICATION AP APPROACH 1 WP 07 652JM 4449 6500113 NOSE GEAR REMAINED IN UP POSITION WHEN GEAR SELECTED TO DOWN POSITION. EMERGENCY EXTENSION PERFORMED AND GEAR EXTENDED AND SHOWED GEAR SAFE LIGHTS. UNEVENTFUL LANDING AND TAXI TO RAMP. INSPECTION FOUND DAMAGED UPLOCK SUPPORT BRACKET. CI TATION 650 SB 650-53-15 REV 1 IS RECOMMENDED FOR ACFT SN'S 0001-0124. THIS INSTALLS IMPROVED SUPPORT BRACKET ASSY AND A LONG WITH SB 650-32-22 REV 2, AND SB 650-32-29 REV 2 IMPROVEMENTS TO UPLOCK HOOK ASSY AND UPLOCK SPRING. SUBMITTER STAT ED EACH AIRCRAFT IN THIS S/N RANGE SHOULD BE INSPECTED FOR ANY DEFECTS IN THIS AREA. 2 L 7 2 4F A9NM 1997071700628 19970717 00628 CE 1997 7 17 97ZZZX3175 1 19970608 G 2800 FUEL SYSTEM HELIO H295 HT295 4300803 CE ENGINE WATER CONTAM G A A UNSCHED LANDING Y ENGINE STOPPAGE CL CLIMB 1 WP 09 68874 1707 WATER CONTAMINATION OF FUEL SYSTEM RESULTED IN ENGINE STOPPAGE SHORTLY AFTER TAKEOFF RESULTING IN SUBSTANTIAL DAMAGE TO AIRCRAFT, IN OFF-FIELD LANDING LESS FAVORABLE TERRAIN MAY HAVE RESULTED IN SERIOUS OR FATAL INJURIES. DETERMINED THAT D UE TO NO MAIN FUEL TANK DRAINS OR ADEQUATE SUMP OR GASCOLATOR VOLUME, UNDRAINABLE WATER OR CONTAMINATION MAY EXIST IN AL L HELIO MODELS ESPECIALLY TRI-GEAR VERSIONS. SUBMITTER RECOMMENDS ADDING MAIN TANK DRAINS AND COLLECTOR SUMP OF ONE-HAL F GALLON OR MORE. THIS ALTERATION HAS BEEN COMPLETED ON THIS AIRCRAFT AND HAS PROVEN SUCCESSFUL. 1 H 7 1 3O 1A8 1997071700629 19970717 00629 WP 1997 7 17 97ZZZX3176 1 19970701 G 6322 29227 HUB 369D25630 HUGHES 369 369D 4470706 WP COOLER BLOWER SEPARATED G K NONE O OTHER IN INSP/MAINT 1 WP 07 DURING BUILD-UP, LOWER BEARING SLINGER RING LOCKED UP. USING TOOL TO PRESS OUT LOWER BEARINGS, THE ENTIRE RACE PRESSED OUT OF HUB. 1 G 7 1 3U H3WE 1997072400069 19970724 00069 NE 1997 7 24 97ZZZX3186 3 19970701 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 3613 2922NR HJ537 FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997072400070 19970724 00070 SO 1997 7 24 97ZZZX3187 2 19970630 G 8520 653136 CRANKSHAFT CONT O360 LTSIO360KB 17025 SO FILLET AREA CRACKED B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 3523 1786 B022MI 314329 THIS COMPONENT CAME OUT OF AN IN STOCK ENGINE. CRANKSHAFT FAILED UT INSPECTION PER TCM MHS-200. ALL 4 FILLET AREAS HAD INDICATIONS IN EXCESS OF 40 PERCENT FSH. 3 O E9CE 1997072400071 19970724 00071 NE 1997 7 24 97ZZZX3188 3 19970601 G 6111 AG100 BLADE HAMSTD 12D 12D40 NE PROP LE/TE MISREPAIR B NWOR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 732033 UNAUTHORIZED REPAIR TO LEADING AND TRAILING EDGES OF BLADES BY WELDING TO INCREASE CHORD. BLADE SN 732033 ALSO INCORPOR ATES STC'D BEARING MODIFICATION. BLADE REPAIR INDICATED BY NON-DESTRUCTIVE TESTING AND ANODIZATION PROCEDURE. 5 C P257 1997072400072 19970724 00072 NE 1997 7 24 97ZZZX3189 3 19970601 G 6111 AG100 BLADE HAMSTD 12D 12D40 NE PROP LE/TE MISREPAIR B NWOR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 764957 UNAUTHORIZED REPAIR TO LEADING AND TRAILING EDGES OF BLADES BY WELDING TO INCREASE CHORD. BLADE SN 732033 ALSO INCORPOR ATES STC'D BEARING MODIFICATION. BLADE REPAIR INDICATED BY NON-DESTRUCTIVE TESTING AND ANODIZATION PROCEDURE. 5 C P257 1997072400073 19970724 00073 GL 1997 7 24 97ZZZX3190 3 19970601 G 6114 HUB HARTZL HCC2Y HCC2YR4 GL NR 2 SOCKET CRACKED B S NWOR K NONE O OTHER IN INSP/MAINT 1 SW 05 DN1378 TOP HALF HUB, BLADE SOCKET NR 2 CRACKED AND SEPARATED FROM HUB EAR DIAGONALLY ACROSS CORNER OF HUB. DISCOVERED DUE TO G REASE LEAK, DISASSEMBLY. 5 C P920 1997072400074 19970724 00074 EA 1997 7 24 97ZZZX3191 2 19970623 G 7414 1052947 ROTOR S6LN200 PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA MAGNETO WORN B B2ER K NONE O OTHER IN INSP/MAINT 1 EA 23 510WA 720 C139602ER 277405436 RL676840 REMOVED MAGNETO FOR INSPECTION. FOUND ROTOR CRACKED NEAR MAGNET. HOUSING WALLS FOUND TO BE WORN. THERE ALSO WAS NO BE ARING, THE METAL FROM THE BEARING WAS INSIDE THE MAGNETO. 1 L 7 2 3O 3 O 1A10 1E4 1997072400075 19970724 00075 NE 1997 7 24 97ZZZX3192 2 19970706 G 8520 10992 LINK ROD SCWZER G164 G164B 3952802 EA PWA R1340 R134053 52016 NE NR 9 CYLINDER FAILED G O OTHER E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS AG AGRICULTURE 1 GL 15 6633K 637 400B 21637 DURING AERIAL APPLICATION OPERATIONS, NR 9 CYLINDER CONNECTING ROD FAILED AT MASTER ROD CONNECTION PIN. SEVERE IMPACT D AMAGE TO ROD. PISTON CONTACTED CYLINDER HEAD WHICH BROKE INTO 3 PIECES. CAUSE OF FAILURE UNKNOWN AT THIS TIME. 1 Q 7 1 3R 3 R 1A16 5E2 1997072400076 19970724 00076 EU 1997 7 24 97ZZZX3193 2 19970604 G 8520 887051 CRANKSHAFT AMTR KITFOX KITFOX 05613LZ GL ROTAX 582 ROTAX582 55555 EU PTO SIDE ROD FAILED C K NONE O OTHER NR NOT REPORTED 1 AL 01 85TA 110 HCU085 4171942 CRANKSHAFT CONNECTING ROD BEARING FAILED CAUSING PISTON CONNECTING ROD TO FAIL WHICH LOCKED ENGINE. ENGINE COOLANT AND EXHAUST TEMPERATURE NORMAL PRIOR TO FAILURE. OIL INJECTION PUMP CHECKED OUT SATISFACTORILY. 1 H 7 1 3I 3 I NC EXPA1H71 EXPE3I 1997072400077 19970724 00077 NE 1997 7 24 97ZZZX3194 3 19970702 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PROPELLER CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 4582 2422NR HJ377 PROPELLER INSPECTION FOUND FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997072400078 19970724 00078 CE 1997 7 24 97ZZZX3195 1 19970616 G 2730 50524410601 BELLCRANK BEECH 200 B200 1152922 CE ELEVATOR MISDRILLED B XE9R K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 07 1114K BB1559 FIRST PHASE INSPECTION FOUND SLACK IN HORIZONTAL CONTROL. LOCATED PLACE OF LOOSE CONNECTION FORWARD ELEVATOR BELLCRANK TO PUSH/PULL TUBE WAS MISDRILLED TO .3125 INCH; SUPPOSED TO BE .25 INCH. 1 L 7 2 4T A24CE 1997072400079 19970724 00079 NM 1997 7 24 97ZZZX3196 1 19970227 G 6322 B1741 FAN O320B2C ROBSIN R22 R22BETA NM ENGINE BLOWER CRACKED B BJDR K NONE O OTHER IN INSP/MAINT 1 GL 15 2311X 834 1972 ENGINE COOLING FAN HAD TOTAL TIME OF 833.7 HOURS. ROBINSON HAD NO REPAIR OR OVERHAUL FOR THIS PART. SUBMITTER STATED P ART SHOULD LAST AT LEAST 2,000 HOURS, THEN BE OVERHAULED. 1 G 7 1 3O H10WE 1997072400080 19970724 00080 EU 1997 7 24 97ZZZX3197 1 19970701 G 6500 22208BC060012L SCREW SNIAS 350 AS350B2 8680813 EU T/R DRIVE SHAFT DEFECTIVE B A RC0R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 17 4035W 400 2912 DURING C/W SB 05.08 PARA 1C(2A) WHEN REINSTALLING SCREW INTO BEARING SUPPORT MOUNT BRACKET, MECHANIC STATED THAT TORQUE DID NOT FEEL STABLE. REMOVED AND INSPECTED, FOUND NO OBVIOUS DEFECTS. REINSTALLED TORQUED NUT AND, AGAIN, DID NOT FEEL LIKE TORQUE STABILIZED. ATTEMPTED TO TORQUE TO MAXIMUM, TORQUE BOLT FAILED. EUROCOPTER AS350B2 PARTS MANUAL, SCREW, PN 22208BC060012C, ITEM 230, FIGURE 65.10.10, PG 3. 1 G 7 1 3U H9EU 1997072400081 19970724 00081 1997 7 24 97ZZZX3198 4 19970611 G 2312 RT5000 TRANSCEIVER SNIAS 350 AS350B2 8680813 EU SQUELCH CKT FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 09 4055L 1360 2916 AIRCRAFT TRANSCEIVER RT 5000 RECEIVED WITH BROKEN SQUELCH EVERY 4 SECONDS, NEVER RECEIVED. SN 1360 RT 5000 RECEIVED WIT H CONSTANT SQUELCH. BOTH ITEMS WERE SENT IN PRIOR FOR THESE DISCREPANCIES TO GLOBAL WOLFSBURG/BENDIX KING. 1 G 7 1 3U H9EU 1997072400082 19970724 00082 1997 7 24 97ZZZX3199 4 19970611 G 2312 RT5000 TRANSCEIVER SNIAS 350 AS350B2 8680813 EU SQUELCH CKT FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 09 4055L 1367 2916 AIRCRAFT TRANSCEIVER RT 5000 RECEIVED WITH BROKEN SQUELCH EVERY 4 SECONDS, NEVER RECEIVED. SN 1360 RT 5000 RECEIVED WIT H CONSTANT SQUELCH. BOTH ITEMS WERE SENT IN PRIOR FOR THESE DISCREPANCIES TO GLOBAL WOLFSBURG/BENDIX KING. 1 G 7 1 3U H9EU 1997072400083 19970724 00083 SW 1997 7 24 97ZZZX3200 1 19970701 G 3340 A402RW LENS HUGHES 500N 500N 3027374 SW STROBE CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 524FB 197 LN004 DURING MORNING WALK-AROUND, FORWARD LOWER STROBE LENS FOUND TO BE CRACKED ON SEAM. SECOND CRACK 2 INCHES DOWN PROCEEDIN G TO CLAMP AREA. 1 G 7 1 3U NC H3WE 1997072400084 19970724 00084 SW 1997 7 24 97ZZZX3201 1 19970403 G 6720 500N3139 MOUNT HUGHES 500N 500N 3027374 SW NOTAR FAN XMSN CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 522FB 5253 LN002 AFT TRANSMISSION MOUNT CRACKED FROM RIVET, OUTWARD THROUGH EXTRUSION WEB AT UPPER LEFT MOUNT, PN 500N3139, STA 137.50 B ULKHEAD. 1 G 7 1 3U NC H3WE 1997072400085 19970724 00085 SW 1997 7 24 97ZZZX3202 1 19970701 G 3340 A402RW LENS WHELEN HUGHES 500N 500N 3027374 SW STROBE CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 526FB 185 LN006 DURING DAILY WALK-AROUND, STROBE LENS FOUND CRACKED ALONG SEAM. 1 G 7 1 3U NC H3WE 1997072400086 19970724 00086 SW 1997 7 24 97ZZZX3203 1 19970531 G 2510 369H6512501 SEAT BELT HUGHES 500N 500N 3027374 SW COPILOT FAILED G K NONE O OTHER CR CRUISE 1 WP 07 527FB 211 LN007 SEAT BELT LOOSENS DURING FLIGHT. DOES NOT HOLD WHEN TIGHTENED. 1 G 7 1 3U NC H3WE 1997072400087 19970724 00087 SW 1997 7 24 97ZZZX3204 1 19970531 G 3340 A402RW LENS HUGHES 500N 500N 3027374 SW STROBE CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 527FB 50 LN007 FOUND AFT LOWER STROBE LENS CRACKED AND SEPARATED AT SEAM. 1 G 7 1 3U NC H3WE 1997072400088 19970724 00088 SW 1997 7 24 97ZZZX3205 1 19970531 G 2510 369H6512501 SEAT BELT HUGHES 500N 500N 3027374 SW PILOT FAULTY G K NONE O OTHER CR CRUISE 1 WP 07 527FB 211 LN007 SEAT BELT DOES NOT HOLD IN TIGHTEN MODE. ALLOWS BELT TO SLIDE LOOSE DURING FLIGHT. 1 G 7 1 3U NC H3WE 1997072400089 19970724 00089 NM 1997 7 24 97ZZZX3206 1 19970601 G 6210 A1561 BOOT A0162 ROBSIN R22 R22BETA NM M/R BLADE LEAK B A BJDR K NONE K FLUID LOSS IN INSP/MAINT 1 GL 15 8350M 31 9717C 2665 SHIP HAD A TOTAL TIME OF 30.5 HOURS. THE INNER BOOT CLAMP PN A165-1 DID NOT HAVE ENOUGH TORQUE TO PREVENT LEAKAGE OF TH E FLUID. THE MM DOES NOT HAVE A TORQUE FOR THIS CLAMP. A LOSS OF ENOUGH FLUID COULD CAUSE SERIOUS PROBLEMS (M/R OUT OF BALANCE, LACK OF LUBRICATION). 1 G 7 1 3O H10WE 1997072400091 19970724 00091 GL 1997 7 24 97ZZZX3208 1 19970516 G 6710 28161861 SOCKET ENSTRM F28 F28C 3300407 GL COLLECTIVE CRACKED D A A UNSCHED LANDING O OTHER HO HOVERING 1 EA 25 15SA 3093 469 AFTER GROUND RUN AND HOVER TO CHECK ENGINE PERFORMANCE, AIRCRAFT WAS LANDED AND COLLECTIVE WAS LOWERED TO SECURE FRICTIO N. MODERATE PRESSURE WAS APPLIED AND BEFORE FRICTION COULD BE SET, A BANG WAS HEARD. THE PILOT'S COLLECTIVE STICK DROP PED APPROXIMATELY 1 INCH. FURTHER INSPECTION, FOUND PILOT'S COLLECTIVE SOCKET HAD CRACKED ON AFT SIDE ABOVE BOLTS SECUR ING TO TORQUE TUBE. 1 G 7 1 3O H1CE 1997072400092 19970724 00092 SW 1997 7 24 97ZZZX3209 1 19970619 G 6720 22006B161416 BUSHING BELL 206 206L3 1182108 SW TAILBOOM CRACKED D A K NONE O OTHER IN INSP/MAINT 1 EA 13 173P 3129 51370 BUSHING CRACKED, THREE PLACES IN FLANGE. BUSHING IS LOCATED IN BELLCRANK SUPPORT AT THE AFT END OF THE TAILBOOM, AND IS PART OF THE TAIL ROTOR CONTROL SYSTEM. FAILED BUSHING IS THE UPPER OF TWO BUSHINGS LOCATED IN THE BELLCRANK SUPPORT. N O DAMAGE WAS FOUND IN THE SUPPORT ASSEMBLY. CRACK MAY HAVE BEEN CAUSED BY OVERTORQUING OF BELLCRANK BOLTS. AIRCRAFT WA S PREVIOUSLY INVOLVED IN INCIDENT IN WHICH TAILBOOM WAS DAMAGED, AND REBUILT. 1 G 7 1 3U H2SW 1997072400093 19970724 00093 WP 1997 7 24 97ZZZX3210 1 19970410 G 6710 C0561 SPRING ASSY ROBSIN R44 R44 7640120 WP CYCLIC TRIM WORN B A BJDR K NONE F FLT CONT AFFECTED NR NOT REPORTED 1 GL 15 244BF 288 C5811 0250 ARM C581-1 WAS BINDING AND WEARING INTO SHAFT. THIS CAUSED THE LATERAL SPRING ASSEMBLY TO LOCK MOMENTARILY. EXCESSIVE WEAR ON THE SPRING SHAFT COULD AFFECT THE FLIGHT CONTROLS AND AIRCRAFT CONTROL ABILITY. 1 G 7 1 3O H11NM 1997072400094 19970724 00094 WP 1997 7 24 97ZZZX3211 1 19970410 G 6320 C0455 SWITCH ROBSIN R44 R44 7640120 WP M/R GEARBOX FAILED B BJDR K NONE O OTHER IN INSP/MAINT 1 GL 15 244BF 288 0250 TEMPERATURE SWITCH MALFUNCTIONED FOR NO OBVIOUS REASON. CAUSED INTERMITTENT OVERTEMP LIGHT OF M/R GEARBOX. 1 G 7 1 3O H11NM 1997072400095 19970724 00095 NM 1997 7 24 97ZZZX3212 1 19970314 G 6322 B1741 FAN VANE ROBSIN R22 R22BETA NM ENGINE COOLING CRACKED B BJDR K NONE O OTHER IN INSP/MAINT 1 GL 15 40725 1085 1830 COOLING FAN HAD TOTAL TIME OF 1085.1 HOURS. VANES CRACKED AT WELDS. ROBINSON HAS NO REPAIR OR OVERHAUL FOR THIS PART. SUBMITTER STATES PART SHOULD BE REPAIRA BLE AND SHOULD LAST 2,000 HOURS AND THEN BE OVERHAULED. 1 G 7 1 3O H10WE 1997072400097 19970724 00097 NE 1997 7 24 97ZZZX3214 1 19970516 G 5511 7608020063051 SPAR SKRSKY S76 S76B 8143007 NE HORIZ STABILIZER DAMAGED B S8GR K NONE O OTHER IN INSP/MAINT 1 NE 03 76UT 533 A25300155 760443 INVESTIGATION REVEALED ARCING PIT (.1562 INCH BY .3437 INCH) DEPTH .041 INCH IN UPPER HORIZONTAL STABILIZER SPAR ON LEFT SIDE OF SPAR SUPPORT FITTING KEVLAR WRAP. LEFT UPPER HORIZONTAL SUPPORT FITTING SHIM REVEALED ARCING HOLE, SUPPORT FIT TING REVEALED NO APPRECIABLE DAMAGE FROM ARCING. ARCING WAS DUE TO POSITION LIGHTS POWER (28VDC) WIRE ATTACHED TO HORIZ ONTAL STABILIZER CONDUCTING THROUGH GRAPHITE AND WIRE MESH WRAPPING THROUGH THIN LAYER OF KEVLAR WRAPPING. MOISTURE INT RUSION OR SMALL IMPERFECTION IN KEVLAR WRAPPING ALLOWED CURRENT FLOW TO HORIZONTAL STABILIZER SUPPORT FITTING. 1 G 7 2 4U H1NE 1997072400098 19970724 00098 NE 1997 7 24 97ZZZX3215 1 19970507 G 3397 WIRE SKRSKY S76 S76B 8143007 NE POSITION LIGHT MISINSTALLED B S8GR K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 03 76UT 532 760443 POSITION LIGHT CIRCUIT BREAKER TRIPPED. INVESTIGATION REVEALED LT POSITION LIGHT POSITIVE WIRE (WIRE NR 15201J22) WAS CO NNECTED TO POSITION LIGHT GROUND WIRE SPLICE, AND GROUND WIRE (WIRE NR L5204B20) WAS CONNECTED TO POSITION LIGHT GROUND WIRE SPLICE, AND GROUND WIRE (WIRE NR L5202B20) WAS CONNECTED TO POSITION LIGHT POSITIVE WIRE SPLICE. POSITION LIGHT WI RES WERE RE-CORRECTED PER SIKORSKY WIRE PRINT NR 76552-1056. NO FURTHER WIRING PROBLEM EXISTS IN POSITION LIGHT SYSTEM. 1 G 7 2 4U H1NE 1997073100031 19970731 00031 WP 1997 7 31 97ZZZX3320 1 19970310 G 6310 V31001 SWITCH C0511 ROBSIN R44 R44 7640120 WP DRV BELT TENSION BROKE B BJDR K NONE O OTHER IN INSP/MAINT 1 GL 15 244BF 188 0250 ENGINE/TRANSMISSION COUPLING, VIBRATION OF ACTUATOR CAUSED ACTUATOR SPRINGS TO VIBRATE ON BOTH SWITCHES AND, THEREFORE, ONE BELT TENSION SWITCH TO BREAK. SWITCH BROKE IN CLOSED POSITION. SPRINGS TOO WEAK TO WITHSTAND VIBRATION. 1 G 7 1 3O H11NM 1997073100032 19970731 00032 WP 1997 7 31 97ZZZX3321 1 19970310 G 6310 B1151 BEARING ROBSIN R44 R44 7640120 WP ENG/XMSN ACTUATE WORN B BJDR K NONE O OTHER IN INSP/MAINT 1 GL 15 244BF 188 0250 ENG/TRANSMISSION COUPLING, LOWER BEARING OF ACTUATOR WHICH IS CONNECTED TO LOWER SHAFT AND BEARING ASSEMBLY WORE OUT. T HIS CAUSED THE ACTUATOR ASSEMBLY TO VIBRATE AND, THEREFORE, ONE BELT TENSION SWITCH TO BREAK. BEARING TOO WEAK TO HOLD UP TO THE PRESSURE AND VIBRATIONS. 1 G 7 1 3O H11NM 1997073100033 19970731 00033 CE 1997 7 31 97ZZZX3322 1 19970424 G 5711 169110000605 SPAR BENDIX BEECH 23 A23 1151204 CE WING CORRODED H K NONE O OTHER IN INSP/MAINT 1 NM 01 3579R 1950 M769 WING SPAR CORROSION DUE TO BONDING MATERIAL AND OUTDOOR ELEMENTS. TIED DOWN OUTSIDE FOR SEVERAL YEARS WITHOUT USE. 1 L 7 1 3O A1CE 1997073100034 19970731 00034 SO 1997 7 31 97ZZZX3323 1 19970626 G 2410 07A21443 BRACKET FORD DOFF10300J GULSTM AA5 AA5B 3960105 SO ALERNATOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 17 36ER 1428 AA5B0897 INSPECTION FOUND CRACKS AT AFT HOLE IN WHICH THE ALTERNATOR BRACKET MOUNTS TO ENGINE AND WHERE THE THROUGH-BOLT HOLDS AL TERNATOR TO ENGINE. SUBMITTER SUSPECTS CAUSE, INFERIOR DESIGN OR METAL TYPE. 1 L 7 1 3O A16EA 1997073100035 19970731 00035 CE 1997 7 31 97ZZZX3324 1 19970708 G 3710 242 PUMP AIRBORNE BEECH 36 A36 1151604 CE VACUUM SYSTEM FAILED E K NONE O OTHER NR NOT REPORTED 1 SW 05 361BC 270 13826 E1331 VACUUM PUMP FAILED. BOTH FILTERS CHANGED. REASON FOR FAILURE, UNKNOWN AT THIS TIME. 1 L 7 1 3O 3A15 1997073100036 19970731 00036 SO 1997 7 31 97ZZZX3325 1 19970626 G 2410 07A21443 BRACKET FORD DOFF10300J GULSTM AA5 AA5B 3960105 SO CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 15 3773N 1907 A80507 AA5B1229 INSPECTION FOUND ALTERNATOR BRACKET HAD CRACKS THAT WENT THROUGH THE THICKNESS OF THE BRACKET. SUSPECT CAUSE COULD BE H OW PROCESS OF BRACKET IS MADE OR THE TYPE OF METAL BEING USED. 1 L 7 1 3O A16EA 1997073100037 19970731 00037 SO 1997 7 31 97ZZZX3326 1 19970625 G 7110 COWLING PIPER PA32 PA32R300 7103213 SO ENG TOP COWL DEPARTED D A O OTHER D INFLIGHT SEPARATION NR NOT REPORTED 1 SW 99 4BR 4008 32R7780140 INSTRUCTED FLIGHT RETURNED TO HOME BASE WITH FRONT RIGHT CORNER OF COWL DISLODGED AT THE PIN LOCATION AND RAISED UP .50 INCH. UNIT WAS INSPECTED AND FIT OK. SIDE LATCHES WERE ADJUSTED TO TIGHTEN UP ATTACHMENT ON PINS. AIRCRAFT WAS FLOWN 250 MILES WITHOUT INCIDENT. UPON DEPARTURE FOR RETURN TRIP, COWLING PIN FAILED ALLOWING TOP COWL TO LEAVE AIRCRAFT. SU BSEQUENT DAMAGE WAS DONE TO RIGHT ELEVATOR. LEFT ONE-THIRD OF COWL WAS STILL ATTACHED TO AIRCRAFT BY SIDE LATCHES. LAN DING WAS SAFELY MADE AT AIRPORT WITHOUT FURTHER INCIDENT. 1 L 7 1 3O A3SO 1997073100038 19970731 00038 1997 7 31 97ZZZX3327 4 19970710 G 6113 075263717 BULKHEAD CESSNA 182 182R 2072731 CE SPINNER MOUNT FAILED D K NONE O OTHER NR NOT REPORTED 1 SO 13 5535N 1355 18267777 SPINNER BULKHEAD CRACKED BEWEEN BOLT HOLES AND SEPARATED CAUSING SPINNER TO WOBBLE. ACTION OF SPINNER CAUSED DAMAGE TO BOTH PROPELLER BLADES AT THE ROOTS, AND DAMAGE TO PROPELLER HUB, SPINNER AND BULKHEAD. SUBMITTER STATED CLOSE INSPECTIO N OF SPINNER BULKHEAD MOUNTING BOLT HOLES AT REGULAR INTERVALS MAY PREVENT SEPARATION AND FURTHER DAMAGE. 1 L 7 1 3O NT 3A13 1997073100040 19970731 00040 CE 1997 7 31 97ZZZX3329 1 19970421 G 3340 HDACF1428 POWER SUPPLY WHELEN BEECH 45 T34A 1152008 CE STROBE CONNECTOR FAULTY D K NONE O OTHER IN INSP/MAINT 1 NM 01 655K 5812093 DURING INSTALLATION OF WHELEN POWER SUPPLY PN HDA-CF-14/28 WHILE ATTEMPTING TO CONNECT STROBE HARNESS SOCKET AND JUMPER SOCKET, POWER SUPPLY SOCKET DISCONNECTED AND PUSHED INTO SUPPLY BOX. THIS OCCURRED TWICE WITH VERY MINIMUM FORCE BEING USED TO INSTALL CONNECTOR. THIS REQUIRES REMOVING COVER TO RE-ENGAGE POWER SUPPLY CONNECTOR. SUBMITTER SUGGESTS MANUFAC TURER WHELEN IMPROVE METHOD OF SECURING CONNECTOR SOCKET IN POWER SUPPLY UNIT. 1 L 7 1 3O 5A3 1997073100042 19970731 00042 SO 1997 7 31 97ZZZX3331 1 19970628 G 5711 082202 SPAR LUSCOM 8 8A 8190104 SO WING CORRODED H K NONE O OTHER IN INSP/MAINT 1 WP 07 71599 1511 3026 2.5 INCH BY 2.5 INCH AREA OF INTERGRANULAR CORROSION ON WING SPAR FOUND WHILE INSTALLING DLAHF S.R. NR 2 PRIOR TO ISSUAN CE OF AD 96-24-17. AD 96-24-17 ADEQUATELY DESCRIBED PROBLEM AND SOLUTION. SPAR REPLACED 6/97. 1 H 7 1 3O A694 1997073100043 19970731 00043 SW 1997 7 31 97ZZZX3332 1 19970601 G 5500 3500617 FITTING MOONEY M20 M20C 5870208 SW EMPENNAGE CORRODED D S K NONE O OTHER IN INSP/MAINT 1 EA 05 73DX 2868 SUPPORTING STRUCTURES AND ATTACHING RIVETS FOR EMPENNAGE ATTACH FITTINGS PN 350061-7, AND DASH 8, WITH SEVERE CORROSION. CORROSION IN THIS AREA DIFFICULT TO DETECT UNTIL EXTREMELY ADVANCED. NINETY PERCENT OF ATTACHING RIVETS FAILED DUE TO CORROSION. SUSPECT CAUSE: AIRCRAFT BASED IN PUERTO RICO FOR 22 YEARS. 1 L 7 1 3O 2A3 1997073100045 19970731 00045 SO 1997 7 31 97ZZZX3334 2 19970702 G 8530 643619 PISTON CESSNA 210 T210M 2073451 CE CONT O520 TSIO520R 17040 SO NR 1 ERODED G A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 SW 17 761FM 790 21062222 245658R SHORTLY AFTER TAKEOFF, PILOT LOST ENGINE POWER AND CRASH LANDED SHORT OF RUNWAY. POST-ACCIDENT INVESTIGATION REVEALED C YL NR 1 SHOWED SIGNS OF EXCESSIVE HEAT. UPON REMOVAL OF CYL ASSY, THE PISTON WAS FOUND SEVERELY ERODED AROUND MUCH OF T HE UPPER PERIMETER. THIS EROSION COMPETELY DESTROYED A SIGNIFICANT PORTION OF THE TOP AND SECOND PISTON RING GROOVES. T HE TOP OF THE PISTON AND THE COMBUSTION SIDE OF THE CYL HEAD SHOWED SIGNS OF SEVERE PITTING WHICH MAY HAVE BEEN CAUSED B Y PISTON AND PISTON RING FRAGMENTS. ADDITIONALLY, THE INTAKE VALVE WAS FOUND SEIZED IN THE OPEN POSITION. THIS FAILURE MAY HAVE BEEN CAUSED BY DETONATION. THE PISTON AND CYL WERE SENT TO THE MFG FOR FURTHER EVALUATION. 1 H 7 1 3O 3 O 3A21 E8CE 1997073100046 19970731 00046 CE 1997 7 31 97ZZZX3335 1 19970616 G 2721 26131013 TRIM SHAFT CESSNA 208 208B 2073701 CE RUD PEDAL BAR WORN D K NONE O OTHER IN INSP/MAINT 1 SW 15 771FE 208B0267 INSPECTION FINDING RUDDER TRIM NUT (SHAFT) WEARS OUT. VIBRATION AND PRESSURE ARE CONCENTRATED ON A SMALL AREA OF THIS P ARTICULAR PART AND THE PART BEING MADE OF SOFTER METAL WEARS OUT. 1 H 7 1 3T A37CE 1997073100047 19970731 00047 SO 1997 7 31 97ZZZX3336 1 19970702 G 2750 6267900 BRACKET PIPER PA32 PA32301 7103207 SO FLAP HANDLE FAILED D A K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 SW 11 82723 1946 328306002 FOUND AILERON CABLES HANGING UP. DISCOVERED RIGHT AILERON-RUDDER INTERCONNECT CLAMP CATCHING ON BROKEN BRACKET. SUSPEC T CAUSE, STEPPING ON FLAP HANDLE AND/OR EXCESSIVE FORCE APPLIED ON RETRACTION AND EXTENSION. LOCATION IS FORWARD ATTACH POINT FOR FLAP HANDLE. 1 L 7 1 3O A3SO 1997073100048 19970731 00048 EA 1997 7 31 97ZZZX3337 2 19970601 G 7310 LW120980100 LINE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA NR 2 CYL INJ CRACKED E L E A ENGINE SHUTDOWN UNSCHED LANDING E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CR CRUISE 1 SO 09 760SC 317785074 L827461A FUEL INJECTOR LINE LEAKING, CRACKED DURING CRUISE. CAUSE UNKNOWN, POSSIBLE VIBRATION. RECOMMENDATION: SUBMITTER SUGGE STED TO REVISE SB 342B PAGE 24 TO DELETE THE OPTIONAL CONSTRUCTION AND TO REQUIRE THAT THE LINE BE CLAMPED PER ITEMS 35, 36, 50, 58 OR INSTALLED AS THE PARTS MANUAL PC-315-5. 1 L 7 2 3O 3 O A20SO E14EA 1997073100049 19970731 00049 SW 1997 7 31 97ZZZX3338 1 19970701 G 5730 SKIN 160010 GULSTM 690TP 695A 7630519 SW LT WING STA 39L CORRODED B L VE2R K NONE O OTHER IN INSP/MAINT 1 SW 05 79PH 4976 96029 ACFT RETURNED FOR FUSELAGE INSP AND FINAL REPAIRS OF THE RT WING. DURING INSP, CORROSION FND IN THE LT WING IN SAME ARE A, WS 39, BOTTOM SIDE, FWD OF THE MAIN SPAR. EFFECTED PARTS, THE L/E SKIN, STR NR 6 INBD, AND 2 ANGLES FWD. EXTENT OF CORROSION REQUIRED THESE PARTS TO BE REPLACED. BOTH AREAS CONTAIN FUEL BLADDERS AND NO PROVISIONS FOR WEEP HOLES TO ALL OW TRAPPED MOISTURE TO ESCAPE. AFTER REMOVAL OF RT L/E SKIN, FURTHER INSP FOUND CORROSION ON RT WING, UPPER MAIN SPAR C AP, UPPER FACE OF FWD FLANGE. PREVIOUS MODELS HAVE CUSTOMER BULLETINS ADDRESSING CORROSION ON THE LOWER SPAR CAP. CORR OSION REMOVED AND REMAINING THICKNESS MEASURED BY NDT AND RESULTS WERE SUBMITTED TO GTEC, INC., FOR DISPOSTION. 1 H 7 2 4T 2A4 1997073100050 19970731 00050 SW 1997 7 31 97ZZZX3339 1 19970701 G 5730 SKIN GULSTM 690TP 695A 7630519 SW RT WING STA 39R CORRODED B L VE2R K NONE O OTHER IN INSP/MAINT 1 SW 05 79PH 4976 96029 ACFT RETURNED FOR FUSELAGE INSP AND FINAL REPAIRS OF THE RT WING. DURING INSP, CORROSION FND IN THE LT WING IN SAME ARE A, WS 39, BOTTOM SIDE, FWD OF THE MAIN SPAR. EFFECTED PARTS, THE L/E SKIN, STR NR 6 INBD, AND 2 ANGLES FWD. EXTENT OF CORROSION REQUIRED THESE PARTS TO BE REPLACED. BOTH AREAS CONTAIN FUEL BLADDERS AND NO PROVISIONS FOR WEEP HOLES TO ALL OW TRAPPED MOISTURE TO ESCAPE. AFTER REMOVAL OF RT L/E SKIN, FURTHER INSP FOUND CORROSION ON RT WING, UPPER MAIN SPAR C AP, UPPER FACE OF FWD FLANGE. PREVIOUS MODELS HAVE CUSTOMER BULLETINS ADDRESSING CORROSION ON THE LOWER SPAR CAP. CORR OSION REMOVED AND REMAINING THICKNESS MEASURED BY NDT AND RESULTS WERE SUBMITTED TO GTEC, INC., FOR DISPOSTION. 1 H 7 2 4T 2A4 1997073100127 19970731 00127 NM 1997 7 31 97ZZZX3346 1 19970707 G 3213 65650303 BOGIE BEAM BOEING 707 707320C 1383668 NM MLG CRACKED B VQ4R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 19 2648 THE MLG BOGIE BEAM WAS RECEIVED IN OVERHAULED CONDITION WITH TWO LARGE CRACKS AT THE TOW LUG. THE BEAM WAS SUBMITTED TO BOEING FOR A REPAIR PROCEDURE AAG-MIA-97-0133TR. 2 L 7 4 4F 4A26 1997073100128 19970731 00128 CE 1997 7 31 97ZZZX3347 1 19970702 G 2720 101630000601 TORQUE TUBE BEECH 200 200BEECH 1152920 CE RUDDER CORRODED D A K NONE O OTHER IN INSP/MAINT 1 SO 13 206P BB469 UPON REMOVAL OF THE RUDDER, A BIRD NEST AND WATER WAS FOUND INSIDE THE TORQUE TUBE CREATING A CORROSION PROBLEM INSIDE A T TORQUE TUBE. THERE IS NO DRAIN HOLE IN THE BELLCRANK OR TORQUE TUBE TO ALLOW WATER TO DRAIN FROM THE TUBE. 1 L 7 2 4T A24CE 1997073100129 19970731 00129 NM 1997 7 31 97ZZZX3348 1 19970703 G 5312 BULKHEAD BOEING 727 727251 138408H NM BS 1183 LBL 37 BEAM CRACKED B S EE4Y K NONE O OTHER IN INSP/MAINT 1 SO 23 259US 64341 2962 19978 THE CRACK WAS FOUND IN THE AFT BULKHEAD VERTICAL BEAM LBL 36.83 (LT/RT). THE SUSPECT CAUSE WAS THE RESULT OF FATIGUE TH AT WAS CAUSED BY PRESSURIZED FLIGHTS. SUBMITTER RECOMMENDATION: THERE SHOULD BE A LIMITED TIME TO INSTALL THE PREVENTI VE MODIFICATION PER SB B727-53-0192. 2 L 7 3 4F A3WE 1997073100130 19970731 00130 NM 1997 7 31 97ZZZX3349 1 19970703 G 5312 BULKHEAD BOEING 727 727251 138408H NM BS 1183 RBL 37 BEAM CRACKED B EE4Y K NONE O OTHER IN INSP/MAINT 1 SO 23 259US 64341 2962 19978 THE CRACK WAS FOUND IN THE AFT BULKHEAD VERTICAL BEAM LBL 36.83 (LT/RT). THE SUSPECT CAUSE WAS THE RESULT OF FATIGUE TH AT WAS CAUSED BY PRESSURIZED FLIGHTS. SUBMITTER RECOMMENDATION: THERE SHOULD BE A LIMITED TIME TO INSTALL THE PREVENTI VE MODIFICATION PER SB B727-53-0192. 2 L 7 3 4F A3WE 1997073100131 19970731 00131 NM 1997 7 31 97ZZZX3350 1 19970703 G 5312 BULKHEAD BOEING 727 727251 138408H NM BS 1183 LBL 26 CRACKED B S EE4Y K NONE O OTHER IN INSP/MAINT 1 SO 23 259US 19978 THE CRACK WAS FOUND IN THE AFT BULKHEAD VERTICAL BEAM LBL 26.83 WL 257.0. THE CRACK IS ATTRIBUTED TO PRESSURIZATION CYC LES. RECOMMENDATION: THE SB 53-0182 RECOMMENDED TO INSTALL THE PREVENTIVE MODIFICATION AT OR BEFORE 60,000 CYCLES. SU BMITTER RECOMMENDED THE PREVENTIVE MODIFICATION MUST BE INSTALLED AT OR BEFORE 45,000 CYCLES. 2 L 7 3 4F A3WE 1997073100133 19970731 00133 NE 1997 7 31 97ZZZX3352 2 19970706 G 7311 10585F EXCHANGER BEECH 300 300BEECH 1152930 CE PWA PT6 PT6A60A 52043 NE FUEL/OIL COOLER CRACKED B S XE9R E ENGINE SHUTDOWN J K WARNING INDICATION FLUID LOSS CL CLIMB 1 CE 07 642JL 6060 884 FA30 PCE95067 ON TAKEOFF, ENGINE LOST OIL PRESSURE. ENGINE SHUT DOWN AND NORMAL LANDING MADE. PROBLEM FOUND TO BE ONE LONG CRACK AT WELD ON SIDE OF HEAT EXCHANGER. SUSPECT FATIGUE OR AGE. 2 L 7 2 4T 4 T A24CE E4EA 1997073100134 19970731 00134 EU 1997 7 31 97ZZZX3353 1 19970708 G 2422 501123501 INVERTER BRAERO DH125 BAE125800A 1500285 EU NR 2 FAILED E O OTHER J WARNING INDICATION CL CLIMB 1 EA 25 801MB 1860 1107 258067 AFTER TAKEOFF, PILOT REPORTED NR 2 INVERTER FAIL LIGHT WITH CORRESPONDING NR 2 SSU (SIGNAL SUMMING UNIT) FAIL LIGHT AND NR 2 SSU CIRCUIT BREAKER TRIPPED. SUSPECT CAUSE: NR 2 INVERTER SPIKED BEFORE COMPLETE FAILURE CAUSING IT TO DAMAGE CIR CUITRY IN THE SSU UNIT. NR 2 INVERTER WAS REPLACED. NR 2 SSU UNIT WAS REPAIRED. 2 L 7 2 4F RT A3EU 1997073100135 19970731 00135 SO 1997 7 31 97ZZZX3354 1 19970623 G 2750 1159SCH2105 VALVE GULSTM G1159 G1159 3953505 SO FLAP CONTROL MISWIRED B A UO2R K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 19 902MP 454B 241 SOMETIMES FLAPS WOULD GO PAST THE DESIRED SETTING. PROBLEM WAS TRACED TO A STICKING FLAP CONTROL VALVE. ORDERED AND IN STALLED OVERHAULED FLAP CONTROL VALVE. WITH FLAP HANDLE 'UP', FLAPS EXTENDED. USED POWER SUPPLY TO CONTROL NEW VALVE. WHEN THE EXTEND COIL WAS POWERED, THE FLAPS RETRACTED. WHEN THE RETRACT COIL WAS POWERED, THE FLAPS EXTENDED. THE FLA PS MANUAL CONTROL WORKED NORMALLY. ORDERED AND INSTALLED ANOTHER FLAP CONTROL VALVE. THIS ONE WORKED NORMALLY. 2 L 7 2 4F RT A12EA 1997073100136 19970731 00136 NM 1997 7 31 97ZZZX3355 1 19970601 G 5313 STRINGER BOEING 727 727287 1384020 NM BS 1166 S29R CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 920PG 21688 DURING C-CHECK INSPECTION, LEVEL 2 CORROSION WAS NOTED ON S29R AT FS 1166. 2 L 7 3 4F RT A3WE 1997073100137 19970731 00137 NM 1997 7 31 97ZZZX3356 1 19970601 G 5330 SKIN BOEING 727 727287 1384020 NM BS 1070 S18L GOUGED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 920PG 21688 DURING C-CHECK INSPECTION, SEVERAL GOUGES WERE NOTED ON AIRCRAFT SKIN PANEL AT FS 1070L AT S18L. 2 L 7 3 4F RT A3WE 1997073100138 19970731 00138 NM 1997 7 31 97ZZZX3357 1 19970601 G 5315 FLOOR BEAM BOEING 727 727287 1384020 NM FS 1130 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 920PG 21688 DURING C-CHECK INSPECTION, FOUND LEVEL 2 CORROSION ON FLOOR BEAM LOWER CHORD AT FS 1130. 2 L 7 3 4F RT A3WE 1997073100427 19970731 00427 EU 1997 7 31 97ZZZX3376 1 19970708 G 6710 109011057105 ROD END 109011059105 AGUSTA A109 A109A2 0260120 EU M/R BLUE DISPLACED B KUVR A UNSCHED LANDING E VIBRATION/BUFFET NR NOT REPORTED 1 SO 19 8WH 707 432 7256 PILOT NOTICED UNUSUAL VERTICAL VIBRATION AND PRECAUTIONARY LANDING WAS MADE. FOUND BLUE M/R PITCH CHANGE LINK ROD END B EARING POPPED OUT OF ITS HOUSING CAUSING EXCESSIVE RADIAL PLAY. SUSPECT CAUSE, AGE AND/OR TIME ON PART. UNUSUAL WEAR N OT NOTICED ON PRE-FLIGHT INSPECTION. 1 G 7 2 3U H7EU 1997073100428 19970731 00428 NE 1997 7 31 97ZZZX3377 1 19970710 G 6320 643520536101 MAIN SHAFT 643520500048 SKRSKY S64 S64F NE MAIN GEARBOX CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 159AC 2852 984 18 64084 PART WAS MPI'D AND FOUND TO HAVE ONE CRACK INDICATION LOCATED AT THE UPPER END OF THE LOWER SPLINES. THE INDICATION EXT ENDS FROM THE SPLINE RADIUS AND GOES TOWARD THE TOOTH FACE AT APPROXIMATELY A 45 DEGREE ANGLE. LENGTH OF INDICATION IS APPROXIMATELY 0.050 INCH LONG. NO OTHER INDICATIONS WERE FOUND. 2 G 7 2 4U H6EA 1997073100429 19970731 00429 1997 7 31 97ZZZX3378 1 19970707 G 2620 01876296 CARTRIDGE KIDDE 89524001 FIREX CONTAINER MALFUNCTION D A K NONE O OTHER IN INSP/MAINT 1 SO 05 AEN220 CARTRIDGE FAILED TO BURST FIREX CONTAINER DISC ONCE FIRED. SUSPECT CAUSE: DURING OVERHAUL AND SERVICE OF CONTAINER, OX YGEN SYSTEMS OR THE AIRLINES (CANADIAN) REPLACED CARTRIDGE WITH ONE MANUFACTURED BY OVERLAND AVIATION. ALTHOUGH OVERLAN D AVIATION HAS FAA PMA, THEY DO NOT INCORPORATE LATEST DESIGN CHANGES BY CONTAINER DESIGNER AND MANUFACTURER, WALTER KID DE AEROSPACE. SUBMITTER RECOMMENDS ONLY MANUFACTURER'S APPROVED COMPONENTS SHOULD BE USED WHEN OVERHAULING OR SERVICING A FIREX CONTAINER. 1997073100430 19970731 00430 CE 1997 7 31 97ZZZX3379 1 19970703 G 3252 17430213 CYLINDER 17430203 CESSNA 177 177B 2073708 CE SHIMMY DAMPENER FAILED D K NONE O OTHER IN INSP/MAINT 1 NM 11 19974 2505 17702617 SHIMMY DAMPENER HOUSING FAILED DURING FLIGHT. UNIT FAILED AT THE OUTER PORTION OF OUTER RETAINING RING FLANGE. FAILURE WAS ON DOWN-WIND LEG AFTER A NORMAL TOUCH AND GO. SUBMITTER STATES OWNER MENTIONED SEVERAL YEARS AGO, TWO SEPARATE SEV ERE SHIMMY INSTANCES THAT COULD HAVE CREATED CRACKS. PRIOR TO FAILURE, UNIT WAS VISUALLY INSPECTED FOR LEAKS AND CHECKE D FULL STROKE FOR AIR IN SYSTEM. 1 H 7 1 3O A13CE 1997073100431 19970731 00431 EA 1997 7 31 97ZZZX3380 2 19970703 G 7310 38B0100006D0210 HOSE DEUTSCH CESSNA 177 177B 2073708 CE LYC O360 O360A1F 41514 EA FUEL PUMP LEAK D K NONE K FLUID LOSS IN INSP/MAINT 1 NM 11 19974 141 17702617 L2276836A DURING ANNUAL INSPECTION, FUEL WAS SHUT OFF FOR CLEANING CARBURETOR, DRAIN, AND GASCULATOR. UPON TURNING FUEL ON, FUEL LEAKED FROM HOSE IN A STEADY STREAM. HOSE WAS LOCATED ON LOW PRESSURE SIDE FEEDING ENGINE DRIVEN PUMP. HOSE WAS ALSO I N A LOCATION WHERE IT WAS NOT AGITATED BY THE PREVENTATIVE MAINTENANCE. SUBMITTER STATED THIS IS THE SECOND DEUTSCH HOS E FAILURE ON THIS AIRCRAFT WITH LOW TIME. 1 H 7 1 3O 3 O A13CE E286 1997073100432 19970731 00432 SO 1997 7 31 97ZZZX3381 1 19970707 G 5541 40039003 RIB PIPER PA31T PA31T1 7103126 SO RUDDER CORRODED B A RC2R K NONE O OTHER IN INSP/MAINT 1 NE 03 27BF 6432 31T8104038 DURING A 100-HOUR INSPECTION, A RIVET WAS FOUND MISSING ON THE BOTTOM OF THE RUDDER WHERE THE TORQUE TUBE IS RIVETED TO THE BOTTOM RIB. CLOSER INSPECTION REVEALED HOLE WAS CORRODED. DRILLED AND PEELED BACK SKIN. FOUND STEEL TORQUE TUBE RU STED AND BOTTOM RIB HEAVILY CORRODED. REMOVED AND REPLACED AFFECTED PARTS WITH NEW. SUBMITTER STATED PROBLEM COULD BE CAUSED BY PLUGGED DRAIN HOLES OR DISSIMILAR METALS. RECOMMEND CLOSE INSPECTION OF THIS AREA AND TO ENSURE DRAIN HOLES A RE CLEAR. 1 L 7 2 3T A8EA 1997073100433 19970731 00433 SO 1997 7 31 97ZZZX3382 1 19970707 G 2720 40040007 TORQUE TUBE PIPER PA31T PA31T1 7103126 SO RUDDER RUSTED B RC2R K NONE O OTHER IN INSP/MAINT 1 NE 03 27BF 6432 31T8104038 DURING A 100-HOUR INSPECTION, A RIVET WAS FOUND MISSING ON THE BOTTOM OF THE RUDDER WHERE THE TORQUE TUBE IS RIVETED TO THE BOTTOM RIB. CLOSER INSPECTION REVEALED HOLE WAS CORRODED. DRILLED AND PEELED BACK SKIN. FOUND STEEL TORQUE TUBE RU STED AND BOTTOM RIB HEAVILY CORRODED. REMOVED AND REPLACED AFFECTED PARTS WITH NEW. SUBMITTER STATED PROBLEM COULD BE CAUSED BY PLUGGED DRAIN HOLES OR DISSIMILAR METALS. RECOMMEND CLOSE INSPECTION OF THIS AREA AND TO ENSURE DRAIN HOLES A RE CLEAR. 1 L 7 2 3T A8EA 1997073100434 19970731 00434 CE 1997 7 31 97ZZZX3383 1 19970717 G 2571 VENT CESSNA 180 180K 2072624 CE BATTERY BOX PLUGGED D K NONE O OTHER IN INSP/MAINT 1 EA 05 2643K 1805023 AT ANNUAL INSPECTION, NOTICED CORROSION ON THE MAIN ELECTRICAL CONTACTOR AND THE STARTER RELAY. SUSPECT THE BATTERY WAS VENTING OUT BY THE CABLES. CHECKING THE BATERY BOX VENT, IT WAS FILLED WITH MUD DAUBER LARVA. THIS AIRCRAFT HAD ACCUM ULATED 36 HOURS SINCE THE LAST OVERHAUL. 1 H 7 1 3O 5A6 1997073100435 19970731 00435 CE 1997 7 31 97ZZZX3384 1 19970630 G 3243 MS2877132 O-RING PARKERHANFIN 30100 CESSNA 421 421B 2076014 CE LT BRAKE WORN D O OTHER K FLUID LOSS TX TAXI/GRND HDL 1 GL 05 41019 421B0401 LEFT BRAKE INOPERABLE CAUSING PILOT TO LOSE CONTROL AND STRIKE ANOTHER AIRCRAFT. INVESTIGATION FOUND NO FLUID IN BRAKE, CAUSED BY O-RINGS BEING OLD, WORN, AND HARD AND LEAKING. REPLACED O-RINGS AND SERVICED BRAKE SYSTEM. OPERATION WAS NO RMAL. 1 L 7 2 3O A7CE 1997073100436 19970731 00436 EU 1997 7 31 97ZZZX3385 1 19970711 G 2820 645471037842 SAFETY VALVE PILATS PC12 PC12 7090550 EU DIFF CONTROL DEFECTIVE B LF1R K NONE K FLUID LOSS IN INSP/MAINT 1 EA 07 62JT 1074 83B0013 107 PILATUS PN 959-90-91-131 SAFETY VALVE. DURING NORMAL CLEANING, NOTED THAT JET FUEL WAS COMING OUT OF THE DIFFERENTIAL C ONTROL VALVE ASSY PORTION OF THE SAFETY VALVE. CLOSER INVESTIGATION SHOWED SMALL BELLOWS AND POPPET VALVE UNSERVICEABLE . CAUSE - THE STATIC ATMOSPHERIC PRESSURE LINE IS OPEN TO ATMOSPHERE IN THE FUEL FILTER BAY, AND FUEL LEAKING OR REMAIN ING WOULD OR COULD END UP IN THE VALVE. 1 L 7 1 3T RT A78EU 1997073100438 19970731 00438 CE 1997 7 31 97ZZZX3387 1 19970718 G 2810 603890215 FUEL CELL BEECH 60 60 1153602 CE FUEL SYSTEM DETERIORATED D K NONE K FLUID LOSS IN INSP/MAINT 1 SW 17 713V 7714757 P16 FUEL CELL BEGAN LEAKING IN MARCH, 1994; WAS REMOVED AND SENT TO A/C FUEL CELLS WORLDWIDE, INC., FOR REPAIR. A/C CONDEMN ED CELL AND REBUILT CELL WAS PURCHASED FOR REPLACEMENT (WORK ORDER NR 9938, INSPECTED 4-18-94) IN APRIL, 1994. JUNE, 19 97, REPLACEMENT CELL REMOVED FOR LEAKS AND RETURNED TO A/C FUEL CELLS FOR WARRANTY REPAIR. WARRANTY REPAIR REFUSED, A/C CONDEMNED REPLACEMENT CELL. AIRCRAFT FUEL SYSTEM KEPT FULL AT ALL TIMES. REASON FOR DETERIORATION NOT KNOWN. 1 L 7 2 3O A12CE 1997073100439 19970731 00439 CE 1997 7 31 97ZZZX3388 1 19970718 G 2810 603890223 FUEL CELL BEECH 60 60 1153602 CE FUEL SYSTEM DETERIORATED D K NONE K FLUID LOSS IN INSP/MAINT 1 SW 17 713V 7862689N P16 FUEL CELL BEGAN LEAKING IN MARCH, 1994; WAS REMOVED AND SENT TO A/C FUEL CELLS WORLDWIDE, INC., FOR REPAIR. A/C CONDEMN ED CELL AND REBUILT CELL WAS PURCHASED FOR REPLACEMENT (WORK ORDER NR 9681, INSPECTED 4-12-94) IN APRIL, 1994. OCTOBER, 1996, REPLACEMENT CELL REMOVED FOR LEAKS AND RETURNED TO A/C FUEL CELLS FOR WARRANTY REPAIR. WARRANTY REPAIR REFUSED, A/C CONDEMNED REPLACEMENT CELL. AIRCRAFT FUEL SYSTEM KEPT FULL AT ALL TIMES. REASON FOR DETERIORATION NOT KNOWN. 1 L 7 2 3O A12CE 1997073100440 19970731 00440 SO 1997 7 31 97ZZZX3389 1 19970717 G 7820 FL099005705 MUFFLER GULSTM GA7 GA7 3960401 SO TAIL PIPE CRACKED D A K NONE O OTHER IN INSP/MAINT 1 WP 23 779GA 4300 GA7066 DURING ANNUAL INSPECTION, RIGHT EXHAUST MUFFLER WAS PRESSURIZED AND FOUND CRACKED AT TAIL PIPE OUTLET. A LARGE QUANTITY OF SOOT (EXHAUST GAS RESIDUE) WAS SEEN FLOWING OUT OF THE CRACK AND INTO THE DUCTING TO THE CABIN HEAT SYSTEM. THIS DE FECT HAD BEEN LEAKING FOR SOME TIME AND VERY DIFFICULT TO SEE DUE TO THE LOCATION, THE LT MUFFLER SHOWED SIMILAR DEFECTS . 1 L 7 2 3O A17SO 1997073100441 19970731 00441 CE 1997 7 31 97ZZZX3390 1 19970613 G 3211 24411001 PIVOT CESSNA 172 172RG 2072438 CE MLG SHEARED G O OTHER O OTHER AP APPROACH 1 GL 03 9851B 172RG PILOT NOTICED GEAR ON RIGHT SIDE HANGING DOWN DURING APPROACH TO LAND AIRCRAFT. AFTER SEVERAL TRIES, PLOT DECIDED TO LA ND GEAR UP. THERE WERE NO INJURIES, AND MINOR DAMAGE TO THE PROP AND BELLY OF AIRCRAFT. INSPECTION OF THE MAIN GEAR RE VEALED THE GEAR INSIDE THE PIVOT ASSEMBLY HAD SHEARED. THIS WAS SUSPECTED TO BE CAUSED BY HARD LANDINGS OR AIRCRAFT MIS USE. THIS IS A FLIGHT SCHOOL AIRCRAFT. 1 H 7 1 3O 3A17 1997080700252 19970807 00252 CE 1997 8 7 97ZZZX3399 1 19970717 G 2720 0024100343 TUBE BEECH 58 58 1152740 CE RUD INTERCONNECT CHAFED B A EHHR K NONE O OTHER IN INSP/MAINT 1 EA 17 1093G 207 TH1793 DURING 100-HOUR INSPECTION, FOUND RUDDER INTERCONNECT TUBE CHAFED THROUGH BY A FLOOR ATTACHMENT SCREW - TOO LONG OR WRON G LOCATION. SUBMITTER STATED HAVE FOUND SIMILAR DAMAGE ON OTHER AIRCRAFT. THIS TUBE HAS A THICK SIDE WALL AND HAS A 1. 50 INCH LONG ARCING CHAFE MARK WHICH CUTS THROUGH TUBE SIDE WALL. 1 L 7 2 3O 3A16 1997080700253 19970807 00253 EA 1997 8 7 97ZZZX3400 2 19970701 G 8540 STD2167 BOLT LW13797 BEECH 23 19A 1151214 CE LYC O320 O320E2C 41508 EA IDLER GEARSHAFT BROKEN D K NONE O OTHER IN INSP/MAINT 1 NM 10 16BD 5570 1613 MB456 L2612927A DURING ROUTINE INSPECTION TO C/W AD 96-09-10C (OIL PUMP IMPELLER INSP), THE ACCESSORY CASE WAS REMOVED FROM THE ENGINE. UPON INSP OF THE CRANKSHAFT IDLER GEARS, THE LT SIDE GEAR WOBBLED SIGNIFICANTLY. UPON REMOVAL OF THE IDLER GEAR, DETER MINED THE LOWER BOLT SECURING IDLER GEAR SHAFT MOUNT (PN LW-13797), HAD BROKEN AT THE INTERFACE BETWEEN THE SHAFT MOUNT AND THE CRANKCASE. THE THREADED PORTION OF THE BOLT WAS STILL IN THE CRANKCASE. THE BOLT HEAD AND SHANK COULD NOT BE L OCATED. THIS CAUSED THE IDLER GEARSHAFT TO MOVE AND WORK ON THE ALUMINUM CRANKCASE CREATING AN ENLARGED OPENING THROUGH WHICH OIL PASSES TO LUBRICATE THE IDLER GEAR. SUBMITTER STATED CAUSE OF FAILURE MAY BE IMPROPER TORQUE OF THE BOLT. 1 L 7 1 3O 3 O A1CE E274 1997080700254 19970807 00254 CE 1997 8 7 97ZZZX3401 1 19970714 G 2750 50250052 BELLCRANK CESSNA 310 310Q 2074242 CE RT FLAP BROKEN B S EIYR K NONE O OTHER IN INSP/MAINT 1 WP 07 20SS 310Q0521 PILOT REPORTED LOOSENESS IN RIGHT, INBOARD FLAP DURING PRE-FLIGHT. INSPECTION REVEALED INBOARD BELLCRANK ARMS, 2 EACH, BROKEN LOOSE FROM ASSY. SUBMITTER RECOMMENDS THOROUGH INSPECTION OF FLAP CONTROL SYSTEM DURING ANNUAL INSPECTION. 1 L 7 2 3O 3A10 1997080700255 19970807 00255 CE 1997 8 7 97ZZZX3402 1 19970601 G 2823 HE7805 SELECTOR VALVE BEECH 95 95B55 1152729 CE FUEL SYSTEM LEAK B H8AR K NONE W K INADEQUATE Q C FLUID LOSS IN INSP/MAINT 1 EA 05 2018Q TC2165 FUEL VALVE BEGAN LEAKING 24 HOURS AFTER INSTALLATION FROM NEW. 1 L 7 2 3O RT 3A16 1997080700256 19970807 00256 CE 1997 8 7 97ZZZX3403 1 19970601 G 2823 HE7805 SELECTOR VALVE BEECH 95 95B55 1152729 CE FUEL SYSTEM LEAK B H8AR K NONE W K INADEQUATE Q C FLUID LOSS IN INSP/MAINT 1 EA 05 2018Q A97060097 TC2165 THIS VALVE INSTALLED TO REPLACE 2 OTHER PREVIOUS VALVES INSTALLED AS NEW THAT FAILED A SHORT TIME AFTER INSTALLATION. 1 L 7 2 3O RT 3A16 1997080700257 19970807 00257 CE 1997 8 7 97ZZZX3404 1 19970601 G 2823 HE7805 SELECTOR VALVE BEECH 95 95B55 1152729 CE FUEL SYSTEM LEAK B A H8AR K NONE K FLUID LOSS IN INSP/MAINT 1 EA 05 2018Q 3 A97040073 TC2165 FUEL VALVE INSTALLED TO REPLACE DEFECTIVE NEW FUEL VALVE WITH ONLY 24 HOURS TIME. THIS VALVE BEGAN TO LEAK WITH 25 HOUR S TIME IN SERVICE. 1 L 7 2 3O RT 3A16 1997080700258 19970807 00258 CE 1997 8 7 97ZZZX3405 1 19970601 G 5711 17107036 SPAR CESSNA 177 177B 2073708 CE CARRY THROUGH CORRODED D K NONE O OTHER IN INSP/MAINT 1 NM 01 35090 2897 17702201 FOUND ON ANNUAL INSPECTION, INTERGRANULAR CORROSION ON CARRY-THROUGH SPAR. SOME SPOTS 2 INCHES AND .0625 INCH DEEP, PLU S OTHER CORROSION. SUBMITTER STATED THIS IS HARD TO SEE WITHOUT REMOVING HEADLINER. 1 H 7 1 3O A13CE 1997080700259 19970807 00259 CE 1997 8 7 97ZZZX3406 1 19970624 G 3230 ADNE4JW ROD END CESSNA 402 402C 207590R CE NLG BEARING FAILED A A GULC O OTHER O OTHER LD LANDING 1 NE 01 401BK 3500 402C0297 NOSE GEAR COLLAPSED UPON LANDING. THE NOSE GEAR ROD END BEARING SEPARATED FROM HOUSING ALLOWING NOSE GEAR TO BECOME SEP ARATED FROM NOSE GEAR ACTUATOR. THIS ALLOWED ACTUATOR TO FULLY EXTEND AND GIVE THE PILOT THE APPEARANCE OF 3 GREEN, DOW N, AND LOCKED, BUT, ACTUALLY, THE NOSE GEAR WAS NO LONGER CONNECTED TO THE NOSE GEAR ACTUATOR. THE BEARING ITSELF WAS S TILL CONNECTED TO THE NOSE GEAR. SUSPECT CAUSE, NO REQUIREMENT TO 'TIME CHANGE' THESE ITEMS. SUBMITTER STATED THESE AR E OPERATED TO 'FAILURE' ITEMS. THEY SHOULD BE TIME CHANGED OR ROUTINELY DYE PENETRANT INSPECTED. HAVE CONTACTED THE AC O IN WICHITA. AC E-117W. SEE AD 84-20-02. 1 L 7 2 3O A7CE 1997080700261 19970807 00261 NE 1997 8 7 97ZZZX3408 2 19970717 G 7310 AE7010000H1700 HOSE AEROQUIP CNDAIR CL600 CL6002A12 1900304 EA GE CF34 CF341A NE LT PYLON RUPTURED D A K NONE K FLUID LOSS NR NOT REPORTED 1 SW 05 601TX 3005 THE MOTIVE FLOW FUEL LINE THAT RUNS FROM THE LEFT WHEELWELL TO THE LEFT PYLON RUPTURED CAUSING FUEL TO VENT OVERBOARD. T HE FUEL THAT VENTED OVERBOARD THEN MIGRATED AFT INTO THE TAIL CONE AREA CREATING A POTENTIAL HAZARD. 2 L 7 2 4F 4 F RT A21EA E15NE 1997080700262 19970807 00262 CE 1997 8 7 97ZZZX3409 1 19970709 G 7120 05131324 MOUNT CESSNA 175 175 2072502 CE UPPER RT FAILED D A K NONE O OTHER IN INSP/MAINT 1 SO 07 7151M 55451 ACFT OWNER REPORTED THE COWL DID NOT FIT RIGHT. UPON EXAMINATION, DETERMINED THE RT STRINGER ASSY, ENGINE MOUNT UPPER, HAD FAILED AT THE POINT WHERE THE UPPER RT ENGINE MOUNT BOLT PASSES THROUGH THE MOUNTING BRACKET. THE FIREWALL ATTACH R IVETS HAD RIPPED OUT FOR ABOUT 3 INCHES IN EACH DIRECTION ALLOWING WEIGHT OF ENGINE TO PULLTHE FIREWALL OUT ABOUT O.50 I NCH DISPLACING THE COWL WHICH IS ATTACHED TO THE ENGINE MOUNT. EXAMINATION OF THE LT STRINGER ASSY, ENG MOUNT UPPER, RE VEALED THAT THAT PART HAD CRACKED AND WAS AT NEAR FAILURE. THE ENGINE MOUNTING WAS VERY NEAR FAILURE. NEW PARTS WILL B E INSTALLED AND ACFT RETURNED TO SERVICE. 1 H 7 1 3O NT 3A17 1997080700263 19970807 00263 CE 1997 8 7 97ZZZX3410 1 19970709 G 7120 05131323 MOUNT CESSNA 175 175 2072502 CE LT UPPER CRACKED D A K NONE O OTHER IN INSP/MAINT 1 SO 07 7151M 55451 ACFT OWNER REPORTED THE COWL DID NOT FIT RIGHT. UPON EXAMINATION, DETERMINED THE RT STRINGER ASSY, ENGINE MOUNT UPPER, HAD FAILED AT THE POINT WHERE THE UPPER RT ENGINE MOUNT BOLT PASSES THROUGH THE MOUNTING BRACKET. THE FIREWALL ATTACH R IVETS HAD RIPPED OUT FOR ABOUT 3 INCHES IN EACH DIRECTION ALLOWING WEIGHT OF ENGINE TO PULLTHE FIREWALL OUT ABOUT O.50 I NCH DISPLACING THE COWL WHICH IS ATTACHED TO THE ENGINE MOUNT. EXAMINATION OF THE LT STRINGER ASSY, ENG MOUNT UPPER, RE VEALED THAT THAT PART HAD CRACKED AND WAS AT NEAR FAILURE. THE ENGINE MOUNTING WAS VERY NEAR FAILURE. NEW PARTS WILL B E INSTALLED AND ACFT RETURNED TO SERVICE. 1 H 7 1 3O NT 3A17 1997080700264 19970807 00264 NE 1997 8 7 97ZZZX3411 2 19970716 G 8550 CH48103 FILTER CHAMPION MAULE M6 M6235 5460160 SO LYC O540 IO540W1A5 41532 NE ENGINE OIL LEAKS D K NONE K FLUID LOSS IN INSP/MAINT 1 NM 11 91AR 35 7446C L2226848A OIL FILTER WAS INSTALLED ON 6-28-97. NOTED AT THE TIME THAT THE LOCKING TAB WAS NEARLY FLAT AGAINST THE BOWL OF THE CAN NISTER, SUCH THAT THE TAB HAD TO BE BENT SLIGHTLY TO ADMIT .032 INCH SAFETY WIRE. NO LEAKS WERE FOUND AFTER A GROUND RU N-UP. AFTER 3 HOURS OF SERVICE, THE FILTER DEVELOPED A LEAK AROUND THE BASE OF THE LOCKING TABS CAUSING A LOSS OF 1 QUA RT IN A 20 MINUTE FLIGHT ON 7-14-97. INSPECTION OF THE FILTER CASE REVEALS CRACKS AT THE SITE OF EACH OF THE 4 SPOT WE LDS WHICH ATTACH THE LOCKING TABS. 1 H 7 1 3O 3 O 3A23 1E4 1997080700265 19970807 00265 GL 1997 8 7 97ZZZX3412 3 19970717 G 6111 M10083K BLADE CESSNA 208 208 2073702 CE HARTZL H3B3M HCB3M GL STA 24 DAMAGED D P K NONE O OTHER IN INSP/MAINT 1 AL 01 192AV 9281A 20800215 G13137 PROPELLER DE-ICE BOOT BURNED OUT AND DAMAGED PROPELLER BLADE AT STA 24. SUBMITTER STATES A POSSIBLE CAUSE, ROCK NICK ON BOOT. 1 H 7 1 3T NT A37CE 5 C P9NE 1997080700266 19970807 00266 GL 1997 8 7 97ZZZX3413 3 19970724 G 6114 HUB PIPER PA46 PA46310P 7104605 SO HARTZL HCC2Y BHCC2YF1 GL BLADE CLAMP CRACKED B LF1R K NONE O OTHER IN INSP/MAINT 1 EA 07 2604X AM2737 PROPELLER WAS OVERHAULED DURING ANNUAL AND WAS FOUND TO HAVE A CRACK IN HUB. CRACK WAS LOCATED AROUND BLADE CLAMP AREA OF HUB AT BOLT HOLE. PROPELLER HAD NOT BEEN OVERHAULED SINCE 1989 (993.0 TSOH). SUBMITTER HIGHLY RECOMMENDS THE PROPEL LER BE OVERHAULED EVERY 5 YEARS PER MANUFACTURER. HARTZELL AD 77-12-06 COMPLIANCE IS NOW 12,000 HOURS WHICH MOST PROPS WILL NEVER REACH. 1 L 7 1 3O A25SO 5 C P920 1997080700267 19970807 00267 GL 1997 8 7 97ZZZX3414 3 19970715 G 6111 BLADE SLNSBY T67 T67M260 8323006 EU HOFMAN HOV123 HOV123KV GL PROPELLER LOOSE D A UNSCHED LANDING E VIBRATION/BUFFET AB AEROBATIC 1 SW 17 3037C 871 2134 B696 AFTER AEROBATICS, EXCESSIVE NOSE/PROPELLER VIBRATION WAS FELT, VERY ROUGH AND LOW AIRSPEED. ACFT LANDED SAFELY. FOUND NR 1 PROPELLER BLADE HAD EXCESSIVE PLAY. REMOVED AND REPLACED THE PROPELLER. PROPELLER WAS SENT TO MANUFACTURER FOR IN SPECTION AND REPAIR. 1 L 7 1 3O NT A73EU 5 C P5EU2 1997080700268 19970807 00268 EA 1997 8 7 97ZZZX3415 2 19970623 G 8530 7224Z ROCKER BOX TAB PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA COVER WORN B APCR K NONE O OTHER IN INSP/MAINT 1 NM 01 3582X 180 318052105 L421361A ROCKER PIN RETAINING TAB ON COVER WORN EXCESSIVELY. THIS ENGINE HAS 180 HOURS TSOH! 1 L 7 2 3O 3 O A20SO E14EA 1997080700269 19970807 00269 SO 1997 8 7 97ZZZX3416 1 19970722 G 5280 4752932 HINGE PIPER PA31 PA31350 7103110 SO RT MLG DOOR BROKEN D O OTHER J WARNING INDICATION AP APPROACH 1 AL 01 45052 318152063 GEAR WOULD NOT EXTEND, GREEN LIGHTS FOR LT MLG AND NLG. RED INTRANSIT LIGHT STAYED ON. CYCLED GEAR UNTIL 3 GREEN. LAN DED, FOUND FORWARD HINGE ON RT INNER GEAR DOOR BROKEN. PART NUMBER IS IMPROVED VERSION THAT TERMINATES REPETITIVE AD. 1 L 7 2 3O A20SO 1997080700270 19970807 00270 SO 1997 8 7 97ZZZX3417 1 19970721 G 2913 HYC5005 POWER PACK PRESTOLITE PIPER PA32 PA32R300 7103213 SO MLG HYD FAILED D O OTHER J WARNING INDICATION AP APPROACH 1 SO 09 47423 3521 32R7880006 LANDING GEAR ONLY PARTIALLY EXTENDED WITH NOSE AND RT MAIN LOCKED, BUT LT MAIN UNLOCKED, CIRCUIT BREAKER KEPT TRIPPING N OT ALLOWING LT MAIN TO EXTEND FULLY. EMERGENCY EXTENSION WAS ATTEMPTED (FREEFALL), BUT NO HELP. LANDING WAS MADE ON GR ASS STRIP WITH MINIMAL DAMAGE. POWER PACK REMOVED FOR OVERHAUL AND REINSTALLED. GEAR OPERATION WAS GOOD IN NORMAL AND EMERGENCY MODES. 1 L 7 1 3O A3SO 1997080700271 19970807 00271 GL 1997 8 7 97ZZZX3418 3 19970623 G 6111 BLADE CESSNA 150 152 2071835 CE MCAULY 1A103 1A103TCM GL BOLT HOLE CRACKED B PI4R K NONE O OTHER IN INSP/MAINT 1 SO 07 5139B 6964 3464 15283771 R773437 CRACKED ON NR 1 BLADE SIDE AT TOP, NEXT TO HOLE, APPROXIMATELY .50 INCH LONG. FOUND DURING INSPECTION REQUIRED BY AD 97 -06-16 AND SB 221B, 1 H 7 1 3O NT 3A19 5 N P50GL 1997080700272 19970807 00272 SO 1997 8 7 97ZZZX3419 2 19970721 G 8530 532129 VALVE BEECH 58 58P 1152744 CE CONT O520 TSIO520WB 17040 SO ENGINE INTAKE WRONG PART B L XA14 K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 17 68BB 177 TJ317 274344R DURING AN ANNUAL INSPECTION, FOUND LEAKING EXHAUST VALVES ON NR 2, NR 4, AND NR 6 CYLINDERS, ON LT ENGINE. SINCE TOTAL TIME OF THIS ENGINE WAS ONLY 177.3 HOURS SINCE REBUILT, THE CUSTOMER DECIDED TO REMOVE ALL CYL'S FOR INSP AND/OR REPAIR. CYL'S DISASSEMBLED, 2 INTAKE VALVES WERE TCM PN 532129. ACCORDING TO RESEARCH, THESE INTAKE VALVES ARE NOT PROPER P/N FOR THIS MODEL ENGINE. OTHER 4 INTAKE VALVES WERE PROPER P/N, HOWEVER, INTAKE VALVE SEATS APPEAR TO HAVE BEEN CUT TOO WIDE. ALL 6 EXHAUST VALVES WERE REJECTED DUE TO EXCESSIVE STEM WEAR AND THE VALVE FACES WERE BURNED. ALSO, FOUND A RIN G STEP IN EACH CYL AND MAY REQUIRE BORING OF EACH OF THE CYLINDERS. ENGINE REBUILT BY TCM, MOBILE, ALA, 4-3-96. 1 L 7 2 3O 3 O A23CE E8CE 1997080700273 19970807 00273 CE 1997 8 7 97ZZZX3420 1 19970717 G 2822 41400015 PUMP DUKES CESSNA 182 TR182 2072735 CE FUEL BOOST CRACKED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 01 736YQ 18704 R18200790 DUKES ELECTRIC FUEL PUMP RELIEF VALVE ASSEMBLY HAD BEEN CROSS-THREADED ON ORIGINAL ASSEMBLY. OVER TIME, STRESS CAUSED P UMP BODY TO CRACK. IF NOT FOUND, PROBLEM COULD HAVE ALLOWED RELIEF VALVE TO BE EJECTED FROM PUMP BODY CAUSING COMPLETE FAILURE AND MASSIVE FUEL LEAK AND ENGINE FAILURE. 1 H 7 1 3O 3A13 1997080700274 19970807 00274 CE 1997 8 7 97ZZZX3421 1 19970721 G 2434 DOFF10300G ALTERNATOR FORD CESSNA 172 R172K 2072431 CE FWD HOUSING CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 16 758BZ 370 2060285 R1722977 TOTAL AIRCRAFT TIME 3,176.9 HOURS. DURING AN ANNUAL INSPECTION, THE ALTERNATOR FORWARD HOUSING WAS FOUND CRACKED AT THE WEB SUPPORTS. SUBMITTER SUGGESTS ALTERNATOR BE INSPECTED IN MORE DETAIL. 1 H 7 1 3O 3A17 1997080700275 19970807 00275 EA 1997 8 7 97ZZZX3422 2 19970520 G 8530 75068 VALVE LYC O320 O320E3D 41508 EA NR 3 CYL EXH BROKEN D A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 NM 05 PILOT EXPERIENCED LOSS OF POWER DURING CRUISE FLIGHT. EXCESSIVE VIBRATION AND POWER LOSS LED HIM TO MAKE A PRECAUTIONA RY/EMERG LANDING IN WHICH AIRCRAFT WAS HEAVILY DAMAGED. FAA/NTSB INSPECTED ENGINE, FOUND NR 3 CYLINDER EXHAUST VALVE BR OKEN OFF AT BASE OF VALVE, AND VALVE HEAD BLOCKING EXHAUST IN STACK FROM NR 4 CYLINDER. 3 O E274 1997080700276 19970807 00276 1997 8 7 97ZZZX3423 4 19970722 G 2561 KS9 LIFE VEST EAAEROMARINE VEST CELL FAIL TEST B KO1R K NONE L NO TEST IN INSP/MAINT 1 EA 25 B51720 LIFE VEST FAILED THE MANUFACTURER'S 2-POUND P.S.I. INFLATION TEST. 1997080700277 19970807 00277 1997 8 7 97ZZZX3424 4 19970701 G 2561 KS9 LIFE VEST EAAEROMARINE VEST CELL FAIL TEST B KQ1R K NONE L NO TEST IN INSP/MAINT 1 EA 07 B31112 LIFE VEST FAILED THE MANUFACTURER'S 2-POUND P.S.I. TEST. 1997080700278 19970807 00278 GL 1997 8 7 97ZZZX3425 2 19970703 G 7323 2526146 SPOOL BEARING BENDIX 252466713 ALLSN 250C 250C20 03013 GL GOVERNOR WRONG PART G K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 21 2117 9658 PER AD 82-24-05, INSPECTION REQUIRED TO DETERMINE IF SPOOL BEARING IS CORRECT TYPE. PREVIOUS REPAIR STATION INSPECTED IT AND STATED ON REPAIR TAG THAT SPOOL BEARING WAS CORRECT, WHEN, IN FACT, IT WAS NOT. 3 U E4CE 1997080700279 19970807 00279 EA 1997 8 7 97ZZZX3426 2 19970712 G 7310 6390102 HOSE PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA FIREWALL LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 NM 05 9779W 2823267 INSPECTION FOUND AIRCRAFT FUEL HOSES DETERIORATED AND LEAKING. HOSES FROM FIREWALL FORWARD NEED FIRE SLEEVE REMOVED AND CHECKED FOR CORROSION. P/N AFFECTED 639017, 6390102, 6390114, AND P/N 6390118. ACFT TT: 600 - 1200 HOURS. 1 L 7 1 3O 3 O 2A13 E274 1997080700280 19970807 00280 EA 1997 8 7 97ZZZX3427 2 19970712 G 7310 639017 HOSE PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA FIREWALL LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 NM 05 56055 287325563 INSPECTION FOUND AIRCRAFT FUEL HOSES DETERIORATED AND LEAKING. HOSES FROM FIREWALL FORWARD NEED FIRE SLEEVE REMOVED AND CHECKED FOR CORROSION. P/N AFFECTED 639017, 6390102, 6390114, AND P/N 6390118. ACFT TT: 600 - 2400 HOURS. 1 L 7 1 3O 3 O 2A13 E274 1997080700281 19970807 00281 EA 1997 8 7 97ZZZX3428 2 19970712 G 7310 63901114 HOSE PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA FIREWALL LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 NM 05 7167R 2821876 INSPECTION FOUND AIRCRAFT FUEL HOSES DETERIORATED AND LEAKING. HOSES FROM FIREWALL FORWARD NEED FIRE SLEEVE REMOVED AND CHECKED FOR CORROSION. P/N AFFECTED 639017, 6390102, 6390114, AND P/N 6390118. ACFT TT: 600 - 2400 HOURS. 1 L 7 1 3O 3 O 2A13 E274 1997080700282 19970807 00282 EU 1997 8 7 97ZZZX3429 1 19970723 G 5330 7253501712 PANEL SAAB SF340 340B 7860101 EU BELLY FAILED B L A YTQR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 15 250AE 340B250 OPERATOR FORWARDED ACFT SAAB 340 BELLY PANEL PN 7253501-712 TO BE REPAIRED. PANELS OUTER FIBERGLASS LAYER USED AS A SEA L PLY OVER ANTI-STATIC MATERIAL IS FAILING. PANEL HAD BEEN PREVIOUSLY REPAIRED USING SAAB APPROVED PROCEDURE. SUBMITTE R STATES PROCEDURE IS UNRELIABLE. 2 L 7 2 4T RT A52EU 1997080700283 19970807 00283 GL 1997 8 7 97ZZZX3430 2 19970722 G 7250 23031478 BEARING ALLSN 250C 250C30P 03013 GL TURBINE NR 8 FAILED D O OTHER J WARNING INDICATION NR NOT REPORTED 1 NM 11 327 MP00460 CAE895526 BEARING FAILED IN-FLIGHT, CAUSED CHIP LIGHT. OIL FLOWED ALL NOZZLES AND OIL LINES AT DISASSEMBLY. ALL CLEAR. ALL OTHE R BEARINGS, VISUAL OK. 3 U E1GL 1997080700284 19970807 00284 CE 1997 8 7 97ZZZX3431 1 19970717 G 5540 1155240599 HINGE CASTING BEECH 90 C90A 1152911 CE RUDDER CRACKED H K NONE O OTHER IN INSP/MAINT 1 WP 25 478JA 4846 LJ1163 MULTIPLE CRACKS ON THE BASE OF RUDDER HINGE CASTING WHERE IT ATTACHES TO VERTICAL FIN. NORMAL TORQUE ON REMOVAL. INSPE CTION REQUIREMENT FOR CASTINGS IS 12,000 HOURS. 1 L 7 2 3T RT 3A20 1997080700286 19970807 00286 1997 8 7 97ZZZX3433 4 19970701 G 2561 SMV2102 LIFE VEST JCRIND CELL FAILED TEST B KQ1R K NONE L NO TEST IN INSP/MAINT 1 EA 07 00008 LIFE VEST FAILED THE MANUFACTURER'S 2 P.S.I. INFLATION TEST. 1997080700287 19970807 00287 1997 8 7 97ZZZX3434 4 19970701 G 2561 H2L8 LIFE VEST AMERICANSFTY CELL FAILED TEST B KQ1R K NONE L NO TEST IN INSP/MAINT 1 EA 07 190 LIFE VEST FAILED THE MANUFACTURER'S 2 P.S.I. INFLATION TEST. 1997080700288 19970807 00288 NE 1997 8 7 97ZZZX3435 2 19970716 G 8530 ROCKER BOSS DHAV DHC3 DHC3 2800202 EA PWA R1340 R134059 52016 NE CYLINDER EXHAUST SEPARATED D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 AL 03 17689 300 431 CYLINDER HEAD EXHAUST ROCKER BOSS SEPARATED FROM HEAD. OCCURRED DURING TAKEOFF CLIMB. STUCK VALVE. CORRECT LEAD CONTE NT OF FUEL. 1 H 7 1 3R 3 R A815 5E2 1997080700289 19970807 00289 SO 1997 8 7 97ZZZX3436 2 19970620 G 8530 538304 PUSH ROD CONT O520 IO520F 17032 SO NR 5 CYL INT BROKEN D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 AL 03 1366 553699 AFTER NORMAL FLIGHT AND ON TURN-AROUND, ENGINE ON POWER CHECK RAN VERY ROUGH AND WOULD NOT RESPOND NORMALLY TO THROTTLE ADVANCE. FOUND NR 5 CYLINDER WITH ONE BROKEN (INTAKE) PUSH ROD AND EXHAUST PUSH ROD BENT. ENGINE SHOP ADVISED VALVE ST EMS STUCK. 15W50 AEROSHELL WAS IN USE AT THIS TIME. 3 O E5CE 1997080700290 19970807 00290 NM 1997 8 7 97ZZZX3437 1 19970708 G 7830 122510 BODY 1U1225 BOEING 737 737222 1384473 NM ISOLATION VALVE CRACKED B S IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 667 1923 THE 1U1225'S ISOLATION BODY, PN 1225-10, IS SUSCEPTIBLE TO PINHOLES AND CRACKS ALONG THE BODY'S SEAMS AND WITHIN THE FIT TING PORTS. RONSON MIGHT CONSIDER MANUFACTURING A STRONGER BODY, PERHAPS A CHANGE OF MATERIAL. 2 L 7 2 4F A16WE 1997080700291 19970807 00291 NM 1997 8 7 97ZZZX3438 1 19970710 G 2720 8816041 COIL PARKERHANFIN 8816001001 BOEING 737 737* NM RUDDER PCU JOINT CRACKED B IU6D K NONE O OTHER IN INSP/MAINT 1 NM 01 3017 JOINT WHERE THE CONNECTOR ATTACHES TO THE COIL IS CRACKED. JOINT IS NARROW AND WEAK. SUBMITTER STATES; CAN SEE RECURRI NG PROBLEMS WITH CRACKING. RECOMMEND MAKING JOINT STRONGER. 2 L 7 2 4F RT A16WE 1997080700292 19970807 00292 NM 1997 8 7 97ZZZX3439 1 19970708 G 2761 65C268634 HOUSING 65C26864 BOEING 737 737* NM SPOILER ACTUATOR CRACKED B IU6D K NONE O OTHER IN INSP/MAINT 1 NM 01 8898 0499 IT HAS BEEN NOTED THAT THE 65-44960, 65C26864, AND 251A1510 SPOILER ACTUATORS HAVE BEEN EXPERIENCING CRACKING AT THE ROD END END OF THE HOUSING ASSEMBLIES, PN'S 65C26863-1, DASH 4 AND DASH 6. 2 L 7 2 4F RT A16WE 1997080700294 19970807 00294 NM 1997 8 7 97ZZZX3441 1 19970627 G 2520 608041 STANCHION AA99S3 BOEING 767 767 1385102 NM LITTER CORRODED B TR1R K NONE O OTHER IN INSP/MAINT 1 SW 05 LITTER STANCHIONS SHOW SIGNS OF CORROSION AT ATTACH WELD. IT APPEARS THE MATERIAL WAS EXPOSED TO MOISTURE DURING SHIPME NT OR STORAGE. CAUSE AND PREVENTION ARE UNDER INVESTIGATION BY RAYTHEON. THE PARTS ARE BEING REPLACED BY KNOWN SERVICE ABLE PARTS. THIS MATERIAL PART OF THE CIVIL RESERVE AIR FLEET AEROMEDICAL EVACUATION SHIP SET SYSTEM ASSIGNED STC SA503 9SW-D WHICH INSTALLS ONTO A B767-200/300. 2 L 7 2 4F EXPA2L72 1997080700295 19970807 00295 NM 1997 8 7 97ZZZX3442 1 19970627 G 2520 608051 STANCHION 05395 BOEING 767 767 1385102 NM LITTER CORRODED B TR1R K NONE O OTHER IN INSP/MAINT 1 SW 05 LITTER STANCHIONS SHOW SIGNS OF CORROSION AT ATTACH WELD. IT APPEARS THE MATERIAL WAS EXPOSED TO MOISTURE DURING SHIPME NT OR STORAGE. CAUSE AND PREVENTION ARE UNDER INVESTIGATION BY RAYTHEON. THE PARTS ARE BEING REPLACED BY KNOWN SERVICE ABLE PARTS. THIS MATERIAL PART OF THE CIVIL RESERVE AIR FLEET AEROMEDICAL EVACUATION SHIP SET SYSTEM ASSIGNED STC SA503 9SW-D WHICH INSTALLS ONTO A B767-200/300. 2 L 7 2 4F EXPA2L72 1997080700297 19970807 00297 EU 1997 8 7 97ZZZX3444 1 19970718 G 6120 57A3044 FEEDBACK BLOCK SOCATA TBM TBM700 8682000 EU PROP BETA WORN B LF1R K NONE O OTHER IN INSP/MAINT 1 EA 07 800GS 5 DURING ANNUAL INSPECTION, FOUND CARBON 'BETA' FEEDBACK BLOCK SEVERELY WORN. THIS HAD CAUSED DAMAGE TO FEEDBACK RING AS WELL. THIS OCCURRED DUE TO BLOCK NOT MOVING FREELY IN ARM. (LACK OF LUBRICATION). AIRCRAFT HAD NOT BEEN INSPECTED FOR 160 HOURS. NORMAL CYCLE IS 100, 200, AND 400 HOURS FOR THIS AIRCRAFT. THIS DISCREPANCY MAY HAVE BEEN CAUGHT BEFORE DA MAGE TO PROPELLER OCCURRED IF 100-HOUR INSPECTION HAD BEEN C/W. 1 L 7 1 3T RT A60EU 1997080700298 19970807 00298 EU 1997 8 7 97ZZZX3445 1 19970627 G 3246 AH42671 WHEEL HALF HWKSLY DH125 BH125400A 4230138 EU MLG CRACKED H K NONE O OTHER IN INSP/MAINT 1 NM 11 89SR 1693 NA778 WHEEL HALF WAS TESTED FOR MILLION AIR; SALT LAKE CITY, UTAH IAW DUNOP 32-40-2(4) 6-28-84, FOUND CRACKED. 2 L 7 2 4J A3EU 1997080700300 19970807 00300 NE 1997 8 7 97ZZZX3447 2 19970717 G 7320 HOSE HAMFLU HFB320 HFB320 4071204 EU GE CJ610 CJ6105 30006 NE T2 SENSE LOOSE H O OTHER X ENGINE FLAMEOUT CR CRUISE 1 GL 23 92045 3474 1041 249020 RIGHT ENGINE FLAMED OUT AT FL 370. ENGINE RE-STARTED IAW AFM AIR START PROCEDURES. ENGINE INSPECTED AND NO DAMAGE NOTE D. TIGHTENED LOOSE T2 SENSE HOSE. C/W ALTITUDE ACCELERATION TEST FLIGHT. OPS CHECK GOOD. 2 L 7 2 4J 4 J A14EU 1E16 1997080700301 19970807 00301 EU 1997 8 7 97ZZZX3448 1 19970714 G 6320 109040304105 INPUT QUILL 109040002107 AGUSTA A109 A109C 0260118 EU M/R TRANSMISSION SPALLED H A A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 GL 15 911D 1178 7637 APPROXIMATELY 5 MINUTES AFTER TAKEOFF, MAIN TRANSMISSION CHIP LIGHT CAME ON AND WOULD NOT ZAP OFF. PILOT RETURNED. TEC HNICIAN REMOVED AND INSPECTED BOTH CHIP PLUGS. TOP CHIP PLUG WAS CLEAN. BOTTOM CHIP PLUG HAD 4 LARGE CHIPS ON IT. TRA NSMISSION FILTER WAS REMOVED AND FOUND TO CONTAIN AN EXCESSIVE AMOUNT OF METAL FILINGS. TECHNICIANS WHO OPENED THE GEAR BOX AND FOUND EXCESSIVE SPALLING ON THE INPUT QUILL AND GLEASON CROWN GEAR. THEY ALSO FOUND A POSSIBLE CRACK IN ONE OF THE INPUT QUILL TEETH. 1 G 7 2 3U H7EU 1997080700302 19970807 00302 WP 1997 8 7 97ZZZX3449 1 19970710 G 2510 269A40661 COVER ASSY HUGHES 269 269C 4470504 WP COCKPIT JAMMED THROTTLE D A O OTHER J WARNING INDICATION CR CRUISE 1 WP 27 61458 0008 FLIGHT AFTER ANNUAL INSP FOR M/R TRACK AND BALANCE, THROTTLE STUCK FULL ON IN CRUISE FLT NOT ALLOWING REDUCTION IN POWER WITHOUT OVERSPEED OF ENG AND ROTOR. CAUSE FOUND IN-FLIGHT AND CORRECTED. BETWEEN PILOT'S AND COPILOT'S SEAT IS A VERT ICAL PANEL THAT WHEN INSTALLED, THE LIP THAT SHOULD TUCK IN NEXT TO THE PILOT'S SEAT GOT TUCKED BACK INTO THE FLT CONTRO L AREA (ON OPPOSITE SIDE OF VERT RIB GUARD). FREE THROTTLE MOVEMENT WAS STILL ALLOWED IN BOTH DIRECTIONS UNTIL FULL THR OTTLE ACHIEVED. AT THIS TIME, LIP OF PANEL KEPT THROTTLE BELLCRANK FROM ROTATING IN THE OFF DIRECTION. AREA OF CONTACT IS THE PANEL-TO-BELLCRANK/OVERTRAVEL SPRING ASSY. THIS WAS CORRECTED AND ACFT RETURNED TO SERVICE. 1 G 7 1 3O 4H12 1997080700303 19970807 00303 CE 1997 8 7 97ZZZX3450 1 19970701 G 2823 HE7805 SELECTOR VALVE BEECH 95 95B55 1152729 CE FUEL SYSTEM LEAK B H8AR K NONE W K INADEQUATE Q C FLUID LOSS IN INSP/MAINT 1 EA 05 2018Q A97050056 TC2165 THIS VALVE INSTALLED TO REPLACE 2 OTHER PREVIOUS VALVES INSTALLED AS NEW THAT FAILED A SHORT TIME AFTER INSTALLATION. 1 L 7 2 3O RT 3A16 1997080700324 19970807 00324 NE 1997 8 7 97ZZZX3451 1 19970618 G 6410 7610105101041 BLADE SKRSKY S76 S76 8143010 NE TAIL ROTOR DEFECTIVE B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 5402T 6196 A13700421 760140 TAIL ROTOR BLADE ASSY WAS REPAIRED BY SIKORSKY JUST 422.4 HOURS AGO. PAINT AND EROSION STRIP NEEDS TO BE REWORKED. 1 G 7 2 3U H1NE 1997080700325 19970807 00325 EU 1997 8 7 97ZZZX3452 1 19970701 G 6410 10531980 BLADE BOLKMS 105 BO105S 5626006 EU TAIL ROTOR DEFECTIVE B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 50588 648 534 S780 TWO BLADES REPAIRED BY EUROCOPTERS ONLY 306.4 HOURS AGO. LEAIDNG EDGE AND TIP CAP NEEDS REWORK AND PAINTING. 1 G 7 2 3U H3EU 1997080700326 19970807 00326 EU 1997 8 7 97ZZZX3453 1 19970701 G 6410 10531980 BLADE BOLKMS 105 BO105S 5626006 EU TAIL ROTOR DEFECTIVE B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 50588 572 534 S780 TWO BLADES REPAIRED BY EUROCOPTERS ONLY 306.4 HOURS AGO. LEAIDNG EDGE AND TIP CAP NEEDS REWORK AND PAINTING. 1 G 7 2 3U H3EU 1997080700327 19970807 00327 NE 1997 8 7 97ZZZX3454 1 19970709 G 6210 7615009000049 BLADE SKRSKY S76 S76 8143010 NE MAIN ROTOR CRACKED B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 5403C 7191 A08600213 760141 BLADE HAS A COMPLETE CHORD-WISE CRACK IN THE NICKEL LEADING EDGE ABRASION STRIP LOCATED 170 INCHES FROM THE ROOT END OF BLADE. THE NICKEL STRIP IS SEPARATED OUTBOARD OF THE CRACK ON LOWER SIDE, 12 INCHES ALONG TRAILING EDGE OF STRIP AND IN BOARD OF THE CRACK 2.50 INCHES. THE DEPTH OF SEPARATION IS APPROXIMATELY OUT TO THE LEADING EDGE. BLADE WAS REMOVED FR OM SERVICE AND SENT TO SIKORSKY FOR REPAIR. 1 G 7 2 3U H1NE 1997080700328 19970807 00328 NE 1997 8 7 97ZZZX3455 1 19970701 G 3340 A402 LENS SKRSKY S76 S76 8143010 NE STROBE CRACKED B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 5414X 207 760152 STROBE LENS IS CRACKED ALONG SEAM. 1 G 7 2 3U H1NE 1997080700329 19970807 00329 EU 1997 8 7 97ZZZX3456 1 19970610 G 7714 9580111270 PICKUP AEROSP SA365 AS365N2 8680815 EU ENGINE MALFUNCTION B KY1R K NONE O OTHER NR NOT REPORTED 1 EA 07 65MD 1383 N3622 6464 OVERSPEED SENSOR LIGHT STAYS ON. 1 G 7 2 3U RT H10EU 1997080700330 19970807 00330 NE 1997 8 7 97ZZZX3457 1 19970602 G 3340 A402AR LENS SKRSKY S76 S76A 8143006 NE STROBE SPLIT B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 72649 760292 BRAND NEW PART OUT OF STOCK, SPLIT ALONG GLUE LINE. LENS HALVES NOT BONDED TOGETHER PROPERLY. THIS WAS TO REPLACE THE L ENS INSTALLED THAT WAS REMOVED FOR THE SAME REASON. 1 G 7 2 3U H1NE 1997080700331 19970807 00331 NE 1997 8 7 97ZZZX3458 1 19970601 G 3340 A402AR LENS SKRSKY S76 S76A 8143006 NE STROBE SPLIT B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 72649 760292 STROBE LIGHT LENS SPLIT IN HALF, GLUE DOES NOT HOLD HALVES TOGETHER ALONG BOND LINE. 1 G 7 2 3U H1NE 1997080700332 19970807 00332 NE 1997 8 7 97ZZZX3459 1 19970601 G 6210 7615009100052A BLADE SKRSKY S76 S76A 8143006 NE MAIN ROTOR DISBOND B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 72649 7304 A0861577 760292 TWO AREAS OF DISBOND ON MAIN ROTOR BLADE. (TOP SURFACE STARTS AT BLADE STA 232 AND EXTENDS SPANWISE APPROXIMATELY 4 INC HES ALONG LEADING EDGE STRIP, EXTENDING AFT APPROXIMATELY 4 INCHES CHORDWISE). LOWER SURFACE STARTING AT BLADE STA 237, APPROXIMATELY EXTENDING SPANWISE 4 INCHES, LOCATED AFT OF LEADING EDGE 3 INCHES APPROX .75 IN CHORDWISE. 1 G 7 2 3U H1NE 1997080700333 19970807 00333 1997 8 7 97ZZZX3460 4 19970623 G 3444 6222938001 INDICATOR AEROSP SA365 SA365N1 8680668 EU RADAR ALT FLAG STUCK B KY1R K NONE O OTHER IN INSP/MAINT 1 EA 07 79MD 2260 6352 RADAR ALTIMETER FLAG 'STUCK' (WILL NOT MOVE). DOES NOT TEST. 1 G 7 2 3U H10EU 1997080700334 19970807 00334 EU 1997 8 7 97ZZZX3461 1 19970623 G 7714 H2901428 INDICATOR AEROSP SA365 SA365N1 8680668 EU AUTOTAK NG MALFUNCTION B KY1R K NONE N FALSE WARNING NR NOT REPORTED 1 EA 07 79MD 6352 'ERR' DISPLAYED AT ALL TIMES. 1 G 7 2 3U H10EU 1997080700335 19970807 00335 EU 1997 8 7 97ZZZX3462 1 19970620 G 2436 026 REGULATOR AEROSP SA365 SA365N1 8680668 EU DC SYSTEM FAILED B KY1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 07 95MD 4822 6320 VOLTAGE REGULATOR FAILED DUE TO CROSSED WIRING AND TERMINALS. 1 G 7 2 3U H10EU 1997080700341 19970807 00341 NM 1997 8 7 97ZZZX3467 1 19970326 G 3246 10321700 BOLT 40124 PIPER PA60 PA60601P 7106012 NM WHEEL CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 23 14SP 61P0494202 DURING A ROUTINE TIRE CHANGE, ONE OF THE WHEEL BOLTS WAS FOUND CRACKED ALL THE WAY AROUND THE BOTTOM OF THE HEAD. 1 M 7 2 3O RT A17WE 1997080700343 19970807 00343 EU 1997 8 7 97ZZZX3469 2 19970526 G 8530 CARB SOCKET AMTR RANS RANSS12 05618JF GL ROTAX 582 ROTAX582 55555 EU INTAKE MANIFOLD LOOSE H K NONE W INADEQUATE Q C NR NOT REPORTED 1 GL 13 100 THE CARBURETOR SOCKET VIBRATED LOOSE FROM THE INTAKE MANIFOLD. NO SAFETY WIRING OF THE CLAMPS AS RECOMMENDED BY ROTAX. CARBS HAD FELT SECURE ON PRE-FLIGHT INSPECTION. 1 H 7 1 3I 3 I NC EXPA1H71 EXPE3I 1997080700344 19970807 00344 SW 1997 8 7 97ZZZX3470 1 19970612 G 6230 206010336005 DRIVE LINK BELL 206 206L1 1182107 SW M/R MAST WORN B ZV1R K NONE O OTHER IN INSP/MAINT 1 SW 03 DRIVE LINK ASSY HAS EXCESSIVE PLAY AT TWO PLACES. SEE BELL MM L-3 FIG 62:21. AT TEAR DOWN FOUND BEARINGS AND SPACERS W ORN BEYOND LIMITS. TOTAL TIME OF PARTS LESS THAN 1,000 HOURS. ONE YEAR SINCE REPLACEMENT. 1 G 7 1 3U H2SW 1997080700345 19970807 00345 1997 8 7 97ZZZX3471 2 19970701 G 7322 661529 BEARING HAMSTD JFC564 FUEL CONTGROL WRONG PART B JYDR K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 09 BOGUS BEARINGS PURCHASED NEW SURPLUS FROM CALIFORNIA PROPELLER UNDER EAC P.O. K4495. PART PACKAGED IN JUNE 1997. WHEN INSTALLING IN FUEL CONTROL, BEARING CAME APART. ONLY PART MARKING IS SBB 3 USA AND LOCATED ON INNER RACE. PARTS PURC HASED FROM HAMILTON STD (PN 561529) ARE MADE FROM 2 COMPONENTS: INNER AND OUTER RACE AND HAVE P/N MARKED ON OD WITH HAM ILTON STANDARD STAMP. BOGUS BEARING DESIGNED FOR LOAD IN 1 DIRECTION AND CORRECT BEARING PN 561529 IS DESIGNED TO BE LOADED IN BOTH DIRECTIONS. BEARING IS NOT SURPLUS, BUT SOLD AS SURPLUS. MFG OF BOGUS BEARING CONTACTED AND VERIFIED TH EY NEVER PRODUCED A BEARING WITH PN 561529 AND SOME ONE ILLEGALLY MIS-IDENTIFIED THEIR BEARING PN SBB 3 AS PN 561529. 1997080700346 19970807 00346 EU 1997 8 7 97ZZZX3472 1 19970721 G 5711 33719912 SPAR SOCATA TB20 TB20TRINIDAD 8680695 EU RT WING CORRODED D L A K NONE O OTHER IN INSP/MAINT 1 SO 21 2527E 878 DURING AN ANNUAL INSPECTION OF THIS AIRCRAFT, A CONSIDERABLE AMOUNT OF CORROSION OF THE RIGHT WING SPAR WAS FOUND WITH S OME FORM OF DELAMINATION. THE PRIMARY CORROSION WAS FOUND ON THE RIGHT WING SPAR NEAR THE RIB ONTO WHICH THE LANDING GE AR IS ATTACHED. 1 L 7 1 3O RT A51EU 1997080700347 19970807 00347 GL 1997 8 7 97ZZZX3473 3 19970722 G 6111 V8433N4 BLADE GULSTM 500 500RKWELL 0141102 SW HARTZL HCA3V HCA3VK2 GL SHANK CRACKED D S K NONE O OTHER IN INSP/MAINT 1 SW 15 373 D51435 BJ527 BLADE CRACKED IN SHANK AREA. REFER TO HARTZELL SB 61-217, REV 1. 1 H 7 2 3O 6A1 5 C P6EA 1997080700348 19970807 00348 GL 1997 8 7 97ZZZX3474 3 19970724 G 6111 V8433N4 BLADE GULSTM 500 500RKWELL 0141102 SW HARTZL HCA3V HCA3VK2 GL SHANK CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 15 10385 1989 D96215 BJ119 CRACK IN BLADE SHANK AREA. 1 H 7 2 3O 6A1 5 C P6EA 1997080700349 19970807 00349 EA 1997 8 7 97ZZZX3475 2 19970608 G 8530 60828 PIN PLUG PIPER PA28 PA28140 7102802 SO LYC O320 O320E3D 41508 EA NR 3 PISTON FAILED G A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 GL 27 520ST 1675 287225337 L3424227A THIS AIRPLANE MADE AN EMERGENCY LANDING ON A HIGHWAY AT NIGHT. NO DAMAGES TO THE AIRCRAFT OR THE PASSENGERS. A TEAR-DO WN INSPECTION OF THE ENGINE WAS COMPLETED WITH THE FOLLOWING RESULTS. NR 3 CYLINDER PISTON PIN PLUG SEVERELY WORN. ALU MINUM FROM THE PLUG AND ASSOCIATED PISTON HAD PLUGGED THE OIL SYSTEM CAUSING CONNECTING ROD BEARING TO OVERHEAT AND FAIL . THIS PISTON PIN PLUG COULD HAVE BEEN INSTALLED WHEN THE ENGINE WAS OVERHAULED IN 1976. SUBMITTER STATED LYCOMING HAS SINCE CHANGED THE DESIGN OF THIS PART TO PREVENT THIS FROM OCCURRING. 1 L 7 1 3O 3 O 2A13 E274 1997080700350 19970807 00350 CE 1997 8 7 97ZZZX3476 1 19970728 G 6120 SUPPORT CESSNA 172 172D 2072410 CE PROP GOV CONTROL CRACKED D A K NONE O OTHER IN INSP/MAINT 1 WP 05 56EC 17249661 DURING REMOVAL FOR OIL PUMP AD COMPLIANCE, FOUND TWO OF THE THREE SUPPORT FINGERS CONNECTING THE PROPELLER GOVERNOR CONT ROL CABLE CRACKED AT THE THREE-FINGER JUNCTION WELD, AND THE CABLE WAS SUPPORTED BY ONE FINGER. FAILURE OF THAT FINGER WOULD CAUSE LOSS OF PROP PITCH CONTROL. THIS CRACK WOULD BE DIFFICULT TO SEE DURING ROUTINE INSPECTIONS. RE-WELDED AND RETURNED TO SERVICE. FAILURE MODE UNKNOWN, SUSPECT INDUCED VIBRATION; TY-WRAPPED TO ADJACENT HOSE. AVCON 180 CONVERSI ON FOR CESSNA 172. 1 H 7 1 3O NT 3A12 1997080700351 19970807 00351 GL 1997 8 7 97ZZZX3477 3 19970722 G 6110 PROPELLER CESSNA 150 152 2071835 CE MCAULY 1A103 1A103TCM GL BOLT HOLES CRACKED H S K NONE O OTHER IN INSP/MAINT 1 SO 07 67402 7346 3673 15281817 R772947 TWO CRACKS FOUND AT EDGE OF BOLT HOLES, APPROXIMATELY .50 INCH LONG. FOUND DURING INSPECTION REQUIRED BY SB 221 AND AD 97-06-16. 1 H 7 1 3O NT 3A19 5 N P50GL 1997080700352 19970807 00352 SO 1997 8 7 97ZZZX3478 1 19970701 G 3211 6705400 TRUNNION 6710004 PIPER PA28 PA28R200 7102811 SO NLG CRACKED D S K NONE O OTHER IN INSP/MAINT 1 WP 09 9350K 28R7635233 DURING ANNUAL INSPECTION, TWO FINE CRACKS WERE DISCOVERED IN THE UPPER RIGHT TRUNNION MOUNTING ARM, ON THE AFT SIDE, AND ONE ON THE FORWARD SIDE. CRACKS VERIFIED BY DYE PENETRANT INSPECTION. AFT CRACK APPROXIMATELY 1 INCH LONG EXTENDING F ROM .33 INCH UNDER BRACE TO .33 INCH OVER TOP. FORWARD CRACK APPROXIMATEY .75 INCH LONG, EXTENDING SLIGHTLY UNDER AND O VER BRACE. SUBMITTER SUSPECTS HARD LANDINGS AND/OR EXCEEDING TURN LIMITS ON TOW. 1 L 7 1 3O 2A13 1997080700353 19970807 00353 CE 1997 8 7 97ZZZX3479 1 19970701 G 2720 PEDAL CESSNA 170 170A 2072304 CE RUDDER EXCESS WEAR D A K NONE O OTHER IN INSP/MAINT 1 SW 99 9526A 190897 RUDDER PEDALS WERE REMOVED TO FACILITATE OTHER MAINTENANCE. UPON REMOVAL, FOUND PEDAL ATTACH HOLES SEVERELY ELONGATED. TO REPAIR, A .125 INCH DOUBLER OF 6061-T6 WAS USED ON EACH SIDE OF THE PEDAL AS THE PEDAL PIN WAS JUST LONG ENOUGH TO A CCOMODATE THE EXTRA THICKNESS. ALL 4 PEDALS WERE DAMAGED IN THIS WAY. SUSPECT CAUSE, 48 YEARS OF FLIGHT. RECOMMEND PE RIODIC INSPECTION ON OLDER AIRCRAFT. 1 H 7 1 3O A799 1997080700354 19970807 00354 EA 1997 8 7 97ZZZX3480 2 19970711 G 8550 OIL PUMP GRTLKS 2T1 2T1A2 3910101 NM LYC O360 AEIO360B1G6 41514 EA GEARS DEFECTIVE B PB2R K NONE O OTHER IN INSP/MAINT 1 GL 23 L1961951A DURING AD RESEARCH, AD 96-09-10, ENGINE WAS SUBJECT TO VERIFICATION. ENGINE MANUFACTURED (FIRST TEST FLIGHT) OCTOBER, 1 978, AND HAS 330 HOURS TOTAL TIME SINCE NEW. THIS ENGINE WAS NOT LISTED IN BULLETIN 524 UNDER AEIO - SO LYCOMING WAS CO NSULTED AND ADVISED THAT ENGINES ARE LISTED BY SUFFIX, NOT PREFIX, AS STATED IN BULLETIN; THEREFORE, ENGINE FALLS UNDER IO-360 AND HAS STEEL AND ALUMINUM GEARS. 1 Q 7 1 3O 3 O A18EA 1E10 1997080700355 19970807 00355 SO 1997 8 7 97ZZZX3481 1 19970722 G 2821 2W072322 FUEL FILTER AIRMAZE PIPER PA46 PA46350P SO THREADED POST LOOSE B A WC7R K NONE O OTHER IN INSP/MAINT 1 GL 25 113WB 108 1Q90 4622193 WHILE SERVICING THE FUEL BOWL FILTER SEGMENTS, THE THREADED POST WHICH RETAINS AND SECURES THE FILTERS AND BOWL TO THE A SSY BODY WAS FOUND LOOSE AND HELD IN BY ONLY ONE THREAD (1 FULL TURN). POST AND BODY HAVE APPROXIMATELY 8 THREADS. SUS PECT CAUSE WAS THAT POST MAY NOT HAVE BEEN FULLY THREADED OR SECURED INTO ASSY BODY. 1 L 7 1 3O RT A25SO 1997080700356 19970807 00356 SO 1997 8 7 97ZZZX3482 2 19970618 G 8530 6461401 STUD 643207 CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO NR 1 CYLINDER BROKEN D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 GL 17 25SC 414A0114 233993R THE LEFT ENGINE NR 1 CYLINDER HAD 5 BROKEN HOLD-DOWN STUDS (ALL 3 ON THE BOTTOM AND 2 FORWARD ON TOP) WHICH CAUSED A VIB RATION AND RPM REDUCTION AT FULL POWER. ALL THE STUDS WERE BROKEN JUST UNDER THE HOLD-DOWN NUTS. REPLACEMENT OF ALL ST UDS ON THAT CYLINDER CORRECTED THE PROBLEM. USUALLY, IT IS JUST ONE DEFECTIVE STUD AND THE REST FOLLOW UNDER THE EXTA L OAD. SUBMITTER RECOMMENDS REPLACEMENT OF ALL STUDS AT OVERHAUL. ENGINE TSO: 1394.7 HOURS. 1 L 7 2 3O 3 O A7CE E8CE 1997080700357 19970807 00357 SO 1997 8 7 97ZZZX3483 1 19970722 G 7820 7105302 MUFFLER PIPER J3 J3C65 7100510 SO EXHAUST CRACKED D S K NONE O OTHER IN INSP/MAINT 1 GL 27 3390N 2654 22592 INSPECTION FOUND MUFFLER CRACKED. WELDED WITH STAINLESS STEEL. 1 H 7 1 3O A691 1997080700359 19970807 00359 CE 1997 8 7 97ZZZX3485 1 19970701 G 5320 0713643 BULKHEAD CESSNA 182 182J 2072722 CE STBD TUNNEL CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 01 2787F 2936 182586887 PILOTS HAD COMMENTED ON A 'CLICKING' SOUND SOMEWHERE IN THE CABIN FOR SOME TIME. DURING AN ANNUAL INSPECTION, THE STARB OARD TUNNEL BULKHEAD WAS FOUND CRACKED IN AREA OF THE FUEL LINE (TO FIREWALL BULKHEAD FITTING). POSSIBLE CAUSE OF DAMAG E MAY BE FROM SEVERE NOSE WHEEL SHIMMY. NOSE STRUT, TORQUE LINKS, SHIMMY DAMPENER, WERE REPAIRED AT ANNUAL. SUBMITTER STATES THIS AIRCRAFT HAS NOT BEEN WELL MAINTAINED IN THE PAST. 1 H 7 1 3O NT 3A13 1997080700360 19970807 00360 CE 1997 8 7 97ZZZX3486 1 19970612 G 3213 50411082 BEARING CESSNA 414 414A 2075907 CE LT/RT MLG WRONG PART D K NONE O OTHER IN INSP/MAINT 1 GL 27 30EE 3900 414A0443 PULLED STRUTS TO RESEAL. DISCOVERED UPPER BEARING BLOCKS, AD 90-02-13, REQUIRES MAGNAFLUX EACH 1,000 HOURS, BUT SERIAL NUMBER DOES NOT APPLY TO 414A AFTER 0340. THESE WERE NOT BROKEN, BUT HAVE FOUND SEVERAL ON EARLIER AIRCRAFT COVERED BY THE AD BROKEN. 1 L 7 2 3O A7CE 1997080700361 19970807 00361 CE 1997 8 7 97ZZZX3487 1 19970718 G 2822 S23271 SWITCH CESSNA 206 U206F 2073333 CE THROTTLE FAILED D A K NONE O OTHER IN INSP/MAINT 1 NM 08 35854 20602759 P/N S-2327-1 FUEL PUMP THROTTLE SWITCH ACTIVATION ARM BREAKS INTERNALLY. SUBMITTER STATED THIS IS THE 4TH SWITCH IN THE LAST 12 MONTHS. THIS LAST SWITCH HAS 40 HOURS OPERATION TIME. 1 H 7 1 3O A4CE 1997080700362 19970807 00362 EA 1997 8 7 97ZZZX3488 2 19970711 G 8550 SCREEN PIPER PA32 PA32260 7103206 SO LYC O540 O540E4B5 41532 EA OIL SUCTION REQUIRED CHANGE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 09 3669W 32578 L1033140 REMOVED ENGINE FOR OVERHAUL WITH APPROXIMATELY 2,100 HOURS SINCE LAST OVERHAUL. OIL SUCTION SCREEN SAFETY WIRE WAS PAIN TED WITH ENGINE PAINT. ENGINE LAST OVERHAUL WAS 10-71. MANY ANNUALS AND OIL CHANGES WITHOUT THIS SCREEN BEING PULLED. VERY POOR MAINTENANCE. 1 L 7 1 3O 3 O A3SO E295 1997080700363 19970807 00363 SO 1997 8 7 97ZZZX3489 1 19970701 G 5510 HORIZ STABILIZER LUSCOM 8 8B 8190106 SO LOWER PORT INBD CORRODED D K NONE O OTHER IN INSP/MAINT 1 SW 01 37049 1431 1710 AIRCRAFT DISMANTLED FOR RENOVATION. UPON STRIPPING HORIZONTAL STABILIZER OF PAINT, CORROSION SPOTS WERE NOTICED ON LOWE R INBOARD SKIN - PORT SIDE. SKIN WAS DRILLED OFF AND A SUPER-HUGE MOUSE NEST WAS LYING IN THE AFT POSITION. MOUSE URIN E HAD CORRODED THE LOWER SKIN AND TWO RIBS TO THE POINT OF DESTRUCTION. MOUSE ENTRANCE APPEARS TO BE IN CABLE EXIT IN C ENTER OF STABILIZER AND AFT OF FRONT SPAR INTO RIB BAYS. THIS AREA CANNOT BE INSPECTED VISUALLY, OTHERWISE, THIS FIFTY-S IX YEAR OLD AIRCRAFT ENJOYS A RELATIVELY SOUND STRUCTURE. 1 H 7 1 3O A694 1997011600842 19970116 00842 CE 1997 1 16 97ZZZX349 1 19970106 G 3010 15323 DISTRIBUTOR MTSBSI MU2 MU2B60 5780460 CE ANTI ICE BOOT FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 05 175CA 42557U 736SA DURING A 150 HR INSPECTION, IT WAS DISCOVERED THAT THE VERTICAL AND HORIZONTAL BOOTS WERE NOT INFLATING. THIS AREA IS I MPOSSIBLE FOR THE PILOT TO SEE DURING A FUNCTION CHECK AND MUST BE INSPECTED REGULARLY. 1 H 7 2 3T RT A10SW 1997080700364 19970807 00364 SO 1997 8 7 97ZZZX3490 1 19970623 G 5553 RIVETS PIPER PA34 PA34200T 7103406 SO VERT STAB LT SHEARED B A APCR K NONE O OTHER IN INSP/MAINT 1 NM 01 4490F 347670339 RIVETS ON LT SIDE (3 OUT OF 4) SHEARED WHERE AFT SPAR OF VERTICAL STABILIZER ATTACHES TO EMPENNAGE. THESE RIVETS HAVE BE EN REPLACED BEFORE, BUT COULD NOT DETERMINE T.I.S. SINCE REPAIR. SUBMITTER STATED THIS IS THE SECOND PA-34-200T IN FLEE T FOUND WITH SHEARED RIVETS IN THIS AREA. 1 L 7 2 3O A7SO 1997080700365 19970807 00365 EA 1997 8 7 97ZZZX3491 2 19970722 G 8550 DIP STICK GULSTM 112 112TCA 7630307 SW LYC O360 TO360C1A6 41514 EA ENGINE OIL ERROR C K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 17 4655W 13185 L31369A THIS ENGINE AT OIL CHANGE REQUIRES TEN QUARTS OF OIL TO BRING DIPSTICK TO READ EIGHT QUARTS. 1 L 7 1 3O 3 O A12SO E26EA 1997080700366 19970807 00366 CE 1997 8 7 97ZZZX3492 1 19970723 G 7602 S17771 CONTROL CESSNA 150 150J 2071820 CE ENGINE MIXTURE BROKE D K NONE O OTHER NR NOT REPORTED 1 WP 21 60001 15069997 MIXTURE CONTROL BROKE AT CARBURETOR APPROXIMATELY .1250 INCH FROM END OF CABLE. 1 H 7 1 3O 3A19 1997080700367 19970807 00367 EA 1997 8 7 97ZZZX3493 1 19970725 G 5540 AN36A BOLT SCWZER G164 G164C 3952803 EA RUDDER ATTACH EXCESS WEAR B A MU2R K NONE O OTHER IN INSP/MAINT 1 CE 09 6555K 4C UPON REMOVAL OF RUDDER, THE UPPER ATTACH BOLT WAS FOUND SEVERELY WORN TO THE POINT FAILURE WAS INEVITABLE. THIS PROBLEM HAS BEEN NOTED BEFORE ON A R-985 B-MODEL. THE SUSPECT CAUSE FOR THIS DEFECT WAS LACK OF PROPER INSPECTION. WITH PROPE R INSPECTION AND PREVENTIVE MAINTENANCE, THIS DEFECT WOULD NOT BE A PROBLEM. SUBMITTER RECOMMENDS THAT EVERY 2,000 HOUR S THE RUDDER ATTACH BOLTS BE REMOVED AND VISUALLY INSPECTED. 1 Q 7 1 3R 1A16 1997080700368 19970807 00368 SO 1997 8 7 97ZZZX3494 1 19970715 G 3230 AN2319A BOLT PIPER PA32 PA32R301 7103218 SO NLG DOWNLOCK BROKEN B A MZER O OTHER J WARNING INDICATION AP APPROACH 1 GL 15 69160 32R8513016 PILOT REPORTED COULD NOT GET NOSE GEAR DOWN LIGHT WHEN GEAR SELECTED DOWN IN-FLIGHT. EMERGENCY EXTENSION UNSUCCESSFUL. PILOT LANDED AIRPLANE UNEVENFULLY. MAINTENANCE PERSONNEL FOUND BOLT BROKEN ON DOWNLOCK TO ACTUATOR. BENT DOWNLOCK, AN D ROD END SEIZED. SEVERAL INSPECTIONS HAVE FOUND THE SAME BOLT BENT AND REQUIRED REPLACEMENT. RECOMMEND A STRONGER BOL T BE INSTALLED. 1 L 7 1 3O A3SO 1997080700369 19970807 00369 SO 1997 8 7 97ZZZX3495 2 19970703 G 8530 637836 VALVE SPRING 642343 CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO NR 2 CYLINDER FAILED D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 GL 17 85SC 717 421C0026 R604049L THE PILOT NOTICED A VIBRATION AT CRUISE POWER AFTER AN HOUR OF FLIGHT. AFTER LANDING, INVESTIGATION REVEALED THE RIGHT ENGINE WOULD INCREASE IN VIBRATION WITH AN INCREASE IN RPM AND NOT DEVELOP FULL RPM. TROUBLESHOOTING REVEALED THE NR 2 CYLINDER HAD BOTH INNER VALVE SPRINGS BROKEN WHICH ALLOWED THE VALVES TO FLOAT AS RPM WAS INCREASED. REPLACEMENT OF THE VALVE SPRINGS CORRECTED THE PROBLEM. SUBMITTER STATED THIS IS THE SECOND INSTANCE TO ENCOUNTER A BROKEN INNER VALVE SP RING ON THIS SAME TYPE OF ENGINE. 1 L 7 2 3O 3 O A7CE E7CE 1997080700370 19970807 00370 SW 1997 8 7 97ZZZX3496 1 19970603 G 6310 SKCP2281103 DRIVESHAFT BELL 204 UH1H 1181407 SW ENG TRANSMISSION FAILED B NTWR A UNSCHED LANDING E VIBRATION/BUFFET EX EXTERNAL LOAD 1 NM 01 85NW 903 497 2553 6600792 DRIVESHAFT CAUSED HIGH FREQUENCY VIBRATION DURING EXTERNAL LOAD OPERATIONS. DRIVESHAFT FAILED COMPLETELY AFTER APPROXIM ATELY ONE MINUTE WHILE AIRCRAFT WAS RETURNING TO ITS LANDING AREA. AIRCRAFT SUSTAINED HARD LANDING WITH NO PILOT INJURI ES. 1 G 7 1 4U EXPA1G71 1997080700371 19970807 00371 WP 1997 8 7 97ZZZX3497 1 19970728 G 2921 4365082 DIAPHRAGM 43442795002 DOUG DC8 DC8* WP ACCUMULATOR TORN B DM4R K NONE O OTHER NR NOT REPORTED 1 SO 19 JW2779A NEW BLADDER DIAPHRAGM INSTALLED IN ACCUMULATOR JULY, 1996. UNIT FAILED JULY, 1997. BLADDER TORN AND LEAKING. THIRD TY PE FAILURE SEEN WITH THIS PART NUMBERED BLADDER. BLADDER PMA PART FROM KAPCO (DOUGLAS LICENSEE). 2 L 7 4 4J F 4A25 1997080700372 19970807 00372 EA 1997 8 7 97ZZZX3498 1 19970722 G 2434 VHP430KH3 CELL SAFT 40783 CNDAIR CL600 CL6001A11 1900302 EA BATTERY SHORTED B WC7R K NONE M OVER TEMP NR NOT REPORTED 1 GL 25 100LR 111 083318 1064 AIRCRAFT BATTERY CHARGER DROPPING OFF-LINE. REMOVED AND SHIPPED BATTERY TO INSPECTION AND SERVICE. FOUND SHORTED CELL, STRAPS HAD BURNED SMALL HOLE THROUGH SIDE OF CELL. BATTERY WILL BE SHIPPED BACK TO MANUFACTURER DUE TO LOW TSN. 2 L 7 2 4F RT A21EA 1997080700373 19970807 00373 CE 1997 8 7 97ZZZX3499 1 19970724 G 5500 26120691 GUSSET CESSNA 208 208B 2073701 CE TAIL CONE CHAFED D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 09 723FX 208B0456 WHILE REMOVING THE ELEVATOR TRIM ACTUATOR, DISCOVERED THE TRIM CONTROL CABLE WAS INCORRECTLY ROUTED BENEATH THE GUSSET I N THE TAIL CONE RATHER THAN THROUGH THE GUSSET. THIS CAUSED THE CABLES TO RIDE AGAINST THE AFT FLANGE OF THE GUSSET. M INIMAL DAMAGE WAS DONE TO THE GUSSET WITH LESS THAN .0312 INCH REMOVED FROM THE GUSSET FLANGE AND NO DAMAGE TO THE CONTR OL CABLES. THERE WAS NO INDICATION THAT THE CABLES HAD BEEN REMOVED OR RE-ROUTED SINCE THE AIRCRAFT WAS NEW. RECOMMEND INSPECTING OTHER AIRCRAFT IN THIS RANGE OF SERIAL NUMBERS FOR INCORRECTLY ROUTED TRIM CABLES. 1 H 7 1 3T A37CE 1997080700374 19970807 00374 EU 1997 8 7 97ZZZX3500 1 19970723 G 2430 Z00N7707115228 CONNECTOR SOCATA TBM TBM700 8682000 EU BATTERY BURNED B A LF1R K NONE O OTHER IN INSP/MAINT 1 EA 07 800GS 801 5 WHILE REMOVING BATTERY FOR MAINTENANCE, FOUND NEGATIVE TERMINAL ON CONNECTOR ARCED AND BURNED. THE NEGATIVE POST IN BAT TERY RECEPTACLE WAS ALSO DAMAGED AND POSSIBLY CAUSED BY WORN CONNECTOR (SOCKET ENLARGED) NOT PROVIDING GOOD CONTACT. CO NNECTOR SHOULD BE CHECKED WITH GO/NO-GO GAUGE ANYTIME BATTERY MAINTENANCE IS PERFORMED. CONNECTOR AND RECEPTACLE REPLAC ED. 1 L 7 1 3T RT A60EU 1997080700376 19970807 00376 NE 1997 8 7 97ZZZX3502 2 19970607 G 7250 ENGINE BOEING 747 747SR46 NM PWA JT9 JT9D7 52054 NE NR 3 LP TURBINE FAILED B A GK4Y A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 WP 03 478EV 21033 PPG/AKL - FLT EZ6987 - EN ROUTE, DIVERTED TO NAN DUE NR 3 ENGINE FAILURE DURING CLIMB. NR 3 ENGINE INSPECTIONS CARRIED OUT AND SEVERAL LP TURBINE BLADES FOUND SEVERELY DAMAGED. AOG EVERGREEN MECHANICS AND ATS ENGINEERS CARRIED OUT ENGINE CHANGE AND ENGINE POWER RUN SATISFACTORY. 2 L 7 4 4F 4 F A20WE E20EA 1997080700377 19970807 00377 NE 1997 8 7 97ZZZX3503 2 19970720 G 7200 ENGINE BOEING 747 747SR46 NM PWA JT9 JT9D7 52054 NE NR 2 FAILED B A GK4Y A UNSCHED LANDING O M OTHER OVER TEMP CL CLIMB 1 WP 03 478EV 21033 PPG/AKL - FLT EZ6987 - EN ROUTE, DIVERTED TO NAN DUE NR 2 ENGINE SHUT DOWN (OVER TEMP) DURING CLIMB. DURING GROUND INSP ECTION, MELTED METAL PIECES FOUND IN TAIL PIPE AREA, NR 2 ENGINE. EVERGREEN DECIDED TO TRANSFER CARGO TO RELIEVING AIRC RAFT AND FERRY N478EV ON 3 ENGINES TO HONG KONG. A ONE-OFF APPROVAL TO PREPARE AIRCRAFT PER EZ INSTRUCTIONS GIVEN TO AT S. CERTIFICATION CARRIED OUT BY EZ MECHANIC. 2 L 7 4 4F 4 F A20WE E20EA 1997080700378 19970807 00378 CE 1997 8 7 97ZZZX3504 1 19970716 G 2820 W99106 COUPLING LEAR 55 55C 5170706 CE LT FUEL SUPPLY FAILED B A VIBR A UNSCHED LANDING K FLUID LOSS NR NOT REPORTED 1 SO 13 111US 3359 147 CLAMP ON COUPLING OPENED AND FELL OFF. COUPLING LOCATED IN FUEL SUPPLY LINE JUST BELOW LEFT FUEL FILTER IN TAIL CONE. A IRCRAFT CREW NOTICED DECREASING FUEL QUANTITY AND DIVERTED TO BNA. LEFT ENGINE THROTTLE SET TO IDLE WHEN PROBLEM NOTICE D. ENGINE FLAMED OUT ON FINAL APPROACH. AIRCRAFT LANDED WITH 800 POUNDS FUEL ON BOARD. LOST 3,650 POUNDS OF FUEL IN L ESS THAN 30 MINUTES. FUEL IN TAIL CONE AREA DRAINED OUT THROUGH DRAIN HOLES, BUT WAS A HAZARDOUS SITUATION DUE TO EQUIP MENT LOCATED IN TAIL CONE. COUPLING REMOVED AND REPLACED WITH NEW DESIGN COUPLING. 2 L 7 2 4F RT A10CE 1997080700416 19970807 00416 EU 1997 8 7 97ZZZX3506 1 19970718 G 6230 4619305032 ROTOR MAST 4638001004 BOLKMS 105 BO105C 5626005 EU TRANSMISSION CRACKED B A ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 501AL 7071 1117 S58 DURING MAIN ROTOR HUB REMOVAL, NOTED THE MAIN ROTOR MAST FLANGE WAS CRACKED. THE MAST FLANGE WAS FOUND CRACKED APPROXIM ATELY THREE-FOURTHS AROUND. THE CRACK WAS NEAR THE RADIUS OF THE FLANGE AND THE STUD HOLES. 1 G 7 2 3U H3EU 1997081400118 19970814 00118 EU 1997 8 14 97ZZZX3537 1 19970509 G 2820 S25CX315 BELLCRANK BRAERO DH125 BAE125800A 1500285 EU FUEL SYS LP COCK CORRODED B A JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 800N 6739 DURING A ROUTINE 600-HOUR INSPECTION, THE FUEL SYSTEM LP COCK BELLCRANK AND CROSSFEED BELLCRANK WERE FOUND EXTENSIVELY C ORRODED. THIS AREA IS BETWEEN THE MAIN GEAR WHEELWELLS BELOW THE POTTY AREA. EVIDENCE OF 'BLUE POTTY WATER' SATURATED THE AREA. ACCESS TO THIS AREA IS THROUGH PANELS W511 AND W512 IN THE MAIN GEAR WHEELWELLS. THE BELLCRANKS WERE CHANGED AND THE AREA CLEANED. SPECIAL ATTENTION SHOULD BE GIVEN DURING INSPECTIONS TO THE POTTY AREA IN LIGHT OF THE CORROSIVE CONTENT OF LAV CONTAINERS. 2 L 7 2 4F RT A3EU 1997081400119 19970814 00119 GL 1997 8 14 97ZZZX3538 2 19970722 G 7250 6889069 COUPLING 23035128 ALLSN 250C 250C30P 03013 GL TURBINE N2 FAILED TEST D K NONE L NO TEST IN INSP/MAINT 1 NM 11 842 58787 CAE895526 N2 COUPLING FAILED SPLINE TEST. 3 U E1GL 1997081400120 19970814 00120 NM 1997 8 14 97ZZZX3539 1 19970723 G 2710 1293841 PISTON ASSY 129307 BOEING 747 747* NM AIL ACTUATOR BENT B S IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 K135 INSPECTION OF AILERON ACTUATOR FOUND PISTON ATTACHMENT POINTS WHERE THE PISTON ATTACHES TO THE PISTON CONNECTOR, 15 ARE BENT OUTWARDS. AREA OF PISTON BENT UNDER NORMAL OPERATION. 2 L 7 4 4F RT A20WE 1997081400121 19970814 00121 SO 1997 8 14 97ZZZX3540 2 19970729 G 7260 632018 DRIVE GEAR BEECH 33 F33A 1151425 CE CONT O520 IO520BA 17032 SO ALT DRIVE DAMAGED H O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 EA 25 111HR 807 CE512 249272R ALTERNATOR FAILED IN-FLIGHT. NORMAL LANDING MADE. ELECTRICALLY ALTERNATOR CHECKED OK. SAW ROTOR NOT MOVING WITH PROPE LLER. REMOVED ALTERNATOR. ALTERNATOR DRIVE GEAR AND ALTERNATOR FACE DRIVE GEAR TEETH WORN AWAY. REMOVED DRIVE. PIECE S OF BUSHING FELL OUT OF ASSY. DISASSEMBLED ALTERNATOR. DRIVE END BEARING SLOPPY. ALTERNATOR SHAFT WORN UNEVENLY AT BE ARING. ROTOR HAD BEEN RUBBING ON STATOR. FOUND METAL IN OIL FILTER. ENGINE REMOVED FOR OVERHAUL. 1 L 7 1 3O 3 O 3A15 E5CE 1997081400122 19970814 00122 CE 1997 8 14 97ZZZX3541 1 19970729 G 2410 640934 DRIVE ASSY PRESTOLITE ALX9424 BEECH 33 F33A 1151425 CE CONT O520 IO520BA 17032 SO ALT DRIVE FAILED H O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 EA 25 111HR 807 5120624 CE512 249272R ALTERNATOR FAILED IN-FLIGHT. NORMAL LANDING MADE. ELECTRICALLY ALTERNATOR CHECKED OK. SAW ROTOR NOT MOVING WITH PROPE LLER. REMOVED ALTERNATOR. ALTERNATOR DRIVE GEAR AND ALTERNATOR FACE DRIVE GEAR TEETH WORN AWAY. REMOVED DRIVE. PIECE S OF BUSHING FELL OUT OF ASSY. DISASSEMBLED ALTERNATOR. DRIVE END BEARING SLOPPY. ALTERNATOR SHAFT WORN UNEVENLY AT BE ARING. ROTOR HAD BEEN RUBBING ON STATOR. FOUND METAL IN OIL FILTER. ENGINE REMOVED FOR OVERHAUL. 1 L 7 1 3O 3 O 3A15 E5CE 1997081400123 19970814 00123 CE 1997 8 14 97ZZZX3542 1 19970701 G 2720 0024100397 BELLCRANK BEECH 95 95B55 1152729 CE RUDDER PEDAL FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 05 6663C 2160 TC2265 RUDDER PEDAL INTERCONNECT REARWARD PROTRUDING ARM BROKE COMPLETELY OFF APPROXIMATELY 1 INCH FORWARD OF INTERCONNECT ROD PIVOT. BELLCRANK BROKE DURING GROUND OPERATIONS WHEN FLIGHT INSTRUCTOR APPLIED PRESSURE ON RUDDER PEDAL OPPOSITE OF THE STUDENT, IN ORDER TO PREVENT AN EXCESSIVELY SHARP TURN. BROKEN CROSS-SECTION DOES REVEAL PREVIOUS EXISTING CRACK. 1 L 7 2 3O RT 3A16 1997081400124 19970814 00124 CE 1997 8 14 97ZZZX3543 1 19970721 G 7602 5038901223 CONTROL CABLE BEECH 58 58 1152740 CE RT ENG MIXTURE FAILED B FFKR E A ENGINE SHUTDOWN UNSCHED LANDING Y ENGINE STOPPAGE CL CLIMB 1 SO 05 1HW 1155 TH271 RIGHT ENGINE FAILED APPROXIMATELY 5 MINUTES AFTER TAKEOFF. ENGINE SECURED IAW ENGINE OUT CHECK LIST AND RETURNED TO AIR PORT WITH NO FURTHER PROBLEMS. CABLE FAILED .50 INCH FROM ROD-END ON ENGINE SIDE OF CABLE. CABLE WAS INSTALLED CORRECT LY, CLEANED, AND LUBED AT EACH 100-HOUR INSPECTION INTERNAL. RECOMMEND LARGER CABLE. 1 L 7 2 3O 3A16 1997081400125 19970814 00125 WP 1997 8 14 97ZZZX3544 1 19970719 G 6520 HPPBR49 BEARING HILLER UH12 UH12E 4360122 WP LYC O540 VO540C2A 41532 EA T/R GEARBOX MISMANUFACTURED B A OUGR K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 17 H03037 NEW REPLACEMENT BEARING RECEIVED WITH INSTRUCTIONS FROM MRC (BEARING MFG), AND HILLER SL UH12-25-1 DESCRIBING INSTALLATI ON INSTRUCTIONS WITH REGARDS TO THE FILING NOTCHES AND BEARING MARKINGS ON THE OUTER RACE. THESE INSTRUCTIONS ORIENT TH E BEARING SO THE MAJOR THRUST LOAD IS ON THE RACES THAT DO NOT HAVE FILING NOTCHES. THIS BEARING WAS RECEIVED WITH MARK INGS OPPOSITE THE WRITTEN INSTRUCTIONS. BEARING RETURNED TO HILLER. 1 G 7 1 3O 3 O 4H11 E304 1997081400127 19970814 00127 WP 1997 8 14 97ZZZX3546 1 19970718 G 7330 369H81443 BYPASS SWITCH 38655 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL FUEL PUMP FAILED B A GHHR K NONE O OTHER IN INSP/MAINT 1 NM 01 1109P 301 T1927 1100849D CAE833681 SWITCH FAILED TO CLOSE AT PRESCRIBED LIMITS OF DN-41.1 DURING A 300-HOUR INSPECTION. THIS IS THE 7TH SWITCH TO FAIL IN LESS THAN 500 HOURS OF OPERATION SINCE FIRST FAILURE REPORTED ON 12-10-96. THAT FAILURE COULD HAVE PREVENTED AN ENGINE FAILURE DUE TO FUEL CONTAMINATION IF THE SWITCH WOULD HAVE WORKED PROPERLY. SUBMITTER RECOMMENDS A MANDATORY 100-HOUR I NSPECTION INTERVAL. NOTE: AC NR 43-16, FUEL NOZZLE FILTER, 'NO FUEL BYPASS INDICATION'. NR 7313, PAGE 13. 1 G 7 1 3U 3 U H3WE E4CE 1997081400130 19970814 00130 GL 1997 8 14 97ZZZX3549 2 19970710 G 7250 223031938 NOZZLE 6898735 AGUSTA A109 A109A2 0260120 EU ALLSN 250C 250C20B 03013 GL GP TURBINE FAILED B A KUVR K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SO 19 8WH 709 CAT35469 7256 CAE832740 ENGINE PRODUCING LOW POWER. INSPECTED 2ND STAGE TURBINE NOZZLE. FOUND TURBINE WHEEL SHROUD FLAKING AND SEPARATING CAUS ING EXCESSIVE TURBINE WHEEL TIP CLEARANCE. FOUND OUTER BAND CRACKED RADIALLY CAUSING GAS PATH LEAKAGE. THIS PART SHOUL D MAKE 1,750 HRS AT LEAST. THIS, ALONG WITH NR 2 TURBINE WHEEL EROSION, CAUSED HIGH N1, HIGH TEMPERATURE, AND LOW POWER . 1 G 7 2 3U 3 U H7EU E4CE 1997081400131 19970814 00131 GL 1997 8 14 97ZZZX3550 2 19970710 G 7250 6886407 WHEEL 6898735 AGUSTA A109 A109A2 0260120 EU ALLSN 250C 250C20B 03013 GL GP TURBINE ERODED B KUVR O OTHER P NO WARNING INDICATION IN INSP/MAINT 1 SO 19 8WH 709 X121765 7256 CAE832740 ENGINE PRODUCING LOW POWER. REMOVED TURBINE ASSY AND SEPARATED GAS PRODUCER FROM POWER TURBINE. FOUND NR 1 TURBINE WHE EL SEVERELY CORRODED AFTER ONLY 708.5 HRS TT. WHEEL LIFE IS 1775.0 HRS. TIP CLEARANCE WAS ALSO EXCESSIVE. NO EVIDENCE OF FOD. LEADING EDGES WERE FLATTENED. THIS, ALONG WITH NOZZLE SEPARATION, CAUSED HIGH N1 WITH HIGH TEMPERATURE AND LOW POWER. 1 G 7 2 3U 3 U H7EU E4CE 1997081400132 19970814 00132 EA 1997 8 14 97ZZZX3551 2 19970625 G 8530 ROCKER SHAFT ENSTRM F28 F28F 3300412 GL LYC O360 HIO360F1AD 41514 EA NR 2 CYLINDER FAILED D A A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 WP 23 99YC 48 809 L27061514 LOOSE RETAINING NUTS WORKED OFF STUDS ALLOWING THE PORT COVER TO FALL OFF AND NR 2 CYLINDER INTAKE VALVE ROCKER ARM SHAF T TO FALL OUT OF THE ENGINE RESULTING IN A CRASH LANDING. SUGGEST REVIEWING ENSTROM PRODUCTION CERTIFICATE AND TIGHTEN T HE INSPECTION PROCEDURE TO REDUCE THE CHANCES THAT ANOTHER HELICOPTER WILL BE RELEASED WITH HIDDEN LOOSE PARTS. 1 G 7 1 3O 3 O H1CE 1E10 1997081400133 19970814 00133 CE 1997 8 14 97ZZZX3552 1 19970620 G 3244 850X10X10PR TIRE GOODYEARAERO MTSBSI MU2 MU2B60 5780460 CE RT MLG FAILED D K NONE O OTHER LD LANDING 1 SW 01 360RA 201 740SA DURING A LANDING JUNE 20, 1997, THE RIGHT MAIN LANDING GEAR TIRE TREAD SEPARATED FROM APPROXIMATELY TWO-THIRDS OF THE CI RCUMFERENCE OF THE TIRE. A NEW TIRE AND SERVICEABLE WHEEL WERE INSTALLED IAW THE MANUFACTURER'S MM PROCEDURES AND THE L ANDING GEAR AREA WAS VISUALLY INSPECTED FOR DAMAGE. NO DEFECTS WERE APPARENT. THE AIRCRAFT WAS RETURNED TO SERVICE. 1 H 7 2 3T RT A10SW 1997081400134 19970814 00134 CE 1997 8 14 97ZZZX3553 1 19970620 G 3230 030A3876012 GEARBOX MTSBSI MU2 MU2B60 5780460 CE RT MLG ACTUATOR FAILED D L A O OTHER J WARNING INDICATION CL CLIMB 1 SW 01 360RA 3405 740SA INVESTIGATION FOLLOWING LANDING WITH RT MLG RETRACTED FOUND THE RT MAIN TO LT MAIN DRIVE SHAFT (PN 030A-38610-21) DISCON NECTED. THE RT MAIN ACTUATOR WAS TURNED MANUALLY UNTIL THE RT LANDING GEAR WAS IN THE DOWN POSITION. INSPECTIONS REVEA LED THE LOWER AFT ATTACH BOLT FOR THE RT MLG ACTUATOR WAS LOOSE AND THAT THE NUT WAS NOT ON THE BOLT. THE ACFT WAS PLAC ED ON JACKS AND A VISUAL INSPECTION REVEALED THE RT MLG ACTUATOR GEARBOX HOUSING HAD FAILED AND THE REMAINING THREE FAS TENERS WERE LOOSE ALLOWING ENOUGH MOVEMENT BETWEEN THE GEARBOX AND THE ACFT STRUCTURE TO DISCONNECT THE INTERCONNECT DRI VE SHAFT. BOTH MLG ACTUATOR GEARBOXES WERE REMOVED AND ALL ATTACHING HARDWARE WAS REPLACED WITH NEW ITEMS. 1 H 7 2 3T RT A10SW 1997081400135 19970814 00135 CE 1997 8 14 97ZZZX3554 1 19970724 G 5210 504300431329 SUPPORT BEECH 200 B200 1152922 CE DOOR HINGE CRACKED B S A VG4R K NONE O OTHER IN INSP/MAINT 1 SO 15 770AE 3323 BB1226 LOOSE AFT RIVETS IN CABIN DOOR HINGE LED TO FURTHER INVESTIGATION. FOUND HINGE SUPPORT INSIDE DOOR ASSY CRACKED TO A LE NGTH OF 4 INCHES THROUGH 4 EACH RIVET HOLES. SUGGEST HINGE AFT RIVETS MAY HAVE BEEN IN A LOOSE CONDITION FOR AN EXCESSI VE LENGTH OF TIME. 1 L 7 2 4T A24CE 1997081400212 19970814 00212 NM 1997 8 14 97ZZZX3555 1 19970430 G 6322 B1741 FAN WHEEL ROBSIN R22 R22BETA NM COOLING FAN CRACKED D A K NONE O OTHER IN INSP/MAINT 1 SO 17 4033S 100 1501 CRACKS FOUND DURING 100-HOUR INSPECTION OF AIRCRAFT IN FAN WHEEL ASSEMBLY, SECOND FAN WHEEL INSTALLED SINCE AIRCRAFT REB UILT BY FACTORY. FAN WAS BALANCED AT EACH INSTALLATION YET CONTINUED TO CRACK. TOTAL AIRCRAFT TIME SINCE REBUILT, 499. 0 HOURS. 1 G 7 1 3O H10WE 1997081400526 19970814 00526 NM 1997 8 14 97ZZZX3560 1 19970805 G 5551 69144105 PIN BOEING 727 727251 138408H NM RT H STAB ATTACH BROKEN B A JR2R K NONE O OTHER IN INSP/MAINT 1 SW 15 279US 21158 DURING C-CHECK, REMOVAL OF HORIZONTAL STABILIZER REVEALED THAT RT STABILIZER ATTACHMENT PIN WAS SEVERELY RUSTED AND BROK EN IN HALF. ALSO, FOUND FAIL-SAFE BOLT INSIDE PIN SEVERELY RUSTED. SUBMITTER STATED PART FAILURE DUE TO LACK OF LUBRIC ATION. 2 L 7 3 4F A3WE 1997081400527 19970814 00527 WP 1997 8 14 97ZZZX3561 2 19970110 G 7200 ENGINE CASA C212 C212CC 2410204 EU GARRTT TPE331 TPE33110 01514 WP NR 2 FAILED D O OTHER Y ENGINE STOPPAGE CR CRUISE 1 AL 03 348CA 1996 175 P37050 NR 2 ENGINE SHUT DOWN IN-FLIGHT DUE TO ZERO TORQUE AND DECREASING ENGINE RPM FUEL FLOW. ENGINE OIL OVER-SERVICE SUSPECT ED DUE TO OIL TANK VENT VALVE OPEN. 2 H 7 2 4T 4 T A43EU E4WE 1997081400529 19970814 00529 GL 1997 8 14 97ZZZX3563 1 19970622 G 7160 AIR CLEANER AMTR HORNET HORNET 05630FL GL ENGINE INT DEPARTED G A A UNSCHED LANDING O OTHER CR CRUISE 1 WP 09 414R 96 0008 AMATEUR-BUILT AIRCRAFT. DURING FLIGHT, ENGINE PROPELLER FAILED. AN OFF-AIRPORT LANDING WAS MADE. AIRCRAFT SUSTAINED D AMAGE TO LANDING GEAR. INVESTIGATION DETERMINED THAT ONE ENGINE AIR CLEANER ASSY WAS MISSING, BELIEVED TO HAVE STRUCK THE PROPELLER. FILTER IS A K & N MODEL AIR CLEANER. NO PART NUMBER AVAILABLE. NOT KNOWN WHEN AIR CLEANERS LAST MAINTA INED. 1 H 7 1 3I NT EXPA1H71 1997081400530 19970814 00530 1997 8 14 97ZZZX3564 4 19970604 G 3452 071015071301 TRANSPONDER BELL 230 230 1182149 SW CONTROL PANEL MALFUNCTION B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV X1154 23019 CONTROL PANEL WILL NOT SQUAWK 1200 WHEN TURNED TO VFR POSITION. 1 G 7 2 3U NC H9SW 1997081400531 19970814 00531 1997 8 14 97ZZZX3565 4 19970215 G 3454 071121627 CONTROL HEAD BELL 230 230 1182149 SW NAV CONTROL FAILS B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 716 5960 23019 NAVIGATION CONTROL HEAD LOSES MEMORY. 1 G 7 2 3U NC H9SW 1997081400532 19970814 00532 1997 8 14 97ZZZX3566 4 19970215 G 3422 5050031926 GYRO BELL 230 230 1182149 SW COCKPIT DG FLAG FAILED B TI1R K NONE N FALSE WARNING IN INSP/MAINT 1 SW 05 4UV 1476 23019 DIRECTIONAL GYRO FLAG WILL NOT RETRACT. 1 G 7 2 3U NC H9SW 1997081400533 19970814 00533 1997 8 14 97ZZZX3567 4 19970131 G 3455 071121009 CONTROL BELL 230 230 1182149 SW COCKPIT ADF FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 690 5271 23019 ADF CONTROL HEAD WOULD NOT POWER UP. 1 G 7 2 3U NC H9SW 1997081400534 19970814 00534 1997 8 14 97ZZZX3568 4 19970228 G 3160 066040211111 SYMBOL GENERATOR BELL 230 230 1182149 SW COCKPIT MALFUNCTION B TI1R K NONE O OTHER AP APPROACH 1 SW 05 4UV 1945 23019 AIRCRAFT SWAYS WHEN ON GPS APPROACH. 1 G 7 2 3U NC H9SW 1997081400535 19970814 00535 SW 1997 8 14 97ZZZX3569 1 19970217 G 3340 7028502 STROBE BELL 230 230 1182149 SW ANTI COLLISION SHORTED B TI1R K NONE M OVER TEMP NR NOT REPORTED 1 SW 05 4UV 23019 BEACON SHORTED AND BURNED. CIRCUIT BREAKER TRIPS WHEN POWER APPLIED. 1 G 7 2 3U NC H9SW 1997081400536 19970814 00536 SW 1997 8 14 97ZZZX3570 1 19970208 G 2430 A1077V RELAY BELL 230 230 1182149 SW DC SYSTEM FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 705 CL23999 23019 A1 STUD BURNED THROUGH. REMOVED TO CW TB 230-95-10. 1 G 7 2 3U NC H9SW 1997081400537 19970814 00537 SW 1997 8 14 97ZZZX3571 1 19970115 G 2430 A1077V RELAY BELL 230 230 1182149 SW DC SYSTEM INTERMITTENT B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 661 TA03729 23019 RELAY INTERMITTENTLY STICKS - GENERATOR WILL NOT COME ON LINE (INTERMITTENT). 1 G 7 2 3U NC H9SW 1997081400538 19970814 00538 SW 1997 8 14 97ZZZX3572 1 19970414 G 2422 PC125123C INVERTER BELL 230 230 1182149 SW AC SYSTEM INTERMITTENT B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 853 5494 23019 INTERMITTENT INVERTER. 1 G 7 2 3U NC H9SW 1997081400539 19970814 00539 1997 8 14 97ZZZX3573 4 19970301 G 3421 222375033101 INDICATOR BELL 222 222U 1182140 SW COCKPIT ATITUDE INOPERATIVE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 219HM 163 0158 47573 ATTITUDE INDICATOR INOPERATIVE. 1 G 7 2 3U H9SW 1997081400540 19970814 00540 1997 8 14 97ZZZX3574 4 19970408 G 3455 071123400 ANTENNA KA44B BOLKMS 117 BK117A4 5626017 EU ADF FAULTY B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117NG 61 62593 7083 ADF WILL NOT TRACK RMI NEEDLE. 1 G 7 2 3U H13EU 1997081400541 19970814 00541 EU 1997 8 14 97ZZZX3575 1 19970220 G 3340 6034745 POWER SUPPLY BOLKMS 117 BK117A1 5626010 EU ANTI COLLISION DEFECTIVE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117LF 0853 7013 ANTI-COLLISION LIGHT POWER SUPPLY NOISY. CAUSED RADIO INTERFERENCE AND SPIKES ON AMPMETER. 1 G 7 2 3U H13EU 1997081400542 19970814 00542 SW 1997 8 14 97ZZZX3576 1 19970223 G 2435 23032048 GENERATOR BELL 222 222 1182122 SW START GEN FAILED B TI1R K NONE H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 SW 05 911LW 315 7723 47520 GENERATOR CAME OFF-LINE AND WOULD NOT RESET. 1 G 7 2 3U H9SW 1997081400543 19970814 00543 1997 8 14 97ZZZX3577 2 19970710 G 7210 23055464 COVER ENG GEARBOX DEFECTIVE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 TOP STUD FOR TURBINE MOUNT WILL NOT TORQUE. COVER ONLY HAS 50.1 HOURS SINCE OVERHAULED. REMOVED AND REPLACED. 1997081400544 19970814 00544 1997 8 14 97ZZZX3578 4 19970625 G 3452 066106200 TRANSPONDER KING KT76 COCKPIT INOPERATIVE B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 38776 TRANSPONDER UNIT INOPERATIVE WHEN INSTALLED. REMOVED AND REPLACED. 1997081400629 19970814 00629 1997 8 14 97ZZZX3579 4 19970728 G 2312 4000103000 RECEIVER RT450 BOLKMS 117 BK117B1 5626012 EU COCKPIT INOPERATIVE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 214AE 811 7206 TRANSCEIVER WILL NOT TRANSMIT. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1997081400630 19970814 00630 1997 8 14 97ZZZX3580 4 19970619 G 3422 5050031926 DIRECTIONAL GYRO BOLKMS BK117 BK117C1 5626025 EU COCKPIT DEFECTIVE B TI1R K NONE O OTHER NR NOT REPORTED 1 SW 05 317MC 25005 7505 TOTAL TIME INSTALLED 221.2 HOURS. INTERMITTENT - GYRO SLOW TO SPOOL AND SPINS IN-FLIGHT. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1997081400631 19970814 00631 1997 8 14 97ZZZX3581 4 19970625 G 3416 B4553110004 ALTIMETER BOLKMS BK117 BK117C1 5626025 EU COCKPIT DEFECTIVE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 5341 7505 ALTIMETER FAILED LEAK CHECK. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1997081400632 19970814 00632 1997 8 14 97ZZZX3582 4 19970625 G 3416 1042011968E ALTIMETER BOLKMS BK117 BK117C1 5626025 EU COCKPIT MALFUNCTION B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 151552 7505 ALTIMETER CODE OFF FLAG ALWAYS 'ON'. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1997081400633 19970814 00633 EU 1997 8 14 97ZZZX3583 1 19970717 G 5210 1172427401 GUIDE ASSY BOLKMS BK117 BK117C1 5626025 EU DOOR WORN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 7505 DOOR TRACK LATCH WORN. REF: RMA NR R011538. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1997081400634 19970814 00634 SW 1997 8 14 97ZZZX3584 1 19970621 G 7810 230063301101 EXHAUST DUCT BELL 230 230 1182149 SW ENGINE EXHAUST CRACKED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 995 23019 CRACKED EXHAUST DUCT. REMOVED AND REPLACED. 1 G 7 2 3U NC H9SW 1997081400635 19970814 00635 SW 1997 8 14 97ZZZX3585 1 19970702 G 6400 222012711107 LINK BELL 230 230 1182149 SW T/R CTWT WORN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 23019 TAIL ROTOR COUNTERWEIGHT HAS WORN BEARINGS. REMOVED AND REPLACED 2 EACH. 1 G 7 2 3U NC H9SW 1997081400636 19970814 00636 SW 1997 8 14 97ZZZX3586 1 19970702 G 6720 230312001101 PITCH LINK BELL 230 230 1182149 SW T/R WORN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 23019 PITCH LINK HAS WORN BEARINGS. REMOVED AND REPLACED. 1 G 7 2 3U NC H9SW 1997081400637 19970814 00637 SW 1997 8 14 97ZZZX3587 1 19970704 G 2430 1820300150 SHUNT BELL 230 230 1182149 SW DC SYSTEM BURNT B TI1R K NONE J WARNING INDICATION NR NOT REPORTED 1 SW 05 4UV 23019 SHUNT DISCOLORED CAUSING GENERATOR NOT TO COME ON LINE. REMOVED AND REPLACED. 1 G 7 2 3U NC H9SW 1997081400638 19970814 00638 SW 1997 8 14 97ZZZX3588 1 19970621 G 7810 230063301102 EXHAUST DUCT BELL 230 230 1182149 SW ENGINE EXHAUST CRACKED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 995 23019 CRACKED EXHAUST DUCT. REMOVED AND REPLACED. 1 G 7 2 3U NC H9SW 1997081400639 19970814 00639 EU 1997 8 14 97ZZZX3589 1 19970710 G 7714 1179405603 INDICATOR NG BOLKMS 117 BK117B1 5626012 EU ENGINE N1 FLUCTUATES B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 460H 227 7142 N1 GAUGE FLUCTUATING 70 PERCENT N1. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1997081400640 19970814 00640 SW 1997 8 14 97ZZZX3590 1 19970619 G 3510 IDP5 OXY INDICATOR BELL 206 206L1 1182107 SW OXYGEN SYSTEM FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 519EH 6250001 45429 OXYGEN INDICATOR WOULD NOT SAY SET. READ-OUT WOULD HUNT UP AND DOWN SCALE. REF: AR NR 707-8312. REMOVED AND REPLACED . 1 G 7 1 3U H2SW 1997081400641 19970814 00641 1997 8 14 97ZZZX3591 4 19970617 G 2211 11788292 COMPUTER BOLKMS 117 BK117A3 5626015 EU COCKPIT SPAS FAILED B TI1R K NONE J WARNING INDICATION CR CRUISE 1 SW 05 527MB 0489113 7103 SPAS COMPUTER CAUTION LIGHT ILLUMINATES INTERMITTENTLY IN-FLIGHT. UNIT FAILED AFTER ONLY 178 HOURS. REMOVED AND REPLAC ED. (X) 1 G 7 2 3U H13EU 1997081400642 19970814 00642 SW 1997 8 14 97ZZZX3592 1 19970620 G 7810 2060643000005 EXHAUST STACK BELL 206 206L1 1182107 SW ENGINE CRACKED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 721SP 339 45486 EXHAUST DUCT CRACKED. REMOVED AND REPLACED. 1 G 7 1 3U H2SW 1997081400653 19970814 00653 1997 8 14 97ZZZX3594 4 19970314 G 2211 11788292 COMPUTER BOLKMS 117 BK117A3 5626015 EU SPAS MALFUNCTION B TI1R K NONE J WARNING INDICATION NR NOT REPORTED 1 SW 05 1140H 0588089 7078 SPAS LIGHT WILL NOT EXTINGUISH ON ANNUNCIATOR PANEL. 1 G 7 2 3U H13EU 1997081400654 19970814 00654 EU 1997 8 14 97ZZZX3595 1 19970331 G 2620 301011032 FIRE BOTTLE BOLKMS 117 BK117A3 5626015 EU FIRE EXT SYSTEM FAILED B TI1R K NONE O OTHER NR NOT REPORTED 1 SW 05 117LS 22706A2 7113 FIRE EXTINGUISHER BOTTLE LOST PRESSURE AND CONTENTS. 1 G 7 2 3U H13EU 1997081400655 19970814 00655 EU 1997 8 14 97ZZZX3596 1 19970404 G 7712 G555674 TRANSDUCER BOLKMS 117 BK117A4 5626017 EU TORQUE ERRATIC B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117NG 21 928 7083 TORQUE INDICATION ERRATIC. 1 G 7 2 3U H13EU 1997081400656 19970814 00656 EU 1997 8 14 97ZZZX3597 1 19970427 G 6730 391110002 ACTUATOR BOLKMS 117 BK117B1 5626012 EU SPAS DEFECTIVE B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 214AE 2523 237 7206 PART RECEIVED DEFECTIVE. ACTUATOR WILL NOT SELF-TEST, AND MOVES TOO SLOWLY. 1 G 7 2 3U H13EU 1997081400657 19970814 00657 1997 8 14 97ZZZX3598 4 19970501 G 3424 10290 GYRO BOLKMS 117 BK117B1 5626012 EU COCKPIT RATE FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 214AE 0112 7206 RATE GYRO WILL NOT STABILIZE AND OUTPUT CONSTANTLY FLUCTUATES. 1 G 7 2 3U H13EU 1997081400658 19970814 00658 1997 8 14 97ZZZX3599 4 19970528 G 3421 2223750333101 INDICATOR BELL 222 222U 1182140 SW COCKPIT ATTITUDE INOPERATIVE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 219HM 8 0068 47573 ATTITUDE INDICATOR INOPERATIVE. ONLY 7.6 HRS SINCE INSTALLED AFTER OVERHAUL. 1 G 7 2 3U H9SW 1997081400659 19970814 00659 SW 1997 8 14 97ZZZX3600 1 19970612 G 6220 222031605109 FLEXURE BELL 222 222U 1182140 SW M/R DEBONDED B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 219HM LK0078 47573 INSPECTION PRIOR TO INSTALLATION REVEALED SHEAR PAD TO BE DEBONDED. PART RECEIVED BAD FROM STOCK. 1 G 7 2 3U H9SW 1997081400660 19970814 00660 EU 1997 8 14 97ZZZX3601 1 19970425 G 7712 117902131 VARTOM BOLKMS BK117 BK117C1 5626025 EU RPM CONTROL FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 7505 FAILS TO REACH 108 PERCENT MODE. TORQUE SPLITS AND HUNTING. 1 G 7 2 3U NC H13EU 1997081400661 19970814 00661 EU 1997 8 14 97ZZZX3602 1 19970424 G 7714 L211790 CONTROL BOX BOLKMS BK117 BK117C1 5626025 EU N2 CONTROL WORN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 7505 CONTROL BOX HAS INTERNAL WEAR FROM CABLE. STIFF IN OPERATION. 1 G 7 2 3U NC H13EU 1997081400662 19970814 00662 EU 1997 8 14 97ZZZX3603 1 19970607 G 2822 1176415103 PUMP BOLKMS BK117 BK117C1 5626025 EU FUEL BOOST FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 172109 7505 BOOST PUMP TRIPS CIRCUIT BREAKER. WILL NOT ROTATE. 1 G 7 2 3U NC H13EU 1997081400663 19970814 00663 EU 1997 8 14 97ZZZX3604 1 19970611 G 2820 1176415503 SEAL BOLKMS BK117 BK117C1 5626025 EU FUEL DIST DEFECTIVE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 7505 RUBBER SWELLED ON SEAL. 1 G 7 2 3U NC H13EU 1997081400664 19970814 00664 EU 1997 8 14 97ZZZX3605 1 19970611 G 2822 1176415103 PUMP BOLKMS BK117 BK117C1 5626025 EU FUEL BOOST INTERMITTENT B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 172111 7505 BOOST PUMP OPERATION INTERMITTENT, HARD TO TURN ON. RUNS ROUGH. 1 G 7 2 3U NC H13EU 1997081400665 19970814 00665 NE 1997 8 14 97ZZZX3606 2 19970329 G 7261 0292105230 PUMP BOLKMS BK117 BK117C1 5626025 EU LYC LTS101 LTS101650B1 41560 NE ENGINE OIL LOW PRESSURE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 109 233SO 7505 DEFECTIVE OIL PUMP, LOW OIL. PRESSURE AT FULL ENGINE RPM. 1 G 7 2 3U 3 U NC H13EU E5NE 1997081400666 19970814 00666 EU 1997 8 14 97ZZZX3607 1 19970314 G 7714 L211790 CONTROL BOX BOLKMS BK117 BK117C1 5626025 EU N2 CONTROL MALFUNCTION B TI1R K NONE O OTHER CR CRUISE 1 SW 05 317MC 39 7505 ROUGH RUNNING, N2 CONTROL. 1 G 7 2 3U NC H13EU 1997081400667 19970814 00667 1997 8 14 97ZZZX3608 4 19970615 G 2210 060002600 GYRO BELL 230 230 1182149 SW AUTOPILOT DEFECTIVE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 2677 23019 OSCILLATION FELT IN CYCLIC CONTROL WHEN AUTOPILOT ENGAGED. REMOVED AND REPLACED AUTOPILOT GYRO. 1 G 7 2 3U NC H9SW 1997081400668 19970814 00668 SW 1997 8 14 97ZZZX3609 1 19970423 G 6330 222331618105 ISOLATION MOUNT BELL 230 230 1182149 SW TRANSMMISSION WORN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 875 1081 23019 BEARING WORN ON ISOLATION MOUNT. 1 G 7 2 3U NC H9SW 1997081400669 19970814 00669 SW 1997 8 14 97ZZZX3610 1 19970424 G 6220 222031613103 LIFT LINK BELL 230 230 1182149 SW M/R BEARING FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 875 23019 LIFT LINK LOWER BEARING SEPARATED FROM ELASTOMER. 1 G 7 2 3U NC H9SW 1997081400670 19970814 00670 SW 1997 8 14 97ZZZX3611 1 19970404 G 2436 222375060115 REGULATOR BELL 230 230 1182149 SW DC SYSTEM DEFECTIVE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 834 93020 23019 GENERATOR LIGHT WOULD NOT GO OUT. REGULATOR DEFECTIVE. 1 G 7 2 3U NC H9SW 1997081400671 19970814 00671 SW 1997 8 14 97ZZZX3612 1 19970404 G 6200 222012711107 BEARING BELL 230 230 1182149 SW LIK ASSY LOOSE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 834 23019 BEARING LOOSE IN COUNTERWEIGHT. 1 G 7 2 3U NC H9SW 1997081400672 19970814 00672 1997 8 14 97ZZZX3613 4 19970603 G 2312 071121570 CONTROL HEAD BELL 230 230 1182149 SW COCKPIT VHF DEFECTIVE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 6951 23019 CONTROL HEAD MEMORY FOR STANDBY DOES NOT HOLD. 1 G 7 2 3U NC H9SW 1997081400673 19970814 00673 1997 8 14 97ZZZX3614 4 19970514 G 3422 40205773 GYRO BOLKMS 117 BK117A3 5626015 EU COCKPIT DG DRIFTS B TI1R K NONE O OTHER NR NOT REPORTED 1 SW 05 4493X 5 80031622 S7038 DIRECTIONAL GYRO DRIFTS OFF HEADING. FAILED AFTER ONLY 4.5 HOURS OPERATION. 1 G 7 2 3U H13EU 1997081400674 19970814 00674 SW 1997 8 14 97ZZZX3615 1 19970506 G 5620 WINDOW BELL 222 222 1182122 SW LT REAR FAILED B TI1R K NONE O OTHER CR CRUISE 1 SW 05 911LW 47520 LEFT REAR WINDOW SHATTERED INSIDE THE AIRCRAFT IN-FLIGHT. 1 G 7 2 3U H9SW 1997081400675 19970814 00675 SW 1997 8 14 97ZZZX3616 1 19970110 G 6510 222044625105 DRIVE SHAFT BELL 222 222 1182122 SW T/R OUT OF LIMITS B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 911MK A776 47515 TAIL ROTOR DRIVE AFTER INSTALLATION, PART WAS DETERMINED TO BE DEFECTIVE FROM FACTORY. END PLATE OUT OF LIMITS PER BHT 222 OMM. 1 G 7 2 3U H9SW 1997081400676 19970814 00676 1997 8 14 97ZZZX3617 4 19970401 G 2211 7004206901 COMPUTER BOLKMS 117 BK117A3 5626015 EU CSAS MALFUNCTION B TI1R K NONE J WARNING INDICATION NR NOT REPORTED 1 SW 05 911MZ 90100300 7098 PITCH AND ROLL CSAS CAUTION LIGHT ILLUMINATED INTERMITTENTLY. 1 G 7 2 3U H13EU 1997082100059 19970821 00059 SW 1997 8 21 97ZZZX3619 1 19970616 G 2510 222020656107 PAD BELL 230 230 1182149 SW PILOT SEAT TORN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 23019 PROTECTIVE PAD TORN. REMOVED AND REPLACED. 1 G 7 2 3U NC H9SW 1997082100060 19970821 00060 SW 1997 8 21 97ZZZX3620 1 19970226 G 7700 22206084101 SWITCH BELL 230 230 1182149 SW ENGINE PRESSURE FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 763 0644 23019 SWITCH INOPERABLE. 1 G 7 2 3U NC H9SW 1997082100061 19970821 00061 EU 1997 8 21 97ZZZX3621 1 19970529 G 7120 11760101111 SUPPORT BOLKMS BK117 BK117C1 5626025 EU ENGINE MOUNT WORN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 7505 LOWER MOUNT POINTS WORN AND WORMING OUT. 1 G 7 2 3U NC H13EU 1997082100062 19970821 00062 EU 1997 8 21 97ZZZX3622 1 19970513 G 7712 117940691 INDICATOR BOLKMS BK117 BK117C1 5626025 EU DUAL TORQUE DEFECTIVE B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 253 DUAL TORQUE INDICATOR RECEIVED BAD FROM STOCK. ON INSTALLING, INDICATOR WOULD NOT CALIBRATE (SLOPE NR 1). NEEDLE 1 STUC K AT 20 PERCENT, WITH POWER OFF, IT GOES TO ZERO. 1 G 7 2 3U NC H13EU 1997082100063 19970821 00063 EU 1997 8 21 97ZZZX3623 1 19970424 G 7714 L21176209 CABLE CASE BOLKMS BK117 BK117C1 5626025 EU ENGINE N1 CONT BINDING B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 2002 7505 CABLE CASING ROUGH IN OPERATION. CABLE BINDS. 1 G 7 2 3U NC H13EU 1997082100064 19970821 00064 1997 8 21 97ZZZX3624 4 19970507 G 3421 222375033101 INDICATOR BELL 222 222U 1182140 SW COCKPIT ATTITUDE FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 219HM 0158 47573 ATTITUDE INDICATOR, FLAG WILL NOT STAY PULLED. 1 G 7 2 3U H9SW 1997082100065 19970821 00065 1997 8 21 97ZZZX3625 4 19970404 G 3421 222375033101 INDICATOR BELL 222 222U 1182140 SW COCKPIT ATTITUDE FAILED B TI1R K NONE B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 SW 05 219HM 41 0025 47573 PILOT SMELLED BURNING ODOR. OFF FLAG PULLED. ATTITUDE INDICATOR FAILED AFTER ONLY 40.9 HOURS INSTALLED. 1 G 7 2 3U H9SW 1997082100066 19970821 00066 NE 1997 8 21 97ZZZX3626 2 19970620 G 8530 VALVE DOUG DC3 DC3 3021401 WP PWA R1830 R183092 52020 NE NR 1 CYLINDER FAILED D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SW 17 941AT 693 4293040 431414 NR 1 CYLINDER VALVE HEAD CAME OFF AND SPLIT CYLINDER HEAD. ALSO, DAMAGED PISTON. 2 L 7 2 4R 4 R A669 5E4 1997082100067 19970821 00067 EA 1997 8 21 97ZZZX3627 1 19970802 G 2612 24403057 FIRE LOOP CNDAIR CL600 CL6002B16 1900305 EA RT ENGINE SEPARATED E O OTHER N FALSE WARNING CL CLIMB 1 WP 09 757MC 876 5177 RIGHT ENGINE FIRE LIGHT ILLUMINATED DURING CLIMB-OUT. EXTINGUISHED WITH THROTTLE RETARD, FOUND CORE FIRE LOOP BAD. WIL L REPLACE WITH NEW LOOP. 2 L 7 2 4F RT A21EA 1997082100068 19970821 00068 WP 1997 8 21 97ZZZX3628 2 19970720 G 7200 ENGINE LEAR 35 31A 5170531 CE GARRTT TFE731 TFE73123B WP RIGHT ENGINE FLAME OUT E A A UNSCHED LANDING X ENGINE FLAMEOUT CL CLIMB 1 WP 09 108FX 1296 104 P99319 RIGHT ENGINE ROLLED BACK AND FLAMED OUT CLIMBING FROM 44,000 FEET TO 45,000 FEET. NO INDICATION OF PROBLEM UNTIL AIRCRA FT YAWED. CONDITIONS SPEED - .74 TO .75 MACH. OAT = -61C. POWER = MAX COUNTS. AIRCRAFT DESCENDED TO 25,000 FEET, UNA BLE TO WINDMILL START. STARTER ENGAGED AND START SUCCESSFUL WITHIN PARAMETERS. OTHER CONDITIONS, AIRCRAFT ON AUTOPILOT AND CREW HAD NOT TOUCHED THE THROTTLE. GRAVITY FLOW OPEN, STANDBY PUMPS OFF. AIRCRAFT DIVERTED. ENGINE CYCLES, 957. 2 L 7 2 4F 4 F RT A10CE E6WE 1997082100069 19970821 00069 EA 1997 8 21 97ZZZX3629 2 19970722 G 7322 FLOAT FACET 105199 PIPER PA38 PA38112 7103812 SO LYC O235 O235L2C 41505 EA CARBURETOR COLLAPSED D K NONE O OTHER IN INSP/MAINT 1 WP 17 2452T 1415 CR01775 3878A0807 L1827815 AIRCRAFT CAME IN FOR ENGINE WORK. REMOVED CARBURETOR, RE-INSTALLED CARBURETOR. ATTACHED FUEL LINES. TURNED ON FUEL. F UEL BOWL NEEDLE JET FAILED TO STOP FUEL. REMOVED CARBURETOR, REMOVED BOWL, FOUND FLOAT COLLAPSED ON BOTH SIDES. NO EXP LANATION FOR CAUSE. 1 L 7 1 3O 3 O A18SO E223 1997082100070 19970821 00070 SO 1997 8 21 97ZZZX3630 1 19970727 G 5751 35640010 RIB PIPER PA28 PA28RT201 7102818 SO AILERON CENTER CRACKED D S K NONE O OTHER IN INSP/MAINT 1 EA 05 8098R 4672 28R8018003 WHILE REPLACING THE SKIN ON THE OUTBOARD SIDE OF THE LEFT AILERON, THE CENTER RIB WAS FOUND CRACKED IN THE FORWARD ATTAC H FLANGE. THIS AREA IS RIGHT BEHIND THE ACTUATING PUSH ROD. BOLTS WERE TIGHT. TOTALLY INACCESSIBLE TO VIEW. 1 L 7 1 3O 2A13 1997082100071 19970821 00071 EU 1997 8 21 97ZZZX3631 1 19970724 G 2910 LINE SOCATA TB20 TB20TRINIDAD 8680695 EU HYDRAULIC PUMP CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 05 25SW 2061 360 POOR PUMP MOUNTING BY OEM GIVES INSUFFICIENT VIBRATION ATTENUATION. ALUMINUM HYDRAULIC LINES ON PUMP FITTINGS CRACKED A T FLARES. SUBMITTER STATED SHOULD USE FLEXIBLE LINES. 1 L 7 1 3O RT A51EU 1997082100072 19970821 00072 CE 1997 8 21 97ZZZX3632 1 19970716 G 3250 12606321 SPACER 1260664411 CESSNA 206 U206F 2073333 CE NLG STEERING FAILED D S A O OTHER O OTHER LD LANDING 1 NE 05 1523U 6804 U20602234 PILOT REPORTED SQUEALING IN NOSE ON LANDING ROLL OUT, JUST BEFORE NOSE GEAR COLLAPSED DAMAGING PROPELLER AND NOSE OF AIR CRAFT. INVESTIGATION FOUND SPACER IN NOSE GEAR STEERING BUNGEE CRACKED OFF WHICH WOULD HAVE ALLOWED THE NOSE GEAR TO FR EE SWIVEL WITH NO CONTROL. 1 H 7 1 3O A4CE 1997082100538 19970821 00538 EU 1997 8 21 97ZZZX3659 1 19970626 G 6730 7004305901 ACTUATOR BOLKMS BK117 BK117C1 5626025 EU CSAS FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117NC 8 91080342 7509 CSAS ACTUATOR REMOVED DUE TO LACK OF TRAVEL. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1997082100539 19970821 00539 1997 8 21 97ZZZX3660 4 19970627 G 2312 064105430 TRANSCEIVER KY196A BOLKMS BK117 BK117C1 5626025 EU COCKPIT VHF FAILED B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 117NC 22666 7509 TRANSCEIVER OUT OF BOX FAILURE. NEW PART DEFECTIVE ON RECEIPT. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1997082100540 19970821 00540 1997 8 21 97ZZZX3661 4 19970612 G 3421 4021541671 GYRO BOLKMS BK117 BK117C1 5626025 EU COCKPIT HORIZ DEFECTIVE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117NC 8 92082228 7509 HORIZONTAL GYRO WILL NOT FULLY ALIGN. (REF: RMA NR R011312). REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1997082100541 19970821 00541 EU 1997 8 21 97ZZZX3662 1 19970628 G 6320 IPT20RT1100080G PRESS TRANSDUCER BOLKMS BK117 BK117C1 5626025 EU M/R GEARBOX FAILED B TI1R O OTHER J WARNING INDICATION CR CRUISE 1 SW 05 117NC 38555196 7509 TRANSDUCER DROPPED FROM 2.5 TO 1.0 BARS IN-FLIGHT. REF: RMA NR R011617. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1997082100542 19970821 00542 EU 1997 8 21 97ZZZX3663 1 19970628 G 2422 PC250 STATIC INVERTER BOLKMS BK117 BK117C1 5626025 EU AC SYSTEM MALFUNCTIONED B TI1R K NONE O OTHER NR NOT REPORTED 1 SW 05 117NC 5370 7509 INVERTER CAUSES INTERMITTENT FAILURES IN SYSTEMS IT PROVIDES BUSS FOR. REMOVED AND REPLACED 1 G 7 2 3U NC H13EU 1997082100543 19970821 00543 GL 1997 8 21 97ZZZX3664 2 19970617 G 7322 23059933 FUEL CONTROL BELL 206 206L3 1182108 SW ALLSN 250C 250C30P 03013 GL NR 1 ENGINE MALFUNCTION B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 206AZ 77 BR55429 51007 DELAYED STARTS, FAST TOT RISE, NO MODULATE OR RE-LIGHT. REMOVED AND REPLACED FCU. 1 G 7 1 3U 3 U H2SW E1GL 1997082100546 19970821 00546 SW 1997 8 21 97ZZZX3666 1 19970506 G 3340 4501283 LIGHT BELL 222 222U 1182140 SW SEARCH FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 222HX 63487 47533 WILL NOT EXTEND OR ROTATE. WAS REPAIRED FOR SAME DISCREPANCY ON LAST REPAIR AND WOULD NOT WORK WHEN ISSUED FROM STOCK. 1 G 7 2 3U H9SW 1997082100584 19970821 00584 CE 1997 8 21 97ZZZX3667 1 19970808 G 7120 265102215 MOUNT RING CESSNA 208 208 2073702 CE ENGINE CRACKED B P H7NR K NONE O OTHER IN INSP/MAINT 1 SW 17 225 ENGINE MOUNT RING REPAIRED PER CESSNA MM CHAPTER 71-21-00, PAGE 801, APRIL, 1996. ROUGHLY 100 HOURS AFTER INSTALLING DO UBLER PER MANUAL SPECIFICATIONS, THE OPPOSITE SIDE AT THE MOUNT CRACKED IN THE WELD. 1 H 7 1 3T NT A37CE 1997082100585 19970821 00585 CE 1997 8 21 97ZZZX3668 1 19970808 G 7120 265102215 MOUNT RING CESSNA 208 208 2073702 CE ENGINE CRACKED B H7NR K NONE O OTHER IN INSP/MAINT 1 SW 17 274 ENGINE MOUNT RING REPAIRED PER CESSNA MM, CHAPER 71-20-00, PAGE 801, APRIL, 1996. ROUGHLY 100 TO 200 HOURS AFTER REPAIR . (TIME IS UNSURE.) CRACK APPEARED ON THE OPPOSITE SIDE OF THE MOUNT RING FROM WHERE THE DOUBLER WAS INSTALLED. 1 H 7 1 3T NT A37CE 1997082100586 19970821 00586 1997 8 21 97ZZZX3669 4 19970807 G 2561 P0723E105P LIFE VEST EAAEROMARINE CELL VALVE FAIL TEST D K NONE L NO TEST IN INSP/MAINT 1 EA 07 36607 FAILED THE MANUFACTURER'S RECOMMENDED 2 PSI CELL TEST. 1997082100587 19970821 00587 1997 8 21 97ZZZX3670 1 19970728 G 2821 07560052 STRAINER CESSNA FUEL SYSTEM MISMANUFACTURED D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 13 TWO NEW PARTS RECEIVED FROM CESSNA. INLET STANDPIPE NOT FULLY INSERTED BEFORE CRIMP ALLOWING STANDPIPE TO FALL OUT. FU EL WOULD BYPASS STAINER SCREEN. DEFECT FOUND BY MECHANIC BEFORE INSTALLATION. 1997082100588 19970821 00588 SO 1997 8 21 97ZZZX3671 2 19970731 G 8520 652541 NUT CESSNA 182 182R 2072731 CE CONT O470 O470U 17026 SO CYL HOLD DOWN BROKEN D P K NONE O OTHER IN INSP/MAINT 1 SO 09 4804 1800 18268321 NUT WAS BROKEN THROUGH COMPLETELY. ALL TORQUE WAS RELEASED. THIS NUT WAS INSTALLED AT ENGINE OVERHAUL IAW CONT SB M92- 9. 1 L 7 1 3O 3 O NT 3A13 E273 1997082100589 19970821 00589 SO 1997 8 21 97ZZZX3672 1 19970701 G 3211 1742000 FITTING SUPPORT PIPER PA23 PA23250 7102308 SO GEAR WELL RT CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 15 14005 274623 FITTING SUPPORT CRACKS WERE DISCOVERED AT 85 HOURS AFTER ANNUAL (SIX MONTHS AGO). ALL BOLTS WERE LOOSE AND HOLES WERE E GG-SHAPED. CRACKS WERE FOUND AT BOTTOM AFT DRAG LINK SUPPORT. ALL BOLTS WRE LOOSE IN TRUNNION SUPPORT PADS, AS WELL. A LSO, THE AFT REINFORCEMENT CHANNEL BOLTS WERE LOOSE, BOTH SIDES. SUBMITTER STATED IF BOLTS ARE FOUND LOOSE, A CLOSE INS PECTION SHOULD BE MADE OF THE AFT SUPPORT MOUNTS. 1 L 7 2 3O 1A10 1997082100590 19970821 00590 SO 1997 8 21 97ZZZX3673 1 19970701 G 3211 1742001 FITTING SUPPORT PIPER PA23 PA23250 7102308 SO GEAR WELL RT CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 15 14005 274623 FITTING SUPPORT CRACKS WERE DISCOVERED AT 85 HOURS AFTER ANNUAL (SIX MONTHS AGO). ALL BOLTS WERE LOOSE AND HOLES WERE E GG-SHAPED. CRACKS WERE FOUND AT BOTTOM AFT DRAG LINK SUPPORT. ALL BOLTS WRE LOOSE IN TRUNNION SUPPORT PADS, AS WELL. A LSO, THE AFT REINFORCEMENT CHANNEL BOLTS WERE LOOSE, BOTH SIDES. SUBMITTER STATED IF BOLTS ARE FOUND LOOSE, A CLOSE INS PECTION SHOULD BE MADE OF THE AFT SUPPORT MOUNTS. 1 L 7 2 3O 1A10 1997082100591 19970821 00591 SO 1997 8 21 97ZZZX3674 1 19970701 G 3211 1742002 FITTING SUPPORT PIPER PA23 PA23250 7102308 SO GEAR WELL LT CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 15 14005 274623 FITTING SUPPORT CRACKS WERE DISCOVERED AT 85 HOURS AFTER ANNUAL (SIX MONTHS AGO). ALL BOLTS WERE LOOSE AND HOLES WERE E GG-SHAPED. CRACKS WERE FOUND AT BOTTOM AFT DRAG LINK SUPPORT. ALL BOLTS WRE LOOSE IN TRUNNION SUPPORT PADS, AS WELL. A LSO, THE AFT REINFORCEMENT CHANNEL BOLTS WERE LOOSE, BOTH SIDES. SUBMITTER STATED IF BOLTS ARE FOUND LOOSE, A CLOSE INS PECTION SHOULD BE MADE OF THE AFT SUPPORT MOUNTS. 1 L 7 2 3O 1A10 1997082100592 19970821 00592 SO 1997 8 21 97ZZZX3675 1 19970701 G 3211 1742003 FITTING SUPPORT PIPER PA23 PA23250 7102308 SO GEAR WELL LT CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 15 14005 274623 FITTING SUPPORT CRACKS WERE DISCOVERED AT 85 HOURS AFTER ANNUAL (SIX MONTHS AGO). ALL BOLTS WERE LOOSE AND HOLES WERE E GG-SHAPED. CRACKS WERE FOUND AT BOTTOM AFT DRAG LINK SUPPORT. ALL BOLTS WRE LOOSE IN TRUNNION SUPPORT PADS, AS WELL. A LSO, THE AFT REINFORCEMENT CHANNEL BOLTS WERE LOOSE, BOTH SIDES. SUBMITTER STATED IF BOLTS ARE FOUND LOOSE, A CLOSE INS PECTION SHOULD BE MADE OF THE AFT SUPPORT MOUNTS. 1 L 7 2 3O 1A10 1997082100593 19970821 00593 CE 1997 8 21 97ZZZX3676 1 19970723 G 7120 9691001061 MOUNT BEECH 58 58 1152740 CE RT ENGINE CRACKED B HE4R K NONE O OTHER IN INSP/MAINT 1 SO 11 1814W 2907 1010 TH267 RIGHT ENGINE MOUNT CRACKED AT THE TOP OUTBOARD ISOLATOR ATTACH WELD JOINT. THIS ENGINE HAD THE MODIFIED BRACKETS INSTAL LED PREVIOUSLY WHICH RELIEVES THE AD INSPECTION. 1 L 7 2 3O 3A16 1997082100595 19970821 00595 CE 1997 8 21 97ZZZX3678 1 19970611 G 7603 ROD END CESSNA 170 170B 2072306 CE THROTTLE WRONG BOLTS B V2AR K NONE W INADEQUATE Q C IN INSP/MAINT 1 AL 03 2814C 26357 AIRCRAFT WAS IN MAINTENANCE FOR CARBURETOR HEAT PROBLEM AND MECHANIC NOTED THAT AD 86-24-07 WAS NOT C/W. AIRCRAFT HAS B EEN MODIFIED WITH INSTALLATION OF 180 HP LYCOMING ENGINE IAW STC SA421CE AND SA749CE. AD 86-24-07 DOES NOT LIST 170B AS APPLICABLE. SE 79-6 DOES NOT CALL OUT SPECIFIC MODELS, BUT DOES REQUIRE DRILLED BOLTS ON ALL BALL BEARING TYPE CONTROL S. 1 H 7 1 3O A799 1997082100596 19970821 00596 CE 1997 8 21 97ZZZX3679 1 19970801 G 5712 57222061 CANTED RIB CESSNA 441 441 2076020 CE RT WING CRACKED B A WTXR K NONE O OTHER IN INSP/MAINT 1 NM 07 40KM 4450 4410053 DURING A PHASE INSPECTION, FOUND BOTH RT AND LT CANTED RIBS TOP CAPS TO BE CRACKED. CRACKS START AT AFT SIDE OF FORWARD WING SPAR AND RUN AFT, PARALLEL TO THE BEND RADIUS. STOP DRILLED BOTH ENDS OF EACH CRACK PER CESSNA ENGINEERING INSTRU CTIONS. 1 L 7 2 3T RT A28CE 1997082100597 19970821 00597 CE 1997 8 21 97ZZZX3680 1 19970801 G 5712 57222062 CANTED RIB CESSNA 441 441 2076020 CE LT WING CRACKED B WTXR K NONE O OTHER IN INSP/MAINT 1 NM 07 40KM 4450 4410053 DURING A PHASE INSPECTION, FOUND BOTH RT AND LT CANTED RIBS TOP CAPS TO BE CRACKED. CRACKS START AT AFT SIDE OF FORWARD WING SPAR AND RUN AFT, PARALLEL TO THE BEND RADIUS. STOP DRILLED BOTH ENDS OF EACH CRACK PER CESSNA ENGINEERING INSTRU CTIONS. 1 L 7 2 3T RT A28CE 1997082100599 19970821 00599 GL 1997 8 21 97ZZZX3682 3 19970716 G 6114 HUB CESSNA 185 A185F 2072821 CE HARTZL HCC3Y PHCC3YF1 GL AFT SIDE CRACKED D A K NONE O OTHER IN INSP/MAINT 1 SW 03 61092 912 18504107 EE2084A PROPELLER WAS REMOVED TO REPAIR OIL LEAK. A SIX INCH CRACK WAS FOUND ON THE AFT SIDE OF THE HUB. 1 H 7 1 3O 3A24 5 C P25EA 1997082100600 19970821 00600 EA 1997 8 21 97ZZZX3683 2 19970707 G 7421 REM37BY SPARK PLUG CHAMPION CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA ENGINE FOULED D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 WP 09 68452 200 15282300 L2048215 PILOT REPORTED INTERMITTENT ROUGH ENGINE OPERATION EN ROUTE. PILOT HAD FAILED TO LEAN THE ENGINE, CONSEQUENTLY, FOULING ALL 4 LOWER PLUGS. AN OFF-AIRPORT LANDING WAS MADE. NO DAMAGE TO AIRCRAFT. REPLACED LOWER PLUGS AND FLEW AIRCAFT BAC K TO AIRPORT WITHOUT INCIDENT. NO OTHER FAULTS FOUND. 1 H 7 1 3O 3 O NT 3A19 E223 1997082100601 19970821 00601 CE 1997 8 21 97ZZZX3684 1 19970729 G 7160 86245834 AIR BOX CESSNA 180 180 2072602 CE NR 4 CYL RISER FAILS D A K NONE O OTHER IN INSP/MAINT 1 SO 16 THE OPERATOR HAS A FLEET, SIX, OF THESE AIRCRAFT. A PROBLEM HAD DEVELOPED CONCERNING THE CARBURETOR HEAT AIRBOX. THE C OVER IS ATTACHED WITH A PAIR OF SCREWS ON ONE SIDE AND A TONGUE AND SLOT ARRANGEMENT ON THE OTHER. THE SLOTS WEAR OUT A T AN ALARMING RATE CAUSING THAT PART OF THE BOX ASSY TO DEPART THE AIRCRAFT. IN A SHORT TIME, THE CLAMPS HOLDING THE AI RBOX BREAK AND AIR BOX FALLS TO BOTTOM OF COWL. NEW PART BREAKS IN ABOUT 100 HOURS OR LESS. 1 H 7 1 3O NC 5A6 1997082100602 19970821 00602 CE 1997 8 21 97ZZZX3685 1 19970731 G 5720 4520031 BATHTUB FITTING BEECH 18 H18 1151012 CE SPAR STRAP BROKEN B MOGR K NONE O OTHER IN INSP/MAINT 1 GL 25 223JW 3497 BA716 WHILE JACKING UP AIRCRAFT DURING ANNUAL INSPECTION, A 'POPPING' NOISE WAS HEARD COMING FROM CENTER SECTION. INSPECTION REVEALED RIGHT CENTER SPAR STRAP BATHTUB FITTING HAD ITS UPPER FORWARD EAR BROKEN OFF. THIS STRAP HAD BEEN INSTALLED UN DER HAMILTON STC NR SA2000WE ON 6-23-71. MAINTENANCE RECORDS DO NOT REFLECT ANY MAINTENANCE ON STRAP SINCE INSTALL. HA MILTON DOES NOT PROVIDE ANY MAINTENANCE GUIDANCE. SUBMITTER RECOMMENDS DYE-PENETRANT INSPECTION AT 500-HOUR INTERVALS. 1 L 7 2 3R A765 1997082100606 19970821 00606 SO 1997 8 21 97ZZZX3689 1 19970728 G 7810 EXHAUST STACK PIPER J3 J3C65 7100510 SO RIGHT SIDE CRACKED D S K NONE O OTHER IN INSP/MAINT 1 GL 27 27145 4393 EXHAUST STACK CRACKED AT NR 1 CYLINDER. CRACK WELDED WITH STAINLESS STEEL. 1 H 7 1 3O A691 1997082100607 19970821 00607 SO 1997 8 21 97ZZZX3690 1 19970701 G 8120 4091701 TURBOCHARGER PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA SEAL OIL LEAK D K NONE B K SMOKE/FUMES/ODORS/SPARKS FLUID LOSS IN INSP/MAINT 1 EA 01 30SC 318152098 RL22668A OIL AND SMOKE NOTICED FROM EXHAUST. FOUND OIL SEAL IN TURBO LEAKING. REPLACED TURBO. 1 L 7 2 3O 3 O A20SO E14EA 1997082100608 19970821 00608 EA 1997 8 21 97ZZZX3691 2 19970703 G 7310 HOSE PIPER PA32 PA32260 7103206 SO LYC O540 O540E4B5 41532 EA PUMP/FIREWALL DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 SO 15 33831 327500032 FUEL HOSE AT LEFT SIDE OF FIREWALL TO ENGINE DRIVEN FUEL PUMP DEVELOPS LOSS OF FUEL PRESSURE ON TAKEOFF. HOSE SUCKS IN AIR WHICH DOES NOT LET FUEL FLOW. SUBMITTER RECOMMENDS THESE FUEL HOSES BE PRESSURE CHECKED AT EVERY ANNUAL OR WHEN THI S TYPE OF PROBLEM OCCURS. 1 L 7 1 3O 3 O A3SO E295 1997082100609 19970821 00609 SO 1997 8 21 97ZZZX3692 2 19970716 G 8500 ENGINE CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO RIGHT ENGINE RPM LOSS D O OTHER J WARNING INDICATION CR CRUISE 1 GL 03 414GB 1468 414A0457 276791R PILOT REPORTED RIGHT ENGINE FLUCTUATED IN-FLIGHT. WHEN PROPELLER LEVER WAS MOVED, RPM DECREASED. TROUBLESHOT SYSTEM. A DJUSTED IDLE MIXTURE AND SPEED. ADJUSTED FOR 30 RPM RISE AND 600 RPM IDLE PER MM. GROUND CHECK OK. UPON FURTHER INVES TIGATION, FOUND LOW FUEL PRESSURE PUMPS IN OFF POSITION. THIS MODEL REQUIRES PUMPS TO BE ON DURING FLIGHT. TEST FLEW A IRCRAFT FOR 2 HOURS WITH NO PROBLEMS. AIRCRAFT RETURNED BACK TO SERVICE. 1 L 7 2 3O 3 O A7CE E8CE 1997082100610 19970821 00610 SO 1997 8 21 97ZZZX3693 2 19970721 G 8550 OIL TUBE CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO CRANKSHAFT DISLODGED D K NONE O OTHER IN INSP/MAINT 1 SW 07 5203A 21063306 511938 DISCOVERED AT MAJOR OVERHAUL. NEW VAR CRANKSHAFT INSTALLED 1985, ACCUMULATED 1,550 HOURS. FOUND NR 3 OIL TUBE (INSIDE SHAFT) HAD DISLODGED AND WORKED ITS WAY OUT AND HAD PRACTICALLY CUT THE BEARING IN HALF. SUBMITTER BELIEVES THE VAR CRA NKSHAFT HAS AS MANY OR MORE PROBLEMS IN THE FIELD AS ITS OLDER PREDECESSOR. MANUFACTURING FLAW. NEED BETTER QUALITY CO NTROL. 1 H 7 1 3O 3 O 3A21 E8CE 1997082100611 19970821 00611 SO 1997 8 21 97ZZZX3694 2 19970626 G 8530 646612 VALVE 641917A12 CESSNA 172 172A 2072404 CE CONT O300 O300D 17022 SO NR 4 CYLINDER FAILED G A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 NM 11 6844X 108 47744 VALVE FAILED, CAUSED LOW POWER, AIRCRAFT HAD A FORCED LANDING. VALVE PARTS AND SEAT SENT TO NTSB. 1 H 7 1 3O 3 O 3A12 E253 1997082100612 19970821 00612 EA 1997 8 21 97ZZZX3695 2 19970520 G 8530 VALVE MOONEY M20 M20F 5870214 SW LYC O360 IO360A1A 41514 EA ENG NR 4 EXHAUST STUCK G A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 GL 03 6950V 1147 221323 L164151A ENGINE RAN ROUGH AT TAKEOFF, AIRCRAFT LOST POWER. AIRCRAFT SUSTAINED SUBSTANTIAL DAMAGE DURING A FORCED LANDING. EXAMI NATION FOR THE ENGINE REVEALED AN OPEN EXHAUST VALVE, CYLINDER NR 4. ENGINE HAD A CYLINDER, NR 4 EXHAUST VALVE STUCK. 1 L 7 1 3O 3 O 2A3 1E10 1997082100614 19970821 00614 SO 1997 8 21 97ZZZX3697 2 19970720 G 8530 CYLINDER CESSNA 182 182H 2072718 CE CONT O470 O470R 17026 SO NR 2 CYLINDER CRACKED D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 EA 13 8303S 4344 1100 18256403 1314455R4 CYLINDER CRACKED FROM TOP SPARK PLUG HOLE TO BOTTOM SPARK PLUG HOLE AROUND THE EXHAUST VALVE. HEAD OPENED UP BY THE EXH AUST VALVE AND BLEW OUT THE SIDE AND BURNED FINS OFF THE CYLINDER. ENGINE SKIPPED AND RAN ON THE OTHER 5 CYLINDERS. CY LINDER BURNED PRETTY BAD BY THE TIME ACFT LANDED. 1 H 7 1 3O 3 O NT 3A13 E273 1997082100615 19970821 00615 GL 1997 8 21 97ZZZX3698 3 19970722 G 6114 D42145 HUB BEECH 76 76 1153005 CE HARTZL HCM2Y HCM2YR GL BLADE SOCKET CRACKED B PC7R K NONE O OTHER IN INSP/MAINT 1 WP 09 803FC 706 FB979 ME150 FB979 PROPELLER WAS DISASSEMBLED TO CHECK FOR GREASE LEAK. HUB EDDY CURRENT INSPECTED PER INSTRUCTIONS SB 164, AND DEFECT NOT ED IN ONE BLADE SOCKET. PHOTOS TAKEN OF HUB AND EDDY CURRENT TEST OF HUB. HUB RED TAG (REJECT) ALL OTHER PARTS GREEN ( SERVICEABLE). HARTZELL SB NR 164 WARNS, 'UNEXPLAINED VIBRATION OR GREASE LEAKAGE INCIDENTS DEMAND IMMEDIATE INSPECTION FOR CRACKED HUB'. 1 L 7 2 3O A29CE 5 C P43GL 1997082100616 19970821 00616 CE 1997 8 21 97ZZZX3699 1 19970725 G 7810 NH100089750 CLAMP 99103001 CESSNA 421 421C 2076016 CE EXHAUST CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 01 88604 421C0604 OVERBOARD EXHAUST PIPE CLAMP HAD 2 INCH CRACK AROUND CLAMP. REMOVED CLAMP AND INSTALLED NEW ONE. 1 L 7 2 3O A7CE 1997082100617 19970821 00617 1997 8 21 97ZZZX3700 4 19970701 G 6113 D3830 BULKHEAD BEECH 55 D55 1152730 CE SPINNER CRACKED B UW4R K NONE O OTHER IN INSP/MAINT 1 SO 15 8491N TE607 THIS SPINNER BULKHEAD WAS A NEW PART THAT HAD ONLY 57 HOURS WHEN IT CRACKED. THE CRACK WAS LOCATED IN THE FRONT PLATE U NDER THE SCREW HEADS THAT HOLD THE PLATES THAT MOUNT THE BULKHEAD TO THE CRANKSHAFT. THE SPINNER WAS INSTALLED WITH THE PROPER AMOUNT OF SHIMS IN THE FRONT BULKHEAD. 1 L 7 2 3O 3A16 1997082100618 19970821 00618 EA 1997 8 21 97ZZZX3701 2 19970725 G 7314 RG17980D PUMP ROMEC PIPER PA32 PA32300 7103212 SO LYC O540 IO540E1B5 41532 EA ENGINE FUEL LEAK I K NONE K FLUID LOSS IN INSP/MAINT 1 WP 13 8969N 607 3240769 ON 100-HOUR INSPECTION, FUEL PUMP WAS FOUND LEAKING AT RELIEF VALVE. SUBMITTER STATED HAVE HAD APPROXIMATELY 6 PUMPS IN THE LAST YEAR WITH THIS PROBLEM WITH MOST HAVING LESS THAN 1,000 HOURS TSO. 1 L 7 1 3O 3 O A3SO 1E4 1997082100619 19970821 00619 NE 1997 8 21 97ZZZX3702 2 19970804 G 8530 399353 CYLINDER BEECH 18 H18 1151012 CE PWA R985 R985AN14B 52008 NE BARREL CRACKED H K NONE O OTHER IN INSP/MAINT 1 SW 09 954 181 BA670 24865 WHILE C/W AD 78-08-07 (CYLINDER CRACKS), FOUND CYLINDER WALL HAS EXHAUST RESIDUE AFTER 181 HOURS IN SERVICE. 35 HOURS S INCE LAST VISUAL INSPECTION 12 MONTHS PREVIOUSLY. CYLINDER HAD ULTRA SONIC INSPECTION IN 1993. 1 L 7 2 3R 3 R A765 5E1 1997082100620 19970821 00620 EA 1997 8 21 97ZZZX3703 2 19970714 G 8530 75874 CYLINDER PIPER PA28 PA28R180 7102809 SO LYC O360 IO360B1E 41514 EA EXHAUST PORT CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 01 4620J 1380 28R30503 L469151A DURING ANNUAL INSPECTION, THREE OF THE CYLINDERS WERE FOUND CRACKED IN THE EXHAUST PORTS. RESEARCH OF LOG BOOKS INDICAT E CYLINDERS WERE OVERHAULED BY CHROME PLATE IN 1979. 1 L 7 1 3O 3 O 2A13 1E10 1997082100622 19970821 00622 SO 1997 8 21 97ZZZX3705 1 19970701 G 2434 680500 ALTERNATOR PIPER PA28 PA28181 7102807 SO FORWARD PIVOT BROKEN EAR B LF1R K NONE O OTHER IN INSP/MAINT 1 EA 07 9277N 2843051 DURING ANNUAL INSPECTION, FOUND FORWARD ALTERNATOR HOUSING BROKEN AT PIVOT BOLT EAR. INSPECTED INSTALLATION AND DETERMIN ED BELT TENSION TOO TIGHT. LYCOMING SI 1129A PERTAINS TO THIS SUBJECT. PROPER BELT TENSION IS PARTICULARLY CRITICAL ON LYCOMING ENGINES. 1 L 7 1 3O 2A13 1997082100623 19970821 00623 1997 8 21 97ZZZX3706 1 19970731 G 2140 488636 HEAT EXCHANGER STWARNER 940DB12 COMB HEATER PLATE FAILED H A K NONE O OTHER IN INSP/MAINT 1 SO 09 1332 HEAT EXCHANGER ENDPLATE CORROSION CAUSED THE END PLATE TO BURN OUT. SUBMITTER STATED EXCESSIVE TIME AND LACK OF ATTENTI ON TO AD'S ALLOWED THIS CONDITION TO EXIST. RECOMMEND AD ON AIRCRAFT 940 SERIES HEATERS INSTALLED IN PIPER PA-23'S, PA- 30'S AND CESSNA 310, 310B, 310C, 310D, AND LAKE AMPHIBS. A SLIGHT BUMP WAS ALL IT TOOK TO DISPLACE THE ENDPLATE ON THE HEAT EXHANGER. THERE IS CURRENTLY AN AD ON 940'S INSTALLED IN PIPER AIRCRAFT, BUT NOT ON CESSNA AIRCRAFT. 1997082800001 19970828 00001 CE 1997 8 28 97ZZZX3708 1 19970601 G 5523 TRIM TAB CESSNA 206 U206 2073306 CE ELEVATOR CORE SOAKED H L A O OTHER O OTHER DE DESCENT 1 EU 01 2FOR U20601076 PARACHUTING FLIGHT - FL 100, AFTER JUMP IN DESCENT SPEED 100 MPH ELEVATOR FLUTTER, FAST AND HEAVY MOVEMENTS 2-3 SECONDS, DISAPPEARED WHEN SPEED 80 MPH. TRIM ACTUATOR WAS LOOSE FROM BROKEN STABILIZER BRACKET, FREE MOVEMENT 2 INCHES. NEARBY RIB WAS ALSO BROKEN. FREE PLAY OF ACTUATOR ITSELF WAS IN ORDER. TRIM TAB URETHANE CORE WAS WET, WHEN WEIGHED, THE TAB WAS TWICE AS HEAVY COMPARED WITH NEW SPARE. ALSO, THE ELEVATOR TRAILING EDGE URETHANE CORE WAS WET AND ELEVATOR FAR OU T OF MASS COMPENSATION VALUES BECAUSE OF WATER IN URETHANE. TOT: 4,983 HOURS. 1 H 7 1 3O A4CE 1997082800002 19970828 00002 CE 1997 8 28 97ZZZX3709 1 19970601 G 5523 TRIM TAB CESSNA 206 U206 2073306 CE ELEVATOR OUT OF BALANCE H A O OTHER O OTHER DE DESCENT 1 EU 01 2FOR U20601076 PARACHUTING FLIGHT - AFTER JUMP TRIMMED NOSE DOWN, IN DESCENT 150 MPH, ELEVATOR VIBRATION WHICH DISAPPEARED WHEN SPEED 130 MPH. TRIM TAB UNDERSIDE SKIN WAS DEFORMED UNDER BRACKET ASSEMBLY AND TRIM ACTUATOR WAS LOOSE FROM FASTENERS. ELEVA TOR MASS BALANCE WAS FAR OUT OF LIMITS. ELEVATOR TRAILING EDGE AND TRIM TAB URETHANE CORE WERE WET WHICH WAS THE REASON FOR OUT OF BALANCE. SEVERAL OTHER CASES OF TRIM TABS AND TRAILING EDGES HEAVILY CORRODED BECAUSE OF WATER IN URETHANE. TOT: 2,800 HOURS. 1 H 7 1 3O A4CE 1997082800003 19970828 00003 CE 1997 8 28 97ZZZX3710 1 19970728 G 6120 2995060105 CONTROL CABLE CESSNA 177 177 2073704 CE PROPELLER GOV MISCONNECTED H K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 09 29531 17700945 WHILE RELOCATING THIS AIRCRAFT FOLLOWING AN ANNUAL INSPECTION, THE AIRCRAFT WAS TAXIED TO THE RUN-UP AREA FOR A RUN-UP. PILOT NOTICED PROPELLER CONTROL WAS VERY SENSITIVE AND COULD ONLY GET 1,900 RPM MAX FROM THE ENGINE. AFTER SHUTTING DO WN AND REMOVING ENGINE COWLING TO INVESTIGATE, MECHANIC NOTED THE PROPELLER GOVERNOR CABLE WAS CONNECTED TO THE PROPELLE R GOVERNOR LEVER IN A HOLE THAT WOULD NOT ALLOW FULL TRAVEL. THE CABLE WAS DISCONNECTED AND RECONNECTED IN THE PROPER H OLE. ENGINE PERFORMED WITHOUT FURTHER TROUBLE. THIS AIRCRAFT HAD BEEN SIGNED OFF WITH A FRESH ANNUAL BY AN APPROPRIATE LY RATED IA. THE CABLE WAS DISCONNECTED TO REPLACE THE CONNECTING BOLT. AIRCRAFT TOTAL TIME BEING 1,169.5 HOURS. 1 H 7 1 3O NT A13CE 1997082800004 19970828 00004 CE 1997 8 28 97ZZZX3711 1 19970326 G 3242 16425E BRAKE DISC BEECH 36 A36 1151604 CE RT MLG FAILED H O OTHER O OTHER LD LANDING 1 SW 99 36VU 1232 E2429 AFTER HEAVY BRAKING, PILOT REPORTED RT BRAKE FAILURE. INSPECTION REVEALED RT BRAKE DISC HAD TORN AWAY FROM WHEEL ASSY. THIS FAILURE IS IDENTICAL TO FAILURE LISTED A.M.T. MAGAZINE DATE MAY/JUNE 1997. 1 L 7 1 3O 3A15 1997082800005 19970828 00005 EA 1997 8 28 97ZZZX3712 1 19970807 G 5610 6003303019 WINDSHIELD CNDAIR CL600 CL6002B16 1900305 EA PILOT SIDE HEAT FAILED D K NONE O OTHER NR NOT REPORTED 1 WP 05 43R 1095 1515 5134 PILOT'S WINDSHIELD HEAT INOPERATIVE. TROUBLESHOT TO OPEN HEATING ELEMENT. REMOVED AND REPLACED WINDSHIELD HEAT THEN WO RKED CORRECTLY. SUBMITTER STATED WINDSHIELDS ONLY AVERAGE 2,500 HOURS FLEET WIDE. SOME FOR HEAT PROBLEMS AND SOME FOR CRACKS. 2 L 7 2 4F RT A21EA 1997082800006 19970828 00006 SO 1997 8 28 97ZZZX3713 1 19970729 G 5553 STABILIZER PIPER PA34 PA34200T 7103406 SO V STAB ATTACH RIVETS SHEARED B A APCR K NONE O OTHER IN INSP/MAINT 1 NM 01 8407C 347670137 EIGHT RIVETS WERE SHEARED ON BOTH SIDES OF VERTICAL STABILIZER (WHERE VERTICAL STABILIZER ATTACHED TO EMPENNAGE). SUBMI TTER STATED THIS MAKES SIX AIRPLANES IN FLEET THAT HAVE HAD SOME OR ALL OF THESE RIVETS IN THIS CONDITION. 1 L 7 2 3O A7SO 1997082800007 19970828 00007 CE 1997 8 28 97ZZZX3714 1 19970808 G 2731 12600741 ACTUATOR CESSNA 172 172RG 2072438 CE ELEV TRIM TAB GEAR PIN FAILED B A DSBR O OTHER F FLT CONT AFFECTED NR NOT REPORTED 1 GL 25 9423D 4652 172RG00285 DURING FLIGHT, PILOT NOTICED TRIM NOT RESPONSIVE (ELEVATOR). INSPECTION OF SYSTEM FOUND PINS FELL OUT OF ACTUATOR WHIC H ATTACH GEAR TO SHAFT. THE TRIM WHEEL MOVED NORMALLY, BUT TAB STAYED IN ONE POSITION. 1 H 7 1 3O 3A17 1997082800008 19970828 00008 NE 1997 8 28 97ZZZX3715 2 19970725 G 7210 358206 BEARING 3101807X GARRTT TPE331 TPE3316252M 01514 NE START/GEN GEAR MAKING METAL B L A DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 332 P20381 S.O.A.P. SAMPLE RETURNED MAJOR CARBON STEEL PLATELETS AND TRACE COPPER. DISASSEMBLY OF ENGINE REVEALED BEARING SEPARATO R OUTER DIAMETER TO OUTER RACE LAND CLEARANCE INSUFFICIENT RESULTING IN RUBBING. BEARING OUTER RACE HAS HEAT DISCOLORAT ION. BEARING SERIAL NR 0184. NOTE: S.O.A.P. WITH CARBON STEEL PLATELETS AND COPPER WOULD BE EXCLUSIVELY RELATED TO TH IS PART NUMBER PMA BEARING FOR THE TPE331. BEARING CAN BE EASILY INSPECTED FOR DISCOLORATION BY REMOVING STARTER GENERA TOR AND BEARING SEAL RETAINER. E2WE 1997082800009 19970828 00009 NE 1997 8 28 97ZZZX3716 2 19970725 G 7210 358206 BEARING GARRTT TPE331 TPE3316252M 01514 NE START/GEN GEAR MAKING METAL B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 332 P20381 S.O.A.P. SAMPLE RETURNED MAJOR CARBON STEEL PLATELETS AND TRACE COPPER. DISASSEMBLY REVEALED BEARING SEPARATOR OUTSIDE DIAMETER TO OUTER RACE LAND CLEARANCE INSUFFICIENT RESULTING IN RUBBING. BEARING OUTER RACE HAS HEAT DISCOLORATION. BE ARING S/N 0129. NOTE: S.O.A.P. SHOWING CARBON STEEL PLATELETS AND COPPER WOULD BE EXCLUSIVELY RELATED TO THIS PART NUM BER PMA BEARING FOR THE TPE331. BEARING OPPOSITE THIS BEARING (SAME P/N) CAN BE INSPECTED FOR SIGNS OF DISCOLORATION BY REMOVING STARTER/GENERATOR AND SEAL RETAINER. ACCESSIBLE BEARING RECEIVES LESS LUBRICATION, THEREFORE, EXHIBITS DISCOL ORATION AT LOWER TIME IN SERVICE. E2WE 1997082800010 19970828 00010 CE 1997 8 28 97ZZZX3717 1 19970701 G 3241 1206P27 PRESSURE SWITCH CESSNA 500 550 2076604 CE ANTI SKID BRAKE FAILED B L ZU4R K NONE O OTHER IN INSP/MAINT 1 SO 09 26496 459 2497 550607 DURING A DAILY INSPECTION, A/C POWER WAS TURNED ON. THE ANTI-SKID BRAKE PUMP BEGAN TO RUN, BUT WOULD NOT SHUT OFF ONCE SYSTEM PRESSURE WAS MADE. TROUBLESHOOTING REVEALED A BAD IN-LINE PRESSURE SWITCH. SWITCH WAS INSTALLED 459.4 HOURS AGO . TAKING INTO CONSIDERATION THE ONLY TIME THE SWITCH FUNCTIONS IS BETWEEN 900 TO 1300 PSI, THE ACTUAL OPERATING TIME IS ACCUMULATED DURING GROUND OPERATION, WHICH IS MUCH LESS. 1 L 7 2 4F A22CE 1997082800011 19970828 00011 EA 1997 8 28 97ZZZX3718 2 19970724 G 7210 3024765 SUNGEAR DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043 EA GEAR BOX FATIGUE H O OTHER J WARNING INDICATION CR CRUISE 1 SO 23 2FOR 6653 766 PCE42155 ENGINE FAILED IN CRUISE. INVESTIGATION REVEALED THE FRACTURE OF THE RGB 1ST STAGE SUN GEAR FAILED DUE TO FATIGUE. THE ORIGINAL CAUSE OF THE FATIGUE COULD NOT BE DETERMINED. THE RGB DECOUPLING WAS CAUSED BY AN OVERSPEED CONDITION OF PT RO TOR RESULTING IN LIBERATION OF THE PT BLADES DUE TO TENSILE OVERLOAD. THE ENGINE WAS OVERHAULED AND RELEASED ON THE AUG UST 6, 1996 AND FAILED AT TSO 409 HOURS/1623 CSO. 1 H 7 2 3T 4 T A9EA E4EA 1997082800013 19970828 00013 CE 1997 8 28 97ZZZX3719 1 19970728 G 5540 MS244614 BEARING BEECH 90 C90A 1152911 CE RUDDER FROZEN B A NN3R K NONE O OTHER IN INSP/MAINT 1 WP 25 RUDDER BEARING HAS BEEN FOUND FROZEN ON 5 AIRCRAFT OUT OF 18. IN CHAPTER 12, SERVICING, THERE IS NO LUBE CALLED OUT FOR THE RUDDER BEARINGS. A.T.A. 12-20-00, PAGE 233. 1 L 7 2 3T RT 3A20 1997082800014 19970828 00014 EA 1997 8 28 97ZZZX3720 2 19970718 G 7313 3014704 ADAPTER ASSY PWA PT6 PT6* 52043 EA FUEL NOZZLE LEAKAGE B A UE5R K NONE O OTHER IN INSP/MAINT 1 NE 01 DURING LEAK TEST OF A PT6A FUEL NOZZLE ADAPTER ASSY, LEAKAGE WAS DETECTED COMING FROM A WELD ON TOP OF THE FUEL NOZZLE A DAPTER ASSY. THIS IS THE SECOND ADAPTER ASSY FOUND LEAKING IN THIS AREA. SUGGEST THAT ALL WELDS BE CHECKED ADDITIONALL Y DURING FUEL NOZZLE ADAPTER LEAK TEST. 3 T E2NE 1997082800015 19970828 00015 EU 1997 8 28 97ZZZX3721 1 19970806 G 2621 A813625 SWITCH COVER KIDDE 81360021 AIRBUS 300 A300* EU ENG FIRE BOTTLE MISOVERHAULED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 99 U861 DURING PRELIMINARY INSPECTION OF ENGINE FIRE BOTTLE ASSY, NOTICED THE ORIGINAL PRESSURE SWITCH COVER, PN A813625, HAD BE EN RE-WELDED TO THE LEG STUMPS CONTRARY TO THE DIRECTIONS AS WRITTEN ON WALTER KIDDE SB 813600-26-01. THIS SB SPECIFICA LLY DIRECTS THE PERSON PERFORMING THE HYDROSTATIC TEST OF THIS SPHERE TO CUT THE SWITCH COVER LEGS, FILE DOWN THE LEG ST UMPS, REMOVE THE PRESSURE SWITCH, PN 282141, DISCARD THE ORIGINAL SWITCH COVER, PN A813625, AND, AFTER HYDROTEST, TO REP LACE THE ORIGINAL SWITCH COVER WITH A KIT, CONSISTING OF A COLLAR, PN A813635-1, COVER, PN A813636-1, AND ATTACHING SCRE WS, PN MS167997-3, AND MS16995-3. 2 L 7 2 4F RT A35EU 1997090300001 19970903 00001 EU 1997 9 3 97ZZZX3722 1 19970806 G 2621 A813625 SWITCH COVER KIDDE 81360021 AIRBUS 300 A300* EU ENG FIRE BOTTLE MISOVERHAULED D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 99 90230EK DURING PRELIMINARY INSPECTION OF ENGINE FIRE BOTTLE ASSY, NOTICED THE ORIGINAL PRESSURE SWITCH COVER, PN A813625, HAD BE EN RE-WELDED TO THE LEG STUMPS CONTRARY TO THE DIRECTIONS AS WRITTEN ON WALTER KIDDE SB 813600-26-01. THIS SB SPECIFICA LLY DIRECTS THE PERSON PERFORMING THE HYDROSTATIC TEST OF THIS SPHERE TO CUT THE SWITCH COVER LEGS, FILE DOWN THE LEG ST UMPS, REMOVE THE PRESSURE SWITCH, PN 282141, DISCARD THE ORIGINAL SWITCH COVER, PN A813625, AND, AFTER HYDROTEST, TO REP LACE THE ORIGINAL SWITCH COVER WITH A KIT, CONSISTING OF A COLLAR, PN A813635-1, COVER, PN A813636-1, AND ATTACHING SCRE WS, PN MS167997-3, AND MS16995-3. 2 L 7 2 4F RT A35EU 1997082800016 19970828 00016 NE 1997 8 28 97ZZZX3723 2 19970616 G 7240 BD5144 COMB CHAMBER BOEING 747 747136 1384883 NM PWA JT9 JT9D7A 52054 NE DIFFUSER CASE CRACKED D J E A DUMP FUEL ENGINE SHUTDOWN UNSCHED LANDING M OVER TEMP CL CLIMB 1 SW 99 47362 729237 685964 ON INITIAL CLIMB, NR 2 ENGINE OVERTEMP LIGHT ILLUMINATED (970 DEGREE CELSIUS INDICATED). PARAMETERS RAN DOWN AND ENGINE FIRE CHECK LIST CARRIED OUT. A THREE-ENGINE APPROACH AND LANDING CARRIED OUT FOLLOWING FUEL DUMP PROCEDURE. GROUND CH ECKS REVEALED ENGINE COMBUSTION CHAMBER OUTER CASING (CCOC) CRACKED AT L-FLANGE LOCATION. PART TOTAL CYCLES, 10,669. 2 L 7 4 4F 4 F A20WE E20EA 1997082800017 19970828 00017 CE 1997 8 28 97ZZZX3724 1 19970715 G 3234 660036118 SELECTOR VALVE LEAR 55 55LEAR 5170702 CE MLG INOPERATIVE B DELR O OTHER J WARNING INDICATION AP APPROACH 1 CE 03 121US 565 LANDING GEAR WOULD NOT EXTEND. GEAR HAD TO BE BLOWN DOWN WITH EMERGENCY SYSTEM. REPLACED GEAR DOOR SELECTOR VALVE WITH AN OVERHAULED UNIT. CYCLED GEAR NUMEROUS TIMES (45). OPS AND LEAK CHECKED GOOD. AIRCRAFT HOURS: 3,105.1. AIRCRAFT LANDINGS (CYCLES): 2,138. 2 L 7 2 4F A10CE 1997082800018 19970828 00018 CE 1997 8 28 97ZZZX3725 1 19970701 G 5280 45A3081 HINGE 45A30304 BEECH MU300 400BEECH CE MLG DOOR CRACKED B AKGR K NONE O OTHER IN INSP/MAINT 1 CE 05 1564B 3502 RJ64 AT A 200-HOUR INSPECTION, FOUND THE UPPER CHANNEL ON BOTH GEAR DOORS JUST ABOVE THE FORWARD DOOR HINGE CRACKED. AFTER R EMOVING THE CHANNEL, FOUND THE FORWARD HINGE CRACKED ALSO. THIS PROBLEM HAS BEEN ADDRESSED BY BEECH IN COMMUNIQUE NR 26 . 2 H 7 2 4F RT A16SW 1997082800019 19970828 00019 CE 1997 8 28 97ZZZX3726 1 19970701 G 5280 HINGE CHANNEL 45A30304 BEECH MU300 400BEECH CE MLG DOOR CRACKED B AKGR K NONE O OTHER IN INSP/MAINT 1 CE 05 1564B 3502 RJ64 AT A 200-HOUR INSPECTION, FOUND THE UPPER CHANNEL ON BOTH GEAR DOORS JUST ABOVE THE FORWARD DOOR HINGE CRACKED. AFTER R EMOVING THE CHANNEL, FOUND THE FORWARD HINGE CRACKED ALSO. THIS PROBLEM HAS BEEN ADDRESSED BY BEECH IN COMMUNIQUE NR 26 . 2 H 7 2 4F RT A16SW 1997082800021 19970828 00021 CE 1997 8 28 97ZZZX3728 1 19970728 G 3231 45A386713141 CONTROL CABLE BEECH MU300 400BEECH CE LT MLG DOOR EXT BROKEN B A AKGR K NONE O OTHER IN INSP/MAINT 1 CE 05 1564B 1103 RJ64 WHEN PERFORMING AN EMERGENCY GEAR EXTENSION TEST, THE LEFT GEAR WOULD NOT COME DOWN. FOUND THE LEFT DOOR OPEN (EMERGEN CY) PULL CABLE BROKEN. IF THIS HAD HAPPENED IN-FLIGHT, THE CREW WOULD NOT HAVE BEEN ABLE TO GET THE LEFT GEAR DOWN USIN G THE EMERGENCY SYSTEM. 2 H 7 2 4F RT A16SW 1997082800022 19970828 00022 NE 1997 8 28 97ZZZX3729 2 19970721 G 7320 SENSE PROBE CESSNA 650 650 2076802 CE GARRTT TFE731 TFE7313B 01518 NE NR 2 ENG PT2 PLUG LOOSE D A O OTHER O OTHER CL CLIMB 1 NM 01 39WP 6500039 NR 2 ENGINE SURGED TWICE DURING CLIMB-OUT. INDICATIONS WERE OBSERVED ON BOTH FAN AND FUEL FLOW. AIRCRAFT ALSO YAWED. F OUND NR 2 ENGINE PT2 LENS PROBE PLUG LOOSE, ALSO, DIRTY WITH RUST-LIKE MATERIAL. CLEANED PROBE AND PLUG. SWAPPED PT2 P ROBE LT TO RT PER INNOTECH REP'S ADVISE. RAN ENGINE TO TAKEOFF (92 PERCENT FAN) NORMAL AND MANUAL. NO FLUCTUATIONS OR SURGES NOTED. OPS CHECKED OK. (X) 2 L 7 2 4F 4 F A9NM E6WE 1997082800023 19970828 00023 WP 1997 8 28 97ZZZX3730 2 19970423 G 7260 30728692 SPLINED ADAPTER BENDIX 8060300 AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE7313 01518 WP START/GENERATOR STRIPPED B DELR K NONE O OTHER IN INSP/MAINT 1 CE 03 900JB 59 P76321C WHEN ATTEMPTING TO START NR 2 ENGINE, STARTER SPUN, BUT ENGINE DID NOT ROTATE. FOUND THE SPLINED ADAPTER STRIPPED INSID E OF GEARBOX. REPLACED SPLINE ADAPTER. 2 L 7 3 4F 4 F A46EU E6WE 1997082800024 19970828 00024 SW 1997 8 28 97ZZZX3731 1 19970804 G 6230 206040576105 BEARING BELL 206 206L3 1182108 SW M/R MAST MAKING METAL B GS1R K NONE O OTHER IN INSP/MAINT 1 EA 03 111SP 494 MB333 51325 MAIN ROTOR MAST BEARING MAKING METAL. REPLACED WITH NEW MAST BEARING. 1 G 7 1 3U H2SW 1997082800026 19970828 00026 EA 1997 8 28 97ZZZX3733 2 19970717 G 8520 LW12596 BOLT LW13422 HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA NR 4 CYL CON ROD FAILED B A FW7R O OTHER E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CR CRUISE 1 EA 07 6129Q S1629 L2476251A AT 500.0 HOURS TSO, THE ENGINE FAILED IN-FLIGHT. ENGINE TEAR DOWN REVEALED NR 4 CONNECTING ROD HAD FAILED, PUNCHING A H OLE THROUGH THE CRANKCASE. THE TWO CONNECTING ROD BOLTS HAD FAILED ALLOWING THE CONNECTING ROD TO COME LOOSE FROM THE C RANKSHAFT. THE BOLTS WENT TO THE NTSB FOR ANALYSIS. THE ENGINE WAS OVERHAULED NOVEMBER, 1996, LYC SB 240N REQUIRES REP LACEMENT OF THE CONNECTING ROD BOLTS AT OVERHAUL. EXAMINING THE WORK ORDER FROM THE OVERHAUL, IT WAS UNCLEAR IF THOSE B OLTS HAD BEEN REPLACED. 1 G 7 1 3O 3 O 4H12 1E10 1997082800027 19970828 00027 SW 1997 8 28 97ZZZX3734 1 19970724 G 6730 206076062107 ACTUATOR BELL 407 407 SW SERVO PILOT VALV LEAKING B GS1R K NONE K FLUID LOSS IN INSP/MAINT 1 EA 03 7249U 9 53152 SERVO ACTUATOR LEAKING AT PILOT VALVE. REPLACED WITH NEW SERVO ACTUATOR. 1 G 7 1 3U O H2SW 1997082800055 19970828 00055 SO 1997 8 28 97ZZZX3735 2 19970630 G 7414 MAGNETO CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE MISTIMED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 07 145 WHILE CHECKING MAGNETO TIMING DURING AN ANNUAL INSPECTION, DISCOVERED THE TIMING WAS SET AT TOP DEAD CENTER. ENGINE WAS FACTORY OVERHAULED BY TCM 2 YEARS AGO. IT NOW HAS 145 HOURS ON IT. THE MECHANIC THAT ANNUALED THE AIRCRAFT LAST STATE D IN THE LOG BOOK HE CHECKED THE TIMING. THE TAMPERPROOF PAINT WAS STILL ON THE MAG AND ENGINE AND HAD NOT BEEN DISTURB ED. 1 H 7 1 3O 3 O 3A21 E8CE 1997082800056 19970828 00056 EA 1997 8 28 97ZZZX3736 2 19970716 G 8530 LW19001 VALVE CESSNA 172 172N 2072434 CE LYC O320 O320D2J 41508 EA NR 1 CYL EXH VLV STICKING H A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 99 172HR 4528 422 17269272 L1173539A DURING CRUISE FLIGHT, PILOT REPORTED ROUGH RUNNING ENGINE. PILOT REDUCED POWER AND LANDED SAFELY WITHOUT INCIDENT. MEC HANICS INSPECTING THE ENGINE DISCOVERED A SEVERELY BENT PUSH ROD AND HOUSING ON NR 1 CYLINDER. FURTHER INSPECTION REVEA LED THE EXHAUST VALVE STEM CAP SEPARATED FROM THE VALVE STEM AND LODGED BETWEEN THE VALVE ROCKER AND VALVE STEM. MECHAN ICS DETERMINED THIS MALFUNCTION WAS APPARENTLY CAUSED BY THE EXHAUST VALVE STICKING FROM EXCESSVIE CARBON BUILD-UP. 1 H 7 1 3O 3 O NT 3A12 E274 1997082800057 19970828 00057 SO 1997 8 28 97ZZZX3737 1 19970809 G 5711 SPAR LUSCOM 8 8A 8190104 SO WING CORROSION D K NONE O OTHER IN INSP/MAINT 1 WP 07 2066K 921 4793 COMPLIED WITH AD 96-24-17 IAW LUSCOMBE RECOMMENDATION NR 2. INSTALLED O.L.A.H.F. KIT NR 2. NO DAMAGING CORROSION WAS F OUND. SUBMITTER RECOMMENDED SPRAYING WING INTERIOR WITH CF 50 CORROSION PROOFING. 1 H 7 1 3O A694 1997082800058 19970828 00058 SO 1997 8 28 97ZZZX3738 2 19970714 G 8520 649277 LIFTER CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO CYL NR 1/2 SPALLED B CBCR K NONE O OTHER IN INSP/MAINT 1 NM 03 27FV 352 21063483 293828R DURING ROUTINE INSPECTION ON TCM FACTORY REMANUFACTURED TSIO520R (TIME 352.1 HOURS), CYLINDERS NR 1 AND NR 2 HAVE EXHAUS T VALVE LEAKING. UPON CYLINDER REMOVAL AND HYDRAULIC LIFTER INSPECTION, REVEALED SPALLED LIFTERS IN NR 1 INTAKE AND EXH AUST POSTION. 1 H 7 1 3O 3 O 3A21 E8CE 1997082800060 19970828 00060 CE 1997 8 28 97ZZZX3740 1 19970731 G 2430 RSX1678 LIMITER POST 66082052 LEAR 35 35A 5170602 CE GEN CONT PANEL DAMAGED D A K NONE O OTHER IN INSP/MAINT 1 GL 25 43TJ 6696 X170 121 PILOT REPORTED AIR CONDITIONING AS INOPERATIVE. ALSO, THAT IT WAS NOT DRAWING ELECTRICAL CURRENT. UPON INSPECTION, FOUN D THE 150-AMP CURRENT LIMITER WAS NOT BLOWN, BUT THE END WAS BURNED OFF. THE DAMAGE ALSO EXTENDED TO THE STUD USED TO A TTACH THE A.C. CURRENT LIMITER TO THE GENERATOR CONTROL PANEL. SUBMITTER STATED DEFECT COULD POSSIBLY BE LINKED TO IMPR OPER TORQUE OF THE NUT USED TO FASTEN CURRENT LIMITER TO THE PANEL OR THE NUT MAY HAVE VIBRATED LOOSE RESULTING IN ELECT RICAL ARCING FROM THE LIMITER TO THE POST. 2 L 7 2 4F A10CE 1997082800061 19970828 00061 SO 1997 8 28 97ZZZX3741 1 19970806 G 2820 4123006 HOSE PIPER PA31 PA31P350 7103111 SO RT WING ROOT LEAK D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 25 4157E 747 31P8414047 AEROQUIPT 601000-8D-0130 HOSE WAS FOUND LEAKING (FAST DRIP) ON INSPECTION. SIMILAR HOSE ON OTHER SIDE OF AIRCRAFT SEEPI NG. PART LOCATION RT WING ROOT. CURRENT DATES, A2Q91, CD3Q90, PT-4-91, 06827, RUBBER PSI-1000. INSTALLED 4-25-91, 667 .1 HOURS. TIME NOW, 1,414 HOURS. SUBMITTER STATED PART LEAKS WHERE IT TOUCHES FUEL PUMP, PROBABLY GETS HOT. 1 L 7 2 3O RT A8EA 1997082800062 19970828 00062 SW 1997 8 28 97ZZZX3742 1 19970601 G 2820 75685 HOSE ASSY ADEL 19372 TMPSON NAVION NAVIONA 6150104 SW FUEL PUMP DETERIORATED D K NONE O OTHER IN INSP/MAINT 1 CE 07 4339K 3481 672 NAV41339 DURING AN ANNUAL INSPECTION, THE RUBBER HOSE ASSEMBLY PROVIDING FUEL TO THE ELECTRIC FUEL PUMP WAS REMOVED. THE RUBBER HOSE STOCK WAS EXTREMELY FRAYED BY BOTH SOCKETS. THE WIRE SUPPORT WINDING WAS UNWOUND AND PROTRUDING. THE IDENTIFICATI ON TAG SHOWED THE ASSEMBLY DATE AS 1/47. THIS HOSE ASSEMBLY WAS ORIGINAL EQUIPMENT ON THIS AIRCRAFT AND SHOULD HAVE BEE N REPLACED YEARS AGO. THE HOSE ASSEMBLY IS ALMOST IMPOSSIBLE TO SEE WHEN INSTALLED. SEE NAVION PARTS CATALOG, 4TH RYAN EDITION, FIGURE 18, INDEX 50. WHILE IT WAS NOT YET LEAKING, SUBMITTER STATED THE DANGEROUS SITUATION THIS HOSE ASSEMBLY CREATED UNDERSCORES THE IMPORTANCE OF INSPECTING AND REPLACING THOSE ASSEMBLIES. 1 L 7 1 3O A782 1997082800063 19970828 00063 CE 1997 8 28 97ZZZX3743 1 19970811 G 7160 SCAT12 DUCT FACET NA6 BEECH 23 23 1151202 CE AIR INTAKE COLLAPSED G O OTHER Y W ENGINE STOPPAGE INADEQUATE Q C NR NOT REPORTED 1 EA 13 6083N M1176 ENGINE LOST RPM AND STOPPED. INSPECTION REVEALED AIR INTAKE DUCT COLLAPSED BETWEEN CARB AIRBOX AND CARB. INCORRECT TYP E AND PART NUMBER DUCT INSTALLED PREVIOUSLY. SCAT 12 SHOULD BE SCEET 12 (DOUBLE WALL). BOTH SCAT AND SCEET ARE SAME CO LOR AND SIMILAR IN APPEARANCE WHEN VIEWED FROM OUTSIDE AFTER DUCT IS INSTALLED. SCEET AND SCAT COULD BE MADE MORE EASIL Y IDENTIFIABLE. 1 L 7 1 3O A1CE 1997082800064 19970828 00064 CE 1997 8 28 97ZZZX3744 1 19970801 G 7120 04511201 MOUNT CESSNA 150 150M 2071830 CE ENGINE SEPARATED D K NONE O OTHER IN INSP/MAINT 1 SO 06 66728 5406 15076237 ENGINE MOUNT SEPARATED FROM LOWER STRUT COLLAR. WAS NOTICED DURING SCHEDULED INSPECTION. THE SEPARATION CAUSED THE STRU T TO MOVE FORWARD WHICH CAUSED EXCESSIVE SLACK IN CABLES (RUDDER). CABLES WERE RESTING ON THE FUSELAGE BOTTOM. SUSPECT ED NLG LANDING BY STUDENT PILOT. NO RECOMMENDATION TO PREVENT ITS RECURRENCE. 1 H 7 1 3O 3A19 1997082800065 19970828 00065 SO 1997 8 28 97ZZZX3745 2 19970731 G 8550 10291004641 SEPARATOR TANK BEECH 58 58P 1152744 CE CONT O520 TSIO520WB 17040 SO LT ENG AIR/OIL LEAK D K NONE K FLUID LOSS IN INSP/MAINT 1 GL 17 6742X 3319 TJ267 237557R WHILE TROUBLESHOOTING AN OIL LEAK, SUBMITTER FOUND AIR OIL SEPARATOR TANK CRACKED AROUND THE INLET TUBE COMING FROM THE TURBOCHARGER. TWO CRACKS WERE RUNNING PARALLEL ALMOST 350 DEGREES AROUND THE TUBE. CRACKS HAD BEEN MASKED BECAUSE SOME ONE PREVIOUSLY COVERED THEM WITH RTV. INSPECTION OF THIS TANK SHOULD BE C/W AND ADDITIONAL SUPPORT THROUGH THE USE OF A CLAMP IS RECOMMENDED. 1 L 7 2 3O 3 O A23CE E8CE 1997082800066 19970828 00066 CE 1997 8 28 97ZZZX3746 1 19970806 G 2410 5395473119 BELT CESSNA 182 182H 2072718 CE ALTERNATOR DEBONDED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 25 8529S 18256629 AN ALTERNATOR DRIVE BELT PURCHASED FROM API PARTS INTERNATIONAL WAS RECEIVED IN A DE-BONDED CONDITION ALONG WITH A SECON D BELT WHICH WAS NORMAL. CURE DATE ON DEFECTIVE PART, 1Q96/3Q01. 1 H 7 1 3O NT 3A13 1997082800067 19970828 00067 1997 8 28 97ZZZX3747 4 19970804 G 3416 3431 CASTING UNITEDINST 5934PAA58 CESSNA 340 340CESSNA 2076404 CE ALTIMETER CREEP B EI4R K NONE O OTHER IN INSP/MAINT 1 SO 15 9KW 81605 3400227 THE END-SHAKES (BACK AND FORTH MOVEMENT) OF THE THREE CRITICAL ROTATING SHAFTS OF THE MECHANISM OF THIS ALTIMETER WERE C HECKED. THE OHM CALLS OUT .0020 INCH MINIMUM END-SHAKE. ONE END- SHAKE MEASURED .00020 INCH. THIS IS TEN TIMES SMALLE R THAN THE SPECIFICATION. WITH THIS CONDITION, THE INSTRUMENT COULD HANG UP THE POINTERS OF THE ALTIMETER UNDER A COLD TEMPERATURE OPERATING CONDITION. THE MANUFACTURER HAS INDICATED THAT AN END-SHAKE OF .0004 INCH OR LESS COULD CAUSE A PO INTER HANG UP UNDER COLD OPERATING CONDITIONS. 1 L 7 2 3O 3A25 1997082800068 19970828 00068 GL 1997 8 28 97ZZZX3748 3 19970729 G 6114 HUB CESSNA 207 T207A 2073614 CE MCAULY D3A34 D3A34C401 GL NR 3 SOCKET CRACKED B W59R K NONE O OTHER IN INSP/MAINT 1 WP 07 9317M 1524 T20700680 795451 PENETRANT INSPECTION DURING NORMAL OVERHAUL INDICATED A FINE LINEAR CRACK OR SCRATCH. SUBSEQUENT EDDY CURRENT TESTING U SING PHASE PLANE ANALYSIS INSTRUMENTATION REVEALED A CRACK APPROXIMATELY 1.5 INCHES LONG, ESTIMATED OVER .040 INCH DEEP ON THE EXTERIOR SURFACE OF NR 3 BLADE SOCKET ON THE LEADING EDGE SIDE SLIGHTLY ABOVE CENTERLINE OF THE HUB. THIS CONDIT ION IS NOT COMMONLY FOUND IN THE 'THREADLESS' STYLE OF MCAULY HUBS AND MAY BE OVERLOOKED WITHOUT EDDY CURRENT TEST. 1 H 7 1 3O A16CE 5 C P47GL 1997082800069 19970828 00069 EA 1997 8 28 97ZZZX3749 2 19970805 G 7414 GEAR ELECTROSYS 1038256011 CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA MAG DISTRIBUTOR TEETH MISSING A E96R K NONE O OTHER IN INSP/MAINT 1 EA 09 42GV 526 5071348R R18200219 L1881740A DURING A 100-HOUR INSPECTION, REMOVED MAG FOR IMPULSE COUPLING AD. FOUND SEVERAL TEETH MISSING FROM BOTH DISTRIBUTOR GE ARS AND ONE GEAR CRACKED. ALSO NOTED LARGE CRACKS ON THE TOPS OF BOTH COILS. ENGINE AND MAG TIME SINCE FACTORY OVERHAU L 526.4 HOURS. CAUSE OF PROBLEM UNKNOWN. ON PRE-INSPECTION RUN-UP, MAG DROP 150/150. 1 H 7 1 3O 3 O RT 3A13 E295 1997082800070 19970828 00070 CE 1997 8 28 97ZZZX3750 1 19970805 G 3230 AHML6NMB ROD END BEECH 36 A36 1151604 CE NLG RETRACT FAILED G L A K NONE W INADEQUATE Q C NR NOT REPORTED 1 GL 03 1849W E428 THE ROD END BEARING CASE CRACKED CAUSING IT TO SPREAD OPEN; THUS, CAUSING EXTENSION OR RETRACTION OF NOSE GEAR TO BE IMP OSSIBLE. THIS ROD END WAS FOUND IN THE IMPROPER PLACE POSSIBLY NOT BEING MADE TO TAKE THAT RADIAL LOAD. BEECH SI NR 07 60-010 SUGGESTS THE REPLACEMENT OF ANY BEARINGS WITH AN NMB SUFFIX SUGGEST FOLLOWING PARTS MANUAL VERY CLOSELY WHEN REPL ACING PARTS. 1 L 7 1 3O 3A15 1997082800071 19970828 00071 SO 1997 8 28 97ZZZX3751 1 19970725 G 3213 9818000 GEAR LEG PIPER PA36 PA36375 7103620 SO LT MLG BROKE D S K NONE O OTHER IN INSP/MAINT 1 SO 09 3975E 2420 367902013 AIRCRAFT WAS IN HANGAR. PILOT WAS ON WING TO CHECK OIL AND LEFT MAIN LANDING GEAR BROKE WHERE THE GEAR ENTERS THE FUSEL AGE. CLEAN BREAK. NO SIGN OF CRACKS. 1 L 7 1 3O A10SO 1997082800073 19970828 00073 CE 1997 8 28 97ZZZX3753 1 19970730 G 5311 16940002561 FRAME BEECH 23 B24R 1151253 CE BS 68 CORRODED B S A ALN2 K NONE O OTHER IN INSP/MAINT 1 GL 07 4343W MC264 ESTIMATE 10 - 15 INCHES OF MATERIAL ERODED AWAY FROM SEVERE CORROSION. PART IS IN CONTACT WITH 'CAT' DUCTING PN 111728- 808-23 FRESH AIR INLET TO CABIN. SUBMITTER SUGGESTS DETAILED INSPECTION OF AREA AT NEXT 100-HOUR ANNUAL. 1 L 7 1 3O A1CE 1997082800074 19970828 00074 CE 1997 8 28 97ZZZX3754 1 19970801 G 3230 608100895 DOWNLOCK CABLE BEECH 60 B60 1153605 CE DOWNLOCK RELEASE FAILED G P K NONE O OTHER NR NOT REPORTED 1 GL 15 541HR 2076 P587 DOWNLOCK RELEASE CABLE FAILED AT TURNBUCKLE. SAFETY WIRE WAS ALL THAT HELD TURNBUCKLE TOGETHER. 1 L 7 2 3O A12CE 1997082800075 19970828 00075 CE 1997 8 28 97ZZZX3755 1 19970806 G 5320 STRUCTURE CESSNA 140 140A 2071604 CE CARRY THRU SPAR CORRODED D L K NONE O OTHER IN INSP/MAINT 1 WP 01 5629C 15582 FOLLOWING RIGHT HAND WING REMOVAL FOR PAINTING, INSPECTION OF THE FUSELAGE REAR SPAR CARRY-THROUGH STRUCTURE REVEALED MO DERATE TO SEVERE CORROSION. THE AREA OF CORROSION WAS BETWEEN THE FRONT FACE OF THE REAR SPAR AND THE BULKHEAD ATTACHME NT TO THE SPAR. IT IS LOCATED .50 INCH INBOARD OF THE REAR WING SPAR ATTACHMENT BLOCK THAT IS BOLTED TO THE SPAR CARRY- THROUGH. THE CORROSION HAD EATEN THROUGH THE BULKHEAD 100 PERCENT. FIVE OF THE TEN RIVETS THAT ATTACH THE BULKHEAD TO T HE SPAR HAD RIVET HEADS MISSING DUE TO CORROSION. 1 H 7 1 3O 5A2 1997082800076 19970828 00076 CE 1997 8 28 97ZZZX3756 1 19970716 G 3213 AN547 BOLT CESSNA 172 172RG 2072438 CE NLG AXLE BROKEN G L A O OTHER O OTHER TO TAKEOFF 1 WP 09 6273R 172RG0135 DURING INSTRUCTIONAL FLIGHT INVOLVING TAKEOFF AND LANDINGS, THE PILOT WAS INFORMED VIA RADIO FROM ANOTHER AIRCRAFT THAT THE ACFT NOSE WHEEL HAD FALLEN OFF. HE PROCEEDED TO SEE WHERE HE MADE A SUCCESSFUL EMERGENCY LANDING. INSPECTION OF TH E ACFT NLG ASSY INDICATED THE NLG AXLE BOLT, AN 5-47, HAD FAILED. NOTE: THE REMAINS OF THIS BOLT WERE STILL IN THE RT HAND SIDE OF THE NLG FORK ASSY. CLOSER INSPECTION OF THIS BOLT INDICATED IT HAD BEEN PREVIOUSLY FRACTURED/CRACKED. TOT AL TIME ON THIS BOLT IS UNKNOWN. 1 H 7 1 3O 3A17 1997082800077 19970828 00077 WP 1997 8 28 97ZZZX3757 1 19970813 G 2421 977J4123 STATOR HOUSING SUNDSTRANDEM 977J4132 DOUG DC10 DC10* WP AC GENERATOR OVERSIZED B L MG4R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 19 DURING DISASSEMBLY OF BEARING LINER FROM THE HOUSING, A SHIM WAS FOUND AROUND THE HOUSING INSIDE DIAMETER WHERE THE BEAR ING LINER SITS. THE HOUSING I.D. WHERE BEARING LINER SITS IS OVERSIZED AND SHIM WAS INSTALLED BY UNKNOWN SHOP TO ACCOMM ODATE THE NEW BEARING LINER. THIS PRACTICE IS NOT ACCEPTABLE WITH THE MANUFACTURER'S SPECS. 2 L 7 3 4F A22WE 1997082800078 19970828 00078 GL 1997 8 28 97ZZZX3758 1 19970625 G 2520 SEAT ENSTRM F28 F28F 3300412 GL RT PAX SEAT DEFORMED C P A UNSCHED LANDING O OTHER CL CLIMB 1 WP 21 99YC 48 809 THIN COMPOSIT BENCH SEAT ACROSS 15.50 INCH WIDE ALUMINUM SEAT STRUCTURE. NOT ADEQUATE FOR TWO PASSENGERS. LOSS OF ENGI NE POWER WHEN A VALVE ROCKER ARM SHAFT FELL OUT OF THE ENGINE AND A DEFECTIVE LOW ROTOR RPM WARNING HORN RESULTED IN A C RASH LANDING AND DAMAGE TO ALL MAJOR COMPONENTS OF THE HELICOPTER. THE THIN COMPOSIT SEAT BOTTOM DEFORMED AND EACH PASS ENGER'S PELVIS WAS TWISTED BY THE IMPACT CAUSING SEVERE DAMAGE TO THEIR VERTEBRA, AND A BROKEN RIB AND MANY BRUISES. 1 G 7 1 3O H1CE 1997082800079 19970828 00079 GL 1997 8 28 97ZZZX3759 1 19970625 G 6240 726607 AMPLIFIER ELECTROCORP ENSTRM F28 F28F 3300412 GL ROTOR RPM WARN FAILED C L A UNSCHED LANDING O OTHER CL CLIMB 1 WP 21 99YC 48 809 DURING CLIMB-OUT AT 200 FEET AND 60 MPH, THE ENGINE LOST POWER DUE TO THE NR 2 CYLINDER INTAKE VALVE ROCKER ARM SHAFT FA LLING OUT OF THE CYLINDER HEAD. THE LOW ROTOR RPM WARNING HORN, A MAJOR SAFETY FEATURE IN MARKETING THE MODEL F28F, DID NOT SOUND OFF ALTHOUGH IT CHECKED OUT AT WARM-UP. THE ENGINE SPEED DEGRADED RAPIDLY TO 2,300 RPM BEFORE TROUBLE WAS DE TECTED AND AUTOROTATION BEGAN. THE RESULTS WERE A VERY HARD CONTACT WITH THE GROUND AND DAMAGE TO THREE OCCUPANTS, AND DAMAGE TO ALL MAJOR COMPONENTS OF THE HELICOPTER. AFTER THE DUST SETTLED, THE HORN STILL WAS NOT BLOWING. 1 G 7 1 3O H1CE 1997082800080 19970828 00080 SW 1997 8 28 97ZZZX3760 1 19970808 G 6322 369D25623 BELT HUGHES 500N 500N 3027374 SW BLOWER CRACKED H PO7L K NONE O OTHER IN INSP/MAINT 1 WP 07 524FB 900 LN004 TWO EACH BLOWER BELTS WITH LOG B.04 HA1634, FOUND CRACKED VERTICALLY ON OUTSIDE LAYER OF BELT. BOTH BELTS CRACKED AT SA ME LOCATION IN RELATION TO PART NUMBER STAMP. 1 G 7 1 3U NC H3WE 1997082800081 19970828 00081 SW 1997 8 28 97ZZZX3761 1 19970729 G 6720 500N71123 LINK HUGHES 500N 500N 3027374 SW FAN PITCH SEIZED H PO7L K NONE O OTHER IN INSP/MAINT 1 WP 07 524FB 300 LN004 DURING 300-HOUR INSPECTION, FOUND BEARINGS LOCKED UP IN FAN PITCH CHANGE ARM AREA. 1 G 7 1 3U NC H3WE 1997082800185 19970828 00185 SW 1997 8 28 97ZZZX3767 1 19970724 G 6710 A21810064603 TRIM SWITCH HUGHES 500N 500N 3027374 SW CYCLIC STICK FAILED H A PO7L K NONE O OTHER IN INSP/MAINT 1 WP 07 523FB 276 LN003 PILOT TRIM SWITCH STICKING IN ALL DIRECTIONS. 1 G 7 1 3U NC H3WE 1997082800186 19970828 00186 SW 1997 8 28 97ZZZX3768 1 19970808 G 6322 369D25623 BELT HUGHES 500N 500N 3027374 SW BLOWER CRACKED H PO7L K NONE O OTHER IN INSP/MAINT 1 WP 07 523FB 600 LN003 BELT WAS FOUND CRACKED VERTICALLY ON 300-HOUR INSPECTION. CRACKED ON OUTSIDE LAYER. BOTH BELTS CRACKED AT LOCATION IN RELATION TO PART NUMBER STAMP. 1 G 7 1 3U NC H3WE 1997082800187 19970828 00187 NE 1997 8 28 97ZZZX3769 2 19970625 G 7250 BEARING SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D NE TURBINE MO4 FAILED D K NONE O OTHER IN INSP/MAINT 1 NM 03 92LG 2193 9441 2575 9198 15.9 AIRCRAFT FLIGHT HOURS AFTER CHANGING 2-3 MODULES. ALL ENGINE CHIP PLUGS HAD METAL ON THEM. ENGINE REPAIRED AND NO TIFIED THAT FREE TURBINE BEARING HAD FAILED. PART TOTAL CYCLES, 8,080. 1 G 7 1 3U 3 U H9EU E19EU 1997082800379 19970828 00379 CE 1997 8 28 97ZZZX3778 1 19970728 G 2436 REGULATOR BENDIX 7 RKWELL NA265 NA26540 6402608 CE TERMINAL CORRODED H K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 09 614 PART RECEIVED FROM SUPPLY WITH CORROSION ON TERMINAL ENDS. THESE ARE NEWLY OVERHAULED UNITS. SUBMITTER STATED THIS IS A N ONGOING PROBLEM, APPARENTLY, THIS AREA IS NOT BEING LOOKED AT DURING OVERHAUL. 2 L 7 2 4J A2WE 1997082800380 19970828 00380 CE 1997 8 28 97ZZZX3779 1 19970728 G 2436 REGULATOR BENDIX 7 RKWELL NA265 NA26540 6402608 CE TERMINAL CORRODED H K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 09 704 PART RECEIVED FROM SUPPLY WITH CORROSION ON TERMINAL ENDS. THESE ARE NEWLY OVERHAULED UNITS. SUBMITTER STATED THIS IS A N ONGOING PROBLEM, APPARENTLY, THIS AREA IS NOT BEING LOOKED AT DURING OVERHAUL. 2 L 7 2 4J A2WE 1997082800381 19970828 00381 GL 1997 8 28 97ZZZX3780 3 19970730 G 6111 83867 CLAMP HARTZL AIRTRC AT500 AT502 0390303 SW HARTZL HCB3T HCB3TN3 GL BLADE CRACKED B S PI4R K NONE O OTHER IN INSP/MAINT 1 SO 07 EG7906 BU529 INSPECTION FOUND BLADE CLAMP CRACKED. 1 L 7 1 3T NC A9SW 6 C P15EA 1997082800382 19970828 00382 SO 1997 8 28 97ZZZX3781 1 19970811 G 3246 1159SCL20343 WHEEL GULSTM G1159 GIV 3980115 SO MLG CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 15 23M 2789 224 JUN8647 1022 AT TIRE CHANGE INSPECTION, THREE CRACKS WERE FOUND IN KEYWAY BOSSES. THESE CRACKS ARE AT THE INBOARD END OF THE BOSSES. WE ARE WORKING WITH THE MANUFACTURER TO DETERMINE THE CAUSE OF THE CRACKS. SUBMITTER RECOMMENDS THESE AREAS BE INSPEC TED WITH AN EDDY CURRENT MACHINE AT EACH TIRE CHANGE. 2 L 7 2 4F RT A12EA 1997082800383 19970828 00383 CE 1997 8 28 97ZZZX3782 1 19970717 G 2913 PUMP RKWELL NA265 NA26540 6402608 CE SHAFT SEAL DAMAGED H K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 09 316NT 8 MX193803A 282060 HYDRAULIC PUMP WAS REMOVED AFTER 7.9 HOURS TIME IN SERVICE DUE TO SHAFT SEAL FAILURE AND EXCESSIVE FLUID LEAKAGE. PUMP, SN MX193803A, REJECTED FOR INSTALLATION DUE TO SHAFT SEAL WAS DAMAGED AND STICKING OUT AROUND THE PUMP DRIVE SHAFT. BOT H PUMPS WERE OVERHAULED BY REPAIR STATION. PUMP, SN MX193803A, TSO: 0.0. PUMP, SN MXW243463A, TSO: 7.9 HOURS. 2 L 7 2 4J A2WE 1997082800384 19970828 00384 CE 1997 8 28 97ZZZX3783 1 19970717 G 2913 PF24390615BCE PUMP RKWELL NA265 NA26540 6402608 CE SHAFT SEAL DAMAGED H K NONE K FLUID LOSS IN INSP/MAINT 1 SO 09 316NT 8 MX243463A 282060 HYDRAULIC PUMP WAS REMOVED AFTER 7.9 HOURS TIME IN SERVICE DUE TO SHAFT SEAL FAILURE AND EXCESSIVE FLUID LEAKAGE. PUMP, SN MX193803A, REJECTED FOR INSTALLATION DUE TO SHAFT SEAL WAS DAMAGED AND STICKING OUT AROUND THE PUMP DRIVE SHAFT. BOT H PUMPS WERE OVERHAULED BY REPAIR STATION. PUMP, SN MX193803A, TSO: 0.0. PUMP, SN MXW243463A, TSO: 7.9 HOURS. 2 L 7 2 4J A2WE 1997082800385 19970828 00385 EA 1997 8 28 97ZZZX3784 1 19970808 G 5551 C2TP159A BRACKET DHAV DHC2 DHC2MK1 2800102 EA LT HORIZ STAB CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 19 67897 2119 1045 DURING 100-HOUR INSPECTION AND C/W AD 90-02-22, FOUND 2 INCH CRACK ON OUTBOARD SIDE OF THE LEFT HORIZONTAL STABILIZER ( TAIL PLANE) ATTACHMENT BRACKET, PN C2TP159A. AD 90-02-22 CALLS FOR INSPECTION OF THE FUSELAGE MOUNTED BRACKETS, P/N'S C2-FS-543A AND C2-FS-544A, AND NOT FOR INSPECTION OF BRACKETS MOUNTED ON THE HORIZONTAL STABILIZER P/N'S C2TP159A AND C2 TP160A. THIS AIRCRAFT IS A FLOAT PLANE. SUBMITTER BELIEVES CAUSE OF THIS DEFECT IS THE EXCESSIVE FORCE APPLIED TO THE HORIZONTAL STABILIZER (TAIL PLANE) DURING 'RAMPING' OR 'BEACHING' OF THE AIRCRAFT BY GROUND PERSONNEL AFTER FLIGHT. AD 90-02-22 SHOULD BE REVISED TO INCLUDE THE INSPECTION OF THE STABILIZER MOUNTED BRACKETS, P/N'S C2TP159A AND C2TP160A. 1 H 7 1 3R A806 1997082800386 19970828 00386 CE 1997 8 28 97ZZZX3785 1 19970806 G 5210 MS3548941 SEAL GROMMET CESSNA 500 S550 2076607 CE MAIN DOOR FAILED D O OTHER J WARNING INDICATION CR CRUISE 1 SO 11 72AM S5500004 PILOT REPORTED RAPID DE-PRESSURIZATION AT ALTITUDE AND NOTED DOOR SEAL AT MAIN ENTRANCE DOOR LEAK. MAINTENANCE FOUND DO OR SEAL GROMMET DRY-ROTTED AND CRACKED. INSTALLED NEW GROMMET, P/N MS35489-41, AND PERFORMED OPERATIONAL CHECK, NO DEFE CTS OF DOOR SEAL NOTED. THIS GROMMET IS DIFFICULT TO INSPECT FOR CRACKS WHILE INSTALLED. PROCEDURES FOR REMOVAL AND RE PLACEMENT OF THIS GROMMET ARE FOUND IN CESSNA S550 MM, 52-10-01, PAGE 206. AIRCRAFT TT: 3437.6 HOURS. 1 L 7 2 4F RT A22CE 1997082800387 19970828 00387 EA 1997 8 28 97ZZZX3786 3 19970716 G 6110 527 RETAIN NUT WACO YMF YMF 9600412 EA SNSNCH W96JB W96JB EA PROPELLER SHAFT FAILED D L A A UNSCHED LANDING O OTHER NR NOT REPORTED 1 WP 13 553T F5C050 AC9806 AIRCRAFT ACCIDENT IN WHICH PROPELLER SEPARATED FROM AIRCRAFT. SUSPECT CAUSE: RETAINING NUT FAILURE. SUBMITTER RECOMME NDATION: RETAINING NUT BE REPLACED AT SPECIFIC INTERVALS. RETAINING NUT BE INSPECTED PRIOR TO EACH PROPELLER INSTALLAT ION. 1 Q 7 1 3R ATC542 5 N P170 1997082800388 19970828 00388 CE 1997 8 28 97ZZZX3787 1 19970715 G 2810 08233435 BLADDER CESSNA 310 310K 2074228 CE LT AUX FUEL MISMANUFACTURED D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 09 F1375 UNABLE TO INSTALL LT WING AUXILIARY FUEL CELLS, DUE TO INCORRECT DIMENSIONS BETWEEN CENTER OF AUX FUEL GAUGE TRANSMITTER FLANGE OPENING AND FUEL DRAIN HOSE NIPPLE. DISTANCE BTWN CENTERS OF AUX FUEL GAUGE XMITTER FLANGE OPENING AND ENG FUEL HOSE NIPPLE IS 6.312 INCHES FOR OEM BLADDER, 5.688 INCHES (SN F-1375) AND 5.812 INCHES (SN F-2341) FOR DURAFLEX BLADDER S, A .624 INCH AND .50 INCH DIFFERENCE FROM OEM. SUBMITTER RECOMMENDS QC AND MFG BE CHKD FOR SIGNS OF DEVIATION FROM EN GINEERING PROCEDURES, PLANNING, AND PROCESS CONTROL. 1 L 7 2 3O 3A10 1997082800389 19970828 00389 CE 1997 8 28 97ZZZX3788 1 19970715 G 2810 08233435 BLADDER CESSNA 310 310K 2074228 CE LT AUX FUEL MISMANUFACTURED D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 09 F2341 UNABLE TO INSTALL LT WING AUXILIARY FUEL CELLS, DUE TO INCORRECT DIMENSIONS BETWEEN CENTER OF AUX FUEL GAUGE TRANSMITTER FLANGE OPENING AND FUEL DRAIN HOSE NIPPLE. DISTANCE BTWN CENTERS OF AUX FUEL GAUGE XMITTER FLANGE OPENING AND ENG FUEL HOSE NIPPLE IS 6.312 INCHES FOR OEM BLADDER, 5.688 INCHES (SN F-1375) AND 5.812 INCHES (SN F-2341) FOR DURAFLEX BLADDER S, A .624 INCH AND .50 INCH DIFFERENCE FROM OEM. SUBMITTER RECOMMENDS QC AND MFG BE CHKD FOR SIGNS OF DEVIATION FROM EN GINEERING PROCEDURES, PLANNING, AND PROCESS CONTROL. 1 L 7 2 3O 3A10 1997082800390 19970828 00390 EA 1997 8 28 97ZZZX3789 2 19970515 G 8550 10168500 WASHER PIPER PA60 PA60602P 7106015 NM LYC O540 TIO540U2A 41532 EA OIL PUMP WORN D K NONE O OTHER IN INSP/MAINT 1 NM 05 858CH 600 608265006 DURING C/W SB 600-131, SUBSTANTIATED BOTH SCAVANGE OIL PUMPS WERE DUE IMMINENT FAILURE. REPLACED PARTS REQUIRED. 1 M 7 2 3O 3 O RT A17WE E14EA 1997082800391 19970828 00391 CE 1997 8 28 97ZZZX3790 1 19970814 G 2820 FUEL LINE CESSNA 172 172N 2072434 CE FRAME HOLE CHAFING D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 05 FOLLOWING AIRCRAFT INTERIOR REMOVAL, FOUND FUEL DISTRIBUTION LINES CHAFING ON FUSELAGE FRAMES. LINES WERE RIDING HARD O N EDGE OF CUT-OUTS. CHAFE WAS THROUGH RUBBER SLEEVE AND WAS METAL-TO-METAL ON THE LINE. 1 H 7 1 3O NT 3A12 1997082800392 19970828 00392 NE 1997 8 28 97ZZZX3791 3 19970717 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 8685 4536 HJ76A FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997082800394 19970828 00394 EA 1997 8 28 97ZZZX3793 1 19970814 G 6220 114R205035 HUB 414R20019 BOEING 234 234 1385049 EA M/R HEAD CRACKED B S CHIR K NONE O OTHER IN INSP/MAINT 1 NM 09 2FOR 1157 203 A41453 MJ001 CRACK DISCOVERED DURING POST-FLIGHT INSPECTION. CRACK ON TOP SURFACE OF CENTER SECTION BETWEEN RESERVOIR MOUNT HOLE AND TIE BAR BOLT ACCESS HOLE. EXTENDS THROUGH RESERVOIR HOLE DOWN INTO WEB OF CENTER SECTION. ROTOR HUB OPERATED ON MJ022 IN 'LR' CONFIGURATION BY HELIKOPTER SERVICE NORWAY. ONLY OPERATED 7 DAYS AND 55 HOURS IN 'UT' LOGGING ENVIRONMENT. PA RT NEW FROM BOEING APRIL 1994, INSTALLED BY HS AT COMPONENT TT 6,928.9 HOURS. OVERHAULED BY HS JUNE 1995 AT COMPONENT T T 7,883.5 HOURS. 2 G 7 2 4U H9EA 1997082800395 19970828 00395 EA 1997 8 28 97ZZZX3794 2 19970526 G 7322 2539561 SEAL RSA5AD1 PIPER PA24 PA24260 7102406 SO LYC O540 IO540D4A5 41532 EA INJECTOR SERVO LEAK D A O OTHER K E R FLUID LOSS VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 SO 16 991K 244055 L138248 SERVO WAS OVERHAULED ON APPROXIMATELY 1-28-97. COMPONENT OPERATED WITHOUT PROBLEM UNTIL 5-11-97 WHEN IT HAD ACCUMULATED 30 HOURS IN SERVICE. ON 5-11-97, EXPERIENCED IN-FLIGHT ENGINE ROUGHNESS WHICH ABATED SOMEWHAT WITH EXCESSIVELY LEANING OF THE MIXTURE. UPON LANDING, ENGINE POWER COULD NOT BE SUSTAINED DUE TO EXCESSIVELY RICH MIXTURE. UPON DISASSEMBLY, FOUND THAT SEAL PN 2539561 WAS LEAKING FUEL INTO THE AIR CHAMBER. 1 L 7 1 3O 3 O 1A15 1E4 1997090400259 19970904 00259 SO 1997 9 4 97ZZZX3802 1 19970810 G 3250 955100 MOUNT PIPER PA34 PA34200 7103405 SO BROKE D K NONE O OTHER LD LANDING 1 EA 17 1380T 4230 347250302 SUPPORT WELD BROKE ON STEERING/RUDDER TAB DURING LANDING GEAR MALFUNCTION. SUGGEST DYE CHECK EVERY 500 HOURS AND REPLAC ED ALL NEW HARDWARE. 1 L 7 2 3O A7SO 1997090400260 19970904 00260 CE 1997 9 4 97ZZZX3803 1 19970808 G 3260 99101366 ACTUATOR CESSNA 425 425 2076018 CE RT MLG DOWNLOCK INTERMITTENT D O OTHER N FALSE WARNING AP APPROACH 1 NM 09 146GW 266 1 4250146 RIGHT MLG SHOWED UNSAFE INDICATION WHEN EXTENDED. AFTER SEVERAL CYCLES, STILL NO DOWN AND LOCKED INDICATION. TROUBLESH OT SYSTEM AND FOUND DOWN AND LOCKED SWITCH WITHIN RT MLG ACTUATOR TO BE UNRELIABLE INTERMITTENTLY. REPLACED RT MLG ACTU ATOR ASSY. 1 L 7 2 3T RT A7CE 1997090400261 19970904 00261 CE 1997 9 4 97ZZZX3804 1 19970816 G 3233 22430022 FITTING CESSNA 182 R182 2072734 CE NLG ACTUATOR BROKEN D K NONE O OTHER IN INSP/MAINT 1 NM 11 182BG 2077 R18200256 DURING NON-ROUTINE MAINTENANCE, FOUND NOSE GEAR ACTUATOR ATTACH FITTING UPPER RT LEG BROKEN AT ATTACH BOLT HOLE. REPLAC ED WITH NEW PART. REVIEW OF LOG BOOKS INDICATE THIS AIRCRAFT HAD BEEN SEVERELY DAMAGED IN THE NOSE GEAR AREA (AS WELL A S HAVING 3 GEAR UP LANDINGS) WITH NO MENTION OF THE FITTING BEING REPLACED DURING REPAIRS. SUSPECT FITTING WAS DAMAGED DURING PREVIOUS ACCIDENT. NOTE: AD 91-11-09 AND CESSNA MEB 88-4 APPLY TO CESSNA T303 AIRCRAFT WHICH USED A VERY SIMILAR FITTING. 1 H 7 1 3O RT 3A13 1997090400262 19970904 00262 EA 1997 9 4 97ZZZX3805 2 19970805 G 7314 RG9080J7A PUMP ROMEC PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA LT ENGINE LEAKING D A A E F UNSCHED LANDING ENGINE SHUTDOWN ACTIVATE FIRE EXT. J K A WARNING INDICATION FLUID LOSS FLAME/FIRE CR CRUISE 1 SW 11 3533L 104 C6509 317952181 L745861A DURING NORMAL FLIGHT, PILOT NOTICED LEFT ENGINE WAS USING EXCESSIVE AMOUNT OF FUEL. PILOT DEVIATED FROM INTENDED DESTIN ATION TO NEAREST AIRPORT. DURING LANDING, LEFT ENGINE CAUGHT FIRE. LEFT ENGINE WAS SHUT DOWN AND FIREWALL SHUT-OFF WAS ACTUATED. UPON INSPECTING WITH ELECTRIC FUEL BOOST TURNED ON, FUEL WAS FOUND LEAKING FROM SEAM OF ENGINE-DRIVEN FUEL P UMP. 1 L 7 2 3O 3 O A20SO E14EA 1997090400263 19970904 00263 SO 1997 9 4 97ZZZX3806 1 19970613 G 8011 MZ4222 STARTER PIPER PA23 PA23250 7102308 SO RT ENGINE LOOSE D K NONE O OTHER IN INSP/MAINT 1 SO 33 40259 797 9M000004 277305069 RIGHT STARTER DRAGGING WHEN ENGAGED. FOUND MOTOR HOUSING LOOSE. ONE SCREW MISSING AND THREE OTHERS LOOSE. THIS IS THE SECOND STARTER FOUND LIKE THIS. THE SIXTH STARTER BY OUR OPERATION. THESE STARTERS ARE OVERHAULED BY CRS NR MO6R900J. 1 L 7 2 3O 1A10 1997090400264 19970904 00264 CE 1997 9 4 97ZZZX3807 1 19970805 G 7810 99102998 HEADER CESSNA 340 340A 2076405 CE WASTEGATE CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 13 6274X 340A0458 WHEN C/W AD 75-23-08 R5, FOUND HEADER CRACKED APPROXIMATELY TWO-THIRDS OF CIRCUMFERENCE ON THE WASTEGATE CONNECTOR PIPE. THIS AREA IS SUBJECT TO HEAT AND STRESSES WHEN IN OPERATION. 1 L 7 2 3O 3A25 1997090400265 19970904 00265 CE 1997 9 4 97ZZZX3808 1 19970814 G 5741 ATTACHMENT CESSNA 172 172A 2072404 CE WING ROOT DAMAGED C A K NONE O OTHER IN INSP/MAINT 1 NM 09 7377T 6650 46977 DAMAGED LEADING EDGE/MAIN SPAR/TRAILING EDGE AT WING CONNECTIONS TO FUSELAGE. A NEED FOR REINFORCEMENT IN THESE AREAS A ND IN MAIN FUSELAGE SECTIONS NEED TO BE REINFORCED WITH ADDITIONAL BRACE AND HEAVY DUTY CONNECTION BRACING PLATES DUE T O EXCESSIVE ICE AND SNOW ACCUMULATION ON AIRFRAME WHICH MAY HAVE EXCEEDED NEGATIVE LOAD FACTOR OF AIRFRAME. 1 H 7 1 3O 3A12 1997090400266 19970904 00266 CE 1997 9 4 97ZZZX3809 1 19970804 G 5312 00244002377 BULKHEAD BEECH 58 58 1152740 CE BS 257.6 CRACKED B R2JR K NONE O OTHER IN INSP/MAINT 1 EA 21 788CF 5084 TH870 DURING PHASE 2 INSPECTION OF TAIL AREA, CRACKING AND STOP-DRILLING NOTICED ON STA 257.6 BULKHEAD AT HORIZONTAL SPARE ATT ACH POINTS. STOP-DRILLING IS NOT AN APPROVED REPAIR PER BEECH SI 990, REV 2 PART II. A P/N 55-4030-5S REINFORCEMENT KI T NEEDED TO BE INSTALLED. KIT INSTALLED, AIRCRAFT RETURNED TO SERVICE. SI 990, WHICH REQUIRES INSPECTION, MODIFICATION , OR REPLACEMENT, SHOULD BE C/W EACH INSPECTION ON THESE BULKHEADS. REFER TO BEECH SI 990 FOR DETAILS. 1 L 7 2 3O 3A16 1997090400267 19970904 00267 CE 1997 9 4 97ZZZX3810 1 19970818 G 5312 12128582 BULKHEAD CESSNA 206 U206 2073306 CE BS 230.187 CRACKED D S K NONE O OTHER IN INSP/MAINT 1 AL 03 8030Z 4883 U2060430 INSPECTION FOUND TAIL CONE BULKHEAD AT BS 230.187 CRACKED. REPLACED WITH P/N 1212130-2. 1 H 7 1 3O A4CE 1997090400269 19970904 00269 SO 1997 9 4 97ZZZX3812 1 19970818 G 2750 8290503 BELLCRANK PIPER PA46 PA46350P SO RT FLAP DRIVE BROKEN B P A VA1R K NONE O OTHER NR NOT REPORTED 1 SW 19 91649 1233 4622029 RIGHT HAND FLAP DRIVE BELLCRANK ASSY P/N 82905-3 CRACKED AND TWISTED APPROXIMATELY .33 INCH OF CIRCUMFERENCE ON .75 INCH TUBE (MAIN BACKBONE OF TUBE). 1 L 7 1 3O RT A25SO 1997090400270 19970904 00270 SO 1997 9 4 97ZZZX3813 2 19970803 G 8530 641793 VALVE SEAT CESSNA 150 150F 2071814 CE CONT O200 O200A 17020 SO NR 2 INT VALVE CARBONED UP B L B9CR A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 EA 03 6674F 15063274 38263A FOLLOWING TAKEOFF, ENGINE LOST POWER. SAFE LANDING MADE. INVESTIGATION FOUND NR 2 CYLINDER LOST POWER DUE TO VALVE SEA T CARBON BUILD-UP CAUSING COMPRESSION LOSS AND BLOWBY TO OTHER CYLINDERS. 1 H 7 1 3O 3 O 3A19 E252 1997090400271 19970904 00271 SO 1997 9 4 97ZZZX3814 1 19970820 G 7810 LW15806 PIPE FLANGE PIPER PA32 PA32301T 7103209 SO UPPER RT EXHAUST CRACKED D L A K NONE O OTHER IN INSP/MAINT 1 NM 01 856RC 328024003 ROUTINE INSPECTION FOUND EXHAUST STAIN AT RT UPPER COWL AT FIRST CLAMP WAS SUSPECT. FURTHER INSPECTION FOUND INTERMEDIA TE EXHAUST PIPE FLANGE CRACKED. FLANGE WAS STRESS CRACKED AROUND ENTIRE CIRCUMFERENCE. PART TOTAL TIME .050 HRS. 1 L 7 1 3O A3SO 1997090400274 19970904 00274 SW 1997 9 4 97ZZZX3815 1 19970819 G 7120 2762114003 TRUSS MOUNT SWRNGN SA227 SA227AC 8780603 SW ENG NACELLE CRACKED B A H7NR K NONE O OTHER IN INSP/MAINT 1 SW 17 308007 MOUNT HAD BEEN INSPECTED AND SIGNED OFF ON SB 227-71-008. HOWEVER, WHEN RECEIVED IN THE SHOP, THE REAR TRUSS MOUNT WAS NOT WELDED. IT IS VERY DIFFICULT TO SEE IF THE MOUNT IS WELDED BY DOING SB 227-71-008 AS IT IS CALLED OUT. CAN EASILY BE MISSED. IF NOT REPAIRED, TRUSS CAN CRACK AT NON-WELDED AREA. 2 L 7 2 4T RT A8SW 1997090400275 19970904 00275 WP 1997 9 4 97ZZZX3816 2 19970806 G 7230 30770391 OUTER LINER GARRTT TFE731 TFE7312 01518 WP ENGINE MISREPAIRED B A IY2R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 15 RECEIVED FROM ALLIED SIGNAL REPAIR AND OVERHAUL SHOP. ONE EACH LINER OUTER TRANSITION P/N 3077039-1. THIS PART IS REWO RKED FROM A P/N 3071611-1. HOWEVER, THE PART RECEIVED WAS NOT AIRWORTHY. THE INNER SURFACE SHOULD HAVE BEEN COATED WIT H A THERMAL BARRIER COATING (TBC). THIS STEP WAS OMITTED. A SECOND AREA OF CONCERN IS THE SIGN-OFF IN THE REMARKS SECT ION OF THE 8130-3. THIS BLOCK STATES THE PART WAS WORKED AND INSPECTED PER MANUAL 72-02-71 (731 HEAVY MM). THIS MANUAL DOES NOT FURNISH ANY DETAILS ON THE MODIFICATION OF THIS PART. PART HAS BEEN RETURNED TO ALLIED SIGNAL, RMA NR 300133. 4 F E6WE 1997090400276 19970904 00276 EU 1997 9 4 97ZZZX3817 1 19970820 G 2752 21007 ARMATURE D79 FOKKER F27 F27MK400 4990626 EU FLAP MOTOR ARCING D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 05 2MIL 1702 10652 INSPECTION FOUND FLAP MOTOR ARMATURE WINDINGS ARCING AT COMMUTATOR SEGMENT RISERS. ARMATURE HAS OPEN CIRCUITED WINDINGS . CAUSED BY LATHE TURNING COMMUTATOR SEGMENTS TO CLEAN UP PREVIOUS COMPLAINT OF 'INSULATORS PROTRUDING FROM BETWEEN COM MUTATOR SEGMENTS'. LATHE TURNING REDUCED THICKNESS OF SEGMENTS BREAKING ELECTRICAL CONTACT BETWEEN ARMATURE WINDING AND COMMUTATOR SEGMENT BARS. FLAP MOTOR FAILURE OCCURRED AFTER LANDING. PART TOTAL CYCLES, 154. 2 H 7 2 4T A817 1997090400278 19970904 00278 CE 1997 9 4 97ZZZX3819 1 19970815 G 3240 1206P27 SWITCH CESSNA 500 550 2076604 CE POWER BRAKE FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 03 26496 492 2648 550607 MECHANIC NOTICED POWER BRAKE PUMP STOPPED CYCLING AFTER FLIGHT, IT NORMALLY CYCLES EVERY MINUTE OR SO TO RECHARGE PRESSU RE ACCUMULATOR. LACK OF CYCLING TRACED TO OPEN PRESSURE SWITCH WHICH WAS REPLACED AND OPS RETURNED TO NORMAL. SUBMITTE R HAS HAD TO CHANGE THESE SWITCHES 15 TIMES OVER THE LAST 7 YEARS ON FLEET OF FOUR C-550'S. 1 L 7 2 4F A22CE 1997090400279 19970904 00279 CE 1997 9 4 97ZZZX3820 1 19970714 G 5610 50420066354 WINDOW BEECH 100 B100 1152919 CE COPILOT D DELAMINATED B S W6NR K NONE O OTHER IN INSP/MAINT 1 GL 25 500KD BE79 FOUND COPILOT'S D-WINDOW STARTING TO DELAMINATE ON LOWER PORTION DUE TO OVERSIZED WINDOW WAS INSTALLED IN A NORMAL SIZE FUSELAGE OPENING. WINDOW WAS RUBBING ON FUSELAGE SKIN AT THE RECESSED AREA OF THE WINDOW. BEECHCRAFT IPC ONLY LISTS OV ERSIZED WINDOWS. 1 L 7 2 4T A14CE 1997090400280 19970904 00280 CE 1997 9 4 97ZZZX3821 1 19970806 G 2810 10192006711 PLATE ASSY 1009200671 BEECH 90 F90 1152909 CE FUEL VENT FLOAT LOOSE B S EHHR K NONE K FLUID LOSS IN INSP/MAINT 1 EA 17 96TT 6100 LA26 FUEL VENTING FROM RIGHT HEATED FUEL VENT. FOUND FUEL LEAKING PAST AUXILIARY TANK FLAPPER VALVE. LOOSE/WORN RIVETS ALLO WED VALVE TO UNSEAT AND FUEL LEAKED BY GRAVITY FEED. REPLACED RIVETS THAT HOLD HINGE HALF TO PLATE. 1 L 7 2 4T A31CE 1997090400282 19970904 00282 CE 1997 9 4 97ZZZX3822 1 19970816 G 2720 504200337 BEAM BEECH 99 99 1154002 CE RUD PEDAL BS 115 CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 15 108BA 26664 U40 RUDDER PEDAL QUADRANT MOUNT BEAM CRACKED. CRACK WAS FOUND ON THE BOTTOM BEND UNDER SUPPORT BRACKET (RUDDER) BOLT HOLES. SUSPECT POSSIBLE CAUSE, RUDDER CABLE TENSION TOO HIGH. 1 L 7 2 3T A14CE 1997090400283 19970904 00283 NE 1997 9 4 97ZZZX3823 3 19970715 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE BLADE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 4596 2500NR HJ382 INSPECTION OF PROPELLER FOUND FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997090400284 19970904 00284 CE 1997 9 4 97ZZZX3824 1 19970804 G 3244 028700 TIRE CESSNA 500 560CESSNA 2076750 CE LT MLG FAILED B R2JR K NONE O OTHER IN INSP/MAINT 1 EA 21 92SS 258 6003P00676 5600388 DURING MAINTENANCE TIRE SERVICING PRIOR TO FLIGHT, NOTICED LEFT MAIN TIRE TREAD WAS COMING OFF TIRE CASING. TIRE HAD TO BE CHANGED BEFORE FLIGHT. TIRE WAS AVIATOR 12-PLY AND TIRE PRESSURE AND TIRE TREAD LOOKED NORMAL. TIRE PRESSURE WAS B EING CHECKED AS PART OF NORMAL PRE-FLIGHT BY AN A & P MECHANIC. LANDINGS, 263. 2 L 7 2 4F RT A22CE 1997090400285 19970904 00285 CE 1997 9 4 97ZZZX3825 1 19970714 G 2434 DOFF10300B ALTERNATOR FORD CESSNA 150 152 2071835 CE DC SYSTEM FAILED D O OTHER J WARNING INDICATION NR NOT REPORTED 1 SW 15 68175 33 0082833 15285318 ALTERNATOR FAILED IN-FLIGHT 33.0 HOURS AFTER OVERHAUL. 1 H 7 1 3O NT 3A19 1997090400286 19970904 00286 SO 1997 9 4 97ZZZX3826 1 19970826 G 5510 STABILATOR PIPER PA28 PA28140 7102802 SO RT/LT STABILATOR CORRODED H A K NONE O OTHER IN INSP/MAINT 1 EA 07 6747W 3014 2820871 RIVET HEAD FOUND MISSING ON BOTTOM OF RT STABILATOR. INSPECTION REVEALED THE AREA IN FRONT OF SPAR ON BOTH LT AND RT ST ABILATOR WERE FILLED WITH MOUSE NESTING DEBRIS. ACCESS COULD ONLY BE MADE BY REMOVING BOTH TIP RIBS. CORROSION WAS LIG HT, BUT ALL BOTTOM RIVETS ALONG SPAR ON RT SIDE WERE REPLACED. THIS AIRCRAFT IS STORED IN A CLOSED HANGAR WITH A CONCRE TE FLOOR. THE POTENTIAL PROBLEMS FROM THIS CONDITION GOING UNNOTICED ARE SEVERE, SO LOOK SHARP! 1 L 7 1 3O 2A13 1997090400493 19970904 00493 SW 1997 9 4 97ZZZX3827 1 19970819 G 7120 2762114003 TRUSS MOUNT SWRNGN SA227 SA227AC 8780603 SW ENG AFT MOUNT CRACKED B A H7NR K NONE O OTHER IN INSP/MAINT 1 SW 17 TRUSS MOUNT CRACKED AT TUBE THAT ATTACHES THE REAR UPPER ENGINE MOUNT. THIS MOUNT WAS WELDED UNDER THE LUG POINT AND WA S NOT EFFECTED BY THE CALL OUT OF SB 227-71-008. FIRST WELDED ONE SUBMITTER HAS SEEN CRACKED. PRIOR CRACKS HAD BEEN TH OSE NOT WELDED. 2 L 7 2 4T RT A8SW 1997090400494 19970904 00494 NE 1997 9 4 97ZZZX3828 2 19970724 G 7210 8941191 COUPLER GARRTT TPE331 TPE3316252M 01514 NE RED GEARBOX INSERT LOOSE B A RG4R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 03 W97190070 NEW PART RECEIVED WITH INTERNAL SPLINE INSERT LOOSE. IF PART WAS INSTALLED IN ENGINE AND FAILED, ENGINE WOULD EITHER NT S WHILE RUNNING, OR NOT NTS UPON ENGINE IN-FLIGHT FAILURE. E2WE 1997090400495 19970904 00495 1997 9 4 97ZZZX3829 1 19970725 G 2436 VR515G CONTROL UNIT ELECTRODELTA E3402A ALTERNATOR CONT DEFECTIVE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 15 THIS UNIT (ZERO TIME SINCE REPAIR) WAS REMOVED FROM SHELF STOCK AND INSTALLED IN PLACE OF AIRCRAFT'S FAULTY ACU. DURING INSTALLATION, NOTED THERE WAS NO OUTPUT VOLTAGE TO ALTERNATOR FIELD. UNIT WAS REMOVED WITH ZERO TIME IN SERVICE SINCE INSTALLATION. 1997090400496 19970904 00496 1997 9 4 97ZZZX3830 1 19970725 G 2436 VR55G CONTROL UNIT ELECTRODELTA ALTERNATOR DEFECTIVE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 15 0031243 THIS UNIT (NEWLY OVERHAULED) WAS REMOVED FROM SHELF STOCK AND INSTALLED IN PLACE OF AIRCRAFT'S FAULTY ALTERNATOR CONTROL UNIT. DURING INSTALLATION, NOTED THERE WAS NO OUTPUT VOLTAGE TO ALTERNATOR FIELD. UNIT WAS REMOVED WITH ZERO TIME IN SERVICE SINCE INSTALLATION. 1997090400497 19970904 00497 CE 1997 9 4 97ZZZX3831 1 19970725 G 2436 VR515G CONTROL UNIT ELECTRODELTA 2032601 CESSNA 150 152 2071835 CE ALTERNATOR CONT FAILED D O OTHER J WARNING INDICATION CR CRUISE 1 SW 15 68725 101 15282338 LOW VOLTAGE LIGHT ILLUMINATED IN-FLIGHT. INSPECTION REVEALED NO VOLTAGE TO FIELD TERMINAL ON ALTERNATOR. VERIFIED POWE R SUPPLY TO ACU. NO ACU OUTPUT. INSTALLATION OF TWO ACU'S (ZERO TIME SINCE REPAIR/OVERHAUL) DID NOT RESTORE POWER. IN STALLATION OF ZEFTRONICS ACU P/N R25400 RESTORED POWER AND SYSTEM FUNCTIONED NORMALLY. 1 H 7 1 3O NT 3A19 1997090400500 19970904 00500 SO 1997 9 4 97ZZZX3834 2 19970815 G 8530 CYLINDER CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO CYLINDER HEAD CRACKED B L VA1R K NONE O OTHER IN INSP/MAINT 1 SW 19 105LY 807 414A0060 L509474 THE TWO REPORTED ENGINES EXHIBITED FUEL STAINS ADJACENT TO THE ENGINE FUEL INJ ECTORS ON 9 OF A POSSIBLE 12 CYLINDERS. F URTHER EXAMINATION REVEALED CYLINDER HEAD CRACKS UNDER CYLINDER FINS (AT THE INTAKE PORTS) AND THROUGH THE SPARK PLUG BO SSES ON EACH OF THE CYLINDERS. SUBMITTER STATED IF ALLOWED TO GO UNCHECKED, THE CRACKS COULD PROGRESS TO A POINT WHERE THE CYLINDER TO HEAD INTEGRITY WOULD BE LOST AND CYLINDER PERFORMANCE JEOPARDIZED. 1 L 7 2 3O 3 O A7CE E8CE 1997090400501 19970904 00501 GL 1997 9 4 97ZZZX3835 2 19970806 G 7240 23031260 COMBUSTION CASE BELL 206 206B 1181511 SW ALLSN 250C 250C20J 03013 GL RT ARM PIT SEAM CRACKED B B31R K NONE J R WARNING INDICATION PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SO 17 163BH 2227 3027 CAE270600 PILOT REPORTED HIGH TOT, LOW POWER. INSPECTED COMBUSTION CASE, FOUND CRACK ALONG SEAM WHERE HALVES WERE WELDED TOGETHER . THIS AREA IS ALSO REINFORCED WITH WIRE MESH BRAZED FOR SUPPORT. THE CRACK WAS BEHIND WIRE MESH. A LARGER REINFORCEM ENT PATCH MIGHT HELP. 1 G 7 1 3U 3 U H2SW E4CE 1997090400502 19970904 00502 EU 1997 9 4 97ZZZX3836 1 19970607 G 2822 BOOST PUMP SNIAS 350 AS350B2 8680813 EU BELLY PANEL WIRE CHAFED D K NONE O OTHER IN INSP/MAINT 1 NM 11 96LG 1160 2817 RIGHT FUEL BOOST PUMP STOPPED. TROUBLESHOT BOOST PUMP SYSTEM AND FOUND WIRE CHAFED THROUGH FROM BELLY PANEL RUBBING ON WIRE AND FUEL TANK. EITHER THE BELLY PANEL WAS MIS-ALIGNED OR THE FUEL TANK WAS MIS-ALIGNED OR CUT OUT IN BELLY PANEL W AS NOT LARGE ENOUGH. SUBMITTER RECOMMENDS FACTORY VERIFY CLEARANCE AROUND FUEL TANK-SUMP-BOSS AREA. 1 G 7 1 3U H9EU 1997090400503 19970904 00503 EU 1997 9 4 97ZZZX3837 1 19970625 G 2911 704A34240015 ACCUMULATOR SNIAS 350 AS350B2 8680813 EU T/R CONTROL LOST PRESSURE D K NONE F FLT CONT AFFECTED NR NOT REPORTED 1 NM 11 93LG 2654 TAIL ROTOR CONTROLS LOST ACCUMULATOR PRESSURE, FOUND VALVE STEM LOOSE. SUBMITTER STATED THIS HAS HAPPENED SEVERAL TIMES WITH ALL ACCUMULATORS (INCLUDING M/R) ON 3 DIFFERENT AIRCRAFT. SUBMITTER RECOMMENDS USING ACCUMULATOR WITH JAM NUT AND SHUT-OFF FOR VALVE STEM. 1 G 7 1 3U H9EU 1997090400504 19970904 00504 1997 9 4 97ZZZX3838 4 19970728 G 3414 206075725103 INDICATOR BELL 407 407 SW COCKPIT AIR SPD FAILED B GS1R K NONE O OTHER NR NOT REPORTED 1 EA 03 7249U 10 53152 AIR SPEED INDICATOR FAILED. REPLACED WITH NEW AIRSPEED INDICATOR. 1 G 7 1 3U O H2SW 1997090400505 19970904 00505 EU 1997 9 4 97ZZZX3839 1 19970625 G 2916 RESERVOIR SNIAS 350 AS350B2 8680813 EU HYDRAULIC SYSTEM WATER CONTAM D S A K NONE O OTHER IN INSP/MAINT 1 NM 11 93LG 2654 2654 ON SEVERAL OCCASIONS AND 3 DIFFERENT AIRCRAFT NOTICED WATER DROPLETS IN HYDRAULIC RESIDUE FILLER NECK SCREEN. SUBMITTER SUSPECTS CAP DESIGN AS PROBLEM, OCCURS MAINLY AFTER SITTING OUT IN RAIN OR SNOW. HYDRAULIC RESERVOIR IS POSITIONED WIT H NO PROTECTION FROM WEATHER BY COWLINGS. IT IS BELOW MAST OPENING IN COWLING. RECOMMEND RE-DESIGN CAP. 1 G 7 1 3U H9EU 1997090400506 19970904 00506 EU 1997 9 4 97ZZZX3840 1 19970714 G 6320 109040306105 INPUT QUILL A09040002107 AGUSTA A109 A109C 0260118 EU MAIN GEARBOX SPALLED D A A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 GL 15 911D 1178 361 7637 APPROXIMATELY 5 MINUTES AFTER TAKEOFF, MAIN TRANSMISSION CHIP LIGHT CAME ON AND WOULD NOT ZAP OFF. PILOT RETURNED TO MA INT BASE. TECHNICIAN REMOVED AND INSPECTED BOTH CHIP PLUGS. TOP CHIP PLUG WAS CLEAN. BOTTOM CHIP PLUG HAD 4 LARGE CHI PS ON IT. TRANSMISSION FILTER WAS REMOVED AND FOUND TO CONTAIN AN EXCESSIVE AMOUNT OF METAL FILINGS. (200 HOUR OIL AND FILTER CHANGE HAD BEEN C/W APPROXIMATELY 23 HOURS PRIOR TO THIS WITH NOTHING ABNORMAL NOTED). AGUSTA AEROSPACE TECHNIC IANS OPENED THE GEARBOX AND FOUND EXCESSIVE SPALLING ON THE INPUT QUILL AND GLEASON CROWN GEAR. 1 G 7 2 3U H7EU 1997090400507 19970904 00507 NE 1997 9 4 97ZZZX3841 1 19970811 G 6210 641520201048 BLADE 64M47805074 SKRSKY S64 S64E 8142604 NE MAIN ROTOR CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 2FOR 3473 64065 SPAR IS CRACKED ON THE BOTTOM SIDE BACKWALL RADIUS APPROXIMATELY 112.1 INCHES FROM TIP END. SPAR AT CRACK LOCATION SHOW S NO OBVIOUS SIGNS OF DAMAGE ON THE EXTERIOR SURFACE. 2 G 7 2 4U H4EA 1997090400509 19970904 00509 SO 1997 9 4 97ZZZX3843 2 19970812 G 8530 CYLINDER CESSNA 172 172H 2072424 CE CONT O300 O300D 17022 SO NR 1 SEPARATED B KU1R A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 EA 07 3838R 970 17255338 34890D6D AIRCRAFT WAS IN-FLIGHT WHEN NR 1 CYLINDER BARREL SEPARATED FROM HEAD CAUSING A FORCED LANDING. NO FURTHER DAMAGE OCCURR ED TO AIRCRAFT AND NO INJURIES OCCURRED DURING THIS INCIDENT. SUSPECT CAUSE WAS ATTRIBUTED TO AGE AND TIME ON CYLINDER. 1 H 7 1 3O 3 O NT 3A12 E253 1997090400510 19970904 00510 EU 1997 9 4 97ZZZX3844 2 19970730 G 8530 SEAL AMTR SEAREY SEAREY 05625X5 GL ROTAX 912 ROTAX912 55555 EU NR 3 CYL EXH VLV FAILED G K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 EA 23 7475Q 32 1DK028 4400900 NUMEROUS PILOT LOG BOOK REPORTS OF A ROUGH RUNNING ENGINE. ATTEMPTS TO CORRECT BY REPLACING SPARK PLUGS, LEADS, FUEL FI LTER, ETC., DID NOT CORRECT PROBLEM. INVESTIGATION DISCLOSED THAT BOTH SPARK PLUGS IN NR 3 CYLINDER WERE OIL SOAKED. I T APPEARED THE EXHAUST VALVE STEM SEAL ON NR 3 CYLINDER HAD FAILED. 1 H 7 1 3I 3 I RC 1H71EXPA EXPE3I 1997091100100 19970911 00100 NE 1997 9 11 97ZZZX3846 2 19970707 G 7230 766962 CASE ASSY PWA JT8 JT8D1 52044 NE COMPRESSOR CARBON BUILD UP B L CD4R K NONE O OTHER IN INSP/MAINT 1 SO 17 CD1239 INSPECTION OF COMPRESSOR CASE ASSY FOUND EXCESSIVE CARBON BUILD-UP. 4 F E2EA 1997091100101 19970911 00101 NE 1997 9 11 97ZZZX3847 2 19970707 G 7230 766962 CASE ASSY PWA JT8 JT8D1 52044 NE COMPRESSOR CARBON BUILD UP B CD4R K NONE O OTHER IN INSP/MAINT 1 SO 17 CK4178 INSPECTION OF COMPRESSOR CASE ASSY FOUND EXCESSIVE CARBON BUILD-UP. 4 F E2EA 1997091100102 19970911 00102 1997 9 11 97ZZZX3848 1 19970707 G 7500 634607 DIFFUSER DUCT PWA JT8 JT8D1 52044 NE P/D OF PORT AREA CRACKED B S CD4R K NONE O OTHER IN INSP/MAINT 1 SO 17 1970 INSPECTION FOUND DIFFUSER DUCT WITH LENGTHY CRACKING ON OUTSIDE DIAMETER ADJACENT TO PORT AREAS. 4 F E2EA 1997091100103 19970911 00103 1997 9 11 97ZZZX3849 1 19970707 G 7500 616288 DIFFUSER DUCT PWA JT8 JT8D1 52044 NE O/D OF PORT AREA CRACKED B S CD4R K NONE O OTHER IN INSP/MAINT 1 SO 17 A45 DIFFUSER DUCT INSPECTION FOUND LENGTHY CRACKING ON OUTSIDE DIAMETER ADJACENT TO PORT AREAS. 4 F E2EA 1997011600879 19970116 00879 WP 1997 1 16 97ZZZX385 1 19970116 G 5740 FITTING WTHRLY 620 620 9630602 WP WING ATTACH RUSTED D L A K NONE O OTHER IN INSP/MAINT 1 SW 07 2004G 1555 WHEN PERFORMING AN ANNUAL INSP, IT WAS NOTED THAT ALL THE WING TO CENTER SECTION FITTINGS WERE SEVERELY RUSTED, NO PITTI NG HAS YET OCCURRED ON ANY OF THESE FITTINGS, BUT SOME POWDERY DEPOSITS CAN BE SEEN BETWEEN THE LOWER CAP FITTINGS AND T HE SPAR WEB ON THE RT LOWER FRONT FITTING. THESE ARE STEEL FITTINGS BOLTED TO AN ALUMINUM SPAR WEB. THESE FITTINGS APP EAR TO NOT HAVE ANY PRIMER OR PROTECTIVE COATING OF ANY KIND ON THEM. 1 L 7 1 3R A26WE 1997091100104 19970911 00104 NE 1997 9 11 97ZZZX3850 2 19970624 G 7240 748265 COMBUSTION CHAMB PWA JT8 JT8D1 52044 NE INNER SEAM CRACKED B CD4R K NONE O OTHER IN INSP/MAINT 1 SO 17 4873 INSPECTION OF COMBUSTION CHAMBER FOUND CRACKS IN FUSION WELD THIRD INNER SEAM. ALL UNITS WERE REJECTED, 7 EACH. 4 F E2EA 1997091100105 19970911 00105 NE 1997 9 11 97ZZZX3851 2 19970624 G 7240 748265 COMBUSTION CHAMB PWA JT8 JT8D1 52044 NE INNER SEAM CRACKED B CD4R K NONE O OTHER IN INSP/MAINT 1 SO 17 MM1101 INSPECTION OF COMBUSTION CHAMBER FOUND CRACKS IN FUSION WELD THIRD INNER SEAM. ALL UNITS WERE REJECTED, 7 EACH. 4 F E2EA 1997091100106 19970911 00106 NE 1997 9 11 97ZZZX3852 2 19970624 G 7240 748265 COMBUSTION CHAMB PWA JT8 JT8D1 52044 NE INNER SEAM CRACKED B CD4R K NONE O OTHER IN INSP/MAINT 1 SO 17 5358 INSPECTION OF COMBUSTION CHAMBER FOUND CRACKS IN FUSION WELD THIRD INNER SEAM. ALL UNITS WERE REJECTED, 7 EACH. 4 F E2EA 1997091100107 19970911 00107 NE 1997 9 11 97ZZZX3853 2 19970624 G 7240 748265 COMBUSTION CHAMB PWA JT8 JT8D1 52044 NE INNER SEAM CRACKED B CD4R K NONE O OTHER IN INSP/MAINT 1 SO 17 APM0100493 INSPECTION OF COMBUSTION CHAMBER FOUND CRACKS IN FUSION WELD THIRD INNER SEAM. ALL UNITS WERE REJECTED, 7 EACH. 4 F E2EA 1997091100108 19970911 00108 NE 1997 9 11 97ZZZX3854 2 19970624 G 7240 748265 COMBUSTION CHAMB PWA JT8 JT8D1 52044 NE INNER SEAM CRACKED B CD4R K NONE O OTHER IN INSP/MAINT 1 SO 17 3766 INSPECTION OF COMBUSTION CHAMBER FOUND CRACKS IN FUSION WELD THIRD INNER SEAM. ALL UNITS WERE REJECTED, 7 EACH. 4 F E2EA 1997091100109 19970911 00109 NE 1997 9 11 97ZZZX3855 2 19970624 G 7240 748265 COMBUSTION CHAMB PWA JT8 JT8D1 52044 NE INNER SEAM CRACKED B CD4R K NONE O OTHER IN INSP/MAINT 1 SO 17 APM010044 INSPECTION OF COMBUSTION CHAMBER FOUND CRACKS IN FUSION WELD THIRD INNER SEAM. ALL UNITS WERE REJECTED, 7 EACH. 4 F E2EA 1997091100110 19970911 00110 NE 1997 9 11 97ZZZX3856 2 19970624 G 7240 748265 COMBUSTION CHAMB PWA JT8 JT8D1 52044 NE INNER SEAM CRACKED B CD4R K NONE O OTHER IN INSP/MAINT 1 SO 17 GK4968 INSPECTION OF COMBUSTION CHAMBER FOUND CRACKS IN FUSION WELD THIRD INNER SEAM. ALL UNITS WERE REJECTED, 7 EACH. 4 F E2EA 1997091100113 19970911 00113 1997 9 11 97ZZZX3859 4 19970821 G 2562 ACKE01 ELT ACK BATTERY CORRODED B JVYR K NONE O OTHER IN INSP/MAINT 1 WP 05 TWO TIMES WITHIN TWO WEEKS FOUND ACK TECHNOLOGIES ELT'S, MODEL ACK E01, INOPERABLE. ON DISASSEMBLY, FOUND THE D-CELL BA TTERIES, TERMINALS, AND CIRCUIT BOARD CORRODED. TERMINALS AND CIRCUIT BOARDS WERE CLEANED, NEW BATTERIES INSTALLED, BU T THE ELT WAS STILL INOPERABLE. CAUSE - BAD SEALING. 1997091100114 19970911 00114 1997 9 11 97ZZZX3860 4 19970821 G 2561 P0101 VEST EAAEROMARINE FAILED D K NONE O OTHER IN INSP/MAINT 1 EA 07 B31230 VEST FAILED THE MANUFACTURER'S 2-POUND PSI TEST. BAD SEAM. 1997091100115 19970911 00115 CE 1997 9 11 97ZZZX3861 1 19970725 G 7160 04500665 SEAL CESSNA 150 152 2071835 CE CARB AIR BOX CRACKED D K NONE O OTHER IN INSP/MAINT 1 NE 01 24870 15280426 CARBURETOR BOX SEAL CESSNA PART MADE FROM THIN PLASTIC, LESS THAN 200 HOURS, AND CRACKS OUT DUE TO VIBRATION. ALL MODEL CESSNAS WITH CARBURETOR AIR BOX SEALS VIBRATE AND CRACK APART INTO ENGINE COMPARTMENT. SUBMITTER STATED SHOULD BE CONS TRUCTED OF MORE DURABLE MATERIAL. REPLACEMENT REQUIRED ALMOST EVERY 100 HOURS. 1 H 7 1 3O NT 3A19 1997091100116 19970911 00116 CE 1997 9 11 97ZZZX3862 1 19970731 G 5711 SPAR CESSNA 150 150M 2071830 CE RT WING CORRODED D K NONE O OTHER IN INSP/MAINT 1 NE 01 45434 3731 15076917 RIGHT REAR SPAR, WS 40, BENT AND CRACKED. LOG RESEARCH SHOWS INCIDENT 2 YEARS PRIOR. WING CORROSION WAS VISABLE AT A G LANCE. 1 H 7 1 3O 3A19 1997091100117 19970911 00117 CE 1997 9 11 97ZZZX3863 1 19970805 G 2434 653983 HUB FORD DOFF10300F CESSNA 150 150M 2071830 CE ALTERNATOR WORN D K NONE O OTHER IN INSP/MAINT 1 NE 01 45434 3731 0071253 15076917 ALTERNATOR HUB LOOSE ON WOODRUFF KEY AND WORE SHAFT TO .0312 INCH. STEP WEAR WAS EVIDENT BY MOVING FAN A FULL WINDOW. 1 H 7 1 3O 3A19 1997091100118 19970911 00118 CE 1997 9 11 97ZZZX3864 1 19970728 G 2430 S199411 SWITCH CESSNA 150 152 2071835 CE ALTERNATOR CONT FAILED D K NONE O OTHER IN INSP/MAINT 1 NE 01 48858 282 15281007 OWNER REPORTED DEAD BATTERY. BATTERY FOUND TOO HOT TO TOUCH, AND DEVOID OF ELECTROLYTE. TROUBLESHOOTING INDICATED SYST EM VOLTAGE TO BE 1.6 VOLTS ABOVE NORMAL VALUES. FOUND INTERMITTENT RESISTANCE IN ALTERNATOR CONTROL SWITCH. RECOMMEND REGULAR SYSTEM VOLTAGE CHECKS. 1 H 7 1 3O NT 3A19 1997091100120 19970911 00120 SW 1997 9 11 97ZZZX3866 1 19970731 G 6230 206040576103 BEARING BELL 206 206L3 1182108 SW MAST FAILED B EOPR K NONE O OTHER IN INSP/MAINT 1 AL 01 360AL 1141 ZV1265 51462 MAST BEARING, P/N 206-040-576-103, ONE BALL BROKE APART. BEARING TT UNKNOWN. TSO: 1,141.9 HOURS. MAST WAS INSPECTED FOR SUSPECTED LIGHTNING STRIKE AT 430.3 HOURS TSO. NO DEFECTS NOTED. REPLACED BEARING. 1 G 7 1 3U H2SW 1997091100121 19970911 00121 SO 1997 9 11 97ZZZX3867 1 19970818 G 5280 4752932 HINGE PIPER PA31 PA31350 7103110 SO GEAR DOOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 141ME 318152117 INSPECTION FOUND GEAR DOOR HINGE WITH A CRACK IN INNER ASPECT OF RADIUS. PART IS NEW STYLE TO C/W TERMINATING ACTION OF AD 802605. 1 L 7 2 3O A20SO 1997091100122 19970911 00122 EA 1997 9 11 97ZZZX3868 2 19970813 G 7314 1C69 PUMP AIRBORNE PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA LT MAIN XSFER INOPERATIVE B EKIR K NONE O OTHER IN INSP/MAINT 1 WP 07 110SK 419 31P7630006 R71162 LEFT MAIN TRANSFER PUMP OVERHAULED BY 2-14-96, INSTALLED 7-8-96. PUMP INOPERABLE. SENDING TO RAPCO FOR DETERMINATION O F PROBLEM. SHORT SERVICE LIFE. 1 L 7 2 3O 3 O A8EA E19EA 1997091100123 19970911 00123 SO 1997 9 11 97ZZZX3869 1 19970812 G 5520 5423224 ELEVATOR PIPER PA31 PA31350 7103110 SO LT ELEV TIP CRACKED H K NONE O OTHER IN INSP/MAINT 1 CE 09 27299 4082 317752128 ELEVATOR TIP CORRODED. FOUND AS A RESULT OF C/W SB 998A DATED 8-4-97. 1 L 7 2 3O A20SO 1997091100124 19970911 00124 SO 1997 9 11 97ZZZX3870 1 19970812 G 5520 5423235 ELEVATOR PIPER PA31 PA31350 7103110 SO RT ELEV TIP CRACKED H K NONE O OTHER IN INSP/MAINT 1 CE 09 27299 4082 317752128 ELEVATOR TIP CORRODED. FOUND AS A RESULT OF C/W SB 998A DATED 8-4-97. 1 L 7 2 3O A20SO 1997091100125 19970911 00125 SO 1997 9 11 97ZZZX3871 1 19970820 G 3230 4033600 DRAG LINK PIPER PA31 PA31350 7103110 SO NLG CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 01 3235F 317952200 DURING INSPECTION NOSE GEAR RT DRAG LINK FOUND LINK CRACKED IN AREA WHERE IDLER LINK ROD ATTACHES. SUBMITTER STATED HAV E HAD SIMILAR CRACKS IN ONE OTHER LINK ASSY. SUSPECT AGE, FATIGUE, AND HARD LANDING. 1 L 7 2 3O A20SO 1997091100126 19970911 00126 SO 1997 9 11 97ZZZX3872 1 19970818 G 3233 WTC21151 ACTUATOR WIEBEL PIPER PA31 PA31350 7103110 SO RT MLG BROKEN D K NONE O OTHER IN INSP/MAINT 1 NM 01 3535F 8279 FOUND RIGHT MAIN GEAR ACTUATOR CRACKED AND BROKEN IN THREADED AREA OF ROD ASSY. CRACK LOCATED AT AREA WHERE THREADS STA RT ON ROD. AIRCRAFT HIGH TIME (+18,000 HOURS). AGE FATIGUE A POSSIBILITY. 1 L 7 2 3O A20SO 1997091100127 19970911 00127 EA 1997 9 11 97ZZZX3873 2 19970709 G 8520 CONNECT ROD PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA NR 5 CYLINDER FAILED E A E A ENGINE SHUTDOWN UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 NM 01 36PB 1250 317405128 L722561A CLIMBING THROUGH 4,000 FEET OUT OF PDX, PILOT NOTED PROMINENT VIBRATION. PILOT TRIED TO DETERMINE WHICH ENGINE WAS SOUR CE OF VIBRATION, BUT WITHIN 30 SECONDS, THE LEFT ENGINE STOPPED PRODUCING POWER (DID NOT SEIZE). PROPELLER WAS FEATHERE D AND AIRCRAFT RETURNED TO PDX. ENGINE TEAR-DOWN REVEALED THAT NR 5 CONNECTING ROD HAD COME LOOSE. SUSPECT CAUSED BY T HE BREAKING OF ONE OF THE CONNECTING ROD BOLTS. 1 L 7 2 3O 3 O A20SO E14EA 1997091100129 19970911 00129 EA 1997 9 11 97ZZZX3875 2 19970812 G 7414 6224 MAGNETO SLICK MOONEY M20 M20M 5870222 SW LYC O540 TIO540AF1A 41532 EA LT MAGNETO CONTAMINATED D K NONE O OTHER IN INSP/MAINT 1 EA 13 40JE 473 91030020 270161 L943161A DURING ANNUAL INSPECTION, BOTH MAGNETOS WERE REMOVED TO C/W SLICK RECOMMENDED 500-HOUR INTERNAL EXAMINATION. RIGHT MAGN ETO CHECKED OK, NEEDED ONLY MINOR INTERNAL CLEANING AND POINTS ADJUSTMENT. LEFT MAG HAD A GOOD AMOUNT OF INTERNAL CONTA MINATION FROM THE PRESSURIZATION PORT. DISTRIBUTOR GEAR AND ROTOR GEAR WERE SOFT. CLEANED MAGNETO, REPLACED NECESSARY PARTS AND RETURNED TO SERVICE. THE LINES GOING TO THESE MAGNETOS SHOULD HAVE AN IN-LINE FILTER INSTALLED TO PREVENT THI S KIND OF CONTAMINATION. AT THIS TIME, BOTH MAGNETOS WERE STILL OPERATING CORRECTLY, BUT THE LEFT MAG WOULD HAVE FAILED OR MALFUNCTIONED SHORTLY. 1 L 7 1 30 3 O RT 2A3 E14EA 1997091100130 19970911 00130 SO 1997 9 11 97ZZZX3876 1 19970816 G 5280 4752932 HINGE PIPER PA31 PA31350 7103110 SO GEAR DOOR CRACKED D S K NONE O OTHER IN INSP/MAINT 1 AL 03 4112D 318353004 INSPECTION FOUND GEAR DOOR HINGE WITH A CRACK IN INNER ASPECT OR RADIUS. PART IS NEW STYLE TO C/W TERMINATING ACTION OF AD 8026-05. 1 L 7 2 3O A20SO 1997091100131 19970911 00131 CE 1997 9 11 97ZZZX3877 1 19970801 G 5260 LP389 WINDOW CESSNA 172 172RG 2072438 CE BAGGAGE COMPT PLUG MISSING D K NONE O OTHER IN INSP/MAINT 1 EA 21 4723R 172R0018 PLUG ABOUT 8 INCHES IN DIAMETER MISSING IN REAR WINDOW. REPLACED WINDOW ABOUT 2 YEARS AGO FOR SAME REASON. 1 H 7 1 3O 3A17 1997091100133 19970911 00133 EA 1997 9 11 97ZZZX3879 2 19970813 G 7414 DISTRIBUTOR GEAR SLICK 4373 PIPER PA44 PA44180 7104402 SO LYC O360 O360A1H 41514 EA MAGNETO WORN B NX42 K NONE O OTHER IN INSP/MAINT 1 SO 15 925ER 492 96081211 4496012 L3521236A MAGNETO WAS RECEIVED BY THIS REPAIR STATION FOR A MANUFACTURER'S RECOMMENDED 500-HOUR INSPECTION. INTERNAL INSPECTION RE VEALED THE TEETH ON BOTH THE ROTOR AND DISTRIBUTOR GEARS WERE EXCESSIVELY WORN. IT WAS FURTHER NOTED THAT MOISTURE CONT AMINATION HAD RESULTED IN SUBSTANTIAL CORROSION OF THE BREAKER POINTS AND INTERNAL HARDWARE. 1 L 7 2 3O 3 O A19S0 E286 1997091100134 19970911 00134 CE 1997 9 11 97ZZZX3880 1 19970710 G 2720 5052432625 PEDAL ARM BEECH 200 200BEECH 1152920 CE RUDDER PEDAL WORN D A K NONE O OTHER IN INSP/MAINT 1 SO 33 174PW 8858 BB64 DURING PHASE 3 OF BEECH 200-HOUR INSPECTION PROGRAM, REQUIRED INSPECTION OF RUDDER PEDALS PER CHAPTER 27-20-00, PAGE 206 . FOUND BOLT HOLES ON RUDDER PEDAL ARMS WORN BEYOND LIMITS. PART IS MAGNESIUM, AND PART THAT REPLACES ARM IS ALUMINUM P/N 50-524326-33. 1 L 7 2 4T A24CE 1997091100135 19970911 00135 1997 9 11 97ZZZX3881 4 19970801 G 3440 HG1075AE03 IRU HONEYWELL CNDAIR CL600 CL6002B16 1900305 EA COCKPIT MALFUNCTION B XJRR K NONE O OTHER NR NOT REPORTED 1 EA 25 449ML 685 INERTIAL REF UNIT P/N HG1075AE03 S/W 685 WAS INSTALLED AFTER FACTORY BENCH CERTIFIED. ON FIRST FLIGHT, IT WAS REPORTED TO HAVE EXCESSIVE DRIFT. IT WAS REPLACED WITH ANOTHER UNIT AND SYSTEM OPERATED NORMALLY. (X) 2 L 7 2 4F RT A21EA 1997091100136 19970911 00136 NE 1997 9 11 97ZZZX3882 2 19970515 G 7210 430101401 BEARING LYC LTS101 LTS101750B1 41560 NE GEARBOX PTO SPALLED B YKER K NONE O OTHER IN INSP/MAINT 1 EA 17 3016 W89H011 LE45745 ENGINE WAS RECEIVED FOR MAKING METAL. CHIP ANALYSIS INDICATED METAL WAS COMING FROM GEARBOX. UPON DISASSEMBLY, FOUND T HE PTO FORWARD BEARING TO HAVE SEVERE SPALLING OF BALLS AND RACES. ALSO, FOUND SEVERAL WORN BEARING LINERS IN THE GEARB OX CASE AND COVER. 3 U E5NE10 1997091100137 19970911 00137 EA 1997 9 11 97ZZZX3883 2 19970728 G 8530 45433 VALVE SEAT 45414 TCRAFT BL BL65 8850350 EA LYC O145 O145B2 41502 EA CYL INTAKE FAILED D O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 GL 07 36020 675 2985 41822 INTAKE VALVE SEAT DROPPED OUT OF CYLINDER HEAD. NO DAMAGE TO ENGINE. PARTIAL LOSS OF POWER. 1 H 7 1 3O 3 O A700 TC210 1997091100138 19970911 00138 1997 9 11 97ZZZX3884 1 19970801 G 3246 AHA2063 WHEEL DUNLOP MLG CRACKED D S K NONE O OTHER IN INSP/MAINT 1 SW 99 SH027 CRACKS FOUND USING MAGNAFLUX ED 530 EDDY CURRENT TESTER. NEED TO REMOVE BOLT, KEY WAY, AND KEEPER TO SEE CRACKS ON S/N WHEEL SH027. CRACKS WERE FOUND ON 6 OF THE BOLT HOLES AND ON S/N SB097. CRACKS FOUND ON 4 OF THE BOLT HOLES. APPROXIM ATELY 190 LANDINGS. 1997091100139 19970911 00139 1997 9 11 97ZZZX3885 1 19970801 G 3246 AHA2063 WHEEL DUNLOP MLG CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 SB097 CRACKS FOUND USING MAGNAFLUX ED 530 EDDY CURRENT TESTER. NEED TO REMOVE BOLT, KEY WAY, AND KEEPER TO SEE CRACKS ON S/N WHEEL SH027. CRACKS WERE FOUND ON 6 OF THE BOLT HOLES AND ON W/N SB097. CRACKS FOUND ON 4 OF THE BOLT HOLES. APPROXIM ATELY 250 LANDINGS. 1997091100278 19970911 00278 CE 1997 9 11 97ZZZX3886 1 19970814 G 5520 35660040607 ELEVATOR BEECH 35 C35BEECH 1151508 CE LT ELEVATOR OUT OF BALANCE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 21 656D 4692 D2924 ANNUAL INSPECTION FOUND ELEVATOR AND AILERONS OUT OF BALANCE DUE TO RECENT PAINT JOB. UNITS HAD NOT BEEN STRIPPED PRIOR TO PAINTING OR CHECKED FOR BALANCE. NO REFERENCE TO AD 87-02-02 OR AD 94-20-04 WAS FOUND IN RECORDS. 1 L 7 1 3O A777 1997091100279 19970911 00279 CE 1997 9 11 97ZZZX3887 1 19970814 G 5520 35660040608 ELEVATOR BEECH 35 C35BEECH 1151508 CE RT ELEVATOR OUT OF BALANCE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 21 656D 4692 D2924 ANNUAL INSPECTION FOUND ELEVATOR AND AILERONS OUT OF BALANCE DUE TO RECENT PAINT JOB. UNITS HAD NOT BEEN STRIPPED PRIOR TO PAINTING OR CHECKED FOR BALANCE. NO REFERENCE TO AD 87-02-02 OR AD 94-20-04 WAS FOUND IN RECORDS. 1 L 7 1 3O A777 1997091100280 19970911 00280 CE 1997 9 11 97ZZZX3888 1 19970814 G 5751 35135025 AILERON BEECH 35 C35BEECH 1151508 CE LT/RT AILERON OUT OF BALANCE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 21 656D 4692 D2924 ANNUAL INSPECTION FOUND ELEVATOR AND AILERONS OUT OF BALANCE DUE TO RECENT PAINT JOB. UNITS HAD NOT BEEN STRIPPED PRIOR TO PAINTING OR CHECKED FOR BALANCE. NO REFERENCE TO AD 87-02-02 OR AD 94-20-04 WAS FOUND IN RECORDS. 1 L 7 1 3O A777 1997091100281 19970911 00281 EA 1997 9 11 97ZZZX3889 1 19970801 G 3240 BRAKE ASSY SCWZER G164 G164A 3952704 EA PARKING BRAKE NOT MODIFIED D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 03 941X 455 INSPECTION FINDING THAT AG CATS 'G164A' MANUFACTURED PRIOR TO FEBRUARY 15, 1967, HAVE NOT BEEN MODIFIED PER ENGINEERING CHANGE ORDER S164-1845. CHANGE PREVENTS CHANCE OF ACCIDENTAL LOCKING OF RT BRAKE MASTER CYLINDER DURING FLIGHT MANEUVER ING. 1 Q 7 1 3R 1A16 1997091100282 19970911 00282 SW 1997 9 11 97ZZZX3890 1 19970801 G 2720 12411 WRIST SHAFT BBAVIA 7 7ECA 21101NN SW TOE BRAKE PIN WORN H L A K NONE O OTHER IN INSP/MAINT 1 NE 05 1400 1974 AND LATER, 73CA CITABRIA AIRCRAFT WHICH UTILIZE TOE BRAKES. AT APROXIMATELY 1,700 HOURS TT, FOUND WRIST PINS IN RU DDER/BRAKE PEDAL WORN TO ALMOST FAILURE. LOSS OF PIN WOULD INTERFERE WITH BRAKE OR RUDDER ACTION. 1 H 7 1 3O A759 1997091100283 19970911 00283 EU 1997 9 11 97ZZZX3891 1 19970808 G 7810 1079 BRACKET GROB G115 G115C 1660303 EU RT EXHAUST SEPARATED D L A K NONE O OTHER IN INSP/MAINT 1 WP 27 115FN 482 82061C1 RIGHT SIDE EXHAUST/MUFFLER ASSY BRACKET CRACKED AND BECAME SEPARATED AT FIREWALL MOUNT CONTACTING COWLING CAUSING HEAT DAMAGE TO LOWER COMPOSITE COWLING. UPON REMOVAL, NOTED THE INTERNAL BAFFLE IN THE MUFFLER HAD ALSO RECEIVED HEAT DAMAGE , BECAME CORRODED, AND SEPARATED FROM THE WALL OF MUFFLER IN SMALL SECTIONS, BECOMING LODGED IN EXIT PIPE OF EXHAUST ASS Y PARTIALLY BLOCKING THE EXIT PORT. 1 L 7 1 3O NT A57EU 1997091100286 19970911 00286 EU 1997 9 11 97ZZZX3894 1 19970904 G 6720 350A33214501 ROD SNIAS 350 AS350B2 8680813 EU T/R PITCH WORN B L A K NONE O OTHER IN INSP/MAINT 1 SW 03 6097Z 2820 DURING A DAILY VISUAL INSPECTION, DISCOVERED THE BEARING IN THE OUTBOARD END OF THE TAIL ROTOR PITCH CHANGE ROD HAD ALMO ST COMPLETELY SEPARATED FROM THE HOUSING. THE PILOT OF THE PREVIOUS FLIGHT DID NOT NOTICE ANY ABNORMALITIES IN THE OPER ATION OF THE AIRCRAFT OR THE TAIL ROTOR CONTROL SYSTEM. IT APPEARS THE BEARING WAS ONE FLIGHT AWAY FROM A TOTAL FAILURE WHICH COULD HAVE RESULTED IN COMPLETE LOSS OF THE HELICOPTER AND ITS OCCUPANTS. NOTE: THIS IS THE SECOND SUCH FAILURE OF THIS PITCH CHANGE ROD BEARING EXPERIENCED BY THIS OPERATOR. THE FIRST FAILURE RESULTED IN AN CATASTROPHIC AIRCRAFT ACCIDENT. 1 G 7 1 3U H9EU 1997091100287 19970911 00287 SO 1997 9 11 97ZZZX3895 2 19970819 G 8530 654652A1 CYLINDER BEECH 58 58P 1152744 CE CONT O520 TSIO520* 17040 SO NR 2 SCORED G K NONE O OTHER IN INSP/MAINT 1 GL 15 138PB 20 TJ273 274196R DURING COMPLETION OF CONTINENTAL CRITICAL SB CSB 97-10A, FOUND NR 2 CYLINDER SEVERELY SCORED DURING A BORESCOPE INSPECTI ON. DAMAGE COVERS 50 PERCENT OF TOTAL CYLINDER WALL AND IS BEYOND PISTON PIN WEAR AREA. HIGH AMOUNT OF ALUMINUM SHAVIN GS FOUND IN OIL FILTER. AD 97-15-01 DOES NOT APPLY TO THIS ENGINE, BUT SAME CYLINDER COATING PROCESS IS USED ON I0-520 CYLINDERS. THIS WAS A NEW CYLINDER FROM CONTINENTAL. RECOMMEND AD REVISION. 1 L 7 2 3O 3 O A23CE E8CE 1997091100288 19970911 00288 SO 1997 9 11 97ZZZX3896 1 19970801 G 7922 53E49600 VERNATHERM PIPER PA31 PA31350 7103110 SO ACCESSORY CASE SEAT LOOSE D K NONE M OVER TEMP NR NOT REPORTED 1 EA 13 3581X 318052096 ENGINE INDICATION OF HIGH OIL TEMPERATURE. SEAT IN ACCESSORY CASE FOR VERNATHERM CAME LOOSE PREVENTING POSITIVE FLOW OF OIL TO COOLER. WEAR PATTERN ON VERNATHERM AND SEAT INDICATE THE SEAT WAS INSTALLED COCKED AT AN ANGLE. RECORDS INDICA TE ENGINE WAS OVERHAULED AT LYCOMING FACTORY. 1 L 7 2 3O A20SO 1997091100289 19970911 00289 SW 1997 9 11 97ZZZX3897 1 19970803 G 5300 7129012 TUBE BBAVIA 7 7ECA 21101NN SW FUSELAGE BROKE G A K NONE O OTHER LD LANDING 1 EA 07 4178Y 118777 FOUND LEFT MAIN GEAR FOLDED ON LANDING. 7-1290-12 TUBE BROKE AT PREVIOUS WELD REPAIR WHERE LEFT MAIN GEAR ATTACHES. NO ENTRY FOR REPAIR IN LOGS. WELDS WERE NOT AIRWORTHY. NO PENETRATION, SIGNS OF PREVIOUS CRACKING AND CORROSION INSIDE W ELDS. 1 H 7 1 3O A759 1997091100290 19970911 00290 GL 1997 9 11 97ZZZX3898 1 19970828 G 5300 STCSA1008WE FABRIC BLANCA 17 1730 1220432 GL FUSELAGE DEFECTIVE G K NONE O OTHER IN INSP/MAINT 1 GL 15 4855V 30109 AIRCRAFT RECOVERED 9/90. HANGARED UNTIL 5/97. HAIL STORM PUNCHED HOLES IN ALL FABRIC COVERED SURFACES. SAME MODEL AIR CRAFT WITH 23 YEAR OLD FABRIC HAD NO HOLES AND WAS PARKED ALONG SIDE. FABRIC APPEARS TO BE WEAK, BUT PUNCH TEST INDICAT ES GOOD CONDITION. PAINT IS DARK IN COLOR. RECOMMEND REVIEW BY STC HOLDER. 1 L 7 1 3O 1A3 1997091100291 19970911 00291 CE 1997 9 11 97ZZZX3899 1 19970821 G 2720 355241066 PUSHROD BEECH 35 K35 1151524 CE LT RUDDERVATOR CORRODED D K NONE O OTHER IN INSP/MAINT 1 SO 15 5NB 5045 D5956 WHILE C/W AD 97-06-11, LEFT PUSH ROD WAS FOUND FULL OF WATER. UPON PAINT REMOVAL IN PREPARATION FOR DYE/PEN INSPECTION, AN APPROXIMATE .25 INCH HOLE WAS FOUND CORRODED THROUGH THE WALL THICKNESS AT THE LOWER FORWARD END OF THE ROD. THIS A REA WAS NOT VISIBLE DURING NORMAL INSPECTION AS IT HAD NOT YET PENETRATED THE PAINT COATING. THERE WAS APPROXIMATELY 10 PERCENT OF THE CROSS-SECTION AREA MISSING. 1 L 7 1 3O 3A15 1997091100292 19970911 00292 CE 1997 9 11 97ZZZX3900 1 19970818 G 5510 0531037 REINFORCEMENT CESSNA 172 172P 2072436 CE HORIZ STABILIZER CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 25 54381 3858 17274968 UPON INSPECTION PER SB 94-8-A, THE SKIN WAS FOUND CRACKED. THE SKIN AND REINFORCEMENT WERE REPLACED WITH NEW PARTS. NO OTHER PROBLEMS FOUND. 1 H 7 1 3O NT 3A12 1997091100293 19970911 00293 CE 1997 9 11 97ZZZX3901 1 19970818 G 5512 053200123 SKIN CESSNA 172 172P 2072436 CE HORIZ STABILIZER CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 25 54381 3858 17274968 UPON INSPECTION PER SB 94-8-A, THE SKIN WAS FOUND CRACKED. THE SKIN AND REINFORCEMENT WERE REPLACED WITH NEW PARTS. NO OTHER PROBLEMS FOUND. 1 H 7 1 3O NT 3A12 1997091100295 19970911 00295 SO 1997 9 11 97ZZZX3902 1 19970816 G 7810 653332 EXHAUST CLAMP PIPER PA28 PA28R201T 7102813 SO TURBO EXHAUST FAILED C A O OTHER J WARNING INDICATION CR CRUISE 1 WP 07 777JD 2752 28R7703156 TURBOCHARGER EXHAUST CLAMP BOLT PARTED IN-FLIGHT. LOST EGT AND LANDING GEAR STATUS LIGHTS DUE TO 7 WIRES BEING BURNED O N FIREWALL. WAS ABLE TO MAKE PRECAUTIONARY LANDING WITHIN 5 MINUTES AT AIRPORT. SUBMITTER STATED PROBLEM LIKELY METAL FATIGUE DUE TO AGE AND HEAT CYCLING. SUBMITTER RECOMMENDS THAT ALL SUCH CLAMPS IN SERVICE THIS LONG. (20 YEARS) BE REP LACED AS SOON AS POSSIBLE. 1 L 7 1 3O 2A13 1997091100296 19970911 00296 SO 1997 9 11 97ZZZX3903 2 19970821 G 7322 105284 CARBURETOR FACET MA45 CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO BUTTERFLY VALVE STUCK D A O OTHER J WARNING INDICATION CR CRUISE 1 SO 06 95868 877 18266665 230582R PILOT REPORTED AT CRUISE, PREPARED FOR DESCENT, THROTTLE STUCK FUEL OPEN. AIRCRAFT LANDED AND SHUT OFF ENGINE WITH MIXT URE. UPON INSPECTION, DISCONNECTED THROTTLE, FOUND PROBLEM TO BE IN CARBURETOR. BUTTERFLY VALVE STUCK FULL, WILL NOT C LOSE. CARBURETOR REPAIR SHOP RESULTS: CARBURETOR FULL STOP EXCESSIVE WEAR ALLOWS BUTTERFLY VALVE TO TRAVEL FURTHER THA N NORMAL JAMMING PIN INSIDE BODY; THUS, LOCKING IN FULL THROTTLE POSITION. 1 H 7 1 3O 3 O NT 3A13 E273 1997091100297 19970911 00297 CE 1997 9 11 97ZZZX3904 1 19970807 G 7602 5038901019 CONTROL CABLE BEECH 58 58 1152740 CE MIX CONTROL DEFECTIVE G E A ENGINE SHUTDOWN UNSCHED LANDING O OTHER CR CRUISE 1 GL 03 8590R TH645 DURING FLIGHT, PILOT COULD NOT GET PROPER MIXTURE CONTROL ON LEFT ENGINE. P.I.C. SHUT ENGINE OFF AND LANDED AIRCRAFT WI THOUT ANY FURTHER INCIDENT. MECHANIC DISCOVERED DEFECTIVE MIXTURE CONTROL CABLE. CABLE WAS REMOVED AND REPLACED. AIRC RAFT OPS CHECKED OK. 1 L 7 2 3O 3A16 1997091100298 19970911 00298 SO 1997 9 11 97ZZZX3905 1 19970818 G 3411 6391334 HOSE PIPER PA44 PA44180 7104402 SO PITOT/STATIC CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 16 921ER 940 4496008 AIRSPEED INDICATION REPORTED READING LOW. FOUND EACH FLEX HOSE RELATED TO SYSTEM CRACKED AND SPLIT. REPLACED HOSES. O PERATION NORMAL ON LEAK CHECK. 1 L 7 2 3O A19S0 1997091100299 19970911 00299 WP 1997 9 11 97ZZZX3906 1 19970827 G 2436 598711 RESISTOR 707306A DOUG DC10 DC10* WP CSD LOAD CONTROL FAILED B DM4R K NONE O OTHER IN INSP/MAINT 1 SO 19 579 1011 RESISTORS FAILED CAUSING CSD LOAD CONTROLLER TO FAIL AND MAINTAIN PROPER CYCLES. THIS IS THE SECOND TYPE OF THIS FAILUR E. ORIGINAL PARTS CAME FROM MANUFACTURER. 2 L 7 3 4F A22WE 1997091100300 19970911 00300 WP 1997 9 11 97ZZZX3907 1 19970827 G 2436 59046562 RESISTOR 707306A DOUG DC10 DC10* WP CSD LOAD CONTROL FAILED B DM4R K NONE O OTHER IN INSP/MAINT 1 SO 19 579 1011 RESISTORS FAILED CAUSING CSD LOAD CONTROLLER TO FAIL AND MAINTAIN PROPER CYCLES. THIS IS THE SECOND TYPE OF THIS FAILUR E. ORIGINAL PARTS CAME FROM MANUFACTURER. 2 L 7 3 4F A22WE 1997091100301 19970911 00301 WP 1997 9 11 97ZZZX3908 1 19970826 G 3242 2445902 DISC BFGOODRICH 21565 DOUG DC8 DC8* WP BRAKE ASSY BROKEN B XC4R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 19 2197 1476 ON RECEIPT OF BRAKE ASSEMBLY, DISC WAS FOUND BROKEN IN HALF. HAVE WITNESSED NUMEROUS FAILURES AND DAMAGES. DESIGN FLAW WHEN A PART BREAKS IN HALF. 2 L 7 4 4J F 4A25 1997091100302 19970911 00302 NM 1997 9 11 97ZZZX3909 1 19970709 G 2820 25W653120692 FUEL LINE ISRAEL 1125 1125 NM FUEL SYSTEM BURST B A JGVR K NONE K FLUID LOSS IN INSP/MAINT 1 CE 09 166RM 3296 047 WHILE PRESSURIZING THIS FUEL LINE WITH AIR TO FIND A LEAK IN A DIFFERENT AREA, THIS LINE BURST DUE TO IT CHAFING ON ANOT HER LINE. THIS LINE NORMALLY CARRIES ABOUT 300 PSI, AND HAD IT BURST IN-FLIGHT, IT WOULD HAVE SPRAYED THE TAILCONE WITH FUEL. REPLACED THE LINE AND PROVIDED SEPARATION. SUGGEST THAT THIS AREA SPECIFICALLY GETS LOOKED AT ON THE INSPECTION GUIDE. ALSO, INFORMED GALAXY AEROSPACE TECHNICAL PEOPLE. 2 L 7 2 4F RT A16NM 1997091100303 19970911 00303 CE 1997 9 11 97ZZZX3910 1 19970710 G 5610 1014200807 WINDOW BEECH 200 200BEECH 1152920 CE PILOT'S STORM CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 33 174PW BB64 ON AAIP INSPECTION, FOUND PILOT'S STORM WINDOW WITH MANY CRACKS AROUND LATCH ON WINDOW AND ONE CRACK FROM HOLE-TO-HOLE W HERE TWO SCREWS SECURE LATCH. 1 L 7 2 4T A24CE 1997091100304 19970911 00304 NE 1997 9 11 97ZZZX3911 3 19970822 G 6111 RFC11T BLADE 14RF9 SAAB SF340 340B 7860101 EU HAMSTD 14RF 14RF19 NE FILLET/SHANK CRACKED B BN4R K NONE O OTHER IN INSP/MAINT 1 WP 05 282AE 11947 864106 340B282 AFTER DYE PENETRANT INSPECTION, TWO CRACKS WERE FOUND ON SHANK OUTSIDE DIAMETER OF BLADE. DEFECT MEASURES AT .476 INCH LENGTH BY .143 INCH WIDE. 2 L 7 2 4T RT A52EU 6 C P11NE 1997091700002 19970917 00002 SO 1997 9 17 97ZZZX3912 1 19970731 G 2430 38B934B COVERTER GULSTM G1159 GIV 3980115 SO RIGHT SYSTEM FAILED D K NONE O OTHER IN INSP/MAINT 1 NE 05 200PM N1197 1147 AFTER STARTING RIGHT ENGINE, THE RT A.C. MAIN BUSS WOULD DROP OFF LINE AND THE A.C. RESET LIGHT WOULD COME ON. SELECTIN G THE RT CONVERTER 'ON' WOULD POWER THE RT BUSS, BUT COULD NOT RESET A.C. RESET LIGHT. A.C. WAS SHUT DOWN AND TROUBLESH OT TO RT POWER CONVERTER. AFTER REMOVING CONVERTER, FOUND BURN MARK ON OUTBOARD SIDE OF CONVERTER COVER. 2 L 7 2 4F RT A12EA 1997091100307 19970911 00307 CE 1997 9 11 97ZZZX3915 1 19970825 G 3240 AP6644 LINING BEECH 58 58 1152740 CE BRAKE SHOE MISDRILLED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 15 329H TH219 THE ATTACHMENT HOLES OF BRAKE LININGS ARE IN DIFFERENT LOCATIONS FROM ONE BRAKE LINE TO ANOTHER. ON CERTAIN LININGS, IT WILL NOT SIT FLUSH ON THE BRAKE SHOE. 1 L 7 2 3O 3A16 1997091100308 19970911 00308 CE 1997 9 11 97ZZZX3916 1 19970827 G 2810 S24851 VALVE CESSNA 150 152 2071835 CE FUEL DRAIN MISMANUFACTURED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 15 4711H 15283968 FUEL DRAIN VALVE DELIVERED NEW FROM CESSNA WOULD NOT SEAT PROPERLY. PART MANUFACTURERED BY AUTO VALVE INC, DAYTON, OHIO 45427. CURE DATE 1Q96. ASSY DATE 1Q97. 1 H 7 1 3O NT 3A19 1997091100309 19970911 00309 EA 1997 9 11 97ZZZX3917 2 19970821 G 7414 M3975 COIL SLICK CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA LT MAGNETO FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 15 68956 551 15282415 INSPECTION FOUND BAD COIL IN MAGNETO. MAGNETO IN LEFT POSITION. AIRCRAFT ENGINE WOULD DIE WHEN LEFT MAG WAS SELECTED. 1 H 7 1 3O 3 O NT 3A19 E223 1997091100310 19970911 00310 SO 1997 9 11 97ZZZX3918 1 19970818 G 5521 4007514 SPAR PIPER PA31 PA31325 7103105 SO LT ELEVATOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 13 83PA 3244 318112050 DURING INSPECTION PER PIPER SB 998A, FOUND CRACKED IN UPPER FLANGE RADIUS AS DESCRIBED. NO CRACKS IN AREA OF OUTBOARD H INGE ATTACH REINFORCEMENT. 1 L 7 2 3O A20SO 1997091100311 19970911 00311 SO 1997 9 11 97ZZZX3919 1 19970818 G 5521 4007516 SPAR PIPER PA31 PA31325 7103105 SO RT ELEVATOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 13 83PA 3244 318112050 DURING INSPECTION PER PIPER SB 998A, FOUND CRACKS IN BOTH UPPER AND LOWER FLANGE RADIUS AS DESCRIBED. NO CRACKS IN AREA OF OUTBOARD HINGE ATTACH REINFORCEMENT. 1 L 7 2 3O A20SO 1997091100312 19970911 00312 EA 1997 9 11 97ZZZX3920 2 19970818 G 7322 CF30768 FLOAT FACET 105253 CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA CARBURETOR FAILED D O OTHER Y ENGINE STOPPAGE AP APPROACH 1 WP 07 9635B 581 1096 172RG0933 L2982536A PILOT REPORTED ENGINE QUIT ON FINAL APPROACH OVER RUNWAY. DELIVERED TO MAINTEANCE, UNABLE TO GET GOOD RUN-UP. DISCOVER ED CARBURETOR FLOAT FULL OF FUEL. REPLACED WITH SERVICEABLE FLOAT. ENGINE OPS CHECK GOOD. 1 H 7 1 3O 3 O 3A17 E286 1997091100313 19970911 00313 CE 1997 9 11 97ZZZX3921 1 19970826 G 2730 5052447413 PUSH ROD BEECH 90 C90A 1152911 CE LT ELEV TRIM BROKEN B A JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 1NP 3489 LJ1289 PILOT NOTICED LEFT ELEVATOR TRIM TAB LOOSE AND ROD BROKEN. INVESTIGATION REVEALED BUSHING AT TAB ATTACH SEIZED AND APPL IED SIDE LOAD ON PUSH ROD. ROD BROKE AT BOTTOM OF THREADS OF ADJUSTMENT END. FURTHER INVESTIGATION REVEALED ROD HAD EX ISITNG CRACK APPROXIMATELY ONE-THIRD DIAMETER. INSTALLED NEW ROD ASSY AND FUNCTION CHECKED OK. 1 L 7 2 3T RT 3A20 1997091100314 19970911 00314 NE 1997 9 11 97ZZZX3922 2 19970815 G 8530 399359 CYLINDER AIRTRC AT300 AT301 0390103 SW PWA R1340 R1340AN1 52016 NE NR 1 CYL HEAD CRACKED H FYKG A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 SO 11 4411S 1045 3010071 519053 ENGINE LOST POWER AFTER TAKEOFF. MADE FORCED LANDING INTO FIELD. SUBSTANTIAL DAMAGE TO AIRCRAFT. PILOT HAS MINOR INJU RIES. INVESTIGATION HAS REVEALED THAT NR 1 CYLINDER HEAD CRACKED INTO 2 PIECES. SUBMITTER SUBMITTED SAFETY RECOMMENDAT ION FOR EVALUATION AND ACTION. 1 L 7 1 3R 3 R A9SW 5E2 1997091100315 19970911 00315 GL 1997 9 11 97ZZZX3923 1 19970807 G 5711 RIB AMTR EMRAUD EMERAUDSUPER GL WING SPAR SEPARATION H L A K NONE O OTHER IN INSP/MAINT 1 GL 03 2FOR 1100 INVESTIGATION FOR RIB SEPARATION FROM WING SPAR FOUND THE DESIGN OF LANDING GEARINSTALLATION TO BE A CAUSAL FACTOR. THI S INSTALLATION (EXTENDING FORWARD AND ATTACHED TO MAIN SPAR) INDUCES A TWISTING MOTION ON THE MAIN SPAR DURING LANDING. A HARD 3-POINT OR OFF-FIELD LANDING ATTEMPTS TO TWIST THE SPAR. THE TWISTING MOMENT IS ONLY RESTRAINED BY THE SECURITY OF THE GLUED RIBS. FAILURE MODE IS SUBTLE SHOWING UP AS SQUEEKS IN THE WING WHEN ROCKING THE WING DURING THE PRE-FLIGH T, BAGGINESS OR WRINKLES IN THE FABRIC, OR POSSIBLY WING LOW IF PROGRESSED FAIRLY FAR ALONG (NUMEROUS WING RIBS HAVING S EPARATED FROM THE SPAR). 1 L 7 1 3O EXPA1L71 1997091100316 19970911 00316 EU 1997 9 11 97ZZZX3924 1 19970811 G 3250 STEERING COLLAR SLNSBY T67 T67M260 8323006 EU NLG STRUT CRACKED D A K NONE O OTHER IN INSP/MAINT 1 SW 17 900 DURING 100-HOUR INSPECTION, THE NOSE STEERING COLLAR ON NOSE STRUT WAS FOUND CRACKED. A ONE-TIME INSPECTION WAS PERFORM ED FOR THE REST OF THE FLEET (57). EIGHTEEN AIRCRAFT WERE FOUND WITH NOSE WHEEL STEERING COLLAR CRACKED. UNKNOWN CAUSE AND NO RECOMMENDATION AT THIS TIME. 1 L 7 1 3O NT A73EU 1997091100321 19970911 00321 WP 1997 9 11 97ZZZX3927 2 19970814 G 7250 8650821 MAIN SHAFT NUT SWRNGN SA226 SA226T 8780122 SW GARRTT TPE331 TPE33110U 01514 WP AFT RETENTION FAILED B A DSC2 K NONE O OTHER IN INSP/MAINT 1 SW 17 46KC T332 P35090C TURBINE (MAINSHAFT) RETENTION NUT FAILED (CRACKED IN HALF) DURING OPERATION OF ENGINE ON THE GROUND. IT WAS OBSERVED TH E PROPELLER WOULD NOT ROTATE FREELY AND THE ENGINE HAD SEIZED. UPON DISASSEMBLY OF ENGINE, OBSERVED THAT ONE THREAD OF THE NUT (IN TWO PIECES) WAS COMPLETELY MISSING. SUBMITTER STATED FAILURE OF THIS NUT DURING FLIGHT OPERATION WILL RESUL T IN ENGINE FAILURE AND/OR UNCONTAINED FAILURE OF THE ENGINE. ENGINE TSN: 3,012.0 HRS; CSN: 4,525 HRS; TSO: 179.1 HR S. CSO: 190. 2 L 7 2 4T 4 T RT A5SW E4WE 1997091100434 19970911 00434 CE 1997 9 11 97ZZZX3934 1 19970806 G 5711 0024300189 WEB BEECH 33 F33A 1151425 CE CARRY THRU SPAR CRACKED B A IYOR K NONE O OTHER IN INSP/MAINT 1 WP 07 1568P CE1298 INSPECTION FOUND FORWARD SPAR CARRY-THROUGH CRACKED. A CRACK OF 1.3 INCHES IN LENGTH WAS DISCOVERED IN MID-SECTION OF L OWER BEND RADIUS IN A VERTICAL DIRECTION FOLLOWING THE BEND. THE CRACK SEEMS TO OCCUR IN THE AREA OF THE FORWARD SUPPOR T (RT SIDE). POSSIBLE CAUSE IS HARD LANDINGS. SUBMITTER STATED POSSIBLE FIX, MANUFACTURE WEB WITH A MUCH THICKER/STRON GER ALLOY. CRACK WAS STOP-DRILLED AS SPECIFIED IN AD NR 95-04-03 WHICH DOES NOT APLY TO THIS SERIAL NUMBER. 1 L 7 1 3O 3A15 1997091100435 19970911 00435 1997 9 11 97ZZZX3935 4 19970822 G 2561 PO201105 LIFE VEST EAAEROMARINE SEAM FAILED TEST B KQ1R K NONE L NO TEST IN INSP/MAINT 1 EA 07 J31311 LIFE VEST FAILED THE MANUFACTURER'S 2-POUND PSI TEST. 1997091100436 19970911 00436 1997 9 11 97ZZZX3936 4 19970822 G 2561 PO201105 VEST EAAEROMARINE SEAM FAILED TEST B KQ1R K NONE L NO TEST IN INSP/MAINT 1 EA 07 J31169 LIFE VEST FAILED THE MANUFACTURER'S 2-POUND PSI TEST. 1997091100437 19970911 00437 EA 1997 9 11 97ZZZX3937 3 19970803 G 6110 PROPELLER PIPER J3 J3C65 7100510 SO SNSNCH 76AM M76AM EA ENGINE DEPARTED G A UNSCHED LANDING E C VIBRATION/BUFFET F.O.D. CR CRUISE 1 NM 04 1477N 2732 96 23141 3595 THIRTY MINUTES AFTER TAKEOFF, PILOT REPORTS VIBRATION AND THEN PROPELLER SEPARATED FROM ENGINE. PILOT SAYS NOT SURE IF BIRD STRIKE OR PART FAILURE. AIRCRAFT LANDED WITHOUT INJURY TO PILOT OR FURTHER DAMAGE TO AIRCRAFT. 1 H 7 1 3O A691 5 N 1P210 1997091100438 19970911 00438 1997 9 11 97ZZZX3938 4 19970812 G 3430 1N6391 DIODE CESSNA 172 172RG 2072438 CE ALTERNATOR BUS FAILED B WIWR O OTHER H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 WP 07 361ES 172R80011 ALTERNATOR IN-FLIGHT FAILURE TOGETHER WITH FAILURE OF NAV 1 AND GPS. ALTERNATOR FIELD BREAKER OPEN. REPLACED TWO SHORT ED DIODES WITH CESSNA P/N 1N6391. AIRCRAFT WITH ONE HOUR TEST FLIGHT WAS UNEVENTFUL AND AIRWORTHY WITH ALL ELECTRICAL D EVICES WORKING. 1 H 7 1 3O 3A17 1997091100439 19970911 00439 GL 1997 9 11 97ZZZX3939 1 19970803 G 3240 105 MASTER CYLINDER AMTR DESIGN ONEDESIGN 05616SA GL BRAKE MALFUNCTIONED G K NONE O OTHER LD LANDING 1 GL 15 62790 44 940144 UPON LANDING, LEFT BRAKE LOCKED-UP. UPON INSPECTION, FOUND PARKING BRAKE LEVER MOVED UP BLOCKING PRESSURE. RELEASED LE VER TO OFF POSITION, BRAKES RETURNED TO NORMAL. SUBMITTER STATED PARKING BRAKE LEVERS WERE NOT USED AND SHOULD HAVE BEE N SAFETIED TO OPEN POSITION OR HOOKED UP FOR USE. 1 L 7 1 3O NC EXPA1L71 1997091100440 19970911 00440 SO 1997 9 11 97ZZZX3940 1 19970811 G 3230 701112245 RELAY PIPER PA32 PA32R301 7103218 SO MLG FAILED D O OTHER J WARNING INDICATION NR NOT REPORTED 1 SO 09 96KC 30 3246087 GEAR IN-TRANSIT LIGHT CAME ON IN-FLIGHT WHEN GEAR SELECTOR HANDLE IN UP POSITION. GEAR CONTROL/LIGHT CIRCUIT BREAKER TR IPPED AND COULD NOT BE RESET. GEAR MANUALLY EXTENDED. FOUND UP GEAR RELAY SHORTED. LANDING GEAR MOTOR HAD STAYED ON C AUSING NOSE GEAR ACTUATOR TO BLOW SEALS AND DUMP ALL FLUID FROM POWERPACK CAUSING PUMP TO FAIL. PRESSURE SWITCH DID NOT SHUT MOTOR OFF. FOUND 12-VOLT GEAR UP AND DOWN RELAYS IN A 24-VOLT SYSTEM. 1 L 7 1 3O A3SO 1997091100441 19970911 00441 EU 1997 9 11 97ZZZX3941 1 19970828 G 3230 SWITCH AMD FALC20 FALCOND 2720304 EU UPLOCK OUT OF RIG B RO5R K NONE O OTHER NR NOT REPORTED 1 NE 05 2FOR DA20 AIRCRAFT IS EGYPTIAN REGISTERED. GEAR DOORS ON LANDING GEAR WOULD NOT RETRACT WHEN GEAR WAS RETRACTED. CHECKED UPLOCK SWITCHES AND FOUND THE NOSE GEAR UPLOCK SWITCH WOULD NOT CLOSE TO ALLOW THE GEAR DOORS TO CLOSE. ALSO, FOUND THE MECHAN ICAL UNLOCK CONTROLS MOVED TOO HARD. LUBED MECHANICAL UNLOCK AND MOVES OKAY. COMPLETED A RETRACT TEST AND GEAR PERFORM ED PROPERLY. 2 L 7 2 4F A7EU 1997091100442 19970911 00442 EA 1997 9 11 97ZZZX3942 1 19970812 G 8110 12579 SUPERCHARGER SCWZER G164 G164A 3952704 EA PWA R1340 R1340AN1 52016 NE ENGINE BEARING FAILED H K NONE O OTHER NR NOT REPORTED 1 EA 23 48395 672 1628 21888 PLASTIC BEARING CAGE FAILED. CAUSED BEARING TO FAIL RESULTING IN TOTAL SUPERCHARGER FAILURE. 1 Q 7 1 3R 3 R 1A16 5E2 1997091100443 19970911 00443 CE 1997 9 11 97ZZZX3943 1 19970826 G 3250 358250522 IDLER ARM BEECH 45 A45 1152006 CE STEERING ROD FROZEN D S K NONE O OTHER IN INSP/MAINT 1 SO 19 34MR 5308 G39 WHILE TAXIING, A SQUEAK WAS HEARD FROM THE NOSE WHEEL AREA. WITH THE AIRCRAFT ON JACKS, THE NOISE WAS ISOLATED TO THE S TEERING ROD IDLER ARM, P/N 35-825052-2. THE ONLY WAY TO INSPECT THIS PART IS TO REMOVE THE ENTIRE COLLAR AND SHAFT. TH E IDLER ARM SHOULD BE FREELY MOVABLE ON THE SHAFT. IN THIS CASE, IT WAS FOUND TO BE FROZEN. ONLY AFTER SOAKING IN PENE TRATING OIL FOR SEVERAL DAYS AND THEN USING CONSIDERABLE FORCE, WAS THE ARM SEPARATED FROM THE SHAFT. 1 L 7 1 3O 5A3 1997091100444 19970911 00444 CE 1997 9 11 97ZZZX3944 1 19970829 G 7120 MOUNT CESSNA 210 T210N 2073456 CE ENG LT REAR CHAFED D K NONE O OTHER IN INSP/MAINT 1 SW 03 6621A 580 21063559 NR 2 CYLINDER REMOVED FOR LOW COMPRESSION. THIS EXPOSED LEFT REAR MOUNT. IT WAS FOUND TO HAVE WEAR IN IT CAUSED BY PRO PELLER CONTROL CABLE HOUSING CHAFING AGAINST IT. THE DAMAGE WAS CLOSE TO THE CUT-OUT FOR THE BARREL NUT, SO TCM RECOMME NDED CHANGING MOUNT. SUBMITTER STATED THIS AREA IS VERY DIFFICULT TO SEE WHEN ENGINE INTAKE AND EXHAUST SYSTEM ARE INST ALLED. THERE WAS NO PROVISION FOR SUPPORT OF THE PROPELLER CONTROL IN THIS AREA. 1 H 7 1 3O 3A21 1997091100445 19970911 00445 CE 1997 9 11 97ZZZX3945 1 19970829 G 6120 643935 BRACKET CESSNA 210 T210N 2073456 CE ENG LT REAR CHAFED D K NONE O OTHER IN INSP/MAINT 1 SW 03 6621A 580 21063559 NR 2 CYLINDER REMOVED FOR LOW COMPRESSION. THIS EXPOSED LEFT REAR MOUNT. IT WAS FOUND TO HAVE WEAR IN IT CAUSED BY PRO PELLER CONTROL CABLE HOUSING CHAFING AGAINST IT. THE DAMAGE WAS CLOSE TO THE CUT-OUT FOR THE BARREL NUT, SO TCM RECOMME NDED CHANGING MOUNT. SUBMITTER STATED THIS AREA IS VERY DIFFICULT TO SEE WHEN ENGINE INTAKE AND EXHAUST SYSTEM ARE INST ALLED. THERE WAS NO PROVISION FOR SUPPORT OF THE PROPELLER CONTROL IN THIS AREA. 1 H 7 1 3O 3A21 1997091100447 19970911 00447 CE 1997 9 11 97ZZZX3947 1 19970801 G 2150 1155550259 SHAFT SPLINES 115555020605 BEECH 300 300BEECH 1152930 CE AIR COND COMP WORN B S XE9R K NONE O OTHER IN INSP/MAINT 1 CE 07 642JL 255 FA30 AFTER PILOT COMPLAINED OF NO AIR CONDITIONING, TROUBLESHOT AND FOUND QUILL SHAFT FOR COMPRESSOR DRIVE ON RT ENGINE HAD T HE AFT SPLINES ON SHAFT WORN OFF AND SPLINES ON PULLEY WORN DOWN. THERE WAS NO EVIDENCE OF BEARINGS AT PULLEY DRIVE SEI ZING OR WORN OUT. SPLINES AT ACCESSORY CASE END WERE GOOD. THIS IS THE SECOND TIME IN 250 HOURS THAT THIS HAS HAPPENED . 2 L 7 2 4T A24CE 1997091100448 19970911 00448 SW 1997 9 11 97ZZZX3948 1 19970829 G 7160 BA81031 FILTER BBAVIA 8 8GCBC 1220803 SW ENGINE INDUCTION DEFECTIVE B L KO2R O OTHER R PARTIAL RPM/PWR LOSS CR CRUISE 1 CE 01 5063W 1 33L80 ENGINE AIR FILTER WAS CHANGED DURING ANNUAL. EN ROUTE, AIRCRAFT ENGINE RAN ROUGH. OWNER WAS ADVISED TO CHANGE AIR FILT ER. AFTER NEW FILTER INSTALLED, POWER RUN DOWN RUNWAY WAS MADE AND ENGINE PERFORMANCE NORMAL. BRACKETT FILTERS BA 810 3-1 REMOVED AND WAS REPLACED WITH A P10-6150 FILTER. 1 H 7 1 3O A21CE 1997091100449 19970911 00449 CE 1997 9 11 97ZZZX3949 1 19970829 G 7160 BA2510 FILTER CESSNA 182 R182 2072734 CE ENGINE INDUCTION DEFECTIVE B KO2R O OTHER R PARTIAL RPM/PWR LOSS CR CRUISE 1 CE 01 4773S 59 R18201423 CRUISE AT 7,500 FEET AND ENGINE ROUGHNESS NOTED. MAGNETO CHECK OK. LEANING PROCEDURES DIFFERENT THAN NORMAL. FOUND IN DUCTION FILTER TO BE AT FAULT. CHANGED BRACKETT P/N BA 2510 FOR A CESSNA P13-1E67 AND OPERATION NORMAL. 1 H 7 1 3O RT 3A13 1997091800250 19970918 00250 WP 1997 9 18 97ZZZX3968 1 19970825 G 5511 RIB DOUG EA3B EA3B 3026209 WP HORIZ STAB LE CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 01 575HA 144865 DURING REPAIR TO THE LEADING EDGE OF THE HORIZONTAL STABILIZER, DISCOVERED THAT 13 OF 15 RIBS IN THE INBOARD SECTION (RT LEADING EDGE) HAD CRACKS AT THE TRAILING EDGE IN THE RADIUS OF THE BEND IN THE RIB. SUBSEQUENT INSPECTION OF THE LT SI DE REVEALED ONLY ONE CRACKED RIB. REMOVAL AND INSPECTION OF SPARE UNIT SHOWED 12 OF THE 15 INBOARD RIBS CRACKED. 2 H 7 2 4J RT EXPA2H72 1997091800251 19970918 00251 WP 1997 9 18 97ZZZX3969 1 19970828 G 5350 RADOME DOUG EA3B EA3B 3026209 WP ACFT BELLY DEPARTED D A O OTHER O OTHER DE DESCENT 1 WP 01 575HA 001 144865 DURING THE FIRST TEST FLIGHT OF THE NEW BELLY RADOME FOR TIER II: WHILE IN A HIGH SPEED DESCENT OUT OVER THE OCEAN, THE RADOME DEPARTED THE AIRCRAFT. THE AIRCRAFT LANDED WITHOUT INCIDENT. INVESTIGATION INTO THE INCIDENT REVEALED THAT A S HOCK WAVE FORMED ON THE RADOME WHICH CHANGED THE LOAD FACTORS BEYOND THE ORIGINAL ANALYSIS FINDINGS. THE AFT SECTION OF THE RADOME WAS PULLED DOWN TEARING OUT THE MOUNTING FASTENERS RESULTING IN A BREAK-UP OF THE ENTIRE RADOME. 2 H 7 2 4J RT EXPA2H72 1997091800252 19970918 00252 GL 1997 9 18 97ZZZX3970 1 19970629 G 2820 FILTER AMTR NIEUPO NIEUPORT12 0564041 GL LT CARBURETOR PLUGGED D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 GL 23 169RD 005 FUEL LINE INADVERTENTLY LEFT OPEN FOR 2 MONTHS DURING OTHER REPAIRS. LINE ASSEMBLED WITHOUT PROPER INSPECTION. POST-AC CIDENT INSPECTION REVEALED UNKNOWN CONTAMINATE IN FILTER OF LT CARBURETOR. RECOMMEND ALWAYS PLUGGING LINES DURING DIS-A SSEMBLY. ALWAYS PURGE LINES AND CHECK FLOW PRIOR TO ASSEMBLY. SUSPECT MUD/WASP NEST IN FUEL LINE. 1 Q 7 1 3O NC EXP1Q71 1997091800254 19970918 00254 CE 1997 9 18 97ZZZX3971 1 19970129 G 3211 24411009 PIVOT CESSNA 172 172RG 2072438 CE RT MLG CRACKED D A K NONE K FLUID LOSS IN INSP/MAINT 1 SW 99 172CM 3254 172RG0787 DURING A MAINTENANCE RUN, DISCOVERED THE RIGHT BRAKES HAD FAILED. INVESTIGATION REVEALED THE BELLY WAS COVERED IN HYDRA ULIC FLUID. INSPECTION OF RT MAIN GEAR PIVOT DISCLOSED HYDRAULIC FLUID LEAKING FROM THE SPLINES OF PIVOT. PREVIOUS EXP ERIENCE WITH CRACKS ON THE SPLINES INDICATES A COMPLETE FAILURE OF THE PIVOT ASSEMBLY WHICH WILL NOT ALLOW GEAR TO EXTEN D. SUBMITTER RECOMMENDS REMOVAL OF ACTUATOR AND INSPECTION FOR CRACKS FROM CESSNA SEB 90-1R2 AT LEAST FIRST 2,000 T.I.S . AND EACH 250 HOURS THEREAFTER. 1 H 7 1 3O 3A17 1997091800255 19970918 00255 1997 9 18 97ZZZX3972 4 19970829 G 2562 G SWITCH ACK E01 CESSNA 182 182P 2075816 CE ELT INOPERATIVE D K NONE O OTHER IN INSP/MAINT 1 CE 07 182AP 291 018504 18261843 G-SWITCH WAS FOUND INOPERATIVE DURING INSPECTION PER FAR 91.207. ELT IS 2 YEARS OLD, ELT DID FUNCTION OK IN 'ON' POSITI ON. 1 H 7 1 3O NT TA13 1997091800256 19970918 00256 EA 1997 9 18 97ZZZX3973 2 19970703 G 7414 M3525 COIL SLICK 4281 PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA MAGNETO FAILED D K NONE O OTHER IN INSP/MAINT 1 GL 19 2182B 600 110289 287990124 L2565336A SUBMITTER STATES IT IS COMMON FOR THE M3525 ORANGE MAGNETO COILS TO FAIL. THE REPLACEMENT COILS ARE BLACK M3975 OR K397 5 AND HAVE BEEN AVAILABLE FOR A FEW YEARS. 1 L 7 1 3O 3 O 2A13 E286 1997091800257 19970918 00257 EA 1997 9 18 97ZZZX3974 2 19970904 G 7414 CAM SLICK 4347 MOONEY M20 M20C 5870208 SW LYC O360 O360A1D 41514 EA MAGNETO FRACTURED B E96R O OTHER R PARTIAL RPM/PWR LOSS CR CRUISE 1 EA 09 444DJ 60 9411 7000075 PILOT REPORTED ROUGH ENGINE OPS AND HIGH EGT. INSPECTION REVEALED RIGHT MAGNETO CAMSHAFT FRACTURED AND SEPARATED BELOW CAM AT OUTER BUSHING. FRACTURED SURFACE DISPLAYED EVIDENCE OF PREVIOUS FRACTURE. SIXTY HOURS TIME SINCE NEW. AIRCRAFT TOTAL TIME: 2,202.9 HOURS. CORROSION WAS EVIDENT ON FRACTURE SURFACE. FAILURE OCCURED 8-29-97. 1 L 7 1 3O 3 O 2A3 E286 1997091800258 19970918 00258 GL 1997 9 18 97ZZZX3975 1 19970802 G 5711 SPAR AMTR BG12A BG12A 79001CG GL RT WING ATTACH BROKEN G A O OTHER O OTHER CR CRUISE 1 GL 01 5516V 400 1026 DURING TOW OPERATION, WING CENTER SECTION SPAR FAILED NEAR RIGHT FUSELAGE ATTACH POINT. WOOD DETERIORATION DUE TO AGE A ND WATER ACCUMULATION POSSIBLE. HARDWARE FOUND RUSTY. AIRCRAFT WAS BEING OPERATED OVER DESIGN GROSS WEIGHT WITH AN AFT C.G. CONDITIONS OF AIRCRAFT USE AND STORAGE FOR PREVIOUS 12 YEARS UNKNOWN. SUBMITTER RECOMMENDS THOROUGH CONDITION IN SPECTIONS ON WOOD AIRCRAFT ESPECIALLY AFTER STORAGE. 1 L 0 0 0 0 EXPA1L00 1997091800259 19970918 00259 SO 1997 9 18 97ZZZX3976 1 19970813 G 7170 84029017 COLLECTOR TANK PIPER PA46 PA46350P SO RT WHEEL CRACKED B A SO5R K NONE K FLUID LOSS IN INSP/MAINT 1 NE 03 64TW 79 4636054 TOP INBOARD EDGE WELD CRACKED APPROXIMATELY 2 INCHES ALLOWING FUEL TO LEAK INTO WHEEL AREA. BRAKES DIRECTLY BEHIND COLL ECTOR TANK WHEN GEAR RETRACTED. SUBMITTER STATED POSSIBLE CAUSE: OIL CANNING OF TANK OR EXCESSIVE HEAD PRESSURE WHEN W ING TOPPED OFF. 1 L 7 1 3O RT A25SO 1997091800260 19970918 00260 SO 1997 9 18 97ZZZX3977 2 19970818 G 8520 CRANKSHAFT CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO NR 4 JOURNAL BROKE H O OTHER Y E ENGINE STOPPAGE VIBRATION/BUFFET CR CRUISE 1 SW 99 6620Z 2138 730 U20606347 520431 PILOT REPORTED A STRONG VIBRATION FOLLOWED BY A LOUD MECHANICAL BANG IN THE ENGINE DURING FLIGHT. SECONDS LATER THE ENG INE ABRUPTLY STOPPED. AN ENGINE 'TEAR DOWN' INSPECTION WAS PERFORMED AND REVEALED THE CRANKSHAFT BROKE AT THE NR 4 'CRA NKSHAFT MAIN BEARING JOURNAL'. 1 H 7 1 3O 3 O A4CE E8CE 1997091800261 19970918 00261 SO 1997 9 18 97ZZZX3978 2 19970725 G 8520 A830M1 CRANKSHAFT CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO NR 2 MAIN JRNL FAILED G K NONE O OTHER NR NOT REPORTED 1 AL 05 9412Z 1383 420606473 574416 CRANKSHAFT SEPARATED BETWEEN NR 2 ROD BEARING AND NR 2 MAIN BEARING JOURNALS. FRETTING NOTED ON CASE MATING HALVES. NR 1 CYLINDER WAS PREVIOUSLY REMOVED AND REPLACED APPROXIMATELY 555 HOURS BEFORE FAILURE OF CRANK. NR 2 MAIN BEARING HAD SHOWED SIGNS OF SPINNING. 1 H 7 1 3O 3 O A4CE E5CE 1997091800263 19970918 00263 GL 1997 9 18 97ZZZX3980 2 19970801 G 7322 2526146 BUSHING BENDIX ALLSN 250C 250C20B 03013 GL FUEL CONTROL FAULTY B HEFR K NONE O OTHER IN INSP/MAINT 1 WP 21 322442 AD 82-24-05 DESCRIBED METHOD OF IDENTIFICATION OF FAULTY PART. UPON INSPECTION OF FUEL CONTROL, FOUND FAULTY PART INSTA LLED THOUGH UNIT WAS OVERHAULED 4-23-92. THIS IS THE FOURTH UNIT FOUND WITH PRE-AD BUSHING. RECOMMEND SOURCE INSPECTIO N AND/OR ONE TIME IN-SERVICE INSPECTION. 3 U E4CE 1997091800264 19970918 00264 EU 1997 9 18 97ZZZX3981 1 19970905 G 2150 2055701 TURBINE FOKKER F27 F27MK400 4990626 EU CABIN COOLING SEIZED D A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 SO 05 2MIL 92769 10652 FLIGHT CREW SMELLED A 'STRONG ELECTRICAL ODOR' IN THE COCKPIT AND CABIN. THE ODOR WAS REMINISCENT OF BURNING ELECTRICAL INSULATION AND/OR SHORTED ELECTRICAL WIRING. THE AIRPLANE CHIEF NOTED THE AIR CONDITIONING AND HEATING DUCT TEMPERATUR E TO BE OVER 160 DEGREES FAHRENHEIT. ALSO, THE ODOR WAS MOST NOTICEABLE NEAR THE VENT OUTLETS. TROUBLESHOOTING REVEALE D THE COOLING TURBINE SHAFT WAS SEIZED, IT COULD NOT BE TURNED WITH HAND PRESSURE. THE COOLING TURBINE ASSEMBLY WAS REP LACED AND THE AIRPLANE RETURNED TO SERVICE. 2 H 7 2 4T A817 1997091800265 19970918 00265 GL 1997 9 18 97ZZZX3982 3 19970829 G 6111 22171 PIN BLOCK HARTZL HCC2Y HCC2YR2 GL BLADE PIN BROKEN D K NONE O OTHER IN INSP/MAINT 1 EA 13 BC512 BLADE PIN BLOCK WAS FOUND BROKEN AFTER DISASSEMBLY FOR INSPECTION. SUSPECT CAUSE: IMPROPER USE OF BLADE PADDLES. 5 C P920 1997091800266 19970918 00266 SO 1997 9 18 97ZZZX3983 1 19970807 G 5520 764054 BEARING PIPER PA31 PA31350 7103110 SO ELEVATOR HINGE WORN D K NONE O OTHER IN INSP/MAINT 1 SW 99 27478 71700 7852026 DURING INSPECTION, THE ELEVATOR BEARINGS WERE BEING INSPECTED AND UPON LIFTING UP ON ELEVATOR, A LOUD CLUNKING NOISE WAS HEARD. UPON CLOSER INVESTIGATION, COULD SEE THE HEAD OR THE BOLT ROCKING UP AND DOWN IN THE BEARING. ELEVATOR WAS REM OVED AND BEARING FELL APART. THIS IS THE SECOND ONE FOUND. 1 L 7 2 3O A20SO 1997091800267 19970918 00267 NE 1997 9 18 97ZZZX3984 2 19970705 G 8530 45942 PUSH ROD DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985* 52008 NE NR 1 CYL EXHAUST BROKEN G A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 AL 03 5164G 124 506 MM2214 ENGINE BEGAN RUNNING ROUGH. NR 1 CYLINDER EXHAUST ROCKER PUSH ROD BARREL PN 39288 WAS FOUND BROKEN JUST BELOW STEEL BAL L FITTING PN 11473. PART FATIGUE COULD HAVE PLAYED A PART. TOTAL TIME ON PART UNKNOWN. TOTAL TIME ON ENGINE WAS 6256 .3 HOURS. TIME SINCE OVERHAUL, 124.1 HOURS. 1 H 7 1 3R 3 R A806 5E1 1997091800268 19970918 00268 GL 1997 9 18 97ZZZX3985 1 19970719 G 3213 194044 BOLT BLANCA 17 1730 1220432 GL LT MLG SCISSORS FAILED B S A OMKR O OTHER O OTHER LD LANDING 1 NM 03 6564V 30245 THE LEFT MAIN GEAR FAILED ON LANDING. THE LOWER SCISSOR ATTACH BOLT, BELLANCA PN 19404-4, APPEARED TO HAVE FAILED ALLOW ING THE LOWER GEAR SEGMENT TO ROTATE 180 DEGREES. 1 L 7 1 3O 1A3 1997091800269 19970918 00269 GL 1997 9 18 97ZZZX3986 1 19970801 G 3213 194096 GEAR LEG BLANCA 17 1730 1220432 GL RT MLG FAILED B OMKR K NONE O OTHER NR NOT REPORTED 1 NM 03 6667V 30018 AIRCRAFT EXPERIENCED A FAILURE OF THE RIGHT MAIN GEAR LOWER GEAR SEGMENT. THE LOWER TUBE FAILED AT THE SCISSOR ATTACH P OINT CAUSING THE WHEEL TO ROTATE 180 DEGREES. 1 L 7 1 3O 1A3 1997091800270 19970918 00270 EA 1997 9 18 97ZZZX3987 1 19970810 G 7603 35N126144 CONTROL CABLE SCWZER G164 G164 3952702 EA THROTTLE BROKEN D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SW 99 634U 370 CABLE BROKE CAUSING LOSS OF POWER. AIRCRAFT LANDED, FLIPPED OVER CAUSING FATAL INJURY TO PILOT. THROTTLE CABLE WAS FOU ND BROKEN BEHIND FIRE WALL WHERE CABLE MAKES A TURN TO THE LEFT SIDE OF THE AIR FRAME. TIME ON AIR FRAME, 10,035 HOURS, AND NO RECORD OF CABLE BEING CHANGED. 1 Q 7 1 3R 1A16 1997091800271 19970918 00271 SO 1997 9 18 97ZZZX3988 2 19970825 G 8550 CHRISTEN802 OIL VALVE AMTR SKYBLT SKYBOLT GL CONT O470 IO470C 17026 SO INVERTED OIL SYS CORRODED D L A UNSCHED LANDING J WARNING INDICATION NR NOT REPORTED 1 SW 99 16HH 200 001 DURING FLIGHT, OIL PRESS WAS INDICATING LOW (10-30 PSI) AND ERRATIC. AFTER LANDING, DURING TAXI, OIL PRESS INDICATION W AS 0-10 PSI. PRESS XMITTER REMOVED AND A DIRECT READING GAUGE CONFIRMED THAT ON-BOARD INDICATIONS WERE CORRECT. PRESS REGULATOR AND BYPASS VALVES WERE CHECKED, FOUND NORMAL AND UNOBSTRUCTED. ENG IS EQUIPPED WITH A CHRISTEN 802 INVERTE D OIL VALVE INSTALLED AT THE SUPPLY SIDE OF THE OIL PUMP. UPON REMOVAL AND DISASSEMBLY OF SAME, THE UPPER OF THE TWO CH ROME BALLS (1.1250 INCH DIAMETER) WAS FOUND CORRODED CAUSING OIL PUMP TO SUCK AIR WHILE IN THE UPRIGHT ATTITUDE AND ENA BLING CAVITATION. THE LOWER BALL, UNLIKE THE UPPER, IS CONTINUOUSLY BATHED IN OIL AND WAS FOUND IN LIKE-NEW CONDITION. 1 Q 7 1 3O 3 O EXPA1Q71 E273 1997091800272 19970918 00272 SW 1997 9 18 97ZZZX3989 1 19970908 G 6220 214010104121 ROTOR GRIP 214010100207 BELL 214 214ST 1182106 SW M/R HEAD CRACKED D S A K NONE O OTHER IN INSP/MAINT 1 EU 01 745H 1642 875 AL1229 28197 MAIN ROTOR GRIP, DRAG BRACE ATTACHMENT, LOWER LUG CRACKED, 1.25 INCHES LONG. DEFECT IDENTIFIED VISUALLY DURING 5,000 HR /5 YEAR E-CHECK. DEFECT BECAME APPARENT DURING DISASSEMBLY. DEFECTIVE PART BEING RETURNED TO BELL FOR INVESTIGATION. 2 G 7 2 4U H10SW 1997091800273 19970918 00273 GL 1997 9 18 97ZZZX3990 2 19970112 G 7313 5233414 SCREEN 6890917 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20 03013 GL FUEL NOZZLE CONTAMINATED D L A A UNSCHED LANDING Y ENGINE STOPPAGE NR NOT REPORTED 1 WP 13 7012G 510981D ON JANUARY 12, 1997, A HUGHES 369D WAS INVOLVED IN AN ACCIDENT DUE TO FUEL STARVATION (SEE ACCIDENT NR LAX97LA088). THE STARVATION APPEARS TO HAVE BEEN CAUSED BY CONTAMINATION COLLECTING ON THE FUEL NOZZLE SCREEN RESTRICTING THE FLOW AND S UBSEQUENTLY COLLAPSING THE FILTER SCREEN UNDER HIGH ENGINE POWER SETTINGS. THESE POWER SETTINGS REQUIRE HIGHER FUEL PRE SSURE AND VOLUME. THE SCREEN WAS P/N 5233414 AND WAS OF A 104 MICRON MESH FILTER QUALITY. THESE SCREENS ARE A SUB-PART OF THE FUEL NOZZLES, P/N 6890917, AND ARE INSTALLED IN THE ALLISON 250-C20 SERIES ENGINES. 1 G 7 1 3U 3 U H3WE E4CE 1997091800247 19970918 00247 GL 1997 9 18 97ZZZX3992 1 19970801 G 5751 SPADE AMTR LASER LASER200 05626X5 GL RT AILERON BROKE G S K NONE O OTHER IN INSP/MAINT 1 SW 99 295L 002 RIGHT AILERON SPADE BENT AND BROKE JUST ABOVE TIG WELD. 1 L 7 1 3I NC EXPA1L71 1997091800248 19970918 00248 WP 1997 9 18 97ZZZX3993 1 19970820 G 6410 369A1613507 BLADE HUGHES 369 369HS 4470728 WP T/R CRACKED B A H8OR K NONE O OTHER IN INSP/MAINT 1 NM 07 33TM 3512 8708 550746S DURING POST-FLIGHT INSPECTION AFTER APPROXIMATELY A 2-HOUR FLIGHT, PILOT NOTICED PINHOLE IN T/R BLADE LEADING EDGE WITH APPROXIMATELY 1 INCH CRACKS DOWN BOTH SIDES OF BLADES. THESE BLADES HAD NEW DESIGN ABRASION STRIPS INSTALLED IAW AD 95- 03-11 ON 1-2-96 AT PART TTSN 2,505.0 HOURS. ORIGINAL SKIN INBOARD OF NEW STRIP APPARENTLY ERODED AND/OR CORRODED THROUG H. RECOMMEND X-RAY (OR OTHER INSPECTION) DURING 5,600 HOUR TIME LIFE. 1 G 7 1 3U H3WE 1997091800249 19970918 00249 GL 1997 9 18 97ZZZX3994 1 19970626 G 3230 LANDING GEAR AMTR VENTUR VENTURE 05618V8 GL NLG & MLG MALFUNCTIONED D L O OTHER J WARNING INDICATION AP APPROACH 1 NE 05 60BP 51 LANDING GEAR WOULD NOT EXTEND UNTIL PILOT OPENED BYPASS VALVE TO USE EMERGENCY HAND PUMP. GEAR FELL TO DOWN POSITION, B UT WOULD NOT EXTEND AND LOCK. A GEAR-UP LANDING WAS MADE WITH EXTENSIVE DAMAGE TO AIRCRAFT. 1 L 7 1 3O RT EXPA1L71 1997091800399 19970918 00399 CE 1997 9 18 97ZZZX3998 1 19970819 G 5753 122101015 TRACK CESSNA 185 A185F 2072821 CE RT FLAP INB-FWD RIVET SHEARED D O OTHER F FLT CONT AFFECTED NR NOT REPORTED 1 GL 21 185ND 2249 18504369 FLAPS WOULD NOT RETRACT FULLY. FOUND RIGHT FLAP INBOARD TRACK FORWARD LOWER ATTACH POINT RIVETS SHEARED. FLAP WELD SKI N TO BRACKET ATTACH POINTS ALSO CRACKED. LEFT FLAP INBOARD TRACK REPLACED PREVIOUS YEAR. AIRCRAFT OPERATED FULL TIME O N 3730 AMPHIBIAN FLOATS. 1 H 7 1 3O 3A24 1997091800400 19970918 00400 CE 1997 9 18 97ZZZX3999 1 19970707 G 3010 DEICE BOOT BFGOODRICH BEECH 60 B60 1153605 CE WING-PROP DEFECTIVE B L CNZ2 K NONE O OTHER IN INSP/MAINT 1 WP 01 21FH P35G WING AND PROPELLER DE-ICE BOOTS FAILED AFTER BEING TREATED BY A PROCESS CALLED 'NU-BOOTS' WHICH USED 'MEK' TO REFURBISH THE RUBBER. BF GOODRICH DOES NOT APROVE THIS PROCESS. THE OWNER HAS GROUNDed THE AIRCRAFT UNTIL ALL BOOTS ARE REPLACED . 1 L 7 2 3O A12CE 1997091800401 19970918 00401 GL 1997 9 18 97ZZZX4000 1 19970826 G 3220 SPRING AMTR EAGLE CHRISEAGLE2 GL TAIL WHEEL FAILED D A K NONE O OTHER LD LANDING 1 GL 21 37BB 597 BENNETT0001 TAIL WHEEL SPRING WAS MADE OF LAMINATED FIBERGLASS. BOUNCED LANDING CAUSED SPRING TO BREAK IN HALF. PARTS BOOK SHOWS S TEEL LEAF SPRINGS AS ORIGINAL EQUIPMENT. NO INDICATION OF WHEN OR WHY FIBERGLASS SPRING INSTALLED. 1 Q 7 1 3O EXPA1Q71 1997091800402 19970918 00402 SO 1997 9 18 97ZZZX4001 1 19970815 G 2810 649541 BLADDER PIPER PA25 PA25235 7102504 SO ATTACH SNAPS FAILED D A A UNSCHED LANDING Y ENGINE STOPPAGE NR NOT REPORTED 1 GL 21 4590Y 4263 254271 PILOT MADE EMERGENCY LANDING DUE TO FUEL STARVATION. FOUND FUEL BLADDER FAILED DUE TO ATTACHING SNAPS WERE UNSNAPPED. 1 L 7 1 3O 2A10 1997091800403 19970918 00403 SO 1997 9 18 97ZZZX4002 1 19970801 G 5610 6971200 WINDOW PIPER PA34 PA34200 7103405 SO PILOT LT SIDE DEPARTED D O OTHER C F.O.D. CR CRUISE 1 WP 23 41298 347450106 PILOT'S LEFT SIDE WINDOW DEPARTED AIRCRAFT DURING FLIGHT. PILOTS REPORTED NO ADVERSE FLIGHT CHARACTERISTICS AFTER WINDO W DEPARTED. PILOT REPORTED THAT WINDOW WAS CRACKED AT WING WINDOW PRIOR TO FLIGHT. SUSPECT CAUSE OF TOTAL FAILURE WAS WING WINDOW LEFT OPEN FOR COOLING AND BROKEN SECTION OF WINDOW WAS CAUGHT IN AIRFLOW CAUSING TOTAL FAILURE. NO OTHER DA MAGE TO AIRCRAFT. 1 L 7 2 3O A7SO 1997091800404 19970918 00404 SO 1997 9 18 97ZZZX4003 2 19970825 G 8520 643207 CRANKCASE CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO CYL NR 2 STUD CRACKED C S K NONE K FLUID LOSS IN INSP/MAINT 1 NE 01 524CA 1328 402C0522 290318R CREW REPORTED OIL LEAK, RIGHT ENGINE. UPON FURTHER INSPECTION, FOUND 1.25 INCH TO 1.5 INCH LONG CRACK IN CRANKCASE JUST AFT OF NR 2 CYLINDER, SEVENTH STUD, LOCATED IN WEB BETWEEN OIL COOLER MOUNTING AREA AND CYLINDER ATTACH AREA. 1 L 7 2 3O 3 O A7CE E8CE 1997091800407 19970918 00407 SO 1997 9 18 97ZZZX4006 1 19970827 G 2910 6390170 LINE PIPER PA34 PA34200T 7103406 SO GEAR RETRACT MALFUNCTION D K NONE O OTHER IN INSP/MAINT 1 EA 07 75226 3825 34670237 THERE IS A POSSIBILITY THE HYDRAULIC HOSE TO THE GEAR RETRACTION ACTUATOR MAY HAVE BEEN PICKED UP BY THE UPPER DRAG LINK BOLT WHEN THE GEAR WAS SELECTED DOWN. COULD NOT DUPLICATE THE GEAR EXTENSION PROBLEM. 1 L 7 2 3O A7SO 1997091800408 19970918 00408 SO 1997 9 18 97ZZZX4007 1 19970905 G 2150 424910 KEY PIPER PA31T PA31T 7103124 SO AIR COND DRIVE FAILED B ISOR K NONE O OTHER IN INSP/MAINT 1 SO 05 8CF 8020062 PILOT REPORTED AIR CONDITIONER INOPERATIVE. INSPECTION REVEALED THAT AIR CONDITIONER QUILL SHAFT DRIVE PULLEY WAS LOOSE ON QUILL SHAFT. RESULTING HEAT BUILD-UP DEFORMED QUILL SHAFT, PULLEYS, AND ATTACH HARDWARE, AND DESTROYED DRIVE BELTS. REPLACED QUILL SHAFT, BOTH BEARINGS, PULLEYS, BELTS, AND ASSOCIATED HARDWARE. SYSTEM OPERATIONAL CHECKED NORMALLY. 1 L 7 2 3T A8EA 1997091800409 19970918 00409 NE 1997 9 18 97ZZZX4008 2 19970827 G 8530 116733CP CYLINDER DOUG DC3 DC3AS1C3G 3021440 WP PWA R1830 R183092 52020 NE NR 11 FAILED G E ENGINE SHUTDOWN E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 99 24320 1283 20197 350920 AIRCRAFT WAS IN CRUISE FLIGHT WHEN ENGINE STARTED TO RUN ROUGH. ENGINE WAS SECURED AND PROPELLER FEATHERED. INVESTIGAT ION SHOWED THAT ROCKER ARM OR CYLINDER HEAD FAILED. CYLINDER TO BE REPLACED AND OPERATIONAL CHECK OF ENGINE DONE. 2 L 7 2 4R 4 R A669 5E4 1997091800410 19970918 00410 NM 1997 9 18 97ZZZX4009 1 19970702 G 5230 C54667EA205 PISTON 54C54667E01 BOEING 727 727 1384001 NM CARGO DOOR ACT ROD SEPARATED D K NONE O OTHER IN INSP/MAINT 1 NM 01 1510 RH0039 PISTON ROD SEPARATED FROM PISTON BODY DURING PRE-DISASSEMBLY PROOF PRESSURE TEST. SUSPECT CAUSE: METAL FATIGUE AT CHRO ME RUN-OUT, BASE OF PISTON ROD. 2 L 7 3 4F A3WE 1997012300329 19970123 00329 GL 1997 1 23 97ZZZX401 3 19970106 G 6111 CDA334 CLAMP MTSBSI MU2 MU2B60 5780460 CE HARTZL HCB4T HCB4TN5 GL PROP BLADE CRACKED D S A K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 SW 15 37AL 933 752SA DURING A 150 HOUR INSPECTION, A CLAMP WAS FOUND CRACKED ON THE LEFT PROP. THE PILOT THAT DELIVERED THE AIRCRAFT FOR THE INSPECTION REPORTED VIBRATION FROM THE RIGHT ENGINE. RECOMMENDED TO INSPECT PROPS IAW HC-SL-61-165 ANY TIME THERE IS G REASE LEAKAGE OR VIBRATION. 1 H 7 2 3T RT A10SW 6 C P40EA 1997091800411 19970918 00411 SW 1997 9 18 97ZZZX4010 1 19970902 G 2710 500042293 CONTROL CABLE GULSTM 690TP 695A 7630519 SW LT AIL WS 142 FRAYED H K NONE O OTHER IN INSP/MAINT 1 GL 25 7896G 3116 96070 WHILE PERFORMING SB 226, THE LEFT AILERON CABLE WAS FOUND SEVERELY FRAYED AT WS 142.0. THE CABLE WAS PROPERLY ROUTED AN D RUBBING ON THE FAIRLEAD AS IT WAS INTENDED TO DO. SUBMITTER SUGGESTS INSPECTING ALL OF AILERON CABLES BEHIND WING TO FLAP FAIRINGS WHILE PERFORMING SB 226. 1 H 7 2 4T 2A4 1997091800412 19970918 00412 SW 1997 9 18 97ZZZX4011 1 19970825 G 2930 SS10127 SWITCH SWRNGN SA226 SA226TC 8780404 SW HYDRAULIC PRESS CRACKED E K NONE N FALSE WARNING NR NOT REPORTED 1 NM 11 71Z TC245 HYDRAULIC WARN LIGHT (RT) ACTIVATED. LIGHT WAS FALSE WARNING DUE TO PRESSURE SWITCH HAD A CRACKED WELD. 2 L 7 2 4T RT A8SW 1997091800415 19970918 00415 NE 1997 9 18 97ZZZX4013 2 19970827 G 7250 BLADE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D217C 52053 NE HPT AND LPT FAILED B L A ASMF O OTHER J WARNING INDICATION TO TAKEOFF 1 SW 07 2FOR 23744 718075 DURING TAKEOFF, ENGINE EXPERIENCED A CONTAINED FAILURE ON THE HPT AND LPT INCLUDING SEPARATION OF THE EXHAUST CONE. DUR ING INVESTIGATION, NUMEROUS PIECES OF THE TURBINE WERE FOUND IN THE ENGINE EXHAUST AREA AND RUNWAY. A METALLURGICAL EXA MINATION IS BEING ACCOMPLISHED BY PW FIELD REP. AN ENGINE BORESCOPE WAS ACCOMPLISHED A WEEK PRIOR TO FAILURE, NO DAMAGE REPORTED DURING THIS INSPECTION. ENGINE IS SCHEDULED FOR TEAR-DOWN AND CAUSE OF FAILURE WILL BE PROVIDED TO THE FAA. 2 L 7 2 4F 4 F RT A6WE E9NE 1997091800416 19970918 00416 SW 1997 9 18 97ZZZX4014 1 19970520 G 5510 540011300009 STABILIZER BAR BELL 204 UH1E 1181401 SW STAB ATTACH BOLT FAILED D L A K NONE O OTHER IN INSP/MAINT 1 SW 99 121FC 278 Q191167 151858 ON A DAILY INSPECTION OF THE HELICOPTER, 2 BOLT HEADS WERE POPPED OFF THE STABILIZER BAR MOUNTING AREA AND ALL OTHER BOL TS WERE LOOSE. RECORDS INDICATED 110 HRS AGO, ONE BOLT WAS FOUND LOOSE ON A PREVIOUS INSPECTION. SUBMITTER RECOMMENDS THE AN 6H BOLTS AND MS2000266 WASHERS OF THE MILITARY CONFIGURATION BE CHANGED TO THE NAS1306 BOLTS AND AN960-616 WASHER S OF THE BELL HELICOPTER CONFIGURATION. BOLT HAS MUCH HIGHER TENSILE STRENGTH AND WASHER HAS BETTER CONTACT AREA ON BOL T HEAD. 1 G 7 1 4U EXPA1G71 1997012300330 19970123 00330 NE 1997 1 23 97ZZZX402 1 19970108 G 6720 7640003191043 CONTROL CABLE SKRSKY S76 S76A 8143006 NE T/R CONTROL MISMANUFACTURED B L A ALGR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 WHILE ATTEMPTING TO INSTALL A NEW TAIL ROTOR CABLE, THE TECHNICIAN DISCOVERED THAT THE THREADED 'MALE' END OF THE CABLE WAS THREADED IMPROPERLY. THE CABLE WAS THREADED WITH LEFT-HAND THREADS INSTEAD OF THE REQUIRED RIGHT-HAND THREADS. THE OPERATOR FOUND NINE OTHER NEW CABLES IN THEIR STOCK THAT WERE THREADED INCORRECTLY. THE CABLES WERE ALL PURCHASED DIRE CTLY FROM AN AUTHORIZED SIKORSKY PARTS DISTRIBUTOR AND CONTAINED SIKORSKY PACKAGING. 1 G 7 2 3U H1NE 1997091800783 19970918 00783 SW 1997 9 18 97ZZZX4024 1 19970822 G 6710 A21810064603 SWITCH HUGHES 500N 500N 3027374 SW STICK TRIM FAILED G A K NONE F FLT CONT AFFECTED NR NOT REPORTED 1 WP 07 527FB 164 LN007 RUNAWAY TRIM, FORE AND AFT, DUE TO STICK TRIM SWITCH FAILURE. 1 G 7 1 3U NC H3WE 1997091800784 19970918 00784 1997 9 18 97ZZZX4025 1 19970903 G 7333 912767 SENSOR ALLSN AE300 AE3007A GL FUEL FLOW LEAKS B AG4R K NONE K FLUID LOSS IN INSP/MAINT 1 NM 01 8087 INVESTIGATION FOR SENSOR LEAK FOUND SCREW THAT RETAINS SKEW RUDDER BROKE AT HEAD. ALLOWED SKEW RUDDER TO BACK OUT ALLOW ING FUEL TO LEAK. CAUSE OF HEAD BREAKAGE UNDER INVESTIGATION. BEING REPORTED TO AFFECTED ENGINE MANUFACTURERS. THIS I S THE THIRD INCIDENT IN EIGHT MONTHS. LEAKAGE IS MINIMAL AND SHOULD NOT CONSTITUTE A FIRE HAZARD. 4 F TE6CH 1997092500001 19970925 00001 1997 9 25 97ZZZX4032 4 19970813 G 2562 ELT10 ELT NARCO CESSNA 310 310R 2074245 CE OUTPUT WEAK B BXSR K NONE O OTHER IN INSP/MAINT 1 EA 09 123RA 394 A23108 310R0221 DURING ROUTINE ELT CHECK, FOUND THE ELT HAD A WEAK SIGNAL. ELT WAS REPAIRED, RECERTIFIED, AND NEW BATTERY BY NARCO ON 1 2-21-95. BATTERY DUE OFF DATE IS JANUARY 17, 1998. A REPLACEMENT BATTERY WAS TRIED, BUT DID NOT FIX THE PROBLEM. 1 L 7 2 3O 3A10 1997092500002 19970925 00002 CE 1997 9 25 97ZZZX4033 1 19970507 G 2701 05131663 WHEEL CESSNA 172 172E 2072412 CE CONTROL WHEEL BROKE D S O OTHER O OTHER AP APPROACH 1 GL 03 35975 4778 17250797 COPILOT'S CONTROL WHEEL BROKE APPROXIMATELY IN HALF WITH THE OUTBOARD HALF SEPARATING FROM THE INBOARD. THE INBOARD HAL F REMAINED ATTACHED TO THE TUBE. THIS HAPPENED WHEN THE INSTRUCTOR WAS CORRECTING THE PILOT'S CROSS-WIND LANDING TECHNI QUE. THE LAST ANNUAL INSPECTION WAS 1-2-91. 1 H 7 1 3O NT 3A12 1997092500003 19970925 00003 SO 1997 9 25 97ZZZX4034 1 19970902 G 5712 670151 RIB PIPER PA28 PA28R180 7102809 SO WS 49.25 RIVET SHEARED B MZER K NONE O OTHER IN INSP/MAINT 1 GL 15 3741T 3750 28R30957 RIB NR 3 AT STA 69.24 WHERE ANGLES RIVET TO FALSE SPAR RIVETS SHEAR ALLOWING STRUT TO PUSH UP THROUGH UPPER SKIN. ALSO DAMAGES RIB NR 2 AT STA 49.25 AND CRACKS BOTH UPPER AND LOWER FALSE SPAR CAPS. POSSIBLE CAUSE, HARD LANDING OPERATING W ITH FLAT STRUT OR OVERPRESSURIZED STRUT AND TIRE. 1 L 7 1 3O 2A13 1997092500006 19970925 00006 CE 1997 9 25 97ZZZX4037 1 19970801 G 3231 08411066 BELLCRANK CESSNA 310 310R 2074245 CE RT MLG DOOR BROKEN H K NONE O OTHER IN INSP/MAINT 1 CE 03 4264J 2511 310R0201 RIGHT MAIN INBOARD GEAR DOOR WOULD NOT CLOSE AFTER EXTENSION. FOUND BROKEN IDLER BELLCRANK. GEAR WAS FOUND RIGGED PROP ERLY. SUBMITTER STATED CAUSE OF MALFUNCTION UNKNOWN. 1 L 7 2 3O 3A10 1997092500007 19970925 00007 SO 1997 9 25 97ZZZX4038 1 19970902 G 5712 RIB PIPER PA28 PA28R180 7102809 SO WS 69.24 RIVET SHEARED B MZER K NONE O OTHER IN INSP/MAINT 1 GL 15 4932J 4603 28R30653 RIB NR 3 AT STA 69.24 WHERE ANGLES RIVET TO FALSE SPAR RIVETS SHEAR ALLOWING STRUT TO PUSH UP THROUGH UPPER SKIN. ALSO DAMAGES RIB NR 2 AT STA 49.25 AND CRACKS BOTH UPPER AND LOWER FALSE SPAR CAPS. SUSPECT CAUSE, HARD LANDING OPERATING WI TH FLAT STRUT OR OVER PRESSURIZED STRUT AND TIRE. 1 L 7 1 3O 2A13 1997092500008 19970925 00008 CE 1997 9 25 97ZZZX4039 1 19970818 G 2410 626543 DRIVE BUSHING CESSNA 172 R172E 2072413 CE ALTERNATOR DISTORTED D K NONE O OTHER IN INSP/MAINT 1 NM 11 49885 480 R1720156 IN RESPONSE TO TCM SB 95-31 (ALT DRIVE), A CHECK OF WEAR HAS BEEN KEPT SINCE NEW. AT ZERO TIME, RADIAL TRAVEL OF ALTERN ATOR FAN WAS ZERO TO .1250 INCH. AT 200 HOURS, FAN TRAVEL WAS .25 INCH TO .3750 INCH. AT 480 HOURS SINCE NEW, THE FAN TRAVEL WAS .75 INCH TO 1 INCH. BUSHINGS WERE DISTORTED, BUT NOT APPARENTLY READY TO FAIL. 1 H 7 1 3O 3A17 1997092500010 19970925 00010 CE 1997 9 25 97ZZZX4041 1 19970819 G 3340 4313 TAXI LIGHT CESSNA 185 A185F 2072821 CE LIGHT WRONG PART H O OTHER W INADEQUATE Q C NR NOT REPORTED 1 NM 04 70487 18502190 PILOT REPORTED LANDING LIGHT CIRCUIT BREAKER KEPT TRIPPING. UPON INVESTIGATION, FOUND LANDING LIGHT CIRCUIT WAS DRAWING 22 AMPS. (LANDING LIGHT CIRCUIT BREAKER IS A 20-AMP CIRCUIT BREAKER). FURTHER INVESTIGATION REVEALED THE TAXI LIGHT HA D BEEN REPLACED WITH A 4313. 250W LAMP. THE PARTS BOOK CALLS FOR A 4509. 100W LAMP. INSTALLED CORRECT LAMP. CIRCUIT D RAWS 10 AMPS. 1 H 7 1 3O 3A24 1997092500011 19970925 00011 CE 1997 9 25 97ZZZX4042 1 19970904 G 8120 INTERCOOLER BEECH 35 V35A 1151544 CE TURBOCHARGER LEAKS G K NONE K FLUID LOSS IN INSP/MAINT 1 SW 15 7786R 270 D8884 LEAKAGE AT OUTLET CONNECTION OF INTERCOOLER FOR TURBOCHARGER ON ENGINE. OUTLET OF INTERCOOLER IS SQUARE AND A ROUND RUB BER HOSE IS CLAMPED TO THE SQUARE OUTLET. OVER TIGHTNING OF CLAMP COULD CAUSE COLLAPSE OF OUTLET. HOSE PINCHES DURING CONNECTION AND LEAKS, VERY HARD TO STOP LEAK. STC NR SA5223NM AND SE 5222NM. 1 L 7 1 3O 3A15 1997092500012 19970925 00012 CE 1997 9 25 97ZZZX4043 1 19970828 G 5532 STABILIZER CESSNA 172 172RG 2072438 CE VERTICAL STAB RIVETS LOOSE B WIWR K NONE O OTHER IN INSP/MAINT 1 WP 07 360ES 355 17280010 DURING INSPECTION, FOUND WORKING RIVETS ON TOP OF STABILIZER SKIN JUST UNDERNEATH FAIRING FOR HORIZONTAL STABILIZER TO F USELAGE. 1 H 7 1 3O 3A17 1997092500013 19970925 00013 EA 1997 9 25 97ZZZX4044 2 19970821 G 8530 LWQ15014 ROCKER ARM PIPER PA44 PA44180T 7104404 SO LYC O360 LTO360E1A6 41515 EA LT ENG VALVES EXCESS WORN D K NONE O OTHER IN INSP/MAINT 1 SW 05 49AT 605 448407041 RL30374T 605 HOURS TT ON ENGINES. EXCESSIVE WEAR BEWEEN ROCKER ARM AND FULCRUM. ONE FAILURE IN-FLIGHT. INSPECTION OF OTHER ENG INE REVEALED SAME RESULTS. REPLACED MOST OF THE ROCKER ARMS AND FULCRUMS ON AIRCRAFT. SUBMITTER RECOMMENDS INSPECTION EVERY ANNUAL OR 100 HOURS. SUSPECT CAUSE - LACK OF LUBRICATION (DESIGN FLAW). 1 L 7 2 3O 3 O A19SO E26EA 1997092500014 19970925 00014 EA 1997 9 25 97ZZZX4045 2 19970821 G 8530 LWQ15014 ROCKER ARM PIPER PA44 PA44180T 7104404 SO LYC O360 LTO360E1A6 41515 EA RT ENG VALVES EXCESS WORN D K NONE O OTHER IN INSP/MAINT 1 SW 05 49AT 605 448407041 RL20673T 605 HOURS TT ON ENGINES. EXCESSIVE WEAR BEWEEN ROCKER ARM AND FULCRUM. ONE FAILURE IN-FLIGHT. INSPECTION OF OTHER ENG INE REVEALED SAME RESULTS. REPLACED MOST OF THE ROCKER ARMS AND FULCRUMS ON AIRCRAFT. SUBMITTER RECOMMENDS INSPECTION EVERY ANNUAL OR 100 HOURS. SUSPECT CAUSE - LACK OF LUBRICATION (DESIGN FLAW). 1 L 7 2 3O 3 O A19SO E26EA 1997092500015 19970925 00015 CE 1997 9 25 97ZZZX4046 1 19970903 G 3411 589100211 FILTER COVER 353244903 BEECH 33 F33A 1151425 CE STANDBY AIR MELTED D K NONE O OTHER IN INSP/MAINT 1 WP 07 5581T 601 CE1350 DURING A PROGRESSIVE INSPECTION, THE MECHANIC FOUND THE FILTER COVER HAD BEEN HEATED TO A POINT AT WHICH THE COVER MELTE D AND TURNED THE FILTER TO A BROWN BURNT DISTORTED COLOR WHERE THE COVER HAD MELTED. UPON FURTHER INSPECTION, THERE WAS NO EVIDENCE OF EXHAUST LEAK OR LEAKS OF ANY OTHER KIND. NO DISCREPANCIES WERE FOUND. SUSPECT CAUSE COULD BE THE MATER IAL OF WHICH THE PART IS MADE. ALL ENGINE INDICATING GAUGES SHOWED THE ENGINE OPERATING IN NORMAL CONDITIONS. THE PART WAS REPLACED WITH A NEW PART AND SINCE THEN, HAVE NOT SHOWN ANY SIGNS OF MELTING. 1 L 7 1 3O 3A15 1997092500016 19970925 00016 CE 1997 9 25 97ZZZX4047 1 19970801 G 5520 1705200 BRACKET PIPER PA23 PA23150 7102303 CE LT ELEV HINGE CRACKED D S A K NONE O OTHER IN INSP/MAINT 1 EA 17 1258P 23284 WHILE PERFORMING TAIL AREA INSPECTION PER AD 63-26-03, FOUND LEFT ELEVATOR OUTBOARD HINGE BRACKET CRACKED IN AREA OF HIN GE. THIS AREA OF THE HINGE IS NOT NORMALLY VISIBLE. THE ELEVATOR HAD BEEN LEFT HANGING IN A VERTICLE POSITION WHEN THE ELEVATOR TORQUE TUBE WAS REMOVED TO INSPECT THE CASTINGS AT THE END BRACKETS. IF THIS AIRCRAFT HAD FORGED PARTS INSTALL ED, THIS INSPECTION WOULD NOT HAVE BEEN PERFORMED AND THE CRACKED HINGE WOULD NOT HAVE BEEN VISIBLE. SUBMITTER SUGGESTS THAT THIS INSPECTION BE AN AD NOTE. FAILURE OF THIS PART WOULD BE CATASTROPHIC. 1 L 7 2 3O RT 1A10 1997092500017 19970925 00017 CE 1997 9 25 97ZZZX4048 1 19970818 G 5551 AN509416R13 SCREW CESSNA 210 T210M 2073451 CE H STAB MOUNT BROKEN B WIWR K NONE O OTHER IN INSP/MAINT 1 WP 07 6241B 5081 21062719 100 HOUR INSPECTION FOUND A BROKEN SCREW P/N AN 509-416R13 IN THE HORIZONTAL STABILIZER MOUNT AND MOUNT BRACKET P/N 1212 128-1 CRACKED IN THREE PLACES. 1 H 7 1 3O 3A21 1997092500018 19970925 00018 CE 1997 9 25 97ZZZX4049 1 19970818 G 5551 12121281 BRACKET CESSNA 210 T210M 2073451 CE H STAB MOUNT CRACKED B WIWR K NONE O OTHER IN INSP/MAINT 1 WP 07 6241B 5081 21062719 100 HOUR INSPECTION FOUND A BROKEN SCREW P/N AN 509-416R13 IN THE HORIZONTAL STABILIZER MOUNT AND MOUNT BRACKET P/N 1212 128-1 CRACKED IN THREE PLACES. 1 H 7 1 3O 3A21 1997092500019 19970925 00019 SO 1997 9 25 97ZZZX4050 1 19970829 G 2140 FRIDE214EL HEATER PIPER PA31T PA31T 7103124 SO HEAD FLANGE CRACKED B A GW1R K NONE O OTHER IN INSP/MAINT 1 EA 03 77NL 165 A95120043 31T7720038 THE COMBUSTION HEATER WAS PRESSURE DECAY CHECKED DURING PRE-PURCHASE EVALUATION. ALTHOUGH NOT REQUIRED BY AD 96-20-07, T HE MANUFACTURER RECOMMENDS A PRESSURE DECAY CHECK AT 500 HOURS INITIAL AND 100-HOUR REPETITIVE INTERVALS. THE HEATER FA ILED THE PRESSURE CHECK AND THE UNIT WAS REMOVED FOR A BENCH CHECK. FURTHER INVESTIATION REVEALED A CRACK WELD AT THE C OMBUSTION HEAD RETAINING FLANGE. THE UNIT WAS REPLACED. 1 L 7 2 3T A8EA 1997092500020 19970925 00020 1997 9 25 97ZZZX4051 4 19970731 G 6122 20749 FLY WEIGHT MCAULY C290D3FT16 PROP GOVERNOR BROKEN B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 793826 PROP GOV FLY WEIGHT CAME APART DURING OPERATION. SB 214 NOT C/W. 1997092500021 19970925 00021 1997 9 25 97ZZZX4052 2 19970812 G 7414 ES103827901 COIL BENDIX D4RN2021 MAG CRACKED B KC2R K NONE O OTHER IN INSP/MAINT 1 GL 03 469 5082070R BOTH COILS IN THIS DUAL MAG HAVE CRACKS IN POTTING COMPOUND EXPOSING COIL WINDINGS AND LEAKING HIGH TENSION VOLTAGE. BO TH COILS ARE ELECTROSYSTEMS MANUFACTURED COILS. HAVE SEEN OTHER ELECTRICAL SYSTEM COILS WITH SIMILAR CRACKS. DOES NOT S EEM TO OCCUR WITH BENDIX/TCM COILS. THESE CRACKS COULD RESULT IN A 'DEAD' MAG. 1997092500022 19970925 00022 GL 1997 9 25 97ZZZX4053 3 19970904 G 6114 HUB BEECH 45 A45 1152006 CE MCAULY 2A36C 2A36C23 GL BOTH SOCKETS CRACKED G A K NONE O OTHER IN INSP/MAINT 1 NM 03 1506 737046 PROPELLER WAS IN FOR OVERHAUL. DURING INSPECTION WITH EDDY CURRENT, BOTH HUB SOCKETS WERE FOUND CRACKED IN THE THREADS ON THE ENGINE SIDE OF THE HUB. THESE THREADS HOLD THE BLADES IN THE PROP. 1 L 7 1 3O 5A3 5 C P880 1997092500023 19970925 00023 GL 1997 9 25 97ZZZX4054 3 19970904 G 6114 HUB CESSNA 188 188B 2073007 CE MCAULY 2A34C D2A34C98 GL NR 2 SOCKET CRACKED G K NONE K FLUID LOSS IN INSP/MAINT 1 NM 03 800 921076 PROPELLER WAS IN FOR A SUSPECTED LEAK INTERNALLY. AFTER DISASSEMBLY, THE PISTON WAS WORN BEYOND ALLOWABLE LIMITS WHICH ALLOWED ENGINE OIL TO PASS THE PISTON SEAL INTO THE HUB CAVITY FILLING IT UP AND CAUSING HYDRAULIC LOCK AND STOPPED THE PROP FROM ACTUATING. FURTHER, INSPECTION OF THE PROPELLER HUB SHOWED A CRACK IN THE BLADE RETENTION THREADS OF NR 2 HUB SOCKET ON THE ENGINE SIDE. 1 L 7 1 3O A9CE 5 C P3EA 1997092500024 19970925 00024 EA 1997 9 25 97ZZZX4055 2 19970828 G 7310 LW127996S180 HOSE RSA5AD1 CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA FUEL SERVO LEAK B WIWR K NONE O OTHER IN INSP/MAINT 1 WP 07 97100 42 70124311 17280100 L2709351A DEFECTIVE HOSE FOUND DURING ROUTINE INSPECTION. CLAMPS FOR HEAT SLEEVE WERE TIGHTENED EXCESSIVELY, LEAKING AT THAT AREA . 1 H 7 1 3O 3 O 3A17 E286 1997092500025 19970925 00025 NE 1997 9 25 97ZZZX4056 2 19970305 G 7230 1B5130 BEARING BOEING 757 757* NM PWA 2037 PW2037 NE NR 1 FAILED B WA2D O OTHER B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION NR NOT REPORTED 1 NE 03 3085 41337 P727175 AIRCRAFT EXPERIENCED SMOKE IN COCKIT/CABIN AND LOSS OF N1 INDICATION. GROUND INSPECTION DISCLOSED N1 ROTOR SHIFT/METAL IN TAILPIPE. DISASSEMBLY INSPECTION DISCLOSED NR 1 MAIN BEARING FAILURE (SEVERE DISTRESS FROM A SINGLE BALL FRACTURE). BEARING DELIVERED TO P & W MERL LAB FOR REVIEW. 2 L 7 2 4F 4 F RT A2NM E17NE 1997092500026 19970925 00026 NE 1997 9 25 97ZZZX4057 3 19970804 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 3907 NR2673 HJ437 INSPECTION FOUND FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS, - 4 SLOTS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997092500027 19970925 00027 NE 1997 9 25 97ZZZX4058 3 19970905 G 6111 57C0792 BEARING BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE NR 4 BLADE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 8056 3860 HJ163A INSPECTION FOUND NR 4 BLADE BEARING CRACKED INTO SEVERAL PIECES BOTH INNER AND OUTER HALVES. 2 L 7 2 4T RT A24CE 5 C P10NE 1997092500028 19970925 00028 NE 1997 9 25 97ZZZX4059 3 19970826 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 4498 2501NR HJ383 INSPECTION FOUND FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. TWO SLOTS CR ACKED. 2 L 7 2 4T RT A24CE 5 C P10NE 1997092500029 19970925 00029 NE 1997 9 25 97ZZZX4060 3 19970825 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 4601 2728NR HJ445 INSPECTION FOUND FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997092500030 19970925 00030 NE 1997 9 25 97ZZZX4061 3 19970730 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 4539 2530NR HJ481 PROPELLER INSPECTION FOUND FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARFD RADIUS OD PITCH PIN ENGAGEMENT SLOTS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997092500045 19970925 00045 1997 9 25 97ZZZX4062 1 19970910 G 7100 3038 HOSE AEROQUIP ENGINE MISMANUFACTURED E K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 01 IMPROPER MANUFACTURE OF HOSE INTERIOR FOUND DURING ASSY OF NEW HOSE. HOSE MFG DATE 3Q96. 1997092500046 19970925 00046 SO 1997 9 25 97ZZZX4063 1 19970912 G 2121 AE1711AA0 FAN TECHNOFAN EMB 120 EMB120RT SO GROUND COOL FAILED B XC4R K NONE O OTHER IN INSP/MAINT 1 SO 19 2851 6 THIS IS A NEW GENERATION FAN ASSEMBLY, PRODUCT IMPROVEMENT. UPON DISASSEMBLY, FOUND DRIVER P.C. BOARD OVERHEATED AND LO OSE SOLDER JOINTS. THIS FAN IS MADE IN FRANCE. RESOLDERED DEFECTIVE CONNECTIONS TEST RAN FAN, RETURN TO SERVICE. 2 L 7 2 4T RT A31SO 1997092500048 19970925 00048 EA 1997 9 25 97ZZZX4065 1 19970818 G 7931 601509193 TRANSDUCER CNDAIR CL600 CL6002B16 1900305 EA RT ENG OIL PRESS FAILED C E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 SO 17 175ST 3428 5023 SHORTLY AFTER DEPARTING FXE, RIGHT ENGINE OIL PRESSURE DROPPED TO ZERO PSI. RIGHT ENGINE WAS SHUT DOWN AND AIRCRAFT RET URNED TO DEPARTING AIRPORT FXE. REPLACED ENGINE OIL PRESSURE TRANSDUCER, RETURNED AIRCRAFT TO SERVICE. 2 L 7 2 4F RT A21EA 1997092500050 19970925 00050 CE 1997 9 25 97ZZZX4066 1 19970630 G 3244 265F864 TIRE GOODYEARAERO BEECH 200 200BEECH 1152920 CE NLG FAILED D O OTHER O OTHER TO TAKEOFF 1 EA 05 6051C 815 31542128 BB499 AT ROTATION ON AIRCRAFT TAKEOFF ROLL, CREW HEARD A BANG. LANDING GEAR WAS LEFT EXTENDED, AND A NORMAL LANDING WAS MADE. INVESTIGATION REVEALED THAT CENTER TREAD SECTION HAD SEPARATED FROM TIRE. NOSE TIRE REMAINED INFLATED. SUBMITTER STA TED GOODYEAR MANUAL SPEAKS TO CAUSES OF TREAD SEPARATION. 1 L 7 2 4T A24CE 1997092500051 19970925 00051 CE 1997 9 25 97ZZZX4067 1 19970821 G 3246 AHA1814 WHEEL ASSY RAYTHN DH125 HAWKER800XP CE MLG BOLT FAILED H K NONE O OTHER IN INSP/MAINT 1 NM 11 800XP 258266 WHEEL ASSY BOLT FAILED. BOLT WAS TESTED IAW MIL-STD-1949 A/2, 5-29-90. 2 L 7 2 4F RT A3EU 1997092500052 19970925 00052 NE 1997 9 25 97ZZZX4068 2 19970510 G 7230 55H705 BLADE PW4158 AIRBUS 310 A310324 3930206 EU PWA 4152 PW4152 NE 5TH STAGE HPC FAILED B A WA2D O OTHER Y ENGINE STOPPAGE CR CRUISE 1 NE 03 838AB 152 B24921 676 P724921 EN ROUTE GOING THROUGH FL 370 IN SMOOTH AIR, CREW HEARD ENGINE SURGE AND NOTED PARAMETER DECREASE. AIR START ATTEMPTED UNSUCCESSFULLY. FLIGHT DIVERTED TO ORLANDO. DISASSEMBLY REVIEW BY P & W ENGINEERING HAS LED TO A PRELIMINARY CONCLUSIO N OF A SINGLE 5TH STAGE COMPRESSOR BLADE FAILURE (FRACTURE). THE FAILED MATERIAL (INCLUDING 5TH DISK) HAS BEEN DELIVERED TO PRATT & WHITNEY ENGINEERING. ENGINE TT, 8,484.5; TC 2,575; TSO, 151.33 HOURS; CSO, 91. 2 L 7 2 4F RT A35EU E24NE 1997013000001 19970130 00001 SW 1997 1 30 97ZZZX413 1 19970108 G 7120 2762002001 MOUNT SWRNGN SA226 SA226* SW ENG FIREWALL NOT WELDED B P A H7NR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 17 DEFECTIVE LOWER MOUNT ATTACH POINT WHERE THE MOUNT IS ATTACHED TO THE FIREWALL. THE WELDING OF THE TUBE TO THE MOUNT FA CE PLATE IS NOT COMPLETE. WELD WAS NEVER COMPLETED FROM THE MANUFACTURER. SUBMITTER STATED NEED TO COMPLETELY WELD ALL THE WAY AROUND TO ASSURE NO WEAKNESS IN THE TRUSS ATTACH POINT. 2 L 7 2 4T RT A56W 1997092500253 19970925 00253 CE 1997 9 25 97ZZZX4137 1 19970823 G 3244 850X10 TIRE MCCREARY HELIO H295 H295 4300802 CE MLG FAILED H O OTHER O OTHER TO TAKEOFF 1 AL 01 6465V 951 AIH4260 1417 AIRCRAFT WAS INVOLVED IN NUMEROUS OFF-AIRPORT OPERATIONS. AS AIRCRAFT WAS ON TAKEOFF RUN, UPPER TIRE SIDEWALL AND TUBE WERE PUNCTURED, POSSIBLY CAUSED BY ROCKS. CONDITIONS WERE ROUGH AND PRESUMABLY THE PUNCTURES WERE NOT THE FAULT OF THE TIRE AND TUBE. SUBMITTER WOULD RECOMMEND, HOWEVER, THAT TIRES INVOLVED IN OFF-AIRPORT OPERATION BE CHANGED AT 600-700 H OURS TO INSURE INTEGRITY OF THE TIRE. 1 H 7 1 3O 1A8 1997092500255 19970925 00255 SO 1997 9 25 97ZZZX4139 1 19970728 G 3242 BRAKE LINING PIPER PA24 PA24250 7102404 SO WHEEL FAILED B QB2R K NONE O OTHER IN INSP/MAINT 1 GL 15 242007 INSTALL NEW RIVETS IN WHEELS AND BRAKE LININGS. 1 L 7 1 3O 1A15 1997013000003 19970130 00003 NM 1997 1 30 97ZZZX414 1 19970106 G 2761 65233494 ACTUATOR BOEING 707 707321 138365B NM SPOILER BROKEN B TR1R K NONE O OTHER IN INSP/MAINT 1 SW 05 404PA 630 DA198 18835 SPOILER ACTUATOR ROD END BROKEN AT PISTON END AND EVIDENCE OF INTERNAL FAILURE. '2ND OCCURRENCE'. APPEARED TO BREAK AT END OF THREAD. PROBABLY OVERTORQUED. 2 L 7 4 4J 4A26 1997092500256 19970925 00256 CE 1997 9 25 97ZZZX4140 1 19970801 G 3246 C1630040102 WHEEL CESSNA 210 T210L 2073449 CE MLG CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 17 117P 21061407 BOTH MAIN WHEELS CRACKED. THESE ARE 3-PIECE WHEELS USED ON VARIOUS CESSNA SINGLES IN THE 1970'S. THIS SUBMITTER FEELS A MORE LIKELY CAUSE (OTHER THAN OVERTORQUING) IS STRESS CAUSED BY PULLING SMALL AMOUNTS OF ALUMINUM THROUGH THE THREADS EACH TIME THE BOLTS ARE REMOVED WHICH TENDS TO SPREAD THE HOLE. 1 H 7 1 3O 3A21 1997092500261 19970925 00261 CE 1997 9 25 97ZZZX4145 1 19970814 G 5220 002430008287 WINDOW SEAL BEECH 36 A36 1151604 CE LT EMERG EXIT MISINSTALLED D S A K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 17 3147L 370 E2882 DURING ANNUAL INSPECTION, LEFT CABIN EXIT WINDOW COULD NOT BE OPENED. WINDOW HAD BEEN SEALED CLOSED BY A BEAD OF RTV AP PLIED TO FORWARD SEAL AREA. 1 L 7 1 3O 3A15 1997092500262 19970925 00262 SO 1997 9 25 97ZZZX4146 1 19970903 G 3230 9539400 CHANNEL ASSY PIPER PA34 PA34200T 7103406 SO NLG CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 15 38884 5755 347770352 WHILE PERFORMING A GEAR SWING, NOSE GEAR WOULD NOT RETRACT FULLY. UNDER FURTHER INSPECTION, FOUND THE NOSE GEAR HAD JUM PED OUT OF THE TRACK ASSY. REPLACED THE UPPER CHANNEL ASSY. OPS CHECK GOOD. SUSPECT CAUSE: IMPROPER TOWING, EXCEEDIN G TOWING LIMITS. 1 L 7 2 3O A7SO 1997092500263 19970925 00263 CE 1997 9 25 97ZZZX4147 1 19970909 G 2437 C6695600105 AMMETER CESSNA 210 T210N 2073456 CE INST PANEL MISMARKED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 6621A 21063559 WHILE REPLACING BAD AMMETER, NOTICED THE MARKINGS FOR PLUS AND MINUS WERE OPPOSITE OF THE ORIGINAL GAUGE. THE AMMETER W AS BENCH CHECKED FOR PROPER DEFLECTION AND IT WAS FOUND MIS-MARKED. WHEN INSTALLED AND HOOKED UP AS THE ORIGINAL GAUGE WAS, OPS CHECK NORMAL. 1 H 7 1 3O 3A21 1997092500264 19970925 00264 EA 1997 9 25 97ZZZX4148 2 19970908 G 7414 1051324 IMPULSE SPRING 105136045 PIPER PA28 PA28180 7102808 SO LYC O360 O360A4A 41514 EA MAGNETO BROKEN B QKKR K NONE O OTHER IN INSP/MAINT 1 CE 01 7853N 11 991382 285310 L1383936A MAGNETO IMPULSE SPRING FOUND BROKEN INTO 3 PARTS. PART WAS INSTALLED 10-20-94, AND USED 11 HOURS TOTAL. SUBMITTER SUSP ECTS CORROSION ON PART STARTED PROBLEM. SUSPECT MATERIAL MAY BE ANOTHER PROBLEM. FACTORY CHANGED APPEARANCE OF PART IN EARLY '94. AS OF THIS TIME, ANOTHER CHANGE IN APPEARANCE OCCURRED THIS YEAR. 1 L 7 1 3O 3 O 2A13 E286 1997092500265 19970925 00265 SO 1997 9 25 97ZZZX4149 2 19970905 G 8540 640925 ADAPTER PIPER PA34 PA34200T 7103406 SO CONT O360 LTSIO360EB 17025 SO RT ENG GEAR CASE BROKEN B DC1R K NONE O OTHER IN INSP/MAINT 1 EA 07 8174H 29 348070155 266219R TACHOMETER DRIVE ADAPTER IS A 90-DEGREE DRIVE THAT REVERSES OUTPUT ROTATION AND ANGLE OF OUTPUT FROM ENGINE TO DRIVE TAC HOMETER SHAFT. FOUND MOUNTING NUT AND FLANGE STILL ON ENGINE ACCESSORY CASE AND ADAPTER HANGING ON TACHOMETER DRIVESHAF T. FLANGE BROKEN OFF OF ADAPTER. SUSPECT CAUSE, DEFECTIVE PART. ADAPTER IS A TELEDYNE CONTINENTAL MOTORS PART. 1 L 7 2 3O 3 O A7SO E9CE 1997092500266 19970925 00266 CE 1997 9 25 97ZZZX4150 1 19970904 G 3231 0024100381 SHAFT BEECH 58 58 1152740 CE NLG FAILED D S A K NONE O OTHER IN INSP/MAINT 1 SW 11 7222V 2599 TH1430 PILOT REPORTED A GROUND OBSERVER INFORMED NLG DOORS REMAINED OPENED AFTER THE GEAR WAS UP. PILOT HEARD NOISES COMING FR OM NOSE AREA DURING RECENT FLIGHTS. INSP REVEALED LOWER PORTION OF CAM PLATE SLOT ON THE SHAFT THAT CLOSES THE NOSE GEA R DOORS BROKE OFF AND BREAK HAD BEEN POLISHED SMOOTH BY CAM PIN INDICATING THE COND HAD EXISTED FOR SOME TIME. THE NOIS E HEARD WAS THE DOORS POPPING BACK OPEN, UNDER SPRING TENSION, AFTER THE CAM SLOT AND SHAFT WERE TAKEN OVER CENTER. A N EW SHAFT ASSY WAS INSTALLED, GEAR DOORS ADJUSTED, AND ACFT RETURNED TO SERVICE. THE PLANE WAS 35 HRS INTO ANNUAL INSPEC TION. RECOMMEND BEECH SB 2601 PERTAINING TO BEECH 33, 35, AND 36 BE APPLIED TO INCLUDE THE BARON SERIES AIRCRAFT. 1 L 7 2 3O 3A16 1997092500268 19970925 00268 CE 1997 9 25 97ZZZX4152 1 19970804 G 5531 1862012 SPAR 186200603 BEECH 18 H18 1151012 CE V-FIN ASSY CRACKED D A K NONE O OTHER IN INSP/MAINT 1 SW 09 954 8654 BA670 INSPECTION FOUND LOWER SECTION OF LEFT VERTICAL FIN HAD SEVERAL CRACKS EMANATING FROM UPPER LIGHTENING HOLE. CRACKS GRE W LARGER WHEN SLIGHT SIDE PRESSURE APPLIED TO VERTICAL FIN. 1 L 7 2 3R A765 1997092500275 19970925 00275 CE 1997 9 25 97ZZZX4156 1 19970909 G 3230 RELEASE CABLE BEECH MU300 400A 1155402 CE LT EMERG MLG EXT FRAYED B P A ERYR K NONE O OTHER IN INSP/MAINT 1 SO 11 39HF 1392 RK65 DURING THE REQUIRED 200-HOUR INSPECTION INTERVAL, FOUND THE LEFT MAIN GEAR EMERGENCY RELEASE CABLE STRANDS BROKEN AT UPL OCK RELEASE CABLE END. SHOULD THIS CABLE BREAK, THE LEFT STRUT WILL NOT EXTEND WHEN EMERGENCY EXTEND LEVER IS ACTUATED. THIS FACILITY HAS FOUND COMPLETELY BROKEN CABLE ENDS ON 2 OTHER 400A AIRCRAFT. 2 H 7 2 4F RT A16SW 1997092500276 19970925 00276 CE 1997 9 25 97ZZZX4157 1 19970825 G 4930 15000022 FUEL PUMP DUKES LEAR 60 60LEAR 5170707 CE APU LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 07 8270 4 0130 60063 APU FUEL PUMP LEAKING. FORWARDED TO DUKE INC., FOR REPAIR/OVERHAUL AND FAILURE REPORT. 2 L 7 2 4F RT A10CE 1997092500277 19970925 00277 CE 1997 9 25 97ZZZX4158 1 19970825 G 4930 15000022 FUEL PUMP DUKES LEAR 60 60LEAR 5170707 CE APU LEAK D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 07 8271 1 0120 60066 APU PUMP IS LEAKING. SENT TO DUKES INC., FOR REPAIR/OVERHAUL. REQUEST FAILURE ANALYSIS AND OVERHAUL. 2 L 7 2 4F RT A10CE 1997092500279 19970925 00279 CE 1997 9 25 97ZZZX4159 1 19970814 G 2121 EMG724 VENT BLOWER BEECH 2000 2000 1152000 CE CABIN FAILED B AKGR H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CE 05 8074S 1092 443 NC33 CREW HAD SMOKE IN THE CABIN IN-FLIGHT. PROBLEM FOUND TO BE COMING FROM THE VENT BLOWER. 1 L 7 2 4T RT A38ACE 1997092500280 19970925 00280 NM 1997 9 25 97ZZZX4160 1 19970913 G 2612 WIRE BOEING 727 727 UTILSYS NM FIRE LOOP LT W/W LOOSE G A J UNSCHED LANDING DUMP FUEL N FALSE WARNING CL CLIMB 1 WP 07 ON DEPARTURE FROM PHX, GOT FIRE WARNING BELL, BUT NO OTHER INDICATION OF A FIRE. DUMPED FUEL AND RETURNED TO PHX, UNEVE NTFUL LANDING. FOUND GROUND WIRE LOOSE ON THE FIRE LOOP IN THE LT WHEELWELL, TIGHTENED WIRE AND FUNCTION TEST NORMAL. 2 L 7 3 4J RT A3WE 1997092500608 19970925 00608 EU 1997 9 25 97ZZZX4161 1 19970711 G 5280 WSBS16ATC32Z BEARING 7229150148 SAAB SF340 SF340A 7850100 EU RT MLG DOOR MIGRATED B AY55 K NONE O OTHER IN INSP/MAINT 1 SO 03 747P 340A029 RIGHT MLG DOOR HYDRO TUBE SUPPORT BRACKET BEARING MIGRATED .3125 INCH OUT OF THE HYDRO TUBE SUPPORT BRACKET ASSEMBLY INB OARD. UPON REPLACEMENT OF SWAGE BEARING, FOUND INBOARD SIDE OF BEARING UNSWAGED CAUSING BEARING TO MIGRATE INWARD. 2 L 7 2 4T RT A52EU 1997100200055 19971002 00055 NE 1997 10 2 97ZZZX4183 2 19970801 G 7230 1B3506 DISK PWA 2037 F117PW100 NE HPC MODULE CRACKED B WA2D K NONE O OTHER IN INSP/MAINT 1 NE 03 857 S69965 PWE170097 ENGINE REMOVED FOR EGT LIMITATION. DISASSEMBLY INSPECTION DETECTED CRACKED BLADE SLOTS ON DISK (6TH STAGE). DISK REMOVE D FROM ROTOR AND FORWARDED TO PRATT & WHITNEY ENGINEERING IN THE BLADED CONDITION. CYCLES: 2,127. 4 T E17NE 1997100200056 19971002 00056 EA 1997 10 2 97ZZZX4184 2 19970825 G 8530 SHROUD TUBE PIPER PA32 PA32260 7103206 SO LYC O540 O540E4B5 41532 EA NR 2 CYLINDER FRACTURED D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 23 4365T 327200019 L1482440 AFTER RUN-UP, OIL FILM NOTED ON LEFT SIDE OF ENGINE. OIL CAME FROM DENT IN PUSH ROD SHROUD TUBE WHICH WAS FOUND COMPLET ELY FRACTURED AT DENT LOCATION. PUSH ROD HAD APPARENTLY RUBBED SHROUD AND CAUSED THE FRACTURE. DENT WAS ABOUT .0937 IN CH DEEP. OTHER SHROUD TUBES HAD MINOR DENTS APPARENTLY LONG-STANDING. 1100 HRS SMOH/POTENTIAL FOR EXCITING MOMENTS IF NOT CORRECTED. 1 L 7 1 3O 3 O A3SO E295 1997100200057 19971002 00057 EA 1997 10 2 97ZZZX4185 2 19970825 G 8550 71737 DRAIN TUBE PIPER PA32 PA32260 7103206 SO LYC O540 O540E4B5 41532 EA NR 2 ROCKER CHAFED D K NONE O OTHER IN INSP/MAINT 1 EA 01 4365T 327200019 L1482440 NR 2 CYLINDER 71737 ROCKER DRAIN TUBE CHAFED THROUGH ABOUT 90 PERCENT OF WALL THICKNESS BY BOTTLE RETAINER (PIN EASILY P ENETRATED 'PAPER-THIN' WALL') 68761 TUBES (3 OF EACH) HAD SUBSTANTIAL WEAR MARKS, AGAIN, TRIM BOTTLE RETAINER. NOTE: TY WRAPS ARE NOT A GOOD SUBSTITUTE FOR ADEL CLAMPS. 1 L 7 1 3O 3 O A3SO E295 1997100200058 19971002 00058 EA 1997 10 2 97ZZZX4186 2 19970825 G 8550 68761 DRAIN TUBE PIPER PA32 PA32260 7103206 SO LYC O540 O540E4B5 41532 EA NR 2 CYLINDER CHAFED D K NONE O OTHER IN INSP/MAINT 1 EA 01 4365T 327200019 L1482440 NR 2 CYLINDER 71737 ROCKER DRAIN TUBE CHAFED THROUGH ABOUT 90 PERCENT OF WALL THICKNESS BY BOTTLE RETAINER (PIN EASILY P ENETRATED 'PAPER-THIN' WALL') 68761 TUBES (3 OF EACH) HAD SUBSTANTIAL WEAR MARKS, AGAIN, TRIM BOTTLE RETAINER. NOTE: TY WRAPS ARE NOT A GOOD SUBSTITUTE FOR ADEL CLAMPS. 1 L 7 1 3O 3 O A3SO E295 1997100200059 19971002 00059 SO 1997 10 2 97ZZZX4187 1 19970825 G 7160 651427 VALVE PIPER PA32 PA32260 7103206 SO LYC O540 O540E4B5 41532 EA CARB AIR BOX SEAL MISSING D K NONE O OTHER IN INSP/MAINT 1 EA 01 4365T 327200019 L1482440 SEALING FELT ON AIR BOX VALVE MISSING FROM OUTER EDGES EXCEPT FOR A 1 INCH SECTION THAT WAS 'HANGING ON'. THE FELT MATER IAL IS SANDWICHED BETWEEN 2 METAL PLATES WITH SOME FELT PROTRUDING TO PROVIDE SEAL. THE PROTRUDING PART WAS ALMOST ALL MISSING. THE POTENTIAL DANGER COULD BLOCK OR RESTRICT FUEL FLOW IF LODGED ACROSS VENTURI. IN THIS INSTANCE, MOST MATER IAL WAS GONE, SO NO PROBLEM EXCEPT FOR SEALING. 1 L 7 1 3O 3 O A3SO E295 1997100200060 19971002 00060 SO 1997 10 2 97ZZZX4188 1 19970312 G 3230 9582900 LINK ASSY PIPER PA34 PA34200 7103405 SO NLG DOWNLOCK ROD END FAILED D A O OTHER O OTHER LD LANDING 1 WP 01 4484T 347250110 P/N 452334 BEARING. ROD END WHICH IS PART OF LINK ASSY, NLG DOWNLOCK, FAILED BY BENDING AND PARTING IN THREADED PORTION . NLG COLLAPSED ON LANDING ROLL-OUT. WHEN BENT, NLG DRAG BRACE WILL NOT BE OVERCENTER, BUT A DOWN AND LOCKED GREEN LIG HT WILL BE ON. THIS IS DUE TO DESIGN OF SYSTEM. 1 L 7 2 3O A7SO 1997100200061 19971002 00061 EU 1997 10 2 97ZZZX4189 2 19970905 G 7314 996592 PUMP ROTAX DIAMON DA20A1 DA20A1 05626UX GL ROTAX 912 ROTAX912 55555 EU ENGINE LINE CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 GL 21 545SS 299 10118 ENGINE DRIVEN FUEL PUMP LINE CRACKED AT PUMP WALL RESULTING IN FUEL DRIPPING INTO LOWER COWL AREA. CRACK IS AT BEND IN LINE WHERE IT MEETS PUMP. APPEARS LINE WAS BENT TO FACILITATE ROUTING. INSTALLED NEW PUMP. 1 L 7 1 3O 3 I NT TA4CH EXPE3I 1997100200062 19971002 00062 CE 1997 10 2 97ZZZX4190 1 19970909 G 3213 22411001 AXLE FITTING CESSNA 172 172RG 2072438 CE RT MLG CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 07 5316R 5211 172RG0053 CASTING CRACKED IN TWO LOCATIONS. CRACKS WERE LOCATED AT 90 DEGREES TO THE BOLT HOLES, AND PARALLEL TO THE BORE DIAMETE R. ONE CRACK APPROXIMATELY 2.500 INCHES LONG WAS LOCATED IN THE WEB SECTION ABOVE THE BOLT HOLES. SECOND CRACK LOCATED IN THE LOWER WEB SECTION BELOW THE BOLT HOLES AND APPROXIMATELY 1.500 INCHES LONG. CRACKS WERE NOT DEEP ENOUGH IN DEPT H TO INTERSECT THE BOLT HOLES. 1 H 7 1 3O 3A17 1997100200063 19971002 00063 SW 1997 10 2 97ZZZX4191 1 19970815 G 3260 ISE13 SWITCH GULSTM 112 112 0144701 SW NLG MISADJUSTED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 17 1195J 195 FOUND NOSE GEAR MICROSWITCH INSTALLED TO FULL FORWARD LIMIT ON MOUNTING BRACKET. BRACKET MOUNTED ON ENGINE MOUNT WITH H OSE CLAMPS. FOUND BRACKET INSTALLED TOO FAR AFT. THIS PREVENTED PROPER ADJUSTMENT OF MICROSWITCH WHICH WAS MAKING CONT ACT WITH PAINTED SURFACE ON TOP OF NOSE GEAR. ADJUSTED BRACKET AND MICROSWITCH TO PROPER LOCATION. NO INFORMATION ON B RACKET ADJUSTMENT IN MM. BRACKET NOT SHOWN IN PARTS MANUAL. 1 L 7 1 3O A12SO 1997100200064 19971002 00064 EU 1997 10 2 97ZZZX4192 1 19970905 G 5610 CANOPY GROB 103TWN G103ATWINII 1660206 EU COCKPIT OPENED C A K NONE O OTHER CL CLIMB 1 EA 11 47938 1400 3841K87 BOUNCING ON TAKEOFF ROLL AND TURBULENCE ON TOW CAUSED CANOPY LOCK HANDLE TO UNLOCK AND CANOPY OPENED IN-FLIGHT BREAKING THE REAR HINGE AND GLASS. IT DID NOT BREAK LOOSE FROM THE GLIDER. RECOMMEND OVERCENTER TYPE LOCK SPRING TO HOLD LATCH CLOSED. 1 K 0 0 3O 0 G39EU 1997100200065 19971002 00065 WP 1997 10 2 97ZZZX4193 1 19970728 G 2622 893244 EXTINGUISHER KIDDE DOUG DC8 DC8* WP FIRE BOTTLE INOPERABLE B A C6RR K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 23 73155DB FIRE EXTINGUISHER WAS RECEIVED INTO SHOP AS CONDITION UNKNOWN, NO TAG. UPON DISASSEMBLY, THE FOLLOWING DISCREPANCIES WE RE NOTED RENDERING UNIT INOPERABLE. AGENT REMOVED NOT HALON 1301 AS SPECIFIED. ADDITIONAL COPPER DISK INSTALLED UNDER RUPTURED DISK, NOT O.E.M. RUPTURED DISK NOT RECOGNIZED AS APPROVED PART. GAUGE READS 'O' PSI. FAA NOTE: PART ORIGINA TED OUTSIDE U.S. 2 L 7 4 4J F 4A25 1997100200066 19971002 00066 WP 1997 10 2 97ZZZX4194 1 19970728 G 2622 893244 EXTINGUISHER KIDDE DOUG DC8 DC8* WP FIRE BOTTLE INOPERATIVE B A C6RR K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 23 17409DW FIRE EXTINGUISHER WAS RECEIVED INTO SHOP AS CONDITION UNKNOWN. NO TAG. UPON DISASSEMBLY, THE FOLLOWING DISCREPANCIES W ERE NOTED, RENDERING UNIT INOPERATIVE. AGENT REMOVED NOT HALCON 1301 AS SPECIFICED. ADDITIONAL DISK INSTALLED UNDER RU PTURED DISK, NOT O.E.M. RUPTURED DISK NOT RECOGNIZED AS APPROVED PART. FAA NOTE: PART ORIGINATED OUTSIDE U.S. 2 L 7 4 4J F 4A25 1997100200067 19971002 00067 WP 1997 10 2 97ZZZX4195 1 19970728 G 2622 893244 EXTINGUISHER KIDDE DOUG DC8 DC8* WP FIRE BOTTLE INOPERATIVE B A C6RR K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 23 25701DH FIRE EXTINGUISHER WAS RECEIVED INTO SHOP AS CONDITION UNKNOWN. NO TAG. UPON DISASSEMBLY, THE FOLLOWING DISCREPANCIES W ERE NOTED, RENDERING UNIT INOPERATIVE. AGENT REMOVED NOT HALON 1301 AS SPECIFIED. ONLY TRACE OF AGENT IN CONTAINER. G AUGE READING 100 PSI. FAA NOTE: PART ORIGINATED OUTSIDE U.S. 2 L 7 4 4J F 4A25 1997100200068 19971002 00068 WP 1997 10 2 97ZZZX4196 1 19970728 G 2622 893244 EXTINGUISHER KIDDE DOUG DC8 DC8* WP FIRE BOTTLE INOPERATIVE B A C6RR K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 23 18112C4 FIRE EXTINGUISHER WAS RECEIVED INTO SHOP AS CONDITION UNKNOWN. NO TAG. UPON DISASSEMBLY, THE FOLLOWING DISCREPANCIES W ERE NOTED, RENDERING UNIT INOPERATIVE. AGENT REMOVED NOT HALON 1301 AS SPECIFIED. ADDITIONAL COPPER DISK INSTALLED UND ER SAFETY PLUG. (PLUG IN BLOWN CONDITION). RUPTURED DISK NOT RECOGNIZED AS APPROVED PART. GAUGE READS 'O' PSI. FAA N OTE: PART ORIGINATED OUTSIDE U.S. 2 L 7 4 4J F 4A25 1997100200070 19971002 00070 WP 1997 10 2 97ZZZX4198 1 19970905 G 7110 5162658 COWLING DOUG DC4 C54BDC 3021516 WP NR 2 ENG LT TORN D L A K NONE O OTHER NR NOT REPORTED 1 AL 01 44911 10461 LOWER PORTION OF COWLING MOVED INTO PROPELLER. COWLING ALIGNMENT PIN MAY HAVE MOVED OUT OF ITS SLOT WHEN THE LEFT HAND COWL WAS REMOVED THEN REINSTALLED. THIS WOULD LET THE WHOLE COWL ASSEMBLY ROTATE. IF THE COWL ASSEMBLY ROTATES APROXIM ATELY 2 TO 3 INCHES, IT WILL LEAVE ITS ALIGNMENT LUGS AND BECOME LOOSE. THIS IS WHAT IS BELIEVED TO HAVE HAPPENED DUE T O THE RUB MARKS ON THE COWL AND EXPERIMENTS ON THE AIRCRAFT. DOUGLAS SB DC-4 NR 46 HAD NOT BEEN C/W IN THIS APPLICATION . DOUGLAS SB DC-4 NR 46 IS BEING C/W ON THE ENTIRE FLEET. 2 L 7 4 4R A762 1997100200072 19971002 00072 CE 1997 10 2 97ZZZX4200 1 19970801 G 3510 101380491 HOSE BEECH 200 B200 1152922 CE OXYGEN SYSTEM SPLIT H K NONE O OTHER IN INSP/MAINT 1 NM 11 8093W 1861 BB1396 OXYGEN HOSE IN LEFT HEADLINER AFT OF COCKPIT 'D' WINDOW WAS FOUND SPLIT WHEN SYSTEM WAS ACTIVATED. HOSE IS A SHORT FLEX IBLE HOSE THAT IS VERY TWISTED WHEN INSTALLED. RECOMMEND A REPLACEMENT OF SHORTER OXYGEN HOSE FOR THIS AREA. 1 L 7 2 4T A24CE 1997100200073 19971002 00073 WP 1997 10 2 97ZZZX4201 2 19970913 G 7261 30719499 REGULATOR AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE731* 01518 WP OIL PUMP MALFUNCTION D E ENGINE SHUTDOWN O OTHER CL CLIMB 1 SW 99 97LT 1298 614057316 202 DURING CLIMB THROUGH 18,000 FEET, OIL PRESSURE INCREASED TO 58 PSI, JUST BELOW RED LINE. AFTER 30 MINUTES WITH OIL PRES SURE FLUCTUATING AND DROPPING TO 25 PSI, CREW SHUT ENGINE DOWN. SUSPECT CAUSE STICKING OR FAILED OIL PUMP REGULATOR. E NGINE TT: 3,641 HOURS. CSN: 2,204. 2 L 7 3 4F 4 F A46EU E6WE 1997100200074 19971002 00074 SO 1997 10 2 97ZZZX4202 1 19970801 G 5711 SPAR CAPSTRIP LUSCOM 8 8A 8190104 SO WING SEPARATED D K NONE O OTHER IN INSP/MAINT 1 SW 99 AS REQUIRED, CONDUCTED THE WING INSPECTION ON LUSCOMBE METAL WING IAW APPENDIX TO FAA AD96-24-17. FOUND NO INTERGRANULA R CORROSION. DID FIND SOME LOOSE INSULATION AND URINE STAINS WHICH WAS EASILY REMOVED WITH COAT HANGERS AND BY SPRAYING OUT THE WING WITH A HOSE. WHILE LIFTING THE WING TO INSPECT THROUGH THE STRUT HOLE AND AT THE INBOARD ROOT AREA HEARD A 'POP' IN THE WING THAT WAS NOT EXPECTED, THOUGHT IT MIGHT BE OIL CANNING OF THE SKINS IN THE WING TOP. LATER INSPECTI ON FOUND THE CABIN ROOF SKIN HAD BEEN DEFORMED AT THE WING ROOT, AND THAT THE REAR SPAR CAPSTRIP HAD SEPARATED FROM THE SPAR WEB AT THE WING ATTACHMENT FITTING. THE CRACK IS .75 INCH LONG. 1 H 7 1 3O A694 1997100200075 19971002 00075 SO 1997 10 2 97ZZZX4203 1 19970829 G 2510 79536000 FRAME ASSY PIPER PA28 PA28140 7102802 SO COCKPIT BROKEN H A K NONE O OTHER IN INSP/MAINT 1 EA 11 2269Q 4775 287725189 WHILE REPLACING SEAT COVERING, FOUND SEAT FRAME TUBING BROKEN AND SEPARATED AT BOTH LEFT AND RIGHT FRONT POINTS WHERE SE AT FRAME IS WELDED TO VERTICAL SUPPORT THAT CONTAINS SEAT TRACK CLAMP. THIS SEAT HAS BEEN IN SERVICE FOR 20 YEARS. SUS PECT CAUSE: THE STRESS OF MANY LANDINGS AND TAKEOFFS AND LOTS OF PUSHING ON THE SEAT BACK BY USERS. 1 L 7 1 3O 2A13 1997100200076 19971002 00076 SO 1997 10 2 97ZZZX4204 2 19970909 G 7414 36066 DRIVE GEAR SLICK 4201 CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO RT MAG TEETH STRIPPED D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 WP 05 11308 98 90020099 15075317 251159 RUN-UP AT 1,700 RPM AT PROP OF 300 RPM ON THE RT MAG WAS NOTICED, LT MAG AT 1,800-1,900 RPM. ENGINE STARTED TO BACKFIRE WHILE RUNNING ON THE RT MAG. DECIDED NOT TO TAKE OFF, BROUGHT THE AIRPLANE OVER TO MAINTENANCE. RT MAG REMOVED AND MA G DRIVE GEAR HAD 3 TEETH MISSING. ENGINE WAS REMOVED. ENGINE HAD 98 HOURS ON TACHOMETER SINCE MAJOR OVERHAUL. 1 H 7 1 3O 3 O 3A19 E252 1997100200077 19971002 00077 SO 1997 10 2 97ZZZX4205 1 19970801 G 3233 21151 ACTUATOR WIEBEL PIPER PA31 PA31P350 7103111 SO MLG FAULTY D K NONE O OTHER NR NOT REPORTED 1 NM 03 237MA 2961 31P8414037 PILOT REPORTED INDICATION OF UNWANTED LANDING GEAR EXTENSION. AFTER TROUBLESHOOTING HYDRAULIC SYSTEM, FOUND RT MAIN ACT UATOR O-RING AND SCRAPER SEAL ARE OLD. TEST FLIGHT OK, NO PROBLEM. 1 L 7 2 3O RT A8EA 1997100200078 19971002 00078 EA 1997 10 2 97ZZZX4206 2 19970909 G 8520 81619401 BEARING PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA ENGINE FLAKED B EIRR K NONE O OTHER IN INSP/MAINT 1 GL 25 252MA 32 31P33 RL37262 ENGINE REMOVED AFTER FINDING BEARING MATERIAL IN OIL SCREEN. DISASSEMBLED, FOUND ABOUT 1.5 SQUARE INCHES OF MATERIAL FL AKED OFF OF BEARING. SUSPECT POOR BOND TO BEARING. 1 L 7 2 3O 3 O A8EA E19EA 1997100200079 19971002 00079 SO 1997 10 2 97ZZZX4207 2 19970801 G 7320 630119 FITTING 6405636A1 PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360* 17025 SO LT ENGINE BROKEN B S A VIB3 O OTHER K Y FLUID LOSS ENGINE STOPPAGE CR CRUISE 1 SO 03 34ME 347870045 FITTING BROKE IN THREADS WHERE THEY SCREW INTO THROTTLE CONTROL. ENGINE QUIT IN FLIGHT. CONTINUED FLIGHT ON OTHER ENGI NE TO BNA. PILOT SAW FUEL COMING FROM COWLING AFTER ENGINE QUIT. REMOVED AND REPLACED BROKEN FITTINGS. LEAK AND OPS C HECK OK. FITTING APPEARED DAMAGED BY PREVIOUS REMOVAL ATTEMPT. THIS AREA IS MISTAKEN FOR HAVING A SCREEN TO INSPECT, B UT NO SCREEN IS INSTALLED. 1 L 7 2 3O 3 O A7SO E9CE 1997100200080 19971002 00080 SO 1997 10 2 97ZZZX4208 1 19970909 G 5321 FLOOR PANEL PIPER PA23 PA23250 7102308 SO BAG COMPT DAMAGED D S K NONE O OTHER IN INSP/MAINT 1 CE 09 40599 7586 277405345 REAR BAGGAGE FLOOR DAMAGED FROM ABUSE LOADING FREIGHT. 1 L 7 2 3O 1A10 1997100200081 19971002 00081 NE 1997 10 2 97ZZZX4209 2 19970911 G 7414 1068256011 MAGNETO BENDIX D6LN3000 MAULE M6 M6235 5460160 SO LYC O540 IO540W1A5 41532 NE ENGINE CASE CRACKED D K NONE O OTHER IN INSP/MAINT 1 AL 05 56464 3158 388 4678 7416C L2187448A MAGNETO CASE BROKEN AT TOP HOLD-DOWN LOCATION. DISCREPANCY DISCOVERED DURING 100-HOUR INSPECTION. 1 H 7 1 3O 3 O 3A23 1E4 1997100200082 19971002 00082 GL 1997 10 2 97ZZZX4210 3 19970731 G 6114 HUB CESSNA 150 152 2071835 CE MCAULY 1A103 1A103TCM GL SPINNER CHAFED B L DINR K NONE O OTHER IN INSP/MAINT 1 EA 17 67510 44 15281879 RB003 REPLACED PROPELLER DUE TO FAILED AD 97-06-16. NEW PROPELLER HAS A LARGER HUB AND THERE IS INTERFERENCE WITH PROPELLER S PINNER. 1 H 7 1 3O NT 3A19 5 N P50GL 1997100200084 19971002 00084 EA 1997 10 2 97ZZZX4212 2 19970801 G 8530 7510 COVER PLATE MOONEY M20 M20F 5870214 SW LYC O360 IO360A1A 41514 EA NR 1 INTAKE DISPLACED G A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 EA 07 9595M 75 670172 L391451A ENGINE BEGAN TO RUN ROUGH IN FLIGHT, PRECAUTIONARY LANDING. FOUND INTAKE ROCKER SHAFT ON NR 1 CYLINDER HAD MOVED OUT OF POSITION DUE TO LOSS OF COVER PLATE, 7510. CAUSE OF COVER PLATE LOSS UNDETERMINED. SUBMITTER RECOMMENDS PERIODICAL RE -CHECK OF COVER PLATE NUT TORQUE. 1 L 7 1 3O 3 O 2A3 1E10 1997100200085 19971002 00085 EU 1997 10 2 97ZZZX4213 1 19970905 G 6220 704A33633156 STOP BEARING SNIAS 350 AS350B 8680801 EU BLUE BLADE FAILED H A UNSCHED LANDING E VIBRATION/BUFFET NR NOT REPORTED 1 WP 13 4AK 2193 2544 PILOT REPORTS VERTICAL VIBRATION AND RETURNED TO BASE. INSPECTION REVEALED 'BLUE' M/R SPHERICAL STOP BEARING, P/N 204A3 3-633 156, FAILED. REPLACED ALL THREE M/R SPHERICAL STOPS WITH P/N 704A33633-109. RUN-UP OPS CHECK GOOD. 1 G 7 1 3U H9EU 1997100200086 19971002 00086 EU 1997 10 2 97ZZZX4214 1 19970915 G 2913 5026780 PUMP SNIAS 350 AS350BA 8680817 EU HYDRAULIC SYSTEM WORN SPLINE D A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 WP 13 599BK 5640 20221913 2735 DURING IN-FLIGHT, HYDRAULIC LIGHT ILLUMINATED AND HYDRAULIC HORN CAME ON. PILOT MADE A PRECAUTIONARY LANDING AT AIRPORT TERMINAL. INSPECTED HYDRAULIC PUMP AND FOUND WORN SPLICE. REMOVED HYDRAULIC PUMP ASSY AND INSTALLED SERVICEABLE HYDRA ULIC PUMP ASSY. 1 G 7 1 3U NC H9EU 1997100200087 19971002 00087 EA 1997 10 2 97ZZZX4215 2 19970815 G 8530 PISTON PIN HELIO H295 H295 4300802 CE LYC O480 GO480G1D6 41527 EA CYLINDER NR 5 BROKEN D K NONE O OTHER IN INSP/MAINT 1 SO 33 2FOR 499 17328 1244 L33937 OPERATORS WERE NOTIFIED AIRCRAFT'S ENGINE CONTAINED A PISTON PIN FROM THE BATCH LISTED IN LYC SB 527C. AIRCRAFT WAS REM OVED FROM SERVICE AND ALL CYLINDERS REMOVED TO VISUALLY INSPECT FOR BATCH NR 17328. CYLINDER NR 5 REVEALED BROKEN PIN. NUMERS WERE NOT CLEARLY VISIBLE, SO ALL PINS WERE CHANGED WITH NEW PINS DIRECT FROM LYCOMING. 1 H 7 1 3O 3 O 1A8 E275 1997100200088 19971002 00088 CE 1997 10 2 97ZZZX4216 1 19970131 G 4920 COMPRESSOR SUNDSTRANDEM T62T404 RKWELL NA265 NA26565 7630107 CE APU BLADE FAILED D A K NONE O OTHER IN INSP/MAINT 1 SO 03 920DY 296 795508 46550 PILOTS REPORTED THE APU WAS MAKING A HIGH PITCHED UNUSUAL NOISE. INSPECTION REVEALED A PIECE OF ONE COMPRESSOR BLADE HA D BROKEN AND STRUCK SEVERAL OTHER BLADES. NO OTHER DAMAGE NOTED AT THIS TIME. APU IS BEING SENT TO A REPAIR FACILITY F OR FURTHER EVALUATION. CYCLES, 1,146. 2 L 7 2 4J A2WE 1997100200089 19971002 00089 NE 1997 10 2 97ZZZX4217 2 19970813 G 7530 10138002521 VALVE PARKER BEECH B300 B300 1159232 CE PWA PT6 PT6A60 52043 NE NR 1 ENG BLEED BROKEN D K NONE O OTHER IN INSP/MAINT 1 NM 01 4S 12AJ36 FL107 DISCOVERED ON POST-FLIGHT INSPECTION, NR 1 ENGINE BLEED AIR FLOW CONTROL VALVE HAS A BROKEN CONTROL LINKAGE ARM. APPEAR S LIKE BALL SOCKET WORN OUT. REPLACED BLEED AIR CONTROL VALVE ASSEMBLY WITH NEW UNIT OBTAINED FROM BEECH. 2 L 7 2 4T 4 T RT A24CE E4EA 1997100900099 19971009 00099 GL 1997 10 9 97ZZZX4247 1 19970916 G 2810 VENT AMTR RANS RANSS7 0561265 GL FUEL TANK PLUGGED D A A UNSCHED LANDING Y ENGINE STOPPAGE AP APPROACH 1 SW 99 8251B 1194142 ON APPROACH, THE ENGINE QUIT CAUSING THE PILOT TO LAND SHORT OF RUNWAY. THE AIRCRAFT RECEIVED DAMAGE TO THE LT MLG, PROP ELLER, AND RT WING. INVESTIGATION REVEALED THE LT FUEL TANK WAS EMPTY AND THE RT TANK WAS NEARLY FULL. THE CARBURETOR B OWLS WERE EMPTY. BY BACK-BLOWING FROM THE FUEL PUMP LINE, THE RT FUEL TANK WAS PRESSURIZED. UNABLE TO BLOW BACK THROU GH VENT. BUILDER STATED WHEN INSTALLING VENT, HE FOUND IT TO BE BLOCKED AND HAD TO BE RE-DRILLED. PROBLEM COULD BE WIT H VENT AS RECEIVED OR MAY HAVE BECOME PLUGGED DURING INSTALLATION. SUGGEST VENT SYSTEM BE TESTED FOR PROPER OPERATION. 1 H 7 1 3I NC EXPA1H71 1997100900100 19971009 00100 SO 1997 10 9 97ZZZX4248 2 19970917 G 8530 637837 SPRING CESSNA 310 T310R 2074246 CE CONT O520 TSIO520B 17040 SO NR 3 CYL EXH VLV BROKEN D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 GL 21 180 176718R ENGINE RUNNING ROUGH. EXHAUST VALVE LEAKING ON COMPRESSION TEST. FOUND OUTER SPRING BROKEN 180 HOURS S.F.R. 1 L 7 2 3O 3 O 3A10 E8CE 1997100900101 19971009 00101 GL 1997 10 9 97ZZZX4249 1 19970923 G 3213 GEAR LEG AMTR KITFOX KITFOX 05613LZ GL LT MLG FAILED D S A O OTHER O OTHER TX TAXI/GRND HDL 1 WP 01 102KM 178 1702 AFTER AIRCRAFT LANDED ON RUNWAY AND PROCEEDED TO THE TAXIWAY. THE LEFT LANDING GEAR FAILED AT WELD AREA. 1 H 7 1 3I NC EXPA1H71 1997100900102 19971009 00102 CE 1997 10 9 97ZZZX4250 1 19970908 G 5711 NAS464P5 BOLTS BEECH 76 76 1153005 CE WING CENTER LOOSE D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 21 2009X 1486 ME66 DURING 100-HOUR INSPECTION, THE CENTER SECTION WING BOLTS THAT ATTACH THE LOWER WING SPAR PLATE TO THE WING SPAR (I.E., 20 WING BOLTS) WERE ALL FOUND UNDERTORQUED BY ONE-HALF TO ONE FULL TURN. THE NAS464P5 BOLTS SHOULD BE TORQUED 100-140 I NCH/POUND. 1 L 7 2 3O A29CE 1997100900104 19971009 00104 CE 1997 10 9 97ZZZX4252 1 19970729 G 2460 M0012 J BOX LAMAR CESSNA 172 172RG 2072438 CE FIRE WALL FAILED D O OTHER H B ELECT. POWER LOSS-50 PC SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 WP 07 360ES 266 80075612 17280010 IN-FLIGHT ELECTRIAL FAILURE OF ALL ELECTRICAL EQUIPMENT BEING SERVICED BY BUS NR 1. PILOT COMMENTED SPARKS COMING FROM UNDERNEATH INSTRUMENT PANEL. NO BREAKERS TRIPPED. FOUND WIRE BUNDLE RESTING ON CIRCUIT BREAKER. WIRE BURNED OUT LAYIN G ACROSS WARNING BREAKER (WIRE NR BP1307) MECHANICALLY INSTALLED LUG CONNECTORS TO BUS NR 1, BUS NR 2, BUT SPLICE ABOVE WIRE. 1 H 7 1 3O 3A17 1997100900105 19971009 00105 1997 10 9 97ZZZX4253 4 19970821 G 6122 34828014 GOVERNOR SIGMATEK MOONEY M20 M20C 5870208 SW PROPELLER FAULTY D A O OTHER O OTHER CR CRUISE 1 GL 19 3984N 1633 300 680012 INSTALLED 3-BLADE PROPELLER IAW STC SA 4529NM. STC MAKES NO MENTION OF PROPELLER GOVERNOR. AFTER 3 HOURS OF OPERATION, PROPELLER BEGAN SURGING 100-200 RPM FROM 2,400 RPM. AFTER NUMEROUS TESTS, DETERMINED THE EDO AIRE (GARWIN) PROPELLER G OVERNOR CANNOT SUPPLY THE VOLUME OF OIL REQUIRED BY THIS PROPELLER. REMOVED THIS PROPELLER AND RETURNED TO THE ORIGINAL 2-BLADE HC-C2YK-1BF/F7666A PROPELLER. OPERATES NORMALLY AFTER 8 HOURS. 1 L 7 1 3O 2A3 1997100900107 19971009 00107 CE 1997 10 9 97ZZZX4255 1 19970918 G 2750 500000863CR CONTROL CABLE CESSNA 414 414A 2075907 CE RT FLAP BROKEN B DBCR O OTHER F FLT CONT AFFECTED AP APPROACH 1 GL 13 444BC 414A0340 PILOT REPORTED LOUD BANG WHEN FLAPS SELECTED DOWN. LEFT FLAP JAMMED AND RIGHT FLAP WAS UNCONTROLLABLE. PILOT MANAGED A SAFE LANDING. INSPECTION REVEALED THE RIGHT FLAP EXTEND CABLE HAD BROKEN WHERE THE CABLE WRAPS AROUND THE FIRST SET OF PULLEYS OUTBOARD OF THE ACTUATOR. ALSO, THE TURNBUCKLE AND CABLE TERMINAL ENDS JAMMED THE ACTUATOR RENDERING IT INOPER ABLE. THE AREA WHERE THE CABLE SEPARATED IS VERY DIFFICULT TO ACCESS. 1 L 7 2 3O A7CE 1997101500003 19971015 00003 NE 1997 10 15 97ZZZX4256 2 19970824 G 7320 3057T20P02 HARNESS AMD FALC50 FALCON2000 2730170 NM CFE CFE73811B NE LT ENG FADEC CHAFED H K NONE O OTHER IN INSP/MAINT 1 EA 11 790Z 584 31 105125 FADEC WIRING HARNESS CHAFED WHERE IT PASSES THROUGH CLAMP. SUBMITTER STATED CLAMP NEEDS CUSHION TO PREVENT WIRE FROM BE ING DAMAGED. 2 K 7 3 4F 4 F RT A50NM E44NE 1997100900108 19971009 00108 NM 1997 10 9 97ZZZX4257 1 19970919 G 5711 41513102 SPAR CAP UNIVAR 415 415E 0420308 NM RT WING CORRODED D P A K NONE O OTHER IN INSP/MAINT 1 GL 19 94827 2361 4941 SEVERE CORROSION ON LOWER CENTER SECTION SPAR CAP. CORROSION WAS FOUND AFTER RT WING WAS REMOVED FOR REPAIR DURING ANNU AL INSPECTION. CORROSION CANNOT BE DETECTED WITH WING INSTALLED. SUBMITTER RECOMMENDED PANEL BE INSTALLED ON BOTTOM SK IN PANEL TO CHECK FOR CORROSION. 1 L 7 1 3O A787 1997100900109 19971009 00109 NE 1997 10 9 97ZZZX4258 1 19970918 G 2120 HOSE CONAER LA4 LA4200 5110310 NE ALTERNATOR OMITTED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 15 9WA 520 THE 2-6050-27 HOSE CONNECTS THE ALTERNATOR COOLING PORT TO THE FLEXIBLE DUCT (SCAT HOSE) THAT BRINGS AIR FROM ABOVE ENGI NE TO THE ALTERNATOR. THIS NON-CONDUCTIVE HOSE HAD BEEN OMITTED (AFTER ENGINE CHANGE) WHICH ALLOWED THE WIRE IN THE FLE X DUCT TO CHAFE ON AND MAKE CONTACT WITH THE ALTERNATOR FIELD TERMINAL CAUSING ALTERNATOR/REGULATOR FAILURE. 1 H 7 1 3O 1A13 1997100900110 19971009 00110 1997 10 9 97ZZZX4259 4 19970921 G 2561 KSD35 LIFE VEST EAAEROMARINE CELL FAIL TEST B KQ1R K NONE L NO TEST IN INSP/MAINT 1 EA 07 F99068 LIFE VEST FAILED 2-POUND PSI TEST. 1997100900111 19971009 00111 1997 10 9 97ZZZX4260 1 19970901 G 2432 BTCA520 BATTERY MARATHON CELL ASSY DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 SW 99 FOUND EXCESSIVE FOAMING OF CELLS. EXCESSIVE SALTS ON TOP/BOTTOM OF BATTERY CAN ASSY. ONE CELL HAD HOLE THROUGH PLASTIC CASING. 1997100900112 19971009 00112 GL 1997 10 9 97ZZZX4261 1 19970911 G 5312 BONDING DIAMON DA20A1 DA20A1 05626UX GL TAILCONE BLKHD CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 11 332CH 904 10032 DURING A PRE-PURCHASE INSPECTION, A CRACK WAS NOTICED IN THE BONDING PASTE (THICKENED RESIN) ATTACHING THE AFT BULKHEAD TO THE TAIL CONE AT THE LOWER LEFT CORNER. THE CRACK IS 2.25 INCHES LONG. THE MANUFACTURER STATED THIS TYPE OF CRACK O CCURS FROM STRIKING THE TAIL ON THE GROUND (OVER ROTATING) ON TAKEOFF. SUBMITTER RECOMMENDED INSTALLING A SHOCK ABSORBI NG MATERIAL ONTO THE TAIL SKID IN PLACE OF THE NYLON ABRASION STRIP. 1 L 7 1 3O NT TA4CH 1997100900113 19971009 00113 EA 1997 10 9 97ZZZX4262 2 19970919 G 7322 HA6 CARBURETOR FACET CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA MIXTURE STOP WORN D K NONE O OTHER IN INSP/MAINT 1 CE 03 4975V DL41158 172RG0440 FULL THROTTLE STOP WORN CAUSING A LEAN MIXTURE. WHEN THE PART IS FULL RICH WITH THE SCREW TYPE MIX CONTROL, PRESSURE IS PUT ON THE FULL RICH STOP. STOP IS BEHIND A COVER PLATE WHICH HAMPERS VISABILITY. WEAR CAUSES THE METER HOLE ON MIXTU RE TO OVER-CENTER CAUSING A MORE LEAN MIXTURE. 1 H 7 1 3O 3 O 3A17 E286 1997100900114 19971009 00114 CE 1997 10 9 97ZZZX4263 1 19970801 G 3260 MOUNT PIPER PA24 PA24180 7102402 CE GEAR WARN SWITCH DISPLACED D O OTHER P NO WARNING INDICATION LD LANDING 1 SW 17 7667P 3121 242880 AIRCRAFT WAS LANDED GEAR-UP ON GRASS RUNWAY. PILOT STATED HE HEARD NO WARNING HORN. WHEN LIFTED AIRCRAFT TO LOWER GEAR , HORN CHECKED INOPERABLE. CLOSER LOOK SHOWED THE SWITCH MOUNT ON THROTTLE HAD BEEN PUSHED AWAY FROM A SHAFT NOT ALLOWI NG SWITCH TO OPERATE. ALSO, SWITCH WAS ADJUSTED TO MAXIMUM POSITION AWAY FROM THROTTLE ROD. THE SWITCH MOUNT LOOKED LI KE IT WAS MOVED FROM CONTACT WITH WIRE BUNDLE ROUTED ABOVE SWITCH. RECOMMEND CHECK CLEARANCE BETWEEN SWITCH MOUNT AND A NYTHING ROUTED NEARBY. 1 L 7 1 3O NT 1A15 1997100900116 19971009 00116 EA 1997 10 9 97ZZZX4265 2 19970919 G 8530 60828 PIN PLUG PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA PISTON FAILED G K NONE O OTHER IN INSP/MAINT 1 NE 03 9083D 288690050 L3125536A PISTON PIN PLUG FAILURE DUE TO PISTON PIN MIGRATION FORCING THE PLUG TO THE BARREL WALL. UPON ZERO COMPRESSION CHECK, R EMOVED CYLINDER AND PLUG WAS FOUND IN A SMALL BALL RIDING WITHIN THE PISTON PIN. BOTH COMPRESSION RINGS AND OIL CONTROL RING DAMAGED ALONG WITH CAM AND CAM FOLLOWER. 1 L 7 1 3O 3 O 2A13 E286 1997100900117 19971009 00117 SO 1997 10 9 97ZZZX4266 2 19970902 G 7322 MA45 CARBURETOR CESSNA 182 182P 2075816 CE CONT O470 O470R 17026 SO SERIAL NUMBER NOT MARKED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 23 952CC CL02472 18263638 CARBURETORS BEING PRODUCED BY PRECISION AIRMOTIVE ARE NOT IN C/W MARVEL-SCHEBELER AD 63-22-03. THE LETTER 'V' IS NOT STA MPED UNDER THE SERIAL NUMBER. SUBMITTER STATED REQUIRE PRECISION AIRMOTIVE TO RECERTIFY ALL CARBURETORS THEY HAVE PRODU CED THIS WAY OR REVISE AD 63-22-03 TO REFLECT THE CURRENT MANUFACTURING PROCESS. 1 H 7 1 3O 3 O NT TA13 E273 1997100900162 19971009 00162 SO 1997 10 9 97ZZZX4267 2 19970902 G 7322 MA45 CARBURETOR CESSNA 182 182P 2075816 CE CONT O470 O470R 17026 SO SERIAL NUMBER NOT MARKED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 23 953CC CL02784 18264109 CARBURETORS BEING PRODUCED BY PRECISION AIRMOTIVE ARE NOT IN COMPLIANCE WITH MARVEL-SCHEBELER AD 63-22-03. THE LETTER ' V' IS NOT STAMPED UNDER THE SERIAL NUMBER. SUBMITTER STATED REQUIRE PRECISION AIRMOTIVE TO RECTIFY ALL CARBURETORS THEY HAVE PRODUCED THIS WAY OR REVISE AD 63-22-03 TO REFLECT THE CURRENT MANUFACTURING PROCESS. 1 H 7 1 3O 3 O NT TA13 E273 1997101500005 19971015 00005 SO 1997 10 15 97ZZZX4268 2 19970902 G 7322 MA45 CARBURETOR CESSNA 182 182Q 2072732 CE CONT O470 O470R 17026 SO SERIAL NUMBER NOT MARKED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 23 954CC BD0115 18265290 CARBURETORS BEING PRODUCED BY PRECISION AIRMOTIVE ARE NOT IN COMPLIANCE WITH MARVEL-SCHEBELER AD 63-22-03. THE LETTER ' V' IS NOT STAMPED UNDER THE SERIAL NUMBER. SUBMITTER STATED REQUIRE PRECISION AIRMOTIVE TO RECTIFY ALL THE CARBURETORS THEY HAVE PRODUCED THIS WAY OR REVISE AD 63-22-03 TO REFLECT THE CURRENT MANUFACTURING PROCESS. 1 H 7 1 3O 3 O NT 3A13 E273 1997100900163 19971009 00163 1997 10 9 97ZZZX4269 1 19970918 G 3710 D9181 FILTER AIRBORNE VAC SYS FAILED D S K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 WHEN INSTALLING VAC SYS FILTER, ONE OF THE FILTER ENDS STARTED TO BREAK APART. 1997100900164 19971009 00164 CE 1997 10 9 97ZZZX4270 1 19970901 G 2710 0510105224 CONTROL CABLE CESSNA 172 172M 2072418 CE LT AILERON FRAYED B A ESMR K NONE O OTHER IN INSP/MAINT 1 SO 11 13378 4101 17262714 LEFT PRIMARY AILERON CABLE WAS FOUND FRAYED DURING ROUTINE INSPECTION. SEVERAL HARD TO SEE AREAS OF CABLE WERE FRAYED ( TOTAL TIME ON CABLE 4,101.1 HOURS. SUBMITTER RECOMMENDED CABLES BE REPLACED ON A TIME CHANGE BASIS, CABLE PN 0510105-22 4. 1 H 7 1 3O NT 3A12 1997100900165 19971009 00165 SO 1997 10 9 97ZZZX4271 1 19970925 G 3244 65010 TIRE GOODYEARAERO PIPER PA31T PA31T 7103124 SO LT/RT MLG FAILED D O OTHER O OTHER TO TAKEOFF 1 SW 99 160NA 187 31T7720060 AFTER LANDING AND TAXI IN, NOTICED THE LT TIRE S/N 414622043304 HAD A BULGE ON THE INBOARD SIDE OF THE TREAD AND SIDE WA LL AREA. THIS TIRE WAS REMOVED AND REPLACED WITH NEW. NEXT FLIGHT, RT TIRE S/N 41462322 LOST ITS TREAD ON INBOARD SIDE FULL CIRCUMFERENCE DURING TAKEOFF, BREAKING OFF THE RT INBOARD GEAR DOOR ACTUATOR BOTTOM FITTING. AS THE GEAR RETRACTE D, HYDRAULIC FLUID FOR THE ENGINE DRIVEN PUMPS WAS DEPLETED, AND GEAR HAD TO BE HAND PUMPED DOWN USING EMERGENCY PROCEDU RES. THE TIRE REMAINED PROPERLY INFLATED AND AN UNEVENTFUL LANDING WAS MADE. SUBMITTER STATED TIRES WITH S/N'S 41468XX X MAY BE A BAD BATCH. CAREFULLY INSPECT TIRES WITHIN THIS S/N RANGE. 1 L 7 2 3T A8EA 1997100900166 19971009 00166 CE 1997 10 9 97ZZZX4272 1 19970917 G 3340 GE4522 LANDING LIGHT CESSNA 172 172M 2072418 CE BULB DETERIORATED D K NONE O OTHER IN INSP/MAINT 1 NE 01 20402 59 17261261 LANDING LIGHT REPLACED FOR BROKEN ELEMENT. THIS LAMP, AS WELL AS THE 4509 AND THE 4596, HAVE DETERIORATED TO THE POINT THE AVERAGE LIFE IS 50 HOURS TACH TIME. 1 H 7 1 3O NT 3A12 1997100900167 19971009 00167 SO 1997 10 9 97ZZZX4273 1 19970922 G 5720 6206102 DOUBLER PIPER PA28 PA28161 7102803 SO WING WALK CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 16 8079Y 6547 288016049 THE WING WALK SKIN WAS FOUND TO SAG WHEN STEPPED ON. INVESTIGATION REVEALED THE REINFORCEMENT DOUBLER RIVETED TO THE UN DERSIDE OF THE WING WALK SKIN WAS CRACKED ALL ALONG THE BUTT RIB AREA. 1 L 7 1 3O 2A13 1997100900168 19971009 00168 CE 1997 10 9 97ZZZX4274 1 19970922 G 2810 303013 FUEL CELL CESSNA 206 U206F 2073333 CE FITTINGS LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 WP 23 8433Q 534 U20603292 FUEL CELL IS AN FAA/PMA REPLACEMENT FOR CESSNA PN 1200065-13. THE CONDITION AT REMOVAL WAS -- PERISHED. THE FITTINGS D ISINTEGRATED. THE TANK ITSELF WAS IN OK CONDITION, BUT ALL THE PARTS THAT WERE SUPPOSED TO BE BONDED TO THE TANK JUST P ULLED OFF LIKE THE BONDING WAS NOT CORRECTLY DONE. THIS TANK WAS MAINTAINED FULL AT ALL TIMES AND REFILLED AFTER FLIGHT . FUEL CELL MANUFACTED BY: A.I.R., MEMPHIS, TN. DATE OF MANUFACTURE: 3/90. CONSTRUCTION NR: P2315. 1 H 7 1 3O A4CE 1997100900169 19971009 00169 CE 1997 10 9 97ZZZX4275 1 19970922 G 2810 303012 FUEL CELL CESSNA 206 U206F 2073333 CE FITTINGS LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 WP 23 8433Q 586 U20603292 FUEL CELL IS AN FAA/PMA REPLACEMENT FOR CESSNA PN 1200065-12. THE CONDITION AT REMOVAL WAS -- PERISHED. THE FITTINGS D ISINTEGRATED. THE TANK ITSELF WAS IN OK CONDITION, BUT ALL THE PARTS THAT WERE SUPPOSED TO BE BONDED TO THE TANK JUST P ULLED OFF LIKE THE BONDING WAS NOT CORRECTLY DONE. THIS TANK WAS MAINTAINED FULL AT ALL TIMES AND REFILLED AFTER FLIGHT . FUEL CELL MANUFACTURED BY A.I.R. OF MEMPHIS, TN. DATE OF MANUFACTURE: 9/90. CONSTRUCTION NR: P2315. 1 H 7 1 3O A4CE 1997100900170 19971009 00170 SO 1997 10 9 97ZZZX4276 1 19970909 G 5610 WINDOW MAULE M5 M5210TC 5460140 SO RT FRONT RIVETS FAILED H A O OTHER D INFLIGHT SEPARATION CR CRUISE 1 NM 11 56294 9001C FRONT WINDOW RIVETS FAILED IN-FLIGHT LEADING TO TOTAL LOSS OF RT FRONT WINDOW FROM THE AIRCRAFT. TT: 902 HOURS. 1 H 7 1 3O NC 3A23 1997100900171 19971009 00171 NE 1997 10 9 97ZZZX4277 3 19970917 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 4652 2623NR HJ423 FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. TWO CRACKS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997100900172 19971009 00172 NE 1997 10 9 97ZZZX4278 3 19970917 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 4529 2772NR HJ454 FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. FOUR CRACKS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997100900174 19971009 00174 EA 1997 10 9 97ZZZX4279 1 19970729 G 3260 601577889 HARNESS CNDAIR CL600 CL6002B16 1900305 EA NLG WIRING DEFECTIVE C A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 EA 11 1622 2385 5077 AFTER TAKEOFF UPON GEAR RETRACTION, GREEN LIGHTS OUT, RED LIGHT IN HANDLE FLASHING. RED DOOR OPEN LIGHT ON. AIRCRAFT R ETURNED TO AIRPORT. REPLACED THE NOSE LANDING GEAR WIRING HARNESS PN 601-57788-9. C/W LANDING GEAR RETRACTION AND EXTE NSION CHECK. OPS CHECK OK. WORK PERFORMED BY GARRETT AVIATION SERVICES IAH CRS XB1R606K W/O 36279. 2 L 7 2 4F RT A21EA 1997100900175 19971009 00175 CE 1997 10 9 97ZZZX4280 1 19970731 G 5751 258WS21419A BEARING 259GWG1111A RAYTHN DH125 HAWKER800XP CE LT AILERON HINGE FAILED D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 11 2169X DHB589 258315 INSTALLED NEW AILERON HINGE BEARING ASSY. DURING INSTALLATION OF AILERON HINGE BOLT, BEARING CAME APART. HAD BEARING A SSY BEEN ASSEMBLED AND INSPECTED PER S26-4558 SPEC, ITEM WOULD NOT HAVE BEEN SOLD TO OUTSIDE COMPANY AS SERVICEABLE PART . 2 L 7 2 4F RT A3EU 1997100900176 19971009 00176 NE 1997 10 9 97ZZZX4281 2 19970918 G 7322 7191991 DRIVE GEAR HAMSTD 7436025 PWA JT8 JT8D1 52044 NE FUEL CONT WORN B BN4R O OTHER J WARNING INDICATION TO TAKEOFF 1 WP 05 71968 3536 92097 ENGINE AUTO ACCEL AT TAKEOFF. WORN SPLINES ON FUEL CONTROL DRIVE GEAR LED TO ZERO SPEED FAIL SAFE FUEL FLOW. DRIVE GEA R AND DRIVESHAFT WERE REPLACED. 4 F E2EA 1997100900177 19971009 00177 CE 1997 10 9 97ZZZX4282 1 19970805 G 3241 AC039803 MAXERET COVER AHA1814 RAYTHN DH125 HAWKER800XP CE NR 2 MAIN WHEEL DAMAGED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 11 2169X 11 UK036 258315 LEFT MAIN GEAR MAXERET COVERS CUT ALMOST IN TWO. CAUSE: MAIN WHEEL AXLE NUT RETAINING BOLT PN DHS1426-5DD NOT INSTALLE D CORRECTLY. BOLT IS SUPPOSED TO BE CUT AT INSTALLATION TO CLEAR INSIDE OF MAXERET COVER. HOWEVER, THE MM IS NOT CLEAR . IT DOES NOT SAY TO CUT BOLT AT INSTALLATION AND WHEN NEW BOLTS ORDERED FROM I.P.C., IT COMES TOO LONG. 2 L 7 2 4F RT A3EU 1997100900178 19971009 00178 CE 1997 10 9 97ZZZX4283 1 19970805 G 3241 AC039803 MAXERET COVER AHA1814 RAYTHN DH125 HAWKER800XP CE NR 1 MAIN WHEEL DAMAGED D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 11 2169X 11 UK022 258315 LEFT MAIN GEAR MAXERET COVERS CUT ALMOST IN TWO. CAUSE: MAIN WHEEL AXLE NUT RETAINING BOLT PN DHS1426-5DD NOT INSTALLE D CORRECTLY. BOLT IS SUPPOSED TO BE CUT AT INSTALLATION TO CLEAR INSIDE OF MAXERET COVER. HOWEVER, THE MM IS NOT CLEAR . IT DOES NOT SAY TO CUT BOLT AT INSTALLATION AND WHEN NEW BOLTS ORDERED FROM I.P.C., IT COMES TOO LONG. 2 L 7 2 4F RT A3EU 1997100900179 19971009 00179 CE 1997 10 9 97ZZZX4284 1 19970428 G 2133 1036481 OUTFLOW VALVE AIRESRCH BEECH 90 C90 1152913 CE CABIN FAILED D A O OTHER J WARNING INDICATION CL CLIMB 1 SO 05 22BM 6290 203034 LJ360 AFTER TAKEOFF, CABIN PRESSURIZATION STARTED TO PRESSURIZE TO 6,000 FEET CLIMB UNTIL THE SAFETY VALVE OPENED, THE CABIN W ENT TO A 6,000 FOOT DESCENT. THE CABIN CONTINUED TO OSCILLATE IN THIS MANNER UNTIL PILOT DUMPED THE CABIN AND CONTINUED UNPRESSURIZED. ON TEST FLIGHT, MECHANIC FOUND VALVE RETAINER PLUG BLOCKING OUTLET CAUSING PRESSURIZATION FLUCTUATION. D EFECT IS COVERED IN BEECH SL (SL 1162 AND SL 1109) AND AIRESEARCH 5-2243, BUT DOES NOT COVER PART NUMBER OR SERIAL NUMBE R OF DEFECTIVE VALVE. THIS COULD CAUSE A SERIOUS PROBLEM IF THERE IS AN UNKNOWN SAFETY VALVE DEFECT. 1 L 7 2 3T 3A20 1997100900180 19971009 00180 CE 1997 10 9 97ZZZX4285 1 19970908 G 2742 EM440 ACTUATOR CESSNA 650 650 2076802 CE SECONDARY TRIM MALFUNCTION D K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 21 2606 5 650194 DURING PREFLIGHT, DISCOVERED THE SECONDARY TRIM OPERATED BACKWARDS. THE OVERHAULED ACTUATOR WAS INSTALLED 5 HOURS PREVI OUSLY. SUBMITTER STATED REVIEW OVERHAUL, FUNCTIONAL TEST AND QUALITY CONTROL PROCEDURES AT ELECTROMECH TECHNOLOGIES. F OLLOW MM PROCEDURES AFTER INSTALLATION. 2 L 7 2 4F A9NM 1997100900181 19971009 00181 SO 1997 10 9 97ZZZX4286 1 19970909 G 8120 LW15592832 CLAMP PIPER PA46 PA46350P SO LYC O540 TIO540AE2A 41532 EA TURBOCHARGER FAILED D O OTHER O OTHER CR CRUISE 1 EA 07 722ET 295 463047 L971461A AT ALTITUDE, TURBOCHARGER FAILED DUE TO INTER COOLER CLAMP SEPARATION. THIS IS SECOND SET OF CLAMPS THAT HAVE SEPARATED . THE CRIMPED END HAS COME APART. 1 L 7 1 3O 3 O RT A25SO E14EA 1997100900182 19971009 00182 NE 1997 10 9 97ZZZX4287 2 19970722 G 7260 3020692 BEVEL GEAR 3020694 CESSNA 500 500CESSNA 2076602 CE PWA JT15 JT15D1 52060 NE GEARBOX FRACTURED B APJR E ENGINE SHUTDOWN O OTHER CR CRUISE 1 EA 11 787BA 5014 3254 1092 5000143 PCE76357 THE ACCESSORY GEARBOX MAIN DRIVESHAFT HAD FRACTURED. THE REPORTED IN-FLIGHT SHUTDOWN WAS A RESULT FROM FRACTURE OF THE A CCESSORY GEARBOX MAIN SHAFT DRIVE BEVEL GEAR DUE TO FATIGUE INITIATING AT A GEAR TOOTH RADIUS. THE FRACTURED GEAR CAUSE D MECHANICAL DAMAGE TO ITS MATING INPUT GEAR TEETH AND GOUGED BOTH THE GEARBOX HOUSING AND ITS COVER. TO ALLEVIATE THIS CONDITION, A GEAR FEATURING AN INCREASED MATERIAL THICKNESS AT THE GEAR WEB WAS INTRODUCED INITIALLY BY SB 7152 (2-80), SUPERSEDED BY SB 7258 (6-87), THEN BY SB 7269 (3-88) FEATURING GEARS MANUFACTURED FROM SUPERIOR MATERIAL AND ACCOMMODAT ING LARGER BACK LASH. 1 L 7 2 4F 4 F A22CE E1NE 1997100900183 19971009 00183 1997 10 9 97ZZZX4288 4 19970910 G 3415 99120769 SWITCH CESSNA 500 550 2076604 CE MACH AIRSPD WARN FAILED D K NONE O OTHER IN INSP/MAINT 1 SO 09 846HS 629 5500669 DURING POST-FLIGHT CHECK, THE MACH AIRSPEED WARNING SYSTEM WOULD NOT TEST PROPERLY. TROUBLESHOOTING REVEALED A BAD MACH AIRSPEED WARNING SWITCH. REPLACED SWITCH AND SYSTEM TESTED AND OPERATED CORRECTLY. SUBMITTER STATED THIS SWITCH HAS P OOR RELIABILITY. THIS IS THE 3RD SWITCH REPLACED IN 12 MONTHS. FAILURE OF THE SWITCH CAUSES THE CREW TO LOSE MACH OVER SPEED WARNING. 1 L 7 2 4F A22CE 1997100900184 19971009 00184 SO 1997 10 9 97ZZZX4289 1 19970905 G 2613 1173T119 SWITCH GULSTM G1159 GIV 3980115 SO RT ALT OVERHEAT FAILED D A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 EA 25 399CC 4234 2496 1051 AIRCRAFT DEPARTED. EN ROUTE EXPERIENCED RT ENGINE ALTERNATOR OVERHEAT MESSAGE ON EICAS. PIC TOOK CORRECTIVE ACTION AND RETURNED. TROUBLESHOOTING REVEALED RT ALT OVERHEAT SWITCH FAILED IN TRIPPED CONDITION. REMOVED AND REPLACED WITH NEW S WITCH. OPS CHECK AOK. 2 L 7 2 4F RT A12EA 1997100900185 19971009 00185 CE 1997 10 9 97ZZZX4290 1 19970904 G 2710 1455077645 CONTROL CABLE CESSNA 500 550 2076604 CE AILERON MISMANUFACTURED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 13 4614N 5500659 DURING SCHEDULED CABLE INSPECTION, THE AILERON CABALE WHICH RUNS THROUGH THE FUSELAGE WAS FOUND TO HAVE BROKEN STRANDS. UPON RECEIPT OF THE NEW CABLE, FOUND THE TERMINAL END WAS INCORRECT (CLEVIS TYPE INSTEAD OF 'EYE' TYPE). THE MANUFACTU RER WAS CONTACTED AND STATED 4 OTHER CABLES WERE FOUND IMPROPERLY MANUFACTURED. 1 L 7 2 4F A22CE 1997100900186 19971009 00186 CE 1997 10 9 97ZZZX4291 1 19970902 G 6120 D60711 PITCH CHANGE ROD BEECH 1900 1900D 1154162 CE PROPELLER CRACKED B RC2R K NONE K FLUID LOSS IN INSP/MAINT 1 NE 03 839CA 1640 B739 UE36 PITCH CHANGE ROD CRACKED IN LAST THREAD ON ENGINE SIDE. CRACK PROPAGATED THROUGH THREAD TO INSIDE CAUSING OIL LEAK. CR ACK FOUND DURING MAGNETIC PARTICLE INSPECTION AND VERIFIED DURING PRESSURE CHECK OF ROD OUTSIDE OF PROPELLER. ROD WAS N EW AT OVERHAUL. 2 L 7 2 4T RT A24CE 1997100900187 19971009 00187 NM 1997 10 9 97ZZZX4292 1 19970705 G 2823 D2316P CONNECTOR BOEING 747 747122 1384872 NM FUEL SOV MISWIRED B NE1Y K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 33 854FT 19754 APPARENT MALFUNCTION DETECTED DURING OPERATIONAL CHECKS OF THE ENGINE FUEL SHUT OFF VALVES. IT WAS NOTICED THE INDICATO R LIGHTS DID NOT RESPOND TO MOVEMENT OF THE ENGINE START LEVERS ON THE PEDESTAL; WHEREAS, NORMAL RESPONSE WAS OBSERVED D URING OPERATION OF THE FIRE SWITCHES ON THE OVERHEAD PANEL. INVESTIGATION SHOWED THAT WIRES W629-1Q1221-20 AND 1Q1223-2 0 WERE SPLICED TOGETHER NEAR CONNECTOR D2316P. THE WIRING DIAGRAM SHOWED THESE WIRES AS TERMINATING IN PINS 12 AND 11 O F CONNECTOR D2316P. SIMILAR DISCREPANCIES WERE FOUND FOR EACH OF THE OTHER ENGINE SHUT OFF VALVES. THE EFFECT OF THIS MODIFICATION WAS TO BYPASS THE FUNCTION OF THE ENGINE FUEL SHUT OFF SWITCHES ASSOCIATED WITH THE ENGINE START LEVERS. 2 L 7 4 4F A20WE 1997100900188 19971009 00188 NM 1997 10 9 97ZZZX4293 1 19970705 G 2823 D2454P CONNECTOR BOEING 747 747122 1384872 NM FUEL SOV MISWIRED B NE1Y K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 33 854FT 19754 APPARENT MALFUNCTION DETECTED DURING OPERATIONAL CHECKS OF THE ENGINE FUEL SHUT OFF VALVES. IT WAS NOTICED THE INDICATO R LIGHTS DID NOT RESPOND TO MOVEMENT OF THE ENGINE START LEVERS ON THE PEDESTAL; WHEREAS, NORMAL RESPONSE WAS OBSERVED D URING OPERATION OF THE FIRE SWITCHES ON THE OVERHEAD PANEL. INVESTIGATION SHOWED THAT WIRES W629-1Q1221-20 AND 1Q1223-2 0 WERE SPLICED TOGETHER NEAR CONNECTOR D2316P. THE WIRING DIAGRAM SHOWED THESE WIRES AS TERMINATING IN PINS 12 AND 11 O F CONNECTOR D2316P. SIMILAR DISCREPANCIES WERE FOUND FOR EACH OF THE OTHER ENGINE SHUT OFF VALVES. THE EFFECT OF THIS MODIFICATION WAS TO BYPASS THE FUNCTION OF THE ENGINE FUEL SHUT OFF SWITCHES ASSOCIATED WITH THE ENGINE START LEVERS. 2 L 7 4 4F A20WE 1997100900189 19971009 00189 NM 1997 10 9 97ZZZX4294 1 19970822 G 2823 D2454P CONNECTOR BOEING 747 747122 1384872 NM FUEL SOV MISWIRED B NE1Y K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 33 853FT 29753 APPARENT MALFUNCTION DETECTED DURING OPERATIONAL CHECKS OF THE ENGINE FUEL SHUT OFF VALVES. IT WAS NOTICED THE INDICATO R LIGHTS DID NOT RESPOND TO MOVEMENT OF THE ENGINE START LEVERS ON THE PEDESTAL; WHEREAS, NORMAL RESPONSE WAS OBSERVED D URING OPERATION OF THE FIRE SWITCHES ON THE OVERHEAD PANEL. INVESTIGATION CONFIRMED THAT WIRES W629-1Q1221-20 AND 1Q122 3-20 WERE SPLICED TOGETHER NEAR CONNECTOR D2316P. THE WIRING DIAGRAM SHOWED THESE WIRES AS TERMINATING IN PINS 12 AND 1 1 OF CONNECTOR D2316P. SIMILAR DISCREPANCIES WERE FOUND FOR EACH OF THE OTHER ENGINE SHUT OFF VALVES. THE EFFECT OF THI S MODIFICATION WAS TO BYPASS THE FUNCTION OF THE ENGINE FUEL SHUT OFF SWITCHES ASSOCIATED WITH THE ENGINE START LEVERS. 2 L 7 4 4F A20WE 1997100900190 19971009 00190 NM 1997 10 9 97ZZZX4295 1 19970822 G 2823 D2316P CONNECTOR BOEING 747 747122 1384872 NM FUEL SOV MISWIRED B NE1Y K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 33 853FT 29753 APPARENT MALFUNCTION DETECTED DURING OPERATIONAL CHECKS OF THE ENGINE FUEL SHUT OFF VALVES. IT WAS NOTICED THE INDICATO R LIGHTS DID NOT RESPOND TO MOVEMENT OF THE ENGINE START LEVERS ON THE PEDESTAL; WHEREAS, NORMAL RESPONSE WAS OBSERVED D URING OPERATION OF THE FIRE SWITCHES ON THE OVERHEAD PANEL. INVESTIGATION CONFIRMED THAT WIRES W629-1Q1221-20 AND 1Q122 3-20 WERE SPLICED TOGETHER NEAR CONNECTOR D2316P. THE WIRING DIAGRAM SHOWED THESE WIRES AS TERMINATING IN PINS 12 AND 1 1 OF CONNECTOR D2316P. SIMILAR DISCREPANCIES WERE FOUND FOR EACH OF THE OTHER ENGINE SHUT OFF VALVES. THE EFFECT OF THI S MODIFICATION WAS TO BYPASS THE FUNCTION OF THE ENGINE FUEL SHUT OFF SWITCHES ASSOCIATED WITH THE ENGINE START LEVERS. 2 L 7 4 4F A20WE 1997100900191 19971009 00191 SO 1997 10 9 97ZZZX4296 1 19970904 G 5610 1159SCB31014 WINDSHIELD GULSTM G1159 G1159A 3970109 SO RT COCKPIT SHATTERED D O OTHER O OTHER CR CRUISE 1 GL 19 98RP 2153 84426473 328 PILOT REPORTED FLYING AT 41,000 FEET. NOTICED THE WINDSHIELD HEAT LIGHT WAS OUT. RECYCLED CIRCUIT BREAKER AND SWITCHED BACK ON. AFTER A SHORT PERIOD OF TIME, NOTICED A SMALL CRACK MOVING ACROSS WINDSHIELD, THEN A LOUD POP WAS HEARD AND T HE OUTER LAYER SHATTERED INTO A SPIDER WEB PATTERN LEAVING A BURN TRAIL ACROSS THE CENTER. THE CREW SELECTED A LOWER AL TITUDE AND PRESSURE DIFFERENTIAL. 2 L 7 2 4F A12EA 1997100900193 19971009 00193 CE 1997 10 9 97ZZZX4297 1 19970901 G 2752 556517538 GEARBOX CESSNA 500 550 2076604 CE FLAP SHAFT SHEARED D S K NONE O OTHER IN INSP/MAINT 1 SO 13 800LA 107 1116 5500295 DRIVE GEAR SHEARED AT NARROW PORTION OF GEAR. THIS IS UPDATED MODEL THAT IS SUPPOSED TO PREVENT SHEARING SHAFT IN THIS L OCATION. 1 L 7 2 4F A22CE 1997100900194 19971009 00194 CE 1997 10 9 97ZZZX4298 1 19970918 G 2730 5052443931 CONTROL CABLE BEECH 90 E90 1152914 CE ELEVATOR CONTROL BROKEN B L A DBCR A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 GL 13 7TD 2754 LW276 FOLLOWING TAKEOFF, AIRCRAFT RETURNED DUE TO ELEVATOR MALFUNCTION. INSPECTION FOUND ELEVATOR CABLE BROKEN DUE TO CHAFE O N A CLAMP ON THE BLEED AIR LINE. EMERGENCY GEAR HANDLE FORCES BLEED LINE DOWNWARD ON TO ELEVATOR CABLE. SUGGEST RE-ROU TE BLEED LINE. 1 L 7 2 3T 3A20 1997100900195 19971009 00195 1997 10 9 97ZZZX4299 4 19970527 G 2562 12630423 SWITCH DORNEMARGLN SLNSBY T67 T67M260 8323006 EU ELT MALFUNCTION D K NONE O OTHER IN INSP/MAINT 1 SW 17 3045H 917 2141 WHILE PERFORMING AN ANNUAL ELT INSPECTION, FOUND THE ELT SENSOR DID NOT COME ON. 1 L 7 1 3O NT A73EU 1997100900196 19971009 00196 EA 1997 10 9 97ZZZX4300 2 19970811 G 7414 67542 BEARING PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA LT MAG DRIVE FAILED D K NONE O OTHER IN INSP/MAINT 1 EA 23 40200 1618 277304997 L398748 FOUND LEFT MAGNETO DRIVE BEARING ASSEMBLY COMING APART. BEARING ASSEMBLY WAS WEARING INTO GEAR RETAINER ASSEMBLY PN LW-1 9096. SUBMITTER STATES INSPECTION OF THESE PARTS SHOULD BE ACCOMPLISHED EACH TIME MAGNETO IS REMOVED. 1 L 7 2 3O 3 O 1A10 1E4 1997100900197 19971009 00197 CE 1997 10 9 97ZZZX4301 1 19970826 G 2810 929200203 FUEL CELL BEECH 90 E90 1152914 CE LT NACELLE LEAKING D S K NONE K FLUID LOSS IN INSP/MAINT 1 CE 03 3700M LW340 UPON RETURN FROM A CHECK FLIGHT, THE LEFT NACELLE FUEL CELL STARTED LEAKING (MASSIVELY) JUST PRIOR TO ENGINE SHUT DOWN. WHEN THE FUEL SHUT OFF VALVES WERE SET TO THE OFF POSITION, FUEL CONTINUED TO LEAK. AN INVESTIGATION DISCLOSED THE LEFT NACELLE MAIN FUEL LINE NIPPLE HAD BECOME BRITTLE AND CRACKED AT THE BLADDER. DISCUSSIONS WITH BEECH CRAFT AND SEVERAL FUEL CELL REPAIR CENTERS INDICATED THAT NIPPLE MATERIAL COMPOSITION HAD BEEN CHANGED AFTER 1979 TO IMRPOVE ITS DURABILIT Y. SUBMITTER RECOMMENDED THAT ANY FUEL CELL OVER 15 YEARS OLD BE A CANDIDATE FOR REPLACEMENT OF THE OPERATOR'S CONVENIE NCE. 1 L 7 2 3T 3A20 1997100900198 19971009 00198 NM 1997 10 9 97ZZZX4302 1 19970801 G 5720 14050R REINFORCEMENT UNIVAR 415 415C 0420302 NM RT WING CORRODED H S K NONE O OTHER IN INSP/MAINT 1 CE 03 87114 3938 287 SEVERE CORROSION FOUND DURING ANNUAL. THIS OCCURED SINCE LAST ANNUAL JULY, 1996. CORROSION COULD NOT BE OBSERVED THROU GH INSPECTION HOLES IN WING. CAN ONLY BE SEEN WITH AILERON FULLY IN UP POSITION AND LOOKING UPWARD FROM THE GROUND. IT IS NOT READILY SEEN LOOKING DOWN THROUGH THE GAP BETWEEN WING AND AILERON. SUBMITTER RECOMMENDED OTHER OWNERS INSPECT BEFORE NEXT FLIGHT AND 3 TO 4 TIMES A YEAR THEREAFTER. 1 L 7 1 3O A718 1997100900199 19971009 00199 SO 1997 10 9 97ZZZX4303 2 19970901 G 8530 VALVE CESSNA 172 172 2072402 CE CONT O300 O300A 17022 SO ENGINE EXHAUST STUCK D K NONE O OTHER IN INSP/MAINT 1 SW 17 3780 ENGINE FOUND WITH EXHAUST VALVE STICKING OPEN. AIRCRAFT HAD BEEN RUN ON AUTO GAS. SMOH: 925 HOURS. 1 H 7 1 3O 3 O NT 3A12 E253 1997100900200 19971009 00200 SO 1997 10 9 97ZZZX4304 2 19970901 G 8530 VALVE UNIVAR 415 415C 0420302 NM CONT A75 C7512 17005 SO ENGINE EXHAUST STUCK D K NONE O OTHER IN INSP/MAINT 1 SW 17 415C 2875 FOUND ENGINE EXHAUST VALVE STUCK. AIRCRAFT HAD BEEN RUN ON AUTO GAS. SMOH: 625 HOURS. 1 L 7 1 3O 3 O A718 E233 1997100900201 19971009 00201 EA 1997 10 9 97ZZZX4305 2 19970901 G 8530 VALVE PIPER PA20 PA20135 7102010 SO LYC O290 O290D2 41506 EA ENGINE EXHAUST STICKING D K NONE O OTHER IN INSP/MAINT 1 SW 17 2200 FOUND ENGINE EXHAUST VALVE STICKING. AIRCRAFT HAD BEEN OPERATED ON AVIA GAS. VALVE REQUIRED DISSASSEMBLY, CLEANING, AN D LAPPING IN. SMOH: 525 HOURS. 1 H 7 1 3O 3 O 1A4 E229 1997100900202 19971009 00202 NM 1997 10 9 97ZZZX4306 1 19970901 G 5720 CORD CHILD S2 S2BPITTS 0110304 NM RIB LACE FAILED B SPDR K NONE O OTHER IN INSP/MAINT 1 SW 11 6034U 350 5133 DURING INSP, LOOSE FABRIC WAS FOUND ON TOP RT INBD SECT OF TOP WING (NO FABRIC TORN). SUCTION CUP WAS ABLE TO LIFT FABR IC FROM WING RIBS, BOTH TOP AND BOTTOM. A FABRIC PUNCH TEST WAS COMPLETED AND FOUND FABRIC OK. UNDER SUPERVISION OF TH E FAA, TOP WING FABRIC WAS DISSECTED IN LOOSE AREA AND FOUND RIB LACING CORD HAD BROKEN ALLOWING FABRIC TO LIFT FROM THE RIBS. A PULL TEST OF THE RIB LACING CORD REVEALED THE CORD ONLY PULLED 25 TO 30 POUNDS BEFORE BREAKING. RIB LACING CO RD WAS WAXED COTTON CORD. THE COMPLETE ACFT WAS COVERED USING GRADE 'A' COTTON, BUT STILL TESTED IN THE ORANGE USING A SEYBOTH NR 3 FABRIC TESTER AND A MAULE TESTER. LOG ENTRIES IN ACFT LOGS SHOWED SB NR 18 HAD BEEN C/W ANNUALLY. 1 Q 7 1 3O A8SO 1997100900203 19971009 00203 NE 1997 10 9 97ZZZX4307 3 19970916 G 6112 B40330 LEADS BEECH 200 B200 1152922 CE MCAULY 4HFR34 4HFR34C754 NE PROPELLER HEAT DEFECTIVE B MZ4R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 17 2FOR BB558 NEW PROPELLER DE-ICE HEAT LEADS WERE PURCHASED FROM AVIATION PROPELLERS, INC., MIAMI. THESE LEADS WERE IN THE ORIGINAL CESSNA AIRCRAFT PACKAGING. WHEN THE PACKAGE WAS OPENED AND LEADS INSPECTED, FOUND OF THE 5 PACKAGED LEADS, 2 LEADS HAD LOOSE TERMINAL ENDS THAT WERE EASILY PULLED LOOSE FROM THE WIRE. AVIATION PROPELLERS WAS INFORMED AND ADVISED TO CHECK THEIR STOCK. THEY INDICATED THEY WOULD ADVISE CESSNA. 1 L 7 2 4T A24CE 6 C 3PNE 1997100900204 19971009 00204 WP 1997 10 9 97ZZZX4308 2 19970901 G 7260 31017261 SHAFT GULSTM 690TP 690A 0141722 SW GARRTT TPE331 TPE3315 01514 WP TORQUE SENSOR SHEARED D E ENGINE SHUTDOWN Y ENGINE STOPPAGE AP APPROACH 1 SW 99 333CA 4719 11136 P06230 WITH AIRCRAFT AT 4,000 FEET WHILE BEING VECTORED FOR LANDING, LEFT ENGINE FAILED. PILOT COMPLETED ENGINE SHUT DOWN. UN EVENTFUL LANDING MADE. MAINTENANCE FOUND TORQUE SENSOR SHAFT HAD SHEARED. THIS GEAR ALSO DRIVES THE OIL SCAVENGE PUMP AND THE FUEL PUMP; THUS, WHEN THE ENGINE LOST FUEL PRESSURE, THE ENGINE FLAMED OUT. TORQUE SENSOR REPLACED WITH NEW STY LE 3101726-3. 1 H 7 2 3T 4 T 2A4 E4WE 1997100900205 19971009 00205 NE 1997 10 9 97ZZZX4309 2 19970801 G 7250 1A9843 BEARING BOEING 757 757231 1384950 NM PWA 2037 PW2037 NE NR 4 FAILED B WA2D K NONE O OTHER IN INSP/MAINT 1 NE 03 705TW 28479 P727216 ENGINE REMOVED, POSITION NR 2, AT LAX ON 7-14-97 DUE METAL IN SCREEN/CARBON IN FILTER. DISASSEMBLY INSPECTION REVEALED ROLLER TANG LIBERATION IN BEARING. BEARING WAS HAND CARRIED TO PRATT & WHITNEY ENGINEERING FOR INVESTIGATION. 2 L 7 2 4F 4 F RT A2NM E17NE 1997100900206 19971009 00206 EU 1997 10 9 97ZZZX4310 1 19970926 G 5753 A57966100002 RIB FITTING A57966000164 AIRBUS 300 A300B4103 3930104 EU LT INBD TE FLAP CRACKED B C20R K NONE O OTHER IN INSP/MAINT 1 WP 07 13983 0092 AFTER REMOVING THE INNER FLAP L/E SKIN FROM AROUND THE INBOARD FLAP ATTACHMENT POINT, THE RIB FITTING (5TH FROM INBOARD) WAS FOUND TO HAVE SIDE FLANGE WITH A SMALL CRACK OF APPROXIMATELY .25 INCH WHICH WAS CONFIRMED BY DYE PENETRANT. THE L /E SKIN IN THIS AREA HAD SEVERAL DENTS, BUT THE CRACK DOES NOT APPEAR RELATED. 2 L 7 2 4F A35EU 1997100900207 19971009 00207 EU 1997 10 9 97ZZZX4311 1 19970926 G 5753 A57966101902 RIB FITTING A5796602016 AIRBUS 300 A300B4203 3930306 EU RT INBD TE FLAP CRACKED B C20R K NONE O OTHER IN INSP/MAINT 1 WP 07 862PA 5D1212 211 AFTER REMOVING THE INNER FLAP L/E SKIN DUE TO FOD, THE L/E RIB FITTING (5TH FROM INBD) WHICH CONTAINS AN ATTACHMENT POIN T FOR THE FLAP WAS FOUND TO HAVE ALL 4 SIDE FLANGES CRACKED AND BENT APPROXIMATELY 1 INCH FROM THE BOTTOM SIDE OF THE FI TTING. THIS FITTING IS APPROXIMATELY 6 FEET FROM THE FOD AREA BEING REPAIRED AND DOES NOT APPEAR RELATED. THERE IS NO OTHER OBVIOUS DAMAGE IN THE AREA. 2 L 7 2 4F A35EU 1997100900208 19971009 00208 GL 1997 10 9 97ZZZX4312 3 19970905 G 6110 BOLT PIPER PA31 PA31325 7103105 SO HARTZL HCE3Y HCE3YR2 GL PROP CTWEIGHT MISINSTALLED B Q2AR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 17 41879 2218 11 317712069 DJ4714 DURING ANNUAL INSPECTION, PROPELLER COUNTERWEIGHT ATTACH BOLTS FOUND UNSAFTIED POST OVERHAUL. HARTZELL MANUAL NR 117D R EQUIRES THESE BOLTS TO BE REPLACED AT OVERHAUL AND RE-DRILLED FOR ROLL-PIN SAFETY. THESE BOLTS WERE RE-USED AFTER OVERHA UL SINCE THEY WERE DRILLED IN A LOCATION WHICH COULD NOT BE SAFTIED WITH A ROLL-PIN. 1 L 7 2 3O A20SO 5 C P33EA 1997100900209 19971009 00209 SO 1997 10 9 97ZZZX4313 1 19970905 G 2820 6010008 HOSE AEROQUIP PIPER PA31 PA31325 7103105 SO FUEL SYSTEM LEAK B Q2AR K NONE K FLUID LOSS IN INSP/MAINT 1 SW 17 41879 2218 317712069 DURING ANNUAL INSPECTION, FUEL HOSES AT FUEL SELECTOR AND STRAINERS WERE MOVED FOR INSPECTION FOR HARDNESS. ALL FUEL HO SES BEGAN TO LEAK FUEL THROUGH EXTERIOR BRAID AFTER BEING DISTURBED. NEW HOSES CONFORMING TO MIL-H-879U INSTALLED. ORI GINAL HOSES MANUFACTURED 2 QTR 1974. 1 L 7 2 3O A20SO 1997100900210 19971009 00210 CE 1997 10 9 97ZZZX4314 1 19970909 G 2701 07606331 BEARING CESSNA 182 182P 2075816 CE CONTROL COLUMN FAILED B A Q2AR O OTHER F FLT CONT AFFECTED CR CRUISE 1 SW 17 344K 11956 18263709 PILOT'S CONTROL COLUMN FORWARD SUPPORT ROLLER BEARING FAILED AND CAUSED AILERON CONTROL BINDING IN-FLIGHT. 1 H 7 1 3O NT TA13 1997100900211 19971009 00211 SO 1997 10 9 97ZZZX4315 1 19970901 G 3246 4090A WHEEL PIPER PA32 PA32R300 7103213 SO INBOARD HALF CRACKED B Q2AR K NONE O OTHER IN INSP/MAINT 1 SW 17 62295 2921 32R7680336 INSPECTION FOUND INBOARD PORTION OF WHEEL HALF BEAD CRACKED ONE-THIRD WAY AROUND WHEEL CAUSING WHEEL TO CONTACT BRAKE CY LINDER. 1 L 7 1 3O A3SO 1997100900488 19971009 00488 SW 1997 10 9 97ZZZX4316 1 19970905 G 2823 10648BH11 SWITCH BELL 222 222 1182122 SW FUEL SOV FAILED H A O OTHER Y ENGINE STOPPAGE CR CRUISE 1 GL 23 40EA 1586 47061 FUEL VALVE SWITCH VIBRATED LOOSE DURING FLIGHT CAUSING FUEL VALVE TO CLOSE AND ENGINE TO SHUT DOWN DUE TO FUEL STARVATIO N. SUSPECTED CAUSE OF FAILURE MECHANICAL LOCKING (INTERNAL). SUBMITTER RECOMMENDS REPLACEMENT OF SWITCH FOLLOWING 7,50 0 CYCLES OF SWITCH OPERATION. CYCLES BASED ON 2 ENGINE STARTS PER HOUR, 4 SWITCH OPERATIONS PLUS 1,500 OPERATIONS FOR M AINTENANCE WORK AND GROUND RUNS, ETC. 1 G 7 2 3U H9SW 1997101600001 19971016 00001 EA 1997 10 16 97ZZZX4327 2 19970901 G 7414 10682014 DISTRIBUTOR GEAR BENDIX D2000 CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MAGNETO TEETH FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 17 733WT 1046 4085256NCBD 17268613 RL1293 ENGINE FAILED PRE-TAKEOFF MAGNETO CHECK. PILOT RAN ENGINE AT HIGH RPM AND LEANED ENGINE TO SEE IF PLUGS WERE FOULED. A FTER REDUCING POWER ON SECOND MAGNETO CHECK, MAG WAS DEAD. FOUND 3 TEETH MISSING ON DISTRIBUTOR GEAR. MAG HAS 1,045 HO URS TSMO. 1 H 7 1 3O 3 O NT 3A12 E274 1997101600002 19971016 00002 SO 1997 10 16 97ZZZX4328 1 19970901 G 5510 STABILIZER LUSCOM 8 8A 8190104 SO HORIZONTAL STAB CORRODED D P A K NONE O OTHER IN INSP/MAINT 1 WP 07 3400 AIRCRAFT GROUND LOOPED AND DAMAGED HORIZONTAL TIP. 1991 STORED INSIDE. REMOVED TIP AND SKINS FOR REPAIR NOTING EXCESSI VE INTERNAL CORROSION (AIRCRAFT PARKED OVER GRASS). NO INSPECTION HOLES TO ALLOW FOR INSPECTION. APPARENTLY, NO INSPECT IONS CONDUCTED AT ANNUAL INSPECTION. NOTED SIMILAR LACK OF ACCESS TO WINGS FOR INSPECTIONS. 1 H 7 1 3O A694 1997101600004 19971016 00004 SO 1997 10 16 97ZZZX4330 2 19970828 G 8520 642185A1 STUD ASSY CESSNA 210 P210N 2073454 CE CONT O520 TSIO520P 17040 SO CRANKSHAFT MISTORQUED D K NONE J WARNING INDICATION IN INSP/MAINT 1 WP 07 4811K 621 P21000330 278610R LOW OIL PRESSURE; ALL EXTERIOR INSPECTION AND TESTS EXHAUSTED. REMOVED ENGINE AND DIS-ASSEMBLED. FOUND VISUAL SIGNS OF ENGINE MAIN BEARING BORE MISALIGNMENT, I.E., MAIN BEARING PATTERN COVERING ONLY 50 PERCENT OF AREA, ALL FIVE JOURNALS. LOG BOOK ENTRY SHOWS PROPELLER STRIKE, DISASSEMBLY, INSPECTION, REPAIRS AND RE-ASSEMBLY, 99.6 HRS, PREVIOUSLY ON 8-29-9 6, BY CUSTOM AIRMOTIVE, TULSA, OK. W.O. NR 14148; FAA REPAIR STATION NR DC2R763K. SUSPECT IMPROPER TORQUE, AND/OR IMPR OPER TORQUE SEQUENCE AS SET FORTH IN THE MFG M & O MANUAL. 1 H 7 1 3O 3 O 3A21 E8CE 1997101600005 19971016 00005 CE 1997 10 16 97ZZZX4331 1 19970915 G 3231 ARB4EDUS ROD END CESSNA 402 402C 207590R CE RT GEAR DOOR BROKE D K NONE O OTHER NR NOT REPORTED 1 NE 01 67886 402C0435 RIGHT LANDING GEAR DOOR CONTROL ROD BROKE AT ROD END, DOOR WOULD HANG DOWN WITH GEAR UP. INSTALLED NEW CONTROL ROD AND RIGGED. NO FURTHER TROUBLE. 1 L 7 2 3O A7CE 1997101600006 19971016 00006 SO 1997 10 16 97ZZZX4332 1 19970926 G 3230 AN17727 BOLT 1624004 PIPER PA23 PA23250 7102308 SO DRAG LEG LINK FAILED H S K NONE O OTHER IN INSP/MAINT 1 CE 09 54757 8979 277554068 WHEN APPLYING GREASE TO CENTER DRAG LEG ATTACH BOLT, THE MECHANIC NOTICED THE HEAD OF BOLT SLID OUT .25 INCH, AND BECAME WEDGED IN FITTING PN 19155-03 LANDING GEAR LOCK SPRING UPPER WHICH PREVENTED BROKEN PORTION OF BOLT FROM FALLING OUT. 1 L 7 2 3O 1A10 1997101600007 19971016 00007 SO 1997 10 16 97ZZZX4333 1 19970921 G 2150 IDLER PULLEY PIPER PA32 PA32300 7103212 SO AIR COND BEARING FAILED H P O OTHER O OTHER LD LANDING 1 SW 99 28893 327940123 AFTER LANDING, THE IDLER PULLEY ASSY DETACHED FROM BEARING ASSY. PULLEY COULD HAVE HUNG UP IN FLY-WHEEL RING GEAR. NEW ENGINE INSTALLED JUST PRIOR TO FAILURE. RECOMMEND NEW BEARING BE INSTALLED AT ENGINE OVERHAUL. 1 L 7 1 3O A3SO 1997101600008 19971016 00008 SO 1997 10 16 97ZZZX4334 1 19970924 G 3240 451209 MASTER CYLINDER SCOTT PIPER PA18 PA18150 7101828 SO BRAKE MISSERVICED B A CF4R O OTHER O OTHER LD LANDING 1 AL 03 2355H 187909175 BRAKE MASTER CYLINDERS SERVICED BY AN OUTSIDE SHOP DUE TO 'LOW FLUID LEVEL'. MECH TOLD PILOT THE BRAKES WERE 'PUMPED UP HARD'. PILOT USED CABIN HEAT DURING NEXT FLIGHT. UPON LANDING, BRAKES WERE 'LOCKED UP'. ACFT GROUND LOOPED DURING LA NDING DAMAGING LT WING. AFTER ACFT SET FOR ABOUT AN HOUR, THE BRAKES WERE 'FREE', AND ABLE TO ROLL THE ACFT. SUBMITTER SUSPECTS THE MECHANIC DID NOT USE THE PROPER SERVICING PROCEDURE OVERSERVICING MASTER CYLINDER. UPON APPLICATION OF CA BIN HEAT, FLUID EXPANDED, LOCKING BRAKES. 1 H 7 1 3O 1A2 1997101600009 19971016 00009 CE 1997 10 16 97ZZZX4335 1 19970926 G 3222 12436231 YOKE CESSNA 206 U206E 2073350 CE NLG FAILED D A K NONE O OTHER NR NOT REPORTED 1 AL 03 9129M 3000 U20601529 CESSNA HEAVY DUTY NOSE FORK SHEARED NEXT TO 4 BOLTS THAT SECURE IT TO THE NOSE STRUT. PN 1243620-1 NOSE GEAR HUB WAS NO T BROKEN AND DID NOT FAIL NOR DID THE 4 BOLTS. THE YOKE SHOWED NO SIGNS OF CORROSION OR CRACKS PREVIOUS TO ACCIDENT. 1 H 7 1 3O A4CE 1997101600010 19971016 00010 NE 1997 10 16 97ZZZX4336 2 19970925 G 7310 430137601 FUEL MANIFOLD BOLKMS 117 BK117A4 5626017 EU LYC LTS101 LTS101650B1 41560 NE NR 1 ENGINE LEAK E A K NONE K FLUID LOSS IN INSP/MAINT 1 EA 07 230H 960 1TJ03956 7134 45261 PIN HOLE LEAK IN TUBING BETWEEN NOZZLES. HIGH PRESSURE FUEL SPRAYING INTO ENGINE COMPARTMENT. SUBMITTER STATED THE TUB ING BETWEEN NOZZLES SHOULD BE REPLACED AT OVERHAUL. ALLIED SIGNAL SHOULD FIELD FLEX HOSE MANIFOLD ASAP. 1 G 7 2 3U 3 U H13EU E5NE 1997101600011 19971016 00011 NE 1997 10 16 97ZZZX4337 2 19970925 G 7310 FUEL MANIFOLD BOLKMS 117 BK117A4 5626017 EU LYC LTS101 LTS101650B1 41560 NE NR 2 ENGINE LEAK E K NONE K FLUID LOSS IN INSP/MAINT 1 EA 07 230H 32 7136 45186 HIGH PRESSURE LEAK AT BRAZE JOINT. FUEL SPRAYING IN ENGINE COMPARTMENT. SUBMITTER STATED BRAZE JOINT TUBING SHOULD BE REPLACED AT OVERHAUL. 1 G 7 2 3U 3 U H13EU E5NE 1997101600012 19971016 00012 SW 1997 10 16 97ZZZX4338 1 19970925 G 6300 369A5361 BEARING 369A535041 HUGHES 500N 500N 3027374 SW ORIDE CLUTCH SEAL CLIP FAILED G K NONE O OTHER NR NOT REPORTED 1 WP 07 522FB 256 LN002 LOWER SEAL RETAINING CLIP FELL OUT DURING FLIGHT. FOUND DURING 100-HOUR INSPECTION. 1 G 7 1 3U NC H3WE 1997101600013 19971016 00013 SW 1997 10 16 97ZZZX4339 1 19970925 G 6300 369A5361 BEARING HUGHES 500N 500N 3027374 SW ORIDE CLUTCH SEAL CLIP FAILED G K NONE O OTHER NR NOT REPORTED 1 WP 07 527FB 297 369A535041 LN007 LOWER BEARING SEAL CLIP FELL OUT DURING FLIGHT. FOUND DURING 300-HOUR INSPECTION. 1 G 7 1 3U NC H3WE 1997101600014 19971016 00014 SW 1997 10 16 97ZZZX4340 1 19970925 G 2550 HL16600170 HOIST BREEZE BELL 206 206L4 1182110 SW RESCUE MALFUNCTION D O OTHER O OTHER HO HOVERING 1 WP 23 6197N 230 52014 DURING A TRAINING PERIOD, THE CABLE CUTTER ENGAGED THE CABLE CAUSING A PARTIAL FAILURE OF THE CABLE WHILE A CREW MEMBER WAS BEING LOWERED. THE HOIST HAS BEEN RETURNED TO THE MANUFACTURER FOR ANALYSIS. A FOLLOW-UP REPORT STATES MFG ANALYSI S FOUND THE CABLE CUTTER WAS INCORRECTLY INSTALLED, CAUSING CABLE TO FRAY. 1 G 7 1 3U NC H2SW 1997101600015 19971016 00015 WP 1997 10 16 97ZZZX4341 1 19970919 G 6220 269A1329 RING HUGHES 269 TH55A 4471004 WP DROOP STOP MISINSTALLED D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 09 8047L 470699 DURING AN ANNUAL INSPECTION, DISCOVERED THE DROOP STOP RING WAS PREVIOUSLY INSTALLED INVERTED. THE MAIN ROTOR HEAD WAS ASSEMBLED THREE YEARS AND 60 HOURS PRIOR TO THIS INSPECTION. 1 G 7 1 3R 1997101600017 19971016 00017 EA 1997 10 16 97ZZZX4342 1 19970905 G 2621 898526 FIRE BOTTLE KIDDE BOEING 234 234 1385049 EA APU DISCHARGED B CHIR K NONE O OTHER IN INSP/MAINT 1 NM 09 2FOR 54981EJ MJ005 AIRCRAFT WAS ON HELIPAD WHEN THE FIRE BOTTLE DISCHARGED. INVESTIGATION REVEALED THE THERMAL RELIEF VALVE HAD ACTIVATED AND BOTTLE PRESSURE WAS ZERO. THE SKIN OF THE ACFT IS VERY CLOSE TO THE BOTTLE AND IS PAINTED BLACK ON THE OUTSIDE AND IN A POSITION OF DIRECT SUNLIGHT IN THE A.M. THE OAT ON THE HELIPAD WAS 74 DEGREES FAHRENHEIT. THE FIRE BOTTLE COMPART MENT INSIDE SKIN TEMP WAS 132 DEGREES FAHRENHEIT. THE INSIDE SKIN TEMP OF SKIN THAT HAS AN OUTSIDE PAINT OF WHITE NEAR SAME AREA WAS 107 DEGREES FAHRENHEIT. (A COMPANY CALIBRATED INSTRUMENT WAS USED.) MM, CHAPTER 26-20-00, PAGE 8, PARAGR APH E, STIPULATES HIGH PRESSURE BLOW-OFF BETWEEN 208 DEGREES TO 220 DEREES FAHRENHEIT. (X) 2 G 7 2 4U H9EA 1997101600018 19971016 00018 NE 1997 10 16 97ZZZX4343 2 19970918 G 7314 RG37060A PUMP BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE RT ENGINE FAILED B A PAIR K NONE K FLUID LOSS NR NOT REPORTED 1 SO 05 995WS 1756 B1269 UE175 PCE114388 FUEL PUMP ON RT ENG FAILED CAUSING FUEL TO DRAIN FROM VENTED PLUG DURING OPERATION. THIS VENTED PLUG INSTALLED ON THE P UMP IS NOT PLUMBED TO DRAIN FUEL OUT OF ENG COMPT DURING PUMP FAILURE. THIS FAILURE WAS NOT DISCOVERED TILL AFTER FLIGH T WHEN FUEL WAS NOTED DRIPPING FROM RT NACELLE. FURTHER INSP FOUND LOWER REAR ENG COMPT SOAKED WITH FUEL. BEECH 1900D IPC ATA 71-70-00 DOES NOT SHOW A DRAIN PLUMBED TO THIS VENT PLUG. NOTED THE DRAIN MANIFOLD PN 101-910099-19 AND DASH 20 ATA 71-70-00 ITEM 18 DOES SHOWS AN EXTRA NIPPLE AS VERIFIED ON ACTUAL ACFT. RECOMMEND VENTED DRAIN ON FUEL PUMP IS PLU MBED TO THIS EXTRA NIPPLE ON DRAIN MANIFOLD TO PREVENT FUEL FROM DRAINING INTO ENG COMPT DURING PUMP FAILURE. 2 L 7 2 4T 4 T RT A24CE E26NE 1997101600019 19971016 00019 NE 1997 10 16 97ZZZX4344 3 19970919 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 4618 2049NR HJ378A INSPECTION FOUND FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. TWO CRACKS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997101600023 19971016 00023 NE 1997 10 16 97ZZZX4347 1 19970917 G 6220 6510311065102 BRACKET BOLT 651001130080 SKRSKY S64 S64F NE M/R DAMPER CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 159AC 997 64084 DURING OVERHAUL OF THE MAIN ROTOR HEAD, A FLUORESCENT MAGNETIC PARTICLE INSPECTION REVEALED A TOTAL OF 4 CRACK INDICATIO NS IN BOLT HEAD TO SHANK RADIUS. LARGEST CRACK IS 0.200 INCH IN LENGTH RADIALLY AROUND SHANK. THREE SMALL CRACKS ARE 0 .040 INCH LONG EACH. NO REASON FOR THE CRACKING IS APPARENT. 2 G 7 2 4U H6EA 1997101600024 19971016 00024 NE 1997 10 16 97ZZZX4348 2 19970917 G 7250 4560119360 CIRCLIP SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D NE MO 3 BEARING MISSING D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 11 6099P 2818 9365 DURING CLEANING OF REAR BEARING SUPPORT ASSEMBLY, INSPECTION FOUND THE CIRCLIP THAT HOLDS REAR BEARING POWER TURBINE GUI DE VANE MISSING. SUSPECT CAUSE: DURING LAST MAINTENANCE PROCEDURES BY TURBOMECA CO., CIRCLIP WAS NOT INSTALLED. A/C T T: 1,699.5 HOURS. ENG TT: 1,563.2 HOURS. 1 G 7 1 3U 3 U H9EU E19EU 1997101600025 19971016 00025 SW 1997 10 16 97ZZZX4349 1 19970823 G 3213 214052052101 CROSSTUBE BELL 214 214ST 1182106 SW SKID GEAR FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 99 745H 28197 REAR CROSSTUBE FRACTURED DURING GROUND HANDLING OF AIRCRAFT (RAISED ON WHEELS). TOTAL WT. A/C, 13,535 POUNDS. ACCEPTAB LE MOVEMENT LIMITATION, 14,500 POUNDS. 2 G 7 2 4U H10SW 1997101600029 19971016 00029 NE 1997 10 16 97ZZZX4351 1 19970915 G 3234 0911077004 CONTROL VALVE SKRSKY S76 S76B 8143007 NE LANDING GEAR MISWIRED D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 03 54C 0557A 760348 THE LANDING GEAR CONTROL VALVE REMOVED FOR OCCASIONAL POPPING OF THE 'MANUAL RESET' BUTTON WHICH KEPT THE GEAR FROM BEIN G RETRACTED. AN O/H VALVE, ARKWIN IND, INC., PN 0911077-004, SIKORSKY PN 76650-02802-0911077-004, SIKORSKY PN 76650-028 02-104, SN 0557A WAS INSTALLED IN HELICOPTER. WHEN ATTEMPTING TO OPERATE THE GEAR, DISCOVERED WITH THE GEAR HANDLE IN T HE DOWN POSITION, THE GEAR WOULD RETRACT, AND EXTEND WHEN IN THE UP POSITION. AFTER FURTHER INVESIGATION, FOUND THE UP AND DOWN SOLENOIDS ON THE VALVE WERE WIRED BACKWARDS. ANOTHER VALVE WAS INSTALLED AND THE GEAR OPERATED NORMALLY. 1 G 7 2 4U H1NE 1997101600031 19971016 00031 NM 1997 10 16 97ZZZX4352 1 19970908 G 5313 STRINGER BOEING 737 7372H4 138448C NM BS 360 - BS 908 CRACKED B EF2R K NONE O OTHER IN INSP/MAINT 1 SW 05 26SW 68390 21117 NUMEROUS FASTENER HOLES CRACKED BEYOND LIMITS, STR 4L, STA 360 TO STA 908, AND STR 4R, STA 360 TO STA 908. NUMEROUS FAS TENER HOLES CRACKED BEYOND LIMITS, STR 10R, STA 727 TO STA 908, AND STR 10L, STA 360 TO STA 540, AND STA 727 TO STA 908. ABOVE MENTIONED LIMITS BASED ON AD 94-25-05. REPAIRED PER DALFORT AVIATION XEA NR X2-53-171, REV 5, DATED 8-5-97. APP ROVAL DATA: FAA FORM 8110-3, DATED 7-9-97. 2 L 7 2 4F A16WE 1997101600032 19971016 00032 NM 1997 10 16 97ZZZX4353 1 19970908 G 5313 STRINGER BOEING 737 7372H4 138448C NM BS 498 - BS 887 CRACKED B EF2R K NONE O OTHER IN INSP/MAINT 1 SW 05 26SW 68390 21117 ONE EACH ATTACHMENT HOLE CRACKED BEYOND LIMITS, STR 14R, STA 734 AND STR 10L, STA'S 498 AND 500. ONE EACH ATTACHMENT HO LE CRACKED BEYOND LIMITS, STR 14L, STA 416 AND STA 443, AND, STR 20L, STA 827 AND STA 887. ABOVE MENTIONED LIMITS BASED ON AD 94-25-05. REPAIRED PER DALFORT AVIATION XEA NR X2-53-173, REV 3, DATED 7-1-97. APPROVAL DATA: FAA FORM 8110-3, DATED 6-26-97. 2 L 7 2 4F A16WE 1997101600033 19971016 00033 NM 1997 10 16 97ZZZX4354 1 19970908 G 5313 STRINGER BOEING 737 7372H4 138448C NM BS 485 - BS 957 CRACKS B EF2R K NONE O OTHER IN INSP/MAINT 1 SW 05 26SW 68390 21117 THREE EACH ATTACHMENT HOLES OUT OF ALLOWABLE LIMITS. LOCATED AT STR 10L AT STATIONS 445, 485, AND 507. LIMITS BASED ON DALFORT AVIATION XEA NR X2-53-168, REV 2, DATED 6-30-97. TWO ATTACHMENT HOLES CRACKED BEYOND ALLOWABLE LIMITS. LOCATE D ON LOWER ROW SKIN LAP ON STR 10R AT STA 957.25. LIMITS BASED ON AD 94-25-05. REPAIRED PER DALFORT AVIATION XEA NR X2 -53-167, REV 1 DATED 6-4-97. BOEING SB 53A117 REV 1 AND FAA AD 94-25-05. 2 L 7 2 4F A16WE 1997101600034 19971016 00034 NM 1997 10 16 97ZZZX4355 1 19970908 G 5313 STRINGER BOEING 737 7372H4 138448C NM BS 344 CRACKED B EF2R K NONE O OTHER IN INSP/MAINT 1 SW 05 26SW 68390 21117 ONE EACH ATTACHMENT HOLE CRACKED BEYOND ALLOWABLE LIMITS, LOWER ROW SKIN LAP. LOCATED AT STA 344, STR 14R. LIMITS BASE D ON AD 95-25-05. REPAIRED PER DALFORT AVIATION XEA NR X2-53-177 REV 1 DATED 7-17-97 AND XEA NR X2-53-17 REV 3 DATED 7- 1-97. APPROVAL DATA: FAA FORM 8110-3 DATED 7-17-97. 2 L 7 2 4F A16WE 1997101600035 19971016 00035 NM 1997 10 16 97ZZZX4356 1 19970908 G 5313 STRINGER BOEING 737 7372H4 138448C NM STA 540 HOLES WORN B EF2R K NONE O OTHER IN INSP/MAINT 1 SW 05 26SW 68390 21117 TWO EACH ATTTACHMENT HOLES CRACKED BEYOND ALLOWABLE LIMITS. LOCATED IN LOWER ROW SKIN LAP ON STR 14L, STA 540. LIMITS BASED ON AD 94-25-05. REPAIRED PER DALFORT AVIATION XEA NR X2-53-184 REV 1 DATED 8-20-97. APPROVAL DATA: FAA FORM 8110 -3 DATED 8-19-97. 2 L 7 2 4F A16WE 1997101600036 19971016 00036 NM 1997 10 16 97ZZZX4357 1 19970908 G 5313 STRINGER BOEING 737 7372H4 138448C NM BS 380 DOUBLER CRACKED B EF2R K NONE O OTHER IN INSP/MAINT 1 SW 05 26SW 68390 21117 PREVIOUS REPAIR IS NOT IN C/W SB 737-53-A 1177 AND THE INNER DOUBLER IS CRACKED AT STA 380, STR 19R. REPAIRED PER DALFO RD AVIATION XEA NR X2-53-182 REV 1 DATED 7-31-97. APPROVAL DATA: FAA 8110-3 DATED 8-18-97. 2 L 7 2 4F A16WE 1997101600037 19971016 00037 NM 1997 10 16 97ZZZX4358 1 19970908 G 5315 FLOOR BEAM BOEING 737 7372H4 138448C NM BS 685 CRACKED B EF2R K NONE O OTHER IN INSP/MAINT 1 SW 05 26SW 68390 21117 FLOOR BEAM CRACKED, STA 685, STR 62R. REPAIRED PER DALFORT AVIATION XEA NR X2-53-180 REV 1 DATED 7-18-97. APPROVAL DAT A: FAA FORM 8110-3 DATED 7-29-97. 2 L 7 2 4F A16WE 1997101600038 19971016 00038 NM 1997 10 16 97ZZZX4359 1 19970908 G 5313 STRINGER BOEING 737 7372H4 138448C NM BS 393 OUT OF LIMITS B EF2R K NONE O OTHER IN INSP/MAINT 1 SW 05 26SW 68390 21117 ONE EACH 0.233 INCH DIAMETER HOLE OUT OF ALLOWABLE LIMITS PER DALFORT AVIATION XEA NR X2-53-168. LOCATED AT STR 10L, STA 393. REPAIRED PER DALFORT AVIATION XEA NR X2-53-168, REV 3 DATED 6-30-97. APPROVAL DATA: FAA FORM 8110-3 DATED 6-27- 97. 2 L 7 2 4F A16WE 1997013000141 19970130 00141 EA 1997 1 30 97ZZZX436 2 19970103 G 7322 95351610 O-RING BENDIX RSA5AD1 MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA FUEL SERVO CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 NE 01 1980J 724 724 241000 DURING ANNUAL INSPECTION, A PRESSURE TEST OF THE ENGINE FUEL SYSTEM REVEALED A LEAK AT THE MIXTURE CONTROL SHAFT WHICH D RIPPED ON THE MUFFLER BELOW . REPLACEMENT OF O - RINGS 953516-10 AND 951401 CURED THE LEAK. SUBMITTER SUGGESTED CLOSE INSPECTION AND PRESSURE TESTING SHOULD EASILY FIND THIS PROBLEM. 1 L 7 1 3O 3 O 2A3 1E10 1997101600039 19971016 00039 NM 1997 10 16 97ZZZX4360 1 19970908 G 5313 STRINGER BOEING 737 7372H4 138448C NM BS 269 - BS 285 CRACKED B EF2R K NONE O OTHER IN INSP/MAINT 1 SW 05 26SW 68390 21117 THREE ATTACHMENT HOLES CRACKED BEYOND LIMITS, LOWER SKIN LAP ROW AT STA 269 THROUGH STA 285, STR 19L. LIMITS BASED ON A D 64-25-05. REPAIRED PER DALFORT AVIATION XEA NR X2-53-176 DATED 7-1-97 AND XEA NR X2-53-173 REV 3 DATED 7-1-97. APPRO VAL DATA: FAA FORM 8110-3 DATED 7-17-97. 2 L 7 2 4F A16WE 1997101600040 19971016 00040 NM 1997 10 16 97ZZZX4361 1 19970901 G 5330 SKIN BOEING 727 72730 1384008 NM BS 360 - BS 441 CRACKED B EF2R K NONE O OTHER IN INSP/MAINT 1 SW 05 113 18935 FOUND AND REPAIRED CRACKS IN THE FUSELAGE SKIN AT THE FOLLOWING LOCATIONS. STA 418, STR 21L, 2 EACH. STA 370 - STA 385 , STR 22L, 5 EACH. STA 400 BELOW STR 23L, 1 EACH. STA 420, STR 20L, 2 EACH. STA 385, STR 23L, 1 EACH. REPAIRED CORRO SION AT FS 415, STR 23L. ALL 6 EACH REPAIRS MADE PER BOEING AIRCRAFT SRM 53-30-3, FIGURE 14. 2 L 7 3 4F A3WE 1997101600041 19971016 00041 NM 1997 10 16 97ZZZX4362 1 19970826 G 5755 CASTING BOEING 727 72730 1384008 NM RT INBD SPOILER CRACK B EF2R K NONE O OTHER IN INSP/MAINT 1 SW 05 113 18935 RIGHT HAND INBOARD SPOILER CASTING CRACKED TOP INBOARD AFT ATTACH HOLE. REPAIRED PER APPROVED DATA BOEING AIRCRAFT COOP ERATION ENGINEERING INSTRUCTIONS, REFERENCE TELEX NR 32-9430 AND BOEING AIRCRAFT DRAWING SKETCH NR 65-19222. 2 L 7 3 4F A3WE 1997101600042 19971016 00042 NM 1997 10 16 97ZZZX4363 1 19970825 G 5330 SKIN BOEING 727 72730 1384008 NM BS 360 - BS 441 DEFECTIVE B EF2R K NONE O OTHER IN INSP/MAINT 1 SW 05 113 18935 AN EXISTING REPAIR HAS BEEN INSTALLED THE FULL LENGTH OF TH FUSELAGE FROM BS 360 TO BS 441 AT LONGERON 19R TO LONGERON 2 6R. THE EXISTING REPAIR WILL BE CHANGED BY DALFORT AVIATION UNDER XEA, NR X1-53-691. REVISION ONE. APPROVED DATA BOEI NG 727 SRM 53-30-3, FIGURE 14, BOEING AIRCRAFT DRAWING NR 65-18215 AND NR 65-18219. 2 L 7 3 4F A3WE 1997101600408 19971016 00408 1997 10 16 97ZZZX4369 1 19970924 G 6123 A3496 FEATHER SPRING HARTZL HCB4M HCB4MP3 GL PROPELLER BROKEN B ME4D K NONE O OTHER IN INSP/MAINT 1 SO 15 FW1410 DURING INSPECTION OF PROPELLER, FEATHER SPRING WAS FOUND BROKEN IN TWO. DEFECTIVE SPRING RETURNED TO HARTZEL PROPELLER, INC. 6 C P56GL 1997013000142 19970130 00142 EA 1997 1 30 97ZZZX437 2 19970103 G 7322 951401 O-RING BENDIX RSA5AD1 MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA FUEL SERVO CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 NE 01 1980J 724 724 241000 DURING ANNUAL INSPECTION, A PRESSURE TEST OF THE ENGINE FUEL SYSTEM REVEALED A LEAK AT THE MIXTURE CONTROL SHAFT WHICH D RIPPED ON THE MUFFLER BELOW . REPLACEMENT OF O - RINGS 953516-10 AND 951401 CURED THE LEAK. SUBMITTER SUGGESTED CLOSE INSPECTION AND PRESSURE TESTING SHOULD EASILY FIND THIS PROBLEM. 1 L 7 1 3O 3 O 2A3 1E10 1997101600409 19971016 00409 CE 1997 10 16 97ZZZX4370 1 19970918 G 5280 NAS1204 BOLT RKWELL NA265 NA26565 7630107 CE MLG DOOR FAILED B QL1R O OTHER D INFLIGHT SEPARATION CR CRUISE 1 EA 13 265A 12231 46547 LANDING GEAR DOOR DEPARTED AIRCRAFT IN-FLIGHT (GEAR UP). LAB REPORT DEFINED PROBLEM IN ONE HINGE ATTACH BOLT ON DOOR TH AT FATIGUED DUE TO 'HIGH CYCLE' VIBRATION CAUSING CRACKING AND WHEN DOOR DROPPED DOWN, WIND CAUGHT IT BREAKING HINGE AND ROD END AND DOOR BROKE AWAY FROM AIRCRAFT CAUSING SUBSTANTIAL COWLING, ENGINE, AND PYLON DAMAGE. CAUSE OF VIBRATION NO T KNOWN. ONLY SUBMITTER RECOMMENDATION, REMOVE AND MAGNAFLUX BOLTS AT A PARTICULAR INTERVAL. THERE WAS NO MANUFACTURE RECOMMENDATION ON INSPECTION INTERVAL FOR THESE BOLTS. 2 L 7 2 4J A2WE 1997101600410 19971016 00410 SO 1997 10 16 97ZZZX4371 1 19970601 G 2730 1159C20157 BEARING GULSTM G1159 GIV 3980115 SO ELEVATOR TRIM FROZE D L A O OTHER F FLT CONT AFFECTED CR CRUISE 1 WP 13 575SF 1233 FLIGHT FROM PERTH TO MELBOURNE, AUSTRALIA, PILOT DISCOVERED ELEVATOR/TRIM SYSTEM INOPERATIVE WHEN AN ATTEMPT TO SEEK A LOWER ALTITUDE. APPEARED AS THOUGH THE ELEVATOR SYSTEM WAS FROZEN. THE SYSTEM BECAME FREE AT A LOWER ALTITUDE AND A SA FE LANDING WAS MADE. DURING A POST-FLIGHT INSPECTION, EXAMINATION OF THE COMPLETE TAIL COMPARTMENT ELEVATOR SYSTEM REVE ALED NO DEFECTS OR ABNORMALITIES THAT WOULD CAUSE THE PROBLEM. THE TWO PREVIOUS DAYS IN PERTH, THE AIRCRAFT WAS PARKED OUTSIDE IN TWO FULL DAYS OF HEAVY RAINS. IT IS SUBMITTER'S CONTENTION THAT WATER MADE ITS WAY INTO THE BUNGEE (BEARING PN 1159C20157 AT FLIGHT STATION 765) MECHANISM; THUS, FREEZING AT ALTITUDE WHICH WOULD IMPEDE ELEVATOR/TRIM OPERATIONS. 2 L 7 2 4F RT A12EA 1997101600411 19971016 00411 NE 1997 10 16 97ZZZX4372 2 19970918 G 7230 500588701 STATOR 716728 PWA JT8 JT8D219 52053 NE 7TH STAGE DAMAGED D K NONE O OTHER IN INSP/MAINT 1 SW 05 27978 4747 VB0240 716728 ENGINE REMOVED FROM SERVICE DUE TO METAL IN THE TAILPIPE. DISASSEMBLY OF THE ENGINE REVEALED HEAVY INTERNAL FAILURE OF THE HIGH PRESSURE COMPRESSOR STATOR AND ROTOR BEGINNING WITH 7TH STAGE. FAILURE INVESTIGATION IS IN PROGRESS AT GREENWI CH. 4 F E9NE 1997101600412 19971016 00412 NE 1997 10 16 97ZZZX4373 2 19970917 G 7230 500588701 STATOR 716728 PWA JT8 JT8D217A 52053 NE 7TH STAGE DAMAGED D K NONE O OTHER IN INSP/MAINT 1 SW 05 VZ0194 709895 ENGINE REMOVED FROM SERVICE DUE TO TURBINE FAILURE. DISASSEMBLY OF THE ENGINE REVEALED HEAVY INTERNAL FAILURE OF THE HI GH COMPRESSOR STATOR AND ROTOR BEGINNING WITH 7TH STAGE. FAILURE INVESTIGATION IS IN PROGRESS AT GREENWICH. 4 F E9NE 1997101600413 19971016 00413 SW 1997 10 16 97ZZZX4374 1 19970923 G 2913 PV304426 PUMP SWRNGN SA226 SA226TB 8780406 SW HYDRAULIC SYSTEM FAILED B TRKR O OTHER J WARNING INDICATION NR NOT REPORTED 1 SO 15 59EZ 3554 1423 394 AIRCRAFT LOST PARTIAL HYDRAULIC PRESSURE. GEAR PUT DOWN AND AIRCRAFT LANDED UNEVENTFULLY. RT ENGINE STIFF TO TURN BY H AND. PULLED HYDRAULIC PUMP AND FOUND 90 PERCENT SEIZED. INSTALLED NEW PUMP, OPERATION CHECKED GOOD. 2 L 7 2 4T RT A5SW 1997101600414 19971016 00414 CE 1997 10 16 97ZZZX4375 1 19970915 G 3610 265510162 TUBE LEAR 35 31A 5170531 CE BLEED AIR DENTED B NVIR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 107FX 102 RECEIVED NEW BLEED AIR TUBE ASSY FROM LEARJET WITH SEVERAL LARGE DENTS. RETURNED UNUSED TO LEARJJET FOR REPLACEMENT. R ECEIVED 2ND TUBE ASSY WITH NO DAMAGE. INSTALLED ON AIRCRAFT AND RETURNED TO SERVICE. (PN 2655101-62). 2 L 7 2 4F RT A10CE 1997101600415 19971016 00415 CE 1997 10 16 97ZZZX4376 1 19970915 G 7714 1313483 INDICATOR LEAR 35 31A 5170531 CE ENGINE N2 INOPERATIVE B NVIR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 107FX 105B0062 102 RECEIVED NEW N2 INDICATOR UNIT FROM LEARJET. REMOVED FROM BOX, UNIT INOPERABLE. RETURNED UNUSED TO LEARJET FOR REPLACE MENT. RECEIVED SECOND UNIT. INSTALLED ON AIRCRAFT AND RETURNED TO SERVICE. (PN 131348-3). 2 L 7 2 4F RT A10CE 1997101600416 19971016 00416 1997 10 16 97ZZZX4377 4 19970915 G 3418 54800032 COMPUTER LEAR 55 55LEAR 5170702 CE STALL WARNING INOPERATIVE B NVIR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 150MS 3400 062006 55049 RECEIVED NEW STALL COMPUTER UNIT FROM LEARJET, REMOVED FROM BOX, UNIT NOT OPERATING CORRECTLY. LT TONE TOO LONG, RT WOU LD NOT TEST. RETURNED UNUSED TO LEARJET FOR REPLACEMENT. RECEIVED SECOND UNIT, INSTALLED ON AIRCRAFT AND RETURNED TO S ERVICE. (PN 5480003-2). 2 L 7 2 4F A10CE 1997101600417 19971016 00417 1997 10 16 97ZZZX4378 4 19970915 G 3421 501111501 SERVO AMP LEAR 25 25B 5170511 CE NR 2 HORIZ GYRO FAILED B NVIR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 752CA 137 RECEIVED REPAIRED SERVO AMP UNIT FROM LEARJET, REMOVED FROM BOX, UNIT OPERATED NORMALLY FOR 5 MINUTES AFTER WHICH TIME A N ELECTRICAL BURNING SMELL WAS EMITTED AND UNIT QUIT OPERATING. RETURNED SAME TO LEARJET FOR REPLACMENT. RECEIVED SECO ND UNIT. INSTALLED ON AIRCRAFT AND RETURNED TO SERVICE. (PN 501-0005-01). 2 L 7 2 4J A10CE 1997101600418 19971016 00418 SO 1997 10 16 97ZZZX4379 2 19971001 G 8520 CRANKCASE CESSNA 421 421B 2076014 CE CONT O520 GTSIO520H 17032 SO NR 2 CYL ATTACH CRACKED H K NONE O OTHER IN INSP/MAINT 1 EA 03 145ES 1719 800 421B0143 218081R CRANKCASE CRACKED BOTTOM NR 2 CYLINDER ATTACH, AFT .4375 INCH CYLINDER STUD. 1 L 7 2 3O 3 O A7CE E7CE 1997013000143 19970130 00143 SO 1997 1 30 97ZZZX438 1 19970110 G 8011 MHB4014 STARTER PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA ENGINE FAILED D K NONE O OTHER IN INSP/MAINT 1 AL 01 27755 1 A114356 317852148 L96168A AIRCRAFT LANDED IN FT YUKON AND SHUT DOWN. UPON TRYING TO START THE RIGHT ENGINE, THE BENDIX ENGAGED, BUT STARTER WOULD NOT SPIN THE PROP. STARTER WAS RECENTLY OVERHAULED. 1 L 7 2 3O 3 O A20SO E14EA 1997101600419 19971016 00419 SO 1997 10 16 97ZZZX4380 1 19971002 G 2430 587829 SWITCH PIPER PA28 PA28181 7102807 SO ALTERNATOR FAULTY B LF1R K NONE O OTHER IN INSP/MAINT 1 EA 07 2104U 4000 287990327 OWNER COMPLAINED OF FLUCTUATING AMMETER AND LIGHTS. ALTERNATOR, REGULATOR, AND OVERVOLTAGE REGULATOR HAD BEEN PREVIOUSL Y REPLACED. AFTER BYPASSING ALTERNATOR SWITCH, FLUCTUATIONS WENT AWAY. PROBLEM CAUSED BY AGE OF SWITCH. SUBMITTER STA TED HAVE SEEN THIS ON OTHER AIRCRAFT. ONE WAY TO PREVENT PROBLEM COULD BE TO REPLACE UNIT AFTER 2,000 HOURS. 1 L 7 1 3O 2A13 1997101600420 19971016 00420 1997 10 16 97ZZZX4381 4 19970925 G 6122 B41832 FLYWEIGHT E3 PIPER PA34 PA34200T 7103406 SO PROPELLER GOV ARM CRACK D K NONE O OTHER IN INSP/MAINT 1 SO 17 2121X 1728 1701S 347970180 GOVERNOR FLYWEIGHT ARM HAS A DIAGONAL CRACK INDICATION APPROXIMATELY .75 INCH LONG. COULD NOT REMOVE IT WITH LIGHT BUFF ING. 1 L 7 2 3O A7SO 1997101600421 19971016 00421 SO 1997 10 16 97ZZZX4382 1 19970924 G 5521 40075 SPAR PIPER PA31 PA31350 7103110 SO ELEV/SPAR & RIB CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 15 282JN 6557 317552005 UPON COMPLYING WITH PIPER SB 998A INSPECTION OF ELEVATOR SPAR, FOUND THE SPAR CRACKED INBOARD OF THE OUTBOARD HINGE. ON LY ABOUT .25 INCH OF THE CRACK WAS VISIBLE. THE END RIB HAD A CRACK WHERE THE SKIN STIFFENER CHANNEL IS RIVETED TO IT A ND ONE SKIN STIFFENER CHANNEL END WAS BROKEN OFF WHERE IT ATTACHED TO THE END RIB. ALSO, THE RIB THAT THE BALANCE WEIGH TS ATTACHES. ALL THREE ANCHOR ATTACHES HAD CRACKS RUNNING ACROSS THE NUTPLATES RIGHT OUTBOARD OF RIVET ATTACH HOLES. 1 L 7 2 3O A20SO 1997101600422 19971016 00422 1997 10 16 97ZZZX4383 4 19970924 G 6113 4393303 BULKHEAD PIPER PA31 PA31350 7103110 SO SPINNER CRACKED D S K NONE O OTHER IN INSP/MAINT 1 GL 15 282JN 6557 317552005 BULKHEAD CRACKED WHERE STARTER RING GEAR ATTACHES (FOUND TWO HOLES CRACKED). 1 L 7 2 3O A20SO 1997101600423 19971016 00423 SO 1997 10 16 97ZZZX4384 1 19970912 G 8011 MHB4104 STARTER PIPER PA31 PA31350 7103110 SO RT ENGINE FAILED H K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 EA 05 4108D 1788 11B0006 318352018 PILOT REPORTED SPARKS FROM FORWARD RT COWLING DURING STARTING OF ENGINE. INSPECTED RT ENGINE STARTER AND FOUND FIELD CO IL HOUSING LOOSE AND BINDING ON ARMATURE. REMOVED AND REPLACED STARTER WITH OVERHAULED UNIT. 1 L 7 2 3O A20SO 1997101600424 19971016 00424 CE 1997 10 16 97ZZZX4385 1 19971002 G 2140 45C40 COMBUSTION TUBE D83A28 BEECH 58 58 1152740 CE HEATER CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 11 3197W 3114 TH427 PRESSURE CHECKED HEATER FOR COMBUSTION TUBE LEAK CHECK. FAILED CHECK AND HEATER WAS DISASSEMBLED. LOCATED SEVERAL CRAC KS AT HEATER WELDS. INSTALLED NEW COMBUSTION TUBE PN 45C40, SN 970902. RE-CHECK FOR LEAKS OK. 1 L 7 2 3O 3A16 1997101600425 19971016 00425 CE 1997 10 16 97ZZZX4386 1 19970905 G 3710 442CW PUMP BEECH 80 65B80 1152812 CE LT ENG VAC FAILED D K NONE O OTHER NR NOT REPORTED 1 WP 13 46MA 1145 LD413 VACUUM PUMP FAILED UNDER NORMAL OPERATING CONDITIONS. SUBMITTER STATED THIS PUMP HAD AN EXCEPTIONALLY LONG SERVICE LIFE . 1 L 7 2 3O 3A20 1997101600426 19971016 00426 NE 1997 10 16 97ZZZX4387 2 19970925 G 8530 2433952 VALVE BEECH 18 E18S 1151006 CE PWA R985 R985AN14B 52008 NE ENG CYL EXH BROKE D K NONE O OTHER NR NOT REPORTED 1 WP 13 5611D 1460 BA316 22664 EXHAUST VALVE BROKE DURING A FULL POWER APPLICATION. SUSPECT CAUSE MAY BE REDUCED LEAD CONTENT IN FUEL. 1 L 7 2 3R 3 R A765 5E1 1997101600427 19971016 00427 GL 1997 10 16 97ZZZX4388 3 19970715 G 6111 BUSHING CESSNA 182 182 2072702 CE HARTZL HC82V HC82V* GL BLADE PITCH BROKEN D A K NONE O OTHER IN INSP/MAINT 1 SW 99 6285A 33085 13044 PILOT REPORTED VIBRATION AND POWER LOSS. INVESTIGATION FOUND PITCH CHANGE PHENOLIC BUSHING ON ONE BLADE BROKEN ALLOWING BLADE TO MOVE TO LOWER PITCH THAN OTHER BLADE. 1 H 7 1 3O NT 3A13 5 C P23EA 1997101600428 19971016 00428 SO 1997 10 16 97ZZZX4389 1 19971002 G 3234 592610 VALVE PIPER PA46 PA46310P 7104605 SO MLG SELECTOR O-RING FAILED B ESMR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 11 825WS 0502 468408059 RECEIVED NEW VALVE FROM PIPER, BUT VALVE WAS DATED '4Q86'. INSTALLED VALVE AND CYCLED GEAR. THE OUTDATED O-RINGS IN VA LVE 'BLEW OUT' ON THE FIRST RUN. 1 L 7 1 3O A25SO 1997101600429 19971016 00429 SO 1997 10 16 97ZZZX4390 1 19971002 G 3234 592610 VALVE PIPER PA46 PA46310P 7104605 SO MLG SELECTOR O-RING BROKEN B ESMR K NONE O OTHER NR NOT REPORTED 1 SO 11 825WS 0525 468408059 LANDING GEAR SELECTOR VALVE INTERNAL O-RINGS FAILED CAUSING HYDRAULIC PUMP TO RUN CONTINUOUSLY. 1 L 7 1 3O A25SO 1997101600430 19971016 00430 SO 1997 10 16 97ZZZX4391 2 19970920 G 8520 VAR CRANKSHAFT CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO NR 2 MAIN BROKE D A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 AL 03 9412Z 1382 A830M1 U20606473 574416 WHILE IN CRUISE FLIGHT, CRANKSHAFT BROKE WHERE NR 1 ROD THROW COMES OFF REAR OF NR 2 MAIN. AIRCRAFT ON FLOATS, MADE EME RGENCY LANDING ON DRY LAKE BED. FLOATS SHEARED OFF, PLANE WENT UPSIDE DOWN, AND PLANE IS DESTROYED. 1 H 7 1 3O 3 O A4CE E5CE 1997101600431 19971016 00431 1997 10 16 97ZZZX4392 4 19970923 G 6113 4393304 BULKHEAD PIPER PA31 PA31325 7103105 SO LT SPINNER CRACKED D S K NONE O OTHER IN INSP/MAINT 1 GL 15 979SP 4103 7812015 SPINNER BULKHEAD CRACKED (LEFT BULKHEAD) FROM SPINNER DOME ATTACH SCREW HOLE AROUND AND DOWN BACK OF BULKHEAD, BUT NOT T HROUGH DOUBLER. 1 L 7 2 3O A20SO 1997102300112 19971023 00112 SW 1997 10 23 97ZZZX4407 1 19970617 G 6420 406312100101 BEARINGS 407012101105 BELL 407 407 SW T/R YOKE WORN B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 417AL 903 A99 53054 PRE-FLIGHT CHECK FOUND 2 EACH BEARINGS 406-312-100-101 INNER RACES WORN BEYOND LIMITS. ONE EACH OUTER RACE CRACKED. BE ARINGS LOCATION INBOARD ON YOKE. 1 G 7 1 3U O H2SW 1997102300113 19971023 00113 SW 1997 10 23 97ZZZX4408 1 19970728 G 7722 206375006101 INDICATOR SEL019D51 BELL 206 206L1 1182107 SW TOT STUCK B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 1067D 299BA 45435 AT START-UP, TOT INDICATOR POINTER STOP ARM STUCK TO THE LATEX RUBBER BUMPER. THIS TYPE OF RUBBER BECOMES STICKY IN THE HIGH SUMMER TEMPERATURES. REPLACE BUMPER WITH RUBBER OR TEFLON THAT DOES NOT BECOME STICKY. 1 G 7 1 3U H2SW 1997102300114 19971023 00114 SW 1997 10 23 97ZZZX4409 1 19970813 G 7722 206375007103 INDICATOR BELL 206 206L4 1182110 SW TOT STUCK B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 177AL B383BA 52157 AT INITIAL START, TOT INDICATOR STOP ARM STICKING TO LATEX BUMPER. REPLACE BUMPER WITH A DIFFERENT MATERIAL. 1 G 7 1 3U NC H2SW 1997102300116 19971023 00116 SW 1997 10 23 97ZZZX4411 1 19970723 G 7722 206375006101 INDICATOR SEL019DS1 BELL 206 206L1 1182107 SW TOT STUCK B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 2025G 282BA 45690 WHEN STARTING OR OPERATING HELICOPTER, THERE WAS NO TOT TEMPERATURE INDICATION. FOUND POINTER STOP ARM STUCK TO THE STO P BUMPER. VERIFIED VISUALLY AFTER REMOVING THE INSTRUMENT FROM THE CASE. REPLACE STOP ARM BUMPER WITH A MATERIAL THAT DOES NOT GET STICKY WHEN EXPOSED TO THE HEAT. 1 G 7 1 3U H2SW 1997102300118 19971023 00118 GL 1997 10 23 97ZZZX4413 2 19970722 G 7250 23053299 WHEEL BLADES 23035128 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL FIRST STAGE ERODED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 768AL 1980 1641 X138841 760031 TURBINE ASSEMBLY RECEIVED DUE TO 2,000 HOUR OVERHAUL. FOUND FIRST STAGE WHEEL HAD BURNED AND ERODED BLADES CAUSED BY SU LFIDATION. 1 G 7 2 3U 3 U H1NE E1GL 1997102300128 19971023 00128 NE 1997 10 23 97ZZZX4423 1 19970521 G 6720 7640003191043 CONTROL CABLE SKRSKY S76 S76A 8143006 NE T/R CONTROL MISMANUFACTURED B A ALGR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 1547K 760085 DURING FLIGHT CONTROL RIGGING, TECHNICIAN COULD NOT RIG THE TAIL ROTOR IAW CHAPTER 67-20-00, PARAGRAPH 1, PAGE 501 OF TH E SA4077-76-2 MM. UPON REMOVING CONTROL CABLE 76400-03191-043, FOUND THE CABLE WAS .375 INCH SHORTER THAN THAT OF A KNO WN SERVICEABLE CABLE. UPON FURTHER INVESTIGATION FOUND NO OTHER CABLES BAD (SHORT) AT THIS TIME. MANUFACTURER NEEDS TO TIGHTEN QUALITY CONTROL PROCEDURES CONCERNING THE PRODUCTION OF THIS COMPONENT. 1 G 7 2 3U H1NE 1997102300129 19971023 00129 NE 1997 10 23 97ZZZX4424 1 19970521 G 6720 7640003191051 CONTROL CABLE SKRSKY S76 S76A 8143006 NE FLIGHT CONTROL MISMANUFACTURED B A ALGR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 1547K 760085 DURING FLIGHT CONTROL RIGGING, TECHNICIAN COULD NOT RIG THE TAIL ROTOR IAW CHAPTER 67-20-00, PARAGRAPH 1, PAGE 501 OF TH E SA4077-76-2 MM. UPON REMOVAL OF CONTROL CABLE 76400-03191-051, FOUND THE CABLE WAS .25 INCH SHORTER THAN A KNOWN SERV ICEABLE CABLE. UPON FURTHER INVESTIGATION 2 MORE CABLES OF THE SAME PART NUMBER WERE FOUND IN STOCK TO BE .25 INCH SHOR T. THE MANUFACTURER NEEDS TO TIGHTEN QUALITY CONTROL PROCEDURES CONCERNING THE PRODUCTION OF THIS COMPONENT. 1 G 7 2 3U H1NE 1997102300130 19971023 00130 SW 1997 10 23 97ZZZX4425 1 19970812 G 6320 206040530101 CASE ASSEMBLY 206040004115 BELL 206 206L4 1182110 SW M/R GEARBOX CORRODED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 174AL 4410 1484 A294 52067 TRANSMISSION REMOVED AND SENT TO COMPONENT SHOP FOR 4,500 HOUR OVERHAUL. EXCESSIVE CORROSION WAS FOUND ON MAIN CASE UND ER INPUT QUILL FLANGE. ALSO, UNDER OIL JET. THIS IS THE FIRST TIME THESE AREAS HAVE BEEN DISASSEMBLED SINCE NEW AIRCRA FT WAS DELIVERED FROM B.H.T. CAUSE: MOISTURE PRESENT IN THE UNPROTECTED MAGNESIUM. RECOMMEND THESE AND OTHER AREAS BE PROTECTED BY PRIMER WHEN THE TRANSMISSION CASE IS NEW. 1 G 7 1 3U NC H2SW 1997102300131 19971023 00131 GL 1997 10 23 97ZZZX4426 2 19970813 G 7261 23058110 SCAVENGE TUBE 23004545 BELL 206 206L4 1182110 SW ALLSN 250C 250C30P 03013 GL NR 1 BEARING CHAFED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 177AL 52157 CAE895014 UPON DISASSEMBLY OF ENGINE FOR T/C, FOUND SCAVENGE TUBE HAD EXCESSIVE CHAFING FROM CONTACT WITH COMPRESSOR SCROLL. EXCE SSIVE CHAFING ON TUBE DUE TO MISALIGNMENT CAUSING CONTACT WITH SCROLL. SUBMITTER STATED ENSURE PROPER CLEARANCE BETWEEN NR 1 SCAVENGE TUBE AND SCROLL AFTER INSTALLATION. 1 G 7 1 3U 3 U NC H2SW E1GL 1997102300132 19971023 00132 SW 1997 10 23 97ZZZX4427 1 19970728 G 7722 206375006101 INDICATOR SEL019D51 BELL 206 206L1 1182107 SW TOT STUCK B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 3195P B309BA 45789 AT START-UP, FOUND TOT INDICATOR POINTER STOP ARM STICKING TO THE LATEX RUBBER BUMPER. THIS TYPE OF RUBBER BECOMES STIC KY IN THE HIGH SUMMER TEMPERATURE IN SOUTH LOUISIANA. REPLACE BUMPER WITH RUBBER OUT TEFLON THAT DOES NOT BECOME STICKY . 1 G 7 1 3U H2SW 1997102300133 19971023 00133 SW 1997 10 23 97ZZZX4428 1 19970509 G 6220 206011100159 HUB 206011100159 BELL 206 206L3 1182108 SW M/R HUB CORRODED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 365AL 2388 1193 A2867 51376 DEFECT DISCOVERED AT 1,200 HOUR INSPECTION. FOUND PITTING CORROSION I SPLINES OF TRUNNION. SUBMITTER STATES MANUFACTU RER'S RECOMMENDED LUBRICANT NOT SUFFICIENT. RECOMMEND A SUFFICIENT LUBRICANT FOR THIS APPLICATION. MANUFACTURER SPECIF IES MIL-C-16173 GRADE 2 ON MAST TO TRUNNION SPLINES. BELIEVE A HEAVY GREASE WOULD HOLD UP BETTER IN THIS LOCATION. 1 G 7 1 3U H2SW 1997102300136 19971023 00136 GL 1997 10 23 97ZZZX4431 2 19970605 G 7250 23053299 WHEEL BLADES 23035128 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL GP SECT 1ST STG BROKEN B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 768AL 1648 X138702 760031 TURBINE ASSEMBLY WAS RECEIVED WITH ENGINE ASSEMBLY DUE TO MAKING METAL. UPON INSPECTION OF G.P. SECTION, FOUND SULFIDAT ION ON 1ST STAGE WHEEL. 1ST STAGE WHEEL: PN 23053299, SN X-138702, TT 1,348.1 HOURS, TC 1,697. SCRAPPED DUE TO MISSIN G BROKEN AND CRACKED BLADES CAUSED BY SULFURDATION. 1 G 7 2 3U 3 U H1NE E1GL 1997102300137 19971023 00137 SW 1997 10 23 97ZZZX4432 1 19970519 G 6310 2060401173 COUPLING 206040015015 BELL 206 206L1 1182107 SW INPUT DRIVE WORN B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 206SL 81 A2030437 45245 IN-FLIGHT AND GROUND RUN, FOUND INTERMITTENT HIGH PITCHED WHINE IN CABIN. INNER COUPLING FOUND TO HAVE UNACCEPTABLE WEA R PATTERN. OUTER COUPLING WAS SERVICEABLE; NEITHER COUPLING WAS WORN BEYOND DIMENSIONAL LIMITS. 1 G 7 1 3U H2SW 1997102300138 19971023 00138 SW 1997 10 23 97ZZZX4433 1 19970813 G 7722 206375006101 INDICATOR BELL 206 206L1 1182107 SW TOT STUCK B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 3890B B319BA 45480 AT START, TOT INDICATOR POINTER STOP ARM STICKING TO LATEX BUMPER. REPLACE BUMPER WITH A DIFFERENT MATERIAL. 1 G 7 1 3U H2SW 1997102300202 19971023 00202 1997 10 23 97ZZZX4436 4 19970918 G 6113 D6199 BULKHEAD MOONEY M20 M20M 5870222 SW SPINNER CRACKED D A K NONE O OTHER IN INSP/MAINT 1 SW 05 1087M 93 270047 REAR SPINNER BULKHEAD CRACKED ALL THE WAY AROUND AT RADIUS OF BACKPLATE AND ATTACHING HUB. SUSPECT CAUSE IS INSUFFICIEN T SHIMMING AT FRONT BULKHEAD ALLOWING NOSE OF SPINNER TO WOBBLE AND STRESS BACKPLATE. SEARCH OF AIRCRAFT RECORDS LISTS TWO PREVIOUS FAILURES AT 681.5 HOURS AND 1,125.6 HOURS. AIRCRAFT TOTAL TIME 1,218.7 HOURS. 1 L 7 1 30 RT 2A3 1997102300203 19971023 00203 CE 1997 10 23 97ZZZX4437 1 19970901 G 2820 FUEL LINE BEECH 45 T34B 1152014 CE RT SUMP VALVE BLOCKED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 01 349MF 144030 GENERAL - APPLIES TO ALL AIRCRAFT. DURING TROUBLESHOOTING FUEL SYSTEM FOR LEFT AND RIGHT TANK, UNEVEN FUEL FLOW, FOUND PIECE OF AFTER-MARKET 6 INCH ROUND GAS TANK OCTANE RATING PLACARD/STICKER LODGED IN FUEL LINE AT SUMP CHECK VALVE PARTIA LLY RESTRICTING FUEL FLOW FROM RIGHT TANK. SMALL PIECE OF VINYL PLACARD APPARENTLY CHIPPED OFF BY FUELING NOZZLE DURING RE-FUEL. SUBMITTER SUGGESTS PLACARDS/STICKERS BE APPLIED FAR ENOUGH AWAY FROM TANK INLETS TO PRECLUDE BEING CHIPPED BY FUELING NOZZLE AND ENTERING SYSTEM. 1 L 7 1 3O 5A3 1997102300204 19971023 00204 CE 1997 10 23 97ZZZX4438 1 19970901 G 5343 50420021 TRUSS CESSNA 402 402CESSNA 207590K CE NLG DRAG BRACE CRACKED D S K NONE O OTHER IN INSP/MAINT 1 WP 07 3278Q 9160 4020078 NOSE LANDING GEAR DRAG BRACE TRUSS CRACK FOUND DURING SCHEDULED INSPECTION OF LANDING GEAR. STARTED AT WELD, PROGRESSED APPROXIMATELY .8750 INCH OF TUBING DIAMETER. SUBMITTER STATED CAUSE UNKNOWN, POSSIBLY AGE. 1 L 7 2 3O A7CE 1997102300205 19971023 00205 CE 1997 10 23 97ZZZX4439 1 19970930 G 3231 08411066 BELLCRANK CESSNA 340 340A 2076405 CE GEAR DOOR BROKE B K NONE O OTHER AP APPROACH 1 NM 10 36885 3250 340A0681 GEAR DOOR UPPER ARM BROKE MID-WAY BETWEEN BEARING AND PIVOT. OCCURRED AT GEAR EXTEND LEAVING DOOR HANGING OPEN UPON LAN DING. 1 L 7 2 3O 3A25 1997013000149 19970130 00149 EA 1997 1 30 97ZZZX444 2 19970110 G 7314 RG9080J4A FUEL PUMP ROMEC PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA ENGINE GASKET FAILED D K NONE K FLUID LOSS IN INSP/MAINT 1 AL 01 4082T 424 D8588 318152089 L214368A GASKET PUSHED OUT OF VALVE BODY AND DUMPED ALL THE FUEL OVERBOARD. 1 L 7 2 3O 3 O A20SO E14EA 1997102300206 19971023 00206 EA 1997 10 23 97ZZZX4440 2 19970701 G 7322 30764 FLOAT MA45 PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA CARBURETOR LEAKS B A WTXR K NONE A FLAME/FIRE IN INSP/MAINT 1 NM 07 965BK 562 1284 287690271 L3300036A DURING A RUN-UP PRIOR TO FLIGHT, SMOKE WAS SEEN COMING OUT OF THE COWLING. THE FIRE THAT FOLLOWED CAUSED SUBSTANTIAL DA MAGE TO THE AIRCRAFT FIREWALL FORWARD. THE ENGINE WAS SENT TO THIS FACILITY FOR INSPECTION AND REPAIR RELATED TO DAMAGE FROM THE FIRE. DURING OVERHAUL OF THE CARBURETOR, THE TECHNICIAN NOTED THE FLOAT WAS FULL OF FUEL ON ONE SIDE. FURTHE R EXAMINATION SHOWED THE FLOAT HAD A SMALL LEAK ON THE FRONT NEAR THE SOLDER JOINT. THE CAUSE MAY BE A DEFECTIVE SOLDER JOINT. SUBMITTER STATED TO PREVENT RECURRENCE, IT IS NECESSARY TO LEAK CHECK THE FLOAT AT OVERHAUL. 1 L 7 1 3O 3 O 2A13 E286 1997102300207 19971023 00207 GL 1997 10 23 97ZZZX4441 3 19971003 G 6111 V84334 BLADE HARTZL HCA2V HCA2VK2 GL NR 2 BUTT CRACKED B ME4R K NONE O OTHER IN INSP/MAINT 1 SO 19 H1339 PROPELLER RECEIVED FOR AD NOTE INSPECTION (97-18-02). AFTER DISASSEMBLY, NR 2 BLADE FOUND CRACKED IN 'V' OF BLADE BUTT. 5 C P24EA 1997102300208 19971023 00208 EA 1997 10 23 97ZZZX4442 2 19971001 G 8530 LW13623 PISTON PIPER PA38 PA38112 7103812 SO LYC O235 O235L2C 41505 EA ENGINE DAMAGED D K NONE O OTHER IN INSP/MAINT 1 NM 11 2452L 2689 P1075 3879A0707 L1882315 A CYLINDER WAS REMOVED DUE TO OIL FOWLING OF THE SPARK PLUGS. A CHUNK OF METAL WAS MISSING FROM THE PISTON. REMOVED TH E OTHER 3 CYLINDERS AND FOUND 3 OF THE 4 PISTONS WERE DAMAGED IN THIS WAY. ALL CYLINDER COMPRESSIONS TESTED GOOD, MID 7 0/80. 1 L 7 1 3O 3 O A18SO E223 1997102300209 19971023 00209 CE 1997 10 23 97ZZZX4443 1 19971002 G 5320 12104022 DOOR SILL CESSNA 210 210E 2073416 CE REAR CORNER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 13 2393F 2500 21058593 DURING INSPECTION, REMOVED CHROME TRIM OVER DOOR SILL, FOUND REAR CORNER BROKEN ACROSS TOP. TRIM NOT USUALLY REMOVED FO R INSPECTION. SUBMITTER STATED POSSIBLE CAUSE, HARD LANDING. CLOSER INSPECTION REVEALS SOME PREVIOUS RIVETS REPLACED I N AREA, NO LOG ENTRY. RECOMMEND REMOVAL OF TRIM AND CLOSE INSPECTION DUE TO HIGH STRESS AREA AND HIDDEN DAMAGE. 1 H 7 1 3O 3A21 1997102300210 19971023 00210 SO 1997 10 23 97ZZZX4444 1 19970929 G 5521 4007516 SPAR PIPER PA31 PA31350 7103110 SO RT OTBD ELEV CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 25 27368 4788 317852010 COMPLIED WITH PIPER SB 998A, DATED 8-4-97. CUT OPEN AND INSPECTED ELEVATOR SPAR FOR CRACKS. FOUND .75 INCH CRACK IN TI P OF RIGHT ELEVATOR AND RIVET SHEARED ON SUPPORT TAB. SPAR REPLACED. 1 L 7 2 3O A20SO 1997102300211 19971023 00211 SO 1997 10 23 97ZZZX4445 1 19971001 G 2434 4111810 ALTERNATOR ELECTROSYS PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA DC SYSTEM FAILED B R7LR K NONE O OTHER IN INSP/MAINT 1 WP 25 6807F 43 7071719 287790170 L22439 INSTALLED ELECTROSYSTEMS ALTERNATOR. PART FAILED 42 HOURS LATER. SUBMITTER STATED SERVICE LIFE OF OVERHAULED UNIT SHOU LD BE SLIGHTLY BETTER THAN 42 HOURS. 1 L 7 1 3O 3 O 2A13 E286 1997102300212 19971023 00212 GL 1997 10 23 97ZZZX4446 3 19971007 G 6111 BLADE CESSNA 207 T207A 2073614 CE MCAULY D3A34 D3A34C401 GL PROPELLER CRACKED E K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 WP 07 75870 20700648 795454 PILOT REPORTED SLIGHT ENGINE VIBRATION AND PROPELLER SLOW TO RESPOND IN RETURN TO LOW PITCH. DISASSEMBLY REVEALED ONE B LADE WAS CRACKED 180 DEGREES NEAR BEARING SURFACE AT ROOT END. CAUSE UNKNOWN. CATASTROPHIC FAILURE IMMINENT. BLADE UN DER ANALYSIS AT MCCAULEY. 1 H 7 1 3O A16CE 5 C P47GL 1997102300213 19971023 00213 CE 1997 10 23 97ZZZX4447 1 19970930 G 5730 08220009 SKIN CESSNA 402 402B 207590P CE WING NACELLE CRACKED B OWFR K NONE O OTHER IN INSP/MAINT 1 CE 05 901BC 8205 402B0379 MID-WAY BETWEEN FORWARD AND AFT SPAR UNDER NACELLE SKIN INBOARD OF NACELLE AUXILIARY FUEL TANK FOUND CRACKS IN WING SKIN . WOULD NOT HAVE BEEN FOUND UNLESS SKIN OVER WING LOCKER AND AUXILIARY FUEL TANK WAS REMOVED FOR REPAIR. NO ACCESS. 1 L 7 2 3O A7CE 1997102300214 19971023 00214 1997 10 23 97ZZZX4448 4 19971002 G 2562 E01 ELT ACK CESSNA 182 182P 2075816 CE G SWITCH INOPERATIVE D K NONE O OTHER IN INSP/MAINT 1 CE 07 60741 533 009197 18264089 ELT 6 - SWITCH INOPERATIVE. ELT OPS CHECK OK IN 'ON' POSITION, ELT INSTALLED 7-94. THIS IS SECOND ACK ELT WITH INOPERAT IVE G - SWITCH IN LAST 2 MONTHS. 1 H 7 1 3O NT TA13 1997102300215 19971023 00215 SO 1997 10 23 97ZZZX4449 2 19970905 G 8520 530213 CONNECT ROD CESSNA 172 172F 2072414 CE CONT O300 O300D 17022 SO ENGINE BROKEN D K NONE O OTHER IN INSP/MAINT 1 SW 03 8695U 1330 17252599 25454D77DR ENGINE CONNECTING ROD BROKE AT ROD CAP .25 INCH BEFORE THREAD. 1 H 7 1 3O 3 O NT 3A12 E253 1997102300217 19971023 00217 CE 1997 10 23 97ZZZX4451 1 19970829 G 3710 HOSE CESSNA 172 172P 2072436 CE VACUUM SYSTEM DETERIORATED D A K NONE O OTHER IN INSP/MAINT 1 SW 99 9677A 2411 17276201 VACUUM SYSTEM SHOWED LOW VACUUM. PER MM, PUMP REMOVED AND CHECKED SATISFACTORILY. VACUUM REGULATOR REPLACED. SYSTEM S TILL LOW. INSTRUMENT PANEL REMOVED AND SPECIAL REINFORCED HOSE TO AND FROM REGULATOR FOUND TERRIBLY DECOMPOSED AND SIMP LY TOUCHING IT WOULD CRUMBLE. THE INSIDE RED LINER AND OUTSIDE BLACK LAYER WERE OF CRAYON CONSISTANCY. VACUUM GAUGE CL EANED OUT AND LINES REPLACED. SYSTEM OPERATING SATISFACTORILY. 1 H 7 1 3O NT 3A12 1997102300218 19971023 00218 CE 1997 10 23 97ZZZX4452 1 19970916 G 3230 358251854 RETRACT ROD BEECH 35 C35BEECH 1151508 CE NLG CORRODED D K NONE O OTHER IN INSP/MAINT 1 EA 21 656D 4693 D2924 DURING ANNUAL INSPECTION, AIRCRAFT RECORDS AND CONDITION INDICATED LANDING GEAR RETRACT SYSTEM BE REMOVED. INSPECT AND RECONDITION AS NEEDED. ROD ENDS WERE REMOVED FROM THE AFT NLG RETRACT ROD AND A LEVEL 3 CORROSION CONDITION WAS FOUND F ULL OF HEAVY RUST SCALE. STEEL SHOT WAS ADDED IN ROD ASSY TO CLEAN OUT RUST. INSPECTION SHOWED PIN HOLE PENETRATION TH ROUGH TUBE WALL OF AFT END. UNIT APPEARS TO BE 'SEALED', NO CORROSION PREVENTATIVE COMPOUND FOUND INSIDE. 1 L 7 1 3O A777 1997102300219 19971023 00219 CE 1997 10 23 97ZZZX4453 1 19970916 G 2720 AN386212A TAPER PIN BEECH 35 C35BEECH 1151508 CE LT PEDAL WORN D K NONE O OTHER IN INSP/MAINT 1 EA 21 656D 4693 D2924 WHILE TAXIING AIRCRAFT, NOTED STEERING RESPONSE USING COPILOT'S PEDALS WAS POOR TRYING TO STEER LEFT. OKAY STEERING TO RIGHT. DURING INSPECTION, TAPER PIN THAT COUPLES PILOT SIDE LT RUDDER PEDAL TO TORQUE TUBE WAS FOUND LOOSE. PIN WAS R EMOVED AND FOUND 'NECKED-DOWN'. BY SYSTEM DESIGN, THIS PEDAL IS THE 'MASTER' PEDAL AND THE OTHER 3 PEDALS ARE SLAVED TO IT THROUGH BELLCRANKS AND PUSHRODS. THE CUMULATIVE 'SLOP' IN THE SYSTEM ROD ENDS WAS FOUND TO BE ABOUT EQUAL AND THE L OOSE TAPER IN WOULD NOT ALLOW ADEQUATE LEFT STEERING COMMANDS. PIN WAS REPLACED. 1 L 7 1 3O A777 1997102300221 19971023 00221 EU 1997 10 23 97ZZZX4455 1 19970926 G 3250 860122 STEERING SECTOR JETAIR JETSTM JETSTM4101 1500501 EU NLG LOCK UP D A K NONE O OTHER IN INSP/MAINT 1 NE 01 1291 APB961595 UNIT RETURNED TO REPAIR STATION FOR REPAIR. DURING TESTING WITH HYDRAULIC BENCH, UNIT WOULD LOCK IN THE CLOCKWISE DIREC TION AND NOT RELEASE PRESSURE. MALFUNCTION COULD POSSIBLY LOCK NOSE LANDING GEAR STEERING OFF-CENTER. SUBMITTER STATED PROBLEM WAS FOUND ON 2 UNITS WITH SEQUENTIAL SERIAL NUMBER RECEIVED FROM 2 DIFFERENT AIRLINES. 2 L 7 2 4T RT A41NM 1997102800002 19971028 00002 CE 1997 10 28 97ZZZX4456 1 19971009 G 2750 1455077639 CONTROL CABLE CESSNA 500 550 2076604 CE FLAP PRESELECT FRAYED D K NONE O OTHER IN INSP/MAINT 1 SW 13 12549 5500501 DURING FLAP RIGGING, FOUND FLAP PRE-SELECT CABLE FRAYED. ORDERED P/N 14550-776-39 CABLE ASSY. FOUND BALL SWEDGE LOCATE D AT 106.69 INCH. CONFIRM LOCATION OF SWEDGE BALL WITH CESSNA. CABLE REMOVED FROM AIRCRAFT WAS 103.0 INCHES. CESSNA I N PROCESS OF BUILDING A SPECIAL CABLE. CESSNA PART MANUAL, CHAPTER 27-90-00, PAGE 2, ITEM 81. 1 L 7 2 4F A22CE 1997102300222 19971023 00222 WP 1997 10 23 97ZZZX4457 2 19970902 G 7322 8972001A SUPPORT CESSNA 441 441 2076020 CE GARRTT TPE331 TPE33110 01514 WP FUEL CONTROL CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 07 3330S 4410205 P77291 FUEL CONTROL SUPPORT SPLIT BETWEEN TWO BOLT HOLES. PART NEEDS TO BE LONGER. 1 L 7 2 3T 4 T RT A28CE E4WE 1997102300223 19971023 00223 WP 1997 10 23 97ZZZX4458 2 19970930 G 7322 89778017 FUEL CONTROL WOODWARD SWRNGN SA226 SA226T 8780122 SW GARRTT TPE331 TPE33110U 01514 WP LT ENGINE FAILED B OWFR K NONE O OTHER NR NOT REPORTED 1 CE 05 48HH 2826 28 1477622 T304 P35030 FUEL CONTROL, INTERNAL FAILURE. FAILED TO RESPOND TO POWER LEVER MOVEMENT. 2 L 7 2 4T 4 T RT A5SW E4WE 1997102300224 19971023 00224 CE 1997 10 23 97ZZZX4459 1 19971003 G 2730 115610010325 TORQUE TUBE BEECH 99 C99 1154006 CE ELEVATOR CRACKED B A EHHR K NONE O OTHER IN INSP/MAINT 1 EA 17 6656N 482 54 U213 ELEVATOR TORQUE TUBE CRACKED AT TAPER PIN HOLE .3750 INCH LONG. PLAY BETWEEN TUBE AND CASTING FOUND DURING ROUTINE INSP ECTION. FURTHER INVESTIGATION REVEALED CRACK. INSTALLED NEW 115-610010-325 ASSEMBLY. 1 L 7 2 3T A14CE 1997102300225 19971023 00225 CE 1997 10 23 97ZZZX4460 1 19970922 G 3231 12838002115 CONTROL CABLE BEECH MU300 400A 1155402 CE EMERG RELEASE BROKEN B KI2R K NONE O OTHER IN INSP/MAINT 1 CE 01 85CR 2039 RK22 WHILE ACCOMPLISHING PRE-FLIGHT INSPECTION, TECHNICIAN NOTICED THERE WERE BROKEN STRANDS WHERE CABLE SWAGES INTO MS20668 CABLE EYE OF LEFT HAND EMERGENCY GEAR DOOR UPLOCK RELEASE CABLE. SUBMITTER STATED CAUSE OF FAILURE IS IMPROPER CABLE EY E POSITIONING WHICH RESULTS IN SHORT RADIUS 90 DEGREE BEND OF CABLE. ON PRE-FLIGHT INSPECTIONS NEED TO VERIFY CABLE AND EYE POINT DOWN AS OPPOSED TO BEING VERTICAL. 2 H 7 2 4F RT A16SW 1997102300226 19971023 00226 WP 1997 10 23 97ZZZX4461 2 19971003 G 7323 8210260 GOVERNOR WOODWARD SWRNGN SA226 SA226AT 8780405 SW GARRTT TPE331 TPE33110U 01514 WP RT ENGINE FAILED B QWFR D RETURN TO BLOCK Y ENGINE STOPPAGE TX TAXI/GRND HDL 1 NM 05 727DP 1163 AT039 54207 INTERNAL FAILURE. BEARING FAILED ON FOLLOWER GEAR IN THE PRESSURE PUMP ENGINE SHUT DOWN ON TAXIING OUT FOR TAKEOFF. 2 L 7 2 4T 4 T RT A5SW E4WE 1997102300227 19971023 00227 1997 10 23 97ZZZX4462 4 19970929 G 3441 10090910104 INVERTER GULSTM G1159 G1159A 3970109 SO IRU NR 2 FAN FAILED D K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 SO 09 843HS 2345 496 DURING PRE-DEPARTURE CHECK OF AIRCRAFT, A BURNING ODOR WAS DETECTED IN AFT BAGGAGE AREA. UPON CLOSER INSPECTION, SMOKE NOTED COMING FROM BENEATH THE HAT SHELF. POWER WAS REMOVED AND THE NR 2 HG-1075 INERTIAL REFERENCE UNIT WAS REMOVED. T HE IRU FAN INVERTER WAS FOUND TO BE THE SOURCE OF THE SMOKE. INSTALLED HONEYWELL DC BLOWER KIT, PN 26012423-105, IN ALL 3 IRU'S AND RETURNED AIRCRAFT TO SERVICE. 2 L 7 2 4F A12EA 1997102300230 19971023 00230 NE 1997 10 23 97ZZZX4464 2 19970930 G 7230 PWA419403 BEARING SKF PWA JFTD12 JFTD12A5A 52047 NE ENGINE COMP FAILED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 1692 178 677820 BEARING REMOVED FROM ENG DURING OVERHAUL WITH TT OF 1691.6 HRS. DURING OVERHAUL, BEARING WAS INSPECTED AND 2 UNUSUAL CO NDITIONS FOUND: BALLS EXHIBITED SEVERE SCRATCHES AND RETAINER SHOWED SMEARED SILVER PLATING IN THE BALL RETENTION AREA . AFTER ANALYSIS, REPORT SHOWED RESIDUAL SILICA CARBIDE EMBEDDED IN THE BRONZE RETAINER CAUSING THE BALL SCRATCHES. SI LICA CARBIDE WAS LIKELY FROM A MEDIA BLAST DURING MFG PROCESS. THE SILVER PLATING DISCREPANCY WAS ATTRIBUTED TO A LACK OF CLEARANCE BETWEEN THE RETAINER AND BALL DURING THE STAKING PROCESS. A TYPICAL CLEARANCE OF 0.002 INCH IS NORMAL. FO UND CLEARANCE TO BE NEAR 0.0000 INCH. AS THE SILVER PLATING WAS WORN, THE EMBEDDED SILICA CARBIDE SCRATCHED THE BALLS. 4 U E15EA 1997102300231 19971023 00231 SO 1997 10 23 97ZZZX4465 1 19970521 G 8120 MILH5593 HOSE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA TURBO CONTROLLER BROKEN D L A K NONE O OTHER IN INSP/MAINT 1 SO 03 100 318252019 L294168A DURING THE 100-HOUR INSPECTION AT 908 HOURS ON 3-17-97 WHILE CHECKING HOSES FOR CONDITION NOTICED THE NR 4 HOSE, MIL-H-5 93, THAT ATTACHED TO THE TURBO DIFFERENTIAL PRESSURE CONTROLLER WAS BROKEN AT THE MS27404 FITTING. THIS HOSE GOES TO TH E OIL SUMP AND INDUCTION HOUSING. NOTICED THE HOSE WAS VERY HARD AT THE FITTING END DUE TO HEAT. DUE TO THE EXTRA LENG TH OF HOSE, THE HOSE WAS CUT OFF AND A NEW FITTING INSTALLED PLUS A FIRE SLEEVE TO TAKE CARE OF THE HEAT ON BOTH ENGINES . DURING THE NEXT 100-HOUR INSPECTION ON 5-21-97, THE HOSE ON BOTH ENGINES WAS BROKEN OFF AGAIN DUE TO HEAT. UNABLE TO IDENTIFY THE HOSE PART NUMBER IN THE LYCOMING MICROFICHE. 1 L 7 2 3O 3 O A20SO E14EA 1997102300232 19971023 00232 EA 1997 10 23 97ZZZX4466 2 19970923 G 8550 ENGINE GULSTM AA1 AA1C 0631214 SO LYC O320 O320D3G 41508 EA OIL PUMP MISOVERHAULED B TRKR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 15 399X 2110 310 AA1C0192 L838839 DURING ANNUAL INSPECTION, COULD NOT FIND VALID SIGN-OFF FOR AD 81-18-04 OR AD 96-09-10 (OIL PUMP AD). PARTS NOTIFICATIO N NR 96-083 DATED 5-5-97. NO PAPER WORK FOR RETURNING PARTS TO SERVICE (YELLOW TAGS) OR AD COMPLIANCE WAS FOUND. ENGIN E WAS TORN DOWN AND INSPECTED AND NORMAL PARTS CERTIFIED AND YELLOW TAGGED. OIL PUMP AD WAS FOUND NOT TO BE DONE. C/W AD NOTE AND ASSEMBLY) ENGINE AND TEST FLEW AIRCRAFT. NO OTHER PROBLEMS FOUND WITH THE ENGINE. 1 L 7 1 3O 3 O A11EA E274 1997102300233 19971023 00233 NE 1997 10 23 97ZZZX4467 2 19971006 G 8500 ENGINE DOUG DC4 C54BDC 3021516 WP PWA R2000 R2000* 52023 NE NR 4 FAILED D E ENGINE SHUTDOWN E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 AL 01 44911 1156 10461 108107 NR 4 ENGINE STARTED RUNNING ROUGH IN CRUISE. MANIFOLD PRESSURE BEGAN TO INDICATE HIGH AND FLUCTUATING. ENGINE SHUT DOW N AND LANDED WITH NO FURTHER PROBLEMS. INTERNAL FAILURE, METAL IN SCREEN. ENGINE SENT TO REPAIR STATION FOR TEAR-DOWN AND EVALUATION. 2 L 7 4 4R 4 R A762 5E5 1997102300234 19971023 00234 EU 1997 10 23 97ZZZX4468 1 19970925 G 7160 SCREEN RHNFLU EXT300 EA300L 70218DG EU AIR INTAKE BROKEN B A FE6R K NONE O OTHER IN INSP/MAINT 1 NM 11 609JW 179 033 THE AIRCRAFT'S COWLING MOUNTED ALUMINUM AIR INTAKE SCREEN FOUND BROKEN ALONG THE UPPER AND LOWER EDGES. THE SCREEN WAS ONLY SECURED ON THE EDGES. FAILURE WOULD RESULT IN PIECES ENTERING THE FUEL INJECTION BODY, WHICH IS UNFILTERED, ON THI S AIRCRAFT. A NEW SCREEN, OBTAINED FROM THE MANUFACTURER, IS OF A HEAVIER GAUGE AND IS OF STAINLESS STEEL. SUBMITTER S TATED EARLIER AIRCRAFT SHOULD BE REQUIRED TO INCORPORATE THE MODIFIED SCREEN. 1 M 7 1 3O NC EA67U 1997102300235 19971023 00235 CE 1997 10 23 97ZZZX4469 1 19971001 G 3230 2441003F PIVOT SPLINES CESSNA 172 172RG 2072438 CE RT MLG SHEARED G O OTHER O OTHER CL CLIMB 1 SW 15 5510R 6252 172RG0066 RIGHT MAIN LANDING GEAR PIVOT SPLINE SHEARED OFF DURING GEAR RETRACTION. AIRCRAFT LANDED WITH GEAR-UP CONFIGURATION. M INOR DAMAGE TO FUSELAGE UNDERCARRIAGE AND PROPELLER. SUSPECT CAUSE - EXCEEDED LIFE CYCLES. SUBMITTER RECOMMENDATION: A N AD ISSUED MAKING CESSNA SEB 90-1 MANDATORY AND RE-INSPECTION INTERVAL AT 500 HOURS. REFER TO FAA SAFETY RECOMMENDATIO N 95.294. 1 H 7 1 3O 3A17 1997102300237 19971023 00237 SW 1997 10 23 97ZZZX4470 1 19970826 G 6220 407010150103 FRAHM ASSY BELL 407 407 SW M/R HEAD DETERIORATED B ALGR K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 SW 03 437AL A173 53141 LATERAL VIBRATION IN AIRCRAFT. FOUND ALL RUBBER PARTS DETERIORATED (ERASER TYPE WEAR) INSIDE FRAHM ASSEMBLY. 1 G 7 1 3U O H2SW 1997102300241 19971023 00241 NE 1997 10 23 97ZZZX4473 2 19970929 G 7250 ENGINE PWA JT8 JT8D15 52051 NE LPT ROTOR FAILED G O OTHER J WARNING INDICATION TO TAKEOFF 1 SW 05 708390 ENGINE WAS REMOVED FROM SERVICE DUE TO LPT FAILURE AT TAKEOFF. PRELIMINARY DISASSEMBLY FINDINGS REVEALED SEVERAL T4 BLA DES BROKEN AT AIRFOIL WITH EXCESSIVE DAMAGE TO LPT MODULE, T1 DISK AND EXHAUST CASE. THE OUTER EXHAUST DUCT HAD RUPTURE D DURING FAILURE. FAILURE INVESTIGATION IS IN PROCESS AT GREENWICH. 4 F E2EA 1997102300242 19971023 00242 SO 1997 10 23 97ZZZX4474 1 19970901 G 3340 A7755028V LIGHT WHELEN PIPER PA46 PA46310P 7104605 SO RT TAXI DISTORTED D K NONE O OTHER IN INSP/MAINT 1 EA 05 711XL 4608062 NOTICED REFLECTIVE MATERIAL WAS DISTORTED. SUSPECT CONDITION WAS CAUSED BY EXCESSIVE HEAT. REPLACED WITH NEW UNIT. 1 L 7 1 3O A25SO 1997102300243 19971023 00243 CE 1997 10 23 97ZZZX4475 1 19971001 G 5523 9661000667 TRIM TAB ASSY BEECH 55 E55 1152732 CE ATTACH HORN BROKEN D A UNSCHED LANDING E F VIBRATION/BUFFET FLT CONT AFFECTED CL CLIMB 1 EA 25 9800L 1215 TE813 LEFT ELEVATOR TRIM TAB HORN ATTACH BROKE IN-FLIGHT JUST AFTER TAKEOFF. AIRCRAFT ENCOUNTERED VIBRATION AND RETURNED TO L AND. INSPECTION FOUND ATTACH HORN OF TRIM TAB BROKEN AND SHOWED SIGNS OF PREVIOUS CRACK. SUSPECT CAUSE TIGHTENING BOLT AND PINCHING HORN CAUSING STRESS AND THEN CRACK. (BOLT SHOULD BE FREE TO ROTATE). REPLACED WITH NEW STYLE TAB. REF: BEECH SI 0610-152, REV II. PART NUMBER FOR NEW STYLE OFFERRED NOT ORIGINAL PART THAT FAILED. 1 L 7 2 3O 3A16 1997102300244 19971023 00244 CE 1997 10 23 97ZZZX4476 1 19971008 G 5330 SKIN CESSNA 210 210D 2073414 CE TOP CABIN CRACKED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 07 3785Y 21058285 TOP CABIN SKIN TORN (OIL CANNED) FROM AERODYNAMIC FORCES ACTING ON THE COMM 1 ANTENNA. THE ANTENNA WAS IMPROPERLY MOUNT ED. IT WAS MOUNTED DIRECTLY TO THE CABIN SKIN WITHOUT THE USE OF A DOUBLER. SUBMITTER STATED TO PREVENT THIS OCCURRENC E FROM HAPPENING AGAIN, DOUBLER MUST BE USED WHEN MOUNTING ANTENNAS TO THE AIRCRAFT STRUCTURE. 1 H 7 1 3O 3A21 1997102300246 19971023 00246 CE 1997 10 23 97ZZZX4478 1 19970930 G 2810 CELL BEECH 90 E90 1152914 CE FUEL SYSTEM SEAM LEAK B ADKR K NONE K W FLUID LOSS INADEQUATE Q C IN INSP/MAINT 1 SW 05 551MS LW113 INSTALLED NEW PMA FUEL TANK IN AIRCRAFT. TANK STARTED LEAKING FROM A SEAM IN THE TANK. SUBMITTER STATED THIS IS THE SE COND OCCURRENCE. REPLACED CELL WITH ANOTHER CELL. 1 L 7 2 3T 3A20 1997102300416 19971023 00416 CE 1997 10 23 97ZZZX4480 1 19971013 G 5720 2324011XXX EXTRUSION LEAR 55 55LEAR 5170702 CE WING TE CORRODED B S QU2R K NONE O OTHER IN INSP/MAINT 1 EA 17 1983Y 4293 079 THE TRAILING EDGE EXTRUSIONS ON WINGS, FLAPS, AND FLIGHT CONTROLS WERE FOUND CORRODED AT EXPOSED EDGE WITH A FEW SMALL A REAS OF BULBED EDGE COMPLETELY GONE. DISASSEMBLY OF TRAILING EDGES WAS REQUIRED TO DETERMINE THE EXTENT OF DAMAGE. NO CORROSION WAS FOUND BEYOND THE 'BULBED' EXPOSED EDGE. ALL EXTRUSIONS WERE REPLACED. 2 L 7 2 4F A10CE 1997102300417 19971023 00417 CE 1997 10 23 97ZZZX4481 1 19971013 G 5753 543301534 EXTRUSION LEAR 55 55LEAR 5170702 CE FLAP TE CORRODED B QU2R K NONE O OTHER IN INSP/MAINT 1 EA 17 1983Y 4293 079 THE TRAILING EDGE EXTRUSIONS ON WINGS, FLAPS, AND FLIGHT CONTROLS WERE FOUND CORRODED AT EXPOSED EDGE WITH A FEW SMALL A REAS OF BULBED EDGE COMPLETELY GONE. DISASSEMBLY OF TRAILING EDGES WAS REQUIRED TO DETERMINE THE EXTENT OF DAMAGE. NO CORROSION WAS FOUND BEYOND THE 'BULBED' EXPOSED EDGE. ALL EXTRUSIONS WERE REPLACED. 2 L 7 2 4F A10CE 1997102300418 19971023 00418 EU 1997 10 23 97ZZZX4482 1 19970919 G 6220 350A31190101 STARFLEX SNIAS 350 AS350B 8680801 EU BLUE BLADE FAILED D A WV0M A UNSCHED LANDING E VIBRATION/BUFFET HO HOVERING 1 EA 09 8WV 1957 M1609 1413 PILOT EXPERIENCED A VIBRATION WHILE IN APPROX 5 FOOT HOVER. GROUND OBSERVESENCES NOTED A SIGNIFICANT BLADE DEVIATION AT THE ONSET OF VIBRATION IN HOVER. PILOT LOWERED AIRCRAFT TO GROUND AND AT TOUCH DOWN, SEVERITY OF VIBRATION INCREASED. COLLECTIVE WAS BOTTOMED AND ENGINE SHUT DOWN INITIATED WITH CONDITION LEVER. LARGE OSCILLATIONS CONTINUED AS ROTOR SLO WED. AFTER AIRCRAFT WAS SECURED, NOTED THE STARFLEX BLUE BLADE FINGER HAD FAILED COMPLETELY AT APPROX 50 PERCENT SPAN. TAIL BOOM AND JUNCTION WERE DAMAGED AS WELL AS TRANSMISSION SUPPORTS DUE TO LARGE AMPLITUDE OF VIBRATION. NOTE: STARF LEX LIFE LIMIT IS 2,200 HOURS. 1 G 7 1 3U H9EU 1997102300419 19971023 00419 1997 10 23 97ZZZX4483 1 19971010 G 3411 D9181 FILTER VACUUM SYSTEM DEFECTIVE D P K NONE O OTHER IN INSP/MAINT 1 WP 07 200 DEFECTIVE PARKER AEROSPACE VACUUM FILTER RUBBER MATERIAL. SECOND PART WITH THE SAME DEFECT IN THE LAST TWO MONTHS. 1997102300420 19971023 00420 SO 1997 10 23 97ZZZX4484 2 19971001 G 8520 64200 CRANKCASE BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO NR 6 CYL FLANGE CRACKED D O OTHER E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NR NOT REPORTED 1 SO 03 112BS 243824R TH628 243824R RIGHT ENGINE CRANKCASE CRACKED AT THE UPPER STUD AREA OF THE NR 6 CYLINDER ALLOWING THE CYLINDER TO COMPLETELY SEPARATE FROM THE CASE CAUSING ENGINE FAILURE UNDER NORMAL FLIGHT CONDITIONS. SUBMITTER RECOMMENDATION: DYE PENETRANT, INSPECTI ON CRANKCASE REF: AD 77-13-22, FOR EARLIER MODEL ENGINES. 1 L 7 2 3O 3 O 3A16 E5CE 1997102300421 19971023 00421 CE 1997 10 23 97ZZZX4485 1 19971002 G 3411 RA1J47 AIR FILTER RAPCO BEECH 58 58 1152740 CE IN LINE AIR CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 15 4626A 309 TH39 THE IN-LINE AIR FILTER WAS FOUND CRACKED ALTHOUGH NOT SEVERE AT THIS TIME. PART MAY HAVE ONLY LASTED ANOTHER 25-50 HOUR S. AD 97-16-10 WAS ISSUED AGAINST THESE TYPE FILTERS, BUT THE FILTER IS NOT IN THE LOT NUMBER SPECIFIED BY AD. 1 L 7 2 3O 3A16 1997102300422 19971023 00422 CE 1997 10 23 97ZZZX4486 1 19971002 G 3411 RA1J47 AIR FILTER RAPCO BEECH 58 58 1152740 CE INST AIR FAILED D K NONE O OTHER IN INSP/MAINT 1 SO 15 4626A 309 TH39 THE IN-LINE AIR FILTER FOR THE INSTRUMENT AIR WAS FOUND SEVERELY CRACKED ALMOST TO THE POINT OF COMPLETE SEPARATION. AN AD 97-16-10 WAS ISSUED ON THESE TYPE FILTERS, BUT THESE FILTERS WERE NOT INCLUDED BECAUSE OF LOT NUMBER. BATCH NR 0279 7. 1 L 7 2 3O 3A16 1997102300423 19971023 00423 SO 1997 10 23 97ZZZX4487 1 19970905 G 3230 1497615 ALIGNMENT ROLLER PIPER PA24 PA24250 7102404 SO NLG MALFUNCTION D O OTHER J WARNING INDICATION AP APPROACH 1 WP 05 5240P 24271 ON TAKE OFF CLIMB, RETRACTION, NOSE GEAR ROLLER TRAVELED OUTSIDE OF 'Y' CHANNEL CAUSING THE NOSE WHEEL TO RETRACT SIDE W AYS. CIRCUIT BREAKER TRIPPED WHEN GEAR WAS APPROXIMATELY 7/8 OF THE WAY UP. ALL ATTEMPTS TO DEPLOY THE GEAR TO A LOCKE D DOWN POSITION WERE UNSUCCESSFUL. ON LANDING, AFTER ATTEMPTING UNUSUAL ATTITUDES ETC., GEAR COLLAPSED. 1 L 7 1 3O 1A15 1997102300424 19971023 00424 SO 1997 10 23 97ZZZX4488 1 19971007 G 2430 455151 CONTACTOR PIPER PA44 PA44180 7104402 SO BATTERY BURNED D O OTHER B H SMOKE/FUMES/ODORS/SPARKS ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 SO 16 926ER 29 4496016 THE PILOT REPORTED AN ELECTRICAL POWER LOSS FOLLOWED BY THE SMELL OF ELECTRICAL SMOKE. THE BATTERY CONTACTOR WAS FOUND BURNED AT THE 'X2' TERMINAL. THE TERMINAL WAS FOUND LOOSE. 1 L 7 2 3O A19S0 1997102300425 19971023 00425 GL 1997 10 23 97ZZZX4489 3 19971010 G 6114 84032L HUB SPIDER PIPER PA24 PA24 7102402 SO HARTZL HC92Z HC92ZK8 GL PROPELLER CRACKED D S K NONE O OTHER IN INSP/MAINT 1 GL 23 5358P 1377L 24306 1377L CUSTOMER PURCHASED PROPELLER NEW IN 1977. IN 1991 WITH 639 HOURS, PROPELLER STRUCK A TOW BAR RESULTING IN MINOR BLADE D AMAGE. PROP WAS TAKEN IN FOR REPAIR AND AD 73-02-01 WAS C/W. IN SEPTEMBER OF 1977 WITH 876 TT HOURS, PROP WAS BROUGHT IN FOR ROUTINE OVERHAUL. DURING MAGNAFLUX INSPECTION, A 1 INCH CRACK WAS DETECTED IN ONE ARM OF THE HUB SPIDER. 1 L 7 1 3O 1A15 5 C P892 1997102300434 19971023 00434 GL 1997 10 23 97ZZZX4492 1 19971002 G 6320 28131709R TRANSMISSION ENSTRM F28 F28F 3300412 GL M/R MAKING METAL C A PP0M K NONE J WARNING INDICATION IN INSP/MAINT 1 WP 01 8626S 174 4517S79C 786 TRANSMISSION GENERATING CHIP LIGHTS SINCE NEW ON AVERAGE OF 7-10 HOURS OF OPERATION. MFG SUGGESTED LESS SENSITIVE CHIP PLUG. XMSN CONTINUED TO GENERATE METAL. ACFT REMOVED FROM SERVICE WHEN PIECES REACHED .25 INCH IN LENGTH. MFG HAS NO PUBLISHED CRITERIA FOR CHIPS. REMOVED XMSN WITH 174 HOUR TTSN. SPARE 'REMANUFACTURED', XMSN INSTALLED. MFG FEELS META L GENERATION IS 'NORMAL' BREAK-IN FOR THIS TRANSMISSION. AVERAGE LIFE ON THIS XMSN IS 200-700 HOURS. PUBLISHED TBO IS 1,200 HOURS. 1 G 7 1 3O H1CE 1997102300435 19971023 00435 CE 1997 10 23 97ZZZX4493 1 19971008 G 3240 1015800281 BRAKE LINE BEECH 200 200BEECH 1152920 CE COPILOT BRAKE CHAFED B PAIR K NONE O OTHER IN INSP/MAINT 1 SO 05 142SR 7230 BB380 PHASE 3 INSP FOUND COPILOT'S LT RUDDER PEDAL PUSH/PULL TUBE RUBBING BRAKE LINE. THE AFT ROD END ON THE PUSH/PULL TUBE I S ATTACHED WITH CASTLE NUT AND COTTER PIN. THE END OF THE COTTER PIN WAS THE PART RUBBING THE BRAKE TUBE. IT CHAFED A GROOVE AND THERE WAS ABOUT .010 INCH OF MATERIAL REMAINING. INSTALLED A NEW LINE AND REPOSITIONED TO GIVE PROPER CLEARA NCE. IF THIS LINE HAD RUPTURED, A LOSS OF BRAKE PRESSURE WOULD HAVE OCCURRED. 1 L 7 2 4T A24CE 1997102300436 19971023 00436 CE 1997 10 23 97ZZZX4494 1 19970929 G 2710 676014514 FEEL BUNGEE CESSNA 750 750 2076810 CE LT AIL FEEL FREEZE UP G S A B EMER. DESCENT F FLT CONT AFFECTED CR CRUISE 1 GL 15 944H 422 750011 PILOT REPORTED RECEIVING 'TRIM LEFT AILERON WARNING' AT FL 41,000, 20,000, AND A FINAL WARNING AFTER LEVELING OFF JUST B ELOW 11,000. AFTER EACH OF THE 2 WARNINGS, PILOT DISCONNECTED AUTOPILOT AND FOUND NO DISCREPANCIES. WHEN PILOT DISCONN ECTED AUTOPILOT AFTER THIRD WARNING, UNABLE TO TURN ACFT TO THE LEFT. FLIGHT CREW DISCONNECTED CONTROL COLUMNS, DECLARE D EMERGENCY, AND PREPARED FOR FINAL APPROACH. DURING FINAL APPROACH SEQUENCE, FIRST OFFICER FELT AND HEARD A THUMP IN C ONTROL YOKE. FLIGHT CREW RE-CONNECTED CONTROL YOKES. AFTER GAINING FULL CONTROL OF ACFT, LANDED SAFELY. AFTER INVESTI GATION, DETERMINED LT AILERON FEEL BUNGEE WAS COLLECTING WATER AND FREEZING DURING HIGH ALTITUDE FLIGHT. 2 L 7 2 4J RT T00007WI 1997102300824 19971023 00824 CE 1997 10 23 97ZZZX4496 1 19971013 G 2731 040010757 CONTROL CABLE CESSNA 150 152 2071835 CE ELEV TRIM TAB FRAYED D K NONE O OTHER IN INSP/MAINT 1 SO 15 24264 15280183 DURING 100-HOUR INSPECTION, NOTED THE UPPER ELEVATOR TRIM TAB CABLE HAD SEVERAL BROKEN STRANDS. UPON REMOVAL, FOUND THE .0937 INCH 7 BY 7 CABLE WAS BROKEN IN TWO AREAS. ONE FORWARD OF AND THE OTHER AFT OF THE PULLEYS WHICH CHANGE CABLE DI RECTION IN THE HORIZONTAL STABILIZER. BREAK FORWARD OF PULLEY HAD ONLY ONE STRAND LEFT. AFT OF PULLEY HAD TWO STRANDS. ANNUAL INSPECTION WAS DONE IN APRIL, 1997. LAST 100-HOUR INSPECTION ACCOMPLISHED IN JULY, 1997. BOTH ELEVATOR TRIM T AB CABLES AND CHAIN WERE REPLACED. SUBMITTER RECOMMENDS CLOSER LOOK AT ALL CABLES WHERE THEY GO AROUND PULLEYS. 1 H 7 1 3O NT 3A19 1997102300825 19971023 00825 EA 1997 10 23 97ZZZX4497 2 19971008 G 7421 SR87 SPARK PLUG CESSNA 177 177 2073704 CE LYC O320 O320D2A 41508 EA INSULATOR BROKEN D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 WP 23 3420T 140 17700720 L2095127AC ENGINE RPM DROPPED TO APPROXIMATELY 2,000 RPM ON CLIMB-OUT. GROUND RUN-UP WAS NORMAL BEFORE AND AFTER FLIGHT AND DURING FIRST 200 FEET OF CLIMB OUT. INSPECTION OF INDUCTION, FUEL AND IGNITION SYSTEMS, REVEALED TWO AUBURN SR-87 AC PLUGS WI TH BROKEN INSULATORS ON THE COMBUSTION END. EACH INSULATOR WAS IN TWO PIECES BROKEN LENGTHWISE WITH CENTER ELECTRODE. C AUSE OF BROKEN INSULATORS UNDETERMINED. 1 H 7 1 3O 3 O NT A13CE E274 1997102300827 19971023 00827 CE 1997 10 23 97ZZZX4499 1 19971009 G 5330 51113031 SKIN CESSNA 425 425 2076018 CE LT FUSELAGE CRACKED D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 03 6886V 5126 4250154 DURING REMOVAL OF WINDSHIELD RETAINER FOR REPLACMENT OF WINDSHIELD, FOUND APPROXIMATEY 2 INCH LONG CRACK UNDER LT LOWER CORNER OF WINDSHIELD RETAINER. CRACK APPARENTLY CAUSED BY IMPROPER REMOVAL PROCEDURES OF RETAINER DURING A PREVIOUS WIN DSHIELD CHANGE. AN ENGINEERING ORDER FROM CESSNA WAS REQUIRED TO REPAIR DAMAGE CAUSING THE OPERATOR ADDED EXPENSE AND D OWN-TIME. SUBMITTER STATED THE MAINTENANCE MANUAL PROCEDURES SHOULD BE FOLLOWED CLOSELY TO PREVENT THESE TYPES OF DAMAG E FROM OCCURRING. 1 L 7 2 3T RT A7CE 1997102300828 19971023 00828 CE 1997 10 23 97ZZZX4500 1 19971016 G 5711 SPAR BBAVIA 8 8KCAB 2110612 CE WING CRACKED B A CS3R K NONE O OTHER IN INSP/MAINT 1 WP 17 76KF 2615 15374 DURING ANNUAL INSPECTION, PERFORMED WING SPAR INSPECTION PER AMERICAN CHAMPION SL 406 FOR WOOD SPARS: AC-43-16 ALERT N R 226 MAY97: FOUND EXTENSIVE COMPRESSION CRACKS AT FRONT, REAR AT BOTTOM OF BOTH WING SPARS. AIRCRAFT USED FOR AEROBAT IC FLIGHT. AD 87-18-09 PREVIOUSLY C/W. NO ACCIDENT DAMAGE IN LOGS. AIRCRAFT ALWAYS HANGARED. EXTRA INSPECTION PANELS REQUIRED TO DISCOVER EXTENT OF CRACKING AND TO FACILITATE ACCESS. 1 H 7 1 3O A21CE 1997102300829 19971023 00829 CE 1997 10 23 97ZZZX4501 1 19971009 G 3250 0813000105 BRACKET CESSNA 310 310L 2074230 CE STEER BELLCRANK CRACKED B CS3R K NONE O OTHER IN INSP/MAINT 1 WP 17 2239F 3000 310L0039 ON DEPLOYMENT OF LANDING GEAR NOSE, WHEEL STUCK 60 DEGREES TO LEFT OF CENTER. PERFORMED GEAR SWING, FOUND ATTACH BRACKE TS FOR STEERING BELLCRANK CRACKED. REPLACED BRACKETS. GEAR RETRACTION NORMAL. 1 L 7 2 3O 3A10 1997102300830 19971023 00830 CE 1997 10 23 97ZZZX4502 1 19971009 G 3250 0813000106 BRACKET CESSNA 310 310L 2074230 CE STEER BELLCRANK CRACKED B S A CS3R K NONE O OTHER IN INSP/MAINT 1 WP 17 2239F 3000 310L0039 ON DEPLOYMENT OF LANDING GEAR NOSE, WHEEL STUCK 60 DEGREES TO LEFT OF CENTER. PERFORMED GEAR SWING, FOUND ATTACH BRACKE TS FOR STEERING BELLCRANK CRACKED. REPLACED BRACKETS. GEAR RETRACTION NORMAL. 1 L 7 2 3O 3A10 1997102300831 19971023 00831 CE 1997 10 23 97ZZZX4503 1 19971011 G 2820 O-RING CESSNA 172 172F 2072414 CE SUMP STRAINER DETERIORATED D K NONE B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 EA 23 8688U 3600 17252592 A FUEL ODOR BECAME NOTICEABLE THEN STRONG IN THE CABIN OVER A SHORT PERIOD OF TIME. THE WHOLE FUEL SYSTEM WAS CHECKED A ND NO LEAKS WERE VISIBLE. ONLY AFTER A FUEL STAIN (RED MOTOR GAS) WAS SEEN ON THE BELLY WAS THE SEEP TRACED TO THE FUEL (STRAINER SUMP) WHERE THE O-RING SEAL AT THE TOP HAD DETERIORATED ALLOWING AN ALMOST INVISIBLE SEEP. O-RING REPLACMENT STOPPED THE PROBLEM. TIME AT 3,600 HOURS. 1 H 7 1 3O NT 3A12 1997102300832 19971023 00832 GL 1997 10 23 97ZZZX4504 1 19971003 G 5797 WIRE AMTR PITTS PITTSSPECS1C GL DRAG ANTI-DRAG LOOSE D L A K NONE O OTHER IN INSP/MAINT 1 GL 05 93LR RN2851 SEVERAL LOOSE WING DRAG AND ANTI-DRAG WIRES DISCOVERED DURING ANNUAL INSPECTION OF A HOMEBUILT PITTS S1C. IN ORDER TO C HECK ALL WIRES, ADDITIONAL INSPECTION HOLES HAD TO BE MADE IN THE WINGS. WITH ALL WIRES ACCESSIBLE FURTHER INSP REVEALE D ALL 8 DRAG WIRES AND 5 OF THE 8 ANTI-DRAG WIRES LOOSE. ACCESS HOLES WERE ADDED AT ALL WIRE ATTACHMENT LOCATIONS. AT THIS POINT, DISCOVERED NUTS MEANT TO SECURE THESE WIRES HAD WORKED LOOSE. THE WIRES WERE TIGHTENED AND SECURED. IT WAS NOT POSSIBLE TO DETERMINE WHAT CAUSED WIRE NUTS TO WORK LOOSE. TIME AND VIBRATION ARE THOUGHT TO BE THE MAJOR FACTORS INVOLVED. 1 Q 7 1 3O EXPA1Q71 1997102300833 19971023 00833 NE 1997 10 23 97ZZZX4505 1 19971010 G 3233 9720031 ACTUATOR ROD CONAER LA4 LA4200 5110310 NE NLG ACTUATOR FAILED D S A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 NE 05 1105L 702 696 AFTER TAKEOFF, MLG RETRACTED NORMALLY AND NLG REMAINED EXTENDED. LANDING GEAR WAS RE-EXTENDED AND A SAFE LANDING WAS MA DE. MAINTENANCE INSP FOUND THE THREADED END OF NLG ACTUATOR ROD HAD BROKEN OFF ALLOWING NLG ACTUATOR TO HANG FREELY IN THE WHEELWELL. THE NLG DOWNLOCK HELD AND THE AIRCRAFT WAS NOT DAMAGED. THE SUSPECT CAUSE OF FAILURE WAS IMPROPER NOSE GEAR RIGGINGS. SUBMITTER STATED AIRCRAFT MM IS VAGUE ON THIS SUBJECT. 1 H 7 1 3O 1A13 1997102300834 19971023 00834 SO 1997 10 23 97ZZZX4506 1 19970930 G 5720 RIVETS PIPER PA28 PA28R180 7102809 SO WING ASSY DEFECTIVE B L RMMR K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 01 4620J 5128 28R30503 DURING REPLACEMENT OF PAN UNDER WING WALK IN THE GEAR WELL, RIB WAS FOUND CRACKED. THE WING WAS REMOVED AND FOUND SEVERA L WING ATTACHMENT BOLTS CORRODED. BOLTS AND SPECIAL WASHERS NOT IN PROPER LOCATIONS PER PA28 MM. (WING ATTACH). NO SH IMS AT EITHER WING SPAR. SEVERAL RIVETS NOT INSTALLED. (HOLES NOT DRILLED), CHERRY MAX RIVETS THAT WERE TOO SHORT INST ALLED. OTHER RIVETS BUCKED POORLY. BOTH AILERON CABLES WORN, NO STRAND BROKEN, BUT REPLACED FOR PREVENTATIVE MAINTENAN CE. LEFT WING ATTACHMENT BOLTS REPLACED ONE AT A TIME. SEVERAL FOUND CORRODED. 1 L 7 1 3O 2A13 1997102300835 19971023 00835 SO 1997 10 23 97ZZZX4507 1 19970930 G 2710 CONTROL CABLE PIPER PA28 PA28R180 7102809 SO AILERON WORN B RMMR K NONE O OTHER IN INSP/MAINT 1 CE 01 4620J 5128 28R30503 DURING REPLACEMENT OF PAN UNDER WING WALK IN THE GEAR WELL, RIB WAS FOUND CRACKED. THE WING WAS REMOVED AND FOUND SEVERA L WING ATTACHMENT BOLTS CORRODED. BOLTS AND SPECIAL WASHERS NOT IN PROPER LOCATIONS PER PA28 MM. (WING ATTACH). NO SH IMS AT EITHER WING SPAR. SEVERAL RIVETS NOT INSTALLED. (HOLES NOT DRILLED), CHERRY MAX RIVETS THAT WERE TOO SHORT INST ALLED. OTHER RIVETS BUCKED POORLY. BOTH AILERON CABLES WORN, NO STRAND BROKEN, BUT REPLACED FOR PREVENTATIVE MAINTENAN CE. LEFT WING ATTACHMENT BOLTS REPLACED ONE AT A TIME. SEVERAL FOUND CORRODED. 1 L 7 1 3O 2A13 1997102300836 19971023 00836 SO 1997 10 23 97ZZZX4508 1 19970930 G 5711 6212100 SHIMS PIPER PA28 PA28R180 7102809 SO WING SPAR MISSING B RMMR K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 01 4620J 5128 28R30503 DURING REPLACEMENT OF PAN UNDER WING WALK IN THE GEAR WELL, RIB WAS FOUND CRACKED. THE WING WAS REMOVED AND FOUND SEVERA L WING ATTACHMENT BOLTS CORRODED. BOLTS AND SPECIAL WASHERS NOT IN PROPER LOCATIONS PER PA28 MM. (WING ATTACH). NO SH IMS AT EITHER WING SPAR. SEVERAL RIVETS NOT INSTALLED. (HOLES NOT DRILLED), CHERRY MAX RIVETS THAT WERE TOO SHORT INST ALLED. OTHER RIVETS BUCKED POORLY. BOTH AILERON CABLES WORN, NO STRAND BROKEN, BUT REPLACED FOR PREVENTATIVE MAINTENAN CE. LEFT WING ATTACHMENT BOLTS REPLACED ONE AT A TIME. SEVERAL FOUND CORRODED. 1 L 7 1 3O 2A13 1997102300837 19971023 00837 SO 1997 10 23 97ZZZX4509 1 19970930 G 5741 BOLTS PIPER PA28 PA28R180 7102809 SO WING ATTACH WRONG PLACEMENT B RMMR K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 01 4620J 5128 28R30503 DURING REPLACEMENT OF PAN UNDER WING WALK IN THE GEAR WELL, RIB WAS FOUND CRACKED. THE WING WAS REMOVED AND FOUND SEVERA L WING ATTACHMENT BOLTS CORRODED. BOLTS AND SPECIAL WASHERS NOT IN PROPER LOCATIONS PER PA28 MM. (WING ATTACH). NO SH IMS AT EITHER WING SPAR. SEVERAL RIVETS NOT INSTALLED. (HOLES NOT DRILLED), CHERRY MAX RIVETS THAT WERE TOO SHORT INST ALLED. OTHER RIVETS BUCKED POORLY. BOTH AILERON CABLES WORN, NO STRAND BROKEN, BUT REPLACED FOR PREVENTATIVE MAINTENAN CE. LEFT WING ATTACHMENT BOLTS REPLACED ONE AT A TIME. SEVERAL FOUND CORRODED. 1 L 7 1 3O 2A13 1997102300838 19971023 00838 SO 1997 10 23 97ZZZX4510 1 19970930 G 5741 BOLTS PIPER PA28 PA28R180 7102809 SO WING ATTACH CORRODED B RMMR K NONE O OTHER IN INSP/MAINT 1 CE 01 4620J 5128 28R30503 DURING REPLACEMENT OF PAN UNDER WING WALK IN THE GEAR WELL, RIB WAS FOUND CRACKED. THE WING WAS REMOVED AND FOUND SEVERA L WING ATTACHMENT BOLTS CORRODED. BOLTS AND SPECIAL WASHERS NOT IN PROPER LOCATIONS PER PA28 MM. (WING ATTACH). NO SH IMS AT EITHER WING SPAR. SEVERAL RIVETS NOT INSTALLED. (HOLES NOT DRILLED), CHERRY MAX RIVETS THAT WERE TOO SHORT INST ALLED. OTHER RIVETS BUCKED POORLY. BOTH AILERON CABLES WORN, NO STRAND BROKEN, BUT REPLACED FOR PREVENTATIVE MAINTENAN CE. LEFT WING ATTACHMENT BOLTS REPLACED ONE AT A TIME. SEVERAL FOUND CORRODED. 1 L 7 1 3O 2A13 1997102300839 19971023 00839 SO 1997 10 23 97ZZZX4511 1 19970930 G 5720 6767300 PAN PIPER PA28 PA28R180 7102809 SO GEAR WELL CRACKED B RMMR K NONE O OTHER IN INSP/MAINT 1 CE 01 4620J 5128 28R30503 DURING REPLACEMENT OF PAN UNDER WING WALK IN THE GEAR WELL, RIB WAS FOUND CRACKED. THE WING WAS REMOVED AND FOUND SEVERA L WING ATTACHMENT BOLTS CORRODED. BOLTS AND SPECIAL WASHERS NOT IN PROPER LOCATIONS PER PA28 MM. (WING ATTACH). NO SH IMS AT EITHER WING SPAR. SEVERAL RIVETS NOT INSTALLED. (HOLES NOT DRILLED), CHERRY MAX RIVETS THAT WERE TOO SHORT INST ALLED. OTHER RIVETS BUCKED POORLY. BOTH AILERON CABLES WORN, NO STRAND BROKEN, BUT REPLACED FOR PREVENTATIVE MAINTENAN CE. LEFT WING ATTACHMENT BOLTS REPLACED 1 AT A TIME. SEVERAL FOUND CORRODED. 1 L 7 1 3O 2A13 1997102300840 19971023 00840 CE 1997 10 23 97ZZZX4512 1 19970901 G 2140 22540151 HEAT EXCHANGER CESSNA 182 TR182 2072735 CE CABIN HEAT CRACKED B L VX3R K NONE O OTHER IN INSP/MAINT 1 NM 03 4840T 2223 R18201775 INSPECTION OF HEAT EXCHANGER FOUND BACK SIDE OF UNIT SPIRAL FINS CRACKED AND LEAKING. ALSO, FORWARD FLANGE COUPLED TO N R 1 CYLINDER EXHAUST RISER DETERIORATED. THESE CRACKS AND LEAKS ARE A HAZARD DUE TO CARBON MONOXIDE IN CABIN HEAT. 1 H 7 1 3O 3A13 1997102300841 19971023 00841 CE 1997 10 23 97ZZZX4513 1 19970901 G 5712 082217579 RIB CESSNA 414 414 2075908 CE WHEELWELL CRACKED D L K NONE O OTHER IN INSP/MAINT 1 SW 01 69943 3709 4140645 MAIN LANDING GEAR SUPPORT STRUCTURE, LT AND RT, MLG WHEELWELL - CRACKS ARE OCCURRING IN THE RIBS, PN 0822175-79, -74, CE NTER RIB WEB, ORIGINATING AT UPPER AFT CORNER OF THE CUT-OUT HOLE (WHERE THE OPERATING PUSH/PULL ROD PASSES THROUGH) PRO PAGATING TOWARDS TOP OF RIB. WING SKINS, P/N 0822000-9, UPPER, INBOARD ARE CRACKING ABOVE RIB, INSIDE BAGGAGE LOCKER (N ACELLE). MLG SIDE BRACE SUPPORT CASTINGS, P/N 0822180-7, -8, ARE BOLTED TO THE RIBS, (P/N 0822175-79,-74). BOTH CASTIN GS FOUND LOOSE AND ONE, -8, CRACKED. 1 L 7 2 3O RT A7CE 1997102300842 19971023 00842 CE 1997 10 23 97ZZZX4514 1 19970901 G 5720 08221808 CASTING CESSNA 414 414 2075908 CE MLG SIDE BRACE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 01 69943 3709 4140645 MAIN LANDING GEAR SUPPORT STRUCTURE, LT AND RT, MLG WHEELWELL - CRACKS ARE OCCURRING IN THE RIBS, PN 0822175-79, -74, CE NTER RIB WEB, ORIGINATING AT UPPER AFT CORNER OF THE CUT-OUT HOLE (WHERE THE OPERATING PUSH/PULL ROD PASSES THROUGH) PRO PAGATING TOWARDS TOP OF RIB. WING SKINS, P/N 0811000-9, UPPER, INBOARD ARE CRACKING ABOVE RIB, INSIDE BAGGAGE LOCKER (N ACELLE). MLG SIDE BRACE SUPPORT CASTINGS, P/N 0822180-7, -8, ARE BOLTS TO THE RIBS, (P/N 822175-79,-74). BOTH CASTINGS FOUND LOOSE AND ONE, -8, CRACKED. 1 L 7 2 3O RT A7CE 1997102300843 19971023 00843 CE 1997 10 23 97ZZZX4515 1 19970901 G 5720 08221807 CASTING CESSNA 414 414 2075908 CE MLG SIDE BRACE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 01 69943 3709 4140645 MAIN LANDING GEAR SUPPORT STRUCTURE, LT AND RT, MLG WHEELWELL - CRACKS ARE OCCURRING IN THE RIBS, PN 0822175-79, -74, CE NTER RIB WEB, ORIGINATING AT UPPER AFT CORNER OF THE CUT-OUT HOLE (WHERE THE OPERATING PUSH/PULL ROD PASSES THROUGH) PRO PAGATING TOWARDS TOP OF RIB. WING SKINS, P/N 0811000-9, UPPER, INBOARD ARE CRACKING ABOVE RIB, INSIDE BAGGAGE LOCKER (N ACELLE). MLG SIDE BRACE SUPPORT CASTINGS, P/N 0822180-7, -8, ARE BOLTS TO THE RIBS, (P/N 822175-79,-74). BOTH CASTINGS FOUND LOOSE AND ONE, -8, CRACKED. 1 L 7 2 3O RT A7CE 1997102300844 19971023 00844 CE 1997 10 23 97ZZZX4516 1 19970901 G 5730 08220009 SKIN CESSNA 414 414 2075908 CE LT/RT WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 01 69943 3709 4140645 MAIN LANDING GEAR SUPPORT STRUCTURE, LT AND RT, MLG WHEELWELL - CRACKS ARE OCCURRING IN THE RIBS, PN 0822175-79, -74, CE NTER RIB WEB, ORIGINATING AT UPPER AFT CORNER OF THE CUT-OUT HOLE (WHERE THE OPERATING PUSH/PULL ROD PASSES THROUGH) PRO PAGATING TOWARDS TOP OF RIB. WING SKINS, P/N 0811000-9, UPPER, INBOARD ARE CRACKING ABOVE RIB, INSIDE BAGGAGE LOCKER (N ACELLE). MLG SIDE BRACE SUPPORT CASTINGS, P/N 0822180-7, -8, ARE BOLTS TO THE RIBS, (P/N 822175-79,-74). BOTH CASTINGS FOUND LOOSE AND ONE, -8, CRACKED. 1 L 7 2 3O RT A7CE 1997102300845 19971023 00845 CE 1997 10 23 97ZZZX4517 1 19970901 G 5712 082217574 RIB CESSNA 414 414 2075908 CE WHEELWELL CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 01 69943 3709 4140645 MAIN LANDING GEAR SUPPORT STRUCTURE, LT AND RT, MLG WHEELWELL - CRACKS ARE OCCURRING IN THE RIBS, PN 0822175-79, -74, CE NTER RIB WEB, ORIGINATING AT UPPER AFT CORNER OF THE CUT-OUT HOLE (WHERE THE OPERATING PUSH/PULL ROD PASSES THROUGH) PRO PAGATING TOWARDS TOP OF RIB. WING SKINS, P/N 0811000-9, UPPER, INBOARD ARE CRACKING ABOVE RIB, INSIDE BAGGAGE LOCKER (N ACELLE). MLG SIDE BRACE SUPPORT CASTINGS, P/N 0822180-7, -8, ARE BOLTS TO THE RIBS, (P/N 822175-79,-74). BOTH CASTINGS FOUND LOOSE AND ONE, -8, CRACKED. 1 L 7 2 3O RT A7CE 1997102300846 19971023 00846 CE 1997 10 23 97ZZZX4518 1 19970901 G 5312 501302014 BULKHEAD CESSNA 414 414 2075908 CE NLG WELL CRACKED D L K NONE O OTHER IN INSP/MAINT 1 SW 01 69943 4140645 NOSE WHEELWELL SUBSTRUCTURE - CRACKS, LOOSE AND SHEARED RIVETS WERE FOUND ON BOTH SIDES OF NOSE GEAR WHEELWELL SUBSTRUCT URE. BULKHEAD, P/N 5013020-14, HAD CRACKED BUTT END, RIVETS SHEARED WHERE T-ANGLES, P/N 5213028-6 AND P/N 5013022-5 ARE RIVETED GUSSETS, P/N 521328-4 AND P/N 5013022-801. LOOSE AND WORKING RIVETS WERE FOUND IN LOWER END OF STIFFENERS, P/N 5013044, -3, AND -11. DOUBLERS, P/N 521-3045-3 LT, AND -2 RT, WERE FOUND CRACKED AT UPPER AFT CORNER RADIUS RELIEF CUT- OUTS. 1 L 7 2 3O RT A7CE 1997102300847 19971023 00847 CE 1997 10 23 97ZZZX4519 1 19970901 G 5320 52130286 T ANGLE CESSNA 414 414 2075908 CE NLG WELL RIVET SHEARED D K NONE O OTHER IN INSP/MAINT 1 SW 01 69943 4140645 NOSE WHEELWELL SUBSTRUCTURE - CRACKS, LOOSE AND SHEARED RIVETS WERE FOUND ON BOTH SIDES OF NOSE GEAR WHEELWELL SUBSTRUCT URE. BULKHEAD, P/N 5013020-14, HAD CRACKED BUTT END, RIVETS SHEARED WHERE T-ANGLES, P/N 5213028-6 AND P/N 5013022-5 ARE RIVETED GUSSETS, P/N 521328-4 AND P/N 5013022-801. LOOSE AND WORKING RIVETS WERE FOUND IN LOWER END OF STIFFENERS, P/N 5013044, -3, AND -11. DOUBLERS, P/N 521-3045-3 LT, AND -2 RT, WERE FOUND CRACKED AT UPPER AFT CORNER RADIUS RELIEF CUT- OUTS. 1 L 7 2 3O RT A7CE 1997013000157 19970130 00157 SO 1997 1 30 97ZZZX452 1 19970103 G 5711 62070006 SPAR 66601004 PIPER PA28 PA28180 7102808 SO LT WING CORRODED D A K NONE O OTHER IN INSP/MAINT 1 NE 02 8968J 3437 282991 FOUND DURING INSPECTION SEVERE INTERGRANULAR CORROSION OF LT WING SPAR JUST OUTBOARD OF GEAR ATTACHMENT. REQUIRED SPAR REPLACEMENT. AIRCRAFT HAD SPENT 90 PERCENT OF ITS LIFE NEAR THE OCEAN. REMOVAL OF FUEL TANK OR CLOSE INSPECTION WITH A MIRROR AND LIGHT WILL LOCATE THIS PROBLEM. WING SPAR P/N 66601-004. 1 L 7 1 3O 2A13 1997102300848 19971023 00848 CE 1997 10 23 97ZZZX4520 1 19970901 G 5320 50130225 T ANGLE CESSNA 414 414 2075908 CE NLG WELL RIVET SHEARED D K NONE O OTHER IN INSP/MAINT 1 SW 01 69943 4140645 NOSE WHEELWELL SUBSTRUCTURE - CRACKS, LOOSE AND SHEARED RIVETS WERE FOUND ON BOTH SIDES OF NOSE GEAR WHEELWELL SUBSTRUCT URE. BULKHEAD, P/N 5013020-14, HAD CRACKED BUTT END, RIVETS SHEARED WHERE T-ANGLES, P/N 5213028-6 AND P/N 5013022-5 ARE RIVETED GUSSETS, P/N 521328-4 AND P/N 5013022-801. LOOSE AND WORKING RIVETS WERE FOUND IN LOWER END OF STIFFENERS, P/N 5013044, -3, AND -11. DOUBLERS, P/N 521-3045-3 LT, AND -2 RT, WERE FOUND CRACKED AT UPPER AFT CORNER RADIUS RELIEF CUT- OUTS. 1 L 7 2 3O RT A7CE 1997102300849 19971023 00849 CE 1997 10 23 97ZZZX4521 1 19970901 G 5320 50130443 STIFFENER CESSNA 414 414 2075908 CE NLG WELL RIVETS LOOSE D K NONE O OTHER IN INSP/MAINT 1 SW 01 69943 4140645 NOSE WHEELWELL SUBSTRUCTURE - CRACKS, LOOSE AND SHEARED RIVETS WERE FOUND ON BOTH SIDES OF NOSE GEAR WHEELWELL SUBSTRUCT URE. BULKHEAD, P/N 5013020-14, HAD CRACKED BUTT END, RIVETS SHEARED WHERE T-ANGLES, P/N 5213028-6 AND P/N 5013022-5 ARE RIVETED GUSSETS, P/N 521328-4 AND P/N 5013022-801. LOOSE AND WORKING RIVETS WERE FOUND IN LOWER END OF STIFFENERS, P/N 5013044, -3, AND -11. DOUBLERS, P/N 521-3045-3 LT, AND -2 RT, WERE FOUND CRACKED AT UPPER AFT CORNER RADIUS RELIEF CUT- OUTS. 1 L 7 2 3O RT A7CE 1997102300850 19971023 00850 CE 1997 10 23 97ZZZX4522 1 19970901 G 5320 501304411 STIFFENER CESSNA 414 414 2075908 CE NLG WELL RIVETS LOOSE D K NONE O OTHER IN INSP/MAINT 1 SW 01 69943 4140645 NOSE WHEELWELL SUBSTRUCTURE - CRACKS, LOOSE AND SHEARED RIVETS WERE FOUND ON BOTH SIDES OF NOSE GEAR WHEELWELL SUBSTRUCT URE. BULKHEAD, P/N 5013020-14, HAD CRACKED BUTT END, RIVETS SHEARED WHERE T-ANGLES, P/N 5213028-6 AND P/N 5013022-5 ARE RIVETED GUSSETS, P/N 521328-4 AND P/N 5013022-801. LOOSE AND WORKING RIVETS WERE FOUND IN LOWER END OF STIFFENERS, P/N 5013044, -3, AND -11. DOUBLERS, P/N 521-3045-3 LT, AND -2 RT, WERE FOUND CRACKED AT UPPER AFT CORNER RADIUS RELIEF CUT- OUTS. 1 L 7 2 3O RT A7CE 1997102300851 19971023 00851 CE 1997 10 23 97ZZZX4523 1 19970901 G 5320 52130453 DOUBLER CESSNA 414 414 2075908 CE NLG LT WELL CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 01 69943 4140645 NOSE WHEELWELL SUBSTRUCTURE - CRACKS, LOOSE AND SHEARED RIVETS WERE FOUND ON BOTH SIDES OF NOSE GEAR WHEELWELL SUBSTRUCT URE. BULKHEAD, P/N 5013020-14, HAD CRACKED BUTT END, RIVETS SHEARED WHERE T-ANGLES, P/N 5213028-6 AND P/N 5013022-5 ARE RIVETED GUSSETS, P/N 521328-4 AND P/N 5013022-801. LOOSE AND WORKING RIVETS WERE FOUND IN LOWER END OF STIFFENERS, P/N 5013044, -3, AND -11. DOUBLERS, P/N 521-3045-3 LT, AND -2 RT, WERE FOUND CRACKED AT UPPER AFT CORNER RADIUS RELIEF CUT- OUTS. 1 L 7 2 3O RT A7CE 1997102300852 19971023 00852 CE 1997 10 23 97ZZZX4524 1 19970901 G 5320 52130452 DOUBLER CESSNA 414 414 2075908 CE NLG RT WELL CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 01 69943 4140645 NOSE WHEELWELL SUBSTRUCTURE - CRACKS, LOOSE AND SHEARED RIVETS WERE FOUND ON BOTH SIDES OF NOSE GEAR WHEELWELL SUBSTRUCT URE. BULKHEAD, P/N 5013020-14, HAD CRACKED BUTT END, RIVETS SHEARED WHERE T-ANGLES, P/N 5213028-6 AND P/N 5013022-5 ARE RIVETED GUSSETS, P/N 521328-4 AND P/N 5013022-801. LOOSE AND WORKING RIVETS WERE FOUND IN LOWER END OF STIFFENERS, P/N 5013044, -3, AND -11. DOUBLERS, P/N 521-3045-3 LT, AND -2 RT, WERE FOUND CRACKED AT UPPER AFT CORNER RADIUS RELIEF CUT- OUTS. 1 L 7 2 3O RT A7CE 1997103000026 19971030 00026 CE 1997 10 30 97ZZZX4525 1 19971010 G 2571 DRAIN TUBE CESSNA 182 182Q 2072732 CE BATTERY BOX LEAKING D K NONE O OTHER IN INSP/MAINT 1 SW 09 WHILE PERFORMING 100-HOUR INSPECTION, NOTICED DRAIN TUBE FROM BATTERY BOX HAD BEEN LEAKING ACID INTO REAR FUSELAGE. SUB MITTER STATED THIS BATTERY BOX IS MOUNTED RIGHT OVER CONTROL CABLES AND CABLES COULD BE DAMAGED. 1 H 7 1 3O NT 3A13 1997103000027 19971030 00027 EU 1997 10 30 97ZZZX4526 1 19970918 G 7810 MUFFLER GROB G115 G115C 1660303 EU LT INLET FLANGE SEPARATED B HIAR K NONE O OTHER IN INSP/MAINT 1 WP 27 115SR 489 MUFFLER INLET FLANGE COMPLETELY SEPARATED FROM BODY OF MUFFLER (LEFT SIDE MUFFLER). 1 L 7 1 3O NT A57EU 1997103000028 19971030 00028 SO 1997 10 30 97ZZZX4527 1 19971018 G 2750 40092009 BELLCRANK PIPER PA22 PA22160 7102214 SO FLAP BROKE D K NONE O OTHER IN INSP/MAINT 1 NM 10 3465Z 227387 REFERENCE ALERT NR 231. REPLACED A FLAP BELLCRANK. PUSH/PULL TUBE END BROKE OFF AT BOLT HOLE DURING INSPECTION WHILE R ECOVERING OPERATION WAS BEING ACCOMPLISHED. TOTAL TIME, 1,914.1 HOURS. SUBMITTER STATED PART APPEARS TO BE ORIGINAL. T HIS COULD HAVE CAUSED A SPLIT FLAP CONDITION. SUBMITTER STATED AD SHOULD BE IN ORDER TO INSPECT THE FLEET AS IT APPEARS TO BE A COMMON PROBLEM. REF: FIG 8, INDEX 92, PAZZ PARTS CATALOG, FEB 1961. 1 H 7 1 3O 1A6 1997103000029 19971030 00029 CE 1997 10 30 97ZZZX4528 1 19970828 G 3213 50411081 BEARING CESSNA 414 414 2075908 CE MLG BARREL CRACKED B OF1R K NONE O OTHER IN INSP/MAINT 1 EA 25 414DK 4798 4140532 IN C/W AD 90-02-13, THE MAIN GEAR BARREL INNER BEARING WAS FOUND CRACKED. NEW P/N 5141109-1 BEARING INSTALLED. 1 L 7 2 3O RT A7CE 1997103000030 19971030 00030 CE 1997 10 30 97ZZZX4529 1 19971001 G 2820 1560013S0350 HOSE STRATOFLEX CESSNA 210 T210N 2073456 CE ENGINE COMPT LEAKS D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 25 4905C 311 21063664 STRATOFLEX HOSE ASSY LEAKS. HOSE HARD AND BRITTLE. SUBMITTER STATED HOSES IN THE ENGINE COMPARTMENT OF TURBO AIRCRAFT DO NOT SEEM TO LAST AS LONG (DUE TO HEAT). ONLY 2 YEARS, 6 MONTHS OLD. 1 H 7 1 3O 3A21 1997103000031 19971030 00031 CE 1997 10 30 97ZZZX4530 1 19970303 G 2810 41534 FUEL VENT 714147 BBAVIA 8 8KCAB 2110612 CE INVERTED SYSTEM OBSTRUCTED G A A UNSCHED LANDING Y ENGINE STOPPAGE AB AEROBATIC 1 WP 09 5027F 57179 AIRCRAFT EXPERIENCED ENGINE FAILURE DURING AEROBATIC FLIGHT. PILOT ATTEMPTED TO RESTART ENGINE WITH NO SUCCESS. AIRCRA FT LANDED ON ROAD, LOST DIRECTIONAL CONTROL, AND IMPACTED A FENCE PARALLELING THE ROAD. SUBSTANTIAL DAMAGE WAS DONE. I NVESTIGATION WAS DONE ON FUEL SYSTEM BY NTSB AND RESULTED IN FINDING CONTAMINATION IN THE FUEL IN THE HEADER TANK WHEN I T WAS DRAINED. ALSO, INVERTED FUEL VENT WAS FOUND TO HAVE OVER 50 PERCENT OBSTRUCTION AT AN ELBOW FITTING OF A SOLID MA TERIAL THAT COVERED THE INLET. THE SHAPE OF THE PARTICLE CONFORMED TO THE SHAPE OF THE UNOBSTRUCTED PORTION OF THE ELBO W INLET AND EDGE. 1 H 7 1 3O A21CE 1997103000032 19971030 00032 CE 1997 10 30 97ZZZX4531 1 19970926 G 2810 541611322 VENT TUBE TABS LEAR 55 55LEAR 5170702 CE REFUEL VENT CRACKED B QU2R K NONE O OTHER IN INSP/MAINT 1 EA 17 1983Y 4293 079 WELDED TABS AT UPPER END OF VENT TUBE (QUANTITY 3) WHICH FORM ATTACH POINTS FOR THE TUBE WERE FOUND CRACKED DURING FUEL CELL MAINTENANCE. CAUSE UNKNOWN. 2 L 7 2 4F A10CE 1997103000035 19971030 00035 CE 1997 10 30 97ZZZX4534 1 19971003 G 2730 115610010325 TORQUE TUBE BEECH 99 C99 1154006 CE ELEVATOR CRACKED D A K NONE O OTHER IN INSP/MAINT 1 EA 17 6645N 481 U213 FOUND TORQUE TUBE CRACKED DURING ROUTINE INSPECTION. CRACK ORIGINATED AT THE TAPER PIN HOLE AT THE INBOARD CASTING. 1 L 7 2 3T A14CE 1997103000036 19971030 00036 CE 1997 10 30 97ZZZX4535 1 19971010 G 2720 551426022 CONTROL CABLE CESSNA 501 501 2076603 CE RUDDER SERVO BROKEN D A K NONE O OTHER IN INSP/MAINT 1 SO 09 833JL 278 5010045 RUDDER SERVO CABLE BROKEN. DISCOVERED CONDITION WHEN C/W SCHEDULED PHASE 5 CESSNA CITATION INSPECTION. NEW CABLE INSTA LLED 8-16-94 AT 3,362 HOURS. FOUND BROKEN AT 3,640.2 HOURS. SUBMITTER STATED SAFETY OF FLIGHT ITEM!! 1 L 7 2 4F A27CE 1997103000037 19971030 00037 CE 1997 10 30 97ZZZX4536 1 19971010 G 2720 551426024 CONTROL CABLE CESSNA 501 501 2076603 CE RUDDER SERVO BROKEN D K NONE O OTHER IN INSP/MAINT 1 SO 09 833JL 278 5010045 RUDDER SERVO CABLE BROKEN. DISCOVERED CONDITION WHEN C/W SCHEDULED PHASE 5 CESSNA CITATION INSPECTION. NEW CABLE INSTA LLED 8-16-94 AT 3,362 HOURS. FOUND BROKEN AT 3,640.2 HOURS. SUBMITTER STATED SAFETY OF FLIGHT ITEM!! 1 L 7 2 4F A27CE 1997103000038 19971030 00038 NM 1997 10 30 97ZZZX4537 1 19970808 G 7110 COWLING BOEING 727 727 1384001 NM ENG NR 1-NR 3 CORRODED B EG4R K NONE O OTHER IN INSP/MAINT 1 SO 25 RL825 SEVERE CORROSION UNDER FIRESHIELD. FIRESHIELD MUST BE REMOVED TO DETECT OR REPAIR. CORROSION DAMAGE CAUSED BY FAILURE OF BOND ALLOWING MOISTURE TO ENTER. 2 L 7 3 4F A3WE 1997103000039 19971030 00039 NM 1997 10 30 97ZZZX4538 1 19970808 G 7110 6519507222 COWLING BOEING 727 727 1384001 NM ENG NR 1- NR 3 CORRODED B EG4R K NONE O OTHER IN INSP/MAINT 1 SO 25 RC1155 SEVERE CORROSION UNDER FIRESHIELD. FIRESHIELD MUST BE REMOVED TO DETECT AND REPAIR CORRISON DAMAGE CAUSED BY FAILURE OF BOND ALLOWING MOISTURE TO ENTER. 2 L 7 3 4F A3WE 1997103000040 19971030 00040 NM 1997 10 30 97ZZZX4539 1 19970808 G 7110 B277101704 COWLING BOEING 727 727 1384001 NM ENG NR 1-NR 3 CORRODED B EG4R K NONE O OTHER IN INSP/MAINT 1 SO 25 RC137 SEVERE CORROSION UNDER FIRESHIELD. DISCOVERED WHEN CONVERTING COWLING FROM 65-19507-245 TO HUSK KIT MODEL. FIRESHIELD MUST BE REMOVED TO DETECT AND REPAIR CORROSION. 2 L 7 3 4F A3WE 1997103000041 19971030 00041 NM 1997 10 30 97ZZZX4540 1 19970808 G 7110 6519507249 COWLING BOEING 727 727 1384001 NM ENG NR 1-NR 3 CORRODED B EG4R K NONE O OTHER IN INSP/MAINT 1 SO 25 K32939 SEVERE CORROSION UNDER FIRESHIELD. FIRESHIELD MUST BE REMOVED TO DETECT AND REPAIR. CORROSION DAMAGE CAUSED BY FAILURE OF BOND ALLOWING MOISTURE TO ENTER. 2 L 7 3 4F A3WE 1997103000042 19971030 00042 NM 1997 10 30 97ZZZX4541 1 19971015 G 5347 TRACK SUPPORT BOEING 757 75723APF 1384966 NM RT BS 860-BS 880 CORRODED B EB1R K NONE O OTHER IN INSP/MAINT 1 EA 13 572CA 24868 RIGHT SEAT TRACK SUPPORT, SECOND FROM CENTER BS 860 TO BS 880, HAS INTERGRANULAR CORROSION. REPAIRED SEAT TRACK PER SRM 53-00-52. TAT: 2,628.8 HOURS. TAC: 5,944. 2 L 7 2 4F RT A2NM 1997103000043 19971030 00043 NM 1997 10 30 97ZZZX4542 1 19971015 G 5230 SEAM TAPE BOEING 757 75723APF 1384966 NM CARGO COMPT WRONG PART B EB1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 13 572CA 24868 SEAM TAPE IN MAIN CARGO COMPARTMENT DOES NOT MEET FAR 25.853 REQUIREMENTS. REMOVED TAPE AND RETAPED WITH APPROVED TAPE. TAT: 2,628.8 HOURS. TAC: 5,944. 2 L 7 2 4F RT A2NM 1997103000044 19971030 00044 NM 1997 10 30 97ZZZX4543 1 19971015 G 5315 FLOOR BEAM BOEING 757 75723APF 1384966 NM BS 880 LBL 45.5 CORRODED B EB1R K NONE O OTHER IN INSP/MAINT 1 EA 13 572CA 24868 STA 880 FLOOR BEAM BETWEEN LBL 45.5 AND LBL 24.75, FORWARD UPPER CHORD OUTBOARD, FLOOR BOARD FASTENERS HOLE LOWER SIDE, HAS INTERGRANULAR CORROSION. REPAIR SEAT TRACK PER SRM 53-00-51. TAT: 2,628.8 HOURS. TAC: 5,944. 2 L 7 2 4F RT A2NM 1997103000045 19971030 00045 NM 1997 10 30 97ZZZX4544 1 19971015 G 5347 SEAT TRACK BOEING 757 75723APF 1384966 NM BS 880-BS 900 CORRODED B EB1R K NONE O OTHER IN INSP/MAINT 1 EA 13 572CA 24868 RIGHT SEAT TRACK SECOND FROM CENTER SUPPORT CORRODED AT FS 880 TO FS 900. CLEANED AND TREATED CORROSION PER SRM 53-00-5 2. TAT: 2,628.8 HOURS. TAC: 5,944. 2 L 7 2 4F RT A2NM 1997103000046 19971030 00046 NM 1997 10 30 97ZZZX4545 1 19971015 G 5347 SEAT TRACK BOEING 757 75723APF 1384966 NM BS 880 RT CORRODED B EB1R K NONE O OTHER IN INSP/MAINT 1 EA 13 572CA 24868 RIGHT SEAT TRACK FIRST FROM CENTER SUPPORT STIFFENER CORRODED AT FS 880. REMOVED AND REPLACED ATTACH BRACKET PER SRM 51 -30-51 AND SRM 51-30-40. TAT: 2,628.8 HOURS. TAC: 5,944. 2 L 7 2 4F RT A2NM 1997103000047 19971030 00047 NM 1997 10 30 97ZZZX4546 1 19971015 G 5347 SEAT TRACK BOEING 757 75723APF 1384966 NM BS 880 RT CORRODED B EB1R K NONE O OTHER IN INSP/MAINT 1 EA 13 572CA 24868 RIGHT SEAT TRACK SECOND FROM CENTER SUPPORT STIFFENER CORRODED AT FS 880. REMOVED AND REPLACED ATTACH BRACKET PER SRM 5 1-30-51 AND SRM 51-30-40. TAT: 2,628.8 HOURS. TAC: 5,944. 2 L 7 2 4F RT A2NM 1997103000048 19971030 00048 NM 1997 10 30 97ZZZX4547 1 19971015 G 5347 SEAT TRACK BOEING 757 75723APF 1384966 NM BS 900 RT CORRODED B EB1R K NONE O OTHER IN INSP/MAINT 1 EA 13 572CA 24868 INTERGRANULAR CORROSION AROUND FASTENER HOLES BETWEEN CENTER AND RT NR 1 SEAT TRACK AT BS 900. REPAIRED FLOOR BOARD CHA NNEL BETWEEN CENTER AND NR 1 SEAT TRACK PER SRM 53-01-60. TAT: 2,628.8 HOURS. TAC: 5,944. 2 L 7 2 4F RT A2NM 1997103000049 19971030 00049 NM 1997 10 30 97ZZZX4548 1 19971015 G 5315 FLOOR BEAM BOEING 757 75723APF 1384966 NM BS 879 CORRODED B EB1R K NONE O OTHER IN INSP/MAINT 1 EA 13 572CA 24868 FLOOR BEAM CORRODED AT FS 879 OUTBOARD OF SECOND SEAT TRACK FROM CENTER RT. REPAIR FLOOR BEAM PER SRM 53-00-51. TAT: 2 ,628.8 HOURS. TAC: 5,944. 2 L 7 2 4F RT A2NM 1997103000050 19971030 00050 NM 1997 10 30 97ZZZX4549 1 19971015 G 5347 SEAT TRACK BOEING 757 75723APF 1384966 NM BS 880-900 LT CORRODED B EB1R K NONE O OTHER IN INSP/MAINT 1 EA 13 572CA 24868 FLOATING SEAT TRACK LT SIDE STA 880 TO STA 900 HAS INTERGRANULAR CORROSION AND IS CRACKED. FABRICATED AND INSTALLED REP AIR ON SEAT TRACK PER DER DWG 97039. TAT: 2,628.8 HOURS. TAC: 5,944. 2 L 7 2 4F RT A2NM 1997103000051 19971030 00051 NM 1997 10 30 97ZZZX4550 1 19971015 G 5347 SEAT TRACK BOEING 757 75723APF 1384966 NM BS 970 RT CORRODED B EB1R K NONE O OTHER IN INSP/MAINT 1 EA 13 572CA 24868 INTERGRANULAR CORROSION ON SEAT TRACK SUPPORT RT, SECOND TRACK FROM CENTER PALLET POSITION NR 7 AT FS 970 RT. CLEANED A ND TREATED CORROSION AND INSTALLED STRAP REPAIR ON SUPPORT PER DER DWG 97040A. TAT: 2,628.8 HOURS. TAC: 5,944. 2 L 7 2 4F RT A2NM 1997103000052 19971030 00052 NM 1997 10 30 97ZZZX4551 1 19971015 G 5347 SEAT TRACK BOEING 757 75723APF 1384966 NM BS 880-900 LT CORRODED B EB1R K NONE O OTHER IN INSP/MAINT 1 EA 13 572CA 24868 LT OUTBOARD FLOATING SEAT TRACK STA 880 TO STA 900 HAS INTERGRANULAR CORROSION. REMOVED AND REPLACED UPPER SECTION PER SRM 53-00-52. TAT: 2,628.8 HOURS. TAC: 5,944. 2 L 7 2 4F RT A2NM 1997103000053 19971030 00053 1997 10 30 97ZZZX4552 4 19970901 G 3418 370110 STALL VANE BEECH 1900 1900C 1154161 CE ELECT PINS STUCK B A FV1R K NONE N FALSE WARNING IN INSP/MAINT 1 EA 11 31134 209 UC42 STALL WARNING HORN STAYED ON CONTINUOUSLY. UPON INSPECTION, FOUND STALL VANE STUCK IN POSITION. WHEN REMOVING CANNON P LUG FROM ASSEMBLY PRIOR TO REMOVING ASSY FROM AIRCRAFT, FOUND VANE WAS FREE. AFTER REMOVING ASSEMBLY FROM AIRCRAFT, FOU ND THE BOARD THE ELECTRICAL PINS WERE ON LOOSE. FURTHER INSPECTION REVEALED IF THE PINS WERE PUSHED IN (LIKE ATTACHING CANNON PLUG), IT WOULD BIND THE MOVEMENT OF THE STALL VANE INTERNALLY. PART WAS REPLACED WITH NEW. OPERATION WAS SATIS FACTORY. DURING FUTURE INSPECTIONS, IT MAY BE ADVISABLE TO MOVE CANNON PLUG ON STALL VANE AND SEE IF VANE BINDS. 2 L 7 2 4T RT A24CE 1997103000054 19971030 00054 SO 1997 10 30 97ZZZX4553 1 19971003 G 3320 BR9800003 LIGHT TUBE BRUCE GULSTM G1159 GIV 3980115 SO RT AFT CABIN INOPERABLE D P K NONE M OVER TEMP IN INSP/MAINT 1 GL 05 3PG 1260 DURING A ROUTINE LIGHT INSPECTION, THE RIGHT AFT CABIN DOWN-WASH FLUORESCENT LIGHT TUBE WAS FOUND INOPERABLE. ON TUBE R EMOVAL, FOUND BURN SPOT ABOUT .50 INCH FROM THE METAL END CONNECTOR. THE HEADLINERS WAS ALSO CHARRED. 2 L 7 2 4F RT A12EA 1997103000055 19971030 00055 NM 1997 10 30 97ZZZX4554 1 19971008 G 2820 15256 HOSE AEROQUIP 35461002 CHRIS HUSKY A1 221020X NM AFT FUEL LEAK D K NONE K FLUID LOSS IN INSP/MAINT 1 WP 11 2UJ 1140 BOTH REAR FUEL LINE HOSES HAVE FAILED WITHIN A WEEK OF EACH OTHER. FUEL WAS FOUND SEEPING THROUGH THE OUTER COVERING OF HOSE. AEROQUIP NR 1525-6. 1 H 7 1 3O NC A22NM 1997103000056 19971030 00056 CE 1997 10 30 97ZZZX4555 1 19971007 G 2434 6560T ALTERNATOR BEECH 35 E35 1151512 CE DC SYSTEM WEAK D K NONE O OTHER IN INSP/MAINT 1 CE 03 33246 D3990 INSTALLED JASCO ALTERNATOR KIT PER STC SA999WE. WOULD NOT CARRY TWO LANDING LIGHTS. REPLACED REGULATOR AND ALTERNATOR WIRE WAS DOUBLE-CHECKED AND WAS WIRED CORRECTLY. NEW UNIT WOULD NOT CARRY BOTH LANDING LIGHTS. REMOVED UNIT AND WILL O VERHAUL GENERATOR. SUBMITTER STATED RECEIVED BAD ALTERNATORS. 1 L 7 1 3O A777 1997103000057 19971030 00057 CE 1997 10 30 97ZZZX4556 1 19970911 G 3230 12436351 TORQUE LINK CESSNA 206 TU206G 2073357 CE NLG CRACKED D S K NONE O OTHER IN INSP/MAINT 1 AL 05 7396C 3627 U20603920 INSPECTION FOUND NLG UPPER TORQUE LINK ASSY CRACKED. 1 H 7 1 3O A4CE 1997103000058 19971030 00058 EU 1997 10 30 97ZZZX4557 1 19970902 G 5102 EN1848 LINE LBL 210A LBL210A 5180004 EU SUPERCHUTE BROKE D S A K NONE E VIBRATION/BUFFET NR NOT REPORTED 1 SW 99 234TZ 371 121 ONE OF SEVEN SUPERCHUTE RETAINING LINES FABRICATED FROM P/N EN 1848 KEVLAR CORE 3.5MM ROPE BROKE WHERE IT MAKES A 180 DE GREE LOOP AROUND THE 5MM (.1875 INCH) SIDE OF THE GUIDE RING ATTACHED TO THE INSIDE OF THE ENVELOPE. THE BREAKING OF TH E RETAINING LINE ALLOWED THE PARACHUTE TO OPEN SLIGHTLY ALLOWING MINOR UNCONTROLLED VENTING FROM THE ENVELOPE. 1 B 0 0 0 0 B82EU 1997103000059 19971030 00059 EU 1997 10 30 97ZZZX4558 1 19970904 G 5102 B1D7 GAUGE COLT COLT COLT180A 2301219 EU BURNER GAS PRESS DAMAGED D A K NONE O OTHER IN INSP/MAINT 1 WP 09 728TC 305 2505 FUEL PRESSURE GAUGE USED ON MODEL C3 AND C3T BURNER ASSY HAS AN OPERATING RANGE OF ZERO TO 200 PSI. WHEN FUEL TANK PRES SURE IS ABOVE 150 PSI, OPENING THE LIQUID FUEL SHUT-OFF VALVE ON THE TANK CAUSES A PRESSURE SURGE IN THE BURNER FUEL SYS TEM DRIVING THE PRESSURE GAUGE BEYOND ITS OPERATING LIMIT DAMAGING ITS INTERNAL MECHANISM. THE GAUGE IS NOT REPAIRABLE AND MUST BE REPLACED WHEN DAMAGED. THIS HAS BEEN A RECURRING PROBLEM IN 10 BURNER SYSTEMS. 1 B 0 0 0 0 B3EU 1997013000161 19970130 00161 EA 1997 1 30 97ZZZX456 2 19970106 G 7414 10357426 DISTRIBUTOR BLK S6RN25 LYC O360 O360* 41514 EA MAG BUSHING SPUN B WS9R K NONE O OTHER IN INSP/MAINT 1 NM 07 569484 MAG RUBBER BLOCK CENTER BUSHING SPUN IN BLOCK. 3 O E286 1997103000177 19971030 00177 NM 1997 10 30 97ZZZX4566 1 19970929 G 7830 315T440328 TRACK BEAM 315T4014112A BOEING 747 747* NM THRUST REVERSER EXCESS WEAR B R4JY K NONE O OTHER IN INSP/MAINT 1 WP 33 B162 000043 SUBMITTER REPORTS AN INCREASE OF BOEING 747 PW4000 SERIES ENGINE THRUST REVERSER, LOWER TRACK BEAM EXCESS WEAR. THE WEA R WAS FOUND ALONG THE AUXILIARY TRACK. 2 L 7 4 4F RT A20WE 1997103000178 19971030 00178 NM 1997 10 30 97ZZZX4567 1 19971001 G 7830 315T440328 TRACK BEAM 315T4014117A BOEING 747 747* NM THRUST REVERSER EXCESS WEAR B R4JY K NONE O OTHER IN INSP/MAINT 1 WP 33 9VSMK 000082 INSPECTION FOUND PW4000 SERIES ENGINE THRUST REVERSER HAD LOWER TRACK BEAM EXCESS WEAR. THE WEAR WAS FOUND ALONG AUXILI ARY TRACK. 2 L 7 4 4F RT A20WE 1997103000179 19971030 00179 NM 1997 10 30 97ZZZX4568 1 19971001 G 7830 315T440328 TRACK BEAM 315T4014120A BOEING 747 747* NM THRUST REVERSER EXCESS WEAR B R4JY K NONE O OTHER IN INSP/MAINT 1 WP 33 B2464 000107 FOUND BOEING 747, PW4000 SERIES ENGINE THRUST REVERSER HAD LOWER TRACK BEAM EXCESS WEAR. THE WEAR WAS FOUND ALONG AUXIL IARY TRACK. 2 L 7 4 4F RT A20WE 1997103000180 19971030 00180 NM 1997 10 30 97ZZZX4569 1 19970929 G 7830 315T440327 TRACK BEAM 315T401489A BOEING 747 747* NM THRUST REVERSER EXCESS WEAR B R4JY K NONE O OTHER IN INSP/MAINT 1 WP 33 9VSMA 7488 000008 SUBMITTER REPORTS AN INCREASE OF BOEING 747 PW4000 SERIES ENGINE THRUST REVERSER WITH LOWER TRACK BEAM EXCESS WEAR. THE WEAR WAS FOUND ALONG THE AUXILIARY TRACK. 2 L 7 4 4F RT A20WE 1997013000162 19970130 00162 GL 1997 1 30 97ZZZX457 3 19970106 G 6114 07015C87 HUB CESSNA 310 310R 2074245 CE MCAULY 3AF32C 3AF32C87 GL PROP THREADS CRACKED B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 4190 557 785253 INSPECTION FOUND RETENTION THREADS OF HUB CRACKED. 1 L 7 2 3O 3A10 5 C P22EA 1997103000181 19971030 00181 NM 1997 10 30 97ZZZX4570 1 19971001 G 7830 315T440327 TRACK BEAM 315T4014113A BOEING 747 747* NM THRUST REVERSER EXCESS WEAR B R4JY K NONE O OTHER IN INSP/MAINT 1 WP 33 B2460 000048 FOUND BOEING 747, PW4000 SERIES ENGINE THRUST REVERSER WITH LOWER TRACK BEAM EXCESS WEAR. THE WEAR WAS FOUND ALONG AUXI LIARY TRACK. 2 L 7 4 4F RT A20WE 1997103000182 19971030 00182 EA 1997 10 30 97ZZZX4571 1 19971015 G 7830 MS32154018 CLIP CNDAIR CL600 CL6002B16 1900305 EA T/R BLOCKER DOOR MISSING D A K NONE O OTHER IN INSP/MAINT 1 EA 25 399SW 5009 THRUST REVERSER BLOCKER DOOR CONTROL ARM PIN RETAINER CLIPS FOUND MISSING WITH ABNORMAL REGULARITY. SUBMITTER RECOMMEND ATION: RE-DESIGN WITH DRILLED PIN AND INSTALL COTTER PIN VERSUS RETAINER CHIP. 2 L 7 2 4F RT A21EA 1997103000183 19971030 00183 NM 1997 10 30 97ZZZX4572 1 19970327 G 5347 BAC15201566 SEAT TRACK BOEING 747 7472D7B 1384803 NM BS 1810-1850 BROKEN B CISY K NONE O OTHER IN INSP/MAINT 1 EA 31 523MC 21782 DURING A-CHECK, FOUND SEAT TRACK BROKEN AT STA 1810 TO STA 1850 ON MAIN CARGO DECK AND FLOOR FITTING DAMAGED. FLOOR FIT TING REPLACED AND SEAT TRACK REPLACED PER SRM 53-10-05, FIG 33, SHEET 4. 2 L 7 4 4F RT A20WE 1997103000184 19971030 00184 EU 1997 10 30 97ZZZX4573 1 19971009 G 5345 11722201103 HINGE 117222061 BOLKMS 117 BK117B2 5626013 EU EQUIP DECK CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 25 300CP 248 7249 DURING LOWERING OF THE OPTIONAL EQUIPMENT DECK PANEL, NOTED THE LEFT HAND HINGE ASSY WAS CRACKED IN HALF. FURTHER INSPE CTION REVEALED RIGHT HAND HINGE CRACKED AND FAILURE WAS IMMINENT. MATERIAL THICKNESS AND TYPE ARE NOT SUFFICIENT TO SUP PORT PANEL WITH OPTIONAL EQUIPMENT INSTALLED. NEW HINGES FROM MANUFACTURER WITH SAME PART NUMBER WERE LARGER AND MADE O F DIFFERENT MATERIAL. 1 G 7 2 3U NC H13EU 1997103000368 19971030 00368 EA 1997 10 30 97ZZZX4574 2 19971001 G 8520 71640 PLUG 75073 PIPER PA31 PA31 7103102 SO LYC O540 TIO540J2BD 41532 EA CRANKSHAFT LOOSE B EVGR E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 SO 33 2FOR 2538 840 31474 L907861A FLIGHT OVER THE GULF OF MEXICO. PROPELLER RPM STARTED TO DROP OFF. PROP CONTROL WAS ADVANCED, BUT AFTER ONE HOUR, PROP ELLER WENT TO FEATHERED POSITION. AFTER SAFE LANDING, A VARIETY OF TESTS REVEALED THE PLUG, PN 71640, WAS LOOSE INSIDE THE CRANKSHAFT ALLOWING OIL TO BYPASS PROPELLER GOVERNOR. AFTER PLUG WAS PROPERLY SEATED, TESTING REVEALED NORMAL OPERA TION ONCE AGAIN. NO METAL WAS FOUND IN FILTER OR SCREWS. OTHER ENGINE WAS CHECKED AND FOUND OK. NO RECOMMENDATION. 1 L 7 2 3O 3 O A20SO E14EA 1997103000369 19971030 00369 SO 1997 10 30 97ZZZX4575 1 19971012 G 3340 GE4609 LIGHT PIPER PA28 PA28180 7102808 SO LANDING FAILED D K NONE O OTHER IN INSP/MAINT 1 NE 01 186KG 12 283158 LANDING LIGHT FAILED 12 FLIGHT HOURS AFTER INSTALLATION. 1 L 7 1 3O 2A13 1997103000370 19971030 00370 SO 1997 10 30 97ZZZX4576 1 19970710 G 7810 40B19975 PIPE PIPER PA46 PA46350P SO EXHAUST SYSTEM DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 SW 99 193MM 925 4622134 DURING C/W SB 521, FOUND ENTIRE EXHAUST CROSSOVER PIPE DEFECTIVE EXCEPT PIPE P/N 40B19974. REPLACED ALL DEFECTIVE PIPES WITH NEW. 1 L 7 1 3O RT A25SO 1997103000371 19971030 00371 SO 1997 10 30 97ZZZX4577 1 19970917 G 7810 40B19975 PIPE PIPER PA46 PA46350P SO RT CROSSOVER DETACHED D K NONE O OTHER IN INSP/MAINT 1 SW 99 193PM 507 4622143 C/W SB 521, FOUND CROSSOVER PIPE ENGAGEMENT NOT SATISFACTORY PER SB. RT CROSSOVER PIPE REPLACED WITH NEW. 1 L 7 1 3O RT A25SO 1997103000372 19971030 00372 SO 1997 10 30 97ZZZX4578 1 19970807 G 7810 40B19975 PIPE PIPER PA46 PA46350P SO EXHAUST FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 99 255SW 1642 1613 4622064 C/W SB 521, FOUND CROSSOVER ASSY PULLED PART. 1 L 7 1 3O RT A25SO 1997013000163 19970130 00163 GL 1997 1 30 97ZZZX458 3 19970106 G 6114 D7015C87 HUB CESSNA 310 310R 2074245 CE MCAULY 3AF32C 3AF32C87 GL PROP THREADS CRACKED B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 4190 555 785021 INSP FOUND RETENTION THREADS OF HUB CRACKED. 1 L 7 2 3O 3A10 5 C P22EA 1997103000374 19971030 00374 CE 1997 10 30 97ZZZX4580 1 19971008 G 2910 MANIFOLD ASSY CESSNA 414 414A 2075907 CE HYDRAULIC SYSTEM DEFECTIVE H A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 WP 13 6604C 5060 414A0030 PILOT REPORTED THE 'HYDRAULIC PRESSURE' LIGHT WOULD NOT EXTINGUISH WHEN THE LANDING GEAR WAS RETRACTED. RED TRANSIT LIG HT EXTINGUISHED. GEAR CYCLED 5 TIMES IN THE AIR WITH NO CHANGE. AIRCRAFT RETURNED TO STATION. AIRCRAFT PLACED ON JACK S. GEAR CYCLED 5 TIMES. COULD NOT DUPLICATE DISCREPANCY. HYDRAULIC PRESSURE SWITCH, P/N 9910287-10, REPLACED. GEAR C YCLED 12 TIMES, NO DISCREPANCIES. AIRCRAFT TEST FLOWN. 'HYDRAULIC PRESSURE' LIGHT WOULD NOT EXTINGUISH. AIRCRAFT RETU RNED TO STATION. HYDRAULIC MANIFOLD ASSEMBLY REPLACED. GEAR CYCLED 6 TIMES. AIRCRAFT TEST FLOWN AND RELEASED FOR FLIG HT. SUSPECT MANIFOLD ASSEMBLY, P/N 9910188-1, LEAKING INTERNALLY. 1 L 7 2 3O A7CE 1997103000375 19971030 00375 SW 1997 10 30 97ZZZX4581 1 19971007 G 2810 INSPECTION COVER MOONEY M20 M20C 5870208 SW FUEL TANK WRONG SEALER D K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 17 6021Q 3232 ALL THE FUEL TANK COVERS HAD THE WRONG TYPE FUEL TANK ACCESS COVER SEALANT. SEALANT WAS RED IN COLOR. SUBMITTER RECOMM ENDS INSPECTING THE FUEL SYSTEM. USE A HIGH-OCTANE FUEL RESISTANT SEALANT AS USED IN AD 89-18-08 GULFSTREAM. 1 L 7 1 3O 2A3 1997103000376 19971030 00376 CE 1997 10 30 97ZZZX4582 1 19971007 G 3240 8302781 TORQUE PLATE C1630320207 CESSNA 206 U206G 2073356 CE BRAKE ASSY CRACKED D K NONE O OTHER IN INSP/MAINT 1 NE 05 756HK 4714 U20604102 DURING A PRE-FLIGHT INSPECTION, NOTED RUB MARKS ON INSIDE OF BRAKE DISC. FURTHER INVESTIGATION FOUND THE TORQUE PLATE C RACKED AT THE BUSHING FOR THE SLIDE PINS OF THE CALIPER. SUBMITTER STATED THIS IS THE SECOND CRACKED TORQUE PLATE ON LT SIDE OF A 206 SUBMITTER HAS FOUND. 1 H 7 1 3O A4CE 1997103000377 19971030 00377 1997 10 30 97ZZZX4583 4 19971005 G 2562 DMELT81 ELT DORNEMARGLN CESSNA 172 172P 2072436 CE G SWITCH FAILED TEST D K NONE O OTHER IN INSP/MAINT 1 NE 05 9935L 1300 9485 17276651 ELT FAILED G-FORCE TEST REQUIRED BY FAR 91.207D. ONLY VERY HARD BLOWS WITH A HAMMER WOULD ACTIVATE G-SWITCH. MANUAL OP ERATION OF THE ELT WAS NORMAL AND NO CORROSION WAS FOUND. 1 H 7 1 3O NT 3A12 1997103000378 19971030 00378 SO 1997 10 30 97ZZZX4584 2 19970901 G 8530 CYLINDER CESSNA 188 A188A 2073008 CE CONT O520 IO520D 17032 SO NR 2 CYL EX PORT CRACKED D S K NONE O OTHER IN INSP/MAINT 1 SW 99 9958G 500 18800758 15988071D DURING 100-HOUR INSPECTION, EXHAUST STACK WAS REMOVED. CRACK APPROXIMATELY 1 INCH LONG WAS FOUND IN EXHAUST PORT OF NR 2 CYLINDER IN THE INBOARD WALL. THE CYLINDERS ARE CONTINENTAL CYLINDERS THAT WERE OVERHAULED 500 HOURS AGO. 1 L 7 1 3O 3 O A9CE E5CE 1997103000380 19971030 00380 EU 1997 10 30 97ZZZX4586 1 19971013 G 5320 117223251 BRACKET ASSY BOLKMS 117 BK117B2 5626013 EU BS 4963 CRACKED B S A BAQR K NONE O OTHER IN INSP/MAINT 1 EA 03 955ME 7243 INSTALLED ELECTRONIC OVERSPEED BRACKET FOR NR 2 ENGINE SLIGHTLY FORWARD OF STA 4963 AT AIRCRAFT TT 2.2 HOURS. AT AIRCRA FT TT 1,848.3 HOURS DURING A 600-HOUR INSPECTION, CRACKS FOUND ON STRINGERS AT BL 215R AND BL 34R AS WELL AS BRACKET ASS Y, P/N 117-223251. 1 G 7 2 3U NC H13EU 1997103000381 19971030 00381 EU 1997 10 30 97ZZZX4587 1 19971013 G 5313 STRINGER BOLKMS 117 BK117B2 5626013 EU BL 34R CRACKED B BAQR K NONE O OTHER IN INSP/MAINT 1 EA 03 955ME 7243 INSTALLED ELECTRIC OVERSPEED BRACKET FOR NR 2 ENGINE SLIGHTLY FORWARD OF STA 4963 AT AIRCRAFT TT 2.2 HOURS. AT AIRCRAFT TT 1,848.3 HOURS DURING A 600-HOUR INSPECTION, CRACKS FOUND ON STRINGERS AT BL 215R AND BL 34R AS WELL AS BRACKET ASSY, P/N 117-223251. 1 G 7 2 3U NC H13EU 1997103000382 19971030 00382 EU 1997 10 30 97ZZZX4588 1 19971013 G 5313 STRINGER BOLKMS 117 BK117B2 5626013 EU BL 215R CRACKED B BAQR K NONE O OTHER IN INSP/MAINT 1 EA 03 955ME 7243 INSTALLED ELECTRIC OVERSPEED BRACKET FOR NR 2 ENGINE SLIGHTLY FORWARD OF STA 4963 AT AIRCRAFT TT 2.2 HOURS. AT AIRCRAFT TT 1,848.3 HOURS DURING A 600-HOUR INSPECTION, CRACKS FOUND ON STRINGERS AT BL 215R AND BL 34R AS WELL AS BRACKET ASSY, P/N 117-223251. 1 G 7 2 3U NC H13EU 1997103000386 19971030 00386 SO 1997 10 30 97ZZZX4589 1 19971020 G 7810 40J21019 HEAT SHIELD PIPER PA46 PA46350P SO LT EXHAUST PIPE CHAFES PIPE D K NONE O OTHER IN INSP/MAINT 1 SW 99 396PM 304 4636024 HEAT SHIELD COMES LOOSE AND CHAFES ON THE CROSSOVER SECTION OF THE EXHAUST SYSTEM CAUSING A HOLE IN THE LEFT PIPE. 1 L 7 1 3O RT A25SO 1997103000387 19971030 00387 NM 1997 10 30 97ZZZX4590 1 19970618 G 5311 FRAME BOEING 747 747245F 1384897 NM LT/RT NLG WELL CRACKED B CISY K NONE O OTHER IN INSP/MAINT 1 EA 31 636FE 21764 INSPECTION OF THE NOSE WHEELWELL STRUCTURE PER AD 96-26-04 REVEALED CRACKING IN THE STA 300 AND STA 320 FRAME (LT AND RT ). REPAIR ACCOMPLISHED IAW E.O. NR 4753AD36 AND 4753A039 SUPPLIED BY ATLASAIR. 2 L 7 4 4F A20WE 1997103000388 19971030 00388 EU 1997 10 30 97ZZZX4591 1 19971006 G 5210 DOOR AEROSP SA365 SA365N1 8680668 EU LT FWD PAX DOOR DEPARTED B KO1R A UNSCHED LANDING D INFLIGHT SEPARATION CL CLIMB 1 EA 25 111EP 2734 6309 THE AIRCRAFT RETURNED WITHIN A FEW MINUTES OF ITS DEPARTURE, THE LEFT FORWARD PASSENGER DOOR HAD DEPARTED THE AIRCRAFT, IN-FLIGHT. INSPECTION REVEALED NO DEFECTS IN THE JETTISON SYSTEM. THE JETTISON LEVER WAS IN THE JETTISON POSITION WITH THE SAFETY WIRE BROKEN UPON THE AIRCRAFT RETURN. INSPECTION REVEALED A BROKEN UPPER LATCH AND BROKEN CENTER STRIKER FI TTING SUPPORT WHICH APPEARS TO BE THE RESULTING DAMAGE FROM THE DOOR DEPARTING THE AIRCRAFT. THE AIRCRAFT SUSTAINED NO FURTHER DAMAGE. THE DOOR WAS RECOVERED. 1 G 7 2 3U H10EU 1997103000393 19971030 00393 EU 1997 10 30 97ZZZX4596 1 19971001 G 5320 117223251 BRACKET ASSY BOLKMS 117 BK117B1 5626012 EU BS 4963 CRACKED B S A BAQR K NONE O OTHER IN INSP/MAINT 1 EA 03 5405G 7179 INSTALLED ELECTRONIC OVERSPEED BRACKET FOR NR 2 ENGINE SLIGHTLY FORWARD OF STA 4963 AT AIRCRAFT TT, 4,853.7 HOURS AT AIR CRAFT TT, 5,399.3 HOURS DURING A 600-HOUR INSPECTION. CRACKS WERE FOUND ON STRINGERS AT BL 215R AND BL 34R AS WELL AS B RACKET ASSY. 1 G 7 2 3U H13EU 1997103000394 19971030 00394 EU 1997 10 30 97ZZZX4597 1 19971001 G 5313 STRINGER BOLKMS 117 BK117B1 5626012 EU BL 34R CRACKED B BAQR K NONE O OTHER IN INSP/MAINT 1 EA 03 5405G 7179 INSTALLED ELECTRONIC OVERSPEED BRACKET FOR NR 2 ENGINE SLIGHTLY FORWARD OF STA 4963 AT AIRCRAFT TT, 4,853.7 HOURS AT AIR CRAFT TT, 5,399.3 HOURS DURING A 600-HOUR INSPECTION. CRACKS WERE FOUND ON STRINGERS AT BL 215R AND BL 34R AS WELL AS B RACKET ASSY. 1 G 7 2 3U H13EU 1997103000395 19971030 00395 EU 1997 10 30 97ZZZX4598 1 19971001 G 5313 STRINGER BOLKMS 117 BK117B1 5626012 EU BL 215R CRACKED B S A BAQR K NONE O OTHER IN INSP/MAINT 1 EA 03 5405G 7179 INSTALLED ELECTRONIC OVERSPEED BRACKET FOR NR 2 ENGINE SLIGHTLY FORWARD OF STA 4963 AT AIRCRAFT TT, 4,853.7 HOURS AT AIR CRAFT TT, 5,399.3 HOURS DURING A 600-HOUR INSPECTION. CRACKS WERE FOUND ON STRINGERS AT BL 215R AND BL 34R AS WELL AS B RACKET ASSY. 1 G 7 2 3U H13EU 1997103000490 19971030 00490 CE 1997 10 30 97ZZZX4599 1 19971015 G 3222 55423087 BEARING 55420009 CESSNA 500 550 2076604 CE NLG STRUT NUT LOOSE B A KJ4R O OTHER J WARNING INDICATION CL CLIMB 1 SO 15 47SW 5500444 NLG WOULD CYCLE IN THE NOSE WHEELWELL. HYDRAULIC PRESSURE 'ON' LIGHT WOULD ILLUMINATE EVERY TIME THE GEAR CYCLED. FOUN D THE NOSE STRUT BEARING HAD LOOSENED AND BACKED OFF. THIS ALLOWED THE STRUT TO EXTEND BEYOND LIMITS. WITH THE STRUT E XTENDED BEYOND LIMITS, THE GEAR UPLOCK HOOK WOULD NOT ENGAGE IN UPLOCK AND THE GEAR WOULD START TO DROP OUT OF THE WHEEL WELL. THIS WOULD TURN ON THE HYD DRIVE AND THE GEAR BACK UP INTO THE WHEELWELL. 1 L 7 2 4F A22CE 1997013000165 19970130 00165 CE 1997 1 30 97ZZZX460 1 19970108 G 2612 FIRE WARN BEECH 200 200BEECH 1152920 CE RT ENG MALFUNCTION B BUER A UNSCHED LANDING N FALSE WARNING CR CRUISE 1 GL 23 120RJ BB423 PILOT REPORTED RIGHT ENGINE FIRE LIGHT ANNUNCIATOR CAME ON IN-FLIGHT. AIRCRAFT LANDED IN NASHVILLE, TN. A MECHANIC INS PECTED RIGHT ENGINE AND FOUND NO EVIDENCE OF FIRE OR HEAT DAMAGE. ALSO FUNCTIONALLY TESTED FIRE DETECTION SENSORS AND F OUND OPERATION NORMAL. (NOTE: FIRE LIGHT WAS NOT ON WHEN MECHANIC ARRIVED AT AIRCRAFT). UPON RETURN TO HOME BASE (PTK ), PILOT REPORTED NO FURTHER PROBLEMS. APPARENTLY A FALSE INDICATION. VIB33668K/A.D.I. W.O. 1 L 7 2 4T A24CE 1997103000492 19971030 00492 SW 1997 10 30 97ZZZX4601 1 19971015 G 2710 INDICATOR SWRNGN SA227 SA227AT 8780610 SW AILERON TRIM GEAR STRIPPED B W6NR K NONE O OTHER IN INSP/MAINT 1 GL 25 665A 3186 AT427 UPON CHECKING AILERON TRIM FOR PROPER RIGGING, THE INDICATOR WAS NOT MOVING AS AILERON TRIM WHEEL WAS TURNED. FURTHER I NVESTIGATION FOUND THE GEAR ASSY FOR THE INDICATOR HAD MOST OF THE TEETH STRIPPED OFF. THE AILERON TRIM TABS WERE MOVIN G OK. THE GEAR WAS REPLACED AND TRIM SYSTEM WORKED NORMALLY. 2 L 7 2 4T RT A5SW 1997103000493 19971030 00493 EU 1997 10 30 97ZZZX4602 1 19971016 G 3610 AC08991 FILTER PLATE DUNLOP ACM28786 FOKKER F27 F27MK400 4990626 EU PNEU SYS DEFORMED D A K NONE O OTHER IN INSP/MAINT 1 SO 05 2MIL 7185 10668 DUNLOP MANUAL DM 1184, REV 90, PART 3, CHAP 5, PAGE 5, DURING C-CHECK INSPECTION FOUND UPON DISASSEMBLY OF THE FILTER AS SY, ACM 28786, THE ELEMENT WAS PROTRUDING THROUGH THE UPPER PERFORATED PLATE (OR SCREEN), AC08991. THE PLATE WAS ALSO D EFORMED IN A CONE SHAPE MATCHING THE CONCAVE SHAPE OF THE COVER ACO 43370. THE PLATE HAS A SERIES OF DRILLED HOLES WHIC H INSCRIBE A SQUARE PATTERN APPROXIMATELY .25 INCH IN SIZE AT THE VERY CENTER. THREE OF THE FOUR LEGS FORMED BY THIS HO LE PATTERN WERE BROKEN. THE CENTER PORTION OF THE PLATE WAS BENT UPWARDS INTO THE FILTER ASSEMBLY'S OUTLET PORT. 2 H 7 2 4T A817 1997103000494 19971030 00494 EU 1997 10 30 97ZZZX4603 1 19971007 G 3250 893954 STEERING UNIT 893442 FOKKER F27 F27MK400 4990626 EU NLG BINDING D L K NONE O OTHER IN INSP/MAINT 1 SO 05 2MIL 447 10652 INSPECTION FOR MALFUNCTION OF SLUGGISH NLG STEERING FOUND AIR MOTOR BINDING DUE TO SPLINE SHAFT CONTACTING 2ND STAGE RED UCTION GEAR INPUT GEAR. ADDED SHIMS TO PREVENT CONTACT AND STOP BINDING. 2 H 7 2 4T A817 1997103000495 19971030 00495 EU 1997 10 30 97ZZZX4604 1 19971010 G 5751 3701014031 WEIGHT FOKKER F27 F27MK400 4990626 EU LT AILERON WRONG PART D L A K NONE O OTHER IN INSP/MAINT 1 SO 05 2MIL 6753 10652 FOKKER F27 SM, CHAPTER 51-50-00, 'CONTROL SURFACE BALANCING'. LT AILERON REMOVED FOR BALANCE CHECK AFTER REPLACEMENT OF THE LT BALANCE TAB. BALANCE TAB REPLACED DUE TO COLLISION WITH CESSNA 340 WHILE PARKED AT ALLEGHENY COUNTY AIRPORT, PI TTSBURGH, PA. THE BALANCE CHECK REVEALED ADDITIONAL WEIGHT REQUIRED TO BE PLACED BENEATH THE FRONT NOSE COVER. UPON RE MOVAL OF THE FRONT NOSE COVER, FOUND 4 UNAPPROVED BALANCE WEIGHTS MADE FROM LEAD SHEETING SANDWICHED BETWEEN THE ADJUSTM ENT WEIGHTS. THESE UNAPPROVED WEIGHTS WERE NOT PLACED IN THE SEQUENCE ILLUSTRATED IN FIGURE TWO, 'SEQUENCE OF WEIGHT DI STRIBUTION'. THE LEAD WEIGHTS WERE REMOVED AND REPLACED WITH GENUINE FOKKER BALANCE WEIGHTS. 2 H 7 2 4T A817 1997013000166 19970130 00166 CE 1997 1 30 97ZZZX461 1 19970102 G 2133 EVA66 EVA TUBING BEECH 100 B100 1152919 CE AFT CABIN VENT MELTED B A JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 531CB 2802 BE133 INVESTIGATION FOR MELTED AND COLLAPSED EVA OUTFLOW VALVE TUBING FOUND CABIN AFT VENT WAS BLOCKED WITH BAGGAGE AND AIR VE NT WAS DETACHED. APPARENTLY CABIN AIR (HEAT) WAS SUFFICIENT ENOUGH TO MELT/COLLAPSE TUBING. THE ONLY DAMAGED TUBING WA S AT THE AREA OF THE AFT VENT. 1 L 7 2 4T A14CE 1997110600157 19971106 00157 SO 1997 11 6 97ZZZX4617 1 19970730 G 3230 BOLT PIPER PA34 PA34200 7103405 SO NLG DRAG LINK FAILED H L A O OTHER J WARNING INDICATION AP APPROACH 1 EU 01 2FOR 1350 347570244 INVESTIGATION FOR NLG COLLAPSE ON LANDING FOUND BOLT CONNECTING DRAG LINK TO GEAR STRUT BROKEN. BOLT HAD A FATIGUE CRAC K WHICH WORKED THROUGH BOLT DUE TO CYCLIC LOADING UNTIL BOLT FAILED DURING GEAR EXTENSION. 1 L 7 2 3O A7SO 1997110600158 19971106 00158 SO 1997 11 6 97ZZZX4618 1 19971018 G 2820 AN8406D HOSE FITTING PIPER PA20 PA20 7102002 SO RT FUEL TANK PLUGGED G S A A UNSCHED LANDING Y ENGINE STOPPAGE CL CLIMB 1 NM 09 150KS 20678 THIS AIRCRAFT WAS INVOLVED IN AN ACCIDENT. ON CLIMB-OUT, AIRCRAFT LOST POWER. LANDED ON LAST 100 FEET OF RUNWAY. AIRC RAFT NOSE-OVER, AND CAME TO A STOP INVERTED. AFTER REPAIR, NEW OWNER WAS INSPECTING FUEL SYSTEM AND FOUND RT FUEL TANK AFT OUTLET FITTING COMPLETELY PLUGGED WITH WHAT APPEARS TO BE DIRT. 1 H 7 1 3O 1A4 1997110600159 19971106 00159 CE 1997 11 6 97ZZZX4619 1 19971009 G 7120 121343316 MOUNT CESSNA 206 U206F 2073333 CE RT AFT SUPPORT CRACKED D S K NONE O OTHER IN INSP/MAINT 1 NE 05 1523U 6804 U20602234 WHILE INSPECTING BEFORE RE-INSTALLING ENGINE, FOUND RT REAR ENGINE MOUNT SUPPORT HAD A 1 INCH CRACK. A REPLACEMENT PART WAS INSTALLED. AGE WAS PROBABLY THE CAUSE. 1 H 7 1 3O A4CE 1997110600160 19971106 00160 CE 1997 11 6 97ZZZX4620 1 19971009 G 5753 12201041 RIB 122010024 CESSNA 206 U206F 2073333 CE RT FLAP CRACKED D S K NONE O OTHER IN INSP/MAINT 1 NE 05 1533U 6804 U20602234 DURING A 100-HOUR INSPECTION, NOTED BLACK STAINS AROUND THE BRACKET WHICH ATTACHES THE OUTBOARD PUSH ROD TO THE RIGHT FL AP. FURTHER INVESTIGATION REVEALED A CRACK IN THE NOSE RIB AT STA 112.50. A NEW PART WAS INSTALLED. SUBMITTER SUGGEST S AGE AND MUCH USE WERE REASONS FOR FAILURE. 1 H 7 1 3O A4CE 1997110600161 19971106 00161 SO 1997 11 6 97ZZZX4621 1 19971010 G 2913 1213HGB310 PUMP PIPER PA31T PA31T 7103124 SO LT ENG HYD LEAKED D O OTHER J WARNING INDICATION AP APPROACH 1 NE 05 29CA 3636 OA81422 31T780076 PILOT REPORTED THE LANDING GEAR HAD A PROBLEM DURING EXTENSION COMPLETING ITS CYCLE. AFTER SEVERAL TRIES, THE CYCLE COM PLETED AND A SAFE LANDING MADE. WHILE TROUBLESHOOTING, NOTED HYDRAULIC FLUID LEAKING FROM THE DRAIN IN THE BASE OF THE HYD PUMP ON LT ENG AND SPREAD OVER THE UNDERSIDE OF THE WING. AN OVERHAULED PUMP WAS INSTALLED. A NEW FILTER ON THE LT WAS INSTALLED AND THE RESERVOIR WAS FILLED. THE GEAR WAS CYCLED 3 TIMES ON JACKS WITH NO FAULTS. SUBSEQUENT TEST FLIG HT NOTED NO FAULTS THROUGH SEVERAL CYCLES. 1 L 7 2 3T A8EA 1997110600162 19971106 00162 CE 1997 11 6 97ZZZX4622 1 19970901 G 2720 PULLEY BEECH 33 F33A 1151425 CE RUDDER CABLE MISSING D S A K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 99 6054D CE856 DURING A GEAR UP LANDING REPAIR, NOTICED A RUDDER CABLE PULLEY MISSING AND HAD NEVER BEEN INSTALLED AT BEECH. CABLE DEF ECTION DUE TO THE MISSING PULLEY WORE THE PAINT OFF STRUCTURE. A NEW PULLEY INSTALLED, RUDDER RE-RIGGED. 1 L 7 1 3O 3A15 1997110600163 19971106 00163 CE 1997 11 6 97ZZZX4623 1 19970903 G 3230 MS28775112 O-RING CESSNA 210 T210N 2073456 CE NLG ACTUATOR FAILED D S O OTHER K FLUID LOSS AP APPROACH 1 WP 07 6355C 2000 21063874 NLG ACTUATOR FWD O-RING BECAME HARD, BRITTLE, WAS CUT IN 2 SPOTS .25 INCH APART, THEN ROLLED. WHEN GEAR EXTENDED FOR LA NDING, HYD PUMP FORCED ALL THE HYD FLUID OVERBOARD THROUGH THE CUT O-RING. ELECTRIC HYD PUMP CONTINUED TO RUN UNTIL THE MAIN GEAR CIRCUIT BREAKER OPENED. AUX HYDRAULIC HAND PUMP WAS USED TO GET THIS GEAR DOWN, ALL THE HYD FLUID WAS PUMPED OVERBOARD. THE NLG WENT TO THE DOWN AND LOCKED POSITION, BUT THE MLG WENT TO THE TRAIL POSITION. NLG HELD ENG AND PRO P UP, BUT WEIGHT OF ACFT CAUSED MLG TO COLLAPSE. SUBSTANTIAL DAMAGE TO BELLY AND TAIL. NO INJURIES. 1 H 7 1 3O 3A21 1997110600164 19971106 00164 CE 1997 11 6 97ZZZX4624 1 19971022 G 3244 650C861 TIRE CESSNA 421 421C 2076016 CE TREAD AREA FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 99 68670 390 22531060 421C1084 THIS TUBE-TYPE MAIN LANDING GEAR TIRE WAS INSTALLED AND OPERATED FOR 390 FLIGHT HOURS. ESTIMATE 290 LANDINGS. THE TIRE WAS FOUND TO HAVE BULGES ON THE EDGE OF THE TREAD AREA. THESE BULGES FEEL LIKE AIR POCKETS BETWEEN THE TREAD AND THE C ORD. THE TIRE WAS DEFLATED AND REMOVED FOR INSPECTION AND VERIFIED TO HAVE SEPARATION OF THE TREAD APPROXIMATELY 1 INCH WIDE BY 10 INCHES LONG. THE TIRE WAS REPLACED WITH A NEW UNIT. 1 L 7 2 3O A7CE 1997110600165 19971106 00165 SO 1997 11 6 97ZZZX4625 2 19971002 G 8520 CRANKCASE CESSNA 172 R172K 2072431 CE CONT O360 IO360K 17025 SO NR 2 CYL BASE FRACTURED D K NONE O OTHER IN INSP/MAINT 1 SW 99 7342K 3392 1911 R1722060 355058 LT CRANKCASE BROKE OFF AT THE TOP SIDE AT THE PERIMETER OF NR 2 CYLINDER BASE. SUSPECT CAUSE, FAILURE OF FWD THROUGH-BO LT NUT OR THREADS OR POSSIBLE INTERNAL FLAW IN CRANKCASE HALF. 1 H 7 1 3O 3 O 3A17 E1CE 1997110600166 19971106 00166 CE 1997 11 6 97ZZZX4626 1 19971009 G 7810 EXHAUST ELBOW CESSNA 414 414A 2075907 CE EXHAUST WYE CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 03 78NG 414A0617 DURING MAINTENANCE CHECK, EXHAUST STAIN NOTED ALONG A WELD ON THE ELBOW FROM THE EXH WYE TO THE EXH WASTEGATE. CLOSER E XAMINATION SHOWED THE ELBOW CRACKED ALONG EDGE OF THE WELD ON BOTH SIDES. ON THIS PARTICULAR PART, WHICH IS IDENTIFIED AS A PMA REPLACEMENT PART, THE ELBOW IS MADE IN TWO PIECES FITTED TOGETHER AT AN APPROXIMATE 45 DEGREE INTERSECTION TO M AKE THE NECESSARY 90 DEGREE INSTALLATION REQUIREMENT. ORIGINAL EQUIPMENT ELBOWS AS NOTED ON OTHER ACFT (CESSNA 340A/414 AND OTHER 414A'S) DO NOT HAVE SUCH A SPLICE WELD AS THIS ONE DOES AND CRACKS IN THIS PARTICULAR AREA HAVE NOT BEEN OBSE RVED IN THOSE PARTS. 1 L 7 2 3O A7CE 1997110600167 19971106 00167 EA 1997 11 6 97ZZZX4627 2 19971018 G 7414 M3048 SHAFT SLICK 4370 CONAER LA4 LA4 5110302 NE LYC O360 O360A1A 41514 EA MAG ROTOR WORN D S O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SW 99 1011L 184 94110078 254 PILOT REPORTED ENGINE RUNNING ROUGH. PERFORMED TROUBLESHOOTING, FOUND RT MAGNETO ROTOR SHAFT AND ROTOR GEAR WORN BEYOND LIMITS. GEAR WAS FOUND LOOSE ON SHAFT. THIS IS THE SECOND SUCH 4300 SERIES TYPE MAGNETO WITH APPROXIMATELY 500 HOURS TT WITH THE SAME PROBLEM. 1 H 7 1 3O 3 O 1A13 E286 1997110600168 19971106 00168 EA 1997 11 6 97ZZZX4628 2 19971018 G 7414 M3827 GEAR SLICK 4370 CONAER LA4 LA4 5110302 NE LYC O360 O360A1A 41514 EA MAG ROTOR WORN D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SW 99 1011L 184 9410078 254 PILOT REPORTED ENGINE RUNNING ROUGH. PERFORMED TROUBLESHOOTING, FOUND RT MAGNETO ROTOR SHAFT AND ROTOR GEAR WORN BEYOND LIMITS. GEAR WAS FOUND LOOSE ON SHAFT. THIS IS THE SECOND SUCH 4300 SERIES TYPE MAGNETO WITH APPROXIMATELY 500 HOURS TT WITH THE SAME PROBLEM. 1 H 7 1 3O 3 O 1A13 E286 1997110600169 19971106 00169 CE 1997 11 6 97ZZZX4629 1 19970920 G 3222 16981001215513 COMPRESSION ASSY BEECH 23 C23 1151242 CE NLG STRUT FAILED D O OTHER O OTHER LD LANDING 1 GL 17 180ED 3575 M1622 COMPRESSION ASSEMBLY CRACKED ALLOWING PIN TO COME OUT. ON LANDING, NOSE FORKS SEPARATED FROM COMPRESSION ASSY. THIS AL LOWED NOSE FORKS TO COLLAPSE ALLOWING PROPELLER TO STRIKE THE RUNWAY CAUSING SUDDEN STOPPAGE OF THE ENGINE. 1 L 7 1 3O A1CE 1997110600170 19971106 00170 SO 1997 11 6 97ZZZX4630 1 19971004 G 3030 CONNECTOR PIPER PA42 PA42 7104202 SO PITOT HEAT SW BURNED D K NONE O OTHER IN INSP/MAINT 1 NE 03 28DA 3574 428001078 CONNECTOR E324 WAS FOUND SEVERELY OVERHEATED IN SWITCH PANEL OVERHEAD. CONTROLS PITOT STALL/HEAT. SUSPECT UNDERRATED C ONNECTOR FOR AMPERAGE. 1 L 7 2 4T A23SO 1997110600171 19971106 00171 SO 1997 11 6 97ZZZX4631 1 19971002 G 5730 6206102 SKIN PIPER PA28 PA28R200 7102811 SO RT INBD WING CRACKED B FTUR K NONE O OTHER IN INSP/MAINT 1 NE 05 4516X 3485 28R7635068 DURING 100-HOUR INSPECTION, THE FORWARD WING WALK AREA WAS FOUND CRACKED. THE AREA IS DIFFICULT TO INSPECT AND MUST BE VIEWED THROUGH THE LANDING GEAR WELL. THE SKIN IS DOUBLED WITH A CORRUGATED PIECE AND THE CRACKS WERE LOCATED AT EACH R ADIUS OF THE CORRUGATIONS. SKIN ASSEMBLY REPLACED. 1 L 7 1 3O 2A13 1997110600172 19971106 00172 SO 1997 11 6 97ZZZX4632 1 19971002 G 5743 NAS680A4 NUTPLATE PIPER PA28 PA28R200 7102811 SO MLG FWD TRUNNION CRACKED B A FTUR K NONE O OTHER IN INSP/MAINT 1 NE 05 4516X 3485 28R7635038 RIGHT FUEL TANK REMOVED TO FACILITATE OTHER MAINTENANCE. INBOARD LOWER NUTPLATE ON THE FORWARD GEAR TRUNNION WAS FOUND CRACKED. PART TT 3,484.7 HOURS. GEAR WAS REMOVED, NUTPLATE REPLACED. 1 L 7 1 3O 2A13 1997110600173 19971106 00173 SO 1997 11 6 97ZZZX4633 2 19970901 G 8520 20428 BEARING BOEING 75 E75 1380120 CE CONT R670 W6706N 17016 SO REAR MAIN FAILED D A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 WP 25 5010V 755351 26870 THIS ENGINE HAD 385 HOURS SINCE OVERHAUL. THE PILOT NOTED A DROP IN OIL PRESSURE HEADED FOR THE NEAREST AIRPORT 8 MILES AWAY. BEFORE REACHING THE AIRPORT, ELECTED TO MAKE AN EMERGENCY LANDING ON A ROAD. AFTER CHECKING THE SUMP SCREEN, A LARGE QUANTITY OF METAL WAS FOUND. TEAR DOWN REVEALED THE REAR MAIN BEARING HAD FAILED. 1 Q 7 1 3R 3 R A743 E162 1997110600175 19971106 00175 GL 1997 11 6 97ZZZX4635 3 19971016 G 6114 D4521 SPACER CESSNA 172 172 2072402 CE MCAULY 1C160 1C160DTM GL PROPELLER CRACKED G K NONE O OTHER IN INSP/MAINT 1 WP 07 53945 3096 17274832 83454 SPACER ON PROPELLER FOUND CRACKED THROUGH N.D.T. INSPECTION. FOUND AT 100-HOUR INSPECTION, A PROPELLER RE-PROFILING. 1 H 7 1 3O NT 3A12 5 N P910 1997110600176 19971106 00176 SO 1997 11 6 97ZZZX4636 2 19971020 G 8530 635448CN CYLINDER CESSNA 402 402B 207590P CE CONT O520 TSIO520E 17040 SO NR 6 CRACKED B FSER E ENGINE SHUTDOWN E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 NE 05 567JS 427 402B1090 510032E DURING FLIGHT FROM EWR TO PWM, THE PILOT EXPERIENCED THE LEFT ENGINE FAILURE. ENGINE WAS SHUT DOWN. FOUND NR 6 CYLINDE R CRACKED AT CYLINDER BASE CAUSING COMPLETE FAILURE. ENGINE COMPLETELY DISASSEMBLED AND INSPECTED. 1 L 7 2 3O 3 O A7CE E8CE 1997110600177 19971106 00177 SO 1997 11 6 97ZZZX4637 2 19971007 G 7414 101630601 MAGNETO BENDIX S6RN205 CESSNA 310 310K 2074228 CE CONT O470 IO470V 17026 SO ENGINE DEFECTIVE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 21 6961L A33006 310K0061 DURING ANNUAL INSPECTION, NO RECORDS EXIST OF ANY MAGNETO MAINTENANCE. ALL 4 MAGS REMOVED FOR TCM 500-HOUR CHECK. THIS MAG HAD POINTS IN CONFIGURATION OF COUNTERCLOCKWISE ROTATION, SHOULD HAVE BEEN FOR CW BY P/N AND IPB. TWO MAGS HAD LOOS E BEARINGS, ALL 4 HAD WORN DISTRIBUTOR BLOCKS. THREE SETS HAD BURNED POINTS, BAD CONDENSER, 2 COILS WITH CRACKS. BOTH ENGINES WERE 'MAJOR OVERHAULED' 162.1 HRS AND 369.4 HRS, ENGINE ONLY. NEITHER HAD ACCESSORIES, FUEL SYSTEM, ETC., OVER HAULED WITH THE 'MAJORS'. 1 L 7 2 3O 3 O 3A10 3E1 1997110600178 19971106 00178 CE 1997 11 6 97ZZZX4638 1 19971016 G 8120 4066109029 TURBOCHARGER BEECH 36 B36TC 1151609 CE CONT O520 TSIO520UB 17040 SO ENGINE SEAL LEAK D K NONE K FLUID LOSS IN INSP/MAINT 1 NM 11 7250Z NE0111 EA449 527070 FOUND OIL LEAKING FROM TURBOCHARGER ON COMPRESSOR SIDE AND EXHAUST SIDE OF TURBOCHARGER. SENT IN FOR OVERHAUL AND FOUND EXHAUST TURBINE WHEEL OUT OF BALANCE WHICH WORE OUT THE OIL SEALS ON THE HOT AND COLD SIDE OF TURBO. ESTIMATED TIME ON PART, 1,000 HOURS. 1 L 7 1 3O 3 O 3A15 E8CE 1997110600179 19971106 00179 CE 1997 11 6 97ZZZX4639 1 19971017 G 2436 VR600 REGULATOR CESSNA 150 150M 2071830 CE DC SYSTEM FAILED D O OTHER H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 NE 03 8193U 15077908 AIRCRAFT ELECTRICAL SYSTEM EXPERIENCED ON ABRUPT MALFUNCTION, NO CHARGING CONDITION. FOUND VOLTAGE REGULATOR FAILED. 1 H 7 1 3O 3A19 1997013000169 19970130 00169 CE 1997 1 30 97ZZZX464 1 19970106 G 8120 22501191 CONTROL ARM CESSNA 182 182R 2072731 CE WASTEGATE MISDRILLED B S WS9R K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 07 WASTEGATE CONTROL ARM (NEW PART) WAS MIS-DRILLED. SUBMITTER HAD TO ORDER 4 UNITS BEFORE RECEIVING A USEABLE PART. 1 L 7 1 3O NT 3A13 1997110600180 19971106 00180 CE 1997 11 6 97ZZZX4640 1 19971008 G 3230 504501019 TORQUE TUBE CESSNA 414 414 2075908 CE LT MLG CRACKED B DYPR K NONE O OTHER IN INSP/MAINT 1 NM 09 854RM 2844 4140959 CRACK FOUND AT THE FORK BOLT ATTACHMENT. FOUND DURING ANNUAL INSPECTION. CRACK LENGTH WAS .50 INCH. 1 L 7 2 3O RT A7CE 1997110600181 19971106 00181 SO 1997 11 6 97ZZZX4641 2 19971009 G 8530 PISTON PIN CESSNA 172 172F 2072414 CE CONT O300 O300D 17022 SO NR 6 CYLINDER FAILED H P K NONE O OTHER IN INSP/MAINT 1 SW 99 8682U 804 17252585 28901D OIL SCREEN FULL OF METAL AND COLLAPSED. FOUND PIN PLUG NR 6 CYLINDER FAILED. PIN PLUG IN NR 2 CYLINDER EXPANDED AND LO OSENED. SUBMITTER STATED ALUMINUM PLUGS ARE SWAGED. MAYBE A RELIEF HOLE TO RELIEVE INTERNAL PRESSURE MIGHT BE CONSIDER ED TO PREVENT EXCESSIVE WEAR. 1 H 7 1 3O 3 O NT 3A12 E253 1997110600182 19971106 00182 1997 11 6 97ZZZX4642 1 19971021 G 2434 02373 ALTERNATOR FORD DC SYSTEM FAILED D A UNSCHED LANDING O OTHER CR CRUISE 1 WP 17 5093285 SCREWS THAT RETAIN BEARING IN PULLEY END OF HOUSING BACKED OUT. THIS ALLOWED ENTIRE SHAFT PULLEY AND FAN TO SHIFT BACK IN HOUSING UNTIL FAN BLADES CONTACTED HOUSING. ONE BLADE SEPARATED FROM HOUSING AND MADE A HOLE IN COWLING. AIRCRAFT L ANDED SAFELY. SMOH: 40 HOURS. 1997110600183 19971106 00183 1997 11 6 97ZZZX4643 2 19971013 G 7414 103910881 COIL BENDIX 103493704 ENGINE MAG BURNT B EVGR K NONE O OTHER IN INSP/MAINT 1 SO 33 P2SIG 15 K189610FR MAGNETO STOPPED OPERATION 14.5 HOURS AFTER COIL WAS REPLACED. INSPECTION REVEALED BURNT COIL. UNKNOWN CAUSE, NO RECOMM ENDATIONS. 1997110600184 19971106 00184 1997 11 6 97ZZZX4644 2 19970909 G 7421 REM40E SPARK PLUG CHAMPION ENG IGNITION DEFECTIVE B L A CDMR K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 17 SUBMITTER REPORTS NEW CHAMPION SPARK PLUGS ARE BEING RECEIVED THAT ARE DEFECTIVE. DIFFERENT P/N'S FROM SEVERAL SHIPMENT S ARE FOUND TO BE WEAK, DISCOLORED OR WEAK WHEN TESTED. PLUGS WERE TESTED FROM ZERO TO 125 PSI WITH PROPER GAP. ESTIMA TED DEFECTIVE QUANTITY AT 20-50 PERCENT. REM 38E DATE CODE 3D97. REM 40E DATE CODE 1H97 AND 3K96. 1997110600185 19971106 00185 CE 1997 11 6 97ZZZX4645 1 19971015 G 2121 66001122 BLOWER MOTOR LEAR 25 25B 5170511 CE CABIN SEIZED B A TJ4R A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 GL 11 111MP 656 139 ELECTRICAL SMOKE AND FUMES NOTED AFTER TAKEOFF. AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE NOTED THE CABIN BLOWER M OTOR HAD SEIZED AND OVERHEATED. NO OTHER DAMAGE NOTED. REPLACED BLOWER MOTOR ASSY. SYSTEMS CHECK GOOD. 2 L 7 2 4J A10CE 1997110600186 19971106 00186 NM 1997 11 6 97ZZZX4646 1 19970916 G 5511 SPAR BOEING 727 72723 1384004 NM LT H STAB AFT CRACKED B A LVTR K NONE O OTHER IN INSP/MAINT 1 WP 01 1972 18428 DURING ROUTINE INSPECTION OF AIRCRAFT, TWO CRACKS WERE FOUND ON THE LT HORIZONTAL STABILIZER'S AFT SPAR LOWER CHORD. EA CH CRACK WAS APPROXIMATELY 1.5 INCH LONG. ONE CRACK WAS AT STABILIZER STA 169 AND THE OTHER WAS AT STABILIZER STA 179. 2 L 7 3 4F A3WE 1997110600187 19971106 00187 CE 1997 11 6 97ZZZX4647 1 19971017 G 5533 55120966 SKIN CESSNA 500 500CESSNA 2076602 CE VENTRAL FIN CORRODED B MUCR K NONE O OTHER IN INSP/MAINT 1 GL 13 12AM 6303 5000235 PRE-UNIT, S/N 0274, AIRCRAFT UTILIZE - .020 INCH SKIN FILLED WITH FOAM FOR RIGIDITY IN THE CONSTRUCTION OF THE VENTRAL F IN. THE FOAM ALLOWS MOISTURE TO COLLECT AND CORROSION TO DEVELOP ON THE INSIDE SURFACES OF THE SKINS. POST-UNIT, S/N 0 274, DELETES THE FOAM. 1 L 7 2 4F A22CE 1997110600188 19971106 00188 CE 1997 11 6 97ZZZX4648 1 19971023 G 3250 STEERING MECH LEAR 60 60LEAR 5170707 CE NLG DEFECTIVE D A O OTHER E VIBRATION/BUFFET LD LANDING 1 SW 05 216FX 235 104 103 PILOT REPORTED NOSE GEAR VIBRATION ON LANDING THAT KICKED NOSE WHEEL STEERING OFF. REMOVED NOSE GEAR ASSEMBLY AND FOUND STEERING MECHANISM ASSEMBLY LOOSE ON MOUNT BOLTS. OPENED STEERING BOX AND FOUND ALL 3 MOUNT BOLTS BACKED OFF ONE-QUART ER TURN. FOUND NO DAMAGE TO BOX OR NOSE GEAR. INSTALLED 3 NEW BOLTS, P/N NAS144-13, PER LEAR 60 MM CHAPTER 32-50-02. R EINSTALLED NOSE GEAR ASSEMBLY. PERFORMED GEAR SWING AND TAXI TESTS. ALL OPS CHECKS NORMAL. 2 L 7 2 4F RT A10CE 1997110600189 19971106 00189 WP 1997 11 6 97ZZZX4649 1 19971024 G 2740 36479971 ACME NUT 2706386503 DOUG DC8 DC851 3021920 WP LONGITUDE TRIM FAILED B A DM4R K NONE O OTHER IN INSP/MAINT 1 SO 19 508DC 45935 ACME NUT THREADS STRIPPED MAKING LONGITUDINAL TRIM MECHANISM DRIVE UNIT TOTALLY INOPERABLE. THIS NUT DRIVES THE JACKSCE W UP OR DOWN. THE INSIDE DIAMETER IS TOTALLY STRIPPED WHICH WILL NOT ALLOW ANY MOVEMENT OF THE JACKSCREW. THERE ARE TW O JACKSCREWS PER AIRCRAFT (RT AND LT). THE OTHER UNIT REMOVED HAD EXCESSIVE BACKLASH WHICH EXCEEDS MANUFACTURER'S LIMIT S. BACKLASH OF SECOND UNIT .090 INCH MAXIMUM ALLOWABLE IS .045 INCH. MAJOR FAILURE!! 2 L 7 4 4F 4A25 1997013000170 19970130 00170 SW 1997 1 30 97ZZZX465 1 19970110 G 7120 2762114083 MOUNT SWRNGN SA227 SA227* SW ENG TRUSS NOT WELDED B A H7NR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 17 AREA UNDER PLATE OR UPPER AFT MOUNT NOT WELDED. PLATE P/N'S 27-62114-073/074 ATTACHES TO TUBES 27-62114-019 AND 27-6211 4-023. WHILE THIS MOUNT HAD NOT CRACKED, WE INSPECT ALL MOUNTS NOW TO MAKE SURE THEY ARE WELDED. SUBMITTER HAS SEEN CR ACKS IN THIS AREA IN THE PAST AND HAS FILED PREVIOUS M OR D REPORTS ON THAT. 2 L 7 2 4T RT A5SW 1997110600190 19971106 00190 CE 1997 11 6 97ZZZX4650 1 19970901 G 5321 241139574 FLOORBOARD LEAR 35 35A 5170602 CE BAG COMPT DELAMINATED D K NONE O OTHER IN INSP/MAINT 1 EA 03 88JA 10162 118 THE BAGGAGE COMPARTMENT FLOOR IS CONSTRUCTED OF BONDED, HONEYCOMB MATERIAL. IT HAS TWO SECTIONS, FORWARD AND AFT, THAT ARE SPLICED TOGETHER. DURING AN A2 PHASE INSPECTION, A DELAMINATION WAS DISCOVERED INVOLVING THE UPPER SKIN OF THE FORW ARD FLOORBOARD. IT IS SIGNIFICANT ENOUGH TO REQUIRE REPLACMENT OF THE FLOORBOARD. 2 L 7 2 4F A10CE 1997110600192 19971106 00192 NE 1997 11 6 97ZZZX4652 2 19970929 G 7260 208327004 GEARBOX CASE LYC LF507 LF5071F NE STARTER COVER DAMAGED H K NONE O OTHER IN INSP/MAINT 1 NE 03 ALL THREADED INSERTS HAVE BEEN PULLED WHERE STARTER COVER (P/N 2-083-260-XX) MOUNTS TO GEARBOX. OUTER RACE OF BEARING R EMAINS IN BEARING LINER. SIGNIFICANT DAMAGE TO AREA ADJACENT TO BEARING LINER. ALL HOLES WHERE INSERTS WERE INSTALLED ARE ELONGATED. GR823, S/N M125B-039. 4 F E6NE 1997110600193 19971106 00193 GL 1997 11 6 97ZZZX4653 2 19971013 G 7210 BEARING BOLKMS 105 BO105C 5626005 EU ALLSN 250C 250C20B 03013 GL SPARE DRIVE FAILED H K NONE J WARNING INDICATION IN INSP/MAINT 1 SW 99 105RH S55 CAE835553 NR 1 ENGINE CHIP LIGHT CAME ON AFTER START-UP. MAINTENANCE FOUND PASTE ON UPPER AND LOWER CHIP PLUGS. CLEANED PLUGS, O IL SAMPLE WAS TAKEN; 1.2 HOURS LATER, NR 1 ENGINE CHIP LIGHT CAME ON AGAIN. MAINTENANCE REMOVED PLUGS. UPPER PLUG HAD CHIPS AND SLIVER. LOWER PLUG HAD PASTE AND CHIPS. ENGINE WAS REMOVED FROM SERVICE AND SENT TO ENGINE SHOP. ENGINE SHO P FOUND ENGINE GEARBOX SPARE DRIVE BEARING CAGE CAME LOOSE AND WAS RATTLING AROUND IN GEARBOX. TIME SINCE LAST INSPECT ION, 90.1 HRS. OIL SAMPLE FROM LAST 100-HR INSP SHOWED NO ABNORMAL METALS. 1 G 7 2 3U 3 U H3EU E4CE 1997110600194 19971106 00194 CE 1997 11 6 97ZZZX4654 1 19971008 G 2140 0800400237 FUEL LINE CESSNA 310 310R 2074245 CE HEATER MAIN FUEL CHAFED D A K NONE O OTHER IN INSP/MAINT 1 SO 15 4251C 310R1382 MAIN HEATER FUEL FEED LINE FOUND TO HAVE CORROSION AND CHAFING SPOTS. RECOMMEND VISUAL INSPECTION THOROUGHLY, AND REPLA CED IF DEFECTS ARE FOUND. 1 L 7 2 3O 3A10 1997110600195 19971106 00195 CE 1997 11 6 97ZZZX4655 1 19971008 G 2140 0800400239 LINE ASSY CESSNA 310 310R 2074245 CE PUMP TO HEATER CORRODED D A K NONE K FLUID LOSS IN INSP/MAINT 1 SO 15 4251C 310R1382 LINE FROM HEATER FUEL PUMP TO HEATER INLET FOUND TO HAVE CORROSION, A PIN HOLE, AND CHAFING SPOTS. 1 L 7 2 3O 3A10 1997013000217 19970130 00217 SO 1997 1 30 97ZZZX466 1 19970106 G 2810 P46132 FUEL CELL PIPER PA31T PA31T2 7103127 SO LT WING LEAKS G K NONE K W FLUID LOSS INADEQUATE Q C IN INSP/MAINT 1 EA 07 A343 PURCHASED AS A DIRECT REPLACEMENT FOR PIPER P/N 462-722. FUEL CELL S/N A343 WAS INSTALLED AND LEAKED IMMEDIATELY AFTER INSTALLATION. THREE ADDITIONAL FUEL CELLS WERE SHIPPED TO INSTALLER, TWO OF THREE WERE INSTALLED, BUT WOULD NOT FIT FOR VARIOUS REASONS. THE THIRD WAS NOT INSTALLED DUE TO THE PREVIOUS INSTALLATION PROBLEMS. 1 L 7 2 3T RT A8EA 1997110600842 19971106 00842 GL 1997 11 6 97ZZZX4660 3 19971013 G 6114 HUB MCAULY 3AF32C 3AF32C87 GL NR 2 SOCKET CRACKED B DJFR K NONE O OTHER IN INSP/MAINT 1 EA 23 120 787900 782900 FOUND HUB CRACKED DURING OVERHAUL, NR 2 BLADE SOCKET. 5 C P22EA 1997110600843 19971106 00843 EA 1997 11 6 97ZZZX4661 1 19970826 G 5415 513485 CASTING 51859410 LKHEED P2V P2V5F 5260110 EA ENGINE PYLON CRACKED D A K NONE O OTHER IN INSP/MAINT 1 WP 13 9855F 131445 WHILE ACCOMPLISHING A FLEET-WIDE INSPECTION OF AIRCRAFT, A CASTING CRACK WAS FOUND ON A SECOND UNIT WITHIN FLEET. 4 M 7 2 4R RT A17EA 1997110600844 19971106 00844 SO 1997 11 6 97ZZZX4662 1 19970809 G 5415 513485 CASTING 51859410 LKHEED P2V SP2HJOHNSON 5269601 SO ENGINE PYLON CRACKED D A K NONE O OTHER IN INSP/MAINT 1 WP 13 14835 X646 148358 WHILE ACCOMPLISHING PRE-FLIGHT, CREW NOTICED MORE MOVEMENT IN THE RIGHT (NR 2) JET THAN THE LEFT. FURTHER INVESTIGATIO N BY MAINTENANCE REVEALED A CRACK EXTENDING HORIZONTALLY THROUGH THE P/N 513485 FORWARD JET PYLON MOUNT CASTING. 2 M 7 4 4R J A1RM 1997110600845 19971106 00845 1997 11 6 97ZZZX4663 2 19970918 G 7414 M3975 COIL SLICK 4370 MAGNETO FAILED B KC2R K NONE O OTHER IN INSP/MAINT 1 GL 03 500 053096 DURING 500-HOUR INSPECTION, FOUND COIL SECONDARY TO HAVE OPEN CIRCUIT. SUBMITTER STATED COULD LEAD TO DEAD MAGNETO. 1997110600850 19971106 00850 SO 1997 11 6 97ZZZX4668 1 19970516 G 2701 7927600 CONTROL WHEEL PIPER PA28 PA28140 7102802 SO PILOT SIDE BROKE D K NONE O OTHER NR NOT REPORTED 1 WP 01 15831 7452 287325174 THE CONTROL WHEEL COMPLETELY BROKE BETWEEN THE OUTER GRIP AND THE HUB. PILOT REPORTED THE BROKEN PART TO THE FLIGHT SCH OOL AFTER FLYING AT THE AIRFIELD ON A DAY WITH HIGH CROSS-WINDS. THE BROKEN CONTROL WHEEL WAS REPLACED WITH A SERVICEAB LE PART. 1 L 7 1 3O 2A13 1997110600851 19971106 00851 SO 1997 11 6 97ZZZX4669 2 19971023 G 8530 646286 VALVE CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO CYL 1-2-5 EXH WORN D A K NONE O OTHER IN INSP/MAINT 1 SW 01 97090 1062 18266974 286534R INSPECTION FOUND THE NITRALOY GUIDES WORE THE EX VALVE STEMS LEAVING STEPS IN THE STEM AT THE ENDS OF TRAVEL IN THE GUID E. ONE VALVE HAD .070 INCH WEAR. SUBMITTER STATED CONTINENTAL SHOULD ISSUE A BULLETIN OR SERVICE LETTER ALERTING MECHA NICS OF THIS PROBLEM. 1 H 7 1 3O 3 O NT 3A13 E273 1997110600852 19971106 00852 SO 1997 11 6 97ZZZX4670 2 19971015 G 8520 537466 THROUGH BOLT MOONEY M20 M20K 5870220 SW CONT O360 TSIO360KB 17025 SO CRANKCASE BROKEN D K NONE O OTHER IN INSP/MAINT 1 SO 03 3580H 1154 250426 309434 DURING AN ANNUAL INSPECTION, THE BOTTOM CRANKCASE THROUGH-BOLT LOCATED BETWEEN NR 1 AND NR 3 CYLINDER POSITION WAS FOUND BACKED OUT FROM THE CASE ALMOST TO THE POINT OF FALLING OUT OF ITS MOUNTING HOLE BY APPROXIMATELY 1.1250 INCHES. WHEN BOLT WAS REMOVED, FOUND THE OTHER END AT THE THREADED PORTION MISSING FROM BEING BROKEN OFF. NO OIL LEAK WAS PRESENT. N O OTHER CASE BOLTS OR CYLINDER STUDS WERE AFFECTED FROM THIS OCCURRENCE. 1 L 7 1 3O 3 O 2A3 E9CE 1997110600853 19971106 00853 CE 1997 11 6 97ZZZX4671 1 19970925 G 3222 NOSE GEAR BEECH 23 C23 1151242 CE TRUNNION DEPARTED D A UNSCHED LANDING O OTHER CL CLIMB 1 SO 03 24041 M1930 NOSE GEAR DEPARTED AIRCRAFT ON TAKEOFF. THE NOSE GEAR TRUNNION INSIDE THE ENGINE MOUNT CRACKED AT BOLT HOLES FOR NOSE W HEEL STEERING. THE CRACK PROGRESSED FROM THE BOLT HOLES TO CIRCLE THE TRUNNION DOWN WIND UNTIL IT COMPLETED 360 DEGREES. AT THAT TIME, THE GEAR DEPARTED THE AIRCRAFT. SUSPECT HARD LANDING IN CROSS-WIND OR POSSIBLE TOWING AND TURNING TOO F AR. 1 L 7 1 3O A1CE 1997110600854 19971106 00854 SW 1997 11 6 97ZZZX4672 1 19970923 G 2710 73006000 PUSH/PULL TUBE MOONEY M20 M20J 5870219 SW AILERON BROKEN B L A HX1R K NONE O OTHER IN INSP/MAINT 1 EA 25 3515H 3345 241034 DURING CONTROL CHECK JUST PRIOR TO TAKEOFF, NOTED THE RIGHT AILERON DID NOT MOVE. INVESTIGATION REVEALED THE PUSH ROD L OCATED IN THE BELLY OF THE AIRCRAFT WAS BROKEN AT A WELD WHERE PART HAS A 90 DEGREE BEND. THE BREAK WAS JUST AT THE EDG E OF THE WELD. IT APPEARED THE CRACK STARTED ON THE INSIDE OF THE 90 DEGREE BEND AND TRAVELED UP THROUGH THE METAL TO N ON-WELDED PORTION. 1 L 7 1 3O 2A3 1997110600855 19971106 00855 SW 1997 11 6 97ZZZX4673 1 19971028 G 6420 206011809005 PITCH HORN BELL 206 206L1 1182107 SW T/R HUB DEFECTIVE H K NONE O OTHER IN INSP/MAINT 1 NM 11 PITCH HORN ON T/R HUB ASSY HAS A LOOSE STUD. 1 G 7 1 3U H2SW 1997110600856 19971106 00856 SW 1997 11 6 97ZZZX4674 1 19971020 G 2915 206076036101 VALVE BELL 407 407 SW HYD RELIEF FAILED B GS1R K NONE O OTHER IN INSP/MAINT 1 EA 03 98VG 15 70128384 53171 INSPECTION FOUND HYDRAULIC RELIEF VALVE FAILED. REPLACED WITH NEW RELIEF VALVE. 1 G 7 1 3U O H2SW 1997110600857 19971106 00857 NE 1997 11 6 97ZZZX4675 3 19971013 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 4579 HJ484 INSPECTION FOUND FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. TWO CRACKS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997110600858 19971106 00858 NE 1997 11 6 97ZZZX4676 3 19971001 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 4605 HJ460 FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. THREE CRACKS. 2 L 7 2 4T RT A24CE 5 C P10NE 1997110600859 19971106 00859 EU 1997 11 6 97ZZZX4677 1 19971013 G 5210 7253501551 DOOR PANEL SAAB SF340 340B 7860101 EU DOUBLER DEFECTIVE B A YTQR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 15 250AE 340B250 INSPECTION FOUND DOUBLER HAS 2 HOLES BURNED THROUGH BY ELECTRICAL ARCING. STATIC ELECTRIC BUILD-UP ON OUTER PANEL TRAVE LING THROUGH RIVETS TO DOUBLER AND DISCHARGING THROUGH DOUBLER. THIS IS BEING CAUSED BY A POOR DESIGN OF NOT HAVING THE RIVETS INSULATED FROM ANTI-STATIC MATERIAL ON OUTER SURFACE ENHANCED BY THE REPAIR USING EXPANDED METAL AS ANTI-STATIC PROTECTION. THIS REPAIR DOES NOT BOND ADEQUATELY AND GROUND IS NOT RELIABLE AT THE EDGES. SUBMITTER STATED RIVETS SHOU LD BE SEALED OVER WITH FIBERGLASS PRIOR TO REPAIRING THE ANTI-STATIC AND EXPANDED METAL SHOULD NOT BE USED IF IT CANNOT BE RELIED ON TO HAVE A GOOD BOND. NOTE: THERE IS AN OIL CHECK DOOR IN PANEL, A FIRE COULD HAPPEN. 2 L 7 2 4T RT A52EU 1997110600860 19971106 00860 EU 1997 11 6 97ZZZX4678 1 19971013 G 5210 7253501551 DOOR PANEL SAAB SF340 340B 7860101 EU OUTER SURFACE DEFECTIVE B A YTQR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 15 250AE 340B250 INSPECTION FOUND THE ANTI-STATIC MATERIAL WAS FALLING OFF. THE PANEL HAD PREVIOUSLY BEEN REPAIRED LESS THAN ONE YEAR. T HE REPAIR IS A SAAB APPROVED REPAIR THAT BONDS STATIC ELECTRICITY CONDUCTIVITY MATERIAL (EXPANDED ALUMINUM) TO REPLACE T HE ALUMINUM FOIL. THE SAAB PROCEDURE IS INADEQUATE TO ACHIEVE A RELIABLE BOND. SUBMITTER STATED SAAB AND/OR THE FAA SH OULD IMMEDIATELY DISAPPROVE THIS PROCEDURE AND ALL PANELS REPAIRED PER THIS PROCEDURE SHOULD BE REPAIRED USING THE SAAB APPROVED PROCEDURE OF FLAME SPRAY. NOTE: ON 7-23-97, PN 7253501-712, HAD SAME PROBLEM AND DEFECT REPORT WAS SUBMITTED. 2 L 7 2 4T RT A52EU 1997110600865 19971106 00865 SW 1997 11 6 97ZZZX4681 1 19971020 G 6330 222031622105 ROD END BELL 222 222 1182122 SW NODAL BEAM WORN B GS1R K NONE O OTHER IN INSP/MAINT 1 EA 03 911EC 303 47505 NODAL BEAM INSPECTION FOUND ROD END WORN. REPLACED WITH NEW ROD END. 1 G 7 2 3U H9SW 1997110700009 19971107 00009 NE 1997 11 7 97ZZZX4682 2 19971024 G 7210 7757543 BEARING HAMSTD 6044T35P10 SAAB SF340 SF340A 7850100 EU GE CT7TP CT79B 30030 NE GC49 GEAR CASE SPALLED B SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 13407 UDAG083 GEE785379 DISASSEMBLY OF GEAR CASE REVEALED THE INPUT ROLLER BEARING RACE CRACKED, PINION GEAR BEARING SURFACE SPALLED, LEFT AND R IGHT IDLER GEAR RETAINING RINGS BROKE, AND NO TORQUE ON LEFT IDLER GEAR NUT. PINION, SN IC641356. INPUT BEARING, SN 9- 259. REF: OPERATOR CONTROL NR SI3R97012, 97ZZZX4683, AND 97ZZZX4684. 2 L 7 2 4T 4 T RT A52EU E8NE 1997110700010 19971107 00010 NE 1997 11 7 97ZZZX4683 2 19971024 G 7210 7922261 RETAINER RING HAMSTD 6044T35P10 SAAB SF340 SF340A 7850100 EU GE CT7TP CT79B 30030 NE GL49 GEAR CASE BROKEN B SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 13407 UDAG0838 GEE785379 DISASSEMBLY OF GEAR CASE REVEALED THE INPUT ROLLER BEARING RACE CRACKED, PINION GEAR BEARING SURFACE SPALLED, LEFT AND R IGHT IDLER GEAR RETAINING RINGS BROKE, AND NO TORQUE ON LEFT IDLER GEAR NUT. PINION, SN IC641356. INPUT BEARING, SN 9- 259. REF: OPERATOR CONTROL NR SI3R97012, 97ZZZX4682, AND 97ZZZX4684. 2 L 7 2 4T 4 T RT A52EU E8NE 1997110700011 19971107 00011 NE 1997 11 7 97ZZZX4684 2 19971024 G 7210 7757533 IDLER GEAR NUT HAMSTD 6044T35P10 SAAB SF340 SF340A 7850100 EU GE CT7TP CT79B 30030 NE GC49 GEAR CASE LOOSE TORQUE B SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 13407 UDAG0838 GEE785379 DISASSEMBLY OF GEAR CASE REVEALED THE INPUT ROLLER BEARING RACE CRACKED, PINION GEAR BEARING SURFACE SPALLED, LEFT AND R IGHT IDLER GEAR RETAINING RINGS BROKE, AND NO TORQUE ON LEFT IDLER GEAR NUT. PINION, SN IC641356. INPUT BEARING, SN 9- 259. REF: OPERATOR CONTROL NR SI3R97012, 97ZZZX4682, AND 97ZZZX4683. 2 L 7 2 4T 4 T RT A52EU E8NE 1997110600870 19971106 00870 CE 1997 11 6 97ZZZX4685 1 19970417 G 3244 850T061 TIRE GOODYEARAERO MTSBSI MU2 MU2B36 5780412 CE RT MLG SEPARATED D K NONE O OTHER LD LANDING 1 NM 09 869P 300 51701608 692 RIGHT HAND MAIN GEAR TIRE TREAD SEPARATED FROM CASING ALONG INBOARD EDGE FOR APPROXIMATELY 1 INCH. SEPARATION WAS NOTIC ED DURING A POST-FLIGHT WALK AROUND INSPECTION. THIS WAS ONE OF THREE SIMILAR OCCURRENCES WITHIN 30 DAYS ON TWO DIFFERE NT MU-2'S. TIRE WAS RETURNED TO MFG FOR EVALUATION. 1 H 7 2 3T RT A10SW 1997110600871 19971106 00871 CE 1997 11 6 97ZZZX4686 1 19970430 G 3244 850T061 TIRE GOODYEARAERO MTSBSI MU2 MU2B36 5780412 CE LT MLG SEPARATED D K NONE O OTHER LD LANDING 1 NM 09 500PJ 228 51582304 668 LEFT HAND MAIN GEAR TIRE TREAD SEPARATED FROM CASING ALONG INBOARD EDGE FOR APPROXIMATELY 10 INCHES. OCCURRED ON LANDIN G. TIRE REMAINED INFLATED. THIS WAS ONE OF THREE SIMILAR OCCURRENCES WITHIN 30 DAYS ON TWO DIFFERENT MU-2'S. TIRE WAS RETURNED TO MFG FOR EVALUATION. 1 H 7 2 3T RT A10SW 1997110600872 19971106 00872 CE 1997 11 6 97ZZZX4687 1 19970402 G 3244 850T061 TIRE MTSBSI MU2 MU2B36 5780412 CE RT MLG SEPARATED D K NONE O OTHER IN INSP/MAINT 1 NM 09 500PJ 284 51710805 668 RIGHT HAND MAIN GEAR TIRE TREAD SEPARATED FROM CASING ALONG INBOARD EDGE COMPLETELY AROUND CIRCUMFERENCE. OCCURRED ON L ANDING. TIRE REMAINED INFLATED. TREAD STAYED ATTACHED AROUND OUTBOARD EDGE CIRCUMFERENCE. THIS WAS ONE OF THREE SIMIL AR OCCURRENCES WITHIN 30 DAYS ON TWO DIFFERENT AIRCRAFT (BOTH MU-2'S). TIRE RETURNED TO MFG FOR EVALUATION. 1 H 7 2 3T RT A10SW 1997111300039 19971113 00039 EA 1997 11 13 97ZZZX4705 2 19971016 G 8530 LW12892 THRUST BUTTON PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA ROCKER HSAFT MISSING B N3XR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 15 167ER 387 2841183 RL1870239A DURING C/W LYC SB 301 AND SB 388 ALL ROCKER SHAFT THRUST BUTTONS WERE DISCOVERED MISSING. THIS IS A FACTORY REMANUFACUR ED ENGINE. 1 L 7 1 3O 3 O 2A13 E274 1997111300040 19971113 00040 SW 1997 11 13 97ZZZX4706 1 19971009 G 6310 406340102101 SEAL BELL 407 407 SW FREEWHEEL LEAK C L1PM K NONE K FLUID LOSS IN INSP/MAINT 1 WP 23 1116H 136 53046 FREEWHEELING UNIT FORWARD SEAL LEAKS EXCESSIVELY. REPLACED SEAL AND CORRECTED LEAK. AIRCRAFT TT: 135.5 HOURS. 1 G 7 1 3U O H2SW 1997111300041 19971113 00041 SW 1997 11 13 97ZZZX4707 1 19970625 G 6410 206016201131 BEARING BELL 206 206B 1181511 SW T/R BLADE BINDING C L1PM K NONE O OTHER IN INSP/MAINT 1 WP 23 212LA 104 CS2814 3957 ACFT TT: 13,497.8 HOURS. 104.2 HR. TWO NEW T/R BLADES P/N 206-016-201-131, SN CS-2814 AND SN CS-2815 WERE INSTALLED. PILOT'S COMPLAINT ABOUT T/R PEDAL PROBLEM. HELICOPTER WAS INSPECTED AND THE FOUR BEARINGS (2 EACH ON BLADES) ON T/R B LADES WERE FOUND BINDING. BEARING MATERIAL WAS COMING APART. T/R BLADES WERE CHANGED AND PROBLEM WENT AWAY. 1 G 7 1 3U H2SW 1997111300042 19971113 00042 SW 1997 11 13 97ZZZX4708 1 19970625 G 6410 206016201131 BLADE BELL 206 206B 1181511 SW T/R BEARING BINDING C L1PM K NONE O OTHER IN INSP/MAINT 1 WP 23 212LA 104 CS2815 3957 ACFT TT: 13,497.8 HOURS. 104.2 HR. TWO NEW T/R BLADES P/N 206-016-201-131, SN CS-2814 AND SN CS-2815 WERE INSTALLED. PILOT'S COMPLAINT ABOUT T/R PEDAL PROBLEM. HELICOPTER WAS INSPECTED AND THE FOUR BEARINGS (2 EACH ON BLADES) ON T/R B LADES WERE FOUND BINDING. BEARING MATERIAL WAS COMING APART. T/R BLADES WERE CHANGED AND PROBLEM WENT AWAY. 1 G 7 1 3U H2SW 1997111300043 19971113 00043 GL 1997 11 13 97ZZZX4709 2 19971011 G 7230 VANE BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL ENG COMP FAILED B LS1R A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 EA 13 206BX 10565 398 2872 CAE833239 PRECAUTIONARY LANDING DUE TO COMPRESSOR STALL. FOUND CASE EROSION AND LOSS OF VANE. 1 G 7 1 3U 3 U H2SW E4CE 1997111300044 19971113 00044 SW 1997 11 13 97ZZZX4710 1 19971028 G 6320 206040040005 GEARSHAFT BELL 206 206B3 1181506 SW XMSN SPLINES WORN B A KBTR K NONE O OTHER IN INSP/MAINT 1 NM 07 55TV 2997 B1212149 3788 TRANSMISSION GEARSHAFT SPLINES SEVERLY WORN. SUSPECT CAUSE DUE TO LENGTH OF CALENDAR TIME INSTALLED INDICATING BREAKDOW N OF THE LUBRICANT. PERIOD OF INSTALLATION WAS 13 YEARS. RECOMMEND A CALENDAR LIMITATION OF 4 YEARS AS WELL AS THE EXI STING HOURLY FREQUENCY (TO SUNGEAR). 1 G 7 1 3U H2SW 1997111300045 19971113 00045 SW 1997 11 13 97ZZZX4711 1 19971009 G 6220 407010150101A FRAHM ASSY BELL 407 407 SW M/R WORN C L1PM K NONE E VIBRATION/BUFFET NR NOT REPORTED 1 WP 23 58236 317 53069 RUBBER BOOT CAME LOOSE AND SPRINGS ROTATED INSIDE FRAHM. HELICOPTER HAD A 4 PER VIBRATION AND COULD NOT BE ELIMINATED. REPLACED FRAHM ASSY AND BALANCED HELICOPTER ROTOR SYSTEM TO ACCEPTABLE LEVELS. 1 G 7 1 3U O H2SW 1997111300048 19971113 00048 CE 1997 11 13 97ZZZX4714 1 19971001 G 2810 FUEL TANK CESSNA 172 172M 2072418 CE RT WING TANK CHAFED D K NONE O OTHER IN INSP/MAINT 1 GL 23 9359H 5640 17266115 AFTER REMOVING RIGHT FUEL TANK TO CHECK FOR LEAK, FOUND WEAR ON BOTTOM OF TANK INDENTED WITH RIVET HEAD MARKS. THE TANK RESTS ON A REINFORCEMENT PLATE THAT IS RIVETED TO STIFFENERS. USING A UNIVERSAL TYPE RIVET HEAD, A RUBBER CHAFE STRIP IS LAID OVER THE RIVET HEADS, BUT DUE TO WEIGHT AND MOVEMENT OF THE TANK, THE RUBBER HAS MOVED IN SPOTS REVEALING BARE R IVET HEADS. ALSO, RUBBER HAS BECOME BRITTLE AND HARD. IF LEFT UNCHECKED, RIVETS WOULD HAVE WORN THROUGH TANK IN MULTIP LE SPOTS. SUGGEST COUNTERSUNK RIVETS. 1 H 7 1 3O NT 3A12 1997111300049 19971113 00049 NE 1997 11 13 97ZZZX4715 2 19971027 G 7314 MFP200 PUMP CHNDLREVANS DOUG DC10 DC10* WP GE CF6 CF650* 30018 NE ENGINE FUEL DAMAGED B SF3R K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 03 29362 9483 CGW10285 PUMP RETURNED FOR OVERHAUL AND SB COMPLIANCE. FOUND BEYOND REPAIR AND FOD BOLT WAS WEDGED BETWEEN VANES OF IMPELLER SEC TION ALONG WITH WASHER FRAGMENTS. INTERNAL DAMAGE TO IMPELLER VANES AND GOUGED HOUSING. UNIT COULD HAVE SEIZED AND SHE ARED SHAFT. 2 L 7 3 4F 4 F A22WE E23EA 1997111300050 19971113 00050 EA 1997 11 13 97ZZZX4716 1 19971107 G 2530 2003681 HEATER ELEMENT 1440A10T CNDAIR CL600 CL6001A11 1900302 EA COFFEE POT EXPLODED H K NONE O OTHER IN INSP/MAINT 1 GL 25 711SX 4500 84211098 3007 THE HEATER ELEMENT FAILED WITH AN EXPLOSIVE LIKE CHARGE THAT SENT THE FAILED ELEMENT AND WIRES INTO THE HONEYCOMB GALLEY TOP. 2 L 7 2 4F RT A21EA 1997111300051 19971113 00051 EA 1997 11 13 97ZZZX4717 1 19971027 G 3230 601P57208101 SWITCH CNDAIR CL600 CL6002B16 1900305 EA NLG UPLOCK FAILED D O OTHER J WARNING INDICATION CL CLIMB 1 EA 25 399CF 5084 NOSE LANDING GEAR WOULD NOT RETRACT AFTER TAKEOFF. FOUND PROBLEM TO BE NOSE LANDING GEAR PROXIMITY SWITCH FAILED CAUSIN G THE GEAR NOT TO RETRACT. 2 L 7 2 4F RT A21EA 1997111300052 19971113 00052 CE 1997 11 13 97ZZZX4718 1 19971027 G 2912 99123727 FILTER CESSNA 525 525 2076601 CE HYDRAULIC SYSTEM FAULTY B NVIR O OTHER J WARNING INDICATION CR CRUISE 1 SW 05 525J 5250184 PILOT REPORTED A LEFT HYDRAULIC LOW FLOW LIGHT CAME ON INTERMITTENTLY IN-FLIGHT. INSPECTED AND FOUND HYDRAULIC FILTER W AS SLOW IN PASSING FLUID. INSTALLED NEW FILTER AND OPERATIONAL CHECKS WERE GOOD. 1 L 7 2 4F RT A1WI 1997111300053 19971113 00053 WP 1997 11 13 97ZZZX4719 2 19970630 G 7250 30727121 BLADE 30727303 AMD FALC10 FALCON10 2730101 EU GARRTT TFE731 TFE7312 01518 WP HP TURBINE FAILED B A AE0R O OTHER X ENGINE FLAMEOUT CR CRUISE 1 SO 03 42EH 1244 KAOU 28 IN-FLIGHT SHUT DOWN AND LOCK-UP OF ENGINE OCCURRED. ENGINE SENT TO THIS FACILITY FOR INSPECTION AND REPAIR. FOUND 4 EA CH 3072712-1 HP TURBINE BLADES HAD RELEASED AT MID-SPAN OF BLADES. THIS WAS A CONTAINED FAILURE. THE BLADES AND TURBIN E DISK WERE NEW AT LAST MAJOR PERIODIC INSPECTION AND HAVE 1,244.0 HOURS AND 781 CYCLES TIME SINCE NEW. FOD FROM BLADE RELEASE ALSO RUINED ALL OTHER HP BLADES, PLUS ALL 1ST, 2ND, AND 3RD, LP TURBINE BLADES. CAUSE OF FAILURE IS UNKNOWN AT THIS TIME ALTHOUGH ENGINE DOES NOT HAVE SB TFE731-72-3434, RELOCATED A4 NOZZLE ASSY, INCORPORATED, WHICH SUPPOSEDLY HELP S PREVENT THIS PROBLEM. THE FAILED BLADES ARE OF THE LATEST DESIGN. (SB TFE731-72-3099). CYCLES, 781. 2 L 7 2 4F 4 F A33EU E6WE 1997111300054 19971113 00054 WP 1997 11 13 97ZZZX4720 2 19970630 G 7250 30727121 BLADE 30727303 AMD FALC10 FALCON10 2730101 EU GARRTT TFE731 TFE7312 01518 WP HP TURBINE FAILED B A AE0R O OTHER X ENGINE FLAMEOUT CR CRUISE 1 SO 03 42EH 1244 KADJ 28 P73180C IN-FLIGHT SHUT DOWN AND LOCK-UP OF ENGINE OCCURRED. ENGINE SENT TO THIS FACILITY FOR INSPECTION AND REPAIR. FOUND 4 EA CH 3072712-1 HP TURBINE BLADES HAD RELEASED AT MID-SPAN OF BLADES. THIS WAS A CONTAINED FAILURE. THE BLADES AND TURBIN E DISK WERE NEW AT LAST MAJOR PERIODIC INSPECTION AND HAVE 1,244.0 HOURS AND 781 CYCLES TIME SINCE NEW. FOD FROM BLADE RELEASE ALSO RUINED ALL OTHER HP BLADES, PLUS ALL 1ST, 2ND, AND 3RD, LP TURBINE BLADES. CAUSE OF FAILURE IS UNKNOWN AT THIS TIME ALTHOUGH ENGINE DOES NOT HAVE SB TFE731-72-3434, RELOCATED A4 NOZZLE ASSY, INCORPORATED, WHICH SUPPOSEDLY HELP S PREVENT THIS PROBLEM. THE FAILED BLADES ARE OF THE LATEST DESIGN. (SB TFE731-72-3099). CYCLES, 781 2 L 7 2 4F 4 F A33EU E6WE 1997111300055 19971113 00055 WP 1997 11 13 97ZZZX4721 2 19970630 G 7250 30727121 BLADE 30727303 AMD FALC10 FALCON10 2730101 EU GARRTT TFE731 TFE7312 01518 WP HP TURBINE FAILED B A AE0R O OTHER X ENGINE FLAMEOUT CR CRUISE 1 SO 03 42EH 1244 KADN 28 P73180C IN-FLIGHT SHUT DOWN AND LOCK-UP OF ENGINE OCCURRED. ENGINE SENT TO THIS FACILITY FOR INSPECTION AND REPAIR. FOUND 4 EA CH 3072712-1 HP TURBINE BLADES HAD RELEASED AT MID-SPAN OF BLADES. THIS WAS A CONTAINED FAILURE. THE BLADES AND TURBIN E DISK WERE NEW AT LAST MAJOR PERIODIC INSPECTION AND HAVE 1,244.0 HOURS AND 781 CYCLES TIME SINCE NEW. FOD FROM BLADE RELEASE ALSO RUINED ALL OTHER HP BLADES, PLUS ALL 1ST, 2ND, AND 3RD, LP TURBINE BLADES. CAUSE OF FAILURE IS UNKNOWN AT THIS TIME ALTHOUGH ENGINE DOES NOT HAVE SB TFE731-72-3434, RELOCATED A4 NOZZLE ASSY, INCORPORATED, WHICH SUPPOSEDLY HELP S PREVENT THIS PROBLEM. THE FAILED BLADES ARE OF THE LATEST DESIGN. (SB TFE731-72-3099). CYCLES, 781 2 L 7 2 4F 4 F A33EU E6WE 1997111300056 19971113 00056 WP 1997 11 13 97ZZZX4722 2 19970630 G 7250 30727121 BLADE 30727303 AMD FALC10 FALCON10 2730101 EU GARRTT TFE731 TFE7312 01518 WP HP TURBINE FAILED B A AE0R O OTHER X ENGINE FLAMEOUT CR CRUISE 1 SO 03 42EH 1244 KADM 28 P73180C IN-FLIGHT SHUT DOWN AND LOCK-UP OF ENGINE OCCURRED. ENGINE SENT TO THIS FACILITY FOR INSPECTION AND REPAIR. FOUND 4 EA CH 3072712-1 HP TURBINE BLADES HAD RELEASED AT MID-SPAN OF BLADES. THIS WAS A CONTAINED FAILURE. THE BLADES AND TURBIN E DISK WERE NEW AT LAST MAJOR PERIODIC INSPECTION AND HAVE 1,244.0 HOURS AND 781 CYCLES TIME SINCE NEW. FOD FROM BLADE RELEASE ALSO RUINED ALL OTHER HP BLADES, PLUS ALL 1ST, 2ND, AND 3RD, LP TURBINE BLADES. CAUSE OF FAILURE IS UNKNOWN AT THIS TIME ALTHOUGH ENGINE DOES NOT HAVE SB TFE731-72-3434, RELOCATED A4 NOZZLE ASSY, INCORPORATEDN WHICH SUPPOSEDLY HELP S PREVENT THIS PROBLEM. THE FAILED BLADES ARE OF THE LATEST DESIGN. (SB TFE731-72-3099). CYCLES, 781 2 L 7 2 4F 4 F A33EU E6WE 1997111300057 19971113 00057 CE 1997 11 13 97ZZZX4723 1 19971025 G 3250 BUNGEE CESSNA 500 560CESSNA 2076750 CE NLG STEERING WORN D S K NONE O OTHER IN INSP/MAINT 1 SW 03 560FB 1829 5600148 DURING TROUBLESHOOTING FOR NLG NOISE DUE TO OUT OF BALANCE NLG WHEEL, FOUND NLG STEERING BUNGEE WORN. WEAR WOULD ALLOW BUNGEE TO DROP DOWN AND BIND UP PULLEY BRACKET. BRACKET WOULD THEN FAIL DURING NOSE WHEEL STEERING TO LEFT. 2 L 7 2 4F RT A22CE 1997111300059 19971113 00059 1997 11 13 97ZZZX4724 1 19971015 G 6123 A3496 SPRING HARTZL HCB5M HCB5MP3 GL PROP FEATHER BROKEN B FG6R K NONE O OTHER IN INSP/MAINT 1 NM 11 2059 EV181 PROPELLER WOULD NOT AUTOFEATHER ON SHUT DOWN. DISASSEMBLY AND INSPECTION REVEALED FEATHER SPRING BROKEN IN 7 PIECES. 6 C P44GL 1997111300060 19971113 00060 GL 1997 11 13 97ZZZX4725 3 19970314 G 6110 RA19832 CLAMP ASSY PIPER PA31T PA31T 7103124 SO HARTZL HCB3T HCB3TN3 GL PROPELLER FAILED D K NONE W INADEQUATE Q C NR NOT REPORTED 1 GL 09 23407 4008 628 31T7920055 BU9757 CLAMP ASSY RAPCO P/N RA1983-2 WAS SUBSTITUTED FOR A BFG 3E1883-2 UNDER THE ASSUMPTION OF JORDAN PROPELLER SERVICE CRS NR 2273. THIS IS REPORTED AS AN FAA-PMH APPROVED PART WHICH IS IN FACT A NON FAA-PMA PART. THIS CLAMP ASSY FAILED CAUSIN G THE FOLLOWING REPAIRS: 2 CLAMP ASSY'S PN 3E1883-2, 1 - 1E1150-2 TERMINAL STRIP, 1-4E1889-2 LEAD, 1-57-4E1555-1 SLIP RING, 1 - MS21919-DG4 CLAMP. 1 L 7 2 3T A8EA 6 C P15EA 1997111300061 19971113 00061 EA 1997 11 13 97ZZZX4726 2 19971021 G 8520 CONNECTING ROD PIPER PA32 PA32RT300 7103215 SO LYC O540 IO540K1G5 41532 EA NR 2 CYLINDER FAILED E A UNSCHED LANDING E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CL CLIMB 1 EA 21 2200J 3223 1250 32R7985041 L1927248A ENGINE HAD A CATASTROPHIC FAILURE 10 MINUTES AFTER TAKEOFF. A SUCCESSFUL EMERGENCY LANDING WAS MADE IN A HAY FIELD. PI LOT AND PASSENGER WERE NOT INJURED, AIRCRAFT WAS SUBSTANTIALLY DAMAGED. THE NR 2 CONNECTING ROD CREATED FOUR HOLES IN T HE ENGINE CASE AND THE CAMSHAFT AND A CAM FOLLOWER WERE BROKEN IN THE SAME AREA. 1 L 7 1 3O 3 O A3SO 1E4 1997111300062 19971113 00062 CE 1997 11 13 97ZZZX4727 1 19970929 G 3233 ACTUATOR CESSNA 210 210L 2073448 CE LT MLG SPLIT G A O UNSCHED LANDING OTHER K FLUID LOSS CL CLIMB 1 SW 01 321BT 21060127 AIRCRAFT DEPARTED ON A FAR 135 FLIGHT AT APPROXIMATELY 1400 HOURS TO PORTALES, N.M. UPON DEPARTURE, THE LANDING GEAR WO ULD NOT RETRACT. THE PILOT ELECTED TO RETURN TO ALBUQUERQUE INTERNATIONAL AIRPORT. WHEN HE MOVED THE GEAR HANDLE TO TH E UP POSITION, NOTHING HAPPENED. APPARENTLY, THE LEFT GEAR WAS LOCKED OVERCENTER, BUT THE RIGHT MAIN WAS UNLOCKED. WHE N THE AIRCRAFT TOUCHED DOWN, THE RIGHT GEAR LEG COLLAPSED. DURING INSPECTION OF THE LANDING GEAR, DISCOVERED THE LEFT A CTUATOR HAD SPLIT ALLOWING THE FLUID TO LEAK OUT OF THE SYSTEM. 1 H 7 1 3O 3A21 1997111300063 19971113 00063 SO 1997 11 13 97ZZZX4728 2 19971011 G 8530 649317 CYLINDER CESSNA 206 U206B 2073322 CE CONT O520 IO520F 17032 SO NR 5 CRACKED B LJQR K NONE O OTHER IN INSP/MAINT 1 EA 09 3435L 1428 176 U2060735 1680686F NR 5 CYLINDER ASSY CRACKED ONE-THIRD AROUND STEEL BARREL APPROXIMATELY 1 INCH BELOW CYLINDER HEAD. 1 H 7 1 3O 3 O A4CE E5CE 1997111300064 19971113 00064 CE 1997 11 13 97ZZZX4729 1 19971020 G 5553 NAS464P3A7 BOLT CESSNA 150 152 2071835 CE V FIN BRACKET WRONG PART G K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 16 48877 152781022 PURCHASED PART FROM CESSNA. PART DID NOT MATCH OLD PART, REORDERED AND NOTIFIED CESSNA ACCORDINGLY. SECOND ORDER ALSO DID NOT MATCH. BOLTS RECEIVED WERE NAS464P3A8 BOLTS, AND WERE TOO LONG TO USE - BOLTS HOLDING VERTICAL FIN TO FUSELAGE BRACKET. 1 H 7 1 3O NT 3A19 1997111300065 19971113 00065 CE 1997 11 13 97ZZZX4730 1 19971022 G 2910 20801179 LINE CESSNA 177 177RG 2073709 CE HYDRAULIC SYSTEM LEAK G A O OTHER K FLUID LOSS NR NOT REPORTED 1 SW 11 52786 1284 177RG1270 HYDRAULIC LINE BEGAN LEAKING ON GEAR RETRACTION CAUSING HYDRAULIC MOTOR/PUMP TO PUMP ALL USABLE HYDRAULIC FLUID OVERBOAR D. RESULT WAS LANDING WITH GEAR DANGLING FROM AIRCRAFT. THE CAUSE OF THE LEAK WAS A CORROSION PIT. LINE IS LOCATED IN THE COCKPIT PEDESTAL CAUSING INSPECTABILITY PROBLEM. 1 H 7 1 3O A20CE 1997111300066 19971113 00066 CE 1997 11 13 97ZZZX4731 1 19971010 G 2720 041130613 TORQUE TUBE CESSNA 172 172F 2072414 CE RUDDER BAR CORRODED D A K NONE O OTHER IN INSP/MAINT 1 SO 25 7900U 2135 17251900 ACFT OWNER/PILOT REPORTED TURN COORDINATOR INDICATING 1 FULL BALL OUT OF CENTER AND EXCESSIVE RUDDER PRESS REQUIRED TO H OLD COORDINATION. MX DETERMINED RUDDER WOULD ONLY MOVE IN ONE DIRECTION WHEN MOVED FROM OUTSIDE ACFT. WHEN ATTEMPT MAD E TO MOVE THE RUDDER FROM INSIDE ACFT, STIFF OPERATION OBSERVED. ALSO, SEVERE CORROSION FOUND ON RUDDER PEDAL. CARPETI NG CLOSE TO THIS AREA WAS DAMP. NO OTHER CORROSION IN STRUCTURE FOUND. THIS AREA IS DIRECTLY BELOW LOWER FWD WINDSHIEL D STRAP, AND CORROSION POSSIBLY CAUSED BY A LEAKING WINDSHIELD. RECOMMEND AREA BE CHECKED CLOSELY, AND LEAKS IN WINDHSH IELD BE REPAIRED. IF CORROSION IS FOUND ON THESE BARS, THEY WOULD REQUIRE REMOVAL TO CLEAN AND INSPECT. 1 H 7 1 3O NT 3A12 1997111300067 19971113 00067 CE 1997 11 13 97ZZZX4732 1 19971010 G 2720 041130614 TORQUE TUBE CESSNA 172 172F 2072414 CE RUDDER BAR CORRODED D K NONE O OTHER IN INSP/MAINT 1 SO 25 7900U 2135 17251900 ACFT OWNER/PILOT REPORTED TURN COORDINATOR INDICATING 1 FULL BALL OUT OF CENTER AND EXCESSIVE RUDDER PRESS REQUIRED TO H OLD COORDINATION. MX DETERMINED RUDDER WOULD ONLY MOVE IN ONE DIRECTION WHEN MOVED FROM OUTSIDE ACFT. WHEN ATTEMPT MAD E TO MOVE THE RUDDER FROM INSIDE ACFT, STIFF OPERATION OBSERVED. ALSO, SEVERE CORROSION FOUND ON RUDDER PEDAL. CARPET ING CLOSE TO THIS AREA WAS DAMP. NO OTHER CORROSION IN STRUCTURE FOUND. THIS AREA IS DIRECTLY BELOW LOWER FWD WINDSHIE LD STRAP, AND CORROSION POSSIBLY CAUSED BY A LEAKING WINDSHIELD. RECOMMEND AREA BE CHECKED CLOSELY, AND LEAKS IN WINDHS HIELD BE REPAIRED. IF CORROSION IS FOUND ON THESE BARS, THEY WOULD REQUIRE REMOVAL TO CLEAN AND INSPECT. 1 H 7 1 3O NT 3A12 1997111300068 19971113 00068 GL 1997 11 13 97ZZZX4733 3 19971010 G 6111 BLADE CESSNA 150 150 2071802 CE MCAULY 1A100 1A100MCM GL PROPELLER CRACKED D A K NONE O OTHER IN INSP/MAINT 1 SO 25 8474G 3975 15062574 F1268 DURING ROUTINE ANNUAL INSPECTION, THE PROPELLER WAS STRIPPED OF PAINT. AFTER VISUAL INSPECTION, A CRACK MEASURING .5625 INCH IN LENGTH WAS FOUND APPROXIMATELY 14.50 INCHES IN FROM THE TIP OF THE 'FACE' (BACK) OF THE PROPELLER BLADE. THIS CRACK WAS ONLY VISIBLE AFTER THE PAINT WAS REMOVED FROM THE PROPELLER. IT IS RECOMMENDED THE PAINT BE REMOVED FROM THE PROPELLER AT EACH SCHEDULED INSPECTION OF THE AIRCRAFT. CAUSE OF THE CRACK WAS NOT FULLY DETERMINED. 1 H 7 1 3O NT 3A19 5 N P918 1997111300291 19971113 00291 NE 1997 11 13 97ZZZX4737 2 19971010 G 7320 30B1449G N2 PROBE 1240KDC03005 LEAR 60 60LEAR 5170707 CE PWA 305 PW305 NE LT ENG EEC DEFECTIVE D O OTHER X ENGINE FLAMEOUT CR CRUISE 1 CE 03 8271 769 066 252 DURING 40-HOUR FLT, LT ENG COMPUTER LIGHT ILLUMINATED. UPON LANDING, AN 'EA' FAULT (N2 INPUT INTERFACE) IN THE ENG (EDU ) CLEARED AFTER CYCLING PWR. HANDBOOK STATED 'CONT NORMAL ENG OPER". ON NEXT LEG DURING DESCENT THRU 25K FT, LT ENG SH UT DOWN. EDU CONTAINED AN 'EB' FAULT (N2 RATE OR RANGE). FADEC REMOVED WITH BOTH N2 PROBES FROM LT ENG. TESTING OF TH E FADEC REVEALED NO PROB. ONE N2 PROBE HAD A BENT PIN IN THE CONNECTOR. SIGNAL RESULTING FROM THE BENT PIN CREATED AN UNUSUAL SIGNAL FREQ THAT THE FADEC INTERPRETED AS A FLUCTUATING N2 SPEED. FADEC SCHEDULED FUEL TO CORRECT FOR FLUCTUATI NG N2 SPEED. FADEC SCHEDULED FUEL TO CORRECT FOR FLUCTUATING N2 AND FUEL FLOW ROLLED BACK FAR ENOUGH TO FLAME OUT ENG. 2 L 7 2 4F 4 F RT A10CE E35NE 1997111300292 19971113 00292 GL 1997 11 13 97ZZZX4738 2 19971020 G 7323 23057869 GOVERNOR HUGHES 500N 500N 3027374 SW ALLSN 250C 250C20R2 GL ENGINE N2 FAILED C A PO7M A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 WP 07 522FB 9770 638 29255 LN002 CAE832363 DURING FLIGHT, GOVERNOR LOCKED-UP INTERNALLY CAUSING ENGINE TO SPOOL DOWN TO GROUND IDLE. THIS CAUSED ACFT TO MAKE A PR ECAUTIONARY LANDING AT NIGHT ON 10-20-97. 1 G 7 1 3U 3 U NC H3WE E4CE 1997111300293 19971113 00293 NM 1997 11 13 97ZZZX4739 1 19971023 G 2621 DH7 WIRE HARNESS DOUG MD11 MD11 3023602 NM NR 1 FIRE WARN DEFECTIVE H E ENGINE SHUTDOWN N FALSE WARNING CR CRUISE 1 EU 01 103EV 48415 NR 1 ENGINE IN-FLIGHT SHUT DOWN. MAINTENANCE CHECKED 'ENG 1 FIRE' MESSAGE AND AS PRECAUTION, OPENED COWLING, CHECKED A AND B FIRE LOOPS. CONDITION NORMAL. GROUND TEST FOUND LOOP B MESSAGE. AIRCRAFT REJECT TAKEOFF ON NEXT FLIGHT DUE TO ' ENG DET '' WARNING MESSAGE AND SOUND. CHECK FOUND WIRE HARNESS DH7 TERMINAL, CONDITION - NO GOOD. 2 L 7 3 4F RT A22WE 1997111300294 19971113 00294 EU 1997 11 13 97ZZZX4740 1 19971002 G 2435 23079005 GENERATOR BAG JETSTM JETSTM3101 1500215 EU START/GEN FAILED D K NONE O OTHER NR NOT REPORTED 1 WP 07 752JX 60 3466 752 GENERATOR PORTION OF STARTER/GENERATOR FAILED. UNIT FAILED UNDER NORMAL OPERATION AND LOAD. SUSPECT DIODE FAILED. 2 L 7 2 4T RT A21EU 1997111300295 19971113 00295 CE 1997 11 13 97ZZZX4741 1 19971028 G 2435 62581038 FILTER CAPACITOR CESSNA 500 560CESSNA 2076750 CE START/GEN OVERHEATED B CWQR K NONE M OVER TEMP IN INSP/MAINT 1 GL 05 561EJ 3954 5600035 DURING PHASE 1 THROUGH 4 INSPECTION, OBSERVED THE LEFT ENGINE STARTER/GENERTOR R.F. NOISE SUPPRESSION CAPACITOR UNIT HAD EVIDENCE OF EXTREME OVERHEAT. OUTER CASE DISTORTED AND DISCOLORED. TERMINAL ISOLATOR DISTORTED AND CHARRED. CONTINUE D OPERATION COULD HAVE RESULTED IN AN IN-FLIGHT FIRE. 2 L 7 2 4F RT A22CE 1997111300297 19971113 00297 CE 1997 11 13 97ZZZX4743 1 19971027 G 3213 05411989 SPRING ASSY CESSNA 172 R172K 2072431 CE MLG CORRODED D K NONE O OTHER IN INSP/MAINT 1 SW 99 1092V 2283 R1722115 FOUND DURING A SCHEDULED INSPECTION. MAIN LANDING GEAR AND SPRING ASSEMBLY CORRODED AND RUSTY. AIRCRAFT TOTAL TIME 2,2 83.2 HOURS. THE SUSPECT CAUSE WAS FAILURE OF NOT REMOVING GEAR FAIRINGS DURING INSPECTIONS. SUBMITTER RECOMMENDATION I S TO REMOVE FAIRINGS, CLEAN AND PAINT GEAR SPRINGS EACH 100/ANNUAL INSPECTION. 1 H 7 1 3O 3A17 1997111300298 19971113 00298 CE 1997 11 13 97ZZZX4744 1 19971027 G 3213 054119810 SPRING ASSY CESSNA 172 R172K 2072431 CE MLG CORRODED D K NONE O OTHER IN INSP/MAINT 1 SW 99 1092V 2283 R1722115 FOUND DURING A SCHEDULED INSPECTION. MAIN LANDING GEAR AND SPRING ASSEMBLY CORRODED AND RUSTY. AIRCRAFT TOTAL TIME 2,2 83.2 HOURS. THE SUSPECT CAUSE WAS FAILURE OF NOT REMOVING GEAR FAIRINGS DURING INSPECTIONS. SUBMITTER RECOMMENDATION I S TO REMOVE FAIRINGS, CLEAN AND PAINT GEAR SPRINGS EACH 100/ANNUAL INSPECTION. 1 H 7 1 3O 3A17 1997112000094 19971120 00094 CE 1997 11 20 97ZZZX4749 1 19971018 G 2701 0411257 U-JOINT CESSNA 172 172H 2072424 CE LT CONTROL YOKE WORN D A K NONE O OTHER IN INSP/MAINT 1 SO 13 2642L 5887 17255842 DURING ANNUAL INSPECTION, PILOT SIDE CONTROL HAD EXCESS LOOSE MOTION. THE U-JOINT THAT CONNECTS THE CONTROL WHEEL SHAFT TO THE YOKE WAS WORN ENOUGH, THAT IT WAS SOON TO BE HAZARDOUS TO FLIGHT SAFETY. SUMITTER STATED THIS IS THE FOURTH ONE SEEN IN THIS SHAPE. THIS NEEDS TO BE CHECKED AT EACH INSPECTION. 1 H 7 1 3O NT 3A12 1997112000095 19971120 00095 CE 1997 11 20 97ZZZX4750 1 19971018 G 7820 MUFFLER CESSNA 172 172H 2072424 CE RT EXH RISER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 13 2642L 2800 17255842 BOTH MUFFLERS WERE FOUND CRACKED AT RISERS AND BAFFLES WERE COLLAPSED AND HAD BEEN FOR SOME TIME. THIS WOULD NOT ALLOW ENGINE TO DEVELOP FULL POWER. FOUND DURING ANNUAL INSPECTION. 1 H 7 1 3O NT 3A12 1997112000096 19971120 00096 CE 1997 11 20 97ZZZX4751 1 19971018 G 7820 MUFFLER CESSNA 172 172H 2072424 CE LT EXH RISER CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 13 2642L 2800 17255842 BOTH MUFFLERS WERE FOUND CRACKED AT RISERS AND BAFFLES WERE COLLAPSED AND HAD BEEN FOR SOME TIME. THIS WOULD NOT ALLOW ENGINE TO DEVELOP FULL POWER. FOUND DURING ANNUAL INSPECTION. 1 H 7 1 3O NT 3A12 1997112000097 19971120 00097 EU 1997 11 20 97ZZZX4752 2 19971021 G 7260 3353001100 GEARBOX CFMINT CFM56 CFM563B2 13802 EU ASSORY GRBOX FAILURE B P A LY2R K NONE O OTHER NR NOT REPORTED 1 CE 07 213 58633 856647 SUSPECTED GEAR FAILURE INTERNAL TO THE ACCESSORY GEARBOX. GEAR FAILED AND WAS UNCONTAINED IN THE GEARBOX HOUSING. FAIL ED UNIT RETURNED TO SNECMA. 4 F E21EU 1997112000098 19971120 00098 CE 1997 11 20 97ZZZX4753 1 19971029 G 3243 0541139 PLUG CESSNA 210 210N 2073453 CE BRAKE VENT PLUG BROKEN B S DVPR K NONE O OTHER IN INSP/MAINT 1 SO 03 PART RECEIVED FROM STOCK. WHEN SCREWED INTO MASTER CYLINDER BY HAND, SIDE OF PLUG BROKE OFF. A SECOND PLUG WAS INSTALL ED BY HAND AND IT BROKE IN THE SAME AREA. THESE PLUGS ARE MADE FROM BRITTLE PLASTIC AND WERE SUPPLIED BY CESSNA. 1 H 7 1 3O 3A21 1997112000099 19971120 00099 SO 1997 11 20 97ZZZX4754 1 19971017 G 5711 6244802 FITTING PIPER PA28 PA28151 7102805 SO REAR SPAR CORRODED D K NONE O OTHER IN INSP/MAINT 1 WP 09 33810 287515303 DURING INSPECTION PER SB 977 FOUND REAR SPAR CARRY THRU LOWER FITTING (LEFT) BADLY CORRODED. REPLACED PART. 1 L 7 1 3O 2A13 1997112000100 19971120 00100 EA 1997 11 20 97ZZZX4755 2 19971008 G 8550 76152 HOUSING PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA FILTER MOUNT PAD LEAK D K NONE K FLUID LOSS IN INSP/MAINT 1 GL 27 46SD 50 278054040 RL1661948A A FLAW IN THE CASTING NEAR THE UPPER LEFT HAND CORNER OF THE OIL FILTER ADAPTER MOUNTING PAD WAS ALLOWING OIL UNDER PRES SURE TO LEAK THROUGH THE CASTING. THE ENGINE HAD BEEN OVERHAULED BY LYCOMING 50 HOURS PRIOR TO THE OCCURRENCE. 1 L 7 2 3O 3 O 1A10 1E4 1997112000101 19971120 00101 CE 1997 11 20 97ZZZX4756 1 19971030 G 5312 05132823 BULKHEAD CESSNA 172 172N 2072434 CE LT FWD DOORPOST CRACKED B S DVPR K NONE O OTHER IN INSP/MAINT 1 SO 03 733JS 8509 17268335 INSPECTION REVEALED A CRACK IN THE LOWER HINGE LOCATION ON THE LEFT HAND DOORPOST. CRACK WAS APPROXIMATELY 1.25 INCHES LONG. DOORPOST WAS REPLACED. NOTE: CRACK ORIGINATES AT AFT HINGE ATTACH HOLE AND PROGRESSES IN EITHER DIRECTION. 1 H 7 1 3O NT 3A12 1997112000102 19971120 00102 SO 1997 11 20 97ZZZX4757 1 19971009 G 3230 8640902 SWITCH PIPER PA44 PA44180 7104402 SO RT MLG DOWNLOCK SEPARATED D K NONE O OTHER NR NOT REPORTED 1 SW 99 723KD 6465 7731 447995274 DOWN LIMIT SWITCH INTERIOR SEPARATED FROM SWITCH HOUSING, WIRES BECAME JAMMED UNDER DOWNLOCK HOOK CAUSING INCOMPLETE ENG AGEMENT OF HOOK, WHEN SUBJECTED TO SIDELOAD HOOKS DISENGAGED AND GEAR RETRACTED. 1 L 7 2 3O A19S0 1997112000104 19971120 00104 CE 1997 11 20 97ZZZX4759 1 19971030 G 5312 05132823 BULKHEAD CESSNA 172 172N 2072434 CE LT FWD DOORPOST CRACKED B P DVPR K NONE O OTHER IN INSP/MAINT 1 SO 03 734FX 8314 17268829 DURING TROUBLESHOOTING ON THE LEFT HAND DOOR HOLD OPEN STOP, NOTICED WHEN THE DOOR WAS OPENED AGAINST THE STOP, THE BOTT OM FUSELAGE DOOR HINGE ATTACHMENT MOVED. FURTHER INSPECTION REVEALED A CRACK IN THE AFT FORWARD DOORPOST APPROXIMATELY 2.75 INCHES LONG NECESSITATING REPLACEMENT OF THE DOOR POST. AN INSPECTION OF THE FLEET OF 172'S FOUND THE SAME CONDITI ON ON 6 OUT OF 9 AIRCRAFT. M.D. REPORTS WILL BE FILED ON EACH. 1 H 7 1 3O NT 3A12 1997112000105 19971120 00105 CE 1997 11 20 97ZZZX4760 1 19971030 G 5312 051300634 BULKHEAD CESSNA 172 172N 2072434 CE LT FWD DOORPOST CRACKED B S A DVPR K NONE O OTHER IN INSP/MAINT 1 SO 03 734EQ 8176 17268800 INSPECTION REVEALED A CRACK IN THE LOWER DOOR HINGE LOCATION ON THE LEFT HAND DOORPOST. CRACK WAS APPROXIMATELY 1.6250 INCHES LONG. CRACK ORIGINATES AT AFT HINGE ATTACH HOLE AND PROGRESSES IN EITHER DIRECTION. DOORPOST WAS REPLACED. 1 H 7 1 3O NT 3A12 1997112000106 19971120 00106 SO 1997 11 20 97ZZZX4761 1 19971015 G 2430 587837 SWITCH PIPER PA34 PA34200T 7103406 SO BATTERY MASTER FAILED D O A OTHER UNSCHED LANDING H ELECT. POWER LOSS-50 PC CR CRUISE 1 GL 21 7693F 347770068 MASTER SWITCH 'OPENED' INTERNALLY CAUSING COMPLETE ELECTRICAL FAILURE DURING FLIGHT. GEAR WAS EXTENDED BY EMERGENCY MEA NS AND LANDING WAS NORMAL. NEW MASTER SWITCH CORRECTED PROBLEM. 1 L 7 2 3O A7SO 1997112000108 19971120 00108 CE 1997 11 20 97ZZZX4763 1 19971016 G 8120 406C109005 TURBOCHARGER GARRTT CESSNA 210 T210M 2073451 CE CENTER SECT LOOSE D S K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 99 761KC 1438 UIR0136P 21062308 AT ANNUAL INSPECTION, NOTED THE CENTER SECTION WAS LOOSE AT THE BOLTS THAT HOLD THE CENTER SECTION TO THE HOT SIDE OF T HIS UNIT. THIS HAS BEEN LEAKING AS THERE WAS EVIDENCE OF EXHAUST IN THIS AREA. IT IS ASSUMED THESE BOLTS WERE LEFT LOOS E DURING INSTALLATION TO ALLOW TURBO BOLTS TO ALIGN DURING INSTALLATION. SUBMITTER STATED ALL BOLTS AND NUTS SHOULD BE CHECKED FOR TORQUE BEFORE SAFTEYING AND/OR BENDING OVER LOCK TABS. 1 H 7 1 3O 3A21 1997112000109 19971120 00109 SO 1997 11 20 97ZZZX4764 2 19971029 G 8530 SPRING BEECH 55 95C55 1152708 CE CONT O520 IO520C 17032 SO NR 2 CYL EXH VLV BROKEN D K NONE O OTHER IN INSP/MAINT 1 SW 05 9469S 40 TE67 287152R ENGINE RAN ROUGH. INSPECTION FOUND NR 2 EXHAUST OUTER VALVE SPRING BROKEN. 1 L 7 2 3O 3 O 3A16 E5CE 1997112000110 19971120 00110 SO 1997 11 20 97ZZZX4765 1 19971002 G 3230 6703103 FITTING PIPER PA28 PA28R200 7102811 SO LT MLG RETRACT BROKEN B B2ER K NONE O OTHER IN INSP/MAINT 1 EA 23 9392N 3774 28R35102 WHEN INSPECTING LANDING GEAR FOUND FITTING-GEAR RETRACTION, RIGHT AND LEFT, BROKEN WHERE ROD IS MOUNTED. WHEN THIS PART IS BROKEN IT PREVENTS LANDING GEAR TO EXTEND AND LOCK. 1 L 7 1 3O 2A13 1997112000111 19971120 00111 SO 1997 11 20 97ZZZX4766 1 19971002 G 3230 6703102 FITTING PIPER PA28 PA28R200 7102811 SO RT MLG RETRACT BROKEN B A B2ER K NONE O OTHER IN INSP/MAINT 1 EA 23 9392N 3774 28R35102 WHEN INSPECTING LANDING GEAR FOUND FITTING-GEAR RETRACTION, RIGHT AND LEFT, BROKEN WHERE ROD IS MOUNTED. WHEN THIS PART IS BROKEN IT PREVENTS LANDING GEAR TO EXTEND AND LOCK. 1 L 7 1 3O 2A13 1997112000112 19971120 00112 GL 1997 11 20 97ZZZX4767 3 19971029 G 6114 D5858C402 HUB CESSNA 188 T188C 2073012 CE MCAULY D3A34 D3A34C402 GL NR 3 SOCKET CRACKED B PI4R K NONE O OTHER IN INSP/MAINT 1 SO 07 9675K T18803966T 891723 INSPECTION FOUND HUB CRACKED (OVER 3 INCHES LONG) ON FRONT OF NR 3 BLADE SOCKET AND AROUND BOTH LIPS OF NR 3 BLADE SOCKE T. NR 3 BLADE BEARING BROKEN AND BUTT AREA OF NR 3 BLADE DAMAGED BEYOND REPAIRABLE LIMITS (BLADE MODEL: G90DFA-10). S CRAP HUB SENT TO MCCAULEY FOR EVALUATION. CAUSE OF CRACK UNKNOWN. 1 L 7 1 3O A9CE 5 C P47GL 1997112000113 19971120 00113 CE 1997 11 20 97ZZZX4768 1 19971029 G 3242 06603300 LINING PARKERHANFIN 99448 CESSNA 310 310R 2074245 CE LT MLG BRAKE WORN B A B3OR K NONE K FLUID LOSS IN INSP/MAINT 1 SW 03 98834 310R0603 BRAKE LINING WORN THIN. CALIPER PISTON OUT TOO FAR ALLOWING FLUID TO BYPASS O-RINGS OR FLUID LEVEL WAS LOW FROM CALIPER LEAK AND NO FLUID IN MASTER CYLINDER. O-RINGS LOOKED GOOD. 1 L 7 2 3O 3A10 1997112000115 19971120 00115 SO 1997 11 20 97ZZZX4770 1 19971015 G 2150 22045402 ACM AIRESRCH EMB 120 EMB120RT SO DEFECTIVE H K NONE O OTHER IN INSP/MAINT 1 SO 19 21778 348 69512 ACM UNSATISFACTORY DUE TO HIGH FRICTION FROM BEARING. LIGHT WEAR FOUND ON SHAFT AND RADIAL BEARINGS. SUSPECT CAUSE OF FAILURE: CONTAMINATION AND POSSIBLE ENVIRONMENT. SUBMITTER RECOMMENDS PERIODIC SERVICE OF WATER/PARTICLE SEPARATOR PER MANUFACTURER'S MM. 2 L 7 2 4T RT A31SO 1997112000116 19971120 00116 NM 1997 11 20 97ZZZX4771 1 19971031 G 3252 65445787 MANIFOLD 65447714 BOEING 737 7373T0 1384582 NM SHIMMY DAMPER CHAFED B DM4R K NONE O OTHER IN INSP/MAINT 1 SO 19 TSC2519 INSPECTION FOUND MANIFOLD ASSY OF DAMPER ASSY CHAFED DUE TO HOSE RUBBING ON OUTSIDE DIAMETER OF COMPENSATOR LOCATION. R EPEAT DEFECT. 2 L 7 2 4F RT A16WE 1997112000117 19971120 00117 NM 1997 11 20 97ZZZX4772 1 19971031 G 2121 X11375 BEARING SUNDSTRANDEM 215201 BOEING 727 727232 1384082 NM FAN FAILED B DM4R K NONE O OTHER IN INSP/MAINT 1 SO 19 713 252 FAN BALL BEARING STARTING TO COME APART. PARTIAL FAILURE OF BEARING. 712.42 HOURS SINCE NEW PART INSTALLED. 2 L 7 3 4F A3WE 1997112000118 19971120 00118 NM 1997 11 20 97ZZZX4773 1 19971031 G 2121 X11374 BEARING SUNDSTRANDEM 215201 BOEING 737 737232 1384475 NM FAN FAILED B DM4R K NONE O OTHER IN INSP/MAINT 1 SO 19 713 FAN BEARING FAILED (BALL BEARING). BEARING CAME APART. ALSO, CAUSED DAMAGE TO END BELL 11840-1. 712.42 HOURS SINCE NE W PART WAS INSTALLED. 2 L 7 2 4F RT A16WE 1997112000119 19971120 00119 WP 1997 11 20 97ZZZX4774 2 19970923 G 7323 8954932 PISTON AIRESRCH 8954907 GARRTT TPE331 TPE3315 01514 WP TURB GOV LEAK B A DJFR K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 23 P459C WHEN PARTS ARE MANUFACTURED, THEY ARE PAINTED WITH ZINC CHROMATE. SUBMITTER HAS FOUND ON NEARLY EVERY GOVERNOR DISASSEM BLED FRAGMENTS AND LARGE AMOUNTS OF PAINT LODGED UNDER O-RINGS WHERE THEY CONTACT SEALING AREAS. THEY CAUSE INTERNAL LE AKS AND EXTERNAL LEAKS AT THE CONTROL SHAFT. RECOMMEND ELIMINATION OF CHROMATE PRIMER ON PISTON AND COVER ASSY. 4 T E4WE 1997112000120 19971120 00120 CE 1997 11 20 97ZZZX4775 1 19971104 G 5753 CC50380 BEARING CESSNA 500 S550 2076607 CE FLAP ATTACH WORN B CWQR K NONE O OTHER IN INSP/MAINT 1 GL 05 211QS 0011 DURING AIRCRAFT INSPECTION, DETERMINED THE FLAP ATTACH BEARINGS WERE WORN. RETRIEVED TWO NEW BEARINGS FROM STOCK. INSP ECTED NEW BEARINGS. ONE BEARING HAD COTTER KEY HOLE DRILLED TOO FAR DOWN ON THREADED PORTION OF SHANK TO ALLOW PROPER A TTACHMENT OF NUT. THE OTHER BEARING HAD TWO COTTER KEY HOLES DRILLED IN IT, PERPENDICULAR FROM EACH OTHER. 1 L 7 2 4F RT A22CE 1997112000121 19971120 00121 CE 1997 11 20 97ZZZX4776 1 19971104 G 5753 CC50380 BEARING CESSNA 500 S550 2076607 CE FLAP ATTACH MISMANUFACTURED B CWQR K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 05 211QS 0011 DURING AIRCRAFT INSPECTION, DETERMINED THE FLAP ATTACH BEARINGS WERE WORN. RETRIEVED TWO NEW BEARINGS FROM STOCK. INSP ECTED NEW BEARINGS. ONE BEARING HAD COTTER KEY HOLE DRILLED TOO FAR DOWN ON THREADED PORTION OF SHANK TO ALLOW PROPER A TTACHMENT OF NUT. THE OTHER BEARING HAD TWO COTTER KEY HOLES DRILLED IN IT, PERPENDICULAR FROM EACH OTHER. 1 L 7 2 4F RT A22CE 1997112000122 19971120 00122 SW 1997 11 20 97ZZZX4777 1 19971023 G 6230 206010443001 BEARING BELL 206 206B3 1181506 SW M/R MAST FAILED B IIFR K NONE O OTHER IN INSP/MAINT 1 SW 03 374M 193 19213 4161 FOUND M/R MAST BEARING INNER RACE BREAKING DOWN. 1 G 7 1 3U H2SW 1997112000123 19971120 00123 CE 1997 11 20 97ZZZX4778 1 19971029 G 7810 K1250860M203 EXHAUST CESSNA 210 T210N 2073456 CE TURBO INLET CRACKED B S A B3OR K NONE O OTHER IN INSP/MAINT 1 SW 03 9403Y 230 21064498 WHILE CHANGING A CRACKED TURBO INLET (PN K1250860M-105), THE HEAT EXCHANGER WAS FOUND CRACKED. OUT OF 4 AIRCRAFT WITH T HIS STC EXHAUST, ALL 4 HAVE HAD THE TURBO INLETS CRACK. THE REPLACEMENTS ARE ASSEMBLED DIFFERENTLY, APPARENTLY TO PREVE NT THIS PROBLEM. THE HEAT EXCHANGER IS THE SECOND ONE FOUND CRACKED AT THE WELD LINE WHERE THE NR 6 CYLINDER RISER ATTA CHES. 1 H 7 1 3O 3A21 1997112000124 19971120 00124 EA 1997 11 20 97ZZZX4779 2 19970924 G 8520 72877 LIFTER BEECH 23 C23 1151242 CE LYC O360 O360A4J 41514 EA NR 2 CYLINDER BROKEN G K NONE K FLUID LOSS IN INSP/MAINT 1 GL 19 1851Z 1770 M2343 L1892236A TEAR DOWN REVEALED ALL LIFTER BODY HEADS BROKEN OFF AT CAM CONTACT POINT. BROKEN PIECES THEN LODGED BETWEEN CAM LOBES A ND ENGINE CASE RESULTING IN THE ENGINE CASE BEING CRACKED AND BROKEN IN SEVERAL PLACES AND LOSS OF ENGINE OIL. SUSPECT INITIAL FAILURE OF NR 2 CYLINDER INTAKE LIFTER BODY. POSSIBLE METAL FATIGUE. PIECES FROM THIS WERE DEPOSITED BENEATH O THER BODIES CAUSING FURTHER BREAKAGE. 1 L 7 1 3O 3 O A1CE E286 1997112000514 19971120 00514 WP 1997 11 20 97ZZZX4786 2 19971007 G 7250 30714314 EXHAUST NOZZLE GARRTT TFE731 TFE7313 01518 WP BEARING FLANGE MISREPAIRED B L IY2R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 15 1539 OP017939 EXHAUST NOZZLE WAS SENT TO REPAIR AND OVERHAUL SHOP FOR REPAIR OF INNER BEARING BORE FLANGE. INSPECTION OF PART FOLLOWI NG 'REPAIR' REVEALED THE FOLLOWING DISCREPANCIES. INNER BEARING BORE WAS NOT REPAIRED. PART WAS MODIFIED TO PN 3077095 -4. THIS PART IS USED WHEN C/W SB 72-3482. REWORKS SECTION AIRWORTHINESS TAG STATES 'PART HAS BEEN WORKED AND INSPECTE D IAW MANUAL NR 72-02-15 REVISION 00'. THIS MANUAL DOES NOT CONTAIN ANY BEARING FLANGE OR MODIFICATION DATA TO REWORK T HIS NOZZLE FROM PN 3071431-4 TO PN 3077095-4. 4 F E6WE 1997112000515 19971120 00515 1997 11 20 97ZZZX4787 4 19971029 G 2561 PO201 LIFE VEST EAAEROMARINE INFLATE TUBE FAIL TEST B KO1R K NONE L NO TEST IN INSP/MAINT 1 EA 25 C03137 FAILED THE MANUFACTURER'S 2-POUND PSI INFLATION TEST. 1997112000516 19971120 00516 1997 11 20 97ZZZX4788 4 19971029 G 2561 P0201105 LIFE VEST EAAEROMARINE CELLS FAIL TEST B KO1R K NONE L NO TEST IN INSP/MAINT 1 EA 25 H24916 FAILED THE MANUFACTURER'S 2-POUND PSI INFLATION TEST. 1997112000517 19971120 00517 1997 11 20 97ZZZX4789 4 19971001 G 2561 P0101C LIFE VEST EAAEROMARINE INFLATE TUBE FAIL TEST B KO1R K NONE L NO TEST IN INSP/MAINT 1 EA 25 C92873 FAILED THE MANUFACTURER'S 2-POUND PSI INFLATION TEST. 1997112000518 19971120 00518 1997 11 20 97ZZZX4790 4 19971001 G 2561 P0201 LIFE VEST EAAEROMARINE TUBE FAIL TEST B KO1R K NONE L NO TEST IN INSP/MAINT 1 EA 25 C03470 FAILED THE MANUFACTURER'S 2-POUND PSI INFLATION TEST. 1997112000519 19971120 00519 1997 11 20 97ZZZX4791 4 19971001 G 2561 M3L8 LIFE VEST PANAVION SEAM FAIL TEST B KO1R K NONE L NO TEST IN INSP/MAINT 1 EA 25 352 FAILED THE MANUFACTURER'S 2-POUND PSI INFLATION TEST. 1997112000520 19971120 00520 1997 11 20 97ZZZX4792 1 19971016 G 2810 FLAPPER VALVE USRUBBER 3538013511 FUEL CELL STUCK D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 01 W2507 UPON RECEIVING OVERHAULED LEFT WING FUEL CELL, FOUND FLAPPER VALVE IN FUEL TANK STUCK CLOSED AND COULD NOT BE OPENED. 1997112000521 19971120 00521 CE 1997 11 20 97ZZZX4793 1 19971001 G 5711 CARRY THRU SPAR CESSNA 210 T210L 2073449 CE CABIN OVERHEAD CORRODED D S K NONE O OTHER IN INSP/MAINT 1 EA 07 121RJ 21059735 INSPECTION FOUND CABIN OVERHEAD CARRY-THROUGH SPAR CORRODED WHERE FRESH AIR DUCT PASSES THROUGH. SUSPECT DISSIMILAR ME TAL CONTACT. 1 H 7 1 3O 3A21 1997112000522 19971120 00522 CE 1997 11 20 97ZZZX4794 1 19971108 G 5350 10210002617 FAIRING BEECH 58 58P 1152744 CE LT WING DEFORMED B RF1R K NONE O OTHER IN INSP/MAINT 1 SW 01 132Z 4990 TJ284 UPON INSPECTION OF AIRCRAFT, NOTED LT WING INBOARD FAIRING DENTED AND DEFORMED. WING HAD JUST BEEN REMOVED AND REINSTAL LED FOR A STRUCTURAL INSPECTION 7.5 HOURS PRIOR. 1 L 7 2 3O A23CE 1997112000523 19971120 00523 CE 1997 11 20 97ZZZX4795 1 19971108 G 3230 GEARBOX BEECH 58 58P 1152744 CE LANDING GEAR OUT OF RIG B RF1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 132Z 4990 8 TJ284 UPON INSPECTION OF AIRCRAFT, THE LANDING GEAR HAD NO INTERNAL GEAR CLEARANCE IN ACTUATOR GEARBOX. AIRCRAFT HAD BEEN RIG GED 7.5 HOURS PRIOR AFTER THE NOSE GEAR FORWARD ROD END HAD BEEN REPLACED. 1 L 7 2 3O A23CE 1997112000524 19971120 00524 EA 1997 11 20 97ZZZX4796 2 19971104 G 8530 CYLINDER PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA NR 2 CYL BARREL CRACKED D A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SO 16 162ER 3000 282 2841152 L1478339A THE PILOT REPORTED A ROUGH ENGINE AND MADE A PRECAUTIONARY LANDING. A COMPRESSION GAUGE REVEALED THE NR 2 CYLINDER LEAK ING BETWEEN THE HEAD AND BARREL (6 INCHES FROM THE MOUNTING FLANGE). THIS IS BETWEEN THE COOLING FINS AT THE BASE OF TH E EXHAUST PORT. THE CRACK IS ABOUT 4 INCHES LONG. THE CYLINDER WAS WAS REMOVED AND A NEW ONE INSTALLED. 1 L 7 1 3O 3 O 2A13 E274 1997112000525 19971120 00525 CE 1997 11 20 97ZZZX4797 1 19970922 G 3240 581710240 BRAKE LINE CESSNA 402 402C 207590R CE LT MASTER CYL FAILED D K NONE K FLUID LOSS IN INSP/MAINT 1 SO 16 3246M 15038 402C0294 THE LT MASTER CYLINDER BRAKE LINE CRACKED BECAUSE CONTINUAL FLEXING DURING BRAKING CAUSED THE LINE TO CRACK AT THE 180-D EGREE END. 1 L 7 2 3O A7CE 1997112000526 19971120 00526 CE 1997 11 20 97ZZZX4798 1 19971105 G 3222 0543034497 TORQUE LINK CESSNA 182 182G 2072716 CE NLG CRACKED D A K NONE O OTHER IN INSP/MAINT 1 GL 05 3281S 4848 18255781 DURING AN ANNUAL INSPECTION, THE UPPER TORQUE LINK OF THE NOSE LANDING GEAR WAS FOUND CRACKED IN THE RADIUS OF THE UPPER FORGED RIB ADJACENT TO THE ATTACH BOLT HOLE. BOTH SIDES WERE CRACKED. 1 H 7 1 3O NT 3A13 1997112000527 19971120 00527 SW 1997 11 20 97ZZZX4799 1 19971020 G 3250 STEERING SYSTEM MOONEY M20 M20L 5870221 SW RUD-NLG FAILED D S A O OTHER O OTHER LD LANDING 1 SO 05 3426X 3399 DURING TOUCH AND GO LANDING, LOST CONTROL OF ACFT FOLLOWING TOUCH DOWN. ACFT RECEIVED SUBSTANTIAL DAMAGE AFTER VEERING TO LEFT. NLG BROKE AND RT MLG COLLAPSED. IT IS BELIEVED RUDDER NLG STEERING SYSTEM BOLT SHEARED. 1 L 7 1 3O RT 2A3 1997112000528 19971120 00528 CE 1997 11 20 97ZZZX4800 1 19971031 G 5511 RIB CESSNA 150 152 2071835 CE HORIZONTAL STAB CRACKED B S A AIHR K NONE O OTHER IN INSP/MAINT 1 GL 11 4837P 7200 15284828 INSPECTION FOUND FAR RIGHT RIB IN HORIZONTAL STABILIZER CRACKED. LOWER CRACK FOUND TO BE 1 INCH, WHILE TOP, .75 INCH. T HESE CRACKS ARE OVER AND BELOW THE ELEVATOR HINGE ATTACH POINT. IF NOT FOUND, COULD, IN TIME, CAUSE SEPARATION OF ELEVA TOR FROM STABILIZER. 1 H 7 1 3O NT 3A19 1997112000529 19971120 00529 CE 1997 11 20 97ZZZX4801 1 19971030 G 2720 24670014 TORQUE TUBE CESSNA 172 172RG 2072438 CE RUDDER CONTROL BROKEN D S A O OTHER F FLT CONT AFFECTED NR NOT REPORTED 1 SW 13 6529V 7969 172RG0755 PILOT REPORTED LOSS OF RUDDER CONTROL IN-FLIGHT ALTHOUGH HE WAS ABLE TO MAINTAIN CONTROL OF THE AIRCRAFT AND MADE AN UNE VENTFUL LANDING. FOUND THE AFT (RIGHT HAND) RUDDER PEDAL TORQUE TUBE WAS BROKEN APPROXIMATELY 7/8 OF THE WAY AROUND THE TUBE JUST TO THE LEFT SIDE OF THE SECTOR GEAR. THIS ALLOWED THE TWO SECTOR GEARS TO DISENGAGE WHICH UNSYNCHRONIZED THE TWO TORQUE TUBES. BECAUSE OF THIS, THE RUDDER CABLE TENSION WAS UNABLE TO BE MAINTAINED. 1 H 7 1 3O 3A17 1997112000530 19971120 00530 SO 1997 11 20 97ZZZX4802 1 19971105 G 8120 LW31S444 BOLT LW18302 PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA LEFT ENGINE FAILED G K NONE O OTHER NR NOT REPORTED 1 AL 01 7164D 318052013 L859461A TURBOCHARGER MOUNT LOWER RIGHT HAND ATTACH BOLT LOOSENED AND VIBRATED UNTIL THE NUT AND COTTER KEY FAILED. BOLT THEN DE PARTED THE ENGINE. 1 L 7 2 3O 3 O A20SO E14EA 1997112000531 19971120 00531 GL 1997 11 20 97ZZZX4803 3 19971022 G 6111 M10083 BLADE CESSNA 208 208B 2073701 CE HARTZL H3B3M HCB3M GL BLADE FACE CRACKED C A K NONE O OTHER IN INSP/MAINT 1 NE 01 931FE 5378 2091 9865 208B0031 6B256 INSPECTION FOUND ALL 3 BLADES HAVE CHORDWISE CRACKS BEYOND THE 3.5 INCH LIMIT. ALL CRACKS LEAD UP TO AND POSSIBLY UNDER THE EROSION SHIELD. THE CRACKS WERE FOUND DURING INSPECTION PER HARTZELL JB 169A. PROPELLER REMOVED FROM SERVICE AT T HIS TIME. 1 H 7 1 3T A37CE 5 C P9NE 1997112000532 19971120 00532 GL 1997 11 20 97ZZZX4804 3 19971022 G 6111 M10083 BLADE CESSNA 208 208B 2073701 CE HARTZL H3B3M HCB3M GL BLADE FACE CRACKED C K NONE O OTHER IN INSP/MAINT 1 NE 01 931FE 5378 2091 9870 208B0031 6B256 INSPECTION FOUND ALL 3 BLADES HAVE CHORDWISE CRACKS BEYOND THE 3.5 INCH LIMIT. ALL CRACKS LEAD UP TO AND POSSIBLY UNDER THE EROSION SHIELD. THE CRACKS WERE FOUND DURING INSPECTION PER HARTZELL JB 169A. PROPELLER REMOVED FROM SERVICE AT T HIS TIME. 1 H 7 1 3T A37CE 5 C P9NE 1997112000533 19971120 00533 GL 1997 11 20 97ZZZX4805 3 19971022 G 6111 M10083 BLADE CESSNA 208 208B 2073701 CE HARTZL H3B3M HCB3M GL BLADE FACE CRACKED C K NONE O OTHER IN INSP/MAINT 1 NE 01 931FE 5378 2091 9872 208B0031 6B256 INSPECTION FOUND ALL 3 BLADES HAVE CHORDWISE CRACKS BEYOND THE 3.5 INCH LIMIT. ALL CRACKS LEAD UP TO AND POSSIBLY UNDER THE EROSION SHIELD. THE CRACKS WERE FOUND DURING INSPECTION PER HARTZELL JB 169A. PROPELLER REMOVED FROM SERVICE AT T HIS TIME. 1 H 7 1 3T A37CE 5 C P9NE 1997112000534 19971120 00534 NM 1997 11 20 97ZZZX4806 1 19971001 G 2780 SWIVEL JOINT BOEING 727 727251 138408H NM LE SLAT ACTUATOR LEAKED D K NONE K FLUID LOSS CR CRUISE 1 SW 99 252US 19971 ON DHL CHARTER FLIGHT HYD/ARL, TOTAL A-SYSTEM HYDRAULIC FAILURE REPORTED INTO AUCKLAND. AIRCRAFT REQUIRED TOW FROM RUNW AY. HYDRAULIC LEAK TRACED TO LOOSE SWIVEL JOINT ON L/E SLAT ACTUATOR. SWIVEL JOINT CORRECTLY TIGHTENED AND SYSTEM REPL ENISHED. AIRCRAFT OPERATED BY KITTY HAWK AIRLINES. 2 L 7 3 4F A3WE 1997112000535 19971120 00535 CE 1997 11 20 97ZZZX4807 1 19971023 G 5753 35165050231 BRACKET BEECH 300 300BEECH 1152930 CE RT OTBD FLAP SUP WORN D S K NONE O OTHER IN INSP/MAINT 1 CE 01 770GX 2228 RIGHT OUTBOARD FLAP SUPPORT BRACKET WORN AT INBOARD AFT ROLLER BRACKET P/N 35-165050-31. ROLLER FRETTED INTO BRACKET WE ARING ABOUT HALF WAY THROUGH METAL. SAME AS AD 97-14-16 ON 1900 BEECH. 2 L 7 2 4T A24CE 1997112000536 19971120 00536 CE 1997 11 20 97ZZZX4808 1 19971020 G 2740 45AS61023137 ACTUATOR BEECH MU300 400A 1155402 CE PITCH TRIM MALFUNCTIONED B KI2R H DEACTIVATE SYST/CIRCUITS F FLT CONT AFFECTED CR CRUISE 1 CE 01 85CR 970611 RK22 PILOTS NOTED AUTOPILOT WOULD NOT TRIM AIRCRAFT. PILOT DE-SELECTED AUTOPILOT AND TRIM FUNCTIONED CORRECTLY IN MANUAL MOD E 'NORMAL' POSITION, HOWEVER, WOULD NOT FUNCTION WHEN 'EMERGENCY' TRIM WAS SELECTED. ON THE GROUND, BOTH 'NORMAL' AND ' EMERGENCY' POSITIONS WORKED. AUTOPILOT OUTPUTS TESTED OK. PITCH ACTUATOR REPLACED. AIRCRAFT FUNCTIONED NORMALLY. SPE CIFIC FAILURE OR CAUSE UNKNOWN AT THIS TIME. 2 H 7 2 4F RT A16SW 1997112000537 19971120 00537 EU 1997 11 20 97ZZZX4809 1 19971014 G 7170 0174078010 VALVE AEROSP SA365 SA365N1 8680668 EU START DRAIN LEAKS B KY1R K NONE K FLUID LOSS IN INSP/MAINT 1 EA 07 95MD 4174 A66B 6320 START DRAIN VALVE UNIT LEAKS. REPAIR AS NECESSARY. 1 G 7 2 3U H10EU 1997112000538 19971120 00538 GL 1997 11 20 97ZZZX4810 2 19971016 G 7532 23053176 BLEED VALVE BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL ENGINE STICKING D O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 NM 11 37488 447 FF28030 2188 CAE823399 VALVE APPARENTLY IS STICKING IN THE CLOSED POSITION AND DOES NOT OPEN UP WHEN POWER DEMAND IS DECREASED. THIS CREATES A MOMENTARY COMPRESSOR STALL RESULTING IN GUNSHOT TYPE SOUNDS COMING FROM THE EXHAUST ON THE TURBINE. 1 G 7 1 3U 3 U H2SW E4CE 1997112000539 19971120 00539 WP 1997 11 20 97ZZZX4811 1 19971105 G 7170 A7297 DRAIN TUBE ROBSIN R44 R44 7640120 WP RT FIREWALL LEAKS D A K NONE O OTHER IN INSP/MAINT 1 NE 01 159RP 95 0342 DRAIN TUBE OPENING IS LOCATED INSIDE AIRFRAME IN TRANSMISSION AREA. WHEN SUMP DRAIN VALVE LEAKS, FUEL DRAINS INTO AND A CCUMULATES AT JUNCTION OF FIREWALLS CREATING EXTREME FIRE HAZARD. SUBMITTER RECOMMENDS REVISING THE SUMP DRAIN PLUMBING ALA R22 SYSTEM TO PROVIDE POSITIVE OVERBOARD VENTING OF FUEL IN THE EVENT OF DRAIN VALVE SEEPAGE. REF: R44 IPC FIG 8- 5, ITEMS 8 AND 10. 1 G 7 1 3O H11NM 1997112000540 19971120 00540 EA 1997 11 20 97ZZZX4812 2 19970831 G 7420 P LEAD BBAVIA 7 7GCBC 1220601 SW LYC O320 O320A2B 41508 EA LT-RT MAG SHORTED G L A A UNSCHED LANDING Y ENGINE STOPPAGE NR NOT REPORTED 1 EA 17 1880G 50 FORCED LANDING DUE TO ENGINE STOPPAGE. INVESTIGATION DETERMINED ENGINE STOPPAGE DUE TO WIRE BETWEEN MASTER SWITCH LOCAT ED ABOVE AND LEFT OF PILOT'S HEAD AND THE OVERVOLTAGE RELAY LOCATED ON RIGHT UPPER SIDE OF ENGINE FIREWALL BECOMING EXTR EMELY HOT. THE EXTREME TEMPERATURE MELTED WIRE'S INSULATION AND P-LEAD WIRES IN SAME WIRE BUNDLE. THIS SHORTED THE LEF T AND RIGHT MAGNETOS CAUSING ENGINE TO CEASE OPERATION. THERE IS NO CIRCUIT PROTECTION FOR THE WIRE IN QUESTION BETWEEN MASTER SWITCH AND OVERVOLTAGE RELAY. SUBMITTER SUGGESTED A SB TO REQUIRE A BREAKER SWITCH BE INSTALLED IN PLACE OF STA NDARD MASTER SWITCH AND THIS SB BE MANDATED BY AD. 1 H 7 1 3O 3 O NC A759 E274 1997112000541 19971120 00541 CE 1997 11 20 97ZZZX4813 1 19971114 G 8011 ESEBB142A BENDIX DRIVE MHB4014 BEECH 76 76 1153005 CE STARTER FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 99 258 BENDIX DRIVER FAILED AFTER 194 HOURS, REPLACED WITH SAME, FAILED AFTER 62 HOURS, REPLACED WITH SAME, FAILED AFTER 396.6 HOURS. REPLACED WITH EBB142A. EBB142A FAILED TO EXTEND AT 258 HOURS, CLEANED AND LUBED PER MFG, FAILED TO EXTEND AFTER 21 HOURS. 1 L 7 2 3O A29CE 1997112000731 19971120 00731 CE 1997 11 20 97ZZZX4814 1 19971108 G 5741 105090A0321UJ CRUSH WASHER BEECH 58 58P 1152744 CE LT WING BOLT DEFORMED B A RF1R K NONE O OTHER IN INSP/MAINT 1 SW 01 132Z 8 TJ284 UPON INSPECTION OF AIRCRAFT, FOUND LEFT WING SETTING AT A HIGHER ANGLE OF INCIDENCE. FURTHER INSPECTION REVEALED THE UP PER AFT CRUSH WASHER AND BOLT HAD SLIPPED DOWN APPROXIMATELY .25 INCH CAUSING LEFT WING TO HAVE MORE LIFT. AIRCRAFT HAD JUST FINISHED WITH A STRUCTURAL INSPECTION. ALL EIGHT WING BOLTS WERE REMOVED AND MAGNAFLUXED. THE CRUSH WASHER CLEAR LY HAD 2 SETS OF SERRATIONS WHERE IT HAD SLIPPED AND WAS RETORQUED. 1 L 7 2 3O A23CE 1997112000732 19971120 00732 CE 1997 11 20 97ZZZX4815 1 19971108 G 5312 00244002455 BULKHEAD BEECH 58 58P 1152744 CE AFT FUSELAGE MISINSTALLED B RF1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 132Z 8 TJ284 UPON INSPECTION OF AIRCRAFT, FOUND AFT FUSELAGE BULKHEAD IMPROPERLY RIVETED. RIVET HEADS CLEARLY HAVE DENTS ALMOST LOOK ING LIKE WRONG SET WAS USED TO DRIVE RIVETS. MOST OF THE UPSET ENDS WERE NOT PROPERLY BURRED. ALL RIVETS WERE REMOVED AND REPLACED AND PROPERLY RIVETED. 1 L 7 2 3O A23CE 1997112000733 19971120 00733 CE 1997 11 20 97ZZZX4816 1 19971108 G 5260 00243007621 STEP BEECH 58 58P 1152744 CE RT SIDE CRACKED B RF1R K NONE O OTHER IN INSP/MAINT 1 SW 01 132Z 4990 8 TJ284 UPON INSPECTION OF AIRCRAFT, FOUND RIGHT SIDE ASSIST STEP CRACKED WHERE IT HAD BEEN WELDED 7.5 HOURS AGO. 1 L 7 2 3O A23CE 1997112000734 19971120 00734 CE 1997 11 20 97ZZZX4817 1 19970825 G 2701 15131682 WHEEL CESSNA 172 172D 2072410 CE PILOT YOKE BROKE D O OTHER O OTHER LD LANDING 1 NM 09 21089 2770 17249608 PILOT CONTROL YOKE BROKE, LEFT SIDE BOTTOM, IN LANDING FULL STALL CONDITION. PLASTIC MAY HAVE AGED. AIRCRAFT IS A 1962 MODEL AND HAS BEEN PARKED OUTSIDE MOST OF THE TIME. 1 H 7 1 3O NT 3A12 1997112000735 19971120 00735 SO 1997 11 20 97ZZZX4818 1 19971101 G 2410 BELT PIPER PA32 PA32R301 7103218 SO ALT DRIVE FAILED G A A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CR CRUISE 1 EA 13 415WR 160 3246072 AIRCRAFT ON IFR FLIGHT PLAN LOST ALL ELECTRICAL POWER. LANDED WITHOUT ACCIDENT. INSPECTION REVEALED THE ALTERNATOR IDL E PULLEY WHICH TENSIONS THE BELT WAS CHAFING ON A COWLING STIFFENER CAUSING THE BELT TO TEAR. THIS IS A NEW AIRCRAFT, T OTAL TIME, 159.8 HOURS. PIPER SERVICE CENTER STATED A SL WAS ISSUED TO RELOCATE THE STIFFENER, BUT THIS AIRCRAFT WAS OV ERLOOKED AT THE DISTRIBUTER. 1 L 7 1 3O A3SO 1997112000736 19971120 00736 SO 1997 11 20 97ZZZX4819 1 19971101 G 7810 4701402 BRACKET PIPER PA31 PA31P 7103120 SO RT EXHAUST FAILED D A O OTHER O OTHER CL CLIMB 1 SO 01 7325L 317400206 DURING TAKEOFF, RT TAILPIPE FELL OFF AIRCRAFT. EXHAUST BURNED A HOLE IN LOWER COWL. INVESTIGATION FOUND ISOLATOR BRACK ETS BROKEN, AND ALL EXHAUST SLIP JOINTS LOOSE. SUSPECT LOOSE JOINTS CAUSED VIBRATION THAT BROKE ISOLATOR BRACKET. SUBM ITTER RECOMMENDS THE EXHAUST SYSTEM BE PRESSURE TESTED TO FIND LOOSE SLIP JOINTS. 1 L 7 2 3O A8EA 1997112000737 19971120 00737 SO 1997 11 20 97ZZZX4820 2 19971011 G 8530 CYLINDER BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO RT ENG NR 4 FAILED D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SW 15 82LB 148 TH910 1720929CX PILOT REPORTED RIGHT ENGINE RUNNING ROUGH. INVESTIGATION FOUND NR 4 CYL HEAD SEPARATED FROM BARREL. THE CYLINDER HAD B EEN INSTALLED 148 HOURS BEFORE. RECENTLY OVERHAULED. TOTAL TIME ON CYLINDERS ARE NOT RECORDED. SUBMITTER RECOMMENDS T HAT CYLINDERS BE SCRAPPED AFTER THEIR SECOND RUN OR TIME LIFE LIMIT BE ESTABLISHED BY THE MFG ON CURRENT PRODUCTION ENGI NE. 1 L 7 2 3O 3 O 3A16 E5CE 1997112000738 19971120 00738 1997 11 20 97ZZZX4821 4 19971113 G 2564 R0297A109 RAFT EAAEROMARINE T12 TEMP TIES MISPACKED D L K NONE O OTHER IN INSP/MAINT 1 SO 19 WHILE CONDUCTING A PRELIMINARY INSPECTION ON RAFT, TEMPORARY WEB TIES WERE FOUND INSTALLED. THESE TIES ARE USED AS SHOP AIDS FOR PACKING THE RAFT AND MUST BE REMOVED BEFORE THE UNITS ARE RETURNED TO SERVICE. 1997112000739 19971120 00739 SW 1997 11 20 97ZZZX4822 1 19971028 G 6320 20604562101 SUNGEAR 206040002029 BELL 206 206B3 1181506 SW TRANSMISSION WORN H A K NONE O OTHER IN INSP/MAINT 1 NM 11 55TV 2998 B122661 3788 SPLINES SEVERELY WORN AND 3 CRACKED. SUSPECT CAUSE DUE TO LENGTH OF CALENDAR TIME INSTALLED INDICATING A BREAK DOWN OF THE LUBRICANT. PERIOD OF INSTALLATION WAS 13 YEARS. SUBMITTER RECOMMENDS A CALENDAR LIMITATION OF 4 YEARS AS WELL AS T HE EXISTING HOURLY FREQUENCY. 1 G 7 1 3U H2SW 1997112000741 19971120 00741 SW 1997 11 20 97ZZZX4824 1 19971023 G 6410 212010750105 BLADE BELL 205 205A1 1181414 SW T/R BLADE TIP FAILED B GDMR A UNSCHED LANDING E VIBRATION/BUFFET NR NOT REPORTED 1 NM 09 58HJ A9635 30314 WHILE CARRYING OUT OPERATIONS ON THE AFTERNOON OF 10-23-97, PILOT REPORTED INCREASE OF VIBRATION WHILE IN-FLIGHT RETURNI NG TO LANDING SITE. AIRCRAFT WAS SHUT DOWN. ON EXAMINATION OF TAIL ROTOR, INSIDE PART OF TIP WAS FOUND MISSING. NO OT HER DAMAGE WAS APPARENT AND SUBSEQUENT TAIL ROTOR REPLACMENT AND BALANCING CURED PROBLEM. (X) 1 G 7 1 4U H1SW 1997112000743 19971120 00743 CE 1997 11 20 97ZZZX4826 1 19971028 G 2435 BEARING CESSNA 525 525 2076601 CE START/GEN FAILED D O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 SO 09 31SG 100 5250207 PILOT REPORTED RT GENERATOR FAILURE. UPON INITIAL INSPECTION, THE RT STARTER/GENERATOR HAD A STRONG BURNT SMELL. AFTER FURTHER INSPECTION, DISCOVERED THE ARMATURE SUPPORT BEARING HAD FAILED AND PIECES OF THE BEARING CAGE HAD SHORTED THE S TARTER/GENERATOR COMPONENTS. 1 L 7 2 4F RT A1WI 1997112000744 19971120 00744 CE 1997 11 20 97ZZZX4827 1 19971030 G 2742 45AS61023137 ACTUATOR BEECH MU300 400A 1155402 CE PITCH TRIM FAILED D K NONE O OTHER NR NOT REPORTED 1 GL 05 197PF 59 970704 RK33 THE PILOT REPORTED THE PITCH TRIM ACTUATOR FAILED IN THE STANDBY MODE. AIRCRAFT SYSTEMS WERE CHECKED AND FOUND TO BE OK . REPLACED THE PITCH TRIM ACTUATOR WITH A NEW UNIT. SUBMITTER STATED THIS IS THE 4TH ACTUATOR TO BE INSTALLED SINCE JA NUARY, 1997. THE AUTOPILOT SYSTEM OF THE AIRCRAFT OPERATES THROUGH THE STANDBY MOTOR ON THIS ACTUATOR; THUS, AFFECTING THE OPERATION OF THE AIRCRAFT. AIRCRAFT TOTAL TIME: 2,261.1 HOURS. 2 H 7 2 4F RT A16SW 1997112000745 19971120 00745 EU 1997 11 20 97ZZZX4828 1 19971017 G 2450 724440250AV2 TERMINAL BLOCK BRAERO DH125 BAE125800A 1500285 EU ELECT PANEL OVERHEATED D K NONE M OVER TEMP IN INSP/MAINT 1 GL 07 526M 5097 258032 AFTER FINDING OUT ABOUT THE PROBLEM THAT ANOTHER BAE125 HAD WITH TERMINAL STRIP, INSPECTED N526M AND FOUND TERMINAL STRI P HM TO ALSO BE DISTORTED AND OVERHEATED. THE TERMINAL STRIP WAS REPLACED WITH A NEW ONE AND 6 WIRES HAD TERMINALS REPL ACED THAT WERE ALSO OVERHEATED. 2 L 7 2 4F RT A3EU 1997112000747 19971120 00747 NE 1997 11 20 97ZZZX4830 2 19971005 G 7412 103832251 EXCITER BOLKMS 117 BK117A4 5626017 EU LYC LTS101 LTS101650B1 41560 NE NR 1 ENGINE FAILED B R7MR K NONE O OTHER IN INSP/MAINT 1 NM 11 118LF 869 95284159 7137 LE45135E IGNITION EXCITER UNIT INOPERATIVE. FAILED TO IGNITE ENGINE. REPLACED WITH NEW UNIT, CORRECTED PROBLEM. 1 G 7 2 3U 3 U H13EU E5NE 1997112000748 19971120 00748 EU 1997 11 20 97ZZZX4831 1 19971019 G 7170 0174078010 VALVE AEROSP SA365 SA365N1 8680668 EU START DRAIN LEAKS B KY1R K NONE K FLUID LOSS IN INSP/MAINT 1 EA 07 38MD 831 C187B 6335 DRAIN VALVE LEAKS AT SEAMS. 1 G 7 2 3U H10EU 1997112000749 19971120 00749 EU 1997 11 20 97ZZZX4832 1 19970821 G 6320 4638302024 BEARING BOLKMS 105 BO105CBS 5626008 EU M/R GEARBOX SPALLED B EOPR K NONE O OTHER IN INSP/MAINT 1 AL 01 492HL 4105 S803 TRANSMISSION RECEIVED FOR METAL IN OIL. INSPECTION REVEALED NOTHING ABNORMAL EXCEPT LT INPUT PINION AND 4638-302-024 BE ARING HAD A FEW SLIGHT DENTS OR MARKS IN ROLLERS AND ROLLER PATH ON PINION. BEARING WAS CUT APART AND THE OUTER RACE WA S FOUND VERY SPALLED. REPAIRED TRANSMISSION. REPLACED BEARING. 1 G 7 2 3U NC H3EU 1997112600104 19971126 00104 NE 1997 11 26 97ZZZX4837 1 19971105 G 7120 698609 STABILIZER RING SKRSKY S64 S64A 8142504 NE RING TO FLANGE CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 STABILIZER RING ATTACHES THE REAR SUPPORT SYSTEM TO THE FREE TURBINE ASSEMBLY. IT IS NOT AN ENGINE MOUNT BUT A DAMPER M OUNT. THIS PART WAS FOUND CRACKED AT ONE OF THE RING TO FLANGE TRANSITION POINTS. THE CRACK GOES FROM ONE SIDE OF THE RING TO THE OTHER, AND EXTENDS APPROXIMATELY 0.500 INCH ON EACH SIDE. THIS DEFECT WAS FOUND DURING FLUORESCENT PENETRAN T INSPECTION (FPI). PART DOES NOT HAVE A FINITE LIFE. THE CRACK WAS DETECTED VISUALLY. 2 G 7 2 4U H1EA 1997112600105 19971126 00105 CE 1997 11 26 97ZZZX4838 1 19971023 G 2913 LEE PLUG CESSNA 210 210C 2073412 CE HYD PWR PACK MISSING B L NA3R O OTHER K FLUID LOSS AP APPROACH 1 WP 11 3670Y 3839 13 21058170 THE HYDRAULIC POWER PACK FAILED WHEN PILOT ATTEMPTED TO EXTEND LANDING GEAR. THE HYDRAULIC POWER PACK LOST ALL PRESSURE AND DUMPED HYDRAULIC FLUID OUT THE BACK. THE AIRCRAFT LANDED GEAR UP. SENT HYDRAULIC POWER PACK TO THE COMPANY THAT O VERHAULED UNIT IN 1994. THIS COMPANY'S EVALUATION OF THE POWER PACK'S FAILURE WAS DUE TO A MISSING LEE PLUG AND STATED THE LEE PLUG HOLE IS OVERSIZED AND WILL NOT HOLD WHEN PRESSURE IS APPLIED. 1 H 7 1 3O 3A21 1997112600106 19971126 00106 1997 11 26 97ZZZX4839 3 19971107 G 6112 RA12884 DEICE BOOT RAPCO BEECH 80 65B80 1152812 CE NR 2 PROP WIRES FAILED C K NONE O OTHER IN INSP/MAINT 1 GL 15 110BA 1345 LD279 DEICE BOOT LEAD BREAKS 12 INCHES FROM TERMINALS AFTER FOLLOWING NEW INSTALLATION SUGGESTIONS. 1 L 7 2 3O 3A20 1997112600107 19971126 00107 1997 11 26 97ZZZX4840 3 19971003 G 6112 RA12884 DEICE BOOT RAPCO BEECH 80 65B80 1152812 CE NR 1 PROP WIRES FAILED C S K NONE O OTHER IN INSP/MAINT 1 GL 15 107BA 540 LD358 DEICE BOOT LEADS ARE CONTINUING TO BREAK APPROXIMATELY 12 INCHES FROM THE TERMINALS EVEN AFTER RAPCO'S NEW INSTALLATION SUGGESTIONS. 1 L 7 2 3O 3A20 1997112600108 19971126 00108 SO 1997 11 26 97ZZZX4841 1 19971016 G 2750 6273800 BRACKET PIPER PA28 PA28140 7102802 SO FLAP CONTROL CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 04 16JP 5000 2825956 CRACKS AT CORNER RADIUS OF ATTACH FLANGE ON FLAP HANDLE SUPPORT BRACKET. 1 L 7 1 3O 2A13 1997112600109 19971126 00109 SO 1997 11 26 97ZZZX4842 2 19971028 G 7322 63291611 FUEL METERING CESSNA 340 340A 2076405 CE CONT O520 TSIO520NB 17040 SO ENGINE FUEL OBSTRUCTED G A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 NM 04 118BH 183 C109311AR 340A0003 290962 PILOT NOTED REDUCED FUEL FLOW AND SOME POWER LOSS ON CLIMB-OUT. RETURNED TO AIRPORT. INVESTIGATION FOUND .3750 INCH LO NG BY .1250 INCH WIDE PIECE OF FERROUS MATERIAL LODGED IN FUEL METERING UNIT DOWNSTREAM OF INLET SCREEN RESTRICTING FUEL FLOW. OBJECT SENT TO TCM ANALYZATION LAB. SOURCE OF OBJECT DETERMINED TO HAVE ORIGINATED FROM CLEANING BATH POROUS ME DIA. 1 L 7 2 3O 3 O 3A25 E8CE 1997112600110 19971126 00110 GL 1997 11 26 97ZZZX4843 1 19971112 G 2823 FU560 SELECTOR VALVE AMTR LANCAR LANCAIR 05616TS GL FUEL SELECTOR MISMANUFACTURED G A K NONE O OTHER IN INSP/MAINT 1 WP 01 477RM 12 LIV060 POST-ACCIDENT INVESTIGATION BY THE NTSB DISCOVERED THE FUEL SELECTOR VALVE SUPPLIED BY THE KIT MANUFACTURER WAS FOUND MO DIFIED FROM ORIGINAL DESIGN CONFIGURATION. THE VALVE WAS MODIFIED BY A 'NON-MANUFACTURER SOURCE'. THE CONFIGURATION OF THE VALVE WAS CHANGED FROM AN 'OFF/LEFT/RIGHT' OPERATION TO A 'OFF/BOTH/LEFT/RIGHT' MODE OF OPERATION. THE KIT MANUFAC TURER DOES NOT RECOMMEND A 'BOTH' POSITION FOR THESE AIRCRAFT. TESTS SHOWED WHEN ONE FUEL TANK WAS EMPTY AND THE OPPOSI TE TANK WAS BEING USED, THE SUBJECT VALVE WOULD ALLOW AIR FROM THE EMPTY TANK TO BE DRAWN INTO THE FUEL SYSTEM; THUS, CA USING OVERLY LEAN MIXTURES AND/OR INTERRUPTION IN FUEL FLOW. 1 L 7 1 3O RT EXPA1L71 1997112600111 19971126 00111 CE 1997 11 26 97ZZZX4844 1 19971110 G 5312 05132823 BULKHEAD CESSNA 172 172N 2072434 CE LT FWD DOOR POST CRACKED B DVPR K NONE O OTHER IN INSP/MAINT 1 SO 03 734UC 8613 17269116 INSPECTION REVEALED A CRACK APPROXIMATELY 1.1250 INCHES LONG ON THE LT AFT SECTION OF THE FORWARD DOOR POST. CRACK STAR TS ON THE REAR HOLE OF THE LOWER DOOR HINGE ATTACHMENT. CRACK PROGRESSES EITHER SIDE FROM HOLE. 1 H 7 1 3O NT 3A12 1997112600112 19971126 00112 CE 1997 11 26 97ZZZX4845 1 19971110 G 5312 051300634 BULKHEAD CESSNA 172 172N 2072434 CE LT FWD DOOR POST CRACKED B DVPR K NONE O OTHER IN INSP/MAINT 1 SO 03 734UC 8613 17269116 INSPECTION REVEALED A CRACK APPROXIMATELY 1.1250 INCHES LONG ON THE LT AFT SECTION OF THE FORWARD DOOR POST. CRACK STAR TS ON THE REAR HOLE OF THE LOWER DOOR HINGE ATTACHMENT. CRACK PROGRESSES EITHER SIDE FROM HOLE. 1 H 7 1 3O NT 3A12 1997112600113 19971126 00113 1997 11 26 97ZZZX4846 4 19971025 G 3416 5035P ENCODER PIPER PA46 PA46310P 7104605 SO END SHAKE HANG UP B EI4R K NONE O OTHER IN INSP/MAINT 1 SO 15 701TF 4608104 INCOMING INSPECTION, TWO CRITICAL SHAFTS IN THE MECHANISM HAD ZERO END SHAKE. THE OVERHAUL MANUAL CALLS OUT A MINIMUM E ND SHAKE OF .0020 INCH. THE ZERO END SHAKE CONDITION IN SIMILAR INSTRUMENTS HAS CAUSED THE POINTERS TO HANG UP IN DESCE NT AFTER A 1-1/2 HOUR COLD SOAK AT 35 DEGREES FAHRENHEIT. THE FACTORY HAS INDICATED THAT AN END SHAKE OF .0004 INCH OR LESS WILL CAUSE POINTER HANG-UPS AFTER A COLD TEST. 1 L 7 1 3O A25SO 1997112600114 19971126 00114 SO 1997 11 26 97ZZZX4847 1 19971027 G 7160 8547402 AIRBOX PIPER PA28 PA28181 7102807 SO INDUCTION AIR CRACKED B SL5R K NONE O OTHER IN INSP/MAINT 1 NE 03 9258N 317 2843014 DURING ANNUAL INSPECTION, FOUND INDUCTION AIRBOX CRACKED. CRACKS WERE IN CARBURETOR INLET VALVE PORTION OF BOX ON EITH ER SIDE OF CARBURETOR ATTACHMENT ADAPTER. SUSPECT CAUSE OF CRACKS IS EXCESSIVE SIDE LOADING OF DUCT THAT ATTACHES AIRBO X TO THE AIR INLET ON LEFT SIDE OF COWLING. IF DUCT ATTACHMENT AT COWL WAS PLACED AT A BETTER ANGLE, THE SIDE LOAD WOUL D BE REDUCED. IN ORDER TO DRAIN THE CARBURETOR BOWL, THE AIRBOX MUST BE REMOVED FROM THE CARBURETOR. ALSO, THE SUPPORT CLAMP FOR THE CARBURETOR HEAT CONTROL CABLE CHAFES ONE OF THE ENGINE MOUNT TUBES. A RE-ROUTED LONGER CONTROL CABLE SHO ULD ELIMINATE CHAFE PROBLEM. 1 L 7 1 3O 2A13 1997112600115 19971126 00115 WP 1997 11 26 97ZZZX4848 1 19971113 G 2722 AN2616 BOLT 59140665501 DOUG DC9 DC932 3022066 WP RUD ACTUATOR BENT B A MZ2R K NONE O OTHER IN INSP/MAINT 1 GL 13 620NW 145 47533 DISCOVERED ON PRIMARY INSPECTION, 2 EACH BOLTS (DC9 IPC 27-20-8, FIG 2, IT 320), P/N AN26-16, SEVERELY BENT, PARTIALLY S HEARED. LINK (DC9 IPC 27-20-8, FIG 2, IT 345), P/N 3914065-3. UPPER EAR BENT, LOWER EAR BROKEN WITH SECTION MISSING. U NABLE TO LOCATE MISSING SECTION. 2 L 7 2 4F A6WE 1997112600116 19971126 00116 WP 1997 11 26 97ZZZX4849 1 19971113 G 2722 39140653 LINK DOUG DC9 DC932 3022066 WP LOWER EAR BROKEN B A MZ2R K NONE O OTHER IN INSP/MAINT 1 GL 13 620NW 145 47533 DISCOVERED ON PRIMARY INSPECTION, 2 EACH BOLTS (DC9 IPC 27-20-8, FIG 2, IT 320), P/N AN26-16, SEVERELY BENT, PARTIALLY S HEARED. LINK (DC9 IPC 27-20-8, FIG 2, IT 345), P/N 3914065-3. UPPER EAR BENT, LOWER EAR BROKEN WITH SECTION MISSING. U NABLE TO LOCATE MISSING SECTION. 2 L 7 2 4F A6WE 1997112600117 19971126 00117 NE 1997 11 26 97ZZZX4850 2 19971103 G 7314 0253231013 PUMP BEECH 90 F90 1152909 CE PWA PT6 PT6A135 52043 NE LT ENG FUEL FAILED D K NONE O OTHER NR NOT REPORTED 1 GL 21 701NC 4878 1577 8680 LA55 PCE92163 LEFT ENGINE HIGH PRESSURE FUEL PUMP FAILED. DISASSEMBLY REVEALED DRIVE COUPLER SPLINES WORN OUT ON PUMP. OIL MISTING H OLE PLUGGED, SPLINES RUNNING DRY. THIS CONDITION CAN BE REVEALED BY PUSHING A PIPE CLEANER INTO PUMP DRAIN CAVITY. RUS T DEPOSITS INDICATE LACK OF LUBRICATION TO DRIVE COUPLER. RECOMMEND PERIODIC INSPECTION OF PUMP DRAINS FOR THIS CONDITI ON. 1 L 7 2 4T 4 T A31CE E4EA 1997112600118 19971126 00118 WP 1997 11 26 97ZZZX4851 2 19971104 G 7240 PLENUM BEECH 100 B100 1152919 CE GARRTT TPE331 TPE3316 01514 WP RT ENG FAILED D L A C ABORTED TAKEOFF A J FLAME/FIRE WARNING INDICATION TO TAKEOFF 1 EA 17 400AC 9187 850 BE12 P27009 ENG FAILURE AT T/O. CREW HEARD A LOUD POP, THE RT ENG ITT TEMP ROSE AND FLAMES FROM THE RT ENG. UNABLE TO KILL THE ENG USING THE EMERG CUTOFF LEVER, LEVER WAS JAMMED. THE ENG WAS SHUT DOWN USING THE FIREWALL SOV. FIRE BOTTLE WAS DISCHAR GED AND FIRE WAS PUT OUT. THE LEFT ENG SECURED AND ACFT EVAC. INSP REVEALED THAT THE PLENUM CASE BROKE OPEN RADIALLY T OWARD THE TOP OF THE ENG. THE OPENED PART WAS JAMMED BEHIND THE EMERG CUTOFF LEVER RENDERING IT INOP. INSP OF THE PLEN UM CASE SUGGESTS THAT A CRACK BEGAN AT THE POINT WHERE THE WELDS OF BLEED AIR, AND THE P3 BOSSES COME TOGETHER. THE CRA CK PROGRESSED TO WHERE THE PLENUM FAILED IN SUCH A WAY THAT THE SHEET METAL RIPPED OPEN TOTAL IS 24 INCHES. 1 L 7 2 4T 4 T A14CE E4WE 1997112600119 19971126 00119 SW 1997 11 26 97ZZZX4852 1 19971111 G 2913 PV304426 PUMP VICKERS MX534590C FRCHLD SA227 SA227DC 3377521 SW RT ENG HYD LEAKING B VH2R K NONE K FLUID LOSS IN INSP/MAINT 1 SW 17 459DF 9 DC803M PILOT REPORTED HYDRAULIC LEAK RT ENGINE. MECHANIC FOUND RT ENGINE HYDRAULIC PUMP LEAKING AT AFT END OF CASE. PUMP REMO VAL REVEALED THREE OF FOUR VALVE PLATE AND CONTROLS SUBASSEMBLY MOUNTING SCREWS SHEARED CAUSING LEAKAGE. 2 L 7 2 4T RT A18SW 1997112600276 19971126 00276 WP 1997 11 26 97ZZZX4860 1 19971003 G 5210 90210001 DOOR HUGHES 369 369HS 4470728 WP CABIN RT MAIN DEPARTED D L A O OTHER D INFLIGHT SEPARATION CR CRUISE 1 WP 09 831FG 830511S DURING FLIGHT, THE RIGHT MAIN DOOR OPENED, THEN DEPARTED THE AIRCRAFT. THE DOOR HINGES WERE MODIFIED BY THE INSTALLATIO N OF QUICK REMOVAL DOOR HINGES STC SH2530 NM. DISCOVERED DURING INSPECTION THAT THE LATCHING FEATURE USED WAS NOT PROPE RLY ENGAGED ALLOWING THE DOOR TO DEPART THE HELICOPTER. SUBMITTER STATED THE STC DOES NOT CONTAIN PRE-FLIGHT INFORMATIO N FOR THE PILOT TO FOLLOW. THE STC NEEDS TO BE REVISED TO INCORPORATE PILOT INFO. 1 G 7 1 3U H3WE 1997112600277 19971126 00277 NE 1997 11 26 97ZZZX4861 2 19971023 G 7210 446746 BEARING 758300 PWA JT8 JT8D217 52053 NE N2 GEARBOX FAILED D K NONE O OTHER NR NOT REPORTED 1 SW 05 15446 708486 ENGINE REMOVED FROM SERVICE DUE TO IN-FLIGHT SHUT DOWN FOR LOW OIL PRESSURE. DISASSEMBLY REVEALED FAILURE OF OIL PUMP D RIVE GEAR FORWARD BEARING IN THE N2 GEARBOX. CAUSE OF THE BEARING FAILURE IS UNDER INVESTIGATION BY GREENWICH. 4 F E9NE 1997112600280 19971126 00280 NM 1997 11 26 97ZZZX4864 1 19971001 G 5730 PANEL BOEING 727 72730 1384008 NM LT WING NR 15 LEAKING H L A UNSCHED LANDING K FLUID LOSS CR CRUISE 1 SW 99 113 18935 DEFECT - IN-FLIGHT LEAK FROM LEFT WING. FOUND 9 LOOSE FASTENERS ON INBOARD END OF FUEL ACCESS PANEL NR 15 ON LEFT WING. SUSPECT IMPROPER TORQUE OF FASTENERS DURING LAST HEAVY MAINTENANCE VISIT. RE-TORQUED FASTENERS IAW BOEING MM 28-11-21 . ADDITIONALLY, MARKED FASTENERS WITH ALIGNMENT MARKS TO AID VISUAL INSPECTION. RE-FUELED AIRCRAFT. NO FURTHER LEAKS NOTED. 2 L 7 3 4F A3WE 1997112600281 19971126 00281 NE 1997 11 26 97ZZZX4865 2 19971007 G 7320 ACL102 ACTUATOR BOEING 107 1072 9420604 EA GE CT58 CT581401 30011 NE NR 1 ENGINE MALFUNCTIONED B CHIR K NONE O OTHER NR NOT REPORTED 1 NM 09 P2CHD 1324 027 2003 ENGINE WOULD BEEP UP, BUT NOT DOWN. EMERG SYS WORKED AS REQUIRED. FOUND THE SYS WOULD APPEAR TO WORK NORMALLY ON THE G ROUND, BUT WOULD FAIL DURING RAPID CLTV INPUTS. EVEN THE EMERGENCY SYSTEM FAILED TO BREAK IT FREE. TAPPING THE UNIT WI TH A SCREW DRIVER 'BROKE' THE SYSTEM FREE ALLOWING 'NORMAL'OPS. REPLACED THE ACTUATOR. RESUMED OPERATIONS. TROUBLESHO OTING FOUND THE ACTUATOR WAS 'SLOW' AND NOTICEABLY QUIETER THAN THE NORMALLY OPERATING NR 2 ENG ACTUATOR. INSTALLED ACT UATOR S/N 038; TT NEW. THIS UNIT AT FIRST APPEARED TO WORK ALSO. THEN IT TOO WOULD FAIL UNDER CLTV INPUT, QUIET AND SL OW. 2 G 7 2 4U 4 U 1H16 1E3 1997120400222 19971204 00222 CE 1997 12 4 97ZZZX4866 1 19971006 G 7602 5038901021 CONTROL CABLE BEECH 55 95A55 1152704 CE MIXTURE BROKEN B EBTR K NONE O OTHER IN INSP/MAINT 1 GL 09 12CM 52 TC300 RIGHT MIXTURE CABLE WORKING FINE AND SMOOTH. MADE FLIGHT, ENGINE WOULD NOT SHUT DOWN. FOUND CABLE BROKEN AT WELD JOINT ON ENGINE END UNDER SOLID SHEATH. INSTALLED NEW CABLE. 1 L 7 2 3O 3A16 1997120400223 19971204 00223 CE 1997 12 4 97ZZZX4867 1 19971010 G 2434 DOFF10300J ALTERNATOR FORD BEECH 23 C24R 1151254 CE DC SYSTEM FAILED B NV2R A UNSCHED LANDING H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 CE 07 23993 227 5090305 MC476 ALTERNATOR FAILED IN IMC. AIRCRAFT WAS LANDED GEAR UP. SUBSTANTIAL DAMAGE. NO INJURIES. INSTALLED NEW ALTERNATOR. O PS CHECKED OK. FAILED ALTERNATOR OVERHAUL. ON 11-15-96. INSTALLED 5-19-97. 1 L 7 1 3O A1CE 1997120400224 19971204 00224 GL 1997 12 4 97ZZZX4868 3 19971111 G 6114 D4885C61 HUB CESSNA 337 337C 2075712 CE MCAULY 2AF34C D2AF34C61 GL NR 2 SOCKET CRACKED A A K NONE O OTHER IN INSP/MAINT 1 GL 07 2543S 683261 3370843 683261 A CRACK WAS FOUND IN THE REAR OF BLADE SOCKET NR 2 DURING A DYE PENETRANT INSPECTION. THE HUB WAS RED TAGGED AND RETIRE D FROM SERVICE. THE PROPELLER HAD BEEN IN SERVICE 3 YEARS SINCE LAST OVERHAUL AND AD 91-15-04 HAD BEEN C/W AT THAT TIME . 1 H 7 2 3O A6CE 5 C P5EA 1997120400225 19971204 00225 CE 1997 12 4 97ZZZX4869 1 19971016 G 3234 MS25126E SWITCH CESSNA 340 340CESSNA 2076404 CE GEAR SELECT FAILED B BXSR O OTHER J WARNING INDICATION AP APPROACH 1 EA 09 340JE 5304 3400046 LANDING GEAR WOULD NOT EXTEND WHEN GEAR DOWN WAS SELECTED. GEAR WAS MANUALLY EXTENDED WITH NO PROBLEM. TROUBLESHOT AND FOUND THE GEAR POSITION SELECTOR SWITCH WOULD REMAIN OPEN IN THE DOWN POSITION. SWITCH REPLACED. 1 L 7 2 3O 3A25 1997120400226 19971204 00226 EA 1997 12 4 97ZZZX4870 2 19971101 G 8520 CRANKCASE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA NR 2 CYL BOSS CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 SW 99 3525B 1440 317952121 L397661A DURING TROUBLESHOOTING OF OIL LEAK, A CRACK IN THE ENGINE CASE WAS DISCOVERED. CRACK RUNS FROM LIFTER OIL GALLEY 1 INCH FORWARD OF AND ABOVE NR 2 CYLINDER BOSS TO 9 O'CLOCK POSITION ON CYLINDER BOSS HOLE. A SECOND CRACK INSIDE THE CASE PA RALLELS THE OUTER CASE CRACK EXCEPT IT STARTS AT THE UPPER FORWARD CYLINDER BASE STUD IN THE 11 O'CLOCK POSITION. THE T WO THRU-BOLTS AT REAR OF NR 2 CYLINDER WERE ALSO LOOSE IN THE CASE. CYLINDER NUTS WERE TIGHT. 1 L 7 2 3O 3 O A20SO E14EA 1997120400227 19971204 00227 GL 1997 12 4 97ZZZX4871 3 19970930 G 6114 HUB CESSNA 210 210C 2073412 CE MCAULY 2A34C D2A34C49 GL MT FLANGE CRACKED B RC2R K NONE O OTHER IN INSP/MAINT 1 NE 03 3674Y 886 21058174 757098 PROPELLER INSPECTION FOUND 2 CRACKS DURING DYE PENETRANT INSPECTION. CRACKS APPEAR TO BEGIN FROM STUD HOLE AND PROGRESS OVER THE EDGE TO HUB MOUNTING FLANGE SURFACE. 1 H 7 1 3O 3A21 5 C P3EA 1997120400228 19971204 00228 SO 1997 12 4 97ZZZX4872 2 19971101 G 7414 M3081 POINTS SLICK CESSNA 182 182L 2072726 CE CONT O470 O470R 17026 SO MAG WEAK B FE6R A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 NM 11 42818 613 6210 18259203 1919918R FOUND POINTS WITH VERY LOW SPRING TENSION. CAUSED ENGINE TO RUN ROUGH AND QUIT IN FLIGHT AT HIGHER RPM'S. 1 H 7 1 3O 3 O NT 3A13 E273 1997120400229 19971204 00229 GL 1997 12 4 97ZZZX4873 3 19970805 G 6114 C98 HUB CESSNA 188 A188B 2073005 CE MCAULY 2A34C D2A34C98 GL NR 1 SOCKET CRACKED D A K NONE O OTHER IN INSP/MAINT 1 NM 03 800 18802473T 921076 PROPELLER IN FOR RESEAL AND A CRACK WAS FOUND IN THE BLADE RETENTION THREADS OF NR 1 HUB SOCKET. THE CRACK HAD NOT YET GONE THROUGH THE HUB TO THE OUTSIDE. 1 L 7 1 3O A9CE 5 C P3EA 1997120400230 19971204 00230 SO 1997 12 4 97ZZZX4874 1 19971119 G 2140 COMBUSTION LINER JANITROL 65D793 PIPER PA31 PA31350 7103110 SO HEATER CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 05 4108D 486 8813071F 318352018 HEATER FAILED PRESSURE DECAY TEST. UPON REMOVAL, CRACK WAS NOTED IN COMBUSTION LINER. 1 L 7 2 3O A20SO 1997120400231 19971204 00231 1997 12 4 97ZZZX4875 4 19971112 G 6122 B20897 TOP COVER MCAULY C290D3T23 PROP GOVERNOR FAILED B ME4D K NONE O OTHER IN INSP/MAINT 1 SO 15 8860617 UPON INSPECTION OF GOVERNOR, TOP COVER WAS FOUND COMPLETELY BROKEN OFF. NEW TOP COVER WAS INSTALLED AND DEFECTIVE COVER WAS SCRAPPED. 1997120400232 19971204 00232 1997 12 4 97ZZZX4876 4 19971106 G 6122 DRIVE GEAR D210680 BEECH 35 35BEECH 1151502 CE CRACKED B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 1748420KMY INSPECTION FOUND GOVERNOR DRIVE GEAR CRACKED. INDICATION STARTED BETWEEN TEETH AND EXTENDED AROUND CORNER. 1 L 7 1 3O A777 1997120400233 19971204 00233 GL 1997 12 4 97ZZZX4877 3 19971106 G 6114 HUB ARM PIPER PA23 PA23160 7102304 SO HARTZL HC82 HC82VL2 GL PROPELLER CRACKED B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 633 K2861N INSPECTION FOUND CRACK ON OUTSIDE RADIUS OF NR 1 HUB ARM APPROXIMATELY 1 INCH LONG. 1 L 7 2 3O 1A10 5 C P23EA 1997120400234 19971204 00234 EA 1997 12 4 97ZZZX4878 2 19971113 G 7414 10349234 DISTRIBUTOR GEAR S4LN1227 PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA ENG LT MAG FAILED B UC2R A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 GL 19 40024 2515 519 A181618 28R7737128 L17006651A PILOT REPORTED ENGINE RUNNING VERY ROUGH DURING ROUTINE TRAINING FLIGHT. THE AIRCRAFT RETURNED TO THE AIRPORT AND MADE AN UNEVENTFUL LANDING. AN INSPECTION OF THE LEFT MAGNETO WAS PERFORMED AND THE DISTRIBUTOR GEAR WAS FOUND TO HAVE SEVER AL MISSING TEETH AND WAS BROKEN INTO THREE SEPARATE PIECES. 1 L 7 1 3O 3 O 2A13 1E10 1997120400235 19971204 00235 EA 1997 12 4 97ZZZX4879 2 19971108 G 8530 LW13623 PISTON CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA CYLINDER NR 1 FAILED D K NONE O OTHER IN INSP/MAINT 1 GL 19 64874 985 15281457 L1510615 INSPECTION FOUND HALF OF PISTON SKIRT BROKEN AWAY AND MISSING FROM BOTTOM RING GROOVE TO JUST BEFORE EACH PISTON PIN BOS S. OWNER HAD REPORTED AN INCREASE IN OIL COMSUMPTION. VISUAL INSPECTION OF ENGINE WAS OK. CYLINDER COMP ALL CHECKED 7 0 OVER 80 OR BETTER. OIL CHANGE WAS NOT DUE FOR ANOTHER 25 HOURS. BOTTOM SPARK PLUGS SHOWED ONLY VERY LITTLE OIL DAMPN ESS ON CYLINDER NR 1. HOWEVER, A 'POP' COULD BE HEARD DURING THE COMP CHECK OF CYLINDER NR 1 JUST AS THE PISTON PAST TD C (IT SOUNDED SIMILAR TO THE MAG IMPULSE). FURTHER CHECKS FOUND THE OIL QUICK DRAIN HARD TO OPERATE (PLUGGED WITH DEBRI S) AND, OF COURSE, THE OIL FILTER CONTAMINATED. 1 H 7 1 3O 3 O NT 3A19 E223 1997120400236 19971204 00236 CE 1997 12 4 97ZZZX4880 1 19971118 G 7120 MOUNT CESSNA 206 TU206G 2073357 CE ENGINE SHOCK FAILED B RF1R K NONE O OTHER IN INSP/MAINT 1 SW 01 61DW 620604257 FORWARD ENGINE SHOCK MOUNTS FLATTENED CAUSING OIL TEMPERATURES TO INCREASE. INSTALLED NEW ENGINE SHOCK MOUNTS WHICH RAI SED OIL COOLER INTO PROPER AIR STREAM FOR BETTER COOLING. 1 H 7 1 3O A4CE 1997120400237 19971204 00237 GL 1997 12 4 97ZZZX4881 3 19970930 G 6111 S90A BLADE CESSNA 210 210C 2073412 CE MCAULY 2A34C D2A34C49 GL RETAIN THREAD CRACKED B S RC2R K NONE O OTHER IN INSP/MAINT 1 NE 03 3674Y 886 C437YS 21058174 757098 CRACK FOUND DURING PROPELLER DYE PENETRANT INSPECTION. CRACK PRESENT IN RETENTION THREAD. 1 H 7 1 3O 3A21 5 C P3EA 1997120400238 19971204 00238 CE 1997 12 4 97ZZZX4882 1 19971106 G 2430 A7002C7 RELAY CESSNA 206 U206G 2073356 CE GEN REV CUR SHORTED B RF1R K NONE H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 SW 01 9959R B77901 U20607000 GENERATOR WOULD NOT STAY ON LINE, FOUND REVERSE CURRENT RELAY FULL OF WATER WHICH SHORTED RELAY. AIRCRAFT SAT OUTSIDE I N HEAVY RAIN. SUGGEST SEALING ELECTRICAL BOX WITH NEOPHRENE GASKET AND WIRE BUNDLE WITH SILICON. THIS AIRCRAFT IS A SO LOY CONVERSION. 1 H 7 1 3O A4CE 1997120400239 19971204 00239 CE 1997 12 4 97ZZZX4883 1 19971119 G 2823 VALVE CESSNA 210 T210N 2073456 CE FUEL SELECTOR DEFECTIVE B RF1R K NONE O OTHER IN INSP/MAINT 1 SW 01 4891U 4177 21064834 LEFT/RIGHT FUEL TANK NOT FEEDING ENGINE EQUALLY. LT FUEL QUANTITY SLOWER TO EMPTY. ACTING LIKE ONLY FEEDING FROM RT TA NK. FUEL RETURN PORTION OF FUEL SELECTOR INTERNALLY LEAKING CAUSING RETURN FUEL FLOW TO LT TANK ONLY. RESEAL FUEL SELE CTOR VALVE. 1 H 7 1 3O 3A21 1997120400240 19971204 00240 EU 1997 12 4 97ZZZX4884 1 19971009 G 2161 9599020134 VALVE PILATS PC12 PC12 7090550 EU CABIN TEMP FAILED D K NONE O OTHER IN INSP/MAINT 1 EA 07 612PC 436 146 PILOT REPORTED AIRCRAFT HAD NO HEAT. TROUBLESHOT E.C.S. SYSTEM. FOUND HEAT VALVE INOPERABLE. WOULD NOT OPERATE IN AUT O OR MANUAL MODES. REPLACED VALVES. OPS CHECKED GOOD. 1 L 7 1 3T RT A78EU 1997120400241 19971204 00241 EU 1997 12 4 97ZZZX4885 1 19970917 G 2161 9599020134 VALVE PILATS PC12 PC12 7090550 EU CABIN TEMP FAILED D K NONE O OTHER IN INSP/MAINT 1 EA 07 1TC 1114 1957676 130 PILOTS AND OWNERS REPORT THE COCKPIT AND CABIN ARE GETTING TOO HOT AND CANNOT CONTROL TEMPERATURE WITH THE E.C.S. IN AUT OMODE AND THE MANUAL MODE. VISUALLY INSPECTED TEMPERATURE CONTROL VALVE AND CANNOT SEE VALVE OPENING OR CLOSING. 1 L 7 1 3T RT A78EU 1997120400242 19971204 00242 CE 1997 12 4 97ZZZX4886 1 19971105 G 3230 08421201 LINKAGE CESSNA 310 310N 2074234 CE NLG RETRACT FAILED G O OTHER J WARNING INDICATION AP APPROACH 1 GL 03 500SH 310N0108 AFTER SELECTING GEAR DOWN ON APPROACH, PILOT NOTICED NOSE GEAR NOT DOWN AND LOCKED. PILOT MADE SEVERAL ATTEMPTS, BUT GE AR WAS JAMMED. PILOT LANDED, NOSE GEAR COLLAPSED. MINOR DAMAGE TO AIRCRAFT. NO INJURIES TO PILOT. MAINTENANCE INSPEC TION REVEALED THE NOSE GEAR MAY HAVE BEEN RIGGED IMPROPERLY OR GEAR LINKAGE FAILED DUE TO PRIOR HARD LANDINGS. 1 L 7 2 3O 3A10 1997120400243 19971204 00243 CE 1997 12 4 97ZZZX4887 1 19971010 G 2750 PULLEY CESSNA 401 401 207590C CE FLAP FAILED D A K NONE O OTHER IN INSP/MAINT 1 SW 05 31DB 4010202 ON 100-HOUR INPSPECTION, FOUND FLAP PULLEY ON ACTUATOR CABLE (RETURN CABLE) UNDER AND AFT OF BATTERY BOX FAILED. CENTER BEARING HAD FROZEN DUE TO BATTERY ACID LEAKING FROM BROKEN DRAIN LINE. WHEN BEARING FROZE, IT BROKE LOOSE FROM PULLEY AND PULLEY WAS ROTATING ON OUTER BEARING RACK. SUBMITTER SUGGESTS CLOSE INSPECTION OF THIS AREA DURING INSPECTIONS. 1 L 7 2 3O A7CE 1997120400244 19971204 00244 SO 1997 12 4 97ZZZX4888 1 19971111 G 3213 40327000 HOUSING PIPER PA31 PA31350 7103110 SO RT MLG CRACKED E S A K NONE O OTHER IN INSP/MAINT 1 GL 07 38KC 318352033 FOUND RIGHT MAIN LANDING GEAR HOUSING CRACKED. CRACK ORIGINATED UNDER CLAMP WHICH ATTACHED BRAKE LINE GUARD TO HOUSING. CRACK WAS APPROXIMATELY 1 INCH AND BEGAN BELOW CASTING MARK ON AFT SIDE OF STRUT. 1 L 7 2 3O A20SO 1997120400245 19971204 00245 CE 1997 12 4 97ZZZX4889 1 19971024 G 2710 0510105322 CONTROL CABLE CESSNA 185 185F 2072820 CE AILERON FRAYED G A K NONE O OTHER IN INSP/MAINT 1 AL 03 4952E 1573 18503918 CABLES (ALL 3) WERE FRAYED ON FUSELAGE 90 DEGREE PULLEYS. THE AIRCRAFT HAD BEEN TREATED INTERNALLY WITH 'THERMAL GARD'. THE TREATMENT WAS FOR ANTI-CORROSION. THE TREATMENT FORMED A SMOOTH BARRIER THAT MADE VISUAL INSPECTION LOOK OK. CLEA NING CABLES WITH SOLVENT AND CLOTH RAGS REVEALED MANY BROKEN STRANDS. 1 H 7 1 3O 3A24 1997013000336 19970130 00336 CE 1997 1 30 97ZZZX489 1 19970109 G 7170 10138901165 CHECK VALVE BEECH 90 C90A 1152911 CE LT FUEL PURGE CONTAMINATED D A O A OTHER UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS TO TAKEOFF 1 GL 03 40MH 1313 LJ1258 ON TAKEOFF, ACFT FILLED WITH SMOKE AND FUEL ODOR. PILOT SHUT FLOW PACKS OFF AND A/C CLEARED. NORMAL LANDING. INVESTIG ATED AND FOUND LT FUEL PURGE TANK CHECK VALVE CONTAMINATED. CLEANED CHECK VALVE AND TEST FLIGHT WAS NORMAL. SUBMITTER RECOMMENDS THAT CHECK VALVES BE ADDED TO THE 12 MO PURGE TANK FILTER INSPECTION ON ALL KING AIRS. 1 L 7 2 3T RT 3A20 1997120400246 19971204 00246 CE 1997 12 4 97ZZZX4890 1 19971024 G 2710 0510105113 CONTROL CABLE CESSNA 185 185F 2072820 CE AILERON FRAYED G K NONE O OTHER IN INSP/MAINT 1 AL 03 4952E 1573 18503918 CABLES (ALL 3) WERE FRAYED ON FUSELAGE 90 DEGREE PULLEYS. THE AIRCRAFT HAD BEEN TREATED INTERNALLY WITH 'THERMAL GARD'. THE TREATMENT WAS FOR ANTI-CORROSION. THE TREATMENT FORMED A SMOOTH BARRIER THAT MADE VISUAL INSPECTION LOOK OK. CLEA NING CABLES WITH SOLVENT AND CLOTH RAGS REVEALED MANY BROKEN STRANDS. 1 H 7 1 3O 3A24 1997120400247 19971204 00247 SO 1997 12 4 97ZZZX4891 2 19971103 G 8520 CONNECTING ROD CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO NR 6 CYLINDER FAILED D A UNSCHED LANDING E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CR CRUISE 1 CE 03 747PB 622 414A1006 R800589 PILOT REPORTED NR 2 ENGINE BEGAN RUNNING ROUGH, THEN FAILED TOTALLY. SUCCESSFUL SINGLE ENGINE LANDING AT SUS. REMOVED COWLING, FOUND NR 6 CYLINDER CONNECTING ROD FAILED WHICH PENETRATED CRANKCASE DESTROYING ENGINE. 1 L 7 2 3O 3 O A7CE E8CE 1997120400248 19971204 00248 1997 12 4 97ZZZX4892 4 19971008 G 2561 ACRL81A BATTERY EAAEROMARINE LIFE VEST SWOLLEN B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 THE LAST 15 VESTS INSPECTED HAVE HAD BAD LIGHTS (SWOLLEN BATTERIES). ALL OF THE LIGHTS ARE FROM THE SAME BATCH MAR 97 A ND ARE ONLY 6 MONTHS FROM DATE OF MANUFACTURE. SUBMITTER STATED BATTERIES FROM OCT 96 ARE ALL FINE, IT JUST SEEMS TO BE A BATCH PROBLEM. 1997120400249 19971204 00249 GL 1997 12 4 97ZZZX4893 3 19971029 G 6111 C1301 CLAMP MTSBSI MU2 MU2B60 5780460 CE HARTZL HCB4T HCB4TN5 GL PROP NR 3 BLADE CRACKED G L K NONE O OTHER IN INSP/MAINT 1 SO 13 21CJ 4642 2493 EJ2394 789SA CDA3007 INSPECTION REPORT CONDUCTED BY HARTZELL PROPELLER INC., REVEALED CRACK IN PROPELLER BLADE CLAMP. SUSPECT CAUSE OF CRACK DUE TO FATIGUE. 1 H 7 2 3T RT A10SW 6 C P40EA 1997120400250 19971204 00250 GL 1997 12 4 97ZZZX4894 3 19971029 G 6111 C1301 CLAMP MTSBSI MU2 MU2B60 5780460 CE HARTZL HCB4T HCB4TN5 GL PROP NR 4 BLADE CRACKED G A K NONE O OTHER IN INSP/MAINT 1 SO 13 21CJ 4642 2493 789SA CDA3007 INSPECTION REPORT CONDUCTED BY HARTZELL PROPELLER INC., REVEALED CRACK IN PROPELLER BLADE CLAMP. SUSPECT CAUSE OF CRACK DUE TO FATIGUE. 1 H 7 2 3T RT A10SW 6 C P40EA 1997120400251 19971204 00251 NE 1997 12 4 97ZZZX4895 2 19971113 G 7210 103019501 LOCKCUP 103035012 BELL 205 205A1 1181414 SW LYC T53 T5317A 41549 NE OUTPUT GEARBOX CRACKED B ZP3R K NONE O OTHER IN INSP/MAINT 1 WP 07 58HJ 1745 2291 30314 LE07520C FOLLOWING DISASSEMBLY OF ENGINE FOR METAL CONTAMINATION, DISCOVERED 2 EACH OF THE LOCKCUPS HAD FAILED. CUPS CRACKED AND SPLIT AT THE LOCKING TANGS WHICH ENGAGE THE PLANETARY GEARSHAFTS. THE RETAINING NUTS WHICH THE LOCKCUPS RETAIN, REMAIN ED IN PLACE AND THE PIECES OF THE LOCKCUPS WERE FOUND IN THE SCAVENGE SCREEN OF THE ACCESSORY DRIVE GEARBOX AND LAYING I N THE OUTPUT REDUCTION GEARBOX. 1 G 7 1 4U 4 U H1SW E17EA 1997120400496 19971204 00496 EU 1997 12 4 97ZZZX4896 1 19971008 G 6410 10531980 BLADE BOLKMS 105 BO105S 5626006 EU T/R ERODED B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 5352Y 961 572 S781 PAINT PEELING AT LEADING EDGE ERODED INTO POLY STRIP AND FIBERGLASS WEBBING. THESE TWO BLADES REPAIRED JUNE 18, 1997. T OTAL TIME ON BLADES 647.9 HOURS. 1 G 7 2 3U H3EU 1997120400497 19971204 00497 EU 1997 12 4 97ZZZX4897 1 19971008 G 6410 10531980 BLADE BOLKMS 105 BO105S 5626006 EU T/R ERODED B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 5352Y 961 574 S781 PAINT PEELING AT LEADING EDGE ERODED INTO POLY STRIP AND FIBERGLASS WEBBING. THESE TWO BLADES REPAIRED JUNE 18, 1997. T OTAL TIME ON BLADES 647.9 HOURS. 1 G 7 2 3U H3EU 1997120400500 19971204 00500 SW 1997 12 4 97ZZZX4900 1 19970930 G 6510 406040340101 DISC BELL 407 407 SW T/R DRIVE CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 407AL 53044 DAILY INSPECTION AND C/W NOTAM NR 51A-97, FOUND DISC CRACKED. ON NR 7 DISC ASSEMBLY, NR 7 DISC OF THE PACK - 1 DISC ONL Y. 1 G 7 1 3U O H2SW 1997120400501 19971204 00501 SW 1997 12 4 97ZZZX4901 1 19971014 G 6510 406040340101 COUPLING BELL 407 407 SW T/R D/S COUPLING CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 407AL 53044 DAILY INSPECTION FOUND NR 7 TAIL ROTOR DRIVESHAFT COUPLING, NR 10 DISC ON PACK CRACKED. 1 G 7 1 3U O H2SW 1997120400502 19971204 00502 SW 1997 12 4 97ZZZX4902 1 19970930 G 6510 406040340101 DISC PACK BELL 407 407 SW NR 7 T/R CPLNG CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 417AL 53054 DAILY CHECK NOTAM 51A-97 OCCURRED DURING NORMAL FLIGHT, FOUND NR 7 COUPLING CRACKED 2 LAMINATES NR 1 AND NR 2 PACK HAS T EN DISCS. 1 G 7 1 3U O H2SW 1997120400503 19971204 00503 SW 1997 12 4 97ZZZX4903 1 19970930 G 6322 406040339105 BEARING 406040320101 BELL 407 407 SW T/R DRIVE ROUGH B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 417AL 634 960711 53054 NR 2 SHAFT REMOVED FROM AIRCRAFT DUE TO ROUGH BEARING. FOUND BEARING 406-040-339-105 INSTALLED AT AIRCRAFT HOURS 808.0 HOURS ROUGH. ALSO, SHAFT 406-040-320-101, TT 1410.8 HOURS. FORWARD SPLINES WORN AND CORRODED BEYOND LIMITS. 1 G 7 1 3U O H2SW 1997120400504 19971204 00504 SW 1997 12 4 97ZZZX4904 1 19971102 G 6510 406040340101 DISC PACK BELL 407 407 SW T/R SHAFT CRACKED B S ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 437AL 53141 ON 50-HOUR P.M.I., AND AD 97-22-15, FOUND NR 10 OF 10 DISC CRACKED IN 2 PLACES. 1 G 7 1 3U O H2SW 1997120400505 19971204 00505 SW 1997 12 4 97ZZZX4905 1 19970909 G 6510 406040340101 DISC 407040302101 BELL 407 407 SW T/R DRIVE CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 437AL 53141 DURING DAILY INSPECTION, FOUND T/R DRIVE DISC HAS CRACK STARTING ON INSIDE DIAMETER GOING TOWARDS OUTSIDE DIAMETER, NR 1 DISC (FIRST ON PACK). 1 G 7 1 3U O H2SW 1997120400506 19971204 00506 SW 1997 12 4 97ZZZX4906 1 19970930 G 6500 406017113101 MAST NUT 407012100101 BELL 407 407 SW T/R LOOSE B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 437AL 53141 DAILY INSPECTION FOUND COMPLETE LOSS OF TORQUE ON T/R MAST NUT. THE NUT COULD BE REMOVED BY HAND. THE SAFETY WIRE BETW EEN THE NUT AND THE SUPPORT, (P/N 407-012-106-103) KEPT THE NUT FROM SPINNING OFF OF THE TAIL ROTOR GEARBOX OUTPUT SHAFT . 1 G 7 1 3U O H2SW 1997120400507 19971204 00507 SW 1997 12 4 97ZZZX4907 1 19970924 G 6510 406040340101 DISC BELL 407 407 SW T/R DISC PACK CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 437AL 53141 SCHEDULED INSPECTION FOUND DISC CRACKED. 1 G 7 1 3U O H2SW 1997120400509 19971204 00509 SW 1997 12 4 97ZZZX4909 1 19971023 G 6220 407010150101A DAMPER ASSY BELL 407 407 SW M/R DETERIORATED B S ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 437AL 58 53141 DAILY INSPECTION FOUND FRAHM DAMPER ASSY RUBBER DETERIORATING AND STICKING OUT OF DAMPER. 1 G 7 1 3U O H2SW 1997120400510 19971204 00510 SW 1997 12 4 97ZZZX4910 1 19971029 G 6510 406040340101 DISC PACK BELL 407 407 SW T/R SHAFT CRACKED B S ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 437AL 53141 DURING 50-HOUR PMI AND MAINTENANCE NOTAM NR 51B-97, FOUND NR 1 DISC IN PACK ASSEMBLY OF 10 DISC TOTAL, CRACKED IN TWO PL ACES. 1 G 7 1 3U O H2SW 1997120400511 19971204 00511 NE 1997 12 4 97ZZZX4911 1 19971013 G 3230 1945E72A02 JURY BRACE 1945E175A02 SKRSKY S76 S76A 8143006 NE RT GEAR FAILED B ALGR O A OTHER UNSCHED LANDING J WARNING INDICATION AP APPROACH 1 SW 03 741SW 760070 DURING LANDING CHECK, THE RIGHT MAIN LANDING GEAR FAILED TO LOCK DOWN. AFTER RECYCLING THE LANDING GEAR, THE PROBLEM RE MAINED. RETURNED TO BASE. FOUND RIGHT HAND JURY BRACE BROKEN. REPLACED BRACE AND SWUNG GEAR. OPS CHECK GOOD. RETURN ED TO SERVICE AT 1,745 HOURS. 1 G 7 2 3U H1NE 1997120400512 19971204 00512 NM 1997 12 4 97ZZZX4912 1 19971101 G 7120 65187225 MOUNT BOEING 727 727225 1384077 NM NR 1 ENG FWD CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON NR 1 ENGINE FORWARD MOUNT. 2 L 7 3 4F A3WE 1997120400513 19971204 00513 NM 1997 12 4 97ZZZX4913 1 19971101 G 5313 STRINGER BOEING 727 727225 1384077 NM BS 1183 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON S19R AT STA 1183. 2 L 7 3 4F A3WE 1997120400514 19971204 00514 NM 1997 12 4 97ZZZX4914 1 19971101 G 5320 SUPPORT BOEING 727 727225 1384077 NM BS 1070-1090 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN FLOOR SUPPORT FRAME, STA 1070 TO STA 1090 AT S27L. 2 L 7 3 4F A3WE 1997120400515 19971204 00515 NM 1997 12 4 97ZZZX4915 1 19971101 G 5315 FLOOR BEAM BOEING 727 727225 1384077 NM BS 344 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN FLOOR BEAM UPPER CHORD FROM LBL 55 TO RBL 42. 2 L 7 3 4F A3WE 1997120400516 19971204 00516 NM 1997 12 4 97ZZZX4916 1 19971101 G 5347 SEAT TRACK BOEING 727 727225 1384077 NM BS 344-480 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN SEAT TRACK FROM STA 344 TO STA 480 AT LBL 45. 2 L 7 3 4F A3WE 1997120400517 19971204 00517 NM 1997 12 4 97ZZZX4917 1 19971101 G 5330 SKIN BOEING 727 727225 1384077 NM BS 1150-1183 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON EXTERNAL SKIN, STA 1150 TO STA 1183 BETWEEN S14R AND S20R. 2 L 7 3 4F A3WE 1997120400518 19971204 00518 NM 1997 12 4 97ZZZX4918 1 19971101 G 5315 FLOOR BEAM BOEING 727 727225 1384077 NM BS 1130 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN FLOOR BEAM STA 1130, OUTBOARD OF RBL 24. 2 L 7 3 4F A3WE 1997120400519 19971204 00519 NM 1997 12 4 97ZZZX4919 1 19971101 G 5320 CHORD BOEING 727 727225 1384077 NM NLG BOX BS 328 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON RT SIDE NOSE GEAR BOX LOWER CHORD AT FLOOR WEB, STA 328 TO STA 344. 2 L 7 3 4F A3WE 1997120400520 19971204 00520 NM 1997 12 4 97ZZZX4920 1 19971101 G 5313 STRINGER BOEING 727 727225 1384077 NM BS 950-950A CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON S27R BETWEEN STA 950 AND STA 950A. 2 L 7 3 4F A3WE 1997120400521 19971204 00521 NM 1997 12 4 97ZZZX4921 1 19971101 G 5347 SEAT TRACK BOEING 727 727225 1384077 NM BS 990-1030 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN SEAT TRACK AT LBL 24 FROM STA 990 TO STA 1030. 2 L 7 3 4F A3WE 1997120400522 19971204 00522 NM 1997 12 4 97ZZZX4922 1 19971101 G 5347 SEAT TRACK BOEING 727 727225 1384077 NM BS 344-480 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION WAS NOTED ON CABIN SEAT TRACK AT LBL 24 FROM STA 344 TO STA 480. 2 L 7 3 4F A3WE 1997120400523 19971204 00523 NM 1997 12 4 97ZZZX4923 1 19971101 G 5347 SEAT TRACK BOEING 727 727225 1384077 NM BS 1000-1030 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN LEFT HAND INBOARD SEAT TRACK FROM STA 1000 TO STA 1030. 2 L 7 3 4F A3WE 1997120400524 19971204 00524 NM 1997 12 4 97ZZZX4924 1 19971101 G 5311 FRAME BOEING 727 727225 1384077 NM BS 1166 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON FRAME 1166 BETWEEN S27R AND S28R. 2 L 7 3 4F A3WE 1997120400525 19971204 00525 NM 1997 12 4 97ZZZX4925 1 19971101 G 5315 FLOOR BEAM BOEING 727 727225 1384077 NM BS 380 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN FLOOR BEAM UPPER CHORD AT STA 380 FROM RBL 20 TO RBL 45. 2 L 7 3 4F A3WE 1997120400526 19971204 00526 NM 1997 12 4 97ZZZX4926 1 19971101 G 5510 BEAM BOEING 727 727225 1384077 NM HORIZ RT STAB TE CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON RT HAND HORIZONTAL STABILIZER UPPER TRAILING EDGE BEAM CHORD. 2 L 7 3 4F A3WE 1997120400527 19971204 00527 NM 1997 12 4 97ZZZX4927 1 19971101 G 5510 BEAM BOEING 727 727225 1384077 NM HORIZ LT STAB TE CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON LEFT HAND HORIZONTAL STABILIZER UPPER TRAILING EDGE BEAM CHORD. 2 L 7 3 4F A3WE 1997120400528 19971204 00528 NM 1997 12 4 97ZZZX4928 1 19971101 G 5313 STRINGER BOEING 727 727225 1384077 NM BS 460-480 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON S18R BETWEEN STA 460 AND STA 480. 2 L 7 3 4F A3WE 1997120400529 19971204 00529 NM 1997 12 4 97ZZZX4929 1 19971101 G 5315 FLOOR BEAM BOEING 727 727225 1384077 NM BS 328 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON UPPER T-CHORD FLOOR BEAM STA 328 AT LBL 55. 2 L 7 3 4F A3WE 1997120400530 19971204 00530 NM 1997 12 4 97ZZZX4930 1 19971101 G 5320 SUPPORT BOEING 727 727225 1384077 NM BS 440-460 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN FLOOR SUPPORT BETWEEN STA 440 - STA 460 AT RBL 12. 2 L 7 3 4F A3WE 1997120400919 19971204 00919 SW 1997 12 4 97ZZZX4933 1 19971116 G 6520 4764521215 CASE 476400751 BELL 47 47G2A1 1181014 SW T/R GEARBOX CORRODED H L A K NONE O OTHER IN INSP/MAINT 1 SW 99 73953 2292 831 A133292 2866 WHILE TROUBLESHOOTING FOR A LOOSE TAIL ROTOR GUARD IN TAIL ROTOR GEARBOX HOUSING, PULLED THE GUARD OUT OF THE GEARBOX AN D FOUND FERTILIZER PACKED INTO CAVITY. WHILE SCRAPING FERTILIZER OUT OF CAVITY, FOUND CORROSION HAD EATEN THROUGH MAGNE SIUM HOUSING. THE PACKED FERTILIZER WAS KEEPING THE OIL FROM LEAKING OUT. 1 G 7 1 3O 2H3 1997120400920 19971204 00920 NE 1997 12 4 97ZZZX4934 2 19970924 G 7230 717623 FRONT HUB PWA JT8 JT8D17 52049 NE COMPRESSOR CORRODED B VF5R K NONE O OTHER IN INSP/MAINT 1 NE 03 9V8439 FRONT HUB RECEIVED FOR SCHEDULED OVERHAUL. PART INSPECTED PER INSP 01, JT8D ENGINE MANUAL 481672 SECTION 72-36-17. TIE -ROD, SHIELDING, AND COUNTERWEIGHT HOLES WERE FOUND WITH EXCESSIVE CORROSION AND PITTING. PART TAGGED SCRAP AND RETURNE D. 4 F E2EA 1997120400921 19971204 00921 CE 1997 12 4 97ZZZX4935 1 19971031 G 2150 HOSE BEECH 200 A200 1152921 CE AIR COND MISINSTALLED G L A B A EMER. DESCENT UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 EA 23 200NY 5 BC25 ACFT MILES FROM DESTINATION WHEN CREW NOTICED CABIN TEMP WAS HIGH. CABIN CONTROL WAS ON 'AUTO MODE'. CHANGING TO 'MANU AL MODE' AND TOGGLING DOWN TEMPERATURE RESULTED IN A LOUD POP OR BANG THOUGHT TO BE RAPID DECOMPRESSURIZATION. A MIST F ORMED IN THE CABIN, SMOKE ISSUED FROM OVERHEAD VENTS, AND STRONG OIL SMELL UPSET OCCUPANTS. EMERGENCY DECLARED. UNEVEN TFUL LANDING ACCOMPLISHED. FWD EVAPORATOR FOUND RUPTURED IN CAPILLARY/COOLING FIN AREA IN CENTER OF EVAPORATOR. FURTHE R INVEST FND AIR COND SUCTION AND DISCHARGE LINES INSTALLED REVERSED WHEN REPLACED WITH NEW 4.5 HRS PREVIOUSLY. REPAIR STATION REPLACED HOSE, INSPECTOR DOUBLE INSPECTED. 1 L 7 2 4T A24CE 1997120400922 19971204 00922 EU 1997 12 4 97ZZZX4936 1 19971120 G 2432 RG390E BATTERY AMD FALC50 FALCON900 2700160 EU DC SYSTEM LEAKING D K NONE O OTHER IN INSP/MAINT 1 GL 05 26LB 675 CBC263178 51 BATTERY'S SUPPORT SLEEVE ON THE OUTSIDE OF BATTERY SLIDES DOWN IN-FLIGHT OR LANDING ABOUT 2 INCHES. CONCORDE FAX SAID T O PUSH SLEEVE UP AND PUT TAPE ON BOTTOM OF SLEEVE 2 L 7 3 4F RT A46EU 1997120400923 19971204 00923 EU 1997 12 4 97ZZZX4937 1 19971120 G 2432 RG390E BATTERY AMD FALC50 FALCON900 2700160 EU DC SYSTEM LEAKING D K NONE O OTHER IN INSP/MAINT 1 GL 05 26LB 675 CBC263179 51 BATTERY'S SUPPORT SLEEVE ON THE OUTSIDE OF BATTERY SLIDES DOWN IN-FLIGHT OR LANDING ABOUT 2 INCHES. CONCORDE FAX SAID T O PUSH SLEEVE UP AND PUT TAPE ON BOTTOM OF SLEEVE 2 L 7 3 4F RT A46EU 1997120400924 19971204 00924 EU 1997 12 4 97ZZZX4938 1 19971120 G 2432 RG390E BATTERY BRAERO DH125 BAE125800A 1500285 EU DC SYSTEM DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 SW 99 461W CBC262926 NA0461 BATTERY SUPPORT SLEEVE ON THE OUTSIDE OF BATTERY SLIDES DOWN 2 INCHES. CONCORDE FAX SAID TO PUSH SLEEVE UP AND TAPE BOT TOM OF SLEEVE. 2 L 7 2 4F RT A3EU 1997120400925 19971204 00925 EU 1997 12 4 97ZZZX4939 1 19971120 G 2432 RG390E BATTERY BRAERO DH125 BAE125800A 1500285 EU DC SYSTEM DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 SW 99 461W CBC262927 NA0461 BATTERY SUPPORT SLEEVE ON THE OUTSIDE OF BATTERY SLIDES DOWN 2 INCHES. CONCORDE FAX SAID TO PUSH SLEEVE UP AND TAPE BOT TOM OF SLEEVE. 2 L 7 2 4F RT A3EU 1997013000341 19970130 00341 CE 1997 1 30 97ZZZX494 1 19970122 G 2741 509100501 SENSOR LEAR 35 35A 5170602 CE STAB MACH TRIM MISWIRED B A ESMR O OTHER J W WARNING INDICATION INADEQUATE Q C CR CRUISE 1 SO 11 815L 142 CREW REPORTED MACH TRIM FAULT LIGHT AND WARNING TONE ABOVE .74 MACH. REPLACED HORIZONTAL STABLIZER POSITION SENSOR PER LEARJET A.M.M. PROBLEM RECURRED WITH ADDITION OF RAPID NOSE UP OR DOWN TRIM CHANGE ABOVE .69 MACH. AFTER MUCH TROUBLES HOOTING, FOUND NEW SENSOR WIRED 180 DEGREES OUT OF PHASE. ANOTHER SENSOR CORRECTED THE PROBLEM. 2 L 7 2 4F A10CE 1997120400926 19971204 00926 EU 1997 12 4 97ZZZX4940 1 19971120 G 2432 RG390E BATTERY BRAERO DH125 BAE125800A 1500285 EU DC SYSTEM DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 GL 05 74NP CBC275940 NA0449 BATTERY'S SUPPORT SLEEVE ON THE OUTSIDE OF BATTERY SLIDES DOWN IN-FLIGHT OR LANDING ABOUT 2 INCHES. CONCORDE FAX SAID T O PUSH TO PUSH SLEEVE UP AND PUT TAPE ON BOTTOM OF SLEEVE. 2 L 7 2 4F RT A3EU 1997120400927 19971204 00927 EU 1997 12 4 97ZZZX4941 1 19971120 G 2432 RG390E BATTERY BRAERO DH125 BAE125800A 1500285 EU DC SYSTEM DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 GL 05 74NP CBC275939 NA0449 BATTERY'S SUPPORT SLEEVE ON THE OUTSIDE OF BATTERY SLIDES DOWN IN-FLIGHT OR LANDING ABOUT 2 INCHES. CONCORDE FAX SAID T O PUSH SLEEVE UPA ND PUT TAPE ON BOTTOM OF SLEEVE. 2 L 7 2 4F RT A3EU 1997120400928 19971204 00928 EU 1997 12 4 97ZZZX4942 1 19971121 G 2432 RG390E BATTERY BRAERO DH125 HS125700A 4230170 EU DC SYSTEM LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 SW 99 810CR CBC273784 NA0251 BATTERY SUPPORT SLEEVE ON THE OUTSIDE OF BATTERY SLIDES DOWN 2 INCHES AND LEAKING. CONCORDE FAX SAID TO PUSH SLEEVE UP AND TAPE BOTTOM OF SLEEVE. 2 L 7 2 4F A3EU 1997120400929 19971204 00929 EU 1997 12 4 97ZZZX4943 1 19971121 G 2432 RG390E BATTERY BRAERO DH125 HS125700A 4230170 EU DC SYSTEM LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 SW 99 571CH CBC275865 NA0256 BATTERY SUPPORT SLEEVE ONTHE OUTSIDE OF BATTERY SLIDES DOWN 2 INCHES AND LEAKING. CONCORDE FAX SAID TO PUSH SLEEVE UP A ND TAPE BOTTOM OF SLEEVE. 2 L 7 2 4F A3EU 1997120400930 19971204 00930 EU 1997 12 4 97ZZZX4944 1 19971121 G 2432 RG390E BATTERY BRAERO DH125 HS125700A 4230170 EU DC SYSTEM DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 GL 05 825CT CBC275936 NA0229 BATTERY SUPPORT SLEEVE ON THE OUTSIDE OF BATTERY SLIDES DOWN 2 INCHES. CONCORDE FAX SAID TO PUSH SLEEVE UP AND TAPE BOT TOM OF SLEEVE. 2 L 7 2 4F A3EU 1997120400931 19971204 00931 EU 1997 12 4 97ZZZX4945 1 19971121 G 2432 RG390E BATTERY BRAERO DH125 HS125700A 4230170 EU DC SYSTEM DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 GL 05 825CT CBC275939 NA0229 BATTERY SUPPORT SLEEVE ON THE OUTSIDE OF BATTERY SLIDES DOWN 2 INCHES. CONCORDE FAX SAID TO PUSH SLEEVE UP AND TAPE BOT TOM OF SLEEVE. 2 L 7 2 4F A3EU 1997120400932 19971204 00932 SO 1997 12 4 97ZZZX4946 1 19971118 G 3240 244667 CARRIER BFGOODRICH 21585 EMB 120 EMB120 3260201 SO BRAKE NR 2 BROKEN B XC4R K NONE O OTHER IN INSP/MAINT 1 SO 19 204SW 3578 0500 120243 UPON DISASSEMBLY OF BRAKE NR 3, CARRIER AND LINING WERE FOUND BROKEN INTO THREE PIECES. CARRIER LINING WAS A NEW PART I NSTALLED AT LAST OVERHAUL. NOTE: BRAKE POSITION NR 2. 2 L 7 2 4T RT A31SO 1997120400933 19971204 00933 SO 1997 12 4 97ZZZX4947 1 19971118 G 3240 244677 CARRIER BFGOODRICH 21585 EMB 120 EMB120 3260201 SO BRAKE NR 4 BROKEN B XC4R K NONE O OTHER IN INSP/MAINT 1 SO 19 2085 0070 UPON DISASSEMBLY OF BRAKE ASSEMBLY, NR 3 CARRIER AND LINING WERE FOUND BROKEN IN HALF. CARRIER LINING WAS A NEW PART IN STALLED AT LAST OVERHAUL. BRAKE POSITION NR 4, EMB120. BRAKE HOUSING STAMPED WITH INCORRECT TORQUE VALUE. THERE HAVE BEEN NUMEROUS FAILURES OF THIS PART NUMBERED BRAKE. 2 L 7 2 4T RT A31SO 1997120400934 19971204 00934 GL 1997 12 4 97ZZZX4948 3 19971106 G 6110 13019S CLAMP AIRTRC AT500 AT502 0390303 SW HARTZL HCB3T HCB3TN3 GL PROPELLER CRACKED B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 DD4974 BU471 INSPECTION FOUND PROPELLER CLAMP CRACKED AT BOLT HOLE. 1 L 7 1 3T NC A9SW 6 C P15EA 1997120400935 19971204 00935 SO 1997 12 4 97ZZZX4949 2 19971101 G 8550 BYPASS SPRING CESSNA 210 210 2073402 CE CONT O520 IO520L 17032 SO OIL FILTER ADAPT FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 99 OIL FILTER BYPASS SPRING FOUND BROKEN AND DISC FOUND UNDER ENGINE OIL PRESSURE VALVE. ENGINE HAD NO OIL PRESSURE AFTER START-UP. BYPASS DISC FOUND UNDER ENGINE OIL PRESSURE RELIEF VALVE PREVENTING ENGINE FROM DEVELOPING ANY PRESSURE. 1 H 7 1 3O 3 O RT 3A21 E5CE 1997013000342 19970130 00342 CE 1997 1 30 97ZZZX495 1 19970108 G 3230 030A387611 CASTING MTSBSI MU2 MU2B35 5780411 CE MLG THRUST GR BX EAR BROKEN D S A K NONE O OTHER IN INSP/MAINT 1 SO 09 92ST 6124 610 AT 100 HR INSP, LANDING GEAR THRUST GEAR BOX CASTING MOUNT EAR WAS FOUND BROKEN AND MOUNT BOLTS LOOSE. SUSPECT CAUSE TO BE SHIM SPACERS USED BETWEEN BOX AND AIRCRAFT STRUCTURE. INSP OF OPPOSITE SIDE (RIGHT) REVEALED THAT MOUNT BOLTS WERE LOOSE ALSO. SUBMITTER STATES OTHER MU 2 TECHNICIANS HAVE FOUND THIS CONDITION ON OTHER LONG BODY AGING MU 2'S. SUBMITT ER SUGGESTS THAT THESE BOX MOUNT BOLTS BE CHECKED AT 100 OR 150 HOUR INSPECTIONS. 1 H 7 2 3T RT A10SW 1997120400936 19971204 00936 1997 12 4 97ZZZX4950 4 19971101 G 2561 SMV2102 LIFE VEST JCRIND CELL FAILED B KQ1R K NONE L NO TEST IN INSP/MAINT 1 EA 07 1937 LIFE VEST FAILED THE MANUFACTURER'S 2-POUND PSI TEST. 1997120400937 19971204 00937 1997 12 4 97ZZZX4951 4 19971112 G 3416 10172001999 ALTIMETER COCKPIT STICKS B JY2R K NONE O OTHER NR NOT REPORTED 1 GL 23 156258 UNIT WAS HANGING UP. UNIT ALSO MADE A 400 FOOT 'JUMP' ON ASCENT. THE ALTIMETER WAS 'CLOCKING' ABOVE 8,000 FEET. 1997120400938 19971204 00938 EA 1997 12 4 97ZZZX4952 2 19971111 G 7322 NUT CESSNA 172 172N 2072434 CE LYC O360 O360A4M 41514 EA CARBURETOR MOUNT MISSING C K NONE O OTHER IN INSP/MAINT 1 SW 99 291 ALL FOUR NUTS, FLAT AND LOCK WASHERS, WERE DISCOVERED MISSING FROM THE FOUR STUDS ON THE INTAKE MANIFOLD THAT THE CARBUR ETOR IS MOUNTED ON. PROBLEM DISCOVERED WHEN ENGINE FAILED ON LANDING AND WOULD NOT RESTART. CURRENT COMBINATION OF NUT , LOCK WASHER AND FLAT WASHER IS NOT SUFFICIENT TO WITHSTAND ENGINE VIBRATION. SUBMITTER RECOMMENDS PERIODIC TORQUE CHE CKS OR DIFFERENT LOCKING DEVICE. 1 H 7 1 3O 3 O NT 3A12 E286 1997120400939 19971204 00939 1997 12 4 97ZZZX4953 4 19971117 G 3454 5222450114 RECEIVER COLLINS SUBASSY MISREPAIRED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 01 12477 IAW MANUFACTURER'S MM DATA, THE APPLIANCE DESCRIBED IN BLOCK 6 CONTAINS SUB-ASSEMBLIES INAPPROPRIATE TO THE PARTICULAR P ART NUMBER DENOTED ON THE DATA PLATE. 1997120400940 19971204 00940 1997 12 4 97ZZZX4954 4 19971117 G 3454 5222450115 RECEIVER SUBASSY MISREPAIRED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 01 2446 IAW MANUFACTURER'S MM DATA, THE APPLIANCE DESCRIBED IN BLOCK 6 CONTAINS SUB-ASSEMBLIES INAPPROPRIATE TO THE PARTICULAR P ART NUMBER DENOTED ON THE DATA PLATE. THIS UNIT, IF PROPERLY REPAIRED, COULD BE RETURNED TO SERVICE. 1997120400941 19971204 00941 CE 1997 12 4 97ZZZX4955 1 19971117 G 7921 LW10025 OIL COOLER BEECH 60 B60 1153605 CE ENGINE OIL LEAKING B A TE1R K NONE K FLUID LOSS IN INSP/MAINT 1 SW 05 7288D 6 429 P81 THE FIRST OIL COOLER WAS INSTALLED WHEN THE ORIGINAL OIL COOLER DEVELOPED A LEAK AT 2426.8 HOURS. THIS OIL COOLER DEVEL OPED A LEAK AFTER ABOUT 6 HOURS. OIL COOLER NR 2 WAS INSTALLED AND DEVELOPED A LEAK AFTER 2 HRS. THE NR 2 OIL COOLER W AS CUT IN TWO TO SEE IF THE CAUSE OF THE LEAKS COULD BE DETERMINED. FOUND LAST LEAK REPAIRED BY FILLING THE LEAKING SEG MENT WITH INDUSTRIAL TYPE EPOXY. THIS UNIT WAS REPLACED WITH A NEW UNIT. 1 L 7 2 3O A12CE 1997120400942 19971204 00942 CE 1997 12 4 97ZZZX4956 1 19971117 G 7921 LW10025 OIL COOLER BEECH 60 B60 1153605 CE ENGINE OIL LEAKING B TE1R K NONE K FLUID LOSS IN INSP/MAINT 1 SW 05 7288D 2 668 P81 THE FIRST OIL COOLER WAS INSTALLED WHEN THE ORIGINAL OIL COOLER DEVELOPED A LEAK AT 2426.8 HOURS. THIS OIL COOLER DEVEL OPED A LEAK AFTER ABOUT 6 HOURS. OIL COOLER NR 2 WAS INSTALLED AND DEVELOPED A LEAK AFTER 2 HRS. THE NR 2 OIL COOLER W AS CUT IN TWO TO SEE IF THE CAUSE OF THE LEAKS COULD BE DETERMINED. FOUND LAST LEAK REPAIRED BY FILLING THE LEAKING SEG MENT WITH INDUSTRIAL TYPE EPOXY. THIS UNIT WAS REPLACED WITH A NEW UNIT. 1 L 7 2 3O A12CE 1997120400943 19971204 00943 1997 12 4 97ZZZX4957 3 19971107 G 6112 RA129884 DEICE BOOT RAPCO BEECH 80 65B80 1152812 CE NR 1 PROPELLER FAILED D S K NONE O OTHER NR NOT REPORTED 1 GL 15 110BA 438 LD279 PROPELLER DEICE LEAD BREAK 12 INCHES FROM TERMINALS AFTER FOLLOWING NEW INSTALLATION INSTRUCTIONS. 1 L 7 2 3O 3A20 1997120400944 19971204 00944 SO 1997 12 4 97ZZZX4958 1 19971101 G 7160 HOSE PIPER PA18 PA18135 7101820 SO ENGINE INDUCT FAILED D A K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 AL 05 1458C 182657 LINING OF INDUCTION HOSES SWELLED INWARD THEN CRACKED AROUND THE INSIDE DIAMETER CIRCUMFERENCE. SOME LINING BROKE OFF A ND PASSED THROUGH COMBUSTION CHAMBERS. THE SWELLED LINING THAT REMAINED SWELLED OUT ENOUGH TO OBSTRUCT FLOW CAUSING THE ENGINE TO RUN ROUGH AT HIGH THROTTLE SETTINGS AND LOSE 200 TO 250 RPM'S AT FULL THROTTLE. THE PROBLEM WAS HARD TO ISOL ATE BECAUSE THE LINING WOULD SHRINK BACK WHEN THE ENGINE WAS NOT RUN FOR SEVERAL DAYS. THIS ENGINE WAS A FRESH FACTORY OVERHAUL. 1 H 7 1 3O 1A2 1997120400945 19971204 00945 SO 1997 12 4 97ZZZX4959 2 19971114 G 8530 626992 PISTON CESSNA 182 182G 2072716 CE CONT O470 O470R 17026 SO PIN BOSS CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 01 3235S 1277 18255735 1305724R4 SIX ENGINE PISTONS FOUND CRACKED IN PISTON PIN BOSS. CRACKS WERE ALL IN SAME AREA, UPPER PIN BOSS RUNNING PARALLEL TO P ISTON PIN. ONE PISTON HAD LOST ONE-FOURTH OF THE CASTING AROUND PIN. THIS CONDITION DID NOT CAUSE ANY OPERATIONAL PROB LEMS. JUDGING FROM CARBON CONDITION, HAD EXISTED SOME TIME. THIS PISTON IS SAME DESIGN AS SA626992 WHICH IS COVERED BY AD96-12-04. 1 H 7 1 3O 3 O NT 3A13 E273 1997013000343 19970130 00343 CE 1997 1 30 97ZZZX496 1 19970115 G 5753 HINGE CESSNA 140 140 2071602 CE LT FLAP CRACKED H S A K NONE O OTHER IN INSP/MAINT 1 SW 11 1917V 14111 DURING ANNUAL INSPECTION, THE LEFT WING FLAP HINGES WERE FOUND CRACKED. LEFT AND RIGHT ONLY. THE AREA OF THE CRACKS WA S FOUND AT THE ATTACHING SCREW HOLES. THE CRACKS ORIGINATED IN THE HOLES AND RAN TO EACH CORNER OF THESE HINGES. PARTS TOTAL TIME UNKNOWN. 1 H 7 1 3O NC A768 1997120400946 19971204 00946 CE 1997 12 4 97ZZZX4960 1 19971010 G 3230 2162 SPROCKET BEECH 18 C45H 1151018 CE NLG FAILED D O OTHER O OTHER AP APPROACH 1 SO 17 486JB 4500 AF858 LANDING GEAR FAILED TO EXTEND UPON LANDING AT ORLANDO INTERNATIONAL DUE TO THE POSITION OF ACFT. AFTER REMOVAL FROM THE RUNWAY, A DETERMINATION OF CAUSE IS NOT POSSIBLE. 1 L 7 2 3R A765 1997120400947 19971204 00947 EU 1997 12 4 97ZZZX4961 2 19970501 G 8510 834050 RING GEAR AMTR KITFOX KITFOX 05613LZ GL ROTAX 582 ROTAX582 55555 EU ENG STARTER FAILED C P K NONE O OTHER IN INSP/MAINT 1 SW 99 61DM 185 606 PRE-FLIGHT INSPECTION FOUND METAL FILINGS AROUND STARTER. FURTHER INSP REVEALED A LARGE CRACK NEAR A BOLT HOLE ON THE S TARTER RING GEAR THAT WAS SEPARATED BY .125 INCH. SMALLER CRACKS WERE NOTED EMANATING FROM OTHER BOLT HOLES. REASON FO R THE CRACKING IS UNKNOWN, HOWEVER, IT HAS BEEN LEARNED THIS IS NOT AN ISOLATED CASE IN THE OLDER ROTAX 582 ENGINES WITH THIS TYPE STARTER. APPARENTLY, SERVICE BULLETIN WAS PUBLISHED TO REPLACE THESE RING GEARS WITH A HEAVIER BUILT UNIT, H OWEVER, THAT SB WAS NOT AVAILABLE TO THE AUTHOR. THIS RING GEAR WAS ON THE VERGE OF COMPLETE SEPARATION. SUBMITTER REC OMMENDS ALL OWNERS OF ROTAX 582/532 ENGINES PRODUCED PRIOR TO 1994 HAVE A VERY CLOSE LOOK AT THE STARTER RING GEAR. 1 H 7 1 3I 3 I NC EXPA1H71 EXPE3I 1997120400948 19971204 00948 CE 1997 12 4 97ZZZX4962 1 19971110 G 3320 CM35351 POTENTIOMETER CESSNA 402 402C 207590R CE DIMMER BOARD FAILED C A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 NE 01 7037E 402C0471 AN ODOR OF ELECTRICAL SMOKE FILLED THE CABIN. AIRCRAFT LANDED WITHOUT INCIDENCE. FOUND THE DIMMER BOARD AT FAULT. DIM MER ASSY REPLACED AND AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 3O A7CE 1997120400949 19971204 00949 EA 1997 12 4 97ZZZX4963 2 19971031 G 7414 6263 MAGNETO SLICK PIPER PA46 PA46350P SO LYC O540 TIO540AE2A 41532 EA ENG LT WORN D K NONE O OTHER IN INSP/MAINT 1 CE 09 914DC 747 89100028 4622127 L937661A PILOT REPORTED HIGH MAG DROP ON LEFT MAG. RUN-UP INDICATED NEARLY COMPLETE MAG FAILURE. DURING DISASSEMBLY, A LARGE AM OUNT OF DUST WAS NOTED IN THE AREA OF THE CONTACT ASSEMBLY AND CONTACTS WERE BARELY OPENING. THE CAM WAS FOUND SEVERELY WORN. NO REASON FOR THE UNUSUAL WEAR WAS NOTED. 1 L 7 1 3O 3 O RT A25SO E14EA 1997120400950 19971204 00950 EA 1997 12 4 97ZZZX4964 2 19971120 G 8530 CC20B PISTON RING CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA NR 1 CYLINDER FAILED B GYWR K NONE O OTHER IN INSP/MAINT 1 SW 13 9773B 854 172RG1027 L2815936A EXCESSIVE OIL OUT OF ENGINE BREATHER PROMPTED ENGINE COMPRESSION CHECK WHICH REVEALED LOW COMPRESSION ON NR 1 CYLINDER. REMOVAL OF CYLINDER REVEALED TOP COMPRESSION RING SHATTERED INTO APPROX .25 INCH SEGMENTS AND SECOND COMPRESSION RING B ROKEN IN SEVERAL PLACES. OIL RING FOUND STUCK IN GROOVE. PISTON WAS DAMAGED IN RING GROOVES, BUT CYLINDER SHOWED NO SI GN (VISUAL OR DIMENSIONAL) OF DAMAGE. ADJACENT CYLINDER WAS REMOVED FOR INSPECTION, BUT NO DEFECTS WERE FOUND. NO APPA RENT OR OBVIOUS CAUSE NOTED OR DETECTED. 1 H 7 1 3O 3 O 3A17 E286 1997120400951 19971204 00951 EU 1997 12 4 97ZZZX4965 1 19971101 G 2435 30702093 DRIVESHAFT AMD FALC10 FALCON10 2730101 EU START/GEN WORN D K NONE O OTHER IN INSP/MAINT 1 SW 09 61TJ 041 STARTER/GENERATOR DRIVESHAFT AND STARTER/GENERATOR DRIVESHAFT SPLINES WORN COMPLETLY AWAY CAUSING GENERATOR TO CEASE FUN CTIONING DURING OTHERWISE NORMAL FLIGHT. POSSIBLY LARGER SPLINES COULD HAVE PREVENTED THIS PROBLEM. 2 L 7 2 4F A33EU 1997120400952 19971204 00952 CE 1997 12 4 97ZZZX4966 1 19971117 G 5541 55331160 RIB CESSNA 500 550 2076604 CE RUDDER CRACKED B A SI6R K NONE O OTHER IN INSP/MAINT 1 SW 17 387HA 5921 0465 UPON REMOVAL OF THE LEFT LOWER RUDDER CLOSEOUT SKIN, THE INTERSPAR RIB WAS FOUND CRACKED ACROSS THE ENTIRE WIDTH OF THE RIB. THE DAMAGE TO THE RIB WAS A CLEAR INDICATION OF A CRACK CAUSED BY FATIGUE. THE DECREASED INTEGRITY ALSO CAUSED TH E ATTACHING RUDDER SKIN TO CRACK. 1 L 7 2 4F A22CE 1997120400953 19971204 00953 NM 1997 12 4 97ZZZX4967 1 19971025 G 2781 TORQUE TUBE BOEING 757 75723A 1384967 NM SLAT NR 9 LOOSE W ANCF A UNSCHED LANDING J WARNING INDICATION NR NOT REPORTED 1 SO 23 987AN 25494 CTG/EWR - FLT 024 - EICAS MSG L.E. SLAT AYSM. DISPLAYED WITH FLAP LEVER UP. FLAP POINTERS STOPPED BETWEEN UP AND 1 DEGR EE. FLIGHT RETURNED TO CTG. SLAT NR 9 TRANSMITTER TORQUE TUBE L.E. WAS FOUND LOOSE. TORQUE TUBE COUPLING ADJUSTED AND REGULATED SYSTEM ACCORDING MM 27-58-01, PAGE 507. TEST ON GROUND OK. 2 L 7 2 4F RT A2NM 1997120400954 19971204 00954 CE 1997 12 4 97ZZZX4968 1 19971117 G 3710 1013202661 TUBE ASSY BEECH 90 C90A 1152911 CE VACUUM SYSTEM CHAFED D K NONE O OTHER IN INSP/MAINT 1 WP 25 491JV 2299 LJ1349 VACUUM TUBE ASSY WAS WORN THROUGH IN A 3 INCH BY .1250 INCH AREA. THE RADAR CRT WAS RESTING ON PIPE. THERE WAS NO LEAK WHEN THE PANEL WAS AT REST. MOVING THE GEAR HANDLE EXPOSED THE LEAK BY MOVING THE RADAR UNIT FOWARD. THIS WAS FOUND W HEN PERFORMING A RETRACTION CHECK ON JACKS IN THE HANGAR. 1 L 7 2 3T RT 3A20 1997120400955 19971204 00955 SW 1997 12 4 97ZZZX4969 1 19971104 G 6220 206010154003 WASHER BELL 206 206B3 1181506 SW M/R HUB CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 25 1200 M/R HUB S/N JILM 5051. WASHER WAS FOUND CRACKED STRAIGHT OUT INSIDE DIAMETER TO OUTSIDE DIAMETER DURING HUB OVERHAUL. W ASHERS ARE NOT SPECIFIED TO BE M.P.I. NORMAL OVERHAUL PROCEDURES ARE TO M.P.I. THESE ITEMS. 1 G 7 1 3U H2SW 1997120400956 19971204 00956 WP 1997 12 4 97ZZZX4970 1 19971116 G 2810 37510007 TANK HUGHES 369 369D 4470706 WP AUX FUEL COLLAPSED B A LS1R K NONE O OTHER NR NOT REPORTED 1 EA 13 5027P 2 611002D AUXILIARY FUEL TANK COLLAPSED DUE TO VACUUM FROM FUEL TRANSFER TO MAIN TANK. UPON INVESTIGATION, FOUND MASKING TAPE WAS PLUGGING THE VENT STANDPIPE APPARENTLY TO PREVENT PAINT FROM ENTERING THE VENT TUBE WHEN THE TANK WAS PAINTED BY THE MA NUFACTURER. AIRCRAFT WAS LANDED WITHOUT INCIDENT. 1 G 7 1 3U H3WE 1997120400957 19971204 00957 SW 1997 12 4 97ZZZX4971 1 19971002 G 6230 206010443001 DUPLEX BEARING 206010450113 BELL 206 206L1 1182107 SW SWASHPLATE BRINELLED D K NONE O OTHER IN INSP/MAINT 1 SW 03 577E 510 GDJG90426 45577 THIS IS NR 6 AND NR 7 DUPLEX BEARING CHANGE FOR BRINELLING ON RACES PARTICULARLY THE LOWER INNER RACE. ALL HAVE BEEN CH ANGED WITH LESS THAN 100-HOUR TT SINCE NEW. 1 G 7 1 3U H2SW 1997120400958 19971204 00958 SW 1997 12 4 97ZZZX4972 1 19971002 G 6230 206010443001 DUPLEX BEARING 206010450113 BELL 206 206L1 1182107 SW SWASHPLATE BRINELLED D K NONE O OTHER IN INSP/MAINT 1 SW 03 2611 411 GDJG90483 45417 THIS IS NR 6 AND NR 7 DUPLEX BEARING CHANGE FOR BRINELLING ON RACES PARTICULARLY THE LOWER INNER RACE. ALL HAVE BEEN CH ANGED WITH LESS THAN 100-HOUR TT SINCE NEW. 1 G 7 1 3U H2SW 1997121100003 19971211 00003 SW 1997 12 11 97ZZZX4975 1 19970926 G 2430 SM20ACD200A21 RELAY BELL 206 206L1 1182107 SW DC SYSTEM INTERMITTENT B ZV1R K NONE O OTHER IN INSP/MAINT 1 SW 03 40LP 708 45233 INTERMITTENT OPERATION. 1 G 7 1 3U H2SW 1997121100004 19971211 00004 GL 1997 12 11 97ZZZX4976 2 19970911 G 7323 23057869 GOVERNOR BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ENGINE MALFUNCTIONED B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 5366Y 1586 86090403 S782 GOVERNOR HAS NO MORE ADJUSTMENT FOR COMPENSATION. REPLACED GOVERNOR. 1 G 7 2 3U 3 U H3EU E4CE 1997121100005 19971211 00005 GL 1997 12 11 97ZZZX4977 2 19970922 G 7323 23057869 GOVERNOR BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ENGINE FAILED B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 8776 436 86220668 S776 UNABLE TO ADJUST DROOP COMP. REPLACED GOVERNOR. 1 G 7 2 3U 3 U H3EU E4CE 1997121100006 19971211 00006 SW 1997 12 11 97ZZZX4978 1 19970924 G 6510 406040340101 DISK BELL 407 407 SW T/R DISK PACK CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 417AL 53054 SCHEDULED INSPECTION FOUND DISK PACK DISK CRACKED. THREE REPORTS RECEIVED DATED 9-24-97 ON T/R DISK PACK DISK CRACKED. 1 G 7 1 3U O H2SW 1997121100007 19971211 00007 SW 1997 12 11 97ZZZX4979 1 19970924 G 6510 406040340101 DISK BELL 407 407 SW T/R DISK PACK CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 417AL 53054 SCHEDULED INSPECTION FOUND DISK PACK DISK CRACKED. REMOVED AND REPLACED. THREE REPORTS RECEIVED DATED 9-24-97 ON T/R D ISK PACK DISK CRACKED. 1 G 7 1 3U O H2SW 1997121100008 19971211 00008 NM 1997 12 11 97ZZZX4980 1 19971101 G 5347 SEAT TRACK BOEING 727 727225 1384077 NM BS 1060-1070 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN SEAT TRACK, STA 1060 TO STA 1070 AT RBL 45. 2 L 7 3 4F A3WE 1997121100009 19971211 00009 NM 1997 12 11 97ZZZX4981 1 19971101 G 5347 SEAT TRACK BOEING 727 727225 1384077 NM BS 1010-1030 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION WAS NOTED ON CABIN SEAT TRACK BETWEEN STA 1010 - STA 1030 AT LBL 45. 2 L 7 3 4F A3WE 1997121100010 19971211 00010 NM 1997 12 11 97ZZZX4982 1 19971101 G 5311 FRAME BOEING 727 727225 1384077 NM BS 1030 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION WAS NOTED ON FRAME 1030 BETWEEN S17L AND S26L. 2 L 7 3 4F A3WE 1997121100011 19971211 00011 NM 1997 12 11 97ZZZX4983 1 19971101 G 5315 FLOOR BEAM BOEING 727 727225 1384077 NM BS 480 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON UPPER CHORD FLOOR BEAM STA 480 BETWEEN RBL 65 AND LBL 24. 2 L 7 3 4F A3WE 1997121100012 19971211 00012 NM 1997 12 11 97ZZZX4984 1 19971101 G 5315 FLOOR BEAM BOEING 727 727225 1384077 NM BS 420 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION WAS NOTED ON UPPER CHORD FLOOR BEAM STA 420 BETWEEN RBL 12 AND LBL 14. 2 L 7 3 4F A3WE 1997121100013 19971211 00013 NM 1997 12 11 97ZZZX4985 1 19971101 G 5320 SUPPORT BOEING 727 727225 1384077 NM BS 380-400 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN FLOOR SUPPORT BETWEEN STA 380 TO STA 400 AT RBL 12. 2 L 7 3 4F A3WE 1997121100014 19971211 00014 NM 1997 12 11 97ZZZX4986 1 19971101 G 5311 FRAME BOEING 727 727225 1384077 NM BS 1050 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON FRAME WEB AT STA 1050 AT S19L. 2 L 7 3 4F A3WE 1997122900001 19971229 00001 NM 1997 12 29 97ZZZX4987 1 19971101 G 5320 SUPPORT BOEING 727 727225 1384077 NM BS 420-440 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN FLOOR SUPPORT BETWEEN STA 420 - STA 440 AT RBL 12. 2 L 7 3 4F A3WE 1997121100015 19971211 00015 NM 1997 12 11 97ZZZX4988 1 19971101 G 5312 STIFFENER BOEING 727 727225 1384077 NM BULKHEAD LT 1183 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON STIFFENER FORWARD FACE BOTTOM OF BULKHEAD 1183 AT LBL 18. 2 L 7 3 4F A3WE 1997121100016 19971211 00016 NM 1997 12 11 97ZZZX4989 1 19971101 G 5312 STIFFENER BOEING 727 727225 1384077 NM BULKHEAD RT 1183 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON FORWARD FACE 1183 BULKHEAD STIFFENER, LOWER SECTION, AT RBL 18. 2 L 7 3 4F A3WE 1997121100017 19971211 00017 NM 1997 12 11 97ZZZX4990 1 19971101 G 5311 FRAME BOEING 727 727225 1384077 NM BS 740 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, EXFOLIATION CORROSION NOTED ON FORWARD FACE OF STA 740 FRAME SPLICE AT S9R. 2 L 7 3 4F A3WE 1997121100018 19971211 00018 NM 1997 12 11 97ZZZX4991 1 19971101 G 5330 SKIN BOEING 727 727225 1384077 NM BS 1150-1183 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON FUSELAGE SKIN BETWEEN STA 1150 AND STA 1183 BETWEEN S14R AND S20R. 2 L 7 3 4F A3WE 1997121100019 19971211 00019 NM 1997 12 11 97ZZZX4992 1 19971101 G 5313 STRINGER BOEING 727 727225 1384077 NM BS 950-1010 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION AND CRACKING NOTED ON S27R BETWEEN STA 950 AND STA 1010. 2 L 7 3 4F A3WE 1997121100020 19971211 00020 NM 1997 12 11 97ZZZX4993 1 19971101 G 7120 65187226 MOUNT BOEING 727 727225 1384077 NM NR 3 ENGINE CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON NR 3 ENGINE FORWARD MOUNT. 2 L 7 3 4F A3WE 1997121100021 19971211 00021 NM 1997 12 11 97ZZZX4994 1 19971101 G 5311 FRAME BOEING 727 727225 1384077 NM BS 1166 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON BULKHEAD FRAME STA 1166. 2 L 7 3 4F A3WE 1997121100022 19971211 00022 NM 1997 12 11 97ZZZX4995 1 19971101 G 5320 WEB BOEING 727 727225 1384077 NM LT BS 259.3 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, INTERGRANULAR CORROSION NOTED ON WEB LT SIDE FRAME 259.3. 2 L 7 3 4F A3WE 1997121100023 19971211 00023 NM 1997 12 11 97ZZZX4996 1 19971101 G 5320 WEB BOEING 727 727225 1384077 NM RT BS 259.5 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, INTERGRANULAR CORROSION NOTED ON WEB RT SIDE FRAME 259.5. 2 L 7 3 4F A3WE 1997121100024 19971211 00024 NM 1997 12 11 97ZZZX4997 1 19971101 G 5320 CHORD BOEING 727 727225 1384077 NM BS 1030 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN FLOOR BEAM UPPER CHORD AT STA 1030, FROM RBL 45 TO RBL 65. 2 L 7 3 4F A3WE 1997121100025 19971211 00025 NM 1997 12 11 97ZZZX4998 1 19971101 G 5320 CHORD BOEING 727 727225 1384077 NM BS 1130 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON LOWER CHORD CABIN FLOOR BEAM AT STA 1130, LBL 24. 2 L 7 3 4F A3WE 1997121100026 19971211 00026 NM 1997 12 11 97ZZZX4999 1 19971101 G 5320 ANGLE BOEING 727 727225 1384077 NM BS 1010-1030 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON RIGHT HAND CUSP FLOOR SUPPORT ANGLE BETWEEN STA 1010 AND STA 1030. 2 L 7 3 4F A3WE 1997121100027 19971211 00027 NM 1997 12 11 97ZZZX5000 1 19971101 G 5320 SUPPORT BOEING 727 727225 1384077 NM BS 1035-1050 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN FLOOR SUPPORT BETWEEN STA 1035 AND STA 1050 AT LBL 12. 2 L 7 3 4F A3WE 1997121100028 19971211 00028 NM 1997 12 11 97ZZZX5001 1 19971101 G 5320 SUPPORT BOEING 727 727225 1384077 NM BS 1035 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN FLOOR SUPPORT STA 1035 AT LBL 20. 2 L 7 3 4F A3WE 1997121100029 19971211 00029 NM 1997 12 11 97ZZZX5002 1 19971101 G 5320 SUPPORT BOEING 727 727225 1384077 NM BS 312-344 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN FLOOR SUPPORT BETWEEN STA 312 AND STA 344 AT LBL 30. 2 L 7 3 4F A3WE 1997121100030 19971211 00030 NM 1997 12 11 97ZZZX5003 1 19971101 G 5320 SUPPORT BOEING 727 727225 1384077 NM BS 1030-1166 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON AFT BAGGAGE PIT FLOOR SUPPORT BETWEEN STA 1030 AND STA 1166 AT LBL 17. 2 L 7 3 4F A3WE 1997121100031 19971211 00031 NM 1997 12 11 97ZZZX5004 1 19971101 G 5320 SUPPORT BOEING 727 727225 1384077 NM BS 1030-1166 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON AFT BAGGAGE PIT FLOOR SUPPORT, STA 1030 TO STA 1166 AT BL ZERO. 2 L 7 3 4F A3WE 1997121100032 19971211 00032 NM 1997 12 11 97ZZZX5005 1 19971101 G 5320 CHORD BOEING 727 727225 1384077 NM BS 480 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN FLOOR BEAM UPPER CHORD AT STA 480. 2 L 7 3 4F A3WE 1997121100033 19971211 00033 NM 1997 12 11 97ZZZX5006 1 19971101 G 5320 ANGLE SUPPORT BOEING 727 727225 1384077 NM BS 480 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON 2 ANGLE SUPPORTS STA 480 AT S20L. 2 L 7 3 4F A3WE 1997121100034 19971211 00034 NM 1997 12 11 97ZZZX5007 1 19971101 G 5320 ANGLE BOEING 727 727225 1384077 NM BS 1183 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON THE 1183 BULKHEAD VERTICAL STIFFENER ATTACH ANGLE AT RBL 18. 2 L 7 3 4F A3WE 1997121100035 19971211 00035 NM 1997 12 11 97ZZZX5008 1 19971101 G 5347 SEAT TRACK BOEING 727 727225 1384077 NM BS 1010-1030 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN SEAT TRACK RIGHT HAND OUTBOARD FROM STA 1010 TO STA 1030. 2 L 7 3 4F A3WE 1997121100036 19971211 00036 NM 1997 12 11 97ZZZX5009 1 19971101 G 5347 SEAT TRACK BOEING 727 727225 1384077 NM BS 1050 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON CABIN SEAT TRACK AT LBL 24 AT STA 1050. 2 L 7 3 4F A3WE 1997121100037 19971211 00037 NM 1997 12 11 97ZZZX5010 1 19971101 G 5320 CHORD BOEING 727 727225 1384077 NM BS 400 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON PREVIOUS REPAIR TO UPPER T-CHORD ON FLOOR BEAM STA 400 APPROXIMATELY RBL 12 TO RBL 20 . 2 L 7 3 4F A3WE 1997121100038 19971211 00038 NM 1997 12 11 97ZZZX5011 1 19971101 G 5313 STRINGER BOEING 727 727225 1384077 NM BS 460-480 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 352PA 20616 DURING C-CHECK, CORROSION NOTED ON S19R BETWEEN STA 460 AND STA 480. 2 L 7 3 4F A3WE 1997121100112 19971211 00112 CE 1997 12 11 97ZZZX5029 1 19971105 G 7160 265201052 INLET LEAR 35 35A 5170602 CE RT ENGINE CRACKED B BAQR K NONE O OTHER IN INSP/MAINT 1 EA 03 20DK 376 35143 CRACKS FOUND ON THE INSIDE OF THE ENGINE INLET AT THE FORWARD INLET RING FLANGE. CRACKS FOUND DURING A PHASE A3 - 300-H OUR INSPECTION. INSPECTION REFERENCE NUMBERS 30-20-00, 71-10-10. AIRCRAFT TOTAL TIME: 7,862.3 HOURS. AIRCRAFT TOTAL CYCLES: 7,469 HOURS. 2 L 7 2 4F A10CE 1997013000431 19970130 00431 CE 1997 1 30 97ZZZX503 1 19970103 G 2820 5200106206 FUEL LINE CESSNA 310 310R 2074245 CE CROSSFEED LEAKING B A AHTR K NONE K FLUID LOSS IN INSP/MAINT 1 GL 11 1743E 6716 310R1559 DURING ANNUAL INSP, THE LEFT CROSS-FEED FUEL LINE WAS FOUND TO HAVE FUEL STAIN IN AN AREA WHERE THE FUEL LINE PASSES THR OUGH THE CABIN AT THE MAIN SPAR. THE AREA WAS ONLY VISIBLE WITH UPHOLSTERY REMOVED. MUCH LABOR WAS REQUIRED TO REMOVE AND REPLACE THE FUEL LINE. ON REMOVAL, SEVERAL PIN HOLES DUE TO CORROSION WERE FOUND WHEN THE LINE WAS PUT UNDER PRESSU RE. 1 L 7 2 3O 3A10 1997121100113 19971211 00113 CE 1997 12 11 97ZZZX5030 1 19971105 G 7160 265201051 INLET LEAR 35 35A 5170602 CE LT ENGINE CRACKED B A BAQR K NONE O OTHER IN INSP/MAINT 1 EA 03 20DK 131 35143 CRACKS WERE FOUND ON THE INSIDE OF THE ENGINE INLET AT THE FORWARD INLET RING FLANGE. CRACKS WERE FOUND DURING A PHASE A3 - 300-HOUR INSPECTION. INSPECTION REFERENCE NUMBERS 30-20-00, 71-10-10. AIRCRAFT TOTAL TIME: 7,862.3 HOURS. AIRCR AFT TOTAL CYCLES: 7,469 HOURS. 2 L 7 2 4F A10CE 1997121100114 19971211 00114 1997 12 11 97ZZZX5031 4 19971009 G 3416 804710 ALTIMETER AMD FALC50 FALCON50MYST 2730106 EU STANDBY ALT ERROR B A AMCR K NONE O OTHER IN INSP/MAINT 1 GL 09 254DV 9003B 085 UPON RECEIVING AN OVERHAULED STANDBY ALTIMETER, INSPECTION REVEALED THE DIGIT INDEXING TO BE 1,000 FEET OFF. FIELD ELEV ATION SETTING INDICATED THE PROPER BAROMETRIC PRESSURE (780 FEET, 3014 HG), BUT ROTATING THE KNOB UP TO 1,000 FEET SHOWE D THE DIGITS READING 0,000. PART RETURNED. THIS UNIT HAD AN OVERHAULED DATE OF 8-22-97. 2 L 7 3 4F A46EU 1997121100115 19971211 00115 CE 1997 12 11 97ZZZX5032 1 19971112 G 2750 556517531 GEARBOX CESSNA 500 550 2076604 CE LT FLAP SHEARED H K NONE O OTHER IN INSP/MAINT 1 GL 25 45NS 975 5500479 WHILE TROUBLEHSHOOTING FLAP DRIVE FAILURE, FOUND LEFT FLAP GEARBOX DRIVESHAFT SHEARED. THIS WAS CAUSED BY RIGHT FLAP GE ARBOX SEIZING. REPLACED GEARBOX WITH UPGRADED DASH 38 UNIT iAW CESSNA SB 558-27-16, REV 7. 1 L 7 2 4F A22CE 1997121100116 19971211 00116 EU 1997 12 11 97ZZZX5033 1 19970904 G 3710 25VF3323309 VACUUM LINE BRAERO DH125 HS125700A 4230170 EU FRAME 9 CHAFED B DJFR K NONE O OTHER IN INSP/MAINT 1 EA 23 701NW NA0206 A PRESSURIZATION BUMP WAS FELT WHEN MAIN AIR VALVES WERE TURNED ON OR THROTTLES WERE MOVED. FOUND RT AILERON CABLE HAD CHAFED THROUGH VACUUM LINE AT FRAME 9 ON RT SIDE OF AIRCRAFT. SUSPECT CABLE TENSION HAD BEEN RELAXED, THEN TENSIONED, W HICH PUT THE CABLE ON THE LOWER SIDE OF THE LINE INSTEAD OF ON TOP. SUBMITTER SUGGESTS VISUAL INSPECTION OF LINE WHEN A CCESS IS AVAILABLE AS WELL AS INSTALLING ADDITIONAL CLAMP AT FRAME 9. CARE SHOULD BE TAKEN WHENEVER CABLE TENSIONS ARE RELAXED TO PREVENT REPOSITIONING OF THE CABLE WHEN LOOSE. 2 L 7 2 4F A3EU 1997121100117 19971211 00117 EU 1997 12 11 97ZZZX5034 1 19971003 G 3246 2600360 WHEEL HALF BENDIX 26003411 BAC 111 111401AK 1480268 EU MLG BROKEN D K NONE O OTHER IN INSP/MAINT 1 NE 03 765B 122 B0246 BAC067 15 INCH SECTION SEPARATED/BROKE OFF FROM A MAIN LANDING GEAR WHEEL HALF. 2 L 7 2 4F A5EU 1997121100124 19971211 00124 NM 1997 12 11 97ZZZX5038 1 19971112 G 7160 35453 AIR BOX CHRIS HUSKY A1 221020X NM VALVE SHAFT WORN D A K NONE O OTHER IN INSP/MAINT 1 EA 13 29076 490 1022 AIR INTAKE BOX SHAFT, ARM AND SLEEVE BUSHINGS FOUND BADLY WORN. APPEARS TO BE CAUSED BY ENGINE VIBRATION EVEN THOUGH PR OPELLER WAS BALANCED AT 532.5 HRS TO .013 IPS. BOX BY DESIGN IS NOT REPAIRABLE DUE TO SHAFT WELDED TO PLATE. SUBMITTER RECOMMENDED BOX BE RE-DESIGNED BY MFG TO INCORPORATE SEALED BALL OR NEEDLE BEARINGS AND PLATE BE ATTACHED TO SHAFT USIN G MACHINE SCREWS AND NUTS ALLOWING FOR FIELD REPAIRS OF BOX ASSY. 1 H 7 1 3O NC A22NM 1997121100125 19971211 00125 CE 1997 12 11 97ZZZX5039 1 19971031 G 5751 MS244624 BEARING CESSNA 208 208B 2073701 CE LT AIL OB HINGE FROZEN D A K NONE O OTHER IN INSP/MAINT 1 CE 09 738FX 996 208B0482 DURING INSPECTION, AILERON CONTROL WAS DISCOVERED TO HAVE UNUSUALLY HIGH RESISTANCE. RESISTANCE WAS EVENTUALLY ISOLATED TO THE LEFT AILERON. BOTH BEARINGS WERE REPLACED AND THE OUTBOARD BEARING WAS FOUND ALMOST FROZEN WITH CORROSION. THE SE ARE SEALED BEARINGS AND HAD NO OUTWARD SIGNS TO INDICATE A PROBLEM. NO REASON FOR THE CORROSION WAS NOTED. 1 H 7 1 3T A37CE 1997121100126 19971211 00126 1997 12 11 97ZZZX5040 4 19971107 G 2215 089606705 SCREWS KING KS270A PIPER PA46 PA46350P SO PITCH SERVO LOOSENED D S A K NONE O OTHER NR NOT REPORTED 1 EA 07 9284X 235 28553 4636087 SERVO NOT WORKING PROPERLY. REMOVED FROM AIRCRAFT AND FOUND THREE SCREWS BACKED OUT UNTIL THEY HIT PLATE 073-0515-03. S CREWS NEED LOCTITE. 1 L 7 1 3O RT A25SO 1997121100127 19971211 00127 SO 1997 12 11 97ZZZX5041 1 19971126 G 3230 BRACKET PIPER PA31T PA31T 7103124 SO MLG UPLOCK CRACKED D S A O OTHER J WARNING INDICATION AP APPROACH 1 GL 11 311AC 3700 31T8120016 MAIN LANDING GEAR UPLOCK SUPPORT BRACKET CRACKED ALLOWING UPLOCK HOOK TO LOCK SIDEWAYS LODGING BETWEEN ROLLER AND GEAR L EG. LEFT MAIN GEAR WOULD NOT EXTEND UNTIL AIRCRAFT WAS PUT THROUGH NEGATIVE GRAVITY. SECOND AIRCRAFT FOUND WITH THIS P ROBLEM. 1 L 7 2 3T A8EA 1997121100128 19971211 00128 SO 1997 12 11 97ZZZX5042 1 19971113 G 5743 67041 TRUNNION BOLT PIPER PA34 PA34200 7103405 SO MLG MOUNT LOOSE D L A K NONE O OTHER IN INSP/MAINT 1 NM 11 19SW 7650 347250119 INSPECTION FOUND THE MLG TRUNNION MOUNTING BOLTS LOOSE ON THEIR BRACKETS. THIS LOOSENING CAUSES THE HOLES IN THE WING S PAR TO ELONGATE. SUBMITTER STATED THEY HAVE FOUND THE BOLTS LOOSE REGULARLY ON ALL OF FLEET PA28R AND PA34 AIRCRAFT. 1 L 7 2 3O A7SO 1997121100129 19971211 00129 EU 1997 12 11 97ZZZX5043 1 19971114 G 3830 5583112140 DRAIN CABLE AMD FALC50 FALCON900 2700160 EU FWD LAVATORY DISPLACED B A YL1R O OTHER F FLT CONT AFFECTED TX TAXI/GRND HDL 1 SW 11 72WS 155 14 CREW ON TAXI CHECKING FLIGHT CONTROL MOVEMENT NOTICED A RESTRICTION IN RUDDER MOVEMENT. THE RUDDER WAS LIMITED TO APPRO XIMATELY HALF TRAVEL TO THE LEFT AND A LOUD CLUNKING NOISE WAS HEARD WITH THE APPLICATION OF RIGHT RUDDER PEDAL. THE NO ISE SEEMED TO BE COMING FROM UNDER THE FORWARD LAVATORY FLOOR. THE AIRCRAFT RETURNED TO DFJC MAINTENANCE AREA FOR AN IN VESTIGATION, FOUND FORWARD LAVATORY DRAIN CABLE RESTING AGAINST TORQUE TUBE FOR RUDDER RESTRICTING FULL MOVEMENT. 2 L 7 3 4F RT A46EU 1997121100130 19971211 00130 CE 1997 12 11 97ZZZX5044 1 19971114 G 3020 ANTI ICE TUBE BEECH 100 B100 1152919 CE LT ENG INTAKE BROKEN D A O OTHER X ENGINE FLAMEOUT CR CRUISE 1 CE 01 564CA 5496 233 BE58 LEFT ENGINE FLAME-OUT AT 7,000 FEET HOLDING AT FLYING COLD IN ICING CONDITION. INTAKE ANTI-ICE HAD BEEN ON FOR HALF AN HOUR. FOUND ONE ANTI-ICE TUBE FLARE BROKEN OFF. SUSPECT SOME LOSS OF BLEED AIR IN THIS AREA COULD HAVE ATTRIBUTED TO I CE FORMING ON INTAKE LIP AND COMING DISLODGED PRIOR TO FLAME-OUT. AIRCRAFT IS OPERATED BY CARVER AERO, INC. 1 L 7 2 4T A14CE 1997121100131 19971211 00131 CE 1997 12 11 97ZZZX5045 1 19971013 G 5210 511151515 HINGE CESSNA 441 441 2076020 CE CABIN DOOR CRACKED B S WTXR K NONE O OTHER IN INSP/MAINT 1 NM 07 2FOR 4946 4410067 WHILE AIRCRAFT WAS UNDERGOING A SCHEDULED INSPECTION, NOTED THE RIVETS IN THE THE AFT LOWER CABIN DOOR HINGE APPEARED TO BE LOOSE. FURTHER VISUAL AND EDDY CURRENT INSPECTION SHOWED THE HINGE WAS CRACKED AT ALL THREE RIVET LOCATIONS. THE R IVETS HAD BEEN INSTALLED PREVIOUSLY IAW CESSNA BULLETIN PJN81-21. HINGE WAS REMOVED AND NEW PART INSTALLED. 1 L 7 2 3T RT A28CE 1997121100187 19971211 00187 EU 1997 12 11 97ZZZX5046 1 19971012 G 7712 G555674 TRANSDUCER BOLKMS 117 BK117A4 5626017 EU ENGINE TORQUE FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117NG 688 7083 TORQUE INDICATOR BEGAN TO SPIN THEN FROZE BELOW ZERO. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1997121100188 19971211 00188 EU 1997 12 11 97ZZZX5047 1 19970926 G 7712 G555674 PRESSURE XDUCER BOLKMS 117 BK117A4 5626017 EU ENGINE TORQUE FAILED B TI1R K NONE O OTHER NR NOT REPORTED 1 SW 05 117NG 508 7083 TORQUE STARTED FLUCTUATING THEN TOTAL FAILURE. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1997121100189 19971211 00189 EU 1997 12 11 97ZZZX5048 1 19970501 G 6710 10513142 ROD END BOLKMS BK117 BK117C1 5626025 EU M/R CORRODED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 7505 ROD END REJECTED DUE TO CORROSION. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1997121100190 19971211 00190 EU 1997 12 11 97ZZZX5049 1 19971010 G 2121 19A2772 FAN BOLKMS BK117 BK117C1 5626025 EU AIR DIST INTERMITTENT B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 7505 FAN INTERMITTENT. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1997013000433 19970130 00433 SO 1997 1 30 97ZZZX505 1 19970107 G 2720 63451000 BRACKET PIPER PA28 PA28180 7102808 SO RUDDER PEDAL CRACKED D S A K NONE O OTHER IN INSP/MAINT 1 GL 15 2316R 3800 285487 DURING ANNUAL INSPECTION, CENTER RUDDER PEDAL BRACKET FOUND CRACKED AT 4 LOWER BOLT HOLES. SUSPECT NOSE WHEEL SHIMMY AN D PART DESIGN FOR FAILURE. SUBMITTER RECOMMENDS A THOROUGH INSPECTION ANNUALLY FOR THESE CRACKS. 1 L 7 1 3O 2A13 1997121100191 19971211 00191 EU 1997 12 11 97ZZZX5050 1 19970501 G 6710 10513141 ROD END BOLKMS BK117 BK117C1 5626025 EU M/R CORRODED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 7505 ROD END REJECTED DUE TO CORROSION. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1997121100192 19971211 00192 1997 12 11 97ZZZX5051 4 19971013 G 3421 060002600 GYRO KBV350 BELL 230 230 1182149 SW COCKPIT VG FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 3137 23019 GYRO WILL NOT SPOOL UP COMPLETELY. REMOVED AND REPLACED. 1 G 7 2 3U NC H9SW 1997121100193 19971211 00193 NE 1997 12 11 97ZZZX5052 2 19971016 G 7421 9550166670 IGNITER BOLKMS BK117 BK117C1 5626025 EU LYC LTS101 LTS101650B1 41560 NE ENGINE WORN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 7505 IGNITER PLUG WORN DOWN. REMOVED AND REPLACED. 1 G 7 2 3U 3 U NC H13EU E5NE 1997121100194 19971211 00194 1997 12 11 97ZZZX5053 4 19971017 G 3421 060002600 GYRO BELL 230 230 1182149 SW COCKPIT VG FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 2640 23019 GYRO SLOW TO TURN UP. REMOVED AND REPLACED. 1 G 7 2 3U NC H9SW 1997121100195 19971211 00195 EU 1997 12 11 97ZZZX5054 1 19971005 G 2435 23032022 STARTER/GEN BOLKMS 117 BK117A3 5626015 EU ENGINE CHAFED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4493X 32 18046 S7038 REMOVED NR 2 STARTER/GENERATOR. FAN CHAFED HOLE IN SCREEN. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1997121100196 19971211 00196 EU 1997 12 11 97ZZZX5055 1 19971016 G 3244 5090004910 INDICATOR BOLKMS 117 BK117A3 5626015 EU TURN/BANK FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 527MB 4 483A 7103 CIRCUIT BREAKER TRIPS. INDICATOR HAS INTERNAL SHORT. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1997121100197 19971211 00197 1997 12 11 97ZZZX5056 4 19971019 G 3421 4021541671 INDICATOR BOLKMS 117 BK117A3 5626015 EU HORIZON DEFECTIVE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 911MZ 84041072 7098 BAD INPUTS TO YAW CSAS. NOTE: RED IMPACT INDICATOR. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1997013000434 19970130 00434 CE 1997 1 30 97ZZZX506 1 19970109 G 3233 1693800601 ACTUATOR BEECH 23 C24R 1151254 CE LT MLG PISTON BROKEN D O OTHER J WARNING INDICATION NR NOT REPORTED 1 NE 01 292WC 2796 0710 MC460 PILOT DECLARED IN-FLIGHT EMERGENCY. HEARD LOUD POP AND HAD TO MAINTAIN RIGHT AILERON TO KEEP DIRECTIONAL CONTROL. THEN GOT MAIN GEAR GREEN DOWN AND LOCKED LIGHTS. THEN PUT ALL GEAR DOWN AND LOCKED. TROUBLESHOOTING REVEALED LT MAIN GEAR ACTUATOR PISTON BROKEN FROM PISTON ROD. SUSPECT CAUSE OUT OF RIG SITUATION AFTER REMOVAL OF ACTUATOR OR DEFECT IN PART, OR ASSEMBLY OF PISTON WITH LOCKNUT OVERTORQUE. 1 L 7 1 3O A1CE 1997013000435 19970130 00435 SO 1997 1 30 97ZZZX507 1 19970103 G 2822 2B644 PUMP AIRBORNE PIPER PA34 PA34200T 7103406 SO LT ENG FAILED D K NONE O OTHER IN INSP/MAINT 1 NE 01 5979F 5305 9B607 347770029 LEFT ENGINE FUEL PUMP (WHICH HAS HIGH AND LOW POSITONS) WOULD NOT WORK ON LOW SETTING DUE TO A HIGH RESISTANCE IN THE MO TOR. IT EVENTUALLY BURNED OUT THE RESISTOR THAT HIGH AND LOW ARE WIRED TO. WHILE TROUBLESHOOTING THE RESISTOR (WHICH W AS ORIGINALLY THOUGHT TO BE THE PROBLEM), THE PUMP WAS FOUND TO BE NOT WORKING ON THE LOW SETTING, AND NOISEY ON HIGH SE TTING. REMOVED PUMP FOR FURTHER CHECKING, AND AFTER REMOVING PUMP, A CLUNKING SOUND CAME FROM THE PUMP WHEN YOU SHOOK I T. TOOK PUMP APART, FOUND FUEL IN THE MOTOR, AND LOOSE FIELD. (FIELD IS JUST GLUED IN). THE NOISE (CLUNKING) WAS THE FIELD BANGING UP AGAINST THE ARMATURE. WHEN IN A/C AND TURNED ON, MAGNETISM CAUSED LOOSE FIELD TO STICK TO THE ARMATURE 1 L 7 2 3O A7SO 1997121100495 19971211 00495 WP 1997 12 11 97ZZZX5076 1 19971125 G 7400 369A45143 EPO ASSEMBLY HUGHES 369 369D 4470706 WP ENG REIGNITION FAILED D K NONE O OTHER IN INSP/MAINT 1 EA 13 1097J 439 9000801D DEFECT IN EPO ASSEMBLY CAUSED ENGINE OUT AND AUTO RE-LITE TO COME ON SENDING THE EPO ASSEMBLY IN FOR REPAIR AND/OR AN OV ERHAUL. 1 G 7 1 3U H3WE 1997121100496 19971211 00496 1997 12 11 97ZZZX5077 4 19971118 G 3421 500DCF INDICATOR BELL 206 206B3 1181506 SW HORIZON REF FAILED D K NONE O OTHER IN INSP/MAINT 1 EA 13 206BY 454 3628 2871 HORIZON REFERENCE INDICATOR WILL NOT CAGE. 1 G 7 1 3U H2SW 1997121100497 19971211 00497 GL 1997 12 11 97ZZZX5078 2 19971112 G 7210 6894171 GEARBOX BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20 03013 GL MOUNT BROKEN D K NONE O OTHER IN INSP/MAINT 1 NM 11 105LC 4962 S789 836121 ENGINE HAD GEARBOX THAT HAD UPPER LEFT COMPRESSOR MOUNT BROKEN OFF. FOUND NO REASON FOR BREAKAGE. 1 G 7 2 3U 3 U H3EU E4CE 1997121100498 19971211 00498 NE 1997 12 11 97ZZZX5079 2 19971208 G 7321 7911004092 EEC HAMSTD EEC1311 PWA 4060 PW4060 52119 NE ENGINE CONTROL MALFUNCTIONED B L A SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 8758 C94062044 ELECTRONIC ENGINE CONTROL UNIT PASSED FUNCTIONAL TESTING, BUT EXHIBITED AN HISTORICAL RAM PARITY CODE (BINARY HICCUP) IN ITS FAULT MEMORY. INTERNAL INSPECTION REVEALED A TOTAL OF 20 QUESTIONABLE SOLDER JOINTS ON UNIT'S GATE ARRAYS. EACH A SSEMBLY WAS INVOLVED. THE SUSPECTED SOLDER JOINT EXHIBITED SUCH CONDITIONS AS STRESS FRACTURES AND/OR INSUFFICIENT SOLD ER. THESE CONDITIONS CAN LEAD TO INTERMITTENT OPERATION OF THE FULL AUTHORITY ENGINE CONTROL AND MAY CAUSE EITHER CONTR OL CHANNEL TO BECOME INOPERABLE. HAMILTON STANDARD ENGINEERING HAS BEEN NOTIFIED AND IS PRESENTLY EVALUATING THIS CONDI TION. UNITS ARE UTILIZED ON PW4000 SERIES ENGINES. 4 F E24NE 1997013000436 19970130 00436 GL 1997 1 30 97ZZZX508 3 19970106 G 6114 HUB BEECH 23 A2324 1151226 CE MCAULY 2D34C 2D34C8 GL NR 2 SOCKET CRACKED B W59R K NONE O OTHER IN INSP/MAINT 1 WP 07 6955Q MA303 67170 PROPELLER SUBMITTED FOR OVERHAUL AND TO C/W AD 91-15-04. DURING NDI, A 25 INCH LONG CRACK WAS DISCOVERED IN NR 2 BLADE SOCKET. LAST OVERHAUL IN 1985. A RESEAL FOR A LEAK WAS PERFORMED ON 4-25-91. 1 L 7 1 3O A1CE 5 C P7EA 1997121100499 19971211 00499 EU 1997 12 11 97ZZZX5080 1 19971008 G 6520 4639311003 BEARING BOLKMS 117 BK117A3 5626015 EU T/R GEARBOX MISMANUFACTURED B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 983 TOLERANCES TOO TIGHT, WOULD NOT FIT ON SHAFT CORRECTLY. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1997121100500 19971211 00500 1997 12 11 97ZZZX5081 4 19971016 G 3453 4530089 LORAN AVA1000 CESSNA 650 650 2076802 CE COCKPIT MALFUNCTIONED B TI1R K NONE N FALSE WARNING IN INSP/MAINT 1 SW 05 18527 LORAN GIVES CONSTANT BATTERY WARNING MESSAGE. REMOVED AND REPLACED. 2 L 7 2 4F A9NM 1997121100501 19971211 00501 CE 1997 12 11 97ZZZX5082 1 19970804 G 2740 99141973B CONTROLLER CESSNA 650 650 2076802 CE STAB CONTROL MALFUNCTIONED B L K3GR K NONE O OTHER IN INSP/MAINT 1 WP 23 UNIT REPORTED TO CAUSE AN INTERMITTENT TRIM FAIL ANNUNCIATOR LIGHT. 2 L 7 2 4F A9NM 1997121100502 19971211 00502 NM 1997 12 11 97ZZZX5083 1 19971112 G 2510 25W122201502 SEAT ISRAEL 1125 1125 NM PILOT LT AFT BROKEN D P K NONE O OTHER IN INSP/MAINT 1 SW 11 2487 082 1125046 DURING A C-CHECK INSPECTION, THE PILOT'S SEAT BACK ON THE LEFT ATTACH POINT, THE SPACER TUBE WAS FOUND BROKEN. SUSPECT THE BOLTS WORKED LOOSE ALLOWING ADDITIONAL STRESS TO BE PLACED UPON THE SPACER TUBE. CHECK OF THE BOLTS DURING INSPECTI ONS BY VISUAL AND WITH WRENCH TO ENSURE THE BOLTS REMAIN TIGHT. 2 L 7 2 4F RT A16NM 1997121100503 19971211 00503 SW 1997 12 11 97ZZZX5084 1 19971124 G 2432 RG390E BATTERY SWRNGN SA226 SA226T 8780122 SW DC SYSTEM DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 GL 05 CBC275815 BATTERY SUPPORT SLEEVE ON THE OUTSIDE OF BATTERY SLIDES DOWN 2 INCHES IN-FLIGHT OR DURING LANDING ABOUT 2 INCHES. CONCO RDE FAX SAID TO PUSH SLEEVE UP AND PUT TAPE ON BOTTOM OF SLEEVE. 2 L 7 2 4T RT A5SW 1997121100504 19971211 00504 EA 1997 12 11 97ZZZX5085 2 19971117 G 7314 RG7570K4 PUMP ROMEC BEECH 60 B60 1153605 CE LYC O541 TIO541E1A4 41536 EA FUEL SYSTEM LEAKING D K NONE K FLUID LOSS NR NOT REPORTED 1 NM 09 1551L 20694 219 B1939 P391 PUMP WAS SPEWING FUEL AT CASE PARTING LINE AT REGULATOR. GASKET HAD PUSHED ITS WAY OUT FROM BETWEEN HALVES. RESEALED B Y REPAIR STATION. WAS TOLD THIS WAS OFTEN SEEN DUE TO THINNESS OF GASKET IF ONLY OIL OR GREASE WERE PRESENT ON MATING S URFACES WHEN ASSEMBLED. RECOMMEND NEW GASKET DESIGN. 1 L 7 2 3O 3 O A12CE E10EA 1997121100505 19971211 00505 NM 1997 12 11 97ZZZX5086 1 19971101 G 5311 FRAME BOEING 727 727251 138408H NM BS 848 LT SEPARATED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 258US 19977 DURING C-CHECK INSPECTION, STR 5L AND STR 6L HAD PULLED FASTENERS AND SEPARATING AT FRAME STA 848. 2 L 7 3 4F A3WE 1997121100506 19971211 00506 NM 1997 12 11 97ZZZX5087 1 19971101 G 5311 FRAME BOEING 727 727251 138408H NM BS 848 RT SEPARATED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 258US 19977 DURING C-CHECK INSPECTION, STR 6R HAD PULLED FASTENERS AND SEPARATED FROM FRAME AT STA 848. 2 L 7 3 4F A3WE 1997121100507 19971211 00507 NM 1997 12 11 97ZZZX5088 1 19971101 G 5313 STRINGER BOEING 727 727251 138408H NM BS 848 CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 258US 19977 DURING C-CHECK INSPECTION, STR 17L WAS FOUND CRACKED AT STA 848. 2 L 7 3 4F A3WE 1997121100508 19971211 00508 NM 1997 12 11 97ZZZX5089 1 19971101 G 5311 FRAME BOEING 727 727251 138408H NM BS 825 SEPARATED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 258US 19977 DURING C-CHECK INSPECTION, STR 5L AND STR 6L HAD PULLED FASTENERS AND SEPARATED FRAME AT STA 825. 2 L 7 3 4F A3WE 1997121100509 19971211 00509 NM 1997 12 11 97ZZZX5090 1 19971101 G 5743 TRUNNION BEAM BOEING 727 727251 138408H NM LT MLG WELL BOLTS SHEARED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 258US 19977 DURING C-CHECK INSPECTION, TWO SHEARED BOLTS WERE FOUND ON THE LEFT HAND MAIN LANDING GEAR TRUNNION BEAM AT STA 18A. 2 L 7 3 4F A3WE 1997121100510 19971211 00510 EU 1997 12 11 97ZZZX5091 1 19971104 G 2840 162J CONNECTOR AMD FALC50 FALCON900 2700160 EU FUEL QUANTITY BROKEN B A JZBR K NONE O OTHER IN INSP/MAINT 1 EA 25 404VL 687 158 AIRCRAFT READ ZERO ON GROUP THREE FUEL QUANTITY. TROUBLESHOT TO A BROKEN WIRE ON 162J CONNECTOR. WHEN CONNECTOR WAS RE MOVED, THE POTTING COMPOUND WAS DISINTEGRATING. SUBMITTER STATED TWO OTHER CASES OF SAME PROBLEM ON SAME CONNECTOR. 2 L 7 3 4F RT A46EU 1997121100511 19971211 00511 CE 1997 12 11 97ZZZX5092 1 19971112 G 2913 165FE00503 MOTOR ASSY VICKERS 939789 RKWELL NA265 NA26565 7630107 CE HYDRAULIC PUMP FAILED B RO3R O OTHER E VIBRATION/BUFFET CR CRUISE 1 CE 03 652MK 22 MX58523 46536 STRONG VIBRATION FELT IN AFT SECTION OF AIRCRAFT DURING FLIGHT. HYDRAULIC SYSTEM PRESSURE COULD NOT BE MAINTAINED USING NR 1 HYDRAULIC PUMP. NR 1 HYDRAULIC PUMP HAD FAILED. FOUND METAL CONTAMINATION IN BOTH PRESSURE AND RETURN FILTERS, P UMP HAD BEEN MODIFIED AT TIME OF INSTALLATION BY C/W VICKERS SL -29-940070-1. HYDRAULIC PUMP SENT TO MANUFACTURER FOR T EAR-DOWN. AWAITING RESULTS AT THIS TIME. 2 L 7 2 4J A2WE 1997121100512 19971211 00512 EU 1997 12 11 97ZZZX5093 1 19971124 G 2432 RG390E BATTERY BRAERO DH125 BAE125800A 1500285 EU DC SYSTEM DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 GL 05 300LS CBC275862 BOTH BATTERIES SUPPORT SLEEVE ON THE OUTSIDE OF BATTERY SLIDES DOWN 2 INCHES IN-FLIGHT OR DURING LANDING. CONCORDE FAX SAID TO PUSH SLEEVE UP AND PUT TAPE ON BOTTOM OF SLEEVE. 2 L 7 2 4F RT A3EU 1997121100513 19971211 00513 EU 1997 12 11 97ZZZX5094 1 19971124 G 2432 RG390E BATTERY BRAERO DH125 BAE125800A 1500285 EU DC SYSTEM DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 GL 05 300LS CBC275863 BOTH BATTERIES SUPPORT SLEEVE ON THE OUTSIDE OF BATTERY SLIDES DOWN ABOUT 2 INCHES IN-FLIGHT OR DURING LANDING. CONCORD E FAX SAID TO PUSH SLEEVE UP AND PUT TAPE ON BOTTOM OF SLEEVE. 2 L 7 2 4F RT A3EU 1997121100514 19971211 00514 CE 1997 12 11 97ZZZX5095 1 19971104 G 2740 99141973B ACTUATOR CONTROL CESSNA 650 650 2076802 CE PITCH TRIM FAILED D K NONE J F WARNING INDICATION FLT CONT AFFECTED NR NOT REPORTED 1 GL 19 500FR 249 650208 AIRCRAFT PRIMARY PITCH TRIM INOPERABLE. IF NOSE UP OR DOWN WAS SELECTED, PITCH TRIM WOULD NOT MOVE AND PITCH TRIM FAIL ANNUNCIATOR WOULD COME ON. TROUBLESHOT DOWN TO ACTUATOR CONTROL UNIT. ORDERED AND INSTALLED REPLACEMENT UNIT. TURNED AIRCRAFT POWER ON, PITCH TRIM FAIL ANNUNCIATOR WOULD COME ON IMMEDIATELY AND PITCH TRIM WOULD BE INOPERABLE. RE-CHECKED SYSTEM DOWN TO ACTUATOR CONTROL UNIT. ORDERED AND INSTALLED ANOTHER REPLACMENT UNIT. THIS ONE WORKED. 2 L 7 2 4F A9NM 1997121100515 19971211 00515 EU 1997 12 11 97ZZZX5096 1 19971124 G 2432 RG390E BATTERY AMD FALC50 FALCON900 2700160 EU DC SYSTEM DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 GL 05 900NE CBC262741 83 BOTH SUPPORT SLEEVES ON THE OUTSIDE OF BATTERY SLIDES DOWN ABOUT 2 INCHES IN-FLIGHT OR DURING LANDING. CONCORDE FAX SAI D TO PUSH SLEEVE UP AND PUT TAPE ON BOTTOM OF SLEEVE. 2 L 7 3 4F RT A46EU 1997121100516 19971211 00516 EU 1997 12 11 97ZZZX5097 1 19971124 G 2432 RG390E BATTERY AMD FALC50 FALCON900 2700160 EU DC SYSTEM DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 GL 05 900NE CBC262740 83 BOTH SUPPORT SLEEVES ON THE OUTSIDE OF BATTERY SLIDES DOWN ABOUT 2 INCHES IN-FLIGHT OR DURING LANDING. CONCORDE FAX SAI D TO PUSH SLEEVE UP AND PUT TAPE ON BOTTOM OF SLEEVE. 2 L 7 3 4F RT A46EU 1997121100517 19971211 00517 SO 1997 12 11 97ZZZX5098 2 19971119 G 8530 630046 PIN PLUG BEECH 36 A36 1151604 CE CONT O550 IO550B SO NR 2 CYL PISTON BROKEN D K NONE O OTHER IN INSP/MAINT 1 GL 19 1528K 1149 E2453 675431 ON REMOVAL OF NR 2 CYLINDER FOR LOW COMPRESSION, THE ONE-PIECE FORGED ALUMINUM PLUG IN THE CENTER OF THE WRIST PIN WAS F OUND BROKEN IN TWO, TWO INCHES FROM THE END. 1 L 7 1 3O 3 O 3A15 E3SO 1997121100518 19971211 00518 SO 1997 12 11 97ZZZX5099 1 19971125 G 5540 51108004 HINGE PIPER PA31 PA31310 7103103 SO RUDDER SEIZED D A K NONE O OTHER IN INSP/MAINT 1 EA 09 272HJ 3572 317712055 FOUND THE RUDDER TOP HINGE BOLT SEIZED IN THE HINGE BEARING AND COULD NOT BE FREED. BOTH HINGE ASSEMBLIES (THE RUDDER A ND VERTICAL STABILIZER) HAD TO BE REPLACED. THE CORROSION WAS SEVERE AND THERE WAS NO EVIDENCE OF LUBRICATION. 1 L 7 1 3O RT A20SO 1997013000438 19970130 00438 CE 1997 1 30 97ZZZX510 1 19970118 G 2810 120006524 NIPPLE CESSNA 182 182Q 2072732 CE RT FUEL BLADDER FAILED D K NONE O OTHER IN INSP/MAINT 1 CE 07 735SN 1044 18265649 WHILE CHANGING FUEL LINE CONNECTION HOSES ON LT AND RT FUEL BLADDER, NIPPLES BROKE OFF. NO EVIDENCE OF CRACKING OR PREV IOUS LEAKING NOTED. SUSPECT CAUSE - OLD AGE? 1 H 7 1 3O NT 3A13 1997121100519 19971211 00519 SO 1997 12 11 97ZZZX5100 1 19971125 G 5530 4805500 HINGE PIPER PA31 PA31310 7103103 SO VERT STABILIZER SEIZED D K NONE O OTHER IN INSP/MAINT 1 EA 09 272HJ 3572 317712055 FOUND THE RUDDER TOP HINGE BOLT SEIZED IN THE HINGE BEARING AND COULD NOT BE FREED. BOTH HINGE ASSEMBLIES (THE RUDDER A ND VERTICAL STABILIZER) HAD TO BE REPLACED. THE CORROSION WAS SEVERE AND THERE WAS NO EVIDENCE OF LUBRICATION. 1 L 7 1 3O RT A20SO 1997121100520 19971211 00520 1997 12 11 97ZZZX5101 4 19971115 G 2210 065501100 SWITCH KING KFC200 PIPER PA31 PA31350 7103110 SO AUTOPILOT FAILED D K NONE O OTHER IN INSP/MAINT 1 AL 01 4082T 541 318152089 PILOT REPORTED UPON COMPLETION OF PRE-FLIGHT CHECK, ACCELEROMETER SWITCH WOULD NOT TEST OR DISCONNECT AUTOPILOT AS REQUI RED BY POH INSTRUCTIONS. THE SYSTEM WAS FOUND TO DISCONNECT IN THE DOWN POSITION SOMETIMES, AND WOULD NOT DISCONNECT IN THE UP POSITION. THE SWITCH IS OF VERY POOR DESIGN AND CONSTRUCTION. INNER AND OUTER HOUSINGS ARE OF DISSIMILAR METAL AND DO NOT EXPAND AND CONTRACT AT THE SAME RATE NOT ALLOWING THE SWITCH TO MOVE AT DIFFERENT TEMPS. WHOLE SYSTEM IS OV ER-ENGINEERED. ONE SIMPLE TSO TO REMOVE THE SWITCH FROM THE SYSTEM WOULD CURE THE PROBLEM. IF SWITCH IS USED FOR WHAT IT WAS DESIGNED, PILOT HAS ALREADY LOST CONTROL OF THE AIRCRAFT!! 1 L 7 2 3O A20SO 1997121100521 19971211 00521 1997 12 11 97ZZZX5102 4 19971119 G 2210 065501100 SWITCH KING KFC200 PIPER PA31 PA31350 7103110 SO AUTOPILOT MALFUNCTIONED D K NONE O OTHER IN INSP/MAINT 1 AL 01 4082T 306 318152089 DURING A PRE-FLIGHT CHECK, PILOT TESTED THE ACCELEROMETER SWITCH. IT WOULD TEST OK IN THE DOWN POSITION, BUT WOULD NOT TEST IN THE UP POSITION. SUBMITTER RECOMMENDS THAT THE PART BE TSO'D OUT OF THE SYSTEM. 1 L 7 2 3O A20SO 1997121100522 19971211 00522 SO 1997 12 11 97ZZZX5103 1 19971124 G 3710 211CC PUMP PIPER PA28 PA28180 7102808 SO VACUUM SYSTEM FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 07 4240T 1 70588 287205112 PUMP FAILED ON FIRST TAKEOFF. VACUUM PUMP NEWLY OVERHAULED. 1 L 7 1 3O 2A13 1997121100523 19971211 00523 CE 1997 12 11 97ZZZX5104 1 19971117 G 5531 17330021 SPAR CESSNA 177 177RG 2073709 CE VERTICAL FIN CRACKED D A K NONE O OTHER IN INSP/MAINT 1 SO 13 691DB 177RG1314 VERTICAL FIN SPAR CRACKED ON BOTH SIDES RIGHT BEHIND TOP RUDDER HINGE. CRACKS MEASURE CLOSE TO .75 INCH ON BOTH SIDES. VERTICAL FIN NOT DISTORTED AND RUDDER HINGE SHOWS NO DAMAGE. CAUSE OF CRACKS UNKNOWN. 1 H 7 1 3O A20CE 1997121100524 19971211 00524 EU 1997 12 11 97ZZZX5105 2 19971026 G 8500 ENGINE AMTR 500 MINI500 13015HW GL ROTAX 582 ROTAX582 55555 EU POWER SECTION FAILED G A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 WP 05 7234Y 231 DURING PATTERN WORK, ENGINE FAILED AT ABOUT 500 FEET AFTER TAKEOFF. HELICOPTER WAS DESTROYED. REASON FOR ENGINE FAILUR E NOT GIVEN. 1 G 7 1 3I 3 I NC EXPA1G71 EXPE3I 1997121100525 19971211 00525 CE 1997 12 11 97ZZZX5106 1 19971120 G 5520 50350053 FITTING CESSNA 421 421C 2076016 CE LT ELEVATOR CRACKED B WIWR K NONE O OTHER IN INSP/MAINT 1 WP 07 2656B 4500 421C0711 DURING A 100-HOUR INSPECTION, THE END FITTING ON THE LT ELEVATOR WAS FOUND CRACKED AT THE HOLE FOR THE TAPERED PIN. IT APPEARS THE END FITTING HAD BEEN REMOVED FROM THE AIRCRAFT BEFORE. SUBMITTER STATED THE USE OF PROPER TORQUE WHEN INSTA LLING THE TAPERED PINS WOULD PREVENT CRACKS AT THE PIN HOLE FROM OCCURRING. 1 L 7 2 3O A7CE 1997121100527 19971211 00527 EU 1997 12 11 97ZZZX5108 1 19971119 G 7714 TG010005006 TACH GENERATOR PARTEN P68 P68TCOBS 6780108 EU ENGINE FAILED B RF1R K NONE O OTHER IN INSP/MAINT 1 SW 01 737 313 40004OTC TACHOMETER GENERATOR FAILED. HIGH TIME ON PART. SUSPECT NOT ENOUGH LUBRICATION FOR TIME ON PART. SUBMITTER STATED CHA NGE AT PROPER LIFE LIMIT. 1 H 7 2 30 A31EU 1997121100528 19971211 00528 CE 1997 12 11 97ZZZX5109 1 19971029 G 3213 169810000663 HOUSING BEECH 23 C23 1151242 CE NLG WHEEL FAILED G O OTHER O OTHER LD LANDING 1 GL 15 6638B 5200 M2217 NOSE WHEEL ASSEMBLY FAILED, DEPARTED AIRCRAFT SHORTLY AFTER TOUCH-DOWN. LANDING COMPLETED ON MAINS AND NOSE GEAR TRUSS COLLAR. INVESTIGATION REVEALED STRESS CRACKS IN PISTON SLEEVE AT ATTACH POINTS; SUSPECT CAUSED BY OVERSTEERING DURING G ROUND TO WING WITH POWER TUG. SUBMITTER RECOMMENDS INSPECTING NOSE GEAR STEERING LIMIT STOP NUT SLEEVE. IF NYLON BUSHI NG IS DENTED, NOSE GEAR SHOULD BE DISASSEMBLED AND INSPECTED. 1 L 7 1 3O A1CE 1997013000439 19970130 00439 CE 1997 1 30 97ZZZX511 1 19970118 G 2810 120006523 NIPPLE BTC67 CESSNA 182 182Q 2072732 CE LT FUEL BLADDER FAILED D K NONE O OTHER IN INSP/MAINT 1 CE 07 735SN 1044 7682749 18265649 WHILE CHANGING FUEL LINE CONNECTION HOSES ON LT AND RT FUEL BLADDER, NIPPLES BROKE OFF, NO EVIDENCE OF CRACKING OR PREVI OUS LEAKAGE NOTED. SUSPECT CAUSE OLD AGE? 1 H 7 1 3O NT 3A13 1997121100529 19971211 00529 SO 1997 12 11 97ZZZX5110 1 19970801 G 2913 38998005 PUMP PIPER PA32 PA32R301T 7103220 SO HYDRAULICS FAILED D L K NONE O OTHER NR NOT REPORTED 1 CE 05 84KA 3488 32R8129052 ELECTRO HYDRAULIC PUMP RUNS, BUT PRODUCED INSUFFICIENT HYDRAULIC PRESSURE TO MOVE GEAR PAST HALF RETRACT POSITION. FOUN D FLUID LEVEL FULL. NO EXTERNAL LEAKS. PUMP SENT TO PIPER FOR REPAIR, BUT THEY LOST UNIT SOMEPLACE, SO WAS UNABLE TO F IND OUT WHAT WAS WRONG. INSTALLED NEW PUMP IN AIRCRAFT. 1 L 7 1 3O A3SO 1997121100530 19971211 00530 CE 1997 12 11 97ZZZX5111 1 19971111 G 2720 12606311 ROD END CESSNA 206 U206G 2073356 CE RUDDER BAR FAILED D A K NONE O OTHER IN INSP/MAINT 1 NE 05 995RA 3084 U20604252 DURING PRE-FLIGHT INSPECTION, EXCESSIVE FREE MOVEMENT IN RUDDER WAS NOTED. FURTHER INVESTIGATION REVEALED THE ROD END B ETWEEN THE RUDDER BAR AND BUNGEE HAD CRACKED OFF. THE PART SHOWED EVIDENCE OF HAVING BEEN CRACKED FOR A WHILE. THIS PA RT SEEMS TO BE VERY SMALL FOR THE STRESS IT COMES UNDER. SUBMITTER RECOMMENDS TOUGHER MATERIAL OR INCREASED SIZE. THIS IS THE FOURTH BROKEN ROD END SUBMITTER HAS FOUND ON U206 SERIES AIRCRAFT. 1 H 7 1 3O A4CE 1997121100531 19971211 00531 SO 1997 12 11 97ZZZX5112 1 19970911 G 7603 5697905 CABLE ASSY PIPER PA42 PA42720 7104212 SO NR 1 THROTTLE PARTED B S A S88R K NONE O OTHER IN INSP/MAINT 1 SO 21 9091J 3446 425501035 DURING PRE-FLIGHT OPERATIONAL CHECKS, THE LEFT ENGINE THROTTLE CABLE STAINLESS STEEL RIBBON CORE PARTED WHERE THE CABLE PASSES THROUGH A CUT-OUT IN THE AILERON BELLCRANK RT MOUNTING BRACKET. ENGINE CONTROL WAS LOST AND THE MISSION ABORTED. INVESTIGATION REVEALED THE CABLE INSTALLATION VIOLATED THE 7 INCH MINIMUM BEND RADIUS AT THE POINT OF PARTING. THE CU T-OUT AREA IN THE BRACKET WAS SUBSEQUENTLY ENLARGED TO RELIEVE THE CABLE BEND. THE CABLE ASSEMBLY WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 4T A23SO 1998050600139 19980506 00139 WP 1998 5 6 97ZZZX5113 2 19971119 G 7230 30756432 RETAINER SEAL GARRTT TFE731 TFE731* 01518 WP HP COMP NR 5 MISIDENTIFIED B IY2R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 15 DURING INSTALLATION OF SB 72-3596 R5 (REPLACEMENT OF MAIN SHAFT CARBON SEALS AND ASSOCIATED COMPONENTS), MECHANIC FOUND THE NR 5 SEAL RUNNER RETAINER PN 3075635-2 WAS IDENTIFIED AS PN 3075643-2. THIS PART NUMBER IS FOR THE NR 4 SEAL RUNNER RETAINER. INSPECTION STAMP ADJACENT TO PART NUMBER IS 16/868. THIS SERVICE BULLETIN IS VERY COMPLEX AND IS HARD TO ID PARTS WITHOUT CURRENT PART NUMBER. SUBMITTER STATED ALLIED SIGNAL MUST DO A BETTER JOB WITH SUPERVISION AND TRAINING O F THEIR INSPECTION PERSONNEL. PART HAS BEEN RETURNED TO ALLIED SIGNAL, PHX. 4 F E6WE 1998050600140 19980506 00140 1998 5 6 97ZZZX5114 4 19971121 G 3418 1513 LIFT DETECTOR BEECH 55 E55 1152732 CE SWITCH SHORTED B A RT2R K NONE O OTHER IN INSP/MAINT 1 GL 11 163SP 219 336576 TE872 AIRCRAFT WAS ON RAMP AFTER LANDING IN WET SNOW. WITH ADDITIONAL SNOW ACCUMULATING ON THE AIRCRAFT, THE STALL WARNING HO RN BEGAN TO SOUND. PILOT SILENCED HORN WITH CIRCUIT BREAKER AND ADVISED MAINTENANCE. LIFT DETECTOR WAS FOUND SHORTED I NTERNALLY. AFTER EXTERNAL HEATING OF THE LIFT DETECTOR TO REMOVE MOISTURE, FUNCTION CHECKS WERE NORMAL. SUBMITTER RECO MMENDS MANUFACTURER USE ENVIRONMENTALLY SEALED MICROSWITCH IN THE LIFT DETECTOR ASSEMBLY TO AVOID FALSE STALL INDICATION S. 1 L 7 2 3O 3A16 1998050600141 19980506 00141 CE 1998 5 6 97ZZZX5115 1 19971103 G 5512 5062000153 SKIN 50600001623 BEECH 90 E90 1152914 CE LT HORIZ STAB CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 03 228RA 5794 LW197 AFTER REMOVAL OF THE SURFACE DE-ICE BOOT, A SMALL CRACK APPROXIMATELY .6250 INCH LONG WAS FOUND RADIATING FROM A RIVET H OLE ON THE LEFT HORIZONTAL STABILIZER AT STA 63.0. THE CRACK WAS RADIATING OUTBOARD AND AFT. CRACKED AREA WAS REMOVED AND A FLUSH DOUBLER WAS INSTALLED. 1 L 7 2 3T 3A20 1998050600142 19980506 00142 CE 1998 5 6 97ZZZX5116 1 19971009 G 5522 101610000606 ELEVATOR BEECH 200 200BEECH 1152920 CE RT OUTBOARD DAMAGED D K NONE O OTHER IN INSP/MAINT 1 NM 03 520MC 8540 BB43 AFTER A HANGAR RASH INCIDENT, THE RIGHT ELEVATOR WAS BEING REPAIRED FOR DAMAGE TO THE FIBERGLASS TIP. AFTER REMOVAL OF THE TIP, THREE HOLES IN THE OUTBOARD TRAILING EDGE AREA OF THE SKIN WERE FOUND FILLED WITH BODY FILLER. THE FILLER WAS REMOVED AND AN ALUMINUM DOUBLER WAS INSTALLED AFTER BEING APPROVED ON FORM 8110-3. 1 L 7 2 4T A24CE 1998050600143 19980506 00143 CE 1998 5 6 97ZZZX5117 1 19971113 G 5753 BRACKET BEECH 200 200BEECH 1152920 CE RT OTBD FLAP CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 03 56CC 893 BB189 DURING INSPECTION, A .50 INCH CRACK WAS NOTED WHERE THE BRACKET FOR THE FLAP INNER CONNECT ATTACHES ON THE RIGHT OUTBOAR D FLAP. IT APPEARS THE ROD END FOR THE INNER CONNECT WAS LOOSE WHERE IT ATTACHED TO THE BRACKET AND ALLOWED ENOUGH PLAY FOR THE ROD END TO STRIKE THE BASE OF THE BRACKET CAUSING A CRACK. 1 L 7 2 4T A24CE 1998050600144 19980506 00144 CE 1998 5 6 97ZZZX5118 1 19971113 G 5753 SKIN BEECH 200 200BEECH 1152920 CE INBD FLAP CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 03 56CC 8093 BB189 DURING INSPECTION, A .75 INCH CRACK WAS FOUND NEAR A RIVET WHICH ATTACHES THE ENGINE NACELLE TRAILING EDGE FAIRING TO TH E INBOARD FLAP. THE CRACK WOULD NOT HAVE RESULTED IN ANY DAMAGE, BUT SINCE IT IS PART OF A CONTROL SURFACE, RESULTED IN BEING A MAJOR REPAIR. 1 L 7 2 4T A24CE 1998050600145 19980506 00145 CE 1998 5 6 97ZZZX5119 1 19971113 G 5730 PANEL BEECH 200 200BEECH 1152920 CE RT WING OTBD CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 23 56CC 8093 BB189 THE INBOARD AREA OF THE RIGHT OUTBOARD WING PANEL HAS A .3750 INCH CRACK FROM THE TOP OF THE RADIUS CUT-OUT ON THE LEADI NG EDGE FAIRING. 1 L 7 2 4T A24CE 1998050600146 19980506 00146 CE 1998 5 6 97ZZZX5120 1 19971118 G 5620 1014301835 WINDOWS BEECH 200 200BEECH 1152920 CE NR 5 RT DELAMINATED D K NONE O OTHER IN INSP/MAINT 1 NM 03 60PD BB58 DURING ROUTINE CLEANING OF THE AIRCRAFT WINDOWS, DELAMINATION BUBBLES WERE NOTED NEAR THE BOTTOM EDGE AREA OF THE NR 5 P ASSENGER WINDOW. BUBBLES WERE ABOUT THE SIZE OF A PENCIL ERASER OR SMALLER. TOTAL AREA WAS APPROXIMATELY 8 INCHES BY . 50 INCH. WINDOW WAS REPLACED WITH NEW. 1 L 7 2 4T A24CE 1998050600147 19980506 00147 SO 1998 5 6 97ZZZX5121 1 19971027 G 5412 3575305 FIREWALL PIPER PA28 PA28R201T 7102813 SO TURBO AREA CORRODED B H8AR K NONE O OTHER IN INSP/MAINT 1 EA 05 36751 28R7803339 DURING MAINTENANCE FOR ALTERNATOR FAILURE, FOUND FIREWALL HAD A HOLE DUE TO CORROSION. SUSPECT CORROSION DUE TO HEAT EX POSURE FROM TURBOCHARGER. 1 L 7 1 3O 2A13 1998050600148 19980506 00148 SO 1998 5 6 97ZZZX5122 1 19970917 G 5412 3575305 FIREWALL PIPER PA28 PA28R201T 7102813 SO TURBO AREA CORRODED B H8AR K NONE O OTHER IN INSP/MAINT 1 EA 05 6166H 2108 28R7803093 HOLE IN FIREWALL OBSERVED DURING ANNUAL INSPECTION. UPON REMOVAL, FOUND INTERIOR CORROSION MUCH MORE ADVANCED THAN EXTE RIOR. HOLE SEEMED TO BE CAUSED BY CONSTANT EXPOSURE TO TURBOCHARGER OPERATING TEMPERATURES. PLASTIC ON AFT SIDE OF FIR EWALL EXHIBITED SIGNS OF THERMAL BREAKDOWN AND CHARRING. 1 L 7 1 3O 2A13 1998050600149 19980506 00149 CE 1998 5 6 97ZZZX5123 1 19971017 G 7120 05131329 BRACKET CESSNA 175 175 2072502 CE ENG MT ATTACH CRACKED B S A BX4R K NONE O OTHER IN INSP/MAINT 1 NM 03 7518M 55818 ALL FOUR ENGINE MOUNT BRACKETS ON THE FORWARD END OF THE ENGINE MOUNT STRINGERS WERE CRACKED AND HOLE AREA BENT OUT. TH IS AREA BULGED OUT AROUND BOLT HOLE. AIRCRAFT HAS LYCOMING 180 HP MOD. 1 H 7 1 3O NT 3A17 1998050600150 19980506 00150 CE 1998 5 6 97ZZZX5124 1 19971017 G 7120 051313210 BRACKET CESSNA 175 175 2072502 CE ENG MT ATTACH CRACKED B BX4R K NONE O OTHER IN INSP/MAINT 1 NM 03 7518M 55818 ALL FOUR ENGINE MOUNT BRACKETS ON THE FORWARD END OF THE ENGINE MOUNT STRINGERS WERE CRACKED AND HOLE AREA BENT OUT. TH IS AREA BULGED OUT AROUND BOLT HOLE. AIRCRAFT HAS LYCOMING 180 HP MOD. 1 H 7 1 3O NT 3A17 1998050600151 19980506 00151 CE 1998 5 6 97ZZZX5125 1 19971017 G 7120 051313211 BRACKET CESSNA 175 175 2072502 CE ENG MT ATTACH CRACKED B BX4R K NONE O OTHER IN INSP/MAINT 1 NM 03 7518M 55818 ALL FOUR ENGINE MOUNT BRACKETS ON THE FORWARD END OF THE ENGINE MOUNT STRINGERS WERE CRACKED AND HOLE AREA BENT OUT. TH IS AREA BULGED OUT AROUND BOLT HOLE. AIRCRAFT HAS LYCOMING 180 HP MOD. 1 H 7 1 3O NT 3A17 1998050600152 19980506 00152 1998 5 6 97ZZZX5126 4 19971107 G 6113 075263717 BULKHEAD CESSNA 182 182P 2075816 CE SPINNER CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 23 7353S 2302 18265144 FOUND SPINNER BULKHEAD CRACKED AT ATTACHMENT BOLTS. SUBMITTER STATED THIRD BULKHEAD FOUND CRACKED THIS YEAR. OTHER AIR CRAFT RECORDS SHOW PART TIMES AT 1,560 - 1,890 HOURS. 1 H 7 1 3O NT TA13 1998050600153 19980506 00153 CE 1998 5 6 97ZZZX5127 1 19971021 G 3242 164306151 DISC CESSNA 172 172P 2072436 CE RT MLG OVERHEATED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 03 97LP 17274398 UPON INSTALLATION OF NEW CLEVELAND BRAKE DISC AND LININGS ON RT MAIN WHEEL, ACFT WAS TAXIED FOR RUN-UP AND LOUD SQUEELIN G EMITTED FROM RT BRAKE. PAINT ON DISC DAMAGED LININGS AND CAUSED OVERHEATING. REMOVED PAINT FROM DISC WHERE PADS RIDE , INSTALLED NEW LININGS, CHECKED SATISFACTORILY. SUBMITTER STATED NEW BRAKE DISC'S SHOULD NOT BE PAINTED WHERE LININGS RIDE. CONTACTED PARKER HANNIFIN CORP. 1 H 7 1 3O NT 3A12 1998050600154 19980506 00154 SO 1998 5 6 97ZZZX5128 2 19971105 G 7322 1048931 CARBURETOR FACET MA45 CESSNA 182 182P 2075816 CE CONT O470 O470S 17026 SO MIX LEVER WORN D A UNSCHED LANDING Y ENGINE STOPPAGE NR NOT REPORTED 1 NM 03 1331S CL02539 18264895 464286 INSPECTION OF ENGINE AFTER EMERGENCY LANDING FOUND WHEN MIXTURE WAS FULL RICH, MIXTURE LEVER ON CARBURETOR COULD BE PUSH ED TO FULL LEAN WHILE CONTROL CABLE STAYED. CABLE ATTACH BOLT WAS NOT WORN AT ALL, BUT CONTROL LEVER DID HAVE A GROOVE WORN INTO IT ALLOWING LEVER TO MOVE. THE ORIGINAL LOG BOOKS WERE LOST IN 1984. NO LOG BOOK ENTRY SINCE THEN TO INDICAT E REPAIR OR OVERHAUL OF CARBURETOR. TOTAL TIME OF AIRCRAFT AND ENGINE, 1,809.1 HOURS. IT IS UNKNOWN IF ENGINE WAS EVER OVERHAULED. 1 H 7 1 3O 3 O NT TA13 E273 1998050600155 19980506 00155 CE 1998 5 6 97ZZZX5129 1 19971101 G 3252 14421121 BARREL CESSNA 172 172RG 2072438 CE SHIMMY DAMPENER FAILED D A K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 SW 99 5331V 172RG0506 AIRCRAFT WAS BROUGHT TO MAINTENANCE AFTER A TRAINING FLIGHT WITH REPORT OF A SEVERE NOSE WHEEL VIBRATION. AN INSPECTION REVEALED THAT THE END OF THE SHIMMY DAMPENER BARREL CLOSEST TO THE SERVICE HOLE WAS BROKEN OFF. THE OUTER RETAINING LI NE AND BEARING HEAD WERE MISSING. 1 H 7 1 3O 3A17 1998050600156 19980506 00156 EA 1998 5 6 97ZZZX5130 2 19971125 G 7414 MAGNETO ELECTROSYS PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA DISTRIB GEARS FAILED D P A UNSCHED LANDING Y ENGINE STOPPAGE CL CLIMB 1 SW 99 59829 1602 6070845 317652081 L780661A AFTER DEPARTURE AND CLIMBING THROUGH 1,200 FEET AGL, PILOT REPORTED THE LEFT ENGINE POPPED TWICE AND SHUT DOWN. UPON IN SPECTION, FOUND THE MAGNETO DISTRIBUTOR DRIVE GEARS WERE STRIPPED. ALSO NOTED WAS THE BUSHING IN THE DISTRIBUTOR WAS WO RN OUT. 1 L 7 2 3O 3 O A20SO E14EA 1998050600158 19980506 00158 EU 1998 5 6 97ZZZX5132 1 19971101 G 3310 1179203103 CONTROL 830000501 BOLKMS 117 BK117A3 5626015 EU LIGHTS OVERHEAT D K NONE M OVER TEMP IN INSP/MAINT 1 SW 99 911MZ 0550 7098 INSPECTED RHEOSTAT, WIRING, AND INTENSITY CONTROL UNIT. FOUND CONTROL UNIT TO HAVE STRONG ELECTRICAL ODOR. REPLACED WI TH NEW UNIT. OPS CHECK GOOD. 1 G 7 2 3U H13EU 1998050600164 19980506 00164 SW 1998 5 6 97ZZZX5133 1 19970929 G 6410 406016100119 BLADE 407012101107 BELL 407 407 SW T/R CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 457AL 1257 A1518 53151 POST-FLIGHT FOUND TAILROTOR BLADE CRACKED AT INBOARD RADIUS INSIDE TOWARD LEADING EDGE. POSSIBLY STARTED AT CORROSION S POT. 1 G 7 1 3U O H2SW 1998050600165 19980506 00165 EU 1998 5 6 97ZZZX5134 1 19971105 G 5302 1052180110033 PLATE BOLKMS 105 BO105C 5626005 EU TAILBOOM MOUNT CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 502AL S103 DISCOVERED DURING DAILY INSPECTION, WORKING RIVETS AT TAIL ROTOR DRIVESHAFT FORWARD ATTACH BRACKET. REMOVED BRACKET AND DISCOVERED PLATE CRACKED AT RIVET HOLE. 1 G 7 2 3U H3EU 1998010700001 19980107 00001 GL 1998 1 7 97ZZZX5135 1 19971116 G 2721 SWITCH AMTR GAIR GLASAIRIII 05691HK GL RUDDER TRIM STUCK D A C D ABORTED TAKEOFF RETURN TO BLOCK F FLT CONT AFFECTED TO TAKEOFF 1 WP 23 540FT 2107 RUDDER TRIM ROCKER SWITCH STUCK IN LEFT POSITION CAUSING FULL LEFT RUDDER TRIM DURING TAKEOFF ROLL. TAKEOFF ABORTED. A FTER MAXIMUM APPLICATION OF BRAKES, BRAKE LINE FAILED AND SUBSEQUENT BRAKE FIRE. SWITCH FAILURE WAS ABLE TO BE DUPLICAT ED APPROXIMATELY 1 OUT OF 10 ACTUATIONS OF SWITCH. 1 L 7 1 3O RT EXPA1L71 1997121800045 19971218 00045 EA 1997 12 18 97ZZZX5136 1 19971125 G 3244 256K433 TIRE CNDAIR CL600 CL6001A11 1900302 EA SIDEWALL DEFECTIVE B A JO1R K NONE O OTHER IN INSP/MAINT 1 EA 25 90UC 71020931 1023 DURING POST-FLIGHT INSPECTION, A BUBBLE WAS FOUND ON THE SIDEWALL OF TIRE. AFTER TIRE WAS REPLACED, THE S/N WAS CHECKED AGAINST ANOTHER TIRE THAT HAD BEEN REMOVED PREMATURELY FOR AIR LEAKING FROM WEEP HOLES IN SIDEWALL. THAT TIRE S/N WAS 7102030. SINCED THESE 2 TIRES WERE PURCHASED IN A LOT OF 3, THE THIRD TIRE, SN 71020929, WAS RESEARCHED. THIS TIRE HAD ALSO BEEN REMOVED FROM SERVICE PREMATURELY BECAUSE IT HAD BEEN FOUND ON A POST-FLIGHT WITH VERY LOW PRESSURE. A VISIBLE PUNCTURE HOLE HAD BEEN PRESUMED TO BE AT FAULT, THOUGH THE TIRE WAS NOT TOTALLY FLAT. SUBMITTER STATED IT APPEARS SOME SORT OF MANUFACTURING DEFECT IN THAT S/N BATCH CAUSED ALL 3 DEFECTS. 69 LANDINGS SINCE NEW. 2 L 7 2 4F RT A21EA 1997121800046 19971218 00046 SO 1997 12 18 97ZZZX5137 2 19971202 G 8550 1250922200 ADAPTER CESSNA 210 210M 2073450 CE CONT O520 IO520L 17032 SO OIL FILTER VALVE FAILED B YEBR K NONE O OTHER IN INSP/MAINT 1 CE 05 6175N 1969 21062946 294661R AS PART OF THE 600-HOUR INSPECTION OF OIL FILTER ADAPTER REQUIRED BY SEB 93-1R1, THE RELIEF VALVE SEALING 'DISK' WAS FOU ND ASKEW AND NOT SEALING PROPERLY. FURTHER INSPECTION REVEALED THE SPRING THAT HOLDS THE 'DISK' IN PLACE HAD BEEN CHAFE D MORE THAN HALFWAY THROUGH BY ITS SUPPORT CAGE. UNDETECTED, THIS COULD HAVE SERIOUSLY DAMAGED THE ENGINE. 1 H 7 1 3O 3 O 3A21 E5CE 1997121800047 19971218 00047 SO 1997 12 18 97ZZZX5138 1 19971113 G 3230 406163 BRACKET PIPER PA31T PA31T 7103124 SO LT MLG UPLOCK CRACKED B A RT2R K NONE O OTHER IN INSP/MAINT 1 GL 11 103SP 4200 31T8020024 AFT UPLOCK HOOK SUPPORT BRACKET FOR LMLG FOUND CRACKED WHILE GEAR OPERATIONAL CHECKS WERE BEING PERFORMED. CRACK HAD PR OPAGATED ACROSS 95 PERCENT OF THE BRACKET. COMPLETE FAILURE WAS IMMINENT AND WOULD HAVE CAUSED ADDITIONAL LANDING GEAR COMPONENT DAMAGE. IT HAD BEEN ONLY 12 HOURS SINCE THE LANDING GEAR HAD UNDERGONE A DETAILED INSPECTION DURING SCHEDULED MAINTENANCE. 1 L 7 2 3T A8EA 1997121800048 19971218 00048 CE 1997 12 18 97ZZZX5139 1 19971202 G 2750 0512128 BRACKET CESSNA 180 180K 2072624 CE LT FLAP PULLEY BROKEN D K NONE F FLT CONT AFFECTED NR NOT REPORTED 1 SO 13 18WL 6913 18053178 PILOT REPORTED LEFT FLAP WOULD NOT FULLY EXTEND. AN INSPECTION WAS CONDUCTED AND THE FLAP PULLEY BRACKET WAS FOUND BROK EN. THIS CONDITION CAUSED FLAP CABLE TO HAVE EXCESSIVE SLACK. 1 H 7 1 3O 5A6 1997013000442 19970130 00442 CE 1997 1 30 97ZZZX514 1 19970103 G 5320 081308942 DOUBLER CESSNA 310 310R 2074245 CE NLG WHEELWELL CRACKED B AHTR K NONE O OTHER IN INSP/MAINT 1 GL 11 98848 6347 310R0614 DURING ANNUAL INSP, A CRACK WAS NOTICED IN THE DOUBLER FOR THE NLG TRUNNION ATTACH POINT. UPON FURTHER INVESTIGATION, B OTH RT AND LT DOUBLERS WERE FOUND CRACKED. THE DOUBLERS ARE LOCATED AT THE LT AND RT OUTBOARD LOCATIONS ACCESSIBLE THRO UGH THE NOSE BAGGAGE COMPARTMENT. SUBMITTER STATES CRACKS IN THE SAME AREAS HAVE BEEN FOUND ON OTHER 310R MODELS. 1 L 7 2 3O 3A10 1997121800049 19971218 00049 CE 1997 12 18 97ZZZX5140 1 19971016 G 7920 035A470105 LINE MTSBSI MU2 MU2B60 5780460 CE OIL COOLER CRACKED E A UNSCHED LANDING J K WARNING INDICATION FLUID LOSS CR CRUISE 1 SO 13 972ST 745SA PILOT LOST OIL PRESSURE. SHUT DOWN ENGINE AND DEVELOPED EMERGENCY AND LANDED AT CAE. FOUND OIL COOLER STAINLESS OIL LI NE CRACKED. REPLACED LINE WITH SERVICEABLE LINE. 1 H 7 2 3T RT A10SW 1997121800050 19971218 00050 CE 1997 12 18 97ZZZX5141 1 19971028 G 7920 035A470105 LINE MTSBSI MU2 MU2B60 5780460 CE ENGINE OIL FAILED E O OTHER K J FLUID LOSS WARNING INDICATION AP APPROACH 1 SO 13 942ST 756SA PILOT NOTICED OIL PRESSURE DROPPING ON SHORT FINAL. LANDED AT CLT. SHUT DOWN ENGINE WHILE TAXIING IN. MAINTENANCE FOU ND OIL LINE LEAKING. REPLACED LINE. 1 H 7 2 3T RT A10SW 1997013000443 19970130 00443 CE 1997 1 30 97ZZZX515 1 19970103 G 5320 081308947 DOUBLER CESSNA 310 310R 2074245 CE NLG WHEELWELL CRACKED B AHTR K NONE O OTHER IN INSP/MAINT 1 GL 11 98848 6347 310R0614 DURING ANNUAL INSP, A CRACK WAS NOTICED IN THE DOUBLER FOR THE NLG TRUNNION ATTACH POINT. UPON FURTHER INVESTIGATION, B OTH RT AND LT DOUBLERS WERE FOUND CRACKED. THE DOUBLERS ARE LOCATED AT THE LT AND RT OUTBOARD LOCATIONS ACCESSIBLE THRO UGH THE NOSE BAGGAGE COMPARTMENT. SUBMITTER STATES CRACKS IN THE SAME AREAS HAVE BEEN FOUND ON OTHER 310R MODELS. 1 L 7 2 3O 3A10 1997121800729 19971218 00729 EU 1997 12 18 97ZZZX5152 2 19971122 G 7310 FSFL24 FUEL LINE AMTR RANS RANSS10 0561654 GL ROTAX 582 ROTAX582 55555 EU ENGINE COMPT BURNED G A K NONE O OTHER NR NOT REPORTED 1 SO 13 803DR 0297180 4401676 THE VINYL/PLASTIC TUBING USED THROUGHOUT THE ENGINE COMPARTMENT IS MADE OF A HIGHLY FLAMMABLE MATERIAL SUPPLIED BY THE K IT MANUFACTURER. THIS TUBING LAYING AGAINST THE HOT EXHAUST LINE MAY HAVE CONTRIBUTED CONTRIBUTED TO THE FIRE OF THIS A IRCRAFT CAUSING SUBSTANTIAL DAMAGE. SUBMITTER RECOMMENDED KIT MANUFACTURER'S SUPPLY NON-FLAMMABLE MATERIAL IN THEIR AMA TEUR BUILT KIT FOR THE ENGINE COMPARTMENTS. THIS AIRCRAFT HAD AN EXPERIMENTAL AIRWORTHINESS CERTIFICATE AND FAR 43 DOES NOT APPLY. 1 M 7 1 3I 3 I NC EXPA1M71 EXPE3I 1997121800730 19971218 00730 NE 1997 12 18 97ZZZX5153 2 19971212 G 7310 3011155 TRANSFER TUBE PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67 52043 NE NOZZLE MANIFOLD CORRODED B A FE6R K NONE O OTHER IN INSP/MAINT 1 NM 11 159PB 357 159 PCE940012 ENGINE FUEL NOZZLES WERE REMOVED FOR FIRST NOZZLE FLOW TEST SINCE ENGINE MANUFACTURED. UPON ASSEMBLY OF THE FUEL NOZZLE S BACK ON THE ENGINE, IT WAS NOTED THAT 3 FUEL MANIFOLD TRANSFER TUBES HAD VERY DEEP CORROSION PITS. PENETRATION OF THE WALL THICKNESS PROBABLY EXCEEDS 50 PERCENT. SUBMITTER BELIEVES THESE TUBES HAVE NOT BEEN IN SERVICE LONG ENOUGH TO HAV E CORRODED AND SUSPECT DEFECT IN MATERIAL AT MANUFACTURER. ALL 3 DEFECTIVE PARTS HAVE THE FOLLOWING PART NUMBER AND COD E: 3011155 8 1229 CPWA-ASPT. REPLACED DEFECTIVE PARTS WITH NEW. 1 L 7 1 3T 4 T RT A78EU E26NE 1997121800731 19971218 00731 GL 1997 12 18 97ZZZX5154 2 19971210 G 7313 6890917 FUEL NOZZLE HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL INLET SCREEN FAILED G A K NONE O OTHER IN INSP/MAINT 1 WP 13 5119V 256 A628963 1000800D CAE834267 FUEL NOZZLE INLET SCREEN, ALSO KNOWN AS (LAST CHANCE FILTER) SHOWS SIGNS OF INITIAL COLLAPSE. COLLAPSED SCREEN CANNOT B E DETECTED WITHOUT DISASSEMBLY OF NOZZLE. SCREEN IS BEING MANUFACTURED FROM TOO THIN OF MATERIAL AND IS COLLAPSING UNDE R NORMAL CONDITIONS WITHOUT DETECTION. THIS COLLAPSE WILL CAUSE PARTIAL ENGINE POWER LOSS OR TOTAL ENGINE FAILURE. 1 G 7 1 3U 3 U H3WE E4CE 1997121800733 19971218 00733 NM 1997 12 18 97ZZZX5156 1 19971009 G 6220 A005A HUB ROBSIN R22 R22MARINER NM MAIN ROTOR WORN D L A K NONE O OTHER IN INSP/MAINT 1 AL 03 8324U 752 2570M DURING 100-HOUR INSPECTION, EVIDENCE OF FRETTING NOTED AT MAIN ROTOR HUB ATTACH BOLT THRUST WASHERS. DISASSSEMBLY REVEA LED SEVERE WEAR ON MAIN ROTOR HEAD HUB BEARINGS AND THE JOURNALS RIDING INSIDE THESE BEARINGS WHICH ALLOWED RELATIVE MOT ION BETWEEN M/R HUB AND THE ATTACH BOLT. THE HUB WAS REMOVED AND RETURNED TO ROBINSON FACTORY. THE HELICOPTER HAD BEEN INSPECTED 100 HOURS (LESS THAN ONE MONTH PREVIOUSLY) AND NO DEFECTS DISCOVERED IN THE MAIN ROTOR SYSTEM. SUBMITTER DOE S NOT KNOW WHAT CAUSED THIS RAPID WEAR, BUT THE HELICOPTER IS USED IN A HARSH ENVIRONMENT. 1 G 7 1 3O H10WE 1997121800734 19971218 00734 1997 12 18 97ZZZX5157 4 19971114 G 3421 RCA26BK12 INDICATOR RCALLEN BELL 206 206B 1181511 SW GYRO ATTITUDE FAILED B LS1R K NONE O OTHER IN INSP/MAINT 1 EA 13 90322 820737 1736 ATTITUDE GYRO INDICATOR WILL NOT HOLD ATTITUDE. 1 G 7 1 3U H2SW 1997121800735 19971218 00735 CE 1997 12 18 97ZZZX5158 1 19971204 G 1100 K04504003 DATA PLATE CESSNA 150 150L 2071826 CE RT MUFFLER DETACHED D K NONE O OTHER IN INSP/MAINT 1 EA 01 1283Q 300 34802 15072583 DURING AN OIL CHANGE AND ENGINE CHECK, FOUND THAT ON THE LEFT MUFFLER, THE DATA PLATE TACK WELDS HAD FAILED AND THE DATA PLATE ITSELF WAS LOCATED INSIDE THE CABIN HEAT SCAT HOSE. IF THIS DATA PLATE HAD COME LOOSE ON THE RIGHT MUFFLER, IT V ERY LIKELY MIGHT BE INJESTED INTO THE CARBURETOR WHEN CARBURETOR HEAT WAS SELECTED. 1 H 7 1 3O 3A19 1997121800736 19971218 00736 CE 1997 12 18 97ZZZX5159 1 19971112 G 2750 0400107145 CONTROL CABLE CESSNA 150 152 2071835 CE LT FLAP FAILED G A A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 GL 15 48863 9050 15281011 DURING STALL RECOVERY WORK, THE FLAPS WERE BEING MOVED TO A 20 DEGREE POSITION WHEN THE LEFT FLAP RETRACTED TO FULL UP T RAIL POSITION AND RIGHT FLAP REMAINED DOWN (THIS OCCURRED AFTER A LOUD BANG). THE ACFT ROLLED LEFT. PILOT INITIATED EM ERGENCY PROCEDURES AND LANDED PLANE. LEFT FLAP CABLE BROKE AT SWAGED BALL END. 1 H 7 1 3O NT 3A19 1997121800737 19971218 00737 SO 1997 12 18 97ZZZX5160 1 19971113 G 3211 67040015 ATTACH BRACKET PIPER PA34 PA34200 7103405 SO RT TRUNNION LOOSE D K NONE O OTHER IN INSP/MAINT 1 SO 13 55777 538 347350244 WHILE C/W PIPER SB 906, FOUND TRUNNION ATTACH FITTING LOOSE. THEY WERE REPLACED IN 1995 BECAUSE OF ELONGATED HOLES. TO RQUE CHECK HAS BEEN DONE SINCE BULLETIN CAME OUT. THE GEAR PROBLEM IN THIS PLANE HAS INCREASED CONTINUALLY. 1 L 7 2 3O A7SO 1997121800738 19971218 00738 SO 1997 12 18 97ZZZX5161 1 19971113 G 3211 67040014 ATTACH BRACKET PIPER PA34 PA34200 7103405 SO LT TRUNNION LOOSE D K NONE O OTHER IN INSP/MAINT 1 SO 13 55777 538 347350244 WHILE C/W PIPER SB 906, FOUND TRUNNION ATTACH FITTING LOOSE. THEY WERE REPLACED IN 1995 BECAUSE OF ELONGATED HOLES. TO RQUE CHECK HAS BEEN DONE SINCE BULLETIN CAME OUT. THE GEAR PROBLEM IN THIS PLANE HAS INCREASED CONTINUALLY. 1 L 7 2 3O A7SO 1997121800739 19971218 00739 SO 1997 12 18 97ZZZX5162 2 19971121 G 8530 636697 VALVE SEAT CESSNA 421 421C 2076016 CE CONT O520 GTSIO520N 17032 SO NR 2 CYL INTAKE FAILED B VA1R K NONE O OTHER IN INSP/MAINT 1 SW 19 6798V 4 654654A 421C1254 604727 NEW TCM CYLINDER ASSYS INSTALLED AT ENGINE OVERHAUL. DATE STAMPED ON ROCKER BOSS: 7-97. AFTER BREAK-IN FLIGHT AND TES T FLIGHTS, NR 2 CYL ON LT ENGINE WAS NOTED TO HAVE LOW COMPRESSION: 18/80. LEAKAGE DETERMINED TO BE PAST INTAKE VALVE. REMOVAL AND DISASSY REVEALED VALVE NO LONGER SEATED. CYLINDER WAS LEAK CHECKED BEFORE ASSY WITH NONE NOTED. SEAT HAS SHIFTED AND NO LONGER ALIGNS WITH GUIDE. SUSPECT SEAT ASSY NOT FULLY SEATED WHEN ASSEMBLED. WITH CYLINDER HEAD AT OPE RATING TEMPERATURE, VALVE PUSHES SEAT FULLY IN AND NO LONGER ALIGNS WITH VALVE FACE. THIS IS THE FIFTH CYLINDER AT THIS REPAIR STATION WITH SAME FAILURE. ALL ARE INTAKE SEATS AND START TO LEAK AFTER FIRST FEW HRS OF OPERATION FROM NEW. 1 L 7 2 3O 3 O A7CE E7CE 1997121800740 19971218 00740 CE 1997 12 18 97ZZZX5163 1 19971101 G 5210 PUMP CESSNA 210 P210N 2073454 CE SEAL INFLATE FAILED D A H A F DEACTIVATE SYST/CIRCUITS UNSCHED LANDING ACTIVATE FIRE EXT. B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 NM 11 731NX P21000515 PILOT STATED DOOR SEAL INFLATION PUMP STARTED OPERATING CONTINUOUSLY IN FLIGHT, AND HE WAS UNABLE TO TURN IT OFF. THE C ABIN BEGAN TO FILL WITH SMOKE, SO ALL ELECTRICAL EQUIPMENT WAS TURNED OFF WITH MASTER SWITCH, AND EMERGENCY LANDING WAS MADE. A FIRE AT LEFT LOWER UPHOLSTERY PANEL ADJACENT TO PILOT'S LEFT KNEE WAS EXTINGUISHED WITH HAND FIRE EXTINGUISHER. 1 H 7 1 3O 3A21 1997121800741 19971218 00741 CE 1997 12 18 97ZZZX5164 1 19971022 G 3230 ES12704 SPOOL VALVE CESSNA 210 210B 2073410 CE CONT O470 IO470S 17026 SO MLG PWR PACK STUCK D K NONE O OTHER NR NOT REPORTED 1 GL 27 9740X 21058040 THE SPOOL VALVE IN THE LANDING GEAR POWER PACK MANIFOLD VALVE ASSEMBLY WAS FOUND STUCK IN THE GEAR UP MODE. PULLED SOLE NOID OUT, DEPRESSED THE SPOOL VALVE COUPLE OF TIMES, AND IT SPRUNG BACK INTO THE GEAR DOWN MODE. THEN GEAR WAS HAND PUM PED DOWN AND LOCKED. REASON FOR VALVE TO STICK IN GEAR UP MODE IS UNKNOWN AT THIS DATE. 1 H 7 1 3O 3 O 3A21 3E1 1997121800742 19971218 00742 CE 1997 12 18 97ZZZX5165 1 19971209 G 8097 WIRE BEECH 58 58 1152740 CE STARTER SHORTED D K NONE O OTHER IN INSP/MAINT 1 SO 01 1071F TH1771 ENGINE WOULD NOT STAR, HIGH AMP DRAW WITH RELAY ENGAGED. FOUND STARTER WIRE SHORTED AGAINST ENGINE MOUNT. TTAF: 381.8 HOURS. STARTER WIRES NEED TO BE INSPECTED AND TIED BACK. 1 L 7 2 3O 3A16 1997121800743 19971218 00743 CE 1997 12 18 97ZZZX5166 1 19971120 G 2752 995241221 GEAR BEECH 80 65B80 1152812 CE FLAP GEARBOX FAILED D K NONE O OTHER IN INSP/MAINT 1 EA 15 131BA 39 012 LD297 INVESTIGATION FOR CAUSE OF FLAP GEAR BOX FAILURE FOUND POOR TEETH ENGAGEMENT OF GEARBOX TEETH AND MOTOR GEAR TEETH. 1 L 7 2 3O 3A20 1997121800744 19971218 00744 CE 1997 12 18 97ZZZX5167 1 19971120 G 2752 995240253 GEAR BEECH 80 65B80 1152812 CE FLAP FAILED D K NONE O OTHER IN INSP/MAINT 1 EA 15 131BA 39 1981 LD297 INVESTIGATION FOR CAUSE OF FLAP GEAR BOX FAILURE FOUND POOR TEETH ENGAGEMENT OF GEARBOX TEETH AND MOTOR GEAR TEETH. 1 L 7 2 3O 3A20 1997121800746 19971218 00746 SO 1997 12 18 97ZZZX5169 1 19971128 G 2140 44008 SOLENOID JANITROL PIPER PA31 PA31350 7103110 SO HEATER LEAKING E A K NONE K FLUID LOSS IN INSP/MAINT 1 AL 01 300ED 31785208 DURING WORK ON REAR HEATER, HAD COVER OFF OF FUEL SHUT OFF SOLENOID. NOTICED FUEL LEAKING FROM GROMMET ON BODY OF SOLEN OID. REMOVED PART FROM SERVICE AS IT PRESENTED A FIRE HAZARD. 1 L 7 2 3O A20SO 1997121800748 19971218 00748 CE 1997 12 18 97ZZZX5171 1 19971204 G 3710 HOSE CESSNA 185 A185F 2072821 CE VACUUM SYSTEM LEAK D K NONE O OTHER IN INSP/MAINT 1 NE 05 735GE 860 18504447 VACUUM HOSES ORIGINALLY INSTALLED BECAME BRITTLE AND CRACKED ALONG THE HOSE ALLOWING LEAKAGE INTO SYSTEM. ALL LINES WER E REPLACED. 1 H 7 1 3O 3A24 1997121800749 19971218 00749 GL 1997 12 18 97ZZZX5172 1 19971126 G 7602 A740 CONTROL CABLE AMTR VANS RV6 05608 GL CARB MIXTURE BROKEN H A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 WP 23 44JR 114 24545 MIXTURE CONTROL CABLE BROKE IN CRUISE FLIGHT CAUSING FORCED LANDING. SUBMITTER SUGGESTS CAUSE AS VIBRATION STRESS. REC OMMEND USING HEAVIER CABLE WITH THREADED TERMINATION. 1 L 7 1 3O NC EXPA1L71 1997121800751 19971218 00751 SO 1997 12 18 97ZZZX5174 2 19971205 G 8530 637781 VALVE CESSNA 207 207A 2073604 CE CONT O520 IO520F 17032 SO NR 1 CYLINDER FAILED D S O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 AL 01 75703 1478 20700639 810181R PILOT REPORTED THAT IN CRUISE FLIGHT, THE ENGINE BEGAN RUNNING ROUGH. IT WAS FOUND THE NR 1 CYLINDER HAD ZERO COMPRESSI ON. WHEN THE EXHAUST VALVE WAS REMOVED FROM THE ENGINE, DISCOVERED THE VALVE HAD A MISSING CHUNK. SUSPECT CAUSE - CARB ON BETWEEN VALVE AND SEAT CAUSING RAW FUEL TO PASS BY THE VALVE AND BURN THE VALVE WHEN IGNITED. .25 INCH BY .25 INCH G ONE FROM VALVE TOP. 1 H 7 1 3O 3 O A16CE E5CE 1997121800752 19971218 00752 EA 1997 12 18 97ZZZX5175 2 19971125 G 8540 LW12539 PUMP ADAPTER BEECH 80 65A80 1152808 CE LYC O540 IGSO540A1A 41532 EA MOUNT FLANGE CRACKED D S K NONE O OTHER IN INSP/MAINT 1 GL 15 95LL 237 LD235 L105954 FOUND HYDRAULIC PUMP ADAPTER WITH CRACKED MOUNT FLANGE. SUBMITTER STATED WILL CRACK AROUND ANY OF THE 4 HOLD-DOWN FLANG ES. 1 L 7 2 3O 3 O 3A20 1E7 1997121800753 19971218 00753 GL 1997 12 18 97ZZZX5176 3 19971202 G 6114 D7015C87 HUB CESSNA 340 340A 2076405 CE MCAULY 3AF32C 3AF32C87 GL RETAIN THREADS CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 07 780493 EXCESSIVE CORROSION AND A CRACK WAS FOUND IN THE RETENTION THREADS. SUBMITTER STATED PROPER COMPLIANCE TIMES ADHERED TO COULD HAVE LESSENED THE SEVERITY OF THE SITUATION. 1 L 7 2 3O 3A25 5 C P22EA 1997121800754 19971218 00754 GL 1997 12 18 97ZZZX5177 3 19971202 G 6114 D7015C87 HUB CESSNA 340 340A 2076405 CE MCAULY 3AF32C 3AF32C87 GL BLADE SOCKET CORRODED B CP2R K NONE O OTHER IN INSP/MAINT 1 SW 15 780370 EXCESSIVE CORROSION IN THREADS OF BLADE SOCKETS. SUBMITTER STATED PROPER COMPLIANCE TIMES ADHERED TO MAY HAVE LESSENED THE PROBLEMS. 1 L 7 2 3O 3A25 5 C P22EA 1997121800755 19971218 00755 EA 1997 12 18 97ZZZX5178 2 19971211 G 8550 CH48110 OIL FILTER CHAMPION SLNSBY T67 T67M260 8323006 EU LYC O540 AEIO540D4A5 41532 EA FLANGE CRACKED D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 17 CRACKS WERE FOUND ON ENGINE OIL FILTERS (NEW FILTERS). THIS CRACK IS ON THE BASE FLANGE INSIDE OF BASE SEAL AND OUTBOAR D OF INLET HOLES. SUSPECT CAUSE MIGHT BE ASSEMBLY DEFECT. SUBMITTER RECOMMENDED EMERGENCY AD ISSUE ON THIS OIL FILTER AND REPLACE IF FOUND CRACKED. 1 L 7 1 3O 3 O NT A73EU 1E4 1997121800756 19971218 00756 NE 1997 12 18 97ZZZX5179 2 19971121 G 8520 5999 ROLLER PWA R1340 R1340AN1 52016 NE VALVE TRAIN SPALLED B CP2R K NONE O OTHER IN INSP/MAINT 1 SW 15 456 25165 VALVE TRAIN ROLLER AND CAM SPALLED. DISCOVERED WHILE PERFORMING REPAIR TO THE ENGINE. BOTH THE CAM AND ROLLER WERE FAI LING BY SPALLING. 3 R 5E2 1997121800757 19971218 00757 NE 1997 12 18 97ZZZX5180 2 19971121 G 8520 11768 CAM PWA R1340 R1340AN1 52016 NE VALVE TRAIN SPALLED B CP2R K NONE O OTHER IN INSP/MAINT 1 SW 15 456 25165 VALVE TRAIN ROLLER AND CAM SPALLED. DISCOVERED WHILE PERFORMING REPAIR TO THE ENGINE. BOTH THE CAM AND ROLLER WERE FAI LING BY SPALLING. 3 R 5E2 1997121800758 19971218 00758 NE 1997 12 18 97ZZZX5181 2 19971124 G 8520 5999 ROLLER PWA R1340 R1340AN2 52016 NE VALVE TRAIN SPALLED B CP2R K NONE O OTHER IN INSP/MAINT 1 SW 15 ZP101676 VALVE TRAIN ROLLER FOUND SPALLED. WHILE PERFORMING MAINTENANCE AND REPAIRS ON THE ENGINE. 3 R 5E2 1997121800759 19971218 00759 EA 1997 12 18 97ZZZX5182 2 19971117 G 8500 LW127984S172 HOSE LYC O360 IO360A1B6 41514 EA ENGINE MISMANUFACTURED B HUNR K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 01 NEW REPLACEMENT HOSE ASSY HAS A SCARF-CUT 'FLAPPER' INSIDE THE TAGGED END. (DEFECT FROM THE MANUFACTURING PROCESS). 3 O 1E10 1997121800760 19971218 00760 NE 1997 12 18 97ZZZX5183 2 19971117 G 8520 ROLLER PWA R1340 R1340AN1 52016 NE VALVE TRAIN SPALLED B CP2R K NONE O OTHER IN INSP/MAINT 1 SW 15 23562 VALVE TRAIN ROLLER AND CAM SPALLED. DISCOVERED WHILE PERFORMING REPAIRS AND MAINTENANCE TO THE ENGINE FOR OTHER REASONS . PARTS WERE FOUND SPALLING AND FLAKING. 3 R 5E2 1997121800761 19971218 00761 NE 1997 12 18 97ZZZX5184 2 19971117 G 8520 11768 CAM PWA R1340 R1340AN1 52016 NE VALVE TRAIN SPALLED B CP2R K NONE O OTHER IN INSP/MAINT 1 SW 15 23562 VALVE TRAIN ROLLER AND CAM SPALLED. DISCOVERED WHILE PERFORMING REPAIRS AND MAINTENANCE TO THE ENGINE FOR OTHER REASONS . PARTS WERE FOUND SPALLING AND FLAKING. 3 R 5E2 1997121800762 19971218 00762 EU 1997 12 18 97ZZZX5185 1 19971212 G 3244 60068PLY TIRE PARTEN P68 P68 EU RT MLG DELAMINATED H O OTHER O OTHER LD LANDING 1 EA 01 605 200 321150B RIGHT MAIN TIRE BLEW ON LANDING. PILOTS STATED LANDING WAS NORMAL. INSPECTION OF TIRE AND WHEEL ASSY REVEALED TUBE WAS RUPTURED BY TIRE INNER SIDEWALL DELAMINATION. SUSPECT POSSIBLE DEFECTIVE TIRE CASING. 1 H 7 2 3O A31EU 1997121800763 19971218 00763 EU 1997 12 18 97ZZZX5186 1 19971125 G 7810 MUFFLER SOCATA TB10 TB10TOBAGO 8680696 EU ENGINE EXHAUST CRACKED H S A K NONE O OTHER IN INSP/MAINT 1 NM 01 105U 207 591 EXHAUST HEAT MUFFLER WAS FOUND TO HAVE HOLES IN EXHAUST INTO CABIN HEAT SHROUD EMITTING EXHAUST GAS INTO CABIN HEAT SYST EM. EXHAUST SYSTEM WAS NEW IN 10-10-96 WHEN ENGINE WAS OVERHAULED. (PART LOOKED RELATIVELY NEW). 1 L 7 1 30 NT A51EU 1997121800764 19971218 00764 CE 1997 12 18 97ZZZX5187 1 19971106 G 5610 45AS31001013 WINDSHIELD BEECH MU300 400A 1155402 CE COCKPIT DEFECTIVE B MZ4R O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 SO 17 135BJ 315 96218H4117 RK135 PILOT REPORTED SMOKE IN THE COCKPIT. AFTER TROUBLESHOOTING, FOUND LEFT WINDSHIELD HEAT GROUND STRAP LOOSE. DAMAGE OCCU RRED TO FACILITATE WINDSHIELD REPLACEMENT. TEST FLIGHT CARRIED OUT AFTER WINDSHIELD AND WINDSHIELD HEAT CONTROL BOX WAS REPLACED. ALL SYSTEMS CHECKED OK. 2 H 7 2 4F RT A16SW 1997122400001 19971224 00001 GL 1997 12 24 97ZZZX5189 3 19971112 G 6114 D3389C67 HUB MCAULY 2A34C D2A34C67 GL NR 2 SOCKET CRACKED B ME4R K NONE O OTHER IN INSP/MAINT 1 SO 19 683527 PROPELLER RECEIVED FOR OVERHAUL. AFTER DISASSEMBLY DURING HUB INSPECTION, HUB DISCOVERED CRACKED NR 2 BLADE SOCKET INSI DE 6 THREADS IN AT 5 O'CLOCK POSITION. 1.50 INCHES LONG. CRACK DISCOVERED USING 10X POWER MICROSCOPE. HUB RETURNED TO CUSTOMER. 5 C P3EA 1997122400002 19971224 00002 SO 1997 12 24 97ZZZX5190 1 19971208 G 5521 4595106 SPAR PIPER PA31T PA31T 7103124 SO ELEVATOR CRACKED B JEMR K NONE O OTHER IN INSP/MAINT 1 CE 01 200NB 6426 31T7720035 ELEVATOR SKIN CRACKED FROM THE INSIDE. INVESTIGATION REVEALED CRACKS IN LOWER SPAR RADIUS OUTBOARD HINGE BRACKET. THIS WAS ON BOTH LEFT AND RIGHT ELEVATORS. 1 L 7 2 3T A8EA 1997122400006 19971224 00006 SO 1997 12 24 97ZZZX5194 1 19971208 G 5521 4595106 SPAR PIPER PA31T PA31T 7103124 SO ELEVATOR CRACKED B A JEMR K NONE O OTHER IN INSP/MAINT 1 CE 01 35RT 4000 31T7820018 FOUND ELEVATOR SKIN CRACKED FROM THE INSIDE. INVESTIGATION REVEALED CRACKS IN SPAR RADIUS OUTBOARD HINGE BRACKET. 1 L 7 2 3T A8EA 1997122400007 19971224 00007 1997 12 24 97ZZZX5195 4 19971202 G 6113 055023613 SPINNER CESSNA 172 172 2072402 CE PROPELLER CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 25 64763 50 17275620 FATIGUE CRACK FOUND IN PROPELLER SPINNER. 50 HOURS TT. 1 H 7 1 3O NT 3A12 1997122400008 19971224 00008 1997 12 24 97ZZZX5196 4 19971202 G 6113 055023613 SPINNER CESSNA 172 172P 2072436 CE PROPELLER CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 25 64763 36 17275620 FATIGUE CRACK FOUND IN PROPELLER SPINNER. 35 HOURS TT. 1 H 7 1 3O NT 3A12 1997122400009 19971224 00009 1997 12 24 97ZZZX5197 4 19971202 G 6113 055023613 SPINNER CESSNA 172 172P 2072436 CE PROPELLER CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 25 64763 45 17275620 FATIGUE CRACK FOUND IN PROPELLER SPINNER. 45 HOURS TT. 1 H 7 1 3O NT 3A12 1997122400010 19971224 00010 1997 12 24 97ZZZX5198 4 19971209 G 2312 484208 RELAY PIPER PA28 PA28RT201 7102818 SO AVIONIC POWER BURNT B FO6R K NONE O OTHER IN INSP/MAINT 1 NM 09 81897 2388 28R8018063 WHILE TROUBLESHOOTING, INTERMITTENT RADIO OPERATION FOUND AVIONIC POWER RELAY TERMINAL NR 2 IN VERY DETERIORATED CONDITI ON DUE TO OVER HEATING. ADJACENT WIRING WAS ALSO DAMAGED. SUSPECT CORROSION ON TERMINAL. SUBMITTER STATED DUE TO LOCA TION IN AN AREA PRONE TO MOISTURE, RECOMMEND SEALING TERMINALS WITH RTV. 1 L 7 1 3O 2A13 1997122400011 19971224 00011 EU 1997 12 24 97ZZZX5199 1 19971125 G 5210 DOOR SOCATA TB10 TB10TOBAGO 8680696 EU PILOT SIDE CRACKED D S A K NONE O OTHER IN INSP/MAINT 1 NM 01 105U 2502 591 BOTH PILOT'S AND COPILOT'S DOORS WERE FOUND CRACKED ALONG THE DOOR HINGE LINE ON THE INSIDE STRUCTURE OF THE DOOR. 2,50 1 HOURS TOTAL TIME. A FIELD APPROVED REPAIR WAS NEEDED AS SOCATA HAD NO APPROVED STRUCTURAL REPAIR MANUALS. CRACK IS 1 2 INCHES LONG ON PILOT'S SIDE, AND 14 INCHES LONG ON COPILOT'S SIDE. INSIDE, DOOR IS CONSTRUCTED OF SOFT 'O' CONDITION MATERIAL WHICH CONTRIBUTED TO WEAKNESS OF DOOR IN THIS AREA. 1 L 7 1 30 NT A51EU 1997122400012 19971224 00012 EU 1997 12 24 97ZZZX5200 1 19971125 G 5210 DOOR SOCATA TB10 TB10TOBAGO 8680696 EU COPILOT CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 01 105U 2502 591 BOTH PILOT'S AND COPILOT'S DOORS WERE FOUND CRACKED ALONG THE DOOR HINGE LINE ON THE INSIDE STRUCTURE OF THE DOOR. 2,50 1 HOURS TOTAL TIME. A FIELD APPROVED REPAIR WAS NEEDED AS SOCATA HAD NO APPROVED STRUCTURAL REPAIR MANUALS. CRACK IS 1 2 INCHES LONG ON PILOT'S SIDE, AND 14 INCHES LONG ON COPILOT'S SIDE. INSIDE, DOOR IS CONSTRUCTED OF SOFT 'O' CONDITION MATERIAL WHICH CONTRIBUTED TO WEAKNESS OF DOOR IN THIS AREA. 1 L 7 1 30 NT A51EU 1997122400014 19971224 00014 GL 1997 12 24 97ZZZX5202 3 19971201 G 6110 C52701 BEARING CESSNA 208 208 2073702 CE MCAULY 3AF34C 3GFR34C703 GL PROP ASSY DEFECTIVE B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 5NPAN 4109 1217 NB0127 931720 INSPECTION FOUND PROPELLER ASSEMBLY BEARING HAD SHARP INDICATIONS ON BOTH SIDES DIRECTLY ACROSS FROM EACH OTHER APPROXIM ATELY .3750 INCH ON ONE SIDE AND .6250 INCH ON THE OTHER SIDE. 1 H 7 1 3T NT A37CE 5 C P60GL 1997122400022 19971224 00022 WP 1997 12 24 97ZZZX5204 2 19971202 G 7200 ENGINE BEECH 100 B100 1152919 CE GARRTT TPE331 TPE3316252B 01514 WP RT ENGINE FAILURE D O OTHER X ENGINE FLAMEOUT AP APPROACH 1 EA 25 150YA BE124 P27257 ENGINE FAILURE ON FINAL. PILOT REPORTED 20 KNOT CROSSWINDS WITH GUSTS. AIRCRAFT HAD BEEN IN ICING CONDITIONS. SUSPECT CAUSE OF FAILURE, INGESTION OF ICE. 1 L 7 2 4T 4 T A14CE E2WE 1997122400023 19971224 00023 EU 1997 12 24 97ZZZX5205 1 19971203 G 2840 166FT2 CONNECTOR AMD FALC50 FALCON50MYST 2730106 EU RT FEED TANK INTERMITTENT B JZBR K NONE O OTHER IN INSP/MAINT 1 EA 25 96DS 2534 209 GROUP THREE FUEL QUANTITY READ ZERO INTERMITTENTLY. FOUND COLD SOLDERED WIRE ON CONNECTOR 166FT2 AND FOUND SEALANT DISI NTEGRATING. 2 L 7 3 4F A46EU 1997122400024 19971224 00024 CE 1997 12 24 97ZZZX5206 1 19971205 G 2915 4614 RELIEF VALVE CESSNA 500 560CESSNA 2076750 CE HYD SYSTEM MALFUNCTION B IW1R K NONE O OTHER IN INSP/MAINT 1 EA 25 331QS 2417 5600331 TROUBLESHOOTING FOR INCOMPLETE RETRACT CYCLE FOUND HYDRAULIC RELIEF VALVE OPENING PREMATURELY. 2 L 7 2 4F RT A22CE 1997122400025 19971224 00025 CE 1997 12 24 97ZZZX5207 1 19971208 G 2915 4614 RELIEF VALVE CESSNA 500 560CESSNA 2076750 CE HYD SYSTEM MALFUNCTION B IW1R K NONE O OTHER IN INSP/MAINT 1 EA 25 348QS 1699 1441A 5600348 CREW REPORTS GEAR FAILS TO COMPLETE RETRACT CYCLE. FOUND 1500 PSI RELIEF VALVE OPENING PREMATURELY @ 1100 PSI. THIS CA USED REPORTED CONDITION. FOUND THIS SAME CONDITION ON 560-0331 WITH 1417 HOURS. SUBMITTER RECOMMENDS TO ADD PRESSURE C HECK AT 300 HOUR INTERVALS WHEN GEAR SWINGS ARE PERFORMED. 2 L 7 2 4F RT A22CE 1997122400026 19971224 00026 EU 1997 12 24 97ZZZX5208 1 19971020 G 3411 PIT844271 TUBE FOKKER F27 F27MK400 4990626 EU PITOT BS 3000 CHAFED D K NONE O OTHER IN INSP/MAINT 1 SO 05 2MIL 7185 10668 PITOT TUBE BENEATH COCKPIT FLOOR (STA 3000) BETWEEN 'DRAINS' AND AIR DATA COMPUTER FOUND CHAFED BY AILERON FLIGHT CONTRO L CABLE. ALUM TUBING CHAFED THRU .028 INCH WALL THICKNESS, 'FLASHING' BLOCKED HOLE PREVENTING PITOT SYS LEAK. DEFECT L OCATED 32 INCHES FROM RT END FITTING. TUBING'S LT END HAS DASH 6 TUBING (3.50 INCHES LONG) WELDED TO DASH 4 ALUMINUM TU BING APPROX 47 INCHES LONG. ONLY 1 CLAMP INSTALLED IN 50-INCH SPAN. TUBING MAY HAVE BEEN BENT BY WORKERS AND ROUTED IN CORRECTLY, I.E., BETWEEN AILERON CABLES INSTEAD OF BENEATH. SUBMITTER RECOMMENDS RE-ROUTING TUBING BENEATH AILERON CAB LES AND ADD ADDITIONAL CLAMPS TO SUPPORT TUBING. REF, FOKKER F27 IPC CHAP 34-10-07 FIG 01L-100. 2 H 7 2 4T A817 1997122400028 19971224 00028 SO 1997 12 24 97ZZZX5209 1 19971208 G 5610 JF4897LF WINDOW PPG LKHEED 1329 132923E 5263116 SO COCIPIT LT AFT MISINSTALLED B S A MGTY K NONE O OTHER IN INSP/MAINT 1 EA 35 155AV 83H51401 5104 LOCKHEED JETSTAR COCKPIT LT REAR SIDE WINDOW (IPC 2-232 FIG 23 ITEM D). WHEN A DEFECT ON LT COCKPIT DV WINDOW WAS INVES TIGATED, FOUND LT REAR COCKPIT SIDE WINDOW, REAR UPPER AND LOWER WINDOW RETAINERS HAD NOT BEEN BOLTED TO WINDOW SUPPORT STRUCTURE. RETAINERS WERE ONLY ATTACHED TO FUSELAGE OUTER SKIN. OVER 30 ATTACHMENT BOLTS ARE MISSING AND LOWER RETAINE R IS NOW MISALIGNED BY APPROX .1875 INCH OUTBOARD. VISUAL AND NDT INSPECTIONS ARE BEING CARRIED OUT ON WINDOW AREA OF F USELAGE. LOCKHEED HAS BEEN INFORMED AND ARE INVESTIGATING REPAIR REQUIREMENTS. ON REAR RT COCKPIT WINDOW, 2 ATTACHMENT BOLTS WERE FOUND MISSING FROM TOP RETAINER. 2 L 7 4 4J 2A15 1997013000449 19970130 00449 GL 1997 1 30 97ZZZX521 2 19970116 G 7250 23031909A ENERGY RING ALLSN 250C 250C30P 03013 GL ENG WORN TANGS D K NONE O OTHER IN INSP/MAINT 1 NM 11 5830 1797 DD11270 CAT90681 THE 4 TANGS ON THE ENERGY ABSORBING RING ARE WORN ON WIDTH AND ONE IN HEIGHT AND WORN INTO THE PT SUPPORT. SUBMITTER ST ATES THIS HAPPENS ON ALL C30 TURBINES. NEEDS MORE SUPPORT. 3 U E1GL 1997122400473 19971224 00473 SW 1997 12 24 97ZZZX5211 1 19971119 G 2710 730006000 CONTROL LINK MOONEY M20 M20J 5870219 SW RT AILERON BROKEN B S A HUNR O OTHER F FLT CONT AFFECTED NR NOT REPORTED 1 NM 01 201ZU 2137 240544 IN-FLIGHT FAILURE. OWNER-PILOT NOTICED SLOPPY AILERON RESPONSE, SAW RT AILERON 'VIBRATING', NOT RESPONDING TO CONTROL I NPUT. RIGHT CONTROL LINK ROD ASSEMBLY LOCATED AT BELLCRANK BELOW CABIN FLOOR HAD BROKEN ALONG FACTORY WELD THEN THROUGH THE TUBING WALL. THE BREAK ALONG THE WELD SHOWED SIGNS OF AGE, THE BREAK THROUGH THE TUBE WALL APPEARED RECENT. INSPE CTORS DETERMINED THE AILERONS UP AND DOWN STOPS SHOWED NO SIGNS OF DAMAGE AND THE REST OF THE AILERON SYSTEM SHOWED NO S IGNS OF DAMAGE OR ABUSE. NOTE, THE REPLACMENT PART IS SAME PART NUMBER, BUT REINFORCED AT BOTH 90 DEGREE CORNERS. 1 L 7 1 3O 2A3 1997122400474 19971224 00474 1997 12 24 97ZZZX5212 4 19971209 G 6113 04500463 BULKHEAD CESSNA 150 150L 2071826 CE PROP SPINNER CRACKED D S K NONE O OTHER IN INSP/MAINT 1 SO 15 21965 521 15074573 PROPELLER REMOVED FOR CLEANING AND PAINTING. THE SPINNER BACKPLATE WAS FOUND CRACKED 270 DEGREES JUST OUTSIDE PROPELLER BOLT HOLES. SUBMITTER RECOMMENDS AD FOR INSPECTION EVERY 500 HOURS. HARD TO SEE CRACK WITH PROPELLER INSTALLED ON AIRC RAFT. 1 H 7 1 3O 3A19 1997122400479 19971224 00479 NE 1997 12 24 97ZZZX5216 1 19971125 G 6520 7636104008101 COUPLING SKRSKY S76 S76A 8143006 NE INTERMED GRBOX CRACKED B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 72649 209 760292 COUPLING WAS FOUND CRACKED IN 7 PLACES. IT WAS LOCATED AT THE INTERMEDIATE GEARBOX OUTPUT FLANGE. THE PREVIOUS COUPLIN G WAS ALSO CRACKED. THE RUN-OUT WAS CHECKED AND FOUND WITHIN MANUFACTURER'S LIMITS. THE NR 5 T/R DRIVESHAFT AND INTER MEDIATE GEARBOX WERE REMOVED FOR FURTHER EVALUATION. NEW COUPLING WAS INSTALLED. RUN-OUT CHECK IS WITHIN MANUFACTURER' S LIMITS. 1 G 7 2 3U H1NE 1997122400480 19971224 00480 NE 1997 12 24 97ZZZX5217 2 19971203 G 7323 430128903 GOVERNOR SNIAS 350 AS350D 8680803 EU LYC LTS101 LTS101600A3 41560 NE ENGINE PT MALFUNCTIONED D L A O OTHER J WARNING INDICATION HO HOVERING 1 WP 21 816CE 991 1436 LE43432C GOVERNOR UNITS HAD A MANDATORY SB REQUIRED BY JUNE, 1997. STARTED COMPLYING BY DECEMBER, 1996. AFTER INSTALLATION OF FI RST MODEL UNIT, STARTED EXPERIENCING RPM ADJUSTMENT PROBLEMS. AFTER 20 HOURS, BUT NO MORE THAN 200 HOURS, UNITS WOULD F AIL TO HOLD RPM SETTINGS. SUBMITTER STATED THIS ONE WAS THE WORST WITH A SEVERE RPM OSCILLATION IN A HOVER. HAVE NOW C HANGED 7 UNITS SINCE DECEMBER, 1996. 1 G 7 1 3U 3 U H9EU E5NE 1997122400481 19971224 00481 NE 1997 12 24 97ZZZX5218 2 19971213 G 7310 430128601 MANIFOLD BELL 222 222U 1182140 SW LYC LTS101 LTS101750C1 41560 NE ENGINE FUEL CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 GL 13 781SA 993 7175C 47537 LE47163 FUEL LEAK NOTED ON POST-FLIGHT INSPECTION. FUEL MANIFOLD WAS FOUND TO HAVE A CRACK OR HOLE AT 5 O'CLOCK POSITION. UNAB LE TO DETECT WITH NAKED EYE. FUEL POOLED IN ENGINE COMPARTMENT AREA MAKING THIS A VERY DANGEROUS SITUATION. FUEL LEAKI NG ONTO THE TURBINE SECTION AND DRIPPING ONTO THE DECK. 1 G 7 2 3U 3 U H9SW E5NE 1997013000450 19970130 00450 GL 1997 1 30 97ZZZX522 2 19970116 G 7250 23031478 BEARING ALLSN 250C 250C30P 03013 GL TURB NR 8 WORN D K NONE O OTHER IN INSP/MAINT 1 NM 11 1797 CAT90681 INSP FOUND OD OF BEARING BELOW MIN DIMENSION AND INTERNAL CLEARANCE TOO MUCH. 0.0034 INCH MAX AND BEARING WAS 0.00364 I NCH. ALLOWED STATOR SEAL TO BE RUBBED BY 35/37 ROTATING SEAL. 3 U E1GL 1997013000451 19970130 00451 NE 1997 1 30 97ZZZX523 3 19970110 G 6111 7756721 BLADE PIN HAMSTD HAMSTD 14SF 14SF7 NE BLADE BUTT WRONG PART D K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 23 21221 6176 REFERENCE: FR25734. PROP RETURNED FOR A BURNED HEATER. INSP FOUND WRONG BLADE PIN HAD BEEN INSTALLED: PROPER P/N IS 775672-2. ACTUAL PIN WAS P/N 775672-1. DIFFERENCE IS IN OVERHAUL LENGTH. SHORTER PIN (DASH 1) CANNOT ASSURE ADEQUATE ENGAGEMENT. 6 C P7NE 1997013000452 19970130 00452 WP 1997 1 30 97ZZZX524 1 19970113 G 5512 SKIN DOUG DC10 DC1015 3022118 WP LT HORIZ STAB DENTED D K NONE O OTHER IN INSP/MAINT 1 WP 09 1003L 48258 TEMPORARY REPAIR INSTALLED ON LT HORIZ STAB UPPER SIDE STA XE 103 YA189. REMOVED REPAIR FOUND DENTS. OUT OF LIMITS. C UT OUT DENTED AREAS IAW DOUGLAS DWG 312891/96-10-16-18. FABRICATED DOUBLERS PER SAME DWG. ALODINED AND PRIMED IAW DC 1 0 SRM 51-21-01. INSTALLED DOUBLERS IAW DOUGLAS DWG 312891/96-10-16-18. 2 L 7 3 4F A22WE 1997020600182 19970206 00182 NE 1997 2 6 97ZZZX528 3 19970115 G 6111 6607132886 BLADE SAAB SF340 SF340A 7850100 EU ROTOL R354 R3544123F13 NE OUTER SLEEVE CRACKED B S A MS1R K NONE O OTHER IN INSP/MAINT 1 EA 27 110XJ 15215 6452 SF3401321366 340A110 DRG178687 DURING INSPECTION FOR OVERHAUL, FOUND OUTER SLEEVE CRACKED WHERE PTFE TAPE FITS. PROPELLER HAD BEEN REMOVED FOR ROUTINE MAINTENANCE. 2 L 7 2 4T RT A52EU 6 C P61GL 1997020600187 19970206 00187 SO 1997 2 6 97ZZZX532 1 19970106 G 2710 62701122 CONTROL CABLE PIPER PA28 PA28161 7102803 SO LT AILERON FRAYED B A DYTR K NONE O OTHER IN INSP/MAINT 1 SO 15 167ER 9404 2841183 UPON INSPECTION OF AIRCRAFT CONTROL SYSTEMS, FOUND LEFT AILERON CABLE AT WS 57.00, WHERE THE CABLE PASSES THROUGH GUIDIN G PULLEY, WORN AND WITH BROKEN STRANDS ABOUT .50 INCH OF LENGTH. THIS CRS MAINTAINS A FLEET OF 17 LIKE TRAINING AIRCRAF T. 1 L 7 1 3O 2A13 1997020600188 19970206 00188 1997 2 6 97ZZZX533 4 19970110 G 2562 BP1040 BATTERY EAGLE SWRNGN SA227 SA227TT SW ELT LEAKING H K NONE O OTHER IN INSP/MAINT 1 GL 25 99JW TT450 DURING AN INSPECTION, THE ELT BATTERY WAS DUE FOR REPLACEMENT. FOUND BATTERY LEAKING WHEN REMOVED. NO DAMAGE WAS FOUND TO ELT UNIT. OPS CHECKS SATISFACTORY WITH NEW BATTERY INSTALLED. APPEARED TO LEAK AROUND CORNER OF CASE THAT WAS SEAL ED AT MANUFACTURER. 2 L 7 2 4T RT A5SW 1997020600191 19970206 00191 CE 1997 2 6 97ZZZX536 1 19970107 G 7160 BA4106 FILTER HOUSING CESSNA 150 152 2071835 CE CARB INTAKE MISMOUNTED H K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 21 5289B 15283827 IN ORDER TO C/W AD 95-03-02 AND SUBSEQUENT 96-09-06, BRACKETT AIR FILTER, THE FILTER HOUSING MUST BE REMOVED FROM THE AI R BOX. WHEN RE-INSTALLING THE FILTER HOUSING OR DURING INITIAL INSTALLATION, IT IS POSSIBLE TO ALLOW THE HOUSING TO DRO P DOWN FAR ENOUGH SO THAT THE FILTER HOUSING HITS THE BOTTOM COWLING DUE TO THE UP/DOWN MOVEMENT OF THE CESSNA MOUNTING HARDWARE ON THE AIR BOX. THIS RESULTED IN LOOSENING OF THE CARB BOWL ATTACH BOLTS, DAMAGE TO THE VENTURI AND MAIN JET, AND THE ACCELERATOR PUMP SPRAY BAR BROKE OFF AND DROPPED INTO THE AIR BOX. 1 H 7 1 3O NT 3A19 1997020600192 19970206 00192 1997 2 6 97ZZZX537 2 19970106 G 7414 10349237 GEAR 103493505 BEECH 58 58 1152740 CE 298741 MAGNETO CORRODED D K NONE O OTHER IN INSP/MAINT 1 SO 15 31T 440 C119640F TH121 INSP FOUND COOKED, CORRODED BRUSH IN DIST GEAR DUE TO ARCING. CARBON BRUSH IN LARGE GEAR ASSY RT MAGNETO, PN 10-349350- 5, MAY HAVE BEEN BROKEN PRIOR TO OR DURING ASSY OF MAGNETO. 1 L 7 2 3O 3A16 1997020600193 19970206 00193 SO 1997 2 6 97ZZZX538 2 19970106 G 8530 21361 VALVE KEEPER CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO EXH VLV STRIPPED D S K NONE O OTHER IN INSP/MAINT 1 EA 25 714BE 2165 15079044 255436 INSP FOUND THE LOCKING PORTION OF THE INSIDE DIAMETER OF PN 21361 (KEEPER) WAS STRIPPED AWAY ALLOWING EXHAUST VALVE TO E NTER COMBUSTION CHAMBER OF CYL NR 1 DURING FLIGHT. KEEPERS ARE OBVIOUSLY OF LESS HARDNESS THAN VALVE STEM. TIME IN SER VICE, OSCILLATORY FORCES, AND POSSIBLY DETONATION PEAK PRESSURES MAY HAVE RESULTED IN FAILURE. PERHAPS PART HARDNESS WA S INSUFFICIENT. 1 H 7 1 3O 3 O 3A19 E252 1997020600194 19970206 00194 SW 1997 2 6 97ZZZX539 1 19970117 G 5720 2893 FITTING BBAVIA 7 7GCBC 1220601 SW LT WING SPAR CRACKED G A K NONE O OTHER IN INSP/MAINT 1 SO 17 7596F 23970 DURING INVESTIGATION OF FATAL ACCIDENT (MIA97FA047), THE LEFT FORWARD LIFT STRUT TO WING SPAR FITTING WAS FOUND CRCKED I N 2 PLACES AT THE OUTBOARD WELD TERMINALS. ONE CRACK CROSSED THE FITTING FLANGE AND PROGRESSED .3750 INCH VERTICALLY ON THE WEB OF THE FITTING. THE OTHER WAS ONLY ON THE FLANGE. THESE CRACKS WERE NOT CONTRIBUTORY TO THE ACCIDENT. AD 96- 18-02 DOES NOT APPLY TO THIS S/N AIRCRAFT. 1 H 7 1 3O NC A759 1997020600243 19970206 00243 SW 1997 2 6 97ZZZX540 1 19970107 G 6230 206010443001 DUPLEX BARING 206010450113 BELL 206 206L1 1182107 SW SWASHPLATE ROUGH B ZV1R K NONE O OTHER IN INSP/MAINT 1 SW 03 2618 239 GDJG90483 45503 SWASHPLATE REMOVED DUE TO ROUGHNESS OF OUTER RING ROTATION. AT DISASSEMBLY, FOUND DUPLEX BEARING INNER RACE PITTED. TH IS IS THE FOURTH BEARING FOUND DEFECTIVE WITH LESS THAN 1,000 HOURS. THIS IS THE THIRD BEARING USED IN THIS SWASHPLATE IN LAST 12 MONTHS. 1 G 7 1 3U H2SW 1997020600244 19970206 00244 GL 1997 2 6 97ZZZX541 2 19970103 G 7250 6898735 TURBINE HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL PT SUPPORT CRACKED B S EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 5074R 6995 524 CAT33968 1151D CAE832750 DURING REPLACMENT OF THE NR 1 NOZZLE, A CRACK WAS FOUND IN THE P/T SUPPORT BODY JUST AFT OF THE 6 AND 7 BEARING. SUMP B OSS UNIT WAS SENT IN FOR REWORK. 1 G 7 1 3U 3 U H3WE E4CE 1997020600245 19970206 00245 CE 1997 2 6 97ZZZX542 1 19970102 G 7160 BA8110 FILTER CESSNA 180 180G 2072616 CE CARB AIR INTAKE DEFECTIVE D L A A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 NE 05 4666U 18051366 DURING CLIMB NEAR TOTAL POWER LOSS. INVESTIGATION FOUND BRACKET AIR FILTER FAULTY DUE TO BOTTOM CHANNEL CAUSES WATER/IC E CONTAMINATION OF ENGINE INTAKE BELLOWS JUST FORWARD OF AIR BOX. 1 H 7 1 3O 5A6 1997020600388 19970206 00388 CE 1997 2 6 97ZZZX544 1 19970121 G 5711 CARRY THRU SPAR BEECH 33 F33A 1151425 CE FUSELAGE CRACKED B A VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 8252T 6690 CE1545 INSP FOUND CRACKS IN CARRY THROUGH STRUCTURE. AD 95-04-03 NOT VALID BY SERIAL NUMBER. THIS IS THE 14TH AIRCRAFT REPORT ED. 1 L 7 1 3O 3A15 1997020600389 19970206 00389 CE 1997 2 6 97ZZZX545 1 19970121 G 5711 CARRY THRU SPAR BEECH 33 F33A 1151425 CE FUSELAGE CRACKED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 8173C 6740 CE1541 INSP FOUND CRACKS IN CARRY THRU STRUCTURE. AD 95-04-03 NOT VALID BY SERIAL NUMBER. THIS IS THE 15TH AIRCRAFT REPORTED. 1 L 7 1 3O 3A15 1997020600390 19970206 00390 CE 1997 2 6 97ZZZX546 1 19970121 G 5711 CARRY THRU SPAR BEECH 33 F33A 1151425 CE FUSELAGE CRACKED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 5530A 8493 CE1342 INSP FOUND CRACKS IN CARRY THRU STRUCTURE. AD 95-04-03 NOT VALID BY SERIAL NUMBER. THIS IS THE 16TH AIRCRAFT REPORTED. 1 L 7 1 3O 3A15 1997020600393 19970206 00393 CE 1997 2 6 97ZZZX549 1 19970103 G 3230 99101543 CYLINDER CESSNA 402 402CESSNA 207590K CE EMERG GEAR EXT CRACKED B T4OR K NONE O OTHER IN INSP/MAINT 1 NE 03 RECEIVED CYLINDER FOR HYDROSTATIC TEST. DURING INTERNAL INSPECTION, FOUND CRACK IN SHOULDER AREA. LENGTH OF CRACK APPR OX .33 INCH TO .50 INCH IN CIRCUMFERENCE. CESSNA PART NO. 9910154-3 SERIAL NR 1816. MANUFACTURED FOR FUTURECRAFT CORP. PART NR 900294-4. THIS CYLINDER IS USED FOR EMERGENCY GEAR BLOWDOWN. THIS CYLINDER'S LAST HYDROSTATIC TEST WAS 6/84. CRACK MAY HAVE OCCURRED WHILE BEING OVER PRESSURIZED. 1 L 7 2 3O A7CE 1997020600371 19970206 00371 CE 1997 2 6 97ZZZX558 1 19970106 G 7160 189100143 ADAPTER BEECH 18 H18 1151012 CE LT ENG CARB AIR DISCONNECTED D K NONE O OTHER IN INSP/MAINT 1 GL 25 223JW BA716 DURING INSPECTION OF LEFT ENGINE EXHAUST AS A RESULT OF RIGHT EXHAUST FAILURE, FOUND INBOARD HEAT DUCT DISCONNECTED. TH IS WAS DUE TO COLLAPSE OF THE END OF THE ADAPTER ASSY. UPON DISASSEMBLY OF SYSTEM, FOUND BOTH LEGS OF ADAPTER COLLAPSED FROM OVERTORQUE OF DUCT CLAMPS. REMOVED AND REPLACED ADAPTER. 1 L 7 2 3R A765 1997020600372 19970206 00372 CE 1997 2 6 97ZZZX559 1 19970106 G 7160 189100143 ADAPTER BEECH 18 H18 1151012 CE RT ENG CARB AIR BURNED D K NONE O OTHER IN INSP/MAINT 1 GL 25 223JW BA716 WHILE REPAIRING DAMAGE CAUSED BY EXHAUST STACK FAILURE, FOUND OUTBOARD END OF ADAPTER UPPER SIDE BURNED AND MELTED APPRO XIMATELY 3 INCHES. MATERIAL MIGRATED INTO INDUCTION HEAD VALVE AND FUEL INJECTOR SERVO. REPLACED ADAPTER ASSY. 1 L 7 2 3R A765 1997020600373 19970206 00373 CE 1997 2 6 97ZZZX560 1 19970106 G 7810 18950016 EXHAUST STACK BEECH 18 H18 1151012 CE RT ENG NR 7 CYL HOLED D K NONE O OTHER IN INSP/MAINT 1 GL 25 223JW BA716 PILOT REPORTED RIGHT ENGINE QUIT WHEN INDUCTION HEAT SELECTED DURING RUN-UP. CARBURETOR TEMPERATURE GAUGE WENT OFF TOP OF SCALE. INVESTIGATION REVEALED 2 INCH BY 4 INCH HOLES IN OUTBOARD UPPER STACK ASSEMBLY OF OLD POOR QUALITY REPAIR. A LSO, STACK MISSING NUMEROUS STUDS. STACK WAS SENT OUT FOR REPAIR. ALSO, FOUND HEAT DUCT AND ADAPTER ASSEMBLY DAMAGED A ND MELTED FIBERGLASS IN INTAKE SCOOP, FUEL INJECTOR SERVO FUEL INJECTOR SCREEN. 42.4 HOURS SINCE ANNUAL INSPECTION AND REMOVAL FROM PART 135 OPERATION. 1 L 7 2 3R A765 1997020600374 19970206 00374 CE 1997 2 6 97ZZZX561 1 19970107 G 7160 130358 SPRING BEECH 18 H18 1151012 CE CARB AIR VALVE MISSING D K NONE O OTHER IN INSP/MAINT 1 GL 25 223JW BA716 WHILE CLEANING DEBRIS FROM EXHAUST FAILURE, FOUND SPRING MISSING. SPRING HAD APPARENTLY BEEN MISSING FOR SOME TIME FROM APPEARANCE OF MOUNTING HOLES. 1 L 7 2 3R A765 1997020600375 19970206 00375 CE 1997 2 6 97ZZZX562 1 19970107 G 3020 111716AX5XX9 DUCT BEECH 18 H18 1151012 CE RT ENGINE DETERIORATED D K NONE O OTHER IN INSP/MAINT 1 GL 25 223JW BA716 DURING REPAIR OF RIGHT EXHAUST, FOUND DUCT BADLY DETERIORATED AND COLLAPSED. OLD DUCT APPEARED TO BE SINGLE WALL SCAT H OSE. NEW DUCT WAS DOUBLE WALLED, HEAVIER, AND BLACK INSTEAD OF ORANGE. REPLACED DUCT. 42.4 HRS SINCE ANNUAL. 1 L 7 2 3R A765 1997020600376 19970206 00376 CE 1997 2 6 97ZZZX563 1 19970107 G 3020 111716AX5XX9 DUCT BEECH 18 H18 1151012 CE LT ENGINE DETERIORATED D K NONE O OTHER IN INSP/MAINT 1 GL 25 223JW BA716 WHILE REPAIRING EXHAUST SYSTEM, FOUND DUCT COLLAPSED AND BADLY DETERIORATED. OLD DUCT APPEARED TO BE ORANGE SINGLE WALL SCAT HOSE. NEW DUCT WAS BLACK HEAVY DOUBLE WALLED AND BORE BEECH P/N NR I.D. ON OLD DUCT. REMOVED AND REPLACED DUCT. 1 L 7 2 3R A765 1997020600377 19970206 00377 CE 1997 2 6 97ZZZX564 1 19970107 G 3020 183800005 DUCT BEECH 18 H18 1151012 CE RT ENG HEAT HOLE CHAFED D K NONE O OTHER IN INSP/MAINT 1 GL 25 223JW BA716 WHILE CONDUCTING OTHER WORK ON RIGHT ENGINE, FOUND HOLE CHAFED IN INBOARD INDUCTION HEAT DUCT. THIS AREA HAD PREVIOUSLY BEEN REPAIRED USING A SILICONE SEALER MATERIAL. REPLACED DUCT AND POSITIONED CLEAR OF EXHAUST. 42.4 HRS SINCE ANNUAL. 1 L 7 2 3R A765 1997020600378 19970206 00378 CE 1997 2 6 97ZZZX565 1 19970107 G 3020 183800003 DUCT BEECH 18 H18 1151012 CE RT ENG OTBD HOLE BURNED D K NONE O OTHER IN INSP/MAINT 1 GL 25 223JW BA716 FOUND OUTBOARD INDUCTION HEAT DUCT BURNED THROUGH (APPROXIMATELY 6 INCH HOLE). OLD DUCT APPEARED TO BE SCAT HOSE. NEW PART WAS MUCH HEAVIER AND OVAL SHAPED. REPLACED DUCT. 1 L 7 2 3R A765 1997020600379 19970206 00379 CE 1997 2 6 97ZZZX566 1 19970106 G 7810 18950016 EXHAUST STACK BEECH 18 H18 1151012 CE LT ENG BULGED D K NONE O OTHER IN INSP/MAINT 1 GL 25 223JW BA716 LEFT ENGINE EXHAUST WAS INSPECTED AFTER FAILURE OF RIGHT ENGINE EXHAUST STACK. EXHAUST STACK WAS FOUND BULGED IN SAME A REA AS FAILURE OF RIGHT STACK (NR 7 CYL). THIS AREA HAD A PRIOR QUALITY REPAIR AND WAS MISSING NUMEROUS HEAT STUDS. ST ACK WAS SENT OUT FOR REPAIR. 42.4 HRS SINCE ANNUAL. 1 L 7 2 3R A765 1997020600380 19970206 00380 EA 1997 2 6 97ZZZX567 2 19970106 G 7310 HOSE PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA CYL 1-3 LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 03 6206Y 273433 L917248 THIS LINE LOOKED VERY GOOD. NOT STIFF OR CHAFED IN ANY WAY. HOWEVER, THE RUBBER HOSE BELOW THE BRAIDED COVER RUPTURED AND ALLOWED FUEL TO SOAK BETWEEN CYLINDERS NR 1 AND NR 3 CREATING AN IN-FLIGHT FIRE HAZARD. ONLY WAY TO CHECK OR TEST I S REMOVAL OF LINE AND PRESSURIZE WITH AIR UNDER WATER. 1 L 7 2 3O 3 O 1A10 1E4 1997020600382 19970206 00382 CE 1997 2 6 97ZZZX569 1 19970117 G 3260 5801 INDICATOR 8000 CESSNA 208 208 2073702 CE RT MLG MALFUNCTION E A K NONE P NO WARNING INDICATION IN INSP/MAINT 1 NE 03 208RD 250 20800054 AIRCRAFT WAS FLYING AT 3,000 FEET, REPORTED TEMP OF 22 DEGREES FAHRENHEIT. AIRCRAFT DID NOT GET RIGHT MAIN LANDING GEAR DOWN AND LOCKED LIGHT. INVESTIGATION DETERMINED LANDING GEAR MAGNETIC POSITION INDICATOR WAS FROZEN. AFTER AIRCRAFT W ARMED UP, INDICATOR FUNCTIONED PROPERLY. EXTREME COLD COULD HAVE CAUSED THE BI-METALIC COMPONENTS TO SHRINK CAUSING THE M NOT TO MAKE CONTACT, OR MOISTURE PENETRATED SWITCH AND FROZE BETWEEN METAL TABS. POTTING SWITCH MAY SOLVE THIS PROBLE M. 1 H 7 1 3T NT A37CE 1997020600384 19970206 00384 CE 1997 2 6 97ZZZX571 1 19970122 G 5741 C512122 FITTING CESSNA 150 150H 2071818 CE REAR SPAR ATTACH CRACKED G L A K NONE O OTHER IN INSP/MAINT 1 GL 19 7046S 5089 5089 15067746 REMOVED THE REAR WING SPAR ATTACH BLOCK FITTINGS, CESSNA P/N C512122, FROM EACH END OF THE REAR SPAR/DOORPOST CARRY-THRO UGH CHANNEL FOR INSPECTION. AFTER CLEANING, IT WAS NOTED THE RIGHT FITTING WAS CORRODED AND CONTAINED A CRACK EXTENDING DIAGONALLY FROM THE FORWARD OUTSIDE BASE CORNER THROUGH TO THE CORRESPONDING INSIDE CORNER. FURTHER INSPECTION OF THIS COMPONENT INDICATES THE CLEVIS END, WHICH MATES WITH THE REAR WING SPAR ATTACHMENT STRUCTURE, HAD BEEN COMPRESSED TO A POINT WHERE THE BASE OF THE LEG YIELDED RESULTING IN THE CRACK. 1 H 7 1 3O 3A19 1997020600385 19970206 00385 CE 1997 2 6 97ZZZX572 1 19970122 G 2751 0510105231 CONTROL CABLE CESSNA 182 182P 2075816 CE FLAP INDICATOR FRAYED D L K NONE O OTHER IN INSP/MAINT 1 GL 13 58776 3390 18262288 DURING A 100 HR INSPECTION, THE FLAP INDICATOR CABLE WAS FOUND TO BE FRAYED. THIS CONDITION WAS NOTED TO BE JUST AFT OF THE FORWARD PULLEY UNDER THE FLOOR WITH THE FLAPS IN THE FULL DOWN POSITION. FURTHER INVESTIGATION FOUND THAT WHEN THE FLAPS WERE IN THE FULL UP POSITION, THE CABLE BECAME EXCESSIVELY SLACK AND THE FRAYED PORTION CONTACTED THE FORWARD SID E OF THE HOLE WHERE IT PASSES THROUGH THE FLOOR BOARD. 1 H 7 1 3O NT TA13 1997020600386 19970206 00386 CE 1997 2 6 97ZZZX573 1 19970121 G 8120 99102998 EXHAUST WYE CESSNA 414 414 2075908 CE OUTLET TUBE CRACKED B L A VX3R K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 03 74DH 520 520 4140948 TURBO EXHAUST WYE RECEIVED FOR INSP AND REPAIR. FOUND UNIT HAD A CRACK AROUND WELD ON OUTLET TUBE SIDE. IT WAS EVIDENT TUBE AND INTERNAL DIVIDER HAD BEEN REPLACED. IMPROPER MATERIALS HAD BEEN UTILIZED IN THE FABRICATION OF THE OUTLET TUB E AND DIIVDER. 1 L 7 2 3O RT A7CE 1997020600387 19970206 00387 SO 1997 2 6 97ZZZX574 2 19970114 G 7322 6467582 INJECT PUMP PIPER PA28 PA28RT201T 7102817 SO CONT O360 TSIO360FB 17025 SO IDLE CUTOFF PIN DETACHED H L A A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 GL 11 28MC 1500 J238730B2 28R7931271 UPON REACHING AN ALT OF 4500 FEET, THE PILOT LEANED THE MIXTURE CONT. AT THE POINT OF ENG ROUGHNESS, HE ATTEMPTED TO EN RICHEN THE MIXTURE. THE MIXTURE WOULD NOT ADVANCE. IN THE PROCESS OF TRYING TO FREE THE MIXTURE, THE ENG QUIT, AND THE MIXTURE COULD NOT BE ADVANCED FROM THE IDLE CUT-OFF POSITION. PILOT MADE EMERG LANDING. THE AIRCRAFT WAS NOT DAMAGED. THE ENG INSTALLED ON THIS ACFT UTILIZES A TCM P/N 646758-2 FUEL INJECT PUMP. THIS FUEL INJECTION PUMP INCORPORATES TH E FUEL MIXTURE CONT AS AN INTEGRAL PART. AN INVEST OF THIS 'UNSCHEDULED LANDING' REVEALED THAT THE MIX CONT ARM MECH ST OP (STEEL ROLL PIN) HAD LOOSENED AND MIGRATED OUT OF POSITION LOCKING THE MIXTURE CONT ARM IN THE IDLE CUTOFF POSIT. 1 L 7 1 3O 3 O 2A13 E9CE 1997020600539 19970206 00539 WP 1997 2 6 97ZZZX575 1 19970122 G 2621 246875 SWITCH GAUGE 899827 DOUG DC8 DC8* WP FIRE EXTINGUISHE SHORTED B YN2R K NONE O OTHER IN INSP/MAINT 1 WP 01 25481DH SWITCH GAUGE ON FIRE EXTINGUISHER BOTTLE HAS INTERNAL SHORT. SHORT IS NOT DETECTABLE BY SWITCH GAUGE CHECK PROCEDURE IN FIRE EXTINGUISHER OVERHAUL MANUAL. TO DETECT A DEFECTIVE SWITCH GAUGE, CHECK PINS 1, 2, AND 3 FOR CONTINUITY WITH THE GAUGE CASE. IF ANY PIN HAS CONTINUITY WITH GAUGE CASE, SWITCH GAUGE IS DEFECTIVE. 2 L 7 4 4J F 4A25 1997020600540 19970206 00540 EU 1997 2 6 97ZZZX576 1 19970123 G 3244 226K086 TIRE GOODYEARAERO AMD FALC10 FALCON10 2730101 EU NR 4 MAIN LEAKING D K NONE O OTHER IN INSP/MAINT 1 GL 09 654PC 46 53461996 131 DURING ROUTINE AIR CHECK, FOUND TIRE PRESSURE LOW (NORMAL 145 POUNDS). RE-CHECKED TIRE FOR 3 DAYS, FOUND TO LOSE 11 TO 15 POUNDS PER DAY. THIS TIRE WAS OKAY ON THE FIRST 40 HOURS OF SERVICE. REMOVED, FOUND 5 SIDEWALL BLEED VENTS LEAKING. REPLACED WHEEL AND TIRE ASSY, NO FURTHER ACTION. 2 L 7 2 4F A33EU 1997020600541 19970206 00541 NE 1997 2 6 97ZZZX577 2 19970101 G 7250 1358M12P05 BLADE GE CFM56 CFM565A 13802 NE ENG HPT FAILED B L A LY2R K NONE O OTHER NR NOT REPORTED 1 CE 07 15782 731642 INSP FOR ENG FAILURE FOUND ALL HPT BLADES BROKEN AT PLATFORM. IT APPEARS THAT NR 8 BLADE S/N 4L764 WAS THE FIRST BLADE TO FAIL. CAUSE OF FAILURE UNKNOWN AT THIS TIME. OEM AND OWNER ARE DOING EXTENSIVE INVESTIGATION. 4 F E29NE 1997020600542 19970206 00542 SO 1997 2 6 97ZZZX578 2 19970101 G 8530 646283 VALVE CONT O520 IO520* 17032 SO CYL INTAKE DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 NM 01 INTAKE VALVE ON 470/520 SERIES ENGINES BUILT BY CONTINENTAL. THE VALVE FACE IS TOO SOFT AND SHOWS SEVERE WEAR. SUBMITT ER CHECKED OVER 50 DIFFERENT CYLINDERS WITH HOURS RANGING FROM 150 HOURS TOTAL TIME TO 1500 HOURS TOTAL TIME AND ALL VAL VES WITH THIS PART NUMBER HAVE SIGNS OF SEVERE WEAR. 3 O E5CE 1997020600543 19970206 00543 GL 1997 2 6 97ZZZX579 2 19970122 G 7250 23034713 PT SHAFT ALLSN 250C 250C20B 03013 GL N2 SPLINE CHIPPED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 11 4612 1163 63005 CAT37434 ENGINE REJECTED DUE TO N2 SPLINE CHIPPED SHAFT. THE FRONT END OF THE SPLINE WAS CHIPPED. SUBMITTER BELIEVES THIS IS CA USED AT INSTALLATION OF TURBINE GEARBOX. 3 U E4CE 1997020600544 19970206 00544 WP 1997 2 6 97ZZZX580 2 19970106 G 7322 3598037 DRIVESHAFT WOODWARD 89778024 GARRTT TPE331 TPE33110U 01514 WP FCU INPUT WORN B DSCR K NONE O OTHER IN INSP/MAINT 1 GL 25 1548 1711117 P63045 FUEL CONTROL DRIVESHAFT WAS FOUND TO BE WORN BEYOND MM LIMITS DURING ENGINE REPAIR. THE CURRENT FUEL CONTROL PART NUMBE R (89770-24) INDICATES C/W EITHER ALLIED SIGNAL SB 73-0227 OR SB 73-0228. THE PRE SB CONTROLS WERE THE SUBJECT OF AD 94- 26-07. C/W THESE BULLETINS HAS, IN THE PAST, SOLVED THE PROBLEM OF EXCESSIVE WEAR TO THESE PARTS; HOWEVER, THIS PART CO NTINUES TO SHOW PRE-BULLETIN COMPLIANCE WEAR PATTERNS. THE CONTROL HAS BEEN FORWARDED TO WOODWARD FOR EVALUATION. 4 T E4WE 1997020600546 19970206 00546 NM 1997 2 6 97ZZZX582 1 19970115 G 3230 108410 VALVE BODY 1U10B4 BOEING 727 727 1384001 NM MLG DOOR VALVE CRACKED B DM4R K NONE K FLUID LOSS IN INSP/MAINT 1 SO 19 1439 SEQUENCE VALVE BODY HAS FATIGUE CRACK NEAR PORT VC AND LEAKS WITH 2,500 PSI APPLIED. BODY IS ALUMINUM. CASTING UNIT HA S A TOTAL TIME OF 84,556.19 BUT UNKNOWN HOURS ON ACTUAL BODY. 2 L 7 3 4F A3WE 1997020600557 19970206 00557 EA 1997 2 6 97ZZZX592 2 19970116 G 7261 3030350 CHIP DETECTOR PIPER PA42 PA42720 7104212 SO PWA PT6 PT6A61 52043 EA RT ENG BROKEN D A UNSCHED LANDING J K WARNING INDICATION FLUID LOSS CR CRUISE 1 EA 05 777YP 425501008 PCE99016 IN-FLIGHT, PILOT NOTICED TORQUE FLUCTUATION AND LOSS OF OIL PRESSURE. LANDED WITHOUT INCIDENT. RT ENGINE AND COWLING C OVERED WITH OIL. INSPECTED ENGINE AND FOUND CHIP DETECTOR BROKEN CAUSING ALL ENG OIL TO DRAIN FROM POWER SECTION. 1 L 7 2 4T 4 T A23SO E4EA 1997020600558 19970206 00558 NM 1997 2 6 97ZZZX593 1 19970106 G 7160 6550642512 DUCT ASSY BOEING 727 727276 138408R NM NR 2 ENG INLET CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 908PG 20951 DURING C-7 INSPECTION, CORROSION WAS NOTED IN SEVERAL AREAS THOUGHOUT NR 2 ENGINE INLET UPPER 'S' DUCT ASSY. 2 L 7 3 4F RT A3WE 1997020600562 19970206 00562 EU 1997 2 6 97ZZZX597 1 19970110 G 3830 A1AW0012 LINE BRAERO 1000 BAE1251000 1500287 EU GALLEY DRAIN CRACKED B DXTR K NONE O OTHER IN INSP/MAINT 1 GL 07 525QS 259025 80 INCH LONG GALLEY DRAIN LINE WAS FOUND CRACKED FROM WATER EXPANSION. THIS LINE RUNS FROM GALLEY ALONG LOWER SIDE PLAT ES INSIDE CABIN AREA. ATTACH POINTS FOR LINE ONLY ALLOW A LEVEL INSTALLATION UNTIL JUST BEFORE IT ANGLES BELOW THE CABI N. THE CRACK WAS IN THE LEVEL AREA. 2 L 7 2 4F RT A3EU 1997020600563 19970206 00563 NM 1997 2 6 97ZZZX598 1 19970106 G 7160 6520770535 DUCT ASSY BOEING 727 727276 138408R NM NR 2 ENG INLET CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 908PG 20951 DURING C-7 INSPECTION, CORROSION WAS NOTED IN SEVERAL AREAS THROUGHOUT NR 2 ENG INLET LOWER S-DUCT ASSY. 2 L 7 3 4F RT A3WE 1997021300047 19970213 00047 SW 1997 2 13 97ZZZX600 1 19970114 G 7120 2762114083 TRUSS MOUNT SWRNGN SA227 SA227* SW ENG UPPER AFT NOT WELDED B P A H7NR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 17 407015 INSP OF FAIRCHILD MDL SA227, TPE331 ENG MOUNT TRUSS REVEALED AREA UNDER PLATE OR UPPER AFT MOUNT NOT WELDED. PLATE P/N 27-62114-073/074 ATTACHES TO TUBES 27-62114-019 AND -023. NO CRACK NOTED BUT SUBMITTER NOW INSPECTS ALL MOUNTS TO MAKE SURE THEY ARE WELDED IN THIS AREA. HAVE NOTED CRACKS ON PRIOR MOUNTS AND HAVE FILED M OR D'S ON THEM. NOTE STAMP FROM MANUFACTURE IS EITHER WSA5 OR WSA6 ON ALL THOSE WE HAVE SEEN THE PROBLEM ON. 2 L 7 2 4T RT A5SW 1997021300048 19970213 00048 SW 1997 2 13 97ZZZX601 1 19970114 G 7120 2762114083 MOUNT SWRNGN SA227 SA227* SW ENG UPPER AFT NOT WELDED B A H7NR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 17 311017 FOUND AREA UNDER PLATE ON ENG UPPER AFT MOUNT NOT WELDED. PLATE P/N 27-62114-073/074 ATTACHES TO TUBES 27-62114-019 AND -023. NO CRACK NOTED, BUT SUBMITTER NOW INSPECTS ALL MOUNTS TO MAKE SURE THIS AREA IS WELDED. ALSO, NOTE STAMP WSA5 O R WSA6 ON THE ONES FOUND NOT WELDED. NOTE 2ND REPORT THIS DATE. 2 L 7 2 4T RT A5SW 1997021300049 19970213 00049 EA 1997 2 13 97ZZZX602 2 19970126 G 8520 CONNECTING ROD PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA LT ENG FAILED E A UNSCHED LANDING Y K ENGINE STOPPAGE FLUID LOSS CR CRUISE 1 AL 01 101LJ 1435 1435 31267 L173861 AFTER PREVIOUS FLIGHT SHUTDOWN DUE TO OIL LOSS FROM BROKEN OIL LINE, OIL LINE WAS REPLACED AND ENGINE GROUND RUN. A/C W AS ON FERRY FLIGHT FROM ARCTIC VILLAGE TO FAIRBANKS WHEN LEFT ENGINE SUFFERED IMMEDIATE STOPPAGE. THE AIRCRAFT WAS LAND ED EN ROUTE AT FORT YUKON. UPON INSPECTION IT WAS FOUND A CONNECTING ROD HAD FAILED AND GONE THROUGH THE CRANKCASE CAUS ING IMMEDIATE ENGINE FAILURE. A/C WAS LANDED SAFELY. 1 L 7 2 3O 3 O A20SO E14EA 1997021300050 19970213 00050 EA 1997 2 13 97ZZZX603 2 19970123 G 8550 LINE PIPER PA31 PA31310 7103103 SO LYC O540 TIO540A2B 41532 EA TURBO FAILED E A E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 AL 01 101LJ 31267 L173861 ON A FLIGHT FROM FBXS TO ARCTIC VILLAGE, THE PILOT LOST MANIFOLD PRESSURE AND OIL PRESSURE. THE PILOT THEN SHUT DOWN TH E LEFT ENGINE IN-FLIGHT AND LANDED AT ARCTIC VILLAGE. AFTER LANDING, IT WAS DETERMINED THE OIL LINE FROM THE TURBO WAST EGATE WAS BROKEN BEHIND THE FITTING CAUSING LOSS OF OIL. THIS RESULTED IN A CORRESPONDING LOSS OF OIL AND MANIFOLD PRES SURE. 1 L 7 1 3O 3 O RT A20SO E14EA 1997021300051 19970213 00051 SW 1997 2 13 97ZZZX604 1 19970124 G 8011 MZ4222 STARTER PRESTOLITE MOONEY M20 M20J 5870219 SW MOUNT BOLTS LOOSE D K NONE O OTHER IN INSP/MAINT 1 EA 07 201SQ 34 4071886 240298 WHILE ATTEMPTING TO START A/C AFTER LANDING AND GETTING FUEL, PILOT REPORTED STARTER STOPPED WORKING AND MIXTURE CABLE W OULD NOT MOVE. FOUND STARTER HOUSING ATTACH BOLTS COMPLETELY SHEARED OFF AND MISSING ALLOWING STARTER TO REST ON MIXTUR E CONTORL ARM AT FUEL CONTROL UNIT. SUBMITTER STATES THIS IS THE 2ND OCCURRENCE OF THIS SAME PROBLEM ON THIS SAME A/C. 1 L 7 1 3O 2A3 1997021300054 19970213 00054 EA 1997 2 13 97ZZZX607 2 19970101 G 7414 DISTRIBUTOR GEAR BENDIX S6LN1208 BEECH 60 B60 1153605 CE LYC O541 TIO541E1C4 41536 EA LT ENG MAG TEETH MISSING D A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 NE 05 711CE 750 A099004E P437 L114659 ENG QUIT IN FLT. RETURNED TO 5B5. FOUND ON BOTH MAGNETOS ALMOST 100 PERCENT OF THE TEETH ON DISTRIBUTOR GEARS WERE MIS SING (SHEARED OFF), BOTH DISTRIBUTOR GEAR CONTACT FINGERS BROKEN OFF AND WEDGED BETWEEN GEAR AND DIST. BLOCK CAUSING TOT AL LOSS OF IGNITION. 1 L 7 2 3O 3 O A12CE E10EA 1997021300055 19970213 00055 EA 1997 2 13 97ZZZX608 2 19970101 G 7414 DISTRIBUTOR GEAR BENDIX S6LN1209 BEECH 60 B60 1153605 CE LYC O541 TIO541E1C4 41536 EA LT ENG MAG TEETH MISSING D A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 NE 05 711CE 750 A129015F P437 L114659 ENG QUIT IN FLT. RETURNED TO 5B5. FOUND ON BOTH MAGNETOS ALMOST 100 PERCENT OF THE TEETH ON DISTRIBUTOR GEARS WERE MIS SING (SHEARED OFF), BOTH DISTRIBUTOR GEAR CONTACT FINGERS BROKEN OFF AND WEDGED BETWEEN GEAR AND DIST. BLOCK CAUSING TOT AL LOSS OF IGNITION. 1 L 7 2 3O 3 O A12CE E10EA 1997021300058 19970213 00058 SO 1997 2 13 97ZZZX611 2 19970117 G 8500 ENGINE CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO MIXTURE MALFUNCTION D A UNSCHED LANDING O OTHER CL CLIMB 1 NM 08 9438M U20604546 248770R OAT - 18 DEGREES, WX CLEAR. TAKEOFF NORMAL. WHEN POWER REDUCED, ENGINE WENT VERY RICH. PULLED MIX TO KEEP ENGINE RUNN ING. M.P. AND F.F. READ NORMAL. LANDED. LOW RPM OK. CHECKED BOTH METERED AND UNMETERED FUEL PRESSURES ARE WITH THE B OOK. FLEW A/C AFTER, ALL WAS NORMAL. ORIG FUEL CONT REPLACED AT 302.8 TSO, NEXT AT 472.9 TSO. ENG NOW HAS 1182.3 TSO. 1 H 7 1 3O 3 O A4CE E8CE 1997021300059 19970213 00059 CE 1997 2 13 97ZZZX612 1 19970101 G 8011 643259A CLUTCH CESSNA 185 185 2072802 CE STARTER DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 AL 05 9855X 850 1850055 DURING ROUTINE INSPECTION, COULD NOT 'ROCK' PROPELLER. ENGINE WOULD NOT TURN BACKWARD EVEN WITH CONSIDERABLE TORQUE APP LIED. (600 FEET/POUNDS). AFTER REMOVING STARTER CLUTCH PN 643259A, ENGINE TURNED FREELY. IF ENGINE WERE TO KICK BACK DURING START, POSSIBLE SIGNIFICANT DAMAGE TO ENGINE COULD OCCUR. 1 H 7 1 3O NC 3A24 1997021300061 19970213 00061 GL 1997 2 13 97ZZZX614 3 19970123 G 6114 HUB CESSNA 188 A188B 2073005 CE MCAULY 2A34C D2A34C98 GL NR 2 SOCKET CRACKED B UCXR K NONE O OTHER IN INSP/MAINT 1 SW 15 731XN 2988 1143 18803239T 822946 UPON NDT (EDDY CURRENT INSP) IAW MCCAULEY SB 205B, A MICROSCOPIC CRACK WAS FOUND IN THE LOADED SIDE OF THE 3RD THREAD IN THE NR 2 BLADE SOCKET. THE HUB WAS SENT TO MCCAULEY FOR VERIFICATION. 1 L 7 1 3O A9CE 5 C P3EA 1997021300062 19970213 00062 EU 1997 2 13 97ZZZX615 1 19970115 G 7500 1379287L403 LINE BAG JETSTM JETSTM3101 1500215 EU GARRTT TPE331 TPE33110U 01514 WP ENG BLEED FAILED E A K NONE O OTHER CR CRUISE 1 SW 11 BLEED AIR LINE FAILED AT ENGINE ATTACHMENT FLANGE. WELD CRACKED AND LINE SEPARATED IN-FLIGHT. ACFT WAS 10 HRS OUT OF IN SP WITH NO LEAKS EVIDENT IN THE INSP. S/B 21-JM-7797 (OPTIONAL) WAS NOT C/W AT THIS TIME. 2 L 7 2 4T 4 T RT A21EU E4WE 1997021300063 19970213 00063 EU 1997 2 13 97ZZZX616 1 19970122 G 2710 5135123 TORQUE TUBE 513025501 ISRAEL 1124 1124A 4500103 EU AILERON WORN D A K NONE O OTHER IN INSP/MAINT 1 SW 15 2BG 365 UPON PERFORMING SB 1124-27-129 AND AD 96-24-11, FOUND WEAR INDICATED PER AD AND SB. FURTHER INSPECTION INDICATED GROOVE S ON THE BOTTOM OF THE TUBE CAUSED BY THE EDGES OF THE ROLLERS. PILOT STATED THAT THE OTHER TUBE PREVIOUSLY REPLACED HA D THE SAME GROOVES IN IT. TWO GROOVES AT THE BOTTOM OF THE TUBE, BOTH ENDS. GROOVES ARE .50 INCH LONG, AROUND .010 INC H TO .015 INCH WIDE, AND .015 INCH TO .020 INCH DEEP, INDICATING POSSIBLE FAILURE OF TUBE THAT THE AD AND SB DO NOT ADDR ESS OR REQUIRE INSPECTION. 2 M 7 2 4F A2SW 1997021300064 19970213 00064 SO 1997 2 13 97ZZZX617 1 19970127 G 3241 ANTI SKID GULSTM G1159 G1159A 3970109 SO R CONT VALVE WIRE DAMAGED H C D ABORTED TAKEOFF RETURN TO BLOCK J WARNING INDICATION TO TAKEOFF 1 GL 23 5105 5453 445 THE ANIT-SKID LIGHT ILLUMINATED DURING TAKEOFF ROLL. THE CREW ABORTED AND RETURNED TO THE RAMP. THE SYSTEM WAS RESET WI TH NO FURTHER FAILURES. WHEN THE AIRCRAFT RETURNED TO DTW, AN IN-DEPTH INSPECTION OF THE ANTI-SKID SYSTEM REVEALED INSU LATION ON A WIRE AT THE RIGHT CONTROL VALVE WAS DAMAGED. REPAIRED THE WIRE. 2 L 7 2 4F A12EA 1997021300067 19970213 00067 EU 1997 2 13 97ZZZX620 1 19970118 G 2740 TB1034006104 LEVER SOCATA TB20 TB20TRINIDAD 8680695 EU HORIZ STAB BENT G O OTHER F FLT CONT AFFECTED CL CLIMB 1 EA 13 2803A 956 1036 INSP FOUND BOTH PITCH CONTROL LEVERS BENT OUTWARD FROM CENTER. PILOT EXPERIENCED INSUFFICIENT NOSE DOWN PITCH CONTROL J UST AFTER TAKEOFF. MOST LIKELY CAUSE DETERMINED TO BE A HIGH TAIL WIND GUST OR JET WASH HITTING BACK OF AIRCRAFT WHILE PARKED AND CHOCKED ON FBO RAMP. CONTROL YOKE GUST LOCKS WERE IN PLACE AT TIME PROBLEM DEVELOPED. 1 L 7 1 3O RT A51EU 1997021300068 19970213 00068 EU 1997 2 13 97ZZZX621 1 19970118 G 2740 TB1034006103 LEVER TB2034001000 SOCATA TB20 TB20TRINIDAD 8680695 EU HORIZ STAB BENT G A O OTHER F FLT CONT AFFECTED CL CLIMB 1 EA 13 2803A 956 1036 INSP FOUND BOTH PITCH CONTROL LEVERS BENT OUTWARD FROM CENTER. PILOT EXPERIENCED INSUFFICIENT NOSE DOWN PITCH CONTROL J UST AFTER TAKEOFF. MOST LIKELY CAUSE DETERMINED TO BE A HIGH TAIL WIND GUST OR JET WASH HITTING BACK OF AIRCRAFT WHILE PARKED AND CHOCKED ON FBO RAMP. CONTROL YOKE GUST LOCKS WERE IN PLACE AT TIME PROBLEM DEVELOPED. 1 L 7 1 3O RT A51EU 1997021300069 19970213 00069 SO 1997 2 13 97ZZZX622 1 19970112 G 5741 AN17612 SPAR BOLTS PIPER PA28 PA28R201T 7102813 SO WING ATTACH CORRODED E K NONE O OTHER IN INSP/MAINT 1 SW 11 101 WHEN INSP WINGS PER SB 88C, FOUND ALL WING SPAR ATTACH BOLTS TO BE CORRODED WITH PITS. BOLTS INSTALLED 101 HRS PRIOR ON 4-20-92. BOLTS WERE APPARENTLY INSTALLED USED AND WITHOUT LUBE. 1 L 7 1 3O 2A13 1997022500001 19970225 00001 CE 1997 2 25 97ZZZX624 1 19970120 G 5540 57330142 BRACKET 573300071 CESSNA 404 404CESSNA 2075901 CE RUD BAL WT CRACKED D A K NONE O OTHER IN INSP/MAINT 1 SW 99 409EX 12346 4040436 ON PRE-FLIGHT INSPECTION, PILOT NOTICED 'CLUNKING' SOUND IN RUDDER WHEN IT WAS MOVED. INSPECTION OF RUDDER FOUND BALANC E WEIGHT SEPARATED FROM MOUNTING BRACKET WHICH WAS CRACKED OUT AT BOTH NUTPLATES WHICH ATTACH WEIGHT. REPAIRED MOUNTING BRACKET. HIGH AIRCRAFT TIME. WEAK DESIGN, MOUNT BRACKET IS ONLY .040 INCH 2024-T3 WITH TWO .25 INCH NUTPLATES RIVETE D TO IT TO HOLD APPROXIMATELY 8 POUNDS OF LEAD WEIGHT. NOTE: THIS BRACKET IS ACCESSIBLE FOR INSPECTION BY REMOVING SCR EWS FOR FAIRINGS AND BALANCE WEIGHT WITHOUT REMOVING RUDDER FROM AIRCRAFT. 1 L 7 2 3O A25CE 1997021300071 19970213 00071 CE 1997 2 13 97ZZZX625 1 19970114 G 5711 05230202 SPAR CAP CESSNA 175 175 2072502 CE RT WING CORRODED D S K NONE O OTHER IN INSP/MAINT 1 SW 99 7464M 55764 AFTER REMOVING FUEL TANK COVER PANELS TO REPLACE SOME GASKETS DURING AN ANNUAL INSP, INTERGRANULAR CORROSION WAS FOUND O N SPAR CAP FWD OF THE RT TANK. WING LEADING EDGE WAS REMOVED FOR FURTHER INSP AND THE SAME TYPE OF CORROSION WAS FOUND ALONG THE FULL LENGTH OF SPAR CAP. THE SPAR CAP REQUIRED REPLACEMENT. THIS CORROSION COULD NOT BE SEEN UNTIL FUEL TANK COVER PANELS WERE REMOVED. LT WING SPAR CAP DID NOT APPEAR TO HAVE ANY CORROSION. RECOMMEND PULLING FUEL TANK COVER P ANELS EVERY 5 YRS TO INSP FOR CORROSION. 1 H 7 1 3O NT 3A17 1997021300072 19970213 00072 SO 1997 2 13 97ZZZX626 1 19970110 G 2820 9515327 FUEL LINE PIPER PA34 PA34200 7103405 SO LT WING CHAFED D K NONE O OTHER IN INSP/MAINT 1 WP 23 57368 347450054 MAIN FUEL LINE, PN 95153-27 (LEFT) AND DASH 28 (RIGHT) CHAFED 90 PERCENT THROUGH BY CABIN HEAT DUCT, PN 63633-91, IN AFT NACELLE. INSPECTION OF THIS AREA REQUIRES REMOVING AFT NACELLE TOP PANEL, STANDING ON WING, AND USING MIRROR TO EXAMIN E AFT OUTBOARD CORNER WHERE MAIN FUEL LINE PASSES UNDER CABIN HEAT DUCT. SUBMITTER SUGGESTS EVERY SENECA I AFTER 1972 W ILL HAVE THIS PROBLEM. SOLUTION: BEND FUEL LINE AWAY FROM DUCT, INSPECT AND PROTECT. 1 L 7 2 3O A7SO 1997021300073 19970213 00073 SO 1997 2 13 97ZZZX627 1 19970110 G 2820 9515328 FUEL LINE PIPER PA34 PA34200 7103405 SO RT WING CHAFED D A K NONE O OTHER IN INSP/MAINT 1 WP 23 57368 347450054 MAIN FUEL LINE, PN 95153-27 (LEFT) AND DASH 28 (RIGHT) CHAFED 90 PERCENT THROUGH BY CABIN HEAT DUCT, PN 63633-91, IN AFT NACELLE. INSPECTION OF THIS AREA REQUIRES REMOVING AFT NACELLE TOP PANEL, STANDING ON WING, AND USING MIRROR TO EXAMIN E AFT OUTBOARD CORNER WHERE MAIN FUEL LINE PASSES UNDER CABIN HEAT DUCT. SUBMITTER SUGGESTS EVERY SENECA I AFTER 1972 W ILL HAVE THIS PROBLEM. SOLUTION: BEND FUEL LINE AWAY FROM DUCT, INSPECT AND PROTECT. 1 L 7 2 3O A7SO 1997021300074 19970213 00074 CE 1997 2 13 97ZZZX628 1 19970128 G 7120 08515543 MOUNT BRACKET CESSNA 310 310Q 2074242 CE LT ENG LT FWD CRACKED G K NONE O OTHER IN INSP/MAINT 1 GL 09 1240G 310Q1091 INSP FOUND LT ENG, FWD LT MOUNT, AFT BRACKET CRACKED. 1 L 7 2 3O 3A10 1997021300075 19970213 00075 SO 1997 2 13 97ZZZX629 2 19970101 G 8550 631056 COVER ASSY BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO OIL PUMP LEAKING B FBLR K NONE K FLUID LOSS IN INSP/MAINT 1 SO 17 3093W 520 520 TH403 267601H PILOT COMPLAINING OF OIL LEAK. FOUND OIL PUMP LEAKING FROM CASTING SCAR IN UNIT. 1 L 7 2 3O 3 O 3A16 E5CE 1997021300076 19970213 00076 CE 1997 2 13 97ZZZX630 1 19970127 G 2720 TRIM ARM CESSNA 310 T310R 2074246 CE ELEV TRIM IND MISINDEXED D A K NONE O OTHER IN INSP/MAINT 1 WP 25 4949A 4171 310R1505 ELEVATOR TRIM INDICATOR ARM FREQUENTLY BECOMES MISINDEXED GIVING ERRONEOUS TRIM SETTING INDICATIONS. A PILOT'S KNEE, RE STING AGAINST THE TRIM WHEEL, CAN DISPLACE THE WHEEL ENOUGH TO CAUSE THE TRIM ARM TO MOVE OUT OF THE SPIRAL GROOVE AND I NTO ANOTHER GROOVE. AN IDENTICAL PROBLEM OCCURS IN THE OTHER COMPANY OWNED 310R. THE TRIM WHEEL AND ATTACHING PARTS AR E TIGHT AND IN GOOD CONDITION. APPROVED PREVENTATIVE ACTIONS ARE NOT APPARENT. 1 L 7 2 3O 3A10 1997021300077 19970213 00077 SO 1997 2 13 97ZZZX631 2 19970101 G 8530 PE92EL ROCKER CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO NR 2 CYL EXH BROKE B EVGR K NONE O OTHER NR NOT REPORTED 1 SO 33 2FOR 150 U20606295 283128R THE NR 2 EXHAUST 'ROLLER ROCKER' BROKE MID-WAY BETWEEN THE PUSH ROD SOCKET AND THE ROCKER ARM SHAFT. STC 8594SW. 1 H 7 1 3O 3 O A4CE E8CE 1997021300078 19970213 00078 CE 1997 2 13 97ZZZX632 1 19970101 G 2842 385BN812 SENSOR CESSNA 206 U206F 2073333 CE TIP TANK QTY RUSTED D K NONE O OTHER IN INSP/MAINT 1 SO 08 2FOR U20602415 THE FUEL QTY SENDER IN THE TIP TANK (FLINT) CORRODED SEVERELY DUE TO THE TANK BEING LEFT EMPTY MOST OF THE TIME. CONDEN SATION AND RUST TOTALLY DESTROYED THE SENDER. RECOMMEND KEEPING SOME FUEL IN THE TIP TANKS AT ALL TIMES. STC SA1335SO. 1 H 7 1 3O A4CE 1997021300079 19970213 00079 CE 1997 2 13 97ZZZX633 1 19970101 G 3231 0024100381 SHAFT ASSY BEECH 58 58 1152740 CE NLG DOORS BROKEN B HBKR A O UNSCHED LANDING OTHER P NO WARNING INDICATION CL CLIMB 1 SW 11 3711Y TH828 PILOT REPORTED THAT NOSE GEAR DOORS FAILED TO CLOSE WHEN THE GEAR WAS RETRACTED. INFORMED THAT THE DOORS WERE OPEN BY C ONTROL TOWER PERSONNEL; PILOT HAD NO COCKPIT INDICATION THAT THE GEAR WAS FUNCTIONING ABNORMALLY. THE PILOT MANUALLY EX TENDED THE GEAR AND LANDED WITHOUT DAMAGE. UPON INSPECTION, PART OF THE NOSE GEAR DOOR RETRACTION MECHANISM WAS FOUND B ROKEN. SPECIFICALLY, THE SLOTTED TAB NEAR THE CENTER OF THE NOSE GEAR RETRACTION PIVOT SHAFT HAD BROKEN, LOSING ITS LOW ER PORTION. SINCE THIS PORTION OF THE TAB TAKES ALL THE FORCE OF GEAR DOOR CLOSURE, THE GEAR DOORS DID NOT CLOSE. THIS TAB IS RATHER FLIMSY, AND OFTEN FAILS WITHOUT ANY SIGNS OF IMPENDING FAILURE. 1 L 7 2 3O 3A16 1997021300081 19970213 00081 SO 1997 2 13 97ZZZX635 1 19970109 G 2140 CONNECTOR PIPER PA31 PA31350 7103110 SO HEATER BLOWER BURNED D L A K NONE M OVER TEMP IN INSP/MAINT 1 SW 99 3581C 6924 318052091 DURING AN INSPECTION, MAINTENANCE FOUND A MOLEX CONNECTOR LOCATED JUST FORWARD OF THE CIRCUIT BREAKER PANEL, BEHIND THE SIDE PANEL ON THE PILOT'S SIDE BURNED AND THE WIRE HEATED APPROX .50 INCH OUT OF THE CONNECTOR. THIS MOLEX CONNECTOR NR E303 PER THE NAVAJO CHIEFTAIN SERVICE MANUAL WIRING DIAGRAM. THE WIRE THAT IS OVERHEATING FOUND TO BE FOR THE HEATER BL OWER, FROM A 20-AMP CIRCUIT BREAKER. 1 L 7 2 3O A20SO 1997021300464 19970213 00464 CE 1997 2 13 97ZZZX678 1 19970116 G 3234 SELECTOR VALVE CESSNA 441 441 2076020 CE NLG MISWIRED D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 555JJ 5777 4410004 THE NOSE GEAR RETRACTED DURING ENGINE START WITH THE GEAR SELECTOR DOWN AND THREE GREEN GEAR IND LIGHTS. INVESTIGATION FOUND THE LEFT DOWNLOCK SWITCH FAILED IN THE CONTROL CIRCUIT APPLYING POWER TO THE LOADING VALVE AND HYD SLECTOR VALVE. PIN B AND D IN CONNECTOR P52 WERE FOUND REVERSED. SL PJ81-15 WAS C/W. 1 L 7 2 3T RT A28CE 1997021300466 19970213 00466 SO 1997 2 13 97ZZZX680 1 19970123 G 3250 452334 ROD END PARKERHANFIN 456015 PIPER PA28 PA28181 7102807 SO NLG STEERING FAILED B T6UR K NONE O OTHER IN INSP/MAINT 1 SO 01 3023M 287890285 NOSE STEERING SHIMMY DAMPER ROD END BROKEN AT THREAD SHAFT. 1 L 7 1 3O 2A13 1997021300467 19970213 00467 EA 1997 2 13 97ZZZX681 2 19970114 G 7414 1068256011 MAGNETO PIPER PA28 PA28236 7102815 SO LYC O540 O540J3A5 41532 EA MAG HOLD DOWN BASE WORN B T6UR K NONE O OTHER IN INSP/MAINT 1 SO 01 419CC C079508G 287911268 SNL21652 HOLD DOWN BASE FOR MAGNETO WAS WORN. CAUSED HOLD DOWN CLAMP TO BE INEFFECTIVE. 1 L 7 1 3O 3 O 2A13 E295 1997021300469 19970213 00469 CE 1997 2 13 97ZZZX683 1 19970117 G 8097 J12A4 WIRE BEECH 58 58 1152740 CE RT ENG STARTER SHORTED B A MZ4R K NONE O OTHER IN INSP/MAINT 1 SO 17 1064C 228 TH1764 THE RIGHT ENGINE STARTER CABLE (WIRE) NR J12A4) WAS FOUND TO HAVE SHORTED TO THE ENGINE MOUNT. THIS CAUSED DAMAGE TO TH E ENGINE MOUNT P/N 96-910010-85 WHICH IN TURN WAS REPLACED WITH A NEW MOUNT. A NEW STARTER WIRE WAS INSTALLED AND ROUTE D TO PREVENT ANY FUTURE CHAFING. SUBMITTER STATED THIS IS NOW THE THIRD INCIDENT OF THIS TYPE ON THE SAME MODEL AIRCRAF T WITH LOW TIME. RAYTHEON AIRCRAFT WAS NOTIFIED. 1 L 7 2 3O 3A16 1997021300470 19970213 00470 EA 1997 2 13 97ZZZX684 2 19970128 G 7414 103825881 COIL 1068291018 PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA LT MAG CRACKED D K NONE O OTHER NR NOT REPORTED 1 SO 25 4108P 299 A1459506 318352014 RL12768A PILOT REPORTED LEFT HAND MAGNETO FAILED. REMOVED MAG, FOUND BOTH LEFT HAND S/N A-145-9506 AND RIGHT HAND S/N M-145-9505 IGNITION COILS P/N 10-382588-1 CRACKED. CRACKS ORIGINATE ON BOTH COILS AT IRON CORE AND EXTEND OUTWARD. ON LEFT HAND COIL, CRACK ALSO PRESENT AT SURFACE FACING ROTATING MAGNET. SUBMITTED MAGNETO TO MFG FOR EVALUATION FOR POSSIBLE DEFECT S IN COILS PRODUCED DURING THIS PERIOD OF TIME. 1 L 7 2 3O 3 O A20SO E14EA 1997021300471 19970213 00471 EA 1997 2 13 97ZZZX685 2 19970128 G 7414 103825881 COIL 1068291018 PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA LT MAG CRACKED D K NONE O OTHER NR NOT REPORTED 1 SO 25 4108P 299 M1459505 318352014 RL12768A PILOT REPORTED LEFT HAND MAGNETO FAILED. REMOVED MAG, FOUND BOTH LEFT HAND S/N A-145-9506 AND RIGHT HAND S/N M-145-9505 IGNITION COILS P/N 10-382588-1 CRACKED. CRACKS ORIGINATE ON BOTH COILS AT IRON CORE AND EXTEND OUTWARD. ON LEFT HAND COIL, CRACK ALSO PRESENT AT SURFACE FACING ROTATING MAGNET. SUBMITTED MAGNETO TO MFG FOR EVALUATION FOR POSSIBLE DEFECT S IN COILS PRODUCED DURING THIS PERIOD OF TIME. 1 L 7 2 3O 3 O A20SO E14EA 1997022000125 19970220 00125 CE 1997 2 20 97ZZZX752 1 19970128 G 5320 5043014323 SUPPORT BEECH 100 A100 1152915 CE AIR STAIR DOOR BROKEN D K NONE O OTHER IN INSP/MAINT 1 GL 11 115DT 11300 B212 AFTER READING A REPORT IN THE JAN ISSUE ABOUT AIR STAIR STRUCTURE CRACKS, EXAMINED OUR (ACFT DOOR). FOUND THAT THE AIR STAIR DAMPNER UPPER ATTACH POINT WAS FLEXING DURING TRANSITION. FURTHER INVESTIGATION REVEALED THAT THE STRINGERS THAT THE ATTACH POINT IS SECURED TO HAD BROKEN AWAY FROM THE FUSELAGE. IT IS SUSPECTED THAT THE STRUCTURE HAD WORK-HARDENED AND BECAME BRITTLE. THE UPPER SUPPORT WHICH WAS SLIGHTLY BENT AND TWISTED IS ATTACHED WITH SIX 10-32 SCREWS, OF THESE, FIVE WERE BENT 7 DEGREES-20 DEGREES AND ONE WAS SHEARED. THE FUSELAGE NEEDS REINFORCED IN THIS AREA. 1 L 7 2 3T A14CE 1997022000126 19970220 00126 1997 2 20 97ZZZX753 4 19970204 G 2397 WIRE SLNSBY T67 T67M260 8323006 EU INTERPHONE CHAFED D K NONE O OTHER IN INSP/MAINT 1 SW 17 3045S 2142 WIRE BUNDLE CHAFING ON INSTRUMENT MOUNT BRACKET BEHIND RADIOS. DISCREPANCY IS THE INTERCOM DOES NOT TRANSMIT CLEARLY. C UTS IN AND OUT. INSPECTED, FOUND A WIRE CHAFE THROUGH DUE TO THE WIRE BUNDLE ON THE RADIO MOUNT BRACKET. RECOMMEND RE- ROUTING OF THE WIRE BUNDLE AND INSTALL A CHAFE PAD. 1 L 7 1 3O NT A73EU 1997022000128 19970220 00128 SO 1997 2 20 97ZZZX755 1 19970125 G 7130 6711961 MOUNT PIPER PA28 PA28R201 7102816 SO ENG DEFECTIVE D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 11 531PU 4193 T2124 2837039 ENGINE MOUNT REMOVED DURING ENGINE CHANGE DUE TO WEAR IN LOWER TUBES CAUSED BY LOWER COWLING CLAMPS. AFTER TUBES REPLAC ED BY APPROVED MOUNT REPAIR SERVICE, FOUND THAT DOWNLOCK BLOCK WAS INCORRECTLY WELDED ON RESULTING IN NOSE GEAR DRAG BRA CE NOT BEING OVER CENTER AND 'LOCKED'. NOTE: LANDING GEAR WORKED NORMALLY AND INDICATORS WERE CORRECT. TOOK 3 ADDITIO NAL REPAIR ATTEMPTS BEFORE CORRECT AND SERVICEABLE. 1 L 7 1 3O 2A13 1997022000129 19970220 00129 SO 1997 2 20 97ZZZX756 1 19970206 G 2432 G35 BATTERY GILLBATT PIPER PA34 PA34200T 7103406 SO NOSE COMPT BURNED D L A O OTHER B M SMOKE/FUMES/ODORS/SPARKS OVER TEMP CR CRUISE 1 SO 13 74FF 214 347570300 PILOT REPORTED A SMELL OF AND TRACES OF SMOKE IN CABIN THAT WAS BRIEF. NO CAUSES COULD BE DETERMINED IN-FLIGHT. ALTS W ERE CHARGING AND ALL SYSTEMS SEEMED NORMAL. AFTER LANDING, PILOT NOTICED PAINT BUBBLED ON TOP OF NOSE CONE AND LOOKED I N BAGGAGE COMP. SOOT COVERED THE ENTIRE AREA, AND NOSE WHEEL/BATTERY COVER WAS SEVERELY BURNED. WHEN COVER WAS REMOVED , BATTERY WAS EXPOSED AND APPEARED TO HAVE MELTED DOWN AND BURNED AWAY. 1 L 7 2 3O A7SO 1997022000130 19970220 00130 SO 1997 2 20 97ZZZX757 1 19970122 G 5210 46624003 DOUBLER PIPER PA31T PA31T 7103124 SO DOOR SUPPORT CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 05 8CF 3603 31T8020062 DURING EVENT 1 AND 2 INSPECTION OF ACFT, FOUND MULTIPLE CRACKS IN DOUBLER BEHIND END FRAME OF CABIN DOOR. (HINGE END OF DOOR). SUSPECT STRESS FATIGUE DUE TO HINGE AND HINGE PIN WEAR, ALLOWING DOOR TO FLEX DURING BOARDING OPERATIONS, ETC. DISASSEMBLED HINGE END OF CABIN DOOR; INSTALLED NEW DOUBLER AND HINGE ASSY IAW PIPER MAINTENANCE INSTRUCTIONS. 1 L 7 2 3T A8EA 1997022000132 19970220 00132 NE 1997 2 20 97ZZZX759 1 19970117 G 2140 BWT1367611 ELBOW SKRSKY S76 S76C 8143008 NE BAG COMPT RUPTURED B KS4R K NONE O OTHER IN INSP/MAINT 1 SO 17 702H 126 760460 CUSTOMER COMPLAINED OF HOT AIR EXITING BAGGAGE COMPARTMENT WHEN UNLOADING BAGGAGE IN COLD WEATHER. UPON REMOVING CENTER OVERHEAD BAGGAGE SHROUD, FOUND C-4 HEATER DUCT ELBOW P/N BWT13671-1 RUPTURED ALLOWING HOT AIR FROM HEATER TO ENTER BAGG AGE COMPARTMENT. REPLACED ELBOW WITH NEW PART. FORWARDED OLD PART TO MANUFACTURER FOR EVALUATION. 1 G 7 2 3U NC H1NE 1997022000133 19970220 00133 NM 1997 2 20 97ZZZX760 1 19970123 G 2710 AN3208 ROD ATTACH BOEING 727 72723 1384004 NM LT OUTB OIL NUT MISSING B A I44R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 19 727WF 20045 DURING C-CHECK INSPECTION OF THE LEFT OUTBOARD AILERON CONTROL ROD TO AILERON, INSPECTION REVEALED THE ATTACH BOLT'S NUT , WASHER, AND COTTER PIN WERE NOT INSTALLED (MISSING). THE BOLT MIGRATED APPROX .125 INCH OUTBOARD. SUSPECT DURING AIL ERON INSTALLATION, THE MECHANIC FAILED TO INSTALL THE NUT, WASHER, AND COTTER PIN, AND THE HINGE COVER WAS INSTALLED WHI CH PREVENTS A VISUAL CHECK OF THE INSTALLATION. 2 L 7 3 4F A3WE 1997022000134 19970220 00134 NM 1997 2 20 97ZZZX761 1 19970106 G 5330 SKIN BOEING 727 727287 1384020 NM FS 300 GOUGED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 914PG 22603 DURING C-CHECK INSPECTION, DEEP GOUGES WERE NOTED IN AIRCRAFT SKIN AT FS 300 FROM S17R TO S18R. 2 L 7 3 4F RT A3WE 1997022000135 19970220 00135 NM 1997 2 20 97ZZZX762 1 19970106 G 5330 SKIN BOEING 727 727287 1384020 NM FS 355 S21R GOUGED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 914PG 22603 DURING C-CHECK INSPECTION, A DEEP GOUGE AND CRACK IN THE AIRCRAFT SKIN AT STA 355 JUST BELOW S21R. 2 L 7 3 4F RT A3WE 1997022000136 19970220 00136 NM 1997 2 20 97ZZZX763 1 19970106 G 5330 SKIN BOEING 727 727287 1384020 NM FS 370-375 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 914PG 22603 DURING INSPECTION OF EPCP CARD C53-100-01, PT 4, LEVEL 2, CORROSION WAS NOTED UNDER SKIN, RT FWD FS 370 TO 375, JUST BEL OW S17R. 2 L 7 3 4F RT A3WE 1997022000138 19970220 00138 EU 1997 2 20 97ZZZX765 1 19970124 G 2422 ASH6641PF INVERTER LELAND BRAERO DH125 BAE125800A 1500285 EU NR 1 FAILED D L A O OTHER J WARNING INDICATION AP APPROACH 1 SW 15 EJ838M DATE OF INCIDENT UNKNOWN. USER REPORTED THAT A/C HAD BEEN FLYING IN HEAVY RAIN FOR APPROX. 45 MINUTES (NOV. 95). DURING FINAL APPROACH, THE NR 1 MAIN INVERTER FAIL ANNUNCIATOR ILLUMINATED. CREW CONTINUED APPROACH AND HAD NORMAL ENDING. W HILE TAXIING, CREW ATTEMPTED TO RESET NR 1 INVERTER. THIS RESULTED IN SEVERAL CIRCUIT BREAKERS TRIPPING, AND NUMEROUS A VIONICS FAIL FLAGS. AFTER RESET, VARIOUS SYSTEMS REMAINED INOPERATIVE. BOTH INVERTERS AND NUMEROUS OTHER COMPONENTS WE RE REPLACED. GROUND AND IN-FLIGHT TEST OF AFFECTED SYSTEMS WERE FOUND SATISFACTORY AFTER REPAIRS. 2 L 7 2 4F RT A3EU 1997022000139 19970220 00139 EU 1997 2 20 97ZZZX766 2 19970206 G 7250 DIFFUSER CASE HWKSLY DH125 DH1253ARA 423013P EU RROYCE VIPER VIPER522 54552 EU RT ENG CRACKED D S A K NONE O OTHER IN INSP/MAINT 1 SO 01 125HS 5421 NA701 522008 DIFFUSER CASE (RT ENG) CRACKED AT 11:00 (A.L.F.) POSITION. LENGTH OF CRACK IS 4.1250 INCHES. 2 L 7 2 4J 4 J A3EU E3EU 1997022000140 19970220 00140 1997 2 20 97ZZZX767 4 19970129 G 2562 4520130 BATTERY PACK ARTEX 1104002 BEECH MU300 400A 1155402 CE ELT LEAKING B OG5R K NONE O OTHER IN INSP/MAINT 1 GL 21 3196N 242 59679 RK96 DURING SCHEDULED BATTERY INSPECTION, FOUND 2 BATTERY CELLS LEAKING. ELT WAS REPLACED 242.2 HOURS PREVIOUS FOR SAME PROB LEM. THIS IS THE 6TH ELT TO BE REPLACED BY THIS OPERATOR ON A 2 AIRCRAFT FLEET. TWO PREVIOUS MALFUNCTION/DEFECT REPORT S LISTED CRACKED ELT CASES DUE TO SEVERE LEAKAGE AND RUPTURE OF CASE. 2 H 7 2 4F RT A16SW 1997022000141 19970220 00141 CE 1997 2 20 97ZZZX768 1 19970127 G 2121 45053 BLOWER MOTOR CESSNA 650 650 2076802 CE AIR DIST SEIZED D A K NONE B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 GL 03 600JD 1093 0200 6500236 BLOWER MOTOR SEIZED CAUSING EXCESSIVE CURRENT DRAW. THE 15-AMP CIRCUIT BREAKER PROTECTING THE CIRCUIT FAILED TO OPEN. T HIS CAUSED THE WIRING FOR THE BLOWER MOTOR TO GET HOT AND EMIT SMOKE AND FOUL ODOR. THE COCKPIT AUX HEATER THEN CIRCULA TED THE SMOKE INTO THE COCKPIT. THE BLOWER MOTOR IS RATED AT ABOUT 8 AMPS. THE CIRCUIT BREAKER SIZE SHOULD BE CLOSER T O THE RATE CURRENT DRAW OF THE MOTOR. 2 L 7 2 4F A9NM 1997022000146 19970220 00146 WP 1997 2 20 97ZZZX773 1 19970130 G 3246 2601483 BOLT 2608891 DOUG DC9 DC983 3022083 WP WHEEL FAILURE B A3LD K NONE O OTHER IN INSP/MAINT 1 EA 05 B1087 INSP FOUND WHEEL BOLTS WITH FATIGUE RELATED FAILURE. SUSPECT INSUFFICIENT PRELOAD TORQUE. TWO REPORTS THIS S/N. SUBMI TTER STATES USE SNUG ANGLE TORQUE METHOD. 2 L 7 2 4F RT A6WE 1997022000147 19970220 00147 WP 1997 2 20 97ZZZX774 1 19970130 G 3246 2601483 BOLT BENDIX 2608891 DOUG DC9 DC983 3022083 WP WHEEL FAILURE B A3LD K NONE O OTHER IN INSP/MAINT 1 EA 05 B2393 INSP FOUND WHEEL BOLT WITH FATIGUE RELATED FAILURE. SUSPECT INSUFFICIENT PRELOAD TORQUE. SUBMITTER STATES USE SNUG ANG LE TORQUE METHOD. 2 L 7 2 4F RT A6WE 1997022000148 19970220 00148 CE 1997 2 20 97ZZZX775 1 19970129 G 2435 BEARING LEARSIEGLER 23080002 RKWELL NA265 NA26565 7630107 CE START/GEN FAILED D H A DEACTIVATE SYST/CIRCUITS UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 EA 13 265A 6225 648 1599 46547 SABRELINER RT ENGINE EXPERIENCED A VIBRATION. TURNING GENERATOR OFF SILENCED THE VIBRATION. WHEN TURNING BACK ON, VIBR ATION STARTED AGAIN. GENERATOR LIGHT DID NOT COME ON. LANDED ACFT. SAFELY, CHANGED STARTER/GEN, PROBLEM WENT AWAY. 2 L 7 2 4J A2WE 1997022000153 19970220 00153 CE 1997 2 20 97ZZZX780 1 19970101 G 3520 727725 BREAKER BEECH 200 200BEECH 1152920 CE OXY BARO SYS FAILED B BXSR K NONE O OTHER IN INSP/MAINT 1 EA 09 200BE 6500 BB832 WHILE DEMONSTRATING THE FUNCTION OF THE CABIN BAROMETRIC SWITCH TO A TRAINEE, IT WAS FOUND THAT WHEN POWER WAS APPLIED T O THE SOLENOID ON THE BAROMETRIC SYSTEM, THE OXYGEN VALVE DID NOT OPEN AND DROP THE MASKS. TROUBLESHOOTING FOUND A VOLT AGE DROP AT THE CIRCUIT BREAKER. WHEN THE C/B WAS REPLACED, THE SYSTEM WORKED AS ADVERTISED. THERE IS NO FUNCTIONAL TE ST OF THE ELECTRICAL PORTION OF THE OXYGEN AUTO DEPLOY SYSTEM, BUT IT MIGHT BE A GOOD IDEA TO PERFORM IT WHEN THE BARO V ALVE IS OVERHAULED IN 24 MOS. 1 L 7 2 4T A24CE 1997022000156 19970220 00156 EA 1997 2 20 97ZZZX783 1 19970129 G 7830 22850785261 SAM PANEL CNDAIR CL600 CL6002B16 1900305 EA THRUST REV TORN OFF C A K NONE O OTHER IN INSP/MAINT 1 NE 03 900CL 2545 5122 DURING A POST FLIGHT INSP OF THE LEFT ENGINE, THE 6 O'CLOCK SAM PANEL WAS FOUND MISSING. THE PANEL WAS TORN OFF AFTER C RACKS IN THE RETAINING BRACKETS CAUSED THEM TO FAIL. THE PANEL WAS RECOVERED AT THE END OF THE RUNWAY. REPAIRED BY CAN ADAIR SB 601-1084 AND FITTED A NEW SAM PANEL. 2 L 7 2 4F RT A21EA 1997022000157 19970220 00157 NM 1997 2 20 97ZZZX784 1 19970131 G 3244 H40X14520 TIRE BOEING 737 7373T0 1384582 NM WHEEL LINER SEPARATION B A3LD K NONE O OTHER IN INSP/MAINT 1 EA 05 INSP FOUND PARTIAL TIRE LINER SEPARATION. CAUSE UNDER INVESTIGATION BY THE TIRE MANUFACCTUR5ER (GOODYEAR). 2 L 7 2 4F RT A16WE 1997022000472 19970220 00472 SO 1997 2 20 97ZZZX785 2 19970203 G 8550 631056A1 COVER ASSY BEECH 58 58TC 1152746 CE CONT O520 TSIO520WB 17040 SO OIL PUMP LEAK D K NONE K W FLUID LOSS INADEQUATE Q C IN INSP/MAINT 1 WP 25 6669X 90 TK108 518929 THE COVER TO OIL PUMP IS SEALED WITH GASKET CEMENT (FORM-A-GASKET PERMATEX) AND A NR 50 SILK THREAD. THE COVER WAS NOT PROPERLY INSTALLED AND TORQUED CAUSING IT TO LEAK OIL WHEN THE SEAL FAILED AFTER A TWO HOUR FLIGHT HAD LEAKED 3 QTS OIL. 1 L 7 2 3O 3 O A23CE E8CE 1997022000476 19970220 00476 GL 1997 2 20 97ZZZX789 3 19970129 G 6114 HUB BEECH 35 N35 1151528 CE MCAULY 2A36C 2A36C23 GL PROP FLANGE FAILED G L A O OTHER D INFLIGHT SEPARATION TO TAKEOFF 1 WP 07 7HB D6750 756778 DURING TAKEOFF WHILE ROTATING FOR LIFT-OFF, THE PROP HUB FAILED, THE PILOT LOST CONTROL, THE ACFT VEERED OFF THE RUNWAY, FLIPPED OVER AND WAS DESTROYED. THE THREE OCCUPANTS RECEIVED MINOR INJURIES. THE PROP FAILED AT THE HUB. THE PROP INS TANTANEOUSLY SEPARATED FROM THE AIRCRAFT. AN AUDIT OF THE ACFT RECORDS WAS ACCOMPLISHED TO DETERMINE IF PREVIOUS DAMAGE HAD OCCURRED, AND TO DETERMINE C/W FAR. WHILE RESEARCHING AD RECORDS, IT WAS FOUND THAT AD 89-26-08 HAD NOT BEEN C/W. IT WAS ALSO DETERMINED THAT AD 89-26-08 DID NOT APPLY ACCORDING TO THE APPLICABILITY SECTION OF THE AD. THE APPLICABIL ITY SECTION STATES THAT THE AD APPLIES TO MCCAULEY MDL 2A36C23/84B-0, THE FAILED PROP IS A MCCAULY MDL 2A36C23 - P - E. 1 L 7 1 3O 3A15 5 C P880 1997022000477 19970220 00477 SO 1997 2 20 97ZZZX790 2 19970120 G 7414 DISTRIBUTOR BLK SLICK 4301 CESSNA 140 140 2071602 CE CONT C85 C8512F 17008 SO LT MAG WORN D K NONE O OTHER IN INSP/MAINT 1 CE 01 1859V 54 96060509 14038 28583712 TROUBLESHOT IGNITION SYSTEM. FOUND LEFT MAGNETO TO BE PROBLEM. DISASSEMBLED MAGNETO AND FOUND ROTOR GEAR RUBBING ON DI STRIBUTOR BLOCK HOUSING. DISTRIBUTOR BLOCK HOUSING WAS WARPED. ALSO FOUND BUSHING IN DISTRIBUTOR BLOCK HOUSING WAS WOR N THROUGH ON SIDE TOWARDS CONDENSER. WEAR HAD PROGRESSED INTO PLASTIC SURROUNDING BUSHING. SEVERE ARCING AND CARBON TR ACKING WAS PRESENT IN HOUSING. FOUND THAT THE ROTOR GEAR WAS NOT PRESSED INTO PLACE AS IS REQUIRED IN SLICK SM. SUBMIT TER STATES THE SEALING MARK IS PUT ON MAGNETO HOUSING SCREW AT FACTORY HAD NOT BEEN BROKEN PRIOR TO MECHANIC DOING SO FO R INSPECTION. 1 H 7 1 3O 3 O NC A768 E233 1997022000480 19970220 00480 CE 1997 2 20 97ZZZX793 1 19970131 G 3211 071349520 BRACKET CESSNA 180 180 2072602 CE MLG CORRODED B A5OR K NONE O OTHER IN INSP/MAINT 1 SO 09 2937A 3092 30173 DURING INSPECTION OF THE LANDING GEAR, THE OUTBOARD LT LANDING GEAR BRACKET WAS FOUND WITH HEAVY INTERGRANULAR CORROSION (I/G) TO THE LOWER FITTING. SUSPECT CAUSE IS IMPROPER HEAT TREATING DURING MANUFACTURE. SUBMITTER STATES THIS IS THE FOURTH SUCH FITTING FOUND WITH I/G CORROSION. RECOMMEND CLOSE INSPECTION OF LANDING GEAR BRACKETS DURING INSPECTION OF OLDER AIRCRAFT. 1 H 7 1 3O NC 5A6 1997022000483 19970220 00483 CE 1997 2 20 97ZZZX796 1 19970130 G 2434 DOFF10300B ALTERNATOR FORD CESSNA 210 210L 2073448 CE DC SYS FAILED G A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CR CRUISE 1 GL 03 50DB 6680 21060107 FORD ALTERNATOR FAILED IN-FLIGHT. A/C RAN OFF A/C BATTERY. MAINTENANCE INSTALLED OVERHAULED ALTERNATOR AND A/C WAS RET URNED TO SERVICE. 1 H 7 1 3O 3A21 1997022000484 19970220 00484 CE 1997 2 20 97ZZZX797 1 19970127 G 2912 MS288786 PACKING AN62342 CESSNA 414 414A 2075907 CE HYD FILTER CUT H O OTHER J K WARNING INDICATION FLUID LOSS AP APPROACH 1 WP 13 5614C 414A0203 PILOT REPORTED THAT BOTH LEFT AND RIGHT HYDRAULIC PRESSURE CAUTION LIGHTS WERE ILLUMINATED. LANDING GEAR WOULD NOT EXTE ND. LANDING GEAR WAS EXTENDED USING THE EMERGENCY EXTENSION PROCEDURE. AIRPLANE WAS JACKED AND THE LANDING GEAR OPERAT IONAL CHECK WAS PERFORMED. FLUID WAS DISCOVERED LEAKING FROM THE RIGHT HYDRAULIC FILTER P/N AN6234-2. IT WAS FURTHER D ISCOVERED THAT THE PACKING P/N MS28778-6 USED TO PACK THE ELBOW P/N 833-6D AND HYDRAULIC FILTER ASSEMBLY P/N AN6234-2 HA D RUPTURED. PACKING REPLACED. EMERGENCY BLOW DOWN BOTTLE SERVICED AND LANDING GEAR OPERATIONAL CHECK COMPLETED IAW CES SNA SM. AIRPLANE RETURNED TO SERVICE. 1 L 7 2 3O A7CE 1997022000485 19970220 00485 EA 1997 2 20 97ZZZX798 2 19970128 G 8530 SL10301A1 CYLINDER CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA NR 3 CYL EXH VLV FAILED D A UNSCHED LANDING E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS NR NOT REPORTED 1 SO 13 6599B 1432 15283958 L2163215 EXHAUST VALVE IN CYLINDER NR 3 BROKE AT STEM, INGESTING INTO CYLINDER, CREATING A HOLE IN THE PISTON. PIECES OF VALVE A ND PISTON ENTERED ENGINE, CONTAMINATING THE OIL. AN OFF AIRPORT LANDING WAS MADE WITHOUT INCIDENT. AFTER TEAR DOWN, TH E CONNECTING ROD WAS FOUND BENT AND CRACKED. 1 H 7 1 3O 3 O NT 3A19 E223 1997022000486 19970220 00486 SO 1997 2 20 97ZZZX799 1 19970202 G 2710 2094304 CONTROL CABLE PIPER PA24 PA24250 7102404 SO AILERON FRAYED D K NONE O OTHER IN INSP/MAINT 1 EA 05 6862P 241998 AILERON CONTROL CABLES WHERE THEY PASS THROUGH WHEELWELLS APPEARED RUSTY, BUT NO BROKEN STRANDS. WHEN REMOVED TO INSPEC T PER AC 43-13-1A, CHAPTER 4, PARA 198, AND FIGURE 4.14, MANY BROKEN STRANDS APPEARED. 1 L 7 1 3O 1A15 1997022000487 19970220 00487 SO 1997 2 20 97ZZZX800 1 19970202 G 2710 2094302 CONTROL CABLE PIPER PA24 PA24250 7102404 SO AILERON FRAYED D K NONE O OTHER IN INSP/MAINT 1 EA 05 6862P 241998 AILERON CONTROL CABLES WHERE THEY PASS THROUGH WHEELWELLS APPEARED RUSTY, BUT NO BROKEN STRANDS. WHEN REMOVED TO INSPEC T PER AC 43-13-1A, CHAPTER 4, PARA 198, AND FIGURE 4.14, MANY BROKEN STRANDS APPEARED. 1 L 7 1 3O 1A15 1997022000488 19970220 00488 SO 1997 2 20 97ZZZX801 1 19970202 G 2710 1430006 CONTROL CABLE PIPER PA24 PA24250 7102404 SO AILERON FRAYED D A K NONE O OTHER IN INSP/MAINT 1 EA 05 6862P 241998 AILERON CONTROL CABLES WHERE THEY PASS THROUGH WHEELWELLS APPEARED RUSTY, BUT NO BROKEN STRANDS. WHEN REMOVED TO INSPEC T PER AC 43-13-1A, CHAPTER 4, PARA 198, AND FIGURE 4.14, MANY BROKEN STRANDS APPEARED. 1 L 7 1 3O 1A15 1997022000490 19970220 00490 CE 1997 2 20 97ZZZX803 1 19970202 G 5312 07126161 BULKHEAD CESSNA 182 182M 2072728 CE AFT CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 05 71766 2172 59746 AFT BULKHEAD CRACKED BETWEEN RUDDER CABLE CUTOUT AND THE BULKHEAD FLANGE. INSTALLED NEW BULKHEAD ASSY C/W AD 72-07-09 A MDT 39-1988, PARA A,B,C,D,E, 123 F,G,I. 1 H 7 1 3O NT 3A13 1997022000492 19970220 00492 CE 1997 2 20 97ZZZX805 1 19970130 G 3233 ACTUATOR CESSNA 210 T210L 2073449 CE MLG BOLT LOOSE B RC0R K NONE O OTHER IN INSP/MAINT 1 SW 17 93285 298 21060341 DURING ANNUAL INSPECTION, FOUND ONE ATTACHMENT BOLT ON EACH MLG ACTUATOR BACKED OUT. SUBMITTER STATES CESSNA SHOULD ADD RESS BY CHANGING P/N BOLTS HAVING BOLT HEADS DRILLED FOR SAFETY WIRE AS IN CAP INSP NR 32-30-01 WHICH IS NOT APPLICABLE TO THIS S/N AIRCRAFT. 1 H 7 1 3O 3A21 1997022000493 19970220 00493 SW 1997 2 20 97ZZZX806 1 19970128 G 8120 635218S6S1800 HOSE MOONEY M20 M20K 5870220 SW CONT O360 TSIO360MB 17025 CE TURBO OIL BIND H K NONE O OTHER IN INSP/MAINT 1 SW 99 DURING C/W SB M81-21, IT WAS NOTED TURBO OIL LINE WAS SHORT AND IN A BIND. SUBMITTER SUGGESTS ADDING 45 DEGREE FITTING ON HOSES TO RELIEVE PROBLEM. 1 L 7 1 3O 3 O 2A3 E9CE 1997022000495 19970220 00495 EU 1997 2 20 97ZZZX808 1 19970123 G 2916 137300D435 RESERVOIR BAG JETSTM JETSTM3101 1500215 EU HYD SYS CORRODED D A K NONE O OTHER IN INSP/MAINT 1 SW 11 13487 PART REMOVED FOR CLEANING DUE TO BAD S.O.A.P. SAMPLE OF HYDRAULIC SYSTEM. AT REMOVAL, FOUND THE INSIDE OF TANK SEVERELY CORRODED. WHEN CORROSION WAS CLEANED, FOUND NUMEROUS PITS - SOME WENT THROUGH THE TANK. 2 L 7 2 4T RT A21EU 1997022700060 19970227 00060 CE 1997 2 27 97ZZZX813 1 19970205 G 7430 103572001 SWITCH BEECH 36 A36TC 1151603 CE ENGINE IGNITION FAILED D K NONE O OTHER IN INSP/MAINT 1 GL 11 772M 3267 EA14 ON PRE-INSPECTION RUN UP, IT WAS NOTED THAT THE ENGINE WAS NOT PRODUCING ACCEPTABLE POWER. DISCOVERED IGNITION SWITCH W AS STILL IN THE 'START' POSITION. WHEN PHYSICALLY SWITCHING BACK TO THE 'BOTH' POSITION, THE ENGINE RESUMED NORMAL POWE R. TRYING SWITCH SEVERAL MORE TIMES PRODUCED THE SAME RESULTS. (SWITCH STAYING IN THE START POSITION). INTERNAL INSPE CTION REVEALED NO OBVIOUS DEFECTS. PROBLEM RESOLVED BY REPLACEMENT OF SWITCH. 1 L 7 1 3O 3A15 1997022700061 19970227 00061 SO 1997 2 27 97ZZZX814 1 19970205 G 7430 103572001F SWITCH BENDIX PIPER PA28 PA28161 7102803 SO ENG IGN DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 GL 11 9086N 5000 8520 288616057 THIS SWITCH IS NOT INCLUDED IN AD 76-07-12. HAS WHITE DOT ADJACENT TO BENDIX LOGO. MAGS DO GROUND WHEN IN 'OFF' POSITI ON, BUT WHEN SWITCH TURNED COUNTER CLOCKWISE PAST 'OFF', ENGINE RESTARTS. 1 L 7 1 3O 2A13 1997022700063 19970227 00063 GL 1997 2 27 97ZZZX816 3 19970202 G 6111 V8433N4R BLADE GULSTM 680 680 0141602 SW HARTZL HCA3V HCA3VK2 GL BUTT CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 23 849 BJ685 INSPECTION FOUND PROPELLER BLADE BUTT CRACKED. PROBLEM IS COVERED UNDER AD NR 68-19-04. AIRCRAFT HAS IO720 ENGINE STC. 1 H 7 2 3O 2A4 5 C P6EA 1997022700065 19970227 00065 CE 1997 2 27 97ZZZX818 1 19970114 G 3230 9038001011 SWITCH BEECH 23 C24R 1151254 CE MLG SAFETY MALFUNCTION B A RH6R K NONE O OTHER NR NOT REPORTED 1 NE 01 24028 3153 MC486 LANDING GEAR RETRACTED DUE TO SAFETY PRESSURE SWITCH NOT DISENGAGING WHEN AIRSPEED DECREASES. FOUND DEFECTIVE BELLOWS N EEDED SUCTION PRESSURE TO FULLY DISCONNECT GEAR SYSTEM. SUBMITTER RECOMMENDS INSTALLING A SQUAT SWITCH INSTEAD. NO PRE VENTIVE MAINTENANCE POSSIBLE. REMOVE AND REPLACE ONLY. 1 L 7 1 3O A1CE 1997022700066 19970227 00066 CE 1997 2 27 97ZZZX819 2 19970212 G 7322 63255531 LEVER 6293097A1 CESSNA 210 210L 2073448 CE THROTTLE BODY WORN B DDNR K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 27 29069 500 21059794 DURING AN ANNUAL INSPECTION, BRASS METAL FLAKES WERE NOTED ON THE THROTTLE CABLE ROD END. UPON DISASSEMBLY, THE THROTTL E ARM HOLE, WHERE THE CABLE ATTACHES, WAS FOUND SEVERELY WORN. WEAR WAS SO EXCESSIVE THE ARM WAS WORN TO WITHIN .0625 I NCH FROM COMPLETE FAILURE. THE CAUSE OF THIS DEFECT WAS THAT THE REQUIRED BUSHING, P/N 632554-1, WAS NOT INSTALLED. TH IS RESULTED IN THE STEEL BOLT WEARING INTO THE SOFTER BRASS ARM. 1 H 7 1 3O 3A21 1997022700067 19970227 00067 SO 1997 2 27 97ZZZX820 2 19970118 G 8550 632801 PICK UP CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO OIL SUMP PLUGGED D K NONE O OTHER IN INSP/MAINT 1 SO 03 307FM 700 421C0323 608291 PILOT REPORTED THE RT ENGINE OIL PRESSURE WAS HIGH ON THE GROUND NEAR RED LINE, BUT WOULD FALL IN PRESSURE AT ALTITUDE, THE HIGHER THE ALTITUDE, THE LOWER THE OIL PRESSURE WOULD FALL REACHING BOTTOM RED LINE AT 12,000 FEET. THE OIL PRESSUR E SPRING WAS REPLACED AND THE VALVE AND SEAT WERE LAPPED HAVING NO CHANGE IN PROBLEM. THE OIL PAN WAS THEN REMOVED AND ORANGE RTV WAS FOUND IN SUCTION TUBE BLOCKING APPROXIMATELY 90-95 PERCENT OF SCREEN. 1 L 7 2 3O 3 O A7CE E7CE 1997022700068 19970227 00068 SO 1997 2 27 97ZZZX821 1 19970131 G 7603 2489402 CONTROL CABLE PIPER PA31 PA31350 7103110 SO RT ENG THROTTLE BINDING D O OTHER O OTHER NR NOT REPORTED 1 NM 01 3590L 318052146 PILOT REPORTED RT ENGINE THROTTLE STICKING AT 30 INCHES MP. UNABLE TO RETARD THROTTLE TO IDLE. UPON MAINTENANCE INSPEC TION, CABLE SLEEVE AT ENGINE HAD COME DISLODGED FROM PRIMARY HOUSING AND WAS KINKING CABLE WHICH PREVENTED RETARDING OF THROTTLE. SLEEVE WAS RE-SWEGED INTO HOUSING AND OPS CHECKED GOOD. CABLE WAS REPLACED DURING ROUTINE MAINTENANCE THIS D ATE FOLLOWING RETURN TO MAINTENANCE BASE. 1 L 7 2 3O A20SO 1997022700071 19970227 00071 EA 1997 2 27 97ZZZX824 2 19970121 G 8530 SL17235AD VALVE CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA CYLINDER EXHAUST WORN B RH6R K NONE O OTHER IN INSP/MAINT 1 NE 01 4635L 600 15287201 INVESTIGATION FOR A PROGRESSIVE DETERIORATION OF ENGINE FOUND EXCESSIVE WEAR ON VALVE STEMS, VALVE SEATS DEFECTIVE, RING AND PISTON WEAR EXCESSIVE. SUBMITTER STATES ENGINE WOULD NOT MAKE 2,400 TBO. ENGINE OIL CHANGED AT 50-HOUR INTERVALS. PHILLIPS 20W50XC OIL USED. 1 H 7 1 3O 3 O NT 3A19 E223 1997022700072 19970227 00072 SO 1997 2 27 97ZZZX825 1 19970206 G 5712 784758 RIB PIPER PA28 PA28R180 7102809 SO LT WELL CRACKED D K NONE O OTHER IN INSP/MAINT 1 NE 01 4990J 5137 28R30746 REMOVED THE LT AND RT MLG SIDE BRACE STUDS TO C/W AD 95-20-07. PRIOR TO INSTALLING THE SIDE-STAY ASSY SUPPORT BRACKET, THE MECHANIC CLEANED THE MATING SURFACE AT THE SPAR AND RIB, AND NOTICED A CRACK IN THE RIBS, P/N 78475-4 AND P/N 78475- 5 IN THE BEND RADIUS OF THE FORWARD VERTICAL FLANGE. THE CRACKS WERE ABOUT .50 INCH TO .75 INCH LONG. 1 L 7 1 3O 2A13 1997022700073 19970227 00073 SO 1997 2 27 97ZZZX826 1 19970206 G 5712 784754 RIB PIPER PA28 PA28R180 7102809 SO RT WELL CRACKED D A K NONE O OTHER IN INSP/MAINT 1 NE 01 4990J 5137 28R30746 REMOVED THE LT AND RT MLG SIDE BRACE STUDS TO C/W AD 95-20-07. PRIOR TO INSTALLING THE SIDE-STAY ASSY SUPPORT BRACKET, THE MECHANIC CLEANED THE MATING SURFACE AT THE SPAR AND RIB, AND NOTICED A CRACK IN THE RIBS, P/N 78475-4 AND P/N 78475- 5 IN THE BEND RADIUS OF THE FORWARD VERTICAL FLANGE. THE CRACKS WERE ABOUT .50 INCH TO .75 INCH LONG. 1 L 7 1 3O 2A13 1997022700074 19970227 00074 SO 1997 2 27 97ZZZX827 1 19970211 G 2750 SWITCH PIPER PA31 PA31310 7103103 SO FLAP UPLIMIT STICKING B VDNR K NONE F FLT CONT AFFECTED NR NOT REPORTED 1 SW 09 50779 2333 31740993 PILOT REPORT THAT FLAPS WOULD NOT EXTEND. FOUND FLAPS UPLIMIT SWITCH STICKING. CLEANED AND LUBED SWITCH, OPS CHECK SAT ISFACTORY. 1 L 7 1 3O RT A20SO 1997022700078 19970227 00078 SO 1997 2 27 97ZZZX829 1 19970210 G 2710 67550000 BRACKET PIPER PA28 PA28R200 7102811 SO AIL BELLCRANK CRACKED D S A K NONE O OTHER IN INSP/MAINT 1 CE 07 55275 3441 287335209 THE LOWER RT AILERON BELLCRANK BRACKET WAS CRACKED JUST ABOVE FORWARD AND REAR ATTACH BOLTS. SUSPECT CAUSE TAIL INTO WI ND AND NO CONTROL LOCK. 1 L 7 1 3O 2A13 1997022700079 19970227 00079 CE 1997 2 27 97ZZZX830 1 19970213 G 2913 993880029 POWER PACK BEECH 99 C99 1154006 CE LT MLG MALFUNCTION G A K NONE O OTHER IN INSP/MAINT 1 AL 01 575W 286 U204 NITROGEN PRE-CHARGE LEAKED PAST ACCUMULATOR PISTON CAUSING PRESSURE BUILD-UP IN RETRACT SIDE OF LANDING GEAR SYSTEM AND COLLAPSE OF LEFT MAIN GEAR WHILE AIRCRAFT WAS BEING TOWED. SUBMITTER STATED LATER DASH NUMBER HYDRAULIC POWER PACK INCO RPORATES A VENT VALVE TO PRECLUDE THIS PRESSURE BUILD-UP IN THE EVENT OF ACCUMULATOR LEAKAGE. SUBMITTER RECOMMENDS THIS POWER PACK BE RETRO FITTED TO EARLIER AIRCRAFT. MAIN LANDING GEAR WERE FITTED WITH SAFETY PINS FOR GROUND HANDLING OPE RATIONS. 1 L 7 2 3T A14CE 1997022700080 19970227 00080 SO 1997 2 27 97ZZZX831 2 19970205 G 7322 46A70 VENTURI CESSNA 150 150J 2071820 CE CONT O200 O200A 17020 SO CARBURETOR WORN D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SO 03 60228 3040 15070157 230864R OWNER REPORTED ENGINE BEING ROUGH AT LOW RPM AND POOR ACCELERATION AND HESITATION WHILE ADDING POWER, AND NOT RUNNING BE LOW 1,000 RPM. INSPECTION REVEALED A TWO-PIECE VENTURI STILL INSTALLED AND WORN TO A POINT OF NEAR SEPARATION. AD 93-1 8-03 FOR INSTALLING A ONE-PIECE WAS NOT INSTALLED ALTHOUGH A V-STAMP HAD BEEN APPLIED TO THE DATA PLATE INDICATING COMPL IANCE. NO LOG BOOK ENTRY OF THAT SPECIFIC AD HAD BEEN MADE, JUST AN ENTRY OF 'AD'S CHECKED OR C/W', AT 12-26-93. AD EF FECTIVE DATE = 10-29-93. 1 H 7 1 3O 3 O 3A19 E252 1997022700081 19970227 00081 SW 1997 2 27 97ZZZX832 1 19970101 G 5310 32741 TUBE MOONEY M20 M20C 5870208 SW FUSELAGE CRACKED D S K NONE O OTHER IN INSP/MAINT 1 NM 13 6230U 2857 2069 FUSELAGE STEEL TUBE CRACKED .50 INCH FROM AFT WELD LOCATION. CRACK SEPARATION WAS APPROXIMATELY .25 INCH WIDE THROUGH T HE TUBE. CRACK WAS DETECTED DURING AN ANNUAL INSPECTION. TUBE ALSO HAD A NOTICEABLE DOWNWARD BEND MID-POINT OF THE TUB E. THE BEND IS APPROXIMATELY .50 INCH DEEP, 6 INCHES IN LENGTH. 1 L 7 1 3O 2A3 1997022700082 19970227 00082 CE 1997 2 27 97ZZZX833 1 19970130 G 5312 04121751 BULKHEAD 04120022 CESSNA 150 150A 2071804 CE TAIL CONE CRACKED D A K NONE O OTHER IN INSP/MAINT 1 NM 11 7207X 7109 15059307 ON THE MOST AFT BULKHEAD OF FS 200.375, THERE WERE CRACKS IN BOTH CORNERS BETWEEN THE FLANGES AND THE WEBS AT THE RUDDER STOP BOLTS. WHILE THE AIRCRAFT WAS TIED DOWN, THE RUDDER WAS LEFT UNSECURED AND FREE TO BE BLOWN BACK AND FORTH BY THE WIND. THE SUSPECT CAUSE WAS THAT THE RUDDER WAS NOT SECURED IN ANY WAY ALLOWING IT TO BE BLOWN BACK AND FORTH BY THE W IND BEATING IT AGAINST THE RUDDER STOP BOLTS. THIS BENT THE BULKHEAD FLANGES UNTIL IT CRACKED IN THE CORNERS. 1 H 7 1 3O 3A19 1997022700084 19970227 00084 CE 1997 2 27 97ZZZX835 1 19970104 G 2510 04111031 SEAT FRAME CESSNA 150 150F 2071814 CE LT/RT CREW SEAT CRACKED D S A K NONE O OTHER IN INSP/MAINT 1 SO 01 8346G 4056 15062446 FOUND BOTH PILOT AND COPILOT SEAT BACK FRAMES CRACKED DURING AN ANNUAL INSPECTION. IF LEFT UNDETECTED, POSSIBLE SEAT BA CK FAILURE. THIS SHOULD BE INSPECTED CLOSELY DURING EACH INSPECTION. INSPECTION MAY REQUIRE PARTIAL REMOVAL OF UPHOLST ERY IN THIS AREA. THIS PROBLEM HAS BEEN FOUND ON SEVERAL OTHER A/C AS WELL. 1 H 7 1 3O 3A19 1997022700085 19970227 00085 CE 1997 2 27 97ZZZX836 1 19970210 G 7931 0500106292 LINE CESSNA 182 182K 2072724 CE OIL GAUGE LEAK D K NONE K FLUID LOSS IN INSP/MAINT 1 WP 15 899F 4479 18258163 OIL PRESSURE LINE BEHIND INSPECTION PANEL LEAKING ON TOP BETWEEN GAUGE AND FIREWALL. PILOT REPORTED OIL ON FLOOR BY PED AL. NOT ABLE TO SEE AREA FROM BELOW. 1 H 7 1 3O NT 3A13 1997022700086 19970227 00086 CE 1997 2 27 97ZZZX837 1 19970212 G 5740 NAS15033M BOLT BEECH 35 M35 1151526 CE WING ATTACH CORRODED D A K NONE O OTHER IN INSP/MAINT 1 NM 09 9580R D6178 AIRCRAFT INSPECTION FOUND 1 WING BOLT CORRODED AND OTHERS WITH SOME PITTING. ACFT HAD NEVER HAD BOLTS INSPECTED. BEECH MM GIVES BOLTS AND HARDWARE REPLACEMENT AT 15 YRS AND ANTI-CORROSION TREATMENT. MM ALSO STATES BOLTS TO BE MAGNAFLUXED AND CORROSION TREATED EVERY 5 YEARS. NONE OF REQUIREMENTS HAD BEEN DONE. 1 L 7 1 3O 3A15 1997022700182 19970227 00182 WP 1997 2 27 97ZZZX840 1 19970206 G 2752 3774158501 BARREL DOUG DC8 DC8* WP FLAP ACTUATOR BROKEN B DM4R K NONE O OTHER IN INSP/MAINT 1 SO 19 FLAP ACTUATOR CYLINDER BARREL RECEIVED BROKEN AT CRANK MOUNT BORE. SUSPECT CAUSE IS METAL FATIGUE DUE TO CORROSION. 2 L 7 4 4J F 4A25 1997022700183 19970227 00183 NE 1997 2 27 97ZZZX841 2 19970207 G 7322 7766841 PILOT VALVE HAMSTD JFC3123 BAG BAE146 BAE146200A 1500266 EU LYC ALF502 ALF502R3 41580 NE SLEEVE FRACTURED D K NONE O OTHER IN INSP/MAINT 1 WP 05 749A REF: FR25681. CRACKED SHIELD BRACKET. RETENTION LIPS OF PILOT VALVE SLEEVE FRACTURED (BOTH LIPS). PART RETURNED TO H AMILTON STANDARD FOR EVALUATION. 2 H 7 4 4F 4 F RT A49EU E6NE 1997022700184 19970227 00184 SW 1997 2 27 97ZZZX842 1 19970131 G 3250 MS245474 SWITCH SWRNGN SA226 SA226T 8780122 SW STEERING ARMING OUT OF ADJUST B L A KD4R O OTHER O OTHER TO TAKEOFF 1 SO 17 188SC 4093 T276 PILOT REPORTED LOSS OF NOSE WHEEL STEERING ON TAKEOFF ROLL. DIRECTIONAL CONTROL WAS LOST AND AIRCRAFT RAN OFF OF THE RU NWAY ONTO THE GRASS. AIRCRAFT WAS NOT DAMAGED AND NO INJURIES RESULTED. AIRCRAFT WAS FERRIED TO MAINTENANCE BASE AND A COMPLETE FUNCTIONAL CHECK OF THE NOSE WHEEL STEERING SYSTEM WAS PERFORMED. THE ONLY DEFECT NOTED WAS THAT THE SPEED LE VER NOSE STEERING ARMING SWITCH P/N MS24547-4 WAS OUT OF ADJUSTMENT CAUSING THE NOSE WHEEL STEERING TO NOT ACTIVATE WHEN THE SPEED LEVERS WERE RETARDED. 2 L 7 2 4T RT A5SW 1997022700187 19970227 00187 EA 1997 2 27 97ZZZX845 1 19970114 G 5700 C6W10057 STRUT DHAV DHC6 DHC6300 EA LT WING CORRODED B E6AY K NONE O OTHER IN INSP/MAINT 1 EA 31 61UT 549 WING SUPPORT STRUTS (P/N C6W1005-7 LEFT, C6W1005-8 RIGHT). FOUND EXFOLIATON CORROSION ON BEAM FLANGES 12 TO 18 INCHES F ROM LOWER ATTACH POINTS WHILE PERFORMING INTERNAL STRUT BEAM INSPECTION IAW FAA AD 87-04-23. SUBMITTER SUGGESTS CORROSI ON CAUSED BY ELECTROLYTIC ACTION OF DISSIMILAR METAL CONTACT WITH SKIN ATTACHMENT STEEL SCREWS AND PRESENCE OF MOISTURE IN STRUTS. AIRCRAFT TOTAL TIME: 28,791.3 HOURS. 1 H 7 2 3T A9EA 1997022700188 19970227 00188 EA 1997 2 27 97ZZZX846 1 19970114 G 5700 C6W10058 STRUT DHAV DHC6 DHC6300 EA RT WING CORRODED B E6AY K NONE O OTHER IN INSP/MAINT 1 EA 31 61UT 549 WING SUPPORT STRUTS (P/N C6W1005-7 LEFT, C6W1005-8 RIGHT). FOUND EXFOLIATON CORROSION ON BEAM FLANGES 12 TO 18 INCHES F ROM LOWER ATTACH POINTS WHILE PERFORMING INTERNAL STRUT BEAM INSPECTION IAW FAA AD 87-04-23. SUBMITTER SUGGESTS CORROSI ON CAUSED BY ELECTROLYTIC ACTION OF DISSIMILAR METAL CONTACT WITH SKIN ATTACHMENT STEEL SCREWS AND PRESENCE OF MOISTURE IN STRUTS. AIRCRAFT TOTAL TIME: 28,791.3 HOURS. 1 H 7 2 3T A9EA 1997022700189 19970227 00189 CE 1997 2 27 97ZZZX847 1 19970203 G 3210 1058100197 A FRAME BEECH 76 76 1153005 CE LT MLG CRACKED B UC2R K NONE O OTHER IN INSP/MAINT 1 GL 19 6632J 4476 ME337 WHEN INSTALLING LANDING GEAR 'A' FRAMES PER AD 91-14-14 AND SB 2361 REV 3, THE RIGHT AND LEFT 'A' FRAMES WERE REMOVED FR OM THE AIRCRAFT FOR FURTHER INSPECTION. A MAGNAFLUX INSPECTION OF THESE PARTS WAS PERFORMED AND THE 'A' FRAMES WERE FOU ND CRACKED. THE MAGNAFLUX INSPECTION IS NOT CALLED OUT FOR IN SB 2361, REV 3, BUT THE CRACKS THAT WERE FOUND DID NOT SH OW UP WITH THE DYE PENETRANT INSPECTION AS REQUIRED BY SB 2361, REV 3. RECOMMEND REPLACING THE OLD STYLE 'A' FRAMES WIT H THE NEW STYLE 'A' FRAMES AS LISTED IN SB 2361, REV 3. 1 L 7 2 3O A29CE 1997022700190 19970227 00190 CE 1997 2 27 97ZZZX848 1 19970203 G 3210 1058100198 A FRAME BEECH 76 76 1153005 CE RT MLG CRACKED B UC2R K NONE O OTHER IN INSP/MAINT 1 GL 19 6632J 4476 ME337 WHEN INSTALLING LANDING GEAR 'A' FRAMES PER AD 91-14-14 AND SB 2361 REV 3, THE RIGHT AND LEFT 'A' FRAMES WERE REMOVED FR OM THE AIRCRAFT FOR FURTHER INSPECTION. A MAGNAFLUX INSPECTION OF THESE PARTS WAS PERFORMED AND THE 'A' FRAMES WERE FOU ND CRACKED. THE MAGNAFLUX INSPECTION IS NOT CALLED OUT FOR IN SB 2361, REV 3, BUT THE CRACKS THAT WERE FOUND DID NOT SH OW UP WITH THE DYE PENETRANT INSPECTION AS REQUIRED BY SB 2361, REV 3. RECOMMEND REPLACING THE OLD STYLE 'A' FRAMES WIT H THE NEW STYLE 'A' FRAMES AS LISTED IN SB 2361, REV 3. 1 L 7 2 3O A29CE 1997022700191 19970227 00191 CE 1997 2 27 97ZZZX849 1 19970207 G 2730 1155240463 TORQUE TUBE BEECH 100 B100 1152919 CE ELEVATOR WORN B A BCBR K NONE O OTHER IN INSP/MAINT 1 EA 03 717D BE91 'PLAY' WAS NOTED BETWEEN THE ELEVATORS. INSPECTION FOUND ELEVATOR PINS TO TORUQE TUBE WORN. REAMING, PER SM, DID NOT R EMOVE ALL THE PLAY. REPLACED TORQUE T UBE ASSY WITH NEW PINS. THERE WAS NO ABNORMAL FLIGHT CONDITIONS BEFORE OR AFTER. TORQUE TUBE INSPECTION IS REQUIRED EACH 1,000 HOURS, 126.6 HOURS SINCE LAST PRIMARY INSPECTION. 1 L 7 2 4T A14CE 1997022700192 19970227 00192 CE 1997 2 27 97ZZZX850 1 19970129 G 2931 P50018LMBE GAUGE BEECH 200 B200 1152922 CE ACCUM PRESS STUCK B LX5R K NONE O OTHER IN INSP/MAINT 1 GL 19 961LL 290 BB1139 THIS GAUGE IS PART OF STC SA 4378-WP AVIA DESIGN, INC., HYDRAULIC LANDING GEAR RETRACTION SYSTEM. GAUGE FOUND STUCK AT 1,150 PSI DURING AIRCRAFT INSPECTION. SUBMITTER RECOMMENDS A BETTER QUALITY GAUGE BE USED IN SYSTEM. 1 L 7 2 4T A24CE 1997022700193 19970227 00193 NE 1997 2 27 97ZZZX851 3 19970208 G 6111 A2202 BEARING BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE INBOARD BLADE SPLIT B P GLBR K NONE O OTHER IN INSP/MAINT 1 CE 01 94UX 6635 2882 34 UE94 PROPELLER WAS DISASSEMBLED DUE TO 'LOOSE' BLADES (IN EXCESS OF .75 INCH FORE/AFT). ON INSPECTION, FOUND BLADE S/N 982 I NNER BEARING RACE (1 SIDE OF SPLIT BEARING) SPLIT (CRACKED) 1 INCH THROUGH CENTER OF BALL RUN AREA, BALLS WERE PITTED. 2 L 7 2 4T RT A24CE 5 C P10NE 1997022700194 19970227 00194 NE 1997 2 27 97ZZZX852 3 19970208 G 6111 A2202 BEARING BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE INBOARD BLADE BROKEN B P A GLBR K NONE O OTHER IN INSP/MAINT 1 CE 01 94UX 6635 2882 9 UE94 HJ211 PROPELLER WAS DISASSEMBLED DUE TO LOOSE BLADES (IN EXCESS OF .75 INCH FORE/AFT). ON INSPECTION, FOUND BLADE S/N 930 INN ER BEARING RACE DAMAGED. ONE SIDE OF SPLIT RACE CRACKED INTO DOWN CENTER OF BALL RIDE AREA AND OTHER HALF OF SPLIT RACE CRACKED UP ABOUT ONE-FOURTH OF RADIUS AND BROKEN, ALONG WITH FLATTENED UPPER SURFACE. 2 L 7 2 4T RT A24CE 5 C P10NE 1997022700195 19970227 00195 NE 1997 2 27 97ZZZX853 2 19970211 G 7250 668736 BEVEL GEARSHAFT PWA JFTD12 JFTD12A5A 52047 NE NR 2 SENSE CABLE CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 97 FOUND CRACK INDICATIONS DURING FMPI INSIDE SQUARE DRIVE OF GEARSHAFT. INDICATORS APPEAR SHARP. A WELL DEFINED CRACK-T YPE INDICATION IS SEEN INSIDE CORNERS OF SHAFT. OUTSIDE DIAMETER SHOWS BROAD FUZZY INDICATIONS THAT CORRESPOND DIRECTLY TO INSIDE INDICATIONS. SHAFT S/N 97 SHOWS 3 INDICATIONS. 4 U E15EA 1997022700196 19970227 00196 NE 1997 2 27 97ZZZX854 2 19970211 G 7250 668736 BEVEL GEARSHAFT PWA JFTD12 JFTD12A5A 52047 NE NR 2 SENSE CABLE CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 84 FOUND CRACK INDICATIONS DURING FMPI INSIDE SQUARE DRIVE OF GEARSHAFT. INDICATORS APPEAR SHARP. A WELL DEFINED CRACK-T YPE INDICATION IS SEEN INSIDE CORNERS OF SHAFT. OUTSIDE DIAMETER SHOWS BROAD FUZZY INDICATIONS THAT CORRESPOND DIRECTLY TO INSIDE INDICATIONS. SHAFT S/N 84 SHOWS 3 INDICATIONS. 4 U E15EA 1997022700197 19970227 00197 NE 1997 2 27 97ZZZX855 2 19970211 G 7250 668736 BEVEL GEARSHAFT PWA JFTD12 JFTD12A5A 52047 NE NR 2 SENSE CABLE CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 197 FOUND CRACK INDICATIONS DURING FMPI INSIDE SQUARE DRIVE OF GEARSHAFT. INDICATORS APPEAR SHARP. A WELL DEFINED CRACK-T YPE INDICATION IS SEEN INSIDE CORNERS OF SHAFT. OUTSIDE DIAMETER SHOWS BROAD FUZZY INDICATIONS THAT CORRESPOND DIRECTLY TO INSIDE INDICATIONS. SHAFT S/N 197 SHOWS 1 INDICATION. 4 U E15EA 1997022700198 19970227 00198 NE 1997 2 27 97ZZZX856 2 19970211 G 7250 668736 BEVEL GEARSHAFT PWA JFTD12 JFTD12A5A 52047 NE NR 2 SENSE CABLE CRACKED B S JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 FOUND CRACK INDICATIONS DURING FMPI INSIDE SQUARE DRIVE OF GEARSHAFT. INDICATORS APPEAR SHARP. A WELL DEFINED CRACK-T YPE INDICATION IS SEEN INSIDE CORNERS OF SHAFT. OUTSIDE DIAMETER SHOWS BROAD FUZZY INDICATIONS THAT CORRESPOND DIRECTLY TO INSIDE INDICATIONS. ONE ADDITIONAL SHAFT HAD 4 INDICATIONS (UNKNOWN S/N). 4 U E15EA 1997022700239 19970227 00239 NE 1997 2 27 97ZZZX860 1 19970209 G 6320 643520536101 MAIN SHAFT 643520500048 SKRSKY S64 S64F NE M/R GEARBOX CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 158AC 2969 2199 A6148 64081 DURING OVERHAUL OF THE MGB, THE MAIN SHAFT WAS SUBJECTED TO A FMPI. ONE SPLINE WAS FOUND CRACKED ACROSS THE SPLINE WIDT H ON THE UPPER END OF THE LOWER SPLINE. THE CRACK DID NOT APPEAR TO ORIGINATE WHERE THE LOWER PLANETARY SPLINE CONTACTS THE SHAFT, BUT WAS LOCATED APPROXIMATELY .100 INCH ABOVE THE PLANETARY PLATE SPLINE CONTACT ZONE. THE CRACK EXTENDED FR OM THE ROOT OF ONE SPLINE TOOTH TO THE ROOT OF THE ADJACENT SPLINE. IN ADDITION TO THE ONE CRACK, THERE WERE APPROXIMAT ELY 30 ADDITIONAL SPLINES THAT HAD UNUSUAL CRACK-LIKE INDICATIONS IN THE ROOT RADIUS OF THE SPLINES. THE PRESENCE OF TH ESE INDICATIONS COULD NOT BE VERIFIED TO BE THE START OF CRACK. 2 G 7 2 4U H6EA 1997030600001 19970306 00001 CE 1997 3 6 97ZZZX865 1 19970225 G 5520 ELEVATOR CESSNA 180 180 2072602 CE FLIGHT CONTROL MISMOUNTED D L A K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 07 SUBMITTER REPORTS AN INCIDENT OCCURRED IN 1992 AT A CESSNA 180/185 FLY-IN WHEN AN AIRCRAFT WAS NOTED TO HAVE THE ELEVATO RS MOUNTED UPSIDE DOWN. AGAIN, IN FEBRUARY, 1997, A SECOND OCCURRENCE OF ELEVATOR UPSIDE DOWN. BOTH AIRCRAFT HAD JUST COME FROM A PAINT SHOP. IN BOTH CASES, UP-TRAVEL RESTRICTED. 1 H 7 1 3O NC 5A6 1997030600002 19970306 00002 SO 1997 3 6 97ZZZX866 1 19970207 G 3233 401195 BOLT PIPER PA31T PA31T2 7103127 SO LT MLG ACTUATOR BROKEN B A BCBR O OTHER J WARNING INDICATION AP APPROACH 1 EA 03 107MC 4520 31T8166032 LEFT LANDING GEAR WOULD NOT GO DOWN. AFTER REPEATED ATTEMPTS, CO2 EMERGENCY DOWN WAS ACTUATED AND GEAR DID GO DOWN AND LOCK. LANDING WAS NORMAL. INSPECTION REVEALED THE BOLT SECURING THE LANDING GEAR ACTUATOR CYLINDER HAD BROKEN. REF: P A31T2 PARTS FIG 41, ITEM 81. INSPECTION OF THE RT GEAR ACTUATOR ATTACH BOLT FOUND NOTHING ABNORMAL. BOLT APPEARED TO B E IN GOOD CONDITION. ATTACH BOLTS WERE REPLACED. GEAR SERVICED. RETRACTION CHECKS OK. NEW CO2 CARTRIDGE WAS INSTALLE D. 1 L 7 2 3T RT A8EA 1997030600003 19970306 00003 CE 1997 3 6 97ZZZX867 1 19970201 G 5312 07125231 BULKHEAD CESSNA 182 182G 2072716 CE FS 230.187 CRACKED D P K NONE O OTHER IN INSP/MAINT 1 EA 07 28EM 18255209 BULKHEAD WAS FOUND CRACKED AT LEFT RUDDER STOP BOLT AREA. THIS INSPECTION IS REQUIRED BY AD 72-07-09. THE CRACK WAS NO T IN THE AREA CALLED OUT IN THE AD. THE BULKHEAD IS CALLED OUT FOR REPLACEMENT IF FOUND CRACKED. 1 H 7 1 3O NT 3A13 1997030600004 19970306 00004 CE 1997 3 6 97ZZZX868 1 19970211 G 3221 05130481 ANGLE CESSNA 172 172A 2072404 CE NLG LT FITTING CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 03 7229T 46829 FOUND BOTH ANGLES CRACKED AFT OF FIREWALL. UPPER NOSE GEAR FITTING ATTACHES TO ANGLES. RIVETS LOOSE IN FITTING. 1 H 7 1 3O 3A12 1997030600005 19970306 00005 CE 1997 3 6 97ZZZX869 1 19970211 G 3221 05130482 ANGLE CESSNA 172 172A 2072404 CE NLG RT FITTING CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 03 7229T 46829 FOUND BOTH ANGLES CRACKED AFT OF FIREWALL. UPPER NOSE GEAR FITTING ATTACHES TO ANGLES. RIVETS LOOSE IN FITTING. 1 H 7 1 3O 3A12 1997030600006 19970306 00006 SO 1997 3 6 97ZZZX870 1 19970210 G 2740 402346 BOLT PIPER PA30 PA30 7103002 SO STABILATOR HORN CORRODED D A K NONE O OTHER IN INSP/MAINT 1 SO 15 7203Y 2842 30228 WHILE DISASSEMBLING THE STABILATOR TORQUE TUBE, FOUND BOTH (2 EACH) CLOSE TOLERANCE BOLTS VERY CORRODED. SUBMITTER BELI EVES THESE BOLTS SHOULD BE REPLACED BY AGE OF 30 YEARS. 1 L 7 2 3O A1EA 1997030600007 19970306 00007 CE 1997 3 6 97ZZZX871 1 19970211 G 3211 0541153 U-BOLT CESSNA 172 172A 2072404 CE RT MLG BROKEN D S A K NONE O OTHER IN INSP/MAINT 1 CE 03 7229T 46829 INSPECTION FOUND RT MAIN GEAR U-BOLT BROKEN. PART OF U-BOLT STILL IN NUT. NUT FOUND IN AIRCRAFT. 1 H 7 1 3O 3A12 1997030600008 19970306 00008 SO 1997 3 6 97ZZZX872 1 19970210 G 2740 402346 BOLT PIPER PA30 PA30 7103002 SO STABILATOR HORN CORRODED D K NONE O OTHER IN INSP/MAINT 1 SO 15 808BB 3759 30288 WHILE DISASSEMBLING THE STABILATOR TORQUE TUBE, SUBMITTER FOUND BOTH (2 EACH) CLOSE TOLERANCE BOLTS VERY CORRODED. SUBM ITTER BELIEVES THESE SHOULD BE REPLACED BY AGE OF 30 YEARS. DISASSEMBLED ANOTHER STABILATOR HORN AND FOUND THE SAME CON DITION. 1 L 7 2 3O A1EA 1997030600009 19970306 00009 EA 1997 3 6 97ZZZX873 2 19970131 G 7414 BEARING BENDIX 1068291018 PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA MAG FAILED D E ENGINE SHUTDOWN E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 SO 16 31RD 1400 G199105GR 317852059 L185768A CRUISE FLIGHT 7,000 FEET. ENGINE BEGAN RUNNING ROUGH, PRECAUTIONARY SHUT DOWN. FOUND MAGNETO BEARING FAILED. 1 L 7 2 3O 3 O A20SO E14EA 1997030600010 19970306 00010 CE 1997 3 6 97ZZZX874 1 19970212 G 5711 SPAR BEECH 33 F33A 1151425 CE CARRY THROUGH CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 07 8242T 5940 CE1610 INSPECTION FOUND CRCKS IN CARRY-THROUGH STRUCTURE. AD 95-04-03 NOT VALID BY SERIAL NUMBER. SUBMITTER STATED THIS IS TH E 17TH AIRCRAFT REPORTED. 1 L 7 1 3O 3A15 1997030600011 19970306 00011 NM 1997 3 6 97ZZZX875 1 19970115 G 2720 69356071 CAM SEGMENT BOEING 737 737201 1384454 NM PCU WORN B S A IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 THE SHAFT JUST ABOVE THE BALL IS RUBBING/WEARING ON THE YAW DAMPER SLEEVE. WHEN THE UNIT WAS EXTENDED AND THE YAW DAMPE R WAS ENERGIZED IN THE EXTEND POSITION, THE UNIT BOUND AND WOULD NOT RETRACT PER PARA 12, G, 889. THE AREA OF WEAR HAS A RIDGE THAT WILL CATCH ON THE SIDE OF YAW DAMPER SLEEVE CAUSING A BINDING CONDITION. 2 L 7 2 4F A16WE 1997030600012 19970306 00012 NM 1997 3 6 97ZZZX876 1 19970114 G 2720 596005003 SOLENOID BOEING 737 7373G7 1384595 NM RUDDER PCU SHORTED OUT B IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 2531 FLUID PASSING THROUGH ELECTRICAL CONNECTOR SHORTED OUT WIRING. 2 L 7 2 4F RT A16WE 1997030600013 19970306 00013 1997 3 6 97ZZZX877 4 19970115 G 2210 69356111 ACTUATOR SLEEVE BOEING 737 737201 1384454 NM YAW DAMPER WORN B S IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 THE ELONGATED HOLE WHERE THE CAM SEGMENT IS INSERTED INTO THE YAW DAMPER PISTON IS BEING RUBBED AND WORN BY THE CAM SEGM ENT. 2 L 7 2 4F A16WE 1997030600014 19970306 00014 EA 1997 3 6 97ZZZX878 1 19970128 G 5553 C2FS4045A CHANNEL DHAV DHC2 DHC2MK1 2800102 EA FIN ATTACH CRACKED B A V2AR K NONE O OTHER IN INSP/MAINT 1 AL 03 692F 1407 ON VERTICAL FIN ATTACH REINFORCEMENT CHANNEL, THE BOLT HOLES THAT ARE USED TO SECURE RUDDER HINGE CASTING C2FS3705ND WER E FOUND TO HAVE CRACKS RADIATING FROM THEM. LACK OF A CONTROL SURFACE LOCK AND HIGH WINDS OVER WINTER MAY HAVE CONTRIBU TED TO CRACKING. 1 H 7 1 3R A806 1997030600015 19970306 00015 EA 1997 3 6 97ZZZX879 1 19970127 G 2823 C2CE527A DRUM TC17300 DHAV DHC2 DHC2MK1 2800102 EA FUEL SELECTOR CORRODED B V2AR K NONE O OTHER IN INSP/MAINT 1 AL 03 692F 1407 FUEL SELECTOR AFT CABLE DRUM WAS FOUND CORRODED DUE TO INTERGRANULAR CORROSION. CABLE WAS NO LONGER FIRMLY SECURED IN G ROOVES. 1 H 7 1 3R A806 1997030600016 19970306 00016 EA 1997 3 6 97ZZZX880 1 19970128 G 2752 ACTUATOR DHAV DHC2 DHC2MK1 2800102 EA INLET LINE LEAK B V2AR K NONE K FLUID LOSS IN INSP/MAINT 1 AL 03 692F 1407 ON INSPECTION, A HYDRAULIC LEAK WAS FOUND AT FLAP ACTUATOR LINE INLET. ON DISASSEMBLY, DEBRIS WAS NOTICED IN LINE. A F URTHER INSPECTION FOUND ALL COMPONENTS OF FLAP SYSTEM HAD THICK DEBRIS THAT MAY BE MIL5606 CONTAMINATED WITH MOISTURE. 1 H 7 1 3R A806 1997030600019 19970306 00019 SO 1997 3 6 97ZZZX882 1 19970206 G 6120 8930200 ROD END PIPER PA32 PA32R301 7103218 SO LYC O540 IO540K1G5 41532 EA PROP CONTROL RUBBING B S A LF1R K NONE O OTHER IN INSP/MAINT 1 EA 07 9251E 653 3213084 L2527148A PROPELLER CONTROL NOT MAKING FULL TRAVEL. THREADED PORTION OF ROD END ASSY RUBBING A TRACK INTO LT FWD BAFFLE ASSY., P/ N 85565-02. HAVE NOTED THIS ON NEARLY ALL NEW PA32R301 SARATOGA IIHP AIRCRAFT. SUBMITTER STATES NEED TO MANUFACTURE A SUPPORT TO KEEP BAFFLE AWAY FROM RPOPELLER CONTROL OR REDESIGN ROD END. 1 L 7 1 3O 3 O A3SO 1E4 1997030600288 19970306 00288 SO 1997 3 6 97ZZZX884 1 19970204 G 2750 CONTROL CABLE PIPER PA28 PA28161 7102803 SO FLAP CONTROL FRAYED B OG5R K NONE O OTHER IN INSP/MAINT 1 GL 21 120ND 6546 2841218 DURING PHASE ONE INSPECTION, MECHANIC NOTICED DURING RUN-UP PRIOR TO INSPECTION THAT FLAP CONTROL FELT LIKE IT WAS BINDI NG. OPENED A/C FOR INSPECTION AND FOUND CABLE FRAYED AND UNRAVELING WHERE CABLE GOES INTO SWAGED TURNBUCKLE AT FLAP HAN DLE ATTACH POINT. INSTALLED NEW CABLE AND RIGGED. 1 L 7 1 3O 2A13 1997030600289 19970306 00289 EA 1997 3 6 97ZZZX885 2 19970202 G 8520 75190 CAMSHAFT PIPER PA24 PA24260 7102406 SO LYC O540 IO540D4A5 41532 EA GOV DRV GEAR BROKEN D A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 GL 25 1424N 550 244383 L291348 ENGINE OVERSPED IN CRUISE FLIGHT AT 6,500 FEET. MAXIMUM OVERSPEED WITNESSED WAS 3,500 RPM. AIRCRAFT LANDED AT FIRST SU ITABLE AIRFIELD. ON INSPECTION, CAMSHAFT WAS FOUND BROKEN IN TWO BETWEEN FORWARD BEARING AND GOVERNOR DRIVE GEAR CAUSIN G PROPELLER TO DECREASE PITCH CAUSING OVERSPEED. IT APPEARED THE BREAK IN THE CAM ORIGINATED FROM A CRACK AT THE WOODRU F KEY SLOT. NOTE: ENGINE WAS OVERHAULED 550 HOURS AGO DUE TO SUDDEN STOPPAGE (GEAR -UP LANDING). 1 L 7 1 3O 3 O 1A15 1E4 1997030600291 19970306 00291 GL 1997 3 6 97ZZZX887 3 19970101 G 6111 BLADE SLNSBY T67 T67M260 8323006 EU HOFMAN HOV123 HOV123KV GL BASE DELAMINATED D K NONE O OTHER IN INSP/MAINT 1 SW 17 3004H 873 2126 B688 INSPECTION FOUND DELAMINATION AT BASE OF BLADE. SUBMITTER STATED CAUSE UNKNOWN. AWAITING INFORMATION FROM MANUFACTURER . 1 L 7 1 3O NT A73EU 5 C P5EU2 1997030600295 19970306 00295 CE 1997 3 6 97ZZZX891 1 19970108 G 7810 991029919 HEADER ASSY CESSNA 340 340A 2076405 CE EXHAUST WYE CRACKED H S K NONE O OTHER IN INSP/MAINT 1 SW 17 3975C 3113 340A0991 DURING INSPECTION AND AD 75-23-08R5 CHECK, FOUND EXHAUST WYE CRACKED ONE-THIRD OF THE WAY AROUND AT THE BOTTOM IN THE WE LD ZONE. 1 L 7 2 3O 3A25 1997030600296 19970306 00296 SO 1997 3 6 97ZZZX892 1 19970101 G 2410 LW18129 BELT PIPER PA32 PA32R301T 7103220 SO ALTERNATOR DRV FAILED B CPNR O OTHER H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 SW 17 4294P 32R8329015 PILOT REPORTED LOSS OF ALTERNATOR AFTER 4 HOURS OF FLIGHT. INVESTIGATION FOUND ALTERNATOR DRIVE BELT BROKEN. CHECK ALT ERNATOR, BEARINGS, AND PULLEY, FOUND OK. AIR COND BELT LOOSE. REPLACED BELT, SET TENSION. ALL CHECK OK AT RUN-UP. 1 L 7 1 3O A3SO 1997030600297 19970306 00297 GL 1997 3 6 97ZZZX893 3 19970101 G 6111 BLADE SLNSBY T67 T67M260 8323006 EU HOFMAN HOV123 HOV123KV GL BASE DELAMINATED D A K NONE O OTHER IN INSP/MAINT 1 SW 17 7020D 581 2109 B641 INSPECTION FOUND DELAMINATION AT BASE OF BLADE. SUBMITTER STATED CAUSE UNKNOWN. AWAITING INFORMATION FROM MANUFACTURER . 1 L 7 1 3O NT A73EU 5 C P5EU2 1997030600298 19970306 00298 CE 1997 3 6 97ZZZX894 1 19970101 G 3230 3581512521 ROD ASSY BEECH 58 58TC 1152746 CE MLG RETRACT CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 23 97R 2331 TK45 DURING ANNUAL INSPECTION WHILE PERFORMING GEAR SWING, AN UNUSUAL NOISE (THUD) WAS HEARD. FOLLOWING EMERGENCY GEAR EXTEN SION, FOUND CRACKED ROD ASSY AT 8 INCHES OUTBOARD OF ATTACH BOLT. ALSO, NOTED DOWN TENSION SPRING WAS STACKED. SUSPECT CAUSE INCORRECT TENSION AND RIGGING. 1 L 7 2 3O A23CE 1997030600301 19970306 00301 1997 3 6 97ZZZX897 4 19970212 G 3451 066010690001 INDICATOR BELL 412 412EP 1182205 SW DME DEFECTIVE B GS1R K NONE O OTHER IN INSP/MAINT 1 EA 03 1208F 17 15102 36146 UNIT WEAK, WILL NOT ALLOW DME HOLD RELAY TO HOLD. REPLACED WITH NEW DME INDICATOR. 1 G 7 2 4U H4SW 1997030600302 19970306 00302 WP 1997 3 6 97ZZZX898 1 19970113 G 7330 369H81443 SWITCH 38655 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL FUEL BYPASS FAILED B A GHHR A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 NM 01 1109P 730 T41618 1100849D CAE833681 AIRCRAFT EXPERIENCED A POWER LOSS AND MADE A PRECAUTIONARY LANDING. INVESTIGATION SHOWED THAT FUEL CONTAMINATION HAD CO LLAPSED THE FUEL NOZZLE SCREEN SEVERELY RESTRICTING FUEL FLOW TO ENGINE. THE FUEL FILTER WAS COMPLETELY PLUGGED AND IN BYPASS. THE PILOT REPORTED THE FUEL BYPASS LIGHT DID NOT ILLUMINATE. TEST OF SWITCH SHOWED IT TO BE INOPERATIVE AT 24. 5 TO 35 INCHES OF FUEL. 1 G 7 1 3U 3 U H3WE E4CE 1997030600303 19970306 00303 SW 1997 3 6 97ZZZX899 1 19970131 G 6700 204010925009 CONTROL TUBE BELL 212 212 1181420 SW FLIGHT CONTROL DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 SW 09 16973 30882 FOUND ROD END LOOSE IN CONTROL TUBE DUE TO LOOSE AND WORKING RIVETS. REPLACED CONTROL TUBE. 1 G 7 1 4U H4SW 1997030600304 19970306 00304 SW 1997 3 6 97ZZZX900 1 19970117 G 5302 206031004115B TAIL BOOM BELL 206 206B 1181511 SW T/R GEARBOX CRACKED H K NONE O OTHER IN INSP/MAINT 1 SW 15 20395 4472 BCJN08310 3301 AT 100 HOUR INSPECTION, CRACK WAS FOUND AT LEFT HAND REAR ATTACH POINT FOR TAIL ROTOR GEARBOX. CRACK WAS .25 INCH LONG AND EXTENDED THROUGH THE MOUNT HOLE. CRACK WAS ONLY VISIBLE FROM INSIDE THE TAIL BOOM. 1 G 7 1 3U H2SW 1997030600305 19970306 00305 SW 1997 3 6 97ZZZX901 1 19970130 G 2910 70061H000A180A HOSE BELL 206 206B 1181511 SW HYDRAULIC SYSTEM LEAK D K NONE K FLUID LOSS IN INSP/MAINT 1 SW 09 2777Q 2805 FOUND HYDRAULIC LEAK CAUSED BY CHAFING AT ADEL CLAMP SECURING HOSE TO DECK. REPLACED LINE AND INSTALLED SERVICEABLE ADE L CLAMP, P/N MS21919WDG9. 1 G 7 1 3U H2SW 1997030600306 19970306 00306 SW 1997 3 6 97ZZZX902 1 19970130 G 6730 206076031013 SERVO BELL 206 206B 1181511 SW FLIGHT CONTROL BINDING D K NONE O OTHER IN INSP/MAINT 1 SW 09 2777Q 10420 3106 4604 2805 NOTED BINDING IN-FLIGHT CONTROLS. REPLACED RT SERVO. INTERNAL PROBLEMS DUE TO BEING CLOSE TO TBO. 1 G 7 1 3U H2SW 1997030600311 19970306 00311 SW 1997 3 6 97ZZZX907 1 19970116 G 2913 2060760303 PUMP BELL 206 206L1 1182107 SW HYD SYSTEM DEFECTIVE H K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 SW 09 5748H A41803852 45490 NOTED CYCLIC CONTROLS BINDING DURING FLIGHT. LOW HYDRAULIC PRESSURE. REPLACED PUMP ASSY AND RETURNED AIRCRAFT TO SERVI CE. 1 G 7 1 3U H2SW 1997030600313 19970306 00313 EU 1997 3 6 97ZZZX909 1 19970210 G 7170 350A21010148 HOSE SNIAS 350 AS350B2 8680813 EU DRAIN FUEL OIL DISCONNECTED B A RC0R K NONE O OTHER IN INSP/MAINT 1 SW 17 6103X 2723 DURING 100 HOUR INSPECTION, FOUND FUEL/OIL DRAIN LINE ITEM 30 PG 71.70.10, PG 2, EUROCOPTER AS350B2 PARTS MANUAL, HAD CO ME LOOSE CAUSING DRAIN FUEL TO DRAIN INTO ELECTRICAL JUNCTION BOX AREA. THIS PROBLEM WAS ALSO FOUND IN SAME AREA WITH A NOTHER AIRCRAFT OF SAME MODEL. 1 G 7 1 3U H9EU 1997030600314 19970306 00314 WP 1997 3 6 97ZZZX910 1 19970212 G 2430 P505A WIRE HUGHES 369 369E 4470707 WP BATTERY RELAY DETERIORATED D K NONE O OTHER IN INSP/MAINT 1 SO 15 52475 4201 0119E DURING INSPECTION, FOUND WIRES FROM TERMINAL A1 OF K310 BATTERY RELAY TO BATTERY SHUNT AND WIRES FROM THE BATTERY SIDE O F REVERSE CURRENT RELAY TO TERMINAL A1 OF K301 START RELAY HAD SEVERELY CRACKED COVERING EXPOSING BARE WIRES. THESE WIR ES ARE CLAMPED TOGETHER AND COULD HAVE STARTED TOUCHING EACH OTHER AT ANY TIME. ALL OF THESE WIRES SHOW 'NO' SIGNS OF H EAT STRESS OR OVERHEATING. THE CRACKING APPEARS TO BE FROM OLD AGE. SUBMITTER STATES DURING INSPECTIONS, THIS AREA SHO ULD BE INSPECTED CLOSELY. 1 G 7 1 3U H3WE 1997030600315 19970306 00315 WP 1997 3 6 97ZZZX911 1 19970212 G 8097 P505B WIRE HUGHES 369 369E 4470707 WP START RELAY DETERIORATED D A K NONE O OTHER IN INSP/MAINT 1 SO 15 52475 4201 0119E DURING INSPECTION, FOUND WIRES FROM TERMINAL A1 OF K310 BATTERY RELAY TO BATTERY SHUNT AND WIRES FROM THE BATTERY SIDE O F REVERSE CURRENT RELAY TO TERMINAL A1 OF K301 START RELAY HAD SEVERELY CRACKED COVERING EXPOSING BARE WIRES. THESE WIR ES ARE CLAMPED TOGETHER AND COULD HAVE STARTED TOUCHING EACH OTHER AT ANY TIME. ALL OF THESE WIRES SHOW 'NO' SIGNS OF H EAT STRESS OR OVERHEATING. THE CRACKING APPEARS TO BE FROM OLD AGE. SUBMITTER STATES DURING INSPECTIONS, THIS AREA SHO ULD BE INSPECTED CLOSELY. 1 G 7 1 3U H3WE 1997030600316 19970306 00316 WP 1997 3 6 97ZZZX912 1 19970204 G 6320 2014ACR GEAR TOOTH 269A517523 HUGHES 269 269C 4470504 WP M/R XMSN CHIPPED B OG5R K NONE O OTHER IN INSP/MAINT 1 GL 21 6141N 1983 S0456 S1641 DURING AIRCRAFT RUN-UP, ROTOR TACHOMETER WENT TO ZERO. FOUND ONE TOOTH ON RING GEAR CHIPPED. FOUND CHIP JAMMED IN OIL PUMP GEARS WHICH CAUSED OIL PUMP DRIVESHAFT TO SHEAR. SCHWEIZER SB 244.2 ADDRESSES THIS SUBJECT. THIS IS ALSO ADDRESSE D IN THE 50/100 HR CHECK LIST. TRANSMISSION REMOVED AND REPLACED WITH OVERHAULED UNIT. 1 G 7 1 3O 4H12 1997030600317 19970306 00317 NE 1997 3 6 97ZZZX913 1 19970204 G 6320 7635109002050 HOUSING SKRSKY S76 S76B 8143007 NE M/R GEARBOX CRACKED D A K NONE O OTHER IN INSP/MAINT 1 EA 25 76FL 2117 C00100014 760347 WHILE DOING THE ZONE 5 INSPECTION, FOUND A CRACK IN THE UPPER MAIN GEARBOX HOUSING JUST AFT OF THE RIGHT REAR SUPPORT LE G. THE CRACK WAS FOUND IN THE AREA SHOWN IN CHAPTER 5-20-00, PAGE 23, FIGURE 16. THE MAIN GEARBOX WILL BE CHANGED TO F IX THIS PROBLEM. AIRCRAFT TOTAL TIME 2,128.7 HOURS. M/R GEARBOX P/N 7635109600042. 1 G 7 2 4U H1NE 1997030600318 19970306 00318 SW 1997 3 6 97ZZZX914 1 19970129 G 6320 2060401201 PINION 2060400035 BELL 206 OH58A 1181579 SW TRANSMISSION TEETH BROKEN B P QJ5R K NONE O OTHER IN INSP/MAINT 1 NM 05 2372 358 B12577 INSPECTION FOUND PINION WITH A BROKEN TOOTH AND PITTING ON THE REST OF THE TEETH. SUBMITTER BELIEVES THE CAUSE TO BE IM PROPER BACKLASH. 1 G 7 1 3U H2SW 1997030600693 19970306 00693 NE 1997 3 6 97ZZZX916 1 19970214 G 5313 7620204001146 LONGERON SKRSKY S76 S76B 8143007 NE RT TAIL BOOM CRACKED B EGRR K NONE O OTHER IN INSP/MAINT 1 EA 17 5NJ 760346 ANGLE CRACKED AT STA 467. AIRCRAFT TT 2,855.3 HOURS. 1 G 7 2 4U H1NE 1997030600694 19970306 00694 NE 1997 3 6 97ZZZX917 1 19970214 G 5320 7620204002120 ANGLE SKRSKY S76 S76B 8143007 NE FS 467 CRACKED B EGRR K NONE O OTHER IN INSP/MAINT 1 EA 17 5NJ 760346 UPPER SHEAR DECK WEB CRACKED RT SIDE, STA 467. AIRCRAFT TT 2,855.3 HOURS. 1 G 7 2 4U H1NE 1997030600695 19970306 00695 NE 1997 3 6 97ZZZX918 1 19970214 G 5320 7620204002117 DECK WEB SKRSKY S76 S76B 8143007 NE FS 467 CRACKED B EGRR K NONE O OTHER IN INSP/MAINT 1 EA 17 5NJ 760346 RIGHT TAIL BOOM LONGERON CRACKED AT STA 467. AIRCRAFT TT 2,855.3 HOURS. 1 G 7 2 4U H1NE 1997030600696 19970306 00696 WP 1997 3 6 97ZZZX919 1 19970210 G 7160 369A4163 HARNESS HUGHES 369 369D 4470706 WP SCAV AIR SYSTEM CHAFED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 5074R 1151D FOUND SCAV AIR SOLENOID WIRE HARNESS WAS CHAFING ON THE COOLING DUCT FOR THE TRANS OIL COOLER. REPLACED HARNESS. 1 G 7 1 3U H3WE 1997030600697 19970306 00697 WP 1997 3 6 97ZZZX920 1 19970210 G 2550 2TC1415 BREAKER HUGHES 369 369D 4470706 WP CARGO HOOK FAILED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 5074R 1151D CARGO HOOK DID NOT FUNCTION. FOUND CIRCUIT BREAKER WAS INOPERATIVE. AFTER REMOVING CIRCUIT BREAKER COULD HEAR A RATTLE WHEN SHAKING. 1 G 7 1 3U H3WE 1997030600698 19970306 00698 GL 1997 3 6 97ZZZX921 2 19970210 G 7323 369A70023 ACTUATOR HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL GOV DEFECTIVE B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 5074R 8265 1151D DURING RUN-UP IT WAS DISCOVERED THE GOV NEEDED CONSTANT ADJUSTMENT UP AND DOWN WITH THE TRIM MOTOR. IT WAS FOUND THAT T HE TRIM MOTOR HAS SOME INTERNAL SLOP. REPLACED TRIM MOTOR. 1 G 7 1 3U 3 U H3WE E4CE 1997030600699 19970306 00699 GL 1997 3 6 97ZZZX922 2 19970210 G 7310 6844169 LINE HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE FCU CHAFED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 5074R 1151D CAE832750 DURING RE-ASSEMBLY OF THE ENGINE, IT WAS FOUND THAT THE FUEL LINE FROM FCU TO THE CHECK VALVE WAS CONTACTING ANOTHER LIN E. NORMALLY, THIS INDICATES IT IS INSTALLED BACKWARDS, BUT IN THIS CASE, IT HIT BOTH WAYS. NO PART NUMBER WAS FOUND ON THE TUBE, AND A NEW TUBE RECTIFIED THE PROBLEM. SUSPECT IT HAD BEEN A 'FIELD FIX' SOME TIME PAST. 1 G 7 1 3U 3 U H3WE E4CE 1997030600700 19970306 00700 WP 1997 3 6 97ZZZX923 1 19970210 G 5330 369H01123 PANEL HUGHES 369 369D 4470706 WP XMSN SUPPORT CRACKED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 5074R 1151D SUBMITTER STATED THIS IS NOT AN UNCOMMON PROBLEM. THIS PANEL IS ATTACHED TO THE AFT BOTTOM OF THE TRANSMISSION SUPPORT STRUCTURE AND ALSO ATTACHES TO THE REAR DOOR FRAME AS IT COMES UP TO THE TRANS SUPPORT. IT WAS FOUND CRACKED BETWEEN 3 RIVET HOLES WHERE IT ATTACHES TO THE SUPPORT. THE SUPPORT IS STAINLESS STEEL AND THE PANEL IS ALUMINUM AND THE ATTACHIN G RIVETS ARE DASH 5 MODELS. I BELIEVE THE ACT OF INSTALLING THESE HARD RIVETS AIDS IN THE FAILURE OF THESE PANELS. 1 G 7 1 3U H3WE 1997030600701 19970306 00701 WP 1997 3 6 97ZZZX924 1 19970210 G 7160 369H8011 BELL MOUNT HUGHES 369 369D 4470706 WP ENGINE INLET DETERIORATED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 5074R 1151D FOUND ON REMOVAL OF THE ENGINE THAT THE INLET BELL MOUNT WAS NO LONGER PLIABLE, BUT RIGID AND BRITTLE. REPLACED WITH NE W PART. 1 G 7 1 3U H3WE 1997030600724 19970306 00724 EU 1997 3 6 97ZZZX947 1 19970201 G 3212 C178131 HOSE BOLKMS 105 BO105S 5626006 EU FLOAT FAILED B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 5059C S779 HIGH FAILURE RATE OF NR 1 AND NR 4 HOSES ON BO-105S FLOATS D24873-101 AND 102 DUE TO KINKS. REPLACED HOSES. 1 G 7 2 3U H3EU 1997030600725 19970306 00725 EU 1997 3 6 97ZZZX948 1 19970114 G 3212 C178131 HOSE BOLKMS 105 BO105S 5626006 EU FLOAT FAILED B AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 826MB S771 HIGH FAILURE RATE OF NR 1 AND NR 4 HOSES ON BO-105S FLOATS, P/N D24873-101 AND 102 DUE TO KINKS. REPLACED HOSES. 1 G 7 2 3U H3EU 1997030600840 19970306 00840 EU 1997 3 6 97ZZZX952 1 19970121 G 5511 315A3510000101 SPAR AEROSP SA316 SA315B 8680615 EU HORIZ STAB CRACKED D A K NONE O OTHER IN INSP/MAINT 1 WP 07 27443 MR368 2426 SPAR TUBE CRACKED AT RT MOUNTING HOLE, CRACK ORIGINATES AT MOUNTING HOLE AND EXTENDS IN BOTH DIRECTIONS COVERING 50 PERC ENT OF TUBE CIRCUMFERENCE. THIS DEFECT WAS FOUND WHEN THE STABILIZER WAS BROUGHT IN FOR REPAIR OF WORN MOUNT BUSHING. T HIS CRACK COULD NOT BE SEEN AS IT IS COVERED BY HALF SHELL REINFORCEMENTS. SUBMITTER SUGGESTS CAUSE AS LACK OF PREVENTI VE MAINTENANCE, NOT FOLLOWING INSPECTION SCHEDULES. T/R OUT OF BALANCE FOR EXTENDED PERIODS. 1 G 7 1 4U H1IN 1997030600841 19970306 00841 EU 1997 3 6 97ZZZX953 1 19970204 G 6320 350A32106320 GASKET 350A32011000 SNIAS 350 AS350B2 8680813 EU EPICYCLIC MISFIT D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 6084W 1103 2672 THESE PARTS WHEN RECEIVED FROM A.E.C., ARE TOO SMALL IN DIAMETER TO CORRECTLY FIT. AMER EUROCOPTER SAYS TO SOAK THE GAS KET OR TO TEAR THE OUTSIDE PART OF THE BOLT HOLES TO MAKE IT FIT. AFTER TRYING TO GET THE GASKET TO SWELL BY SOAKING, T HE GASKET STILL TORE. AMER EURO IS AWARE OF PROBLEM BUT AS OF LAST PHONE CALL, IS NOT GOING TO CORRECT THE PROBLEM OF B AD FITTING GASKETS. NOTE: SUBMITTER ALSO REPORTED THE SAME DEFECT WAS NOTED ON 3-22-96 ON N6095U, SAME MAKE/MODEL OF A /C. NO M OR D SUBMITTED AT THAT TIME. 1 G 7 1 3U H9EU 1997030600842 19970306 00842 GL 1997 3 6 97ZZZX954 2 19970129 G 7321 252464429 FUEL CONTROL BENDIX BELL 206 206B3 1181506 SW ALLSN 250C 250C20J 03013 GL ENGINE STUCK B OG5R R AUTOROTATION R PARTIAL RPM/PWR LOSS LD LANDING 1 GL 21 188ND 16 319777 3992 CAE270376 DURING AUTOROTATION FLIGHT TRAINING, INSTRUCTER ROLLED THROTTLE TO IDLE. N1 WENT PAST 60 PERCENT N1 IDLE SPEED TO 52 PE RCENT. FOUND PR/PG SHAFT NOT WORKING. SHAFT WOULD NOT FOLLOW CAM ON SHAFT TO ALLOW PR/PG VALVE TO OPEN OR PREVENT UNDE RSHOOTING IDLE. RPM OF 60 PERCENT N1. SUSPECT RUSHING AROUND SHAFT CAME OUT OF POSITION AND ALLOWED CAM TO BEND SHAFT IN FUEL CONTROL. 1 G 7 1 3U 3 U H2SW E4CE 1997030600845 19970306 00845 GL 1997 3 6 97ZZZX957 2 19970211 G 7250 6898735 TURBINE HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE NOZZLE DAMAGE D A K NONE O OTHER IN INSP/MAINT 1 SO 01 40AP 8066 1098 37363 825D 833309 GROUND PERSONNEL NOTICED NOISE COMING FROM ENGINE DURING START-UP AND SHUT DOWN BETWEEN 20 PERCENT AND 60 PERCENT N1 RPM . THE ENGINE RAN NORMAL AT GROUND IDLE. UPON DISASSEMBLY OF THE ENGINE, THE CAUSE OF THE NOISE WAS FOUND TO BE EXCESSI VE HEAT DAMAGE TO THE NR 1 TURBINE NOZZLE AND NR 1 TURBINE WHEEL ALONG WITH SUBSEQUENT DAMAGE TO THE REMAINING TURBINE. SUBMITTER SUGGESTED CAUSE WAS A DEFECTIVE FUEL NOZZLE SINCE NO REPORTS OF A HOT START WERE RECORDED. 1 G 7 1 3U 3 U H3WE E4CE 1997030600847 19970306 00847 GL 1997 3 6 97ZZZX959 3 19970213 G 6114 B4486 MOUNT STUD CESSNA 421 421B 2076014 CE MCAULY 3AF34C 3AF34C92 GL PROPELLER BROKEN D K NONE O OTHER IN INSP/MAINT 1 NM 03 713633 ALIGNMENT DOWEL STUDS WERE BROKEN BELOW HUB MOUNTING FACE SURFACE. 1 L 7 2 3O A7CE 5 C P22EA 1997030600848 19970306 00848 SO 1997 3 6 97ZZZX960 2 19970211 G 8520 CRANKCASE CONT O360 IO360C 17025 SO NR 2 CYL BASE CRACKED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 CE 01 060656R FACTORY REMANUFACTURED ENGINE: OPENED CRATE TO INSTALL ENGINE. FOUND CRACK IN CRANKCASE REAR NR 2 TOP CYLINDER BASE ST UD. CRACK APPROXIMATELY .6250 INCH LONG. ZERO TIME ON ENGINE. 3 O E1CE 1997030600851 19970306 00851 GL 1997 3 6 97ZZZX963 1 19970203 G 5542 2055400000 RUDDER DIAMON DA20A1 DA20A1 05626UX GL TOP TE SKIN DAMAGED D K NONE A FLAME/FIRE IN INSP/MAINT 1 NM 11 10UV 1418 10037 DURING A 100 HOUR INSPECTION, NOTED THE TOP CORNER OF THE TRAILING EDGE OF THE RUDDER WAS DAMAGED (APPARENTLY FROM BEING PUSHED BACKWARDS) CAUSING SKINS TO SEPARATE FROM THE CENTER FILL MATERIAL (OR CORE). THE DAMAGE IS 1.25 INCHES DOWN FRO M THE TOP ALONG THE TRAILING EDGE AND .75 INCH FORWARD OF TRAILING EDGE ALONG TOP OF RUDDER. NO DAMAGE EVIDENT AT HINGE OR MOUNTING AREA. 1 L 7 1 3O NT TA4CH 1997030600852 19970306 00852 EA 1997 3 6 97ZZZX964 2 19970129 G 8530 ECLW12988CP CYLINDER ENSTRM F28 F28C 3300407 GL LYC O360 HIO360E1AD 41514 EA NR 2 FAILED H L GWHV A UNSCHED LANDING A FLAME/FIRE NR NOT REPORTED 1 SW 09 51774 568 06 440 L1970051A ON A NIGHT TRAINING FLIGHT, NR 2 CYLINDER BLEW OUT ABOVE THE EXHAUST PORT. THE BLOW-OUT STEERED THE NR 4 CYLINDER OIL L INE AND STARTED A FIRE. AN EMERGENCY LANDING WAS ACCOMPLISHED WITHOUT INJURY TO THE INSTRUCTOR OR THE STUDENT, HOWEVER, THE AIRCRAFT WAS COMPLETELY DESTROYED BY FIRE. SUBMITTER STATES HAVE HAD TWO OTHER SIMILAR FAILURES OF THESE CERMICROM E CYLINDERS ON THIS ENGINE IN THE LAST 127 HOURS. (TOTAL OF 3.) 1 G 7 1 3O 3 O H1CE 1E10 1997030600853 19970306 00853 CE 1997 3 6 97ZZZX965 1 19970107 G 5320 12121281 BRACKET CESSNA 210 T210L 2073449 CE TAIL ASSY LT CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 02 2074S 3694 21061041 DURING A REPLACEMENT OF A TAIL TIE-DOWN RING AND AFT TAIL CONE BULKHEAD ASSY, P/N 1212130-2 AT STA 230.187, CRACKS WERE FOUND ON BOTH LT AND RT SUPPORT BRACKETS. THESE BRACKETS ARE PART OF THE HORIZONTAL STABILIZER SUPPORT ON AFT SIDE UNDE R P/N 1212128-1 AND DASH 2. THE CRACK LOOKS LIKE IT WAS CAUSED BY TOO MUCH CLEARANCE BETWEEN SUPPORT BRACKET P/N 1212128 -1 AND HORIZONTAL STABILIZER AFT BRACKET P/N 12324000-1. NEW PARTS WILL BE INSTALLED WITH PARTICULAR ATTENTION TO CLEA RANCE BETWEEN PARTS. 1 H 7 1 3O 3A21 1997030600854 19970306 00854 CE 1997 3 6 97ZZZX966 1 19970107 G 5320 12121282 BRACKET CESSNA 210 T210L 2073449 CE TAIL ASSY RT CRACKED D S A K NONE O OTHER IN INSP/MAINT 1 NM 02 2074S 3694 21061041 DURING A REPLACEMENT OF A TAIL TIE-DOWN RING AND AFT TAIL CONE BULKHEAD ASSY, P/N 1212130-2 AT STA 230.187, CRACKS WERE FOUND ON BOTH LT AND RT SUPPORT BRACKETS. THESE BRACKETS ARE PART OF THE HORIZONTAL STABILIZER SUPPORT ON AFT SIDE UNDE R P/N 1212128-1 AND DASH 2. THE CRACK LOOKS LIKE IT WAS CAUSED BY TOO MUCH CLEARANCE BETWEEN SUPPORT BRACKET P/N 1212128 -1 AND HORIZONTAL STABILIZER AFT BRACKET P/N 12324000-1. NEW PARTS WILL BE INSTALLED WITH PARTICULAR ATTENTION TO CLEA RANCE BETWEEN PARTS. 1 H 7 1 3O 3A21 1997030600855 19970306 00855 SO 1997 3 6 97ZZZX967 2 19970220 G 8530 CYLINDER BEECH 35 V35TC 1151540 CE CONT O520 TSIO520DB 17040 SO ENGINE WEAR B CS3R K NONE O OTHER IN INSP/MAINT 1 WP 17 222TB 361 D8242 505012 DURING 100-HOUR INSPECTION, COMPRESSION CHECK REVEALED ALL SIX CYLINDERS LOW. TOTAL TIME 360.5 HOURS SINCE RAM CONVERSI ON TO STC SE3631SW ON ALL CYLINDERS. SUSPECT OVERLEANING. 1 L 7 1 3O 3 O 3A15 E8CE 1997030600856 19970306 00856 SO 1997 3 6 97ZZZX968 2 19970115 G 7310 330996F80240 LINE BEECH 36 B36TC 1151609 CE CONT O520 TSIO520UB 17040 SO ENGINE FUEL LEAKING D O OTHER O OTHER AP APPROACH 1 GL 03 317C 218 EA574 527213 ENGINE WOULD NOT IDLE ON FINAL. PRESSURE CHECKED HOSE AND FOUND SEVERAL LEAKS. (NOT VISIBLE WITH FIRE SLEEVE ON). HOS E DATE 4TH QUARTER '94. A/C AIRWORTHINESS 2-95. 1 L 7 1 3O 3 O 3A15 E8CE 1997030600857 19970306 00857 GL 1997 3 6 97ZZZX969 3 19970213 G 6111 BLADE SLNSBY T67 T67M260 8323006 EU HOFMAN HOV123 HOV123KV GL PROPELLER BASE DELAMINATION D K NONE O OTHER IN INSP/MAINT 1 SW 17 31909 999 2220 B640 INSPECTION OF PROPELLER FOUND A PROPELLER BLADE WITH DELAMINATION AT BASE OF BLADE. (ONE INCH WIDE BY FOUR INCHES LONG) . CAUSE UNKNOWN. AWAITING INFORMATION FROM HOFFMAN PROPELLER. 1 L 7 1 3O NT A73EU 5 C P5EU2 1997030600858 19970306 00858 EU 1997 3 6 97ZZZX970 1 19970213 G 2810 T67G57007 TANK SLNSBY T67 T67M260 8323006 EU LT WING ASSY CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 SW 17 3045H 829 2141 ON A PRE-FLIGHT INSPECTION, A FUEL STAIN WAS NOTICED ON BOTTOM OF LEFT WING. FURTHER INSPECTION FOUND A CRACK ON THE FW D INBOARD SIDE OF THE FUEL TANK. SUBMITTER SUSPECTS POSSIBLE STRESS CRACK. AWATING REPAIR FROM MANUFACTURER. 1 L 7 1 3O NT A73EU 1997030600859 19970306 00859 CE 1997 3 6 97ZZZX971 1 19970124 G 3230 58130441 CHANNEL CESSNA 404 404CESSNA 2075901 CE NLG ACT ATTACH CRACKED D S A K NONE O OTHER IN INSP/MAINT 1 NM 03 355HC 3029 4040110 UPON ACCOMPLISHMENT OF CESSNA SB ME78-31 AND SK404-21 (REPLACEMENT OF NOSE GEAR ACTUATOR ALUMINUM ATTACH LUGS WITH STEEL ATTACH LUGS) FOUND BOTH CHANNELS TO WHICH LUGS ATTACH WERE CRACKED AT AFT CORNER RADII. REPLACED CHANNELS. SUSPECT CA USE: HARD LANDING, LANDING ON NOSE GEAR, POSSIBLE INCORRECT RIGGING OF NOSE GEAR WITH INSUFFICIENT PRELOAD OF ACTUATOR AGAINST DRAG BRACE; THUS, CAUSING SHOCK LOADS TO BE TRANSMITTED THROUGH ACTUATOR TO ATTACH STRUCTURE. 1 L 7 2 3O A25CE 1997030600862 19970306 00862 CE 1997 3 6 97ZZZX974 1 19970205 G 2150 AIR INLET CESSNA 210 P210N 2073454 CE FS 172 AIR COND EXH CONTAMINATED D A K NONE O OTHER IN INSP/MAINT 1 WP 07 6262K P21000395 DURING INSPECTION, EXHAUST RESIDUE WAS DISCOVERED IN TAIL CONE. IT WAS DETERMINED THAT EXHAUST WAS ENTERING THROUGH THE CONDENSER AIR INLET INSTALLED FOR JB SYSTEMS, INC., AIR CONDITIONING STC NR SA71RM. THIS INLET WAS COVERED, AND CESSNA LOUVERS AND DOUBLER INSTALLED IN UPPER LEFT SIDE OF FUSELAGE IAW CESSNA DRAWING NR 2101029. 1 H 7 1 3O 3A21 1997030600863 19970306 00863 SO 1997 3 6 97ZZZX975 2 19970220 G 8530 VALVE CESSNA 210 T210M 2073451 CE CONT O520 TSIO520R 17040 SO NR 1 CYL WORN B CS3R K NONE O OTHER IN INSP/MAINT 1 WP 17 6457B 825 21032768 269711R DURING 100 HOUR INSPECTION, FOUND NR 1 CYLINDER READING 20/80 DURING COMPRESSION CHECK, ALSO, ALL OTHER CYLINDERS IN LOW SIXTIES. TOTAL TIME 824.8 HOURS SINCE TCM. ZERO TIME REBUILD. 1 H 7 1 3O 3 O 3A21 E8CE 1997030600864 19970306 00864 SO 1997 3 6 97ZZZX976 2 19970205 G 8530 649543A1 VALVE CESSNA 150 150K 2071822 CE CONT O200 O200A 17020 SO EXH NR 2 FAILED D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 EA 21 6474G 1270 15071974 285158R DURING FLIGHT, PILOT EXPERIENCED ROUGH RUNNING AND POWER LOSS UPON INSPECTION OF CYLINDERS. FOUND NO COMPRESSION NR 2 C YLINDER. REMOVED CYLINDER, FOUND PISTON HEAD DAMAGED AND EXHAUST VALVE HEAD MISSING. VALVE STEM SEIZED IN GUIDE. SUBM ITTER STATED NEEDS BETTER OILING OF VALVE STEM FOR EXHAUST VALVE. 1 H 7 1 3O 3 O 3A19 E252 1997030600865 19970306 00865 SO 1997 3 6 97ZZZX977 2 19970220 G 8530 CYLINDER CESSNA 210 P210N 2073454 CE CONT O520 TSIO520P 17040 SO ENGINE WORN B CS3R K NONE O OTHER IN INSP/MAINT 1 WP 17 677PC 794 P21000677 278685R DURING 100 HOUR INSPECTION, COMPRESSION CHECK REVEALED ALL SIX CYLINDERS LOW AS FOLLOWS: 35/57/50/51/49/51. CUSTOMER R EPORTED USING 1 QUART PER HOUR PRIOR TO INSPECTION. REGULAR SOAP AT 50-HOUR OIL CHANGE REVEALED NO MAJOR PROBLEMS. TOT AL TIME 793.8 HOURS SINCE TCM. ZERO TIME REBUILD. SUBMITTER SUSPECTS OVERLEANING. 1 H 7 1 3O 3 O 3A21 E8CE 1997030600866 19970306 00866 SO 1997 3 6 97ZZZX978 1 19970211 G 3211 6705403 TRUNNION PIPER PA28 PA28RT201 7102818 SO NLG CRACKED B AIHR K NONE O OTHER IN INSP/MAINT 1 GL 11 8109D 3301 28R8018014 NOSE GEAR TRUNNION ASSY HAS SEVERE CRACK WHERE DOWNLOCK LINK ATTACHES WITH BOLT. REPLACED TRUNNION WITH NEW ASSY. 1 L 7 1 3O 2A13 1997030600867 19970306 00867 SO 1997 3 6 97ZZZX979 1 19970211 G 2910 1114 LINE STRATOFLEX PIPER PA31 PA31350 7103110 SO LT MLG ACTUATOR LEAK D O OTHER K FLUID LOSS NR NOT REPORTED 1 SO 16 824CH 102 318252055 LT NR 534 2Q96. ASSY DATE 9/96. INSTALL DATE 9-26-96. PILOT REPORTED LANDING GEAR NOT GOING UP AND LOCKED. FOUND RES ERVOIR LOW. FOUND UP AND DOWN LINES AT LT GEAR ACTUATOR LEAKING. ALSO, FOUND ONE HOSE ON RT MAIN ACTUATOR LEAKING. PR ESSURE CHECK CONFIRMED LEAK THROUGH HOSE WALL. ALL HOSES SAME LOT NUMBER AND CURE DATE. MANUFACTURED BY PROFESSIONAL A VIATION ASSOCIATES 1 L 7 2 3O A20SO 1997030600868 19970306 00868 EA 1997 3 6 97ZZZX980 2 19970124 G 8530 STD148 UNION LW13561 BEECH 60 A60 1153604 CE LYC O541 TIO541E1C4 41536 EA CYLINDER DRAIN DETACHED D K NONE O OTHER IN INSP/MAINT 1 NM 03 928PT 600 P174 L122259 CYLINDER DRAIN FITTING CAME OUT OF HEAD. DRAIN LINE WAS STILL ATTACHED. THIS CAUSED ERRONEOUS READINGS ON SENSE SYSTEM . 1 L 7 2 3O 3 O A12CE E10EA 1997030600869 19970306 00869 CE 1997 3 6 97ZZZX981 1 19970124 G 7810 77928 PIPE 77944 BEECH 60 A60 1153604 CE NR 3 CYLINDER BLOWN D K NONE O OTHER IN INSP/MAINT 1 NM 03 928PT P174 EXHAUST PIPE AT CYLINDER NR 3 BLEW HOLE IN BOTTOM OF PIPE CAUSING MANIFOLD PRESSURE TO GO TO NON-BOOST. 1 L 7 2 3O A12CE 1997030600871 19970306 00871 WP 1997 3 6 97ZZZX983 2 19970212 G 7250 30720681 BLADE AMD FALC10 FALCON10 2730101 EU GARRTT TFE731 TFE7312 01518 WP NR 2 ENG NR 3 LP SEPARATED D A E ENGINE SHUTDOWN E VIBRATION/BUFFET CL CLIMB 1 GL 05 73B 79 P73298 THE NR 2 ENGINE WAS SHUT DOWN DURING CLIMB-OUT DUE TO EXCESSIVE VIBRATIONS. INITIAL FINDS DURING TEAR DOWN INDICATE THA T SEVERAL BLADES SEPARATED FROM THE NR 3 L.P.T. THIS CAUSED SEVERE VIBRATIONS THAT, IN TURN, CAUSED THE N2 SECTION TO R UB. 2 L 7 2 4F 4 F A33EU E6WE 1997030600873 19970306 00873 WP 1997 3 6 97ZZZX985 2 19970212 G 7210 BELLVILLE WASHER AMD FALC10 FALCON10 2730101 EU GARRTT TFE731 TFE7312 01518 WP PLANETARY GEAR FAILED D A K NONE O OTHER IN INSP/MAINT 1 GL 05 174B 142 P73279 600 HOUR SOAP SAMPLE INDICATED HIGH METAL CONTENT. SUSPECT FROM THE PLANET GEARS. INSPECTION INDICATED BELLVILLE WASHE R WAS SPINNING. PLANET GEARSHAFT AND WASHER REPLACED. ENGINE WAS APPROXIMATELY 600 HOURS OUT OF MPI. 2 L 7 2 4F 4 F A33EU E6WE 1997030600874 19970306 00874 CE 1997 3 6 97ZZZX986 1 19970214 G 5610 10138402518 WINDSHIELD 96152H8779 BEECH 200 200BEECH 1152920 CE COPILOT SMOKED B DEBR K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CE 03 300JK 150 BB532 PILOT REPORTED HEAVY SMOKE IN COCKPIT. INSPECTED AND FOUND L.P. TERMINAL AT WINDSHIELD HAD HIGH RESISTANCE WHICH CAUSED SMOKE AND FIRE IN COCKPIT. REPLACED WINDSHIELD WITH NEW. OPERATION CHECKED GOOD. 1 L 7 2 4T A24CE 1997030600875 19970306 00875 CE 1997 3 6 97ZZZX987 1 19970205 G 5610 10138402516 WINDSHIELD BEECH 300 300BEECH 1152930 CE COPILOT INNER SHATTERED G A A UNSCHED LANDING O OTHER CR CRUISE 1 GL 13 59AH 1689 FA197 COPILOT'S WINDSHIELD INNER PANE OF GLASS SHATTERED IN-FLIGHT AT 35,000 FEET. AN UNEVENTFUL LANDING WAS MADE AT THE NEAR EST AIRPORT TEN MINUTES LATER. WINDSHIELD WAS REPLACED AND AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 2 4T A24CE 1997030600876 19970306 00876 CE 1997 3 6 97ZZZX988 1 19970201 G 5210 551151515 HINGE CESSNA 441 441 2076020 CE CABIN DOOR BROKEN B A PAZR K NONE O OTHER IN INSP/MAINT 1 CE 03 592G 4410361 DURING PREFLIGHT, FOUND THE AFT LOWER CABIN DOOR HINGE BROKEN IN TWO PIECES AT THE LOCATION OF THREE RIVETS INSTALLED TH ROUGH THE HINGE AND DOOR FRAME. NEW HINGE ASSY INSTALLED. 1 L 7 2 3T RT A28CE 1997031300063 19970313 00063 EU 1997 3 13 97ZZZX993 1 19970102 G 6310 4638202007 FREEWHEEL BOLKMS 105 BO105S 5626006 EU M/R DRIVE SLIPPAGE B L AC2R K NONE O OTHER IN INSP/MAINT 1 SW 03 50588 1613 3204 S780 FREEWHEEL UNIT ERRATIC AND SLIPPAGE NOTED. COULD ONLY FIND SPRAG WEAR ON OUTBOARD SIDE. 1 G 7 2 3U H3EU 1998010800060 19980108 00060 GL 1998 1 8 98ZZZX1 2 19971205 G 7313 47086 FILTER ALLSN 250C 250C20B 03013 GL FUEL NOZZLE CONTAMINATED D K NONE O OTHER IN INSP/MAINT 1 WP 23 FUEL NOZZLE FILTER SCREEN WAS FOUND WITH UNKNOWN SUBSTANCE, CONTAMINATED 50 PERCENT OF SCREEN AREA. SUGGEST INSPECTING FUEL PUMP FUEL FILTER FOR POSSIBLE BLOCKAGE CAUSING FUEL PUMP TO GO TO FILTER BYPASS. 3 U E4CE 1998010800069 19980108 00069 GL 1998 1 8 98ZZZX10 1 19971101 G 7931 K3PS4020 SWITCH AMTR 2+2 NORTHMAN22 05620MC GL OIL PRESSURE LEAK D O OTHER K FLUID LOSS CR CRUISE 1 SW 99 239PT 149 597 OIL PRESSURE SWITCH USED TO TURN ON FLIGHT TIME RECORDER ('HOBBS" METER) BEGAN TO LEAK OIL FROM ONE ELECTRICAL TERMINAL. A FEW DROPS OF OIL WERE NOTICED WHILE PRE-FLIGHTING FOR A 2-1/2 HOUR RETURN FLIGHT. AFTER RETURNING, THERE WAS A LARG E OIL LEAK. ENGINE WAS 3 QUARTS LOW. TESTING SWITCH INDICATES LARGE OIL LEAK AT ELECTRIC TERMINAL. 1 H 7 1 3O NT EXPA1H71 1998010800153 19980108 00153 SO 1998 1 8 98ZZZX100 2 19971214 G 7414 6310 MAGNETO SLICK CESSNA 210 210M 2073450 CE CONT O520 IO520L 17032 SO RT MAGNETO FAILED D K NONE O OTHER NR NOT REPORTED 1 SO 06 6831M 1000 2106994 554901 RIGHT MAGNETO DEAD. OPENED MAG, FOUND COPPER AND CARBON DUST EVERYWHERE. FOUND BLOCK AND GEAR BEARINGS WORN SEVERELY A ND GEAR DAMAGED, TEETH VERY SHARP DUE TO MISALIGNMENT OF LARGE GEAR. MAGS WERE NOT INSPECTED AT 500-HOUR INSPECTION AS RECOMMENDED. 1 H 7 1 3O 3 O 3A21 E5CE 1998031200102 19980312 00102 EA 1998 3 12 98ZZZX1001 2 19971220 G 7322 RSA5AD1 SERVO BENDIX MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA FUEL INJECTOR CORRODED B A OF1R K NONE O OTHER IN INSP/MAINT 1 EA 25 4561H 1196 70137 240767 CORROSION FOUND INSIDE FUEL INJECTOR SERVO DIAPHRAGM SECTION WAS IMPEDING MOVEMENT OF DIAPHRAGM RESTRICTING FUEL FLOW. S UBMITTER SUSPECTED WATER LAYING IN THIS AREA CORRODING SMALL SECTION OF INJECTOR HOUSING CAUSED GROWTH OF CORROSION DEPO SIT. LAB REPORT ON CORROSION SENT TO PHILA FSDO. 1 L 7 1 3O 3 O 2A3 1E10 1998031200103 19980312 00103 CE 1998 3 12 98ZZZX1002 1 19971016 G 5511 0432160 SPAR CESSNA 140 140 2071602 CE HORIZONTAL STAB MISSING D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 13 76512 2526 10944 REINFORCEMENT CHANNEL/SPAR WAS MISSING/NOT INSTALLED. IT APPEARED THE SPAR HAD NEVER BEEN INSTALLED FROM THE FACTORY. 1 H 7 1 3O NC A768 1998010800154 19980108 00154 SO 1998 1 8 98ZZZX101 1 19971218 G 3246 40106 WHEEL PIPER PA31T PA31T 7103124 SO LT MLG OUTBOARD BROKEN D P K NONE O OTHER IN INSP/MAINT 1 GL 25 515BA 3600 31T8120044 POST-FLIGHT REVEALED BROKEN OUTBOARD WHEEL HALF ON LEFT MAIN. 1 L 7 2 3T A8EA 1998031200116 19980312 00116 CE 1998 3 12 98ZZZX1014 1 19971229 G 3710 212CW PUMP CESSNA 210 210L 2073448 CE VACUUM SYSTEM FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 13 732DZ 1103 5AC2164 21061446 VACUUM PUMP FAILED. SUBMITTER STATED ROUTINE WEAR CAUSED BY OPERATION HOURS. 1 H 7 1 3O 3A21 1998031200706 19980312 00706 SW 1998 3 12 98ZZZX1016 1 19970120 G 6320 K94120107 OIL PUMP K974002009 KAMAN K1200 K1200 05625F6 SW M/R GEARBOX FAILED H OWVL K NONE O OTHER IN INSP/MAINT 1 NM 11 134KA 0017 A940006 HAD TO REMOVE TRANSMISSION FOR DAMAGED OIL PUMP DRIVE GEAR CAUSED FROM OIL PUMP SEIZURE (NO SHEAR SHAFT ON OIL PUMP). D ATE OF INCIDENT 1-20-97. 1 G 7 1 4F NT TR7BO 1998010800155 19980108 00155 EA 1998 1 8 98ZZZX102 2 19971218 G 7414 4381 MAGNETO SLICK CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA LT MAGNETO FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 15 94112 182 15285600 L2295415 INSTALLED TWO NEW 4381 MAGNETOS ON AN ENGINE REBUILD. LEFT MAG ROTATING MAGNET APPEARS TO HAVE FAILED DUE TO FACTORS UN KNOWN. RESULT IS A BENT SHAFT AT THE IMPULSE COUPLING. NO DAMAGE TO DRIVE GEARS NOTED. 1 H 7 1 3O 3 O NT 3A19 E223 1998031200711 19980312 00711 SO 1998 3 12 98ZZZX1021 1 19970811 G 2913 31800002 POWER PAK PIPER PA23 PA23160 7102304 SO HYDRAULIC SYSTEM RUPTURED C L A K NONE O OTHER LD LANDING 1 NE 05 6918 700 2799 232038 UPON LANDING ROLL-OUT, RT MAIN AND NOSE GEAR COLLAPSED. DROP CHECK IN HANGAR WITH HAND PUMP SHOWED NO ABNORMALITIES DUR ING OPERATION. POWER PAK REMOVED AND SENT FOR TEAR DOWN INSPECTION. THEY FOUND BLOW HOLE IN MAIN HOUSING CASTING AT PO PPET HOLE. EITHER FATIGUED OR A THIN WALL DEFECT EXISTED TO CAUSE BLOW-OUT RESULTING IN SYSTEM PRESSURE GOING BACK TO R ESERVOIR OF POWER PAK. 1 L 7 2 3O 1A10 1998031900261 19980319 00261 CE 1998 3 19 98ZZZX1057 1 19971022 G 3213 105384001 SHOCK STRUT BEECH 76 76 1153005 CE MLG JAMMED D A O OTHER O OTHER CL CLIMB 1 SW 05 6010W 0637 ME98 BOLTS ATTACHING THE UPPER SHOCK STRUT ASSY TO THE UPPER GEAR HOUSING HAD SEVERE STRESS IN THE THREAD AREA. THIS WAS CAU SED BY REPEATED OPERATIONS IN FLIGHT TRAINING. BOLTS FAILED ALLOWING GEAR LEG TO EXTEND AND UPON RETRACTION, JAMMED ON LOWER WING SKIN RESULTING IN A GEAR-UP (2 EXTENDED) LANDING. SUBMITTER SUGGESTED REMOVING BOLTS PERIODICALLY TO CHECK T HREAD AREA FOR DISTRESS. HAVE FOUND 6 OTHERS IN FLEET TO HAVE SAME DAMAGE TO THREADS. 1 L 7 2 3O A29CE 1998031900278 19980319 00278 WP 1998 3 19 98ZZZX1071 2 19970912 G 7200 ENGINE ISRAEL 1124 1124A 4500103 EU GARRTT TFE731 TFE7313 01518 WP RT ENGINE FAILED D O OTHER Y ENGINE STOPPAGE CL CLIMB 1 SO 09 849HS 3992 344 P77437 DURING A TOUCH AND GO LANDING, CONDUCTED FOR CREW PROFICIENCY TRAINING, THE RIGHT ENGINE FAILED SHORTLY AFTER TAKEOFF PO WER WAS SET ON BOTH ENGINES. 2 M 7 2 4F 4 F A2SW E6WE 1998031900279 19980319 00279 NE 1998 3 19 98ZZZX1072 2 19971020 G 7230 50A126 BEARING BOEING 777 777222 1385219 NM PWA PW4077 PW4077 NE NR 3 MAIN FAILED B WA2D O OTHER J WARNING INDICATION LD LANDING 1 NE 03 123 P777079 LOW OIL PRESSURE MESSAGE APPEARED AFTER LANDING IN BEIJING. GROUND INSPECTION FOUND METAL IN FILTER AND CHIP DETECTORS. DISASSEMBLY INSPECTION FOUND NR 3 MAIN BEARING FAILURE. BEARING ROUTED TO PRATT & WHITNEY ENGINEERING FOR INVESTIGATI ON. CUSTOMER: ALL NIPPON AIRWAYS OF JAPAN. CYCLES, 46. 2 L 7 2 4F 4 F RT T0001SE E46NE 1998031900595 19980319 00595 CE 1998 3 19 98ZZZX1086 1 19971125 G 7810 1099500001 EXHAUST STACK BEECH 90 C90A 1152911 CE RT ENG INBD CRACKED B KO1R K NONE O OTHER IN INSP/MAINT 1 EA 25 1568X 230 LJ1368 RT ENGINE INBOARD EXHAUST STACK CRACKED AT DEICE TUBE. PART TT 229.6 HOURS. 1 L 7 2 3T RT 3A20 1998010800411 19980108 00411 SW 1998 1 8 98ZZZX109 1 19971218 G 6120 8954752 CAM ASSY AIRESRCH 8954812 GULSTM 690TP 690B 7630516 SW PROP PITCH CNTRL WORN D A K NONE O OTHER IN INSP/MAINT 1 GL 25 690HT 2138 P680 11467 DURING ENGINE REPAIR RESULTING FROM CATASTROPHIC FAILURE OF PROPELLER GOVERNOR, DISSASSEMBLY OF PROPELLER PITCH CONTROL REVEALED SEVERE WEAR OF CAM SLOT AND PIN ON SLEEVE ASSY 869647-5. THERE IS LITTLE DOUBT THAT THIS ASSY WOULD HAVE FAILE D LONG BEFORE SCHEDULED INSPECTION AT 3,600 HOURS. FAILURE OF THIS ASSY WILL RESULT IN LOSS OF PROPELLER CONTROL. 1 H 7 2 3T 2A4 1998010800070 19980108 00070 NM 1998 1 8 98ZZZX11 1 19971211 G 7830 COWL DOUG MD11 MD11F 3023600 NM RT T/R COWL DAMAGED D K NONE O OTHER IN INSP/MAINT 1 WP 03 105EV 13628 48544 INSPECTION FOUND NR 2 ENGINE T/R COWL RT DAMAGED. ALSO FOUND TRANSLATING COWL RT LOWER SIDE DAMAGE ABOUT 10 CM BY 8 CM WHEN TRANSIT IN ANC. REPLACED RT HALF OF BOTH FAN COWL AND TRANSLATING COWL. 2 L 7 3 4F RT A22WE 1998010800412 19980108 00412 SO 1998 1 8 98ZZZX110 1 19971110 G 3230 6716800 SPRING PIPER PA28 PA28R201 7102816 SO NLG STRUT FAILED D A O OTHER O OTHER AP APPROACH 1 WP 01 36458 28R7837279 WHILE IN-FLT, PILOT REPORTED LOUD BANG. WHEN LANDING GEAR SELECTED, NLG WOULD NOT DOWN AND LOCK. UPON LANDING, NLG RET RACTED. NLG DID NOT LOCK DUE TO INNER SPRING BREAKING. WHEN THE INNER SPRING BROKE AT UPPER HOOK END, THIS BROKEN END CAUGHT OUTER SPRING COIL 2/3 OF THE LENGTH OF THE SPRING JAMMING OUTER SPRING AND CAUSING IT TO REMAIN AT A LENGTH OF 11 INCHES INSTEAD OF A CLOSED LENGTH OF 8 INCHES. THIS CAUSED OUTER SPRING TO BEND INTO A V-SHAPE PREVENTING OUTER SPRIN G FROM PULLING NLG TO A DOWN AND LOCKED POSITION. SUBMITTER STATED INNER SPRING BREAKING AND BENDING OUTER SPRING IS A UNIQUE SITUATION. SUBMITTER SUGGESTED A REPLACEMENT TIME IN HRS OR CALENDAR TIME. 1 L 7 1 3O 2A13 1998010800413 19980108 00413 SO 1998 1 8 98ZZZX111 1 19970910 G 3233 357972 ACTUATOR PIPER PA28 PA28RT201T 7102817 SO NLG BROKEN D K NONE O OTHER NR NOT REPORTED 1 WP 01 2251M 1282 28P7931001 NOSE GEAR ACTUATOR BROKEN AT AFT ATTACH HOLE (BOLT HOLE). COULD HAVE BROKEN WHEN NOSE GEAR WAS FORCED DOWN AFTER ACCIDE NT. 1 L 7 1 3O 2A13 1998010800414 19980108 00414 1998 1 8 98ZZZX112 4 19971218 G 6122 8954908 GOVERNOR WOODWARD GULSTM 690TP 690B 7630516 SW PROPELLER FAILED D A D E RETURN TO BLOCK ENGINE SHUTDOWN J WARNING INDICATION TX TAXI/GRND HDL 1 GL 25 690HT 2138 11467 BETA LIGHT FLICKERED IN-FLIGHT. NO OTHER DISCREPANCIES ON NEXT DEPARTURE DURING TAXI OPERATION . PROPELLER WENT TOWARD COURSE PITCH UNCOMMANDED. ITT WENT TO RED LINE, PILOT SHUT ENGINE DOWN. INTERNAL FAILURE OF PROP GOV RESULTED IN META L EXITING THE PROP GOV THRU OIL PASSAGES. CLOGGED NTS CHECK VALVE WHICH ELIMINATED OIL SUPPLY TO NEGATIVE SIDE OF TORQU E SENSOR. PLUGGED ADAPTER 3101708 ELIMINATING OIL SUPPLY TO POSITIVE SIDE OF TORQUE SENSOR, PLUGGED TURBINE BEARING OIL JET, CONTAMINATED FEATHER VALVE WHICH COMPLETELY DISABLED IT MAKING IT IMPOSSIBLE FOR NTS SYSTEM TO FUNCTION AND PROP C OULD NOT BE FEATHERED MANUALLY. 1 H 7 2 3T 2A4 1998032600306 19980326 00306 EA 1998 3 26 98ZZZX1127 2 19971213 G 8530 CYLINDER CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA NR 1 FAILED H A UNSCHED LANDING E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CR CRUISE 1 SO 21 99295 1620 17276429 L1383239A FOLLOWING 45 MINUTES OF FLIGHT, ENGINE BECAME ROUGH. CARBURETOR HEAT APPLIED, BUT ROUGHNESS THE SAME. APPLIED FULL POW ER AND RETURNED AND ON SHORT FINAL, TOWER REPORTED HEAVY SMOKE. INSPECTION FOUND ENGINE HAD ONLY 3 QUARTS OF OIL LEFT. NR 1 CYLINDER PISTON NICKED AND HEAD CRACKED. 1 H 7 1 3O 3 O NT 3A12 E274 1998032600307 19980326 00307 CE 1998 3 26 98ZZZX1128 1 19970315 G 2434 646843 ALTERNATOR BEECH 33 F33A 1151425 CE WINDING FAILED G A UNSCHED LANDING H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 GL 03 3058S G009230 CE1099 PILOT EXPERIENCED ELECTRICAL SYSTEM FAILURE. MADE EMERGENCY LANDING WITHOUT INCIDENT. FOUND ALTERNATOR FAILED. 1 L 7 1 3O 3A15 1998010800415 19980108 00415 SO 1998 1 8 98ZZZX113 1 19971219 G 2710 BOLT PIPER PA28 PA28181 7102807 SO AILERON WRONG PART D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 15 4511F 287790037 DURING A CUSTOMER REQUESTED AILERON RIGGING CHECK, DISCOVERED THE AFT BOLTS ON BOTH AILERON BELLCRANKS WERE CHAFING ON T HE AILERON CONTROL ROD AS AILERONS WERE MOVED. ALL 4 BOLTS CONNECTING THE AILERON CABLES TO THE BELLCRANKS WERE AN23-12 . AN EXAMINATION OF THE CURRENT PARTS MANUAL REVEALED THE CORRECT BOLT TO BE INSTALLED SHOULD BE A PIPER PN 402-669 (NA S1103-7D BOLT). THERE IS A STRENGTH DIFFERENCE BETWEEN THESE TWO BOLTS AS WELL AS A LENGTH DIFFERENCE. THE AN23-12 IS .0625 INCH LONGER THAN THE NAS1103-7D. 1 L 7 1 3O 2A13 1998010800416 19980108 00416 SO 1998 1 8 98ZZZX114 2 19971014 G 8520 SA649520A3 CAMSHAFT CESSNA 401 401A 207590D CE CONT O520 TSIO520EB 17040 SO ENGINE GALLED B EBTR K NONE O OTHER IN INSP/MAINT 1 GL 09 401GS 168 401A0063 2063570E LIFTER/CAMSHAFT GALLED. LIFTER BODY CHIP FOUND IN OIL FILTER. PRESSURE RELIEF VALVE CAUSING LOW OIL PRESSURE. ENGINE TORN DOWN, NEW PARTS INSTALLED. 1 L 7 2 3O 3 O A7CE E8CE 1998010800417 19980108 00417 SO 1998 1 8 98ZZZX115 2 19971014 G 8520 SA646277 LIFTER CESSNA 401 401A 207590D CE CONT O520 TSIO520EB 17040 SO ENGINE GALLED B EBTR K NONE O OTHER IN INSP/MAINT 1 GL 09 401GS 168 401A0063 2063570E LIFTER/CAMSHAFT GALLED. LIFTER BODY CHIP FOUND IN OIL FILTER. PRESSURE RELIEF VALVE CAUSING LOW OIL PRESSURE. ENGINE TORN DOWN, NEW PARTS INSTALLED. 1 L 7 2 3O 3 O A7CE E8CE 1998010800418 19980108 00418 CE 1998 1 8 98ZZZX116 1 19971004 G 7602 5038901021 CONTROL CABLE BEECH 55 95A55 1152704 CE ENGINE MIXTURE FAILED B EBTR K NONE O OTHER IN INSP/MAINT 1 GL 09 12CM 57 TC300 MIXTURE CABLE FAILED ON SHUT DOWN AFTER FLIGHT. NO PREVIOUS INDICATION OF PROBLEM. INSPECTION SHOWED UNDER SHEATH WELD BROKE THAT SECURES SOLID END TO CABLE PORTION. CANNOT INSPECT HERE DUE TO SHEATH COVERING. NEW SAME PART NUMBER INSTAL LED. 1 L 7 2 3O 3A16 1998010800419 19980108 00419 1998 1 8 98ZZZX117 4 19970515 G 3457 KLX135 GPS HOACAU HK36R HK36R 4170002 EU COCKPIT MISWIRED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 11 400HK 2320 36400 CUSTOMER PURCHASED GPS UNIT FROM AIRCRAFT SPRUCE AND SPECIALTY CO. UPON INSTALLATION IN AIRCRAFT, FOUND UNIT IMPROPERLY WIRED. WIRED IAW ALLIED SIGNAL INSTALLATION MANUAL AND FOUND UNIT TO OPERATE TO SPECIFICATION. MANUAL NR 006-10500-00 01. SUBMITTER RECOMMENDED THAT AVIONICS SHOPS WIRING SYSTEMS REFER TO INSTALLATION MANUAL AND TEST WIRING HARNESS BEFO RE DELIVERING TO CUSTOMER. ALSO, NO MAINTENANCE RELEASE WAS DELIVERED WITH UNIT. 1 K 7 1 3O RC G51EU 1998032600615 19980326 00615 CE 1998 3 26 98ZZZX1173 1 19971201 G 5610 5111604202 WINDSHIELD CESSNA 421 421C 2076016 CE COPILOT DEPARTED D O OTHER D INFLIGHT SEPARATION CR CRUISE 1 NM 05 88584 7500 421C0642 AS THE AIRCRAFT LEVELLED OFF AT 23,000 FEET MSL, THE COPILOT'S WINDSHIELD DEPARTED THE AIRCRAFT WITH ONLY APPROXIMATELY 10 PERCENT REMAINING ATTACHED TO THE AIRFRAME. SPECULATING THAT THE CRACK ORIGINATED AT THE RIGHT LOWER CORNER AND WENT STRAIGHT UP TO THE TOP OF THE WINDSHIELD. SUBMITTER STATED TO PREVENT, SHOULD HAVE RECURRING INSPECTION. REF: MEB 83 -33R. 1 L 7 2 3O A7CE 1998032600621 19980326 00621 1998 3 26 98ZZZX1179 4 19971231 G 2562 EBC102A ELT PIPER J3 PA11 7101102 SO COCKPIT FAILED G K NONE O OTHER IN INSP/MAINT 1 WP 19 5532H 570146 111035 THE ELT DID NOT ACTIVATE ON IMPACT. IT DID TEST USING AN AM RADIO AFTER TURNING ON MANUALLY. THE DATE ON THE BATTERY W AS DUE DECEMBER, 1993. 1 H 7 1 3O A691 1998010800071 19980108 00071 SO 1998 1 8 98ZZZX12 2 19971210 G 7421 RHB32E SPARK PLUG CHAMPION CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO ELECTRODE SHORTED D K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SO 14 4667Q 21059567 294623R UPON INSTALLING NEW SPARK PLUGS, THE ENGINE RAN ROUGH. WHEN INSPECTING THE SPARK PLUGS, THREE WERE FOUND MILLED IMPROPE RLY AND SMALL SLIVERS OF METAL SHORTING THE CENTER ELECTRODE. 1 H 7 1 3O 3 O 3A21 E5CE 1998010800845 19980108 00845 NE 1998 1 8 98ZZZX123 2 19970112 G 7250 3360097040 SHAFT GE CFM56 CFM565A 13802 NE LPT CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 2365 1543 731101 AXIAL CRACK 30CM LONG BEGINNING IN A HOLE AFTER THE THREAD AND GOING FROM THE REAR OF THE SHAFT AND DEFORMATION OF THE S HAFT. PARTS CURRENTLY UNDER SNECMA/CFMI INVESTIGATION. 4 F E29NE 1998010800846 19980108 00846 WP 1998 1 8 98ZZZX124 2 19971224 G 7250 3072316 DISC HUB GARRTT TFE731 TFE7313 01518 WP HPT CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 2540 P76759 FOUND HPT DISC HUB CRACKED DURING NDT INSPECTION AT MAJOR PERIODIC INSPECTION. 4 F E6WE 1998040200002 19980402 00002 EU 1998 4 2 98ZZZX1240 1 19971124 G 6520 350A33215300 BEARING SNIAS 350 AS350B2 8680813 EU T/R GEARBOX DEFECTIVE B FBLR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 17 TAIL ROTOR BEARING IS DEFECTIVE PER SL 1337-65-97, DATED 11-24-97. 1 G 7 1 3U H9EU 1998010800847 19980108 00847 CE 1998 1 8 98ZZZX125 1 19971215 G 3230 KP16BS BEARING FAFNIR BEECH 200 200BEECH 1152920 CE MLG TORQ TUBE FROZEN B MZ4R K NONE O OTHER IN INSP/MAINT 1 SO 17 202AJ 10900 BB511 INVESTIGATION OF LANDING GEAR RETRACT MECHANISM REVEALED SQUEELING NOISE IN AREA OF TORQUE TUBE UNIVERSAL JOINT JUST OUT SIDE FUSELAGE ON RIGHT SIDE. THE KP16BS BEARING WAS FOUND FROZEN/RUSTED IN ITS SUPPORT PLATE WHILE THE SHAFT ADAPTER PN 101-810021-9, SPUN ON THE BEARINGS NON-BEARING SURFACE. A NEW BEARING AND ADAPTER WERE INSTALLED AND THE AIRCRAFT RETUR NED TO SERVICE. 1 L 7 2 4T A24CE 1998040200423 19980402 00423 NE 1998 4 2 98ZZZX1257 1 19971218 G 6210 7615009100053 BLADE SKRSKY S76 S76 8143010 NE M/R CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 705AL 3588 440 A08601843 760267 DISCOVERED DURING 500-HOUR INSPECTION, FOUND M/R BLADE SKIN CRACKED AT FORWARD EDGE OF TRIM TAB. 1 G 7 2 3U H1NE 1998040200424 19980402 00424 NE 1998 4 2 98ZZZX1258 1 19971201 G 3213 7333FT160N SEAL 1945E100B SKRSKY S76 S76 8143010 NE MLG LOWER CYL LEAKING B ALGR K NONE K FLUID LOSS IN INSP/MAINT 1 SW 03 705AL 2747 760267 IN FIELD 12-97, OIL LEAKING FROM STRUT AND PROBLEM SERVICING STRUT. STRUT WOULD NOT ACTUATE PROPERLY. FOUND LOW OIL LE VER IN CYLINDER PREVENTING PROPER ACTUATING OF PISTON HEAD SNUBBER. THIS ALLOWED UNCONTROLLED EXTENSION OF STRUT PISTON DURING AIRCRAFT LIFT-OFF AND HAMMERING OF PISTON HEAD AGAINST EXTENSION STOP AND SHEARING OF PISTON HEAD RETAINING PINS . THIS ALLOWED PISTON TO SEPARATE FROM PISTON HEAD. PISTON JAMMED PISTON HEAD IN TOP OF STRUT CYLINDER AND PREVENTED P ROPER MOVEMENT OF PISTON IN STRUT CYLINDER. 1 G 7 2 3U H1NE 1998040200425 19980402 00425 GL 1998 4 2 98ZZZX1259 2 19971106 G 7210 406340104101 GARLOCK SEAL 23035155 ALLSN 250C 250C28B 03013 GL PTO AFT AREA LEAKING B ALGR K NONE K FLUID LOSS IN INSP/MAINT 1 SW 03 CAG70295 NEW PTO SEALS WERE INSTALLED IN REPAIRED GEARBOX. ENGINE WAS ASSEMBLED AND TESTED ON 11-06-97. AFTER TEST CELL RUN, FO UND AFT PTO SEAL BROKEN AT INNER LIP. NEW PTO SEALS ARE NOT AT SAME DIMENSIONS AS OLD (RED) PTO SEALS. NEW PTO SEALS A RE LARGER IN DIAMETER MAKING INSTALLATION EXTREMELY HARD AND CAUSING SEAL TO BOW AND CAUSE LEAKAGE. SUBMITTER SUGGESTED CHANGE DIAMETER OF SEALS TO MATCH THOSE OF THE OLD (RED) SEALS. 3 U E1GL 1998010800848 19980108 00848 SO 1998 1 8 98ZZZX126 1 19971222 G 3520 8336102 OXYGEN UNIT SCOTT GULSTM G1159 G1159A 3970109 SO CABIN FAILED D A K NONE O OTHER IN INSP/MAINT 1 WP 19 721FF 948 0158 421 WHILE PERFORMING CABIN OXYGEN SYSTEM TEST, FOUND TEN MASKS IN SIX PRESENTATION UNITS WITH NO OXYGEN FLOW AFTER PULLING LANYARD. UNITS ARE MANUFACUTRED BY SCOTT AVIATION. 2 L 7 2 4F A12EA 1998040200428 19980402 00428 EU 1998 4 2 98ZZZX1262 1 19970823 G 7714 614764021 INDICATOR SNIAS 350 AS350B2 8680813 EU ENG TACHOMETER FAILED B YWYR K NONE O OTHER IN INSP/MAINT 1 SW 09 126TV 513 2944 TACHOMETER INDICATOR READ INTERMITTENTLY LOW. 1 G 7 1 3U H9EU 1998040200429 19980402 00429 EU 1998 4 2 98ZZZX1263 1 19970823 G 6520 704A33633171 SPHERICAL STOP SNIAS 350 AS350B2 8680813 EU T/R DEFECTIVE B YWYR K NONE O OTHER IN INSP/MAINT 1 SW 09 126TV 513 2944 BULGES IN T/R SPHERICAL STOP. 1 G 7 1 3U H9EU 1998010800849 19980108 00849 SO 1998 1 8 98ZZZX127 1 19971222 G 3520 8336102 OXYGEN UNIT SCOTT GULSTM G1159 G1159A 3970109 SO CABIN FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 19 721FF 948 0177 421 WHILE PERFORMING CABIN OXYGEN SYSTEM TEST, FOUND TEN MASKS IN SIX PRESENTATION UNITS WITH NO OXYGEN FLOW AFTER PULLING LANYARD. UNITS ARE MANUFACUTRED BY SCOTT AVIATION. 2 L 7 2 4F A12EA 1998040200441 19980402 00441 GL 1998 4 2 98ZZZX1274 2 19971107 G 7210 406340104101 GARLOCK SEAL 23053349 BELL 206 206L4 1182110 SW ALLSN 250C 250C30P 03013 GL PTO FWD SEAL LEAKING B ALGR K NONE K FLUID LOSS IN INSP/MAINT 1 SW 03 CAG95832 NEW PTO SEALS INSTALLED IN REPAIRED GEARBOX ON 9-23-97. ENGINE WAS ASSEMBLED AND TESTED ON 11-07-97. DURING TEST RUN, FOUND FORWARD PTO SEAL LEAKING. NEW PTO SEALS ARE LARGER IN DIAMETER THAN (RED) PTO SEALS PN 524919. UPON INSTALLATION , SEALS ARE EXTREMELY TIGHT CAUSING SEALS TO BOW AND CAUSE LEAKAGE. 1 G 7 1 3U 3 U NC H2SW E1GL 1998041000032 19980410 00032 NM 1998 4 10 98ZZZX1279 1 19970604 G 3231 267222 VALVE BODY 2670296 BOEING 747 747121 1384871 NM NLG DOOR SEQ LEAKING B S IU6R K NONE K FLUID LOSS IN INSP/MAINT 1 NM 01 PA02 NLG SEQUENCE VALVE LEAKING FROM PIN HOLE AT BASE OF DN PORT. 2 L 7 4 4F A20WE 1998010800850 19980108 00850 SO 1998 1 8 98ZZZX128 1 19971222 G 3520 8336102 OXYGEN UNIT SCOTT GULSTM G1159 G1159A 3970109 SO CABIN FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 19 721FF 948 0176 421 WHILE PERFORMING CABIN OXYGEN SYSTEM TEST, FOUND TEN MASKS IN SIX PRESENTATION UNITS WITH NO OXYGEN FLOW AFTER PULLING LANYARD. UNITS ARE MANUFACUTRED BY SCOTT AVIATION. 2 L 7 2 4F A12EA 1998010800851 19980108 00851 SO 1998 1 8 98ZZZX129 1 19971222 G 3520 8336102 OXYGEN UNIT SCOTT GULSTM G1159 G1159A 3970109 SO CABIN FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 19 721FF 948 0175 421 WHILE PERFORMING CABIN OXYGEN SYSTEM TEST, FOUND TEN MASKS IN SIX PRESENTATION UNITS WITH NO OXYGEN FLOW AFTER PULLING LANYARD. UNITS ARE MANUFACUTRED BY SCOTT AVIATION. 2 L 7 2 4F A12EA 1998010800072 19980108 00072 CE 1998 1 8 98ZZZX13 1 19971203 G 3510 1015601401 TUBE ASSY BEECH 200 B200 1152922 CE OXYGEN SYSTEM LEAK D K NONE O OTHER IN INSP/MAINT 1 NM 09 63791 6533 BB1100 OXYGEN SYSTEM LEAK. INSPECTION FOUND B-NUT CRACKED AT AFT BULKHEAD ATTACHMENT (3 PLACES). FURTHER INSPECTION REVEALED B-NUT AT T-FITTING ATTACHMENT CRACKED IN 2 PLACES. 1 L 7 2 4T A24CE 1998010800852 19980108 00852 SO 1998 1 8 98ZZZX130 1 19971222 G 3520 8336102 OXYGEN UNIT SCOTT GULSTM G1159 G1159A 3970109 SO CABIN FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 19 721FF 948 0173 421 WHILE PERFORMING CABIN OXYGEN SYSTEM TEST, FOUND TEN MASKS IN SIX PRESENTATION UNITS WITH NO OXYGEN FLOW AFTER PULLING LANYARD. UNITS ARE MANUFACUTRED BY SCOTT AVIATION. 2 L 7 2 4F A12EA 1998010800853 19980108 00853 SO 1998 1 8 98ZZZX131 1 19971222 G 3520 8336102 OXYGEN UNIT SCOTT GULSTM G1159 G1159A 3970109 SO CABIN FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 19 721FF 948 0172 421 WHILE PERFORMING CABIN OXYGEN SYSTEM TEST, FOUND TEN MASKS IN SIX PRESENTATION UNITS WITH NO OXYGEN FLOW AFTER PULLING LANYARD. UNITS ARE MANUFACUTRED BY SCOTT AVIATION. 2 L 7 2 4F A12EA 1998041000068 19980410 00068 CE 1998 4 10 98ZZZX1315 1 19971105 G 2820 714144 FUEL LINE BBAVIA 8 8KCAB 2110612 CE HEADER TANK LEAKING D A K NONE K FLUID LOSS IN INSP/MAINT 1 NM 01 276R 100 71393 PILOT REPORTED ODOR OF FUEL IN THE COCKPIT. INSPECTION REVEALED FUEL SEEPAGE WHERE THE TUBE ASSEMBLY CONNECTS TO THE TE E AT THE HEADER TANK INLET (THIS IS THE TUBE ASSY FROM THE LEFT WING TANK). THE FLARE WAS FOUND TO HAVE AN OUTSIDE DIAM ETER LARGER THAN THE ASSOCIATED M520819 SLEEVE AND THE TUBE ASSEMBLY WAS EXCESSIVELY MISALIGNED WITH THE TEE CAUSING EXC ESSIVE PRELOAD RESULTING IN DAMAGE TO THE TUBE DURING ASSEMBLY. GOOD STANDARD PRACTICE WOULD PREVENT THIS KIND OF DAMAG E. 1 H 7 1 3O A21CE 1998010800856 19980108 00856 1998 1 8 98ZZZX134 4 19971201 G 6122 C290D3FT1 GOVERNOR PROPELLER MISREPAIRED B DJFR K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 23 741856 AT DISASSEMBLY FOR OVERHAUL, FOUND UNAPPROVED REPAIRS TO THE MAIN HOUSING IDLER GEAR PUMP SOCKET. THE IDLER GEAR STUD F ELL OUT WHEN TURNED UPSIDE DOWN. THIS IS TO BE A PRESSURE FIT. THE STUD WAS STAKED IN 4 PLACES BY USE OF PRICK PUNCH. A LSO FOUND SEVERE SCORING OF THE PUMP WALLS. 1998010800857 19980108 00857 EA 1998 1 8 98ZZZX135 2 19971215 G 8530 LW14077 PISTON PIN LYC O360 LO360E1A6 41514 EA CYLINDER ASSY BROKEN H K NONE O OTHER IN INSP/MAINT 1 EA 11 280 17328 L51072T INSPECTION FOUND PISTON PIN BROKEN AFFECTED BY AD 97-15-11. 3 O E286 1998041000128 19980410 00128 GL 1998 4 10 98ZZZX1351 1 19970708 G 7603 5545271067 CONTROL CABLE ENSTRM F28 F28F 3300412 GL THROTTLE BINDING C PP0M K NONE O OTHER IN INSP/MAINT 1 WP 01 8624B 236 752 THROTTLE CONTROL CABLE INTERNAL BINDING CAUSES PARTIAL TO FULL LOSS OF THROTTLE CONTROL. UNIT IN SERVICE 12 WEEKS. 1 G 7 1 3O H1CE 1998010800858 19980108 00858 SO 1998 1 8 98ZZZX136 2 19971222 G 8520 6524201048 STUD PIPER PA34 PA34200T 7103406 SO CONT O360 LTSIO360EB 17025 SO NR 1 CYL BASE SHEARED D K NONE O OTHER IN INSP/MAINT 1 CE 01 2159S 1268 347970144 306804 NOTICED BASE NUT AND PART OF STUD MISSING ON TOP REAR STUD LOCATION OF NR 1 CYLINDER. NUT HAD COME OFF OTHER END OF STU D. STUD HAD FAILED AT CYLINDER BASE FLANGE. ENGINE OVERHAULED BY MATTITUCK 1,267 HOURS PREVIOUSLY. UNKNOWN IF STUD WA S NEW THEN. (PART IS COMMONLY CALLED A THRU-BOLT). 1 L 7 2 3O 3 O A7SO E9CE 1998010800860 19980108 00860 SO 1998 1 8 98ZZZX138 2 19971223 G 8520 538811 BOLT CESSNA 421 421B 2076014 CE CONT O520 GTSIO520H 17032 SO CRANKCASE FAILED D K NONE O OTHER IN INSP/MAINT 1 SO 06 869CB 421B0863 235117H DURING ROUTINE 50-HOUR EXHAUST SYSTEM INSPECTION, NOTED BOLT AT RIGHT SIDE FORWARD LOWER CRANKCASE JUST ABOVE OIL PAN ST ICKING OUT AND TOUCHING EXHAUST CROSS-OVER TUBE. REMOVED TUBE, FOUND HEAD OF BOLT POPPED OFF. BOLT HEAD OR WASHER PN 4 01507 COULD NOT BE LOCATED IN COWLING. INSTALLED NEW BOLT AND WASHER, TORQUED 165 INCH/POUND PER ENGINE OHM. THIS ENGI NE IS AN AVIALL OVERHAULED ENGINE FOR TCM COMPLETED 5/89. BOLT SIZE: .3750 INCH - 16 INCHES BY 5.25 INCHES LONG. 1 L 7 2 3O 3 O A7CE E7CE 1998010800861 19980108 00861 CE 1998 1 8 98ZZZX139 1 19971110 G 2810 4149200223 FLUSH VENT BEECH 36 A36 1151604 CE RT FUEL TANK BLOCKED D A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SO 13 66514 2600 E1522 PILOT REPORTED A SUDDEN LOSS OF ENGINE POWER RESULTING IN AN OFF-AIRPORT LANDING. ON SITE EXAMINATION REVEALED NO OBVIO US DEFECTS. THE ENGINE WAS RE-STARTED, AND RAN FLAWLESSLY. THE PILOT TOOK OFF AND RETURNED TO BASE WITHOUT FURTHER INC IDENT. UPON DETAILED EXAMINATION OF FUEL SYSTEM, THE RT FUEL TANK FLUSH VENT WAS FOUND BLOCKED BY WHAT APPEARED TO BE A N INSECT NEST. A SIMILAR LOSS OF POWER HAD BEEN EXPERIENCED TWICE BEFORE IN PREVIOUS YEARS WITH THE SAME FINDINGS. 1 L 7 1 3O 3A15 1998041000247 19980410 00247 SW 1998 4 10 98ZZZX1391 1 19970602 G 7712 H19437 INDICATOR KAMAN K1200 K1200 05625F6 SW TORQUE FAILED D K NONE O OTHER IN INSP/MAINT 1 NM 01 313KA 436 138A A940019 TORQUE INDICATOR'S FIRST LED SEGMENT WILL NOT ILLUMINATE. 1 G 7 1 4F NT TR7BO 1998041000248 19980410 00248 SW 1998 4 10 98ZZZX1392 1 19970429 G 2121 K986127001 FAN ASSY KAMAN K1200 K1200 05625F6 SW CABIN HEAT FAILED D K NONE O OTHER IN INSP/MAINT 1 NM 01 313KA 940019 CABIN HEAT FAN ASSY INOPERABLE. PART TT: 233.8 HOURS. SUSPECT CAUSE: ENGINE BLEED AIR PASSES THROUGH FAN ASSY TRANSF ERRING HEAT TO BEARINGS. 1 G 7 1 4F NT TR7BO 1998041000249 19980410 00249 SW 1998 4 10 98ZZZX1393 1 19970508 G 2121 K986127001 FAN ASSY KAMAN K1200 K1200 05625F6 SW CABIN HEAT FAILED D K NONE O OTHER IN INSP/MAINT 1 NM 01 313KA 940019 CABIN HEAT FAN ASSY HOT AND VIBRATION. PART TT: 47.3 HOURS. BEARING FAILURE. SUSPECT CAUSE: ENGINE BLEED AIR PASSES THROUGH FAN ASSY TRANSFERRING HEAT TO BEARINGS. 1 G 7 1 4F NT TR7BO 1998041000250 19980410 00250 SW 1998 4 10 98ZZZX1394 1 19970617 G 2121 K986127001 FAN ASSY KAMAN K1200 K1200 05625F6 SW CABIN HEAT FAILED D K NONE O OTHER IN INSP/MAINT 1 NM 01 313KA 940019 CABIN HEAT FAN ASSY HOT AND VIBRATION. BEARING FAILURE. PART TT: 257.8 HOURS. SUSPECT CAUSE: ENGINE BLEED AIR PASSE S THROUGH FAN ASSY TRANSFERRING HEAT TO BEARINGS. 1 G 7 1 4F NT TR7BO 1998041000251 19980410 00251 SW 1998 4 10 98ZZZX1395 1 19970604 G 6320 1D1326 CHIP DETECTOR KAMAN K1200 K1200 05625F6 SW TRANSMISSION OIL DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 NM 01 313KA 457 940019 REMOVAL FOR NORMAL INSPECTION FOUND PHENOLIC RING MISSING FROM TIP. TT: 456.9 HOURS. 1 G 7 1 4F NT TR7BO 1998041000253 19980410 00253 SW 1998 4 10 98ZZZX1397 1 19970708 G 6320 K978113003 OIL TANK KAMAN K1200 K1200 05625F6 SW XMSN OIL CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 01 313KA 940019 TRANSMISSON OIL TANK CRACK ON TOP AT VENT LINE FITTING. 1 G 7 1 4F NT TR7BO 1998041000255 19980410 00255 SW 1998 4 10 98ZZZX1399 1 19970821 G 6220 KRP168004F IDLERCRANK BRG KAMAN K1200 K1200 05625F6 SW LT RED BLADE FAILED D K NONE O OTHER IN INSP/MAINT 1 NM 01 313KA 917 940019 IDLERCRANK BEARING FAILURES FOUND DURING NORMAL INSPECTION. 1 G 7 1 4F NT TR7BO 1998010800073 19980108 00073 EU 1998 1 8 98ZZZX14 1 19971128 G 5753 T700A5755060000 CARRIER SOCATA TBM TBM700 8682000 EU FLAP BEARING CRACKED B CB5Y K NONE O OTHER IN INSP/MAINT 1 EA 35 79Z 789 19 WHILE CARRYING OUT A 100-HOUR REPETITIVE INSPECTION IAW DGAC AD 94-110, AND SB 70-048-57, IT WAS NOTED THAT ALL 4 FLAP B EARING CARRIAGES WERE CRACKED. THE CRACKS WERE NOT LOCATED IN THE INSPECTION AREAS SHOWN IN THE SB 70-048-57, BUT WERE LOCATED IN THE WEBS. ALL 4 FLAP BEARING CARRIAGES WERE REPLACED WITH MODIFIED ITEMS BEFORE FURTHER FLIGHT. 1 L 7 1 3T RT A60EU 1998010800862 19980108 00862 CE 1998 1 8 98ZZZX140 1 19971226 G 3242 7515 PLATE PARKERHANFIN CESSNA 337 337A 2075704 CE LT BRAKE FAILED D K NONE O OTHER LD LANDING 1 SW 09 9739D 3800 3370466 UPON LANDING, LEFT BRAKE CALIPER TORQUE PLATE BROKE AT UPPER REAR BOLT ATTACH HOLE CAUSING BRAKE CALIPER TO SHIFT INTO T HE INSIDE OF THE BRAKE DISC CAUSING THE LEFT WHEEL TO LOCK UP. THE TORQUE PLATE IS DRILLED OVERSIZED AND THEN BUSHED DO WN TO ACCEPT AXLE ATTACH BOLT. THE OVERSIZED HOLE REDUCES THE HOLE EDGE DISTANCE CONSIDERABLY. 1 H 7 2 3O A6CE 1998041000256 19980410 00256 SW 1998 4 10 98ZZZX1400 1 19970821 G 6220 KRP168004F IDLERCRANK BRG KAMAN K1200 K1200 05625F6 SW LT WHITE BLADE FAILED D K NONE O OTHER IN INSP/MAINT 1 NM 01 313KA 963 940019 IDLERCRANK BEARING FAILURES FOUND DURING NORMAL INSPECTION. 1 G 7 1 4F NT TR7BO 1998041000257 19980410 00257 SW 1998 4 10 98ZZZX1401 1 19970827 G 6220 KRP168004F IDLERCRANK BRG KAMAN K1200 K1200 05625F6 SW LT RED BLADE FAILED D K NONE O OTHER IN INSP/MAINT 1 NM 01 313KA 315 940019 IDLERCRANK BEARING FAILURES FOUND DURING NORMAL INSPECTION. 1 G 7 1 4F NT TR7BO 1998041000258 19980410 00258 SW 1998 4 10 98ZZZX1402 1 19970827 G 6220 KRP168004F IDLERCRANK BRG KAMAN K1200 K1200 05625F6 SW LT WHITE BLADE FAILED D K NONE O OTHER IN INSP/MAINT 1 NM 01 313KA 269 940019 IDLERCRANK BEARING FAILURES FOUND DURING NORMAL INSPECTION. 1 G 7 1 4F NT TR7BO 1998041000259 19980410 00259 1998 4 10 98ZZZX1403 4 19970918 G 3457 066040310111 GPS KAMAN K1200 K1200 05625F6 SW COCKPIT DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 NM 01 313KA 1059 13462 940019 GPS LT CONTROL ROTOR KNOB STICKING. 1 G 7 1 4F NT TR7BO 1998041000260 19980410 00260 SW 1998 4 10 98ZZZX1404 1 19970804 G 6730 107227003 DAMPER KAMAN K1200 K1200 05625F6 SW STABILIZER FAILED D K NONE K FLUID LOSS IN INSP/MAINT 1 NM 01 313KA 807 047 940019 STABILIZER DAMPER LEAKING AT SHAFT SEAL. RECOMMENDATIONS: ENGINE EXHAUST DIRECTED DOWN ON TAIL BOOM. EXCESSIVE HEAT B UILD UP CAUSING EXCESSIVE PRESSURE IN DAMPER. DAMPER TOO HOT TO TOUCH. RECOMMEND COOLING AIR TO DAMPER AND HEAT SHIELD . 1 G 7 1 4F NT TR7BO 1998041000261 19980410 00261 SW 1998 4 10 98ZZZX1405 1 19970930 G 6730 107227003 DAMPER KAMAN K1200 K1200 05625F6 SW STABILIZER FAILED D K NONE K FLUID LOSS IN INSP/MAINT 1 NM 01 313KA 309 074 940019 STABILIZER DAMPER LEAKING AT SHAFT SEAL. RECOMMENDATIONS: ENGINE EXHAUST DIRECTED DOWN ON TAIL BOOM. EXCESSIVE HEAT B UILD UP CAUSING EXCESSIVE PRESSURE IN DAMPER. DAMPER TOO HOT TO TOUCH. RECOMMEND COOLING AIR TO DAMPER AND HEAT SHIELD . 1 G 7 1 4F NT TR7BO 1998041000262 19980410 00262 SW 1998 4 10 98ZZZX1406 1 19971218 G 6730 107227003 DAMPER KAMAN K1200 K1200 05625F6 SW STABILIZER FAILED D K NONE K FLUID LOSS IN INSP/MAINT 1 NM 01 313KA 283 082 940019 STABILIZER DAMPER LEAKING AT SHAFT SEAL. RECOMMENDATIONS: ENGINE EXHAUST DIRECTED DOWN ON TAIL BOOM. EXCESSIVE HEAT B UILD UP CAUSING EXCESSIVE PRESSURE IN DAMPER. DAMPER TOO HOT TO TOUCH. RECOMMEND COOLING AIR TO DAMPER AND HEAT SHIELD . 1 G 7 1 4F NT TR7BO 1998041000263 19980410 00263 SW 1998 4 10 98ZZZX1407 1 19970910 G 6240 K983126001 DUAL TACH KAMAN K1200 K1200 05625F6 SW ROTOR NEEDLE FAILED D K NONE O OTHER IN INSP/MAINT 1 NM 01 313KA 1030 129 940019 DUAL TACH FAILED. ROTOR NEEDLE INOPERATIVE. 1 G 7 1 4F NT TR7BO 1998041000264 19980410 00264 SW 1998 4 10 98ZZZX1409 1 19971104 G 2550 K983157007 LOAD LINK KAMAN K1200 K1200 05625F6 SW EXTERNAL LOAD ERRATIC D K NONE O OTHER IN INSP/MAINT 1 NM 01 313KA 1257 940019 EXTERNAL LOADS READING LIGHT ERRATIC. 1 G 7 1 4F NT TR7BO 1998010800863 19980108 00863 SO 1998 1 8 98ZZZX141 1 19971231 G 2730 12027655021 CONTROL CABLE EMB 120 EMB120ER 3260203 SO BS 13945 FRAYED B MZ4R K NONE O OTHER IN INSP/MAINT 1 SO 17 PHMGH 1200149 DURING THE PERFORMANCE OF A 5A CHECK INSPECTION, THE AFT ELEVATOR CONTROL CABLE WAS FOUND FRAYED AT STA 13945.0. THE CA BLE WAS NOT IN CONTACT WITH ANY OTHER OBJECT IN THE AREA EXCEPT FOR THE PHENOLIC GUIDE. NO WEAR WAS OBSERVED ON THE GUI DE. ACFT TT: 11,229.9 HOURS. ACFT LANDINGS: 11,797. 2 L 7 2 4T RT A31SO 1998041000267 19980410 00267 SW 1998 4 10 98ZZZX1412 1 19970820 G 7712 APTE16775D TRANSMITTER KAMAN K1200 K1200 05625F6 SW TORQUE FLUCTUATIONS D K NONE O OTHER IN INSP/MAINT 1 NM 01 313KA 912 47554260 940019 PILOT REPORTED TORQUE INDICATOR FLUCTUATIONS 1.0 PSI TO 2.0 PSI. RMEOVED S/N 4755-4-260. TOTAL TIME 912.0 HOURS. 1 G 7 1 4F NT TR7BO 1998041000268 19980410 00268 SW 1998 4 10 98ZZZX1413 1 19971230 G 7712 APTE16775D TRANSMITTER KAMAN K1200 K1200 05625F6 SW TORQUE FLUCTUATIONS D K NONE O OTHER IN INSP/MAINT 1 NM 01 313KA 518 49904109 940019 PILOT REPORTED TORQUE INDICATOR FLUCTUATIONS 1.0 PSI TO 2.0 PSI. REMOVED S/N 4990-4-109. TOTAL TIME 517.8 HOURS. 1 G 7 1 4F NT TR7BO 1998041000269 19980410 00269 SW 1998 4 10 98ZZZX1414 1 19970621 G 7931 K983133001 INDICATOR KAMAN K1200 K1200 05625F6 SW ENG OIL PRESS FAILED D O OTHER O OTHER NR NOT REPORTED 1 NM 01 313KA 567 706765 940019 PILOT REPORTED ENGINE OIL PRESSURE DROPPED TO ZERO. NO CAUTION LIGHT. INSTALLED NEW INDICATOR, OPERATION NORMAL. 1 G 7 1 4F NT TR7BO 1998041000270 19980410 00270 SW 1998 4 10 98ZZZX1415 1 19970327 G 2550 H19432 INDICATOR KAMAN K1200 K1200 05625F6 SW LOAD ON HOOK ERRATIC D K NONE O OTHER EX EXTERNAL LOAD 1 NM 01 313KA 141B 940019 LOAD ON HOOK INDICATOR ERRATIC. TT 71 HOURS. 1 G 7 1 4F NT TR7BO 1998041000271 19980410 00271 SW 1998 4 10 98ZZZX1416 1 19970507 G 2550 H19432 INDICATOR KAMAN K1200 K1200 05625F6 SW LOAD ON HOOK ERRATIC D K NONE O OTHER EX EXTERNAL LOAD 1 NM 01 313KA 146B 940019 LOAD ON HOOK INDICATOR ERRATIC. 1 G 7 1 4F NT TR7BO 1998041000272 19980410 00272 SW 1998 4 10 98ZZZX1417 1 19971230 G 2550 H19432 INDICATOR KAMAN K1200 K1200 05625F6 SW LOAD ON HOOK ERRATIC D K NONE O OTHER EX EXTERNAL LOAD 1 NM 01 313KA 141B 940019 LOAD ON HOOK INDICATOR ERRATIC. TT: 1,165 HOURS. 1 G 7 1 4F NT TR7BO 1998010800864 19980108 00864 GL 1998 1 8 98ZZZX142 3 19971212 G 6114 D4883C55 HUB MCAULY 2AF34C 2AF34C55 GL NR 2 SOCKET CRACKED B ME4R K NONE O OTHER IN INSP/MAINT 1 SO 19 723855 723855 UPON INSPECTION, HUB WAS FOUND CRACKED IN BLADE SOCKET NR 2, ROW 1, AND ROW 3. HUB HAS BEEN SCRAPPED. 5 C P5EA 1998041000783 19980410 00783 CE 1998 4 10 98ZZZX1423 1 19971105 G 2820 714144 FUEL LINE BBAVIA 8 8KCAB 2110612 CE HEADER TANK LEAKING D A K NONE K FLUID LOSS IN INSP/MAINT 1 NM 01 276R 100 25 71393 PILOT REPORTED ODOR OF FUEL IN THE COCKPIT. INSPECTION REVEALED FUEL SEEPAGE WHERE THE TUBE ASSEMBLY CONNECTS TO THE TE E AT THE HEADER TANK INLET (THIS IS THE TUBE ASSY FROM THE LEFT WING TANK). THE FLARE WAS FOUND TO HAVE AN OUTSIDE DIAM ETER LARGER THAN THE ASSOCIATED M520819 SLEEVE AND THE TUBE ASSEMBLY WAS EXCESSIVELY MISALIGNED WITH THE TEE CAUSING EXC ESSIVE PRELOAD RESULTING IN DAMAGE TO THE TUBE DURING ASSEMBLY. GOOD STANDARD PRACTICE WOULD PREVENT THIS KIND OF DAMAG E. 1 H 7 1 3O A21CE 1998010800865 19980108 00865 1998 1 8 98ZZZX143 4 19971215 G 2562 DEFT1 ELT DEFT G-SWITCH FAILED B BXSR K NONE O OTHER IN INSP/MAINT 1 EA 09 650 6452 ELT WAS REPAIRED 1-30-96 BY THE MFG, W.O. 1995. UNIT SIGNAL 'SOUNDED' WEAK, AND THE G-SWITCH DID NOT ACTIVATE WITH EITH ER A THROWING MOTION OR A SMACK AGAINST A SYSTEM OBJECT. 1998010800867 19980108 00867 SO 1998 1 8 98ZZZX145 1 19970401 G 3222 6705002 STRUT ASSY PIPER PA32 PA32301 7103207 SO NLG LOOSE B EWCR K NONE O OTHER IN INSP/MAINT 1 SO 05 239A 202 3246022 PLUG IN BOTTOM OF TUBE NOT SECURED BY BOLT THROUGH TUBE AND LANDING GEAR FORK. AIRCRAFT WAS INVOLVED IN A GEAR UP LANDI NG APPROXIMATELY 8 MONTHS AGO. 1 L 7 1 3O A3SO 1998041700599 19980417 00599 SO 1998 4 17 98ZZZX1457 2 19971214 G 8500 ENGINE LUSCOM 8 8A 8190104 SO CONT A65 A658 17003 SO POWER SECTION MALFUNCTIONED G A UNSCHED LANDING Y ENGINE STOPPAGE NR NOT REPORTED 1 GL 03 72013 5147 121 3440 665171646 PILOT REPORTED ENGINE QUIT IN-FLIGHT, PILOT EXECUTED AN EMERGENCY OFF-AIRPORT LANDING. MINOR DAMAGE TO AIRCRAFT. ENGIN E INSPECTED, BUT NOT DISASSEMBLED, ENGINE OIL WAS CLEAN, NO METAL FOUND IN OIL, 6 GALLONS OF FUEL (APPROX) FOUND IN TANK S, ENGINE COMPRESSION APEARS NORMAL, ENGINE TURNS SMOOTH AND NORMAL NOT TIGHT FROM POSSIBLE LOCK-UP. MAGNETO TIMER OK. NO DISCREPANCIES FOUND. 1 H 7 1 3O 3 O A694 E205 1998010800868 19980108 00868 SO 1998 1 8 98ZZZX146 1 19971222 G 2913 1213HBG310A PUMP PIPER PA31 PA31350 7103110 SO RT HYDRAULIC SHEARED D K NONE O OTHER IN INSP/MAINT 1 SO 05 35816 440 14933297 318052091 PILOT REPORTED TO MAINTENANCE THAT THE LANDING GEAR SLOW TO CYCLE. HYDRAULIC PUMP CHECK PERFORMED. RIGHT PUMP INOPERAB LE. UPON REMOVAL, FOUND RIGHT ENGINE DRIVEN HYDRAULIC PUMP SHAFT SHEARED. OPENED PUMP ASSY FOR VISUAL INSPECTION AND F OUND ONE OF THE TWO CHECK VALVE/RESTRICTORS MISSING FROM ITS PLACE. FOUND PART OF MISSING CHECK VALVE/RESTRICTOR IN AIR CRAFT HYDRAULIC FILTER. BELIEVE THIS PART TO HAVE DISLODGED AND WENT THROUGH PUMP GEARS AND JAMMED THEM, 'SHEARING SHAF T'. 1 L 7 2 3O A20SO 1998010800869 19980108 00869 CE 1998 1 8 98ZZZX147 1 19971217 G 5540 MS244624 BEARING CESSNA 441 441 2076020 CE RUDDER HINGE CORRODED D A K NONE O OTHER IN INSP/MAINT 1 SO 15 4441T 4461 4410133 UPON REMOVAL OF RUDDER FOR REPAIR TO RUDDER TOP AND MIDDLE RUDDER NEEDLE, BEARING ASSYS FELL APART, I.E., NEEDLES FELL O UT. PRESENTLY, CESSNA HAS NO INSPECTION INTERVALS FOR THESE BEARINGS. THERE NEEDS TO BE SOME KIND OF INSPECTION INTERV AL IN WHICH THE BEARINGS ARE INSPECTED AND LUBRICATED AT A SPECIFIC TIME. 1 L 7 2 3T RT A28CE 1998010800870 19980108 00870 SO 1998 1 8 98ZZZX148 2 19971212 G 8530 653454 CYLINDER BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO ENGINE NR 6 FAILED E A UNSCHED LANDING E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS CR CRUISE 1 SW 05 577W 3 TH375 287355R DURING A FLIGHT JUST AFTER TAKEOFF, PILOT REPORTED THE ENGINE PERIODICALLY LOST POWER AND VIBRATED. UPON LANDING, PILOT ALSO NOTICED A CONSIDERABLE AMOUNT OF OIL ON THE NACELLE. UPON INVESTIGATION, DISCOVERED THE NR 6 CYLINDER PUSH ROD WA S BENT AND PUSH ROD TUBE HAD BROKEN. AFTER CYLINDER REMOVAL, IT WAS DETERMINED A SCREW HAD BEEN INJESTED INTO THIS CYLI NDER. GOOD HOUSEKEEPING PROCEDURES AND ACCOUNTABILITY OF HARDWARE DURING INSTALLATION WOULD REDUCE THE POSSIBILITY OF T HIS IN THE FUTURE. 1 L 7 2 3O 3 O 3A16 E5CE 1998010800871 19980108 00871 CE 1998 1 8 98ZZZX149 1 19971213 G 2140 83D512 SOLENOID BEECH 76 76 1153005 CE HEATER FUEL FAILED H K NONE O OTHER IN INSP/MAINT 1 WP 07 6046U 120 ME195 COMPLAINT OF OVERHEAT AND SHUT DOWN OF HEATER DURING GROUND OPERATION. INVESTIGATION OF HEATER OPERATION SHOWED HEATER NOT SHUTTING DOWN WITH TEMP CONTROL SWITCH. FOUND FUEL SOLENOID NOT CLOSING. OVERTEMP SENSOR WOULD THEN POP. FOUND BL ACK SEALANT INSIDE SOLENOID. FACTORY (JANAERO DEVICES) NOTIFIED IMMEDIATELY. THIS SOLENOID WAS ON NEW HEATER WITH 120. 3 HOURS SINCE NEW. 1 L 7 2 3O A29CE 1998010800074 19980108 00074 EU 1998 1 8 98ZZZX15 1 19971128 G 5753 T700A5755060101 CARRIER SOCATA TBM TBM700 8682000 EU FLAP BEARING CRACKED B CB5Y K NONE O OTHER IN INSP/MAINT 1 EA 35 79Z 789 19 WHILE CARRYING OUT A 100-HOUR REPETITIVE INSPECTION IAW DGAC AD 94-110, AND SB 70-048-57, IT WAS NOTED THAT ALL 4 FLAP B EARING CARRIAGES WERE CRACKED. THE CRACKS WERE NOT LOCATED IN THE INSPECTION AREAS SHOWN IN THE SB 70-048-57, BUT WERE LOCTED IN THE WEBS. ALL 4 FLAP BEARING CARRIAGES WERE REPLACED WITH MODIFIED ITEMS BEFORE FURTHER FLIGHT. 1 L 7 1 3T RT A60EU 1998010800872 19980108 00872 SW 1998 1 8 98ZZZX150 1 19971201 G 7922 53E22144 VALVE MOONEY M20 M20E 5870212 SW THERMO BYPASS FAILED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 11 RECEIVED PN 53E22144 AND INSTALLED, OIL TEMPERATURE PROBLEM. REMOVED AND HAD TRUED PER SB 1316. FURTHER INSPECTION SHO WED NUT IMPROPERLY CRIMPED ON NEW VALVE, SEAT COULD NOT SIT SQUARELY ON NUT, NO THREADS PROTRUDED OUT THE TOP OF THE CRI MPED NUT. REPLACED WITH NEW VALVE THAT HAD THREADS OUT THE TOP OF THE NUT. 1 L 7 1 3O 2A3 1998010800873 19980108 00873 SO 1998 1 8 98ZZZX151 1 19971210 G 3230 4194902 ROD ASSY PIPER PA31 PA31350 7103110 SO LT MLG SEIZED D K NONE P NO WARNING INDICATION AP APPROACH 1 SO 17 36BM 3209 318252008 CUSTOMER REPORTED THE LT MLG DOWNLOCK LIGHT DID NOT ILLUMINATE WHEN THE LANDING GEAR WAS EXTENDED. AIRCRAFT LANDED WITH OUT INCIDENT. INSPECTION REVEALED THE PN 41949-02 LANDING GEAR LOCK ROD ASSY WAS SEIZED DUE TO LACK OF LUBRICATION PREV ENTING THE DOWNLOCK HOOK FROM FULLY ENGAGING. SUBMITTER STATED THE MM CALLS FOR A 100-HOUR LUBE. A MORE FREQUENT LUBRI CATION MIGHT BE ADVISABLE IN WET/CORROSIVE ENVIRONMENTS. 1 L 7 2 3O A20SO 1998010800874 19980108 00874 SW 1998 1 8 98ZZZX152 1 19971201 G 2820 LINE MOONEY M20 M20C 5870208 SW GASCOLATOR CHAFED D A K NONE O OTHER IN INSP/MAINT 1 SW 99 78987 2600 2021 DURING ANNUAL INSPECTION, FUEL LINE WAS FOUND CHAFED NEARLY THROUGH AT HALF-WAY POINT. CHAFING CAUSED BY CARBURETOR HEA T CONTROL CABLE WHICH PASSES CLOSE TO THIS LINE WHERE IT GOES THROUGH THE FIREWALL. AREA IS VERY DIFFICULT TO INSPECT R EQUIRING A MIRROR AND FLASHLIGHT. CHAFING HAD BEEN OCCURRING FOR SOME TIME. FUEL LINE WAS REMOVED, REPLACED, AND ANTI- CHAFE MATERIAL APPLIED TO CARBURETOR HEAT CONTROL CABLE. 1 L 7 1 3O 2A3 1998010800875 19980108 00875 CE 1998 1 8 98ZZZX153 1 19971226 G 2720 151350013 SUPPORT ASSY CESSNA 337 337A 2075704 CE RUDDER BAR CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 09 9739D 3370466 PILOT COMPLAINED OF INCONSISTENT RUDDER TRIM INPUTS TO MAINTAIN COORDINATED FLIGHT AND 'FUNNY' RUDDER CONTROL INPUTS. I NSPECTION REVEALED BOTH CENTER RUDDER BAR SUPPORTS CRACKED ALLOWING RUDDER BAR TO WANDER WHEREVER IT WANTED TO GO. AIRC RAFT HAS HISTORY OF LANDING ACCIDENTS WHEN REGISTERED IN A FOREIGN COUNTRY, BUT THIS IS A NEW DISCREPANCY WITH NO PREVIO US CONTROL SYSTEM PROBLEMS. 1 H 7 2 3O A6CE 1998010800876 19980108 00876 CE 1998 1 8 98ZZZX154 1 19971226 G 2720 151350014 SUPPORT ASSY CESSNA 337 337A 2075704 CE RUDDER BAR CRACKED D A K NONE O OTHER IN INSP/MAINT 1 SW 09 9739D 3370466 PILOT COMPLAINED OF INCONSISTENT RUDDER TRIM INPUTS TO MAINTAIN COORDINATED FLIGHT AND 'FUNNY' RUDDER CONTROL INPUTS. I NSPECTION REVEALED BOTH CENTER RUDDER BAR SUPPORTS CRACKED ALLOWING RUDDER BAR TO WANDER WHEREVER IT WANTED TO GO. AIRCR AFT HAS HISTORY OF LANDING ACCIDENTS WHEN REGISTERED IN A FOREIGN COUNTRY, BUT THIS IS A NEW DISCREPANCY WITH NO PREVIOU S CONTROL SYSTEM PROBLEMS. 1 H 7 2 3O A6CE 1998042400340 19980424 00340 SO 1998 4 24 98ZZZX1546 1 19971119 G 7603 CONTROL CABLE PIPER PA31T PA31T 7103124 SO RT ENG THROTTLE BROKEN D K NONE O OTHER IN INSP/MAINT 1 WP 11 155CA 7358 31T7820024 RIGHT THROTTLE CABLE BROKE DURING ENGINE POWER UP. PART TOTAL TIME: 7,358.0 HOURS. 1 L 7 2 3T A8EA 1998010800877 19980108 00877 WP 1998 1 8 98ZZZX155 2 19971202 G 7261 8961734 OIL JET 310180711 MTSBSI MU2 MU2B60 5780460 CE GARRTT TPE331 TPE33110 01514 WP GEARBOX BROKE B DJFR E ENGINE SHUTDOWN O OTHER NR NOT REPORTED 1 EA 23 46AK 3227 P1767 754SA P36103C OIL JET BROKE AND LODGED ITSELF IN PLANETARIES AND RING GEAR. RING GEAR BROKE AND COUPLER SHAFT SHEARED RESULTING IN EN GINE SHUT DOWN. 1 H 7 2 3T 4 T RT A10SW E4WE 1998042400346 19980424 00346 SW 1998 4 24 98ZZZX1552 1 19971229 G 3260 ISE13 SWITCH GULSTM 112 112TCA 7630307 SW LT MLG DOWNLOCK FAILED B MCIR O OTHER P NO WARNING INDICATION CL CLIMB 1 WP 11 4708W 1520 13302 LEFT MLG DOWNLOCK SWITCH FAILED TO CLOSE GIVING NO GEAR DOWN INDICATION. FOUND SWITCH INOPERATIVE. REPLACED SWITCH. AI RCRAFT LANDED WITHOUT INCIDENT. RECOMMEND STURDIER SWITCH. 1 L 7 1 3O A12SO 1998042400351 19980424 00351 CE 1998 4 24 98ZZZX1557 1 19971125 G 5330 07133343 SKIN CESSNA 182 182R 2072731 CE LT FORWARD CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 11 9557X 2758 18268553 THE (FUEL CHECK) STEPS ARE MOUNTED WITH AN3 BOLTS ATTACHED TO THE ACFT'S SKIN, P/N 0713334-3, AND P/N 0713334-4, LEFT AN D RIGHT FORWARD SKINS. THE UPPER BACK BOLT WAS THROUGH THE SKIN AND THE BULKHEAD AT STA 1700. THE USE OF THE STEP CAUS ED THE BOLT TO BREAK THE FLANGE ON THE BULKHEAD AND CAUSED A CRACK IN THE OUTER SKIN THROUGH THE BOLT HOLE ABOUT 2 INCHE S LONG. THE UPPER FORWARD BOLT IS ATTACHED TO THE SKIN ONLY WITH AN OVERSIZED WASHER AND HAS SEVERELY DEFORMED THE OUTE R SKIN AT THIS LOCATION. SUBMITTER STATED THIS AREA NEEDS TO BE REINFORCED IF STEPS ARE TO BE USED. 1 L 7 1 3O NT 3A13 1998042400352 19980424 00352 CE 1998 4 24 98ZZZX1558 1 19971125 G 5330 07133343 SKIN CESSNA 182 182R 2072731 CE RT FORWARD CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 11 9557X 2758 18268553 THE (FUEL CHECK) STEPS ARE MOUNTED WITH AN3 BOLTS ATTACHED TO THE ACFT'S SKIN, P/N 0713334-3, AND P/N 0713334-4, LEFT AN D RIGHT FORWARD SKINS. THE UPPER BACK BOLT WAS THROUGH THE SKIN AND THE BULKHEAD AT STA 1700. THE USE OF THE STEP CAUS ED THE BOLT TO BREAK THE FLANGE ON THE BULKHEAD AND CAUSED A CRACK IN THE OUTER SKIN THROUGH THE BOLT HOLE ABOUT 2 INCHE S LONG. THE UPPER FORWARD BOLT IS ATTACHED TO THE SKIN ONLY WITH AN OVERSIZED WASHER AND HAS SEVERELY DEFORMED THE OUTE R SKIN AT THIS LOCATION. SUBMITTER STATED THIS AREA NEEDS TO BE REINFORCED IF STEPS ARE TO BE USED. 1 L 7 1 3O NT 3A13 1998010800878 19980108 00878 CE 1998 1 8 98ZZZX156 1 19971201 G 2820 26001017 LINE CESSNA 208 208B 2073701 CE LT/RT FUEL CHAFED D A K NONE O OTHER IN INSP/MAINT 1 SW 99 410GV 397 208B0632 FORWARD FUEL LINE COMING FROM THE WING AS IT ENTERS RESERVOIR TANK COMPARTMENT. THERE ARE THREE AN3 BOLTS RETAINING A S EAL IN THE SIDE WALL OF COMPARTMENT. FORWARD BOLT CHAFING LINE, BOLT TURNED OUT TO BE AN3-4A, PARTS MANUAL CALLS FOR AN 3-3A. BOTH SIDES OF AIRCRAFT REVEALED THE SAME DISCREPANCY. AIRCRAFT TOTAL TIME 396.5. HOURS. 1 H 7 1 3T A37CE 1998010800879 19980108 00879 1998 1 8 98ZZZX157 4 19971222 G 3460 101741021 POWER SUPPLY AMD FALC50 FALCON2000 2730170 NM FLT MGMT SYSTEM FAILED B QM1R H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 EA 13 77A 660 17 ON A TRANS-OCEANIC FLIGHT, THE NR 1 FMS CIRCUIT BREAKER TRIPPED. UPON RESETTING BY THE AIR CREW, THE NR 1 FMS COMPUTER BEGAN TO SMOKE. AIR CREW SHUT DOWN UNIT. UNIT RETURNED TO MANUFACTURER FOR REPAIRS. REPAIR BY MANUFACTURER REVEALED T HE FAILURE WAS CAUSED BY THE INTERFACE BOARD, PN 00101765. 2 K 7 3 4F RT A50NM 1998042400766 19980424 00766 EU 1998 4 24 98ZZZX1579 1 19971017 G 6410 355A09103601 BEARING SET SNIAS 350 AS350B2 8680813 EU T/R DELAMINATION B VY1R K NONE O OTHER IN INSP/MAINT 1 SW 19 31AS 493 2689 BEARING REMOVED DUE TO DELAMINATION IN EXCESS OF LIMITS. REPLACED WITH NEW PART. 1 G 7 1 3U H9EU 1998010800880 19980108 00880 CE 1998 1 8 98ZZZX158 1 19971217 G 5540 MS244624 BEARINGS CESSNA 441 441 2076020 CE RUDDER HINGE FAILED D K NONE O OTHER IN INSP/MAINT 1 SO 15 84LJ 4268 4410084 UPON REMOVAL FOR STRIP AND PAINT, TOP AND MIDDLE RUDDER NEEDLE BEARING ASSYS FELL APART, I.E., NEEDLES FELL OUT. UNITS WERE RUSTY ALSO. SUBMITTER STATED PRESENTLY THERE IS NO INSPECTION INTERVALS FOR THESE BEARINGS. AIRCRAFT HAS 4,268 HO URS TT AT TIME OF OCCURRENCE. 1 L 7 2 3T RT A28CE 1998042400767 19980424 00767 EU 1998 4 24 98ZZZX1580 1 19971017 G 6520 350A33215300 BEARING SNIAS 350 AS350B2 8680813 EU T/R DELAMIANTED B VY1R K NONE O OTHER IN INSP/MAINT 1 SW 19 31AS 493 2689 BEARING REMOVED DUE TO DELAMINATION IN EXCESS OF LIMITS. REPLACED WITH NEW PART. 1 G 7 1 3U H9EU 1998010800075 19980108 00075 EU 1998 1 8 98ZZZX16 1 19971128 G 5753 T700A5755063100 CARRIER SOCATA TBM TBM700 8682000 EU FLAP BEARING CRACKED B CB5Y K NONE O OTHER IN INSP/MAINT 1 EA 35 79Z 789 19 WHILE CARRYING OUT A 100-HOUR REPETITIVE INSPECTION IAW DGAC AD 94-110, AND SB 70-048-57, IT WAS NOTED THAT ALL 4 FLAP B EARING CARRIAGES WERE CRACKED. THE CRACKS WERE NOT LOCATED IN THE INSPECTION AREAS SHOWN IN THE SB 70-048-57, BUT WERE LOCTED IN THE WEBS. ALL 4 FLAP BEARING CARRIAGES WERE REPLACED WITH MODIFIED ITEMS BEFORE FURTHER FLIGHT. 1 L 7 1 3T RT A60EU 1999013000001 19990130 00001 GL 1999 1 30 98ZZZX1648 1 19971231 G 5102 GAS VALVE CAMRON R420 R420 GL BALLOON ENVELOPE MALFUNCTIONED C K NONE O OTHER CR CRUISE 1 WP 07 GJNEE 3 4232 VALVE AND/OR VALVE INDICATOR SWITCH WORKED SPORADICALLY. DURING FLIGHT, PILOT WAS UNABLE TO POSITIVELY VERIFY OPENING O F VALVE WHEN VALVE LINE WAS PULLED. 1 B 0 0 3X NC EXPA1B00 1999013000002 19990130 00002 GL 1999 1 30 98ZZZX1649 1 19971231 G 5102 CHIMNEY RIP CAMRON R420 R420 GL BALLOON ENVELOPE FAILED C A O OTHER O OTHER LD LANDING 1 WP 07 GJNEE 3 4232 CHIMNEY RIP FAILED TO OPEN WHEN PULLED PREVENTING DEFLATION AND RESULTING IN PROPERTY DAMAGE. UPON LANDING, 3 OF 4 SAFE TY TIES WERE PULLED OPEN BY THE PILOT, BUT THE FOURTH WOULD NOT BREAK. THE FULL WEIGHT OF THE PILOT (210 POUNDS) JUMPIN G 20 INCHES WITH THE RED LINE, WOULD NOT ACTUATE THE RIP. ONCE THE BALLOON WAS BROUGHT UNDER CONTROL, 9 FIREMEN WERE LI FTED OFF THE GROUND BY THE RED LINE BEFORE THE CHIMNEY OPENED. 1 B 0 0 3X NC EXPA1B00 1998011500082 19980115 00082 CE 1998 1 15 98ZZZX166 1 19971217 G 2750 0510105193 CONTROL CABLE CESSNA 172 172R 2072401 CE FLAP MISINSTALLED D S K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 361ES 471 17280011 DURING 100 HOUR INSPECTION, AILERON CABLE WAS BEING REPLACED. FOUND FLAP DIRECT CABLE NOT SAFETIED. THIS CABLE IS LOCA TED BEHIND HEADLINER. IT WOULD HAVE NEVER BEEN DETECTED IF HEADLINER WAS INSTALLED. SUBMITTER RECOMMENDED ACCESS PLATE TO INSPECT CABLES DURING ROUTINE INSPECTION. 1 H 7 1 3O NT 3A12 1998050800885 19980508 00885 EA 1998 5 8 98ZZZX1664 2 19971231 G 7414 10682016 DISTRIBUTOR GEAR ELECTROSYS D6LN3200 PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA MAGNETO CRACKED B L YECR K NONE O OTHER IN INSP/MAINT 1 NM 09 59829 1091 142 L189515GR 317652081 MAGNETO WAS INSTALLED ON LEFT ENGINE 11-24-97, AND WAS REMOVED 12-31-97 DUE TO CRACKED, MISSING TOOTH. PREVIOUS MAGNETO HAD SUFFERED FAILURES OF BOTH DIST GEARS. SUSPECT TORSIONAL VIBRATION IN ENGINE. 1 L 7 2 3O 3 O A20SO E14EA 1998050800886 19980508 00886 EA 1998 5 8 98ZZZX1665 2 19971124 G 7414 10682016 DISTRIBUTOR GEAR ELECTROSYS D6LN2230 PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA MAGNETO CRACKED B P YECR K NONE O OTHER IN INSP/MAINT 1 NM 09 59829 1601 6070845R 317652081 11-24-97, MAGNETO WAS REMOVED FROM LEFT ENGINE OF N NR 59829 DUE TO FAILED DISTRIBUTOR GEAR TEETH. MAGNETO HAD 1,601.16 HOURS SINCE OVERHAUL BY ELECTROSYSTEMS, INC., HOWEVER, GEARS MAY NOT HAVE BEEN NEW AT MAGNETO OVERHAUL. 1 L 7 2 3O 3 O A20SO E14EA 1998011500083 19980115 00083 CE 1998 1 15 98ZZZX167 1 19971212 G 2710 0510105360 CONTROL CABLE CESSNA 172 172R 2072401 CE RT AILERON FRAYED D S A K NONE O OTHER IN INSP/MAINT 1 WP 07 361ES 471 17280011 WHILE PERFORMING A 100-HOUR INSPECTION, FOUND THE RIGHT HAND AILERON CABLE FRAYED/TANGLED AS IF SOMETHING MIGHT HAVE GOT BETWEEN IT AND THE PULLEY IN THE SAME AREA AS THE PULLEY. ALSO, FOUND A ROUND FILE APPROXIMATELY .1875 INCH DIAMETER. IT IS UNCLEAR IF THE FILE GOT BETWEEN THE CABLE AND PULLEY. THE AREA IN CONCERN IS THE PULLEY AT THE FLOOR AND JUST BE HIND THE DOOR ON THE PILOT'S SIDE. 1 H 7 1 3O NT 3A12 1998011500084 19980115 00084 CE 1998 1 15 98ZZZX168 1 19971217 G 2710 0510105360 CONTROL CABLE CESSNA 172 172R 2072401 CE LEFT AILERON MISINSTALLED D S A K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 361ES 471 17280011 DURING 100-HOUR INSPECTION, FOUND LEFT AILERON DIRECT CABLE TURNBUCKLE NOT SAFETIED. THE TURNBUCKLE IS NOT VISIBLE WITH THE HEADLINER INSTALLED. IT WOULD HAVE BEEN UNABLE TO DETECT HAD THE HEADLINER NOT BEEN REMOVED TO REPLACE DAMAGED AIL ERON CABLE. RECOMMEND RE-DESIGN OF HEADLINER TO GAIN ACCESS TO CABLES DURING ROUTINE INSPECTIONS. 1 H 7 1 3O NT 3A12 1998011500085 19980115 00085 EU 1998 1 15 98ZZZX169 1 19971209 G 3610 BYLB504231 VALVE AMD FALC20 FALCON200 2730150 EU BLEED VENTURI MISWIRED B A UO2R K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 19 50MG 431 507 AIRCRAFT HAD A DEFECTIVE VENTURI VALVE (19H). ORDERED AND INSTALLED AN OVERHAULED VALVE. THIS VALVE DID NOT WORK. THE OPEN INDICATION MICROSWITCH IS WIRED INCORRECTLY AND THERE IS ALOT OF PLAY ON THE BUTTERFLY DRIVE ASSEMBLY. ORDERED AN D INSTALLED ANOTHER VALVE FROM DIFFERENT VENDOR. WORKED OK. THE OVERHAUL MANUAL FOR THIS VALVE HAS SEVERAL ERRORS IN I T ALSO. 2 L 7 2 4F RT A7EU 1998050800918 19980508 00918 WP 1998 5 8 98ZZZX1696 1 19970420 G 5400 FORMER DOUG DC10 DC1010 3022110 WP NR 2 ENG PYLON CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 23 910SF AVB709627 46524 MULTIPLE CRACKS WERE FOUND IN FORMER WHICH IS LOCATED IN AREA ABOVE NR 2 ENGINE. FORMER IS A PART OF THE AFT PYLON STANG AREA. 2 L 7 3 4F A22WE 1998010800076 19980108 00076 EU 1998 1 8 98ZZZX17 1 19971128 G 5753 T700A5755063101 CARRIER SOCATA TBM TBM700 8682000 EU FLAP BEARING CRACKED B A CB5Y K NONE O OTHER IN INSP/MAINT 1 EA 35 79Z 789 19 WHILE CARRYING OUT A 100-HOUR REPETITIVE INSPECTION IAW DGAC AD 94-110, AND SB 70-048-57, IT WAS NOTED THAT ALL 4 FLAP B EARING CARRIAGES WERE CRACKED. THE CRACKS WERE NOT LOCATED IN THE INSPECTION AREAS SHOWN IN THE SB 70-048-57, BUT WERE LOCATED IN THE WEBS. ALL 4 FLAP BEARING CARRIAGES WERE REPLACED WITH MODIFIED ITEMS BEFORE FURTHER FLIGHT. 1 L 7 1 3T RT A60EU 1998011500086 19980115 00086 CE 1998 1 15 98ZZZX170 1 19971227 G 2730 05130631 BRACKET CESSNA 172 172G 2072420 CE ELEV BELLCRANK CRACKED D L A K NONE O OTHER IN INSP/MAINT 1 SW 01 4477L 5451 17254572 INSPECTION OF 4 LOOSE RIVETS ON BELLY SKIN BETWEEN WING STRUT LOWER ATTACH POINTS REVEALED THE 'ELEVATOR BELLCRANK BRACK ET', PN 051306301, HAD BEEN FLEXING. ON CLOSER EXAMINATION, MANY CRACKS WERE FOUND IN THE BEND RADII OF THE FORWARD AND AFT FLANGES WITH COMPLETE SEPARATION OF THE LEFT FORWARD FLANGE. 1 H 7 1 3O NT 3A12 1998011500087 19980115 00087 CE 1998 1 15 98ZZZX171 1 19970824 G 2520 SEAT ATTACH CESSNA 170 170 2072302 CE AFT SEAT WRONG PART G L K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 13 3964V 3133 18283 DURING ACCIDENT INVESTIGATION, FOUND RIVNUTS WERE SUBSTITUTED FOR 3 NAS684A3 NUTPLATES FOR REAR SEAT ATTACH HARDWARE. T HE RIVNUTS EXTRUDED THROUGH THE HOLES IN THE STRUCTURE AND ALLOWED THE REAR SEAT TO PARTIALLY BREAK LOOSE. PARTS MANUAL FIG 20, ITEM NR 12. 1 H 7 1 3O NT A799 1998011500088 19980115 00088 SO 1998 1 15 98ZZZX172 2 19970824 G 7310 TEE FITTING CESSNA 170 170 2072302 CE CONT C145 C145* 17012 SO CARBURETOR INLET BROKEN G K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 13 3964V 20 18283 8214D32 INVESTIGATION OBSERVED COMMON HARDWARE FITTINGS HAD BEEN INSTALLED IN LIEU OF AN8266D AS DISPLAYED IN CESSNA PARTS MANUA L FIG 34-32. 1 H 7 1 3O 3 O NT A799 E253 1998051500275 19980515 00275 SO 1998 5 15 98ZZZX1723 1 19970407 G 2710 62102000 SUPPORT PIPER PA32 PA32300 7103212 SO AIL BELLCRANK CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 09 99WD 2221 327540031 DURING AN ANNUAL INSPECTION, BOTH UPPER AILERON BELLCRANKS SUPPORT BRACKETS WERE FOUND CRACKED. AILERONS WERE NOT PROPE RLY RIGGED AND BELLCRANK WAS NOT CONTACTING AFT STUDS CAUSING A TWISTING ACTION ON SUPPORTS IN WINDY CONDITIONS. 1 L 7 1 3O A3SO 1998051500276 19980515 00276 SO 1998 5 15 98ZZZX1724 1 19970407 G 2710 62102001 SUPPORT PIPER PA32 PA32300 7103212 SO AIL BELLCRANK CRACKED D A K NONE O OTHER IN INSP/MAINT 1 NM 09 99WD 2221 327540031 DURING AN ANNUAL INSPECTION, BOTH UPPER AILERON BELLCRANKS SUPPORT BRACKETS WERE FOUND CRACKED. AILERONS WERE NOT PROPE RLY RIGGED AND BELLCRANK WAS NOT CONTACTING AFT STUDS CAUSING A TWISTING ACTION ON SUPPORTS IN WINDY CONDITIONS. 1 L 7 1 3O A3SO 1998011500398 19980115 00398 CE 1998 1 15 98ZZZX173 1 19971219 G 7120 10591001077 MOUNT BEECH 76 76 1153005 CE ENGINE MISMANUFACTURED D S A K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 21 2009X 4677 ME66 UPON ARRIVAL OF A NEW ENGINE MOUNT, DISCOVERED TWO OF THE WELD JOINTS WERE DEFECTIVE. THE GUSSET PLATES ON BOTH UPPER B RACE ARMS WERE NOT WELDED DOWN, ONLY TACK-WELDED TO THE BRACE ARMS. THE MANUFACTURER SAID THAT ALTHOUGH IT WAS NOT CORR ECT, SEVERAL UNITS HAD BEEN SHIPPED WITH THIS CONDITION. SUBMITTER RECOMMENDED THAT ANY DUTCHESS OWNERS THAT HAVE REPLA CED THEIR ENGINE MOUNTS WITH KOSOLA UNITS (LEFT AND RIGHT ARE IDENTICAL), HAVE THE UPPER GUSSET PLATES INSPECTED FOR GAP S UNDER THE PLATES. 1 L 7 2 3O A29CE 1998011500399 19980115 00399 CE 1998 1 15 98ZZZX174 1 19971203 G 2160 1173542 SWITCH CESSNA 650 650 2076802 CE CABIN OVERHEAT FAILED B GJQR K NONE O OTHER IN INSP/MAINT 1 NM 01 39WP 6239 366 650039 DURING SCHEDULED CALIBRATION (OPERATION 12) INSPECTION, CABIN OVERHEAT SWITCH FAILED TEST DUE TO OUT OF TOLERANCE. REPL ACED SWITCH WITH SERVICEABLE ASSEMBLY. NEW SWITCH WAS VERIFIED IN TOLERANCE PRIOR TO INSTALLATION. 2 L 7 2 4F A9NM 1998011500400 19980115 00400 CE 1998 1 15 98ZZZX175 1 19971209 G 3240 1013810125 VALVE BEECH B300 B300 1159232 CE RT BRAKE DEICE FAILED B GJQR K NONE O OTHER IN INSP/MAINT 1 NM 01 4S 313 0531 FL107 PILOT REPORTED RT BRAKE DE-ICE DOES NOT ILLUMINATE ON CYCLE AFTER LANDING OR BEFORE TAKEOFF. REPLACED VALVE ASSEMBLY. S UBMITTER STATED THESE PARTICULAR VALVES HAVE A VERY POOR RELIABILITY FACTOR. THEY ARE NOT RELIABLE AND USUALLY ONLY LAS T ABOUT 6 MONTHS UNTIL THEY FAIL. THIS VALVE HAD 312.6 HOURS AND 372 CYCLES. RECOMMEND MANUFACTURER LOOK FOR THE PROBL EM AND IMPROVE RELIABILITY. 2 L 7 2 4T RT A24CE 1998051500674 19980515 00674 EU 1998 5 15 98ZZZX1754 1 19971213 G 6220 10513143 ROD END BOLKMS 117 BK117A4 5626017 EU M/R WORN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117NG 437 7083 PREMATURE BEARING WEAR. REMOVED AND REPLACED 4 EACH. 1 G 7 2 3U H13EU 1998011500401 19980115 00401 SW 1998 1 15 98ZZZX176 1 19971216 G 6700 369A7301501 BELLCRANK HUGHES 500N 500N 3027374 SW FLIGHT CONTROL BINDING G K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 167 FOUND ON ACCEPTANCE INSPECTION THAT BELLCRANK HAS BOTH PIVOT BEARINGS PRE-LOADED TO A POINT BEARING WILL NOT ROTATE FOR INSTALLATION. 1 G 7 1 3U NC H3WE 1998011500402 19980115 00402 SW 1998 1 15 98ZZZX177 1 19971216 G 6700 369A7301501 BELLCRANK HUGHES 500N 500N 3027374 SW FLIGHT CONTROL BINDING G K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 160 FOUND ON ACCEPTANCE INSPECTION THAT BELLCRANK HAS BOTH PIVOT BEARINGS PRE-LOADED TO A POINT OF NO ROTATION. 1 G 7 1 3U NC H3WE 1998011500404 19980115 00404 SW 1998 1 15 98ZZZX179 1 19970728 G 6322 476205381C SLEEVE BELL 47 47G2 1181008 SW FAN DRIVE CRACKED D S K NONE O OTHER IN INSP/MAINT 1 SO 17 7730 K821 INSPECTION FOUND FAN DRIVE SLEEVE WITH LARGE THRU-CRACKING IN FLANGE AREA. 1 G 7 1 3O H1 1998010800077 19980108 00077 CE 1998 1 8 98ZZZX18 1 19971117 G 2711 NAS35860900 PUSH ROD LEAR 35 35A 5170602 CE AILERON BALANCE CORRODED B L A TJ4R K NONE O OTHER IN INSP/MAINT 1 GL 11 831CW 6651 390 CORROSION INSIDE AILERON BALANCE TAB PUSH RODS. CONDITION FOUND DURING A SCHEDULED INSPECTION. PIN HOLES WERE NOTED ON 3 OF THE 4 PUSH RODS. REPLACED ALL 4 WITH NEW RODS. 2 L 7 2 4F A10CE 1998011500405 19980115 00405 NM 1998 1 15 98ZZZX180 1 19971201 G 5315 FLOOR BEAM BOEING 727 727251 138408H NM BS 460 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 258US 19977 DURING C-CHECK, CORROSION NOTED ON UPPER CHORD OF CABIN FLOOR BEAM. STA 460 FROM RBL 25 TO RBL 45. 2 L 7 3 4F A3WE 1998011500406 19980115 00406 NM 1998 1 15 98ZZZX181 1 19971201 G 5313 STRINGER BOEING 727 727251 138408H NM BS 720C CRACKED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 258US 19977 DURING C-CHECK INSPECTION, STR 15L WAS NOTED CRACKED AT STA 720C. 2 L 7 3 4F A3WE 1998011500408 19980115 00408 CE 1998 1 15 98ZZZX183 1 19971217 G 3230 508202012 RETRACT CHAIN BEECH 90 C90 1152913 CE NLG AFT FAILED D K NONE O OTHER IN INSP/MAINT 1 SW 17 321DM 3849 LW250 NLG AFT RETRACT CHAIN MASTER LINK FAILED. ALL PIECES OF MASTER LINK FOUND AND IN SERVICEABLE CONDITION. RECOMMEND INST ALLATION OF NEW STYLE PRESS FIT LINK, PN 131378-25-2-CL, TO PREVENT RECURRENCE. 1 L 7 2 3T 3A20 1998011500409 19980115 00409 NE 1998 1 15 98ZZZX184 2 19971216 G 8520 5999 ROLLER SCWZER G164 G164B 3952802 EA PWA R1340 R1340* 52016 NE VALVE TAPPET SPALLED D K NONE J WARNING INDICATION IN INSP/MAINT 1 SW 15 175 AT THE TIME OF ROUTINE MAINTENANCE, METAL WAS DISCOVERED IN THE OIL SCREEN AND FILTER AND ALSO THE CHIP DETECTOR LIGHT C AME ON. UPON INSPECTION, FOUND THE VALVE TAPPET ROLLERS SPALLING. 1 Q 7 1 3R 3 R 1A16 5E2 1998011500410 19980115 00410 SO 1998 1 15 98ZZZX185 1 19971222 G 7160 CLAMP PIPER PA46 PA46310P 7104605 SO INDUCTION TUBE FAILED B CW7R O OTHER J WARNING INDICATION CR CRUISE 1 GL 25 146BU 468408057 DURING FLIGHT AT ALTITUDE, AIRCRAFT LOST MANIFOLD PRESSURE RESULTING IN LOSS OF CABIN PRESSURE. ON GROUND, FOUND LEFT F ORWARD INDUCTION TUBE CLAMP OFF. AIRCRAFT WAS A RAM CONVERSION. RE-INSTALLED CLAMP. GROUND CHK OK. SUSPECT LOOSE CLA MP. 1 L 7 1 3O A25SO 1998011500411 19980115 00411 CE 1998 1 15 98ZZZX186 1 19971218 G 2731 12346281 TRIM TAB CESSNA 206 TU206G 2073357 CE ELEVATOR CORRODED B KI2R K NONE O OTHER IN INSP/MAINT 1 CE 01 206PD 3748 676 IN THE PROCESS OF ANNUAL INSPECTION, TECHNICIAN NOTICED WHAT APPEARED TO BE CORROSION STARTING UNDER THE PAINT AROUND TH E RIVET HEADS ON THE UPPER SURFACE OF THE BRACKET FOR THE ELEV TAB CONTROL ROD. WHEN PICKED AT THE RIVET HEADS WITH FIN GERNAIL, SIX OF THE EIGHT RIVET HEADS POPPED OFF. 1 H 7 1 3O A4CE 1998052200038 19980522 00038 SW 1998 5 22 98ZZZX1860 1 19971202 G 2822 A8152B FUEL PUMP WELDON MOONEY M20 M20R 5870225 SW FUEL SYSTEM FAILED B EA6R K NONE O OTHER IN INSP/MAINT 1 NE 01 700RT 488 71756 290097 WHILE UTILIZING THE ELECTRIC FUEL PUMP TO TRANSFER FUEL, THE PUMP FAILED IN ABOUT 15 MINUTES. THIS IS THE SECOND TIME I N A MONTH THIS MODEL WELDON PUMP FAILED IN A MOONEY OVATION. BOTH PUMPS HAVE APPROXIMATELY THE SAME AMOUNT OF TOTAL TIM E. 1 L 7 1 3O RT 2A3 1998011500412 19980115 00412 CE 1998 1 15 98ZZZX187 1 19971216 G 2720 35524106 CONTROL TUBE BEECH 35 V35A 1151544 CE RUDDERVATOR SEIZED D K NONE O OTHER IN INSP/MAINT 1 NM 08 2753A D9052 PER AD 06-11-97, FOUND LEFT RUDDERVATOR TUBE WAS HOLDING TRAPPED WATER AND INBOARD BEARING WAS COMPLETELY SEIZED WITH RU ST. 1 L 7 1 3O 3A15 1998052200592 19980522 00592 EA 1998 5 22 98ZZZX1886 2 19970506 G 8540 67610 STARTER GEAR BELL 47 47 1180602 SW LYC O435 VO435A1A 41516 EA LOCK TABS FAILED B A PB2R K NONE O OTHER IN INSP/MAINT 1 GL 23 300 AFTER REVIEWING APRIL, 1998 ALERTS AL 43-16, ATA 8011, SUBMITTER REPORTS AN ADDITIONAL OCCURRENCE OF LOCK TAB FAILURE. E NGINE/AIRCRAFT WAS ON GROUND AND NO DAMAGE OCCURRED. DISASSEMBLY OF ENGINE REVEALED THAT LOCK TABS DID NOT COVER UP DOW ELS AND ALLOWED THEM TO FALL OUT AND BOLTS TO BE SHEARED. 1 G 7 1 3O 3 O H1 E279 1998011500414 19980115 00414 CE 1998 1 15 98ZZZX189 1 19971201 G 2701 07136671 YOKE SHAFT CESSNA 182 182J 2072722 CE LT CONTROL WHEEL FOULED D K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 EA 21 3546F 18257546 DURING ANNUAL INSPECTION, FOUND UP ELEVATOR TRAVEL BELOW LIMIT BY 30 PERCENT - 18 DEGREES UP - 26 DEGREES PLUS 1 MINUS Z ERO DEG. INSPECTION FOUND 'TINNERMAN' TYPE HOSE CLAMP CAUGHT INBETWEEN LT YOKE SHAFT P/N 0713667-1, AND LT CONTROL WHEE L SUPPORT ASSY STOPPING THE LAST 2.0 INCHES OF TRAVEL. COULD NOT DETERMINE SOURCE OF CLAMP. VARIOUS AVIONICS AND 'BEHI ND PANEL' WORK PERFORMED IN THE LAST 2 YEARS. 1 H 7 1 3O NT 3A13 1998052200605 19980522 00605 EU 1998 5 22 98ZZZX1899 2 19971007 G 7250 9514M71P04 SHAFT BOEING 737 7373B7 1384580 NM CFMINT CFM56 CFM563B2 13802 EU HPT AFT FAILED B L LY2R O OTHER J WARNING INDICATION TO TAKEOFF 1 CE 07 373US 22624 12014 22952 724705 HPT AFT SHAFT FAILED ON TAKEOFF ROLL AT 80 PERCENT N1. HPT AFT SHAFT FAILED AT SEAL TEETH CAUSING EXTENSIVE DAMAGE DOWN STREAM IN THE TURINE 2ND LPT AREAS. 2 L 7 2 4F 4 F RT A16WE E21EU 1998010800078 19980108 00078 SO 1998 1 8 98ZZZX19 2 19971208 G 8520 635439 BEARING BEECH 55 95C55 1152708 CE CONT O520 IO520C 17032 SO NR 2 MAIN FAILED G E O ENGINE SHUTDOWN OTHER J WARNING INDICATION CR CRUISE 1 WP 09 87SC 800 TE441 1260447C ENGINE RPM FLUCTUATING IN-FLIGHT. PRECAUTIONARY ENGINE SHUT DOWN AND FEATHERING ACCOMPLISHED. AIRCRAFT LANDED WITHOUT INCIDENT. INVESTIGATION DISCLOSED THE STARTER ADAPTER FAILED DUE TO LACK OF OIL. THIS OCCURRED AFTER .5 HOURS OF OPERAT ION. DISASSEMBLY OF THE ENGINE DISCLOSED THAT NR 2 MAIN BEARING FAILED ALLOWING THE OIL PRESSURE TO DROP WELL BELOW THE MINIMUM PRESSURE REQUIRED TO LUBRICATE THE STARTER HOUSING, ADAPTER. PRIMARY FAILURE: NR 2 MAIN BEARING. SECONDARY F AILURE: STARTER ADAPTER HOUSING. 1 L 7 2 3O 3 O 3A16 E5CE 1998011500415 19980115 00415 EA 1998 1 15 98ZZZX190 2 19971203 G 7414 103493943 HOUSING BENDIX S49L1209 PIPER PA28 PA28R180 7102809 SO LYC O360 IO360B1E 41514 EA ENGINE MAGNETO CRACKED B RG4R K NONE O OTHER IN INSP/MAINT 1 SO 03 4957J 3885 23458 28R30704 L512051A INSPECTION FOUND BOTH MAGNETO HOUSINGS ARE CRACKED IN SEVERAL PLACES. SUSPECT THAT WHEN NEW COILS WERE INSTALLED, THE W EDGES WERE INSTALLED INCORRECTLY OR OVERDRIVEN INTO POSITION. 1 L 7 1 3O 3 O 2A13 1E10 1998011500416 19980115 00416 EA 1998 1 15 98ZZZX191 2 19971203 G 7414 103493943 HOUSING BENDIX S49L1227 PIPER PA28 PA28R180 7102809 SO LYC O360 IO360B1E 41514 EA ENGINE MAGNETO CRACKED B RG4R K NONE O OTHER IN INSP/MAINT 1 SO 03 4957J 3885 23458 28R30704 L512051A INSP FOUND BOTH MAGNETO HOUSINGS ARE CRACKED IN SEVERAL PLACES. SUSPECT THAT WHEN NEW COILS WERE INSTALLED, THE WEDGES WERE INSTALLED INCORRECTLY OR OVERDRIVEN INTO POSITION. 1 L 7 1 3O 3 O 2A13 1E10 1998011500418 19980115 00418 1998 1 15 98ZZZX193 4 19971231 G 6113 U14426000 SPINNER PIPER PA18 PA18150 7101828 SO PROPELLER CRACKED B RF1R K NONE O OTHER IN INSP/MAINT 1 SW 01 734 185258 DURING 100-HOUR INSPECTION, REMOVED SPINNER AND FOUND CRACKS IN FORWARD SPINNER BULKHEAD PLATE EXTENSION FROM BEND RADIU S ON LEFT AND RIGHT SIDE APPROXIMATELY 1.5 INCHES. 1 H 7 1 3O 1A2 1998011500419 19980115 00419 EU 1998 1 15 98ZZZX194 1 19971216 G 7922 53E22144 VALVE PARTEN P68 P68TCOBS 6780108 EU THERMO BYPASS FAILED B RF1R K NONE J WARNING INDICATION IN INSP/MAINT 1 SW 01 737 209 40004OTC AIRCRAFT HAD HIGH OIL TEMPERATURE AND LOW OIL PRESSURE. REMOVED BYPASS VALVE ASSY AND TESTED. VALVE ONLY MOVED .025 IN CH. REPLACED WITH NEW VALVE. OPS CHECKED GOOD. 1 H 7 2 30 A31EU 1998011500422 19980115 00422 NE 1998 1 15 98ZZZX197 2 19971201 G 7230 556582001 STATOR PWA JT8 JT8D7B 52053 NE ENG C2 CRACKED H K NONE O OTHER IN INSP/MAINT 1 SO 17 55414 654303 ENGINE C2 STATOR CRACKED ON WELDING. 4 F E2EA 1998011500423 19980115 00423 GL 1998 1 15 98ZZZX198 2 19970815 G 7230 301288147D BOOSTER GE CFM CFM562 GL 1ST STAGE MISWELDED H K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 17 FR00566 ENGINE 1ST STAGE BOOSTER INCOMPLETE WELDED PENETRATION. 4 F E2GL 1998010800061 19980108 00061 GL 1998 1 8 98ZZZX2 2 19971215 G 7313 47086 FILTER ALLSN 250C 250C20B 03013 GL FUEL NOZZLE CRUSHED D K NONE O OTHER IN INSP/MAINT 1 WP 23 APPEARS A FOREIGN OBJECT WAS INSERTED INTO THE INLET END OF THE FUEL NOZZLE CONTACTING THE CRUSTING FILTER ASSY. NO FOR EIGN OBJECTS SHOULD EVER BE INSERTED INTO INLET END. 3 U E4CE 1998010800079 19980108 00079 EU 1998 1 8 98ZZZX20 1 19971215 G 2160 104568 VALVE HWKSLY DH125 BH125400A 4230138 EU BLEED CHECK FAILED D A UNSCHED LANDING O OTHER CL CLIMB 1 GL 07 900WG 1989 P9532 NA757 AFTER TAKEOFF, VALVE FAILED IN OPEN POSITION. THIS CAUSED EXCESSIVE HOT BLEED AIR TO REACH COCKPIT. PRESSURIZATION WAS DIFFICULT TO CONTROL AND PILOTS WERE SUBJECTED TO EXTREME HEAT. AIRCRAFT HAD TO DESCEND AND LAND AS SOON AS POSSIBLE. ONLY BY SHUTTING DOWN RIGHT ENGINE COULD THIS PROBLEM BE RESOLVED IN-FLIGHT. 2 L 7 2 4J A3EU 1998010800080 19980108 00080 CE 1998 1 8 98ZZZX21 1 19971211 G 2931 GAUGE BEECH 200 200BEECH 1152920 CE HYD ACCUM IND FAILED B LX5R K NONE O OTHER IN INSP/MAINT 1 GL 19 981LL 392 BB602 THIS GAUGE IS PART OF STC SA 4378WP AVIADESIGN, INC., HYDRAULIC LANDING GEAR RETRACTION SYSTEM. WITH ZERO PRESSURE IN A CCUMULATOR, THIS GAUGE WAS STILL SHOWING 500 P.S.I.G. FOR INDICATION. SUBMITTER RECOMMENDED A BETTER QUALITY GAUGE BE U SED IN SYSTEM. 1 L 7 2 4T A24CE 1998011500435 19980115 00435 SO 1998 1 15 98ZZZX210 2 19970812 G 8520 642001 CRANKCASE CONT O520 IO520C 17032 SO ENG LT/RT HALF CRACKED D S K NONE O OTHER IN INSP/MAINT 1 SO 17 CRANKCASE INSPECTION FOUND BOTH LEFT AND RIGHT HALVES OF ENGINE CASE HAS CRACKING (LENGTHY AND THROUGH). 3 O E5CE 1998061200363 19980612 00363 EA 1998 6 12 98ZZZX2118 2 19971101 G 8530 SL14077 PISTON PIN MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA ENGINE FAILED B VG1R A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SW 05 1144P 587 241187 L1704051AC PISTON PIN BROKE IN-FLIGHT CAUSING MASSIVE DAMAGE INTERNALLY IN ENGINE. THE CRACKSHAFT AND ONE CYLINDER WERE THE ONLY I TEMS SALVAGEABLE. PILOT NOTICED ENGINE ROUGNESS AND LOSS OF OIL PRESSURE. AIRPLANE LANDED WITHOUT DAMAGE TO AIRCRAFT O R PILOT. ENGINE QUIT COMPLETELY AFTER TOUCH-DOWN. 1 L 7 1 3O 3 O 2A3 1E10 1998012200129 19980122 00129 SO 1998 1 22 98ZZZX216 1 19971227 G 5730 WING PLANK GULSTM G159 G159 3952202 SO INBD LOWER CORRODED B QU2R K NONE O OTHER IN INSP/MAINT 1 EA 17 2FOR GULFSTREAM CUSTOMER BULLETIN NR CB 337 REQUIRES X-RAY INSPECTION OF INBOARD LOWER PLANK SPLICES AND ULTRASONIC INSPECTIO N OF THE ADJACENT RISERS. SUBSEQUENT DISASSEMBLY FOR REPAIRS REVEALED EXTENSIVE CORROSION IN SPLICES AND RISERS NOT DET ECTABLE BY THE SPECIFIED TECHNIQUES. 2 L 7 2 4T 1A17 1998012200131 19980122 00131 WP 1998 1 22 98ZZZX218 1 19971210 G 3240 EXPANDER TUBE DOUG DC3 DC3CS1C3G 3021458 WP LT OTBD BRAKE FAILED H K NONE O OTHER NR NOT REPORTED 1 SO 33 58NA 12970 LEFT OUTBOARD BRAKE EXPANDER TUBE FAILED. REMOVED AND REPLACED LEFT OUTBOARD BRAKE ASSY IAW DOUGLAS DC-3 SM. 2 L 7 2 4R A669 1998012200132 19980122 00132 NE 1998 1 22 98ZZZX219 2 19971124 G 8540 ACCESSORY SECT DOUG DC3 DC3AS1C3G 3021440 WP PWA R1830 R183092 52020 NE ENGINE FAILED G VNAA E ENGINE SHUTDOWN E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 GL 07 24320 575 20197 351640 WHILE IN CRUISE FLIGHT, ENGINE RAN ROUGH FOR APPROXIMATELY 5 SECONDS, THEN OIL PSI LIGHT AND FUEL LIGHT CAME ON. ENGINE WAS SHUT DOWN AND PROPELLER FEATHERED. ONCE ON GROUND, IT WAS DETERMINED THE ACCESSORY SECTION WAS NOT WORKING. SUSPE CT EITHER A FAILED GEAR IN THE ACCESSORY SECTION OR POSSIBLY A BROKEN CRANKSHAFT. ENGINE TO BE REPLACED WITH A SERVICEA BLE UNIT. 2 L 7 2 4R 4 R A669 5E4 1998010800081 19980108 00081 CE 1998 1 8 98ZZZX22 1 19971205 G 3230 DRAG BRACE BEECH 200 200BEECH 1152920 CE MLG RT CORRODED B LX5R K NONE P NO WARNING INDICATION NR NOT REPORTED 1 GL 19 981LL BB602 THIS AIRCRAFT IS EQUIPPED WITH AVIADESIGN INC., HYDRAULIC LANDING GEAR SYSTEM. NO DOWN AND LOCKED INDICATION ON RIGHT M AIN LANDING GEAR. SUSPECT CAUSE: FOUND CORROSION ON DRAG BRACE ASSEMBLY PIVOT BOLTS CREATING BINDING SITUATION AND NOT ALLOWING LOCKING MECHANISM TO LOCK COMPLETELY. SUBMITTER RECOMMENDED IN ADDITION TO BEECHCRAFT'S LANDING GEAR LUBRICAT ION REQUIREMENTS, RECOMMEND DRAG BRACE BOLTS BE REMOVED, INSPECTED, AND LUBRICATED AT AVIADESIGN, INC. RECOMMENDED GEAR INSPECTION INTERNALLY. 1 L 7 2 4T A24CE 1998012200135 19980122 00135 EU 1998 1 22 98ZZZX221 1 19971223 G 3520 17450401 FACE CUSHION C3512000 BRAERO DH125 BAE125800A 1500285 EU PAX O2 MASK TORN B JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 961JC 4081 258062 WHILE C/W RAYTHEON SB 35-3014 (INSPECTION OF PASSENGER OXYGEN FACE MASKS FOR TEARS IN FACE CUSHIONS), FIVE MASKS WERE FO UND TORN. THE CORE DATES WERE FROM 1986, NOT 1994 AS LISTED IN THE SB. SUBMITTER STATED THIS IS THE SECOND HAWKER 800 FOUND WITH EXACT SAME PROBLEM. RECOMMEND PB AND RAYTHEON REVISE SB'S TO INCLUDE EARLIER CURE DATES. NELLCOR PURITAN BE NNETT SB NR C351-2000-35-1 R1. 2 L 7 2 4F RT A3EU 1998012200137 19980122 00137 EA 1998 1 22 98ZZZX222 2 19971231 G 8520 CRANKSHAFT PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA NR 4 ROD JOURNAL FAILED D C D ABORTED TAKEOFF RETURN TO BLOCK O OTHER TO TAKEOFF 1 NE 01 2838D 6600 180 287916463 L1304339A AIRCRAFT TOOK OFF FROM HANSCOM AND LANDED AT NANTUCKET WITHOUT INCIDENT. PILOT GOT BACK INTO AIRCRAFT AND TAXIED TO THE RUNWAY. DURING TAKEOFF ROLL, PILOT HEARD A LOUD KNOCKING SOUND AND ABORTED TAKEOFF AND TAXIED BACK TO HANGAR. AFTER P ULLING ALL THE CYLINDERS OFF AND REMOVING ALL CONNECTING RODS, THE NR 4 CONNECTING ROD JOURNAL WAS FOUND CRACKED IN HALF . THE NR 4 CONN ROD WAS HOLDING THE CRANKSHAFT TOGETHER. 1 L 7 1 3O 3 O 2A13 E274 1998012200138 19980122 00138 EA 1998 1 22 98ZZZX223 2 19970102 G 7414 1068291013 MAGNETO BENDIX PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA DRIVE GEAR FAILED D K NONE O OTHER IN INSP/MAINT 1 AL 01 59829 142 L189515GR 317652081 L780661A UPON TAKING THE CAP OFF THE MAGNETO, NOTED THAT ONE OF THE DRIVE GEAR TEETH WAS BROKEN OFF FROM THE NYLON DISTRIBUTOR GE AR. NOTE: THE DIRECTOR OF MAINTENANCE REPORTED A TIMING TOOL WAS NOT USED. 1 L 7 2 3O 3 O A20SO E14EA 1998012200139 19980122 00139 SO 1998 1 22 98ZZZX224 2 19971003 G 8530 ROCKER BOSS CESSNA 175 175 2072502 CE CONT O300 GO300A 17022 SO NR 4 CYLINDER FAILED D K NONE O OTHER IN INSP/MAINT 1 CE 07 7115M 248 55415 53818A DURING ANNUAL INSPECTION, NR 4 CYLINDER COMP AT 50/80 WITH AIR NOISE IN EXHAUST STACK. ON REMOVAL OF ROCKER BOX COVER, THE TOP HALF OF THE LEFT BOSS CAME OUT WITH THE COVER. TEN HOURS PREVIOUSLY, THE COVER HAD BEEN REMOVED AND PUSH ROD TU BES HAD BEEN RESEALED. SUBMITTER STATED THE BOSS MAY HAVE BEEN CRACKED WHEN THE ROCKER ARM SHAFT WAS REMOVED OR INSTALL ED. 1 H 7 1 3O 3 O NT 3A17 E298 1998012200140 19980122 00140 EA 1998 1 22 98ZZZX225 2 19971211 G 7314 RA8987 GASKET LYC O540 TIO540J2BD 41532 EA FUEL PUMP LEAKS B L A YECR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 09 FUEL PUMP OVERHAULED AND BENCH TESTED 2-97 PER RG9080 COMPONENT MM, BUT WAS NOT PLACED INTO SERVICE UNTIL 12/97. PUMP L EAKED AT RA8987 GASKET ON INITIAL START-UP OF ENGINE IN TEST CELL. ALL SCREWS FOUND BELOW MINIMUM 23 INCH/POUND TORQUE REQUIRED BY SB 1015B020. RA8987 GASKET WAS ASBESTOS, BUT IS NOW RUBBER COMBINED WITH DOUBLE RUBBER RELIEF DIAPHRAGMS RA 5326. THERE APPEARS TO BE TOO MUCH PLIABLE MATERIAL IN THE JOINT TO MAINTAIN PROPER PRE-LOAD. THIS IS FIFTH OCCURRENCE . SB 101SB020 DOES NOT ADDRESS PROBLEM SOON ENOUGH TO PREVENT FUTURE LEAKS. RA5326 AND RA8987 MATERIAL SHOULD BE REVIS ED. 3 O E14EA 1998012200142 19980122 00142 SO 1998 1 22 98ZZZX227 2 19971203 G 8530 654064 VALVES CONT O200 O200* 17020 SO VALVE STEM PITTED B P YECR K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 09 3527U INSPECTION OF 6 NEW VALVES FOUND TWO OF THE VALVE STEMS WERE GENERALLY IN POOR CONDITION. FURTHER INSPECTION FOUND DEEP PITS AND SCRATCHES THAT APPEARED TO BE INCLUSIONS OR OTHER IMPURITIES. 3 O E252 1998012200143 19980122 00143 EA 1998 1 22 98ZZZX228 2 19971118 G 7414 10682056 DIST BLOCK D6RN3200 PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA MAGNETO WORN B P YECR K NONE O OTHER IN INSP/MAINT 1 NM 09 3527U 443 317952141 INSPECTION OF MAGNETO DISTRIBUTOR BLOCK FOUND BUSHING WEAR AND WEAR DAMAGE TO LARGE DISTRIBUTOR GEAR. 1 L 7 2 3O 3 O A20SO E14EA 1998010800082 19980108 00082 CE 1998 1 8 98ZZZX23 1 19971211 G 3230 92467 RESTRICTOR VALVE GARKENYON BEECH 200 200BEECH 1152920 CE HYDRAULIC MLG FAILED B LX5R K NONE O OTHER IN INSP/MAINT 1 GL 19 981LL 6236 96 BB602 THIS UNIT IS PART OF STC SA4378WP AVIADESIGN, INC., HYDRAULIC LANDING GEAR SYSTEM. FOUND INTERNAL SCREEN BROKEN OFF. 1 L 7 2 4T A24CE 1998012200145 19980122 00145 EA 1998 1 22 98ZZZX230 2 19971124 G 8550 CH48110 OIL FILTER CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA ENGINE OIL BULGED D O OTHER K FLUID LOSS NR NOT REPORTED 1 WP 05 67932 1 15282107 FILTER REPLACED 11-24-97. ENGINE GROUND CHECKED. 0IL PRESSURE NORMAL. ON NEXT FLIGHT, OIL WAS LOST OVERBOARD. ON EXA MINATION, FILTER WAS FOUND ELONGATED AND BULGED. FILTER TAKEN TO HAGGLIN MOTOR FOR INVESTIGATION. CONCLUSION WAS BULGI NG LIFTED FILTER OFF SEAT, DUMPING OIL. 1 H 7 1 3O 3 O NT 3A19 E223 1998012200146 19980122 00146 SO 1998 1 22 98ZZZX231 1 19971217 G 5711 7850002 RIB PIPER PA34 PA34200 7103405 SO WS 69.24 BROKEN D A K NONE O OTHER IN INSP/MAINT 1 NM 11 42752 347450172 THE FALSE SPAR AND WING RIB AT STA 69.24 ON THE LEFT WING WERE FOUND BROKEN AT THE 100-HOUR INSPECTION. SUBMITTER BELIE VES IT WAS CAUSED BY A HARD OR FAST LANDING, ALTHOUGH NONE WERE REPORTED. AD 73-11-02 REFERS TO THIS PROBLEM, HOWEVER, DOES NOT APPLY TO THIS S/N ACFT. PIPER KIT 760-696V IS INSTALLED. REPAIR WILL BE DONE BY INSTALLATION OF NEW RIB AND F AKE SPAR. 1 L 7 2 3O A7SO 1998012200147 19980122 00147 SO 1998 1 22 98ZZZX232 1 19971217 G 5711 6707900 FALSE SPAR PIPER PA34 PA34200 7103405 SO WS 69.24 BROKEN D K NONE O OTHER IN INSP/MAINT 1 NM 11 42752 347450172 THE FALSE SPAR AND WING RIB AT STA 69.24 ON THE LEFT WING WERE FOUND BROKEN AT THE 100-HOUR INSPECTION. SUBMITTER BELIE VES IT WAS CAUSED BY A HARD OR FAST LANDING, ALTHOUGH NONE WERE REPORTED. AD 73-11-02 REFERS TO THIS PROBLEM, HOWEVER, DOES NOT APPLY TO THIS S/N ACFT. PIPER KIT 760-696V IS INSTALLED. REPAIR WILL BE DONE BY INSTALLATION OF NEW RIB AND F AKE SPAR. 1 L 7 2 3O A7SO 1998012200148 19980122 00148 CE 1998 1 22 98ZZZX233 1 19971209 G 3222 6960311 CYLINDER ASSY CESSNA 185 A185F 2072821 CE NLG STRUT FAILED D K NONE O OTHER NR NOT REPORTED 1 SO 03 61301 5000 18504144 NLG STRUT ATTACH FAILED ON NOSE WHEELS. FLOATS HAVE A HISTORY OF SHIMMY PROBLEMS. THE STRUT UPPER ATTACHMENT BRACKETS MAY HAVE BEEN WEAKENED OVER TIME DUE TO THIS CONDITION. THEY MAY ALSO HAVE BEEN WEAKENED DUE TO NUMEROUS BOW-TYPE DOCKI NGS. PART SHOWED NO RUST OR OTHER PROBLEMS BY VISIBLE INSPECTION. 1 H 7 1 3O 3A24 1998012200149 19980122 00149 CE 1998 1 22 98ZZZX234 1 19971218 G 3240 6919 ANCHOR BOLT PARKERHANFIN 30182 CESSNA 208 208B 2073701 CE BRAKE CALIPER MISMANUFACTURED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 09 727FX 795 208B0468 BRAKE CALIPER PINS (ANCHOR BOLTS) WERE SHORTER THAN PINS INSTALLED ON OTHER BRAKE CALIPERS. THIS WAS A NEW BRAKE ASSEMB LY INSTALLED ON A NEW AIRCRAFT RECEIVED FROM FACTORY. RETURNED TO BRAKE MANUFACTURER FOR REPAIR. 1 H 7 1 3T A37CE 1998012200150 19980122 00150 SO 1998 1 22 98ZZZX235 1 19971223 G 3230 423072 RETRACT LINK PIPER PA42 PA42 7104202 SO LT MLG CRACKED B A JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 811DA 4890 428001029 DURING ROUTINE INSPECTION, 250-HOUR MAGNAFLUX INSPECTION PERFORMED ON RETRACT ARM LINK. LEFT LINK WAS FOUND CRACKED. T IME SINCE LAST INSPECTION, 107 HOURS. NOTE: PA42 MM CONTAINS NO NDT INSTRUCTIONS OR WHAT TYPE OF NDT TO BE USED DURING THIS INSPECTION. LANDINGS, 5,062. 1 L 7 2 4T A23SO 1998012200151 19980122 00151 SO 1998 1 22 98ZZZX236 1 19971201 G 5751 JW10501 AILERON LKHEED 1329 132923D 5263108 SO RT AIL CASTING CRACKED D S K NONE O OTHER IN INSP/MAINT 1 SW 99 27RC 8851 5086 DOING 12-MONTH PERIODIC INSPECTION, FOUND RT AILERON COUNTERWEIGHT CASTING ATTACHMENT CRACKED THROUGH BETWEEN 2 BOLTS. I NCLUDED: PART CATALOGUE, PAGE 2-62, ITEM 68. NOTE: LEFT AILERON CASTING AND NDT INSPECTION CARRIED OUT. NO CRACK FOU ND. 2 L 7 4 4J 2A15 1998010800083 19980108 00083 SW 1998 1 8 98ZZZX24 1 19971112 G 6700 369A7301501 BEARING HUGHES 500N 500N 3027374 SW FLT CONT IDLER BINDING G K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 0175 IDLER BELLCRANK HAS BOTH PIVOT BEARINGS PRE-LOADED TO A POINT OF NO ROTATION. BINDING COULD CAUSE BOLT FAILURE. FOUND ON INCOMING ACCEPTANCE INSPECTION. 1 G 7 1 3U NC H3WE 1998012200155 19980122 00155 SW 1998 1 22 98ZZZX240 1 19971121 G 6410 406016100119 BLADE 407012101105 BELL 407 407 SW T/R CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 407AL 42 A1978 53044 DAILY INSPECTION FOUND CRACK AT ROOT END OF T/R BLADE ON THE INSIDE OF THE LEADING EDGE. SUSPECT CAUSE IS HIGH STRESS A REA. PART IS UNSERVICEABLE. INSTALLED BEEF-UP STRESS BLOCK IN LEADING EDGE AT ROOT END OF BLADE. 1 G 7 1 3U O H2SW 1998012200157 19980122 00157 NE 1998 1 22 98ZZZX242 1 19971209 G 6210 7615009100049 BLADE SKRSKY S76 S76A 8143006 NE M/R DEBONDED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 741SW 11725 A08600881 760070 DISCOVERED DURING 11,750 HOUR INSPECTION, M/R BLADE, LOWER ROOT END LAMINATE DEBONDED BEYOND ALLOWABLE LIMITS PER SA4047 -76-5, CHAPTER 2. SENT TO SIKORSKY AIRCRAFT FOR FURTHER EVALUATION/REPAIR. 1 G 7 2 3U H1NE 1998012200158 19980122 00158 EU 1998 1 22 98ZZZX243 1 19971208 G 6210 355A11002006 BLADE AEROSP AS355 AS355F 8680806 EU M/R CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 5773X 2150 4382 5004 DISCOVERED DURING DAILY INSPECTION, M/R BLADE LOWER SURFACE SKIN CRACKED AT STA 1000 MM LEADING EDGE EROSION STRIPS DEBO NDED. REPAIRED BY CTI, RETURNED TO SERVICE. 1 G 7 2 3U H11EU 1998012200159 19980122 00159 SW 1998 1 22 98ZZZX244 1 19971222 G 6510 406040340101 DISK PACK BELL 407 407 SW T/R SHAFT CRACKED B S ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 437AL 53141 DISCOVERED DURING 25 HOUR INSPECTION, T/R DRIVE SHAFT NR 5 DISK PACK CRACKED ON AFT SIDE IN 2 PLACES. 1 G 7 1 3U O H2SW 1998012200160 19980122 00160 NE 1998 1 22 98ZZZX245 1 19970929 G 6210 7615009100049 BLADE SKRSKY S76 S76A 8143006 NE M/R DEBONDED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 708AL 11505 559 A08601050 760277 MALFUNCTION WAS DISCOVERED DURING 11,750 HOUR INSPECTION, M/R BLADE ROOT END LAMIMATES DEBONDED BEYOND ACCCEPTABLE LIMIT S. 1 G 7 2 3U H1NE 1998012200161 19980122 00161 NE 1998 1 22 98ZZZX246 1 19970929 G 6210 7715009100049 BLADE SKRSKY S76 S76A 8143006 NE M/R DEBONDED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 708AL 11505 559 A08601050 760277 DISCOVERED DURING EVALUATION OF BLADE ASSEMBLY PRIOR TO SHIPMENT TO REPAIR FACILITY, TIP RIB ASSEMBLY DEBONDED. 1 G 7 2 3U H1NE 1998012200162 19980122 00162 EU 1998 1 22 98ZZZX247 1 19971209 G 6210 355A11002011 BLADE AEROSP AS355 AS355F 8680806 EU M/R DAMAGED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 5773X 1594 7403 5004 DISCOVERED DURING DAILY INSPECTION, FOUND M/R BLADE LEADING EDGE DAMAGED AT STA 3955 MM DUE TO IMPACT OF FOREIGN OBJECT. 1 G 7 2 3U H11EU 1998012200163 19980122 00163 SW 1998 1 22 98ZZZX248 1 19971121 G 6510 406040340101 DISK PACK 407040302101 BELL 407 407 SW NR 5 CRACKED B S ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 437AL 53141 FOUND DURING 25 HOUR AD INSPECTION, T/R DRIVESHAFT DISK PACK NR 5 HAS CRACKED COUPLING. CRACKED ON AFT SIDE OF COUPLING . PACK CONSISTS OF 1 DISK. 1 G 7 1 3U O H2SW 1998012200164 19980122 00164 GL 1998 1 22 98ZZZX249 2 19971124 G 7210 6898642 GEAR ALLSN 250C 250C30S 03013 GL GEARBOX WORN B ALGR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 29416 RECEIVING INSPECTION - RECEIVED GEAR FROM ALLISON, TAG INDICATED THE PART WAS NEW. THE VISUAL INSPECTION OF GEAR INDICA TED THE GEAR WAS USED AND UNSERVICEABLE BY AIR LOG ENGINE SHOP STANDARDS. 3 U E1GL 1998010800084 19980108 00084 SW 1998 1 8 98ZZZX25 1 19971112 G 6700 369A7301501 BEARING HUGHES 500N 500N 3027374 SW FLT CONT IDLER BINDING G K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 0186 IDLER BELLCRANK HAS BOTH PIVOT BEARINGS PRELOADED TO A POINT OF NO ROTATION. FOUND DURING INCOMING ACCEPTANCE INSPECTIO N. 1 G 7 1 3U NC H3WE 1998012200165 19980122 00165 SW 1998 1 22 98ZZZX250 1 19971204 G 6210 206015001107 BLADE BELL 206 206L1 1182107 SW M/R DELAMINATED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 1068S 2517 A1305 45436 DISCOVERED DURING DAILY INSPECTION, M/R BLADE SKIN DELAMINATED OVER SPAR AT TIP AND CORROSION OF TIP. 1 G 7 1 3U H2SW 1998012200166 19980122 00166 NE 1998 1 22 98ZZZX251 1 19971211 G 7120 7630907007048 TUBE SKRSKY S76 S76A 8143006 NE ENGINE MOUNT CORRODED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 164AG 760290 DEFECT DISCOVERED DURING 1,750 HOURLY INSPECTION OF ENGINE MOUNTS. WHILE BORESCOPING INSIDE OF TUBE, CORROSION WAS FOUN D THAT EXCEEDED LIMITS. INSIDE OF TUBE ASSEMBLY CORRODED AND PITTED. SUBMITTER SUGGESTED USING BETTER CORROSION PREVEN TATIVE METHODS. 1 G 7 2 3U H1NE 1998012200167 19980122 00167 SW 1998 1 22 98ZZZX252 1 19971203 G 6210 206015001107 BLADE BELL 206 206L1 1182107 SW M/R CORRODED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 206SL 2975 A1556 45245 DISCOVERED DURING DAILY INSPECTION, M/R BLADE HAD CORROSION AND SKIN DEBOND AT BLADE TIP. 1 G 7 1 3U H2SW 1998012200168 19980122 00168 SW 1998 1 22 98ZZZX253 1 19971203 G 6210 206015001107 BLADE BELL 206 206L1 1182107 SW M/R CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 27545 1370 A1856 45234 DISCOVERED DURING DAILY INSPECTION, M/R BLADE SPAR CRACKED AT TIP. 1 G 7 1 3U H2SW 1998012200169 19980122 00169 SW 1998 1 22 98ZZZX254 1 19971203 G 6210 206015001107 BLADE BELL 206 206L3 1182108 SW M/R CORRODED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 362AL 1421 A1670 51471 DISCOVERED DURING DAILY INPSECTION, M/R BLADE SKIN CORRODED AND SEPARATED AT TIP AND RAILING EDGE EXTRUSION CORRODED. 1 G 7 1 3U H2SW 1998012200170 19980122 00170 NE 1998 1 22 98ZZZX255 1 19971202 G 6210 7615009100051 BLADE SKRSKY S76 S76A 8143006 NE M/R DEBONDED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 376AL 7208 487 A08601424 760002 DISCOVERED DURING 500-HOUR INSPECTION, M/R BLADE TIP RIB STRAP AND DOUBLERS DEBONDED. 1 G 7 2 3U H1NE 1998012200171 19980122 00171 SW 1998 1 22 98ZZZX256 1 19971203 G 6210 206015001107 BLADE BELL 206 206L3 1182108 SW M/R CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 365AL 2445 A1639 51376 DISCOVERED DURING DAILY INSPECTION, M/R BLADE SPAR CRACKED AT TIP. 1 G 7 1 3U H2SW 1998012200172 19980122 00172 SW 1998 1 22 98ZZZX257 1 19971203 G 6210 206015001107 BLADE BELL 206 206L1 1182107 SW M/R CORRODED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 3890B 2890 A1323 45480 DISCOVERED DURING DAILY INSPECTION, SKIN CORROSION AND SEPARATION AT TIP. 1 G 7 1 3U H2SW 1998012200173 19980122 00173 SW 1998 1 22 98ZZZX258 1 19971203 G 6210 206015001107 BLADE BELL 206 206L1 1182107 SW M/R CORRODED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 3890B 2758 A1398 45480 DISCOVERED DURING DAILY INSPECTION, M/R BLADE SKIN SEPARATED AND CORRODED AT TIP. 1 G 7 1 3U H2SW 1998012200174 19980122 00174 SW 1998 1 22 98ZZZX259 1 19971203 G 6210 206015001107 BLADE BELL 206 206L1 1182107 SW M/R CORRODED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 3890B 2951 A1254 45480 DISCOVERED DURING DAILY INSPECTION, M/R BLADE SKIN SEPARATED AND CORRODED AT TIP. 1 G 7 1 3U H2SW 1998010800085 19980108 00085 SW 1998 1 8 98ZZZX26 1 19971112 G 6700 369A7301501 BEARING HUGHES 500N 500N 3027374 SW FLT CONT IDLER BINDING G K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 0148 IDLER BELLCRANK HAS BOTH PIVOT BEARINGS PRELOADED TO A POINT OF NO ROTATION. FOUND ON INCOMING ACCEPTANCE INSPECTION. 1 G 7 1 3U NC H3WE 1998012200175 19980122 00175 SW 1998 1 22 98ZZZX260 1 19971209 G 6510 NAS6604D50 BOLT BELL 407 407 SW T/R DRV SUPPORT WORN B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 407AL 1569 53044 SCHEDULED MAINTENANCE FOUND TAIL ROTOR DRIVESHAFT NR 2 BOLT WORN OR STEPPED, FRETTING. 1 G 7 1 3U O H2SW 1998080700176 19980807 00176 EA 1998 8 7 98ZZZX2609 2 19971217 G 8520 SL75060 BOLT PIPER PA32 PA32RT300T 7103216 SO LYC O540 TIO540S1AD 41532 EA CONNECT ROD FAILED D A UNSCHED LANDING B K R SMOKE/FUMES/ODORS/SPARKS FLUID LOSS PARTIAL RPM/PWR LOSS CL CLIMB 1 WP 07 21018 1063 32R7887186 L560461A APPEARS THAT THE CONNECTING ROD BOLT FAILED ALLOWING THE CONNECTING ROD TO SEPARATE FROM THE CRANKSHAFT. THE CONNECTING ROD SEPARATED FROM THE CRANKSHAFT SOON AFTER TAKEOFF. OIL COVERED THE WINDSHIELD AND SMOKE FILLED THE COCKPIT. A SUCC ESSFUL LANDING WAS MADE. THE ENGINE, FOR ABOUT THE PREVIOUS 200 HOURS, HAD A SLIGHT VIBRATION THAT COULD NOT BE PINPOIN TED. 1 L 7 1 3O 3 O A3SO E14EA 1998012200176 19980122 00176 SW 1998 1 22 98ZZZX261 1 19971209 G 6510 406040322101 BEARING BELL 407 407 SW T/R DRIVE HANGER WORN B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 407AL 1569 53044 SCHEDULED MAINTENANCE FOUND TAIL ROTOR DRIVESHAFT NR 2 HANGER BEARING ROUGH AND WORN, AXIAL PLAY. 1 G 7 1 3U O H2SW 1998080700180 19980807 00180 CE 1998 8 7 98ZZZX2613 1 19971228 G 3230 504100112 BELLCRANK CESSNA 310 T310R 2074246 CE RT MLG FAILED B A VIB4 O OTHER O OTHER LD LANDING 1 GL 05 310RH 1916 310R1878 AIRCRAFT INSPECTED FOR THE CAUSE OF THE RIGHT MAIN LANDING COLLAPSE ON LANDING. FOUND THAT PARTS OF THE BELLCRANK ASSEM BLY (P/N 5041001-12) HAD FAILED. THE BOLT (P/N NAS464P4-26) AT THE UPPER END OF THE BELLCRANK HAD BROKEN AND THE END-FI TTING (P/N 0841111-3) AT THE LOWER END OF THE BELLCRANK HAD ALSO BROKEN. SUSPECT THE RIGHT LANDING GEAR HAD EXPERIENCED EXCESSIVE SIDE LOAD AT SOME TIME. 1 L 7 2 3O 3A10 1998080700181 19980807 00181 CE 1998 8 7 98ZZZX2614 1 19971228 G 3230 08411113 FITTING CESSNA 310 T310R 2074246 CE RT MLG BELLCRANK FAILED B VIB4 O OTHER O OTHER LD LANDING 1 GL 05 310RH 1916 310R1878 AIRCRAFT INSPECTED FOR THE CAUSE OF THE RIGHT MAIN LANDING COLLAPSE ON LANDING. FOUND THAT PARTS OF THE BELLCRANK ASSEM BLY (P/N 5041001-12) HAD FAILED. THE BOLT (P/N NAS464P4-26) AT THE UPPER END OF THE BELLCRANK HAD BROKEN AND THE END-FI TTING (P/N 0841111-3) AT THE LOWER END OF THE BELLCRANK HAD ALSO BROKEN. SUSPECT THE RIGHT LANDING GEAR HAD EXPERIENCED EXCESSIVE SIDE LOAD AT SOME TIME. 1 L 7 2 3O 3A10 1998080700182 19980807 00182 CE 1998 8 7 98ZZZX2615 1 19971228 G 3230 NAS464P426 BOLT CESSNA 310 T310R 2074246 CE RT MLG FAILED B VIB4 O OTHER O OTHER LD LANDING 1 GL 05 310RH 1916 310R1878 AIRCRAFT INSPECTED FOR THE CAUSE OF THE RIGHT MAIN LANDING COLLAPSE ON LANDING. FOUND THAT PARTS OF THE BELLCRANK ASSEM BLY (P/N 5041001-12) HAD FAILED. THE BOLT (P/N NAS464P4-26) AT THE UPPER END OF THE BELLCRANK HAD BROKEN AND THE END-FI TTING (P/N 0841111-3) AT THE LOWER END OF THE BELLCRANK HAD ALSO BROKEN. SUSPECT THE RIGHT LANDING GEAR HAD EXPERIENCED EXCESSIVE SIDE LOAD AT SOME TIME. 1 L 7 2 3O 3A10 1998080700183 19980807 00183 SO 1998 8 7 98ZZZX2616 2 19971230 G 8520 CRANKSHAFT CESSNA 402 402B 207590P CE CONT O520 TSIO520E 17040 SO RT ENGINE FAILED D E ENGINE SHUTDOWN E VIBRATION/BUFFET CR CRUISE 1 SW 99 3378Q 77 402B0334 18235172ER ENGINE SHUT DOWN DURING FLIGHT FROM HOUSTON TO DALLAS. UPON TEAR DOWN, DISCOVERED THAT THE CRANKSHAFT HAD BROKEN. SUBM ITTER STATED CAUSE IS UNKNOWN PENDING FURTHER INVESTIGATION. 1 L 7 2 3O 3 O A7CE E8CE 1998012200177 19980122 00177 SW 1998 1 22 98ZZZX262 1 19971209 G 6510 407040321101 BRACKET BELL 407 407 SW T/R DRIVESHAFT WORN B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 407AL 1569 53044 SCHEDULED MAINTENANCE FOUND NR 2 TAIL ROTOR DRIVESHAFT FORWARD BRACKET UPPER BOLT HOLE WORN ELLIPTICAL. 1 G 7 1 3U O H2SW 1998012200178 19980122 00178 SW 1998 1 22 98ZZZX263 1 19971118 G 6322 206061432116 BLOWER HOUSING BELL 407 407 SW OIL COOLER CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 417AL 1442 53054 BLOWER REMOVED BECAUSE OF ROUGH BEARINGS. HOUSING ALSO CRACKED. SHEET METAL HOUSING CRACKED AT RIVETED EDGE WHERE HOUS ING ATTACHES TO 407-062-021-101 OIL COOLER DUCT ASSEMBLY. SUBMITTER SUGGESTED THAT POSSIBLY A POOR FIT PUTTING STRAIN O N SHEET METAL WHEN ATTACHED TO DUCT. 1 G 7 1 3U O H2SW 1998012200179 19980122 00179 SW 1998 1 22 98ZZZX264 1 19971127 G 6510 406040340101 DISK PACK BELL 407 407 SW T/R DRIVE CRACKED B S ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 407AL 53044 IN C/W AD 97-24-17 DURING PHASE 6, FOUND ONE CRACKED LAMINATE OF TAIL ROTOR DRIVESHAFT DISK PACK AT NR 7 HYDRAULIC FORW ARD LAMINATE. 1 G 7 1 3U O H2SW 1998012200355 19980122 00355 1998 1 22 98ZZZX265 1 19971031 G 7714 1179405603 INDICATOR ENGINE NG FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 634 NG INDICATOR FAILED. REMOVED AND REPLACED. 1998012200356 19980122 00356 1998 1 22 98ZZZX266 1 19971115 G 7722 50061036 INDICATOR EXHAUST TEMP MISWIRED B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 175 EXHAUST TEMPERATURE INDICATOR WIRED INCORRECTLY. REMOVED AND REPLACED. 1998012200357 19980122 00357 EU 1998 1 22 98ZZZX267 1 19971106 G 6210 1051585403 BUSHING BOLKMS 117 BK117B1 5626012 EU M/R BLADE DEFECTIVE B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 BUSHING HAS DEFECTIVE PHONELIC LINING. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1998012200358 19980122 00358 EU 1998 1 22 98ZZZX268 1 19971125 G 7714 1179405603 INDICATOR BOLKMS 117 BK117A3 5626015 EU ENGINE NG FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117CH 403 7061 NG INDICATOR SLOW TO INDICATE, FALLS OFF-LINE AT 5 PERCENT ON DECELERATION. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1998081400151 19980814 00151 EA 1998 8 14 98ZZZX2683 2 19970201 G 8530 05K21108CKP CYLINDER PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA NR 2 EXH VALVE FAILED H L K NONE O OTHER IN INSP/MAINT 1 SW 09 611DF 73 318052188 L721861A EXHAUST VALVE FAILURE IN NR 3 CYLINDER RESULTED IN THE INGESTING OF THE VALVE INTO THE CYLINDER BORE. THIS CAUSED EXTEN SIVE DAMAGE TO THE COMBUSTION CHAMBER AND PISTON. METAL WAS THEN PASSED THROUGH ENTIRE ENGINE OIL SYSTEM. DAMAGED PART S INCLUDE ALL BEARINGS AND OIL PUMP IMPELLERS. 1 L 7 2 3O 3 O A20SO E14EA 1998081400152 19980814 00152 EA 1998 8 14 98ZZZX2684 2 19971101 G 8530 05K21108CKP CYLINDER PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA NR 1 EXH VALVE FAILED H K NONE O OTHER IN INSP/MAINT 1 SW 09 611DF 123 318052188 L721861A EXHAUST VALVE FAILURE IN NR 1 CYLINDER RESULTED IN THE INGESTING OF THE VALVE INTO THE CYLINDER BORE. THIS CAUSED EXTEN SIVE DAMAGE TO THE COMBUSTION CHAMBER AND PISTON. METAL WAS THEN PASSED THROUGH ENTIRE ENGINE OIL SYSTEM. DAMAGED PART S INCLUDE ALL BEARINGS AND OIL PUMP IMPELLERS. 1 L 7 2 3O 3 O A20SO E14EA 1998081400155 19980814 00155 SW 1998 8 14 98ZZZX2687 1 19971212 G 2434 1101876 GENERATOR DELCO BBAVIA 7 S7DC 21101NG SW CONT C85 C8512F 17008 SO DC SYSTEM FAILED H P K NONE O OTHER NR NOT REPORTED 1 SO 03 84L 16430 7DC3228 2805G712 PARTS 530412 NUT, 2.531325 GEAR 530407, SLEEVE 4.632050 BUSHING 352030 RETAINER. THESE COMPONENTS FAILED CAUSING THE GE NERATOR SHAFT TO FAIL. THE PARTS WERE CHEWED UP BY THE CAMSHAFT GEAR AND METAL CONTAMINATED THE OIL SYSTEM. THE ACCESS ORY CASE WAS ALSO DAMAGED BEYOND REPAIR. THERE WERE SEVERAL BAD NICKS AND GOUGES BY THE OIL PUMP HOUSING. REQUIRED ENG INE TEAR DOWN AND MAJOR OVERHAUL. 1 H 7 1 3O 3 O A759 E233 1998012200359 19980122 00359 EU 1998 1 22 98ZZZX269 1 19971112 G 7714 1179405603 INDICATOR BOLKMS 117 BK117A3 5626015 EU ENGINE NG FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117CH 634 7061 NG INDICATOR SLOW TO INDICATE. FALLS OFF-LINE ON DECELERATION AT 8 PERCENT. READS ALMOST 2 PERCENT LOW. REMOVED AND R EPLACED. 1 G 7 2 3U H13EU 1998010800086 19980108 00086 SW 1998 1 8 98ZZZX27 1 19971112 G 6700 369A7301501 BEARING HUGHES 500N 500N 3027374 SW FLT CONT IDLER BINDING G K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 0146 IDLER BELLCRANK FOUND TO HAVE BOTH PIVOT BEARINGS PRELOADED TO A POINT OF NO ROTATION. FOUND ON ACCEPTANCE INSPECTION. 1 G 7 1 3U NC H3WE 1998012200360 19980122 00360 EU 1998 1 22 98ZZZX270 1 19971106 G 7714 1179405603 INDICATOR BOLKMS 117 BK117A3 5626015 EU ENGINE NG FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117CH 735 7061 NG INDICATOR SLOW TO INDICATE AND FALLS OFF-LINE ON DECELERATION. PREVIOUSLY SENT FOR WARRANTY REPAIR ON P.O. 93129. F AILED APPROXIMATELY ONE WEEK AFTER INSTALLATION. 1 G 7 2 3U H13EU 1998012200361 19980122 00361 EU 1998 1 22 98ZZZX271 1 19971009 G 2430 SP461300 SWITCH BOLKMS 117 BK117B1 5626012 EU DC SYSTEM FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117LU 7144 SWITCH WILL NOT STAY ENGAGED. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1998012200362 19980122 00362 EU 1998 1 22 98ZZZX272 1 19971028 G 6720 11731822 PITCH LINK ASSY BOLKMS BK117 BK117C1 5626025 EU TAIL ROTOR WORN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117NC 333 7509 PITCH LINK ASSY (2 EACH) BEARINGS WORN. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1998012200363 19980122 00363 1998 1 22 98ZZZX273 4 19971104 G 2211 11788292 COMPUTER BOLKMS BK117 BK117C1 5626025 EU SPAS FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117NC 1191243 7509 SPAS COMPUTER HAS IMPROPER OUTPUT VOLTS. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1998012200364 19980122 00364 EU 1998 1 22 98ZZZX274 1 19971110 G 7714 1179405303 TRIPLE TACH BOLKMS 117 BK117B1 5626012 EU ENGINE N2 FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 214AE 3 282 7206 TRIPLE TACHOMETER N2 NEEDLE HANGS UP AT 98 PERCENT. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1998012200365 19980122 00365 EU 1998 1 22 98ZZZX275 1 19971028 G 6240 1179405303 TRIPLE TACH BOLKMS 117 BK117B1 5626012 EU ROTOR RPM FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 214AE 460 7206 TRIPLE TACHOMETER ROTOR RPM NEEDLE LAGS N2'S IN-FLIGHT. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1998012200366 19980122 00366 1998 1 22 98ZZZX276 4 19971031 G 3416 10222011886 ALTIMETER BOLKMS BK117 BK117C1 5626025 EU COCKPIT ENCODER FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 143025 7505 ALTIMETER DROPS 300 FEET AT 10,000 FEET. WILL NOT HOLD ALTITUDE. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1998012200367 19980122 00367 SW 1998 1 22 98ZZZX277 1 19971104 G 6720 230312001101 PITCH LINK BELL 230 230 1182149 SW TAIL ROTOR WORN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 23019 PITCH LINK WORN OUT OF LIMITS. REMOVED AND REPLACED 2 EACH. 1 G 7 2 3U NC H9SW 1998012200368 19980122 00368 SW 1998 1 22 98ZZZX278 1 19971107 G 6330 222330620103 BEARING BELL 230 230 1182149 SW XMSN MOUNT WORN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 23019 MOUNT BEARING WORN. REMOVED AND REPLACED. 1 G 7 2 3U NC H9SW 1998081400392 19980814 00392 EU 1998 8 14 98ZZZX2783 1 19970121 G 5511 315A3510000101 SPAR AEROSP SA316 SA315B 8680615 EU HORIZ STABILIZER CRACKED B LH3R K NONE O OTHER IN INSP/MAINT 1 WP 07 27443 7R368 2426 SPAR TUBE CRACKED AT RT MOUNTING HOSE, CRACK ORIGINATES AT MOUNTING HOLE AND EXTENDS IN BOTH DIRECTION COVERING 50 PERCE NT OF NBE CIRCUMFERENCE. THIS DEFECT WAS FOUND WHEN THE STABILIZER WAS BROUGHT IN FOR REPAIR OR WORN MOUNTING BUSHINGS. THIS CRACK COULD NOT BE SEEN AS IT IS COVERED BY HALF SHELL REINFORCEMENTS. SUBMITTER STATED LACK OF PREVENTATIVE MAI NTENANCE, NOT FOLLOWING INSPECTION SCHEDULES. T/R OUT OF BALANCE FOR EXTENDED PERIODS. 1 G 7 1 4U H1IN 1998012200369 19980122 00369 SW 1998 1 22 98ZZZX279 1 19971112 G 2430 1820300150 SHUNT BELL 230 230 1182149 SW DC SYSTEM WORN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV 286 23019 SHUNT WORN AND DISCOLORED. REMOVED AND REPLACED 4 EACH. 1 G 7 2 3U NC H9SW 1998010800087 19980108 00087 SW 1998 1 8 98ZZZX28 1 19971112 G 6700 369A7301501 BEARING HUGHES 500N 500N 3027374 SW FLT CONT IDLER BINDING G K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 0142 IDLER BELLCRANK FOUND TO HAVE BOTH PIVOT BEARINGS PRELOADED TO THE POINT OF NO ROTATION OF BEARING. FOUND ON INCOMING P ARTS INSPECTION. 1 G 7 1 3U NC H3WE 1998012200370 19980122 00370 SW 1998 1 22 98ZZZX280 1 19971107 G 6330 222331617101 MOUNT BELL 230 230 1182149 SW TRANSMISSION WORN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 4UV LK0192 23019 ISOLATION MOUNT HAS WORN BEARING. REMOVED AND REPLACED. 1 G 7 2 3U NC H9SW 1998012200371 19980122 00371 1998 1 22 98ZZZX281 4 19971105 G 2312 4000102000 TRANSCEIVER RT138 BELL 222 222 1182122 SW COCKPIT FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 911MK 1408 47515 UPON INITIAL TRANSCEIVER INSTALLATION, CIRCUIT BREAKER TRIPS WHEN TRANSMITTER BUTTON IS KEYED. REMOVED AND REPLACED. 1 G 7 2 3U H9SW 1998012200372 19980122 00372 1998 1 22 98ZZZX282 4 19971113 G 3421 4021541671 ARTIFICIAL HORIZ 92082227 BOLKMS 117 BK117A3 5626015 EU CSAS PITCH NOISY B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 911MZ 7098 ARTIFICIAL HORIZ CAUSES CSAS PITCH ACTUATOR TO FLUCTUATE. SIGNAL OUT OF PINS, X AND Y ARE TOO NOISY SIMULATING PITCH UP OR DOWN. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1998012200373 19980122 00373 1998 1 22 98ZZZX283 4 19971113 G 2211 7004206901 COMPUTER BOLKMS 117 BK117A3 5626015 EU CSAS FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 911MZ 89040228 7098 CSAS COMPUTER CAUSES FLUCTUATIONS IN PITCH ACTUATOR. NOISY SIGNAL COMING OUT OF PINS 18 AND 19. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1998012200374 19980122 00374 SW 1998 1 22 98ZZZX284 1 19971125 G 7120 222060150001 MOUNT BELL 222 222U 1182140 SW BEARING DEFECTIVE B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 222HX 284 47533 ENGINE MOUNT BEARING NOT PROPERLY STAKED. REMOVED AND REPLACED. 1 G 7 2 3U H9SW 1998012200378 19980122 00378 1998 1 22 98ZZZX288 4 19971223 G 6122 210735 GOVERNOR WOODWARD GULSTM 690TP 690B 7630516 SW PROPELLER SEIZED B R2JR E C D ENGINE SHUTDOWN ABORTED TAKEOFF RETURN TO BLOCK J WARNING INDICATION TX TAXI/GRND HDL 1 EA 21 690HT 2139 147543814 11467 ON TAXI, ENGINE HAD TO BE SHUT DOWN DUE TO LOW RPM AND HIGH ITT IN BETA. MAINTENANCE DISCOVERED PROPELLER GOVERNOR HAD FAILED INTERNALLY CAUSING MODERATE AMOUNTS OF GROUND METAL TO BE PUMPED INTO NOSE CASE. GOVERNOR SHAFT SEIZED. ENGINE REMOVED FOR TEAR-DOWN INSPECTION DUE TO ZERO TORQUE AND HIGH OIL PRESSURE AFTER GOVERNOR WAS CHANGED. SUSPECT METAL CON TAMINATION. OIL COOLER, ENGINE, AND OIL CHANGED. ALL OIL LINES FLUSHED. GOV SENT TO GARRETT AND ENGINE SENT TO GARETT SERVICE CENTER. GARRETT P/N IS 894418-6Y. 1 H 7 2 3T 2A4 1998012200379 19980122 00379 SW 1998 1 22 98ZZZX289 1 19971217 G 6720 2060017631 BELLCRANK BELL 206 206L1 1182107 SW ANTI TORQUE MISMANUFACTURED B A ZV1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 DURING REPLACEMENT OF COMPONENTS FOUND COULD NOT RIG TAIL ROTOR FOR FULL PEDAL MOVEMENT. TROUBLESHOOTING FOUND THAT BEL LCRANK P/N 206-001-763-1 AND ROD ASSY P/N 206-011-751-101 WERE CONTACTING. FOUND THAT BELLCRANK DID NOT HAVE THE PROPER DEPTH GROOVE MACHINED IN IT. FOUND 2 OTHER BELLCRANKS IN STOCK WITH SAME PROBLEM. BELL WAS CONTACTED. 1 G 7 1 3U H2SW 1998010800088 19980108 00088 CE 1998 1 8 98ZZZX29 1 19971003 G 5711 SPAR BEECH 18 H18 1151012 CE LT WS 32,46,81 CORRODED B NI2R K NONE O OTHER IN INSP/MAINT 1 CE 03 117ME BA638 CORROSION REVEALED ON FRONT SPAR LT WS 32, WS 46, AND WS 81 AND RT WS 32. REF: AD 75-27-09 R2 AND AMDT 39-3878. 1 L 7 2 3R A765 1998012200387 19980122 00387 GL 1998 1 22 98ZZZX297 2 19971207 G 7323 23057869 GOVERNOR BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ENGINE FAILED B AC2R K NONE O OTHER NR NOT REPORTED 1 SW 03 5366Y 7134 85520222 S782 FLUCTUATING TORQUE SETTING. FOUND GOVERNOR DRIVE BROKEN. REPLACED GOVERNOR. 1 G 7 2 3U 3 U H3EU E4CE 1998012200388 19980122 00388 SW 1998 1 22 98ZZZX298 1 19971112 G 6230 206010336005 DRIVE LINK BELL 206 206L1 1182107 SW M/R MAST WORN B ZV1R K NONE O OTHER IN INSP/MAINT 1 SW 03 2611 45417 EXCESSIVE PLAY AT TWO PLACES. SEE BELL MM L-3 FIG 62-21. ON TEAR-DOWN, FOUND BEARINGS AND SPACERS WORN BEYOND LIMITS. TOTAL TIME OF PARTS LESS THAN 1,000 HOURS/1 YEAR SINCE REPLACEMENT. 1 G 7 1 3U H2SW 1998012200389 19980122 00389 SW 1998 1 22 98ZZZX299 1 19971112 G 6230 206010336005 DRIVE SHAFT BELL 206 206L3 1182108 SW M/R MAST WORN B ZV1R K NONE O OTHER IN INSP/MAINT 1 SW 03 2616 51418 EXCESSIVE PLAY AT TWO PLACES. SEE BELL MM L-3, FIG 62-21. ON TEAR-DOWN, FOUND BEARINGS AND SPACERS WORN BEYOND LIMITS. TOTAL TIMES OF PARTS LESS THAN 1,000 HOURS/1 YEAR SINCE REPLACEMENT. 1 G 7 1 3U H2SW 1998010800062 19980108 00062 CE 1998 1 8 98ZZZX3 1 19971101 G 5347 CM32031 SEAT RAIL CESSNA 500 550 2076604 CE COPILOT RT OTBD WORN H K NONE O OTHER IN INSP/MAINT 1 GL 25 84EA 6514 550484 DURING PHASE 5 INSPECTION, FOUND HOLES WORN TO LIMITS AT CO-PILOT'S RIGHT SEAT RAIL HATCH. SPLICED IN NEW SECTION OF SE AT RAIL IAW CESSNA 550 SRM FIGURE 801. 1 L 7 2 4F A22CE 1998010800089 19980108 00089 CE 1998 1 8 98ZZZX30 1 19971003 G 5711 SPAR BEECH 18 H18 1151012 CE RT WS 32 CORRODED B NI2R K NONE O OTHER IN INSP/MAINT 1 CE 03 117ME BA638 CORROSION REVEALED ON FRONT SPAR LT WS 32, WS 46, AND WS 81 AND RT WS 32. 1 L 7 2 3R A765 1998012200390 19980122 00390 SW 1998 1 22 98ZZZX300 1 19971112 G 6230 206010336005 DRIVE LINK BELL 206 206L3 1182108 SW M/R MAST WORN B ZV1R K NONE O OTHER IN INSP/MAINT 1 SW 03 2619 51375 EXCESSIVE PLAY AT TWO PLACES. SEE BELL MM L-3, FIG 62-21. ON TEAR-DOWN, FOUND BEARINGS AND SPACERS WORN BEYOND LIMITS. TOTAL TIMES OF PARTS LESS THAN 1,000 HOURS/1 YEAR SINCE REPLACEMENT. 1 G 7 1 3U H2SW 1998012200391 19980122 00391 SW 1998 1 22 98ZZZX301 1 19971114 G 6230 206010336005 DRIVE LINK BELL 206 206L1 1182107 SW M/R MAST WORN B ZV1R K NONE O OTHER IN INSP/MAINT 1 SW 03 3899C RH0682 45596 EXCESSIVE PLAY AT TWO PLACES. SEE BELL MM L-3, FIG 62-21. ON TEAR-DOWN, FOUND BEARINGS AND SPACERS WORN BEYOND LIMITS. TOTAL TIMES OF PARTS LESS THAN 1,000 HOURS/1 YEAR SINCE REPLACEMENT. 1 G 7 1 3U H2SW 1998012200392 19980122 00392 SW 1998 1 22 98ZZZX302 1 19971114 G 6230 206010336005 DRIVE LINK BELL 206 206L1 1182107 SW M/R MAST WORN B ZV1R K NONE O OTHER IN INSP/MAINT 1 SW 03 2621 4132 45400 EXCESSIVE PLAY AT TWO PLACES. SEE BELL MM L-3, FIG 62-21. ON TEAR-DOWN, FOUND BEARINGS AND SPACERS WORN BEYOND LIMITS. TOTAL TIMES OF PARTS LESS THAN 1,000 HOURS/1 YEAR SINCE REPLACEMENT. 1 G 7 1 3U H2SW 1998012200393 19980122 00393 SW 1998 1 22 98ZZZX303 1 19971109 G 6510 406040340101 DISC PACK 407040302101 BELL 407 407 SW T/R DRIVE CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 407AL RNFS7130 53044 WHILE C/W AD 97-22-15, FOUND T/R DRIVE DISC PACK CRACKED BETWEEN NR 6 AND NR 7. SUBMITTER RECOMMENDS FLOATING DRIVESHAF TS SIMILAR TO THE BELL 206 SERIES. 1 G 7 1 3U O H2SW 1998012200394 19980122 00394 SW 1998 1 22 98ZZZX304 1 19971109 G 6510 406040340101 DISC PACK 407040302101 BELL 407 407 SW T/R DRIVE CRACKED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 417AL RNFS7132 53054 C/W OF AD 97-22-15, FOUND T/R DRIVE COUPLING DISC PACK AFT LAMINATE 'ONE' CRACKED BETWEEN NR 6 AND NR 7. SUBMITTER RECO MMENDS FLOATING DRIVESHAFTS SIMILAR TO THE BELL 206 SERIES. 1 G 7 1 3U O H2SW 1998012200395 19980122 00395 SW 1998 1 22 98ZZZX305 1 19971111 G 6322 406040339105 BEARING 407040303101 BELL 407 407 SW NR 2 T/R DRIVE ROUGH B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 427AL 1032 D960750 53107 TWENTY-FIVE HOUR INSPECTION FOUND OIL COOLER BLOWER BEARINGS ROUGH. ALSO, SHAFT SPLINES SHOW SIGNS OF LACK OF LUBRICATI ON. SUBMITTER RECOMMENDED IMPROVING BEARING AND LUBRICATION ON SHAFT TO COUPLING SPLINES. 1 G 7 1 3U O H2SW 1998012200396 19980122 00396 SW 1998 1 22 98ZZZX306 1 19971111 G 6322 406040339105 BEARING 407040303101 BELL 407 407 SW NR 2 T/R DRIVE ROUGH B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 427AL 1032 D960728 53107 TWENTY-FIVE HOUR INSPECTION FOUND OIL COOLER BLOWER BEARINGS ROUGH. ALSO, SHAFT SPLINES SHOW SIGNS OF LACK OF LUBRICATI ON. SUBMITTER RECOMMENDED IMPROVING BEARING AND LUBRICATION ON SHAFT TO COUPLING SPLINES. 1 G 7 1 3U O H2SW 1998010800090 19980108 00090 SO 1998 1 8 98ZZZX31 1 19971203 G 5210 4756400 AUXILIARY LOCK 5661705 PIPER PA42 PA42 7104202 SO CABIN DOOR FAILED D C D ABORTED TAKEOFF RETURN TO BLOCK O OTHER TO TAKEOFF 1 SW 99 4100L 5686 428001061 JUST PRIOR TO VR, DOOR HANDLE ROTATED AND DISENGAGED PINS. PILOT ABORTED TAKEOFF, CLOSED DOOR, AND TAXIED BACK TO PARKI NG. INITIAL INSPECTION REVEALED THAT AUXILIARY LOCK DID NOT ENGAGE. 1 L 7 2 4T A23SO 1998012200400 19980122 00400 SW 1998 1 22 98ZZZX310 1 19971110 G 6510 406040340101 DISC PACK BELL 407 407 SW T/R DRIVE CRACKED B S ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 437AL 53141 AD 97-22-15, 25-HOUR TAIL BOOM INSPECTION FOUND CRACKED DISCS NR 2 TO NR 3, NR 1 DISC IN PACK CRACKED, NR 5 TO NR 6 LOCA TION NR 10 DISC IN PACK CRACKED. SUBMITTER RECOMMENDED FLOATING DRIVESHAFTS SIMILAR TO THE BELL 206 SERIES. 1 G 7 1 3U O H2SW 1998012900081 19980129 00081 SO 1998 1 29 98ZZZX312 1 19970109 G 5310 FRAME PIPER PA25 PA25 7102502 SO FUSELAGE CORRODED D K NONE O OTHER IN INSP/MAINT 1 EA 23 6410Z 3006 25546 CORROSION AT TUBING CLUSTER 27 INCHES AFT OF FIREWALL ON LOWER LONGERON. GUSSETS SUPPORTING THE VERTICAL MEMBER HAD ALL OWED DEBRIS AND MOISTURE TO COLLECT ON LONGERON. LONGERON WAS PERFORATED BY RUST FORE AND AFT OF VERTICAL MEMBER ON RT SIDE. A SMALLER PERFORATION EXISTED IN FRONT OF VERTICAL MEMBER ON LT SIDE. GUSSET AREA APPARENTLY FILLED WITH A SEALA NT AT TIME OF MFG. THIS HAD BEEN REMOVED AND RTV SUBSTITUTED IN ITS PLACE. SUBMITTER BELIEVES CORROSION EXISTED PRIOR TO RTV APPLICATION. 1 L 7 1 3O 2A10 1998012900082 19980129 00082 EA 1998 1 29 98ZZZX313 2 19971202 G 8520 18486 CRANKSHAFT UNIVAR 108 1082 9230406 NM FRNKLN 6A4165 6A4165B3 27025 EA PROP FLANGE CRACKED D S K NONE O OTHER IN INSP/MAINT 1 NE 05 9504K 406 1082504 3153 INSPECTION FOUND CRANKSHAFT PROPELLER FLANGE CRACKED BETWEEN HOLES IN TWO PLACES. 1 H 7 1 3O 3 O A767 E238 1998012900085 19980129 00085 SW 1998 1 29 98ZZZX316 1 19971222 G 7931 98087 SWITCH GULSTM 560 560 0141402 SW LT ENG OIL PRESS LEAKING B BXSR K NONE K FLUID LOSS IN INSP/MAINT 1 EA 09 500UB 2685 5600052 LARGE AMOUNTS OF OIL WERE LEAKING FROM THE RT ENGINE. FOUND THE OIL PRESSURE SWITCH INTERNAL SEAL HAD FAILED. 1 H 7 2 3O 6A1 1998012900088 19980129 00088 SO 1998 1 29 98ZZZX319 1 19970625 G 2435 30E20111B GENERATOR GULSTM G1159 G1159B 3953535 SO BRUSHES WORN D K NONE O OTHER IN INSP/MAINT 1 SO 25 338AX 29 1503 30 BLACK SOOT ON COWLING. CHECKED GENERATOR BRUSHES AND FOUND UNDER ONE-QUARTER LIFE REMAINING. 2 L 7 2 4F RT A12EA 1999013000004 19990130 00004 GL 1999 1 30 98ZZZX3195 1 19971231 G 5102 ENVELOPE CAMRON CAMRON R420 R420 GL APPENDIX FAILED C A O OTHER O OTHER CL CLIMB 1 WP 07 GJNEE 1 4232 BALLOON APPENDICES FAILED TO VENT HELIUM FROM THE GAS CELL RESULTING IN RUPTURE OF THE BOTTOM HALF OF THE CELL. APPROXI MATELY ONE HOUR AFTER LAUNCH AT APPROXIMATELY 21,000 FEET, THE GAS CELL RUPTURED WHILE ASCENDING AT APPROXIMATELY 500 FP M. SUSPECT CAUSE, THE APPENDIX TORE LOOSE FROM THEIR ATTACHMENT POINTS. THE LOWER PORTION OF THE APPENDIX AT THE CELL ATTACHMENT RIPPED DUE TO THE WEIGHT OF THE UNRESTRAINED APPENDIX WHICH ALSO CAUSED THE APPENDIX TO SEAL OFF THE HELIUM E XIT POINT AT THE CELL RESULTING IN OVERPRESSURIZATION. RECOMMENDED SEWING APPENDIX CONTINUOUSLY TO ENVELOPE. 1 B 0 0 3X NC EXPA1B00 1998010800091 19980108 00091 CE 1998 1 8 98ZZZX32 1 19971108 G 7602 S12203 CONTROL CABLE CESSNA 210 210B 2073410 CE MIXTURE DEFECTIVE D A K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 14 4345X 21058033 UPON INSTALLATION, TWO NEW MIXTURE CABLES FROM CESSNA WERE FOUND DEFECTIVE IN THE VERNIER LOCK WHICH COULD CAUSE THE MIX TURE TO FLOAT OR JAM. ZERO HOURS ON PART. 1 H 7 1 3O 3A21 1998012900089 19980129 00089 CE 1998 1 29 98ZZZX320 1 19970411 G 5210 DOOR RAYTHN DH125 HAWKER800XP CE DOOR ATTACH MISINSTALLED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 11 404BS 258294 DURING A SCHEDULED INSPECTION OF THE CABIN DOOR ATTACH POINTS, FOUND BOTH ATTACH POINT BOLTS, CASTELLATED NUTS WERE MISS ING COTTER PINS AND VERY LOOSE. NOTED THAT NEITHER BOLT WAS DRILLED TO ACCEPT A COTTER PIN. IN FACT, ONE OF THESE BOLT S WAS SO LONG IT WAS RUBBING AGAINST THE ADJACENT STRUCTURE AS THE DOOR WAS OPENED AND CLOSED. THIS WAS THE FIRST TIME THIS AREA WAS OPENED FOR INSPECTION SINCE DELIVERY OF THE AIRCRAFT FROM RAYTHEON, LITTLE, ROCK, ARK. 2 L 7 2 4F RT A3EU 1998012900090 19980129 00090 CE 1998 1 29 98ZZZX321 1 19971204 G 5210 DOOR RAYTHN DH125 HAWKER800XP CE CABIN NOISY D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 11 404BS 258294 PILOT REPORTED GRINDING NOISE COMING FROM CABIN DOOR WHEN DOOR WAS OPENED OR CLOSED. UPON INSPECTION OF DOOR INTERIOR S TRUCTURE AND COMPONENTS, A NR 11 DRILL BIT WAS FOUND JAMMED BETWEEN TENSATOR MOTOR ASSY AND DOOR STRUCTURE. NO DAMAGE N OTED. GRINDING NOISE STOPPED AFTER DRILL BIT WAS REMOVED. THIS WAS THE FIRST ACCESS OF DOOR INTERIOR AFTER DELIVERY FR OM RAYTHEON, LITTLE ROCK, ARK. 2 L 7 2 4F RT A3EU 1998012900091 19980129 00091 EU 1998 1 29 98ZZZX322 1 19971218 G 2150 51590000 ACM BAG JETSTM JETSTM3201 1500217 EU CABIN AIR OVERSERVICED D A O OTHER B W SMOKE/FUMES/ODORS/SPARKS INADEQUATE Q C DE DESCENT 1 SO 03 861AE A0406321 861 WHILE PERFORMING A FLIGHT IDLE DESCENT RATE CHECK FLIGHT, THE COCKPIT FILLED WITH SMOKE. THE CAPTAIN DECLARED AN EMERGEN CY AND STARTED EMERGENCY PROCEDURES. THE SMOKE SMELLED LIKE OIL. THE CAPTAIN SHUT OFF BOTH BLEEDS. THE SMOKE STOPPED AND THE SMELL DIMINISHED. GROUND CHECKED AND FOUND THE LT ACM OVERSERVICED. PROPERLY SERVICED BOTH ACM'S AND RAN AIRCR AFT ON THE GROUND FOR OVER AN HOUR. NO FURTHER DISCREPANCY WAS NOTICED. 2 L 7 2 4T RT A56EU 1998012900094 19980129 00094 EU 1998 1 29 98ZZZX325 2 19970804 G 7412 NB34 IGNITER GULSTM G1159 G1159B 3953535 SO RROYCE SPEY SPEY5118 54523 EU ENGINE FAILED D K NONE O OTHER IN INSP/MAINT 1 SO 25 338AX 3352 30 IGNITER UNIT OVERHAULED 11 MONTHS, 138 HOURS, 66 CYCLES AGO. FAILED OPS INSPECTION WITH DISCHARGE ONLY EVERY 5-6 SECOND S. SHOULD BE APPROXIMATELY 1 SECOND. 2 L 7 2 4F 4 F RT A12EA E2EU 1998091100050 19980911 00050 EA 1998 9 11 98ZZZX3266 2 19970127 G 8550 LW15628 SEAL PIPER PA31 PA31P350 7103111 SO LYC O540 TIO540V2AD 41532 EA PROPELLER SHAFT FAILED D E A ENGINE SHUTDOWN UNSCHED LANDING J K WARNING INDICATION FLUID LOSS CR CRUISE 1 CE 03 134DE 1436 31P8414005 L839861A WHILE IN CRUISE AT FL 250, PROPELLER RPM WAS TO 1200 AND OIL PRESSURE TO ZERO. ENGINE WAS FEATHERED AND SHUT DOWN AND A SAFE LANDING WAS MADE. INVESTIGATION REVEALED PROPELLER SHAFT SEAL HAD COME LOOSE AND WAS LOOSE ON SHAFT. SUSPECT BRE ATHER SYSTEM HAD FROZEN AND CAUSED CRANKCASE PRESSURE RESULTING IN SEAL BEING DISLODGED. BREATHER SYSTEM WAS INSPECTED AND CLEANED. NEW SEAL WAS INSTALLED AND OIL FILTER WAS CHECKED AND FOUND OK. 1 L 7 2 3O 3 O RT A8EA E14EA 1998012900097 19980129 00097 EU 1998 1 29 98ZZZX328 1 19971125 G 6710 1174123101 BRACKET BOLKMS BK117 BK117C1 5626025 EU CYLIC BROKEN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117NC 393 7509 BRACKET WELDS BROKE. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1998012900098 19980129 00098 1998 1 29 98ZZZX329 4 19971204 G 3453 066011481111 LORAN KLN89 BELL 206 206L 1181522 SW FACEPLATE CRACKED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 206MH 100904 45426 LORAN FACE PLATE DISPLAY CRACKED. REMOVED AND REPLACED. 1 G 7 1 3U H2SW 1998010800092 19980108 00092 CE 1998 1 8 98ZZZX33 1 19971003 G 5711 SPAR BEECH 18 TC45G 1151016 CE LT WS 32 THRU 81 CORRODED B NI2R K NONE O OTHER IN INSP/MAINT 1 CE 03 445DM AF152 CORROSION FOUND ON FRONT SPART, LT WING STATIONS 32, 46, 57, 60, 62, 64, AND 81, AND RT WING STATION 32. REF: AD75-27- 09 R2 AND AMDT 39-3878. 1 L 7 2 3R A765 1998012900099 19980129 00099 GL 1998 1 29 98ZZZX330 2 19971201 G 7323 23004836 GOVERNOR 23004545 BELL 206 206L 1181522 SW ALLSN 250C 250C28B 03013 GL ENGINE FAILED B TI1R K NONE O OTHER NR NOT REPORTED 1 SW 05 206MH 236 BR36199 45426 CAE890566 GOVERNOR REMOVED FOR TORQUE SPIKES WITH POWER CHANGES. COMPONENT OF ENGINE 23004545, S/N CAE890566. REMOVED AND REPLAC ED. 1 G 7 1 3U 3 U H2SW E1GL 1998091100185 19980911 00185 EU 1998 9 11 98ZZZX3302 1 19970416 G 5610 7256110501 RIVET SAAB SF340 SF340A 7850100 EU COCKPIT MISINSTALLED B AY55 K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 03 46XJ 340A046 UPON INSPECTION OF THE PILOT'S AND COPILOT'S SIDE WINDSCREEN, FOUND HI-LOCKS SECURING THE WINDSCREEN PANES TO THEIR FRAM ES HAVE IMPROPER PROTRUSION THROUGH THE COLLARS. THIS HAS CAUSED SEVERAL HI-LOCK COLLARS TO LOOSEN AND VIBRATE OFF. RE F: OPERATOR CONTROL NR 98ZZZX3303. 2 L 7 2 4T RT A52EU 1998091100186 19980911 00186 EU 1998 9 11 98ZZZX3303 1 19970416 G 5610 7256110502 RIVET SAAB SF340 SF340A 7850100 EU COCKPIT MISINSTALLED B AY55 K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 03 46XJ 340A046 UPON INSPECTION OF THE PILOT'S AND COPILOT'S SIDE WINDSCREEN, FOUND HI-LOCKS SECURING THE WINDSCREEN PANES TO THEIR FRAM ES HAVE IMPROPER PROTRUSION THROUGH THE COLLARS. THIS HAS CAUSED SEVERAL HI-LOCK COLLARS TO LOOSEN AND VIBRATE OFF. RE F: OPERATOR CONTROL NR 98ZZZX3302. 2 L 7 2 4T RT A52EU 1998012900100 19980129 00100 EU 1998 1 29 98ZZZX331 1 19971018 G 3213 1175000212 SKID BOLKMS BK117 BK117C1 5626025 EU GEAR SKID WORN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 7505 PROTECTIVE SKID WORN BEYOND LIMITS. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1998012900101 19980129 00101 EU 1998 1 29 98ZZZX332 1 19971018 G 3213 1175000211 SKID BOLKMS BK117 BK117C1 5626025 EU GEAR SKID WORN B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 7505 SKID PROTECTIVE WORN BEYOND LIMITS. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1998012900102 19980129 00102 1998 1 29 98ZZZX333 4 19971110 G 3453 4309805000 LORAN 612B BOLKMS 117 BK117B1 5626012 EU COCKPIT FAILED B TI1R K NONE O OTHER NR NOT REPORTED 1 SW 05 460H 64336 7142 LORAN HEADINGS AND MILEAGE INCORRECT. RE: RMA 652062. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1998012900103 19980129 00103 1998 1 29 98ZZZX334 4 19971204 G 2312 064101900 TRANSCEIVER KY196 BOLKMS 105 BO105S 5626006 EU COCKPIT MALFUNCTION B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 495LF 13850 S645 UNABLE TO AJDUST SIDE TONE/MIC GAIN DOWN TO A SUITABLE LEVEL TO MATCH OUTPUT OF OTHER AVIONICS EQUIPMENT. REMOVED AND R EPLACED. 1 G 7 2 3U H3EU 1998012900104 19980129 00104 EU 1998 1 29 98ZZZX335 1 19971208 G 3610 97914211 VALVE BOLKMS 117 BK117A3 5626015 EU BLEED SOV FAILED B TI1R K NONE O OTHER NR NOT REPORTED 1 SW 05 527MB 1417 7103 VALVE INOPERATIVE. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1998012900105 19980129 00105 GL 1998 1 29 98ZZZX336 2 19971117 G 7532 23005366 BLEED VALVE BELL 206 206L 1181522 SW ALLSN 250C 250C30 03013 GL ENGINE FAILED B TI1R K NONE R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SW 05 721SP 618 FF34189 45486 CAE890696 ENGINE HAD COMPRESSOR STALL AT LOW POWER. REMOVED AND REPLACED BLEED VALVE. 1 G 7 1 3U 3 U H2SW E1GL 1998012900108 19980129 00108 CE 1998 1 29 98ZZZX339 1 19971201 G 3222 67420607 STRUT CESSNA 750 750 2076810 CE NLG MALFUNCTION D A A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 GL 23 5114 370 BMC017 7500017 THE AIRCRAFT DEPARTED DTW AND ON CLIMB-OUT, THE LANDING GEAR HANDLE WOULD NOT MOVE TO THE RETRACT POSITION. THE AIRCRAF T RETURNED TO DTW AND MAINTENANCE WAS ABLE TO DUPLICATE. UNDER CESSNA'S RECOMMENDATION, NEW SB 750-32-05 AND SB 750-32- 10 INCORPORATED TO ELIMINATE PROBLEMS IN NOSE STRUT EXTENSION. 2 L 7 2 4J RT T00007WI 1998010800093 19980108 00093 CE 1998 1 8 98ZZZX34 1 19971003 G 5711 SPAR BEECH 18 TC45G 1151016 CE RT WS 32 CORRODED B NI2R K NONE O OTHER IN INSP/MAINT 1 CE 03 445DM AF152 CORROSION FOUND ON FRONT SPAR, LT WING STATIONS 32, 46, 57, 60, 62, 64, AND 81, AND RT WING STATION 32. REF: AD75-27-0 9 R2 AND AMDT 39-3878. 1 L 7 2 3R A765 1998012900109 19980129 00109 CE 1998 1 29 98ZZZX340 1 19971201 G 3222 67420607 STRUT CESSNA 750 750 2076810 CE NLG MALFUNCTION D A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 GL 23 5116 316 BMC020 7500019 THE AIRCRAFT DEPARTED DTW AND ON CLIMB-OUT, THE LANDING GEAR HANDLE WOULD NOT MOVE TO THE RETRACT POSITION. THE AIRCRAF T RETURNED TO DTW AND MAINTENANCE WAS UNABLE TO DUPLICATE. GALLING WAS DETECTED IN THE CHROME SECTION OF THE STRUT ASSY AND THE UNIT WAS SENT BACK TO WICHITA FOR EVALUATION. 2 L 7 2 4J RT T00007WI 1998012900112 19980129 00112 CE 1998 1 29 98ZZZX344 1 19971231 G 5720 0512122 BEARING BLOCK CESSNA 180 180 2072602 CE RT AFT BLOCK CORRODED D K NONE O OTHER IN INSP/MAINT 1 AL 03 1682C 3706 30382 RIGHT REAR BLOCK IN REAR CARRY-THROUGH BULKHEAD CORRODED IN BOLT HOLE AND INTERGRANULAR CORROSION IN BLOCK. 1 H 7 1 3O NC 5A6 1998012900113 19980129 00113 SO 1998 1 29 98ZZZX345 1 19971231 G 5751 U18279 HINGE FITTING U582731 LUSCOM 8 8F 8190114 SO RT AIL CENTER MISMANUFACTURED B FE6R K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 11 1895B 6322 A NEW FAA PMA RIGHT AILERON IS PURCHASED FROM UNIVAIR AIRCRAFT FOR INSTALLATION ON AIRCRAFT. THE AILERON WOULD NOT FIT ON THE AIRCRAFT AS RECEIVED DUE TO MISALIGNMENT OF THE CENTER HINGE FITTING. NO OTHER AILERON WAS AVAILABLE FROM THIS M ANUFACTURER. THE MANUFACTURER SHIPPED AN UNDRILLED CENTER HINGE FITTING P/N U18279 WHICH WAS INSTALLED ON THE NEW AILER ON. SUBSEQUENT OPERATION WAS NORMAL. 1 H 7 1 3O A694 1998012900117 19980129 00117 CE 1998 1 29 98ZZZX349 1 19971215 G 3060 W31X2M1620 BREAKER CESSNA 340 340A 2076405 CE PROPELLER DEICE FAILED G A A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 SO 13 340MT 340A0741 PROPELLER DE-ICE WAS SELECTED ON AIRCRAFT CLIMBING THROUGH SNOW FLURRIES. THE PROPELLER DE-ICE PIGTAIL WIRES AT PROPELL ER HUB WERE SHORTED TO THE SPINNER. THIS CAUSED SMOKE IN THE COCKPIT. AIRCRAFT RETURNED AND MADE AN UNEVENTFUL LANDING . THE PROPELLER DE-ICE CIRCUIT BREAKER DID NOT TRIP TO THE OFF OR OPEN POSITION ALLOWING THE WIRING FROM THE CIRCUIT BR EAKER TO THE DE-ICE GAUGE TO BURN IN TWO. 1 L 7 2 3O 3A25 1998010800094 19980108 00094 GL 1998 1 8 98ZZZX35 3 19971101 G 6111 BLADE CESSNA 172 172RG 2072438 CE MCAULY 2D34C B2D34C220 GL PROPELLER BROKE G A UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 EA 17 6278R 172RG0139 842548 APPROXIMATELY 4 INCHES OF PROPELLER TIP BROKE OFF IN-FLIGHT. AIRCRAFT MADE EMERGENCY LANDING. 1 H 7 1 3O 3A17 5 C P7EA 1998012900124 19980129 00124 CE 1998 1 29 98ZZZX356 1 19971201 G 3260 YZ2RN7T SWITCH CESSNA 210 T210N 2073456 CE NLG UPLOCK CRACKED D K NONE N FALSE WARNING CL CLIMB 1 SO 16 5515Y 21064233 NOSE GEAR UPLOCK SWITCH PLUNGER CRACKS AT INSERT (PLASTIC). SECOND AIRCRAFT IN LAST YEAR WITH THIS PROBLEM DISCOVERED D URING ANNUAL INSPECTION. THIS CRACKING PERMITS MOISTURE INSIDE THE HOUSING CAUSING ERRONEOUS UNLOCK INDICATIONS IN COCK PIT WHEN GEAR IS ACTUALLY UP AND LOCKED. 1 H 7 1 3O 3A21 1998012900126 19980129 00126 SO 1998 1 29 98ZZZX358 1 19971219 G 3244 30855 TIRE MCCREARY 65010 PIPER PA31T PA31T1 7103126 SO MLG CHAFED E L A K NONE O OTHER IN INSP/MAINT 1 GL 11 2427W 311104005 INSTALLED TIRE ON WHEEL, NOTICED MINIMUM CLEARANCE ON SIDEWALL TIRE HAS TWO GROOVES CUT IN IT BY THE BRAKES. SUBMITTER STATED TIRE IS A DIFFERENT SHAPE THAN A GOODYEAR TIRE. 1 L 7 2 3T A8EA 1998012900127 19980129 00127 CE 1998 1 29 98ZZZX359 1 19971201 G 3310 15703014 DIMMER ASSY CESSNA 172 172R 2072401 CE INST LIGHTS MISWIRED B S A N3XR A UNSCHED LANDING B W SMOKE/FUMES/ODORS/SPARKS INADEQUATE Q C NR NOT REPORTED 1 SO 15 403ER 34 17280245 DURING A TRAINING FLIGHT, THE CREW SMELLED A BURNING SCENT. AFTER FOLLOWING THE EMERGENCY CHECKLIST, THEY WERE GOING TO LAND OFF-FIELD. THE SMELL DIMINISHED AND THEY PROCEEDED TO X-47. DURING THE FOLLOWING INSPECTION, A RESISTOR WAS FOUN D BURNED IN HALF ON THE DIMMER ASSY. IT WAS DISCOVERED THE UNIT IS WIRED INCORRECTLY. IT APPEARS TO BE A FLEET PROBLEM . AFTER A CALL TO CESSNA, DISABLED THE DIMMERS IN THE ENTIRE FLEET. SB 97-33-01 APPLIES. 1 H 7 1 3O NT 3A12 1998010800095 19980108 00095 SO 1998 1 8 98ZZZX36 1 19971124 G 7603 CONTROL LUSCOM 8 8A 8190104 SO THROTTLE FAILED G S A A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 CE 09 71329 2756 LOSS OF ENGINE THROTTLE CONTROL CONTRIBUTED TO A FORCED LANDING AND SUBSEQUENT LOSS OF DIRECTIONAL CONTROL. INVESTIGATI ON DISCLOSED A CRACK IN THE RIGID THROTTLE CONTROL CONDUIT ALLOWING THE FLEXIBLE CONDUIT TO SEPARATE FROM THE FIXED COND UIT HOUSING. RECOMMEND CLOSE INSPECTION OF THIS AREA AT THE 100-HOUR ANNUAL INSPECTION. 1 H 7 1 3O A694 1998012900130 19980129 00130 SO 1998 1 29 98ZZZX362 2 19971211 G 8520 536580 CRANKSHAFT CONT O470 O47011 17026 SO 1ST FILLET CRACKED B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 176 CRANKSHAFT'S FIRST FILLET AREA CLOSEST TO FLANGE HAD A 50 PERCENT FSH INDICATION. 3 O E269 1998012900133 19980129 00133 1998 1 29 98ZZZX365 4 19971221 G 3425 5204210002 INDICATOR BOLKMS 117 BK117B1 5626012 EU HSI FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117LU 1736 7144 HSI INDICATOR ROTATES CLOCKWISE. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1998012900134 19980129 00134 1998 1 29 98ZZZX366 4 19971204 G 3421 4021541671 HORIZON BOLKMS BK117 BK117C1 5626025 EU COCKPIT FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117NC 82100980 7509 INOPERABLE FOR P/R CSAS SYSTEM. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1998012900135 19980129 00135 SW 1998 1 29 98ZZZX367 1 19971204 G 3340 SX5 SEARCH LIGHT BELL 206 206L 1181522 SW NOSE SECTION FAILED B TI1R K NONE O OTHER NR NOT REPORTED 1 SW 05 206MH 1243 45426 SEARCH LIGHT TURNS OFF IN-FLIGHT AND SOMETIMES WILL NOT RE-START. REMOVED AND REPLACED. 1 G 7 1 3U H2SW 1998012900136 19980129 00136 1998 1 29 98ZZZX368 4 19971119 G 3120 JB15307 CLOCK BOLKMS BK117 BK117C1 5626025 EU COCKPIT FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 623638 7505 CLOCK LOSES TIME, RUNS SLOW. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1998010800096 19980108 00096 SO 1998 1 8 98ZZZX37 1 19971212 G 7922 75944 VALVE PIPER PA28 PA28140 7102802 SO THERMO BYPASS DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 EA 05 8215N 2825419 LYCOMING SB 518C APPLIES. FOUND NUT LOOSE. REPLACED VERNATHERM. SUSPECT CAUSE: AGE AND WEAR. 1 L 7 1 3O 2A13 1998010800097 19980108 00097 SO 1998 1 8 98ZZZX38 2 19971205 G 8520 BOLTS LKHEED T33 T33A 5260402 WP CONT O520 IO520BB 17032 SO LOWER CASE LOOSE D K NONE O OTHER IN INSP/MAINT 1 GL 03 8262D 925 CE1645 578815 OIL SUMP QUICK DRAIN WOULD NOT OPEN. REMOVED QUICK DRAIN TO TROUBLESHOOT AND FOUND LOOSE BOLT LAYING ACROSS DRAIN HOLE IN OIL PAN. REMOVED OIL PAN AND FOUND 3 EACH .25 INCH FLANGE BOLTS AND 1 EACH .3125 INCH THROUGH-BOLT LYING IN PAN ALON G WITH NUTS AND WASHERS. ALL OTHER CASE (LOWER) BOLTS WERE LOOSE ENOUGH TO ROTATE. SUBMITTER STATED MOST LIKELY WAS NE VER TIGHTENED PROPERLY AT FACTORY. SHOULD HAVE BEEN TORQUED PROPERLY AND LOCKWASHERS OR TABS INSTALLED. THIS ENGINE HA S 925 HOURS SINCE NEW. MFG DATE 1992. 1 L 7 1 4J 3 O EXPA1L71 E5CE 1998010800098 19980108 00098 SO 1998 1 8 98ZZZX39 1 19971206 G 7820 2448401 MUFFLER PIPER PA24 PA24400 7102408 SO RT SIDE CRACKED D A A UNSCHED LANDING O OTHER CR CRUISE 1 CE 05 8452P 624 2627 RIGHT MUFFLER FAILED CAUSING CARBON MONOXIDE TO ENTER CABIN. PILOT BECAME INCAPACITATED. AIRCRAFT FLEW FOR 1.9 HOURS U NTIL FUEL EXHAUSTION, LANDED IN HAYFIELD. PILOT RECEIVED MINOR INJURIES. AIRCRAFT WAS DESTROYED. ACCIDENT NR CHI 98LA 055. 1 L 7 1 3O 1A15 1998010800063 19980108 00063 SO 1998 1 8 98ZZZX4 2 19971211 G 8520 536580 CRANKSHAFT CONT O470 O47011 17026 SO FIRST FILLET DEFECTIVE B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 176 CRANKSHAFT'S FIRST FILLET AREA CLOSEST TO FLANGE HAD A 59 PERCENT FSH INDICATION. 3 O E269 1998010800099 19980108 00099 SW 1998 1 8 98ZZZX40 1 19971210 G 2430 WIRE MOONEY M20 M20M 5870222 SW BATTERY DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 SO 03 9164Z 321 270213 PILOT REPORTED INTERMITTENT STARTING, VOLTAGE FLUCTUATION, AND LOW BATTERY CHARGE. INSPECTION FOUND NR 1 AND NR 2 BATTE RY GROUND STRAPS AT AIRFRAME ATTACHMENTS TO HAVE HIGH RESISTANCE AT GROUNDING POINT. CLEANED AREAS AND INSTALLED HARDWA RE REFERENCING MOONEY SI M20-97. SYSTEMS CHECKED OK. IT APPEARS THE AIRFRAME PRIMER COATING WAS ACTING AS AN INSULATOR . WHEN REMOVED, THE SYSTEMS OPERATED CORRECTLY. 1 L 7 1 3O RT 2A3 1998010800100 19980108 00100 EA 1998 1 8 98ZZZX41 2 19971118 G 8550 60746 IMPELLER 78528 PIPER PA28 PA28RT201 7102818 SO LYC O360 IO360C1C6 41514 EA OIL PUMP WRONG PART D L K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 03 2083G 28R7918014 L2009651A ENGINE DISASSEMBLED FOR MAJOR OVERHAUL AND DISCOVERED OIL PUMP HAD PREVIOUSLY BEEN ASSEMBLED WITH A LW18110 DRIVEN IMPEL LER WHICH IS CARBURIZED, AND A NR 60746 DRIVE IMPELLER WHICH IS NOT NITRIDE HARDENED. THIS IS CONTRARY TO THE INSTRUCTI ONS IN LYC SB 524. THIS WAS A LYC FACTORY OVERHAULED ENGINE SEVERAL YEARS AGO. THERE WAS NO RECORD OF OIL PUMP REPAIR SINCE OVERHAUL BY LYC. THE IMPELLER, EVEN THOUGH NOT CORRECT IN COMBINATION WITH THE MATING IMPELLER, WAS NOT EXCESSIVE LY WORN. 1 L 7 1 3O 3 O 2A13 1E10 1998010800101 19980108 00101 CE 1998 1 8 98ZZZX42 1 19970825 G 5741 1054200113 FITTING BEECH 76 76 1153005 CE LT WING ATTACH CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 24KK 6447 ME149 INSPECTION FOUND LEFT WING ATTACH FITTING CRACKED. 1 L 7 2 3O A29CE 1998010800102 19980108 00102 CE 1998 1 8 98ZZZX43 1 19970909 G 5741 1054200114 FITTING BEECH 76 76 1153005 CE RT WING ATTACH CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 272BA ME90 INSPECTION FOUND LEFT AND RIGHT WING ATTACH FITTINGS CRACKED. 1 L 7 2 3O A29CE 1998010800103 19980108 00103 CE 1998 1 8 98ZZZX44 1 19970909 G 5741 1054200113 FITTING BEECH 76 76 1153005 CE LT WING ATTACH CRACKED D A K NONE O OTHER IN INSP/MAINT 1 SW 99 272BA ME90 INSPECTION FOUND LEFT AND RIGHT WING ATTACH FITTINGS CRACKED. 1 L 7 2 3O A29CE 1998120400476 19981204 00476 NE 1998 12 4 98ZZZX4435 2 19971017 G 7261 0292105230 PUMP SKRSKY S76 S76A 8143006 NE TMECA ARRIEL ARRIEL1S 60030 NE NR 1 ENGINE MALFUNCTIONED B A EGRR K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 17 886AH 760153 15086 INSTALLED OVERHAULED OIL PUMP S/N 91S0 ON NR 1 ENGINE. DURING RUNS, FOUND OIL PUMP NOT DELIVERING PROPER AMOUNT OF PRES SURE. REMOVED OIL PUMP FROM ENGINE TO INSTALL ANOTHER OIL PUMP. 1 G 7 2 3U 3 U H1NE E19EU 1998120400477 19981204 00477 NE 1998 12 4 98ZZZX4436 2 19971017 G 7261 0292105230 PUMP SKRSKY S76 S76A 8143006 NE TMECA ARRIEL ARRIEL1S 60030 NE NR 1 ENGINE MALFUNCTIONED B A EGRR K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 17 886AH 760153 15086 INSTALLED OVERHAULED OIL PUMP S/N 59S0 ON NR 1 ENGINE. DURING RUNS, FOUND OIL PUMP NOT DELIVERING PROPER AMOUNT OF PRES SURE. REMOVED OIL PUMP (SECOND ONE) TO INSTALL ANOTHER OIL PUMP. INSTALLED NEW OIL PUMP FROM TURBOMECA TO FIX PROBLEM. 1 G 7 2 3U 3 U H1NE E19EU 1998020500210 19980205 00210 EA 1998 2 5 98ZZZX445 2 19971125 G 7314 LW15472 FUEL PUMP CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA ENGINE FUEL WRONG PART B L A DSBR K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 25 9480D 172RG1180 L3014336A A FACTORY OVERHAULED ENGINE WAS BEING INSTALLED WHEN MECH REPORTED UNABLE TO CONNECT THE FUEL LINES TO THE NEW FUEL PUMP (ENG DRIVEN). THE 'IN' AND 'OUT' PORTS WERE REVERSED. MFG WAS CONTACTED, AND A SECOND PUMP SENT, BUT IT WAS THE SAME P/N AS THE ORIG, BUT THE BOX HAD ANOTHER P/N ON IT. A 3RD PUMP REC'D WITH PN 2W16775 WHICH WAS THE CORRECT PART. THE A CFT PARTS MANUAL SHOWS TWO DIFFERENT FUEL SYSTEMS FOR ACFT SN 0001-0890 AND SN 0890 AND ON. THE FRIST TWO PUMPS WOULD H AVE FIT EARLY SERIAL NUMBERED ACFT. 1 H 7 1 3O 3 O 3A17 E286 1998121100011 19981211 00011 SO 1998 12 11 98ZZZX4454 2 19971215 G 8530 653443 VALVE GUIDE CESSNA 182 182P 2075816 CE CONT O470 O470S 17026 SO ENGINE WORN B MK5R K NONE O OTHER IN INSP/MAINT 1 GL 23 952CC 500 18263638 269416R DURING A ROUTINE COMPRESSION CHECK, LEAKAGE WAS FOUND PAST THE EXHAUST VALVE ON THE NR 3 CYLINDER. THE REMOVED CYLINDER , EXHAUST VALVE AND GUIDE WERE FOUND WORN OUT. SUBMITTER SUGGESTED POSSIBLE CAUSE AS DEFECTIVE PARTS AND/OR ASSEMBLY PR OCESS FROM THE FACTORY. 1 H 7 1 3O 3 O NT TA13 E273 1998121100016 19981211 00016 SO 1998 12 11 98ZZZX4459 2 19970217 G 8530 653446 VALVE GUIDE CESSNA 210 210R 2073458 CE CONT O520 IO520L 17032 SO ENGINE CRACKED B MK5R K NONE O OTHER IN INSP/MAINT 1 GL 23 962CC 1351 210649861 294563R A ROUTINE COMPRESSION CHECK INDICATES LEAKAGE ON THE NR 2 CYLINDER. FURTHER INVESTIGATION REVEALS A CRACK ON THE CYLIND ER HEAD THAT EXTENDS FROM THE FUEL INJECTOR HOLE TO THE SPARK PLUG HOLE. SUBMITTER SUGGESTED POSSIBLE CAUSE AS DEFECTIV E CYLINDER HEAD INSTALLED ON THE CYLINDER AT REMANUFACTURE OF THE ENGINE. 1 H 7 1 3O 3 O RT 3A21 E5CE 1998121100018 19981211 00018 SO 1998 12 11 98ZZZX4461 2 19970321 G 8530 653446 VALVE GUIDE CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO ENGINE WORN B MK5R K NONE O OTHER IN INSP/MAINT 1 GL 23 961CC 850 21064620 270385R DURING A ROUTINE COMPRESSION CHECK, EXCESSIVE LEAKAGE PAST THE PISTON RINGS WAS FOUND ON THE THE NR 2 CYLINDER. THE REM OVED CLYINDER WAS FOUND WORN OUT AND THE PISTON RINGS STUCK IN THE RING GROOVES. SUBMITTER SUGGESTED POSSIBLE CAUSE AS EXCESSIVE LEAD SLUDGE BUILD-UP FROM THE USE OF TCM APPROVED MOBIL AV1 OIL. 1 H 7 1 3O 3 O 3A21 E5CE 1998121100019 19981211 00019 SO 1998 12 11 98ZZZX4462 2 19971021 G 8530 653446 VALVE GUIDE CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO ENGINE EXHAUST WORN B MK5R K NONE O OTHER IN INSP/MAINT 1 GL 23 961CC 650 21064620 294754R DURING A ROUTINE COMPRESSION CHECK, LEAKAGE WAS FOUND PAST THE INTAKE VALVE ON THE NR 6 CYLINDER. THE REMOVED CYLINDER, INTAKE VALVE AND GUIDE WERE FOUND WORN OUT. THE VALVE LASH WAS ALSO FOUND TO BE EXCESSIVE ON THE NR'S 2, 4, AND 6 CYLI NDERS. THE PUSH RODS WERE REPLACED WITH .030 INCH OVERSIZE. THE VALVE LASH ON THE NR'S 1, 3, AND 5 CYLINDERS WERE FOUN D TO BE WITHIN SPECIFICATIONS AS THEY ALREADY HAD OVERSIZE PUSH RODS INSTALLED. SUBMITTER SUGGESTED POSSIBLE CAUSE AS D EFECTIVE PARTS AND ASSEMBLY PROCESS FROM THE FACTORY. 1 H 7 1 3O 3 O 3A21 E5CE 1998121100022 19981211 00022 SO 1998 12 11 98ZZZX4465 2 19970520 G 8530 648168 VALVE GUIDE CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO ENGINE EXHAUST WORN B MK5R K NONE O OTHER IN INSP/MAINT 1 GL 23 954CC 400 18265290 809905R DURING A ROUTINE COMPRESSION CHECK, LEAKAGE WAS FOUND PAST THE EXHAUST VALVE ON THE NR 3 CYLINDER. THE REMOVED CYLINDER , EXHAUST VALVE AND GUIDE WERE FOUND WORN OUT. SUBMITTER SUGGESTED POSSIBLE CAUSE AS DEFECTIVE PARTS AND/OR ASSEMBLY PR OCESS FROM THE FACTORY. 1 H 7 1 3O 3 O NT 3A13 E273 1998020500212 19980205 00212 EU 1998 2 5 98ZZZX447 1 19971118 G 6320 4639302052 CLUTCH RACE BOLKMS 105 BO105LSA3 5626020 EU M/R XMSN FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 911SV 133 2033 CLUTCH OUTER RACE FAILED IN TRANSMISSION 4649001006, SN 39. REMOVED AND REPLACED. 1 G 7 2 3U H3AU 1998020500213 19980205 00213 EU 1998 2 5 98ZZZX448 1 19971118 G 6320 4639202011 CLUTCH ASSY 4649001006 BOLKMS 105 BO105LSA3 5626020 EU M/R XMSN FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 911SV 940 2033 CLUTCH ASSY FAILED IN TRANSMISSION 4649001006, SN 39. REMOVED AND REPLACED. 1 G 7 2 3U H3AU 1998020500214 19980205 00214 EU 1998 2 5 98ZZZX449 1 19971118 G 6320 19E2321A BENDIX SHAFT 4649001006 BOLKMS 105 BO105LSA3 5626020 EU M/R XMSN FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 911SV E121U 2033 BENDIX SHAFT FAILED IN TRANSMISSION, 4649001006, SN 39. REMOVED AND REPLACED. 1 G 7 2 3U H3AU 1998010800104 19980108 00104 CE 1998 1 8 98ZZZX45 1 19971201 G 7120 MOUNT BOLT CESSNA 182 182K 2072724 CE ENGINE DETACHED D L A K NONE O OTHER IN INSP/MAINT 1 NE 03 2770Q 18257970 DURING OIL FILTER CHANGE, A REAR LORD MOUNT BOLT WAS FOUND DETACHED. OTHER 3 BOLTS WERE NOT TO TORQUE. ENGINE INSTALLE D IN 1988 AND IT IS SUSPECT BOLTS NOT PROPERLY TORQUED. 1 H 7 1 3O NT 3A13 1998020500220 19980205 00220 EA 1998 2 5 98ZZZX453 2 19971231 G 7250 3033351 CT VANE RING BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA ENGINE TURBINE CRACKED B DJSR K NONE O OTHER IN INSP/MAINT 1 GL 23 36CP 11 BB178 PCE81488 ON 12-31-97, REPAIR STA (RUHR840H) PERFORMED AN HSI FOR IFL GROUP INC., ON ENGINE, SN 81488, REPLACING CT VANE WITH AN O VERHAULED ONE. 10.8 HOURS LATER, HAD A 40 DEGREE INCREASE IN ITT. IFL SPLIT THE ENGINE AND FOUND SOME TIP RUB AND THAT THE CT VANE HAD DEVELOPED CRACKS IN 5 VANES ON TRAILING EDGES. SUSPECT CAUSE OF FAILURE IS THE VANE WAS NOT COMPLETELY STRESS RELIEVED AT THE TIME OF OVERHAUL. 1 L 7 2 4T 4 T A24CE E4EA 1998020500221 19980205 00221 CE 1998 2 5 98ZZZX454 1 19971201 G 2770 551425033 CONTROL CABLE CESSNA 501 501 2076603 CE ELEV CONT LOCK FRAYED B A TRKR K NONE O OTHER IN INSP/MAINT 1 SO 15 501LL 5010185 WHILE PERFORMING PHASE INSPECTION 1 THROUGH 5, FOUND THE ELEVATOR CABLE FRAYED GOING THROUGH THE CONTROL LOCK CONDUIT. T HE MM ALLOWS 3 STRANDS BROKEN IN ANY 10 INCH SECTION. THIS CABLE HAD 6 STRANDS BROKEN. SUSPECT CAUSE FOR THIS IS THE F RONT OF THE CONDUIT THE CABLE RIDES THROUGH HAD NYLON BUSHING. THE AFT END HAS NO BUSHING; THUS, THE CABLE CHAFED THE C ONDUIT. SUBMITTER STATED IF BUSHING WERE INSTALLED IN THE AFT PART OF THE CONDUIT, THIS PROBLEM WOULD NOT EXIST. 1 L 7 2 4F A27CE 1998020500222 19980205 00222 CE 1998 2 5 98ZZZX455 1 19971201 G 3222 67420607 NOSE GEAR CESSNA 750 750 2076810 CE STRUT MALFUNCTIONED C A UNSCHED LANDING O OTHER CL CLIMB 1 GL 23 5113 548 BMC011 7500013 THE AIRCRAFT DEPARTED DTW AND ON CLIMB-OUT, THE LANDING GEAR HANDLE WOULD NOT MOVE TO THE RETRACT POSITION. THE AIRCRAF T RETURNED TO DTW AND MAINTENANCE WAS ABLE TO DUPLICATE. UNDER CESSNA'S RECOMMENDATION, NEW SB 750-32-05 AND SB 750-32- 10 INCORPORATED TO ELIMINATE PROBLEMS IN NOSE STRUT EXTENSION. 2 L 7 2 4J RT T00007WI 1998121100243 19981211 00243 SO 1998 12 11 98ZZZX4554 1 19970910 G 2710 62701200 BALANCE CABLE PIPER PA32 PA32R301 7103218 SO AILERON BROKEN D A K NONE O OTHER IN INSP/MAINT 1 EA 25 9220B 908 3213048 DURING AN ANNUAL INSPECTION, DISCOVERED A FLAT SHINEY AREA ON THE BOTTOM SIDE OF THE LT AILERON BALANCE CABLE. THE LOCA TION OF THE CABLE IN QUESTION IS IN THE LT WING ROOT AREA JUST INBD OF THE WHEELWELL. AN IDLER PULLEY IS LOCATED IN THI S AREA. UPON FURTHER INSPECTION, CABLE WAS FOUND TO HAVE NUMEROUS BROKEN STRANDS. SUBMITTER STATED THE POSSIBLE CAUSE IS AN IDLER PULLEY THAT IS TOO SMALL OR MISALIGNED AND A POSSIBLE FIX WOULD BE TO INSTALL A LARGER PULLEY OR MAKE CABLE LIFE LIMITED TO A MAXIMUM OF 1,000 HOURS. 1 L 7 1 3O A3SO 1998020500223 19980205 00223 WP 1998 2 5 98ZZZX456 1 19971210 G 7921 U16011 OIL COOLER DOUG DC3 DC3C 3021457 WP RT ENGINE FAILED D E ENGINE SHUTDOWN K FLUID LOSS NR NOT REPORTED 1 AL 03 67588 16 441861 20536 OIL COOLER FAILED CAUSING LOSS OF OIL PRESSURE NR 2 ENGINE. SHUT ENGINE DOWN. EMERGENCY CIRCUMSTANCES REQUIRED RESTART OF ENGINE CAUSING ENGINE TO FAIL. 2 L 7 2 4R A669 1998121800009 19981218 00009 SO 1998 12 18 98ZZZX4599 1 19971110 G 7430 LUG IO3572001 PIPER PA28 PA28161 7102803 SO COCKPIT DAMAGED B S CDMR K NONE O OTHER IN INSP/MAINT 1 EA 17 9752C 1000 A1297H 287816524 TERMINAL BLOCK LUG FASTENER SHEARED. THE SCREWS USED TO ATTACH THE TERMINAL LEADS TO THE LUGS ARE DIFFICULT TO MANIPULA TE WITHOUT SPECIAL TOOLS. SUBMITTER SUGGESTED USING ALLEN HEAD SCREWS ON TERMINALS AND INCLUDE TORQUE PROCEDURES FOR PR OPER INSTALLATION. 1 L 7 1 3O 2A13 1998010800105 19980108 00105 SO 1998 1 8 98ZZZX46 1 19971209 G 2436 VR371 REGULATOR ELECTROSYS PIPER PA28 PA28181 7102807 SO ALTERNATOR SHORTED G A O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 WP 23 2819A 5 7071398 287990468 ACFT EXPERIENCED OVERVOLTAGE CONDITION THAT CAUSED SYSTEMS THAT WERE TURNED ON TO FAIL, AND ALL RADIOS TO PRODUCE HEAVY SMOKE. REGULATOR TEAR-DOWN REVEALED LARGE RESISTOR FOUND INSIDE UNIT UNATTACHED. IT APPEARS RESISTOR WAS NOT PROPERLY ATTACHED TO C/B. IF ACFT WAS OPERATING IN IFR CONDITIONS, IT COULD HAVE BEEN AN EASY FATAL. FOUND PMA HOLDER OF VOLTAG E REGULATOR, ELECTROSYSTEMS, CALLS FOR GROUND TO BE ATTACHED DIRECTLY TO ALTERNATOR. PIPER CALLS OUT GROUND BE ATTACHED TO REGULATOR. ELECTROSYSTEMS REP STATED GROUND MUST BE MADE AT ALTERNATOR. IT IS UNKNOWN IF GROUNDING INCONSISTENCY C OULD HAVE PREVENTED FAILURE. INSPECTOR RECOMMENDS THESE VOLTAGE REGULATORS BE INSPECTED FOR POOR SOLDER CONNECTIONS. 1 L 7 1 3O 2A13 1998121800010 19981218 00010 SO 1998 12 18 98ZZZX4600 1 19971215 G 2842 6810102 SENDING UNIT PIPER PA28 PA28161 7102803 SO FUEL CELL WORN D K NONE O OTHER IN INSP/MAINT 1 EA 17 8345Z 3121 288116167 DURING THE ACCOMPLISHMENT OF PIPER SB 1006 AND INSPECTION OF THE FUEL QUANTITY SENDERS, THE HOLE, IN THE FLOAT WHERE THE ARM IS ATTACHED, WAS FOUND SEVERELY WORN. WITH A LITTLE MORE WEAR, THE FLOAT WOULD COME OFF THE ARM. 1 L 7 1 3O 2A13 1998020500233 19980205 00233 SW 1998 2 5 98ZZZX466 1 19971125 G 6310 406040542106 ADAPTER BELL 206 206L4 1182110 SW DRIVE ADAPTER SCORED B GJQR K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 01 404W 2043 A654 52055 DURING INSPECTION DISCOVERED SAFETY WIRE PIGTAIL HAD BEEN TURNED IN WRONG DIRECTION AND HAD WORN A GROOVE IN THE FACE OF THE MAIN DRIVESHAFT ADAPTER. THIS CONDITION, IF NOT DISCOVERED, WOULD EVENTUALLY LEAD TO MAIN DRIVESHAFT FAILURE. 1 G 7 1 3U NC H2SW 1998010800106 19980108 00106 CE 1998 1 8 98ZZZX47 1 19971203 G 3213 51411022 AXLE CESSNA 402 402C 207590R CE RT MLG CRACKED D O OTHER O OTHER TX TAXI/GRND HDL 1 NE 01 406GA 14350 402C0329 PILOT HAD DIFFICULTY DURING TAXI, RT WHEEL BINDING. MAINTENANCE FOUND BRAKE DISC CONTACTING LOWER BARREL OF STRUT. FOU ND AXLE CRACKED UPON TIRE AND WHEEL REMOVAL. 1 L 7 2 3O A7CE 1998020500243 19980205 00243 SW 1998 2 5 98ZZZX475 1 19971203 G 6210 206015001107 BLADE BELL 206 206L3 1182108 SW M/R CORRODED B ALGR K NONE O OTHER IN INSP/MAINT 1 SW 03 3174Y 2114 A1836 51038 DISCOVERED DURING DAILY INSPECTION, M/R BLADE TRAILING EDGE EXTRUSION CORRODED CAUSING APPROXIMATELY 10 INCH LONG SEPARA TION. 1 G 7 1 3U H2SW 1998010800107 19980108 00107 CE 1998 1 8 98ZZZX48 1 19970831 G 5741 1054200113 FITTING BEECH 76 76 1153005 CE LT WING ATTACH CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 5424M 2283 ME31 INSPECTION FOUND LEFT AND RIGHT WING ATTACH FITTINGS CRACKED. 1 L 7 2 3O A29CE 1998020500436 19980205 00436 CE 1998 2 5 98ZZZX489 1 19971223 G 5741 1512122 BEARING BLOCK CESSNA 182 182D 2072710 CE LT/RT WING CORRODED D S A K NONE O OTHER IN INSP/MAINT 1 WP 23 9923T 4697 18253023 UPON REMOVING BOTH WINGS TO INSTALL MONARCH PLASTIC FUEL TANKS, THE REAR SPAR INBOARD ATTACH BLOCKS, LEFT AND RIGHT, WER E FOUND TO HAVE INTERGRANULAR CORROSION IN THE INBOARD SLOT AREA ABOVE THE LARGE BOLT HOLES. CORROSION AREA ABOUT .50 I NCH WIDE BY .1250 INCH DEEP FROM TOP OF BLOCK TO BIG BOLT HOLE ON INBOARD FACE OF SLOT. THIS AREA IS IMPOSSIBLE TO INSP ECT VISUALLY WITHOUT REMOVING THE WINGS. 1 H 7 1 3O NT 3A13 1998010800108 19980108 00108 CE 1998 1 8 98ZZZX49 1 19970831 G 5741 1054200113 FITTING BEECH 76 76 1153005 CE RT WING ATTACH CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 5424M 2283 ME31 INSPECTION FOUND LEFT AND RIGHT WING ATTACH FITTINGS CRACKED. 1 L 7 2 3O A29CE 1998010800064 19980108 00064 EA 1998 1 8 98ZZZX5 2 19971101 G 7414 M3333 IMPULSE COUPLING SLICK 6351 PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1G5 41532 EA DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 AL 05 1132Q 400 96030021 327740046 RL2130848A IMPULSE COUPLING HAS JUST UNDER 400 HOURS TIME IN SERVICE AND IS DEFECTIVE. 1 L 7 1 3O 3 O A3SO 1E4 1998010800109 19980108 00109 CE 1998 1 8 98ZZZX50 1 19971217 G 2434 318 ALTERNATOR FORD CESSNA 185 A185F 2072821 CE DC SYSTEM FAILED H K NONE O OTHER IN INSP/MAINT 1 NM 11 61423 5111176 18504180 ALTERNATOR FAILED. FOUND BRUSHES COMPLETELY WORN OUT IN JUST 608 HOURS. SUBMITTER STATED THIS IS THE SECOND ALTERNATOR FAILURE WITHIN 700 HOURS. 1 H 7 1 3O 3A24 1998010800110 19980108 00110 CE 1998 1 8 98ZZZX51 1 19971019 G 5741 1054200113 FITTING BEECH 76 76 1153005 CE LT WING ATTACH CRACKED D A K NONE O OTHER IN INSP/MAINT 1 SW 99 6049L 10063 ME202 INSPECTION FOUND LEFT WING ATTACH FITTING CRACKED. 1 L 7 2 3O A29CE 1998021100042 19980211 00042 CE 1998 2 11 98ZZZX519 1 19971224 G 7160 9591911295 BUSHING 9591911419 BEECH 95 B95 1153404 CE RT CARB AIR BOX WORN D A E ENGINE SHUTDOWN O OTHER NR NOT REPORTED 1 SW 11 2012C 8269 TD430 THE RIVETS ATTACHING THE WELD ASSY BUSHING PN 95-91912-95 TO THE RT ENGINE CARBURETOR AIR BOX ASSY PN 95-919114-19 WORKE D LOOSE CAUSING THE BUTTERFLY IN THE CARBURETOR HEAT BOX TO BECOME LODGED IN THE CARBURETOR HEAT ON POSITION RESULTING I N A FUEL RICH CONDITION FOR THE ENGINE. WHEN THE CARBURETOR HEAT CONTROL WOULD NOT PUSH IN TO TURN HEAT OFF (BECAUSE OF STUCK BUTTERFLY), THE PILOT OPTED TO SHUT DOWN THE ENGINE. 1 L 7 2 3O 3A16 1998010800111 19980108 00111 NE 1998 1 8 98ZZZX52 2 19971204 G 8530 5999 ROLLER PWA R1340 R1340AN1 52016 NE TAPPET SPALLED B CP2R K NONE O OTHER IN INSP/MAINT 1 SW 15 700 9561 VALVE TAPPET ROLLER WAS FOUND TO BE SPALLING AT THE TIME OF OTHER REPAIR TO THE ENGINE. METAL IN THE OIL SCREEN OR FILT ERS, AND A CHIP DETECTOR LIGHT WOULD BE EARLY WARNING SIGNS OF A PROBLEM. 3 R 5E2 1998021100043 19980211 00043 SO 1998 2 11 98ZZZX520 2 19971114 G 8530 SA630046 PISTON PIN BEECH 55 E55 1152732 CE CONT O520 IO520C 17032 SO NR 3 CYLINDER BROKEN D K NONE O OTHER IN INSP/MAINT 1 SW 11 191WE 740 TE1059 560027 ENGINE DISASSEMBLED FOR OVERHAUL. UPON NR 3 CYLINDER REMOVAL, PISTON PIN PN SA630046 FOUND BROKEN. NO OTHER DAMAGE NOT ED. 1 L 7 2 3O 3 O 3A16 E5CE 1998021100045 19980211 00045 SO 1998 2 11 98ZZZX522 1 19971224 G 2731 6270197 CONTROL CABLE PIPER PA34 PA34200 7103405 SO AP ELEV TRIM FRAYED D K NONE O OTHER IN INSP/MAINT 1 NE 01 15412 1288 347350060 AFT ELEVATOR TRIM/AUTOPILOT CABLE FRAYED WHERE IT GOES AROUND ELECTRIC TRIM AND AUTOPILOT SERVO PULLEYS. 1 L 7 2 3O A7SO 1998021100049 19980211 00049 CE 1998 2 11 98ZZZX526 1 19970123 G 2150 6462933400 BELT BEECH 36 A36 1151604 CE AIR CONDITIONING DELAMINATED B HUNR K NONE O OTHER IN INSP/MAINT 1 NM 01 1066T 292 E2996 AIR CONDITIONING BELT IS A TOOTH-TYPE BELT. FOUND 'TEETH' SECTIONS OF THE INSIDE DIAMETER OF THE BELT LAYING INSIDE THE ENGINE NACELLE. ON INSPECTION, FOUND 2.50 INCH SECTION OF BELT INSIDE EDGE MISSING. ACTT: 292.1 HOURS. 1 L 7 1 3O 3A15 1998010800112 19980108 00112 NE 1998 1 8 98ZZZX53 2 19971210 G 7230 DISK PWA JT9 JT9D7 52054 NE STAGE 8 CRACKED B OI5R K NONE O OTHER IN INSP/MAINT 1 GL 25 29864 347057 DURING COMPLEX INSPECTION (INCOMING INSP), ONE DOVETAIL WAS DISCOVERED DEFECTIVE. CRACK WAS ALONG THE WALL OF THE PRESS URE FACE CONTINUING ON THROUGH APPROXIMATELY HALF-WAY. THIS CRACK HAS THE CRITERIA ON THE DOVETAIL TO CAUSE LIBERATION. 4 F E20EA 1998021100055 19980211 00055 1998 2 11 98ZZZX532 1 19971222 G 2520 SL0231202 CYLINDER SL43008 SEAT RECLINE CRACKED B GVRR K NONE O OTHER IN INSP/MAINT 1 CE 05 CABIN SEAT RECLINE MECHANISM HYDROLOK CYLINDER HAS A CRACK. THE CRACK EXTENDED FROM THE SPLINED FIBER NUT TO THE END OF THE CYLINDER. THE CIRCUMSTANCES UNDER WHICH THE CRACK OCCURRED ARE UNKNOWN, BUT SUBMITTER SUGGESTED THE CAUSE AS FATIG UE. 1998021100060 19980211 00060 CE 1998 2 11 98ZZZX537 1 19971204 G 2822 111TW6003 SWITCH LEAR 35 35A 5170602 CE FUEL BOOST SHORTED D A K NONE O OTHER IN INSP/MAINT 1 WP 07 199CJ 130 071 FUEL BOOST SWITCH IS PART OF SB 35/36-28-11. THE SWITCH HAS AN INTEGRAL LIGHT. THE TWO WIRES FOR THE LIGHT ENTER THE S WITCH IN SUCH A WAY THEY CHAFE AT THE POINT WHERE THEY ENTER THE SWITCH. THIS CREATED A DIRECT SHORT TO GROUND OF THE P OWER WIRE FOR THIS LIGHT. AS A RESULT, THE BOOST PUMP CIRCUIT BREAKER TRIPPED IF THE PUMP WAS TURNED ON. ALSO, BOTH WA RNING LIGHT CIRCUIT BREAKERS TRIPPED IF THE ANNUNCIATOR PRESS-TO-TEST SWITCH WAS PRESSED. THIS HAPPENED ON THE GROUND D URING A PRE-FLIGHT. 2 L 7 2 4F A10CE 1998021100062 19980211 00062 CE 1998 2 11 98ZZZX539 1 19970107 G 5220 1014301835 WINDOW BEECH 200 200BEECH 1152920 CE 1ST CABIN RT CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 33 175SA 7526 BB183 INSPECTION FOUND WINDOW IN ESCAPE HATCH CRACKED. 1 L 7 2 4T A24CE 1998010800113 19980108 00113 EU 1998 1 8 98ZZZX54 1 19971215 G 2435 ARMATURE AUXILEC 8060140 AMD FALC50 FALCON900 2700160 EU START/GEN FAILED B A XC4R K NONE O OTHER IN INSP/MAINT 1 SO 19 601 356 ARMATURE, PN PO55742-7, ANTI-DRIVE END BAND DETACHED. THE WINDINGS AT ANTI-DRIVE END RUBBED STATOR/FRAME ASSEMBLY WINDI NGS TEARING BOTH WINDINGS FROM ARMATURE AND STATOR APART. BRUSH RIGGING HOLDERS BENT/DEFORMED AND END BELL CRACKED. DR IVE END BEARING BALLS AND CAGE DISINTEGRATED. 2 L 7 3 4F RT A46EU 1998021100063 19980211 00063 CE 1998 2 11 98ZZZX540 1 19971126 G 5620 1014301835 WINDOW BEECH 200 200BEECH 1152920 CE 3RD CABIN LT CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 33 175SA 7489 BB183 INSPECTION FOUND WINDOW CRACKED TOWARD FRONT SIDE. 1 L 7 2 4T A24CE 1998021100064 19980211 00064 CE 1998 2 11 98ZZZX541 1 19970107 G 5620 1014301835 WINDOW BEECH 200 200BEECH 1152920 CE 3RD CABIN RT CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 33 175SA 7526 BB183 INSPECTION FOUND WINDOW CRACKED ALMOST ALL THE WAY AROUND AFT SIDE. 1 L 7 2 4T A24CE 1998021100067 19980211 00067 CE 1998 2 11 98ZZZX544 1 19971228 G 3222 1243009201 PISTON ASSEMBLY CESSNA 210 T210L 2073449 CE NOSE GEAR BROKEN G K NONE O OTHER TX TAXI/GRND HDL 1 WP 23 732DK 2838 21061432 AIRCRAFT EXPERIENCED A NOSE LANDING GEAR FAILURE DURING TAXI OPERATIONS AFTER LANDING. SUBSEQUENT INSPECTION REVEALED T HE FORK AND PISTON ASSEMBLY BROKE AT THE CASTING AREA LOCATED AT THE POINT WHERE BOTH FORKS ATTACH TO THE PISTON ASSEMBL Y. 1 H 7 1 3O 3A21 1998021100072 19980211 00072 EU 1998 2 11 98ZZZX549 1 19970131 G 5511 453005509 FITTING ISRAEL 1124 1124 4500102 EU H STAB AFT SPAR CRACKED H A K NONE O OTHER IN INSP/MAINT 1 SW 09 1629 7428 363 CRACKS FOUND IN HORIZONTAL STABILIZER AFT SPAR SPLICE HINGE FITTING OUTBOARD LUGS. LANDINGS, 5,442. 2 M 7 2 4F A2SW 1998010800114 19980108 00114 NE 1998 1 8 98ZZZX55 3 19971203 G 6111 57C0792 BEARING BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE NR 4 BLADE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 8056 3860 HJ163A INNER AND OUTER RACE OF NR 4 BLADE SHANK BEARING FOUND BROKEN AND SEPARATED INTO NUMEROUS PIECES. HUB RENDERED SCRAP AS A RESULT OF BEARING FAILURE. SUBMITTER SUGGESTS ENGINEERING REVIEW OF LOADS IMPOSED AT BLADE/HUB INTERFACE. UNDER LOW C.F. LOADING, IF THE BLADE IS A MAXIMUM ALLOWABLE TIP MOVEMENT, POST SB A190 CONDITION (.750), THE BEARINGS MAY BE EXPE RIENCING CYCLICAL LOADS NOT PRESENT DURING ORIGINAL CERTIFICATION. 2 L 7 2 4T RT A24CE 5 C P10NE 1998021100073 19980211 00073 CE 1998 2 11 98ZZZX550 1 19970107 G 2701 051316714 YOKE CESSNA 182 182F 2072714 CE PILOTS FAILED D K NONE O OTHER IN INSP/MAINT 1 NM 04 3655U 4113 18255055 WHILE CHECKING ELEVATOR TRAVEL, YOKE BROKE WHEN BROUGHT UP AGAINST ELEVATOR STOP LEAVING BROKEN PART IN HAND. RECOMMEND PULL TEST. 1 H 7 1 3O NT 3A13 1998021100080 19980211 00080 CE 1998 2 11 98ZZZX557 1 19971219 G 5553 04311481 FITTING CESSNA 150 150J 2071820 CE VERTICAL STAB CRACKED D S A K NONE O OTHER IN INSP/MAINT 1 GL 15 51400 150699981 INSPECTION FOUND VERTICAL STABILIZER ATTACH FITTING CRACKED. 1 H 7 1 3O 3A19 1998021100082 19980211 00082 WP 1998 2 11 98ZZZX559 2 19971215 G 7240 31021731 DIFFUSER VANE SWRNGN SA226 SA226TB 8780406 SW GARRTT TPE331 TPE33110U 01514 WP HOT SECTOIN FAILED B A WD4R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 17 271DC 2992 T414 P35151C DURING HOT SECTION INSPECTION, FOUND DIFFUSER VANE P/N 3102173-1 BROKEN IN SEVERAL PIECES LYING ON TOP OF THE OUTER TRAN SITION LINER AND WEDGED BETWEEN THE COMPRESSOR HOUSING AND BOTTOM OF TRANSITION LINER. FURTHER INVESTIGATION REVEALED T HAT RECOMMENDED GARRETT SB TPE331-72-0458 HAD NOT BEEN C/W. 2 L 7 2 4T 4 T RT A5SW E4WE 1998010800115 19980108 00115 NE 1998 1 8 98ZZZX56 3 19971203 G 6111 57D0495 FORK BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 7900 4161 2109NR HJ234A INSPECTION FOUND FORWARD EAR OF PITCH CHANGE FORK CRACKED IN INBOARD RADIUS OF PITCH PIN ENGAGEMENT SLOTS. ONE CRACK. 2 L 7 2 4T RT A24CE 5 C P10NE 1998021100083 19980211 00083 NE 1998 2 11 98ZZZX560 3 19971216 G 6111 57C0792 BEARING BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE BLADE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 8658 4101 HJ235A BLADE INNER BEARING HALF CRACKED. CRACK IS APPROXIMATELY 2.750 INCHES LONG IN ONE-HALF ONLY. 2 L 7 2 4T RT A24CE 5 C P10NE 1998021100085 19980211 00085 WP 1998 2 11 98ZZZX562 1 19971223 G 5330 592487250 SKIN DOUG DC9 DC951 3022051 WP BS 908 CORRODED B L ERKR K NONE O OTHER IN INSP/MAINT 1 WP 07 420EA 71164 47689 DURING C-CHECK INSPECTION, DISCOVERED CORROSION ON THE FUSELAGE SKIN LAP SEAM AT BS 908, LONGERON 26R. REPAIRED BY TRIM MING OUT THE CORRODED OVERLAPPING SKIN, HFEC INSPECTING, FABRICATING AND INSTALLING REPAIR SKIN FILLER, INTERNAL FINGER DOUBLER AND EXTERNAL DOUBLER WET WITH SEALANT. ACCOMPLISHED IAW EVERGREEN AIR CENTER - ENGINEERING CHANGE/REPAIR AUTHOR IZATION NR N420EA-53-003-EAC. (X) 2 L 7 2 4F RT A6WE 1998021100086 19980211 00086 NM 1998 2 11 98ZZZX563 1 19971106 G 5730 SKIN BOEING 727 7272J4 1384006 NM LT WING TIP CRACKED B ERKR K NONE O OTHER IN INSP/MAINT 1 WP 07 696CA 48025 22574 DURING C-CHECK INSPECTION, DISCOVERED A CRACK ON THE LEFT HAND REMOVABLE WING TIP SKIN. REPAIRED BY TRIMMING AWAY DAMAG E, HFEC INSPECTING FOR ABSENCE OF CRACKS, FABRICATING AND INSTALLING REPAIR FILLERS, INTERNAL DOUBLER, SHIMS AND STRAP W ET WITH SEALANT AND ORIGINAL FASTENER TYPES. ACCOMPLISHED ON EVERGREEN AIR CENTER - ENGINEERING CHANGE/REPAIR AUTHORIZA TION NR N696CA-57-001-EAC. 2 L 7 3 4F RT A3WE 1998021100087 19980211 00087 CE 1998 2 11 98ZZZX564 1 19971201 G 5412 FIREWALL CESSNA 172 172R 2072401 CE LOWER LEFT CRACKED B S BWRR K NONE O OTHER IN INSP/MAINT 1 CE 07 376ES 271 17280059 DURING ANNUAL INSPECTION, FOUND FIREWALL CRACKED UNDER COWL FASTENER DOUBLER. AIRCRAFT HAS ONLY 271.0 HOURS TOTAL TIME. ADVISED MANUFACTURER CRACK WAS 2 INCHES LONG WITH ANOTHER CRACK 1 INCH LONG PROTRUDING FROM THE 2 INCH CRACK MAKING A 'Y'. 1 H 7 1 3O NT 3A12 1998021100088 19980211 00088 1998 2 11 98ZZZX565 4 19971205 G 3457 066040310111 GPS KLN90A COCKPIT FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 13197 GPS NEVER POWERED UP - HAS BEEN REPAIRED FOR THIS SAME PROBLEM TWICE. REMOVED AND REPLACED. 1998021100089 19980211 00089 1998 2 11 98ZZZX566 1 19971128 G 2436 51530001E1 REGULATOR DC SYSTEM FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 13526 VOLTAGE REGULATOR UNIT FAILED UPON INITIAL USE. REMOVED AND REPLACED. 1998021100090 19980211 00090 1998 2 11 98ZZZX567 4 19971208 G 2350 AA95454 AUDIO PANEL ICS SYSTEM FAILED B TI1R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 05 2998 AUDIO PANEL BAD OUT OF STOCK AFTER REPAIR. AIRCRAFT ICS WILL NOT WORK AT ALL. REMOVED AND REPLACED. 1998010800116 19980108 00116 NE 1998 1 8 98ZZZX57 3 19971203 G 6111 57C792 BEARING BEECH 1900 1900D 1154162 CE HARTZL HCE4A HCE4A3A NE NR 1 BLADE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 9295 4635 HJ239A INNER AND OUTER RACE OF NR 1 BLADE SHANK BEARING FOUND BROKEN AND SEPARATED INTO NUMEROUS PIECES. HUB RENDERED SCRAP AS A RESULT OF BEARING FAILURE. SUBMITTER SUGGESTED ENGINEERING REVIEW OF LOADS IMPOSED AT BLADE/HUB INTERFACE. UNDER LO W C.F. LOADING, IF THE BLADE IS AT MAXIMUM ALLOWABLE TIP MOVEMENT POST SB A190 CONDITION (.750), THE BEARINGS MAY BE EXP ERIENCING CYCLICAL LOADS NOT PRESENT DURING ORIGINAL CERTIFICATION. 2 L 7 2 4T RT A24CE 5 C P10NE 1998010800117 19980108 00117 EA 1998 1 8 98ZZZX58 2 19971101 G 7322 2524054 SERVO AMTR LONGEZ LONGEZ 05690Z8 GL LYC O360 IO360A1B6 41514 EA FUEL INJECTION CORRODED D L A A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 99 999TD 1546 L12564A DURING FLIGHT, ACFT ENGINE LOST POWER FOLLOWING A ONE 'G' POSITIVE MANEUVER. INVESTIGATION FOUND FUEL INJECTION SERVO W AS HANGING UP. SUSPECT CORROSION AND LACK OF LUBE. 1 M 7 1 3O 3 O RT EXPA1M71 1E10 1998010800065 19980108 00065 SO 1998 1 8 98ZZZX6 2 19971210 G 8530 646226 VALVE BEECH 36 A36 1151604 CE CONT O550 IO550B SO NR 3 CYL EXHAUST WORN B NT2R K NONE O OTHER IN INSP/MAINT 1 CE 07 3046K 1107 E2362 675310 CYLINDER NR 3 REMOVED DUE TO EXCESSIVE EXHAUST VALVE LEAKAGE DURING A COMPRESSION TEST. EXHAUST VALVE STEM WAS FOUND WO RN .023 INCH AT TIP OF STEM TO ABOUT THE CENTER OF STEM. GUIDE WAS NOT WORN (NITRALOY). NR 2 CYLINDER WAS REMOVED FOR ANOTHER REASON AND THE EXHAUST VALVE CHECKED OK. NR 6 CYLINDER EXHAUST VALVE WAS REMOVED DUE TO EXCESSIVE WEAR AT 625.7 HOURS. 1 L 7 1 3O 3 O 3A15 E3SO 1998021100123 19980211 00123 1998 2 11 98ZZZX600 4 19971121 G 2562 4520114 BATTERY ELT10 BOLKMS BK117 BK117C1 5626025 EU ELT DISCHARGED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 7505 ELT BATTERY MAX ALLOWABLE DISCHARGE LIMITS REACHED. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1998021100124 19980211 00124 SW 1998 2 11 98ZZZX601 1 19970902 G 6310 222044607003 COUPLING BELL 222 222U 1182140 SW M/R DRIVE CORRODED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 911LW A1275 47520 M/R DRIVE INNER COUPLING PITTING CORROSION ON TEETH. REJECTED. REMOVED AND REPLACED. 1 G 7 2 3U H9SW 1998021100125 19980211 00125 SW 1998 2 11 98ZZZX602 1 19971006 G 6310 222044672101S COUPLING BELL 222 222U 1182140 SW MAIN DRIVE CORRODED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 219HM A954 47573 COUPLING HAS CORROSION, PITTING ON TEETH. DAMAGED BEYOND LIMITS. REJECTED. REMOVED AND REPLACED. 1 G 7 2 3U H9SW 1998021100126 19980211 00126 NE 1998 2 11 98ZZZX603 2 19970804 G 7250 311565201 GAS GENERATOR PWA PT6 PT6A67D NE ENGINE MALFUNCTIONED B MASR K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SW 01 9478 2167 9E962 114179 THIS GAS GENERATOR CASE S/N 9E962 IS PRESENTLY AT E.D.M. FOR INVESTIGATION FOR LOW TORQUE COMPRESSOR STALLING. 4 T E26NE 1998021100127 19980211 00127 WP 1998 2 11 98ZZZX604 2 19971230 G 7250 30727121 BLADE LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP HP TURBINE FAILED B JY2R E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 GL 23 30HJ 2269 226 P74659 DURING CRUISE FLIGHT AT 41,000 FEET, THE RT ENGINE APPARENTLY HAD HP BLADE FAILURE RESULTING IN IN-FLIGHT SHUTDOWN. OPE RATOR DECLARED EMERGENCY AND HAD UNEVENTFUL LANDING AT TUL. DISASSEMBLY OF ENGINE CONFIRMED THE FAILURE. LOT NRS 4161, 4191, AND 4266. NOTE: SB 72-3494 HAD BEEN C/W AND SETS LIFE LIMIT AT 4,500 HOURS ON THIS PART. 2 L 7 2 4F 4 F A10CE E6WE 1998021100133 19980211 00133 CE 1998 2 11 98ZZZX610 1 19971201 G 5720 NUTPLATE BEECH 200 200BEECH 1152920 CE LT LE WING ROOT CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 03 520MC 8600 BB43 DURING AN INSPECTION OF THE AIRCRAFT, THE LEFT LEADING EDGE WING ROOT FAIRING WAS REMOVED TO PERFORM MAINTENANCE. A 2.5 0 INCH CRACK WAS FOUND FROM ONE OF THE RIVETS WHICH HOLD THE NUTPLATE IN PLACE FOR THE WING ROOT FAIRING IN THE PRESSURE VESSEL AREA. CRACK WAS STOP DRILLED AND A DOUBLER WAS INSTALLED. 1 L 7 2 4T A24CE 1998021100134 19980211 00134 CE 1998 2 11 98ZZZX611 1 19971201 G 5730 SKIN BEECH 200 200BEECH 1152920 CE LT/RT WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 03 520MC 8600 BB43 DURING AN EVENT 1 INSPECTION, CRACKS IN THE WING SKIN IN THE AREA OF THE LEFT AND RIGHT LOWER WING BOLT FITTING WERE FOU ND. THESE CRACKS TEND TO GO THROUGH THE HOLES WHERE SCREWS ARE USED TO SECURE THE SKIN TO THE WING SPAR CAP, AND EXTEND TO THE HOLE IN THE SKIN FOR THE FUEL DRAIN. SUBMITTER STATED SEVERAL OF THE E-90 FLEET HAVE HAD DOUBLERS INSTALLED TO REPAIR THIS PROBLEM IN THE PAST. 1 L 7 2 4T A24CE 1998021100135 19980211 00135 CE 1998 2 11 98ZZZX612 1 19971201 G 5730 SKIN BEECH 200 200BEECH 1152920 CE RT WING FUEL CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 03 520MC 8600 BB43 DURING AN EVENT 1 INSPECTION, A .50 INCH CRACK WAS FOUND IN THE SKIN AFT OF THE RIGHT FUEL FILLER CAP. THE CRACK APPEAR S TO BE DUE TO IMPROPER USE OF THE FUEL NOZZLE DURING FUELING. INSTALLATION OF AN INTERNAL DOUBLER WAS REQUIRED. 1 L 7 2 4T A24CE 1998021100136 19980211 00136 CE 1998 2 11 98ZZZX613 1 19971201 G 5712 RIB BEECH 200 200BEECH 1152920 CE LT WS 56-65-75 CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 03 520MC 8600 BB43 DURING AN EVENT 1 INSPECTION, 3 RIBS ON THE LEFT INBOARD WING AT STA 56.00, STA 65.50, AND STA 75.50 AND ONE ON THE RIGH T AT STA 65.50 WERE FOUND CRACKED ON THE FORWARD RIVET WHERE THE STRINGER IS ATTACHED. THE CRACK WENT FROM THE RIVET HO LE FORWARD TO THE EDGE OF THE RIB. SUBMITTER STATED CAUSE IS UNKNOWN, BUT SUSPECT IT IS DUE TO FLEXING OF THE WING. RE PAIRED BY INSTALLING A DOUBLER. 1 L 7 2 4T A24CE 1998021100138 19980211 00138 WP 1998 2 11 98ZZZX615 1 19971110 G 5330 591140659 SKIN DOUG DC9 DC932 3022066 WP BS 221 IMPROPER REPAIR B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 913VV 47318 DURING C-CHECK, FOUND REPAIR THAT DOES NOT MEET FUSELAGE PLATING REPAIR CRITERIA CLASS I, CLASS II, OR CLASS III AT FS 2 21 BETWEEN LONGERON 17LT AND CUSP. FABRICATED REPAIR, DRILLED, TREATED, PRIMED AND INSTALLED IAW ACM SKETCH 97840 REV A AND DAC ROD 97-11-17-ON. 2 L 7 2 4F A6WE 1998021100139 19980211 00139 NE 1998 2 11 98ZZZX616 2 19971222 G 7250 311899101 BLADE PWA PT6 PT6A67 52043 NE GAS GENERATOR DEFECTIVE B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 D.T.S. RECEIVED THREE SETS OF COMPRESSOR TURBINE BLADES (129 EACH) UNDER SALES ORDER 35879, CUSTOMER ORDER NR 8519. EXA MINING THE BLADES REVEALED A SURFACE DEFECT ON THE PARENT METAL ON THREE EACH BLADES THAT EXCEED THE OVERHAUL LIMIT OF 0 .003 INCH. REF: CHAPTER 72-50-02, PAGE 305B (2)(A) OF OVERHAUL MANUAL 3038337. THE THREE BLADES WERE RETURNED TO P & W FOR EVALUATION. 4 T E26NE 1998021100141 19980211 00141 NE 1998 2 11 98ZZZX618 2 19971223 G 7250 311899101 BLADE PWA PT6 PT6A67D NE GAS GENERATOR DEFECTIVE B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 D.T.S. RECEIVED THREE SETS OF COMPRESSOR TURBINE BLADES (129 EACH) UNDER SALES ORDER 36561, CUSTOMER ORDER NR 8612. EXA MINING THE BLADES REVEALED A SURFACE DEFECT ON THE PARENT METAL OF 69 EACH BLADES THAT EXCEEDS THE OVERHAUL LIMITS OF 0. 003 INCH. REF: CHAPTER 72-50-02 PAGE 305B(2)(A) OF OVERHAUL MANUAL 3038337. THE 69 BLADES WERE RETURNED TO P & W FOR EVALUATION. 4 T E26NE 1998021100142 19980211 00142 NE 1998 2 11 98ZZZX619 2 19971222 G 7250 3119899101 BLADE PWA PT6 PT6A67D NE GAS GENERATOR DEFECTIVE B MASR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 01 D.T.S. RECEIVED TWO SETS OF COMPRESSOR TURBINE BLADES (86 EACH) UNDER SALES ORDER NR 36248, CUSTOMER ORDER NR 8661. EXA MINING THE 86 EACH BLADES REVEALED A SURFACE DEFECT OF THE PARENT METAL THAT EXCEEDS OVERHAUL LIMITS OF 0.003 INCH. REF : CHAPTER 72-50-02 PAGE 305B(2)(A) OF OH 3038337. THE BLADE SETS WERE RETURNED TO P & W FOR EVALUATION. 4 T E26NE 1998021100143 19980211 00143 WP 1998 2 11 98ZZZX620 2 19971207 G 7250 3072712 BLADE LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP HP TURBINE FAILED B IY2R E A ENGINE SHUTDOWN UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 SW 15 727GL 2869 127 P74627 DURING FLIGHT AT 41,000 FEET CRUISE, THE RT ENGINE APPARENTLY HAD HP BLADE FAILURE RESULTING IN IN-FLIGHT SHUTDOWN. OPE RATOR DECLARED EMERGENCY AND HAD UNEVENTFUL LANDING IN BALTIMORE, MD. DISASSEMBLY OF ENGINE CONFIRMED THE FAILURE. NOT E: SB 72-3494 HAD BEEN C/W AND SETS LIFE LIMIT AT 4,500 HOURS ON THIS PART. 2 L 7 2 4F 4 F A10CE E6WE 1998021100146 19980211 00146 SW 1998 2 11 98ZZZX623 1 19971202 G 6510 406040340101 DISK PACK BELL 407 407 SW T/R DRIVE CORRODED B VE3D K NONE O OTHER IN INSP/MAINT 1 WP 01 58236 473 53069 INSPECTING HELICOPTER PER AD 97-22-15, FOUND TWO T/R DRIVE DISC PACKS BEYOND DAMAGE LIMIT. DAMAGE WAS DUE TO CORROSION. REPLACED DAMAGED PARTS. 1 G 7 1 3U O H2SW 1998021100478 19980211 00478 CE 1998 2 11 98ZZZX626 1 19971206 G 5712 RIB BEECH 200 200BEECH 1152920 CE WS 46,65,85 CRACKED D A K NONE O OTHER IN INSP/MAINT 1 NM 03 5ST 7206 BB289 RIBS ON THE LEFT WING, ONE STRINGER AFT OF THE LEADING EDGE AT WS 56.50, WS 65.50, AND WS 85.00 ARE CRACKED WHERE THE ST RINGER AND RIB ATTACH. THE CRACKS GO FROM THE RIVET HOLE FORWARD TO THE LEADING EDGE OF RIB SECTION. SUSPECT CRACKS AR E DUE TO THE FLEXING OF THE WING OVER TIME. REPAIRED BY INSTALLATION OF A DOUBLER. 1 L 7 2 4T A24CE 1998021100480 19980211 00480 1998 2 11 98ZZZX628 1 19971211 G 7100 3034 HOSE AEROQUIP ENGINE SYSTEM DEFECTIVE B BXSR K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 09 NEW AEROQUIP HOSE DATED 3Q97 WITH A DEFECT ON THE INSIDE DIAMETER. 1998021100481 19980211 00481 SO 1998 2 11 98ZZZX629 1 19971101 G 2912 756164 SPRING PIPER PA31 PA31310 7103103 SO LT/RT HYD FILTER MISSING B BXSR K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 09 272HJ 3572 317712055 BOTH THE LEFT AND RIGHT HYDRAULIC FILTER HOUSINGS WERE MISSING THEIR SPRINGS. THE SPRINGS HOLD THE FILTER IN PLACE AND WILL COMPRESS SHOULD THE FILTER PLUG UP. IT IS POSSIBLE THE FILTER COULD FALL OFF ITS INSTALLED POSITION WITHOUT THE SP RING IN PLACE. 1 L 7 1 3O RT A20SO 1998021100482 19980211 00482 SO 1998 2 11 98ZZZX630 1 19971101 G 2731 4248403 CONTROL CABLE PIPER PA31 PA31310 7103103 SO ELEVATOR TRIM DEFECTIVE B BXSR K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 09 272HJ 3572 317712055 FOUND THE ELEVATOR TRIM CABLE SPLICED IN TWO PLACES BOTH OF WHICH PASSED AROUND THE SERVO CAPSTAN. THERE IS NO RECORD O F THE SPLICES BEING DONE IN THE LOG BOOKS. THE TRIM SERVO MOTOR HAD BEEN REPLACED 30 HOURS PREVIOUSLY DUE TO IT BEING B URNED OUT (DID THE SPLICES STRESS THE MOTOR?) 1 L 7 1 3O RT A20SO 1998021100483 19980211 00483 SO 1998 2 11 98ZZZX631 1 19971101 G 5520 453226 BOOT PIPER PA31 PA31310 7103103 SO ELEVATOR MISSING B BXSR K NONE O OTHER IN INSP/MAINT 1 EA 09 272HJ 3572 317712055 FOUND ONE ELEVATOR COUNTER BALANCE LEADING EDGE BOOT MISSING AND THE FIBERGLASS SUB-SURFACE WAS ERODED. THE OTHER BOOT WAS TORN WHICH ALLOWS WATER TO GET INISDE THE BOOT WHICH WILL CHANGE THE BALANCE OF THE CONTROL SURFACE. 1 L 7 1 3O RT A20SO 1998021100484 19980211 00484 SO 1998 2 11 98ZZZX632 1 19971101 G 5753 ROLLERS PIPER PA31 PA31310 7103103 SO FLAP SEIZED B BXSR K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 09 272HJ 317712055 FOUND THE FLAP ROLLERS NOT TURNING DUE TO PAINT BEING ON THE ROLLERS AND TRACKS. ALSO, FOUND FLIGHT CONTROL SURFACE HAR DWARE COVERED WITH PAINT (WHERE THE CONTROLS EVEN OFF) AND THE CONTROL SURFACE LEADING EDGES HAD NO PAINT ON THEM. AIRC RAFT WAS PAINTED 1/94 BY CIMARRON AIRCRAFT CORP IN EL RENO, OK. 1 L 7 1 3O RT A20SO 1998021100485 19980211 00485 SO 1998 2 11 98ZZZX633 1 19971101 G 3213 4205907 TRUNNION PIPER PA31 PA31310 7103103 SO MLG CORRODED B BXSR K NONE O OTHER IN INSP/MAINT 1 EA 09 272HJ 3572 317712055 INSPECTION FOUND THE CYLINDER SIDEWALL (ON THE OUTSIDE) WITH DEEP INTERGRANULAR GALVANIC CORROSION. THIS CORROSION IS H ARD TO SPOT DUE TO ITS BEING IN THE GEARWELL AND BEHIND A LARGE HOSE CLAMP BRACKET. 1 L 7 1 3O RT A20SO 1998021100486 19980211 00486 SO 1998 2 11 98ZZZX634 1 19971101 G 2720 40040009 TORQUE TUBE PIPER PA31 PA31310 7103103 SO RUDDER CORRODED B BXSR K NONE O OTHER IN INSP/MAINT 1 EA 09 272HJ 317712055 FOUND THE RUDDER TORQUE TUBE AND WELDED ON ASSEMBLIES VERY CORRODED. THE WELDED ON PLATE IS ABOVE THE BOTTOM RIB ON THE RUDDER AND CAN ONLY BE SEEN THROUGH A SMALL CUT-OUT IN THE RIB WHERE THE TORQUE TUBE PASSES THROUGH. THE BOTTOM RIB (P N 40039-00) WAS ALSO UNAIRWORTHY DUE TO CORROSION. 1 L 7 1 3O RT A20SO 1998021100487 19980211 00487 SO 1998 2 11 98ZZZX635 1 19971101 G 5541 4003900 RIB PIPER PA31 PA31310 7103103 SO RUDDER CORRODED B BXSR K NONE O OTHER IN INSP/MAINT 1 EA 09 272HJ 317712055 FOUND THE RUDDER TORQUE TUBE AND WELDED ON ASSEMBLIES VERY CORRODED. THE WELDED ON PLATE IS ABOVE THE BOTTOM RIB ON THE RUDDER AND CAN ONLY BE SEEN THROUGH A SMALL CUT-OUT IN THE RIB WHERE THE TORQUE TUBE PASSES THROUGH. THE BOTTOM RIB (P N 40039-00) WAS ALSO UNAIRWORTHY DUE TO CORROSION. 1 L 7 1 3O RT A20SO 1998021100489 19980211 00489 CE 1998 2 11 98ZZZX637 1 19971210 G 2460 TB2 TERMINAL BOARD CESSNA 402 402B 207590P CE WS 27.125 SHORTED D A K NONE O OTHER IN INSP/MAINT 1 GL 17 6387X 4430 402B1350 DURING ROUTINE MAINTENANCE, CHANGING RIGHT COWL FLAP CABLE, THE HEATER'S FUEL LINE CONTACTED THE NON-INSULATED TERMINAL BOARD'S STUD AT RIGHT WING STA 27.125. PLACING MASTER SWITCH IN ON POSITION PROVIDED A SHORT CIRCUIT AND FIRE. THE TER MINAL BOARD'S STUDS NEED TO BE INSULATED FROM FUEL AND OIL LINES IN IMMEDIATE AREA. 1 L 7 2 3O A7CE 1998021100494 19980211 00494 SW 1998 2 11 98ZZZX642 1 19971211 G 6710 C4264221 RETAINER RONSON 206003 BELL 206 206BELL 1181502 SW M/R SERVO CRACKED B S B6HR K NONE O OTHER IN INSP/MAINT 1 NM 07 RH1243 SERVO RETAINER CAME BACK FROM NDT, INDICATED CRACKED. 1 G 7 1 3U H2SW 1998021100872 19980211 00872 NE 1998 2 11 98ZZZX670 2 19971201 G 7230 817401 HUB PWA JT8 JT8D15A 52051 NE C1 BLADE SLOT DAMAGED H K NONE O OTHER IN INSP/MAINT 1 SW 05 27593 14794 717164 AFTER LANDING AT SURABAYA, THE NR 1 ENGINE WAS FOUND WITH HEAVY COMPRESSOR DAMAGE. DURING INVESTIGATION, DISCOVERED THE C-1 HUB HAD A SECTION MISSING AT ONE OF THE BLADE SLOTS. PART S/N N96749. 4 F E2EA 1998010800001 19980108 00001 NE 1998 1 8 98ZZZX68 2 19971209 G 7250 657087 CASE 658199 SKRSKY S64 S64F NE PWA JFTD12 JFTD12A5A 52047 NE AFT FLANGE CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 178AC 2205 705 225 64097 638213 WHILE INSTALLED, AFT FLANGE OF CASE SN 225 FRACTURED 360 DEGREES WITHIN THE FLANGE WELD JOINT. FRACTURING OF AFT FLANGE ASSY ELIMINATED THE AFT MOUNT FROM ENG SUPPORT. ENG FREE TO MOVE VERTICALLY, LATERALLY, AND FORE AND AFT, UNRESTRAINED BY AFT MOUNT. THIS MOTION CAUSED DAMAGE TO COMPRESSOR DIFFUSER CASE MOUNT LOCATIONS WHICH WERE DISCOVERED CRACKED SHOR TLY AFTER REPLACEMENT OF FREE TURBINE ASSY. SUBMITTER STATED FAILURE OF AFT FLANGE WAS DUE TO AN IMPROPER REPAIR PERFOR MED BY ANOTHER REPAIR STATION AND CONSISTED OF INCOMPLETE FUSION IN AN EB WELD, MISMATCH BETWEEN WELDED PARTS, AND UNDER CUT IN HAZ ACTING AS A STRESS RISER. DEFECTIVE BY MEANS OF IMPROPER ACCOMPLISHMENT OF APPROVED P & W REPAIR PROCESS. 2 G 7 2 4U 4 U H6EA E15EA 1998021900001 19980219 00001 CE 1998 2 19 98ZZZX688 1 19970109 G 3244 500X5 TIRE BEECH 36 36BEECH 1151602 CE NLG FAILED D K NONE O OTHER LD LANDING 1 SW 05 1194A E159 NOSE LANDING GEAR TIRE BLOWN ON LANDING. NO OTHER TROUBLE. 1 L 7 1 3O 3A15 1998021900002 19980219 00002 CE 1998 2 19 98ZZZX689 1 19970107 G 3710 242 PUMP AIRBORNE BEECH 36 36BEECH 1151602 CE VACUUM SYSTEM FAILED D A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 SW 99 361BC E1331 DEPARTED AIRPORT AND WITHIN 30 MINUTES VACUUM PUMP BROKE. RETURNED TO BASE. NO OTHER TROUBLE. 1 L 7 1 3O 3A15 1998021900008 19980219 00008 SO 1998 2 19 98ZZZX695 1 19971022 G 2434 3656624 ALTERNATOR PIPER PA32 PA32260 7103206 SO FIELD WIRE SHORTING D S A K NONE H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 SO 15 7701J 1 A110854 321068 SUBMITTER HAS FOUND 2 FAULTY ALTERNATORS BACK-TO-BACK WITH THE SAME PROBLEM. THE FIELD WIRE SOLDERED CONNECTIONS, POINT S A AND B, STAND UP OFF OF THE ROTOR TOO HIGH AND MOMENTARILY TOUCH CASE. THIS OCCURRENCE AT HIGH RPM ONLY CAUSES THE F IELD CIRCUIT BREAKER TO TRIP. HARD PROBLEM TO FIND, IT ONLY OCCURS IN-FLIGHT AT HIGH 2,750 RPM, AND, ALT TEST BENCH DOE S NOT SPIN FAST ENOUGH TO FIND THE PROBLEM. 1 L 7 1 3O A3SO 1998010800066 19980108 00066 SO 1998 1 8 98ZZZX7 1 19971211 G 2150 460102 FAN 5134900 PIPER PA31T PA31T 7103124 SO A/C CONDENSER FAILED D A A E UNSCHED LANDING ENGINE SHUTDOWN B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 EA 23 57MR 1086 31T7620022 DURING CRUISE FLIGHT, PILOTS NOTICED SPARKS EMITTING FROM RT AFT NACELLE AT AIR CONDITIONING CONDENSER AIR SCOOP. RT GE NERATOR WAS SHUT OFF, BUT SPARKS CONTINUED. DECISION WAS MADE TO SHUT DOWN RT ENGINE AND PROBLEM SUBSIDED. AIRCRAFT HA D UNEVENTFUL LANDING. AN INVESTIGATION REVEALED AIR CONDITIONER CONDENSER IMPELLER FAN SEPARATED FROM CONDENSER FAN MOT OR SHAFT AND CHAFED A GENERATOR WIRE FROM TERMINAL 'C' TO RT STARTER SOLENOID CAUSING THE FAN BLADES TO ARC ON GENERATOR WIRE. 1 L 7 2 3T A8EA 1998021900153 19980219 00153 WP 1998 2 19 98ZZZX734 1 19971230 G 6320 369D2512711 RING GEAR HUGHES 369 369E 4470707 WP M/R TRANSMISSION BROKEN D A O OTHER J WARNING INDICATION NR NOT REPORTED 1 WP 01 272MK 499 0055701304 0256E PILOTS REPORTED MAIN ROTOR TRANS CHIP LIGHT AND KNOCKING SOUND. CHECKED CHIP PLUGS AND FOUND DARK GRAY INTERNAL LOOKING METAL ON CHIP DETECTOR. REMOVED MAIN ROTOR TRANSMISSION FROM SERVICE. SENT MAIN ROTOR TRANSMISSION TO NAC IN LONG BEA CH. WHEN DISASSEMBLED FOUND BROKEN TOOTH ON OUTPUT RING GEAR, PN 369D25127-11. 1 G 7 1 3U H3WE 1998021900155 19980219 00155 SW 1998 2 19 98ZZZX736 1 19971220 G 7712 407375003107 INDICATOR BELL 407 407 SW ENGINE TORQUE FAILED B VE3R K NONE O OTHER IN INSP/MAINT 1 WP 23 58236 522 84 53069 TORQUE INDICATOR WILL LOSE ALL POWER AT TIMES (INTERMITTENT). REPLACED INDICATOR. 1 G 7 1 3U O H2SW 1998043000245 19980430 00245 CE 1998 4 30 98ZZZX762 1 19971118 G 5753 FLAP CESSNA 182 182Q 2072732 CE RT WING JAMMED G O OTHER F FLT CONT AFFECTED AP APPROACH 1 GL 23 735YG 3239 18265786 ON APPROACH, PILOT SELECTED THE FLAP POSITION. THE RIGHT FLAP JAMMED AND TWISTED INTERFERRING WITH CONTROL OF THE RIGHT AILERON. PILOT LANDED WITHOUT INCIDENT. SUSPECT CAUSE WAS THE WING ATTACHING POINT SHOWED THE ROLLERS BEING LUBRICATE D, BUT WERE WORN; THUS, FAILING, CAUSING FLAP TO BIND WHEN EXTENDED. 1 H 7 1 3O NT 3A13 1998043000255 19980430 00255 EA 1998 4 30 98ZZZX772 2 19971125 G 8520 76948 CRANKSHAFT LYC O320 O320* 41508 EA JOURNAL RADII CRACKED G K NONE O OTHER IN INSP/MAINT 1 NE 03 101280 PART WAS REMOVED FROM INVENTORY AS PRECAUTION. THE CRANKSHAFT WAS RECENTLY SERVICED BY AIR AGENCY AND FOUND TO HAVE CRA CKS IN THE JOURNAL RADII. PART IS SCRAP. 3 O E274 1998010800131 19980108 00131 EU 1998 1 8 98ZZZX78 1 19971105 G 3246 C201801202 WHEEL AMD FALC50 FALCON900 2700160 EU BRAKE LUG CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 09 2465 U689 DURING EDDY CURRENT INSPECTION REQUIRED BY SL 24, FOUND ONE BRAKE DRIVE LUG CRACKED IN SUSPECT AREA NOTED IN SL. 2 L 7 3 4F RT A46EU 1998010800132 19980108 00132 EU 1998 1 8 98ZZZX79 1 19971105 G 3246 C201801202 WHEEL AMD FALC50 FALCON900 2700160 EU BRAKE LUG CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 09 2465 U681 DURING EDDY CURRENT INSPECTION REQUIRED BY SL 24, FOUND FIVE BRAKE DRIVE LUGS CRACKED IN SUSPECT AREA NOTED IN SL. 2 L 7 3 4F RT A46EU 1998022600058 19980226 00058 CE 1998 2 26 98ZZZX792 1 19970912 G 5512 SKIN BEECH 90 E90 1152914 CE LT HORIZ STAB CRACKED D S A K NONE O OTHER IN INSP/MAINT 1 SW 00 379VM 4271 LW27 IT APPEARS THAT VIBRATION AND LEFT HAND PROPELLER HARMONICS CAUSED OIL CANNING BETWEEN TWO STRINGERS THAT INDUCED THE OR IGINAL SKIN CRACK WHICH ENLARGED ITSSELF. FOUND DURING THE BEECH COMPLETE INSPECTION. SUBMITTER STATED IF GONE UNDETEC TED COULD CAUSE HORIZONTAL STABILIZER FAILURE WITH CATASTROPHIC RESULTS. SUBMITTER STATED TWELVE AMT'S AND REPRESENTATIV ES OF AVIATION HAVE NEVER SEEN THIS BEFORE. 1 L 7 2 3T 3A20 1998010800067 19980108 00067 SO 1998 1 8 98ZZZX8 1 19971212 G 5711 SPAR PIPER PA28 PA28RT201 7102818 SO WING FUEL AREA CORRODED D A K NONE O OTHER IN INSP/MAINT 1 EA 21 8368H 5560 28R8118062 COMPLIED WITH MANDATORY SB 1006 DURING ANNUAL INSPECTION. FOUND AND REPAIRED MINOR FUEL LEAKS AND SURFACE CORROSION IN WING SPAR AND WHEELWELL AREAS. REPAIRED LEAK, CLEANED AND TREATED CORROSION AND PAINTED AREA WITH CHEMICAL RESISTANT EP OXY ZINC CHROMATE PRIMER. SUBMITTER SUGGESTS C/W THIS BULLETIN AS SOON AS POSSIBLE ON ALL AFFECTED AIRCRAFT. SHOULD BE MADE AN AD NOTE. 1 L 7 1 3O 2A13 1998010800133 19980108 00133 NM 1998 1 8 98ZZZX80 1 19970725 G 3244 TIRE DOUG MD11 MD11 3023602 NM NR 7 WHEEL FAILED H O OTHER O OTHER LD LANDING 1 SW 99 103EV 48415 AIRCRAFT HAD SUFFERED A NR 7 TIRE TREAD PEEL-OFF ON 7-25-97 AT AMSTERDAM DURING LANDING. THE PEELED OFF TIRE CAUSED 6 F AN BLADES OF NR 3 ENGINE AND RIGHT HAND INBOARD FLAP TO BE DAMAGED. ALL DAMAGED FAN BLADES WERE REPLACED AND RIGHT INB OARD FLAP WAS REPAIRED. THE CAUSE OF NR 7 TIRE PEEL-OFF IS NOT YET DETERMINED. 2 L 7 3 4F RT A22WE 1998010800134 19980108 00134 CE 1998 1 8 98ZZZX81 1 19971212 G 5312 9544001337 BULKHEAD BEECH 95 95B55 1152729 CE BS 271.92 CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 21 111KF 2946 TC633 DURING ANNUAL INSPECTION, FOUND CRACKING IN TAIL AT FS 271.92 BULKHEAD. REPAIRED PER BEECHCRAFT SI 990. AREA VERY HARD TO INSPECT. SI 990 ALSO HAS INSPECTION CRITERIA. CRACKING FOUND ON 3 AIRCRAFT AT THIS STATION WHILE C/W SI 990. SUBM ITTER SUGGESTED BULLETIN AND AD NOTE ON THIS INSPECTION MAKING IT MANDATORY. 1 L 7 2 3O RT 3A16 1998022600442 19980226 00442 1998 2 26 98ZZZX813 4 19971105 G 2210 1015000385 CIRCUIT BOARD BEECH 200 200BEECH 1152920 CE AUTOTRIM MISMANUFACTURED B A ZE4R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 33 38473 BB842 FACTORY NEW REPLACEMENT AUTOTRIM RELAY ASSEMBLY (PC BOARD) CAUSES MANUAL AND AUTOTRIM TO RUN BACKWARDS. ALSO, HAS INCOR RECT GENDER FASTENERS. CAME WITH FEMALE FASTENERS, SHOULD HAVE MALE. 1 L 7 2 4T A24CE 1998010800135 19980108 00135 1998 1 8 98ZZZX82 4 19971212 G 6122 8210115 GOVERNOR WOODWARD MTSBSI MU2 MU2B40 CE PROPELLER FAILED D E A ENGINE SHUTDOWN UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 EA 21 157MA 1708431 424SA IN FLIGHT, RT ENGINE RPM DECAYED AND TORQUE ROSE. ALL OTHER PARAMETERS NORMAL. ENGINE WAS SHUT DOWN. AIRCRAFT RETURNE D TO RIC AND SAFE LANDING MADE. TROUBLESHOT BY MAINTENANCE FOUND BETA SYSTEM OK. PROPELLER GOVERNOR REPLACED WITH OVER HAULED UNIT. SYSTEM CHECKED OK. ON GROUND RUN DURING TROUBLESHOOTING, OLD PROPELLER GOVERNOR WOULD TRY TO FEATHER PROPE LLER WHEN MOVED OUT OF BETA RANGE. GOVERNOR SENT TO WOODWARD FOR OVERHAUL. SUSPECT INTERNAL FAILURE. GARRETT P/N FOR GOV IS 897410-7U. 1 H 7 2 3T A10SW 1998010800136 19980108 00136 SW 1998 1 8 98ZZZX83 1 19971205 G 6220 407010150101A FRAHM ASY BELL 407 407 SW M/R HEAD DEFECTIVE B GS1R K NONE O OTHER IN INSP/MAINT 1 EA 03 407AP 88 A37 53020 INSPECTION FOUND M/R FRAHM ASSY HAD LOOSE SPRINGS. REPLACED WITH NEW FRAHM FROM BELL HELICOPTER. 1 G 7 1 3U O H2SW 1998022600459 19980226 00459 SO 1998 2 26 98ZZZX831 1 19971230 G 2820 MIL6000 HOSE PIPER J3 PA11 7101102 SO FUEL SYSTEM DETERIORATED D A A UNSCHED LANDING Y ENGINE STOPPAGE NR NOT REPORTED 1 WP 23 5532H 111035 DURING A FATAL AIRCRAFT ACCIDENT INVESTIGATION, INTERNAL DETERIORATION OF MIL-6000 HOSE WAS FOUND PLUGGING A VENT LINE. THE HOSE WAS DATED DURING 1977 AND 1986. THE AIRCRAFT WAS OPERATING ON AUTO GAS (STC'D). THIS CONDITION HAS BEEN SEEN AND REPORTED BEFORE. IT IS IMPSSIBLE FOR A CAR GAS USER TO KNOW WHAT IS IN THE PRODUCT/GAS DUE TO REFINERY SWAPPING OF PRODUCT AND CO-MINGLING OF PRODUCTS. SUBMITTER STATED C/W WITH STC, NOT POSSIBLE AS IT IS WRITTEN. 1 H 7 1 3O A691 1998022600464 19980226 00464 1998 2 26 98ZZZX836 1 19971125 G 2720 WD607 PEDAL AMTR RV6 LT RUDDER FAILED G A K NONE O OTHER NR NOT REPORTED 1 CE 09 36AH 430 20814 LEFT RUDDER PEDAL SNAPPED OFF OF CROSS PIECE. ASSEMBLY WAS FACTORY PURCHASED. BOTH PARTS SENT TO NTSB FOR ANALYSIS. N TSB DETERMINED THERE WAS A FATIGUE CRACK ORIGINATING ON THE REAR OUTSIDE PORTION OF THE TORQUE TUBE. 0 1998010800137 19980108 00137 EA 1998 1 8 98ZZZX84 2 19971028 G 7322 293548 BELLOWS MA6AA BELL 47 47G3B 1181026 SW LYC O435 TVO435A1A 41516 EA CARB MIXTURE FAILED G A O OTHER R PARTIAL RPM/PWR LOSS CR CRUISE 1 NM 05 47AH 1086 AH1383 2645 L10652 HELICOPTER LOST ENGINE POWER IN-FLIGHT. DURING GROUND RUN TROUBLESHOOTING PROCESS, THE ENGINE WOULD NOT OPERATE ABOVE 1 500 RPM. THE MARVEL SCHEBELER (MODEL MA-6AA, SN AH-1-383) CARBURETOR WAS BENCH TESTED BY THE NTSB AND WOULD ONLY PERFOR M APPROXIMATELY 50 PERCENT CAPACITY. DURING CARBURETOR TEAR DOWN INSPECTION, FOUND PLASTIC RESIN ADHESIVE MISSING. THI S ADHESIVE LOCKS THE BELLOWS TO THE SHAFT ON THE AUTOMATIC MIXTURE CONTROL (PN 293-548). THIS ALLOWED THE BELLOWS TO M OVE DOWN THE SHAFT, THEREFORE, LIMITING FUEL OUTPUT. 1 G 7 1 3O 3 O 2H3 1E13 1998010800138 19980108 00138 SW 1998 1 8 98ZZZX85 1 19971112 G 6220 369D21200 HUB HUGHES 500N 500N 3027374 SW M/R VIBRATION G K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 WP 07 524FB 1769 70 LN004 ERRATIC TRACK AND BALANCE .89 IPS AT 11:00 TO .15 AT 9:00 CHANGES BY SHAKING COLLECTIVE GRIP LENGTH. ALSO, APPEARS TO C HANGE BY PULLING ON BLADES. 1 G 7 1 3U NC H3WE 1998010800139 19980108 00139 SW 1998 1 8 98ZZZX86 1 19971212 G 6210 206015001107 BLADE BELL 206 206L1 1182107 SW M/R CRACKED B KUVR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 19 166BH 1579 45661 DURING 100-HOUR INSPECTION, NOTICED PATCH ON BLADE LIFTING, REMOVED PATCH. FOUND 10 INCH CRACK RUNNING CHORD-WISE FROM REPAIR. THIS BLADE CAME FROM MANUFACTURER WITH PATCH AS NEW. 1 G 7 1 3U H2SW 1998010800140 19980108 00140 NE 1998 1 8 98ZZZX87 1 19971124 G 3233 1944L200 ACTUATOR S76719441000 SKRSKY S76 S76A 8143006 NE NLG DOWNLOCK FAILED B L A B8FR O OTHER O OTHER LD LANDING 1 GL 25 CGHJL 19088 80 760214 NOSE LANDING GEAR RETRACT ACTUATOR FAILED TO LOCK IN THE COMPRESSED POSITION (GEAR DOWN) CAUSING THE AIRCRAFT NLG TO COL LAPSE (MINOR DAMAGE TO AIRFRAME) WITH NO REPORTED INJURIES. ACTUATOR NEW 1981 AND PERFORMED PER DESIGN UNTIL REMOVAL 19 97 FOR LEAKING. UNIT RESEALED BY AN OUTSIDE CONCERN (NOT BFG) AND INCIDENT OCCURRED SHORTLY THEREAFTER. 1 G 7 2 3U H1NE 1998030500016 19980305 00016 GL 1998 3 5 98ZZZX870 3 19971105 G 6111 V84334 BLADE HARTZL HCA3V HCA3VK2 GL OUTER SHANK CRACKED B WD4R K NONE O OTHER IN INSP/MAINT 1 SO 17 A93342 BJ553 WHILE C/W AD 97-18-02, A LARGE CRACK WAS DISCOVERED IN THE 'V' OF THE DOUBLE SHOULDER BLADE SHANK AREA. 5 C P6EA 1998030500017 19980305 00017 GL 1998 3 5 98ZZZX871 3 19971105 G 6111 V84334 BLADE HARTZL HCA3V HCA3VK2 GL OUTER SHANK CRACKED B WD4R K NONE O OTHER IN INSP/MAINT 1 SO 17 A93340 BJ553 WHILE C/W AD 97-18-02, A LARGE CRACK WAS DISCOVERED IN THE 'V' OF THE DOUBLE SHOULDER BLADE SHANK AREA. 5 C P6EA 1998030500018 19980305 00018 EA 1998 3 5 98ZZZX872 2 19971104 G 8530 LW14995 SHROUD SPRING LYC O360 O360A1D 41514 EA PUSHROD TUBE FAILED D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 23 L666636 THE PUSHROD SHROUD TUBE SPRING RETAINER LOCATED UNDER THE VALVE COVER BROKE, AFTER ABOUT 8 HOURS OF SERVICE, ALLOWING TH E SHROUD TUBE TO MOVE AND CREATE EXCESSIVE OIL LEAKAGE. 3 O E286 1998030500021 19980305 00021 SO 1998 3 5 98ZZZX875 2 19970129 G 8530 65344A6 CYLINDER BEECH 36 A36 1151604 CE CONT O550 IO550B SO NR 5 CRACKED B ES4R K NONE O OTHER IN INSP/MAINT 1 AL 01 2043X 1185 E1387 281961R NR 5 CYLINDER HAD CRACK AT UPPER SPARK PLUG BOSS. THIS ENGINE HAS HAD C/W SID 97-2, SID 97-3, AND PROPER MAINTENANCE DU RING ITS LIFE. BAFFLING, FUEL SYSTEM SETUP, AND GENERAL MAINTENANCE HAVE BEEN CAREFULLY CONTROLLED ON THIS ENGINE. 1 L 7 1 3O 3 O 3A15 E3SO 1998010800141 19980108 00141 CE 1998 1 8 98ZZZX88 1 19971212 G 5740 60110000 FITTING BEECH 60 B60 1153605 CE LT/RT WING DAMAGED D K NONE O OTHER IN INSP/MAINT 1 EA 21 341D P397 WHILE C/W WING BOLT REPLACEMENT AND WING INSPECTION, FOUND LOWER AFT WING FITTINGS ON BOTH WINGS WITH COMPRESSION MARKS. BEECHCRAFT FIELD SERVICE CONTACTED PER MM INSTRUCTIONS. SPECIAL TOOLING AVAILABLE TO RESURFACE FITTING FACE. SUBMITT ER SUGGESTED OWNERS CONFORM TO WING BOLT INSPECTION/REPLACEMENT PER MM INTERVALS. 1 L 7 2 3O A12CE 1998030500033 19980305 00033 CE 1998 3 5 98ZZZX887 1 19971115 G 3211 05411211 GEAR SUPPORT CESSNA 182 182 2072702 CE MLG LT OTBD CRACKED H K NONE O OTHER IN INSP/MAINT 1 EA 23 6346A 6027 33146 BOTH LANDING GEAR OUTBOARD SUPPORT CASTINGS FOUND CRACKED DURING ANNUAL INSPECTION. AIRCRAFT CARRIES 5 PERSONS (PER STC ) DURING SKYDIVING OPERATIONS. NO RECORD OF PREVIOUS CHANGE OF THESE SUPPORTS. LANDING GEAR SHOULD BE CHECKED AFTER HA RD LANDINGS. 1 H 7 1 3O NT 3A13 1998030500034 19980305 00034 CE 1998 3 5 98ZZZX888 1 19971115 G 3211 05411212 GEAR SUPPORT CESSNA 182 182 2072702 CE MLG RT OTBD CRACKED H K NONE O OTHER IN INSP/MAINT 1 EA 23 6346A 6027 33146 BOTH LANDING GEAR OUTBOARD SUPPORT CASTINGS FOUND CRACKED DURING ANNUAL INSPECTION. AIRCRAFT CARRIES 5 PERSONS (PER STC ) DURING SKYDIVING OPERATIONS. NO RECORD OF PREVIOUS CHANGE OF THESE SUPPORTS. LANDING GEAR SHOULD BE CHECKED AFTER HA RD LANDINGS. 1 H 7 1 3O NT 3A13 1998010800142 19980108 00142 WP 1998 1 8 98ZZZX89 2 19971118 G 7210 30724632 DAMPER RING HWKSLY DH125 DH125400A 4230140 EU GARRTT TFE731 TFE7313 01518 WP PINION GEAR FAILED G E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 EA 21 545S 5346 NA0719 P80244 WHILE CRUSING AT 26,000 FEET, PILOT OBSERVED AN INCREASE IN OIL PRESSURE FOLLOWED BY A DROP IN PRESSURE. AS OIL PRESSUR E CONTINUED TO DECREASE TO 25 PSI, THE PILOT COMMANDED AN IN-FLIGHT SHUTDOWN. N1 SPEED WAS REPORTED TO BE AS HIGH AS 10 1.5 PERCENT. FAILURE OF THE FAN PLANETARY GEAR ASSEMBLY CAUSED BY A SEPARATION OF A SECTION OF THE PINION GEAR DAMPER R ING. THE SEPARATED SECTION OF THE DAMPER RING BECAME ENMESHED IN THE PLANETARY GEAR TRAIN AND DAMAGED IT EXTENSIVELY CA USING THE LP SPOOL AND FAN ASSEMBLY TO BECOME DECOUPLED. 2 L 7 2 4J 4 F A3EU E6WE 1998030500038 19980305 00038 CE 1998 3 5 98ZZZX892 1 19971115 G 3211 05411212 GEAR SUPPORT CESSNA 182 182 2072702 CE RT MLG OTBD CRACKED H K NONE O OTHER IN INSP/MAINT 1 EA 23 5553B 6913 33553 BOTH LANDING GEAR OUTBOARD SUPPORT CASTINGS FOUND CRACKED AT ANNUAL INSPECTION. AIRCRAFT CARRY 5 PERSONS (PER STC) DURI NG SKYDIVING OPERATIONS. NO RECORD OF PREVIOUS CHANGE OF THESE SUPPORTS. LANDING GEAR SHOULD BE INSPECTED AFTER HARD L ANDINGS. 1 H 7 1 3O NT 3A13 1998030500039 19980305 00039 CE 1998 3 5 98ZZZX893 1 19971115 G 3211 05411211 GEAR SUPPORT CESSNA 182 182 2072702 CE LT MLG OTBD CRACKED H K NONE O OTHER IN INSP/MAINT 1 EA 23 5553B 6913 33553 BOTH LANDING GEAR OUTBOARD SUPPORT CASTINGS FOUND CRACKED AT ANNUAL INSPECTION. AIRCRAFT CARRY 5 PERSONS (PER STC) DURI NG SKYDIVING OPERATIONS. NO RECORD OF PREVIOUS CHANGE OF THESE SUPPORTS. LANDING GEAR SHOULD BE INSPECTED AFTER HARD L ANDINGS. 1 H 7 1 3O NT 3A13 1998030500040 19980305 00040 SO 1998 3 5 98ZZZX894 2 19970129 G 8530 653447A CYLINDER CESSNA 207 207A 2073604 CE CONT O550 IO550* SO NR 4 CRACKED B ES4R K NONE O OTHER IN INSP/MAINT 1 AL 01 73463 1076 20700593 284588R NR 4 CYLINDER HAD CRACK AT UPPER SPARK PLUG BOSS. THIS ENGINE HAS HAD C/W SID 97-2, SID 97-3, AND PROPER MAINTENANCE. B AFFLING, FUEL SYSTEM SET-UP, AND GENERAL MAINTENANCE HAVE BEEN CAREFULLY CONTROLLED ON THIS ENGINE. 1 H 7 1 3O 3 O A16CE E3SO 1998030500041 19980305 00041 SO 1998 3 5 98ZZZX895 2 19970129 G 8530 653447A1 CYLINDER CESSNA 207 207A 2073604 CE CONT O550 IO550* SO NR 1 CRACKED B ES4R K NONE O OTHER IN INSP/MAINT 1 AL 01 73463 20700593 284588R NR 1 CYLINDER HAD CRACK AT UPPER SPARK PLUG BOSS. THIS ENGINE HAS HAD C/W SID 97-2, SID 97-3, AND PROPER MAINTENANCE. B AFFLING, FUEL SYSTEM SET-UP AND GENERAL MAINTENANCE HAVE BEEN CAREFULLY CONTROLLED ON THIS ENGINE. 1 H 7 1 3O 3 O A16CE E3SO 1998030500044 19980305 00044 EU 1998 3 5 98ZZZX898 2 19971127 G 7421 SPARK PLUG AMTR KITFOX KITFOX 05613LZ GL ROTAX 532 ROTAX532 55555 EU ENGINE FAILED H L K NONE O OTHER IN INSP/MAINT 1 SW 99 1 AN EQUIVALENT AUTOMOTIVE SPARK PLUG WAS USED IN PLACE OF THE ENGINE MANUFACTURER-RECOMMENDED SPARK PLUG DUE TO LOCAL AVA ILABILITY. AFTER APPROXIMATELY 25 HOURS, A ROUTINE INSPECTION CAUSED BOTH SPARK PLUGS TO BE REMOVED. THERE IS ONLY ONE SPARK PLUG PER CYLINDER AND TWO CYLINDERS PER ENGINE. THE FRONT SPARK PLUG, CLOSEST TO THE GEAR REDUCTION UNIT, WAS IN TERNALLY BROKEN - THE METAL ELECTRODE INSIDE THE PORCELAIN HOUSING HAD BROKEN IN HALF AND WAS FREE TO FLOAT INSIDE. 1 H 7 1 3I 3 I NC EXPA1H71 EXPE3I 1998010800068 19980108 00068 EA 1998 1 8 98ZZZX9 2 19971101 G 7414 M3333 IMPULSE COUPLING SLICK 6351 PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1G5 41532 EA DEFECTIVE D K NONE O OTHER IN INSP/MAINT 1 AL 05 8127K 500 46030011 327940268 L22070048A MAGNETO REMOVED AT 500 HOURS TIS DUE TO IMPULSE COUPLING DEFECT. 1 L 7 1 3O 3 O A3SO 1E4 1998010800143 19980108 00143 1998 1 8 98ZZZX90 4 19971111 G 3418 A233103 SWITCH CESSNA 525 525 2076601 CE AOA HEAT FAILED D K NONE O OTHER IN INSP/MAINT 1 GL 09 511AC 1837 5250090 AOA PROBE WOULD NOT HEAT. TRACED PROBLEM TO DEFECTIVE SWITCH. 1 L 7 2 4F RT A1WI 1998030500613 19980305 00613 NE 1998 3 5 98ZZZX905 2 19971020 G 7250 803003 BLADE PWA JT8 JT8D217A 52053 NE LPT ROTOR FAILED B RH2R K NONE O OTHER IN INSP/MAINT 1 SO 19 6047 P709747 ENGINE REMOVED FOR METAL IN THE TAILPIPE. 4 F E9NE 1998010800144 19980108 00144 CE 1998 1 8 98ZZZX91 1 19971215 G 4930 HOSE CESSNA 650 650 2076802 CE APU FUEL LEAKING C A K NONE K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 EA 23 67SF 6500045 CREW COMPLAINED OF FUEL ODOR IN AFT BAGGAGE COMPT. INVEST REVEALED A FUEL HOSE LEAKING THRU OUTER JACKET. HOSE IS APP ROX 16 INCHES LONG AND LOCATED ABOVE RT FWD CEILING OF AFT BAGGAGE COMPT BETWEEN APU FUEL SHUT-OFF VALVE AND A UNION. T HE OTHER SIDE IS ATTACHED TO ANOTHER HOSE WHICH GOES TO THE APU FUEL FILTER. TURBOMACH APU PARTS MANUAL SHOWS 1 HOSE TR AVELING BTWN VALVE AND APU. HOSES REPLACED WITH NEW TSO'D HOSE ASSY. OLD HOSES SHOWED SIGNS OF RUBBER BEING EXTRUDED THRU SS OUTER JACKET AND NO MARKINGS ON EITHER HOSE. COULD NOT DETERMINE IF HOSES WERE ORIGINAL. PATS SB NR SA 289NE-4 (FUEL VALVE RELOCATION) PREVIOUSLY C/W. SUBMITTER SUGGESTED A ONE-TIME INSP OF FUEL HOSES FOR APPROVED HOSE ASSYS. 2 L 7 2 4F A9NM 1998030500621 19980305 00621 EU 1998 3 5 98ZZZX913 1 19971111 G 2430 SP461300 TOGGLE SWITCH BOLKMS 117 BK117B1 5626012 EU DC SYSTEM FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 SWITCH SPRING WEAK. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1998030500625 19980305 00625 EA 1998 3 5 98ZZZX917 2 19970511 G 7314 LW13909 PUMP PIPER PA46 PA46350P SO LYC O540 TIO540AE2A 41532 EA ENGINE FUEL LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 SW 99 102PA 152 D8619 4636068 L976061A ENGINE WILL NOT SHUT DOWN WITH MIXTURE CONTROL. FOUND FUEL PUMP LEAKING INTO UPPER DECK LINE. 1 L 7 1 3O 3 O RT A25SO E14EA 1998010800145 19980108 00145 EU 1998 1 8 98ZZZX92 1 19971217 G 3520 C3512000 MASK BRAERO DH125 BAE125800A 1500285 EU FACE CAP TORN D L K NONE O OTHER IN INSP/MAINT 1 GL 07 601RS 258018 TEAR IN MASK FACE CUSHION PER SB 35-3014 AND SB C351-2000-35. MASK DOES NOT FALL WITHIN SB'S COMPLIANCE EVEN THOUGH THE MASK EXHIBITS THE SAME TEARING AS SPECIFIED IN SB. SUBMITTER SUGGESTED SB C351-2000-35-1 BY PURITAN-BENNETT AND SB 35- 3014 BY RAYTHEON SHOULD INCLUDE ALL MASKS OF THE C351-2000 SERIES. 2 L 7 2 4F RT A3EU 1998030500628 19980305 00628 SO 1998 3 5 98ZZZX920 1 19971223 G 3240 492152 VALVE PIPER PA31 PA31P 7103120 SO PARKING BRAKE MALFUNCTIONED D S K NONE O OTHER IN INSP/MAINT 1 SO 21 7300116 SUBMITTER SUGGESTS PARKING BRAKE VALVE P/N 492152 IS DEFECTIVE. WHEN HANDLE OR LEVER ASSY IS MOVED, IT DISENGAGES AND V ALVE CANNOT BE SET OR RESET. 1 L 7 2 3O A8EA 1998030500637 19980305 00637 EA 1998 3 5 98ZZZX929 2 19971125 G 8520 76948 CRANKSHAFT LYC O320 O320* 41508 EA JOURNAL CRACKED G K NONE O OTHER IN INSP/MAINT 1 NE 03 101280 PART REMOVED FROM INVENTORY AS PRECAUTION. THE CRANKSHAFT WAS RECENTLY SERVICED BY AIR AGENCY AND FOUND TO HAVE CRACKS IN THE JOURNAL RADII. PART IS SCRAP. NELSON W.O. 1 533. 3 O E274 1998010800146 19980108 00146 CE 1998 1 8 98ZZZX93 1 19971212 G 5540 RUDDER CESSNA 500 S550 2076607 CE TIP CAP LIGHTNING STRIKE D K NONE C F.O.D. NR NOT REPORTED 1 EA 21 674JM 3137 S5500127 AIRCRAFT ENTERED SHOP FOR ROUTINE MAINTENANCE AND DURING PRELIM INSPECTION NOTICED RUDDER TIP CAP BURNED AND LOOSE. TEA R DOWN INSP OF RUDDER SHOWED INTERNAL SIGNS OF OVERHEATING. OWNER QUESTIONED AND WAS DETERMINED THAT AT SOME PREVIOUS T IME, ACFT HAD A LIGHTNING STRIKE AND HAD NEVER BEEN INSPECTED PER ATA CHAPTER 5 MM. RUDDER HAD TO BE REBUILT AND DURING INSPECTION, OTHER AREAS OF OF LIGHTNING STRIKES HAD TO BE REPAIRED. SUBMITTER SUGGESTED PILOTS HAVE ACFT INSPECTED AS SOON AS POSSIBLE AFTER LIGHTNING STRIKES. 1 L 7 2 4F RT A22CE 1998010800147 19980108 00147 1998 1 8 98ZZZX94 4 19971219 G 6122 8210260 GOVERNOR WOODWARD BEECH 100 B100 1152919 CE PROPELLER FAILED D A A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 GL 25 924RM 294 981946A BE63 DURING FLIGHT, RIGHT ENGINE FLAMED OUT, NTS AND THE PROP FEATHERED. AN UNEVENTFUL LANDING WAS PERFORMED. UPON INSPECTI ON, FOUND THE ARM HAD FALLEN OFF OF THE PROP GOVERNOR SPLINED SHAFT. THE MOUNT BOLT WAS STILL SECURE IN THE ARM. THIS IS THE SECOND OCCURRENCE OF A B-100, ONE FAILED ARM HAD A SAFETY AND THIS ONE DID NOT. IT IS SUGGESTED THAT ON ENGINE I NSPECTIONS, THE ARM BE PULLED ON FOR SECURITY TEST AND THAT THE MOUNT BOLT BE CHECKED FOR TIGHTNESS. 1 L 7 2 4T A14CE 1998030500655 19980305 00655 SW 1998 3 5 98ZZZX940 1 19971216 G 6310 222044672101 COUPLING BELL 222 222U 1182140 SW DRIVE CORRODED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 219HM 426 A1138 47573 OUTER COUPLING HAS CORROSION ON INTERNAL SPLINES, LESS THAN 1 YEAR ON SERVICE. REMOVED AND REPLACED. 1 G 7 2 3U H9SW 1998030500656 19980305 00656 SW 1998 3 5 98ZZZX941 1 19971216 G 6310 222044672101 COUPLING BELL 222 222U 1182140 SW DRIVE CORRODED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 219HM 426 A1132 47573 OUTER COUPLING HAS CORROSION ON INTERNAL SPLINES. LESS THAN 1 YEAR IN SERVICE. REMOVED AND REPLACED. 1 G 7 2 3U H9SW 1998030500657 19980305 00657 EU 1998 3 5 98ZZZX942 1 19971216 G 6410 117317411 BLADE BOLKMS BK117 BK117C1 5626025 EU T/R DEBONDED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 317MC 121 7505 T/R BLADE DEBONDED. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1998030500662 19980305 00662 EU 1998 3 5 98ZZZX947 1 19971118 G 2810 1176416901 DRAIN VALVE BOLKMS 117 BK117A3 5626015 EU FUEL TANK LEAKING B TI1R K NONE K FLUID LOSS IN INSP/MAINT 1 SW 05 1140H 7078 FUEL TANK HAS STATIC LEAK AT DRAIN VALVE. REMOVED AND REPLACED. 1 G 7 2 3U H13EU 1998030500666 19980305 00666 EU 1998 3 5 98ZZZX951 1 19971228 G 2140 11798439 CONTROL UNIT BOLKMS BK117 BK117C1 5626025 EU HEATER FAILED B TI1R K NONE M OVER TEMP IN INSP/MAINT 1 SW 05 117NC 01016 7509 HEATER OVERHEATED. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1998030500667 19980305 00667 EU 1998 3 5 98ZZZX952 1 19971229 G 3610 HTE200016 VALVE BOLKMS BK117 BK117C1 5626025 EU BLEED SYSTEM FAILED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117NC 492GB364 7509 BLEED VALVE DOES NOT OPERATE. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1998030500668 19980305 00668 EU 1998 3 5 98ZZZX953 1 19971218 G 3610 HTC200016 VALVE BOLKMS BK117 BK117C1 5626025 EU BLEED SYSTEM STICKS B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 117NC 492BG365 7509 VALVE STICKS WHEN SELECTING HEAT. REMOVED AND REPLACED. 1 G 7 2 3U NC H13EU 1998010800149 19980108 00149 CE 1998 1 8 98ZZZX96 1 19971217 G 5312 05132833 BULKHEAD CESSNA 172 172N 2072434 CE LT DOOR POST CRACKED B S DVPR K NONE O OTHER IN INSP/MAINT 1 SO 03 311EH 5246 17269158 INSPECTION REVEALED A CRACK IN THE LEFT HAND DOOR POST AFT SECTION AT THE LOWER DOOR HINGE LOCATION. CRACK STARTS AT TH E AFT SCREW HOLE AND PROGRESSES IN BOTH DIRECTIONS. CRACK IS APPROXIMATELY 1.3750 INCHES LONG. 1 H 7 1 3O NT 3A12 1998043000423 19980430 00423 1998 4 30 98ZZZX960 4 19971002 G 3424 1394T1007Z GYRO CESSNA 310 310R 2074245 CE TURN COORDINATOR FAILED D K NONE I FLT. ATTITUDE INST. NR NOT REPORTED 1 GL 17 3284M 7861084 310R1892 FAILURE OF THE TURN COORDINATOR WAS NOTICED BY THE PILOT BY THE LACK OF MOVEMENT WHILE FLYING, HOWEVER, THE INOP FLAG WA S NOT PULLED TO THE OFF POSITION. SUBMITTER STATED AN UNDERSTANDING THAT THE FLAG SHOULD INDICATE FAILURE WHEN THE GYRO STOPS SPINNING. 1 L 7 2 3O 3A10 1998043000424 19980430 00424 CE 1998 4 30 98ZZZX961 1 19970819 G 2823 98510675 SELECTOR CESSNA 180 180K 2072624 CE FUEL SYSTEM CORRODED D K NONE O OTHER IN INSP/MAINT 1 NE 05 61858 2386 18052807 FOUND FUEL SELECTOR VALVE CORRODED AND FLAKING ON ONE SIDE. THE ONLY WAY TO SEE THIS SIDE OF THE VALVE IS WITH A MIRROR THROUGH THE INSPECTION PANEL ON THE BOTTOM OF THE AIRCRAFT. AIRCRAFT IS ON FLOATS. 1 H 7 1 3O 5A6 1998043000428 19980430 00428 EA 1998 4 30 98ZZZX965 2 19970702 G 7414 M3548 ROTOR 4370 LYC O360 O360A3A 41514 EA ENGINE MAG FAILED D K NONE O OTHER IN INSP/MAINT 1 GL 17 95020074 L769036A INSPECTION FOR MAGNETO FAILURE FOUND ROTOR CONTACT END BROKEN. 3 O E286 1998010800150 19980108 00150 SO 1998 1 8 98ZZZX97 1 19971120 G 3211 ATTACH BOLT PIPER PA28 PA28140 7102802 SO LT MLG BROKEN D A K NONE O OTHER IN INSP/MAINT 1 WP 01 33138 287525161 WHILE PERFORMING SB 1006, NOTED LOWER ATTACH BOLTS OF THE LT MLG STRUT WERE CORRODED AND ONE BROKEN OFF AT THE HEAD (INS IDE). THIS IS THE SECOND SUCH OCCURRENCE FOUND ON TWO AIRCRAFT, AND THE DEFECT WAS IN THE LEFT MLG IN BOTH CASES. THE BOLTS (UPPER AND LOWER) WERE CORRODED. IN BOTH CASES, THEY WERE BROKEN INSIDE THE WING NEXT TO THE SPAR CAP AREA. (IN THE FIRST CASE, 2 UPPER BOLTS WERE ALSO BROKEN). THIS WAS HARD TO DETECT FROM THE OUTSIDE. 1 L 7 1 3O 2A13 1998043000434 19980430 00434 CE 1998 4 30 98ZZZX971 1 19971201 G 5610 5111604202 WINDSHIELD CESSNA 421 421C 2076016 CE COPILOT DEPARTED D O OTHER D INFLIGHT SEPARATION CR CRUISE 1 NM 05 88584 7500 421C0642 AS THE AIRCRAFT LEVELED OFF AT 23,000 FEET MSL, THE COPILOT'S WINDSHIELD DEPARTED THE AIRCRAFT WITH APPROXIMATELY 10 PER CENT LEFT ATTACHED TO THE AIRFRAME. SUSPECT THE FORWARD RIGHT LOWER ATTACH HOLES IS WHERE THE CRACK STARTED, THEN THE C RACK WENT STRAIGHT UP OR AFT TO THE TOP OF THE WINDSHIELD. SHOULD HAVE RECURRING INSPECTION OF ATTACH HOLES. REF: MEB 83-33 R-N1. 1 L 7 2 3O A7CE 1998043000440 19980430 00440 SO 1998 4 30 98ZZZX977 1 19970121 G 3250 2073743 BUSHING 4713400 PIPER PA31T PA31T 7103124 SO NLG STEERING CORRODED B CTYR K NONE O OTHER IN INSP/MAINT 1 GL 21 112BL 31T7720037 NOSE GEAR STEERING BELLCRANK BUSHINGS WERE CORRODED IN WHEELWELL AREA. SYMPTOMS WERE STIFF RUDDER PEDALS. BUSHINGS AND SHAFT, P/N 47080-000, WERE REPLACED. BUSHINGS HAVE NO GREASE ZERK, BUT SHOWED SIGNS OF PREVIOUS LUBRICATION. 1 L 7 2 3T A8EA 1998010800152 19980108 00152 EA 1998 1 8 98ZZZX99 2 19971222 G 7414 ES103827901 COIL ELECTROSYS D4RN2021 CESSNA 172 172M 2072418 CE LYC O320 O320H2AD 41508 EA MAGNETO CRACKED D S K NONE O OTHER IN INSP/MAINT 1 NM 09 73671 452 60060505 17267605 RL750276T DURING 500-HOUR INSPECTION, (PULLED AT 452.2 HOURS TSO), BOTH COILS IN TCM 2000 SERIES MAGNETO WERE FOUND CRACKED. COIL S HAD THE FOLLOWING MARKINGS: 38/95 AND 8-9, 35/75 AND 10-10. MAGNETO WAS OVERHAULED BY ELECTROSYSTEMS, INC., FOR LYCO MING. ENGINE OVERHAULED ON 8-15-96. SUSPECT CAUSE IS MANUFACTURING DEFECT OR DESIGN FLOW. 1 H 7 1 3O 3 O NT 3A12 E274 1999010800571 19990108 00571 SW 1999 1 8 99ZZZM10 1 19970604 G 3213 AN621A BOLT BBAVIA 8 8GCBC 1220803 SW STRUT IMPROPER PART B CL4R K NONE O OTHER IN INSP/MAINT 1 AL 03 778AC 32 38197 38197 FOUND INCORRECT HARDWARD HAD BEEN INSTALLED IN THE UPPER END OF THE LEFT REAR LIFT STRUT. THE BOLT THROUGH THE UPPER EN D OF THE LIFT STRUT WAS APPROXIMATELY 1.5 INCHES PLUS TOO LONG. THE NUT HAD BEEN TIGHTENED UNITL IT BOTTOMED OUT ON THE THREADS, LEAVING THE LIFT STRUT FREE TO SLIDE ON THE BOLT. FLIGHT LOADS HAD BENT THE BOLT AND ELONGATED THE HOLE THROU GH THE STRUT ATTACH FITTING AND THE REAR SPAR. THESE PARTS ARE NOT REPAIRABLE PER AMERICAN CHAMPION AIRWORTHINESS LIMIT ATIONS LIMITATIONS, AND THE LEFT WING WAS REPLACED UNDER FACTOR WARRANTY. (M) 1 H 7 1 3O A21CE 1999010800572 19990108 00572 SW 1999 1 8 99ZZZM11 1 19970601 G 2810 FUEL TANK BBAVIA 8 8GCBC 1220803 SW FUSELAGE CONTAMINATED B CL4R K NONE O OTHER IN INSP/MAINT 1 AL 03 778AC 38197 38197 WHILE TROUBLESHOOTING OTHER PROBLEMS (POWER LOSS) FOUND LARGE AMOUNTS OF ALUMINUM PARTICLES IN THE FUEL SYSTEM. METAL P ARTICLES WERE LEFT FROM MANUFACTURING PROCESS OF THE FUEL TANKS (GRIND MATERIAL PRIOR TO WELDING). REQUIRED REPEATED CL EANING OF THE FUEL SCREENS, AND FLUSH OF THE FUEL SYSTEM. PARTICALS IN THE GASCOLATOR SCREEN WERE ENOUGH TO RESTICT FUE L SUPPLY TO THE ENGINE. (M) 1 H 7 1 3O A21CE 1999010800573 19990108 00573 SW 1999 1 8 99ZZZM12 1 19970601 G 7160 714755 TUBE BBAVIA 8 8GCBC 1220803 SW COWL LOOSE B CL4R A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 AL 03 778AC 18 38197 38197 NEW AIRCRAFT EN ROUTE FROM AMERICAN CHAMPION FACTORY TO ANCHORAGE, AK, SUFFERED POWER LOSS REQUIRING A PRECAUTIONARY LAN DING. INVESTIGATION FOUND THE INDUCTION AIR TUBE BETWEEN THE COWLING AND THE INDUCTION AIRBOX HAD NOT BEEN SECURED TO T HE COWLING (SECURED ONLY TO THE AIRBOX). THE HOSE HAD BEEN SUCKED INTO THE FRONT OF THE AIRBOX, PARTIALLY OBSTRUCTING T HE AIRFLOW INTO THE CARBURETOR. 1 H 7 1 3O A21CE 1999010800348 19990108 00348 CE 1999 1 8 99ZZZX113 1 19971118 G 2820 1200106263 LINE CESSNA 210 T210M 2073451 CE COCKPIT CHAFED B S K NONE K FLUID LOSS IN INSP/MAINT 1 WP 19 761VE 2000 21062546 PILOT REPORTED ERRATIC FUEL FLOW INDICATION. DURING GROUND ENG RUN-UP FOR T/S, A LOUD POP WAS HEARD, LARGE SPARK SHOT F ROM BEHIND COPILOT'S INSTRUMENT PANEL, AND THE 3-AMP STEREO CB OPENED. INVEST REVEALED THE 28-VOLT POWER LEAD FOR THE S TEREO (INSTALLED SEVERAL YEARS AGO) HAD BEEN CHAFING AGAINST P/N 1200106-263 ALUMINUM LINE (DECK PRESS REF LINE FROM AFT SIDE OF FIREWALL TO FUEL FLOW/MAP GAUGE). CHAFING HAD PROGRESSED TO THE POINT WHERE INSULATION HAD WORN AWAY EXPOSING CONDUCTOR WHICH HAD SHORTED AGAINST THE LINE AND ARCING HAD EATEN A .0625 INCH DIA HOLE IN THE LINE. SINCE THIS IS TURB OCHARGED INSTALL, LEAK IN THE DECK PRESS LINE RESULTED IN FUEL FLOW READING EXCESSIVELY HIGH AT HIGH POWER SETTINGS. 1 H 7 1 3O 3A21 1999041700266 19990417 00266 NE 1999 4 17 99ZZZX1524 2 19970530 G 7260 795072 BEVEL GEAR PWA JT8 JT8* 52044 NE GEARBOX CRACKED B K NONE O OTHER IN INSP/MAINT 1 SO 19 AR1811 PART WAS RECEIVED FROM NORTHWEST A/L - ATLANTA FOR INSPECTION AND REPAIR PER PWA ENGINE MANUAL. APPROXIMATELY HALF OF T HE GEAR TEETH WERE SEVERELY CRACKED AND GALLED. 4 F E2EA 1999051400380 19990514 00380 CE 1999 5 14 99ZZZX1978 1 19971117 G 3231 0024100381 BRACE BEECH 58 58P 1152744 CE NLG WW FAILED B P SHOR O OTHER O OTHER NR NOT REPORTED 1 WP 07 XBFTG TJ264 REF: ALERT NR 232, 11-97, PG 3, NOSE LANDING GEAR DOOR FAILURE. DURING ANNUAL INSPECTION, FOUND NOSE GEAR DOORS REMAIN ED OPEN DURING A RETRACTION TEST. INSPECTION OF THE SYSTEM FOUND P/N 002-410038-1 BROKEN. AFTER INSTALLING A NEW PART, THE NOSE GEAR DOORS FUNCTIONED PROPERLY. APPROX TT ON BROKEN PART, 2,000 HOURS. 1 L 7 2 3O A23CE 1999051400397 19990514 00397 CE 1999 5 14 99ZZZX1995 1 19971024 G 7500 TUBE BEECH MU300 400A 1155402 CE BLEED AIR RUPTURED H O OTHER O OTHER NR NOT REPORTED 1 GL 05 AIR CREW REPORTED PROBLEM WITH RT GENERATOR SYSTEM. DURING T/S, TECH NOTICED HOT AIR COMING FROM AFT FUSELAGE. A FUSEL AGE BLEED AIR TUBE WAS FOUND RUPTURED. A BLEED AIR LEAK WAS FOUND WHEN T/S RT GEN. THE CAUSE WAS RT FUSELAGE BLEED AIR TUBE THAT RUPTURED. WHEN TUBE RUPTURED, BLEED AIR DUCT FAIL ANNUNCIATOR LIGHT FAILED TO ILLUMINATE. THE FOUR BLEED AI R TEMPERATURE SWITCHES TAKEN FROM TT-49 ALL TESTED SATISFACTORY CLOSING BETWEEN 354 DEGREES FAHRENHEIT AND 356 DEGREES F AHRENHEIT. THE FAILURE OF THE BLEED AIR TUBE ASSY APPARENTLY DID NOT RAISE TEMPERATURE WITHIN THE AFT FUSELAGE TO A LIM IT WHICH WOULD ILLUMINATE THE 'BLEED AIR FAIL' WARNING LIGHT. (BEECHJET 400T-COMMERICAL COUNTERPART BEEECHJET 400A). 2 H 7 2 4F RT A16SW 1999051400479 19990514 00479 CE 1999 5 14 99ZZZX1999 1 19970204 G 7500 45A63517071 DUCT BEECH MU300 400A 1155402 CE BLEED AIR FAILED H K NONE O OTHER IN INSP/MAINT 1 GL 05 1616 WHEN PRESSURE CHECK PERFORMED FOR LEFT DUCT REPLACEMENT, FOUND THE RIGHT TO BE LEAKING. WHEN REMOVED, FOUND WELD BROKEN IN SAME PLACE AS THE LEFT ONE. (BEECHJET 400T - COMMERCIAL COUNTERPART BEECHJET 400A). 2 H 7 2 4F RT A16SW 1999051400480 19990514 00480 CE 1999 5 14 99ZZZX2000 1 19970301 G 7500 006244563100 CLAMP BEECH MU300 400A 1155402 CE BLEED AIR FAILED H K NONE O OTHER IN INSP/MAINT 1 GL 05 BLEED AIR DUCT FAIL LIGHT - FOUND BROKEN T-BOLT WHICH CAUSED CLAMP TO FALL OFF OF DUCT. CLAMP WAS OVERTORQUED. (BEECHJ ET 400T - COMMERCIAL COUNTERPART BEECHJET 400A). 2 H 7 2 4F RT A16SW 1999051400481 19990514 00481 CE 1999 5 14 99ZZZX2001 1 19970204 G 7500 45A63517061 DUCT BEECH MU300 400A 1155402 CE BLEED AIR FAILED H O OTHER J WARNING INDICATION NR NOT REPORTED 1 GL 05 1616 THE NARROWEST PART OF THE DUCT CLOSE TO THE AIRCRAFT SKIN GOING INTO THE ENGINE WAS CRACKED ALL THE WAY AROUND. AIRCRAF T HAD A BLEED DUCT FAILURE ANNUNCIATOR LIGHT COME ON IN-FLIGHT. DUCT WAS IN TWO PIECES WHEN REMOVED. (SHOULD BE ONE). (BEECHJET 400T - COMMERCIAL COUNTERPART BEECHJET 400A). 2 H 7 2 4F RT A16SW 1999072300540 19990723 00540 EA 1999 7 23 99ZZZX2725 2 19970508 G 7414 BEARING LYC O540 O540E4C5 41532 EA LT MAGNETO FAILED H K NONE O OTHER IN INSP/MAINT 1 SO 23 880 RL2150940A OPERATORS OF AVCO LYCOMING O-540-E4C5 ENGINES FITTED TO BRITTEN NORMAN ISLANDER AIRCRAFT IN GUYANA HAVE BEEN EXPERIENCIN G PREMATURE FAILURE OF THE MAGNETO DRIVE GEAR BEARINGS. THERE HAVE BEEN INSTANCES OF REPORTED HARD STARTING. ON INVEST IGATION, THE BEARINGS ARE DISCOVERED DAMAGED. THE ENGINES ARE THEN REMOVED FROM SERVICE. 3 O E295 1999091000025 19990910 00025 1999 9 10 99ZZZX3297 1 19971112 G 6230 206011811101 YOKE MAIN ROTOR DAMAGED B TI1R K NONE O OTHER IN INSP/MAINT 1 SW 05 3127 AFS5029 TWO INBOARD BUSHING BORES LARGER THAN STANDARD AND SMALLER THAN OVERSIZED. REMOVED AND REPLACED. 1999012200576 19990122 00576 EA 1999 1 22 99ZZZX341 2 19971010 G 8530 ECLN12988CN STUD ENSTRM F28 280C 3300505 GL LYC O360 HIO360E1AD 41514 EA CYLINDER DAMAGED D K NONE O OTHER IN INSP/MAINT 1 SO 03 51703 100 01 1118 L1801851A DURING ANNUAL INSPECTION, 10-10-97, NR 2 CYLINDER COMPRESSION LOW. AFTER INSPECTION OF CYLINDER, FOUND INTAKE VALVE SEA T LOOSE AND VALVE BURNT. SUBMITTER STATED POSSIBLE CAUSE MAY HAVE BEEN OVERBOOSTING ENGINE DURING FLIGHT INSTRUCTION. 1 G 7 1 3O 3 O H1CE 1E10 1999012200577 19990122 00577 EA 1999 1 22 99ZZZX342 2 19971010 G 8530 LW12988 CYLINDER ENSTRM F28 280C 3300505 GL LYC O360 HIO360E1AD 41514 EA ENGINE DAMAGED D K NONE O OTHER IN INSP/MAINT 1 SO 03 51703 1118 L1801851A DURING ANNUAL INSPECTION, 10-10-97, FOUND NR 2 CYLINDER COMPRESSION WAS LOW. AFTER INSPECTION OF CYLINDER, INTAKE VALVE SEAT WAS FOUND LOOSE, INTAKE VALVE WAS BURNT. AT THAT TIME, THE OWNER SHOWED 2 MORE CYLINDERS FROM PAST MAINTENANCE WI TH THE SAME CONDITION, HOWEVER, AFTER RESEARCHING ENGINE LOGS, PART NUMBER IS UNKNOWN. OWNER ESTIMATES 100 HOURS ON THI S PART. OWNER GIVES FLIGHT INSTRUCTION IN AIRCRAFT. SUBMITTER STATED POSSIBLE CAUSE MAY BE OVERBOOSTING ENGINE. 1 G 7 1 3O 3 O H1CE 1E10 1999012900090 19990129 00090 GL 1999 1 29 99ZZZX409 2 19971006 G 7250 6886407 BLADE BOLKMS 105 BO105CBS 5626008 EU ALLSN 250C 250C20B 03013 GL NR 2 ENGINE DAMAGED H O OTHER J WARNING INDICATION NR NOT REPORTED 1 SW 03 54197 1493 X133544 S805 CAE800388F THE PILOT REPORTED THE NR 2 ENGINE BEGAN TO 'BOG DOWN' DURING A PRECAUTIONARY LANDING TO AN OFFSHORE PLATFORM AFTER THE NR 2 ENGINE FIRE WARNING LIGHT ILLUMINATED. METALURGICAL EXAMINATION BY THE ENGINE MANUFACTURER REVEALED THE FIRST STAG E TURBINE WHEEL HAD ONE MISSING AIRFOIL (BLADE) AND SEVERAL OTHERS DAMAGED. THE METALURGICAL REPORTS STATES THE DAMAGE WAS MOST LIKELY CAUSED BY SULFIDATION. 1 G 7 2 3U 3 U NC H3EU E4CE 1999021900016 19990219 00016 SO 1999 2 19 99ZZZX576 2 19971216 G 8520 JOURNAL CESSNA 421 421B 2076014 CE CONT O520 GTSIO520H 17032 SO CRANKCASE CLOGGED E K NONE O OTHER IN INSP/MAINT 1 SW 03 707DM 421B0145 1881017D TWO OIL JOURNALS IN CRANKCASE CLOGGED CAUSING TWO PISTONS TO FREEZE AND FAIL. ON LEFT SIDE OF CRANKCASE THE PISTON BROK E THROUGH CAUSING A FIST SIZE HOLE ON THE RIGHT SIDE OF THE PISTON BROKE THROUGH CAUSING A SILVER DOLLAR SIZE HOLE. 1 L 7 2 3O 3 O A7CE E7CE 1999030500459 19990305 00459 NE 1999 3 5 99ZZZX796 3 19970430 G 6111 8022581 BLADE RFC11710C SAAB SF340 340B 7860101 EU HAMSTD 14RF 14RF19 NE PROPELLER DAMAGED B H2SR K NONE O OTHER IN INSP/MAINT 1 SO 13 330AE 6409 863679 340B330 UPON EXAMINATION OF BLADE BUTT, AN INDICATION IN THE FILLET RADIUS WAS NOTED. THE FILLET RADIUS HAS A PORTION OF MATERI AL MISSING. THE MISSING PORTION IS APPROXIMATELY 0.170 INCH LONG AND APPROXIMATELY 0.050 INCH WIDE AT ITS WIDEST POINT. LOCATION IS APPROXIMATELY 0.500 INCH FROM THE SET SCREW HOLE CENTER APPROXIMTELY 0.250 INCH IN THE COUNTERCLOCKWISE DI RECTION IF VIEWED FROM THE BUTT END. THE AREA IS ORIENTED CIRCUMFERENTIALLY IN THE FILLET RADIUS. 2 L 7 2 4T RT A52EU 6 C P11NE 1999030500485 19990305 00485 NM 1999 3 5 99ZZZX822 1 19970115 G 5311 FRAME BOEING 727 727259 138408J NM BS 950 CORRODED B KT3R K NONE O OTHER IN INSP/MAINT 1 WP 07 203AV 22474 DURING A C-CHECK, CORROSION WAS NOTED ON FRAME STA 950E AT STR 27R. 2 L 7 3 4F A3WE 1999031900750 19990319 00750 1999 3 19 99ZZZX960 4 19970307 G 2562 E01 ELT ACK PIPER PA12 PA12 7101202 SO CABIN FAILED H K NONE L NO TEST IN INSP/MAINT 1 NM 08 3168M 200 017826 121847 ELT DID NOT FUNCTION DURING 100-HOUR CHECK. DECELERATION CHECK PER MANUAL; ALSO, HAD LOOSE SCREW INSIDE SEALED ELT ELEC TRONIC HEAD WHICH WAS REPAIRED BY THE MFG. 1 H 7 1 3O A780 1999031900970 19990319 00970 CE 1999 3 19 99ZZZX969 1 19971117 G 8011 1971890N CLUTCH CESSNA 150 150G 2071816 CE STARTER DAMAGED H K NONE O OTHER IN INSP/MAINT 1 SO 15 3856J 48 9501393 15065156 TEETH ON PINION GEAR WERE GROUND OFF; METAL WAS FOUND IN THE OIL SUMP AND SCREEN. THIS PART WAS NEW. STC SE00262NY CAN ADIAN AERO MANUFACTURING. 1 H 7 1 3O 3A19 1997060500299 19970605 00299 NM 1997 6 5 A3L29707 1 19970503 G 3246 2607046 WHEEL 2601571 BOEING 737 737* NM KEY BOSS FAILED B A3L2 K NONE O OTHER NR NOT REPORTED 1 SW 09 H5300 WHEEL FLANGE FAILURE AT KEY BOSS. CRACK PROPAGATED FROM THE TOP CORNER OF THE KEY BOSS. THERE IS NO NDT INSPECTION REQ UIRED IN THIS AREA. SUBMITTER STATED ADD EDDY CURRENT INSPECTION OF THE SIDE AND TOP OF KEY BOSS RELATIVE TO THE CORNER S. ADDITIONAL INSPECTION/INSPECTION CYCLE CHANGES MAY BE MADE AFTER COMPLETION OF THE OEM EVALUATION. (X) 2 L 7 2 4F RT A16WE 1997122400019 19971224 00019 WP 1997 12 24 A3L297121 1 19971203 G 3246 9560892 TIE BOLT MS21250 DOUG DC9 DC932 3022066 WP WHEEL BROKEN B A3L2 K NONE O OTHER IN INSP/MAINT 1 SW 09 DEC87107 INSPECTION FOUND WHEEL WITH BROKEN TIE BOLT. (X) 2 L 7 2 4F A6WE 1997122400018 19971224 00018 WP 1997 12 24 A3L297122 1 19971204 G 3246 9560892 TIE BOLT DOUG DC9 DC932 3022066 WP WHEEL BROKEN B A3L2 K NONE O OTHER IN INSP/MAINT 1 SW 09 MS21250 INSPECTION FOUND WHEEL WITH BROKEN TIE BOLT. (X) 2 L 7 2 4F A6WE 1997122400016 19971224 00016 WP 1997 12 24 A3L297123 1 19971205 G 3246 2601483 BOLT BENDIX 20608891 DOUG DC9 DC983 3022083 WP WHEEL BROKEN B A3L2 K NONE O OTHER IN INSP/MAINT 1 SW 09 B0160 INSPECTION FOUND WHEEL BOLT WITH FATIGUE RELATED FAILURE. SUSPECT INSUFFICIENT PRE-LOAD TORQUE. SUBMITTER SUGGESTED US ING SNUG AND ANGLE TORQUE METHOD. (X) 2 L 7 2 4F RT A6WE 1998040200010 19980402 00010 WP 1998 4 2 A3L297124 1 19971216 G 3244 40X1424PR225 TIRE 3910063511 DOUG DC9 C9A WP WHEEL FAILED B A3L2 K NONE O OTHER NR NOT REPORTED 1 SW 09 295KH447 TIRE HAD THREAD SEPARATION. PRELIMINARY ANALYSIS REVEALED DEFECTIVE COAT STOCK MATERIAL USED. (X) 2 L 7 2 4F A6WE 1997092500269 19970925 00269 WP 1997 9 25 A3L29713 1 19970905 G 3246 2601483 BOLT BENDIX 26088911A DOUG DC9 DC983 3022083 WP WHEEL FAILED B A3L3 K NONE O OTHER IN INSP/MAINT 1 WP 19 B2119 WHEEL BOLT FATIGUE RELATED FAILURE. INSUFFICIENT PRE-LOAD TORQUE SUSPECTED CAUSE. SUBMITTER SUGGESTS USING SNUG ANGLE TORQUE METHOD. (X) 2 L 7 2 4F RT A6WE 1997103000190 19971030 00190 WP 1997 10 30 A3L29714 1 19971001 G 3246 2601483 BOLT BENDIX 2608891A DOUG DC9 DC981 3022081 WP WHEEL FAILED B A3L2 K NONE O OTHER IN INSP/MAINT 1 SW 09 H0180 INSPECTION FOUND WHEEL BOLT FAILED. FATIGUE RELATED FAILURE. SUSPECT INSUFFICIENT PRE-LOAD TORQUE. SUBMITTER SUGGESTE D USING SNUG ANGLE TORQUE METHOD. (X) 2 L 7 2 4F A6WE 1997103000191 19971030 00191 WP 1997 10 30 A3L29715 1 19971001 G 3246 2601483 BOLT BENDIX 2608891A DOUG DC9 DC981 3022081 WP WHEEL FAILED B A3L2 K NONE O OTHER IN INSP/MAINT 1 SW 09 B0244 INSPECTION FOUND WHEEL BOLT FAILED. FATIGUE RELATED FAILURE. SUSPECT INSUFFICIENT PRE-LOAD TORQUE. SUBMITTER SUGGESTE D USING SNUG ANGLE TORQUE METHOD. (X) 2 L 7 2 4F A6WE 1997103000189 19971030 00189 WP 1997 10 30 A3L29716 1 19971001 G 3246 2601483 BOLT BENDIX 26088911A DOUG DC9 DC981 3022081 WP WHEEL FAILED B A3L2 K NONE O OTHER IN INSP/MAINT 1 SW 09 B3230 INSPECTION FOUND WHEEL BOLT FAILED. FATIGUE RELATED FAILURE. SUSPECT INSUFFICIENT PRE-LOAD TORQUE. SUBMITTER SUGGESTE D USING SNUG ANGLE TORQUE METHOD. (X) 2 L 7 2 4F A6WE 1997103000187 19971030 00187 WP 1997 10 30 A3L29717 1 19971007 G 3244 401424PR225 TIRE 3910063511 DOUG DC9 C9A WP WHEEL SEPARATION B A3L2 K NONE O OTHER NR NOT REPORTED 1 SW 09 295KH095 TIRE HAS THREAD SEPARATION. (X) 2 L 7 2 4F A6WE 1997103000185 19971030 00185 WP 1997 10 30 A3L29718 1 19971009 G 3244 40X1424PR225 TIRE 3910063511 DOUG DC9 C9A WP WHEEL SEPARATION B A3L2 K NONE O OTHER NR NOT REPORTED 1 SW 09 295KH351 TIRE HAS THREAD SEPARATION. (X) 2 L 7 2 4F A6WE 1997103000186 19971030 00186 WP 1997 10 30 A3L29719 1 19971009 G 3244 40X1424PR225 TIRE 3910063511 DOUG DC9 C9A WP WHEEL SEPARATION B A3L2 K NONE O OTHER IN INSP/MAINT 1 SW 09 42220704 TIRE HAS THREAD SEPARATION. (X) 2 L 7 2 4F A6WE 1997103000188 19971030 00188 NM 1997 10 30 A3L2974 1 19971002 G 3246 2601483 BOLT BENDIX 260356112 BOEING 747 747* NM WHEEL FAILED B A3L2 K NONE O OTHER NR NOT REPORTED 1 SW 09 B9919 INSPECTION FOUND WHEEL BOLT FAILED. BROKEN BOLT. (X) 2 L 7 4 4F RT A20WE 1997122400476 19971224 00476 NM 1997 12 24 A3L397121 1 19971215 G 3246 2602540 BOLT BOEING 737 7373A4 1384585 NM WHEEL BROKEN B A3L3 K NONE O OTHER IN INSP/MAINT 1 WP 19 INSPECTION FOUND WHEEL HAS BROKEN BOLT. (X) 2 L 7 2 4F RT A16WE 1998040200012 19980402 00012 WP 1998 4 2 A3L397123 1 19971216 G 3246 2601483 BOLT BENDIX 26088911 DOUG DC9 DC983 3022083 WP WHEEL FAILED B A3L3 K NONE O OTHER IN INSP/MAINT 1 WP 19 B0368 INSPECTION FOUND FATIGUE RELATED FAILURE. SUSPECT INSUFFICIENT PRELOAD TORQUE. SUBMITTER SUGGESTED USING SNUG ANGLE TO RQUE METHOD. (X) 2 L 7 2 4F RT A6WE 1998040200009 19980402 00009 NM 1998 4 2 A3L397124 1 19971218 G 3246 2602540 BOLT BENDIX 26066712 BOEING 737 7373T0 1384582 NM WHEEL FAILED B A A3L3 K NONE O OTHER IN INSP/MAINT 1 WP 19 B6148 INSPECTION FOUND BROKEN BOLT. PREVENTIVE ACTION PENDING COMPLETION OF THE INVESTIGATION. (X) 2 L 7 2 4F RT A16WE 1997092500271 19970925 00271 NM 1997 9 25 A3L3972 1 19970907 G 3246 2602540 BOLT BENDIX 26066712 BOEING 737 7373A4 1384585 NM WHEEL FAILED B A3L3 K NONE O OTHER IN INSP/MAINT 1 WP 19 B6372 WHEEL BOLT FATIGUE RELATED FAILURE. 2 L 7 2 4F RT A16WE 1997092500270 19970925 00270 WP 1997 9 25 A3L3973 1 19970915 G 3246 2601483 BOLT BENDIX 26088911 DOUG DC9 DC983 3022083 WP WHEEL FAILED B A3L3 K NONE O OTHER IN INSP/MAINT 1 WP 19 B1251 WHEEL BOLT FATIGUE RELATED FAILURE. INSUFFICIENT PRE-LOAD TORQUE SUSPECTED CAUSE. SUBMITTER SUGGESTS USING SNUG ANGLE TORQUE METHOD. (X) 2 L 7 2 4F RT A6WE 1997090400272 19970904 00272 NM 1997 9 4 A3LD9708 1 19970820 G 3246 2602540 TIE BOLT 2609801 BOEING 737 737* NM WHEEL ASSY FAILED B A3LD K NONE O OTHER IN INSP/MAINT 1 EA 05 B2850 WHEEL ASSEMBLY TIE BOLT FAILURE. UNDER EVALUATION BY ALS TEST LAB. SUBMITTER STATED ADDITIONAL INSPECTION/INSPECTION C YCLE CHANGES MAY BE MADE AFTER COMPLETION OF THE OEM EVALUATION. (X) 2 L 7 2 4F RT A16WE 1997090400273 19970904 00273 NM 1997 9 4 A3LD9709 1 19970820 G 3246 2602540 TIE BOLT 2609801 BOEING 737 737* NM WHEEL ASSY FAILED B A3LD K NONE O OTHER IN INSP/MAINT 1 EA 05 B3043 WHEEL ASSEMBLY TIE BOLT FAILURE. SUBMITTER STATED ADDITIONAL INSPECTION/INSPECTION CYCLE CHANGES MAY BE MADE AFTER COMP LETION OF THE OEM EVALUATION. (X) 2 L 7 2 4F RT A16WE 1997090400281 19970904 00281 NM 1997 9 4 A3LD9710 1 19970820 G 3246 2602540 TIE BOLT 2606671 BOEING 737 7373A4 1384585 NM WHEEL ASSY FAILED B A3LD K NONE O OTHER IN INSP/MAINT 1 EA 05 B4884 DEFECT: TIE BOLT FAILURE. CAUSE: UNDER EVALUATION BY ALS TEST LAB. PREVENTIVE ACTION: ADDITIONAL INSPECTION/INSPECT ION CYCLE CHANGES MAY BE MADE AFTER COMPLETION OF THE OEM EVALUATION. (X) 2 L 7 2 4F RT A16WE 1997091800413 19970918 00413 WP 1997 9 18 A3LD9711 1 19970908 G 3246 L507949 BEARING BENDIX 95502676 DOUG DC9 DC982 3022082 WP WHEEL ASSY FAILED B A3LD K NONE O OTHER NR NOT REPORTED 1 EA 05 MAR86438 WHEEL ASSY OUTBOARD BEARING FAILURE. (X) 2 L 7 2 4F A6WE 1998040200008 19980402 00008 NM 1998 4 2 A3LD97112 1 19971201 G 3246 2602540 BOLT BENDIX 2609801 BOEING 737 737524 1384721 NM WHEEL ASSY FAILED B A A3LD K NONE O OTHER IN INSP/MAINT 1 EA 05 B2721 INSPECTION FOUND TIE BOLT FAILURE. UNDER INVESTIGATION AND PENDING COMPLETION OF THE INVESTIGATION. (X) 2 L 7 2 4F RT A16WE 1997122400017 19971224 00017 WP 1997 12 24 A3LD97121 1 19971205 G 3246 2601483 BOLT BENDIX 2608891 DOUG DC9 DC983 3022083 WP WHEEL BROKEN B A3LD K NONE O OTHER IN INSP/MAINT 1 EA 05 B0336 INSPECTION FOUND WHEEL BOLT FATIGUE RELATED FAILURE. SUSPECT INSUFFICIENT PRE-LOAD TORQUE. SUBMITTER SUGGESTED USING S NUG ANGLE TORQUE METHOD. (X) 2 L 7 2 4F RT A6WE 1997122400015 19971224 00015 WP 1997 12 24 A3LD97122 1 19971205 G 3246 2601483 BOLT BENDIX 2608891 DOUG DC9 DC983 3022083 WP WHEEL BROKEN B A3LD K NONE O OTHER IN INSP/MAINT 1 EA 05 B2119 INSPECTION FOUND WHEEL BOLT WITH FATIGUE RELATED FAILURE. SUSPECT INSUFFICIENT PRE-LOAD TORQUE. SUBMITTER SUGGESTED US ING SNUG ANGLE TORQUE METHOD. (X) 2 L 7 2 4F RT A6WE 1997122400020 19971224 00020 NM 1997 12 24 A3LD97123 1 19971211 G 3244 49X17 TIRE BENDIX 26019106 BOEING 747 747* NM MLG FAILED B A3LD K NONE C F.O.D. NR NOT REPORTED 1 EA 05 52020556 TIRE FAILURE DUE TO FOREIGN OBJECT DAMAGE. (X) 2 L 7 4 4F RT A20WE 1998040200011 19980402 00011 NM 1998 4 2 AL397122 1 19971216 G 3246 2602540 BOLT BENDIX 26066712 BOEING 737 7373T0 1384582 NM WHEEL FAILED B A A3L3 K NONE O OTHER IN INSP/MAINT 1 WP 19 B4825 INSPECTION FOUND BROKEN BOLT. PREVENTIVE PENDING COMPLETION OF THE INVESTIGATION. (X) 2 L 7 2 4F RT A16WE 1997112000275 19971120 00275 EA 1997 11 20 AU970062 2 19970127 G 8520 CONNECTING ROD GULSTM GA7 GA7 3960401 SO LYC O320 O320D1D 41508 EA NR 4 CYL BROKEN W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S 887939A (AUS) NO4 CYLINDER CONNECTING ROD BROKEN IN AREA JUST BELOW PISTON PIN BOSS 1 L 7 2 3O 3 O A17SO E274 1997112000276 19971120 00276 EU 1997 11 20 AU970063 1 19970117 G 4920 COMPRESSOR GARRTT GTCP36300A AIRBUS 320 A320212 EU APU CORE ENGINE FAILED W K NONE E T VIBRATION/BUFFET ENGINE CASE PENETRATION NR NOT REPORTED 1 AU S 450 (AUS) APU LOAD COMPRESSOR AND GEARBOX SEIZED - LOAD COMPRESSOR PROTRUDING THROUGH OUTER CASING 2 L 7 2 4F RT A28NM 1997112000277 19971120 00277 CE 1997 11 20 AU970064 1 19970123 G 5521 043200121 SPAR CESSNA 150 A152 2071836 CE MCAULY 1A103 1A103TCM GL LT ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH ELEVATOR SPAR CRACKED FROM UPPER OUTBOARD BENDING RADIUS CUTOUT INBOARD ALONG VERTICAL FACE OF SPAR PASSING ADJ ACENT TO UPPER RIVET ATTACHING HINGE HALF PNO 0432001-71 - CRACK LENGTH38MM (1.49IN) - DURING REPAIR ANOTHER CRACK WAS F OUND EXTENDING BELOW LOWER OUTBOARD RIVET ATTACHING TORQUE TUBE ASSEMBLY PNO 0434155-1 - CRACK LENGTH 20MM (0.78IN) - FA IRY EXTENSIVE CORROSION WAS ALSO FOUND AS NO ANTI CORROSION TREATMENT HAD BEEN APPLIED DURING MANUFACTURE 1 H 7 1 3O 3A19 5 N P50GL 1997112000278 19971120 00278 WP 1997 11 20 AU970065 2 19970131 G 7313 31029542 NOZZLE GARRTT TPE3318403S CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL FUEL INJECTOR LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S NONE (AUS) FUEL NOZZLE BODY LEAKING - INVESTIGATION FOUND TWO PIN HOLES IN THE BODY BASE - NOZZLES WERE A NEW ITEM 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 1997112000279 19971120 00279 SO 1997 11 20 AU970066 2 19970129 G 8520 1108414A CRANKCASE CONT IO520A CONT O520 IO520A 17032 SO ENGINE NOSE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 1108414A 1108414A (AUS) THE FOLLOWING DEFECTS WERE FOUND DURING ENGINE STRIP FOR OVERHAUL 1. CRANKCASE CRACKED IN NOSE AREA ADJACENT TO TH ROUGH STUDS 2. CRANKSHAFT CRACKED IN AREA AROUND FORWARD THRUST FACE3. STARTER SHAFT CRACKED4. OIL PUMP BODY AND GEARS W ORN BEYOND LIMITS 3 O E5CE 1997112000280 19971120 00280 CE 1997 11 20 AU970067 1 19970203 G 5720 BRACKET CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL TIP TANK ATTACH CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH WING TIP TANK ATTACHMENT BRACKET CRACKED IN AREA OF TOP REAR RADIUS 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 1997112000281 19971120 00281 EU 1997 11 20 AU970068 1 19970203 G 2910 AS1005D080608 UNION FOKKER F27 F27MK50 EU HYDRAULIC LEAKING W K NONE K J FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S (AUS) LANDING GEAR RETRACTION SYSTEM HYDRAULIC LINE UNION LEAKING - LOSS OF HYDRAULIC FLUID 2 H 7 2 4T RT A817 1997112000282 19971120 00282 EA 1997 11 20 AU970069 2 19970117 G 7250 3013411 BLADE EMB 110 EMB110P2 3260124 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL TURBINE DAMAGED W K NONE O C OTHER F.O.D. IN INSP/MAINT 1 AU S 5074 7E247 56820 (AUS) ALL COMPRESSOR TURBINE BLADES DAMAGED BY FOD - DAMAGE INCLUDED BENDING OF BLADE LEADING EDGES AND MISSING SECTIONS - INVESTIGATION FOUND FOD TO BE A POWER TURBINE CONTAINMENT RING RETAINING BOLT 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 1997112000283 19971120 00283 SO 1997 11 20 AU970070 2 19970206 G 7414 IO349237 GEAR BENDIX S6RN1205 BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO MCAULY 2AF34C 2AF34C55 GL MAGNETO/DISTRIBU MELTED W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S 932309 (AUS) LH ENGINE RH MAGNETO DISTRIBUTOR GEAR MELTED - HT CONTACT SEPARATED FROM GEAR - BEARING FAILED - LARGE PIECE OF SL OW SPEED DISTRIBUTOR GEAR MISSING 1 L 7 2 3O 3 O RT 3A16 3E1 5 C P5EA 1997112000284 19971120 00284 GL 1997 11 20 AU970071 3 19970206 G 6110 PROPELLER BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO MCAULY 2AF34C 2AF34C55 GL PROPELLER ASSEMB LOOSE W K NONE O W OTHER INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) LH ENGINE PROPELLER LOOSE ON CRANKSHAFT - ALL SIX RETAINING NUTS WERE LOOSE - FOLLOWING REMOVAL OF PROPELLER ONE O F TWO DOWELS WAS FOUND TO BE BROKEN - SUSPECT BOLTS WERE NOT TORQUED WHEN PROPELLER WAS REFITTED TWENTY THREE HOURS PREV IOUSLY (DEC 1996) - PERSONNEL/MAINTENANCE ERROR 1 L 7 2 3O 3 O RT 3A16 3E1 5 C P5EA 1997112000285 19971120 00285 CE 1997 11 20 AU970072 1 19970120 G 2434 260000160 HOUSING PRESTOLITE ALV9402 CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL DC GENERATOR-ALT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 167 260000160 270623R (AUS) ALTERNATOR MAIN BEARING COLLAPSED AND OUTER HOUSING CRACKED 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 1997112000286 19971120 00286 CE 1997 11 20 AU970073 1 19970203 G 5210 1144000271 FRAME BEECH 1900C BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA PASS/CREW DOOR BROKEN W K NONE O OTHER CR CRUISE 1 AU S (AUS) CABIN DOOR FRAME EXTENSIVELY CORRODED (RUSTED) AND BROKEN IN AREA ADJACENT TO THE DOOR HINGE - EXTENSIVE DEBONDING OF HONEYCOMB STRUCTURE 2 L 7 2 4T 4 T RT A24CE E4EA 1997112000287 19971120 00287 SW 1997 11 20 AU970074 1 19970115 G 3213 54530011 CYLINDER SWRNGN MLG SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP HARTZL HCB3T HCB3TN5 GL MLG STRUT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S NSN (AUS) MAIN LANDING GEAR UPPER STRUT CYLINDER CRACKED - FOUND DURING INSPECTION IAW AD/SWSA226/78 (SB 226-32-033) 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P15EA 1997112000288 19971120 00288 CE 1997 11 20 AU970075 1 19970115 G 5741 951100162 FITTING BEECH 55 D55 1152730 CE CONT O520 IO520C 17032 SO MCAULY 2AF34C 2AF34C55 GL RT SPAR CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S TE751 (AUS) REAR SPAR RH WING FITTING CORRODED - WING BOLT, NUT AND WASHER ALSO CORRODED - FOUND DURING INSPECTION IAW AD/BEEC H55/79 1 L 7 2 3O 3 O 3A16 E5CE 5 C P5EA 1997112000289 19971120 00289 EA 1997 11 20 AU970076 2 19970210 G 7322 13662 BRACKET MA45 LYC O360 O360A1F6 41514 EA HARTZL HCF2Y HCF2YR1 GL FUEL CONT/CARB CRACKED W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS DE DESCENT 1 AU S 75049014 L34747344 (AUS) CARBURETTOR FLOAT BRACKET BROKEN AND SEPARATED - SEE MDR 96/0669AND MDR 96/1045 FOR SIMILAR DEFECTS 3 O E286 5 C P27EA 1997112000290 19971120 00290 GL 1997 11 20 AU970077 3 19970203 G 6111 A1588B SPRING BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO HARTZL HCJ3Y PHCJ3YF2 GL PROPELLER BLADE FAULTY W K NONE O W OTHER INADEQUATE Q C IN INSP/MAINT 1 AU S 1714 ED2634 (AUS) PROPELLER LATCH SPRING KIT FOUND TO BE MADE UP OF SUPERCEEDED PARTS - FITTED AT LAST OVERHAUL IN USA - PERSONNEL/M AINTENANCE ERROR 1 L 7 2 3O 3 O 3A16 E5CE 5 C P36EA 1997112000291 19971120 00291 SO 1997 11 20 AU970078 2 19970113 G 8550 539523 BUSHING CONT OILPUMP CONT O520 TSIO520M 17040 SO OIL PUMP GEAR BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 291531 (AUS) ENGINE OIL PUMP DRIVEN GEAR BRONZE BUSH BROKEN - AIRCRAFT IS REGISTERED IN PNG AS P2-MFV 3 O E8CE 1997112000292 19971120 00292 SO 1997 11 20 AU970079 1 19970203 G 3040 WIPER ARM EMB 110 EMB110P1 3260122 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL WINDSHIELD BIRD STRIKE W K NONE C F.O.D. DE DESCENT 1 AU S (AUS) AIRCRAFT SUFFERED BIRDSTRIKE - IMPACT DAMAGE ON NLG LEG AND IN AREA OF COPILOTS WINDSCREEN WIPER ARM ACTUATOR POST RESULTING IN MINOR BENDING OF THE WIPER ARM - NIL OTHER DAMAGE 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 1997112000293 19971120 00293 CE 1997 11 20 AU970080 1 19970204 G 3230 08411065 BELLCRANK CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL LANDING GEAR RET BROKEN W K NONE O OTHER TO TAKEOFF 1 AU S (AUS) LH MAIN LANDING GEAR RETRACTION BELLCRANK BROKEN - UNLOCK PUSH/PULL ROD PNO 0840142-1 BENT - LANDING GEAR RETRACTI ON ROD PNO 0840125-15 INCORRECTLY INSTALLED ALLOWING FASTENER COLLAR TO INTERMITTENTLY CONTACT BOLT HEADS 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 1997112000294 19971120 00294 CE 1997 11 20 AU970081 1 19970130 G 3260 JE6 SWITCH CESSNA 402 402B 207590P CE MCAULY 3AF32C 3AF32C87 GL MLG DOWNLOCK FAULTY W K NONE O N OTHER FALSE WARNING TX TAXI/GRND HDL 1 AU S (AUS) LH MAIN LANDING GEAR DOWNLOCK MICROSWITCH LEAF SPRING BROKEN 1 L 7 2 3O A7CE 5 C P22EA 1997112000295 19971120 00295 CE 1997 11 20 AU970082 1 19970203 G 3222 08410021 TORQUE LINK CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO MCAULY 3AF32C 3AF32C93 GL NOSE GEAR STIFF W K NONE O OTHER CL CLIMB 1 AU S (AUS) NOSE LANDING GEAR TORQUE LINKS STIFF IN OPERATION DUE TO THE LOWER ATTACHMENT BOLT BEING OVERTORQUED - NOSE OLEO W OULD NOT FULLY EXTEND CAUSING NLG TO FOUL ON GEAR DOORS -PERSONNEL/MAINTENANCE ERROR 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 1997112000296 19971120 00296 SO 1997 11 20 AU970083 1 19970109 G 2430 W110145724 WIRE W110470720 EMB 120 EMB120RT 3260202 SO PWA 118 PW118A NE DC GENERATING SY WORN W K NONE H ELECT. POWER LOSS-50 PC CL CLIMB 1 AU S (AUS) AUXILIARY GENERATOR WIRES PNO W110-4707-20 AND PNO W110-1457-24 CHAFED IN THE AREA OF THE AIR DATA COMPUTER NO3 CO NNECTOR - SEE MDR 97/0020 FOR FURTHER INFORMATION 2 L 7 2 4T 4 T RT A31SO E20NE 1997112000297 19971120 00297 SO 1997 11 20 AU970084 2 19970203 G 8530 646267CA4 CYLINDER CONT O470U CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO MCAULY 2A34C C2A34C204 GL RECIP ENG WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 466249 466249 (AUS) ENGINE CYLINDER BORES EXCESSIVELY WORN IN TOP AND BOTTOM AREAS OF THE CYLINDER. PISTON RING CAUGHT IN WORN GROOVE CAUSING IT TO BREAK. ENGINE HAS CHROMED CYLINDERS INSTALLED AND IT IS SUSPECTED THAT THE ENGINE WAS OPERATING WITHOUT AD EQUATE LUBRICATION. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997112000298 19971120 00298 NM 1997 11 20 AU970085 1 19970204 G 2530 OVEN BOEING 737 737376 NM BUFFET/GALLEYS FAILED W K NONE O B OTHER SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) OVEN INSERT JAMMED AGAINST FAN. INVESTIGATION FOUND THAT THE LOCATING PEGS WERE MISALIGNED AND NOT LOCATING IN REC EPTACLES.THE FOOD OVERHEATED CAUSING SMOKE. PERSONNEL/MAINTENANCE ERROR 2 L 7 2 4F RT A16WE 1997112000299 19971120 00299 CE 1997 11 20 AU970086 1 19970207 G 5753 052390138 FLAP CESSNA 172 172F 2072414 CE CONT O300 O300C 17022 SO MCAULY 1C172 1C172EM GL TE FLAP STRUCTUR DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH FLAP DISTORTED - FLAP HAD A BUILT IN CHORDWISE TWIST OFAPPROXIMATELY 2.5 DEGREES - FLAP HAD BEEN DAMAGED AND RE PAIRED ON 23/7/68 - FLAP HAD WORN FLAP TRACKS AND FLAP CONDITION WAS FOUND WHEN THE TRACKS WERE REPLACED WITH NEW ITEMS - INBOARD LOWER FLAP TRACK ATTACHMENT BRACKETS ALSO CRACKED - PERSONNEL/MAINTENANCE ERROR 1 H 7 1 3O 3 O NT 3A12 E253 5 N P910 1997112000300 19971120 00300 SO 1997 11 20 AU970087 1 19970202 G 2410 76026 DRIVE BELT PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA HARTZL HCC2Y HCC2YK1 GL ALTERNATOR WRONG PART W K NONE H W ELECT. POWER LOSS-50 PC INADEQUATE Q C TO TAKEOFF 1 AU S L598348 CH11551 (AUS) ALTERNATOR DRIVE BELT STRETCHED AND SLIPPING - INVESTIGATION FOUND THAT THE DRIVE BELT FITTED WAS IN FACT AN AUTOM OTIVE PART (BOSCH 13A0965 FOR FITMENT TO TOYOTA MOTOR VEHICLES) AND NOTAPPROVED FOR FITMENT TO AIRCRAFT - PULLEY PNO 775 79 WAS EXCESSIVELY WORN IN THE GROOVE - PERSONNEL/MAINTENANCE ERROR -UNAPPROVED PART 1 L 7 1 3O 3 O A3SO 1E4 5 C P920 1997112000301 19971120 00301 SO 1997 11 20 AU970088 1 19970201 G 5753 110262192 SUPPORT EMB 110 EMB110P1 3260122 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL TE FLAP STRUCTUR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING FLAP SUPPORT ASSEMBLY CRACKED - FOUND DURING INSPECTION IAWOSIP 2706 - SUSPECT ORIGINAL FITMENT PNO 4A-2621-4 6 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 1997112000302 19971120 00302 1997 11 20 AU970089 4 19970122 G 2562 MN1300 BATTERY E01 PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1G5 41532 EA HARTZL HCC2Y HCC2YK1 GL ELT LEAKING W K NONE O OTHER IN INSP/MAINT 1 AU S 013487 (AUS) ELT BATTERY LEAKING - AIRCRAFT OPERATES IN THE TROPICS - SEE MDR96/2008 FOR SIMILAR DEFECT 1 L 7 1 3O 3 O A3SO 1E4 5 C P920 1997112000303 19971120 00303 EU 1997 11 20 AU970090 1 19970209 G 2436 NB813485 REGULATOR BNORM BN2 BN2B20 1520302 EU LYC O540 IO540K1B5 41532 EA HARTZL HCC2Y HCC2YK2 GL DC VOLTAGE BURNT W K NONE B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) RH ALTERNATOR VOLTAGE REGULATOR BURNT OUT DUE TO FAILURE OF THE DRIVER TRANSISTOR IN THE ALTERNATOR FIELD WINDING 1 H 7 2 3O 3 O A17EU 1E4 5 C P920 1997112000304 19971120 00304 CE 1997 11 20 AU970091 1 19970214 G 5210 1013840961 HANDLE BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL PASS/CREW DOOR BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CABIN DOOR HANDLE BROKEN IN AREA AROUND BEARING HOUSING - HANDLE THEN SEPARATED FROM SQUARE SHAFT. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1997112000305 19971120 00305 GL 1997 11 20 AU970092 3 19970214 G 6111 83023 LATCH CESSNA 441 441 2076020 CE HARTZL HCB3T HCB3TN5 GL PROPELLER BLADE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 2958 BV3932 (AUS) PROPELLER STARTING LATCH CRACKED 1 L 7 2 3T RT A28CE 6 C P15EA 1997112000306 19971120 00306 GL 1997 11 20 AU970093 3 19970207 G 6110 SEAL BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO MCAULY 2AF34C 2AF34C55 GL PROP BLADE NUT PINCHED W K NONE O W OTHER INADEQUATE Q C IN INSP/MAINT 1 AU S 736004 (AUS) PROPELLER BLADE NUT SEALS PINCHED GIVING INEFFECTIVE SEALING -SEALING WAS ACHIEVED BY THE USE OF SILASTIC SEALANT BETWEEN THE BLADE NUT THREADS AND HUB AND LOCK RING ASSEMBLY - INCORRECT ASSEMBLY - PERSONNEL/MAINTENANCE ERROR - PROPEL LER HAD BEEN MODIFIED TO OIL FILLED CONFIGURATION 1 L 7 2 3O 3 O RT 3A16 3E1 5 C P5EA 1997112000307 19971120 00307 GL 1997 11 20 AU970094 3 19970214 G 6112 4E1614 SLIP RING CESSNA 441 441 2076020 CE HARTZL HCB3T HCB3TN5 GL PROPELLER DE-ICE SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S 3011 BV4305 (AUS) PROPELLER SLIP RING SEPARATING FROM DE-ICE PLATTER - SUSPECT NONAPPROVED REPAIR CARRIED OUT 1 L 7 2 3T RT A28CE 6 C P15EA 1997112000308 19971120 00308 SW 1997 11 20 AU970095 1 19970211 G 2612 1734361450 DETECTOR GULSTM 690TP 695B 3970610 SW ROTOL R306 R306382F7 GL RT ENG DET SYS FAULTY W E ENGINE SHUTDOWN N FALSE WARNING NR NOT REPORTED 1 AU S (AUS) RH ENGINE FIRE DETECTORS SUSPECT FAULTY - DETECTORS WERE CHECKEDSATISFACTORY - SUSPECT RH ENGINE EXHAUST SEAL PNO 610652-69 MAY HAVE BEEN LEAKING CAUSING HOT AIR TO BE DIRECTED ONTO FIRE DETECTORS - ALTHOUGH THERE WAS NO EVIDENCE OF L EAKAGE THE SEAL WAS REPLACED 1 H 7 2 4T RT 2A4 6 C P8EU 1997112000309 19971120 00309 EU 1997 11 20 AU970096 2 19970130 G 7310 8151GAF DRAIN VALVE RROYCE FILTERCOVER FOKKER F28 F28MK1000 4990808 EU RROYCE SPEY SPEY55515 54521 EU ENGINE FUEL DIST LEAKING W K NONE O K OTHER FLUID LOSS IN INSP/MAINT 1 AU S 580 9286 (AUS) LH ENGINE LP FUEL FILTER DRAIN VALVE LEAKING FROM FLANGE AREA 2 L 7 2 4F 4 F RT A20EU E2EU 1997112000310 19971120 00310 EU 1997 11 20 AU970097 1 19970126 G 5313 27 STRINGER AIRBUS 300 A300B4203 3930306 EU GE CF6 CF650C2 30018 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FRAME 40 STRINGER 27 RHS CRACKED - FOUND DURING HIGH FREQUENCY EDDY CURRENT INSPECTION IAW SB A300-53-031 0 2 L 7 2 4F 4 F A35EU E23EA 1997112000311 19971120 00311 NM 1997 11 20 AU970098 1 19970103 G 5311 A0202 FRAME ROBSIN R22 R22MARINER NM LYC O320 O320B2C 41508 EA FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 888 2346 (AUS) FUSELAGE UPPER FRAME CRACKED IN AREA UNDER MAIN GEARBOX MOUNT PADS AS REFERRED IN AD/R22/41 AMDT1 1 G 7 1 3O 3 O H10WE E274 1997112000312 19971120 00312 SO 1997 11 20 AU970099 1 19970213 G 2912 MS28775217 O-RING PUROLATOR PR301 PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA HYDRAULIC FILTER FAULTY W K NONE K FLUID LOSS LD LANDING 1 AU S (AUS) HYDRAULIC SYSTEM PUROLATOR FILTER `O' RING SEAL FAULTY - OIL LEAKING - NOSE WHEEL FAILED TO EXTEND - DAMAGE TO FOR WARD FUSELAGE AND PROPELLERS 1 L 7 2 3O 3 O A20SO E14EA 1997112000313 19971120 00313 CE 1997 11 20 AU970100 1 19970122 G 2730 26340171 TORQUE TUBE CESSNA 208 208 2073702 CE PWA PT6 PT6A114 52043 NE ELEVATOR CONTROL CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH ELEVATOR ASSEMBLY TORQUE TUBE CRACKED LONGITUDINALLY THROUGH RIVET HOLE 60MM (2.36IN) FROM INBOARD END - CORROS ION FOUND BETWEEN TUBE AND END FITTING WHICH CAUSED THE TUBE TO EXPAND AND CRACK - SUSPECT INADEQUATE TREATMENT DURING A SSEMBLY - AIRCRAFT OPERATES AS A FLOAT PLANE IN A SALT LADEN ENVIRONMENT 1 H 7 1 3T 3 T NT A37CE E4EA 1997112000314 19971120 00314 SO 1997 11 20 AU970101 2 19970119 G 7314 6328183 PUMP CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL ENGINE FUEL FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S L238102RB 604094 (AUS) LH ENGINE DRIVEN FUEL PUMP INTERNAL FAILURE - INVESTIGATION BY OVERHAUL SHOP COULD FIND NO FAULTS 1 L 7 2 3O 3 O A25CE E7CE 5 C P45GL 1997112000315 19971120 00315 CE 1997 11 20 AU970102 1 19970115 G 2510 SEAT BELT BEECH 23 A2324 1151226 CE LYC O360 IO360A2B 41514 EA MCAULY 2D34C 2D34C9 GL FLIGHT COMPART WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) AUTOMOTIVE WEBBING AND HARDWARE USED FOR SEAT BELTS - UNAPPROVEDPART - PERSONNEL/MAINTENANCE ERROR 1 L 7 1 3O 3 O A1CE 1E10 5 C P7EA 1997112000316 19971120 00316 1997 11 20 AU970103 4 19970123 G 2397 22GAWIRE WIRE BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE MCAULY 4HFR34 4HFR34C754 NE HF COMMUNICATION FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HF INSTALLATION SUSPECT FAULTY - INSUFFICIENT PROTECTION OF 22GAWIRE CONNECTING THE LAMP TO THE 15AMP CIRCUIT BREA KER - IF THE22GA WIRE SHORT CIRCUITS TO THE AIRFRAME IT IS SUSPECTED THAT THE 15AMP CIRCUIT BREAKER WOULD NOT TRIP ALLOW ING THE WIRE TO THEN BURN/OVERHEAT - AIRCRAFT WAS PREVIOUSLY REGISTERED AS VH-RFX 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 1997112000317 19971120 00317 SO 1997 11 20 AU970104 1 19970122 G 2510 SEAT BELT PIPER PA22 PA22108 7102204 SO LYC O235 O235C1B 41505 EA SNSNCH 76AM M76AM EA FLIGHT COMPART WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) NON-APPROVED HARDWARE AND WEBBING USED IN SEAT BELTS - UNAPPROVED PART - PERSONNEL/MAINTENANCE ERROR 1 H 7 1 3O 3 O 1A6 E223 5 N 1P210 1997112000318 19971120 00318 CE 1997 11 20 AU970105 1 19970121 G 3234 99102251 SELECTOR VALVE CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO GEAR SELECTOR FAULTY W K NONE O OTHER LD LANDING 1 AU S 737 (AUS) LANDING GEAR SELECTOR VALVE FAULTY - REPAIRED ITEM HAD BEEN FITTED BEFORE THE PREVIOUS FLIGHT - THE VALVE WAS AGAI N RETURNEDTO THE OVERHAUL FACILITY - THE VALVE COULD NOT BE FAULTED INITIALLY BUT AFTER REPEATED TESTING THE VALVE FAILE D - SUSPECT FAULTY SOLENOID OR HIGH HOURS - SEE MDR 96/1940 FOR FURTHER INFORMATION 1 L 7 2 3O 3 O A7CE E8CE 1997112000319 19971120 00319 CE 1997 11 20 AU970106 1 19970130 G 2450 CIRCUIT BREAKER BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO HARTZL HCJ2Y BHCJ2YF2 GL AC POWER DISTRIB MISWIRED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) TRANSPONDER SYSTEM WIRED TO PRIMARY AH CIRCUIT BREAKER FOLLOWING FAILURE OF CORRECT CB WHICH HAD BEEN DISCONNECTED - CIRCUIT BREAKER MARKED `RADAR' WAS REALLY THE COMPASS SYSTEM (COMPASS SYSTEM CB WAS FOUR CIRCUIT BREAKERS AWAY) - HF CIRCUIT BREAKER NOT MARKED - PERSONNEL/MAINTENANCE ERROR 1 L 7 2 3O 3 O 3A16 E5CE 5 C P37EA 1997112000320 19971120 00320 EU 1997 11 20 AU970107 1 19970218 G 3213 TB1041033000 TORQUE LINK SOCATA TB9 TB9 8680694 EU LYC O320 O320D2A 41508 EA SNSNCH 74D 74DM EA MLG BROKEN W K NONE O OTHER LD LANDING 1 AU S (AUS) RH MAIN LANDING GEAR LOWER TORQUE LINK FAILED AT LOWER ATTACHMENT HOLES 1 L 7 1 3O 3 O NT AS1EU E274 5 N P88614 1997112000321 19971120 00321 EU 1997 11 20 AU970108 1 19970208 G 2720 CONTROL CABLE BNORM BN2 BN2A20 1520220 EU LYC O540 IO540K1B5 41532 EA HARTZL HCC2Y HCC2YK2 GL RUDDER CONTROLS MISROUTED W O OTHER F W FLT CONT AFFECTED INADEQUATE Q C NR NOT REPORTED 1 AU S (AUS) RUDDER PEDAL ADJUSTMENT CABLE INCORRECTLY ROUTED - CABLE ROUTED BELOW THE CONTROL COLUMN ELECTRICAL CORD INSTEAD O F ABOVE IT -THIS CAUSED THE CABLE TO SNAG ON THE ELECTRICAL CORD AND JAM THE CONTROL COLUMN IN THE FULL AFT POSITION - P ERSONNEL/MAINTENANCE ERROR 1 H 7 2 3O 3 O A17EU 1E4 5 C P920 1997112000322 19971120 00322 EA 1997 11 20 AU970109 2 19970129 G 8520 69796 DOWEL LYC O540B2C5 PIPER PA25 PA25235 7102504 SO LYC O540 O540B2C5 41532 EA MCAULY 1A200 1A200FA GL ENG RT CASE SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S L1341740 L1341740 (AUS) RH CRANKCASE NO3 DOWEL SHEARED ALLOWING MOVEMENT OF THE MAINBEARINGS - WEAR ALSO TO CRANKCASE TUNNEL AND SCORING O F THE CRANKCASE JOURNAL - DOWEL WAS SUPERCEDED (STEPPED) TYPE 1 L 7 1 3O 3 O 2A10 E295 5 N P874 1997112000323 19971120 00323 EA 1997 11 20 AU970110 2 19970129 G 8530 SL75089 PISTON SUPAIRPART SL36000NA20 PIPER PA25 PA25235 7102504 SO LYC O540 O540B2C5 41532 EA MCAULY 1A200 1A200FA GL CYLS 1- 3- 5 CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 131132036 L1341740 (AUS) NO1, NO3 AND NO5 PISTONS CRACKED IN AREA OF SKIRT OPPOSITE TO THE PISTON PIN BOSS - NO1, N3 AND NO5 INDUCTION TUBE S FOUND LOOSE ALLOWING UNMETERED AIR INTO ENGINE CAUSING SUSPECTED LEAN MIXTURE - NO5 CYLINDER SPARK PLUGS IN POOR CONDI TION - PISTONS ARE HIGH COMPRESSION TYPE - ENGINE RUNS ON MOGAS 1 L 7 1 3O 3 O 2A10 E295 5 N P874 1997112000324 19971120 00324 NE 1997 11 20 AU970111 2 19970216 G 7250 785259 TURBINE GE CT79B SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE ENGINE DAMAGED W K NONE E VIBRATION/BUFFET TO TAKEOFF 1 AU S 9583 785259 785259 (AUS) RH ENGINE HOT SECTION AND POWER TURBINE MODULES DAMAGED - HOT SECTION 1. 2ND STAGE TURBINE FORWARD COOLING PLATE D AMAGED2. 1ST AND 2ND STAGE TURBINE NOZZLES AND ROTOR DAMAGED POWER TURBINE SECTION 1. 3RD AND 4TH STAGE TURBINE NOZZLES AND ROTOR DAMAGED2. POSSIBLE HEAT DAMAGE TO INLET GUIDE VANES 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 1997120400001 19971204 00001 SO 1997 12 4 AU970112 1 19970129 G 7922 75944 NUT VERNATHERM PIPER PA25 PA25235 7102504 SO LYC O540 O540B2C5 41532 EA MCAULY 1A200 1A200FA GL OIL TEMP VALVE LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S L1341740 (AUS) THERMOSTATIC OIL COOLER BYPASS VALVE (VERNATHERM) NUT LOOSE 1 L 7 1 3O 3 O 2A10 E295 5 N P874 1997120400002 19971204 00002 EU 1997 12 4 AU970113 1 19970215 G 3260 AIR130902 CONNECTOR SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE GEAR POS SWITCH FAULTY W K NONE O OTHER DE DESCENT 1 AU S (AUS) RH MAIN LANDING GEAR DOWNLOCK MICROSWITCH CONNECTOR INCORRECTLY TIGHTENED DURING MAINTENANCE APPROXIMATELY 160 HOU RS PREVIOUS - PLUG LOOSENED DUE TO VIBRATION GIVING INTERMITTENT OPERATION -PERSONNEL/MAINTENANCE ERROR 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 1997120400003 19971204 00003 EA 1997 12 4 AU970114 2 19970129 G 8520 72877 TAPPET LYC CAMSHAFT PIPER PA25 PA25235 7102504 SO LYC O540 O540B2C5 41532 EA MCAULY 1A200 1A200FA GL CAM NR 5 LOBE SPALLED W K NONE O OTHER IN INSP/MAINT 1 AU S L1341740 (AUS) CAMSHAFT NO5 LOBE AND ASSOCIATED TAPPET BODIES (2OFF) SEVERELY SPALLED 1 L 7 1 3O 3 O 2A10 E295 5 N P874 1997120400004 19971204 00004 CE 1997 12 4 AU970115 1 19970219 G 3610 67184 GASKET LEAR 31A LEAR 35 31A 5170531 CE GARRTT TFE731 TFE73123B WP ENGINE BLEED AIR FAILED W A K NONE B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CL CLIMB 1 AU S P99223 (AUS) ENGINE TO PYLON BLEED AIR DUCT GASKET BLOWN OUT AND TWO DUCT SECURING NUTS MISSING (BOLTS INTACT) - SUSPECT BOLTS NOT TORQUED DURING ENGINE INSTALLATION - PERSONNEL/MAINTENANCE ERROR 2 L 7 2 4F 4 F RT A10CE E6WE 1997120400005 19971204 00005 NE 1997 12 4 AU970116 2 19970213 G 7510 44E202A FILTER EMB 120 EMB120RT SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE ENGINE ANTI-ICE CRACKED W K NONE J WARNING INDICATION CL CLIMB 1 AU S RF2084 (AUS) LH ENGINE DE-ICE SYSTEM AIR LINE WATER FILTER HOUSING CRACKED 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 1997120400006 19971204 00006 SO 1997 12 4 AU970117 2 19970215 G 8520 646778 CONNECTING ROD CONT O470U CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO NR 1 CYL FAILED W O OTHER E R K VIBRATION/BUFFET PARTIAL RPM/PWR LOSS FLUID LOSS TO TAKEOFF 1 AU S 434 809808R 809808R (AUS) CONNECTING ROD END CAP SEPARATED - PRELIMINARY INVESTIGATION INDICATES FAILURE IN AREA APPROXIMATELY 10MM (0.393IN ) ABOVE THE BOLT SHOULDER ON THE CAMSHAFT SIDE BEHIND THE HARD FACE FOR THE BEARING SHELL PROGRESSING OUTWARDS UNTIL FAI LURE FROM OVERLOAD -CRANKCASE HOLED IN AREA OF NO1 CYLINDER PUSHROD TUBE FITMENT 1 H 7 1 3O 3 O NT 3A13 E273 1997120400007 19971204 00007 NM 1997 12 4 AU970118 1 19970205 G 2161 6529346 CONTROLLER BOEING 757 757200 1384950 NM CABIN TEMPERATUR FAULTY W K NONE O OTHER CL CLIMB 1 AU S (AUS) AIR CONDITIONING SYSTEM ZONE TEMPERATURE CONTROLLER SUSPECT FAULTY 2 L 7 2 4F RT A2NM 1997120400008 19971204 00008 NM 1997 12 4 AU970119 1 19970212 G 2612 D02860 TUBE 285NOO2821 BOEING 757 757200 1384950 NM FIRE DETECTION SEPARATED W K NONE J WARNING INDICATION DE DESCENT 1 AU S D02860 (AUS) CARGO AREA FIRE WARNING SYSTEM PRINTED CIRCUIT BOARD SUSPECT FAULTY - INVESTIGATION FOUND FAULT CAUSED BY DISCONNE CTED DETECTOR TUBE 2 L 7 2 4F RT A2NM 1997120400009 19971204 00009 WP 1997 12 4 AU970120 1 19970219 G 6410 369A1613507 BLADE HUGHES 369 369HS 4470728 WP ALLSN 250C 250C20B 03013 GL TAIL ROTOR BLADE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 341 BLADE0022228 (AUS) TAIL ROTOR BLADE SKIN CRACKED IN AREA INBOARD OF THE LEADING EDGE PROTECTION STRIP RUNNING CHORDWISE FROM THE LEAD ING EDGE TOWARDS THE TRAILING EDGE - CRACK LENGTH APPROXIMATELY 25.4MM (1IN) 1 G 7 1 3U 3 U H3WE E4CE 1997120400010 19971204 00010 CE 1997 12 4 AU970121 1 19970117 G 3242 101800213 BRAKE DISC BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE BRAKE FAILED W K NONE O OTHER TX TAXI/GRND HDL 1 AU S (AUS) LH OUTBOARD BRAKE ROTATING DISC BROKEN - ONE SEGMENT CRACKED AND FELL OUT CAUSING MINOR DAMAGE TO WHEEL 1 L 7 2 4T 4 T A24CE E4EA 1997120400011 19971204 00011 CE 1997 12 4 AU970122 1 19970128 G 3242 101800213 BRAKE DISC BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE RT OUTBRD FAILED W K NONE O OTHER TX TAXI/GRND HDL 1 AU S (AUS) RH OUTBOARD BRAKE DISC BROKEN - BROKEN PIECE OF DISC DAMAGED WHEEL ASSEMBLY AND BRAKE BACKPLATE - WHEEL JAMMED 1 L 7 2 4T 4 T A24CE E4EA 1997120400012 19971204 00012 SO 1997 12 4 AU970123 1 19970211 G 3260 487862 SWITCH PIPER PA31 PA31350 7103110 SO HARTZL HCE3Y HCE3YR2 GL LANDING GEAR POS FAULTY W K NONE O OTHER TO TAKEOFF 1 AU S (AUS) LH MAIN LANDING GEAR SQUAT SWITCH FAULTY 1 L 7 2 3O A20SO 5 C P33EA 1997120400013 19971204 00013 CE 1997 12 4 AU970124 1 19970216 G 3231 NUT CESSNA 210L CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL LANDING GEAR DOO LOOSE W K NONE O OTHER LD LANDING 1 AU S 294762R (AUS) NOSE LANDING GEAR DOOR ACTUATING ROD JAM NUTS NOT TIGHTENED - PERSONNEL/MAINTENANCE ERROR 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 1997120400014 19971204 00014 SO 1997 12 4 AU970125 2 19970213 G 7314 631683 DRIVE SHAFT CONT FUELPUMP CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO MCAULY 3A32C D3A32C88 GL ENGINE FUEL PUMP WORN W K NONE O OTHER IN INSP/MAINT 1 AU S D117002B 567450 (AUS) ENGINE DRIVEN FUEL PUMP DRIVE SHAFT WORN - DRIVE SHAFT ROUNDED -FEMALE END IN PUMP ALSO WORN 1 H 7 1 3O 3 O 3A21 E5CE 5 C P21EA 1997120400015 19971204 00015 EU 1997 12 4 AU970126 1 19970127 G 6420 1090130059 PITCH LINK AGUSTA A109C AGUSTA A109 A109C 0260118 EU TAIL ROTOR HEAD FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) TAIL ROTOR PITCH LINK BEARINGS NOT STAKED - BEARINGS MOVING IN LINKS AND ONE BEARING DISLODGED - PITCH LINKS HAD B EEN FITTED NEW A WEEK EARLIER - PERSONNEL/MAINTENANCE ERROR 1 G 7 2 3U H7EU 1997120400016 19971204 00016 CE 1997 12 4 AU970127 1 19970218 G 2460 CONNECTOR BEECH 36 A36 1151604 CE CONT O520 IO520B 17032 SO MCAULY 3A32C 3A32C76 GL DC POWER DISTRIB CORRODED W K NONE H ELECT. POWER LOSS-50 PC CR CRUISE 1 AU S (AUS) MAIN ALTERNATOR CABLE TO CURRENT LIMITER AND CURRENT LIMITER TO SHUNT AND MAIN AIRCRAFT DC BUSS CONNECTIONS CORROD ED 1 L 7 1 3O 3 O 3A15 E5CE 5 C P21EA 1997120400017 19971204 00017 CE 1997 12 4 AU970128 1 19970205 G 5610 10138402516 WINDSHIELD BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE FLIGHT COMPART CRACKED W K NONE O OTHER DE DESCENT 1 AU S (AUS) CO-PILOTS WINDSHIELD OUTER LAMINATION CRACKED IN TOP RH CORNER -WINDSHIELD WAS DELAMINATING PRIOR TO CRACKING (THE DELAMINATION WAS WITHIN MANUFACTURERS LIMITS) 1 L 7 2 4T 4 T A24CE E4EA 1997120400018 19971204 00018 EU 1997 12 4 AU970129 1 19970214 G 2752 9787320302 ACTUATOR PILATS PC12 PC12 7090550 EU TE FLAP ACTUATOR NOISY W K NONE O E OTHER VIBRATION/BUFFET IN INSP/MAINT 1 AU S (AUS) FLAP ACTUATOR NOISY - FLAP SHUDDERING ON EXTENSION 1 L 7 1 3T RT A78EU 1997120400019 19971204 00019 GL 1997 12 4 AU970130 3 19970218 G 6114 C88 HUB CESSNA 210 210M 2073450 CE CONT O520 IO520L 17032 SO MCAULY 3A32C D3A32C88 GL NR 2 SOCKET CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 945 775046 (AUS) PROPELLER HUB CRACKED IN NO2 BLADE SOCKET AREA - CRACK LENGTH APPROXIMATELY 6.35MM (0.25IN) - FOUND DURING INSPECT ION IAW AD/PMC/41 FOLLOWING WIRE STRIKE 1 H 7 1 3O 3 O 3A21 E5CE 5 C P21EA 1997120400020 19971204 00020 CE 1997 12 4 AU970131 1 19970204 G 3260 513771 SWITCH CESSNA 210L CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL LANDING GEAR POS STUCK W K NONE O OTHER LD LANDING 1 AU S 61553 (AUS) NOSE LANDING GEAR DOWNLOCK MICROSWITCH STICKING DUE TO DIRT AND OIL CONTAMINATION 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 1997120800001 19971208 00001 NM 1997 12 8 AU970132 1 19970121 G 2410 729490 CSD 729490 BOEING 747 747312 1384932 NM PWA JT9 JT9D7R4G2 52054 NE NR 1 ENG FAILED W K NONE J WARNING INDICATION CR CRUISE 1 AU S 12469 A0348 (AUS) NO1 ENGINE CONSTANT SPEED DRIVE (CSD) FAULTY - CSD FAILED TO DISCONNECT - EVIDENCE OF OVERHEATING - STRIP REPORT I NDICATES OUTPUT SPUR GEAR ACCESSORY GEAR FAILURE 2 L 7 4 4F 4 F RT A20WE E3NE 1997120400021 19971204 00021 1997 12 4 AU970133 4 19970216 G 2210 7690001808103 GYRO SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE AUTOPILOT SYSTEM INOPERATIVE W K NONE F FLT CONT AFFECTED CR CRUISE 1 AU S 306723306739 (AUS) BOTH YAW RATE GYROS FAULTY 1 G 7 2 3U 3 U NC H1NE E19EU 1997120400022 19971204 00022 NM 1997 12 4 AU970134 1 19970101 G 3510 OXYGEN SYSTEM BOEING 747 747312 1384932 NM CREW OXYGEN SYST DEPLETED W K NONE O OTHER CR CRUISE 1 AU S (AUS) FLIGHT CREW OXYGEN SYSTEM PRESSURE DEPLETED. SUSPECT CREW REGULATOR LEFT IN `100% ON' POSITION 2 L 7 4 4F RT A20WE 1997120400023 19971204 00023 CE 1997 12 4 AU970135 1 19970103 G 2910 61510 VALVE CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE HYDRAULIC, MAIN SEIZED W K NONE O OTHER LD LANDING 1 AU S (AUS) HYDRAULIC OPEN CENTRE BYPASS VALVE INTERNAL FAULT - VALVE INTERMITTENTLY SEIZED IN THE OPEN POSITION 1 L 7 2 4F 4 F A22CE E1NE 1997120400024 19971204 00024 SO 1997 12 4 AU970136 1 19970210 G 2910 HYDRAULIC SYSTEM EMB 110 EMB110P1 3260122 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL HYDRAULIC, MAIN CONTAMINATED W K NONE O OTHER CL CLIMB 1 AU S (AUS) LANDING GEAR HYDRAULIC SYSTEM CONTAMINATED WITH AIR 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 1997120800002 19971208 00002 EU 1997 12 8 AU970137 1 19970223 G 2611 72111211000 SMOKE DETECTOR SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE SMOKE DETECTION MALFUNCTION W K NONE N FALSE WARNING CR CRUISE 1 AU S A4607 (AUS) CARGO BAY SMOKE DETECTOR ILLUMINATED WARNING LIGHT - CARGO COMPARTMENT EXTINGUISHER FIRED - CHECK OF COMPARTMENT C OULD FIND NO EVIDENCE OF SMOKE OR FIRE - SUSPECT CAUSED BY HIGH HUMIDITY 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 1997120800003 19971208 00003 GL 1997 12 8 AU970138 3 19970212 G 6111 B24231 CYLINDER PIPER PA60 PA60600 7106001 NM LYC O540 IO540K1J5 41532 EA HARTZL HCC3Y HCC3YR GL PROPELLER BLADE SLUDGED W K NONE O OTHER IN INSP/MAINT 1 AU S 2000 CK1594 (AUS) PROPELLER CYLINDER SLUDGED RESTRICTING OPERATION 1 M 7 2 3O 3 O RT A17WE 1E4 5 C P25EA 1997120400025 19971204 00025 CE 1997 12 4 AU970139 1 19970221 G 7110 COWLING CESSNA 182 182A 2072704 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL ENGINE COWLINGS DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 321072R 715070 (AUS) UNSECURED AND UNATTACHED UPPER AND LOWER ENGINE COWLINGS PICKED UP BY A GUST OF WIND AND BLOWN INTO PROPELLER ARC DURING ENGINE GROUND RUN - DAMAGE TO PROPELLER BLADES AND DESTRUCTION OF COWLS- ENGINE BULK STRIP TO BE CARRIED OUT 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997120400026 19971204 00026 SO 1997 12 4 AU970140 1 19970127 G 3233 3579705 ACTUATOR PIPER PA28 PA28R201T 7102813 SO CONT O360 TSIO360F 17025 SO HARTZL HCC2Y BHCC2YF2 GL LANDING GEAR ACT FAILED W K NONE O OTHER TO TAKEOFF 1 AU S 3350 (AUS) NOSE LANDING GEAR HYDRAULIC ACTUATOR FAILED AT FUSELAGE ATTACHMENT POINT 1 L 7 1 3O 3 O 2A13 E9CE 5 C P920 1997120400027 19971204 00027 WP 1997 12 4 AU970141 2 19970106 G 7310 C1A FILTER DHAVXX DH82 DH82AROBRTSN 2801002 WP DHAVXX GIPSY GIPSYMAJOR1 20004 WP ENGINE FUEL DIST WORN W K NONE O OTHER CR CRUISE 1 AU S 35D2266 23 (AUS) AIRCRAFT FUEL TANK FLOAT DETERIORATED ALLOWING FLOAT PARTICLES TO ENTER AND BLOCK CARBURETTOR MAIN JET - FUEL FILT ER WORN PREVENTING FILTER FROM BLOCKING CONTAMINATION 1 Q 7 1 3I 3 I A8EU A8EU 1997120400028 19971204 00028 SO 1997 12 4 AU970142 2 19970116 G 8520 836752R CRANKCASE CONT O470 CONT O470 O470* 17026 SO NR 2 MAIN SUPPRT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 836752R 836752R (AUS) CRANKCASE NO2 MAIN BEARING SUPPORT CRACKED - EVIDENCE OF MAIN BEARING SADDLE FRETTING - FOUND DURING BULK STRIP FO LLOWING PROPELLER STRIKE 3 O E273 1997120400029 19971204 00029 NM 1997 12 4 AU970143 1 19970218 G 2760 PREPRELCC5141 LINK DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE DRAG CONTROL SYS LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH OUTBOARD ROLL SPOILER LINK ASSEMBLY LOOSE BETWEEN ROD AND RODEND AT BOTH ENDS 2 H 7 2 4T 4 T RT A13NM E20NE 1997120400030 19971204 00030 1997 12 4 AU970144 1 19970209 G 7603 CABLE ROTAX 912 ROTAX912 55555 EU POWER LEVER BROKEN W K NONE O OTHER CR CRUISE 1 AU S 4076069 (AUS) LH THROTTLE CABLE BROKEN AT CARBURETTOR ATTACHMENT PIVOT - CABLE WAS FLEXING DUE TO STIFF PIVOT 3 I EXPE3I 1997120400031 19971204 00031 EU 1997 12 4 AU970145 1 19970206 G 6210 355A11002011 BLADE AEROSP AS355 AS355F1 8680810 EU ALLSN 250C 250C20F 03013 GL MAIN ROTOR BLADE DEBONDED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MAIN ROTOR BLADE INBOARD TRIM TAB DEBONDED AND LOOSE ON BLADE 1 G 7 2 3U 3 U H11EU E4CE 1997120400032 19971204 00032 SO 1997 12 4 AU970146 1 19970219 G 7830 1159SCP4253 CONTROL VALVE PNEUDRAULICS CONTROL GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6118 EU THRUST REVERSER FAULTY W K NONE O J OTHER WARNING INDICATION TO TAKEOFF 1 AU S 986 205 (AUS) RH ENGINE THRUST REVERSER CONTROL VALVE FAULTY 2 L 7 2 4F 4 F RT A12EA E25NE 1997120400033 19971204 00033 NM 1997 12 4 AU970147 1 19970213 G 3246 2605759A WHEEL BENDIX WHEEL BOEING 727 7272J4 1384006 NM PWA JT8 JT8D17 52049 NE WHEEL/SKI/FLOAT FRACTURED W K NONE O OTHER LD LANDING 1 AU S 387 ASSYHALFH015 (AUS) NO4 MAIN WHEEL CENTRE HUB FAILED. DAMAGE TO BRAKE AND WHEEL BEARING. FUSE PLUG MELTED AND TYRE DEFLATED. 2 L 7 3 4F 4 F RT A3WE E2EA 1997120400034 19971204 00034 NM 1997 12 4 AU970148 1 19970208 G 2752 3947 SCREWJACK BOEING 737 737476 NM TE FLAP ACTUATOR WORN W K NONE F FLT CONT AFFECTED DE DESCENT 1 AU S 3947 (AUS) NO2 TRAILING EDGE FLAP SCREWJACK WORN CAUSING THE FLAP BALLNUT ASSEMBLY TO JAM THE SCREWJACK 2 L 7 2 4F RT A16WE 1997120400035 19971204 00035 NM 1997 12 4 AU970149 1 19970210 G 2761 4554 ACTUATOR BOEING 737 737376 NM DRAG CONTROL ACT BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 4554 (AUS) NO5 GROUND SPOILER OUTBOARD ACTUATOR LOWER ATTACHMENT FITTING BROKEN - SUSPECT CAUSED BY CORROSION PITTING OF ALUM INIUM HOUSING 2 L 7 2 4F RT A16WE 1997120400036 19971204 00036 SW 1997 12 4 AU970150 1 19970101 G 2435 150SG117Q STARTER GEN BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL STARTER-GENERATO FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 584 13956 (AUS) STARTER/GENERATOR HAD EXCESSIVE ARMATURE BALANCE BAND GRINDING TO ACHIEVE BALANCE - PERSONNEL/MAINTENANCE ERROR - UNAPPROVED REPAIR 1 G 7 1 3U 3 U H2SW E4CE 1997120400037 19971204 00037 EA 1997 12 4 AU970151 2 19970224 G 8520 L4251627A CAMSHAFT LYC O320A2B LYC O320 O320A2B 41508 EA RECIP ENG WORN W K NONE O OTHER IN INSP/MAINT 1 AU S L4251627A L4251627A (AUS) ENGINE CAMSHAFT CAM LOBES WORN BEYOND LIMITS - ALL CYLINDERS AND ASSOCIATED PARTS UNSERVICEABLE 3 O E274 1997120400038 19971204 00038 EA 1997 12 4 AU970152 2 19970224 G 8520 CAMSHAFT LYC IO540K1B5 LYC O540 IO540K1B5 41532 EA RECIP ENG WORN W K NONE O OTHER IN INSP/MAINT 1 AU S IO540KIB5 (AUS) ENGINE CAMSHAFT LOBES WORN - COUNTERWEIGHT BUSHES OUT OF LIMITS 3 O 1E4 1997120400039 19971204 00039 EA 1997 12 4 AU970153 2 19970224 G 8520 L3398327A CRANKCASE LYC O320E2D LYC O320 O320E2D 41508 EA RECIP ENG WORN W K NONE O OTHER IN INSP/MAINT 1 AU S L3398327A L3398327A (AUS) CRANKCASE SADDLES FRETTING 3 O E274 1997120400040 19971204 00040 EU 1997 12 4 AU970154 1 19970226 G 2910 SA767006155 HOSE BAC 146 146100A 1500260 EU LYC ALF502 ALF502R5 41580 NE HYDRAULIC, MAIN LEAKING W K NONE K FLUID LOSS CR CRUISE 1 AU S (AUS) GREEN SYSTEM HYDRAULIC PRESSURE HOSE CHAFING ON COWLING DOOR- LOSS OF HYDRAULIC FLUID 2 H 7 4 4F 4 F RT A49EU E6NE 1997120400041 19971204 00041 NM 1997 12 4 AU970155 1 19970227 G 5753 113T13698 BRACKET BOEING 767 76733A NM PWA 4056 PW4056 NE TE FLAP STRUCTUR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 4964 (AUS) RH WING OUTBOARD FLAP DEFLECTION CONTROL TRACK FITTING CRACKED ON LH AND RH SIDES - SLIGHT DAMAGE TO RH WING CLOSE -OUT PANEL 2 L 7 2 RT 4 F RT A1NM E24NE 1997120400042 19971204 00042 CE 1997 12 4 AU970156 1 19970206 G 5521 07341023 ADAPTER CESSNA 172 172M 2072418 CE MCAULY 1C160 1C160DTM GL ELEV SPAR/RIB CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH ELEVATOR TORQUE TUBE ADAPTERS CONTAINED SEVERE CORROSION BETWEEN ADAPTERS AND INBOARD RIBS - FLANGES ON ADAPTERS CRACKED DUE TO CORROSION 1 H 7 1 3O NT 3A12 5 N P910 1997120400043 19971204 00043 CE 1997 12 4 AU970157 1 19970124 G 3230 DOWNLOCK CESSNA 210L CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO MCAULY 3A32C D3A32C88 GL GEAR RETRACT CONTAMINATED W K NONE O N OTHER FALSE WARNING LD LANDING 1 AU S NSN (AUS) LH MAIN LANDING GEAR DOWNLOCK HOOK CONTAMINATED WITH DIRT AND GRIT - AIRCRAFT OPERATES FROM DIRT STRIPS 1 H 7 1 3O 3 O 3A21 E5CE 5 C P21EA 1997120400044 19971204 00044 SO 1997 12 4 AU970158 2 19970215 G 8520 574572 CONNECTING ROD CONT IO520F CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO MCAULY D3A34 D3A34C404 GL RECIP ENG BROKEN W K NONE E K R VIBRATION/BUFFET FLUID LOSS PARTIAL RPM/PWR LOSS CL CLIMB 1 AU S 326 574572 574572 930788 (AUS) ENGINE NO5 CYLINDER CONNECTING ROD BIG END BEARING FAILED DUE TO LACK OF LUBRICATION/COOLING CAUSED BY LOSS OF OIL OVERBOARD - LOSS OF OIL WAS THROUGH A WORN AND HOLED EXHAUST PUSHROD TUBE CAUSED BY A BENT PUSHROD, DUE TO STICKING VA LVE - CONNECTING ROD BROKEN - CRANKCASE HOLED 1 H 7 1 3O 3 O A4CE E5CE 5 C P47GL 1997120400045 19971204 00045 SO 1997 12 4 AU970160 1 19970130 G 2460 CONNECTOR EMB 120 EMB120 3260201 SO PWA 118 PW118A NE DC POWER/DISTRIB CONTAMINATED W K NONE H ELECT. POWER LOSS-50 PC CL CLIMB 1 AU S (AUS) RH AUXILIARY GENERATOR ELECTRICAL PLUG CONTAMINATED WITH WATER 2 L 7 2 4T 4 T RT A31SO E20NE 1997120400046 19971204 00046 CE 1997 12 4 AU970161 1 19970219 G 2432 BATTERY BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL BATTERY/CHARGER MALFUNCTION W K NONE H J ELECT. POWER LOSS-50 PC WARNING INDICATION TO TAKEOFF 1 AU S (AUS) BATTERY CHARGE LIGHT ILLUMINATED - BATTERY REMOVED TO BATTERY SHOP - INVESTIGATION COULD FIND NO FAULTS WITH THE B ATTERY 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1997120400047 19971204 00047 SO 1997 12 4 AU970162 1 19970218 G 5270 WARNING SYSTEM EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE DOOR WARNING SYS MALFUNCTION W K NONE N FALSE WARNING TO TAKEOFF 1 AU S (AUS) CARGO DOOR WARNING ILLUMINATED - INVESTIGATION FOUND DOOR CLOSEDAND WARNING SYSTEM SERVICEABLE - DEFECT NOT CONFIR MED 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 1997120400048 19971204 00048 WP 1997 12 4 AU970163 1 19970219 G 6410 369A1613507 BLADE HUGHES 369 369HS 4470728 WP ALLSN 250C 250C20B 03013 GL TAIL ROTOR BLADE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 341 BLADE0022228 (AUS) TAIL ROTOR BLADE SKIN CRACKED IN AREA JUST INBOARD OF THE LEADING EDGE PROTECTIVE STRIP RUNNING CHORDWISE TOWARDS THE TRAILING EDGE - CRACK LENGTH APPROXIMATELY 25.4MM (1IN) 1 G 7 1 3U 3 U H3WE E4CE 1997120400049 19971204 00049 SO 1997 12 4 AU970164 1 19970210 G 2897 WIRE EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE ACFT FUEL INDICA WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH FUEL TANK CAPACITANCE PROBE WIRES CHAFING ON FUEL PLUMBING IN THREE DIFFERENT AREAS 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 1997120400050 19971204 00050 EU 1997 12 4 AU970165 1 19970220 G 3213 TB1041033000 TORQUE LINK SOCATA TB9 TB9 8680694 EU LYC O320 O320D2A 41508 EA SNSNCH 74D 74DM EA LT MLG LOWER BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH MAIN LANDING GEAR LOWER TORQUE LINK BROKEN AT INBOARD ATTACHMENT LUG - OUTBOARD LUG CONTAINS A HAIR LINE CRACK - RH MLG TORQUE LINK CONTAINS SOME PITTING IN THE ATTACHMENT LUG HOLES 1 L 7 1 3O 3 O NT AS1EU E274 5 N P88614 1997120400051 19971204 00051 1997 12 4 AU970166 4 19970204 G 2210 308503 SWITCH BOEING 737 737377 NM AUTOPILOT SYSTEM FAILED W K NONE F FLT CONT AFFECTED CR CRUISE 1 AU S (AUS) RUDDER TRIM SWITCH FAULTY - INVESTIGATION FOUND CONTAMINATION BETWEEN THE SWITCH KNOB AND THE LIGHT PLATE CAUSING THE SWITCH TO STICK 2 L 7 2 4F RT A16WE 1997120400052 19971204 00052 1997 12 4 AU970167 4 19970303 G 2562 MN1300 BATTERY E01 CESSNA 182 182P 2075816 CE MCAULY 2A34C 2A34C203 GL EMERG LOCATOR FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 009190 (AUS) ELT BATTERIES DETERIORATED - WHITE POWDER SUBSTANCE ON EXTERIOR OF ELT - DARK STICKY FLUID IN ELT BATTERY BOX - PL ATING ON SOME BATTERY CONTACTS CORRODED - ELT WOULD NOT FUNCTION - EXPIRE DATE OF BATTERIES JANUARY 1999 1 H 7 1 3O NT TA13 5 C P3EA 1997120400053 19971204 00053 CE 1997 12 4 AU970168 1 19970206 G 5610 531126110 WINDOW CESSNA 340 340A 2076405 CE CONT O520 TSIO520N 17040 SO MCAULY 3AF32C 3AF32C93 GL FLIGHT COMPART FAILED W K NONE O D OTHER INFLIGHT SEPARATION CR CRUISE 1 AU S (AUS) COPILOTS WINDOW FAILED - WINDOW BLEW OUT DURING FLIGHT 1 L 7 2 3O 3 O 3A25 E8CE 5 C P22EA 1997120400054 19971204 00054 EA 1997 12 4 AU970169 2 19970225 G 8540 PLUNGER SOCATA TB10 TB10TOBAGO 8680696 EU LYC O360 O360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL RECIP ENG STICKING W K NONE Y ENGINE STOPPAGE CR CRUISE 1 AU S L3344736A (AUS) ENGINE DRIVEN FUEL PUMP PLUNGER STICKING - INVESTIGATION FOUND THAT THE PLUNGER WAS JAMMED BY A SLIVER OF ALUMINIU M ALLOY APPROXIMATELY 5MM (0.196IN) IN LENGTH - METAL SLIVER APPEARS TO BE A SECTION OF THE REAR COVER RESULTING FROM TH E MACHINING OFTHE FUEL PUMP PLUNGER HOLE 1 L 7 1 30 3 O NT A51EU E286 5 C P920 1997120400055 19971204 00055 CE 1997 12 4 AU970170 1 19970228 G 2432 BATTERY BEECH 55 D55 1152730 CE CONT O520 IO520C 17032 SO MCAULY 3AF32C 3AF32C75 GL BATTERY/CHARGER DISCHARGED W K NONE O OTHER CL CLIMB 1 AU S (AUS) BATTERY VOLTAGE LOW - SUSPECT CAUSED BY ALTERNATOR SWITCHES BEING IN THE `OFF' POSITION 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 1997120400056 19971204 00056 1997 12 4 AU970171 4 19970210 G 2565 2599 SLIDE BOEING 737 737476 NM ESCAPE SLIDE FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 2599 (AUS) SAFETY SLIDE DID NOT DEPLOY DURING TEST - INVESTIGATION FOUND THE SAFETY PIN STILL INSTALLED - SLIDE OPERATED MANU ALLY WHEN SAFETYPIN WAS REMOVED - PERSONNEL/MAINTENANCE ERROR 2 L 7 2 4F RT A16WE 1997120400057 19971204 00057 1997 12 4 AU970172 4 19970304 G 6113 TB1058026001 SPINNER SOCATA TB10 TB10TOBAGO 8680696 EU LYC O360 O360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL PROP SPINNER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S L3313736A (AUS) PROPELLER SPINNER CRACKED FROM ATTACHMENT SCREW HOLES - INVESTIGATION FOUND THAT THE SPINNER WAS NOT A FIRM FIT ON THE PROPELLER HUB 1 L 7 1 30 3 O NT A51EU E286 5 C P920 1997120400058 19971204 00058 CE 1997 12 4 AU970173 1 19970218 G 3710 B906 HOSE S2501SERIES CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL VACUUM DISTRIBUT DETERIORATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) VACUUM PUMP AIR HOSES DETERIORATED AND BREAKING UP INTERNALLY - FOUND DURING INSPECTION IAW CESSNA SEB 96-10 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 1997120400059 19971204 00059 CE 1997 12 4 AU970175 1 19970227 G 2910 10558000121 PIPE BEECH 76 76 1153005 CE HYDRAULIC, MAIN CORRODED W K NONE O J OTHER WARNING INDICATION LD LANDING 1 AU S (AUS) HYDRAULIC PIPE CORRODED - LOSS OF HYDRAULIC FLUID FROM PIN HOLE LEAK 1 L 7 2 3O A29CE 1997120400060 19971204 00060 WP 1997 12 4 AU970176 1 19970211 G 2750 CONTROL ROD DOUG DC3 DC3G202A 3021424 WP HAMSTD 23E 23E50 NE TE FLAP CONTROL CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH WING FLAP OPERATING ROD CRACKED IN AREA OF OUTBOARD LINKAGE CUTOUT 2 L 7 2 4R A618 6 C P603 1997120400061 19971204 00061 NM 1997 12 4 AU970177 1 19970223 G 2435 300SGL127Q STARTER GEN DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE STARTER-GENERATO FAULTY W K NONE H ELECT. POWER LOSS-50 PC CR CRUISE 1 AU S 1115XL (AUS) RH ENGINE STARTER-GENERATOR FAULTY 2 H 7 2 4T 4 T RT A13NM E20NE 1997120400062 19971204 00062 NM 1997 12 4 AU970178 1 19970130 G 5312 BULKHEAD BOEING 737 737377 NM FUSELAGE MAIN BU CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD PRESSURE BULKHEAD CRACKED IN THE FOLLOWING AREAS: 1. FORWARD FACE OF BULKHEAD WEB CRACKED AT RBL 5.7 RUNNI NG BELOW FASTENERS UNDER RADAR SCANNING BRACKET - CRACK LENGTH 7MM (0.275IN) - FOUND USING ULTRASONIC TECHNIQUE 2. FORWA RD FACE OF BULKHEAD WEB CRACKED AT LBL 5.7 RUNNING UNDER EDGE OF BEAM BELOW FASTENERS - CRACK LENGTH 7MM (0.275MM) - FOU ND USING ULTRASONIC TECHNIQUE 3. AFT FACE OF BULKHEAD CRACKED IN LEFT VERTICAL CHORD AT BUTTOCK LINE 5.7 IN THE BOARD R ADIUS OF THE CHORD - CRACK LENGTH 30MM (1.18IN) - FOUND USING EDDY CURRENT METHOD 2 L 7 2 4F RT A16WE 1997120400063 19971204 00063 SO 1997 12 4 AU970179 2 19970116 G 8540 EQ6642 ADAPTER CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL RECIP ENG LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S 900 234315 234315 (AUS) ENGINE STARTER ADAPTER HARMONIC BALANCER LOOSE - WHEN REMOVED ITWAS FOUND THAT ALL THE ENGINE NEEDLE BEARINGS WERE MISSING (SUSPECT IN SUMP) AND METAL WAS WORN FROM THE BEARING HOSING 1 L 7 2 3O 3 O A25CE E7CE 5 C P45GL 1997120800004 19971208 00004 NE 1997 12 8 AU970180 2 19970225 G 7250 785265 BLADE GE CT79B SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE TURBINE SECTION SEPARATED W A K NONE E VIBRATION/BUFFET NR NOT REPORTED 1 AU S 785265 785265 (AUS) LH ENGINE NO3 BEARING SPALLED - 2ND STAGE TURBINE BLADE BROKEN CAUSING EXTENSIVE DAMAGE TO HOT END SECTION AND POW ER TURBINE COMPONENTS 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 1997121100039 19971211 00039 NE 1997 12 11 AU970181 2 19970227 G 7261 OIL SYSTEM BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE TURBINE ENG OIL CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S LF05379 (AUS) NO4 ENGINE OIL FILTER BYPASS BUTTON EXTENDED - FURTHER INVESTIGATION FOUND HEAVY CONTAMINATION OF THE CHIP DETECTO R AND OIL DISCOLOURATION 2 H 7 4 4F 4 F A49EU E6NE 1997121100040 19971211 00040 CE 1997 12 11 AU970183 1 19970305 G 5311 1144200341 FRAME BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MAIN CABIN DOOR FRAME SUPPORT STRUCTURE CRACKED AT FLOOR LEVEL -CRACK LENGTH 135MM (5.31IN) - FOUND USING ADHOC RA DIOGRAPHIC INSPECTION 2 L 7 2 4T 4 T RT A24CE E4EA 1997122900002 19971229 00002 EU 1997 12 29 AU970184 1 19970209 G 2752 ACTUATOR AIRBUS 320 A320212 EU TE FLAP ACTUATOR MIS RIGGED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) RH WING INBOARD AND OUTBOARD TRAILING EDGE FLAPS MISALIGNED - NR 2 FLAP ACTUATOR INCORRECTLY RIGGED 2 L 7 2 4F RT A28NM 1997121100041 19971211 00041 1997 12 11 AU970185 4 19970306 G 2562 ACKE01 ELT PIPER PA18 PA18150 7101828 SO LYC O320 O320B2B 41508 EA SNSNCH 74DM M74DM EA EMERGENCY LOCATO DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ELT BATTERIES DAMAGED AND WORN DUE TO POOR DESIGN OF THE ELT 1 H 7 1 3O 3 O 1A2 E274 5 N P88614 1997121100042 19971211 00042 NM 1997 12 11 AU970186 1 19970228 G 4920 TURBINE GARRTT GTCP85129K BOEING 737 737377 NM APU CORE ENGINE DAMAGED W K NONE E VIBRATION/BUFFET NR NOT REPORTED 1 AU S (AUS) APU TURBINE BUCKLED AND WHEEL PROTRUDED THROUGH ENGINE CASING - DAMAGE TO GEARBOX AREA - RH ENGINE MOUNT SHATTERED 2 L 7 2 4F RT A16WE 1997121100043 19971211 00043 NM 1997 12 11 AU970187 1 19970227 G 2150 32194211 CONTROL VALVE BOEING 737 737377 NM CABIN COOLING SY SEIZED W K NONE O OTHER CL CLIMB 1 AU S (AUS) RH AIR CONDITIONING PACK, SINGLE PACK OPERATION MARGINAL - LH AIR CONDITIONING SYSTEM FAULTY DUE TO 35 DEGREE CON TROL VALVE PNO321942-1-1 BEING SEIZED IN CLOSED POSITION WITH SHAFT SHEARED AND LH TEMPERATURE CONTROL VALVE PNO 398116- 1-1 HAVING LIMITED MOVEMENT 2 L 7 2 4F RT A16WE 1997121100044 19971211 00044 CE 1997 12 11 AU970188 1 19970124 G 3211 24411001 PIVOT CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA MCAULY 2D34C B2D34C220 GL LANDING GEAR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MAIN LANDING GEAR PIVOT ASSEMBLY CRACKED AS INDICATED IN SEB 90-1 REV 2. 1 H 7 1 3O 3 O 3A17 E286 5 C P7EA 1997121100045 19971211 00045 GL 1997 12 11 AU970189 3 19970304 G 6110 PROPELLER MCAULY 3AF32C 3AF32C87 GL AIRCRAFT MANUALS WRONG TORQUE W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) PROPELLER INSTALLATION TORQUE DISCREPANCY - PROPELLER DECAL AND AIRCRAFT MANUAL INDICATE DIFFERENT TORQUE SETTINGS 5 C P22EA 1997122900003 19971229 00003 EA 1997 12 29 AU970190 1 19970221 G 2560 DITCHING DAM DHAV DHC8 DHC8311 1386006 EA EMERGENCY EQUIP FAILURE W K NONE O OTHER DE DESCENT 1 AU S (AUS) LH DITCHING DAM INFLATED - INVESTIGATION FOUND THAT THE CAUSE WAS THE FAILURE OF THE GASKET INSTALLED IN THE DITCH ING DAM ADAPTER 2 H 7 2 4T RT A13NM 1997122900004 19971229 00004 EA 1997 12 29 AU970191 1 19970224 G 2560 DITCHING DAM DHAV DHC8 DHC8311 1386006 EA EMERGENCY EQUIP DEPLOYED W K NONE O OTHER CR CRUISE 1 AU S (AUS) LH UNDERWING DITCHING DAM DEPLOYED IN FLIGHT - SEE MDR 97/0190FURTHER INFORMATION ON SIMILAR DEFECT 2 H 7 2 4T RT A13NM 1997121100046 19971211 00046 CE 1997 12 11 AU970192 1 19970305 G 2110 24112 HOSE 11791005 BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL CABIN COMPRESSOR CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S PCE94638 (AUS) RH AIRCONDITION SYSTEM ENGINE DRIVEN FREON COMPRESSOR SUCTION AND PRESSURE HOSES CONTAMINATED WITH RUBBER PARTICLE S - SUSPECT DEBRIS FROM INCORRECT MANUFACTURING TECHNIQUE - FORWARD AND REAR EVAPORATOR TRANSFER VALVES ALSO CONTAMINATE D 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1997121100047 19971211 00047 GL 1997 12 11 AU970194 3 19970306 G 6111 T10282H BLADE STBROS SC7 SC7SERIES3 8100512 EU HARTZL HCB3T HCB3TN5 GL PROPELLER BLADE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 600 BV2116 (AUS) PROPELLER BLADES CORRODED AT BUTT END - CORROSION WAS BEYOND REPAIRABLE LIMITS - INVESTIGATION FOUND THAT BLADE SH ANK/RADIUS AREA HAD NOT BEEN PROTECTED AT LAST OVERHAUL WHICH WAS CARRIED OUT IN SOUTH AFRICA 1 H 7 2 3T NT A15EU 6 C P15EA 1997121100048 19971211 00048 GL 1997 12 11 AU970195 3 19970306 G 6111 T10282 BLADE STBROS SC7 SC7SERIES3 8100512 EU HARTZL HCB3T HCB3TN5 GL PROPELLER BLADE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 600 BV4069 (AUS) PROPELLER BLADE BUTTS CORRODED BEYOND REPAIR - BLADES NOT PROTECTED DURING LAST OVERHAUL - SEE MDR 97/0194 FOR SIM ILAR DEFECT ON OTHER PROPELLER 1 H 7 2 3T NT A15EU 6 C P15EA 1997121100049 19971211 00049 EU 1997 12 11 AU970196 1 19970227 G 3260 622800200 SWITCH BAG JETSTM JETSTM3107 1500215 EU ROTOL R333 R333482F12 GL LANDING GEAR POS FAILED W K NONE N FALSE WARNING CL CLIMB 1 AU S (AUS) LH MAIN LANDING GEAR DOWN AND LOCKED MICROSWITCH INTERNAL SHORT CIRCUIT DUE TO CORROSION 2 L 7 2 4T RT BA15CAA 6 C P61GL 1997121100050 19971211 00050 GL 1997 12 11 AU970197 3 19970306 G 6111 A1851 BEARING STBROS SC7 SC7SERIES3 8100512 EU HARTZL HCB3T HCB3TN5 GL PROPELLER BLADE CRACKED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 600 BV2116 (AUS) PROPELLER BLADE BEARING CRACKED - SUSPECT BEARING SPLIT BEARING HALVES MISMATCHED AT LAST OVERHAUL - PROPELLERS LA ST OVERHAULED IN SOUTH AFRICA - PERSONNEL/MAINTENANCE ERROR - SEE MDR 97/0194 FOR FURTHER INFORMATION 1 H 7 2 3T NT A15EU 6 C P15EA 1997121100051 19971211 00051 CE 1997 12 11 AU970198 1 19970226 G 5753 35165050230 FLAP BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE TE FLAP STRUCTUR DAMAGED W K NONE O C OTHER F.O.D. LD LANDING 1 AU S (AUS) LH OUTBOARD WING FLAP DAMAGED - SPAR BENT AND SKIN CREASED -INVESTIGATION FOUND A DEAD HARE ON THE RUNWAY 1 L 7 2 4T 4 T A24CE E4EA 1997121100052 19971211 00052 NM 1997 12 11 AU970199 1 19970130 G 2120 DUCT DHAV DHC8 DHC8201 2809001 NM AIR DISTRIBUTION SEPARATED W K NONE O OTHER CL CLIMB 1 AU S (AUS) PRESSURISATION SYSTEM RECIRCULATION FAN TO CABIN PRESSURE DOMEBUL BULKHEAD PIPE ASSEMBLY AIR DUCT LINE SEPARATED 2 H 7 2 4T RT A13NM 1997121100053 19971211 00053 NM 1997 12 11 AU970200 1 19970116 G 3244 TIRE BOEING 747 747238B 1384828 NM MLG NR 4 FWD SEPARATED W K NONE O OTHER TO TAKEOFF 1 AU S (AUS) NO4F BODY LANDING GEAR TYRE TREAD SEPARATED - THE TYRE WAS STILL INFLATED 2 L 7 4 4F A20WE 1997121100054 19971211 00054 NM 1997 12 11 AU970201 1 19970128 G 3244 TIRE BOEING 747 747438 NM MLG NR 4 RTY SEPARATED W K NONE O OTHER LD LANDING 1 AU S (AUS) NO4 RT TYRE TREAD SEPARATED - DAMAGE TO WING TO BODY PANELS (3OFF) 2 L 7 4 4F RT A20WE 1997122900005 19971229 00005 NM 1997 12 29 AU970202 1 19970123 G 2597 WIRE BOEING 767 767338 1385151 NM CARGO BAY BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD CARGO HOLD DRIVE SYSTEM WIRE LOCATED IN THE CARGO HOLD FLOOR AT STA 520 POWER DRIVE UNIT SEVERED, TRIPPE D CIRCUIT BREAKER RESETTING CAUSED A SMALL FIRE CAUSING DAMAGE TO THE WIRING AND ADJACENT INSULATION. 2 L 7 2 4F RT A1NM 1997121100055 19971211 00055 NM 1997 12 11 AU970203 1 19970205 G 3411 HTC7476PP COVER BOEING 747 747238B 1384828 NM PITOT/STATIC SYS DAMAGED W K NONE O OTHER TO TAKEOFF 1 AU S (AUS) LH PITOT PROBE BLOCKED BY A PIECE OF PITOT PROBE COVER MATERIAL 2 L 7 4 4F A20WE 1997121100056 19971211 00056 1997 12 11 AU970204 4 19970111 G 2565 69B520752 CLEVIS BOEING 747 747338 NM ESCAPE SLIDE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NO3 MAIN DOOR OFF WING ESCAPE SLIDE DITCHING CLUTCH CLEVIS CRACKED - FOUND DURING INSPECTION IAW BJC C4/52/013 2 L 7 2 4F RT A20WE 1997122900006 19971229 00006 NE 1997 12 29 AU970205 2 19970217 G 7240 UL23992 PANEL RROYCE RB211524G RROYCE RB211 RB211524G19 NE TURBINE ENGINE C CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S ENGSERNO1318 (AUS) ENGINE COMBUSTION LINER METERING PANEL CRACKED - HEAT SHIELDS DISTORTED - MINOR BURNING OF OUTER LINER - FOUND DUR ING BOROSCOPE INSPECTION - INVESTIGATION FOUND THAT THE PANEL HAD BEEN INCORRECTLY INSTALLED AT THE LAST SHOP VISIT -PER SONNEL/MAINTENANCE ERROR 4 F E30NE 1997121100057 19971211 00057 NM 1997 12 11 AU970206 1 19970203 G 3244 TIRE BOEING 747 747438 NM LT BODY GEAR SEPARATED W K NONE O OTHER TO TAKEOFF 1 AU S (AUS) NO6 LH BODY GEAR TYRE TREAD SEPARATED - DAMAGE TO LH BODY GEARDOOR AND STRUT ROD 2 L 7 4 4F RT A20WE 1997122900007 19971229 00007 1997 12 29 AU970207 1 19970223 G 7330 J221P904 O- RING RROYCE RB211 RB211524G19 NE ENGINE FUEL IND LEAKING W K NONE O K OTHER FLUID LOSS IN INSP/MAINT 1 AU S (AUS) RH ENGINE LOW PRESSURE DIFFERENTIAL PRESSURE SWITCH ELBOW FITTING `O' RING SEAL LEAKING 4 F E30NE 1997121100058 19971211 00058 EU 1997 12 11 AU970208 1 19970306 G 2750 FLAP SYSTEM BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE TE FLAP CONTROL MALFUNCTIONED W K NONE F FLT CONT AFFECTED TO TAKEOFF 1 AU S (AUS) FLAPS WOULD NOT RETRACT - FLAPS WERE RESET AND THEN OPERATED NORMALLY - NO FAULT EVIDENT ON FLAP COMPUTER 2 H 7 4 4F 4 F A49EU E6NE 1997121100059 19971211 00059 NE 1997 12 11 AU970209 2 19970302 G 7250 BLADE EMB 120 EMB120 3260201 SO PWA 118 PW118A NE TURBINE SECTION SEPARATED W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S PCE115469 (AUS) RH ENGINE FIRST STAGE POWER TURBINE BLADE SEPARATED - SECOND STAGE POWER TURBINE DAMAGED - METAL CONTAMINATION OF OIL SYSTEM - FAILURE WAS DUE TO LOW CYCLE FATIGUE COMBINED WITH CORROSION IN THE LIGHTENING CAVITY 2 L 7 2 4T 4 T RT A31SO E20NE 1997121100060 19971211 00060 CE 1997 12 11 AU970210 1 19970305 G 2612 302158 DETECTOR 303267 BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL FIRE DETECTION FAULTY W K NONE N FALSE WARNING CL CLIMB 1 AU S (AUS) RH ENGINE FIRE DETECTORS (3OFF) FAULTY - DETECTOR AMPLIFIER ALSO REPLACED 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1997121100061 19971211 00061 SO 1997 12 11 AU970211 2 19970305 G 7314 2B729 PUMP CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO MCAULY 3FF32 3FF32C501 GL ENGINE FUEL PUMP FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 5 (AUS) ENGINE FUEL PUMP FAULTY - SUSPECT INTERNAL STICKING IN SOLENOID - PUMP HAD COMPLETED 4.8 HOURS TIME SINCE OVERHAUL 1 L 7 2 3O 3 O A7CE E7CE 5 C P45GL 1997121100062 19971211 00062 EU 1997 12 11 AU970212 1 19970305 G 2710 5135121 CONTROL ROD ISRAEL 1124 1124 4500102 EU AILERON CONTROL CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH AILERON CONTROL ROD CONTAINED MEDIUM TO HEAVY CORROSION - FOUND DURING X-RAY INSPECTION 2 M 7 2 4F A2SW 1997121100063 19971211 00063 EU 1997 12 11 AU970213 1 19970219 G 4920 38001881 AUX POWER UNIT AMD FALC50 FALCON900 2700160 EU APU CORE ENGINE FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) APU LEAKING OIL INTO EXHAUST SYSTEM AND AIRCONDITIONING DUCT -SUSPECT INTERNAL SEAL LEAK - THIS DEFECT WAS RECEIVE D FROM NO34 SQUADRON RAAF AND IS FOR INFORMATION ONLY 2 L 7 3 4F RT A46EU 1997121100064 19971211 00064 EA 1997 12 11 AU970214 2 19970208 G 7414 4251R MAGNETO CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160DTM GL MAGNETO/DISTRIBU FAILED W K NONE E VIBRATION/BUFFET CL CLIMB 1 AU S 5109019 L37639 (AUS) MAGNETO FAILED - INSPECTION FOUND HT COIL SECONDARY WIRING OPEN CIRCUIT 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 1997121100065 19971211 00065 CE 1997 12 11 AU970215 1 19970305 G 2510 081278211 SEAT CESSNA 404 404CESSNA 2075901 CE MCAULY 3FF32 3FF32C501 GL COPILOT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) COPILOTS SEAT BASE AUXILIARY SUPPORT STRUCTURE CRACKED IN TWO AREAS 1 L 7 2 3O A25CE 5 C P45GL 1997121100066 19971211 00066 CE 1997 12 11 AU970216 1 19970305 G 5610 10138402515 WINDSHIELD BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL PILOTS CRACKED W K NONE O OTHER CL CLIMB 1 AU S (AUS) PILOTS WINDSHIELD CRACKED IN SEVERAL PLACES - WINDSHIELD HEAT WAS OPERATING AT THE TIME 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1997121100067 19971211 00067 1997 12 11 AU970217 4 19970131 G 2562 E01 ELT AMTR JABIRU JABIRUSK 05602CU GL EMERGENCY LOCATO ACTIVATED W K NONE O OTHER NR NOT REPORTED 1 AU S (AUS) ELT ACTIVATED DURING RADIO TRANSMISSION - THIS DEFECT WAS RECEIVED FROM THE AUF AND IS FOR INFORMATION ONLY 1 H 7 1 IO NC EXPA1H71 1997121100068 19971211 00068 CE 1997 12 11 AU970218 1 19970305 G 5511 0532001 SPAR CESSNA 172 172G 2072420 CE CONT O300 O300C 17022 SO MCAULY 1C172 1C172EM GL HORIZONTAL STABI CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HORIZONTAL STABILISER FORWARD SPAR CRACKED AT CENTRE LIGHTENING HOLE AS INDICATED IN SEB 94-8 - CRACK LENGTH APPRO XIMATELY 10MM (0.393IN) - SUSPECT PROBLEM CONTRIBUTED TO BY INCORRECT GROUND HANDLING 1 H 7 1 3O 3 O NT 3A12 E253 5 N P910 1997121100069 19971211 00069 EA 1997 12 11 AU970219 2 19970301 G 8530 LW12397 CYLINDER PIPER PA28 PA28161 7102803 SO LYC O320 O320E3D 41508 EA SNSNCH 74D 74DM EA NR 3 & 4 CYLS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 1500 VARIOUS (AUS) NO1, NO3 AND NO4 CYLINDERS CRACKED FROM LOWER SPARK PLUG HOLES -CRACKS HEADING TOWARDS EXHAUST VALVE SEAT - CYLIND ERS WERE NITRIDED ITEMS AND HAD COMPLETED TWO ENGINE LIVES 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 1997121100070 19971211 00070 NE 1997 12 11 AU970220 2 19970305 G 7260 J221P035 O-RING SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE RT ENG STARTER DAMAGED W K NONE E K VIBRATION/BUFFET FLUID LOSS CR CRUISE 1 AU S 785598 (AUS) RH ENGINE STARTER DRIVE SEAL FLANGE `O' RING SEAL DAMAGED - FLANGE SEAL HAD BEEN CHANGED 1.2 HOURS PREVIOUS - SUSP ECT PERSONNEL/MAINTENANCE ERROR 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 1997121100071 19971211 00071 SO 1997 12 11 AU970221 1 19970313 G 5751 8639604 RIB 8639804 PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA AILERON STRUCTUR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AILERON NOSE RIBS PNO 86396-04 AND PNO 86398-04 CRACKED ATATTACHMENT BRACKETS 1 L 7 2 3O 3 O A19S0 E286 1997121100072 19971211 00072 CE 1997 12 11 AU970222 1 19970312 G 3233 AFTS1001 COMMUTATOR PRESTOLITE HYH5001 BEECH 76 76 1153005 CE LANDING GEAR ACT OPEN CIRCUIT W K NONE O OTHER LD LANDING 1 AU S AFTS1001 (AUS) LANDING GEAR MOTOR COMMUTATOR SEGMENT OPEN CIRCUIT DUE TO LOOSE CRIMP ON THE WINDING 1 L 7 2 3O A29CE 1997121100073 19971211 00073 NM 1997 12 11 AU970223 1 19970227 G 2750 693923617 PUSHROD BOEING 737 737476 NM TE FLAP CONTROL DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH OUTBOARD TRAILING EDGE FLAP AFT FLAP INBOARD PUSHROD BENT 2 L 7 2 4F RT A16WE 1997121100074 19971211 00074 NM 1997 12 11 AU970224 1 19970227 G 2750 693923617 PUSHROD 693923618 BOEING 737 737476 NM TE FLAP CONTROL DAMAGED W K NONE F FLT CONT AFFECTED DE DESCENT 1 AU S (AUS) RH OUTBOARD TRAILING EDGE FLAP AFT FLAP INBOARD AND OUTBOARD DRIVE RODS PNO 69-39236-17 AND PNO 69-39236-18 BENT 2 L 7 2 4F RT A16WE 1997121100075 19971211 00075 SW 1997 12 11 AU970225 1 19970312 G 3230 2781025003 PIN FRCHLD SA227 SA227CC SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE LANDING GEAR RET INCORRECT FIT W K NONE W INADEQUATE Q C CL CLIMB 1 AU S (AUS) LANDING GEAR EMERGENCY GEAR EXTENSION SHUTOFF VALVE HANDLE LOCK PIN INCORRECTLY FITTED - EMERGENCY GEAR EXTENSION HANDLE WAS PUSHED FORWARD TOWARDS THE EMERGENCY POSITION PREVENTING CORRECT OPERATION OF THE LANDING GEAR RETRACTION SYS TEM - PERSONNEL ERROR 2 L 7 2 4T 4 T RT A18SW E4WE 6 C 3PNE 1997121100076 19971211 00076 EU 1997 12 11 AU970226 1 19970312 G 3260 SWITCH AIRBUS A3233265300 AIRBUS 300 A300B4622R EU PWA 4158 PW4158 NE LANDING GEAR POS FAILED W K NONE N FALSE WARNING TO TAKEOFF 1 AU S NOTKNOWN (AUS) LH MAIN LANDING GEAR UPLOCK SWITCH FAULTY 2 L 7 2 4F 4 F RT A35EU E24NE 1997122900008 19971229 00008 SO 1997 12 29 AU970227 2 19970313 G 7414 4052326A BEARING BENDIX S6RN1225 CESSNA 210 210N 2073453 CE CONT O550 IO550* SO MAGNETO/DISTRIBU FAILED W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S 4052326A 289010R (AUS) MAGNETO CAM END ROTOR BEARING FAILED - MAGNETO CONTAMINATED WITHMETAL DUST 1 H 7 1 3O 3 O 3A21 E3SO 1997121100077 19971211 00077 SO 1997 12 11 AU970228 2 19970314 G 8520 63026143 BUSHING CONT 639199 CONT O360 IO360HB 17025 SO HARTZL HCC2Y BHCC2YF1 GL COUNTERWEIGHT WORN W K NONE O OTHER IN INSP/MAINT 1 AU S NIL 353391 (AUS) ENGINE COUNTERWEIGHT BUSHES AND ROLLERS PNO 639198 AND PNO630261-43 WORN UNEVENLY - INTERNAL CORROSION EVIDENT ON STEEL PARTS 3 O E1CE 5 C P920 1997121100078 19971211 00078 NE 1997 12 11 AU970229 1 19970314 G 6720 7640301111041 SUPPORT SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30 03013 GL T/R CONTROL CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) TAIL ROTOR CONTROL PEDAL CENTRE SUPPORT CRACKED AT THE UPPER SUPPORT TUBE WELDED JOINT 1 G 7 2 3U 3 U H1NE E1GL 1997121100079 19971211 00079 CE 1997 12 11 AU970230 1 19970318 G 5551 17320311 ARM 17320312 CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA MCAULY 2D34C B2D34C207 GL HORIZ STAB WT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) STABILATOR WEIGHT ARM LH AND RH REAR MOUNTING BRACKETS PNO1732031-1 AND PNO 1732031-2 CRACKED ALONG VERTICAL BENDS 1 H 7 1 3O 3 O A20CE 1E10 5 C P7EA 1997121100080 19971211 00080 SO 1997 12 11 AU970231 2 19970316 G 8530 653446 CYLINDER CESSNA 210 210M 2073450 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL FUEL NOZZLE STRIPPED W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S 545 20742978L (AUS) ENGINE CYLINDER HEAD FUEL NOZZLE RETAINING THREADS STRIPPED - FUEL NOZZLE LOOSE - CYLINDER IS 0.0015IN PLUS OVERSI ZE WITH UNKNOWN TOTAL TIME IN SERVICE - AD/CON/60 CARRIED OUT 50 HOURSPRIOR TO FAILURE 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 1997121100532 19971211 00532 CE 1997 12 11 AU970232 1 19970318 G 3297 WIRE CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL LANDING GEAR POS BROKEN W K NONE N FALSE WARNING DE DESCENT 1 AU S (AUS) RH MAIN LANDING GEAR MICROSWITCH EARTH WIRE BROKEN 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 1997121100533 19971211 00533 CE 1997 12 11 AU970233 1 19970318 G 2721 96526000 TRIM JACK BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO RUD TAB CONTROL INCORRECT WIRED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) RUDDER TRIM JACK INCORRECTLY LOCKWIRED - THE TRIM JACK ROD END WAS LOCKED TO THE TRIM JACK HOUSING RETAINING NUT A LLOWING THE TRIM JACK TO ONLY ROTATE ONE TURN - THIS CONDITION HAD EXISTED FOR APPROXIMATELY 800 HOURS - PERSONNEL/MAINT ENANCE ERROR 1 L 7 2 3O 3 O 3A16 E5CE 1997121100534 19971211 00534 CE 1997 12 11 AU970234 1 19970319 G 5753 3515605084 RIB BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO TE FLAP STRUCT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH FLAP RIB CRACKED IN AREA OF FLAP ACTUATOR ATTACHMENT - CRACK EMANATES FROM FORWARD ATTACHMENT BOLT HOLE IN A PR EVIOUSLY REPAIRED AREA - SUSPECT CRACK DUE TO INCORRECT REPAIR 1 L 7 2 3O 3 O 3A16 E5CE 1997121100535 19971211 00535 WP 1997 12 11 AU970235 2 19970113 G 8530 77 NUT DHAVXX DH82 DH82AROBRTSN 2801002 WP DHAVXX GIPSY GIPSYMAJOR1 20004 WP CYL HOLD DOWN LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S 77 (AUS) CYLINDER HEAD HOLD DOWN NUTS LOOSE - HEAD MOVING ON CYLINDER BARREL 1 Q 7 1 3I 3 I A8EU A8EU 1997121100536 19971211 00536 WP 1997 12 11 AU970236 2 19970113 G 8520 77 TAPPET DHAVXX DH82 DH82AROBRTSN 2801002 WP DHAVXX GIPSY GIPSYMAJOR1 20004 WP ENG VALVES OUT OF ADJUST W K NONE O OTHER IN INSP/MAINT 1 AU S 77 (AUS) ALL VALVE TAPPET CLEARANCES OUT OF ADJUSTMENT 1 Q 7 1 3I 3 I A8EU A8EU 1997121100537 19971211 00537 WP 1997 12 11 AU970237 2 19970113 G 7414 28729 POINTS BTH AG46 DHAVXX DH82 DH82AROBRTSN 2801002 WP DHAVXX GIPSY GIPSYMAJOR1 20004 WP MAGNETO OUT OF ADJUST W K NONE O OTHER IN INSP/MAINT 1 AU S 28729 77 (AUS) MAGNETO POINTS CLOSED - TIMING OUT OF ADJUSTMENT 1 Q 7 1 3I 3 I A8EU A8EU 1997121100538 19971211 00538 WP 1997 12 11 AU970238 2 19970113 G 8530 NUT DHAVXX DH82 DH82AROBRTSN 2801002 WP DHAVXX GIPSY GIPSYMAJOR1 20004 WP ENG EXH MANIFOLD LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S 77 (AUS) ENGINE EXHAUST MANIFOLD ATTACHMENT NUTS LOOSE - ONE NUT MISSING - ONE STUD IN CYLINDER HEAD PULLED 1 Q 7 1 3I 3 I A8EU A8EU 1997121100539 19971211 00539 SO 1997 12 11 AU970239 1 19970205 G 2700 CONTROL CABLE PIPER PA34 PA34200T 7103406 SO HARTZL HCC2Y BHCC2YF2 GL FLIGHT CONTROLS BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) UNKNOWN CABLE BROKEN - LIMITED INFORMATION PROVIDED 1 L 7 2 3O A7SO 5 C P920 1997121100540 19971211 00540 WP 1997 12 11 AU970240 2 19970113 G 7322 CARBURETTOR DHAVXX DH82 DH82AROBRTSN 2801002 WP DHAVXX GIPSY GIPSYMAJOR1 20004 WP FUEL CONTL/CARB CONTAMINATED W A UNSCHED LANDING Y ENGINE STOPPAGE TO TAKEOFF 1 AU S 77 (AUS) CARBURETTOR BANJO FITTING CONTAMINATED WITH WATER AND SEDIMENT -AIRCRAFT CRASHED ON TAKEOFF 1 Q 7 1 3I 3 I A8EU A8EU 1997121800766 19971218 00766 GL 1997 12 18 AU970241 3 19970317 G 6111 660715620 CLAMP ROTOL R352 R3526123F1 GL PROPELLER BLADE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 6056 012COMPSN (AUS) PROPELLER BLADE LOOSE - INVESTIGATION FOUND P.T.F.E BAND CLAMP FAILED ALLOWING THE PRELOAD RING TO MOVE OUT OF POS ITION -SUSPECT CAUSED BY OVERTORQUING THE CLAMP BOLT 6 C P16NG 1997121100541 19971211 00541 SO 1997 12 11 AU970242 1 19970210 G 7921 O-RING PIPER PA18 PA18150 7101828 SO LYC O320 O320A2B 41508 EA SNSNCH 74DM M74DM EA ENG OIL COOLER DETERIORATED W O OTHER K FLUID LOSS CR CRUISE 1 AU S (AUS) ENGINE OIL COOLER TO PRESSURE LINE `O'- RING SEAL DETERIORATED AND LEAKING 1 H 7 1 3O 3 O 1A2 E274 5 N P88614 1997121100542 19971211 00542 SO 1997 12 11 AU970243 1 19970318 G 2822 421136 PUMP WELDON 421136 PIPER PA31 PA31350 7103110 SO HARTZL HCE3Y HCE3YR2 GL FUEL BOOST PUMP FAILED W K NONE O OTHER DE DESCENT 1 AU S 1507 09619 (AUS) FUEL BOOST PUMP FAULTY - INVESTIGATION FOUND ONE OF THE MOTOR BRUSHES WORN AWAY - A COUPLING SPLINE BETWEEN THE MO TOR AND THE PUMP WAS BADLY WORN - PUMP BLADE SUPPORT BLOCK BADLY WORN - COMMUTATOR DAMAGED DUE TO LOSS OF BRUSH 1 L 7 2 3O A20SO 5 C P33EA 1997121100543 19971211 00543 NE 1997 12 11 AU970244 2 19970314 G 7230 COMPRESSOR BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE TURBINE ENGINE STALLED W K NONE R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S 687608 (AUS) NO2 ENGINE COMPRESSOR STALL. 2 L 7 3 4F 4 F RT A3WE E2EA 1997121100544 19971211 00544 NM 1997 12 11 AU970245 1 19970311 G 3246 300654 WHEEL BFGOODRICH 31448 DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE WHEEL/SKI/FLOAT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 1462 (AUS) NOSE WHEEL CRACKED IN AREA OF BEAD SEAT - CRACK LENGTH 4MM(0.157IN) - FOUND USING EDDY CURRENT INSPECTION AND CONF IRMED USING FLUORESCENT DYE PENETRANT 2 H 7 2 4T 4 T RT A13NM E20NE 1997121100545 19971211 00545 CE 1997 12 11 AU970246 1 19970307 G 5321 04102381 FLOOR CESSNA 150 A152 2071836 CE MCAULY 1A103 1A103TCM GL FUSELAGE FLOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 9182 JH049 (AUS) FLOOR CRACKED IN AREA OF SEAT RAIL ATTACHMENT AT REAR - SEAT RAIL HAS A RIGHT ANGLE END WHICH CUTS INTO FLOOR 1 H 7 1 3O 3A19 5 N P50GL 1997121100546 19971211 00546 SO 1997 12 11 AU970247 2 19970228 G 7313 627335D13B INJECTOR CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL NR 2 CYL FUEL BLOCKED W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S 756 294689 912185 (AUS) NO2 CYLINDER FUEL INJECTOR NOZZLE BLOCKED 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 1997122900025 19971229 00025 EU 1997 12 29 AU970248 1 19970117 G 5210 FITTING AIRBUS 320 A320212 EU PAX/CREW DOOR MIS RIGGED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) L1 DOOR ARM/DISARM CAM WORN ALLOWING ARMING LEVER TO MOVE FROM DISARMED TO ARMED POSITION WITHOUT REMOVING THE SAF ETY PIN -INVESTIGATION FOUND THAT THE BORE OF THE BALL PIN FITTING WAS NOT CENTRAL UNDER THE CAM ALLOWING THE ARMING CAM TO RIDE PAST THESAFETY PIN 2 L 7 2 4F RT A28NM 1997121100547 19971211 00547 CE 1997 12 11 AU970249 1 19970307 G 5711 052340053 SPAR CESSNA 182 182D 2072710 CE CONT O470 O470L 17026 SO MCAULY 2A34C 2A34C66 GL WING SPAR STRUCT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 5562 18253162 191414 725435 (AUS) WING REAR SPAR CRACKED IN RADIUS OF WING ATTACHMENT WEB 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997121100548 19971211 00548 NM 1997 12 11 AU970250 1 19970312 G 2721 441 SWITCH BOEING 737 73733A 1384673 NM RUDDER TAB CONT STICKING W K NONE O OTHER IN INSP/MAINT 1 AU S 441 (AUS) RUDDER TRIM SWITCH STICKING DUE TO GROOVES ON CAMSHAFT 2 L 7 2 4F RT A16WE 1997121100549 19971211 00549 CE 1997 12 11 AU970251 1 19970307 G 5312 07193005 BULKHEAD CESSNA 182 182D 2072710 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL FUSELAGE LT AFT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 5563 18253162 191414 725435 (AUS) FUSELAGE LH BULKHEAD CRACKED 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997121100550 19971211 00550 CE 1997 12 11 AU970252 1 19970307 G 5711 18253162 SPAR CESSNA 182 182D 2072710 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL WING SPAR STRUCT CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 18253162 191414 725435 (AUS) LH WING FRONT MAIN SPAR CORRODED - SEE MDR 97/0255 TO MDR 97/0265 FOR ADDITIONAL DEFECTS REPORTED UNDER THE SAME M DR NUMBER 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997122900026 19971229 00026 GL 1997 12 29 AU970253 3 19970319 G 6111 SM28775339 SEAL HARTZL BEECH 76 76 1153005 CE HARTZL HCM2Y HCM2YR GL PROPELLER BLADE LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 995 FB275 (AUS) PROPELLER BLADE SEALS LEAKING GREASE - INVESTIGATION FOUND BLADE SEALS TO BE INCORRECT PART - SEALS HAD BEEN SUPER SEDED BY SEALS PNO Q4339 IN SL 148 DATED 18/3/83 - PERSONNEL/MAINTENANCE ERROR 1 L 7 2 3O A29CE 5 C P43GL 1997121100551 19971211 00551 SO 1997 12 11 AU970254 1 19970317 G 5312 VARIOUS BULKHEAD PIPER PA34 PA34200 7103405 SO LYC O360 IO360C1E6 41514 EA HARTZL HCC2Y HCC2YK2 GL FUSELAGE MAIN BU CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE REAR BULKHEAD CORRODED IN AREA OF STABILATOR ATTACHMENT BRACKETS - RIVETS POPPED AT FRAME OF FORWARD FIN ATTACHMENT AREA- FOLLOWING REMOVAL OF TOP AFT FUSELAGE SKIN AND SKIN ON FIN AND STABILISER. WIDE SPREAD SURFACE CORROS ION WAS FOUND WHERE FRAMES AND STRINGERS ATTACH - SUSPECT DUE TO LACK OF CORROSION PROTECTION DURING MANUFACTURE 1 L 7 2 3O 3 O A7SO 1E10 5 C P920 1997121100552 19971211 00552 CE 1997 12 11 AU970255 1 19970307 G 5712 18253162 RIB CESSNA 182 182D 2072710 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL WING RIB STRUCTU CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 18253162 191414 725435 (AUS) LH AND RH WINGS CORRODED IN AREA BETWEEN RIBS AND SKIN - SEE MDR97/0252 FOR ADDITIONAL INFORMATION 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997121100553 19971211 00553 CE 1997 12 11 AU970256 1 19970307 G 5730 18253162 SKIN CESSNA 182 182D 2072710 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL WING PLATES CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 18253162 191414 725435 (AUS) LH AND RH WING TOP AND BOTTOM SKINS CORRODED - WING INSPECTION PANELS ALSO CORRODED - SOME RIVETS MISSING - SEE MD R 97/0252 FORADDITIONAL INFORMATION 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997121100554 19971211 00554 CE 1997 12 11 AU970257 1 19970307 G 5753 18253162 FLAP CESSNA 182D CESSNA 182 182D 2072710 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL TE FLAP STRUCTUR CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 18253162 191414 725435 (AUS) LH AND RH WING FLAPS CORRODED - SEE MDR 97/0252 FOR ADDITIONALINFORMATION 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997121100555 19971211 00555 CE 1997 12 11 AU970258 1 19970307 G 5751 18253162 AILERON CESSNA 182 182D 2072710 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL AILERON STRUCTUR CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 18253162 191414 725435 (AUS) LH AND RH AILERONS CORRODED - SEE MDR 97/0252 FOR ADDITIONALINFORMATION 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997121100556 19971211 00556 CE 1997 12 11 AU970259 1 19970307 G 5330 18253162 SKIN CESSNA 182 182D 2072710 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL FUSELAGE MAIN PL CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 18253162 191414 725435 (AUS) FUSELAGE SKINS CORRODED IN AREA OF ALL SKIN JOINTS IN BOTTOMS OF BOTH CABIN ENTRY DOORS AND DOOR HINGE ATTACHMENT AREAS, CABIN ROOF CORRODED - SEE MDR 97/0252 FOR ADDITIONAL INFORMATION 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997121100557 19971211 00557 CE 1997 12 11 AU970260 1 19970307 G 5312 18253162 BULKHEAD CESSNA 182 182D 2072710 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL FUSELAGE BULKHD CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 18253162 191414 725435 (AUS) REAR FUSELAGE BULKHEAD CORRODED IN AREA OF DORSAL FIN ATTACHMENT- SEE MDR 97/0252 FOR ADDITIONAL INFORMATION 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997121100558 19971211 00558 CE 1997 12 11 AU970261 1 19970307 G 5313 18253162 STRINGER CESSNA 182 182D 2072710 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 18253162 191414 725435 (AUS) FUSELAGE STRINGERS CORRODED - SEE MDR 97/0252 FOR ADDITIONAL INFORMATION 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997121100559 19971211 00559 CE 1997 12 11 AU970262 1 19970307 G 5520 18253162 ELEVATOR CESSNA 182 182D 2072710 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL ELEVATOR STRUCT CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 18253162 191414 725435 (AUS) LH AND RH ELEVATORS CORRODED - SEE MDR 97/0252 FOR ADDITIONAL INFORMATION 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997121100560 19971211 00560 CE 1997 12 11 AU970263 1 19970307 G 5540 18253162 RUDDER CESSNA 182 182D 2072710 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL RUDDER STRUCTURE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 191414 725435 (AUS) RUDDER CORRODED - SEE MDR 97/0252 FOR ADDITIONAL INFORMATION 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997121100561 19971211 00561 CE 1997 12 11 AU970264 1 19970307 G 5312 05B0069 BULKHEAD CESSNA 182D CESSNA 182 182D 2072710 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 18253162 191414 725435 (AUS) FORWARD CENTRE BULKHEAD LOCATED UNDER FLOOR SEVERELY CORRODED - SEE MDR 97/0252 FOR ADDITIONAL INFORMATION 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997121100562 19971211 00562 CE 1997 12 11 AU970265 1 19970307 G 5711 121002926 SPAR CESSNA 182 182D 2072710 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL WING SPAR STRUCT CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 18253162 191414 725435 (AUS) CENTRE SECTION REAR CARRY THROUGH SPAR CORRODED - SEE MDR 97/0252 FOR ADDITIONAL INFORMATION 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997121100563 19971211 00563 GL 1997 12 11 AU970266 3 19970319 G 6110 PROPELLER CESSNA 310 310Q 2074242 CE CONT O470 IO470V 17026 SO MCAULY 3AF32C 3AF32C87 GL PROPELLER ASSY FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 691 149313VO 721730 (AUS) LH PROPELLER SUSPECT OUT OF BALANCE - LH ENGINE FORWARD ENGINE MOUNT LOOSE - INVESTIGATION FOUND PROBLEM CAUSED BY BLADE ANGLES AND PROFILES 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 1997121100564 19971211 00564 SW 1997 12 11 AU970267 1 19970317 G 2810 5630061502 FUEL CELL GULSTM 500 500S 0141107 SW LYC O540 IO540E1B5 41532 EA HARTZL HCA3V HCA3VK2 GL FUEL STORAGE LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) RH WING FUEL CELL LEAKING - ON REMOVAL OF THE TANK EXTENSIVE DETERIORATION OF THE INTERNAL AND EXTERNAL COATING OF TANK WAS EVIDENT - THE CELL WAS MANUFACTURED IN NOVEMBER 1978 AND CONSTRUCTED FROM BTC-67 MATERIAL 1 H 7 2 3O 3 O 6A1 1E4 5 C P6EA 1997121100565 19971211 00565 SO 1997 12 11 AU970268 1 19970304 G 2750 110P28311298 SELECTOR SWITCH EMB 110 EMB110P1 3260122 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL TE FLAP CONTROL BROKEN W K NONE F FLT CONT AFFECTED LD LANDING 1 AU S (AUS) AFTER TOUCH DOWN THE COPILOTS KNEE ACCIDENTLY BROKE THE FLAP SELECTOR LEVER - INVESTIGATION LATER FOUND THE LEVER EXCESSIVELY WORN AND WEAKENED DUE TO THE CONTINUAL SLIDING CONTACT WITH THE DETENT PLATE 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 1997121100566 19971211 00566 SW 1997 12 11 AU970269 1 19970323 G 2913 1084 VALVE SWRNGN 2781009015 FRCHLD SA227 SA227DC 3377521 SW GARRTT TPE331 TPE33112UA 01514 WP MCAULY 4HFR34 4HFR34C652 NE HYDRAULIC PUMP BINDING W K NONE O OTHER CL CLIMB 1 AU S 842 1084 (AUS) POWER PACK INTEGRAL BY-PASS VALVE ASSEMBLY STIFF TO OPERATE DUE TO BINDING O-RING SEAL 2 L 7 2 4T 4 T RT A18SW E4WE 6 C 3PNE 1997122900027 19971229 00027 1997 12 29 AU970270 1 19970307 G 2434 634442 ALTERNATOR CONT O360 IO360HB 17025 SO HARTZL HCC2Y BHCC2YF1 GL DC GENERATOR-ALT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S E309017 353391 (AUS) ALTERNATOR FRONT HOUSING CONTAINED FIVE CRACKS AROUND THE FLANGES - ON ENGINE STRIP DOWN (REFER MDR 97/0228) IT W AS FOUND THAT THE COUNTER WEIGHT ROLLERS ON THE CRANKSHAFT HAD EXCESSIVE WEAR AND THE ASSOCIATED VIBRATION IS SUSPECTED TO HAVE BEEN THE CAUSE 3 O E1CE 5 C P920 1997121100567 19971211 00567 SO 1997 12 11 AU970271 2 19970321 G 8520 276347R CRANKCASE CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL NR 2 CYL PAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 276347R (AUS) AT ENGINE OVERHAUL THE FOLLOWING COMPONENTS WERE FOUND UNSERVICEABLE:1. CRANKCASE WAS FPI AND WAS FOUND CRACKED IN SIDE NO2 CYLINDER PAD2. CAMSHAFT LOBE CRACKED - CRACK LENGTH 19MM (0.75IN) 3. QUILL SHAFT HAD BADLY GALLED SPLINES 1 L 7 2 3O 3 O A25CE E7CE 5 C P45GL 1997121100568 19971211 00568 EA 1997 12 11 AU970272 2 19970317 G 8520 L1716940A BUSHING LYC O540E4CS LYC O540 O540E4C5 41532 EA CRANK IDLER GEAR WORN W K NONE O OTHER IN INSP/MAINT 1 AU S L1716940A L1716940A (AUS) AT ENGINE OVERHAUL THE FOLLOWING WAS FOUND: 1. CRANKCASE GOVERNER IDLER GEAR BUSHING HEAVILY WORN 2. CRANKSHAFT GE AR LOCK BOLT HAD SNAPPED IN THE CRANKSHAFT AND THE GEAR HAD DAMAGED THE DOWEL HOLE - ALSO DAMAGED WERE THE CRANKSHAFT GE AR AND IDLER GEARS 3. CAMSHAFT LOBES DAMAGED ENGINE CAME FROM A PNG REGISTERED AIRCRAFT 3 O E295 1997121100569 19971211 00569 EA 1997 12 11 AU970273 2 19970213 G 8520 LW18840 CAMSHAFT MOONEY M20 M20E 5870212 SW LYC O360 IO360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL RECIP ENG LOBES WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 1080 L120351A CA116 (AUS) ENGINE WAS BULK STRIPPED FOLLOWING METAL CONTAMINATION OF OIL FILTER - CAMSHAFT LOBES FOUND TO BE WORN 1 L 7 1 3O 3 O 2A3 1E10 5 C P920 1997121100570 19971211 00570 SO 1997 12 11 AU970274 2 19970321 G 8530 649168CEA3 CYLINDER CESSNA 310 310N 2074234 CE CONT O470 IO470V 17026 SO MCAULY 3AF32C D3AF32C80 GL RECIP ENG BORE WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 1480787U (AUS) ENGINE CYLINDER (PNO 649168CEA3) BORES WORN BEYOND LIMITS - CYLINDERS ARE CERMICHROME TYPE 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 1997121100571 19971211 00571 SO 1997 12 11 AU970275 2 19970318 G 8520 2400925R SADDLE CONT IO520F CONT O520 IO520F 17032 SO RECIP ENG MAIN FRETTED W K NONE O OTHER IN INSP/MAINT 1 AU S 2400925R 240925 (AUS) AT ENGINE OVERHAUL THE FOLLOWING WAS FOUND: 1. CRANKCASE MAIN BEARING SADDLE EVIDENCE OF FRETTING AND NO4 CAMTUNN EL SCORED 2. CAMSHAFT WAS INSPECTED USING MPI AND CRACKS WERE FOUND ON TWO LOBES. ENGINE WAS FROM A PNG REGISTERED AIRC RAFT 3 O E5CE 1997121100572 19971211 00572 WP 1997 12 11 AU970276 2 19970318 G 7261 31080801 PIPE 31035781 FRCHLD SA227 SA227DC 3377521 SW GARRTT TPE331 TPE33112UA 01514 WP MCAULY 4HFR34 4HFR34C652 NE TURB ENGINE OIL LEAKING W K NONE K FLUID LOSS TX TAXI/GRND HDL 1 AU S P70220 (AUS) LH ENGINE PIPES PNO 3103578-1 (TURBINE BEARING OIL SUPPLY LINE) AND PNO 3108080-1 (NTS ORIFICE LINE) CHAFING TOGET HER - OIL LEAKING - SUSPECT INCORRECT FITTING AT ASSEMBLY 296 HOURS PREVIOUSLY 2 L 7 2 4T 4 T RT A18SW E4WE 6 C 3PNE 1997121100573 19971211 00573 SO 1997 12 11 AU970277 2 19970317 G 8520 280127R CRANKCASE CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL RECIP ENG DEFECTIVE W K NONE O OTHER IN INSP/MAINT 1 AU S 280127R (AUS) AT ENGINE OVERHAUL THE CRANKCASE WAS BOLTED TOGETHER AND TUNNELS WERE MEASURED OUT OF LIMITS 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 1997121100574 19971211 00574 EA 1997 12 11 AU970278 2 19970311 G 8530 12416 CYLINDER CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA MCAULY 1C160 1C160DTM GL NR 1 CYL PLUG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 1343 RL1534839A (AUS) NO1 CYLINDER CRACKED FROM BOTH SPARK PLUG HOLES - CRACK LENGTHS 19.05MM (0.75IN) - EXHAUST VALVE SEAT BORE CRACKED - CRACK LENGTH 12.7MM (0.5IN) 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 1997121100575 19971211 00575 EU 1997 12 11 AU970279 1 19970321 G 5310 STRUCTURE BNORM BN2 BN2A21 1520221 EU LYC O540 IO540K1B5 41532 EA HARTZL HCC2Y HCC2YK2 GL AIRCRAFT GENERAL CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AIRCRAFT STRUCTURE CONTAINED EXTENSIVE CORROSION:-1. MAINPLANES HAD SEALING MATERIAL MISSING FROM LOWER SPAN LAMIN ATES BETWEEN FUSELAGE AND ENGINE NACELLE ALLOWING MOISTURE INGRESS AND CORROSION 2. WING SKINS PEELED BACK TO REVEAL EX FOLIATION CORROSION IN AN AREA OF THE INTERSPAR STRINGER ONE BACK FROM THE FRONT SPAR IN AN AREA JUST OUTBOARD OF THE FUEL BAY AT APPROXIMATELY STN 200 3. HORIZONTAL STABILISER EXTENSIVE SURFACE CORROSION4. VERTICAL STABILISER EXTENSIVE S URFACE CORROSION5. ELEVATOR BALANCE WEIGHTS BADLY CORRODED IN STEEL SECTIONS 1 H 7 2 3O 3 O A17EU 1E4 5 C P920 1998010500020 19980105 00020 SO 1998 1 5 AU970280 2 19970327 G 8540 530406 HUB CONT CONT O360 IO360HB 17025 SO HARTZL HCC2Y BHCC2YF1 GL DC GEN ALT DRIVE SHEARED W K NONE H ELECT. POWER LOSS-50 PC CL CLIMB 1 AU S 872 C269002 353397 (AUS) ALTERNATOR DRIVE HUB SHEARED AT BOTH SHOULDERS - BROKEN PARTS ENTERED ENGINE OIL SYSTEM 3 O E1CE 5 C P920 1997121100576 19971211 00576 EA 1997 12 11 AU970281 2 19970321 G 8530 VALVE MOONEY M20 M20J 5870219 SW LYC O360 IO360A3B6 41514 EA HARTZL HCC2Y HCC2YK1 GL NR 3 CYL EXH FAILED W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S L2297151A (AUS) NO3 CYLINDER EXHAUST VALVE HEAD FAILED 1 L 7 1 3O 3 O 2A3 1E10 5 C P920 1997121100577 19971211 00577 NE 1997 12 11 AU970282 2 19970313 G 7261 15515 CHIP DETECTOR TMECA 0292005250 SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE TURBINE ENG OIL CONTAMINATED W K NONE E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 AU S 15515 15515 (AUS) NO1 ENGINE OIL SYSTEM CHIP DETECTORS CONTAMINATED - TYPE III PARTICLE (METAL SLIVER) ON MPI 1 CHIP DETECTOR - TYPE II PARTICLES (DARK DUST) ON MAGNETIC PLUGS - OIL AND FILTER CHANGEDAND ENGINE GROUND RUN SERVICEABLE 1 G 7 2 3U 3 U NC H1NE E19EU 1997121100578 19971211 00578 GL 1997 12 11 AU970283 3 19970306 G 6114 NAS6606D604 BOLT LYC O320 O320D1A 41508 EA HARTZL HCC2Y HCC2YL1 GL PROPELLER HUB WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S AX685 (AUS) PROPELLER HUB BOLTS (4OFF) INCORRECT PARTS. BOLTS MEASURE .375 -CORRECT MEASUREMENT .371. PERSONNEL/MAINTENANCE ER ROR. UNAPPROVED PART. 3 O E274 5 C P920 1997121100579 19971211 00579 GL 1997 12 11 AU970284 3 19970324 G 6114 D22017 HUB HARTZL HCC2YL1BF LYC O320 O320D1A 41508 EA HARTZL HCC2Y HCC2YL1 GL PROPELLER HUB FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S AX685 AX685 (AUS) PROPELLER HUB BOLT HOLES (4OFF) TOO LARGE DUE TO INCORRECT DIAMETER BOLTS BEING USED - SEE MDR 97/0283 3 O E274 5 C P920 1997121100580 19971211 00580 NM 1997 12 11 AU970285 1 19970304 G 2700 41552172S CONTROL CABLE UNIVAR 415 415D 0420306 NM MCAULY 1B90 1B90CM GL FLIGHT CONTROL FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CONTROL CABLES ATTACHED TO PRIMARY CONTROL QUADRANT IN CONTROL COLUMN YOKE HAD FAULTY SWAGING - DURING TESTING CAB LES PULLED THROUGH THE NICOPRESS SLEEVES AT A LOAD OF 610 LBS (NORMAL FAILURE LOAD 2200 LBS TO 2300LBS) - AIRCRAFT IS IM PORTED FROM THE USA AND IS UNDERGOING INITIAL COFA - US REGISTRATION N94022 1 L 7 1 3O A787 5 N P842 1997121100581 19971211 00581 1997 12 11 AU970286 4 19970307 G 2561 42216 MANIFOLD KSR35L8W LIFE JACKET DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S 1 42216 (AUS) LIFE JACKET INFLATION MANIFOLD DELAMINATING AT WELD - LOSS OF AIR 1997121100582 19971211 00582 NE 1997 12 11 AU970287 2 19970314 G 7261 15514 OIL SYSTEM TMECA 0292005250 SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE TURBINE ENG OIL CONTAMINATED W K NONE E J VIBRATION/BUFFET WARNING INDICATION NR NOT REPORTED 1 AU S 15514 15514 (AUS) NO2 ENGINE CHIP DETECTORS, MAGNETIC PLUGS AND FILTER CONTAMINATED WITH METAL PARTICLES 1 G 7 2 3U 3 U NC H1NE E19EU 1997121100583 19971211 00583 CE 1997 12 11 AU970288 1 19970310 G 3222 SK1759 FORK CESSNA 172 172N 2072434 CE NOSE GEAR BROKEN W K NONE O OTHER LD LANDING 1 AU S (AUS) NOSE LANDING GEAR FORK SHEARED IN AREA OF PISTON TUBE ATTACHMENT- A HEAVY LANDING INSPECTION HAD BEEN CARRIED OUT 40 HOURSPREVIOUSLY 1 H 7 1 3O NT 3A12 1997121100584 19971211 00584 SW 1997 12 11 AU970289 1 19970329 G 3230 27810321013 PIPE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP LANDING GEAR RET LEAKING W K NONE O K OTHER FLUID LOSS IN INSP/MAINT 1 AU S (AUS) LH MAIN LANDING GEAR `UP' RIGID PIPE HOLED AND LEAKING - PIPE IS MANUFACTURED FROM ALUMINIUM ALLOY 2 L 7 2 4T 4 T RT A8SW E4WE 1997121100585 19971211 00585 1997 12 11 AU970290 4 19970318 G 6122 8971609 GOVERNOR WOODWARD 8971609 CESSNA 441 441 2076020 CE HARTZL HCB3T HCB3TN5 GL PROP GOV FAULTY W K NONE O OTHER CR CRUISE 1 AU S 24 P474C (AUS) RH ENGINE PROPELLER GOVERNOR FAULTY 1 L 7 2 3T RT A28CE 6 C P15EA 1997121100586 19971211 00586 CE 1997 12 11 AU970291 1 19970219 G 5500 EMPENNAGE CESSNA 441 441 2076020 CE HARTZL HCB3T HCB3TN5 GL EMPENNAGE STRUCT LIGHTNING STRIKE W K NONE C F.O.D. NR NOT REPORTED 1 AU S (AUS) AIRCRAFT LIGHTENING STRIKE - ENTRY POINT APPEARS TO BE LH FLAP AND AILERON - BOTH ELEVATORS HAD EXIT HOLES ADJACEN T TO OUTER STATIC WICKS - RUDDER TOP FAIRING HAD EXIT HOLE AND EVIDENCE OF BURNING - UPPER RUDDER SKIN HAD EVIDENCE OF A RCING 1 L 7 2 3T RT A28CE 6 C P15EA 1997121100587 19971211 00587 CE 1997 12 11 AU970292 1 19970311 G 6120 7715649001 VALVE GARRTT TPE3318 CESSNA 441 441 2076020 CE HARTZL HCB3T HCB3TN5 GL PROP CONTROL STICKING W K NONE J WARNING INDICATION DE DESCENT 1 AU S P31597 (AUS) NTS CHECK VALVE ON GEARCASE STICKING ALLOWING HIGH PRESSURE GOVERNOR OIL TO ACTIVATE BETA SWITCH 1 L 7 2 3T RT A28CE 6 C P15EA 1997121100588 19971211 00588 EU 1997 12 11 AU970293 1 19970401 G 5751 BALANCE WEIGHT SOCATA AILERON SOCATA TB10 TB10TOBAGO 8680696 EU LYC O360 O360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL AILERON LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AILERON BALANCE WEIGHT LOOSE - `POP' RIVETS MOVING 1 L 7 1 30 3 O NT A51EU E286 5 C P920 1997121100589 19971211 00589 EU 1997 12 11 AU970294 1 19970401 G 3211 115C5031 BRACKET GROB G115 G115C 1660303 EU LYC O360 O360A1F6 41514 EA HARTZL HCF2Y HCF2YR1 GL LT MLG ATTACH CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH MAIN LANDING GEAR ATTACHMENT BRACKET CRACKED AT FORWARD LOWER SECTION 1 L 7 1 3O 3 O NT A57EU E286 5 C P27EA 1997121100590 19971211 00590 SO 1997 12 11 AU970295 2 19970221 G 8530 652956 VALVE CONT IO520BB BEECH 36 A36 1151604 CE CONT O520 IO520B 17032 SO MCAULY 3A32C 3A32C76 GL NR 3 & 4 EXH FAULTY W K NONE O OTHER CR CRUISE 1 AU S 3 573078 573078 (AUS) NO4 CYLINDER EXHAUST VALVE FAULTY - FURTHER INVESTIGATION FOUND NO3 CYLINDER EXHAUST VALVE IN SIMILAR CONDITION - METAL CONTAMINATION OF OIL SYSTEM 1 L 7 1 3O 3 O 3A15 E5CE 5 C P21EA 1997121100591 19971211 00591 SO 1997 12 11 AU970296 2 19970225 G 8520 294762R CRANKCASE CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO MCAULY 2A34C E2A34C73 GL NR 4 & 5 MAIN CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 294762R (AUS) ENGINE BULK STRIPPED FOLLOWING PROPELLER STRIKE - CRANKCASE FOUND TO BE CRACKED BETWEEN NO4 AND NO5 MAIN BEARING S ADDLES - FOUND USING FPI 1 H 7 1 3O 3 O 3A21 E5CE 5 C P3EA9 1997121100592 19971211 00592 CE 1997 12 11 AU970297 1 19970320 G 3222 12434262 TORQUE LINK CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO MCAULY 3A32C D3A32C88 GL NOSE GEAR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NOSE LANDING GEAR TORQUE LINK CRACKED ON FORWARD REINFORCING WEBS 1 H 7 1 3O 3 O 3A21 E5CE 5 C P21EA 1997121100593 19971211 00593 EU 1997 12 11 AU970298 1 19970401 G 5712 TB101106100 RIB SOCATA TB10 TB10TOBAGO 8680696 EU LYC O360 O360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL RT WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH WING ROOT RIB LOWER FLANGE CORRODED IN AREA OF RIB TO LOWER WING SKIN ATTACHMENT RIVETS - AIRCRAFT OPERATES IN A SALT LADENENVIRONMENT AND IS NOT HANGARED 1 L 7 1 30 3 O NT A51EU E286 5 C P920 1997121100594 19971211 00594 CE 1997 12 11 AU970299 1 19970124 G 5210 10542001815 LATCH BEECH 76 76 1153005 CE PASS/CREW DOOR STICKING W K NONE D INFLIGHT SEPARATION TO TAKEOFF 1 AU S (AUS) LH DOOR LATCH STICKING - SUSPECT CAUSED BY LACK OF LUBRICATION 1 L 7 2 3O A29CE 1997121100595 19971211 00595 SW 1997 12 11 AU970300 1 19970324 G 5320 STRUCTURE BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE STRUCTURE CRACKED WHERE VERTICAL CONTROL TUNNEL JOINS ROOF STRUCTURE IN AREA BELOW SERVO MOUNTING - FOUN D DURING INSPECTION IAW AD/BELL206/82 1 G 7 1 3U 3 U H2SW E1GL 1997121100596 19971211 00596 NM 1997 12 11 AU970301 1 19970324 G 3240 DSC252A40230 HOSE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE LT MLG BRAKE FAILED W K NONE O K OTHER FLUID LOSS IN INSP/MAINT 1 AU S (AUS) LH MAIN LANDING GEAR BRAKE HOSE FAILED AT LOWER FITTING - LOSS OF HYDRAULIC FLUID 2 H 7 2 4T 4 T RT A13NM E20NE 1997121100597 19971211 00597 NM 1997 12 11 AU970302 1 19970308 G 2424 CR907 DIODE WESTINGHOUSE GCU BOEING 737 737377 NM AC REGULATOR SHORTED W K NONE B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 AU S 28822 WG436ANSETTS (AUS) GENERATOR CONTROL UNIT FAULTY - INVESTIGATION FOUND DIODE CR907 SHORT CIRCUITED ALLOWING TRANSFORMER T901 TO OVERH EAT 2 L 7 2 4F RT A16WE 1997121100598 19971211 00598 1997 12 11 AU970303 1 19970323 G 7722 CA15000 CABLE SW14507 CFMINT CFM56 CFM563C 13802 EU ENG EGT/TIT IND FAILED W K NONE O OTHER CR CRUISE 1 AU S 14507 (AUS) ENGINE FORWARD EGT EXTENSION CABLE FAILED 4 F E21EU 1997121100599 19971211 00599 NM 1997 12 11 AU970304 1 19970130 G 5610 66193551 PIN BOEING 737 737476 NM NR 2 SLIDER RT INCORRECT FIT W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NO2 RH SLIDING WINDOW FAILED TO OPEN USING EXTERNAL RELEASE HANDLE - PIN WAS FOUND TO BE TOO SHORT 2 L 7 2 4F RT A16WE 1997121100600 19971211 00600 EU 1997 12 11 AU970305 1 19970313 G 2460 M6009336 RELAY FOKKER F27 F27MK50 EU DC POWER DISTRIB FAULTY W K NONE O OTHER TO TAKEOFF 1 AU S (AUS) DC EMERGENCY BUS 1 SELECT CONTACTOR SUSPECT FAULTY 2 H 7 2 4T RT A817 1997121100601 19971211 00601 CE 1997 12 11 AU970306 1 19970120 G 5712 082217517 RIB 082217518 CESSNA 402 402B 207590P CE MCAULY 3AF32C 3AF32C87 GL LT WHEEL BAY CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH WHEEL BAY CENTRE RIB UPPER CAP CRACKED IN AREA ACROSS ALLTHREE UPPER BRACKET BOLT HOLES 1 L 7 2 3O A7CE 5 C P22EA 1997121100602 19971211 00602 SO 1997 12 11 AU970307 1 19970319 G 2752 489426 ACTUATOR PIPER PA31 PA31350 7103110 SO HARTZL HCE3Y HCE3YR2 GL TE FLAP ACTUATOR WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FLAP ACTUATOR WORN BEYOND LIMITS 1 L 7 2 3O A20SO 5 C P33EA 1997121100603 19971211 00603 NE 1997 12 11 AU970308 2 19970310 G 7230 BEARING BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE NR 3 ENG NR 2 FAILED W K NONE O OTHER CL CLIMB 1 AU S LFO5869 (AUS) NO3 ENGINE NO2 BEARING FAILED - METAL CONTAMINATION OF OIL SYSTEM 2 H 7 4 4F 4 F A49EU E6NE 1997121100604 19971211 00604 GL 1997 12 11 AU970309 3 19970402 G 6110 A1588B SPRING HARTZL PHCJ3YF2VF BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO HARTZL HCJ3Y PHCJ3YF2 GL PROP ASSEMBLY FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 1505 ED1529 ED1529 (AUS) PROPELLER CONTAINED THE FOLLOWING DEFECTS:- 1. LATCH PNO B318 BROKEN. 2. LATCH BOLTS PNO A1595 (2OFF) SHEARED AND ONE BOLT BENT 3. CYLINDER PNO B2423-1 DAMAGED 4. PISTON PNO B3237 WORN 5. INCORRECT PRESSURE DECAL FITTED. PERSONNEL/MAI NTENANCE ERROR 1 L 7 2 3O 3 O 3A16 E5CE 5 C P36EA 1997121100605 19971211 00605 EA 1997 12 11 AU970310 2 19970325 G 8520 72877 TAPPET BODY PIPER PA60 PA60600 7106001 NM LYC O540 IO540K1J5 41532 EA NR 3 CYL INT BROKEN W K NONE O K OTHER FLUID LOSS IN INSP/MAINT 1 AU S 797 L1777448A (AUS) NO3 CYLINDER INLET VALVE TAPPET BODY BROKEN - PUSHROD TUBES LIGHTLY DISPLACED AND LEAKING OIL 1 M 7 2 3O 3 O RT A17WE 1E4 1997122900028 19971229 00028 NE 1997 12 29 AU970311 2 19970304 G 7250 ENGINE LYC ALF502 ALF502H 41580 NE TURBINE SECTION FAULTY W K NONE O OTHER NR NOT REPORTED 1 AU S LF07007 (AUS) NO3 ENGINE VIBRATION WITH SPARKS FROM TAILPIPE - N2 SEIZED WHEN ENGINE SHUT DOWN 4 F E6NE 1997121100606 19971211 00606 CE 1997 12 11 AU970312 1 19970211 G 2910 S2178C40150 HOSE CESSNA 210 210N 2073453 CE CONT O520 IO520F 17032 SO MCAULY D3A34 D3A34C404 GL HYDRAULIC, MAIN FAILED W K NONE K FLUID LOSS CL CLIMB 1 AU S (AUS) LANDING GEAR HYDRAULIC HOSE FAILED AT FITTING - SUSPECT INCORRECT HOSE FITTED - UNAPPROVED PART - PERSONNEL/MAINTE NANCE ERROR 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 1997121100607 19971211 00607 EU 1997 12 11 AU970313 1 19970329 G 3610 SEAL BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE PNEU DISTRIB LEAKING W K NONE M J OVER TEMP WARNING INDICATION CR CRUISE 1 AU S (AUS) ANTI-ICE AIR DUCT SEALS LOCATED AT REAR END OF SPINE LEAKING -NO4 ENGINE AIR VALVE CONNECTOR. SUSPECT MOISTURE IN GRESS 2 H 7 4 4F 4 F A49EU E6NE 1997121100608 19971211 00608 SW 1997 12 11 AU970314 1 19970324 G 7120 6250001 MOUNT GULSTM 114 GULSTM 112 114 7630314 SW LYC O540 IO540T4B5 41532 EA HARTZL HCC2Y HCC2YR1 GL ENGINE MOUNT SEC BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 14278 L1645948A (AUS) ENGINE MOUNT ASSEMBLY TUBE CRACKED AT LH NLG TRUNNION - TRUNNION PIN DEFORMED - AIRCRAFT USED FOR PILOT TRAINING 1 L 7 1 3O 3 O A12SO 1E4 5 C P920 1997121100609 19971211 00609 CE 1997 12 11 AU970315 1 19970404 G 3240 0500118126 PIPE CESSNA 182 182Q 2072732 CE MCAULY 2A34C 2A34C203 GL MLG BRAKE DAMAGED W K NONE W K INADEQUATE Q C FLUID LOSS IN INSP/MAINT 1 AU S (AUS) LH BRAKE LINE PUNCTURED BY `PK' TYPE SCREW FITTED FOLLOWING REPAINTING - LOSS OF BRAKE FLUID - PERSONNEL/MAINTENAN CE ERROR 1 H 7 1 3O NT 3A13 5 C P3EA 1997121100610 19971211 00610 1997 12 11 AU970316 4 19970402 G 2562 E01 ELT PIPER PA18 PA18150 7101828 SO LYC O320 O320A2B 41508 EA SNSNCH 74DM M74DM EA EMERG LOCATOR LOW POWER W K NONE O OTHER IN INSP/MAINT 1 AU S 014709 (AUS) ELT OUTPUT BELOW SPECIFICATION 1 H 7 1 3O 3 O 1A2 E274 5 N P88614 1997121100611 19971211 00611 CE 1997 12 11 AU970317 1 19970321 G 5753 501600036 BRACKET BEECH FLAP BEECH 55 95C55 1152708 CE CONT O520 IO520C 17032 SO MCAULY 3AF32C 3AF32C75 GL TE FLAP STRUCTUR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S TE423 (AUS) RH FLAP ACTUATOR ATTACHMENT BRACKET CRACKED AND SEPARATED FROM FLAP AT THE CENTRE ATTACHMENT SCREW. WHEN DOWNWARD S PRESSURE WAS APPLIED TO THE TRAILING EDGE OF THE FLAP - INVESTIGATION FOUND APREVIOUS REPAIR UNDER THE BRACKET ALSO CR ACKED AND THE RIB BELOWTHE REPAIR PNO 50-160012-2 CRACKED AND DEFORMED 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 1997121100612 19971211 00612 SO 1997 12 11 AU970318 1 19970322 G 2915 D559A6D37 VALVE EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HYDRAULIC PRESSU FAULTY W K NONE K J FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S (AUS) LH HYDRAULIC RESERVOIR AIR PRESSURE RELIEF FAULTY - SEAL DETERIORATED 2 L 7 2 4T 4 T RT A31SO E20NE 1997121100613 19971211 00613 GL 1997 12 11 AU970319 1 19970222 G 3246 WHEEL AMTR MAXAIR XP503 9570746 GL AMTR 582 582 GL TAIL WHEEL SEPARATED W K NONE O D OTHER INFLIGHT SEPARATION LD LANDING 1 AU S (AUS) TAIL WHEEL SEPARATED FROM AIRCRAFT - AIRCRAFT RAN OFF STRIP - DAMAGE TO RH WING TIP , PITOT AND RH UNDERCARRIAGE L EG - THIS DEFECT WAS RECEIVED FROM THE AUF AND IS FOR INFORMATION ONLY 1 H 7 1 3I 3 I NT EXPA1H71 EXP31 1997121100614 19971211 00614 GL 1997 12 11 AU970320 1 19970225 G 3244 TYRE AMTR JABIRU JABIRUSK 05602CU GL LT MLG DEFLATED W K NONE O OTHER LD LANDING 1 AU S (AUS) LH MAIN LANDING GEAR TYRE FLAT - AIRCRAFT RAN OFF STRIP AND HIT A MOUND OF DIRT TEARING OFF THE FRONT WHEEL AND MO UNTING BEFORE DIGGING THE NOSE INTO THE GROUND AND FLIPPING OVER - THIS DEFECT WAS RECEIVED FROM THE AUF AND IS FOR INFO RMATION ONLY 1 H 7 1 IO NC EXPA1H71 1997121100615 19971211 00615 NM 1997 12 11 AU970324 1 19970216 G 2560 65B096339 FITTING BOEING 747 747SP38 NM EMERG EQUIP BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MAIN ENTRANCE DOOR L4 GIRT BAR AFT SLIDE FITTING BROKEN 2 L 7 4 4F RT A20WE 1997121100616 19971211 00616 NM 1997 12 11 AU970325 1 19970305 G 5754 FAIRING BOEING 747 747SP38 NM LEADING EDGE DEV FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NO7 LEADING EDGE FLAP BULLNOSE FAIRING OPERATING RODS AND HINGES BROKEN AWAY - FLAP HANGING BY BONDING STRAPS 2 L 7 4 4F RT A20WE 1997121100617 19971211 00617 NM 1997 12 11 AU970326 1 19970306 G 2752 2473T1001 MOTOR BOEING 747 747438 NM TE FLAP ACTUATOR FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ALTERNATE TRAILING EDGE FLAP DRIVE MOTOR FAULTY 2 L 7 4 4F RT A20WE 1997122900029 19971229 00029 NE 1997 12 29 AU970327 2 19970307 G 7240 LINER RROYCE RB211524D4 RROYCE RB211 RB211524D419 54555 NE ENG COMB CHAMBER BURNT W K NONE E B J VIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION TO TAKEOFF 1 AU S (AUS) NO3 ENGINE COMBUSTION CHAMBER OUTER LINER BURNT THROUGH IN TWO PLACES 4 F E12EU 1997122900030 19971229 00030 NE 1997 12 29 AU970328 2 19970308 G 7240 LINER RROYCE RB211524D4 RROYCE RB211 RB211524D419 54555 NE ENG COMB CHAMB BURNT W K NONE E B J VIBRATION/BUFFET SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION TO TAKEOFF 1 AU S (AUS) NO3 ENGINE COMBUSTION CHAMBER OUTER LINER BURNT AND HOLED IN TWO PLACES ADJACENT TO THE AFT FLANGE IN THE 3 O'CLOC K POSITION 4 F E12EU 1997121100618 19971211 00618 1997 12 11 AU970329 4 19970311 G 2565 PN7A124836 SLIDE BOEING 747 747SP38 NM RT UPPER DECK FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S PN7A124836 (AUS) RH UPPER DECK ESCAPE SLIDE FAILED TO FULLY DEPLOY DURING TEST DUE TO THE FAILURE OF THE FUSEABLE LINKS/BOLTS TO RE LEASE THE INFLATED SLIDE 2 L 7 4 4F RT A20WE 1997121100619 19971211 00619 NM 1997 12 11 AU970330 1 19970315 G 2560 LATCH BOEING 767 767338 NM ESCAPE SLIDE SEIZED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH OFF-WING ESCAPE SLIDE DOOR LATCHES SEIZED DUE TO LACK OF LUBRICATION AND CORROSION (RUST) ON THE CAM LATCHES 2 L 7 2 4F RT A1NM 1997122900031 19971229 00031 1997 12 29 AU970331 1 19970207 G 7830 TB377 TERMINAL BLOCK RROYCE RB211 RB211524G19 NE THRUST REVERSER INCORRECT FIT W K NONE O OTHER LD LANDING 1 AU S 13248 (AUS) NO3 ENGINE THRUST REVERSER TB377 MOD TERMINAL BLOCK INCORRECTLY FITTED RESULTING IN SHORT CIRCUITED CONNECTIONS WH ICH IN TURN ACTIVATED A RELAY IN THE THRUST REVERSER LOCKING CONTROLS - PERSONNEL/MAINTENANCE ERROR 4 F E30NE 1997121100620 19971211 00620 EA 1997 12 11 AU970332 2 19970409 G 8550 MS208234D ELBOW PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL LT ENG OIL LINE LOOSE W K NONE K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S L1413751A (AUS) LH ENGINE OIL PRESSURE LINE 45 DEGREE ELBOW FITTING LOOSE AND LEAKING - FITTING IS LOCATED ON THE CABIN HEAT EXCHA NGER EXHAUST MANIFOLD 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1998010500021 19980105 00021 GL 1998 1 5 AU970333 1 19970321 G 3222 4000004 GEAR LEG AMTR EXPRES EXPRESSFT 056201G GL LYC O540 IO540N1A5 41532 EA HARTZL HCF3Y HCF3YR1 GL NLG FAILED W K NONE O OTHER LD LANDING 1 AU S (AUS) NOSE LANDING GEAR LEG FAILED 1 L 7 1 3O 3 O NT EXPA1L71 1E4 5 C P31EA 1997121100621 19971211 00621 CE 1997 12 11 AU970334 1 19970402 G 3232 BOLT BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3A NE LT MLG DOOR MISSING W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) LH MAIN LANDING GEAR OUTBOARD DOOR ACTUATING ARM ATTACHMENT BOLT MISSING - SUSPECT SPLIT PIN WAS NOT FITTED AT LAS T MAINTENANCE -PERSONNEL/MAINTENANCE ERROR 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 1997121100622 19971211 00622 CE 1997 12 11 AU970335 1 19970304 G 7110 LATCH BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE RT ENG COWLING NOT SECURED W A K NONE D INFLIGHT SEPARATION CL CLIMB 1 AU S (AUS) RH ENGINE UPPER FRONT COWL SEPARATED FROM THE LOWER COWL AT THE FRONT LH COWL HOOK - INVESTIGATION FOUND THAT THE COWL HAD BEEN INCORRECTLY LATCHED - PERSONNEL/MAINTENANCE ERROR 2 L 7 2 4T 4 T RT A24CE E26NE 1997121800767 19971218 00767 WP 1997 12 18 AU970336 2 19970314 G 7200 ENGINE GARRTT TPE331 TPE33110U 01514 WP ROTOL R333 R333482F12 GL ENGINE LOW POWER W K NONE R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S (AUS) RH ENGINE LOW TORQUE DURING TAKEOFF - INVESTIGATION COULD FIND NO FAULT EXCEPT THAT WHEN THE BLEED AIR WAS TURNED ON THE POWER DROPPED - AIRCREW MAINTAINED BLEED AIR WAS TURNED OFF DURING TAKEOFF - NO CONCLUSIVE CAUSE COULD BE FOUND A ND ENGINE TORQUE HAS BEEN OK SINCE 4 T E4WE 6 C P61GL 1997121800220 19971218 00220 EU 1997 12 18 AU970337 1 19970401 G 2710 ND45B351 ACTUATOR BNORM BN2MK3 BN2AMK3 1520203 EU LYC O540 O540E4C5 41532 EA HARTZL HCC2Y HCC2YK2 GL AILERON CONTROL BROKEN W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) LH AILERON ACTUATOR ROD OUTER SEGMENT BROKEN DUE TO OUTER BALLJOINT SEIZING - RH AILERON OUTER BALL JOINT ALSO SEI ZED WITHATTACHMENT BOLT LOOSE IN BRACKET - PERSONNEL/MAINTENANCE ERROR 1 H 7 3 3O 3 O A29EU E295 5 C P920 1998010500004 19980105 00004 1998 1 5 AU970338 1 19970309 G 7722 CONNECTOR GARRTT TPE331 TPE33110U 01514 WP ROTOL R333 R333482F12 GL ENG. EGT/TIT IND CONTAMINATED W K NONE O OTHER CL CLIMB 1 AU S (AUS) RH ENGINE EGT INDICATION ERRATIC - INVESTIGATION FOUND THAT THE ENGINE FIREWALL CONNECTOR WAS CONTAMINATED WITH OI L 4 T E4WE 6 C P61GL 1997121800221 19971218 00221 SW 1997 12 18 AU970339 1 19970319 G 7120 2762114081 TRUSS SWRNGN SA227 SA227AT 8780610 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL ENGINE MOUNT SEC CRACKED W A K NONE O OTHER IN INSP/MAINT 1 AU S P44263 (AUS) ENGINE MOUNT ASSEMBLY CRACKED BETWEEN TWO WELDED SEAMS IN AREA OF UPPER REAR CLUSTER 2 L 7 2 4T 4 T RT A5SW E4WE 6 C P61GL 1997121800222 19971218 00222 EA 1997 12 18 AU970340 2 19970322 G 8520 3813 STUD 5015 PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL RECIP ENG CYL FRACTURED W K NONE E F VIBRATION/BUFFET FLT CONT AFFECTED CR CRUISE 1 AU S 910 L823761A (AUS) LH ENGINE NO1 CYLINDER HOLDDOWN STUDS PNO 38-13 (2OFF) AND PNO50-15 (2OFF) FRACTURED - INDUCTION TUBE SEPARATED FR OM SUMP 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1997121800223 19971218 00223 CE 1997 12 18 AU970341 1 19970330 G 2710 NAS261064 CONTROL CABLE BEECH 36 A36 1151604 CE CONT O520 IO520B 17032 SO MCAULY 3A32C 3A32C76 GL AILERON CONTROL CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AILERON CONTROL CABLE CONTAINED SEVERE CORROSION AND FRAYING IN AREA BENEATH CLAMP BETWEEN AUTOPILOT ROLL SERVO TO CONTROL CABLE 1 L 7 1 3O 3 O 3A15 E5CE 5 C P21EA 1997121800224 19971218 00224 CE 1997 12 18 AU970342 1 19970409 G 2720 03101965 SPRING CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL RUDDER CONTROLS BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH RUDDER PEDAL RETURN SPRING BROKEN 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 1997121800225 19971218 00225 CE 1997 12 18 AU970343 1 19970410 G 2720 031019612 SPRING CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL RUDDER CONTROLS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH RUDDER PEDAL RETURN SPRING BROKEN 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 1997121800226 19971218 00226 1997 12 18 AU970344 4 19970404 G 2562 E01 ELT EMERG LOCATOR FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 017240 (AUS) ELT FAULTY - NO OPERATION 1997121800227 19971218 00227 1997 12 18 AU970345 4 19970410 G 2562 E01 ELT EMERG LOCATOR FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 012344 (AUS) ELT DOES NOT CONFORM TO MANUFACTURERS SPECIFICATIONS 1997121800228 19971218 00228 GL 1997 12 18 AU970346 3 19970407 G 6114 1A103TCM HUB MCAULY CESSNA 150 152 2071835 CE MCAULY 1A103 1A103TCM GL PROP HUB SEC CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 400 771094 771094 (AUS) PROPELLER HUB CRACKED THROUGH TWO BOLT HOLES - SUSPECT PROPELLER HAS NOT BEEN INSPECTED IAW AD/PFP/17 AMDT2 -PERSO NNEL/MAINTENANCE ERROR 1 H 7 1 3O NT 3A19 5 N P50GL 1997121800229 19971218 00229 EU 1997 12 18 AU970347 1 19970412 G 6120 6068TS4PO1 HARNESS SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R390 R3904123F27 NE PROP CONTROL FAULTY W K NONE O OTHER CR CRUISE 1 AU S 785499 DAP0055 (AUS) LH PROPELLER CONTROL HARNESS FAULTY 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P31NE 1997121800230 19971218 00230 WP 1997 12 18 AU970348 1 19970329 G 2810 269A8321 VENT HUGHES HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA FUEL STORAGE BLOCKED W K NONE Y ENGINE STOPPAGE DE DESCENT 1 AU S NA L2336651 (AUS) FUEL TANK VENT BLOCKED BY MUD WASP NEST 1 G 7 1 3O 3 O 4H12 1E10 1997121800231 19971218 00231 EA 1997 12 18 AU970349 2 19970323 G 8520 66734 STUD LYC HILLER UH12 UH12E 4360122 WP LYC O540 VO540C2A 41532 EA RECIP ENG CYL BROKEN W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 AU S 385 L89543 L89543 (AUS) NO2 CYLINDER HOLD DOWN STUDS BROKEN - INVESTIGATION FOUND SIX CYLINDER BASE NUTS MISSING, THIRTY NUTS LOOSE AND ON LY TWELVE NUTS TO BE TIGHT - CRANKCASE PARTING SURFACES AND CYLINDER MOUNT PADS FRETTED - NUMEROUS INTERNAL WRENCHING. C YLINDER BASE NUTLANDS BADLY DAMAGED PREVENTING PROPER TIGHTENING OF THE NUTS -ENGINE WAS LAST OVERHAULED IN THE USA - PE RSONNEL/MAINTENANCE ERROR 1 G 7 1 3O 3 O 4H11 E304 1997121800232 19971218 00232 GL 1997 12 18 AU970350 3 19970411 G 6114 E18396 HUB CESSNA 172 172D 2072410 CE CONT O300 O300C 17022 SO MCAULY 1C172 1C172EM GL PROP HUB SEC CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S E18396 (AUS) PROPELLER HUB CRACKED IN AREA OF NO1 BLADE BOLT HOLES - REWORK OF HUB REVEALED ONE MAIN CRACK APPROXIMATELY 15.875 MM (0.625IN) LONG TOGETHER WITH THREE SUB-SURFACE CRACKS APPROXIMATELY 6.35MM (0.25IN) LONG 1 H 7 1 3O 3 O NT 3A12 E253 5 N P910 1997121800233 19971218 00233 1997 12 18 AU970351 4 19970411 G 2562 E01 ELT EMERG LOCATOR FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 014712 (AUS) ELT DOES NOT MEET MANUFACTURERS SPECIFICATIONS 1997121800234 19971218 00234 1997 12 18 AU970352 4 19970410 G 2562 E01 ELT EMERG LOCATOR FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 17250 (AUS) ELT DOES NOT MEET MANUFACTURERS SPECIFICATIONS 1997121800235 19971218 00235 1997 12 18 AU970353 4 19970410 G 2562 E01 ELT EMERG LOCATOR FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 017244 (AUS) ELT DOES NOT MEET MANUFACTURERS SPECIFICATIONS 1997121800236 19971218 00236 EU 1997 12 18 AU970354 1 19970403 G 2611 72111211000 SMOKE DETECTOR SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE SMOKE DETECTION ACTIVATION W K NONE N FALSE WARNING NR NOT REPORTED 1 AU S (AUS) CARGO COMPARTMENT SMOKE DETECTORS GIVING FALSE WARNING -INVESTIGATION FOUND NO EVIDENCE OF FIRE OR SMOKE - SUSPECT CAUSED BY FAILING FLUORESCENT LAMPS IN THE TOILET AREA 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 1997121800237 19971218 00237 CE 1997 12 18 AU970355 1 19970318 G 5510 17320311 BRACKET 17320312 CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA MCAULY 2D34C B2D34C207 GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) STABILATOR WEIGHT ARM REAR MOUNTING BRACKETS PNO 1732031-1 ANDPNO 1732031-2 CRACKED ON VERTICAL BENDS 1 H 7 1 3O 3 O A20CE 1E10 5 C P7EA 1997121800238 19971218 00238 CE 1997 12 18 AU970356 1 19970316 G 2731 12600741 ACTUATOR 12600741 CESSNA 182 182Q 2072732 CE MCAULY 2A34C 2A34C203 GL ELEV TAB CONTROL SEIZED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ELEVATOR TRIM TAB ACTUATOR SEIZED - INVESTIGATION FOUND THE ACTUATOR JACK SCREW TO BE CORRODED (RUSTY) OVER THE EN TIRE LENGTH WITH NO EVIDENCE OF LUBRICATION - CAUSED BY A COMBINATION OF HIGH PRESSURE WASHES REMOVING GREASE FROM THE J ACK AND OPERATIONS IN A COASTAL ENVIRONMENT 1 H 7 1 3O NT 3A13 5 C P3EA 1997121800239 19971218 00239 CE 1997 12 18 AU970357 1 19970409 G 5210 20394254013 HOOK 2039 CESSNA 441 441 2076020 CE HARTZL HCB3T HCB3TN5 GL PASS/CREW DOOR BROKEN W K NONE O J D OTHER WARNING INDICATION INFLIGHT SEPARATION CL CLIMB 1 AU S (AUS) LARGE CABIN DOOR TOP LOCKING HOOK FAILED 1 L 7 2 3T RT A28CE 6 C P15EA 1997121800240 19971218 00240 SO 1997 12 18 AU970358 2 19970414 G 8520 63026143 ROLLER CONT COUNTERWEIGH CONT O360 IO360HB 17025 SO HARTZL HCC2Y BHCC2YF1 GL RECIP ENG SHAFT WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 353396 (AUS) CRANKSHAFT COUNTERWEIGHT ROLLERS WORN UNEVENLY 3 O E1CE 5 C P920 1997121800241 19971218 00241 CE 1997 12 18 AU970359 1 19970315 G 3246 LM67010 BEARING LM67048 CESSNA 182 182Q 2072732 CE MCAULY 2A34C 2A34C203 GL WHEEL/SKI/FLOAT DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NOSE AND MAIN WHEEL BEARINGS SEIZED - ALL BEARINGS WERE DRY AND THE LITTLE GREASE REMAINING WAS ALSO HARD AND DRY - SUSPECT CAUSED BY USE OF HIGH PRESSURE WATER DURING PAINT STRIPPING 1 H 7 1 3O NT 3A13 5 C P3EA 1997121800242 19971218 00242 CE 1997 12 18 AU970360 1 19970404 G 2410 632436 NUT PRESTOLITE ALTERNATOR CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO MCAULY 3FF32 3FF32C501 GL DC GEN-ALT DRIVE BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 581 6L000106 292183R (AUS) ALTERNATOR DRIVE CLUTCH ASSEMBLY SEPARATED FROM ALTERNATOR DUE TO FAILURE OF THE SLOTTED HOLDING NUT - DAMAGE TO E NGINE GEARS AND CRANKCASE ASSEMBLY - METAL CONTAMINATION OF ENGINE 1 L 7 2 3O 3 O A7CE E7CE 5 C P45GL 1997121800243 19971218 00243 EU 1997 12 18 AU970361 1 19970408 G 3222 6846005 TUBE PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL NOSE/TAIL GEAR FRACTURED W K NONE W INADEQUATE Q C LD LANDING 1 AU S 432 (AUS) NOSE LANDING GEAR STRUT INNER TUBE FRACTURED APPROXIMATELY 203MM(8IN) FROM THE TOP- INNER TUBE APPEARS TO HAVE BEE N SILVERSOLDERED AROUND THE POINT OF FRACTURE BY UNKNOWN PERSONS -PERSONNEL/MAINTENANCE ERROR - UNAPPROVED REPAIR 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1997121800244 19971218 00244 NM 1997 12 18 AU970362 1 19970307 G 3320 65B115210 LIGHT BOEING 747 747338 NM PASS COMPART SMOKING W K NONE B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 AU S (AUS) CABIN SIDEWALL LIGHTING SYSTEM LIGHT TUBE TOMBSTONE LOCATED ATSEAT POSITION 30ABC SMOULDERING 2 L 7 2 4F RT A20WE 1997121800245 19971218 00245 NM 1997 12 18 AU970363 1 19970324 G 2550 CONTAINER BOEING 767 767338 NM CARGO COMPART LOOSE W K NONE W INADEQUATE Q C DE DESCENT 1 AU S (AUS) CARGO CONTAINERS (4OFF) IN AFT CARGO HOLD FORWARD OF THE CARGO HOLD DOOR WERE UNLOCKED ALLOWING MOVEMENT OF THE CO NTAINERS - INVESTIGATION FOUND LOCKS TO BE SERVICEABLE - FLOOR LOCKS AT POSITIONS 41L AND 41R WERE NOT RAISED - PERSONNE L/MAINTENANCE ERROR 2 L 7 2 4F RT A1NM 1997121800246 19971218 00246 1997 12 18 AU970364 4 19970330 G 2310 65B4051227 ANTENNA BOEING 747 747SP38 NM HF COMMUNICATION SEPARATED W K NONE D INFLIGHT SEPARATION CL CLIMB 1 AU S (AUS) LH HF ANTENNA BROKE OFF 2 L 7 4 4F RT A20WE 1997121800247 19971218 00247 NM 1997 12 18 AU970365 1 19970322 G 3244 TYRE BOEING 747 747438 NM MLG NR 9 SEPARATED W K NONE O OTHER TO TAKEOFF 1 AU S (AUS) RH BODY LANDING GEAR NO9 TYRE TREAD SEPARATED - INVESTIGATION FOUND THE CARCASS TO BE INTACT AND STILL INFLATED - MINOR DAMAGETO DOOR ROD AND FIRE DETECTION WIRE 2 L 7 4 4F RT A20WE 1997121800248 19971218 00248 NE 1997 12 18 AU970366 2 19970407 G 7261 781142 PIPE PWA JT9D7R4 PWA JT9 JT9D7R4D 52054 NE TURBINE ENG OIL WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 716931 (AUS) ENGINE MAIN OIL SUPPLY PIPE WORN THROUGH BY CHAFING ON `J' FLANGE BOLT HEADS 4 F E3NE 1997121800249 19971218 00249 NM 1997 12 18 AU970367 1 19970406 G 2560 342 COVER 7A112718 BOEING 747 747238B 1384828 NM ESCAPE SLIDE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 342 (AUS) RH NO3 MAIN ENTRY DOOR SLIDERAFT COVER MATERIAL TORN ALLOWING THE SLIDE PACK TO FALL FROM THE PACKBOARD - COVER MA TERIAL WAS IN POOR CONDITION WITH EVIDENCE OF MOULD ON THE SURFACES 2 L 7 4 4F A20WE 1997121800250 19971218 00250 CE 1997 12 18 AU970369 1 19970331 G 2460 9036102334 DEVICE BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA DC POWER DISTRIB FAULTY W K NONE J WARNING INDICATION CR CRUISE 1 AU S (AUS) HALL EFFECT DEVICE FOR BATTERY BUS TIE RELAY FAULTY 2 L 7 2 4T 4 T RT A24CE E4EA 1997121800251 19971218 00251 CE 1997 12 18 AU970370 1 19970315 G 5320 805030 CLIP 805031 BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE BULKHEAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CLIPS ATTACHING CHANNEL TO STRINGERS AT REAR PRESSURE BULKHEAD CRACKED ON LH SIDE - CLIP PNO 8050-30, PNO 8050-31, PNO 8050-32,PNO 8050-33 AND PN0 8050-36 1 L 7 2 4T 4 T A24CE E4EA 1997121800252 19971218 00252 GL 1997 12 18 AU970371 3 19970319 G 6111 BLADE MCAULY CESSNA 310 310Q 2074242 CE CONT O470 IO470V 17026 SO MCAULY 3AF32C 3AF32C87 GL PROPELLER BLADE FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 691 721730 149313VO 721730 (AUS) INCORRECT PROPELLER BLADES FITTED TO PROPELLER - BLADES FITTED ARE NOT THE BLADES LISTED IN THE LOG BOOK - REDUCED DIAMETER PROPELLER FITMENT NOT RECORDED - PROPELLER BLADE ANGLES VARIED BETWEEN BLADES - BLADE PROFILE INCORRECT - NO2 BLADE ACTUATING PIN DRILLING OUT OF TOLERANCE - PERSONNEL/MAINTENANCE ERROR 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 1998010500005 19980105 00005 NE 1998 1 5 AU970372 2 19970411 G 7230 COMPRESSOR LYC ALF502 ALF502H 41580 NE TURBINE ENG COMP VIBRATION W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S 7052 (AUS) ENGINE CONTINUED TO WINDMILL FOR APPROXIMATELY 30 MINUTES AFTER BEING SHUT DOWN FOR HIGH VIBRATIONS - SUSPECT VIBR ATIONS CAUSED BY ICE FORMATION ON THE FAN 4 F E6NE 1998010500006 19980105 00006 NE 1998 1 5 AU970373 2 19970413 G 7230 BEARING LYC ALF502 ALF502H 41580 NE TURBINE ENG COMP FAILED W K NONE O OTHER CR CRUISE 1 AU S 7051 (AUS) NO2 ENGINE NO2 BEARING SUSPECT FAILED - METAL CONTAMINATION OF OIL SYSTEM 4 F E6NE 1997121800253 19971218 00253 CE 1997 12 18 AU970374 1 19970407 G 2460 727725 CIRCUIT BREAKER BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO MCAULY 3AF34C 3AF34C502 GL DC POWER DISTRIB FAILED W K NONE O OTHER DE DESCENT 1 AU S (AUS) LANDING GEAR RELAY CIRCUIT BREAKER FAILED 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 1997121800254 19971218 00254 CE 1997 12 18 AU970375 1 19970416 G 5711 351100611 SPAR BEECH 33 E33 1151422 CE CONT O470 IO470K 17026 SO MCAULY 2A36C 2A36C23 GL WING SPAR STRUCT INCORRECT REPAIR W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) LH WING SPAR INCORRECTLY REPAIRED IN AREA BETWEEN STA 136.188 ANDSTA 148.875 - CORROSION HAD BEEN REMOVED FROM THE SPAR CAP TO A DEPTH OF 2.6162MM BY 50.8MM WIDE BY 26.9MM LONG (0.103IN DEEP BY2.0IN WIDE BY 1.060IN LONG) - REPAIR HAD BEEN CARRIED OUT THROUGH THICKNESS OF LEADING EDGE SKIN WITH RIVETS GROUND OFF - REPAIR WAS ALSO POORLY FINISHED OFF WIT H FILLER - REPAIR HAS NOT BEEN CARRIED OUT TO DIMENSIONS SPECIFIED IN ENGINEERING ORDER -PERSONNEL/MAINTENANCE ERROR 1 L 7 1 3O 3 O 3A15 3E1 5 C P880 1997121800255 19971218 00255 CE 1997 12 18 AU970376 1 19970414 G 2460 70243 LOOM CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL INST PANEL MIS ROUTED W K NONE O F OTHER FLT CONT AFFECTED IN INSP/MAINT 1 AU S 70243 (AUS) WIRING LOOM BEHIND INSTRUMENT PANEL INTERFERING WITH CORRECT OPERATION OF ELEVATOR CONTROL IN THE `FULL UP' POSITI ON - AILERON CHAIN TO AILERON CABLE ATTACHMENT LOCKING SPLIT PIN HAD ONE LEG BROKEN OFF AND DAMAGED INTERCOM WIRING 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 1997121800256 19971218 00256 EA 1997 12 18 AU970377 2 19970415 G 7313 INJECTOR LYC PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA FUEL INJECT NO 2 BLOCKED W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 AU S L520261A (AUS) NO2 FUEL INJECTOR NOZZLE PARTIALLY BLOCKED BY UNKNOWN FOREIGN MATTER 1 L 7 2 3O 3 O A20SO E14EA 1997121800257 19971218 00257 CE 1997 12 18 AU970378 1 19970325 G 2710 TURNBUCKLE CESSNA 441 441 2076020 CE HARTZL HCB3T HCB3TN5 GL AILERON CONTROL FOULED W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 AU S (AUS) LH REAR AILERON CABLE TURNBUCKLE BETWEEN LH REAR AILERON CABLE PNO 5815103-26 AND BELLCRANK PNO 5815114-1 INTERMIT TENTLY CATCHING ON FLOOR SUPPORT BRACKET 1 L 7 2 3T RT A28CE 6 C P15EA 1998010500007 19980105 00007 WP 1998 1 5 AU970379 2 19970418 G 7322 89711014 FCU CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL FUEL CONT MALFUNCTIONED W K NONE E M VIBRATION/BUFFET OVER TEMP DE DESCENT 1 AU S 3447 A727C P31378 (AUS) ENGINE FUEL CONTROL UNIT SUSPECT FAULTY - ENGINE SURGED AND EGT REACHED APPROXIMATELY 520 DEGREES C (OVERTEMP) - A N HOT END INSPECTION WAS CARRIED OUT WITH NO MAJOR DAMAGE FOUND 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 1997121800258 19971218 00258 EU 1997 12 18 AU970380 1 19970214 G 3244 769 TYRE BNORM BN2 BN2A8 1520209 EU LYC O540 O540E4C5 41532 EA HARTZL HCC2Y HCC2YK2 GL TIRE FAULTY W K NONE O OTHER LD LANDING 1 AU S 769 L2398840A A43934 (AUS) RH MAIN LANDING GEAR TYRE AND WHEEL UNSERVICEABLE. 1 H 7 2 3O 3 O A17EU E295 5 C P920 1997121800259 19971218 00259 1997 12 18 AU970381 4 19970220 G 3457 CI158C2 ANTENNA BEECH 36 A36 1151604 CE CONT O520 IO520BA 17032 SO MCAULY 2A36C 2A36C23 GL GLOBAL POSITION FAILED W K NONE O D OTHER INFLIGHT SEPARATION IN INSP/MAINT 1 AU S (AUS) GPS ANTENNA SHEARED OFF FLUSH WITH MOUNT BASE 1 L 7 1 3O 3 O 3A15 E5CE 5 C P880 1997121800260 19971218 00260 SO 1997 12 18 AU970382 2 19970414 G 8520 639292 SPLIT PIN CONT MOONEY M20 M20K 5870220 SW CONT O360 TSIO360G 17025 SO RECIP ENG MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S 101 309723 309723 (AUS) NO4 AND NO5 CONNECTING RODS BOTH HAD ONE MISSING SPLIT PIN. PIECES OF SPLIT PIN FOUND IN OIL SYSTEM AND UNDER OIL PRESSURE RELIEF VALVE. INVESTIGATION AND MEASUREMENTS FOUND THAT UNDER CERTAIN CIRCUMSTANCES THE SPLIT PIN CAN CONTACT T HE CYLINDER SKIRT. 1 L 7 1 3O 3 O 2A3 E9CE 1997121800261 19971218 00261 SW 1997 12 18 AU970383 1 19970107 G 5741 201751 ANGLE AIRTRC AT300 AT301 0390103 SW PWA R1340 R1340AN1 52016 NE HAMSTD 22D 22D40 NE WING ATTACH CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH INBOARD AND OUTBOARD WING ATTACHMENT ANGLES CRACKED IN THE AREA OF THE TOP RADIUS - CRACK LENGTHS 20MM TO 25MM BY 1MM DEEP (0.787IN TO 0.98IN BY 0.039IN DEEP) - CRACKING WAS FOUND WITH THE NAKED EYE AND CONFIRMED BY DYE PENETRANT 1 L 7 1 3R 3 R A9SW 5E2 5 C P736 1997121800262 19971218 00262 NM 1997 12 18 AU970384 1 19970407 G 3213 10100105 STRUT MESSIER DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE MLG FAULTY W K NONE O OTHER NR NOT REPORTED 1 AU S DCL03584 (AUS) RH MAIN LANDING GEAR SHOCK STRUT OVEREXTENDED CAUSING TORQUE LINKS TO OVERCENTRE - SUSPECT CAUSED BY FAILURE OF OL EO EXTENSION STOPS OR DAMPER RING 2 H 7 2 4T 4 T RT A13NM E20NE 1997121800263 19971218 00263 CE 1997 12 18 AU970385 1 19970227 G 2822 2B729 PUMP CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO MCAULY 3FF32 3FF32C501 GL FUEL BOOST PUMP FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 22 (AUS) ELECTRICAL BOOST PUMP FAULTY - INVESTIGATION FOUND CHIPPED VANE WHICH CAUSED IMPELLER UNBALANCE AND WEAR TO THE VA NES AND PUMP CAVITY 1 L 7 2 3O 3 O A7CE E7CE 5 C P45GL 1997121800264 19971218 00264 CE 1997 12 18 AU970386 1 19970415 G 7330 580010729 LINE CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL ENG FUEL IND FRACTURED W K NONE O OTHER TO TAKEOFF 1 AU S (AUS) LH ENGINE TURBOCHARGER PRESSURE DISCHARGE SENSE LINE FRACTURED AT END FITTING 1 L 7 2 3O 3 O A25CE E7CE 5 C P45GL 1997121800265 19971218 00265 CE 1997 12 18 AU970387 1 19970409 G 2913 M710501 MOTOR BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE MCAULY 4HFR34 4HFR34C754 NE HYDRAULIC PUMP SHORTED W K NONE O OTHER DE DESCENT 1 AU S 293 (AUS) HYDRAULIC POWER PACK ELECTRIC MOTOR COMMUTATOR SHORT CIRCUITED 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 1997121800266 19971218 00266 SO 1997 12 18 AU970388 1 19970224 G 2823 755837 O-RING SCOTT 492189 PIPER PA34 PA34200T 7103406 SO HARTZL HCC2Y BHCC2YF2 GL FUEL SELECTOR DETERIORATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH FUEL SELECTOR VALVES HAD DETERIORATED SPOOL VALVE `O' RING SEALS 1 L 7 2 3O A7SO 5 C P920 1997121800267 19971218 00267 CE 1997 12 18 AU970389 1 19970307 G 5751 122005212 HINGE CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO MCAULY 3A32C D3A32C90 GL AIL STRUCTURE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH AILERON HINGE ATTACHMENT ANGLE CRACKED FROM BOTTOM RELIEF NOTCH - CRACK LENGTH APPROXIMATELY 6.35MM (0.25IN) 1 H 7 1 3O 3 O A4CE E5CE 5 C P21EA 1997121800268 19971218 00268 1997 12 18 AU970390 4 19970305 G 2565 1747 SLIDE BOEING 737 737376 NM ESCAPE SLIDE FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 1747 (AUS) DOOR 2R ESCAPE SLIDE GROUND MAINTENANCE SAFETY PIN FOUND INSTALLED IN ACTUATION MECHANISM - PERSONNEL/MAINTENANCE ERROR 2 L 7 2 4F RT A16WE 1998010500008 19980105 00008 EU 1998 1 5 AU970391 1 19970418 G 5610 115G260024 GUIDE GROB G115 G115C 1660303 EU LYC O360 O360A1F6 41514 EA HARTZL HCF2Y HCF2YR1 GL FLIGHT COMPART DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CANOPY RH AFT GUIDE BLOCK SPLIT 1 L 7 1 3O 3 O NT A57EU E286 5 C P27EA 1997121800269 19971218 00269 SO 1997 12 18 AU970392 2 19970224 G 8520 652541 NUT CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO MCAULY D3A34 D3A34C401 GL RECIP ENG CYL CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 284172R (AUS) NO6 CYLINDER LOWER FORWARD THROUGH BOLT NUT CRACKED DUE TO CADMIUM EMBRITTLEMENT 1 H 7 1 3O 3 O 3A24 E5CE 5 C P47GL 1997121800270 19971218 00270 EU 1997 12 18 AU970393 2 19970330 G 7310 580 VALVE CFMINT CFM56 CFM563C 13802 EU ENGINE FUEL DIST FAULTY W K NONE O OTHER NR NOT REPORTED 1 AU S 9287 580 (AUS) NO1 ENGINE FUEL VALVE REMAINED CLOSED WITH THE START LEVER AT IDLE - INVESTIGATION FOUND FUEL VALVE ACTUATOR BRUSH ES WORN WITH SOME CARBON AND SWARF IN THE BRUSH AREA 4 F E21EU 1997121800271 19971218 00271 SW 1997 12 18 AU970394 1 19970417 G 5311 310032509 FRAME GULSTM 500 500S 0141107 SW LYC O540 IO540E1B5 41532 EA FUSELAGE MAIN FR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH FUSELAGE FRAME CRACKED - FOUND DURING INSPECTION IAW AD/AC/93 1 H 7 2 3O 3 O 6A1 1E4 1997121800272 19971218 00272 SW 1997 12 18 AU970395 1 19970417 G 5730 17004569 SKIN 170045321 GULSTM 500 500S 0141107 SW LYC O540 IO540E1B5 41532 EA WING PLATES/SKIN CRACKED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 809 (AUS) LH WING LOWER SKINS PNO170045-69 AND PNO 170045-321 CRACKED IN AREA OF CUTOUTS - INVESTIGATION FOUND THAT WING SKI NS FITTED ON 25/2/96 HAD BEEN MACHINED BEYOND LIMITS BEFORE FITMENT - FOUND DURING INSPECTION IAW AD/AC/92 - PERSONNEL/M AINTENANCE ERROR 1 H 7 2 3O 3 O 6A1 1E4 1998010500009 19980105 00009 EU 1998 1 5 AU970396 1 19970103 G 2700 NO11492NO21 COMPUTER AIRBUS 320 A320212 EU FLIGHT CONTROLS FAULTY W K NONE F FLT CONT AFFECTED CL CLIMB 1 AU S NO11492NO21 (AUS) NO1 AND NO2 ELAC (ELEVATOR/AILERON COMPUTER) FAULTY - WORKSHOP TESTING FOUND FAULTS WITH BOTH COMPUTERS BUT COULD NOT CONFIRM THAT THE FAULTS CONTRIBUTED TO THE FAILURES 2 L 7 2 4F RT A28NM 1997121800273 19971218 00273 SW 1997 12 18 AU970397 1 19970217 G 6310 212040176101 BOOT BELL DRIVESHAFT BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE ENGINE/TRANS DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 42002410 (AUS) ENGINE TO TRANSMISSION DRIVESHAFT BOOT ASSEMBLY FAILED FOR APPROXIMATELY 50% OF CIRCUMFERENCE 1 G 7 2 4U 4 U H4SW E22EA 1997121800274 19971218 00274 GL 1997 12 18 AU970398 3 19970401 G 6111 IA101 BLADE CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL PROPELLER BLADE FAILED W K NONE E D VIBRATION/BUFFET INFLIGHT SEPARATION CR CRUISE 1 AU S G10202 (AUS) SECTION OF PROPELLER BLADE SEPARATED - APPROXIMATELY 279.4MM(11IN) OF BLADE TIP SEPARATED - AIRCRAFT IS USED FOR C ATTLE MUSTERING FROM UNSEALED STRIPS - EVIDENCE OF STONE DAMAGE ON BLADES 1 H 7 1 3O 3 O 3A19 E252 5 N P918 1997121800275 19971218 00275 SO 1997 12 18 AU970399 1 19970407 G 5711 6205401 SPAR PIPER PA28 PA28140 7102802 SO WING SPAR STRUCT CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH WING REAR SPAR CORRODED IN ROOT AREA BENEATH STEEL ATTACHMENT BRACKET 1 L 7 1 3O 2A13 1997121800276 19971218 00276 EU 1997 12 18 AU970400 1 19970214 G 5343 769 DOUBLER BNORM BN2 BN2A8 1520209 EU LYC O540 O540E4C5 41532 EA HARTZL HCC2Y HCC2YK2 GL LANDING GEAR ATT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 769 L2398840A A43934 (AUS) LH AND RH MAIN LANDING GEAR UPPER LEG SUPPORT REAR DOUBLERS CRACKED. SEE MDR 97/0380 FOR ADDITIONAL INFORMATION 1 H 7 2 3O 3 O A17EU E295 5 C P920 1997121800277 19971218 00277 EU 1997 12 18 AU970401 1 19970214 G 5500 769 BEARING BNORM BN2 BN2A8 1520209 EU LYC O540 O540E4C5 41532 EA HARTZL HCC2Y HCC2YK2 GL EMPENNAGE STRUCT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 769 L2398840A A43934 (AUS) FLIGHT CONTROL BEARINGS AND HINGES UNSERVICEABLE. SEE MDR 97/0380 FOR ADDITIONAL INFORMATION 1 H 7 2 3O 3 O A17EU E295 5 C P920 1997121800278 19971218 00278 SO 1997 12 18 AU970402 1 19970407 G 5342 6264504 BRACKET PIPER PA28 PA28140 7102802 SO STAB ATTACH CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) STABILISER FITTING BRACKET CORRODED BETWEEN BRACKET AND SKIN 1 L 7 1 3O 2A13 1997121800279 19971218 00279 EU 1997 12 18 AU970403 1 19970214 G 5753 769 FLAP BNORM BN2 BN2A8 1520209 EU LYC O540 O540E4C5 41532 EA HARTZL HCC2Y HCC2YK2 GL TE FLAP STRUCTUR DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 769 L2398840A A43934 (AUS) FLAPS IN NEED OF MAJOR REPAIR. SEE MDR 97/0380 FOR ADDITIONAL INFORMATION 1 H 7 2 3O 3 O A17EU E295 5 C P920 1997121800280 19971218 00280 EU 1997 12 18 AU970404 1 19970214 G 5751 769 AILERON BNORM BN2 BN2A8 1520209 EU LYC O540 O540E4C5 41532 EA HARTZL HCC2Y HCC2YK2 GL AILERON STRUCTUR DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 769 L2398840A A43934 (AUS) AILERON IN NEED OF MAJOR REPAIR. SEE MDR 97/0380 FOR ADDITIONAL INFORMATION 1 H 7 2 3O 3 O A17EU E295 5 C P920 1997121800281 19971218 00281 EU 1997 12 18 AU970405 1 19970214 G 5520 769 ELEVATOR BNORM BN2 BN2A8 1520209 EU LYC O540 O540E4C5 41532 EA HARTZL HCC2Y HCC2YK2 GL ELEV STRUCTURE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 769 L2398840A A43934 (AUS) LH ELEVATOR CRACKED. SEE MDR 97/0380 FOR ADDITIONAL INFORMATION 1 H 7 2 3O 3 O A17EU E295 5 C P920 1997121800282 19971218 00282 EU 1997 12 18 AU970406 1 19970214 G 5310 769 STRUCTURE BNORM BN2 BN2A8 1520209 EU LYC O540 O540E4C5 41532 EA HARTZL HCC2Y HCC2YK2 GL FUSELAGE STRUCTU CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 769 L2398840A A43934 (AUS) AIRCRAFT STRUCTURE CONTAINED LARGE AMOUNTS OF CORROSION. FOUND DURING UNSCHEDULED INSPECTION IAW AD/BN-2/53. SEE M DR 97/0380 FOR ADDITIONAL INFORMATION 1 H 7 2 3O 3 O A17EU E295 5 C P920 1997121800283 19971218 00283 SO 1997 12 18 AU970407 1 19970407 G 5342 6245100 FITTING PIPER PA28 PA28140 7102802 SO STAB ATTACH CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD FIN ATTACHMENT PLATE BRACKETS CORRODED - TWO OF THE FIVE PLATE ATTACHMENT RIVETS WERE ALSO CORRODED AWAY 1 L 7 1 3O 2A13 1997121800284 19971218 00284 CE 1997 12 18 AU970408 1 19970422 G 5743 951100206 ADAPTER BEECH 951100206 BEECH 60 60 1153602 CE LYC O541 TIO541E1C4 41536 EA HARTZL HCF3Y HCF3YR2 GL WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S NSN (AUS) LANDING GEAR ATTACHMENT BRACKET CRACKED 1 L 7 2 3O 3 O A12CE E10EA 5 C P31EA 1997121800285 19971218 00285 EA 1997 12 18 AU970409 2 19970407 G 8520 L4926027A CRANKCASE LYC PIPER PA18 PA18150 7101828 SO LYC O320 O320B2B 41508 EA SNSNCH 74DM M74DM EA RECIP ENG CASE WORN W K NONE O OTHER IN INSP/MAINT 1 AU S L4926027A L4926027A (AUS) ENGINE CRANKCASE TUNNEL OUT OF LIMITS - CAMSHAFT LOBES WORN 1 H 7 1 3O 3 O 1A2 E274 5 N P88614 1997121800286 19971218 00286 NE 1997 12 18 AU970410 2 19970404 G 7250 2121100R73 NOZZLE BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE TURBINE SECTION DAMAGED W A K NONE E VIBRATION/BUFFET NR NOT REPORTED 1 AU S 5981 LF05505A (AUS) NO3 ENGINE SECOND STAGE TURBINE BLADES (3OFF) HAD APPROXIMATELY ONE THIRD OF THE BLADE MISSING AND THREE MORE BLAD ES WITH APPROXIMATELY ONE QUARTER OF THE BLADE MISSING - INVESTIGATION FOUND THAT THE SECOND STAGE TURBINE NOZZLE REAR I NNER SHROUD WAS CRACKED ALLOWING THE SHROUD TO RUB ON THE SECOND STAGE TURBINE DISC 2 H 7 4 4F 4 F A49EU E6NE 1997121800287 19971218 00287 NM 1997 12 18 AU970411 1 19970408 G 2520 SEAT BOEING 737 737377 NM PASS COMPART WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) SEATS 8A AND 8G BLOCKING OFF EMERGENCY EXIT WHEN IN UPRIGHT POSITION DUE TO WEAR 2 L 7 2 4F RT A16WE 1997121800288 19971218 00288 NM 1997 12 18 AU970412 1 19970119 G 7722 EGT SYSTEM BOEING 737 737377 NM CFMINT CFM56 CFM563B2 13802 EU ENG. EGT/TIT IND FAULTY W K NONE O OTHER DE DESCENT 1 AU S (AUS) NO2 ENGINE TGT INDICATIONS ABOVE 1000 DEGREES ON TWO OCCASIONS BEFORE FALLING TO ZERO DEGREES - INTERFACE AND LOWE R ELECTRICAL COUPLING AS WELL AS INDICATOR WERE CHANGED - INVESTIGATION OF INDICATION SYSTEM COULD FIND NO FAULTS 2 L 7 2 4F 4 F RT A16WE E21EU 1997121800289 19971218 00289 NM 1997 12 18 AU970413 1 19970125 G 7722 EGT SYSTEM BOEING 737 737377 NM CFMINT CFM56 CFM563B2 13802 EU ENG. EGT/TIT IND FAULTY W K NONE O OTHER TO TAKEOFF 1 AU S (AUS) NO2 ENGINE EGT SYSTEM FAULTY 2 L 7 2 4F 4 F RT A16WE E21EU 1997121800290 19971218 00290 SO 1997 12 18 AU970414 1 19970421 G 2822 2C2720H PUMP EMB 110 EMB110P2 3260124 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL FUEL BOOST PUMP FAILED W K NONE K FLUID LOSS CR CRUISE 1 AU S 2AB10 (AUS) LH MAIN FUEL BOOST PUMP FAILED 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 1997121800291 19971218 00291 NE 1997 12 18 AU970415 2 19970326 G 7260 408218016 GEAR LYC BELL 222 222U 1182140 SW LYC LTS101 LTS101750C1 41560 NE TURB ENG ASSORY FAILED W K NONE E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 AU S W83K001 LE47028 (AUS) NO1 ENGINE ACCESSORY GEARBOX MODULE TORQUEMETER GEAR ASSEMBLY DAMAGED - GEAR HAD SHEARED THE HEAD OFF ONE OF THE E IGHT BOLTS USED TO HOLD THE ASSEMBLY TOGETHER - TORQUEMETER PISTON HAD WORN A GROOVE IN THE HOUSING - METAL CONTAMINATIO N OF ENGINE OIL SYSTEM 1 G 7 2 3U 3 U H9SW E5NE 1997121800292 19971218 00292 SO 1997 12 18 AU970417 2 19970221 G 8530 CYLINDER CONT BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO MCAULY 2AF34C 2AF34C55 GL RECIP ENG GLAZED W K NONE O OTHER CR CRUISE 1 AU S (AUS) ENGINE CYLINDERS GLAZED - VALVE GUIDES WORN - NO2 CYLINDER ALSO CONTAINED A BROKEN OIL CONTROL RING - AIRCRAFT HAD NOT BEEN OPERATATED FOR SEVERAL YEARS AND IT IS SUSPECTED THAT THE ENGINES HAD NOT BEEN INHIBITED IN ANY WAY 1 L 7 2 3O 3 O RT 3A16 3E1 5 C P5EA 1997121800293 19971218 00293 SO 1997 12 18 AU970418 2 19970410 G 8520 112536R CRANKSHAFT CONT CESSNA 206 P206B 2073309 CE CONT O520 IO520A 17032 SO MCAULY 3A32C D3A32C88 GL RECIP ENG SHAFT FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 112536R 112536R 725001 (AUS) ENGINE CRANKSHAFT FAILED FROM CRACKING AT THE REAR FILLET RADIUS OF NO2 MAIN BEARING JOURNAL DUE TO FRICTION FROM CONTACT WITH THE BEARING SHELLS 1 H 7 1 3O 3 O A4CE E5CE 5 C P21EA 1997121800294 19971218 00294 SO 1997 12 18 AU970419 1 19970415 G 3230 4085400 PIPE PIPER PA31 PA31350 7103110 SO HARTZL HCE3Y HCE3YR2 GL GEAR RETRACT CRACKED W K NONE O K OTHER FLUID LOSS LD LANDING 1 AU S (AUS) LANDING GEAR HYDRAULIC PRESSURE PIPE FRACTURED AROUND FLARE 1 L 7 2 3O A20SO 5 C P33EA 1997121800295 19971218 00295 CE 1997 12 18 AU970420 1 19970409 G 3260 20700291 SWITCH CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA MCAULY 2D34C B2D34C207 GL GEAR POSITION FAULTY W K NONE O N OTHER FALSE WARNING DE DESCENT 1 AU S (AUS) NOSE LANDING GEAR DOWN MICROSWITCH WIRE BROKEN OFF 1 H 7 1 3O 3 O A20CE 1E10 5 C P7EA 1997121800296 19971218 00296 NM 1997 12 18 AU970421 1 19970412 G 4920 38420722 TURBINE GARRTT GTCP85 BOEING 737 737376 NM APU CORE ENGINE FAILED W A K H NONE DEACTIVATE SYST/CIRCUITS E VIBRATION/BUFFET NR NOT REPORTED 1 AU S 3257 P115 (AUS) APU FAILED - DEBRIS EXITING FROM EXHAUST - INVESTIGATION FOUNDTHAT THE TURBINE WHEEL AND SHAFT ASSEMBLY FAILED AND HUB SEPARATED DUE TO `HAFNIUM INCLUSION' 2 L 7 2 4F RT A16WE 1997121800297 19971218 00297 NM 1997 12 18 AU970422 1 19970416 G 2782 1360 ACTUATOR BOEING 737 737476 NM LE FLAP ACTUATOR FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 1360 (AUS) NO5 LEADING EDGE SLAT ACTUATOR EYE END BROKEN - SUSPECT CAUSED BY CORROSION PITTING 2 L 7 2 4F RT A16WE 1997121800298 19971218 00298 NM 1997 12 18 AU970423 1 19970120 G 5610 WINDOW BOEING 747 747312 1384932 NM FLIGHT COMPART CRACKED W K NONE O OTHER CR CRUISE 1 AU S (AUS) COCKPIT WINDOW R3 LOCATED BEHIND FIRST OFFICER DELAMINATED AND THEN CRACKED 2 L 7 4 4F RT A20WE 1998010500010 19980105 00010 NE 1998 1 5 AU970424 2 19970317 G 7230 DIFFUSER BOEING 747 747312 1384932 NM PWA JT9 JT9D7R4G2 52054 NE TURB ENG COMP CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S P715107 (AUS) NO1 ENGINE NO6 MOUNTING BOSS LOCATED ON THE DIFFUSER CASE CRACKED ON RH SIDE. CRACK LENGTH 4.762MM (0.1875IN). FOU ND DURING EDDY CURRENT INSPECTION. 2 L 7 4 4F 4 F RT A20WE E3NE 1997121800299 19971218 00299 NM 1997 12 18 AU970425 1 19970318 G 5330 SKIN BOEING 747 747312 1384932 NM FUSELAGE MAIN PL DEBONDED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) SECTION 41 RHS SKIN PANELS DEBONDING IN TWO AREAS. 2 L 7 4 4F RT A20WE 1998010700002 19980107 00002 NE 1998 1 7 AU970426 2 19970319 G 7250 BLADE BOEING 747 747312 1384932 NM PWA JT9 JT9D7R4G2 52054 NE TURBINE SECTION FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S P715154 (AUS) NO3 ENGINE FIRST STAGE TURBINE BLADE BROKEN AT MID SPAN. INVESTIGATION FOUND 30% OF BLADES HAD BULLSEYE EROSION ON THE CONCAVE SIDE. FOUND DURING BOROSCOPE INSPECTION. 2 L 7 4 4F 4 F RT A20WE E3NE 1997121800300 19971218 00300 CE 1997 12 18 AU970428 1 19970426 G 3260 S21121 STRIKER CESSNA 310 310L 2074230 CE CONT O470 IO470U 17026 SO MCAULY 2AF34C D2AF34C81 GL GEAR POSITION CRACKED W K NONE O N OTHER FALSE WARNING LD LANDING 1 AU S (AUS) RH MAIN LANDING GEAR MICROSWITCH STRIKER ARM CRACKED AND SEPARATED FROM SWITCH 1 L 7 2 3O 3 O 3A10 3E1 5 C P5EA 1997121800301 19971218 00301 1997 12 18 AU970429 4 19970421 G 2561 51001 VALVE EAAEROMARINE LIFEJACKET LIFE JACKET CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 4228342244 (AUS) LIFEJACKET MANIFOLD VALVE CRACKED. FOUND DURING PRESSURE TESTING. THE LIFEJACKET WAS MANUFACTURED IN 1989. 1997121800302 19971218 00302 NM 1997 12 18 AU970430 1 19970316 G 5102 MANIFOLD RAVEN RX7 RX7 7480503 NM BALLOON REPORTS BROKEN W K NONE K FLUID LOSS TO TAKEOFF 1 AU S 126 (AUS) BALLOON PROPANE GAS TANK MANIFOLD FAILED AT BRASS NIPPLE - LOSS OF PROPANE GAS INTO ATMOSPHERE (POTENTIAL FIRE/EXP LOSION HAZARD)- CAUSED BY EXTENSION OF FITTING AND ADDITION OF QUICK DISCONNECT COUPLING OUTSIDE THE COWL OF THE LP GAS CYLINDER PLACING A LOAD ON THE FITTING - PERSONNEL/MAINTENANCE ERROR 1 B 0 6 O O A15CE 1997121800303 19971218 00303 NE 1997 12 18 AU970433 2 19970423 G 7260 GEARBOX AYRES S2 S2RT34NORMAL 0970106 SO PWA PT6 PT6A34AG 52053 NE HARTZL HCB3T HCB3TN3 GL TURB ENG ASSORY MAKING METAL W K NONE O OTHER LD LANDING 1 AU S PCE56012 (AUS) ENGINE ACCESSORY GEARBOX CONTAMINATED WITH WHITE METAL SLIVERS 1 L 7 1 3T 4 T A3SW E4EA 6 C P15EA 1997121800304 19971218 00304 CE 1997 12 18 AU970434 1 19970428 G 5730 SKIN CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL WING PLATES/SKIN MIS REPAIR W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) AIRCRAFT HAS EVIDENCE OF WING SKIN REPLACEMENT AS WELL AS DISASSEMBLY OF AILERONS, FLAPS, TAILPLANE AND HORIZONTAL STABILISER - REPAIR WORK IS OF SUB-STANDARD QUALITY - NO EVIDENCE OF REPAIR WORK IN LOG BOOK - PERSONNEL/MAINTENANCE ER ROR -UNAPPROVED REPAIR 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 1997121800305 19971218 00305 EA 1997 12 18 AU970436 2 19970410 G 8530 LW16740 VALVE LYC O320H2AD LYC O320 O320H2AD 41508 EA RECIP ENG EXH UNAPPROVED PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) WHEN FITTING A NEW CYLINDER KIT TO THE ENGINE IT WAS FOUND THAT THE INCORRECT EXHAUST VALVE WAS FITTED TO THE CYLI NDER - EXHAUST VALVE PNO LW16740 (ANGLE VALVE CYLINDER) WAS FITTED INSTEAD OFTHE CORRECT PNO LW19001 - PERSONNEL/MAINTEN ANCE ERROR - UNAPPROVED PART 3 O E274 1997121800306 19971218 00306 SO 1997 12 18 AU970437 2 19970422 G 8540 239168R GEAR CONT CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL RECIP ENG DAMAGED W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 AU S 239168R 239168R (AUS) ENGINE STARTER ADAPTER GEAR TEETH MISSING - CRANKCASE GEAR AND CAMSHAFT CLUSTER GEAR TEETH ALSO MISSING - DAMAGE A LSO TO LH AND RH MAGNETO ADAPTER PLATES AND LH AND RH MAGNETO DRIVE GEARS 1 L 7 2 3O 3 O A25CE E7CE 5 C P45GL 1997121800307 19971218 00307 SO 1997 12 18 AU970438 1 19970418 G 2913 OAS29303 POWER PACK OZONE OAS29303 PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA HYDRAULIC PUMP FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 634 (AUS) HYDRAULIC POWER PACK FAULTY - SUSPECT INTERNAL LEAK 1 L 7 2 3O 3 O A20SO E14EA 1997121800308 19971218 00308 EA 1997 12 18 AU970439 2 19970424 G 7414 D4RN3000 MAGNETO BENDIX CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL MAGNETO/DISTRIBU FAILED W K NONE E R Y VIBRATION/BUFFET PARTIAL RPM/PWR LOSS ENGINE STOPPAGE CR CRUISE 1 AU S 86080151 L823176 (AUS) MAGNETO FAILED 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 1997121800309 19971218 00309 WP 1997 12 18 AU970440 2 19970425 G 7322 8974575 VALVE GARRTT FRCHLD SA227 SA227DC 3377521 SW GARRTT TPE331 TPE33112UA 01514 WP MCAULY 4HFR34 4HFR34C652 NE FUEL CONTROL FAULTY W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S 607 88082651879 P70208 940963 (AUS) LH ENGINE TEMPERATURE LIMITER BYPASS VALVE FAULTY 2 L 7 2 4T 4 T RT A18SW E4WE 6 C 3PNE 1997121800310 19971218 00310 SO 1997 12 18 AU970441 2 19970407 G 8530 350027 CYLINDER CONT CESSNA 337 337F 2075725 CE CONT O360 IO360C 17025 SO MCAULY 2AF34C D2AF34C306 GL RECIP ENG CYL CRACKED W K NONE O E K OTHER VIBRATION/BUFFET FLUID LOSS IN INSP/MAINT 1 AU S 350027 350027 (AUS) NO4 CYLINDER CRACKED IN AREA BEHIND ROCKER COVERS - OIL LEAK 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 1997121800768 19971218 00768 SO 1997 12 18 AU970442 2 19970407 G 8520 6419441048 BOLT CONT CESSNA 337 337F 2075725 CE CONT O360 IO360C 17025 SO MCAULY 2AF34C D2AF34C306 GL RECIP ENG CASE BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 350027 350027 (AUS) ENGINE CRANKCASE THROUGH BOLTS (2OFF) SHEARED - TWO OPPOSITE SIDE THROUGH BOLTS LOOSE 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 1997121800769 19971218 00769 EA 1997 12 18 AU970443 2 19970428 G 8530 VALVE LYC PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA HARTZL HCE3Y HCE3YR2 GL ENG EXH NR 1 FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S L83868A (AUS) RH ENGINE NO1 CYLINDER EXHAUST VALVE FAILED - DAMAGE CAUSED TO PISTON AND CYLINDER HEAD - PART OF VALVE ALSO PASSE D THROUGH THETURBOCHARGER TURBINE - NO3 CYLINDER EXHAUST VALVE ALSO CRACKED 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1997121800770 19971218 00770 NE 1997 12 18 AU970444 2 19970414 G 7210 CP6B1208 BEARING PWA BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE ENG RED GR BOX SPALLED W K NONE E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 AU S CP6B1208 162009262180 (AUS) ENGINE REDUCTION GEARBOX HAD EXCESSIVE METAL CONTAMINATION - CHIP DETECTOR LIGHT ILLUMINATED - INVESTIGATION FOUND LH AND RH NO10 BEARINGS SPALLED 1 G 7 2 4U 4 U H4SW E22EA 1998010500022 19980105 00022 WP 1998 1 5 AU970445 2 19970429 G 7320 8974768 COMPENSATOR CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL ENG EGT LOOSE W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 AU S P31374C (AUS) LH ENGINE EGT COMPENSATOR CONNECTOR PLUG LOOSE AND CORRODED 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 1997121800771 19971218 00771 SO 1997 12 18 AU970446 1 19970219 G 2434 SUPPRESSOR PIPER PA28 PA28RT201 7102818 SO LYC O360 IO360C1C6 41514 EA MCAULY 2D34C 2D34C215 GL DC GENERATOR-ALT SEPARATED W K NONE H ELECT. POWER LOSS-50 PC CR CRUISE 1 AU S (AUS) ALTERNATOR SUPPRESSOR SEPARATED FROM ALTERNATOR - SUPPRESSOR CONNECTING WIRE SHORT CIRCUITING ON EXHAUST SYSTEM CA USING FAILURE OF VOLTAGE REGULATOR 1 L 7 1 3O 3 O 2A13 1E10 5 C P7EA 1997121800772 19971218 00772 SO 1997 12 18 AU970447 1 19970502 G 5711 20207T901 SPAR CAP AYRES S2 S2RT34NORMAL 0970106 SO PWA PT6 PT6A34AG 52053 NE HARTZL HCB3T HCB3TN3 GL WING SPAR STRUCT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING LOWER SPAR CAP CRACKED THROUGH SPLICE HOLE - CRACK LENGTH APPROXIMATELY 31.75MM (1.25IN) - FOUND DURING MAGNE TIC PARTICLE INSPECTION IAW SB-AG-39 1 L 7 1 3T 4 T A3SW E4EA 6 C P15EA 1997121800773 19971218 00773 1997 12 18 AU970448 4 19970502 G 3416 BG3E ALTIMETER CESSNA 206 U206A 2073316 CE CONT O520 IO520F 17032 SO MCAULY 3A32C D3A32C90 GL COCKPIT ERROR W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ALTIMETER OT OF CALIBRATION - AT 5000FT THERE WAS A 500FT ERROR - AT 6000FT THERE WAS A 700FT ERROR - ALTIMETER IS OF CHINESE MANUFACTURE - FOUND DURING INSPECTION IAW AD/INST/8 AMDT3 1 H 7 1 3O 3 O A4CE E5CE 5 C P21EA 1997121800774 19971218 00774 CE 1997 12 18 AU970449 1 19970429 G 2435 96150 BEARING LUCAS BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA STARTER-GEN FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 96150 (AUS) LH ENGINE STARTER GENERATOR DRIVE BEARING FAILED 2 L 7 2 4T 4 T RT A24CE E4EA 1997121800775 19971218 00775 SO 1997 12 18 AU970450 1 19970418 G 7602 CABLE PIPER PA28 PA28R201T 7102813 SO CONT O360 TSIO360F 17025 SO HARTZL HCC2Y BHCC2YF2 GL MIXTURE CONTROL STUCK W K NONE O OTHER CR CRUISE 1 AU S (AUS) MIXTURE CONTROL CABLE STUCK - CABLE RUNS ADJACENT TO TURBOCHARGER - THROTTLE CABLE AND PROPELLER CONTROL CABLES AL SO RUN ADJACENT TO THE TURBOCHARGER 1 L 7 1 3O 3 O 2A13 E9CE 5 C P920 1997121800776 19971218 00776 1997 12 18 AU970451 4 19970428 G 6113 65805200 SPINNER PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA SNSNCH 76E 76EM8 EA PROP SPINNER MISSING W K NONE D INFLIGHT SEPARATION NR NOT REPORTED 1 AU S (AUS) PROPELLER SPINNER DOME SEPARATED - SPINNER RETAINING SCREWS WERE INTACT - SPINNER DOME IS OF FIBREGLASS CONSTRUCTI ON 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 1997121800777 19971218 00777 NM 1997 12 18 AU970452 1 19970417 G 2150 78279010 AIRCYCLE MACHINE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE CABIN COOLING SY FAILED W K NONE O OTHER CR CRUISE 1 AU S 921268 (AUS) AIR CONDITIONING SYSTEM AIR CYCLE MACHINE FAULTY 2 H 7 2 4T 4 T RT A13NM E20NE 1997121800778 19971218 00778 NM 1997 12 18 AU970453 1 19970228 G 5310 FUSELAGE BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE FUSELAGE STRUCT CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE CONTAINED LEVEL 2 CORROSION. FOUND DURING INSPECTION 2 L 7 3 4F 4 F RT A3WE E2EA 1997121800779 19971218 00779 NM 1997 12 18 AU970454 1 19970228 G 5310 FUSELAGE BOEING 737 73733A 1384673 NM FUSELAGE STRUCT CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LEVEL 2 CORROSION FOUND DURING INSPECTION 2 L 7 2 4F RT A16WE 1997121800780 19971218 00780 NM 1997 12 18 AU970455 1 19970228 G 5310 FUSELAGE BOEING 767 767277 NM GE CF6 CF680A 30025 NE FUSELAGE STRUCT CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE CONTAINED LEVEL 2 CORROSION - FOUND DURING INSPECTION 2 L 7 2 4F 4 F RT A1NM E13NE 1997121800781 19971218 00781 GL 1997 12 18 AU970456 1 19970418 G 5720 WINGLET AMTR LNCAIR 320LANCAIR 056129G GL WING MISC COLLAPSED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WINGLET INNER CORE COLLAPSED - AIRCRAFT IS AMATEUR BUILT 1 L 7 1 3O RT EXPA1L71 1997121800782 19971218 00782 SO 1997 12 18 AU970457 1 19970501 G 5512 4015514 SKIN 4015515 PIPER PA31 PA31350 7103110 SO HARTZL HCE3Y HCE3YR2 GL HORIZONTAL STAB CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH HORIZONTAL STABILISER LEADING EDGE SKINS PNO 40155-14 AND PNO 40155-15 CONTAINED SEVERE INTERGRANNULAR C ORROSION -FOUND FOLLOWING REMOVAL OF DE-ICE BOOTS 1 L 7 2 3O A20SO 5 C P33EA 1997121800783 19971218 00783 SO 1997 12 18 AU970458 1 19970411 G 5751 RIB PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA AILERON STRUCTUR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AILERON NOSE RIBS (5OFF6) CRACKED AT HINGE BRACKET LOCATION 1 L 7 2 3O 3 O A19S0 E286 1997121800784 19971218 00784 SO 1997 12 18 AU970459 1 19970502 G 5711 20207T902 SPAR CAP AYRES S2 S2RT34NORMAL 0970106 SO PWA PT6 PT6A34AG 52053 NE HARTZL HCB3T HCB3TN3 GL WING SPAR STRUCT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH WING LOWER SPAR CAP CONTAINED TWO CRACKS FROM 6.35MM (0.25IN)BOLT HOLE - ONE CRACK EXTENDS 3.048MM (0.120IN) FO RWARD FROM THE HOLE AND ONE CRACK EXTENDS 0.508MM (0.020IN) REARWARDS - FOUND DURING MAGNETIC PARTICLE INSPECTION IAW SB -AG-39 1 L 7 1 3T 4 T A3SW E4EA 6 C P15EA 1997121800785 19971218 00785 GL 1997 12 18 AU970460 2 19970324 G 7412 8331149522 EXCITER BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL ENGINE IGN FAILED W K NONE O OTHER NR NOT REPORTED 1 AU S 1 CAE800109BA (AUS) ENGINE EXCITER BOX FAULTY - EXCITER BOX WAS A REPLACEMENT FOR A DEFECTIVE EXCITER BOX PREVIOUSLY REMOVED FOR CORRO DED OUTPUT TERMINAL - BOX WAS OK FOR THE FIRST START BUT THEN FAILED 1 G 7 1 3U 3 U H2SW E4CE 1997121800786 19971218 00786 SO 1997 12 18 AU970461 1 19970322 G 2430 WIRE PIPER PA30 PA30 7103002 SO LYC O320 IO320B1A 41508 EA HARTZL HCE2Y HCE2YL2 GL LT ALTERNATOR SHORTED W O OTHER H W ELECT. POWER LOSS-50 PC INADEQUATE Q C CR CRUISE 1 AU S (AUS) LH ALTERNATOR MAIN CABLE SHORT CIRCUITING ON EXHAUST PIPE - LOOSE TERMINALS ON BATTERY SUPPLY RELAYS - INVESTIGATI ON FOUND THAT THE ALTERNATOR SYSTEM WAS NOT AN APPROVED INSTALLATION (SYSTEM HADBEEN CHANGED FROM GENERATOR TO ALTERNATO R) - UNAPPROVED MODIFICATION - PERSONNEL/MAINTENANCE ERROR 1 L 7 2 3O 3 O A1EA 1E12 5 C P9EA 1997121800787 19971218 00787 SO 1997 12 18 AU970462 2 19970424 G 8530 538304 PUSHROD CONT CESSNA 207 207 2073602 CE CONT O520 IO520F 17032 SO MCAULY D3A34 D3A34C404 GL ENG NR 4 CYL DISTORTED W K NONE O OTHER IN INSP/MAINT 1 AU S 286435R 286435R (AUS) NO4 CYLINDER EXHAUST VALVE PUSHROD BENT - NO4 AND NO5 CYLINDER EXHAUST VALVES STIFF - NO2 CYLINDER INLET VALVE ROU GH INOPERATION - NO4 CYLINDER PISTON HAD CONTACTED THE NO4 EXHAUST VALVE - CYLINDERS ARE SUPERIOR ITEMS PNO SA52000A1 1 H 7 1 3O 3 O A16CE E5CE 5 C P47GL 1997121800788 19971218 00788 SO 1997 12 18 AU970463 2 19970430 G 8520 652560 CRANKCASE CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO MCAULY 3A32C D3A32C88 GL BEARING JOURNAL WORN W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 294694R (AUS) CRANKCASE MAIN BEARING JOURNALS AND OUTER SHELL SURFACES WORN EXCESSIVELY - CRANKSHAFT CENTRE MAIN JOURNAL BADLY S CORED - SUSPECT INCORRECT LINE BORING DURING OVERHAUL 1 H 7 1 3O 3 O 3A21 E5CE 5 C P21EA 1997121800789 19971218 00789 NE 1997 12 18 AU970464 2 19970405 G 7313 775723 SEAL BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE FUEL INJ NOZZLE LEAKING W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 2731 687513 (AUS) NO1 ENGINE NO9 COMBUSTION CAN FUEL INJECTOR NOZZLE SEAL LEAKING. INVESTIGATION FOUND THAT THE PROBLEM WAS CAUSED B Y IMPROPER MAINTENANCE ACTIVITIES DURING NOZZLE OVERHAUL.PERSONNEL/MAINTENANCE ERROR. 2 L 7 3 4F 4 F RT A3WE E2EA 1997121800790 19971218 00790 NM 1997 12 18 AU970465 1 19970427 G 2520 309312 NUT BOEING 737 737476 NM AFT CABIN SEAT FAULTY W K NONE O OTHER DE DESCENT 1 AU S 309312 (AUS) REAR CABIN SEATS 15 DEF FORWARD INBOARD LEG MOUNT ANCHOR NUT FAULTY - SEAT ROWS 16 DEF AND 17 DEF ALSO LOOSE IN TR ACKS 2 L 7 2 4F RT A16WE 1997121800791 19971218 00791 SO 1997 12 18 AU970466 1 19970417 G 5711 20207T901 SPAR CAP 20207T902 AYRES S2 S2RT34NORMAL 0970106 SO PWA PT6 PT6A34AG 52053 NE HARTZL HCB3T HCB3TN3 GL WING SPAR STRUCT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH WING LOWER SPAR CAPS PNO 20207-T901 AND PNO 20207-T902 CRACKED - LH LOWER SPAR CAP HAS ONE CRACK IN TWO HOLES - RH LOWER SPAR CAP HAS TWO CRACKS IN OUTBOARD HOLE - FOUND DURING FLUORESCENT MAGNETIC PARTICLE INSPECTION IAW AG -39 1 L 7 1 3T 4 T A3SW E4EA 6 C P15EA 1997121800792 19971218 00792 SO 1997 12 18 AU970467 1 19970502 G 5711 SPAR CAP AYRES S2 S2RT34NORMAL 0970106 SO PWA PT6 PT6A34AG 52053 NE HARTZL HCB3T HCB3TN3 GL WING SPAR STRUCT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH WING LOWER SPAR CAP CRACKED FROM 6.35MM (0.25IN) HOLE - ONECRACK 12.395MM (0.488IN) EXTENDS FORWARD AND ONE CRA CK 7.975MM(0.314IN) EXTENDS REARWARDS - FOUND DURING MAGNETIC PARTICLE INSPECTION - SEE MDR 97/0447 FOR ADDITIONAL INFOR MATION 1 L 7 1 3T 4 T A3SW E4EA 6 C P15EA 1997121800793 19971218 00793 SO 1997 12 18 AU970468 1 19970502 G 5711 SPAR CAP AYRES S2 S2RT34NORMAL 0970106 SO PWA PT6 PT6A34AG 52053 NE HARTZL HCB3T HCB3TN3 GL WING SPAR STRUCT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH WING LOWER FORWARD SPAR CAP CRACKED FROM 6.35MM (0.25IN) HOLE- ONE CRACK 3.098MM (0.122IN) EXTENDED FORWARD AND ONE CRACK0.508MM (0.020IN) EXTENDED REARWARD - FOUND DURING MAGNETIC PARTICLE INSPECTION - SEE MDR 97/0459 FOR FURTHER INFORMATION 1 L 7 1 3T 4 T A3SW E4EA 6 C P15EA 1997121800794 19971218 00794 WP 1997 12 18 AU970469 2 19970502 G 7314 PUMP GARRTT TPE331 TPE33110U 01514 WP ROTOL R333 R333482F12 GL ENGINE FUEL PUMP LOW PRESSURE W K E NONE ENGINE SHUTDOWN O OTHER LD LANDING 1 AU S PA2080 (AUS) LH ENGINE DRIVEN FUEL PUMP OUTLET PRESSURE AT LOW END OF LIMITS - FCU METERING VALVE ALSO SET AT LOW END OF LIMITS 4 T E4WE 6 C P61GL 1997121800795 19971218 00795 EU 1997 12 18 AU970470 1 19970222 G 2722 A5547065020490 FITTING AIRBUS 300 A300B4203 3930306 EU GE CF6 CF650C2 30018 NE RUDDER ACTUATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RUDDER ACTUATOR HINGE FITTING CRACKED ON OUTER FLANGE RADIUS AND INNER WEB 2 L 7 2 4F 4 F A35EU E23EA 1997121800796 19971218 00796 EU 1997 12 18 AU970471 1 19970505 G 5330 SKIN BAC 146 146300A 1500267 EU FUSELAGE AFT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE SKIN CRACKED ON LH SIDE IN AREA OF AFT FRAME 10 BELOW THE LOWER LAP JOINT - CRACK LENGTH 68.5MM (2.7IN) - DAMAGE CAUSED BY IMPACT WITH TARMAC VEHICLE 2 H 7 4 4F RT A49EU 1997121800797 19971218 00797 NE 1997 12 18 AU970472 2 19970430 G 7321 8004142003 EEC EMB 120 EMB120 3260201 SO PWA 118 PW118A NE FUEL CONT EEC FAULTY W K NONE O R OTHER PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S (AUS) LH ENGINE ELECTRONIC CONTROL (EEC) SUSPECT FAULTY 2 L 7 2 4T 4 T RT A31SO E20NE 1997121800798 19971218 00798 SO 1997 12 18 AU970473 1 19970417 G 3230 4A7222119 HOSE EMB 110 EMB110P1 3260122 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL MLG RETRACT LEAKING W K NONE K J FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S (AUS) MAIN LANDING GEAR DOWNLOCK HOSE LEAKING FROM FITTING 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 1997121800799 19971218 00799 SO 1997 12 18 AU970474 1 19970429 G 5410 4066701 ANGLE PIPER PA31 PA31350 7103110 SO HARTZL HCE3Y HCE3YR2 GL RT ENG MOUNT LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S DJ10865A (AUS) RH ENGINE NACELLE LOWER ANGLE SHEAR PLATE LOCATED AT WS65.69 ANDWS89.31 HAD LOOSE AND WORKING RIVETS ALLOWING FORE AND AFT MOVEMENT OF THE LOWER ENGINE MOUNT ATTACHMENT BRACKETS 1 L 7 2 3O A20SO 5 C P33EA 1997121800800 19971218 00800 WP 1997 12 18 AU970475 2 19970422 G 7260 31030351 BEARING GARRTT GEAR FRCHLD SA227 SA227DC 3377521 SW GARRTT TPE331 TPE33112UA 01514 WP MCAULY 4HFR34 4HFR34C652 NE ENG ACESSORY BOX DISINTEGRATED W K NONE O J OTHER WARNING INDICATION CR CRUISE 1 AU S 3P3767 P70144 (AUS) ENGINE ACCESSORY GEARBOX BEARING CAGE DISINTEGRATED - METAL CONTAMINATION OF CHIP DETECTOR 2 L 7 2 4T 4 T RT A18SW E4WE 6 C 3PNE 1997121800801 19971218 00801 WP 1997 12 18 AU970476 2 19970430 G 7230 31033336 BEARING FRCHLD SA227 SA227DC 3377521 SW GARRTT TPE331 TPE33112UA 01514 WP MCAULY 4HFR34 4HFR34C652 NE TURB ENG COMP DISINTEGRATED W K NONE O J OTHER WARNING INDICATION CL CLIMB 1 AU S P70143 (AUS) ENGINE MAIN COMPRESSOR SHAFT BEARING DISINTEGRATED - METAL CONTAMINATION OF OIL SYSTEM 2 L 7 2 4T 4 T RT A18SW E4WE 6 C 3PNE 1997121800802 19971218 00802 SO 1997 12 18 AU970477 1 19970419 G 3246 300820 WHEEL BFGOODRICH EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE WHEEL/SKI/FLOAT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 0095 (AUS) MAIN WHEEL ASSEMBLY INNER WHEEL HALF CONTAINED MULTIPLE CRACKS IN THE LOWER DRIVE LUGS - FOUND DURING FLUORESCENT DYE PENETRANT INSPECTION 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 1997121800803 19971218 00803 SO 1997 12 18 AU970478 2 19970407 G 8530 648029 PISTON CONT BEECH 55 9555 1152702 CE CONT O470 IO470L 17026 SO MCAULY 2AF36C 2AF36C39 GL RECIP ENG BURNT W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S CS914624L CS914624L (AUS) ENGINE PISTON BURNT - ENGINE METAL CONTAMINATION - SUSPECT CAUSED BY POORLY OVERHAULED FUEL SYSTEM 1 L 7 2 3O 3 O 3A16 3E1 5 C P911 1997121800804 19971218 00804 NE 1997 12 18 AU970479 2 19970509 G 7260 DRIVE BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE NR3 ENG OIL PUMP FAILED W K NONE O K OTHER FLUID LOSS TO TAKEOFF 1 AU S LF05454 (AUS) NO3 ENGINE OIL PUMP DRIVE FAILED - METAL CONTAMINATION OF OIL SYSTEM - DURING GEARBOX REMOVAL A THREADED INSERT WA S PULLED FROM THE FAN HOUSING 2 H 7 4 4F 4 F A49EU E6NE 1997121800805 19971218 00805 NE 1997 12 18 AU970480 2 19970425 G 7230 793353 COMPRESSOR CASE BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE TURB ENG COMP DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 20555 687388 (AUS) NO1 ENGINE INTERMEDIATE COMPRESSOR CASE HOLED AT THE 12 O'CLOCK POSITION BY THE ENGINE LIFTING BEAM FORWARD ATTACH MENT FITTINGPNO F72714-2 - ENGINE WAS LIFTED WITH ONLY THE UPPER FORWARD CONE BOLT ENGAGED ALLOWING THE ENGINE TO ROLL T O THE RIGHT AND CONTACTING THE LIFTING BEAM - PERSONNEL/MAINTENANCE ERROR 2 L 7 3 4F 4 F RT A3WE E2EA 1997121800806 19971218 00806 NM 1997 12 18 AU970481 1 19970307 G 3230 2041561ANSETTSN HYDRAULIC FUSE BOEING 767 767277 NM GE CF6 CF680A 30025 NE RT MLG RETRACT FAULTY W K NONE O OTHER NR NOT REPORTED 1 AU S 2041561ANSET (AUS) RH MAIN LANDING GEAR TRUCK POSITIONER `UP' LINE HYDRAULIC FUSE FAULTY 2 L 7 2 4F 4 F RT A1NM E13NE 1997121800807 19971218 00807 CE 1997 12 18 AU970482 1 19970506 G 7603 LINKAGE BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO HARTZL HCJ3Y PHCJ3YF2 GL POWER LEVER WORN W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S ED454 (AUS) LH ENGINE CONTROL LINKAGES FAULTY - THE FOLLOWING DEFECTS WERE FOUND:- 1. THROTTLE CONTROL LINKAGE SEVERELY WORN 2 . THROTTLE ROD END SEPARATED FROM CAGE 3. NYLEX NUT USED ON THROTTLE CROSS SHAFT 4. NYLEX NUT ON MIXTURE CONTROL NOT IN SAFETY 5. MIXTURE CONTROL ROD END SLIGHTLY WORN. PROPELLER CONTROL ROD END FAILED 7. RH ENGINE THROTTLE AND MIXTURE CONT ROLS USING NYLEX NUTS FOUND DURING INSPECTION FOR PROPELLER STRIKE - UNAPPROVED PART - 1 L 7 2 3O 3 O 3A16 E5CE 5 C P36EA 1997121800808 19971218 00808 EU 1997 12 18 AU970483 1 19970402 G 5230 HANDLE AIRBUS 320 A320212 EU CARGO/BAG DOOR FAULTY W K NONE J WARNING INDICATION IN INSP/MAINT 1 AU S (AUS) MAIN CARGO DOOR LATCH HANDLE WOULD NOT FULLY ENGAGE - SUSPECT CAUSED BY INTERFERENCE BETWEEN THE CARGO DOOR HANDLE AND THE HANDLE LOCKING MECHANISM CAUSING A PRELOAD AGAINST THE HANDLE LATCH HOOK 2 L 7 2 4F RT A28NM 1997121800809 19971218 00809 CE 1997 12 18 AU970484 1 19970510 G 3230 35815109 UPLOCK CABLE BEECH B76 BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO MCAULY 3AF34C 3AF34C502 GL MLG RETRACT FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LANDING GEAR UPLOCK CABLE FAILED AT OUTBOARD SWAGED FITTING DUE TO CORROSION OF THE EXPOSED STRANDS 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 1997121800810 19971218 00810 SO 1997 12 18 AU970485 1 19970508 G 3234 1203859400 SELECTOR EMB EMB 120 EMB120 3260201 SO PWA 118 PW118A NE LANDING GEAR SEL FAULTY W K NONE O OTHER DE DESCENT 1 AU S 12040 (AUS) LANDING GEAR SELECTOR FAULTY - SUSPECT CAUSED BY FAULTY MICRO SWITCHES 2 L 7 2 4T 4 T RT A31SO E20NE 1997121800811 19971218 00811 SO 1997 12 18 AU970486 1 19970216 G 2410 73965009 DRIVE BELT PIPER PA32 PA32RT300T 7103216 SO LYC O540 TIO540S1AD 41532 EA ALTERNATOR-GENER FAILED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) ALTERNATOR DRIVE BELT FAULTY - PERSONNEL/MAINTENANCE ERROR 1 L 7 1 3O 3 O A3SO E14EA 1997121800812 19971218 00812 GL 1997 12 18 AU970487 3 19970510 G 6111 FC84686R BLADE PIPER PA31 PA31350 7103110 SO HARTZL HCE3Y HCE3YR2 GL PROPELLER BLADE FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S DJ9134A (AUS) PROPELLER BLADES BELOW MANUFACTURERS MINIMUM LIMITS BY AT LEAST 9.398MM (0.370IN) AT TIP STATIONS - LOG BOOK INADE QUATE FOR CASA RELEASE - PROPELLER HAD BEEN IMPORTED FROM THE USA AND WAS UNDERGOING ASSEMBLY AND CERTIFICATION BEFORE U SE -PERSONNEL/MAINTENANCE ERROR 1 L 7 2 3O A20SO 5 C P33EA 1997122400271 19971224 00271 SO 1997 12 24 AU970488 1 19970509 G 7713 6136402 PIPE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL MANIFOLD PRESS CHAFED W K NONE O R OTHER PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 AU S (AUS) RH ENGINE MANIFOLD PRESSURE RIGID PIPE FROM ENGINE BULKHEAD FITTING CHAFED THROUGH BY LH COWL FLAP ACTUATOR ROD PN O 42574.00 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1997122400272 19971224 00272 EA 1997 12 24 AU970489 2 19970512 G 8500 HOSE PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA HARTZL HCC2Y HCC2YR2 GL ENGINE UNAPPROVED PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) ALL ENGINE HOSES FAULTY - WHEN FIRE SLEEVING WAS REMOVED THE HOSES WERE FOUND TO BE MANUFACTURED FROM MIL-H-6000 L OW PRESSURE HOSE AND NON COMPATIBLE MS FITTINGS - HOSES LEAKED DURING PRESSURE TESTING - SOME HOSES WERE ALSO FOUND TO B E MANUFACTURED FROM 306 TYPE LOW PRESSURE HOSE - PERSONNEL/MAINTENANCE ERROR - UNAPPROVED PART 1 L 7 2 3O 3 O A19S0 E286 5 C P920 1997122400273 19971224 00273 NE 1997 12 24 AU970490 2 19970405 G 7240 COMBUSTOR BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE NR 1 ENG HOLED W A K NONE O OTHER IN INSP/MAINT 1 AU S 687513 (AUS) NO1 ENGINE NO9 COMBUSTION CAN BURNT THROUGH AT FUEL NOZZLE NUTFACE. FOUND DURING BOROSCOPE INSPECTION. INVESTIGATI ON FOUND THAT THE PROBLEM WAS CAUSED BY DISCREPANCIES IN THE OVERHAUL OF THE FUEL NOZZLE ASSEMBLIES. PERSONNEL/MAINTENAN CE ERROR. 2 L 7 3 4F 4 F RT A3WE E2EA 1997122400274 19971224 00274 GL 1997 12 24 AU970491 2 19970304 G 7261 23001819 NOZZLE ALLSN ALLSN 250C 250C20B 03013 GL ENG NR 6 BEARING WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 135 CAE834661 CAE834661 (AUS) NO6 AND NO7 BEARING OIL NOZZLE WORN AND CORRODED 3 U E4CE 1997122400275 19971224 00275 1997 12 24 AU970492 1 19970226 G 7810 4606AC CLAMP ALLSN 250C 250C20B 03013 GL ENG EX COLLECTOR BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S CAE834661 (AUS) ENGINE EXHAUST PIPE CLAMP BROKEN AT RIVET LINE 3 U E4CE 1997122400276 19971224 00276 NE 1997 12 24 AU970493 2 19970514 G 7250 BEARING BAC 146 146100A 1500260 EU LYC ALF502 ALF502R5 41580 NE TURBINE SECTION FAILED W K NONE O K OTHER FLUID LOSS CR CRUISE 1 AU S 5936 (AUS) ENGINE OIL PRESSURE LOSS - SUSPECT NO4/5 BEARING FAILURE 2 H 7 4 4F 4 F RT A49EU E6NE 1997122400277 19971224 00277 EU 1997 12 24 AU970494 1 19970505 G 2197 WIRE PILATS PC12 PC12 7090550 EU CABIN PRESS CONT WORN W O OTHER O OTHER CR CRUISE 1 AU S (AUS) LOSS OF CABIN PRESSURISATION - CAUSED BY CHAFED AND BURNT WIRING ON PARK BRAKE CABLE NUT BEHIND TRIM PANEL IN AREA OF PILOT'S FEET - BURNT WIRING ALSO CAUSED LOSS OF FLOOD FANS AND FAILURE OF CABIN TEMPERATURE GAUGE 1 L 7 1 3T RT A78EU 1997122400278 19971224 00278 GL 1997 12 24 AU970495 2 19970514 G 7260 6854521 SEAL ALLSN SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30 03013 GL GRBOX COOLER FAILED W K NONE O K OTHER FLUID LOSS CL CLIMB 1 AU S CAG90667 (AUS) NO2 ENGINE ACCESSORY GEARBOX OIL COOLER BLOWER DRIVE SEAL FAILED- LOSS OF ENGINE OIL 1 G 7 2 3U 3 U H1NE E1GL 1997122400279 19971224 00279 NM 1997 12 24 AU970496 1 19970424 G 5551 65B035632 FITTING BOEING 747 747312 1384932 NM HORIZONTAL STAB DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH HORIZONTAL STABILISER HINGE FITTING GOUGED ON INBOARD SURFACE- INVESTIGATION FOUND THAT THE HINGE BEARING RETAI NER HAD ROTATED THROUGH APPROXIMATELY 90 DEGREES CAUSING THE DAMAGE - THE GOUGE WAS APPROXIMATELY 2.54MM (0.100IN) DEEP BY 12.7MM (0.5IN) WIDE THROUGH A 90 DEGREE ARC - THE BORE OF THE FITTING HOUSING THE BEARING SLEEVE HAD 0.1524MM (0.006I N) OVALITY 2 L 7 4 4F RT A20WE 1998010600012 19980106 00012 EU 1998 1 6 AU970497 1 19970516 G 7160 NH2466808108 DUCT NH24668 SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE ENGINE AIR INT BURNT W K NONE O B OTHER SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 AU S 5103 JLSF325C 785235 (AUS) RH ENGINE INLET LOWER DUCT BURNT AROUND THE INNER UPPER LIP ATTHE PARTICLE SEPARATOR MOUNTING FLANGE 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 1997122400280 19971224 00280 NM 1997 12 24 AU970498 1 19970319 G 2170 1808494 COALESCER BAG BOEING 737 737377 NM HUMIDITY CONTROL DIRTY W K NONE O OTHER CR CRUISE 1 AU S (AUS) LH AIRCONDITIONING PACK WATER SEPARATOR COALESCER BAG DIRTY 2 L 7 2 4F RT A16WE 1997122400281 19971224 00281 NM 1997 12 24 AU970499 1 19970409 G 2913 21830 BEARING BOEING 737 737377 NM HYDRAULIC PUMP FAILED W K NONE K J FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S 8029 220484ANSETT (AUS) HYDRAULIC `B' SYSTEM ELECTRIC PUMP TRUNNION BEARINGS FAILED.DAMAGE CAUSED TO PUMP ROTATING GROUP, PUMP HOUSING AND ELECTRIC MOTOR. 2 L 7 2 4F RT A16WE 1997122400282 19971224 00282 EU 1997 12 24 AU970500 1 19970131 G 2120 9566300 ARMATURE AIRBUS 320 A320212 EU AIR DISTRIBUTION OPEN CIRCUIT W K NONE O OTHER IN INSP/MAINT 1 AU S 69ANSETTSN00 (AUS) AVIONICS EQUIPMENT VENTILATION SYSTEM SKIN AIR OUTLET VALVE MOTOR ARMATURE HAD OPEN CIRCUIT ON THREE ADJACENT COMM UTATOR SEGMENTS 2 L 7 2 4F RT A28NM 1997122400283 19971224 00283 EU 1997 12 24 AU970501 1 19970211 G 5610 NP1653114 WINDSHIELD AIRBUS 320 A320212 EU FLIGHT COMPART CRACKED W K NONE O OTHER CR CRUISE 1 AU S 96205H3073AN (AUS) FIRST OFFICERS WINDSCREEN OUTER PANE CRACKED 2 L 7 2 4F RT A28NM 1997122400284 19971224 00284 EU 1997 12 24 AU970502 1 19970504 G 3411 147013207 TUBE BNORM BN2 BN2A6 1520205 EU LYC O540 O540E4C5 41532 EA HARTZL HCC2Y HCC2YK2 GL PITOT/STATIC SYS DETERIORATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PITOT-STATIC SYSTEM LINES LEAKING - INVESTIGATION FOUND LEAKS WERE FROM HEAT SHRINK TUBING (THERMOFIT) USED AT JOI NS IN THE PLUMBING AND APPLIED DURING MANUFACTURE - FOUND DURING INSPECTION IAW AD/INST/9 (PITOT/STATIC SYSTEM LEAK CHEC K) 1 H 7 2 3O 3 O A17EU E295 5 C P920 1997122400285 19971224 00285 CE 1997 12 24 AU970503 1 19970519 G 2612 61423473275 FIRE DETECTOR BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL RT ENG FAULTY W K NONE O N OTHER FALSE WARNING TO TAKEOFF 1 AU S (AUS) RH ENGINE FIRE WARNING SYSTEM FIRE DETECTOR FAULTY - SUSPECT MOISTURE INGRESS AS RAIN FELL DURING THE PREVIOUS NIG HT 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1997122400286 19971224 00286 WP 1997 12 24 AU970504 1 19970514 G 6310 C1842 BEARING ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA TRANSMISSION ROUGH W K NONE O J OTHER WARNING INDICATION IN INSP/MAINT 1 AU S SNS (AUS) ENGINE TO TRANSMISSION CLUTCH UPPER SHEAVE BEARING NOISY AND ROUGH IN OPERATION - NO EVIDENCE OF LUBRICATION - TEL ETEMP INDICATOR HAD NOT ACTIVATED 1 G 7 1 3O 3 O H11NM E295 1997122400287 19971224 00287 1997 12 24 AU970505 4 19970420 G 2350 AVIX HEADSET CESSNA 310 310L 2074230 CE CONT O470 IO470U 17026 SO MCAULY 2AF34C D2AF34C81 GL AUDIO INTEGRATIN DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HEADSET LEAD MELTED DUE TO SHORT CIRCUIT BETWEEN CO-PILOTS PHONEJACK AND INSTRUMENT LIGHTING WIRE 1 L 7 2 3O 3 O 3A10 3E1 5 C P5EA 1997122400288 19971224 00288 GL 1997 12 24 AU970506 3 19970502 G 6114 861246 LATCH MCAULY CESSNA 404 404CESSNA 2075901 CE MCAULY 3FF32 3FF32C501 GL PROPELLER HUB FAILED W K NONE O OTHER LD LANDING 1 AU S 861246 861246 (AUS) RH PROPELLER LOW PITCH LATCHES FAILED 1 L 7 2 3O A25CE 5 C P45GL 1997122400289 19971224 00289 CE 1997 12 24 AU970507 1 19970506 G 2510 081278211 SEAT CESSNA 404 404CESSNA 2075901 CE MCAULY 3FF32 3FF32C501 GL COPILOT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CO-PILOTS SEAT CUSHION BASE FRAME SIDE MEMBER CRACKED 1 L 7 2 3O A25CE 5 C P45GL 1997122400290 19971224 00290 CE 1997 12 24 AU970508 1 19970513 G 5347 58112133 SEAT TRACK CESSNA 404 404CESSNA 2075901 CE MCAULY 3AF34C 3AF34C74 GL BS 300 CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH OUTBOARD SEAT TRACK CONTAINED EXFOLIATION CORROSION IN AREA OF FLOOR PANEL ATTACHMENT HOLE IN HORIZONTAL FLANGE AT FS 300.00 - SUSPECT CAUSED BY LIQUID FLOOR POLISH - POLISH WAS AN UNAPPROVEDPRODUCT 1 L 7 2 3O A25CE 5 C P22EA 1997122400291 19971224 00291 1997 12 24 AU970509 4 19970512 G 2564 EAMT6 LIFE RAFT LIFE RAFT FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S TF269 (AUS) LIFERAFT INCORRECTLY PACKED - GAS BOTTLE DUE FOR HYDROSTATIC TEST ON 10/96 - LIFERAFT HAD JUST ARRIVED FROM OVERSE AS -PERSONNEL/MAINTENANCE ERROR 1997122400292 19971224 00292 EU 1997 12 24 AU970510 1 19970518 G 5312 BULKHEAD FOKKER F28 F28MK4000 4990810 EU RROYCE SPEY SPEY55515 54521 EU FUSELAGE MAIN BU CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD PRESSURE BULKHEAD CRACKED IN THREE AREAS:-1. FORWARD PRESSURE BULKHEAD REAR SIDE AT HORIZONTAL BEAM 7 LEFT OF BL325L - CRACK LENGTH 76.2MM (3IN)2. FORWARD PRESSURE BULKHEAD REAR SIDE AT HORIZONTAL BEAM 7 RIGHT OF BL325R - CRA CK LENGTH 127MM (5IN) 3. FORWARD PRESSURE BULKHEAD BETWEEN THE FUSELAGE CENTRE LINE AND STRINGER 3 WHERE THE BULKHEAD M EETS THE LOWER FUSELAGE SKIN - CRACK LENGTH 107.6MM (4.24IN)CRACKS 1 AND 2 FOUND DURING INSPECTION IAW ER F28-53-10-20 - CRACK 3 FOUND DURING INSPECTION IAW ER F28-53-10-19F 2 L 7 2 4F 4 F RT A20EU E2EU 1997122400293 19971224 00293 SO 1997 12 24 AU970511 2 19970407 G 7314 6381549 PUMP CONT 6381549 BEECH 55 9555 1152702 CE CONT O470 IO470L 17026 SO MCAULY 2AF36C 2AF36C39 GL ENGINE FUEL PUMP FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 20 3580 CS94624C (AUS) ENGINE DRIVEN FUEL PUMP FAULTY - ROTOR SHAFT UNSERVICEABLE -INCORRECT IDLE ADJUSTMENT SCREW FITTED (TOO SHORT) - T HRUST PLATES DAMAGED DUE TO INCORRECT CLEARANCES - WATER DAMAGE TO RELIEF VALVE AREA - UNIT HAD JUST RETURNED FROM OVERH AUL -PERSONNEL/MAINTENANCE ERROR 1 L 7 2 3O 3 O 3A16 3E1 5 C P911 1997122400294 19971224 00294 SO 1997 12 24 AU970512 2 19970407 G 7322 6252192 FCU CONT 6252192 BEECH 55 9555 1152702 CE CONT O470 IO470L 17026 SO MCAULY 2AF36C 2AF36C39 GL FUEL CONTROL/CAR FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 20 22168 CS94624C (AUS) FUEL CONTROL UNIT FAULTY - FCU WOULD NOT SHUT OFF IN `IDLE CUTOFF' POSITION - RETURN SPRING NOT FITTED - PERSONNEL /MAINTENANCE ERROR 1 L 7 2 3O 3 O 3A16 3E1 5 C P911 1997122400295 19971224 00295 SO 1997 12 24 AU970513 2 19970407 G 7313 62733312 NOZZLE CONT 627335D12C BEECH 55 9555 1152702 CE CONT O470 IO470L 17026 SO MCAULY 2AF36C 2AF36C39 GL FUEL INJECT NOZ FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 20 X6 CS94624L (AUS) ALL FUEL INJECTOR NOZZLES OUT OF CALIBRATION - FUEL FLOW TOO LOW- FOUR NOZZLES ALSO INTERMITTENT IN OPERATION - PE RSONNEL/MAINTENANCE 1 L 7 2 3O 3 O 3A16 3E1 5 C P911 1997122400296 19971224 00296 SO 1997 12 24 AU970514 1 19970516 G 2510 CF1010 SEAT BELT PIPER PA31 PA31350 7103110 SO HARTZL HCE3Y HCE3YR2 GL FLIGHT COMPART WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) SEAT BELT FAULTY - UNAPPROVED PART - PERSONNEL/MAINTENANCE ERROR 1 L 7 2 3O A20SO 5 C P33EA 1997122400297 19971224 00297 SO 1997 12 24 AU970515 2 19970407 G 8530 648029 PISTON CONT BEECH 55 9555 1152702 CE CONT O470 IO470L 17026 SO MCAULY 2AF36C 2AF36C39 GL RECIP ENG BURNT W K NONE O OTHER IN INSP/MAINT 1 AU S CS94624L CS94624L (AUS) PISTON BURNT AND TORCHED - ENGINE METAL CONTAMINATION 1 L 7 2 3O 3 O 3A16 3E1 5 C P911 1997122400298 19971224 00298 SO 1997 12 24 AU970516 2 19970407 G 7320 6314273 VALVE CONT 6314273 BEECH 55 9555 1152702 CE CONT O470 IO470L 17026 SO MCAULY 2AF36C 2AF36C39 GL FUEL CONTROLLING FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 20 4117 CS914624L (AUS) ENGINE MANIFOLD VALVE FAULTY - INCORRECT OVERHAUL - SEAL COLLAPSED ON ONE SIDE - PLUNGER OUT OF ROUND - NEEDLE AND NUT OF UNKNOWN ORIGIN - GASKET PNO 627124 FITTED - UNAPPROVED PART - PERSONNEL/MAINTENANCE ERROR 1 L 7 2 3O 3 O 3A16 3E1 5 C P911 1997122400299 19971224 00299 EA 1997 12 24 AU970517 2 19970502 G 7322 RSA5AD1 FCU LYC O540 IO540* 41532 EA FUEL CONT/CARB WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 42178 (AUS) FUEL CONTROL UNIT WAS A SUPERSEDED MODEL 3 O 1E4 1997122400300 19971224 00300 1997 12 24 AU970518 4 19970429 G 3421 6229681001 EADI COLLINS EFD84 BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3A NE ATT & DIR GYRO FAILED W K NONE I FLT. ATTITUDE INST. CL CLIMB 1 AU S 203 (AUS) CAPTAINS ELECTRONIC ATTITUDE DIRECTION INDICATOR (EADI) FAILED DUE TO INTERNAL FAULT 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 1997122400301 19971224 00301 CE 1997 12 24 AU970519 1 19970508 G 3242 O-RING BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA LT BRAKE FAULTY W K NONE K FLUID LOSS NR NOT REPORTED 1 AU S (AUS) LH BRAKE SYSTEM FLUID LOSS - SUSPECT CAUSED BY BRAKE BODY INLET FITTING `O' RING SEAL 2 L 7 2 4T 4 T RT A24CE E4EA 1997122400302 19971224 00302 CE 1997 12 24 AU970522 1 19970509 G 3234 CIRCUIT BOARD BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA GEAR SELECTOR FAULTY W K NONE O OTHER DE DESCENT 1 AU S (AUS) LANDING GEAR PRINTED CIRCUIT BOARD FAULTY 2 L 7 2 4T 4 T RT A24CE E4EA 1997122400303 19971224 00303 CE 1997 12 24 AU970523 1 19970512 G 3242 9535088 ADAPTER BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA LT INB BRAKE LOOSE W K NONE K FLUID LOSS TX TAXI/GRND HDL 1 AU S (AUS) LH INBOARD BRAKE UNIT ADAPTER LOOSE - LOSS OF BRAKE FLUID - PERSONNEL/MAINTENANCE ERROR 2 L 7 2 4T 4 T RT A24CE E4EA 1998010600013 19980106 00013 WP 1998 1 6 AU970524 2 19970424 G 7200 ENGINE GARRTT TPE331 TPE33110U 01514 WP ROTOL R333 R333482F12 GL RT ENGINE LOW POWER W K NONE R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 AU S (AUS) RH ENGINE LOW POWER 4 T E4WE 6 C P61GL 1997122400304 19971224 00304 NM 1997 12 24 AU970525 1 19970418 G 2612 WARNING SYSTEM RROYCE BOEING 747 747438 NM NR 2 ENG FAULTY W K F NONE ACTIVATE FIRE EXT. O N OTHER FALSE WARNING DE DESCENT 1 AU S (AUS) NO2 ENGINE FIRE WARNING - NO EVIDENCE OF FIRE - BOTH FIRE BOTTLES DISCHARGED 2 L 7 4 4F RT A20WE 1997122400305 19971224 00305 NM 1997 12 24 AU970526 1 19970413 G 2780 65B151721 LINK BOEING 747 747238B 1384828 NM LE FLAP CONTROL BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) VARIABLE CAMBER LEADING EDGE FLAP LINK BROKEN - BROKEN LINK HAD IN TURN BROKEN A LEADING EDGE SUPPORT STRUCTURE BE AM AND ALSO PENETRATED AND CRACKED THE LOWER FIBREGLASS FIXED PANEL PNO 65B10873-28 - CRACK LENGTH 762MM (30IN) 2 L 7 4 4F A20WE 1997122400306 19971224 00306 CE 1997 12 24 AU970527 1 19970415 G 3242 16402706 BRAKE DISC BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO MCAULY 2AF34C 2AF34C55 GL RT MLG WORN W K NONE O OTHER LD LANDING 1 AU S (AUS) RH MAIN LANDING GEAR BRAKE WORN - BRAKE LOCKED UP CAUSING TYRE TO BLOW OUT 1 L 7 2 3O 3 O RT 3A16 3E1 5 C P5EA 1997122400307 19971224 00307 EA 1997 12 24 AU970528 2 19970429 G 7322 57429 SPINDLE BENDIX RGA PIPER PA32 PA32R300 7103213 SO LYC O540 IO540K1G5 41532 EA HARTZL HCC2Y HCC2YK1 GL FUEL CONT/CARB SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S 1990 57429 L1464648A (AUS) ENGINE FUEL CONTROL UNIT IDLE MIXTURE ADJUSTMENT SPINDLE MISSING- SUSPECT CAUSED BY FAILURE OF POSITIONING SPRING WHICH THEN ALLOWED THE ADJUSTMENT SPINDLE TO VIBRATE FREE 1 L 7 1 3O 3 O A3SO 1E4 5 C P920 1997122400308 19971224 00308 CE 1997 12 24 AU970529 1 19970515 G 5347 58112131 SEAT TRACK CESSNA 404 404CESSNA 2075901 CE MCAULY 3AF34C 3AF34C74 GL SEAT/CARGO ATTAC CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) SEAT TRACK CRACKED IN AREA OF FORWARD HORIZONTAL FLANGE 1 L 7 2 3O A25CE 5 C P22EA 1997122400309 19971224 00309 EA 1997 12 24 AU970530 2 19970509 G 8530 3116 STUD LYC CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL ENG CYL BROKEN W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S 2058 L755076 L755076 (AUS) NO1 CYLINDER EXHAUST VALVE ROCKER STUD BROKEN - INLET VALVE BROKEN AND PUSHROD BENT 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 1997122400310 19971224 00310 EA 1997 12 24 AU970531 2 19970519 G 8520 L261143 CRANKCASE LYC LYC O540 VO540C2A 41532 EA RECIP ENG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S L261143 L261143 (AUS) ENGINE CRANKCASE CRACKED AND TUNNEL OUT OF LIMITS - CRANKSHAFT WORN BEYOND LIMITS - CAMSHAFT LOBES DAMAGED 3 O E304 1998010600014 19980106 00014 SO 1998 1 6 AU970532 2 19970507 G 8520 676405 CRANKCASE CONT BEECH 58 58 1152740 CE CONT O550 IO550* SO MCAULY 3AF32C 3AF32C512 GL RECIP ENG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 676405 676405 (AUS) ENGINE CRANKCASE LH HALF CRACKED IN AREA OF NO2 BEARING SADDLE -NO6 CONNECTING ROD CAP CONTAINED MULTIPLE CRACKING - SUSPECT CRACKING ORIGINATED FROM CORROSION PITTING 1 L 7 2 3O 3 O 3A16 E3SO 5 C P22EA 1997122400311 19971224 00311 EU 1997 12 24 AU970533 1 19970518 G 5312 BULKHEAD FOKKER F28 F28MK4000 4990810 EU RROYCE SPEY SPEY55515 54521 EU FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD PRESSURE BULKHEAD CRACKED IN THREE PLACES:- 1. REAR SIDE OF FORWARD PRESSURE BULKHEAD WEB AT HORIZONTAL BE AM NO7 LEFT OF BL325L - CRACK LENGTH 76.2MM (3IN) 2. REAR SIDE OF FORWARD PRESSURE BULKHEAD WEB AT HORIZONTAL BEAM NO7 R IGHT OF BL325R - CRACK LENGTH 127MM (5IN) 3. BETWEEN FUSELAGE CENTRELINE AND STRINGER NO3 WHERE THE CIRCUMFERENCE OF TH E FORWARD PRESSURE BULKHEAD MEETS THE BOTTOM FUSELAGE SKIN - CRACK LENGTH 107.69MM (4.24IN)CRACKS NO1 AND NO2 WERE FOUN D DURING INSPECTION IAW ERF28-53-10-20 - CRACK NO3 FOUND DURING INSPECTION IAW ER 2 L 7 2 4F 4 F RT A20EU E2EU 1997122400312 19971224 00312 EA 1997 12 24 AU970534 2 19970519 G 8520 L1474639A CAMSHAFT LYC ROBSIN R22 R22BETA NM LYC O320 O320B2C 41508 EA ENGINE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S L1474639A L1474639A (AUS) ENGINE CAMSHAFT LOBE DAMAGED - HARDENING BREAKING DOWN 1 G 7 1 3O 3 O H10WE E274 1997122400313 19971224 00313 CE 1997 12 24 AU970535 1 19970516 G 5312 BULKHEAD CESSNA 172 172M 2072418 CE MCAULY 1C160 1C160DTM GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LOWER AFT DOORPOST BULKHEAD CRACKED - FOUND DURING INSPECTION IAW CESSNA SEB 97-1 1 H 7 1 3O NT 3A12 5 N P910 1997122400314 19971224 00314 CE 1997 12 24 AU970536 1 19970516 G 5312 BULKHEAD CESSNA 172 172L 2072432 CE MCAULY 1C160 1C160DTM GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LOWER AFT DOOR POST BULKHEAD CRACKED - FOUND DURING INSPECTION IAW CESSNA SEB 97-1 1 H 7 1 3O NT 3A12 5 N P910 1997122400315 19971224 00315 CE 1997 12 24 AU970537 1 19970429 G 5312 BULKHEAD CESSNA 172 172M 2072418 CE MCAULY 1C160 1C160DTM GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LOWER AFT DOOR POST BULKHEAD CRACKED - FOUND DURING INSPECTION IAW CESSNA SEB 97-1 1 H 7 1 3O NT 3A12 5 N P910 1997122400316 19971224 00316 CE 1997 12 24 AU970538 1 19970516 G 5312 BULKHEAD CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LOWER AFT DOOR POST BULKHEAD CRACKED - FOUND DURING INSPECTION IAW CESSNA SEB 97-1 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 1998010600015 19980106 00015 1998 1 6 AU970539 1 19970502 G 7110 COWLING ENGINE COWLING DAMAGED W K NONE D INFLIGHT SEPARATION TO TAKEOFF 1 AU S (AUS) ENGINE COWL DAMAGED - SUSPECT COWL LATCH INCORRECTLY FASTENED OR LATCH FAILED 1997122400317 19971224 00317 SO 1997 12 24 AU970540 2 19970501 G 8520 465705 CRANKSHAFT CONT CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 465705 465705 (AUS) CRANKSHAFT CONTAINED TWO CRACKS IN NO6 CONNECTING ROD WEB - CRANKCASE BEARING TUNNEL OUT OF LIMITS - DAMAGE CAUSED BY HEAVY LANDING AND PROPELLER STRIKE 1 H 7 1 3O 3 O NT 3A13 E273 1997122400318 19971224 00318 EA 1997 12 24 AU970541 2 19970514 G 7414 M3975 COIL SLICK 4371 LYC O360 O360A4K 41514 EA MCAULY 1A170 1A170FFA GL MAGNETO/DIST OPEN W K NONE O OTHER IN INSP/MAINT 1 AU S 92020112 (AUS) MAGNETO COIL OPEN CIRCUITED ON HIGH TENSION SIDE 3 O E286 5 N P857 1997122400319 19971224 00319 EA 1997 12 24 AU970542 2 19970519 G 8520 L2538548A CAMSHAFT LYC BNORM BN2 BN2B20 1520302 EU LYC O540 IO540K1B5 41532 EA HARTZL HCC2Y HCC2YK2 GL ENGINE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S L2538548A L2538548A (AUS) CAMSHAFT LOBE CASE HARDENING DAMAGED 1 H 7 2 3O 3 O A17EU 1E4 5 C P920 1997122400320 19971224 00320 CE 1997 12 24 AU970543 1 19970509 G 2730 126047512 CONTROL CABLE CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL ELEVATOR CONTROL WORN W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) ELEVATOR CONTROL CABLE WORN - CABLE HAD BEEN INCORRECTLY ROUTED OVER A PULLEY GUARD PNO NAS 427K11 ON THE PULLEY L OCATED SECOND FROM THE FRONT - AIRCRAFT HAD BEEN REBUILT 242.3 HOURS PREVIOUSLY FOLLOWING AN ACCIDENT - PERSONNEL/MAINTE NANCE ERROR 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 1997122400321 19971224 00321 NM 1997 12 24 AU970544 1 19970513 G 5312 BULKHEAD BOEING 737 737377 NM FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD PRESSURE BULKHEAD CRACKED AT SIDE CHORD RADIUS LH SIDE AT WL207 - CRACK LENGTH APPROXIMATELY 76.2MM (3IN) 2 L 7 2 4F RT A16WE 1997122400322 19971224 00322 EA 1997 12 24 AU970545 2 19970521 G 8520 L2538448A CAMSHAFT LYC BNORM BN2 BN2B20 1520302 EU LYC O540 IO540K1B5 41532 EA HARTZL HCC2Y HCC2YK2 GL ENGINE DETERIORATED W K NONE O OTHER IN INSP/MAINT 1 AU S L2538448A L2538448A (AUS) CAMSHAFT LOBE CASE HARDENING BREAKING DOWN - CRANKSHAFT GEAR ALSO HAD BREAKING DOWN OF THE CASE HARDENING 1 H 7 2 3O 3 O A17EU 1E4 5 C P920 1997122400323 19971224 00323 CE 1997 12 24 AU970546 1 19970523 G 2910 572700258 LINE CESSNA 441 441 2076020 CE HARTZL HCB3T HCB3TN5 GL HYDRAULIC MAIN FAILED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) HYDRAULIC LINE BURST DURING RIG TESTING AT APPROXIMATELY 220PSI 1 L 7 2 3T RT A28CE 6 C P15EA 1997122400324 19971224 00324 EU 1997 12 24 AU970547 1 19970520 G 2823 D1N808G6 UNIVERSAL JOINT GROB G115 G115C 1660303 EU LYC O360 O360A1F6 41514 EA FUEL SELECTOR FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUEL SELECTOR SHAFT LOWER UNIVERSAL JOINT RETAINER PIN (1OFF4)MISSING 1 L 7 1 3O 3 O NT A57EU E286 1997122400325 19971224 00325 1997 12 24 AU970548 1 19970519 G 7602 115C6030 BRACKET LYC O360 O360A1F6 41514 EA HARTZL HCF2Y HCF2YR1 GL MIXTURE CONTROL CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MIXTURE CONTROL CABLE SUPPORT BRACKET FAILED IN AREA OF ATTACHMENT CLAMP 3 O E286 5 C P27EA 1997122400326 19971224 00326 SO 1997 12 24 AU970549 2 19970508 G 8530 TM652952A CYLINDER CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO MCAULY 2A34C 2A34C203 GL ENG NR 4 BROKEN W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S 286509R (AUS) NO4 CYLINDER HEAD SEPARATED FROM THE BARREL - INVESTIGATION FOUND THAT THE FAILURE OCCURRED AT THE TOP OF THE THRE ADED SECTION OF THE HEAD TO BARREL JUNCTION 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997122400327 19971224 00327 EA 1997 12 24 AU970550 2 19970401 G 8550 PUMP PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA SNSNCH 74DM M74DM EA ENGINE FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S L1504527A (AUS) ENGINE OIL PUMP FAULTY - AD/LYC/81 AMDT3 HAD NOT BEEN COMPLIED WITH - SINTERED IRON IMPELLER STILL FITTED 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 1997122400328 19971224 00328 GL 1997 12 24 AU970551 1 19970524 G 2701 5102 TORQUE TUBE AMTR PITTS S1E 7221024 GL LYC O360 AEIO360B4A 41514 EA SNSNCH 76E 76EM8 EA CONTROL COLUMN CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CONTROL COLUMN TORQUE TUBE HOUSING CRACKED - AIRCRAFT IS MODIFIED WITH AN `ULTIMATE WING' INSTALLED - THIS WING HA S FULL SPAN AILERONS WITH INCREASED CHORD 1 Q 7 1 EO 3 O NC EXPA1Q71 1E10 5 N P4EA 1997122400329 19971224 00329 CE 1997 12 24 AU970552 1 19970522 G 2432 40576 BATTERY BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL DC SYS FAILED W K NONE H ELECT. POWER LOSS-50 PC CL CLIMB 1 AU S (AUS) MAIN BATTERY LOW VOLTAGE 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1997122400330 19971224 00330 EU 1997 12 24 AU970553 1 19970517 G 5312 5215075013 STIFFENER FOKKER F27 F27MK50 EU FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) REAR PRESSURE BULKHEAD STIFFENER CORRODED 2 H 7 2 4T RT A817 1997122400331 19971224 00331 SO 1997 12 24 AU970554 1 19970205 G 3222 702057505 STRUT GULSTM AA5 AA5 0631410 SO LYC O320 O320E2G 41508 EA NOSE GEAR CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NOSE LANDING GEAR STRUT CORRODED (RUSTED) AND SEIZED IN TORQUE TUBE FITTING - PROTECTION BOOT OLD AND DETERIORATED 1 L 7 1 3O 3 O A16EA E274 1997122400332 19971224 00332 CE 1997 12 24 AU970555 1 19970425 G 3260 JE1 SWITCH CESSNA 337 337 2075702 CE CONT O360 IO360C 17025 SO MCAULY 2AF34C D2AF34C306 GL LANDING GEAR FAULTY W K NONE O N OTHER FALSE WARNING LD LANDING 1 AU S (AUS) LH MAIN LANDING GEAR DOWN LIMIT MICROSWITCH LEVER BROKEN OFF 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 1997122400333 19971224 00333 SO 1997 12 24 AU970556 1 19970520 G 2910 6770016 PIPE PIPER PA32 PA32R300 7103213 SO LYC O540 IO540K1G5 41532 EA HARTZL HCC2Y HCC2YK1 GL HYDRAULIC MAIN CORRODED W K NONE K FLUID LOSS CR CRUISE 1 AU S (AUS) HYDRAULIC PIPE CONTAINED PIN HOLE CORROSION - CORROSION CAUSED BY LEAKING WINDOW SEALS - LOSS OF HYDRAULIC FLUID 1 L 7 1 3O 3 O A3SO 1E4 5 C P920 1997122400334 19971224 00334 EA 1997 12 24 AU970557 2 19970517 G 8550 68761 PIPE LYC PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA HARTZL HCE2Y HCE2YK2 GL RECIP ENG HOLED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S L797548 L797548 (AUS) RH ENGINE NO6 CYLINDER ROCKER OIL DRAIN LINE CHAFED ON BAFFLE STAY - ROCKER DRAIN PIPE ATTACHMENT HOSES PERISHED - PERSONNEL/MAINTENANCE ERROR 1 L 7 2 3O 3 O 1A10 1E4 5 C P9EA 1997122400335 19971224 00335 WP 1997 12 24 AU970558 1 19970521 G 6320 269A517515 CASE HUGHES 269A517515 HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA MAIN ROTOR GRBOX BROKEN W K NONE E VIBRATION/BUFFET NR NOT REPORTED 1 AU S WGC5875 (AUS) MAIN ROTOR TRANSMISSION UPPER CASE FLIGHT CONTROL SYSTEM LH MOUNTING LUG BROKEN - INDICATIONS APPEAR THAT THE LUG HAD BEEN CRACKED FOR SOME TIME - SUSPECT MOUNTING BOLT OVERTORQUED DURING INSTALLATION 1 G 7 1 3O 3 O 4H12 1E10 1997122400336 19971224 00336 SO 1997 12 24 AU970559 2 19970522 G 8520 838092R CRANKCASE CONT CESSNA 182 182M 2072728 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C203 GL ENGINE OUT OF LIMITS W K NONE O OTHER IN INSP/MAINT 1 AU S 838092R 838092R (AUS) ENGINE CRANKCASE OUT OF LIMITS - FOUND DURING BULK STRIP DUE TO METAL CONTAMINATION - OTHER DEFECTS FOUND INCLUDED :-1. CAMSHAFT LOBE CASE HARDENING WORN AND LOBE CRACKED 2. THREE CYLINDERS UNSERVICEABLE WITH ONE CYLINDER WORN THROUGH THE HARD CHROME3. INCORRECT PISTON RINGS WERE FITTED PERSONNEL/MAINTENANCE ERROR 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997122400337 19971224 00337 SO 1997 12 24 AU970560 2 19970522 G 8530 653443 VALVE GUIDE CESSNA 182 182H 2072718 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL ENG EXH WORN W K NONE O OTHER IN INSP/MAINT 1 AU S ST5424ST5425 223546 (AUS) NO3 AND NO4 CYLINDER EXHAUST VALVE GUIDES WORN - AIRCRAFT IS INVOLVED IN PARACHUTING OPERATIONS 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997122400338 19971224 00338 CE 1997 12 24 AU970561 1 19970523 G 5312 05121761LH BULKHEAD 05121872RH CESSNA 172 172P 2072436 CE MCAULY 1C160 1C160DTM GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH LOWER AFT DOOR POST BULKHEADS PNO 0512176-1 (LH) ANDPNO 0512187-2 (RH) CRACKED - FOUND DURING INSPECTION IAW CESSNA SEB 97-1 1 H 7 1 3O NT 3A12 5 N P910 1997122400339 19971224 00339 SO 1997 12 24 AU970562 1 19970517 G 7820 7766902 MUFFLER PIPER PA38 PA38112 7103812 SO LYC O235 O235L2C 41505 EA SNSNCH 72C 72CK EA ENGINE EXH DISTORTED W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S 520 L1904915 K1549 (AUS) REAR MUFFLER BAFFLE DISTORTED AND PARTIALLY BLOCKING OUTLET 1 L 7 1 3O 3 O A18SO E223 5 N P9045 1997122400340 19971224 00340 CE 1997 12 24 AU970563 1 19970529 G 5312 05121871LH BULKHEAD 05121872RH CESSNA 172 172P 2072436 CE MCAULY 1C160 1C160DTM GL FUSELAGE MAIN CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH LOWER DOOR POST BULKHEADS PNO 0512187-1 (LH) AND PNO0512187-2 (RH) CRACKED - FOUND DURING INSPECTION IAW SERVICEBULLETIN SEB 97-1 1 H 7 1 3O NT 3A12 5 N P910 1997122400341 19971224 00341 1997 12 24 AU970564 1 19970526 G 7602 115C6030 BRACKET LYC O360 O360A1F6 41514 EA HARTZL HCF2Y HCF2YR1 GL MIXTURE CONTROL CRACKED W K NONE E VIBRATION/BUFFET NR NOT REPORTED 1 AU S (AUS) MIXTURE CONTROL CABLE SUPPORT/ATTACHMENT BRACKET CRACKED IN AREAOF CABLE ATTACHMENT CLAMP 3 O E286 5 C P27EA 1997122400342 19971224 00342 SO 1997 12 24 AU970565 2 19970505 G 8530 530830 PISTON PIN RROYCE CESSNA 150 150B 2071806 CE CONT O200 O200A 17020 SO MCAULY 1A100 1A100MCM GL ENGINE GALLED W K NONE O OTHER IN INSP/MAINT 1 AU S 20R374 20R374 (AUS) PISTON PIN PLUG LOOSE AND GALLING ON CYLINDER BORE 1 H 7 1 3O 3 O 3A19 E252 5 N P918 1997122400343 19971224 00343 NM 1997 12 24 AU970566 1 19970429 G 5753 BACB30MR8 BOLT BOEING 767 767338 NM TE FLAP BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH OUTBOARD TRAILING EDGE FLAP BOLT BROKEN - FOUND DURING INSPECTION IAW ENGINEERING DIRECTIVE ED 19/97 2 L 7 2 4F RT A1NM 1998010600016 19980106 00016 NE 1998 1 6 AU970567 2 19970510 G 7200 ENGINE RROYCE RB211 RB211524G19 NE ENGINE NR 2 FIRE WARNING W K NONE N F FALSE WARNING FLT CONT AFFECTED LD LANDING 1 AU S (AUS) NO2 ENGINE FIRE WARNING - BOTH FIRE BOTTLES DISCHARGED - NO INDICATION OF FIRE EVIDENT 4 F E30NE 1997122400344 19971224 00344 NM 1997 12 24 AU970568 1 19970506 G 5315 BEAM BOEING 747 747338 NM FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) UPPER DECK FLOOR BEAM AT BS 330 CRACKED ON LH AND RH SIDES - LH SIDE CRACK LENGTH 41.2MM (1.625IN) - CRACK LENGTH RH SIDE 76.2MM(3IN) - FLOOR BEAM HAD NOT BEEN MODIFIED IAW ENGINEERING ORDER15672 - AREA IS PART OF SECTION 41 2 L 7 2 4F RT A20WE 1997122400345 19971224 00345 NM 1997 12 24 AU970569 1 19970510 G 5315 CHORD BOEING 747 747338 NM FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) UPPER DECK CHORD AT LBL 60 CRACKED - FOUND DURING REPAIR OF FLOOR BEAM FOUND IN MDR 97/0568 2 L 7 2 4F RT A20WE 1997122400346 19971224 00346 NM 1997 12 24 AU970570 1 19970517 G 5315 WEB BOEING 747 747238B 1384828 NM FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) UPPER DECK FLOOR BEAM UPPER WEB AT RBL63 CRACKED THROUGH FOUR FASTENER HOLES - CRACK LENGTH 127MM (5IN) - FOUND DU RING INSPECTION IAW ENGINEERING DIRECTIVE 28/97 REVISION1 2 L 7 4 4F A20WE 1997122400347 19971224 00347 1997 12 24 AU970571 4 19970513 G 2565 101651303 SLIDE BOEING 767 767338 NM ESCAPE SLIDE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) DOOR L1 ESCAPE SLIDE INADVERTENTLY DEPLOYED - SLIDE WOULD NOT INFLATE 2 L 7 2 4F RT A1NM 1997122400348 19971224 00348 NE 1997 12 24 AU970572 3 19970525 G 6110 4HFR34C652G PROPELLER MCAULY FRCHLD SA227 SA227DC 3377521 SW MCAULY 4HFR34 4HFR34C652 NE PROP ASSEMBLY FLUCTUATES W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S 940963 940963 (AUS) PROPELLER CAUSING RPM FLUCTUATIONS - PROPELLER WAS STRIPPED AND INSPECTED WITH NO SATISFACTORY CAUSE OF THE PROBLE M FOUND 2 L 7 2 4T RT A18SW 6 C 3PNE 1997122400349 19971224 00349 NM 1997 12 24 AU970573 1 19970525 G 3213 BOLT BOEING 747 747238B 1384828 NM MAIN GEAR LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NO1 AND NO14 MAIN LANDING GEAR WHEEL AXLE NUT SAFETY BOLTS (ONE OF TWO PER WHEEL) LOOSE - WHEEL HUB CAPS HAD BROKE N ATTACHMENT LUGS 2 L 7 4 4F A20WE 1997122400350 19971224 00350 NM 1997 12 24 AU970574 1 19970526 G 5315 WEB BOEING 747 747SP38 NM FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FLOOR BEAM WEB AND CHORD CRACKED IN AREA AT BS330/RBL60.31 -WEB CRACK LENGTH 50.8MM (2IN) EXTENDING THROUGH TWO FA STENER HOLES - CHORD CRACKED FROM FASTENER HOLES IN THREE AREAS - CRACK LENGTHS 0.508MM (0.020IN), 1.016MM (0.040IN) AND 6.350MM (0.25IN) - FOUND DURING INSPECTION IAW ED 28/97 2 L 7 4 4F RT A20WE 1997122400351 19971224 00351 1997 12 24 AU970575 4 19970526 G 6122 8971605 GOVERNOR WOODWARD 8971605 CESSNA 441 441 2076020 CE HARTZL HCB3T HCB3TN5 GL PROP GOVERNOR CRACKED W K NONE O K OTHER FLUID LOSS IN INSP/MAINT 1 AU S 4899 P670C (AUS) LH ENGINE PROPELLER GOVERNOR HOUSING CRACKED AT RH SIDE UPPER LUG 1 L 7 2 3T RT A28CE 6 C P15EA 1997122400352 19971224 00352 1997 12 24 AU970577 4 19970602 G 2562 ELT104 ELT PIPER PA28 PA28RT201T 7102817 SO CONT O360 TSIO360F 17025 SO HARTZL HCC2Y BHCC2YF1 GL EMERG LOCATOR FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 017242 (AUS) ELT FAULTY - `G' SWITCH UNSERVICEABLE - BATTERIES OF EUROPEAN ORIGIN FITTED - BATTERY INSULATORS WORN - EVIDENCE O F MOISTURE INGRESS 1 L 7 1 3O 3 O 2A13 E9CE 5 C P920 1997122400353 19971224 00353 SO 1997 12 24 AU970578 1 19970528 G 5730 SKIN GULSTM AA5 AA5A 3960106 SO LYC O320 O320E2G 41508 EA WING PLATES/SKIN DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH WING LOWER SKIN DELAMINATING - ELEVATOR TRIM TAB ALSO DELAMINATED - FOUND DURING INSPECTION IAW SB -155 1 L 7 1 3O 3 O A16EA E274 1997122400354 19971224 00354 SO 1997 12 24 AU970579 1 19970528 G 5751 AILERON GULSTM AA5 AA5A 3960106 SO LYC O320 O320E2G 41508 EA AILERON WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AILERON CONTROL CABLES LOOSE - AILERON BEARINGS WORN - OUTBOARD TORQUE TUBES WORN - TRIM TABS LOOSE - FOUND DURING INSPECTION IAW SB 165A 1 L 7 1 3O 3 O A16EA E274 1998010600017 19980106 00017 NE 1998 1 6 AU970580 2 19970524 G 7261 OIL SYSTEM BOEING 747 747312 1384932 NM PWA JT9 JT9D7R4G2 52054 NE TURBINE ENG OIL LOW QUANTITY W K E NONE ENGINE SHUTDOWN K FLUID LOSS CR CRUISE 1 AU S 715081 (AUS) NO3 ENGINE LOST ALL OIL - SUSPECT CAUSED BY TEMPORARY FAULT WITH NO3 CARBON SEAL 2 L 7 4 4F 4 F RT A20WE E3NE 1997122400355 19971224 00355 EA 1997 12 24 AU970581 2 19970526 G 8520 L913361A CAMSHAFT LYC PIPER PA31 PA31325 7103105 SO LYC O540 TIO540F2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S L913361A L913361A (AUS) ENGINE CAMSHAFT LOBE CASE HARDENING CRACKED - FOUND DURING MAGNETIC PARTICLE INSPECTION 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1997122400356 19971224 00356 SW 1997 12 24 AU970582 1 19970516 G 1100 DATA PLATE BELL 47 47G3B1 1181028 SW LYC O435 TVO435B1A 41516 EA FUSELAGE FAULTY W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) LARGE NUMBERS OF DISCREPANCIES WERE FOUND IN RELATION TO SERIAL NUMBERS - DATA PLATE FITTED DOES NOT MATCH CASA RE CORDS - SUSPECT MAJOR REBUILD CARRIED OUT FOLLOWING ACCIDENT IN 1988 -PERSONNEL/MAINTENANCE ERROR 1 G 7 1 3O 3 O 2H3 1E13 1997122400357 19971224 00357 SO 1997 12 24 AU970583 2 19970521 G 8520 643200 CRANKCASE CONT CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 1753 565359 565359 (AUS) LH AND RH CRANKCASE HALVES CRACKED IN AREA OF NO1 AND NO4 CYLINDER BASE FLANGE 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 1997122400358 19971224 00358 CE 1997 12 24 AU970584 1 19970509 G 3211 12416142 STUD CESSNA CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO MAIN GEAR LOOSE W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) LH AND RH MAIN LANDING GEAR DOWNLOCK SUPPORT ASSEMBLY FORWARD RETAINING STUDS LOOSE - AIRCRAFT HAD BEEN RECENTLY R EBUILT FOLLOWING AND ACCIDENT 242.3 HOURS PREVIOUSLY - PERSONNEL/MAINTENANCE ERROR 1 H 7 1 3O 3 O 3A21 E5CE 1997122400359 19971224 00359 EA 1997 12 24 AU970585 2 19970529 G 8520 L173368A CAMSHAFT LYC PIPER PA31 PA31325 7103105 SO LYC O540 LTIO540F2BD 41533 EA HARTZL HCE3Y HCE3YR2 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S L173368A L173368A (AUS) ENGINE CAMSHAFT LOBE CASE HARDENING CRACKED - COUNTERWEIGHT BUSHINGS WORN 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1997122400360 19971224 00360 1997 12 24 AU970586 4 19970516 G 2300 RADIO SYSTEM BELL 47 47G3B1 1181028 SW LYC O435 TVO435B1A 41516 EA E/E COMPARTMENT UNAPPROVED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) RADIOS FITTED WITHOUT CERTIFICATION - PERSONNEL/MAINTENANCE ERROR - UNAPPROVED PART 1 G 7 1 3O 3 O 2H3 1E13 1997122400361 19971224 00361 SW 1997 12 24 AU970587 1 19970516 G 3340 LIGHTS BELL 47 47G3B1 1181028 SW LYC O435 TVO435B1A 41516 EA EXTERIOR MISSING W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) NO LANDING LIGHTS FITTED - PERSONNEL/MAINTENANCE ERROR 1 G 7 1 3O 3 O 2H3 1E13 1997122400362 19971224 00362 SW 1997 12 24 AU970588 1 19970516 G 5310 TUBE BELL 47 47G3B1 1181028 SW LYC O435 TVO435B1A 41516 EA FUSELAGE DAMAGED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) TWO STRUCTURAL TUBES DAMAGED - PERSONNEL/MAINTENANCE ERROR 1 G 7 1 3O 3 O 2H3 1E13 1997122400363 19971224 00363 1997 12 24 AU970589 4 19970516 G 2562 ELT BELL 47 47G3B1 1181028 SW LYC O435 TVO435B1A 41516 EA COCKPIT WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) INCORRECT ELT FITTED - PERSONNEL/MAINTENANCE ERROR - UNAPPROVED PART. 1 G 7 1 3O 3 O 2H3 1E13 1997122400364 19971224 00364 SW 1997 12 24 AU970590 1 19970516 G 7160 CONTROLLER BELL 47 47G3B1 1181028 SW LYC O435 TVO435B1A 41516 EA ENGINE AIR INT SEIZED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) CARBURETTOR HEAT CONTROL SEIZED - PERSONNEL/MAINTENANCE ERROR 1 G 7 1 3O 3 O 2H3 1E13 1997122400365 19971224 00365 SW 1997 12 24 AU970591 1 19970516 G 2622 EXTINGUISHER BELL 47 47G3B1 1181028 SW LYC O435 TVO435B1A 41516 EA FIRE PROTECTION FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) FITMENT OF FIRE EXTINGUISHER NOT ENTERED IN LOG BOOKS 1 G 7 1 3O 3 O 2H3 1E13 1997122400366 19971224 00366 SW 1997 12 24 AU970592 1 19970516 G 2823 FUEL SHUTOFF BELL 47 47G3B1 1181028 SW LYC O435 TVO435B1A 41516 EA FUEL SELECTOR DISCONNECTED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUEL CUTOFF DISCONNECTED 1 G 7 1 3O 3 O 2H3 1E13 1997122400367 19971224 00367 SW 1997 12 24 AU970593 1 19970516 G 5302 TOOLBOX BELL 47 47G3B1 1181028 SW LYC O435 TVO435B1A 41516 EA ROTORCRAFT TAIL UNAPPROVED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) TOOLBOX MOUNTED IN TAIL BOOM - PERSONNEL/MAINTENANCE ERROR -UNAPPROVED PART 1 G 7 1 3O 3 O 2H3 1E13 1997122400368 19971224 00368 SW 1997 12 24 AU970594 1 19970516 G 7714 TACHOMETER BELL 47 47G3B1 1181028 SW LYC O435 TVO435B1A 41516 EA ENGINE RPM IND WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) INCORRECT TACHOMETER FITTED - PERSONNEL/MAINTENANCE ERROR - UNAPPROVED PART 1 G 7 1 3O 3 O 2H3 1E13 1997122400369 19971224 00369 SW 1997 12 24 AU970595 1 19970516 G 2510 CABIN BELL 47 47G3B1 1181028 SW LYC O435 TVO435B1A 41516 EA FLIGHT COMPART FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) SUSPECT CABIN RENEWED WITH NO LOG BOOK ENTRY -PERSONNEL/MAINTENANCE ERROR 1 G 7 1 3O 3 O 2H3 1E13 1997122400370 19971224 00370 SW 1997 12 24 AU970596 1 19970516 G 2510 INERTIA REEL BELL 47 47G3B1 1181028 SW LYC O435 TVO435B1A 41516 EA FLIGHT COMPART FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) SEAT BELT INERTIA REEL FAULTY - PERSONNEL/MAINTENANCE ERROR 1 G 7 1 3O 3 O 2H3 1E13 1997122400371 19971224 00371 SW 1997 12 24 AU970597 1 19970516 G 2841 INDICATOR BELL 47 47G3B1 1181028 SW LYC O435 TVO435B1A 41516 EA FUEL QTY FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUEL GAUGES FAULTY - PERSONNEL/MAINTENANCE ERROR 1 G 7 1 3O 3 O 2H3 1E13 1997122400372 19971224 00372 SO 1997 12 24 AU970598 1 19970602 G 5711 202731 WEB AYRES AYRES S2 S2RT34NORMAL 0970106 SO PWA PT6 PT6A34AG 52053 NE HARTZL HCB3T HCB3TN3 GL WING SPAR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH WING SPAR INBOARD WEB CRACKED - FOUND FOLLOWING REMOVAL OF SPAR CAPS FOR INSPECTION IAW SB-AG-39 1 L 7 1 3T 4 T A3SW E4EA 6 C P15EA 1997122400373 19971224 00373 CE 1997 12 24 AU970600 1 19970530 G 5312 DOOR POST CESSNA CESSNA 172 172P 2072436 CE MCAULY 1C160 1C160DTM GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE BULKHEAD DOOR POST FRAME CRACKED 1 H 7 1 3O NT 3A12 5 N P910 1997122400374 19971224 00374 SO 1997 12 24 AU970601 1 19970428 G 3297 MILW227591618 WIRE PIPER PA28 PA28RT201 7102818 SO LYC O360 IO360C1C 41514 EA MCAULY 2D34C 2D34C215 GL GEAR SWITCH BROKEN W O OTHER O P OTHER NO WARNING INDICATION DE DESCENT 1 AU S (AUS) LH MAIN LANDING GEAR DOWNLOCK MICROSWITCH WIRE BROKEN AT TERMINAL 1 L 7 1 3O 3 O 2A13 1E10 5 C P7EA 1997122400375 19971224 00375 SW 1997 12 24 AU970602 1 19970603 G 2752 7003131 ACTUATOR AIRTRC AT300 AT301 0390103 SW PWA R1340 R1340AN1 52016 NE TE FLAP FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 3383 (AUS) FLAP ACTUATOR OVER TRAVEL STOP SEPARATED CAUSING DAMAGE TO THE THREAD AND LOSS OF BALLS FROM THE BALLNUT ASSEMBLY - FOUND DURING DISASSEMBLY FOR INCORPORATION OF AD/AT/19 - SERVICE LETTER 140 1 L 7 1 3R 3 R A9SW 5E2 1997122400376 19971224 00376 SO 1997 12 24 AU970604 1 19970603 G 5753 6232800 RIB PIPER PIPER PA28 PA28140 7102802 SO LYC O320 O320E2A 41508 EA SNSNCH 74DM M74DM EA TE FLAP CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 2822857 (AUS) FLAP RIBS PNO 62328-00 AND PNO 62328-01 CORRODED DUE TO DISSIMILAR METAL CORROSION BETWEEN ATTACHMENT BRACKET AND RIBS 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 1997122400377 19971224 00377 SO 1997 12 24 AU970605 1 19970603 G 5711 20273T002 WEB AYRES AYRES S2 S2RT34NORMAL 0970106 SO PWA PT6 PT6A34AG 52053 NE HARTZL HCB3T HCB3TN3 GL WING SPAR STRUCT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH WING INBOARD SPAR LOWER WEB ANGLE CRACKED THROUGH RIVET HOLE - CRACK LENGTH 91.44MM (3.6IN) - ANOTHER CRACK FOU ND ON UPPER WEB ANGLE - CRACK LENGTH 22.85MM (0.9IN) - FOUND DURING REMOVAL OF SPAR CAPS FOR INSPECTION IAW SB-AG-39 1 L 7 1 3T 4 T A3SW E4EA 6 C P15EA 1998010600018 19980106 00018 1998 1 6 AU970606 1 19970523 G 2410 630406 DRIVE HUB CONT CONT O360 IO360HB 17025 SO HARTZL HCC2Y BHCC2YF1 GL ALTERNATOR-GEN SHEARED W K NONE H ELECT. POWER LOSS-50 PC CR CRUISE 1 AU S 285 C269007 265176R (AUS) ALTERNATOR DRIVE HUB SHEARED 3 O E1CE 5 C P920 1997122400378 19971224 00378 SO 1997 12 24 AU970607 1 19970603 G 5711 20273T001 WEB AYRES AYRES S2 S2RT34NORMAL 0970106 SO PWA PT6 PT6A34AG 52053 NE HARTZL HCB3T HCB3TN3 GL WING SPAR STRUCT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH WING LOWER SPAR WEB ANGLE CRACKED IN THREE PLACES - CRACK LENGTHS 53.34MM (2.1IN), 66.04MM (2.6IN) AND 44.45MM (1.75IN) - FOUND FOLLOWING SPAR CAP REMOVAL FOR INSPECTION IAW SB-AG-39 1 L 7 1 3T 4 T A3SW E4EA 6 C P15EA 1997122400379 19971224 00379 SO 1997 12 24 AU970608 1 19970601 G 7160 AIR BOX PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA ENGINE AIR INT BLOCKED W K NONE O OTHER CR CRUISE 1 AU S L2148036A (AUS) CARBURETTOR AIR BOX PARTIALLY BLOCKED BY MUD HORNETS NEST - EVIDENCE OF HORNET IN CARBURETTOR 1 L 7 1 3O 3 O 2A13 E286 1997122400380 19971224 00380 SO 1997 12 24 AU970609 1 19970516 G 3230 9572402 MOUNT PIPER PA34 PA34200T 7103406 SO HARTZL HCC2Y BHCC2YF2 GL GEAR ATTACH LOOSE W K NONE O OTHER NR NOT REPORTED 1 AU S (AUS) NOSE LANDING GEAR RETRACTION ACTUATOR MOUNTING BRACKET SEPARATED FROM CHANNEL PNO 95599-02 DUE TO INCORRECT RIVETS - AIRCRAFT HAD BEEN REPAIRED APPROXIMATELY 800 HOURS PREVIOUSLY -PERSONNEL/MAINTENANCE ERROR 1 L 7 2 3O A7SO 5 C P920 1997122400381 19971224 00381 SW 1997 12 24 AU970610 1 19970521 G 2750 5101017 PULLEY GULSTM 680 680FL 0141608 SW AIRCRAFT SUB-STA FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) NEW CABLE PULLEY FAULTY - GROOVE TOO NARROW FOR CABLE TO SIT CORRECTLY INTO GROOVE - PULLEY WAS TO BE FITTED TO VH -DCA AN AEROCOMMANDER 680FL TO COMPLY WITH AD/AC/88 1 H 7 2 3O 2A4 1998010800256 19980108 00256 1998 1 8 AU970611 1 19970604 G 2520 AV94103 SEAT PASS COMPART ILLEGAL REPAIR W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) BENNETTS SEAT CONVERTER STOWAGE COMPARTMENT (SEAT MOUNTED CONTAINER) INCORRECTLY REPAIRED - PERSONNEL/MAINTENANCE ERROR - UNAPPROVED REPAIR 1997122400382 19971224 00382 SO 1997 12 24 AU970612 1 19970407 G 7920 HOSE LYC PIPER PA18 PA18150 7101828 SO LYC O320 O320A2B 41508 EA SNSNCH 74DM M74DM EA ENGINE OIL DIST FAILED W K NONE K FLUID LOSS CR CRUISE 1 AU S (AUS) FLEXIBLE OIL HOSE FROM REAR OF ENGINE TO OIL COOLER FAILED - HOSE HAD BEEN ROUTED BETWEEN CRANKCASE AND EXHAUST ST ACKS AND HADHARDENED AND BURNT 1 H 7 1 3O 3 O 1A2 E274 5 N P88614 1997122400383 19971224 00383 SO 1997 12 24 AU970613 1 19970603 G 7603 455185 THROTTLE 487819 PIPER PA24 PA24 7102402 SO LYC O360 O360A1A 41514 EA POWER LEVER WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) SUSPECT INCORRECT THROTTLE CONTROL FITTED - NO MICROSWITCH IS FITTED FOR THE UNDERCARRIAGE WARNING SYSTEM AND THE WIRING IS SECURED BEHIND THE INSTRUMENT PANEL - PERSONNEL/MAINTENANCE ERROR - UNAPPROVED PART 1 L 7 1 3O 3 O 1A15 E286 1997122400384 19971224 00384 EA 1997 12 24 AU970614 2 19970526 G 7414 M3183 CONDENSER SLICK 4Z70 PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA SNSNCH 76E 76EM8 EA MAGNETO/DIST FAILED W K NONE O OTHER CR CRUISE 1 AU S F90090270 L2656936A (AUS) RH MAGNETO CONDENSER OPEN CIRCUIT 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 1997122400385 19971224 00385 CE 1997 12 24 AU970615 1 19970509 G 5711 04224063 STIFFENER 04224075 CESSNA 150 A150K 2071824 CE CONT O200 O200A 17020 SO MCAULY 1A101 1A101DCM GL WING SPAR CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S NA (AUS) LH WING SPAR FORWARD STIFFENER PLATE AND SPAR TOP PLATE CONTAINED EXFOLIATION CORROSION 1 H 7 1 3O 3 O 3A19 E252 5 N P918 1997122400386 19971224 00386 SW 1997 12 24 AU970616 1 19970502 G 3246 13685L BEARING BFGOODRICH SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE3313UW 01514 WP HARTZL HCB3T HCB3TN5 GL WHEEL/SKI/FLOAT DISINTEGRATED W K NONE O OTHER TO TAKEOFF 1 AU S 1343 (AUS) LH OUTBOARD WHEEL BEARING CONE DISINTEGRATED - WHEEL SEPARATED FROM AXLE DURING TAKEOFF - WHEEL RETAINING NUT STIL L IN PLACE 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P15EA 1997122400387 19971224 00387 CE 1997 12 24 AU970617 1 19970530 G 3320 M2275916 HARNESS M2275920 BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA PASSENGER COMPAR BURNT W K NONE B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) CABIN READING LIGHT HARNESS WIRES BURNT - WIRES WERE CHAFING ON CABIN ROOF PANELS DUE TO INADEQUATE SECURITY AND P ROTECTION OFTHE HARNESS 2 L 7 2 4T 4 T RT A24CE E4EA 1997122400388 19971224 00388 NE 1997 12 24 AU970618 2 19970606 G 7321 7918094004 EEC PWA PWA120 PW125B NE FUEL CONTROL FAULTY W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 AU S 031 (AUS) LH ENGINE ELECTRONIC ENGINE CONTROL (EEC) FAULTY - DURING INVESTIGATION ALL CONNECTOR PLUGS WERE REMOVED AND CLEAN ED ANDTHE ENGINE GROUND RUN WITH NO FURTHER FAULTS 4 T E20NE 1997122400389 19971224 00389 GL 1997 12 24 AU970619 3 19970603 G 6114 C23 HUB MCAULY BEECH 35 V35A 1151544 CE CONT O520 IO520BA 17032 SO MCAULY 2A36C 2A36C23 GL PROP HUB FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 1200 770832 770832 (AUS) PROPELLER HUB THREADS FAILED EDDY CURRENT INSPECTION - NO2 BLADE LOOSE IN HUB DUE TO BLADE NUT NOT BEING TORQUED A T LAST ASSEMBLY (SUSPECT AT INITIAL ASSEMBLY AT FACTORY APPROXIMATELY 20 YEARSPREVIOUSLY) - PERSONNEL/MAINTENANCE ERROR 1 L 7 1 3O 3 O 3A15 E5CE 5 C P880 1997122400390 19971224 00390 1997 12 24 AU970620 4 19970603 G 6113 587330 BULKHEAD PIPER PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA PROP SPINNER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PROPELLER SPINNER AFT BULKHEAD CRACKED AND A SMALL SECTION OF THE FLANGE SEPARATED - THE SECTION WHICH SEPARATED C ONTAINED TWO OF THE DOME MOUNTING SCREWS - DAMAGE ALSO TO SPINNER DOME 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 1997122400391 19971224 00391 NM 1997 12 24 AU970621 1 19970527 G 2510 PIN 3A020004107 BOEING 747 747238B 1384828 NM FLIGHT COMPARTME OUT OF ADJUST W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FIRST OFFICERS SEAT ADJUSTMENT LOCKING PIN ENGAGING IN SEAT TRACK BY ONLY 3MM (0.118IN) 2 L 7 4 4F A20WE 1998010600019 19980106 00019 CE 1998 1 6 AU970622 1 19970412 G 6123 8907 ACCUMULATOR BEECH 76 76 1153005 CE HARTZL HCM2Y HCM2YR GL PROP FEATHER FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S RH (AUS) PROPELLER UNFEATHERING ACCUMULATOR LEAKING INTERNALLY CAUSING LOSS OF AIR CHARGE - SUSPECT WORN PISTON `O' RING SE ALS 1 L 7 2 3O A29CE 5 C P43GL 1997122400392 19971224 00392 CE 1997 12 24 AU970623 1 19970609 G 5312 75469 BULKHEAD CESSNA CESSNA 172 172P 2072436 CE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 75469 (AUS) LH AND RH FUSELAGE DOOR FRAME BULKHEADS CRACKED BEHIND LAP JOINT 1 H 7 1 3O NT 3A12 1997122400393 19971224 00393 EU 1997 12 24 AU970624 1 19970529 G 3212 325761 SHEAR HEAD GARRTT D24762104 SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE EMERGENCY FLOAT FAILED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 1002 (AUS) EMERGENCY FLOTATION DEVICE INFLATED DURING FILLING OF BOTTLE -DAMAGE CAUSED TO SIDE DOOR AND LOWER STRUCTURE - SAF ETY LOCK PINON SHEAR HEAD FITTED AT THE TIME - INVESTIGATION FOUND THAT THE PISTON ASSEMBLY THAT PREVENTS BOTTLE DISCHAR GE WAS NOT FULLYENGAGED IN THE SHEAR HEAD ALTHOUGH WITNESS MARKS INDICATED THAT THE PISTON HAD BEEN FULLY ENGAGED AT SOM E TIME -PERSONNEL/MAINTENANCE ERROR 1 G 7 1 3U 3 U H9EU E19EU 1997122400394 19971224 00394 NM 1997 12 24 AU970625 1 19970528 G 7921 A6492 OIL COOLER 20008A ROBSIN R22 R22BETA NM LYC O320 O320B2C 41508 EA ENGINE OIL CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S L952129125 (AUS) ENGINE OIL COOLER CRACKED AND LEAKING - COOLER HAD COMPLETED ONLY 0.7 HOURS SINCE NEW 1 G 7 1 3O 3 O H10WE E274 1997122400395 19971224 00395 GL 1997 12 24 AU970626 2 19970513 G 7230 6890550 COMPRESSOR BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL ENGINE FOD W K NONE C F.O.D. IN INSP/MAINT 1 AU S CAC80223 0001NTZ (AUS) COMPRESSOR DAMAGED BY FOD - INSPECTION SUGGESTS THAT THE FOD WAS A SOFT OBJECT SUCH AS A WASPS NEST RATHER THAN A HARD METALIC TYPE OBJECT 1 G 7 1 3U 3 U H2SW E4CE 1997122400396 19971224 00396 GL 1997 12 24 AU970627 3 19970516 G 6111 A163353 SEAL BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO MCAULY 2AF34C 2AF34C55 GL PROPELLER BLADE FAILED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 736273 (AUS) PROPELLER BLADE NUT TO HUB SEAL LEAKING 1 L 7 2 3O 3 O RT 3A16 3E1 5 C P5EA 1997122400397 19971224 00397 SO 1997 12 24 AU970628 2 19970609 G 8520 554828 CRANKSHAFT CONT CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO MCAULY 3A32C D3A32C88 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 554828 554828 (AUS) ENGINE CRANKSHAFT CRACKED ON OIL SLINGER FACE - STARTER SHAFT HAD FOUR CRACKED TEETH - CAMSHAFT CRACKED ON GOVERNO R GEAR SPIGOT - CRANKSHAFT GEAR UNSERVICEABLE - TWO COUNTERWEIGHTS UNSERVICEABLE IAW M93-4 - CRANKCASE FRETTING ON BEARI NG SADDLES - SUSPECT ENGINE SUBJECTED TO A PROPELLER STRIKE 1 H 7 1 3O 3 O 3A21 E5CE 5 C P21EA 1997122400398 19971224 00398 EU 1997 12 24 AU970629 1 19970108 G 2913 MX446203 PUMP AIRBUS 320 A320212 EU HYDRAULIC PUMP FAILED W A K NONE K FLUID LOSS CL CLIMB 1 AU S MX446203 (AUS) NO1 ENGINE DRIVEN HYDRAULIC PUMP FAILED - INVESTIGATION FOUND THAT ALL THE PISTONS HAD SEPARATED FROM THE PISTON S HOES - THE YOKE CONTROL SPRING BROKEN - PUMP CONTAMINATED WITH METAL - LOSS OF HYDRAULIC FLUID THROUGH DRIVE SHAFT SEAL 2 L 7 2 4F RT A28NM 1997122400399 19971224 00399 EA 1997 12 24 AU970630 2 19970610 G 8520 LW15452 CRANKCASE LYC LYC O540 LTIO540J2BD 41533 EA HARTZL HCE3Y HCE3YR2 GL RECIP ENG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 2037 L51768A L51768A (AUS) RH ENGINE CRANKCASE CRACKED ADJACENT TO NO3 CYLINDER - CRACK 82.55MM (3.25IN) INTERNAL LENGTH AND 114.3MM (4.5IN) EXTERNAL LENGTH 3 O E14EA 5 C P33EA 1997122400400 19971224 00400 EU 1997 12 24 AU970631 1 19970527 G 2750 STRUT AIRBUS 320 A320212 EU TE FLAP CONTROL OUT OF ADJUST W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH TRAILING EDGE FLAP INTERCONNECT STRUT OUT OF ADJUSTMENT 2 L 7 2 4F RT A28NM 1997122400401 19971224 00401 EU 1997 12 24 AU970632 1 19970528 G 2750 676101258 RESOLVER BAC 146 146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE TE FLAP CONTROL OUT OF ADJUST W K NONE F FLT CONT AFFECTED CL CLIMB 1 AU S 10632ANSETTS (AUS) GREEN SYSTEM FLAP CONTROL UNIT RESOLVER OUT OF ADJUSTMENT - LH FLAP ASYMMETRY BRAKE SOLENOID SHORT CIRCUIT 2 H 7 4 4F 4 F RT A49EU E6NE 1997122400402 19971224 00402 1997 12 24 AU970633 4 19970528 G 2330 7430213003 CONTROL UNIT BOEING 737 737376 NM ENTERTAIN SYS FAULTY W K NONE B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) VIDEO SYSTEM CONTROL UNIT FAULTY - UNIT SMOKING WITH ACCOMPANYING SMELL 2 L 7 2 4F RT A16WE 1997122400403 19971224 00403 NM 1997 12 24 AU970634 1 19970520 G 2760 2732513 CONTROL CABLE BOEING 737 737376 NM DRAG CONTROL SYS FAILED W O OTHER O OTHER NR NOT REPORTED 1 AU S 678 (AUS) GROUND SPOILER CABLE FAILED 2 L 7 2 4F RT A16WE 1997122400404 19971224 00404 NM 1997 12 24 AU970635 1 19970131 G 5755 65671868 FITTING BOEING 737 73733A 1384673 NM GE CFM56 CFM563B1 13802 NE SPOILER FRACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NO5 GROUND SPOILER PANEL OUTBOARD ACTUATOR HINGE BRACKET BROKEN ACROSS THE HINGE ATTACHMENT BEARING LUG 2 L 7 2 4F 4 F RT A16WE E2GL 1997122400405 19971224 00405 CE 1997 12 24 AU970636 1 19970611 G 5311 74785 FRAME CESSNA CESSNA 172 172P 2072436 CE MCAULY 1C160 1C160DTM GL FUSELAGE MAIN CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 74785 (AUS) LH AND RH FUSELAGE FRAMES CRACKED FROM RELIEF NOTCH TOWARDS UPPER OUTBOARD `HI-SHEAR' FASTENER OF OUTBOARD UNDERCA RRIAGE CASTING 1 H 7 1 3O NT 3A12 5 N P910 1997122400406 19971224 00406 NM 1997 12 24 AU970637 1 19970407 G 5312 BULKHEAD BOEING 737 737377 NM FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD PRESSURE BULKHEAD CRACKED IN THE FOLLOWING AREAS:-1. FORWARD FACE OF BULKHEAD WEB CONTAINED THREE CRACKS I N AREA BELOW RADAR SCANNING MOUNTING BRACKETS AT RBL 5.7 - CRACK LENGTHS 15MM (0.59IN) - 14MM (0.55IN) AND 3MM (0.118IN) - FOUND USING ULTRASONIC TECHNIQUE 2. AFT FACE OF BULKHEAD LEFT VERTICAL CHORD INBOARD RADIUS CRACKED AT LB 5.7 - CRACK LENGTH 22MM (0.866IN) - FOUND USING EDDY CURRENT TECHNIQUE FOUND DURING INSPECTION IAW ER B73-53-10-39 2 L 7 2 4F RT A16WE 1997122400407 19971224 00407 NM 1997 12 24 AU970638 1 19970524 G 5320 BOE20030031 SEAL BOEING 737 737377 NM FUSELAGE DAMAGED W K NONE O OTHER CR CRUISE 1 AU S (AUS) APU PNEUMATIC DUCT SEAL IN AFT PRESSURE BULKHEAD TORN. 2 L 7 2 4F RT A16WE 1997122400408 19971224 00408 NM 1997 12 24 AU970639 1 19970518 G 2750 5701831 SEAL BOEING 737 73733A 1384673 NM TE FLAP CONTROL DAMAGED W K NONE F FLT CONT AFFECTED NR NOT REPORTED 1 AU S 5380 (AUS) TRAILING EDGE FLAPS NO4 JACKSCREW BALLNUT FELT SEALS DAMAGED ALLOWING WATER INGRESS 2 L 7 2 4F RT A16WE 1997122400409 19971224 00409 GL 1997 12 24 AU970640 1 19970422 G 2700 FLIGHT CONTROLS AMTR JABIRU JABIRUSK 05602CU GL FLIGHT CONTROL LOOSE W A UNSCHED LANDING F FLT CONT AFFECTED NR NOT REPORTED 1 AU S (AUS) AIRCRAFT CONTROLS LOOSE - AIRCRAFT MADE AN EMERGENCY LANDING IN A PLOUGHED PADDOCK BREAKING THREE BOLTS AND A SADD LE ON THE LH MAIN LANDING GEAR, THE LH BRAKE LINE AND DAMAGING ALL THE SPATS - THIS DEFECT WAS RECEIVED FROM THE AUF AND IS FOR INFORMATION ONLY 1 H 7 1 IO NC EXPA1H71 1997122400410 19971224 00410 NM 1997 12 24 AU970641 1 19970505 G 5312 WEB BOEING 737 737377 NM FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD PRESSURE BULKHEAD WEB CONTAINED THREE CRACKS IN AREA BELOW THE RADAR SCANNING MOUNTING BRACKETS - TWO CRAC KS LOCATED AT LBL 5.7 - ONE CRACK LOCATED AT RBL 5.7 - CRACK LENGTHS 10MM(0.393IN) - FOUND DURING EDDY CURRENT INSPECTIO N IAW ER B73-53-10-39A 2 L 7 2 4F RT A16WE 1998010800257 19980108 00257 1998 1 8 AU970642 4 19970515 G 2565 65C1990120 CABLE BOEING 737 737377 NM ESCAPE SLIDE FRAYED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD ENTRY DOOR ESCAPE SLIDE LATCH CABLE FRAYED IN AREA OF SWAGED BALL END TERMINAL 2 L 7 2 4F RT A16WE 1998010800258 19980108 00258 EU 1998 1 8 AU970643 1 19970607 G 2910 9302631 HOSE SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE HYD MAIN RUPTURED W K NONE K FLUID LOSS CR CRUISE 1 AU S (AUS) HYDRAULIC HOSE BETWEEN HYDRAULIC PUMP AND FILTER HOUSING FAILED 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 1998010800259 19980108 00259 EA 1998 1 8 AU970644 2 19970611 G 7414 M3975 COIL SLICK 4381 CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL ENGINE OPEN CIRCUIT W K NONE O OTHER IN INSP/MAINT 1 AU S 94010058 (AUS) MAGNETO COIL OPEN CIRCUITED 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 1998010800260 19980108 00260 CE 1998 1 8 AU970645 1 19970612 G 2730 ANS11A BOLT MS21042L5 CESSNA 172 172R 2072401 CE ELEVATOR CONTROL LOOSE W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) LOWER ELEVATOR PULLEY LOCATED AT BULKHEAD AFT OF ELEVATOR BELLCRANK HAD NUT PNO MS21042L5 AND BOLT PNO ANS-11A LOO SE BUT STILL IN SAFETY - PERSONNEL/MAINTENANCE ERROR 1 H 7 1 3O NT 3A12 1998010800261 19980108 00261 CE 1998 1 8 AU970646 1 19970610 G 5312 05121871 BULKHEAD 05121872RH CESSNA 172 172P 2072436 CE MCAULY 1C160 1C160DTM GL DOOR POST CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE BULKHEAD LH AND RH LOWER AFT DOOR POSTS PNO 0512187-1 LH AND PNO 0512187-2 RH CRACKED IN AREA INDICATED B Y SERVICE BULLETIN 1 H 7 1 3O NT 3A12 5 N P910 1998010800262 19980108 00262 NE 1998 1 8 AU970647 3 19970611 G 6110 6607 SLIDEBLOCK 09241 ROTOL R390 R3904123F27 NE PROPELLER ASSY DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S DRG102086 (AUS) PROPELLER ADJACENT SLIDEBLOCKS (2OFF) DISLODGED AND DAMAGED 6 C P31NE 1998010800263 19980108 00263 SO 1998 1 8 AU970648 1 19970526 G 2140 39D18 COMBUSTOR JANITROL 90D281 PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360KB 17025 SO MCAULY 3AF32C 3AF32C508 GL HEATING SYSTEM CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 11801238 (AUS) CABIN HEATER COMBUSTION CAN SPLIT AROUND CIRCUMFERENCE FORAPPROXIMATELY 60MM (2.36IN) - HEATER WAS BEING OVERHAULE D TO COMPLY WITH REQUIREMENTS OF AD/AIRCON/9 AMDT5 PARA3 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 1998010800264 19980108 00264 SO 1998 1 8 AU970649 1 19970603 G 5270 SWITCH EMB 110 EMB110P2 3260124 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL DOOR WARNING SYS OUT OF ADJUST W K NONE N FALSE WARNING TO TAKEOFF 1 AU S (AUS) REAR ENTRY DOOR MICROSWITCH OUT OF ADJUSTMENT 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 1998010800265 19980108 00265 CE 1998 1 8 AU970650 1 19970610 G 3213 50450181 WASHER CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL MLG SCISSOR FAULTY W K NONE O OTHER LD LANDING 1 AU S (AUS) MAIN LANDING GEAR SCISSOR LINK CENTRE BOLT PULLED THROUGH LOWER LINK ALLOWING WHEEL TO ROTATE LATERALLY - DURING L ANDING THE TYRE AND TUBE BLEW OUT - SUSPECT CAUSED BY FAULTY WASHER AND/OR BUSHING 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 1998010800266 19980108 00266 CE 1998 1 8 AU970651 1 19970612 G 5730 95110014206 SKIN BEECH BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO MCAULY 2AF34C 2AF34C55 GL WS 66 TO 80 CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S TC1317 (AUS) RH WING LOWER SKIN CORRODED THROUGH AT FORWARD INBOARD END -CORROSION INITIATED BETWEEN SKIN AND DOUBLER INSTALLED AT INBOARD END OF SKIN BETWEEN WS 66.0 AND WS 80.0 1 L 7 2 3O 3 O RT 3A16 3E1 5 C P5EA 1998010800267 19980108 00267 SO 1998 1 8 AU970652 1 19970514 G 5320 DOOR POST EMB 110 EMB110P2 3260124 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL FUSELAGE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE DOOR PILLAR AND DOOR MAIN CABLE ATTACHMENT BRACKET CRACKED. 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 1998010800268 19980108 00268 SO 1998 1 8 AU970653 1 19970605 G 3234 12037544001 VALVE EMB 120 EMB120 3260201 SO PWA 118 PW118A NE EMERG GEAR SEL DAMAGED W K NONE O OTHER CR CRUISE 1 AU S (AUS) EMERGENCY LANDING GEAR SELECTOR VALVE `O' RING SEAL DAMAGED 2 L 7 2 4T 4 T RT A31SO E20NE 1998010800269 19980108 00269 1998 1 8 AU970655 4 19970607 G 6122 A259 SPRING HARTZL F624 PROPELLER GOV FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S B3804T (AUS) PROPELLER CSU SPEEDER SPRING FAULTY - THIS WAS THE THIRD SPRING FITTED 1998010800270 19980108 00270 EA 1998 1 8 AU970656 2 19970613 G 7414 10682014 GEAR BENDIX D4RN2021 BEECH 76 76 1153005 CE LYC O360 LO360A1G6 41514 EA ENG MAG DIST FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S R3460K L28671A (AUS) MAGNETO DISTRIBUTOR GEAR TEETH MISSING 1 L 7 2 3O 3 O A29CE 1E10 1998010800271 19980108 00271 SO 1998 1 8 AU970657 1 19970605 G 3260 SWITCH EMB 110 EMB110P1 3260122 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL LANDING GEAR POS INCORRECT WIRED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) LH MAIN LANDING GEAR DOWNLOCK SWITCH FAULTY - FAILED INSULATION TEST IAW SB/110/32-0052 REV3 - INVESTIGATION FOUND THAT THE SWITCH HAD BEEN WIRED DIRECTLY INTO THE LOOM INSTEAD OF THROUGH THE PLUG - THE WIRING SPLICES HAD EVENTUALLY C ORRODED CAUSING CRACKING - PERSONNEL/MAINTENANCE ERROR 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 1998010800272 19980108 00272 SO 1998 1 8 AU970658 1 19970520 G 3242 54413 BRAKE ADJUSTER BFGOODRICH 21585 EMB 120 EMB120 3260201 SO PWA 118 PW118A NE BRAKE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 900 (AUS) BRAKE UNIT ADJUSTERS CORRODED AND SEIZED PREVENTING THE BRAKE PISTONS FROM MOVING THE BRAKE STATOR PACK 2 L 7 2 4T 4 T RT A31SO E20NE 1998010800273 19980108 00273 SO 1998 1 8 AU970659 1 19970613 G 3230 M81934222 BUSHING C040120 EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE MLG CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 7556 (AUS) NOSE LANDING GEAR MAIN DRAG AND LOCKING STRUT PIVOT BUSHINGS AND SHIMS WERE CORRODED 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 1998010800274 19980108 00274 CE 1998 1 8 AU970660 1 19970526 G 2432 407610 BATTERY BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE BATTERY FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 062129 (AUS) BATTERY FAULTY - REPORTED AS FLAT PRIOR TO ENGINE START - ON COMPLETION OF THE FLIGHT THE BATTERY WAS INSPECTED AN D WAS FOUNDTO HAVE BULGED ALL AROUND BY AT LEAST 6.35MM (0.25IN) - NO WARNING LIGHTS HAD ILLUMINATED DURING THE FLIGHT 2 H 7 2 4F 4 F RT A16SW E25EA 1998010800275 19980108 00275 EA 1998 1 8 AU970661 2 19970527 G 7322 CK34843 SCREW FACET CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL CARB MIX ADJ MISSING W K NONE O R OTHER PARTIAL RPM/PWR LOSS LD LANDING 1 AU S CK34843 L516076T (AUS) CARBURETTOR MIXTURE ADJUSTMENT SCREW MISSING - SUSPECT BROKEN FRICTION SPRING ALLOWED SCREW TO UNWIND 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 1998010800276 19980108 00276 NE 1998 1 8 AU970662 2 19970526 G 7210 3BE COMBINING GRBOX BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE ENGINE FAULTY W K NONE J K WARNING INDICATION FLUID LOSS DE DESCENT 1 AU S CPGB13019 PCE89648 (AUS) ENGINE COMBINING GEARBOX FAULTY - SUSPECT FAULTY CARBON SEAL ALLOWED OIL TO TRANSFER INTO GEARBOX CAUSING OVERFILL ING AND LOSS OF OIL OVERBOARD 1 G 7 2 4U 4 U H4SW E22EA 1998010800277 19980108 00277 GL 1998 1 8 AU970663 2 19970521 G 7260 MS210433 NUT ALLSN SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30 03013 GL ENG 2.5 BEARING SEPARATED W K NONE O OTHER CR CRUISE 1 AU S CAG90574 CAE890296S (AUS) NO2 ENGINE GEARBOX 2.5 BEARING SUPPORT RETENTION NUTS (2OFF6) MISSING - NUTS WERE EVENTUALLY FOUND IN THE OIL PUMP SCAVENGE LINE - NUTS WERE NOTED TO BE OF AN UNUSUAL TYPE - SUSPECT UNAPPROVRD PART 1 G 7 2 3U 3 U H1NE E1GL 1998010800278 19980108 00278 EU 1998 1 8 AU970664 1 19970401 G 6330 350A38101832 MOUNT AEROSP AS355 AS355F1 8680810 EU ALLSN 250C 250C20F 03013 GL M/R TRANS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MAIN TRANSMISSION BI-DIRECTIONAL MOUNT CRACKED - FOUND DURING INSPECTION IAW AD/AS355/47 1 G 7 2 3U 3 U H11EU E4CE 1998010800279 19980108 00279 EA 1998 1 8 AU970665 2 19970610 G 8530 SL134441 PISTON PIN SUPAIRPART PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA ENG NR 3 CYL FAILED W K NONE O K OTHER FLUID LOSS IN INSP/MAINT 1 AU S A995 L922939A (AUS) NO3 CYLINDER PISTON PIN FAILED RESULTING IN FAILURE OF NO3 PISTON. PARTS OF NO3 PISTON LODGED BENEATH NO4 CYLINDER EXHAUST TAPPET CAUSING IT TO FAIL ALSO. SECONDARY DAMAGE CAUSED TO CRANKCASE, CONNECTING RODS, CAMSHAFT, NO3 CYLINDER S KIRT AND NO1, NO2 AND NO3 CYLINDER TAPPETS. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 1998010800280 19980108 00280 CE 1998 1 8 AU970666 1 19970531 G 3230 LANDING GEAR BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE EMERG EXT LEVER FAULTY W K NONE O OTHER DE DESCENT 1 AU S (AUS) LANDING GEAR EXTENSION SYSTEM FAULTY - UNABLE TO MOVE EMERGENCY EXTENSION LEVER - LANDING GEAR 60AMP CIRCUIT BREAK ER POPPED - CIRCUIT BREAKER RESET, EMERGENCY SYSTEM DISENGAGED AND LANDING GEAR EXTENDED NORMALLY - INSPECTION COULD FIN D NO APPARENT DEFECT IN SYSTEM APART FROM A BUILDUP OF GREASE AROUND THE CLUTCH AREA - GREASE CLEANED OFF AND CLUTCH LUB RICATED, NEW MOTOR FITTED AS A PRECAUTION - RETRACTION CHECKS CARRIED OUT WITH NO FAULTS EVIDENT 1 L 7 2 4T 4 T A24CE E4EA 1998010800281 19980108 00281 SO 1998 1 8 AU970667 1 19970617 G 5711 202732LH WEB AYRES AYRES S2 S2RT34NORMAL 0970106 SO PWA PT6 PT6A34AG 52053 NE HARTZL HCB3T HCB3TN3 GL WING SPAR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 6038 (AUS) LH WING INBOARD WEB CRACKED 1 L 7 1 3T 4 T A3SW E4EA 6 C P15EA 1998010800282 19980108 00282 CE 1998 1 8 AU970668 1 19970603 G 2434 0012084 ALTERNATOR CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL DC GEN ALT WORN W K NONE H ELECT. POWER LOSS-50 PC CR CRUISE 1 AU S 0012084 (AUS) ALTERNATOR BRUSHES WORN - SUSPECT CAUSED BY BRUSH BOUNCE 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 1998010800283 19980108 00283 EA 1998 1 8 AU970669 2 19970616 G 8520 LW13769 CRANKCASE LYC O720 IO720A1B 41546 EA THRU BOLTS WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 295 L116754A (AUS) CRANKCASE FRETTING IN AREA OF CRANKCASE THROUGH BOLTS 3 O 1E15 1998010800284 19980108 00284 EA 1998 1 8 AU970670 2 19970606 G 8520 L2755736A CRANKCASE LYC LYC O360 O360A4K 41514 EA MCAULY 1A170 1A170FFA GL CYL BASE PAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S L2755736A L2755736A (AUS) ENGINE CRANKCASE CRACKED IN WEB BETWEEN CYLINDER BASE PADS -CRANKSHAFT GEAR SPALLED - CAM GEAR TEETH SPALLED - FUE L PUMP IDLER GEAR TEETH SPALLED - OIL PUMP HOUSING SCORED - STARTER RING GEAR CHIPPED 3 O E286 5 N P857 1998010800285 19980108 00285 EU 1998 1 8 AU970671 1 19970610 G 5343 7253620722 SUPPORT SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE RT NLG BRACE WORN W K NONE O OTHER IN INSP/MAINT 1 AU S C157 (AUS) RH NOSE LANDING GEAR SUPPORT ASSEMBLY WORN BY DRAG BRACE DUE TO MIGRATION OF THE NLG DRAG BRACE TRUNNION BEARING A ND PIN 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 1998010800286 19980108 00286 EU 1998 1 8 AU970672 1 19970613 G 2612 89905202 FIRE DETECTOR SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE RT ENG FAULTY W K NONE O N OTHER FALSE WARNING NR NOT REPORTED 1 AU S 0497 4201 (AUS) RH ENGINE FIRE DETECTOR CONTROL UNIT FAULTY 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 1998010800287 19980108 00287 SO 1998 1 8 AU970673 2 19970612 G 8520 CRANKCASE CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL ENG NR 2 CYL CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 683 172716R (AUS) LH CRANKCASE HALF CRACKED AT TOP REAR BELOW LH MAGNETO AND CENTER BETWEEN SPINE AND NO2 CYLINDER - CRACK LENGTH 76 .2MM(3IN) RUNNING FORE AND AFT 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 1998010800288 19980108 00288 EA 1998 1 8 AU970674 2 19970618 G 8550 CH48110 FILTER LYC O360 O360A1F6 41514 EA HARTZL HCF2Y HCF2YR1 GL ENG OIL SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S L3472336A (AUS) DURING FILTER REMOVAL, THE THREADED ADAPTER SECTION OF THE FILTER WAS RETAINED IN THE ENGINE HOUSING - THE FILTER/ ADAPTER IS A SINGLE UNIT WITH THE ADAPTER BEING PART OF THE FILTER WHICH DOES NOT BELONG TO THE ENGINE 3 O E286 5 C P27EA 1998010800289 19980108 00289 EU 1998 1 8 AU970675 1 19970619 G 2121 7861601 FAN ASSEMBLY EC35 FOKKER F27 F27MK50 EU LT AIR COND SEIZED W K NONE O B OTHER SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S 860835 (AUS) LH AIRCONDITIONING SYSTEM RECIRCULATING FAN SEIZED 2 H 7 2 4T RT A817 1998010800290 19980108 00290 EU 1998 1 8 AU970677 1 19970614 G 3230 L38710SA SWIVEL SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A2 30030 NE ROTOL R354 R3544123F13 NE RT MLG HYD SHEARED W K NONE K J FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S 665 (AUS) RH HYDRAULIC SWIVEL UNION IN LANDING GEAR DOWNLOCK LINE SHEARED THE INTERNAL SPINDLE ALLOWING LOSS OF HYDRAULIC FL UID 2 L 7 2 4T 4 T RT A52EU E8NE6 6 C P61GL 1998010800291 19980108 00291 1998 1 8 AU970678 4 19970615 G 6122 89741010AC GOVERNOR WOODWARD 89741010AC FRCHLD SA227 SA227DC 3377521 SW MCAULY 4HFR34 4HFR34C652 NE PROPELLER FAULTY W K NONE K J FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S 305 2482734A (AUS) LH ENGINE PROPELLER GOVERNOR LEAKING OIL FROM THE REAR BODY JOINT - INVESTIGATION FOUND THE TWO SCREWS ATTACHING T HE SPEED SETTING SHAFT EXTERNAL RETURN SPRING BRACKET TO THE GOVERNOR BODY WERE LOOSE BUT STILL LOCKWIRED ALLOWING A GAP TO EXIST 2 L 7 2 4T RT A18SW 6 C 3PNE 1998010800292 19980108 00292 CE 1998 1 8 AU970679 1 19970311 G 3221 PLATE CESSNA 310 310L 2074230 CE CONT O470 IO470U 17026 SO MCAULY 3AF32C D3AF32C80 GL NLG DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 10470VO9 (AUS) NOSE LANDING GEAR FACE PLATE DAMAGED 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 1998010800293 19980108 00293 SW 1998 1 8 AU970680 1 19970616 G 2612 1734361600F DETECTOR FENWAL 1734361600 FRCHLD SA227 SA227DC 3377521 SW MCAULY 4HFR34 4HFR34C652 NE RT ENGINE FAULTY W K NONE N FALSE WARNING TX TAXI/GRND HDL 1 AU S (AUS) RH ENGINE FIRE WARNING SYSTEM SENSOR FAULTY 2 L 7 2 4T RT A18SW 6 C 3PNE 1998011300004 19980113 00004 EA 1998 1 13 AU970681 2 19970608 G 7414 10682014 DISTRIBUTOR BENDIX D4LN3000 BEECH 76 76 1153005 CE LYC O360 O360A1G 41514 EA MAGNETO STRIPPED W K NONE O OTHER CL CLIMB 1 AU S 15 23344 (AUS) MAGNETO PLASTIC DISTRIBUTOR GEAR TEETH STRIPPED 1 L 7 2 3O 3 O A29CE E286 1998010800294 19980108 00294 CE 1998 1 8 AU970682 1 19970619 G 2400 ELECTRICAL SYS CESSNA 310 310L 2074230 CE CONT O470 IO470U 17026 SO MCAULY 3AF32C D3AF32C80 GL LT FIREWALL FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AIRCRAFT EXPERIENCED ELECTRICAL PROBLEMS. FIBREGLASS PROTECTIVE SHIELD OVER LH AND RH FIELD FUSES ON THE LH FIREWA LL HAD CHAFED THROUGH THE LH ALTERNATOR FIELD CABLE. PERSONNEL/MAINTENANCEERROR 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 1998010800295 19980108 00295 GL 1998 1 8 AU970683 1 19970623 G 3213 GM0013 PIVOT AMTR LNCAIR 320LANCAIR 056129G GL MLG LUG CRACKED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) LH MAIN LANDING GEAR PIVOT LUGS CRACKED - AIRCRAFT HAD BEEN MODIFIED 28 HOURS PREVIOUSLY BY FITMENT OF HEAVY DUTY OUTBACK LANDING GEAR KIT - COMPARISON OF THE LH AND RH MAIN LANDING GEAR LUGS FOUND THAT THE MATERIAL THICKNESS ON THE C RACKED LH LUGS WAS ONLY 3.175MM (0.125IN) COMPARED TO 6.35MM (0.25IN) ON THE RH LANDING GEAR LUGS - INVESTIGATION FOUND THAT THE LANDING GEAR KIT SUPPLIED CONTAINED ONE HEAVY DUTY LEG AND ONE LIGHT DUTY LEG 1 L 7 1 3O RT EXPA1L71 1998010800296 19980108 00296 WP 1998 1 8 AU970684 1 19970612 G 6310 A1902 DRIVE BELT ROBSIN R22 R22 7640102 WP LYC O320 O320B2C 41508 EA ENG TRANS FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE TO TRANSMISSION DRIVE FORWARD `V' BELT SPLIT AND ROLLED OFF PULLEY. 1 G 7 1 3O 3 O H10WE E274 1998010800297 19980108 00297 CE 1998 1 8 AU970685 1 19970311 G 7120 MOUNT CESSNA 310 310L 2074230 CE CONT O470 IO470U 17026 SO MCAULY 3AF32C D3AF32C80 GL ENGINE MOUNT BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 10470VO9 (AUS) RH ENGINE REAR ENGINE MOUNT RUBBER BROKEN. 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 1998010800298 19980108 00298 CE 1998 1 8 AU970686 1 19970311 G 7160 DOOR CESSNA 310 310L 2074230 CE CONT O470 IO470U 17026 SO MCAULY 3AF32C D3AF32C80 GL ENGINE AIR INT LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S 10470VO9 (AUS) ENGINE ALTERNATE AIR DOOR BRACKET LOOSE AND INCORRECTLY RIGGED 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 1998010800299 19980108 00299 CE 1998 1 8 AU970687 1 19970311 G 5220 EXIT DOOR CESSNA 310 310L 2074230 CE CONT O470 IO470U 17026 SO MCAULY 3AF32C D3AF32C80 GL EMERGENCY EXIT SEALED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 10470VO9 (AUS) EMERGENCY EXIT DOOR SEALED CLOSED. SEALANT HAD TO BE CUT TO ALLOW THE EXIT TO BE REMOVED. AD/GEN/37 LAST CARRIED O UT ON THE 15TH OCTOBER 1996. PERSONNEL/MAINTENANCE ERROR. 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 1998010800300 19980108 00300 SO 1998 1 8 AU970688 2 19970619 G 8530 CYLINDER CESSNA 310 310L 2074230 CE CONT O470 IO470U 17026 SO MCAULY 3AF32C D3AF32C80 GL ENG NR 2 & NR 6 DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NO2 AND NO6 CYLINDERS DAMAGED BY INGESTION OF SEPARATED ALTERNATE AIR DOOR BRACKET. PERSONNEL/MAINTENANCE ERROR. 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 1998010800301 19980108 00301 CE 1998 1 8 AU970689 1 19970619 G 7160 BRACKET CESSNA 310 310L 2074230 CE CONT O470 IO470U 17026 SO MCAULY 3AF32C D3AF32C80 GL ENGINE AIR INT SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE ALTERNATE AIR DOOR BRACKET SEPARATED AND INGESTED INTO ENGINE 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 1998010800302 19980108 00302 CE 1998 1 8 AU970690 1 19970619 G 7602 NUT CESSNA 310 310L 2074230 CE CONT O470 IO470U 17026 SO MCAULY 3AF32C D3AF32C80 GL MIXTURE CONTROL LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE MIXTURE CONTROL CABLE OUTER SHEATH NUT NOT ATTACHED 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 1998010800303 19980108 00303 CE 1998 1 8 AU970691 1 19970619 G 2434 ALTERNATOR CESSNA 310 310L 2074230 CE CONT O470 IO470U 17026 SO MCAULY 3AF32C D3AF32C80 GL DC GEN-ALT FIELD INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ALTERNATOR EMERGENCY FIELD SYSTEM INOPERATIVE. SEE MDR 97/0682FOR ADDITIONAL INFORMATION. 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 1998010800304 19980108 00304 CE 1998 1 8 AU970692 1 19970619 G 2432 DIODE CESSNA 310 310L 2074230 CE CONT O470 IO470U 17026 SO MCAULY 3AF32C D3AF32C80 GL BATTERY MASTER INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) BATTERY MASTER SYSTEM DIODE INOPERATIVE. 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 1998010800305 19980108 00305 CE 1998 1 8 AU970693 1 19970619 G 7120 MOUNT CESSNA 310 310L 2074230 CE CONT O470 IO470U 17026 SO MCAULY 3AF32C D3AF32C80 GL RT ENGINE WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH ENGINE RH REAR ENGINE MOUNT LANDS WORN EXCESSIVELY. SEE MDR97/0685 FOR DEFECT ON RH ENGINE LH REAR MOUNT FAILUR E 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 1998010800306 19980108 00306 EA 1998 1 8 AU970694 2 19970603 G 7322 2525464 BEARING BENDIX FCU BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL FUEL CONTROL FAILED W K NONE O R OTHER PARTIAL RPM/PWR LOSS DE DESCENT 1 AU S 3374 A45667 PCE85046 (AUS) RH ENGINE FUEL CONTROL UNIT (FCU) FAULTY - BEARING FAILED - FCU TO FUEL PUMP DRIVE COUPLING SHEARED 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1998010800307 19980108 00307 SO 1998 1 8 AU970695 1 19970617 G 5711 202732LH WEB AYRES AYRES S2 S2RT34NORMAL 0970106 SO PWA PT6 PT6A34AG 52053 NE HARTZL HCB3T HCB3TN3 GL WING SPAR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 6038 (AUS) LH WING INBOARD WEB CRACKED - DUPLICATE OF MDR 97/0667 1 L 7 1 3T 4 T A3SW E4EA 6 C P15EA 1998010800308 19980108 00308 SO 1998 1 8 AU970696 1 19970523 G 2510 SEAT BELT PIPER PA28 PA28180 7102808 SO LYC O360 O360A4A 41514 EA SNSNCH 76E M76EMMS EA FLIGHT COMPART WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) SEAT BELTS REWEBBED WITH INCORRECT HEMCO BRAND SEAT BELT HARDWARE - THIS HARDWARE WAS REQUIRED TO BE REMOVED FROM SERVICE IAW AD/RES/27 - PERSONNEL/MAINTENANCE ERROR - UNAPPROVED PART 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA4 1998010800309 19980108 00309 1998 1 8 AU970697 4 19970219 G 3417 HG480B13 ADC BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE AIR DATA COMP FAULTY W K NONE F FLT CONT AFFECTED CL CLIMB 1 AU S (AUS) NO1 AIR DATA COMPUTER FAILED. WORKSHOP INSPECTION FOUND THAT THE PITOT AND STATIC TRANSDUCERS FAILED THE CALIBRATI ON TEST BUT WERE NOT CONSIDERED TO BE THE CAUSE OF THE FAILURE. FURTHER INVESTIGATION FOUND A DRY SOLDER JOINT ON ONE OF THE DC POWER SUPPLY CONNECTING PINS AND DETERIORATED HEAT SINK COMPOUND FORTHE DIODES. 2 L 7 3 4F 4 F RT A3WE E2EA 1998010800310 19980108 00310 NM 1998 1 8 AU970698 1 19970505 G 3213 4540 CYLINDER BOEING 767 767204 NM GE CF6 CF680A 30025 NE LT MLG CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 18809 4540 (AUS) LH MAIN LANDING GEAR OUTER CYLINDER FORWARD TRUNNION CONTAINEDSEVERAL AREAS OF CORROSION 2 L 7 2 4F 4 F RT A1NM E13NE 1998010800311 19980108 00311 CE 1998 1 8 AU970699 1 19970622 G 2730 07341023 TORQUE TUBE CESSNA 053200173LH CESSNA 172 172H 2072424 CE CONT O300 O300C 17022 SO MCAULY 1C172 1C172EM GL ELEVATOR CONTROL CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH ELEVATOR TORQUE TUBE COLLARS PNO 0734102-3 (INBOARD) AND PNO 0734102-4 (OUTBOARD) SEVERELY CORRODED - RI VET HEADS LOST - RIBS, SKIN AND STRINGERS ALSO CORRODED 1 H 7 1 3O 3 O NT 3A12 E253 5 N P910 1998011300005 19980113 00005 EA 1998 1 13 AU970700 2 19970624 G 8520 GUIDE WRIGHT LKHEED 1049 C121C 5262118 WP WRIGHT R3350 R3350* 67040 EA HAMSTD 43E 43E60 NE NR 2 CYL INT VLV FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 980 W560299 (AUS) NO2 ENGINE FRONT SUMP PLUG CONTAMINATED WITH A SMALL PIECE OF FERROUS MATERIAL - INVESTIGATION FOUND PIECE OF META L HAD CHIPPED OFF NO2 CYLINDER INLET VALVE TAPPET GUIDE 2 L 7 4 4R 4 R 6A5 E272 6 C P871 1998010800312 19980108 00312 NE 1998 1 8 AU970701 1 19970611 G 7712 9550165380 TRANSMITTER TMECA SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE NR 1 ENG TORQ FAULTY W K NONE O OTHER CR CRUISE 1 AU S 15528 15528 (AUS) NO1 ENGINE TORQUE TRANSMITTER FAULTY 1 G 7 2 3U 3 U NC H1NE E19EU 1998010800313 19980108 00313 EU 1998 1 8 AU970702 1 19970507 G 5712 RIB AIRBUS 320 A320212 EU LT RT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH WING INNER REAR SPAR GEAR SUPPORT RIBS CRACKED IN THE FOLLOWING HOLES:- 1. LH WING HOLE 822. RH WING HOL E 823. RH WING HOLE 87FOUND DURING EDDY CURRENT INSPECTION 2 L 7 2 4F RT A28NM 1998010800314 19980108 00314 SO 1998 1 8 AU970703 2 19970326 G 8530 639272 CYLINDER CONT 639272 CESSNA 210 210M 2073450 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL NR 6 CYL INJ WORN W K NONE O OTHER CL CLIMB 1 AU S 548 20742973L (AUS) NO6 CYLINDER FUEL INJECTOR NOZZLE HOLE WORN OUT 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 1998010800315 19980108 00315 SO 1998 1 8 AU970704 2 19970510 G 8530 639272 CYLINDER CONT 639272 CESSNA 210 210M 2073450 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL SPARK PLUG HOLE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 53 R9059 20742973L (AUS) ENGINE CYLINDER CRACKED BETWEEN TOP SPARK PLUG HOLE AND INJECTOR NOZZLE - SUSPECT CYLINDER HAD BEEN WELD REPAIRED 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 1998010800316 19980108 00316 SO 1998 1 8 AU970705 2 19970510 G 8530 639272 CYLINDER CONT 639272 CESSNA 210 210M 2073450 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL SPARK PLUG HOLE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 601 20742973L (AUS) ENGINE CYLINDER CRACKED BETWEEN TOP SPARK PLUG HOLE AND INJECTOR NOZZLE 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 1998010800317 19980108 00317 NM 1998 1 8 AU970706 1 19970617 G 2760 CONTROL VALVE BOEING 747 747238B 1384828 NM NR 4 SPOILER FAULTY W K NONE O OTHER LD LANDING 1 AU S (AUS) NO4 SPOILER CONTROL VALVE FAULTY 2 L 7 4 4F A20WE 1998010800318 19980108 00318 SO 1998 1 8 AU970707 1 19970620 G 3230 9529900 STUD 9529902 PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA HARTZL HCC2Y HCC2YK1 GL LT RT MLG FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH MAIN LANDING GEAR SIDE BRACE STUDS SUSPECT FAULTY - FOUND DURING MAGNETIC PARTICLE INSPECTION 1 L 7 1 3O 3 O 2A13 1E10 5 C P920 1998010800319 19980108 00319 EU 1998 1 8 AU970708 1 19970315 G 2460 WIRE BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE ENG FIRE EXT COLD SOLDER W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE FIRE EXTINGUISHER CARTRIDGE FIRING CIRCUIT WIRE HAD HIGH RESISTANCE DUE TO POORLY SOLDERED JOINT AK-A1. WIR E IS LOCATED BETWEEN CIRCUIT BREAKER 1WB9 AND AIRCRAFT ELECTRICAL GROUND VIA UPPER PRODUCTION BREAK 221-01-00 (CONTACT A K-A1). 2 H 7 4 4F 4 F A49EU E6NE 1998010800320 19980108 00320 NM 1998 1 8 AU970709 1 19970515 G 6720 A0311 PITCH CONTROL ROBSIN R22 R22BETA NM LYC O320 O320B2C 41508 EA TAIL ROTOR CONT FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S L1618239A (AUS) TAIL ROTOR PITCH CHANGE ASSEMBLY FAULTY - ASSEMBLY WAS REFITTED AT THE 2000 HOURLY SERVICING WITH NO WORK RELEASE ORDER OR RELEASE NUMBER SHOWING IT TO BE OVERHAULED BY ROBINSON HELICOPTER - PERSONNEL/MAINTENANCE ERROR - UNAPPROVED PA RT 1 G 7 1 3O 3 O H10WE E274 1998010800321 19980108 00321 WP 1998 1 8 AU970710 2 19970621 G 7321 210132214 COMPUTER CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL ENG FUEL CONT FAILED W K NONE O R OTHER PARTIAL RPM/PWR LOSS CR CRUISE 1 AU S 1746 P31075 (AUS) ENGINE FUEL COMPUTER ELECTRONIC FAILURE 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 1998010800322 19980108 00322 NM 1998 1 8 AU970711 1 19970610 G 2761 65448517 ACTUATOR BOEING 737 73733A 1384673 NM NR 4 SPOILER BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 5019 (AUS) NO4 SPOILER OUTBOARD ACTUATOR FORWARD ATTACHMENT LUG BROKEN OFF - MINOR DAMAGE TO STRUCTURE ADJACENT TO ACTUATOR 2 L 7 2 4F RT A16WE 1998011300006 19980113 00006 CE 1998 1 13 AU970712 1 19970602 G 3260 0003610121 ACTUATOR BEECH 58 58A CE CONT O520 IO520C 17032 SO MCAULY 3AF34C 3AF34C502 GL MLG POS SWITCH BROKEN W K NONE O P OTHER NO WARNING INDICATION LD LANDING 1 AU S (AUS) LH MAIN LANDING GEAR MICROSWITCH ACTUATOR STRIKER PLATE BROKEN 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 1998010800323 19980108 00323 NM 1998 1 8 AU970713 1 19970515 G 6322 A1814 BEARING ROBSIN R22 R22BETA NM LYC O320 O320B2C 41508 EA COOLING FAN OUT OF HOURS W K NONE O OTHER IN INSP/MAINT 1 AU S L1618239A (AUS) FANSHAFT ASSEMBLY LOWER BEARING OUT OF HOURS - BEARING HAD NOTBEEN REPLACED AT THE 2000 HOURLY INSPECTION - FANSHA FT ASSEMBLY HAD NO RELEASE NUMBER FROM ROBINSON HELICOPTERS 1 G 7 1 3O 3 O H10WE E274 1998010800324 19980108 00324 NM 1998 1 8 AU970714 1 19970529 G 5320 POST BOEING 737 737377 NM WINDOW C-D CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WINDOW POSTS C-D CRACKED IN THE FOLLOWING AREAS:- 1. LH SIDE - CRACK LENGTH 20MM (0.787IN)2. RH SIDE - CRACK LENGT H 40MM (1.574IN)FOUND DURING EDDY CURRENT INSPECTION 2 L 7 2 4F RT A16WE 1998010800325 19980108 00325 NM 1998 1 8 AU970715 1 19970610 G 5754 69388023 ARM BOEING 737 737377 NM LT FOREFLAP CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH FOREFLAP SUPPORT ARM CRACKED THROUGH BOLT HOLE 2 L 7 2 4F RT A16WE 1998010800326 19980108 00326 NM 1998 1 8 AU970716 1 19970515 G 6230 A0172 SWASHPLATE ROBSIN R22 R22BETA NM LYC O320 O320B2C 41508 EA MAIN ROTOR MAST DEFECTIVE W K NONE O OTHER IN INSP/MAINT 1 AU S L1618239A (AUS) SWASHPLATE ASSEMBLY OUT OF HOURS - ASSEMBLY HAD NO RELEASE NUMBER FOR OVERHAUL AT 2000 HOURS 1 G 7 1 3O 3 O H10WE E274 1998010800327 19980108 00327 NM 1998 1 8 AU970717 1 19970610 G 5312 651630084 CHORD BOEING 737 737377 NM FWD PRESS BLKHD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD PRESSURE BULKHEAD LH SIDE CHORD CRACKED IN RADIUS AT WL 207 - CRACK LENGTH 40MM (1.574IN) AND WL 195 - CRA CK LENGTH 51.5MM (2.027IN) - FOUND DURING INSPECTION IAW ER B73-53-10-39 2 L 7 2 4F RT A16WE 1998010800328 19980108 00328 NM 1998 1 8 AU970718 1 19970529 G 5320 POST BOEING 737 737377 NM LT & RT WINDOW CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH C-D WINDOW POSTS CRACKED IN UPPER CORNERS - FOUND DURING EDDY CURRENT INSPECTION 2 L 7 2 4F RT A16WE 1998010800329 19980108 00329 SO 1998 1 8 AU970719 1 19970626 G 7700 INDICATOR SYSTEM EMB 110 EMB110P2 3260124 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL ENGINE OUT OF ADJUST W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH AND LH TORQUE SYSTEMS, RH AND LH T5 INDICATORS, RH T5 CIRCUIT RESISTANCE, LH AND RH FUEL PRESSURE INDICATION SY STEMS, RH LOWFUEL WARNING SYSTEM, LH AND RH FUEL QUANTITY SYSTEMS, LH OIL PRESSURE INDICATION, LH GYRO COMPASS, STANDBY COMPASS AND RH GYRO COMPASS SYSTEM ALL OUT OF ADJUSTMENT. 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 1998010800330 19980108 00330 1998 1 8 AU970720 4 19970219 G 2565 1RDOOR00061LDOO SLIDE AIRBUS 300 A300B4203 3930306 EU GE CF6 CF650C2 30018 NE DOOR 1L & 1R FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 1RDOOR00061L (AUS) DOOR 1L AND 1R ESCAPE SLIDES HAD MAINTENANCE PINS FITTED -PERSONNEL/MAINTENANCE ERROR 2 L 7 2 4F 4 F A35EU E23EA 1998010800331 19980108 00331 EU 1998 1 8 AU970721 1 19970513 G 3620 EL12400 DETECTOR AMD FALC50 FALCON900 2700160 EU BLEED OVHEAT FAULTY W K NONE N FALSE WARNING CR CRUISE 1 AU S (AUS) BLEED AIR OVERHEAT DETECTOR UNIT FAULTY - THIS DEFECT WAS RECEIVED FROM NO34 SQUADRON RAAF AND IS FOR INFORMATION ONLY 2 L 7 3 4F RT A46EU 1998010800332 19980108 00332 EU 1998 1 8 AU970722 1 19970517 G 3620 EL12400 DETECTOR AMD FALC50 FALCON900 2700160 EU BLEED OVHEAT FAULTY W K NONE N FALSE WARNING CR CRUISE 1 AU S (AUS) BLEED AIR OVERHEAT DETECTOR UNIT FAULTY - THIS DEFECT WAS RECEIVED FROM NO34 SQUADRON RAAF AND IS FOR INFORMATION ONLY 2 L 7 3 4F RT A46EU 1998010800333 19980108 00333 EU 1998 1 8 AU970723 1 19970522 G 3260 D576871 BRACKET AMD FALC50 FALCON900 2700160 EU MLG POS SWITCH CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH MAIN LANDING GEAR PROXIMITY SWITCH ATTACHMENT BRACKET CRACKED- THIS DEFECT WAS RECEIVED FROM NO34 SQUADRON RAAF AND IS FOR INFORMATION ONLY 2 L 7 3 4F RT A46EU 1998010800334 19980108 00334 CE 1998 1 8 AU970724 1 19970630 G 5341 08113507 FITTING CESSNA 411 411 2075902 CE CONT O520 GTSIO520C 17032 SO MCAULY 3AF34C 3AF34C74 GL RT WING ATTACH CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) UPPER RH FUSELAGE WING ATTACHMENT FITTING CONTAINED EXFOLIATION CORROSION ON LOWER SURFACE 1 L 7 2 3O 3 O A7CE E7CE 5 C P22EA 1998010800335 19980108 00335 EU 1998 1 8 AU970725 1 19970626 G 3240 704841 CONTROL VALVE FOKKER F27 F27MK50 EU RT MLG BRAKE FAULTY W K NONE O OTHER LD LANDING 1 AU S 101 (AUS) RH ALTERNATE BRAKE CONTROL VALVE FAULTY - BOTH RH MLG TYRES BLEW 2 H 7 2 4T RT A817 1998010800336 19980108 00336 NE 1998 1 8 AU970726 2 19970627 G 7250 6082T17G01 TURBINE GE 6082T17G01 SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE LT ENGINE FAILED W A K NONE O OTHER TO TAKEOFF 1 AU S 2184 GEL085343 785239 7250 (AUS) LH ENGINE POWER TURBINE MODULE FAILED - INVESTIGATION FOUND THAT THE STAGE 2 FORWARD COOLING PLATE HAD SEPARATED A T THE OUTER RIM- THE COOLING PLATE WAS A PRE SB 72-392 ITEM 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 1998010800337 19980108 00337 GL 1998 1 8 AU970727 3 19970620 G 6111 BV561 BLADE HARTZL MTSBSI MU2 MU2B30 5780410 SW HARTZL HCB3T HCB3TN5 GL RT PROPELLER SEPARATED W K E NONE ENGINE SHUTDOWN E D VIBRATION/BUFFET INFLIGHT SEPARATION CR CRUISE 1 AU S BV561 BV561 (AUS) RH PROPELLER NO3 BLADE SEPARATED AT BLADE ROOT. EXTENSIVE DAMAGE CAUSED TO REDUCTION GEARBOX, ENGINE, ENGINE MOUNT S, COWLING AND NACELLE. 1 H 7 2 3T A2PC 6 C P15EA 1998010800338 19980108 00338 GL 1998 1 8 AU970729 1 19970610 G 2701 54130SF198ZA CONTROL COLUMN AMTR XL EAGLEXL2 GL HAND GRIP BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CONTROL COLUMN HAND GRIP BROKEN 1 H 7 1 3I EXPA1H71 1998010800339 19980108 00339 SO 1998 1 8 AU970730 2 19970627 G 8540 21502 SEAL CONT O240 IO240A SO VAC PUMP PAD LOOSE W K NONE O K OTHER FLUID LOSS IN INSP/MAINT 1 AU S 806015 (AUS) VACUUM PUMP DRIVE SHAFT SEAL LOOSE - FOUND WHEN PAD BLANKING PLATE REMOVED TO RECTIFY OIL LEAK - NO VACUUM PUMP FI TTED TO THIS AIRCRAFT 3 O E7SO 1998010800340 19980108 00340 CE 1998 1 8 AU970731 1 19970601 G 2434 ALV9407 ALTERNATOR CONT CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO MCAULY 3FF32 3FF32C501 GL DC GEN-ALT FAILED W K NONE H ELECT. POWER LOSS-50 PC CR CRUISE 1 AU S (AUS) LH ALTERNATOR FAILED - INSPECTION FOUND THAT THE FAILURE WAS DUE TO THE DIODE PLATE GROUND WIRE BEING LOOSE 1 L 7 2 3O 3 O A7CE E7CE 5 C P45GL 1998010800341 19980108 00341 SO 1998 1 8 AU970732 2 19970622 G 8520 642001 CRANKCASE CONT CESSNA 402 402A 207590M CE CONT O520 TSIO520E 17040 SO MCAULY 3AF32C 3AF32C87 GL NR 3 & NR 5 CYL CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 610 200545 (AUS) CRANKCASE CRACKED IN AREA OF NO3 AND NO5 CYLINDER PADS - CRACKS RADIATED FROM CYLINDER BASE STUD HOLES 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 1998010800342 19980108 00342 EA 1998 1 8 AU970733 2 19970319 G 8520 SL11575 BEARING LYC PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA HARTZL HCE3Y HCE3YR2 GL NR 3 JOURNAL FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S L86868AC L86868AC (AUS) NO3 BEARING FAULTY - BEARING DOWEL ON NO3 JOURNAL HAD MOVED - SUSPECT INCORRECT FITMENT 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1998010800343 19980108 00343 EA 1998 1 8 AU970734 2 19970603 G 8520 LW16514 CAMSHAFT LYC PIPER PA44 PA44180 7104402 SO LYC O360 LO360E1A6 41514 EA HARTZL HCC2Y HCC2YR2 GL ENGINE SPALLED W K NONE O OTHER IN INSP/MAINT 1 AU S L31872 (AUS) CAMSHAFT LOBES SPALLED AND VALVE LIFTER FACES DAMAGED - METAL CONTAMINATION OF OIL SYSTEM - LW16702ADDITIVE USED A T EACH OILCHANGE 1 L 7 2 3O 3 O A19S0 E286 5 C P920 1998010800344 19980108 00344 EA 1998 1 8 AU970735 2 19970603 G 8520 LW16514 CAMSHAFT LYC PIPER PA44 PA44180 7104402 SO LYC O360 LO360E1A6 41514 EA HARTZL HCC2Y HCC2YR2 GL ENGINE LIFTER SPALLED W K NONE O OTHER IN INSP/MAINT 1 AU S L31872 (AUS) ENGINE CAMSHAFT LOBES SPALLED AND VALVE LIFTER FACES DAMAGED -METAL CONTAMINATION OF OIL SYSTEM - LW16702 ADDITIVE USED AT EACH OIL CHANGE 1 L 7 2 3O 3 O A19S0 E286 5 C P920 1998010800345 19980108 00345 CE 1998 1 8 AU970736 1 19970517 G 3230 70000150 CIRCUIT BREAKER BEECH 90 C90 1152913 CE PWA PT6 PT6A20 52043 EA HARTZL HCB3T HCB3TN3 GL MLG MOTOR INTERMITTENT W K NONE O OTHER CL CLIMB 1 AU S (AUS) LANDING GEAR MOTOR 50AMP CIRCUIT BREAKER INTERMITTENT 1 L 7 2 3T 3 T 3A20 E4EA 6 C P15EA 1998010800346 19980108 00346 WP 1998 1 8 AU970737 1 19970617 G 3710 CV6770 PUMP V3035 DOUG DC3 DC3CR183090C 3021466 WP PWA R1830 R183092 52020 NE HAMSTD 23E 23E50 NE LT ENG VAC FAULTY W K NONE O OTHER DE DESCENT 1 AU S P96668 629 (AUS) LH ENGINE DRIVEN VACUUM PUMP FAULTY 2 L 7 2 4R 4 R A669 5E4 6 C P603 1998011300007 19980113 00007 SO 1998 1 13 AU970738 1 19970627 G 5711 20207T902 SPAR CAP AYRES AYRES S2 S2RT65 SO PWA PT6 PT6A65AG 52043 NE HARTZL HCB5M HCB5MP3 GL RT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 010DC (AUS) RH WING LOWER SPAR CAP CRACKED FROM BOLT HOLE - CRACK LENGTH 3.048MM (0.120IN) - FOUND DURING MAGNETIC PARTICLE IN SPECTION 1 L 7 1 4F 4 T RT A4SW E4EA 6 C P44GL 1998010800347 19980108 00347 GL 1998 1 8 AU970739 3 19970623 G 6114 D22015 HUB HARTZL CONT O360 IO360HB 17025 SO HARTZL HCC2Y BHCC2YF1 GL SEAL GROOVE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S AM3027 AM3027 (AUS) PROPELLER HUB EXTENSIVELY CORRODED IN MOUNTING SEAL GROOVE 3 O E1CE 5 C P920 1998011300008 19980113 00008 1998 1 13 AU970740 1 19970301 G 6123 C5328 SPRING MCAULY 4HFR34 4HFR34C652 NE PROP FEATHER FRACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S 890966 (AUS) PROPELLER FEATHERING/UNREVERSING SPRING FAILED 6 C 3PNE 1998010800348 19980108 00348 GL 1998 1 8 AU970741 3 19970616 G 6114 DP215 HUB HARTZL HARTZL HCE2Y HCE2YR2 GL PROP HUB ILLEGAL MOD W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S DP215 DP215 (AUS) PROPELLER HUB HAD UNAPPROVED MODIFICATIONS - HUB HAD BEEN ILLEGALLY MODIFIED FROM -E2YR TO -E2YL CONFIGURATION BY INSERTION OF VARIOUS ILLEGALLY MADE BUSHES BEING INSERTED INTO THE DOWELHOLES - PERSONNEL/MAINTENANCE ERROR - UNAPPROVED MODIFICATION 5 C P9EA 1998010800349 19980108 00349 SO 1998 1 8 AU970742 1 19970621 G 3232 WTE22461 ACTUATOR WIEBEL WTE22461 EMB 120 EMB120 3260201 SO PWA 118 PW118A NE MLG DOOR BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 1075 (AUS) LH OUTBOARD MAIN LANDING GEAR DOOR ACTUATOR TOP BEARING LUG BROKEN 2 L 7 2 4T 4 T RT A31SO E20NE 1998010800350 19980108 00350 GL 1998 1 8 AU970743 2 19970622 G 7230 6853337 COMPRESSOR ALLSN BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL ENGINE COMP FOD W K NONE E R C VIBRATION/BUFFET PARTIAL RPM/PWR LOSS F.O.D. CL CLIMB 1 AU S 3045 CAT22383P CAT22383P (AUS) COMPRESSOR DAMAGED BY FOD 1 G 7 1 3U 3 U H2SW E4CE 1998011500128 19980115 00128 NM 1998 1 15 AU970744 1 19970430 G 5312 STRAP BOEING 747 747312 1384932 NM BS 1241 CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE BULKHEAD SPLICE STRAP LOCATED AT BS1241 CRACKED ON LHAND RH SIDES AT FORWARD AND AFT HOLES 2 L 7 4 4F RT A20WE 1998011500129 19980115 00129 NM 1998 1 15 AU970745 1 19970516 G 5411 FASTENER BOEING 747 747312 1384932 NM NR 1 & NR4 PYLON LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NO1 AND NO4 PYLON AFT DIAGONAL BRACE FORWARD MOUNT FITTINGS HAD LOOSE HILOCK FASTENERS. 2 L 7 4 4F RT A20WE 1998011500130 19980115 00130 NM 1998 1 15 AU970746 1 19970516 G 2700 CABLE GUARD BOEING 747 747312 1384932 NM FLIGHT CONTROL CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NUMEROUS CABLE GUARD ASSEMBLIES IN MAIN CABIN CABLE VERTICAL RUNS CRACKED AND EMBRITTLED - CABLE OPERATING SYSTEMS INCLUDED AILERON, WING FLAP, NOSEWHEEL STEERING AND LANDING GEAR BRAKES -IN ADDITION VERTICAL CABLE GUARDS IN FORWARD C ARGO COMPARTMENTFOR NO3 AND NO4 ENGINE CONTROL CABLES WERE FOUND BROKEN 2 L 7 4 4F RT A20WE 1998011500131 19980115 00131 NM 1998 1 15 AU970747 1 19970527 G 5315 BEAM BOEING 747 747312 1384932 NM BS 980 CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) UPPER DECK FLOOR BEAM STRUCTURE AT BS 980 CONTAINED CORROSION IN AREA OF CART LIFT CUTOUT ON THE AFT FACE OF THE U PPER CHORD BETWEEN RBL 20 AND RBL 30 - CORROSION WAS CLASSIFIED AS LEVEL 2 AND LEVEL 3 - FOUND DURING INSPECTION IAW BOE ING ALERT SB 747-53A2400 - MINOR CORROSION ALSO FOUND ON UPPER FAILSAFE STRAP 2 L 7 4 4F RT A20WE 1998011500132 19980115 00132 NM 1998 1 15 AU970748 1 19970528 G 5313 STRINGER BOEING 747 747312 1384932 NM BS 1820-1840 CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) STRINGERS 51L AND 51R LOCATED IN AFT CARGO COMPARTMENT FUSELAGE BILGE AREA (SECTION 46) CONTAINED EXFOLIATION CORR OSION IN AREAS FROM BS 1820 TO BS 1840:- STRINGER 51L - EXFOLIATION CORROSION IN VERTICAL FLANGE OF TOP HAT SECTION OF E XTRUDED STRINGER STRINGER 51R - CORROSION IN BASE OF TOP HAT EXTRUDED STRINGER - CRACK ALSO FOUND AT BS 1860 2 L 7 4 4F RT A20WE 1998011500133 19980115 00133 NM 1998 1 15 AU970749 1 19970527 G 5320 CHORD BOEING 747 747312 1384932 NM BS 400 CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NOSE WHEEL WELL STRUCTURE LOWER CHORD AT BS 400 BADLY CORRODED FROM STRINGER 42L TO STRINGER 42R 2 L 7 4 4F RT A20WE 1998011500134 19980115 00134 NE 1998 1 15 AU970750 2 19970425 G 7210 314166A BEARING PWA BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE RED GRBOX NR 10 SPALLED W K NONE O OTHER IN INSP/MAINT 1 AU S 2416 CP6B1208 62519128 (AUS) RH REDUCTION GEARBOX NR10 BEARING SPALLED ON BALLS AND INNER ANDOUTER RACES - LH REDUCTION GEARBOX NR10 BEARING HA D SLIGHT SPALLING ON THE INNER RACE AND DENTS ON THE BEARING SPLIT LINEEDGE 1 G 7 2 4U 4 U H4SW E22EA 1998011500135 19980115 00135 1998 1 15 AU970752 4 19970508 G 6113 NUT PIPER PA31 PA31 7103102 SO LYC O540 TIO540A1A 41532 EA HARTZL HCE3Y HCE3YR2 GL PROP SPINNER LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH PROPELLER SPINNER FORWARD SECURING NUT LOOSE AND LOCKWIRE BROKEN - THREAD ON STUD STRIPPED 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1998011500136 19980115 00136 NM 1998 1 15 AU970754 1 19970611 G 5312 BS178 BULKHEAD BOEING 737 737376 NM BS 178 CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PRESSURE BULKHEAD WEB AT BS 178 CRACKED IN FIVE PLACES ADJACENT TO WEATHER RADAR SUPPORT BRACKET ATTACHMENTS 2 L 7 2 4F RT A16WE 1998011500137 19980115 00137 SO 1998 1 15 AU970755 1 19970622 G 2731 4173428 CONTROL CABLE PIPER PA31 PA31350 7103110 SO HARTZL HCE3Y HCE3YR2 GL ELEV TAB CONT DAMAGED W O OTHER F FLT CONT AFFECTED CR CRUISE 1 AU S (AUS) ELEVATOR FORWARD TRIM CABLE KINKED IN AREA OF TRIM SERVO PULLEY 1 L 7 2 3O A20SO 5 C P33EA 1998011500138 19980115 00138 CE 1998 1 15 AU970756 1 19970519 G 5220 EXIT DOOR CESSNA 402 402B 207590P CE MCAULY 3AF32C 3AF32C87 GL EMERGENCY EXIT SEPARATED W K NONE D INFLIGHT SEPARATION CR CRUISE 1 AU S (AUS) EMERGENCY EXIT DOOR SEPARATED FROM AIRCRAFT - AIRCRAFT HAD JUST COMPLETED A STRIP AND REPAINT AND IT IS SUSPECTED THAT THE EXIT DOOR HAD BEEN DISTURBED DURING THIS PROCESS 1 L 7 2 3O A7CE 5 C P22EA 1998011500139 19980115 00139 NM 1998 1 15 AU970760 1 19970424 G 2897 11892221 WIRE 6098976 BOEING 747 747312 1384932 NM FUEL BOOST PUMP FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 11892221 (AUS) NO2 FUEL BOOST PUMP ELECTRICAL WIRING INSULATION FAILED DUE TO CONDUCTIVE CORROSION AT THE WIRE TERMINAL ASSEMBLY 2 L 7 4 4F RT A20WE 1998011500140 19980115 00140 CE 1998 1 15 AU970761 1 19970612 G 5720 21976 FITTING BBAVIA 8 8KCAB 2110612 CE LYC O320 AEIO320E2B 41508 EA SNSNCH 74D 74DM EA WING STRUT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING STRUT ATTACHMENT FITTING CRACKED - FOUND DURING MAGNETIC PARTICLE INSPECTION IAW AD/CHA22/2 - CRACK ORIGINATE D FROM AIRCRAFT TIEDOWN ATTACHMENT 1 H 7 1 3O 3 O A21CE 1E12 5 N P88614 1998011500141 19980115 00141 CE 1998 1 15 AU970762 1 19970507 G 3242 1773 PIN PARKERHANFI KIT19961 CESSNA 195 195A 2073110 CE JACOBP R755 R755A2 35006 SW HAMSTD 2B 2B20 NE BRAKE FAULTY W K NONE O OTHER LD LANDING 1 AU S 3151 6317 (AUS) LH BRAKE FAILED. TWO LININGS SEPARATED FROM BACKING PLATE AND WHEEL ASSEMBLY. LH WING TIP, LH ELEVATOR AND STABILI SER TIP CONTACTED RUNWAY. INVESTIGATION FOUND THAT THE BRAKE DISCS HAD BEEN GROUND AND WERE APPROXIMATELY 1.524MM (0.060 IN) UNDER SIZE.THE AIRCRAFT WAS ON THE FIRST FLIGHT FOLLOWING A PERIODIC INSPECTION. PERSONNEL/MAINTENANCE ERROR 1 H 7 1 3R 3 R A790 TC237 5 C P255 1998011500142 19980115 00142 CE 1998 1 15 AU970763 1 19970609 G 2910 5817127 PIPE CESSNA 404 404CESSNA 2075901 CE MCAULY 3AF34C 3AF34C74 GL HYDRAULIC WORN W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) HYDRAULIC PRESSURE PIPE ATTACHED TO `T' UNION WORN AND CRACKED 1 L 7 2 3O A25CE 5 C P22EA 1998011500143 19980115 00143 CE 1998 1 15 AU970768 1 19970630 G 2820 R58 PIPE CESSNA CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL LT &RT FUEL TANK MIS-INSTALLED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S R0058 (AUS) FUEL TRANSFER SYSTEM INCORRECTLY FITTED - FUEL LINES TO THE TRANSFER PUMP WERE REVERSED - PROBLEM FOUND IN BOTH RH AND LH FUEL TANKS - PERSONNEL/MAINTENANCE ERROR 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 1998011500144 19980115 00144 EA 1998 1 15 AU970769 2 19970630 G 8550 76539 VALVE PIPER PA28 PA28236 7102815 SO LYC O540 O540J3A5 41532 EA HARTZL HCF2Y HCF2YR1 GL ENG OIL FILTER WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 49 L219474A (AUS) ENGINE OIL FILTER VALVE STUCK - FILTER COLLAPSED AND FILTER HOUSING BASE GASKET BLEW OUT - SUSPECT CAUSED BY COLD MORNING STARTS (VISCOUS OIL) AND POOR STARTING TECHNIQUES 1 L 7 1 3O 3 O 2A13 E295 5 C P27EA 1998011500145 19980115 00145 SO 1998 1 15 AU970770 2 19970624 G 7314 64621217A1 PUMP CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO ENGINE FUEL PUMP WORN W K NONE O OTHER CR CRUISE 1 AU S A109710BR 27763R (AUS) ENGINE DRIVEN FUEL PUMP VANES DAMAGED. SMALL PORTIONS OF THE PUMP BLADES LODGED IN THE RELIEF VALVE 1 L 7 2 3O 3 O 3A10 E5CE 1998011500146 19980115 00146 NM 1998 1 15 AU970771 1 19970626 G 3242 AHA1693 BRAKE BOEING 757 757260PF NM NR6 MLG WHEEL WORN W K NONE O A OTHER FLAME/FIRE NR NOT REPORTED 1 AU S (AUS) NO6 MAIN WHEEL BRAKE ASSEMBLY CAUGHT FIRE WHEN PARK BRAKE SET - FLASH FIRE WAS EXTINGUISHED BY ITSELF - SUSPECT GR EASE INCORRECTLY APPLIED BETWEEN AXLE BUSH AND SPACE DURING WHEELCHANGE IGNITED 2 L 7 2 4F RT A2NM 1998011500147 19980115 00147 EU 1998 1 15 AU970772 1 19970217 G 2420 HC924H915 LOOM BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE NR 1 AC GEN CHAFED W K NONE H ELECT. POWER LOSS-50 PC NR NOT REPORTED 1 AU S (AUS) NO1 GENERATOR PHASE `B' GENERATOR FEEDER CABLE AND NEUTRAL CURRENT TRANSFORMER SHORT CIRCUITING DUE TO CHAFING ON `P' CLIP 2 H 7 4 4F 4 F A49EU E6NE 1998011500148 19980115 00148 EU 1998 1 15 AU970773 1 19970322 G 3234 9361 CLUTCH BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE GEAR SELECTOR SLIPPED W K NONE O OTHER IN INSP/MAINT 1 AU S 786GB290HANS (AUS) LANDING GEAR SELECTOR VALVE ACTUATOR CLUTCH SLIPPING. 2 H 7 4 4F 4 F A49EU E6NE 1998011500149 19980115 00149 NE 1998 1 15 AU970775 1 19970420 G 3230 LANDING GEAR SKRSKY S76 S76A 8143006 NE TMECA ARRIEL ARRIEL1S 60030 NE GEAR RETRACT MALFUNCTION W O OTHER O OTHER CL CLIMB 1 AU S (AUS) LANDING GEAR WOULD NOT RETRACT - SUSPECT INTERMITTENT PROBLEM CAUSED BY THERMAL EXPANSION 1 G 7 2 3U 3 U H1NE E19EU 1998012100002 19980121 00002 EU 1998 1 21 AU970776 1 19970613 G 5350 365A231424 FAIRING AEROSP SA365 SA365C 8680667 EU TMECA ARRIEL ARRIEL1A 60030 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CONNECTING FAIRING CRACKED 1 G 7 2 3U 3 U H10EU E19EU 1998011500150 19980115 00150 SO 1998 1 15 AU970778 1 19970620 G 5280 DOOR PIPER PA34 PA34200T 7103406 SO MCAULY 3AF34C 3AF34C503 GL GEAR DOOR DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LANDING GEAR DOOR OUTER SKIN SEPARATED FROM INTERNAL STRUCTURE -DAMAGE HAD BEEN COVERED WITH SILASTIC 1 L 7 2 3O A7SO 5 C P22EA 1998011500151 19980115 00151 SO 1998 1 15 AU970779 1 19970620 G 3211 67415W TRUNNION PIPER PA34 PA34200T 7103406 SO MCAULY 3AF34C 3AF34C503 GL MLG DEFECTIVE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MAIN LANDING GEAR LEG TRUNNION FAULTY - THE FOUR MAIN ATTACHMENTHOLES WERE OVERSIZE COMPARED TO THE FASTENERS - HO LES WERE7.937MM (0.3125IN) DIAMETER INSTEAD OF 6.35MM (0.25IN) 1 L 7 2 3O A7SO 5 C P22EA 1998011500152 19980115 00152 CE 1998 1 15 AU970780 1 19970620 G 5341 512122 BLOCK CESSNA CESSNA 172 172H 2072424 CE CONT O300 O300C 17022 SO MCAULY 1C172 1C172EM GL WING ATTACH CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 17255097 (AUS) FUSELAGE REAR SPAR WING ATTACHMENT BLOCK CRACKED AND CORRODED 1 H 7 1 3O 3 O NT 3A12 E253 5 N P910 1998011500153 19980115 00153 CE 1998 1 15 AU970781 1 19970206 G 5341 512122 BLOCK CESSNA CESSNA 172 172H 2072424 CE CONT O300 O300C 17022 SO MCAULY 1C172 1C172EM GL WING ATTACH CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 17254962 (AUS) FUSELAGE REAR SPAR WING ATTACHMENT BLOCK CRACKED AND CORRODED BETWEEN BLOCKS AND INNER SURFACE OF SPAR 1 H 7 1 3O 3 O NT 3A12 E253 5 N P910 1998011500154 19980115 00154 CE 1998 1 15 AU970783 1 19970624 G 5520 12346251 HINGE CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO MCAULY 3A32C D3A32C90 GL ELEV LT OUTB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH OUTBOARD ELEVATOR HINGE ASSEMBLY CRACKED ALONG WELD - CRACK LENGTH APPROXIMATELY 8MM (0.314IN) 1 H 7 1 3O 3 O A4CE E5CE 5 C P21EA 1998011500155 19980115 00155 CE 1998 1 15 AU970784 1 19970630 G 5511 523198 SPAR CESSNA CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL HORIZ STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HORIZONTAL STABILISER FORWARD SPAR PNO 0523001-98 AND CENTRE SKIN PNO 0532001-23 CRACKED - SPAR HAD PREVIOUSLY BEE N REPAIRED -FOUND DURING INSPECTION IAW AD/C170/59 AND CESSNA SB 94-8 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 1998011500156 19980115 00156 SW 1998 1 15 AU970787 1 19970628 G 2913 RD24336 COUPLING ROMEC 206076022 BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL HYDRAULIC PUMP FAILED W K NONE K FLUID LOSS CR CRUISE 1 AU S B4327 (AUS) HYDRAULIC PUMP DRIVE COUPLING FAILED 1 G 7 1 3U 3 U H2SW E4CE 1998011500157 19980115 00157 EU 1998 1 15 AU970788 1 19970630 G 6410 355A1244 BLADE SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE TAIL ROTOR DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) TAIL ROTOR BLADE LEADING EDGE EROSION STRIP DELAMINATED (DEBONDED) - DEBONDING EXTENDS SPANWISE FROM AN AREA 105MM (4.13IN) FROM THE INBOARD END OF THE STRIP TO 98MM (3.85IN) FROM THE OUTBOARD END AND CHORDWISE FROM THE TRAILING EDGE T O 25MM (1IN) TOWARDS THE LEADING EDGE 1 G 7 1 3U 3 U H9EU E19EU 1998011500158 19980115 00158 NE 1998 1 15 AU970792 2 19970427 G 7532 85711ANSETTSN VALVE GE CF6 CF680A 30025 NE RT BLEED WORN W K NONE O OTHER NR NOT REPORTED 1 AU S 850711ANSETT (AUS) RH BLEED AIR VALVE FAULTY. WORKSHOP INSPECTION FOUND VALVE SHAFT WORN AT CONVEX SEALING RING. 4 F E13NE 1998011500159 19980115 00159 EU 1998 1 15 AU970795 1 19970620 G 5311 TB121112 FRAME SOCATA TB10 TB10TOBAGO 8680696 EU LYC O360 O360A1A 41514 EA HARTZL HCC2Y HCC2YK2 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FRAME NO9 CRACKED AT TOP RH RADIUS IN AREA ABOVE STABILATOR ATTACHMENT FITTING - FOUND DURING INSPECTION IAW AD/TB10/11/01 1 L 7 1 30 3 O NT A51EU E286 5 C P920 1998011500160 19980115 00160 EU 1998 1 15 AU970798 1 19970415 G 3244 DR2723T TIRE BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE LT MLG NR 2 FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S GV144291ANSS (AUS) LH MAIN LANDING GEAR NO2 MAIN WHEEL TYRE DEFLATED DUE TO SIDEWALL FAILURE. 2 H 7 4 4F 4 F A49EU E6NE 1998011500161 19980115 00161 SO 1998 1 15 AU970799 2 19970620 G 8530 64137 CYLINDER PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360E 17025 SO MCAULY 3AF34C 3AF34C503 GL NR 2 - 4 &6 DISTORTED W K NONE O OTHER IN INSP/MAINT 1 AU S 780 3683 (AUS) NO6 CYLINDER EXHAUST FLANGE DISTORTED - 2MM (0.078IN) GAP ON FORWARD SIDE - FURTHER INVESTIGATION FOUND NO2 AND NO 4 CYLINDERS WITH APPROXIMATELY 1MM (0.039IN) GAPS - HEAT DAMAGE TO ENGINE COWLS FROM LEAKING EXHAUST GASSES - NEW GASKET S HAD BEEN FITTED APPROXIMATELY 50 HOURS PREVIOUSLY 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 1998011500162 19980115 00162 SO 1998 1 15 AU970800 1 19970620 G 3246 13889 BEARING 13836 PIPER PA34 PA34200T 7103406 SO MCAULY 3AF34C 3AF34C503 GL RT MLG WHEEL DETERIORATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH MAIN WHEEL BEARINGS PNO 13889 AND PNO 13836 IN POOR CONDITION- WATER FOUND IN BEARING HOUSING INDICATING AIRCRA FT HAD BEEN SUBJECTED TO WET CONDITIONS 1 L 7 2 3O A7SO 5 C P22EA 1998011500163 19980115 00163 1998 1 15 AU970801 4 19970620 G 2562 ELT114 BATTERY ELT1104 CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO MCAULY 3AF32C 3AF32C505 GL EMERG LOCATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 55139 (AUS) ELT BATTERY PACK CRACKED AND LEAKING - ELT BATTERY MOUNTING TRAY AND STRUCTURE BENEATH ELT CONTAMINATED 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 1998011500164 19980115 00164 CE 1998 1 15 AU970805 1 19970603 G 3260 LIGHT BULB BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE NLG GEAR POS FAILED W K NONE O P OTHER NO WARNING INDICATION DE DESCENT 1 AU S (AUS) NOSE LANDING GEAR INDICATOR LIGHTS BLOWN 2 L 7 2 4T 4 T RT A24CE E26NE 1998011500165 19980115 00165 1998 1 15 AU970808 4 19970624 G 2210 AUTOPILOT DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE AFCS SYSTEM MALFUNCTION W K NONE J WARNING INDICATION LD LANDING 1 AU S (AUS) AUTOFLIGHT CONTROL SYSTEM (AFCS) SUSPECT FAULTY - UNUSUAL ADVISORY MESSAGES 2 H 7 2 4T 4 T RT A13NM E20NE 1998011500166 19980115 00166 NM 1998 1 15 AU970809 1 19970626 G 2434 GENERATOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE DC GEN-ALT FAILED W K NONE H ELECT. POWER LOSS-50 PC CR CRUISE 1 AU S (AUS) LH AND RH ENGINE DRIVEN DC GENERATORS FAILED - LH AC BUS ALSO FAILED - SUSPECT CAUSED BY STATIC DISCHARGE 2 H 7 2 4T 4 T RT A13NM E20NE 1998011500167 19980115 00167 1998 1 15 AU970810 4 19970528 G 2565 7A12544 SLIDE BOEING 747 747338 NM NR 3 MAIN ENTRY FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S G3672 (AUS) NO3 MAIN ENTRY DOOR ESCAPE SLIDE DEFLATE DURING TEST - SUSPECT CAUSED BY TEARING OF THE FABRIC BY THE DOOR DUST SE AL PLASTIC RETAINER METAL CORNER 2 L 7 2 4F RT A20WE 1998012100003 19980121 00003 GL 1998 1 21 AU970811 2 19970619 G 7310 PIPE GE CF6 CF680C GL LT ENGINE FUEL LEAKING W K NONE K FLUID LOSS NR NOT REPORTED 1 AU S (AUS) LH ENGINE FUEL FILTER BYPASS LINE LEAKING 4 F E23EA 1998011500168 19980115 00168 NM 1998 1 15 AU970812 1 19970625 G 2730 251U211 ROD BOEING 747 747438 NM ELEVATOR CONTROL CHAFING W K NONE O OTHER NR NOT REPORTED 1 AU S (AUS) ELEVATOR CONTROL SYSTEM LH AND RH ELEVATOR SERVO CONTROL ROD SAFETY NUTS CONTACTING FORK ENDS ON TORQUE TUBE 2 L 7 4 4F RT A20WE 1998011500169 19980115 00169 CE 1998 1 15 AU970815 1 19970617 G 3297 42C18 WIRE CESSNA CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO MCAULY 3AF32C 3AF32C505 GL GEAR SELECTOR SHORTED W O OTHER O OTHER DE DESCENT 1 AU S 402C1008 (AUS) LANDING GEAR SELECTOR WIRE SHORT CIRCUITED IN AREA BEHIND INSTRUMENT PANEL 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 1998012100004 19980121 00004 EU 1998 1 21 AU970816 1 19970601 G 5102 GIMBLE CAMRON A315 A315 EU BALLOON BURNER DAMAGED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) BALLOON BURNER GIMBLE BLOCK DAMAGED - SUSPECT CAUSED BY UNAUTHORIZED DISASSEMBLY AND ASSEMBLY BY UNQUALIFIED PERSO NNEL -PERSONNEL/MAINTENANCE ERROR - UNAPPROVED MAINTENANCE 1 B 0 0 0 0 B1EU 1998011500170 19980115 00170 NM 1998 1 15 AU970817 1 19970629 G 6320 2222 GEAR ROBSIN ROBSIN R22 R22BETA NM LYC O320 O320B2C 41508 EA M/R GEARBOX FAULTY W K NONE O J OTHER WARNING INDICATION IN INSP/MAINT 1 AU S 627 2222 (AUS) MAIN ROTOR TRANSMISSION GEAR FAULTY - METAL CONTAMINATION OF CHIP DETECTOR 1 G 7 1 3O 3 O H10WE E274 1998011500171 19980115 00171 1998 1 15 AU970820 4 19970430 G 3417 FAD1862 TRANSDUCER SMITHSIND DAGC BOEING 737 73733A 1384673 NM AIR DATA COMP INTERMITTENT W K NONE F FLT CONT AFFECTED DE DESCENT 1 AU S 1097 (AUS) NO1 DIGITAL AIR DATA COMPUTER (DADC) FAULTY - FAULT TRACED TO INTERMITTENT OUTPUT SIGNAL DATA FROM THE STATIC PRES SURE TRANSDUCER 2 L 7 2 4F RT A16WE 1998011500172 19980115 00172 1998 1 15 AU970824 4 19970624 G 2210 AUTOPILOT DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE AFCS SYSTEM FAULTY W K NONE F J FLT CONT AFFECTED WARNING INDICATION LD LANDING 1 AU S (AUS) AUTOFLIGHT CONTROL SYSTEM (AFCS) SUSPECT FAULTY - UNUSUAL ADVISORY MESSAGES - SEE MDR 97/0808 FOR SIMILAR DEFECT 2 H 7 2 4T 4 T RT A13NM E20NE 1998011500173 19980115 00173 NM 1998 1 15 AU970825 1 19970501 G 5320 POST BOEING 737 737377 NM NR 1 WINDOW LT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH NO1 WINDOW POST CRACKED IN OUTBOARD UPPER CORNER - FOUND DURING EDDY CURRENT INSPECTION IAW ER B73-53-10-36 2 L 7 2 4F RT A16WE 1998011500174 19980115 00174 NM 1998 1 15 AU970826 1 19970603 G 5312 BULKHEAD BOEING 737 737377 NM BS 178 CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FORWARD PRESSURE BULKHEAD AT STATION 178 CRACKED IN SIXPLACES - FOUND USING EDDY CURRENT AND ULTRASONIC I NSPECTIONS IAWER B73-53-10-39A 2 L 7 2 4F RT A16WE 1998011500549 19980115 00549 NM 1998 1 15 AU970827 1 19970121 G 5320 POST BOEING 737 737377 NM LT NR 1 WINDOW CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH NO1 WINDOW POST CRACKED IN AREA OF SUB SURFACE GUSSET FROM CORNER RADIUS TO RIVET - FOUND DURING EDDY CURRENT I NSPECTION IAW ER B73-53-10-36 2 L 7 2 4F RT A16WE 1998011500550 19980115 00550 NM 1998 1 15 AU970828 1 19970530 G 5312 BULKHEAD BOEING 737 737377 NM FUSELAGE LT FWD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD PRESSURE BULKHEAD CRACKED IN THE FOLLOWING AREAS:-1. LH FORWARD PRESSURE BULKHEAD SIDE CHORD RADIUS AT WL 195 - CRACK LENGTH 63.5MM (2.5IN)2. LH INTERCOSTAL ADJACENT TO BULKHEAD AT WL 1953. RH INTERCOSTAL ADJACENT TO BULKHEAD AT WL 195 2 L 7 2 4F RT A16WE 1998011500551 19980115 00551 NM 1998 1 15 AU970829 1 19970530 G 5312 BULKHEAD BOEING 737 737377 NM FUSELAGE FWD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FORWARD PRESSURE BULKHEAD WEB CRACKED IN FIVE PLACES - FOUND DURING EDDY CURRENT AND ULTRASONIC INSPECTIO N IAW ERB73-53-10-39A 2 L 7 2 4F RT A16WE 1998011500552 19980115 00552 CE 1998 1 15 AU970833 1 19970612 G 2720 RUDDER SYSTEM BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE RUDDER BOOST MALFUNCTION W K NONE F FLT CONT AFFECTED TO TAKEOFF 1 AU S (AUS) RUDDER BOOST SYSTEM FAULTY - MAINTENANCE CHECKS OF SYSTEM COULD FIND NO FAULTS 1 L 7 2 4T 4 T A24CE E4EA 1998011500553 19980115 00553 CE 1998 1 15 AU970834 1 19970626 G 2731 TRIM SYSTEM BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE ELEV TAB CONTROL MALFUNCTION W K NONE F FLT CONT AFFECTED CL CLIMB 1 AU S (AUS) ELEVATOR TRIM FAULTY - MAINTENANCE CHECKS COULD FIND NO FAULTSWITH THE TRIM SYSTEM - SUSPECT CAUSED BY ICING 1 L 7 2 4T 4 T A24CE E4EA 1998011500554 19980115 00554 SO 1998 1 15 AU970840 1 19970418 G 5711 227791 SPAR CAP 202077902 AYRES S2 S2RT34NORMAL 0970106 SO PWA PT6 PT6A34AG 52053 NE HARTZL HCB3T HCB3TN3 GL LT & RT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH WING LOWER SPAR CAPS PNO 202077901 AND PNO 202077902CRACKED IN SPLICE BLOCK HOLES 1 L 7 1 3T 4 T A3SW E4EA 6 C P15EA 1998011500555 19980115 00555 SW 1998 1 15 AU970841 1 19970622 G 6410 261621131 BLADE BELL BELL 206 206B3 1181506 SW ALLSN 250C 250C20B 03013 GL TAIL ROTOR DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S ATO23 (AUS) TAIL ROTOR BLADE DELAMINATED IN DOUBLER AREA 1 G 7 1 3U 3 U H2SW E4CE 1998011500556 19980115 00556 1998 1 15 AU970844 4 19970531 G 2350 TRANSCEIVER CESSNA 404 404CESSNA 2075901 CE MCAULY 3FF32 3FF32C501 GL MIC JACK FAILED W K NONE O OTHER CR CRUISE 1 AU S (AUS) RADIO FAILED TO TRANSMIT - CORROSION ON MICROPHONE JACK CONTACTS 1 L 7 2 3O A25CE 5 C P45GL 1998011500557 19980115 00557 NM 1998 1 15 AU970845 1 19970507 G 2910 B47664192 HOSE BOEING 737 73733A 1384673 NM RT MLG UOLOCK BURST W K NONE K FLUID LOSS TO TAKEOFF 1 AU S (AUS) RH MAIN LANDING GEAR UPLOCK ACTUATOR RETRACTION HOSE BURST NEAR UPPER END - LOSS OF SYSTEM `A' HYDRAULIC FLUID 2 L 7 2 4F RT A16WE 1998011500558 19980115 00558 CE 1998 1 15 AU970849 1 19970603 G 2434 BEARING BEECH 23 C23 1151242 CE LYC O360 O360A4J 41514 EA SNSNCH 76E 76EM8S5 EA DC GENERATOR-ALT COLLAPSED W K NONE H ELECT. POWER LOSS-50 PC CR CRUISE 1 AU S L197236A (AUS) ALTERNATOR DRIVE END BEARING COLLAPSED 1 L 7 1 3O 3 O A1CE E286 5 N P4EA 1998011500559 19980115 00559 EA 1998 1 15 AU970850 2 19970603 G 8530 VALVE CONT BEECH 23 C23 1151242 CE LYC O360 O360A4J 41514 EA SNSNCH 76E 76EM8S5 EA NR 3 CYL EXH DAMAGED W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S L197236A (AUS) NO3 CYLINDER EXHAUST VALVE HEAD DAMAGED - APPROXIMATELY 50% OFTHE HEAD WAS MISSING 1 L 7 1 3O 3 O A1CE E286 5 N P4EA 1998011500560 19980115 00560 NE 1998 1 15 AU970853 2 19970616 G 8520 23112 BOLT PWA DHAV DHC2 DHC2EVANS 2801832 EA PWA R985 R985AN14B 52008 NE CTRWT RETAIN FAILED W K NONE E Y VIBRATION/BUFFET ENGINE STOPPAGE NR NOT REPORTED 1 AU S 23112 23112 (AUS) ENGINE FAILED - CAUSED BY FAILURE OF THE COUNTERWEIGHT RETAINING BOLT ALLOWING COUNTERWEIGHT TO DEPART CRANKSHAFT AND SEIZE THE ENGINE 1 H 7 1 3O 3 R A806 5E1 1998011500561 19980115 00561 EU 1998 1 15 AU970855 1 19970504 G 5610 TA5189ANSETTSN WINDSHIELD AIRBUS 320 A320212 EU COCKPIT CRACKED W K NONE O OTHER CL CLIMB 1 AU S TA50189ANSET (AUS) CAPTAINS WINDSHIELD CRACKED - SUSPECT CAUSED BY WATER INGRESS LEADING TO ARCING IN HEATING SYSTEM 2 L 7 2 4F RT A28NM 1998011500562 19980115 00562 1998 1 15 AU970859 4 19970529 G 2562 ELT114 ELT CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL EMERG LOCATOR FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 57820 (AUS) ARTEX ELT CRACKED AND BATTERY LEAKING CAUSING CORROSION - ELT HAD ONLY BEEN FITTED ON 27 FEB 1997 FOLLOWING SIMILA R CRACKING OF THE PREVIOUS ELT 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 1998011500563 19980115 00563 SO 1998 1 15 AU970867 1 19970618 G 5313 LONGERON PIPER PA18 PA18150 7101828 SO LYC O320 O320A2B 41508 EA SNSNCH 74DM M74DM EA FUSELAGE RT DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE LOWER RH LONGERON BENT AND DIAGONAL TUBE BENT INWARDS 1 H 7 1 3O 3 O 1A2 E274 5 N P88614 1998011500564 19980115 00564 EU 1998 1 15 AU970872 1 19970610 G 3230 C2424561 UPLOCK AMD FALC50 FALCON900 2700160 EU NLG FAULTY W K NONE O J OTHER WARNING INDICATION CL CLIMB 1 AU S U465 (AUS) NOSE LANDING GEAR UPLOCK BOX FAULTY - THIS DEFECT WAS RECEIVED FROM NO34 SQUADRON RAAF AND IS FOR INFORMATION ONLY 2 L 7 3 4F RT A46EU 1998011500565 19980115 00565 1998 1 15 AU970876 4 19970303 G 3416 P933 ALTIMETER COCKPIT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 0496 (AUS) ALTIMETER FAULTY - READING 10,000 FEET AT SEA LEVEL - INVESTIGATION FOUND THAT ONE OF THE TWO ANEROID CAPSULES HAD LOST ITS VACUUM - ALTIMETER WAS FITTED TO A JABIRU - REPORT ENTERED IAW AD/INST/39 1998011500566 19980115 00566 1998 1 15 AU970880 4 19970412 G 2562 ELT114 ELT BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO MCAULY 3AF34C 3AF34C502 GL EMERG LOCATOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ELT COMPLETELY DESTROYED DUE TO BUILDUP OF WATER IN MOUNTING TRAY - WATER IN TRAY GETS INTO ELT BATTERY COMPARTMEN T CAUSING CORROSION AND EVENTUAL FAILURE 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 1998011500567 19980115 00567 NE 1998 1 15 AU970881 2 19970420 G 7261 51663 PUMP RR369004 BELL 222 222U 1182140 SW LYC LTS101 LTS101750C1 41560 NE LT ENGINE OIL FAILED W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S 420 LE47215 (AUS) LH ENGINE DRIVEN OIL PUMP FAULTY. OIL PRESSURE FLUCTUATING. 1 G 7 2 3U 3 U H9SW E5NE 1998011500568 19980115 00568 CE 1998 1 15 AU970882 1 19970506 G 2510 SEAT BELT CESSNA 182 182H 2072718 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL COCKPIT WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) SEAT BELT WAS AUTOMOTIVE PRODUCT - PERSONNEL/MAINTENANCE ERROR -UNAPPROVED PART 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1998011500569 19980115 00569 CE 1998 1 15 AU970883 1 19970422 G 5711 SPAR BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING FORWARD SPAR FORWARD AND REAR RH WEBS CRACKED - FOUND DURING INSPECTION IAW AD/BEECH55/62 AMDT4 AND BEECH SB2 269 1 L 7 2 3O 3 O 3A16 E5CE 1998011500570 19980115 00570 NM 1998 1 15 AU970884 1 19970420 G 6320 A61 TRANSMISSION ROBSIN A0061 ROBSIN R22 R22BETA NM LYC O320 O320B2C 41508 EA M/R GEARBOX MAKING METAL W K NONE O OTHER IN INSP/MAINT 1 AU S 1044 (AUS) MAIN ROTOR TRANSMISSION METAL CONTAMINATION. SUSPECT CAUSED BY FATIGUE SPALLING OF PINION AND RING GEARS. 1 G 7 1 3O 3 O H10WE E274 1998011500571 19980115 00571 1998 1 15 AU970885 4 19970510 G 6122 DCFS29D2AT GOVERNOR CESSNA 404 404CESSNA 2075901 CE MCAULY 3FF32 3FF32C501 GL PROPELLER OUT OF ADJUST W K NONE O OTHER IN INSP/MAINT 1 AU S 760832 (AUS) PROPELLER GOVERNOR HIGH RPM OUT OF ADJUSTMENT 1 L 7 2 3O A25CE 5 C P45GL 1998011500572 19980115 00572 CE 1998 1 15 AU970886 1 19970422 G 3230 9911543 VALVE CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO BLOWDOWN SYS FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 1 1454 (AUS) LANDING GEAR BLOWDOWN BOTTLE OUTLET VALVE FAULTY - INVESTIGATION FOUND THAT THE `O' RING ON THE VALVE POPPET ASSEM BLY WAS MISSING- REMAINS OF THE `O' RING WERE FOUND DOWNSTREAM IN THE EMERGENCY GEAR BLOWDOWN SYSTEM 1 L 7 2 3O 3 O A7CE E8CE 1998011500573 19980115 00573 CE 1998 1 15 AU970887 1 19970415 G 2910 9911883 VALVE CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO HYD MANIFOLD FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 1066 (AUS) HYDRAULIC MANIFOLD VALVE FAULTY - DURING STRIPDOWN OF THE VALVE PIECES OF `O' RING WERE FOUND - SUSPECT `O' RING C AME FROM THE EMERGENCY GEAR DOWN BOTTLE PNO 9910154-3 (MDR 97/0886) 1 L 7 2 3O 3 O A7CE E8CE 1998011500574 19980115 00574 CE 1998 1 15 AU970888 1 19970307 G 5753 T1221115 ROLLER CESSNA CESSNA 182 182Q 2072732 CE LT TE FLAP WORN W K NONE F FLT CONT AFFECTED LD LANDING 1 AU S (AUS) LH FLAP ROLLERS PNO T-1221010-5 AND PNO R-0523921X3 WORN - FLAP JAMMED ON TRACK SUPPORT BRACKETS 1 H 7 1 3O NT 3A13 1998011500575 19980115 00575 GL 1998 1 15 AU970890 3 19970518 G 6114 SCREW CESSNA 404 404CESSNA 2075901 CE MCAULY 3FF32 3FF32C501 GL RT PROP HUB LOOSE W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 82243 (AUS) RH PROPELLER DOME SCREWS LOOSE - SCREWS WERE CORRECTLY LOCKWIRED- FIVE OF THE SCREWS HAD SHEARED HEADS - SUSPECT S CREWS INCORRECTLY TORQUED AT LAST OVERHAUL OR SHOP VISIT -PERSONNEL/MAINTENANCE ERROR 1 L 7 2 3O A25CE 5 C P45GL 1998011500576 19980115 00576 CE 1998 1 15 AU970891 1 19970620 G 3234 363851 SELECTOR BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO HARTZL HCJ3Y PHCJ3YF2 GL GEAR SELECTOR BROKEN W K NONE O OTHER NR NOT REPORTED 1 AU S (AUS) LANDING GEAR SELECTOR SWITCH SHAFT BROKEN. INSPECTION FOUND LOCATING TANG ON EMERGENCY LANDING GEAR EXTENSION HAND LE ALSO BROKEN AND FORK END TO DRIVE SHAFT DAMAGED. EXTENSION HANDLE HOUSING ALSO CRACKED. 1 L 7 2 3O 3 O 3A16 E5CE 5 C P36EA 1998011500577 19980115 00577 SO 1998 1 15 AU970893 2 19970519 G 7414 M2369 IMPULSE COUPLING SLICK 662 CESSNA 206 U206F 2073333 CE CONT O520 IO520F 17032 SO MCAULY 3A32C D3A32C90 GL MAGNETO INCORRECT ASSY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 9020553 572674 (AUS) MAGNETO IMPULSE COUPLING INCORRECTLY ASSEMBLED 1 H 7 1 3O 3 O A4CE E5CE 5 C P21EA 1998011500578 19980115 00578 SO 1998 1 15 AU970894 1 19970302 G 2841 755452 INDICATOR PIPER PA23 PA23250 7102308 SO LYC O540 IO540K1A5 41532 EA HARTZL HCC2Y HCC2YK2 GL FUEL QUANTITY FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) RH FUEL GAUGE EMPTY POTENTIOMETER LOOSE IN PC BOARD - INVESTIGATION FOUND POTENTIOMETER HAD BEEN INCORRECTLY SOLDE RED TO THE PC BOARD 1 L 7 2 3O 3 O 1A10 1E4 5 C P920 1998011500579 19980115 00579 SW 1998 1 15 AU970898 1 19970625 G 6320 264321 BEARING BELL BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL M/R GEARBOX SPALLED W K NONE O OTHER IN INSP/MAINT 1 AU S BKW12075 (AUS) MAIN ROTOR TRANSMISSION DUPLEX BEARING SPALLED - METALCONTAMINATION OF GEARBOX 1 G 7 1 3U 3 U H2SW E4CE 1998011500580 19980115 00580 CE 1998 1 15 AU970908 1 19970318 G 5512 SKIN CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO MCAULY 2A34C E2A34C73 GL HORIZ STAB LE SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) STABILISER LEADING EDGE SEPARATED FROM THREE RIBS 1 H 7 1 3O 3 O 3A21 E5CE 5 C P3EA9 1998011500581 19980115 00581 CE 1998 1 15 AU970909 1 19970318 G 5541 RIB CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO MCAULY 2A34C E2A34C73 GL RUDDER CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) TOP RUDDER RIB AND BALANCE WEIGHT STRUCTURE SEVERELY CORRODED 1 H 7 1 3O 3 O 3A21 E5CE 5 C P3EA9 1998011500582 19980115 00582 CE 1998 1 15 AU970910 1 19970318 G 5551 123241 BRACKET 12324002 CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO MCAULY 2A34C E2A34C73 GL HORIZ STAB ATT CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HORIZONTAL STABILISER LH AND RH ATTACHMENT BRACKETS PNO 1232400-1 AND PNO 1232400-2 CONTAINED INTERGRANNULAR CORRO SION 1 H 7 1 3O 3 O 3A21 E5CE 5 C P3EA9 1998011500583 19980115 00583 1998 1 15 AU970911 1 19970623 G 7120 VTB131REVG BEARING GE CF6 CF680A 30025 NE LT AFT ENG MOUNT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 58136 (AUS) LH ENGINE AFT ENGINE MOUNT LINK BEARING INNER RACE CRACKED IN TWO PLACES. LOWER FITTING ASSEMBLY BEARING INNER RAC E CRACKED IN ONEPLACE. 4 F E13NE 1998011500584 19980115 00584 CE 1998 1 15 AU970912 1 19970318 G 1100 MAINTENANCE LOG CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO MCAULY 2A34C E2A34C73 GL AIRCFT GEAR DOOR INCOMPLETE W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) LOG BOOK ENTRY INDICATED AN STC HAD BEEN INCORPORATED REGARDING A LANDING GEAR DOOR REMOVAL MODIFICATION - NO DATA ACCOMPANIED THE AIRCRAFT RECORDS AND THERE WAS NO ENGINEERING ORDER AUTHORISING THE STC - NO WEIGHT CHANGES WERE RECORD ED IN THE LOG BOOK 1 H 7 1 3O 3 O 3A21 E5CE 5 C P3EA9 1998011500585 19980115 00585 CE 1998 1 15 AU970913 1 19970318 G 5330 SKIN CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO MCAULY 2A34C E2A34C73 GL LT FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH UPPER FUSELAGE TAILCONE LAP JOINT CORRODED BETWEEN AFT WINDOW AND REAR BULKHEAD - SEVERE INTERNAL CORROSION ADJ ACENT TO HF ANTENNA CERAMIC INSULATOR 1 H 7 1 3O 3 O 3A21 E5CE 5 C P3EA9 1998011500586 19980115 00586 SO 1998 1 15 AU970915 1 19970520 G 7602 BEARING PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360E 17025 SO MCAULY 3AF34C 3AF34C502 GL MIXTURE CONTROL BINDIING W K NONE O OTHER IN INSP/MAINT 1 AU S 3683 (AUS) LH ENGINE MIXTURE CONTROL ROD END BEARING AND CONTROL ARM BINDING ON FCU 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 1998011500587 19980115 00587 EU 1998 1 15 AU970921 1 19970617 G 2450 S26531 CIRCUIT BREAKER BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE RT WINDSHLD HEAT ARCED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH WINDSHIELD HEATING SYSTEM PHASE `B' SUPPLY CIRCUIT BREAKER DAMAGED FROM INTERNAL ARCING. 2 H 7 4 4F 4 F A49EU E6NE 1998011500588 19980115 00588 SO 1998 1 15 AU970933 1 19970101 G 5531 9812 SPAR PIPER PA36 PA36375 7103620 SO LYC O720 IO720D1C 41546 EA VERT STAB CRACKED W K NONE F D FLT CONT AFFECTED INFLIGHT SEPARATION TO TAKEOFF 1 AU S (AUS) FIN REAR SPAR CRACKED ALLOWING TOP AND MIDDLE RUDDER ATTACHMENT BRACKETS TO SEPARATE 1 L 7 1 3O 3 O A10SO 1E15 1998011500589 19980115 00589 NM 1998 1 15 AU970937 1 19970531 G 2730 162313 COMPUTER BOEING 737 737377 NM ELEV FEEL CONT MALFUNCTIONED W K NONE F FLT CONT AFFECTED NR NOT REPORTED 1 AU S (AUS) ELEVATOR FEEL COMPUTER SUSPECT FAULTY - WORKSHOP INVESTIGATIONCOULD FIND NO DEFECTS 2 L 7 2 4F RT A16WE 1998011500590 19980115 00590 NM 1998 1 15 AU970938 1 19970410 G 3260 1899 SENSOR BOEING 737 73733A 1384673 NM MLG OUT OF ADJUST W K NONE O OTHER CL CLIMB 1 AU S (AUS) AIR SAFETY PROXIMITY SENSOR OUT OF ADJUSTMENT 2 L 7 2 4F RT A16WE 1998011500591 19980115 00591 SO 1998 1 15 AU970939 1 19970319 G 5541 98126 SPAR PIPER PA36 PA36375 7103620 SO LYC O720 IO720D1C 41546 EA RUDDER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RUDDER SPAR CRACKED ON BOTH SIDES OF HINGE - HINGE BRACKET PNO76847-02 ALSO CRACKED 1 L 7 1 3O 3 O A10SO 1E15 1998011500592 19980115 00592 NM 1998 1 15 AU970941 1 19970618 G 5230 FRAME BOEING 737 737377 NM CARGO/BAG DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD CARGO DOOR FRAME CRACKED AT DOOR FRAME RADIUS FROM LOWERAFT CORNER AND RUNNING UP THE AFT SIDE OF THE DOOR - CRACK LENGTH APPROXIMATELY 210MM (9IN) - INVESTIGATION FOUND FURTHER CRACKING IN THE FOLLOWING LOCATIONS:-1. HORIZONT AL CROSS BEAM ATTACHMENT ANGLE - CRACK LENGTH 70MM (3IN)2. HORIZONTAL CROSS BEAM WEB CRACKED COMPLETELY THROUGH - CRACK LENGTH 100MM (4IN) 2 L 7 2 4F RT A16WE 1998011500593 19980115 00593 EA 1998 1 15 AU970948 2 19970630 G 7414 M381 CAPACITOR SLICK 4372 PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL MAGNETO BURNT W K NONE O OTHER IN INSP/MAINT 1 AU S 91030039 RL2427351A (AUS) MAGNETO CAPACITOR AND POINTS BURNT - FOUND DURING INSPECTION IAWAD/ELECT/46 AMDT 6 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1998011500594 19980115 00594 GL 1998 1 15 AU970952 1 19970521 G 6100 PROPELLER AMTR MAXAIR XP503 9570746 GL AMTR 582 582 GL PROP BLADE LE FOD W K NONE C F.O.D. NR NOT REPORTED 1 AU S (AUS) PILOTS VISOR FLEW OFF AND STRUCK PROPELLER CAUSING A SMALL SECTION OF THE LEADING EDGE TO SEPARATE - THIS DEFECT W AS RECEIVED FROM THE AUF AND IS FOR INFORMATION ONLY 1 H 7 1 3I 3 I NT EXPA1H71 EXP31 1998011500595 19980115 00595 NM 1998 1 15 AU970954 1 19970625 G 5312 BULKHEAD BOEING 737 73733A 1384673 NM FUSELAGE FWD WEB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD PRESSURE BULKHEAD WEB FORWARD FACE CRACKED IN THE FOLLOWING AREAS:- 1. THREE CRACKS LOCATED AT RBL 5.7 UND ER RADAR SCANNING SUPPORT BRACKETS - CRACK LENGTHS 15MM (0.59IN), 20MM (0.787IN) AND 24MM (0.944IN) 2. ONE CRACK LOCAT ED AT LBL 5.7 UNDER RADAR SCANNING SUPPORT BRACKETS - CRACK LENGTH 23MM (0.905IN) 3. ONE CRACK RUNNING VERTICALLY ADJACE NT TO BLO JUST ABOVE WL 1845 - CRACK LENGTH 18MM (0.708IN) FOUND DURING ULTRASONIC AND EDDY CURRENT INSPECTIONS IAW ER 2 L 7 2 4F RT A16WE 1998011500596 19980115 00596 EU 1998 1 15 AU970959 1 19970516 G 5754 MF2687ANSETTS BRAKE AIRBUS 320 A320212 EU SLAT SYS FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S MF2687ANSETT (AUS) SLAT SYSTEM WING TIP BRAKE FAULTY 2 L 7 2 4F RT A28NM 1998011500597 19980115 00597 WP 1998 1 15 AU970991 1 19970614 G 6320 23529 GEAR HILLER HILLER UH12 UH12E 4360122 WP LYC O540 VO540C2A 41532 EA M/R GEARBOX DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 535 10089 (AUS) MAIN ROTOR TRANSMISSION UPPER PLANETARY RING GEAR TOOTH CHIPPED - MINOR DAMAGE TO ONE UPPER PLANETARY GEAR 1 G 7 1 3O 3 O 4H11 E304 1998011500598 19980115 00598 EU 1998 1 15 AU971020 1 19970612 G 2621 FIRE BOTTLE BAC 146 146100A 1500260 EU LYC ALF502 ALF502R5 41580 NE NR 4 ENG MIS WIRED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) NO4 ENGINE FIRE EXTINGUISHER BOTTLE SQUIB WIRES WB14 AND WB15 CROSSED BETWEEN CONNECTOR RF (442-00-00) 2 H 7 4 4F 4 F RT A49EU E6NE 1998011500599 19980115 00599 EU 1998 1 15 AU971035 1 19970621 G 2710 A788171 QUADRANT FOKKER F28 F28MK4000 4990810 EU RROYCE SPEY SPEY55515 54521 EU RT WING AIL OUTB CONTAMINATED W K NONE O F OTHER FLT CONT AFFECTED IN INSP/MAINT 1 AU S (AUS) RH WING OUTBOARD AILERON LOWER QUADRANT BEARING WATER INGRESS 2 L 7 2 4F 4 F RT A20EU E2EU 1998011500600 19980115 00600 EU 1998 1 15 AU971040 1 19970607 G 3246 U1886ANSETTSN3 WHEEL AIRBUS 320 A320212 EU INB NR 1 DRIVE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U1886ANSETTS (AUS) INBOARD WHEEL HALF CRACKED AT THE BASE OF NO1 DRIVE TENON ATPOSITIT POSITION NO4 2 L 7 2 4F RT A28NM 1998011500601 19980115 00601 EU 1998 1 15 AU971041 1 19970607 G 3246 U261ANSETTSN WHEEL AIRBUS 320 A320212 EU MLG NR 1 DRIVE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U2061ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED AT THE BASE OF NO1 DRIVE TENON 2 L 7 2 4F RT A28NM 1998011500602 19980115 00602 EU 1998 1 15 AU971042 1 19970607 G 3246 U259ANSETTSN WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U2059ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED AT THE BASE OF NO1 DRIVE TENON 2 L 7 2 4F RT A28NM 1998011500603 19980115 00603 EU 1998 1 15 AU971043 1 19970607 G 3246 U28ANSETTSN WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U2080ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED AT THE BASE OF FOUR DRIVE TENONS AT POSITION NO3 2 L 7 2 4F RT A28NM 1998011500604 19980115 00604 EU 1998 1 15 AU971044 1 19970607 G 3246 U2227ANSETTSN WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U2227ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED THROUGH CENTRE AREA ON TWO DRIVE TENONS AT POSITION NO4 2 L 7 2 4F RT A28NM 1998011500605 19980115 00605 EU 1998 1 15 AU971045 1 19970607 G 3246 U247ANSETTSN WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U2047ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED THROUGH THE CENTRE AREA ON NO1 DRIVE TENON 2 L 7 2 4F RT A28NM 1998011500606 19980115 00606 EU 1998 1 15 AU971046 1 19970607 G 3246 U1864ANSETTSN3 WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U1864ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED THROUGH CENTRE AREA ON ONE DRIVE TENON IN POSITION NO2 2 L 7 2 4F RT A28NM 1998011500607 19980115 00607 EU 1998 1 15 AU971047 1 19970607 G 3246 U23ANSETTSN WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U2003ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED THROUGH CENTRE AREA ON TWO DRIVE TENONS AT POSITION NO4 2 L 7 2 4F RT A28NM 1998011500608 19980115 00608 EU 1998 1 15 AU971048 1 19970607 G 3246 U212ANSETTSN WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U2102ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED IN TUBE WELL AREA AT POSITION NO2 2 L 7 2 4F RT A28NM 1998011500609 19980115 00609 EU 1998 1 15 AU971049 1 19970607 G 3246 U278ANSETTSN WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U2078ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED THROUGH CENTRE ON THREE DRIVE TENONS AT POSITION NO4 2 L 7 2 4F RT A28NM 1998011500610 19980115 00610 EU 1998 1 15 AU971050 1 19970607 G 3246 C2252 WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U1865ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED AT THE BASE OF TWO DRIVE TENONS AT POSITION NO1 - FOUND DURING EDDY CURRENT INSPEC TION 2 L 7 2 4F RT A28NM 1998011500611 19980115 00611 EU 1998 1 15 AU971051 1 19970607 G 3246 C2252 WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U2060ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED AT THE BASE OF FIVE DRIVE TENONS AT POSITION NO3 - FOUND DURING EDDY CURRENT INSPE CTION 2 L 7 2 4F RT A28NM 1998011500612 19980115 00612 EU 1998 1 15 AU971052 1 19970607 G 3246 C2252 WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U911ANSETTSN (AUS) MAIN WHEEL INBOARD HALF CRACKED AT THE BASE OF ONE DRIVE TENON AT POSITION NO3 - FOUND DURING EDDY CURRENT INSPECT ION 2 L 7 2 4F RT A28NM 1998011500613 19980115 00613 EU 1998 1 15 AU971053 1 19970607 G 3246 C2252 WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U2005ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED AT THE BASE OF ONE DRIVE TENON AT POSITION NO2 - FOUND DURING EDDY CURRENT INSPECT ION 2 L 7 2 4F RT A28NM 1998011500614 19980115 00614 EU 1998 1 15 AU971054 1 19970607 G 3246 U362ANSETTSN WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U3062ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED IN THE CENTRE OF ONE DRIVE TENONAT POSITION NO3 - FOUND DURING EDDY CURRENT INSPEC TION 2 L 7 2 4F RT A28NM 1998011500615 19980115 00615 EU 1998 1 15 AU971055 1 19970607 G 3246 F4894ANSETTSN WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S F4894ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED THROUGH CENTRE AREAS OF THREE DRIVE TENONS AT POSITION NO1 - FOUND DURING EDDY CUR RENTINSPECTION 2 L 7 2 4F RT A28NM 1998011500616 19980115 00616 EU 1998 1 15 AU971056 1 19970607 G 3246 U298ANSETTSN WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U2908ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED THROUGH CENTRE OF FOUR DRIVE TENONS AT POSITION NO2 - FOUND DURING EDDY CURRENT IN SPECTION 2 L 7 2 4F RT A28NM 1998011500617 19980115 00617 EU 1998 1 15 AU971057 1 19970607 G 3246 U363ANSETTSN WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U3063ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED THROUGH THE CENTRE OF SIX DRIVE TENONS AT POSITION NO2 - FOUND DURING EDDY CURRENT INSPECTION 2 L 7 2 4F RT A28NM 1998011500618 19980115 00618 EU 1998 1 15 AU971058 1 19970607 G 3246 C225151 WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U2670ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED THROUGH THE GUIDE PIN HOLES OF TWO TENONS AT POSITION NO2 - FOUND DURING EDDY CURR ENT INSPECTION 2 L 7 2 4F RT A28NM 1998011500619 19980115 00619 EU 1998 1 15 AU971059 1 19970607 G 3246 C225151 WHEEL AIRBUS 320 A320212 EU MLG INB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U4709ANSETTS (AUS) MAIN WHEEL INBOARD HALF CRACKED AT THE BASE OF FOUR DRIVE TENONS AT POSITION NO4 - FOUND DURING EDDY CURRENT INSPE CTION 2 L 7 2 4F RT A28NM 1998011500620 19980115 00620 EU 1998 1 15 AU971060 1 19970607 G 3246 C2262 WHEEL AIRBUS 320 A320212 EU MLG OUTB HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S U2052ANSETTS (AUS) MAIN WHEEL OUTBOARD HALF CRACKED IN BEAD SEAT AREA AT POSITIONNO4 2 L 7 2 4F RT A28NM 1998011500621 19980115 00621 NM 1998 1 15 AU971069 1 19970516 G 2923 MF19655ANSETT SEAL BOEING 767 767204 NM GE CF6 CF680A 30025 NE HYD PUMP RAT LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S MF190655ANSE (AUS) RAM AIR TURBINE (RAT) HYDRAULIC PUMP HOUSING SEALS LEAKING. 2 L 7 2 4F 4 F RT A1NM E13NE 1998011500622 19980115 00622 1998 1 15 AU971088 4 19970219 G 2211 COMPUTER AIRBUS 320 A320212 EU AUTO FLIGHT SYST MALFUNCTIONED W K NONE J WARNING INDICATION CL CLIMB 1 AU S (AUS) FLIGHT CONTROL ELAC 2 PITCH FAULT INDICATED ON ECAM. BOTH ELAC COMPUTERS AND SPOILER COMPUTER CHANGED AND SENT TO WORKSHOP FOR INVESTIGATION WITH NO FAULTS FOUND. 2 L 7 2 4F RT A28NM 1998012100006 19980121 00006 EU 1998 1 21 AU971092 1 19970516 G 3010 HTE984 ACTUATOR BAC 146 146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE LT RT WING AI FAULTY W K NONE J WARNING INDICATION CL CLIMB 1 AU S AIVL88636 (AUS) LH AND RH WING OUTER ANTI-ICE VALVES BOTH HAD SLIPPING CLUTCHES. 2 H 7 4 4F 4 F RT A49EU E6NE 1998011500623 19980115 00623 SW 1998 1 15 AU971105 1 19970508 G 1100 DATA PLATE BELL 47 47G3B1 1181028 SW LYC O435 VO435A1F 41516 EA AIRCRAFT MAINT INCORRECT DATA W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S L294656 (AUS) SUSPECT INCORRECT DATA PLATE FITTED TO HELICOPTER. AIRCRAFT HAD BEEN EXTENSIVELY REBUILT IN 1989. PERSONNEL/MAINTE NANCE ERROR. 1 G 7 1 3O 3 O 2H3 E279 1998011500624 19980115 00624 SW 1998 1 15 AU971106 1 19970523 G 6710 KSP5 BEARING BELL 47 47G3B1 1181028 SW LYC O435 VO435A1F 41516 EA M/R CYCLIC WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LATERAL CYCLIC TORQUE TUBE FORWARD SUPPORT BEARING WORN. 1 G 7 1 3O 3 O 2H3 E279 1998011500625 19980115 00625 SW 1998 1 15 AU971112 1 19970508 G 2622 EXTINGUISHER BELL 47 47G3B1 1181028 SW LYC O435 VO435A1F 41516 EA FIRE BOTTLE WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) UNAPPROVED TYPE OF DRY POWDER FIRE EXTINGUISHER FITTED. UNAPPROVED PART. 1 G 7 1 3O 3 O 2H3 E279 1998012200180 19980122 00180 SW 1998 1 22 AU971113 1 19970523 G 6710 KSP4 BEARING BELL 47 47G3B1 1181028 SW LYC O435 VO435A1F 41516 EA MAIN ROTOR CONTR WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) COLLECTIVE LEVER FORWARD BEARING WORN. PERSONNEL/MAINTENANCE ERROR. 1 G 7 1 3O 3 O 2H3 E279 1998012200181 19980122 00181 NM 1998 1 22 AU971120 1 19970610 G 7160 31317 DOOR PIPER PA60 PA60600 7106001 NM LYC O540 IO540K1J5 41532 EA ENGINE AIR INT SEPARATED W K NONE O OTHER LD LANDING 1 AU S L176948A (AUS) ENGINE ALTERNATE AIR DOOR SEPARATED FROM INDUCTION AIR BOX ASSEMBLY AND JAMMED THE THROTTLE BUTTERFLY 1 M 7 2 3O 3 O RT A17WE 1E4 1998012200182 19980122 00182 1998 1 22 AU971128 4 19970527 G 3417 HG48B13 ADC BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE AIR DATA COMP FAULTY W K NONE O OTHER CR CRUISE 1 AU S P122ANSETTSN (AUS) NO2 AIR DATA COMPUTER (ADC) FAILED. INVESTIGATION FOUND A DRY SOLDER JOINT ON A PIN CONNECTION AND THE HEAT SINK C OMPOUND BETWEEN THE POWER DIODES AND THEIR INTERFACE WITH THE MODULE CIRCUIT CARD HAD DETERIORATED. 2 L 7 3 4F 4 F RT A3WE E2EA 1998012200183 19980122 00183 EA 1998 1 22 AU971134 2 19970415 G 7421 REM38E SPARK PLUG LYC O360 O360A4K 41514 EA MCAULY 1A170 1A170FFA GL ENGINE IGN INTERMITTENT W K NONE O E OTHER VIBRATION/BUFFET CR CRUISE 1 AU S (AUS) SPARK PLUGS INTERMITTENT IN OPERATION. 3 O E286 5 N P857 1998012200184 19980122 00184 1998 1 22 AU971142 4 19970526 G 3417 HG48B42 ADC BOEING 737 73733A 1384673 NM AIR DATA COMP MALFUNCTION W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NO2 AIR DATA COMPUTER (ADC) SUSPECT FAULTY. WORKSHOP INVESTIGATION COULD FIND NO FAULTS. 2 L 7 2 4F RT A16WE 1998012200185 19980122 00185 EU 1998 1 22 AU971163 1 19970423 G 3233 21519 BEARING AIRBUS 320 A320212 EU LT RT MLG ACT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 2960 LHDAASG94RH (AUS) LH AND RH MAIN LANDING GEAR ACTUATOR ROD END SPHERICAL BEARINGS CRACKED IN SEVERAL PLACES ACROSS THE PIVOTING BALL . 2 L 7 2 4F RT A28NM 1998012200186 19980122 00186 EU 1998 1 22 AU971199 1 19970603 G 2752 L74ANSETT58 ACTUATOR AIRBUS 320 A320212 EU TE FLAP ACTUATOR CORRODED W K NONE J F WARNING INDICATION FLT CONT AFFECTED NR NOT REPORTED 1 AU S L704ANSETT05 (AUS) LH NO2 FLAP ACTUATOR FAULTY - TORQUE LIMITER TRIPPED - STRIP INVESTIGATION FOUND SOME INTERNAL COMPONENTS CORRODED AND PITTED- SUSPECT CAUSED BY MOISTURE IN THE ACTUATOR 2 L 7 2 4F RT A28NM 1998012200187 19980122 00187 CE 1998 1 22 AU971218 1 19970210 G 5312 713683 BULKHEAD CESSNA 182 182Q 2072732 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C203 GL DOOR POST CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE DOOR POST BULKHEAD CRACKED IN AREA OF STRESS RELIEF NOTCH. CRACK LENGTH 3.175MM (0.125IN). FOUND DURING I NVESTIGATION IAW AD/180/75 AMDT1. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1998012200188 19980122 00188 NM 1998 1 22 AU971224 1 19970528 G 2612 FIRE DETECTOR BOEING 737 737377 NM APU FIRE WARN FAULTY W K NONE N FALSE WARNING DE DESCENT 1 AU S (AUS) APU FALSE FIRE WARNING. SUSPECT CAUSED BY MOISTURE IN FIREDETECTOR SYSTEM. 2 L 7 2 4F RT A16WE 1998012200189 19980122 00189 NM 1998 1 22 AU971237 1 19970618 G 3244 DR2582T TIRE BOEING 737 737377 NM LT NLG WHEEL SEPARATED W K NONE O OTHER TO TAKEOFF 1 AU S KA251ANSETTS (AUS) LH NOSEWHEEL TYRE TREAD SEPARATED. DAMAGE TO LH FRONT CORNER OF E & E BAY DOOR. 2 L 7 2 4F RT A16WE 1998012200190 19980122 00190 NM 1998 1 22 AU971262 1 19970213 G 3246 265759A WHEEL BENDIX BOEING 727 7272J4 1384006 NM PWA JT8 JT8D17 52049 NE NR 4 MLG FRACTURED W K NONE O OTHER LD LANDING 1 AU S 387 ASSYHALFH015 (AUS) NO4 MAIN WHEEL HALF FAILED IN THE CENTRE HUB AREA. DAMAGE CAUSEDTO THE BRAKE AND WHEEL BEARING. FUSE PLUG MELTED A ND TYRE DEFLATED. 2 L 7 3 4F 4 F RT A3WE E2EA 1998012200191 19980122 00191 CE 1998 1 22 AU971272 1 19970314 G 3260 ISET3 SWITCH CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL RT MLG DWNLOCK FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH MAIN LANDING GEAR DOWNLOCK MICROSWITCH AND WIRING DETERIORATED DUE TO AGE. FURTHER INVESTIGATION FOUND THE RH M LG DOWNLOCK SYSTEM INCORRECTLY WIRED. 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 1998012200192 19980122 00192 CE 1998 1 22 AU971274 1 19970630 G 2436 DGR3 REGULATOR CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO MCAULY 3A32C D3A32C90 GL DC GEN SYS FAILED W K NONE H ELECT. POWER LOSS-50 PC CR CRUISE 1 AU S (AUS) REGULATOR (2OFF) FAILED DUE TO SHORT CIRCUIT. SUSPECT CAUSED BY FAULTY ALTERNATOR. 1 H 7 1 3O 3 O A4CE E5CE 5 C P21EA 1998012200193 19980122 00193 EA 1998 1 22 AU971332 2 19970620 G 8530 LW13561 CYLINDER PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA INLET VALVE SEAT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 1017 L32562 (AUS) ENGINE CYLINDER CRACKED FROM INDUCTION TUBE FACE TOWARDS THE INLET VALVE SEAT. CRACK LENGTH 31.75MM (1.25IN) 1 L 7 2 3O 3 O A8EA E19EA 1998012200194 19980122 00194 EA 1998 1 22 AU971333 2 19970502 G 8530 LW13561 CYLINDER PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541E1A 41539 EA INLET VALVE SEAT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 1379 L21962 (AUS) ENGINE CYLINDER CRACKED FROM INDUCTION TUBE MOUNT FACE TOWARDSTHE INLET VALVE SEAT. CRACK LENGTH 25.4MM (1IN). 1 L 7 2 3O 3 O A8EA E19EA 1998012200195 19980122 00195 WP 1998 1 22 AU971368 2 19971008 G 7200 ENGINE GARRTT TPE331 TPE33112UA 01514 WP ROTOL R333 R333482F12 GL POWER SECT DEFECTIVE W K NONE O R OTHER PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S (AUS) LH ENGINE LOW ON POWER. 4 T E4WE 6 C P61GL 1998012200196 19980122 00196 NM 1998 1 22 AU971369 1 19970305 G 2730 364ANSETTSN FEEL UNIT BOEING 737 73733A 1384673 NM ELEVATOR CONTROL FAULTY W K NONE F FLT CONT AFFECTED NR NOT REPORTED 1 AU S 364ANSETTSN0 (AUS) ELEVATOR FEEL AND CENTERING UNIT FAULTY. SOME LINKAGE COMPONENTS DAMAGED. 2 L 7 2 4F RT A16WE 1998012600003 19980126 00003 NE 1998 1 26 AU971370 3 19970118 G 6110 28449 SPACER HAMSTD 23D 23D40 NE PROP ASSEMBLY WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S ADH3465AQM ADH3465AQM (AUS) INCORRECT SPACER FITTED TO PROPELLER. PERSONNEL/MAINTENANCE ERROR. UNAPPROVED PART. 6 C P719 1998012200197 19980122 00197 CE 1998 1 22 AU971371 1 19971017 G 5312 713683 BULKHEAD CESSNA 182 182P 2075816 CE MCAULY 2A34C 2A34C203 GL LT DOOR POST CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD DOOR POST BULKHEAD CRACKED IN RELIEF NOTCH ON LH SIDE.AIRCRAFT IS USED FOR PARACHUTING OPERATIONS. 1 H 7 1 3O NT TA13 5 C P3EA 1998012200198 19980122 00198 NE 1998 1 22 AU971372 2 19971102 G 7250 34451CL VANE PWA 125B PWA PWA120 PW125B NE HP TURBINE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 7002 124011 12411 (AUS) HP TURBINE INLET GUIDE VANE ASSEMBLY HAD ONE VANE COMPLETELY BURNED AWAY AT APPROXIMATELY THE 8 O'CLOCK POSITION. 4 T E20NE 1998012200199 19980122 00199 EA 1998 1 22 AU971374 2 19970924 G 7230 MS97147 BOLT PILATS PC6T PC6BH2 7090210 EU PWA PT6 PT6A20 52043 EA HARTZL HCB3T HCB3TN3 GL COMP TURBINE BROKEN W K NONE E VIBRATION/BUFFET CL CLIMB 1 AU S PCE21674 (AUS) COMPRESSOR TURBINE VANE BOLTS (3OFF) HAD THE BOLT HEADS SEPARATE AND BECOME TRAPPED BETWEEN THE VANE AND TURBINE D ISC CAUSING DAMAGE TO THE DISC IN THE AREA OF THE FIR TREE AND THE VANE.SUSPECT BOLTS WERE NOT REPLACED DURING THE LAST REPAIR WHICH WAS FOR AN ENGINE OVERTEMP. 1 H 7 1 3T 3 T 7A15 E4EA 6 C P15EA 1998012200200 19980122 00200 EA 1998 1 22 AU971375 2 19971024 G 8520 L236224 CRANKCASE LYC LYC O540 O540E4C5 41532 EA ENGINE FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S L2362240 L236224 (AUS) CRANKCASE TUNNEL MEASUREMENTS OUT OF LIMITS. 3 O E295 1998012600004 19980126 00004 NM 1998 1 26 AU971376 1 19970716 G 7603 AS26117 BOLT BOEING 747 747SP38 NM RROYCE RB211 RB211524D419 54555 NE POWER LEVER RUBBING W K NONE O OTHER CL CLIMB 1 AU S (AUS) NO2 ENGINE THRUST LEVER PLA TRANSDUCER ROD END EYE BOLT BINDING WITH FFR POWER LEVER INPUT ROD. 2 L 7 4 4F 4 F RT A20WE E12EU 1998012200201 19980122 00201 GL 1998 1 22 AU971377 2 19971028 G 7240 6894 HEAT SHIELD AEROSP AS355 AS355F1 8680810 EU ALLSN 250C 250C20F 03013 GL NR 1 ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S CAE84232 (AUS) NO1 ENGINE HEAT SHIELD CRACKED. 1 G 7 2 3U 3 U H11EU E4CE 1998012200202 19980122 00202 CE 1998 1 22 AU971378 1 19970219 G 5541 5331513 SPAR CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA MCAULY 2D34C B2D34C220 GL RUDDER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RUDDER SPAR CRACKED ADJACENT TO TOP HINGE POINT. 1 H 7 1 3O 3 O 3A17 E286 5 C P7EA 1998012200203 19980122 00203 NM 1998 1 22 AU971379 1 19970812 G 5411 65B8912 BRACE BOEING 747 747238B 1384828 NM NR 4 ENG STRUT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NO4 ENGINE STRUT DIAGONAL BRACE REAR OUTBOARD LUG CRACKED. FOUND DURING INSPECTION IAW FAA AD89-07-15 (CASA AD/B74 7/70). 2 L 7 4 4F A20WE 1998012200204 19980122 00204 NM 1998 1 22 AU971380 1 19970622 G 3411 PIPE BOEING 747 747438 NM PITOT/STATIC SYS DISCONNECTED W K NONE F FLT CONT AFFECTED CR CRUISE 1 AU S (AUS) CENTRE AIR DATA COMPUTER (ADC) PITOT/STATIC LINES DISCONNECTED. 2 L 7 4 4F RT A20WE 1998012200205 19980122 00205 SW 1998 1 22 AU971381 1 19971101 G 2910 2781322682 PIPE FRCHLD SA227 SA227CC SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE HYDRAULIC CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HYDRAULIC PIPE SPLIT IN RADIUS LOCATED ON THE FIRST BEND FORWARD OF THE RH ENGINE FIREWALL. 2 L 7 2 4T 4 T RT A18SW E4WE 6 C 3PNE 1998012200206 19980122 00206 NM 1998 1 22 AU971382 1 19970811 G 2460 SG62 SOCKET BOEING 747 747438 NM DC POWER DISTRIB MELTED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) DOOR 4L VACUUM CLEANER ELECTICAL SOCKET BURNT AND MELTED. SUSPECT CAUSED BY EXCESSIVE CURRENT DRAW FROM WHATEVER D EVICE HAD BEEN PLUGGED IN AT THE TIME. IN ADDITION THE DEVICE HAD NOT BEEN MAKING FULL CONTACT WITH THE SOCKET FINGERS. 2 L 7 4 4F RT A20WE 1998012200207 19980122 00207 NM 1998 1 22 AU971383 1 19970827 G 5414 SKIN BOEING 747 747238B 1384828 NM NR 1 NR 4 NAC CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NO1 AND NO4 ENGINE NACELLE STRUT OUTBOARD SKIN AND DOUBLER CRACKED BEYOND LIMITS. 2 L 7 4 4F A20WE 1998012200208 19980122 00208 SO 1998 1 22 AU971384 2 19971031 G 8520 578462 CRANKCASE CONT CONT O520 IO520B 17032 SO ENG LT CASE HALF CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 578462 578462 (AUS) ENGINE LH CRANKCASE HALF CRACKED IN AREA OF NO3 BEARING SADDLE. 3 O E5CE 1998012200209 19980122 00209 GL 1998 1 22 AU971386 3 19971007 G 6111 BLADE GULSTM 680 680FLP 0141610 SW LYC O720 IO720B1B 41546 EA HARTZL HCA3V HCA3VK2 GL PROPELLER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 473 L19654A BJ1196 (AUS) PROPELLER BLADE CRACKED. CRACK ORIGINATED FROM A NICK IN THE BLADE LOCATED APPROXIMATELY 76.2MM (3IN) FROM THE BLA DE TIP.CRACK LENGTH 12.7MM (0.5IN). SUSPECT THE CRACK WAS INITIATED BY A PIECE OF METAL WIRE WHICH WAS FOUND IN THE BLAD E DURING DRESSING OUT OF THE CRACK. 1 H 7 2 3O 3 O 2A4 1E15 5 C P6EA 1998012200210 19980122 00210 CE 1998 1 22 AU971387 1 19970915 G 3231 84116 BELLCRANK CESSNA 402 402B 207590P CE MCAULY 3AF32C 3AF32C87 GL MLG RT DOOR CRACKED W K NONE O OTHER LD LANDING 1 AU S (AUS) RH MAIN LANDING GEAR DOOR IDLER BELLCRANK BROKEN. FURTHER INVESTIGATION FOUND THE LH IDLER BELLCRANK CRACKED IN TH E SAMEAREA. 1 L 7 2 3O A7CE 5 C P22EA 1998012200211 19980122 00211 NM 1998 1 22 AU971388 1 19971022 G 5311 A22 FRAME ROBSIN R22 R22BETA NM LYC O320 O320B2C 41508 EA FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 1344 (AUS) FUSELAGE FRAME CRACKED. AIRCRAFT IS USED IN MUSTERING OPERATIONS. 1 G 7 1 3O 3 O H10WE E274 1998012200212 19980122 00212 CE 1998 1 22 AU971389 1 19971017 G 3230 24136 PAD CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA MCAULY 2D34C B2D34C207 GL LANDING GEAR MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LANDING GEAR PADS MISSING. PADS ARE VULCANISED/BONDED TO A STEELSHELL. CORROSION APPEARS TO HAVE SPREAD BETWEEN TH E PAD AND THE SHELL CAUSING DELAMINATION. 1 H 7 1 3O 3 O A20CE 1E10 5 C P7EA 1998012200213 19980122 00213 CE 1998 1 22 AU971390 1 19971017 G 3230 MS16555354 PIN CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA MCAULY 2D34C B2D34C207 GL MLG DWNLOCK DISTORTED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LANDING GEAR DOWNLOCK PINS BENT DUE TO DEFECTIVE PADS (SEE MDR97/1389). WHEN THE DAMAGED PINS WERE REMOVED AND COM PARED TO THE REPLACEMENT ITEMS THEY APPEARED TO BE MANUFACTURED FROM A SOFTER MATERIAL (AN5 BOLTS). PERSONNEL/MAINTENANC E ERROR. 1 H 7 1 3O 3 O A20CE 1E10 5 C P7EA 1998012200214 19980122 00214 CE 1998 1 22 AU971391 1 19971017 G 7922 75944 VALVE LYC CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA MCAULY 2D34C B2D34C207 GL THERMO BYPASS DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S L1076851A L176851A (AUS) ENGINE OIL COOLER BYPASS VALVE (VERNATHERM) FACE BADLY SCORED FROM CONTACT WITH VALVE SEAT WHICH WAS ALSO DAMAGED. FOUND DURING INSPECTION IAW AD/LYC/78 AMDT5 WHICH WAS OVERDUE BY SEVERAL HUNDRED HOURS. PERSONNAL/MAINTENANCE ERROR. 1 H 7 1 3O 3 O A20CE 1E10 5 C P7EA 1998012200215 19980122 00215 SW 1998 1 22 AU971392 1 19970921 G 5313 263132914 FITTING BELL 206 206L 1181522 SW ALLSN 250C 250C30P 03013 GL AFT FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AFT FUSELAGE LONGERON FITTING CRACKED. 1 G 7 1 3U 3 U H2SW E1GL 1998012200216 19980122 00216 SO 1998 1 22 AU971393 1 19971106 G 3232 756265 SPRING OZONE PIPER PA31 PA31350 7103110 SO HARTZL HCE3Y HCE3YR2 GL LT MLG DOOR BROKEN W K NONE O OTHER LD LANDING 1 AU S 2115 (AUS) LH MAIN LANDING GEAR DOOR ACTUATOR SPRING BROKEN. 1 L 7 2 3O A20SO 5 C P33EA 1998012200217 19980122 00217 NE 1998 1 22 AU971394 2 19971103 G 8530 71167 VALVE DHAV DHC3 DHC3 2800202 EA PWA R1340 R134059 52016 NE HAMSTD 23D 23D40 NE NR 2 CYL EXH LEAKING W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S 979 1866 (AUS) NO2 CYLINDER EXHAUST VALVE LEAKING. 1 H 7 1 3R 3 R A815 5E2 6 C P719 1998012200218 19980122 00218 NM 1998 1 22 AU971395 1 19971019 G 5101 AIRCRAFT DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE STRUCTURE LIGHTNING STRIKE W K NONE C F.O.D. CL CLIMB 1 AU S (AUS) AIRCRAFT SUFFERED A LIGHTNING STRIKE. DAMAGE TO BOTH PROPELLERS,RH AND LH INBOARD WINGS AND INBOARD FLAPS. 2 H 7 2 4T 4 T RT A13NM E20NE 1998012200219 19980122 00219 NM 1998 1 22 AU971396 1 19971028 G 3230 8415 ACTUATOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE NLG RETRACT SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S DCL24489 (AUS) NOSE LANDING GEAR DRAG BRACE ACTUATOR SEPARATED FROM AND DAMAGED NOSE GEAR WHEEL WELL STRUCTURE. 2 H 7 2 4T 4 T RT A13NM E20NE 1998012200220 19980122 00220 CE 1998 1 22 AU971397 1 19970926 G 3211 5411212 SUPPORT CESSNA 182 182A 2072704 CE CONT O470 O470L 17026 SO MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 486689L4 (AUS) LANDING GEAR SUPPORT CRACKED. 1 H 7 1 3O 3 O NT 3A13 E273 1998012200221 19980122 00221 SW 1998 1 22 AU971398 1 19971108 G 6322 47661297 COOLING FAN BELL 47 BELL 47 47G3B 1181026 SW LYC O435 TVO435D1B 41516 EA ROTORCRAFT CORRODED W K NONE O OTHER CL CLIMB 1 AU S 359 A345157 (AUS) COOLING FAN CORRODED. TWO ADJACENT BLADES BROKEN OFF. BROKEN BLADES CUT THROUGH THE VOLTAGE REGULATOR COVER AND IM PACTED THE REGULATOR COOLING FINS. THEY THEN TRAVELLED DOWNWARDS, DAMAGING THE FUEL GAUGE LINE BEFORE COMING TO REST ON THE TAIL ROTOR CONTROL CABLES. 1 G 7 1 3O 3 O 2H3 1E13 1998012200222 19980122 00222 CE 1998 1 22 AU971399 1 19970930 G 2933 SIGHT GLASS CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO MCAULY 3AF32C 3AF32C505 GL HYD QUANTITY DAMAGED W K NONE K J FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S (AUS) RH HYDRAULIC RESERVOIR SIGHT TUBE SPLIT AND LEAKING FLUID UNDER PRESSURE. HYDRAULIC CONTROL VALVE ALSO FOUND TO BE UNSERVICEABLE. 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 1998012200223 19980122 00223 1998 1 22 AU971400 4 19971027 G 2565 7152 ACTUATOR AIRBUS 7015000002 AIRBUS 300 A300B4203 3930306 EU GE CF6 CF650C2 30018 NE ESCAPE SLIDE FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 29769 ACTUATOR9148 (AUS) DOOR 1R ESCAPE SLIDE DOOR ACTUATOR FAULTY. ACTUATOR DID NOT OPEN THE DOOR CORRECTLY WITH THE SLIDE PUSHING THE DOO R FULLY OPEN. IT WAS ALSO NOTICED THAT THE EMERGENCY EQUIPMENT FELL OUT OF THE SLIDE. THE SLIDE DEPLOYED FULLY. 2 L 7 2 4F 4 F A35EU E23EA 1998012200224 19980122 00224 NM 1998 1 22 AU971401 1 19971028 G 2824 45744 ACTUATOR BOEING 737 737476 NM FUEL CROSSFEED FAULTY W K NONE J WARNING INDICATION CR CRUISE 1 AU S 2413 3842 (AUS) FUEL SYSTEM CROSSFEED VALVE ACTUATOR SEIZED. 2 L 7 2 4F RT A16WE 1998012200225 19980122 00225 EU 1998 1 22 AU971402 1 19970721 G 5730 SKIN BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE LT RT WING DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING UPPER SKIN LOWER SURFACE DAMAGED IN AREA OF STRINGERS AT RIBS 0 AND 2 ON BOTH LH AND RH SIDES. FOUND DURING I NSPECTION IAW ER BA6-57-10-9A. 2 H 7 4 4F 4 F A49EU E6NE 1998012200226 19980122 00226 EU 1998 1 22 AU971403 1 19971103 G 2710 6852193 CONTROL CABLE PARTEN P68 P68B 6780104 EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL AILERON CONTROL FRAYED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH OUTBOARD AILERON CABLE STRANDS BROKEN. FOUND DURING INSPECTION IAW AD/P68/44 (PARTENAVIA SB 75 REV3). 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1998012200824 19980122 00824 EU 1998 1 22 AU971404 1 19971017 G 2621 5733312 FIRE BOTTLE BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE FIRE BOTTLE LOW QUANTITY W K NONE O OTHER IN INSP/MAINT 1 AU S 5418 CL9116ANSETT (AUS) APU FIRE EXTINGUISHER BOTTLE UNDERWEIGHT BY 0.4KG. EVIDENCE OFCORROSION ON THE BOTTLE. 2 H 7 4 4F 4 F A49EU E6NE 1998012200825 19980122 00825 SO 1998 1 22 AU971405 1 19970918 G 3213 653194 CYLINDER PIPER PA28 PA28151 7102805 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S L36727A A55147 (AUS) MAIN LANDING GEAR CYLINDER CRACKED IN TORQUE LINK ATTACHMENTPOINTS. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 1998012200826 19980122 00826 EU 1998 1 22 AU971406 1 19971103 G 2710 6852193 CONTROL CABLE PARTEN P68 P68B 6780104 EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL AILERON CONTROL FRAYED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH AILERON OUTBOARD CONTROL CABLE STRANDS BROKEN. FOUND DURINGINSPECTION IAW AD/P68/44 (PARTENAVIA SB 75 REV3). 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1998012200827 19980122 00827 EU 1998 1 22 AU971407 1 19971103 G 2710 6852195 CONTROL CABLE PARTEN P68 P68B 6780104 EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL AILERON CONTROL FRAYED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AILERON BALANCE CABLE STRANDS BROKEN. FOUND DURING INSPECTIONIAW AD/P68/44 (PARTENAVIA SB 75 REV3). 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1998012200828 19980122 00828 EU 1998 1 22 AU971408 1 19971103 G 2710 6852196 CONTROL CABLE PARTEN P68 P68B 6780104 EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL AILERON CONTROL FRAYED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH AILERON BALANCE CABLE STRANDS BROKEN. FOUND DURING INSPECTIONIAW AD/P68/44 (PARTENAVIA SB 75 REV3). 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1998012200829 19980122 00829 EU 1998 1 22 AU971409 1 19971103 G 2730 6853211 CONTROL CABLE PARTEN P68 P68B 6780104 EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL ELEVATOR CONTROL FRAYED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH FORWARD ELEVATOR CABLE STRANDS BROKEN. FOUND DURING INSPECTION IAW AD/P68/44 (PARTENAVIA SB 75 REV3). 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1998012200830 19980122 00830 EU 1998 1 22 AU971410 1 19971103 G 2750 6855312 CONTROL CABLE PARTEN P68 P68B 6780104 EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL TE FLAP CONTROL FRAYED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH FLAP CABLE STRANDS BROKEN. FOUND DURING INSPECTION IAW AD/P68/44 (PARTENAVIA SB 75 REV3). 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1998012200831 19980122 00831 EU 1998 1 22 AU971411 1 19971002 G 2621 573332 FIRE BOTTLE BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE FIRE BOTTLE EMPTY W K NONE O OTHER IN INSP/MAINT 1 AU S 5910 1248ANSETT00 (AUS) NO2 ENGINE INBOARD FIRE EXTINGUISHER BOTTLE ALMOST EMPTY. SUSPECT CAUSED BY CORROSION ON HEAD ASSEMBLY AND FILL FI TTINGS ALLOWING LEAKAGE. 2 H 7 4 4F 4 F A49EU E6NE 1998012200832 19980122 00832 EU 1998 1 22 AU971412 1 19970913 G 2621 573332 FIRE BOTTLE BAC 146 146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE APU FIRE BOTTLE EMPTY W K NONE O OTHER IN INSP/MAINT 1 AU S 6993 CN2147ANSETT (AUS) APU FIRE BOTTLE EMPTY. SUSPECT CAUSED BY CORROSION ON HEAD ANDFILL FITTINGS ALLOWING BOTTLE TO LEAK. 2 H 7 4 4F 4 F RT A49EU E6NE 1998012200833 19980122 00833 NM 1998 1 22 AU971413 1 19970808 G 3244 397812 TIRE BOEING 737 73733A 1384673 NM GE CFM56 CFM563B1 13802 NE NR 4 MAIN SEPARATED W K NONE O OTHER TO TAKEOFF 1 AU S 6456ANSETTSN (AUS) NO4 MAIN LANDING GEAR TYRE TREAD SEPARATED. DAMAGE CAUSED TO FLAPS, MLG DOORS AND STABILISER LEADING EDGE. DAMAGE CAUSED BY A FOREIGN OBJECT PENETRATING THE TOP SIX PLYS OF THE TYRE. 2 L 7 2 4F 4 F RT A16WE E2GL 1998012200834 19980122 00834 SO 1998 1 22 AU971414 1 19971110 G 7110 COWLING PIPER PA31 PA31 7103102 SO LYC O540 TIO540A1A 41532 EA HARTZL HCE3Y HCE3YR2 GL ENGINE COWLING DEPARTED W K NONE D W INFLIGHT SEPARATION INADEQUATE Q C DE DESCENT 1 AU S (AUS) LH ENGINE COWLING SEPARATED FROM AIRCRAFT IN FLIGHT. THE TOP COWL WAS JAMMED ON THE LEADING EDGE OF THE OUTBOARD W ING BY THESLIPSTREAM WHILE THE BOTTOM COWL WAS LOST. THIS WAS THE FIRST FLIGHT AFTER THE COWLS WERE REMOVED TO CARRY OUT AD/PHZL/60 A4. SUSPECT THAT THE COWLS WERE NOT CORRECTLY SECURED AFTER MAINTENANCE. PERSONNEL/MAINTENANCE ERROR. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1998012200835 19980122 00835 NM 1998 1 22 AU971415 1 19971031 G 7540 ELECTRICAL SYS DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE BLEED AIR IND CONTAMINATED W K NONE N FALSE WARNING CL CLIMB 1 AU S (AUS) BLEED AIR SYSTEM ELECTRICAL CIRCUIT CONTAMINATED WITH WATER DUE TO HEAVY RAIN. 2 H 7 2 4T 4 T RT A13NM E20NE 1998012200836 19980122 00836 EU 1998 1 22 AU971416 1 19970708 G 2133 82768 TORQUE LIMITER AIRBUS 320 A320212 EU PRESSURE REG FAULTY W K NONE J WARNING INDICATION CL CLIMB 1 AU S 74ANSETTSNO0 (AUS) AVIONICS COOLING SYSTEM INLET VALVE TORQUE LIMITER FAULTY. 2 L 7 2 4F RT A28NM 1998012200837 19980122 00837 SO 1998 1 22 AU971417 1 19971011 G 5520 7172 HINGE PIPER PA31 PA31350 7103110 SO HARTZL HCE3Y HCE3YR2 GL ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH ELEVATOR OUTBOARD HINGE CRACKED AND RIVET SHEARED. 1 L 7 2 3O A20SO 5 C P33EA 1998012200838 19980122 00838 EA 1998 1 22 AU971418 2 19970925 G 8530 74541 VALVE LYC PIPER PA28 PA28151 7102805 SO LYC O320 O320E2D 41508 EA ENG NR 3 CYL EXH FAILED W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S 1664 L25227A (AUS) NO3 CYLINDER EXHAUST VALVE HEAD HAD APPROXIMATELY 30% MISSING.DAMAGE CAUSED TO THE TOP OF THE PISTON. 1 L 7 1 3O 3 O 2A13 E274 1998012200839 19980122 00839 NE 1998 1 22 AU971419 2 19970801 G 7200 ENGINE RROYCE RB211 RB211524G19 NE LT ENGINE SMOKE W K NONE B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 AU S (AUS) LH ENGINE CAUSING SMOKE/MISTING/ODOUR IN THE CABIN AND SMOKE ALARM ACTIVATION IN THE AFT TOILET. INVESTIGATION FOU ND THAT THE LH ENGINE HAD COMPLETED A COMPRESSOR WASH PRIOR TO THE FLIGHT. 4 F E30NE 1998012200840 19980122 00840 NM 1998 1 22 AU971420 1 19971020 G 5210 41T6844 SWITCH BOEING 767 767238 NM PWA JT9 JT9D7R4E 52054 NE PASS NR 1 DOOR FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 000022 (AUS) LH SIDE NO1 DOOR CLOSE SWITCH FAULTY. THE DOOR WAS UNABLE TO BE OPENED EITHER BY MANUAL OR ELECTRICAL MEANS. 2 L 7 2 4F 4 F RT A1NM E3NE 1998012200841 19980122 00841 NM 1998 1 22 AU971421 1 19971015 G 2497 WIRE BOEING 767 767338 1385151 NM DC POWER DISTRIB WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) GENERATOR FEEDER CABLE CHAFED AND SHOWING EVIDENCE OF BURN MARKS. LOCATED AT WING STATION S325 (NR 6 LE SLAT). IN VESTIGATION FOUND THAT THE CABLE HAD CHAFED ON AN ADJACENT PNEUMATIC OVERHEAT DETECTOR CLIP. 2 L 7 2 4F RT A1NM 1998012200842 19980122 00842 WP 1998 1 22 AU971422 1 19971107 G 6220 51452 PIN HILLER HILLER UH12 UH12E 4360122 WP LYC O540 VO540C2A 41532 EA MAIN ROTOR HEAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 10527A (AUS) MAIN ROTOR HEAD TENSION/TORSION PIN CRACKED. 1 G 7 1 3O 3 O 4H11 E304 1998012200843 19980122 00843 NE 1998 1 22 AU971423 2 19971102 G 7210 CP6B2254 COMBINING GRBOX BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE TURBINE ENGINE MAKING METAL W K NONE O J OTHER WARNING INDICATION TO TAKEOFF 1 AU S 2056 CP6B2254 CPGB2254 (AUS) ENGINE COMBINING GEARBOX METAL CONTAMINATION. SUSPECT CAUSED BY DETERIORATION OF BEARING CAGE. 1 G 7 2 4U 4 U H4SW E22EA 1998012200844 19980122 00844 EU 1998 1 22 AU971424 2 19971111 G 7200 ENGINE CFMINT CFM56 CFM563C 13802 EU NR 1 FAILED W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 AU S 725274 (AUS) NR 1 ENGINE HAD LOSS OF POWER AND SEVERE VIBRATION. 4 F E21EU 1998012200845 19980122 00845 NM 1998 1 22 AU971425 1 19970926 G 3244 H42X16X19 TIRE BOEING 737 737377 NM LT MLG FAILED W K NONE O OTHER TO TAKEOFF 1 AU S 531106239327 (AUS) BOTH LH MAIN WHEEL TYRES FAILED. SUSPECT NO1 OUTBOARD TYRE FAILED FIRST DUE TO FOD. NO2 TYRE THEN FAILED DUE TO HI GH ENERGY BRAKING COMBINED WITH RAPID DECELERATION. DAMAGE TO FLAPS, MLG DOORS AND BRAKE LINES. SMALL AMOUNTS OF TYRE DE BRIS ALSO ENTERED THE LH ENGINE CAUSING MINOR DAMAGE TO FAN BLADES. 2 L 7 2 4F RT A16WE 1998012200846 19980122 00846 EU 1998 1 22 AU971426 1 19970711 G 2150 VFT215 SUPPORT AIRBUS 320 A320212 EU CABIN COOLING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 32ANSETTSN00 (AUS) SKIN AIR INLET VALVE FAULTY. INSPECTION FOUND EXCESSIVE AMOUNTS OF CORROSION IN THE MANUAL CONTROL HANDLE SUPPORT ASSEMBLY WHICH CAUSED THE VALVE TO SEIZE AND ALSO PREVENTED DEPLOYMENT OF THE CONTROL HANDLE PREVENTING MANUAL CLOSURE O F THE VALVE. 2 L 7 2 4F RT A28NM 1998012200847 19980122 00847 NE 1998 1 22 AU971427 2 19971112 G 7200 ENGINE BOEING 747 747312 1384932 NM PWA JT9 JT9D7R4G2 52054 NE ENGINE NR 1 FAILED W K NONE O R M OTHER PARTIAL RPM/PWR LOSS OVER TEMP CR CRUISE 1 AU S 71517 (AUS) NO1 ENGINE LOST POWER AND EXCEEDED EGT LIMITS. 2 L 7 4 4F 4 F RT A20WE E3NE 1998012200848 19980122 00848 1998 1 22 AU971428 4 19971012 G 2350 61433 SWITCH CESSNA 404 404CESSNA 2075901 CE MCAULY 3FF32 3FF32C501 GL PILOT PTT FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PILOTS PTT SWITCH LOCATED ON LH CONTROL WHEEL FAILED INTERNALLY IN THE TRANSMIT MODE 1 L 7 2 3O A25CE 5 C P45GL 1998012200849 19980122 00849 SO 1998 1 22 AU971429 2 19971027 G 7310 641486 PIPE CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL LT ENG FUEL DIST CRACKED W K NONE O K OTHER FLUID LOSS CR CRUISE 1 AU S (AUS) LH ENGINE FUEL INJECTOR PIPE BETWEEN MANIFOLD AND INJECTOR CRACKED IN AREA WHERE NIPPLE IS BRAZED TO THE INJECTOR LINE. 1 L 7 2 3O 3 O A25CE E7CE 5 C P45GL 1998012200850 19980122 00850 NM 1998 1 22 AU971430 1 19971114 G 5311 A22 FRAME ROBSIN R22 R22BETA NM LYC O320 O320B2C 41508 EA FUSELAGE UPPER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 2396 (AUS) FUSELAGE UPPER FRAME CRACKED IN WELD IN AREA DESCRIBED IN AD/R22/41 A1. 1 G 7 1 3O 3 O H10WE E274 1998012200851 19980122 00851 CE 1998 1 22 AU971431 1 19971119 G 3233 35825944 ACTUATOR BEECH 58 58 1152740 CE MCAULY 3AF32C 3AF32C512 GL NLG BROKEN W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) NOSE LANDING GEAR RETRACTION ACTUATOR AFT ATTACHMENT LUG BROKEN OFF. 1 L 7 2 3O 3A16 5 C P22EA 1998012200852 19980122 00852 NM 1998 1 22 AU971432 1 19971117 G 5311 A22 FRAME ROBSIN R22 R22BETA NM TAILBOOM UPPER MIS REPAIR W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) REPLACEMENT FUSELAGE UPPER FRAME CONTAINED UNAUTHORISED WELD REPAIR IN THE AREA OF THE TAIL BOOM ATTACHMENT. UNAPP ROVED REPAIR. PERSONNEL/MAINTENANCE ERROR. 1 G 7 1 3O H10WE 1998012200853 19980122 00853 CE 1998 1 22 AU971433 1 19971007 G 3297 WIRE CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL LT MLG POS BROKEN W K NONE P NO WARNING INDICATION LD LANDING 1 AU S (AUS) LH MAIN LANDING GEAR DOWNLOCK MICROSWITCH WIRE BROKEN. 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 1998012200854 19980122 00854 CE 1998 1 22 AU971434 1 19971026 G 2810 FUEL SYSTEM CESSNA 182 182H 2072718 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL FUEL STORAGE CONTAMINATED W A UNSCHED LANDING E Y VIBRATION/BUFFET ENGINE STOPPAGE CR CRUISE 1 AU S 288427R (AUS) FUEL SYSTEM CONTAMINATED BY WATER. ENGINE FAILURE RESULTED IN FORCED LANDING. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1998012200855 19980122 00855 CE 1998 1 22 AU971435 1 19971112 G 3297 WIRE CESSNA 404 404CESSNA 2075901 CE MCAULY 3FF32 3FF32C501 GL LT MLG POS BROKEN W K NONE P NO WARNING INDICATION LD LANDING 1 AU S (AUS) LH MAIN LANDING GEAR DOWNLOCK MICROSWITCH EARTH WIRE (NO4) BROKEN AT TERMINAL. 1 L 7 2 3O A25CE 5 C P45GL 1998012200856 19980122 00856 NM 1998 1 22 AU971436 1 19971019 G 3242 262125 BRAKE BOEING 747 747338 NM LT BODY GEAR WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) INCORRECT BRAKE ASSEMBLY FITTED TO LH BODY GEAR POSITION 7R. THE BRAKE UNIT WAS A &$&SP TYPE UNIT. PERSONNEL/MAINT ENANCE ERROR.UNAPPROVED PART. 2 L 7 2 4F RT A20WE 1998012200857 19980122 00857 NM 1998 1 22 AU971437 1 19971029 G 5753 65B1159844 LUG BOEING 747 747338 NM RT NR 5 TE FLAP DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NO5 RH TRAILING EDGE FOREFLAP CARRIAGE AND TOGGLE ASSEMBLY DAMAGED. ONE ATTACHMENT LUG BROKEN OFF. 2 L 7 2 4F RT A20WE 1998012600013 19980126 00013 GL 1998 1 26 AU971439 3 19971021 G 6111 BLADE BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE MCAULY 3G34C7 3GFR34C701 GL LT PROP TIP FOD W K NONE O C OTHER F.O.D. IN INSP/MAINT 1 AU S PCE93583 86287 (AUS) LH PROPELLER BLADE TIP BENT. BLOOD ON THE BLADE LEADS TO THE ASSUMPTION OF AND ANIMAL STRIKE. 1 L 7 2 4T 4 T A24CE E4EA 5 C P60GL 1998012200858 19980122 00858 EU 1998 1 22 AU971440 1 19970923 G 2910 137935A77 HOSE BAG JETSTM JETSTM3107 1500215 EU ROTOL R333 R333482F12 GL RT ENG HYD FAILED W K NONE K FLUID LOSS CL CLIMB 1 AU S (AUS) HYDRAULIC PRESSURE HOSE LOCATED BETWEEN THE RH ENGINE DRIVEN HYDRAULIC PUMP AND THE FIREWALL HAD FAILED. LOSS OF H YDRAULIC FLUID. 2 L 7 2 4T RT BA15CAA 6 C P61GL 1998012200859 19980122 00859 1998 1 22 AU971441 1 19971020 G 7922 VALVE GARRTT TPE331 TPE33110U 01514 WP ROTOL R333 R333482F12 GL RT ENG OIL COOL SEIZED W K NONE O OTHER CR CRUISE 1 AU S (AUS) RH ENGINE OIL COOLER THERMOSTATIC BYPASS VALVE STUCK. 4 T E4WE 6 C P61GL 1998012200860 19980122 00860 EU 1998 1 22 AU971442 1 19971021 G 2810 CAP BAG JETSTM JETSTM3107 1500215 EU ROTOL R333 R333482F12 GL FUEL STORAGE SERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUEL CAPS FOUND TO BE SERVICEABLE FOLLOWING EAA-QA INVESTIGATION. 2 L 7 2 4T RT BA15CAA 6 C P61GL 1998012600014 19980126 00014 NM 1998 1 26 AU971443 1 19971011 G 2421 727792H IDG BOEING 757 757200 1384950 NM AC GEN-ALT FAILED W K NONE H J ELECT. POWER LOSS-50 PC WARNING INDICATION TO TAKEOFF 1 AU S A0443 (AUS) LH INTEGRATED DRIVE GENERATOR (IDG) FAULTY. 2 L 7 2 4F RT A2NM 1998012200861 19980122 00861 NM 1998 1 22 AU971444 1 19970307 G 3244 222K682 TIRE H31X97513 DHAV DHC8 DHC8102 2809003 NM MLG FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) TYRES (2OFF) FAILED. LIMITED INFORMATION PROVIDED. 2 H 7 2 4T RT A13NM 1998012200862 19980122 00862 EU 1998 1 22 AU971445 1 19971120 G 5720 FLAP SHROUD BNORM BN2 BN2A26 1520226 EU LYC O540 IO540K1B5 41532 EA HARTZL HCC2Y HCC2YK2 GL LT RT WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH WINGS CONTAINED CORROSION IN AREAS OF FLAP SHROUDS AND REAR BAYS. 1 H 7 2 3O 3 O A17EU 1E4 5 C P920 1998012200863 19980122 00863 EU 1998 1 22 AU971446 1 19971120 G 3250 NB4199 RING BNORM BN2 BN2A26 1520226 EU LYC O540 IO540K1B5 41532 EA HARTZL HCC2Y HCC2YK2 GL NLG STEERING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NOSE WHEEL STEERING DRIVE RING CRACKED. FOUND DURING INSPECTION IAW SB 214 ISSUE 1. 1 H 7 2 3O 3 O A17EU 1E4 5 C P920 1998012200864 19980122 00864 EU 1998 1 22 AU971447 1 19971120 G 2731 TRIM BOX BNORM BN2 BN2A26 1520226 EU LYC O540 IO540K1B5 41532 EA HARTZL HCC2Y HCC2YK2 GL ELEV TAB CONT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ELEVATOR TRIM BOX CRACKED. 1 H 7 2 3O 3 O A17EU 1E4 5 C P920 1998012200865 19980122 00865 EU 1998 1 22 AU971448 1 19971120 G 5521 NB3151 RIB BNORM BN2 BN2A26 1520226 EU LYC O540 IO540K1B5 41532 EA HARTZL HCC2Y HCC2YK2 GL ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ELEVATOR RIB CRACKED. LOOSE AND MISSING RIVETS. 1 H 7 2 3O 3 O A17EU 1E4 5 C P920 1998012200866 19980122 00866 EU 1998 1 22 AU971449 1 19971120 G 5410 NB23721 ANGLE NB203721 BNORM BN2 BN2A26 1520226 EU LYC O540 IO540K1B5 41532 EA HARTZL HCC2Y HCC2YK2 GL LT NACELLE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH NACELLE BOX ANGLE LOCATED FORWARD OF PNO NB-20-C-5677 CRACKED. 1 H 7 2 3O 3 O A17EU 1E4 5 C P920 1998012200867 19980122 00867 EU 1998 1 22 AU971450 1 19971120 G 5410 NB21843 WEB BNORM BN2 BN2A26 1520226 EU LYC O540 IO540K1B5 41532 EA HARTZL HCC2Y HCC2YK2 GL NAC LT & RT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NACELLE LH AND RH WEBS CRACKED. FOUND DURING INSPECTION IAW SB200. 1 H 7 2 3O 3 O A17EU 1E4 5 C P920 1998012200868 19980122 00868 NM 1998 1 22 AU971451 1 19971114 G 5751 HINGE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE LT AIL OUTB DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AILERON OUTBOARD ATTACHMENT HINGE DAMAGED. 2 H 7 2 4T 4 T RT A13NM E20NE 1998012200869 19980122 00869 WP 1998 1 22 AU971452 2 19971114 G 7200 ENGINE GARRTT TPE331 TPE33112UA 01514 WP ROTOL R333 R333482F12 GL RT ENGINE FAILED W K NONE O R OTHER PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S (AUS) RH ENGINE LOW POWER. 4 T E4WE 6 C P61GL 1998012200870 19980122 00870 EU 1998 1 22 AU971453 1 19971120 G 5520 ELEVATOR BNORM BN2 BN2A26 1520226 EU LYC O540 IO540K1B5 41532 EA HARTZL HCC2Y HCC2YK2 GL ELEV STRUCTURE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ELEVATOR CORRODED. 1 H 7 2 3O 3 O A17EU 1E4 5 C P920 1998012200871 19980122 00871 EU 1998 1 22 AU971454 1 19971120 G 5510 STABILIZER BNORM BN2 BN2A26 1520226 EU LYC O540 IO540K1B5 41532 EA HARTZL HCC2Y HCC2YK2 GL HORIZ STAB CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HORIZONTAL STABILISER CORRODED. 1 H 7 2 3O 3 O A17EU 1E4 5 C P920 1998012200872 19980122 00872 EA 1998 1 22 AU971455 2 19971117 G 8520 L789661A CRANKCASE LYC PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S L789661A L789661A (AUS) ENGINE CRANKCASE CRACKED. INVESTIGATION FOLLOWING ENGINE STRIP FOUND TWO DAMAGED CAM FOLLOWERS. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1998012200873 19980122 00873 SW 1998 1 22 AU971456 1 19971117 G 6710 25743H BOLT BELL BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE M/R CONTROL INCORRECT PART W K NONE O OTHER IN INSP/MAINT 1 AU S A265 (AUS) COLLECTIVE LEVER ASSEMBLY PIN PNO 412-010-422-103 FALLEN OUT. THE PIN IS LOCATED ON THE TRANSMISSION CASING. BOLT PNO 20-057-4-3H AND WASHER PNO AN460-416 WAS ATTACHED TO THE PIN WITH LOCKWIRE. INVESTIGATION FOUND THAT THE BOLT PNO 20 -057-4-3H WAS THE INCORRECT PART, THE CORRECT PART NUMBER WAS PNO NAS6604H5 WHICH IS 3.175MM (0.125IN) LONGER. THE REMAI NING COLLECTIVE LEVER PIN ALLOWED THE COLLECTIVE LEVER PNO 412-010-401-109 TO BE MISALIGNED RESULTING IN THE LEVER RUBBI NG ON THE MAIN ROTOR MAST.PERSONNEL/MAINTENANCE ERROR. UNAPPROVED PART. 1 G 7 2 4U 4 U H4SW E22EA 1998012200874 19980122 00874 CE 1998 1 22 AU971457 1 19971124 G 3222 5452112 FORK CESSNA 402 402B 207590P CE MCAULY 3AF32C 3AF32C87 GL NLG FORK FITTING FAILED W K NONE O OTHER LD LANDING 1 AU S (AUS) NOSE LANDING GEAR FORK END FITTINGS CRACKED. NLG FAILED TO LOCK DOWN. 1 L 7 2 3O A7CE 5 C P22EA 1998012200875 19980122 00875 1998 1 22 AU971458 4 19970501 G 2310 KHA95 TRANSCEIVER BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL HF COMM FAULTY W K NONE O OTHER NR NOT REPORTED 1 AU S (AUS) HF RADIO SCRATCHY AND WEAK ON TRANSMIT. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1998012200876 19980122 00876 1998 1 22 AU971459 4 19971124 G 3457 GPS SYSTEM KING KC555 CESSNA 340 340CESSNA 2076404 CE CONT O520 TSIO520K 17040 SO MCAULY 2AF34C D2AF34C71 GL GLOBAL POSIT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) GPS INTERFACE TO HSI AND AIRDATA SYSTEM FAULTY ALLOWING AIRCRAFT TO WANDER IN AUTOPILOT NAV MODE. 1 L 7 2 3O 3 O 3A25 E8CE 5 C P5EA 1998012200878 19980122 00878 EU 1998 1 22 AU971461 1 19970819 G 5312 WEB FOKKER F28 F28MK4000 4990810 EU RROYCE SPEY SPEY55515 54521 EU FWD PRESS BLKHD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD PRESSURE BULKHEAD CRACKED IN TWO PLACES:- 1. WEB AT HORIZONTAL BEAM 7 LOCATED OUTBOARD OF VERTICAL BEAM B L325L 2. WEB AT HORIZONTAL BEAM 8 LOCATED OUTBOARD OF VERTICAL BEAM BL325L FOUND DURING VISUAL INSPECTION IAW ER F28-53 -10-20G. 2 L 7 2 4F 4 F RT A20EU E2EU 1998012200879 19980122 00879 EU 1998 1 22 AU971462 2 19971118 G 7270 3353465 GUIDE VANE CFMINT CFM56 CFM563C 13802 EU NR 1 ENG FAN FRACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S 721712 (AUS) NO1 ENGINE FAN OUTLET GUIDE VANE FAILED AT MID SPAN AND DEPARTED FROM THE ENGINE. 4 F E21EU 1998012200880 19980122 00880 EU 1998 1 22 AU971463 1 19970806 G 5240 DOOR FOKKER F28 F28MK4000 4990810 EU RROYCE SPEY SPEY55515 54521 EU RT SERVICE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH SERVICE/EMERGENCY DOOR CONTAINED TWO CRACKS IN THE LOWER AFT CORNER RUNNING UNDER THE REPAIR DOUBLERS. CRACK LE NGTHS 5MM AND 6MM (0.19IN AND 0.23IN). FOUND DURING EDDY CURRENT INSPECTION IAW ER F28/53/30/18C. 2 L 7 2 4F 4 F RT A20EU E2EU 1998012200881 19980122 00881 NM 1998 1 22 AU971464 1 19971103 G 7312 113 HEATER BOEING 747 747312 1384932 NM PWA JT9 JT9D7R4G2 52054 NE NR 1 ENG FUEL STRIPPED W K NONE O K OTHER FLUID LOSS CR CRUISE 1 AU S 113 (AUS) NO1 ENGINE P.H.I. FUEL HEATER ASSEMBLY FUEL OUT UNION PN MS9193-07 LOOSE. FURTHER INVESTIGATION FOUND THAT THE THR EAD INSIDE THE HEATER ASSEMBLY WAS STRIPPED . 2 L 7 4 4F 4 F RT A20WE E3NE 1998012200882 19980122 00882 SO 1998 1 22 AU971465 1 19971124 G 5513 63585 TRIM TAB PIPER PIPER PA28 PA28235 7102810 SO LYC O540 O540B2B5 41532 EA HARTZL HCC2Y HCC2YK1 GL HORIZ STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) STABILATOR TRIM TABS CRACKED AT INBOARD END ADJACENT TO THE ACTUATING ARM ATTACHMENT. CRACKING EVIDENT IN SKIN PAN ELS AND INBOARD RIB. 1 L 7 1 3O 3 O 2A13 E295 5 C P920 1998012200883 19980122 00883 CE 1998 1 22 AU971466 1 19971121 G 7100 HOSE BEECH 33 35C33 1151408 CE CONT O470 IO470K 17026 SO MCAULY 2A36C 2A36C23 GL POWERPLANT SYS FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 867856K 72339 (AUS) ALL FLUID HOSES IN ENGINE COMPARTMENT NOT PROTECTED BY FIRE SLEEVES. PERSONNEL/MAINTENANCE ERROR. 1 L 7 1 3O 3 O 3A15 3E1 5 C P880 1998012200884 19980122 00884 EA 1998 1 22 AU971467 2 19971118 G 8530 VALVE SEAT BELL 47 47J2A 1181106 SW LYC O435 TVO435B1A 41516 EA ENG NR 4 CYL EXH SEPARATED W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 AU S 160 L88252 (AUS) NO4 CYLINDER EXHAUST VALVE SEAT SEPARATED FROM CYLINDER. NO2 CYLINDER EXHAUST VALVE AND VALVE GUIDE UNSERVICEABLE. NO2 CYLINDER HEAD EXTENSIVELY CRACKED. 1 G 7 1 3O 3 O 2H1 1E13 1998012200885 19980122 00885 SW 1998 1 22 AU971468 1 19970813 G 8120 466115 TURBOCHARGER BELL 47 47G3B 1181026 SW LYC O435 TVO435D1A 41516 EA EXH TURBO FAILED W K NONE O R OTHER PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S L311952 (AUS) ENGINE TURBOCHARGER FAILED. INVESTIGATION FOUND THAT THE EXHAUST TURBINE HAD BEEN SKIDDING ON THE REAR THRUST FACE . 1 G 7 1 3O 3 O 2H3 1E13 1998012200886 19980122 00886 CE 1998 1 22 AU971469 1 19971114 G 5730 E352 RIVET BEECH E3052 BEECH 36 A36 1151604 CE CONT O520 IO520BA 17032 SO MCAULY 2A36C 2A36C23 GL LT RT WING SKIN DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH WING UPPER SKIN ATTACHMENT RIVETS SANDED TO A DEGREE WHEREBY UP TO 2/3 OF THE RADIUS MATERIAL HAS BEEN R EMOVED. THE SANDING HAS ALSO REMOVED ALODINE SURFACE TREATMENT FROM THE UPPER WING SURFACES. 1 L 7 1 3O 3 O 3A15 E5CE 5 C P880 1998012600015 19980126 00015 EA 1998 1 26 AU971471 2 19971107 G 8500 ENGINE HUGHES 269 269C 4470504 WP LYC O360 HO360* 41514 EA POWER PLANT FAILED W A UNSCHED LANDING E R Y VIBRATION/BUFFET PARTIAL RPM/PWR LOSS ENGINE STOPPAGE CL CLIMB 1 AU S L3486836A (AUS) ENGINE SUFFERED A POWER LOSS FOLLOWED BY A STOPPAGE. AIRCRAFT CRASHED. 1 G 7 1 3O 3 O 4H12 E286 1998012200887 19980122 00887 EA 1998 1 22 AU971472 2 19971118 G 8500 L181964A ENGINE LYC PIPER PA25 PA25235 7102504 SO LYC O540 O540B2C5 41532 EA MCAULY 1A200 1A200FA GL LT MAG DRIVE FAILED W K NONE E R Y VIBRATION/BUFFET PARTIAL RPM/PWR LOSS ENGINE STOPPAGE CL CLIMB 1 AU S 1999 L1819640A L181964A 14711 (AUS) ENGINE STOPPED. INITIAL INVESTIGATION FOUND THE LH MAGNETO DRIVE GEAR TO BE DAMAGED AND THE SUPPORT BEARING FAILED . ROTATING THE PROPELLER DID NOT CAUSE THE REAR CASE GEAR TRAIN TO OPERATE. 1 L 7 1 3O 3 O 2A10 E295 5 N P874 1998012200888 19980122 00888 CE 1998 1 22 AU971473 1 19971127 G 3260 1SE13 SWITCH CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL RT MLG DWNLOCK BROKEN W K NONE O P OTHER NO WARNING INDICATION DE DESCENT 1 AU S LH56586 LH768457 (AUS) RH MAIN LANDING GEAR DOWNLOCK MICROSWITCH LEVER BROKEN OFF. 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 1998012200889 19980122 00889 CE 1998 1 22 AU971474 1 19971127 G 5341 16941318 FRAME BEECH 23 A23 1151204 CE CONT O346 IO346A 17033 SO WING ATTACH MIS REPAIR W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) FUSELAGE TO WING ATTACHMENT FRAME FILED OUT ON THE INSIDE RADIUS AND INCORRECT RIVET FITTED TO THE FORWARD WING MA IN SPAR SUPPORT. PERSONNEL/MAINTENANCE ERROR. UNAPPROVED PART/REPAIR. 1 L 7 1 3O 3 O A1CE E3CE 1998012200890 19980122 00890 CE 1998 1 22 AU971475 1 19971127 G 5512 169621661 STABILIZER BEECH 23 A23 1151204 CE CONT O346 IO346A 17033 SO HORIZ STAB INCORRECT MOD W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) STABILATOR INCORRECTLY MODIFIED IAW SI 1167. THE STABILISER HAD ONLY TWO INSPECTION PANELS FITTED TO THE UNDERSIDE INSTEAD OF THE FOUR STIPULATED IN SI 1167. 1 L 7 1 3O 3 O A1CE E3CE 1998012200891 19980122 00891 WP 1998 1 22 AU971476 1 19971030 G 7160 269A81523 VALVE HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA ENGINE AIR INT ILLEGAL MOD W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S RL2215751A (AUS) INTAKE ALTERNATE AIR VALVE ILLEGALLY MODIFIED. THE VALVE WAS SEALED CLOSED WITH SEALANT AND A PLASTIC OIL BOTTLE W AS GLUED OVER THE TOP. PERSONNEL/MAINTENANCE ERROR. UNAPPROVED MODIFICATION. 1 G 7 1 3O 3 O 4H12 1E10 1998012200892 19980122 00892 CE 1998 1 22 AU971477 1 19971127 G 5730 16911686 PANEL 110000663 BEECH 23 A23 1151204 CE CONT O346 IO346A 17033 SO WING INSP PANEL INCORRECT MOD W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING INSPECTION PANELS INCORRECT SIZE. SI 0824-035 REV11 STIPULATES THE PANELS SHOULD BE 127MM (5IN) IN DIAMETER B UT THOSE FITTED ARE ONLY 100MM (4IN) DIAMETER MAKING ACCESS DIFFICULT. 1 L 7 1 3O 3 O A1CE E3CE 1998012200893 19980122 00893 WP 1998 1 22 AU971478 1 19971031 G 6310 269A546 HUB HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA ENG-TRANS MIS INSTALLED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S RL2215751A (AUS) ENGINE TO TRANSMISSION UPPER CLUTCH HUB INSTALLED THE WRONG WAY AROUND. BEARING SEAT SHOULDER SHEARED OFF. PERSONN EL/MAINTENANCE ERROR. 1 G 7 1 3O 3 O 4H12 1E10 1998012200894 19980122 00894 SO 1998 1 22 AU971479 2 19971127 G 7414 13571651 COIL BENDIX 201205 BEECH 23 A23 1151204 CE CONT O346 IO346A 17033 SO ENG MAG FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH MAGNETO COILS BREAKING DOWN. MAGNETO LEADS ALSO FAULTY. 1 L 7 1 3O 3 O A1CE E3CE 1998012200895 19980122 00895 WP 1998 1 22 AU971480 1 19971031 G 7112 269A853311 SCROLL HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA ENG AIR BAFFLE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S RL2215751A (AUS) ENGINE SCROLL ASSEMBLY LOWER MOUNT SEPARATED. UPPER RH BRACKET PNO 269A8597 WAS ALSO FOUND TO BE UNSERVICEABLE. TH E SCROLL WAS FOULING ON THE IMPELLER. 1 G 7 1 3O 3 O 4H12 1E10 1998012200896 19980122 00896 WP 1998 1 22 AU971481 1 19971031 G 6310 269A5582 PULLEY HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA ENG-TRANS WORN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) DRIVE BELT IDLER PULLEY HAD THE ANODIZED COATING WORN THROUGH IN ALL GROOVES. 1 G 7 1 3O 3 O 4H12 1E10 1998012200897 19980122 00897 EU 1998 1 22 AU971482 1 19971120 G 5343 FITTING MUDRY 10 CAP10B EU LYC O360 AEIO360B2F 41514 EA HOFMAN HO29 HO29HM180 EU LT RT FWD ATTACH CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH FORWARD UNDERCARRIAGE ATTACHMENT BLOCKS CRACKED. FOUND DURING INSPECTION IAW SB15 2(B). 1 L 7 1 3O 3 O A36EU 1E10 5 N P3EU 1998012200898 19980122 00898 NE 1998 1 22 AU971483 2 19971126 G 7261 CHIP DETECTOR BAC 146 146100A 1500260 EU LYC ALF502 ALF502R5 41580 NE NR 1 ENG SEPARATED W K NONE O K OTHER FLUID LOSS CR CRUISE 1 AU S (AUS) NO1 ENGINE FULL FLOW CHIP DETECTOR DISLODGED ALLOWING A MASSIVE OIL LEAK. ENGINE WAS INSPECTED IAW MAINTENANCE MAN UAL WITH NO FAULT FOUND AND RETURNED TO SERVICE. 2 H 7 4 4F 4 F RT A49EU E6NE 1998012200899 19980122 00899 NM 1998 1 22 AU971484 1 19970624 G 5311 A22 FRAME ROBSIN ROBSIN R22 R22MARINER NM LYC O320 O320B2C 41508 EA RT MLG GRBOX MT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 1088 2346 (AUS) FUSELAGE UPPER FRAME TUBE FROM RH REAR MAIN GEARBOX MOUNT PAD TO THE RH DECK BOLT CRACKED THROUGH WELD UNDER THE G EARBOX MOUNT PAD. 1 G 7 1 3O 3 O H10WE E274 1998012200900 19980122 00900 SW 1998 1 22 AU971485 1 19971017 G 5744 27344277 BRACKET SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL LT AIL PIVOT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AILERON CENTRE ATTACHMENT BRACKET CRACKED ON UPPER AND LOWER WEBS AT AILERON INPUT BELLCRANK PIVOT BOLT ATTACHM ENT AREA. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 1998012200901 19980122 00901 CE 1998 1 22 AU971486 1 19971127 G 3411 RA1JA7 FILTER BEECH 33 F33A 1151425 CE CONT O520 IO520B 17032 SO MCAULY 3A32C 3A32C76 GL DIRECTIONAL GYRO CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) INLINE PRESSURE FILTER TO DIR GYRO CRACKED AND LEAKING. 1 L 7 1 3O 3 O 3A15 E5CE 5 C P21EA 1998012200902 19980122 00902 EU 1998 1 22 AU971487 1 19971018 G 2913 74A33694 DRIVE BELT AEROSP 704A3431006 SNIAS 350 AS350D 8680803 EU ALLSN 250C 250C30 03013 GL HYDRAULIC PUMP LOOSE W K NONE O OTHER CR CRUISE 1 AU S 10658770 (AUS) HYDRAULIC PUMP DRIVE BELT LOOSE. SEE MDR 97/1319 FOR ADDITIONAL INFORMATION 1 G 7 1 3U 3 U H9EU E1GL 1998012200903 19980122 00903 SO 1998 1 22 AU971488 1 19971106 G 7920 338 HOSE PIPER PA28 PA28180 7102808 SO LYC O360 O360A3A 41514 EA SNSNCH 76E 76EM8 EA ENG OIL DIST DETERIORATED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 1647936 18469K (AUS) OIL COOLER HOSES (2OFF) FAULTY. OIL SEEPING THROUGH FIRE SLEEVE. 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 1998012200904 19980122 00904 SO 1998 1 22 AU971489 1 19971126 G 3411 LINE PIPER J3 J3 7100502 SO CONT MCAULY 1A103 1A103TCM GL PITOT/STATIC SYS DISCONNECTED W K NONE I FLT. ATTITUDE INST. CL CLIMB 1 AU S (AUS) STATIC LINE DISCONNECTED AT REAR OF ASI. PERSONNEL/MAINTENANCE ERROR. 1 H 7 1 3O ATC660 5 N P50GL 1998012200905 19980122 00905 EU 1998 1 22 AU971490 1 19971126 G 2910 A2714201200000 HOSE AIRBUS 300 A300B4203 3930306 EU GE CF6 CF650C2 30018 NE GREEN HYD LEAKING W K NONE K FLUID LOSS TO TAKEOFF 1 AU S A27142012000 (AUS) HYDRAULIC HOSE TO THE ALL SPEED AILERON LOCATED AT THE LH WING REAR FALSE SPAR ON RIB 6A FAILED. LOSS OF GREEN SYS TEM HYDRAULIC FLUID. 2 L 7 2 4F 4 F A35EU E23EA 1998012200906 19980122 00906 GL 1998 1 22 AU971491 1 19971105 G 3230 TORQUE TUBE AMTR SEAREY SEAREY 05625X5 GL ROTAX 912 ROTAX912 55555 EU LANDING GEAR RET DISTORTED W K NONE O OTHER LD LANDING 1 AU S (AUS) LANDING GEAR COLLAPSED. INVESTIGATION FOUND THAT THE LANDING GEAR TORQUE TUBE ASSEMBLY WAS TWISTED WHEN THE AIRCRA FT FELL OFF A STAND DURING ASSEMBLY. AIRCRAFT IS AMATEUR BUILT. 1 H 7 1 3I 3 I RC 1H71EXPA EXPE3I 1998012200907 19980122 00907 NM 1998 1 22 AU971492 1 19971128 G 5330 SKIN DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE BS 521 - 545 DAMAG W K NONE C F.O.D. LD LANDING 1 AU S (AUS) REAR FUSELAGE DAMAGED JUST FORWARD OF THE CARGO DOOR DUE TO IMPACT BY BAGGAGE HANDLERS TRACTOR. NO TEARING OR CRAC KING OF THE SKIN WAS EVIDENT ALTHOUGH THE LIMITS OF THE DAMAGE ARE BEYOND THE SIZE ALLOWABLE TO CONTINUE WITHOUT REPAIR. DAMAGE WAS LOCATED BETWEEN FS 521 AND FS 545 AND CROSSES FRAMES AT FS 531.5 AND FS 539 BETWEEN STRINGERS 22 AND 23 LEFT . THE MAXIMUM DEPTH BETWEEN THE FRAMES IS 5.334MM (0.210IN), 5.588MM (0.220IN) AND 4.572MM(0.180IN). 2 H 7 2 4T 4 T RT A13NM E20NE 1998012200908 19980122 00908 SW 1998 1 22 AU971493 1 19971025 G 2460 PSM CIRCUIT BREAKER AIRTRC AT300 AT301 0390103 SW PWA R1340 R1340AN1 52016 NE HAMSTD 12D 12D40 NE DC POWER DISTRIB FAULTY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) ALL CIRCUIT BREAKERS FAILED TO MEET MANUFACTURERS REQUIREMENTS. 1 L 7 1 3R 3 R A9SW 5E2 5 C P257 1998012200909 19980122 00909 SW 1998 1 22 AU971494 1 19971128 G 2460 CIRCUIT BREAKER AIRTRC AT300 AT301 0390103 SW PWA R1340 R1340AN1 52016 NE HAMSTD 12D 12D40 NE DC POWER DISTRIB FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CIRCUIT BREAKERS FAULTY. 1 L 7 1 3R 3 R A9SW 5E2 5 C P257 1998012200910 19980122 00910 SW 1998 1 22 AU971495 1 19971201 G 2460 CIRCUIT BREAKER AIRTRC AT300 AT301 0390103 SW PWA R1340 R1340AN1 52016 NE HAMSTD 22D 22D40 NE DC POWER DISTRIB FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CIRCUIT BREAKERS FAULTY. 1 L 7 1 3R 3 R A9SW 5E2 5 C P736 1998012200911 19980122 00911 1998 1 22 AU971496 4 19971202 G 3424 1394T1005Y INDICATOR AIRTRC AT300 AT301 0390103 SW PWA R1340 R1340AN1 52016 NE HAMSTD 22D 22D40 NE TURN & BANK FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) TURN AND SLIP INDICATOR FAULTY. WHITE PAINT BEHIND SLIP BALL IS CRAZED AND FLAKING. ON/OFF FLAG IS PUSHED BACK ONT O TURN AND SLIP INDICATOR. INSTRUMENT FAILED AD/INST8 AMDT3. 1 L 7 1 3R 3 R A9SW 5E2 5 C P736 1998012600016 19980126 00016 NE 1998 1 26 AU971497 2 19971119 G 7322 SENSOR BOEING 727 72777C 1380420 NM PWA JT8 JT8D7A 52053 NE FUEL CONTROL FOD W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S 657272 (AUS) NO1 ENGINE P2 INLET BLOCKED BY A WASP. 2 L 7 3 4F 4 F A3WE E2EA 1998012200912 19980122 00912 SO 1998 1 22 AU971498 1 19971110 G 7820 66894003 MUFFLER PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA BAFFLE CRACKED W K NONE O E R OTHER VIBRATION/BUFFET PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 AU S L817539A (AUS) MUFFLER BAFFLE COLLAPSED INTERNALLY CAUSING PARTIAL BLOCKING OF THE MUFFLER OUTLET. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 1998012200913 19980122 00913 EU 1998 1 22 AU971499 1 19970801 G 3234 9036001 GEAR BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE LANDING GEAR SEL SLIPPING W K NONE O OTHER DE DESCENT 1 AU S 788GB324H890 (AUS) LANDING GEAR SELECTOR VALVE ACTUATOR TORQUE LIMITER SLIPPING. 2 H 7 4 4F 4 F A49EU E6NE 1998012200914 19980122 00914 EU 1998 1 22 AU971500 1 19970820 G 3260 HTE9449 SWITCH BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE MLG POS FAULTY W K NONE O P OTHER NO WARNING INDICATION CL CLIMB 1 AU S 353 1187GB108HAN (AUS) LANDING GEAR SELECTOR VALVE AND ACTUATOR ASSEMBLY MICROSWITCH ACTUATING ARM PIVOT PIN DISLODGED. 2 H 7 4 4F 4 F A49EU E6NE 1998012200915 19980122 00915 CE 1998 1 22 AU971502 1 19971111 G 3297 WIRE BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO NLG BROKEN W K NONE O P OTHER NO WARNING INDICATION CL CLIMB 1 AU S 10552 (AUS) NOSE LANDING GEAR INDICATOR ARM ACTUATING WIRE BROKEN. 1 L 7 2 3O 3 O 3A16 E5CE 1998012200916 19980122 00916 EU 1998 1 22 AU971503 1 19971113 G 3242 PISTON BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE BRAKE LEAKING W K NONE K FLUID LOSS CR CRUISE 1 AU S (AUS) RH NO3 BRAKE AUXILIARY PISTON LEAKING. LOSS OF HYDRAULIC FLUID FROM GREEN SYSTEM. 2 H 7 4 4F 4 F A49EU E6NE 1998012200917 19980122 00917 EU 1998 1 22 AU971504 1 19971129 G 2910 HOSE BAC 146 146100A 1500260 EU LYC ALF502 ALF502R5 41580 NE GREEN HYD FAILED W K NONE K FLUID LOSS DE DESCENT 1 AU S (AUS) RH LANDING GEAR RETRACTION ACTUATOR PRESSURE HOSE FAILED. LOSS OF GREEN SYSTEM HYDRAULIC FLUID. 2 H 7 4 4F 4 F RT A49EU E6NE 1998012200918 19980122 00918 NM 1998 1 22 AU971505 1 19971202 G 5512 SKIN DHAV DHC8 DHC8202 2809007 NM HORIZ STAB LE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH HORIZONTAL STABILISER UPPER AND LOWER LEADING EDGES CONTAINED CORROSION AROUND FASTENER HOLES. AIRCRAFT OPERATES IN A SALT LADEN ENVIRONMENT AND IS WASHED REGULARLY, HOWEVER THE HEIGHT OF THE TAILPLANE MAKES THE WASHING OF T HIS AREA DIFFICULT. 2 H 7 2 4T RT A13NM 1998012200919 19980122 00919 EU 1998 1 22 AU971506 1 19971125 G 2913 O-RING BRAERO 1000 BAE1251000 1500287 EU PWA 305 PW305 NE NR 1 HYD PUMP. FAILED W K NONE K FLUID LOSS CL CLIMB 1 AU S (AUS) NO1 ENGINE HYDRAULIC PUMP HIGH PRESSURE FITTING `O' RING SEAL FAILED. LOSS OF HYDRAULIC FLUID. 2 L 7 2 4F 4 F RT A3EU E35NE 1998012200920 19980122 00920 EA 1998 1 22 AU971507 2 19971107 G 8530 76190 CYLINDER GULSTM 500 500S 0141107 SW LYC O540 IO540E1B5 41532 EA ENGINE INCORRECT ASSY W K NONE E R W VIBRATION/BUFFET PARTIAL RPM/PWR LOSS INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) RH ENGINE CONTAINED THREE CYLINDERS WITH INCORRECT BARREL/PISTON RING COMBINATION. LH ENGINE HAD ONE CYLINDER WITH INCORRECT RINGS. THE AFFECTED CYLINDERS WERE CHROMED CYLINDERS (CERMICROME) BUT DURING THE PREVIOUS ASSEMBLY WERE MISTA KEN FOR NITRIDED CYLINDERS AND FITTED WITH THE APPROPRIATE PISTON RINGS (CHROME) FOR THAT TYPE CYLINDER RESULTING IN CHR OME RINGS IN A CHROME CYLINDER. PERSONNEL/MAINTENANCE ERROR 1 H 7 2 3O 3 O 6A1 1E4 1998021100003 19980211 00003 1998 2 11 AU971508 4 19971203 G 6113 BULKHEAD MCAULY 1A135 1A135BRM GL PROP SPINNER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S OK12 (AUS) PROPELLER SPINNER BULKHEAD CRACKED IN AREA AROUND THREE MOUNTING BOLT HOLES. 5 N P842 1998012200921 19980122 00921 CE 1998 1 22 AU971509 1 19971126 G 5210 20394254013 HOOK CESSNA 441 441 2076020 CE HARTZL HCB3T HCB3TN5 GL CABIN DOOR BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CABIN DOOR UPPER HOOK BROKEN. 1 L 7 2 3T RT A28CE 6 C P15EA 1998012200922 19980122 00922 EU 1998 1 22 AU971510 1 19971111 G 7830 CF6RHFRAF1 THRUST REVERSER AIRBUS 300 A300B4203 3930306 EU GE CF6 CF650C2 30018 NE ENGINE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 24701 (AUS) RH OUTBOARD THRUST REVERSER CORRODED AND DAMAGED. METAL STRUT LEADING EDGE DAMAGED AREA BROKEN OFF AND LODGED IN C ASCADE FORWARD RECESS CAUSING A BLOCKER DOOR TO BREAK AND SEVERE BLOCKER DOOR CARRIAGE DAMAGE. 2 L 7 2 4F 4 F A35EU E23EA 1998012200923 19980122 00923 EU 1998 1 22 AU971511 1 19971120 G 7500 DUCT AIRBUS 300 A300B4203 3930306 EU GE CF6 CF650C2 30018 NE BLEED AIR DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NO2 ENGINE 15TH STAGE DUCT CRACKED CIRCUMFERENTIALLY. NUMEROUS TIE ROD ENDS SNAPPED OFF. HP RECOUP TUBE SEVERELY C HAFFED. 2 L 7 2 4F 4 F A35EU E23EA 1998012200924 19980122 00924 NE 1998 1 22 AU971512 2 19970703 G 7310 1602ANSETTSNO MANIFOLD BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE ENGINE FUEL CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 1602ANSETTSN LF05183 (AUS) NO2 ENGINE INBOARD FUEL MANIFOLD CRACKED. FOUND DURING EDDY CURRENT INSPECTION IAW ER ALF73-10-20 PART 2B. 2 H 7 4 4F 4 F A49EU E6NE 1998012200925 19980122 00925 CE 1998 1 22 AU971513 1 19971126 G 2720 SPRING 1015241863 BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL RUDDER CONTROL FAULTY W K NONE F W FLT CONT AFFECTED INADEQUATE Q C NR NOT REPORTED 1 AU S (AUS) RUDDER BOOST CABLE TENSION SPRING STRETCHED. INCORRECT TENSION ON THE CABLE ALLOWED THE RUDDER BOOST ACTUATOR ARM TO JAM UNDER THE LIP OF THE BULKHEAD. THE BULKHEAD WAS ALSO DAMAGED. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1998012200926 19980122 00926 EA 1998 1 22 AU971514 2 19970825 G 8520 UO435 CRANKCASE LYC TVO435D1B LYC O435 TVO435D1B 41516 EA ENGINE FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S L1284 L1284 (AUS) CRANKCASE FAULTY. LIMITED INFORMATION PROVIDED. 3 O 1E13 1998012200927 19980122 00927 CE 1998 1 22 AU971515 1 19971108 G 5610 WINDSHIELD BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE COCKPIT RT BIRD STRIKE W K NONE O C OTHER F.O.D. TO TAKEOFF 1 AU S (AUS) BIRDSTRIKE ON RH WINDSCREEN. NIL DAMAGE. 1 L 7 2 4T 4 T A24CE E4EA 1998012200928 19980122 00928 CE 1998 1 22 AU971516 1 19971113 G 3260 1013646281 SWITCH BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE MLG INTERMITTENT W K NONE O N OTHER FALSE WARNING LD LANDING 1 AU S (AUS) LANDING GEAR DOWNLOCK MICROSWITCH INTERMITTENT OPERATION. 1 L 7 2 4T 4 T A24CE E4EA 1998012200929 19980122 00929 CE 1998 1 22 AU971517 1 19971129 G 3246 AN547 BOLT CESSNA 210 210N 2073453 CE NLG FORK FAILED W K NONE O OTHER LD LANDING 1 AU S (AUS) NOSE WHEEL ATTACHMENT BOLT FAILED. WHEEL TWISTED IN NLG FORK. SUSPECT BROKEN BOLT. 1 H 7 1 3O 3A21 1998012200930 19980122 00930 SO 1998 1 22 AU971518 2 19971122 G 8530 641917A12 VALVE CESSNA 150 150G 2071816 CE CONT O200 O200A 17020 SO ENG EXH NR 4 STICKING W A UNSCHED LANDING O R OTHER PARTIAL RPM/PWR LOSS LD LANDING 1 AU S 633146A (AUS) NO4 CYLINDER EXHAUST VALVE STUCK OPEN. LOSS OF POWER AND ROUGH RUNNING RESULTED IN A FORCED LANDING IN THE BUSH. 1 H 7 1 3O 3 O 3A19 E252 1998012200931 19980122 00931 CE 1998 1 22 AU971519 1 19971116 G 3213 51410059 TORQUE LINK CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL MLG SEPARATED W K NONE O OTHER LD LANDING 1 AU S (AUS) LH MAIN LANDING GEAR TORQUE LINK SEPARATED AT THE CENTRE HINGE POINT. THE CENTRE HINGE BOLT COMPLETE WITH NUT, SPL IT PIN, BUSHES AND WASHERS PULLED THROUGH THE LOWER TORQUE LINK. SUSPECT CAUSED BY WORN BUSHES AND/OR IMPROPER SHIMMING OF THE CENTRE HINGE POINT. 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 1998012200932 19980122 00932 SO 1998 1 22 AU971520 1 19971201 G 2810 99321 CAP PIPER PA31 PA31350 7103110 SO HARTZL HCE3Y HCE3YR2 GL RT OUTB FUEL SEPARATED W K NONE O D OTHER INFLIGHT SEPARATION IN INSP/MAINT 1 AU S (AUS) RH OUTBOARD FUEL CAP SEPARATED FROM TANK. INVESTIGATION FOUND THAT THE CAP WAS STILL LOCKED INTO THE ADAPTER RING WHICH HAD SEPARATED FROM THE FILLER HOLE DUE TO THE LOCKING TABS ON THE ADAPTER NOT ENGAGING IN THE FILLER SLOT HOLES AL LOWING THEADAPTER TO ROTATE AND COME LOOSE. FURTHER INSPECTION OF THE OTHER FUEL CAPS FOUND THE RH INBOARD CAP ADAPTER L OCKING TABS NOT ENGAGED. 1 L 7 2 3O A20SO 5 C P33EA 1998012200933 19980122 00933 CE 1998 1 22 AU971521 1 19971205 G 5210 3540001818 HINGE BEECH 58 58 1152740 CE MCAULY 3AF32C 3AF32C512 GL CABIN DOOR FRACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MAIN CABIN DOOR UPPER FORWARD HINGE FRACTURED AT THE HINGE BOLT HOLE. SUSPECT INITIATED BY INTERGRANULAR CORROSION DUE TO DISSIMILAR METAL CONTACT. 1 L 7 2 3O 3A16 5 C P22EA 1998012600017 19980126 00017 EA 1998 1 26 AU971522 2 19971203 G 7414 IO51324 SPRING BENDIX IO382754 BEECH 76 76 1153005 CE LYC O360 O360A1G 41514 EA RT ENG MAG BROKEN W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CL CLIMB 1 AU S 1414 (AUS) RH ENGINE MAGNETO IMPULSE COUPLING SPRING BROKEN. 1 L 7 2 3O 3 O A29CE E286 1998012200934 19980122 00934 GL 1998 1 22 AU971523 1 19971120 G 5712 C1W317A1 RIB DHAV DHC1 DHC1TMK10 2801712 GL LYC O360 IO360A1A 41514 EA RT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S L1768851 (AUS) RH WING ROOT RIB CRACKED IN AREA OF FLAP CABLE PULLEY ATTACHMENT. 1 L 7 1 3O 3 O EXPA1L71 1E10 1998012200935 19980122 00935 1998 1 22 AU971524 4 19971207 G 6122 89741016 GOVERNOR ROTOL R333 R333482F12 GL LT ENG PROP GOV MALFUNCTION W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S 2454730B (AUS) LH ENGINE PROPELLER GOVERNOR SLUGGISH IN OPERATION. 6 C P61GL 1998012200936 19980122 00936 CE 1998 1 22 AU971525 1 19971209 G 3710 RAIJ47 FILTER BEECH 33 F33A 1151425 CE CONT O520 IO520BA 17032 SO MCAULY 2A36C 2A36C23 GL VACUUM SYS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) VACUUM SYSTEM CLEAR INLINE PRESSURE FILTER CRACKED AROUND JOINT. 1 L 7 1 3O 3 O 3A15 E5CE 5 C P880 1998012200937 19980122 00937 EU 1998 1 22 AU971526 1 19971012 G 5210 350A25126820 FITTING AEROSP AS355 AS355F1 8680810 EU ALLSN 250C 250C20F 03013 GL RT DOOR AFT MT CRACKED W K NONE O OTHER CL CLIMB 1 AU S (AUS) RH SLIDING DOOR REAR ROLLER MOUNT CRACKED AND BROKEN. WHEN THE DOOR WAS OPENED THE DOOR ATTEMPTED TO SEPARATE FROM THE AIRCRAFT BUT WAS HELD IN PLACE BY A PASSENGER. 1 G 7 2 3U 3 U H11EU E4CE 1998012200938 19980122 00938 SW 1998 1 22 AU971527 1 19971115 G 5345 412418001 FITTING BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE HOIST BEAM CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HOIST BEAM ATTACHMENT FITTING CRACKED. 1 G 7 2 4U 4 U H4SW E22EA 1998012200939 19980122 00939 CE 1998 1 22 AU971528 1 19971202 G 2612 IN4007 DIODE BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL FIRE DETECTION SHORTED W K NONE E N VIBRATION/BUFFET FALSE WARNING TO TAKEOFF 1 AU S (AUS) FIRE AUDIO BOX DIODE SHORT CIRCUITED. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1998012200940 19980122 00940 SO 1998 1 22 AU971529 1 19971114 G 7922 53E22144 VALVE PIPER PA31 PA31 7103102 SO LYC O540 TIO540A1B 41532 EA HARTZL HCE3Y HCE3YR2 GL ENG OIL TEMP FAULTY W K NONE O OTHER CR CRUISE 1 AU S L169461 (AUS) ENGINE OIL COOLER BYPASS VALVE FAULTY. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1998012200941 19980122 00941 NE 1998 1 22 AU971530 2 19971201 G 7250 SEAL BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE ENG NR 4 BRG FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S LF05937A (AUS) ENGINE NO4 BEARING SEAL FAULTY. OIL PRESENT IN TAILPIPE. 2 H 7 4 4F 4 F A49EU E6NE 1998012200942 19980122 00942 WP 1998 1 22 AU971531 2 19971207 G 7322 CH14583 PIN A148HIM DHAVXX DH82 DH82AROBRTSN 2801002 WP DHAVXX GIPSY GIPSYMAJOR1 20004 WP THROTTLE LEVER MISSING W K NONE O R OTHER PARTIAL RPM/PWR LOSS CR CRUISE 1 AU S V1809 940 (AUS) TAPER PIN SECURING THROTTLE LEVER PN CH46158 TO THE THROTTLE SPINDLE PN CH14470 MISSING. THIS ALLOWED THE THROTTL E LEVER TO MOVE WITHOUT MOVING THE THROTTLE BUTTERFLY. 1 Q 7 1 3I 3 I A8EU A8EU 1998012200943 19980122 00943 1998 1 22 AU971532 4 19971127 G 2360 STATIC WICK BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE LT AILERON LIGHTNING STRIKE W K NONE C F.O.D. TO TAKEOFF 1 AU S (AUS) AIRCRAFT SUFFERED A LIGHTNING STRIKE. INSPECTION FOUND THE ONLY POINT OF THE STRIKE WAS ON THE LH AILERON STATIC W ICK. 2 H 7 4 4F 4 F A49EU E6NE 1998012200944 19980122 00944 NE 1998 1 22 AU971533 2 19971201 G 7260 SEAL BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE NR 4 ENG IDG LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S LF05290 (AUS) NO4 ENGINE IDG LIP SEAL LEAKING. 2 H 7 4 4F 4 F A49EU E6NE 1998012200945 19980122 00945 EU 1998 1 22 AU971534 1 19971122 G 2432 92583 CELL 97500640 BAC 146 146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE BATTERY OVERHEATED W K NONE B M SMOKE/FUMES/ODORS/SPARKS OVER TEMP CR CRUISE 1 AU S C0824ANSETTS (AUS) MAIN AIRCRAFT BATTERY INTERNAL MONOBLOCS OVERHEATED AND DISTORTED. 2 H 7 4 4F 4 F RT A49EU E6NE 1998012200946 19980122 00946 SW 1998 1 22 AU971535 1 19971204 G 3260 2782186057 INDICATOR FRCHLD SA227 SA227CC SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE RT MLG FAULTY W K NONE N FALSE WARNING LD LANDING 1 AU S (AUS) RH MAIN LANDING GEAR POSITION LIGHT FAULTY. 2 L 7 2 4T 4 T RT A18SW E4WE 6 C 3PNE 1998012200947 19980122 00947 SO 1998 1 22 AU971536 2 19971103 G 8520 6419311075 BOLT BEECH 55 95C55 1152708 CE CONT O520 IO520C 17032 SO MCAULY 3AF32C 3AF32C75 GL LT NR 6 CYL BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 12684470C (AUS) LH NO6 CYLINDER UPPER THROUGH BOLT BROKEN IN LINE WITH THECYLINDER BASE FLANGE. 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 1998012200948 19980122 00948 SW 1998 1 22 AU971537 1 19971207 G 3411 STATIC PORT SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP LT STATIC PORT CONTAMINATED W K NONE I FLT. ATTITUDE INST. TO TAKEOFF 1 AU S (AUS) LH STATIC PORT BLOCKED BY WATER FOLLOWING HEAVY RAIN. 2 L 7 2 4T 4 T RT A8SW E4WE 1998012200949 19980122 00949 SO 1998 1 22 AU971538 1 19971113 G 7922 53E22144 VALVE PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA ENGINE OIL TEMP FAULTY W K NONE O K OTHER FLUID LOSS CL CLIMB 1 AU S L83056IA (AUS) ENGINE OIL TEMPERATURE VALVE FAULTY. 1 L 7 2 3O 3 O A20SO E14EA 1998012200950 19980122 00950 NM 1998 1 22 AU971539 1 19970918 G 5312 WEB BOEING 737 737377 NM FWD PRESS BLKHD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD PRESSURE BULKHEAD WEB CRACKED IN SEVEN PLACES:- A. AREA UNDER THE RADAR SCANNING MOUNTING BRACKETS CONTAIN ED FOUR CRACKS BETWEEN LBL 5.5 AND RBL 5.7 - CRACK LENGTHS 27MM (1.06IN), 13MM (0.5IN) AND TWO CRACKS OF 16MM (0.630IN) B. TWO CRACKS EITHER SIDE OF BLO JUST ABOVE WL 184 - CRACK LENGTHS 29MM (1.14IN) AND 20MM (0.787IN) C. ONE CRACK IN THE WEB ANGLE RADIUS INBOARD OF LBL 5.9 - CRACK LENGTH 28MM (1.1IN)FOUND DURING ULTRASONIC AND EDDY CURRENT INSPECTION IAW ERB73-53-10-39A 2 L 7 2 4F RT A16WE 1998012200951 19980122 00951 NM 1998 1 22 AU971540 1 19971013 G 2163 6171661 SENSOR BOEING 737 737377 NM RT AIR COND FAILED W K NONE O OTHER CR CRUISE 1 AU S 1274022ANSET (AUS) RH AIR CONDITIONING PACK RAM AIR TEMPERATURE SENSOR OPEN CIRCUITED CAUSING THE RAM AIR DOOR AND OUTLET LOUVRES TO CLOSE AND LIMIT COOLING AIR OVER PRIMARY AND SECONDARY HEAT EXCHANGERS. 2 L 7 2 4F RT A16WE 1998012200952 19980122 00952 EA 1998 1 22 AU971541 2 19970721 G 8530 JT162 VALVE SEAT BNORM BN2 BN2B26 1520350 EU LYC O540 O540E4B5 41532 EA HARTZL HCC2Y HCC2YK2 GL ENG EXHAUST SEPARATED W K NONE O OTHER CR CRUISE 1 AU S 2021 JT162 L231764A (AUS) EXHAUST VALVE SEAT SEPARATED FROM CYLINDER HEAD. 1 H 7 2 3O 3 O RT A17EU E295 5 C P920 1998012200953 19980122 00953 EU 1998 1 22 AU971542 1 19971203 G 5315 A38 BEAM FOKKER F28 F28MK1000 4990808 EU RROYCE SPEY SPEY55515 54521 EU GALLEY FLOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FLOOR BEAM CRACKED AT EDGE OF PREVIOUS REPAIR IN AREA BENEATH GALLEY AND FIRST CONSOLE. CRACK LENGTH 20MM (0.787IN ). FOUND DURING CORROSION CONTROL PROGRAMME WHICH CONSTITUTES PART OFAD/F28/66. 2 L 7 2 4F 4 F RT A20EU E2EU 1998012200954 19980122 00954 EU 1998 1 22 AU971543 1 19971128 G 3251 SELECTOR VALVE BAG JETSTM JETSTM3107 1500215 EU ROTOL R333 R333482F12 GL NLG STEERING FAULTY W K NONE O OTHER TO TAKEOFF 1 AU S (AUS) NLG STEERING METERING VALVE (FOUR-WAY SELECTION) FAULTY. 2 L 7 2 4T RT BA15CAA 6 C P61GL 1998012200955 19980122 00955 CE 1998 1 22 AU971544 1 19971210 G 5246 65523121 DOOR CESSNA 500 550 2076604 CE FLUID SERVICE SEPARATED W K NONE O OTHER CR CRUISE 1 AU S (AUS) LH ENGINE OIL ACCESS DOOR MISSING. CREW HAD REPORTED NOISE DURING FLIGHT 1 L 7 2 4F A22CE 1998012200956 19980122 00956 CE 1998 1 22 AU971545 1 19971128 G 2701 1695241879 TORQUE TUBE BEECH 76 76 1153005 CE PILOT CONTROL SEPARATED W K NONE F FLT CONT AFFECTED CR CRUISE 1 AU S (AUS) PILOTS SIDE CONTROL COLUMN TORQUE TUBE BROKE OFF AT RIVETED JOINT DURING FLIGHT. 1 L 7 2 3O A29CE 1998012200957 19980122 00957 NM 1998 1 22 AU971546 1 19971006 G 5310 STRUCTURE BOEING 747 747238B 1384828 NM FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE STRUCTURE CONTAINED NUMEROUS CRACKS IN SECTION 41. FOUND DURING INSPECTION IAW AD/B747/85, SECTION 41. 2 L 7 4 4F A20WE 1998012200958 19980122 00958 SO 1998 1 22 AU971547 2 19971127 G 8520 649896 CRANKSHAFT BEECH 36 A36 1151604 CE CONT O520 IO520BA 17032 SO MCAULY 3A32C 3A32C76 GL ENGINE BROKEN W K NONE E Y VIBRATION/BUFFET ENGINE STOPPAGE CR CRUISE 1 AU S 323 551558 551558 744478 (AUS) ENGINE CRANKSHAFT BROKEN. 1 L 7 1 3O 3 O 3A15 E5CE 5 C P21EA 1998012200959 19980122 00959 CE 1998 1 22 AU971548 1 19971107 G 5522 96616911112 SKIN BEECH 96610006 BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO RT ELEV OUTB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 6357 (AUS) ELEVATOR SKIN OUTBOARD OF THE RH TRIM TAB FOUND WITH SMALL CRACK. WITH FIRM FORCE APPLIED TO THE TRAILING EDGE, TH E CRACK OPENED UP TO 127MM (5IN) IN LENGTH. CLOSER INSPECTION REVEALED SEVERAL MORE CRACKS. CRACKING WAS INITIATED BY C ORROSION. SUSPECT SKINS ARE MADE OF MAGNESIUM ALLOY. 1 L 7 2 3O 3 O 3A16 E5CE 1998012200960 19980122 00960 CE 1998 1 22 AU971549 1 19971114 G 3213 5541397 SLEEVE CESSNA 6541000003 CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE LT MLG OLEO BROKEN W K NONE J WARNING INDICATION CL CLIMB 1 AU S 0126 (AUS) LH OLEO WOULD NOT EXTEND AFTER TAKE-OFF PREVENTING LANDING GEAR RETRACTION. LATER THE OLEO EXTENDED ALLOWING GEAR RETRACTION. THE OLEO WAS DISASSEMBLED AND SPACER PNO 5541208-1 WAS FOUND JAMMED INSIDE OF A BROKEN BEARING LOWER SLEEVE PNO 5541309-7. 1 L 7 2 4F 4 F A22CE E1NE 1998012200961 19980122 00961 CE 1998 1 22 AU971550 1 19970924 G 2110 BEARING 1131325 BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL CABIN AIR COMP SEIZED W K NONE O OTHER CR CRUISE 1 AU S (AUS) AIRCONDITIONER BELT SNAPPED. INVESTIGATION FOUND THAT THE AIRCONDITIONING COMPRESSOR WAS TIGHT TO TURN AND BINDING . THE ASSEMBLY WAS STRIPPED AND ONE THRUST BEARING WAS FOUND WELDED AND SEIZED. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1998012600018 19980126 00018 1998 1 26 AU971551 1 19971211 G 8010 X6112 CONTACTOR LYC O360 IO360LYC* 41514 EA ENGINE CRANKING FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WHEN THE MASTER SWITCH WAS SELECTED `ON' THE ENGINE TURNED OVER. SUSPECT THE STARTER CONTACTOR WAS ENGAGED. 3 O 1E10 1998012200962 19980122 00962 1998 1 22 AU971553 4 19971210 G 3442 MI591162 TRANSCEIVER FOKKER F27 F27MK600 4990706 EU RROYCE DART DART5327R 54509 NE ROTOL R4304 R1934304 EU WEATHER RADAR FAILED W K NONE B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 AU S 2373 (AUS) RADAR TRANSMITTER/RECEIVER FAILED. 2 H 7 2 4T 4 T A817 E297 6 C P899 1998012200963 19980122 00963 NM 1998 1 22 AU971554 1 19971202 G 2820 895 VALVE BOEING 737 737476 NM FUEL DIST FAILED W K NONE O OTHER CR CRUISE 1 AU S 9779 895 (AUS) FUEL CROSSFEED VALVE FAULTY. 2 L 7 2 4F RT A16WE 1998012200964 19980122 00964 NM 1998 1 22 AU971555 1 19971203 G 2820 889 VALVE BOEING 737 737476 NM FUEL DIST FAULTY W K NONE O OTHER CR CRUISE 1 AU S 5814 889 (AUS) FUEL CROSSFEED VALVE FAULTY. 2 L 7 2 4F RT A16WE 1998012200965 19980122 00965 SW 1998 1 22 AU971556 1 19971031 G 2432 G172942 CAP GILLBATT G88 AIRTRC AT300 AT301 0390103 SW PWA R1340 R1340AN1 52016 NE HAMSTD 12D 12D40 NE BATTERY FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S G01729420 (AUS) BATTERY VENT CAP VULCANISED CLOSED. GAS BUILDUP CAUSED ACID TO VENT FROM AN ADJACENT CELL. 1 L 7 1 3R 3 R A9SW 5E2 5 C P257 1998012200966 19980122 00966 EU 1998 1 22 AU971557 2 19970927 G 7421 SPARK PLUG ROTAX 912 ROTAX912 55555 EU ENG IGN FOULED W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 AU S (AUS) ENGINE SPARK PLUG FOULED. THIS DEFECT WAS RECEIVED FROM THE AUF AND IS FOR INFORMATION ONLY. 3 I EXPE3I 1998012200967 19980122 00967 SW 1998 1 22 AU971559 1 19971216 G 2460 CIRCUIT BREAKER AIRTRC AT300 AT301 0390103 SW PWA R1340 R1340AN1 52016 NE DC POWER DIST FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CIRCUIT BREAKERS FAULTY. 1 L 7 1 3R 3 R A9SW 5E2 1998012200968 19980122 00968 EU 1998 1 22 AU971560 1 19970605 G 5753 F5B16324B3 BRACKET AMD FALC50 FALCON900 2700160 EU TE FLAP CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) DROP SHAPED FOREFLAP BRACKETS CORRODED. THIS DEFECT WAS RECEIVED FROM NO34 SQUADRON RAAF AND IS FOR INFORMATION ON LY. 2 L 7 3 4F RT A46EU 1998012200969 19980122 00969 EU 1998 1 22 AU971561 1 19971107 G 2751 F5B1142121A1 SPRING F50B11400212 AMD FALC50 FALCON900 2700160 EU TE FLAP POSITION FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) TRAILING EDGE FLAP MICROSWITCH BUTTERFLY ARM SPRINGS LOST TENSION AND SLIPPED OFF THE ARM. THIS DEFECT WAS RECEIVE D FROM NO34 SQUADRON RAAF AND IS FOR INFORMATION ONLY. 2 L 7 3 4F RT A46EU 1998012200970 19980122 00970 CE 1998 1 22 AU971562 1 19971217 G 2910 PIPE CESSNA 441 441 2076020 CE HARTZL HCB3T HCB3TN5 GL HYD MAIN SYS LEAKING W K NONE K FLUID LOSS DE DESCENT 1 AU S (AUS) HYDRAULIC PIPE LEAKING IN AREA OF HYDRAULIC PACK. 1 L 7 2 3T RT A28CE 6 C P15EA 1998012200971 19980122 00971 CE 1998 1 22 AU971563 1 19971203 G 3520 1138495 HOSE BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE PASSENGER OXYGEN FAILED W K NONE O OTHER CL CLIMB 1 AU S (AUS) OXYGEN SYSTEM ON/OFF CONTROL CABLE FAILED. OXYGEN SYSTEM REMAINED ON FOR AN EXTENDED TIME CAUSING THE SUPPLY HOSE TO THE CASUALTY OXYGEN MASK TO RUPTURE AND ALLOWING THE OXYGEN SYSTEM TO DISCHARGE TO 0PSI. 1 L 7 2 4T 4 T A24CE E4EA 1998012600019 19980126 00019 EA 1998 1 26 AU971564 2 19971216 G 7497 WIRE LYC O360 IO360LYC* 41514 EA IGNITION SWITCH CHAFED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WIRE FROM IGNITION SWITCH TO START SOLENOID CHAFING ON FLAP CIRCUIT BREAKER TERMINAL SCREW. MAGNETO P LEAD SHIELD WIRE ALSO CHAFED AND SEVERED. BATTERY WIRE TO IGNITION SWITCH CHAFED WITH BARE WIRE VISIBLE. SEE MDR 97/1551 FOR ADDITIO NAL INFORMATION. 3 O 1E10 1998012200972 19980122 00972 SO 1998 1 22 AU971565 1 19971215 G 2710 246317 CONTROL CABLE PIPER PA31 PA31350 7103110 SO LT AIL CONTROL BROKEN W O OTHER F FLT CONT AFFECTED TX TAXI/GRND HDL 1 AU S (AUS) DURING TAXI AFTER LANDING, THE AILERON CONTROLS ROLLED LEFT AND DIDN'T ROLL BACK WITH RUDDER INPUT. AILERONS STILL HAD FULL AND FREE MOVEMENT BUT WITH A BIAS OF SLIGHT SPRING PRESSURE TO THE LEFT CONTROL DOWN. INVESTIGATION FOUND THE LH AILERON/RUDDER INTER-CONNECT CABLE HAD BROKEN. 1 L 7 2 3O A20SO 1998012200973 19980122 00973 NM 1998 1 22 AU971566 1 19971027 G 3232 21ANSETTSN PISTON SEAT BOEING 767 767277 NM NLG VALVE FRACTURED W K NONE E J VIBRATION/BUFFET WARNING INDICATION CL CLIMB 1 AU S 39237 00021ANSETTS (AUS) AFTER TAKE-OFF, THE GEAR DOOR DISAGREE MESSAGE WARNING DISPLAYED AND EXCESSIVE NOSE GEAR VIBRATIONS WERE FELT DURI NG GEAR RETRACTION. GROUND INVESTIGATION FOUND THAT THE NLG PRIORITY VALVE'S PISTON SEAT ASSEMBLY PNO 01715201B2-1 HAD FRACTURED PREVENTING BALL PNO MS134359 FROM SEATING. 2 L 7 2 4F RT A1NM 1998012200974 19980122 00974 NE 1998 1 22 AU971567 2 19971129 G 7210 CPGB147 COMBINING GRBOX PWA BELL 212 212 1181420 SW PWA PT6T PT6T3B 52045 NE NR 1 ENGINE MAKING METAL W K NONE J WARNING INDICATION CL CLIMB 1 AU S CPGB1047 667 (AUS) NO1 ENGINE CHIP ILLUMINATION DURING CLIMB. INVESTIGATION FOUND METAL FROM THE COMBINING GEARBOX TO BE OUTSIDE OF M ANUFACTURERS LIMITS. 1 G 7 1 4U 4 U H4SW E22EA 1998012200975 19980122 00975 GL 1998 1 22 AU971568 3 19971217 G 6114 A2433 BOLT HARTZL CHILD S2 S2APITTS 0110201 NM LYC O360 AEIO360B4A 41514 EA HARTZL HCC2Y HCC2YK4 GL PROP HUB BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S DN1577 DN1577 (AUS) WHEN THE PROPELLER WAS REMOVED DUE TO EXCESSIVE GREASE LEAKAGE AT THE BLADE BUTTS, THE THREADED END OF ONE HUB CLA MPING BOLT WAS FOUND TO BE MISSING. 1 Q 7 1 3O 3 O A8SO 1E10 5 C P920 1998012200976 19980122 00976 EA 1998 1 22 AU971569 2 19971221 G 8530 7386P PUSHROD LYC LW16703 CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA NR 2 CYL EXH LOOSE W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 AU S A29945 L164215 (AUS) PILOT REPORTED REDUCTION IN RPM AND ROUGH RUNNING IN FLIGHT.INVESTIGATION FOUND THE NO2 CYLINDER EXHAUST PUSHROD E ND FITTINGS WERE LOOSE, WITH ONE END OF THE PUSHROD SPLAYED AND CRACKED. 1 H 7 1 3O 3 O NT 3A19 E223 1998012200977 19980122 00977 EU 1998 1 22 AU971570 1 19971218 G 7120 BRACKET PARTEN P68 P68B EU ENGINE MOUNT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE MOUNT TO WING ATTACHMENT BRACKETS (3OFF) WERE FOUND CRACKED:1. LH LOWER INBOARD PNO 68-1.2027,2. RH UPPER I NBOARD PNO 68-1.2025-1 AND 3. RH UPPER OUTBOARD PNO 68-1.2025-3. FOUND IAW AD/P68/28A3, SECTION 3. 1 H 7 2 3O A31EU 1998012600020 19980126 00020 GL 1998 1 26 AU971571 3 19971210 G 6114 22117 HUB PIPER PA36 PA36300 7103612 SO LYC O540 IO540K1G5 41532 EA HARTZL HCC2Y HCC2YK1 GL PROP HUB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S L1788248A 95 (AUS) PROPELLER HUB WAS PREVIOUSLY INSPECTED AT THE 50HR INTERVAL IAW HARTZELL SB164C AND FOUND SATISFACTORY. WHEN INSPE CTED AT THE 100 HOURLY, A PARTICULARLY LARGE CRACK WAS FOUND IN THE REAR HALF OF THE RADIUS AT THE BLADE ROOT. 1 L 7 1 3O 3 O A10SO 1E4 5 C P920 1998012200978 19980122 00978 CE 1998 1 22 AU971572 1 19971216 G 3230 LANDING GEAR BEECH 200 200BEECH 1152920 CE GEAR RETRACT SYS MALFUNCTION W K NONE E J VIBRATION/BUFFET WARNING INDICATION CL CLIMB 1 AU S (AUS) AFTER TAKE-OFF THE LG WAS SELECTED UP AND VIBRATION AND NOISE WAS HEARD DURING RETRACTION WITH EXTENDED WINDING TI ME - RED HANDLE UNSAFE LIGHT REMAINED ON WHEN GEAR APPEARED TO BE UP. GROUND INVESTIGATION COULD NOT REPRODUCE THE PROBL EM. GEAR MICROSWITCHES WERE CHECKED FOR ADJUSTMENT/WEAR, AND THE NLG DRIVE CHAIN AND SPROCKETS WERE ALSO INSPECTED. 1 L 7 2 4T A24CE 1998012200979 19980122 00979 CE 1998 1 22 AU971573 1 19971215 G 7333 849E TRANSMITTER GULL 903800097 BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA FUEL FLOW SENSOR FAILED W K NONE O OTHER CR CRUISE 1 AU S 8490E (AUS) DURING FLIGHT THE LT ENGINE FUEL FLOW GAUGE REDUCED INDICATION FROM 550 PPH TO 100 PPH AND DIDN'T ALTER WITH POWER CHANGES. GROUND INVESTIGATION FOUND THE LT FUEL TRANSMITTER WAS FAULTY. 1 L 7 2 4T 4 T A24CE E4EA 1998012200980 19980122 00980 SO 1998 1 22 AU971574 1 19971203 G 7120 12A1997 MOUNT PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL ENGINE MOUNT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S L256661A DJ834A (AUS) LH LOWER I/B ENGINE MOUNT CRACKED AT THE TURBOCHARGER MOUNT HOLE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1998012200981 19980122 00981 SO 1998 1 22 AU971575 1 19971203 G 7120 7679 MOUNT PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL ENGINE MOUNT SEC CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S L168668A DJ9482A (AUS) RH LOWER O/B ENGINE MOUNT CRACKED AT THE TURBOCHARGER MOUNT HOLE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1998012200982 19980122 00982 SW 1998 1 22 AU971576 1 19971223 G 2730 MS211518 ROD END SWRNGN SA227 SA227AC 8780603 SW ELEVATOR CONTROL CREASED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ELEVATOR CONTROL ROD END BEARING RETAINER/DUST SEAL CREASED ON BOTH SIDES OF ROD END DUST COVERS. FOUND DURING AD/ SWSA226-82. 2 L 7 2 4T RT A8SW 1998012200983 19980122 00983 1998 1 22 AU971577 1 19971223 G 7312 WA281 HEATER STWARNER 10718D PWA PWA120 PW125B NE LT FUEL HEAT FAULTY W K NONE M J OVER TEMP WARNING INDICATION CR CRUISE 1 AU S WA281 12451 (AUS) DURING CRUISE THE LH FUEL HEATER HIGH TEMPERATURE LIGHT ILLUMINATED. FAULT WAS TRACED TO THE FUEL HEATER ELEMENT. 4 T E20NE 1998012200984 19980122 00984 CE 1998 1 22 AU971578 1 19971218 G 7714 A8266 TACHOMETER 503800343 BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA ENGINE RPM IND DEFECTIVE W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S A8266 (AUS) DURING AN INSPECTION OF A TURBINE TACHOMETER PRIOR TO TESTING,THE FRONT LENS WAS FOUND TO SHOW EVIDENCE OF MOISTUR E CONTAMINATION (FOGGING). FURTHER INVESTIGATION FOUND THAT THE CASE HAD BEEN SEALED WITH RTV TYPE SEALANT AND NOT HERME TICALLY SOLDER SEALED. ON TESTING THE INSTRUMENT WAS FOUND TO HAVE EXCESSIVE FRICTION AND SCALE ERROR. FOUND IAW AD/INST /9. INCORRECT PROCEDURE/PERSONNEL ERROR. 1 L 7 2 4T 4 T A24CE E4EA 1998012200985 19980122 00985 CE 1998 1 22 AU971579 1 19971117 G 2810 7161246 VALVE CESSNA 150 150M 2071830 CE FUEL VENT FAILED W O OTHER Y ENGINE STOPPAGE CR CRUISE 1 AU S (AUS) ENGINE STOPPED DURING CRUISE. INVESTIGATION FOUND A RESTRICTION (AN INSECT) IN THE LH FUEL TANK VENT TUBE. ALSO, THE VENT TUBE VALVE WAS 'STICKY'. 1 H 7 1 3O 3A19 1998012200986 19980122 00986 EU 1998 1 22 AU971580 1 19971222 G 5711 SPAR BNORM BN2 BN2A26 1520226 EU WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING SPAR HAS CRACKS RANGING FROM 12.7MM (0.5IN) TO OVER 25.4MM (1IN). FOUND IAW PBN SB 237. 1 H 7 2 3O A17EU 1998012200987 19980122 00987 SO 1998 1 22 AU971581 2 19971222 G 7414 M173 COIL SLICK 667 CESSNA 175 175A 2072504 CE CONT O300 GO300A 17022 SO ENG RT MAGNETO CRACKED W K NONE R PARTIAL RPM/PWR LOSS LD LANDING 1 AU S 25 691228 (AUS) AFTER APPROXIMATELY 45 MINUTES FLIGHT TIME AND DURING POSTLANDING CHECKS, THE RH MAGNETO WAS SHOWING A 'DEAD CUT'. THEMAGNETO WAS SUBSEQUENTLY REMOVED AND DISMANTLED, AND THE COIL WAS FOUND TO BE SPLIT OPEN AND LEAKING. 1 H 7 1 3O 3 O 3A17 E298 1998012200988 19980122 00988 NE 1998 1 22 AU971582 2 19971230 G 7200 PCE1434 ENGINE PWA AYRES S2 S2RT15NORMAL 0970105 SO PWA PT6 PT6A15AG 52043 NE HARTZL HCB3T HCB3TN3 GL POWER SECT FAILED W K NONE O OTHER CR CRUISE 1 AU S PCE14034 PCE1434 BU3965 (AUS) ENGINE SUFFERED COMPLETE FAILURE DURING CRUISE - CAUSE UNKNOWN AT THIS STAGE. 1 L 7 1 3T 4 T A3SW E4EA 6 C P15EA 1998021100498 19980211 00498 CE 1998 2 11 AU971583 1 19971215 G 2810 FUEL SYSTEM CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA MCAULY 2D34C B2D34C214 GL LT TANK CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH FUEL TANK AND FUEL SYSTEM CONTAMINATED WITH SUGAR. 1 H 7 1 3O 3 O RT 3A13 E295 5 C P7EA 1998021800003 19980218 00003 EU 1998 2 18 AU971584 1 19970919 G 5610 NF20216246ISS4 WINDSHIELD BAC 146 146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE 1ST OFFICER CRACKED W K NONE O OTHER CL CLIMB 1 AU S L227216ANSET (AUS) FIRST OFFICERS WINDSCREEN CRACKED IN SEVERAL PLACES. SUSPECT CRACK ORIGINATED FROM A LOCALISED HOT SPOT ALONG THE LOWER EDGE OF THE WINDSHIELD. 2 H 7 4 4F 4 F RT A49EU E6NE 1998021800004 19980218 00004 EU 1998 2 18 AU971585 1 19971014 G 3213 40429 MLG GROB G115 G115C 1660303 EU SNSNCH 72C 72CK EA MAIN LANDING GEA DISTORTED W K NONE O OTHER LD LANDING 1 AU S 250 (AUS) RH MAIN LANDING GEAR LEG BENT AND LOWER FRONT ATTACHMENT BUSH LOOSE. SPIN FIN FAIRING REAR SECTION DAMAGED. CAUSED BY HEAVY LANDING. 1 L 7 1 3O NT A57EU 5 N P9045 1998021100499 19980211 00499 NE 1998 2 11 AU971586 2 19971212 G 7200 ENGINE LYC ALF502 ALF502R5 41580 NE NR 3 ENGINE FAILED W K NONE O OTHER LD LANDING 1 AU S LF05852A (AUS) NO3 ENGINE CHIP DETECTORS CONTAMINATED. LOW PRESSURE SPOOL DIFFICULT TO ROTATE BY HAND. 4 F E6NE 1998021100500 19980211 00500 SO 1998 2 11 AU971587 1 19970729 G 5311 7746709 FRAME PIPER PA38 PA38112 7103812 SO SNSNCH 74D 74DM EA FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE REAR SPAR FRAME CRACKED IN BOTH LOWER CORNERS. FOUND DURING INSPECTION IAW AD/PA38/25. 1 L 7 1 3O A18SO 5 N P88614 1998021100501 19980211 00501 SO 1998 2 11 AU971588 1 19971218 G 3234 1203859400 CONTROL BOX EMB 120 EMB120 3260201 SO PWA 118 PW118A NE GEAR SELECTOR MALFUNCTION W K NONE O OTHER TO TAKEOFF 1 AU S 120186 (AUS) LANDING GEAR CONTROL BOX FAULTY. 2 L 7 2 4T 4 T RT A31SO E20NE 1998021100502 19980211 00502 EU 1998 2 11 AU971589 1 19971120 G 7500 1555M14604 DUCT AIRBUS 300 A300B4203 3930306 EU GE CF6 CF650C2 30018 NE ENGINE BLEED AIR CRACKED W A K NONE O OTHER IN INSP/MAINT 1 AU S DUCTASS9067M 528139 (AUS) NO2 ENGINE 14TH STAGE AIR DUCT CRACKED FOR 66% OF CIRCUMFERENCE.NUMEROUS TIE ROD ENDS SNAPPED OFF. HP RECOUP TUBE SEVERELY CHAFED. 2 L 7 2 4F 4 F A35EU E23EA 1998021100503 19980211 00503 1998 2 11 AU971590 4 19971215 G 2562 MN1300 BATTERY E01 CESSNA 207 207 2073602 CE CONT O520 IO520F 17032 SO MCAULY D3A34 D3A34C404 GL EMERG LOCATOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 009618 (AUS) ELT BATTERIES CORRODED AND LEAKING. 1 H 7 1 3O 3 O A16CE E5CE 5 C P47GL 1998021100504 19980211 00504 SO 1998 2 11 AU971591 1 19971230 G 5347 6255704 SEAT TRACK PIPER PA28 PA28235 7102810 SO LYC O540 O540B4B5 41532 EA HARTZL HCC2Y HCC2YK1 GL RT OUTB SEAT CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH OUTBOARD SEAT TRACK CONTAINED EXFOLIATION CORROSION. 1 L 7 1 3O 3 O 2A13 E295 5 C P920 1998021100505 19980211 00505 EU 1998 2 11 AU971592 1 19971222 G 2621 57333012 FIRE BOTTLE BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE APU FIRE BOTTLE EMPTY W K NONE O OTHER IN INSP/MAINT 1 AU S CN3915ANSETT (AUS) APU FIRE EXTINGUISHER BOTTLE EMPTY. NO EVIDENCE OF DISCHARGE. FOUND DURING REMOVAL FOR REWEIGH. 2 H 7 4 4F 4 F A49EU E6NE 1998021100506 19980211 00506 EU 1998 2 11 AU971593 1 19971129 G 2621 57333012 FIRE BOTTLE BAC 146 146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE NR 3 ENG BOTTLE EMPTY W K NONE O OTHER IN INSP/MAINT 1 AU S 1729ANSETT05 (AUS) NO3 ENGINE INBOARD FIRE EXTINGUISHER EMPTY. FOUND DURING REWEIGH. 2 H 7 4 4F 4 F RT A49EU E6NE 1998021100507 19980211 00507 NE 1998 2 11 AU971594 2 19971218 G 7250 BLADE LYC ALF502 ALF502R5 41580 NE NR 4 ENG TURB FAILED W O OTHER E X VIBRATION/BUFFET ENGINE FLAMEOUT CL CLIMB 1 AU S LF05502A (AUS) NO4 ENGINE FAILED. SUSPECT 1ST STAGE HP TURBINE BLADE FAILURE. 4 F E6NE 1998021100508 19980211 00508 NM 1998 2 11 AU971595 1 19970307 G 2910 33582 SPRING V243602 BOEING 767 767277 NM GE CF6 CF680A 30025 NE HYD SYS FRACTURED W K NONE O OTHER TO TAKEOFF 1 AU S 2041561ANSET (AUS) HYDRAULIC SYSTEM RH FUSE PNO V2-4360-2 SPRING PNO 33582 FAILED. SPLIT RING PNO 33581 DAMAGED AND RESET PISTON PNO 33589 JAMMED INSIDE ADAPTER PNO 33590. 2 L 7 2 4F 4 F RT A1NM E13NE 1998021100509 19980211 00509 EU 1998 2 11 AU971596 1 19970918 G 5610 NP1701022 WINDSHIELD BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE 1ST OFFICERS B DELAMINATED W K NONE O OTHER CR CRUISE 1 AU S 94075H3810AN (AUS) FIRST OFFICERS `B' WINDSCREEN DELAMINATED AND A SECTION OF THE OUTER PANE SEPARATED. SUSPECT CAUSED BY MOISTURE IN GRESS INTO CONDUCTIVE LAYER CAUSING ARCING. 2 H 7 4 4F 4 F A49EU E6NE 1998021100510 19980211 00510 EU 1998 2 11 AU971597 1 19970918 G 5610 NP1701012 WINDSHIELD PPG NP1701012 BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE 1ST OFFICERS A CRACKED W K NONE O OTHER CL CLIMB 1 AU S 94187H8936AN (AUS) FIRST OFFICERS `A' WINDSCREEN ARCING FOLLOWED SHORTLY BY CRACKING OF THE OUTER PANE. SUSPECT CAUSED BY MOISTURE IN GRESS. 2 H 7 4 4F 4 F A49EU E6NE 1998021100511 19980211 00511 EU 1998 2 11 AU971598 1 19971223 G 2612 CONNECTOR BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE NR 3 ENG DETECT LOOSE W K NONE F N FLT CONT AFFECTED FALSE WARNING LD LANDING 1 AU S (AUS) NO3 ENGINE FALSE FIRE WARNING DUE TO LOOSE AND DIRTY ELECTRICAL CONNECTOR PLUG. FIRE BOTTLE ACTIVATED. 2 H 7 4 4F 4 F A49EU E6NE 1998021100512 19980211 00512 EU 1998 2 11 AU971599 1 19971224 G 2621 57333012 FIRE BOTTLE BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE NR 2 ENG INB EMPTY W K NONE O OTHER IN INSP/MAINT 1 AU S 6151 CM9503ANSETT (AUS) NO2 ENGINE INBOARD FIRE EXTINGUISHER BOTTLE EMPTY. FOUND DURING REMOVAL FOR REWEIGH. 2 H 7 4 4F 4 F A49EU E6NE 1998021100513 19980211 00513 EU 1998 2 11 AU971600 1 19971227 G 2621 57333012 FIRE BOTTLE KIDDE 57333012 BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE NR 1 ENG OUTB CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 5697 CM76545ANSET (AUS) NO1 ENGINE OUTBOARD FIRE EXTINGUISHER BOTTLE APPROXIMATELY 0.7KG UNDERWEIGHT DURING INSPECTION IAW BA6-26-20-15. C ORROSION WAS ALSO FOUND ON APPROXIMATELY 20% OF THE NECK AREA. 2 H 7 4 4F 4 F A49EU E6NE 1998021800005 19980218 00005 NE 1998 2 18 AU971601 2 19971122 G 7250 BLADE BOEING 747 747312 1384932 NM PWA JT9 JT9D7R4G2 52054 NE NR 1 ENG 1ST STG FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S P715074 (AUS) NO1 ENGINE FIRST STAGE TURBINE BLADE FAILED. APPROXIMATELY 50%OF THE BLADE WAS MISSING. SUSPECT STAGE ONE BLADES S UBJECTED TO HIGHER THAN NORMAL TEMPERATURES. 2 L 7 4 4F 4 F RT A20WE E3NE 1998021100514 19980211 00514 NM 1998 2 11 AU971602 1 19971025 G 3244 0397812 TIRE 314392 BOEING 737 73733A 1384673 NM RT OUTB TIRE SEPARATED W K NONE F FLT CONT AFFECTED CL CLIMB 1 AU S 6442ANSETTSN (AUS) RH OUTBOARD TYRE TREAD SEPARATED DUE TO FATIGUE IN THE SHOULDER SECTION. TYRE REMAINED INFLATED. DAMAGE CAUSED TO THE AIRFRAME. 2 L 7 2 4F RT A16WE 1998021100515 19980211 00515 NM 1998 2 11 AU971603 1 19971001 G 5312 BULKHEAD BOEING 737 737377 NM FWD PRESSURE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD PRESSURE BULKHEAD CRACKED IN THE FOLLOWING LOCATIONS:-1. THREE CRACKS IN THE BULKHEAD WEB BETWEEN LBL 5.7 AND RBL 5.7 LOCATED UNDER THE RADAR SCANNER MOUNTING BRACKETS - CRACK LENGTHS 24MM (0.944IN) - 14MM (0.551IN) - 13MM (0 .511IN) 2. CRACK IN VERTICAL BULKHEAD CHORD AT LBL 5.7 - CRACK LENGTH 8MM (0.314IN)FOUND DURING ULTRASONIC AND EDDY CUR RENT INSPECTION IAW ERB73-53-10-39C ANDSB B737-53-1173. 2 L 7 2 4F RT A16WE 1998021100516 19980211 00516 NM 1998 2 11 AU971604 1 19971020 G 7830 S315N3702 LOCK BOEING 737 737377 NM CFMINT CFM56 CFM563B2 13802 EU LT INB TR FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S N05236ANSETT (AUS) LH INBOARD THRUST REVERSER SYNCH LOCK FAULTY. WORKSHOP TESTING COULD FIND NO MALFUNCTION. 2 L 7 2 4F 4 F RT A16WE E21EU 1998021100517 19980211 00517 EU 1998 2 11 AU971605 2 19971205 G 7210 GESNMABN9440 BEARING GE INLETGEARBOX CFMINT CFM56 CFM563C 13802 EU GRBOX BRG NR 3 FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 61X25767 856367 (AUS) ENGINE INLET GEARBOX NO3 THRUST BEARING FAILED. A FRAGMENT MISSING FROM THE INNER RACE WAS FOUND LODGED IN THE FAN FRAME. 4 F E21EU 1998021100518 19980211 00518 NM 1998 2 11 AU971606 1 19971216 G 5620 85323497101 CLIP DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE PASS WINDOW CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WINDOW TO WINDOW FRAME ATTACHMENT CLIPS CRACKED IN RADIUS OF FOLD LINE. 2 H 7 2 4T 4 T RT A13NM E20NE 1998021100519 19980211 00519 CE 1998 2 11 AU971607 1 19971216 G 5320 52130409 WEB CESSNA C404 CESSNA 404 404CESSNA 2075901 CE MCAULY 3FF32 3FF32C501 GL LT NOSE WELL CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 4040820 (AUS) LH NOSE WHEEL WELL WEB CRACKED IN AREA OF NLG ATTACHMENT FORWARDTWO BOLT HOLES. 1 L 7 2 3O A25CE 5 C P45GL 1998021100520 19980211 00520 CE 1998 2 11 AU971608 1 19971216 G 5320 521304010 WEB CESSNA C404 CESSNA 404 404CESSNA 2075901 CE MCAULY 3FF32 3FF32C501 GL RT NOSE WELL CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 4040820 (AUS) RH NOSE WHEEL WELL WEB CRACKED IN AREA OF NLG ATTACHMENT FORWARDTWO BOLT HOLES. 1 L 7 2 3O A25CE 5 C P45GL 1998021100521 19980211 00521 CE 1998 2 11 AU971609 1 19971215 G 7540 903800021 SWITCH BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL BLEED AIR IND MIS WIRED W K NONE J WARNING INDICATION CR CRUISE 1 AU S (AUS) LH BLEED AIR WARNING SWITCH PRESSURE LINE TRANSPOSED WITH RH SWITCH. RH BLEED AIR SENSE LINE CONTAINED A SMALL HOL E WHICH HAD ACTIVATED THE (INCORRECT) WARNING LIGHT. PERSONNEL/MAINTENANCE ERROR. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1998021100522 19980211 00522 EU 1998 2 11 AU971610 2 19971111 G 7230 BEARING CFMINT CFM56 CFM563C 13802 EU NR 1 ENG NR 4 FAILED W K NONE O R OTHER PARTIAL RPM/PWR LOSS CL CLIMB 1 AU S 725274 (AUS) NO1 ENGINE NO4 BEARING FAILED. 4 F E21EU 1998021100523 19980211 00523 NM 1998 2 11 AU971611 1 19971222 G 2560 B732560133 CABLE BOEING 737 737377 NM AFT ESCAPE SLIDE BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AFT ENTRY DOOR ESCAPE SLIDE COVER RELEASE CABLE BROKEN IN LOOP AT THE GIRT BAT ATTACHMENT END. 2 L 7 2 4F RT A16WE 1998021100524 19980211 00524 NM 1998 2 11 AU971612 1 19971215 G 5320 SKIN BOEING 737 737377 NM RT C-D WINDOW CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH C-D FLIGHT COMPARTMENT WINDOW POST UPPER GUSSET SKIN CRACKED.CRACK LENGTH 3.175MM (0.125IN). FOUND DURING EDDY CURRENT INSPECTION. 2 L 7 2 4F RT A16WE 1998021100525 19980211 00525 NM 1998 2 11 AU971613 1 19971229 G 5312 651630084 BULKHEAD BOEING 737 737376 NM FWD PRESSURE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FORWARD PRESSURE BULKHEAD CRACKED IN TEN SEPARATE POSITIONS. 2 L 7 2 4F RT A16WE 1998021100526 19980211 00526 CE 1998 2 11 AU971614 1 19971218 G 7714 AN55443 TACH GENERATOR BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL ENGINE N1 FAILED W K NONE O OTHER DE DESCENT 1 AU S AF5005874 (AUS) RH ENGINE N1 TACH GENERATOR DRIVE SHAFT SHEARED 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1998021100527 19980211 00527 NE 1998 2 11 AU971615 2 19970801 G 7311 1601422 FUEL HEATER GE CF6 CF680A 30025 NE ENGINE FUEL-OIL CRACKED W K NONE O K OTHER FLUID LOSS IN INSP/MAINT 1 AU S AEY00350ANSS 580347 (AUS) LH ENGINE FUEL/OIL HEAT EXCHANGER CRACKED AND LEAKING AT FORWARD END HEADER. CRACK LENGTH 25.4MM (1IN). 4 F E13NE 1998021100528 19980211 00528 CE 1998 2 11 AU971616 1 19971112 G 5540 513300032 BRACKET 513300011 CESSNA 402 402A 207590M CE MCAULY 3AF32C 3AF32C87 GL RUDDER HINGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LOWER RUDDER HINGE ATTACHMENT BRACKET CRACKED. LOWER RUDDER RIB BADLY CORRODED. 1 L 7 2 3O A7CE 5 C P22EA 1998021100529 19980211 00529 NE 1998 2 11 AU971617 2 19970702 G 7230 ENGINE GE CF6 CF680A 30025 NE RT ENGINE DEFECTIVE W K NONE E VIBRATION/BUFFET NR NOT REPORTED 1 AU S 580233 (AUS) RT ENGINE VIBRATING. SUSPECT HIGH PRESSURE COMPRESSOR ROTOR SLIGHTLY OUT OF BALANCE. ENGINE HAS A HISTORY OF VIB RATIONS. 4 F E13NE 1998021100530 19980211 00530 NM 1998 2 11 AU971619 1 19971216 G 5312 651630084 BULKHEAD BOEING 737 737476 NM FWD PRESSURE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FORWARD PRESSURE BULKHEAD CRACKED IN TWO POSITIONS. 2 L 7 2 4F RT A16WE 1998021100531 19980211 00531 SO 1998 2 11 AU971620 1 19971226 G 3230 9555123 MOUNT PIPER PA34 PA34200 7103405 SO LYC O360 IO360C1E6 41514 EA HARTZL HCC2Y HCC2YK2 GL MLG RETRACT CRACKED W K NONE O OTHER CL CLIMB 1 AU S (AUS) NOSE LANDING GEAR MOUNT TUBE TO CENTERING CHANNEL WELD FAILED. 1 L 7 2 3O 3 O A7SO 1E10 5 C P920 1998021100532 19980211 00532 NM 1998 2 11 AU971621 1 19971202 G 5312 651630084 BULKHEAD BOEING 737 737376 NM FWD PRESSURE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FORWARD PRESSURE BULKHEAD CRACKED IN EIGHT POSITIONS. 2 L 7 2 4F RT A16WE 1998021100533 19980211 00533 EU 1998 2 11 AU971622 1 19971230 G 2810 F1701468401 PANEL FOKKER F27 F27MK50 EU FUEL STORAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) REFUELLING POINT PANEL CRACKED IN NUMEROUS PLACES. 2 H 7 2 4T RT A817 1998021100534 19980211 00534 EU 1998 2 11 AU971623 1 19971118 G 5312 BULKHEAD PARTEN P68 P68B EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL FWD FUSELAGE CRACKED W K NONE O W OTHER INADEQUATE Q C IN INSP/MAINT 1 AU S (AUS) FRONT BULKHEAD CRACKED THROUGH TWO BOLT HOLES. FOUND FOLLOWING REMOVAL OF THE UPPER NOSE LEG MOUNT PLATE DUE TO TO WING DAMAGE. DAMAGE CAUSED BY INCORRECT GROUND HANDLING. 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 1998021100535 19980211 00535 SO 1998 2 11 AU971624 1 19971223 G 5751 8639802 RIB PIPER LHAILERON PIPER PA32 PA32R301 7103218 SO LYC O540 IO540K1G5 41532 EA HARTZL HCC2Y HCC2YK1 GL AILERON NOSE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AILERON HINGE NOSE RIB CRACKED. CRACK LENGTH 40MM (1.57IN).ADDITIONAL CRACKING ALSO EVIDENT. 1 L 7 1 3O 3 O A3SO 1E4 5 C P920 1998021100536 19980211 00536 NM 1998 2 11 AU971625 1 19971216 G 5620 85323497101 CLIP DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE PASS WINDOW CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WINDOW CLIPS CRACKED AT RADIUS ALONG FOLD LINE. 2 H 7 2 4T 4 T RT A13NM E20NE 1998021100537 19980211 00537 NE 1998 2 11 AU971626 2 19971103 G 7210 MS949034 BOLT BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3A NE LT ENG RED GRB FAILED W A K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH ENGINE REDUCTION GEARBOX FIRST STAGE PLANET GEAR CARRIER BOLT FAILED. INVESTIGATION FOUND THAT THE BOLT HEAD HA D SEPARATED AND ENTERED THE FIRST STAGE GEAR TRAIN. EXAMINATION OF THE CARRIER BOLTS REVEALED FOUR BOLTS FRACTURED IN TH E THREADED AREA AND ONE BOLT FRACTURED UNDER THE BOLT HEAD. SUSPECT BOLTS OVERTORQUED DURING ASSEMBLY. PERSONNEL/MAINTEN ANCE ERROR. METAL CONTAMINATION OF ENGINE. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 1998021100538 19980211 00538 CE 1998 2 11 AU971627 1 19971213 G 3231 S11044 ROD END CESSNA 310Q CESSNA 310 310Q 2074242 CE CONT O470 IO470V 17026 SO MCAULY 2AF34C D2AF34C71 GL RT MLG DOOR SEIZED W K NONE O OTHER CL CLIMB 1 AU S NA (AUS) RH NOSE LANDING GEAR DOOR RETRACTION RODEND BROKEN. DOOR CAUGHT THE NOSE GEAR DURING RETRACTION AND JAMMED THE NLG HALFWAY UP.RODEND BEARING PARTIALLY SEIZED DUE TO LACK OF LUBRICATION. 1 L 7 2 3O 3 O 3A10 3E1 5 C P5EA 1998021100539 19980211 00539 SO 1998 2 11 AU971628 2 19971230 G 8530 570008 CYLINDER CONT IO520L CESSNA 210 210L 2073448 CE CONT O520 IO520L 17032 SO MCAULY 2A34C E2A34C73 GL ENG NR 1 CYL CRACKED W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S 1382 570008 570008 (AUS) NO1 CYLINDER HEAD CRACKED. 1 H 7 1 3O 3 O 3A21 E5CE 5 C P3EA9 1998021800006 19980218 00006 NM 1998 2 18 AU971629 1 19970517 G 2432 63412 CELL SAFT 401767 BOEING 747 747* NM BATTERY FAILED W K NONE H B ELECT. POWER LOSS-50 PC SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S 93165 (AUS) AIRCRAFT MAIN BATTERY CELL FAILED AND BATTERY OVERHEATED. BATTERY CHARGER PNO 2-792-02 DAMAGED. AIRCRAFT IS FOREIG N REGISTEREDN124KK. 2 L 7 4 4F RT A20WE 1998021100540 19980211 00540 SW 1998 2 11 AU971630 1 19971216 G 5512 528 SKIN MTSBSI MU2B30 MTSBSI MU2 MU2B30 5780410 SW HARTZL HCB3T HCB3TN5 GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 528 (AUS) HORIZONTAL STABILISER LEADING EDGE SKINS CRACKED. CRACKS ORIGINATE FROM RIB RIVETS FOR THE OUTBOARD ELEVATOR HINGE . CRACK LENGTH 50.8MM (2IN). FOUND DURING INSPECTION IAW AD/MU2/35. 1 H 7 2 3T A2PC 6 C P15EA 1998021100541 19980211 00541 NM 1998 2 11 AU971631 1 19971230 G 2750 PUSHROD BOEING 747 747312 1384932 NM TE FLAP CONTROL WRONG PART W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT INBOARD TRAILING EDGE NR 5 AFT FLAP PUSHROD INCORRECT PART. PUSHROD WAS ALSO 20.637MM (0.8125 INCH) TOO SHORT. GENEVA CAMS NR 5 AND NR 6 ALSO TRANSPOSED. 2 L 7 4 4F RT A20WE 1998021100542 19980211 00542 WP 1998 2 11 AU971632 2 19971229 G 8520 447 CRANKSHAFT DHAVXX DH82 DH82AROBRTSN 2801002 WP DHAVXX GIPSY GIPSYMAJOR1 20004 WP ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 447 UK (AUS) ENGINE CRANKSHAFT CRACKED. FOUND DURING ULTRASONIC INSPECTION IAW AD/DHE/18A4. 1 Q 7 1 3I 3 I A8EU A8EU 1998021100543 19980211 00543 EU 1998 2 11 AU971633 1 19971213 G 3242 AHO809723 RIVET DUNLOP BRAKEUNIT BAG JETSTM JETSTM3107 1500215 EU ROTOL R333 R333482F12 GL BRAKE SHEARED W K NONE O OTHER LD LANDING 1 AU S FD133 (AUS) LH MAIN LANDING GEAR BRAKE PAD RIVET SHEARED. BRAKE PADS WEDGED BETWEEN THE STATOR AND ROTOR ASSEMBLIES.. THRUST P LATE ASSEMBLY PNO AHO 84638 ALSO DAMAGED AND DISTORTED 2 L 7 2 4T RT BA15CAA 6 C P61GL 1998021100826 19980211 00826 CE 1998 2 11 AU971634 1 19971220 G 5220 50111302 WINDOW CESSNA 402 402CESSNA 207590K CE MCAULY 3AF32C 3AF32C87 GL EMERGENCY EXIT FAILED W K NONE D INFLIGHT SEPARATION CR CRUISE 1 AU S (AUS) EMERGENCY EXIT WINDOW FAILED AT THE TOP. AS THE WINDOW SWUNG DOWN IT TORE THROUGH THE TWO ATTACHMENT POINTS AND CA USED MINOR DAMAGE TO THE WING SKIN. 1 L 7 2 3O A7CE 5 C P22EA 1998021100827 19980211 00827 NE 1998 2 11 AU971635 2 19971022 G 7261 3527 OIL SYSTEM TMECA ARRIEL1S SKRSKY S76 S76A 8143006 NE TMECA ARRIEL ARRIEL1S 60030 NE ENGINE OIL FLUCTUATES W K NONE O K OTHER FLUID LOSS CR CRUISE 1 AU S 3527 3527 (AUS) LH ENGINE VENTED OIL OVERBOARD. OIL PRESSURE FLUCTUATING. 1 G 7 2 3U 3 U H1NE E19EU 1998021100828 19980211 00828 CE 1998 2 11 AU971636 1 19971231 G 7810 991030132 EXHAUST PIPE CESSNA 402 402B 207590P CE CONT O520 TSIO520E 17040 SO MCAULY 3AF32C 3AF32C87 GL ENGINE COLLECTOR CRACKED W K NONE O R OTHER PARTIAL RPM/PWR LOSS CR CRUISE 1 AU S 238901 696105 (AUS) RH ENGINE INBOARD EXHAUST HEADER PIPE CRACKED UNDER CLAMP ATFLANGE JOINT. 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 1998021100829 19980211 00829 SO 1998 2 11 AU971637 2 19970922 G 8500 ENGINE CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO MCAULY 3AF32C 3AF32C87 GL RT ENGINE MALFUNCTION W K NONE E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 AU S 278486R (AUS) RH ENGINE RUNNING ROUGH IN CRUISE. GROUND RUN COULD FIND NO FAULT. 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 1998021100830 19980211 00830 SO 1998 2 11 AU971638 2 19971212 G 8520 276439R CRANKCASE CONT GTSIO520M CESSNA 404 404CESSNA 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 276439R 276439R (AUS) CRANKCASE CRACKED. FOUND DURING INSPECTION IAW TCM CSB 97-9. 1 L 7 2 3O 3 O A25CE E7CE 5 C P45GL 1998021800008 19980218 00008 EU 1998 2 18 AU971639 1 19971231 G 5730 SKIN BAC 146 146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) UPPER WING SURFACE SKIN CRACKED IN THREE PLACES. CRACKS EMANATING FROM THE CENTRE FUEL TANK OVERWING REFUEL CAP CU TOUT IN THE WINGPLANK SKIN. 2 H 7 4 4F 4 F RT A49EU E6NE 1998021100831 19980211 00831 NM 1998 2 11 AU971640 1 19971226 G 2760 BACC2A3A03051FG CONTROL CABLE BOEING 737 737377 NM SPOILER WS 230 BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NO6 FLIGHT SPOILER CABLE WSB2-4 FAILED ADJACENT TO THE PULLEYS AT RH WING STN 230 AT WBL157.0. EVIDENCE OF ADVANCE D INTERNALCORROSION. 2 L 7 2 4F RT A16WE 1998021100832 19980211 00832 NM 1998 2 11 AU971641 1 19971201 G 2761 654494713 HOUSING BOEING ACTUATOR BOEING 737 73733A 1384673 NM LT INB SPOILER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 23588 5765ANSETTSN (AUS) LH INBOARD GROUND SPOILER OUTBOARD ACTUATOR HOUSING PIVOT BEARING LUG BROKEN. SUSPECT CAUSED BY FATIGUE CRACKING O RIGINATING FROM MINOR CORROSION PITTING IN THE CENTRE OF THE BEARING BORE. 2 L 7 2 4F RT A16WE 1998021100833 19980211 00833 NM 1998 2 11 AU971642 1 19971018 G 2520 737M254570114 SEAT BOEING 737 737476 NM CABIN SEPARATED W K NONE O OTHER NR NOT REPORTED 1 AU S 3082 317143 (AUS) PASSENGER SEAT OUTBOARD FORWARD SEAT LEG TRACK FITTING SEPARATEDFROM FLOOR TRACK. SEAT WAS LOCATED AT ROW 21 A B C . 2 L 7 2 4F RT A16WE 1998021100834 19980211 00834 EU 1998 2 11 AU971643 1 19970722 G 3231 A52810000500051 ARM AIRBUS 300 A300B4203 3930306 EU GE CF6 CF650C2 30018 NE NLG DOOR BROKEN W K NONE O J OTHER WARNING INDICATION LD LANDING 1 AU S (AUS) NOSE LANDING GEAR LH AFT DOOR ACTUATING ROD BROKEN. 2 L 7 2 4F 4 F A35EU E23EA 1998021100835 19980211 00835 NM 1998 2 11 AU971644 1 19971226 G 3230 273T63016 ACTUATOR BOEING 273T63016 BOEING 767 767277 NM GE CF6 CF680A 30025 NE LT MLG FAILED W K NONE O OTHER TO TAKEOFF 1 AU S 00181AANSETT (AUS) LH MAIN LANDING GEAR LEFT HAND DRAG BRACE ACTUATOR PISTON ROD SHEARED IN THREADED AREA. 2 L 7 2 4F 4 F RT A1NM E13NE 1998021100836 19980211 00836 CE 1998 2 11 AU971645 1 19971205 G 2822 476411 PUMP CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO FUEL BOOST FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUEL TRANSFER PUMP INTERNAL ELECTRICAL FAULT. FEED THROUGH WIRE BROKEN AT SPOT WELD. 1 L 7 2 3O 3 O 3A10 E5CE 1998021100837 19980211 00837 CE 1998 2 11 AU971646 1 19970608 G 2750 500000861 CONTROL CABLE CESSNA 421 421C 2076016 CE MCAULY 3FF32 3FF32C501 GL TE FLAP CONTROL BROKEN W O OTHER F FLT CONT AFFECTED DE DESCENT 1 AU S (AUS) FLAP CABLE SNAPPED. 1 L 7 2 3O A7CE 5 C P45GL 1998021100838 19980211 00838 NE 1998 2 11 AU971647 1 19971216 G 2910 SS48CT3A132000 HOSE SKRSKY S76 S76A 8143006 NE TMECA ARRIEL ARRIEL1S 60030 NE MAIN HYD HOLED W K NONE K FLUID LOSS CL CLIMB 1 AU S (AUS) NO2 HYDRAULIC SYSTEM PRESSURE HOSE TO RETRACTION ACTUATOR CONTAINED A SMALL PIN HOLE LEAK. 1 G 7 2 3U 3 U H1NE E19EU 1998021100839 19980211 00839 SO 1998 2 11 AU971648 1 19970925 G 7922 53E22144 VALVE LYC 53E22144 PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA HARTZL HCE3Y HCE3YR2 GL THERMO BYPASS FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 80961 L2551 (AUS) ENGINE OIL SYSTEM THERMAL BYPASS VALVE (VERNATHERM) RETAINING CLIP FAILED PREVENTING THE VALVE FROM CORRECT OPERA TION. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1998021800009 19980218 00009 EU 1998 2 18 AU971649 1 19971106 G 5210 BUSHING AIRBUS 320 A320212 EU CABIN DOOR FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MAIN CABIN DOOR R1, R2 AND L2 CONNECTING LINK LOWER BUSHES MIGRATED. FOUND DURING INSPECTION IAW ER A32-52-10-7B. 2 L 7 2 4F RT A28NM 1998021800010 19980218 00010 EU 1998 2 18 AU971650 1 19971230 G 5210 BUSHING AIRBUS 320 A320212 EU CABIN DOOR FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) L1 AND R1 MAIN CABIN DOOR LOWER CONNECTION LINK BUSHES MIGRATED.FOUND DURING INSPECTION IAW ER A32-52-10-7C. 2 L 7 2 4F RT A28NM 1998021800011 19980218 00011 EU 1998 2 18 AU971651 1 19971125 G 5210 BUSHING AIRBUS 320 A320212 EU CABIN DOOR FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) L1, L2 AND R1 MAIN CABIN DOOR LOWER LINK BUSHES MIGRATED. FOUND DURING INSPECTION IAW ER A32-52-10-7C. 2 L 7 2 4F RT A28NM 1998021100840 19980211 00840 EU 1998 2 11 AU971652 1 19971125 G 2913 401852 PUMP SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A1 30030 NE ROTOL R354 R3544123F13 NE HYDRAULIC FAULTY W K NONE M J OVER TEMP WARNING INDICATION TX TAXI/GRND HDL 1 AU S 2967 IB32 (AUS) HYDRAULIC PUMP FAULTY. PUMP MOTOR OVERHEATED. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P61GL 1998021100841 19980211 00841 CE 1998 2 11 AU971653 1 19971225 G 7540 903800021 SWITCH BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL BLEED AIR IND MIS INSTALLED W K NONE W INADEQUATE Q C CR CRUISE 1 AU S (AUS) LH AND RH BLEED AIR SENSE LINES TRANSPOSED. LH LINE CONNECTED TO RH SWITCH AND VICE VERSA. A HOLE IN THE RH SENSE LINE ACTIVATED THE LH BLEED AIR WARNING. SEE MDR 97/1609 FOR MORE INFORMATION. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 1998021100842 19980211 00842 EU 1998 2 11 AU971654 2 19971209 G 7322 0164168190 FCU SNIAS AS332 AS332L 8680809 EU TMECA MAKILA MAKILA1A 60040 EU NR 2 ENG FC FAULTY W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S 534 6315 1123 (AUS) NO2 ENGINE FUEL CONTROL UNIT FAULTY. 2 G 7 2 4U 4 U H4EU E12NE 1998021100843 19980211 00843 GL 1998 2 11 AU971655 2 19971211 G 7210 23004220 COVER ALLSN 250C30 ALLSN 250C 250C30 03013 GL ENG NR 3-4 BRG BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S CAG70066 CAE895019 (AUS) ENGINE NO3 AND NO4 BEARING HOUSING BROKEN AT PREVIOUSLY REPAIRED AREA. ENGINE WAS BEING OVERHAULED FOLLOWING AND E NGINE FAILURE WHICH RESULTED IN A HARD LANDING AND SUDDEN STOPPAGE. ENGINE IS FROM A PNG REGISTERED AIRCRAFT P2-HBB. 3 U E1GL 1998021100844 19980211 00844 EU 1998 2 11 AU971656 1 19970720 G 3230 C288393 SPRING AIRBUS 300 A300B4203 3930306 EU GE CF6 CF650C2 30018 NE LT MLG BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 5625 (AUS) LH MAIN LANDING GEAR AFT DOWNLOCK ASSEMBLY AFT OUTER DOWNLOCK SPRING BROKEN AND SPRING LOWER ATTACHMENT FITTING BE NT. 2 L 7 2 4F 4 F A35EU E23EA 1998021100845 19980211 00845 EU 1998 2 11 AU971657 1 19971111 G 7830 CF6RHFRAF1 THRUST REVERSER AIRBUS 300 A300B4203 3930306 EU GE CF6 CF650C2 30018 NE R 2 ENG OUTB CORRODED W A K NONE O OTHER IN INSP/MAINT 1 AU S 24701 R476938 (AUS) NO2 ENGINE OUTBOARD THRUST REVERSER HALF CORRODED AND DAMAGED.METAL STRUT LEADING EDGE DAMAGED AND BROKEN OFF LODG ING INCASCADE FORWARD RECESS CAUSING A BLOCKER DOOR TO BREAK AND SEVERE BLOCKER DOOR CARRIAGE DAMAGE. 2 L 7 2 4F 4 F A35EU E23EA 1998021100846 19980211 00846 NM 1998 2 11 AU971658 1 19970915 G 5220 TRIM BOEING 737 737376 NM EMERGENCY EXIT BLOCKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) COCKPIT DOOR EMERGENCY HATCH PULL HANDLE TRIM INTERFERING WITH THE MEL DOCUMENT HOLDER PREVENTING THE HATCH FROM F ALLING INTOTHE COCKPIT AS DESIGNED. 2 L 7 2 4F RT A16WE 1998021100847 19980211 00847 1998 2 11 AU971659 1 19971113 G 7830 SLEEVE CFMINT CFM56 CFM563B2 13802 EU NR 2 ENG TR WORN W K NONE O N OTHER FALSE WARNING DE DESCENT 1 AU S (AUS) NO2 ENGINE THRUST REVERSER INBOARD `SLEEVE NOT STOWED' PROXIMITY SWITCH SLEEVE WORN AND OUT OF ADJUSTMENT. 4 F E21EU 1998021100848 19980211 00848 NM 1998 2 11 AU971660 1 19970922 G 2520 737M254570114 SEAT BOEING 737 7374Q8 NM CABIN SEPARATED W K NONE O OTHER LD LANDING 1 AU S 344238 (AUS) PASSENGER SEAT AFT OUTBOARD SEAT LEG TRACK FITTING SEPARATED FROM THE FLOOR TRACK DUE TO THE LOCKING SCREW BACKING OUT OF THE TRACK FITTING. THE SEAT WAS LOCATED AT POSITION ROW 14 DEF. 2 L 7 2 4F RT A16WE 1997042400868 19970424 00868 CE 1997 4 24 BCBR3786 1 19970315 G 2497 WIRE CESSNA 206 U206F 2073333 CE ACFT CLOCK MISINSTALLED B BCBR K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 03 59146 2210 U20602624 DURING AN AUTOPILOT INSTALLATION, THE PLUS (POS) WIRE TO THE A/C CLOCK CONTACTED GROUND. THE WIRE OVERHEATED AND BURNED THROUGH THE PVC INSULATION. THIS WIRE WAS CONNECTED TO THE BATTERY SIDE OF THE MASTER SOLENOID WITH NO CIRCUIT PROTECT ION, WIRE WAS NOT ROUTED PER AC43.13-1A AND IT WAS WRAPPED AROUND THE FUEL AND PRIMER LINES THEN THROUGH THE FIREWALL. T HE WIRE WAS RUN AROUND THE PILOT'S YOKE SUPPORT BRACKET. NO CHAFE PROTECTION WAS PROVIDED. MINOR WIRE BUNDLE DAMAGE OC CURRED. (X) 1 H 7 1 3O A4CE 1997121100118 19971211 00118 SO 1997 12 11 BTVR110597 1 19971106 G 2121 39714411 VALVE GULSTM G1159 G1159A 3970109 SO COOLING FAN FAILED B BTVR K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 GL 23 803CC 7085 P467 378 DURING GROUND OPERATION WITH THE APU OPERATING, THE FLIGHT CREW DETECTED A STRONG 'HOT SMELL' IN THE CABIN. AFTER A PHO NE CONFERENCE WITH HOME BASE MAINTENANCE, THE COOLING TURBINE WAS SUSPECTED. PRESSURIZATION SYSTEM WAS DEFERRED USING M .E.L. PROCEDURES AND ACFT RETURNED TO HOME BASE. FURTHER T/S REVEALED THE GROUND COOLING FAN DID NOT APPEAR TO OPERATE PROPERLY WHICH WOULD CAUSE THE AIR CONDITIONING DISTRIBUTION AND SUPPLY DUCTING'S TEMPERATURE TO INCREASE PRODUCING A 'H OT SMELL'. THE FAN'S CONTROL VALVE WAS CHANGED. THE SYSTEM WAS OPERATED FOR AN EXTENDED PERIOD WITH NO DEFECTS. AIRCR AFT RETURNED TO SERVICE. (X) 2 L 7 2 4F A12EA 1997092500049 19970925 00049 CE 1997 9 25 BTVR82997 1 19970829 G 5320 620022012 HEAT BARRIER 62002201 CESSNA 650 650 2076802 CE RT AFT FUSELAGE CORRODED B P BTVR K NONE O OTHER IN INSP/MAINT 1 GL 23 367G 7770 6500053 EXHAUST OUTLET WAS REMOVED FOR WELD REPAIR. FUSELAGE DOUBLER WAS CORRODED THROUGH (2 PLACES) WITH SUBSEQUENT CORROSION ON AIRCRAFT SKIN. REPAIRED IAW CESSNA REPORT S650-0033/01RD WHICH REPLACED HEAT BARRIER WITH HIGH TEMP (RED) RTV 106. T HIS WILL PREVENT INGRESS OF WATER WHICH CAUSED RESULTING CORROSION. (X) 2 L 7 2 4F A9NM 1998031900251 19980319 00251 CE 1998 3 19 CA930526402 1 19970218 G 2910 HYDRAULIC FLUID CESSNA 206 TU206G 2073357 CE PUMP INLET CONTAMINATED W K NONE O J OTHER WARNING INDICATION LD LANDING 1 CA (CAN) WHILE TROUBLESHOOTING FLOAT GEAR MOTOR INOP, FOUND HYDRAULIC FLUID HAD DIRT, FUNGI GROWTH (A BLACK MASS) COVERING THE PUMP INLET SCREEN. WIPAIRE SERVICE LETTER NR 15 REFERS TO THIS SUBJECT. 1 H 7 1 3O A4CE 1997042800088 19970428 00088 NM 1997 4 28 CA970106009 1 19970122 G 3297 WIRE DHAV DHC8 DHC8102 2809003 NM NLG DOWNLOCK BROKEN W O OTHER J WARNING INDICATION AP APPROACH 1 CA (CAN) ON GEAR DOWN SELECTION, YELLOW CAUTION LIGHT ON MOMENTARILY. NOSE WHEEL RED AND AMBER DOOR LIGHT ON. WHEN GEAR HAN DLE TOUCHED, ALL GREEN LIGHTS ON. AFTER LANDING, RED NOSE GEAR LIGHT ON AGAIN WITH GEAR HANDLE LIGHT AND WARNING HORN. N OSE WHEEL STEERING LOST. INSPECTION FOUND ONE WIRE TO NOSE DOWNLOCK SWITCH BROKEN AND HARNESS FLATTENED WHERE IT PASSES OVER TRUNNION. 2 H 7 2 4T RT A13NM 1997042800097 19970428 00097 NM 1997 4 28 CA970109001 1 19970103 G 2100 3033716X2 SEALS DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE AIR COND SYS LEAKING W D RETURN TO BLOCK B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA 120854 (CAN) HAZE IN CABIN AND LAV. SMOKE DETECTOR SOUNDED. #1 AND #2 ENGINE COMPRESSOR DRAINS CHECKED FOR OIL. NONE FOUND. P2. 5 AND P3 SWITCHING VALVE PISTON RINGS REPLACED. 2 H 7 2 4T 4 T RT A13NM E20NE 1997042800098 19970428 00098 NE 1997 4 28 CA970109002 3 19970103 G 6112 SFA13M1ROA BLADE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE DEICE BOOT BURNED BOOT W K NONE O OTHER IN INSP/MAINT 1 CA 8380 8380 120226 881010 (CAN) #2 PROPELLER BLADE DE-ICE BOOT SHORTED BURNED RUBBER OFF THE BLADE. BLADE REPAIRED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 1997042800100 19970428 00100 EU 1997 4 28 CA970109012 1 19970106 G 2910 AE2463921G01 HYDRAULIC LINE AIRBUS 320 A320211 3930320 EU LT GEAR DOOR LEAKING W K NONE J K WARNING INDICATION FLUID LOSS TX TAXI/GRND HDL 1 CA (CAN)DURING TAXI TO RAMP GREEN HYDRAULIC SYSTEM FAILED. INVESTIGATION REVEALED HYDRAULIC LINE ON LH GEAR DOOR RETRACT FO UND LEAKING. DEFECTIVE LINE REPLACED. 2 L 7 2 4F RT A28NM 1997050100354 19970501 00354 EU 1997 5 1 CA970109013 1 19970106 G 5610 WINDSHIELD STA320241 AIRBUS 320 A320211 3930320 EU FIRST OFFICER CRACKED W A B UNSCHED LANDING EMER. DESCENT B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CR CRUISE 1 CA 760 (CAN) AT CRUISE FIRST OFFICERS WINDSHIELD CRACKED, ALTITUDE REDUCED AS PER FCOM. THERE WAS LOSS OF HEAT TO RIGHT WINDSHI ELD, OUTER PANE ARCING NOTED, CB PULLED. WINDSHIELD REPLACED. 2 L 7 2 4F RT A28NM 1997050100355 19970501 00355 EU 1997 5 1 CA970109014 1 19970106 G 3233 MS2125008020 BOLT AIRBUS D57252160 AIRBUS 320 A320211 3930320 EU RH LANDING GEAR CHAFE TANK W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) DURING ROUTINE MAINTENANCE FUEL FOUND LEAKING AT RH MAIN LANDING GEAR ACTUATOR FITTING DUE TO BOLTS BEING TOO LONG . BOLTS REPLACED WITH CORRECT TYPE AS SPECIFIED IN DRAWING NO.D57252160 AND TANK RESEALED. 2 L 7 2 4F RT A28NM 1997050100367 19970501 00367 WP 1997 5 1 CA970110002 2 19970115 G 7321 30708165 PT SENSOR LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP #2 ENGINE FAULTY W A H UNSCHED LANDING DEACTIVATE SYST/CIRCUITS R PARTIAL RPM/PWR LOSS CL CLIMB 1 CA 9657 P74369 (CAN) DURING TAKEOFF THE #2 ENGINE RPM BEGAN TO OSCILLATE. THE ENGINE COMPUTER WAS SELECTED TO THE OFF POSITION. THE ENG INE RPM STABILIZED BUT WOULD NOT MAKE POWER, APPROXIMATELY 80 PERCENT N1. THE AIRCRAFT RETURNED TO BASE AND LANDED WITHO UT INCIDENT. TROUBLESHOOTING FOUND THE PT2 SENSOR PROBE TO BE THE FAULT, ALTHOUGH NO DAMAGE TO THE PROBE WAS EVIDENT. TH E PROBE WAS REPLACED AND THE ENGINE GROUND RUN WITH THE COMPUTERS ON AND OFF CARRIED OUT. ALL PARAMETERS NORMAL AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F A10CE E6WE 1997050100368 19970501 00368 NM 1997 5 1 CA970110003 1 19970101 G 2435 1243106 STARTER DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE #1 ENG FAILED W O F OTHER ACTIVATE FIRE EXT. B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA 575A 120549 (CAN) CREW ABORTED START DUE TO SMOKE FROM #1 ENGINE NACELLE. ON PREVIOUS FLIGHT GENERAL CAUTION LIGHT HAD FAILED WITH E XCITER BREAKER POP. STARTER/GENERATOR REPLACED. 2 H 7 2 4T 4 T RT A13NM E20NE 1997050100372 19970501 00372 EA 1997 5 1 CA970114001 2 19970105 G 8550 CH48103 OIL FILTER CHAMPION PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA ENG OIL COLLAPSED W K NONE O OTHER IN INSP/MAINT 1 CA L613961A (CAN) DURING OIL FILTER REPLACEMENT, THE OIL FILTER WAS FOUND COLLAPSED. COLD WEATHER OPERATION IS THE SUSPECTED CAUSE. LYCOMING SERVICE BULLETIN #1442 COMPLIED WITH TO PREVENT REOCCURRENCE. 1 L 7 2 3O 3 O A20SO E14EA 1997050100382 19970501 00382 EA 1997 5 1 CA970114019 2 19970107 G 8550 CCB3700 VALVE DRAIN CURTIS PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA BOTTOM #1 ENGINE LEAKING W O OTHER K FLUID LOSS CR CRUISE 1 CA 1925 L159368A (CAN) OIL LEAK ON #2 ENGINE FOLLOWING FLIGHT. INSPECTION FOUND THE OIL DRAIN COCK LEAKING. OIL SEAL APPEARED AGED AND HA RDENED. OIL SEAL REPLACED AND DRAIN COCK CLEANED AND REPLACED. 1 L 7 2 3O 3 O A20SO E14EA 1997050100387 19970501 00387 WP 1997 5 1 CA970114026 1 19970101 G 2150 21700091 AIR CYCLING MACH DOUG DC9 DC932 3022066 WP PWA JT8 JT8D7A 52053 NE LH AIR CONDITION FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA P656990D (CAN) LEFT HAND AIR CONDITIONING PACK CAUSED OIL SMELL IN CABIN. LEFT AIR CONDITIONING AIR CYCLING MACHINE CHANGED. OPER ATION AND LEAK CHECKED CARRIED OUT. SYSTEM CHECKED SERVICEABLE. 2 L 7 2 4F 4 F A6WE E2EA 1997050100388 19970501 00388 EU 1997 5 1 CA970114027 1 19970106 G 2750 FLAP LIMITER AIRBUS 320 A320211 3930320 EU OUTB FLAP DRIVE FAILED W O OTHER O F OTHER FLT CONT AFFECTED AP APPROACH 1 CA (CAN) FLAPS FAILED TO EXTEND ON APPROACH. FLAPLESS LANDING CARRIED OUT. MAINTENANCE FOUND RIGHT INBOARD FLAP OUTBOARD DR IVE LIMITER TRIPPED. FLAPS OPERATED NORMALLY AFTER LANDING. FLAP OUTBOARD DRIVE LIMITER RESET, INSPECTION HOLES CHECKED FOR CONTAMINATION. OPERATIONAL CHECKED CARRIED OUT SERVICEABLE. 2 L 7 2 4F RT A28NM 1997050100389 19970501 00389 WP 1997 5 1 CA970114028 1 19970104 G 2131 21011403 CONTROLLER DOUG DC9 DC932 3022066 WP PWA JT8 JT8D7A 52053 NE NR 1 PRESSURE FAILED W B G EMER. DESCENT O2 MASK DEPLOYED O OTHER CR CRUISE 1 CA P657224D (CAN) LOSS OF PRESSURIZATION AT 12,600 FT. CABIN OVER 10,000 FT. OXYGEN MASKS DEPLOYED. BITE CHECK CARRIED OUT AND SHOWE D #1 CONTROLLER AT FAULT. BOTH AUTO PRESSURIZATION CONTROLLERS CHANGED AND OPERATIONALLY CHECKED SERVICEABLE. 2 L 7 2 4F 4 F A6WE E2EA 1997050100390 19970501 00390 EA 1997 5 1 CA970114029 1 19970101 G 3260 16215103 BRACKET CNDAIR CL600 CL6002B19 EA GE CF34 CF343A 30015 NE NLG PROX SWITCH DAMAGED W O OTHER J WARNING INDICATION CL CLIMB 1 CA 5312 807157 (CAN) AFTER NOSE GEAR RETRACTION, NOSE GEAR REMAINED DOWN. GEAR DISAGREE AND NOSE DOOR OPEN MESSAGES APPEARED. FOUND NOS E LANDING GEAR CENTERING PROXIMITY SWITCH BRACKET DAMAGED. BRACKET REPLACED AND SWITCH ADJUSTED. 2 L 7 2 4F 4 F RT A21EA E15NE 1997050100392 19970501 00392 SW 1997 5 1 CA970115002 1 19970107 G 6322 204060448001 BLOWER BELL 204 204B 1181404 SW LYC T53 T5313B 41549 NE OIL COOLER ROUGH BEARING W K NONE O OTHER IN INSP/MAINT 1 CA LE18135A (CAN) BEARINGS IN OIL COOLER BLOWER SOUND ROUGH AND DRY WHEN FAN IS TURNED BY HAND. BLOWER REMOVED AND BEARINGS REPLACED . 1 G 7 1 4U 4 U H1SW E17EA 1997050100393 19970501 00393 EA 1997 5 1 CA970115006 1 19970108 G 2421 755469C IDG SUNDSTRANDEM CNDAIR CL600 CL6002B19 EA GE CF34 CF343A 30015 NE #2 ENGINE FAILED W C D ABORTED TAKEOFF RETURN TO BLOCK O OTHER TO TAKEOFF 1 CA 2253 H807335 (CAN) AIRCRAFT REJECTED TAKEOFF DUE TO #2 GENERATOR TRIPPING OFF LINE. INTEGRATED DRIVE GENERATOR REPLACED. 2 L 7 2 4F 4 F RT A21EA E15NE 1997050100395 19970501 00395 SW 1997 5 1 CA970115008 1 19970103 G 7603 MS20392211 CLEVIS PIN SWRNGN 2761002009 SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP POWER LEVER FRETTING W K NONE O OTHER IN INSP/MAINT 1 CA P54024 (CAN) IN REFERENCE TO SERVICE DIFFICULTY ADVISORY AV-96-06, INSPECTION CARRIED OUT ON THE CLEVIS PIN IN THE POWER LEVER SYSTEM. THE PINS IN THE LEFT AND RIGHT ENGINES WERE NOTICEABLY WORN, AND THE COTTER PIN HOLES ELONGATED. BOTH CLEVIS AND COTTER PINS WERE REPLACED. 2 L 7 2 4T 4 T RT A8SW E4WE 1997050100396 19970501 00396 CE 1997 5 1 CA970117001 1 19970104 G 2730 1156100181 SUPPORT BEECH 115610010325 BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA ELEV TORQ TUBE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 9005 PCE50045 (CAN) CRACK FOUND ON THE INBOARD TAPER PIN HOLE ON THE TORQUE TUBE SUPPORT BRACKET WHERE IT ATTACHES TO THE ELEVATOR. 1 L 7 2 3T 4 T A14CE E4EA 1997050100397 19970501 00397 GL 1997 5 1 CA970117002 3 19970109 G 6111 900CA2 PROP BLADE CESSNA 180 180F 2072614 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C203 GL LEADING EDGE STONE NICKED W K NONE O OTHER IN INSP/MAINT 1 CA 134 842373R4 750677 (CAN) DURING CORROSION INSP PROPELLER BLADES WERE FOUND "STONE" NICKED. NICKS WERE TRIMMED OUT. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 1997050100398 19970501 00398 EU 1997 5 1 CA970117006 1 19970109 G 3230 LANDING GEAR AEROSP ATR42 ATR42300 8680920 EU PWA 120 PW120 NE HAMSTD 14SF 14SF5 NE NOSE ICED UP W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 120905 880501 (CAN) AFTER TAKEOFF THE NOSE LANDING GEAR DID NOT RETRACT. MAINTENANCE FOUND THE NOSE GEAR BAY CONTAMINATED WITH A LOT O F SNOW AND ICE. 2 H 7 2 4T 4 T RT A53EU E20NE 6 C P7NE 1997050100399 19970501 00399 GL 1997 5 1 CA970117007 1 19970104 G 3270 TAILSKID AMTR REBEL REBEL 05612SG GL END BROKEN W K NONE O OTHER TX TAXI/GRND HDL 1 CA 74 (CAN) PILOT LOST RUDDER CONTROL WHILE TAXIING ON GRASS STRIP COVERED BY ONE INCH OF SNOW. INVESTIGATION REVEALED THE TAI L SKID TO BE BROKEN. SUBMITTER CONTACTED THE MANUFACTURER AND WAS INFORMED OF A MODIFICATION TO THE DESIGN. 1 L 7 1 3O NC EXPA1L71 1997061900496 19970619 00496 EU 1997 6 19 CA970121002 1 19970115 G 3241 AC60742 MAXARET DUNLOP BRAERO 748 HS7482A 4231001 EU ANTI SKID SYS LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA 227 (CAN) VALVE STEM LEAKING AT SOLDER JOINT. SPRING DAMAGED DUE TO OVERHEATING DURING SOLDERING. 2 L 7 2 3T A24EU 1997050600006 19970506 00006 EU 1997 5 6 CA970121005 2 19970101 G 7320 196 FUELFLOW REG FOKKER F28 F28MK1000 4990808 EU RROYCE SPEY SPEY55515 54521 EU #1 ENGINE FAULTY W C D ABORTED TAKEOFF RETURN TO BLOCK J WARNING INDICATION TO TAKEOFF 1 CA 2944 L820 9635 (CAN) ON TAKEOFF ROLL THE #1 ENGINE WOULD NOT SPOOL UP TO FULL POWER. AIRCRAFT RETURNED TO GATE. MAINTENANCE FOUND THE F UEL FLOW REGULATOR TO BE FAULTY. THE FUEL FLOW REGULATOR WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A20EU E2EU 1997050100400 19970501 00400 EA 1997 5 1 CA970121006 1 19970109 G 3010 15323 DEICE VALVE BENDIX DHAV DHC6 DHC6100 EA PWA PT6 PT6A20 52043 EA WING DE ICE FAILED W O OTHER O OTHER AP APPROACH 1 CA 120 42952U PCE21305 (CAN) ON APPROACH AIRCRAFT ENCOUNTERED HEAVY ICING CONDITIONS. AFTER LANDING THE INBOARD HALF OF WING FOUND COVERED WITH ICE. WING DEICE DISTRIBUTOR VALVE WAS CYCLED BUT DID NOT WORK. VALVE REPLACED. A MOD WILL BE INTRODUCED TO INSTALL HEAT ER AROUND THE VALVES AS THE PREVIOUS VALVE HAD MOISTURE IN IT. 1 H 7 2 3T 3 T A9EA E4EA 1997050800720 19970508 00720 SW 1997 5 8 CA970121007 1 19970113 G 6520 2060404077 OUTPUT SHAFT BELL 206040400005 BELL 206 206BELL 1181502 SW T/R GR BOX WORN W K NONE O OTHER IN INSP/MAINT 1 CA 2085 B13551 (CAN) UPON DISASSEMBLY OF T/R GEARBOX FOR MIDLIFE INSPECTION, THE SEAL JOURNAL AREA OF THE OUTPUT SHAFT WAS FOUND TO BE SEVERELY WORN TO A DEPTH OF 0.20 INCHES IN A V-SHAPED UNDERCUT FOR THE ENTIRE CIRCUMFERENCE OF THE SHAFT. THIS WORN AREA IS DIRECTLY ADJACENT TO THE OUTPUT SEAL LOCATION ON THE OUTPUT CAP OF THE GEARBOX. BEFORE DISASSEMBLY, THE GEARBOX RUN- OUT WAS CHECKED AND FOUND WITHIN LIMITS AND NO LEAKAGE WAS EVIDENT FROM THE OUTPUT SEAL AREA. HOWEVER, THE INTERIOR OF T HE GEARBOX WAS COATED IN A FINE PASTE AS WERE ALL THE RELATED INTERNAL PARTS. 1 G 7 1 3U H2SW 1997050800721 19970508 00721 CE 1997 5 8 CA970121009 1 19970113 G 3260 10038100601 SWITCH 10038100601 BEECH 100 A100 1152915 CE PWA PT6 PT6A34 52043 EA MLG DOWNLOCK INTERMITTENT W A UNSCHED LANDING P NO WARNING INDICATION AP APPROACH 1 CA PCE56069 (CAN) DURING APPROACH, PILOTS UNABLE TO GET GEAR DOWN INDICATION. RETURNED TO BASE AND FLYBY CONFIRMED GEAR DOWN. MAINTE NANCE FOUND THE DOWNLOCK SWITCH TO BE INTERMITTENT. 1 L 7 2 3T 4 T A14CE E4EA 1997051300021 19970513 00021 EU 1997 5 13 CA970121010 1 19970108 G 7160 350A54112220 INLET DUCT SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D NE START/GEN AIR LOST IN FLIGHT W K NONE D INFLIGHT SEPARATION IN INSP/MAINT 1 CA 9322 (CAN) STARTER GENERATOR AIR INLET DUCT WAS LOST IN FLIGHT. SUSPECT CAUSE OF SEPARATION IS LOOSENING OF SECURING CLAMP. 1 G 7 1 3U 3 U H9EU E19EU 1997050800722 19970508 00722 SW 1997 5 8 CA970121011 1 19970113 G 3246 13600L BEARING BFGOODRICH 313571 SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL NR 2 MLG WHEEL ROLLERS MISSING W A K NONE O OTHER TX TAXI/GRND HDL 1 CA 5024 P447414 106175 (CAN) OUTSIDE BEARING ON #2 MAIN WHEEL ASSEMBLY FAILED AND RESULTED IN WHEEL DEPARTING THE AIRCRAFT. THE BEARING ROLLERS LEFT THE BEARING CAGE ALLOWING THE WHEEL TO EXIT THE AXLE OVER THE SPACER, WASHER AND NUT. INNER BEARING WAS EXCESSIVEL Y WORN, THERE WAS STILL GREASE IN BEARING. NO SPACER FOUND BETWEEN WHEEL HALVES. AXLE ON DAMAGE ON OPPOSITE WHEEL. INSPE CTION PROGRAM BEING IMPLEMENTED FOR INITIAL INSPECTION OF WHEEL BEARINGS, CUPS AND AXLES ON ALL SA226/227 AIRCRAFT. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 1997050800723 19970508 00723 EA 1997 5 8 CA970122001 1 19970109 G 2920 MX499336 HYDRAULIC LINE SPERRYVICRS 731840 DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE STDBY POWER LEAKING W C D ABORTED TAKEOFF RETURN TO BLOCK J K WARNING INDICATION FLUID LOSS TX TAXI/GRND HDL 1 CA MX499336 123192 (CAN) DURING TAXI CREW NOTICED HYDRAULIC LEAK AND LOSS OF FLUID FROM THE #1 HYDRAULIC SYSTEM. HYDRAULIC LINE AT THE STA NDBY POWER UNIT FOUND LOOSE AND LEAKING 2 H 7 2 4T 4 T RT A13NM E20NE 1997061900500 19970619 00500 1997 6 19 CA970122002 4 19970117 G 2562 0025004 BATTERY DAYTON EB2BCD BOEING 75 B75N1 1380144 CE LYC R680 R680B4E 41540 EA ELT CASE LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA 39254 13378 (CAN) AFTER TWO YEARS ARTEX BATTERY LEAKED AND CORRODED CHASSIS AND INSIDE OF CASE. 1 Q 7 1 3R 3 R A743 TC108 1997050800724 19970508 00724 NE 1997 5 8 CA970122004 2 19970114 G 7250 310900301 PT BLADE PWA 118 PW118 NE ENGINE FRACTURED W K NONE O OTHER IN INSP/MAINT 1 CA 19129 10153 115070 (CAN) THE OPERATOR OBSERVED POWER TURBINE DAMAGE AND THE ENGINE WAS SENT FOR INVESTIGATION. DISASSEMBLY REVEALED THE ENG INE SUFFERED A PRIMARY FAILURE OF ONE POWER TURBINE BLADE. THE FRACTURE WAS THROUGH THE CORED POCKET APPROXIMATELY 1/4" ABOVE THE INNER PLATFORM. IT WAS CONCLUDED THE FAILURE OCCURRED DUE TO HIGH TIME ON THE BLADE. 4 T E20NE 1997050800726 19970508 00726 CE 1997 5 8 CA970128001 1 19970115 G 5210 05170392 DOOR HANDLE CESSNA 0711023105 CESSNA 180 180J 2072622 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C203 GL STEEL INSERT BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 153 462647 950479 (CAN) A NEW STYLE OF HANDLE WAS INSTALLED WITH A STEEL BUSHING IN AN ALUMINUM HANDLE. THE TWO PART ASSEMBLY SEPARATED AT THE UNION. THE PART WAS SENT BACK FOR WARRANTY. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 1997050800727 19970508 00727 GL 1997 5 8 CA970128003 1 19970118 G 5610 2056501100 CANOPY DIAMON 2056501100 DIAMON DA20A1 DA20A1 05626UX GL L/H LOCK BARREL CRACKED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA 100 (CAN) A 30 INCH CRACK DEVELOPED IN THE CANOPY, RADIATING FROM THE CANOPY LOCK CYLINDER ON THE LEFT OF THE CANOPY RAIL AN D MOVING UPWARDS TO THE 11 O'CLOCK POSITION. 1 L 7 1 3O NT TA4CH 1997050800728 19970508 00728 GL 1997 5 8 CA970128004 1 19970117 G 2752 FLAP ACTUATOR DIAMON DA20A1 DA20A1 05626UX GL BELLY BROKEN WIRE W O OTHER F FLT CONT AFFECTED TX TAXI/GRND HDL 1 CA (CAN) ICE IN THE BELLY OF THE AIRCRAFT PREVENTED THE FLAP ACTUATOR FROM FUNCTIONING AND POPPED THE CIRCUIT BREAKER. A BR OKEN WIRE WAS FOUND UPON THAWING THE ICE. SUBMITTER BELIEVES THE WIRE BROKE WHILE DEPLOYING THE FLAPS. 1 L 7 1 3O NT TA4CH 1997050800729 19970508 00729 EA 1997 5 8 CA970128005 2 19970122 G 8550 75288 SHAFT GULSTM 112 112 0144701 SW LYC O360 IO360C1D6 41514 EA HARTZL HCE2Y HCE2YR1BF GL OIL PUMP WORN KEYWAY W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 985 L955051A DK330 (CAN) DURING COMPLIANCE WITH AD 96-09-10 IT WAS DISCOVERED THE DRIVE GEAR AND DRIVE SHAFT CONTAINED A KEYWAY. THE KEYWAY AND DRIVE GEAR WERE WORN APPROXIMATELY 0.060". THIS KEYWAY SHOULD HAVE BEEN REMOVED BY AD 75-08-09, BUT THIS ENGINE, BY SERIAL NUMBER, IS NOT APPLICABLE TO AD 75-08-09. A REPLACEMENT DRIVE SHAFT WAS INSTALLED. 1 L 7 1 3O 3 O A12SO 1E10 5 C P9EA 1998040200031 19980402 00031 EA 1998 4 2 CA970128006 1 19970124 G 7830 12675862 PNEUMATIC DR UNI CNDAIR CL601 CL6012A12 1900303 EA GE CF34 CF341A NE LT ENGINE MIS ADJUSTED W D RETURN TO BLOCK J WARNING INDICATION TX TAXI/GRND HDL 1 CA GEE350177 (CAN) LEFT THRUST REVERSER PDU UNLOCKED, LIGHT REMAINED ON WHEN THRUST REVERSER STOWED. FLEX LOCK FOUND DISENGAGED. IN TERNAL TIMING FOUND OUT OF LIMITS. REPLACED PNEUMATIC DRIVE UNIT. 1 L 7 2 4F 4 F RT A21AE E15NE 1997050800730 19970508 00730 CE 1997 5 8 CA970128007 1 19970120 G 7931 100381173 INDICATOR AEROMECH BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA #2 ENG OIL PRESS FAULTY W A E UNSCHED LANDING ENGINE SHUTDOWN J N WARNING INDICATION FALSE WARNING CR CRUISE 1 CA 27C18 PCE50253 (CAN) AIRCRAFT WAS IN CRUISE WHEN THE RIGHT HAND OIL PRESSURE INDICATOR WAS FLICKERING, ALL OTHER PARAMETERS WERE NORMAL . SEVERAL MINUTES LATER THE OIL PRESSURE WENT TO "0". THE #2 ENGINE WAS SHUTDOWN. POST FLIGHT INSPECTION FOUND THE OIL P RESSURE/TEMPERATURE GAUGE TO BE FAULTY. THE GAUGE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 3T 4 T A14CE E4EA 1997051300023 19970513 00023 EA 1997 5 13 CA970128010 1 19970120 G 2435 215T5091010 DUCT INLET AIRPTS 215T5091018 CNDAIR CL215 CL2151A10 EA START/GEN SPLIT W K NONE O OTHER IN INSP/MAINT 1 CA 161 (CAN) WELD ON COOLING DUCT FOR STARTER GENERATOR HAS NO METAL PENETRATION. SKIN JOINT SPLIT AND PARTS ALMOST CHAFED THR OUGH AN OIL RETURN LINE. BOTH DUCT INLETS WERE IN SIMILAR CONDITION. ONE OF THE SPLITS WAS .25 INCH AND THE OTHER .50 INCH WIDE. INSPECTION CARRIED OUT AS PER CANADAIR REQUEST. 2 H 7 2 4R A14EA 1997050800731 19970508 00731 CE 1997 5 8 CA970128011 1 19970122 G 5210 50430043163 CHANNEL BEECH 50430043622 BEECH 80 65B80 1152812 CE LYC O540 IGSO540A1D 41532 EA CABIN DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 7437 RL370750 (CAN) CABIN DOOR HINGE HAD EXCESSIVE PLAY. WHILE REPLACING THE RIVETS A CRACK WAS FOUND IN THE STRUCTURE. 1 L 7 2 3O 3 O 3A20 1E7 1997050800732 19970508 00732 WP 1997 5 8 CA970129001 1 19970113 G 3222 MS288891 AIR VALVE DOUG DC9 DC932 3022066 WP PWA JT8 JT8D7A 52053 NE NLG OLEO LEAKING W O OTHER J WARNING INDICATION CL CLIMB 1 CA P657766D (CAN) ON TAKEOFF, UNABLE TO RAISE NOSE GEAR AND NOSE GEAR LIGHT CAME ON. QUICK REFERENCE HANDBOOK CHECK LIST CARRIED OUT . ON ARRIVAL FOUND NOSE GEAR OLEO FLAT. NOSE GEAR SERVICED AND SCHRADER VALVE REPLACED. 2 L 7 2 4F 4 F A6WE E2EA 1997050800733 19970508 00733 WP 1997 5 8 CA970129002 1 19970114 G 2841 DC26F16265 FUEL INDICATOR DOUG DC9 DC932 3022066 WP PWA JT8 JT8D7A 52053 NE RH FUEL QUANTITY INOPERATIVE W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA P656873D (CAN) ELECTRICAL SMELL DETECTED AND RH FUEL QUANTITY INDICATOR FAILED. TROUBLESHOOTING OF SNAG REVEALED RH INDICATOR CIR CUIT BREAKER HAD POPPED. DEFECTIVE INDICATOR REPLACED AND SYSTEM CHECKED SERVICEABLE. 2 L 7 2 4F 4 F A6WE E2EA 1997050800734 19970508 00734 EA 1997 5 8 CA970129003 1 19970112 G 3230 BRACKET CNDAIR CL600 CL6002B19 EA GE CF34 CF343A 30015 NE NOSE GEAR OUT OF ADJUST W A UNSCHED LANDING O OTHER CL CLIMB 1 CA 3517 807267 (CAN) AFTER TAKEOFF UNABLE TO RETRACT NOSE GEAR. TARGET BRACKET REMOVED AND REPAIRED. 2 L 7 2 4F 4 F RT A21EA E15NE 1997050800735 19970508 00735 EA 1997 5 8 CA970129004 1 19970115 G 2740 70607 HSTU CNDAIR CL600 CL6002B19 EA GE CF34 CF343A1 30015 NE H STAB TRIM FAILED W O OTHER J WARNING INDICATION CL CLIMB 1 CA 3204 807281 (CAN) AFTER TAKEOFF FLIGHT REPORTED STABILIZER TRIM MESSAGE ON ECAM. HORIZONTAL STABILIZER TRIM UNT (HSTU) REPLACED. 2 L 7 2 4F 4 F RT A21EA E15NE 1997050800736 19970508 00736 WP 1997 5 8 CA970129005 1 19970115 G 2530 CA167072 RECEPTACLE DOUG DC9 DC932 3022066 WP PWA JT8 JT8D7A 52053 NE GALLEY SHORTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA P654065D (CAN) ELECTRICAL SMELL DETECTED IN FLIGHT DECK. MAINTENANCE TROUBLESHOOTING FOUND #4 OVEN RECEPTACLE BURNT. OVEN RECEPTA CLE REPLACED AND CHECKED SERVICEABLE. 2 L 7 2 4F 4 F A6WE E2EA 1997050800745 19970508 00745 NE 1997 5 8 CA970129017 2 19970101 G 7220 FAN BLADES PWA 4056 PW4056 NE #2 ENGINE SHINGLED/DAMAGED W O OTHER E VIBRATION/BUFFET TO TAKEOFF 1 CA P724426 (CAN) HIGH VIBRATION ON #2 ENGINE WITH FAN BLADE SHINGLING. INSPECTION FOUND ALL FAN BLADES SHINGLED, MOST OF THE BLADES HAD EXTENSIVE DAMAGE IN THE SHROUD AREA. THE ENGINE PICKED UP HEAVY SNOW DURING TAKEOFF. ALL FAN BLADES REMOVED. STAGE 2 FAN EXIT VANES AND EXHAUST CHECKED SERVICEABLE. FAN BLADE SET REPLACED. GROUND RUN AND VIBRATION SURVEY CARRIED OUT SE RVICEABLE. 4 F E24NE 1997050800746 19970508 00746 EA 1997 5 8 CA970129018 2 19970123 G 7261 O-RING DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043 EA TRANSFER TUBE LEAKING W E A ENGINE SHUTDOWN UNSCHED LANDING O K OTHER FLUID LOSS CR CRUISE 1 CA PCE40147 (CAN) OIL PRESSURE AND TORQUE FLUCTUATION IN FLIGHT NECESSITIATED ENGINE SHUTDOWN OF #1 ENGINE. POST FLIGHT INSPECTION F OUND AN "O" RING ON THE OIL TRANSFER TUBE AT THE "C" FLANGE WAS WORN FLAT AND LEAKING, CAUSING OIL TO LEAK ON THE EXHAUS T CAN. 1 H 7 2 3T 4 T A9EA E4EA 1997050800749 19970508 00749 NM 1997 5 8 CA970130008 1 19970109 G 2150 AIRCYCLE MACHINE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE AIR COND SEIZED W O H OTHER DEACTIVATE SYST/CIRCUITS B O SMOKE/FUMES/ODORS/SPARKS OTHER CR CRUISE 1 CA 120275 (CAN) PILOT REPORTED AIRCRAFT OPERATING WITH BATTERY ONLY AS AN ELECTRICAL BURNING SMELL WAS NOTED IN THE COCKPIT. MAINT ENANCE FOUND THE AIR CYCLE MACHINE SEIZED. PILOT PROCEDURE IS TO SHUT DOWN BLEED SYSTEMS AND THEN GENERATORS UNTIL SMOKE CLEARS. 2 H 7 2 4T 4 T RT A13NM E20NE 1997050800750 19970508 00750 NM 1997 5 8 CA970130012 1 19970123 G 2761 A44700007 ACTUATOR DOWTY DHAV DHC8 DHC8101 2809002 NM LH INB SPOILER JAMMED W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA 9661 1743 (CAN) AFTER LIFT OFF THE CREW EXPERIENCED A LEFT WING DOWN ROLL, AND INPUT OPPOSITE WHEEL FORCE TO CORRECT. AN EMERGENCY DECLARED AND AIRCRAFT LANDED OK. ON GROUND THE CREW NOTED THAT THE LEFT HAND INBOARD ROLL SPOILER INDICATION ON THE PFC S INDICATOR, SHOWING SOME UP DEFLECTION. GROUND CREW CONFIRMED THAT THE LH INBOARD ROLL SPOILER ACTUATOR WAS JAMMED IN T HE MID POSITION AND WOULD NOT RETRACT. ACTUATOR SENT TO DOWTY FOR STRIP DOWN. 2 H 7 2 4T RT A13NM 1997050800751 19970508 00751 EA 1997 5 8 CA970130013 2 19970119 G 7414 1038255514 MAGNETO BENDIX O4RN2000 CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL DIST GEAR BROKEN TEETH W A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 CA 700 L830076T 731179 (CAN) SHORTLY AFTER TAKEOFF THE ENGINE BEGAN TO RUN ROUGH AND LOSE POWER. AIRCRAFT RETURNED TO BASE. RUN UP THE FOLLOWIN G DAY REVEALED THE LEFT MAGNETO WAS DEAD. DISASSEMBLY OF THE MAGNETO REVEALED BROKEN TEETH ON THE DISTRIBUTOR GEARS. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 1997050800752 19970508 00752 GL 1997 5 8 CA970130014 3 19970122 G 6111 900H1316E BLADE MCAULY 2D34C B2D34C214 GL BLADE AIRFOIL DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 918 (CAN) HEAVY STONE DAMAGE TO LEADING EDGE ON PROPELLER FACE SIDE. 5 C P7EA 1997050800753 19970508 00753 EA 1997 5 8 CA970130017 1 19970124 G 2730 C3CF1957 CONTROL CABLE DHAV DHC3 DHC3 2800202 EA PWA R1340 R134059 52016 NE STA.308 FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA 9594 (CAN) AS A RESULT OF THE ELEV CABLE RUBBING ON THE PULLEY SOME CABLE STRANDS WERE BROKEN. 1 H 7 1 3R 3 R A815 5E2 1997050800754 19970508 00754 EA 1997 5 8 CA970130018 1 19970124 G 2720 C3CF1975 CONTROL CABLE DHAV DHC3 DHC3 2800202 EA PWA R1340 R134059 52016 NE STA.60 FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA 9594 (CAN) RUDDER CABLE FRAYED AT TWO PLACES, ON THE RUDDER QUADRANT AND ON A PULLEY TWO FEET AFT. 1 H 7 1 3R 3 R A815 5E2 1998040200034 19980402 00034 CE 1998 4 2 CA970130019 1 19970117 G 2910 651713670 HYD LINE CESSNA 500 560CESSNA 2076750 CE RESERVIOR RETURN CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA 1430 (CAN) DURING A PHASE 3 INSPECTION, A GROUNDING STRAP (P/N 047-5824-01) OF KHF950 AMPLIFIER (NOT INSTALLED) WAS FOUND TO BE LOOSE AND CHAFING THE HYDRAULIC RESERVOIR RETURN LINE. LINE CHAFED APPROX 75 PER CENT THROUGH THE WALL THICKNESS. G ROUNDING STRAP SECURED PROPERLY AND LINE REPLACED. PART TC: 1,149. 2 L 7 2 4F RT A22CE 1997050800755 19970508 00755 NE 1997 5 8 CA970130020 2 19970121 G 7250 311260201 TURBINE BLADES PWA PW121 PW121 52124 NE AIRFOIL FRACTURED W K NONE O OTHER IN INSP/MAINT 1 CA 17523 13037 120518 (CAN) THE ENGINE HAD SUFFERED FRACTURE OF TWO LP TURBINE BLADES. 4 T E20NE 1997050800756 19970508 00756 CE 1997 5 8 CA970130022 1 19970122 G 5610 1143840202 WINDSHIELD BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA COCKPIT RT CRACKED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA PCE32052 (CAN) PLANE WAS AT 24,000 FEET CRUISING ALTITUDE WHEN R/H WINDSHIELD CRACKED IN PIECES. AIRCRAFT MADE AN UNSCHEDULED, SA FE, LANDING FOR REPAIR. 2 L 7 2 4T 4 T RT A24CE E4EA 1997050800757 19970508 00757 GL 1997 5 8 CA970131002 3 19970123 G 6111 F76632R PROP BLADE HARTZL HCC3Y PHCC3YF1 GL LE FACE SIDE STONE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 219 FE1345 (CAN) INSPECTION FOUND LIGHT STONE DAMAGE TO THE LEADING EDGE OF THE PROPELLER FACE SIDE. 5 C P25EA 1997050800758 19970508 00758 EA 1997 5 8 CA970131004 1 19970123 G 3230 SWITCH CNDAIR CL600 CL6002B19 EA GE CF34 CF343A 30015 NE NOSE GEAR BENT W O OTHER O OTHER CL CLIMB 1 CA 5480 807157 (CAN) GEAR DISAGREEMENT ON TAKEOFF. GEAR CYCLED TWICE, SAME INDICATION. NOSE GEAR SHOWED DOWN DOOR OPEN. GEAR EXTENDED, 3 GREEN LIGHTS. FOUND NOSE GEAR EXTEND PROXIMITY SWITCH BENT AWAY FROM TARGET. 2 L 7 2 4F 4 F RT A21EA E15NE 1997050800759 19970508 00759 EU 1997 5 8 CA970131005 1 19970124 G 3213 GEAR AIRBUS 320 A320211 3930320 EU MLG LOW INFLATION W O OTHER J WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER TAKEOFF, LANDING GEAR SHOCK ABSORBER FAULT CAME ON. LANDING GEAR WOULD NOT RETRACT. INVESTIGATION REVEALED B OTH MAIN LANDING GEAR OLEOS INFLATION WERE LOW. BOTH GEARS SERVICED AND CHECKED SERVICEABLE. 2 L 7 2 4F RT A28NM 1997050800760 19970508 00760 NM 1997 5 8 CA970203001 1 19970108 G 7500 CABIN DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE BLEED AIR SMOKE W O OTHER B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA 19190 120854 (CAN) REPEAT OF PREVIOUS SMOKE IN CABIN PROBLEM. AFTER BLEEDS SELECTED ON #1 ENGINE THE CABIN FILLED WITH SMOKE. THIS TI ME OIL WAS FOUND IN THE ENGINE BLEED AIR SYSTEM. 2 H 7 2 4T 4 T RT A13NM E20NE 1997050800761 19970508 00761 1997 5 8 CA970203003 4 19970121 G 2200 FLIGHT RECORDER AIRBUS 320 A320211 3930320 EU AUTOLAND INOPERATIVE W H DEACTIVATE SYST/CIRCUITS N FALSE WARNING LD LANDING 1 CA (CAN) AUTOLAND WITH 5 KTS TAILWIND CAUSED HEAVY LANDING. AIRBUS ADVISED AND REPLIED WITH CAUSE FROM DOWNLOADED DFDR INFO INCLUDING SIDE WIND FACTORS NOT REPORTED AT TIME OF INCIDENT. ALL AUTOLANDS SUSPENDED UNTIL FURTHER NOTICE. 2 L 7 2 4F RT A28NM 1997050800762 19970508 00762 EA 1997 5 8 CA970203006 1 19970116 G 2910 AN62074 CHECK VALVE PARKER DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043 EA FLAPS LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 331 PCE42076 (CAN) DURING PREFLIGHT THE HYDRAULIC SYSTEM FOUND TO CYCLE DUE TO LOW PRESSURE. FLAP CHECK VALVE FOUND LEAKING. 1 H 7 2 3T 4 T A9EA E4EA 1997061900510 19970619 00510 1997 6 19 CA970203007 4 19970123 G 3416 265411 COUNTER BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE ALTIMETER STICKING W K NONE O OTHER IN INSP/MAINT 1 CA P653620B (CAN) DURING BI-ANNUAL CALIBRATION IT WAS IDENTIFIED THAT THE COUNTER IN THE ALTIMETER WAS CAUSING THE INSTRUMENT TO STI CK AT VARIOUS ALTITUDES. REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 1997050800764 19970508 00764 CE 1997 5 8 CA970203010 1 19970124 G 5210 1014301071 CHANNEL BEECH 1014301071 BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA CABIN DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 12865 PCE80204 (CAN) WITH CABIN DOOR OPEN, A CRACK WAS FOUND IN THE UPPER FRAME MEMBER. THE CRACK WAS APPROXIMATELY 6 INCHES LONG, ALON G THE DOOR HINGE RIVET LINE, RUNNING FROM THE AFT EDGE FORWARD. 1 L 7 2 4T 4 T A24CE E4EA 1997051900001 19970519 00001 NE 1997 5 19 CA970203011 2 19970124 G 7240 RK47289 COMB CHAMBER BRAERO 748 HS7482B 1500248 EU RROYCE DART DART5352 54509 NE NOSE CONE BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 19460 1860 (CAN) DURING INSPECTION THE NOSE CONE OF ONE OF THE COMBUSTION CHAMBERS WAS FOUND BROKEN AWAY FROM THE COMBUSTION CHAMBE R BODY. 2 L 7 2 3T 4 T A24EU E297 1997050800765 19970508 00765 EA 1997 5 8 CA970203012 1 19970124 G 3020 7SC0058012 DE-ICER BOOT BFGOODRICH DHAV DHC7 DHC7102 2802708 EA PWA PT6 PT6A50 52043 EA HAMSTD 24PF 24PF305 GL #4 NACELLE SEPARATED W K NONE O OTHER IN INSP/MAINT 1 CA PCE86302 237483 (CAN) AFTER LANDING AND DURING WALKAROUND BEFORE TURN AROUND, PILOT NOTICED OUTBOARD OF #4 NACELLE BOOT MISSING. BOOT FO UND ON BUTTON OF RUNWAY. 2 H 7 4 4T 4 T A20EA E4EA 6 C P1NE 1997051500277 19970515 00277 EU 1997 5 15 CA970203013 1 19970124 G 2913 6506606 HYD PUMP AIRBUS 310 A310324 3930206 EU PWA 4152 PW4152 NE #1 SYSTEM SHEARED SPLINE W H DEACTIVATE SYST/CIRCUITS K FLUID LOSS CR CRUISE 1 CA 717722 (CAN) GREEN HYDRAULIC SYSTEM DEPLETED IN FLIGHT. GROUND INSPECTION FOUND THE #1 GREEN SYSTEM ENGINE DRIVEN PUMP (EDP) D RIVE SHAFT HAD SHEARED INTERNALLY. PUMP CASE LEAKED, CAUSING LOSS OF GREEN SYSTEM HYDRAULIC FLUID. 2 L 7 2 4F RT A35EU E24NE 1997051500278 19970515 00278 NE 1997 5 15 CA970203015 2 19970119 G 7200 ENGINE BOEING 727 727277 138408S NM PWA JT8 JT8D17A 52049 NE #3 ENGINE FAILED W D RETURN TO BLOCK K O FLUID LOSS OTHER NR NOT REPORTED 1 CA 10955 3794 P709477 (CAN) ON #3 ENGINE START N2 IMMEDIATELY ROSE TO 35 PERCENT THEN DROPPED TO 30 PERCENT AND FLUCTUATED. NO N1 ROTATION. OI L QUANTITY DROPPED TO ONE GALLON. ENGINE REPLACED. 2 L 7 3 4F 4 F RT A3WE E2EA 1997051500280 19970515 00280 WP 1997 5 15 CA970204002 1 19970122 G 3260 902624917 ANNUNCIATR PANEL CVAC 440 440 2422902 WP ALLSN 501D 501D13 03004 GL LT MLG INDICATIO LOOSE WIRE W O OTHER P NO WARNING INDICATION LD LANDING 1 CA 501795 (CAN) LEFT HAND MAIN LANDING GEAR DID NOT INDICATE DOWN AND LOCKED. MAINTENANCE TROUBLESHOOTING REVEALED A LOOSE WIRE ON THE REAR OF THE LH LANDING GEAR DOWN (GREEN) LIGHT SOCKET. WIRE REPAIRED. 2 L 7 2 4R 4 T 6A6 E282 1997051500281 19970515 00281 EA 1997 5 15 CA970204004 1 19970126 G 3260 SENSOR CNDAIR CL600 CL6002B19 EA GE CF34 CF343A 30015 NE NOSE LANDNG GEAR OUT OF ADJUST W K NONE O OTHER CL CLIMB 1 CA 2364 807337 (CAN) NOSE LANDING GEAR FAILED TO RETRACT ON TAKEOFF. NOSE GEAR PROXIMITY SENSOR ADJUSTED. 2 L 7 2 4F 4 F RT A21EA E15NE 1997051500282 19970515 00282 NE 1997 5 15 CA970204005 2 19970123 G 7250 MS969611 BOLT PWA 118 PW118 NE INTERSTAGE CASE FRACTURED W K NONE O OTHER IN INSP/MAINT 1 CA 11982 115571 (CAN) THE ENGINE WAS SENT FOR A SCHEDULED OVERHAUL. UPON DISASSEMBLY IT WAS DISCOVERED THE ENGINE HAD POWER TURBINE DAMA GE RESULTING FROM AN INTERSTAGE CASE BOLT FAILURE. THE ENGINE WAS PRE MOD 21175 AND THE LIBERATED BOLT HEAD INFLICTED IM PACT DAMAGE TO ALL THE 1ST STAGE PT ROTOR BLADES AND TO THE 2ND STAGE PT STATOR LOCKING LUGS. SECONDARY DAMAGE FROM PIEC ES OF DAMAGED PT1 BLADES WAS ALSO SUSTAINED BY THE PT STATOR AIRFOILS AND THE PT2 BLADE LEADING EDGES. IT IS THOUGHT THA T CORROSION OF THE BOLT BELOW THE HEAD COUPLED WITH SOME FLANGE CORROSION LEAD TO THE FRACTURE OF THE BOLT. 4 T E20NE 1997051500283 19970515 00283 CE 1997 5 15 CA970206001 1 19970124 G 7810 EXHAUST DUCT BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA AT #3 BEARING BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 3950 PCE50550 (CAN) DURING TROUBLESHOOTING OF HIGH OIL PRESSURE PROBLEM, NOTED OIL STAIN AND SMELL. FURTHER INSPECTION FOUND EXHAUST D UCT BROKEN AWAY AT #3 BEARING COVER. POWER SECTION SENT FOR REPAIR. 1 L 7 2 3T 4 T A14CE E4EA 1997051500284 19970515 00284 EU 1997 5 15 CA970206002 1 19970127 G 7700 M2217BB THRUST METER FOKKER F28 F28MK1000 4990808 EU RROYCE SPEY SPEY55515 54521 EU NR 1 ENG STUCK W C D ABORTED TAKEOFF RETURN TO BLOCK O OTHER TO TAKEOFF 1 CA 7853 140 9111 (CAN) CREW REJECTED TAKEOFF DUE TO #1 ENGINE THRUST INDEX ON LEFT HAND THRUST METER BEING STUCK AT 85 PERCENT AND UNABLE TO ADJUST. AIRCRAFT RETURNED TO BASE AND THE THRUST INDICATOR WAS REPLACED. 2 L 7 2 4F 4 F RT A20EU E2EU 1997051500285 19970515 00285 EU 1997 5 15 CA970206003 2 19970120 G 7320 CASC211 REGULATOR FOKKER F28 F28MK1000 4990808 EU RROYCE SPEY SPEY55515 54521 EU #2 ENG FUEL FLOW FAULTY W C D ABORTED TAKEOFF RETURN TO BLOCK E J VIBRATION/BUFFET WARNING INDICATION TO TAKEOFF 1 CA 4227 2584 9279 (CAN) ON TAKEOFF ROLL THE #2 ENGINE DID NOT PRODUCE TAKEOFF RATED THRUST. THE TAKEOFF WAS REJECTED. MAINTENANCE FOUND TH E PROBLEM TO BE AN AIR LEAK. CORR UJOINT AND 3 GASKETS WERE REPLACED ON THE #2 ENGINE FUEL FLOW REGULATOR AT THE P3 CONN ECTION. ENGINE WAS GROUND RUN SERVICEABLE AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A20EU E2EU 1997051500286 19970515 00286 EA 1997 5 15 CA970206004 1 19970122 G 3010 MS33205 CIRCUIT BREAKER DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE ELEV HORN HEAT FAILED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 123192 (CAN) PILOT NOTED THAT THE LEFT ELEVATOR HORN HEAT CAUTION LIGHT CAME ON. HORN CIRCUIT BREAKER WAS FOUND UNSERVICEABLE. 2 H 7 2 4T 4 T RT A13NM E20NE 1997051500287 19970515 00287 GL 1997 5 15 CA970206005 3 19970127 G 6110 PROPELLER CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO MCAULY D3A34 D3A34C404 GL BALANCE HIGH VIBRATION W K NONE E VIBRATION/BUFFET CR CRUISE 1 CA 13 291253R 529A (CAN) HARTZELL PROPELLER INSTALLED AS PER STC #SA685AL. TROUBLESHOT VIBRATION SINCE INSTALLATION. INSTALLED SECOND PROP AND DID DYNAMIC BALANCE, THIS CHANGED THE POSITION OF VIBRATION. REMOVED PROP AND INSTALLED ZERO TIME MCCAULEY PROP. VIB RATION GONE. 1 H 7 1 3O 3 O A4CE E5CE 5 C P47GL 1998041700423 19980417 00423 WP 1998 4 17 CA970206006 2 19970129 G 7314 307085046 FUEL PUMP BRAERO DH125 HS125700A 4230170 EU GARRTT TFE731 TFE7313R 01518 WP ENGINE FAILED W E ENGINE SHUTDOWN X ENGINE FLAMEOUT IN INSP/MAINT 1 CA 4573 P84447 (CAN) ENGINE DRIVEN FUEL PUMP HAD NO OUTPUT PRESSURE, UNABLE TO GET START AFTER ENGINE SPOOLED DOWN FROM IDLE. TEAR DOW N REPORT REVEALED DAMAGED BEARING AT VANE STAGE WITH METAL IN UNIT AND ROTOR SMEARED. PART TC: 3,248. 2 L 7 2 4F 4 F A3EU E6WE 1997051500288 19970515 00288 EU 1997 5 15 CA970206008 1 19970108 G 2910 NOR407S VALVE BODY A24518001 AMD FALC50 FALCON50MYST 2730106 EU NR 1 HYD SYS MISSING W K NONE K FLUID LOSS CR CRUISE 1 CA 1857 (CAN) AIRCRAFT LANDED WITH A COMPLETE LOSS OF #1 HYDRAULIC SYSTEM. PRESSURE REDUCING VALVE BODY FOUND CRACKED AND LEAKIN G HYDRAULIC FLUID. TEAR DOWN INSPECTION OF VALVE FOUND BALL BEARING MISSING. 2 L 7 3 4F A46EU 1997051500290 19970515 00290 CE 1997 5 15 CA970206013 1 19970109 G 8011 64150020 STARTER CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO DRIVE STRIPPED W K NONE O OTHER IN INSP/MAINT 1 CA 387 254684H (CAN) STARTER WOULD NOT ENGAGE. FAULTY STARTER CLUTCH DAMAGED STARTER DRIVE. 1 H 7 1 3O 3 O 3A19 E252 1997051500291 19970515 00291 EA 1997 5 15 CA970206014 2 19970123 G 7261 O-RING DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043 EA C FLANGE WORN W E A ENGINE SHUTDOWN UNSCHED LANDING O OTHER CR CRUISE 1 CA PCE40147 (CAN) "O" RING ON THE OIL PRESSURE TRANSFER TUBE AT THE "C" FLANGE WAS FOUND WORN FLAT IN ONE AREA, CAUSING OIL TO LEAK OUT ON TO THE EXHAUST CAN. THIS CAUSED A FLUCTUATION IN OIL PRESSURE AND TORQUE PROMOTED THE PILOT TO DO A PRECAUTIONARY SHUTDOWN AND RETURN TO BASE. 1 H 7 2 3T 4 T A9EA E4EA 1997051500292 19970515 00292 NE 1997 5 15 CA970206019 2 19970126 G 7220 FAN LKHEED 1011 1011385114 WP RROYCE RB211 RB21122B02 54555 NE #3 ENGINE SEIZED W K NONE O OTHER IN INSP/MAINT 1 CA 38292 3239 10321 (CAN) NO N1 ROTATION DURING START OF #3 ENGINE. LP FAN FOUND SEIZED. ENGINE REPLACED. 2 L 7 3 4F 4 F A23WE E12EU 1997051500293 19970515 00293 EA 1997 5 15 CA970206020 2 19970131 G 7314 27720007 FUEL PUMP SUNDSTRAND BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA DRAIN PIPE LEAKING W K NONE K FLUID LOSS LD LANDING 1 CA 4505 PE1416 CPPS61075 (CAN) AFTER TEST FLIGHT FOLLOWING 600 HOUR INSPECTION FUEL WAS SEEN COMING FROM THE DRAIN AT THE BOTTOM OF THE ENGINE. I NSPECTION FOUND THE FUEL WAS COMING FROM THE PIPE THAT DRAINS THE AUTOMATIC FUEL CONTROL SEAL. CLOSER INVESTIGATION FOUN D THE ENGINE DRIVEN FEUL PUMP WAS LEAKING AND THE DRAIN FOR THE FUEL SEAL WAS BLOCKED CAUSING FUE TO EVACUATE FROM THE A FCU SEAL. BOTH THE FUEL CONTROL AND THE FUEL PUMP WERE REPLACED. 1 G 7 1 4U 4 U H4SW E22EA 1997051500294 19970515 00294 EU 1997 5 15 CA970206021 2 19970131 G 7250 BLADE FOKKER F28 F28MK1000 4990808 EU RROYCE SPEY SPEY55515 54521 EU #2 ENG LP TURB MISSING W A E ENGINE SHUTDOWN E VIBRATION/BUFFET CL CLIMB 1 CA 29600 27348 9299 (CAN) DURING CLIMB THROUGH FL270 THE CREW HEARD A "BANG" AND FELT A VIBRATION FROM #2 ENGINE, WHILE THE ENGINE WAS STILL MAKING POWER. AIRCRAFT RETURNED TO THE POINT OF DEPARTURE. INITIAL INSPECTION REVEALED A LOW PRESSURE TURBINE BLADE MIS SING. THIS ENGINE SUFFERED A SIMILAR FAILURE ON 5 JANUARY 1990. THERE IS NO RECORD OF AN SDR AT THAT OCCURRENCE. 2 L 7 2 4F 4 F RT A20EU E2EU 1997051500295 19970515 00295 NE 1997 5 15 CA970206022 2 19970129 G 7230 311161801 BEARING PWA 120 PW120A NE HP ROTOR FAILED W E ENGINE SHUTDOWN O OTHER CR CRUISE 1 CA 16992 120767 (CAN) ENGINE WAS SENT FOR REPAIR AFTER A LOSS OF OIL PRESSURE AND AN INFLIGHT SHUTDOWN. METAL WAS FOUND IN THE REDUCTION GEARBOX, OIL FILTERS, CHIP DETECTORS. DISASSEMBLY OF THE ENGINE REVEALED TWO FAILURES, THE #4 BEARING AND THE AC GENERA TOR. IT IS THE OPINION OF THE R&O SHOP THAT THE FAILURE OF THE #4 BEARING WAS THE CAUSE OF THE AC GENERATOR FAILURE. 4 T E20NE 1997051500296 19970515 00296 NM 1997 5 15 CA970210004 1 19970123 G 2720 CIRCUIT BREAKER DHAV DHC8 DHC8202 2809007 NM RUD CONTROL FAILED W A UNSCHED LANDING J WARNING INDICATION TO TAKEOFF 1 CA (CAN) ON TAKEOFF AND ACCELERATING THROUGH APPROXIMATELY 140 KIAS, THE RUDDER PRESSURE AND RUDDER FULL PRESSURE AND #1 RU DDER HYDRAULIC WARNING LIGHTS CAME ON. ON DECELERATION THROUGH APPROXIMATELY 140 KIAS, THE WARNING EXTINGUISHED. LANDED OK. FAULTY CIRCUIT BREAKER FOUND. 2 H 7 2 4T RT A13NM 1997061900522 19970619 00522 CE 1997 6 19 CA970211001 1 19970131 G 3240 124K0016CL0150 HOSE BFGOODRICH 215297 CESSNA 500 560CESSNA 2076750 CE RT BRAKE LEAKING W L ABORTED APPROACH L NO TEST AP APPROACH 1 CA 1245 (CAN) PILOT CONFIRMED NO BRAKE PEDAL PRESSURE. LONG LANDING CARRIED OUT SAFELY. INSPECTION FOUND A LEAK OF HYDRAULIC FLU ID FROM UNDER THE HOSE COVER APPROXIMATELY 1 INCH FROM THE SWAGE FITTING ON THE RIGHT HAND BRAKE FLEX HOSE. NEW HOSE INS TALLED. 2 L 7 2 4F RT A22CE 1997051500299 19970515 00299 SO 1997 5 15 CA970211002 1 19970202 G 8120 4067870010 TURBINE SHAFT AIRESEARCH 4091709001R PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA ENG TURBO SHEARED W E ENGINE SHUTDOWN J K WARNING INDICATION FLUID LOSS CR CRUISE 1 CA 3 ZGO29356 L216068A (CAN) TURBOCHARGER WAS INSTALLED AS PART OF AN OVERHAULED ENGINE. TURBOCHARGER WAS PREOILED AND GROUND RUNS WERE SATISFA CTORY. TWO TRAINING FLIGHTS WERE CARRIED OUT PRIOR TO THE FAILURE. PILOT REPORTED FLUCTUATING OIL PRESSURE AND SHUT THE ENGINE DOWN. POST FLIGHT INVESTIGATION FOUND THE TURBINE SHAFT HAD SHEARED ALLOWING THE COMPRESSOR TO DESTROY ITSELF. 1 L 7 2 3O 3 O A20SO E14EA 1997051500300 19970515 00300 NE 1997 5 15 CA970211004 2 19970204 G 7322 32447593 FUEL CONTROL CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE #1 ENGINE FAULTY W A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CR CRUISE 1 CA 71718 (CAN) DURING CRUISE FLIGHT THE #1 ENGINE ROLLED BACK FROM CRUISE POWER TO APPROXIMATELY 80 PERCENT N2 AT FL390. AFTER LA NDING THE "O" RINGS IN THE P3 PLUMBING WAS REPLACED AND THE ENGINE GROUND RUN SERVICEABLE. FOLLOWING DAY THE SAME PROBLE M RECURRED AND THE FUEL CONTROL UNIT WAS REPLACED. THE ENGINE RUN AND TEST FLIGHT WERE CARRIED OUT SERVICEABLE AND THE A IRCRAFT RETURNED TO SERVICE. 1 L 7 2 4F 4 F A22CE E1NE 1997051500301 19970515 00301 NM 1997 5 15 CA970211005 1 19970202 G 3220 NOSE GEAR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HYD SYS SLOW TO EXTEND W K NONE O OTHER DE DESCENT 1 CA 120542 (CAN) ON DESCENT NOSE GEAR SLOW TO EXTEND, BUT FINALLY INDICATED DOWN AND LOCKED. EXCESSIVE AMOUNT OF AIR FOUND IN HYDRA ULIC SYSTEM FROM MAINTENANCE ON PREVIOUS DAY (NOSE GEAR HAD BEEN REPLACED THE DAY BEFORE). 2 H 7 2 4T 4 T RT A13NM E20NE 1997051500302 19970515 00302 EU 1997 5 15 CA970211006 2 19970201 G 7260 DRIVE BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU ACCESSORY GEARBX FAILED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA 5919 7344 (CAN) AIRCRAFT WAS IN CRUISE FLIGHT WHEN THE PILOT REPORTED LOSS OF ACCESSORY GEARBOX ON #1 ENGINE. POST FLIGHT INSPECTI ON FOUND THE #1 ENGINE INTERNAL DRIVE FOR THE ACCESSORY GEARBOX FAILED, RESULTING IN METAL CONTAMINATION OF THE LUBRICAT ION SYSTEM. THE CONTAMINATION WAS WIDESPREAD AFFECTING ALL MAIN LINE BEARINGS, REDUCTION GEAR LAYSHAFTS AND PROPSHAFT, A S WELL AS OIL PUMPS AND LOWER BEVEL DRIVES. 2 L 7 2 3T 4 T A24EU A196 1997051500303 19970515 00303 SO 1997 5 15 CA970212003 1 19970204 G 3220 9582900 LINK ASSY PIPER PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360EB 17025 SO MCAULY NLG BROKEN W K NONE O OTHER LD LANDING 1 CA 5737 307973H (CAN) AIRCRAFT WAS ON A PILOT TRAINING FLIGHT. PILOT SELECTED GEAR DOWN AND THE SYSTEM INDICATED DOWN AND LOCKED. 3 GR EEN AND VISUAL IDENT THROUGH THE SIDE MIRROR. UPON TOUCHDOWN THE NOSE GEAR COLLAPSED. AWAITING FURTHER INFORMATION. 1 L 7 2 3O 3 O A7SO E9CE 1997051500304 19970515 00304 CE 1997 5 15 CA970212004 1 19970127 G 3411 STATIC TUBE CESSNA 414 414 2075908 CE CONT O520 TSIO520N 17040 SO MCAULY TAIL STATIC PORT SPLIT W K NONE O OTHER IN INSP/MAINT 1 CA 503283 (CAN) SUSPECT WATER IN THE LINE, BETWEEN THE STATIC PORT AND THE SUMP, FROZE AND SPLIT THE PIPE. 1 L 7 2 3O 3 O RT A7CE E8CE 1997051500305 19970515 00305 EA 1997 5 15 CA970212008 2 19970130 G 7322 CARBURETOR CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA ENGINE ICING W A B E UNSCHED LANDING EMER. DESCENT ENGINE SHUTDOWN E VIBRATION/BUFFET CR CRUISE 1 CA L243976 (CAN) THE AIRCRAFT WAS FLYING IN -30 DEGREES CELCIUS TEMPERATURE. AFTER 30 MINUTES OF FLIGHT THE ENGINE QUIT. THE PILOT MANUALLY PRIMED THE ENGINE AND IT RAN AFTER EACH SHOT. POST FLIGHT INSPECTION OF THE CARBURETOR AND FILTER FOUND MANY WA TER DROPLETS. IT IS CONCLUDED WATER IN THE FUEL, PERHAPS THROUGH CONDENSATION, CAUSED CARBURETOR ICING. 1 H 7 1 3O 3 O NT 3A12 E274 1997051500306 19970515 00306 EA 1997 5 15 CA970213008 2 19970207 G 7532 310082903 BLEED VALVE DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043 EA COMPRESSOR ORIFICE DIRTY W K NONE O OTHER IN INSP/MAINT 1 CA 1174 9E551 PCE42076 (CAN) DURING START THE #2 ENGINE TEMPERATURE WAS HOTTER THAN #1 ENGINE. THE COMPRESSOR BLEED VALVE WAS CHANGED AND DURIN G SUBSEQUENT STARTS THE TEMPERATURE WAS COOLER. TREND MONITORING CONFIRMED THE COOLER OPERATION. 1 H 7 2 3T 4 T A9EA E4EA 1997051500307 19970515 00307 1997 5 15 CA970213009 4 19970207 G 3444 2300303000 DRIVE MOTOR COLLINS 6221204002 DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043 EA RADIO ALT INTERMITTENT W H DEACTIVATE SYST/CIRCUITS O OTHER CL CLIMB 1 CA 691 PCE42076 (CAN) DURING TAKEOFF ROTATION THE RADIO ALTIMETER WOULD FLAG AND NOT REACTIVATE UNTIL 25 TO 30 MINUTES LATER. SYSTEM DEA CTIVATED. DRIVE MOTOR ASSEMBLY IN THE INDICATOR WAS FAULTY. 1 H 7 2 3T 4 T A9EA E4EA 1997051500308 19970515 00308 EA 1997 5 15 CA970213012 2 19970211 G 7261 3020958 RELIEF VALVE 3026887 BEECH 99 B99 1154004 CE PWA PT6 PT6A27 52043 EA OIL SYSTEM SCORED W C E ABORTED TAKEOFF ENGINE SHUTDOWN O OTHER TO TAKEOFF 1 CA 40919 (CAN) ON TAKEOFF THE AIRCRAFT EXPERIENCED A MAJOR YAW TO THE LEFT. THE YAW WAS OF A SURGING NATURE AND THE LEFT HAND ENG INE WAS SHUTDOWN. THE AIRCRAFT RETURNED TO ITS DEPARTURE POINT. POST FLIGHT INSPECTION FOUND THE PRESSURE REGULATOR HAD EXCESSIVE SCORING ON THE SEAT FACE.THE SEAT WAS REPLACED AND THEAIRCRAFT WAS GROUND RUN SERVICEABLE AND THE AIRCRAFT RET URNED TO SERVICE. 1 L 7 2 3T 4 T A14CE E4EA 1997051500309 19970515 00309 NE 1997 5 15 CA970213013 2 19970205 G 7250 310750201 BLADE PWA PW120 PW123 NE LP TURBINE FRACTURED W O OTHER O OTHER NR NOT REPORTED 1 CA 6094 123189 (CAN) THE ENGINE WAS SENT FOR REPAIR AFTER THE OPERATOR REPORTED AN LP TURBINE BLADE FAILURE. DISASSEMBLY OF THE ENGINE FOUND THE LP TURBINE BLADE FAILURE WAS CAUSED BY CORROSION IN THE CORE POCKETS OF 3 LP TURBINE BLADES. SECONDARY DAMAGE FROM THE FAILURE CAUSED DAMAGE TO THE 1ST AND 2ND STAGE PT BLADES; THE 1ST AND 2ND STAGE PT STATORS; THE REMAINING LP TU RBINE BLADES; THE LP SHROUD SEGMENTS AND THE LP STATOR. THE #3 AND #6 BEARINGS WERE SCRAPPED AS A PRECAUTION. 4 T E20NE 1997051500310 19970515 00310 NE 1997 5 15 CA970217001 2 19970207 G 7210 310119101 BEARING PWA 120 PW120A NE RED GRBX NR 10 SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 10334 120225 (CAN) THE REDUCTION GEARBOX WAS SENT FOR INVESTIGATION OF METAL CONTAMINATION AND OVERHAUL. DISASSEMBLY OF THE RED GB RE VEALED THE SOURCE OF THE METAL CONTAMINATION WAS A SPALLED #10 BEARING. THIS BEARING IS A LIFED ITEM AND IT IS THE OPINI ON OF THE REPAIR SHOP THAT THIS BEARING FAILED AT REACHING THE END OF ITS LIFE. 4 T E20NE 1997051500313 19970515 00313 WP 1997 5 15 CA970218001 1 19970131 G 2750 BOLT DOUG DC9 DC932 3022066 WP PWA JT8 JT8D7 52053 NE FLAP CONTROL LOOSE W A O OTHER F FLT CONT AFFECTED AP APPROACH 1 CA P654059D (CAN) UNABLE TO RETRACT FLAPS TO LESS THAN 15 DEGREES DUE TO FLAP LEVER JAMMING. TROUBLESHOOTING REVEALED FLAP CONTROL L EVER INTERFERENCE CAUSED BY LOOSE BOLT. BOLT TIGHTENED AND LEVER MECHANISM OPERATED NORMALLY CHECKED SERVICEABLE. 2 L 7 2 4F 4 F A6WE E2EA 1997051500314 19970515 00314 EA 1997 5 15 CA970218002 1 19970130 G 3260 BRACKET CNDAIR CL600 CL6002B19 EA GE CF34 CF343A1 30015 NE NLG PROX SWITCH WORN W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 3984 807194 (CAN) ON DEPARTURE CREW GOT AN AURAL MESSAGE AND AN EICAS MESSAGE. GEAR DISAGREE, NOSE DOOR OPEN. CENTERING TARGET LOOKE D WORN. PROXIMITY SWITCH S23 BRACKET REPLACED. 2 L 7 2 4F 4 F RT A21EA E15NE 1997051500315 19970515 00315 NE 1997 5 15 CA970218003 2 19970210 G 7250 50062201 TIEBOLT PWA JT9 JT9D7R4D 52054 NE LP TURBINE FRACTURED W K NONE O OTHER IN INSP/MAINT 1 CA 15602 107J (CAN) THE ENGINE WAS SENT FOR REPAIR AFTER OIL WAS FOUND IN THE EXHAUST. DURING DISASSEMBLY IT WAS FOUND THAT THE 3RD ST AGE TURBINE TIE BOLT HAD FRACTURED. SECONDARY DAMAGE CAUSED BY THE TIE BOLT FAILURE WAS THE HP TURBINE FRONT HUB; LP TUR NBINE STAGES 3,4,5 WERE SCRAPPED. THE #3 AIRSEAL WAS REPAIRED. 4 F E3NE 1997051500316 19970515 00316 SW 1997 5 15 CA970219003 1 19970115 G 2820 206061667001 TUBE ASSEMBLY BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL FUEL SYS CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 90 CAE821536 (CAN) ALUMINUM MAIN FUEL SYSTEM SUPPLY TUBE HAS A STEEL SLEEVE BETWEEN THE "B" NUT AND THE TUBE (FLARE), THIS SLEEVE WAS FOUND BADLY CORRODED. THE TUBE FLARE AND ADJOINING FITTING WERE ALSO CORRODED ALMOST TO THE POINT OF FAILING. 1 G 7 1 3U 3 U H2SW E4CE 1997051500317 19970515 00317 1997 5 15 CA970219005 4 19970209 G 6113 4393308 BULKHEAD PIPER PA31 PA31350 7103110 SO HARTZL HCE3Y HCE3YR2A GL PROP SPINNER BROKEN W K NONE O OTHER CR CRUISE 1 CA 1566 DJ7957 (CAN) WHILE INITIATING DESCENT THE PILOT NOTICED A CHANGE IN THE PROFILE OF THE PROPELLER SPINNER (NOSE). AFTER LANDING HE INSPECTED THE PROPELLER AND SPINNER AND FOUND THE BULKHEAD BROKEN. MAINTENANCE INSTALLED A NEW BULKHEAD ASSEMBLY AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1 L 7 2 3O A20SO 5 C P33EA 1997051500318 19970515 00318 SW 1997 5 15 CA970219006 1 19970205 G 2710 2770018011 CONTROL CABLE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL AILERON FRAYED W A K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 CA 1447 44131C 108152 (CAN) WHILE COMPLYING WITH FAIRCHILD 'B' INSPECTION, LEFT AILERON CONTROL CABLE WAS FOUND WITH THREE BROKEN STRANDS WHER E THE CABLE RUNS THROUGH THE PHENOLIC GUIDE BLOCK ATTACHED TO THE FUSELAGE BULKHEAD AT STATION 227-271. FAA AD 87-02-02 CALLS FOR CHECKS EVERY 400 HOURS AND REPLACEMENT AT 10,000 HOURS. THIS CABLE HAS BEEN INSPECTED AT EACH 'B' CHECK, THAT IS EVERY 200 HOURS AND SHOWED NO PROBLEMS UNTIL NOW. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 1997051900003 19970519 00003 EA 1997 5 19 CA970219007 2 19970209 G 8550 LW14728 DIPSTICK PIPER PA31 PA31 7103102 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCC4Y HCC4YR2 GL ENG OIL SYS BROKEN W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 84 L491261A FH780 (CAN) ON POST FLIGHT INSPECTION AN OIL LEAK WAS FOUND. INVESTIGATION FOUND THE OIL LEAK WAS A RESULT OF A BROKEN OIL DIP STICK. THE ROD HAD FALLEN OUT OF THE HANDLE DUE TO A MISSING PIN. 1 L 7 2 3O 3 O A20SO E14EA 5 C P52GL 1997051500319 19970515 00319 1997 5 15 CA970219009 2 19970213 G 7414 D6LN3200 MAGNETO BENDIX DISTRIBUTOR GEAR FAILURE W K NONE O OTHER IN INSP/MAINT 1 CA E19127 (CAN) MAJOR FAILURE OF THE DISTRIBUTOR GEAR. MAGNETO HOUSING WAY OUT OF SPECIFICATIONS. THIS IS A 2000 SERIES MAGNETO TH AT HAS BEEN RE-IDENTIFIED AS A 3000 SERIES BY OBLITERATING AND RESTAMPING THE NAME PLATE. THE ENGINE WAS RECENTLY OVERHA ULED. 1997051500320 19970515 00320 EU 1997 5 15 CA970219011 2 19970129 G 7250 TURBINE BLADE FOKKER F28 F28MK1000 4990808 EU RROYCE SPEY SPEY55515 54521 EU AFT TURBINEWHEEL MISSING W A A E UNSCHED LANDING ENGINE SHUTDOWN E VIBRATION/BUFFET CL CLIMB 1 CA 29603 9299 (CAN) #2 ENGINE EXPERIENCED SUDDEN VIBRATIONS THROUGH FL270. ALL ENGINE PARAMETERS WERE FINE BUT VIBRATIONS COULD BE FEL T THROUGH THE AIRCRAFT AND POWER LEVERS. ENGINE WAS SHUTDOWN AND THE AIRCRAFT RETURNED TO ITS POINT OF DEPARTURE. POST F LIGHT INSPECTION FOUND A BLADE MISSING FROM THE AFT TURBINE WHEEL. THE ENGINE WAS REPLACED, THE AIRCRAFT GROUND RUN SERV ICEABLE AND THE AIRCRAFT RETURNED TO SERVICE. THE FAILED ENGINE WAS SENT TO ROLLS ROYCE FOR INVESTIGATION, FURTHER REPOR T TO FOLLOW. 2 L 7 2 4F 4 F RT A20EU E2EU 1997051500321 19970515 00321 EA 1997 5 15 CA970219013 1 19970213 G 2421 731579 GENERATOR CNDAIR CL600 CL6002A12 1900304 EA GE CF34 CF341A NE IDG CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 CA 350143 (CAN) INTEGRATED DRIVE GENERATOR OIL LEVEL FOUND LOW ON DAILY INSPECTION. CHIP DETECTOR PULLED AND FOUND METAL CONTAMINA TED. 2 L 7 2 4F 4 F RT A21EA E15NE 1997051500322 19970515 00322 SO 1997 5 15 CA970219014 1 19970209 G 3710 GASKET PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA VACUUM PUMP LEAKING W E A ENGINE SHUTDOWN UNSCHED LANDING K R FLUID LOSS PARTIAL RPM/PWR LOSS CR CRUISE 1 CA L286061A (CAN) AFTER TAKEOFF THE PILOT NOTICED A DROP IN MANIFOLD AND OIL PRESSURES ON #2 ENGINE. THE ENGINE WAS SHUTDOWN AND THE AIRCRAFT RETURNED TO BASE. POST FLIGHT INSPECITON FOUND THE #2 ENGINE COWLING SATURATED WITH ENGINE OIL. FURTHER INVEST IGATION FOUND THE VACUUM PUMP GASKET WAS LEAKING. THE PUMP WAS NEWLY INSTALLED AND THE FAULTY GASKET CAME WITH THE PUMP. A NEW LYCOMING VACUUM PUMP GASKET P/N 8313 WAS INSTALLED AND THE ENGINE GROUND RUN SERVICEABLE. 1 L 7 2 3O 3 O A20SO E14EA 1997051500323 19970515 00323 GL 1997 5 15 CA970219016 1 19970203 G 6520 28135255R GEARBOX ENSTRM F28 280 3300502 GL LYC O360 HIO360C1A 41514 EA T/R MAKING METAL W K NONE O OTHER IN INSP/MAINT 1 CA 719 RL672751A (CAN) CHIPS FOUND ON DETECTOR DURING 100 HOUR INSPECTION. 1 G 7 1 3O 3 O H1CE 1E10 1997051500324 19970515 00324 NE 1997 5 15 CA970219017 2 19970210 G 7260 M06118 GEARBOX LKHEED 1011 1011385114 WP RROYCE RB211 RB21122B02 54555 NE ACCESSORY GRBOX MAKING METAL W K NONE O OTHER IN INSP/MAINT 1 CA 1930 10145 ACESSORY GEAR BOX MAKING METAL 2 L 7 3 4F 4 F A23WE E12EU 1997051500325 19970515 00325 NE 1997 5 15 CA970219018 2 19970206 G 7210 310924401 BEARING PWA PW121 PW121 52124 NE RED GEARBX NR 15 SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 9773 121239 (CAN) THE REDUCTION GEARBOX WAS SENT FOR REPAIR AND INVESTIGATION AFTER THE OPERATOR REPORTED THE ENGINE WAS MAKING META L. DISASSEMBLY OF THE REDUCTION GEARBOX FOUND THE CAUSE OF THE ENGINE CONTAMINATION WAS A SPALLED ROLLER OF THE #15 BEAR ING. THE #15 BEARING ROLLERS AND OUTER RACE HAD EXTENSIVE ELECTRICAL PITTING. IT IS THE OPINION OF THE REPAIR FACILITY T HAT THE LIKELY CAUSE OF THE FAILURE WAS A LIGHTNING STRIKE. 4 T E20NE 1998120400001 19981204 00001 SW 1998 12 4 CA970219019 1 19970205 G 6730 RH0119 BEARING RONSON 206076062003 BELL 206 206L 1181522 SW RT HYD SERVO TORN W K NONE O OTHER IN INSP/MAINT 1 CA 11959 RH0119 (CAN) ON DAILY INSPECTION, RT HYDRAULIC SERVO, BEARING CONNECTING TUBE ASSY 206-001-193-001, PART OF TEFLON LINING OF BE ARING FOUND ON THE DECK AND THE REST OF THE TEFLON SLIPPED PARTLY OUT OF THE BEARING. 1 G 7 1 3U H2SW 1997052900233 19970529 00233 NE 1997 5 29 CA970220003 2 19970210 G 7210 310703301 BEARING PWA 120 PW120A NE RED GRBOX NR 15 SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 12306 121098 (CAN) REDUCTION GEARBOX WAS SENT FOR INVESTIGATION AFTER METAL CONTAMINATION WAS FOUND IN THE ENGINE. DISASSEMBLY OF THE GEARBOX FOUND THE #15 BEARING SEVERELY SPALLED ON THE OUTER RACE WITH SUBSTANTIAL MATERIAL LOSS. THE #15 AND #18 BEARIN GS BOTH HAD ELECTRICAL EROSION TYPE CHAIN PITTING TYPICAL OF LOW ENERGY ELECTRICAL DISCHARGE AND ALSO SOME DEEPER, ARCIN G TYPE PITTING, TYPICAL OF HIGH ELECTRICAL DISCHARGE. THE MAGNETISM IN THE RGB IS RELATIVELY MINOR AND CERTAINLY NOT TYP ICAL OF THE MAGNETIC PROFILE THAT TYPICALLY ARISES FOLLOWING A LIGHTNING STRIKE. IT IS THE OPINION OF R&O THAT THE RGB W AS SUFFERING FROM LOW LEVEL ELECTRICAL EROSION PITTING WHICH EITHER LED TO THIS FAILURE OR WOULD HAVE CAUSED FAILURE IN 4 T E20NE 1997052900234 19970529 00234 EA 1997 5 29 CA970221003 1 19970217 G 3241 600870005 SENSOR CNDAIR CL600 CL6002A12 1900304 EA ANTI SKID BROKEN W D RETURN TO BLOCK J L WARNING INDICATION NO TEST TX TAXI/GRND HDL 1 CA 1068 (CAN) DURING TAXI, ANTI-SKID TEST CARRIED OUT. TEST FAILED - INDICATING INBOARD FAIL. WHEEL SPEED SENSOR FOUND DAMAGED, AS WELL AS WIRE HARNESS. 2 L 7 2 4F RT A21EA 1997062600008 19970626 00008 CE 1997 6 26 CA970221004 1 19970218 G 2913 542088030008 PRESSURE SWITCH CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO GEAR MOTOR INTERMITTENT W L ABORTED APPROACH G P MULTIPLE FAILURE NO WARNING INDICATION LD LANDING 1 CA 291550R (CAN) PILOT UNABLE TO GET INDICATION OF GEAR DOWN AND LOCKED. FLEW BY TOWER AND THEN LANDED SAFELY. GEAR MOTOR FOUND UNS ERVICEABLE BUT WORKED IN THE SHOP AFTER REMOVAL. REPLACED THE PRESSURE SWITCH AND INSTALLED A DIODE AS PER SERVICE LETTE R, IN ORDER TO EXTEND THE SWITCH LIFE. 1 H 7 1 3O 3 O A4CE E8CE 1997052900235 19970529 00235 EA 1997 5 29 CA970221005 2 19970211 G 7322 105135 CARBURETOR SCREW FACET MA4SPA CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA ENGINE LOOSE W O OTHER O OTHER TX TAXI/GRND HDL 1 CA 950 CK714171 RL125876TA (CAN) THE ENGINE DID NOT STOP AFTER THE MIXTURE CONTROL WAS CLOSED. THE ENGINE WAS STOPPED BY SHUTTING OFF THE MAGS. INS EPCTION FOUND THAT FOUR SCREWS THAT HOLD THE CARBURETOR HALVES TOGETHER WERE LOOSE AND ONE OF THE SCREWS WAS BROKEN. THE BROKEN SCREW WAS REMOVED AND REPLACED AND THE CARBURETOR WAS REASSEMBLED AND INSTALLED. THE ENGINE GROUND RUN SERVICEAB LE AND THE AIRCRAFT WAS RETURNED TO SERVICE. 1 H 7 1 3O 3 O NT 3A12 E274 1998040200039 19980402 00039 CE 1998 4 2 CA970225002 1 19970114 G 3010 99141432 CONTROLLER 99141432 CESSNA 650 650 2076802 CE GARRTT TFE731 TFE7313 01518 WP FLAP ANTI ICE FAILED W O OTHER J WARNING INDICATION CR CRUISE 1 CA 3011 P87242 (CAN) DURING CRUISE FLIGHT, THE LEFT HAND STABILIZER ANTI-ICE FAIL LIGHT ILLUMINATED. FLIGHT LANDED AND CONTROLLER WAS CHANGED. 2 L 7 2 4F 4 F A9NM E6WE 1997052900236 19970529 00236 EA 1997 5 29 CA970225006 1 19970217 G 2570 SHAFT DOWTY 215750096 CNDAIR CL215 CL2151A10 EA DOOR UPLOCK SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA 1286 (CAN) DOOR UPLOCK ACTUATOR SHAFT SHEARED WHILE MAINTENANCE WAS BEING CARRIED OUT ON WATER BOMBER SYSTEM. 2 H 7 2 4R A14EA 1997052900237 19970529 00237 1997 5 29 CA970226003 4 19970212 G 6113 CA4393308 BACKPLATE PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA HARTZL HCE3Y HCE3YR2A GL SPINNER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 25 RL139461C DJ11451A (CAN) THE SPINNER BACKPLATE WAS FOUND CRACKED ON INSPECTION. THE REPORT STATES THAT THIS IS THE THIRD BACKPLATE (IDENTIC AL PART NUMBERS) THAT HAS CRACKED ON THIS ENGINE SINCE OCTOBER 9, 1996. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1997052900239 19970529 00239 EA 1997 5 29 CA970226005 2 19970220 G 8530 75362 CYLINDER BNORM BN2 BN2A 1520204 EU LYC O540 O540E4C5 41532 EA #1 POSITION CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 1444 L1281340 (CAN) COMPRESSION CHECK AT INSPECTION REVEALED A CRACKED #1 CYLINDER. THE CRACK WAS AT THE LOWER SPARK PLUG HOLE. 1 H 7 2 3O 3 O A17EU E295 1997052900240 19970529 00240 EA 1997 5 29 CA970226007 1 19970204 G 5741 85334180 FITTING DHAV DHC8 DHC8311 1386006 EA STA. 424 CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA 6714 (CAN) FUSELAGE TO WING ATTACH FITTINGS AT FUSELAGE STRINGER 3 WERE CHAFED BY FLAP SECONDARY DRIVE CABLE SHEATHS. 2 H 7 2 4T RT A13NM 1997060500754 19970605 00754 EA 1997 6 5 CA970226008 1 19970204 G 5741 85334180 FITTING DHAV DHC8 DHC8311 1386006 EA STA.424 CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA 7346 (CAN) FUSELAGE TO WING ATTACH FITTINGS AT FUSELAGE STRINGER 3 WERE FOUND CHAFED BY FLAP SECONDARY DRIVE CABLE SHEATHS. 2 H 7 2 4T RT A13NM 1997052900241 19970529 00241 1997 5 29 CA970226057 4 19970214 G 6113 57A24041 LOW PITCH STOP BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO HARTZL HCC2Y BHCC2YF2 GL LH SPINNER STRIPPED THREADS W K NONE O OTHER IN INSP/MAINT 1 CA 1029 CS922825L AN6527 (CAN) DURING A DAILY INSPECTION THE L/H PROPELLER SPINNER WAS FOUND LOOSE. FURTHER INSPECTION REVEALED THE LOCK WIRE SEC URING THE PROP SPINNER TO THE LOW PITCH STOP ASSEMBLY WAS BROKEN AND THE THREADS ON THE LOW PITCH STOP WERE STRIPPED. TH E LOW PITCH STOP WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 3O 3 O RT 3A16 3E1 5 C P920 1997052900242 19970529 00242 EA 1997 5 29 CA970226058 2 19970217 G 7261 3026887 REGULATOR BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA #1 ENG OIL PRESS NOT ENGAGED W D E RETURN TO BLOCK ENGINE SHUTDOWN E VIBRATION/BUFFET CL CLIMB 1 CA PCE51808 (CAN) SHORTLY AFTER TAKEOFF THE #1 ENGINE LOST OIL PRESSURE AND HAD TO BE SHUTDOWN. INSPECTION OF THE OIL PRESSURE REGUL ATOR FOUND THE CLIP ON THE OIL PRESSURE HOUSING WAS NOT FULLY ENGAGED. THE REGULATOR WAS DISASSEMBLED AND INSPECTED, NO FAULT WAS FOUND. THE REGULATOR WAS REASSEMBLED AND INSTALLED. THE ENGINE RUN-UP SERVICEABLE AND THE AIRCRAFT RETURNED TO SERVICE. IT WAS CONCLUDED THAT THE OIL PRESSURE REGULATOR WAS NOT PROPERLY ENGAGED AND IT CAME LOOSE AND LOST OIL AND T ORQUE. 1 L 7 2 3T 4 T A14CE E4EA 1998041700500 19980417 00500 SO 1998 4 17 CA970226063 1 19970219 G 3710 441CC PUMP AIRBORNE PIPER PA31 PA31350 7103110 SO VAC SYS FAILED W O OTHER J WARNING INDICATION CR CRUISE 1 CA 1034 47740 (CAN) VACUUM PUMP FAILED IN-FLIGHT. SPLINE BROKEN AND DISINTEGRATED. PUMP WAS SEIZED. SUBMITTER SUGGESTED THAT INSPECT ION BE CARRIED OUT EVERY 500 HOURS TO DETERMINE PUMP SMOOTH OPERATION. 1 L 7 2 3O A20SO 1997052900243 19970529 00243 EA 1997 5 29 CA970226064 1 19970129 G 3260 864806 PSEU CNDAIR CL600 CL6002B19 EA GE CF34 CF343A1 30015 NE MLG FAILED W K NONE J WARNING INDICATION DE DESCENT 1 CA 2379 807343 (CAN) ON DESCENT THE PROXIMITY SYSTEM FAULT LIGHT CAME ON ALONG WITH GEAR DOWN RED LIGHTS. WHEN LANDING GEAR LEVER SELEC TED DOWN NOTHING HAPPENED. LANDING GEAR MANUAL EXTENSION CARRIED OUT. PROXIMITY SENSOR ELECTRONIC UNIT REPLACED. 2 L 7 2 4F 4 F RT A21EA E15NE 1997052900244 19970529 00244 WP 1997 5 29 CA970226065 1 19970211 G 3230 BRAKE HOSE DOUG DC9 DC932 3022066 WP PWA JT8 JT8D7A 52053 NE LT MLG MISALIGNED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA P653990D (CAN) UNABLE TO RAISE L/H MAIN LANDING GEAR. ALSO GEAR DOOR LIGHT REMAINED ON. QRH CARRIED OUT, NIL SUCCESS. MAINTNENANC E INVESTIGATION REVEALED UPPER FORWARD BRAKE HOSE SUPPORT HAD COME IN CONTACT WITH UPLATCH GUARD BAR. ALSO FOUND LH CEIL ING STOP DAMAGED. REPAIRS CARRIED OUT, OLEO SERVICED, GEAR SWING CHECKED SERVICEABLE. 2 L 7 2 4F 4 F A6WE E2EA 1997052900245 19970529 00245 WP 1997 5 29 CA970226067 1 19970213 G 3222 LANDING GEAR DOUG DC9 DC932 3022066 WP PWA JT8 JT8D7A 52053 NE NLG OLEO FLAT W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA P657363D (CAN) AFTER TAKEOFF GEAR LEVER SELECTED UP, RED NOSE GEAR UNSAFE LIGHT REMAINED ON. NOSE GEAR APPEARED TO RETRACT PARTIA LLY. QRH CARRIED OUT, SAME CONDITION REMAINED. GEAR SELECTED DOWN AND AIRCRAFT SAFELY LANDED. MAINTENANCE TROUBLESHOOTIN G FOUND NOSE OLEO FLAT WITH PISTON CHROME DAMAGE. NOSE LANDING GEAR OLEO PISTON ASSEMBLY CHANGED. GEAR SERVICED AND OPER ATIONALLY CHECKED SERVICEABLE. 2 L 7 2 4F 4 F A6WE E2EA 1997062600048 19970626 00048 SW 1997 6 26 CA970226068 1 19970218 G 6710 206001397101 PIVOT SUPPORT BELL 206 206B 1181511 SW FRICTION SPLIT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PIVOT SUPPORT FOUND CRACKED FROM FRICTION SPLIT TO BASE OF SUPPORT. APPROXIMATELY 1" CRACK. 1 G 7 1 3U H2SW 1997060300002 19970603 00002 1997 6 3 CA970226069 1 19970216 G 7120 NAS6606D62 BOLT BARRYCTRLS 9505402 GARRTT TPE331 TPE33111U 01514 WP REAR ENG MOUNT SHEARED W K NONE O OTHER IN INSP/MAINT 1 CA 4305 P75077 (CAN) DURING LEFT ENGINE MAINTENANCE THE BOLT FOR REAR ENGINE MOUNT WAS FOUND SHEARED OFF WITH WEAR TO ELASTOMER MOUNT S HANK. DELAMINATION OF ELASTOMER MOUNT ALSO FOUND. 4 T E4WE 1997052900246 19970529 00246 NM 1997 5 29 CA970226071 1 19970218 G 3260 864202 SENSOR DOWTY 8200105 DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE DRAG STRUT FAILED W H L DEACTIVATE SYST/CIRCUITS ABORTED APPROACH J WARNING INDICATION AP APPROACH 1 CA DCL190 120699 (CAN) DURING CLIMB, CRUISE AND DESCENT THE MAIN GEAR DOOR LIGHTS AND NOSE GEAR UNSAFE LIGHT PLUS GEAR INTRANSIT LIGHT WE RE ON PERIODICALLY. ON APPROACH, NOSE GEAR WOULD INDICATE UNSAFE AND THEN SAFE. ALTERNATE EXTENSION CARRIED OUT. NOSE LA NDING GEAR DOWN LOCK SENSORS AND DRAG STRUT SENSOR WERE UNSERVICEABLE. BOTH SENSORS REPLACED. 2 H 7 2 4T 4 T RT A13NM E20NE 1997052900247 19970529 00247 CE 1997 5 29 CA970227001 1 19970216 G 7922 3024999 RETAINING PLATE BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA BYPASS VALVE BROKEN W A E UNSCHED LANDING ENGINE SHUTDOWN K FLUID LOSS CR CRUISE 1 CA 6643 PCE81135 (CAN) OIL LEAK LED TO INFLIGHT SHUTDOWN. POST FLIGHT INSPECTION FOUND THERMOSTATIC OIL BYPASS VALVE RETAINING PLATE BROK EN. THIS ALLOWED OIL PRESSURE TO FORCE OUT THE PLUG WHICH LED TO AN OIL LEAK CAUSING THE INFLIGHT SHUTDOWN. 1 L 7 2 4T 4 T A24CE E4EA 1998041700503 19980417 00503 CE 1998 4 17 CA970227003 1 19970218 G 3246 3A0505901 DRAG LINK WIPAIR 3730 CESSNA 206 TU206G 2073357 CE MLG STIFF W K NONE O J OTHER WARNING INDICATION LD LANDING 1 CA (CAN) GEAR WOULD NOT LOCK DOWN, FOUND MAIN DRAG LINK CENTER JOINT STIFF. BOLT REMOVED AND HOLE CLEANED. LUBED AREA AND REASSEMBLED. WIPAIRE RECOMMENDED DISASSEMBLING AND CLEANING EVERY THREE YEARS. 1 H 7 1 3O A4CE 1997052900248 19970529 00248 EA 1997 5 29 CA970228005 2 19970221 G 8530 LW11775 PLUG PISTON PIN PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA #5 CYLINDER BROKEN W E A ENGINE SHUTDOWN UNSCHED LANDING B K M SMOKE/FUMES/ODORS/SPARKS FLUID LOSS OVER TEMP CR CRUISE 1 CA 1730 L217368A (CAN) PILOT NOTICED RISE IN OIL TEMPERATURE AND SMOKE FROM #2 ENGINE. ENGINE WAS SHUTDOWN AND PRECAUTIONARY LANDING WAS CARRIED OUT. POST FLIGHT INSPECTION FOUND THE #2 ENGINE, #5 CYLINDER PISTON PIN PLUG BROKEN AND THE DEBRIS HAD SEIZED TH E RINGS CAUSING THE CRANKCASE TO PRESSURIZE AND DISCHARGE OIL OUT OF THE OIL BREATHER PIPE. 1 L 7 2 3O 3 O A20SO E14EA 1997060500755 19970605 00755 NM 1997 6 5 CA970228006 1 19970130 G 2121 DSC704 CLAMP DHAV DHC8 DHC8201 2809001 NM AT DUCT LOOSE W B I A EMER. DESCENT CABIN DEPRESSURIZATION UNSCHED LANDING D INFLIGHT SEPARATION CL CLIMB 1 CA (CAN) DURING CLIMB AT APPROXIMATELY 15,000 FEET, A DUCT CONNECTION DECOUPLED AT THE RECIRCULATION FAN. THE CABIN DEPRESS URIZED. THE CREW FOLLOWED PUBLISHED PROCEDURES AND LANDED SAFELY. THERE WERE NO INJURIES. DUCT CONNECTION HAD RECEIVED M AINTENANCE 2 DAYS EARLIER AND NOT BEEN PROPERLY SECURED. 2 H 7 2 4T RT A13NM 1997060500756 19970605 00756 NE 1997 6 5 CA970228007 2 19970219 G 7532 310092205 HP BLEED VALVE BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE #1 ENGINE FAULTY W O OTHER O OTHER DE DESCENT 1 CA 303 PCE93184 (CAN) ON DESCENT THERE WERE TWO LOUD BANGS FROM #1 ENGINE AND A FLASH OF FLAME FROM THE ENGINE EXHAUST DUCT. AFTER FIVE SECONDS THIS EVENT REPEATED ITSELF. AN EMERGENCY WAS DECLARED AND AN UNEVENTFUL LANDING WAS CARRIED OUT. POST FLIGHT INV ESTIGATION FOUND THE #1 ENGINE HIGH PRESSURE BLEED VALVE HAD FAILED. THE VALVE WAS REPLACED. 1 L 7 2 4T 4 T A24CE E4EA 1997060500757 19970605 00757 EU 1997 6 5 CA970228008 1 19970222 G 3230 C24589000 UPLOCK BOX AEROSP ATR42 ATR42300 8680920 EU PWA 120 PW120 NE HAMSTD 14SF 14SF5 NE NOSE FROZEN W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 16640 N446 120940 900533 (CAN) AIRCRAFT RETURNED TO BLOCKS AFTER LANDING BECAUSE NOSE LANDING GEAR WOULD NOT LOCK IN UP POSITION. UPLOCK BOX FROZ EN. HEAT APPLIED TO FREE. 2 H 7 2 4T 4 T RT A53EU E20NE 6 C P7NE 1997060500758 19970605 00758 NE 1997 6 5 CA970304005 2 19970301 G 7200 ENGINE CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE HP TURB MAKING METAL W A E O UNSCHED LANDING ENGINE SHUTDOWN OTHER X B O ENGINE FLAMEOUT SMOKE/FUMES/ODORS/SPARKS OTHER CL CLIMB 1 CA 1960 71748 (CAN) DURING CLIMB AFTER TAKEOFF A LOUD BANG WAS HEARD FOLLOWED BY A FLAME OUT. THE ENGINE WAS SHUTDOWN AS PER PROCEDURE S AND THE AIRCRAFT RETURNED TO BASE. POST FLIGHT INSPECTION FOUND FERROUS METAL LAYING IN THE TAILCONE. BOROSCOPE OF THE H.P. TURBINE REVEALED TIP CONTACT WITH SHROUD SEGMENTS WITH A LARGE QUANTITY OF ABRADED MATERIAL STILL REMAINING IN THE H.P./L.P. TURBINE AREA. THE MAIN OIL FILTER WAS CHECKED AND IT AND THE OIL WERE RETAINED FOR SOAP ANALYSIS.A LARGE QUAN TITY OF METAL (FERROUS AND NON-FERROUS) CAN BE SEEN IN THE OIL ALONG WITH DISTINCT DISCOLORATION. NO IMPACT DAMAGE APPAR ENT TO THE ENGINE. 1 L 7 2 4F 4 F A22CE E1NE 1997070100003 19970701 00003 1997 7 1 CA970305002 4 19970219 G 2220 AH144910006 AIRSPEED IND AH144910006 BOEING 727 727171C 1384057 NM COCKPIT CALIB ERROR W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 1291B (CAN) MACH-AIRSPEED INDICATOR - RANGE 60-420 KNOTS CALIBRATED IN MPH. COMMAND SPEED, AUTO THROTTLE CALIBRATED 180 KNOTS OUT OF PHASE. RECALIBRATED. 2 L 7 3 4F A3WE 1997060500760 19970605 00760 EU 1997 6 5 CA970305003 1 19970220 G 2720 NB452153 PEDAL BEAMS BNORM BNORM BN2 BN2A 1520204 EU LYC O540 O540E4C5 41532 EA RUD PEDAL CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA L1281340 (CAN) DURING INSPECTION PER PBN SB 56 AND 111, FOUND PILOTS LEFT AND RIGHT RUDDER PEDAL BEAM CRACKED. ALSO FOUND JO-BOLT S LOOSE ON THE STEERING LEVER. NOTE: NB/M/948 AND 428 HAD BOTH BEEN INSTALLED 2500 CYCLES PREVIOUSLY. 1 H 7 2 3O 3 O A17EU E295 1997060500762 19970605 00762 EU 1997 6 5 CA970305005 2 19970224 G 7322 CCU5151106A5 FUEL CONTRL UNIT BRAERO 748 HS7482A 4231001 EU RROYCE DART DART5342 EU #1 ENGINE FAULTY W A A UNSCHED LANDING O OTHER CR CRUISE 1 CA 459 7344 (CAN) SHORTLY AFTER REACHING CRUISE ALTITUDE THE RPM ON #1 ENGINE REACHED 14,500 RPM. THE PROP SYNC. WAS TURNED OFF AND THE RPM RETURNED TO NORMAL CRUISE RPM. A SHORT WHILE LATER WITH PROP SYNC. ON THE RPM AGAIN INCREASED, A PRECAUTIONARY L ANDING WAS CARRIED OUT. POST FLIGHT INSPECTION FOUND THE FCU FAULTY AND THE FCU WAS REPLACED AND THE AIRCRAFT RETURNED T O SERVICE. 2 L 7 2 3T 4 T A24EU A196 1999031200242 19990312 00242 NM 1999 3 12 CA970305006 1 19970204 G 3213 10851110000 WELD STINSON 10851110000 UNIVAR 108 1082 9230406 NM FRNKLN 6A4165 6A4165B3 27025 EA MCAULY 1A170 1A170DM GL MLG FAILED W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 CA 2925 31318 P80126 (CAN) THE WELD THAT HOLDS THE AXLE ATTACHMENT BUSHING TO THE LANDING GEAR LEG FAILED. REPLACED. 1 H 7 1 3O 3 O A767 E238 5 N P857 1997060500763 19970605 00763 NE 1997 6 5 CA970305007 2 19970223 G 7200 ENGINE BOEING 720 720B 1383804 NM PWA JT3D JT3D1 52039 NE #3 ENGINE MAKING METAL W O OTHER J WARNING INDICATION CL CLIMB 1 CA 48558 15384 633053 (CAN) DURING CLIMB THE #3 ENGINE OIL PRESSURE AND TEMPERATURE INCREASED SLIGHTLY ABOVE MAXIMUM. PREVIOUS POWER SETTING W ERE RESTORED AND THE ENGINE PARAMETERS RETURNED TO NEAR NORMAL. POST FLIGHT INSPECTION FOUND METAL IN THE N2 GEARBOX OIL STRAINER AND ENGINE MAIN OIL FILTER. THE ENGINE WAS REPLACED. 2 L 7 4 4J 4 F 4A28 1E8 1998050100216 19980501 00216 CE 1998 5 1 CA970306001 1 19970215 G 3213 07416302 FITTING 07416302 CESSNA 182 182P 2075816 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C* GL RT MLG BROKEN W O OTHER O OTHER LD LANDING 1 CA 1616 459512 743560 (CAN) ON LANDING, RT GEAR CONTACTED SNOW BANK AND SEPARATED AT AXLE FITTING. BROKEN GEAR SHOWED SIGNS OF CORROSION ABOU T 1/3 DIAMETER AT INBOARD AXLE FITTING. REPLACED. 1 H 7 1 3O 3 O NT TA13 E273 5 C P3EA 1998050100217 19980501 00217 CE 1998 5 1 CA970306002 1 19970219 G 2730 115610010325 TORQUE TUBE BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA P50876 (CAN) ELEVATOR TORQUE TUBE ATTACH CASTING CRACKED FROM INBOARD TAPER HOLE TO INBOARD EDGE OF CASTING. REPLACED. PART T T: 18,624 HOURS. 1 L 7 2 3T 4 T A14CE E4EA 1997062600467 19970626 00467 1997 6 26 CA970306003 1 19970227 G 7120 SHAFT LORD LM827SDA7 ENG MOUNT WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) TWO DIFFERENT LORD MOUNT ASSEMBLIES USED TO MOUNT THE TPE331 ENGINE FOR THE SA226 AIRCRAFT RECEIVED AFTER OVERHAUL WITH FOLLOWING DISCREPANCIES. LM827-2 CENTRE SHAFT, WORN IN TWO PLACES, MAXIMUM WEAR SPOT 0.010 BELOW MINIMUM DIMENSION AS PER FAIRCHILD MAINTENANCE MANUAL. NIL CRACKS FOUND. THE SUPPLIED SANDWICH MOUNTS WERE INSPECTED PER MM - #1 PAD AT M AXIMUM LIMIT. DISBONDING AND METAL RUBBER SEPARATION WAS EVIDENT WITH DEPTH OF DISBONDING REACHING 0.250" IN ONE SANDWIC H. MAXIMUM ALLOWABLE IS 0.010. SUPPLIED WASHERS WERE STANDARD AN970D WASHERS INSTEAD OF THE 'THICK ALUMINUM' LM827-7 WAS HER AS REQUIRED. THE OTHER MOUNT ASSEMBLY SHAFT WAS ALSO WORN IN TWO PLACES. 1998050100218 19980501 00218 1998 5 1 CA970306004 4 19970227 G 3424 4644600 EJECTOR 548092 PIPER PA31T PA31T 7103124 SO PWA PT6 PT6A28 EA TURN/BANK ICED W D RETURN TO BLOCK I FLT. ATTITUDE INST. TX TAXI/GRND HDL 1 CA 52694 (CAN) VACUUM TURN AND BANK INDICATOR FAILED TO COME ON LINE AFTER AIRCRAFT WAS SITTING OUTSIDE AT BELOW ZERO DEGREES. F OUND EJECTOR TIP PLUGGED WITH ICE. HOSE REPLACED TO EJECTOR SO THAT EJECTOR TIP IS NO LONGER THE LOWEST PART OF SYSTEM. 1 L 7 2 3T 4 T A8EA E4EA 2000020500768 20000205 00768 CE 2000 2 5 CA970306006 1 19970227 G 2701 05600144 YOKE 05600144 CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 3599 L528676T 733668 (CAN) CONTROL YOKE CRACKED JUST ABOVE ELEVATOR ATTACH BEARING. REPLACED. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 1997060500764 19970605 00764 NM 1997 6 5 CA970306008 1 19970220 G 2760 A44700009 ACTUATOR DOWTY DHAV DHC8 DHC8101 2809002 NM LT OUTB DEPLOYED W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA 10446 1713 (CAN) AFTER DEPARTURE THE LEFT OUTBOARD ROLL SPOILER REMAINED DEPLOYED. CREW RETURNED TO AIRPORT. LEFT OUTBOARD SPOILER ACTUATOR REPLACED. ACTUATOR SENT FOR STRIP DOWN. 2 H 7 2 4T RT A13NM 1997060500765 19970605 00765 NE 1997 6 5 CA970306013 2 19970227 G 7260 PACKING PWA 120 PW120A NE #5 BEARING AREA BROKEN W O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 CA 7234 121319 (CAN) THE ENGINE WAS REMOVED FROM SERVICE AFTER REPORTS OF SMOKE IN THE CABIN, ONE TIME SO SEVERE IT SET OFF THE SMOKE A LARM. DISASSEMBLY OF THE ENGINE FOUND THE #5 BEARING AREA PACKING HAD DETERIORATED AND BROKEN. THERE WAS A CONSIDERABLE AMOUNT OF OIL IN AREAS WHERE OIL IS NOT SUPPOSED TO EXIST. IT IS CONCLUDED THE PROBLEM HAS ARISEN FROM A COMBINATION OF SEAL CLEARANCE DETERIORATIONS UPSETTING THE BALANCE OF THE SECONDARY AIR SYSTEM AND THE BROKEN PACKINGS. 4 T E20NE 1997060500766 19970605 00766 EA 1997 6 5 CA970310001 2 19970225 G 7200 ENGINE PWA PT6 PT6A50 52043 EA #4 POSITION FAILED W E ENGINE SHUTDOWN X ENGINE FLAMEOUT AP APPROACH 1 CA (CAN) ON DESCENT THE POWER LEVERS WERE CLOSED TO INCREASE DESCENT AND THE FIRST OFFICER NOTICED THE #4 ENGINE FUEL PRESS URE CAUTION LIGHT CAME ON. THE AUXILIARY FUEL PUMP WAS SELECTED ON. DURING FINAL TURN AT 1,500 FEET THE #4 ENGINE TORQUE WAS VERY LOW AND THE ENGINE FAILED. THE AIRCRAFT COMPLETED A SUCCESSFUL 3 ENGINE LANDING. THERE IS NO FURTHER REPORT. 4 T E4EA 1997060500767 19970605 00767 GL 1997 6 5 CA970310004 3 19970307 G 6111 C34112 BEARING CESSNA 180 180H 2072618 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C201 GL PROP BLADE WARPED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 3229 824 275613R 716093 (CAN) THE C3411-2 BEARING RACE WAS INSTALLED DURING THE ASSEMBLY STAGE OF THE OVERHAUL AND DURING THE BEARING SEATING IN SPECTION IT WAS FOUND THAT THE BEARING SEATING AREA WAS NOT CONTACTING THE PROPELLER HUB. THE BEARING WAS REMOVED AND CH ECKED FOR FLATNESS ON A PRECISION GRANITE STONE AND AN AREA 2" LONG DID NOT CONTACT THE STONE. THE BEARING WAS REMOVED F ROM SERVICE. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 1997061700005 19970617 00005 GL 1997 6 17 CA970310005 3 19970306 G 6111 BLADE CESSNA 150 150G 2071816 CE CONT O200 O200A 17020 SO MCAULY 1A100 1A100MCM GL TIP STATION CORRODED W O OTHER O W OTHER INADEQUATE Q C IN INSP/MAINT 1 CA 5319 2846 657636A E4829 (CAN) PROPELLER WAS SENT FOR 5 YEAR INSPECTION. CORROSION WAS FOUND PAINTED OVER. PROP HAD NOT BEEN INSPECTED SINCE 1970 . 1 H 7 1 3O 3 O 3A19 E252 5 N P918 1998050100220 19980501 00220 GL 1998 5 1 CA970310006 2 19970217 G 7230 6871643 BEARING CVAC 440 440 2422902 WP ALLSN 501D 501D13 03004 GL REAR NR 2 FAILED W E ENGINE SHUTDOWN J K WARNING INDICATION FLUID LOSS LD LANDING 1 CA 501795 (CAN) NR 1 ENGINE SHUT DOWN AFTER LANDING DUE TO LOW OIL PRESSURE QUANTITY. MAINTENANCE FOUND THAT THE TURBINE SECTION REAR BEARING SCAVENGE PUMP WAS DAMAGED AND LEAKING. THE ENGINE TURBINE HAD SHIFTED BACK AND DAMAGED THE PUMP. IT IS SU SPECTED THE COMPRESSOR SECTION NR 2 BEARING HAD FAILED. OVERHAUL FACILITY CONFIRMED THAT COMPRESSOR ROTOR BEARING HAD F AILED ALLOWING THE COMPRESSOR ROTOR TO SHIFT FORWARD CONTACTING THE STATOR VALVE AIRSEALS AND INNER BAND. 2 L 7 2 4R 4 T 6A6 E282 1997060500768 19970605 00768 NE 1997 6 5 CA970310008 2 19970212 G 7260 BEVEL DRIVE GEAR PWA 120 PW120A NE ACCESSORY GEARBX FRACTURED W O OTHER E VIBRATION/BUFFET CR CRUISE 1 CA 11567 120583 (CAN) #2 ENGINE HAD A UNCOMMANDED SHUTDOWN IN CRUISE. POST FLIGHT INSPECTION FOUND THE CAUSE OF THE FAILURE WAS A FRACTU RE OF THE ANGLE BEVEL DRIVE GEAR. 4 T E20NE 1997060500769 19970605 00769 NE 1997 6 5 CA970310009 2 19970221 G 7260 STARTER DIRVE PWA PW121 PW121 52124 NE ACCESSORY GEARBX BROKEN W E ENGINE SHUTDOWN R B PARTIAL RPM/PWR LOSS SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA 124688 (CAN) DURING CRUISE THE #2 ENGINE WAS REPORTED TO HAVE A LOSS OF TORQUE. SUBSEQUENT ATTEMPTS TO REGAIN POWER RESULTED IN ENGINE GRINDING NOISE WITH SMOKE IN THE CABIN AND A LOSS OF OIL PRESSURE. THE ENGINE WAS SHUTDOWN. POST FLIGHT INSPECTI ON FOUND A BROKEN STARTER DRIVE GEAR. 4 T E20NE 1997060500770 19970605 00770 NE 1997 6 5 CA970310010 2 19970226 G 7313 FUEL NOZZLES PWA PW120 PW124B NE #1 ENGINE LEAKING W A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 CA 9874 7832 124367 (CAN) ON AIRCRAFT ROTATION THE #1 ENGINE TORQUE FELL TO ZERO. THE PILOT SATISFACTORILY COMPLETED A SINGLE ENGINE GO AROU ND. GROUND INSPECTION REVEALED A HEAVY FUEL LEAK FROM THE FUEL MANIFOLD DRAIN. THIS WAS THE FIRST FLIGHT AFTER A FUEL NO ZZLE CHANGE. IT WAS REPORTED THAT A FUEL LEAK CHECK HAD BEEN CARRIED OUT AFTER THE FUEL NOZZLE CHANGE. 4 T E2ONE 2000020500769 20000205 00769 CE 2000 2 5 CA970312001 1 19970219 G 5610 5042006924 WINDSHIELD 5042006924 BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA HARTZL HCB3T HCB3TN3 GL COCKPIT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA P50876 BU3196 (CAN) PILOT'S WINDSHIELD CRACKED IN UPPER RIGHT CORNER POSSIBLY STARTING AT SCREW HOLE APPROXIMATELY 3 INCHES LONG AFTER REMOVAL. REPLACED. 1 L 7 2 3T 4 T A14CE E4EA 6 C P15EA 1997060500772 19970605 00772 NE 1997 6 5 CA970312008 2 19970304 G 8530 ST90P10ER CYLINDER DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE #5 CYLINDER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 1263 204816 (CAN) DURING INSPECTION THE #5 CYLINDER WAS FOUND CRACKED FROM THE FRONT SPARK PLUG HOLE TO THE REAR SPARK PLUG HOLE, AC ROSS THE TOP OF THE CYLINDER BETWEEN THE COOLING FINS. THE CYLINDER WAS REPLACED. 1 H 7 1 3R 3 R A806 5E1 1997060500773 19970605 00773 NE 1997 6 5 CA970314003 2 19970308 G 7322 3028325 AIR LINE BELL 212 212 1181420 SW PWA PT6T PT6T3B 52045 NE P3 FILTER BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA PS62080 (CAN) #2 ENGINE WOULD NOT START IN AUTO MODE. P3 AIR LINE WAS FOUND BROKEN FROM THE P3 AIR FILTER HOUSING. NEW PART INST ALLED. 1 G 7 1 4U 4 U H4SW E22EA 1997060500774 19970605 00774 GL 1997 6 5 CA970314004 3 19970307 G 6111 S90AT4 PROP BLADE CESSNA 185 A185E 2072818 CE MCAULY 2A34C D2A34C58 GL LEADING EDGE CORROSION W K NONE O OTHER IN INSP/MAINT 1 CA 1299 588 744911 (CAN) LIGHT EROSION/CORROSION FOUND ON THE LEADING EDGE OF THE PROPELLER BLADE DURING INSPECTION. THE SUBMITTER SUGGESTS THAT THIS SHOULD HAVE BEEN TRIMMED OUT. 1 H 7 1 3O 3A24 5 C P3EA 1997070300241 19970703 00241 EA 1997 7 3 CA970314005 1 19970307 G 2430 720846B GEN CONTROL UNIT SUNDSTRAND CNDAIR CL600 CL6001A11 1900302 EA NR 2 APU GEN FAILED W L ABORTED APPROACH G H I MULTIPLE FAILURE ELECT. POWER LOSS-50 PC FLT. ATTITUDE INST. AP APPROACH 1 CA (CAN) DURING FLIGHT APU STARTED AND STABILIZED. THE #2 AC ESSENTIAL BUS WAS KNOCKED OFF LINE. APU GENERATOR CONTROL UNIT REPLACED AS WELL AS #2 GENERATOR CONTROL UNIT. 2 L 7 2 4F RT A21EA 1997060500775 19970605 00775 NE 1997 6 5 CA970318005 2 19970303 G 7322 FUEL CONTRL UNIT BENDIX PIPER PA42 PA42 7104202 SO PWA PT6 PT6A42 52043 NE ENGINE FAULTY W E A ENGINE SHUTDOWN UNSCHED LANDING Y O ENGINE STOPPAGE OTHER CL CLIMB 1 CA 5871 2870 80882 (CAN) ENGINE TORQUE AND TEMPERATURE CONTINUED TO INCREASE AS THROTTLE WAS RETARDED. PILOT SELECTED THROTTLE TO OFF POSIT ION, TEMPERATURE STILL INCREASED. ENGINE WAS SHUTDOWN. POST FLIGHT INSPECTION FOUND FUEL CONTROL UNIT FAULTY. FCU WAS RE PLACED. 1 L 7 2 4T 4 T A23SO E4EA 1997060500776 19970605 00776 NE 1997 6 5 CA970319001 2 19970310 G 7320 511749 TUBE ASSY BOEING 737 7372A3 138448A NM PWA JT8 JT8D9A 52048 NE PT 7 MANIFOLD BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 665233 (CAN) #2 ENGINE E.P.R. GAUGE WAS READING LOW. MAINTENANCE FOUND THE PT7 MANIFOLD LINE BROKEN. THE LINE WAS REPLACED AND THE ENGINE GROUND RUN SERVICEABLE. THE AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 2 4F 4 F A16WE E2EA 1997060500777 19970605 00777 NE 1997 6 5 CA970319003 2 19970303 G 7250 3040911D CT DISK BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3A NE DISK PLATFORM WORN W K NONE O OTHER IN INSP/MAINT 1 CA 1835 PCE114295 HJ332 (CAN) DURING HSI THE CT DISK ASSEMBLY WAS FOUND RUBBING ON THE CT AIR SEAL. FURTHER INSPECTION FOUND THAT EIGHT BLADE RO OTS ON THE OPPOSITE SIDE OF THE DISK ALONG WITH THE DISK PLATFORM WERE GROOVED. THE DEPTHS OF THE GROOVES WERE TO AN UNA CCEPTABLE LIMIT. THE CT DISK ASSEMBLY AND THE AIR SEAL WERE REPLACED. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 1997070300264 19970703 00264 1997 7 3 CA970319004 1 19970313 G 3246 44 SPREADER BAR EDOFLOATS 442425 FLOAT REAR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) SEVERE INTERGRANULAR CORROSION AND A 12" LONG CRACK FOUND IN THE REAR SPREADER BAR. SUBMITTER NOTES IT WAS DIFFICU LT TO FIND BECAUSE ALL BUT 1" TO 2" WAS INSIDE THE FLOAT. DATE OF FLOAT MANUFACTURE WAS 1946. 1997060500778 19970605 00778 SO 1997 6 5 CA970325001 2 19970304 G 8530 653446A11 CYLINDER ASSY CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO MCAULY 3AF32C 3AF32C505 GL INTAKE PORT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 1173 519163H 820491 (CAN) DURING INSPECTION FUEL STAINS WERE FOUND AT THE COOLING FIN AREA ON ONE OF THE CYLINDERS. THE CYLINDER WAS REMOVED . FURTHER INVESTIGATION REVEALED A CRACK STARTING ABOVE THE VALVE SEAT UP AND TOWARD THE INTAKE PORT. THE CYLINDER WAS R EPLACED. 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 1997060500779 19970605 00779 SO 1997 6 5 CA970325002 2 19970313 G 8530 653446A11 CYLINDER ASSY CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO MCAULY 3AF32C 3AF32C505 GL INTAKE PORT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 1200 290342R 950419 (CAN) DURING INSPECTION FUEL STAINS WERE FOUND ON ONE CYLINDER OF THE LH ENGINE AND ONE CYLINDER OF THE RH ENGINE IN THE AREA OF THE COOLING FINS. FURTHER INSPECTION FOUND THE CYLINDERS WERE CRACKED. MAINTENANCE HAVE CONCLUDED THE CYLINDERS ARE CRACKING AS A ARESULT OF SHOCK COOLING. IT WAS REPORTED THAT THE AIRCRAFT WAS OPERATED AT VERY LOW AMBIENT TEMPERAT URES. THE CYLINDERS WERE REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 1997060500780 19970605 00780 EA 1997 6 5 CA970325005 2 19970307 G 8520 SL72877 TAPPET BODY LYC O540 LTIO540J2BD 41533 EA CAM LOBES WORN W K NONE O OTHER IN INSP/MAINT 1 CA 49 RL13968A (CAN) DURING INSPECTION FERROUS AND NON-FERROUS METAL WAS FOUND IN THE OIL FILTER. CAMSHAFT LOBES #2 EXHAUST AND #5 AND #6 INTAKE AND CORRESPONDING TAPPET BODIES STARTING TO FAIL FROM SPALLING. REAR SECTION OF FRONT MAIN BEARING OVERHEATED WITH SURFACE MATERIAL MELTED, ROLLING AND FLAKING OFF THE BACKING. THESE FAILURES ARE NORMALLY ASSOCIATED WITH LACK OF L UBRICATION. AVCO LYCOMING RECOMMENDS AN OIL ADDITIVE BE ADDED. 3 O E14EA 1997060500781 19970605 00781 EA 1997 6 5 CA970325006 2 19970217 G 8520 SL13885 FRONT BEARING SUPAIRPART LYC O540 TIO540A2C 41532 EA CRANKSHAFT OVERHEATED W K NONE O OTHER IN INSP/MAINT 1 CA 49 L744561A (CAN) PROP HARD TO CONTROL IN FLIGHT. INSPECTION FOUND NON FERROUS METAL IN THE MAIN OIL FILTER AND THE FINGER SCREENS. THE REAR SECTION OF THE FRONT MAIN BEARING INSIDE DIAMETER OVERHEATED WITH SURFACE MATERIAL MELTING, ROLLING AND FLAKING OFF THE BEARING BACK. PROP GOVERNOR OIL PRESSURE IS TAKEN FROM THE FRONT MAIN OIL GALLEY, DIRECTING OIL THROUGH THE CEN TRE SECTION OF THE FRONT MAIN BEARING THROUGH THE CRANKSHAFT AND TO THE PROPELLER. FULL FEATHERING CHECK OF THE PROP IS NOT RECOMMENDED ON THE GROUND ON A NEWLY OVERHAULED ENGINE, CONTINUING TO DO SO CAN CAUSE LOSS OF OIL TO THE REAR HALF F RONT MAIN BEARING. THIS TYPE OF FAILURE IS CONSISTANT WITH LACK OF LUBRICATION DURING COLD WEATHER & EXERCISING THE PROP 3 O E14EA 1997060500782 19970605 00782 EA 1997 6 5 CA970325007 2 19970220 G 8520 SL72877 TAPPET BODY SUPAIRPART SL19340 LYC O540 TIO540J2BD 41532 EA CAM EXH LOBE WORN W O OTHER O OTHER NR NOT REPORTED 1 CA 930 HO15 L664861A (CAN) PILOT REPORTED HIGH EGT ON DESCENT AFTER MAKING A POWER REDUCTION. INSPECTION FOUND THE CAMSHAFT #1 EXHAUST LOBE A ND #1 TAPPET BODY HAD 1/3 OF THE FACE MATERIAL WORN OFF AND RESTRICTING THE EXHAUST VALVE FROM FULL MOVEMENT. THE MAIN O IL FILTER HAD METAL CONTAMINATION. THE ENGINE MANUFACTURER CLAIMS THE CAMSHAFT LOBE PITTED AND WORN DUE TO CONTACT BETWE EN THE LOBE AND A SPALLED OR CHIPPED LIFTER BODY. LOBE DISTRESS IS SECONDARY AND BEGINS AFTER LIFTERS BECOME SPALLED BEC AUSE OF INSUFFICIENT LUBRICATION FROM EITHER COLD STARTS AND RUN UPS DURING COLD WEATHER OR FROM OVER DILUTION. AVCO LYC OMING RECOMMENDS THE USE OF AN OIL ADDITIVE P/N 16702 ANTI-SCUFFING AGENT TO REDUCE WEAR. S.I. 1409 REFERS. 3 O E14EA 1997061200848 19970612 00848 GL 1997 6 12 CA970325011 3 19970401 G 6111 90DCA2 BLADE CESSNA 180 180J 2072622 CE CONT O470 O470S 17026 SO MCAULY 2A34C 2A34C203 GL LEADING EDGE EROSION W K NONE O OTHER IN INSP/MAINT 1 CA 952 462382 750693 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER BLADE FOUND ERODED ON THE LEADING EDGE. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 1997061200850 19970612 00850 GL 1997 6 12 CA970325013 3 19970318 G 6114 4715 HUB MCAULY 2A34C 2A34C* GL RETAIN THREADS CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 1079 333 763171 (CAN) INSPECTION FOUND THE PROPELLER HUB CRACKED AT THE BLADE RETENTION THREADS. THE BLADE RETENTION NUT WAS ALSO CRACKE D. 5 C P3EA 1997070300273 19970703 00273 1997 7 3 CA970325017 4 19970307 G 2562 006062 BATTERY PACK DORNEMARGLN DMELT61 PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA ELT LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA 53639 L758039A (CAN) ELT BEING CHECKED FOR RECERTIFICATION. BATTERY PACK WAS 2 YEARS OVERDUE AND WAS VERY BADLY LEAKING. BOTTOM OF BATT ERY CASE WAS COMPLETELY CORRODED, THE SIDEWALL HAD A HOLE ABOUT 1 INCH IN DIAMETER. 1 L 7 1 3O 3 O 2A13 E274 2000020500775 20000205 00775 CE 2000 2 5 CA970325020 1 19970317 G 2820 AN9173D TEE CESSNA 185 A185E 2072818 CE CONT O520 IO520D 17032 SO FUEL SYSTEM CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 570278 851411 (CAN) TEE FITTING UNDER THE LEFT FLOOR CRACKED LOOSING A SMALL AMOUNT OF FUEL. REPLACED. 1 H 7 1 3O 3 O 3A24 E5CE 1998050100228 19980501 00228 CE 1998 5 1 CA970326006 1 19970303 G 7160 055018016 ARM ASSY CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA CARB HEAT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 2242 L1394339A (CAN) DURING RUN-UP, CARBURETOR HEAT INOPERATIVE. CARBURETOR HEAT CONTROL ARM BROKEN. REPLACED. 1 H 7 1 3O 3 O NT 3A12 E274 2000020500776 20000205 00776 SO 2000 2 5 CA970326011 1 19970314 G 3250 1497676 ARM PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA HARTZL HCE2Y HCE2YR2 GL NLG STEERING CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 6892 L104448 BP3110 (CAN) A/C VERY HARD TO STEER ON TAXIING. ACCUMULATION OF DUST AND DIRT IN STEERING ARM BUSHINGS CAUSED BINDING IN STEER ING LINKAGE. CLEANED AND LUBRICATED. 1 L 7 2 3O 3 O 1A10 1E4 5 C P9EA 1997070300286 19970703 00286 NM 1997 7 3 CA970401001 1 19970320 G 2720 69382933 CENTERING UNIT BOEING 69382933 BOEING 737 737* NM RUDDER FEEL IMPROPER ASSY W A K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 49080 800 9998 (CAN) DURING A ROUTINE AD INSPECTION A ROUGHNESS WAS DETECTED IN THE RUDDER FEEL AND CENTERING UNIT. THE HOUSING ASSEMBL Y WAS INSTALLED IN THE REVERSE POSITION ON THE CENTERING UNIT. THE UNIT HAD BEEN RECENTLY OVERHAULED. 2 L 7 2 4F RT A16WE 1998031900903 19980319 00903 CE 1998 3 19 CA970401008 1 19970311 G 2810 FILLER TUBE CESSNA 172 172M 2072418 CE RT WING OUTB CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 1400 (CAN) SMALL AMOUNT OF FUEL STAIN NOTED AT INBOARD LOWER TRAILING EDGE OF RIGHT HAND WING. USUALLY OCCURRED AFTER FILLIN G TANK. INSPECTION FOUND A CRACK IN THE WELD AT THE FILLER TUBE. 1 H 7 1 3O NT 3A12 1997061200859 19970612 00859 GL 1997 6 12 CA970401010 3 19970324 G 6111 BLADE MCAULY 1A103 1A103TCM GL PROP BENT W K NONE O OTHER IN INSP/MAINT 1 CA 775237 (CAN) PROPELLER BLADE WAS RECEIVED BENT. ATTEMPT TO STRAIGHTEN BLADE WAS MADE PRIOR TO RECEIPT AT PROP SHOP. BLADE WAS B ENT BEYOND LIMITS. 5 N P50GL 1998050100230 19980501 00230 CE 1998 5 1 CA970401014 1 19970324 G 3222 96B200163 STRUT 96B200163 BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 2454 287103R (CAN) CRACK FOUND IN OLEO TO STRUT CASTING. REPLACED. 1 L 7 2 3O 3 O 3A16 E5CE 1997061200861 19970612 00861 GL 1997 6 12 CA970402002 3 19970325 G 6111 D5044 BLADE CESSNA 177 177RG 2073709 CE MCAULY 2D34C B2D34C207 GL LEADING EDGE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 2157 595 735063 (CAN) STONE DAMAGE ON THE LEADING EDGE AND THE FACE OF THE PROPELLER BLADE. THE BLADE REQUIRED FILING AND GRINDING. THE PROPELLER HUB BREATHER SEALANT WAS MISSING. 1 H 7 1 3O A20CE 5 C P7EA 1997061200862 19970612 00862 GL 1997 6 12 CA970402003 3 19970326 G 6111 BLADE MCAULY 1C160 1C160DTM GL LEADING EDGE EROSION W K NONE O OTHER IN INSP/MAINT 1 CA 1062 730409 (CAN) INSPECTION FOUND LIGHT EROSION ON THE LEADING EDGE OF THE PROPELLER. FILING WAS REQUIRED TO REMOVE THE EROSION. 5 N P910 1997070300290 19970703 00290 NM 1997 7 3 CA970402004 1 19970324 G 7603 STOP MECHANISM DHAV 87610018003 DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE LT PWR LEVER MISALIGNED W E ENGINE SHUTDOWN O OTHER TX TAXI/GRND HDL 1 CA 21897 0 (CAN) DURING ENGINE RUN ON GROUND, THE PILOT BRISKLY BROUGHT BACK THE LEFT POWER LEVER. THE LEVER PASSED THROUGH FLIGHT IDLE GATE STOP AND CONTINUED INTO THE BETA RANGE. AIRCRAFT MANUFACTURER INVESTIGATE AND FOUND THE MISALIGNMENT WITH POWE R LEVER STOP WHICH WAS THERE SINCE MANUFACTURE. A NEW UNIT INSTALLED P/N 87610018-007. 2 H 7 2 4T 4 T RT A13NM E20NE 1997061200863 19970612 00863 NE 1997 6 12 CA970407001 2 19970325 G 7250 414129001 PT ROTOR SNIAS 350 AS350D 8680803 EU LYC LTS101 LTS101600A3 41560 NE ROTOR WHEEL BLADES DISPLACED W K NONE O OTHER IN INSP/MAINT 1 CA 676 203 43085CE (CAN) DURING INSPECTION THE POWER TURBINE ROTOR WAS FOUND TO HAVE SOME OF THE TURBINE BLADES DISPLACED AXIALLY BEYOND LI MITS. ALL BLADES BEYOND LIMITS HAD MOVED AFT. THE ENGINE WAS REMOVED FROM SERVICE AND A ZERO TIME TSO ENGINE INSTALLED. 1 G 7 1 3U 3 U H9EU E5NE 1997061200864 19970612 00864 EA 1997 6 12 CA970407004 2 19970326 G 8520 76097 CAMSHAFT LYC O320 O320E2D 41508 EA LOBES SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 1754 L1993027A (CAN) INSPECTION FOUND CAMSHAFT LOBES SPALLED AND TAPPET BODIES WERE PITTED. THE SPALLING ON THE LOBES WAS A RESULT OF C ORROSION ON THE LOBES AND ON THE TAPPET BODIES. THE CORROSION WAS A RESULT OF LONG PERIODS OF ENGINE INACTIVITY AND NO E VIDENCE OF INHIBITING BEING CARRIED OUT. THIS ENGINE HAS BEEN IN SERVICE SINCE 1968 AND HAS ACCUMULATED 1745 HOURS. 3 O E274 1998031900905 19980319 00905 SW 1998 3 19 CA970407005 1 19970306 G 2821 112B NIPPLE 20911 BBAVIA 7 7ECA 21101NN SW FIREWALL WORN W K NONE O OTHER IN INSP/MAINT 1 CA 5936 (CAN) GASCOLATOR FOUND LOOSE IN ITS MOUNTING BRACKET. NIPPLE REMOVED AND FOUND CHAFED 90 TO 95 PERCENT THROUGH THE WALL FROM THE FIREWALL AS THE NIPPLE PASSES THROUGH A HOLE IN FIREWALL. DESIGN OF GASCOLATOR DOES NOT PERMIT USE OF BULKHEAD FITTING TO SECURE UNIT AS IT PASSES THROUGH THE FIREWALL. 1 H 7 1 3O A759 1997061200865 19970612 00865 GL 1997 6 12 CA970407006 3 19970326 G 6111 FL7666A2 BLADE CONAER LA4 LA4 5110302 NE LYC O360 IO360A1B 41514 EA HARTZL HCC2Y HCC2YK1 GL LEADING EDGE ERODED W K NONE O OTHER IN INSP/MAINT 1 CA 495 281 L716951A CH14770 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. BLADE LEADING EDGE ERODED/CORRODED. FILING AND DRESSING OUT REQUIRED. 1 H 7 1 3O 3 O 1A13 1E10 5 C P920 1997061200866 19970612 00866 GL 1997 6 12 CA970407007 3 19970326 G 6114 B24573 FORK CONAER LA4 LA4 5110302 NE LYC O360 IO360A1B 41514 EA HARTZL HCC2Y HCC2YK1 GL PROPELLER WORN OUT W K NONE O OTHER IN INSP/MAINT 1 CA 495 281 L716951A CH14770 (CAN) INSPECTION FOUND PROPELLER FORK WORN. 1 H 7 1 3O 3 O 1A13 1E10 5 C P920 1997061200867 19970612 00867 GL 1997 6 12 CA970407008 3 19970327 G 6114 3921 HUB PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360KB 17025 SO MCAULY 3AF32C 3AF32C508 GL PROP THREADS FLATENED W K NONE O OTHER IN INSP/MAINT 1 CA 1009 315475 814635 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION AND HUB THREADS WERE FOUND FLATTENED, DUE TO REMOVING AND INSTALLING T HE PROPELLER. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 1997061200868 19970612 00868 GL 1997 6 12 CA970407009 3 19970327 G 6111 82NFA6 BLADE PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360KB 17025 SO MCAULY 3AF32C 3AF32C508 GL LEADING EDGE ERODED W K NONE O OTHER IN INSP/MAINT 1 CA 1009 315475 814635 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION AND THE BLADES WERE FOUND ERODED AND REQUIRED FILING. THE TIP ANGLES W ERE OUT OF SPECIFICATIONS AND REQUIRED TWISTING. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 1997070300291 19970703 00291 NE 1997 7 3 CA970407012 3 19970325 G 6114 538867 HUB HAMSTD 43D 43D50 NE BARREL LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA 202016 (CAN) INSPECTION FOUND THE HUB BARREL LOOSE AND SCORED FROM WORKING AGAINST THE BARREL SUPPORTS. THE SHIM SIZES WAS INCR EASED AND THE INTERFERENCE FIT WAS RESTORED. SERVICE BULLETIN #632B REFERS. 6 C P8879 1997070300292 19970703 00292 GL 1997 7 3 CA970407013 3 19970327 G 6111 L82NFA6 BLADE PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360KB 17025 SO MCAULY 3AF32C 3AF32C509 GL LEADING EDGE ERODED W K NONE O OTHER IN INSP/MAINT 1 CA 1009 315475 814786 (CAN) INSPECTION FOUND PROPELLER LEADING EDGE ERODED/CORRODED, WHICH REQUIRED FILING. THE BLADE TIP ANGLES WERE OUT OF S PECIFICATIONS AND REQUIRED TWISTING. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 1997070300301 19970703 00301 EA 1997 7 3 CA970408008 1 19970331 G 5230 75230413001 FITTING ASSEMBLY DHAV DHAV DHC7 DHC7102 2802708 EA PWA PT6 PT6A50 52043 EA FWD PIN MECH CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 26190 0 (CAN) CRACKED BAGGAGE DOOR FITTING AT LOWER FORWARD PIN. FOUR AIRCRAFT FOUND WITH SAME PROBLEM. 2 H 7 4 4T 4 T A20EA E4EA 1997071700371 19970717 00371 EA 1997 7 17 CA970408011 1 19970331 G 5411 C6W151071 FRAME DHAV C6W100311 DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043 EA RH STA 66.76 CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 25983 25983 (CAN) DURING INSPECTION AND ENGINE CHANGE, FOUND INTER-GRANULAR CORROSION ON FRAME ASSEMBLY ON RIGHT HAND NACELLE AFT OF FIREWALL. SEVERE CORROSION PITTING NOTED ON WING NOSE SPAR LEADING EDGE WHERE THE NACELLE STRUCTURE ATTACHES BETWEEN ST A. 97.50 AND 122.50. 1 H 7 2 3T 4 T A9EA E4EA 1998041700506 19980417 00506 NM 1998 4 17 CA970408013 1 19970316 G 6220 A1541 BEARINGS ROBSIN R22 R22BETA NM MAST/HUB WORN W K NONE E VIBRATION/BUFFET CR CRUISE 1 CA 1708 (CAN) VIBRATION REPORTED. ROTOR HEAD DISMANTLED. AT THE ATTACHMENT POINT OF THE HUB TO THE MAST, THE BEARINGS (A-106-5 AND A-648-1) AS WELL AS THE RINGS (A-152-1) WERE EXCESSIVELY WORN. THE TWO BEARINGS (A-648-1) WERE OUT OF ROUND TO THE EXTENT OF DAMAGING THE M/R HUB (A-154-1) BEYOND REPAIR. 1 G 7 1 3O H10WE 1998050100231 19980501 00231 SO 1998 5 1 CA970408015 1 19970327 G 3230 41789000 FORK PIPER PA31 PA31 7103102 SO RT MLG BROKEN W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) RIGHT MAIN LANDING GEAR REMAINED DOWN AND LOCKED ON RETRACTION. RT MLG LOCK ROD FORK BROKE POSSIBLY ON UP SELECTI ON. REPLACED. 1 L 7 2 3O A20SO 1997072400917 19970724 00917 EA 1997 7 24 CA970408017 1 19970331 G 2520 WOOD VENEER CNDAIR CL600 CL6002B16 1900305 EA CABIN INTERIOR UNTREATED W A K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) COMPLIANCE TO REQUIREMENTS OF FAR 25.853(A), APPENDIX F, PARAGRAPH (A)(1)(I) FOR 60 SECOND BURN TEST CANNOT BE FUL LY DEMONSTRATED FOR WOOD VENEER. WOOD VENEER INSTALLED IN CL6002B16 AIRCRAFT AS NOT TREATED WITH FLAME RETARDANT. 34 RE PORTS IN CANADIAN DATA BASE CONTROL NUMBERS 970408017 THRU 970408051. 2 L 7 2 4F RT A21EA 1997071700375 19970717 00375 1997 7 17 CA970409004 1 19970402 G 3010 153212A DEICE VALVE BENDIX DRAIN HOLE CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA RF3960 (CAN) DEICE DISTRIBUTION VALVE FAILED BECAUSE OF CORROSION. CORROSION CAUSED BY ACCUMULATION OF MOISTURE-DRAIN HOLE PLUG GED BY POTTING COMPOUND USED FOR INSTALLATION OF ELECTRICAL HEATERS. 1997071700377 19970717 00377 GL 1997 7 17 CA970409006 3 19970403 G 6111 FERRULE CESSNA 180 180 2072602 CE CONT O470 O470L 17026 SO MCAULY 2A36C 2A36C29 GL PROPELLER MISDRILLED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 3417 108 478557K 62911 (CAN) ON INSPECTION ONE OF THE PROPELLER FERRULE WAS FOUND TO HAVE FIVE HOLES. THE MAXIMUM IS FOUR. 1 H 7 1 3O 3 O NC 5A6 E273 5 C P880 1997072200002 19970722 00002 GL 1997 7 22 CA970409007 3 19970403 G 6110 PROPELLER PIPER PA30 PA30 7103002 SO LYC O320 IO320B1A 41508 EA HARTZL HCE2Y HCE2YL2 GL PROP ASSY CORROSION W K NONE O OTHER IN INSP/MAINT 1 CA 920 596 L170455A BG4669 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. 1 L 7 2 3O 3 O A1EA 1E12 5 C P9EA 1997072200003 19970722 00003 GL 1997 7 22 CA970409008 3 19970403 G 6114 PROPELLER PIPER PA30 PA30 7103002 SO LYC O320 IO320B1A 41508 EA HARTZL HCE2Y HCE2YL2 GL HUB CORROSION W K NONE O OTHER IN INSP/MAINT 1 CA 920 596 L170455A BG4670 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. HUB CORRODED AND REQUIRED REWORK. 1 L 7 2 3O 3 O A1EA 1E12 5 C P9EA 1998031900907 19980319 00907 SO 1998 3 19 CA970409012 1 19970402 G 2730 AN34 BOLT PIPER PA31 PA31350 7103110 SO BUNGEE SPRING WORN W K NONE O OTHER IN INSP/MAINT 1 CA 10201 (CAN) WHILE DOING SB 626C, ON REMOVAL OF OLD ELEVATOR DOWN SPRING AND LINK, BOLT AN3-4 RETAINING LINK TO EYEBOLT ON TUBE ASSEMBLY, (P/N 40847-00) WAS FOUND QUITE WORN DUE TO MISSING WASHER BETWEEN NUT AND EYEBOLT AND IMPROPER TORQUING. 1 L 7 2 3O A20SO 1997071700401 19970717 00401 EA 1997 7 17 CA970421033 1 19970403 G 3610 C6VW10253 DUCT DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043 EA LT ENG FIREWALL CRACKED W H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION CR CRUISE 1 CA PCE42076 (CAN) DURING CRUISE THE PNEUMATIC LOW PRESSURE LIGHT CAME ON INDICATING A LEAK IN THE SYSTEM. THE CREW SHUT OFF THE BLEE D AIR SYSTEM. MAINTENANCE FOUND A CRACKED DUCT AFT OF THE LEFT ENGINE FIREWALL. 1 H 7 2 3T 4 T A9EA E4EA 1997071700402 19970717 00402 NM 1997 7 17 CA970421034 1 19970403 G 2420 902F2425 PANEL WESTINGHOUSE BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE NR 2 GEN INTERMITTENT W H DEACTIVATE SYST/CIRCUITS L NO TEST CR CRUISE 1 CA 2540 2540 PL1522 P653620B (CAN) DURING FLIGHT #2 GENERATOR TRIPPED OFF LINE DUE TO UNDER EXCITATION AND UNDER FREQUENCY. GENERATOR CONTROL PANEL R EPLACED. 2 L 7 3 4F 4 F A3WE E2EA 1997071700403 19970717 00403 EA 1997 7 17 CA970421035 1 19970403 G 2430 1N1184 DIODE DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043 EA AUX BATTERY OPEN CIRCUIT W K NONE O OTHER IN INSP/MAINT 1 CA PCE42076 (CAN) DURING FIRST START OF THE DAY, R/H ENGINE STARTED OK, BUT COULD NOT START 2ND ENGINE. AUXILIARY BATTERY BUSS DIODE FOUND FAILED PREVENTING START RELAYS FROM OPERATING AFTER THE AUXILIARY BATTERY HAD LOST ITS CHARGE 1 H 7 2 3T 4 T A9EA E4EA 1997070300303 19970703 00303 EA 1997 7 3 CA970421065 1 19970331 G 5230 75230413001 FITTING ASSEMBLY DHAV DHAV DHC7 DHC7* EA PWA PT6 PT6A50 52043 EA FWD PIN MECH CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 26115 0 (CAN) CRACKED BAGGAGE DOOR FITTING AT LOWER FORWARD PIN. FOUR AIRCRAFT FOUND WITH SAME PROBLEM. 2 H 7 4 4T 4 T RT A20EA E4EA 1997070300304 19970703 00304 EA 1997 7 3 CA970421066 1 19970331 G 5230 75230413001 FITTING ASSEMBLY DHAV DHAV DHC7 DHC7102 2802708 EA PWA PT6 PT6A50 52043 EA FWD PIN MECH CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 33157 0 (CAN) CRACKED BAGGAGE DOOR FITTING AT LOWER FORWARD PIN. FOUR AIRCRAFT FOUND WITH SAME PROBLEM. 2 H 7 4 4T 4 T A20EA E4EA 1997071700411 19970717 00411 EA 1997 7 17 CA970421074 3 19970401 G 6111 BLADE PIPER PA22 PA22 7102202 SO SNSNCH 74DM M74DM EA BLADE DECALS CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 26020 (CAN) AIRWORTHINESS DIRECTIVE 66-23-02, ONE TIME NON REPETITIVE AD ONLY PARTIALLY COMPLIED WITH. CORROSION FROM WATER BA SED DECALS STILL ON THE BLADES. THIS IS THE FIRST SHOP VISIT FOR THIS PROPELLER SINCE IMPORT INTO CANADA IN 1967. 1 H 7 1 3O 1A6 5 N P88614 1997071700414 19970717 00414 EA 1997 7 17 CA970421077 3 19970401 G 6111 BLADE SNSNCH 74D 74DM EA WIDTH BELOW SPEC W K NONE O OTHER IN INSP/MAINT 1 CA 4899 1600 K38628 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. BLADE FOUND BELOW MINIMUM WIDTH. 5 N P88614 1997071700415 19970717 00415 GL 1997 7 17 CA970421078 3 19970410 G 6111 BLADE CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL FACE STONE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 1515 1515 RL449376T 82510 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. BLADE FACE FOUND WITH STONE DAMAGE AND CORROSION, GRINDING OF STONE D AMAGE AND THE LEADING EDGE REQUIRED FILLING. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 1997071700416 19970717 00416 GL 1997 7 17 CA970421079 3 19970410 G 6114 B24915 PITCH CHANGE ROD HARTZL HCJ3Y PHCJ3YF2 GL SEAL AREA WORN W K NONE O OTHER IN INSP/MAINT 1 CA 2411 490 ED2161 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PITCH CHANGE ROD WORN THROUGH CHROME. 5 C P36EA 1997071700420 19970717 00420 GL 1997 7 17 CA970421083 3 19970410 G 6111 BLADE CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL FACE CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 1515 1515 RL449376T 82510 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. BLADE FACE FOUND CORRODED, LEADING EDGE DAMAGE, ANGLES AND FACE ALIGN MENT OUT OF SPECIFICATIONS. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 1997071700421 19970717 00421 GL 1997 7 17 CA970421084 3 19970414 G 6111 7666A2 BLADE HARTZL HCC2Y HCC2YK1 GL LEADING EDGE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 516 516 AW2519 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. NICKS AND CHIPS NEEDED REPAIRS. 5 C P920 1997071700422 19970717 00422 GL 1997 7 17 CA970421085 3 19970411 G 6111 BLADE CESSNA 177 177 2073704 CE MCAULY 1C172 1C172TM GL LEADING EDGE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 1448 1448 E8961 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. MANY GOUGES AND DENTS WERE FOUND. PROPELLER WAS LAST IN THE SHOP IN 1 968. THE PROPELLER WAS OVERHAULED. 1 H 7 1 3O NT A13CE 5 N P910 1997071700425 19970717 00425 GL 1997 7 17 CA970421088 3 19970415 G 6111 S82NC2 BLADE MCAULY 3A32C D3A32C90 GL AIRFOIL OUT OF SPECS W K NONE O OTHER IN INSP/MAINT 1 CA 704 374 750621 (CAN) PROPELLER BLADE PITCH FOUND OUT OF SPECIFICATIONS. 5 C P21EA 1997071700426 19970717 00426 GL 1997 7 17 CA970421089 3 19970415 G 6111 BLADE MCAULY 1B90 1B90CM GL PROP BENT W K NONE O OTHER IN INSP/MAINT 1 CA 317 317 78359 (CAN) ONE PROPELLER BLADE FOUND BENT. POSSIBLY IT HAD BEEN STRAIGHTENED. 5 N P842 1997071700427 19970717 00427 CE 1997 7 17 CA970421092 1 19970410 G 3211 05411211 SUPPORT CESSNA 05112894 CESSNA 182 182 2072702 CE CONT O470 O470L 17026 SO MCAULY 2A34C 2A34C50 GL TOP REAR CASTING CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 2000 2000 693105LR 731568 (CAN) BOTH MLG CASTING HAD BEEN REPLACED. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997071700432 19970717 00432 NE 1997 7 17 CA970422015 2 19970411 G 7260 310625901 BEVEL DRIVE GEAR PWA PWA PW121 PW121 52124 NE ACCESSORY GEARBX FRACTURED W K NONE O OTHER IN INSP/MAINT 1 CA 11568 11568 120583 (CAN) ENGINE WAS SENT FOR INVESTIGATION AFTER OPERATOR REPORTED A SUSPECTED #4 BEARING FAILURE. DISASSEMBLY FOUND THE #4 BEARING AREA FAILURE WAS THE SPLITTING OF THE HP IMPELLER BEVEL GEAR. ONE OF THE MOST COMMON CAUSES OF THE #4 BEARING A REA FAILURE IS THE BACKING OFF OF THE IMPELLER BEVEL GEAR RETAINING NUT. THIS RESULTS IN UNUSUAL STRESSES AND EXCESSIVE FRETTING AND RUBBING BETWEEN PARTS. UNUSUAL RUBBING AND FRETTING WAS SEEN BETWEEN THE COMPONENTS IN THE #4 BEARING STACK -UP. 4 T E20NE 1997071700433 19970717 00433 NE 1997 7 17 CA970422016 2 19970411 G 7210 310924401 BEARING PWA 119 PW119B NE RED GR BOX NR 15 SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 6714 6714 116040 (CAN) REDUCTION GEARBOX WAS SENT FOR INVESTIGATION OF METAL CONTAMINATION. DISASSEMBLY OF THE RGB FOUND THE SOURCE OF TH E METAL CONTAMINATION WAS A SPALLED #15 BEARING. IT IS NOT CLEAR WHAT CAUSED THE BEARING TO SPALL. THERE WAS NO MAGNETIS M BEYOND LIMITS AND NO EVIDENCE OF HEAVY ELECTRICAL DISCHARGE PITTING ON THE UNSPALLED PORTION OF THE BEARING, SO LIGHTN ING STRIKE DOES NOT APPEAR TO BE THE LIKELY CAUSE. 4 T E20NE 1997071700434 19970717 00434 NE 1997 7 17 CA970422017 2 19970331 G 7260 311196801 TOWERSHAFT PWA 118 PW118 NE SPIRAL BEVL GEAR FRACTURED W K NONE O OTHER IN INSP/MAINT 1 CA 16633 535 115212 (CAN) THE ENGINE WAS SENT FOR REPAIR AFTER THE OPERATOR REPORTED A FAILED TOWERSHAFT. DISASSEMBLY CONFIRMED THE TOWERSHA FT HAD FRACTURED IN TWO PLACES, BELOW THE UPPER SPIRAL BEVEL GEARSHAFT. EXAMINATION OF THE TWO FRACTURE SURFACES SHOWS T HAT THE UPPER FAILURE APPEARS TO BE COMPLETELY FATIGUE WHILE THE LOWER FAILURE WAS BATTERED. IT IS CONCLUDED THAT THE UP PER FAILURE OCCURRED FIRST ALLOWING MISMATCH OF THE GEARS WHICH CAUSED THE EXCESSIVE SIDE LOADS, THE BEARING FAILURE AND FINALLY THE SHEARING OF THE SHAFT AT THE LOWER LOCATION. 4 T E20NE 1997071700435 19970717 00435 EU 1997 7 17 CA970422019 1 19970411 G 3243 AC67750 BRAKE VALVE DOWTY STBROS SD3 SD360 8100606 EU LEFT MAIN DEFECTIVE W O OTHER O OTHER LD LANDING 1 CA HL240 (CAN) AFTER LANDING WHEN BRAKES APPLIED, THE LEFT MAIN WHEEL LOCKED AND THE AIRCRAFT STARTED TO PULL TO THE LEFT. RIGHT RUDDER AND BRAKES APPLIED TO KEEP AIRCRAFT STRAIGHT. WHEN AIRCRAFT CAME TO REST THE LEFT TIRE BLEW AND RIGHT TIRE HAD RO TATED ON THE RIM. THE BRAKE CONTROL VALVE WAS FOUND DEFECTIVE. 2 H 7 2 4T A41EU 1997071700438 19970717 00438 GL 1997 7 17 CA970422029 3 19970411 G 6111 BLADE HARTZL HCE3Y HCE3YR2 GL LEADING EDGE STONE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 2276 538 DJ9805A (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. STONE DAMAGE FOUND ON THE LEADING EDGE OF THE PROPELLER. 5 C P33EA 1997071700439 19970717 00439 GL 1997 7 17 CA970422030 3 19970416 G 6111 G80VAO BLADE CESSNA 185 A185F 2072821 CE MCAULY D3A34 D3A34C403 GL PROP NOT TO SPECS W K NONE O OTHER IN INSP/MAINT 1 CA 1522 498 860158 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PITCH DISTRIBUTION FOUND TO BE NOT TO SPECIFICATIONS OF THE MANUFACTU RES MANUAL. 1 H 7 1 3O 3A24 5 C P47GL 1997071700440 19970717 00440 GL 1997 7 17 CA970422031 3 19970416 G 6110 PROPELLER MCAULY 1C160 1C160DTM GL HUB ASSY CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 6656 5178 DE032 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER REQUIRED OVERHAUL DUE TO CORROSION. 5 N P910 1997071700443 19970717 00443 GL 1997 7 17 CA970422036 3 19970414 G 6111 T10173B8 BLADE HARTZL HCB3T HCB3TN3 GL LEADING EDGE STONE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 10049 1152 BU2118 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND PROPELLER REVERSING HAS DAMAGED THE PROPELLER, THROU GH FOD, ON THE LEADING EDGE AND CAMBER. THE TIP ANGLE ON #3 BLADE WAS OUT OF SPECS. 6 C P15EA 1997071700444 19970717 00444 GL 1997 7 17 CA970422037 3 19970414 G 6111 78CTA0 BLADE MCAULY 2D34C B2D34C207 GL LEADING EDGE STONE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 1200 384 755560 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. STONE DAMAGE REPAIR HAD BEEN DONE ON THE LEADING EDGE. FILE MARKS LEF T IN ON THE ATTEMPTED REPAIR. THE FILE MARKS ARE GOING IN THE CORD WISE DIRECTION. 5 C P7EA 1998041700534 19980417 00534 CE 1998 4 17 CA970423014 1 19970415 G 2752 556517538 ACTUATOR 556517538 CESSNA 500 560CESSNA 2076750 CE LT FLAP GRBOX SHEARED W K NONE O OTHER TX TAXI/GRND HDL 1 CA 136 1207961 (CAN) FLAPS WILL NOT MOVE WHEN SELECTED. MOVED INTERMITTENTLY, NOT EVERY SELECTION. LT FLAP GEARBOX OUTPUT SPROCKET SE VERED FROM OUTPUT SHAFT. PUT ALL THE LOAD ON RT MOTOR. NEW RT MOTOR INSTALLED AND GEARBOX. PART TC: 223. 2 L 7 2 4F RT A22CE 1997071700458 19970717 00458 GL 1997 7 17 CA970423017 3 19970410 G 6111 BLADE MCAULY 1C160 1C160DTM GL PROP OUT OF SPECS W K NONE O OTHER IN INSP/MAINT 1 CA 6740 725640 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND THE BLADES TO BE DIFFERENT LENGTHS; BLADE ANGLES OUT OF SPECS AT STATIONS 33 AND 36, TWISTING REQUIRED; LEADING EDGE BLUNT FROM FILING, REQUIRED DRESSING AND HUB NOT STAMPE D. 5 N P910 1997071700459 19970717 00459 GL 1997 7 17 CA970423018 3 19970411 G 6111 BLADE MCAULY 2D34C B2D34C211 GL BLADE FACE CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 847 219 765267 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. BLADE FACE REQUIRED GRINDING DUE TO CORROSION. 5 C P7EA 1997071700465 19970717 00465 SO 1997 7 17 CA970425002 2 19970418 G 7414 6310 MAGNETO SLICK CESSNA 182 182K 2072724 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL IMPULSE COUPLING BROKEN SPRING W O OTHER E VIBRATION/BUFFET TX TAXI/GRND HDL 1 CA 500 92120139 1338047R 785403 (CAN) ENGINE EXPERIENCED LARGE MAG DROP, ON LEFT MAGNETO, DURING RUN-UP. MAGNETO WAS REMOVED AND INSPECTION FOUND THE IM PULSE COUPLING SPRING WEAK AND NOT RETURNING TO ITS NORMAL RUN POSITION. THE IMPULSE COUPLING WAS DISASSEMBLED AND A BRO KEN SPRING WAS FOUND. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997071700466 19970717 00466 GL 1997 7 17 CA970425005 3 19970428 G 6111 BLADE MCAULY 2A36C 2A36C29 GL PROP NICKED W K NONE O OTHER IN INSP/MAINT 1 CA 907 107 621581 (CAN) PROPELLER BLADE FOUND NICKED DURING INSPECTION. 5 C P880 1998041700543 19980417 00543 EU 1998 4 17 CA970425006 2 19970417 G 7520 922253 COOLING HOSE ROTAX 912 ROTAX912 55555 EU NR 1 EXHAUST CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA 263 4412587 (CAN) CHAFING OF COOLANT LINE GREATER THAN 50 PERCENT OF WALL THICKNESS. NR 1 EXHAUST SPRING SOURCE OF CHAFING. 3 I EXPE3I 1997071700467 19970717 00467 SO 1997 7 17 CA970428001 2 19970414 G 7322 20764 FLOAT ASSEMBLY MARVELSCHEB NA45 CESSNA 180 180E 2072612 CE CONT O470 O470R 17026 SO FLOAT BRACKET BROKEN W K NONE K FLUID LOSS NR NOT REPORTED 1 CA 3988918 836582R (CAN) OWNER COMPLAINED OF CONTINUOUS FUEL LEAK FROM THE CARBURETOR. DISASSEMBLY OF THE CARBURETOR FOUND THE FLOAT SECTIO N SEPARATED FROM THE FLOAT BRACKET AND LAYING IN THE BOTTOM OF THE FLOAT CHAMBER. 1 H 7 1 3O 3 O 5A6 E273 1997071700468 19970717 00468 EA 1997 7 17 CA970428003 3 19970423 G 6111 BLADE SNSNCH 76E 76EM8S5 EA LEADING EDGE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 1216 21484K (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND THE PROPELLER LEADING EDGE AND FACE NICKED AT STATIO N 23" STATION. AREA REQUIRED FILLING AND GRINDING. 5 N P4EA 1998050100232 19980501 00232 CE 1998 5 1 CA970428011 1 19970410 G 3242 06130019 BRAKE CESSNA 172 172M 2072418 CE RT MLG CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) RIGHT BRAKE HOUSING CRACKED. REPLACED. 1 H 7 1 3O NT 3A12 1997072400722 19970724 00722 EA 1997 7 24 CA970429006 3 19970422 G 6111 BLADE PIPER PA22 PA22150 7102210 SO LYC O320 O320A2B 41508 EA SNSNCH 74D 74DM EA PROP CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 2341 47 L3154727A A44820 (CAN) PROPELLER RECEIVED FOR REPITCH. INSPECTION FOUND THE PROPELLER BLADES BENT WITH GOUGES AND CORROSION WHICH REQUIRE D GRINDING AND FILLING. 1 H 7 1 3O 3 O 1A6 E274 5 N P88614 1997072400723 19970724 00723 GL 1997 7 24 CA970429007 3 19970422 G 6111 S90AT4 BLADE CESSNA 185 A185F 2072821 CE MCAULY 2A34C D2A34C58 GL PROP LE OUT OF SPECS W K NONE O OTHER IN INSP/MAINT 1 CA 196 910362 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND THE BLADE PITCH DISTRIBUTION OUT OF SPECIFICATIONS. 1 H 7 1 3O 3A24 5 C P3EA 1997072400724 19970724 00724 GL 1997 7 24 CA970429008 3 19970422 G 6111 G90DFA10 BLADE MCAULY D3A34 D3A34C402 GL PROP OUT OF SPECS W K NONE O OTHER IN INSP/MAINT 1 CA 572 216 816273 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND THE BLADE PITCH DISTRIBUTION OUT OF SPECIFICATIONS. 5 C P47GL 1997072400725 19970724 00725 GL 1997 7 24 CA970429009 3 19970422 G 6111 S90AT4 BLADE CESSNA 185 A185F 2072821 CE MCAULY 2A34C D2A34C58 GL PROP CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 912 185 KH111YS 726057 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. BLADES THREADS CHECKED FOR CRACKS AND FOUND THAT FAILURE WAS IMMINENT . THE BLADE WAS SCRAPPED. 1 H 7 1 3O 3A24 5 C P3EA 1997072400726 19970724 00726 GL 1997 7 24 CA970429010 3 19970423 G 6111 G90DCA2 BLADE CESSNA 180 180H 2072618 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C203 GL PROP CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 425 986375RR 851761 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. TEN YEARS SINCE LAST OVERHAUL. INSPECTION FOUND BLADES CORRODED. TIP ANGLES OUT. FACE ALIGNMENT OUT. ONE ACTUATING PIN; TWO PISTON PINS AND CYLINDER CORRODED. REPAIRS MADE AND CORRODED PART S REPAIRED OR REPLACED. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 1997072400727 19970724 00727 GL 1997 7 24 CA970429011 3 19970422 G 6111 BLADE MCAULY 1A90 1A90CF GL PROP TIPS BENT W K NONE O OTHER IN INSP/MAINT 1 CA 356 LB004 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND PROPELLER BLADES PULLED FORWARD 1/32", BLADES REQUIR ED STRAIGHTENING. 5 N P842 1997072400731 19970724 00731 GL 1997 7 24 CA970501003 3 19970416 G 6111 R90DCA10 BLADE CESSNA 172 R172K 2072431 CE CONT O360 IO360KB 17025 SO MCAULY 2A34C 2A34C203 GL LEADING EDGE SPRAY CUT W K NONE O OTHER IN INSP/MAINT 1 CA 3516 141 356178 748255 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND SPRAY CUTS ON THE LEADING EDGE AND THE TIP ANGLES OU T. THE BLADE EDGES WERE FILED AND THE TIP ANGLES WERE REPAIRED. 1 H 7 1 3O 3 O 3A17 E1CE 5 C P3EA 1997121100267 19971211 00267 SW 1997 12 11 CA970505007 1 19970415 G 2820 AN737TW74 CLAMP CHAMP BBAVIA 8 8GCBC 1220803 SW LYC O360 O360C2A 41514 EA FUEL HOSE WRONG TYPE W O OTHER K w FLUID LOSS INADEQUATE Q C IN INSP/MAINT 1 CA L1867836A (CAN) SHORTLY AFTER REFUELING THE AIRCRAFT, A MAJOR FUEL LEAK OCCURRED. INVESTIGATION REVEALED THAT THE INCORRECT SIZE O F CLAMPS WERE INSTALLED ON AN INTERCONNECT FUEL TANK HOSE. THE CLAMP FOUND IN USE WAS AN AN737TW-74. THE PARTS MANUAL SH OWS AN AN737TW-56 CLAMP. THIS PROBLEM IS RELATIVE TO BELLANCA SCOUTS WITH THE 70 GAL LONG RANGE FUEL TANK. 1 H 7 1 3O 3 O A21CE E286 1998041700549 19980417 00549 1998 4 17 CA970505008 1 19970425 G 7714 2071000501 TACH CABLE ROTAX 912 ROTAX912 55555 EU FIRE SHIELD DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 943 4380693 (CAN) TACH CABLE PROTECTIVE SLEEVE FOUND MELTED AND SEPARATED FROM THE ATTACH POINT TO THE ENGINE. REPLACED. 3 I EXPE3I 1997072400736 19970724 00736 GL 1997 7 24 CA970505009 3 19970428 G 6114 57B2256 THRUST PLATE PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA HARTZL HCC2Y HCC2YK1 GL PROP HUB WORN W K NONE O OTHER IN INSP/MAINT 1 CA 1851 449 L1253048 CH13991 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. THRUST PLATE FOUND WORN CAUSING 32-9731616 BEARING TO BE LOOSE. THIS BEARING IS A PRESS FIT WHEN NEW. 57-A2202 BEARING RACE HAD CORROSION PITTING AS WELL AS BALL DAMAGE. 79-0100016 BALLS HA D CORROSION AND BALL DAMAGE. PITCH DISTRIBUTION ON #1 BLADE WAS OUT OF SPECIFICATIONS. 1 L 7 1 3O 3 O A3SO 1E4 5 C P920 1998050100233 19980501 00233 SO 1998 5 1 CA970505015 1 19970417 G 5330 1974500 RUBBER EXTRUSION PIPER PA23 PA23250 7102308 SO WING/FUSELAGE MISSING W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 6913 (CAN) FRETTING WHERE WING TO FUSELAGE FAIRING ATTACHES TO WING AND FUSELAGE, NO RUBBER CHAFING STRIPS INSTALLED. STRIPS INSTALLED. PART TT: 6,957 HOURS. 1 L 7 2 3O 1A10 1997072400741 19970724 00741 EA 1997 7 24 CA970505021 1 19970413 G 2750 855D1007 BPSU CNDAIR CL600 CL6002B19 EA GE CF34 CF343A1 30015 NE FLAPS FAILED W K NONE J WARNING INDICATION NR NOT REPORTED 1 CA 2181 GEE807385 (CAN) FLAPS FAILED MESSAGE ON EICAS. FLAPS UNABLE TO EXTEND. BRAKE AND POSITIONING SENSOR UNIT REPLACED. ALSO FLAP ELECT RONIC CONTROL UNIT AND POWER DRIVE UNITS REPLACED. FECU P/N 865D100-5 AND PDU P/N 860D100-18. 2 L 7 2 4F 4 F RT A21EA E15NE 1998050100234 19980501 00234 CE 1998 5 1 CA970506001 1 19970327 G 3150 993642461 AMPLIFIER BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA FAILED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA 10515 PCE50113 (CAN) INTEGRATED CIRCUITS WITHIN TRIM CONTROL AMPLIFIER FAILED. NO AURAL WARNING OF TRIM IN MOTION. REPLACED. 1 L 7 2 3T 4 T A14CE E4EA 1998050100235 19980501 00235 CE 1998 5 1 CA970506002 1 19971113 G 2913 204038 FILTER BEECH 1900 1900D 1154162 CE HYD SYS CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 CA 207 (CAN) HYDRAULIC FILTER BYPASS INDICATOR POPPED. FILTER CONTAMINATED. REPLACED. 2 L 7 2 4T RT A24CE 1997072400751 19970724 00751 GL 1997 7 24 CA970506004 3 19970430 G 6111 BLADE MCAULY 1A105 1A105SCM GL PROP OUT OF SPEC W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 1565 G14725 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. ONE PROP BLADE WAS 1/4" LONGER THAN THE OTHER AND TRIMMING WAS REQUIR ED. 5 N P918 1997072400753 19970724 00753 GL 1997 7 24 CA970506007 3 19970430 G 6111 FL7666A42 BLADE CONAER LA4 LA4200 5110310 NE LYC O360 IO360A1B 41514 EA HARTZL HCC2Y HCC2YK1 GL PROP FACE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 1170 775 L223535A1 CH25937 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. #1 PROPELLER BLADE HAD DAMAGE TO THE FACE SIDE DUE TO BOLT OR SCREW D AMAGE WHICH WAS NOT DRESSED OUT, WHEN PROPELLER WAS RECEIVED FOR INSPECTION. 1 H 7 1 3O 3 O 1A13 1E10 5 C P920 1997072400754 19970724 00754 GL 1997 7 24 CA970506008 3 19970430 G 6111 BLADES MCAULY 1A101 1A101HCM GL PRO LEAD EDGE NICKED W K NONE O OTHER IN INSP/MAINT 1 CA 4514 G10892 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. LEADING EDGES FOUND BLUNT AND REQUIRED FILING. DEEP NICKS WERE FOUND IN THE BLADE FACES WHICH REQUIRED GRINDING. 5 N P918 1997072400755 19970724 00755 EA 1997 7 24 CA970506009 3 19970429 G 6111 BLADES SNSNCH 74DM M74DM EA PROP LEAD EDGE NICKED W K NONE O OTHER IN INSP/MAINT 1 CA 6948 590 K13223 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. TIPS PULLED FORWARD, LIGHT CORROSION ALL OVER, GRINDING WAS REQUIRED. LEADING EDGE NICKED, FILING WAS REQUIRED 5 N P88614 1997072400756 19970724 00756 GL 1997 7 24 CA970506010 3 19970429 G 6111 S82NC2 BLADE CESSNA 210 T210L 2073449 CE CONT O520 TSIO520H 17040 SO MCAULY 3A32C D3A32C* GL PROP LEAD EDGE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 486 227 506056 736801 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. LEADING EDGE OF THE PROPELLER BLADE WAS FOUND DAMAGED. REWORK AND GRI NDING WAS REQUIRED TO FIX THE AIRFOIL ON ALL BLADES. 1 H 7 1 3O 3 O 3A21 E8CE 5 C P21EA 1997072500026 19970725 00026 SO 1997 7 25 CA970506013 2 19970430 G 8530 649317A PISTON PIN CONT CESSNA 340 340CESSNA 2076404 CE CONT O520 TSIO520NB 17040 SO MCAULY 3AF32C 3AF32C* GL INSIDE SLEEVE BROKEN W K NONE O OTHER NR NOT REPORTED 1 CA 1050 514056 775668 (CAN) CYLINDER WAS REMOVED DUE TO LOW COMPRESSION AND INCREASE IN OIL CONSUMPTION. INSPECTION FOUND THE HEADS OF THE PIS TON PINS MUSHROOMED OVER. FURTHER INSPECTION REVEALED THE ALUMINUM PLUG BROKEN IN HALF. NO DAMAGE WAS FOUND ON THE STEEL PIN. INSPECTION OF THE OTHER PISTON PINS FOUND NO FAULT. ENGINE WAS REASSEMBLED. 1 L 7 2 3O 3 O 3A25 E8CE 5 C P22EA 1998050100237 19980501 00237 SO 1998 5 1 CA970506016 1 19970428 G 2740 3314902 SPRING PIPER PA23 PA23250 7102308 SO STAB BUNGEE WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) STABILATOR BUNGEE SPRING WORN CORRODED AND WEAK. WIRE DIAMETER OF LOOP FLATTENED WHERE LOOP CONTACT IS MADE WITH HOOKING HOLE. SPRING WIRE REDUCED BY 50 PERCENT. LOOP AT OTHER END SHOWS SIGNS OF HARDENING AND SURFACE CORROSION. RE PLACED. 1 L 7 2 3O 1A10 1997072400769 19970724 00769 EA 1997 7 24 CA970507009 1 19970423 G 3246 300478 WHEEL HALF DHAV 31354 DHAV DHC7 DHC7102 2802708 EA INBOARD CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 2278 606 (CAN) DURING EDDY CURRENT INSPECTION SEVERAL CRACK INDICATIONS WERE FOUND AT SEVERAL LUG BOSSES ALONG THE BOTTOM SIDE, P ARALLEL TO THE WHEEL BOLT HOLES. THE CRACKS VARIED IN LENGTH FROM 1/2" TO OVER 1" AND TO A DEPTH OF OVER .060. 2 H 7 4 4T A20EA 1998120400002 19981204 00002 1998 12 4 CA970507014 1 19970424 G 2435 03601018 BEARING LUCAS 23046020 START/GEN WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 5835 (CAN) BEARINGS REMOVED AT OVERHAUL DID NOT HAVE OEM LOGO AND WERE THE WRONG FAFNIR PART NUMBER. 1997072400775 19970724 00775 NE 1997 7 24 CA970507020 2 19970430 G 7210 310703301 BEARING PWA 120 PW120A NE RED GR BOX NR 15 SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 23051 20057 120188 (CAN) ENGINE WAS SENT FOR INVESTIGATION OF OIL LEAK AND METAL CONTAMINATION OF THE RGB. DISASSEMBLY OF THE RGB FOUND THE CAUSE OF THE METAL CONTAMINATION TO BE SPALLING OF THE #15 BEARING. THE EXTENSIVE MAGNETISM AND WIDESPREAD ELECTRICAL D ISCHARGE PITTING DAMAGE ON THIS AND OTHER BEARINGS LEAVES LITTLE DOUBT THAT THIS WAS CAUSED BY ELECTRICAL DISCHARGE AS A RESULT OF A LIGHTNING STRIKE. THIS DID NOT APPEAR TO CAUSE ANY SECONDARY DAMAGE. THE OIL LEAK APPEARED TO HAVE OCCURRED WHEN PACKING AND AIR/OIL SEALS AROUND THE #5 BEARING DETERIORATED. OVER TIME THE INTEGRITY OF THE PACKING IS LOST. IN T HIS CASE THE TURBOMACHINE WAS AT 20057.4 HOURS AND IT IS NOT SURPRISING TO FIND THIS DETERIORATION. 4 T E20NE 1997072400782 19970724 00782 NM 1997 7 24 CA970508008 1 19970502 G 2822 2580005 PUMP ARGOTEC 2580005 BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE NR 2 TANK RT AFT FAILED W H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION DE DESCENT 1 CA 1003679B P653620B (CAN) DURING DESCENT THE LOW PRESSURE LIGHT FOR THE #2 TANK R/H AFT BOOST PUMP CAME ON. THE PUMP WAS SELECTED OFF AND TH E FLIGHT COMPLETED WITHOUT INCIDENT. PUMP REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 1997072400783 19970724 00783 NM 1997 7 24 CA970508009 1 19970502 G 2730 680005003 BOOST PACK BERTEA CORP 680005003 BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE LH ELEVATOR LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 1973 P653620B (CAN) DURING PREFLIGHT THE L/H ELEVATOR BOOST PACK WAS FOUND LEAKING WHEN HYDRAULIC SYSTEM NOT POWERED, REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 1997070300310 19970703 00310 EA 1997 7 3 CA970508010 1 19970501 G 5320 85300016113 CLOSING ANGLE DHAV DHC8 DHC8311 1386006 EA X387.35,Y265 CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 13595 (CAN) FUSELAGE TO WING LEFT FORWARD CLOSING ANGLE FOUND WITH 4" CRACK IN RADIUS. INSPECTION OF OTHER CLOSING ANGLES FOUN D RIGHT FORWARD CLOSING ANGLES ALSO CRACKED 3" IN RADIUS. 2 H 7 2 4T RT A13NM 1997072400784 19970724 00784 GL 1997 7 24 CA970508014 3 19970505 G 6114 5262 CYLINDER CESSNA 180 180H 2072618 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL PROPELLER SCORED W K NONE O OTHER IN INSP/MAINT 1 CA 1332 205 2028969R 714226 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER CYLINDER WAS SCORED AND WORN AND HAD TO BE REPLACED. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 1997072400785 19970724 00785 NE 1997 7 24 CA970508015 3 19970502 G 6114 51459 SPIDER HAMSTD 2D 2D30 NE PROPELLER CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 1147 AC4116028 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. ONE CHAFING RING BROKEN, CYLINDER OVERSIZE. PROPELLER OVERHAULED. 5 C P206 1998050100238 19980501 00238 CE 1998 5 1 CA970513006 1 19970426 G 5313 07120486 LONGERON CESSNA 185 A185F 2072821 CE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 5017 (CAN) .5 INCH CRACK AT TOP END OF RT REINFORCEMENT LONGERON, DUE TO CORROSION. RT BRACKETS 07123021 AND 2 AND REINFORCE MENTS 0712304-15 AND 16 REPLACED. AIRCRAFT TT: 5,017 HOURS. 1 H 7 1 3O 3A24 1997070300311 19970703 00311 EA 1997 7 3 CA970513008 1 19970501 G 2720 85500015001 ROD DHAV DHC8 DHC8311 1386006 EA TRAILING RUDDER WORN W K NONE O OTHER IN INSP/MAINT 1 CA 13595 (CAN) TRAILING RUDDER UPPER RADIUS ROD FORWARD ROD END BEARING P/N DSC4-4 FOUND LOOSE IN RADIUS ROD. JAMB NUT FOUND LOOS E. ROD END WAS RETAINED IN RADIUS ROD ONLY BY 3/32" RIVET. THREADS ON RADIUS ROD WERE WORN OUT. 2 H 7 2 4T RT A13NM 1998050100240 19980501 00240 CE 1998 5 1 CA970513011 1 19970507 G 3297 WIRE BEECH 100 A100 1152915 CE PWA PT6 PT6A34 52043 EA RT MLG DOWN BROKEN W A UNSCHED LANDING P NO WARNING INDICATION CR CRUISE 1 CA PCE40241 (CAN) WHILE ON TRAINING, THE CREW SELECTED THE GEAR DOWN AND THE AIRCRAFT RESPONDED NORMALLY, EXCEPT RT GEAR DOWN LIGHT FAILED TO ILLUMINATE. FLY-BY CONFIRMED THAT GEAR DOWN. A/C LANDED. FOUND BROKEN WIRE, REPAIRED. 1 L 7 2 3T 4 T A14CE E4EA 1997072400792 19970724 00792 GL 1997 7 24 CA970513013 3 19970430 G 6114 HUB CESSNA 150 152 2071835 CE MCAULY 1A103 1A103TCM GL PROPELLER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 5100 3984 (CAN) DURING COMPLIANCE WITH FAA AD 97-06-16 DYE PENETRANT INSPECTION DID NOT FIND THE CRACK, WHICH WAS FOUND THROUGH ED DBY CURRENT INSPECTION. CRACK AREA HOLLOWED AS PER SB 221B TO DEPTH OF .010, CRACK WAS THEN EVIDENT. CRACK AREA HOLLOWED TO .040 AND CRACK WAS NO LONGER VISIBLE WITH LPI. EDDY CURRENT COULD NOT BE USED DUE TO HOLLOW AT CRACK LOCATION. MCCAU LEY ADVISED, IF CRACK NOT VISIBLE WITH LPI RETURN PROPELLER TO SERVICE. 1 H 7 1 3O NT 3A19 5 N P50GL 1997072400793 19970724 00793 GL 1997 7 24 CA970513014 3 19970507 G 6114 PROPELLER HARTZL HCC2Y HCC2YK1 GL PITCH CHANGE INCORRECT RADIUS W K NONE O OTHER IN INSP/MAINT 1 CA 1335 CH9773 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND INCORRECT RADIUS ON PITCH CHANGE BLOCK. 5 C P920 1997072400794 19970724 00794 NE 1997 7 24 CA970513015 2 19970430 G 7414 SB9RU3 MAGNETO BOSCH PWA R985 R985* 52008 NE ENGINE FAULTY W K NONE O OTHER IN INSP/MAINT 1 CA 476 20175 (CAN) MAGNETO APPEARED TO BE TIMED PROPERLY BUT THE POINTS WOULD CLOSE 135 DEGREES AFTER TOP DEAD CENTRE. MAGNETO WAS SE NT FOR OVERHAUL 3 R 5E1 1998041700556 19980417 00556 EU 1998 4 17 CA970513016 2 19970425 G 7320 CHOKE CABLE ROTAX 912 ROTAX912 55555 EU ENGINE BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 4380693 (CAN) THE CHOKE CABLE WAS FOUND BROKEN WHERE IT THREADS INTO THE 90 DEGREE ROUTING UNIT. 3 I EXPE3I 1997072400798 19970724 00798 NE 1997 7 24 CA970513025 2 19970501 G 7210 310924401 BEARING PWA 120 PW120A NE RED GRBOX NR 15 SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 19463 13282 RH477 120224 (CAN) THE ENGINE WAS SENT FOR INVEST. OF METAL CONTAMINATION & SUBSEQUENT OVERHAUL. DISASSY FOUND- #15 BEARING SEVERELY SPALLED ON ONE ROLLER WITH SUBSTANTIAL MATERIAL LOSS. THIS DAMAGE WAS MORE THAN SUFFICIENT TO EXPLAIN- METAL CONTAMINATI ON OBSERVED.-RE DOES NOT APPEAR TO BE ANY SIGNIFICIENT SECONDARY DAMAGE.- #15 & #18 BEARINGS BOTH HAD ELECTRICAL EROSION TYPE CHAIN PITTING TYPICA L OF LOW ENERGY ELECTRICAL DISCHARGE & ALSO SOME DEEPER ARCING TYPE PITTING TYPICAL OF HIGHER ENERGY ELECTRICAL DISCHARGE.- MAGNETISM IN- RGB WAS RELATIVELY MINOR & NOT TYPICAL OF- MAGNETISM PR OFILE THAT TYPICALL Y ARISES FOLLOWING A LIGHTNING STRIKE. IT IS UNCLEAR IF THIS WAS CAUSED BY A LIGHTNING STRIKE. 4 T E20NE 1997072400799 19970724 00799 NE 1997 7 24 CA970513026 2 19970501 G 7210 310703301 BEARING PWA 118 PW118 NE RED GRBOX NR 15 SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 21801 1445 115165 (CAN) THE ENGINE WAS SENT FOR INVESTIGATION AFTER THE REDUCTION GEARBOX WAS FOUND WITH METAL CONTAMINATION. DISASSEMBLY FOUND THE CAUSE OF THE CONTAMINATION WAS THE SPALLING OF THE #15 BEARING. HIGH MAGNETISM ON SEVERAL COMPONENTS AND ELECT RICAL PITTING ON THE #15 AND #19 BEARINGS INDICATE THE ENGINE EXPERIENCED A LIGHTNING STRIKE. THE FAILURE OF THE #15 BEA RING IS THOUGHT TO HAVE BEEN INITIATED BY THE LIGHTNING STRIKE. 4 T E20NE 1998040200081 19980402 00081 CE 1998 4 2 CA970514002 1 19970419 G 3222 55422232 SPACER CESSNA 500 560CESSNA 2076750 CE AXLE SHAFT NLG SEIZED W K NONE O OTHER IN INSP/MAINT 1 CA 600 (CAN) LEFT HAND NOSE WHEEL SPACER FOUND SEIZED TO THE AXLE SHAFT. 2 L 7 2 4F RT A22CE 1997072400800 19970724 00800 NE 1997 7 24 CA970514004 2 19970430 G 8530 CYLINDER DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985* 52008 NE #9 CYLINDER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 476 20175 (CAN) DURING INSPECTION #9 CYLINDER WAS FOUND CRACKED ON THE TOP BETWEEN THE TWO SPARK PLUG HOLES 1 H 7 1 3R 3 R A806 5E1 1997072400801 19970724 00801 GL 1997 7 24 CA970514005 3 19970506 G 6111 T10173AB6Q BLADE HARTZL HCB3T HCB3TN3 GL PROP LE STONE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 3924 967 BU16054 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER BLADES FOUND DAMAGED FROM GRAVEL - VERY ROUGH - TRIMMED OUT . BALLS FROM BEARINGS SCUFFED AND WERE REPLACED. DE-ICE BRACKETS WERE FOUND CRACKED AND THEY WERE REPLACED. 6 C P15EA 1997072400804 19970724 00804 NE 1997 7 24 CA970514008 2 19970501 G 7322 FUEL CONTRL UNIT PWA 119 PW119B NE #2 ENGINE FAULTY W O OTHER O OTHER CL CLIMB 1 CA 2420 116150 (CAN) DURING CLIMB THE ENGINE POWER FLUCTUATED ABOUT 50 PERCENT WITH THE AIRCRAFT YAWING. REPLACEMENT OF THE FUEL CONTRO L UNIT CLEARED THE PROBLEM. 4 T E20NE 1997072500028 19970725 00028 NE 1997 7 25 CA970514009 2 19970312 G 7311 FUEL OIL COOLER PWA PW120 PW126A NE #2 ENGINE FAULTY W E ENGINE SHUTDOWN J WARNING INDICATION CL CLIMB 1 CA 9208 29 124041 (CAN) JUST AFTER TAKEOFF THE #2 ENGINE OIL PRESSURE BEGAN TO FLUCTUATE AND LATER IN THE FLIGHT WHEN THE OIL PRESSURE DRO PPED BELOW 41 PSI THERE WAS A COCKPIT WARNING. THE #2 ENGINE WAS SHUTDOWN. THE FUEL/ OIL COOLER WAS REPLACED. 4 T E2ONE 1998050100242 19980501 00242 CE 1998 5 1 CA970520001 1 19970403 G 3213 07410016 GEAR LEG CESSNA 185 A185F 2072821 CE MLG SKI BROKEN W C ABORTED TAKEOFF E VIBRATION/BUFFET TO TAKEOFF 1 CA 7672 (CAN) ON TAKEOFF, THE LEG OF THE SKI EQUIPPED AIRCRAFT BROKE. POSSIBLY PREVIOUSLY CRACKED. REPLACED. 1 H 7 1 3O 3A24 1998050100244 19980501 00244 CE 1998 5 1 CA970520007 1 19970507 G 5720 1214223 DOUBLERS CESSNA 210 210F 2073418 CE CONT O520 IO520A 17032 SO RT LT WELLS CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 2826 (CAN) CRACKS FOUND ON AFT GEAR WELL BULKHEAD DOUBLERS LT AND RT WELLS. CRACKS EXTEND AROUND BOLT HOLES AND RUN VERTICAL ON DOUBLERS. DOUBLERS REPLACED. 1 H 7 1 3O 3 O 3A21 E5CE 1997072400920 19970724 00920 GL 1997 7 24 CA970520009 3 19970512 G 6114 790100016 BALL BEARING BEECH 23 C24R 1151254 CE LYC O360 IO360A1B6 41514 EA HARTZL HCM2Y HCM2YR GL PROPELLER GALLED W K NONE O OTHER IN INSP/MAINT 1 CA 902 413 L17179 EN383 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. BALL BEARINGS FOUND GALLED. 1 L 7 1 3O 3 O A1CE 1E10 5 C P43GL 1997072400921 19970724 00921 GL 1997 7 24 CA970520010 3 19970512 G 6111 F766A2 BLADE MOONEY M20 M20E 5870212 SW LYC O360 IO360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL BALANCE HOLE CORROSION W K NONE O OTHER IN INSP/MAINT 1 CA 601 L141351A 26853 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. ONE BLADE REJECTED DUE TO CORROSION IN THE BALANCE HOLE. HUB PILOT BO RE OVERSIZE AND HUB HAD CORROSION. 1 L 7 1 3O 3 O 2A3 1E10 5 C P920 1998050100246 19980501 00246 SO 1998 5 1 CA970520014 1 19970508 G 3242 6830 SHIM CLEVELAND 19983 PIPER PA31 PA31350 7103110 SO BRAKE MISSING W K NONE K W FLUID LOSS INADEQUATE Q C IN INSP/MAINT 1 CA S4295GL (CAN) WHEELS AND BRAKES PREVIOUSLY MODIFIED PER STC AND DWGS. DUE FOR 100 HR INSP. RT BRAKE FOUND LEAKING, O-RINGS. R T SIDE BOTH BRAKES O-RINGS FOUND FRIED ONTO CASING AND STICKING TO PISTONS. SHIM PIPER 762421, CLEVLAND 68-30, MISSING ON ONE BRAKE AND HOME MADE METAL SHIMS FOUND ON TWO LININGS AND MISSING ON THIRD. LT, BOTH SHIMS MISSING, O-RINGS HEATE D. NO LOCK WASHERS ON BOLTS. REPLACED. 1 L 7 2 3O A20SO 1997072400924 19970724 00924 GL 1997 7 24 CA970521001 3 19970508 G 6112 SA70111 BRACKET CESSNA 340 340A 2076405 CE CONT O520 TSIO520NB 17040 SO MCAULY 3AF32C 3AF32C93 GL DE-ICE LEAD BROKEN W K NONE D INFLIGHT SEPARATION NR NOT REPORTED 1 CA 884 290384R 789543 (CAN) AFTER LANDING THE PILOT NOTICED THE LH PROPELLER DE-ICE LEAD HANGING FROM THE PROPELLER SPINNER. INSPECTION FOUND THE DE-ICE LEAD BRACKET WHICH RETAINS THE PLUG-IN CONNECTION ON THE BLADE ROOT HAD BROKEN. THE BRACKET, CLIP AND PLUG AS SEMBLY HAD DEPARTED THE BLADE ROOT AND STRUCK THE AFT FACE OF THE PROPELLER AND THEN CONTACTED THE AIRCRAFT FUSELAGE CAU SING SOME DENTING. THE PROPELLER DE-ICE PARTS WERE REPLACED, THE BLADE DAMAGE WAS DRESSED OUT AND THE FUSELAGE SKIN WAS REPAIRED. 1 L 7 2 3O 3 O 3A25 E8CE 5 C P22EA 2000021200003 20000212 00003 SO 2000 2 12 CA970521006 1 19970514 G 3242 16432A617 BRAKE CLEVELAND 11915 PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA HARTZL HCE2Y HCE2YR2 GL MLG DAMAGED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA L104448 BP3110 (CAN) DISC 16432A617 FOUND WITH THREE BOLTS LOOSE AND BOLT HOLES ELONGATED IN DISC. TWO BOLTS FOUND WITH CRACKS. WHEN PRIED, A PIECE 1 INCH BY 2.5 INCHES OF THE LATERAL WALL OF DISC CAME OFF. WAS NOT EVIDENT LAST 59 HR INSP. REPLACED. MAY BE SOME CONFUSION WITH KITS 119-15 AND 119150. 1 L 7 2 3O 3 O 1A10 1E4 5 C P9EA 2000021200004 20000212 00004 EA 2000 2 12 CA970521007 2 19970514 G 7414 NUT AERO RECIP A182AS11 PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA HARTZL HCE2Y HCE2YR2 GL LT MAGNETO CORRODED W A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 CA 1636 L104448 BP3110 (CAN) IN CRUISE, LEFT ENGINE STARTED TO RUN ROUGH. AIRCRAFT LANDED. MAG CHECK CARRIED OUT, 300 RPM DROP WITH LEFT MAG OFF. NR 4 CYLINDER LEAD DISCONNECTED, RETAINING NUT MISSING ONLY SMALL RING PART FROM NUT FOUND. INTERGRANULAR CORROSI ON. REPLACED. 1 L 7 2 3O 3 O 1A10 1E4 5 C P9EA 1997072400927 19970724 00927 1997 7 24 CA970521010 1 19970429 G 3244 39X1322PR TIRE GOODYEARAERO MLG PATCHED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) TIRE INSPECTION CARRIED OUT PRIOR TO INSTALLATION AND FOUND WITH PATCH ON INSIDE OF TIRE. 1997072400928 19970724 00928 GL 1997 7 24 CA970521011 3 19970506 G 6111 T10173AB6Q BLADE HARTZL HCB3T HCB3TN3 GL LEADING EDGE STONE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 3924 967 BU15994 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER BLADES FOUND DAMAGED FROM GRAVEL - VERY ROUGH - TRIMMED OUT . BALLS FROM BEARINGS SCUFFED AND WERE REPLACED. DE-ICE BRACKETS WERE FOUND CRACKED AND THEY WERE REPLACED. 6 C P15EA 1998050100248 19980501 00248 CE 1998 5 1 CA970523005 1 19970505 G 7160 5123015 CONTROL CABLE CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA CARB HEAT BROKEN W O OTHER O OTHER TX TAXI/GRND HDL 1 CA 2830 L3008227A (CAN) CARBURETOR HEAT CABLE BROKE OFF 3 INCHES FROM KNOB DURING GROUND CHECK. REPLACED. 1 H 7 1 3O 3 O NT 3A12 E274 1997072400929 19970724 00929 CE 1997 7 24 CA970523006 1 19970514 G 7810 311494001 EXHAUST DUCT CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE AFT EDGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 672 PCE71819 (CAN) DURING INSPECTION A CRACK WAS FOUND IN THE EXHAUST DUCT. THE ONE INCH CRACK WAS RADIATING AXIALLY FORWARD FROM THE AFT EDGE OF THE DUCT. THE DEFECTIVE PART WAS REPLACED BY PRATT & WHITNEY SERVICE CENTRE. 1 L 7 2 4F 4 F A22CE E1NE 1997070300313 19970703 00313 EA 1997 7 3 CA970523007 1 19970508 G 2720 RUDDER DHAV DHAV DHC8 DHC8311 1386006 EA FLIGHT CONTROL JAMMED W A A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) APPARENT RUDDER JAM IMMEDIATELY AFTER ROTATION. FOLLOWING ROTATION INTO A MODERATED CROSSWIND CORRECTIVE RUDDER WA S APPLIED. RUDDER PEDALS WERE STIFF AND EVEN WITH A CONSIDERABLE FORCE APPLIED THE RUDDER ONLY HAD A LIMITED AMOUNT OF D IRECTIONAL CONTROL. CONTROL GIVEN TO F.O. FOR VERIFICATION. PRECAUTIONARY LANDING CARRIED OUT OK. EMERGENCY DECLARED. PI LOT CLAIMED RUDDER COULD BE OPERATED DURING THE FLIGHT USING THE AUTOPILOT AND TRIM SYSTEM. CONTROL CABLES CIRCUITS CHEC KED OFF. THE TWO RUDDER ACTUATORS AND THE RUDDER DAMPER WERE REPLACED AS A PRECAUTION. 2 H 7 2 4T RT A13NM 1998050100249 19980501 00249 SO 1998 5 1 CA970523012 1 19970512 G 5510 1001 VORTEX GEN PIPER PA31 PA31350 7103110 SO HORIZ STAB MISSING W K NONE D F INFLIGHT SEPARATION FLT CONT AFFECTED IN INSP/MAINT 1 CA 957 (CAN) VORTEX GEN MISSING ON TOP OF WING STN 174.5 AND BOTTOM OF RT STAB AT STN BL 9 8.25. SUBMITTER STATED POSSIBLY LOO SENED DURING WASHING AND FELL OFF DURING TAXI OR FLIGHT. VG ON STAB IS PARTLY ON CORNER OF TRIM PANEL. AIRCRAFT TT: 1 0,273 HOURS. 1 L 7 2 3O A20SO 1997072400934 19970724 00934 NE 1997 7 24 CA970526003 2 19970430 G 7261 OIL PUMP EMB 120 EMB120 3260201 SO PWA 118 PW118 NE PROP CONTROL CRACKED W O OTHER O OTHER CL CLIMB 1 CA 115447 (CAN) DURING CLIMB THE #2 ENGINE MAIN OIL PRESSURE WENT TO ZERO AND NP WENT TO 102.8. THE CREW TRIED TO FEATHER THE PROP ELLER WITHOUT SUCCESS. POST FLIGHT INVESTIGATION FOUND THE PROPELLER CONTROL UNIT OIL PUMP WAS CRACKED. 2 L 7 2 4T 4 T RT A31SO E20NE 1997072400944 19970724 00944 EA 1997 7 24 CA970527008 2 19970520 G 7322 324475316 FUEL CONTRL UNIT PWA PT6 PT6A50 52043 EA NR 4 ENG SHEARED SHAFT W E ENGINE SHUTDOWN O OTHER CR CRUISE 1 CA 3991 86288 (CAN) IN CRUISE AT 16,600 FEET THE #4 ENGINE SURGED. THE TORQUE, T5 AND NG ALL CLIMBED BEYOND OPERATING LIMITS. EMERGENC Y PROCEDURES WERE CONDUCTED AND THE ENGINE SHUTDOWN. POST FLIGHT INSPECTION FOUND THE FUEL CONTROL UNIT TO FUEL PUMP INP UT SHAFT HAD SHEARED CAUSING THE ENGINE TO OVERSPEED. BOTH THE ENGINE AND PROPELLER WILL BE SHIPPED FOR INVESTIGATION WI TH A REPORT TO FOLLOW. 4 T E4EA 1998041700570 19980417 00570 CE 1998 4 17 CA970527010 1 19970515 G 3222 58420005 FORK TUBE CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO MCAULY 3AF32C 3AF32C505 GL RT MLG BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 4204 278157R 810799 (CAN) AME NOTICED THE RIGHT HAND LOWER AXLE ATTACH POINT WAS BROKEN. DAMAGE APPEARS TO HAVE BEEN CAUSED BY A BEARING SE IZURE. 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 1997072400947 19970724 00947 GL 1997 7 24 CA970527013 3 19970521 G 6114 792100018 BEARING BALLS PIPER PA24 PA24 7102402 SO LYC O360 O360A1A 41514 EA HARTZL HC92Z HC92ZK8 GL HUB BEARINGS CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 1920 198 L300536 1328L (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. THE PROPELLER BLADE BEARING BALLS WERE FOUND CORRODED AND REMOVED FRO M SERVICE. 1 L 7 1 3O 3 O 1A15 E286 5 C P892 1997072500030 19970725 00030 GL 1997 7 25 CA970527014 3 19970521 G 6110 PROPELLER CESSNA 208 208 2073702 CE MCAULY 3G34C7 3GFR34C701 GL PROP ASSY MIS OHAULED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 950255 (CAN) PROPELLER RECEIVED FOR BENCH CHECK. NUMEROUS FAILURES FOUND INCLUDING: WRONG TYPE OF DE-ICER BOOT; BULKHEAD INSTAL LED ON WRONG SIDE OF SLIP RING; LOW STOP COLLAR INSTALLED IN WRONG POSITION; LOW STOP COLLAR RUNOUT WAS GREATER THAN MAX ALLOWABLE; SLIP RING RUNOUT WAS .012" MAX .010"; BALANCE OUT BY 21 WEIGHTS ON ONE BLADE; COARSE THREAD SCREW IN FINE TH READ HOLE; INCORRECT LINK PIN BOLT INSTALLED; DE-ICER LEADS INSTALLED INCORRECTLY; FOUND 1/2" OF LOCKING WIRE IN PROPELL ER HUB BALL BEARING AND RACE; WRONG SCREWS INSTALLED TO RETAIN SLIP RING; 3 CYLINDER SCREWS NOT LOCKWIRED. PROPELLER REP AIRED. 1 H 7 1 3T NT A37CE 5 C P60GL 1997072400957 19970724 00957 NM 1997 7 24 CA970528010 1 19970526 G 2420 976J1198 GENERATOR BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE NR 3 ENGINE GROUND FAULT W H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION CR CRUISE 1 CA 4402 P653620B (CAN) DURING CRUISE FLIGHT THE #3 ENGINE DRIVEN GENERATOR TRIPPED OFF LINE DUE TO A DIFFERENTIAL FAULT INDICATION. CSD D ISCONNECTED AND FLIGHT CONTINUED WITHOUT INCIDENT. UNABLE TO DUPLICATE, GENERATOR REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 1997072400962 19970724 00962 GL 1997 7 24 CA970529002 3 19970514 G 6111 S82NC2 BLADE CESSNA 185 A185F 2072821 CE MCAULY 3A32C D3A32C* GL LEADING EDGE SPRAY CUT W K NONE O OTHER IN INSP/MAINT 1 CA 307 816394 (CAN) 1/4" WAS REMOVED FROM THE LEADING EDGES OF THE PROPELLER BLADES AND HAD TO REDUCE BLADES TO MINIMUM DIAMETER TO RE TAIN PROPER TIP SHAPE. THE PROPELLER BLADES WERE DAMAGED BY WATER SPRAY CUTS. 1 H 7 1 3O 3A24 5 C P21EA 1997072400963 19970724 00963 GL 1997 7 24 CA970529004 3 19970512 G 6111 BLADE MCAULY 1C160 1C160DTM GL LEAD EDGE & FACE STONE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 1786 728962 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. STONE DAMAGE TO THE PROPELLER LEADING EDGE REQUIRED FILING, AND STON E DAMAGE TO THE PROPELLER FACE REQUIRED GRINDING. 5 N P910 1997072400971 19970724 00971 GL 1997 7 24 CA970530002 3 19970523 G 6111 90DCA2 BLADE CESSNA 180 180J 2072622 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C203 GL LEADING EDGE SPRAY CUT W K NONE O OTHER IN INSP/MAINT 1 CA 1075 350 21212171RR 750680 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. SPRAY CUTS ON THE LEADING EDGE REQUIRED FILING. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 1997072400972 19970724 00972 GL 1997 7 24 CA970530003 3 19970522 G 6111 80VA0 BLADES MCAULY D3A34 D3A34C403 GL ALL BLADES CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 896 626 812046 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. ALL THREE BLADES WERE FOUND CORRODED AT THE SNAP RING GROOVES 5 C P47GL 1997072400973 19970724 00973 GL 1997 7 24 CA970530004 3 19970520 G 6111 90DCA10 BLADE CESSNA 172 R172K 2072431 CE CONT O360 IO360KB 17025 SO MCAULY 2A34C 2A34C203 GL LEADING EDGE SPRAY CUT W K NONE O OTHER IN INSP/MAINT 1 CA 1032 469 235885 773631 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER BLADE HAD SPRAY CUT ON LEADING EDGE. THE PROPELLER HUB REAR BORE AS OVERSIZE. 1 H 7 1 3O 3 O 3A17 E1CE 5 C P3EA 1997072400974 19970724 00974 GL 1997 7 24 CA970530005 3 19970521 G 6111 BLADE CESSNA 172 172M 2072418 CE MCAULY 1A175 1A175* GL LEADING EDGE SPRAY CUT W K NONE O OTHER IN INSP/MAINT 1 CA 1934 815 P77660 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. LEADING EDGES OF PROPELLER BLADES FOUND WITH SPRAY CUTS. 1 H 7 1 3O NT 3A12 5 N P857 1997072400975 19970724 00975 GL 1997 7 24 CA970530006 3 19970523 G 6111 BLADE CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL LEADING EDGE STONE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 11298 1863 265467H G15399 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. STONE DAMAGE WAS FOUND ON THE LEADING EDGES OF THE PROPELLER BLADES W HICH REQUIRED FILING. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 1998050100250 19980501 00250 SO 1998 5 1 CA970530008 1 19970522 G 5210 9699506 SKIN PIPER PA32 PA32R301 7103218 SO LYC O360 AEIO360A1A 41514 EA HARTZL HCA2V BHCA2VF3 GL PAX DOOR DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 CA 366 L25667484 HK76A (CAN) AFT CABIN DOOR SKIN DELAMINATED IN AREA OF FORWARD LOWER LATCH. REPAIRED. 1 L 7 1 3O 3 O A3SO 1E10 5 C P24EA 1997073100403 19970731 00403 GL 1997 7 31 CA970602008 3 19970601 G 6114 HUB MCAULY 1A103 1A103TCM GL FORWARD FACE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 8260 R77216 (CAN) PROPELLER REMOVED FOR COMPLIANCE WITH AD 97-06-16. USING EDDY CURRENT NDT CRACKS WERE FOUND IN THE FORWARD FACE OF THE PROPELLER HUB. 5 N P50GL 1997073100412 19970731 00412 GL 1997 7 31 CA970603012 3 19970529 G 6114 1939 PISTON CESSNA 182 182F 2072714 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C50 GL PROPELLER WORN W K NONE O OTHER IN INSP/MAINT 1 CA 823 1711 846093R4 745275 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PISTON FOUND WORN, PISTON REPLACED. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997073100413 19970731 00413 EA 1997 7 31 CA970603013 3 19970527 G 6111 BLADES PIPER PA28 PA28151 7102805 SO LYC O320 O320E3D 41508 EA SNSNCH 74D 74DM EA PROP LE EDGE STONE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 3041 L3455727A A52300 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. STONE DAMAGE FOUND ON THE LEADING EDGES OF THE PROPELLER BLADES. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 1997073100423 19970731 00423 EA 1997 7 31 CA970603024 1 19970523 G 5210 44424352 ACTUATOR CNDAIR CL600 CL6002B19 EA GE CF34 CF343A1 30015 NE MAIN PAX DOOR FAILED W A UNSCHED LANDING O OTHER NR NOT REPORTED 1 CA 2440 GEE807385 (CAN) AFTER FLIGHT ATTENDANT REPORTED LOUD NOISE COMING FROM PASSENGER DOOR, FLIGHT RETURNED TO START POINT. MAIN PASSEN GER DOOR AFT SNUBBER SHOWED LACK OF CABLE TENSION AND THE LEFT CABLE BRACKET HUNG DOWN AND DAMAGED THE DOOR ON CLOSURE. PASSENGER DOOR REPAIRED, AND THE DOOR CUT OUT SEAL DEPRESSOR REPAIRED. NEW CABIN DOOR ASSIST ACTUATOR INSTALLED. 2 L 7 2 4F 4 F RT A21EA E15NE 1998050100255 19980501 00255 SO 1998 5 1 CA970603027 1 19970526 G 3220 9617800 SPRING PIPER PA34 PA34200 7103405 SO LYC O360 IO360C1E6 41514 EA HARTZL HCC2Y HCC2YK2 GL MLG LOOSE W A UNSCHED LANDING J WARNING INDICATION LD LANDING 1 CA L954751A AU8165A (CAN) NLG LIGHT WOULD NOT COME ON TO INDICATE DOWN AND LOCKED. FLY-BY INDICATED NLG IN LANDING POSITION. AIRCRAFT LAND ED AND NOSE GEAR COLLAPSED SHORTLY AFTER TOUCHDOWN. MOST FLUID LOST DUE TO PERFORATED PRESSURE LINE P/N 95153-43 AFTER GEAR SELECTED UP. EMERGENCY GEAR DOWN MECHANISM FAILED TO LOCK THE GEAR DOWN DUE TO SPRING P/N 96178-00 WAS OFF ITS HOO KS. SPRING RECONNECTED AND LINE REPLACED. 1 L 7 2 3O 3 O A7SO 1E10 5 C P920 2000021200005 20000212 00005 SO 2000 2 12 CA970603028 1 19970524 G 3246 754759 WHEEL PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA HARTZL HCE2Y HCE2YK2 GL MLG BROKEN W K NONE O OTHER LD LANDING 1 CA 9165 L810948 BP9052 (CAN) DURING LANDING, PILOT NOTICED THERE WAS A TIRE BLOW-OUT ON THE RT SIDE. MAINTENANCE CHECK REVEALED WHEEL RIM WAS CRACKED FIVE INCHES. 1 L 7 2 3O 3 O 1A10 1E4 5 C P9EA 1997072400977 19970724 00977 NE 1997 7 24 CA970604004 2 19970522 G 7200 ENGINE DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE #1 ENGINE FAILED W A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 CA 4 AE0014 (CAN) DURING TEST FLIGHT FOR SNAG CLEARANCE AND IN RESPONSE TO HIGH ITT AND AN INDICATION OF A POSSIBLE UNCONTROLLED UNF EATHERING OF THE #1 ENGINE ON AN AIR RESTART, THE PILOT-IN-COMMAND SHUT DOWN AND SECURED THE AFFECTED ENGINE IN ACCORDAN CE WITH STANDARD COMPANY TEST FLIGHT PROCEDURES. THE AIRCRAFT DIVERTED AND AN UNEVENTFUL LANDING WAS CARRIED OUT. THE PR OP COULD NOT BE TURNED ON THE GROUND. FURTHER REPORT TO FOLLOW. 2 H 7 2 4T 4 T RT A13NM E20NE 1997073100426 19970731 00426 EA 1997 7 31 CA970604005 1 19970515 G 7931 GAUGE DHAV DHC8 DHC8311 1386006 EA PWA #1 ENGINE FAILED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB THE #1 ENGINE OIL PRESSURE WENT TO THE RED LINE. UNSCHEDULED LANDING CARRIED OUT. OIL PRESSURE GAUGE REPLACED. 2 H 7 2 4T RT A13NM 1997072400978 19970724 00978 NE 1997 7 24 CA970604006 2 19970515 G 7200 ENGINE DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE NR 2 ENGINE FAILED W A UNSCHED LANDING P O NO WARNING INDICATION OTHER CL CLIMB 1 CA (CAN) DURING CLIMB #2 ENGINE TORQUE WAS FLUCTUATING +5 PERCENT AND FUEL FLOW WAS ALSO FLUCTUATING. THE CLIMB WAS ABORTED AND THE AIRCRAFT RETURNED TO BASE, REPORT TO FOLLOW. 2 H 7 2 4T 4 T RT A13NM E20NE 1997081500005 19970815 00005 GL 1997 8 15 CA970604007 3 19970529 G 6114 2421 LOW STOP PIPER PA28 PA28235 7102810 SO LYC O540 O540B4B5 41532 EA HARTZL HCC2Y HCC2YK1 GL PROPELLER HUB WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 140 L1355740 CH21303 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND AN INCORRECT STOP INSTALLED. LOW STOP NUT WOULD NOT LOCK. A LONGER STOP WAS INSTALLED. 1 L 7 1 3O 3 O 2A13 E295 5 C P920 1997081400276 19970814 00276 GL 1997 8 14 CA970604008 3 19970522 G 6114 HUB MCAULY 1A103 1A103TCM GL PROP CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 5461 R770128 (CAN) EDDY CURRENT NDT INSPECTION FOUND CRACKS IN THE PROPELLER HUB. THE CRACKS WERE REPAIRED AND THE PROPELLER RETURNED TO SERVICE. 5 N P50GL 1997081400277 19970814 00277 EA 1997 8 14 CA970604009 1 19970518 G 3244 0316140 TIRES CNDAIR CL600 CL6002B19 EA GE CF34 CF343A1 30015 NE BOTH NLG WHEEL BLOWN W C ABORTED TAKEOFF G O MULTIPLE FAILURE OTHER TO TAKEOFF 1 CA 0 (CAN) BOTH LEFT AND RIGHT NOSE GEAR TIRES BLEW ON TAKEOFF ROLL. BOTH TIRES, AS WELL AS BOTH LEFT AND RIGHT NOSE WHEELS S UFFERED EXTENSIVE DAMAGE. NO REPORT OF DAMAGE TO GEAR OR DOORS. INVESTIGATION UNDERWAY. 2 L 7 2 4F 4 F RT A21EA E15NE 1997081400278 19970814 00278 NE 1997 8 14 CA970604011 2 19970529 G 7210 310703201 BEARING PWA 120 PW120A NE RED GRBOX NR 19 SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 13156 121112 (CAN) REDUCTION GEARBOX WAS SENT FOR INVEST. DUE TO METAL CONTAMINATION. DISASSY FOUND- CAUSE OF- METAL CONTAMINATION WA S- #19 BEARING WHICH WAS SEVERELY SPALLED ON- INNER RACE WITH SUBSTANTIAL MATERIAL LOSS. THIS DAMAGE WAS MORE THAN SUFFI CIENT TO EXPLAIN- METAL CONTAMINATION OBSERVED.- #15 BEARING WAS REJECTED FOR ELECTRICAL DISCHARGE PITTING BUT HAD SHED NO SERIOUS QUANTITY OF MATERIAL & WAS NOT- SOURCE OF- METAL.-RE IS NO MEASUREABLE RESIDUAL MAGNETISM ON ANY OF- STEEL CO MPONENTS, SO LIGHTNING IS NOT BELIEVED TO BE INVOLVED. BASED ON- PRESENCE OF ELECTRICAL DISCH ARGE PITTING ON- #15 BEARI NG,- #19 BEARING ALSO SUFFERED SOME ELECTRICAL DISCHARGE WHICH RESULTED IN SPALLING & MATERIAL LOSS. 4 T E20NE 1998050100157 19980501 00157 SO 1998 5 1 CA970605007 1 19970522 G 7112 BAFFLE PIPER PA32 PA32R301 7103218 SO LYC O360 AEIO360A1A 41514 EA HARTZL HCA2V BHCA2VF3 GL ENGINE AIR WORN W K NONE O OTHER IN INSP/MAINT 1 CA 366 L25667484 HK76A (CAN) GOVERNOR ROD END BOLT RUBBING AGAINST FORWARD ENGINE BAFFLE CAUSING GROOVE GREATER THAN 50 PERCENT OF THE THICKNES S OF THE BAFFLE. STATICALLY THE BAFFLE IS OK, BUT IN-FLIGHT UNDER AIR LOADS THE BAFFLE MOVES AGAINST THE BOLT CAUSING R UBBING AGAINST THE BAFFLE. BAFFLE SECURED. 1 L 7 1 3O 3 O A3SO 1E10 5 C P24EA 1997072400980 19970724 00980 EA 1997 7 24 CA970605010 1 19970522 G 3244 0316140 TIRE CNDAIR CL600 CL6002B19 EA GE CF34 CF343A1 30015 NE LT AND RT NLG BLOWN W C D ABORTED TAKEOFF RETURN TO BLOCK G O MULTIPLE FAILURE OTHER TO TAKEOFF 1 CA (CAN) BOTH LEFT AND RIGHT NOSE LANDING GEAR TIRES BLEW ON TAKEOFF ROLL AT 100 KNOTS. COMPLETE LOSS OF PRESSURE. TAKEOFF ABORTED. SEVERE DAMAGE TO BOTH TIRES. SIGNIFICANT DAMAGE TO NOSE LANDING GEAR WHEEL RIM ASSEMBLIES. ALSO DAMAGE TO AFT N OSE GEAR DOOR. 2 L 7 2 4F 4 F RT A21EA E15NE 1997081400282 19970814 00282 NE 1997 8 14 CA970605011 2 19970526 G 7210 310703301 BEARING PWA 120 PW120 NE RED GRBOX NR 15 SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 14091 120934 (CAN) REDUCTION GEARBOX (RGB) WAS SENT FOR REPAIR AFTER REPORT THAT THE RGB WAS MAKING METAL. DISASSEMBLY REVEALED THE C AUSE OF THE RGB MAKING METAL WAS THE SPALLING OF THE #15 BEARING. THE #15 BEARING HAD ELECTRICAL PITTING SUGGESTING DAMA GE FROM ELECTRICAL DISCHARGE AS THE MOST LIKELY REASON FOR THE SPALLING. NONE OF THE COMPONENTS IN THE RGB HAD HIGH MAGN ETISM ON DISASSEMBLY SO A LIGHTNING STRIKE IS NOT CONSIDERED LIKELY. IT THEREFORE APPEARS THAT THE ELECTRICAL DISCHARGE ORIGINATED FROM STRAY DISCHARGE FROM EXTERNAL SOURCE. THE #15 BEARING BOLTS WERE LOOSE. THESE BOLTS TYPICALLY BACK OFF I F THERE IS A BEARING FAILURE. 4 T E20NE 1998050100154 19980501 00154 CE 1998 5 1 CA970609020 1 19970514 G 7120 11891002537 TRUSS BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 20229 PCE32139 FW1017 (CAN) WHILE CARRYING OUT ROUTINE INSPECTION PER AWD 95-02-18 AND SB 2255, A CRACK WAS FOUND ON THE ENGINE MOUNT. MOUNT ASSEMBLY REPLACED. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 1997081400289 19970814 00289 GL 1997 8 14 CA970609023 3 19970524 G 6111 S90AT8 BLADE CESSNA 182 182G 2072716 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL PROP STONE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 415 258 1319545R4 802961 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. STONE DAMAGE ON FACE AND LEADING EDGE OF PROPELLER BLADES. DAMAGE REP AIRED AND CYLINDER SUPPORT REPLACED. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 1997081400290 19970814 00290 GL 1997 8 14 CA970609024 3 19970530 G 6111 A16344 BEARINGS CESSNA 180 180A 2072604 CE CONT O470 O470K 17026 SO MCAULY 2A36C 2A36C18 GL BLADE WORN RUSTY W K NONE O OTHER IN INSP/MAINT 1 CA 2265 602 485949K4 62425 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. BALANCE WEIGHTS AND BALLS AND SCREWS RUSTY AND WORN. PARTS REPLACED. 1 H 7 1 3O 3 O 5A6 E273 5 C P880 1997081400292 19970814 00292 GL 1997 8 14 CA970609026 3 19970527 G 6111 BLADE MCAULY 1A103 1A103TCM GL PROP BELOW SPEC W K NONE O OTHER IN INSP/MAINT 1 CA 13668 5408 RP772951 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND THE PROPELLER BLADE BELOW MINIMUM WIDTH AT STATION 3 3" FOR 67" DIAMETER. 5 N P50GL 1997081400293 19970814 00293 GL 1997 8 14 CA970609027 3 19970522 G 6111 B3905 ACTUATING PIN MCAULY 2A34C 2A34C203 GL BLADE WORN W K NONE O OTHER IN INSP/MAINT 1 CA 351 767305 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. BLADE ACTUATING PIN WAS FOUND WITH THE CHROME WORN. 5 C P3EA 1997081400294 19970814 00294 GL 1997 8 14 CA970609028 3 19970530 G 6114 5480 HUB MCAULY 2A34C 2A34C66 GL PROP CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 863 76 768777 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. EXTERIOR OF HUB WAS FOUND CORRODED WITH CRACKS IN THE THREADS. HUB WA S REPLACED WITH HUB S/N 773509. BLADE NUT WAS FOUND CRACKED AND WAS REPLACED. THE CYLINDER SUPPORT WAS ALSO REPLACED. 5 C P3EA 1997081400295 19970814 00295 GL 1997 8 14 CA970609029 3 19970530 G 6111 90DHB16E BLADE MOONEY M20 M20J 5870219 SW MCAULY 2D34C B2D34C214 GL SNAP RING GROOVE CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 898 733779 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECITON. BLADE(S) FOUND CORRODED, BLADES WERE MACHINED TO REMOVE CORROSION. BL ADE AND HUB WERE ANODIZED. ACTUATING PIN FOUND WORN, PIN WAS REPLACED. 1 L 7 1 3O 2A3 5 C P7EA 1997081400296 19970814 00296 GL 1997 8 14 CA970609030 3 19970603 G 6111 90DCA2 BLADE MCAULY MCAULY 2A34C 2A34C203 GL LEADING EDGE SPRAY CUT W K NONE O OTHER IN INSP/MAINT 1 CA 812 911650 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER BLADES WERE TRIMMED. THE CYLINDER AND SNAP RINGS WERE REPLA CED. 5 C P3EA 1997081400297 19970814 00297 GL 1997 8 14 CA970609031 3 19970602 G 6114 HUB MCAULY 1A103 1A103TCM GL PROP CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA RP771358 (CAN) PROPELLER WAS REMOVED FOR COMPLIANCE WITH FAA AD 97-06-16. PROPELLER WAS FOUND CRACKED. 5 N P50GL 1997081400302 19970814 00302 CE 1997 8 14 CA970610003 1 19970516 G 5740 MS21042L5 LOCK NUT CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO MCAULY D3A34 D3A34C402 GL WING STRUT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 248666R 807440 (CAN) THE NUT WHICH HOLDS THE LOWER WING STRUT TO THE WING STRUT FITTING WAS FOUND TO BE CRACKED. NUT REPLACED 1 H 7 1 3O 3 O A4CE E8CE 5 C P47GL 1998050100152 19980501 00152 CE 1998 5 1 CA970610006 1 19970602 G 3246 55422232 SPACER CESSNA 500 560CESSNA 2076750 CE PWA JT15 JT15D5 52112 NE WHEEL SEIZED W K NONE O OTHER IN INSP/MAINT 1 CA 611 PCE500171 (CAN) RIGHT NOSE WHEEL SPACER FOUND SEIZED TO AXLE SHAFT. EXCESSIVE FRICTION BETWEEN SEAL AND SPACER CAUSING THE SPACE R TO HEAT UP AND SEIZE TO SHAFT. SECOND CASE WITHIN 11.1 HOURS. REF: CESSNA SL 560-32-27. 2 L 7 2 4F 4 F RT A22CE E25EA 1997081400308 19970814 00308 NE 1997 8 14 CA970610011 2 19970527 G 7250 CT BLADES PWA PT6 PT6A135 52043 NE ENGINE FRACTURED W O OTHER O OTHER DE DESCENT 1 CA 1320 92562 (CAN) DURING DESCENT THERE WAS A LOUD BANG. THE PILOT SECURED THE ENGINE. POST FLIGHT INSPECTION AT THE "C" FLANGE REVEA LED SEVERAL CT BLADES FRACTURED. THE ENGINE IS BEING RETURNED TO THE MANUFACTURER. 4 T E4EA 1997081400312 19970814 00312 GL 1997 8 14 CA970612004 3 19970604 G 6111 A1303A BLADE BEARING CONAER LA4 LA4 5110302 NE LYC O360 O360A1A 41514 EA HARTZL HC92Z HC92ZK8 GL EXTERIOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 271 L347636 2236L (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTIOIN. BLADE BEARINGS, BALLS, BLADE CLAMPS AND CYLINDER WERE FOUND CORRODED . PARTS WERE REPLACED. 1 H 7 1 3O 3 O 1A13 E286 5 C P892 1997081400314 19970814 00314 GL 1997 8 14 CA970612006 3 19970605 G 6114 3905 PIN BASE ASSEMBL CESSNA 172 R172K 2072431 CE CONT O360 IO360K 17025 SO MCAULY 2A34C 2A34C203 GL PROP WORN W K NONE O OTHER IN INSP/MAINT 1 CA 356092 799714 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PIN BASE ASSEMBLY REPLACED DUE TO WE 1 H 7 1 3O 3 O 3A17 E1CE 5 C P3EA 1997081400315 19970814 00315 GL 1997 8 14 CA970612007 3 19970612 G 6111 BLADE MCAULY 1A101 1A101DCM GL LEADING EDGE STONE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 1124 G4112 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND THE BLADE(S) LEADING EDGES DAMAGED BY STONES. 5 N P918 1997081400317 19970814 00317 NE 1997 8 14 CA970612010 2 19970531 G 8530 81888 PISTON PWA 84898 PWA R2800 R280079 52026 NE #8 CYLINDER BROKEN W E ENGINE SHUTDOWN E VIBRATION/BUFFET CR CRUISE 1 CA 746 086036 (CAN) ENGINE WAS SHUTDOWN IN FLIGHT DUE TO ROUGH RUNNING ENGINE. POST FLIGHT INSPECTION FOUND THE #8 CYLINDER PISTON BRO KEN. THE SUBMITTER SUGGESTS THAT A HYDRAULIC LOCK PREVIOUSLY MAY HAVE CONTRIBUTED TO THIS FAILURE. 4 R 5E8 1998040200082 19980402 00082 CE 1998 4 2 CA970612011 1 19970522 G 5530 04310093 BRACKET 04310093 CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL VERTICAL FIN SEPERATED W K NONE O OTHER IN INSP/MAINT 1 CA 10358 L2354915 RJG015 (CAN) WHILE INSPECTING THE VERTICAL FIN, A CRACKLING NOISE WAS NOTED. INSPECTION REVEALED A FINE CRACK BETWEEN THE BRAC KETS. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 1998050100150 19980501 00150 SO 1998 5 1 CA970612013 1 19970607 G 3260 CONNECTOR PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA HARTZL HCE2Y HCE2YR2 GL MLG DISCONNECTED W O OTHER N FALSE WARNING AP APPROACH 1 CA 5997 L261348 BP3109 (CAN) AIRCRAFT WAS DESCENDING AND SELECTED GEAR BUT DID NOT GET A DOWN AND LOCKED SIGNAL. VERIFICATION WAS CARRIED OUT FOR DOWN AND LOCKED AND AIRCRAFT LANDED. INSPECTION FOUND THE CONNECTOR WIRE BUNDLE DISCONNECTED. NO APPARENT REASON. 1 L 7 2 3O 3 O 1A10 1E4 5 C P9EA 1998050100149 19980501 00149 1998 5 1 CA970612014 1 19970606 G 7910 LID AMTRRW 152 ROTWY152 99999 GL OIL FILTER COVER SEPERATED W F ACTIVATE FIRE EXT. A FLAME/FIRE NR NOT REPORTED 1 CA 20 1266 (CAN) THE FITTING SEPARATED FROM THE COVER ALLOWING AN OIL LEAK INTO THE ENGINE COMPARTMENT. A FIRE STARTED RESULTING I N TOTAL LOSS OF AIRCRAFT. NO INJURY. 3 O EXPE3O 1998050100148 19980501 00148 SO 1998 5 1 CA970618001 1 19970607 G 5531 6697200 RIB PIPER PA28 PA28160 7102806 SO LYC O320 O320B2B 41508 EA SNSNCH 74D 74DM EA VERTICAL STAB CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 4509 L476739 A48782 (CAN) VERTICAL STABILIZER REMOVED FOR PAINT STRIPPING. THE TWO RIBS P/N 66972-00 AND P/N 63506-00 WERE FOUND CORRODED A ND NEEDED REPLACING. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 1997081400324 19970814 00324 GL 1997 8 14 CA970618015 3 19970610 G 6111 BLADE MCAULY 1A170 1A170* GL LEADING EDGE BLUNTED W K NONE O OTHER IN INSP/MAINT 1 CA 2587 MC044 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. THE PROPELLER BLADE(S) WERE FOUND BLUNTED. 5 N P857 1997081400325 19970814 00325 GL 1997 8 14 CA970618016 3 19970610 G 6114 C840 HUB HARTZL HC82V HC82V* GL PROP RUSTY W K NONE O OTHER IN INSP/MAINT 1 CA 1302 14 T1315N (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER HUB AND BLADES CLAMPS WERE FOUND RUSTY. PARTS WERE REPLATED . 5 C P23EA 1997081400326 19970814 00326 GL 1997 8 14 CA970618017 3 19970610 G 6114 2345 ROD PITCH CHANGE MCAULY 2A34C 2A34C203 GL HUB PITTED BENT W K NONE O OTHER IN INSP/MAINT 1 CA 5525 579 745125 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND AN INTERNAL OIL LEAK AND THE PROPELLER PITCH CHANGE ROD PITTED AND BENT. PROPELLER REPAIRED AND THE PITCH CHANGE ROD AND CYLINDER SUPPORT WERE REPLACED. 5 C P3EA 1997081400328 19970814 00328 EU 1997 8 14 CA970618019 1 19970525 G 3230 DSB1102 PROX SENSOR MESSIER D22121300 AIRBUS 310 A310304 EU LH LANDING GEAR FAILED W A UNSCHED LANDING G J MULTIPLE FAILURE WARNING INDICATION CL CLIMB 1 CA 15977 879 00B257 (CAN) UNABLE TO RETRACT LANDING GEAR ON SYSTEM #1, SYSTEM #2 SELECTED AND GEAR RETRACTED. AFTER PASSING 'TAKE-OFF INHIB' (LIFT OFF PLUS 1 MINUTE) THE FOLLOWING FAILURES OCCURRED. CABIN PRESSURE REG #1 - CAPT. PITOT HEAT AND TAT HEAT - F/O P ITOT HEAT - FAC #1 - ATS #1. THE LH LANDING GEAR SHOCK ABSORBER (65 GB) WAS REPLACED. CONFIRMED UNSERVICEABLE BY METER C HECK. RETRACTION TEST CARRIED OUT SERVICEABLE. 2 L 7 2 4F RT A35EU 1998050100144 19980501 00144 SO 1998 5 1 CA970618022 1 19970611 G 7810 3342002 EXHAUST STACK PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA HARTZL HCE2Y HCE2YR2 GL CONNECTOR BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 6971 L104448 BP3110 (CAN) INSPECTION FOUND THE EXHAUST CROSSOVER PIPE BROKEN AT THE SHROUD. ALSO THE ALTERNATE AIR SPRING DOOR MISSING. HI NGE BROKEN. DOOR FOUND IN BOTTOM OF AIR BOX. 1 L 7 2 3O 3 O 1A10 1E4 5 C P9EA 1997081400473 19970814 00473 EU 1997 8 14 CA970620012 2 19970603 G 8520 VALVE LIFTERS ROTAX 912 ROTAX912 55555 EU HEAD ASSY STICKING W C D ABORTED TAKEOFF RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 CA 316 4412587 (CAN) ENGINE FAILED TO DEVELOP FULL POWER ON TAKEOFF. INSPECTION FOUND THE VALVES AND LIFTERS STICKING. THE HEAD ASSEMBL Y AND ALL THE LIFTERS WERE REPLACED. 3 I EXPE3I 1997081400479 19970814 00479 NE 1997 8 14 CA970620020 2 19970609 G 7210 310062301 BEARING PWA 118 PW118 NE RED GEARBX NR 18 SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 18127 6260 115381 (CAN) THE ENGINE WAS REMOVED DUE TO METAL CONTAMINATION IN THE REDUCTION GEARBOX. ON INITIAL DISASSEMBLY THERE WAS NO SI GN OF OBVIOUS DAMAGE WITH SIGNIFICANT MATERIAL LOSS UNTIL THE #18 BEARING WAS REMOVED. THE BEARING HAD SUBSTANTIAL SPALL ING ON THE INNER RACE. THE SPALLING WAS LARGELY CONTINUOUS OVER APPROXIMATELY 150 DEGREES OF CIRCUMFERENCE, BEING FORMED BY WHAT APPEARED TO BE A SERIES OF CONNECTING PATCHES. THE REGULAR SPACING AND PATCHY APPEARANCE OF THE SPALLING STRONG LY SUGGESTS THAT IT ORIGINATED WITH BRINNELLING OF THE BEARING FROM SOME AXIAL LOADING AT SOME TIME. THERE IS NO SIGNIFI CANT MAGNETISM AND LIGHTNING IS NOT THOUGHT TO BE A FACTOR. 4 T E20NE 1998050100142 19980501 00142 WP 1998 5 1 CA970624001 1 19970609 G 6300 D1742 FANWHEEL ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA CENTER HUB CRACKED W C A ABORTED TAKEOFF UNSCHED LANDING G S MULTIPLE FAILURE AFFECT SYSTEMS HO HOVERING 1 CA 44 L2453840A (CAN) BEFORE FIRST FLIGHT OF DAY, AIRCRAFT IN HOVER. CLUTCH LIGHT FLICKERING AND PILOT HEARS GROWLING AND FEELS VIBRATI ON. INSPECTION FOUND CENTER HUB IN THE FAN HAD CRACKED COMPLETELY AROUND CAUSING THE CENTER HUB BOLTS TO LOOSEN OFF. T HERE WAS ALSO A LOT OF METAL TRANSFER BETWEEN FAN WHEEL AND TAPERED SHAFT OF BEARING ASSY (P/N C007-5). 1 G 7 1 3O 3 O H11NM E295 1997081400480 19970814 00480 1997 8 14 CA970624003 4 19970616 G 6113 A2405 LOCK NUT HARTZL HCE2Y HCE2YL2 GL SPINNER WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA BG679 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER SPINNER NUT FOUND TO BE P/N A2405-3 WHICH IS THE WRONG PART , THE NUT WAS REPLACED WITH THE PROPER NUT P/N A2405-1. 5 C P9EA 1997082200001 19970822 00001 NE 1997 8 22 CA970624004 3 19970616 G 6111 70096 BEARING HAMSTD 12D 12D40 NE PROP BLADE PITTED W K NONE O OTHER IN INSP/MAINT 1 CA 18786 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER ROLLER BEARINGS WERE FOUND PITTED AND OUT OF SHAPE. 5 C P257 1997081400481 19970814 00481 GL 1997 8 14 CA970624005 3 19970612 G 6114 4457 ACTUATING PIN MAULE M5 M5210C 5460134 SO CONT O360 IO360D 17025 SO MCAULY 2A34C D2A34C67 GL LINK AREA WORN W K NONE O OTHER IN INSP/MAINT 1 CA 85 62849R 755340 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. ACTUATING PIN FOUND WORN. THE PIN WAS REPLACED. 1 H 7 1 3O 3 O 3A23 E1CE 5 C P3EA 1997081800013 19970818 00013 NE 1997 8 18 CA970624006 3 19970613 G 6114 51539 CYLINDER HAMSTD 2D 2D30 NE PROP CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 2322 618 37245 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. CYLINDER AND HUB BARREL WERE FOUND CORRODED. THE HUB BARREL WAS PLATE D AND THE CYLINDER WAS REPLACED. 5 C P206 1997081400482 19970814 00482 GL 1997 8 14 CA970624007 3 19970612 G 6114 2431 HUB BOLTS PIPER PA30 PA30 7103002 SO LYC O320 IO320B1A 41508 EA HARTZL HCE2Y HCE2YL2 GL PROP CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 2708 625 L361555A BG3532 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER HUB NUTS AND BOLTS FOUND CORRODED. HUB NUTS AND BOLTS WERE REPLACED. 1 L 7 2 3O 3 O A1EA 1E12 5 C P9EA 1997091100349 19970911 00349 NE 1997 9 11 CA970624020 2 19970604 G 7230 794909 HP COMP DISC PWA JT9 JT9D7AH 52054 NE 9TH STAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 52272 2576 H85185 U42 (CAN) DURING DISASSEMBLY AND INSPECTION OF THE HIGH PRESSURE COMPRESSOR A CRACK, BEYOND ACCEPTABLE LIMITS, WAS FOUND IN THE BLADE SLOT AREA OF THE 9TH STAGE DISC. THE 9TH STAGE DISC WAS SCRAPPED AND SENT TO THE MATERIAL REVIEW DEPARTMENT FO R EVALUATION. 4 F E20EA 1997091100350 19970911 00350 NE 1997 9 11 CA970624021 2 19970604 G 7240 80455401 GASKET ASSEMBLY PWA JT9 JT9D7AH 52054 NE #3 BEARING AREA PINCHED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 52272 2500 U54 (CAN) DURING REMOVAL AND INSPECTION OF THE DIFFUSER CASE, IN THE #3 BEARING COMPARTMENT, A GASKET ASSEMBLY OF SPIRAL WOU ND WAS FOUND PINCHED ALLOWING HOT AIR TO ENTER THE COMPARTMENT. ACCUMULATION OF SOFT COKING ON THE RIGHT HAND SIDE OF TH E FRONT SUPPORT RESULTED IN SUBSEQUENT CLOGGING OF THE #3 SCAVENGE SCUPPER DRAIN ALLOWING THE OIL TO OVER FLOW IN THE EN GINE, EXITING IN THE EXHAUST AREA. THE FRONT COOLING AIR DUCT WAS REMOVED TO VERIFY AND INSTALLATION OF THE PARTS. THE C RUSHED SEAL WILL BE REPLACED AND THE DIFFUSER CASE WILL BE REBUILT. 4 F E20EA 1997091100357 19970911 00357 NE 1997 9 11 CA970624029 2 19970527 G 7250 312001101 TURBINE BLADE DHAV DHC3 DHC3 2800202 EA PWA PT6 PT6A135 52043 NE BASE OF BLADE BROKEN W A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 CA 3446 1420 PCE92562 (CAN) INFLIGHT ENGINE FAILURE, EMERGENCY LANDING ON SMALL LAKE. POST FLIGHT INSPECTION FOUND COMPRESSOR TURBINE WHEEL BL ADE FRACTURED, DAMAGING ADJACENT BLADES. THE FAILED BLADE WAS VERIFIED AND IT SHOWED TO HAVE AN OIL CRACK OF ABOUT 3/16" , PROGRESSING FROM THE LEADING EDGE OF THE BLADE TOWARDS THE CENTRE (OF THE CHORD) AT ABOUT 1/8" FROM THE BASE. 1 H 7 1 3R 4 T A815 E4EA 1997091100361 19970911 00361 1997 9 11 CA970624033 1 19970613 G 7921 311161801 OIL COOLER PWA 118 PW118 NE ENG OIL LEAK W E ENGINE SHUTDOWN J WARNING INDICATION TO TAKEOFF 1 CA 16201 1949 115419 (CAN) THE ENGINE WAS SENT FOR REPAIR AFTER THE OPERATOR REPORTED AN IN-FLIGHT SHUTDOWN AFTER THERE WAS AN OIL WARNING ON TAKEOFF ROLL. INSPECTION FOUND THE HP ROTOR LOCKED AND THE ENGINE HAD LOST 10 QUARTS OF OIL. DISASSEMBLY OF THE ENGINE FOUND THE #4 AND #5 BEARING HAD LOST METAL WITH HEAVY RUBBING DAMAGE TO THE HP STUB SHAFT, HP IMPELLER, HP IMPELLER HOUS ING AND MOST OF THE AIR SEALS IN THE AREA OF THE HP ROTATING ASSEMBLY. ALL THIS DAMAGE WAS FOUND TO BE DUE TO LOSS OF OI L CAUSED BY LEAK IN THE AIRFRAME OIL COOLER. 4 T E20NE 1997091100362 19970911 00362 EU 1997 9 11 CA970625002 1 19970612 G 2913 PVB0222 PUMP AMD FALC50 FALCON50MYST 2730106 EU #2 ENG HYD FAILED W E ENGINE SHUTDOWN J E WARNING INDICATION VIBRATION/BUFFET CR CRUISE 1 CA 2938 2938 (CAN) AT CRUISE, AN UNUSUAL NOISE AND VIBRATION WAS HEARD AND FELT FOLLOWED BY #2 HYDRAULIC PUMP FAIL LIGHT. #1 SYSTEM P RESSURE WAS NORMAL. ALTHOUGH NOT REQUIRED, #2 ENGINE WAS SHUT DOWN AS A PRECAUTIONARY MEASURE. POST FLIGHT INSPECTION DE TERMINED THAT #2 HYDRAULIC PUMP HAD FAILED. 2 L 7 3 4F A46EU 1997091100363 19970911 00363 GL 1997 9 11 CA970625004 3 19970619 G 6114 HUB MCAULY 1A103 1A103TCM GL PROP CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 8376 921 SRP770650 (CAN) PROPELLER RECEIVED FOR COMPLIANCE WITH FAA AD 97-06-16. PROPELLER HUB FOUND CRACKED. 5 N P50GL 1997091100368 19970911 00368 NE 1997 9 11 CA970625009 2 19970612 G 7210 311657801 SPUR GEARSHAFT PWA 120 PW120 NE REDUCTION GEARBX SPALLED W K NONE O OTHER NR NOT REPORTED 1 CA 9298 121229 (CAN) THE REDUCTION GEARBOX WAS SENT FOR REPAIR AFTER IT WAS FOUND MAKING METAL. THE SOURCE OF THE METAL WAS FOUND TO BE SPALLING OF ALL 3 OF THE SECOND STAGE GEARS. THERE WAS NO EVIDENCE OF DAMAGE FROM ELECTRICAL DISCHARGE OR LUBRICATION P ROBLEMS. THERE WAS SOME MISALIGNMENT OF THE SECOND STAGE BEARING BORES THAT DOES NOT APPEAR TO BE SECONDARY DAMAGE FROM FRETTING. IT APPEARS LIKELY THAT THE SECOND STAGE GEARS SPALLED DUE TO BEARING BORE MISALGINMENT. 4 T E20NE 1997091100369 19970911 00369 NE 1997 9 11 CA970625010 2 19970613 G 7210 210703301 BEARING PWA 120 PW120A NE RED GRBOX NR 15 SPALLED W K NONE O OTHER NR NOT REPORTED 1 CA 11922 121186 (CAN) REDUCTION GEARBOX WAS SENT FOR INVESTIGATION AFTER THE OPERATOR REPORTED IT WAS MAKING METAL. DISASSEMBLY OF THE R EDUCTION GEARBOX FOUND THE CAUSE OF THE MAKING METAL WAS THE SPALLING OF THE #15 BEARING. THE #18 AND #19 BEARINGS AND T HE OVERSPEED GOVERNOR FRONT BEARING HAD ELECTRICAL ARCING DAMAGE. SEVERAL COMPONENTS HAD VERY HIGH MAGNETISM. IT IS MOST LIKELY THE #15 BEARING FAILED (SPALLED) DUE TO LIGHTNING STRIKE. 4 T E20NE 1998050100133 19980501 00133 WP 1998 5 1 CA970626015 1 19970514 G 6220 A6481 BEARING ROBSIN R22 R22 7640102 WP LYC O320 O320B2C 41508 EA TEETER HINGE CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA 837 L1404639A (CAN) AT 100-HOUR INSPECTION, THE MAIN ROTOR TEETER HINGE BEARING WAS FOUND CHAFED AND ELONGATED. 1 G 7 1 3O 3 O H10WE E274 1997091700003 19970917 00003 EU 1997 9 17 CA970626017 1 19970619 G 2611 72111211000 SMOKE DETECTOR SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE AVIONICS RACK FAILED W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA 0 (CAN) DURING CLIMB, THE AVIONICS RACK SMOKE WARNING LIGHT CAME ON. NO INDICATION OF FIRE OR SMOKE IN AVIONICS RACK. SUBS EQUENT INVESTIGATION REVEALED NO REASON EXCEPT THAT AVIONICS RACK WAS EXTREMELY DUSTY AND THE DUST COULD HAVE ACTIVATED THE WARNING SENSOR. SENSOR REPLACED. 2 L 7 2 4T 4 T RT A52EU E8NE 1997091100377 19970911 00377 CE 1997 9 11 CA970626019 1 19970617 G 5280 4752932 DOOR HINGE PIPER 4752934 CESSNA 172 172G 2072420 CE LYC O360 O360A1A 41514 EA L/H GEAR DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 8464 L2821836A (CAN) ON INSPECTION THE AFT DOOR HINGE WAS FOUND CRACKED ON THE INSIDE OF THE RADIUS OF THE CURVE. SUBMITTER STATES THAT THIS PARTICULAR HINGE IS NOT PART OF PIPER SERVICE BULLETIN 682 AND AD 80-26-05. 1 H 7 1 3O 3 O NT 3A12 E286 1998050100131 19980501 00131 EU 1998 5 1 CA970630002 1 19970623 G 6420 350A33215300 HINGE SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE BUSHING MOUNT DELAMINATED W K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 CA 81 4436 (CAN) DELAMINATIONS CAUSED EXCESSIVE VIBRATION (HIGH FREQ) IN-FLIGHT AND ON GROUND. SPLITS AND DELAMINATIONS IN EXCESS OF ALLOWABLE LIMITS OCCURRED AT VERY LOW T.S.N. 1 G 7 1 3U 3 U NC H9EU E19EU 1998050100130 19980501 00130 SW 1998 5 1 CA970630003 1 19970613 G 6220 206010189001 BEARING 2060101009 BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL GRIP CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA QSH0038 CAE820326 (CAN) WHEN REPLACING GRIPS FOR TX FOUND BEARING WITH A CRACKED SEPARATOR. 1 G 7 1 3U 3 U H2SW E4CE 1997091100378 19970911 00378 NE 1997 9 11 CA970630004 2 19970609 G 7313 FUEL NOZZELS PWA PWA120 PW125B NE NR 1 ENGINE LEAKING W C D ABORTED TAKEOFF RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 CA 11458 125093 (CAN) DURING THE TAKEOFF ROLL THE #1 ENGINE LOST POWER AND THE "ENGINE OUT" LIGHT ILLUMINATED. THE TAKEOFF WAS ABORTED A ND THE AIRCRAFT RETURNED TO THE GATE. SUBSEQUENT INSPECTION REVEALED A HEAVY FUEL LEAK THROUGH THE ENGINE DRAIN. THE FUE L NOZZLES WERE REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 4 T E20NE 1998050100127 19980501 00127 1998 5 1 CA970702021 4 19970618 G 6113 0550338K200 SPINNER PROP 0550338K200 CESSNA 172 R172K 2072431 CE CONT O360 IO360K 17025 SO MCAULY 2A34C 2A34C203 GL SCREW HEADS CRACKED W A UNSCHED LANDING E VIBRATION/BUFFET CR CRUISE 1 CA 63 355352 776506 (CAN) THE PROP SPINNER WAS CHANGED DUE TO CRACKING AT 21.7 HOURS. AT 62.5 HOURS THE NEW SPINNER TORE AT THE SCREW ATTA CH HOLES. SUBMITTER INSTALLED AN OLDER SPINNER AND SUGGESTS A MANUFACTURING FAULT. 1 H 7 1 3O 3 O 3A17 E1CE 5 C P3EA 1998050100126 19980501 00126 SO 1998 5 1 CA970702024 1 19970620 G 3222 9572300 TRUNNION PIPER PA34 PA34200 7103405 SO LYC O360 IO360C1E6 41514 EA HARTZL HCC2Y HCC2YK2 GL NOSE GEAR BROKEN W K NONE O OTHER TX TAXI/GRND HDL 1 CA 5982 L985751A AU8166A (CAN) APPROXIMATELY 1.5 INCH SECTION OF THE TRUNNION LUG ON THE RIGHT HAND SIDE BROKE OFF. THIS ALLOWED THE NOSE GEAR T O TRACK OUT OF POSITION BY APPROXIMATELY 15 DEGREES. 1 L 7 2 3O 3 O A7SO 1E10 5 C P920 1998050100125 19980501 00125 SO 1998 5 1 CA970703001 1 19970620 G 5520 5423224 SPAR PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 7604 RL523561A DJ9916A (CAN) WHILE COMPLYING WITH PIPER SB 998, BOTH ELEVATOR SPARS WERE FOUND CRACKED. REPAIRS COMPLETED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1998050100123 19980501 00123 SO 1998 5 1 CA970707015 1 19970515 G 5730 SKIN PIPER PA46 PA46310P 7104605 SO CONT O520 TSIO520BE 17040 SO HARTZL HCC2Y BHCC2YF1 GL UPPER WING DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 1722 528369 AM2891 (CAN) FOUND UPPER AND LOWER WING SURFACE SPAR RIVETS SMOKING. SUBMITTER STATES THAT A SIMILAR PROBLEM WAS ADDRESSED IN PIPER SB 796A. 1 L 7 1 3O 3 O RT A25SO E8CE 5 C P920 1999081200323 19990812 00323 SO 1999 8 12 CA970707023 1 19970623 G 3240 3068 LINING CLEVELAND 3068 PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA BRAKE WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 7162 L163261 (CAN) INCORRECT BRAKE LININGS AND PADS FOUND ON BRAKE ASSEMBLY. REPLACED WITH CORRECT PARTS. 1 L 7 2 3O 3 O A20SO E14EA 2000021200006 20000212 00006 2000 2 12 CA970707024 1 19970623 G 3240 753703 PARTS CATALOGUE PARTS CATALOGUE INCORRECT W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) SUBMITTER STATES THAT FIG 41 REV APR 1980 MAIN BRAKE ASSY HAS A FAULT. 1998040200083 19980402 00083 EA 1998 4 2 CA970709003 1 19970616 G 5531 VERTICAL STAB FLEET 80 FLEET80 EA CONT C85 C8512F 17008 SO SNSNCH 76A 76AK EA LEADING EDGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 13069 26862 42595 (CAN) LEADING EDGE 4130 TUBE OF VERTICAL STABILIZER FOUND CRACKED THROUGH JUST ABOVE THE SOCKET ON THE FUSELAGE. 1 H 7 1 3O 3 O 788 E233 5 N 1P210 1998050100120 19980501 00120 SO 1998 5 1 CA970709005 1 19970621 G 5520 5423224 SPAR PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 8934 L366161A DJDJ10707A (CAN) COMPLETED SB 998 AND FOUND BOTH SPARS CRACKED. REPAIRS AND REPLACEMENTS COMPLETED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1998050100119 19980501 00119 CE 1998 5 1 CA970709010 1 19970626 G 7120 05131323 RAIL CESSNA 172 172K 2072430 CE LYC O320 O320E2D 41508 EA MCAULY 1A175 1A175ATM GL BOLT HOLE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 15020 L4880327A P73951 (CAN) DURING MAINTENANCE, IT WAS DISCOVERED THAT THE LEFT HAND ENGINE RAIL WAS CRACKED. P/N 0513132-3 STRINGER ASSY IN THE FUSELAGE FRONT SECTION WAS REPLACED. THE ENGINE RAIL WAS CRACKED AROUND THE ENGINE MOUNT BOLT HOLE. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P857 1998040200085 19980402 00085 CE 1998 4 2 CA970710003 1 19970624 G 3320 5104WW BULB BEECH 1900 1900C 1154161 CE CABIN FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) DURING CRUISE FLIGHT, A PASSENGER NOTICED SMOKE COMING FROM AN OVEHEAD PANEL. INVESTGATION FOUND A BURNT FLOURESC ENT TUBE WHICH WAS REPLACED BY MAINTENANCE. 2 L 7 2 4T RT A24CE 1997092500699 19970925 00699 WP 1997 9 25 CA970710009 1 19970623 G 5751 LONGERON DOUG DC9 DC932 3022066 WP PWA JT8 JT8D7A 52053 NE AILERON CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ENGINEERING ORDER EDDY CURRENT INSPECTION E.O. NO.07-238D AILERON LONGERON 6L AT FUSELAGE STN 688 FOUND CRA CKED. CONFIRMED BY VISUAL INSPECTION. NEW SECTION OF LONGERON REPLACED AS PER STRUCTURAL REPAIR MANUAL 53-02 PAGE 2A. 2 L 7 2 4F 4 F A6WE E2EA 1997092500714 19970925 00714 CE 1997 9 25 CA970715017 1 19970619 G 2730 1200161 SPRING CESSNA 1200161 CESSNA 185 A185F 2072821 CE MCAULY 2A34C D2A34C58 GL ELEV FEEL FAILED W K NONE F FLT CONT AFFECTED CR CRUISE 1 CA 3225 751359 (CAN) SPRING FAILED IN FLIGHT. A CHANGE IN ELEVATOR FEEL WAS NOTED IN CRUISE AS WELL AS LANDING. 1 H 7 1 3O 3A24 5 C P3EA 1998040200086 19980402 00086 1998 4 2 CA970715018 1 19970607 G 2710 CONTROL CABLE REAR STRUT WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AILERON CABLE VIBRATING ON REAR WING STRUT CAUSES WEAR ON BOTH THE AILERON CABLE AND THE STRUT. SUBMITTER STATES THAT THE OLDER WOODEN SUPPORTS DID NOT EXPERIENCE THIS PROBLEM. IT ONLY OCCURRED WITH THE NEW PLASTIC SUPPORTS. 1997092900005 19970929 00005 EA 1997 9 29 CA970715019 2 19970325 G 8530 VALVE SEAT PIPER PA32 PA32RT300T 7103216 SO LYC O540 TIO540S1AD 41532 EA #6 CYL EXHAUST COCKED W O OTHER R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 CA 1010 L584861A (CAN) DURING INSPECTION #6 CYLINDER WAS FOUND TO HAVE ZERO COMPRESSION. ON REMOVAL OF THE CYLINDER IT WAS FOUND THAT THE EXHAUST VALVE SEAT HAD LIFTED AND WAS COCKED AT AN ANGLE HOLDING THE EXHAUST VALVE OPEN. THIS RESULTED IN LACK OF COMPR ESSION AND CAUSED ADDITIONAL DAMAGE TO THE ENGINE. 1 L 7 1 3O 3 O A3SO E14EA 1998040200087 19980402 00087 EA 1998 4 2 CA970715020 2 19970609 G 7320 10038901832 PRESSURE SWITCH BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL INTERNAL MALFUNCTIONED W O OTHER J WARNING INDICATION CR CRUISE 1 CA PCE32053 FW5B2 (CAN) DURING NORMAL OPERATIONS, THE FLIGHT CREW REPORTED THAT THE LEFT NO FUELTRANSFER INDICATION WAS NOT ACTUATING. MA INTENANCE REPLACED THE PRESSURE SWITCH AND THE SYSTEM TESTED OK AND THE AIRCRAFT WAS RELEASED. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 1998040200088 19980402 00088 CE 1998 4 2 CA970715021 1 19970609 G 7931 5038912133 PRESSURE SWITCH BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL INTERNAL MALFUNCTIONED W O OTHER N FALSE WARNING TX TAXI/GRND HDL 1 CA PCE32053 FW5B2 (CAN) DURING GROUND OPERATIONS, THE CREW NOTICED THE RIGHT HAND LOW PRESSURE ANNUNCIATOR WAS ACTIVATED. MAINTENANCE REPL ACED THE PRESSURE SWITCH AND TESTED THE SYSTEM SERVICEABLE. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 1998040200089 19980402 00089 CE 1998 4 2 CA970715023 1 19970709 G 2450 S1232510 CIRCUIT BREAKER BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL INTERNAL FAILED W O OTHER J WARNING INDICATION CR CRUISE 1 CA 3397 PCE32053 FW5B2 (CAN) CREW SNAGGED THE NR 1 INVERTER WOULD TRIP BUT WAS RESETTABLE. THE SNAG WAS NOT DUPLICATED ON THE GROUND. TROUBLES HOOTING FOUND THE BREAKER WOULD SWITCH ON AND OFF WITHOUT PLUNGER ACTIVATION IF VIBRATION WAS INDUCED. BREAKER REPLACED . 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 1998040200090 19980402 00090 CE 1998 4 2 CA970715024 1 19970707 G 3260 5038004811 RELAY BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL INTERNAL REPLACED W O OTHER J WARNING INDICATION AP APPROACH 1 CA 3397 PCE32053 FW5B2 (CAN) CREW NOTED THAT DURING GEAR RETRACTION/EXTENSION CYLCES, THE TRANSIT LIGHT WOULD INTERMITTENTLY CYCLE ON AND OFF. MAINTENANCE FOUND THE K1 RELAY WAS FAILING. RELAY REPLACED AND AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 1997092500717 19970925 00717 EA 1997 9 25 CA970715026 3 19970708 G 6111 BLADES SNSNCH 74D 74DM EA PROP BELOW LIMITS W K NONE O OTHER IN INSP/MAINT 1 CA 4597 863 K27325 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND THE BLADE(S) WIDTH BELOW MINIMUM LIMITS. 5 N P88614 1997092500719 19970925 00719 NE 1997 9 25 CA970715031 2 19970708 G 7250 311260201 TURBINE BLADE PWA 120 PW120 NE LP TURBINE FRACTURED W K NONE O OTHER NR NOT REPORTED 1 CA 16057 6803 (CAN) ENGINE DID NOT MEET POWER ASSURANCE LIMITS SO IT WAS SENT TO R&O. DISASSY FOUND- ENGINE HAD SUSTAINED 2 (2) LP TUR BINE BLADE FRACTURES WITH- LOSS OF- OUTER 40 PCT OF BOTH AIRFOILS.THIS RESULTED IN SECONDARY DAMAGE TO- NEIGHRING & DOWN STREAM COMPONENTS.- PRIME CAUSE FOR- LP BLADE AIRFOIL FAILURES WAS PROBABLY DAMAGE TO- BLADE MATERIAL MICROSTRUCTURE: TY PICALLY THIS COULD OCCUR IN AN OVERTEMP EVENT. HOWEVER,- OPERATOR RPTS THAT HIS EXCEEDANCE MONITORING EQUIP SHOW NO SUCH EXCEEDANCE EITHER IN STEADY RUNNING OR IN A STARTING TRANSIENT.- R&O SHOP HAS NO EVIDENCE OF- ENGINE PRIOR TO- LAST HSI OR WHETHER-RE WAS EVIDENCE OF HOT STREAKING AT THAT TIME. 4 T E20NE 1997092500720 19970925 00720 NE 1997 9 25 CA970715032 2 19970704 G 7250 310641201 BEARING HOUSING PWA 118 PW118 NE 6&7 BEARING AREA BURNING DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 17820 3821 115351 (CAN) THE ENGINE WAS SENT TO R&O FOR REPLACEMENT OF A TIME EXPIRED HP IMPELLER AND FOR AN HSI. DISASSEMBLY FOUND THERE W AS UNUSUAL DAMAGE TO THE PT1 STATOR PT1 DISK. THERE HAD BEEN A FIRE IN THE FORWARD CAVITY CAUSED BY OIL LEAKAGE FROM THE #6 AND #7 BEARING AREA. RESULTING DAMAGE WAS SUSTAINED BY THE PT1 DISK AND BLADES, FRONT DISK SEAL, PT1 STATOR AND BAFF LES, #6 AND #7 BEARING HOUSING BAFFLE AND INSULATION BLANKET. THE SPECIFIC CAUSE OF THE OIL LEAKAGE WAS NOT DETERMINED W ITH ANY DEGREE OF CERTAINTY. 4 T E20NE 1997092500722 19970925 00722 EA 1997 9 25 CA970716002 2 19970612 G 8520 679 BOLT HILLER UH12 UH12E 4360122 WP LYC O540 VO540C2A 41532 EA CAMSHAFT GEAR SHEARED W A B UNSCHED LANDING EMER. DESCENT Y ENGINE STOPPAGE CL CLIMB 1 CA 144 L244243 (CAN) ENGINE FAILED IN FLIGHT. ON DISASSEMBLY IT WAS FOUND THAT THE CAMSHAFT GEAR SCREWS HAD SHEARED EXCEPT FOR ONE THAT WAS STILL INTACT, BUT LYING IN THE OIL SUMP. THE LOCKTABS WERE STILL BENT OVER. IT APPEARS THAT EITHER A LOCKTAB BROKE LETTING A BOLT COME LOOSE OR A BOLT BROKE. AT REASSEMBLY THE NEW BOLTS WERE INSTALLED WITH LOCKTITE AND LOCKTABS. 1 G 7 1 3O 3 O 4H11 E304 1997092500730 19970925 00730 EA 1997 9 25 CA970722007 1 19970715 G 6120 8190026 PRESSURE SWITCH DHAV DHC6 DHC6300 EA PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL RT ENGINE FAILED W H DEACTIVATE SYST/CIRCUITS O OTHER TX TAXI/GRND HDL 1 CA 315113 PCE42076 BU10602 (CAN) DURING PREFLIGHT RUN UP THE CREW COULD NOT ARM THE AUTOFEATHER CIRCUIT. THE SYSTEM WAS TURNED OFF. THE PRESSURE SW ITCH ON THE RIGHT HAND ENGINE HAD FAILED. 1 H 7 2 3T 4 T A9EA E4EA 6 C P15EA 1997092500731 19970925 00731 NM 1997 9 25 CA970722008 1 19970715 G 2130 32167431 VALVE ALLIED SIGNA 32167431 BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE LT PACK OPEN W K NONE O OTHER TX TAXI/GRND HDL 1 CA 987 P596 P653620B (CAN) DURING OPERATION OF APU ON GROUND THE LH PACK SHOWED TEMPERATURE WITH THE PACK SHUT-OFF VALVE CLOSED INDICATING TH AT THE VALVE BUTTERFLY WAS NOT COMPLETELY CLOSED. VALVE REPLACED 2 L 7 3 4F 4 F A3WE E2EA 1997092500732 19970925 00732 NM 1997 9 25 CA970722009 1 19970715 G 2927 SEAL 72909 BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE HYD REG SYS LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA P653620B (CAN) DURING ROUTINE SERVICING OF THE HYDRAULIC SYSTEM RESERVOIR HEADER PRESSURE THE REGULATOR HAD A SEAL FAILURE RESULT ING IN PRESSURE LOSS. THE REGULATOR WAS CHANGED AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 3 4F 4 F A3WE E2EA 1997101600726 19971016 00726 EA 1997 10 16 CA970722015 2 19970710 G 7414 4250 MAGNETO CESSNA 172 172L 2072432 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160CTM GL ACROSS COIL CASE CRACKED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 2793 823 9080221 42844127A 724333 (CAN) DURING ANNUAL INSPECTION THE MAGNETO COIL WAS FOUND CRACKED ACROSS ITS CASE. FAA AD 81-16-05 WHICH PERTAINS TO THI S SUBJECT WAS SIGNED OFF IN THE ENGINE LOG BOOKS, BUT WAS NOT COMPLIED WITH. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2000021200007 20000212 00007 CE 2000 2 12 CA970722016 1 19970710 G 5312 BULKHEAD CESSNA 172 172L 2072432 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160CTM GL BS 8.12 - 124 WORN W K NONE O OTHER IN INSP/MAINT 1 CA 2793 42844127A 724333 (CAN) DURING THE INSPECTION ON REMOVAL OF THE FLOOR INSPECTION COVERS, IT WAS DISCOVERED THAT THE RUDDER AND ELEVATOR CA BLES HAD BEEN RIDING ON AND CUTTING THE BULKHEADS BELOW THE FLOOR FROM STA 8.12 TO STA 124.00. CABLES REMOVED AND INSPE CTED AND FOUND TO BE SERVICEABLE. WEAR AREAS OF BULKHEAD REPAIRED. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 1997101600730 19971016 00730 GL 1997 10 16 CA970722022 3 19970716 G 6111 BLADES MCAULY 1B90 1B90CM GL PROP STONE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 54940 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. STONE DAMAGE WAS FOUND ON THE PROPELLER BLADES. THIS WAS NOT REPAIRED IN THE FIELD AND COULD HAVE LED TO PROPELLER BLADE FAILURE. 5 N P842 1997101600731 19971016 00731 GL 1997 10 16 CA970722023 3 19970714 G 6114 B24913 PITCH CHANGE HARTZL HCC3Y HCC3YR GL SEAL AREA ROD WORN W K NONE O OTHER IN INSP/MAINT 1 CA 680 CK328 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. THE PITCH CHANGE ROD WAS FOUND WORN THROUGH THE CHROME AT THE SEAL AR EA 5 C P25EA 1997101600732 19971016 00732 GL 1997 10 16 CA970722024 3 19970715 G 6114 B24913 PITCH CHANGE HARTZL HCC3Y HCC3YR GL SEAL AREA ROD WORN W K NONE O OTHER IN INSP/MAINT 1 CA 680 CK397 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND THE PITCH CHANGE ROD WORN THROUGH THE CHROME AT THE SEAL AREA. 5 C P25EA 1997101600733 19971016 00733 GL 1997 10 16 CA970722025 3 19970711 G 6111 BLADE MCAULY 1C160 1C160DTM GL PROP STONE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 2200 725070 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND THE PROPELLER BLADES DID NOT MEET THE MINIMUM WIDTH FOR 75" BLADES. BLADES WERE CUT TO 74" TO MEET MINIMUM DIAMETER FOR INSTALLATION. 5 N P910 1997101600741 19971016 00741 WP 1997 10 16 CA970722036 1 19970705 G 2150 21700091 AIRCYCLE MACHINE DOUG DC9 DC932 3022066 WP PWA JT8 JT8D7A 52053 NE RT AIR COND FAILED W D RETURN TO BLOCK B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA 0 (CAN) SMOKE ALARM IN LAVATORY SOUNDED ALONG WITH SMELL OF SMOKE AFTER PUSH BACK. AIRCRAFT RETURNED TO GATE. INSPECTED LA VATORY, WASTE CONTAINER, LIGHTING, LAVATORY PUMP, BEHIND CEILING AND UNDER SINK, NO FAULT FOUND. LAVATORY DEACTIVATED PE R MINIMUM EQUIPMENT LIST. CIRCUIT BREAKER PULLED FOR LIGHTING AND LAVATORY. RIGHT HAND AIR CONDITIONING AIR CYCLING MACH INE AND COALESCER BAG (P/N 18084-1) REPLACED. 2 L 7 2 4F 4 F A6WE E2EA 1997101600743 19971016 00743 WP 1997 10 16 CA970722038 1 19970706 G 2150 21700091 AIR CYCLE MACH DOUG DC9 DC932 3022066 WP PWA JT8 JT8D7A 52053 NE RT AIR COND FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA 0 (CAN) CABIN FILLED WITH SMOKE AFTER AUXILIARY POWER UNIT STARTED AND PACK TURNED ON. MAINTENANCE REPLACED RH AIR CONDITI ONING AIR CYLING MACHINE AND COALESER BAG (P/N 180849-1). 2 L 7 2 4F 4 F A6WE E2EA 1997101600746 19971016 00746 EA 1997 10 16 CA970728004 2 19970717 G 7414 10357174 BREAKER POINTS BENDIX S4LN20 PIPER PA12 PA12 7101202 SO LYC O320 O320A2A 41508 EA MAG BROKEN W D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TX TAXI/GRND HDL 1 CA 100 L498127 (CAN) ENGINE RUNNING ROUGH ON TAXI. CAM FOLLOWER OF POINTS ASSEMBLY FOUND BROKEN. THIS IS THE SECOND SET OF POINTS TO FA IL WITH THE SAME CONDITION, IN THE SAME MAGNETO, WITHIN 100 HOURS OF OPERATION. CLOSER INSPECTION FOR PROBABLE CAUSE FOU ND NOTCHES IN THE CAM, P/N 10-88543-1. THE CAM AND POINTS WERE REPLACED. 1 H 7 1 3O 3 O A780 E274 1997102300439 19971023 00439 1997 10 23 CA970728005 2 19970716 G 7421 REM40E SPARK PLUGS CHAMPION ENGINE FAULTY W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING SPARK PLUGS CHECKS ON INSPECTIONS NUMEROUS PLUGS WERE FOUND WITH LOOSE SCREWS HOLDING THE SPRING AND RESIST OR IN THE TERMINAL END. IN SOME CASES WHEN THE LEAD WAS REMOVED THE SCREW, SPRING AND RESISTOR FELL OUT. ALSO SOME PLUGS HAD LOOSE CERAMIC INSULATORS. FURTHER CHECK OF THE FLEET FOUND THAT 30-40 PERCENT OF THE SPARK PLUGS IN SERVICE WERE IN THE SAME CONDITION. THE REMEDIAL ACTION WILL CONSIST OF SWITCHING THE FLEET TO AUBURN SPARK PLUGS. 2000021200009 20000212 00009 CE 2000 2 12 CA970728008 1 19970716 G 2720 04115261 TUBE WELD CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO MCAULY 1A101 1A101HCM GL RUDDER PEDAL CRACKED W A UNSCHED LANDING F FLT CONT AFFECTED AB AEROBATIC 1 CA 21R302H G12035 (CAN) RUDDER PEDAL TUBE WELD AT TORQUE TUBE CONNECTION FOUND TO BE CRACKED. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 1997100900541 19971009 00541 NE 1997 10 9 CA970728010 3 19970718 G 6114 C5503 BETA ROD PIPER PA31T PA31T 7103124 SO PWA PT6 PT6A28 EA MCAULY 4HFR34 4HFR34C652 NE AT THE SEAL CHROME WORN W K NONE O OTHER IN INSP/MAINT 1 CA 1917 52694 911229 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND THE BETA ROD CHROME WORN IN THE SEAL AREA. 1 L 7 2 3T 4 T A8EA E4EA 6 C 3PNE 1997100900542 19971009 00542 NE 1997 10 9 CA970728011 3 19970717 G 6114 C5503 BETA ROD PIPER PA31T PA31T 7103124 SO PWA PT6 PT6A28 EA MCAULY 4HFR34 4HFR34C652 NE AT THE SEAL CHROME WORN W K NONE O OTHER IN INSP/MAINT 1 CA 1917 52694 911226 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND THE BETA ROD CHROME WORN AT THE SEAL AREA. 1 L 7 2 3T 4 T A8EA E4EA 6 C 3PNE 1997100900543 19971009 00543 EA 1997 10 9 CA970728012 3 19970721 G 6111 BLADE SNSNCH 74D 74DM EA PROP CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 1002 A52008 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND THE PROPELLER BLADE CORRODED ON THE LEADING EDGES AN D THE FACE. 5 N P88614 1998050100107 19980501 00107 SW 1998 5 1 CA970728013 1 19970627 G 6322 206061505115 OIL TANK BELL 407 407 SW ALLSN 250C 250C47B GL TOP CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 696 CAE847014 (CAN) OIL FOUND ON DECK UNDER ENGINE OIL RESERVIOR. FOUND OIL TANK CRACKED ON TOP. ALSO FOUND BROKEN OIL TANK SUPPORT S AND OIL COOLER BLOWER SUPPORT BRACKETS. BROKEN ANGLE BRACKETS AT STA 192.0, WL 73.25. CAUSE OF CRACKS APPEARS TO BE EXCESSIVE VIBRATION OF T/R DRIVE OIL COOLER BLOWER SHAFT/FLYWHEEL ADAPTER. 1 G 7 1 3U 3 U O H2SW E1GL 1998050100106 19980501 00106 SW 1998 5 1 CA970728014 1 19970710 G 6322 206032305129A BRACKET BELL 407 407 SW ALLSN 250C 250C47B GL OIL COOLER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 570 CAE847021 (CAN) CRACKS FOUND ON OIL COOLER BLOWER SUPPORT BRACKETS AT STA 192.0, WL 73.25. ALSO FOUND CRACKED ANGLE BRACKETS, FRA ME AND BONDED OIL COOLER PANEL ASSY OIL COOLER TRANSITION BRACKET HAD SMALL CRACK. 1 G 7 1 3U 3 U O H2SW E1GL 1998040200091 19980402 00091 CE 1998 4 2 CA970731012 1 19970725 G 5511 SPAR CESSNA 172 172H 2072424 CE CONT O300 O300D 17022 SO MCAULY 1C172 1C172EM GL HORIZ STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 2314 34787D6D E3577 (CAN) HORIZONTAL STABILIZER FRONT SPAR AND CENTER SKIN FOUND CRACKED PER CESSNA SEB 94-8. 1 H 7 1 3O 3 O NT 3A12 E253 5 N P910 1998040200092 19980402 00092 SW 1998 4 2 CA970731013 1 19970728 G 3210 71461 GEAR LEG 71461 BBAVIA 8 8GCBC 1220803 SW LYC O360 O360C2E 41514 EA MCAULY 1A200 1A200* GL LT MLG BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 3045 L188836A 105353 (CAN) LEFT MAIN GEAR FAILED DURING TAXI ONTO RUNWAY FROM GRASS LANDING AREA. FAILURE OCCURRED IN THE MAIN GEAR LEG JUST PAST THE ATTACHMENT SADDLE. GEAR LEG COMPLETELY SEPARATED FROM THE AIRCRAFT STRUCTURE. WING AND PROP CONTACTED THE GR OUND. 1 H 7 1 3O 3 O A21CE E286 5 N P874 1998040200093 19980402 00093 CE 1998 4 2 CA970731022 1 19970723 G 2932 GPP125023 PRESS SWITCH WIPLINEINC GPP125023 CESSNA 208 208 2073702 CE MCAULY 3AF34C 3GFR34C703 GL HYD SYSTEM DEFECTIVE W O OTHER O OTHER LD LANDING 1 CA 600 PCE17490 950917 (CAN) DURING NORMAL OPERATIONS, THE GEAR ON THE AMPHIBIOUS FLOATS WAS EXTENDED AND THE CREW NOTED A LONGER THAN NORMAL E XTENSION PERIOD. MAINTENANCE FOUND THAT ONE PUMP ONLY WAS BEING UTILIZED DUE TO A FAULTY PRESSURE SWITCH. 1 H 7 1 3T NT A37CE 5 C P60GL 1998040200096 19980402 00096 CE 1998 4 2 CA970731025 1 19970725 G 2782 ACTUATOR BEECH 1900 1900C 1154161 CE LE FLAP CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING PRE-FLIGHT CHECKS, THE FLAPS WERE SELECTED AND THEN FROZE DURING ACTUATION. MAINTENANCE FOUND A CORRODED W IRE AT THE ASSYMETRY SWITCH. 2 L 7 2 4T RT A24CE 1997102300447 19971023 00447 EU 1997 10 23 CA970731027 1 19970704 G 3411 PITOT LINE AIRBUS 310 A310304 EU LT PITOT FOD W C D ABORTED TAKEOFF RETURN TO BLOCK C J F.O.D. WARNING INDICATION TO TAKEOFF 1 CA (CAN) TAKEOFF ABORTED DUE TO AIRSPEED DISCREPANCY BETWEEN L/H & R/H SIDE OF 40 KNOTS. THE L/H PITOT LINE WAS PURGED AND A WASP WAS REMOVED. PITOT STATIC TEST WAS CARRIED OUT AND CHECKED SERVICEABLE. 2 L 7 2 4F RT A35EU 1998040200098 19980402 00098 NE 1998 4 2 CA970806001 2 19970723 G 7510 19357226 PACKING BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE BLEED AIR SYS FAILED W D H RETURN TO BLOCK DEACTIVATE SYST/CIRCUITS J M WARNING INDICATION OVER TEMP TX TAXI/GRND HDL 1 CA 1451 PCEPS0007 HJ701 (CAN) BLEED AIR ANNUNCIATOR LIGHT ILLUMINATED ON THE RIGHT HAND SIDE. CREW RETURNED TO HANGAR. INSPECTION FOUND THE P ACKINGS ON THE BLEED AIR SYSTEM WERE BURNT AND HARD. SUBMITTER SUSPECTS THE USE OF THE WRONG PACKINGS. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 1997102300454 19971023 00454 GL 1997 10 23 CA970806007 3 19970729 G 6114 PROPELLER MCAULY 1A100 1A100MCM GL HUB CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 2562 G1457 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER HUB AND BLADE(S) LEADING EDGES WERE FOUND CORRODED. 5 N P918 1997102300455 19971023 00455 GL 1997 10 23 CA970806008 3 19970729 G 6111 S90AT4 BLADE MCAULY 2A34C D2A34C58 GL PROP DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 114 851326 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. THE PROPELLER BLADE WAS FOUND TO HAVE SPRAY CUT 5 C P3EA 1997102300456 19971023 00456 EA 1997 10 23 CA970806009 3 19970730 G 6114 HUB SNSNCH 74DM M74DM EA PROP CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 695 3859 K5121 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND THE PROPELLER HUB CORRODED AND THE PROPELLER BLADES NICKED. FIELD REPAIRED AND THE BLADES WERE BELOW MINIMUM LIMITS. 5 N P88614 1997102300463 19971023 00463 NM 1997 10 23 CA970807005 1 19970806 G 3230 65617405 CYLINDER BOEING 65617405 BOEING 737 737200 1384453 NM MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 0242 (CAN) TWO OVERHAULED CYLINDERS DISPLAYED MULTIPLE CRACKS ON AFT TRUNNION BEARING AREA. ALSO DISPLAYED A BURN MARK, WITH REWORK FLAT SPOT FORMED ON CYLINDER SURFACE. THE CHROME PLATE AND BAKE PROCESS WERE DELAYED 38.5 HOURS AND BOEING MAX BE TWEEN PROCESSES IS 12 HOURS. TOTAL BAKE TIME SHOWN WAS 11 HOURS AND BOEING PROCESS CALLS FOR 12 HOURS BAKE. REMOVED FROM SERVICE. 2 L 7 2 4F A16WE 1997102800006 19971028 00006 1997 10 28 CA970807048 4 19970731 G 6122 B20749 FLY WEIGHT MOONEY M20 M20K 5870220 SW MCAULY 2A34C 2A34C* GL PROP GOVERNOR WORN W K NONE O OTHER IN INSP/MAINT 1 CA 1800 880448 (CAN) EXCESSIVE WEAR FOUND ON PROPELLER GOVERNOR FLY WEIGHT ASSEMBLY, FLY WEIGHT PINS AND CARRIER CAUSING FLY WEIGHT TO COME LOOSE. 1 L 7 1 3O 2A3 5 C P3EA 1997102300469 19971023 00469 WP 1997 10 23 CA970807053 1 19970722 G 7620 4913805AS03624 CABLE DOUG DC9 DC932 3022066 WP PWA JT8 JT8D7A 52053 NE LH ENG FUEL SOV FRAYED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING WALK AROUND INSPECTION, LEFT HAND FUEL FIRE SHUTOFF CABLE FOUND FRAYED. FUEL FIRE SHUTOFF CABLE REPLACED. T ENSION ADJUSTED AND OPERATIONALLY CHECKED SERVICEABLE. 2 L 7 2 4F 4 F A6WE E2EA 1997091100385 19970911 00385 NE 1997 9 11 CA970811003 2 19970807 G 7200 ENGINE BOEING 727 727200 138407E NM PWA JT8 JT8D15 52051 NE #3 POSITION MAKING METAL W O OTHER J WARNING INDICATION DE DESCENT 1 CA 685593 (CAN) ON DESCENT #3 ENGINE LOW OIL PRESSURE LIGHT ILLUMINATED, ACCOMPANIED WITH A DROP IN OIL PRESSURE INDICATION. THE F LIGHT CONTINUED WITH THE OIL PRESSURE LIGHT BEING EXTINGUISHED BY MANIPULATION OF THE #3 ENGINE THRUST LEVER. POST FLIGH T INSPECTION FOUND THE #3 ENGINE MAIN OIL FILTER WITH METAL CONTAMINATION. THE ENGINE WAS REMOVED FROM THE AIRCRAFT. 2 L 7 3 4F 4 F RT A3WE E2EA 1997102300471 19971023 00471 GL 1997 10 23 CA970811004 3 19970801 G 6114 PROPELLER CESSNA 172 172I 2072426 CE MCAULY 1C160 1C160CTM GL BLADES & HUB CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 958 3391 720160 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. BLADES AND HUB CORRODED UNDER PAINT. LAST PROP SHOP INSPECTION CARRIE D OUT ON 13 JULY 1982. 1 H 7 1 3O NT 3A12 5 N P910 1997102300472 19971023 00472 EA 1997 10 23 CA970811005 3 19970801 G 6111 BLADES PIPER PA28 PA28180 7102808 SO LYC O360 O360A4A 41514 EA SNSNCH 76E 76EM8S5 EA PROP LE STONE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 486 773 L1794036A 15139K (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER BLADES LEADING EDGES FOUND DAMAGED FROM STONES. BLADES REQU IRED WIDTH REDUCTION. 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 1997102300474 19971023 00474 SO 1997 10 23 CA970811007 2 19970731 G 8530 530830 PLUG PISTON PIN LUSCOM 8 8F 8190114 SO CONT C90 C9012F 17009 SO NR2 CYLINDER WORN W K NONE O OTHER IN INSP/MAINT 1 CA 43775312 (CAN) PISTON PIN PLUG IN NR2 CYLINDER CAME LOOSE AND CAUSED WEAR ON THE CYLINDER WALL. METAL WAS FOUND IN THE OIL FILTER . ALL CYLINDERS WERE REMOVED FOR INSPECTION. 1 H 7 1 3O 3 O A694 E252 1997102300475 19971023 00475 EA 1997 10 23 CA970811008 1 19970617 G 3234 SWITCH 7179015 CNDAIR CL600 CL6002B19 EA GE CF34 CF343A1 30015 NE GEAR CONTROL DEFECTIVE W O OTHER J O WARNING INDICATION OTHER AP APPROACH 1 CA 6560 59 (CAN) DURING GEAR DOWN SELECTION, MAIN AND NOSE GEAR DID NOT EXTEND. NOSE DOORS OPEN "GEAR DISAGREE" WARNING MESSAGE ON EICAS. GEAR INDICATION ON EICAS 3 WHITE BOXES. DURING EVENT CREW ALSO REPORTED "CAS MISCOMP" STATUS MESSAGE ON EICAS. DE NOTING THE WARNING MESSAGE-DISAGREE BETWEEN GEAR POSITION AND HANDLE POSITION. CREW PROCEDED WITH QRH PROCEDURE-GEAR EXT ENSION USING MANUAL RELEASE SYSTEM. GEAR EXTENDED AND LOCKED. LANDING GEAR CONTROL HANDLE ASSEMBLY REPLACED. 2 L 7 2 4F 4 F RT A21EA E15NE 1997091100386 19970911 00386 EU 1997 9 11 CA970811011 1 19970728 G 2701 NB45D859 COLUMN BNORM BN2 BN2B26 1520350 EU COCKPIT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 8850 (CAN) WHILE INSPECTING CONTROL COLUMN ON A REGULAR INSPECTION, AN EXCESSIVE WEAR WAS NOTED, A SLIGHT VERTICAL FORCE APPL IED ON THE CONTROL WHEEL, BROKE THE COLUMN IN TWO PARTS. 1 H 7 2 3O RT A17EU 1998040200100 19980402 00100 CE 1998 4 2 CA970812010 1 19970723 G 7120 145100830 TUBE CONT IO360C CESSNA 337 337 2075702 CE CONT O360 IO360C 17025 SO MCAULY 2AF34C D2AF34C59 GL ENGINE MOUNT BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 4165 60071CR 60071CR 725721 (CAN) DURING ANNUAL INSPECTION, IT WAS FOUND THAT A REAR ENGINE MOUNT WAS BROKEN. LOWER RIGHT HAND TUBE 1.5 INCHES BELO W THE WEB. CRACKED THROUGH THE ENTIRE DIAMETER. 1 H 7 2 3O 3 O A6CE E1CE 5 C P5EA 1998050100091 19980501 00091 1998 5 1 CA970815011 4 19970813 G 2562 4520130 BATTERY PACK ARTEX 1104 PIPER PA44 PA44180 7104402 SO LYC O360 O360A1H 41514 EA HARTZL HCC2Y HCC2YR2 GL ELT DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 540 55867 L58271A AU8729A (CAN) UPON REMOVAL FOR TRANSFER TO ANOTHER AIRCRAFT, THE SPLIT IN THE CASE AND THE LEAKING ELECRTOLYTE WAS FOUND. THE E XPIRATION WAS FEB/98 AND THE RECERTIFICATION WAS DEC/97, WELL WITHIN LIMITS. 1 L 7 2 3O 3 O A19S0 E286 5 C P920 1998040200103 19980402 00103 SO 1998 4 2 CA970815015 1 19970802 G 3230 DOWNLOCK PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL MLG DIRTY W O OTHER O OTHER LD LANDING 1 CA L254161A DJ9746A (CAN) RIGHT HAND GEAR DOWNLOCK FOUND DIRTY AND WOULD NOT OPERATE FREELY. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1997110600621 19971106 00621 1997 11 6 CA970815016 4 19970801 G 3460 4020571904 V-NAV CONTROLLER CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE INSTRUMENT PANEL FAULTY W H DEACTIVATE SYST/CIRCUITS O OTHER DE DESCENT 1 CA 5560 PCE70986 (CAN) V-NAV SELECTOR SWITCH MOVED INADVERTENTLY BETWEEN POSITIONS DUE TO WORN SWITCH. THIS DISABLED THE ALTITUDE ALERTER AND AIRCRAFT DESCENDED BELOW ASSIGNED ALTITUDE. SWITCH HAS BEEN SAFETIED IN ALERTER POSITION UNTIL PARTS ARE AVAILABLE. PLACARD INSTALLED IN COCKPIT TO PROVIDE WARNING OF V-NAV INOPERATIVE STATUS. 1 L 7 2 4F 4 F A22CE E1NE 1997091100387 19970911 00387 EU 1997 9 11 CA970820002 1 19970730 G 5220 A26500701 DOOR FOKKER A26500701 FOKKER F28 F28MK1000 4990808 EU EMERGENCY EXIT CORROSION W K NONE L NO TEST IN INSP/MAINT 1 CA 37626 454USS (CAN) DURING TRAINING THE SERVICE EMERGENCY DOOR FAILED IN EMERGENCY MODE. OTHER AIRCRAFT CHECKED AND DOOR FAILED IN EME RGENCY MODE. FLEET CHECK BEING CARRIED OUT. INVESTIGATION REVEALED CORROSION IN OPERATING SPRINGS AND BOWDEN CABLES. REP LACED. 2 L 7 2 4F RT A20EU 1997110600628 19971106 00628 EA 1997 11 6 CA970820009 1 19970716 G 3320 1640513 CONNECTOR DHAV DHC8 DHC8311 1386006 EA X164.91 RH BURNT W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) WITH GPU CONNECTED TO AIRCRAFT ON RAMP AND BATTERY MASTER/AUXILIARY BATTERY/MAIN BATTERY SWITCHES ON. ELECTRICAL B URNING SMELL AND SMOKE NOTED COMING FROM BETWEEN TOILET PANEL AND SEAT 1D OVERHEAD STOWAGE. SERVICE BULLETIN A8-33-39, D ATED 15 AUGUST 1997 RELEASED TO MPROVE CONNECTOR POWER CAPABILITIES. 2 H 7 2 4T RT A13NM 1997110600630 19971106 00630 NE 1997 11 6 CA970820011 3 19970730 G 6111 7756722 BLADE PIN HAMSTD SFA13M10A HAMSTD 14SF 14SF7 NE PROPELLER BLADE WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 7100 850431 (CAN) INCORRECT PROPELLER BLADE PIN INSTALLED. NO PART NUMBER ON THE PIN. HAMILTON STANDARD HAVE SIMILAR LOOKING PARTS, THE DIFFERENCES ARE DASH NUMBER AND LENGTH. 775672-1 LENGTH 2.48", 775672-2 LENGTH 2.58". HAMILTON STANDARD SB 14SF-61-A 43 WAS ISSUED TO ADDRESS THIS PROBLEM. THE SUBMITTER STATES THIS IS THE THIRD TIME HE HAS CAME ACROSS THIS PROBLEM. 6 C P7NE 1997110600631 19971106 00631 EA 1997 11 6 CA970820012 2 19970815 G 7314 RG908014A FUEL PUMP PIPER PA46 PA46350P SO LYC O540 TIO540AE2A 41532 EA DIAPHRAGM RUPTURED W O OTHER K FLUID LOSS NR NOT REPORTED 1 CA D8549 L970461A (CAN) FUEL PUMP DIAPHRAGM RUPTURED CAUSING FUEL TO LEAK ON THE UPPER DECK. LYCOMING SB #487 REFERS. 1 L 7 1 3O 3 O RT A25SO E14EA 1998050100090 19980501 00090 NM 1998 5 1 CA970820019 1 19970807 G 5302 A02323 SKIN ROBSIN R22 R22BETA NM LYC O320 O320B2C 41508 EA TAIL BOOM DENTED W O OTHER O OTHER LD LANDING 1 CA 750 2542 L1445639A (CAN) DURING SIMULATED ENGINE OUT IN HOVER OVER SOFT GROUND, THE ENGINE FAILURE CAUSED THE HELICOPTER TO ROTATE RIGHT AN D AT GROUND CONTACT THERE WAS A COUNTERSHOCK. THIS LED TO THE TAIL CONE DAMAGE. DAMAGE LOCATED ABOUT 5 O'CLOCK A FEW INCHES BEHIND THE ATTACH POINT. 1 G 7 1 3O 3 O H10WE E274 1997112600288 19971126 00288 EA 1997 11 26 CA970822003 1 19970812 G 5312 C2FS533 BULKHEAD DHAV DHC2 DHC2MK3 2800107 EA FS228 CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 9385 (CAN) DURING 100 HOUR INSPECTION CRACKS WERE FOUND AT FUSELAGE STATION 228 ON THE BULKHEAD, ATTACHED TO THE VERTICAL STA BILIZER SPAR. EMPENNAGE REMOVED AND BULKHEAD WAS REPLACED. TOTAL TIME ACCUMULATED SINCE LAST ANNUAL WAS 65 HOURS. NO REP ORTS OF ROUGH WATER OR HARD LANDINGS OR FLIGHT TURBULENCE HAD BEEN REPORTED. 1 H 7 1 3T A806 1997120300015 19971203 00015 SO 1997 12 3 CA970822005 2 19970628 G 7314 6468241 FUEL PUMP CESSNA 206 U206F 2073333 CE CONT O520 IO520A 17032 SO MCAULY D3A34 D3A34C402 GL ENG DRIVEN SEIZED W A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 CA 290 679506 901382 (CAN) ENGINE LOST POWER IN CRUISE DUE TO ENGINE DRIVEN FUEL PUMP FAILURE. THE PILOT COULD NOT MAINTAIN ALTITUDE WITH THE AUXILIARY ELECTRIC PUMP AND LANDED IN OPEN WATER ON A LAKE. THE PUMP WAS REPLACED AT A MARINA. INSPECTION OF THE PUMP R EVEALED A LARGE ACCUMULATION OF RUST AND CORROSION ON THE FUEL PUMP BLADES, WHICH SEIZED THE PUMP AND SHEARED THE DRIVE COUPLING. IT WAS DETERMINED THAT THE AIRCRAFT HAD SAT IN A HEATED HANGAR FOR 4 TO 5 MONTHS PREVIOUS TO THE INCIDENT. A T HOROUGH WINTERIZATION PROGRAM OR MORE FREQUENT USAGE OF THE AIRCRAFT PERHAPS WOULD HAVE PREVENTED THE CORROSION AND SUBS EQUENT FAILURE. 1 H 7 1 3O 3 O A4CE E5CE 5 C P47GL 2000021200010 20000212 00010 CE 2000 2 12 CA970902004 1 19970812 G 5210 99420024605 HATCH BEECH 99 B99 1154004 CE PWA PT6 PT6A28 EA HARTZL HCB3T HCB3TN3 GL CREW DOOR SEPARATED W A UNSCHED LANDING D INFLIGHT SEPARATION CL CLIMB 1 CA PCE41120 BU7723 (CAN) AFTER TAKEOFF, THE CREW HATCH OPENED AND SEPARATED FROM AIRCRAFT. THE AIRCRAFT LANDED WITHOUT INCIDENT. NEW DOOR INSTALLED, LATCHING MECHANISM CHECKED SERVICEABLE. AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 3T 4 T A14CE E4EA 6 C P15EA 1998050100087 19980501 00087 SW 1998 5 1 CA970902013 1 19970821 G 5302 BEAM BELL 204 204B 1181404 SW LYC T53 T5313B 41549 NE TAIL BOOM CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA LE07531 (CAN) TAIL BOOM ATTACHMENT POINT T-CAP BEAM FOUND CRACKED. SOME RIVETS ALSO SHEARED. CRACK WAS ALONG TWO HI-SHEAR RIVE T HOLES. 1 G 7 1 4U 4 U H1SW E17EA 1997112600297 19971126 00297 GL 1997 11 26 CA970902017 3 19970820 G 6114 B3905 PIN MCAULY 2A34C 2A34C203 GL BASE ASSEMBLY FAILED LOAD TEST W K NONE O OTHER IN INSP/MAINT 1 CA 532 1676 765503 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. BASE ASSEMBLY PIN FAILED THE LOAD TEST. 5 C P3EA 1997112600298 19971126 00298 GL 1997 11 26 CA970902018 3 19970821 G 6111 S90AT10 BLADE MCAULY 2A34C 2A34C66 GL THREADED AREA DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 744344 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. A PROPELLER BLADE THREADS WAS FOUND SCRATCHED 5 C P3EA 1997112600302 19971126 00302 EA 1997 11 26 CA970902023 2 19970628 G 7414 10349371 IMPULSE COUPLING BENDIX 103493704 BLANCA 17 1731A 1220435 GL LYC O540 IO540K1E5 41532 EA LH MAGNETO WORN W A B UNSCHED LANDING EMER. DESCENT Y ENGINE STOPPAGE CR CRUISE 1 CA 217 A25960 L989948 (CAN) AIRCRAFT EXPERIENCED LOSS OF ENGINE POWER IN FLIGHT. EMERGENCY NO POWER LA NDING CARRRIED OUT IN FIELD. AIRCRAFT R EMOVED FROM FIELD AND DISASSEMBLY OF ENGINE REVEALED THE LEFT HAND MAGNETO IMPULSE COUPLING LOCKED-UP, STRIPPING THE GEA RS IN THE ACCESSORY CASE, CAUSING COMPLETE ENGINE FAILURE. 1 L 7 1 3O 3 O A18CE 1E4 1997112600303 19971126 00303 GL 1997 11 26 CA970902024 3 19970822 G 6111 S90AT2 BLADE CESSNA 185 185 2072802 CE CONT O470 IO470F 17026 SO MCAULY 2A34C D2A34C58 GL PITCH DISTRIBUT OUT OF SPECS W K NONE O OTHER IN INSP/MAINT 1 CA 485 768043F 912433 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. THE PROP BLADES AIRFOIL PITCH DISTRIBUTION WAS NOT TO SPECIFICATIONS. THE HUB PILOT TUBE BORE (P/N 4715) WAS OVERSIZE. 1 H 7 1 3O 3 O NC 3A24 3E1 5 C P3EA 1997112600304 19971126 00304 GL 1997 11 26 CA970902025 3 19970825 G 6114 57A2433 HUB BOLTS HARTZL HCC2Y HCC2YK1 GL UNDER BOLT HEADS CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 1391 CH12805 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. THE HUB BOLTS WERE FOUND CORRODED UNDER THE BOLT HEADS. THE PROPELLER BLADES BALL BEARING WERE FOUND GALLED. 5 C P920 2000021200013 20000212 00013 SO 2000 2 12 CA970902032 1 19970824 G 2432 BATTERY PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL E/E BAY DISCHARGED W H DEACTIVATE SYST/CIRCUITS H ELECT. POWER LOSS-50 PC UK UNKNOWN 1 CA 10440 L564961A DJ9380A (CAN) A SHORT PERIOD OF TIME AFTER THE AIRCRAFT WAS PARKED, THE ANTI-COLLISION LIGHT APPEARED TO BE OPERATING. IT WAS THOUGHT THE MASTER SWITCH WAS LEFT ON. THIS WAS NOT THE CASE. THE NEXT MORNING, THE AIRCRAFT COULD NOT BE STARTED DUE TO A WEAK BATTERY. IT WAS REMOVED AND SERVICED, REINSTALLED. FURTHER INVESTIGATION REVEALED MASTER SWITCH CAN BE ACTI VATED BY RAIN IF COVER FOR CIRCUIT BREAKER IS NOT PROPERLY SEALED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 1997112600308 19971126 00308 NE 1997 11 26 CA970902033 2 19970725 G 7322 P3 LINE DORNER DO32 DO328100 2996000 NM PWA 119 PW119B NE O/S GOVERNOR FRACTURED W E ENGINE SHUTDOWN R PARTIAL RPM/PWR LOSS CR CRUISE 1 CA 3482 116125 (CAN) ENGINE POWER ROLLED BACK TO SUB-IDLE DURING CRUISE. THE ENGINE WAS SHUTDOWN AND THE AIRCRAFT MADE AN UNEVENTFUL SI NGLE ENGINE LANDING AT ITS DESTINATION. POST FLIGHT INSPECTION REVEALED THE P3 LINE TO BE FRACTURED ADJACENT TO THE OVER SPEED GOVERNOR. THE TUBE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE 2 H 7 2 4T 4 T RT A45NM E20NE 1997112600309 19971126 00309 NE 1997 11 26 CA970902034 2 19970811 G 7261 REGULATOR PWA PWA120 PW125B NE NR2 ENG OIL PRES FAULTY W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 8645 124052 (CAN) DURING CLIMB THE OIL PRESSURE ON NR2 ENGINE, BEGAN TO FLUCTUATE BELOW THE MINIMUM OPERATING LEVEL. THE AIRCRAFT RE TURNED TO DEPARTURE POINT, AT REDUCED POWER. POST FLIGHT INSPECTION FOUND THE OIL PRESSURE REGULATING VALVE TO BE FAULT Y. THE VALVE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 4 T E20NE 1997112600310 19971126 00310 NE 1997 11 26 CA970902035 2 19970814 G 7314 FUEL PUMP PWA PWA120 PW125B NE NR1 ENG HP FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 11974 1991 124253 (CAN) A POPPING SOUND WAS HEARD IMMEDIATELY AFTER TAKEOFF ACCOMPANIED BY DECAYING PARAMETERS AND AN "ENGINE OUT" WARNING LIGHT ON NR1 ENGINE. THE ENGINE WAS SHUTDOWN AND THE AIRCRAFT RETURNED TO ITS POINT OF DEPARTURE. POST FLIGHT INSPECTIO N FOUND THE HP FUEL PUMP TO BE FAULTY. THE FUEL PUMP WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 4 T E20NE 1997112600311 19971126 00311 NE 1997 11 26 CA970902036 2 19970814 G 7322 FUEL CONTROL PWA PWA120 PW125B NE N1 ENGINE FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 11974 1991 124253 (CAN) A POPPING SOUND WAS HEARD IMMEDIATELY AFTER TAKEOFF ACCOMPANIED BY DECAYING PARAMETERS AND AN "ENGINE OUT" WARNING LIGHT ON NR1 ENGINE. THE ENGINE WAS SHUTDOWN AND THE AIRCRAFT RETURNED TO ITS DEPARTURE POINT. POST FLIGHT INSPECTION F OUND THE MAIN FUEL CONTROL UNIT TO BE FAULTY. THE MAIN FUEL WAS REPLACED AND THE AIRCRAFT RETIURNED TO SERVICE. 4 T E20NE 1997112600313 19971126 00313 SO 1997 11 26 CA970903002 2 19970410 G 8500 ENGINE CESSNA 340 340A 2076405 CE CONT O520 TSIO520N 17040 SO MCAULY 3AF32C 3AF32C93 GL #2 POSITION FAILED W A UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 CA 228252 785844 (CAN) NR 2 ENGINE FAILED 1 L 7 2 3O 3 O 3A25 E8CE 5 C P22EA 1997112600315 19971126 00315 1997 11 26 CA970903004 1 19970603 G 7810 99710000804 EXHAUST MANIFOLD 2075000000 ROTAX 912 ROTAX912 55555 EU UPPER BEND SEPARATED W A A UNSCHED LANDING O OTHER CR CRUISE 1 CA 669 4076163 (CAN) EXHAUST MANIFOLD SEPARATED AT THE UPPER WELD. THE MANIFOLD WAS REPLACED. FAILURE OF THE WELD CAUSED: NYLON WRAP TO MELT INTO PROP CONTROL CABLE AND CAUSE IT TO FREEZE. PROP CONTROL UNSERVICEABLE. PROP CONTROL REPLACED. FIRE PROTECTION SLEEVE ON THE TACHOMETER CABLE ABSORBED MELTED TACH CABLE ON THE PROTECTIVE WRAP. TACH CABLE REPLACED. 3 I EXPE3I 1997120300016 19971203 00016 EA 1997 12 3 CA970903005 1 19970828 G 3610 215081505 DUCT BLEED AIR CNDAIR CL600 CL600* EA LYC ALF502 ALF502* 41580 EA 8TH STAGE CRACKED W A O OTHER M OVER TEMP CL CLIMB 1 CA LF030205 (CAN) ON CLIMB THROUGH 1,500 FEET, THE TEMPERATURE ON NR1 ENGINE SUDDENLY INCREASED BY 100 DEGREES, POWER WAS REDUCED AN D IN CRUISE THE NR1 ENGINE TEMPERATURE WAS 40 DEGREES HIGHER THAN THE NR2 ENGINE. ON LANDING THERE WAS NO THRUST REVERSE RS AVAILABLE ON THE NR1 ENGINE. INVESTIGATION FOUND 8TH STAGE BLEED AIR DUCT HAD CRACKED THROUGH 360 DEGREES AT THE WELD AND COULD NOT SUPPLY AIR TO DEPLOY THE THRUST REVERSERS. 2 L 7 2 4F 4 F RT A21EA E6NE 2000021200014 20000212 00014 CE 2000 2 12 CA970903007 1 19970717 G 2150 1143800025 PRE COOLER BEECH 1900 1900C 1154161 CE AIR DISTRIBUTION LEAKING W O OTHER O OTHER CR CRUISE 1 CA 12818 (CAN) ENGINE ECTM INDICATING RISING ITT. ALSO NOTICED THROTTLE SPLIT IN CRUISE BUT MARGINAL IMPROVEMENT WITH BLEED AIR OFF ON RT ENGINE. PRECOOLER FOUND TO BE LEAKING AROUND FINS AND SEAMS. PRECOOLER REPLACED. 2 L 7 2 4T RT A24CE 1997112600318 19971126 00318 NE 1997 11 26 CA970903012 2 19970823 G 7250 PT SHAFT PWA PW120 PW124B NE NR1 ENGINE FRACTURED W O OTHER B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA 10012 3251 124420 (CAN) DURING TAXI THERE WAS AN ODOUR OF OIL AND A DROP IN NR1 ENGINE PARAMETERS. GROUND INSPECTION FOUND THE TURBOMACHIN ERY CHIP DETECTOR AND THE NR4/5 SCAVENGE LINES HEAVILY CONTAMINATED WITH METAL. FURTHER INVESTIGATION FOUND THE PT SHAFT HAD FRACTURED IN THE VICINITY OF THE NR4 BEARING. 4 T E2ONE 1997112600331 19971126 00331 CE 1997 11 26 CA970904016 1 19970617 G 2435 646275 STARTER CESSNA 185 A185F 2072821 CE MCAULY D3A34 D3A34C403 GL BRUSHES FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 490 W249036 770031 (CAN) STARTER FAILED AS BOTH INSULATED BRUSHES WERE SEVERED PROBABLY FROM VIBRATION NEXT TO WHERE BRUSH LEAD IS SANDWICH ED BETWEEN TWO POLE STRAPS AND SPOT WELDED CLEAR THROUGH. ALL FOUR FIELD COILS WERE LOOSE ON THEIR RESPECTIVE POLE SHOES AND HAD CHAFED HALF WAY THROUGH THE INSULATION. THE SUBMITTER STATES THIS IS AN IMPROPER AND UNACCEPTABLE MANUFACTURING PROCESS. 1 H 7 1 3O 3A24 5 C P47GL 1997121100273 19971211 00273 NM 1997 12 11 CA970904023 1 19970718 G 3241 39043A VALVE CRANE 39043A BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE MLG ANTI-SKID LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 956B P653620B (CAN) LH MAIN LANDING GEAR ANTI-SKID VALVE LEAKING. REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 1997121100274 19971211 00274 NM 1997 12 11 CA970904024 1 19970815 G 5320 WEB BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE BS312R WL169 CORROSION W K NONE O OTHER IN INSP/MAINT 1 CA 43881 P653620B (CAN) CORROSION ON WEB WL 169 BS 312RLAVATORY CHEMICAL LEAK. REPAIRED. 2 L 7 3 4F 4 F A3WE E2EA 1997121100275 19971211 00275 NM 1997 12 11 CA970904025 1 19970815 G 5330 SKIN BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE LAV SERV PANEL CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 43881 P653620B (CAN) SKIN FORWARD OF FORWARD LAVATORY SERVICE PANEL HAS BULGE AT THE FASTENERS. CORROSION ON THE LOWER SKIN OF THE LAP JOINT. SKIN 2 L 7 3 4F 4 F A3WE E2EA 2000021200020 20000212 00020 CE 2000 2 12 CA970904038 1 19970821 G 3230 MS243311 SWITCH AIRIGHT 1143800411 BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL MLG FAILED W L ABORTED APPROACH J WARNING INDICATION AP APPROACH 1 CA PCE32053 FW562 (CAN) ON APPROACH, LT MAIN LANDING GEAR NOT SHOWING GREEN BUT TRANSIT LIGHTS EXTINGUISHED. EMERGENCY LANDING SAFELY CAR RIED OUT. MAINTENANCE INVESTIGATION FOUND ACTUATOR DOWNLOCK MICROSWITCH INTERMITTENT. SWITCH REPLACED AND SYSTEM CHECK ED SERVICEABLE. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2000021200021 20000212 00021 CE 2000 2 12 CA970904039 1 19970821 G 2420 WIRE BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL AC SYSTEM FAILED W O OTHER J WARNING INDICATION CR CRUISE 1 CA PCE32053 FW562 (CAN) DURING FLIGHT, THE NR 1 INVERTER CAPTION LIGHT WOULD COME ON, INDICATING INVERTER FAILURE, THEN THE 26 VAC PILOT G YRO HORIZON CIRCUIT BREAKER WOULD TRIP AND SELECTION OF NR 2 INVERTER WOULD ALSO INDICATE FAILURE. FAILURE SEEMED TO O CCUR DURING RIGHT TURNS. MAINTENANCE CHECK REVEALED WIRE BUNDLE FROM THE GYRO HAD TO MAKE A TIGHT TURN AT THE CANNON P LUG. THIS CONFIGURATION CAUSED A WIRE OF THE BUNDLE TO OCCASIONALLY SHORT OUT. WIRE BUNDLE AND TUBE ROUTING ADJUSTED AND WIRE REPAIRED. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2000021200023 20000212 00023 CE 2000 2 12 CA970904041 1 19970822 G 5210 LATCH ZENAIR 20F324 ZINAIR CH2000 CH2000 9950100 CE CREW DOOR FAILED W A UNSCHED LANDING D INFLIGHT SEPARATION AB AEROBATIC 1 CA 40 (CAN) LATCH OPENED IN-FLIGHT RESULTING IN DOOR SEPARATING FROM AIRCRAFT. LATCH TOO EASY TO OPEN, ONE PLANE MOTION, TWO NOTCHES. BULKY CLOTHING OR IN THIS CASE A KNEE BOARD WORN BY THE PILOT ON RAISING THE KNEE OPENED LATCH. 1 L 7 1 3O NT TA5CH 1998050100081 19980501 00081 EU 1998 5 1 CA970905001 1 19970902 G 2750 677ONL312014 BOLT Z4243430000 ZLIN 242 Z242L 9970204 EU FLAP BENT W K NONE O OTHER IN INSP/MAINT 1 CA 1451 (CAN) DISSASSEMBLY OF THE FLAP CONTROL BELLCRANK AT THE 1500 HR INSPECTION FOUND THE BOLT ATTACHING THE FLAP CONTROL CAB LE TO THE BELLCRANK WAS BENT AT THE MIDWAY POINT. THE OTHER WING BELLCRANK BOLT WAS FOUND IN THE SAME CONDITION. 1 L 7 1 3O 0 A76EU 1997112600337 19971126 00337 GL 1997 11 26 CA970905002 3 19970828 G 6112 4E15551 SLIP RING HARTZL HCB3T HCB3TN3 GL PROP SHORTED W K NONE O OTHER IN INSP/MAINT 1 CA 1854 6338 BU13148 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND THE DE-ICE SLIP RING SHORTED OUT AT THE TRACKS. THIS WAS CAUSING INTERMITTENT DE-ICE OPERATION. 6 C P15EA 1997112600338 19971126 00338 EA 1997 11 26 CA970905003 3 19970826 G 6111 BLADE SNSNCH 74D 74DM EA LEADING EDGE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 2050 1191 A51432 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND STONE DAMAGE TO THE LEADING EDGE AND FACE OF THE PRO PELLER BLADES 5 N P88614 1997112600339 19971126 00339 GL 1997 11 26 CA970905004 3 19970828 G 6111 S90M1D BLADE MCAULY 2A36C 2A36C33 GL BLADE THREADS CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 609 178 62476 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND THE PROPELLER BLADE CRACKED. THE SUBMITTER SUGGESTS THAT IF THE FIVE YEAR INSPECTION HAD NOT BEEN CARRIED OUT THE BLADE WOULD HAVE FAILED PERHAPS WITH THE LOSS OF AIRCRAFT. 5 C P880 1997112600340 19971126 00340 NE 1997 11 26 CA970905005 2 19970827 G 7210 310924401 BEARING PWA 120 PW120 NE RED GRBOX NR 15 SPALLED W K NONE O OTHER NR NOT REPORTED 1 CA 11970 3315 121047 (CAN) THE REDUCTION GEARBOX WAS FOUND TO BE GENERATING METAL ANALYSED AS BEING M50.- RGB WAS SENT FOR INVEST. OF- METAL CONTAMINATION & RESTROATION. DISASSY OF- RGB FOUND- SOURCE OF THE METAL CONTAMINATION WAS DEFINITELY- SPALLING OF- NR15 BEARING ON ITS OUTER RACE. THIS BEARING WAS- ORIG BEARING INST AT PRODUCTION.-RE IS AMPLE INDICATION OF ELECTRICAL DISCH ARGE PIT TING ON- OTHER SURFACES OF- FAILED BEARING & THIS WOULD APPEAR TO BE A CLEAR CASE OF LOW LEVEL ELECTRICAL DISCH ARGE PITTING LEADING TO FAILURE OF- BEARING. MAGNETISM IS MINIMAL ON ALL GEARS, PROP SHAFT & PCU COUPLING & BEARINGS.-RE FORE LIGHTNING IS NOT THOUGHT TO BE INVOLVED IN THIS FAILURE: 4 T E20NE 1997101600747 19971016 00747 NM 1997 10 16 CA970909002 1 19970826 G 3240 2661943 BRAKE HOUSING 214665 DHAV DHC8 DHC8* NM PISTON HOUSING CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 12716 (CAN) LIQUID PENETRANT AND EDDY CURRENT INSPECTION WERE COMPLETED ON DHC8-100 BRAKE HOUSINGS. ON ONE UNIT ALL (6) PISTON CAVITIES WERE FOUND CRACKED JUST BELOW THE INLET AND BLEEDER PORTS. ON THE SECOND THREE PISTON CAVITIES WERE FOUND CRAC KED IN THE SAME AREA. 2 H 7 2 4T RT A13NM 2000021200027 20000212 00027 CE 2000 2 12 CA970909007 1 19970818 G 3213 12438116 COLLAR 743627 CESSNA 206 P206B 2073309 CE CONT O520 IO520A 17032 SO MCAULY 3A32C D3A32C* GL STRUT BROKEN W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 CA 2106 1116936A 8601219 (CAN) THE AIRCRAFT IS USED FOR TRANSPORTING SKY DIVERS AND IS SUBJECT TO LONG TAKEOFF RUNS AND CROSSWINDS. THIS CONDITI ON SUBJECTS THE LANDING GEAR STRUT TO HIGH STRESS LOADS WHICH CONTRIBUTED TO THE STRUT COLLAR FAILURE. 1 H 7 1 3O 3 O A4CE E5CE 5 C P21EA 1997101600748 19971016 00748 NE 1997 10 16 CA970909008 2 19970821 G 7320 311717502 MFCU DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE P3 AIR LEAK LEAKING W A UNSCHED LANDING K FLUID LOSS CL CLIMB 1 CA 39 (CAN) FUEL VENTING FROM STARBOARD OUTBOARD NACA VENT ON CLIMB OUT. MFCU, P3 AIR LEAKING INTERNALLY INTO DRAIN RETURN TO FUEL TANK RESULTING IN FUEL TANK PRESSURIZATION AND SUBSEQUENT VENTING. MFCU REPLACED. UNIT RETURNED TO P&W FOR INVESTIG ATION. 2 H 7 2 4T 4 T RT A13NM E20NE 1998041700717 19980417 00717 NE 1998 4 17 CA970909010 2 19970820 G 7322 FUEL CONTROL GE CF343B1 CNDAIR CL600 CL6002B19 EA GE CF34 CF343B1 NE LT ENGINE FAILED W E ENGINE SHUTDOWN J WARNING INDICATION TX TAXI/GRND HDL 1 CA (CAN) WHEN PULLING BACK FROM GATE WITH THRUST REVERSER LEVER ABOUT .500 INCH FORWARD OF FLIGHT IDLE THE LEFT ENGINE RAN AWAY. ALL INDICATIONS WERE HEADING FOR RED. ENGINE SHUT DOWN. ONLY INDICATION NOTICED ABOVE RED WAS N1. THE ITT WENT 926 DEGREES FOR 1.2 SECOND AND THE N1 WENT 100.9 FOR 1.3. FCU REPLACED. 2 L 7 2 4F 4 F RT A21EA E15NE 2000021200029 20000212 00029 CE 2000 2 12 CA970909018 1 19970825 G 3230 991028710 PRESSURE SWITCH CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO MCAULY 3AF32C 3AF32C505 GL MLG FAILED W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA 290847R 950199 (CAN) ON GEAR RETRACTION AFTER TAKEOFF, THE HYDRAULIC PRESSURE LIGHT REMAINED ILLUMINATED. LANDING GEAR EXTENDED, LIGHT REMAINED ON. MAINTENANCE INVESTIGATION FOUND AN INOPERATIVE PRESSURE SWITCH. THE SWITCH WAS REPLACED AND RETRACTION T ESTS CARRIED OUT, SERVICEABLE. 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 2000021200030 20000212 00030 SO 2000 2 12 CA970909019 1 19970825 G 5610 WINDOW PIPER PA31 PA31 7103102 SO COCKPIT DAMAGED W O OTHER O OTHER CR CRUISE 1 CA (CAN) COPILOT'S WINDOW DAMAGED BY HEAT FROM EXHAUST STACK. SUSPECT THIS CONDITION CAUSED BY PROPELLER IN THE FEATHERED POSITION AND AIRCRAFT NOT TURNED INTO THE WIND. AIRCRAFT RECENTLY HAD ROM AIR KIT INSTALLED STC SA4723NM AND LOW DRAG E XHAUST ASSY IAW STC SA00046SE. IT APPEARS UNDER RIGHT CONDITION, PROPS IN FEATHER AND TAIL WIND EXHAUST HEAT CAN DAMAGE WINDOW ON RT SIDE. 1 L 7 2 3O A20SO 1998041700716 19980417 00716 EU 1998 4 17 CA970910003 1 19971003 G 3230 1035052 DRIVER GROB 103CAT G103TWNASTIR 1660202 EU MLG BENT W O OTHER O OTHER LD LANDING 1 CA 135 (CAN) GEAR SELECTED DOWN AND WAS BELIEVED TO BE DOWN AND LOCKED. AT TOUCHDOWN, THE GEAR RETRACTED AND AIRCRAFT SLID ON ITS BELLY TO A STOP. INSPECTION FOUND THE ACTUATING HANDLE IN THE FORWARD COCKPIT BENT. THIS IS SECOND OCCURRENCE FOR THIS AIRCRAFT AND DRIVER TO BE BENT. 1 K 0 0 G39EU 1997112600345 19971126 00345 SO 1997 11 26 CA970910004 2 19970714 G 7322 MA3SPA CARBURETOR CESSNA 150 150C 2071808 CE CONT O200 O200A 17020 SO CARB HEAT BOX WORN W K NONE O OTHER IN INSP/MAINT 1 CA 7190 104115 250488A48 (CAN) DURING CARBURETOR INSPECTION THE FORWARD SUPPORT BRACKET WAS FOUND LOOSE, FURTHER INSPECTION REVEALED THE SCREWS H OLDING THE BRACKET TO THE CARBURETOR HEAT BOX WERE LOOSE, EVEN THOUGH THE SCREWS WERE INSTALLED WITH LOCKWASHERS AND WER E PROPERLY LOCKWIRED. INSPECTION OF THE SCREWS FOUND THE THREADS WERE WORN AND DID NOT GRIP. THE LOCATION OF THESE SCREW S INSIDE THE CARBURETOR HEAT BOX COULD CREATE A INGESTION PROBLEM, THE ONLY WAY TO PROPERLY INSPECT THESE SCREWS IS TO R EMOVE THE AIR FILTER BOX. 1 H 7 1 3O 3 O 3A19 E252 1998041700715 19980417 00715 CE 1998 4 17 CA970910005 1 19970827 G 2400 2048141 GROUND BLOCK CESSNA 500 560CESSNA 2076750 CE PWA JT15 JT15D5 52112 NE ELECTRICAL POWER NOT GROUNDED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) GROUND BLOCK POORLY GROUNDED TO AIRFRAME. SURFACES CLEANED AND GOOD BOND SUPPLIED. 2 L 7 2 4F 4 F RT A22CE E25EA 1997112600347 19971126 00347 EA 1997 11 26 CA970910007 3 19970904 G 6111 BLADE SNSNCH 74D 74DM EA LEADING EDGE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA K37599 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. STONE DAMAGE WAS FOUND ON THE LEADING EDGE OF THE PROPELLER BLADE 5 N P88614 1997112600348 19971126 00348 EA 1997 11 26 CA970910008 3 19970904 G 6111 BLADE SNSNCH 74D 74DM EA LEADING EDGE ERODED W K NONE O OTHER IN INSP/MAINT 1 CA K36246 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. LEADING EDGE OF THE PROPELLER BLADE(S) WAS FOUND ERODED 5 N P88614 1997112600349 19971126 00349 NE 1997 11 26 CA970910009 3 19970902 G 6114 B5264 CYLINDER MOONEY M20 M20C 5870208 SW LYC O360 O360A1D 41514 EA MCAULY C3D36C C3D36C41582 NE PROP SEAL AREA OVERSIZE W K NONE O OTHER IN INSP/MAINT 1 CA 123 L734036A 920431 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. THE CYLINDER WAS FOUND TO BE OVERSIZE. 1 L 7 1 3O 3 O 2A3 E286 5 N SA645NE 1997120300019 19971203 00019 GL 1997 12 3 CA970910010 3 19970829 G 6114 3474 ROD MCAULY 3AF32C 3AF32C* GL REAR HUB SCORED W K NONE O OTHER IN INSP/MAINT 1 CA 910662 (CAN) PROPELLER RECEIVED FOR GREASE LEAK. THE RODS WERE FOUND HEAVILY SCORED AND WERE REPLACED. 5 C P22EA 1997112600350 19971126 00350 GL 1997 11 26 CA970910011 3 19970829 G 6114 LOW PITCH STOP BEECH 36 A36 1151604 CE CONT O520 IO520BA 17032 SO MCAULY 2A36C 2A36C23 GL PROP MIS ADJUSTED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 594 280739R 765471 (CAN) AIRCRAFT NOT GETTING FULL RPM. PROPELLER AND GOVERNOR REMOVED FOR BENCH CHECK. GOVERNOR SET CORRECTLY. PROPELLER W AS SET TOO HIGH PREVIOUS SETTING, INCORRECT REFERENCE STATIONS WERE USED. 1 L 7 1 3O 3 O 3A15 E5CE 5 C P880 1997112600351 19971126 00351 EA 1997 11 26 CA970910012 3 19970905 G 6111 BLADE SNSNCH 76AK M76AK EA LEADNG EDGE/FACE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 6690 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER BLADE FOUND WITH STONE DAMAGE. 5 N 1P210 1998111300583 19981113 00583 EU 1998 11 13 CA970910013 1 19970831 G 2550 878 SPRING SIREN S16096 SNIAS 350 AS350B2 8680813 EU CARGO HOOK MISINSTALLED W O OTHER D W INFLIGHT SEPARATION INADEQUATE Q C CR CRUISE 1 CA 58 878 (CAN) DURING GEOSURVEY WITH A POD HANGING FROM THE CARGO HOOK, APPROXIMATELY 30 MINUTES AFTER TAKEOFF, CARGO RELEASED UN COMMANDED AND THE POD DROPPED AND WAS DESTROYED. DISASSEMBLY OF THE CARGO HOOK REVEALED THAT THE RELEASE LEVER RETURN S PRING WAS NOT ENGAGED IN THE HOLE AT THE BOTTOM OF THE CASING, THEREFORE, NOT DRIVING THE LEVER TO THE FULLY LOCKED POSI TION. PART TC: 23 1 G 7 1 3U H9EU 1998111300584 19981113 00584 EU 1998 11 13 CA970910014 1 19970817 G 2550 864 LEVER SIREN S16096 SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE CARGO HOOK JAMMED W O OTHER O OTHER HO HOVERING 1 CA 185 864 4550 (CAN) CARGO HOOK WOULD NOT RELEASE ELECTRICALLY OR MANUALLY. THE LOCKING MECHANISM WOULD NOT ROTATE WITHIN THE ASSEMBLY ALTHOUGH THE SOLENOID, HEARD CLICKING RELEASING THE TORQUE ON THE RELEASE LEVER BUSHING THRU BOLT, ALLOWED THE HOOK TO WORK PROPERLY. MISMACHINED PARTS, EITHER THE LEVER FULCRUM IS TOO WIDE OR ITS BUSHING NOT WIDE ENOUGH ALLOWING THE SIDE PLATE TO CLAMP IT SOLID. PART TC: 30. 1 G 7 1 3U 3 U NC H9EU E19EU 1997120300020 19971203 00020 NE 1997 12 3 CA970910017 2 19970825 G 7250 30A1102 LPT DISK LEAR 60 60LEAR 5170707 CE PWA 305 PW305 NE 3RD STAGE MIS MANUFACTURE W A K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 50 CA0043 (CAN) A TURBINE DISK MACHINED, AS A TRIAL, TO AN UNAPPROVED PROCESS WAS ERRONEOUSLY ASSEMBLED INTO A MODULE AND SUBSEQUE NTLY BUILT INTO ENGINE CA0043 CURRENTLY ON LEARJET 60-103. THE UNAPPROVED PART WAS REPLACED. THIS IS AN ISOLATED CASE AN D NO OTHER DISKS ARE AFFECTED. 2 L 7 2 4F 4 F RT A10CE E35NE 1997121100277 19971211 00277 EA 1997 12 11 CA970915003 3 19970903 G 6111 BLADE SNSNCH 74DM M74DM EA PROP LE FACE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 2159 211 K30298 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. THE PROPELLER BLADES WERE FOUND TO HAVE STONE DAMAGE TO THE LEADING E DGES AND THE FACE. 5 N P88614 2000021200033 20000212 00033 CE 2000 2 12 CA970915004 1 19970910 G 3246 40177A WHEEL CESSNA 208 208B 2073701 CE MCAULY 3AF34C 3GFR34C703 GL NLG CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 415 PCEPC0489 262459 (CAN) DURING INSPECTION, CORROSION WAS FOUND IN THE BEARING AREA OF NOSE WHEEL. THE BEARING SEALS WERE FOUND IN GOOD CON DITION. WATER APPEARS TO HAVE ENTERED THE AREA FROM THE NOSE FORK AND SPACER TRAVELING DOWN AXEL TUBE INTO THE BEARING AREA. 1 H 7 1 3T A37CE 5 C P60GL 1998041700713 19980417 00713 CE 1998 4 17 CA970915005 1 19970904 G 5712 16214018 RIB CESSNA 188 A188B 2073005 CE CONT O550 IO550D 17042 SO HARTZL HCC3Y HCC3YF1 GL WS 36.12 CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 1887 284027R EC1042A (CAN) WHILE CARRYING OUT A 100 HR INSPECTION THE AME, FOUND CRACKS AT THE WING RIBS AT STATION 22.87 AND STATION 36.12. THREE CRACKS WERE FOUND IN THE SECOND AND THIRD LIGHTENING HOLE IN P/N 1621401-8 AND THREE CRACKS WERE FOUND IN THE FIR ST, SECOND AND THIRD LIGHTENING HOLES. 1 L 7 1 3O 3 O A9CE E3SO 5 C P25EA 1998041700712 19980417 00712 CE 1998 4 17 CA970915006 1 19970903 G 5712 162100917 RIB 162100917 CESSNA 188 A188B 2073005 CE CONT O550 IO550D 17042 SO HARTZL HCC3Y HCC3YF1 GL WS 20 CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 1638 284028 EC1037A (CAN) WHILE PERFORMING A 100 HR INSPECTION, THE AME FOUND A CRACK AT THE WING RIB AT STATION 20.62. THE CRACK IS APPROXI MATELY .75 INCH LONG STARTING FROM THE LIGHTENING HOLE WHICH IS LOCATED 11 INCHES FORWARD OF THE REAR WING ATTACHMENT. 1 L 7 1 3O 3 O A9CE E3SO 5 C P25EA 1997112600354 19971126 00354 NE 1997 11 26 CA970915007 2 19970904 G 7250 311755401 INTERSTAGE CASE PWA 120 PW120 NE REAR FLANGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 10040 121182 (CAN) THE ENGINE WAS REMOVED FROM SERVICE AFTER A ROUTINE BORESCOPE INSPECTION FOUND THE LEADING EDGES OF ALL THE PT1 TU RBINE BLADES HAD DISTINCT NOTCHED AT THE VERY ROOT OF THE BLADE WITHIN THE AIRFOIL TO PLATFORM RADIUS. DISASSEMBLY FOUND THE NOTCHES IN THE PT1 TURBINE BLADE LEADING EDGES WERE CAUSED BY RUBBING CONTACT WITH THE INNER HUB OF THE PT1 STATOR. THE PT1 STATOR WAS ABLE TO MOVE REARWARD BECAUSE THE PT RETAINING BOLTS WERE ALL FRACTURED ON THE LH SIDE OF THE ENGINE , ELIMINATING ANY AXIAL RESTRAINT AT THE OUTER DIAMETER. THE STATOR WAS PUSHED REARWARD ON THE LEFT HAND SIDE OF THE ENG INE BY MASSIVE LOCALIZED SWELLING OF THE INTERSTAGE CASE REAR FLANGE CAUSED BY CORROSION. 4 T E20NE 2000021200034 20000212 00034 CE 2000 2 12 CA970916004 1 19970131 G 2910 1145800501 LINE 1145800007 BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE HYD SYSTEM CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 246 PS0050 HJ666 (CAN) ON INSPECTION, HYDRAULIC LEAK FOUND UNDER LT CENTER SECTION. INVESTIGATION REVEALED LEAK LOCATION WAS FROM LINE BETWEEN POWER PACK AND FILLER. CRACKED LINE REPLACED. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2000021200035 20000212 00035 CE 2000 2 12 CA970916005 1 19970905 G 5712 07221991 RIB CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO MCAULY D3A34 D3A34C403 GL WING BUCKLED W K NONE O OTHER IN INSP/MAINT 1 CA 1079 572171 790584 (CAN) THE BENT RIB CONDITION PROBLEM HAS BEEN PREVIOUSLY FOUND ON OTHER INSPECTIONS. IT APPEARS THIS CONDITION OCCURS I N AREA ABOVE THE AILERON HINGE OUTBOARD SECTION AND IS ALSO THE AREA WHERE THE AILERON BALANCE WEIGHTS ARE LOCATED. 1 H 7 1 3O 3 O 3A24 E5CE 5 C P47GL 1998041700710 19980417 00710 SO 1998 4 17 CA970916007 1 19970626 G 2913 66WAY3002 PUMP APEX 66WAY3002 GULSTM G159 G159 3952202 SO RROYCE DART DART5298X 54507 EU HYDRAULIC SYSTEM FAILED W O OTHER J WARNING INDICATION CR CRUISE 1 CA 6 6218 16062 (CAN) CREW REPORTED NR 1 HYDRAULIC PUMP PRESSURE FAIL LIGHT ON. PUMP REPLACED. 2 L 7 2 4T 4 T 1A17 E297 1998041700709 19980417 00709 SO 1998 4 17 CA970916008 1 19970626 G 2910 159H10002477LGU4 LINE GULSTM G159 G159 3952202 SO RROYCE DART DART5298X 54507 EU ROTOL R4304 R1844304 EU HYD SYSTEM CHAFED W O OTHER K FLUID LOSS CR CRUISE 1 CA 16062 DRG2262 (CAN) CREW REPORTED LOSS OF HYDRAULIC FLUID. CLAMP ON RT EXT HYD LINE CHAFED THROUGH AT CLAMP. LT AND RT DRIVEN PUMPS , FILTERS REPLACED AND LINE AND CLAMPS REPLACED. 2 L 7 2 4T 4 T 1A17 E297 6 C P899 1997121100284 19971211 00284 NM 1997 12 11 CA970916015 1 19970901 G 2410 700842A CSD SUNDSTRAND BOEING 720 720023B 1383841 NM PWA JT3D JT3D1 52039 NE QUILL SHAFT FAILED W H DEACTIVATE SYST/CIRCUITS J WARNING INDICATION TX TAXI/GRND HDL 1 CA 7815 11762 645267 (CAN) ON GROUND CHECK PRIOR TO TAKEOFF THE NR1 ENGINE GENERATOR CAME OFF LINE AND COULD NOT BE RESET, SO CONSTANT SPEED UNIT/GENERATOR ASSEMBLY WAS DISCONNECTED AND FLIGHT WAS CARRIED OUT AS PLANNED. ON DISASSEMBLY, OF THE CONSTANT SPEED DR IVE (CSD), THE OIL LEVEL WAS FOUND TO BE BELOW MINIMUM AND FURTHER INVESTIGATION FOUND THE CARBON SEAL WAS BROKEN AT THE GENERATOR END OF THE CSD. THE QUILL SHAFT WAS ALSO BROKEN AT THE ENGINE END OF THE CSD. 2 L 7 4 4F 4 F 4A28 1E8 1999082000210 19990820 00210 EU 1999 8 20 CA970916017 1 19970903 G 6320 350A32106038 SCREW 350A35110121 SNIAS 350 AS350D 8680803 EU LYC LTS101 LTS101600A2 41560 NE M/R GEARBOX WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) DURING DISASSEMBLY OF DRIVE SHAFT, 3 OF 12 SCREWS FOUND WERE THE WRONG TYPE. THERE WAS NO SPLIT PIN HOLE, AND TH EY HAD BEEN INSTALLED WITH A HEXAGONAL, INTERNAL LOCK NUT. THE ENDS HAD BEEN CENTER PUNCHED TO PEEN ENDS OVER. SCREWS SHOULD BE CASTELATED WITH SPLIT PIN. 1 G 7 1 3U 3 U H9EU E5NE 1998041700704 19980417 00704 GL 1998 4 17 CA970916019 2 19970908 G 7314 SPLINES TRW 6896810 SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL FUEL PUMP WORN W K NONE O OTHER IN INSP/MAINT 1 CA 2522 T0278 CAE890603S (CAN) FUEL PUMP SPLINE SHAFT END WORN. REPLACED. 1 G 7 2 3U 3 U H1NE E1GL 1997121100286 19971211 00286 EA 1997 12 11 CA970918005 3 19970911 G 6110 PROPELLER SNSNCH 74DM M74DM EA HUB ASSY CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 3004 723 K11765 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND THE PROPELLER HAD EXTENSIVE CORROSION AND AN OVERHAU L WAS REQUIRED. 5 N P88614 1998041700699 19980417 00699 CE 1998 4 17 CA970918009 1 19970909 G 5730 632205313 SKIN CESSNA 525 525 2076601 CE WING MISSING W K NONE O OTHER TX TAXI/GRND HDL 1 CA 920 (CAN) PILOT REPORTED 3 INCH BY 4 INCH SEGMENT OF LOWER WING SKIN MISSING. REPLACED. AIRCRAFT TT: 794 HOURS. 1 L 7 2 4F RT A1WI 1997121100288 19971211 00288 NE 1997 12 11 CA970918010 2 19970819 G 7250 BLADE PWA 120 PW120 NE NR2 ENG LPT FRACTURED W A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 CA 10265 120162 (CAN) THE PILOT ELECTED TO RETURN TO HIS POINT OF DEPARTURE AFTER THE ENGINE SUFFERED A DROP IN TORQUE FROM 80 PERCENT T O 30 PERCENT. POST FLIGHT INVESTIGATION FOUND A LOW PRESSURE TURBINE BLADE HAD FRACTURED. 4 T E20NE 1997121100289 19971211 00289 EA 1997 12 11 CA970918011 2 19970617 G 7250 BLADE PWA PT6 PT6A28 EA NR2 ENG CT FRACTURED W O OTHER Y ENGINE STOPPAGE TO TAKEOFF 1 CA 3970 41175 (CAN) THE NR2 ENGINE HAD AN UNCOMMANDED SHUTDOWN DURING TAKEOFF. INVESTIGAITON REVEALED A COMPRESSOR TURBINE BLADE ROOT FRACTURE. IT WAS REPORTED THE CT BLADES WERE NOT MANUFACTURED BY PRATT & WHITNEY CANADA. 4 T E4EA 1997121100290 19971211 00290 NE 1997 12 11 CA970918012 2 19970821 G 7260 GARLOCK SEAL PWA PT6 PT6A67D NE ACCESSORY GEARBX DISLODGED W E ENGINE SHUTDOWN J WARNING INDICATION NR NOT REPORTED 1 CA 8039 155 114043 (CAN) THE NR1 ENGINE WAS SHUTDOWN FOLLOWING A LOW OIL PRESSURE WARNING. POST FLIGHT INSPECTION FOUND AN ACCESSORY GEARBO X GARLOCK SEAL OUTSIDE OF ITS CARRIER 4 T E26NE 1997121100291 19971211 00291 NE 1997 12 11 CA970918013 2 19970909 G 7250 BLADES PWA PT6 PT6A66 52043 NE 2ND STAGE FRACTURED W O OTHER Y ENGINE STOPPAGE TO TAKEOFF 1 CA 1437 104027 (CAN) THE NR4 ENGINE SHUTDOWN DURING THE TAKEOFF ROLL AT ABOUT 90 KNOTS. INSPECTION REVEALED 16 SECOND STAGE BLADES HAD FRACTURED. 4 T E26NE 1997121100296 19971211 00296 GL 1997 12 11 CA970922011 3 19970720 G 6114 SNAP RING CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO MCAULY D3A34 D3A34C402 GL PROPELLER BLADE MISSING W K NONE D INFLIGHT SEPARATION CR CRUISE 1 CA 25 248666R 807440 (CAN) A PROPELLER BLADE SNAP RING DEPARTED THE BLADE DURING FLIGHT. POST FLIGHT INSPECTION REVEALED A LOOSE PROPELLER BL ADE AND A BROKEN PITCH LINK. 1 H 7 1 3O 3 O A4CE E8CE 5 C P47GL 1997122900013 19971229 00013 GL 1997 12 29 CA970923004 3 19970916 G 6111 F7666A2 BLADE MOONEY M20 M20E 5870212 SW LYC O360 IO360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL PROP CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 1977 1033 RL264351A CH22032 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER BLADE AND THE HUB NUTS (P/N A2043-1) WERE FOUND CORRODED AN D WERE REPLACED. 1 L 7 1 3O 3 O 2A3 1E10 5 C P920 1997122900014 19971229 00014 GL 1997 12 29 CA970923005 3 19970816 G 6114 B18032 CYLINDER HARTZL HCB3T HCB3TN3 GL PROP WORN W K NONE O OTHER IN INSP/MAINT 1 CA 1814 BU462 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. CYLINDER AND BEARING FOUND WORN AND STAINED AND WERE REPLACED 6 C P15EA 1997122900015 19971229 00015 GL 1997 12 29 CA970923006 3 19970816 G 6114 790100018 BEARINGS HARTZL HCB3T HCB3TN3 GL PROP HUB STAINED W K NONE O OTHER IN INSP/MAINT 1 CA 1976 BU463 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. BEARING BALLS FOUND STAINED AND WERE REPLACED 6 C P15EA 1997121100308 19971211 00308 NM 1997 12 11 CA970923007 1 19970808 G 2731 82700550 CONTROL CABLE DHAV DHC8 DHC8301 NM PWA PW120 PW123 NE ELEVATOR TRIM BROKEN W O OTHER D F INFLIGHT SEPARATION FLT CONT AFFECTED AP APPROACH 1 CA 4150 (CAN) ON APPROACH THE FLIGHT CREW DISCOVERED THAT THE AIRCRAFT WOULD NOT RESPOND TO COCKPIT ELEVATOR TRIM WHEEL INPUTS. LANDING OK. INSPECTION FOUND THAT THE CHAIN/CABLE ASSEMBLY LOCATED IN THE HORIZONTAL STABILIZER HAD BROKEN. 2 H 7 2 4T 4 T RT A13NM E20NE 1997101600752 19971016 00752 NM 1997 10 16 CA970923008 1 19970914 G 3200 LANDING GEAR DHAV DHC8 DHC8* NM PWA PW120 PW123 NE MLG & NLG COLLAPSED W O OTHER O OTHER LD LANDING 1 CA (CAN) FOLLOWING A NORMAL APPROACH AND DURING LANDING THE AIRCRAFT CAME TO REST ON THE RUNWAY WITH THE MAIN AND NOSE LAND ING GEAR PARTIALLY RETRACTED. 2 H 7 2 4T 4 T RT A13NM E20NE 1997121100310 19971211 00310 GL 1997 12 11 CA970923015 3 19970915 G 6111 BLADE HARTZL HCA3V PHCA3VF4 GL SHANK AREA CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA E6872 BR269 (CAN) PROPELLER BLADE FOUND CRACKED ON INSPECTION. THE CRACK WAS IN THE SHANK AREA TOWARDS THE TRAILING EDGE 5 C P6EA 1997121100312 19971211 00312 SO 1997 12 11 CA970930002 2 19970924 G 7310 630662 FUEL INJECT LINE CESSNA 172 R172K 2072431 CE CONT O360 IO360K 17025 SO MCAULY 2A34C 2A34C203 GL NR 6 INJECTOR BROKEN W A B E UNSCHED LANDING EMER. DESCENT ENGINE SHUTDOWN B R SMOKE/FUMES/ODORS/SPARKS PARTIAL RPM/PWR LOSS CR CRUISE 1 CA 104 28656R 785950 (CAN) DURING FLIGHT THE ENGINE WAS RUNNING ROUGH WITH A LOSS OF POWER. THERE WAS ALSO THE SMELL OF FUEL. POST FLIGHT INS PECTION FOUND THE NR6 FUEL INJECTOR LINE BROKEN AT THE DISTRIBUTOR CENTRE OF THE ENGINE. THE CAUSE OF THE FAILURE WAS TH E THROTTLE CONTROL COMING IN CONTACT WITH THE FUEL INJECTOR LINE. 1 H 7 1 3O 3 O 3A17 E1CE 5 C P3EA 1997121100314 19971211 00314 GL 1997 12 11 CA970930011 3 19970913 G 6111 BLADE MCAULY 1C160 1C160DTM GL PROP WORN W K NONE O OTHER IN INSP/MAINT 1 CA 735103 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND THE BLADES HAD BEEN REPAIRED IN THE FIELD AND WERE N OW BELOW THE MINIMUM LIMITS. 5 N P910 1997121100315 19971211 00315 GL 1997 12 11 CA970930012 3 19970919 G 6111 90DCA14 BLADE CESSNA 172 R172K 2072431 CE CONT O360 IO360KB 17025 SO MCAULY 2A34C 2A34C203 GL PROP LE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 949 614 356178 772161 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER BLADE FOUND WITH STONE DAMAGE. PROPELLER BLADE WAS TRIMMED. 1 H 7 1 3O 3 O 3A17 E1CE 5 C P3EA 1997121100316 19971211 00316 GL 1997 12 11 CA970930013 3 19970924 G 6111 BLADE CESSNA 150 A150M 2071831 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL PROP LE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 4791 1068 254665A48 K20611 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. STONE DAMAGE WAS FOUND ON THE LEADING EDGE OF THE PROPELLER BLADES, B LADES WERE TRIMMED. MOUNTING BOLTS (P/N B4622-12) WERE FOUND BENT AND WERE REPLACED. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 1997121100317 19971211 00317 GL 1997 12 11 CA970930014 3 19970923 G 6111 BLADE MCAULY 1C160 1C160DTM GL PROP LE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 1506 LD008 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. STONE DAMAGE WAS FOUND ON THE LEADING EDGE AND FACE OF THE BLADE 5 N P910 1999082700100 19990827 00100 GL 1999 8 27 CA970930019 2 19970922 G 7321 78109010 PACKING BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL FCU FAILED W R A AUTOROTATION UNSCHED LANDING X J ENGINE FLAMEOUT WARNING INDICATION HO HOVERING 1 CA CAE820809 (CAN) IN HOVER, WHILE WAITING TO RELEASE EXTERNAL LOAD, ROTORCRAFT LOST POWER, AUTOROTATED AND LANDED. THE MAIN ROTOR B LADES AND SKID GEAR WERE DAMAGED BEYOND REPAIR AND SCRAPPED. AIRFRAME IS DAMAGED AND MUST BE TRANSPORTED BACK TO BASE F OR REPAIRS (ALIGNMENT). IT WAS LATER DETERMINED THAT THE POWER LOSS WAS CAUSED BY AN INTERNAL PACKING WITHIN THE FCU BL OCKING THE FUEL FLOW AT ONE OF THE FUEL PORTS. 1 G 7 1 3U 3 U H2SW E4CE 1998041700691 19980417 00691 EU 1998 4 17 CA970930021 1 19970918 G 7160 F10A5B10201111 ENG INLET GRUMAN F10A5B10201 AMD FALC10 FALCON10 2730101 EU GARRTT TFE731 TFE7312 01518 WP LT ENG FAILED W A UNSCHED LANDING C O F.O.D. OTHER CL CLIMB 1 CA 159 A144 P73403 (CAN) A PIECE OF THE ENG INLET FROM THE 9 O'CLOCK POSITION BROKE OFF AND WAS INGESTED INTO THE ENGINE. A/C REQUIRED TO MAKE UNSCHEDULED LANDING. INVESTIGATION REVEALED DAMAGE TO FAN AREA, FOUND PIECE OF METAL WEDGED IN STATOR VANES. SEVE N FAN BLADES REPLACED AND BORESCOPE CHECKED CARRIED OUT. THE LT ENG INLET HAS BEEN REPLACED 4 TIMES IN THE LAST 4 YEARS . PART TC: 161. 2 L 7 2 4F 4 F A33EU E6WE 1997121100320 19971211 00320 1997 12 11 CA970930024 4 19970919 G 6122 8210181A PUMP AEROSP ATR42 ATR42* 8680900 EU PWA PW121 PW121 52124 NE OVSPEED GOV DEFECTIVE W O OTHER J WARNING INDICATION NR NOT REPORTED 1 CA 17943 550 120526 (CAN) THE ENGINE EXPERIENCED A PT OVERSPEED WHICH LASTED FOR A DURATION OF 43 SECONDS OVER 110 PERCENT NP SPEED REACHING A MAXIMUM OF 118.1 PERCENT. THE ENGINE WAS REMOVED AND SHIPPED FOR INSPECTION. DISASSEMBLY FOUND NO DAMAGE TO THE PRINC IPAL PT COMPONENTS ATTRIBUTED TO THE OVERSPEED CONDITION. IT WAS FOUND THE PROPELLER OVERSPEED GOVERNOR HYDRAULIC PUMP W AS GENERATING LESS THAN 50 PERCENT OF REQUIRED PRESSURE. THE CAUSE OF THE OVERSPEED WAS THE FAILURE OF THE PROPELLER OVE RSPEED GOVERNOR HYDRAULIC PUMP TO PRODUCE SUFFICIENT PRESSURE TO CONTROL THE PCU, WHICH CAUSED THE PROPELLER TO GO INTO PITCH LOCK AT A FINER PITCH, RESULTING IN NP OVERSPEED. NO REASON FOR THE LOW PRESSURE OUTPUT OF THE PUMP WAS FOUND. 2 H 7 2 4T 4 T RT A53EU E20NE 1997121100321 19971211 00321 NE 1997 12 11 CA970930025 2 19970919 G 7210 31073301 BEARING PWA 118 PW118A NE RED GRBOX NR 15 SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 18C510 115410 (CAN) THE REDUCTION GEARBOX WAS FOUND BY THE OPERATOR TO HAVE METAL CONTAMINATION AND WAS SHIPPED FOR INVESTIGATION AND REPAIR. DISASSEMBLY FOUND THE SOURCE OF THE METAL CONTAMINATION TO BE THE NR15 BEARING WHICH HAD SPALLED BADLY ON THE IN NER RACE. SUBSTANTIAL RESIDUAL MAGNETISM WAS FOUND ON A NUMBER OF STEEL COMPONENTS AND IT IS CONCLUDED THAT A LIGHTNING STRIKE WAS PROBABLY THE PRIMARY CAUSE OF THIS FAILURE. SECONDARY DAMAGE FROM THE CONTAMINANTS WAS MINIMAL AND ONLY THE N R18 AND NR19 BEARINGS, WHICH WERE FOUND TO HAVE ELECTRICAL DISCHARGE TYPE DAMAGE, REQUIRED REPLACEMENT. 4 T E20NE 1997121100323 19971211 00323 GL 1997 12 11 CA971003006 3 19971003 G 6111 BLADE MCAULY 1A102 1A102OCM GL PROP CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 2711 K19961 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. INSPECTION FOUND CORROSION ON THE PROPELLER BLADE FACE 5 N P918 1998041700685 19980417 00685 EA 1998 4 17 CA971007001 1 19970818 G 6300 A02D31473R EXTENSION A020301110 BOEING 107 1072 9420604 EA UPPER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 2618 K1P3154 (CAN) ON 100 HOUR INSPECTION IAW SB 107-393, A POSITIVE IDENTIFICATION WAS DETECTED. MAG PARTICLE INSPECTION FOUND A CR ACK IN A PIN HOLE APPROX 0.150 INCH LONG. 2 G 7 2 4U 1H16 1998041700684 19980417 00684 EA 1998 4 17 CA971007002 1 19970915 G 6320 107D22319 CASE 107D2011515A BOEING 107 1072 9420604 EA LOWER LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA A9107A (CAN) TRANSMISSION STARTED LEAKING OIL. CRACK FOUND IN LOWER CASE. OIL COMING FROM MIXBOX. 2 G 7 2 4U 1H16 1997121800414 19971218 00414 EA 1997 12 18 CA971007005 1 19970921 G 2720 82710019001 PIVOT ASSEMBLY DHAV DHC8 DHC8311 1386006 EA RUDDER PEDAL BINDING W A C D ABORTED TAKEOFF RETURN TO BLOCK F FLT CONT AFFECTED TO TAKEOFF 1 CA (CAN) DURING THE TAKEOFF ROLL, AT APPROXIMATELY 80 KNOTS, THE RUDDER PEDALS BECAME RESTRICTED. TAKEOFF ABORTED. INSPECTI ON CARRIED OUT. PIVOT ASSEMBLY AND ASSOCIATED BUSHINGS WERE REPLACED. 2 H 7 2 4T RT A13NM 1998041700682 19980417 00682 SW 1998 4 17 CA971007014 1 19970929 G 5530 206020113181 SKIN 206020113223 BELL 407 407 SW VERT STAB DAMAGED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) INSPECTION OF FINS FOUND THAT TWO GRINDING MARKS WERE MADE DURING MANUFACTURE AT AFT BOTTOM SECTION OF FORMERS FOR INSTALLATION OF FAIRINGS. AN ASB WILL BE ISSUED TO COVER. 1 G 7 1 3U O H2SW 1997121100331 19971211 00331 EA 1997 12 11 CA971010001 1 19970930 G 5413 75421151103 LONGERON DHAV DHC7 DHC7102 2802708 EA PWA PT6 PT6A50 52043 EA STA.XN50-XN79 CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 28775 (CAN) HEAVY CORROSION FOUND ON UPPER AND LOWER SURFACES OF THE UPPER LONGERONS. SEVERE CORROSION FOUND ON LONGERONS FROM STA.XN50 TO XN79.0. THIS CORROSION WAS NOT EVIDENT UNTIL THE COWL SEALS AND LATCH PLATES WERE REMOVED. FURTHER SEVERE C ORROSION WAS FOUND UNDER TITANIUM DOUBLERS FROM XN79 TO XN96. UPON REMOVAL OF THE NACELLE UPPER LONGERON IT WAS NOTED TH AT NORMAL PROCEDURES REQUIRED BY EQUALIZED INSPECTION CARD R61 WOULD NOT DETECT THIS CORROSION. 2 H 7 4 4T 4 T A20EA E4EA 1997121100332 19971211 00332 SO 1997 12 11 CA971010008 2 19970927 G 7322 104439 CARBURETOR CESSNA 172 172D 2072410 CE CONT O300 O300C 17022 SO ENGINE FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING K Y FLUID LOSS ENGINE STOPPAGE CR CRUISE 1 CA 1153 31632D4C (CAN) DURING CRUISE THE ENGINE BEGAN TO SUFFER POWER LOSS WITHOUT WARNING. EMERGENCY LANDING WAS CARRIED OUT. POST FLIGH T INSPECTION FOUND FUEL POURING FROM THE CARBURETOR. THE CARBURETOR WAS REPLACED WITH AN OVERHAULED UNIT AND THE ENGINE WAS GROUND RUN SERVICEABLE. 1 H 7 1 3O 3 O NT 3A12 E253 1998041700675 19980417 00675 1998 4 17 CA971010011 2 19971001 G 7510 2306696 FIRESHIELD SPOTWELDS LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA 4 (CAN) SIX SPOTWELD RETAINING ANTI-ICING SOLENOID VALVE ASSEMBLY BRACKETS TO FIRESHIELD ASSY ARE UNDONE CAUSING BRACKET T O SEPARATE FROM FIRESHIELD. SUSPECT INCORRECT WELDING PROCESS. REPLACED. 1998041700674 19980417 00674 SW 1998 4 17 CA971010012 1 19970708 G 2750 500012231 CONTROL CABLE GULSTM 690TP 695A 7630519 SW RT INB FLAP BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 5330 (CAN) 75 PERCENT OF RT INBOARD FLAP CABLE STRANDS BROKEN. REPLACED. 1 H 7 2 4T 2A4 1998020500479 19980205 00479 WP 1998 2 5 CA971014003 2 19971005 G 7260 31017015 PINION ASSEMBLY SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP GEARBOX PRIMARY FAILURE W A E UNSCHED LANDING ENGINE SHUTDOWN G J MULTIPLE FAILURE WARNING INDICATION CL CLIMB 1 CA P54215 (CAN) AIRCRAFT WAS IN-FLIGHT WHEN THE L/H CHIP LIGHT ILLUMINATED, OIL PRESSURE DROPPED 50 PSI, TORQUE FLUCTUATED, FEATHE RED ENGINE. TEARDOWN REVEALED THAT ROTATING GROUP COULD NOT BE TURNED. FORWARD BEARINGIN THE HIGH SPEED PINION BEARING A SSEMBLY HAD FAILED. SUBMITTER NOTES THAT HIGH SPEED PINION ASSEMBLY REQUIRES DYNAMIC BALANCING AFTER REPAIR OR MODIFICAT ION. THERE IS NO INDICATION THAT THIS WAS DON E. SUBMITTER SENT FOLLOW-UP REPORT TO VERIFY THAT LAB ANALYSIS FOUND THAT THE FRONT ROLLER BEARING HAD A ROLLER END/GUIDE FLANGE PRIMARY FAILURE. 2 L 7 2 4T 4 T RT A8SW E4WE 1997121100338 19971211 00338 EU 1997 12 11 CA971015014 1 19971003 G 2410 735874C GENERATOR DRIVE AIRBUS 310 A310304 EU NO ENGINE GEN OVERHEATED W H A DEACTIVATE SYST/CIRCUITS UNSCHED LANDING H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA (CAN) DURING CRUISE NR1 I.D.G. HAD AN OVERHEAT TEMPERATURE READING OF 189 DEGREES. I.D.G. DISCONNECTED AND AIRCRAFT RETU RNED TO BASE. AS A PRECAUTIONARY MEASURE THE I.D.G. HEAT EXCHANGER AND GENERATOR CONTROL UNIT WERE REPLACED ALONG WITH T HE I.D.G. 2 L 7 2 4F RT A35EU 1997122900018 19971229 00018 NE 1997 12 29 CA971015024 2 19971015 G 8500 ENGINE DHAV DHC3 DHC3 2800202 EA WSK PZL PZLM18 67203 NE POWER SECT MAKING METAL W K NONE O OTHER IN INSP/MAINT 1 CA 923 KAB734402 (CAN) EXCESSIVE OIL CONSUMPTION AND METAL IN THE OIL SCREEN. TEARDOWN REPORT NOT YET AVAILABLE. 1 H 7 1 3R 4 R A815 E10NE 1997121800426 19971218 00426 NM 1997 12 18 CA971015026 1 19970925 G 2934 EA1093A2408 TRANSMITTER BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE A SYS HYD INTERMITTENT W K NONE O OTHER AP APPROACH 1 CA P653620B (CAN) DURING APPROACH 'A' SYSTEM HYDRAULIC QUANTITY WOULD FLUCTUATE IN TURBULENCE, QUANTITY TRANSMITTER REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 1997121800427 19971218 00427 1997 12 18 CA971015027 4 19970919 G 2370 5224058002 CVR TAPE COLLINS CVR BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE COCKPIT BROKEN W H DEACTIVATE SYST/CIRCUITS L NO TEST NR NOT REPORTED 1 CA 770 P653620B (CAN) COCKPIT CVR FAILED TEST FUNCTION, CONTINUOUS TAPE REPLACED SERVICEABLE. 2 L 7 3 4F 4 F A3WE E2EA 1997121800428 19971218 00428 NM 1997 12 18 CA971015028 1 19971001 G 2710 652440014 LOCKOUT BOEING 552440014 BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE RH AILERON TORN BOOT W K NONE O OTHER IN INSP/MAINT 1 CA P653620B (CAN) DUST BOOT ON RIGHT HAND AILERON LOCKOUT MECHANISM TORN, REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 1997121800429 19971218 00429 NM 1997 12 18 CA971015029 1 19971001 G 5260 65178202 SEAL BOEING 65178202 BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE AIR STAIR LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA OA535 P653620B (CAN) AIRSTAIR ACTUATOR LEAKING. REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 1997121800430 19971218 00430 NM 1997 12 18 CA971015030 1 19971001 G 2133 35584 SEAT ALLIED SIGNA 10328051 BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE LT OUTFLOW LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA 35584 P653620B (CAN) LEFT HAND OUTFLOW VALVE SEAT LEAKING. REPLACED 2 L 7 3 4F 4 F A3WE E2EA 1997122400029 19971224 00029 NM 1997 12 24 CA971015031 1 19971002 G 8012 97925431 START VALVE ALLIED SIGNA 97925431 BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE NR 2 ENGINE HOLE W K NONE O OTHER IN INSP/MAINT 1 CA P1921 P653620B (CAN) NR2 ENGINE START VALVE HAS HOLE IN BODY. REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 1997121100343 19971211 00343 NM 1997 12 11 CA971015032 1 19971007 G 7830 65378316 SELECTOR VALVE BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE THRUST REVERSER LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 3725 1917 P653620B (CAN) DURING A "C" CHECK INSPECTION THE THRUST REVERSER SELECTOR VALVE OF NR1 ENGINE WAS FOUND TO HAVE A LEAKING SHAFT S EAL, THE SELECTOR WAS REMOVED AND A SERVICEABLE UNIT INSTALLED AND THE SYSTEM RETURNED TO SERVICE. 2 L 7 3 4F 4 F A3WE E2EA 1997122400030 19971224 00030 NM 1997 12 24 CA971015033 1 19971007 G 5260 65178132 LOCK BOEING 65178132 BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE AIR STAIR LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA RC625 P653620B (CAN) AIRSTAIR LOCK ACTUATOR LEAKING. REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 1997122400031 19971224 00031 NM 1997 12 24 CA971015034 1 19971007 G 2780 65319467 SEAL BOEING 65319467 BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE LE FLAP VALVE LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 515 P653620B (CAN) LEADING EDGE DEVICE SELECTOR VALVE LEAKING BEYOND LIMITS. REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 1997122400032 19971224 00032 NM 1997 12 24 CA971015035 1 19971007 G 7500 69253011 FLANGE BOEING 69253011 BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE BLEED DUCT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA P653620B (CAN) BLEED AIR DUCT CRACKED AT FLANGE. REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 1997122400033 19971224 00033 NM 1997 12 24 CA971015036 1 19971007 G 7500 65322481 DUCT BOEING 65322481 BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE BLEED DUCT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA P653620B (CAN) BLEED AIR DUCT CRACKED AT FLANGE. REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 1997122400034 19971224 00034 NM 1997 12 24 CA971015037 1 19971009 G 3230 651781011 ROD END BEARING BOEING 651781011 BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE NLG LK ACTUATOR LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA RC1036 P653620B (CAN) NOSE LANDING GEAR LOCK ACTUATOR ROD END BEARING LOOSE. ACTUATOR REPLACED. 2 L 7 3 4F 4 F A3WE E2EA 1997122400035 19971224 00035 NM 1997 12 24 CA971015038 1 19971009 G 3010 F61C0058M1 VALVE BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE LT WING TAI LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA P653620B (CAN) LEFT HAND WING TAI VALVE LEAKING ALLOWING HOT AIR TO BYPASS WHEN CLOSED. 2 L 7 3 4F 4 F A3WE E2EA 1998040100006 19980401 00006 SW 1998 4 1 CA971015065 1 19971007 G 7110 212060805121 COWLING BELL 412 412 1182202 SW PWA PT6T PT6T3 52045 EA LT SIDE DEPARTED W K NONE D INFLIGHT SEPARATION CR CRUISE 1 CA 1 (CAN) EVERYTHING NORMAL ON TEST FLIGHT. AFTER SHUTDOWN IT WAS NOTED THAT LEFT COWLING WAS MISSING. A FASTENER REQUIRED PER ASB 412-95-87 HAD NOT BEEN INSTALLED. THE LEFT STABILIZER WAS DAMAGED AT ITS JUNCTION WITH TAILBOOM BY COWL. 1 G 7 2 4U 4 U H4SW E22EA 1997121100349 19971211 00349 SO 1997 12 11 CA971016002 2 19971008 G 8530 648042 PISTON RING PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360E 17025 SO ENG CYL BROKEN W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 256 312042 (CAN) DURING CYLINDER REMOVAL TO CORRECT AN OIL CONSUMPTION PROBLEM, IT WAS FOUND THAT PISTON RING (P/N 684042) WAS BROK EN. IT APPEARS THERE WAS A CASTING PROBLEM DURING MANUFACTURER. 1 L 7 2 3O 3 O A7SO E9CE 1997121100351 19971211 00351 NE 1997 12 11 CA971016004 2 19970922 G 7240 767279 COMB OUTER CASE PWA JT8 JT8D7B 52053 NE FLANGE HOLES CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 56357 P657387D (CAN) DURING A SCHEDULED INSPECTION THE COMBUSTION OUTER CASE WAS FOUND CRACKED AT TWO MOUNTING BOLT HOLES ON THE REAR F LANGE. THE FIRST CRACK EXTENDS HALF THE DEPTH OF THE HOLE AND 1/2" IN LENGTH. THE SECOND CRACK EXTENDS THREE QUARTERS TH E DEPTH OF THE HOLE AND 3/4" IN LENGTH. THE CASE P/N 767279 WAS MODIFIED FROM P/N 490547 AT 32023 CYCLES. THE CRACKS WER E FOUND BY FLUORESCENT PENETRANT INSPECTION. 4 F E2EA 1997122400038 19971224 00038 NE 1997 12 24 CA971016018 2 19970926 G 7210 312005001 INPUT PINION DHAV DHC8 DHC8* NM PWA 120 PW120A NE REDUCTION GEARBX SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 7394 121359 (CAN) RGB SENT FOR INVEST. AFTER A SPALLED INPUT PINION WAS FOUND DURING A BORESCOPE INSP FOLLOWING AN OVERTORQUE OF 170 PCT.DAMAGE CONFIRMED TO- INPUT PINION TEETH,THIS WAS ACCOMPANIED B Y FROSTING A SPALLING OF- TEETH OF BOTH 1ST STAGE HE LICAL GEARS.3 NUTS FOUND LOOSE.2 KEYWASHERS FOUND CRACKED & BOTH LAYSHAFT NUTS WERE FINGER TIGHT.HEAVY IMPACT DAMAGE ALS O DISCOVERED ON #15 BEARING & S PALLING ON 1ST STAGE GEARS IS FAIRLY TYPICAL OF 1ST STAGE GEAR TOOTH DAMAGE EVEN IN RGB' S NOT EXPOSED TO HIGH TORQUENO IND. THAT DAMAGE WAS RELATED TO OVERTORQUELOOSE NUTS & CRACKED WASHERS ARE INDICATIVE OF LONG TERM VIBRATION PROBLEMS CAUSED BY LOOSE GEARS.P&W HAVE RELEASED A MOD TO-IR COMPONENTS WHICH INCORPORATE STIFFER G 2 H 7 2 4T 4 T RT A13NM E20NE 1998032600494 19980326 00494 SW 1998 3 26 CA971016020 1 19971008 G 2910 MS21926W6 ELBOW BELL 212 212 1181420 SW HYD LINE CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) A SLIGHT LEAK AT A HYDRAULIC LINE P/N 212-076-348-1 BECAME WORSE WHEN THE 'B' NUT WAS TIGHTENED. ELBOW WAS FOUND CRACKED IN 2 LOCATIONS ABOUT 180 DEGREES APART. THE CRACKS RADIATED FROM END OF FLARE. 1 G 7 1 4U H4SW 1998041700433 19980417 00433 CE 1998 4 17 CA971020006 1 19970920 G 5510 AN447 BOLT BEECH 23 A23 1151204 CE STAB ACT TUBE DAMAGE W K NONE O OTHER IN INSP/MAINT 1 CA 2033 (CAN) UPON REMOVAL OF STABILATOR ACTUATING TUBE BALANCE WEIGHT, IMPACT DAMAGE TO THE ATTACHMENT BOLT WAS FOUND. DAMAGE APPEARED TO BE CAUSED BY REPETITIVE IMPACT RESULTING FROM BALANCE WEIGHT STRIKING THE MICARTA STOP BLOCK. AIRCRAFT TT: 2,033 HOURS. 1 L 7 1 3O A1CE 1997122400043 19971224 00043 EA 1997 12 24 CA971020009 1 19971007 G 2731 TWF2128U BEARING C6CT10103 DHAV DHC6 DHC6 2802606 EA PWA PT6 PT6A27 52043 EA ELEV TRIM NOT LUBED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 0 (CAN) NEW BEARINGS WERE RECEIVED FROM STORES TO REPLACE WORN ELEVATOR TRIM AND FLAP INERCONNECT SCREW JACK BEARINGS. A N UMBER OF THE NEW BEARINGS WERE NOT LUBRICATED INTERNALLY. THEY APPEARED TO BE DRY. THESE WERE RETURNED TO DE HAVILLAND F OR INSPECTION. THESE BEARINGS WERE MANUFACTURED BY MINIATURE PRECISION BEARINGS, DIVISION OF MPB CORP., KEENE, NEW HAMPS HIRE. BEARINGS WERE BOXED AND SEALED IN PLASTIC BAGS WHEN RECEIVED. MANUFACTURE DATE 12/86 AND 8/88. 1 H 7 2 3T 4 T RT A9EA E4EA 1997122400044 19971224 00044 GL 1997 12 24 CA971020010 3 19971010 G 6111 90DCA14 BLADE MCAULY 2A34C 2A34C203 GL PROP LEAD EDGE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 2082 733 766423 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. STONE DAMAGE WAS FOUND ON THE LEADING EDGES 5 C P3EA 1998043000046 19980430 00046 NM 1998 4 30 CA971020015 1 19970904 G 3234 574205 SELECTOR VALVE DHAV DHC8 DHC8102 2809003 NM MLG FAILED W A UNSCHED LANDING O OTHER AP APPROACH 1 CA 450 (CAN) WITH NORMAL APPROACH FOR LANDING AND GEAR SELECTION, GEAR FAILED TO COME DOWN. ALTERNATE SELECTION MADE, OK. LA NDED OK. SELECTOR VALVE REPLACED. 2 H 7 2 4T RT A13NM 1997122400047 19971224 00047 NE 1997 12 24 CA971020016 2 19970926 G 7250 BLADE PWA 118 PW118 NE LP TURBINE FRACTURED W E ENGINE SHUTDOWN O OTHER CR CRUISE 1 CA 115417 (CAN) THE ENGINE WAS SHUTDOWN IN FLT AFTER LOSS OF OIL PRESSURE: POST FLT- PT WAS STIFF TO TURN, SO- ENGINE WAS SENT FOR INSP & OVERHAUL. DISASSY REVEALED 2 LP TURBINE BLADES WITH 50 PERCENT OF- AIRFOIL MISSING; OVERTEMP DAMAGE TO ALL 4 STA GES OF TURBINE BLADES; A FAILED NR6 BEARING; A FRACTURED NR6 & NR 7 BEARING VENT TUBE; NR 6 &NR 7 BEARING HOUSING SEPARA TED & SPLIT IN-HALF;- PRESSURE RELIEF VALVE STUCK OPEN. IT IS- OPINION OF- SUBMITTER THAT- INIT FAILURE OF 2 (2) LP TURB INE BLADE AIRFOILS WAS- CAUSE OF- DAMAGE & SHUTDOWN. IT APPEARS THAT THIS FAILURE OCCURRED SOMETIME PRIOR TO- IFSD &- RE SULTING OUT OF BALANCE & VIBRATION WAS- CAUSE OF SECONDARY DAMAGE & LOSS OF OIL PRESSURE: 4 T E20NE 1998041700435 19980417 00435 EU 1998 4 17 CA971021001 1 19971015 G 2435 036010 BEARING LUCAS 23080005 BRAERO DH125 BAE125800A 1500285 EU START/GEN FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 2747 (CAN) BEARING FAILURE CAUSED DAMAGE TO ARMATURE. 2 L 7 2 4F RT A3EU 1997122400048 19971224 00048 GL 1997 12 24 CA971021004 3 19971015 G 6110 BLADE CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL PROP ASSY CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 1740 262 61799SA K18946 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER WAS FOUND WITH EXTENSIVE CORROSION ALL OVER. THE PROPELLER WAS OVERHAULED. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 1998010600002 19980106 00002 GL 1998 1 6 CA971021005 3 19971015 G 6111 BLADE MCAULY 1C160 1C160DTM GL BLADE LE/FACE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 5614 IA016 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. STONE DAMAGE WAS FOUND TO THE PROPELLER BLADE ON THE LEADING EDGE AND THE FACE. 5 N P910 1998041700438 19980417 00438 GL 1998 4 17 CA971021013 2 19971007 G 7250 705280 BEARING ALLSN 501D 501D13D 03004 GL NR 3 FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING E VIBRATION/BUFFET HO HOVERING 1 CA 122 501780 (CAN) THE ENGINE SUFFERED AN IN-FLIGHTT FAILURE DURING DESCENT. POST-FLIGHT INSP AND INVEST FOUND PRIMARY FAILED ITEM A S TURBINE COUPLING SHAFT. ENGINE AND COMPONENTS SHIPPED TO MFG FOR EVALUATION. MFG DISPUTES ORIG FINDINGS AND STATES T HE INITIATING EVENT WAS LOSS OR REDUCTION OF OIL SUPPLY TO NR 3 BEARING AREA WHICH REQUIRED MOST OF ITS OIL SUPPLY TO CO OL BEARING, FOR REASONS UNKNOWN. IT APPEARS BEARING AND CAGE RETENTION FAILED AND IT MIGRATED FORWARD. ONCE OFF LOCATI ON AND WEARING INTO CLAMP NUT, ORBITING SHAFT CAUSED FRACTURE AND FATIGUE FAILURE OF COUPLING SHAFT. 4 T E282 1998042900018 19980429 00018 WP 1998 4 29 CA971021014 1 19971008 G 2610 ELEMENT CVAC 340 340CVAC 242270A WP ALLSN 501D 501D13D 03004 GL NR 2 ENG SHORTED W E F D ENGINE SHUTDOWN ACTIVATE FIRE EXT. RETURN TO BLOCK N FALSE WARNING TX TAXI/GRND HDL 1 CA 501754 (CAN) SHORTLY AFTER BEGINNING TAXIING AND PRIOR TO TAKEOFF, THE CAPTAIN REACTED TO A FIRE WARNING FROM ZONE 2 OF THE AI RCRAFT'S NR 2 ENGINE BY SHUTTING THE ENG DOWN AND RELEASING FIRE AGENT IN THE AFFECTED AREA. FIRE ELEMENT WAS FOUND FAU LTY AND REPLACED. 2 L 7 2 4R 4 T 6A6 E282 1998032600498 19980326 00498 SW 1998 3 26 CA971021023 1 19971002 G 6510 406040340101 DISC PACK BELL 407 407 SW NR 7 AFT OUTER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 303 (CAN) AS PER AD CF-97-19, INSPECTION OF TAIL ROTOR DRIVE SHAFT THOMAS COUPLINGS CARRIED OUT. THE AFT OUTER DISC OF THE NR 7 DISC PACK WAS FOUND BROKEN IN TWO PLACES. DISC PACKS TAKEN FOR TESTING BY BELL. BHTC IS REDESIGNING DISCS TO OVER COME MID-SPAN CRACKING. 1 G 7 1 3U O H2SW 1998010600004 19980106 00004 GL 1998 1 6 CA971024009 3 19970930 G 6114 5872 HUB MCAULY 3A32C D3A32C* GL PROP ASSY CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 1102 871205 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROPELLER HUB AND PROPELLER BLADES (P/N G82NDB-2) FOUND EXTREMELY COR RODED. IT WAS 5 YEARS FROM THE LAST CORROSION INSPECTION AND 10 YEARS FROM THE LAST OVERHAUL. THE PROPELLER WAS OVERHAUL ED 5 C P21EA 1998032600499 19980326 00499 EU 1998 3 26 CA971024010 1 19971006 G 6310 4619303081 BEARING 4638001001 BOLKMS 105 BO105S 5626006 EU MAIN XMSN PEELING W K NONE O OTHER IN INSP/MAINT 1 CA 852 884 (CAN) MAIN TRANSMISSION LEFT INTERMEDIATE SHAFT BEARING FOUND PEELING. 1 G 7 2 3U H3EU 1997122400069 19971224 00069 SO 1997 12 24 CA971027008 2 19970918 G 8530 654651A2 CYLINDER ASSY CESSNA 185 A185F 2072821 CE CONT O520 IO520F 17032 SO MCAULY 2A34C D2A34C58 GL ENGINES EXCESSIVE WEAR W K NONE E R W VIBRATION/BUFFET PARTIAL RPM/PWR LOSS INADEQUATE Q C IN INSP/MAINT 1 CA 10 10 1109615A 703083 (CAN) TEN HOURS AFTER COMPLIANCE OF FAA AD 97-15-01 (SS BY FAA AD 97-21-02), SIDE LOADING OF THE PISTON, THE AIRCRAFT OW NER COMPLAINED TO THE OVERHAUL SHOP OF ENGINE VIBRATION AND POWER LOSS. INSPECTION OF THE OVERHAULED ENGINE REVEALED EXC ESSIVE AND PREMATURE CYLINDER BARREL WEAR. THESE CYLINDERS WERE FACTORY "NEW" AND WERE STAMPED "P" IDENTIFYING THEM AS B EING INSPECTED BY THE FACTORY IN ACCORDANCE WITH CONTINENTAL SB 97-10 (SB 97-10A). 1 H 7 1 3O 3 O 3A24 E5CE 5 C P3EA 1997121100360 19971211 00360 CE 1997 12 11 CA971027010 1 19970717 G 2822 480532 FUEL PUMP CESSNA 210 T210L 2073449 CE CONT O520 TSIO520H 17040 SO RIGHT AUXILIARY RUSTED W K NONE O OTHER IN INSP/MAINT 1 CA 506848 (CAN) RIGHT AUXILIARY FUEL PUMP FOUND RUSTED. ALSO LEFT AND RIGHT CHECK VALVES PART NO. FACKV-5-100-6 FOUND CLOGGED. THI S AS A RESULT OF INSTALLATION OF FLINT AUXILIARY SYSTEM STC SA2862WE, SA3266NM OR SA4300WE ACCORDING TO SUBMITTER. 1 H 7 1 3O 3 O 3A21 E8CE 1997121100361 19971211 00361 CE 1997 12 11 CA971027011 1 19970503 G 2822 477003 FUEL PUMP CESSNA 206 U206G 2073356 CE LEFT AUXILIARY RUSTED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LEFT AUXILIARY FUEL PUMP CORRODED AND BOTH THE LEFT AND RIGHT CHECK VALVES P/N FACKV-4-100-6 FUND CLOGGED. THIS AI RCRAFT HAS FLINT STC SYSTEM STEEL PARTS WHICH ACCORDING TO SUBMITTER ARE CAUSING THE CORROSION AND CAN CLOG FUEL SYSTEM. STC SA4368WE. 1 H 7 1 3O A4CE 1997121100362 19971211 00362 CE 1997 12 11 CA971027012 1 19970717 G 2842 FA2091 FUEL TRANSDUCER CESSNA 206 U206G 2073356 CE LEFT HAND RUSTED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THE LEFT FUEL TRANSDUCER FOUND RUSTED, REPLACED BY NEW PLASTIC TYPE. THIS AIRCRAFT HAS THE FLINT AUXILIARY SYSTEM STC SA4366WE INSTALLED WHICH CONTAINS STEEL PARTS AND ACCORDING TO SUBMITTER IS CAUSING THE CORROSION AND CAN CLOG FUEL SYSTEM. 1 H 7 1 3O A4CE 1997121100363 19971211 00363 CE 1997 12 11 CA971027013 1 19970312 G 2822 477003 FUEL PUMP CESSNA 206 U206G 2073356 CE LEFT AUXILIARY RUSTED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) LEFT AUXILIARY FUEL PUMP FOUND RUSTED. THIS AIRCRAFT CONTAINS FLINT AUXILIARY SYSTEM AS PER STC SA4368WE WHICH CON TAINS STEEL PARTS AND ACCORDING TO SUBMITTER CAUSES THE RUSTING AND COULD CLOG THE FUEL SYSTEM. THE AIRCRAFT REGISTRATIO N IS NOW C-FJST 1 H 7 1 3O A4CE 1997122400074 19971224 00074 CE 1997 12 24 CA971028007 1 19971020 G 2720 505244483 PUSH ROD BEECH 50524402613 BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA PILOT RUD ARM WORN W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 CA 3172 PCE25636 (CAN) DURING A PHASE 3 INSPECTION, IT WAS FOUND THAT THE PILOTS RUDDER ARM ASSEMBLY (P/N 50-524415-10) HAD APPROXIMATELY 0.020 INCHES DEEP WEAR ON THE INNER SURFACE OF THE FORK LUG WHERE THE PUSH ROD ATTACHES RH ARM. UPON REMOVAL OF THE PUS H ROD, IT WAS FOUND THAT THE BEARING IN THE ROD END OF THE PUSH ROD WAS DAMAGED. IT WAS DETERMINED THAT THE DAMAGE WAS C AUSED BY A METAL OBJECT THAT WAS WEDGED BETWEEN THE BEARING AND THE LUG WALL. THIS CREATED THE WEAR. NEW PARTS INSTALLED . 1 L 7 2 3T 4 T RT 3A20 E4EA 1997122400077 19971224 00077 EU 1997 12 24 CA971028013 1 19971022 G 3242 5010783 DISC 50068572 AEROSP ATR42 ATR42300 8680920 EU PWA 120 PW120 NE HAMSTD 14SF 14SF5 NE LT NR 1 BRAKE BROKEN W K NONE O OTHER TX TAXI/GRND HDL 1 CA 17207 1155 SEP87536 0 0 (CAN) DURING TAXI, AIRCRAFT SUDDENLY PULLED TO THE LEFT. AIRCRAFT HAD TO STOP AS TAXIING NO LONGER POSSIBLE. NR1 BRAKE A ND WHEEL REPLACED. INSPECTION OF BRAKE FOUND THAT THE STATIONARY DISC WAS BROKEN AND THE LOOSE PART WAS JAMMING THE WHEE L. 2 H 7 2 4T 4 T RT A53EU E20NE 6 C P7NE 1998041700666 19980417 00666 SO 1998 4 17 CA971031002 1 19971024 G 3260 1CH214 SWITCH PIPER PA31 PA31350 7103110 SO MLG FAILED W O OTHER J WARNING INDICATION DE DESCENT 1 CA (CAN) ON SELECTING GEAR DOWN, RT GEAR SHOWED GREEN AND RED UNSAFE LIGHT ON. SEVERAL RETRACTIONS CARRIED OUT, NO CHANGE. TOWER REPORTED GEAR APPEARED NORMAL AND A/C LANDED SAFELY. MAINTENANCE INSPECTED GEAR AND CONFIRMED GEAR WAS LOCKED A ND SWITCH IN NORMAL POSITION. DEFECTIVE SWITCH REPLACED. 1 L 7 2 3O A20SO 1997122400079 19971224 00079 GL 1997 12 24 CA971031003 3 19971023 G 6114 C5262 CYLINDER BEECH 23 A24R 1151252 CE LYC O360 IO360A1B 41514 EA MCAULY 2D34C 2D34C9 GL PROP HUB WORN W K NONE O OTHER IN INSP/MAINT 1 CA 428 247 L685851F 694582 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. CYLINDER FOUND WORN AND WAS REPLACED. THE PROPELLER BLADE (P/N S78FBM -1.5) WAS FOUND NICKED ON THE LEADING EDGE AND THE FACE AND WAS TRIMMED. 1 L 7 1 3O 3 O A1CE 1E10 5 C P7EA 1998010600005 19980106 00005 GL 1998 1 6 CA971031004 3 19971024 G 6114 57A2202 BEARING HARTZL HCC2Y BHCC2YF2 GL PROP ASSY DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 1111 528 AN6954A (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. PROP BEARING WAS FOUND DAMAGED ON THE INNER RACE. ONE BOLT (P/N 57A24 33) WAS FOUND CORRODED IN THE SHANK AREA. 5 C P920 1997122400087 19971224 00087 EA 1997 12 24 CA971031018 2 19971020 G 7314 GR9080J7A FUEL PUMP ROMEC PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA CASE DRAIN LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA D7138 L586361A (CAN) PRIOR TO RUN-UP, DURING THE FUEL PUMP PRESSURE AND LEAK TEST, THE FUEL PUMP WAS LEAKING FUEL FROM THE PUMP CASE DR AIN, WHEN THE BOOSTER PUMPS OR THE AUXILIARY PUMP WERE ACTIVATED. THE ENGINE WAS STARTED WITH USUAL FIRE PRECAUTIONS OBS ERVED. THE FUEL LEAK DID NOT STOP. THE ENGINE WAS SHUTDOWN AND THE FUEL PUMP REMOVED. THE OVERHAUL SHOP REPORTED THE PUM P SEAL INSIDE DID NOT SEAT. THE FUEL PUMP FROM THE TX'D ENGINE WAS INSTALLED AND THE PUMP AND ENGINE TESTED SERVICEABLE. 1 L 7 2 3O 3 O A20SO E14EA 1997122400088 19971224 00088 NM 1997 12 24 CA971031019 1 19970826 G 3242 2661943 HOUSING BFGOODRICH 214665 DHAV DHC8 DHC8* NM BRAKE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 12716 0220R (CAN) LIQUID PENETRANT AND EDDY CURRENT INSPECTION WERE COMPLETED ON DHC8 BRAKE HOUSINGS IN ACCORDANCE WITH BF GOODRICH COMPONENT MAINTENANCE MANUAL (CMM). ON THIS S/N 3 PISTON CAVITIES WERE FOUND CRACKED JUST BELOW THE INLET AND BLEEDER PO RTS. DATE OF MANUFACTURE IS JANUARY 1985. 2 H 7 2 4T RT A13NM 1998041700446 19980417 00446 CE 1998 4 17 CA971104003 1 19971024 G 3260 IEN1186 SWITCH CESSNA 500 560CESSNA 2076750 CE NLG DOWNLOCK FAILED W L ABORTED APPROACH P J NO WARNING INDICATION WARNING INDICATION AP APPROACH 1 CA 2246 (CAN) LANDING GEAR SELECTED DOWN AND ONLY THE MAIN GEAR INDICATED DOWN AND LOCKED. AFTER SEVERAL CYCLES, AN EMERGENCY L ANDING WAS SUCCESSFULLY CARRIED OUT. ACTUATOR CHECKED OK. NLG DOWNLOCK SWITCH REPLACED. OLD NLG SWITCH WAS NOT SEALED, POSSIBLE WATER AND FREEZING CAUSED PROBLEM. PART TC: 3,300. 2 L 7 2 4F RT A22CE 1998041700665 19980417 00665 CE 1998 4 17 CA971104004 1 19971029 G 2750 500000863 CABLE ASSY CESSNA 402 402C 207590R CE FLAP BROKEN WIRES W K NONE O OTHER IN INSP/MAINT 1 CA 13636 (CAN) DURING THE ROUTINE INSPECTION, BROKEN WIRES/STRANDS OF THE FLAP CONTROL CABLE ASSY WERE FOUND. DEFECTIVE CABLE AS SY AND PULLEY P/N S378-4 REPLACED AND SYSTEM CHECKED. 1 L 7 2 3O A7CE 1998043000052 19980430 00052 NE 1998 4 30 CA971104014 2 19971023 G 7250 MS969611 BOLTS PWA PW121 PW121 52124 NE 1ST STG STATOR FRACTURED W K NONE O OTHER IN INSP/MAINT 1 CA 16178 121019 (CAN) TURBOMACHINE SENT FOR INVESTIGATION AND REPAIR AFTER OPERATOR REPORTED POWER TURBINE DAMAGE. THE CAUSE OF THE PT D AMAGE WAS A FAILURE OF SEVEN, 1ST STAGE STATOR RETAINING BOLTS. FAILURE OF THE 1ST STAGE STATOR RETAINING BOLTS APPEARS TO BE THE RESULT OF CORROSION AT THE REAR FLANGE OF THE TURBINE INTERSTAGE CASE WITH ALL OTHER DAMAGE OBSERVED BEING SE CONDARY. 4 T E20NE 1998043000054 19980430 00054 CE 1998 4 30 CA971106002 1 19971030 G 3260 2078101 CONNECTOR BEECH 36 A36 1151604 CE CONT O550 IO550B SO NLG DOWNLOCK LOOSE W L ABORTED APPROACH N FALSE WARNING AP APPROACH 1 CA 682290 (CAN) DURING LANDING, NOSE WHEEL DOWN LOCK LIGHT CAME ON INTERMITTENTLY. AIRCRAFT LANDED SAFELY. TROUBLESHOOTING REVEA LED A BULKHEAD ELECTRICAL CONNECTOR FROM WHEEL BAY TO THE ENGINE COMPARTMENT WAS DISCONNECTED EVEN THOUGH IT WAS IN PLAC E. THE PLASTIC TAB LOCK RING COULD NOT BE SECURED WITH THE PLUG FULLY INSERTED IN THE RECEPTACLE. 1 L 7 1 3O 3 O 3A15 E3SO 1998043000055 19980430 00055 GL 1998 4 30 CA971106003 1 19971030 G 2820 EP160B01BXXC0360 FUEL LINE DIAMON DA20A1 DA20A1 05626UX GL FUEL PUMP SWAGE SWOLLEN W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) EIGHT INCH HOSE RECEIVED FROM MANUFACTURER NEW. FLOW TEST FOUND TO HAVE RESTRICTIONS CAUSING A FAN PATTERN IN THE FLOW. 1 L 7 1 3O NT TA4CH 1998043000056 19980430 00056 GL 1998 4 30 CA971106004 1 19971031 G 2820 FP160B01BXXC0360 FUEL HOSE DIAMON DA20A1 DA20A1 05626UX GL FUEL PUMP SWAGE BENT W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) BRACKET AT ENGINE DRIVEN PUMP OF FUEL SUPPLY LINE FOUND BENT AND WILL NOT FIT THE AIRCRAFT. SUBMITTER SCRAPPED HO SES. 1 L 7 1 3O NT TA4CH 1998043000064 19980430 00064 SO 1998 4 30 CA971110003 2 19971030 G 8520 CRANKCASE CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO NR 1 CYL BORE CRACKED W K NONE E K VIBRATION/BUFFET FLUID LOSS CR CRUISE 1 CA 1038 239802R (CAN) PILOT REPORTED NR 1 ENGINE WAS RUNNING ROUGH. MAINTENANCE FOUND OIL LEAKS AND EVIDENCE OF COMBUSTION DETONATION A T NR 1 CYLINDER. FURTHER INSPECTION FOUND NR 36 STUD WAS PULLED OUT OF THE CRANKCASE THREADS. THE NR 1 CYLINDER BORE I N THE CRANKCASE WAS FOUND CRACKED FROM NR 35 STUD THREADS UP INTO THE CYLINER BORE. THE ENGINE WAS REMOVED FOR REPAIR A ND A FACTORY REMANUFACTURED ENGINE WAS INSTALLED. 1 L 7 2 3O 3 O A7CE E7CE 1998041700662 19980417 00662 SO 1998 4 17 CA971110007 1 19971031 G 7603 554528 CABLE PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA THROTTLE BROKEN W E ENGINE SHUTDOWN Y ENGINE STOPPAGE AP APPROACH 1 CA 4385 RL19077T (CAN) RT ENGINE CONTROL FAILED ON APPROACH. INVESTIGATION REVEALED BREAK OCCURRED AT COCKPIT END OF THROTTLE CONTROL AP PROXIMATELY .25 INCH FROM SWAGED FITTING. BOTH CONTROL CABLES RT AND LT REPLACED. 1 L 7 2 3O 3 O A19S0 E286 1998043000068 19980430 00068 EU 1998 4 30 CA971110009 1 19971030 G 2611 CG7PO SMOKE DETECTOR AIRBUS 310 A310324 3930206 EU PWA 4152 PW4152 NE FORWARD CARGO INOPERATIVE W A F UNSCHED LANDING ACTIVATE FIRE EXT. N FALSE WARNING CL CLIMB 1 CA (CAN) AFTER TAKEOFF, ECAM MESSAGE INDICATED FORWARD CARGO COMPARTMENT SMOKE INDICATION. ENGINEER ON BOARD CHECKED THE C OMPARTMENT. NO FAULT INDICATION, FIRE BOTTLES DISCHARGED AS PER PROCEDURES. SUBSEQUENT INVESTIGATION REVEALED SMOKE DE TECTOR INOPERATIVE. SERVICEABLE SMOKE DETECTOR INSTALLED. 2 L 7 2 4F RT A35EU E24NE 1998031900910 19980319 00910 EU 1998 3 19 CA971110010 1 19971103 G 2611 CG7PO SMOKE DETECTOR AIRBUS 310 A310324 3930206 EU AFT CARGO INOPERATIVE W H DEACTIVATE SYST/CIRCUITS J N WARNING INDICATION FALSE WARNING IN INSP/MAINT 1 CA 3634 (CAN) AFTER WALK-AROUND AND DURING COCKPIT CHECK AND CARGO DOOR OPEN, ECAM MESSAGE INDICATED SMOKE WARNING. TROUBLESHOO TING REVEALED AFT CARGO DETECTOR AT FAULT. SMOKE DETECTOR DEACTIVATED TO PREVENT FURTHER FALSE WARNINGS. AIRCRAFT DISPA TCHED UNDER MEL 26-10. 2 L 7 2 4F RT A35EU 1998041700448 19980417 00448 CE 1998 4 17 CA971110016 1 19971006 G 2820 5426002013 TUBE LEAR 60 60LEAR 5170707 CE FUEL SYS CHAFED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 292 (CAN) ELEVATOR AND RUDDER CABLES FOULING ON CROSSOVER TUBE AND TUBE PUNCTURED. SB A60-28-3 AND AD 95-14-09. PART TC: 1 85. 2 L 7 2 4F RT A10CE 1998043000072 19980430 00072 1998 4 30 CA971110020 4 19970919 G 2562 4520130 BATTERY PACK ARTEX ELT1104 ELT CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 55805 (CAN) DURING ANNUAL TEST ON ELT, IT WAS NOTED THAT WATER HAD INFILTRATED THE BATTERY PACK AND THE BATTERY WAS CORRODED. 1998043000073 19980430 00073 1998 4 30 CA971110021 4 19970919 G 2562 4520130 BATTERY PACK ARTEX ELT1104 ELT CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 55871 (CAN) DURING ANNUAL TEST ON ELT, IT WAS NOTED THAT WATER HAD INFILTRATED THE BATTERY PACK AND THE BATTERY WAS CORRODED. 1998043000074 19980430 00074 GL 1998 4 30 CA971112001 3 19971030 G 6111 BLADE MCAULY 1A101 1A101HCM GL PROP LE & FACE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 2956 G7659 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. STONE DAMAGE FOUND ON THE PROPELLER BLADE LEADING EDGE AND FACE. 5 N P918 1998043000075 19980430 00075 GL 1998 4 30 CA971112002 3 19971103 G 6111 FJC8459B8R BLADE HARTZL HCC2Y BHCC2YF2 GL DEICE BOOT CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 2367 330 AN338 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. CORROSION FOUND UNDER DEICER BOOT. 5 C P920 1998031900912 19980319 00912 GL 1998 3 19 CA971112003 3 19971030 G 6111 G9DHB16E BLADE MOONEY M20 M20J 5870219 SW MCAULY 2D34C B2D34C214 GL LE & FACE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 1307 631 822166 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. STONE DAMAGE FOUND ON THE LEADING EDGES AND THE FACE OF THE BLADES. THE BLADES WERE REPAIRED AND ANODIZED. 1 L 7 1 3O 2A3 5 C P7EA 1998031900914 19980319 00914 NE 1998 3 19 CA971112005 2 19971024 G 7322 FCU B-NUT PWA PWA120 PW125B NE P3 LINE LOOSE W C D ABORTED TAKEOFF RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 CA 11733 6745 124229 (CAN) TAKEOFF WAS ABORTED WHEN NR 2 ENGINE TORQUE FAILED TO MEET TARGET. TROUBLESHOOTING REVEALED A LOOSE "B" NUT ON TH E P3 LINE TO THE MAIN FUEL CONTROL UNIT. PART TC: 13,987. 4 T E20NE 1998031900915 19980319 00915 NE 1998 3 19 CA971112006 2 19971010 G 7322 HMU PWA 305 PW305 NE NR ENGINE FAULTY W E A ENGINE SHUTDOWN UNSCHED LANDING J X WARNING INDICATION ENGINE FLAMEOUT CR CRUISE 1 CA 740 35224 (CAN) DURING LEVEL FLIGHT AT FL 140, THE NR 1 ENGINE LOW FUEL PRESSURE WARNING LIGHT ILLUMINATED FOLLOWED BY AN AUDIBLE ENGINE SHUTDOWN. THE AIRCRAFT DIVERTED AND AN UNEVENTFUL LANDING WAS CARRIED OUT. POST-FLIGHT INVESTIGATION FOUND A PRO BLEM WITH THE HYDRO MECHANICAL FUEL CONTROL UNIT. THE UNIT WAS REPLACED AND CHECKED SERVICEBLE. THE AIRCRAFT WAS RETUR NED TO SERVICE. 4 F E35NE 1998031900916 19980319 00916 EA 1998 3 19 CA971112007 2 19971014 G 7313 TRANSFER TUBE PWA PT6 PT6A65B 52043 EA FUEL NOZZLE MIS-POSITIONED W C D ABORTED TAKEOFF RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 CA 22517 626 3224 (CAN) THE PILOT ABORTED THE TAKEOFF WHEN THE TORQUE ON NR 2 ENGINE FELL BELOW 1,100 FEET/POUNDS. POST-FLIGHT INSPECTION REVEALED A FUEL NOZZLE TRANSFER TUBE TO BE MIS-POSITIONED IN ITS LOCK PLATE AND LEAKING FUEL. THE FUEL NOZZLES HAD BEEN REPLACED THE DAY BEFORE. 4 T E4EA 1998041700661 19980417 00661 SO 1998 4 17 CA971112009 1 19971104 G 3220 4531603 HOUSING ASSY 5521402 PIPER PA31 PA31350 7103110 SO NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 10594 (CAN) IMPROPER TOWING AND TAXIING HAS CONTRIBUTED TO THE FAILURE OF THE NOSE LANDING ASSY HOUSING. TURNING RIGHT, HOUSI NG IS WEAKER IN DESIGN AND AFTER CRACKING COLLAR SLIPS UNDER STOPS, FORCES IT OUT, THEN THE STEERING MECHANISM ACTS AS A LIMITER. IN THIS CASE, BOLTS 401268 (AN3H-10A) AND 400743 (AN25-38) HAVEBEEN FOUND BENT. ONE BOLT AN3H-10A NEARLY SHE ARED AND TWO AN3-7A BOLTS RETAINING STEER ARM TO CYLINDER SHOWED SIGNS OF STRAIN. 1 L 7 2 3O A20SO 1998031900569 19980319 00569 1998 3 19 CA971113022 1 19971017 G 3710 6198 ADAPTER VACUUM PUMP FUSED W A UNSCHED LANDING K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA 48 (CAN) SHORTLY AFTER TAKEOFF, SMELL OF OIL, IND OF NO VACUUM PRESS. PILOT RETURNED TO DEPART POINT. INSP FOUND OIL LEAK ING DOWN SIDE OF A/C AND INVEST FOUND FAULT TO BE VACUUM PUMP ADAPTER. NON-FERROUS METAL FOUND IN OIL SCREEN. VACUUM P UMP DRIVE ADAPTOR WOULD NOT SEPARATE FROM ACCESSORY CASE DESPITE LOOSE ON MOUNTING STUDS. ADAPTER DRIVE APPEARED NOT CE NTERED, EVIDENCE OF EXCESSIVE HEAT BUILDUP IN ADAPTER HOUSING. REAR CASE REMVD, REVEALED PUMP DRIVE SHAFT HAD OVERHEATE D, MELTED ALUMINUM CASING IN WHICH IT ROTATES CAUSING IT TO MUSHROOM AND PREVENT REMOVAL OF VACUUM PUMP DRIVE SHAFT. EN GINEER RETURNED TO MFG, WHO SUGGESTED FAULT CAUSED BY VACUUM PUMP BEING INST TOO LOOSE. HEAT BUILDUP WAS ALSO A FACTOR. 1998031900568 19980319 00568 NM 1998 3 19 CA971113030 1 19971023 G 5320 DOOR FRAME BOEING 727 727171C 1384057 NM PWA JT8 JT8D7A 52053 NE BS 1110 CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 43982 P65362B (CAN) AFT CARGO DOOR FRAME AT BS 1110 STRINGER 26 RIGHT TO 27 RIGHT WAS FOUND CORRODED. REPAIRED. AIRCRAFT TT: 43,882 HOURS. 2 L 7 3 4F 4 F A3WE E2EA 1998031900559 19980319 00559 EA 1998 3 19 CA971113075 2 19971028 G 7250 T12411 BLADE BEECH 99 99 1154002 CE PWA PT6 PT6A28 EA BLADE ROOT FRACTURED W K NONE O OTHER IN INSP/MAINT 1 CA 11869 3979 PCE41175 (CAN) TEAR DOWN REPORT INDICATES A SINGULAR CT BLADE FAILURE DUE TO FATIGUE WAS THE SOURCE OF THE DAMAGE TO THE ENGINE. THE CT BLADE WAS A PMA PART. PART TC: 4,759. 1 L 7 2 3T 4 T A14CE E4EA 1997121100365 19971211 00365 EA 1997 12 11 CA971117001 1 19970930 G 5413 75421131104 LONGERON DHAV DHC7 DHC7102 2802708 EA PWA PT6 PT6A50 52043 EA STA.XN50-XN79 CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 28775 (CAN) HEAVY CORROSION FOUND ON UPPER AND LOWER SURFACES OF THE UPPER LONGERONS. SEVERE CORROSION FOUND ON LONGERONS FROM STA.XN50 TO XN79.0. THIS CORROSION WAS NOT EVIDENT UNTIL THE COWL SEALS AND LATCH PLATES WERE REMOVED. FURTHER SEVERE C ORROSION WAS FOUND UNDER TITANIUM DOUBLERS FROM XN79 TO XN96. UPON REMOVAL OF THE NACELLE UPPER LONGERON IT WAS NOTED TH AT NORMAL PROCEDURES REQUIRED BY EQUALIZED INSPECTION CARD R61 WOULD NOT DETECT THIS CORROSION. 2 H 7 4 4T 4 T A20EA E4EA 1997121100366 19971211 00366 EA 1997 12 11 CA971117002 1 19970930 G 5413 75421128101 LONGERON DHAV DHC7 DHC7102 2802708 EA PWA PT6 PT6A50 52043 EA STA.XN50-XN79 CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 28775 (CAN) HEAVY CORROSION FOUND ON UPPER AND LOWER SURFACES OF THE UPPER LONGERONS. SEVERE CORROSION FOUND ON LONGERONS FROM STA. XN50 TO XN79.0. THIS CORROSION WAS NOT EVIDENT UNTIL THE COWL SEALS AND LATCH PLATES WERE REMOVED. FURTHER SEVERE COROSION WAS FOUND UNDER TITANIUM DOUBLERS FROM XN79 TO XN96. UPON REMOVAL OF THE NACELLE UPPER LONGERON IT WAS NOTED TH AT NORMAL PROCEDURES REQUIRED BY EQUALIZED INSPECTION CARD R61 WOULD NOT DETECT THIS CORROSION. 2 H 7 4 4T 4 T A20EA E4EA 1997121100367 19971211 00367 EA 1997 12 11 CA971117003 1 19970930 G 5413 75421128102 LONGERON DHAV DHC7 DHC7102 2802708 EA PWA PT6 PT6A50 52043 EA STA.XN50-XN79 CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 28775 (CAN) HEAVY CORROSION FOUND ON UPPER AND LOWER SURFACES OF THE UPPER LONGERONS. SEVERE CORROSION FOUND ON LONGERONS FROM STA. XN50 TO XN79.0. THIS CORROSION WAS NOT EVIDENT UNTIL THE COWL SEALS AND LATCH PLATES WERE REMOVED. FURTHER SEVERE CORROSION WAS FOUND UNDER TITANIUM DOUBLERS FROM XN79 TO XN96. UPON REMOVAL OF THE NACELLE UPPER LONGERON IT WAS NOTED T HAT NORMAL PROCEDURES REQUIRED BY EQUALIZED INSPECTION CARD R61 WOULD NOT DETECT THIS CORROSION. 2 H 7 4 4T 4 T A20EA E4EA 1998041700660 19980417 00660 CE 1998 4 17 CA971117004 1 19971106 G 3340 32448 CONNECTORS BEECH 90 65A90 1152908 CE PWA PT6 PT6A20 52043 EA LT LANDING LIGHT BURNT W K NONE O OTHER IN INSP/MAINT 1 CA PCE21451 (CAN) IN COMPLYING WITH AIRCRAFT SERVICES MEMO EWS 97-04, FOUND ONE OVERHEATED KNIFE CONNECTOR. AFFECTED AREA REPLACED WITH RELEASABLE WIRE SPLICE. 1 L 7 2 3T 3 T 3A20 E4EA 1998041700659 19980417 00659 CE 1998 4 17 CA971117010 1 19971110 G 2750 C3010010211 COUPLING CESSNA 150 152 2071835 CE FLAP DAMAGE W C D ABORTED TAKEOFF RETURN TO BLOCK O OTHER TO TAKEOFF 1 CA 11523 (CAN) DURING CHECK, FOUND THAT ALTHOUGH FLAP MOTOR WAS TURNING NORMALLY, FLAPS DID NOT APPEAR TO BE RESPONDING QUICKLY. INVESTIGATION REVEALED DEFECTIVE SPLINE COUPLING ON FLAP MOTOR SHAFT. 1 H 7 1 3O NT 3A19 1998050100078 19980501 00078 CE 1998 5 1 CA971117011 1 19971106 G 2435 62581038 CAPACITOR ASSY CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE L/H GENERATOR BURNED W K NONE M OVER TEMP IN INSP/MAINT 1 CA 2245 71721 (CAN) THE LT GENERATOR WAS RESET TWICE TO BRING IT BACK ON LINE AND THE AIRCRAFT DEPARTED. MAINTENANCE PERSONNEL RAN TH E ENGINE TO CHECK FOR GENERATOR PROBLEMS, BUT EVERYTHING WAS NORMAL. AFTER REMOVING THE LT LOWER ENGINE COWLING TO DO A VISUAL, IT WAS NOTICED THAT THE CAPACITOR ASSY WAS BADLY BURNED INCLUDING SOME WIRING IN THE SAME VICINITY. ONE LEAD W AS FOUND BURNED THROUGH AND BROKEN WHICH OPENED THE CIRCUIT. THIS IS THE SECOND OCCURRENCE ON THIS FLEET. 1 L 7 2 4F 4 F A22CE E1NE 1998031900553 19980319 00553 CE 1998 3 19 CA971118002 1 19970920 G 5510 AN447 BOLT 16962000037 BEECH 23 A23 1151204 CE STAB TUBE WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) UPON REMOVAL OF STABILATOR ACTUATING TUBE BALANCE WEIGHT, DAMAGE TO THE ATTACHMENT BOLT WAS FOUND. THE DAMAGE SEC TIONS OF THE BOLT CORRESPONDED WITH THE DIAMETER OF THE STABILATOR ACTUATING TUBE. THE DAMAGE APPEARS TO HAVE BEEN CAUSE D BY REPETITIVE IMPACT OF THE BALANCE WEIGHT STRIKING THE MICARTA STOP BLOCK (WHICH LIMITS CONTROL SURFACE MOVEMENT). A IRCRAFT TT: 2,033 HOURS. 1 L 7 1 3O A1CE 1998031900549 19980319 00549 GL 1998 3 19 CA971118007 3 19971113 G 6111 BLADE MCAULY 1C160 1C160CTM GL LE & FACE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 2681 682 722304 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. STONE DAMAGE WAS FOUND ON THE LEADING EDGE AND FACE OF THE BLADE. 5 N P910 1998031900547 19980319 00547 CE 1998 3 19 CA971118009 1 19971024 G 2612 FIRE LOOP BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA RT FIRE WARN LOOSE W K NONE J WARNING INDICATION AP APPROACH 1 CA (CAN) DURING LANDING APPROACH, RT FIRE WARNING LIGHT CAME ON INTERMITTENTLY. ON ROLL-OUT, LIGHT CONTINUED TO FLICKER IN RELATION TO TAXIING VIBRATIONS. MAINTENANCE INVESTIGATION REVEALED A CLAMP RETAINING THE LOOP HAD COME LOOSE, ALLOWING THE LOOP TO CONTACT EXHAUST CASE. FAULT RECORDED AND AIRCRAFT RELEASED. 2 L 7 2 4T 4 T RT A24CE E4EA 1998031900546 19980319 00546 EA 1998 3 19 CA971118010 2 19971027 G 7200 ENGINE PWA PT6 PT6A65B 52043 EA NR 2 ENGINE FAILED W E ENGINE SHUTDOWN A E J FLAME/FIRE VIBRATION/BUFFET WARNING INDICATION AP APPROACH 1 CA 324 (CAN) ON APPROACH WHEN POWER WAS BEING REDUCED, A LOUD BANG WAS HEARD AND A FLASH OF LIGHT WAS SEEN FROM THE NR 2 ENGINE . ALL ENGINE INDICATIONS WERE READING "0". ENGINE WAS SECURED AND THE AIRCRAFT LANDED. PO-FLIGHT INSPECTION FOUND THE ACCESSORY GEARBOX AND THE REDUCTION GEARBOX SEIZED. DEBRIS OF UNKNOWN ORIGIN WAS FOUND IN THE POWER TURBINE AND THE EXH AUST AREA. 4 T E4EA 1998031900540 19980319 00540 SO 1998 3 19 CA971125002 2 19971007 G 7322 MA45 CARBURETOR MARVELSCHEB CESSNA 180 180J 2072622 CE CONT O470 O470S 17026 SO FLOAT FAILED W K NONE O K OTHER FLUID LOSS IN INSP/MAINT 1 CA 404 CL0634 46219 (CAN) DURING INSPECTION FUEL WAS FOUND LEAKING FROM THE THROAT OF THE CARBURETOR. INVESTIGATION FOUND THE FLOAT ASSEMBL Y BROKEN OFF. NO INDICATION OF A PROBLEM FROM THE AIRCRAFT OWNER REGARDING ENGINE OPERATION. 1 H 7 1 3O 3 O 5A6 E273 1998100900149 19981009 00149 1998 10 9 CA971128005 4 19971104 G 2210 CONTROL CABLE ARC 300A CESSNA 172 R172K 2072431 CE CONT O360 IO360KB 17025 SO MCAULY 2A34C 2A34C203 GL AFCS MISINSTALLED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 235869R 775070 (CAN) AUTOPILOT NOT FUNCTIONING PROPERLY. AILERON SERVO CABLES INSTALLED IN REVERSE, REPAIRED. 1 H 7 1 3O 3 O 3A17 E1CE 5 C P3EA 1998031900526 19980319 00526 EU 1998 3 19 CA971208005 2 19971125 G 8520 CRANKSHAFT ROTAX 912 ROTAX912 55555 EU PTO END BENT W K NONE E VIBRATION/BUFFET CR CRUISE 1 CA 4 441266 (CAN) VIBRATION NOTICED DURING PRODUCTION TEST FLIGHT. GEARBOX REMOVED TO INVESTIGATE. RUN OUT OF CRANKSHAFT AT P.T.O. (POWER TAKEOFF END) CHECKED IN ACCORDANCE WITH ROTAX F3 MAINTENANCE MANUAL, MEASURED AT.003. REQUIREMENTS NEW ARE 0.00 + 0.03 (MM)/0.00 + 0.0012 (IN), WEAR LIMIT 0.06 (MM)/0.002 (IN). 3 I EXPE3I 1998111300585 19981113 00585 EU 1998 11 13 CA971208006 1 19971010 G 2550 877 PIN SIREN S16096 SNIAS 350 AS350B2 8680813 EU CARGO HOOK MISSING W K NONE O OTHER CR CRUISE 1 CA 294 877 (CAN) AFTER I5 HOURS INTO A GEOSURVEY FLIGHT WITH A POD ON THE CARGO HOOK, THE CARGO HOOK SUDDENLY RELEASED ON ITS OWN, LOSING AN EXPENSIVE PIECE OF EQUIPMENT. DISASSEMBLY OF THE CARGO HOOK REVEALED THAT THE MECHANICAL RELEASE PIN WAS MISS ING PREVENTING THE RELEASE LEVER FROM RETURNING TO ITS FULLY LOCKED POSITION. 1 G 7 1 3U H9EU 1998031900520 19980319 00520 NM 1998 3 19 CA971208014 1 19971127 G 3242 2661942 PISTON HOUSING BFGOODRICH 214662 DHAV DHC8 DHC8102 2809003 NM BRAKE ASSY CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 21443 0926 (CAN) DURING INSPECTION OF THE BRAKE ASSEMBLY, CRACKS APPROXIMATELY .25 INCH LONG WERE FOUND IN TWO OF THE CYLINDERS OF THE PISTON HOUSING. PART TC: 23,433. 2 H 7 2 4T RT A13NM 1998031900514 19980319 00514 EA 1998 3 19 CA971210008 1 19971127 G 3244 256K433 TIRE 6008512515 CNDAIR CL600 CL6002B16 1900305 EA NR MAIN SEPARATED W K NONE J WARNING INDICATION TO TAKEOFF 1 CA 310 JUN81145 (CAN) AFTER TAKEOFF, THE WOW INPUT FAIL LIGHT ILLUMINATED. GEAR RETRACTED AND TRIP UNEVENTFUL. FOUND RUBBER ON NR 3 MA IN TIRE MISSING. IN SPOTS, IT WAS DOWN 3-PLY, AROUND THE COMPLETE CIRCUMFERENCE OF TIRE. THE SECTION MISSING WAS FROM THE OUTER RIB TO THE EDGE OF THE TIRE. THE TIRE HELD ITS PRESSURE. SUSPECT FLYING RUBBER DAMAGED THE RIGHT HAND INBOARD WOW PROXIMITY SWITCH. NO OTHER DAMAGE FOUND. PART TC: 166. 2 L 7 2 4F RT A21EA 1998031900508 19980319 00508 NE 1998 3 19 CA971212003 2 19971113 G 7210 3192441 BEARING PWA 120 PW120 NE RED GRBOX NR 15 SPALLED W O OTHER O OTHER NR NOT REPORTED 1 CA 17368 3234 12661 (CAN) REDUCTION GEARBOX (RGB) WAS SENT FOR INSPECTION AND REPAIR AFTER THE OPERATOR REPORTED THE RGB WAS MAKING M50 META L. INVESTIGATION FOUND THE RGB WAS MAKING METAL DUE TO FRACTURING AND SPALLING OF THE INNER RACE OF THE NR 15 BEARING. THE FAILURE APPEARS TO HAVE INITIATED WITH THE FRACTURE THROUGH THE INNER RACE OF THE NR 15 BEARING. THERE IS NO EVIDE NCE OF WHY THE INNER RACE FRACTURED, HOWEVER, IT APPEARS LIKELY THAT THIS WAS THE PRIMARY FAILURE OF THE NR 15 BEARING. PART TC: 17,197. 4 T E20NE 1998041700477 19980417 00477 GL 1998 4 17 CA971216046 3 19971126 G 6114 H6446 HUB MCAULY 2A36C 2A36C23 GL BLADE SOCKET CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 768152 (CAN) PROPELLER SENT FOR FIVE-YEAR INSPECTION. NO REQUIREMENT FOR NDT. COMPANY POLICY OF CARRYING OUT EDDY CURRENT INS PECTION LED TO FINDING OF CRACKS IN THE THREADS OF THE HUB BLADE SOCKETS. 5 C P880 1998041700657 19980417 00657 SO 1998 4 17 CA971216073 1 19971126 G 5270 PIN PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA BS 111.5 BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 7393 L163261 (CAN) PASSENGER DOOR AJAR WARNING LIGHT INOPERATIVE. MUCH TROUBLE TO FIND THAT A PIN IN A BLOCK CONNECTOR UNDER AND BEH IND THE CIRCUIT BREAKER AND SWITCH PANEL HAD BROKEN. THIS PIN CONNECTS WIRES L54EE TO L57ED AND RUNS UNDER SOME UPHOLST ERY TO REAR OF AIRCRAFT. 1 L 7 2 3O 3 O A20SO E14EA 1998041000445 19980410 00445 NE 1998 4 10 CA971216075 2 19971113 G 7210 310703301 BEARING PWA 120 PW120 NE RED GRBOX NR 15 SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 18257 6880 120660 (CAN) REDUCTION GEARBOX (RGB) SENT FOR INSPECTION AND REPAIR AFTER THE RGB WAS FOUND MAKING METAL. DISASSEMBLY OF THE R GB REVEALED THE SOURCE OF THE METAL WAS THE SPALLING OF THE NR 15 BEARING. THE SPALLING OF THE NR 15 BEARING APPEARED T O BE DUE TO ELECTRICAL ARCING DAMAGE. HOWEVER, THE LACK OF HIGH MAGNETISM IN THE RGB WAS NOT CHARACTERISTIC OF A LIGHTNI NG STRIKE. SINCE THERE WERE NO BEARING BORE ALIGNMENT OR LUBRICATION PROBLEMS FOUND, IT APPEARED THAT THE NR 15 BEARING SPALLED DUE TO ELECTRICAL PITTING CAUSED BY STRAY ELECTRICAL DISCHARGE FROM SOME AIRCRAFT COMPONENT. PART TC: 17,903. 4 T E20NE 1998041700656 19980417 00656 1998 4 17 CA971219001 1 19971117 G 7920 LINE FP3000E33E38 ROTAX 912 ROTAX912 55555 EU OIL SYS LOOSE ENDS W K NONE O OTHER IN INSP/MAINT 1 CA 832 4412584 (CAN) ON 100-HOUR INSPECTION, FOUND BRASS CRIMP RINGS ON THE HOSE END WERE LOOSE. ONE SLEEVE HAD COME COMPLETELY OFF. WITH SLEEVES LOOSE THERE IS NOTHING TO HOLD THE HOSE ONTO THE FITTING. 3 I EXPE3I 1998041700655 19980417 00655 SO 1998 4 17 CA971219012 1 19971127 G 5521 4374301 RIB ASSEMBLY 5423235 PIPER PA31 PA31350 7103110 SO RT ELEV CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 12634 (CAN) WHEN REPLACING MAIN SPAR IN RIGHT HAND ELEVATOR PER SB 998A, THE END RIB ASSY WAS FOUND CRACKED WHERE THE SPAR ATT ACHES TO THE RIB. CRACK ABOUT .50 INCH LONG. AIRCRAFT TT: 12,445 HOURS. 1 L 7 2 3O A20SO 1998041700654 19980417 00654 CE 1998 4 17 CA971219015 1 19971124 G 5312 9774400191 BULKHEAD BEECH 100 100BEECH 1152916 CE AFT PRESS CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 10608 (CAN) WHEN GLUED ON INSULATION WAS REMOVED AT REAR SIDE OF AFT PRESSURE BULKHEAD BELOW OUTFLOW VALVES, CORROSION WAS FO UND. SUSPECT MOISTURE TRAPPED BENEATH INSULATION. AIRCRAFT TT: 10,593 HOURS. 1 L 7 2 3T A14CE 1998041700653 19980417 00653 EU 1998 4 17 CA971219020 2 19971118 G 7314 996592 FUEL PUMP ROTAX 912 ROTAX912 55555 EU OUTLET FITTING CRACKED W K NONE K FLUID LOSS NR NOT REPORTED 1 CA 50 4412619 (CAN) FUEL PUMP LEAKS FUEL FROM HIGH PRESSURE PORT WHICH SPRAYS INTO ENGINE COMPARTMENT. 3 I EXPE3I 1998041700652 19980417 00652 CE 1998 4 17 CA971219023 1 19971114 G 3340 3538013243 SWITCH BEECH 33 F33A 1151425 CE LANDING LIGHT BROKEN W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS AP APPROACH 1 CA 3482 (CAN) SLIGHT ELECTRICAL BURNING SMELL NOTED IN COCKPIT BY PILOTS. LANDING LIGHT CIRCUIT BREAKER SWITCH FOUND FUSED IN T HE ON POSITION AND VERY WARM TO TOUCH. TOGGLE COULD BE MOVED WITH NO RESISTANCE. AIRCRAFT USED IN TRAINING AND HIGH US AGE MAY BE CAUSE OF DIFFICULTY. 1 L 7 1 3O 3A15 1998041700651 19980417 00651 SO 1998 4 17 CA971219026 1 19971124 G 2910 159H10002428S20 LINE GULSTM G159 G159 3952202 SO LEFT ENGINE CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 10 (CAN) HYDRAULIC FLUID NOTED BELOW LEFT ENGINE AFTER ARRIVAL. CRACK FOUND IN THE MAIN SUCTION LINE TO THE HYDRAULIC PUMP . FURTHER INSP FOUND THAT THE LEFT INBOARD GEARBOX MOUNT LINK ASSY WORN CAUSING A VIBRATION AND MOVEMENT RESULTING IN F ATIGUE CRACK IN LINE. 2 L 7 2 4T 1A17 1998041000427 19980410 00427 SO 1998 4 10 CA971219030 2 19971117 G 8530 653446D CYLINDER CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO NR 2 CYL FAILED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA 10 22128872D (CAN) ENGINE PROBLEMS IN-FLIGHT. THE AIRCRAFT DIVERTED. POST-FLIGHT INSPECITON FOUND THE NR 2 CYLINDER HAD FAILED AND CAUSED DAMAGE TO 1 AND 2 CYLINDERS, CASING AND CRANKSHAFT. ENGINE REPAIRED AND AIRCRAFT RETURNED TO SERVICE. 1 H 7 1 3O 3 O 3A24 E5CE 1998050100066 19980501 00066 CE 1998 5 1 CA971219037 1 19971130 G 3246 13600LA90069 BEARING LORAL 50060284 BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA RT MLG FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA PCE32185 (CAN) TOWER REPORTED TO PILOT THAT SPARKS WERE SEEN COMING FROM RIGHT HAND MAIN GEAR. RIGHT OUTBOARD MAIN WHEEL INNER B EARING WAS DESTROYED ALLOWING WHEEL TO WOBBLE ON AXLE CAUSING DAMAGE TO WHEEL ASSY AND BRAKE ASSY. IT HAD BEEN 60 HOURS SINCE LAST SERVICE. 2 L 7 2 4T 4 T RT A24CE E4EA 1998041000419 19980410 00419 NE 1998 4 10 CA971219040 2 19971205 G 7261 3006084 OIL FILLER CAP PWA 120 PW120A NE O-RING GROOVE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 120232 (CAN) CRACKED IN "O" RING GROOVE, IMPROPER FITTING OF "O" RING OR IMPROPER "O" RING FITTED TO THE CAP. POTENTIAL LOSS O F SEALING OF OIL TANK AND LOSS OF OIL OUT OF FILLER DURING FLIGHT. 4 T E20NE 1998032600533 19980326 00533 NE 1998 3 26 CA971219044 2 19971117 G 7250 310920201 LP BLADE PWA 120 PW120A NE LP TURBINE FRACTURED W K NONE O OTHER IN INSP/MAINT 1 CA 20391 120340 (CAN) ENGINE SENT FOR INVESTIGATION AND REPAIR AFTER FAILURE OF A LP TURBINE BLADE. DISASSEMBLY OF THE ENGINE CONFIRME D THE FAILURE OF ONE OR MORE PRE SB 20465, HOLLOW CORE, LP TURBINE BLADES. THESE WERE HIGH-TIME BLADES WITH VISIBLE PLA TFORM CORROSION AND IT APPEARS THE FAILURE ORIGINATED FROM A CORROSION SITE WITHIN THE INTERNAL CORED PASSAGE. SECONDAR Y DAMAGE WAS SUSTAINED BY THE LP TURBINE STATOR ASSEMBLY, THE LP SHROUD SEGMENTS, PT1 AND PT2 STATORS, PT1 AND PT2 TURBI NE BLADES. PART TC: 28,434. 4 T E20NE 1998032600534 19980326 00534 NE 1998 3 26 CA971219045 2 19971124 G 7210 310924401 BEARING PWA 120 PW120 NE RED GRBOX NR 15 SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 17734 4541 120378 (CAN) ENGINE SENT FOR REPAIR AFTER REDUCTION GEARBOX WAS FOUND MAKING M50 METAL. DISASSEMBLY OF ENGINE REVEALED SOURCE OF THE M50 METAL CONTAMINATION A SPALLED NR 15 BEARING. NR 15 BEARING HAD ELECTRO-EROSION ON THE OUTER RACE AND ROLLER S. NR 15 BEARING BORE WAS FRETTED AND BEARING HAD SPUN ON THE PROP SHAFT. SUBMITTER SUGGESTED CAUSE OF BEARING FAILURE WAS ELECTRO-EROSION WHICH APPEARED TO BE A STRAY ELECTRICAL DISCHARGE FROM SOME ACFT COMPONENT AND NOT A LIGHTNING STRI KE. THERE WAS SECONDARY DAMAGE ON THE BULL GEAR, LT AND RT 2ND STAGE SPUR GEARS, OVERSPEED GOVERNOR SPUR GEAR AND REDU CTION GEARBOX SCAVENGE PUMP HOUSING. PART TC: 19,818. 4 T E20NE 1998032600535 19980326 00535 NE 1998 3 26 CA971219046 2 19971128 G 7230 311161801 BEARING PWA 118 PW118 NE INTER COMP CASE FAILED W E ENGINE SHUTDOWN O OTHER NR NOT REPORTED 1 CA 20205 11584 BB9310666 15260 (CAN) TURBOMACHINE SENT FOR INVEST AFTER ENGINE EXPERIENCED A DROP IN "ALL PARAMETERS" AND SHUT ITSELF DOWN. A FIREBAL L WAS SEEN COMING FROM REAR OF ENGINE AND UPON LDG, OIL WAS NOTICED BLOWN OUT OF INTAKE. DISASSY OF ENGINE FOUND COMPO NENTS RETAINED BY NR 4 BEARING RETAINING NUT WERE SEVERELY FRETTED AND NR 4 BEARING RETAINING NUT WAS NO LONGER TIGHT. S UBMITTER SUGGESTED NR 4 BEARING FAILED DUE TO BACKING OFF OF NR 4 BEARING RETAINING NUT. HOWEVER, LOSS OF A NR 3 AND NR 4 BEARING AREA MULTIPLE JET OIL NOZZLE PLUG SUGGESTED FAILURE MAY HAVE BEEN DUE TO OIL STARVATION. LOSS OF NR 3 AND NR 4 BEARING AREA MULTIPLE JET OIL NOZZLES FLOODED ENG WITH OIL CAUSING A FIREBALL IN HOT SECTION. PART TC: 20,653. 4 T E20NE 1998032600536 19980326 00536 NE 1998 3 26 CA971219047 2 19971128 G 7210 310703301 BEARING PWA 120 PW120A NE RGB NR 15 SPALLED W K NONE O OTHER IN INSP/MAINT 1 CA 24835 2884 64B454 120167 (CAN REDUCTION GEARBOX SENT FOR INSP AND REPAIR AFTER OPERATOR NOTED A LARGE NUMBER OF SHINY METAL FLAKES IN RGB SCAVENG E FILTER AND ON RGB CHIP DETECTOR. DISASSEMBLY OF ENG REVEALED SOURCE OF METAL CONTAM WAS SPALLING OF NR 15 BEARING. N R 15 BEARING ROLLERS AND UNDAMAGED PORTION OF OUTER RACE HAD CHAINS OF ELECTRICAL DISCHARGE PITTING WHICH APPEAR TO BE C AUSE OF THE SPALLED BEARING. SECONDARY DAMAGE FROM THE SPALLED BEARING LIMITED TO NR 13 LT BEARING. THERE IS SOME DETE CTABLE MAGNETISM ON A RANDOM SCATTERING OF STEEL COMPONENTS. THIS PATTERN IS NOT TYPICAL OF A LIGHTNING STRIKE, SO A LI GHTNING STRIKE IS NOT THOUGHT TO BE A CAUSE OF NR 15 BEARING FAILURE. PART TC: 34,042. 4 T E20NE 1998041700650 19980417 00650 WP 1998 4 17 CA971222002 2 19970907 G 7314 8973809 FUEL PUMP CESSNA 441 441 2076020 CE GARRTT TPE331 TPE33110 01514 WP ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA P77559 (CAN) ENGINE WOULD NOT LIGHT UP DURING START UNTIL 18 PERCENT-20 PERCENT. A NORMAL START LIGHT OFF IS 12 PERCENT-14 PER CENT. FOUND FUEL PUMP OUTPUT PRESSURE AT LOW RPM BELOW SPECS. 1 L 7 2 3T 4 T RT A28CE E4WE 1998041700649 19980417 00649 CE 1998 4 17 CA971222003 1 19971007 G 7700 99103261 TRANSDUCER CESSNA 441 441 2076020 CE GARRTT TPE331 TPE33110 01514 WP ENGINE FAILED W O OTHER R PARTIAL RPM/PWR LOSS CL CLIMB 1 CA P77093 (CAN) TRANSDUCER GAVE INCORRECT SIGNAL TO ENGINE COMPUTER-CAUSING SRL TO BE INCORRECT. THE ERROR WAS GREATER AS THE AIRC RAFT CLIMBED. THUS; TORQUE, FUEL FLOW, AND EGT DID NOT MATCH THE OTHER ENGINE AS THE AIRCRAFT CLIMBED. THIS IS THE P/ P TRANSDUCER. 1 L 7 2 3T 4 T RT A28CE E4WE 1998032600538 19980326 00538 NE 1998 3 26 CA971222005 2 19971212 G 7261 3006084 OIL FILLER CAP PWA 118 PW118 NE "O"RING GROOVE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 115394 (CAN) OIL FILLER CAP SEAL FLANGE FOUND CRACKED. POTENTIAL FOR IN-FLIGHT LOSS OF ENGINE OIL IF FLANGE FAILS. 4 T E20NE 1998032600540 19980326 00540 NM 1998 3 26 CA971222007 1 19971208 G 3320 BV033001248 LAMPHOLDER DHAV DHC8 DHC8102 2809003 NM ROW 2AC BURNT W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 CA (CAN) AFTER TAKEOFF, PASSENGERS SMELLED AND SAW SMOKE AT ROW 2AC OVERHEAD BIN AREA. AIRCRAFT RETURNED TO FIELD. MAINTE NANCE FOUND OVERHEAD LIGHT BULB ARCING AT CONNECTION. 2 H 7 2 4T RT A13NM 1998041700648 19980417 00648 EU 1998 4 17 CA971222008 1 19971212 G 3250 223602000000 BRACKET 273009 ISRAEL 1124 1124 4500102 EU STEERING MT EAR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) UPPER STEERING BRACKET FOUND CRACKED. 2 M 7 2 4F A2SW 1998032600543 19980326 00543 NE 1998 3 26 CA971222011 2 19971203 G 7270 712538 DIFFUSER PWA JT8 JT8D17 52049 NE OUTER SURFACE DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 CA 25551 P707235B (CAN) PRIOR TO ENGINE INSTALLATION, IT WAS NOTICED THAT STRANDS OF MATERIAL WERE HANGING IN THE BY-PASS DUCT, VISIBLE FR OM AFT OF THE ENGINE. REMOVAL OF THE 13TH STAGE BLEED AIR COVER ALLOWED ACCESS TO CONFIRM SEVERE DELAMINATION OF THE DI FFUSER OUTER SURFACE. THE ENGINE HAD JUST BEEN RECEIVED FROM THE ENGINE SHOP. PART TC: 13,954. 4 F E2EA 1998032600544 19980326 00544 NE 1998 3 26 CA971222012 2 19971218 G 7322 FUEL CONTROL PWA PW120 PW123 NE NR 2 ENGINE FAILED W E ENGINE SHUTDOWN O J OTHER WARNING INDICATION CR CRUISE 1 CA 1152 109029 (CAN) THE NR 2 ENGINE WAS SHUT DOWN AT 5,000 FEET FOLLOWING ZERO TORQUE AND 300 DEGREE CELSIUS ITT INDICATION. THE AIRC RAFT CONTINUED TO DESTINATION AND MADE AN UNEVENTFUL SINGLE ENGINE LANDING. POST-FLIGHT INSPECTION FOUND THE MAIN FUEL CONTROL UNIT (MFCU) INPUT DRIVE SHAFT BEARINGS SEVERELY DAMAGED. 4 T E20NE 1998100900151 19981009 00151 SO 1998 10 9 CA971222014 1 19971130 G 5210 4166806 GATE PIPER PA31 PA31350 7103110 SO PASSENGER DOOR MISSING W O OTHER D INFLIGHT SEPARATION DE DESCENT 1 CA (CAN) UPPER PORTION OF PASSENGER DOOR DEPARTED IN-FLIGHT DURING DESCENT AT 18O KNOTS MODERATE TURBULANCE. LOWER PORTION REMAINED. DOOR WAS CLOSED AND LOCKED. REPAIRED. 1 L 7 2 3O A20SO 1998041700647 19980417 00647 CE 1998 4 17 CA971223002 1 19970711 G 7410 103784005 IGNITION BOX CESSNA 441 441 2076020 CE GARRTT TPE331 TPE33110 01514 WP ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA P77093 (CAN) IGNITION BOX FAILED. 1 L 7 2 3T 4 T RT A28CE E4WE 1998032600545 19980326 00545 EA 1998 3 26 CA971223003 1 19971210 G 2700 43100012 CIRCUIT BREAKER DHAV DHC8 DHC8311 1386006 EA 26 VAC.Q1 CHAFED W K NONE J WARNING INDICATION NR NOT REPORTED 1 CA 13 (CAN) THE POWERED FLIGHT CONTROL SYSTEM (PFCS) CIRCUIT BREAKER WAS TRIPPING. CB LOCATED ON THE LEFT 26VAC BUS, POSITION Q1. APPARENT CAUSE WAS THE CIRCUIT BREAKER LOAD TERMINAL WAS SHORTING TO GROUND VIA THE MOUNTING BRACKET SUPPORTING 24 23-P1. BRACKET WAS TRIMMED TO ACCOMMODATE. THIS WAS A FACTORY NEW AIRCRAFT. MANUFACTURER QA WAS NOTIFIED. 2 H 7 2 4T RT A13NM 1998100900152 19981009 00152 CE 1998 10 9 CA971223004 1 19971210 G 5710 262207459 WING CESSNA 208 208B 2073701 CE WS 276 BIRD STRIKE W O OTHER C F.O.D. AP APPROACH 1 CA (CAN) ON APPROACH BIRD STRIKE, DUCK, ON LT WING LEADING EDGE STA 276L. LARGE DENT AND RIB DAMAGE, REPAIRED. 1 H 7 1 3T A37CE 1998100900153 19981009 00153 CE 1998 10 9 CA971223009 1 19971219 G 5320 17120523 STIFFENER 1712000 CESSNA 177 177A 2073706 CE LYC O360 O360A1F 41514 EA FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 4500 L1315436A (CAN) LT AND RT LANDING GEAR UPPER ATTACHMENT CRACKED AT ATTACHMENT HOLES. HOLE EDGE DISTANCE VERY CLOSE. 1 H 7 1 3O 3 O A13CE E286 1998041700645 19980417 00645 GL 1998 4 17 CA971231008 2 19971219 G 7320 6875630 TUBE BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL GOV CRACKED W E B ENGINE SHUTDOWN EMER. DESCENT R PARTIAL RPM/PWR LOSS CR CRUISE 1 CA 5443 CAE821934 (CAN) AIR LINE FROM COMPRESSOR SCROLL TO GOVERNOR CRACKED AT FLARE AT SCROLL END. THIS CAUSED ENGINE TO GO TO IDLE. 1 G 7 1 3U 3 U H2SW E4CE 1998041700644 19980417 00644 GL 1998 4 17 CA971231009 2 19971219 G 7320 6875632 LINE BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL FUEL CONTROL LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 3407 CAE821934 (CAN) FUEL NOTED DRIPPING FROM THE ENGINE COMPARTMENT OVERBOARD DRAIN. FUEL LINE BETWEEN FUEL CONTROL AND GOVERNOR LEAK ING. 1 G 7 1 3U 3 U H2SW E4CE 1998041700643 19980417 00643 SO 1998 4 17 CA971231010 1 19971221 G 2434 30E2041A GENERATOR GULSTM G159 G159 3952202 SO RIGHT HAND FAILED W H DEACTIVATE SYST/CIRCUITS H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA 378 (CAN) RIGHT HAND GENERATOR FAILED IN CRUISE. FIELD COIL FOUND OPEN. 2 L 7 2 4T 1A17 1998100900154 19981009 00154 CE 1998 10 9 CA971231015 1 19971210 G 2720 CONTROL CABLE BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA RUDDER MISINSTALLED W O OTHER F FLT CONT AFFECTED LD LANDING 1 CA PCE50438 (CAN) ON LANDING, THE RUDDER CABLES JAMMED. INVESTIGATION REVEALED THAT THE CABLES WERE ROUTED UNDER THE RUDDER SERVO A TTACH BRACKET. THE SWAGED ENDS CAUGHT THE EDGE OF THE BRACKET AND COULD NOT BE MOVED. CABLES REROUTED. 1 L 7 2 3T 4 T A14CE E4EA 1998032600556 19980326 00556 GL 1998 3 26 CA971231017 3 19971212 G 6111 BLADE MCAULY 1C172 1C172EM GL PROP LE & FACE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 1661 E1180 (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. CORROSION FOUND ON ALL SURFACES ACCOMPANIED BY STONE DAMAGE. 5 N P910 1998032600557 19980326 00557 GL 1998 3 26 CA971231018 3 19971219 G 6114 790100018 BLADE BEARINGS PIPER PA24 PA24250 7102404 SO LYC O540 O540A1A5 41532 EA HARTZL HC82V HC82V* GL PROP CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 3189 813 L27440 288G (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. BLADE BALL BEARINGS AND PILOT TUBE FOUND CORRODED. 1 L 7 1 3O 3 O 1A15 E295 5 C P23EA 1998032600561 19980326 00561 EA 1998 3 26 CA971231022 2 19971229 G 8520 CAMSHAFT PIPER PA22 PA22108 7102204 SO LYC O235 O235C1 41505 EA ENGINE WORN W K NONE R PARTIAL RPM/PWR LOSS CL CLIMB 1 CA 855 2792515 (CAN) ENGINE CAMSHAFT FOUND WORN. ENGINE CAMSHAFT REPLACED. 1 H 7 1 3O 3 O 1A6 E223 1998032600562 19980326 00562 SO 1998 3 26 CA971231023 1 19971211 G 5751 JW3602R CASTING JW10501 LKHEED 1329 132923D 5263108 SO RT AIL CTRWT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 8850 (CAN) DURING INSPECTION, FOUND RT AILERON COUNTERWEIGHT CASTING ATTACH CRACKED THROUGH BETWEEN 2 BOLTS. REPLACED. PART TC: 5,513. 2 L 7 4 4J 2A15 1998041000407 19980410 00407 SW 1998 4 10 CA971231024 1 19971105 G 2810 205061632002 FUEL CELL BELL 205 205A1 1181414 SW LYC T53 T5313B 41549 NE FUEL SYS PEELING W K NONE O OTHER IN INSP/MAINT 1 CA LE07525 (CAN) WHEN RIGHT HAND FUEL SUMP DRAINED, BLACK PARTICLES WERE FOUND. RUBBER COATING OF THE FUEL CELL HAD PEELED OFF. 1 G 7 1 4U 4 U H1SW E17EA 1998100900155 19981009 00155 CE 1998 10 9 CA971231027 1 19971218 G 5740 AN823A BOLT CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL LT WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 5118 RL560676T 79660 (CAN) DURING REMOVAL OF WINGS FOR TRANSPORT, THE LT WING FORWARD ATTACHMENT BOLT FOUND CORRODED. REPLACED. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 1998041000406 19980410 00406 GL 1998 4 10 CA980113001 2 19970818 G 7210 406340104101 SEAL ALLSN 6894171 BELL 206 206BELL 1181502 SW ALLSN 250C 250C20 03013 GL GR BOX PTO SEAL BROKEN W K NONE O OTHER CR CRUISE 1 CA CAG30218 CAE821314 (CAN) PILOT REPORTED ERRATIC TORQUE INDICATIONS. GEARBOX REMOVED. PTO SEAL LIP FOUND TORN, AND PIECES OF BROKEN SEAL WER E BLOCKING TORQUE METER BLEED HOLE. THIS IS THIRD INCIDENT NOTED BY THIS O/H SHOP. 1 G 7 1 3U 3 U H2SW E4CE 1998041700642 19980417 00642 SO 1998 4 17 CA980113003 2 19971230 G 7322 30764 FLOAT MARVELSCHEB MA45 CESSNA 180 180G 2072616 CE CONT O470 O470R 17026 SO CARB BROKEN W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 1326706R (CAN) FUEL DRIPPING HEAVILY FROM CARBURETOR AFTER ENGINE SHUTDOWN. CARBURETOR REMOVED AND DISASSEMBLED. CARBURETOR FLO AT PONTOON SEPARATED FROM STRUCTURE, IT APPEARS BOTH SUPPORT TANGS RADII ARE TOO SMALL WHICH LEADS TO FAILURE FIRST, LOA DING THE SOLDER JOINT TO FAILURE. 1 H 7 1 3O 3 O 5A6 E273 1998041700641 19980417 00641 1998 4 17 CA980113004 4 19971215 G 3452 3420221 RESISTOR RT395A CESSNA 172 172N 2072434 CE TRANSPONDER BURNT W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA 14956 (CAN) SMOKE IN COCKPIT. TRANSPONDER FOUND TO HAVE BURNT DIMMING RESISTOR. REPAIRED AND CERTIFIED. 1 H 7 1 3O NT 3A12 1998041700640 19980417 00640 CE 1998 4 17 CA980113007 1 19971224 G 5740 8178414 WING BOLT BEECH 100 B100 1152919 CE SHANK CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 24 (CAN) WHILE PERFORMING AD CF-81-25R5, A CRACK WAS DETECTED. THE RIGHT HAND LOWER FORWARD BOLT WAS FOUND CRACKED AT THE SHANK. 1 L 7 2 4T A14CE 1998050801410 19980508 01410 EA 1998 5 8 CA980113014 2 19971222 G 7261 1781503 OIL LINE PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA RT NACELLE CUT W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 6730 L372748 (CAN) AT SHUTDOWN, OIL LEAK NOTED OUT UNDER RT NACELLE ONTO LANDING GEAR DOORS. OIL PRESSURE LINE CUT UNDER CLAMP AT FI REWALL, TWO PLACES, WIDTH OF CLAMP. IMPROPER SIZE CLAMP. REPLACED CLAMP. 1 L 7 2 3O 3 O 1A10 1E4 1998050801411 19980508 01411 SO 1998 5 8 CA980113015 1 19971222 G 2710 1430004 CONTROL CABLE PIPER PA23 PA23250 7102308 SO AIL BALANCE CHAFED W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 CA 6731 (CAN) AILERON BALANCE CABLE CHAFING ON FLOOR SKIN AND HYD LINE. CABLE REPLACED, HYL LINE RECLAMPED AND FLOOR SKIN MOVED . 1 L 7 2 3O 1A10 1998060500095 19980605 00095 CE 1998 6 5 CA980113018 1 19971222 G 3230 131378252CL CHAIN KEEPER BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA NLG MISSING W K NONE O OTHER IN INSP/MAINT 1 CA PCE81062 (CAN) NOSE GEAR AFT CHAIN MASTER LINK MISSING AND ADJACENT LINK BENT, ONLY HELD ON BY ONE HOLE. REPAIRED/REPLACED. 1 L 7 2 4T 4 T A24CE E4EA 1998121800368 19981218 00368 GL 1998 12 18 CA980126001 2 19970201 G 7323 252466712 GOVERNOR BENDIX HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA 1086 22928 CAE831201 (CAN) UNABLE TO HOLD STEADY N2 RPM, SURGING OVER/UNDER SPEED. 1 G 7 1 3U 3 U H3WE E4CE 1998121800369 19981218 00369 GL 1998 12 18 CA980126002 2 19970826 G 7323 23007505 GOVERNOR BENDIX HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA 1245 24933 CAE831201 (CAN) ENGINE UNABLE TO HOLD STEADY N2 RPM, CAUSING ACFT TO YAW DURING FLUCTUATIONS. 1 G 7 1 3U 3 U H3WE E4CE 1998121800370 19981218 00370 GL 1998 12 18 CA980126003 2 19970918 G 7323 252476913 GOVERNOR BENDIX HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA 256 23799 CAE831201 (CAN) IN-FLIGHT DROP IN N2 RPM. TRIM DID NOT BRING RPM UP. BEEP RANGE SHIFTED DOWN. UNABLE TO ADJUST WITHIN RANGE. 1 G 7 1 3U 3 U H3WE E4CE 1998121800371 19981218 00371 GL 1998 12 18 CA980126004 2 19971101 G 7323 252466714 GOVERNOR BENDIX HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA 165 24523 CAE831201 (CAN) ENGINE EXPERIENCED A DROP IN ATTAINABLE N2 RPM. ADJUSTMENT ATTEMPTED, BUT HITTING MAX STOP AFTER ADJUSTMENT. 1 G 7 1 3U 3 U H3WE E4CE 2001032100071 20010321 00071 SO 2001 3 21 CA980302002 2 19971120 G 8530 641370 CYLINDER PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360E 17025 SO ENGINE SEPARATED W O OTHER O OTHER NR NOT REPORTED 1 CA 600 (CAN) THE TOP OF THE CYLINDER CONTAINING THE VALVES AND THE ROCKER ARMS SEPARATED FROM THE CYLINDER. 1 L 7 2 3O 3 O A7SO E9CE 2001032200002 20010322 00002 GL 2001 3 22 CA980309006 3 19971220 G 6114 57A22451 BUSHING HCE2YL2BSF PIPER PA30 PA30 7103002 SO LYC O320 IO320B1A 41508 EA HARTZL HCE2Y HCE2YL2 GL PROPELLER HUB MISSING W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) PROPELLER WAS DISMANTLED FOR OVERHAUL. LOWER HUB BUSHING WAS MISSING. NO DAMAGE WAS CAUSED BY THE ABSENCE OF THE B USHING. 1 L 7 2 3O 3 O A1EA 1E12 5 C P9EA 2001032200026 20010322 00026 GL 2001 3 22 CA980313001 1 19971231 G 7334 2028000800 SENSOR DIAMON DA20 DA20A1 GL ROTAX 912 ROTAX912 55555 EU FUEL PRESSURE FAULTY W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA (CAN) FUEL PRESSURE ILLUMINATED (WARNING) IN FLIGHT. POST FLIGHT, FUEL PRESSURE SENSOR WAS REPLACED. THE ENGINE WAS GROU ND RUN SERVICEABLE. 1 L 7 1 3O 3 I NT TA4CH EXPE3I 2001032200058 20010322 00058 EU 2001 3 22 CA980317070 1 19970919 G 2840 647510032 TRANSMITTER SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE FUEL QUANTITY STUCK W K NONE O OTHER IN INSP/MAINT 1 CA 460 (CAN) FUEL QUANTITY GAUGE STICKING AT 55-80% WHEN REFUELING AIRCRAFT. FUEL QUANTITY TRANSMITTER REPLACED. 1 G 7 1 3U 3 U H9EU E19EU 2001032200059 20010322 00059 EU 2001 3 22 CA980317071 1 19971209 G 2840 647510032 TRANSMITTER SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE FUEL QUANTITY INACCURATE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHEN DEFUELING AIRCRAFT, GAUGE READ 20 PERCENT WHEN EMPTY AND LOW LEVEL FUEL LIGHT WAS NOT ILLUMINATED. FUEL TRANS MITTER REPLACED. 1 G 7 1 3U 3 U NC H9EU E19EU 2001032200107 20010322 00107 NE 2001 3 22 CA980318033 2 19971213 G 7230 STATOR CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE COMPRESSOR FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 2303 (CAN) DURING HOT SECTION INSPECTION INTERNAL DAMAGE AND FOD WAS FOUND AROUND THE COMBUSTION LINER. INVESTIGATION FOUND T HAT PART OF THE 3RD STAGE COMPRESSOR FAILED AND DEBRIS FOUND ITS WAY THROUGH THE ENGINE. THE ENGINE WAS REPLACED. 1 H 7 1 3T 3 T A37CE E4EA 2001032600338 20010326 00338 EA 2001 3 26 CA980325016 1 19970526 G 2436 2N5686 TRANSISTOR PHOENIX VR1010241A DHAV DHC6 DHC6300 2802606 EA PWA PT6 PT6A27 52043 EA VOLT REGUALTOR WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 3390B (CAN) POWER TRANSISTOR IN VOLTAGE REGULATOR BASE IS AN UNAPPROVED PART. IT SHOULD BE AN OEM 048504. 1 H 7 2 3T 4 T RT A9EA E4EA 2001032600339 20010326 00339 EA 2001 3 26 CA980325018 2 19970501 G 7414 10682056 DISTRIBUTOR BLK BENDIX 1038291013 PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA RT MAGNETO LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA 32234 (CAN) THE MAGNETO WAS SENT FOR OVERHAUL. ON DISASSEMBLY IT WAS FOUND THAT THE BUSHING, THAT SHOULD HAVE BEEN MOLDED TO T HE DISTRIBUTOR BLOCK, WAS EXTREMELY LOOSE BUT STILL IN PLACE. THE BUSHING CAN BE TILTED 10 DEGREES EITHER SIDE OF CENTRE . THE PART WAS REPLACED AND THE UNIT OVERHAULED AND RETURNED TO SERVICE. 1 L 7 2 3O 3 O A20SO E14EA 1998090400002 19980904 00002 CE 1998 9 4 CA980325019 1 19971106 G 2140 G722023 VALVE SOUTHWIND 8259HR2 CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO MCAULY 3AF32C 3AF32C505 GL HEATER LEAKING W K NONE O OTHER IN INSP/MAINT 1 CA 1 6278 244910R 940455 (CAN) HEATER UNIT OBTAINED AS REPLACEMENT ITEM AND ON FIRST FLIGHT THE PILOTS COMPLAINED THAT THEY WERE NOT ABLE TO CONT ROL HEATER. INVESTIGATION REVEALED THAT THE FUEL SOLENOID VALVE SEAL WAS NOT INSTALLED PROPERLY AND THIS ALLOWED FUEL T O LEAK OUT OF THE COMBUSTION CHAMBER AND WHEN THE VENT PORT WAS PLUGGED, THE FUEL CAME OUT OF THE HEATER EXHAUST. SEAL REPLACED. 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 2001032600346 20010326 00346 EA 2001 3 26 CA980325020 2 19971007 G 7414 10357584 GEAR BENDIX 106006141J12 ROBSIN R22 R22BETA NM LYC O320 O320B2C 41508 EA DISTRIBUTOR DESTROYED W K NONE O OTHER IN INSP/MAINT 1 CA 990 94023 (CAN) MAGNETO WAS SENT FOR 500 HOUR INSPECTION. ON DISASSEMBLY A STEEL WASHER WAS FOUND LOOSE IN THE COIL CAVITY. INSPE CTION REVEALED THE WASHER HAD CAME LOOSE FROM THE GEAR AND AXLE ASSEMBLY ON THE DISTRIBUTOR GEAR. IT WAS ALSO NOTED THAT THE AXLE COULD EASILY BE MOVED WITHIN THE NYLON GEAR. THE DEFECTIVE PART WAS REPLACED AND THE UNIT RETURNED TO SERVICE. 1 G 7 1 3O 3 O H10WE E274 1998100900157 19981009 00157 SO 1998 10 9 CA980325048 1 19971022 G 2923 ESQ125 BRUSHES PRESTOLITE 105476 PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA HYD PUMP BROKEN W E ENGINE SHUTDOWN J WARNING INDICATION LD LANDING 1 CA L1621051A (CAN) HYDRAULIC GEAR POWERPACK FAILED ON LANDING. BRUSHES BROKEN INTO MULTIPLE PIECES. REPLACED. 1 L 7 1 3O 3 O 2A13 1E10 1998041700634 19980417 00634 EU 1998 4 17 CA980330026 1 19971217 G 3260 9321912044 BOLT PILATS PC12 PC12 7090550 EU RT WOW SWITCH SHEARED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 418 (CAN) UNABLE TO SELECT GEAR UP ON DEPARTURE, RETURNED TO BASE. SWITCH CLEANED OF SLUSH. SAME PROBLEM OCCURRED BUT WAS CLEARED BY RESETTING CIRCUIT BREAKER. AFTER RETURN TO BASE, ANNUNCIATOR ILLUMINATED. INVESTIGATION FOUND THAT RT WEIGH T- ON-WHEEL TARGET RETAINING BOLT WAS SHEARED ALLOWING TARGET TO MOVE OCCASIONALLY. BOLT REPLACED AND GEAR SWING CHECKE D OK.N PART TC: 273. 1 L 7 1 3T RT A78EU 1998041700622 19980417 00622 NE 1998 4 17 CA980403008 2 19971228 G 7310 117050001 TUBE ASSEMBLY BELL 205 205A1 1181414 SW LYC T53 T5313B 41549 NE PURGE SYSTEM BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA LE07641 (CAN) TUBE ASSEMBLY, PURGE SYSTEM, FOUND BROKEN AT THE BRAZING. THIS ASSEMBLY IS IN THE FUEL STARTING SYSTEM. 1 G 7 1 4U 4 U H1SW E17EA 1998041700621 19980417 00621 EA 1998 4 17 CA980403009 3 19971230 G 6110 BLADE PIPER PA28 PA28180 7102808 SO SNSNCH 76E 76EM8S5 EA PROP LE & FACE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 CA 1175 17434K (CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. CORROSION FOUND ON FACE SIDE OF THE BLADES ACCOMPANIED BY STONE DAMA GE. 1 L 7 1 3O 2A13 5 N P4EA 1998073100367 19980731 00367 1998 7 31 CA980406001 4 19970713 G 5301 1B1141A120 RELEASE CABLE SCWZER SG2 SGS233 8051604 EA RELEASE LEVER BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 3482 (CAN) REAR RELEASE CABLE BROKE AT RELEASE LEVER, JUST AFT OF SWAGED THIMBLE. 1 K 0 0 G2EA 1998073100380 19980731 00380 EA 1998 7 31 CA980406019 1 19970807 G 2917 HP6101002C1 MANIFOLD CARSON S61 S61LSKRSKY EA HYDRAULIC SYS FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 980 (CAN) ON PRE-FLIGHT CONTINUITY CHECK, PILOT COULD SHUT OFF BOTH HYDRAULIC SYSTEMS AT THE SAME TIME. BOTH PRESSURE GAUGES INDICATED ZERO PSI, BUT SMALL AMOUNT OF HYDRAULIC CONTROL REMAINED. HYDRAULIC MANIFOLD REPLACED. 2 G 7 2 4U H8EA 1998073100381 19980731 00381 GL 1998 7 31 CA980406020 2 19971223 G 7323 23057870 GOVERNOR BENDIX 23057870 HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE MALFUNCTIONED W K NONE O OTHER HO HOVERING 1 CA 360 18351 CAE830896 (CAN) WHEN MAKING BEEP ADJUSTMENTS TO GOVERNOR, ESPECIALLY AT HIGHER POWER DEMANDS, GOVENOR WILL HUNT FOR TWO OSCILLATIO NS AND THEN OVERSPEED. BLUE GREASE FOUND AT SEAL DRAIN. 1 G 7 1 3U 3 U H3WE E4CE 1998080700105 19980807 00105 EU 1998 8 7 CA980407015 1 19970413 G 2913 350A35013003 SPLINE SNIAS 350 AS350B 8680801 EU TMECA ARRIEL ARRIEL1B 6OO30 NE HYD PUMP SHEARED W A H UNSCHED LANDING DEACTIVATE SYST/CIRCUITS G K J MULTIPLE FAILURE FLUID LOSS WARNING INDICATION CR CRUISE 1 CA 4414 (CAN) HYDRAULIC PRESSURE LOST DURING FLIGHT. LOSS OF PRESSURE DUE TO SHEARED INTERNAL SPLINES ON THE HYDRAULIC PUMP DRI VE COUPLING SLEEVE P/N S40. 1 G 7 1 3U 3 U H9EU E19EU 1998090400012 19980904 00012 CE 1998 9 4 CA980415021 1 19971209 G 3230 UPLOCK CESSNA 404 404CESSNA 2075901 CE MCAULY 3FF32 3FF32C501 GL NLG FROZEN W K NONE O OTHER IN INSP/MAINT 1 CA 804566 (CAN) AT TEMPERATURE BELOW ZERO DEGREES, CONDENSATION FROZE ON NOSE GEAR UPLOCK. REPLACED. 1 L 7 2 3O A25CE 5 C P45GL 1998090400027 19980904 00027 CE 1998 9 4 CA980602001 1 19970820 G 2510 SCREW CESSNA 182 182P 2075816 CE CONT O470 O470S 17026 SO MCAULY 2A34C 2A34C203 GL SEAT LOOSE W O OTHER O OTHER CR CRUISE 1 CA 50 464476 765582 (CAN) STC SA00508WI INSTALLED, NEW PILOTS AND COPILOTS SEATS. DURING A RECENT FLIGHT, ON ROTATION, THE PILOTS SEAT SLIP PED AND THE PILOT HAD PROBLEMS REGAINING CONTROL OF THE AIRCRAFT. WHEN CONTROL WAS REGAINED THE AIRCRAFT WAS LANDED. I NVESTIGATION REVEALED THAT THE SEAT BACK COULD BE MOVED APPROX 3 - 4 INCHES. DISASSEMBLY REVEALED THAT THE SET SCREW TH AT LOCKS ON A FLAT AREA OF THE SHAFT HAD LOOSENED ALLOWING THE CAM FREE TO ROTATE. ALSO, WHEN IT LOOSENED, IT ALLOWED T HE CAM TO MISALIGN WITH SUPPORT STRUCTURE AND MISS CONTACT. 1 H 7 1 3O 3 O NT TA13 E273 5 C P3EA 1998100900254 19981009 00254 SW 1998 10 9 CA980615008 1 19970914 G 2821 8975131 FILTER SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL FUEL SYSTEM FAILED W C ABORTED TAKEOFF R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 CA 35 P44424C DRG57282 (CAN) DURING TAKEOFF, THE FUEL BYPASS LIGHT CAME ON WITH A LOSS OF TORQUE ON NR 2 ENGINE. TROUBLESHOOTING WAS CARRIED O UT ON THE BYPASS AND FUEL SYSTEM. THE FLOW DIVIDER FILTER WAS CHECKED AND THE FUEL FILTER WAS REPLACED. GROUND RUNS CO MPLETED WITH NO FAULT FOUND. AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 1998091100465 19980911 00465 EA 1998 9 11 CA980616004 1 19970912 G 5521 SPAR C2TE1A DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985AN14B 52008 NE LT ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 8730 (CAN) LEFT ELEVATOR SPAR FOUND WITH .50 INCH CRACK AT OUTBOARD END NEAR THE OUTBOARD BEARING. SUBMITTER SAYS THAT PRO BLEM CAUSED BY DOCKHANDS USING ELEVATOR TIP TO MANEUVER AIRCRAFT FOR DEPARTURES AND ARRIVALS. 1 H 7 1 3R 3 R A806 5E1 1998111300736 19981113 00736 EU 1998 11 13 CA980915005 1 19971015 G 2750 6X77ONL312014 BOLT ZLIN 242 Z242L 9970204 EU TE FLAP BENT W K NONE O OTHER IN INSP/MAINT 1 CA 1550 (CAN) AT 1,500 HOUR INSPECTION, THE BOLT ATTACHING THE FLAP CONTROL CABLE TO THE BELLCRANK ARM WAS FOUND BENT APPROXIMAT ELY 9 DEGREES AT ITS MID-POINT. INSPECTION OF OPPOSITE BOLT ALSO FOUND BENT. IT IS SUSPECTED THAT THE BOLTS ARE BEING BENT WHEN THE FLAPS ARE SELECTED FULL DOWN WHERE THE AIR LOADS OF THE FLAP ARE TRANSMITTED ON EACH END OF THE SUBJECT BO LTS. 1 L 7 1 3O 0 A76EU 1998111300737 19981113 00737 EU 1998 11 13 CA980915006 1 19971103 G 2750 6X77ONL312014 BOLT ZLIN 242 Z242L 9970204 EU TE FLAP BENT W K NONE O OTHER IN INSP/MAINT 1 CA 1550 (CAN) FLAP CONTROL BELLCRANK BOLT FOUND BENT APPROXIMATELY 7 DEGREES AT ITS MID-POINT. BOTH SIDES THE SAME. 1 L 7 1 3O 0 A76EU 1998121800418 19981218 00418 EA 1998 12 18 CA981013007 1 19970822 G 2731 82700550001 CHAIN DHAV DHC8 DHC8311 1386006 EA ELEVATOR TRIM CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) CRACKS FOUND IN THE ELEVATOR TRIM CHAIN. PART TC: 7,282. 2 H 7 2 4T RT A13NM 1997042200006 19970422 00006 NE 1997 4 22 CHI1752 1 19970326 G 6520 643566400044 INTERMED GEARBOX SKRSKY S64 CH54A 8142501 NE LT MOUNT LUG CRACKED B CHIR K NONE O OTHER IN INSP/MAINT 1 NM 09 548CH 1578 1301 18461 UPON INSPECTION IAW COLUMBIA HELICOPTERS SB 54-65-2, THE LEFT LOWER INTERMEDIATE GEARBOX MOUNT LUG WAS FOUND CRACKED. T HIS WAS FOUND BY FLUORESCENT PENETRANT AND CONFIRMED BY EDDY CURRENT INSPECTIONS. THE CRACK APPEARED TO ORIGINATE AT TH E CORNER OF THE LUG AND PROGRESS TOWARDS THE MOUNT BOLT HOLE APPROXIMATELY .25 INCH LONG. THIS IS A TROUBLESOME AREA AN D THE SUBJECT OF THE ABOVE BULLETIN. SUBMITTER RECOMMENDS A DIFFERENT MATERIAL BE USED IN MANUFACTURE OF THE HOUSING. ( X) 2 G 7 2 4U H16NM 1997042400815 19970424 00815 WP 1997 4 24 CHI1753 1 19970320 G 6210 107R1202 BLADE KAWSKI KV107 KV1072 4820101 WP M/R SPAR VACUUM LEAK B CHIR K NONE O OTHER IN INSP/MAINT 1 NM 09 192CH 4735 A2188 4011 EVACUATED BLADE SPAR INDICATOR SYSTEM (ISIS) SHOWED POSITIVE. BLADE REMOVED FROM SERVICE TO INVESTIGATE SOURCE OF LEAK. THE LEAK WAS DETERMINED COMING FROM A SMALL CORROSION PIT WHICH IS LOCATED IN A TOOLING MARK AT STA 252. THE TOOLING MARK IS APPROXIMATELY 0.38 INCH IN LENGTH ON THE SURFACE OF THE SPAR. REVIEW OF AUG 96 X-RAYS DID NOT REVEAL THE DEFECT . THIS MINUTE DEFECT SHOWED THE EXCELLENT DETECTION CAPABILITIES OF THE ISIS SYSTEM. (X) 2 G 7 2 4U H1PC 1997052200534 19970522 00534 EA 1997 5 22 CHI1773 1 19970428 G 6220 234R21973 SLEEVE 234R21971 BOEING 234 234 1385049 EA M/R HEAD BROKEN B CHIR K NONE O OTHER IN INSP/MAINT 1 NM 09 239CH 1058 A20108 MJ006 THE HORIZONTAL HINGE PIN WAS REMOVED FOR A LEAKING SEAL. THE HINGE PIN WAS REMOVED AND THE LEADING SLEEVE REMAINED IN T HE BEARING. THE SLEEVE WAS SPLIT AND THE BEARING WAS REMOVED WITH THE SLEEVE STILL INSTALLED. A NEW BEARING AND HORIZO NTAL HINGE PIN WERE INSTALLED. THE ROTOR HEAD ASSY A5-1503 HAS ACCUMULATED 212 HOURS SINCE CENTER HUB REPLACEMENT. (X) 2 G 7 2 4U H9EA 1997061200826 19970612 00826 WP 1997 6 12 CHI1789 1 19970520 G 6310 5602326 SHAFT SPLINE HILLER UH12 UH12E 4360122 WP TRANSMISSION CRACKED B CHIR K NONE O OTHER IN INSP/MAINT 1 NM 09 62409 1455 UPPER AND LOWER TRANSMISSION COUPLING SPLINE SHAFT HAS ONE SPLINE CRACKED NEAR OUTER END OF SPLINE. REPLACED CRACKED SH AFT WITH SERVICEABLE UNIT. (X) 1 G 7 1 3O 4H11 1997061200841 19970612 00841 NE 1997 6 12 CHI1791 1 19970523 G 6210 S50F11111SN56A LOCKED IN STUD REXNORD 641520201044 SKRSKY S64 CH54A 8142501 NE M/R BLADE BROKE B CHIR K NONE O OTHER IN INSP/MAINT 1 NM 09 548CH 4058 18461 M/R BLADE STUD BROKE (IN TENSION) DIRECTLY BELOW LOCK RING SPLINES ABOVE FIRST THREAD. REPLACED AFFECTED MAIN ROTOR BLA DE WITH SERVICEABLE BLADE. 2 G 7 2 4U H16NM 1997070300135 19970703 00135 EA 1997 7 3 CHI1801 1 19970603 G 6220 234R21971 PIN 414R2001 BOEING 234 234 1385049 EA FWD YELLOW ARM SLIPPED B CHIR K NONE O OTHER IN INSP/MAINT 1 NM 09 CFHFH 387 A20134 MJ001 ROTOR HEAD WAS INSPECTED WHILE IN THE SHOP FOR ROUTINE MAINTENANCE. IT WAS NOTED THAT THE YELLOW ARM WAS STIFF WHEN MOV ED DOWN ITS HORIZONTAL AXIS (FLAPPING). DISASSEMBLY SHOWED THE LAG BEARING RACE ON THE HORIZONTAL PIN HAD MOVED OUTBOAR D TILL IT TOUCHED THE LAG CAP. CAUSE MAY BE INADEQUATE INTERFERENCE FIT BETWEEN THE PIN AND THE BEARING RACE. (X) 2 G 7 2 4U H9EA 1997101600016 19971016 00016 EA 1997 10 16 CHI1906 1 19970923 G 6300 A02D31473R SHAFT A02D301110 BOEING 107 1072 9420604 EA UPPER PIN HOLE CRACK B CHIR K NONE O OTHER IN INSP/MAINT 1 NM 09 2FOR 2619 NI0289UT 5 DURING ROUTINE 100-HOUR EDDY CURRENT INSPECTION OF SHAFT PIN HOLES, A POSITIVE INDICATION WAS DETECTED. SHAFT WAS REMOV ED FROM THE AIRCRAFT AND SENT TO THE SHOP FOR EVALUATION. MAGNETIC PARTICLE INSPECTION REVEALED A CRACK APPROXIMATELY 0 .150 INCH LONG FROM ONE PIN HOLE. NO OTHER DEFECTS NOTED. PART IS BEING FORWARDED TO BOEING HELICOPTERS FOR FURTHER EV ALUATION. (X) 2 G 7 2 4U 1H16 1997103000385 19971030 00385 EA 1997 10 30 CHI1912 1 19970925 G 6310 107DS2131 CLUTCH 107D2003516 BOEING 107 1072A 9420606 EA MIX BOX NR 1 SLIPPED B CHIR O OTHER O OTHER NR NOT REPORTED 1 NM 09 CGHFI 18119 9 XBW1612 5 AFTER NR 1 IDLER ASSY HAD BEEN REPLACED, AIRCRAFT'S NR 1 CLUTCH, WITH 8.7 HOURS, REPORTED SLIPPING. TRANSMISSION REPLAC ED AND NR 1 IDLER ASSY DISASSEMBLED. AT THAT TIME IT WAS VISUALLY INSPECTED, PARTS WERE ALSO DIMENSIONALLY CHECKED. AI RCRAFT HAD SAME PROBLEM 01-30-97. TSO, 309.9 HOURS. TT, 17,056.3 HOURS. (X) 2 G 7 2 4U 1H16 1997103000384 19971030 00384 EA 1997 10 30 CHI1913 1 19970925 G 6310 107DS2131 CLUTCH 107D2003516 BOEING 107 1072A 9420606 EA MIX BOX NR 1 SLIPPED B CHIR O OTHER O OTHER EX EXTERNAL LOAD 1 NM 09 CGHFI 18110 1 XBW1627 5 NR 1 CLUTCH REPORTED SLIPPING DURING LOGGING OPERATION. NR 1 IDLER ASSY REMOVED AND DISASSEMBLED. VISUAL AND DIMENSION AL CHECK DONE ON PINION SPUR GEAR, IDLER HUB, AND CLUTCH SET. NO PROBLEM FOUND. AIRCRAFT HAD SAME PROBLEM 01-03-97 TSO , 309.9 HOURS. TT, 17,065.3 HOURS. (X) 2 G 7 2 4U 1H16 1997102300229 19971023 00229 1997 10 23 CHI1916 4 19970821 G 2211 COMPUTER HONEYWELL 234VS1007 BOEING 234 234 1385049 EA NR 1 AFCS MALFUNCTION B CHIR O OTHER O OTHER CR CRUISE 1 NM 09 2FOR M0008 MJ005 A YAW KICK WAS FELT IN-FLIGHT. THE KICK WAS ISOLATED TO THE NR 2 AFCS SYSTEM. SUBSEQUENT TROUBLESHOOTING REVEALED THE P ROBLEM TO BE THE NR 2 AFCS COMPUTER CAUSING THE YAW KICK. A SECOND SPARE COMPUTER WAS INSTALLED IN NR 2 POSITION AND TH E SAME PROBLEM WAS THERE. ALSO, A LARGE ENGAGEMENT ERROR WAS NOTICED WHEN TURNING THE SYSTEM ON AND OFF. FINALLY, REPL ACED THE NR 1 AFCS COMPUTER FOR TROUBLESHOOTING AND THE PROBLEM WAS GONE. (X) 2 G 7 2 4U H9EA 1997103000396 19971030 00396 EA 1997 10 30 CHI1921 1 19970930 G 6710 234HS5603 ACTUATOR BOEING 234 234 1385049 EA STICK BOOST MALFUNCTION B CHIR K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 NM 09 241CH 2431 0066V MJ016 ON START-UP, PILOT WAS DOING CONTROL CHECK AND NOTICED HE COULD NOT GET THE FULL TRAVEL AFT THAT IS NORMAL WHILE DOING T HE CONTROL CHECKS. TROUBLESHOOTING REVEALED THAT IF ONLY ONE HYDRAULIC SYSTEM WAS SELECTED, THE ACTUATOR WOULD START BI NDING AND NOT PERMIT FULL TRAVEL OF THE CYCLIC STICK FORWARD OR AFT. IF BOTH HYDRAULIC SYSTEMS WERE SELECTED, THERE WAS NO BINDING IN THE ACTUATOR. THERE WAS NO INDICATION OF A JAMMED ACTUATOR ACCORDING TO THE JAM INDICATOR BUTTONS. REPL ACED ACTUATOR, CONTROL AND TRAVEL CHECKS WERE GOOD. 2 G 7 2 4U H9EA 1997103000383 19971030 00383 EA 1997 10 30 CHI1923 1 19971002 G 2913 PUMP MOTOR SPERRYVICRS BOEING 234 234 1385049 EA AGB HYD LEAKING B CHIR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 09 P2CHI MX358828B MJ003 AT SHUT DOWN OF AIRCRAFT WHILE STARTING APU, AGB HYDRAULIC MOTOR PUMP STARTED LEAKING AND SPRAYING HYDRAULIC OIL. AFTER SHUTTING DOWN OF APU AND CLOSER INSPECTION OF AGB PUMP, FOUND CASE HALF MOUNTING EARS CRACKED IN HALF WHICH SEPARATED B ACK HALF OF PUMP FROM FORWARD DRIVE SECTION. CAUSE UNKNOWN. (X) 2 G 7 2 4U H9EA 1997121100123 19971211 00123 EA 1997 12 11 CHI1957 1 19971119 G 6510 107D33421 ADAPTER BOEING 107 1072 9420604 EA DRIVE SHAFT MISALIGNED B CHIR K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 09 A8671 NEW PART RECEIVED AND ADAPTER HOLES MISALIGNED. (X) 2 G 7 2 4U 1H16 1998043000262 19980430 00262 EA 1998 4 30 CHI2007 1 19970129 G 6310 107DS2131 CLUTCH 107D2003515 BOEING 107 1072 9420604 EA NR 2 SLIPPING B CHIR K NONE O OTHER NR NOT REPORTED 1 NM 09 CGHFI 310 XBW1574 5 NR 2 CLUTCH SLIPPING. (X) 2 G 7 2 4U 1H16 1998043000261 19980430 00261 EA 1998 4 30 CHI2012 1 19971220 G 6220 114RS2133 BEARING 414R200219 BOEING 234 234 1385049 EA AFT ROTOR SPALLED B CHIR K NONE K FLUID LOSS IN INSP/MAINT 1 NM 09 P2CHI 8902 WS3187 MJ003 AFTER SHUTDOWN, NOTICED EXCESSIVE OIL LEAKING FROM AFT HEAD. CLOSER INSPECTION AND SUBSEQUENT REMOVAL OF RED HORIZONTAL HINGE PIN BEARING END CAP REVEALED METAL SHAVINGS COMING FROM RED LEADING HORIZONTAL BEARING. AFTER FURTHER DISASSEMBL Y, FOUND A CRACKED HORIZONTAL HINGE PIN SLEEVE. CAUSE UNKNOWN. (X) 2 G 7 2 4U H9EA 1999040200487 19990402 00487 SW 1999 4 2 CZMA061345 1 19970317 G 2120 212073927003 CONTROLLER BELL 412 412 1182202 SW AIR DISTRIBUTION WORN E CZMA K NONE O OTHER IN INSP/MAINT 1 SO 03 911BE 3358 36018 SERVO INOPERATIVE. 1 G 7 2 4U H4SW 1999040900678 19990409 00678 SW 1999 4 9 CZMA061409 1 19970317 G 2160 212073927001 MOTOR BELL 412 412 1182202 SW TEMP CONTROL WORN E CZMA K NONE O OTHER IN INSP/MAINT 1 SO 03 911BE 3358 36018 MOTOR TEMPERATURE CONTROL INOPERATIVE. 1 G 7 2 4U H4SW 1997102300426 19971023 00426 GL 1997 10 23 GCHA0000013 2 19970817 G 7320 23064693 FADEC BELL 407 407 SW ALLSN 250C 250C47B GL NR 1 ENGINE MALFUNCTION B GCHR A UNSCHED LANDING J WARNING INDICATION HO HOVERING 1 WP 19 175PA JG7ALK0319 53154 847179 DURING POST-INSPECTION TEST FLIGHT, AIRCRAFT EXPERIENCED A FADEC DEGRADE AND RESTART FAULT LIGHT. THIS OCCURRED WHILE I N HOVER PERFORMING A POWER CHECK. AIRCRAFT WAS LANDED AND PILOT ATTEMPTED TO ROLL THROTTLE TO IDLE. WHILE FADEC WAS ST ILL IN AUTOMODE, NR AND NP REMAINED AT 100 PERCENT. MANUAL MODE WAS SELECTED AND THE NR AND NP RETURNED TO IDLE. AFTER THE ENGINE WAS SHUT DOWN, THE LAP TOP COMPUTER LINK REVEALED FADEC DEGRADE. NO FAULT AND RESTART FAULT INDICATED. (X) 1 G 7 1 3U 3 U O H2SW E1GL 1997102300431 19971023 00431 GL 1997 10 23 GCHR0000012 2 19970926 G 7320 23068348 FADEC BELL 407 407 SW ALLSN 250C 250C47B GL NR 1 ENGINE WATER CONTAM B GCHR H A DEACTIVATE SYST/CIRCUITS UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 WP 19 176PA 26 JGALK0315 53160 847179 FADEC FAILURE LIGHT ILLUMINATED IN DEPARTURE TRANSITION. PILOT SWITCHED TO MANUAL MODE AND LANDED AIRCRAFT. AIRCRAFT BEGAN ENGINE OVERSPEED, SYSTEM BACK-UPS CUT IN AND SHUT DOWN ENGINE. SYSTEM TROUBLESHOOTING FAILED TO RETRIEVE FLASH CO DES. ENTRY TO ECU BY LAP TOP LINK FAILED, NO ECU AVAILABLE. ALLISON REPORT ENGINE REMOVED FOR OVERSPEED OVERHAUL. CYC LES, 18. (X) 1 G 7 1 3U 3 U O H2SW E1GL 1997102300430 19971023 00430 SW 1997 10 23 GCHR0000016 1 19971001 G 6322 406040320101 SHAFT BELL 407 407 SW COOLER BLOWER WORN B GCHR K NONE O OTHER IN INSP/MAINT 1 WP 19 176PA 53160 SHAFT IS DIMENSION UNDER MINIMUM. PRODUCT ENGINEERING RECOMMENDS REPLACE SHAFT WITH 407-040-316-101 ADAPTER. (X) 1 G 7 1 3U O H2SW 1997102300429 19971023 00429 SW 1997 10 23 GCHR0000017 1 19971001 G 6322 406040339105 BEARING BELL 407 407 SW T/R O/C SHAFT ROUGH B GCHR K NONE O OTHER IN INSP/MAINT 1 WP 19 176PA 244 53160 PART IS ROUGH. FOUND FORWARD BEARING WORN WHEN REPLACING O/C DRIVESHAFT AND ADAPTER. REMOVED AND REPLACED BEARING. (X ) 1 G 7 1 3U O H2SW 1997102300428 19971023 00428 SW 1997 10 23 GCHR0000019 1 19971001 G 5302 206032305129A ANGLE BELL 407 407 SW TAIL BOOM CRACKED B GCHR K NONE O OTHER IN INSP/MAINT 1 WP 19 176PA 244 53160 ANGLE IS CRACKED. DURING O/C SHAFTING INSPECTION, THE O/C WAS REMOVED. WHEN TRYING TO SECURE THE ATTACHING HARDWARE TO PREVENT LOSS, THE MECHANIC REMOVED AND REPLACED ANGLE. (X) 1 G 7 1 3U O H2SW 1997102300427 19971023 00427 SW 1997 10 23 GCHR0000020 1 19971001 G 5311 206032305127 FRAME BELL 407 407 SW TAIL BOOM CRACKED B GCHR K NONE O OTHER IN INSP/MAINT 1 WP 19 176PA 244 53160 FRAME IS CRACKED. DURING O/C SHAFT-ADAPTER INSPECTION, NUTPLATE WAS FOUND CRACKED. UPON FURTHER INSPECTION, 127 FRAME WAS ALSO FOUND CRACKED. REMOVED AND REPLACED FRAME. (X) 1 G 7 1 3U O H2SW 1997041700557 19970417 00557 NM 1997 4 17 GJOR323E 1 19970314 G 6320 A0061 GEARBOX ROBSIN R22 R22BETA NM M/R GEARBOX MAKING METAL B GJOR K NONE O OTHER IN INSP/MAINT 1 NM 01 4046A 1707 1840 1676 AFTER A TRAINING FLIGHT, PILOT NOTIFIED MAINT OF A STRANGE NOISE THAT APPEARED TO BE EMANATING FROM THE DRIVE SYSTEM. A FTER A VISUAL OF THE MAIN AND TAIL ROTOR DRIVE SYSTEMS, A MAINT GROUND RUN WAS PERFORMED. MAINT CONFIRMED A MEDIUM TO L OW FREQUENCY NOISE RELATED TO THE A006-1 MAIN GEARBOX. THE MAIN GEARBOX CHIP DETECTOR WAS REMOVED AND FOUND COVERED WIT H FERROUS. (X) 1 G 7 1 3O H10WE 1997032700267 19970327 00267 SW 1997 3 27 GJQR97106 1 19970224 G 2915 212076006105 VALVE BELL 212 212 1181420 SW HYD SYS DEFECTIVE H GJQR K NONE O OTHER IN INSP/MAINT 1 SW 13 98W 138 35100 THIS VALVE TRIPS THE REMOTE FILTER CLOGGED INDICATOR WHEN POWER IS APPLIED. INDICATORS ON FILTER ASSY. DO NOT TRIP. F ILTERS ARE CLEAN. REPLACED WITH NEW UNIT FROM BELL HELICOPTER. 1 G 7 1 4U H4SW 1997020600556 19970206 00556 CE 1997 2 6 GMCR97001 1 19970124 G 5610 99143792 WINDOW CESSNA 650 650 2076802 CE RT COCKPIT SHATTERED B GMCR O OTHER O OTHER CR CRUISE 1 GL 23 5118 2177 63H6967 6507013 THIRTY MINUTES AFTER DEPARTURE FROM SLC, THE CREW HEARD A LOUD BANG, AND NOTICED THE OUTER PANE OF THE RIGHT COCKPIT WIN DOW HAD SHATTERED. THE CREW DECLARED AN EMERGENCY AND HAD AN UNEVENTFUL LANDING BACK AT SLC. NO FRAGMENTS OF THE OUTER PANE HAD SEPARATED CREATING ANY FURTHER DAMAGE. REPLACED THE COCKPIT WINDOW. 2 L 7 2 4F A9NM 1997061200878 19970612 00878 SW 1997 6 12 HAI00010003 1 19970602 G 6330 206033516101 FLEXURE BELL 206 206L1 1182107 SW M/R WORN H K NONE O OTHER IN INSP/MAINT 1 FS 01 2251A 45755 FLEXURE BEARINGS WORN AND UNSTAKED. 1 G 7 1 3U H2SW 1997061200879 19970612 00879 SW 1997 6 12 HAI00010066 1 19970606 G 7722 3030083 TRIM COMPENSATOR BELL 412 412 1182202 SW NR 2 ENGINE DEFECTIVE H K NONE O OTHER IN INSP/MAINT 1 FS 01 6559Z 36019 #2 ENGINE ITT INDICATOR IS ERRATIC. TRIM COMPENSATOR FAULTY. 1 G 7 2 4U H4SW 1998042400272 19980424 00272 SW 1998 4 24 HAIGJQR0106 1 19970224 G 2915 212076006105 VALVE BELL 212 212 1181420 SW HYD SYS FAILED H GJQR K NONE O OTHER IN INSP/MAINT 1 SW 13 98W 138 35100 VALVE TRIPS THE REMOTE FILTER CLOGGED INDICATOR WHEN POWER IS APPLIED. INDICATORS ON FILTER ASSY. DO NOT TRIP. FILTERS ARE CLEAN. REPLACED WITH NEW UNIT FROM BELL HELICOPTER. 1 G 7 1 4U H4SW 1998042400273 19980424 00273 SW 1998 4 24 HAIGJQR0107 1 19970224 G 3040 204070907011 WIPER ASSY BELL 212 212 1181420 SW WINDSHIELD FAILED H GJQR K NONE O OTHER IN INSP/MAINT 1 SW 13 98W 177 35100 WIPER ASSY. BROKEN AT OUTBOARD PIVOT PIN. REPLACED WITH NEW UNIT FROM BELL HELICOPTER. 1 G 7 1 4U H4SW 1998042400274 19980424 00274 SW 1998 4 24 HAIGJQR0108 1 19970224 G 7931 1300203 TRANSMITTER BELL 212 212 1181420 SW OIL PRESS FAILED H GJQR K NONE O OTHER IN INSP/MAINT 1 SW 13 98W 161 35100 NO PRESSURE INDICATION ON GAUGE WITH 80 PSI SYSTEM PRESSURE. REPLACED WITH NEW UNIT FROM BELL HELICOPTERS 1 G 7 1 4U H4SW 1998042400275 19980424 00275 SW 1998 4 24 HAIGJQR0109 1 19970224 G 7931 1300205 TRANSMITTER BELL 212 212 1181420 SW OIL PRESS FAILED H GJQR K NONE O OTHER IN INSP/MAINT 1 SW 13 98W 183 35100 PRESSURE GAUGE INDICATES 0 PSI WITH ENGINE RUNNING & 75PSI SYSTEM PRESSURE. REPLACED WITH NEW UNIT FROM BELL HELICOPTER. 1 G 7 1 4U H4SW 1998042400276 19980424 00276 SW 1998 4 24 HAIGJQR0110 1 19970324 G 5610 212030464001 WINDSHIELD BELL 212 212 1181420 SW COCKPIT DAMAGED H GJQR K NONE O OTHER CR CRUISE 1 SW 13 98W 177 35100 WINDSHIELD WAS DEEPLY SCRATCHED BY WIPER ASSY. THAT BROKE DURING FLIGHT. REPLACED WITH NEW WINDSHIELD 1 G 7 1 4U H4SW 1998042400277 19980424 00277 SW 1998 4 24 HAIGJQR0111 1 19970324 G 6210 212015501115 BLADE BELL 212 212 1181420 SW M/R PEELING H GJQR K NONE O OTHER IN INSP/MAINT 1 SW 13 98W 138 35100 LARGE PATCHES OF PAINT PEELING FROM BLADES. 1 G 7 1 4U H4SW 1998042400278 19980424 00278 SW 1998 4 24 HAIGJQR0133 1 19970617 G 7920 206040525101 FILTER HOUSING BELL 206 206L 1181522 SW OIL SYS LEAKS H GJQR K NONE K FLUID LOSS IN INSP/MAINT 1 SW 13 97PM 59 52187 FILTER HOUSING OIL LEAKS 1 G 7 1 3U H2SW 1998042400279 19980424 00279 SW 1998 4 24 HAIGJQR0134 1 19970617 G 7920 206040525101 FILTER HOUSING BELL 206 206L 1181522 SW OIL SYS LEAKS H GJQR K NONE K FLUID LOSS IN INSP/MAINT 1 SW 13 97PM 2 52187 FILTER HOUSING OIL LEAKS 1 G 7 1 3U H2SW 1998042400280 19980424 00280 SW 1998 4 24 HAIGJQR0135 1 19970617 G 7920 206040129001 FILTER HOUSING BELL 206 206L 1181522 SW OIL SYS LEAKS H GJQR K NONE K FLUID LOSS IN INSP/MAINT 1 SW 13 97PM 59 52187 FILTER HOUSING OIL LEAKS 1 G 7 1 3U H2SW 1997101600308 19971016 00308 SW 1997 10 16 HAIGJQR0144 1 19971013 G 7931 209070262101 INDICATOR BELL 212 212 1181420 SW ENG OIL READS HIGH H GJQR K NONE O OTHER IN INSP/MAINT 1 FS 01 98W 365 35100 ENG OIL TEMP PRESS INDICATOR READS HIGH. REPLACED WITH NEW PART FROM BELL. 1 G 7 1 4U H4SW 1998042400281 19980424 00281 SW 1998 4 24 HAIGJQR0147 1 19971024 G 6320 412040111105 SEAL BELL 212 212 1181420 SW INPUT PINNION LEAKING H GJQR K NONE K FLUID LOSS IN INSP/MAINT 1 FS 01 98W 376 35100 SEAL LEAKING AN UNACCEPTABLE AMOUNT OF OIL. REPLACED WITH NEW SEAL FROM BHT. 1 G 7 1 4U H4SW 1998042400282 19980424 00282 SW 1998 4 24 HAIGJQR0148 1 19971024 G 6320 214040805001 THERMOSWITCH BELL 206 206L 1181522 SW M/R GR BOX SHORTED H GJQR K NONE K FLUID LOSS IN INSP/MAINT 1 FS 01 97PM 81 52187 SHORTED - KEEPS LIGHT ON. REPLACED WITH NEW PART FROM CSF. 1 G 7 1 3U H2SW 1998042400283 19980424 00283 SW 1998 4 24 HAIGJQR0158 1 19971231 G 6320 B3703 CHIP DETECTOR BELL 212 212 1181420 SW XMSN DEFECTIVE H GJQR K NONE O OTHER IN INSP/MAINT 1 FS 01 98W 472 35100 NO GROUNDING POINTS THROUGH LOCKING PINS & CASE. REPLACED WITH NEW PART FROM BHT 1 G 7 1 4U H4SW 1997041000470 19970410 00470 GL 1997 4 10 HAIHEEA9214 2 19970318 G 7250 23055430 NOZZLE 23031899 ALLSN 250C 250C20B 03013 GL NR 2 DEFECTIVE E HEEA K NONE R PARTIAL RPM/PWR LOSS IN INSP/MAINT 1 SW 03 CAT70200 ENGINE REMOVED DUE TO TURBINE OVERHAUL. TURBINE DISASSEMBLED DUE TO LOW POWER ON TEST CELL. DISASSEMBLY INSPECTION REVE ALED: MATERIAL FLAKING AND MISSING ON #2 NOZZLE #2 TIP PATH. INSTALLED A DALLAS AIRMOTIVE OVERHAULED #2 NOZZLE. 3 U E4CE 1997041000476 19970410 00476 GL 1997 4 10 HAIHEEA9220 2 19970319 G 7260 23055466 GEARBOX COVER 6894171 ALLSN 250C 250C20B 03013 GL ACCY GR BOX DEFECTIVE E HEEA K NONE W K INADEQUATE Q C FLUID LOSS IN INSP/MAINT 1 SW 03 CAG37111 CAE820964F GEARBOX DISASSEMBLED DUE TO AFT T/M LEAK ON TEST CELL. DISASSEMBLY INSPECTION REVEALED: AFT BUSHING HEIGHTH EXCEEDS PR INT DIMENSION ON GEARBOX COVER. INSTALLED A DALLAS AIRMOTIVE REPAIRED GEARBOX COVER. TIME SINCE REPAIR 0:00. 3 U E4CE 1997041000480 19970410 00480 GL 1997 4 10 HAIHEEA9225 2 19970321 G 7250 23008054 NOZZLE ALLSN 250C 250C28B 03013 GL NR 1 BELOW SPEC E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 RECEIVING INSPECTION REVEALED: MEASURED .044 BELOW MIN. SPECS (6.200) ON #1 NOZZLE AFT ROPE PACKING INNER RIM ID. 3 U E1GL 1997050800028 19970508 00028 1997 5 8 HAIHEEA9446 4 19970419 G 3442 MI5853011 INDICATOR HONEYWELL P500 COCKPIT FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 RADAR INDICATOR DISPLAY SHAKES AND IS DISTORTED. 1997051500227 19970515 00227 1997 5 15 HAIHEEA9505 4 19970423 G 3457 0110005400 GPS 150 GARMIN COCKPIT DEFECTIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 COCKPIT GPS DIRECT TO BUTTON IS UNREADABLE. 1997051500911 19970515 00911 EA 1997 5 15 HAIHEEA9582 2 19970424 G 7200 ENGINE PWA PT6 PT6A41 52043 EA POWER PLANT NOISY E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 PCE80435 ENGINE MAKING NOISE. TIME SINCE REPAIR 0:00. 4 T E4EA 1997052200258 19970522 00258 1997 5 22 HAIHEEA9626 4 19970429 G 3416 LE511 ALTIMETER COCKPIT ENCODER MALFUNCTION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 MODE C READING VERY HIGH FROM TOWER ALTITUDE. 1997061200374 19970612 00374 1997 6 12 HAIHEEA9750 4 19970430 G 3452 C2080A PULSE OSCILLATO KING KT76A TRANSPONDER DEFECTIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 CATHODE PULSE OSCILLATOR CAUSES TRANSPONDER UNIT (KT76A) TO DRAW MORE CURRENT THAN NORMAL. 1997061200920 19970612 00920 1997 6 12 HAIHEEA9843 4 19970513 G 2350 1022824202 HEADSET COCKPIT INTERMITTENT E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 HEADSET INTERMITTENT. 1997061200923 19970612 00923 1997 6 12 HAIHEEA9848 1 19970513 G 3411 10100164 PITOT STATIC AIR SPEED LEAKS E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 STATIC SYS LEAKS DURING PITOT AND STATIC TEST. AIRSPEED INOPERATIVE. 1997061900398 19970619 00398 1997 6 19 HAIHEEA9865 4 19970513 G 3416 6302 ALTITUDE INDICAT COCKPIT ALT STICKS E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 INDICATOR DOES NOT READ CORRECTLY. INDICATOR STAYS STUCK INTERMITTENTLY. 1997062600385 19970626 00385 1997 6 26 HAIHEEA9976 4 19970530 G 3423 2593379001 COMPENSATOR HONEYWELL NR 1 COMPASS DEFECTIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 #1 COMPASS SYSTEM OFF BY 10. 1997041000507 19970410 00507 SW 1997 4 10 HAIW6HR0066 1 19970108 G 6220 222310115117 BEARING 222011101105 BELL 222 222U 1182140 SW M/R WORN EXCESSIVELY E W6HR K NONE O OTHER IN INSP/MAINT 1 WP 21 429MA 1931 47523 PART IS WORN EXCESSIVELY. ELASTOMERIC MATERIAL IS SEPERATING. BEARING WAS PUT IN SERVICE 16 JAN. 1988. PART HELD FOR F UTURE EVALUATION. 1 G 7 2 3U H9SW 1997041000508 19970410 00508 SW 1997 4 10 HAIW6HR0067 1 19970108 G 6220 222310115117 BEARING 222011101105 BELL 222 222U 1182140 SW M/R WORN EXCESSIVELY E W6HR K NONE O OTHER IN INSP/MAINT 1 WP 21 416MA 1189 47526 PART IS WORN EXCESSIVELY. ELASTOMERIC MATERIAL IS SEPERATING. BEARING WAS PUT IN SERVICE 14 JUL. 1989. PART HELD FOR FUT URE EVALUATION. 1 G 7 2 3U H9SW 1997041000509 19970410 00509 SW 1997 4 10 HAIW6HR0068 1 19970113 G 6220 222310115115 BEARING 222011101105 BELL 222 222U 1182140 SW M/R WORN EXCESSIVELY E W6HR K NONE O OTHER IN INSP/MAINT 1 WP 21 416MA 1454 A29 47526 PART IS WORN EXCESSIVELY. ELASTORMERIC EXTRUSION, DELAMINATION & SEPERATION. UNIT FIRST PUT INTO SERVICE 08-03 1983. 1 G 7 2 3U H9SW 1997041000510 19970410 00510 SW 1997 4 10 HAIW6HR0069 1 19970122 G 6230 204011402125 RING ASSY 412010402101 BELL 412 412 1182202 SW M/R MAST WORN EXCESSIVELY E W6HR K NONE O OTHER IN INSP/MAINT 1 WP 21 401MA 137 RE0055 33060 PART IS WORN EXCESSIVELY. GIMBAL SUPPORT BUSHING AREA ELONGATED. 1 G 7 2 4U H4SW 1997041000511 19970410 00511 NE 1997 4 10 HAIW6HR0072 2 19970211 G 7310 430128602 FUEL MANIFOLD BELL 222 222U 1182140 SW LYC LTS101 LTS101750C1 41560 NE ENGINE DEFECTIVE E W6HR E ENGINE SHUTDOWN A FLAME/FIRE IN INSP/MAINT 1 WP 21 429MA 47523 LE47194 ENGINE SHOOTS OUT 2 FOOT FLAME PAST EXHAUST EJECTOR DURING START WITHOUT ANY MGT INDICATION UNTIL START PROGRESSES, THEN REMAINDER OF START IS NORMAL. SUSPECT EXCESS FUEL GETTING INTO ENGINE AT BEGINNING OF START ENGAGEMENT. SHIPPED CORE RE TURN MANIFOLD TO RMH 02-11-97, SHIPPING MEMO# 97-0065. RDM 02/14/97. 1 G 7 2 3U 3 U H9SW E5NE 1997041000512 19970410 00512 SW 1997 4 10 HAIW6HR0076 1 19970313 G 3340 4501283 LIGHT 222175302105 BELL 222 222U 1182140 SW EXT SEARCH BINDING E W6HR K NONE O OTHER IN INSP/MAINT 1 WP 21 429MA 47523 PART IS BINDING. ASSY. WILL NOT MOVE IN ANY DIRECTION. PART HAS BEEN IN SERVICE 3 MONTHS. REQUEST ASSY. TO BE REPAIRED UNDER WARRANTY. REPLACED LIGHT ASSY WITH SERVICEABLE UNIT. 1 G 7 2 3U H9SW 1997041000513 19970410 00513 SW 1997 4 10 HAIW6HR0077 1 19970323 G 2435 23032048 GENERATOR 222060060107 BELL 222 222B 1182124 SW START/GEN ARCED E W6HR K NONE O OTHER IN INSP/MAINT 1 WP 21 406MA LE47154AE 47134 PART IS ARCED. COMMUTATOR APPEARS TO HAVE BURNED SPOTS. STATIC IS HEARD THRU ALL HEAD SETS. REQUEST WARRANTY REPAIR SI NCE THIS UNIT HAS ONLY BEEN IN SERVICE 22.0 HRS / 2 MONTHS. REPLACED WITH TSO:0 UNIT. ALL SYS. FUNCTION PROPERLY. 1 G 7 2 3U H9SW 1997041000514 19970410 00514 SW 1997 4 10 HAIW6HR0078 1 19970328 G 6320 222040061105 CASE ASSY 222040003111 BELL 222 222 1182122 SW M/R DEFECTIVE E W6HR K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 21 PART IS DEFECTIVE. FOUND BOTH SMALLER BORE OIL PASSAGES WHICH SUPPLY OIL TO THE #3 JETS (3EA.) & MAST BEARING TO BE CLO GGED (BETWEEN THE VERTICAL PASSAGE & THE JET BORE) WITH A HARDENED EPOXY - LIKE SUBSTANCE. UPON REMOVAL OF THE EPOXY - LIKEMATERIAL, FOUND BOTH PASSAGES TO BE IN AN UN-FINISHED STATE (NOT COMPLETELY BORED OUT) WHERE THE ANGLED PASSAGES MEE T THE VERTICAL PASSAGES. REPLACED WITH ANOTHER NEW TOP CASE ASSY. 1 G 7 2 3U H9SW 1997041000515 19970410 00515 SW 1997 4 10 HAIW6HR0079 1 19970328 G 6320 222040061105 CASE ASSY 222040003111 BELL 222 222 1182122 SW M/R DEFECTIVE E W6HR K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 21 PART IS DEFECTIVE. FOUND BOTH SMALLER BORE OIL PASSAGES WHICH SUPPLY OIL TO THE #3 JETS (3EA.) & MAST BEARING TO BE CLOG GED (BETWEEN THE VERTICAL PASSAGE & THE JET BORE) WITH A HARDENED EPOXY - LIKE SUBSTANCE. UPON REMOVAL OF THE EPOXY - LI KEMATERIAL, FOUND BOTH PASSAGES TO BE IN AN UN-FINISHED STATE (NOT COMPLETELY BORED OUT) WHERE THE ANGLED PASSAGES MEET THE VERTICAL PASSAGES. THIS IS THE SECOND OCCURRENCE OF THIS SAME TYPE (PREVIOUS OCCURRENCE ON TOP CASE S/N: A217. REPLA CED WITH ANOTHER NEW TOP CASE ASSY. 1 G 7 2 3U H9SW 1997091100567 19970911 00567 SW 1997 9 11 HAIW6HR0080 1 19970429 G 2913 2226513201 PUMP 222180002111 BELL 222 222B 1182124 SW HYD SYS WORN EXCESS E W6HR K NONE O OTHER IN INSP/MAINT 1 WP 21 406MA 47134 PART IS WORN EXCESSIVELY. PUMP LEAKS AT SHAFT SEAL. 1 G 7 2 3U H9SW 1997091100568 19970911 00568 SW 1997 9 11 HAIW6HR0084 1 19970520 G 6340 222375013103 TORQUE SENSOR 222040003117 BELL 222 222U 1182140 SW ROTOR FLUCTUATES E W6HR K NONE O OTHER IN INSP/MAINT 1 WP 21 429MA 179 47523 ROTOR TORQUE NEEDLE FLUCTUATES ABOVE 85% ROTOR TORQUE. PART IN SERVICE 4 MONTHS / 178.9 HOURS. REPLACED SENSOR. 1 G 7 2 3U H9SW 1997091100569 19970911 00569 SW 1997 9 11 HAIW6HR0085 1 19970603 G 5311 222031503101 FRAME ASSY 222031501125 BELL 222 222U 1182140 SW BS 233 CRACKED E W6HR K NONE O OTHER IN INSP/MAINT 1 WP 21 415MA 2772 47568 FRAME ASSY IS CRACKED. CRACKED @ R/H CORNER THRU FASTNER HOLES. PERFORMED REPAIR I/A/W BHT FIELD REPAIR PROCEDURE 96 R1-036 REV. A D.O.T. S.O.C. SERIAL # A4753, DATED 3-19-97. 1 G 7 2 3U H9SW 1997091100570 19970911 00570 SW 1997 9 11 HAIW6HR0086 1 19970603 G 5320 ROOF 222031501125 BELL 222 222U 1182140 SW CABIN CRACKED E W6HR K NONE O OTHER IN INSP/MAINT 1 WP 21 415MA 47568 PART IS CRACKED. ROOF WAS CRACKED DUE TO FRAME ASSY P/N: 222-031-503-101 (STA 233) CRACKING. INSTALLED STRAP DOUBLER P/ N: 222-031-517-179 I/A/W BHT TB 222U-91-56, DATED 1-15-91. 1 G 7 2 3U H9SW 1997091100571 19970911 00571 SW 1997 9 11 HAIW6HR0087 1 19970603 G 5330 222031361121 PANEL ASSY 222131004109 BELL 222 222U 1182140 SW BS 233 CRACKED E W6HR K NONE O OTHER IN INSP/MAINT 1 WP 21 415MA 2772 47568 PANEL ASSY IS CRACKED. APPROX. 10 INCH CRACK STARTING @ R/H AFT CORNER GOING FOWARD AND TOWARDS THE LEFT. THIS CRACK HAPPENED DUE TO STA. 233 FRAME ASSY. P/N: 222-031-503-101 CRACKING. PERFORMED BHT FIELD REPAIR PROCEDURE 96R1-037, D.O. Y. S.O.C. SERIAL # A4266, DATED 11-27-96. 1 G 7 2 3U H9SW 1997091100572 19970911 00572 SW 1997 9 11 HAIW6HR0088 1 19970626 G 6340 506923 TORQUE SENSOR 222040003117 BELL 222 222U 1182140 SW ROTOR FAILED E W6HR K NONE O OTHER CR CRUISE 1 WP 21 429MA 47523 TORQUE SENSOR HAS RESISTANCE-HIGH. INDICATOR NEEDLE INTERMITTENTLY DROPS OFF TO ZERO. UNIT WAS INSTALLED FOR APPROX. 1 MONTH AND HAS 36.5 HRS. SINCE BEING REPAIRED 1 G 7 2 3U H9SW 1997062600413 19970626 00413 1997 6 26 HEEA0010008 1 19970602 G 5520 206023119159 ELEVATOR PIVOT CRACKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 RT ELEV ASSY CRACKED AT PIVOT HOLE. 1997062600420 19970626 00420 1997 6 26 HEEA0010016 1 19970602 G 2930 124043 INDICATOR MASCO HYD PRESS/TEMP READS HIGH E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 TEMPERATURE AND PRESSURE INDICATOR HIGH OUT OF TOLERANCE. 1997071000347 19970710 00347 1997 7 10 HEEA0010236 4 19970625 G 3416 A30 ENCODER ACK ALTIMETER WONT CALIB E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 ENCODER ALTIMETER WILL NOT CALIBRATE. TIME SINCE REPAIR 0:00. 1997071000388 19970710 00388 1997 7 10 HEEA0010278 4 19970625 G 3416 A30 ENCODER ACK COCKPIT ALT ERRATIC E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 ENCODER HAS ERRATIC OUTPUT AND DOES NOT HOLD CALIBRATION. TIME SINCE REPAIR 0:00. 1997071700276 19970717 00276 1997 7 17 HEEA0010319 4 19970626 G 3457 S67157539 ANTENNA COCKPIT GPS INOPERATIVE E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 GPS ANTENNA NO RECEIVE. 1997071700323 19970717 00323 1997 7 17 HEEA0010366 4 19970626 G 2561 3500145NL72 LIFE VEST PIN AEROMARINE INFLATE PIN DEFECTIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 EASTERN AERO MARINE ISSUED SERVICE BULLETIN # SBV-25-2 STATING SOME VESTS MAY HAVE DEFECTIVE INFLATION PINS INSTALLED ON THE BOTTLE INFLATION. PHI HAS FOUND SOME OF THESE SUSPECT PINS ON HOOVER INDUSTRIES VESTS. SERIAL NUMBERS INVOLVED: K 0606803,K0606845, K0606802, K0606852, K0606792, K0606851, K0606769, K0606811, K0606766, K0606840, K0606841, K0606763, K0 606834, K0606791, K0606765, K0606759, K0606810, K0606796, K0606798, K0606805. REPLACED VESTS WITH SERVICEABLE UNITS. 1997071700333 19970717 00333 GL 1997 7 17 HEEA0010378 2 19970701 G 7250 23008064 NOZZLE ALLSN 250C 250C30S 03013 GL 1ST STAGE OVER SPEC E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 RECEIVING INSPECTION REVEALED: MEASURED .015 OVER SPECS (4.445 - 4.450) ON #1 NOZZLE DIMENSION -AM-. 3 U E1GL 1997072400301 19970724 00301 1997 7 24 HEEA0010448 1 19970710 G 7722 206075187001 INDICATOR DUAL TEMP READS LOW E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 DUAL TEMP INDICATOR READS LOW OUT OF TOLERANCE THROUGHOUT SCALE. 1997081400152 19970814 00152 GL 1997 8 14 HEEA0010558 2 19970805 G 7250 6898731 SUPPORT ALLSN 250C 250C20B 03013 GL PWR TURB DEFECTIVE E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 RECEIVING INSPECTION REVEALED: COATING SOFT AND FLAKING OUT OF P.T. SUPPORT 19-24 SEAL BORE. 3 U E4CE 1997081400181 19970814 00181 1997 8 14 HEEA0010587 4 19970806 G 3422 656520 VALVE FLUX VALVE DEFECTIVE E HEEA K NONE L NO TEST IN INSP/MAINT 1 SW 03 FLUX VALVE WILL NOT TEST CORRECTLY BETWEEN PINS A & B. 1997081400209 19970814 00209 1997 8 14 HEEA0010616 1 19970807 G 7712 7645001078106 INDICATOR DUAL TORQUE READS HIGH E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 #2 NEEDLE INDICATES HIGH ON LOW END; CANNOT CALIBRATE. 1997091100577 19970911 00577 1997 9 11 HEEA0010746 4 19970819 G 3442 MI5852221 TRANSCEIVER HONEYWELL RT3002 WX RADAR INOPERATIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 50 INOPERATIVE, WILL NOT COME UP. SENT TO HONEYWELL, TEXAS FOR INSPECTION AND REPAIR. 1997091100609 19970911 00609 1997 9 11 HEEA0010779 4 19970819 G 3442 RD300 RADAR T SW CABLE BURNT E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 COMPONENTS ON 30 MHZ PULSE DISCUMINATOR BOARD BURNT. 1997091100627 19970911 00627 1997 9 11 HEEA0010800 4 19970820 G 2312 40001278501 TRANSCEIVER RT406F COCKPIT FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 NO TRANSMISSION. 1997111300232 19971113 00232 GL 1997 11 13 HEEA0011569 2 19971020 G 7250 6886407 BLADE 6898735 BELL 206 206B3 1181506 SW ALLSN 250C 250C20B 03013 GL NR 1 WHEEL CORRODED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3181J 1736 CAT33490 3771 CAE836333 TURBINE REMOVED DUE TO 1750 HOUR INSPECTION. UPON INSPECTION OF TURBINE PARTS NOTED: MINOR SULFIDATION ON NR 1 WHEEL B LADES. SCRAPPED WHEEL. 1 G 7 1 3U 3 U H2SW E4CE 1997111300233 19971113 00233 SW 1997 11 13 HEEA0011570 1 19971020 G 6320 407040006107 TRANSMISSION BELL 407 407 SW M/R GR BOX MAKING METAL E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 437PH 1054 53072 METAL IN OIL (LOWER CHIP PLUGS). NOTE: TOP CASE P/N 406-040-052-107, S/N A788, REMOVED WITH TRANSMISSION, T.T. 1054:35 HOURS. 1 G 7 1 3U O H2SW 1997111300235 19971113 00235 SW 1997 11 13 HEEA0011572 1 19970927 G 6220 407010104101 CONE BELL 407 407 SW MAIN ROTOR WORN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 417PH 841 53038 REPLACED LOWER CONE AND CONE SET WITH SEAT P/N 407-010-107-103 ON 9-27-97. 1 G 7 1 3U O H2SW 1997111300236 19971113 00236 SW 1997 11 13 HEEA0011573 1 19970927 G 6220 407010111101 CONE BELL 407 407 SW MAIN ROTOR WORN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 417PH 841 53038 REPLACED LOWER CONE AND CONE SET WITH SEAT P/N 407-010-107-103 ON 9-27-97. 1 G 7 1 3U O H2SW 1997111300237 19971113 00237 1997 11 13 HEEA0011574 4 19971020 G 2210 214074305105 AMPLIFIER BELL 214 214ST 1182106 SW ELEVATOR FBWE FAULTY E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 AMPLIFIER WILL NOT ENGAGE. STARTS TO ENGAGE THEN KICKS OFF. TIME SINCE REPAIR 0:00. 2 G 7 2 4U H10SW 1997111300238 19971113 00238 SW 1997 11 13 HEEA0011575 1 19971020 G 6410 214011819101 BEARING 214011801127 BELL 214 214ST 1182106 SW TAIL ROTOR SPUN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 6957Y A130 28139 INBOARD BEARINGS SPUN. 2 G 7 2 4U H10SW 1998062600385 19980626 00385 EU 1998 6 26 HEEA0011577 1 19971021 G 6220 1051410142 BOLT BOLKMS 105 BO105S 5626006 EU MAIN ROTOR MISMANUFACTURED E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 MISMANUFACTURED. BOLT HOLE TOO SMALL FOR KEY. 1 G 7 2 3U H3EU 1997111300239 19971113 00239 1997 11 13 HEEA0011578 4 19971021 G 3452 066106200 TRANSISTOR BELL 206 206L1 1182107 SW TRANSPONDER FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 1078D 45397 NO REPLY FROM TRANSPONDER. REPLACED BROKEN Q411 TRANSISTOR AND OPEN Q409 TRANSISTOR. COOKED UNIT AND BENCH CHECK GOOD. 1 G 7 1 3U H2SW 1997111300240 19971113 00240 1997 11 13 HEEA0011579 4 19971021 G 3452 066106200 CONNECTOR BELL 206 206L1 1182107 SW TRANSPONDER DIRTY E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5745N 45489 NO OUTPUT READ FROM UNIT BY TEST EQUIPMENT. CLEANED REAR CONNECTOR AND UNIT FIRED UP. REPLACED WEAK V301 PHOTO DETECT OR. ALSO REPLACED INTERMITTENT FRONT SWITCH BOARD ASSEMBLY. CLEANED SWITCH BOARD AND AJUSTED PULSE. BENCH CHECK GOOD. 1 G 7 1 3U H2SW 1997111300241 19971113 00241 NE 1997 11 13 HEEA0011580 1 19971021 G 6210 7615009100051A SPAR SKRSKY S76 S76A 8143006 NE M/R BLADE CRACKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 707AE 8836 760276 BLADE HAS A CRACK IN THE SPAR AT THE ROOT END. SCRAPPED BLADE. 1 G 7 2 3U H1NE 1997111300242 19971113 00242 SW 1997 11 13 HEEA0011581 1 19971021 G 5320 206033110239 STIFFENER BELL 206 206L3 1182108 SW CABIN CRACKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 53119 2905 51575 CRACK FROM HI-SHEAR HOLE THROUGH RADIUS AND FLANGE. REPLACED BROOM CLOSET ANGLE USING P/N 206-033-110-239. 1 G 7 1 3U H2SW 1997111300243 19971113 00243 EU 1997 11 13 HEEA0011582 1 19971021 G 5330 1173010615 SKIN BOLKMS 117 BK117B1 5626012 EU BS 10,000 CRACKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 217UC 7152 CRACK AT APPROXIMATELY STATION 10,000. MANUFACTURED REPAIR USING .040 INCH 2024T3, STOP DRILLED CRACK AND INSTALLED REP AIR USING MS20470AD-3 AND 4, CR3243-4, CR3242-4 AND 890 PRO-SEAL. 1 G 7 2 3U H13EU 1997111300244 19971113 00244 1997 11 13 HEEA0011583 4 19971021 G 3453 8015238 LORAN RCU BOLKMS 105 BO105S 5626006 EU COCKPIT FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 81832 S828 LORAN WILL NOT REACH OPERATING MODE. REPLACED WITH SERVICEABLE PART. 1 G 7 2 3U H3EU 1997111300245 19971113 00245 1997 11 13 HEEA0011584 4 19971021 G 3453 8015238 LORAN RCU BOLKMS 105 BO105S 5626006 EU COCKPIT FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 81832 S828 LORAN TAKES UP TO 30 MINUTES TO REACH OPERATION MODE. REPLACED WITH SERVICEABLE PART. 1 G 7 2 3U H3EU 1997111300246 19971113 00246 EU 1997 11 13 HEEA0011585 1 19971021 G 6420 1053178103 BUSHING 11788659 BOLKMS 117 BK117B2 5626013 EU TAIL ROTOR LOOSE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 134AE 7237 T/R BUSHING RING STAKING CAME LOOSE. REPLACED WITH SERVICEABLE PART. 1 G 7 2 3U NC H13EU 1997111300247 19971113 00247 EU 1997 11 13 HEEA0011586 1 19971021 G 6420 10531738101 SLEEVE BOLKMS 117 BK117B1 5626012 EU TAIL ROTOR WORN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 911TL 1809 7198 T/R BEARING SEATS WORN. 1 G 7 2 3U H13EU 1997111300248 19971113 00248 NE 1997 11 13 HEEA0011587 1 19971021 G 6230 SB5162101 BEARING 761040800004 SKRSKY S76 S76A 8143006 NE ROTOR SHAFT ROUGH E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 1546G A07200102 760076 BEARINGS ROUGH; EXCESSIVE PITTING IN RACEWAY. REPLACED WITH NEW BEARING. 1 G 7 2 3U H1NE 1997111300249 19971113 00249 SW 1997 11 13 HEEA0011588 1 19971021 G 6300 214030603111 SEAT BELL 214 214ST 1182106 SW ROTOR SHAFT CORRODED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 59805 28141 CORROSION AT CENTER BORE (SEAT) WHERE BEARING P/N 214-030-602-3 IS INSTALLED. REPLACED WITH NEW SUPPORT. 2 G 7 2 4U H10SW 1997111300250 19971113 00250 SW 1997 11 13 HEEA0011589 1 19971021 G 2460 MS25036127 TERMINAL 407076500103 BELL 407 407 SW COCKPIT CRACKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 427PH 606 53059 CABLES NR P7A8 AND NR P7B8 IN THE CIRCUIT BREAKER PANEL AREA HAVE TERMINALS CRACKED. (REF: DESIGNATOR 2TB1) DUE TO THE STRESSES PUT ON THE CABLES DURING THE OPENING AND CLOSING OF THE OVERHEAD CIRCUIT BREAKER PANEL. THE TERMINAL ENDS COUL D POSSIBLY SEVER CAUSING A MAJOR POWER FAILURE. ANOTHER POSSIBILITY IS THAT ONE CABLE COULD FAIL AND CONTACT THE AIRFRA ME PRODUCING SEVERE ARCING. REPLACED AFFECTED TERMINAL ENDS. 1 G 7 1 3U O H2SW 1997111300251 19971113 00251 GL 1997 11 13 HEEA0011590 2 19971021 G 7261 23063144 FILTER BELL 407 407 SW ALLSN 250C 250C47B GL ENGINE CLOGGED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 407MM 53060 BYPASS BUTTON POPPED ON ENGINE OIL FILTER. REPLACED WITH SERVICEABLE FILTER. 1 G 7 1 3U 3 U O H2SW E1GL 1997111300252 19971113 00252 GL 1997 11 13 HEEA0011591 2 19971021 G 7261 23063144 FILTER BELL 407 407 SW ALLSN 250C 250C47B GL ENGINE CLOGGED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 407MM 53060 ON DAILY INSPECTION, FOUND OIL FILTER BYPASS INDICATOR EXTENDED. REPLACED WITH SERVICEABLE FILTER. 1 G 7 1 3U 3 U O H2SW E1GL 1997111300253 19971113 00253 GL 1997 11 13 HEEA0011592 2 19971021 G 7261 23063144 FILTER BELL 407 407 SW ALLSN 250C 250C47B GL ENGINE CLOGGED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 57416 61 53070 BYPASS BUTTON POPPED. REPLACED WITH SERVICEABLE FILTER. 1 G 7 1 3U 3 U O H2SW E1GL 1997111300254 19971113 00254 GL 1997 11 13 HEEA0011593 2 19971021 G 7261 23063144 FILTER BELL 407 407 SW ALLSN 250C 250C47B GL ENGINE CLOGGED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 57416 78 53070 BYPASS BUTTON POPPED. REPLACED WITH SERVICEABLE FILTER. 1 G 7 1 3U 3 U O H2SW E1GL 1997111300255 19971113 00255 GL 1997 11 13 HEEA0011594 2 19971021 G 7261 23063144 FILTER BELL 407 407 SW ALLSN 250C 250C47B GL ENGINE CLOGGED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 57416 31 53070 BYPASS BUTTON POPPED. REPLACED WITH SERVICEABLE FILTER. 1 G 7 1 3U 3 U O H2SW E1GL 1997111300256 19971113 00256 GL 1997 11 13 HEEA0011595 2 19971021 G 7261 23063144 FILTER BELL 407 407 SW ALLSN 250C 250C47B GL ENGINE CLOGGED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 447PH 23 53114 RECEIVED ON AIRCRAFT WITH BYPASS BUTTON POPPED. REPLACED WITH SERVICEABLE FILTER. 1 G 7 1 3U 3 U O H2SW E1GL 1997111300257 19971113 00257 GL 1997 11 13 HEEA0011596 2 19971021 G 7261 23063144 FILTER BELL 407 407 SW ALLSN 250C 250C47B GL ENGINE CLOGGED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 141MA 53016 FILTER CLOGGED - BYPASSED. REPLACED WITH SERVICEABLE FILTER. 1 G 7 1 3U 3 U O H2SW E1GL 1997111300258 19971113 00258 GL 1997 11 13 HEEA0011597 2 19971021 G 7261 23063144 FILTER BELL 407 407 SW ALLSN 250C 250C47B GL ENGINE CLOGGED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 437PH 55 53072 ENGINE EXTERIOR OIL FILTER BYPASS BUTTON POPPED. REPLACED WITH SERVICEABLE FILTER. 1 G 7 1 3U 3 U O H2SW E1GL 1997111300259 19971113 00259 SW 1997 11 13 HEEA0011598 1 19971021 G 6210 406010121101 STOP PIN BELL 407 407 SW MAIN ROTOR WORN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 437PH 53072 LOWER FLAPPING STOP ON ORANGE BLADE WORN. REPLACED WITH SERVICEABLE STOP. 1 G 7 1 3U O H2SW 1997111300260 19971113 00260 GL 1997 11 13 HEEA0011599 2 19971021 G 7240 6854255 VALVE BELL 407 407 SW ALLSN 250C 250C47B GL ENGINE BROKEN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 437PH 279 53072 DRAIN VALVE BROKE IN COMBUSTION CASE DRAIN BOSS. REPLACED WITH SERVICEABLE DRAIN VALVE. SCRAPPED BROKEN DRAIN VALVE. 1 G 7 1 3U 3 U O H2SW E1GL 1997111300261 19971113 00261 1997 11 13 HEEA0011600 4 19971021 G 3457 13824020109 TNL2000 BELL 407 407 SW COCKPIT FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 407MM 53060 GPS WILL NOT PICKUP SIGNAL AND WPT AND APT/VOR BUTTONS, BACK LIGHTING PARTIALLY INOPERATIVE. 1 G 7 1 3U O H2SW 1997111300262 19971113 00262 1997 11 13 HEEA0011601 4 19971021 G 2370 9806020023 CVR SKRSKY S76 S76A 8143006 NE COCKPIT FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 15460 327 760223 COCKPIT RECORDER REMAINS IN TEST MODE. 1 G 7 2 3U H1NE 1997111300263 19971113 00263 SW 1997 11 13 HEEA0011602 1 19971021 G 5260 212075418105 ACTUATOR BELL 412 412 1182202 SW STAIR MOTOR FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 293CA 33005 STEP WILL NOT MOTOR. 1 G 7 2 4U H4SW 1997111300264 19971113 00264 SW 1997 11 13 HEEA0011603 1 19971021 G 6210 412015300109 BLADE BELL 412 412 1182202 SW MAIN ROTOR DEBONDED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 293CA 8168 33005 TWO UPPER FRETTING PADS UNBONDED. 1 G 7 2 4U H4SW 1997111300265 19971113 00265 1997 11 13 HEEA0011604 4 19971021 G 3416 8503S20LW ALTIMETER COCKPIT LEAKING E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 ALTIMETER HAS EXCESSIVE CASE LEAKAGE AROUND BARO KNOB AT VARIOUS SETTINGS. 1997111300266 19971113 00266 1997 11 13 HEEA0011605 4 19971021 G 2210 7683431 POTENTIOMETER 769000180210 SKRSKY S76 S76A 8143006 NE AUTOFLIGHT SYS FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 1547D 238 81012170 760077 NR 1 YAW KICKING. FOUND POTENTIOMETERS CHECKED BAD IN NULL POSITION. 1 G 7 2 3U H1NE 1997111300267 19971113 00267 NE 1997 11 13 HEEA0011606 1 19971021 G 6410 7610105101041 BLADE SKRSKY S76 S76A 8143006 NE TAIL ROTOR CRACKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 31217 10889 760229 TAIL ROTOR BLADE HAS A CRACKED LEADING EDGE ABRASION STRIP ON PADDLE B. 1 G 7 2 3U H1NE 1997111300268 19971113 00268 1997 11 13 HEEA0011607 4 19971021 G 3421 4021541671 GYRO BOLKMS 117 BK117B2 5626013 EU COCKPIT MALFUNCTIONED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 134AE 7237 UNIT ROLLED TO THE INVERTED POSITION AND STAYED THERE FOR GROUND RUN AND POWER CHECK. AIRCRAFT WAS HOVERED AND TEST FLO WN FOR FURTHER OBSERVATION. GYRO ROLLED UPRIGHT BUT DID NOT REFLECT PROPER ALTITUDE. 1 G 7 2 3U NC H13EU 1997111300269 19971113 00269 EU 1997 11 13 HEEA0011608 1 19971021 G 7921 37010200004 OIL COOLER BOLKMS 105 BO105S 5626006 EU ENGINE LEAKING E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 91070 S145 OIL COOLER WAS REPAIRED BY VENDOR ON 6-11-97. FOUND LEAKING AT TWO PLACES. 1 G 7 2 3U H3EU 1997111300270 19971113 00270 EU 1997 11 13 HEEA0011609 1 19971021 G 7921 37010200004 OIL COOLER BOLKMS 105 BO105S 5626006 EU ENGINE LEAKING E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 91070 S145 OIL COOLER LEAK AT LOW CENTER RIGHT SIDE. 1 G 7 2 3U H3EU 1997111300271 19971113 00271 1997 11 13 HEEA0011610 4 19971021 G 3450 40001452502 TRANSCEIVER RT138F BOLKMS 105 BO105S 5626006 EU COCKPIT FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 137AE S851 TRANSCEIVER RECEIVES, BUT WILL NOT TRANSMIT. 1 G 7 2 3U H3EU 1997111300272 19971113 00272 1997 11 13 HEEA0011611 4 19971021 G 3457 1624820 ANTENNA BELL 206 206L3 1182108 SW FUSELAGE INOPERATIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 6251X 51552 GPS ANTENNA FAULT DISPLAYED, DOES NOT PICKUP ANY SATELLITES. 1 G 7 1 3U H2SW 1997111300273 19971113 00273 1997 11 13 HEEA0011612 4 19971021 G 3457 1624820 ANTENNA BELL 206 206L3 1182108 SW FUSELAGE INOPERATIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 6251X 51552 GPS ANTENNA NOT PICKING UP SATELLITE SIGNAL. 1 G 7 1 3U H2SW 1997111300274 19971113 00274 1997 11 13 HEEA0011613 4 19971021 G 3457 1624820 ANTENNA BELL 206 206L3 1182108 SW FUSELAGE INOPERATIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 6251X 51552 GPS ANTENNA NOT PICKING UP SIGNAL. 1 G 7 1 3U H2SW 1997111300275 19971113 00275 1997 11 13 HEEA0011614 4 19971021 G 3416 212070238007 ALTIMETER BELL 412 412 1182202 SW COCKPIT FLUCTUATES E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 21498 36003 ALTIMETER NEEDLE FLUCTUATES 100 FEET UP AND DOWN PAST ACTUAL READING. 1 G 7 2 4U H4SW 1997111300276 19971113 00276 1997 11 13 HEEA0011615 4 19971021 G 3422 2891ESR GYRO BELL 206 206L1 1182107 SW COCKPIT MALFUNCTIONED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5019G 45247 GYRO MALFUNCTION, COULD NOT ALIGN HEADINGS. 1 G 7 1 3U H2SW 1997111300277 19971113 00277 1997 11 13 HEEA0011616 4 19971021 G 3457 13824120234 RECEIVER BELL 206 206L3 1182108 SW COCKPIT MALFUNCTIONED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 49EA 51507 GPS KEEPS LOSING NUMBERS OVERNIGHT WHEN AIRCRAFT POWER IS TURNED OFF. 1 G 7 1 3U H2SW 1997111300278 19971113 00278 EU 1997 11 13 HEEA0011617 1 19971021 G 5321 350A21135921 PANEL SNIAS 350 AS350B2 8680813 EU CABIN CORRODED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 6097Z 3060 2820 COCKPIT PANEL HAS EXTENSIVE CORROSION AT FORWARD BELLY LATCH BRACKETS. REPLACED WITH SERVICEABLE PART. 1 G 7 1 3U H9EU 1997111300279 19971113 00279 1997 11 13 HEEA0011618 4 19971021 G 3452 066106200 RESISTOR BELL 407 407 SW TRANSPONDER DETERIORATED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 407MM 53060 TRANSPONDER WILL NOT TEST OR IDENT. PERFORMED PRELIMINARY INSPECTION AND FOUND REPLY LIGHT DIM. ALSO FOUND RESISTOR R4 77 DETERIORATED. REPLACED V301 PHOTOCELL AND R477 RESISTOR. BENCH CHECK GOOD. 1 G 7 1 3U O H2SW 1997111300280 19971113 00280 1997 11 13 HEEA0011619 4 19971021 G 2370 GA1000000 RECORDER BRAERO DH125 HS125700A 4230170 EU COCKPIT CVR MALFUNCTIONED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 125CS NA0212 RECORDER NO TEST FUNCTION LIGHT. 2 L 7 2 4F A3EU 1997111300281 19971113 00281 GL 1997 11 13 HEEA0011620 2 19971021 G 7314 3881005 SPINE BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL FUEL PUMP WORN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 1078D 910 45397 CAE860702 FUEL PUMP INTERNAL DRIVE SPLINES WORN. 1 G 7 1 3U 3 U H2SW E1GL 1997111300282 19971113 00282 EU 1997 11 13 HEEA0011621 1 19971021 G 2822 1C454 PUMP SNIAS 350 AS350B2 8680813 EU ENGINE INTERMITTENT E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 6097Z 618 2820 BOOST PUMP INTERMITTENT. 1 G 7 1 3U H9EU 1997111300283 19971113 00283 SW 1997 11 13 HEEA0011622 1 19971021 G 6320 222040003119 TRANSMISSION BELL 230 230 1182149 SW MAIN ROTOR MAKING METAL E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 230UN 1555 23009 M/R TRANSMISSION MAKING METAL. 1 G 7 2 3U NC H9SW 1997111300284 19971113 00284 NE 1997 11 13 HEEA0011623 1 19971022 G 7334 7645001078118 TRANSMITTER SKRSKY S76 S76A 8143006 NE ENGINE FUEL MALFUNCTIONED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 792CH 760193 FUEL PRESSURE SENSOR TRANSMITS LOW OUT OF TOLERANCE. 1 G 7 2 3U H1NE 1997111300285 19971113 00285 NE 1997 11 13 HEEA0011624 1 19971022 G 7334 7645001078119 TRANSMITTER SKRSKY S76 S76A 8143006 NE ENGINE FUEL MALFUNCTIONED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 1547D 760077 FUEL PRESSURE SENSOR MALFUNCTION. INDICATES HIGH OUT OF TOLERANCE. 1 G 7 2 3U H1NE 1997111300286 19971113 00286 EU 1997 11 13 HEEA0011625 1 19971022 G 2844 BSE20660G1 TRANSMITTER BOLKMS 105 BO105S 5626006 EU ENGINE FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 54197 S805 INDICATOR DROPPED TO ZERO. 1 G 7 2 3U H3EU 1997111300287 19971113 00287 EU 1997 11 13 HEEA0011626 1 19971022 G 2844 BSE20660G1 TRANSMITTER BOLKMS 105 BO105S 5626006 EU ENGINE MALFUNCTIONED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3533T S111 TRANSMITS HIGH FROM 50 TO 12.5 PSI. 1 G 7 2 3U H3EU 1997111300288 19971113 00288 EU 1997 11 13 HEEA0011627 1 19971022 G 2844 BSE206150G3 INDICATOR BOLKMS 105 BO105S 5626006 EU COCKPIT INTERMITTENT E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3534T S112 INDICATOR INTERMITTENT, PEGS OUT. 1 G 7 2 3U H3EU 1997111300289 19971113 00289 SW 1997 11 13 HEEA0011628 1 19971022 G 7714 206075682001 INDICATOR BELL 206 206L1 1182107 SW COCKPIT INOPERATIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 10814 45415 ENGINE RPM INDICATOR INOPERATIVE. 1 G 7 1 3U H2SW 1997111300290 19971113 00290 1997 11 13 HEEA0011629 4 19971022 G 3414 8000 INDICATOR BELL 206 206L1 1182107 SW COCKPIT LEAKING E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 21240 45647 AIR SPEED INDICATOR LEAKING. 1 G 7 1 3U H2SW 1997112000125 19971120 00125 1997 11 20 HEEA0011630 4 19971022 G 3414 206070278005 INDICATOR BELL 206 206L1 1182107 SW COCKPIT STICKS E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 21240 45647 VSI NEEDLE STICKS AROUND 500 FEET GOING UP. 1 G 7 1 3U H2SW 1997112000126 19971120 00126 1997 11 20 HEEA0011631 4 19971022 G 3416 5934D1 ALTIMETER BELL 206 206L1 1182107 SW COCKPIT LEAKING E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 21240 45647 ALTIMETER HAS EXCESSIVE CASE LEAKAGE AND FRICTION ERROR. 1 G 7 1 3U H2SW 1997112000127 19971120 00127 SW 1997 11 20 HEEA0011632 1 19971022 G 2436 206075447007 REGULATOR BELL 206 206L1 1182107 SW ENGINE FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5019F 45244 REGULATOR HAS NO VOLTAGE OUTPUT. 1 G 7 1 3U H2SW 1997112000128 19971120 00128 SW 1997 11 20 HEEA0011633 1 19971022 G 7722 35712519129 INDICATOR BELL 206 206L1 1182107 SW COCKPIT FAULTY E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 513EH 45421 ENGINE TEMPERATURE INDICATOR READS 10 DEGREES HIGH. 1 G 7 1 3U H2SW 1997112000129 19971120 00129 SW 1997 11 20 HEEA0011634 1 19971022 G 5520 206023119159 ELEVATOR BELL 206 206L3 1182108 SW TAIL CORRODED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 6161A 51611 ELEVATOR CORRODED BEYOND LIMITS. 1 G 7 1 3U H2SW 1997112000130 19971120 00130 SW 1997 11 20 HEEA0011635 1 19971022 G 3213 212030436007 CAP BELL 412 412 1182202 SW SKID WORN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 293CA 33005 RUBBER DETERIORATED AND WORN. 1 G 7 2 4U H4SW 1997112000131 19971120 00131 SW 1997 11 20 HEEA0011636 1 19971022 G 6320 206033518007 STOP BELL 206 206L3 1182108 SW MAIN ROTOR DETERIORATED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 6160Z 51610 RUBBER STOP DETERIORATED. 1 G 7 1 3U H2SW 1997112000132 19971120 00132 SW 1997 11 20 HEEA0011637 1 19971022 G 2436 206075447007 REGULATOR BELL 206 206L3 1182108 SW ENGINE FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3207Q 51540 GENERATOR DOES NOT COME ON LINE. 1 G 7 1 3U H2SW 1997112000133 19971120 00133 1997 11 20 HEEA0011638 4 19971022 G 3416 1330061 ALTIMETER BELL 206 206L1 1182107 SW COCKPIT MALFUNCTION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 21240 45647 ALTIMETER HAS EXCESSIVE FRICTION ERROR AND CORRODED ON HOUSING. 1 G 7 1 3U H2SW 1997112000134 19971120 00134 NE 1997 11 20 HEEA0011639 1 19971022 G 2932 7645001078121 TRANSMITTER SKRSKY S76 S76A 8143006 NE NR 1 HYD SYS FAULTY E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 22342 760096 SLIGHT FLUCTUATION ON NR 1 HYDRAULIC INDICATOR SYSTEM PRESSURE. 1 G 7 2 3U H1NE 1997112000135 19971120 00135 NE 1997 11 20 HEEA0011640 1 19971022 G 6220 7610608000049 DAMPER SKRSKY S76 S76A 8143006 NE MAIN ROTOR LEAKING E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3122H 760233 DAMPER LEAKING. 1 G 7 2 3U H1NE 1997112000136 19971120 00136 SW 1997 11 20 HEEA0011641 1 19971022 G 7714 206070266009 INDICATOR BELL 206 206L1 1182107 SW COCKPIT STUCK E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 ENGINE RPM NEEDLE STICKS INTERMITTENTLY. 1 G 7 1 3U H2SW 1997112000137 19971120 00137 1997 11 20 HEEA0011642 4 19971022 G 3416 1003511326 ALTIMETER BELL 412 412 1182202 SW COCKPIT BROKEN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 2149S 36002 ALTIMETER HAS LOOSE PARTS INSIDE. 1 G 7 2 4U H4SW 1997112000138 19971120 00138 EU 1997 11 20 HEEA0011643 1 19971022 G 7714 1179405603 INDICATOR BOLKMS 117 BK117A3 5626015 EU COCKPIT OUT OF TOLERANCE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 911NC 7026 ENGINE RPM INDICATOR HIGH OUT OF TOLERANCE ABOVE 50 PERCENT INTERMITTENT OPERATION. 1 G 7 2 3U H13EU 1997112000139 19971120 00139 EU 1997 11 20 HEEA0011644 1 19971022 G 7722 50061036 INDICATOR BOLKMS 105 BO105S 5626006 EU COCKPIT INACCURATE E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 3526T S610 ENGINE TOT INDICATOR WILL NOT CALIBRATE EXCESSIVE FRICTION ERROR. 1 G 7 2 3U H3EU 1997112000140 19971120 00140 EU 1997 11 20 HEEA0011645 1 19971022 G 7722 50061036 INDICATOR BOLKMS 105 BO105S 5626006 EU COCKPIT FAULTY E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3526T S610 ENGINE TOT INDICATOR HAD EXCESSIVE FRICTION ERROR. 1 G 7 2 3U H3EU 1997112000141 19971120 00141 SW 1997 11 20 HEEA0011646 1 19971022 G 6240 214074280105 DETECTOR BELL 214 214ST 1182106 SW MAIN ROTOR INOPERATIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3897N 28106 M/R DECTECTOR INOPERATIVE. 2 G 7 2 4U H10SW 1997120400343 19971204 00343 1997 12 4 HEEA0011647 4 19971022 G 3444 7001840903 TRANSPONDER SKRSKY S76 S76A 8143006 NE COCKPIT FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 1546G 760076 FAILED 4.1 CHECK TEST ON SST BENCH (LED 50 REMAINS ON). 1 G 7 2 3U H1NE 1997112000142 19971120 00142 1997 11 20 HEEA0011648 4 19971022 G 2212 222305005101 SENSOR BELL 214 214ST 1182106 SW COCKPIT MALFUNCTION E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 6957Y 28139 AIRCRAFT DIVES WHEN ALT HOLD ENGAGED. 2 G 7 2 4U H10SW 1997112000143 19971120 00143 1997 11 20 HEEA0011649 4 19971022 G 2210 BHL430515 SENSOR BOLKMS 117 BK117A4 5626017 EU SPAS INOPERATIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 911RZ 7092 SPAS WOULD NOT TEST. 1 G 7 2 3U H13EU 1997112000144 19971120 00144 1997 11 20 HEEA0011650 4 19971022 G 2211 4025008918 COMPUTER BELL 412 412 1182202 SW AFCS MALFUNCTION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 2014K 33020 FAILED 31.2 AND FOLLOWING TEST ON SST. 1 G 7 2 4U H4SW 1997112000145 19971120 00145 1997 11 20 HEEA0011651 4 19971022 G 3416 8800 ENCODER BELL 412 412 1182202 SW COCKPIT FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 22347 36005 ENCODER DOES NOT SUPPLY ANY ALTITUDE READINGS TO TEST BOX. 1 G 7 2 4U H4SW 1997112000146 19971120 00146 NE 1997 11 20 HEEA0011652 1 19971022 G 6210 7615009043050 TIP CAP SKRSKY S76 S76A 8143006 NE MAIN ROTOR MISMANUFACTURED E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 TIP CAP NEEDS BALANCING. RECEIVED PART WITH NO FORWARD WEIGHTS, THEREFORE, TIP CAP IS LIGHT. TIME SINCE REPAIR 0:00. 1 G 7 2 3U H1NE 1997112000147 19971120 00147 NE 1997 11 20 HEEA0011653 1 19971022 G 2841 AT2062 INDICATOR SKRSKY S76 S76A 8143006 NE FUEL TOTALIZER DEFECTIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 4253S 760035 INDICATOR HAS LOOSE PARTS INSIDE. 1 G 7 2 3U H1NE 1997112000148 19971120 00148 SW 1997 11 20 HEEA0011654 1 19971022 G 3213 412030437103 CAP BELL 412 412 1182202 SW CROSS TUBE WORN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 6559Z 36019 CAP WORN AND DETERIORATED. 1 G 7 2 4U H4SW 1997112000149 19971120 00149 SW 1997 11 20 HEEA0011655 1 19971022 G 3213 412030437103 CAP BELL 412 412 1182202 SW CROSS TUBE WORN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 21498 36003 CROSS-TUBE CAP WORN AND DETERIORATED. 1 G 7 2 4U H4SW 1997112000150 19971120 00150 SW 1997 11 20 HEEA0011656 1 19971022 G 5343 212030437007 CAP BELL 212 212 1181420 SW SKID MISSING E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 27805 31106 SKID RUBBER CAME OFF CAP. 1 G 7 1 4U H4SW 1997112000151 19971120 00151 SW 1997 11 20 HEEA0011657 1 19971022 G 6330 206033506101 BEARINGS BELL 206 206L1 1182107 SW RESTRAINT WORN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5014V 45217 M/R TRANSMISSION RESTRAINT HAS BOTH BEARINGS WORN. 1 G 7 1 3U H2SW 1997112000152 19971120 00152 SW 1997 11 20 HEEA0011658 1 19971022 G 7810 212061201012 EJECTOR BELL 412 412 1182202 SW EXHAUST CRACKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 EXHAUST MOUNT BRACKET IS CRACKED. 1 G 7 2 4U H4SW 1997112000153 19971120 00153 NE 1997 11 20 HEEA0011659 1 19971022 G 3350 6013211 BATTERY SKRSKY S76 S76A 8143006 NE CABIN FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 22342 760096 BATTERY HAS DEAD CELL. EMERGENCY LIGHT WILL NOT COME ON. 1 G 7 2 3U H1NE 1997112000154 19971120 00154 CE 1997 11 20 HEEA0011660 1 19971022 G 2130 1013800133 PNEUMOSTAT BEECH 200 200BEECH 1152920 CE CABIN FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 789DS BB478 PNEUMOSTAT FAILED PRESSURE TEST IN-FLIGHT. 1 L 7 2 4T A24CE 1997112000155 19971120 00155 SW 1997 11 20 HEEA0011661 1 19971022 G 6710 206062721109 ACTUATOR BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL MAIN ROTOR INOPRATIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 513EH 45421 M/R ACTUATOR WILL NOT ACTUATE. 1 G 7 1 3U 3 U H2SW E1GL 1997112000156 19971120 00156 SW 1997 11 20 HEEA0011662 1 19971022 G 3212 212050207012 VALVE BELL 212 212 1181420 SW FLOAT BAG DEBONDED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 27805 31106 FLOAT BAG HAS UNBONDED INLET VALVE. 1 G 7 1 4U H4SW 1997112000157 19971120 00157 SW 1997 11 20 HEEA0011663 1 19971022 G 3212 212050207103 VALVE BELL 212 212 1181420 SW FLOATBAG LEAKING E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 27805 31106 FLOAT BAG HAS LEAKING INLET VALVES. 1 G 7 1 4U H4SW 1997112000158 19971120 00158 1997 11 20 HEEA0011664 4 19971022 G 2340 AA20030 AMPLIFIER BELL 206 206L1 1182107 SW COCKPIT OVERHEAT E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 5007N 45184 INTERPHONE AMPLIFIER GETS EXCESSIVELY HOT; THEN SHUTS DOWN. 1 G 7 1 3U H2SW 1997112000159 19971120 00159 SW 1997 11 20 HEEA0011665 1 19971022 G 3212 412050013119 FLOAT BELL 412 412 1182202 SW FUSELAGE BURST E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 22608 33075 FLOAT BAG BUSTED. 1 G 7 2 4U H4SW 1997112000160 19971120 00160 EU 1997 11 20 HEEA0011666 1 19971022 G 7722 TM42739 INDICATOR BOLKMS 105 BO105S 5626006 EU COCKPIT FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5421E S806 TOT INDICATOR HAD EXCESSIVE FRICTION AND READS LOW OUT OF TOLERANCE. 1 G 7 2 3U H3EU 1997112000161 19971120 00161 SW 1997 11 20 HEEA0011667 1 19971022 G 7722 206375007103 INDICATOR BELL 206 206L3 1182108 SW COCKPIT FAILED E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 3108E 51498 TOT NEEDLES WILL NOT INDICATE. 1 G 7 1 3U H2SW 1997112000162 19971120 00162 SW 1997 11 20 HEEA0011668 1 19971022 G 7722 206075188005 BEZEL BELL 206 206L1 1182107 SW INDICATOR LOOSE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 2759U 45267 BEZEL LOOSE FROM TOT GAUGE. 1 G 7 1 3U H2SW 1997112000163 19971120 00163 SW 1997 11 20 HEEA0011669 1 19971022 G 3310 222375012101 POWER SUPPLY BELL 206 206L3 1182108 SW INST LIGHTS INOPERATIVE E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 8588X 51486 INSTRUMENT LIGHTS POWER SUPPLY INOPERATIVE. 1 G 7 1 3U H2SW 1997112000164 19971120 00164 SW 1997 11 20 HEEA0011670 1 19971022 G 2913 214076334105 PUMP BELL 214 214ST 1182106 SW HYDRAULIC SYS FAILED E HEEA K NONE J WARNING INDICATION NR NOT REPORTED 1 SW 03 8045T 28101 LOSS OF UTILITY HYD SYSTEM PRESSURE IN-FLIGHT, PUMP FAILED. 2 G 7 2 4U H10SW 1997112000165 19971120 00165 SW 1997 11 20 HEEA0011671 1 19971022 G 6410 406312100101 BEARING 407012101105 BELL 407 407 SW TAIL ROTOR DAMAGED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 57416 992 53058 53070 INBOARD BEARINGS BEING DAMAGED EXCEEDING LIMITS PER BHT 407MM VOLUME 1 (REV. 4, 12-16-96). REPLACED TWO EACH BEARINGS. 1 G 7 1 3U O H2SW 1997112000166 19971120 00166 1997 11 20 HEEA0011672 4 19971022 G 3421 214175241101 GYROSCOPE BELL 214 214ST 1182106 SW COCKPIT DEFECTIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 6957Y 28139 GYROSCOPE SLOW TO RESPOND. 2 G 7 2 4U H10SW 1997112000167 19971120 00167 1997 11 20 HEEA0011673 4 19971022 G 3421 214175241101 GYROSCOPE BELL 214 214ST 1182106 SW COCKPIT INACCURATE E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 5748M 28102 AIRCRAFT PORPOISES, ROLLS SIDE TO SIDE. 2 G 7 2 4U H10SW 1997112000168 19971120 00168 1997 11 20 HEEA0011674 4 19971022 G 2562 ELT910 TRANSMITTER BELL 412 412 1182202 SW COCKPIT FAULTY E HEEA K NONE J WARNING INDICATION NR NOT REPORTED 1 SW 03 5759N 33002 ELT TRANSMITTER GOES OFF INTERMITTENTLY. 1 G 7 2 4U H4SW 1997112000169 19971120 00169 1997 11 20 HEEA0011675 4 19971022 G 2562 ELT910 TRANSMITTER BELL 206 206L1 1182107 SW COCKPIT FAULTY E HEEA K NONE J WARNING INDICATION NR NOT REPORTED 1 SW 03 2759U 45267 ELT ACTIVATION LIGHT STAYS ON. 1 G 7 1 3U H2SW 1997112000170 19971120 00170 SW 1997 11 20 HEEA0011676 1 19971022 G 7332 124044 INDICATOR BELL 412 412 1182202 SW FUEL SYSTEM OUT OF TOLERANCE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 293CA 33005 INDICATOR READS LOW OUT OF TOLERANCE. 1 G 7 2 4U H4SW 1997112000171 19971120 00171 1997 11 20 HEEA0011677 4 19971022 G 3416 5035P2P44 INDICATOR SKRSKY S76 S76A 8143006 NE COCKPIT READS LOW E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 1546G 760076 INDICATOR READS 100 FEET LOW. 1 G 7 2 3U H1NE 1997112000172 19971120 00172 CE 1997 11 20 HEEA0011678 1 19971022 G 2822 91380003 FUEL PUMP BEECH 200 200BEECH 1152920 CE FUEL SYSTEM LEAKING E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 30PH BB635 FUEL PUMP LEAKING AT DRIVE SHAFT. 1 L 7 2 4T A24CE 1997112000173 19971120 00173 SW 1997 11 20 HEEA0011679 1 19971022 G 2432 214175379103 CHARGER BELL 214 214ST 1182106 SW BATT/ CHARGE SYS DEFECTIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 8045T 28101 CHARGER NOT TOP CHARGING BATTERY. 2 G 7 2 4U H10SW 1997112000174 19971120 00174 SW 1997 11 20 HEEA0011680 1 19971022 G 7931 APTE138100G TRANSMITTER BELL 212 212 1181420 SW ENGINE OIL SYS ERRATIC E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 5736J 31140 ENGINE OIL TRANSMITTER TRANSMITS ERRATIC. 1 G 7 1 4U H4SW 1998062600384 19980626 00384 1998 6 26 HEEA0011681 1 19971022 G 6730 800807 INSERT HYD PISTON MISSING E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 THREADED INSERTS AT BIG END OF PISTON MISSING. 1997112000175 19971120 00175 SW 1997 11 20 HEEA0011682 1 19971022 G 5330 212030378003 PANEL BELL 212 212 1181420 SW CROSSTUBE CRACKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 27805 31106 PANEL BENT AND CRACKED AT CROSSTUBE AREA. 1 G 7 1 4U H4SW 1997112000176 19971120 00176 SW 1997 11 20 HEEA0011683 1 19971022 G 2435 214060056103 STARTER BELL 214 214ST 1182106 SW ENGINE MALFUNCTION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 6957Y 1531 28139 STARTER KICKS GENERATOR OFF ON START UP. 2 G 7 2 4U H10SW 1997112000177 19971120 00177 SW 1997 11 20 HEEA0011684 1 19971022 G 2840 1103P0553 PRESSURE SWITCH BELL 412 412 1182202 SW AUX TANK FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3893N 33010 AUXILIARY TANK TRANSFER PUMP SHUTS OFF AT VARIOUS FUEL LEVELS. 1 G 7 2 4U H4SW 1997112000178 19971120 00178 EU 1997 11 20 HEEA0011685 1 19971022 G 7921 37010200004 OIL COOLER BOLKMS 105 BO105S 5626006 EU NR 2 ENGINE LEAKING E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 86CH S557 NR 2 ENGINE OIL COOLER LEAKING. 1 G 7 2 3U H3EU 1997112000179 19971120 00179 SW 1997 11 20 HEEA0011686 1 19971022 G 5330 206033201249 PANEL BELL 206 206L1 1182107 SW FUSELAGE CORRODED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5007Q 45187 PANEL CORRODED AND SEPARATED. 1 G 7 1 3U H2SW 1997112000180 19971120 00180 SW 1997 11 20 HEEA0011687 1 19971022 G 5320 206033100291A SHELL BELL 206 206L3 1182108 SW FUSELAGE DEBONDED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 6160Y 51609 SHELL DENTED AND SEPARATED. 1 G 7 1 3U H2SW 1997112000181 19971120 00181 1997 11 20 HEEA0011688 4 19971022 G 3120 212075514001 CLOCK BELL 214 214ST 1182106 SW COCKPIT INTERMITTENT E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 6957Y 28139 CLOCK INTERMITTENT. 2 G 7 2 4U H10SW 1997112000182 19971120 00182 EU 1997 11 20 HEEA0011689 1 19971022 G 7714 1179405603 INDICATOR BOLKMS 117 BK117A3 5626015 EU COCKPIT FAILED E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 401PH 7050 RPM INDICATOR WILL NOT INDICATE. 1 G 7 2 3U H13EU 1997112000183 19971120 00183 1997 11 20 HEEA0011690 4 19971022 G 3414 412075009105 INDICATOR BELL 412 412 1182202 SW COCKPIT READS LOW E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 108X 33115 INDICATOR READS LOW APPROXIMATELY 15 MPH. 1 G 7 2 4U H4SW 1997112000184 19971120 00184 SW 1997 11 20 HEEA0011691 1 19971022 G 2930 124043 INDICATOR BELL 212 212 1181420 SW HYDRAULIC SYS STICKING E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 1082G 31109 TEMPERATURE NEEDLE STICKING. 1 G 7 1 4U H4SW 1997112000185 19971120 00185 SW 1997 11 20 HEEA0011692 1 19971022 G 2436 206075447007 REGULATOR BELL 206 206L3 1182108 SW ENGINE FAILED E HEEA K NONE J WARNING INDICATION IN INSP/MAINT 1 SW 03 3108E 51498 REGULATOR MALFUNCTION, WILL NOT REGULATE, TRIPS ON OVER VOLTAGE. 1 G 7 1 3U H2SW 1997112000186 19971120 00186 EU 1997 11 20 HEEA0011693 1 19971022 G 6410 10531980 BLADE BOLKMS 105 BO105S 5626006 EU TAIL ROTOR PEELING E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 911PF 682 S718 PAINT PEELING; RUBBER COATING MISSING AT BLADE TIP. 1 G 7 2 3U H3EU 1997112000187 19971120 00187 SW 1997 11 20 HEEA0011694 1 19971022 G 7714 412075010109 INDICATOR BELL 412 412 1182202 SW COCKPIT FLUCTUATES E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 2298Z 33077 TRIPLE TACHOMETER'S NEEDLES HAVE STICKY OPERATION DURING FUNCTION CHECK. 1 G 7 2 4U H4SW 1997112000188 19971120 00188 1997 11 20 HEEA0011695 4 19971022 G 3423 2593379001 COMPENSATOR BELL 212 212 1181420 SW COCKPIT SHORTED E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 102PH 30899 COMPASS COMPENSATOR SHORTED OUT INTERNALLY. 1 G 7 1 4U H4SW 1997112000189 19971120 00189 NE 1997 11 20 HEEA0011696 1 19971022 G 6340 7690001881103 AMPLIFIER SKRSKY S76 S76A 8143006 NE MAIN ROTOR MALFUNCTIONED E HEEA K NONE E F VIBRATION/BUFFET FLT CONT AFFECTED NR NOT REPORTED 1 SW 03 5435V 760158 TURNING AFFECTS VIBRATION LEVELS IN AMPLIFIER. 1 G 7 2 3U H1NE 1997112000190 19971120 00190 SW 1997 11 20 HEEA0011697 1 19971022 G 2820 2C271 CARTRIDGE BELL 206 206L3 1182108 SW FUEL SYSTEM INOPERATIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 8589X 51487 EJECTOR INOPERATIVE. 1 G 7 1 3U H2SW 1997112000191 19971120 00191 EU 1997 11 20 HEEA0011698 1 19971022 G 7923 209072433103 VALVE BOLKMS 105 BO105S 5626006 EU OIL SYSTEM INOPERATIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3071K S859 OIL SYSTEM VALVE INOPERATIVE. 1 G 7 2 3U H3EU 1997112000192 19971120 00192 SW 1997 11 20 HEEA0011699 1 19971022 G 5510 206023119151A STABILIZER BELL 206 206L3 1182108 SW TAILBOOM DENTED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 6603X 8218 51412 STABILIZER DENTED BEYOND LIMITS. 1 G 7 1 3U H2SW 1997112000193 19971120 00193 SW 1997 11 20 HEEA0011700 1 19971022 G 7810 212061201012 EJECTOR BELL 412 412 1182202 SW EXHAUST CRACKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5759N 33002 EXHAUST RING CRACKED AT WELDS. 1 G 7 2 4U H4SW 1997112000194 19971120 00194 SW 1997 11 20 HEEA0011701 1 19971022 G 3213 412030437103 CAP BELL 412 412 1182202 SW CROSSTUBE DETERIORATED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 21498 36003 CROSS-TUBE RUBBER DETERIORATED. 1 G 7 2 4U H4SW 1997112000195 19971120 00195 SW 1997 11 20 HEEA0011702 1 19971022 G 3213 212030436007 CAP BELL 412 412 1182202 SW CROSSTUBE WORN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 3893N 33010 CROSS-TUBE RUBBER WORN AND CRACKED. 1 G 7 2 4U H4SW 1997112000196 19971120 00196 SW 1997 11 20 HEEA0011703 1 19971022 G 6240 206076373001 TACH GEN SHAFT BELL 206 206L1 1182107 SW MAIN ROTOR WORN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5006F 45181 TACHOMETER GENERATOR HAS WORN SHAFT LOOSE AT LARGE END, CLICKS WHEN TURNED. 1 G 7 1 3U H2SW 1997112000197 19971120 00197 1997 11 20 HEEA0011704 4 19971022 G 3424 206070274005 INDICATOR BELL 206 206L3 1182108 SW COCKPIT INOPERATIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 363BH 51345 TURN AND BANK INDICATOR INOPERATIVE. 1 G 7 1 3U H2SW 1997112000198 19971120 00198 SW 1997 11 20 HEEA0011705 1 19971022 G 6240 412075010109 INDICATOR BELL 412 412 1182202 SW COCKPIT READS LOW E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 5759N 33002 TACHOMETER READS 2 PERCENT LOW. 1 G 7 2 4U H4SW 1997112000199 19971120 00199 1997 11 20 HEEA0011706 4 19971022 G 3444 7001840913 TRANSPONDER BELL 412 412 1182202 SW COCKPIT FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 107X 33113 TRANSPONDER FAILED TEST 5.2 ON SST AND HAS LOW OUTPUT. 1 G 7 2 4U H4SW 1997112000200 19971120 00200 SW 1997 11 20 HEEA0011707 1 19971022 G 6710 206062721109 ACTUATOR BELL 206 206L1 1182107 SW ALLSN 250C 250C28B 03013 GL DROOP COMP FAILED E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 2251Z 45756 ACTUATOR DOES NOT MOVE IN OR OUT. 1 G 7 1 3U 3 U H2SW E1GL 1997112000201 19971120 00201 SW 1997 11 20 HEEA0011708 1 19971022 G 5260 212075418103 ACTUATOR BELL 412 412 1182202 SW STEP INOPERATIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 141PH 33197 ACTUATOR INOPERATIVE. 1 G 7 2 4U H4SW 1997112000202 19971120 00202 EU 1997 11 20 HEEA0011709 1 19971022 G 6240 10594575 TRANSMITTER BOLKMS 105 BO105S 5626006 EU MAST MOMENT FAILED E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 54191 S804 MAST MOMENT LIGHT DOES NOT COME ON. 1 G 7 2 3U H3EU 1997112000203 19971120 00203 EU 1997 11 20 HEEA0011710 1 19971022 G 6240 10594564 INDICATOR BOLKMS 105 BO105S 5626006 EU MAST MOMENT FAILED E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 54191 S804 LIGHT DOES NOT COME ON. 1 G 7 2 3U H3EU 1997112000204 19971120 00204 SW 1997 11 20 HEEA0011711 1 19971022 G 2841 206063633001 INDICATOR BELL 206 206L1 1182107 SW COCKPIT STICKS E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 10778 45391 FUEL GAUGE STICKS. 1 G 7 1 3U H2SW 1997112000205 19971120 00205 EU 1997 11 20 HEEA0011712 1 19971022 G 7722 50061036 INDICATOR BOLKMS 105 BO105S 5626006 EU COCKPIT STICKS E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 5421E S806 TOT NEEDLE HAS EXCESSIVE FRICTION. 1 G 7 2 3U H3EU 1997112000206 19971120 00206 EU 1997 11 20 HEEA0011713 1 19971022 G 6240 KDW021 WARNING BOX BOLKMS 105 BO105S 5626006 EU COCKPIT INOPERATIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5031U S678 RPM WARNING BOX INOPERATIVE. 1 G 7 2 3U H3EU 1997112000207 19971120 00207 NE 1997 11 20 HEEA0011714 2 19971022 G 7200 3017600 ENGINE BELL 412 412 1182202 SW PWA PT6T PT6T3B 52045 NE POWER SECT FAILED E HEEA K NONE J R WARNING INDICATION PARTIAL RPM/PWR LOSS LD LANDING 1 SW 03 5759N 11978 33002 N2 POWER SECTION DROPPED OFF LINE UPON LANDING. CANNOT ROTATE N2: N1 TURNS FREELY. 1 G 7 2 4U 4 U H4SW E22EA 1997112000208 19971120 00208 SW 1997 11 20 HEEA0011715 1 19971022 G 7722 3030083 COMPENSATOR BELL 412 412 1182202 SW ENGINE INTERMITTENT E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 108X 33115 COMPENSATOR ERRATIC AND INTERMITTENTLY INOPERATIVE. 1 G 7 2 4U H4SW 1997112000209 19971120 00209 NE 1997 11 20 HEEA0011716 1 19971022 G 5320 7635109035102 WEB SKRSKY S76 S76A 8143006 NE FUSELAGE UNBONDED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 31219 760230 WEB IS UNBONDED. 1 G 7 2 3U H1NE 1997112000210 19971120 00210 NE 1997 11 20 HEEA0011717 1 19971022 G 6210 7615009043050 SKIN SKRSKY S76 S76A 8143006 NE TIP CAP TORN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 1547D 760077 SKIN TORN ON THE LOWER SIDE, JUST AFT OF THE LEADING EDGE STRIP. 1 G 7 2 3U H1NE 1997112600442 19971126 00442 GL 1997 11 26 HEEA0011718 2 19971022 G 7310 10561320 PIPE BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL ENGINE LEAKING E HEEA K NONE K FLUID LOSS IN INSP/MAINT 1 SW 03 3533T S111 ENGINE FUEL LEAKING FROM SWEDGED RING AT B-NUT. 1 G 7 2 3U 3 U H3EU E4CE 1997112000211 19971120 00211 CE 1997 11 20 HEEA0011719 1 19971022 G 7712 1013890053 TORQUEMETER BEECH 200 200BEECH 1152920 CE ENGINE FAILED E HEEA K NONE O OTHER NR NOT REPORTED 1 SW 03 500PH BL29 CALIBRATION IS OFF, TORQUEMETER TRANSMITS HIGH. 1 L 7 2 4T A24CE 1997112000212 19971120 00212 SW 1997 11 20 HEEA0011720 1 19971022 G 7160 209062214001 ACTUATOR BELL 412 412 1182202 SW AIR INTAKE INOPERATIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 33008 36004 CONPENSATOR INOPERATIVE. 1 G 7 2 4U H4SW 1997112000213 19971120 00213 SW 1997 11 20 HEEA0011721 1 19971022 G 2822 1C641 BOOST PUMP BELL 412 412 1182202 SW FUEL SYSTEM MALFUNCTION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 1202T 33112 PUMP HAS LOW PRESSURE. 1 G 7 2 4U H4SW 1997112000214 19971120 00214 SW 1997 11 20 HEEA0011722 1 19971022 G 6220 204031920003 BEARING BELL 212 212 1181420 SW M/R DAMPER WORN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 1079U 31122 M/R DAMPER BEARINGS WORN. 1 G 7 1 4U H4SW 1997112000215 19971120 00215 SW 1997 11 20 HEEA0011723 1 19971022 G 6510 205030236009 SUPPORT BELL 412 412 1182202 SW TAIL ROTOR SHAFT MISMANUFACTURED E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 2261D 33076 UNABLE TO MOUNT TAIL ROTOR DRIVE SHAFT SUPPORT ON THE ENGINE DECK BECAUSE OF SMALL RADIUS ON LT FORWARD PART OF SUPPORT. TAIL ROTOR DRIVE SHAFT SUPPORT HITS TRIPOD FITTING P/N 212-061-102-001 PREVENTING SUPPORT HOLES TO LINE UP WITH DECK H OLES. 1 G 7 2 4U H4SW 1997112000216 19971120 00216 SW 1997 11 20 HEEA0011724 1 19971022 G 2435 214060056103 STARTER BELL 214 214ST 1182106 SW ENGINE FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 5748M 1295 28102 STARTER ENGAGE LIGHT COMES ON, BUT STARTER WILL NOT ENERGIZE. 2 G 7 2 4U H10SW 1997112000217 19971120 00217 SW 1997 11 20 HEEA0011725 1 19971024 G 5330 212030099071S SKIN BELL 412 412 1182202 SW TAIL BOOM MISMANUFACTURED E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 6559Z 36019 POSITIONED NEW SKIN TO TAILBOOM AND LOCATE AT TOP SECTION NEAR CONTROL TUBE OPENING. FOUND UPPER AREA OF SKIN ROLLED TO O TIGHT. POSITIONED SADDLE SKIN TO WRAP AROUND SKIN P/N 212-030-099-071S AND FOUND .3750 INCH GAP BETWEEN SADDLE SKIN A ND WRAP-AROUND SKIN AT AFT ROLL AREA. 1 G 7 2 4U H4SW 1997112000218 19971120 00218 NE 1997 11 20 HEEA0011726 2 19971024 G 7310 430137601 MANIFOLD BOLKMS 117 BK117B2 5626013 EU LYC LTS101 LTS101750B1 41560 NE FUEL SYSTEM LEAKING E HEEA K NONE K FLUID LOSS IN INSP/MAINT 1 SW 03 132AE 7238 LE45609AEF INSPECTION REVEALED FUEL LEAK IN BEND OF FORWARD LINE BETWEEN FUEL NOZZLES AT 9 O'CLOCK POSITION. REPLACED FUEL MANIFO LD. INSTALLED S/N 1NL06437. 1 G 7 2 3U 3 U NC H13EU E5NE10 1997112000221 19971120 00221 GL 1997 11 20 HEEA0011731 2 19971031 G 7250 23031938 NOZZLE 6898735 ALLSN 250C 250C20B 03013 GL NR 2 1ST STAGE CRACKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 CAT38579F TURBINE DISASSEMBLED DUE TO LOW POWER ON TEST CELL. UPON INSPECTION OF TURBINE PARTS NOTED: CRACKED BEYOND SERVICEABLE LIMITS ON NR2 NOZZLE 1ST STAGE INNER BAND. INSTALLED A DALLAS AIRMOTIVE OVERHAULED NR2 NOZZLE. 3 U E4CE 1997112600125 19971126 00125 1997 11 26 HEEA0011861 4 19971110 G 3416 A30 ENCODER ACK COCKPIT ALT DEFECTIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 CANNOT CALIBRATE UNIT. UNIT DOES NOT HOLD CALIBRATION. NOTE: THIS IS THE 4TH TIME THIS UNIT HAS BEEN TO VENDOR FOR TH E SAME COMPLAINT. REFERENCE RO#976965 AND RO#977921. 1997112600130 19971126 00130 1997 11 26 HEEA0011866 4 19971110 G 3457 0110005400 GPS 150 GARMIN COCKPIT FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 GPS NOT PICKING UP SATELLITES AND ENT. BUTTON VERY INTERMITTENT. 1997112600131 19971126 00131 1997 11 26 HEEA0011867 4 19971110 G 2210 2593996333 TARSYN AUTO FLIGHT MALFUNCTION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 DG PRECESSES EXCESSIVELY. 1997112600145 19971126 00145 1997 11 26 HEEA0011881 4 19971110 G 3442 7000839904 INDICATOR RADAR DEFECTIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 FOUND LOOSE OBJECTS INSIDE RADAR INDICATOR INSTRUMENT. TIME SINCE REPAIR 0:00. 1997112600184 19971126 00184 1997 11 26 HEEA0011957 4 19971112 G 2312 064101902 TRANSCEIVER KING KY196 COCKPIT VHF DISTORTED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 TRANSCEIVER MODULATION AT 118 MHZ DISTORTED. 1997120400407 19971204 00407 1997 12 4 HEEA0012087 2 19971119 G 7314 430112810 FUEL PUMP FUEL SYS WORN E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 FUEL PUMP HAS WORN EXTERNAL DRIVE SPLINES. 1997122400161 19971224 00161 NE 1997 12 24 HEEA0012296 2 19971208 G 7314 430112810 FUEL PUMP LYC LTS101 LTS101650B1 41560 NE ENGINE LEAKING E HEEA K NONE K FLUID LOSS IN INSP/MAINT 1 SW 03 LEAKING FROM DRAIN. INSTALLED UNIT ON AN ENGINE AND RAN ENGINE ON TEST CELL. FUEL PUMP LEAKED FROM THE DRAIN EXCESSIVE LY. 3 U E5NE 1998010800166 19980108 00166 1998 1 8 HEEA0012357 1 19971217 G 3340 700802 POWER SUPPLY STROBE FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 POWER SUPPLY WILL NOT POWER UP. WILL NOT ACTIVATE STROBE. 1998010800611 19980108 00611 1998 1 8 HEEA0012390 1 19971229 G 6720 206001763001 BELLCRANK T/R MIS MFG E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 BELLCRANCK MISMANUFACTURED. 1997011600434 19970116 00434 GL 1997 1 16 HEEA978817 2 19970107 G 7230 23039791 SPLINE ADAPTER 6890550 ALLSN 250C 250C20B 03013 GL ENGINE BELOW SPEC E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 CAC24241 CAE270204 RECEIVING INSPECTION REVEALED: EXTERNAL SPLINES BELOW MANUFACTURERS SPECS ON ADAPTER. INSTALLED A NEW ADAPTER. 3 U E4CE 1997012300192 19970123 00192 1997 1 23 HEEA978883 4 19970114 G 3452 ATC600 TRANSPONDER KING KT76A COCKPIT ATC FAILS E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 AFTER UNIT WARMS UP 45 MINUTES KT76A TRANSPONDER WON'T RECEIVE ATC600 SIGNALS. TIME SINCE REPAIR 0:00. 1997021300326 19970213 00326 GL 1997 2 13 HEEA978907 2 19970120 G 7230 23039791 SPLINE ADAPTER ALLSN 250C 250C20B 03013 GL ENGINE BELOW SPECS E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 RECEIVING INSPECTION REVEALED: SPLINE ADAPTER MEASURED .0039 - .0059 BELOW SPECS (.8994 MIN BP) ON COUPLING EXTERNAL SPL INES OF THE FOLLOWING SERIAL NUMBERS: (1) 65186 .0044 BELOW SPECS (2) 64943 .0059 BELOW SPECS (3) 65060 .0054 BELO W SPECS (4) 65131.0049 BELOW SPECS (5) 65040 .0059 BELOW SPECS AND (6) 65126 .0039 BELOW SPECS. 3 U E4CE 1997021300339 19970213 00339 GL 1997 2 13 HEEA978922 2 19970121 G 7260 6876925 TUBE ASSY. 23001928 ALLSN 250C 250C20B 03013 GL GR BOX DEFECTIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 1744 CAG27204 CAE270204 ENGINE REMOVED DUE TO METAL IN OIL. UPON INSPECTION OF GEARBOX PARTS NOTED THE FOLLOWING: TUBE ASSEMBLY FAILED DIMENSI ONAL CHECK PER CEB1307. INSTALLED A NEW TUBE. 3 U E4CE 1997022000496 19970220 00496 1997 2 20 HEEA978953 4 19970129 G 3416 6302 INDICATOR ALTIMETER STUCK E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 INDICATOR DOES NOT READ CORRECTLY. STAYS STUCK INTERMITTENT. SENT TO EDMO DIST. FOR WARRANTY EXCHANGE. 1997022000511 19970220 00511 1997 2 20 HEEA978968 1 19970129 G 3340 ACR4F RESCUE LIGHT SWITCH FAILED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 LIGHT ON/OFF SWITCH DOES NOT WORK. 1997022700095 19970227 00095 1997 2 27 HEEA979036 4 19970211 G 3442 MI5853011 INDICATOR P500 COCKPIT RADAR MALFUNCTION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 WHEN UNIT IS IN WEATHER MODE AND VARIABLE GAIN IS TURNED OUT OF PRESET, UNIT INTERMITTENTLY SHOWS CYCLE MODE. WHEN FRO NT OF INDICATOR (FACEPLATE) IS WIGGLED CYCLE MODE COMES UP IN WEATHER MODE. ALSO AFTER UNIT HAD BEEN OPERATING FOR APPR OXIMATELY 20MINUTES THE DISPLAY SHRINKS SLIGHTLY THEN COMES BACK TO PROPER SIZE. INTERMITTENT. TIME SINCE REPAIR 0:00. 1997022700104 19970227 00104 1997 2 27 HEEA979047 4 19970211 G 2312 40001278500 TRANSCEIVER RT40 COCKPIT MALFUNCTION E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 TRANSCEIVER UNIT HAS LOW POWER OUT. 1997030600392 19970306 00392 GL 1997 3 6 HEEA979119 2 19970214 G 7230 23033721 BLADES ALLSN 250C 250C20B 03013 GL NR 1 COMP WHEEL DAMAGED E HEEA K NONE O C OTHER F.O.D. IN INSP/MAINT 1 SW 03 RECEIVING INSPECTION REVEALED: MINOR F.O.D. AND CORROSION PITS ON #1 COMPRESSOR WHEEL BLADES. PHI REQUESTING 100% WARRA NTY REPAIR. PART OVERHAULED ON DALLAS AIRMOTIVE W/O# LF1015. 3 U E4CE 1997030600393 19970306 00393 GL 1997 3 6 HEEA979120 2 19970214 G 7250 6892832 SHIELD ALLSN 250C 250C30P 03013 GL NR 3 NOZZLE CRACKED E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 RECEIVING INSPECTION REVEALED: CRACKES ON #3 NOZZLE SHIELD AS MARKED. 3 U E1GL 1997030600416 19970306 00416 GL 1997 3 6 HEEA979151 2 19970226 G 7260 6877171 HOUSING ALLSN 250C 250C20B 03013 GL GR BOX BELOW SPECS E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 GEAR BOX HOUSING RECEIVING INSPECTION REVEALED: MEASURED .0025 BELOW SPECS (3.8490 MIN) ON GEARBOX HOUSING COMPRESSOR M OUNT STUD AS MARKED. 3 U E4CE 1997031300428 19970313 00428 GL 1997 3 13 HEEA979158 2 19970307 G 7260 6877181 HOUSING ALLSN 250C 250C20 03013 GL GR BOX BELOW SPECS E HEEA K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 03 RECEIVING INSPECTION REVEALED: MEASURED .005 LEFT/.006 RIGHT BELOW SPECS ON GEARBOX HOUSING. COMPRESSOR MOUNT PAD STUD S AS MARKED. 3 U E4CE 1997032000342 19970320 00342 1997 3 20 HEEA979166 4 19970312 G 3452 066106200 TRANSCEIVER KING KT76 COCKPIT ATC DEFECTIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 TRANSCEIVER WEAK SENSITIVITY. PERFORMED PRELIMINARY INSPECTION. REPLACED MIXER DIODE CR202. REPAIRED PROBLEM. ADJUSTE D FREQUENCY AND PULSE WIDTH. COOKED UNDER HEAT LAMP, VIBRATED AND PUT IN FREEZER. BENCH CHECK GOOD. 1997032000381 19970320 00381 1997 3 20 HEEA979210 4 19970312 G 3457 0110005400 GPS 150 GARMIN COCKPIT GPS INOPERATIVE E HEEA K NONE O OTHER IN INSP/MAINT 1 SW 03 GPS UNIT INOPERATIVE. 1997052200484 19970522 00484 1997 5 22 IC6R298 4 19970507 G 2350 899927930 SWITCH 899926930 BAG ATP ATP EU COCKPIT FAILED B L IC6R K NONE O OTHER IN INSP/MAINT 1 NM 01 STATION BOX HAS 18 EACH OF SWITCH P/N 8-9992-693-0. SWITCH HAS HIGH FAILURE RATE. FAILURES RESULT IN NOISY AUDIO, LOW VOLUME, OR INOPERATIVE SWITCH FOR AUDIO SELECTION. NEARLY 75 P ERCENT OF STATION BOX REPAIRS REQUIRE REPLACMENT OF AT L EAST ONE SWITCH. NO ALTERNATE AVAILABLE. UFS ONLY CARRIER IN USA OPERATING THIS AIRCRAFT. 2 L 7 2 4T RT A27NM 1997111300410 19971113 00410 WP 1997 11 13 IXXA9700147 1 19970925 G 5330 SKIN DOUG DC8 DC871F 302199D WP BS 1723 CORRODED A IXXA K NONE O OTHER IN INSP/MAINT 1 GL 23 829BX 2636 45994 DURING ROUTINE C-CHECK INSPECTION, A CORROSION BULGE WAS FOUND BETWEEN FUSELAGE STATIONS 1723 AND 1745, LONGERON 23 LEFT . REPAIR ACCOMPLISHED REMOVAL OF THE DAMAGED AREA, FABRICATION AND INSTALLATION OF AN INTERNAL FILLER AND AN EXTERNAL REPAIR DOUBLER IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL 53-2-1. 2 L 7 4 4F RT 4A25 1997111300411 19971113 00411 WP 1997 11 13 IXXA9700148 1 19970925 G 5320 SPLICE DOUG DC8 DC871F 302199D WP BS 600 CRACKED A IXXA K NONE O OTHER IN INSP/MAINT 1 GL 23 829BX 2636 45994 DURING ROUTINE C-CHECK INSPECTION, FOUND LONGERON 31 RIGHT, SPLICE FITTING CRACKED BETWEEN FUSELAGE STATIONS 600 AND 620 . REPAIR ACCOMPLISHED REMOVAL OF DAMAGED FITTING, FABRICATION AND INSTALLATION OF A NEW FITTING IN ACCORDANCE WITH DER APPROVED DRAWING 853-373-97 AND ENGINEERING ORDER 3-DC8-578. 2 L 7 4 4F RT 4A25 1997111300412 19971113 00412 WP 1997 11 13 IXXA9700149 1 19970923 G 5311 FRAME DOUG DC8 DC871F 302199D WP BS 1394 CRACKED A IXXA K NONE O OTHER IN INSP/MAINT 1 GL 23 829BX 2636 45994 DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS FOUND ON THE BELT FRAME AT FUSELAGE STATION 1394, BETWEEN LONGERONS 33 AN D 36 RIGHT. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF AN INTERNAL FILLER AND A REPAI R DOUBLER IN ACCORDANCE WITH DOUGLAS STRUCTURAL REPAIR MANUAL 53-2-0. 2 L 7 4 4F RT 4A25 1997111300413 19971113 00413 WP 1997 11 13 IXXA9700150 1 19971021 G 5330 PLATING DOUG DC8 DC871F 302199D WP BS 25.5 CORRODED A IXXA K NONE O OTHER IN INSP/MAINT 1 GL 23 829BX 2636 45994 DURING ROUTINE C-CHECK INSPECTION, CORROSION WAS FOUND ON THE EXTERNAL PLATING AT FUSELAGE STATION 25.5, BETWEEN LONGERO NS 31 LEFT AND 31 RIGHT. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF AN INTERNAL FILLE R AND AN EXTERNAL REPAIR DOUBLER IN ACCORDANCE WITH DER APPROVED DRAWING 853-395-97 AND ENGINEERING ORDER 53-DC8-593. 2 L 7 4 4F RT 4A25 1997111300414 19971113 00414 WP 1997 11 13 IXXA9700151 1 19971021 G 5320 DOUBLER DOUG DC8 DC871F 302199D WP BS 10 CORRODED A IXXA K NONE O OTHER IN INSP/MAINT 1 GL 23 829BX 2636 45994 DURING ROUTINE C-CHECK INSPECTION, CORROSION WAS FOUND ON THE EXTERNAL FINGER DOUBLER BETWEEN FUSELAGE STATIONS 10 TO 70 , LONGERON 33 RIGHT. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF NEW FINGER DOUBLER IN ACCORDANCE WITH DOUGLAS STRUCTURAL REPAIR MANUAL 53-1-0. 2 L 7 4 4F RT 4A25 1997112600488 19971126 00488 WP 1997 11 26 IXXA9700152 1 19971021 G 5313 LONGERON DOUG DC8 DC871F 302199D WP BS 10 CORRODED A IXXA K NONE O OTHER IN INSP/MAINT 1 GL 23 829BX 2636 45994 DURING ROUTINE C-CHECK INSPECTION, CORROSION WAS FOUND ON LONGERON 33 RIGHT, BETWEEN FUSELAGE STATIONS 10 TO 70. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA, FABRICATION OF LONGERON SECTION IN ACCORDANCE WITH DER APPROVED DRAWING 853-396-9 7 AND ENGINEERING ORDER 53-DC8-594. INSTALLATION IN ACCORDANCE WITH DOUGLAS STRUCTURAL REPAIR MANUAL. 2 L 7 4 4F RT 4A25 1997111300415 19971113 00415 WP 1997 11 13 IXXA9700153 1 19971021 G 5347 SEAT TRACK DOUG DC8 DC871F 302199D WP BS 240 CRACKED A IXXA K NONE O OTHER IN INSP/MAINT 1 GL 23 829BX 2636 45994 DURING ROUTINE C-CHECK INSPECTION, FOUND SEAT TRACK TO BE CRACKED IN MAIN CARGO COMPARTMENT BETWEEN FUSELAGE STATIONS 2 40 AND 247, BUTT LINE X-25. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED TRACK, FABRICATION AND INSTALLATION OF NEW SEAT TRAC K PLUG IN ACCORDANCE WITH ENGINEERING ORDER 53-DC8-580 AND DOUGLAS STRUCTURAL REPAIR MANUAL 53-2-3. 2 L 7 4 4F RT 4A25 1997111300416 19971113 00416 WP 1997 11 13 IXXA9700154 1 19970924 G 5330 SKIN DOUG DC8 DC871F 302199D WP BS 1766 CRACKED A IXXA K NONE O OTHER IN INSP/MAINT 1 GL 23 829BX 45994 DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS FOUND ON THE EXTERNAL PLATING AT FUSELAGE STATION 1766, LONGERON 25 RIGHT . REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF AN INTERNAL FILLER AND AN EXTERNAL REPAI R DOUBLER IN ACCORDANCE WITH DER APPROVED DRAWING 853-372-97 AND ENGINEERING ORDER 53-DC8-576. 2 L 7 4 4F RT 4A25 1997111300417 19971113 00417 WP 1997 11 13 IXXA9700155 1 19970924 G 5320 FITTING DOUG DC8 DC871F 302199D WP BS 1690 CRACKED A IXXA K NONE O OTHER IN INSP/MAINT 1 GL 23 829BX 2636 45994 DURING ROUTINE C-CHECK INSPECTION, FOUND LONGERON 23 RIGHT END FITTING CRACKED AT FUSELAGE STATION 1690. REPAIR ACCOMPL ISHED REMOVAL OF FITTING, FABRICATION AND INSTALLATION OF A NEW END FITTING IN ACCORDANCE WITH DER APPROVED DRAWING 853- 377-97 AND ENGINEERING ORDER 53-DC8-582. 2 L 7 4 4F RT 4A25 1997111300418 19971113 00418 WP 1997 11 13 IXXA9700156 1 19970924 G 5730 PLATING DOUG DC8 DC871F 302199D WP LT WING CRACKED A IXXA K NONE O OTHER IN INSP/MAINT 1 GL 23 829BX 2636 45994 DURING ROUTINE C-CHECK INSPECTION, THE LEFT WING LOWER LEADING EDGE PLATING WAS FOUND WITH TWO CRACKS BETWEEN STATIONS X FS 294 AND 306. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREAS, FABRICATION AND INSTALLATION OF TWO INTERNAL FILLERS, AND TWO EXTERNAL REPAIR DOUBLERS IN ACCORDANCE WITH DER APPROVED DRAWING 857-384-97 AND ENGINEERING ORDER 57-DC8-588. 2 L 7 4 4F RT 4A25 1997111300419 19971113 00419 WP 1997 11 13 IXXA9700157 1 19971003 G 5730 PLATING DOUG DC8 DC871F 302199D WP LT WING CRACKED A IXXA K NONE O OTHER IN INSP/MAINT 1 GL 23 829BX 2636 45994 DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS FOUND ON LEFT WING LEADING EXTERNAL PLATING BETWEEN STATIONS 485 AND 558. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF AN INTERNAL FILLER AND AN EXTERNAL REPAIR DOUBLER IN ACCORDANCE WITH DER APPROVED DRAWING 857-385-97 AND ENGINEERING ORDER 57-DC8-589. 2 L 7 4 4F RT 4A25 1997111300420 19971113 00420 WP 1997 11 13 IXXA9700158 1 19971005 G 5240 PAN DOUG DC8 DC871F 302199D WP RT SERVICE DOOR CRACKED A IXXA K NONE O OTHER IN INSP/MAINT 1 GL 23 829BX 2636 45994 DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS FOUND ON RIGHT AFT SERVICE DOOR PAN, LOWER AFT CORNER. REPAIR ACCOMPLISH ED REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF A REPAIR DOUBLER IN ACCORDANCE WITH DER APPROVED DRAWING 852 -386-97 AND ENGINEERING ORDER 52-DC8-590. 2 L 7 4 4F RT 4A25 1997111300421 19971113 00421 WP 1997 11 13 IXXA9700159 1 19971028 G 3230 4771392501 PIN DOUG DC8 DC871F 302199D WP LT MLG SHEARED A IXXA K NONE O OTHER CL CLIMB 1 GL 23 820BX 46065 EN ROUTE DFW TO TOL UPON GEAR RETRACTION, THE LEFT MAIN GEAR DOWN AND LOCK LIGHT REMAINED ILLUMINATED. THE CREW RECYCLE D THE LANDING GEAR AND THE INDICATION REMAINED THE SAME. THE FLIGHT CONTINUED TO TOL WITH THE LANDING GEAR IN THE DOWN AND LOCKED POSITION AND MADE AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT AND FOUND THE LEFT MAIN GEAR RE TRACT PIN SHEARED. MAINTENANCE REPLACED THE RETRACT PIN IN ACCORDANCE WITH DACO MAINTENANCE MANUAL PROCEDURES. 2 L 7 4 4F RT 4A25 1997041700501 19970417 00501 NE 1997 4 17 JYDR970327 1 19970313 G 6420 6511107001101 SHOULDER BOLT SKRSKY S64 S64E 8142604 NE T/R CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 CGJZK 1336 3U97500205 64003 FOUND CRACK IN FIRST TWO THREADS WITH MPI. FOUND CRACK-LIKE INDICATION ON INNER RACE ABOUT .750 INCH LONG WITH MPI. CO MPONENT P/N 6511007000019. PART MARKINGS: VENDOR CODE - 81996 - U. S. ARMY AVIATION AND TROOP COMMAND. THIS IS A BREA KOUT PART. (X) 2 G 7 2 4U H4EA 1997041700500 19970417 00500 NE 1997 4 17 JYDR970328 1 19970317 G 6320 643520536101 MAIN SHAFT 643520500048 SKRSKY S64 S64F NE LOWER SPLINES CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 163AC 3473 338 65 64093 CRACKS FOUND IN LOWER SPLINES. CRACKS APPEAR TO START IN SPLINE RADIUS AND TRAVEL AT 45 DEGREES TOWARD THE SPLINE TOOTH . INDICATIONS ARE ON THE LOAD SIDE JUST AT OR BELOW ENGAGEMENT AREA. ELEVEN SPLINES WITH INDICATIONS. LONGEST INDICAT ION IS 0.150 INCH LONG AND IS APPROXIMATELY 0.6 INCH BELOW THE TOP OF THE LOWER SPLINE. (X) 2 G 7 2 4U H6EA 1997030300001 19970303 00001 NE 1997 3 3 JZBR14001 2 19970110 G 7320 5085T40G03 HMU AMD FALC50 FALCON2000 2730170 NM CFE CFE73811B NE LT ENG MALFUNCTION B A JZBR K NONE O OTHER IN INSP/MAINT 1 EA 25 2FOR 455 BECH0521 29 P105157 INSTALLED HMU ON ENG FOR TEST AFTER C/W CFE 7388001. PERFORMED 2 NORMAL STARTS SATISFACTORILY. THE 3RD START ATTEMPT A ND SUBSEQUENT ATTEMPTS FAILED. RE-INSTALLED ORIG HMU AND STARTS WERE NORMAL. 2 K 7 3 4F 4 F RT A50NM E44NE 1997041500001 19970415 00001 SO 1997 4 15 JZBR14058 1 19970329 G 2437 1159AU213123 AMPLIFIER GULSTM G1159 G1159 3953505 SO BAT MONITOR FAILED B JZBR K NONE O OTHER IN INSP/MAINT 1 EA 25 711RL 391C 25 CREW REPORTED NR 2 BATT AMPMETER FROZE AT 32 AMPS. TROUBLESHOOTING REVEALED THE BATTERY MONITOR AMP AT FAULT. REMOVED AND REPLACED THE AMPLIFIER WITH A SERVICEABLE UNIT. PERFORMED A FUNCTIONAL TEST IAW THE MM AND ALL WAS GOOD. THE FOLLO WING DAY MAINTENANCE REMOVED AND REPLACED THE MAIN BATTERIES BECAUSE THERE WERE LOANERS ON BOARD. A BATTERY INTEGRITY C K WAS ACCOMPLISHED WITH NO DISCREPANCIES. A FUNCTIONAL TEST OF THE AMP REVEALED THE UNIT HAD FAILED. THE UNIT WAS REPL ACED BY ANOTHER SERVICEABLE UNIT. FUNCTIONAL TEST WAS GOOD AND AIRCRAFT RETURNED TO SERVICE. NOTE: NO TRIPS WERE FLOW N BETWEEN THESE CHANGES. THIS IS THE SECOND UNIT THAT FAILED FOLLOWING REPAIR BY THE MANUFACTURER. (X) 2 L 7 2 4F RT A12EA 1997040300308 19970403 00308 EA 1997 4 3 JZBR14067 1 19970122 G 3240 KEYWAY 6008512361 CNDAIR CL600 CL6002B16 1900305 EA MISSING B JZBR K NONE O OTHER IN INSP/MAINT 1 EA 25 449ML SEPT870004 5022 DURING TIRE CHANGE, FOUND SEVERAL KEYWAYS ON BRAKE ASSEMBLY COMING OFF. RIVETS THAT HOLD KEYWAY TO DISK LOOSE AND MISSI NG. BRAKE WEAK. INDICATOR SHOWED BRAKE TO HAVE WEAR LEFT. (X) 2 L 7 2 4F RT A21EA 1997051500032 19970515 00032 CE 1997 5 15 JZBR14404 1 19970311 G 5610 10138402515 WINDSHIELD BEECH 200 B200 1152922 CE LT COCKPIT SHATTERED B JZBR K NONE O OTHER CL CLIMB 1 EA 25 508MV 94278H5429 BB877 LEFT (PILOT) WINDSHIELD SHATTERED DURING CLIMB-OUT AFTER TAKEOFF. REMOVED AND REPLACED WINDSHIELD IAW MM 56-10-00 AND K IT 101-5043-1. ALL CHECKS WERE GOOD. AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 4T A24CE 1999092400159 19990924 00159 1999 9 24 MVH0064147 4 19970214 G 2312 4000103000 TRANSCEIVER AEROSP SA365 SA365N 8680669 EU COCKPIT MALFUNCTIONED H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 6068 TRANSCEIVER'S RECEIVE LIGHT IS ON ALL THE TIME, AND UNIT RECEIVES INTERMITTENTLY. 1 G 7 2 3U H10EU 1999092400160 19990924 00160 1999 9 24 MVH0064148 4 19970314 G 3416 396005241 ENCODER AEROSP SA365 SA365N 8680669 EU ALTIMETER FAILED H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 5537 6068 ALTIMETER ENCODING PN 39600-5214 SN 350 WILL NOT ENCODE. 1 G 7 2 3U H10EU 1999092400161 19990924 00161 1999 9 24 MVH0064149 4 19970321 G 2312 4000103000 TRANSCEIVER AEROSP SA365 SA365N 8680669 EU COCKPIT FAILED H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 6068 TRANSCEIVER UNIT WILL TRANSMIT FOR A FEW MINUTES, THEN FAILS. 1 G 7 2 3U H10EU 1999092400162 19990924 00162 1999 9 24 MVH0064150 4 19970326 G 2312 CH45202G CONTROL UNIT AEROSP SA365 SA365N 8680669 EU COMMUNICATIONS FAILED H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 3779 6068 UNIT LOCKS UP AND WILL NOT TRANSMIT MOSTLY ON FM2. WILL TRANSMIT AFTER TURNED OFF AND BACK ON. 1 G 7 2 3U H10EU 1999092400163 19990924 00163 1999 9 24 MVH0064151 4 19970326 G 2312 CH460000 CONTROL UNIT AEROSP SA365 SA365N 8680669 EU COMMUNICATIONS FAILED H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 3779 6068 UNIT LOCKS UP AND WILL NOT TRANSMIT MOSTLY ON FM2. WILL TRANSMIT AFTER TURNED OFF AND BACK ON. 1 G 7 2 3U H10EU 1999092400164 19990924 00164 NE 1999 9 24 MVH0064152 2 19970403 G 7321 0164248670 FCU ARRIEL1 AEROSP SA365 SA365N 8680669 EU TMECA ARRIEL ARRIEL1C 60030 NE ENGINE MALFUNCTIONED H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 1345 2106 6068 FUEL CONTROL INOPERABLE. HARD STARTS AND HOT STARTS FIRST START OF THE DAY. 1 G 7 2 3U 3 U H10EU E19EU 1999092400165 19990924 00165 EU 1999 9 24 MVH0064153 1 19970408 G 7714 9580115900 SENSOR ARRIEL1 AEROSP SA365 SA365N 8680669 EU TMECA ARRIEL ARRIEL1C 60030 NE OVERSPEED MALFUNCTIONED H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 1345 2106 6068 2203 OVERSPEED FAIL LIGHT ILLUMINATES INTERMITTENTLY. 1 G 7 2 3U 3 U H10EU E19EU 1999092400166 19990924 00166 1999 9 24 MVH0064157 4 19970425 G 2312 4000102000 TRANSCEIVER AEROSP SA365 SA365N 8680669 EU COCKPIT FAILED H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 6068 TRANSCEIVER WILL NOT TRANSMIT. 1 G 7 2 3U H10EU 1999092400167 19990924 00167 NE 1999 9 24 MVH0064158 2 19970512 G 7321 0164248670 FCU AEROSP SA365 SA365N 8680669 EU TMECA ARRIEL ARRIEL1C 60030 NE ENGINE MALFUNCTIONED H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 422 6068 2060 FUEL CONTROL INOPERATIVE. SLOW STARTS AND FLUCTUATING RPM. 1 G 7 2 3U 3 U H10EU E19EU 1999092400168 19990924 00168 EU 1999 9 24 MVH0064159 1 19970512 G 7712 9580113720 TRANSMITTER AEROSP SA365 SA365N 8680669 EU TMECA ARRIEL ARRIEL1C 60030 NE TORQUE NOT CALIBRATED H BAQA K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 03 63CF 564 6068 2060 TRANSMITTER CALIBRATED IMPROPERLY. 1 G 7 2 3U 3 U H10EU E19EU 1999092400169 19990924 00169 NE 1999 9 24 MVH0064160 2 19970512 G 7200 AR1C ENGINE AEROSP SA365 SA365N 8680669 EU TMECA ARRIEL ARRIEL1C 60030 NE ENGINE BAY MAKING METAL H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 1936 6068 2060 ENGINE MAKING METAL AND MODULE 3 DUE TBO. 1 G 7 2 3U 3 U H10EU E19EU 1999092400170 19990924 00170 EU 1999 9 24 MVH0064168 1 19970723 G 7931 53408A TRANSMITTER AEROSP SA365 SA365N 8680669 EU ENG OIL PRESS INACCURATE H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 689 6068 PRESSURE TRANSMITTER READS 5 BAR WHEN POWER IS ON AND GOES UP FROM THERE. 1 G 7 2 3U H10EU 1999092400171 19990924 00171 1999 9 24 MVH0064174 4 19971028 G 3457 80823000312 GPS AEROSP SA365 SA365N 8680669 EU COCKPIT INOPERATIVE H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 6068 RECEIVED LOANER TNL3000 TRIED TO INSTALL IN A/C. DISPLAY INDICATED GPS PORTION INOPERABLE. 1 G 7 2 3U H10EU 1999092400172 19990924 00172 1999 9 24 MVH0064177 4 19971112 G 3421 H140CAM1 GYRO AEROSP SA365 SA365N 8680669 EU ATTITUDE FAILED H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 6068 INSTALLED OVERHAULED ATTITUDE INDICATOR. WITHIN 5 HOURS, UNIT SHOWED SIGNS OF BEING UNSTABLE IN-FLIGHT SUCH AS AUTOPILO T WOULD NOT STAY ENGAGED; THEN, INDICATOR GOT WORSE AND NOW WILL ROLL OVER IN-FLIGHT. 1 G 7 2 3U H10EU 1999092400173 19990924 00173 EU 1999 9 24 MVH0064178 1 19971118 G 6730 80321 SERVO AEROSP SA365 SA365N 8680669 EU MAIN ROTOR MALFUNCTIONED H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 4003 6068 REMOVED FOR SERVO JAM LIGHT INOPERATIVE. 1 G 7 2 3U H10EU 1999092400174 19990924 00174 1999 9 24 MVH0064181 4 19971216 G 2312 4000102000 TRANSCEIVER AEROSP SA365 SA365N 8680669 EU COCKPIT MISREPAIRED H BAQA K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 03 63CF 6068 TRANSCEIVER INSTALLED IN AIRCRAFT. ON FIRST FLIGHT, TONES WOULD NOT OPEN AND TRANSMIT WAS BROKEN AND GARBLED. 1 G 7 2 3U H10EU 1999092400175 19990924 00175 1999 9 24 MVH0064182 4 19971231 G 2312 40001452502 TRANSCEIVER AEROSP SA365 SA365N 8680669 EU COCKPIT FAILED H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 6068 TRANSCEIVER HAD BROKEN RECEPTION. 1 G 7 2 3U H10EU 1999092400176 19990924 00176 EU 1999 9 24 MVH0064183 1 19971231 G 3213 1801510001 STRUT AEROSP SA365 SA365N 8680669 EU MLG RATCHETS H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 6127 6068 STRUT LEAKING AT SHAFT AND RATCHETS. 1 G 7 2 3U H10EU 1999092400195 19990924 00195 EU 1999 9 24 MVH0064268 1 19970424 G 2420 353Y0314 SENSOR AEROSP SA365 SA365N 8680669 EU AC SYSTEM MALFUNCTIONED H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 6068 INVERTER LIGHT ILLUMINATES OCCASIONALLY. REMOVED AND REPLACED 115 VOLT SENSOR. 1 G 7 2 3U H10EU 1999092400196 19990924 00196 EU 1999 9 24 MVH0064269 1 19970512 G 7921 RH2125 OIL COOLER AEROSP SA365 SA365N 8680669 EU ENGINE CONTAMINATED H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 5824 6068 OIL COOLER - METAL, CONTAMINATED, REQUIRED FLUSHING AND RECERTIFICATION. 1 G 7 2 3U H10EU 1999092400197 19990924 00197 EU 1999 9 24 MVH0064278 1 19971009 G 6300 704A33651118 BEARING 365A31000204 AEROSP SA365 SA365N 8680669 EU M/R DRIVE CONTAMINATED H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 698 981 6068 REMOVED DUE SUSPECTED WEAR AND METAL CONTAMINATION. REMOVED AND REPLACED WITH NEW BEARING. 1 G 7 2 3U H10EU 1999092400198 19990924 00198 EU 1999 9 24 MVH0064279 1 19971009 G 6210 365A31177120 PIN 365A31001202 AEROSP SA365 SA365N 8680669 EU M/R BLADE CORRODED H BAQA K NONE O OTHER IN INSP/MAINT 1 EA 03 63CF 2465 579 6068 REMOVED BLADE PINS SN'S M10720, M9864, M10730, M10306, M10171, M10137, 8044, M9266 DUE TO CORROSION. INSTALLED NEW PIN S SN'S M3081, M3020, M3023, M3024, M3025, M3039, M3187, M3227. 1 G 7 2 3U H10EU 1997052200376 19970522 00376 NE 1997 5 22 PCAA9700363 2 19970409 G 7261 OIL SYSTEM DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE NR 1 ENGINE MALFUNCTION E PCAA A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 EA 13 818EX 235 120448 OIL SYSTEM MALFUNCTION 2 H 7 2 4T 4 T RT A13NM E20NE 1997042400024 19970424 00024 EU 1997 4 24 SADF9700002 1 19970402 G 5240 HC38370010003 SERVICE DOOR BAC 146 AVRO146RJ100 1500096 EU LAV SERVICE OUT OF PLACE A A SADF K NONE O OTHER CR CRUISE 1 SO 23 511MM 4881 E3255 ADZ/BOG - FLT 503 - DURING FLIGHT FROM ADZ/BOG, PILOTS EXPERIENCED PRESSURIZATION PROBLEMS WITH FLUCTUATIONS AND CABIN A LTITUDE CONTROL PROBLEMS. FLIGHT DIVERTED TO PTY, LANDED WITHOUT FURTHER INCIDENT. (X) 2 H 7 4 4F RT A49EU 1997121100120 19971211 00120 EU 1997 12 11 SADF9706 1 19971103 G 3230 HTE210014 VALVE ACTUATOR BAC 146 AVRO146RJ100 1500096 EU GEAR SELECTOR FAILED A SADF A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 SO 23 504NM 6582 391GB450 E3221 AFTER DEPARTURE, LANDING GEAR DID NOT GO UP. IT REMAINED DOWN. FLT 396 AIR TURN-BACK TO BOGOTA. LANDING GEAR ELECTRIC ACTUATOR OF SELECTOR VALVE WAS REPLACED IAW MM. 2 H 7 4 4F RT A49EU 1997071000275 19970710 00275 NE 1997 7 10 SI3R97003 2 19970605 G 7210 7757571 BEARING 6044T35P01 SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A2 30030 NE GC49 GEARBOX SPALLED B S SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 22234 5200 GEE367288 CHIP DETECTOR WAS SHOWING HEAVY CHIP CONTAMINATION. DISASSEMBLY OF GEAR CASE REVEALED THE PROPELLER SHAFT FORWARD ROLLE R BEARING ROLLERS (GROUP 5 FIG 7 ITEM 60 IN CMM 72-11-02) WERE SPALLED. (X) 2 L 7 2 4T 4 T RT A52EU E8NE6 1997071000274 19970710 00274 NE 1997 7 10 SI3R97005 2 19970617 G 7322 35853CNX285 INSERT PWA JT8 JT8* 52044 NE FUEL CONTROL WORN B L SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 18154 3477 "FUEL LEAK NR 2 ENGINE AS OBSERVED BY ANOTHER AIRCRAFT WHILE TAXIING'. THE LEAK WAS CONFIRMED. OF THE 3 BOLTS THAT HOL D TEMPERATURE COMPENSATING BELLOWS ASSY TO MAIN HOUSING, 1 WAS MISSING, AND THE OTHER 2 HAD LOOSENED. THIS ALLOWED FLAN GE SEAL TO EXTRUDE OUT OF ITS GROOVE, AND FUEL TO LEAK PAST. THE ROOT CAUSE IS THE LOCKING FEATURE OF THE INSERTS HAD W ORN BELOW THE MINIMUM OF 2 INCH/POUND RUNNING TORQUE. THIS OVERHAUL AND REPAIR STATION PERFORMS MAINTENANCE ON THESE FU EL CONTROLS, AND HAS INSTITUTED A MANDATORY CHECK OF THE RUNNING TORQUE OF THESE INSERTS. THIS BOLT AND LOCKING INSERT FASTENING SYSTEM IS COMMON TO ALL JFC60 MODELS. (X) 4 F E2EA 1997091100319 19970911 00319 NE 1997 9 11 SI3R97006 2 19970815 G 7210 7757706 RETAIN NUT HAMSTD 5074T51G10 SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE GC 49 DRIVE GEAR LOST TORQUE B S SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 9770 1H100173 GEE785524 DURING DISASSEMBLY OF GEARBOX, RETAINING NUT (P/N 775770-6) WAS REMOVED WITH NO OBTAINABLE TORQUE READING USING TORQUE F IXTURE. HSS SO NR 62971SE. CUST: WINGS WEST (X) 2 L 7 2 4T 4 T RT A52EU E8NE 1997120300023 19971203 00023 NE 1997 12 3 SI3R97007 2 19970819 G 7210 7757602 BEARING HAMSTD 6044T35P10 SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE GC 49 IDLER GEAR SPALLED B S SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 12767 8158 GEE786268 DURING DISASSEMBLY OF GEARBOX, THE RIGHT FORWARD IDLER GEAR BEARING RACE AND ROLLERS WERE FOUND TO BE SPALLED. (P/N 775 660-2, FIG 8, ITEM 85). HSS SO NR 63470SE. CUST: FLAGSHIP A/L. (X) 2 L 7 2 4T 4 T RT A52EU E8NE 1997091100318 19970911 00318 NE 1997 9 11 SI3R97008 2 19970909 G 7210 7757612 BEARING 6044T33TP11 SAAB SF340 SF340A 7850100 EU GE CT7TP CT79C 30030 NE GC 49 GEARCASE CRACKED B S SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 8809 8292 GEE309111 DISASSEMBLY OF CASE REVEALED EXTENSIVE INTERNAL DAMAGE. CONDITIONS ARE NOT REPAIRABLE; THUS, THIS GEAR CASE IS CONSIDER ED SCRAP. INITIAL EVALUATION OF HARDWARE FINDS POSSIBLE INITIAL BREAKDOWN DUE TO RIGHT IDLER AFT BEARING FAILURE, PN 77 5761-2. 2 L 7 2 4T 4 T RT A52EU E8NE 1997110600868 19971106 00868 NE 1997 11 6 SI3R97009 2 19971009 G 7210 7895781 TAB WASHER HAMSTD 5074T51G11 SAAB SF340 SF340A 7850100 EU GE CT7TP CT79B 30030 NE GC49 GEAR CASE BROKEN B S SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 2448 1H100038 GEE309179 DISASSEMBLY OF GEAR CASE REVEALED RIGHT IDLER GEAR FORWARD TAB WASHER WAS BROKEN AND CRACKED (PN 789578-1, ITEM 65B, FIG 1A). (X) 2 L 7 2 4T 4 T RT A52EU E8NE 1997110600869 19971106 00869 NE 1997 11 6 SI3R97010 2 19971009 G 7210 7757571 ROLLER BEARING HAMSTD 644T35P10 SAAB SF340 SF340A 7850100 EU GE CT7TP CT79B 30030 NE GC49 GEAR CASE CRACKED B S SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 13874 UDAG0638 GEE785436 DISASSEMBLY OF GEAR CASE REVEALED FORWARD ROLLER BEARING INNER RACE CRACKED (PN 775757-1, ITEM 60, FIG 7). (X) 2 L 7 2 4T 4 T RT A52EU E8NE 1997110600867 19971106 00867 NE 1997 11 6 SI3R97011 2 19971024 G 7210 7757571 ROLLER BEARING HAMSTD 6044T35P02 SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A2 30030 NE GC49 GEAR CASE CRACKED B S SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 23078 0208 GEE367319 DISASSEMBLY OF GEAR CASE REVEALED THE FORWARD ROLLER BEARING INNER RACE CRACKED (PN 775757-1, ITEM 60 FIG 7). (X) 2 L 7 2 4T 4 T RT A52EU E8NE6 1997110700008 19971107 00008 NE 1997 11 7 SI3R97012 2 19971024 G 7210 7757651 ROLLER BEARING HAMSTD 6044T35P10 SAAB SF340 SF340A 7850100 EU GE CT7TP CT79B 30030 NE GC49 GEAR CASE CRACKED B S SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 13407 UDAG083 GEE785379 DISASSEMBLY OF GEAR CASE REVEALED THE INPUT ROLLER BEARING RACE CRACKED, PINION GEAR BEARING SURFACE SPALLED, LEFT AND R IGHT IDLER GEAR RETAINING RINGS BROKE, AND NO TORQUE ON LEFT IDLER GEAR NUT. PINION, SN IC641356. INPUT BEARING, SN 9- 259. REF: OPERATOR CONTROL NR 97ZZZX4682, 97ZZZX4683, AND 97ZZZX4684. (X) 2 L 7 2 4T 4 T RT A52EU E8NE 1997122400027 19971224 00027 NE 1997 12 24 SI3R97014 2 19971130 G 7210 7757571 BEARING 5074T51G10 SAAB SF340 SF340A 7850100 EU GE CT7TP CT79B 30030 NE GC 49 GEARCASE CRACKED B S SI3R K NONE O OTHER IN INSP/MAINT 1 NE 03 14625 GEE785213 UPON DISASSEMBLY OF GEARBOX, FOUND CRACKED INNER RACE ON THE FORWARD ROLLER BEARING (PN 775757-1 ITEM 60 FIG 7). (X) 2 L 7 2 4T 4 T RT A52EU E8NE 1997092500278 19970925 00278 SO 1997 9 25 XC4R4848 1 19970915 G 2121 T600069 PC BOARD TECHNOFAN AE1711AA0 EMB 120 EMB120RT SO GROUND COOLING LOOSE JOINTS B XC4R K NONE O OTHER IN INSP/MAINT 1 SO 19 5106 29 FAN INOPERATIVE AS RECEIVED. UPON INSPECTION, FOUND ALL COMPONENTS ON DRIVER P.C. BOARD LOOSE. SOLDER JOINTS OVERHEATE D. THIS FAN IS MANUFACTURED IN FRANCE AND IS AN ALLEGED PRODUCT IMPROVEMENT, SAME PROBLEMS AS OLD P/N EVAC2322 FAN ASSE MBLY. (X) 2 L 7 2 4T RT A31SO 1997100900173 19971009 00173 SO 1997 10 9 XC4R4853 1 19970919 G 2121 T600069 PC BOARD TECHNOFAN AE1711AA0 EMB 120 EMB120RT SO GROUND COOL FAN LOOSE B XC4R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 19 3701 100 FAN INOPERATIVE AS RECEIVED. INSPECTION FOUND ALL DRIVER P.C. BOARD SOLDER JOINTS LOOSE AND DEFECTIVE. THIS FAN IS MAN UFACTURED IN FRANCE. THIS REPAIR STATION HAS WITNESSED PREVIOUSLY THE SAME FAULTS ON SAME PART NUMBERED FAN. (X) 2 L 7 2 4T RT A31SO 1997082800012 19970828 00012 SO 1997 8 28 XC4R643M 1 19970806 G 3242 2445902 DISK BFGOODRICH 21585 EMB 120 EMB120RT SO NR 1 BRAKE WORN B XC4R K NONE O OTHER IN INSP/MAINT 1 SO 19 2788 NR 1 ROTATING DISK BROKEN AND MISSING. OTHER ROTATING DISKS AND WEAR PADS OKAY. WEAR PIN INDICATES 90 PERCENT WORN. P ACKINGS AND RETAINERS SHOW NORMAL WEAR. NO OTHER DAMAGE NOTED. SUBMITTER STATED HAVE WITNESSED THE OLD P/N BRAKE ASSEM BLY 2-1479 HAVE THE SAME FAILURE. THE NEW P/N BRAKE IS NO IMPROVEMENT. 2 L 7 2 4T RT A31SO 1997121100132 19971211 00132 SO 1997 12 11 XC4R6637 1 19971124 G 3242 44667 DISC BFGOODRICH 21585 EMB 120 EMB120 3260201 SO NR 3 BROKEN B XC4R K NONE O OTHER IN INSP/MAINT 1 SO 19 2138 0076 UPON RECEIPT OF BRAKE ASSEMBLY FOR OVERHAUL, NR 3 CARRIER LINING WAS FOUND BROKEN IN THREE PIECES. SUBMITTER STATES NUM EROUS PROBLEMS WITH THIS BRAKE ASSEMBLY. 2 L 7 2 4T RT A31SO 1997032700293 19970327 00293 SO 1997 3 27 XC4R9720736 1 19970208 G 2435 230801971 BRUSH LUCAS 23080013 EMB 120 EMB120ER 3260203 SO START/GEN FAILED B A XC4R K NONE O OTHER IN INSP/MAINT 1 SO 19 296SW 277 96384 120325 START/GEN BRUSHES FAILED AFTER 277.0 HOURS OF FLIGHT TIME. THE BRUSH SHUNT LEADS WERE BURNED AND BROKEN OFF. THIS WAS A NEW AIRCRAFT, THIS WAS A NEW STARTER GENERATOR WITH ONLY 277.0 HOURS SINCE NEW. SUBMITTER RECOMMENDS RE-DESIGNING DEF ECTIVE BRUSHES. NOTE: THIS REPAIR STATION HAS SEEN MANY OF THESE BRUSH FAILURES IN THE PAST. (X) 2 L 7 2 4T RT A31SO 1997062600276 19970626 00276 EU 1997 6 26 XC4R9752683 1 19970519 G 2421 31342350 ROTOR 31342001 SAAB SF340 SF340A 7850100 EU AC GENERATOR FAILED B A XC4R K NONE O OTHER NR NOT REPORTED 1 SO 19 1859 579 THIS UNIT SUFFERED A MAIN ROTOR BAND FAILURE DURING OPERATION. ONE EACH OF 2 MAIN ROTOR BANDS DETACHED DURING OPERATION CAUSING EXTENSIVE DAMAGE TO THE ROTOR, EXCITER STATOR, AND MAIN STATOR. THIS FAILURE OCCURRED DURING NORMAL OPERATING CONDITIONS. SUBMITTER STATED THIS FACILITY HAS SEEN NUMEROUS FAILURES SIMILAR TO THIS ONE. RECOMMEND REPLACMENT OF STA INLESS BANDS WITH SOLID RINGS OF ALUMINUM. (X) 2 L 7 2 4T RT A52EU 1997071700625 19970717 00625 SO 1997 7 17 XC4R9763186 1 19970612 G 3240 2662011 PISTON HOUSING BFGOODRICH EMB 120 EMB120RT SO BRAKE ASSY DEFECTIVE B XC4R K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 19 1527 0051 BRAKE ASEMBLY RECEIVED FOR FIRST OVERHAUL WITH INCORRECT LUB TORQUE ON HOUSING 450-470 POUND/INCH, BY B.F.G. SHOULD BE 215-225 POUND/INCH . B.F.G. WAS NOTIFIED AND PART IS TO BE SENT TO B.F.G. FOR INSPECTION AND TO RECTIFY THE FACTORY ERR OR. PART TT SINCE NEW, 1,526.6 HOURS. (X) 2 L 7 2 4T RT A31SO 1997071700626 19970717 00626 SO 1997 7 17 XCR9763120 1 19970612 G 3242 244608 ROTATING DISK BFGOODRICH 214791 EMB 120 EMB120ER 3260203 SO BRAKE ASSY BROKEN B XC4R K NONE O OTHER IN INSP/MAINT 1 SO 19 234SW 926 1656 120300 RECEIVED BRAKE ASSEMBLY FOR OVERHAUL. VISUAL INSPECTION REVEALS ONE EACH ROTATING DISK BROKEN IN HALF. 2 L 7 2 4T RT A31SO