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 2007050700187 20070507 00187 NE 2007 5 7 0088867 3 20051208 G 6111 10075681 BLADE EMB 120 EMB120 3260201 SO HAMSTD 14RF 14RF9 NE PROPELLER CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 PROPELLER BLADE NICKEL SHEATH CRACKED. 2 L 7 2 4T RT A31SO 6 C P11NE 2005050400058 20050504 00058 EA 2005 5 4 041251 1 20050412 G 4950 38462341 CLAMP GARRTT CNDAIR CL600 CL6002A12 1900304 EA APU DUCT BROKEN B K NONE M J OVER TEMP WARNING INDICATION IN INSP/MAINT 1 CE 01 601RC 14 3055 APU HAD BEEN RUNNING ON THE GROUND FOR APPROXIMATELY ONE HOUR AND SHUT ITSELF DOWN DUE TO HIGH OIL TEMP AS INDICATED BY (BYTE) LIGHT. VISUAL INSPECTION SHOWED THAT BLEED AIR ELBOW HAD BROKEN OFF OF EXHAUST STACK CLAMP AT THE WELD. RECOMME ND REGULAR VISUAL INSPECTIONS FOR CRACKS ON THE STRAP THAT HOLDS THE TUBE TO THE CLAMP. IN ADDITION, METHOD OF ATTACHME NT OF TUBE TO THE CLAMP BE MODIFIED TO REDUCE SHARP CORNERS WHERE CRACKS ORIGINATE. 2 L 7 2 4F RT A21EA 2006012500006 20060125 00006 SO 2006 1 25 050143850 1 20051213 G 5100 BOLT PIPER PA28 PA28181 7102807 SO PROPELLER CORRODED B K NONE O OTHER IN INSP/MAINT 1 GL 09 30034 2843576 DURING REMOVAL OF PROP TO ACCESS BELTS, FOUND ONE PROP BOLT SEVERELY PITTED. ONLY THE ONE BOLT SHOWED ANY SIGNS OF CORR OSION. BOLT HAD ONLY 350 HOURS FROM ORIGINAL FACTORY INSTALL. BOLT WAS REPLACED AND DIGITAL PHOTO'S WERE SUPPLIED MFG TECH SERVICES. 1 L 7 1 3O 2A13 2005080200103 20050802 00103 2005 8 2 05085444 4 20050729 G 2300 7000700665 ADC CESSNA 650 650 2076802 CE AVIONICS BAY INTERFERENCE B O OTHER S AFFECT SYSTEMS CR CRUISE 1 CE 03 47AN 6718 6500054 NR 2 COM INTERFERENCE ON FREQUENCY 127.975. INTERFERENCE IS COMING FROM BOTH AZ-810 ADC'S. HONEYWELL TECH SUPPORT INSTR UCTED ME TO INSTALL FOIL TAPE ON ADC EXTERIOR PANEL SEAMS TO ELIMINATE PROBLEM. THE ADC'S SHOULD BE REPAIRED OR MODIFIE D INTERNALLY BY HONEYWELL TO ELIMINATE RF INTERFERENCE. 2 L 7 2 4F A9NM 2005092000055 20050920 00055 SW 2005 9 20 0509137 1 20050906 G 7810 15070001 EXHAUST RISER LKHEED PV1 PV1 5260104 SW PWA R2800 R2800* 52026 NE NR 5 SEPARATED C O OTHER O OTHER NR NOT REPORTED 1 EA 07 234P 5336 NR 5 EXHAUST RISER HAD SEPARATED FROM ENGINE JUST BELOW THE FLANGE WELD. THE OWNER STATED THIS WAS THE SECOND TIME THIS HAS HAPPENED IN 40 HOURS. REPLACED ALL 3 RISERS AND COLLECTOR. 2 M 7 2 4R 4 R RT EXPA2M2 5E8 2005091500006 20050915 00006 GL 2005 9 15 0509137A 1 20050906 G 7810 15070001 EXHAUST RISER CIRRUS SR SR22 2130001 GL NR 5 FAILED C O OTHER O OTHER NR NOT REPORTED 1 EA 07 234PG 0935 NR 5 EXHAUST RISER HAD SEPARATED FROM ENGINE JUST BELOW THE FLANGE WELD. THE OWNER STATED THIS WAS THE SECOND TIME THIS HAS HAPPENED IN 40 HOURS. REPLACED ALL 3 RISERS AND COLLECTOR. 1 L 7 1 3O NT A00009CH 2005091900124 20050919 00124 EA 2005 9 19 05252001 2 20050909 G 7261 STD2217 SEAL LYC CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA ADAPTOR LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 NM 03 98 98 FIRST 100 HOUR INSPECTION AFTER OVERHAUL BY MFG (ENGINE SMOH 98.5). FOUND OIL LEAKING FROM DRY VACUUM PUMP DRIVE. THE EN GINE VACUUM PUMP ADAPTOR DRIVE OIL SEAL WAS NOT SEATED FAR ENOUGH IN ADAPTOR HOUSING CAUSING LEAKAGE. REPLACED ADAPTOR DRIVE OIL SEAL AND REINSTALLED ADAPTOR AND PUMP WITH NEW GASKETS. OPERATIONAL AND LEAK CHECK SATISFACTORY. THIS IS THE SECOND OVERHAULED ENGINE WITH SAME PROBLEM. 1 H 7 1 3O 3 O NT 3A12 E274 2005112800175 20051128 00175 CE 2005 11 28 053006 1 20051102 G 8011 48037901C1 DRIVE ASSY ELECTROSYS CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA STARTER FAILED D K NONE O OTHER NR NOT REPORTED 1 NM 03 97LP 1356 B061774 17274398 RL1952439A ON ENGINE START, STARTER DRIVE DID NOT DISENGAGE AND THE DRIVE GEARS SHEARED OFF, DAMAGING THE ENGINE RING GEAR. THE PIL OT DID NOT DETECT THE FAILURE UNTIL LANDING AND TRYING TO RESTART THE ENGINE. 1 H 7 1 3O 3 O NT 3A12 E274 2005112800173 20051128 00173 EA 2005 11 28 05308 2 20051104 G 8540 STD2217 SEAL LYC CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA ENGINE LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 NM 03 9621V 168 17264401 L4394027A DURING 100 HOUR INSPECTION, FOUND ENGINE VACUUM PUMP DRIVE LEAKING OIL AND CONTAMINATING VACUUM PUMP. REMOVED VACUUM PU MP AND ENGINE VACUUM PUMP ADAPTOR DRIVE ASSEMBLY. FOUND SEAL P/N STD-1774 NOT FULLY INSTALLED IN DRIVE ASSY. REPLACED SE AL AND VACUUM PUMP, OPERATIONAL AND LEAK CHECK SAT. ENGINE HAS 168.7 HOURS SINCE OVERHAUL BY MFG. THIS IS THE SECOND OV ERHAULED ENGINE WITH THIS DISCREPANCY. 1 H 7 1 3O 3 O NT 3A12 E274 2005101900001 20051019 00001 CE 2005 10 19 1005FAA001 1 20051018 G 3340 202331 STROBE BEECH 58 58 1152740 CE WING TIP DAMAGED C K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 15 3694K TH1177 WING TIP STROBE UNIT FLASH TUBE. SOLDER JOINT BETWEEN PIN COMING OUT OF FLASH TUBE AND END CAP IS FAILING DUE TO SOLDER BEAD BEING GROUND FLAT AFTER ATTACHMENT DURING MANUFACTURE. MULTIPLE FAILURES - CONDITION EXISTS ON NEW UNITS. 1 L 7 2 3O 3A16 2005042700151 20050427 00151 GL 2005 4 27 1050326 3 20050330 G 6111 F7666A2 BLADE SOCATA TB20 TB20TRINIDAD 8680695 EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK1 GL PROPELLER CRACKED B O OTHER O OTHER NR NOT REPORTED 1 SW 99 DEREH 387 CH24122 BLADE 1, S/NR H20755R WAS FOUND WITH A 1 INCH CRACK, STARTING FROM LEADING EDGE, ABOUT 4 INCHES FROM BLADE TIP. THE BLAD E WAS ALREADY REWORKED AT THIS AREA BECAUSE OF A EARLIER STONE NICK. PROPELLER WAS OVERHAULED IN MARCH 2003 AND HAS 387 TSO UNTIL CRACK WAS FOUND. 1 L 7 1 3O 3 O RT A51EU 1E10 5 C P920 2006010600097 20060106 00097 EA 2006 1 6 1120057261 2 20051120 G 7261 W2046 PUMP PIPER PA28 PA28R180 7102809 SO LYC O360 IO360B1E 41514 EA HARTZL HCC2Y HCC2YK1 GL AIR-SIPHON PUMP MISMANUFACTURED D A UNSCHED LANDING K FLUID LOSS CR CRUISE 1 WP 11 3843T 732 732 28R30162 L546051A CH21499 PILOT NOTED RAPID LOSS OF ENGINE OIL PRESSURE. INITIATED PRECAUTIONARY LANDING. VISUAL INSPECTION OF MODIFIED P/N 6876 1 DRAINBACK LINE CUTOFF FOR AIR-SIPHON PUMP ( AIR-OIL SEPARATOR STC NR SA3687WE INSTALLATION FOUND SHARP, UNDRESSED AND UNBEADED IAW ORIGINAL INSTALLATION INSTRUCTIONS (CIRCA 1993 BY 337) CAUSED INSIDE OF MIL-6000-5/6 HOSE TO BE CUT CAUSING MASSIVE OIL LEAK. PRESENT STC HOLDER, NOW SUPPLIES ONE-PIECE AIR-SIPHON PUMP P/N W-2046 TO REPLACE THIS ASSEMBLY. REC OMMEND REPLACING ORIGINAL CUTOFF DRAIN TUBES WITH NEW PART TO PREVENT OIL LOSS. 1 L 7 1 3O 3 O 2A13 1E10 5 C P920 2005080900069 20050809 00069 CE 2005 8 9 123197A 1 20050804 G 2133 66001983 OUTFLOW VALVE LEAR 35 31A 5170531 CE GARRTT TFE731 TFE731* 01518 WP TAILCONE FAILED B B EMER. DESCENT J WARNING INDICATION CR CRUISE 1 CE 07 518JG 219 DURING CRUISE, AIRCRAFT LOST PRESSURIZATION. COCKPIT INDICATIONS ALERTED CREW AS DESIGNED. AIRCRAFT PRESSURIZATION AUTO MATICALLY DEFAULTED TO EMERGENCY MODE. 2 L 7 2 4F 4 F RT A10CE E6WE 2005080900058 20050809 00058 CE 2005 8 9 123197B 1 20050804 G 2133 261950010 OUTFLOW VALVE LEAR 35 31A 5170531 CE GARRTT TFE731 TFE731* 01518 WP TAILCONE FAILED B B EMER. DESCENT J WARNING INDICATION CR CRUISE 1 CE 07 518JG 59 219 DURING CRUISE, AIRCRAFT LOSS PRESSURIZATION. COCKPIT INDICATIONS ALERTED CREW AS DESIGNED. AIRCRAFT PRESSURIZATION AUT OMATICALLY DEFAULTED TO EMERGENCY MODE. 2 L 7 2 4F 4 F RT A10CE E6WE 2005070600081 20050706 00081 NM 2005 7 6 138 1 20050701 G 5753 SKIN BOEING 737 737522 138449F NM GE CFM56 CFM56* 13802 NE RT WING TE FLAP GOUGED B K NONE O OTHER IN INSP/MAINT 1 SO 15 954UA 26739 RT WING OB FORE FLAP GOUGED ON OB END. S/O 269008, OPS NR 24931. 2 L 7 2 4F 4 F RT A16WE E2GL 2005060700019 20050607 00019 EU 2005 6 7 14038052105 1 20050521 G 3212 6040102 FLOAT AGUSTA A109 A119 0261102 EU PWA PT6 PT6* 52043 EA MLG ACTIVATED B K NONE O OTHER IN INSP/MAINT 1 EA 17 316PD 14038 DURING MAINT, TECH ATTEMPTED TO INSTALL SAFETY PIN IN RESERVOIR ASSY, FLOATS DEPLOYED. IT WAS LATER DISCOVERED THAT ELEC ACT USED TO DEPLOY FLOATS HAD BEEN PARTIALLY DEPLOYED. CHECK OF SYS REVEALED THAT ACT ONLY ENERGIZES WHILE DEPLOYMENT BUTTON IS DEPRESSED. THIS ALLOWS FOR PARTIAL DEPLOYMENT OF ELEC ACTUATOR WHICH WILL INTERFERE WITH INSTALL OF SAFETY PIN , CAUSING A DANGEROUS SITUATION FOR PERSONNEL IN VICINITY OF FLOATS. SUPPLEMENT DOES NOT STATE THAT PILOT MUST CONTINUE TO DEPRESS DEPLOYMENT BUTTON IN ORDER FOR FLOATS TO DEPLOY, WHICH COULD CAUSE FAILURE TO DEPLOY IN AN EMERG. FMS, ICA' S, AND INSTALLATION INSTRUCTIONS ALL HAVE NOTES TO REMOVE SAFETY PIN BEFORE FLIGHT, NO REQ FOR RE-INSTALLING SAFETY PIN. 1 G 7 2 3U 3 T H7EU E2NE 2005071200062 20050712 00062 NM 2005 7 12 142 1 20050701 G 5230 SKIN BOEING 737 737522 138449F NM CARGO DOOR DAMAGED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 954UA 26739 AFT CARGO DOOR REQUIRES RESKIN. 2 L 7 2 4F RT A16WE 2005041400112 20050414 00112 EA 2005 4 14 1622304 2 20050128 G 8520 AELSTD2213 BOLT LYC LYC O360 IO360A3B6 41514 EA CRANKGEAR FAILED B K NONE O OTHER IN INSP/MAINT 1 EA 23 V53790363 L2754551A DURING ENGINE OVERHAUL, THE PMA CRANKGEAR BOLT P/N: AELSTD2213 MANUFACTURED BY ENGINE COMPONENTS INC FAILED BEFORE REACH ING RECOMMENDED TORQUE VALUE. THE AREA JUST BELOW THE GRIP AREA STRETCHED. 3 O 1E10 2005042700135 20050427 00135 2005 4 27 1838110 1 20050325 G 5312 3541046119 BULKHEAD FUSELAGE CRACKED B K NONE O OTHER IN INSP/MAINT 1 GL 03 8696 4823 FRAME FOUND CRACKED WHEN ASSIST STEP WAS REMOVED FOR REPAIR. THE FLOOR MUST BE REMOVED TO ACCESS THE ATTACHMENT NUTS. TH E BULKHEAD HAD BEEN PREVIOUSLY REPAIRED (AIRCRAFT HAD BEEN INVOLVED IN A GEAR UP INCIDENT IN THE PAST) AND WAS CRACKED P AST THE REPAIR DOUBLER. A NEW BULKHEAD WAS INSTALLED. A CLOSE INSPECTION OF THE STRUCTURE SHOULD BE PERFORMED WHEN THE S TEP IS REPAIRED AS THIS MAY BE THE ONLY TIME THE UNDERLYING MEMBERS CAN BE SEEN. 2005042700306 20050427 00306 CE 2005 4 27 18HP 1 20050331 G 2840 S35944 CONTROL UNIT CESSNA 182 182T 2072703 CE LYC O540 IO540* 41532 EA MCAULY 3D36C B3D36C431 GL FUEL SENDING DEFECTIVE B JRUR K NONE N FALSE WARNING IN INSP/MAINT 1 GL 07 18HP 1300 100 18281071 L2823248A 011464 WHILE RUNNING UP AIRCRAFT AFTER MAINTENANCE, IT WAS NOTICED THAT THE FUEL QTY GAGES WERE JUMPING FROM FULL TO EMPTY AND THE LOW FUEL LIGHT WAS FLASHING. BOTH TANKS WERE FULL AT THE TIME. INSTALLED NEW SENDING UNITS IN BOTH WINGS AND IT SE EMED TO REMEDY THE PROBLEM. 1 H 7 1 3O 3 O NT 3A13 1E4 5 C 2005021700141 20050217 00141 EA 2005 2 17 200501306 1 20050124 G 5340 612826 RACK DHAV DHC2 DHC2MK1 2800102 EA ADC MOUNT CRACKED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 60TF 572563 DURING THE REMOVAL OF THE AIR DATA COMPUTER FOUND TRAY CRACKED AT EACH CORNER OF THE THUMBSCREW CUTOUT AT THE BEND RADII . 1 H 7 1 3R A806 2005041500073 20050415 00073 EA 2005 4 15 20050209 2 20050209 G 8500 70384 SHAFT PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA IDLER GEAR BROKEN B EVGR K NONE P NO WARNING INDICATION IN INSP/MAINT 1 SO 33 1985 1985 L251648 AT ENGINE DISASSEMBLY FOR OVERHAUL AFTER RUNNING FULL LIFE (1985.4 HRS) GOVERNOR IDLER GEAR SHAFT WAS FOUND BROKEN INSID E THE GEAR. ENGINE RAN NORMALLY, NO OTHER DAMAGE NOTED. 1 L 7 2 3O 3 O 1A10 1E4 2005050600085 20050506 00085 CE 2005 5 6 20050413 1 20050412 G 2731 12601491 ACTUATOR CESSNA 206 U206G 2073356 CE ZONE 300 MISMANUFACTURED B EVGR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 33 67JA U20605781 DURING ANNUAL INSP, ELEV TRIM TAB FREE PLAY FOUND TO EXCEED LIMITS. EXCESSIVE PLAY LOCATED IN ACT ASSY. NEW ACT INSTAL LED. WHILE PERFORMING RIGGING CHK, TAB MOVED TO ITS LIMITS & A SECOND AMT OBSERVING CABLE MVMNT IN TAIL CONE. MOVING TAB BACK TO NEUTRAL & JUST PRIOR TO REACHING IT, A BANG HEARD FOLLOWED BY TRIM CABLE GOING SLACK. ON INSP, FOUND PINS T HAT HOLD SPROCKET TO ACT SHEARED. INVEST FOUND SLEEVE SPROCKET MUSHROOMED. HOLES WHERE PINS INSTALL APPEAR TO HAVE BEE N GROUND OR CHISELED. ACT RETURNED TO SUPPLIER. DURING RECEIVING INSP OF 2ND NEW ACT, FOUND SPROCKET NOT MOUNTED SQUAR ELY IN SLEEVE. SECOND ACT RETURNED TO SUPPLIER. SERVICEABLE UNIT REMOVED FROM ANOTHER 206 & INSTALLED PLANE. 1 H 7 1 3O A4CE 2005050600098 20050506 00098 CE 2005 5 6 20050415 1 20050412 G 5714 29503040130 FRAME HELIO H295 H295 4300802 CE WING BOX CRACKED B EVGR K NONE O OTHER IN INSP/MAINT 1 SO 33 62JA 5338 1443 CARRY-THRU CRACKS, REWORKED TO B-401-5 TO MEET REQUIREMENTS OF AD 82-16-08. TOTAL TIME ON THE CARRY THRU IS UNKNOWN. WHILE PERFORMING A 100HR INSPECTION, CRACKS WERE FOUND RADIATING FROM CUT-OUT FOR UPPER WING ATTACH BOLTS ON BOTH SIDES OF CARRY-THRU. 2 LONGEST CRACKS APPROXIMATELY .25 INCH IN LENGTH & ARE VISIBLE ON BOTH INSIDE & OUTSIDE OF TUBE. THERE IS A SECOND SMALLER CRACK AT EACH CUT-OUT. 2 LARGEST CRACKS ARE IN SAME PLACE IN EACH CUT OUT. THEY ALIGN WITH A PART OF THE CENTERING TOOL USED TO TIGHTEN THE UPPER WING ATTACH BOLT. IF IMPROPER TECHNIQUE USED WITH THIS TOOL IT COULD P OSSIBLY CAUSE THESE 2 CRACKS. THERE ARE NO TOOL MARKS ON THE CARRY THRU THAT WOULD INDICATE THAT THIS IS THE CAUSE. 1 H 7 1 3O 1A8 2005051700194 20050517 00194 SO 2005 5 17 200504262992R 1 20050426 G 3210 6775300 BRACKET PIPER PA28 PA28R200 7102811 SO MLG BROKEN P O OTHER O OTHER NR NOT REPORTED 1 SO 15 2992R 28R35382 DURING PREFLIGHT WALK AROUND, THE PILOT NOTICED THE RT MLG DOWN-LOCK SPRING WAS HANGING DOWN BY ONE END. FURTHER INVEST IGATION REVEALED THE SPRING BRACKET HAD BROKEN AND THE MAIN GEAR DOWN-LOCK SPRING WAS NOT ATTACHED TO THE TRUNION. THE BRACKET PLATE FAILED AT THE ATTACH POINT FOR THE DOWN LOCK SPRING. COINCIDENTIALLY THE PILOT/OWNER HAD TAKEN EXTENSIVE PHOTOS OF COMPONENTS WITHIN THE LAST 30 DAYS IN PREPARATION FOR RESTORATION ACTIVITIES AND THE FAILING PART APPEARS TO B E COMPLETELY INTACT. PART PROVIDED NO INDICATIONS OF FAILURE. 1 L 7 1 3O 2A13 2005052400114 20050524 00114 SO 2005 5 24 20050503 2 20050503 G 8550 OIL FILTER CESSNA 206 206CESSNA 2073302 CE CONT O520 IO520* 17032 SO ENGINE FAILED B EVGR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 33 50 DURING RECENT INSPECTIONS, SEVERAL OIL FILTER ELEMENTS WERE FOUND PULLED AWAY FROM METAL RETAINING STRIP WHICH CLAMPS TH E ENDS OF FILTER PAPER. ONE FILTER ELEMENT ALSO HAD A SMALL HOLE PENETRATING FILTER PAPER EACH SIDE OF METAL STRIP. SO METIMES METAL STRIP WAS BENT. THIS CONDITION ALLOWS A SMALL AMOUNT OF OIL TO BYPASS FILTER ELEMENT. CONTACTED MFG, THE Y CONFIRMED THAT SOME FILTERS WITH DATE CODE OF 04-07-2004 AND EARLIER WOULD FAIL IN THIS MANNER DUE TO METAL STRIP BEIN G TOO LONG, INADEQUATE CLAMPING METHOD. TOTAL OF FIVE FILTERS WITH EARLY DATE CODES WERE FOUND DEFECTIVE, SEVEN WERE RE MOVED FROM AC, FIVE FILTERS WERE RETURNED TO MFG UNUSED. MFG REPLACED ALL OUR EARLY DATE CODE FILTERS WITH NEW ONES. 1 H 7 1 3O 3 O A4CE E5CE 2005052400109 20050524 00109 CE 2005 5 24 20050504 1 20050504 G 2730 12601491 ACTUATOR CESSNA 206 U206G 2073356 CE CONT O520 IO520* 17032 SO ZONE 300 DEFECTIVE B EVGR K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 33 67JA U20605781 TRIM TAB ACTUATOR IS DEFECTIVE AS RECEIVED. THIS IS A NEW PART. THE CHAIN SPROCKET HAS A BENT TOOTH. LOT NUMBER: 2Q04 . THIS IS THE THIRD DEFECTIVE, NEW ACTUATOR WE HAVE RECEIVED IN A ROW. AN (EXPERIENCED) ACTUATOR FROM A STORED AIRCRAF T IS BEING USED TEMPORARILY TO KEEP THIS PLANE FLYING. THE DEFECTIVE ACTUATOR IS BEING RETURNED TO THE SUPPLIER. 1 H 7 1 3O 3 O A4CE E5CE 2005052400115 20050524 00115 CE 2005 5 24 20050505 1 20050504 G 5341 TUBE HELIO H295 HT295 4300803 CE FUSELAGE CRACKED B EVGR K NONE O OTHER IN INSP/MAINT 1 SO 33 5387G 1257 WHILE PERFORMING THE 1500 HOUR INSPECTION REQUIRED BY AD 82-16-08, A CRACK WAS FOUND ON THE RT VERTICAL TUBE OF THE CARR Y THRU. THE CRACK WAS LOCATED AT THE TOP WELD OF THE TUBE. THE LENGTH OF THE CRACK IS ROUGHLY HALF THE CIRCUMFERENCE O F THE TUBE ON THE FRONT SIDE. THIS CARRY THRU HAS BEEN MODIFIED IAW STC SA1728CE AND BEARS SN B-537. THIS AREA IS NOT REQUIRED TO BE INSPECTED BY THE AD NOTE. HOWEVER, HAVE FOUND THAT IT IS NOT UNUSUAL TO FIND A CRACK AT EITHER END OF EI THER THE VERTICAL OR DIAGONAL TUBES. 1 H 7 1 3O 1A8 2005070500006 20050705 00006 SO 2005 7 5 20050605B 1 20050701 G 2750 1763400 TORQUE TUBE PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA ZONE 100 CUT D O OTHER O OTHER NR NOT REPORTED 1 SO 15 1100 273645 IN PERFORMING AD 2003-09-13, FOUND TORQUE TUBE WORE/CUT BY LEFT RUDDER CABLE. 2 INCH LOG AND THRU TUBE WALL. TUBE HAS BE EN INSTALLED SINCE 1996 1100 HRS AGO. 1 L 7 2 3O 3 O 1A10 1E4 2005070800001 20050708 00001 GL 2005 7 8 20050615 3 20050615 G 6110 A3495 LOCK PLATE CASA C212 C212CC 2410204 EU GARRTT TPE331 TPE33110R 0517 WP HARTZL HCB4M HCB4M GL PROPELLER SEPARATED M E ENGINE SHUTDOWN E VIBRATION/BUFFET TX TAXI/GRND HDL 1 SW 05 00168 3550 506 336 EAA1838 INSP MX RUN-UP, VIBRATION NR 2 PROP ASSY, VIBRATED A FEW SEC THEN DIMINISHED. DISCOVERED 2 SAFETY WIRED BOLTS HEADS ON GROUND THAT SNAPPED OFF PROP ASSY. SPINNER HAD PUNCTURE DAMAGE, MINOR DAMAGE TO 2 PROP BLADES. SPINNER REMOVED, 2 LOCK WIRED BOLTS HAD SHEARED OFF FROM BLADE CLAMP & START LOCK PLATE ASSY. FOD INSPEC DISCOVERED LOCK PLATE 75 YDS FROM ACF T. NR 2 ENG REPLACED DUE TO SOAP RECOMMENDATION. NR 2 PROPELLER HAD BEEN R&R. PROPELLER BALANCING TASK COMPLETED PRIO R TO INCIDENT. START LOCK PLATE WEAR AT START LOCK CONTACT POINT. START LOCK PN 830 ROTATED PAST CONTACT SURFACE OF ST ART LOCK PLATE (PN A-3495). FORCE APPLIED TO START LOCK PLATE CAUSED 2 ATTACHING BOLTS (A-2016) TO SHEAR. 2 H 7 2 4T 4 T A43EU E4WE 6 C P56GL 2005062300067 20050623 00067 NM 2005 6 23 20050622A 1 20050602 G 5330 SKIN BOEING 737 737300 1384610 NM FUSELAGE DENTED C K NONE O OTHER IN INSP/MAINT 1 SO 15 387UA 24662 DENT IN THE LT FUSELAGE SKIN IN AREA OF S20L AT BS 465. 2 L 7 2 4F RT A16WE 2005092000050 20050920 00050 CE 2005 9 20 20050908 1 20050909 G 5340 B4015 TUBE HELIO H295 H295 4300802 CE ZONE 200 CRACKED B EVGR K NONE O OTHER IN INSP/MAINT 1 SO 33 9185Z 1228 CARRY-THRU VERTICAL TUBE CRACKED ON CARRY-THRU ASSEMBLY. THIS CARRY-THRU IS MODIFIED BY STC SA1590CE. TIME IN SERVICE IS UNKNOWN. ALSO NOTED IS THAT THE VERTICAL TUBE WALL THICKNESS WAS .065 INCH RATHER THAN .120 INCH. THE HEAVIER WALL T HICKNESS OF .120 IS CALLED OUT ON THE DRAWING AND IT IS SURMISED THAT SOME EARLY SERIAL NUMBER CARRY-THRU'S HAD THE LIGH TER WALL TUBE INSTALLED. THIS AIRPLANE WAS TOSSED IN A TORNADO AND SUSTAINED DAMAGE TO THE RT MAIN GEAR ATTACHMENT, PRO PELLER, AND RT WING. INSPECTED THE CARRY-THRU FOR HIDDEN DAMAGE. PLEASE NOTE, HAVE FOUND OTHER CARRY-THRU'S WITH CRACK ED VERTICAL TUBES RESULTING FROM FATIGUE. 1 H 7 1 3O 1A8 2006010500010 20060105 00010 CE 2006 1 5 20051129 1 20051129 G 5711 295030401 TUBE HELIO H295 H295 4300802 CE WING SPAR CRACKED B EVGR K NONE O OTHER IN INSP/MAINT 1 SO 33 641LW 1265 WING SPAR CARRY THRU P/N 295-030-401 IS CRACKED ON LT VERTICAL TUBE, TOP, FRONT SIDE. 1 H 7 1 3O 1A8 2005062400049 20050624 00049 NM 2005 6 24 20052400A 1 20050603 G 5315 FLOORBEAM DOUG MD88 MD88 3023688 NM CABIN CORRODED B K NONE O OTHER IN INSP/MAINT 1 SO 15 12FQ 49766 CABIN FLOOR SUPPORT STRUCTURE FS 256.0 LBL 44 TO RBL 44 HAS CORROSION. 2 L 7 2 4F RT A6WE 2006012500005 20060125 00005 CE 2006 1 25 2005AP012502 1 20051213 G 2752 99105863RX ROLL PIN CESSNA 208 208B 2073701 CE PWA PT6 PT6A114 52043 NE TE FLAPS SHEARED D K NONE O OTHER IN INSP/MAINT 1 WP 21 PK-MP 885 507 208B0989 PCEPC1004 BOTH PRIMARY AND STAND-BY FLAP ACTUATOR WAS IN-OPERATIVE. ACTIVATION OF EITHER SYSTEM WOULD CAUSE THE RESPECTIVE CIRCUIT BREAKER TO OPEN. DISASSEMBLY OF THE ACTUATOR REVEALED A SHEARED ROLL PIN AND ROUGH WORM SHAFT BEARING. 1 H 7 1 3T 3 T A37CE E4EA 2006020900119 20060209 00119 NM 2006 2 9 2005AP02001 1 20051226 G 3220 SUPPORT FITTING BOEING 747 747* NM NLG CRACKED B K NONE O OTHER IN INSP/MAINT 1 EA 33 NOSE WHEEL WELL AREA, LT AND RT TRUNNION SUPPORT FITTING UPPER PART, AFT OF AFT BOLT HOLE WITH CRACK. 2 L 7 4 4F RT A20WE 2006020900120 20060209 00120 NE 2006 2 9 2005AP02002 2 20051226 G 7250 GUIDE VANE BOEING 747 747100 1384825 NM RROYCE RB211 RB211* 54555 NE NR 1 ENGINE CRACKED B K NONE O OTHER IN INSP/MAINT 1 EA 33 ENGINE NR 3 LP TURBINE STAGE 3, NOZZLE GUIDE VANE APPROX 6:10 O'CLOCK POSITION ROOT AREA WITH CRACK. 2 L 7 4 4F 4 F RT A20WE A12EU 2006012500004 20060125 00004 CE 2006 1 25 2005AP052501 1 20051213 G 2752 99105863RX ROLL PIN CESSNA 208 208B 2073701 CE PWA PT6 PT6A114 52043 NE FLAP ACTUATOR SHEARED D K NONE O OTHER IN INSP/MAINT 1 WP 21 PK-MP 885 507 208B0989 PCEPC1004 BOTH PRIMARY AND STAND-BY FLAP ACTUATOR WAS INOPERATIVE. ACTIVATION OF EITHER SYSTEM WOULD CAUSE THE RESPECTIVE CIRCUIT BREAKER TO OPEN. DISASSEMBLY OF THE ACTUATOR REVEALED A SHEARED ROLL PIN AND ROUGH WORM SHAFT BEARING. 1 H 7 1 3T 3 T A37CE E4EA 2005031500223 20050315 00223 SW 2005 3 15 2005F00043 1 20050217 G 8011 23032027 STARTER BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL ENGINE INOPERATIVE G O OTHER O OTHER NR NOT REPORTED 1 SW 03 70Q 3160 CAE840517 SHUT DOWN THE HELICOPTER AT ICY, WHEN ATTEMPTING TO RESTART THE IGNITER WAS FIRING BUT THE COMPRESSOR WAS NOT TURNING. WENT BACK THROUGH THE CHECKLIST, ON THE SECOND ATTEMPT THE SAME THING HAPPENED, WITH MAINTENANCE PRESENT ON THE THIRD AT TEMPT THE COMPERSSOR WAS TURNING AND THE FUEL LIT OFF BUT PRIOR TO REACHING FLIGHT IDEL 30-40 PERCENT THE FLAME WENT OUT . MAINTENANCE REMOVED AND REPLACED THE STARTER GENERATOR, INSPECTED THE COMPRESSOR FOR FOD, INSPECTED FUEL NOZZLE, AIR LINES AND THE FUEL. GROUND RUN CHECK COMPLIED WITH AND STARTED THREE TIMES WITH THE PILOT RESTARTING THE LAST START. N O OTHER DEFECTS FOUND AND STARTING TIME IS 25-35 SECONDS. (M) 1 G 7 1 3U 3 U H2SW E4CE 2005031500276 20050315 00276 NE 2005 3 15 2005F00045 2 20050211 G 7200 ENGINE BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE RIGHT MALFUNCTIONED G O OTHER J WARNING INDICATION CR CRUISE 1 SW 99 87550 UE205 114436 FLT - FLL/EYW - DURING FLIGHT, DETECTED SMOKE IN THE COCKPIT AND CABIN. RIGHT ENGINE LOW PRESSURE ANNUNCIATOR ILLUMINAT ED. REMOVED AND REPLACED RIGHT ENGINE. OPERATIONAL CHECK NORMAL. (M) 2 L 7 2 4T 4 T RT A24CE E26NE 2005031500366 20050315 00366 EU 2005 3 15 2005F00053 1 20050211 G 3234 BELLCRANK BRAERO DH125 BAE125800A 1500285 EU MLG HANDLE OBSTRUCTED G A UNSCHED LANDING C J F.O.D. WARNING INDICATION LD LANDING 1 EA 25 1776H 258091 DURING APPROACH, MLG SELECTOR HANDLE WOULD NOT GO TO DOWN POSITION & ENGAGE DETENT. MLG HANDLE BINDING APPROX 1 INCH FR OM BOTTOM DETENT. CYCLED MLG BUT HANDLE WOULD NOT ENGAGE DOWN DETENT. 3 GREEN DOWN & LOCKED LIGHTS & 3 RED MLG LIGHTS ILLUMINATED. MAIN AUX MLG LIGHTS GREEN & NLG MECH IND PIN INDICATING THE NLG DOWN & LOCKED. ELECTED TO DIVERT TO PERFO RM A TOWER FLYBY & VISUALLY CONFIRM MLG DOWN. LANDED WITHOUT INCIDENT. DID NOT DECLARE AN EMERGENCY. UPON INVESTIGATI ON, FOUND AN OBJECT THAT RESEMBLED A INK PEN CAP LODGED BETWEEN FLOORBOARD & MLG HANDLE BELLCRANK IMPEEDING TRAVEL. OBS TRUCTION REMOVED & MLG SELECTOR CONTROL ADJUST PERFORMED IAW 800A MM. FOUND TO BE OK. RETURNED TO SERVICE. (M) 2 L 7 2 4F RT A3EU 2005062700102 20050627 00102 CE 2005 6 27 2005F00087 1 20050527 G 8011 EB75A DRIVE ASSY CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA STARTER DESTROYED D O OTHER O OTHER NR NOT REPORTED 1 NM 09 98344 124 E103656 17276279 L926339A THE DRIVE GEAR ON THE BENDIX DRIVE SHUTTERED. THIS ALSO CURVED SEVER DAMAGE TO THE TEETH ON THE RING GEAR RENDERING THE RING GEAR UNSEVERICEABLE. WE HAD 2 PREVIOUS PROBLEMS WITH THE BENDIX ON NEW STARTERS THESE. RELATED TO THE DRIVE NOT ENGAUGING OR DISENGAGING PROPERLY. THIS IS A MUCH MORE SEVERE PROBLEM AND IS PROBABLY RELATED TO A MATERIAL DEFECT IN T HE PART. 1 H 7 1 3O 3 O NT 3A12 E274 2005092000047 20050920 00047 SO 2005 9 20 2005F00100 1 20050914 G 3246 C20211170 WHEEL LKHEED P38 P38L 5260206 SO ALLSN V1710 V1710* GL MLG LOOSE B K NONE O OTHER IN INSP/MAINT 1 SO 25 718 2602 82 8187 WHEEL ASSEMBLY RETURNED FOR LOOSE TIE BOLTS, OF 18 TIE BOLTS INSTALLED 2 ARE MISSING 11 ARE LOOSE. MFG HAS NOW ISSUED S L F6137-32-843 IN HOPES THIS WILL RESOLVE. 2 M 7 2 4V 4 V LTC10 EXPE4V 2005092000048 20050920 00048 SO 2005 9 20 2005F00101 1 20050914 G 3246 C20211170 WHEEL LKHEED P38 P38L 5260206 SO ALLSN V1710 V1710* GL LOOSE B O OTHER O OTHER NR NOT REPORTED 1 SO 25 718 2602 82 8187 WHEEL ASSEMBLY RETURNED FOR LOOSE TIE BOLTS, OF 18 TIE BOLTS INSTALLED 2 ARE MISSING 11 ARE LOOSE. MFG HAS NOW ISSUED S L F6137-32-843 IN HOPES THIS WILL RESOLVE. 2 M 7 2 4V 4 V LTC10 EXPE4V 2005102800066 20051028 00066 2005 10 28 2005F00108 1 20050929 G 6120 A30672 BUSHING HARTZL HCB5MP3C HARTZL HCB5M HCB5MP3 GL PROPELLER HUB SEPARATED B CQ4R O OTHER O OTHER LD LANDING 1 AL 03 7 FWA2607 EVA2607 REPAIRED DAMAGED BUSHING BY REPLACING WITH NEW PART. 6 C P44GL 2005122000148 20051220 00148 CE 2005 12 20 2005F00110 1 20051123 G 3610 PNEUMATIC SYSTEM BEECH 58 58 1152740 CE CONT O550 IO550* SO CONTAMINATED D K NONE O OTHER UK UNKNOWN 1 EA 05 401BC TH1668 DURING PROLINGED PERIODS OF OPERATION IN HEAVY PRECIPITATION CONSIDERABLE AMOUNTS OF WATER ENTER INTO THE PNEUMATIC SYST EM. INSP OF PNEUMATIC SYS REVEALED LARGE AMOUNTS OF WATER BEING PASSED THROUGH DEICE BOOT EJECTOR, FURTHER DISASSEMBLY INSP REVEALED SEVERAL OUNCES OF WATER REMAINING IN SYS. SYS WAS PRUGED OF ALL WATER AND DRIED. AC WAS RETURNED TO SERV ICE. FLIGHT CREW REPORTED AC AGAIN WAS OPERATED FOR AN EXTENDED PERIOD OF TIME IN HEAVY PRECIPITATION. THIS AC HAS HIS TORY OF PREMATURE FLIGHT COMMAND INDICATOR FAILURES CAUSED BY RUST AND WATER CONTAMINATION. RELOCATE THE PNEUMATIC SYS FILTER TO AN AREA BEHIND THE ENGINE BAFFLE ASSY WHERE IT WILL NOT BE SUBJECT TO IMPACT WATER. (K) 1 L 7 2 3O 3 O 3A16 E3SO 2005031000172 20050310 00172 NM 2005 3 10 2005FA0000007 1 20050114 G 5312 6517662 BULKHEAD BOEING 727 7272M7 138407S NM FUSELAGE GOUGED A DHLA O OTHER O OTHER TX TAXI/GRND HDL 1 SW 99 750DH 21951 RIGHT STA 950 BULKHEAD GOUGED. 2 L 7 3 4F A3WE 2005012000047 20050120 00047 CE 2005 1 20 2005FA0000009 1 20050104 G 2435 2307900001 STARTER GEN BEECH 100 B100 1152919 CE GARRTT TPE331 TPE3316252B 01514 WP LEFT ENGINE FAILED E D RETURN TO BLOCK H ELECT. POWER LOSS-50 PC TX TAXI/GRND HDL 1 GL 25 88FA 790 BE74 LEFT ENGINE FAILED ROTATE DURING START SEQUENCE INITIATION. MAINTENANCE DETERMINED BRUSHES BURNT, APPROXIMATELY 50 PERC ENT LENGTH/LIFE REMAINING. STARTER/GENERATOR WAS REPLACE, ALONG WITH DC VOLTAGE REGULATOR. NR 1 INVERTER HAD FAILED CO UPLE DAYS PRIOR, NO INDICATION ONE FAILURE CONTRIBUTED TO OTHER. 1 L 7 2 4T 4 T A14CE E2WE 2005020100022 20050201 00022 SW 2005 2 1 2005FA0000014 1 20050121 G 5711 SPAR BBAVIA 7 7AC 2110102 SW CONT A65 A65* 17003 SO WING CRACKED B N3SS O OTHER O OTHER NR NOT REPORTED 1 NM 05 2974E 7AC6560 DURING PRE-PURCHASE, COMPLIED WITH INSPECTION. BOTH SPARS IN BOTH WINGS WERE FOUND TO HAVE LOOSE AND MISSING NAILS THAT HOLD RIBS OT THE SPARS. SEVERAL LONGITUDINAL CRACKS WERE FOUND. RECOMMENDATION TO OWNER WAS TO REPLACE ALL WOOD SPARS , WITH STC METAL SPARS. 1 H 7 1 3O 3 O A759 E205 2005020100019 20050201 00019 CE 2005 2 1 2005FA0000024 1 20050117 G 1430 BOLT CESSNA 210 T210M 2073451 CE CONT O520 TSIO520R 17040 SO WASTEGATE VALVE LOOSE D K NONE O OTHER IN INSP/MAINT 1 SW 05 732YK 287 21061879 294273R 3 OF THE 4 BOLTS THAT ATTACH THE METAL PLATE THAT THE ACTUATOR IS MOUNTED ON TO THE WASTEGATE BODY WERE MISSING. FOURTH BOLT WAS BACKED OUT ABOUT HALF WAY. ALL THREE BOLTS FOUND LOOSE IN ENGINE COMPARTMENT. WASTEGATE ASSEMBLY ONLY 287 FR OM OVERHAUL BY MAIN TURBO.THESE BOLTS ARE NOT EASILY OBSERVABLE AND REQUIRE A MIRROR TO SEE. RECOMMEND INSPECTION AT EA CH OIL CHANGE AND TIGHTEN AS NEEDED. 1 H 7 1 3O 3 O 3A21 E8CE 2005020100020 20050201 00020 CE 2005 2 1 2005FA0000025 1 20050110 G 2121 1013841763 BLOWER BEECH 200 B200 1152922 CE PWA PT6 PT6* 52043 EA COCKPIT ARCED D K NONE B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 NM 07 773TP 1613 1613 BB1722 PILOT REPORTED AN ELECTRICAL SMELL DURING FLIGHT AND THEN THE FORWARD VENTILATION BLOWER WENT INOPERATIVE. FOUND THE BR USHES WORN OUT AND ARCING ON THE ARMATURE. REPLACED WITH OVERHAULED UNIT AND FUNCTIONAL CHECK OK. 1 L 7 2 4T 3 T A24CE E2NE 2005020100023 20050201 00023 CE 2005 2 1 2005FA0000026 1 20050113 G 2700 CONTROL PANEL CESSNA 172 172 2072402 CE CONT O300 O300* 17022 SO PITCH CONTROL WORN G K NONE O OTHER IN INSP/MAINT 1 EA 25 8803B 3663 2 36503 AIRCRAFT WAS SUBSTANTIALLY DAMAGED DURING A LANDING ACCIDENT. PILOT WAS UNABLE TO FLARE AIRPLANE. DURING A POST ACCIDEN T INSPECTION BY FAA INSPECTORS, IT WAS DISCOVERED THAT THE AIRPLANE'S CONTROL TEE PULLEYS FOR THE AILERON SYSTEM WOULD G ET (HUNG UP) ON THE RADIO TRAY ASSEMBLY, WHEN THE CONTROL WHEEL TUBE WOULD REACH HALF TRAVEL. THE CONTROL TEE PIVOT AND THE LEFT INSTRUMENT PANEL CONTROL TUBE BALL SOCKET, EXHIBITED WEAR, AND THE CONTROL TEE COULD BE MOVED LATERALLY ALONG A PORTION OF THE CONTROL TEE PIVOT BOLT. ADDITIONALLY, THE RADIO-MOUNTING TRAY DID NOT INCLUDE THE INSTALLATION OF A VERT ICAL SUPPORT TO HELP ASSURE PROPER CLEARANCE BETWEEN THE TRAY AND THE CONTROL TEE ASSEMBLY. 1 H 7 1 3O 3 O NT 3A12 E253 2005031100095 20050311 00095 EU 2005 3 11 2005FA0000027 1 20050119 G 6320 704A33652036 CAGE SNIAS SNIAS 350 AS350B2 8680813 EU BEARING BROKEN C K NONE O OTHER IN INSP/MAINT 1 NM 03 2367 2367 M1899 1883 BEVEL REDUCTION MODULE P/N 350A32-0300-05 S/N M1899 WAS REMOVED AT TSO: 2367.5 FOR METAL CONTAMINATION. UPON TEARDOWN A NALYSIS IT WAS DISCOVERED THAT THE BEARING CAGE FOR BEARING P/N 704A33-652-036 TSN: 2367.5, WAS BROKEN. SUBSEQUENT DETE RIORATION OF BEARING WAS CAUSE FOR METAL CONTAMINATION. 1 G 7 1 3U H9EU 2005020100062 20050201 00062 GL 2005 2 1 2005FA0000028 1 20050121 G 5740 2057000103 BEARING DIAMON DA20 DA20C1 2990001 GL LT WING LOOSE D K NONE O OTHER IN INSP/MAINT 1 NM 03 932AF 840 C0198 (A) BEARING IN LT WING FOUND LOOSE WITH .0625 INCH PLAY UP AND DOWN. NO PLAY FORE AND AFT. PASTE FROM BEARING ATTACH FOU ND LOOSE IN WING BAY. REMOVED BEARING AND FOUND NO DAMAGE TO END RIB. FOUND WITH WING OFF DURING 1000 HOUR INSPECTION. 1 L 7 1 3O NT TA4CH 2005020100130 20050201 00130 GL 2005 2 1 2005FA0000029 1 20050107 G 3242 ROD AMTR COZY COZY 05613R8 GL LYC O320 O320* 41508 EA RT BRAKE CYL ACT BENT G O OTHER O OTHER TX TAXI/GRND HDL 1 SW 01 154MD 25 154MD RT BRAKE CYLINDER ACTUATING ROD, LOCATED BEHIND RT RUDDER PEDAL, WAS SLIGHTLY BENT AFT. THIS CONDITION CAUSED INSUFFICIE NT BRAKE CYLINDER PISTON TRAVEL AND MAKING THE RT BRAKE INOPERATIVE. 1 M 7 1 3O 3 O NT EXPA1M71 E274 2005041400104 20050414 00104 NE 2005 4 14 2005FA0000030 2 20050119 G 7210 704A33652036 BEARING SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE REDUCTION G/B BROKEN C K NONE O OTHER IN INSP/MAINT 1 NM 03 1883H 2367 2367 1883 BEVEL REDUCTION MODULE (PN 350A32-0300-05, SN M1899) WAS REMOVED AT TSO: 2367.5 FOR METAL CONTAMINATION. UPON TEARDOWN ANALYSIS IT WAS DISCOVERED THAT THE BEARING CAGE FOR BEARING (P/N 704A33-652-036) TSN: 2367.5, WAS BROKEN. SUBSEQUENT D ETERIORATION OF BEARING WAS CAUSE FOR METAL CONTAMINATION. 1 G 7 1 3U 3 U H9EU E19EU 2005031100040 20050311 00040 SW 2005 3 11 2005FA0000065 1 20050103 G 5610 WINDSHIELD SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP COCKPIT CRACKED B OZ5R B EMER. DESCENT J WARNING INDICATION CR CRUISE 1 NM 05 3114G AC583 MRR-M05-01, NR 1 WINDSHIELD CRACKED IN FLIGHT JUST AS CREW STARTED DESCENT. CREW DEPRESSURIZED AC, DESCENDED TO AN APPR OPRIATE ALTITUDE FOR NON-PRESSURIZED FLIGHT, AND DIVERTED TO AN AIRPORT WITH VMC CONDITIONS. CREW LANDED WITH NO FURTHE R INCIDENT. OAT WAS APPROXIMATELY -40 AND WINDSHIELD HEAT WAS ON LOW. INNER GLASS PANE CRACKED, UNDER INVESTIGATION WI TH THE OVERHAUL/REPAIR FACILITY. INNER PANE OF THE HEATED WINDSHIELD CRACKED EXTENSIVELY. REPLACED WINDSHIELD, OPS CHE CK AND LEAK CHECK GOOD. (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005033000080 20050330 00080 SW 2005 3 30 2005FA0000066 1 20050105 G 5270 WARNING SYSTEM SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP PAX DOOR MALFUNCTIONED B OZ5R B EMER. DESCENT J WARNING INDICATION CR CRUISE 1 NM 05 60NE AC760B CREW OBSERVED THE CABIN DOOR LIGHT CAME ON DURING CRUISE. CREW VERIFIED HANDLE WAS IN THE FULL CLOSED POSITION. THE LI GHT WENT OUT DURING DESCENT, AND WAS ON FOR APPROXIMATELY 10 MINUTES. THE LIGHT STAYED OUT FOR THE REMAINDER OF DESCENT AND LANDING. ONE OF THE FOLLOWING: DOOR CLOSING PROCEDURES, DOOR HARD TO CLOSE, DOOR CLICKCLACK RIGGING/ LUBRICATION, OR INDICATORS SWITCH RIGGING. NO FAULT FOUND, COULD NOT GET SYSTEM TO FAIL. COULD NOT DUPLICATE MALFUNCTION, CLEANED ALL CABIN DOOR SWITCHES AND OPS CHECKED DOOR SYSTEM. OPS CHECKED GOOD. (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005033000081 20050330 00081 SW 2005 3 30 2005FA0000067 1 20050106 G 5270 WARNING SYSTEM SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP PAX DOOR MALFUNCTIONED B OZ5R A UNSCHED LANDING N FALSE WARNING CR CRUISE 1 NM 05 60NE AC760B MRR-M05-3, CREW OBSERVED THE CABIN DOOR LIGHT CAME ON DURING CRUISE. CREW VERIFIED HANDLE WAS IN THE FULL CLOSED POSITI ON. THE LIGHT WENT OUT WHEN CABIN DIFFERENTIAL PRESSURE WAS LOWERED. THE LIGHT STAYED OUT FOR THE REMAINDER OF DESCENT AND LANDING. CREW ALSO NOTED THE DOOR SEAL LEAKS. ONE OF THE FOLLOWING: DOOR CLOSING PROCEDURES, DOOR HARD TO CLOSE, DOOR CLICKCLACK RIGGING/ LUBRICATION, OR INDICATOR SWITCH RIGGING. NO FAULT FOUND, COULD NOT GET SYSTEM TO FAIL. COULD NOT DUPLICATE MALFUNCTION, INITALLY DEFERRED IAW MEL. (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005021500129 20050215 00129 EA 2005 2 15 2005FA0000071 2 20050128 G 8500 CRANKCASE GULSTM 500 500B 0141106 SW LYC O540 IO540B1C5 41532 EA ENGINE CRACKED B G6NR O OTHER O OTHER NR NOT REPORTED 1 CE 09 324RR 1386139 CRANKCASE, LARGE CRACK UNDER NR 2 CYLINDER, RESULTING IN MASIVE OIL LOSS. (K) 1 H 7 2 3O 3 O 6A1 1E4 2005031100097 20050311 00097 NM 2005 3 11 2005FA0000074 1 20050110 G 3240 511531 HOUSING BOEING 737 737* NM VALVE CRACKED D IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 4590 HOUSING HAS 4 MOUNTING LUG HOLES. ONE HOLE WAS FOUND CRACKED DURING NDT INSPECTION. FATIGUE, STEEL HOUSING. MECHANIC R P1, JOB NR 192167 (K) 2 L 7 2 4F RT A16WE 2005031100099 20050311 00099 NM 2005 3 11 2005FA0000075 1 20050110 G 2710 654484511 MANIFOLD BOEING 737 737* NM AILERON CRACKED D IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 MANIFOLD CRACKED AT FILTER BOWL MOUNTING PORT. FATIGUE AND OVERPRESSURIZATION. MECHANIC NH2, JOB NR 191795. (K) 2 L 7 2 4F RT A16WE 2005031100100 20050311 00100 NM 2005 3 11 2005FA0000076 1 20050110 G 3230 S6026 CYLINDER BOEING 727 727* NM VALVE CRACKED D IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 3085 CRACKED THROUGH THREADS IN CYL 1 PORT. FATIGUE, STRONGER BODY. MECHANIC JW2, JOB NR 191413. (K) 2 L 7 3 4F RT A3WE 2005031100101 20050311 00101 NM 2005 3 11 2005FA0000077 1 20050110 G 3230 S6026 CYLINDER BOEING 727 727* NM VALVE CRACKED D IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 2370 CRACKED THROUGH THREADS IN CYL 1 PORT. FATIGUE, STRONGER BODY. MECHANIC JW2, JOB NR 191407. (K) 2 L 7 3 4F RT A3WE 2005033000119 20050330 00119 NM 2005 3 30 2005FA0000078 1 20050110 G 3230 S6026 HOUSING BOEING 727 727* NM VALVE CRACKED D IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 2497 CRACKED THROUGH THREADS IN CYL 1 PORT. FATIGUE, STRONGER BODY. MECHANIC JW2, JOB NR 191405. (K) 2 L 7 3 4F RT A3WE 2005030100045 20050301 00045 CE 2005 3 1 2005FA0000079 1 20050127 G 5522 12346204 ELEVATOR CESSNA 210 T210F 2073422 CE CONT O520 IO520* 17032 SO RT & LT MISREPAIRED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 6772R T2100172 DURING AN ANNUAL INSP, FOUND LT ELEVATOR TORQUE TUBE LOOSE, AFTER REPAIR WHILE CHECKING CONTROL SURFACE BALANCE, SURFACE WAS FOUND TO BE BADLY OUT OF BALANCE AT +21 IN LBS. REMOVED T/E AND FOUND IT TO HAVE BEEN REPLACED WITH A FIELD FABRI CATED PART BY PERSONS UNKNOWN. FOUND THE MATERIALS USED TO BE .040 SHEET ALUMINUM, THE FACTORY T/E WAS MADE OUT OF .016 AND WAS FOAM FILLED, REPLACED THE T/E WITH FACTORY PARTS, REPLACED T/E AND TRIM TAB ON OTHER ELEVATOR DUE TO SAME CONDI TION, REBALANCED CONTROL SURFACES AND FOUND TO BE WITHIN RANGE OF 0 TO +5.4 IN LBS. (WP07200509576) (K) 1 H 7 1 3O 3 O 3A21 E5CE 2005032800086 20050328 00086 EA 2005 3 28 2005FA0000093 2 20050216 G 7314 461740 PUMP PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA FUEL SYSTEM INCORRECT B OG5R K NONE K FLUID LOSS IN INSP/MAINT 1 GL 21 357ND 1564 2842185 L1977239A A59575 NOTICED A STICKY SUBSTANCE (OTHER THAN FUEL) LEAKING OUT OF MACHINED HOLE ON SIDE OF FUEL PUMP. THIS MACHINED HOLE COME S WITH THE HOLE SEALED FROM THE MFG. (K) 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2005022400076 20050224 00076 SO 2005 2 24 2005FA0000108 2 20050130 G 8520 SA631991 SHAFT PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360E 17025 SO ENGINE OUT OF ROUND D O OTHER O OTHER NR NOT REPORTED 1 SW 99 123AP 347770015 303972 UPON INSTALLING A SHAFT INTO A ROCKER WITH INADEQUATE TOLERANCE LIMITS, NOTED BINDING IN THREE CLOCK POSITIONS. WITH PRU SSION BLUE, FOUND THAT THE SHAFT IS FORMED IN AN ELIPTICAL OR, MODIFIED TRI-ANGULAR SHAPE WITH REDUCED WEAR SURFACE AREA DUE TO INCONSISTANT DIAMETER OF THE SHAFT. ALL 24 NEW SHAFTS DISPLAYED THE SAME MACHINING RESULTS. THE HIGHEST PRESSU RE POINT WAS AT THE NARROWEST CONTACT POINT. GALLING OF THESE SHAFTS APPEARS TO BE CONSISTANT WITH REDUCED WEAR SURFACE AND CROWNING OF THE SHAFT. WHILE OTHER FACTORS MAY BE ATTRIBUTED TO THE CAUSE OF THE PREMATURE SHAFT FAILURE, THE REDU CTION IN SURFACE AREA IS CONSISTANT WITH ACCELERATED DECOMPOSITION OF BEARING SURFACE. AIRWEST AIRCRAFT ENGINES SUPPLIE 1 L 7 2 3O 3 O A7SO E9CE 2005030200054 20050302 00054 NM 2005 3 2 2005FA0000110 1 20050124 G 3240 511531 HOUSING BOEING 737 737 UTILSYS NM SHUTTLE VALVE CRACKED B IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 3770 MOUNTING LUG CRACKED ON INNER DIAMETER, FATIGUE, STEEL HOUSING. (K) 2 L 7 2 4F RT A16WE 2005033000144 20050330 00144 EU 2005 3 30 2005FA0000112 1 20050118 G 7430 103572101 IGNITION SWITCH GROB 120 G120A 1660208 EU LYC O540 AEIO540* EA COCKPIT INOPERATIVE B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 865AF 85005 PILOT REPORTED STARTER WOULD NOT ENGAGE, AFTER FURTHER INVESTIGATION FOUND IGNITION SWITCH WAS BAD. NO PROBABLE CAUSE O R RECOMMENDATIONS AT THIS TIME. (K) 1 L 7 1 3O 3 O RT A49CE 1E4 2005033000150 20050330 00150 NM 2005 3 30 2005FA0000116 1 20050112 G 5330 SKIN BOEING 727 727225 1384077 NM PWA JT8 JT8D15 52051 NE FUSELAGE MISDRILLED B FDER K NONE O OTHER IN INSP/MAINT 1 WP 23 465FE 21289 DRILL START NOTED AT L-BAND NR 1 ANTENNA FWD RT MOUNT HOLE. BS410, RBL 1. (IN SKIN) FOUND WHILE PERFORMING INSPECTION O F ANTENNA IAW WORKCARD NR 34X4505. (K) 2 L 7 3 4F 4 F A3WE E2EA 2005033000151 20050330 00151 SO 2005 3 30 2005FA0000117 2 20050111 G 8530 AEC631397ST2 CYLINDER HEAD BEECH 36 A36 1151604 CE CONT O550 IO550B SO ENGINE SEPARATED B MW2R K NONE O OTHER IN INSP/MAINT 1 GL 17 362SB 409 E1848 ECI CYLINDER HEAD AND BARRLE SEPERATION. (K) 1 L 7 1 3O 3 O 3A15 E3SO 2005033000152 20050330 00152 WP 2005 3 30 2005FA0000118 2 20050121 G 7210 035A470105 LINE MTSBSI MU2 MU2B60 5780460 CE GARRTT TPE331 TPE33110 01514 WP GEARBOX CRACKED B W6NR E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 GL 25 772DA 772SA NR 8 SCAVENGE OIL LINE FROM ENGINE GEARBOX TO VERNATHERM CRACKED INSIDE THE B-NUT SLEEVE AT GEARBOX. THIS LED TO SIGNIF ICANT LOSS OF OIL AND A PRECAUTIONARY SHUTDOWN IN FLIGHT. AC RETURNED DEPARTURE, UNEVENTFUL LANDING, REPLACED OIL LINE. (K) 1 H 7 2 3T 4 T RT A10SW E4WE 2005033000154 20050330 00154 EA 2005 3 30 2005FA0000119 2 20050110 G 7414 67542 BEARING PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA MAGNETO DRIVE FAILED B YYBR K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 GL 03 22PG 617 277305203 L1767848A CUSTOMER COMPLAINED OF A VIBRATION ON RT ENGINE. INSPECTION REVEALED CAGE FAILURE OF THE RT MAGNETO DRIVE GEAR BEARING (PN 67542). CAUSE OF CAGE FAILURE NOT KNOWN. CANNOT RECOMMEND ACTION TO PREVENT REOCCURRENCE. (K) 1 L 7 2 3O 3 O 1A10 1E4 2005033000156 20050330 00156 CE 2005 3 30 2005FA0000120 1 20050110 G 3213 05412024 BUSHING CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY 1C235 1C235LFA GL MLG STRUT WORN B OF1R K NONE O OTHER IN INSP/MAINT 1 EA 17 9453Z 495 17280193 L2722351A RD071 DURING NORMAL ANNUAL INSPECTION RT MAIN GEAR WAS JACKED AND CHECKED FOR ATTACHMENT FREEPLAY. EXCESSIVE FREEPLAY WAS NOT ED AND UPON FURTHER VISUAL INSPECTION, IT WAS DETERMINED THAT RUBBER EXTRUDING OUT FROM THE GAP BETWEEN THE RT MAIN GEAR LEG AND PN 05912024, GEAR LEG BUSHING WAS RESPONSIBLE FOR THE INCREASED FREEPLAY. REPLACEMENT OF THE PIN - 05412024 RT MAIN GEAR LEG BUSHING WITH NEW ELIMINATED ALL RT GEAR LEG FREEPLAY. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2005033000162 20050330 00162 GL 2005 3 30 2005FA0000122 2 20050131 G 7200 ENGINE BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL MAKING METAL B GS1R O OTHER J WARNING INDICATION LD LANDING 1 EA 03 41PH 1544 PILOT REPORTED HEARING A GRINDING NOISE FROM THE ENGINE WHICH WAS FOLLOWED BY AN ENGINE CHIP LIGHT INDICATION. A POWER ON PRECAUTIONARY LANDING WAS MADE. THE ENGINE WAS REMOVED AND REPLACD WITH A LOANER ENGINE. THE DISCREPANT ENGINE AS A N ASSEMBLY WAS SENT TO REPAIR STA. FOR FURTHER EVALUATION. (K) 1 G 7 1 3U 3 U H2SW E4CE 2005033000164 20050330 00164 WP 2005 3 30 2005FA0000124 2 20050124 G 7210 3101320 HOUSING MTSBSI MU2 MU2B60 5780460 CE GARRTT TFE731 TFE731* 01518 WP SCAV PUMP FAILED B W6NR O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 GL 25 772DA 772SA IN FLIGHT, PILOT NOTICED FLUCTUATING OIL PRESSURE AND TORQUE. PRECAUTIONARY LANDING MADE, FOLLOWING TROUBLESHOOTING ENG INE WAS DISASSEMBLIED GEARBOX SCAVENGE OIL PUMP WAS CRACKED. APPROXIMATELY 7 HOURS PRIOR, THE NR 8 STAINLESS OIL SCAV. LINE CRACKED. APPROXIMATELY 7 HOURS PRIOR THE NR 8 STAINLESS OIL SCAV LINE CRACKED. IT IS BELIEVED OIL PRESSURE CYCLIN G FROM LINE FAILURE FRACTURED SCAV PUMP HSG REPLACED PUMP. (K) 1 H 7 2 3T 4 F RT A10SW E6WE 2005040400104 20050404 00104 CE 2005 4 4 2005FA0000132 1 20050128 G 2720 071362856 SUPPORT CESSNA 182 R182 2072734 CE LYC O540 O540* 41532 EA RUDDER PEDAL DAMAGED B PHKR K NONE O OTHER IN INSP/MAINT 1 CE 01 7579T R18200042 WHILE COMPLETING GROUND RUN, PRIOR TO 100 HOUR INSPECTION, NOTICED RUDDER PEDALS DID NOT FEEL RIGHT. FURTHER INVESTIGAT ION REVEALED THAT THE NUT-PLATES HAD RIPPED THROUGH THE RUDDER PEDAL SUPPORT PIECES. (K) 1 H 7 1 3O 3 O RT 3A13 E295 2005031100001 20050311 00001 SW 2005 3 11 2005FA0000134 1 20050216 G 6230 407010104109 CONE BELL BELL 407 407 1182206 SW ALLSN 250C 250C47B GL M/R MAST WORN D K NONE O OTHER IN INSP/MAINT 1 EA 01 17SP 53444 53444 REPLACED MAIN ROTOR MAST CONE PN 407-010-104-109 FOR HUB SHIFT/MAST NUT TORQUE STABILIZATION PROBLEM. ORDERED NEW CONE P/N 407-010-104-109 FROM MFG. NEW PART WAS RECEIVED WITH A WEAR GROOVE IN CENTER OF CONE FACE (APPEARED USED). REORDER ED ANOTHER NEW CONE AND INSTALLED. INSTALLED MAST NUT AND STABILIZED TORQUE. 1 G 7 1 3U 3 U O H2SW E1GL 2005032800043 20050328 00043 CE 2005 3 28 2005FA0000141 1 20050218 G 3610 99144022 PRECOOLER CESSNA 525 525 2076601 CE WILINT FJ44 FJ44 66000 GL LT PYLON BLOWN D K NONE G M MULTIPLE FAILURE OVER TEMP IN INSP/MAINT 1 SO 25 70KW 2200 5250050 DURING A PREFLIGHT INSPECTION IT WAS NOTED THE PAINT ON THE LOWER SKIN OF THE LEFT PYLON WAS DISCOLORED AND BUBBLED UP. VISUAL INVESTIGATION REVEALED THE PRECOOLER ASSEMBLY HAD FAILED, ALLOWING BLEED AIR INTO THE 6312209-1, DUCT ASSEMBLY, WHICH CAUSED THE 6312209-1 DUCT ASSEMBLY TO FAIL, ALLOWING BLEED AIR INTO THE PYLON. A CONDUCTIVITY CHECK OF THE COMPO NENTS WHICH MAKE UP THE PYLON, PYLON SKINS AND FUSELAGE SKINS IN THE AREA OF THE PYLON SHOWED MANY OF THE COMPONENTS TEM PERATURE TO HAVE CHANGED. THE FUSELAGE SKIN IN THE PYLON AND THE AREAS SURROUNDING THE PYLON WERE NOT AFFECTED BY THE HE AT. 1 L 7 2 4F 4 F RT A1WI E3GL 2005032800048 20050328 00048 CE 2005 3 28 2005FA0000142 1 20050205 G 3211 20410141 SUPPORT CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA MLG ACTUATOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 17 2773V 70 177RG0694 AFTER GEAR EXTENSION PILOT DID NOT GET DOWN AND LOCKED GREEN LIGHT. EMERGENCY PROCEDURES WERE COMPLETED WITH SAME RESULT S. GEAR APPEARED DOWN AND LOCKED BY OBSERVERS ON THE GROUND, DURING LOW APPROACH. UPON TOUCH DOWN THE PILOT REPORTED A SAFE GEAR INDICATION. MAINTENANCE INSPECTION REVEALED MAIN GEAR ACTUATOR SUPPORT BRACKETS (LT AND RT) WERE CRACKED. A LSO FOUND ACTUATOR THROUGH PIN TO BE FRACTURED ON RT SIDE. SPECIFIC CAUSE OF FAILURE UNKNOWN. GEAR SYSTEM OPERATIONALLY CHECKED SATISFACTORY AFTER REPLACEMENT OF DAMAGED PARTS. AIRCRAFT HAD RECEIVED 100 HOUR INSPECTION 70 HOURS PRIOR WITH NO ABNORMALITIES NOTED IN MAIN GEAR ACTUATOR SYSTEM. 1 H 7 1 3O 3 O A20CE 1E10 2005032800050 20050328 00050 SO 2005 3 28 2005FA0000143 1 20050126 G 3252 400910 BOLT PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360* 17025 SO NLG CENTERING MISINSTALLED G K NONE O OTHER IN INSP/MAINT 1 GL 25 249PM 3964 80 347770422 DURING RAMP INSPECTION, INSPECTOR NOTICED BOLT ATTACHING NOSE GEAR CENTERING DEVICE WAS INSTALLED INCORRECTLY, HEAD OF B OLT AT TOP OF HARDWARE STACK. AD 92-13-05 AND SB 893 REQUIRE BOLT TO BE INSTALLED WITH HEAD DOWN AND A CAUTIONARY PLACA RD TO BE AFFIXED. PLACARD WAS ABSENT TOO. MAINTENANCE RECORD CONTAIN DESCRIPTION OF AD BEING ACCOMPLISHED IN 1993. SU BSEQUENT RECORD ENTRY IN 2003 DESCRIBES REPLACEMENT OF CENTERING DEVICE ROD END AND BOLT. SUSPECT PLACARD WAS ABSENT TH EN, TECHNICIAN NOT AWARE OF AD REQUIREMENTS AND INSTALLED BOLT IAW STANDARD PRACTICES, RATHER THAN AD. 1 L 7 2 3O 3 O A7SO E9CE 2005040400005 20050404 00005 2005 4 4 2005FA0000156 2 20050228 G 7322 MA451048931 CARBURETOR ENGINE INOPERATIVE B K NONE O OTHER IN INSP/MAINT 1 NM 07 THROTTLE LEVER LOCKED UP AT ABOUT 20 PERCENT OPEN THROTTLE POSITION. DISASSEMBLED AND INSPECTED. FOUND AIR METERING JE T AND PIN HAD SEPARATED. JET WAS BACKED OUT FAR ENOUGH THAT PIN FELL OUT AND LOCKED-UP. ALSO FOUND THAT RETENSION BALL FOR JET IS MISSING. THERE IS ALSO AND DRAG ON METERING PIN THREADS WHICH ALLOWED IT TO BACK OUT. (K) 2005030200044 20050302 00044 SO 2005 3 2 2005FA0000161 1 20050301 G 2721 6666100 CONNECTOR PIPER PA28 PA28181 7102807 SO LYC O360 O360* 41514 EA RUDDER TRIM BROKEN D K NONE O OTHER IN INSP/MAINT 1 NE 01 7653F 4809 287790205 RUDDER TRIM CONNECTOR FOUND BROKEN OFF DURING ANNUAL INSPECTION. 1 L 7 1 3O 3 O 2A13 E286 2005032800111 20050328 00111 CE 2005 3 28 2005FA0000174 1 20050214 G 5540 NAS682A3 NUT PLATE CESSNA CESSNA 150 150D 2071810 CE CONT O200 O200* 17020 SO RUDDER PIVOT WORN G A UNSCHED LANDING O OTHER CR CRUISE 1 NM 07 901SW 15060734 UPPER RUDDER PIVOT BOLT BACKED OUT OF SELF-LOCKING NUTPLATE AT UPPER RUDDER PIVOT ATTACH AND PIVOT POINT WHILE IN FLIGHT , RUDDER WAS RIPPED FROM THE LOWER BELLCRANK CONTROL AND DEPARTED AIRCRAFT. AIRCRAFT LANDED WITHOUT INCIDENT. RUDDER W AS RECOVERED AND THE UPPER PIVOT BOLT WAS RETAINED IN THE UPPER RUDDER CAP. THE BOLT COULD BE INSERTED IN THE NUTPLATE WITH LIGHT FINGER PRESSURE ONLY, AND REMOVED SAME WAY. NUTPLATE WAS WORN AND LOST ITS LOCKING ABILITY. AT INSTALLATIO N OF A NEW FACTORY RUDDER ASSEMBLY, A DRILLED AN BOLT WAS USED TO INCLUDE A COTTER KEY BELOW THE NUTPLATE. (NM072005036 94)(K) 1 H 7 1 3O 3 O 3A19 E252 2005040400027 20050404 00027 SW 2005 4 4 2005FA0000176 1 20050201 G 7921 654585 OIL COOLER MOONEY M20 M20R 5870225 SW CONT O550 IO550G 17042 SO ENGINE CRACKED B DY1R K NONE O OTHER IN INSP/MAINT 1 EA 13 2138Z 602 290158 679237 DURING ROUTINE OIL CHANGE, AN EXAMINATION OF THE OIL COOLER FLANGE AREA WHERE IT BOLTS ONTO THE ENGINE STUDS WAS FOUND T O BE CRACKED. THE CRACK WAS LOCATED BETWEEN THE STUDS MOUNTING AREA IN THE OIL COLLER SURFACE WELD. THIS IS THE FOURTH INSTANCE OF AN OIL COOLER CRACK FOUND AT THE OIL COOLER BY THIS STA WITHIN THE LAST YEAR. ALL PREVIOUS CRACKED COOLER HAD AT LEAST 500 HOURS TIME IN SERVICE. CLOSE EXAMINATION OF THIS AREA IS RECOMMENDED AT EACH OIL CHANGE OR COWLING REM OVAL. 1 L 7 1 3O 3 O RT 2A3 E3SO 2005040100079 20050401 00079 SO 2005 4 1 2005FA0000177 2 20050204 G 7414 4001 MAGNETO CESSNA 150 150M 2071830 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL ENGINE BROKEN D K NONE O OTHER IN INSP/MAINT 1 WP 21 704YL 394 15078978 255492A48 K19171 FLANGE BROKEN ON RT SIDE FOR SUPPORT OF MAG. FOUND ON ANNUAL INSP. 4001 MAG TT 394. (K) 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2005040100080 20050401 00080 SO 2005 4 1 2005FA0000178 1 20050131 G 2140 COMBUSTION LINER PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360* 17025 SO HEATER CRACKED B CTUR K NONE O OTHER IN INSP/MAINT 1 GL 21 13AG A980311 347770115 WHILE PERFORMING AD 04-21-05, THE HEATER FAILED THE PRESSURE DECAY TEST. REMOVED UNIT AND FOUND CRACKS IN END OF COMBUS TION LINER. UNIT WAS REMOVED AND REPLACED WITH OVERHAULED UNIT. UNIT INSTALLED MAY 1998, AND CONTAINED NEW STYLE CERAM IC LINER. 1 L 7 2 3O 3 O A7SO E9CE 2005040100081 20050401 00081 SO 2005 4 1 2005FA0000179 1 20050210 G 2140 EM608 BLOWER PIPER PA46 PA46350P 7104602 SO LYC O540 TIO540* 41532 EA DEFOGGER SEIZED B K5SR K NONE O OTHER IN INSP/MAINT 1 NM 07 92884 249 4636107 VENT DEFOG BLOWER TRIPPING VENT DEFOG BLOWER CIRCUIT BREAKER. BLOWER ASSY SEIZED. REMOVED AND REPLACED BLOWER ASSY. (K ) 1 L 7 1 3O 3 O RT A25SO E14EA 2005040100085 20050401 00085 EU 2005 4 1 2005FA0000180 1 20050210 G 3500 9571222212 VALVE PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE OXYGEN OUTLET LEAKING B K5SR K NONE O OTHER IN INSP/MAINT 1 NM 07 956PC 323 PCEPR0186 PIOTS OXYGEN OUTLET VALVE LEAKS WHEN MASK PLUGGED IN. SUSPECT INTERNAL SEAL FAILURE. (K) 1 L 7 1 3T 4 T RT A78EU E26NE 2005040100090 20050401 00090 CE 2005 4 1 2005FA0000181 1 20050206 G 2435 BEARING LUCAS BEECH B300 B300 1159232 CE PWA PT6 PT6A11 52043 NE STARTER GEN FAILED B AKGR K NONE O OTHER IN INSP/MAINT 1 CE 05 893MC 98141 FL216 SHAFT BEARING AT THE COOLING FAN END OF THE S/G CAME APART. THIS CAUSE THIS END OF THE COMMUTATOR TO MOVE SIDE TO SIDE AND THE COOLING FUN RUBBED INTO THE HOUSING. (K) 2 L 7 2 4T 3 T RT A24CE E4EA 2005040400029 20050404 00029 EA 2005 4 4 2005FA0000182 1 20050222 G 5210 600380091 TRACK BOMBDR CNDAIR CL600 CL6002B16 1900305 EA GE CF34 CF343B1 NE PAX DOOR LOOSE B K NONE O OTHER IN INSP/MAINT 1 GL 13 43R 2750 5334 872121 TRACK/CHANNELS, 600-380091, ARE U CHANNELS THAT FACE EACH OTHER ALLOWING STRUT, 600-38008-17 AND CAMS, TO MOVE UP AND DO WN INSIDE OF THESE TRACKS. THE TRACKS ARE MANUFACTURED WITH SMALLER SIDES AND POOR ENGAGEMENT/ LOOSE FIT OF THE STRUT/C AMS ALLOW THE CAMS TO LIFT OUT OF THE CHANNELS AND JAMMING THE STRUT. THE END RESULT IS ROD, 600-38003-3 BREAKING RESUL TING IN THE PASSENGER DOOR GROUND SUPPORT PAD NOT EXTENDING AND THE DOOR TOUCHING THE GROUND. HAVE BROUGHT THIS TO THE ATTENTION OF MFG 8 YEARS AGO WHEN I HAD THE SAME PROBLEM WITH OUT CL-601, SN 5134. THEY FAILED TO CORRECT THE PROBLEM A ND IT IS NOW AN ISSUE ON OUR CL-604. 2 L 7 2 4F 4 F RT A21EA E15NE 2005040100086 20050401 00086 NM 2005 4 1 2005FA0000183 1 20050131 G 3510 417N3011414B PSU BOEING 737 73783N 13844HI NM CABIN CONTAMINATED W LLMY K NONE O OTHER IN INSP/MAINT 1 EA 35 312TZ 32579 CONTAMINATION ON INSIDE OF PSU. WHILE CARRING OUT ROUTINE MAINTENANCE ON PAX PSUS, CONTAMINATION WAS FOUND AT ROWS 8,13 , 18, AND 23 LT AND RT. CONTAMINATION APPEARS AS SOME FORM OF CARBON OR GRAPHITE. IT IS LOCATED DIRECTLY BELOW WHERE T HE OVERHEAD BINS JOIN AND HAS SETTLED ON THE OXYGEN MASK COVERS INSIDE THE PSUS, AND AT ROW 8 IT IS LOCATED ON THE GASPE R COVER. INSPECTIO ALSO CARRIED OUT ON SISTER AC. SAME DEFECT FOUND. CONTAMINATION REMOVED AS DETAILED ON NRC 185261. (K) 2 L 7 2 4F RT A16WE 2005040400009 20050404 00009 CE 2005 4 4 2005FA0000184 1 20050214 G 2800 10810001259 ADAPTER BEECH 77 77 1153007 CE LYC O235 O235* 41505 EA FUEL TANK LEAKING D K NONE O OTHER IN INSP/MAINT 1 SW 09 1805V WA270 DOUBLER INSTALLEN IN FUEL TANK HAS NO ACCESS AND MFG CAN NOT TELL US HOW TO STOP FUEL LEAK. 1 L 7 1 3O 3 O A30CE E223 2005033000025 20050330 00025 CE 2005 3 30 2005FA0000187 1 20050215 G 3260 622EN186 SQUAT SWITCH CESSNA 525 525 2076601 CE WILINT FJ44 FJ44 66000 GL LT MLG DEFECTIVE B K NONE O OTHER IN INSP/MAINT 1 WP 07 901CJ 1252 5250278 SQUAT SWITCH FOUND WITH ROLLER MISSING. DURING TROUBLESHOOTING FOR THRUST REVERSER (T) DEPLOYMENT SHORTLY AFTER TAKEOFF . AIRCRAFT RETURNED TO FIELD AND MADE AN UNEVENTFUL LANDING. REPLACED SQUAT SWITCH WITH NEW OF SAME PN. NO OTHER DEFE CTS NOTED ON SWITCH. RECOMMEND THAT PRE-FLIGHT PROCEDURES INCLUDE CHECK FOR PRESENCE AND CONDITION OF SQUAT SWITCH ROLL ERS. (K) 1 L 7 2 4F 4 F RT A1WI E3GL 2005031100005 20050311 00005 NE 2005 3 11 2005FA0000188 2 20050203 G 7314 9234A8 PUMP GE LEAR 24 24D 5170311 CE GE CJ610 CJ6108 30006 NE RT ENG FUEL FLAKING B K NONE O OTHER IN INSP/MAINT 1 EA 23 101VS GAT6864 218 211035A THE INTERNAL COATING IN THE GEAR SECTION OF THE FUEL PUMP STARTED FLAKING OFF AND GOT INTO THE HIGH PRESSURE FUEL LINE T HAT GOES TO THE JET PUMPS IN THE RT WING. THE MATERIAL CLOGGED UP THE ORIFICES IN THE JET PUMPS, NOT ALLOWING FUEL TO BE TRANSFERRED FROM THE TIP TANK TO THE WING. NOTE: THE FUEL PUMP HAD ABOUT 4400 HOURS SINCE O/H. THE DATE WAS 1994 AT O/H IAW SUBMITTER. (EA23200505548) (K) 2 L 7 2 4J 4 J A10CE 1E16 2005031400062 20050314 00062 CE 2005 3 14 2005FA0000190 1 20050223 G 6100 D4951 FORK HARTZL BEECH 1900 1900D 1154162 CE PWA PT6 PT6* 52043 EA HARTZL HCE4A HCE4A3A NE PROPELLER CRACKED B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 HJ1597 HJ1597 NDT SHOWS CRACKED IN 2 PLACES ON FORK. (K) (REF: 12235) 2 L 7 2 4T 3 T RT A24CE E2NE 5 C P10NE 2005042500179 20050425 00179 2005 4 25 2005FA0000191 4 20050223 G 6122 D20880 FLYWEIGHT CESSNA 182 182 2072702 CE LYC O540 IO540V4A5 41532 EA GOVERNOR CRACKED B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 195RB 990056 FLYWEIGHT BASE CRACKED ALSO ASSOCIATED PART, C20886 SPRING HEAD AND B20882-1, SPRING DRIVE ALSO CRACKED. (K) (REF: 221 24) 1 H 7 1 3O 3 O NT 3A13 1E4 2005030800281 20050308 00281 NE 2005 3 8 2005FA0000192 2 20050207 G 8520 375202 CRANKSHAFT SCWZER G164 G164A 3952704 EA PWA R1340 R1340* 52016 NE ENGINE FRACTURED B CP2R K NONE O OTHER IN INSP/MAINT 1 SW 15 ZP102313 THE CRANKSHAFT REAR HALF FRACTURED IN TWO, JUST AFT OF THE MASTER ROD BEARING JOURNAL. (K) 1 Q 7 1 3R 3 R 1A16 5E2 2005042500181 20050425 00181 CE 2005 4 25 2005FA0000193 1 20050204 G 3020 10191011435 RETAINER BEECH B300 B300 1159232 CE PWA PT6 PT6* 52043 EA INERTIAL VANE MISINSTALLED B FTUR K NONE O OTHER IN INSP/MAINT 1 NE 05 5XM FL115 DURING INSP OF ENG INERTIAL VANE CONTROL SYS, IT WAS FOUND THAT RETAINER PLATE, PN 101-910114-35 THAT LOCKS INTO A GROOV E ON SHAFT, PN 101910114129, FOR AFT INTERIAL VANE, WAS NOT INSTALLED CORRECTLY. WHEN RETAINER PLATE IS CORRECTLY INSTA LLED IN GROOVE ON SHAFT ASSY, IT WOULD SECURELY HOLD SHAFT ASSY IN ITS MOUNTING PLATES. RETAINER PLATE IS LOCATED ON VA NE SHAFT END OPPOSITE ACT. THIS ALLOWS SHAFT ASSY TO MOVE BACK AND FORTH WHEN VANE IS OPERATED THROUGH ITS RANGE. FOUN D THAT THIS EXCESS SIDE MOVEMENT WOULD ALSO ALLOW BOLT THAT SECURES SHAFT ASSY TO ACTUATOR COULD CATCH ON SURROUNDING S UPPORT. CONDITION WAS FOUND ON BOTH ENGINES OF THIS AC. SHAFT ASSYS FOR FWD VANE WERE FOUND CORRECTLY INSTALLED. (K) 2 L 7 2 4T 3 T RT A24CE E2NE 2005033000048 20050330 00048 CE 2005 3 30 2005FA0000194 1 20050211 G 2510 551900922 SEAT BACK CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE SEAT CRACKED B K NONE O OTHER IN INSP/MAINT 1 CE 05 1250V 5500439 UPPER CHAIR BASE ASSEMBLY CRACKED AT CHAIR BACK ATTACH POINTS. STRESS ON CHAIR BACK AND METAL FATIGUE PROBABLE CAUSE. ALSO, PREVIOUS INAPPROPRIATE REPAIR. CHAIR WAS REPORTED IAW STC ST01042WI, STRUCTURAL SEAT REPAIR. (CE05200503843) (K) 1 L 7 2 4F 4 F A22CE E1NE 2005033000044 20050330 00044 SO 2005 3 30 2005FA0000195 2 20050207 G 7314 64621238AZR PUMP BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO FUEL SYSTEM INOPERATIVE B VJ3R O OTHER R Y J PARTIAL RPM/PWR LOSS ENGINE STOPPAGE WARNING INDICATION NR NOT REPORTED 1 WP 07 1556A 178 CE1318 830106R ENGINE KEPT DYING AT IDLE. MAINTENANCE TECH TROUBLESHOT SYSTEM AND FOUND THAT THE ENGINE DRIVEN FUEL PUMP PRESSURE WILL NOT STABILIZE. VARIES BETWEEN 7.5 TO 10 PSI. REMOVED AND REPLACED ENGINE DRIVEN FUEL PUMP OPS CHECK NORMAL. PROBABLE CAUSE INTERNAL FAILURE IN FUEL PUMP. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005031400089 20050314 00089 CE 2005 3 14 2005FA0000196 1 20050210 G 3211 MS203922C45 CLEVIS PIN BEECH 90 E90 1152914 CE PWA PT6 PT6A60A 52043 NE RT MAIN GEAR BROKEN B AIHR O OTHER E VIBRATION/BUFFET LD LANDING 1 GL 11 6571S LW171 PILOT REPORTED SOUND (LIKE A TIRE BLOWING OUT) UPON LANDING. THERE WAS SEVERE VIBRATION ON ROLLOUT. THERE WAS NO VIBRA TION ON TAXI BACK TO HANGAR. UPON EXITING AIRCRAFT, PILOT NOTICED RT MAIN GEAR MISALIGNED. FURTHER INSP BY MAINTENANCE , FOUND RETAINING CLEVIS PIN FOR UPPER TORQUE LINK SHEARED, CAUSING PIN TO DRIFT OB, CAUSING THE UPPER TORQUE LINK TO BR EAK AND SEPARATE FROM THE TRUNNION. RECOMMEND REPLACING CLEVIS PINS WITH NEW EVERY TIEM AD 2002-01-10 IS PERFORMED. (GL 11200507567) (K) 1 L 7 2 3T 4 T 3A20 E4EA 2005040400084 20050404 00084 CE 2005 4 4 2005FA0000197 1 20050211 G 7603 7184510 THROTTLE CABLE LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE731* 01518 WP RT FWD DAMAGED D A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 GL 11 858MK 1337 141 AFTER TAKEOFF, THROTTLE WOULD NOT COME BACK. THROTTLE HAD TO BE FORCEABLY PULLED BACK OUT OF TAKEOFF SETTING. CABLE WA S FOUND BAD. (GL11200507568) (K) 2 L 7 2 4F 4 F RT T00008WI E6WE 2005032800109 20050328 00109 CE 2005 3 28 2005FA0000198 1 20050131 G 5753 052340051 SPAR CESSNA 172 172H 2072424 CE CONT O300 O300D 17022 SO RT WING FLAP TRA CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 4992R 12474 17256346 29876D9DR WHILE REPLACING THE FLAP TRACK ASSY, A CRACK APPROX 2 INCHES IN LENGTH AND RUNNING THROUGH THE LOWER RIVET HOLES WAS FOU ND UNDER THE IB FLAP TRACK. PROBABLE CAUSE IS FATIGUE. RECOMMEND THESE AC WITH MORE THAT 8,000 HOURS TT BE INSPECTED B Y BORESCOPE OR OTHER ACCEPTABLE MEANS, AT THE REAR WING SPAR AROUND THE FLAP TRACK ATTACH AREA. (K) 1 H 7 1 3O 3 O NT 3A12 E253 2005040400039 20050404 00039 SO 2005 4 4 2005FA0000199 1 20050118 G 2710 62701099 CONTROL CABLE PIPER PA28 PA28161 7102803 SO LYC O320 O320* 41508 EA AILERON FRAYED B ZKGR K NONE O OTHER IN INSP/MAINT 1 NE 05 2114J 6218 287916224 FOUND BOTH FORWARD AILERON CONTROL CABLES FRAYED. (K) 1 L 7 1 3O 3 O 2A13 E274 2005040400079 20050404 00079 2005 4 4 2005FA0000200 1 20050120 G 2622 V651554 FIRE BOTTLE CABIN DISCHARGED B JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 PORTABLE FIRE EXT NOZZLE WAS FOUND TO BE LOOSE AND BOTTLE COMPLETELY DISCHARGED. REMOVED NOZZLE FROM BOTTLE AND FOUND N OZZLE AND BOTTLE THREADS CORRODED. ALSO, NOZZLE TO BOTTLE O-RING SEAL DETERIORATED. POSSIBLE CAUSE OF DEFECT COULD BE IMPROPER TORQUE VALUE USED DURING BOTTLE ASSEMBLY. 2005040100112 20050401 00112 2005 4 1 2005FA0000202 4 20050127 G 6122 54696 SPOOL HARTZL PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA HARTZL HCC2Y HCC2YK1 GL GOVERNOR MISINSTALLED B W59R K NONE O OTHER IN INSP/MAINT 1 WP 07 55696 3797 28R7335274 GOVERNOR SENT FOR REPAIR DUE TO RPM CONTROL ISSUES AND A HISTORY OF LEAKING. DURING DISASSEMBLY, THE PILOT SPOOL SHAFT THREADS WERE FOUND DAMAGED. IT WAS DISCOVERED THAT AT THE PREVIOUS ASSY OF THIS PART, A FINE THREADED B3808-4 NUT WAS U SED IN PLACE OF THE REQUIRED B3808 (COARSE THREAD) NUT. THE B3808-4 WAS FORCED ONTO THE PILOT SPOOL DISTORTING AND CROS STHREADED IT. UNIT WAS REPORTED TO HAVE BEEN OVERHAULED 3/1/94 AND HAD APPROX 200 HOURS TSO. 1 L 7 1 3O 3 O 2A13 1E10 5 C P920 2005042500193 20050425 00193 SW 2005 4 25 2005FA0000203 1 20050120 G 7820 630112501 MUFFLER MOONEY M20 M20R 5870225 SW CONT O550 IO550* SO ENGINE CRACKED G K NONE O OTHER IN INSP/MAINT 1 NM 09 91678 290129 VERY SIMILAR TO THE CRACKS REFERENCED IN AD NR 95-12-16 BUT ITS OUTSIDE OF THE SN RANGE LISTED. (K) 1 L 7 1 3O 3 O RT 2A3 E3SO 2005040400057 20050404 00057 2005 4 4 2005FA0000204 1 20050104 G 2621 344 EXTINGUISHER CABIN INOPERATIVE B JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 FIRE EXTINGUISHER WENT THROUGH A WEIGHT AND PRESSURE CHECK AND PASSED BOTH CHECKS. UPON REINSTALATION OF THE EXTINGUISH ER INTO THE AC THE TECH NOTICED THE HALON TO BE DEPLETED, ALL SAFETY SEALS WERE IN TACT AND THE EXTINGUISHER WAS NOT CON TACTING ANY OTHER OBJECTIVES WHILE SITTING STATIC IN THE CABINET, THIS IS THE 3RD EXTINGUISHER OF THIS MODEL TO DO THIS. ALSO NOTICED THE CYLINDER HEAD TO BE LOOSE. (K) 2005040100087 20050401 00087 CE 2005 4 1 2005FA0000213 1 20050121 G 5330 97430000604 SKIN BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A60A 52043 NE FUSELAGE MISMANUFACTURED B P6UR K NONE W INADEQUATE Q C IN INSP/MAINT 1 NE 05 905GP 6043 BB789 UPON REMOVAL OF AC TOP SKIN, FOUND 4 RIVETS ON STRINGER NR 4R JUST FWD OF THE EMERGENCY EXIT HATCH TO HAVE NO EDGE DISTA NCE. ABOVE THIS AREA AT FS165.25 AND STRINGER NR 2R THERE WAS FOUND ONE FASTENER HOLE WITH SHORT EDGE DISTANCE. FWD OF THIS AREA AT FS 148.90 AND STRINGER NR 3R, FOUND A DOUBLE DRILLED HOLE WITH NO EDGE DISTANCE BETWEEN THEM. PROB CAUSE: DEFECT IN MANUFACTURING. RESOLUTION: MFG ISSUED ENGINEERING REPAIR FOR THE AFFECTED DISCREPANCY. DOCUMENT NR FR-KA-01 494, REV 2 DATED 01-13-05. 1 L 7 2 4T 4 T A24CE E4EA 2005032800051 20050328 00051 SO 2005 3 28 2005FA0000215 1 20050104 G 5340 51023306 PLATE AMRGEN AG5B AG5B 3990100 SO LYC O360 O360A1D 41514 EA SEATBELTS MISINSTALLED B IG8R K NONE O OTHER IN INSP/MAINT 1 EA 07 123VU 5944 10059 WHILE REPLACING REAR PX SEATBELTS, IT WAS DISCOVERED THAT REINFORCEMENT PLATE HAD BEEN INSTALLED ON FWD SIDE OF AFT SEAT BLKHD UNDER SEATBELT ATTACH BRACKET. (-6) PLATE SHOULD HAVE BEEN INSTALLED ON AFT SIDE OF BLKHD IAW AGAG DWG 5102299. MS203641032 (THIN SHEER NUT) WAS USED TO SECURE AN3-5A RETAINING BOLTS. NUTS SHOULD HAVE BEEN INSTALLED IAW DWG. RESU LTS IN REDUCED SEATBELT ATTACHMENT STRENGTH COMPARED WITH DESIGN CONFIGURATION. AC APPEARED TO HAVE ORIGINAL SEATBELTS INSTALLED, THIS IMPROPER INSTALLATION WAS ACCOMPLISHED DURING ASSY. REAR SEAT SEATBELT OB ATTACH BRACKETS INSP FOR PROP ER INSTALLATION OF PLATE AND PROPER ATTACH HARDWARE PRIOR TO CARRYING REAR SEAT PASSENGERS. (EA07200502731)(K) 1 L 7 1 3O 3 O NT 1L71 E286 2005040100093 20050401 00093 SO 2005 4 1 2005FA0000216 2 20050209 G 8520 CONNECTING ROD CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE FAILED D K NONE O OTHER IN INSP/MAINT 1 GL 11 5130A 21063280 522211 NR 2 CONNECTING ROD FAILED BREAKING CRANKCASE, KNOCKING LT MAG FROM MOUNT. ROD SHOWED FRICTION WELDING TO CRANK PRIOR T O FAIURE. COUNTERWEIGHT DAMAGED BY IMPACT WITH ROD. APPEARS ENG CONTINUED TO OPERATE BRIEFLY FOLLOWING ROD SEIZURE. P ILOT ACCOMPLISHED SUCCESSFUL LANDING IN FIELD, NO APPARENT DAMAGE TO AIRFRAME. ENG HAS HISTORY OF CYL BEING REMOVED FOR TOP O/H WITH 4 BEING CHANGED TWICE. HAD BEEN EXPERIENCING PERSISTENT OVERBOOSTING, PROBLEM HAD BEEN ADDRESSED AT DIFFE RENT TIMES. TURBO CONTROLLER HAD BEEN REPLACED AND WASTEGATE HAD BEEN REMOVED, SERVICED AND REINSTALLED. AFTER COMPLETI ON, APPEARED OVERBOOST PROBLEM MITIGATED. ENGINE FAILED. (GL11200507447) 1 H 7 1 3O 3 O 3A21 E8CE 2005040100088 20050401 00088 CE 2005 4 1 2005FA0000217 1 20050113 G 2710 CONTROL CABLE LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE731* 01518 WP AILERONS FAILED B JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 146XL 1780 187 PRIMARY FLIGHT CONTROL CABLES ARE FAILING INSP, DUE TO WEAR ON CONTROL CABLE FAIRLEADS IN FUSELAGE AND EMPANNAGE. DETAI LED INSP IS PERFORMED AT 4800 HRS. FOLLOWING CABLES FAILE AT 1780.3 HRS. FUSELAGE AILERON CABLES, RUDDER CABLES, ELEVA TOR CABLES. CAUSE IS DUE TO CABLE FAIRLEADS BEING MADE FROM TOO HARD OF MATERIAL CAUSING CONTROL CABLES TO WEAR INSTEAD OF FAIRLEADS. RECOMM: TO PERFORM SB, (FUSELAGE REPLACEMENT OF THE CABIN FLIGHT CONTROL FAIRLEADS) THIS SB INSTALLS DIF FERENT PN FAIRLEAD IN THE AC, WHICH IS MADE OF A SOFTER MATERIAL. (CE09200502297) (K) 2 L 7 2 4F 4 F RT T00008WI E6WE 2005040400045 20050404 00045 CE 2005 4 4 2005FA0000222 1 20050110 G 2720 CONTROL CABLE LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE731* 01518 WP RUDDER WORN B JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 886CA 1183 154 AILERON, ELEVATOR, AND RUDDER SYSTEMS PRIMARY CONTROL CABLES ARE DUE INSPECTION AT 600 HOURS IAW MM, AS A PORTION OF PHA SE B REQUIREMENTS. ALIERON, ELEVATOR AND RUDDER SYSTEMS PRIMARY CONTROL CABLES ARE DUE REMOVAL AND DETAILED INSPECTION AT 4,800 HOURS IAW MM. PRIMARY FLIGHT CONTROL CABLES ARE NOT LISTED MM (REPLACEMENT SCHEDULE). INSTALLED NEW RUDDER CO NTROL CABLES, (PN7627202004-001, 7627202003-001). WORK PERFORMED AFTER INSPECTION IAW PHASE B REQUIREMENTS. (K) (CE0920 0502303) 2 L 7 2 4F 4 F RT T00008WI E6WE 2005031400074 20050314 00074 SW 2005 3 14 2005FA0000224 1 20050215 G 6700 NAS66039D BOLT BELL 407 407 1182206 SW ALLSN 250C 250C47B GL DUAL CONTROL MISINSTALLED D K NONE O OTHER IN INSP/MAINT 1 SW 07 45RX 1064 53412 CAE847447 FOUND THAT MAX POS OF THROT (POWER LEVER ANGLE) COULD NOT BE OBTAINED USING NML ADJ PROC. FOUND COPILOT THROTTLE LINKA GE WAS FOULING ON COLLECT ELBOW (PN 206-001-203-101). LINKAGE IS ATTACHED TO COL THROTTLE LEVER WITH (NAS6603-9D) BOLT INSTALLED W/HEAD FACING FWD. DUE TO INSTALL OF AIR COMM BLEED AIR HTR KIT (PN 407H-200M12 STC:SR00221DE) BOLT HAD BEEN TURNED AROUND W/HEAD FACING AFT. INSTR CALLS TO REPLACE FACTORY BOLT (NAS6603-9D) W/SHORTER BOLT (NAS6603-8D), NOT INST ALLED ON THIS AC. FOUND THAT BOLT (NAS6603-8D) ALSO FOULS IF WASHER/COTTER PIN ARE INSTALLED INCORRECTLY. ONLY FLIGHT FADEC FAILURE WOULD PILOT MOVE THROT PAST (FLIGHT) DETENT POS, USING MAX THROT RANGE. AC TO BE CHECKED FOR COMPLIANCE. 1 G 7 1 3U 3 U O H2SW E1GL 2005040400062 20050404 00062 EU 2005 4 4 2005FA0000226 1 20050214 G 3320 189411 POWER SUPPLY AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE731* 01518 WP CABIN LIGHT FAILED B G46R K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 WP 13 253SJ 107 CREW HAD POWER ON AIRCRAFT AND NOTICED AN ELECTRICAL BURNING SMELL COMING FROM THE CABIN. AFTER INVESTIGATING THEY FOUN D THE CABIN INDIRECT LIGHTING CIRCUIT BREAKER POPPED. THE MAINTENANCE FACILITY TROUBLESHOT THE PROBLEM TO A POWER SUPPL Y THAT HAD BURNED UP. RECOMMEND INVESTIGATION INTO THIS PN POWER SUPPLIES TO SEE IF THEY SHOULD BE TOTALLY REMOVED FROM SERVICE. MFG RECOMMENDED SB F50-335 FOR REPLACING POWER SUPPLIES WITH IMPROVED POWER SUPPLY THAT INCORPORATES A PROTE CTION CIRCUIT. THESE LIGHTING SYS WERE INSTALLED UNDER MFG MODIFICATION F50 M2065+M2674. THIS AIRCRAFT WILL HAVE SB -3 35 INSTALLED AS SOON AS PART CAN BE PROCURED. 2 L 7 3 4F 4 F A46EU E6WE 2005031100068 20050311 00068 EA 2005 3 11 2005FA0000247 1 20050208 G 6700 269A731613 TRIM SYSTEM SCWZER 269 269D 8059501 EA LYC O360 HIO360* 41514 EA CYCLIC STICK FAILED B NKVR K NONE O OTHER DE DESCENT 1 NM 09 2096W 152 S1865 DURING DESCENT TO LANDING THE CYCLIC STICK JAMMED SO AS TO NOT ALLOW ANY LATERAL MOVEMENT TO THE RT BEYOND NEUTRAL POSIT ION. THIS WAS CAUSED BY THE SPRING TUBE COMING OUT OF THE TRIM HOUSING AND LOCKING THE TRIM ARM AT A .7500 EXTENDED POS ITION. THE SPRING TUBE CAME OUT OF THE TRIM HOUSING DUE TO A FAILURE OF THE EPOXY THAT HOLDS IT IN. THIS TRIM ACTUATOR HAS A DIFFERENT COLOR EPOXY THEN OLDER TRIM ACTUATORS. (WHITE-NEW/ GREEN-OLD) (K). 1 G 7 1 3U 3 O 0 4H12 1E10 2005040400055 20050404 00055 NM 2005 4 4 2005FA0000248 1 20050219 G 3030 HEATER GULSTM 200 200 4500308 NM LT PITOT HEAD INOPERATIVE B O OTHER O OTHER NR NOT REPORTED 1 NM 07 363GA 689 207782 063 LT PITOT HEAT INOPERATIVE. FOUND PITOT PROBE HEATING ELEMENT ARCED. REMOVED AND REPLACED LT PITOT PROBE. (K) 2 L 7 2 4F RT A53NM 2005042600011 20050426 00011 SW 2005 4 26 2005FA0000249 1 20050216 G 7110 430061801101 COWLING BELL 430 430 1182150 SW ALLSN 250C 250C40B 03032 NE LT CORRODED D K NONE O OTHER IN INSP/MAINT 1 NM 09 430LF 848 49096 LT HAND TRANSMISSION COWLING FRETTING AGAINST ADJACENT COWLING. DZUS FASTENER DOES NOT HOLD COWLING WITH ENOUGH TENSION , CAUSING FRETTING. MOVEMENT CAUSED CRACK AT BOTTOM DZUS RAIL. (K) 1 G 7 2 3U 3 U RT H9SW E1GL 2005040100034 20050401 00034 CE 2005 4 1 2005FA0000250 1 20050224 G 5610 10138402515 WINDSHIELD BEECH 200 B200 1152922 CE COCKPIT CRACKED D ACOR O OTHER O OTHER CR CRUISE 1 SO 05 415RB 1854 BB1513 PILOT REPORTED WINDSHIELD SHATTERED WHILE CRUISING AT FLIGHT LEVEL 24,000 FT. INNER PANE SHATTERED. (K) 1 L 7 2 4T A24CE 2005040400103 20050404 00103 CE 2005 4 4 2005FA0000251 1 20050210 G 5610 9910491 WINDSHIELD CESSNA 421 421C 2076016 CE COCKPIT FAILED B BNZR O OTHER B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 GL 19 316WC 2004 421C1047 PITOT HEATED GLASS WINDSHIELD FAILED DURING TAKEOFF ROLL. CAUSE UNKNOWN. WINDSHIELD WAS INSTALLED ABOUT 8 YEARS AND 20 04.5 HOURS AGO AND FAILED FOR NO APPARENT REASON. (GL19200502495) (K) 1 L 7 2 3O A7CE 2005031100002 20050311 00002 EA 2005 3 11 2005FA0000252 2 20050131 G 8550 LW18110 IMPELLER CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA OIL PUMP DESTROYED D A UNSCHED LANDING E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 SO 35 100M 1657 17265590 FLYING AT 1700 FT WITH PWR SETTING OF 2400 RPM, VIBRATION OCCURED. SCANNED GAGES, ALL NORMAL. PULLED CARB HEAT AND VIB RATION DISAPPEARED. SCANNED GAGES AGAIN, NOTICED OIL PRESS WAS ZERO. PWR STARTED TO BLEED OFF, RPM`S DROPPED TO 2200, DID NOT RESPOND TO THROTTLE ADVANCE. DESCENDED TO LAND, ENGINE SEIZED. LANDED AC IN A FIELD W/O DAMAGE TO AC, PERSONNE L INJURY. INSP REVEALED OIL SUPPLY AT 7 QTS. NO METAL IN OIL AND PROP WAS FREE TO ROTATE. PILOT INDICATED OIL TEMP WA S NORMAL DURING INCIDENT. UPON DISASSEMBLY OF ENG, FOUND A LARGE AMOUNT OF NON-FERROUS PARTICLES. OIL SCREEN FOUND TO B E CLEAN. DISSASSEMBLED OIL PUMP, FOUND IMPELLER PARTIALLY DESTROYED AND CRACK STARTING AT CENTER BORE. (SO35200508187) 1 H 7 1 3O 3 O NT 3A12 E274 2005031500109 20050315 00109 SO 2005 3 15 2005FA0000255 2 20050121 G 7310 628437 FITTING PIPER PA34 PA34200T 7103406 SO CONT O360 LTSIO360EB 17025 SO RT ENGINE SHEARED B FFKR E A ENGINE SHUTDOWN UNSCHED LANDING K FLUID LOSS CR CRUISE 1 SO 05 21407 91 91 347870435 807968R AIRCRAFT WAS IN CRUISE FLIGHT WHEN IT EXPERIENCED AN IMMEDIATE ENGINE FAILURE ON THE RIGHT ENGINE, PILOT COULD NOT RESTA RT ENGINE. AFTER LANDING MAINTENANCE REPORTED A FITTING ON THE FUEL PUMP FOR THE VAPOR RETURN LINE HAD SHEARED. 1 L 7 2 3O 3 O A7SO E9CE 2005032800066 20050328 00066 CE 2005 3 28 2005FA0000257 1 20050217 G 5610 10138402519 WINDSHIELD BEECH 200 B200 1152922 CE PWA PT6 PT6A60A 52043 NE COCKPIT BROKEN B R1JR B A EMER. DESCENT UNSCHED LANDING O OTHER CR CRUISE 1 SO 15 345WK 2025 BB1580 PILOT REPORTS THAT AT CRUISE ALTITUDE 24,000 FT, EVERYTHING NORMAL THE PILOTS WINDSHIELD OUTER GLASS SHATTERED. TO PREV ENT RECURRENCE, REPLACED WITH KIT-STRESS FREE WINDOW INSTALLATION IAW INSTRUCTIONS PROVIDED. (K) 1 L 7 2 4T 4 T A24CE E4EA 2005032800100 20050328 00100 SO 2005 3 28 2005FA0000258 1 20050219 G 5514 6358500 TAB PIPER PA28 PA28R200 7102811 SO LYC O360 IO360A1A 41514 EA STABILIZER CRACKED C R5NS O OTHER J WARNING INDICATION CR CRUISE 1 EA 05 41343 4853 28R7435171 PILOT NOTED IN FLIGHT WITH MAX NOSE DOWN TRIM AND AIRCRAFT STILL WANTED TO CLIMB. INSP REALIZED THAT STABILATOR TAB HOR N BEGAN TO TEAR AWAY FROM TAB SKINS. THIS DECREASED OVERALL TAB EFFECTIVENESS. STAB TRIM TAB SKIN AND RIBS WERE CRACKE D AT THE IB JACK SCREW CONTROL HORN ATTACH POINT. TAB SKINS (PN 63586-00, 63586-01, NEW STYLE REPLACEMENT (PN 635866-80 0). TAB IB RIB (PN 63587-00, 63587-01, NEW STYLE REPLACEMENT (PN 63587-002, 63587-003). NOTE: KNOTS 2U STAB/TAB GAP SE AL KIT IS INSTALLED ON THIS AIRCRAFT. THIS KIT MAY HAVE CAUSED EXCESSIVE PRESSURE ON THE TAB`S AND CAUSED CRACK TO FORM AT EACH ATTACH POINT. (K) 1 L 7 1 3O 3 O 2A13 1E10 2005033000021 20050330 00021 CE 2005 3 30 2005FA0000259 1 20050222 G 7820 045033862 MUFFLER CESSNA 150 150E 2071812 CE CONT O200 O200A 17020 SO ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 11 3596J 15061296 607525A CRACKING AROUND FRONT RISER. PART HAS BEEN INSPECTED IAW AD 67-03-01. PRESSURE CHECK AS REQUIRED AT 100 DEGREE INTERV ELS. AIRCRAFT NOT FLOWN SINCE LAST ANNUAL. 8.9 HOURS SINCE LAST REQUIRED INSPECTION IAW AD. RECOMMEND INSPECTION ANNU ALLY IAW AD. (K) 1 H 7 1 3O 3 O 3A19 E252 2005032800079 20050328 00079 CE 2005 3 28 2005FA0000264 1 20050309 G 8011 S24432 CONTACTOR CESSNA 206 U206G 2073356 CE CONT O550 IO550* SO STARTER FAILED D RDDR O OTHER J WARNING INDICATION TO TAKEOFF 1 WP 21 PKMPT U20606987 STARTER CONTACTOR DID NOT DISENGAGE AFTER ENGINE START. THIS RESULTED IN FAILURE OF THE STARTER AS WELL. THE SITUATION DID NOT BECOME APPARENT UNTIL AFTER TAKEOFF. THIS AIRCRAFT HAS A (STARTER ENGAGED) WARNING LIGHT INSTALLED BUT IT DID NOT INDICATE CLEARLY UNTIL AFTER TAKEOFF. PERHAPS BECAUSE AT HIGH POWER SETTINGS THE ALTERNATOR PRODUCED MAXIMUM POWER AND AT HIGH SPEED THE STARTER MOTOR WOULD DRAW FEWER AMPS THAN AT LOW SPEED, ALLOWING THE BUS VOLTAGE TO RISE AND ILLUMI NATE THE LAMP BRIGHTER. FIRST LIGHTWEIGHT STARTER INSTALLED ON THIS AC, INDICATION THAT LIGHTWEIGHT STARTERS HAVE HIGHE R CURRENT DRAW THAN LARGER STARTER THAT WAS USED. SUSPECT MFG CONTACTOR CANNOT HANDLE LOAD.(K) 1 H 7 1 3O 3 O A4CE E3SO 2005031000130 20050310 00130 CE 2005 3 10 2005FA0000273 1 20050111 G 2912 99144655 FILTER CESSNA 750 750 2076810 CE HYD SYSTEM LEAKING C K NONE O OTHER IN INSP/MAINT 1 EA 23 4550 0093 HYDRAULIC LEAK FROM RT PYLON NOTED DURING POST FLIGHT, CAUSE: RUDDER STANDBY FILTER ASSEMBLY DIFFERENTIAL PRESSURE INDIC ATOR HAD 1 RETAINING SCREW SHEARED AT THE HEAD P/N AA-2100-11D99. 3000 PSI OF SYSTEM PRESSURE CAUSED O-RING DAMAGE AND T HE SUBSEQUENT LEAK. 2 L 7 2 4J RT T00007WI 2005031000096 20050310 00096 CE 2005 3 10 2005FA0000275 1 20050105 G 2497 3505501 CONNECTOR CESSNA 650 650 2076802 CE ARCED B O OTHER O OTHER NR NOT REPORTED 1 SW 99 49SM 6500132 A WIRE CONNECTOR WAS INSTALLED TO REPLACE A BROKEN CONNECTOR. CONNECTOR WAS INSTALLED AND APPROVED FOR RETURN TO SERVICE BY A CERTIFIED REPAIR STATION.THE WIRE PROVIDED POWER TO THE OVERHEAD LIGHTS. APPROXIMATELY TWO WEEKS AFTER THE MAINTEN ANCE WAS PERFORMED, THE OPERATOR WAS PERFORMING AN OXYGEN MASK DROP TEST. HE HEARD A NOISE AND THEN SMELLED SMOKE AND SA W A SMALL FLAME IN THE HEADLINER AREA NEAR THE CABIN DOOR. THE OPERATOR SHUT OFF POWER AND EXTINGUISHED THE FLAME. INVES TIGATION REVEALED THE CONNECTOR WAS MELTED AND THE WIRING WAS BURNED. THE OXYGEN SUPPLY LINE ADJACENT THE WIRE HAD SOME BURNED STRANDS OF OUTER COVERING. THE OPERATOR REPAIRED THE WIRING AND INSTALLED A NEW OXYGEN LINE. 2 L 7 2 4F A9NM 2005031100076 20050311 00076 CE 2005 3 11 2005FA0000276 1 20050211 G 3246 378941 HEAT SHIELD BFGOODRICH CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE WHEEL CONTAMINATED C O OTHER B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 SO 11 404BT 0708 5605038 AFTER LANDING, SMOKE AND SMALL FLAME OBSERVED FROM LT MAIN GEAR WHEEL. FIRE WAS EXTINGUISHED, NO DAMAGE TO LANDING GEAR OR AIRCRAFT. LT MAIN GEAR WHEEL ASSEMBLY WAS REPLACED AS A PRECAUTION. THE LT WHEEL HAD BEEN RECENTLY CLEANED WITH A WAT ER BASED SOLVENT IAW THE WHEEL CMM. SUSPECT THAT THE PARTS CLEANER USED TO CLEAN THE WHEEL MAY HAVE BEEN CONTAMINATED W ITH A PETROLEUM BASED LIQUID. IAW MFG, THERE HAVE BEEN REPORTED CASES OF WHEEL FIRES DUE TO THE HEAT SHIELD ABSORBING A PETROLEUM SOLVENT. 2 L 7 2 4F 4 F RT A22CE E00059EN 2005031100065 20050311 00065 GL 2005 3 11 2005FA0000277 2 20050120 G 7323 6871461 TUBE SCWZER 269 269D 8059501 EA ALLSN 250C 250C20 03013 GL ENGINE WORN C R AUTOROTATION J WARNING INDICATION CR CRUISE 1 SW 09 8375F 1967 47 0031A CAE845077 THE PILOT WAS FLYING AT APPROX. 600 FEET INDICATED, WHEN HE EXPERIENCED A VIOLENT YAW TO THE RIGHT AND A HIGH PITCH ENG. SOUND. AN EMERGENCY LANDING WAS MADE WITH PARTIAL POWER UNTIL THE LAST 50 FT. AND THEN THE PILOT HAD TO ENTER AUTOROTAT ION WITH NO POWER DUE TO EXCESSIVE SURGING AND YAWING THAT RESULTED. IT HAD BEEN INSTALLED AND WORKING 47.1 HOURS BEFOR E THE OCCURANCE. THE PROBLEM WAS A B-NUT ON THE PR LINE (REGULATED AIR PRESSURE) HAD SOMEHOW BACKED OFF FROM THE POWER T URBINE GOVERNOR. THIS CAUSED GOVERNOR FAILURE, CAUSING EXTREME ERRATIC OPERATION OF THE BENDIX FUEL SYS. COMPONENTS. 1 G 7 1 3U 3 U 0 4H12 E4CE 2005031400085 20050314 00085 SW 2005 3 14 2005FA0000278 1 20050209 G 6230 430310461101 BEARING BELL BELL 430 430 1182150 SW ALLSN 250C 250C40B 03032 NE SWASHPLATE WORN C K NONE O OTHER IN INSP/MAINT 1 EA 01 9SP 992 49086 49086 SWASHPLATE DUPLEX BEARING P/N 430-310-461-101 S/N ZV10085 FOUND WORN ON LOWER RACE. 1 G 7 2 3U 3 U RT H9SW E1GL 2005041900038 20050419 00038 SO 2005 4 19 2005FA0000291 1 20050301 G 8011 STARTER PIPER PA44 PA44180 7104402 SO RT ENGINE STICKING B K NONE O OTHER IN INSP/MAINT 1 SO 15 931ER 2128 86 4496155 THIS STARTER SHOWED NO SIGNS OF FAILURE. DURING MAINTENANCE, THE STARTER WOULD NOT ENGAGE THE RING GEAR. THE STARTER D ID HAVE A LONG SERVICE LIFE, BUT IS SIMILAR IN FAILURE TO MANY, MANY OF THESE STARTERS ON THIS FLEET THAT LASTS ONLY SEV ERAL HOURS, SOMETIMES UNDER 5 HOURS OR NEVER CRANK THE ENGINE THE FIRST TIME AFTER INSTALLATION. 1 L 7 2 3O A19S0 2005032800062 20050328 00062 CE 2005 3 28 2005FA0000297 1 20050209 G 2421 DOFF10300B ALTERNATOR CESSNA 185 A185F 2072821 CE ENGINE CORRODED D K NONE J WARNING INDICATION IN INSP/MAINT 1 NM 11 61423 541 541 18504180 LOW VOLTAGE LIGHT COMES ON OCCASIONALLY-RESET SWITCH AND OPERATES NORMAL. FOUND BRUSHES WORN OUT IN ALTERNATOR. REMOVING ALTERNATOR WAS EXTREMELY DIFFICULT. MOUNTING BOLT WAS FROZEN IN ALTERNATOR. USING PENETRANT HELPED TO FREE THE BOLT. D ISCOVERED THAT FACILITY HAD INSTALLED A STEEL BUSHING IN MOUNTING BOSS DURING OVERHAUL. THE BOLT AND BUSHING WERE RUSTED TOGETHER. THE BUSHING APPEARS TO BE A REPAIR. 1 H 7 1 3O 3A24 2005032800064 20050328 00064 CE 2005 3 28 2005FA0000298 1 20050205 G 3246 D306001 WHEEL CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160CTM GL MLG FAILED D D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 NE 01 13263 3920 17262622 L3598627A 723093 FOUND RT MAIN TIRE WAS LOCKED UP. PUT WHEEL ON DOLLY AND PULLED PLANE TO HANGER. CLOSER LOOK IN HANGER FOUND THAT RIM HA D BLOWN APART. DEFLATED TIRE AND LOOKED INSIDE RIM. FOUND PIECE BROKEN OUT OF CENTER SECTION OF RIM. CRACKS WERE FOUND A ROUND BOLT HOLES OF RIM HALVES. EXAMINED BROKEN PIECE, FOUND THAT PORTION OF CRACK WAS OLD, REST BEING NEW. WITH AIR PR ESSURE IN TIRE, IT WAS TRYING TO BLOW IT APART. HAVE SEEN THIS PROBLEM ALOT WITH MFG WHEELS HAVING CRACKS AROUND BOLT HO LES, BUT HAVEN`T SEEN ONE COME APART. YOU CAN ONLY SEE CRACKS WHEN CHANGING TIRE FROM THE INSIDE. I THINK IT IS FROM OVE R-TIGHTENING BOLTS UPON ASSY WHEN CHANGING TIRES. ALSO, HAVING STEEL BOLTS THREADING INTO ALUMINUM HOUSING. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005032800065 20050328 00065 CE 2005 3 28 2005FA0000299 1 20050205 G 3246 D306001 WHEEL CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160CTM GL ZONE 700 FAILED D O OTHER O OTHER TX TAXI/GRND HDL 1 NE 01 13263 3920 17262622 L3598627A 723093 FOUND RT MAIN TIRE WAS LOCKED UP. PUT WHEEL ON DOLLY AND PULLED PLANE TO HANGER. CLOSER LOOK IN HANGER FOUND THAT RIM HA D BLOWN APART. DEFLATED TIRE AND LOOKED INSIDE RIM. FOUND PIECE BROKEN OUT OF CENTER SECTION OF RIM. CRACKS WERE FOUND A ROUND BOLT HOLES OF RIM HALVES. EXAMINED BROKEN PIECE AND FOUND THAT PORTION OF THE CRACK WAS OLD, REST BEING NEW. WITH AIR PRESSURE IN TIRE, IT WAS TRYING TO BLOW IT APART. HAVE SEEN THIS PROBLEM ALOT WITH MFG OF WHEELS HAVING CRACKS AROU ND BOLT HOLES. BUT NEVER SEEN ONE COME APART. YOU CAN ONLY SEE THE CRACKS WHEN CHANGING TIRE FROM THE INSIDE. MAYBE FROM OVER-TIGHTENING THE BOLTS UPON ASSY WHEN CHANGING TIRES. ALSO, HAVING STEEL BOLTS THREADING INTO ALUMINUM HOUSING. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005032800067 20050328 00067 CE 2005 3 28 2005FA0000300 1 20050130 G 2820 LINE CESSNA 206 206CESSNA 2073302 CE FUEL SYSTEM CHAFED D K NONE K J FLUID LOSS WARNING INDICATION IN INSP/MAINT 1 WP 17 WHILE PERFORMING AN ANNUAL INSPECTION IN THE CABIN SUBFLOOR AREAS, NOTED A FUEL LEAK AT THE PORT 90 DEGREE RIDGID FUEL L INE LINKING THE WING TANK, VIA THE PORT DOOR PILLAR, TO SUBFLOOR LINE THAT CONNECTS TO THE SELECTOR VALVE. IT WAS INSTAL LED BACKWARD. THIS PLACED THE LINE TOO CLOSE TO A FLOOR BULKHEAD, CAUSING CHAFING AND WEAR-THROUGH. THIS CREATED A LEAK BETWEEN THE FUEL TANK AND THE SHUTOFF VALVE BENEATH THE FLOORBOARD. DO NOT HAVE A SRM FOR PN. 1 H 7 1 3O A4CE 2005032800069 20050328 00069 CE 2005 3 28 2005FA0000301 1 20050205 G 3246 D306001 WHEEL CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160CTM GL ZONE 700 FAILED D O OTHER O OTHER TX TAXI/GRND HDL 1 NE 01 13263 3920 17262622 L3598627A 723093 FOUND RT MAIN TIRE WAS LOCKED UP. PUT WHEEL ON DOLLY AND PULLED PLANE TO HANGER. CLOSER LOOK IN HANGER FOUND THAT RIM H AD BLOWN APART. DEFLATED TIRE AND LOOKED INSIDE RIM. FOUND PIECE BROKEN OUT OF CENTER SECTION OF RIM. CRACKS WERE FOUND AROUND BOLT HOLES OF RIM HALVES. EXAMINED BROKEN PIECE AND FOUND THAT PORTION OF CRACK WAS OLD, REST BEING NEW. WITH AI R PRESSURE IN THE TIRE, IT WAS TRYING TO BLOW IT APART. HAVE SEEN THIS PROBLEM ALOT WITH MFG WHEELS HAVING CRACKS AROUND BOLT HOLES. BUT NEVER SEEN ONE COME APART. YOU CAN ONLY SEE CRACKS WHEN CHANGING TIRE FROM INSIDE. THINK IT IS FROM OVE R TIGHTENING THE BOLTS UPON ASSEMBLY WHEN CHANGING TIRES. ALSO, HAVING STEEL BOLTS THREADING INTO ALUMINUM HOUSING. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005032800070 20050328 00070 CE 2005 3 28 2005FA0000302 1 20050205 G 3246 D306001 WHEEL CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160CTM GL ZONE 700 FAILED D O OTHER O OTHER TX TAXI/GRND HDL 1 NE 01 13263 3920 17262622 L3598627A 723093 FOUND RT MAIN TIRE WAS LOCKED UP. PUT WHEEL ON DOLLY AND PULLED PLANE TO HANGER. CLOSER LOOK IN HANGER FOUND THAT RIM HA D BLOWN APART. DEFLATED TIRE AND LOOKED INSIDE RIM. FOUND PIECE BROKEN OUT OF CENTER SECTION OF RIM. CRACKS WERE FOUND A ROUND BOLT HOLES OF RIM HALVES. EXAMINED BROKEN PIECE AND FOUND PORTION OF CRACK WAS OLD, REST BEING NEW. WITH AIR PRES SURE IN TIRE, IT WAS TRYING TO BLOW IT APART. HAVE SEEN THIS PROBLEM ALOT WITH MFG WHEELS HAVING CRACKS AROUND BOLT HOLE S, BUT NEVER SEEN ONE COME APART. CAN ONLY SEE CRACKS WHEN CHANGING TIRE FROM INSIDE. THINK IT IS FROM OVER TIGHTENING T HE BOLTS UPON ASSY WHEN CHANGING TIRES. ALSO, POOR DESIGN HAVING STEEL BOLTS THREADING INTO ALUMINUM HOUSING. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005032800090 20050328 00090 2005 3 28 2005FA0000303 4 20050307 G 3418 TERMINAL CESSNA 182 T182T 2072738 CE LYC O540 TIO540* 41532 EA STALL WARNING LOOSE D O OTHER O OTHER CR CRUISE 1 WP 07 66139 T18208367 STALL WARNING INOP, FOUND STALL WARNING SWITCH TERMINAL SCREW LAYING INSIDE WING, SCREW BACKED OUT IN FLIGHT. 1 H 7 1 3O 3 O NT 3A13 E14EA 2005032800105 20050328 00105 EA 2005 3 28 2005FA0000304 2 20050207 G 8530 LW12425 CYLINDER HEAD PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA ENGINE CRACKED D E ENGINE SHUTDOWN R PARTIAL RPM/PWR LOSS DE DESCENT 1 EA 17 62BA 2588 738 274859 L947248 DESCENDING IN FLIGHT NR 3 CYL ON RT ENG FAILED. ENG WAS SHUTDOWN AND FEATHERED. AC LANDED WITHOUT FURTHER INCIDENT. TH ERE WAS NO FIRE. POST INCIDENT INSP OF AREA FOUND, CYLINDER HAD CRACKED AND DISLOCATED AT INTERFACE AREA OF STEEL BARREL AND CYLINDER HEAD. INTAKE PUSHROD HAD SEPARATED AND WAS LYING ON THE CYLINDER HEAD, WITH CONSIDERABLE OIL LOSS. FURTHER INSP FOUND ENGINE BAFFLING INTACT AND CORRECTLY POSITIONED. CYLINDER PRESENTED NO OBVIOUS FLAWS AT THE MOST RECENT INS P, WITH OIL CONSUMPTION AND COMPRESSION WITHIN NORMAL LIMITS. IT IS SUSPECTED THAT A DEFECT IN CYLINDER REPAIR PROCESS ( I.E., GRINDING) ALLOWED AN ABNORMAL STRESS CONCENTRATION TO CAUSE A FAILURE. CYL WAS REGROUND AND HONED TO P.010. (K) 1 L 7 2 3O 3 O 1A10 1E4 2005032800117 20050328 00117 GL 2005 3 28 2005FA0000305 3 20050203 G 6110 C4451 FERRULE MCAULY CESSNA 210 210J 2073439 CE CONT O520 IO520* 17032 SO MCAULY 3A32C D3A32C88 GL BEARING FLANGE CRACKED B W59R K NONE O OTHER IN INSP/MAINT 1 WP 07 3301S 746891 21059101 746891 DURING DISASSEMBLY FOR OVERHAUL, BLADE RETENTION FERRULE C4451 FOUND CRACKED IN BEARING FLANGE ON NR 2 BLADE. THE CRACK APPEARS TO HAVE STARTED AT AN OLD ACTUATING PIN HOLE AND IS OVER THREE INCHES LONG. S/B 196B HAD NOT BEEN ACCOMPLISHED ON THIS PROPELLER. 1 H 7 1 3O 3 O 3A21 E5CE 5 C P21EA 2005041400111 20050414 00111 CE 2005 4 14 2005FA0000306 1 20050117 G 7921 8406E OIL COOLER BEECH 23 C23 1151242 CE LYC O360 O360A4J 41514 EA SNSNCH 76E 76EM8S5 EA ENGINE CRACKED G E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 SO 05 9JY 442 M2133 IN-FLIGHT ENGINE FAILURE DUE TO OIL STARVATION RESULTING IN AN EMERGENCY LANDING IN TREES. POST ACCIDENT INVESTIGATION R EVEALED A CRACKED OIL COOLER, WHICH ALLOWED ENGINE OIL SUPPLY TO BE PUMPED OVERBOARD. REFERENCE ACCIDENT (NR ATL05CA047 ). 1 L 7 1 3O 3 O A1CE E286 5 N P4EA 2005041500228 20050415 00228 SO 2005 4 15 2005FA0000308 1 20050301 G 1497 39570002 RELAY PIPER PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA SHORTED B NX4T K NONE S AFFECT SYSTEMS IN INSP/MAINT 1 SO 15 934ER 13 13 4496191 CREW NOTED VARIOUS ROCKER SWITCHES, LOCATED ON INSTR PANEL, FAILED TO ILLUMINATE. IT WAS DISCOVERED THAT FUEL PUMP SWIT CHES, LOCATED ON LWR PILOT'S PNL, JUST TO LT OF EMER GEAR EXT, WERE CONTACTING GEAR MUTE RELAY (SMALL METAL BOX) LOCATED DIRECTLY BEHIND THEM. CONTACT WAS MADE THROUGH LWR TRMNLS ON EACH SWITCH, WHICH WAS NOT INSULATED AS WERE SOME OF OTHE R TRMNLS ON SAME SWITCH. TERMINALS ARE WHERE LIGHTING WIRES FOR INTERNAL SWITCH LIGHTS ARE CONNECTED TO SWITCH. THIS C AUSED ALL OF LIGHTS IN ALL OF PNL MOUNTED ROCKER SWITCHES TO NOT ILLUMINATE. EVIDENCE OF ABNORMAL HEAT BEING GENERATED B Y LIGHT DIMMER ASSEMBLIES (P/N 39570-002), SO THAT ASSY WAS REPLACED WITH SERVICEABLE ASSY, RELAY WAS ALSO REPOSITIONED. 1 L 7 2 3O 3 O A19S0 E286 2005042500213 20050425 00213 2005 4 25 2005FA0000309 4 20050307 G 3418 SWITCH CESSNA 182 T182T 2072738 CE LYC O540 TIO540* 41532 EA STALL WARNING INOPERATIVE D O OTHER O OTHER CR CRUISE 1 WP 07 66139 T18208367 STALL WARNING INOP FOUND STALL WARNING SWITCH TERMINAL SCREW LAYING INSIDE WING, SCREW BACKED OUT IN FLIGHT. 1 H 7 1 3O 3 O NT 3A13 E14EA 2005041500085 20050415 00085 EA 2005 4 15 2005FA0000310 2 20050204 G 8500 ENGINE PIPER PA31 PA31325 7103105 SO LYC O540 TIO540F2BD 41532 EA HARTZL HCE2Y HCE2YR2 GL RIGHT FAILED C E ENGINE SHUTDOWN E VIBRATION/BUFFET TX TAXI/GRND HDL 1 SO 17 27447 317812022 L125968A THE PILOT ATTEMPTED TO START THE RT ENGINE, WHILE DOING SO, HE HEARD A LOUD BANG THE ENGINE STARTED, AFTERWARDS, SHUTDO WN THE ENGINE AND EXITED THE AIRCRAFT. UPON INVESTIGATION, OBSERVED SKIN DAMAGE BETWEEN THE INSIDE NACELLE AND FUSELAGE, THE WING LOCKER SUFFERED SKIN DAMAGE ALONG WITH THE WHEEL WELL WHERE OBSERVED DAMAGE TO THE INSPECTION PANEL. THE FLAP ALSO SUSTAINED DAMAGE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P9EA 2005042500199 20050425 00199 SO 2005 4 25 2005FA0000313 1 20050307 G 2140 90D382EL HEATER PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA CABIN SMOKE B NX4T O OTHER B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 WP 07 572ER 401 4496148 NOTICED HEATER SMOKING FROM THE EXHAUST. HAD PILOT TURN TEMP CONTROL TO LOW AND SHUT DOWN THE HEATER. OPENED NOSE CONE AND NOTICED SMOKE AND STRONG BURNING SMELL. THE HEATER INLET AIR CONTROL CABLE HAD MELTED ALONG WITH A GROUND WIRE TERM INAL LOCATED ON THE TOP OF THE HEATER. ALSO THE HEATER ITSELF HAD A BURNED/DISCOLORED AREA ON THE TOP SIDE. THERMAL HE AT BREAKER WAS POPPED. FOUND THE HEATER CABIN BLOWER WAS INOPERATIVE, SO THERE WAS NO AIR CIRCULATION THRU THE HEATER OU TER CAN. REPLACED HEATER ASSEMBLY. THIS IS THE SECOND OCCURRENCE WITHIN THE LAST FOUR DAYS ON THE SAME TYPE OF AIRCRAF T . HAVE CONTACTED THE MFG CONCERNING PROBLEM. 1 L 7 2 3O 3 O A19S0 E286 2005041500169 20050415 00169 GL 2005 4 15 2005FA0000314 3 20050224 G 6114 D4885C61 HUB MCAULY D2AF34C61 CESSNA 336 336 2075602 CE CONT O360 IO360A 17025 SO MCAULY 2AF34C D2AF34C61 GL BLADE SOCKET CRACKED B K NONE K FLUID LOSS IN INSP/MAINT 1 WP 07 3860U 781897 3360160 781897 PROPELLER SENT FOR REPAIR OF RED DYE OIL LEAK. AT DISASSEMBLY HUB WAS FOUND CRACKED IN BLADE RETENTION SOCKET THREADS. 1 H 7 2 3O 3 O A2CE E1CE 5 C P5EA 2005040100010 20050401 00010 NM 2005 4 1 2005FA0000337 1 20050203 G 2760 654494710 HOUSING BOEING BOEING 737 737* NM ACTUATOR CRACKED D IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 1902 PIN HOLES AND CRACKS IN SIDEWALL OF HOUSING. CYCLING FATIGUE. USE NEW IMPROVED STEEL HOUSING AND REMOVED ALUMINUM HOUS INGS FROM SERVICE. (MECHANIC, BA2, JOB 192740) (K) 2 L 7 2 4F RT A16WE 2005042700030 20050427 00030 NM 2005 4 27 2005FA0000338 1 20050203 G 2913 624022 ADAPTER VICKERS BOEING 747 747* NM PUMP ERODED D IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 MX530942 EROSION AROUND STROKING PISTON PORT. PROLINGED FLUID FLOW AGAINST SOFT METAL STRONGER MATERIAL FOR HOUSING. (MECHANIC BS1, JOB 192844) (K) 2 L 7 4 4F RT A20WE 2005040400080 20050404 00080 NE 2005 4 4 2005FA0000339 1 20050131 G 3213 642550120101 AXLE SKRSKY S64 S64E 8142604 NE PWA JFTD12 JFTD12A4A 52047 NE MLG CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 154AC EAC14465 64037 (MDR05-073) FOUND CRACKED DURING NDT INSPECTION. CRACK IS APPROXIMATELY 1 INCH IN LENGTH AND IS IN THE KEY GROOVE. THI S IS FIRST KNOW DEFECT OF THIS TYPE FOR THIS PART. CAUSE IS UNKNOWN AND NO RECOMMENDATIONS TO PREVENT RECURRENCE AT THI S TIME. (K) 2 G 7 2 4U 4 U H4EA E15EA 2005040400071 20050404 00071 NE 2005 4 4 2005FA0000340 1 20050110 G 6220 6595211522102 BEARING RACE SKRSKY SKRSKY S64 S64F 8142610 NE PWA JFTD12 JFTD12A5A 52047 NE M/R HEAD CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 158AC 654 64081 (MDR05-072) THE MRH SLEEVE AND SPINDLE ASSY DEVELOPED AN OIL LEAK WHILE ON AIRCRAFT AND WAS NOTED DURING ROUTE INSPECTIO N. UPON REMOVAL AND REPLACEMENT WITH A SERVICEABLE ASSY, A CRAK WAS FOUND ON THE INNER RACE. VISUAL INSPECTION SHOWS W EAR AND CORROSION TYPICAL FOR THIS PART THAT HAS BEEN IN SERVICE. NO OTHER ABNOMALITIES WITH THE EXCEPTION OF THE CRACK . CRACK IS APPROXIMATELY 3 INCHES IN LENGTH AND RUNS IN AXIAL DIRECTION. THIS IS A FIRST TIME OCCURANCE. CAUSE IS UNK NOWN AND NO RECOMMENDATIONS TO PREVENT RECURRENCE AT THIS TIME. (K) 2 G 7 2 4U 4 U H6EA E15EA 2005040100107 20050401 00107 NE 2005 4 1 2005FA0000341 1 20050131 G 6210 151520604000 SPAR SKRSKY S64 S64E 8142604 NE PWA JFTD12 JFTD12A4A 52047 NE M/R BLADE CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 194AC 5538 64M54385630 64017 (MDR05-074) THE SPAR IS CRACKED ON THE BOTTOM SIDE OF THE BLADE BETWEEN POCKET LOCATIONS NR 5 AND NR 6. CRACK IS APPROX IMATELY .300 INCH IN LENGTH .650 INCH FROM THE BACKWALL RUNNING CHORDWISE TO .950 INCH FROM THE BACKWALL. BLADE HAD A B IM INDICATION AND WAS REMOVED FROM AIRCRAFT. CAUSE IS UNKNOWN AND NO RECOMMENDATIONS TO PREVENT RECURRENCE AT THIS TIME .(K) 2 G 7 2 4U 4 U H4EA E15EA 2005040100017 20050401 00017 SO 2005 4 1 2005FA0000342 1 20050209 G 2910 HYC5005 POWERPACK PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360* 17025 SO HYD SYSTEM FAILED B FFKR A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 SO 05 4358X 1826 347670027 AC DEPARTED, DIVERTED, PILOT THOUGHT THAT HIS LANDING GEAR WAS NOT FULLY IN THE UP AND LOCK POSITION (UNKNOWN IF GEAR UN SAFE LIGHT WAS ON). PILOT SELECTED GEAR DOWN, NOTHING HAPPENED, PULLED EMERGENCY GEAR EXTENSION AND LANDED WITH NO FURT HER INCIDENT. MAINTENANCE INSPECTED SYSTEM AND FOUND THE HYDRAULIC POWER PACK TO HAVE FAILED. REPLACED POWER PACK. (SO 05200506731) 1 L 7 2 3O 3 O A7SO E9CE 2005032800053 20050328 00053 SO 2005 3 28 2005FA0000343 1 20050303 G 2140 CD21701 SOLENOID VALVE PIPER PA31T PA31T 7103124 SO PWA PT6 PT6A60A 52043 NE HEATER FAILED D J8SR K NONE O OTHER IN INSP/MAINT 1 GL 11 220FS 31T7620052 INSTALLED A NEW C&D AIRCRAFT HEATER AS A REPLACEMENT TO THE OLD HEATER UNIT. THE NEW HEATER WOULD RUN APPROX 5 MINUTES AND THEN PRODUCE NO HEAT. TROUBLESHOOTING SHOWED THAT FUEL WAS REACHING TO THE NOZZLE SOLENOID VALVE, BUT NOT PAST. V OLTAGE WAS PRESENT, AS WELL AS A CLICK FROM THE SOLENOID. REPLACED THE SOLENOID VALVE WITH THE SAME PN, AND HAD THE SAM E ISSUE. FURTHER TROUBLESHOOTING, USING SHOP AIR ON THE VALVE AND A BENCH POWER SUPPLY, SHOWED THAT AFTER VALVE WOULD H EAT UP FROM THE ELECTRICAL CURRENT RUNNING THRU IT (APPROX 5 MINUTES) THE UNIT WOULD NOT ALLOW AIR TO PASS. THE MFG WAS ADVISED OF THESE FINDINGS, AND TESTED A REPLACEMENT VALVE OF THE SAME PN, BUT OF A DIFFERENT BATCH NR AND FOUND IT TO 1 L 7 2 3T 4 T A8EA E4EA 2005040100056 20050401 00056 WP 2005 4 1 2005FA0000344 1 20050222 G 5610 3403110307 WINDOW CVAC 340 340CVAC 242270A WP ALLSN 501D 501D22 03005 GL HAMSTD 54H 54H60 NE COCKPIT BLEW OUT D B A EMER. DESCENT UNSCHED LANDING O OTHER CR CRUISE 1 GL 23 391FL 278 DURING CRUISE FLIGHT AT FL230, THE FO SIDE WINDOW BLEW OUT; AT WHICH TIME, AN EMERGENCY DESCENT WAS EXECUTED TO AN UNEVE NT LANDING. (K) 2 L 7 2 4R 4 T 6A6 E282 6 C P906 2005040100067 20050401 00067 EU 2005 4 1 2005FA0000345 1 20050222 G 2731 Z00N6071017251 ACTUATOR SOCATA TBM TBM700 8682000 EU PWA PT6 PT6A64 EA HARTZL HCE4N HCE4N3 NE ELEVATOR TRIM FROZEN D O OTHER J WARNING INDICATION CR CRUISE 1 WP 23 883CA 294 PCEPM174 HH1868 AFTER THE AIRCRAFT HAD BEEN LEFT OUT IN THE RAIN, THE PREVIOUS DAY, THE AC WAS FLOWN. UPON HAND FLYING THE AIRCRAFT TO ALTITUDE, THE PILOT REPORTED THA THE TRIM WHEEL BECAME INCREASINGLY MORE DIFFICULT TO MOVE AS HE ENTERED FREEZING LEVELS . AT OAT -8 THE TRIM WHEEL HAD BECOME COMPLETELY FROZEN. AFTER THE AC HAD TO BE FORCED NOSE OVER, AT OAT +2, THE TRIM WHEEL UNFROZE AND WAS ABLE TO BE TRIMED NORMALLY. (K) 1 L 7 1 3T 4 T RT A60EU E4EA 5 C P10NE 2005040100040 20050401 00040 2005 4 1 2005FA0000346 3 20050221 G 6110 3026652 SEAL PIAGIO P180 P180 6960204 EU PWA PT6 PT6A66 52043 NE PROP SHAFT LEAKING D K NONE O OTHER IN INSP/MAINT 1 EA 25 106SL 1060 1070 RK0087 PROPELLER SHAFT SEAL WAS LEAKING, CAUSING HIGH OIL CONSUMPTION. (K) 1 H 7 2 3O 4 T RT A59EU E26NE 2005040100057 20050401 00057 CE 2005 4 1 2005FA0000347 1 20050218 G 3210 35825110 BRACE BEECH 35 M35 1151526 CE NOSE STRUT CORRODED D O OTHER O OTHER NR NOT REPORTED 1 WP 28 FIND A HIGH PERCENTAGE OF THESE PARTS CORRODED ABOVE THE LOWER BUSHING IN THE GROVE WHERE THE FELT FITS. THIS PART IS M ADE OF MAGNESUM SO THE MOISTURE RETAINED BY THE FLET AND GREASE ALLOWS PART TO CORROD. MFG ALLOWS ONLY 10 PERCENT OF WA LL THICKNESS TO BE REMOVED FROM THE AREA OF THE CORROSION. THE PITS IN THIS PART WERE APPROX 50 TO 75 PERCENT OF WALL T HICKNESS. (K) 1 L 7 1 3O 3A15 2005032800060 20050328 00060 CE 2005 3 28 2005FA0000348 1 20050318 G 5500 0411930 BRACKET CESSNA 150 150C 2071808 CE CONT O200 O200* 17020 SO EMPENAGE INOPERATIVE D K NONE O OTHER IN INSP/MAINT 1 NM 09 1918Z 15059718 (1) RIVET SHEARED AND BRACKET ROTATED, PARTIALLY. THIS WAS CAUSED BY FLAP CABLES BEING RIGGED TOO TIGHT. THIS CAUSED A TWIST IN THE CABLES ALLOWING (1) CABLE TO RIDE UP AND OVER THE OTHER CAUSING IT TO COME OFF AN210-2A PULLEY. THE PILOT REPORTED GREAT DIFFICULTY IN EXTENDING FLAPS. FOLLOW MFG INSTRUCTIONS. (K) 1 H 7 1 3O 3 O 3A19 E252 2005032800044 20050328 00044 SO 2005 3 28 2005FA0000350 2 20050309 G 8530 EXHAUST VALVE CESSNA 150 150F 2071814 CE CONT O200 O200* 17020 SO NR 3 CYLINDER STUCK D K NONE O OTHER IN INSP/MAINT 1 GL 17 6627F 174 15063227 629926A NR 3 CYLINDER HAS A STUCK EXHAUST VALVE. UPON CYLINDER REMOVAL IT WAS FOUND THAT THE VALVE HEAD WAS MUSHROOMED AND THE ROCKER ARM WAS ALSO DAMAGED. THIS CAUSED CONCERN DUE TO THE FACT THAT THE CYLINDER ONLY HAD 174.1 TOTAL HOURS SINCE IT WAS PURCHASED NEW. CYLINDER WAS SENT FOR REPAIRS AND THEN INSTALLED BACK ON THE ENGINE. (K) 1 H 7 1 3O 3 O 3A19 E252 2005032800089 20050328 00089 CE 2005 3 28 2005FA0000351 1 20050302 G 5340 24130351 ANGLE CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA MCAULY 2D34C B2D34C220 GL FUSELAGE CORRODED B DDER O OTHER O OTHER NR NOT REPORTED 1 WP 01 6543V 172RG0766 L2664936A 806017 THIS ANGLE IS WHAT TIES TOGETHER THE WING STRUT, ATTACHES ON THE LT AND RT SIDES OF THE FUSELAGE. IF THIS CORROSION WHE RE TO PROGRESS MUCH FURTHER, IT COULD CAUSE THE STRUTS TO FAIL. (K) 1 H 7 1 3O 3 O 3A17 E286 5 C P7EA 2005042700044 20050427 00044 SO 2005 4 27 2005FA0000352 1 20050307 G 3210 BOLT PIPER PA28 PA28140 7102802 SO LYC O320 O320* 41508 EA RT TORQUE LINK MISSING G K NONE O OTHER IN INSP/MAINT 1 SO 13 3542K 5664 2823617 EXAMINATION OF THE AC REVEALED THAT THE LOWER STRUT, BRAKE AND TIRE ASSY WERE MISSING FROM THE RT MAIN GEAR. UPPER MAIN GEAR TORQUE LINK WAS ATTACHED TO THE UPPER STRUT HOUSING. BRAKE LINE WAS BROKEN OFF AT THE BRAKE CYLINDER FITTING AND LOWER STRUT ASSY WAS MISSING. IT APPEARS THAT TORQUE LINK BOLT FAILED ALLOWING LOWER STRUT ASSY TO EXTEND OUT OF THE ST RUT HOUSING AND FALL FREE OF THE AC. UNABLE TO CONFIRM BASED ON AVAILABLE MAINTENANCE RECORES, BUT AC APPEARS TO HAVE G REASE BOLT REPLACMENT KIT (PN 760-910) INSTALLED. REPETITIVE NDT INSPECTION BE PERFORMED ON LANDING GEAR TORQUE LINK BO LT. (SO13200503296) (K) 1 L 7 1 3O 3 O 2A13 E274 2005040100102 20050401 00102 SO 2005 4 1 2005FA0000353 2 20050224 G 7414 6320 MAGNETO CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO ENGINE FAILED D AIHR K NONE O OTHER IN INSP/MAINT 1 GL 11 468TW 58 414A0071 RT MAGNETO, PN 6320, SN 02091774 FAILED AFTER 58.0 HOURS TOTAL TIME IN SERVICE. INVESTIAGATION FOUND BROKEN CONTACT ASS Y. VISUAL INSPECTION OF BOTH RT AND LT CONTACT ASSY IF SN IS WITHIN 100 OF FAILED PART. NOTE: LT MAGNETO SAME ENGINE P N 6320, SN 02091734 FAILED AT 54.0 HRS TT IN SERVICE. SAME PROBLEM. (GL11200508228) 1 L 7 2 3O 3 O A7CE E8CE 2005042700045 20050427 00045 SO 2005 4 27 2005FA0000354 2 20050224 G 7414 6320 MAGNETO CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO LEFT FAILED B AIHR K NONE O OTHER IN INSP/MAINT 1 GL 11 468TW 414A0071 516571 LT MAGNETO, PN 6320, SN 02091734 FAILED AFTER 54 HOURS TT IN SERVICE. INVESTIGARTION FOUND BROKEN CONTACT ASSY. VISUA L INSPECTION OF BOTH LT AND RT CONTACT ASSY IF SN IS WITHIN 100 HOUR OF FAILED PART. NOTE; RT MAGNETO SAME ENGINE, PN 6 320, SN 02091744 FAILED AT 58.0 HOURS TT IN SERVICE. FROM SAME PROBLEM. (GL11200508227) (K) 1 L 7 2 3O 3 O A7CE E8CE 2005040400040 20050404 00040 SO 2005 4 4 2005FA0000355 1 20050304 G 2721 96319802 TORQUE TUBE PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360* 17025 SO RUDDER ELONGATED B CTUR K NONE O OTHER IN INSP/MAINT 1 GL 21 39655 6496 347870403 DURING INSPECTION, TECH DISCOVERED PLAY IN RUDDER TORQUE TUBE FITTING. TECH INSTALLED SERVICE KIT 764-100V. AD AND SB ADDRESSES INSP AN REPLACEMENT OF THE STEEL TORQUE TUBE FITTING WITH A STEEL REPLACEMENT PART. THIS AC HAD THE STEEL TOR QUE TUBE FITTING INSTALLED PREVIOUSLY. WITH THE STEEL TORQUE TUBE FITTINGS, SEEING THE HOLES ELONGATED. IT IS DIFFICUL T TO NOTICE HOLES ARE ELONGATED DURING INSP SINCE THE RUDDER IS NOT REMOVED FROM THE TORQUE TUBE FITTING DURING TYPICAL SCOPE OF INSP. IF TECH MOVES RUDDER TO THE FULL STOP IN ONE DIRECTION AND THEN SLOWLY MOVES TO OPPOSITE STOP AND GENTLY PUSHES ON THE RUDDER YOU CAN NOTICE SLIP OF TORQUE TUBE WITHIN FITTING. 1 L 7 2 3O 3 O A7SO E9CE 2005040400051 20050404 00051 CE 2005 4 4 2005FA0000356 1 20050215 G 2597 4520133L WIRE ARTEX BEECH MU300 400A 1155402 CE PWA JT15 JT15* 52060 NE BATTERY BROKEN B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 75RL 1195 00831 RK312 REMOVED BATTERY FROM ELT 110-406 FOR VISUAL INSPECTION IAW WITH MFG MM. UPON INITIAL INSPECTION FOUND ONE WIRING TERMIN AL BROKEN OFF OF ONE BATTERY CELL. BATTERY EXPIRATION DATE 6/2006. (K) 2 H 7 2 4F 4 T RT A16SW E1NE 2005040100013 20050401 00013 SO 2005 4 1 2005FA0000357 1 20050321 G 7120 6843949 SUPPORT LKHEED 382 382G 526414U SO ALLSN 501D 501D22A 03006 GL NR 2 ENGINE INCORRECT G NO1Y K NONE O OTHER IN INSP/MAINT 1 EA 35 401LC 4606 8CLMG DURING NR 2 ENGINE REPLACEMENT AND INSTALLATION OF THERMOCOUPLES THE FOLLOWING OBSERVATIONS WERE MADE: 2 COMBUSTION LINE R SUPPORTS HAD BEEN GROUND TO FIT INTO LINER. LOOSE LOCKWIRE ON REAR SCAVANGE PUMP RETAINING NUTS. INLET/ OUTLET OIL T RANSFER TUBE RETAINING SCREWS LOOSE NOT SAFETY WIRED. (K) 2 H 7 4 4T 4 T A1SO E282 2005040100021 20050401 00021 EA 2005 4 1 2005FA0000358 2 20050307 G 8520 AEL18840 CAMSHAFT PIPER PA30 PA30 7103002 SO LYC O320 IO320C1A 41508 EA ENGINE BROKEN C B A EMER. DESCENT UNSCHED LANDING E VIBRATION/BUFFET CL CLIMB 1 SO 13 8833Y 100 301991 L00587655A WHILE CLIMBING OUT OF 4,000 FT, RT ENGINE (2-23-05) SHUTTERED AND BEGAN VIBRATING EXCESSIVELY. RETURNED TO AIRPORT. IN SPECTION REVEALED THE CAMSHAFT HAD BROKEN COMPLETELY INTO 2 PIECES, ENGINE REMOVED AND SENT TO REPAIR FACILITY FOR FURTH ER EVALUATION. ENGINE TT SINCE O/H 100 HOURS. AUTHORISED RELEASE FORM SHOWED NEW PART RELEASED ON APRIL 25, 2002. (K) 1 L 7 2 3O 3 O A1EA 1E12 2005040400086 20050404 00086 SO 2005 4 4 2005FA0000359 1 20050303 G 2140 GASKET JANITROL PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA REGULATOR LEAKING H LM8S O OTHER K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 NM 07 978WC 4496041 PILOT REPORTED SMELLING FUEL WHEN THE COMBUSTION HEATER WAS RUNNING. MAINTENANCE FOUND FUEL SPRAYING FROM A GASKET JOIN T ON THE REGULATOR SIDE OF THE HEATER FUEL SHUTOFF AND REGULATOR VALVE. THIS VALVE WAS REPLACED FOR LEAKING IAW AD. TH IS VALVE WAS INSPECTED FOR LEAKS DURING THE OPS CHECK OF THE HEATER AS PART OF THE ANNUAL INSPECTION ON 11-9-2004, 93.7 AIRCRAFT HOURS PRIOR TO THIS FAILURE. (K) 1 L 7 2 3O 3 O A19S0 E286 2005042700063 20050427 00063 SO 2005 4 27 2005FA0000360 1 20050224 G 7312 HEATER EMB 110 EMB110P1 3260122 SO PWA PT6 PT6A34 52043 EA FUEL/OIL LEAKING D K NONE O OTHER IN INSP/MAINT 1 NE 05 83BA 1 110351 2080 PILOT OBSERVED FLUCTUATING OIL PSI (100-70PSI) BROUGHT POWER BACK TO 200 LBS. TQ AND OIL PSI DROPPED TO 50 PSI. PILOT F EATHERED AND SHUTDOWN EFFECTED ENGINE. AFTER MECH INVESTIGATED THE PROBLEM, FOUND THAT FUEL HAD MIXED WITH THE OIL SUPP LY AND DILUTED IT TO A WATER LIKE CONSISTENCY. BELIEVE THAT THE FUEL OIL HEATER CORE HAS HOLE IN IT WHICH WOULD ALLOW F UEL TO MIX WITH THE ENGINE OIL SUPPLY. (K) 1 L 7 2 4T 4 T A21SO E4EA 2005032800063 20050328 00063 CE 2005 3 28 2005FA0000361 1 20050205 G 5311 504200285758 FRAME BEECH 90 F90 1152909 CE PWA PT6 PT6* 52043 EA FUSELAGE FRACTURED D K NONE O OTHER IN INSP/MAINT 1 GL 05 325WR LA10 DURING 6000 CYCLE AIRFRAME INSPECTION, FOUND LT AND RT CABIN FORMERS FRACTURED INTO 2 PIECES AT STA 177.00 AT WL 90-91 ( APPROXIMATE) CAUSE OF FAILURE UNKNOWN (SUSPECT HARD LANDING). OBTAINED DER FOR REPAIR- CONSULTED MFG TECH SUPPORT ON FI NDINGS. REMOVED AND REPLACED LT AND RT FORMERS. (K) 1 L 7 2 4T 3 T A31CE E2NE 2005042700065 20050427 00065 CE 2005 4 27 2005FA0000363 1 20050117 G 1430 AN37A BOLT CESSNA CESSNA 150 150D 2071810 CE CONT O200 O200* 17020 SO RUDDER WORN G O OTHER O OTHER CR CRUISE 1 NM 07 901SW 15060734 TOP RUDDER HINGE BOLT LOOSENED FROM THE SELF LOCKING NUT PLATE AND CAME OUT CAUSING THE RUDDER ASSEMBLY TO DETACH FROM T HE AC COMPLETELY DURING FLIGHT AT 2000 AGL. THIS BOLT SHOULD HAVE SOME TYPE OF RETAINING MECHANISM IN ADDITION TO THE S ELF LOCKING NUT PLATE. (NM07200502996) (K) 1 H 7 1 3O 3 O 3A19 E252 2005040100061 20050401 00061 CE 2005 4 1 2005FA0000364 1 20050121 G 7810 STC8645SW CLAMP CESSNA 170 170B 2072306 CE CONT C145 C145* 17012 SO TAILPIPE OVERSIZED C K NONE O OTHER IN INSP/MAINT 1 GL 13 3167A 25811 7909D32 BOTH TAILPIPE/MUFFLER CONNECTIONS WERE FOUND TO BE OVERSIZED. THE EXHAUST PIPE CLAMPS WERE NOT OF SUFFICIENT STRENGTH T O SQUEEZE THE OVERSIZED PIPE DOWN ON THE MUFFLER EXHAUST TUBE. THE RESULTING LOOSE FIT WAS ALLOWING EXHAUST FUMES TO SH OOT INTO THE CABIN HEAT AND THE CARBURETOR HEAT SECTIONS OF THE MUFFLERS. ONE THING THAT AGGRAVATED THE CONDITION WAS T HE FACT THAT THE TAILPIPES WERE CRAMMED TOO FAR UP ON THE MUFFLER PIPE. THIS MADE IT INEVITABLE THAT ANY LEAKAGE WOULD ENTER THE MUFFLER/HEAT SHROUD SECTION. SUGGEST GIVING THIS AREA CLOSE SCRUTINY. 1 H 7 1 3O 3 O A799 E253 2005042700067 20050427 00067 CE 2005 4 27 2005FA0000366 1 20050201 G 5711 052340051 SPAR CESSNA 172 172F 2072414 CE CONT O300 O300D 17022 SO RT WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 5134F 13526 17252909 DURING A BORESCOPE INSPECTION, A CRACK WAS FOUND IN THE RT REAR SPAR AT THE IB FLAP TRACK ATTACH POINT. PROBABLE CAUSE IS FATIGUE. THIS IS A VERY HIGH TIME, AC WITH OVER 13, 000 HOURS TT. IT HAS ALSO BEEN USED AS A FLIGHT TRAINER FOR ITS ENTIRE LIFE. (K) 1 H 7 1 3O 3 O NT 3A12 E253 2005040400099 20050404 00099 CE 2005 4 4 2005FA0000369 1 20050120 G 5397 DPA13 CABLE CESSNA 182 182Q 2072732 CE CONT O470 O470U 17026 SO FUSELAGE BURNED D K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 GL 13 735WR 18265747 DEFECT WAS FOUND AT ENGINE REMOVAL AND FIREWALL CLEANING. THE ELECTRICAL CABLE BETWEEN AUX POWER RELAY AND STARTER RELA Y WAS FOUND TO HAVE BURN MARKS AND OBVIOUS DAMAGE TO INSULATION. ADJACENT TO THE DAMAGED PORTION OF THE CABLE WAS A SHE ET METAL SCREW IN THE FIREWALL (INSTALLED WITH THE HEAD OF THE SCREW ON AFT SIDE OF FIREWALL). THE POINTED END OF THE S CREW HAD PIERCED THE INSULATION AND CAUSED SOME ARCING. NEW CABLE INSTALLED ON AIRCRAFT, SCREW REMOVED AND REINSTALLED IN REVERSE POSITION (HEAD OF SCREW ON FORWARD SIDE OF FIREWALL). THE SCREW THAT CAUSED THE DAMAGE IS USED TO ATTACH A P LASTIC SHIELD THAT PROTECTS THE INTERIOR FROM BEING CAUGHT IN THE ELEVATOR CABLE PULLEY THAT IS LOCATED ON AFT SIDE OF F 1 H 7 1 3O 3 O NT 3A13 E273 2005040100097 20050401 00097 SW 2005 4 1 2005FA0000376 1 20050121 G 3210 ED124061 SHAFT GULSTM 690TP 690D 3970405 SW GARRTT TPE331 TPE331* 01514 WP RT MLG BROKEN D K NONE O OTHER IN INSP/MAINT 1 GL 25 909HH 15035 SHAFT SECURING TORQUE LINK TO RT MLG STRUT FOUND BROKEN DURING INSPECTION. THIS TORQUE LINK IS AT TOP OF STRUT AND ROTA TES LOWER STRUT 90 DEGREES DURING RETRACT/ EXTEND CYCLE. INSTALLED NEW SHAFT. (K) 1 H 7 2 3T 3 T 2A4 E2WE 2005032800035 20050328 00035 SW 2005 3 28 2005FA0000377 1 20050106 G 2810 206064633105 FUEL CELL BELL 206 206L4 1182110 SW ALLSN 250C 250C30P 03013 GL AFT DAMAGED C UOHR K NONE O OTHER IN INSP/MAINT 1 GL 13 206GH 3333 52112 DURING A SCHEDUALED 12 MONTH FUEL SYSTEM INSPECTION IAW MM, THE DEFECT WAS NOTED ON A CUSTOMERS AIRCRAFT. THE BOTTOM IN SIDE OF THE AFT FUEL CELL WAS BLISTERED WITH .2500 INCH BLISTER IN DIAMETER, SPACED FROM .5000 INCH TO .2500 INCH APART. THE BLISTERS CONTINUED UP THE SIDE OF THE CELL 6 INCHES WITH THE SPACING BECOMING LARGER BETWEEN BLISTERS. THE FORWAR D 2 FUEL CELLS SHOWED NO DEFETS, ALL FILTERS WERE NORMAL, THE 2 INLINE SCREENS AND INJECTOR PUMP WERE CLEAN ALSO. THE A IRCRAFT MFG WAS NOTIFIED AND THE CELL WAS DETERMINED TO BE UNAIRWORTHY AND WILL BE RETURNED TO THE AIRCRAFT MFG. PROBAB LE CAUSE IS UNKNOWN, RECOMMENDATIONS ARE TO RETURNE THE CELL TO MFG TO EVALUATE DEFECTS.(K) 1 G 7 1 3U 3 U NC H2SW E1GL 2005040400046 20050404 00046 CE 2005 4 4 2005FA0000382 1 20050120 G 3250 204301410 SHIMMY DAMPENER CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA NLG MISINSTALLED D O OTHER O OTHER NR NOT REPORTED 1 NM 09 534DW 177RG1004 DURING PRE-INSPECTION RUN UP/ TASK, STEERING WAS RESTRICTED TO RT. FOUND THAT WHOEVER HAD THE SHIMMY DAMPNER OFF LAST, REVERSED THE GIMBAL THAT ATTACHES IT TO THE ENGINE MOUNT. THERE SHOULD BE A WARNING PLACARD OR MODIFICATION THAT MAKES REVERSAL IMPOSSIBLE. (K) 1 H 7 1 3O 3 O A20CE 1E10 2005040400096 20050404 00096 WP 2005 4 4 2005FA0000383 1 20050322 G 7100 NSL6051513 NOSE COWL DOUG DC10 DC10* WP ENGINE CORRODED B O OTHER O OTHER NR NOT REPORTED 1 SO 25 NOSE COWL SENT TO US FOR REPAIR. DURING EVALUATION SEVERE INTERGRANULAR CORROSION WAS DISCOVERED ON THE OUTER SKIN OF T HE ACOUSTIC BARREL. SUSPECT IMPROPER HEAT TREATMENT AT MFG. PART IS CONSIDERED BEYOND ECONOMICAL REPAIR AND WILL BE SC RAPPED AT THIS LOCATION. (K) 2 L 7 3 4F A22WE 2005040400050 20050404 00050 CE 2005 4 4 2005FA0000384 1 20050112 G 2140 94E422 PRESSURE SWITCH BEECH 58 58 1152740 CE HEATER INTERMITTENT B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 858W 60 TH2060 INVESTIGATED COMPLAINT OF COMBUSTION HEATER NOT OPERATING. DURING TROUBLESHOOTING, FOUND COMBUSTION AIR SWITCH CONTINUI TY INTERMITTENTLY CYCLING OPEN AND CLOSED DURING NORMAL OPERATING PRESSURES. SWITCH DATE CODE: 9/02. REPLACED COMBUSTI ON AIR SWITCH WITH NEW SWITCH, ALSO THERMOSTATIC SWITCH. HEATER OPERATIONS, NORMAL. (K) 1 L 7 2 3O 3A16 2005040100045 20050401 00045 CE 2005 4 1 2005FA0000385 1 20050131 G 5753 052323113 FLAP TRACK CESSNA 172 172H 2072424 CE CONT O300 O300D 17022 SO LT WING WORN D O OTHER O OTHER NR NOT REPORTED 1 SO 09 4989R 17256343 28598D4D WHILE FLAPS WERE BEING RETRACTED, THE LT IB FLAP ATTACH BRACKET CAUGHT ON THE WING COVE PANEL SUPPORT. THIS CAUSED SUBS TANTIAL DAMAGE TO THE COVE PANEL SUPPORT AS WELL AS THE ATTACH BRACKET. CAUSE WAS DETERMINED TO BE WORN FLAP TRACKS. T HE FLAP TRACKS AND ROLLERS WERE REPLACED WITH NEW PARTS AND THE LT FLAP WAS REPLACED WITH A SERVICEABLE ASSY DUE TO LACK OF PARTS AT THE MFG FOR REPAIR. SINCE MFG DOES NOT HAVE LIMITATIONS ON THEIR FLAPS TRACKS, WOULD SUGGEST THAT THEY BE REMOVED AND REPLACED AT 5,000 HOUR INTERVALS. (K) 1 H 7 1 3O 3 O NT 3A12 E253 2005040400047 20050404 00047 CE 2005 4 4 2005FA0000386 1 20050131 G 5753 052323113 FLAP TRACK CESSNA 172 172H 2072424 CE CONT O300 O300D 17022 SO MCAULY 1C172 1C172EM GL LT WING WORN D K NONE O OTHER IN INSP/MAINT 1 SO 09 4992R 17256346 29876D9DR 75113 DURING PREFLIGHT, THE LT OB FLAP TRACK WAS NOTICED TO HAVE DAMAGE. AIRCRAFT WAS IMMEDIATELY GROUNDED AND THE FLAP TRACK S AND ROLLERS WERE REPLACED WITH NEW PARTS. NO FURTHER DAMAGE HAD OCCURRED TO THE FLAP ASSY. SINCE MFG DOES NOT HAVE L IMITATIONS ON THEIR FALP TRACKS, WOULD SUGGEST THAT THEY BE REMOVED AND REPLACED AT 5,000 HOUR INTERVALS. (K) 1 H 7 1 3O 3 O NT 3A12 E253 5 N P910 2005033000039 20050330 00039 CE 2005 3 30 2005FA0000387 1 20050201 G 5711 052340051 SPAR CESSNA 172 172H 2072424 CE CONT O300 O300D 17022 SO MCAULY 1C172 1C172EM GL RT WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 4974R 13293 17256328 29834 XK44008 DURING A BORESCOPE INSPECTION OF THE REAR WING SPAR, A CRACK WAS FOUND AT THE IB FLAP TRACK ATTACH POINT. PROBABLE CAUS E IS FATIGUE. THIS IS A VERY HIGH TIME AC WITH OVER 13,000 HOURS TT. IT HAS ALSO BEEN USED AS A FLIGHT TRAINER FOR ITS ENTIRE LIFE. (K) 1 H 7 1 3O 3 O NT 3A12 E253 5 N P910 2005040100055 20050401 00055 CE 2005 4 1 2005FA0000388 1 20050131 G 5711 052340050 SPAR CESSNA 172 172H 2072424 CE CONT O300 O300D 17022 SO MCAULY 1C172 1C172* GL LT WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 4989R 12536 17256343 28598D4D UF022 WHILE CHANGING THE FLAP TRACKS ON THE LT WING 2 SMALL CRACKS, .2500 INCH LONG, EACH WERE NOTICED ON THE IB AFT WING SPAR AT THE IB FLAP TRACK ATTACH POINT. PROBABLE CAUSE IS FATIGUE. THIS IS A VERY HIGH TIME AIRCRAFT WITH OVER 12,000 HOUR S TT. IT HAS ALSO BEEN USED AS A FLIGHT TRAINER FOR ITS ENTIRE LIFE. (K) 1 H 7 1 3O 3 O NT 3A12 E253 5 N P910 2005042700088 20050427 00088 CE 2005 4 27 2005FA0000389 1 20050131 G 5711 052340051 SPAR CESSNA 172 172H 2072424 CE CONT O300 O300D 17022 SO MCAULY 1C172 1C172EM GL RT WING IB CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 4989R 17256343 28598D4D YC44006 DURING A BORESCOPE INSPECTION, A CRACK WAS FOUND IN THE RT REAR SPAR AT THE IB FLAP TRACK ATTACH POINT. PROBABLE CAUSE IS FATIGUE. THIS IS A VERY HIGH TIME AIRCRAFT WITH OVER 12,000 HOURS TT. IT HAS ALSO BEEN USED AS A FLIGHT TRAINER FOR ITS ENTIRE LIFE. (K) 1 H 7 1 3O 3 O NT 3A12 E253 5 N P910 2005040100059 20050401 00059 SO 2005 4 1 2005FA0000390 1 20050322 G 4950 1159AC2005563 DUCT GULSTM G1159 G1159 3953505 SO APU BLEED SYS DAMAGED B W1JR K NONE O OTHER IN INSP/MAINT 1 WP 01 400M 132 WITH APU RUNNING AND AIR SELECTED ON APU BLEED AIR OPENED HOLE IN INSULATION BY CUTTING BACK INSULATION. FOUND HOLE IN WELDED SEAM BETWEEN TO DUCTS (Y) DUCT NOMINCLATURE IS; DUCT ASSY, APU AND GROUND START. 2 L 7 2 4F RT A12EA 2005032800041 20050328 00041 GL 2005 3 28 2005FA0000395 2 20050316 G 7310 P49389 CHECK VALVE BELL 407 407 1182206 SW ALLSN 250C 250C47B GL FUEL SYSTEM MISINSTALLED C K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 01 18SP 796 53533 COMPONENT INSTALLED ON THE SIDE OF ENGINE. WHEN IT WAS INSPECTED FOUND NUT DISLODGED FROM STUD COVER OF CHECK VALVE. 1 G 7 1 3U 3 U O H2SW E1GL 2005033000017 20050330 00017 CE 2005 3 30 2005FA0000396 1 20050225 G 5712 502205053 RIB CESSNA 421 421B 2076014 CE CONT O520 GTSIO520C 17032 SO WINGS CRACKED B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 421CT 6881 421B0510 DURING AN ANNUAL INSP, NOTED CRACKS IN LT AND RT WING T/E RIBS AT FORWARD END AFT SPAR ATTACHMENT POINT AREAS. AFFECTED RIBS ARE FIRST RIBS IB OF SPOILER SYSTEM ACTUATOR ATTACH POINTS. ALSO FOUND CRACKED AREA IN WING OB T/E SKIN PANEL AT ATTACHMENT POINT TO WS 118.24 T/E RIB, ALSO ADJACENT TO THE RT SPOILER AREA. AIRCRAFT HAD A MFG ELECTRIC/HYDRAULIC SPOI LER SYSTEM INSTALLED PREVIOUSLY IAW STC SA4755NM. SUSPECT IN-FLIGHT STRESSES FROM NORMAL OR HIGH-SPEED OPERATIONS CAN B E CAUSING ACCELERATED FATIGUE IN THESE AREAS. RECOMMEND ROUTINE CLOSE VISUAL INSPECTION OF THESE AREAS. (K) 1 L 7 2 3O 3 O A7CE E7CE 2005033000015 20050330 00015 CE 2005 3 30 2005FA0000397 1 20050225 G 5712 082340063 BULKHEAD CESSNA CESSNA 421 421B 2076014 CE CONT O520 GTSIO520C 17032 SO LT TIP TANK CRACKED B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 421CT 6881 421B0510 DURING AN ANNUAL INSPECTION, FOUND AFT BULKHEAD OF THE LT WING TIP TANK ASSY. CRACKED THROUGH FROM APPROXIMATE CENTER O F THE IB LIGHTENING HOLE HORIZONTALLY TO THE BULKHEAD IB EDGE. CRACKED AREA IS ADJACENT TO AFT ATTACH POINT FOR THE TIP TANK ASSY. AIRCRAFT HISTORY THIS AREA UNKNOWN; MAY HAVE POSSIBLY BEEN CAUSED BY PREVIOUS GROUND MISHANDLING OR (HANGAR RASH) TYPE INCIDENT. (K) 1 L 7 2 3O 3 O A7CE E7CE 2005032800032 20050328 00032 2005 3 28 2005FA0000398 4 20050224 G 3416 ENCODER PIPER PA28 PA28140 7102802 SO LYC O320 O320* 41508 EA ALTIMETER LEAKING B ZV8R K NONE O OTHER IN INSP/MAINT 1 EA 13 95369 2825901 UNIT HAS INTERNAL LEAK. LEAK PROBABLE CAUSE DUE TO AGE. DISCREPENCY FOUND DURING MODE C AND ALTIMETER CORRELATION CHEC K IAW AC43.6B. (K) 1 L 7 1 3O 3 O 2A13 E274 2005033000016 20050330 00016 CE 2005 3 30 2005FA0000399 1 20050303 G 1430 SCREW HONEYWELL KS271C CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA ROLL SERVO BACKED OUT D K NONE O OTHER IN INSP/MAINT 1 SW 11 434SP 3679 172S8302 ROLL SERVO HAD SCREW COME LOOSE AND MADE CONTACT WITH CIRCUIT BOARD CAUSING SHORT AND BURNING UP COMPONENTS ON BOARD. R ECOMMEND TO USE LOCTITE ON SCREWS TO PREVENT SCREWS FROM BACKING OUT OF HOLES. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005033000008 20050330 00008 WP 2005 3 30 2005FA0000400 2 20050303 G 7210 8962321 PLANETARY GEAR MTSBSI MU2 MU2B60 5780460 CE GARRTT TPE331 TPE33110 01514 WP HARTZL HCB4T HCB4TN5 GL REDUCTION G/B FAILED B IZ2R E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 SW 15 644EM 2905 1534SA P36337C CDA3481MI ON 2/26-2005 AN UNCOMMANDED, INFLIGHT CONTAINED SHUTDOWN OCCURED ON THE LT ENGINE DUE TO A GEARBOX FAILURE. THE AIRCRAF T WAS NOT DAMAGED AND MADE A NORMAL LANDING. INVESTIGATION IN THE ENGINE GEARBOX REVEALED THAT THE RING GEAR SUPPORT AN D PLANETARY SPUR GEAR WERE BROKEN. (K) 1 H 7 2 3T 4 T RT A10SW E4WE 6 C P40EA 2005033000010 20050330 00010 WP 2005 3 30 2005FA0000401 2 20050303 G 7210 8967451 RING GEAR MTSBSI MU2 MU2B60 5780460 CE GARRTT TPE331 TPE33110 01514 WP HARTZL HCB4T HCB4TN5 GL REDUCTION G/B BROKEN B IZ2R E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 SW 15 644EM 2905 P36337C 1534 P36337C CDA3481MI ON 2/26/2005, AN UNCOMMANDED, INFLIGHT CONTAINED SHUTDOWN OCCURED ON THE LT ENGINE DUE TO A GEARBOX FAILURE. THE AIRCRA FT WAS NOT DAMAGED AND MADE A NORMAL LANDING. INVESTIGATION IN THE ENGINE GEARBOX REVEALED THAT THE RING GEAR SUPPORT A ND PLANETARY SPUR GEAR WERE BROKEN. (K) 1 H 7 2 3T 4 T RT A10SW E4WE 6 C P40EA 2005033000018 20050330 00018 CE 2005 3 30 2005FA0000402 1 20050209 G 5610 5042006930 WINDSHIELD BEECH 100 B100 1152919 CE GARRTT TPE331 TPE331* 01514 WP COCKPIT BROKEN D O OTHER J WARNING INDICATION CR CRUISE 1 CE 01 564CA 3905 BE58 INSIDE LAYER OF CO-PILOT WINDSHIELD CRACKED WHILE IN-FLIGHT AT 25,000 FT. AIRCRAFT RETURNED. NO PROBABLE CAUSE OR RECO MMENDATION CAN BE MADE TO PREVENT REOCCURRENCE. WINDSHIELD CRACKED FOR NO APPARENT REASON. (K) 1 L 7 2 4T 3 T A14CE E2WE 2005033000009 20050330 00009 EU 2005 3 30 2005FA0000403 1 20050311 G 5420 L713M2055102 BRACKET UROCOP EC135 EC135T1 5620026 EU TMECA ARRIEL ARRIEL1 60030 NE NACELLE CRACKED B A7RR K NONE O OTHER IN INSP/MAINT 1 SW 19 135TG 262 0298 EJECTOR COWLING ALIGNMENT BRACKET CRACKED DUE TO VIBRATION. (K) 1 G 7 2 3U 3 U H88EU E19EU 2005033000012 20050330 00012 CE 2005 3 30 2005FA0000404 1 20050307 G 7810 1019500223 EXHAUST STACK BEECH 200 B200 1152922 CE ENGINE CRACKED B A7RR K NONE O OTHER IN INSP/MAINT 1 SW 19 CRACK IN BARE METAL DUE TO ENGINE VIBRATION. (K) 1 L 7 2 4T A24CE 2005033000013 20050330 00013 SW 2005 3 30 2005FA0000405 1 20050311 G 7810 206064300005 EXHAUST STACK BELL 206 206L 1181522 SW ENGINE CRACKED B A7RR K NONE O OTHER IN INSP/MAINT 1 SW 19 EXHAUST STACK CRACKED IN BASE METAL DUE TO VIBRATION. (K) 1 G 7 1 3U H2SW 2005032800033 20050328 00033 EU 2005 3 28 2005FA0000406 1 20050311 G 5320 L713M2071105 CHANNEL UROCOP EC135 EC135P1 8680990 EU FUSELAGE CRACKED B A7RR K NONE O OTHER IN INSP/MAINT 1 SW 19 422 INLET CHANNEL, CRACKED BASE METAL DUE TO VIBRATION. (K) 1 G 7 2 3U O H88EU 2005033000014 20050330 00014 CE 2005 3 30 2005FA0000407 1 20050308 G 3213 2342100022 STRUT LEAR 60 60LEAR 5170707 CE PWA 305 PW305 NE NLG DAMAGED B WVER K NONE O OTHER IN INSP/MAINT 1 EA 09 247FX 187 DURING 300 HOUR INSPECTION (GEAR SERVICE) THE INNER STRUT CHROME WAS FOUND DAMAGED APPROXIMATELY .001 INCH DEEP. PROBAB LE CAUSE: WEAR OF SEALS CAUSING THE UPPER CAM TO CONTACT THE INNER CYLINDER. INSPECTION REPACK OF THE NOSE LANDING GEAR ASSY AT 3,000 LANDING INSPECTION. (EA09200504488) (K) 2 L 7 2 4F 4 F RT A10CE E35NE 2005033000007 20050330 00007 CE 2005 3 30 2005FA0000408 1 20050302 G 3030 RELAY CESSNA 500 560CESSNA 2076750 CE PWA 545 PW545A NE SENSOR HEAT FAILED D K NONE O OTHER IN INSP/MAINT 1 EA 09 1094L 5605094 DURING POST FLIGHT WALK AROUND, PILOT NOTICED THAT THE ROSEMONT SENSOR HAD ICE ON IT. UPON OPERATIONAL CHECK, FOUND THA T THE SENSOR WAS NOT HEATING. TROUBLESHOOTING THE SYSTEM, FOUND THAT THERE WAS NO POWER TO THE HEATING ELEMENT OF THE P ROBE. UPON FURTHER INVESTIGATION, FOUND THAT THE RELAY KC311 PINS- X1 AND X2 WERE PINNED IN REVERSE ORDER. REPINNED TH E RELAY AND OPS CHECKED THE SYSTEM, GOOD. (EA09200500318) (K) 2 L 7 2 4F 4 F RT A22CE E00059EN 2005032800034 20050328 00034 CE 2005 3 28 2005FA0000409 1 20050211 G 2910 LINE CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA HYDRAULIC SYS CHAFED C O OTHER K J FLUID LOSS WARNING INDICATION LD LANDING 1 SO 05 52668 177RG1241 WHILE INVESTIGATING A GEAR UP LANDING, IT WAS NOTED THAT THE HYDRAULIC LINE FROM THE LANDING GEAR PUMP WAS CHAFING AGAIN ST THE FLIGHT CONTROL CABLES ROUTED IN THE BATTERY COMPARTMENT AREA. SUGGEST INSPECTING THIS AREA FOR CHAFING AND RE-RO UTE HYDRAULIC LINE TO PREVENT CHAFING. WAS REPLACING INTERIOR PANEL AND MAY HAVE BENT THE LINE INTO THE CABLES. (K) 1 H 7 1 3O 3 O A20CE 1E10 2005033000024 20050330 00024 NM 2005 3 30 2005FA0000410 1 20050307 G 7603 THROTTLE BOEING 757 757200 1384950 NM RROYCE RB211 RB211535* NE NR 1 ENGINE MISINSTALLED B LLMY O OTHER W INADEQUATE Q C NR NOT REPORTED 1 EA 35 512TZ 26635 30763 REF: (ATC0515) NR 1 ENGINE THROTTLE TELEFLEX CABLE OUTER SLEEVE RETAINING NUT FOUND TO HAVE COME ADRIFT, ALLOWING THE OU TER PORTION OF TELEFLEX CABLE TO MOVE. THE RETAINING NUT, ALTHOUGH DRILLED FOR WIRE LOCKING, THERE IS NO EVIDENCE OF WI RE LOCKING BEING CARRIED OUT. AC ENTER THE HANGAR WITH TECH LOG DEFECT OF THROTTLE STAGGER, PLA FAULT AND FLUCTUATING E PR. BELIEVE THAT HTIS IS RELATED TO THE ABOVE DEFECT. IN ADDITION, 4 FAN CASE BOLTS AND NUTS WERE FOUND MISSING FROM T HE FAN CASE FLANGE BETWEEN 3 OCLOCK AND 10 OCLOCK POSITIONS. ALL DEFECT RECERTIFICATION HAS BEEN CARRIED OUT AND DOCUME NTED AT REPAIR STATION UNDER W/O: 5200/2005. (K) 2 L 7 2 4F 4 F RT A2NM E12EU 2005032800118 20050328 00118 SW 2005 3 28 2005FA0000413 1 20050111 G 6410 212010750105 BLADE BELL 412 412EP 1182205 SW PWA PT6T PT6T3 52045 EA TAIL ROTOR VIBRATION B VE3R O OTHER O OTHER NR NOT REPORTED 1 WP 01 304FD 936 36229 ON FIRST GROUND RUN, AFTER APPROX 24 HOURS OF HARD RAIN, THE HELICOPTER DEVELOPED A SEVERE VIBRATION. THE VIBRATION WAS TRACED TO A TAIL ROTOR BLADE. SUSPECT BLADE COLLECTED THE RAIN WATER. THE BLADE WAS SCRAPPED IAW THE MM. (K) 1 G 7 2 4U 4 U H4SW E22EA 2005040400019 20050404 00019 CE 2005 4 4 2005FA0000414 1 20050308 G 3297 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO DYNAMIC BRAKE FAILED B VJ3R O OTHER J WARNING INDICATION LD LANDING 1 WP 07 1570A CE1333 830089R PILOT SELECTED GEAR DOWN AND NOTHING HAPPENED. LANDING GEAR WOULD NOT EXTEND. FLIGHT CREW EXTENDED LANDING GEAR MANUAL LY AND LANDED WITHOUT INCIDENT. MAINTENANCE TECH TROUBLESHOT GEAR SYSTEM AND FOUND THAT THE DYNAMIC BRAKE RELAY WAS INT ERMITTENT. PROBABLE CAUSE WAS DUE TO INTERNAL FAILURE WITH RELAY. TO PREVENT RECURRENCE IS INSTALL A NEWER MFG DATE RE LAY WHICH IS AN IMPROVED UNIT IAW MFG. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005033000028 20050330 00028 CE 2005 3 30 2005FA0000415 1 20050311 G 3240 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO BRAKES FAILED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 8240T 3 CE1542 825916R DURING GEAR RETRACTION, GEAR WAS VERY SLOW TO EXTEND. TROUBLESHOOTING SYSTEM FOUND DYNAMIC RELAY WAS LOOSING 12 VOLTS A CROSS DOWN RELAY SIDE. PROBABLE CAUSE AT THIS TIME IS UNKNOWN RETURNED TO MFG FOR ANALYSIS. NO RECOMMENDATION AT THIS TIME. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005033000047 20050330 00047 CE 2005 3 30 2005FA0000416 1 20050310 G 7430 A5109 IGNITION SWITCH CESSNA 172 172R 2072401 CE LYC O360 IO360A1A 41514 EA COCKPIT WORN D K NONE O OTHER IN INSP/MAINT 1 WP 27 106AF 3488 17281055 DURNG ENGINE RUNUP MAGNETO CHECK, IGNITION SWITCH WILL NOT CAUSE RPM TO DROP WHEN KEY IS TURNED TO LT POSITION. WHEN KE Y IS IN LT POSITION, SLIGHT SIDE TO SIDE MOVEMENT OF KEY WILL CAUSE RPM DROP. UPON OPENING SWITCH, FOUND WORN AND ARCHI NG CONTACTS. THE ABOVE MALFUNCTION SEEMS TO OCCUR DUE TO WORN CONTACTS ON SWITCH INTERIOR. DURING RUNUP, FOLLOW MFG CH ECKLIST FOR MAGNETO CHECK. IF ABOVE DEFECT IS FOUND, RECOMMENDATION WOULD BE TO TROUBLESHOOT SYSTEM, VERYIFYING THAT TH E SIDE TO SIDE MOVEMENT OF KEY ALLOWS NORMAL SWITCH OPERATION, UPON DETERMINATION REPLACE OR OVERHAUL IGNITION SWITCH. ( K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005033000038 20050330 00038 NM 2005 3 30 2005FA0000417 1 20050309 G 3340 300909201 LIGHT BOEING 737 737* NM GE CFM56 CFM56* 13802 NE TAILCONE MISINSTALLED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 23 90R 893 32775 WHILE CLEANING LENS, IT APPEARED TO BE LOOSE IN THE HOUSING. A VERY GENTLE PULL RELEASED THE LENS FROM ITS HOUSING. TH E LENS IS THICK GLASS THAT COULD BE A RUNWAY HAZARD IF IT FELL FROM THE AC AND BROKE. PROBABLE CAUSE IS SKYDROL WHICH L EAKED FROM RUDDER PCU AND COMPROMISED THE ADHESIVE FEATURES OF THE SEALANT ATTACHING THE LENS TO THE HOUSING ASSEMBLY. RECOMMEND INSPECTION OF AC THAT HAVE HAD RUDDER PCU SKYDROL LEAKAGE PROBLEMS. SOME TYPE OF MECHANICAL ATTACHMENT OF LEN S TO THE HOUSING SHOULD BE CONSIDERED. (K) 2 L 7 2 4F 4 F RT A16WE E2GL 2005033000034 20050330 00034 WP 2005 3 30 2005FA0000418 1 20050107 G 6510 269A5498005 SHAFT HUGHES 269 269C 4470504 WP LYC O360 HIO360* 41514 EA DRIVE SPLINES WORN D K NONE O OTHER IN INSP/MAINT 1 SO 15 269TJ 414 S1807 DURING ANNUAL INSPECTION GREASE IN LOWER PULLEY SHAFT HAD A RUSTY (BROWN) COLOR (NOTE: ANDEROL GREASE IS BLACK). UPON I NSPECTION PART HAS 414.2 HOURS SINCE NEW, THE SPLINES WERE WORN BEYOND LIMITS. SPECULATION OF MFG AND OUR FACILITY IS T HAT THE GREASE WAS CONTAMINATED. (K) 1 G 7 1 3O 3 O 4H12 1E10 2005033000022 20050330 00022 SW 2005 3 30 2005FA0000419 1 20050107 G 6510 269A5559003 DRIVE SHAFT HUGHES 269 269C1 8059504 SW LYC O360 HIO360* 41514 EA TAIL ROTOR CORRODED D K NONE O OTHER IN INSP/MAINT 1 SO 15 72LP 600 0152 DURING 600 HOUR INSPECTION GREASE IN DRIVE SHAFT HAD A RUSTY (BROWN) COLOR (NOTE: ANDEROL GREASE IS BLACK). UPON INSPEC TION PART HAS 600.0 HOURS SINCE NEW. LIFE LIMIT OF 6000 HRS, THE SPLINES WERE WORN TO THE THICKNESS OF A PIECE OF PAPER (APPROX .090 NEW). SPECULATION OF MFG AND OUR FACILITY IS THAT THE GREASE WAS CONTAMINATED. FIRST 600 HOUR INSPECTION ON THIS AC, SAME GREASE SINCE DELIVERY. (K) 1 G 7 1 3O 3 O O 4H12 1E10 2005032800049 20050328 00049 SW 2005 3 28 2005FA0000420 1 20050107 G 6320 269A5498005 SHAFT HUGHES 269 269C1 8059504 SW LYC O360 HIO360* 41514 EA DRIVE SPLINES WORN D K NONE O OTHER IN INSP/MAINT 1 SO 15 72LP 600 0152 DURING 600 HOUR INSPECTION GREASE IN LOWER PULLEY SHAFT HAD A RUSTY (BROWN) COLOR (NOTE: ANDEROL GREASE IS BLACK). UPON INSPECTION PART HAS 600.0 HOURS SINCE NEW, THE SPLINES SHOWED IRREGULAR WEAR. SPECULATION OF MFG AND OUR FACILITY IS T HAT THE GREASE WAS CONTAMINATED. FIRST 600 HOUR INSPECTION ON THIS AC, SAME GREASE SINCE DELIVERY FROM MFG. (K) 1 G 7 1 3O 3 O O 4H12 1E10 2005040100106 20050401 00106 WP 2005 4 1 2005FA0000421 2 20050125 G 7200 TFE73122B ENGINE LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP RIGHT FAILED B BHKR E ENGINE SHUTDOWN B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CR CRUISE 1 EA 21 96FN 11671 759 186 P74780 WHILE AT FL300, EXPERIENCED AN INFLIGHT FAILURE OF THE RT ENGINE AS FOLLOWS, RT ENGINE INSTRUMENTS, ITT, N1, N2 AND FUEL FLOW ALL BEGAN INCREASING. RT FUEL COMPUTER WAS TURNED OFF, POWER WAS REDUCED TO IDLE. THE ENGINE INSTRUMENTS CONTINU ED TO INCREASE AND JUST PRIOR TO ENGINE SHUTDOWN, A LOUD BANG WAS HEARD FROM THE RT SIDE, FOLLOWED BY A BRIGHT FLASH AND SMELL OF SMOKE IN THE COCKPIT. AC LANDED SAFELY WITHOUT FURTHER INCIDENT. ENGINE WAS REMOVED FROM AIRCRAFT AND SENT T O AN OVERHAUL FACILITY DETAILS OF THE ENGINE DISASSEMBLY FINDINGS ARE CONTAINED IN REPORT NR GR2-703 ATTACHED. IT WAS R ECOMMENDED THAT HP TURBINE BE FWD FOR FURTHER INSPECTION TO DETERMINE MODE FAILURE. (K) 2 L 7 2 4F 4 F A10CE E6WE 2005042700129 20050427 00129 EA 2005 4 27 2005FA0000425 2 20050214 G 8520 SL3601SC PISTON RING PIPER PA28 PA28151 7102805 SO LYC O320 O320D3G 41508 EA ENGINE FAILED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 19 4238F 287715010 L848939A OUT OF CONCERN FROM HAVING 2 PREVIOUS OIL RING FAILURES THAT COULD HAVE BROUGHT ME DOWN. PULLED CYLINDER NR 1 AND NR 2 TO REPLACE RING WITH SAME PRODUCTION DATE AS ONE THAT FAILED. PULLING AND INSPECTING NR 1, FOUND THE RING GAP TO BE EXC ESSIVE, MFG CALLS FOR .0015 TO .0030. , SEEMS LIKE A LOT OF WEAR IN TOO SHORT OF PERIOD. HAD RINGS FROM CYLINDERS NR 1, 2, 4 SENT TO REPAIR STATION TO CHECK FOR HARDNESS OF RINGS. RING NR 1 CYLINDER WAS 1.5 ON C SCALE ROCKWELL MACHINE, NR 2 WAS A 2.0 ON SAME SCALE. CYL NR 4 (RING IN 3 PIECES) LARGE PART OF RING WAS BETWEEN 1.5 AND 2, 2ND PIECE WAS A 5.5, 3RD PIECE WAS 3.5. MAN DATE 10-1-2002. SENT MFG BAD RINGS, SENT NEW RINGS AND OLD RINGS BACK WITH COMMENT. (K) 1 L 7 1 3O 3 O 2A13 E274 2005032800036 20050328 00036 SO 2005 3 28 2005FA0000427 2 20050318 G 8530 AEC631397 CYLINDER HEAD CESSNA 310 T310R 2074246 CE CONT O520 TSIO520NB 17040 SO ENGINE SEPARATED G C ABORTED TAKEOFF E VIBRATION/BUFFET TO TAKEOFF 1 GL 27 96HC 475 475 45285 DURING TAKEOFF PILOT NOTICED A SHUDDER OR VIBRATION. UPON LANDING ENGINE BEGAN TO RUN ROUGH. MAINTENANCE FOUND LT ENGIN E NR 6 CYLINDER HEAD HAD SEPARATED. ENGINE WAS OVERHAULED ON 4-23-2004 AND PUT IN SERVICE ON 5-18-2004. THE ENGINE HAD 475 HOURS SINCE OVERHAUL. THE CYLINDER WAS A NEW, INSTALLED AT OVERHAUL. 1 L 7 2 3O 3 O 3A10 E8CE 2005032800058 20050328 00058 SO 2005 3 28 2005FA0000428 1 20050322 G 5712 78475009 RIB PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA RT WING CRACKED B K NONE O OTHER IN INSP/MAINT 1 SO 15 706ER 2592 2844060 L715451A DURING A VISUAL INSPECTION, A SMALL CRACK WAS FOUND IN THE RT NOSE RIB P/N-62021-005 AND -004. A MORE THOROUGH INSPECTIO N REVEALED THAT AN ADDITIONAL CRACK, MUCH LARGER (ABOUT4 INCHES LONG), WAS FOUND ON THE RIB P/N-78475-009 AND -008. THES E RIBS ARE INCLUDED IN THE MOUNTING ASSEMBLY FOR THE P/N-95643-007 AND -006 AND BRACKET(MAIN GEAR TRUSS). THE OPERATOR O F THIS AIRCRAFT OPERATES A FLEET OF 6 OF THESE AIRCRAFT, AND ALL THE OTHER AIRCRAFT HAD SIMILAR CRACKS, ON BOTH LT AND R T WINGS. THE FLEET IS GROUNDED AND THE AFFECTED PARTS ARE BEING REPLACED. 1 L 7 1 3O 3 O 2A13 1E10 2005032800071 20050328 00071 CE 2005 3 28 2005FA0000429 1 20050318 G 3230 504501024 TORQUE TUBE CESSNA 414 414 2075908 CE CONT O520 TSIO520* 17040 SO MLG CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 05 414RD 4723 4140502 RT TORQUE TUBES CRACKED DURING GEAR RETRACTION. 1 L 7 2 3O 3 O RT A7CE E8CE 2005032800073 20050328 00073 CE 2005 3 28 2005FA0000430 1 20050318 G 3230 504501025 TORQUE TUBE CESSNA 414 414 2075908 CE CONT O520 TSIO520* 17040 SO MLG CRACKED C K NONE O OTHER IN INSP/MAINT 1 WP 05 414RD 4723 4140502 LANDING GEAR TORQUE TUBES ARE CRACKED. 1 L 7 2 3O 3 O RT A7CE E8CE 2005040100048 20050401 00048 GL 2005 4 1 2005FA0000431 3 20050325 G 6110 A249910 SLEEVE HARTZL HARTZL HCE2Y HCE2YL2 GL PISTON ROD INCORRECT D O OTHER O OTHER NR NOT REPORTED 1 SO 01 120 A5639B A5639B PROPELLER WAS REPAIRED AND O/H IN MY SHOP. PROP HAD A2499-10 HIGH PITCH STOP SLEEVE INSTALLED BUT APPARENTLY ASSEMBLER DID NOT KNOW IT TAKES A 2499-9. WHEN ASSEMBLED TO GET BLADE ANGLES CORRECT, ALTERED -10 TO A -9 IAW PRINT A2499. TT O N PROP 120 HRS SINCE NEW. (K) 5 C P9EA 2005042700134 20050427 00134 GL 2005 4 27 2005FA0000432 3 20050325 G 6114 A24182 PISTON ROD PIPER PA32 PA32RT300T 7103216 SO LYC O540 TIO540* 41532 EA HARTZL HCE3Y HCE3YR1 GL PROP HUB MISINSTALLED D K NONE O OTHER IN INSP/MAINT 1 SO 01 39775 32R7887166 FM1248B NEW PROP WAS INSTALLED. ENGINE DEVELOPED METAL. PROP WAS BROUGHT TO SHOP TO BE FLUSHED OUT. AFTER CYL REMOVAL, PITCH CHANGE TUBE (PISTON ROD) WAS FOUND TO BE TORQUED AT 75 FT LBS INSTEAD OF 40 FT LBS. PROP WAS DISASSEMBLED AND REASSEMBL ED TO MAKE SURE FORK WAS NOT UPSIDE DOWN. (K) 1 L 7 1 3O 3 O A3SO E14EA 5 C P33EA 2005040100058 20050401 00058 GL 2005 4 1 2005FA0000433 3 20050325 G 6110 TUBE HARTZL HCC2Y HCC2YK1 GL PISTON PILOT MISREPAIRED D O OTHER O OTHER NR NOT REPORTED 1 SO 01 CH37962B PISTON PILOT TUBE, PAPER TOWEL INSTALLED INSIDE OF TUBE, BLOCKED OIL. PROP HAD / HOUR TIME ON IT. 5 C P920 2005042700133 20050427 00133 2005 4 27 2005FA0000443 4 20050325 G 3420 2300626020 MOTOR COLLINS ADI85A INDICATOR INTERMITTENT B JGVR O OTHER J WARNING INDICATION CL CLIMB 1 CE 09 1536 THE MOTORS HAVE HIGH RESISTANCE BETWEEN THE BRUSHES AND ARMATURE OF THE MOTOR. THIS CAUSES THE MOTOR TO STICK INTERMITTE NTLY, CAUSING A FALSE ATTITUDE DISPLAY IN THE COCKPIT. CREW REPORTED ON CLIMB OUT, THE ADI DISPLAYED AN ATTITUDE FLAG. PITCH AXIS DID NOT RESPOND TO THE ATTITUDE CHANGE. 2005040400013 20050404 00013 2005 4 4 2005FA0000445 4 20050307 G 2562 ELT10 RACK PIPER PA32 PA32301 7103207 SO LYC O540 IO540K1G5 41532 EA HARTZL HCC3Y HCC3YR GL ELT DISLODGED H K NONE O OTHER IN INSP/MAINT 1 EA 21 8310H 149 328306009 L2276448A DY1697 DURING ANNUAL INSPECTION, FOUND ELT LAYING ON THE CONTROL CABLES IN AFT FUSELAGE. LATCH AHD FAILED ON ELT RACK. (EA212 00505230) (K) 1 L 7 1 3O 3 O A3SO 1E4 5 C P25EA 2005040400043 20050404 00043 CE 2005 4 4 2005FA0000446 1 20050304 G 5343 460337 BRACKET BEECH MU300 400A 1155402 CE PWA JT15 JT15* 52060 NE ACTUATOR BROKEN B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 484CW RK334 FLIGHT CREW REPORTED LANDING GEAR UNSAFE LIGHT REMAINED ILLUMINATED AFTER LANDING GEAR RETRACTION FOLLOWING DEPARTURE. CREW ELECTED TO RETURN TO AIRPORT. OBTAINED DOWN AND LOCKED INDICATION ON ALL 3 LANDING GEAR AND LANDED UNEVENTFULLY. UPON JACKING AC FOR INVESTIGATION NOTED LT MAIN GEAR ACTUATOR ATTACH BRACKET BROKEN AND DISTORTED AT LT MAIN GEAR ACTUAT OR ATTACH POINT. ACTUATOR ATTACH HARDWARE STILL SECURE AND SAFTIED IN BROKEN PORTION. THIS SN AC WAS NOTED AS BEING AF FECTED BY MFG. CUSTOMER SL BJ-CSL-1004R1 ISSUED 11/01/2002. BJ-CSL-1004R1 REQUIRED REPLACEMENT OF ALL PN 46033-7, LT M AIN GEAR ACTUATOR BRACKETS ON AFFECTED AC DUE TO INCORRECT HEAT TREATMENT AND CHAMFERING. 2 H 7 2 4F 4 T RT A16SW E1NE 2005040400107 20050404 00107 NM 2005 4 4 2005FA0000447 1 20050315 G 2760 65695223 HOUSING BOEING BOEING 737 737* NM ACTUATOR CRACKED D IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 229 CRACKED BY EXTEND PORT. FATIGUE, UTILIZE IMPROVED STEEL HOUSING. (MECHANIC ECI, JOB NR 193967) (K) 2 L 7 2 4F RT A16WE 2005042700143 20050427 00143 NM 2005 4 27 2005FA0000448 1 20050315 G 2913 65447821 HOUSING BOEING 737 737* NM HYD PUMP CRACKED B IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 61514 1215 HYD PUMP HOUSING IS CRACKED BEHIND PORT (1), FATIGUE. REDESIGN COVER. (MECHANIC FXS, JOB NR 193727) (K) 2 L 7 2 4F RT A16WE 2005042700144 20050427 00144 NM 2005 4 27 2005FA0000450 1 20050301 G 3233 69B802071 HOUSING BOEING BOEING 747 747* NM ACTUATOR CRACKED B IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 SHL793 ACTUATOR HOUSING CRACKED AT THE BASE, FATIGUE OR OVERPRESSURE. REDESIGN HOUSING. (MECHANIC FXS, JOB NR 192820) (K) 2 L 7 4 4F RT A20WE 2005041900042 20050419 00042 SO 2005 4 19 2005FA0000451 1 20050328 G 5712 78475007 RIB PIPER PA44 PA44180 7104402 SO RT WING CRACKED B K NONE O OTHER UK UNKNOWN 1 SO 15 931ER 2186 4496155 SINCE FLEET OF SIX PIPER ARROWS WERE ALL FOUND TO HAVE CRACKED RIBS IN THE SAME LOCATION, FOUND DURING ROUTINE INSPECTIO N. SDRS WERE SENT. DETERMINED TO INSPECT FLEET OF TEN SEMINOLES. THE BASIC WING STRUCTURE IS DESIGNED THE SAME. FOUN D SIMILAR CRACKS IN SEVEN OF THE SEMINOLES. THE CRACKS ARE FOUND IN THE RIB, ADJACENT TO THE FORWARD TRUNNION PLATE (WH ICH MUST BE REMOVED TO PROPERLY SEE THE CRACK). IN THIS PARTICULAR AIRCRAFT THE RIB, P/N 78475-007, LOCATED AT AFT STAT ION 49.25 ON THE RIGHT SIDE, WAS CRACKED. THE LEFT RIB, CRACKED IN OTHER SEMINOLES IS P/N 78475-006 AND LOCATED AT AFT STATION 49.25. 1 L 7 2 3O A19S0 2005040400014 20050404 00014 CE 2005 4 4 2005FA0000452 1 20050317 G 2822 A10055B PUMP CESSNA 206 T206H 2073303 CE LYC O540 TIO540* 41532 EA FUEL BOOST LEAKING D O OTHER K FLUID LOSS NR NOT REPORTED 1 NE 02 65556 53 T20608496 BOOST PUMP WAS LEAKING AT SEAM BETWEEN ELECTRIC MOTOR AND VANE PUMP. FUEL HAD A CHANCE TO LEAK INTO ELECTRIC MOTOR BRUS HES. BELIEVE THIS TO A MAJOR FIRE HAZZARD. BOTH PUMP AND AIRCRAFT WERE NEW. THIS COULD HAVE BEEN PREVENTED BY BETTER QUALITY CONTROL AT THE FACTORY. (K) 1 H 7 1 3O 3 O RT A4CE E14EA 2005042700289 20050427 00289 NE 2005 4 27 2005FA0000453 2 20050314 G 8520 126211 CRANKSHAFT PWA R1340 R1340AN1 52016 NE ENGINE CRACKED B CP2R O OTHER O OTHER NR NOT REPORTED 1 SW 15 1200 P326980 DURING THE OVERHAUL PROCESS, THE FLYWEIGHT LINERS WERE REMOVED AND THE REAR HALF OF THE CRANKSHAFT WAS MAGNETIC PARTICLE INSPECTED. DURING THIS INSPECTION IT WAS DISCOVERED THAT A CRACK HAD DEVELOPED FROM AN ASSEMBLY RIVET HOLE OUT TO THE LINER BORE ON THE COUNTER WEIGHT ARM. UNKNOWN CAUSE. LINERS SHOULD BE REMOVED AT EACH OVERHAUL AND INSPECTED FOR CRACK S IN THIS AREA. (K) 3 R 5E2 2005040400023 20050404 00023 CE 2005 4 4 2005FA0000454 1 20050215 G 5343 24130023 FITTING CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA ACTUATOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 03 6400V 172RG0662 RL1993936A DURING EMERGENCY LANDING GEAR OPERATIONAL CHECK, THE MECHANIC FOUND THE CRACK ON BOTH SIDE CORNER OF THE FITTING NOSE GE AR ACTUATOR ATTACHING PART. IT MAY BE SUSPECTED THAT MATERIAL FATIGUE OR AN UNREPORTED LANDING. (K) 1 H 7 1 3O 3 O 3A17 E286 2005040100004 20050401 00004 GL 2005 4 1 2005FA0000455 3 20050304 G 6114 D22013 HUB HARTZL HCC2Y HCC2YK1 GL PROPELLER CRACKED B ME4R K NONE O OTHER IN INSP/MAINT 1 SO 19 CH14728 (2 EA) CRACKS WERE FOUND USING FLOURESCENT PENETRANT, INSIDE ENGINE SIDE HUB HALF. BOTH CRACKS WERE VERIFIED WITH EDDY CURRENT. CRACKS COUL HAVE BEEN CAUSE FROM A PAST GROUND STRIKE (HARD LANDING). (K) 5 C P920 2005040400024 20050404 00024 NE 2005 4 4 2005FA0000456 2 20050310 G 7250 30600501 TURBINE AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE73140 29001 NE NR 3 ENGINE FAILED C E A ENGINE SHUTDOWN UNSCHED LANDING E J VIBRATION/BUFFET WARNING INDICATION CL CLIMB 1 NM 01 26WP 1754 312 ENGINE SHUT DOWN AT FL360, ON DEPARTURE. FLIGHT CREW AND PASSENGERS HEARD LOUD BANG AND FELT VIBRATION. FLIGHT CREW OB SERVED NR 3 ENGINE N1 SPOOLDOWN AND 25 DEGREE HIGHER THAN NORMAL ITT, ENGINE OIL PRESSURE WAS NORMAL. ENGINE WAS SHUT D OWN AND FLIGHT RETURNED TO DEPARTURE. POSTFLIGHT INSP OF NR3 ENGINE REVEALED DEBRIS IN EXHAUST DUCT. NO VISIBLE DAMAGE TO THE LOW PRESSURE TURBINE. AFT OF FAN OR COMPRESSOR AREA, FWD. SUSPECT COMPONENT FAILURE FWD OF LOW PRESSURE TURBIN E. ENGINE REMOVED FOR REPAIR, SHIPPED TO MFG. PENDING INSP TEARDOWN REPORT FROM MFG. NOT CERTAIN WHAT COMPOENT IN ENGI NE FAILED. (K) 2 L 7 3 4F 4 F A46EU E1NM 2005040100037 20050401 00037 EU 2005 4 1 2005FA0000458 1 20050318 G 7810 1379049H403 EXHAUST STACK BAG JETSTM JETSTM3201 1500217 EU ENGINE CRACKED B A7RR K NONE O OTHER IN INSP/MAINT 1 SW 19 CRACK IN FLANGE DUE TO ENGINE VIBRATION. (K) 2 L 7 2 4T RT A56EU 2005040100006 20050401 00006 EA 2005 4 1 2005FA0000459 2 20050321 G 7414 BL68256013 MAGNETO PIPER PA32 PA32R301T 7103220 SO LYC O540 TIO540* 41532 EA ENGINE INOPERATIVE D O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION NR NOT REPORTED 1 EA 03 32SJ 32R8429016 AIRCRAFT ARRIVED AT HANGAR WITH ROUGH RUNNING ENGINE. FOUND DUEL MAG DEAD AND ON SIDE. REMOVED MAG FROM ENGINE. FOUND TEETH MISSING ON MAG GEAR. WAS TOLD BY OWNER THAT MAG WAS NOT THAT OLD. 1 L 7 1 3O 3 O A3SO E14EA 2005040100008 20050401 00008 EA 2005 4 1 2005FA0000461 2 20050318 G 7322 62F1 STOP PIN PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA THROTTLE BODY WORN B UC2R K NONE O OTHER IN INSP/MAINT 1 GL 19 4146T 224 G508088 2843168 L3625536A STUDENT PILOT REPORTED THROTTLE WOULD NOT ADVANCE BEYOND IDLE. FOUND CARBURETOR BINDKING INTERNALLY. DISASSEMBLED CARB URETOR AND FOUND AIR METERING PIN STOP PIN WORN WHICH ALLOWED AIR METERING PIN TO EXTEND BEYOND NORMAL RANGE AND JAM BET WEEN STOP PIN AND ACTUATING ARM ON PUMP LEVER ASSEMBLY. (K) 1 L 7 1 3O 3 O 2A13 E286 2005040100065 20050401 00065 EU 2005 4 1 2005FA0000462 1 20050316 G 3246 GYS18525 BOLT AMD FALC10 FALCON10 2730101 EU GARRTT TFE731 TFE731* 01518 WP MLG WHEEL BROKEN B UO2R K NONE O OTHER IN INSP/MAINT 1 GL 19 655PE AR75349 199 A BROKEN BOLT WAS NOTICED DURING A TIRE PRESSURE CHECK. THE WHEEL COVER WAS REMOVED TO INVESTIGATE. ALL TEN BOLTS WERE NDT`D BY PAG PARTICLE INSP AND 3 OTHER BOLTS WERE FOUND CRACKED. PART CYCLES (LANDINGS) SINCE O/H IS 176 CSO. (K) 2 L 7 2 4F 4 F A33EU E6WE 2005040100089 20050401 00089 CE 2005 4 1 2005FA0000463 1 20050211 G 8120 GARRTT BEECH 60 B60 1153605 CE LYC O541 TIO541E1C4 41536 EA HARTZL HCF3Y HCF3YR2 GL B CGHR K NONE O OTHER IN INSP/MAINT 1 GL 03 30MM YH023923 P507 L156259 DA1311 WHILE INVESTIGATING OIL LEAK FROM TURBO, FOUND IMPELLER/TURBINE SHAFT HOLD DOWN NUT LOOSE ALLOWING SHAFT TO MOVE LATERAL LY. THIS CAUSED SHAFT TO BECOME UNSEATED AT BEARING SEALS. DISCREPANCY WAS DISCOVERED EARLY ENOUGH TO KEEP IMPELLER AN D TURBINE WHEELS FROM BEING DAMAGED. NOTE: TURBO WAS REPAIRED 1.9 HRS EARLIER. TURBO WAS REPAIRED AND INSTALLED. (K) 1 L 7 2 3O 3 O A12CE E10EA 5 C P31EA 2005040100066 20050401 00066 CE 2005 4 1 2005FA0000464 1 20050317 G 8011 643259 ADAPTER CESSNA 206 U206F 2073333 CE CONT O520 IO520F 17032 SO STARTER DEFECTIVE B YYBR K NONE O OTHER IN INSP/MAINT 1 GL 03 722SJ U20603361 830285R STARTER ADAPTER WAS REMOVED DUE TO DAMAGE CAUSED DURING A (KICK-BACK). INSPECTION FOUND BEARING RETAINING HOLES THAT HA D BEEN KNURLED AT THE FACTORY, MISALIGNED, AND COATED WITH A GREENISH BEARING RETAINING COMPOUND. THE STARTER ADAPTER W ORM DRIVE SHAFT SHOWED SIGNS OF A HEAVY SIDE LOAD. THIS CAUSED THE STARTER ADAPTER TO BIND AND NOT RELEASE. THIS HOUSI NG HAS AN INSPECTION STAMP OF (TA33) AND A DATE STAMP OF (SEPT 15 2003). (K) 1 H 7 1 3O 3 O A4CE E5CE 2005040100064 20050401 00064 CE 2005 4 1 2005FA0000465 1 20050225 G 3610 AA3216CW PUMP BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO DRY AIR DAMAGED B VJ3R O OTHER J WARNING INDICATION CR CRUISE 1 WP 07 5544A CE1343 DURING FLIGHT, FLIGHT CREW NOTICED THAT AIR PRESSURE WAS READING ZERO. LANDED AIRCRAFT AND MAINTENANCE INSPECTED AND FO UND THE ENGINE DRIVEN DRY AIR PUMP SHAFT WAS SHEARED. PROBABLE CAUSE IS UNKNOWN. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005050200076 20050502 00076 2005 5 2 2005FA0000467 4 20050407 G 3421 FITTING CESSNA 172 172S 2072439 CE ATTITUDE GYRO LOOSE D O OTHER O OTHER IN INSP/MAINT 1 WP 25 286SP 172S8238 AIRCRAFT, RELATIVELY NEW PROBLEM BELOW APPEARS TO BE FROM FACTORY INSTALLATION. VACUUM FITTING ON ATTITUDE GYRO LOOSE. THE (90 DEGREE) VACUUM FITTING IN ORDER TO ACCEPT THE VACUUM HOSE FROM RT DIRECTION, WAS NOT PROPERLY SEATED (PIPE THR EAD SYSTEM) SO THAT THE VACUUM TO THE INSTRUMENT WAS REDUCED CAUSING LOW GYRO SPEED AND THUS IMPROPER OPERATION. TURBUL ENCE/HOSE MOVEMENT CAUSED SOME THREAD SEATING AT TIMES TO PRODUCE A USEABLE GYRO, THUS OPERATION WAS ERRATIC. (K) 1 H 7 1 3O NT 3A12 2005050300230 20050503 00230 CE 2005 5 3 2005FA0000468 1 20050322 G 3610 3909740080005 TUNING UNIT RAYTHN 390 390 7150030 CE WILINT FJ44 FJ44 66000 GL FLOW CONTROL BROKEN B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 972PF 582 RB38 DURING REPLACEMENT OF LT BI-FLOW CONTROL VALVE IN CONJUNCTION WITH A SCHEDULED INSPECTION, FOUND PNEUMATIC TUBE IN LT PY LON AREA BENT AND CRACKED IN HALF. SUSPECT MAY BE CAUSED DUE TO PREVIOUS ROUGH HANDLING OR FORCING TUBING DURING BI-FLO W VALVE REPLACEMENT OR RELATED MAINTENANCE IN AREA. RECOMMENDED A MAINTENANCE PRECAUTION BE ADDED TO SEC 21-20-06-401 I N THE 390 MM ADVISING TECH TO HANDLE PNEUMATIC LINES IN THIS AREA WITH CAUTION. (K) 1 7 2 3F 4 F RT A00010WI E3GL 2005050300244 20050503 00244 SO 2005 5 3 2005FA0000469 1 20050222 G 3220 40336000 LINK PIPER PA31 PA31350 7103110 SO LYC O540 TIO540* 41532 EA NLG CRACKED D KU4R K NONE O OTHER IN INSP/MAINT 1 SO 19 38SL 3850 318152167 NLG LINK HAS A CRACKED IAW SL1088. (K) 1 L 7 2 3O 3 O A20SO E14EA 2005050300245 20050503 00245 NM 2005 5 3 2005FA0000472 1 20050304 G 2597 FGFB641103A3 WIRE HARNESS AMD FALC50 FALCON2000 2730170 NM COPILOT SEAT SHORTED B CW1R K NONE O OTHER IN INSP/MAINT 1 EA 11 790L 6108 15 FRACTURED WIRE HARNESS UNDER COPILOT SEAT ARCED AND SHORTED, SPARKS AND COPPER GLOBULES. POSSIBLE FIRE HAZARD IF PAPERS , ETC. UNDER SEAT. CIRCUIT BREAKER WAS SLOW TO RE-ACT. HARNESS NEEDS TO BE MORE RUGGED WITH ATTENTION TO ROUTING AND C LAMPING. (K) 2 K 7 3 4F RT A50NM 2005050300247 20050503 00247 CE 2005 5 3 2005FA0000473 1 20050308 G 3240 3052N CALIPER CESSNA 206 T206H 2073303 CE LYC O540 TIO540* 41532 EA LT BRAKE LEAKING D K NONE O OTHER IN INSP/MAINT 1 EA 23 51824 385 T20608390 NOTICED LT BRAKE LEAKING FLUID ON IB SIDE OF CALIPER. CLEANED, INSPECTED, COULDN`T FIND LEAK. REMOVED CALIPER BENCH TE STED WITH HYD POWER SUPPLY, FOUND CALIPER TO BE LEAKING THROUGH PIN HOLES IN HOUSING IN 3 PLACES. (EA23200505995) 1 H 7 1 3O 3 O RT A4CE E14EA 2005050300248 20050503 00248 SO 2005 5 3 2005FA0000474 1 20050316 G 7120 102403053 SHIELD PIPER PA46 PA46500TP 7104622 SO PWA PT6 PT6* 52043 EA RT ENG MOUNT CHAFED B FTUR K NONE O OTHER IN INSP/MAINT 1 NE 05 5335R 474 4697100 DURING NORMAL EVENT INSPECTION, IT WAS FOUND THAT THE AIR SHIELD WAS CHAFFING AGAINST THE UPPER RT ENGINE MOUNT LEG WHER E IT PASSES THROUGH THE BAFFLE SHIELD FOR THE PLENUM ASSY. RECOMMENDED THAT CLOSE INSPECTION BE GIVEN TO AREA WHERE BAF FLING COULD BE CUTTING INTO THE ENGINE MOUNT. BOTH TIMES THIS WAS FOUND, ENGINE MOUNTS HAD TO BE REPAIRED BY APPROVED W ELDING METHODS BY AUTHORIZED REPAIRED FACILITIES. (K) 1 L 7 1 3O 3 T RT A25SO E2NE 2005050300251 20050503 00251 SW 2005 5 3 2005FA0000475 1 20050306 G 6300 269A54301 SPLINE HUGHES 269 269C1 8059504 SW LYC O360 HO360* 41514 EA MAIN ROTOR BELT STRIPPED D A B UNSCHED LANDING EMER. DESCENT F FLT CONT AFFECTED CR CRUISE 1 SO 15 72LP 1138 0152 WHILE IN CRUISE FLIGHT, TAIL ROTOR FAILURE AT APPROX 700 FT, PILOT WENT TO FLAT PITCH, PUT HELICOPTER IN A DIVE TO AVOID ROTATION FROM TORQUE, PERFORMED FULL AUTOROTATION TO THE GROUND, NO DAMAGE TO HELICOPTER OR INJURIES TO OCCUPANTS. DRI VE GEAR ON TAIL ROTOR INPUT SHAFT STRIPPED AS WELL AS FWD GEAR ON TAIL ROTOR DRIVE SHAFT. SUSPECT POSSIBEL METAL PROBLE M. CURRENT INSPECTION IS 600 AND 1200 HOURS OR 24 MONTHS, POSSIBLY LOWERING INSPECTION INTERVALS TO SAY 300 HOURS. HEL ICOPTER WAS 30 HOURS FROM 1200 HR. (K) 1 G 7 1 3O 3 O O 4H12 E286 2005050300261 20050503 00261 CE 2005 5 3 2005FA0000478 1 20050110 G 3233 ACTUATOR CESSNA 500 550 2076604 CE PWA JT15 JT15* 52060 NE NOSE GEAR WORN B MDOR K NONE O OTHER IN INSP/MAINT 1 CE 07 228CC 5500133 INSTALLED NEWLY OVERHAULED NLG ACTUATOR AND FOUND TO HAVE EXCESSIVE IN LINE MOVEMENT OF TNE LOCKING MECHANISM. MOVEMENT IN EXCESS OF .1250, MAX ALLOWED .035. (K) 1 L 7 2 4F 4 T A22CE E1NE 2005050400093 20050504 00093 NM 2005 5 4 2005FA0000479 1 20050325 G 5340 144490 MOUNT BOEING 747 747* NM VALVE FAILED B IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 VALVE SEPARATED FROM MODULE UPON 45 PSI PROOF PRESSURE TEST. MOUNTING LUGS FAILED AND BROKE OFF, BLOWING THE VALVE OFF THE UNIT. FATIGUE AND INSUFFICIENT MATERIAL ON MOUNT LUGS TO HANDLE PROOF PRESSURE. LOWER PROOF PRESSURE TEST OR REDES IGN MOUNTING LUGS TO WITHHOLD THE PRESSURE. (MECHANIC WC, JOB NR 194178) (K) 2 L 7 4 4F RT A20WE 2005050500001 20050505 00001 NM 2005 5 5 2005FA0000480 1 20050325 G 2913 65447821 HOUSING BOEING 737 737* NM HYD PUMP ERODED B IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 HOUSING HAS A PIN HOLE LEAK ON THE BACKSIDE OF PORT 2, EROSION. REDESIGN HOUSING. (K) 2 L 7 2 4F RT A16WE 2005050500002 20050505 00002 NM 2005 5 5 2005FA0000481 1 20050329 G 3240 511531 HOUSING BOEING 737 737* NM VALVE CRACKED B IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 CRACKED AT PLUG PORT. FATIGUE. (MECHANIC NH2, JOB NR 194399) (K) 2 L 7 2 4F RT A16WE 2005050500003 20050505 00003 NM 2005 5 5 2005FA0000482 1 20050329 G 2710 654484511 MANIFOLD BOEING 737 737* NM FILTER BOWL BROKEN B IU6R K NONE O OTHER IN INSP/MAINT 1 NM 01 5236A FILTER BOWL MOUNTING PORT IS BROKEN OFF AT THE BASE OF THREADS. FATIGUE. (MECHANIC LEB, JOB NR 194521) (K) 2 L 7 2 4F RT A16WE 2005041400103 20050414 00103 NM 2005 4 14 2005FA0000483 1 20050119 G 5740 ATTACH BRACKET CHRIS HUSKY A1 221020X NM LT WING CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SW 99 6RX 1053 DURING A ROUTINE ANNUAL INSPECTION DISCOVERED THE LEFT LOWER WING REAR SPAR ATTACHMENT AFT FITTING CRACKED. THIS INSPEC TION IS REQUIRED EA 50 HOURS BY AD 96-12-03R2 AND MANUFACTURES SERVICE BULLETIN 25. SERVICE BULLETIN 25 INDICATES THE R EPAIR PROCEDURE FOR PITTS S2 & S1 SERIES AIRCRAFT. THIS SERVICE BULLETIN AND THE REPAIR PROCEDURES WILL NOT WORK ON THE S1 AIRCRAFT. THE PARTS INDICATED IN SERVICE BULLETIN 25 WILL NOT WORK ON THE S1 AIRCRAFT. CONTACTED AVIAT AIRCRAFT, T HAT HAVE NOT BEEN RESPONSIVE TO THE PROBLEM, NEED APPROVED REPAIR PROCEDURE FOR THIS PROBLEM.PHONE 740.494.2554 1 H 7 1 3O NC A22NM 2005041400113 20050414 00113 SO 2005 4 14 2005FA0000484 2 20050130 G 8520 SA631991REVC SHAFT PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360E 17025 SO ENGINE OUT OF ROUND D O OTHER O OTHER NR NOT REPORTED 1 WP 17 123AP 347770015 303972 UPON INSTALLING A SHAFT INTO A ROCKER WITH INADEQUATE TOLERANCE LIMITS, NOTED BINDING IN 3 O`CLOCK POSITIONS. WITH PRUSS ION BLUE FOUND SHAFT IS FORMED IN ELIPTICAL OR, MODIFIED TRIANGULAR SHAPE WITH REDUCED WEAR SURFACE AREA DUE TO INCONSIS TANT DIA OF SHAFT. ALL 24 NEW SHAFTS DISPLAYED SAME MACHINING RESULTS. HIGHEST PRESSURE POINT WAS NARROWEST CONTACT PO INT. GALLING OF THESE SHAFTS APPEARS TO BE CONSISTANT WITH REDUCED WEAR SURFACE & CROWNING OF SHAFT. WHILE OTHER FACTO RS MAY BE ATTRIBUTED TO CAUSE OF PREMATURE SHAFT FAILURE, REDUCTUION IN SURFACE AREA IS CONSISTANT WITH ACCELERATED DECO MPOSITION OF BEARING SURFACE. AIRWEST AIRCRAFT ENGINES SUPPLIED PARTS. RETURNED PARTS. 1 L 7 2 3O 3 O A7SO E9CE 2005041500077 20050415 00077 2005 4 15 2005FA0000485 2 20050211 G 7414 MAGNETO ENGINE MALFUNCTIONED C O OTHER O OTHER NR NOT REPORTED 1 GL 09 UPON REINSTALLATION OF A MAGNETO (A 1940'S ERA MAG), INSTALLATION WAS NOT SUCCESSFUL AT FIRST. AFTER DOING THE REPAIR, FOUND THAT THE CONDENSER ON THIS ERA OF MAGNETO CAN BE REMOVED WITH JUST A FLATHEAD SCREWDRIVER AND TAKEN OUT WITHOUT RE MOVING THE MAGNETO FROM THE ENGINE. STUDENTS OF MY MAINTENANCE SCHOOL WERE UNAWARE OF THIS, AND AS AN A&P I WOULD LIKE TO SPREAD THIS SERVICE DIFFICULTY REMEDY AROUND TO THE GENERAL AVIATION PUBLIC. 2005041500166 20050415 00166 CE 2005 4 15 2005FA0000486 1 20050224 G 5315 241139526256 FLOORBEAM LEAR 25 25B 5170511 CE FUSELAGE CRACKED E O OTHER O OTHER DE DESCENT 1 SW 09 911A 12300 163 RIGHT DIVAN FLOOR ATTACH ANGLE P/N 2411395-26-526 CRACKED IN RADIOUS OF BEND 14 INCHES LONG. DISCOVERED WHILE PERFORMING CABIN PRESURE LEAK TEST. 2 L 7 2 4J A10CE 2005041400108 20050414 00108 NM 2005 4 14 2005FA0000487 1 20050120 G 3010 5E2546 ANTI-ICE SYSTEM DORNER DO32 DO328100 2996000 NM MALFUNCTIONED D O OTHER O OTHER NR NOT REPORTED 1 SW 99 503CG 3086 DURING REPLACEMENT OF THE 17VE, ELEVATOR HORN DEICE INDICATION PROBLEM DISCOVERED THAT TEMP SENSOR FOR HORN ASSY HAD FAI LED IN HIGH OHM AREA 288-300 OHM RANGE. PROBLEM WOULD NOT ALLOW FAIL LIGHT ON ASSOCIATED SWITCH ON 17VE PANEL TO ILLUMIN ATE DURING TEST DESCRIBED IN 31-12-13-550-801-A01 ICE, FUEL, & HYD. PANEL 17VE - RETURN TO SERVICE. WITH A FAILURE OF T HIS TYPE THERE IS NO WAY FOR CREW TO EVER NOTICE A FAILURE OF ELEVATOR HORN HEAT OR GET FAIL ANNUNCIATION IN SWITCH LIG HT. 2 H 7 2 4T RT A45NM 2005050500082 20050505 00082 EU 2005 5 5 2005FA0000490 1 20050302 G 6320 350A32314306 GEAR SET SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE MAIN ROTOR CORRODED B FF6R K NONE O OTHER IN INSP/MAINT 1 SW 07 972BH 2804 GEAR SET HAS EXCESSIVE FROSTING AND PITTING. REQUESTING WARRANTY CONSIDERATION. (K) 1 G 7 1 3U 3 U H9EU E19EU 2005050500089 20050505 00089 EU 2005 5 5 2005FA0000491 1 20050406 G 7810 4201AN11600 CLAMP BRAERO DH125 HS125700A 4230170 EU GARRTT TFE731 TFE7313R1H 29001 WP TAILPIPE CRACKED B JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 281BT NA0281 P84262 FLUORESSCENT PENETRANT INSP OF THE TAIL PIPE CLAMP REVEALED ONE NUT TO BE CRACKED. (K) 2 L 7 2 4F 4 F A3EU E6WE 2005050500090 20050505 00090 EA 2005 5 5 2005FA0000492 1 20050321 G 3244 256K433 TIRE CNDAIR CL600 CL6002B16 1900305 EA GE CF34 CF34* NE LT MLG BULGED B JGVR K NONE O OTHER IN INSP/MAINT 1 CE 09 915BD 89 5091 UPON INSPECTION, TECH FOUND BULGE IN SIDEWALL OF LT MLG OB TIRE; SERIAL NR 22000882, 89 TOTAL LANDINGS. (CE09200503308) (K) 2 L 7 2 4F 4 F RT A21EA E15NE 2005050500091 20050505 00091 WP 2005 5 5 2005FA0000493 1 20050329 G 1430 2057D17 SCREW BOEING B17 B17G 1380204 WP WRIGHT R1820 R182097 67020 EA COVER FRACTURED G K NONE O OTHER IN INSP/MAINT 1 GL 13 9563Z 83563 99572 (7) OF THE (10) FRONT COVER RETAINING SCREWS WERE FRACTURED, ALL AT THE SAME LOCATION- (3) THREADS FROM SHANK. ALL (7) HAD WORKED THEIR WAY OUT, (3) HAD STARTED TO CONTACT THE PROPELLER HUB. NR 4 ENGINE AWAITING TEARDOWN REPORT OF NOSE SE CTION. (GL13200506288) (K) 2 L 7 4 4R 4 R L13 5E10 2005050500092 20050505 00092 SO 2005 5 5 2005FA0000494 2 20050206 G 8520 CRANKSHAFT CESSNA 140 140 2071602 CE CONT C85 C8512 17008 SO ENGINE BROKEN D O OTHER E VIBRATION/BUFFET CR CRUISE 1 SO 11 140SG 11573 21757612 THE ENGINE WAS UNDER POWER WHEN THE CRANKSHAFT BROKE. THE ENGINE RAN UNTIL AIRCRAFT WAS ON GROUND. THERE WAS AN EXTREM E VIBRATION. (K) 1 H 7 1 3O 3 O NC A768 E233 2005050500093 20050505 00093 CE 2005 5 5 2005FA0000495 1 20050414 G 7830 SWITCH CESSNA 750 750 2076810 CE ALLSN AE3007 AE3007C GL THRUST REVERSER INTERMITTENT B O OTHER O OTHER LD LANDING 1 GL 03 400JD 115 7500235 LT THRUST REVERSER (TR) PERFORMED UNCOMMANDED STOW DURING THRUST REVERSER USE AFTER LANDING. AFTER ACCESSING THE THROTT LE QUADRANT, IT WAS NOTICED THAT THE WIRES CONNECTED TO THE LT DEPLOY SWITCH WERE STRETCHED VERY TIGHT WHEN THE T/R (PIG GYBACK) LEVERS WERE IN THE DEPLOY POSITION. AFTER RUNNING DIAGNOSTICS USING SOFTWARE PROVIDED BY MFG, IT WAS DETERMINED THAT THE DEPLOY SWITCH WAS FAULTY. DURING THE PROCESS OF ACCESSING THE WIRES TO REPLACE SWITCH, WIRE WAS FOUND TO BE B ROKEN WHERE IT WAS SPLICED. THE SHRINK WRAP THAT WAS AROUND THE WIRE BUNDLE CONTRIBUTED TO THE INTERMITTENT NATURE OF T HE DEFECT. SPLICE WAS REPAIRED AND AN OPERATIONAL CHECK OF THE T/R SYSTEM CONFIRMED THAT THE SYSTEM HAD BEEN FIXED. (K) 2 L 7 2 4J 4 F RT T00007WI TE6CH 2005050500094 20050505 00094 CE 2005 5 5 2005FA0000496 1 20050325 G 2810 052600058 FUEL TANK CESSNA 172 172P 2072436 CE LYC O360 O360A4M 41514 EA RIGHT MISMANUFACTURED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 11 9443L 17276558 DURING INSTALLATION OF NEW TANK, IT WAS DISCOVERED THAT THE BUNGS FOR INSTALLING THE FUEL STRAINER ASSEMBLIES HAVE BEEN BRAZED TO THE TANK INVERSELY. THE BUNG THAT SHOULD HAVE BEEN BRAZED AT THE AFT LOCATION WAS BRAZED IN THE FORWARD MOUNT WAS BRAZED IN THE AFT MOUNT. (K) 1 H 7 1 3O 3 O NT 3A12 E286 2005050500095 20050505 00095 2005 5 5 2005FA0000497 4 20050223 G 6122 D20880 FLYWEIGHT CESSNA 182 182 2072702 CE LYC O540 IO540V4A5 41532 EA GOVERNOR CRACKED B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 195RB 990056 26005C FLYWEIGHT BASE CRACKED ALSO ASSOCIATED PART C20886 SPRING HEAD AND B20882-1. SPRING DRIVE ALSO CRACKED. (K) (22124) 1 H 7 1 3O 3 O NT 3A13 1E4 2005050500096 20050505 00096 NE 2005 5 5 2005FA0000498 3 20050223 G 6110 D4951 FORK BEECH 1900 1900D 1154162 CE PWA PT6 PT6* 52043 EA HARTZL HCE4A HCE4A3A NE PROPELLER CRACKED B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 HJ1597 NDT SHOWS CRACKED IN (2) PLACES ON FORK. (K) (12235) 2 L 7 2 4T 3 T RT A24CE E2NE 5 C P10NE 2005050500097 20050505 00097 2005 5 5 2005FA0000499 4 20050325 G 2562 AK450 ELT AMTR AEROST AEROSTARBIRD 0560582 GL CABIN INOPERATIVE B BD6R K NONE O OTHER IN INSP/MAINT 1 NE 05 32CR 101 0212401 DURING ANNUAL INSPECTION, THE TECH FOUND, DURING THE FUNCTIONAL TEST THAT THE UNIT INDICATED FUNCTION, THE UNIT TRANSMIT TED ON FREQUENCY, BUT DID NOT EMIT THE SWEEP TONE. (K) 1 M 7 1 EXPA1M71 2005050500099 20050505 00099 2005 5 5 2005FA0000500 4 20050327 G 2200 NALGENE280 TUBE BEECH 35 G35 1151516 CE CONT E225 E225* 17015 SO AUTOPILOT DISINTEGRATED D K NONE O OTHER IN INSP/MAINT 1 SO 15 4606D 640 D4771 THIS AUTOPILOT WAS INSTALLED 1/23/95. IT HAS A TUBE THAT IS TEE`D INTO THE STATIC SYSTEM AND RUNS TO THE ALTITUDE HOLD PRESSURE TRANSDUCER. THIS PLASTIC TUBE LOST IS MECHANICAL PROPERTIES AND FELL APART. THIS OPEND UP THE STATIC SYSTEM T O CABIN PRESSURE. RECOMMENDATION-DO NOT USE THIS PLASTIC TUBING ON ANY AIRCRAFT. (K) 1 L 7 1 3O 3 O A777 E267 2005050500101 20050505 00101 NE 2005 5 5 2005FA0000501 3 20050127 G 6111 6607132886 BLADE ROTOL ROTOL R389 R389* NE OUTER SLEEVE CRACKED B MS1R K NONE O OTHER IN INSP/MAINT 1 EA 11 31226 5576 DR6955988 DR6955988 PROPELLER RECEIVED FOR REPAIR OF BURNED OUT DE-ICER. PROP REQUIRED COMPLIANCE OF AD. PROP FAILED AD. PROP WAS DISASSE MBLED AND A CRACK WAS FOUND IN ROOT END OUTER SLEEVE OF NR 4 BLADE, SN 258. BLADE IS REJECTED FROM FURTHER SERVICE. (K ) 6 C P30NE 2005051000042 20050510 00042 CE 2005 5 10 2005FA0000502 1 20050413 G 5210 NAS110321D BOLT BEECH 200 200BEECH 1152920 CE PWA PT6 PT6* 52043 EA CABIN DOOR SHEARED B NBFR K NONE O OTHER IN INSP/MAINT 1 EA 27 48A BC12 DURING ROUTINE MAINTENANCE TO REPLACE CABIN DOOR HARDWARE, FOUND BOLT SHEARED INSIDE BRACKET. THERE HAVE BEEN MULTIPLE SDR`S OF CABIN DOORS OPENING IN FLIGHT DUE TO FAILURE OF SIMILAR HARDWARE. RECOMMEND REPLACEMENT OF DOOR LATCH MECHANIS M PINS AND BOLTS AT 5,000 CYCLES RATHER THAN MFG RECOMMENDED 10,000 CYCLES. (K) 1 L 7 2 4T 3 T A24CE E2NE 2005051000044 20050510 00044 SW 2005 5 10 2005FA0000503 1 20050404 G 2720 2742030021R BELLCRANK SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33111U 01514 WP RUDDER CORRODED B EATR K NONE O OTHER IN INSP/MAINT 1 GL 09 327BA 25422 TC249 DURING A DETAILED EMPENNAGE INSPECTION THE RUDDER BELLCRANK WAS REMOVED FOR OTHER MAINTENANCE AND CORROSION WAS FOUND IN THE MATING AREA WERE THE GUSTLOCK WELDMENT ATTACHED. THE PART BEING MAGNESIUM HAD PITTING OF OVER .060 WITH THE NORMAL OVERALL THICKNESS BEING .1875 OR .187. THE PART WAS REMOVED AND REPLACED WITH A NEW ALUMINUM PART. SB ADDRESSES WATER BUILD UP CORROSION PROBLEMS IN THIS AREA NONE WERE DONE ON THIS AIRCRAFT. NOT SURE IF ANY WOULD CURE THE DISSIMILAR ME TAL BETWEEN THE CHROMOLY GUST LOCK AND THE MAGNESIUM BELLCRANK. (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005051000045 20050510 00045 EU 2005 5 10 2005FA0000504 1 20050402 G 6720 CASE DUNLOP SNIAS 350 AS350B2 8680813 EU SERVO CRACKED B UVIR K NONE O OTHER IN INSP/MAINT 1 NM 07 FE204 EDDY CURRENT INSPECTION IAW MFG COMPONENT MM, IDENTIFIED A CRACK FROM A PLUG HOLE. 1 G 7 1 3U H9EU 2005051000058 20050510 00058 WP 2005 5 10 2005FA0000505 2 20050322 G 7261 30607205 OIL TANK AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE7312B WP NR 3 ENGINE CRACKED C K NONE K FLUID LOSS IN INSP/MAINT 1 NM 01 38WP 292 P115203 DURING POST FLT INSP MAINT NOTICED EXCESSIVE OIL COVERING NR 3 ENGINE AND NACELLE. WITH ENGINE COWL OPENED, OIL WAS PRI MARILY COLLECTED AROUND OIL TANK AREA. ENGINE AND COWL CLEANED AND PREPPED FOR ENGINE RUNS. DURING ENGINE RUN OIL WAS OBSERVED COMING FROM A SMALL .5 INCH CRACK IN THE OIL TANK WALL. CRACK WAS LOCATED APPROXIMATELY 2.25 INCHES BELOW TOP OF TANK AND 3.5 INCHES ABOVE AND LT OF THE OIL FILLER CAP. CRACK APPEARS TO ORIGINATE FROM AN INTERNAL WELD OR WELDED B AFFLE INTERNAL TO TANK ASSY. NEW OIL TANK ORDERED FOR REPLACEMENT AND RECEIVED. SAME PN BUT A DIFFERENT DASH NR. A DI RECT REPLACEMENT OIL TANK IAW MFG. TANK RECEIVED HAD DENT SAME AREA AS CRACKED TANK BEING REPLACED. (K) 2 L 7 3 4F 4 F A46EU E6WE 2005051000059 20050510 00059 CE 2005 5 10 2005FA0000506 1 20050328 G 3250 35820045 ROD END BEECH 33 G33 1151435 CE NLG STEERING SEPARATED D K NONE O OTHER IN INSP/MAINT 1 NM 07 217CH 7457 CD1262 STEERING ROD END, HAS SLID INTO PUSHROD TUBE, AND ATTACHED VIA 2 (.1562) SOLID RIVETS. RIVETS WERE NOT PROPERLY DRIVEN DUE TO COMPRESSING INSIDE HOLLOW PORTION OF TUBE INSTEAD OF AT SHOP HEAD, ALLOWING ROD END TO COME LOOSE. SEPARATION WO ULD CAUSE LOSS OF NOSE STEERING CONTROL. RECOMMEND REPLACEMENT OF SOLID RIVETS WITH CHERRYMAX RIVETS IN ORIGINAL HOLES . (NM07200504925) (K) 1 L 7 1 3O 3A15 2005051000060 20050510 00060 2005 5 10 2005FA0000507 4 20050324 G 3414 70257N01D02 ALTIMETER LEAR 35 35A 5170602 CE GARRTT TFE731 TFE7312B WP COPILOT INOPERATIVE D A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 GL 07 94AA 295 THE COPILOTS ALTIMETER FLAGGED JUST AFTER TAKEOFF, AIRCRAFT RETURNED TO THE FIELD. AFTER CYCLING THE BATTERIES THE ALT IMETER BEGAN WORKING AGAIN. THE COPILOTS ALTIMETER WAS REPLACED AND TESTED WITH NO FURTHER DEFECTS NOTED. THERE HAVE B EEN NO PRIOR PROBLEMS REPORTED ON THIS ALTIMETERY SYSTEM. (K) 2 L 7 2 4F 4 F A10CE E6WE 2005051000061 20050510 00061 2005 5 10 2005FA0000508 4 20050324 G 3414 702490031304 ADC LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP COCKPIT INOPERATIVE D K NONE O OTHER IN INSP/MAINT 1 GL 07 39DK 480 THE PILOTS ALTIMETER FLAGGED DURING PREFLIGHT. THERE ARE NO PRIOR REPORTS OF PROBLEMS ON THE ALTIMETRY SYSTEM. THE ADC WAS REPLACED AND TESTED WITH NO FURTHER DEFECTS NOTED. (K) 2 L 7 2 4F 4 F A10CE E6WE 2005051000064 20050510 00064 2005 5 10 2005FA0000509 4 20050406 G 3416 TRANSPONDER LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP NR 2 MALFUNCTIONED D O OTHER N FALSE WARNING CR CRUISE 1 GL 07 72JF 088 WHILE ENROUTE, IN CRUISE AT FL 370, THE MODE C ON THE NR 2 TRANSPONDER REPORTED A 500 FOOT ERROR. THE CREW SWITCHED TO THE NR 1 TRANSPONDER AND IT REPORTED AN ERROR ALSO. BOTH PRIMARY ALTIMETERS CROSS CHECKED, OK. BOTH PRIMARY ALTIMETRY SYSTEMS AND THE STANDBY ALTIMETER WERE TESTED AND NO DEFECTS WERE NOTED. CONNECTIONS WERE CLEANED AND INSPECTED AT THE ADC. COPILOTS ALTIMETER AND BOTH TRANSPONDERS. THE SYSTEMS WERE RAN TO ALTITUDE AGAIN, STILL WITH NO DEFECTS NOTED. T HE AIRCRAFT IS RVSM COMPLIANT. (K) 2 L 7 2 4F 4 F A10CE E6WE 2005051000086 20050510 00086 CE 2005 5 10 2005FA0000510 1 20050304 G 3230 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO MLG INTERMITTENT B VJ3R A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 WP 07 5582X 107 CE1353 PILOT SELECTED GEAR UP AND NOTHING HAPPENED. AIRCRAFT RETURNED TO BASE. UPON FURTHER TROUBLESHOOTING, FOUND RELAY WAS INTERMITTENT, PROBABLE CAUSE AT THIS TIME UNKNOWN. INSTALLED NEW AND IMPROVED RELAY IAW DATE CODE. FURTHER IMPROVEMENT ON RELAY ARE NEEDED. DATE CODE 0445. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005051000087 20050510 00087 CE 2005 5 10 2005FA0000511 1 20050330 G 3230 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO MLG INTERMITTENT B VJ3R O OTHER J WARNING INDICATION CR CRUISE 1 WP 07 1563A 199 CE1320 830057R WHILE IN FLIGHT, PILOT SWITCHED LANDING GEAR HANDLE TO THE DOWN POSITION AND NO RESPONSE APPROX 2 MIN LATER GEAR CAME DO WN. MAINTENANCE TECH TROUBLESHOT GEAR SYSTEM AND FOUND THAT THE DYNAMIC RELAY WAS INTERMITTENT. NO RECOMMENDATION AT T HIS TIME. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005051000107 20050510 00107 SO 2005 5 10 2005FA0000512 1 20050414 G 5712 00241T004 RIB AYRES S2T STRT34 0970106 SO PWA PT6 PT6* 52043 EA RT WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 11 6124Y 6922 T34198 WING MID-CORD RIB JUST FORWARD OF THE OB AILERON HINGE, FOUND CRACKED WHERE IT IS RIVETED TO THE REAR SPAR. BOTH LT AND RT SIDES SAME. THIS IS NOT EASY TO SEE DUE TO THE POSITION OF THE EXISTING INSPECTION HOLES BUT CAN BE SEEN IF YOU ARE LOOKING FOR IT. SB ADDRESSES PROBLEMS WITH AILERON HINGE BRACKETS AND REAR SPAR CRACKING IN THIS SAME LOCATION AND DUE TO THE SAME STRESS. PROBABLE CAUSE IS REAR SPAR TWISTING DUE TO AILERON LOADS. A VERTICAL STIFFENER AT THIS LOCATION WOULD REDUCE THIS LOAD TO THE SPAR AND RIB. (K) 1 L 7 1 3T 3 T A3SW E2NE 2005051000109 20050510 00109 2005 5 10 2005FA0000514 4 20050324 G 6113 05522311 SPINNER CESSNA 172 172S 2072439 CE MCAULY IC235 IC235LFA7570 EA PROPELLER CRACKED B WIWR K NONE O OTHER IN INSP/MAINT 1 WP 07 154ME 96 172S8534 DURING 100 HR INSPECTION THE FORWARD SPINNER BULKHEAD WAS FOUND TO BE CRACKED AROUND 5 OF THE 6 BOLT HOLES. CAUSE OF TH E PROBLEM IS THAT WHEN THE PROP MOUNTING BOLTS ARE TORQUED TO THE LIMITS GIVEN IN THE SRM THAT THE FORWARD BULKHEAD GET PULLED DOWN SLIGHTLY INTO THE CHAMFER OF THE PROP BOLT HOLES AND THIS IN TURN STRESSES THE PART LEADING TO CRACKING. TO SOLVE THIS PROBLEM, I THINK THAT THE TORQUE OF THE MOUNTING BOLTS AND THE DESIGN OF THE BULKHEAD NEED TO BE EVALUATED A ND CHANGES MADE. (K) 1 H 7 1 3O NT 3A12 5 N P12EA 2005051000110 20050510 00110 CE 2005 5 10 2005FA0000515 1 20050315 G 8120 S25351 CHECK VALVE CESSNA 182 TR182 2072735 CE LYC O540 O540L3C5 41532 EA TURBOCHARGER INOPERATIVE B WIWR K NONE O OTHER IN INSP/MAINT 1 WP 07 1898X R18201898 L19988740A OIL LEAKING OUT OF TURBO CHARGER AFTER ENGINE SHUTDOWN, ENGINE HAD NOT BEEN RUN SINCE CHECK VALVE HAD BEEN INSTALLED. R EMOVED OIL PRESSURE CHECK VALVE FOR INSPECTION, AND NOTED LOOSE NUT, TOTALLY SEPARATED INSIDE THE CHECK VALVE. THIS OBV IOUSLY WAS THAT WAY WHEN IT WAS INSTALLED AS A NEW PART. (K) 1 H 7 1 3O 3 O 3A13 E295 2005051000112 20050510 00112 2005 5 10 2005FA0000516 4 20050406 G 6113 055032112 BULKHEAD CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MCAULY 1A170 1A170E GL PROP SPINNER BROKEN B WIWR K NONE O OTHER IN INSP/MAINT 1 WP 07 972WW 636 172S9072 VF23031 PROP SPINNER AFT BULKHEAD BROKE AT ONE CORNER WITH NUTPLATE, FREEING ONE AFT EDGE OF THE SPINNER WHICH BENT OUTWARD UNDE R CENTRIFUGAL FORCE. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2005051000114 20050510 00114 CE 2005 5 10 2005FA0000517 1 20050329 G 5540 5730261 HINGE CESSNA 421 421B 2076014 CE CONT O520 GTSIO520C 17032 SO RUDDER MISINSTALLED B OACR K NONE O OTHER IN INSP/MAINT 1 NE 05 487DH 421B0362 AIRCRAFT WAS HERE FOR COMPLETE EXTERIOR REPAINT. AFTER REMOVING RUDDER, COMPLIED WITH MFG MEB004. IT IS JUST A VISUAL INSPECTION, BUT IT DOES REQUIRE REMOVING THE RUDDER. FOUND THAT RUDDER HINGE ASSY WAS INSTALLED UPSIDE DOWN. FOUND THA T ABOUT 75 PERCENT OF THE LOWER RUDDER HINGE ASSY ARE INSTALLED UPSIDE DOWN, AND MANY WITH THE BEARING FALLING OUT AND W EARING ON THE RUDDER HINGE BRACKETS. (K) 1 L 7 2 3O 3 O A7CE E7CE 2005051000130 20050510 00130 CE 2005 5 10 2005FA0000518 1 20050408 G 2822 A8160D PUMP CESSNA 182 182T 2072703 CE FUEL BOOST FAILED B NE2R K NONE O OTHER IN INSP/MAINT 1 CE 07 166 81337 RECEIVED BOOST PUMP FOR WARRANTY CREDIT WITH A CUSTOMER COMPLAINT OF (FUEL BOOST PUMP POPS CIRCUIT BREAKER). PRELIMINAR Y INSPECTION OF THE PUMP REVEALED FOREIGN MATERIAL IN THE INLET PORT. FURTHER INSPECTION REVEALED THE FOREIGN MATERIAL TRIED TO PASS THROUGH THE PUMP AND HAD LOCKED THE ROTOR IN THE INSERT. THIS WOULD CAUSE THE PUMP TO DRAW HIGH AMPS. TH IS IS THE SECOND TIME THIS PROBLEM HAS BEEN SEEN IN THE LAST 4 MONTHS. (K) 1 H 7 1 3O NT 3A13 2005051000131 20050510 00131 EA 2005 5 10 2005FA0000519 2 20050405 G 8520 SL15357 PISTON LYC O320 O320H2AD 41508 EA ENGINE BROKEN D K NONE O OTHER IN INSP/MAINT 1 WP 07 1832 DURING A 100 HR INSPECTION, FOUND A SMALL PIECE OF METAL IN THE SUCTION SCREEN. NO METAL WAS FOUND IN THE FILTER, INSPE CTED PIECE AND DETERMINED TO BE FROM A PISTON, REMOVED OIL SUMP AND FOUND SEVERAL MORE PIECES, LOOKED INTO CASE. FOUND THE SKIRT OF NR 3 PISTON TO BE MISSING PIECES. REMOVED NR 3 CYLINDER AND FOUND NO DAMAGE TO THE CYLINDER, REMOVED REMAI NING CYLINDERS AND FOUND NO DAMAGE. CYLINDER REMOVED 661.9 HRS AGO FOR AN ENGINE TEARDOWN AND REINSTALLED, TTSN: 3836.8 , TTSO1832.6. PART HAD A CRACK THAT EXTENDED .5 INCH BEYOND THE BROKEN SECTION HEADED TOWARD THE OIL SCRAPER DRAIN HOLE . (K) 3 O E274 2005042700262 20050427 00262 CE 2005 4 27 2005FA0000520 1 20050330 G 7810 NE102668 CLAMP CESSNA 650 650 2076802 CE GARRTT TFE731 TFE731* 01518 WP TAILPIPE BROKEN G O OTHER M J OVER TEMP WARNING INDICATION CR CRUISE 1 WP 23 XBGRN 9507 6500069 IN FLIGHT, TAILPIPE CLAMP FAILED ALLOWING HOT GASSES TO ENTER NACELLE REGION. PAINT ON HOT AIR SHIELD/DUCTING WAS BLIST ERED. N-1 TACHOMETER BEGAN TO WORK INTERMITTENTLY, ITT IND WENT OUT, FIRE LIGHT CAME ON, HIGH-PRESSURE BLEED AIR DUCT O VERHEAT WARNING CAME ON. LANDING, ENG WAS EXAMINED, NO IND OF DAMAGE TO INTERIOR OF NACELLE. SS SHIELDS, WHICH FORM CO OL AIR DUCT AROUND REAR OF ENGINE, FOUND TO HAVE BLISTERED AND BURNED AWAY PAINT. SHROUDS WERE CLOSELY EXAMINED, FOUND TO BE INTACT WITHOUT DEFORMATION OR RUPTURES. CLAMP WAS REPLACED, TEST RUNS SHOWED ALL INDICATIONS RETURNED TO NORMAL O PERATION, INDICATIONS DURING TEST RUNS THAT INCLUDED HIGH POWER. NO MFG REQUIREMENT TO REPLACE THIS PRIOR TO FAILURE. 2 L 7 2 4F 4 F A9NM E6WE 2005042500180 20050425 00180 EA 2005 4 25 2005FA0000521 2 20050303 G 8550 ES48110 OIL FILTER LYC O540 IO540C4B5 41532 EA ENGINE SEPARATED D O OTHER O OTHER NR NOT REPORTED 1 GL 25 6394 75 RL1979548A BOTH ENGINE OIL FILTERS WERE OPENED AFTER AN OIL CHANGE. BOTH FILTERS HAD THE PAPER FILTER MATERIAL PULLED AWAY FROM TH E METAL CRIMP HOLDING THE ENDS TOGETHER. 3 O 1E4 2005050300219 20050503 00219 GL 2005 5 3 2005FA0000523 1 20050405 G 5210 SKIN CIRRUS SR SR22 2130001 GL LT DOOR DEBONDED B K NONE O OTHER IN INSP/MAINT 1 EA 07 8163Q 0785 LT DOOR HANDLE IS MOUNTED IN A TURNED ALUMINUM RECESS THAT IS SUPPOSED TO BE BONDED TO THE DOOR. THIS RECESS HAS COME LO OSE FROM THE DOOR AND IS FREE TO ROTATE. WHEN IT ROTATES, IT JAMS THE HANDLE AND MAKES THE DOOR EXTREMELY DIFFICULT TO OPEN. THE PART HAS TO BE CUT FROM THE DOOR AND REBONDED TO SECURE IT. 1 L 7 1 3O NT A00009CH 2005050300223 20050503 00223 2005 5 3 2005FA0000524 4 20050406 G 3417 962830A1S8 ADC DHAV DHC2 DHC2* 2800108 EA COCKPIT MALFUNCTIONED B K NONE O OTHER IN INSP/MAINT 1 AL 05 47AK 148 726 THE ADC INSTALLED AS PART OF THE EFIS SYSTEM IAW STC NR SA02207AK WOULD NOT MAINTAIN A CONSTANT ACCURATE ALTITUDE READIN GS. EACH TIME THE READING WAS RESET, THE ALTITUDE READING WOULD DEVIATE UP TO 2000 FT. 1 H 7 1 3R A806 2005050300224 20050503 00224 2005 5 3 2005FA0000525 4 20050406 G 3417 962830A1S8 ADC DHAV DHC2 DHC2* 2800108 EA COCKPIT INOPERATIVE D K NONE O OTHER IN INSP/MAINT 1 AL 05 60077 983 1419 AIR DATA COMPUTER (ADC) INSTALLED AS PART OF THE STC NR SA02207AK REPORTING VARING ALTITUDE ERROR UP TO 500 FT. 1 H 7 1 3R A806 2005050500055 20050505 00055 SO 2005 5 5 2005FA0000526 1 20050208 G 8011 MHB6016 RING GEAR PIPER PA28 PA28161 7102803 SO LYC O320 O320* 41508 EA STARTER FAILED D O OTHER L NO TEST TX TAXI/GRND HDL 1 EA 15 149LH 221 221 2842192 NEW STARTER FAILED AFTER 221.2 HOURS IN SERVICE. FAILED IN THE ENGAGED POSITION, DAMAGING STARTER RING GEAR AND REQUIRIN G REPLACEMENT. 1 L 7 1 3O 3 O 2A13 E274 2005050500056 20050505 00056 SO 2005 5 5 2005FA0000527 1 20050208 G 8011 MHB6016 RING GEAR PIPER PA28 PA28161 7102803 SO LYC O320 O320* 41508 EA STARTER FAILED D O OTHER L NO TEST TX TAXI/GRND HDL 1 EA 15 149LH 221 221 2842192 NEW STARTER FAILED AFTER 221.2 HOURS IN SERVICE. FAILED IN THE ENGAGED POSITION, DAMAGING STARTER RING GEAR AND REQUIRIN G REPLACEMENT. 1 L 7 1 3O 3 O 2A13 E274 2005042700132 20050427 00132 2005 4 27 2005FA0000528 4 20050325 G 3420 2300626020 MOTOR COLLINS ADI85A INDICATOR INTERMITTENT B K NONE O OTHER IN INSP/MAINT 1 CE 09 772 MOTORS HAVE HIGH RESISTANCE BETWEEN THE BRUSHES AND ARMATURE OF THE MOTOR. THIS CAUSES THE MOTOR TO STICK INTERMITTENTLY , CAUSING A FALSE ATTITUDE DISPLAY IN THE COCKPIT. THIS PROBLEM BEGAN WITH MOTORS DATE CODED 04/04. THIS MOTOR WAS VERY NOISY IN OPERATION ALSO. BEARINGS SOUND ROUGH WHILE MOTOR IS OPERATING. 2005050300222 20050503 00222 2005 5 3 2005FA0000529 4 20050406 G 3425 AHRS500GA222 AHRS PIPER PA32 PA32300 7103212 SO COCKPIT FAILED B K NONE O OTHER IN INSP/MAINT 1 AL 05 6117J 327640095 UPON GROUND CALIBRATIONS, SOFTWARE SAID CALIBRATION COMPLETE. DURING FLIGHT CHECK AHRS WANDERED OFF HEADING COURSE UP TO 30 DEGREES AFTER TAKE OFF OF RUNWAY AND DURING LEVEL FLIGHT. 1 L 7 1 3O A3SO 2005050500049 20050505 00049 SO 2005 5 5 2005FA0000530 1 20050128 G 8011 MZ6222 STARTER PIPER PA28 PA28R201 7102816 SO ENGINE FAILED D O OTHER L NO TEST TX TAXI/GRND HDL 1 EA 15 147LH 197 197 2844103 NEW STARTER FAILED AFTER 197.5 HOURS. BENDIX FAILED TO ENGAGE. 1 L 7 1 3O 2A13 2005050500050 20050505 00050 SO 2005 5 5 2005FA0000531 1 20050128 G 8011 MZ6222 STARTER PIPER PA28 PA28R201 7102816 SO ENGINE FAILED D O OTHER L NO TEST TX TAXI/GRND HDL 1 EA 15 147LH 197 197 2844103 NEW STARTER FAILED AFTER 197.5 HOURS. BENDIX FAILED TO ENGAGE. 1 L 7 1 3O 2A13 2005042700276 20050427 00276 SO 2005 4 27 2005FA0000532 1 20050331 G 5712 78475007 RIB PIPER PA44 PA44180 7104402 SO WING CRACKED B O OTHER O OTHER NR NOT REPORTED 1 SO 15 921ER 5631 4496008 SINCE OUR FLEET WERE ALL FOUND TO HAVE CRACKED RIBS IN THE SAME LOCATION (FOUND DURING ROUTINE INSPECTION / SDRS WERE SE NT IN). THE CRACKS ARE FOUND IN THE RIB, ADJACENT TO THE LANDING GEAR TRUSS BRACKET (WHICH MUST BE REMOVED TO PROPERLY SEE THE CRACK). IN THIS PARTICULAR AIRCRAFT THE RIB, P/N 78475-007, LOCATED AT AFT STATION 49.25 ON THE RT SIDE, WAS CR ACKED. THE RIB, P/N 78475-006, LOCATED AT AFT STATION 49.25 ON THE LT SIDE WAS ALSO CRACKED. 1 L 7 2 3O A19S0 2005042700036 20050427 00036 2005 4 27 2005FA0000533 4 20050316 G 3416 AK350 ENCODER ALTIMETER LEAKING B O OTHER O OTHER NR NOT REPORTED 1 NM 09 STATIC AIR INPUT LEAKS 200 FEET PER MINUTE AT 1000 FEET AGL. 2005042700072 20050427 00072 CE 2005 4 27 2005FA0000535 1 20050321 G 3000 BOOT CESSNA 500 560CESSNA 2076750 CE DEICE SYS MALFUNCTIONED D O OTHER O OTHER LD LANDING 1 SW 99 DEICE BOOT MALFUNCTIONED. 2 L 7 2 4F RT A22CE 2005050300201 20050503 00201 SO 2005 5 3 2005FA0000537 1 20050328 G 3220 86280003 DRAG LINK PIPER PA44 PA44180 7104402 SO NLG DAMAGED B K NONE O OTHER IN INSP/MAINT 1 GL 21 295ND 4241 4496030 DURING SCHEDULED INSPECTION THE NLG DRAG LINK PIVOT BOLT WAS FOUND BROKEN IN HALF AND THE NUT AND COTTER PIN END MISSING . THE OTHER END HAD BEGAN MIGRATING OUT AND COLLAPSE OF THE NOSE GEAR WAS EMINENT. THE DRAG LINK WAS DAMAGED BY THE ROTA TION OF THE BOLT HEAD BEING ABLE TO ROTATE. THE ASSY WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 3O A19S0 2005050400035 20050504 00035 EA 2005 5 4 2005FA0000539 2 20050411 G 7322 30804 FLOAT MA3PA CESSNA 150 152 2071835 CE LYC O235 O235N2C 41505 EA MCAULY 1A103 1A103TCM GL CARBURETOR CHAFED D A UNSCHED LANDING O OTHER CR CRUISE 1 EA 11 25446 64 DTO200 15280666 L2367415 775596 ENGINE QUIT IN FLIGHT, PERFORMED AN EMERGENCY LANDING IN A PARKING LOT. EXITING AIRCRAFT FUEL WAS FOUND RUNNING OUT OF C OWL, SHUTOFF FUEL SELECTOR, FUEL STOPPED. MAINTENANCE FOUND FUEL LEAKING FROM CARBURETOR. SENT CARBURETOR TO OVERHAUL SH OP, FOUND PLASTIC FLOAT CHAFFING ON FUEL BOWL BECAUSE OF INSUFFICIENT CLEARANCE CAUSING THE FLOAT TO HANG UP. REASSEMBLE D CARBURETOR WITH A METAL FLOAT KIT WHICH PROVIDED SATISFACTORY CLEARANCE BETWEEN THE FLOAT AND FUEL BOWL. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2005050400083 20050504 00083 SO 2005 5 4 2005FA0000542 1 20050412 G 8011 MZ6222 STARTER PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA ENGINE FAILED D K NONE L NO TEST TX TAXI/GRND HDL 1 EA 15 146LH 143 76 2844102 L3109151A STARTER REPAIRED UNDER W/O 6900 FOR SB A-112. FAILED IN SERVICE 76.4 HOURS LATER. 1 L 7 1 3O 3 O 2A13 1E10 2005050500087 20050505 00087 SO 2005 5 5 2005FA0000543 1 20050401 G 2697 GROUND STUD GULSTM G1159 GIV 3980115 SO ZONE 310 INCORRECT C K NONE W INADEQUATE Q C IN INSP/MAINT 1 NM 09 941AM 776 1499 WHILE PERFORMING TASK NR 262070, RT FIRE BOTTLE WEIGHT CHECK DURING AIRCRAFT FIRST 2C CHECK, IT WAS DISCOVERED THAT GROU ND STUDS E4045 AND E4046 DID NOT HAVE THE WIRE TERMINAL HOLD DOWN NUTS TORQUED. THE WIRE TERMINALS WERE FREE TO MOVE UP AND DOWN ALONG THE STUDS, APPROXIMATELY .6250 INCH. NUTS WERE TORQUED AND FIRE EXTINGUISHING CIRCUITRY INTEGRITY TEST WA S PERFORMED AND FOUND TO BE SATISFACTORY. 2 L 7 2 4F RT A12EA 2005042700074 20050427 00074 EA 2005 4 27 2005FA0000544 2 20050322 G 7320 25765362 SERVO CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MCAULY 1A170 1A170E GL FUEL SYSTEM OUT OF ADJUST B A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CR CRUISE 1 SO 15 479ER 1574 172S8942 L2709951A UC029 ENG QUIT AT 3000 FT, RESTARTED AT 2100 FEET. ENG WAS RESTARTED, MIX IN IDLE CUTOFF POSITION. ENG WOULD NOT GAIN MORE T HAN 500 RPM, FUEL SMELL IN COCKPIT. ENG FAILED AGAIN WHEN AC WAS ON RUNWAY, WOULD NOT RESTART. MECH UNCOWLED, VISUALLY INSPECT POWER PLANT INSTALL. NO DEFECTS WERE NOTED UNTIL FUEL SYS WAS TESTED. FLOWING FUEL (MIXTURE, THROTTLE CLOSED) FUEL FLOW INDICATOR SHOWED 7/HR. (GAUGE ALMOST PEGGED). ALL FUEL NOZZLES WERE REMOVED FROM CYL HEADS, REATTACHED TO DE LIVERY TUBES FOR VISUAL SQUIRT TEST. ALL 4 NOZZLES FLOWED, BUT SQUIRTED APPROX 3 TIMES FARTHER THAN NORMAL (12 FEET). FUEL SERVO WAS REPLACED TO SOLVE OVERALL PROBLEM. POST GROUND RUN UPS WERE NORMAL WITH NO DEFECTS NOTED. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2005042700278 20050427 00278 SO 2005 4 27 2005FA0000547 1 20050331 G 5712 78475007 RIB PIPER PA44 PA44180 7104402 SO WINGS CRACKED B O OTHER O OTHER NR NOT REPORTED 1 SO 15 928ER 4556 4496026 SINCE OUR FLEET OF SIX PIPER ARROWS WERE ALL FOUND TO HAVE CRACKED RIBS IN THE SAME LOCATION (FOUND DURING ROUTINE INSPE CTION / SDRS WERE SENT IN) WE DETERMINED TO INSPECT OUR FLEET OF TEN SEMINOLES. THE BASIC WING STRUCTURE IS DESIGNED TH E SAME. WE FOUND SIMILAR CRACKS IN SEVEN OF THE SEMINOLES. THE CRACKS ARE FOUND IN THE RIB, ADJACENT TO THE LANDING GE AR TRUSS BRACKET(WHICH MUST BE REMOVED TO PROPERLY SEE THE CRACK). IN THIS PARTICULAR AIRCRAFT THE RIB, P/N 78475-007, LOCATED AT AFT STATION 49.25 ON THE RIGHT SIDE, WAS CRACKED. 1 L 7 2 3O A19S0 2005042700153 20050427 00153 CE 2005 4 27 2005FA0000548 1 20050330 G 8011 PM2401 HOUSING CESSNA 172 172S 2072439 CE STARTER BROKEN B K NONE O OTHER IN INSP/MAINT 1 SO 15 406ER 1684 1684 172S9156 THE FORWARD PART OF THE STARTER HOUSING WAS FOUND TO BE TOTALLY BROKEN OFF FROM THE STARTER HOUSING (THE SECTION HOUSING THE BENDIX DRIVE). 1 H 7 1 3O NT 3A12 2005042700279 20050427 00279 SO 2005 4 27 2005FA0000549 1 20050331 G 5712 78475006 RIB PIPER PA44 PA44180 7104402 SO WINGS CRACKED B O OTHER O OTHER NR NOT REPORTED 1 SO 15 925ER 5922 4496012 SINCE OUR FLEET OF SIX PIPER ARROWS WERE ALL FOUND TO HAVE CRACKED RIBS IN THE SAME LOCATION (FOUND DURING ROUTINE INSPE CTION / SDRS WERE SENT IN) WE DETERMINED TO INSPECT OUR FLEET OF TEN SEMINOLES. THE BASIC WING STRUCTURE IS DESIGNED TH E SAME. WE FOUND SIMILAR CRACKS IN SEVEN OF THE SEMINOLES. THE CRACKS ARE FOUND IN THE RIB, ADJACENT TO THE LANDING GE AR TRUSS BRACKET(WHICH MUST BE REMOVED TO PROPERLY SEE THE CRACK). IN THIS PARTICULAR AIRCRAFT THE RIB, P/N 78475-006, LOCATED AT AFT STATION 49.25 ON THE LEFT SIDE, WAS CRACKED. 1 L 7 2 3O A19S0 2005042700125 20050427 00125 CE 2005 4 27 2005FA0000550 1 20050325 G 5511 263202125 RIB CESSNA 208 208B 2073701 CE PWA PT6 PT6* 52043 EA HORIZONTAL STAB MISINSTALLED B K NONE O OTHER IN INSP/MAINT 1 GL 07 103VE 6323 208B0620 UPON INSPECTION OF HORIZONTAL STABILIZER, MECHANIC NOTED THAT ALL RIVETS SECURING FORWARD FLANGE OF RIB P/N 2632021-25 T O FORWARD SPAR WERE MISSING. HOLES WERE DRILLED THRU WITH BARE METAL SHOWING (NO PRIMER IN HOLES). ASSUMPTION IS THAT RIVETS WERE OMITTED AT FACTORY. THIS DISCREPANCY CAN ONLY BE VIEWED THRU ACCESS PANEL ON TOP, IB, RT SIDE OF HORIZONTAL STAB. 1 H 7 1 3T 3 T A37CE E2NE 2005042700126 20050427 00126 2005 4 27 2005FA0000551 4 20050325 G 6113 05503675 SPINNER CESSNA 172 172S 2072439 CE LYC O360 IO360LYC* 41514 EA MCAULY 1A170 1A170E GL PROPELLER CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 07 360SP 1852 172S8777 L2958951A UK23071 1.25 INCH CRACK EMANATING FROM PROPELLER BLADE CUTOUT RUNNING PARALLEL WITH THE FORWARD BULKHEAD. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2005042700127 20050427 00127 2005 4 27 2005FA0000552 4 20050325 G 6113 05503675 SPINNER CESSNA 172 172S 2072439 CE LYC O360 IO360LYC* 41514 EA MCAULY 1A170 1A170E GL PROPELLER CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 07 3532T 1439 172S8820 L2968451A XH23051 1 INCH CRACK EMANATING FROM PROPELLER CUTOUT PARALLEL WITH THE FWD BULKHEAD. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2005050400119 20050504 00119 SO 2005 5 4 2005FA0000553 1 20050413 G 8011 MZ4222 DRIVE ASSY PIPER PA44 PA44180 7104402 SO STARTER FRACTURED D K NONE O OTHER IN INSP/MAINT 1 WP 07 3090A 696 4496183 STARTER BENDIX DRIVE SHATTERED. 1 L 7 2 3O A19S0 2005042700042 20050427 00042 CE 2005 4 27 2005FA0000554 1 20050318 G 3210 504501024 TORQUE TUBE CESSNA 421 421B 2076014 CE MLG CRACKED C K NONE O OTHER IN INSP/MAINT 1 WP 05 41114 1546 421B0458 LANDING GEAR TORQUE TUBE IS CRACKED 1 L 7 2 3O A7CE 2005042700071 20050427 00071 SO 2005 4 27 2005FA0000555 1 20050321 G 5712 78475009 RIB PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA RT WING CRACKED B K NONE O OTHER IN INSP/MAINT 1 SO 15 492B 2859 2844051 L2408751A DURING A VISUAL INSP, A SMALL CRACK WAS FOUND IN THE RT NOSE RIB P/N-62021-005 AND -004. A MORE THOROUGH INSPECTION REVE ALED THAT AN ADDITIONAL CRACK, MUCH LARGER (ABOUT 4 INCH LONG), WAS FOUND ON THE RIB P/N-78475-009 AND -008. THESE RIBS ARE INCLUDED IN THE MOUNTING ASSEMBLY FOR THE P/N-95643-007 AND -006 AND BRACKET(MAIN GEAR TRUSS). THE OPERATOR OF THIS AIRCRAFT HAD SIMILAR CRACKS, ON BOTH LT AND RT WINGS. THE AC IS GROUNDED AND THE AFFECTED PARTS ARE BEING REPLACED. 1 L 7 1 3O 3 O 2A13 1E10 2005042700075 20050427 00075 SO 2005 4 27 2005FA0000556 1 20050322 G 5712 78475009 RIB PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA RT WING CRACKED B K NONE O OTHER IN INSP/MAINT 1 SO 15 708ER 2327 2844067 L3020251A DURING A VISUAL INSPECTION, A SMALL CRACK WAS FOUND IN THE RT NOSE RIB P/N-62021-005 AND -004. A MORE THOROUGH INSPECTI ON REVEALED THAT AN ADDITIONAL CRACK, MUCH LARGER (ABOUT 4 IN LONG), WAS FOUND ON THE RIB P/N-78475-009 AND -008. THESE RIBS ARE INCLUDED IN THE MOUNTING ASSY FOR THE P/N-95643-007 AND -006 AND BRACKET (MAIN GEAR TRUSS). THE OPERATOR OF TH IS AIRCRAFT HAD SIMILAR CRACKS, ON BOTH LT AND RT WINGS. THE FLEET IS GROUNDED AND THE AFFECTED PARTS ARE BEING REPLACED . 1 L 7 1 3O 3 O 2A13 1E10 2005042700066 20050427 00066 SO 2005 4 27 2005FA0000557 1 20050321 G 5712 78475009 RIB PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA WING CRACKED B K NONE O OTHER IN INSP/MAINT 1 SO 15 701ER 2571 2844053 L3013951A DURING VISUAL INSPECTION, A SMALL CRACK WAS FOUND IN THE RT NOSE RIB P/N-62021-005 AND -004. A MORE THOROUGH INSPECTION REVEALED THAT AN ADDITIONAL CRACK, MUCH LARGER (ABOUT 4 INCHES LONG), WAS FOUND ON THE RIB P/N-78475-009 AND -008. THESE RIBS ARE INCLUDED IN THE MOUNTING ASSY FOR THE P/N-95643-007 AND -006 AND BRACKET (MAIN GEAR TRUSS). THE OPERATOR OF T HIS AIRCRAFT HAD SIMILAR CRACKS, ON BOTH LT AND RT WINGS. AC IS GROUNDED AND THE AFFECTED PARTS ARE BEING REPLACED. 1 L 7 1 3O 3 O 2A13 1E10 2005042700137 20050427 00137 CE 2005 4 27 2005FA0000558 1 20050325 G 3233 128054115 ACTUATOR CESSNA 182 R182 2072734 CE NLG BINDING B K NONE O OTHER IN INSP/MAINT 1 CE 07 6370T 481 R18201999 PISTON NUT P/N 9880506-1, DRAGGING ON BEARING END PINS P/N 129009-2. PINS WERE PREVIOUSLY INSTALLED IAW SEB95-20 AND SK2 10-155. PIN CLEARANCE WAS CHECKED ON INSTALLATION, CLEARANCE WAS .020 AND.024. PINS ARE NOW DRAGGING ON PISTON NUT MAKIN G IT DIFFICULT TO MOVE GEAR INTO THE LOCK POSITION. 1 H 7 1 3O RT 3A13 2005051100150 20050511 00150 EA 2005 5 11 2005FA0000559 2 20050421 G 7322 105217 CARBURETOR CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA MCAULY 1C160 1C160DTM GL ENGINE FAILED G O OTHER R PARTIAL RPM/PWR LOSS LD LANDING 1 GL 23 1848 17275405 RL1929439A RK007 ENGINE RPM WOULD NOT REDUCE BELOW 1300 RPM. INSTR ATTEMPTED TO LAND AC, BUT COULD NOT REDUCE AIRSPEED DUE TO HIGH ENG R PM. THROTTLE WAS ADVANCED TO FULL PWR SETTING, BUT ENG FAILED TO ACCELERATE. AC HIT FENCE, WAS DAMAGED. POST-ACCIDENT G ROUND RUN, FOUND ENG WOULD NOT IDLE BELOW 1300 RPM OR ACCELERATE PAST 1800 RPM. COMPRESSION TEST PERFORMED, NR 3 CYL WA S FOUND TO BE 44/80 PSI, LEAKING THROUGH PISTON RINGS. ASSUMED NOZZLE WAS INGESTED INTO THE NR3 CYLINDER. WHEN CARBURETO R WAS REMOVED, IT WAS FOUND THAT ACCELERATOR PUMP DISCHARGE NOZZLE (TUBE) WAS MISSING FROM CARB AIR INLET. TUBE IS PRESS ED-FIT INTO THE INLET CASTING DURING ASSEMBLY. SECOND CARB WAS INSTALLED, ENG RAN AT PROPER IDLE AND FULL POWER RPM. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005050400073 20050504 00073 WP 2005 5 4 2005FA0000560 1 20050408 G 2432 AD430B034LB03 BATTERY DOUG DC9 DC983 3022083 WP ZONE 100 OVERTEMP D O OTHER B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 GL 03 315FV 49707 EXTREME SMOKE REQUIRING EVACUATION OF AIRCRAFT. BATTERIES SHOW EVIDENCE OF EXCESSIVE HEAT. 2 L 7 2 4F RT A6WE 2005042700277 20050427 00277 SO 2005 4 27 2005FA0000562 1 20050331 G 5712 78475006 RIB PIPER PA44 PA44180 7104402 SO WING CRACKED B O OTHER O OTHER NR NOT REPORTED 1 SO 15 923ER 5735 4496010 SINCE OUR FLEET OF SIX PIPER ARROWS WERE ALL FOUND TO HAVE CRACKED RIBS IN THE SAME LOCATION (FOUND DURING ROUTINE INSPE CTION / SDRS WERE SENT IN) WE DETERMINED TO INSPECT OUR FLEET OF TEN SEMINOLES. THE BASIC WING STRUCTURE IS DESIGNED TH E SAME. WE FOUND SIMILAR CRACKS IN SEVEN OF THE SEMINOLES. THE CRACKS ARE FOUND IN THE RIB, ADJACENT TO THE LANDING GE AR TRUSS BRACKET(WHICH MUST BE REMOVED TO PROPERLY SEE THE CRACK). IN THIS PARTICULAR AIRCRAFT THE RIB, PN 78475-006, L OCATED AT AFT STATION 49.25 ON THE RIGHT SIDE, WAS CRACKED. 1 L 7 2 3O A19S0 2005042700043 20050427 00043 CE 2005 4 27 2005FA0000563 1 20050318 G 3210 504501025 TORQUE TUBE CESSNA 414 414 2075908 CE MLG CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 05 414TM 6674 4140419 LANDING GEAR TORQUE TUBE IS CRACKED. 1 L 7 2 3O RT A7CE 2005042700121 20050427 00121 CE 2005 4 27 2005FA0000564 1 20050324 G 5755 SKIN PANEL CESSNA 210 210L 2073448 CE SPEEDBRAKE CRACKED F O OTHER O OTHER NR NOT REPORTED 1 NM 10 350 21059635 LT WING, IB AND AFT OF SPEEDBRAKE, INSTALLATION FORMED A CRACK AT THE WING T/E AND AT THE FORWARD STIFFENER ATTACHMENT P OINT. WING SKIN EXPERIENCES BUFFETING IN AND OUT OF PLANE WITH SPEEDBRAKES DEPLOYED AS A RESULT OF TURBULENCE. THE WIN G PANEL SKIN IS LARGE AND OILCANS IN AND OUT OF PLANE GENERATING SIGNIFICANT TENSILE FORCE ON THE RIVETS AT THE PERIMETE R OF THE PANEL. THE ADDED WING STIFFENER LIMITS THE OILCAN MOVEMENT AND STRESS. CRACK INITIATED AT FORWARD RIVET HOLE F OR ADDED STIFFENER. 1 H 7 1 3O 3A21 2005051600109 20050516 00109 CE 2005 5 16 2005FA0000565 1 20050326 G 3220 0442504201 FORK CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL NOSE STRUT FAILED D O OTHER O OTHER TX TAXI/GRND HDL 1 WP 23 33LJ 9830 15282023 L1776615 R774607 LOWER NOSE FORK FAILED AFTER AIRCRAFT TURNED OFF THE RUNWAY AFTER LANDING. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2005051600111 20050516 00111 CE 2005 5 16 2005FA0000566 1 20050401 G 2822 476087E PUMP CESSNA 210 210 2073402 CE CONT O470 IO470* 17026 SO NLG WW WRONG PART G O OTHER O OTHER TX TAXI/GRND HDL 1 GL 15 9408T 57208 SUSPECT PUMP IS INCORRECT BY PN 4760876 FOR INSTALLATION AC. INTERFERED WITH NOSE LANDING GEAR UPLOCK OPERATION. (K) 1 H 7 1 3O 3 O RT 3A21 E1CE 2005051600112 20050516 00112 NE 2005 5 16 2005FA0000567 2 20050411 G 7250 1847M96P02 SEAL GE BOEING 777 777* UTILUSE NM GE GE90 GE9090B NE HPT ROTOR CRACKED B QEMY K NONE O OTHER IN INSP/MAINT 1 EA 35 11868 2497 M900146 PPVRC2 900146 MDR/001/05: DURING ENG O/H, 2 CRACKS WERE NOTED ING THE HPT INTERSTAGE SEAL. CRACKS ARE ABOUT 45 DEGREES APART AND APPE AR TO ORIGINATE IN THE FWD ARM, OUTER DIAMETER. BOTH CRACKS ARE THROUGH FORWARD RETAINER AND CATENARY. 1 PASSES THROU GH BOTH SEAL TEETH AND THE OTHER HAS STARTED DOWN THE SEAL WEB. (K) 2 L 7 2 4F 4 F RT T00001SE E00049EN 2005051600113 20050516 00113 SO 2005 5 16 2005FA0000568 2 20050401 G 8530 712BCA221 CYLINDER HEAD CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO NR 6 CYLINDER SEPARATED B CTYR O OTHER E VIBRATION/BUFFET CR CRUISE 1 GL 21 901BA 414A0232 521421 THE NR 6 CYLINDER, LT ENGINE. THE AC WAS RUNNING FINE AND ALL OF THE SUDDEN A VIBRATION WAS FELT. INVESTIGATION: THE HEAD WAS FOUND SEPARATED FROM CYLINDER. THE HEAD WAS BEING HELD ON BY THE INTAKE PIPE AND EXHAUST. THE ENGINE AND THIS CYLINDER HAD 72.4 TSMOH, RAM ENGINE; TISN 71-2BCA-221 SN 22537-26. THIS IS A NEW RAM ENGINE WITH ECI NICKEL CYLINDERS. (K) 1 L 7 2 3O 3 O A7CE E8CE 2005051600116 20050516 00116 SO 2005 5 16 2005FA0000569 2 20050315 G 8520 SA634503M010 BEARING CONT O550 IO550F 17042 SO CRANKSHAFT DAMAGED B O3OR K NONE O OTHER IN INSP/MAINT 1 AL 03 284791R UPON DISASSEMBLY IT WAS NOTED THAT THIS BEARING SHELL IS BROKEN. IT IS LOCATED IN NR 2 FROM REAR SADDLE. IT APPEARS TH AT THE BEARING HAS WORKED AND IS POLISHED AS RESULT: THE CRANKSHAFT, SN C159618N HAS OVERSIZED BLADE BUSHING BOSSES. U PON DISASSEMBLY, (LOOSE BUSHINGS) NOTE: FRETTING ON PARTING SURFACE AS A RESULT OF THE BEARING WORKING, THE BEARING TANG IN THE SADDLE HAS BEEN MALFORMED. 3 O E3SO 2005051600117 20050516 00117 SO 2005 5 16 2005FA0000570 1 20050307 G 2820 3011849 LINE EMB 110 EMB110P2 3260124 SO NACELLE CRACKED B EL6R K NONE K FLUID LOSS IN INSP/MAINT 1 EA 23 24AN 110318 FOUND FUEL BYPASS TUBE ASSY CRACKED WHERE TUBE WELDED TO FLARE END OF B-NUT FITTING. TUBE APPEARS TO BE MFG WITH SMALLE R RADIUS TO FIT INSIDE FLARE, CAUSING WEAK POINT. SUGGEST CLOSER INSPECTION AT THIS AREA DURING ROUTINE INSPECTION AND PRESSURE CHECK WITH ELEC PUMPS. NOTE: LINE ASSY LOCATED FROM FUEL CONTROL WAIT FITTING TO START CONTROL VALVE. CAN BE PRESSURED W/ AC ELEC FUEL PUMPS. (K) 1 L 7 2 4T A21SO 2005051600121 20050516 00121 CE 2005 5 16 2005FA0000571 1 20050418 G 3220 STRUT CESSNA 195 195A 2073110 CE TAILWHEEL STUCK G O OTHER O OTHER LD LANDING 1 GL 23 1082D 7694 TAILWHEEL STRUT STUCK FULLY EXTENDED FOR LANDING. SYSTEM DESIGN DOES NOT PERMIT STEERING WHILE STRUT IS IN THIS CONDITI ON. (K) 1 H 7 1 3R A790 2005051600122 20050516 00122 CE 2005 5 16 2005FA0000572 1 20050331 G 3260 1003810061 DOWNLOCK SWITCH BEECH 90 C90 1152913 CE PWA PT6 PT6A60A 52043 NE NLG INTERMITTENT B AKGR O OTHER P NO WARNING INDICATION LD LANDING 1 CE 05 911CX LJ830 DURING NORMAL GEAR EXTENSION, NO NOSE GEAR DOWN LOCK LIGHT INDICATION. CYCLED GEAR SEVERAL TIMES WITH NO CHANGE. MANUA LLY EXTENDED GEAR AND OBTAINED GREEN INDICATION. MAINTENANCE FOUND SWITCH INTERMITTENT. (K) 1 L 7 2 3T 4 T 3A20 E4EA 2005051600142 20050516 00142 NE 2005 5 16 2005FA0000573 2 20050320 G 8520 304430 BOLT DOUG DC6 C118A 3021710 WP PWA R2800 R280052W 52026 NE CRANKSHAFT BROKEN B DA7R O OTHER O OTHER NR NOT REPORTED 1 NM 02 351CE 1697 44599 CRANKSHAFT CONNECTING BOLT BROKE CAUSING LOSS OF ENGINE POWER. DAMAGE TO ENGINE INCLUDED REAR MAIN BEARING AND CRANKSHA FT ASSY. PROBABLE CAUSE COULD BE OVER TORQUE AT ASSY OR METAL FATIGUE. PREVIOUS OVERHAUL AGENCY UNKNOWN AT THIS TIME. (K) 2 L 7 4 4R 4 R 6A3 5E8 2005051600137 20050516 00137 2005 5 16 2005FA0000574 4 20050329 G 2565 LIGHT AIRCRUISERS AIRBUS A319 A319112 3930323 EU CFMINT CFM565 CFM565B6 13802 NE ESCAPE SLIDE FAILED B K NONE O OTHER IN INSP/MAINT 1 EA 33 762US A9077 1358 THE ESCAPE SLIDE LIGHTS DID NOT WORK DUE TO THE CONNECTOR NOT FULLY HOME. THE ELECTRICAL LOOM AND THE CONNECTOR WERE NO T STOWED PROPERLY. (EA33200501197) (K) 2 L 7 2 4F 4 F RT A28NM E37NE 2005051600138 20050516 00138 EU 2005 5 16 2005FA0000575 1 20050404 G 2810 A319 PLACARD AIRBUS A319 A319112 3930323 EU CFMINT CFM565 CFM565B6 13802 NE WING FUEL TANKS FAILED B K NONE O OTHER IN INSP/MAINT 1 EA 33 762US 1358 DEBRIS (PLASTIC RIB AND MANHOLE DOOR IDENTIFICATION DECALS) FOUND ON THE INLET STRAINER OF THE LT AND RT WING FUEL TANK, NR 2 MAIN FUEL PUMP AFT SCREENS DURING C-CHECK. OIT ISSUED BY AIRBUS AND IS APPLICABLE TO MSN1136. (K) 2 L 7 2 4F 4 F RT A28NM E37NE 2005051700004 20050517 00004 2005 5 17 2005FA0000576 4 20050329 G 2565 26C150911 QUICK DISCONNECT AIRCRUISERS AIRBUS A319 A319112 3930323 EU CFMINT CFM565 CFM565B6 13802 NE ESCAPE SLIDE MISSING B K NONE O OTHER IN INSP/MAINT 1 EA 33 762US A9004 1358 WHILE CARRYING OUT A SAMPLE INFLATION ON THE AFT ENTRY DOOR, THE ESCAPE SLIDE FAILE TO RELEASE FROM THE PACK DUE TO THE QUICK DISCONNECT, PN 25C150911, WHICH CONNECTS THE SLIDE RELEASE CABLE TO THE RELEASE MECHANISM ON THE PACKBOARD ASSY BE ING MISSING.(K) 2 L 7 2 4F 4 F RT A28NM E37NE 2005051700005 20050517 00005 2005 5 17 2005FA0000577 4 20050329 G 2565 26C150911 QUICK DISCONNECT AIRCRUISERS AIRBUS A319 A319112 3930323 EU CFMINT CFM565 CFM565B6 13802 NE AFT RT SLIDE LOOSE B K NONE O OTHER IN INSP/MAINT 1 EA 33 762US A9992 1358 DURING A C-CHECK, THE QUICK DISCONNECT WHICH CONNECTS THE SLIDE RELEASE CABLE TO THE RELEASE MECHANISM ON THE PACKBOARD ASSY WAS FOUND LOOSE. THE ELECTRICAL LOOM WAS CONFIGURED FOR A LT DOOR. (K) 2 L 7 2 4F 4 F RT A28NM E37NE 2005051700006 20050517 00006 NE 2005 5 17 2005FA0000578 2 20050420 G 7230 31042163 SPUR GEAR JETAIR JETSTM JETSTM4101 1500501 EU GARRTT TPE331 TPE33114GR 01514 NE COMPRESSOR WORN B AV4R K NONE O OTHER IN INSP/MAINT 1 WP 07 GMAJA 41032 P75048 FORWARD COUPLING STUB SHAFT NUT WAS FOUND FINGER TIGHT CAUSING VIBRATORY FRETTA ND ACCELLERATED WEAR WITH MATERIAL LOSS ON THE SPUR GEAR AND SUBSEUQUENT LOSS OF FUEL CONTROL SPUR GEAR DRIVE. (K) 2 L 7 2 4T 4 T RT A41NM E18NE 2005042700058 20050427 00058 SO 2005 4 27 2005FA0000579 1 20050320 G 5712 78475009 RIB PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C 41514 EA RT WING CRACKED B K NONE O OTHER IN INSP/MAINT 1 SO 15 705ER 2633 2844058 L2995051A DURING A 100HR. INSPECTION, A SMALL CRACK WAS FOUND IN THE RT. NOSE RIB PN-62021-005 AND -004. A MORE THOROUGH INSPECTIO N REVEALED THAT AN ADDITIONAL CRACK, MUCH LARGER (ABOUT 4 INCES LONG), WAS FOUND ON THE RIB PN-78475-009 AND -008. THESE RIBS ARE INCLUDED IN THE MOUNTING ASSEMBLY FOR THE PN-95643-007 AND -006 AND BRACKET (MLG TRUSS). THE OPERATOR OF THIS AIRCRAFT OPERATES A FLEET OF 6 AIRCRAFT, AND ALL THE OTHER AIRCRAFT HAD SIMILAR CRACKS, ON BOTH LT AND RT WINGS. THE FLE ET IS GROUNDED AND THE AFFECTED PARTS ARE BEING REPLACED. 1 L 7 1 3O 3 O 2A13 1E10 2005042700038 20050427 00038 2005 4 27 2005FA0000580 4 20050311 G 3416 A30 ENCODER CESSNA 210 T210N 2073456 CE ALTIMETER ERRATIC B H DEACTIVATE SYST/CIRCUITS P NO WARNING INDICATION CR CRUISE 1 NM 09 5434A 21063436 ALTITUDE OUTPUT BECAME ERRATIC, VARYING SEVERAL HUNDRED FT BOTH ABOVE AND BELOW THE ACTUAL ALTITUDE OVER A PERIOD OF 30 MINUTES. PROBABLY CAUSED BY INTERMITTENT HEATER THERMOSTAT. 1 H 7 1 3O 3A21 2005042700073 20050427 00073 SO 2005 4 27 2005FA0000581 1 20050322 G 5712 78475009 RIB PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA RT WING CRACKED B K NONE O OTHER IN INSP/MAINT 1 SO 15 703ER 2743 2844057 L2983151A DURING A VISUAL INSPECTION, A SMALL CRACK WAS FOUND IN THE RT NOSE RIB. A MORE THOROUGH INSPECTION REVEALED THAT AN ADD ITIONAL CRACK, MUCH LARGER (ABOUT 4 INCHES LONG), WAS FOUND ON THE RIB. THESE RIBS ARE INCLUDED IN THE MOUNTING ASSEMBLY FOR THE BRACKET(MAIN GEAR TRUSS). THE OPERATOR OF THIS AIRCRAFT OPERATES A FLEET OF 6 OF THESE AIRCRAFT, AND ALL THE OT HER AIRCRAFT HAD SIMILAR CRACKS, ON BOTH LT AND RT WINGS. THE FLEET IS GROUNDED AND THE AFFECTED PARTS ARE BEING REPLACE D. 1 L 7 1 3O 3 O 2A13 1E10 2005050500048 20050505 00048 SO 2005 5 5 2005FA0000582 1 20050414 G 5101 89630004 CABLE PIPER PA46 PA46350P 7104602 SO UNKNOWN DAMAGED D K NONE O OTHER IN INSP/MAINT 1 SW 99 DEZPA 360 4622184 CABLE DISCONNECTED FROM CABLE PULL HANDLE. PROBABLY BAD CRIMP. SAME PROBLEM ENCOUNTERED ON OTHER AIRCRAFT OF THIS TYPE A ND PA-46-310P AS WELL. 1 L 7 1 3O RT A25SO 2005051600001 20050516 00001 CE 2005 5 16 2005FA0000583 1 20050422 G 2822 MS2465823D SWITCH BEECH 90 C90A 1152911 CE COCKPIT OVERHEATED B K NONE O OTHER IN INSP/MAINT 1 GL 11 6028Y 71 LJ1728 DISCREPANCY ORIGINALLY AN INOPERATIVE LT BOOST PUMP. DURING THE OPS CHECK OF REPLACEMENT BOOST PUMP, SWITCH WAS NOTED T O BE INTERMITTENT. AFTER GAINING ACCESS TO SWITCH TERMINALS BY REMOVING THE LT FUEL BOOST PUMP SWITCH, TERMINALS WERE FO UND IN AN OVERHEATED CONDITION, CONNECTIONS WERE LOOSE. SWITCH AND TERMINALS WERE REPLACED REMAINING SWITCHES, CB WERE I NSPECTED, OTHER CONNECTIONS WERE ALSO FOUND LOOSE RT SIDE CB PANEL WAS ALSO REMOVED, ELEC COMPONENTS WERE ALSO INSPECTED . 1 L 7 2 3T RT 3A20 2005050300218 20050503 00218 GL 2005 5 3 2005FA0000584 1 20050405 G 7710 CONNECTOR CIRRUS SR SR22 2130001 GL TACH INDICATOR DIRTY B O OTHER N FALSE WARNING CL CLIMB 1 EA 07 529HH 1228 AT HIGH POWER SETTINGS THE RPM AND TEMPERATURE INDICATIONS WOULD BECOME INTERMITTENT. INVESTIGATION REVEALED THE EGT/CHT HARNESS ON THE RT BANK OF CYLINDERS WAS ROUTED TOO CLOSE TO THE EXHAUST SYSTEM AND WAS BURNING THROUGH THE INSULATION O F THE WIRES. CONNECTOR FOR THE TACH INDICATION WAS DISASSEMBLED, CLEANED, AND REASSEMBLED. OPS CHECK FOLLOWING THIS WAS OK. 1 L 7 1 3O NT A00009CH 2005050300216 20050503 00216 SO 2005 5 3 2005FA0000585 1 20050404 G 3213 6531904 STRUT PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA SNSNCH 76E 76EM8S5 EA MLG BROKEN D A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 WP 09 83364 9047 288390035 L3013736A 22486K FAILURE OF THE (CAST) MAIN LANDING GEAR STRUT CYLINDER. CRACK IN UPPER SCISSOR ATTACHMENT RESULTED IN LOSS OF GEAR AND STRUT ASSY DURING TAKE-OFF. 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 2005050500038 20050505 00038 2005 5 5 2005FA0000586 4 20050410 G 6122 C290D4T2 GOVERNOR CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO PROPELLER PLUGGED P C ABORTED TAKEOFF R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 GL 17 5130A 1200 1200 21063280 512211 DEPARTING SOFT FIELD POWER AND RPM FINE ON INITIAL ROLL. AFTER WHEELS BECAME LIGHT, POWER BLED OFF, YIELDING NO FURTHER ACCELERATION OR LIFT. ABORTED TAKE-OFF, NOSE WHEEL GOUGED INTO SOFT SAND, BREAKING NOSE FORK, PITCHING NOSE OF AIRCRAF T INTO DIRT. PROP BLADES BENT, MINOR DAMAGE TO NOSE FAIRINGS. KEEL CHANNEL WARPED, NOSE GEAR DOORS BENT. ENGINE CRANK DIALS IN LIMITS. WILL BE TORN DOWN FOR SUDDEN STOPPAGE. SUSPECT GOVERNOR RETURN MAY HAVE PLUGGED, CAUSING PROP TO INC REASE PITCH. 1 H 7 1 3O 3 O 3A21 E8CE 2005051100224 20050511 00224 SO 2005 5 11 2005FA0000587 2 20050402 G 7200 TSIO360B ENGINE PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360B 17025 SO HARTZL HCC2Y BHCC2YF2 GL LEFT DESTROYED P A UNSCHED LANDING A FLAME/FIRE CR CRUISE 1 SW 09 328RG 2310 347570061 303065 AN1145 AFTER TAKE-OFF THE LT ENGINE SUFFERED A CATASTROPHIC FAILURE. TWO CONNECTING RODS (NR 5, 6) FAILED AND KNOCKED A HOLE IN THE CRANKCASE. THE RESULTING HOLE IN THE CRANKCASE WAS THE LOCATION OF A FIRE WHICH BURNED THROUGH THE COWLING AND CONT INUED BURNING. THE AIRCRAFT WAS LANDED SAFELY. AFTER LANDING THE FIRE WAS EXTINGUISHED. 1 L 7 2 3O 3 O A7SO E9CE 5 C P920 2005051000139 20050510 00139 GL 2005 5 10 2005FA0000588 1 20050420 G 5341 2057000103 WING ROOT DIAMON DA20 DA20C1 2990001 GL LEFT LOOSE C K NONE O OTHER IN INSP/MAINT 1 NM 03 929AF 969 C0195 (A) BEARING IN LT WING FOUND LOOSE WITH .0625 INCH PLAY UP AND DOWN. NO PLAY FORE AND AFT. PASTE FROM BEARING ATTACH FOU ND LOOSE IN WING BAY. REMOVED BEARING AND FOUND NO DAMAGE TO END RIB. FOUND WITH WING OFF DURING 1000 HOUR INSPECTION. 1 L 7 1 3O NT TA4CH 2005042700039 20050427 00039 2005 4 27 2005FA0000590 4 20050314 G 3416 AK350 ENCODER ALTIMETER DEFECTIVE B O OTHER P NO WARNING INDICATION NR NOT REPORTED 1 NM 09 STATIC AIR INPUT LEAKS INTO CASE OF UNIT. UNIT IS NEW FROM STOCK. 2005042700040 20050427 00040 2005 4 27 2005FA0000591 4 20050314 G 3416 AK350 ENCODER ALTIMETER DEFECTIVE B O OTHER P NO WARNING INDICATION NR NOT REPORTED 1 NM 09 STATIC AIR INPUT LEAKS INTO CASE OF UNIT. UNIT IS NEW FROM STOCK. 2005042700131 20050427 00131 2005 4 27 2005FA0000593 4 20050325 G 3420 2300626020 MOTOR COLLINS ADI85A INDICATOR INTERMITTENT C O OTHER O OTHER NR NOT REPORTED 1 CE 09 38 THE MOTORS HAVE HIGH RESISTANCE BETWEEN THE BRUSHES AND ARMATURE OF THE MOTOR. THIS CAUSES THE MOTOR TO STICK INTERMITTE NTLY, CAUSING A FALSE ATTITUDE DISPLAY IN THE COCKPIT. THIS PROBLEM BEGAN WITH MOTORS DATE CODED 04/04 MANUFACTURED BY M OOG, INC. 2005050400069 20050504 00069 WP 2005 5 4 2005FA0000594 1 20050408 G 2432 AD430B034LB03 BATTERY DOUG DC9 DC983 3022083 WP MASTER OVERHEATED D O OTHER B SMOKE/FUMES/ODORS/SPARKS EX EXTERNAL LOAD 1 GL 03 315FV 49707 EXTREME SMOKE REQUIRING EVACUATION OF AIRCRAFT. BATTERIES SHOW EVIDENCE OF EXCESSIVE HEAT. 2 L 7 2 4F RT A6WE 2005050400070 20050504 00070 WP 2005 5 4 2005FA0000595 1 20050408 G 2432 AD430B034LB03 BATTERY DOUG DC9 DC983 3022083 WP MASTER OVERHEATED D O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 GL 03 315FV 49707 EXTREME SMOKE REQUIRING EVACUATION OF AIRCRAFT. BATTERIES SHOW EVIDENCE OF EXCESSIVE HEAT. 2 L 7 2 4F RT A6WE 2005050400071 20050504 00071 WP 2005 5 4 2005FA0000596 1 20050408 G 2432 AD430B034LB03 BATTERY DOUG DC9 DC983 3022083 WP ZONE 100 OVERTEMP D O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 GL 03 315FV 49707 EXTREME SMOKE REQUIRING EVACUATION OF AIRCRAFT. BATTERIES SHOW EVIDENCE OF EXCESSIVE HEAT. 2 L 7 2 4F RT A6WE 2005050400072 20050504 00072 WP 2005 5 4 2005FA0000597 1 20050408 G 2432 AD430B034LB03 BATTERY DOUG DC9 DC983 3022083 WP ZONE 100 OVERTEMP D O OTHER B SMOKE/FUMES/ODORS/SPARKS EX EXTERNAL LOAD 1 GL 03 315FV 49707 EXTREME SMOKE REQUIRING EVACUATION OF AIRCRAFT. BATTERIES SHOW EVIDENCE OF EXCESSIVE HEAT. 2 L 7 2 4F RT A6WE 2005050400114 20050504 00114 SO 2005 5 4 2005FA0000598 2 20050413 G 8530 532200 O-RING CONT O520 IO520* 17032 SO CYLINDER BASE IMPROPER PART G O OTHER W INADEQUATE Q C CR CRUISE 1 GL 13 INCORRECT CYLINDER BASE O-RINGS INSTALLED AT TOP-OVERHAUL. THE O-RINGS INSTALLED APPEARED TO BE THE SIZE FOR THE ENGINE. THESE LARGER CROSS SECTION SEALS WERE PINCHED BETWEEN THE CYLINDER BASE AND THE CRANKCASE. THIS RESULTED IN A LOW THROU GH-BOLT TORQUE. NUMBERS 2 AND 3 MAIN BEARINGS SPUN, DISRUPTING OIL FLOW TO THE NUMBER 4 CONNECTING ROD. THE NUMBER 4 CON NECTING ROD FAILED AND PENETRATED THE CASE. 3 O E5CE 2005050400053 20050504 00053 NE 2005 5 4 2005FA0000599 2 20050401 G 7200 30729202 BEARING RACE ISRAEL 1124 1124 4500102 EU GARRTT TFE731 TFE73131G 29003 NE ENGINE FRACTURED B K NONE O OTHER IN INSP/MAINT 1 WP 07 1052 P77111C ENGINE RETURNED TO SERVICE CENTER FOLLOWING COMMANDED SHUTDOWN IN FLIGHT DUE TO LOW OIL PRESSURE. DURING INSPECTION A F RACTURED CAGE AND OUTER RACE WAS FOUND ON A FORWARD PLANETARY ROLLER BEARING. 2 M 7 2 4F 4 F A2SW E6WE 2005050400052 20050504 00052 CE 2005 5 4 2005FA0000600 1 20050412 G 5730 67221463 SKIN CESSNA 750 750 2076810 CE RT WING CORRODED B K NONE O OTHER IN INSP/MAINT 1 GL 09 906QS 7500206 DURING SCHEDULED INSPECTION FOUND SEVERAL SMALL SPOTS OF CORROSION ON BOTH LEFT AND RIGHT LOWER WING SKINS. PN OF THESE WING SKINS ARE: 67221463, 4 , 67221663,4 AND 67221723. SOME OF THESE AREAS EXCEEDED .007 INCH DEPTH. CONTACTED MFG ENGIN EERING FOR REPAIR DISPOSITION. CAUSE OF CORROSION UNKNOWN. 2 L 7 2 4J RT T00007WI 2005050300215 20050503 00215 2005 5 3 2005FA0000601 4 20050404 G 3420 2300626020 MOTOR COLLINS ADI85A ADI INTERMITTENT B K NONE O OTHER IN INSP/MAINT 1 CE 09 793 CREW REPORTED COMMAND FUNCTION STICKING AND ADI DISPLAYS CMD FLAG. INSPECTION REVEALED MOTOR HAD HIGH START VOLTAGE. MO TOR DATE CODE IS 04/04. MOTOR WAS INSTALLED NEW 11/2004. 2005051900133 20050519 00133 EU 2005 5 19 2005FA0000602 1 20050413 G 2436 R25VON VOLT REGULATOR GROB 120 G120A 1660208 EU LYC O540 AEIO540D4D5 EA INOPERATIVE B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 864AF 85004 L2826348A AFTER 20 MINUTES INTO ENGINE, START CHARGING SYSTEM STILL SHOWING 7 AMPS OF CHARGING. MAINT TECH FOUND VLOTAGE REGULATO R WAS NOT WORKING. VOLTAGE REGULATOR WAS REPLACED AND OPERATIONAL CHECK OF CHARGING SYSTEM CHECK, GOOD. NO RECOMMENDAT IONS AT THIS TIME. 1 L 7 1 3O 3 O RT A49CE 1E4 2005051900134 20050519 00134 EA 2005 5 19 2005FA0000603 2 20050414 G 7314 RG9570K1M PUMP GROB 120 G120A 1660208 EU LYC O540 AEIO540D4D5 EA FUEL SYSTEM MALFUNCTIONED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 861AF 117 85001 PILOT REPORTED THAT IDLE RPM WAS TOO HIGH, 850 RPM. WHILE TECH WAS TRYING TO ADJUST IDLE, FOUND THAT THE FUEL PRESSURE WAS LOW - 16 PSI AND UNABLE TO ADJUST. REPLACEMENT OF ENGINE DRIVEN FUEL PUMP WAS REQUIRED. RECOM TO ADD A METHOD PLUS DATA FOR MAKING ADJUSTMENT IN THE FIELD. (K) 1 L 7 1 3O 3 O RT A49CE 1E4 2005051900135 20050519 00135 NE 2005 5 19 2005FA0000604 1 20050401 G 7330 3033606 LINE SKRSKY S76 S76B 8143007 NE PWA PT6 PT6B36 52043 EA ENG FUEL CHAFED B CW1R K NONE O OTHER IN INSP/MAINT 1 EA 11 780P 760359 36099 FUEL LINE FROM FUEL CONTROL TO FUEL FLOW TRANSMITTER CHAFED APPROCIMATELY 30 PERCENT THROUGH THE WALL THICKNESS AT THE P OINT WHERE IT PASSES THROUGH FRONT FIRE SHIELD. POOR CLAMPING ARRANGEMENT AND PASS THROUGH HOLE DESIGN IN FIRE SHIELD A RE CAUSE OF CHAF AND POTENTIAL FIRE HAZZARD. SUGGEST MFG REDESIGN CLAMPING AND PASS THROUGH HOLES. (K) 1 G 7 2 4U 4 U H1NE E4EA 2005051900136 20050519 00136 CE 2005 5 19 2005FA0000605 1 20050408 G 2435 23048016 STARTER GEN BEECH 90 C90 1152913 CE PWA PT6 PT6* 52043 EA NR 2 ENGINE INOPERATIVE B XUPR K NONE O OTHER IN INSP/MAINT 1 NM 09 71EN 608 LJ632 AFTER START, NR 2 GENERATOR CAME ON LINE AND WAS CARRING A LOAD. NR 2 GEN LOAD METER SHOWED HIGH AMP SPIKE AND DROP OFF LINE, WITH IN-OP LIGHT COMING ON. REPLACED STARTER GEN, SYSTEM OPS TESTED GOOD. (K) 1 L 7 2 3T 3 T 3A20 E2NE 2005051900137 20050519 00137 CE 2005 5 19 2005FA0000607 1 20050401 G 5712 9511003119 RIB BEECH 58 58 1152740 CE CONT O550 IO550* SO LT WING CRACKED B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 128WS 674 TH1982 DURING SCHEDULED ANNUAL INSPECTION, FOUND LT WING BATT RIB AFT ANGLE AT IB MLG DOOR AFT ATTACH POINT CRACKED. HAVE NOTE D SIMILAR CRACKING IN OTHER LOW-TIME RAC MODEL 58 AIRCRAFT. CRACKING SEEMS TO BE RELATED TO INSTALLATION OF MACHINED AL UMINUM DOORS THAT REPLACED OLDER STYLE RIVETED CONSTRUCTION DOORS. SUSPECT STIFFNESS OF NEWER-STYLE CONSTRUCTION DOORS TRANSFERRING INCREASED LOADS TO AIRFRAME STRUCTURE. ADJACENT DOOR ATTACH ANGLES REPLACED FOR CRACKING AT 266.7 HRS TTAF . RECOMMEND CLOSE INSP OF WING RIB ANGLES AT IB DOOR ATTACH POINTS EACH ANNUAL/ 100 HR INSP UNTIL ISSUE RESOLVED BY MFG EO. (K) 1 L 7 2 3O 3 O 3A16 E3SO 2005051900138 20050519 00138 2005 5 19 2005FA0000608 1 20050406 G 4920 BLADE COMPRESSOR WHEEL FATIGUED D K NONE O OTHER IN INSP/MAINT 1 SO 05 031365103481 THIS IMPELLER HAS EXPERIENCED WHAT LOOKS LIKE HIGH CYCLE FATIGUE WITH A VERY LOW TT ON THE UNIT. IT APPEARS TO HAVE FAI LED DUE TO WHAT STARTED AS A FATIGUE CRACK AND RESULTED IN A LARGE PIECE OF THE IMPELLER COMING OFF. THIS IMPELLER AND ANOTHER WERE PURCHASED WITHIN 30 DAYS OF EACH OTHER AND HAVE S/N THAT ARE 2 DIGETS OFF FROM THE OTHER. 2005052400014 20050524 00014 CE 2005 5 24 2005FA0000609 1 20050422 G 7120 04511201 MOUNT CESSNA 150 150M 2071830 CE CONT O200 O200* 17020 SO RT ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 13 63581 15077410 100 HOUR INSPECTION, RT LOWER ENGINE MOUNT TUBE CRACKED. CRACK LOCATED WITHIN 1 INCH OF NOSE WHEEL STRUT SUPPORT CRACK, .7500 INCH IN LENGTH AROUND CIRCUMFERENCE OF TUBE. REPLACED MOUNT. (K) 1 H 7 1 3O 3 O 3A19 E252 2005052400015 20050524 00015 2005 5 24 2005FA0000610 4 20050412 G 3197 WIRE CESSNA 182 182T 2072703 CE LYC O540 IO540* 41532 EA ANNUNCIATOR BROKEN B Z08R K NONE O OTHER IN INSP/MAINT 1 CE 07 2116X 18281318 FOUND ORANGE WIRE FOR THE LOW VOLT ANNUNCATOR FOR THE G-1000 BROKEN INSIDE THE J-BOX WOULD NOT CAUSE THE ANNUNCATOR TO L IGHT UP ON THE PFD (PILOTS FLIGHT DISPLAY). APPEARS WIRE HAVE CHAFED ON J-BOX TO BREAK WIRE. ADDRESSED AND CORRECTED A S REQUIRED. (CE07200512733) (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2005052400016 20050524 00016 CE 2005 5 24 2005FA0000611 1 20050301 G 7797 PIN CESSNA 182 182T 2072703 CE LYC O540 IO540* 41532 EA TRANSDUCER LOOSE B Z08R K NONE O OTHER IN INSP/MAINT 1 CE 07 2116X 75 18281318 G-1000-3 PIN CONNECTOR FOR MANIFOLD PRESSURE TRANSDUCER, THE PINS WILL GET LOOSE AND CAUSE THE MANIFOLD PRESSURE INDICAT ION TO JUMP FROM 7.7 TO 55 MP PSI. TROUBLESHOT, WITH THIS IN THE FUTURE DUE TO VIBRATION OF AIRCRAFT. NOTE: NEVER HAD A RED-X OVER MP INDICATION ON LRU. (CE07200512739) (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2005052400017 20050524 00017 CE 2005 5 24 2005FA0000612 1 20050301 G 7997 PIN CESSNA 182 182T 2072703 CE LYC O540 IO540* 41532 EA TRANSDUCER LOOSE B Z08R K NONE O OTHER IN INSP/MAINT 1 CE 07 2116X 75 18281318 G-1000-3 PIN CONNECTOR FOR OIL PRESSURE TRANSDUCER, THE PINS WILL GET LOOSE AND CAUSE THE OIL PRESSURE INDICATION TO JUM P FROM 45 TO 110 PSI. TROUBLESHOT, RESET PIN TO SHRINK (SHIP SIDE). SUSPECT WILL HAVE PROBLEMS WITH THIS IN THE FUTURE DUE TO VIBRATION OF AIRCRAFT. NOTE: NEVER HAD A RED-X OVER OIL PRESSURE INDICATION ON LRU. (CE07200512740) (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2005052400020 20050524 00020 2005 5 24 2005FA0000613 4 20050429 G 2200 065001802700 SERVO CESSNA 182 182T 2072703 CE LYC O540 IO540* 41532 EA RT WING AUTOPILO CHAFED B Z08R K NONE O OTHER IN INSP/MAINT 1 CE 07 2116X 191 18281318 DURING MFG 200 HOUR INSPECTION FOUND THE AUTOPILOT SERVO CABLE IN THE RT WING RUBBING ON SERVO CABLE GUARD ALMOST RUBBIN G THRU ONE LEG OF GUARD. INSPECTED CABLE FOUND OK. INSTALLED A NEW GUARD AND CLOCKED TO CORRECT POSITION ON SERVO. (C E07200512741) (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2005052400021 20050524 00021 CE 2005 5 24 2005FA0000614 1 20050412 G 7797 62803SG513 CONNECTOR CESSNA 182 182T 2072703 CE LYC O540 IO540* 41532 EA TACH GENERATOR LOOSE B Z08R K NONE O OTHER CR CRUISE 1 CE 07 21454 576 18281228 TACHOMETER INDICATION JUMPS AROUND IN FLIGHT. INSTALLED A NEW TACHOMETER CONNECTOR, IAW MFG SL. OPS CHECK OK. (CE0720 0512734) (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2005052400023 20050524 00023 CE 2005 5 24 2005FA0000615 1 20050412 G 7722 86317 PROBE CESSNA 182 182T 2072703 CE LYC O540 IO540* 41532 EA EGT INOPERATIVE B Z08R K NONE O OTHER IN INSP/MAINT 1 CE 07 21454 576 18281228 DURING LEAN FIND FOR G-1000 WOULD NOT INDICATE NR1 AND NR2 ENGINE CYLINDERS. TROUBLESHOT, USED EGT/CHT TESTER AND FOUN D PROBES BAD ALSO SHIP SIDE CONNECTOR WAS ALSO BAD, FOUND SCREWS LOOSE INSIDE CONNECTOR. REPLACED NR1 AND NR2 ENGINE CY LINDER PROBES AND CORRECTED CONNECTOR ON SHIP SIDE BY CLEANING AND TIGHTENING SCREWS, OPS CHECK OK. (CE07200512735) (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2005052400024 20050524 00024 CE 2005 5 24 2005FA0000617 1 20050412 G 2842 S38524 PROBE CESSNA 182 182T 2072703 CE LYC O540 IO540* 41532 EA FUEL QTY FAILED B Z08R A UNSCHED LANDING N FALSE WARNING CR CRUISE 1 CE 07 21454 576 18281228 DURING FLIGHT, FUEL INDICATIONS WOULD RED-X OUT AND INDICATIONS SHOWING QUANITY JUMPED AROUND LT AND RT SIDE. TROUBLESH OT, AND REPLACED PROBES/ SENDERS IAW MFG. CALIBRATED IAW MFG MM. OPS CHECK OK. NOTE: NEED IMPROVEMENT IN TROUBLESHOOT ING PROCEDURES IN MM AND POSSIBLE BREAKOUT BOXES TO AID IN TROUBLESHOOTING. G-1000 AIRCRAFT. (CE07200512737) (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2005052400025 20050524 00025 EA 2005 5 24 2005FA0000618 2 20050425 G 8550 LW13792P50 SEAL PIPER PA24 PA24260 7102406 SO LYC O540 IO540D4A5 41532 EA CRANKSHAFT FAILED D AKGR K NONE O OTHER IN INSP/MAINT 1 CE 05 9241P 244740 UPON TRYING TO INSTALL THE SOLID OIL SEAL OVER THE CRANKSHAFT FLANGE, THE SEAL FAILED AND TOTALLY SEPERATED IN A STRAIGH T LINE 90 DEGREES TO THE FACE OF THE SEAL. VERY LITTLE FORCE WAS BEING APPLIED TO THE INSTALLING TOOL WHEN THE SEAL FAI LED. THIS WAS SECOND FAILURE OF THE SAME LOT. PRODUCT SHELF LIFE EXPIRATION DATE 4Q07. ACCORDING TO MFG THE SHELF LIF E IS 12 QUARTERS. (K) 1 L 7 1 3O 3 O 1A15 1E4 2005052400026 20050524 00026 EA 2005 5 24 2005FA0000619 2 20050420 G 7320 RA5AD2 SERVO CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MCAULY 1A170 1A170E GL ENGINE FUEL INOPERATIVE B D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 GL 25 494JB 172S9099 L3034351A JHA7660 IT OCCURRED WHEN PERFORMEING AN OUTGOING ENGINE RUN. WHEN THE THROTTLE WS PULLED BACK TO IDLE, ON THE S TOP OF THE SERV O, WHEN WE PULLED A LITTLE HARDER, IT CAUSED THE ENGINE TO STALL AND SHUTDOWN INSTEAD OF JUST DECREASING A FEW MORE RPM. RECOMMEND SB TO CHECK ALL MFG AC FOR THIS CONDITION. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2005052400027 20050524 00027 SO 2005 5 24 2005FA0000620 2 20050413 G 8550 6009 GASKET PIPER PA32 PA32R301 7103218 SO LYC 0540 IO540K1G5D 41532 SO ENGINE MISSING D K NONE K FLUID LOSS IN INSP/MAINT 1 GL 03 2430Y 32R8513002 RL2259448A ON INITIAL GROUND RUN, AFTER INSTALLING FACTORY REMFG, OIL WAS LEAKING FROM ACCY CASE UNDER FUEL PUMP. WHEN FUEL PUMP W AS REMOVED TO REPLACE GASKET, IT WAS FOUND THAT THERE WAS NO GASKET INSTALLED. INSTALLED NEW GASKET, LEAK CHECK GOOD. PROBABLE CAUSE: COMPLACENCE, DISTRACTION, OR INDIFFERENCE. (K) 1 L 7 1 3O 3 O A3SO 1E4 2005052400028 20050524 00028 CE 2005 5 24 2005FA0000621 1 20050411 G 2730 58151035CR CONTROL CABLE CESSNA 404 404 2075901 CE CONT O520 GTSIO520F 17032 SO LT ELEVATOR DAMAGED G K NONE O OTHER IN INSP/MAINT 1 SW 01 5388J 4040666 DURING INSPECTION, FOUND CABLE TO BE BLENDED AT FAIRLEAD APPROX 6 INCHES FROM AFT END OF CABLE. PROBABLE CAUSE FROM NEW STYLE (STAINLESS STEEL) CABLE. NEW STYLE LASTED ONLY FRACTION OF TIME AS OLD STYLE. (SW01200504154) (K) 1 L 7 2 3O 3 O RT A25CE E7CE 2005052400029 20050524 00029 CE 2005 5 24 2005FA0000622 1 20050420 G 3520 100801D40218 BUSHING BEECH BEECH 90 F90 1152909 CE CONTROL CABLE MISSING B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 189JR LA61 INVESTIGATED PASSENGER OXYGEN SYSTEM MASKS DEPLOYING WHEN SYSTEM ARMED. FOUND MANUAL CONTROL CABLE BUSHING MISSING AND PREVENTING MANUAL CONTROL CABLE FROM OPERATING VALVE THROUGH FULL TRAVEL. ALSO, FOUND WIRING TO PASSENGER OXYGEN SHUTOF F VALVE AND BAROMETRIC SWITCH NOT CONNECTED CORRECTLY. REWIRED BAROMETRIC SWITCH AND OXYGEN SHUTOFF VALVE AND CONTROL I AW MM. SYSTEM OPS CHECK OK. HAVE PREVIOUSLY NOTED SIMILAR PROBLEMS FOLLOWING SCHEDULED MAINT THIS AREA. (K) 1 L 7 2 4T A31CE 2005052400007 20050524 00007 EU 2005 5 24 2005FA0000624 1 20050503 G 2780 1075D1003 FCU ISRAEL 1125 ASTRASPX 4500205 EU GARRTT TFE731 TFE73140 29001 NE SLATS OUT OF TOLERANCE Z D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 WP 29 B2001 22 119 THE SLATS FAILED TO EXTEND WHILE PILOTS WERE PERFORMING THE INSPECTIONS BEFORE TAKEOFF. THE SLATS LOCKED OUT WHILE MECH ANIC PLACED THE FLAP/SLAT SELECTOR TO DN POSITION. SLAT UNBALANCE LIGHT CAME ON SIMULTANEOUSLY. TROUBLESHOOTING FOUND T HE FSECU OUTPUT VOLTAGE WAS OUT OF TOLERANCE. 2 L 7 2 4F 4 F RT A16NM E1NM 2005052400128 20050524 00128 CE 2005 5 24 2005FA0000625 1 20050415 G 3210 07416321 BUSHING CESSNA 182 182T 2072703 CE LYC O540 IO540* 41532 EA LT MLG SPLIT D K NONE O OTHER IN INSP/MAINT 1 SW 01 812MC 385 18281208 INNER RUBBER/ PLASTIC MATERIAL NOTED PROTRUDING FROM BOTH SIDES OF BUSHING. MATERIAL INSIDE BUSHING SPLITTING IN SEVERA L AREAS. LT MLG BUSHING ONLY, RT MLG BUSHING APPEARS NORMAL. (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2005052400129 20050524 00129 EA 2005 5 24 2005FA0000626 2 20050425 G 7314 ES10382807 CAPACITOR CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA MAGNETO FAILED D K NONE O OTHER IN INSP/MAINT 1 NE 03 7694V 70 C030929 177RG0904 L1552651A THE MAGNETO WAS OVERHAULED 70 HOURS AGO, THE CAPACITORS WERE SUPPLIED BY OVERHAULER. THE OVERHAUL WAS DONE AND CAPACITO RS ARE FAA PMA`D. 1 H 7 1 3O 3 O A20CE 1E10 2005052400131 20050524 00131 EU 2005 5 24 2005FA0000627 1 20050422 G 7920 30032871 LINE AMD FALC20 FALCON 2720302 EU ENGINE OIL CRACKED B AV4R E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 WP 07 200GT 137 LOW OIL PRESS IN FLIGHT, PRECAUTIONARY SHUTDOWN PERFORMED. 23 PSI LOWEST READING ON OIL PRESS INDICATOR. OIL PRESS NEV ER WENT TO -0- PSI. PRECAUTIONARY SHUTDOWN PERFORMED ON NR2 ENG. DECLARED EMERGENCY. ENG ROTATION WAS NORMAL AFTER SHU TDOWN. OIL QTY INDICATION AT BOTTOM OF DIPSTICK WHEN CKD ON ARRIVAL. OIL LEAKING IN FAN BYPASS AREA OF ENG. FOUND OB SURFACE OIL COOLER, DISCOVERED BOTH AFT MNT BRKTS CRACKED. REPLACED BOTH BRKTS. REPLACED BOTH IB AND OB OIL TUBES. FO UND CRACKS IN UPR, LWR FAIRING, AFT OF FRONT FRM, REPLACED FAIRINGS. FOUND CRACKS IN BOLT HOLES ON 3 DAGMAR ASSY, REPLA CED. FWD SEAL FOR COMP SEC OUTER COWL WORN, REPLACED SEAL. ENG RUN AND LEAK CHECK PERFORMED, NO LEAKS NOTED. 2 L 7 2 4F A7EU 2005052400133 20050524 00133 CE 2005 5 24 2005FA0000628 1 20050425 G 3297 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO MLG INTERMITTENT B VJ3R O OTHER J WARNING INDICATION LD LANDING 1 WP 07 8268T 536 CE1547 PILOT SELECTED GEARDOWN AND NOTHING HAPPENED, PILOT THEN CYCLED GEAR SELECTOR TWICE THEN GEAR WENT DOWN, AC RETURNED TO BASE. ON TROUBLESHOOTING, MECHANIC CYCLED GEAR 4 TIMES THEN RELAY FAILED, PROBABLE CAUSE AT THIS TIME UNKNOWN. INSTALL ED NEW AND IMPROVED RELAY IAW DATE CODE. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005052400134 20050524 00134 CE 2005 5 24 2005FA0000629 1 20050425 G 3200 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO MLG INTERMITTENT B VJ3R A UNSCHED LANDING O OTHER AP APPROACH 1 WP 07 5521A 799 CE1338 PILOT SELECTED GEAR UP AND NOTHING HAPPENED, AIRCRAFT RETURNED TO BASE. ON TROUBLESHOOTING, MECHANIC CYCLED GEAR (8) TI MES THEN RELAY FAILED, PROBABLE CAUSE AT THIS TIME UNKNOWN. INSTALLED NEW AND IMPROVED RELAY IAW DATE CODE. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005052400136 20050524 00136 CE 2005 5 24 2005FA0000630 1 20050127 G 3040 2SC1120A RELAY BEECH MU300 400A 1155402 CE PWA JT15 JT15D1 52060 NE WINDSHIELD HEAT LOOSE G O OTHER B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 EA 17 430CW RK30 CREW SQUAWKED ELEC FUMES AND FOUL ODOR IN COCKPIT. ODOR SEEMED TO LET UP AFTER BATTERY PLACED IN EMERG AND BOTH GENERAT ORS PLACED IN EMERG. MAINT FOUND RT WINDSHIELD HEAT CURRENT SENSE RELAY (L102S) TERMINAL B AND APPROX 2 INCHES OF WIRE INSULATION TO OVERHEAT AND MELT WITH RT WINDSHIELD HEAT ON AND WINDSHIELD SUBJECTED TO COLD TEMP. FOUND WIRE AMP END SE CURED TO SUBJECT RELAY TERMINAL STUD WITH FLAT NUT AND WASHER. NO LOCK WASHER WAS INSTALLED. LACK OF A LOCK WASHER UND ER NUT ENABLED TERMINAL NUT TO BECOME LOOSE AND ARC UNDER CURRENT LOAD. REPLACED DEFECTIVE WIRE AND RELAY WITH NEW. UT ILIZED NEW LOCK WASHERS UNDER NEW NUTS AT REPLACEMENT RELAY TERM STUDS. COCKPIT SYS CHECKD NORMAL. (EA172005057764) (K) 2 H 7 2 4F 4 F RT A16SW E1NE 2005052400137 20050524 00137 2005 5 24 2005FA0000631 4 20050228 G 3418 602517 RELAY PIPER PA46 PA46500TP 7104622 SO PWA PT6 PT6A42 52043 NE HARTZL HCE4N HCE4N3 NE STALL WARNING BURNED B ECWR K NONE O OTHER IN INSP/MAINT 1 SO 15 802MM 4697148 PCERM0158 HH1616 HEAT REMOTE SWITCH MODULE FOR STALL WARNING HEAT (LIFT DETECTOR) HAD SHORTED CAUSING SMOKE IN CABIN/FLIGHT DECK DURING F LIGHT OPERATION. SB 1132 WAS ACCOMPLISHED ON 6/25/2003, AC TT 81.2 HOURS. (K) 1 L 7 1 3O 4 T RT A25SO E4EA 5 C P10NE 2005052400139 20050524 00139 CE 2005 5 24 2005FA0000632 1 20050407 G 5751 97164 BALANCE WEIGHT CESSNA 500 S550 2076607 CE PWA JT15 JT15D4 52112 NE AILERON LOOSE B R2JR K NONE O OTHER IN INSP/MAINT 1 EA 21 1VA 6281 S5500143 WHILE CONDUCTING A PHASE 2 INSP, INSPECTOR NOTICED COCK-EYED BOLT HEADS ON AILERON. FURTHER INVESTIGATION, INCLUDING RE MOVAL OF AILERONS, FOUND STATIC BALANCE WEIGHTS VERY LOOSE. STACK OF WEIGHTS HAD MUCH CORROSION, WHICH CAUSED THE ATTAC H HOLES TO ENLARGE, THEREFORE CAUSING STACK OF WEIGHTS TO BE VERY LOOSE. DETAILED INSP OF THIS AREA NOT ON ANY INSPECTI ON FORM. NEW PARTS INSTALLED. SUGGEST OPERATORS OF THIS MODEL AC, REMOVE AILERONS AND COMPLETE DETAILED INSPECTION OF THESE WEIGHTS. (EA21200505634) (K) 1 L 7 2 4F 4 F RT A22CE E1NE 2005052400142 20050524 00142 CE 2005 5 24 2005FA0000633 1 20050419 G 2510 MS27039104 SCREW CESSNA 750 750 2076810 CE ALLSN AE3007 AE3007C GL CREW SEAT LOOSE B JZ2R K NONE O OTHER IN INSP/MAINT 1 GL 03 300JD 1389 7500202 SCREW WAS FOUND LOOSE ON BOTH PILOT AND CO-PILOT SEATS ON 2 SEPARATE OCCASIONS, 6 MONTHS APART. THE SCREWS WERE RE-TIGH TENED ON BOTH OCCASIONS THIS PROBLEM IS SIGNIFICANT DUE TO THE FACT THAT THE POSSIBLE FAILURE MODE COULD BE LOSS OF SEAT LOCKING CAPABILITY AND THE CREW SEAT BEING FREE TO MOVE FORE AND AFT, THAT A LOCKING FEATURE BE USED FOR THIS SCREW SUC H AS A LOCK WASHER OR LOCTITE COMPOUND. (K) 2 L 7 2 4J 4 F RT T00007WI TE6CH 2005052400143 20050524 00143 NE 2005 5 24 2005FA0000634 1 20050225 G 7810 CLAMP STOLAC UC1 UC1 9220102 NE LYC O360 IO360A1A 41514 EA TAILPIPE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 15 65NE 023 LT ENGINE IB EXHAUST TAILPIPE CRACKED, EXPELLING HEAT INTO ENGINE COMPARTMENT, BURNING PAINT ON COWLING. PART FAILURE O CCURRED BECAUSE OF BROKEN SUPPORT CLAMP, NO PN AVAILABLE DUE TO THE LIMITED PRODUCTION OF THIS AIRCRAFT ON EITHER EXHAUS T TAILPIPE OR SUPPORT CLAMP. SUSPECTED CAUSE OF FAILURE IS FROM ENGINE VIBRATION AND SHOCK LOADS IMPOSED BY WATER OPERA TIONS. ENTIRE EXHAUST SYSTEM SHOULD BE INSPECTED AT EACH 50, 100 HOUR AND ANNUAL INSPECTION SPECIFICALLY THE REAR SUPPO RT CLAMPS FOR CRACKS AND DETERIORATION. (K) 1 H 7 2 3O 3 O A6EA 1E10 2005052400144 20050524 00144 2005 5 24 2005FA0000635 4 20050204 G 3452 KT76C TRANSPONDER CESSNA 172 172R 2072401 CE LYC O360 IO360A1A 41514 EA ATC OUT OF ALIGNMENT B K NONE O OTHER IN INSP/MAINT 1 CE 05 463CM 3138 17280855 TRANSPONDER CAVITY BELOW TRANSMIT POWER TOLERANCE. ALIGNMENT CORRECTS PROBLEM, BUT THIS CAUTION SHOULD NOT BE NEEDED AT THIS TIME. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005052400145 20050524 00145 NE 2005 5 24 2005FA0000636 1 20050505 G 3020 WIRE SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S1 60030 NE BELLMOUTH HEAT BURNED D P7ZR K NONE O OTHER IN INSP/MAINT 1 EA 17 22CP 760530 ENGINE ANTI-ICE SYSTEM, ENGINE HEATED INTAKE BELLMOUTH AND SNOW BLANKET. MAINT FOUND BURNED WIRE AT PLUG J701 AND P701 (PIN A) 16 GAGE WIRE. THEY ALSO FOUND THIS WIRE WAS FED BY A 35 AMP COCKPIT DC PRIMARY BUSS CIRCUIT BREAKER THROUGH A 1 0 GAGE WIRE TO PLUG J3004K AND P3004K PINS F AND C. THE 16 GAGE WIRES (2EA) WAS BUTT CONNECTED TOGETHER TO SINGLE 10 GA GE WIRE. ONE OF 16 GAGE WIRES WAS BURNED COMPLETELY THROUGH. UPON REPAIRING, BURNED WIRE, MECHANIC FOUND THAT 10 GAGE AND 16 GAGE WIRE SHOWS SIGNS OF COPPER OXIDATION IN COLOR, BRITTLE TO TOUCH AND SILVER PLATING ON WIRE WAS FLAKING OFF. FURTHER INVESTIGATION SHOWS THIS MAY BE A MFG DEFECT OF WIRE. FURTHER INVESTIGATION ONGOING WITH MFG OF AC. (K) 1 G 7 2 3U 3 U NC H1NE E19EU 2005052400146 20050524 00146 NE 2005 5 24 2005FA0000637 1 20050505 G 3020 WIRE SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S1 60030 NE BELLMOUTH HEAT BURNED B P7ZR K NONE O OTHER IN INSP/MAINT 1 EA 17 66CP 760532 ENGINE ANTI-ICE SYSTEM, HEATED INTAKE BELLMOUTH, HEATED SNOW BLANKET. MAINT FOUND BURNED WIRE AT PLUG J701 AND P701 (PI N A) 16 GAGE WIRE. THEY ALSO FOUND THIS WIRE WAS FED BY A 35 AMP COCKPIT DC PRIMARY BUSS CIRCUIT BREAKER THROUGH A 10 G AGE WIRE TO PLUG J3004K AND P3004K PINS F AND C. THE 16 GAGE WIRES (2 EA) WAS BUTT CONNECTED TOGETHER TO SINGLE 10 GAG E WIRE. ONE OF 16 GAGE WIRES WAS BURNED COMPLETELY THROUGH. UPON REPAIRING THE BURNED WIRE, MECHANIC FOUND THAT THE 10 GAGE AND 16 GAGE WIRE SHOWS SIGNS OF COPPER OXIDATION IN COLOR, BRITTLE TO TOUCH AND SILVER PLATING ON WIRE WAS FLAKING OFF. FURTHER INVESTIGATION SHOWS THIS MAY BE A MFG DEFECT OF THE WIRE. FURTHER INVESTIGATION ONGOING WITH MFG. (K) 1 G 7 2 3U 3 U NC H1NE E19EU 2005052400147 20050524 00147 CE 2005 5 24 2005FA0000638 1 20050421 G 6100 B5020 SPRING CESSNA 208 208 2073702 CE MCAULY 3AF34C 3GFR34C703 GL PROPELLER STRETCHED B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 208JB 20800362 020561 SPRING ASSY STRETCHED TOO LARGE. (K) 1 H 7 1 3T NT A37CE 5 C P60GL 2005052400148 20050524 00148 SO 2005 5 24 2005FA0000639 1 20050317 G 5312 62444003 BULKHEAD PIPER PA28 PA28160 7102806 SO LYC O320 O320* 41508 EA FUSELAGE CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 21 5654W 4177 28815 FOUND DURING INSPECTION, MINER SKIN WRINKLES LT OF FIN. PREVIOUS DAMAGE TO RUDDER FROM THE REAR FORWARD. (K) 1 L 7 1 3O 3 O 2A13 E274 2005052400149 20050524 00149 SO 2005 5 24 2005FA0000640 1 20050317 G 5312 62444003 BULKHEAD PIPER PA28 PA28140 7102802 SO LYC O320 O320* 41508 EA FUSELAGE CRACKED D K NONE O OTHER IN INSP/MAINT 1 GL 21 7360J 5597 2824712 FOUND DURING INSPECTION. NO EXTERNAL INDICATIONS. NO DAMAGE HISTORY. BULKHEAD AFT FUSELAGE CRACKED AND KINKED. (K) 1 L 7 1 3O 3 O 2A13 E274 2005052400150 20050524 00150 CE 2005 5 24 2005FA0000641 1 20050412 G 5553 53120252 PAN CESSNA 340 340A 2076405 CE CONT O520 TSIO520* 17040 SO VERTICAL STAB CRACKED B CTUR K NONE O OTHER IN INSP/MAINT 1 GL 21 98560 5627 340A0032 DURING ANNUAL INSPECTION TECHNICIAN WAS INSPECTING TAIL SECTION. THE PAN (AFT) IS ATTACHED TO BULKHEAD WHICH ARE PRIMAR Y STRUCTURE (AFT) FOR HORIZONTAL AND VERTICAL STABILIZER. TAIL FLEX IS TRANSFERRING TO THIS ASSY AND IS CAUSING CRACKS IN THE RADIUS. (K) 1 L 7 2 3O 3 O 3A25 E8CE 2005052400151 20050524 00151 CE 2005 5 24 2005FA0000642 1 20050412 G 5553 53120252 PAN CESSNA 340 340A 2076405 CE VERTICAL STAB CRACKED B CTUR K NONE O OTHER IN INSP/MAINT 1 GL 21 234PS 3703 340A0368 DURING ANNUAL INSPECTION, TECH WAS INSPECTING TAIL SECTION. PAN IS ATTACHED TO A BULKHEAD WHICH ARE THE PRIMARY STRUCTU RE (AFT) FOR THE HORIZONTAL AND VERTICAL STABILIZERS. TAIL FLEX IS TRANSFERRING TO THIS ASSY AND IS CAUSING CRACKS ON T HE RADIUS. (K) 1 L 7 2 3O 3A25 2005052400153 20050524 00153 CE 2005 5 24 2005FA0000643 1 20050427 G 5310 00244002457 SPAR BEECH 58 58 1152740 CE CONT O550 IO550* SO FUSELAGE CRACKED D MASS K NONE O OTHER IN INSP/MAINT 1 SW 01 8117V 11655 TH1628 WHERE HORIZONTAL STAB SPAR ATTACHES. THE BULKHEAD IS CUT AWAY, TO ALLOW THIS, AND IS FORMED BY JOGGLE BEND. SIDE TO SI DE. AT THIS JOGGLE, IT IS CRACKED, FORE AND AFT, TO INCLUDE BOTH BULKHEAD AND FORMER. (SW01200504216) (K) 1 L 7 2 3O 3 O 3A16 E3SO 2005052400154 20050524 00154 2005 5 24 2005FA0000644 4 20050420 G 3418 07133481 STALL WARNING CESSNA 172 172S 2072439 CE RT WING INOPERATIVE D Q19S A UNSCHED LANDING P NO WARNING INDICATION CR CRUISE 1 EA 07 50605 311 172S9205 (510901) STUDENT PILOT WAS FLYING W/CFI. DURING STUDENTS FIRST STALL PRACTICE THE WARNING HORN FAILED TO OPERATE THROUG H FULL STALL, CFI HALTED MANEUVER. TROUBLESHOOTING CONFIRMED THAT WARNING HORN WAS DEFECTIVE. REPLACED WITH NEW, OPS C HECK AND TEST FLIGHT WERE COMPLETED, OK PROBABLE CAUSE HAS NOT BEEN DETERMINED AT THIS TIME. (EA07200503884) (K) 1 H 7 1 3O NT 3A12 2005052400155 20050524 00155 NE 2005 5 24 2005FA0000645 2 20050429 G 7200 117M62G05 SEAL BOEING 777 777* UTILUSE NM GE GE90 GE9090B NE ENGINE DEBONDED D QEMY K NONE O OTHER IN INSP/MAINT 1 EA 35 900230 PART WAS PREVIOUSLY REPAIRED. REP REQUIRES USE OF BRAZE AMS 4777 OR SUITABLE TAPE ALTERNATIVE, USED TAPE SPEZ AMS 4779F , WITH OVEN TEMP 1050 DEGREES C. AMS 4779F DOES NOT MELT UNTIL 1068 DEGREES C. HONEYCOMB BECAME DISBONDED AND LIBERATE D CAUSLING HPT 1 BLADE OVERHEAT DISTRESS. BRAZE JOINT FAILED WITHIN 300 CYCLES. 2 L 7 2 4F 4 F RT T00001SE E00049EN 2005052400158 20050524 00158 SW 2005 5 24 2005FA0000646 1 20050414 G 2170 18391021 WATER SEPARATOR GULSTM 111 111RKWELL 0144601 SW INLET FLANGE CORRODED C EW7R K NONE O OTHER IN INSP/MAINT 1 EA 11 (WATER SEPARATOR) RECEIVED PAR, INCOMING INSPECTION REVEALS CORROSION AND PITTING AT NUMEROUS POSITIONS AROUND CIRCUMFER ENCE OF AIR INLET FLANGE. PART FAILED INCOMING INSPECTION. 8130-3 STATES PART IS AN OVERHAULED UNIT. W/O CERTIFIES PA RT AS AIRWORTHY. PART APPEARS TO HAVE CORROSION FOR CONSIDERABLE TIME. 1 L 7 1 3O A11SO 2005052400161 20050524 00161 2005 5 24 2005FA0000647 1 20050420 G 4920 BLADE HONEYWELL COMPRESSOR ROTOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 05 1824 031365103479 THIS IMPELLER HAS EXPERIENCED WHAT LOOKS LIKE HIGH CYCLE FATIGUE WITH A VERY LOW TT ON THE UNIT. IT APPEARS TO HAVE FA ILED DUE TO WHAT STARTED AS A FATIGUE CRACK AND RESULTED IN A LARGE PIECE OF THE IMPELLER COMING OFF. THIS IMPELLER AND ANOTHER WERE PURCHASED WITHIN 30 DAYS OF EACH OTHER AND HAVE SN THAT ARE 2 DIGITS OFF FROM THE OTHER. (K) 2005052400253 20050524 00253 EU 2005 5 24 2005FA0000648 1 20050328 G 2710 120A1186 HINGE GROB 120 G120A 1660208 EU RT AILERON CRACKED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 863AF 1947 85003 ON ROUTINE PHASE INSPECTION, MECHANIC FOUND HINGE ON RT AILERON TRIM TAB CRACKED AT ATTACH POINT FOR PUSH PULL ROD. CAU SE AT THIS TIME UNKNOWN, NO RECOMMENDATIONS AT THIS TIME. (K) 1 L 7 1 3O RT A49CE 2005052400254 20050524 00254 EU 2005 5 24 2005FA0000649 1 20050328 G 2710 120A1185 HINGE GROB 120 G120A 1660208 EU LT AILERON CRACKED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 867AF 1550 85007 ON ROUTINE INSPECTION, MECHANIC FOUND HINGE ON LT AILERON TRIM TAB CRACKED AT ATTACH POINT FOR PUSH PULL ROD. CAUSE AT THIS TIME UNKNOWN, NO RECOMMENDATIONS AT THIS TIME. (K) 1 L 7 1 3O RT A49CE 2005052400255 20050524 00255 EU 2005 5 24 2005FA0000650 1 20050328 G 2710 120A1185 HINGE GROB 120 G120A 1660208 EU LT AILERON CRACKED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 863AF 1947 85003 ON ROUTINE PHASE INSPECTION, MECHANIC FOUND HINGE ON LT AILERON TRIM TAB CRACKED AT ATTACH POINT FOR PUSH PULL ROD. CAU SE AT THIS TIME UNKNOWN, NO RECOMMENDATIONS AT THIS TIME. (K) 1 L 7 1 3O RT A49CE 2005052400294 20050524 00294 EU 2005 5 24 2005FA0000651 2 20050323 G 8530 21130 VALVE GUIDE REIMS 150 F150G 7530120 EU RROYCE O200 RRO200A EU MCAULY 1A100 1A100MCM GL ENGINE LEAKING C K NONE O OTHER IN INSP/MAINT 1 SW 99 HBCBK 0026 21R274 ENGINE PROCURED WITH -0- TSO AND CYLINDERS INSTALLED. AFTER 50 HOURS, REMOVED ALL CYLINDERS DUE TO EXCENTRIC VALVE GUID E BORE AND THEREFORE LEAKING STEM. AT 151 HOURS TSO, ALL CYLINDERS LOW COMPRESSION (53-67 PSI). INSPECTION REVEALED DA MAGED VALVE GUIDES AND CARBON TRACES ON PISTONS. 1 H 7 1 3O 3 O A13EU E31N 5 N P918 2005052400297 20050524 00297 CE 2005 5 24 2005FA0000652 1 20050503 G 3250 3219 PAWL CESSNA CESSNA 185 A185F 2072821 CE CONT O520 IO520* 17032 SO TAIL WHEEL STEER WORN C O OTHER F FLT CONT AFFECTED LD LANDING 1 GL 15 1767R 18502487 APPEARS THAT THE STEERING LOCK PAWL DID NOT ENGAGE SUFFICIENTLY TO LOCK THE TAIL WHEEL. UPON LANDING THE TAIL WHEEL CAS TORED. SWINGING THE AC TO THE RT AND OFF OF THE RUNWAY. AC SUSTAINED DAMAGE TO ITS LT WING. INVESTIGATION DISCLOSED T HAT THE TAIL WHEEL STEERING PAWL WAS WORN TO A POINT THAT IT WOULD NOT SUFFICIENTLY LOCK THE LOCKING COLLAR. REPORTERS CONCERN IS THAT WEAR OF THIS PIN IS NOT EASILY APPARENT EXCEPT THROUGH WRITE-UP BY A PILOT EXPERIENCED WITH THIS PROBLEM . VISUAL INSPECTION OF THE TAIL WHEEL ASSY WOULD NOT DISCLOSE THIS PROBLEM. (GL15200511027) (K) 1 H 7 1 3O 3 O 3A24 E5CE 2005052400298 20050524 00298 CE 2005 5 24 2005FA0000653 1 20050422 G 1430 AN52510 SCREW BEECH BEECH B300 B300 1159232 CE PWA PT6 PT6A60A 52043 NE FAIRING WRONG PART B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 768WT 4974 FL25 DURING SCHEDULED INSPECTION FOUND SCREWS ATTACHING AFT LOWER EDGES OF FORWARD WING ROOT FAIRINGS TO UNDERSIDE WING ROOT FAIRINGS TO BE OF EXCESSIVE LENGTH. SCREW TIPS HAD GOUGED LT AND RT LOWER FUSELAGE SKINS AT THE APPROXIMATE FS 166.300 LOCATION TO 0.020 INCH DEEP. HAVE NOTICED SIMILAR DAMAGE TO OTHER AC SAME LOCATION. REQUIRED DER APPROVED REPAIRS TO P RESSURIZED FUSELAGE SKINS. SUGGEST ANY TECHS INSPECTING THIS AREA PAY CLOSE ATTENTION FOR SCREW TIP DAMAGE, AND TO USE ONLY THE CORRECT LENGTH FAIRING ATTACH SCREWS. RECOMMEND A 1-TIME SB TO INSPECT AND EITHER MODIFY FAIRING ATTACHMENT OR PLACARD. 2 L 7 2 4T 4 T RT A24CE E4EA 2005052400299 20050524 00299 CE 2005 5 24 2005FA0000654 1 20050423 G 2720 1015300573 CONTROL CABLE BEECH B300 B300 1159232 CE PWA PT6 PT6A60A 52043 NE RUDDER LOOSE B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 768WT 4974 FL25 DURING SCHEDULED INSPECTION, FOUND CABLE QUADRANT FOR AUTOPILOT RUDDER SERVO LOOSE ON RUDDER TORQUE SHAFT ASSY. REPLAC ED LOOSE RIVETS W/NEXT SIZE LARGER RIVETS INSTALLED WET W/EA 9309 STRUCTURAL ADHESIVE IAW TECH SUPPORT RECOMMENDATIONS. RECOMMEND THIS AREA BE LOOKED AT CLOSELY ON AC AFTER ACCUMULATION OF 3000 HRS OR MORE. SUSPECT FATIGUE AND RUDDER SERV O TORQUE CAUSING RIVETS TO GRADUALLY LOOSEN. (K) 2 L 7 2 4T 4 T RT A24CE E4EA 2005052400300 20050524 00300 SO 2005 5 24 2005FA0000655 1 20050426 G 5340 FITTING PIPER PA18 PA18150 7101828 SO LYC O320 O320* 41508 EA FUSLEAGE CRACKED D K NONE O OTHER IN INSP/MAINT 1 AL 03 7054 9050 188915 DURING AN ANNUAL INSPECTION THE LT FRONT CABANE V ATTACH POINT ON THE FUSELAGE WAS FOUND TO BE CRACKED. THIS IS THE SEC OND AIRCRAFT IN THE LAST MONTH THAT WAS FOUND ON. THE LANDING GEAR WAS FOUND TO BE OK ON BOTH AC. BOTH AIRCRAFT OPERAT E ON WHEELS, SKIS AND FLOATS. (K) 1 H 7 1 3O 3 O 1A2 E274 2005052400301 20050524 00301 CE 2005 5 24 2005FA0000656 1 20050423 G 3210 124142312 SADDLE CESSNA 210 210E 2073416 CE CONT O520 IO520* 17032 SO MLG CRACKED C K NONE O OTHER IN INSP/MAINT 1 NM 02 4934U 21058634 REPLACED BOTH MLG SADDLES AT ANNUAL INSP. BOTH WERE FOUND TO HAVE HAIR LINE CRACKS IN RADIUS ABOVE IB V-BOLT HOLE USING DYE PENETRANT INSPECTION METHOD. (K) 1 H 7 1 3O 3 O 3A21 E5CE 2005052400302 20050524 00302 CE 2005 5 24 2005FA0000657 1 20050417 G 3220 35825110 BRACE BEECH BEECH 35 G35 1151516 CE CONT E225 E225* 17015 SO NOSE GEAR CORRODED D K NONE O OTHER IN INSP/MAINT 1 WP 07 52WR 3500 D4841 CORROSION PITS APPROXIMENTLY 30 TO 50 PERCENT OF WALL THICKNESS. THIS PART ONLY 10 PERCENT OF WALL THICKNESS ALLOWED BY MFG. THIS PART IS MAGNESUM. THE PITTING IS UNDER THE FLET 35, ABOVE THE LOWER BUSHING, THE FELT IS SATURATED WITH M OISTURE AND GREASE WHICH ALLOWS CORROSION TO ATTACH THE PART. (K) 1 L 7 1 3O 3 O A777 E267 2005052500038 20050525 00038 SO 2005 5 25 2005FA0000658 1 20050420 G 3230 6775300 SPRING PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360* 17025 SO MLG BROKEN B RO4R O OTHER O OTHER LD LANDING 1 WP 07 994BD 140 3449310 OPERATOR DID NOT GET RT MAIN GEAR DOWN INDICATION AFTER EXTENDING LANDING GEAR USING EMERGENCY EXTENSION. AIRCRAFT LAND ED WITHOUT INCIDENT. RT MAIN GEAR OVER-CENTER SPRING ATTACH PLATE WAS FOUND BROKEN. WITH THE HYDRAULIC PUMP DISABLED FO R THE GEAR EXTENSION, THE OVERCENTER BRACE DOWNLOCK HOOK WAS NOT ENGAGED AND THE GEAR WAS NOT LOCKED DOWN AND THE POSITI ON SWITCH WAS NOT ACTIVATED. FURTHER INSPECTION FOUND THAT THE SPRING USED PUTS A TORQUE LOAD ON THE MAIN GEAR ATTACH P LATE CAUSING IT TO TWIST AND SUBSEQUENTLY BREAK. INSPECTION OF THE SAME PLATE ON THE LT MAIN GEAR REVEALED THAT THE SAM E CONDITION EXISTS AND THAT THE SPRING ATTACH PLATE HAS BEGUN TO BEND IN THE SAME AREA. (K) 1 L 7 2 3O 3 O A7SO E9CE 2005052500069 20050525 00069 WP 2005 5 25 2005FA0000662 2 20050423 G 7310 8975131 FUEL FILTER RAYTHN DH125 HAWKER800XP 7150012 CE GARRTT TFE731 TFE731* 01518 WP ENGINE RESTRICTED B E81R A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 GL 03 725TA 258297 CREW REPORTED, 55 MIN INTO FLIGHT, DURING CRUISE AT FL350, NR1 ENGINE (ENG FUEL) ANNUNCIATOR ILLUMINATED. LIGHT EXTINGU ISHED WHEN POWER REDUCED BELOW 90 PERCENT N1. REQUIRED FURTHER POWER REDUCTIONS TO FLIGHT IDLE TO KEEP LIGHT EXTINGUISH ED. DIVERTED FLIGHT, DISCREPANCY VERIFIED AT ARRIVAL. REPLACED ENG FUEL FILTER AND PERFORMED PRECAUTIONARY DRAINING OF WING FUEL TANK SUMPS. NO REPEAT OF FAULT AFTER 45 MINUTES OF EXTENDED GROUND RUNNING AT VARIOUS POWER SETTINGS. REMOV ED FILTER RETURNED TO MAINT FACILITY FOR FURTHER DETAILED INSP. (K) 2 L 7 2 4F 4 F RT A3EU E6WE 2005052500070 20050525 00070 WP 2005 5 25 2005FA0000663 2 20050423 G 7310 8975131 FUEL FILTER RAYTHN DH125 HAWKER800XP 7150012 CE GARRTT TFE731 TFE7315BR WP ENGINE RESTRICTED B E81R K NONE J WARNING INDICATION IN INSP/MAINT 1 GL 03 725TA 258297 P107152 DURING APPROACH, DIVERT REQUIRED FOR NR1 ENGINE (ENG FUEL) ANNUNCIATOR LIGHT ILLUMINATION, GO-AROUND WAS REQUIRED FOR TR AFFIC. DURING GO-AROUND NON FLYING PILOT OBSERVED FICKERING NR2 ENGINE (ENGINE FUEL) ANNUNCIATOR LIGHT INDICATION. VER IFIED DISCREPANCY UPON ARRIVAL AT MAINTENANCE. REPLACED NR2 ENGINE HP FUEL PUMP FILTER AND DRAINED WING FUEL TANK SUMPS . NO FAULT RETURN NOTED DURING 45 MINUTE EXTENDED GROUND RUN AT VARIOUS POWER SETTINGS. REMOVED FILTER RETURNED TO OPE R MAINT FOR FURTHER DETAILED INSP. (K) 2 L 7 2 4F 4 F RT A3EU E6WE 2005052500072 20050525 00072 CE 2005 5 25 2005FA0000664 1 20050422 G 2435 23080050 STARTER GEN BEECH MU300 400A 1155402 CE ENGINE INOPERATIVE B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 480LX 271 RK398 INVESTIGATED PILOT REPORT OF LT ENGINE NOT ROTATING WHEN STARTER BUTTON DEPRESSED. FOUND STARTER GEN NOT ROTATING WITH POWER APPLIED. REPLACED STARTER GEN WITH OVERHAULED UNIT IAW MM. ENGINE START AND GENERATOR OPERATIONS NORMAL. TRANSI ENT AIRCRAFT AT OFF-SITE FACILITY, NO MAINT RECORDS AVAILABLE. UNIT TO BE INSPECTED AND TORN DOWN FOR INVESTIGATION. (K ) 2 H 7 2 4F RT A16SW 2005052500113 20050525 00113 2005 5 25 2005FA0000665 1 20050309 G 3350 BATTERY EMERGENCY LIGHT WRONG PART B JGVR O OTHER O OTHER NR NOT REPORTED 1 CE 09 UNIT CONTAINS 24 NICAD CELLS IN PLACE OF THE 12 LEAD ACID CELLS THAT BELONG IN IT. THE HIGHER VOLTAGE APPEARS TO HAVE B URNED UP THE CELL SWITCH BLOCK. NICAD CELLS ARE NOT AN APPROVED REPLACEMENT CELL FOR THIS UNIT. (K) 2005052500121 20050525 00121 EU 2005 5 25 2005FA0000668 1 20050418 G 2910 NAS16124 O-RING ISRAEL 1124 1124 4500102 EU GARRTT TFE731 TFE731* 01518 WP RESERVOIR DEFECTIVE B AR2R K NONE O OTHER IN INSP/MAINT 1 SW 15 711KE 2182 288 FOLLOWING MAINT TROUBLESHOOTING OF HYD SYS. IT WAS FOUND TO HAVE DEFECTIVE O-RING JUST AFT OF THE HYD RESERVOIR AT A T- FITTING LOCATION. DEFECTIVE O-RING DEPLEATED HYDRAULIC RESERVOIR RUNNING HYDRAULIC SYS OUT OF FLUID. THIS CAUSED THE R T ENGINE DRIVEN HYD PUMP TO CAVITATE AND DAMAGED PUMP INTERNALLY. O-RING WAS REPLACED WITH A NEW O-RING, AND ENGINE DRI VEN HYD PUMP WAS REPLACED. SYS WAS SERVICED AND OP FUNCTION CHECKED AND LEAK CHECKED WITH NO OTHER DISCREPANCIES NOTED. MAINTENANCE CARE WHEN WORKING WITH HYD O-RINGS. SUSPECT O-RING FAILURE DUE TO NORMAL DETERIORATION AND OR IMPROPER I NSTALLATION AT TIME OF LAST MAINT FUNCTION PERFORMED TO THAT FITTING. (K) 2 M 7 2 4F 4 F A2SW E6WE 2005052500122 20050525 00122 SO 2005 5 25 2005FA0000670 2 20050426 G 7261 653814 GEAR PIPER PA12 PA12 7101202 SO CONT O360 TSIO360KB 17025 SO OIL PUMP BROKEN B YYBR K NONE O OTHER IN INSP/MAINT 1 GL 03 92732 1547 12168 L113768A ENGINE LOST POWER FOR UNKNOWN REASONS. ENGINE WAS DISASSEMBLED AND INSPECTED. INVESTIGATION FOUND BROKEN DRIVE DOGS ON THE OIL PUMP GEAR, AS WELL AS GEAR TEETH ON THE CRANKSHAFT GEAR AND OUTSIDE DIAMETER OF THE CAM GEAR. THE REASON FOR T HE FAILURE OF THE OIL PUMP GEAR IS UNKNOWN. I DO NOT BELIEVE THE OIL PUMP PROBLEM CAUSED THE TEETH OF THE OTHER GEARS T O BRAKE. I WOULD BE REMISS IN RECOMMENDING A COURSE OF PREVENTIVE ACTION DUE TO THE LACK OF CAUSAL FACTOR OF THIS OCCUR RENCE. (K) 1 H 7 1 3O 3 O A780 E9CE 2005052300288 20050523 00288 CE 2005 5 23 2005FA0000671 1 20050502 G 3220 1018200741 FORK BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL NLG CRACKED B K NONE O OTHER IN INSP/MAINT 1 SO 25 678SS 6607 150 BB1021 FOUND CRACKED NOSE FORK TUBE AT LOWER WELD AREAS WHILE PERFORMING AD 2004-23-02, DURING ROUTINE PHASE INSPECTION. FORK W AS REPLACED WITH MFG KIT NR 101-8030-1, SN 2463. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2005052500128 20050525 00128 EA 2005 5 25 2005FA0000672 2 20050406 G 8520 75038 CRANKSHAFT PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA ENGINE FAILED B YYBR K NONE O OTHER IN INSP/MAINT 1 GL 03 54231 1400 277554025 ENGINE WAS DISASSEMBLED AND INSPECTED DUE TO CRANKSHAFT FAILURE. FOUND NR3 CHEEK BROKEN. THIS FAILURE CAUSED EXCESSIVE DAMAGE TO THE CRANKCASE, CAMSHAFT, NR1 AND NR 2 CONNECTING ROD, AND THE ASSOCIATED TAPPET BODIES. CAUSE OF THE FAILURE COULD POSSIBLY BE A METALLURGIC DEFECT OR A FORM OF FATIGUE. WITHOUT ACCESS TO A LABORATORY FOR EXTENSIVE TESTING WE C AN NOT ACCURATELY CONCLUDE WHAT CAUSED THIS FAILURE OR HOW LONG THIS DEFECT HAD BEEN PRESENT AT THE TIME OF FAILURE. DU E TO THE LACK OF CONCLUSIVE CAUSE WE WOULD BE REMISS IN SPECULATING THE REMEDY FOR THIS EVENT. (K) 1 L 7 2 3O 3 O 1A10 1E4 2005052500138 20050525 00138 SO 2005 5 25 2005FA0000674 1 20050111 G 3220 40336000 LINK PIPER PA31 PA31350 7103110 SO LYC O540 TIO540* 41532 EA NLG CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 05 4093W 318152176 INSPECTED NOSE GEAR DRAG LINKAGE RETRACT ROD ATTACHMENT AREA IAW SL AND FOUND CRACK USING DYE PENETRANT INSP. (K) 1 L 7 2 3O 3 O A20SO E14EA 2005052500139 20050525 00139 EA 2005 5 25 2005FA0000675 2 20050103 G 7230 COMPRESSOR BEECH 99 99A 1154003 CE PWA PT6 PT6A27 52043 EA LT ENGINE STALLED D E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 GL 13 599CZ U89 LT ENGINE PRODUCED A SERIES OF SOUNDS INDICATIVE OF COMPRESSOR STALL WHEN LEVELED AT FL190. TORQUE RAPIDLY DIMINISHED A ND TEMPERATURE ROSE. PILOT SHUTDOWN ENGINE AS A PRECAUTION. ENGINE REMOVED AND SENT FOR ANALYSIS. (K) 1 L 7 2 3T 4 T A14CE E4EA 2005052500179 20050525 00179 SW 2005 5 25 2005FA0000680 1 20050129 G 2510 140216501 BELLCRANK MOONEY M20 M20M 5870222 SW LYC O540 TIO540* 41532 EA PILOT SEAT CRACKED B K NONE O OTHER IN INSP/MAINT 1 EA 23 1085K 2024 270035 PILOT SEAT HEIGHT ADJUST BELL CRANK CRACKED AND SPLIT OPEN ON RT SIDE. THIS CAUSED SEAT TO LEAN DOWN TO THE RT. CRACK APPEARS TO START AT A WELD ON THE END OF THE TUBE. CRACK CONTINUED IN SPIRAL TOWARD ACTUATOR ATTACH POINT. OPPOSITE EN D OF TUBE BENT AND BINDING. ACTUAL ITEM FAILED IS THE WELDED ARM ASSY. THIS CAUSED THE OTHER 2 PART IN THE ASSEMBLY, T UBE AND BEARINGS TO BE DAMAGED. (EA23200505225) (K) 1 L 7 1 3O 3 O RT 2A3 E14EA 2005052500181 20050525 00181 GL 2005 5 25 2005FA0000682 1 20050103 G 7921 AD36 OIL COOLER AMTR AMD ALARUSCH2T 0033001 GL LYC O235 O235L2A 41505 EA ENGINE CRACKED G A UNSCHED LANDING J WARNING INDICATION NR NOT REPORTED 1 NM 07 215LF 87 201032 ENROUTE, DIVERTED, AFTER REPORTING AN OIL PRESSURE PROBLEM. AIRCRAFT OIL COOLER DEVELOPED LEAK, LANDED AS A PRECAUTIONA RY MEASURE. REMOVED AND REPAIRED OIL COOLER. (NM07200502583) (K) 1 L 7 1 3 O EXPA1L71 E223 2005052500197 20050525 00197 NE 2005 5 25 2005FA0000686 2 20050110 G 7421 IGNITER GE CF700 CF7002D2 30010 NE ENGINE DAMAGED B I2VR K NONE O OTHER IN INSP/MAINT 1 CE 03 249J048 IGNITER WOULD NOT THREAD INTO ENGINE LOSS DURING O/H ASSEMBLY. 1ST THREAD SHOWS DAMAGE AND FURTHER EXAMINATION SHOWS TH READ DIAMETER IS .003 INCH-.004 INCH LARGER THAN THE OTHER NEW IGNITER INSTALLED ON THIS ENGINE. THE UNDAMAGED IGNITER WAS CHECK-THREADED INTO BOTH ENGINE BOSSES WITH NO PROBLEMS. RECOMMMEND CAREFUL CONDITION CHECKS. (K) 4 F E7EA 2005052500198 20050525 00198 2005 5 25 2005FA0000687 4 20050104 G 3424 1394T10010RA INDICATION SYS CESSNA 206 206H 2073301 CE LYC O540 IO540* 41532 EA TURN COORDINATOR INOPERATIVE B S1FR O OTHER N FALSE WARNING CR CRUISE 1 SO 33 962AC 20608057 UNIT WAS INSTALLED IN AIRCRAFT ON 12/20/2004. AFTER APPROX .5 HOURS, PILOT OBSERVED TURN COORDINATOR OFF FLAG, MOMENTS LATER AUTOPILOT DISENGAGED. THIS UNIT REPLACED AN EARLIER INSTALLED OVERHAULED UNIT INSTALLED 7/04. (K) 1 H 7 1 3O 3 O RT A4CE 1E4 2005052500202 20050525 00202 EU 2005 5 25 2005FA0000691 1 20050112 G 3260 120A5191 UPLOCK GROB 120 G120A 1660208 EU LYC O540 AEIO540D4D5 EA MLG INTERMITTENT B VJ3R O OTHER O OTHER CR CRUISE 1 WP 07 862AF 85002 DURING FLIGHT, GEAR SELECTED TO DOWN AND LT MAIN GEAR EXTENSION WAS DELAYED. AFTER ABOUT 25 SECONDS LT MAIN GEAR EXTEND ED. MAINTENANCE TECHNICIAN FOUND LT LANDING GEAR UP LOCK ASSY WAS INTERMITTENT. REPLACED ASSY. NO RECOMMENDATION AT T HIS TIME. (K) 1 L 7 1 3O 3 O RT A49CE 1E4 2005052500203 20050525 00203 CE 2005 5 25 2005FA0000692 1 20050119 G 2701 05117816 CONTROL COLUMN CESSNA 172 172H 2072424 CE CONT O300 O300* 17022 SO COCKPIT CORRODED D K NONE O OTHER IN INSP/MAINT 1 CE 01 2881L 17256081 WHILE ACCOMPLISHING SEB ON CONTROL YOKE, FOUND WATER WHEN INSP HOLE WAS DRILLED AT BASE OF CENTER TUBE. .2500 CUP OF BL ACK RESIDUE WAS FOUND WHEN TUBE WAS CUT OPEN. INSIDE OF CONTROL YOKE TUBE WAS RUSTED MODERATELY THE FULL LENGTH OF CENT ER TUBE. NO LEAK IN FIREWALL OR WINDSHIELD WERE FOUND TO ACCOUNT FOR WATER ENTRY. AC WAS PURCHASED DISASSEMBLED 12 YEA RS AGO, POSSIBLY WATER WAS INTRODUCED AT THAT TIME. INSTALLED SERVICEABLE YOKE AND ACCOMPLISHED SEB SUCCESSFULLY. (CE01 200502663) (K) 1 H 7 1 3O 3 O NT 3A12 E253 2005052500204 20050525 00204 2005 5 25 2005FA0000693 4 20050105 G 6122 O20887 DRIVE GEAR MCAULY GULSTM 114 114TC 0145002 SW LYC O540 TIO540* 41532 EA MCAULY 3D32C B3D32C417 GL FLYWEIGHT SHEARED B W59R O OTHER O OTHER TX TAXI/GRND HDL 1 WP 07 77HK 1200 970719 20020 GOVERNOR FAILED TO CYCLE PROP DURING RUN-UP. AT DISASSEMBLY OF GOVERNOR, GEAR WAS FOUND SHEARED AT THE VALVE SLOTS, JUS T UNDER FLYWEIGHT ASSY. IT APPEARS AS THOUGH THE DRIVE GEAR SEIZED IN THE GOVERNOR BODY ABOVE THE SLOTS. CAUSE UNKNOWN . (K) 1 L 7 1 3O 3 O RT A12SO E14EA 5 C P58GL 2005052600087 20050526 00087 CE 2005 5 26 2005FA0000700 2 20050107 G 7414 01040158 MAGNETO CIRRUS SR SR20 05628AJ GL CONT IO360 IO360* 17025 CE ENGINE SHORTED B BJFR K NONE O OTHER IN INSP/MAINT 1 EA 23 6300B 602 1157 ON A 500 HOUR MAGNETO INSPECTION, FOUND MAGNETO SPARKING INTERNALLY. AC RAN GOOD AND HAD A 100 RPM MAG DROP. INTERNAL SPARKING WAS BETWEEN COIL AND CARBON BRUSH. BRUSH AND SPRING DESTROYED AND PART OF DISTRIBUTOR BLOCK MISSING. RECOMMEN D MANDATORY INTERNAL INSPECTION OF MAGNETOS DURING ANNUAL. NEED TO ADD FARS. (K) 1 L 7 1 3O 3 O NT A00009CH E1CE 2005052600088 20050526 00088 SO 2005 5 26 2005FA0000701 1 20050105 G 3246 1159SCL20343 WHEEL GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6108 NE LT MLG DAMAGED B O OTHER O OTHER NR NOT REPORTED 1 WP 19 44CE 162 1125 UPON LANDING, THE LT IB WHEEL FAILED AT THE FLANGE AREA. APPROX .3333 OF THE FLANGE AREA BROKE AWAY AND ALLOWED THE LOC K RING. (STILL INTACT AND SAFETIED), TO SEPARATE. DEBRIS, (FLANGE OR WHEEL HALF) CROSSED OVER AND HIT THE RT IB WHEEL, GLANCED UP AND PUNCTURED THE RT WING TRAILING EDGE BOX, (COMPOSITE MATERIAL) AND THE TIRE MADE CONTACT WITH THE RT WING FLAP AND DENTED THE IB END OF IT. NOTE: THE WING T/E BOX IS NOT PART OF THE FUEL TANK. IT IS FOR AERODYNAMIC FAIRING OF THE WING. (WP19200504331) (K) 2 L 7 2 4F 4 F RT A12EA E25NE 2005052600109 20050526 00109 CE 2005 5 26 2005FA0000705 1 20050112 G 3200 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO DYNAMIC BRAKE INTERMITTENT B VJ3R O OTHER O OTHER LD LANDING 1 WP 07 5585Y 120 CE1389 830091R PILOT SELECTED GEARDOWN AND NOTHING HAPPENED. LANDING GEAR WOULD NOT EXTEND. FLIGHT CREW EXTENDED LANDING GEAR MANUALL Y AND LANDED WITHOUT INCIDENT. MAINTENANCE TECH TROUBLESHOT GEAR SYSTEM AND FOUND THE DYNAMIC BRAKE RELAY WAS INTERMITT ENT. RECOMMENDATION IS FOR MFG TO INVESTIGATE THIS ISSUE WHICH HAS HAPPENED ON SEVERAL OCCASIONS AND COME UP WITH AN IM PROVED RELAY THAT IS MORE RELIABLE. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005052600117 20050526 00117 CE 2005 5 26 2005FA0000706 1 20050113 G 3240 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO DYNAMIC BRAKER INTERMITTENT B VJ3R A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 WP 07 5582X 527 CE1353 825984R PILOT SELECTED GEAR UP AND NOTHING HAPPENED. STILL INDICATING (3) GREEN LIGHTS LANDING GEAR WOULD NOT RETRACT. MAINTEN ANCE TECH TROUBLESHOT GEAR SYSTEM AND FOUND THAT THE DYNAMIC RELAY WAS INTERMITTENT. NO RECOMMENDATION AT THIS TIME. (K ) 1 L 7 1 3O 3 O 3A15 E5CE 2005052600118 20050526 00118 CE 2005 5 26 2005FA0000707 1 20050108 G 3240 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO DYNAMIC BRAKER INTERMITTENT B VJ3R O OTHER J WARNING INDICATION LD LANDING 1 WP 07 5544A 100 100 CE1343 PILOT SELECTED GEAR DOWN AND NOTHING HAPPENED, BEFORE PILOT COULD COMPLETE HIS CHECK LIST TO CRANK GEAR DOWN, THE GEAR W ENT DOWN ON ITS OWN. AIRCRAFT RETURNED TO BASE. UPON FURTHER TROUBLESHOOTING FOUND RELAY WAS INTERMITTENT, PORBABLE CA USE AT THIS TIME UNKNOWN. THIS IS SUPPOSE TO BE AN IMPROBED RELAY SO THERE IS NO RECOMMENDATION AT THIS TIME. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005053100010 20050531 00010 CE 2005 5 31 2005FA0000710 1 20050430 G 3222 35825110 BRACE BEECH 35 K35 1151524 CE CONT O470 IO470* 17026 SO NLG CORRODED B F5GR K NONE O OTHER IN INSP/MAINT 1 WP 07 826R 5940 D6153 CORROSION PITS APPROXIMATELY 30 TO 50 PERCENT OF WALL THICKNESS. THIS PART ONLY 10 PERCENT OF WALL THICKNESS ALLOWED BY MFG. THIS PART IS MAGNESIUM. THE PIRTING IS UNDER THE FEL 35, ABOVE THE LOWER BUSHING, THE FELT IS SATURATED WITH MOI STURE AND GREASE WHICH ALLOWS CORROSION TO ATTACK THE PART. (K) 1 L 7 1 3O 3 O 3A15 E1CE 2005052600127 20050526 00127 SO 2005 5 26 2005FA0000711 1 20050512 G 2820 FITTING PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA FUEL PUMP CRACKED C K NONE O OTHER IN INSP/MAINT 1 SO 11 975DC 20 20 317812059 RL829961A FUEL LINE FITTING CRACKED AT THE INLET TO THE FUEL PUMP. CRACK WAS LOCATED IN THE BEND RADIUS (45 DEGREE FITTING)OF A S TRATOFLEX HOSE ASSEMBLY. FUEL WAS SPRAYING FROM THE FITTING AFT TOWARDS THE TURBO AND CAUSED AN ENGINE FIRE IN FLIGHT, LT ENGINE. 1 L 7 2 3O 3 O A20SO E14EA 2005053100047 20050531 00047 EA 2005 5 31 2005FA0000713 2 20050426 G 8500 R182097 ENGINE BOEING B17 B17G 1380204 WP WRIGHT R1820 R182097 67020 EA NR 4 FAILED D E ENGINE SHUTDOWN J WARNING INDICATION TO TAKEOFF 1 WP 23 3703G 46 4483546A 046778 UPON TAKEOFF, NOTICED STEADY DROP IN ENGINE OIL PRESSURE. SHUT ENGINE DOWN AT MIN OIL PRESSURE. PRESSURE STILL DECREAS ING. CHECKED SCREENS AND OIL PRESSURE VALVE ON GROUND. COULD NOT GET ENGINE TO MAKE MIN ACCEPTABLE PRESSURE. REMOVED ENGINE. UPON REMOVAL OF PROP, BRONZE OR BRASS WAS IN PROP SHAFT. (K) 2 L 7 4 4R 4 R L13 5E10 2005053100048 20050531 00048 EA 2005 5 31 2005FA0000714 2 20050426 G 8500 R182097 ENGINE BOEING B17 B17G 1380204 WP WRIGHT R1820 R182097 67020 EA NR 2 FAILED D K NONE O OTHER LD LANDING 1 WP 23 3703G 42 4483546A ON FINAL, ENGINE WAS PRODUCING LOW OIL PRESSURE. UPON LANDING, CHECKED SCREENS, OK, CLEANED OIL PRESSURE RELIEF VALVE A ND APU FOR MAX OIL PRESSURE WAS STILL LOW. COULD NOT GET ENGINE TO PRODUCE ACCEPTABLE OIL PRESSURE. REMOVED ENGINE. ( K) 2 L 7 4 4R 4 R L13 5E10 2005053100049 20050531 00049 2005 5 31 2005FA0000715 4 20050421 G 6122 D20880 RETAINER MCAULY LYC O540 IO540* 41532 EA PROP GOVERNOR DAMAGED B GCDR K NONE O OTHER IN INSP/MAINT 1 SO 17 345 001989 FLYWEIGHT RETAINING DISC, DAMAGED. (K) 3 O 1E4 2005053100057 20050531 00057 CE 2005 5 31 2005FA0000716 1 20050420 G 3230 UNKNOWN LEAR 60 60LEAR 5170707 CE PWA 305 PW305 NE NLG MALFUNCTIONED B WVER A UNSCHED LANDING O OTHER CL CLIMB 1 EA 09 797PA 098 DURING DEPARTURE, AFTER MAINTENANCE (ENGINE AND THRUST REVERSER) THE NOSE LANDING GEAR DID NOT RETRACT. THE AC RETURNED TO DEPARTURE FOR REPAIR. PROBABLE CAUSE: THE AC WAS JACKED, THE LANDING GEAR WAS FUNCTIONALLY TESTED IAW MM. THE DIS CREPANCY COULD NOT BE DUPLICATED. SUSPECTED AN AIR LOCK IN THE NOSE LANDING GEAR RETRACTION SYSTEM. A CHECK FLIGHT WAS PERFORMED WITHOUT FURTHER INCIDENT. (EA09200504998) (K) 2 L 7 2 4F 4 F RT A10CE E35NE 2005053100058 20050531 00058 CE 2005 5 31 2005FA0000717 1 20050425 G 5755 24920016 SPOILER PANEL LEAR 60 60LEAR 5170707 CE PWA 305 PW305A 52128 NE RT WING MISMANUFACTURED B WVER K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 09 246FX 183 SPOILER PANEL ASSEMBLY WAS FOUND TO BE WARPED DURING TRIM TO FIT AIRCRAFT IAW SB. PROBABLE CAUSE: MFG ERROR. MFG WILL EVALUATE AND MAKE CHANGE. (EA09200505066) (K) 2 L 7 2 4F 4 F RT A10CE E35NE 2005053100059 20050531 00059 NE 2005 5 31 2005FA0000718 2 20050420 G 7230 1B6509 BLADE PWA PWA 2037 F117PW100 NE ENGINE FRACTURED B PQBR K NONE O OTHER IN INSP/MAINT 1 NE 03 7626 B70312 SUBJECT ENGINE WAS RECEIVED FOR PROACTIVE NIB 10/11TH STATOR REMOVAL. DURING INSPECTION, ONE 9TH STAGE HPC BLADE WAS FO UND FRACTURED WITH APPROX 1.140 LENGTH OF THE BLADE MISSING. THIS IS FIRST SHOP VISIT FOR THE ENGINE. (K) 4 T E17NE 2005052400068 20050524 00068 SO 2005 5 24 2005FA0000719 1 20050502 G 8011 653074A41R ADAPTER PIPER PA34 PA34220T 7103420 SO CONT O360 IO360KB 17025 SO MCAULY 3AF32C 3AF32C508 GL ZONE 500 CRACKED C K NONE O OTHER IN INSP/MAINT 1 GL 09 9267W 1378 1378 3447016 811456 011308 STARTER ADAPTER ASSEMBLY BOLT FLANGE CRACKED AT E THE 10 O'CLOCK POSITION. HOUSING UNIT DOES NOT MATCH STARTER ADAPTER ACCESSORY CASE FOOTPRINT (OVERLAYS), RESULTING IN DIMINISHED LOAD AND VIBRATION DISTRIBUTION. 1 L 7 2 3O 3 O A7SO E1CE 5 C P22EA 2005052400061 20050524 00061 SO 2005 5 24 2005FA0000720 1 20050502 G 8011 653074A41R ADAPTER PIPER PA34 PA34220T 7103420 SO CONT O360 IO360KB 17025 SO MCAULY 3AF32C 3AF32C508 GL STARTER CRACKED C K NONE O OTHER IN INSP/MAINT 1 GL 09 9267W 1378 1378 3447016 811456 011308 STARTER ADAPTER ASSEMBLY BOLT FLANGE CRACKED AT E THE 10 O'CLOCK POSITION. HOUSING UNIT DOES NOT MATCH STARTER ADAPTER ACCESSORY CASE FOOTPRINT (OVERLAYS), RESULTING IN DIMINISHED LOAD AND VIBRATION DISTRIBUTION. 1 L 7 2 3O 3 O A7SO E1CE 5 C P22EA 2005052400062 20050524 00062 SO 2005 5 24 2005FA0000721 1 20050502 G 8011 653074A41R ADAPTER PIPER PA34 PA34220T 7103420 SO CONT O360 IO360KB 17025 SO MCAULY 3AF32C 3AF32C508 GL STARTER CRACKED C K NONE O OTHER IN INSP/MAINT 1 GL 09 9267W 1378 1378 3447016 811456 011308 STARTER ADAPTER ASSEMBLY BOLT FLANGE CRACKED AT E THE 10 O'CLOCK POSITION. HOUSING UNIT DOES NOT MATCH STARTER ADAPTER ACCESSORY CASE FOOTPRINT (OVERLAYS), RESULTING IN DIMINISHED LOAD AND VIBRATION DISTRIBUTION. 1 L 7 2 3O 3 O A7SO E1CE 5 C P22EA 2005052400063 20050524 00063 SO 2005 5 24 2005FA0000722 1 20050502 G 8011 653074A41R ADAPTER PIPER PA34 PA34220T 7103420 SO CONT O360 IO360KB 17025 SO MCAULY 3AF32C 3AF32C508 GL ZONE 500 CRACKED C K NONE O OTHER IN INSP/MAINT 1 GL 09 9267W 1378 1378 3447016 811456 011308 STARTER ADAPTER ASSEMBLY BOLT FLANGE CRACKED AT E THE 10 O'CLOCK POSITION. HOUSING UNIT DOES NOT MATCH STARTER ADAPTER ACCESSORY CASE FOOTPRINT (OVERLAYS), RESULTING IN DIMINISHED LOAD AND VIBRATION DISTRIBUTION. 1 L 7 2 3O 3 O A7SO E1CE 5 C P22EA 2005053100068 20050531 00068 GL 2005 5 31 2005FA0000723 1 20050503 G 7810 15070001 EXHAUST HEADER CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 13 224ST 301 0882 DURING AN ANNUAL INSPECTION OF THIS AC. THE NR5 EXHAUST HEADER WAS FOUND TO BE CRACKED .7500 WAY AROUND THE CIRCUMFEREN CE OF THE PIPE. NR 5 EXHAUST HEADER WAS REPLACED. (K) 1 L 7 1 3O 3 O NT A00009CH E3SO 2005053100069 20050531 00069 SO 2005 5 31 2005FA0000724 1 20050503 G 2140 PRESSURE SWITCH PIPER PA31 PA31350 7103110 SO CABIN HEAT FAILED D K NONE O OTHER IN INSP/MAINT 1 EA 17 130BV 317952216 PERFORMING AD ON THE AFFECTED HEATER IAW SB A-103. UPON COMPLETION OF THE PRESSURE DECAY TEST, PERFORMED AND OPS TEST O F AIR PRESSURE SWITCH. FOUND THE SWITCH FAILED IN A CONTACT CLOSED CONDITION. UPON REMOVING THE SWITCH, NOTICED IT WAS A 94E42-1 SWITCH. THIS IS THE PN THAT (ACCORDING TO SB A-103) HAS BEEN REDESIGNED TO ELIMINATE THE NOTED FAILURE MODE OF OLD SWITCH AND UPGRADE OLDER TECHNOLOGY HEATERS.(K) 1 L 7 2 3O A20SO 2005053100070 20050531 00070 CE 2005 5 31 2005FA0000725 1 20050501 G 8011 ES6462751 STARTER BEECH 35 E35 1151512 CE CONT E225 E225* 17015 SO ENGINE INOPERATIVE B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 7312B D3775 STARTER INOPERATIVE. (K) 1 L 7 1 3O 3 O A777 E267 2005052400008 20050524 00008 EU 2005 5 24 2005FA0000726 1 20050503 G 2780 1075D1003 FCU ISRAEL 1125 ASTRASPX 4500205 EU GARRTT TFE731 TFE73140 29001 NE ZONE 900 OUT OF TOLERANCE Z D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 WP 29 B2001 22 119 THE SLATS FAILED TO EXTEND WHILE PILOTS WERE PERFORMING THE INSPECTIONS BEFORE TAKE-OFF. THE SLATS LOCKED OUT WHILE MEC HANIC PLACED THE FLAP/SLAT SELECTOR TO DN POSITION. SLAT UNBALANCE LIGHT CAME ON SIMULTANEOUSLY. TROUBLE SHOOTING FOUND THE FSECU OUTPUT VOLTAGE WAS OUT OF TOLERANCE. 2 L 7 2 4F 4 F RT A16NM E1NM 2005053100071 20050531 00071 EA 2005 5 31 2005FA0000727 2 20050501 G 8520 LIFTER CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA ENGINE SPALLED C WS9R K NONE O OTHER IN INSP/MAINT 1 NM 07 733ZK 17268677 L297076 LIFTERS SPALLED ON 5/7/2005, BUT NO DAMAGE TO THE CAMSHAFT AT THAT TIME. 2/16/2005 LIFTERS SPALLED AGAIN CAUSING THE CA MSHAFT TO NEED REPLACEMENT. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2005052400064 20050524 00064 SO 2005 5 24 2005FA0000728 1 20050502 G 8011 653074A41R ADAPTER PIPER PA34 PA34220T 7103420 SO CONT O360 IO360KB 17025 SO MCAULY 3AF32C 3AF32C508 GL ZONE 500 CRACKED C K NONE O OTHER IN INSP/MAINT 1 GL 09 9267W 1378 1378 3447016 811456 011308 STARTER ADAPTER ASSEMBLY BOLT FLANGE CRACKED AT E THE 10 O'CLOCK POSITION. HOUSING UNIT DOES NOT MATCH STARTER ADAPTER ACCESSORY CASE FOOTPRINT (OVERLAYS), RESULTING IN DIMINISHED LOAD AND VIBRATION DISTRIBUTION. 1 L 7 2 3O 3 O A7SO E1CE 5 C P22EA 2005052400065 20050524 00065 SO 2005 5 24 2005FA0000729 1 20050502 G 8011 653074A41R ADAPTER PIPER PA34 PA34220T 7103420 SO CONT O360 IO360KB 17025 SO MCAULY 3AF32C 3AF32C508 GL ZONE 500 CRACKED C K NONE O OTHER IN INSP/MAINT 1 GL 09 9267W 1378 1378 3447016 811456 011308 STARTER ADAPTER ASSEMBLY BOLT FLANGE CRACKED AT E THE 10 O'CLOCK POSITION. HOUSING UNIT DOES NOT MATCH STARTER ADAPTER ACCESSORY CASE FOOTPRINT (OVERLAYS), RESULTING IN DIMINISHED LOAD AND VIBRATION DISTRIBUTION. 1 L 7 2 3O 3 O A7SO E1CE 5 C P22EA 2005052400037 20050524 00037 CE 2005 5 24 2005FA0000730 1 20050503 G 3411 651447411 STATIC LINE CESSNA 500 550 2076604 CE PWA 530 PW530A NE CHAFED B K NONE O OTHER IN INSP/MAINT 1 GL 09 669B 890 5501060 ALTERNATE STATIC LINE CHAFED THROUGH IN CO-PILOTS SIDEWALL IN COCKPIT. REPLACED LINE WITH NEW BUT THE LOCATION IS VERY DIFFICULT TO PREVENT CONTINUED CHAFING. RECOMMEND MFG LOOK AT THIS AREA AND POSSIBLE REROUTING. 1 L 7 2 4F 4 F A22CE E00053EN 2005052400038 20050524 00038 CE 2005 5 24 2005FA0000731 1 20050503 G 3411 651447411 STATIC LINE CESSNA 500 550 2076604 CE PWA 530 PW530A NE CHAFED B K NONE O OTHER IN INSP/MAINT 1 GL 09 669B 890 5501060 ALTERNATE STATIC LINE CHAFED THROUGH IN CO-PILOTS SIDEWALL IN COCKPIT. REPLACED LINE WITH NEW BUT THE LOCATION IS VERY DIFFICULT TO PREVENT CONTINUED CHAFING. RECOMMEND MFG LOOK AT THIS AREA AND POSSIBLE REROUTING. 1 L 7 2 4F 4 F A22CE E00053EN 2005052400039 20050524 00039 CE 2005 5 24 2005FA0000732 1 20050503 G 3411 651447411 STATIC LINE CESSNA 500 550 2076604 CE PWA 530 PW530A NE CHAFED B N81R K NONE O OTHER IN INSP/MAINT 1 GL 09 669B 890 5501060 ALTERNATE STATIC LINE CHAFED THROUGH IN CO-PILOTS SIDEWALL IN COCKPIT. REPLACED LINE WITH NEW BUT THE LOCATION IS VERY DIFFICULT TO PREVENT CONTINUED CHAFING. RECCOMEND MFG LOOK AT THIS AREA AND POSSIBLE REROUTING. 1 L 7 2 4F 4 F A22CE E00053EN 2005052400040 20050524 00040 CE 2005 5 24 2005FA0000733 1 20050503 G 3411 651447411 STATIC LINE CESSNA 500 550 2076604 CE PWA 530 PW530A NE CHAFED B N81R K NONE O OTHER IN INSP/MAINT 1 GL 09 669B 890 5501060 ALTERNATE STATIC LINE CHAFED THROUGH IN CO-PILOTS SIDEWALL IN COCKPIT. REPLACED LINE WITH NEW BUT THE LOCATION IS VERY DIFFICULT TO PREVENT CONTINUED CHAFING. RECOMMEND MFG LOOK AT THIS AREA AND POSSIBLE REROUTING. 1 L 7 2 4F 4 F A22CE E00053EN 2005053100081 20050531 00081 2005 5 31 2005FA0000734 4 20050517 G 3452 CI105 ANTENNA PIPER PA46 PA46500TP 7104622 SO NR 1 TRANSPONDER BROKEN B O OTHER D INFLIGHT SEPARATION NR NOT REPORTED 1 SO 11 175WB 4697181 NR 1 TRANSPONDER ANTENNA BROKEN OFF DURING FLIGHT. 1 L 7 1 3O RT A25SO 2005060100018 20050601 00018 CE 2005 6 1 2005FA0000735 1 20050504 G 2821 33199C GASKET RAYTHN BEECH 58 58 1152740 CE CONT O550 IO550* SO FUEL STRAINER OUT OF POSITION B AKGR K NONE O OTHER IN INSP/MAINT 1 CE 05 4488Q 100 TH2088 THE MATERIAL THE UPPER AND LOWER GASKETS ARE NOW MADE OF IS MUCH SOFTER THAN THE ORIGINAL DESIGN. THEY TEND TO COMPRESS AND SLIDE OUT FROM UNDER THE STRAINER WALL INTO THE CENTER OF THE FUEL STRAINER BODY AND BEGAN TO LEAK FUEL. THE STRAI NER HOUSING IS NOT MACHINED TO HOLD THE SOFTER GASKET. (K) 1 L 7 2 3O 3 O 3A16 E3SO 2005060100020 20050601 00020 EU 2005 6 1 2005FA0000736 1 20050513 G 3040 CONNECTOR PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A60A 52043 NE LT WINDSHIELD DAMAGED B K5SR K NONE M OVER TEMP IN INSP/MAINT 1 NM 07 956PC 1536 323 LT WINDSHIELD HEAT FOUND BURNED/OVERHEATED WIRING CONNECTOR AT CENTER ELEMENT POSITIVE WIRE ATTACH TOP OB CORNER OF WIND SHIELD. NO DAMAGE TO WIRING NOTED. SYSTEM WAS PREVIOUSLY INSPECTED IAW SB. ALL ITEMS CHECKED SATISFACTORY. (NO COMPO NENT FAILED, ONLY THE CONNECTOR WAS DAMAGED) (K) 1 L 7 1 3T 4 T RT A78EU E4EA 2005060100050 20050601 00050 EA 2005 6 1 2005FA0000737 2 20050506 G 8520 5015 STUD PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA NR 4 CYLINDER FAILED C K NONE O OTHER IN INSP/MAINT 1 GL 11 9816C 28R7837222 NR 4 CYLINDER BASE STUD FAILED IN TENSION. NUT AND 30 PERCENT OF STUD LENGTH FOUND BETWEEN NR2 AND NR4 CYLINDERS ON THE INNER CYLINDER BAFFLE. NR 4 CYLINDER REMOVED AND REMAINING PARTIAL STUD REMOVED WITH STUD EXTRACTOR. INSTALLED NEW S TUD, PN 50-15 AND REPLACED REMOVED CYLINDER. TORQUED TO RECOMMENDED TORQUE (600 IN LBS) IAW MFG MM. PROBABLE CAUSE: ME TAL FATIGUE DUE TO AGE OF ENG CRANKCASE STUDS AND NR OF CYLINDER REMOVAL AND REPLACEMENTS DURING THE ENG LIFETIME. AC, MOST OF LIFE AS TRAINING AC. THROUGH INSP OF AND OR REPLACEMENT OF CYL BASE STUDS DURING ENG O/H WITH MANDATORY REPLACE MENT TIME PERIODS OR CYCLES. (GL11200510739) (K) 1 L 7 1 3O 3 O 2A13 1E10 2005060100051 20050601 00051 SO 2005 6 1 2005FA0000738 2 20050328 G 8530 FRST712CCA01 CYLINDER BEECH 36 A36 1151604 CE CONT O520 IO520B 17032 SO ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 09 2284L E929 THIS CYLINDER CRACKED ALL THE WAY AROUND THE TOP OF THE BARRELL. DATE OF OCCURANCE 04/26/2004. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005060100056 20050601 00056 NM 2005 6 1 2005FA0000739 1 20050418 G 3213 161N16264 AXLE BOEING 757 757* NM MLG BROKEN G XC2R K NONE O OTHER IN INSP/MAINT 1 WP 01 39308 620 (REF: PO0043200R011)AXLE WAS FOUND BROKEN NEAR THE CENTER POINT THAT WAS CONCEALED BY THE TRUCK BEAM DEGES OF THE FRACTU RE SHOW SEVERE CORROSION AND PEELED CHROME PLATING. (K) 2 L 7 2 4F RT A2NM 2005060100098 20050601 00098 CE 2005 6 1 2005FA0000740 1 20050425 G 2740 07612053 ROLL PIN CESSNA 180 180J 2072622 CE CONT O470 O470* 17026 SO STAB TRIM WHEEL BROKEN D K NONE O OTHER IN INSP/MAINT 1 SO 03 15BF 4774 18052353 FOUND ROLL PIN BROKEN DURING 100 HOUR INSPECTION. APPEARS TO HAVE FAILED UNDER NORMAL OPERATING CONDITIONS. RECOMMEND INSPECTION OF THIS ASSEMBLY WITHIN 25 HOURS AND AT 100 HOUR INSPECTIONS THEREAFTER. (K) 1 H 7 1 3O 3 O 5A6 E273 2005060100101 20050601 00101 CE 2005 6 1 2005FA0000741 1 20050202 G 3710 ADV211CC PUMP CESSNA 172 172P 2072436 CE LYC O320 O320* 41508 EA ENGINE OVERHEATED D K NONE M OVER TEMP NR NOT REPORTED 1 GL 15 54589 299 17275007 REMOVED VACUUM PUMP DUE TO TOTAL FAILURE AND OVERHEAT CONDITION, MELTED TACH CABLE THAT RUNS ABOUT 1 INCH AWAY, THIS IS THE SECOND FAILURE IN THE FLEET WITH OVERHEAT CONDITION, BOTH PUMPS HAD LESS THAN 300 HOURS SINCE NEW. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2005060100102 20050601 00102 CE 2005 6 1 2005FA0000742 1 20050202 G 3710 ADV211CC PUMP CESSNA 172 172P 2072436 CE LYC O320 O320* 41508 EA ENGINE OVERHEATED D K NONE M OVER TEMP NR NOT REPORTED 1 GL 15 65045 287 17275674 REMOVED VACUUM PUMP DUE TO OVERHEAT CONDITION, BACK OF PUMP WAS DISCOLORED, THE TACH CABLE THAT RUNS ABOUT 1 INCH AWAY F ROM THE VACUUM PUMP WAS MELTED ABOUT 4 INCHES. THIS IS THE SECOND PUMP IN THE FLEET WITH THIS TYPE OF FAILURE, BOTH PUP S HAD LESS THAN 300 HOURS SINCE NEW. 1 H 7 1 3O 3 O NT 3A12 E274 2005060100103 20050601 00103 EA 2005 6 1 2005FA0000743 2 20050505 G 8520 LW17226 CRANKSHAFT PIPER PA44 PA44180 7104402 SO LYC O360 IO360E1A 41514 EA RT ENGINE FRACTURED D E ENGINE SHUTDOWN J WARNING INDICATION CR CRUISE 1 NM 09 28721 * 1894 447995296 RL14972T RT ENGINE STARTED RUNNING ROUGH, THEN STOPPED AND WENT INTO FEATHER. AC LANDED WITHOUT INCIDENT. UPON INVESTIGATION IT WAS FOUND THAT WHEN THE PROPELLER WAS ROTATED THE AFT CYLINDERS (NR 3, NR 4) PISTONS WOULD NOT MOVE NOR DID ANY ACCESSO RIES ON THE BACK OF THE ENGINE MOVE. SUSPECT A CLEAN CRANKSHAFT FAILURE (FRACTURE). NO EXTERNAL CRANKCASE DAMAGE NOTED . (K) 1 L 7 2 3O 3 O A19S0 1E10 2005060100106 20050601 00106 2005 6 1 2005FA0000744 1 20050421 G 4980 BAFFLE APU EXHAUST CRACKED B A7RR O OTHER O OTHER NR NOT REPORTED 1 SW 19 INTERNAL LINER MISSING AND BAFFLE PLATES CRACKED. CAUSED BY APU ENGINE VIBRATION. (K) 2005060100120 20050601 00120 EU 2005 6 1 2005FA0000745 1 20050411 G 7160 350A54108004 INTAKE SNIAS 350 AS350* EU ENGINE CRACKED B A7RR O OTHER O OTHER NR NOT REPORTED 1 SW 19 AIR INTAKE, CRACKED BASE METAL DUE TO VIBRATION. (K) 1 G 7 1 3U H9EU 2005060100156 20050601 00156 EA 2005 6 1 2005FA0000746 1 20050411 G 3210 C6UM11108 LANDING GEAR DHAV DHC6 DHC6* 2802606 EA MLG CRACKED B A7RR O OTHER O OTHER NR NOT REPORTED 1 SW 19 MAIN GEAR LEG, CRACK IN BASE METAL DUE TO CYCLIC LANDING STRESSES. (K) 1 H 7 2 3T A9EA 2005060100157 20050601 00157 2005 6 1 2005FA0000747 1 20050412 G 7921 S5411267000000 OIL COOLER UPPER CRACKED B A7RR O OTHER O OTHER NR NOT REPORTED 1 SW 19 UPPER OIL COOLER AND DEICER, BASE METAL CRACKED DUE TO VIBRATION. (K) 2005060100158 20050601 00158 SO 2005 6 1 2005FA0000748 1 20050501 G 8011 DRIVE GEAR PIPER PA28 PA28150 7102804 SO LYC O360 IO360A1A 41514 EA STARTER CORRODED B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 5906W E073209 282814 L991436 STARTER BENDIX DRIVE HAS EVIDENCE OF RUST AND CORROSION ON AT LEAST 1 GEAR TOOTH. THE BENDIX DRIVE GEAR TOOTH BROKE. S HEERING THE REMAINING BENDIX TEETH AS THEY MESHED WITH THE MATING RING GEAR. (K) 1 L 7 1 3O 3 O 2A13 1E10 2005060100159 20050601 00159 EA 2005 6 1 2005FA0000749 2 20050501 G 7322 105217 CARBURETOR PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA ENGINE LEAKING B WS9R O OTHER K FLUID LOSS NR NOT REPORTED 1 NM 07 8405S 288116255 L776239A CARBURETOR LEAKS FROM THROTTLE SHAFT AND FROM ACCELERATOR PUMP. (K) 1 L 7 1 3O 3 O 2A13 E274 2005060100160 20050601 00160 CE 2005 6 1 2005FA0000750 1 20050501 G 8011 ES6462751 STARTER CESSNA 421 421B 2076014 CE CONT O520 GTSIO520H 17032 SO ENGINE INOPERATIVE B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 421GW 131 421B0873 608257 STARTER INOPERATIVE. (K) 1 L 7 2 3O 3 O A7CE E7CE 2005060100161 20050601 00161 CE 2005 6 1 2005FA0000751 1 20050501 G 8011 DRIVE GEAR CESSNA 172 172M 2072418 CE LYC O320 O320* 41508 EA STARTER CRACKED B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 4609Q E053694 17261724 L959339A STARTER BROKE. VISUAL INSPECTION FOUND BENDIX DRIVE GEAR CRACKED AND APPEARS BENT. END BUSHING IS ALSO CRACKED. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2005060100167 20050601 00167 CE 2005 6 1 2005FA0000752 1 20050104 G 2822 A8160D PUMP CESSNA 182 182T 2072703 CE LYC O540 IO540* 41532 EA FUEL SYSTEM OBSTRUCTED B NE2R K NONE O OTHER IN INSP/MAINT 1 CE 07 2182F 142 18281340 RECEIVED BOOST PUMP FOR WARRANTY CREDIT WITH A CUSTOMER COMPLAINT OF (BREAKER POPS WHEN FUEL PUMP IS TURNED ON). PRELIM INARY INSPECTION OF THE PUMP REVEALED FOREIGN MATERIAL IN THE INLET PORT. FURTHER INSPECTION OF THE PUMP REVEALED THE F OREIGN MATERIAL TRIED TO PASS THROUGH THE PUMP AND HAD LOCKED THE ROTOR IN THE INSERT. THIS WOULD CAUSE THE PUMP TO DRA W HIGH AMPS. (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2005060100175 20050601 00175 SO 2005 6 1 2005FA0000753 1 20050503 G 2910 4613800 HYDRAULIC LINE PIPER PA31T PA31T 7103124 SO HYDRAULIC SYS RUPTURED G O OTHER K FLUID LOSS AP APPROACH 1 GL 21 2338V 31T8020049 POST ACCIDENT INSP REVEALED HYD SYSTEM DRAIN/FILL LINE HAD RUPTURED/BURST CAUSING RAPID LOSS OF HYD RESERVOIR CONTENTS. SELECTED GEAR DOWN, GEAR DID NOT EXTEND. ATTEMPTED EMER MANUAL GEAR EXTEN, (FELT GEAR COMING DOWN) LOST HYD PRESSURE. UNABLE TO SECURE GEAR IN DOWN AND LOCKED. AC SUSTAINED DAMAGE DURING EMER LANDING. FAILURE OF HYD DRAIN LINE CAUSED RA PID LOSS OF HYD FLUID RESERVOIR CONTENTS. FAILURE PREVENTED HYD SYS PRESSURE TO BUILD TO ALLOW NORMAL OR EMERGENCY EXTE NSION OF THE LANDING GEAR. LINE FAILED PARALLEL TO GRAIN STRUCTURE RUPTURE APPROX 0.5625 IN LENGTH. WATER CONTAMINATIO N IN LINE FROZE, EXPANDED, CAUSING RUPTURE. SUGGEST REGULAR PURGE/DRAIN OF LINE CONTENTS DURING PLANNED MAINT. (K) 1 L 7 2 3T A8EA 2005060100198 20050601 00198 SO 2005 6 1 2005FA0000754 1 20050511 G 2821 2230600 GASCOLATOR PIPER PA25 PA25235 7102504 SO LYC O540 O540* 41532 EA FUEL SYSTEM CONTAMINATED G K NONE O OTHER IN INSP/MAINT 1 SW 09 4514Y 254066 DURING AN ACCIDENT INVESTIGATION FUEL GASCOLATOR WAS FOUND WITH LARGE AMOUNTS OF WATER AND SOLID CONTAMINANTS. IT WAS N OTED THAT THE PART COULD NOT BE ROTATED TO ENSURE DRAINAGE OF CONTAMINANTS WHEN AC IS ON THE GROUND DUE TO COWL SUPPORT STRUTS INTERFERENCE. GASCOLATOR COULD BE RELOCATED 2 INCHES IB TO ENSURE CLEARANCE OF THE COWL SUPPORT STRUTS. THE CON TAMINANTS COULD NOT BE DRAINED OUT EFFECTIVELY. (SW09200512483) (K) 1 L 7 1 3O 3 O 2A10 E295 2005060100213 20050601 00213 2005 6 1 2005FA0000756 2 20050314 G 8520 SA629340 ROD BOLT ENGINE DEFECTIVE B WS9R K NONE O OTHER IN INSP/MAINT 1 NM 07 UNABLE TO ACHIEVE PROPER BOLT TORQUE AND ALIGN COTTER PIN HOLES WITH CASTELATED NUT. HOLES IN DRILLED HEAD MISALIGNED. (K) 2005060100214 20050601 00214 2005 6 1 2005FA0000757 2 20050314 G 7414 RETAINER BENDIX MAGNETO OUT OF POSITION B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 10 F0FA246R MAGNETO COIL RETAINING WEDGE HAS FALLEN OUT AND BECAME LODGED BETWEEN THE GEAR TEETH, CAUSING THEM TO BREAK OFF. ALSO, APPEARS THAT THE DISTRIBUTOR BLOCK WAS CRACKED AND FAILED DUE TO THIS OTHER DEFECT. (K) 2005060100215 20050601 00215 2005 6 1 2005FA0000758 1 20050322 G 8011 DRIVE GEAR LAMAR LYC IO360 IO360L2A EA STARTER FAILED B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 85522811 L1766751A STARTER BENDIX FAILED, DESTROYING ITSELF AND THE MATING RING GEAR. (K) 3 O 1E10 2005060200056 20050602 00056 EA 2005 6 2 2005FA0000760 2 20050426 G 8500 R182097 ENGINE BOEING B17 B17G 1380204 WP WRIGHT R1820 R182097 67020 EA NR 3 FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 23 3703G 11 4483546A 036743 UPON ANNUAL INSPECTION, ENGINE WAS FOUND TO BE SEIZED, CHECKED FOR OIL IN GIL TANK, 25 GAL REMAINING. ENGINE REMOVED FR OM AC. UPON REMOVAL OF PROPELLER, PROP SHAFT WAS FULL OF METAL. NOSE CASE FAILURE. (K) 2 L 7 4 4R 4 R L13 5E10 2005060200058 20050602 00058 EA 2005 6 2 2005FA0000761 2 20050426 G 8500 R182097 ENGINE BOEING B17 B17G 1380204 WP WRIGHT R1820 R182097 67020 EA NR 3 FAILED D K NONE O OTHER IN INSP/MAINT 1 WP 23 3703G 4483546A 082437 UPON INSTALLATION OF ENGINE AT NR 3 POSITION, METAL WAS FOUND IN PROPELLER SHAFT. ENGINE HAD RUN IN TIME ONLY AS -0- T SMO. ENGINE REMOVED AND NOT RUN ON AIRCRAFT. (K) 2 L 7 4 4R 4 R L13 5E10 2005060200065 20050602 00065 CE 2005 6 2 2005FA0000762 1 20050108 G 3340 3538013243 SWITCH BEECH 58 58 1152740 CE CONT O550 IO550* SO COCKPIT FAULTY D O OTHER M OVER TEMP NR NOT REPORTED 1 EA 17 3267N TH1767 INTERNAL UPPER BRAIDED CONDUCTOR ON LINE SIDE FAILED, SEPARATED FROM ITS CONTACT OR WELD. SPRING MECHANISM FOR SWITCH B ECOMES CONDUCTOR. SPRING CAN NOT HANDLE THE CURRENT OF LANDING LIGHT CIRCUIT, AND OVERHEATS. OVERHEATING OF SPRING CAU SED NYLON TOGGLE ASSY TO FAIL. TOGGLE ASSY IS RENDERED USELESS, SWITCH LOOSES ALL MECHANICAL FUNCTION. SWITCH CONTINUES TO COMPLETE CIRCUIT, OVERHEAT MELTING THE SWITCH HSG. AS HSG AND OTHER INTERNAL COMPONENTS FAIL, SWITCH LOOSES ITS CIR CUIT PROTECTION FEATURE, SMOKE IS EMITTED INTO COCKPIT. THIS PROCESS WILL ONLY DISCONTINUE WHEN ALL POWER IS REMOVED. ONCE POWER IS REMOVED FROM AC, SWITCH WILL COOL ALLOWING UPPER CONTACT TO OPEN, WHICH OPENS THE CIRCUIT. (K) 1 L 7 2 3O 3 O 3A16 E3SO 2005052300131 20050523 00131 CE 2005 5 23 2005FA0000763 1 20050502 G 3230 FITTING CESSNA 206 U206F 2073333 CE FLOAT FAILED G A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION LD LANDING 1 GL 21 114GS U20603077 THIS AIRCRAFT IS EQUIPPED WITH MFG AMPHIBIAN FLOATS. DURING FLIGHT, HYDRAULIC PUMP TURNED ON AND WOULD NOT SHUT OFF. P ILOT PULLED BREAKER AND NOTED BLUE LIGHTS INDICATION GEAR UP WERE NOT LIT. PILOT RESET BREAKER AND SELECTED GEAR DOWN. GEAR WOULD NOT SHOW GREEN ON ANY OF 4 LANDING GEAR. PILOT MADE LANDING WITH MAIL WHEELS PARTIALLY EXTENDED. MINOR DAMA GE TO KEEL STRIPS. INVESTIGATION REVEALED GEAR PRESSURE HOSE BULKHEAD FITTING IN LT FLOAT FAILED DUE TO CORROSION OF B- NUT ON FITTING WERE FRONT STRUT ATTACHES TO FLOAT. 1 H 7 1 3O A4CE 2005052300132 20050523 00132 2005 5 23 2005FA0000764 4 20050502 G 3197 89340002 ANNUNCIATOR PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA COKCPIT MISWIRED B O OTHER N FALSE WARNING CR CRUISE 1 SO 15 939ER 4 4496201 AC WITH INCONSISTENT ANNUNCIATOR INDICATIONS. DURING REPAIR, TROUBLESHOT SYS, CONFIRMED DISCREPANCY: OIL LIGHT AND GEA R WARNING LIGHT FLICKERS ON THEN OFF ON ANNUN PANEL, REMOVED ANNUN PANEL, FOUND WIRE TO PTT LIGHT TEST INTERFACE PLUG PI N 3 TO ANNUN PANEL GROUND MISWIRED. INSTALLED NEW ANNUN PANEL, FOUND LOW BUS LIGHT INOP, HEATER OVER TEMP LIGHT INOP ON PTT TEST. REPAIRED WIRE ON ORIGINAL ANNUN PANEL IAW MFG MM. REINSTALLED ORIGINAL UNIT ONTO PANEL. PLACED AC ON JACKS, PERFORMED GEAR SWING TO VERIFY GEAR UNSAFE WARNING ANNUNCIATOR LIGHT, AND THROTTLE HORN/LIGHT COMBINATION. PERFORMED EN G RUN UP AND VERIFIED OIL LIGHT ANNUNCIATION, PERFORMED PTT LIGHT TEST ON ANNUN PANEL, NO DEFECTS NOTED. 1 L 7 2 3O 3 O A19S0 E286 2005052400010 20050524 00010 SO 2005 5 24 2005FA0000765 1 20050503 G 2741 63585003 TRIM TAB PIPER PA28 PA28161 7102803 SO LYC O360 O360* 41514 EA CRACKED B K NONE O OTHER IN INSP/MAINT 1 EA 21 8461T 9168 288216057 LT AND RT TRIM TABS CRACKED AT IB LOCATION WHERE THEY ARE CONNECTED TOGETHER. SKINS AND IB RIBS WERE CRACKED ABOUT 1 IN CH ON RIBS AND SKINS. 1 L 7 1 3O 3 O 2A13 E286 2005052400042 20050524 00042 EA 2005 5 24 2005FA0000766 2 20050503 G 8530 LW12215 CYLINDER BEECH 60 B60 1153605 CE LYC O541 TIO541E1C4 41536 EA ENGINE CRACKED B K NONE O OTHER IN INSP/MAINT 1 SO 05 34KA 625 P262 L93359 DURING DIFFERENTIAL COMPRESSION TEST, AIR WAS HEARD LEAKING FROM LOWER CYLINDER AREA. COMPRESSION WAS 40/80. USING LIQ UID LEAK DETECTOR, FOUND AIR BLOWING OUT FROM A CRACK IN CYLINDER FIN. REMOVED CYLINDER FROM ENGINE AND NOTED A CRACK I N THE COMBUSTION CHAMBER RUNNING FROM LOWER SPARK PLUG HOLE TO INTAKE VALVE. 1 L 7 2 3O 3 O A12CE E10EA 2005052400141 20050524 00141 EA 2005 5 24 2005FA0000767 2 20050505 G 8520 CAMSHAFT PIPER PA31 PA31325 7103105 SO LYC O540 TIO540F2BD 41532 EA LT ENGINE BROKEN B A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CR CRUISE 1 GL 21 325YH 1413 317812007 L628561A THE LT ENGINE STOPPED IN CRUISE FLIGHT. AFTER INVESTIGATION IT WAS FOUND THE CAM HAD FAILED JUST FORWARD OF THE NR 5 AN D NR 6 CYLINDERS AND CRACKED THE LT CASE HALF. TBO IS 1800HRS, COMPONENT TIME IS 1413.3 TSMOH. 1 L 7 2 3O 3 O A20SO E14EA 2005052400295 20050524 00295 CE 2005 5 24 2005FA0000768 1 20050506 G 7722 86317 PROBE CESSNA 182 182T 2072703 CE LYC O540 IO540AB1A5 EA ENGINE CHT/EGT LOOSE B K NONE J WARNING INDICATION IN INSP/MAINT 1 CE 07 2116X 207 18281318 "OMEGA" BRAND NAME OF CONNECTORS USED ON THE ALCOR CHT/EGT PROBES. THE SCREWS THAT HOLD THE CONNECTOR AND CONNECTION OF THE WIRE FOR THE PROBES WILL WORK LOOSE CAUSING A FALSE OR NO INDICATION ON THE G-1000 SYSTEM. NEEDS TO HAVE SOMEWAY TO LOCK THE SCREWS INTO PLACE, SUCH AS LOCTITE OR A STAR WASHER. NOTE, THIS HAS BEEN AN ONGOING PROBLEM. 1 H 7 1 3O 3 O NT 3A13 1E4 2005052600206 20050526 00206 SO 2005 5 26 2005FA0000769 1 20050513 G 3250 95394 BRACKET PIPER PA34 PA34200T 7103406 SO NLG STEERING BROKEN G L ABORTED APPROACH J WARNING INDICATION AP APPROACH 1 SO 19 865SC 347970265 PILOT REPORTS TO CONTROL TOWER ON FINAL APPROACH, AN UNSAFE NOSE GEAR INDICATION (NO GREEN). TOWER OBSERVED NOSE GEAR, BUT COULD NOT VERIFY DOWN AND LOCK. PILOT ATTEMPTS EMERGENCY GEAR EXTENSION AND CYCLES GEAR. THE NOSE GEAR STILL WILL NO T EXTEND AND LOCK. AIRCRAFT LANDS AND NOSE GEAR COLLAPSES ON TOUCHDOWN. MAINTENANCE PLACES AIRCRAFT ON JACKS AND EXTEND S NOSE GEAR TO DOWN AND LOCKED POSITION. A BRACKET FALLS FROM NOSE GEAR AREA. STEERING BRACKET HELPS KEEP GEAR ALIGNED W HEN EXTENDED AND RETRACTED. 1 L 7 2 3O A7SO 2005060200074 20050602 00074 SO 2005 6 2 2005FA0000770 2 20050519 G 8520 632041F ROD CESSNA 310 T310R 2074246 CE CONT O520 TSIO520B 17040 SO ENGINE BROKEN G E ENGINE SHUTDOWN E VIBRATION/BUFFET CR CRUISE 1 GL 21 6131X 3709 123 310R1296 183838H DURING CRUISE FLT, ENG BEGAN TO VIBRATE SEVERELY AND PILOT SHUTDOWN. TEARDOWN AND INVESTIGATION REVEALED THE NR 2 ROD B ROKE 1/2 WAY BETWEEN PISTON AND CRANK. IT IS SUSPECTED THIS ENG ENCOUNTERED LIQUID LOCK AT SOME TIME CAUSING A BENT ROD THAT EVENTUALLY FAILED. 1 L 7 2 3O 3 O 3A10 E8CE 2005060700190 20050607 00190 CE 2005 6 7 2005FA0000771 1 20050414 G 2510 MM201088 LOCK CESSNA 172 172RG 2072438 CE LYC O320 O320* 41508 EA SEAT BACK SLIPPED D O OTHER O OTHER TX TAXI/GRND HDL 1 GL 17 9795B 5379 172RG1042 L3001936A WHEN COPILOT LEANED AGAINST THE SEAT BACK LOCK FAILED AND ALLOWED THE BACK TO FULLY BE IN THE AFT POSITION. (GL17200503 735) (K) 1 H 7 1 3O 3 O 3A17 E274 2005060700192 20050607 00192 NM 2005 6 7 2005FA0000772 1 20050505 G 5302 500N3422 FITTING DOUG 600N 600N 3027377 NM ALLSN 250C 250C47B GL TAILBOOM CRACKED B IL3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 451DL 638 RN042 UPPER RT TAILBOOM ATTACH FITTING CRACKED. THIS IS THE SAME AREA COVERED IN AD AND SB, 25 HOUR INSPECTION. (K) 1 G 7 1 3U 3 U NC H3WE E1GL 2005060200075 20050602 00075 GL 2005 6 2 2005FA0000773 3 20050519 G 6114 3E1951 PLATE CONT O550 IO550B SO HARTZL HCJ3Y PHCJ3YF2 GL PROPELLER SCORED B K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 25 328M 555 WHILE PERFORMING HARTZELL PROPELLER SERVICE LETTER HC-SL-61-239, AND RAYTHEON MANDATORY SERVICE BULLETIN 61-3706 PART"B" , SCORING WAS FOUND ON ALL PROPELLER SPLIT MOUNTING PLATES, DUE TO NO MOUNTING WASHERS INSTALLED. THE PLATES WERE REPLAC ED WITH NEW ONES, P/N 3E1951, AND THE PROPER WASHERS WERE INSTALLED, P/N A1381. INSPECTION OF THE PROPELLER HUB AND MOUN T STUDS HAD NEGATIVE DEFECTS. 3 O E3SO 5 C P36EA 2005060700194 20050607 00194 CE 2005 6 7 2005FA0000774 1 20050510 G 8011 65556624 STARTER CESSNA 303 T303 2073820 CE CONT O520 LTSIO520AE 17040 SO ENGINE FAILED G O OTHER O OTHER NR NOT REPORTED 1 WP 25 9488C 30 T30300180 246729R DURING TAKEOFF THE (STARTER ENGAGED) LAMP ILLUMINATED INDICATING HAD SELF ENGAGED. AIRCRAFT LANDED. STARTER NOT BURNED UP BUT INTERNAL ACTION SOUNDS UNUSUAL. NOTE: THIS IS THIRD STARTER FAILURE IN 5 WEEKS. (K) 1 L 7 2 3O 3 O A34CE E8CE 2005060700196 20050607 00196 2005 6 7 2005FA0000775 1 20050510 G 2435 M2399 ARMATURE ELECTROSYS STARTER MOTOR UNSERVICEABLE B UC2R O OTHER O OTHER NR NOT REPORTED 1 GL 19 8021149 PILOT REPORTED UNUSUAL NOISE DURING ATTEMPTED START. REMOVED AND DISASSEMBLED STARTER. FOUND THE GEAR SPLINES ON ARMAT URE SHAFT CRACKED AND SHEARED. SHOWS THESE SPLINES ARE NOT VERY DURABLE, RECOMMEND REGULAR OVERHAUL INSPECTION. (K) 2005060700197 20050607 00197 SO 2005 6 7 2005FA0000776 1 20050503 G 5540 FLANGE PIPER PA31T PA31T1 7103126 SO PWA PT6 PT6* 52043 EA RUDDER CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SW 13 85KG 3539 31T1104017 PILOT REPORTED AIRCRAFT YAW IN FLIGHT. CABLE TENSION HAD PREVIOUSLY BEEN ADJUSTED BUT WAS LOOSE AGAIN. FOUND FLANGE CR ACKED AT AFT BOLT ON PILOT SIDE RUDDER TORQUE TUBE BEARING. CAUSE UNKNOWN BUT POSSIBLE EXCESS RUDDER PEDAL FORCE WITH A IRCRAFT ON GROUND AND NOT MOVING. (K) 1 L 7 2 3T 3 T A8EA E2NE 2005060700198 20050607 00198 GL 2005 6 7 2005FA0000777 1 20050413 G 6120 B65091 SPRING CIRRUS SR SR20 05628AJ GL CONT IO360 IO360* 17025 CE HARTZL HCJ3Y PHCJ3YF1 GL PROPELLER DOME FRACTURED B AKGR O OTHER O OTHER NR NOT REPORTED 1 CE 05 269SB 1337 1160 JC130B PROPELLER PITCH WENT UNCONTROLLABLE IN STRAIGHT AND LEVEL FLIGHT. SPRING HAD ONE COMPLETE FRACTURE AND AT LEAST 4 INCOM PLETE FRACTURES. (K) 1 L 7 1 3O 3 O NT A00009CH E1CE 5 C P36EA 2005060800002 20050608 00002 CE 2005 6 8 2005FA0000778 1 20050412 G 6120 B24913 ROD HARTZL BEECH 55 95B55A CE CONT O470 IO470* 17026 SO HARTZL HCC2Y BHCC2YF2 GL PITCH CHANGE CRACKED G O OTHER O OTHER NR NOT REPORTED 1 GL 25 4522S AN493 TC1889 AN493 (17590) OLD STYLE 2 PIECE PITCH CHANGE ROD CRACKED AND SEPARATED AT MATING JOINT IN FLIGHT CAUSING PROPELLER TO INADVERT ENTLY FEATHER. THE PROBABLE CAUSE OF THIS IS DUE TO WEAK CONSTRUCTION. THE MANUFACTURER SHOULD CONSIDER MANDATORY REPL ACEMENT OF ALL OLD STYLE 2 PIECE PITCH CHANGE RODS AT THE TIME OF NEXT DISASSEMBLY AND UPGRADING TO A NEW STYLE 1 PIECE PITCH CHANGE ROD TO PREVENT ANY POSSIBLE RECURRENCE. (K) 1 L 7 2 3O 3 O 3A16 E1CE 5 C P920 2005060800037 20050608 00037 WP 2005 6 8 2005FA0000779 2 20050412 G 7200 ENGINE AMD FALC20 FALCON 2720302 EU GARRTT ATF3 ATF36 29002 WP NR 2 LEAKING B E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION NR NOT REPORTED 1 WP 07 200GT 1373 137 P21 ENGINE EXPERIENCED LOW OIL PRESSURE IN FLIGHT. PRECAUTIONARY SHUTDOWN PERFORMED. 23 PSI LOWEST READING ON OIL PRESSURE INDICATOR. OIL PRESSURE NEVER WENT TO -0- PSI. NO ABNORMAL VIBRATION EXPERIENCED. PRECAUTIONARY SHUTDOWN PERFORMED O N NR 2 ENGINE. EMERGENCY DECLARED. ENGINE ROTATION NORMAL AFTER SHUTDOWN. ENGINE DID NOT LOCK UP. OIL QUANTITY INDIC ATION AT BOTTOM OF DIPSTICK ON ARRIVAL. EVIDENCE OF OIL LEAKING IN FAN BYPASS AREA OF ENGINE. (K) 2 L 7 2 4F 4 F A7EU E7WE 2005060800038 20050608 00038 CE 2005 6 8 2005FA0000780 1 20050405 G 3233 66000264001 ACTUATOR LEAR 60 60LEAR 5170707 CE MLG FAILED B LK2R O OTHER O OTHER NR NOT REPORTED 1 CE 07 WHILE PERFORMING A FUNCTIONAL TEST OF THE MAIN LANDING GEAR SIDE BRACE ACTUATOR, THE TEST BENCH IN OVERHAUL SHOP, FROZE UP. FURTHER INVESTIGATION REVEALED THAT AN ORIFICE LOCATED INSIDE THE ACTUATOR HAD DISLODGED FROM ITS ORIGINAL DESIGNED LOCATION WITHIN THE ACTUATOR. THE DISCREPANT ACTUATORS ARE PART OF A SB FOR IMPROVED BRAKING. (K) 2 L 7 2 4F RT A10CE 2005060800039 20050608 00039 SO 2005 6 8 2005FA0000781 2 20050307 G 7421 RHB32S SPARK PLUG BEECH 36 A36 1151604 CE CONT O550 IO550* SO ENGINE INTERMITTENT B BWVR O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 CE 07 998PM 678 E3251 ENGINE PERFORMANCE ROUGH ABOVE 10,000 FT. APPEARS TO BE LIKE MISS LT OR RT MAG. INSPECTED AIR FILTER, CHECKED OK. INS PECTED LT AND RT MUFFLERS FOR BLOCKAGE CHECKED OK, CHECKED ALL IGNITION WIRES WITH HIGH TENSION TEST ON CHECKED OK. CH ECKED MAG TIMING CHECKED OK. FLOWED FUEL INJECTION LINES AND CLEANED FUEL NOZZLES AND CLEANED MAIN FUEL SCREEN AND ENGI NE FUEL SCREEN. REPLACED ALL 12 SPARK PLUGS AND GASKETS. RAN AND OPS CHECKED GOOD. (K) 1 L 7 1 3O 3 O 3A15 E3SO 2005060800040 20050608 00040 NE 2005 6 8 2005FA0000782 2 20050511 G 8530 399354 CYLINDER HEAD WTHRLY 620 620B 9630605 CE PWA R985 R985AN14B 52008 NE NR 2 SEPARATED G A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 CE 07 9026F 7070 43 1639 20590 DURING SPRAYING OPERATION, THE AIRCRAFT WAS CLIMBING INTO A RT TURN. THE PILOT HEARD A LOUD BANG, AND THE ENGINE BEGAN RUNNING EXTREMELY ROUGH. THE AIRCRAFT MADE A FORCED LANDING. INSPECTION OF THE ENGINE FOUND THE NR 2 CYLINDER HEAD SEP ARATED FROM THE SLEEVE AT THE NR 3 LARGER COOLING FIN FROM THE BOTTOM. AD WAS COMPLIED WITH DURING LAST OVERHAUL, 43 HO URS EARLIER. (CE07200513320) (K) 1 L 7 1 3R 3 R NC A26WE 5E1 2005060800041 20050608 00041 2005 6 8 2005FA0000783 4 20050421 G 6122 D20880 RETAINER MCAULY LYC O540 IO540* 41532 EA FLYWEIGHT DAMAGED B GCDR O OTHER O OTHER NR NOT REPORTED 1 SO 17 001989 (22209) FLYWEIGHT RETAINING DISC DAMAGED. (K) 3 O 1E4 2005060800042 20050608 00042 CE 2005 6 8 2005FA0000784 1 20050510 G 8120 BEARING CESSNA 414 414 2075908 CE CONT O520 TSIO520NB 17040 SO MCAULY 3AF32C 3AF32C* GL TURBOCHARGER FAILED B J7BR A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SW 01 4243C 407 CHL00379 4140539 519943 984062 PILOT EXPERIENCED MANIFOLD FLUCTUATIONS DURING FLIGHT. A PRECAUTIONARY LANDING WAS MADE. AN INSPECTION REVEALED FAILED TURBINE SHAFT BEARINGS. THE TURBOCHARGER WAS REPLACED WITH A NEW IDENTICAL UNIT. (K) 1 L 7 2 3O 3 O RT A7CE E8CE 5 C P22EA 2005060800045 20050608 00045 SW 2005 6 8 2005FA0000785 1 20050511 G 6310 SKCP2281103 DRIVE SHAFT BELL 204 UH1H 1181407 SW LYC T53 T53L13B 41549 NE ENG TO TRANSMISS VIBRATION B LS1R A UNSCHED LANDING E VIBRATION/BUFFET CL CLIMB 1 EA 13 53AG 7221588 LE21990R ( 2005-5-1) PILOT NOTICED VIBRATION AND RUMBLE COMING FROM THE MAIN TRANSMISSION AREA ON TAKEOFF. MECHANIC DID TROUBLE TROUBLESHOOTING PROCEDURES AND NOTICED ONE OF THE FLEX PLATES ON THE MAIN DRIVE SHAFT HAD SNAPPED CAUSING THE DRIVE SHAF T TO BE IN FAIL SAFE MODE. DRIVE SHAFT WAS REPLACED AND PILOT CONTINUED. (K) 1 G 7 1 4U 4 U EXPA1G71 E17EA 2005060800051 20050608 00051 CE 2005 6 8 2005FA0000786 1 20050517 G 7500 45A40304011 TUBE BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE RT ENGINE UNSERVICEABLE B FGQR K NONE O OTHER IN INSP/MAINT 1 SO 01 101CC 2013 RK277 DURING INSPECTION FOUND FLEXIBLE BELLOWS EXTENDED DUE TO THE WIRE BRAID FAILURE. INTEGRITY OF THE BLEED AIR SUPPLY TUBE WAS INTACT. INSPECTION OF THE LT ENGINE TUBE FOUND BRAID PARTIALLY FAILED. BOTH BLEED AIR SUPPLY TUBES WERE REPLACED WITH NEW. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2005060800052 20050608 00052 CE 2005 6 8 2005FA0000787 1 20050518 G 2510 LC6010030C LOCK CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA SEAT BACK FAILED B LW5R O OTHER O OTHER NR NOT REPORTED 1 GL 17 9795B 172RG1042 PILOTS SEAT BACK LOCK MECHANISM SLIPPED AS PILOT LEANED BACK TO GET HIS BAG OUT OF THE REAR SEAT. UPON REMOVAL FRO AC M ECHANICS WERE ABLE TO CAUSE SEAT BACK LOCK MECHANISM TO FAIL. THIS IS THE SECOND FAILURE TO OCCUR WITH THIS MECHANISM. PART LAST FAILURE OCCURRED APPROX A MONTH AGO ON THE CO-PILOTS SEAT (MDR WAS FILED). WE HAVE NOT YET DONE AN INSPECTI ON ON THE AC AS YET, DUE TO THE FACT IT IS A LEASE. PROBABLE CAUSE WAS WEAR IN THE SEAT BACK LOCK MECHANISM, CAUSING IT TO SLIP OR NOT FULLY ENGAGED IN THE LOCKED POSITION. (K) 1 H 7 1 3O 3 O 3A17 E286 2005060800054 20050608 00054 SO 2005 6 8 2005FA0000788 2 20050502 G 7414 K3056 DISTRIBUTOR GEAR SLICK BEECH 58 58 1152740 CE CONT O550 IO550C SO MAGNETO BURNED B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 2224D 991 97011180 TH1824 683550 DURING DISASSEMBLY OF MAGNETO FOR 500 HR INTERNAL INSPECTION, FOUND DISTRIBUTOR FINGER ON DISTRIBUTOR GEAR SEVERELY BURN ED WITH MATERIAL MISSING. FOUND MAGNETO INTERNAL TIMING 2 TEETH OFF FROM SPECIFIED. SUSPECT INCORRECT INTERNAL TIMING CAUSED A LARGE GAP BETWEEN FINGER AND DISTRIBUTOR BLOCK TARGET WHEN FIRING; RESULTING IN EXCESSIVE BURNING AND PITTING O F DISTRIBUTOR FINGER. OTHER FACILITY ALSO FOUND THIS CONDITION ON SEVERAL SIMILAR MODEL MAGNETOS DUE TO INCORRECT INTER NAL TIMING WHEN DISASSEMBLED FOR OVERHAUL. RECORDS INDICATE MAGNETO POINTS AND CAPACITOR REPLACED LAST ANNUAL INSPECTIO N. (K) 1 L 7 2 3O 3 O 3A16 E3SO 2005060800055 20050608 00055 CE 2005 6 8 2005FA0000789 1 20050505 G 1430 RIVET BEECH 200 B200 1152922 CE PWA PT6 PT6* 52043 EA STRINGER CLIP MISSING B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 200ZT 2475 BB1393 DURING VISUAL INSPECTION OF AFT FUSELAGE STRINGERS AT AFT PRESSURE BULKHEAD FOR COMPLIANCE WITH AD, NOTED (1) RIVET MISS ING FROM NR7L STINGER CLIP AT ZEE SECTION ATTACHMENT. RIVET MISSING WAS AT FARTHEST FORWARD POSITION, REQUIRED REMOVING INSULATION AND SEALANT FOR GOOD VISUAL ACCESS. NO DAMAGE WAS NOTED AND RIVET WAS INSTALLED IAW SRM. SUSPECT RIVET NOT INSTALLED AT MANUFACTURE DUE TO CLOSE CLEARANCES AND MARGINAL EDGE DISTANCE. TECHNICIANS SHOULD BE AWARE THAT SOME POR TIONS OF THIS AREA THAT IS REQUIRED TO BE INSPECTED MAY REQUIRE SOME EFFORT TO REMOVE INSULATION, SEALANT, ETC. (K) 1 L 7 2 4T 3 T A24CE E2NE 2005060800056 20050608 00056 EU 2005 6 8 2005FA0000791 1 20050412 G 5740 D5755000220539 FITTING AIRBUS 320 A320211 3930320 EU RT WING SPAR CRACKED B T48R O OTHER O OTHER NR NOT REPORTED 1 GL 09 754US 283 RT WING REAR SPAR TO AILERON SUPPORT FITTING AT APPROX WS 13484 AND RIB 25 (OB OF AILERON OB ACTUATOR), IS CRACKED AT UP PER LUG RADIUS. REMOVED AND REPLACED FITTING (DIAPHRAGM) ASSEMBLY IAW SRM. (K) 2 L 7 2 4F RT A28NM 2005060800190 20050608 00190 2005 6 8 2005FA0000792 4 20050526 G 2562 AK450 ANTENNA ELT BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SW 99 THE ANTENNA BROKE IN THE BASE. (K) 2005061000009 20050610 00009 2005 6 10 2005FA0000793 4 20050526 G 2562 AK450 ANTENNA ELT BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SW 99 THE ANTENNA BROKE IN THE BASE. (K) 2005060700103 20050607 00103 CE 2005 6 7 2005FA0000794 1 20050523 G 5280 DOOR BEECH 95 95B55 1152729 CE CONT O470 IO470* 17026 SO MLG DELAMINATED C O OTHER O OTHER NR NOT REPORTED 1 SO 11 4455B TC2203 IB LANDING GEAR DOORS HAD CORROSION DUE TO DELAMINATION OF FORWARD EDGE OF GEAR DOORS. 1 L 7 2 3O 3 O RT 3A16 E1CE 2005061000053 20050610 00053 CE 2005 6 10 2005FA0000795 1 20050526 G 2420 E3FF10300AA ALTERNATOR CESSNA 210 P210N 2073454 CE ENGINE BURNED OUT D O OTHER O OTHER NR NOT REPORTED 1 GL 27 732RS 68 68 P21000592 OWNER STARTED HEARING RADIO STATIC AND AFTER A FEW MINUTES, LOST ELECTRICAL POWER. ON THE GROUND, MECHANIC CHECKED RE GULATOR, CHECKED OK, CHANGED ALTERNATOR OPS CHECKED OK. PART ONLY HAS 68 HOURS ON THE OVERHAUL. 1 H 7 1 3O 3A21 2005060900053 20050609 00053 CE 2005 6 9 2005FA0000796 1 20050525 G 5312 051310929 DOUBLER CESSNA 172 172P 2072436 CE LYC O320 O320D2J 41508 EA MCAULY 1C160 1C160DTM GL FIREWALL CORRODED D K NONE O OTHER IN INSP/MAINT 1 WP 27 98483 17968 17276298 L946839A BB048 THESE FIREWALL DOULBLERS ARE INSTALLED FROM FACTORY WITH SOME STRUCTURAL STEEL RIVETS PASSING THROUGH THESE ALUMINUM DOU BLERS, CAUSING CORROSION TO FORM ON BOTH LT AND RT DOUBLERS VERY NEAR ENGINE DYNAFOCAL MOUNT LOCATIONS, REQUIRING REPLAC EMENT OF BOTH DOUBLERS. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2005061300063 20050613 00063 SO 2005 6 13 2005FA0000797 1 20050429 G 3243 MASTER CYLINDER PIPER PA18 PA18A150 7101837 SO LYC O320 O320A2B 41508 EA BRAKE ASSY LEAKING G O OTHER K J FLUID LOSS WARNING INDICATION LD LANDING 1 AL 03 624M4 188739 NORTH RIVER BRAKE BOOSTERS INSTALLED WITH STC SA2318NM. BRAKE PLUNGER HAS EXCESSIVE PLAY WHICH CAUSED FLUID TO BYPASS I NTERNALLY. PILOT LOST DIRECTIONAL CONTROL OF THE AIRCRAFT ON LANDING CAUSING SUBSTANTIAL DAMAGE TO THE AIRCRAFT. THREE P REVIOUS LANDINGS THAT DAY THE BRAKE FUNCTIONED NORMALLY. SITUATION COULD BE DUPLICATED BY ALLOWING THE PLUNGER TO FALL TO THE RT SIDE AND THEN BE DEPRESSED WITH NO BRAKE ACTUATION AND NO EXTERNAL FLUID LOSS. 1 H 7 1 3O 3 O 1A2 E274 2005060800100 20050608 00100 2005 6 8 2005FA0000798 1 20050425 G 4920 38007021 IMPELLER APU BROKEN B O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 WP 07 6880 6880 DURING APU OPERATION, A PIECE OF THE 3822400-5 IMPELLER SEPARATED AT THE RIM. THIS RESULTED IN HIGH VIBRATION LEVELS AN D CATASTROPHIC DAMAGE TO THE LOAD COMPRESSOR AND POWER SECTIONS. (K) 2005060800150 20050608 00150 EU 2005 6 8 2005FA0000799 1 20050513 G 5541 PLATE GROB GROB 120 G120A 1660208 EU RUDDER SPAR DEBONDED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 861AF 1997 85001 DURING ROUTINE INSPECTION OF AIRCRAFT, TECH FOUND EXCESSIVE MOVEMENT BETWEEN RUDDER AND RUDDER LEVER ASSY. FURTHER INSP ECTION SHOWED DISBONDING BETWEEN THE RUDDER SPAR AND THE RUDDER LEVER ASSY SPACER PLATE. PROBABLE CAUSE APPEARS TO BE E XCESSIVE FLEXING OF THE SPAR OR IMPROPER BONDING. (SPAR AND SPACER ARE COMPOSITE MATERIAL) THE SPAR MAY NOT BE RIGID EN OUGH IN THIS AREA. RECOMMENDATION AT THIS TIME IS TO INCREASE STRENGTH/RIGIDITY OF THE SPAR AND IMPROVED BONDING METHOD . (K) 1 L 7 1 3O RT A49CE 2005060800154 20050608 00154 EU 2005 6 8 2005FA0000800 1 20050513 G 5541 120A3115 PLATE GROB GROB 120 G120A 1660208 EU RUDDER SPAR DEBONDED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 863AF 1997 85003 DURING FLEET - WIDE INSPECTION OF AIRCRAFT, TECH FOUND EXCESSIVE MOVEMENT BETWEEN RUDDER AND RUDDER LEVER ASSY. FURTHER INSPECTION SHOWED DISBONDING BETWEEN THE RUDDER SPAR AND THE RUDDER LEVER ASSY SPACER PLATE. PROBABLE CAUSE APPEARS TO BE EXCESSIVE FLEXING OF THE SPAR OR IMPROPER BONDING. (SPAR AND SPACER ARE COMPOSITE MATERIAL) THE SPAR MAY NOT BE RIG ID ENOUGH IN THIS AREA. RECOMMENDATION AT THIS TIME IS TO INCREASE STRENGTH/RIGIDITY OF THE SPAR AND IMPROVED BONDING M ETHOD. 1 L 7 1 3O RT A49CE 2005060800155 20050608 00155 EU 2005 6 8 2005FA0000801 1 20050513 G 5541 PLATE GROB GROB 120 G120A 1660208 EU LYC O540 AEIO540* EA RUDDER SPAR DEBONDED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 01 867AF 1589 85007 DURING FLEET-WIDE INSPECTION OF AIRCRAFT, TECH FOUND EXCESSIVE MOVEMENT BETWEEN RUDDER AND RUDDER LEVER ASSY. FURTHER I NSPECTION SHOWED DISBONDING BETWEEN THE RUDDER SPAR AND THE RUDDER LEVER ASSY SPACER PLATE. PROBABLE CAUSE APPEARS TO B E EXCESSIVE FLEXING OF THE SPAR OR IMPROPER BONDING. (SPAR AND SPACER ARE COMPOSITE MATERIAL) THE SPAR MAY NOT BE RIGID ENOUGH IN THIS AREA. RECOMMENDATION AT THIS TIME IS TO INCREASE STRENGTH/RIGIDITY OF THE SPAR AND IMPROVED BONDING MET HOD. (K) 1 L 7 1 3O 3 O RT A49CE 1E4 2005060800161 20050608 00161 CE 2005 6 8 2005FA0000802 1 20050523 G 5540 5433000020 RUDDER LEAR 60 60LEAR 5170707 CE PWA 305 PW305 NE TAIL DAMAGED B WVER K NONE O OTHER IN INSP/MAINT 1 EA 09 249FX 193 UPON REMOVAL AND REPLACEMENT OF RUDDER CABLES, FOUND RUDDER SUPPORT STIFFENER ANGLE CRACKED UNDER RUDDER PRIMARY TRAVEL STOP AT FRAME STA 48, ALSO FOUND RUDDER LEADING EDGE PANELS 331,332, AND 333 TO BE CRACKED AND RUDDER FORWARD SPAR TO BE DAMAGED AT RUDDER CENTER AND UPPER HINGE POINTS WL 92.34 AND WL 122.83. PROBABLE CAUSE: RUDDER OVER TRAVELING WHEN GUS T LOCK NOT INSTALLED AND WHEN PARKED OUTSIDE IN WINDY CONDITIONS. REC: ENSURE FLIGHT CONTROL GUST LOCKS ARE INSTALLED W HEN PARKED OUTSIDE.(EA09200505203) (K) 2 L 7 2 4F 4 F RT A10CE E35NE 2005060800163 20050608 00163 CE 2005 6 8 2005FA0000803 1 20050521 G 5544 5412481026 SUPPORT BRACKET LEAR 60 60LEAR 5170707 CE RUDDER CRACKED B WVER K NONE O OTHER IN INSP/MAINT 1 EA 09 198HB 198 UPON REINSTALLATION OF RUDDER ASSY, FOUND RUDDER SUPPORT BRACKET AND STIFFENER ANGLE CRACKED UNDER RUDDER PRIMARY TRAVEL STOP AT FRAME STA 48. PROBABLE CAUSE: RUDDER OVER TRAVELING AGAINST PRIMARY STOP, WHEN GUST LOCK NOT INSTALLED AND WHE N PARKED OUTSIDE N WINDY CONDITIONS. REC: ENSURE FLIGHT CONTROL GUST LOCKS ARE INSTALLED WHEN PARKED OUTSIDE. (EA09200 505204) (K) 2 L 7 2 4F RT A10CE 2005060800171 20050608 00171 NM 2005 6 8 2005FA0000804 1 20050523 G 2621 M80530044 SEAT KIDDE BOEING 727 727* NM FIRE BOTTLE DAMAGED B P94R K NONE O OTHER IN INSP/MAINT 1 SO 19 89651EK RECEIVED APU FIRE EXTINGUISHER FOR OVERHAUL AFTER FIRING. DURING THE DISASSEMBLY, IT WAS DISCOVERED THAT THE PYROTECHNI C CARTRIDGE MELTED THE STAINLESS STEEL BOTTLE’S SEAT RENDERING THE PRESSURE VESSEL SCRAP. THIS TYPE OF DAMAGE IS CONSIS TENT WITH PREVIOUSLY REPORTED DAMAGE CAUSED BY THIS MFG CARTRIDGES. REPAIR STATION IS VERY CONCERNED SINCE AT LEAST (2) OTHER UNRELATED REPAIR STATIONS HAVE REPORTED SIMILAR PROBLEMS WITH THE PYROTECHNIC CARTRIDGES FROM THIS MFG. (K) 2 L 7 3 4F RT A3WE 2005061300121 20050613 00121 EU 2005 6 13 2005FA0000805 1 20050503 G 2780 1075D1003 CONTROL UNIT ISRAEL 1125 ASTRASPX 4500205 EU ZONE 900 OUT OF TOLERANCE Z D RETURN TO BLOCK F FLT CONT AFFECTED TX TAXI/GRND HDL 1 WP 03 B2001 22 119 THE FSECU HAS A RELIABILITY PROBLEM. HERE IS THE FAULT HISTORY BELOW; SERVICE TIME ON S/N 131 IS 6.1 HOURS. SERVICE TI ME ON S/N 149 IS 0.8 HOURS. SERVICE TIME ON S/N 140 IS 328.2 HOURS. SERVICE TIME ON S/N 107 IS 605.4 HOURS. SERVICE T IME ON S/N 317 IS 38.9 HOURS. VERY LOW TIME ON THESE UNITS THAT FAILED. THE FLIGHT CONTROL SYSTEM IMPROVEMENTS HISTORY AS NOTED HEREIN AFTER; CHANGE THE P/N OF SLAT FLEXIBLE SHAFT NR 1 FROM V25W513320-001 OR V25W513330-001 TO V25W513330-2 01. CHANGE THE P/N OF SLAT PDU FROM V25W513310-001 OR V25W513310-003 TO V25W513310-003 MOD AB. 2 L 7 2 4F RT A16NM 2005061300122 20050613 00122 EU 2005 6 13 2005FA0000806 1 20050503 G 2780 1075D1003 CONTROL UNIT ISRAEL 1125 ASTRASPX 4500205 EU ZONE 900 OUT OF TOLERANCE Z D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 WP 03 B2001 22 119 THE FSECU HAS A RELIABILITY PROBLEM. HERE IS THE FAULT HISTORY BELOW; SERVICE TIME ON S/N 131 IS 6.1 HOURS. SERVICE TI ME ON S/N 149 IS 0.8 HOURS. SERVICE TIME ON S/N 140 IS 328.2 HOURS. SERVICE TIME ON S/N 107 IS 605.4 HOURS. SERVICE T IME ON S/N 317 IS 38.9 HOURS. VERY LOW TIME ON THESE UNITS THAT FAILED. THE FLIGHT CONTROL SYSTEM IMPROVEMENTS HISTORY AS NOTED HEREIN AFTER; CHANGE THE P/N OF SLAT FLEXIBLE SHAFT NR 1 FROM V25W513320-001 OR V25W513330-001 TO V25W513330-2 01. CHANGE THE P/N OF SLAT PDU FROM V25W513310-001 OR V25W513310-003 TO V25W513310-003 MOD AB. 2 L 7 2 4F RT A16NM 2005061400058 20050614 00058 SO 2005 6 14 2005FA0000807 1 20050522 G 2433 WH120 CONVERTER GULSTM G1159 GIV 3980115 SO LAV TOILET FAILED C H DEACTIVATE SYST/CIRCUITS S B AFFECT SYSTEMS SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 NM 09 941AM 843 1499 PILOTS DISCOVERED AUX DC CONV CIRCUIT BREAKER POPPED AFTER LAV WOULD NOT FLUSH. BREAKER WAS RESET, IT IMMEDIATELY POPPE D AGAIN WITH SMALL AMOUNT OF SMOKE EMANATING FROM CABIN CONVERTER, ID 106A1. BREAKER SECURED. FLIGHT COMPLETED SANS FL USH TOILETS AND CABIN READING LIGHTS. NEW UNIT INSTALLED. OPERATIONAL CHECK SATISFACTORY. NOTE: THE FAILED UNIT SERIA L NUMBER WAS WELL ABOVE THE RANGE AFFECTED TO UPDATE TO MOD 5 STATUS PER GAC AND KGS. 2 L 7 2 4F RT A12EA 2005062900004 20050629 00004 CE 2005 6 29 2005FA0000808 1 20050430 G 2740 04321383 CHAIN CESSNA 180 180J 2072622 CE CONT O470 O470* 17026 SO AFT STABILIZER CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SO 03 15BF 18052353 CHAIN LINK CRACKS IN AFT STABILIZER CHAIN. POSSIBLE OVER STRESS OR MFG DEFECT. (K) 1 H 7 1 3O 3 O 5A6 E273 2005062900062 20050629 00062 SO 2005 6 29 2005FA0000810 1 20050118 G 3230 402427 DRAG LINK PIPER PA23 PA23250 7102308 SO LYC O540 TIO540* 41532 EA LT MLG BROKEN B ML2R O OTHER O OTHER NR NOT REPORTED 1 GL 11 63764 277754097 AC WAS ON ROLL OUT AFTER LANDING, WHEN LT MAIN LANDING GEAR DRAG LINK ASSY SEPARATED BETWEEN UPPER LINK ASSY AND LOWER L INK ASSY. THIS ALLOWED LT MLG STRUT ASSY TO FOLD AFT ALLOWING AC TO COLLAPSE ON RUNWAY. WHEN AC WAS RECOVERED, THE LT MLG CENTER DRAG LINK ATTACH BOLT WAS FOUND SHEARED IN CENTER OF BOLT SHANK. BOTH HALVES OF BOLT WERE STILL IN THE LT LO WER DRAG LEG AND WERE ABLE TO BE REMOVED FOR INSP. VISUAL INSP OF BOLT FRACTURE INDICATED AN EXITING CRACK ACROSS APPRO X .7500 PERCENT OF THE BOLT SHANK WITH A NEW CRACK THROUGH REMAINING .2500 PERCENT OF BOLT SHANK. A REPLACEMENT BOLT WA S INSTALLED TO FACILITATE RECOVERY OF AC AND AC WAS TURNED OVER TO OWNER FOR REPAIRS TO BE COMPLETED. (K) 1 L 7 2 3O 3 O 1A10 E14EA 2005062900023 20050629 00023 SO 2005 6 29 2005FA0000811 1 20050509 G 5797 WIRE PIPER PA31 PA31350 7103110 SO RT WING SHORTED B OF1R C ABORTED TAKEOFF A FLAME/FIRE TO TAKEOFF 1 EA 17 151LL 317852025 RT WING EXPLODED ON TAKEOFF ROLL DUE TO IGNITED FUEL VAPORS TRAPPED IN EMPTY WING CAVITY OR OF FUEL CELLS. INSP REVEALE D; RT MAIN FUEL CELL VENT NIPPLE WAS BROKEN OFF, VERY BRITTLE AND DETERIORATED, ALLOWING FUEL VAPORS TO ACCUMULATE IN TH IS CAVITY. PREVIOUSLY INSTALLED COLEMILL WINGTIP AND LANDING LIGHT MODIFICATION WAS PERFORMED, ROUTING ITS 28 VOLT POWE R WIRE FROM ROOT TIP FOLLOWING AFT STRINGER, PASSING THRU RIBS VIA STRINGER CUTOUTS WITH NO PROTECTION. THIS WIRE WAS F OUND TO BE SHORTED AND BURNED OFF WITH EVIDENCE OF EXCESS ARCHING AT WING STA 148, BREAKER WAS POPPED CAUSING IGNITION O F ABOVE FUEL VAPORS. INCIDENT COULD HAVE BEEN AVOIDED, PROPER FUEL CELL INSP AND ROUTING WIRES PROPERLY IAW ADV CIR. 1 L 7 2 3O A20SO 2005062100001 20050621 00001 GL 2005 6 21 2005FA0000812 1 20050607 G 3220 LANDING GEAR AMTR LANCAR LANCAIRES GL CONT O360 TSIO360CB 17025 SO NOSE VIBRATES G O OTHER E VIBRATION/BUFFET LD LANDING 1 WP 19 1169G ES063FB SEVERE NOSE GEAR SHIMMY DURING LANDING. NOSE GEAR STRUT SERVICED WITH MIL-H-5606, REQUIRED 30-WT FORK OIL. NEXT FLT A SEVERE SHIMMY AGAIN. INSP REVEALED ENG MOUNT BROKEN 6 PLACES AS A RESULT. ENG MOUNT & NOSE GEAR STRUT REPLACED, ON NEX T FLT, A SEVERE NOSE GEAR SHIMMY ENCOUNTERED. INSP DISCLOSED NOSE GEAR STRUT HOT TO TOUCH & COLOR OF OIL CHANGED. COWL ING BURNED NEAR TURBO CHARGER. STANDARD LANCAIR ES COWLING WAS NOT DESIGNED FOR A TURBOCHARGED ENG INSTALLATION. HEAT WITHIN COWL TRANSFERS INTO NOSE GEAR STRUT & HEATS STRUT & OIL TO A TEMP THAT RENDERS INTERNAL SHIMMY DAMPENING SYS INEF FECTIVE & DAMAGES OLEO STRUT. TELEDYNE TSIO-360 SERIES ENGINE IS NOT AN ENGINE INSTALLATION RECOMMENDED BY LANCAIR. 1 L 7 1 3 O EXPA1L71 E9CE 2005062900007 20050629 00007 SO 2005 6 29 2005FA0000813 2 20050127 G 8520 653547 MAIN BEARING CESSNA 206 U206G 2073356 CE CONT O550 IO550F 17042 SO MCAULY D3A34 D3A34C402 GL NR 2 DISINTEGRATED G O OTHER O OTHER NR NOT REPORTED 1 AL 03 756XE U20604432 28484012 980169 METAL WAS FOUND IN OIL FILTER. CLEANED WENT FOR TEST FLIGHT, LOST OIL PRESSURE. ENGINE REMOVED, WITNESSED TEARDOWN. F OUND NR 2 MAIN BEARING SPUN AND DISINTEGRATED. CRANKSHAFT CHECKED OUT OK. ENGINE CASE WAS BADLY DAMAGED AT THE NR 2 BE ARING BOSS ENGINE HAD 790 HOURS SFRM. ENGINE OPERATIONS WAS MOSTLY ON A FLOATPLANE. (K) 1 H 7 1 3O 3 O A4CE E3SO 5 C P47GL 2005062900054 20050629 00054 SO 2005 6 29 2005FA0000814 2 20050502 G 8520 A73851 PISTON CESSNA 185 A185F 2072821 CE CONT O200 O200* 17020 SO ENGINE CRACKED D YEBR O OTHER O OTHER NR NOT REPORTED 1 EA 03 26DL 18502287 L859615 REMOVED CYLINDERS ON A FRESHLY OVERHAULED ENGINE PRIOR TO RUNNING AND FOUND A 3 INCH CRACK AROUND THE OIL RING LANDING. (K) 1 H 7 1 3O 3 O 3A24 E252 2005062100159 20050621 00159 EU 2005 6 21 2005FA0000815 1 20050609 G 7910 029907004 PROBE AMD FALC90 FALCON900EX 2730009 EU GARRTT TFE731 TFE731* 01518 WP OIL TANK DAMAGED B K NONE O OTHER IN INSP/MAINT 1 CE 09 166FB 18 P112161 DISCOVERED OIL LEVEL PROBE IN ENGINE OIL TANK TO HAVE ONE RIVET MISSING FROM THE DATA TAG AND THE PLASTIC END CAP CRACKE D AT ONE RIVET HOLE. THE DATA TAG WAS VERY LOOSE BUT STILL ATTACHED BY THE ONE REMAINING RIVET. IF THE DATA TAG OR END CAP WERE TO COME LOOSE, THEY COULD RESTRICT OR PLUG THE ENGINE OIL SUPPLY STANDPIPE. THE DEFECT WAS FOUND DURING AN EN GINE INSTALLATION. THIS IS AN AIRFRAME SYSTEM COMPONENT. 2 L 7 3 4F 4 F RT A46EU E6WE 2005061600216 20050616 00216 NM 2005 6 16 2005FA0000816 1 20050608 G 6220 900R2101006107 HUB DOUG DOUG MD900 MD900 3027375 NM PWC PW207 PW207E NE MAIN ROTOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 EA 11 3PD 127 127 0099990080 90000085 DURING ACCOMPLISHMENT OF AD 2002-10-05- MAIN ROTOR UPPER HUB INSP FOUND (2) BOLT HOLES CRACKED AS DEPICTED IN MD HELICOP TERS SERVICE BULLETIN 900-072. CRACKS WERE FOUND USING MAGNIFIED VISUAL METHOD. HUB WAS SUBSEQUENTLY INSPECTED BY EDDY CURRENT METHOD TO VERIFY CRACKS. EDDY CURRENT INSPECTION USING A BOLT HOLE SCAN FOUND A THIRD HOLE CRACKED. THIS CRAC K WAS NOT VISIBLE AT THE FLANGE SURFACE USING THE MAGNIFIED VISUAL METHOD. TO DATE HUB IS ON ORDER PENDING REPLACEMENT. 1 G 7 2 3U 3 U NC H19NM E42NE 2005062100109 20050621 00109 NE 2005 6 21 2005FA0000817 1 20050214 G 6320 THRUST WASHER SKRSKY S64 S64E 8142604 NE PWA JFTD12 JFTD12A5A 52047 NE M/R GEARBOX WORN B JYDR O OTHER O OTHER NR NOT REPORTED 1 NM 09 173AC 926 64015 MAIN GEAR BOX, SN A6051 REMOVED FOR BRASS CONTAMINATION. UPON DISASSEMBLY DISCOVERED BRASS MATERIAL WAS FROM SECOND STA GE PLANETARY THRUST WASHERS. 34 OUT OF 36 THRUST WASHERS WORN ON ID BEYOND MAX SERVICEABLE LIMITS. 18 EA BEARINGS HAD S HARP EDGES INNER RACE EDGES. CURRENTLY BE EVALUATED BY BEARING SUPPLIER. NEED TO BREAK SHARP EDGES. (K) 2 G 7 2 4U 4 U H4EA E15EA 2005062100111 20050621 00111 NE 2005 6 21 2005FA0000818 2 20050302 G 7250 DUCT SKRSKY S64 S64E 8142604 NE PWA JFTD12 JFTD12A5A 52047 NE TURBINE SECTION CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 189AC 641001 NR 1 ENGINE REMOVED FROM ACFT, DUE TO 5 INCH AXIAL BULGE AT OUTER TURBINE CASE, 2-3 OCLOCK POSITION WITH APPROX .5625 INCH HORIZONTAL CRACK RUNNING THROUGH CENTER MOST PORTION OF THE BULGED AREA. UPON REMOVAL OF ENGINE HOT SECTION, TURB INE OUTLET DUCT FOUND TO HAVE APPROX A 8.5 INCH SECTION OF MATERIAL BROKEN OFF AND PEELED BACK FROM OUTER DUCT AREA AT N R 2 AND NR 3 COMBUSTION CAN POSITIONS. THE P AND D VALVE AND FUEL MANIFOLD ASSEMBLIES WERE INSP AND FOUND TO HAVE NO EV IDENCE OF FAILURE. PROBABLE CAUSE IS UNKNOWN AND NO RECOMMENDATIONS TO PREVENT RECURRENCE AT THIS TIME. (K) 2 G 7 2 4U 4 U H4EA E15EA 2005062100110 20050621 00110 NE 2005 6 21 2005FA0000819 1 20050414 G 6520 6435664071 GEAR SKRSKY S64 S64F 8142610 NE PWA JFTD12 JFTD12A4A 52047 NE T/R GEARBOX CRACKED B JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 159AC 284 64084 TGB AND SERVO ASSY REMOVED FROM ACRFT FOR MAKING METAL. GEARBOX DISASSEMBLED AND DURING VISUAL INSP OF OUTPUT GEAR, ONE TOOTH FOUND CRACKED. FRIVE SIDE OF TOOTH SHOWS THE MAJORITY OF CRACKING, STARTING FROM IB TO ALMOST MIDWAY ON TOOTH EX TENDING ACROSS TIP LAND TO OPPOSITE SIDE, THEN OB. APPEARS TO BE 3 CRACKS EXTENDING THE LENGTH OF GEAR TOOTH AND ENDING UP AT APPROX .2500 INCH AND .3750 INCH FROM THE ROOT. MPI INSP CONFIRMED TOOTH WAS CRACKED. NO OTHER CRACKS FOUND. (K) 2 G 7 2 4U 4 U H6EA E15EA 2005062300074 20050623 00074 NE 2005 6 23 2005FA0000820 2 20050413 G 7250 597602 TURBINE BLADES SKRSKY S64 S64F 8142610 NE PWA JFTD12 JFTD12A5A 52047 NE ENGINE BROKEN B JYDR O OTHER O OTHER NR NOT REPORTED 1 NM 09 159AC 64084 COMPRESSOR ASSY WAS REMOVED FROM AC FOR FAILING VIBRATION ANALYSIS. DURING THE PRELIMINARY INSPECTION IT WAS NOTED THAT A PIECE OF 2ND STAGE TURBINE BLADE OUTER SHROUD KNIFE EDGE WAS MISSING. THE MISSING PIECE WAS APPROXIMATELY .500 INCH LONG AND FROM THE AFT KNIFE EDGE. FURTHER INSPECTION REVEALED NO OTHER DAMAGE. THE BLADE WAS IN OVERHAULED CONDITION W HEN INSTALLED. (K) 2 G 7 2 4U 4 U H6EA E15EA 2005061600270 20050616 00270 GL 2005 6 16 2005FA0000821 1 20050531 G 3240 MS24775222 O-RING CIRRUS SR SR22 2130001 GL CONT O470 TSIO470* 17026 SO BRAKE ASSY FLAT G O OTHER O OTHER NR NOT REPORTED 1 WP 23 8156E 0726 AC LANDED AND DISCOVERED THEY HAD NO RT BRAKE. AC LOST DIRECTIONAL CONTROL AND IMPACTED A PARKED AIRCRAFT CAUSING SUBST ANTIAL DAMAGE TO THE PARKED AIRCRAFT. INVESTIGATION REVEALED THE RT BRAKE O-RING WAS FLAT AND THE HOUSING AND DATA PLAT E SHOWED EXTREME HEAT. REVIEW OF THIS SITUATION FOUND THAT THERE HAVE BEEN MANY OWNER REPORTS IN THE OWNERS NEWSLETTER OF RT BRAKE FAILURES DUE TO THE NEED TO STEER THE AC WHICH HAS A CASTERING NOSE WHEEL. 1 L 7 1 3O 3 O NT A00009CH 3E3 2005061600275 20050616 00275 CE 2005 6 16 2005FA0000822 1 20050605 G 2910 S217840150A HOSE CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA HYD SYSTEM LEAKING G O OTHER K FLUID LOSS NR NOT REPORTED 1 WP 23 7972V 177RG0915 PILOT SELECTED GEAR DOWN ON FINAL APPROACH AND THE GEAR FAILED TO EXTEND. THE INVESTIGATION FOUND THAT THE NOSE GEAR DO WN LINE WAS LEAKING AT THE BULKHEAD END CAUSING TOTAL LOSS OF HYDRAULIC FLUID. THE AIRCRAFT LANDED GEAR UP WITH NO INJU RIES AND MINOR DAMAGE TO THE EXTERIOR OF THE AIRCRAFT. (WP23200509350) (K) 1 H 7 1 3O 3 O A20CE 1E10 2005061600235 20050616 00235 CE 2005 6 16 2005FA0000823 1 20050526 G 2435 03600918 BEARING BEECH B300 B300 1159232 CE PWA PT6 PT6A60A 52043 NE STARTER GEN SEIZED B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 350TT 301 P1047 FL413 PILOT REPORTED RT ENGINE SURGING, SMOKE FROM EXHAUST SIMULTANEOUSLY WITH RT GENERATOR GOING OFF LINE IN CRUISE FLIGHT. FOUND RT STARTER/ GENERATOR ANTI-DRIVE (BRUSH END) BEARING SEIZED, INPUT SHAFT INTACT. REPLACED STARTER/GENERATOR AND EXAMINED OIL FILTER IAW MM FAILED GENERATOR SPECIAL INSPECTION PROCEDURES. NO APPRECIABLE METALLIC PARTICLES NOTED IN O IL FILTER SENT IN FOR ANALYSIS. GENERATOR OPERATINS NORMAL AND ENGINE PERFORMANCE WITHIN MM, SERVICE LIMITS AFTER START ER/GENERATOR REPLACEMENT. 2 L 7 2 4T 4 T RT A24CE E4EA 2005062700103 20050627 00103 WP 2005 6 27 2005FA0000824 1 20050606 G 6230 23600 MAST HILLER UH12 UH12E 4360122 WP ALLSN 250C 250C20B 03013 GL MAIN ROTOR CRACKED D JYBG O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 NM 09 76431 229 992 HELICOPTER EXPERIENCED A PROGRESSIVE LATRIAL VIBRATION. SUBSEQUENT INSPECTION FOUND 2 CRACKS FROM THE PITCH PIN SLOT AR EA OF THE MAST. ONE CRACK FROM THE TOP OF ONE SLOT AND ANOTHER CRACK FROM THE BOTTOM OF THE SAME SLOT PROGRESSING THE O PPOSITE DIRECTION. THE TOP CRACK IS APPROX 1.6 INCHES AROUND THE DIAMETER OF THE MAST AND THE BOTTOM CRACK IS APPROX 1. 3 INCHES. 1 G 7 1 3O 3 U 4H11 E4CE 2005062700104 20050627 00104 SO 2005 6 27 2005FA0000825 1 20050603 G 2421 4111810R ALTERNATOR PIPER PA28 PA28161 7102803 SO LYC O320 O320* 41508 EA ENGINE FROZEN G O OTHER O OTHER NR NOT REPORTED 1 NE 03 36116 214 287816614 ALTERNATOR FROZE UP UPON ENGINE SHUTDOWN. OVERHAULED. 1 L 7 1 3O 3 O 2A13 E274 2005062700105 20050627 00105 SO 2005 6 27 2005FA0000826 1 20050603 G 2421 4111810R ALTERNATOR PIPER PA28 PA28161 7102803 SO LYC O320 O320* 41508 EA ENGINE MALFUNCTIONED G O OTHER O OTHER NR NOT REPORTED 1 NE 03 9284A 342 288616041 ALTERNATOR CREATES WHINE OVER RADIOS AND HAS NO OUTPUT AT IDLE RPM, (VOLTAGE IS BATTERY VOLTAGE) OVERHAULED. (K) 1 L 7 1 3O 3 O 2A13 E274 2005062700106 20050627 00106 NE 2005 6 27 2005FA0000827 1 20050601 G 6420 SB25011 BEARING SKRSKY S61 S61A 814210C NE GE CT58 CT581401 30011 NE TAIL ROTOR BRINELLED D JYER O OTHER O OTHER NR NOT REPORTED 1 NM 09 1043T 1743 61083 AT OVERHAUL, REMOVED HUB BEARING INNER RACES AND FOUND (1 EACH) CRACKED ABOUT 1.5 INCHES DUE TO SEVERE BRINNELING. PROB ABLE CAUSE COULD BE DUE TO GREASE (MINIMAL AMOUTS). RECOMMEND DAILY PURGING OF HUB BEARING TO PREVENT ANOTHER OCCURENCE . (K) 2 G 7 2 4U 4 U H2EA 1E3 2005062700107 20050627 00107 CE 2005 6 27 2005FA0000828 1 20050623 G 3710 B906 HOSE CESSNA 172 172P 2072436 CE VACUUM SYS CRACKED B DINR O OTHER W INADEQUATE Q C NR NOT REPORTED 1 EA 13 51178 5000 17274274 VACUUM SYSTEM HOSES (ORIGINAL EQUIPMENT), RED PLASTIC INNER LINER CRACKING WITH PIECES AND FLAKES BREAKING OFF. COULD C AUSE GYRO OR VACUUM PUMP FAILURE. (K) 1 H 7 1 3O NT 3A12 2005062700109 20050627 00109 EU 2005 6 27 2005FA0000829 1 20050422 G 1100 PLACARD AIRBUS AIRBUS A319 A319112 3930323 EU GE CFM56 CFM56* 13802 NE WING FUEL TANK SEPARATED D O OTHER D C INFLIGHT SEPARATION F.O.D. NR NOT REPORTED 1 NE 03 727UW 1147 1147 DEBRIS (PLASTIC IDENTIFICATION DECALS) FOUND IN LT AND RT FUEL TANK WING ROOT AREAS DURING C-CHECK. QIT ISSUED BY MFG A ND IS APPLICABLE TO MSN1147. (K) 2 L 7 2 4F 4 F RT A28NM E2GL 2005062700110 20050627 00110 2005 6 27 2005FA0000830 4 20050525 G 3417 702490030303 ADC LEAR 35 35A 5170602 CE GARRTT TFE731 TFE731* 01518 WP E/E BAY DEFECTIVE B BSYA O OTHER O OTHER NR NOT REPORTED 1 GL 07 27BL 163 THE PILOTS ALTIMETER AND ALTITUDE ALERTER WERE FLAGGED. THE ADC WAS FOUND TO BE DEFECTIVE AND REPLACED. THE SYSTEM WAS TESTED AND INSPECTED AND FOUND TO COMPLY WITH FAR 91.411 PART 43 AND TO REMAIN RVSM COMPLIANT. THERE HAVE BEEN NO PRIO R REPORTS OF PROBLEMS WITH THIS SYSTEM. (K) 2 L 7 2 4F 4 F A10CE E6WE 2005062700111 20050627 00111 2005 6 27 2005FA0000831 4 20050427 G 3417 702490030303 ADC LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE731* 01518 WP E/E BAY INOPERATIVE B BSYA O OTHER O OTHER NR NOT REPORTED 1 GL 07 4358N 35065 CAPTAIN (LT SIDE) ALTIMETER, VERTICAL SPEED AND ALTITUDE ALERTER INOPERATIVE. FOUND THE PRIMARY ADC INOPERATIVE. REPLA CED THE ADC, TESTED THE PRIMARY ALTIMETERY SYSTEMS, FOUND TO COMPLY WITH FAR AND TOBE RVSM COMPLIANT. THERE HAVE BEEN N O PREVIOUS PROBLEMS WITH THIS SYSTEM. (GL07200508784) 2 L 7 2 4F 4 F A10CE E6WE 2005062700112 20050627 00112 2005 6 27 2005FA0000832 4 20050527 G 3417 702490030303 ADC LEAR 35 35A 5170602 CE GARRTT TFE731 TFE731* 01518 WP LT E/E BAY DEFECTIVE B BSYA O OTHER O OTHER NR NOT REPORTED 1 GL 07 56EM 144 PILOTS ALTIMETER AND ALTITUDE ALERTER WERE FLAGGED. THE ADC WAS FOUND TO BE DEFECTIVE AND REPLACED. THE SYSTEM WAS TES TED AND INSPECTED AND FOUND TO COMPLY AND TO REMAIN RVSM COMPLIANT. THERE HAVE BEEN NO PRIOR REPORTS OF PROBLEMS WITH T HIS SYSTEM. (K) 2 L 7 2 4F 4 F A10CE E6WE 2005062700113 20050627 00113 2005 6 27 2005FA0000833 4 20050506 G 3417 702490030303 ADC LEAR 35 35A 5170602 CE GARRTT TFE731 TFE731* 01518 WP LT E/E BAY DEFECTIVE B BSYA O OTHER O OTHER NR NOT REPORTED 1 GL 07 813AS 167 ON TAKEOFF ROLL OUT, THE PILOTS ALTIMETER, IVSI AND ALTITUDE ALERTER FLAGGED. THE TAKEOFF WAS ABORTED. THE ADC WAS FOU ND TO BE DEFECTIVE AND REPLACED. THE SYSTEM WAS TESTED AND INSPECTED AND FOUND TO COMPLY WITH FAR AND REMAIN RVSM COMPL IANT. THERE HAVE BEEN NO PRIOR REPORTS OF PROBLEMS WITH THIS SYSTEM. (K) 2 L 7 2 4F 4 F A10CE E6WE 2005062700114 20050627 00114 SO 2005 6 27 2005FA0000834 2 20050430 G 7322 30804 FLOAT PRECISION TCRAFT F19 F19 9302703 EA CONT O200 O200* 17020 SO CARBURETOR BENT G A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 AL 01 3691T 70 F098 ENG QUIT DURING TAKEOFF AT APPROX 300-500 AGL. DURING EXAM OF ENG COMPONENTS, IT WAS NOTED ADVANCE POLYMAR FLOAT WAS BE NT AWAY FROM THE FLOAT AT APPROX 45 DEGREE ANGLE. THIS CONDITION WOULD LEAD TO THE FLOW INTO THE CARBURETOR. PRECISION SIL MS-4 REV 1 ADDRESSES NEW ADVANCED POLYMER FLOATS. REF INSTALLATION INSTRUCT E-955. THERE IS NO WARNING OR CAUTION TO ALERT OVERHAULERS TO BE AWARE OF BENT FORK CONDITION IN EITHER OF THESE DOCUMENTS. SPECIFIC CLEAR BETWN FORKED RETR ACTOR AND FLOATBODY. SPECIFIC FLOAT DROP REQUIRED TO ALLOW FUEL TO INFLOW TO CARB BOWL. ILLUSTRATIONS CORRECT RETRACTO R FORK/CLIP POSITIONS. REINSTATE SPRING CLIP ON FLOAT VALVE TO ENSURE POSITIVE PULL ON FLOAT VALVE. 1 H 7 1 3O 3 O NC 1A9 E252 2005062700116 20050627 00116 CE 2005 6 27 2005FA0000835 1 20050602 G 1430 NAS620518D BOLT RAYTHN 390 390 7150030 CE NR 3 FLAP ROLLER CHAFED B YK1R O OTHER O OTHER NR NOT REPORTED 1 SW 11 128JL 385 RB28 UPON REMOVAL OF FLAP ACTUTORS FOUND NR 3 LT AND RT FLAP ACTUATORS WERE DEEPLY GOUGED, DUE TO FLAP TRACK BOLTS INSTALLED BACKWARDS. PN OF BOLT NAS6205-18D. REMOVED BOLT AND INSPECTED AND REINSTALLED IN THE CORRECT DIRECTION. (K) 1 7 2 3F RT A00010WI 2005062800139 20050628 00139 CE 2005 6 28 2005FA0000836 1 20050601 G 2797 CIRCUIT BOARD CESSNA 210 T210M 2073451 CE CONT O520 TSIO520* 17040 SO PITCH TRIM LOOSE D O OTHER O OTHER NR NOT REPORTED 1 CE 07 6033N 21062901 ELECTRIC PITCH TRIM SYSTEM RAN AWAY ON APPROACH. AUTOPILOT/ TRIM DISCONNECT HAD NO EFFECT. PILOT DISENGAGED PITCH TRIM CIRCUIT BREAKER TO STOP THE RUNAWAY. AFTER THE CIRCUIT BREAKER WAS DISENGAGED, THE CONTROL WHEEL VIBRATED ON THE APPRO ACH AT APPROXIMATELY 120 TO 130 KNOTS. FOUND CONTROL WHEEL ELECTRICAL RIBBON CIRCUIT BOARD LOOSE BEHIND INSTRUMENT PANE L CAUSING GROUND. REATTACHED BOARD WITH NEW SCREWS AND SPACERS. OPS CHECK OK. INSPECTED STABILIZERS, RUDDER, ELEVATOR S AND TAB. NO DEFECTS FOUND AT THIS TIME. (K) 1 H 7 1 3O 3 O 3A21 E8CE 2005062800137 20050628 00137 EA 2005 6 28 2005FA0000837 1 20050601 G 5500 C3FS465502 PLATE DHAV DHC3 DHC3 2800202 EA PWA PT6 PT6* 52043 EA TAIL SECTION CRACKED B GJRR O OTHER O OTHER NR NOT REPORTED 1 NM 01 606KA 9702 37 PART FOUND TO BE CRACKED FROM BOTH REAR CORNER EXTENDING 2 INCHES IN LENGTH. PART HAS 9702 HOURS. STA 398-414. (K) 1 H 7 1 3R 3 T A815 E2NE 2005062800001 20050628 00001 SO 2005 6 28 2005FA0000838 1 20050603 G 2433 LS0305002 CONVERTER PIPER PA18 PA18150 7101828 SO LYC O320 O320* 41508 EA DC SYSTEM FAILED D YJ5R K NONE O OTHER IN INSP/MAINT 1 NM 05 4990P 1 188564 CONVERTER WAS INSTALLED IAW MFG INSTRUCTIONS, DIAGRAMS AND INSTALLATION WAS APPROVED WITH A 337. CONVERTER FAILED IN LE SS THAN 10 SECONDS. OUT OF FIVE CONVERTERS, FOUR IN AC AND ONE ON THE TEST BENCH, ALL HAVE FAILED. (K) 1 H 7 1 3O 3 O 1A2 E274 2005062800003 20050628 00003 CE 2005 6 28 2005FA0000839 1 20050517 G 5311 00244002465 FRAME BEECH 36 A36 1151604 CE CONT O550 TSIO550A 41516 SO BULKHEAD CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SW 01 8131H E2755 BULKHEAD FRAME ASSY AT STA 272. CRACKED AT TOP PORTION LT AND RT IN BEND RADIUS, APPROX CRACK TO BE ABOUT .5 INCH ON LT AND 1 INCH ON RT. (K) 1 L 7 1 3O 3 O 3A15 E5SO 2005062800004 20050628 00004 CE 2005 6 28 2005FA0000840 1 20050510 G 5312 00244002465 BULKHEAD BEECH 36 A36 1151604 CE CONT O550 IO550* SO FUSELAGE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 01 8183E E2612 BULKHEAD AT STA 272, REAR AFT FUSELAGE FOUND CRACKS AT TOP PORTION OF BULKHEAD AT RADIUS OVER CRACK APPROX .5 ON LT AND ABOUT 1.5 ON RT ALSO CAUSING DOUBLER TO CRACK OUT THAT HOLDS THE 2 SKINS TOGETHER. (K) 1 L 7 1 3O 3 O 3A15 E3SO 2005062800138 20050628 00138 CE 2005 6 28 2005FA0000841 1 20050510 G 5312 00244002465 BULKHEAD BEECH 36 A36 1151604 CE CONT O550 IO550* SO FUSLEAGE CRACKED D MASS O OTHER O OTHER NR NOT REPORTED 1 SW 01 8026T E2701 WEB BULKHEAD AT STA 272 REAR AFT FUSELAGE, FOUND CRACKS AT TOP PORTION ON RADIUS OF POST. CRACK TO BE APPROX 1 INCH ON LT AND ABOUT .2400 INCH ON RT, ALSO CAUSING DOUBLER TO CRACK OUT THAT HOLDS THE 2 SKINS TOGETHER. PROBABLE CAUSE, JUST HIGH TIME IN AIRFRAME, ALSO MFG TO MAKE A MODIFICATION, SUCH AS A BIGGER DOUBLER TO PREVENT FUTURE CRACKS. (K) 1 L 7 1 3O 3 O 3A15 E3SO 2005062800005 20050628 00005 CE 2005 6 28 2005FA0000842 1 20050517 G 5312 00244002465 BULKHEAD BEECH 36 A36 1151604 CE CONT O550 IO550* SO FUSELAGE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 01 1830V E3087 TAIL BULKHEAD AT STA 272.0, FOUND CRACKS ON TOP PORTION IN BEND RADIUS AREA, APPROX .5 INCH TO .2500 INCH LONG ON TOP, L T AND RT AREA. PROBABLE CAUSE SEEMS TO BE FATIGUE DUE TO HIGH TOTAL TIME ON AIRFRAME. (K) 1 L 7 1 3O 3 O 3A15 E3SO 2005062800127 20050628 00127 2005 6 28 2005FA0000843 4 20050504 G 2562 MN1300 BATTERY ACK CESSNA 172 172M 2072418 CE LYC O320 O320* 41508 EA ELT LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 NE 01 19866 037866 17260817 DURING ANNUAL INSPECTION THE ELT WAS INSPECTED IAW FAR. THE 24 MONTH OLD MN 1300 BATTERIES WERE FOUND LEAKING WITH FLUI D VIVIBLE IN THE BOTTOM OF THE UNITS EACH 12 MONTHS OR REQUIRING A SEALED BATTERY INSTALLATION. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2005062800135 20050628 00135 CE 2005 6 28 2005FA0000844 1 20050517 G 5312 00244002457 BULKHEAD BEECH 58 58 1152740 CE CONT O550 IO550* SO FUSELAGE CRACKED D MASS O OTHER O OTHER NR NOT REPORTED 1 SW 01 8245H TH1635 BULKHEAD CRACKED AT TOP PORTION AT JOGGLED AREA BELOW AFT HORIZONTAL ATTACH BRACKET/SPAR CRACK TO BE ABOUT .2500 INCH ON RT, ABOUT 1 INCH ON LT, CAUSE PROBABLY DUE TO HIGH AIRFRAME TT AND FATIGUE. (SW01200504562) (K) 1 L 7 2 3O 3 O 3A16 E3SO 2005062900027 20050629 00027 EA 2005 6 29 2005FA0000845 1 20050524 G 5320 600310687 FLOOR SUPPORT CNDAIR CL600 CL6001A11 1900302 EA LYC ALF502 ALF502L2C NE FUSELAGE CRACKED B JGVR O OTHER O OTHER NR NOT REPORTED 1 CE 09 40HJ 15110 1058 FLOOR SUPPORT LOCATED AT RBL 9.0 FS 460 CRACKED AT FLANGE. DURING FLOORBEAM REPLACEMENT A VISUAL INSPECTION REVEALED CR ACK AT FLANGE. INSPECTED 3 OTHER FLOOR SUPPORTS IN AIRCRAFT, NO OTHER CRACKS FOUND. THE FLOOR SUPPORT IS CURRENTLY INC LUDED IN THE 60 MONTH BELOW FLOOR INSPECTION TASK. (K) 2 L 7 2 4F 4 F RT A21EA E6NE 2005062200200 20050622 00200 CE 2005 6 22 2005FA0000846 1 20050614 G 2622 99103494 FIRE BOTTLE CESSNA 441 441 2076020 CE CABIN DISCHARGED B K NONE O OTHER IN INSP/MAINT 1 GL 27 441CT 490 4410048 THIS FIRE BOTTLE HAS 1 YEAR ON IT AND THE PRESSURE HAS DROPED TO 20 PSI. THIS IS THE SECOND FIRE BOTTLE THAT DID NOT MA KE IT TO 5 YEARS. OVERHAULED BY KELLY AEROSPACE. (QUALITY OF WORKMANSHIP AND OR PARTS)? THIS NEVER HAS BEEN A PROBLEM . 1 L 7 2 3T RT A28CE 2005062200219 20050622 00219 SO 2005 6 22 2005FA0000847 2 20050614 G 7421 RHB32S SPARK PLUG BEECH 36 A36 1151604 CE CONT O550 IO550* SO ENGINE BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SO 11 2664M 106 28 E2317 675239 SPARK PLUG MAIN INSULATOR BROKE-OFF INTO ENGINE DURING OPERATIONS BETWEEN 88 AND 106 HOURS OF USE. A MAJOR PIECE OF CER AMIC MATERIAL WAS INJESTED INTO THE ENGINE. 1 L 7 1 3O 3 O 3A15 E3SO 2005062300132 20050623 00132 CE 2005 6 23 2005FA0000848 1 20050607 G 3520 10142187 CONTROL CABLE BEECH B300 B300 1159232 CE PAX OXYGEN SYS BROKEN B K NONE L NO TEST IN INSP/MAINT 1 EA 21 6117C 199 FL417 PERFORMING A PHASE 1 INSPECTION, IT IS REQUIRED TO PERFORM A FUNCTIONAL CHECK OF THE PASSENGER OXYGEN SYSTEM. THE TEE H ANDLE CONTROL WAS PULLED TO MANUALLY DEPLOY AND FLOW THE PASSENGER OXYGEN MASKS. THE MASKS DID NOT DEPLOY AND THERE WAS NO OXYGEN FLOW. FURTHER INVESTIGATION REVEALED THAT THE CONTROL CABLE WAS CONNECTED TO THE PASSENGER OXYGEN SHUT OFF V ALVE AND THE CONTROL CABLE WAS BROKEN SOMEWHERE IN THE MIDDLE. THE CONTROL CABLE WAS REPLACED WITH NEW AND PASSEGER OXY GEN SYSTEM OPERATIONAL CHECKED NORMAL. 2 L 7 2 4T RT A24CE 2005062300047 20050623 00047 CE 2005 6 23 2005FA0000849 1 20050606 G 5711 082260041 SPAR CAP CESSNA 310 310D 2074212 CE LT WING CORRODED D O OTHER O OTHER NR NOT REPORTED 1 SO 09 3031R 5772 39115 LT WING REAR UPPER SPAR CAP IN NACHELL/EXHAUST AREA AND OUTBOARD WS 80.0-100.0 APPROX. 20 INCHES, WAS FOUND DURING VISUA L INSPECTION, TO HAVE SEVERE EXFOLIATED INTERGRANULAR CORROSION RINDERING THIS SECTION OF SPAR TO BE UNSERVICABLE. ALSO JUST I/B OF BATTERY BOX ON THE FORWARD SPAR IS AN AREA OF HEAVY SURFACE CORROSION CAUSED BY BATTERY ACID/FUMES ON THE L OWER CAP AND WEB. WS 85.0-89.5 1 L 7 2 3O 3A10 2005062400073 20050624 00073 CE 2005 6 24 2005FA0000850 1 20050621 G 2720 A402092N CONTROL CABLE BEECH 35 35BEECH 1151502 CE RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 421B 434 D1428 LEFT AND RIGHT RUDDER CABLES FOUND FRAYED AT FRONT AND REAR PULLEY POSITIONS. 1 L 7 1 3O A777 2005062400074 20050624 00074 EU 2005 6 24 2005FA0000851 1 20050621 G 2720 A402092N CONTROL CABLE LET L13 L13ACBLANIK 1360312 EU RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 421BA 434 028902 LEFT AND RIGHT RUDDER CABLES FOUND FRAYED AT FRONT AND REAR PULLLEY POSITIONS. 1 K 0 0 G24EU 2005062300053 20050623 00053 SO 2005 6 23 2005FA0000852 1 20050606 G 3250 CLAMP PIPER PA46 PA46350P 7104602 SO NLG MISSING D K NONE O OTHER IN INSP/MAINT 1 SW 99 364ST 4636364 DURING A 100 HOUR INSPECTION IT WAS NOTICED THAT THE CLAMPS THAT SECURE THE PRESSURIZATION BELLOWS TO THE NOSE GEAR STEE RING TUBES WERE NOT INSTALLED. 1 L 7 1 3O RT A25SO 2005062300064 20050623 00064 EA 2005 6 23 2005FA0000853 2 20050610 G 7414 K3822 DISTRIBUTOR BLK SLICK CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA LT MAGNETO MISMANUFACTURED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 09 442ES 2052 97021204 17280350 L2740351A DURING PRELIMINARY RUNUP AT ANNUAL INSP, TECH NOTED ENGINE DIFFICULT TO START, & ROUGH ON LT MAG WHEN COLD. ATTEMPTS TO CHECK TIMING ON LT MAG WITH A MAG SYNCHRONIZER UNSUCCESSFUL. POINTS WERE ERRATIC DURING CLOSING & OPENING. REMOVAL OF CA P DISCLOSED SIGNIFICANT DEBRIS. DISASSEMBLY OF MAG DISCLOSED ROTOR GEAR HAD CONTACTED THE DISTRIBUTOR BLOCK, GRINDING RO TOR GEAR & DISTRIBUTOR GEAR / BLOCK. ROTOR GEAR HAD ALSO WORN A .0625 DEEP GROOVE IN THE CONDENSER. IT APPEARED THE CONT ACT BETWEEN THE ROTOR GEAR & CONDENSER WAS ONLY THING PREVENTING ROTOR GEAR FROM DISENGAGING ROTOR SHAFT, & TOTALLY FAIL ING MAG. THERE WAS EVIDENCE THE ROTOR GEAR HAD NEVER BEEN FULLY SEATED ON THE ROTOR SHAFT. 1 H 7 1 3O 3 O NT 3A12 1E10 2005062400078 20050624 00078 EU 2005 6 24 2005FA0000854 1 20050621 G 2720 A402092AN CONTROL CABLE LET L13 L13ACBLANIK 1360312 EU RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 422BA 442 028903 LEFT AND RIGHT RUDDER CABLES FOUND FRAYED AT FRONT AND REAR PULLEY POSITIONS. 1 K 0 0 G24EU 2005062400079 20050624 00079 EU 2005 6 24 2005FA0000855 1 20050621 G 2720 A402092AN CONTROL CABLE LET L13 L13ACBLANIK 1360312 EU RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 435BA 156 029101 LEFT AND RIGHT RUDDDER CABLES FOUND FRAYED AT FRONT AND REAR PULLEYS. 1 K 0 0 G24EU 2005062900036 20050629 00036 SO 2005 6 29 2005FA0000856 1 20050607 G 3246 16147 WHEEL PIPER PA32 PA32300 7103212 SO LYC O540 IO540* 41532 EA MLG CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SO 05 68SD 327940126 AIRCRAFT LANDING SAFELY, WHILE TAXIING, LT TIRE WENT FLAT. ONCE WHEEL FAIRING REMOVED, NOTED IB WHEEL HALF WAS RUBBING BRAKES. PILOT THEN SAID BEEN SMELLING RUBBER AFTER LANDING BRIEFLY. ONCE DISASSEMBLED, WITH BRAKE DISC REMOVED, IB WHE EL HALF CRACKED ALONG BEAD AREA, 3 INCHES AND RIM BOWED OUT. PILOT REPORTED TIRE REPLACED 6 MONTHS EARLIER. BETTER INS PECTION OF WHEELS AT TIME OF TIRE CHANGE COULD HAVE PREVENTED THIS SITUATION. (K) 1 L 7 1 3O 3 O A3SO 1E4 2005062400083 20050624 00083 EU 2005 6 24 2005FA0000857 1 20050621 G 2720 A740255N CONTROL CABLE LET L23 L23 1360308 EU RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 427BA 579 029009 RIGHT RUDDER CABLE FOUND FRAYED AT FORWARD AND AFT PULLEYS. 1 K 0 0 RC G24EU 2005062400085 20050624 00085 EU 2005 6 24 2005FA0000858 1 20050621 G 2720 A740255N CONTROL CABLE LET L23 L23 1360308 EU RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 434BA 1137 029011 RIGHT RUDDER CABLE FOUND FRAYED AT FORWARD AND AFT PULLEYS. 1 K 0 0 RC G24EU 2005062800146 20050628 00146 2005 6 28 2005FA0000859 1 20050531 G 8011 MZ2399S ARMATURE ELECTROSYS STARTER BROKEN B UC2R O OTHER O OTHER NR NOT REPORTED 1 GL 19 120 A082960 PILOT REPORTED GRINDING NOISE WHEN STARTER WAS ENGAGED WITH NO MOVEMENT OF PROPELLER. REMOVED STARTER AND DISASSEMBLED. FOUND DRIVE SPLINES ON ARMATURE SHAFT BROKEN OFF. THIS IS SECOND SUCH DEFECT FOUND IN A MONTH. NO APPARENT CAUSE WAS FOUND. NO TOLERANCE COULD BE FOUND IN MM FOR SPLINE WEAR. (K) 2005062800091 20050628 00091 CE 2005 6 28 2005FA0000860 1 20050601 G 3240 09102200 CYLINDER CLEVELAND CESSNA 170 170B 2072306 CE CONT C145 C145* 17012 SO BRAKE ASSY CRACKED G K NONE O OTHER IN INSP/MAINT 1 SW 19 3167A 25811 STC SA13GL INSTALLATION. IN BOTH BRAKE ASSEMBLIES, 30-63A, THE 091-02200 CYLINDER ASSEMBLIES WERE FOUND TO BE CRACKED A CROSS AND PARALLEL TO THE 069-00400 ANCHOR BOLT HOLE. THIS IS THE SECOND AIRCRAFT, FOUND WITH CRACKS IN THE 091-02200 C YLINDER ASSEMBLIES. THIS AREA IS READILY ACCESSIBLE AND SHOULD BE PART OF THE PREFLIGHT INSPECTION. THE CRACKS ARE EAS ILY SEEN, WHEN LOOKING FOR THEM. (K) 1 H 7 1 3O 3 O A799 E253 2005062800117 20050628 00117 SO 2005 6 28 2005FA0000861 1 20050610 G 8011 DRIVE GEAR PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA STARTER FAILED D O OTHER O OTHER NR NOT REPORTED 1 EA 25 4583T 28R7235099 BENDIX DRIVE GEAR COMES APART DAMAGING RING GEAR SUPPLIER. (NOT MFG) STATED THIS WAS A COMMON PROBLEM. SECOND INSTANCE FOR THIS AIRCRAFT. (K) 1 L 7 1 3O 3 O 2A13 1E10 2005062800100 20050628 00100 SO 2005 6 28 2005FA0000862 1 20050610 G 8011 DRIVE GEAR PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA STARTER DAMAGED D O OTHER O OTHER NR NOT REPORTED 1 EA 25 55003 140 28R7335166 BENDIX DRIVE GEAR COMES APART DAMAGING RING GEAR SUPPLIER (NOT MFG) STATED THIS WAS A COMMON PROBLEM. (K) 1 L 7 1 3O 3 O 2A13 1E10 2005062800116 20050628 00116 CE 2005 6 28 2005FA0000863 1 20050527 G 3250 1693800821 BOLT BEECH 23 B24R 1151253 CE LYC O360 IO360A1A 41514 EA NLG STEERING SPLIT D O OTHER O OTHER NR NOT REPORTED 1 SW 19 23PD 9 MC408 WHEN RETRACTING AND EXTENDING GEAR THE FORWARD EYE BOLT ON THE NOSE GEAR STEERING BARREL (TUBE) STRUCK THE UPPER BOLT HE AD A NUMBER OF TIMES AND THE HELM BEARING HOUSING SPLIT RENDERING THE NOSE GEAR STEERING INOPERATIVE. AIRCRAFT LANDED W ITHOUT INCIDENT. (SW19200512298) (K) 1 L 7 1 3O 3 O A1CE 1E10 2005062900018 20050629 00018 CE 2005 6 29 2005FA0000864 1 20050521 G 3600 W901B20CE CLAMP BEECH MU300 400A 1155402 CE PWA JT15 JT15D1 52060 NE BLEED AIR DEFECTIVE D XEFR O OTHER O OTHER NR NOT REPORTED 1 GL 03 234DK RK182 DURING FLIGHT, THE CREW HEARD A POP AFTER WING DEICE HAD BEEN TURNED ON. THEY PERFORMED THE NESSARY PROCEDURES ACCORDIN G TO THE CHECKLIST. DETAILED INSPECTION REVEALED THAT THE SUSPECT CLAMP HAD SEPARATED AND CAUSED ENGINE BLEED AIR TO DU MP INTO THE AFT EQUIPMENT AREA. (K) 2 H 7 2 4F 4 F RT A16SW E1NE 2005062400084 20050624 00084 EU 2005 6 24 2005FA0000865 1 20050621 G 2720 A740254N CONTROL CABLE LET L23 L23 1360308 EU RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 428BA 837 029010 LEFT CABLE FOUND FRAYED AT AFT PULLEY. RIGHT CABLE FOUND FRAYED AT FORWARD AND AFT PULLEYS. 1 K 0 0 RC G24EU 2005062900019 20050629 00019 SW 2005 6 29 2005FA0000866 1 20050610 G 2510 140215501 SEAT MOONEY M20 M20J 5870219 SW PILOTS SIDE CRACKED B FGQR O OTHER O OTHER NR NOT REPORTED 1 SO 01 5262F 241667 OPTIONAL VERTICALLY ADJUSTING PILOTS SEAT MOVED AFT DURING TAKEOFF, FOUND LT REAR BELLCRANK ASSY CRACKED WHICH DISTORTED SEAT ALLOWING SEAT PINS NOT TO FULLY ENGAGE SEAT TRACKS. INSTALLED A NEW BELLCRANK AND TUBE. NEW BELLCRANK HAD REINFO RCEMENT STRAPS WELDED AT FAILURE POINT. SEAT OPERATED NORMALLY AFTER REPLACEMENT. (K) 1 L 7 1 3O 2A3 2005062800159 20050628 00159 2005 6 28 2005FA0000867 1 20050602 G 3244 196K089 TIRE MLG DAMAGED B AKGR O OTHER O OTHER NR NOT REPORTED 1 CE 05 IT APPEARS THAT THE TIRE WAS DAMAGED IN THE MOLDING PROCESS. THERE ARE 2 INJURIES IN THE SIDEWALLS OF THE TIRE ALMOST D IRECTLY ACROSS FROM EACH OTHER. AIR ESCAPES FROM THE TIRE VERY SLOWLY UNTIL THE WEIGHT OF THE AC IS PLACED ON IT, EVEN THEN YOU HAVE TO LISTEN CLOSELY TO HEAR THE AIR ESCAPING. (K) 2005062900068 20050629 00068 EU 2005 6 29 2005FA0000868 1 20050519 G 2701 BE4510057 CONTROL COLUMN BEAGLE 121 B1211 1120424 EU CONT O200 O200A 17020 SO COCKPIT CRACKED C O OTHER O OTHER NR NOT REPORTED 1 EA 35 556MA 1505 013 DURING ANNUAL INSPECTION CRACK WAS OBSERVED ON CONTROL COLUMN 1.0 INCHES LENGTH (49 MM). CRACK WAS CONFIRMED BY MAGNETI C PARTICLE INSPECTION. THE COMPONENT FORMS PART OF THE AC FLIGHT CONTROL SYSTEM AND IS CRITICAL TO FLIGHT. BOTH THE LT AND RT FITTING ARE THE SAME PN. PROBABLE CAUSE IS STRESS CORROSION CRACKING. (EA35200501663) 1 L 7 1 3O 3 O A22EU E252 2005062800092 20050628 00092 SO 2005 6 28 2005FA0000869 2 20050322 G 7414 IMPULSE COUPLING BEECH 58 58 1152740 CE CONT O550 IO550* SO MAGNETO LOOSE B R2JR O OTHER O OTHER NR NOT REPORTED 1 EA 21 815P TH1949 DURING ANNUAL INSPECTION, COMPLY WITH 500 HR MAGNETO INTERNAL INSPECTION, WHICH INCLUDES THE IMPULSE COUPLING IAW MFG SB . ONE IMPULSE COUPLING WAS FOUND TO BE VERY LOOSE, DUE TO LOOSE RIVETS, WOULD HAVE FAILED SOON. FAILURE OF THIS TYPE C AN CAUSE EXTENSIVE DAMAGE TO MAGNETO AND ENGINE. MFG INSPECTION CHECKLIST DOES NOT CALL FOR DETAILED INSPECTION OF MAGN ETO IMPULSE COUPLING OR OTHER MAGNETO INTERNAL PARTS OTHER THAN POINTS. REPLACED COUPLING WITH NEW PART. OLD PART ONLY HAD 529 HRS. LOOSE RIVETS AND WORN PAWLS. (K) 1 L 7 2 3O 3 O 3A16 E3SO 2005062800118 20050628 00118 CE 2005 6 28 2005FA0000870 1 20050602 G 2510 551900921 ATTACH BRACKET CESSNA CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE COCKPIT SEAT CRACKED D O OTHER O OTHER NR NOT REPORTED 1 CE 05 157DW 5500253 UPPER CHAIR BASE ASSEMBLY CRACKED AT CHAIR BACK ATTACH POINTS. ALSO, PREVIOUS INAPPROPRIATE REPAIR. CHAIR WAS REPAIRED IAW STC ST01042WI STRUCTURAL SEAT REPAIR. (K) 1 L 7 2 4F 4 F A22CE E1NE 2005062900024 20050629 00024 NE 2005 6 29 2005FA0000871 2 20050608 G 7200 414D32101 ADAPTER BOEING 234 234 1385049 EA LYC AL5512 AL5512 41581 NE ENGINE CRACKED B CHIR O OTHER O OTHER NR NOT REPORTED 1 NM 09 242CH 4955 MJ023 DURING OVERHAUL OF ENGINE AWN ADAPTER, NDT FOUND .450 INCH TOTAL LENGTH CRACK IN THE BOLT HOLE OF LUG NR 1. IN THE BORE OF LUG, CRACK LENGTH IS .300 OF INCH AND ACROSS FACE OF LUG, THE CRACK LENGTH IS .150 OF INCH. ILLUSTRATION DEPICTS LO CATION AND SCHEMATIC OF CRACK FOUND. FIRST TIME CRACK OF THIS NATURE NOTED ON THIS ADAPTER. CHECKED OTHER ADAPTERS MFG UNDER THIS LOT NR. THIS REVIEW CONCLUDED THAT THE CRACKED ADAPTER IS AN ISOLATED INCIDENT AND NOT RELATED TO MATERIAL DEFICIENCIES. (K) 2 G 7 2 4U 4 U H9EA E4NE 2005062900025 20050629 00025 CE 2005 6 29 2005FA0000872 1 20050607 G 8120 AN62946 VALVE CESSNA 210 P210N 2073454 CE CONT O520 TSIO520P 17040 SO MCAULY 3AF34C 3AF34C* GL TURBOCHARGER MISINSTALLED D O OTHER O OTHER NR NOT REPORTED 1 WP 07 4946K TH08A69KFO22 P21000378 278771R 786058 RECEIVED TURBO CHARGER CHECK VALVE AND INSTALLED IN CORRECT ORIENTATION. RAN ENGINE AND THE TURBO CHARGER CAVITATED DUE TO LOSS OF OIL SUPPLY. FURTHER INVESTIGATION REVEALED THE NEW CHECK VALVE WAS BACKWARDS INTERNALLY IE: THE CHECK VALVE WAS AT THE OPPOSITE END OF THE FITTING AND FLOW ARROW COMPARED TO THE ORIGINAL CHECK VALVE. RECOMMEND THAT ALL CHECK V ALVES BE EXAMINED TO VERIFY PROPER PHYSICAL FLOW DIRECTION AND PROPERTIES. (K) 1 H 7 1 3O 3 O 3A21 E8CE 5 C P22EA 2005062800167 20050628 00167 SO 2005 6 28 2005FA0000873 2 20050602 G 8500 ENGINE CONT O520 IO520D 17032 SO MAKING METAL D O OTHER J WARNING INDICATION TX TAXI/GRND HDL 1 AL 05 FACTORY REBUILT ENGINE WAS INSTALLED ON THE AIRFRAME. DURING THE GROUND RUNS, LEAK CHECKS AND FINAL ADJUSTMENTS, THE ME CHANIC NOTED THE PROP GOVERNOR WAS NOT CONTROLLING THE PROP AS IT SHOULD. AFTER PERFORMING CHECKS RECOMMENDED BY THE MF G, PROP WAS REMOVED AND METAL FLAKES WERE NOTED IN THE END OF THE CRANKSHAFT. THE OIL FILTER WAS REMOVED AND INSPECTED AND WHAT APPEARED TO BE BRONZE, AND STEEL PARTICLES WERE FOUND. THE FILTER ALONG WITH AN OIL SAMPLE WERE SUBMITTED TO T HE ENGINE MFG. REQUESTED THE ENGINE BE RETURNED TO THEM FOR FURTHER ANALYSIS. 3 O E5CE 2005062800136 20050628 00136 SO 2005 6 28 2005FA0000874 1 20050607 G 5743 1159SB206233 RIB GULSTM G1159 G1159A 3970109 SO RROYCE SPEY SPEY511* 54523 EU LT MLG GOUGED B BTVR O OTHER O OTHER NR NOT REPORTED 1 GL 23 117MS 8617 4198 335 UPON REMOVAL OF THE BEARING ASSEMBLY FROM THE FORWARD LUG ON THE LT SPONSON RIB FOR THE MAIN LANDING GEAR ASSY, THE BORE OF THE LUG REVEALED A DEEP GROOVE CUT BETWEEN THE 10 O`CLOCK AND 2 O`CLOCK POSITION. FOUND TO BE BEYOND MFG LIMITS. R EPLACED SPONSON RIB. (K) 2 L 7 2 4F 4 F A12EA E2EU 2005062900092 20050629 00092 EU 2005 6 29 2005FA0000875 1 20050621 G 2720 A402092AN CONTROL CABLE LET LET L13 L13ACBLANIK 1360312 EU RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 423BA 375 028904 LEFT AND RIGHT RUDDER CABLES FOUND FRAYED AT FRONT AND REAR PULLEYS. 1 K 0 0 G24EU 2005062900093 20050629 00093 EU 2005 6 29 2005FA0000876 1 20050621 G 2720 A740254N CONTROL CABLE LET LET L23 L23 1360308 EU RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 420BA 1030 029007 LEFT AND RIGHT RUDDER CABLES FOUND FRAYED AT AFT PULLEYS. 1 K 0 0 RC G24EU 2005062900096 20050629 00096 EU 2005 6 29 2005FA0000877 1 20050621 G 2720 A740255N CONTROL CABLE LET LET L23 L23 1360308 EU RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 430BA 1183 029012 LEFT RUDDER CABLE FOUND FRAYED AT AFT PULLEY. RIGHT RUDDER CABLE FOUND FRAYED AT FORWARD AND AFT PULLEYS. 1 K 0 0 RC G24EU 2005062900097 20050629 00097 EU 2005 6 29 2005FA0000878 1 20050621 G 2720 A740255N CONTROL CABLE LET LET L23 L23 1360308 EU RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 431BA 826 029013 LEFT AND RIGHT RUDDER CABLES FOUND FRAYED AT AFT PULLEYS. 1 K 0 0 RC G24EU 2005062900098 20050629 00098 EU 2005 6 29 2005FA0000879 1 20050621 G 2720 A740255N CONTROL CABLE LET LET L23 L23 1360308 EU RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 437BA 970 029015 LEFT AND RIGHT RUDDER CABLES FOUND FRAYED AT AFT PULLEYS. 1 K 0 0 RC G24EU 2005062900099 20050629 00099 EU 2005 6 29 2005FA0000880 1 20050621 G 2720 A740255N CONTROL CABLE LET LET L23 L23 1360308 EU RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 419BA 1032 029006 LEFT AND RIGHT RUDDER CABLES FOUND FRAYED AT AFT PULLEYS. 1 K 0 0 RC G24EU 2005062900100 20050629 00100 EU 2005 6 29 2005FA0000881 1 20050621 G 2720 A740254N CONTROL CABLE LET LET L23 L23 1360308 EU RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 410BA 805 029005 LEFT RUDDER CABLE FOUND FRAYED AT FORWARD AND AFT PULLEYS. 1 K 0 0 RC G24EU 2005062900101 20050629 00101 CE 2005 6 29 2005FA0000882 1 20050621 G 2720 A402092N CONTROL CABLE BEECH 35 35BEECH 1151502 CE RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 421B 434 D1428 LEFT AND RIGHT RUDDER CABLES FOUND FRAYED AT FRONT AND REAR PULLEY POSITIONS. 1 L 7 1 3O A777 2005062900102 20050629 00102 CE 2005 6 29 2005FA0000883 1 20050621 G 2720 A402092N CONTROL CABLE BEECH 35 35BEECH 1151502 CE RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 421B 434 D1428 LEFT AND RIGHT RUDDER CABLES FOUND FRAYED AT FRONT AND REAR PULLEY POSITIONS. 1 L 7 1 3O A777 2005062900117 20050629 00117 EU 2005 6 29 2005FA0000884 1 20050621 G 2720 A740255N CONTROL CABLE LET LET L23 L23 1360308 EU RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 438BA 415 029016 RIGHT RUDDER CABLE FOUND FRAYED AT FORWARD AND AFT PULLEYS. 1 K 0 0 RC G24EU 2005062900119 20050629 00119 EU 2005 6 29 2005FA0000885 1 20050621 G 2720 A740255N CONTROL CABLE LET LET L23 L23 1360308 EU RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 433BA 673 029014 RIGHT RUDDER CABLE FOUND FRAYED AT FORWARD AND AFT PULLEYS. 1 K 0 0 RC G24EU 2005062800121 20050628 00121 SO 2005 6 28 2005FA0000886 1 20050607 G 5530 SHEAR WEB GULSTM G1159 G1159A 3970109 SO RROYCE SPEY SPEY511* 54523 EU VERTICAL STAB DAMAGED B BTVR O OTHER O OTHER NR NOT REPORTED 1 GL 23 117MS 8617 335 REPAIRED FORWARD VERTICAL SHEAR WEB ASSY OF THE VERTICAL STABILIZER DUE TO HOLE ELONGATION. (K) 2 L 7 2 4F 4 F A12EA E2EU 2005062900028 20050629 00028 SO 2005 6 29 2005FA0000887 1 20050607 G 5542 SKIN GULSTM G1159 G1159 3953505 SO RROYCE SPEY SPEY511* 54523 EU RUDDER LE CRACKED B BTVR O OTHER O OTHER NR NOT REPORTED 1 GL 23 117MS 8617 GAC334 335 REPAIRED SKIN ON RUDDER LEADING EDGE AT THE NR 2 RUDDER HINGE POINT. (K) 2 L 7 2 4F 4 F RT A12EA E2EU 2005070700035 20050707 00035 EA 2005 7 7 2005FA0000888 2 20050620 G 8530 SL36006WA20P CYLINDER HUGHES 269 269C1 8059504 SW LYC O360 HO360C1A 41514 EA ENGINE CRACKED B K NONE O OTHER IN INSP/MAINT 1 WP 27 2024Z 1106 1106 0098 L3678936A DURING 100HR COMPRESSION CHECK, AIR WAS FOUND TO BE LEAKING AROUND TOP SPARK PLUG AREA. FURTHER INSPECTION NOTED CRACK ALONG TOP COOLING FIN AREA. UPON REMOVING CYLINDER, CRACK WAS FOUND TO RUN FROM AREA AROUND TOP SPARKPLUG HOLE THROUGH EXHAUST SEAT AND THROUGH TO EXHAUST FLANGE MOUNTING STUD. 1 G 7 1 3O 3 O O 4H12 E286 2005070700036 20050707 00036 EA 2005 7 7 2005FA0000889 2 20050620 G 8530 SL36006WA20P CYLINDER HUGHES 269 269C1 8059504 SW LYC O360 HO360C1A 41514 EA ENGINE CRACKED B K NONE O OTHER IN INSP/MAINT 1 WP 27 2024Z 1106 1106 0098 L3678936A DURING 100HR COMPRESSION CHECK, AIR WAS FOUND TO BE LEAKING AROUND TOP SPARK PLUG AREA. FURTHER INSPECTION NOTED CRACK ALONG TOP COOLING FIN AREA. UPON REMOVING CYLINDER, CRACK WAS FOUND TO RUN FROM AREA AROUND TOP SPARKPLUG HOLE THROUGH EXHAUST SEAT AND THROUGH TO EXHAUST FLANGE MOUNTING STUD. 1 G 7 1 3O 3 O O 4H12 E286 2005062800151 20050628 00151 SO 2005 6 28 2005FA0000890 2 20050601 G 8530 CYLINDER CESSNA 310 310Q 2074242 CE CONT O470 IO470V 17026 SO MCAULY 3AF32C 3AF32C87 GL NR 1 CRACKED D EAVV O OTHER O OTHER NR NOT REPORTED 1 GL 09 1249G 310Q1100 1482908V 727202 FOUND CASE CRACKED BEYOND REPAIR AT NR 1 CYLINDER, FOUND 2 THRU BOLTS SHEARED AND 5 CYLINDER STUDS BROKEN ON NR 1 CYLIND ER. THRU BOLTS DEFECTIVE CAUSING A CHAIN REACTION IN SHEARING CYLINDER STUDS. SINCE CYLINDER WAS NO LONGER SEATED SQUA RELY TO THE CASE, THIS CAUSED THE CASE TO CRACK WHILE ENGINE WAS IN OPERATION. (K) 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 2005062700207 20050627 00207 GL 2005 6 27 2005FA0000891 1 20050622 G 5514 5221007 BRACKET NAMER T6 SNJ4 6400414 GL HORIZONTAL STAB CORRODED D K NONE O OTHER IN INSP/MAINT 1 GL 13 7070C 8813164 WHILE PERFORMING REPAIRS TO RT AND LT HORIZONTAL STABILIZERS, IT WAS DISCOVERED THAT THE OUTBOARD AND CENTER HINGE TEE R EINFORCEMENT BRACKETS, P/N 52-21007 AND 52-21008, OF BOTH STABILIZERS WERE SEVERLY CORRODED. THESE BRACKETS REINFORCE T HE REAR SPAR WHERE THE ELEVATOR HINGE BRACKET ASSEMBLIES BOLT ON. BOTH TEE REINFORCEMENT BRACKETS OF BOTH STABILIZERS W ERE REPLACED WITH NEW PARTS. FAILURE OF THESE REINFORCEMENTS COULD CAUSE THE BOLTS FOR THE ELEVATOR HINGE BRACKET ASSEM BLIES TO PULL THROUGH THE SPAR. 1 L 7 1 3R A2575 2005062700211 20050627 00211 GL 2005 6 27 2005FA0000892 1 20050622 G 5514 5221008 BRACKET NAMER T6 SNJ4 6400414 GL HORIZONTAL STAB CORRODED D K NONE O OTHER IN INSP/MAINT 1 GL 13 7070C 8813164 WHILE PERFORMING REPAIRS TO RT AND LT HORIZONTAL STABILIZERS, IT WAS DISCOVERED THAT THE OUTBOARD AND CENTER HINGE TEE R EINFORCEMENT BRACKETS, P/N'S 52-21007 AND 52-21008, OF BOTH STABILIZERS WERE SEVERLY CORRODED. THESE BRACKETS REINFORCE THE REAR SPAR WHERE THE ELEVATOR HINGE BRACKET ASSEMBLIES BOLT ON. BOTH TEE REINFORCEMENT BRACKETS OF BOTH STABILIZERS WERE REPLACED WITH NEW PARTS. FAILURE OF THESE REINFORCEMENTS COULD CAUSE THE BOLTS FOR THE ELEVATOR HINGE BRACKET ASS EMBLIES TO PULL THROUGH THE SPAR. 1 L 7 1 3R A2575 2005062900073 20050629 00073 CE 2005 6 29 2005FA0000893 1 20050623 G 1100 07050429 PLACARD CESSNA 182 182S 2072701 CE CABIN REVERSED Z K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 99 2465N 194 5 18280658 DURING INITIAL AUSTRALIAN CERTIFICATE OF AIRWORTHINESS INSPECTION, LT & RT CABIN DOOR HANDLE ESCUTCHEON/PLACARDS FOUND T O BE TRANSPOSED. THIS MEANS THAT INTERIOR DOOR HANDLE OPERATION INSTRUCTION IS IN REVERSE SENSE & EXIT HANDLE CANNOT BE OPERATED PER THE INSTRUCTIONS. ESCUTCHEONS SWAPPED TO CORRECT SIDES. 1 H 7 1 3O NT 3A13 2005062900074 20050629 00074 CE 2005 6 29 2005FA0000894 1 20050623 G 1100 0705042910 PLACARD CESSNA 182 182S 2072701 CE ZONE 800 REVERSED Z K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 99 2465N 194 5 18280658 DURING INITIAL AUSTRALIAN CERTIFICATE OF AIRWORTHINESS INSPECTION, LT & RT CABIN DOOR HANDLE ESCUTCHEON/PLACARDS FOUND T O BE TRANSPOSED. THIS MEANS THAT INTERIOR DOOR HANDLE OPERATION INSTRUCTION IS IN REVERSE SENSE & EXIT HANDLE CANNOT BE OPERATED PER THE INSTRUCTIONS. ESCUTCHEONS SWAPPED TO CORRECT SIDES. 1 H 7 1 3O NT 3A13 2005063000113 20050630 00113 SO 2005 6 30 2005FA0000895 2 20050617 G 7322 ARM CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO CARBURETOR DAMAGED D O OTHER O OTHER NR NOT REPORTED 1 NE 05 145RC 6566 120 FOUND THAT THE FLOAT VALVE ARM WAS HITTING THE RETAINER HUB WHEN THE VALVE WAS FULLY ENGAGED. IT WOULD APPEAR THAT THE ARM COULD SUFFER ENOUGH DAMAGE TO SEVER THE ARM FROM THE FLOAT BASE AND THAT WOULD ALLOW THE FLOAT VALVE CLOSE AND SHUT THE FLOW OF FUEL OFF FROM THE ENGINE. PHOTOS OF THE VALVE. (K) 1 L 7 2 3O 3 O A7CE E8CE 2005070100008 20050701 00008 CE 2005 7 1 2005FA0000896 1 20050512 G 5730 17220044 SKIN CESSNA 177 177A 2073706 CE LYC O360 O360* 41514 EA RT WING CORRODED B PVCR K NONE O OTHER IN INSP/MAINT 1 NM 01 30297 2369 17701178 DURING AN ANNUAL INSP, RT WING IB L/E SKIN WAS FOUND CORRODED THROUGH BENEATH STRINGER. A POSSIBLE CAUSE FOR THE EXCESS IVE CORROSION MAY BE WATER SEEPING THROUGH THE AIR INLET HOSE INSTALLED ABOVE THE AFFECTED AREA. THIS WATER ENTERS THRO UGH THE L/E AIR INLET AND CREATES RUST IN THE STEEL WIRE WOUND HOSE AND DRIPS RUST CONTAMINATED WATER ON THE WING SURFAC E BELOW WHICH MAY ACCELERATE THE CORROSION PROCESS. IT IS RECOMMENDED THAT CLOSE ATTENTION BE PAID TO THAT PART OF THE WING AND TO THE CONDITION OF THE VENT HOSE DIRECTLY ABOVE IT ESPECIALLY IN AIRCRAFT THAT ARE STORED OUTDOORS. APPLYING CORROSION RESISTANT CHEMICAL TO INSIDE OF WING WOULD ALSO HELP SITUATION. (K) 1 H 7 1 3O 3 O A13CE E286 2005070100009 20050701 00009 SO 2005 7 1 2005FA0000897 1 20050506 G 5711 82200696 SPAR PIPER PA46 PA46350P 7104602 SO LYC O540 TIO540* 41532 EA RT WING CRACKED B PVCR O OTHER O OTHER NR NOT REPORTED 1 NM 01 27PG 5238 4622104 DURING ANNUAL INSPECTION, NOTE THAT SEVERAL RIVETS ATTACHING THE RT WING SKIN TO THE LOWER WING SPAR WERE BECOMING LOOSE (SMOKING) JUST OB OF THE MAIN GEAR DOOR AND INBOARD OF THE RIB AT WS79.5. DURING INSP OF INSIDE OF WING IN SAME AREA, A CRACK WAS FOUND ON BOTTOM OF AFT SIDE OF SPAR ANGLE WHICH STARTS AT AFT END OF THE ANGLE AND PROPAGATES FORWARD THROUG H AND BEYOND THE FIRST 2 ADJACENT BOTTOM RIVETS IB OF THE RIB AT WS 79.5. IT APPEARS THAT THE WING FLEXES CONSIDERABLY IN THAT AREA AS EVIDENCED BY THE LOOSE RIVETS. LOOSE RIVETS IN THAT AREA MAY HAVE CREATED LESS THAN DESIRABLE STRUCTURA L INTEGRITY IN AFFECTED AREA. THIS AREA SHOULD BE GIVEN SPECIAL ATTENTION ESPECIALLY IF LOOSE RIVETS ARE FOUND. (K) 1 L 7 1 3O 3 O RT A25SO E14EA 2005070100010 20050701 00010 EA 2005 7 1 2005FA0000898 2 20050601 G 7414 21C2153902 HOUSING CESSNA 182 182T 2072703 CE LYC O540 IO540A1A5 41532 EA LT MAG ADAPTER LEAKING D O OTHER O OTHER NR NOT REPORTED 1 NM 01 3532K 18280974 RL2019148A AFTER ENGINE INSTALLATION, 2 HOURS INTO BREAK IN PERIOD, OIL LEAK DISCOVERED IN BOSS OF CAMSHAFT IDLER GEAR. LT MAY ADA PTER BASE, CUT TOO WIDE; HOLE THROUGH TO SHAFT SUPPORT OF IDLER GEAR. (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2005070100011 20050701 00011 SO 2005 7 1 2005FA0000899 1 20050619 G 3213 6549000 CYLINDER PIPER PA28 PA28180 7102808 SO LYC O360 O360* 41514 EA RT MAIN GEAR CRACKED G O OTHER O OTHER NR NOT REPORTED 1 SW 11 1835T 287105112 UPON LANDING, RT MAIN GEAR SCISSORS ATTACHMENT LUGS BROKE FREE FROM THE CYLINDER. CODE C, WHEEL WITH SCISSORS DAMAGED R T FLAP. (K) 1 L 7 1 3O 3 O 2A13 E286 2005070100012 20050701 00012 CE 2005 7 1 2005FA0000900 1 20050614 G 2810 21219 BLADDER BEECH 36 A36 1151604 CE CONT O520 IO520BA 17032 SO HARTZL HCC3Y PHCC3YF1 GL FUEL CELL CONTAMINATED B RG4R O OTHER O OTHER NR NOT REPORTED 1 SO 03 428BD 10 E950 822861R EE4506B CUSTOMER NOTED WHITE PARTICLES FROM QUICK DRAINS, INSPECTED, FOUND WHAT OWNER FOUND, WHITE PARTICLES. REMOVED FUEL BLAD DERS. INSPECTED FOUND WHITE POWDER/ASH ON VARIOUS PLACES OF BOTH FUEL BLADDERS. FUEL BLADDERS MFG 7/04 AND 8/04. WHI TE POWDER IS COMING FROM THE INSIDE OF FUEL BLADDERS. REPLACED BLADDERS WITH NEW FROM MFG UNDER WARRANTY. MFG IS AWARE OF THIS PROBLEM. CLEANED COMPLETE SYSTEM. (K) 1 L 7 1 3O 3 O 3A15 E5CE 5 C P25EA 2005070100014 20050701 00014 CE 2005 7 1 2005FA0000901 1 20050614 G 2810 212110 BLADDER BEECH 36 A36 1151604 CE CONT O520 IO520BA 17032 SO HARTZL HCC3Y PHCC3YF1 GL FUEL CELL CONTAMINATED B RG4R O OTHER O OTHER NR NOT REPORTED 1 SO 03 428BD 10 E950 822861R EE4506B CUSTOMER NOTED WHITE PARTICLES FROM QUICK DRAINS. INSPECTED, FOUND WHAT OWNER FOUND WHITE PARTICLES. REMOVED FUEL BLAD DERS. INSPECTED, FOUND WHITE POWDER/ASH ON VARIOUS PLACES OF BOTH FUEL BLADDERS. FUEL BLADDERS MFG 7/04 AND 8/04. WH ITE POWDER IS COMING FROM THE INSIDE OF FUEL BLADDERS. REPLACED BLADDERS WITH NEW FROM MFG, UNDER WARRANTY. CLEANED CO MPLETE SYSTEM. (K) 1 L 7 1 3O 3 O 3A15 E5CE 5 C P25EA 2005070100024 20050701 00024 CE 2005 7 1 2005FA0000902 1 20050614 G 2810 BLADDER CESSNA 310 310R 2074245 CE CONT O520 IO520* 17032 SO LT FUEL CELL LEAKING D O OTHER K FLUID LOSS NR NOT REPORTED 1 WP 09 101G 310R0017 THE LT OB BLADDER HAD A SMALL SEEPING LEAK AND WAS IGNITED CAUSING AN EXPLOSION. THE SOURCE OF IGNITION IS UNKNOWN, BU T THE SECOND SENDING UNIT IS SUSPECTED. 1 L 7 2 3O 3 O 3A10 E5CE 2005070100026 20050701 00026 CE 2005 7 1 2005FA0000903 1 20050527 G 7330 10238901211 TRANSMITTER BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO FUEL FLOW FALSE INDICATION B VJ3R O OTHER N FALSE WARNING NR NOT REPORTED 1 WP 07 1570A 3 CE1333 830089R PILOT REPORTED THAT FUEL FLOW WENT TO ZERO INDICATION DURING CLIMB OUT. ALL OTHER ENGINE INDICATIONS NORMAL. UPON TROU BLESHOOTING OF THE FUEL FLOW SYSTEM FOUND FUEL FLOW TRANSMITTER WAS SENGIND ZERO FUEL FLOW READINGS TO FUEL FLOW INSTRUM ENT. NO RECOMMENDATIONS AT THIS TIME. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005070100072 20050701 00072 SO 2005 7 1 2005FA0000904 1 20050624 G 3210 653193 LANDING GEAR PIPER PA28 PA28180 7102808 SO LYC O360 O360A4A 41514 EA SNSNCH 76E 76EM8S5 EA RIGHT BROKEN D O OTHER O OTHER LD LANDING 1 SW 11 1835T 5695 38 287105112 RL3980836A 76EMS5060 RT MAIN LANDING GEAR BROKE DURING LANDING AT PBF. 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 2005070100073 20050701 00073 SO 2005 7 1 2005FA0000905 1 20050624 G 3210 653193 LANDING GEAR PIPER PA28 PA28180 7102808 SO LYC O360 O360A4A 41514 EA SNSNCH 76E 76EM8S5 EA ZONE 700 BROKEN D O OTHER O OTHER LD LANDING 1 SW 11 1835T 5695 38 287105112 RL3980836A 76EMS5060 RT MAIN LANDING GEAR BROKE DURING LANDING AT PBF. 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 2005070100074 20050701 00074 SO 2005 7 1 2005FA0000906 1 20050624 G 3210 653193 LANDING GEAR PIPER PA28 PA28180 7102808 SO LYC O360 O360A4A 41514 EA SNSNCH 76E 76EM8S5 EA ZONE 700 BROKEN D O OTHER O OTHER LD LANDING 1 SW 11 1835T 5695 38 287105112 RL3980836A 76EMS5060 RT MAIN LANDING GEAR BROKE DURING LANDING AT PBF. 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 2005070100050 20050701 00050 NM 2005 7 1 2005FA0000908 1 20050426 G 3230 45035 HOUSING PNEUDRAULICS BOEING 737 737* NM VALVE GOUGED B IU6R O OTHER O OTHER NR NOT REPORTED 1 NM 01 20509M BORE IS GOUGED CAUSING LEAKAGE. TOO MUCH PLAY BETWEEN POPPET AND BORE. IMPROVE POPPET DESIGN TO HAVE TEFLON GUIDES TO PREVENT GOUGING. (K) 2 L 7 2 4F RT A16WE 2005070100051 20050701 00051 NM 2005 7 1 2005FA0000909 1 20050426 G 2913 65447821 HOUSING BOEING 737 737* NM HYD PUMP CRACKED B IU6R O OTHER O OTHER NR NOT REPORTED 1 NM 01 62917 HOUSING CRACKED. HOUSING IS TOO WEAK. MAKE HOUSING STRONGER. (K) 2 L 7 2 4F RT A16WE 2005070100052 20050701 00052 NM 2005 7 1 2005FA0000910 1 20050420 G 2782 71001297 HOUSING SMITHSIND BOEING 727 727* NM ACTUATOR BROKEN B IU6R O OTHER O OTHER NR NOT REPORTED 1 NM 01 CAI836 AIRCRAFT RETURNED FROM A FLIGHT WITH HYDRAULIC FLUID LEAKING FROM ACTUATOR. FLIGHT ENGINEER WALK AROUND, FOUND BODY END BROKE OFF AT RETAINER END. UNKNOWN, THIS IS A NEW AND IMPROVED POST SB BODY. (K) (REF: 194950/LEB) 2 L 7 3 4F RT A3WE 2005070100053 20050701 00053 NM 2005 7 1 2005FA0000911 1 20050525 G 3232 63141 CAP SARGENT BOEING 727 727* NM ACTUATOR CRACKED B IU6R O OTHER O OTHER NR NOT REPORTED 1 NM 01 3007 CAP IS CRACKED IN BOTTOM OF PORT C. CAP IS TOO WEAK. MAKE CAP STRONGER. (K) (REF: 195902/FXS) 2 L 7 3 4F RT A3WE 2005070100054 20050701 00054 NM 2005 7 1 2005FA0000912 1 20050525 G 3252 39346901 CYLINDER DOUG MD900 MD900 3027375 NM SHIMMY DAMPER DELAMINATED B IU6R O OTHER O OTHER NR NOT REPORTED 1 NM 01 CHROME HAS DELAMINATED IN CYLINDER BORE. IMPROPER PLATING. IMPROVE CHROME PLATING METHOD TO IMPROVE ADHESION TO CYLIND ER. (K) (REF: 195920/JMG) 1 G 7 2 3U NC H19NM 2005070100055 20050701 00055 NM 2005 7 1 2005FA0000913 1 20050525 G 3252 39143567 CAP DOUG MD900 MD900 3027375 NM SHIMMY DAMPER CRACKED B IU6R O OTHER O OTHER NR NOT REPORTED 1 NM 01 CAP IS CRACKED ON PORT SIDE. CATASTROPHIC FAILURE. MANFACTURE CAP FROM SOLID BLOCK OF MATERIAL INSTAD OF CASTING PART. (K) (REF: 195920/JMG) 1 G 7 2 3U NC H19NM 2005070100056 20050701 00056 NM 2005 7 1 2005FA0000917 1 20050613 G 3230 45035 HOUSING BOEING 737 737* NM MLG VALVE CORRODED B IU6R O OTHER O OTHER NR NOT REPORTED 1 NM 01 BORE IS PITTED CAUSING LEAKAGE. MOISTURE ALLOWED THROUGH VENT CORRODEING THE UPPER BORE AND WEAKENING THE MATERIAL. IM PROVE DESIGN TO PREVENT MOISTURE FROM REACHING BORE. (K) (REF: 196593/ FXS) 2 L 7 2 4F RT A16WE 2005070100057 20050701 00057 CE 2005 7 1 2005FA0000920 1 20050607 G 2752 503801534 DRIVE ASSY RAYTHN BEECH 1900 1900D 1154162 CE PWA PT6 PT6* 52043 EA FLAP ACTUATOR SHEARED B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 81SK 17610 1543 335L94 UE81 RT IB FLAP ACTUATOR WOULD NOT ACTUATE. UPON TEARDOWN INSPECTION DISCOVERED THE 90 DEGREE DRIVE ASSEMBLY, FLAP CABLE CON NECTOR COUPLING HAD SHEARED THE ROLL PIN THAT CONNECTS THE COUPLING TO A DRIVE GEAR. THIS 90 DEGREE DRIVE ASSEMBLY HAS NO FIELD MAINTENANCE REQUIREMENTS BEYOND LUBING AND CHECKING GEAR FREEPLAY. THIS PART IS NOT ALLOWED TO BE REPAIRED IN THE FIELD AND NO INSTRUCTIONS TO INSPECT THE SHEAR PINS. THE FLAP ACTUATOR WAS LAST EACH 10,000 CYCLE INSPECTED 9/04. (K) 2 L 7 2 4T 3 T RT A24CE E2NE 2005070100059 20050701 00059 NM 2005 7 1 2005FA0000921 1 20050612 G 5330 SKIN PANEL BOEING 737 737291 138448W NM PWA JT8 JT8D15A 52051 NE FUSELAGE CORRODED B KQ7R O OTHER O OTHER NR NOT REPORTED 1 SW 17 583CC 21069 REMOVED CORROSION UNDER SKIN LAP JOINT, BS 787 TO BS 847, S-18R FWD OF AFT CARGO DOOR. CUT OUT CORRODED SECTION, FABRIC ATED FILLER, DOUBLER AND TRIPLER. INSTALLED IAW B737 SRM. FOUND DURING INSPECTION OF AD. EXTERNAL VISUAL INSPECTION O F SKIN FOR CORROSION AND DELAMINATION AT ALL LAP JOINTS IAW SB. (K) 2 L 7 2 4F 4 F A16WE E2EA 2005070100060 20050701 00060 NM 2005 7 1 2005FA0000922 1 20050613 G 5314 KEELBEAM BOEING 737 737291 138448W NM PWA JT8 JT8D15A 52051 NE FUSELAGE CRACKED B KQ7R O OTHER O OTHER NR NOT REPORTED 1 SW 17 583CC 61161 21069 FOUND 8 INCH CRACK AND CORROSION IN LOWER RT KEELBEAM LOWER CHORD DURING C-CHECK. REMOVED CORRODED RT KEELBEAM LOWER CH ORD SECTION BS 540. CUT OUT APPROX 8 INCHES LOWER CHORD. 2 L 7 2 4F 4 F A16WE E2EA 2005070100063 20050701 00063 2005 7 1 2005FA0000923 4 20050614 G 3100 RMU1OH MONITOR BELL 407 407 1182206 SW ALLSN 250C 250C47B GL BROKEN B FKFR O OTHER O OTHER NR NOT REPORTED 1 SO 03 139PD 53631 3 MONITORS WERE INSTALLED DURING THE COMPLETION OF THE HELICOPTER ON AN FORM THAT WAS FIELD APPROVED. DURNG LEVEL FLIGH T, AT 6500 FEET, THE OUTER PANE OF GLASS SHATTERED FROM THE FRONT OF THE MONITOR WITH VARIOUS SIZE PIECES HITTING THE CR EW. MFG SENT 2 ENGINEERS WHO REVIEWED THE PROJECT. THE UNITS ARE PRESSURE TESTED FROM THE FACTORY AND APPROVED TO 30,0 00 FEET. (K) 1 G 7 1 3U 3 U O H2SW E1GL 2005070600060 20050706 00060 CE 2005 7 6 2005FA0000924 1 20050615 G 3234 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO MLG INTERMITTENT B VJ3R A UNSCHED LANDING O OTHER CL CLIMB 1 WP 07 8112T 225 CE1539 830118R AFTER TAKEOFF AND GEAR HANDLE SELECTED FOR GEAR UP. THE LANDING GEAR WOULDN’T CYCLE UP. STILL SHOWING 3 GREEN LIGHTS A ND ON INTRASIT LIGHT. MAIN TECH TROUBLESHOOT SYSTEM AND FOUND THAT THE DYNAMIC RELAY WAS INTERMITTENT. NO RECOMMENDATI ONS AT THIS TIME. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005070600080 20050706 00080 EA 2005 7 6 2005FA0000925 2 20050614 G 7320 RSA5AD1 SERVO GROB 120 G120A 1660208 EU LYC O540 AEIO540D4D5 EA FUEL INJECTOR MALFUNCTIONED B VJ3R A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION NR NOT REPORTED 1 WP 07 865AF 230 85005 RL2631948A PILOT REPORTED ENGINE QUIT AFTER LANDING WITH BOOST PUMP ON. ON GROUND RUN PERFORMING MIXTURE IDLE CHECK, WE FOUND WITH BOOST PUMP OFF, WE HAD .5 INCH MANIFOLD PRESSURE DROP AND WITH BOOST PUMP ON. WE HAD 1.5 INCH MANIFOLD PRESURE DROP. ON FURTHER INVESTIGATION, WE FOUND ICO LEVER STICKY AND ROUGH WHEN YOU MOVE IT. AT THIS TIME NO PROBABLE CAUSE OR RECOM MENDATION. (K) 1 L 7 1 3O 3 O RT A49CE 1E4 2005070600061 20050706 00061 CE 2005 7 6 2005FA0000926 1 20050614 G 3610 AA3216CW PUMP BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO INSTRUMENT AIR WEAK B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 8240T 126 CE1542 825916R PILOT REPORTED LOW INSTRUMENT AIR PRESSURE AT 1000 RPM. TROUBLESHOOTING SYSTEM FOUND TO BE OK, DETERMINED AIR PUMP WAS NOT PUTTING OUT SUFFICIENT PRESSURE. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005070600077 20050706 00077 CE 2005 7 6 2005FA0000927 1 20050611 G 3234 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO MLG INTERMITTENT B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 8240T 172 CE1542 825916R LANDING GEAR WOULD NOT RETRACT AFTER THE 5TH CYCLE OF THE LANDING GEAR. MAINTENANCE TECHNICIAN TROUBLESHOOT GEAR SYSTEM AND FOUND THAT THE DYNAMIC RELAY WAS INTERMITTENT. NO RECOMMENDATION AT THIS TIME. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005070600073 20050706 00073 CE 2005 7 6 2005FA0000928 1 20050616 G 3234 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO MLG INTERMITTENT B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 8240T 8 CE1542 825916R GEAR HANDLE HAS TO BE RECYCLED BEFORE GEAR COMES UP. MAINTENANCE TECHNICIAN TROUBLESHOOT GEAR SYSTEM AND FOUND THAT THE DYNAMIC RELAY WAS INTERMITTENT. NO RECOMMENDATION AT THIS TIME. DYNAMIC RELAY MFG 0504. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005070600066 20050706 00066 CE 2005 7 6 2005FA0000929 1 20050507 G 2840 10238901211 TRANSMITTER BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO FUEL FLOW READS HIGH B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 1570A 534 CE1333 830089R DURING POST PHASE INSPECTION RUN-UP. TECHNICIAN FOUND FUEL FLOW READING 25.5 PSI AT HIGH RPM. INSTALLED FUEL PRESSURE METERING GAGES AND FOUND FUEL TRANSMITTER READING HIGH ON ENGINE INSTRUMENT. NO RECOMMENDATIONS AT THIS TIME. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005070600074 20050706 00074 SW 2005 7 6 2005FA0000930 1 20050323 G 3233 2751016003 ACTUATOR SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP RT MLG WW BROKEN D O OTHER O OTHER NR NOT REPORTED 1 WP 23 782C AC525 EMERG LAND MADE WITH RT GEAR UNSAFE LIGHT. AFTER SHUT-DOWN, RT LANDING GEAR, IB ACTUATOR WAS FOUND BROKEN AT FWD MOUNT, HANGING DWN BELOW GEAR DOORS FROM AFT MOUNT. (NOTE: EACH LANDING GEAR HAS 2 ACTUATORS, OB ACTUATOR HAD NO DAMAGE). BR OKEN ACTUATOR APPEARS TO BE ORIG ACTUATOR, NO RECORDS CAN BE FOUND INDICATING REPLACEMENT SINCE AC WAS NEW. ACTUATOR RE PLACEMENT SINCE IS (ON CONDITION) WITH NO REQUIRED OH TIME. BROKEN ACTUATOR WAS REMOVED, REPLACED, SENT FOR ANALYSIS. MFG DETERMINED THAT CRACK AT FWD MTNG HOLE, WHICH LEAD TO FAILURE, ORIGINATED IN SMALL FLAW IN METAL. GRADUALLY GREW TO POINT OF FAILURE. STATED THAT THIS IS ISOLATED INCIDENT, AND FEEL THAT NO FURTHER ACTION IS REQUIRED. (K) 2 L 7 2 4T 4 T RT A8SW E4WE 2005070600075 20050706 00075 SO 2005 7 6 2005FA0000931 2 20050624 G 7414 4309 MAGNETO DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO ENGINE BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SO 05 169PA 134 C0270 650053 AFTER REMOVAL OF THE RT MAGNETO, INSPECTED THE MAGNETO AND FOUND THAT ONE END OF THE FORKEND OF THE ROTOR SHAFT HAD BROK EN OFF CAUSING THE POINT TO FAIL TO OPEN. THE MAGNETO WAS STILL UNDER WARRANTY, WAS UNABLE TO INSPECT MAGNETO FOR FURTH ER DAMAGE. (K) 1 L 7 1 3O 3 O NT TA4CH E7SO 2005070600070 20050706 00070 EA 2005 7 6 2005FA0000932 1 20050616 G 5330 60135003 SKIN CNDAIR CL600 CL6002B16 1900305 EA GE CF34 CF34* NE FUSELAGE CORRODED B O OTHER O OTHER NR NOT REPORTED 1 SW 05 604FJ 5478 5001 AT LT AND RT FS 755, STRINGER 3,4,5 EXTENSIVE CORROSION WAS FOUND WHERE ACU DUCT IS ATTACHED TO SKIN PANEL. NUMEROUS RI VETS WERE MISSING FROM THE STRINGERS DUE TO CORROSION DAMAGE. AIRCRAFT WAS MFG IN SEPT OF 1986. (K) 2 L 7 2 4F 4 F RT A21EA E15NE 2005070600071 20050706 00071 CE 2005 7 6 2005FA0000933 1 20050616 G 6100 NAS1149C0332R WASHER HARTZL BEECH 58 58 1152740 CE HARTZL HCJ3Y PHCJ3YF2 GL HUB ASSY IMPROPER PART B EHHR K NONE W INADEQUATE Q C IN INSP/MAINT 1 EA 17 21YM ED4437B TH2005 ED4437B WHILE PERFORMING SB WHICH INCLUDES PROPELLER, REMOVING THE MOUNTING PLATE FROM THE SLIP RING, FOUND THAT THE WASHERS USE D TO HOLD THESE ITEMS TOGETHER ARE TOO WIDE AND SCORED, THE PROP HUB. WERE ABLE TO POLISH OUT THE SCOPE MARKS ON THE HU B AND MODIFY THE WASHERS TO HAVE A SLIGHT FLATEN AREA ON ONE SIDE AS NOT TO CONTACT THE HUB. (K) 1 L 7 2 3O 3A16 5 C P36EA 2005070600072 20050706 00072 NE 2005 7 6 2005FA0000934 2 20050621 G 8520 12611 CRANKSHAFT PWA R1340 R1340AN1 52016 NE ENGINE CRACKED B CP2R O OTHER O OTHER NR NOT REPORTED 1 SW 15 24877 THE CRANK PIN OF THE REAR HALF CRACKED FROM THE CRANK PIN RADIUS THRU TO THE REAR MAIN BEARING RADIUS. AFTER CLEANING A ND CLOSE EXAMINATION, IT IS OUR OPINION THAT THE CRACK ORIGINATED AT THE CRANK PIN RADIUS. MACHINE MARKS ON THE REMAINI NG PORTION OF THE RADIUS INDICATE A PREVIOUS REWORK OF THIS AREA. (K) 3 R 5E2 2005070600068 20050706 00068 SO 2005 7 6 2005FA0000935 1 20050621 G 5102 FFAX7B ENVELOPE BALWKS FIREFY FIREFLY7B 10501A9 SO BALLOON FAILED C O OTHER L NO TEST NR NOT REPORTED 1 WP 05 1539G 263 10249 BALLOON ENVELOPE FAILED FUEL CONSUMTION FLIGHT TEST. (K) 1 B 0 0 A14SO 2005070600064 20050706 00064 2005 7 6 2005FA0000936 4 20050616 G 2297 4020570901 CONTROL PANEL HONEYWELL AUTOPILOT MISWIRED D O OTHER O OTHER NR NOT REPORTED 1 EA 27 MODE CNTRL PNL WAS SENT FROM MFG AS REPLACEMENT FOR FAILED UNIT. NAV/HSI FUNCTION WHICH ALLOWS SELECTION SOURCE SIDE TH AT AUTOPILOT IS GOING TO USE IS REVERSED. WHEN SELECT SIDE ONE AND (1) ON PANEL IS ILLUMINATED AUTOPILOT IS ACTUALLY US ING SIDE (2) HSI OR SOURCE. WHEN SELECT SIDE (2) AND (2) IS ILLUMINATED ON PNL, USING SIDE (1) HSI OR SOURCE. PROBLEM WAS DISCOVERED DURING FUNCTIONAL TEST OF PNL AFTER INSTALLATION. SWITCH WAS WIRED IMPROPERLY DURING OH, MALFUNCTION WAS NOT CAUGHT DURING FINAL TESTING. DURING FINAL CKOUT, THIS FUNCTION SHOULD BE VERIFIED, IF BUGS, POINTERS AND ETC. ARE NOT SET IDENTICAL ON BOTH SIDES, AUTOPILOT IS GOING TO BE USING OFFSIDE DATA, AC WILL NOT RESPOND AS COMMANDED. (K) 2005070700033 20050707 00033 CE 2005 7 7 2005FA0000937 1 20050502 G 2750 0512128 BRACKET CESSNA 185 A185F 2072821 CE CONT O520 IO520* 17032 SO CONTROL CABLE BROKEN B YEBR O OTHER E VIBRATION/BUFFET NR NOT REPORTED 1 CE 05 26DL 2230 18502287 PILOT REPORTED THAT THE FLAPS FELT FUNNY AND THAT THEY MADE A GRINDING NOISE. INSPECTION OF FLAP SYSTEM FOUND PULLEY BR ACKET FOR LT FLAP EXTEND CABLE HAD BROKEN AT 2 OF THE 4 MOUNTING SCREW TABS. 1 H 7 1 3O 3 O 3A24 E5CE 2005070700016 20050707 00016 CE 2005 7 7 2005FA0000938 1 20050127 G 3220 AHML6 ROD END BEECH 36 A36 1151604 CE CONT O520 IO520* 17032 SO NLG BROKEN G L ABORTED APPROACH D INFLIGHT SEPARATION AP APPROACH 1 GL 05 25625 E393 DURING APPROACH TO LAND, IT WAS DISCOVERED BY THE PILOT THAT THE NOSE GEAR WOULD NOT EXTEND. NORMAL AND EMERGENCY GEAR EXTENSION WAS PERFORMED WITHOUT SUCCESS. THE AIRCRAFT MADE A SUCCESSFUL NOSE GEAR RETRACTED EMERGENCY LANDING. EXAMINA TION BY MAINTENANCE TECHNICIANS REVEALED THAT THE AFT ROD END ON THE NOSE GEAR RETRACT ROD ASSEMBLY HAD FAILED. THE ROD END WAS INSPECTED BY A METALLURGICAL LAB AND FOUND TO BE A FRESH BREAK WITH NO INDICATION OF PRIOR CRACKING. A NEW ROD END WAS INSTALLED, GEAR RIGGED AND AIRCRAFT WAS RETURNED TO SERVICE. 1 L 7 1 3O 3 O 3A15 E5CE 2005070700017 20050707 00017 SO 2005 7 7 2005FA0000939 1 20050701 G 3211 SUPPORT TUBE AYRES AYRES S2T STRT34 0970106 SO PWA PT6 PT6A60A 52043 NE LANDING GEAR FRACTURED G O OTHER O OTHER TO TAKEOFF 1 WP 09 4009J 16326 6015 THE RT LANDING GEAR COLLAPSED DURING TAKEOFF FROM A ROUGH DIRT STRIP. A LANDING GEAR SUPPORT TUBE BROKE NEAR ONE ATTACH POINT. CORROSION WAS PRESENT. 1 L 7 1 3T 4 T A3SW E4EA 2005070700032 20050707 00032 SO 2005 7 7 2005FA0000940 1 20050621 G 2731 1561805 ARM PIPER PIPER PA23 PA23250 7102308 SO LYC O540 TIO540* 41532 EA ELEVATOR TAB CORRODED G B EMER. DESCENT D INFLIGHT SEPARATION CR CRUISE 1 SW 17 2521M 277954072 WHILE INVESTIGATION AIRCRAFT ACCIDENT NR DFW05LA167 THE STABILATOR TRIM TAB ROD WAS DISCOVERED SEPARATED AT APPROX 3 INC HES FROM TAB. VISUAL INSPECTION REVEALED CORROSION ON THE INTERIOR OF THE PART. FUTHER DETAILED INSPECTION SHOWED MINI MAL SHEAR LIP, LEADING FAILURE TO BE CORROSION FATIGUE DUE TO REPEATED LOADING. THE OPERATOR REPORTED LOSS OF STABILATO R TRIM AT 8,000 FT AND VIOLENT SHAKING OF AIRCRAFT. 1 L 7 2 3O 3 O 1A10 E14EA 2005071200124 20050712 00124 SO 2005 7 12 2005FA0000941 1 20050620 G 7603 554528 THROTTLE CABLE PIPER PA44 PA44180 7104402 SO RT ENGINE BROKEN B A UNSCHED LANDING O OTHER AP APPROACH 1 WP 05 570ER 2457 20 4496146 DURING CROSS COUNTRY TO KINGMAN, DURING A TOUCH AND GO PROCEDURE THE STUDENT DECREASED THE THROTTLES BUT THE RIGHT ENGIN E POWER DID NOT REDUCE. DECLARED AN EMERGENCY AND DURING THE LANDING FLARE THE MIXTURE WAS CUT OFF KILLING THE ENGINE. MAINTENANCE PERSONNEL FOUND THE THROTTLE CABLE HAD BROKEN APPROXIMATELY .5 INCH INSIDE THE INSIDE THE CABLE SHEATH AT T HE CABIN END OF THE CABLE. IT APPEARS TO HAVE BEEN CAUSED BY FLEXING AT THIS POINT DURING THROTTLE CHANGES. 1 L 7 2 3O A19S0 2005071100148 20050711 00148 SO 2005 7 11 2005FA0000942 1 20050708 G 3260 LANDING GEAR PIPER PA23 PA23160 7102304 SO LYC O360 IO360A1A 41514 EA HARTZL HCC2Y HCC2YK2 GL NOSE NO INDICATION D O OTHER P NO WARNING INDICATION LD LANDING 1 EA 17 PILOT DID NOT HAVE A GREEN LIGHT FOR THE NOSE GEAR ON HIS FINAL APPROACH. ATC WAS NOTIFIED AND A VISUAL WAS CONFIRMED TH AT HIS NOSE GEAR WAS IN A DOWN ATTITUDE. NO INFORMATION WAS GIVEN UPON HOW MANY TIMES THE GEAR WAS CYCLED IF AT ALL. PIL OT LANDED UNEVENTFUL. THE AIRCRAFT WAS INSPECTED ON THE RUNWAY AND THE NOSE GEAR INDICATOR WAS ILLUMINATED. THE AIRCRAFT WAS PUT ON JACKS , GEAR WAS CYCLED , AND AN ADJUSTMENT WAS MADE TO COMPENSATE FOR NORMAL WEAR. 1 L 7 2 3O 3 O 1A10 1E10 5 C P920 2005071200067 20050712 00067 SO 2005 7 12 2005FA0000943 1 20050701 G 2750 1763400 TORQUE TUBE PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA ZONE 100 CUT D O OTHER O OTHER NR NOT REPORTED 1 GL 15 1100 273645 PERFORMING AD 2003-09-13, FOUND TORQUE TUBE WORE/CUT BY LEFT RUDDER CABLE, 2 INCHES LONG AND THRU TUBE WALL. TUBE HAS B EEN INSTALLED SINCE 1996 1100 HRS AGO. 1 L 7 2 3O 3 O 1A10 1E4 2005071200068 20050712 00068 SO 2005 7 12 2005FA0000944 1 20050701 G 2750 1763400 TORQUE TUBE PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA ZONE 100 CUT D O OTHER O OTHER NR NOT REPORTED 1 GL 15 1100 273645 PERFORMING AD 2003-09-13, FOUND TORQUE TUBE WORE/CUT BY LEFT RUDDER CABLE, 2 INCHES LONG AND THRU TUBE WALL. TUBE HAS B EEN INSTALLED SINCE 1996 1100 HRS AGO. 1 L 7 2 3O 3 O 1A10 1E4 2005071200085 20050712 00085 CE 2005 7 12 2005FA0000945 1 20050623 G 2710 12339 CONTROL CABLE BBAVIA 7 7KCAB 21101P3 CE LYC O320 IO320E2A 41508 EA SNSNCH 74D 74DM EA AILERONS SLIPPED P A UNSCHED LANDING O OTHER CR CRUISE 1 NM 05 41690 97 39973 AILERON CABLE SLIPPED OUT OF THE INBOARD NICOPRESS SLEEVE ON THE FORWARD AILERON CABLE IN THE LEFT WING. ALL 4 (LEFT AN D RIGHT WING) CABLES WERE PURCHASED NEW FROM AMERICAN CHAMPION AIRCRAFT IN AUG, 2002 AND INSTALLED DURING THE REBUILD OF THE AIRCRAFT. ALL NICOPESS SLEEVES ON ALL 4 CABLES WERE CHECKED AND FOUND TO BE OUTSIDE OF THE GO/NO-GO GAUGE LIMIT. 1 H 7 1 3O 3 O A759 1E12 5 N P88614 2005071200144 20050712 00144 CE 2005 7 12 2005FA0000947 1 20050630 G 3220 COLLAR CESSNA 185 A185E 2072818 CE TAIL WHEEL MISSING H O OTHER W INADEQUATE Q C LD LANDING 1 WP 05 4530F 1851015 THE AIRPLANE GROUNDLOOPED. DISASSEMBLY REVEALED THAT THE TAIL WHEEL-LOCKING COLLAR WAS NOT INSTALLED ON THE TAILWHEEL A SSEMBLY. ALSO, THE STEERING NOTCH ON THE TAILWHEEL STEERING ARM WAS WORN SO THAT A LIGHT AMOUNT OF PRESSURE BY HAND WOU LD ALLOW THE TAILWHEEL TO BE TURNED ABOUT ITS STEERING AXIS. THE MISSING LOCKING COLLAR WAS NOT APPARENT UNTIL THE TAIL WHEEL WAS DISASSEMBLED. 1 H 7 1 3O 3A24 2005072100171 20050721 00171 SO 2005 7 21 2005FA0000950 2 20050115 G 7314 6559211A2 PUMP MOONEY M20 M20R 5870225 SW CONT O550 IO550G 17042 SO FUEL SYSTEM FAILED P O OTHER O OTHER LD LANDING 1 SO 11 10368 87 290286 684961 THIRD FUEL PUMP FAILURE ON AIRCRAFT/ENGINE IN APPROX 90 HRS. FUEL PUMP RETURNED TO CONT FOR ANALYSIS BUT THEY WERE NOT A BLE TO LOCATE FOR TESTING/ANALYSIS. NEITHER MOONEY OR CONTINENTAL HAVE BEEN ABLE TO DETERMINE CAUSE OF PUMP FAILURES. 1 L 7 1 3O 3 O RT 2A3 E3SO 2005071300066 20050713 00066 SO 2005 7 13 2005FA0000951 2 20050524 G 8520 CONNECTING ROD CESSNA 206 U206G 2073356 CE CONT O550 IO550F 17042 SO MCAULY D3A34 D3A34C402 GL ENGINE FAILED P A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION DE DESCENT 1 SW 15 4950Z 601 U20606055 284866R 992752 IN SLOW DESCENT FOR LANDING AT 3,000 FT AGL, SEVERE VIBRATION OCCURRED AND THEN WITHIN 30 SECONDS A LOUD BANG AND OIL CO VERING WINDSHIELD AND SIDE WINDOWS. DIVERTED FLT ABOUT 5-6 MILES AWAY AND MADE SAFE LANDING AT AIRPORT. UPON INSPECTION, NR 2 ROD PENETRATED TOP OF ENGINE CASE AND SUBSEQUENTLY SHEARED MAGNETO OFF OF CASE. SOME INDICATION OF CRANKSHAFT FAIL URE, BUT UNKNOWN AT THIS TIME AS MFG HAS REQUESTED TO TEAR DOWN ENGINE AT FACTORY. 1 H 7 1 3O 3 O A4CE E3SO 5 C P47GL 2005071300085 20050713 00085 CE 2005 7 13 2005FA0000953 1 20050627 G 5740 5414030 ANGLE NAMER T6 AT6G 6400434 CE PWA R1340 R1340* 52016 NE LT WING CORRODED D K NONE O OTHER IN INSP/MAINT 1 NE 01 92778 5114799 UPON COMPLYING WITH EMERGENCY AD 2005-12-51 IT WAS DISCOVERED THE LT OUTER WING LOWER BOLTING ANGLE P/N 54-14030 WAS HEA VILY DAMAGED BY PITTING, FILIFORM & ESPECIALLY EXFOLIATION TYPE CORROSIONS. THIS DAMAGE WAS ONLY FOUND AFTER STRIPPING PAINT & PRIMER AWAY TO PERFORM THE REQUIRED ZYGLO INSPECTION BY AD 2005-12-51. DAMAGE WAS NOT APPARENT WITH PRIMER PAIN T IN PLACE. THIS TYPE DAMAGE WAS ALSO FOUND ON THE LH FWD LOWER WING CENTER SECTION BOLTING ANGLE. THIS DAMAGE WAS ALS O MIRRORED ON THE RT WING & CENTER SECTION BOLTING ANGLES. RECOMMEND CLOSE VISUAL, ZYGLO OR EDDY CURRENT INSPECTION OF ALL WING ATTACH ANGLES AT REGULAR INTERVALS. 1 L 7 1 3R 3 R A2575 5E2 2005071500030 20050715 00030 CE 2005 7 15 2005FA0000954 1 20050714 G 3246 19949 WHEEL BEECH 35 V35A 1151544 CE CONT O520 IO520* 17032 SO MLG CORRODED D O OTHER O OTHER NR NOT REPORTED 1 SO 03 22PK 21 D8647 THIS KIT WAS PURCHASED NEW AND OF THE 4 WHEEL HALVES THAT ARE PART OF THE KIT, AFTER ONLY ONE YEAR OF USE, 3 SHOWED SUCH SIGNS OF CORROSION THAT IT IS QUESTIONABLE IF THE LIFE OF THE 3 WHEEL HALVES WOULD BE OVER 2 YEARS. AFTER ITS OWN INSP ECTION, THE MANUFACTURE DENYS ANY RESPONSIBILITY NOR INTEREST IN THE MATTER. I FIND IT WORTHY OF INVESTIAGATION AS TO W HY THE ONE WHEEL HALF CONTINUES TO BE IN VERY GOOD SHAPE WHILE THE OTHER 3 ARE IN SUCH A STATE OF DETERIORATION. 1 L 7 1 3O 3 O 3A15 E5CE 2005071500031 20050715 00031 CE 2005 7 15 2005FA0000955 1 20050714 G 3246 19949 WHEEL BEECH 35 V35A 1151544 CE CONT O520 IO520* 17032 SO ZONE 700 CORRODED D O OTHER O OTHER NR NOT REPORTED 1 SO 03 22PK 21 D8647 THIS KIT WAS PURCHASED NEW AND OF THE 4 WHEEL HALVES THAT ARE PART OF THE KIT, AFTER ONLY ONE YEAR OF USE, 3 SHOWED SUCH SIGNS OF CORROSION THAT IT IS QUESTIONABLE IF THE LIFE OF THE 3 WHEEL HALVES WOULD BE OVER 2 YEARS. AFTER ITS OWN INSP ECTION, THE MANUFACTURE DENYS ANY RESPONSIBILITY NOR INTEREST IN THE MATTER. I FIND IT WORTHY OF INVESTIAGATION AS TO W HY THE ONE WHEEL HALF CONTINUES TO BE IN VERY GOOD SHAPE WHILE THE OTHER 3 ARE IN SUCH A STATE OF DETERIORATION. 1 L 7 1 3O 3 O 3A15 E5CE 2005072000028 20050720 00028 CE 2005 7 20 2005FA0000959 1 20050621 G 8011 DRIVE ASSY CESSNA 182 TR182 2072735 CE LYC O540 O540L3C5 41532 EA STARTER FAILED B YEBR O OTHER O OTHER NR NOT REPORTED 1 CE 05 6317T E111092 R18201975 L2322740A INSTALLED FACTORY OVERHAULED ENGINE ONTO AIRCRAFT. THE STARTER BENDIX WAS ENGAGED WHEN ENGINE WAS INSTALLED. AFTER FIR ST START THE STARTER WOULD SPIN BUT BENDIX WOULD NOT RE-ENGAGE STARTER RING GEAR ON ENGINE. REPLAED WITH OVERHAULED SPA CE STARTER (SN E123085). (K) 1 H 7 1 3O 3 O 3A13 E295 2005072000114 20050720 00114 CE 2005 7 20 2005FA0000960 1 20050715 G 2750 45A6103511 CABLE BEECH MU300 400A 1155402 CE TE FLAPS BROKEN B K NONE L NO TEST IN INSP/MAINT 1 SO 11 746TA 6580 RK146 FLAP FOLLOW-UP CABLE WAS DISCOVERED CORRODED AND BROKEN IN HALF DURING AN INSPECTION. 2 H 7 2 4F RT A16SW 2005072000163 20050720 00163 NM 2005 7 20 2005FA0000961 1 20050704 G 5712 SA3A RIB UNIVAR 415 415C 0420302 NM CONT A75 C7512 17005 SO SNSNCH 76AK M76AK EA WING CORRODED D O OTHER O OTHER NR NOT REPORTED 1 NM 03 2172H 2687 2795 NA NA WHILE COMPLYING WITH SB 31 METHOD 1 (INSTALLING INSPECTION PANELS) AND AD 02-26-02, FOUND LEFT INBOARD WALK BOX RIB AFT ANGLE SUPPORT COMPROMISED WITH SEVERE EXFOLIATION DAMAGE. THE ORIGINAL PIECE WAS IN A BAY COATED WITH DIRT. THE AIRCRA FT HAD BEEN STORED WITH WINGS OFF FOR 7 YEARS AND NO DEFECTS WERE NOTED WHILE LOOKING IN THE WING CENTER SECTION PRIOR T O ASSEMBLY. SINCE A BOROSCOPE HAS LIMITED ABILITY, I RECOMEND INSTALLING THE PANELS TO ALLOW REMOVAL OF DIRT AND OTHER DEBRIS THAT ACCUMULATES OVER TIME. MANUFACTURED AN ANGLE ALUMINUM BRACE FROM STANDARD ANGLE ALUMINUM TO REPLACE ORIGINA L PART. 1 L 7 1 3O 3 O A718 E233 5 N 1P210 2005072000169 20050720 00169 SO 2005 7 20 2005FA0000966 1 20050706 G 2710 86396002 RIB PIPER PIPER PA32 PA32R301 7103218 SO AILERON CRACKED D K NONE O OTHER IN INSP/MAINT 1 NE 03 755BE 3872 32R8213009 LEFT AILERON OUTBOARD HINGE HALF WAS CORRODED. AILERON WAS DISASSEMBLED TO REPLACE HINGE HALF. UPON REMOVING AN3 BOLTS AND HINGE HALF FROM NOSE RIB, THE LOWER BOLT HOLE IN THE NOSE RIB WAS FOUND TO HAVE A HALF INCH CRACK ADJACENT TO THE H OLE.IT IS NOT POSSIBLE TO INSPECT THIS AREA WITHOUT DISASSEMBLY OF THE AILERON. 1 L 7 1 3O A3SO 2005072100003 20050721 00003 SO 2005 7 21 2005FA0000967 1 20050609 G 5741 ATTACH FITTING GULSTM G1159 G1159B 3953535 SO RROYCE SPEY SPEY511* 54523 EU RT WING CORRODED B N38R O OTHER O OTHER NR NOT REPORTED 1 EA 05 510SR 070 IAW MM TO COMPLY WITH THE 24 MONTH NDT REQUIREMENTS UNDER THE ULTRASONIC PART OF THE INSPECTION CORROSION WAS FOUND ON B OTH THE LT AND RT WING ATTACHMENT FITTINGS AT FS 452, BL33, LT AND RT. TECH OPS REQUIRES COMPLIANCE WITH ASC FOR A 3 PI ECE FITTING PLATE. (K) 2 L 7 2 4F 4 F RT A12EA E2EU 2005072100001 20050721 00001 NM 2005 7 21 2005FA0000968 1 20050621 G 8011 DRIVE GEAR UNIVAR 108 108 9230402 NM LYC O540 O540L3C5 41532 EA STARTER MALFUNCTIONED B YEBR O OTHER O OTHER NR NOT REPORTED 1 CE 05 6317M E123085 1084317 REMOVED DEFECTIVE STARTER (SN E111092 FROM ENGINE. INSTALLED OVERHAULED STARTER ONTO ENGINE WITH BENDIX ENGAGED. AFTER FIRST START, THE STARTER WOULD SPIN BUT NOT RE-ENGAGE STARTER BENDIX INTO RING GEAR ON ENGINE. INSTALLED PRESTOLITE S TARTER. OPERATION AND GROUND RUN CHECKED GOOD. (K) 1 H 7 1 3O 3 O A767 E295 2005072100005 20050721 00005 SO 2005 7 21 2005FA0000969 2 20050628 G 7414 IO400309 IMPULSE COUPLING CESSNA 210 210M 2073450 CE CONT O550 IO550* SO MAGNETO WORN B YEBR O OTHER O OTHER NR NOT REPORTED 1 CE 05 6175N 959 114 FOICA070R 21062946 289173R MAGS REMOVED FOR TROUBLESHOOTING OF ENGINE HIGH ALTITUDE OPERATION PROBLEM. DURING PREINSTALLATION INSPECTION OF COUPLI NGS. ONE WAS FOUND WORN BEYOND LIMITS. (K) 1 H 7 1 3O 3 O 3A21 E3SO 2005072100016 20050721 00016 SO 2005 7 21 2005FA0000970 2 20050701 G 8530 SA55000A1 CYLINDER HEAD CONT O550 IO550F 17042 SO ENGINE SEPARATED D O OTHER D INFLIGHT SEPARATION NR NOT REPORTED 1 SW 99 679521 HEAD SEPARATED FROM CYLINDER IN FLIGHT. NO INJURIES. NO INCIDENT. (K) 3 O E3SO 2005072100006 20050721 00006 CE 2005 7 21 2005FA0000971 1 20050627 G 5543 SKIN CESSNA 210 T210* CE TRIM TAB DAMAGED D O OTHER O OTHER NR NOT REPORTED 1 SW 13 NEW TRIM TAB RECEIVED IN PRIMER. UPON PAINTING, NOW SHOWS CREASE IN UPPER SKIN FROM IB END APPROX 18 INC IN CENTER OF S KIN. CREASE PASSES THROUGH RIVETS IN FRONT OF BLOCK STIFFENER FOR TRIM ACTUATOR FITTING. FONT RIVETS IN BLOCK OVER DRI VEN CAUSING BUCKLE IN SKIN AT RIVETS. SUSPECT INTERNAL BLOCK DAMAGED. POOR WORKMANSHIP AND INSPECTION AT FACTORY. (K) 1 H 7 1 3O 3A21 2005072100180 20050721 00180 CE 2005 7 21 2005FA0000972 1 20050718 G 5342 AN45A BOLT CESSNA 150 152 2071835 CE HORIZONTAL STAB LOOSE D O OTHER O OTHER NR NOT REPORTED 1 WP 05 4898B 15283697 AFTER USING AN ORBITAL WAXING BUFFER ON THE HORIZONTAL STABILIZER, THE OWNER NOTICED LOOSENESS AT THE HORIZONTAL STABILI ZER LEADING EDGE AND THE OUTBOARD EDGE. INVESTIGATION REVEALED THAT BOTH FOWARD ATTACH BOLTS, P/N AN44-5A (IPC FIG 18A I TEM 1) WERE LOOSE. BOLTS WERE RETORQUED PER MAINTENANCE MANUAL. THE VIBRATION ACTION OF THE BUFFER APPEARENTLY CAUSED T HE LOOSENESS. 1 H 7 1 3O NT 3A19 2005072200090 20050722 00090 SO 2005 7 22 2005FA0000974 2 20050721 G 7414 6310 MAGNETO CESSNA 182 182P 2075816 CE CONT O470 O470S 17026 SO ENGINE CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 SO 06 113SG 721 18264758 FOUND AN OIL LEAK COMING FROM THE BASE OF THE LEFT MAGNETO. REMOVED MAG TO REPLACE GASKET. FELT SOMETHING ON THE MOUNTIN G FLANGE OF THE MAG. FOUND A SECTION OF THE FLANGE ABOUT 1 1/4 INCH CRACKED WHERE THE HOLD DOWN CLIP CLAMPS THE MAG TO T HE ENGINE CASE. A LITTLE HAND PRESSURE AND THE CRACKED SECTION CAME OFF. 1 H 7 1 3O 3 O NT TA13 E273 2005072200091 20050722 00091 SO 2005 7 22 2005FA0000975 2 20050721 G 7414 6310 MAGNETO CESSNA 182 182P 2075816 CE CONT O470 O470S 17026 SO ENGINE CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 SO 06 113SG 721 18264758 FOUND AN OIL LEAK COMING FROM THE BASE OF THE LEFT MAGNETO. REMOVED MAG TO REPLACE GASKET. FELT SOMETHING ON THE MOUNTIN G FLANGE OF THE MAG. FOUND A SECTION OF THE FLANGE ABOUT 1 1/4 INCH CRACKED WHERE THE HOLD DOWN CLIP CLAMPS THE MAG TO T HE ENGINE CASE. A LITTLE HAND PRESSURE AND THE CRACKED SECTION CAME OFF. 1 H 7 1 3O 3 O NT TA13 E273 2005072200092 20050722 00092 SO 2005 7 22 2005FA0000976 2 20050721 G 7414 6310 MAGNETO CESSNA 182 182P 2075816 CE CONT O470 O470S 17026 SO ENGINE CRACKED D K NONE K FLUID LOSS IN INSP/MAINT 1 SO 06 113SG 721 18264758 FOUND AN OIL LEAK COMING FROM THE BASE OF THE LEFT MAGNETO. REMOVED MAG TO REPLACE GASKET. FELT SOMETHING ON THE MOUNTIN G FLANGE OF THE MAG. FOUND A SECTION OF THE FLANGE ABOUT 1 1/4 INCH CRACKED WHERE THE HOLD DOWN CLIP CLAMPS THE MAG TO T HE ENGINE CASE. A LITTLE HAND PRESSURE AND THE CRACKED SECTION CAME OFF. 1 H 7 1 3O 3 O NT TA13 E273 2005072200196 20050722 00196 EA 2005 7 22 2005FA0000977 1 20050628 G 3234 7455025 CONTROL HANDLE CNDAIR CL600 CL6002B16 1900305 EA GE CF34 CF34* NE MLG FAILED D O OTHER O OTHER NR NOT REPORTED 1 WP 28 22SF 72 5589 WHEN LANDING GEAR HANDLE MOVED TO EXTEND. NO MOVEMENT OF GEAR OR INDICATION OF MOVEMENT NOTED. (K) 2 L 7 2 4F 4 F RT A21EA E15NE 2005072200210 20050722 00210 WP 2005 7 22 2005FA0000978 1 20050625 G 7160 5930645509 NOSE COWL DOUG DC9 DC983 3022083 WP PWA JT8 JT8D NE ENGINE DEBONDED B UMXR O OTHER O OTHER NR NOT REPORTED 1 SO 19 190AN 53190 SKIN PANELS HAVE DELAMINATED AT FWD EDGE, COMMON TO LIP SKIN. EVIDENCE OF HIGH TEMPERATURE AS FIBERGLASS APPEARS DARKEN ED AND IS BRITTLE. OUTER SKINS OF BARREL ARE DEBONDED AND DISCOLORED BY HIGH TEMPERATURE. PROBABLE CAUSE: ANTI-ICE LE FT OPERATING FOR LONG PERIOD OF TIME ON GROUND. (K) 2 L 7 2 4F 4 F RT A6WE E2EA 2005072200207 20050722 00207 CE 2005 7 22 2005FA0000979 1 20050502 G 3212 MC2711B ACTUATOR CESSNA 180 180 2072602 CE CONT O470 O470* 17026 SO FLOAT DEFECTIVE D O OTHER O OTHER NR NOT REPORTED 1 AL 05 3126D 257 31924 LT MAIN LANDING GEAR FAILED DOWN AND LOCKED POSITION, UPON INSPECTION, O-RING IN ACTUATOR PLUNGER ASSY, MS28775-214 WAS FOUND DEFECTIVE, REPLACED WITH SAME PN RE INSTALLED ACTUATO TO FLOAT ASSY. OPS CHECKED OK, NO DEFECTS NOTED. (AL052005 02475) (K) 1 H 7 1 3O 3 O NC 5A6 E273 2005072200208 20050722 00208 CE 2005 7 22 2005FA0000980 1 20050614 G 5320 53120252 PAN CESSNA 340 340A 2076405 CE CONT O520 TSIO520* 17040 SO TAIL CRACKED B CTUR O OTHER O OTHER NR NOT REPORTED 1 GL 21 340AX 5627 340A0020 AFT PAN ASSY IN TAIL CRACKED. THIS IS A RECURRING ISSUE WITH OUT FLEET. PROBABLE CAUSE IS EXCESS FLEX IN TAIL. RECOMM END CLOSER INSPECTION DURING 100 HR/ANNUAL INSPECTIONS. (GL21200502750) (K) 1 L 7 2 3O 3 O 3A25 E8CE 2005072200211 20050722 00211 CE 2005 7 22 2005FA0000981 1 20050531 G 5312 00244002465 BULKHEAD BEECH 36 A36 1151604 CE CONT O550 IO550* SO FUSELAGE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SW 01 8248K 19200 E2678 BULKHEAD CRACKED APPROX .3750 INCH ON UPPER LT AREA ON BEND RADIUS, BULKHEAD TIES IN VERTICAL AND HORIZONTAL STABILIZERS TOGETHER. FATIGUE DUE TO HIGH TT ON AIRFRAME, PROBABLE CAUSE? (SW01200504869) (K) 1 L 7 1 3O 3 O 3A15 E3SO 2005072200213 20050722 00213 CE 2005 7 22 2005FA0000982 1 20050322 G 5610 10138402518 WINDSHIELD BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A60A 52043 NE COCKPIT FAILED G O OTHER O OTHER NR NOT REPORTED 1 EA 17 905GP 4636 BB789 PILOTS WERE INCRUISE WITH WINDSHIELD HEAT ON AND WINDSHIELD (INNER) SHATTERED. TALKED TO TECH AND WAS STATED IT WAS USU ALLY THE INNER THAT SHATTERS. ALTITUDE 22,000 FT CLEAR, -35 DEGREES C. NO TURBLANCE, NO ICING. (EA17200508780) (K) 1 L 7 2 4T 4 T A24CE E4EA 2005072200212 20050722 00212 CE 2005 7 22 2005FA0000983 1 20050505 G 3230 HMX5FG ROD END BEECH 35 M35 1151526 CE CONT O470 IO470C 17026 SO NLG DEFECTIVE D O OTHER O OTHER NR NOT REPORTED 1 SW 15 374Z 5320 D6554 722830C THE BEARING END PARTED FROM THE THREAD PORTION OF THE ROD END, CAUSING COLAPSE OF THE NOSE LANDING GEAR. THE DEFECT APP EARED ON ROLL OUT AFTER LANDING, WHEN THE NOSE GEAR COLLAPSED. STRUCTURAL FAILURE OF THE ROD END. (SW15200512716) (K) 1 L 7 1 3O 3 O 3A15 E273 2005072200214 20050722 00214 CE 2005 7 22 2005FA0000984 1 20050706 G 3230 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO CABIN INTERFERENCE B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 1564A 333 CE1321 GEAR REMAINS DOWN WHEN GEAR HANDLE IS SELECTED FOR GEAR UP. MAINTENANCE TECH TROUBLESHOOT GEAR SYS AND FOUND THAT THE D YNAMIC RELAY WAS INTERMITTENT. NO RECOMMENDATION AT THIS TIME. DYNAMIC RELAY MFD 0445. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005072200215 20050722 00215 GL 2005 7 22 2005FA0000985 1 20050701 G 8011 STARTER STNSON 10 10STNSON 8632004 GL FRNKLN 6A4165 6A4165* 27025 EA ENGIEN INOPERATIVE B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 944C 1083944 THIS STARTER MOTOR REPORTED TO BE INOPERATIVE. PLACED IN SERVICE 3/1/2005. REMOVED FROM SERVICE 6/16/2005. 1 H 7 1 3O 3 O A709 E238 2005072200220 20050722 00220 EA 2005 7 22 2005FA0000986 2 20050628 G 7322 272 CARBURETOR CESSNA 177 177 2073704 CE LYC O320 O320* 41508 EA ENGINE MALFUNCTIONED B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 29530 17700944 CUSTOMER REPORTS THAT ENGINE QUIT ON FINAL. ON THE GROUND PILOT WITNESSED GAS POURING OUT FROM BOTTOM OF COWL. (K) 1 H 7 1 3O 3 O NT A13CE E274 2005072200216 20050722 00216 NE 2005 7 22 2005FA0000988 2 20050722 G 7210 70BM055420 MODULE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE ENGINE MAKING METAL B HXSR O OTHER O OTHER NR NOT REPORTED 1 AL 05 802TH 2211 9023 PILOT REPORTED ENGINE CHIP LIGHT ON HIS WAY TO HANGAR. MECHANIC DID THE INSPECTIONS IAW MFG MM AND FOUND A SMALL SINGLE FLAKE ON THE ELECTRIC MAG PLUG WHICH MONITORS THE REAR BEARING OIL RETURN LINE. MECHANIC ALSO THEN FOUND MULTIPLE FLAK ES OF PLATEING ON THIS CHIP PLUG. REMOVED THE (ENGINE SN9695) AND INSTALLED (ENGINE SN 9120). SENT ENGINE FOR EVALUATI ON AND REPAIR. 1 G 7 1 3U 3 U H9EU E19EU 2005072200221 20050722 00221 EU 2005 7 22 2005FA0000989 1 20050606 G 7931 APTE176S150G TRANSMITTER SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE OIL PRESSURE FAILED B HXSR O OTHER O OTHER NR NOT REPORTED 1 AL 05 6080R 2685 AIRCRAFT WAS LIFTING OFF FOR A STANDARD TOUR AND THEN REPORTED A LOSS OF OIL PRESSURE. THE PILOT THEN RETURNED TO BASE WITH NO TROUBLE AND REPORTED TO MAINTENANCE. MECHANIC FOUND THAT THE OIL PRESSURE SENSOR HAD FAILED AND REPLACED PART. AIRCRAFT HAS BEEN RETURNED TO SERVICE. (K) 1 G 7 1 3U 3 U NC H9EU E19EU 2005072200222 20050722 00222 GL 2005 7 22 2005FA0000991 1 20050630 G 5740 ATTACH ANGLE NAMER T6 AT6C 6400412 GL PWA R1340 R1340* 52016 NE WING CRACKED D O OTHER O OTHER NR NOT REPORTED 1 GL 17 7678Z 889156 WING ATTACH ANGLE, CRACKING BETWEEN ROWS OF FASTENERS. (K) 1 L 7 1 3R 3 R A2575 5E2 2005072200226 20050722 00226 GL 2005 7 22 2005FA0000992 1 20050722 G 5740 ATTACH ANGLE NAMER T6 AT6D 6400416 GL PWA R1340 R1340* 52016 NE LT WING CORRODED D O OTHER O OTHER NR NOT REPORTED 1 GL 13 7621Z 8815945 WING ATTACH ANGLE, CORROSION WITH LINEAR INDICATIONS. (K) 1 L 7 1 3R 3 R A2575 5E2 2005072500001 20050725 00001 GL 2005 7 25 2005FA0000993 1 20050630 G 5740 ATTACH ANGLE NAMER T6 SNJ2 6400404 GL PWA R1340 S1H1 52016 NE LT WING CORRODED D O OTHER O OTHER NR NOT REPORTED 1 GL 11 40HS 2027 WING ATTACH ANGLE, CORROSION WITH LINEAR INDICATIONS. (K) 1 L 7 1 3R 3 R A2575 E129 2005072500003 20050725 00003 CE 2005 7 25 2005FA0000994 1 20050609 G 2820 530010841 LINE CESSNA 340 340A 2076405 CE CONT O520 TSIO520* 17040 SO FUEL CROSSFEED CORRODED B CTUR O OTHER O OTHER NR NOT REPORTED 1 GL 21 98560 5593 340A0032 DURING ANNUAL INSPECTION FOUND FUEL STAINS ON CROSSFEED LINE UNDER CABIN FLOOR PANEL. FOUND CROSSFEED LINE CORRODED THR OUGH. LINE WAS LEAKING AT A CORRODED AREA. THERE WAS NOTHING TOUCHING FUEL LINE. (GL21200502745) (K) 1 L 7 2 3O 3 O 3A25 E8CE 2005072500006 20050725 00006 SO 2005 7 25 2005FA0000995 1 20050624 G 5514 1159CS2000013 ANGLE GULSTM G1159 G1159A 3970109 SO RROYCE SPEY SPEY511* 54523 EU HORIZONTAL STAB CORRODED B LS3R O OTHER O OTHER NR NOT REPORTED 1 WP 19 723MM 357 DURING REPLACEMENT OF AFT TAIL COMPT BULKHEAD CAP-ANGLE, HORIZ AND VERT STABILIZERS REQUIRED REMOVAL. AFTER REMOVAL, TE CH FOUND RECENT REPAIR ACCOMPLISHED BY 3RD PARTY REPAIR STATION HAD NUMEROUS ISSUES. REPAIR WAS ACCOMPLISHED, DUE TO FI NDING CORROSION DURING 24 MONTH INSPECTION. STEEL STRAPS WERE REPLACED. FOUND FOLLOWING DISCREPANCIES: BETWEEN STA 0 TO 80.81 ON LT, RT LEADING EDGES. FOUND 200+ FASTENERS. MUCH SOFTER FASTENER AND IS NOT APPROVED FOR THIS INSTALLATION . CORROSION/RUST ON STEEL STRAPS, LT AND RT TOP SKIN-114 INCORRECT FASTENERS EACH SIDE. AFT SPAR-60 INCORRECT FASTENER S. CTR SECTION UNDER FAIRING WHERE STRAPS OVERLAP-110 INCORRECT FASTENERS. CORROSION FOUND ON STEEL STRAP IN PANEL. 2 L 7 2 4F 4 F A12EA E2EU 2005072500004 20050725 00004 CE 2005 7 25 2005FA0000996 1 20050627 G 8011 PINION GEAR LAMAR CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA STARTER BROKEN D O OTHER O OTHER NR NOT REPORTED 1 NM 01 510LP 85041608 172S9510 THIS STARTER PINION GEAR FAILED. PIECES OF THE GEAR JAMMED THE STARTER MOTOR AND DAMAGED THE RING GEAR. THIS IS THE SE COND OCCURRENCE OF THIS INCIDENT ON THIS AIRCRAFT. MFG MENTIONED THAT THERE HAS BEEN PROBLEM IN PAST. IN ALL CASES BUT THIS LAST ONE, TEETH HAVE BEEN BROKEN OFF OF THE RING GEAR. THE CURRENT INCIDENT HAS ONLY DAMAGED THE RING GEAR TEETH. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005072500007 20050725 00007 CE 2005 7 25 2005FA0000997 1 20050624 G 3240 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO DYNAMIC BRAKE FAILED B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 5540P 414 CE1335 DURING GEAR EXTENSION, GEAR DID NOT EXTEND. TROUBLESHOOTING SYSTEM FOUND DYNAMIC RELAY, DOWN SIDE OF RELAY TO RELEASE A ND ALLOW GEAR TO EXTEND DOWN. PROBABLE CAUSE IS STICKING DOWN RELAY MODULE RETURNED TO MFG FOR ANALYSIS. RECOMMENDATIO N IS FOR MFG TO DEVELOP AN IMPROVED PRODUCT. MFD 0425. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005072500023 20050725 00023 CE 2005 7 25 2005FA0000998 1 20050623 G 5553 3364000039 FITTING BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO VERTICAL STAB CRACKED B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 5544A 18044 CE1343 WHILE PERFORMING UNSCHEDULED MAINTENANCE, VERTICAL STABILIZER WAS REMOVED, WHILE THE MECHANIC WAS INSPECTING THE FITTING S FOR REINSTALLATION OF THE VERTICAL STABILIZER NOTICED A CRACK COMING FROM BOTTOM RT LOWER MOUNTING HOLE ON FORWARD FIT TING. AT THIS TIME NO PROBABLE CAUSE OR RECOMMENDATION. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005072500024 20050725 00024 SO 2005 7 25 2005FA0000999 2 20050601 G 8530 CCST712BCA CYLINDER HEAD CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE SEPARATED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 7235F 1156 21063038 236433R NR 2 CYLINDER HEAD SEPARATED FROM BARREL. OCURRENCE OCCURRED DURING DEPARTURE FROM AIRPORT, ENROUTE. PROBABLE CAUSE IS WORN CYLINDER OR POSSIBLE OVERBOOST. RECOMMEND WHEN PERFORMING COMPRESSION TEST THAT YOU PRESSURIZE AND SOAP CYLINDER AT BARREL AND HEAD ASSEMBLY. (CE03200509143) 1 H 7 1 3O 3 O 3A21 E8CE 2005072500009 20050725 00009 CE 2005 7 25 2005FA0001000 1 20050606 G 5754 10112012341 SKIN BEECH B300 B300 1159232 CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL LT WING LE DELAMINATED B LX5R O OTHER O OTHER NR NOT REPORTED 1 GL 19 991LL 4190 FL142 DURING A POST FLIGHT CHECK, A MECHANIC NOTICED A BULGE ON THE UNDERSIDE OF THE IB LEADING EDGE OF THE LT WING. UPON FUR THER INVESTIGATION, A DELAMINATION AREA OF APPROXIMATELY 22 INCHES X 10 INCHES WAS FOUND. AFTER REMOVAL OF THE LEADING EDGE AND CLOSER EXAMINATION THE DELAMINATION WAS CONTAINED WITHIN THE EXHAUST GAS FLOW PATH FROM THE LT ENGINE IB EXHAU ST STACK. AFTER CONTACTING MFG, IT WAS DETERMINED THAT THE PART WAS NOT REPAIRABLE AND THE PART MUST BE REPLACED. (GL1 9200504135) 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2005072500032 20050725 00032 SO 2005 7 25 2005FA0001001 1 20050621 G 2720 62701100 CONTROL CABLE PIPER PA28 PA28181 7102807 SO LYC O360 O360* 41514 EA RUDDER WORN B UC2R O OTHER O OTHER NR NOT REPORTED 1 GL 19 4149G 2843191 LT FORWARD RUDDER CABLE WORN AT FAIRLEAD PASSING THROUGH CENTER WING SPAR AT FS 108.17. THE CABLE BECAME WORN DUE TO CO NTINUOUS CHAFING ON THE PHENOLIC FAIRLEAD. THE CABLE IS NOT CENTER IN THE FAIRLEAD OPENING EITHER THROUGH IMPROPER POSI TIONING OF THE FAIRLEAD OR FROM IMPROPER POSITIONING OF THE PULLEY QUADRANTS DURING AIRCRAFT ASSEMBLY. THE REMEDY FOR T HIS DEFECT WOULD BE TO INCREASE THE OPENING BY WHICH THE CABLE PASSES THROUGH THEREBY ALLOWING SUFFICIENT CLEARANCE FOR THE CABLE AND ELIMINATE CHAFING. (K) 1 L 7 1 3O 3 O 2A13 E286 2005072500028 20050725 00028 SO 2005 7 25 2005FA0001002 1 20050621 G 2710 62701099 CONTROL CABLE PIPER PA28 PA28181 7102807 SO LYC O360 O360* 41514 EA AILERONS WORN B UC2R O OTHER O OTHER NR NOT REPORTED 1 GL 19 4149G 2843191 LT AND RT PRIMARY AILERON CABLES SEVERELY WORN AT WING PULLEYS LOCATED AT WS 49.25. CABLES HAVE APPROXIMATELY 4725.4 TT . THIS DEFECT IS NOT A RESULT OF BINDING PULLEYS BUT MOST PROBABLY DUE TO SUB-STANDARD CABLE USED DURING MFG, SPECIFICA LLY STAINLESS STEEL CABLE. ALTHOUGH SB 1048 IS ACCOMPLISHED AT EACH 100 HOUR AND ANNUAL INSPECTION, IT BY NO MEANS SOLV ES THIS PROBLEM. IT WOULD BE RECOMMENDED THAT ALL STAINLESS STEEL CABLES BE ELIMINATED AND GALVANIZED STEEL CABLES BE I NSTALLED. (K) 1 L 7 1 3O 3 O 2A13 E286 2005072500029 20050725 00029 EA 2005 7 25 2005FA0001003 1 20050706 G 2121 2651601 FAN CNDAIR CL600 CL6002B16 1900305 EA GE CF34 CF34* NE TRU COOLING FAILED D O OTHER O OTHER NR NOT REPORTED 1 SO 25 779AZ 5141 5176 DURING OPS CHECK OF TRANSFORMER RECTIFIER SYSTEM, IT WAS NOTICED THAT THERE WAS NO AIRFLOW FROM THE INTERNAL COOLING FAN . REMOVED AND REPLACED COOLING FAN ASSEMBLY WITH NEW AND IMPROVED UNIT. THERE WAS NO NOTIFICATION TO THE FLIGHT CREW T HAT THIS FAN HAD FAILED. (K) 2 L 7 2 4F 4 F RT A21EA E15NE 2005072500010 20050725 00010 CE 2005 7 25 2005FA0001004 1 20050705 G 3240 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO DYNAMIC BREAKER INTERMITTENT B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 1556A 222 CE1318 ON ROUTINE PHASE INSPECTION, THE MECHANIC PUT THE GEAR DOWN AND NOTHING HAPPENED. ON TROUBLESHOOTING, THE MECHANIC FOUN D THE RELAY WAS INTERMITTENT, PROBABLE CAUSE AT THIS TIME UNKNOWN. INSTALLED NEW AND IMPROVED RELAY IAW DATE CODE. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005072500034 20050725 00034 2005 7 25 2005FA0001005 4 20050629 G 6113 05522311 BULKHEAD CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA MCAULY 1A170 1A170E GL PROP SPINNER CRACKED B WIWR O OTHER O OTHER NR NOT REPORTED 1 WP 07 796WW 296 172S8635 DURING ANNUAL INSPECTION THE FORWARD SPINNER BULKHEAD WAS FOUND TO BE CRACKED AROUND 5 OF THE SIX BOLT HOLES. THINK THA T THE CAUSE OF THE PROBLEM IS THAT WHEN THE PROP MOUNTING BOLTS ARE TORQUED TO THE LIMITS GIVEN IN THE SRM THAT THE FORW ARD BULKHEAD GET PULLED DOWN SLIGHTLY INTO THE CHAMFER OF THE PROP BOLT HOLES AND THIS IN TURN STRESS THE PART LEADING T O CRACKING. TO SOLVE THIS PROBLEM, THINK THAT THE POSSIBILITY OF DIMPLING OF THE BOLT HOLES MIGHT CORRECT THE CRACKING. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2005072500030 20050725 00030 2005 7 25 2005FA0001006 4 20050630 G 6113 05522311 BULKHEAD CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA MCAULY 1A170 1A170E GL PROP SPINNER CRACKED B WIWR O OTHER O OTHER NR NOT REPORTED 1 WP 07 154ME 187 172S8534 DURING 100 HR INSPECTION THE FORWARD SPINNER BULKHEAD WAS FOUND TO BE CRACKED AROUND ALL SIX (6) BOLT HOLES. THINK THAT THE CAUSE OF THE PROBLEM IS THAT WHEN THE PROP MOUNTING BOLTS ARE TORQUED TO THE LIMITS GIVEN IN THE SRM AND THAT THE F ORWARD BULKHEAD GETS PULLED DOWN SLIGHTLY INTO THE CHAMFER OF THE PROP BOLT HOLES AND THIS IN TURN STRESSES THE PART LEA DING TO CRACKING. TO SOLVE THIS PROBLEM, THINK THAT THE TORQUE OF THE MOUNTING BOLTS AND THE DESIGN OF THE BULKHEAD NEE D TO BE EVALUATED AND CHANGES MADE. ANOTHER SOLUTION MIGHT BE TO ADD A PLATE OVER THE MOUNTING AREA MUCH LIKE THE ONE R EQUIRED FOR SOME 152 PROP INSTALLATIONS TO ALLOW THE STRESS FROM THE MOUNTING BOLTS TO BE MORE EVENLY DISTRIBUTED. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2005072500031 20050725 00031 EA 2005 7 25 2005FA0001007 1 20050712 G 5711 SPAR CAP DHAV DHC6 DHC6300 2802606 EA LT WING DAMAGED B JRPR O OTHER O OTHER NR NOT REPORTED 1 WP 21 8PMLK 12456 477 SMOKING MS20470DD8 RIVETS OBSERVED AT WS122 - 140 PROX DURING SCHEDULED INSPECTION. THESE RIVETS ARE CRITICAL TO WING INTEGRITY. IT APPEARS THAT THE RIVETS DID NOT PROPERLY ENGAGE THE HOLE DURING OEM INSTALLATION. SUGGEST ALL WING BOXES WITHIN 10 SERIAL NUMBER RANGE BE CLOSELY INSPECTED FOR SAME. NOTE: MFG DATES FOR THE IDENTIFIED WING BOXES ARE MAY 199 5 IN ALL CASES. (K) 1 H 7 2 3T RT A9EA 2005072500027 20050725 00027 CE 2005 7 25 2005FA0001008 1 20050722 G 3233 12802412 PISTON ROD CESSNA CESSNA 182 R182 2072734 CE NLG ACTUATOR WORN B D RETURN TO BLOCK K FLUID LOSS TX TAXI/GRND HDL 1 WP 07 2253T 3958 R18200008 NOSE GEAR ACTUATOR FOUND LEAKING DURING PREFLIGHT. MAINTENANCE DISASSEMBLED AND FOUND A GROOVE AROUND THE PISTON ROD (P /N 1280241-2) WHERE THE 'O'RING AND BACKUP RINGS RIDE. REPLACED PISTON ROD ASSEMBLY, INSTALLED NEW SEALS. RE-RIGGED GE AR AND RELEASED A/C. 1 H 7 1 3O RT 3A13 2005072500057 20050725 00057 CE 2005 7 25 2005FA0001009 1 20050701 G 2750 BELLCRANK CESSNA 206 206H 2073301 CE LYC O540 IO540* 41532 EA TE FLAPS BINDING B YEBR O OTHER O OTHER NR NOT REPORTED 1 CE 05 239LF 5 20608239 L30392 BINDING IN FLAP DR SYS AT BELLCRANKS WHERE ROD ENDS ATTACH. FLAP DR RODENDS WERE FOUND DIGGING INTO BELLCRANK ARMS AS T HEY OPERATED, NML TRAVEL AS SHOWN BY RUB MARKS ON RODENDS. BELLCRANK ARMS, EXCESS CLAMPED BY RODEND ATTACH BOLTS, SOME BOLTS NOT TIGHTENED SECURELY LEAVING ROD END TO MOVE UP AND DOWN ON BOLT SHANK. WASHERS WERE INSTALLED BETWEEN RODEND B RG, BELLCRANK TO RELIEVE CLAMPING STRAIN ON ARMS, PROVIDE CLEARANCE FOR RODENDS TO OPERATE W/O BINDING ON ARMS. INTERCO NNECT RODENDS WERE FOUND BINDING AT END OF TRAVEL IN DWN POSITION. BELLCRANK ANGLE DURING RIGGING, ADJUSTING RIGGING TO CLOCK BELLCRANK TRAVEL INTO USEABLE ARC THAT PREVENTS BINDING AT ENDS OF ITS RANGE WILL HELP PREVENT FURTHER DAMAGE. (K) 1 H 7 1 3O 3 O RT A4CE 1E4 2005072500061 20050725 00061 SO 2005 7 25 2005FA0001010 2 20050610 G 7414 M3081 POINTS SLICK PIPER PA46 PA46310P 7104605 SO CONT O520 TSIO520BE 17040 SO MAGNETO BROKEN B GB7R O OTHER O OTHER NR NOT REPORTED 1 EA 13 818JP 300 01120433 468408047 528395 CONTACT SPRING BROKEN IN 300.7 HRS OF OPERATION. (K) 1 L 7 1 3O 3 O RT A25SO E8CE 2005072500054 20050725 00054 SO 2005 7 25 2005FA0001011 2 20050610 G 7414 M3081 POINTS SLICK PIPER PA46 PA46310P 7104605 SO CONT O520 TSIO520BE 17040 SO MAGNETO BROKEN B GB7R O OTHER O OTHER NR NOT REPORTED 1 EA 13 818JP 311 01120434 468408047 528395 CONTACT SPRING BROKNE IN 311.1 HOURS OF OPERATION. (K) 1 L 7 1 3O 3 O RT A25SO E8CE 2005072500062 20050725 00062 SO 2005 7 25 2005FA0001012 2 20050617 G 8530 CYLINDER HEAD CESSNA 210 210D 2073414 CE CONT O520 IO520A 17032 SO ENGINE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 NM 01 210AW 71 21058492 1105724A ENGINE WITH 450.0 TIS AND CYLINDER NR 2 WITH THE SAME TIS, BUT 31.0 HOURS SINCE REMOVAL/REPAIR/REINSTALLATION. DURING C RUISE FLIGHT, ENG BECAME VERY ROUGH WITH LOSS OF POWER. NORMAL LANDING WAS MADE. UPON INSP OF ENG, FOUND NR 2 CYL (COL D). PERFORMED COMPRESSION CHECK, NR 2 CYL HAD NO COMPRESSION. BOROSCOPED CYL AND FOUND CRACK PRESENT IN THE ALUMINUM C YL HEAD APPROX CENTERED ON EXHAUST VALVE SEAT AND EXTENDING IN CIRCULAR PATTERN, 2 PLUS INCHES IN EITHER DIRECTION. AFT END SEEMED TO RELIEVE ITSELF ON EDGE OF LWR SPARK PLUG BOSS (LWR SPARK PLUG HAD NO TORQUE WHAT SO EVER). THERE WAS A H OLE (.25 INCH WIDE X .375 INCH LONG) ON FWD END OF CRACK WITH EXHAUST GASES/DEPOSITS PRESENT ON CYL COOLING FINS. (K) 1 H 7 1 3O 3 O 3A21 E5CE 2005072500063 20050725 00063 EU 2005 7 25 2005FA0001013 1 20050701 G 5751 10425002 PLATE AVIAT S1S PITTSS1S 72206BW EU AILERON BROKEN B LQJR O OTHER O OTHER NR NOT REPORTED 1 NM 04 CGZRO 800 1024 AT APPROX 200 MPH, LT AILERON SPADE PLATE FRONT ATTACH POINT BROKE, ALLOWING SPADE PLATE TO PIVOT DOWNWARD TO A FULL VER TICAL POSITION WHERE IT STAYED UNTIL LANDING. PHOTO EVIDENCE ATTACHED SHOWS SIGNS OF PREVIOUS CRACKING AS SHOWN BY RUST . QUESTIONS ARISE AT AN ADEQUATE PREFLIGHT CHECK BEFORE FAILURE. INDICATIONS OF AEROBATIC MANEUVERS (SNAP ROLLS) IN EX CESS OF RECOMMENDED LIMITS. A DAILY AND ANNUAL INSPECTION OF THE SPADE ASSEMBLIES WILL BE ADDED TO THE MM. (K) 1 Q 7 1 3O NC A8SO 2005072500070 20050725 00070 2005 7 25 2005FA0001015 4 20050517 G 3100 31004562801 LOGIC CARD PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360* 17025 SO IDU TRAY MALFUNCTIONED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 7333L 347670099 SCC CARD INSTALLED AS PART OF THE EFIS-SV SYSTEM IAW STC NR SA02203AK WOULD NOT ALLOW THE MOVING MAP PAGE TO APPEAR ON T HE IDU DURING START UP. (ALO5200502600) (K) 1 L 7 2 3O 3 O A7SO E9CE 2005072500064 20050725 00064 2005 7 25 2005FA0001016 4 20050611 G 3160 4300270502 DISPLAY CESSNA 210 210C 2073412 CE CONT O470 IO470* 17026 SO COCKPIT MALFUNCTIONED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 3715Y 21058215 DURING GROUND FUNCTIONAL CHECKS FOLLOWING INITIAL INSTALLATION FOUND THE MX20 MULTIFUNCTION DISPLAY WOULD NOT ACCEPT DAT A FROM THE GNS480. ADDITIONALLY, THE MX20 HAD NO MAP DISPLAY UPON GPS ACQUISITION. (AL05200502601) (K) 1 H 7 1 3O 3 O 3A21 E1CE 2005072500071 20050725 00071 2005 7 25 2005FA0001017 4 20050507 G 3160 4306081100000 TRANSCEIVER CASA C212 C212200 2410304 EU GARRTT TPE331 TPE331* 01514 WP COCKPIT MALFUNCTIONED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 287MA 287 DURING INITIAL INSTALLATION FOUND THE LOCKING HOLE ON THE RADIO WAS DAMAGED, NOT ALLOWING THE UNIT TO SEAT IN THE TRAY P ROPERLY. UNIT WAS REPLACED. (AL200502602) (K) 2 H 7 2 4T 3 T RT A43EU E2WE 2005072500065 20050725 00065 2005 7 25 2005FA0001018 4 20050405 G 3100 4306081100000 TRANSCEIVER CESSNA 207 207A 2073604 CE CONT O520 IO520* 17032 SO COCKPIT MALFUNCTIONED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 7394U 20700437 DURING INITIAL PROGRAMMING FOLLOWING INITIAL INSTALLATION, FOUND THE APM WOULD NOT PROGRAM. (K) 1 H 7 1 3O 3 O A16CE E5CE 2005072500069 20050725 00069 2005 7 25 2005FA0001019 4 20050407 G 3160 4306081100000 TRANSCEIVER CESSNA 207 207A 2073604 CE CONT O520 IO520* 17032 SO COCKPIT MALFUNCTIONED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 5277J 20700772 DURING GROUND FUNCTIONAL CHECKS FOLLOWING INITIAL INSTALLATION, MX20 DISPLAYS THE ERROR MESSAGE (GDL90 REQUIRES MAINTENA NCE). UPON INSTALLATION OF ANOTHER UNIT, ERROR MESSAGE CLEARED, SYSTEM OPERATION SATISFACTORY. (AL05200502604) (K) 1 H 7 1 3O 3 O A16CE E5CE 2005072500074 20050725 00074 2005 7 25 2005FA0001020 4 20050404 G 3160 5900051 ANTENNA CESSNA 207 207 2073602 CE CONT O520 IO520* 17032 SO UAT UNSERVICEABLE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 1673U 20700273 DURING UPGRADE OF UAT, FOUND LOWER UAT ANTENNA UNSERVICEABLE. (ALO5200502605) (K) 1 H 7 1 3O 3 O A16CE E5CE 2005072600085 20050726 00085 2005 7 26 2005FA0001021 4 20050423 G 3160 5900051 ANTENNA CESSNA 172 172M 2072418 CE LYC O320 O320* 41508 EA FUSELAGE UNSERVICEABLE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 1453V 17263590 DURING UPGRADE OF UAT, FOUND UPPER UAT ANTENNA UNSERVICEABLE. (ALO5200502606) (K) 1 H 7 1 3O 3 O NT 3A12 E274 2005072600095 20050726 00095 2005 7 26 2005FA0001022 4 20050421 G 3160 5900051 ANTENNA CESSNA 207 207 2073602 CE CONT O520 IO520* 17032 SO FUSELAGE UNSERVICEABLE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 91099 20700073 DURING UPGRADE OF UAT, FOUND LOWER UAT ANTENNA UNSERVICEABLE. (AL05200502607) (K) 1 H 7 1 3O 3 O A16CE E5CE 2005072600096 20050726 00096 2005 7 26 2005FA0001023 4 20050421 G 3160 5900051 ANTENNA CESSNA 207 207 2073602 CE CONT O520 IO520* 17032 SO FUSELAGE UNSERVICEABLE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 91002 20700003 DURING UPGRADE OF UAT, FOUND UPPER UAT ANTENNA UNSERVICEABLE. (AL05200502608) (K) 1 H 7 1 3O 3 O A16CE E5CE 2005072600099 20050726 00099 2005 7 26 2005FA0001024 4 20050429 G 3160 5900051 ANTENNA CESSNA 207 207A 2073604 CE CONT O520 IO520* 17032 SO FUSELAGE UNSERVICEABLE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 73067 20700558 FOUND UAT ANTENNA BAD DURING UAT UPGRADE. (ALO5200502609) (K) 1 H 7 1 3O 3 O A16CE E5CE 2005072500076 20050725 00076 2005 7 25 2005FA0001025 4 20050426 G 3160 5900051 ANTENNA CESSNA 207 207A 2073604 CE CONT O520 IO520* 17032 SO UAT UNSERVICEABLE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 9869M 20700744 FOUND LOWER UAT ANTENNA BAD DURING UAT UPGRADE. (K) 1 H 7 1 3O 3 O A16CE E5CE 2005072600070 20050726 00070 2005 7 26 2005FA0001026 4 20050423 G 3160 5900051 ANTENNA CESSNA 207 207A 2073604 CE CONT O520 IO520* 17032 SO FUSELAGE INOPERATIVE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 7384U 20700431 FOUND LOWER UAT ANTENNA BAD DURING UAT UPGRADE. (AL05200502611) (K) 1 H 7 1 3O 3 O A16CE E5CE 2005072600086 20050726 00086 2005 7 26 2005FA0001028 4 20050424 G 3160 5900051 ANTENNA CESSNA 207 207A 2073604 CE CONT O520 IO520F 17032 SO FUSELAGE UNSERVICEABLE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 9399M 20700652 FOUND LOWER UAT ANTENNA BAD DURING UAT UPGRADE. (AL05200502613) (K) 1 H 7 1 3O 3 O A16CE E5CE 2005072600087 20050726 00087 2005 7 26 2005FA0001029 4 20050329 G 3160 5900051 ANTENNA CESSNA 207 207A 2073604 CE CONT O520 IO520* 17032 SO FUSELAGE UNSERVICEABLE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 7320U 20700397 FOUND LOWER UAT ANTENNA BAD DURING UAT UPGRADE. (AL05200502614) (K) 1 H 7 1 3O 3 O A16CE E5CE 2005072600082 20050726 00082 2005 7 26 2005FA0001032 4 20050419 G 3160 5900051 ANTENNA CESSNA 207 207A 2073604 CE CONT O520 IO520F 17032 SO FUSELAGE INOPERATIVE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 9728M 20700721 DURING UPGRADE OF UAT FOUND BOTH UAT ANTENNAS UNSERVIEABLE. (AL05200502617) (K) 1 H 7 1 3O 3 O A16CE E5CE 2005072600101 20050726 00101 2005 7 26 2005FA0001033 4 20050412 G 3160 5900051 ANTENNA CESSNA 207 207A 2073604 CE CONT O520 IO520F 17032 SO FUSELAGE INOPERATIVE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 9728M 20700721 DURING UPGRADE OF UAT FOUND BOTH UAT ANTENNAS UNSERVICEABLE. (AL05200502618) (K) 1 H 7 1 3O 3 O A16CE E5CE 2005072600017 20050726 00017 SO 2005 7 26 2005FA0001034 1 20050611 G 3260 920070 PROXIMITY SWITCH GULSTM G1159 G1159 3953505 SO RROYCE SPEY SPEY5118 54523 EU MLG LOOSE B ZLWR A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 SW 05 900DH 111 AC DEPARTED FOR 3 DAY TRIP. AC MADE A STOP TO PICK UP 1 PASSENGER, THEN TOOK OFF AND HEADED TO PICK UP ANOTHER PASSENGE R. ON EXTENDING THE GEAR, LT GEAR DOWN AND LOCKED LIGHT FAILED TO LITE. CREW TRIED 6 TIMES BY RETRACTING AND EXTENDING GEAR TO NO AVIAL. CREW THEN BLEW GEAR DOWN WITH EMERGENCY EXTENSION SYS., STILL NO LIGHT. PERFORMED A LOW AND SLOW PA ST TOWER TO CONFIRM GEAR WAS DOWN, PROCEEDED TO LAND WITHOUT INCIDENT. PIC CALLED AND SAID THAT THERE WAS A CONNECTOR P LUG LOOSE IN THE LT WHEEL WELL. THE PLUG WAS REATTACHED, GEAR PINNED IN THE DOWN AND LOCKED POSITION, DEPLOY HANDLE AND D-RING STOWED. AC WAS FLOWN BACK ON FERRY PERMIT WITH THE GEAR DOWN AND LOCKED. GEAR WAS SWUNG IAW MM. (K) 2 L 7 2 4F 4 F RT A12EA E2EU 2005072600025 20050726 00025 CE 2005 7 26 2005FA0001035 1 20050602 G 5340 6805101A MOUNT BRACKET CESSNA 206 U206F 2073333 CE CONT O520 IO520* 17032 SO ENGINE CRACKED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 8419Q 280 U20603279 DURING A 100 HOUR INSPECTION, FOUND THE MOUNT FOR THE FUEL FLOW TRANSDUCER CRACKED AT THE BEND RADIUS OF ALL 4 MOUNTING FLANGES. (K) 1 H 7 1 3O 3 O A4CE E5CE 2005072600023 20050726 00023 CE 2005 7 26 2005FA0001036 1 20050331 G 5340 BRACKET RAYTHN DH125 HAWKER800XP 7150012 CE GARRTT TFE731 TFE731* 01518 WP WING TO FUSELAGE WORN C O OTHER O OTHER NR NOT REPORTED 1 GL 13 6NR 258701 WHILE FLYING THROUGH TURBULENCE SITTING IN THE VIP CHAIR (CABIN RT FWD FACING) A SLIGHT VIBRATION CAN BE FELT COMING THR OUGH THE FLOOR AND WILL DIMINISH AFTER LEAVING TURBULENCE. AFTER TALKING WITH MFG TECH SUPPORT, THIS PROBLEM IS COME TO BE KNOWN AS (WING CLUNK). IT IS CAUSED BY THE PLAY IN THE BRACKET VERTICAL LINK SPHERICAL BEARING AND ATTACH BOLT, IE ONE OR ALL. THERE IS NO SB, IL, COMMUNIQUÉ OUT ON THIS PROBLEM BUT MFG IS AWARE AND HAS A REPAIR KIT OUT THAT ONLY CAN BE DONE AT MFG SERVICE CENTER. (GL13200508700) (K) 2 L 7 2 4F 4 F RT A3EU E6WE 2005072600044 20050726 00044 EU 2005 7 26 2005FA0001037 1 20050323 G 7720 704A37642043 TRANSMITTER SNIAS 350 AS350BA 8680817 EU LYC LTS101 LTS101* NE ENGINE FAILED D C33R O OTHER O OTHER NR NOT REPORTED 1 SO 09 209CH 32 2494 TRANS-PRESS FAILED AFTER A FEW HOURS OF OPERATION. (K) 1 G 7 1 3U 3 U NC H9EU E5NE 2005072600045 20050726 00045 EU 2005 7 26 2005FA0001038 1 20050725 G 5210 SLIDE KAWSKI BOLKMS 117 BK117B2 5626013 EU CABIN DOOR WORN E A UNSCHED LANDING D INFLIGHT SEPARATION LD LANDING 1 SW 09 440HH 7923 313 7238 ON FINAL APPROACH TO LANDING, AT 55 KTS AIRSPEED, THE PILOT GAVE PERMISSION FOR THE MEDICAL CREW TO OPEN DOORS. THE PAR AMEDIC (IN THE RT SEAT) OPENED HIS DOOR. THE NURSE (IN THE LT SEAT) OPERATED THE DOOR LATCH AND BEGAN TO SLIDE THE DOOR OPEN. THE DOOR DEPARTED THE HELICOPTER AND FLEW THROUGH THE MAIN ROTOR SYSTEM AND WAS DESTROYED.INVESTIGATION REVEALED WORN FORWARD SLIDER, P/N T6408-103, WORN UPPER DOOR RAIL, P/N 117-24271-01, AND WORN LOWER RAIL, P/N 117-24283-03, COMB INED TO LET LOWER DOOR GUIDES POP OFF THE RAIL. THE WIND THEN CAUGHT THE DOOR ABD BLEW IT OFF OF THE TOP RAIL, DEFORMIN G THE RAIL SUBSTANTIALLY. 1 G 7 2 3U NC H13EU 2005072600158 20050726 00158 NM 2005 7 26 2005FA0001040 1 20050623 G 2782 111015 PISTON SMITHSIND BOEING 727 727* NM ACTUATOR BROKEN B IU6R O OTHER O OTHER NR NOT REPORTED 1 NM 01 4251ADE PISTON BROKE AT THE KEY GROVE, FATIGUE. (196962/FXS) (K) 2 L 7 3 4F RT A3WE 2005072600161 20050726 00161 EA 2005 7 26 2005FA0001041 2 20050701 G 8530 3813 STUD AMTR SKYBLT SKYBOLT GL LYC O540 IO540C4B5 41532 EA NR 3 CYLINDER BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SW 09 25KC 2 L90040 AC WAS ENROUTE WHEN PILOT HEAR (PUFF) NOISE AND SAW OIL BEGINNING TO COME FROM ENGINE COMPARTMENT. HE THROTTLED BACK AN D DID A PRECAUTIONARY LANDING AT THE NEAREST AIRPORT. THROTTLED BACK AND DID A PRECAUTIONARY LANDING. UPON INSPECTION IT WAS FOUND THAT 4 OF 8, NR 3 CYL BASE NUT STUDS (2 EA PN 3813, 2 EA PN 5015) HAD BROKEN OFF ABOUT EVEN WITH HEIGHT OF CYLINDER BASE FLANGE. APPROX 90 PERCENT OF REMAINING CYL BASE NUTS ON ENTIRE ENG WERE FINGER LOOSE. CASE AND CYLINDER WERE NDT AND NO CRACKS WERE FOUND. NEW STUDS AND NUTS WERE INSTALLED AT FAILED LOCATION, ALL CYL BASE NUTS WERE TORQUED IAW MM. SUSPECT CYL BASE NUTS WERE NOT PROPERLY TORQUED OR PROPER TORQUING SEQUENCE WAS NOT UTILIZED AT OVERHAUL. (K) 1 Q 7 1 3O 3 O EXPA1Q71 1E4 2005072600167 20050726 00167 SO 2005 7 26 2005FA0001042 1 20050708 G 7110 631996 RETAINER PIPER PA34 PA34220T 7103420 SO CONT O360 LTSIO360KB 17025 SO COWLING CRACKED B FMOR O OTHER O OTHER NR NOT REPORTED 1 SO 15 6085A 230 3448021 319073 PILOT REPORTED, AFTER LANDING, HE DISCOVERED OIL ALL OVER THE RT COWLING AND UNDER THE WING BEHIND THE RT ENGINE. COWLI NG WAS REMOVED AND A HOLE WAS FOUND IN THE NR 5 CYL INTAKE VALVE COVER. VALVE COVER WAS REMOVED AND FOUND THAT ROCKER R ETAINER HAD BROKEN IN HALF. HALF OF RETAINER WAS STILL CAPTURED BY NUT AND REMAINED IN PLACE. OTHER HALF HAD FALLEN AW AY AND BECAME WEDGED BETWEEN ROCKER ARM AND VALVE COVER CAUSING THE HOLE IN THE COVER. CLY NR 1 INTAKE VALVE RETAINER W AS FOUND TO BE CRACKED. REMAINTING ARMS AND RETAINERS WERE INSPECTED ON BOTH ENGINES. TWO BROKEN RETAINERS, NEW ROCKER ARM AND PIN FOR CYL NR 5 WERE REPLACED. AC THEN RETURNED TO SERVICE. PROBABLE CAUSE, OVER TORQUED AT O/H. (K) 1 L 7 2 3O 3 O A7SO E9CE 2005072600212 20050726 00212 CE 2005 7 26 2005FA0001043 1 20050718 G 3233 EA1614 ACTUATOR CESSNA 210 210C 2073412 CE CONT O470 IO470* 17026 SO RT MLG BROKEN D O OTHER O OTHER NR NOT REPORTED 1 CE 09 3695Y 4276 21058195 GEAR ACTUATOR WAS FOUND TO BE SPLIT DOWN THE SIDE AND THE TOP HAD BROKEN INTO TWO PIECES. THE PILOT REPORTED HEARING A LOUD POP DURING THE GEAR CYCLE. THE EMERGENCY HAND PUMP WAS USELESS DUE TO THIS PROBLEM. THE AIRCRAFT MADE A SAFE LAND ING AFTER A GROUND CREW PULLED THE GEAR DOWN WHILE THE PILOT FLEW DOWN THE RUNWAY. (K) 1 H 7 1 3O 3 O 3A21 E1CE 2005072600219 20050726 00219 SW 2005 7 26 2005FA0001044 1 20050714 G 2800 512509 GASCOLATOR MOONEY M20 M20R 5870225 SW CONT O550 IO550G 17042 SO FUEL SYSTEM LEAKING D O OTHER O OTHER NR NOT REPORTED 1 SW 17 10368 265 290286 684961 DURING TROUBLESHOOTING, IT WAS DISCOVERED THAT THE GASCOLATOR WAS ALLOWING AIR TO BE INTRODUED INTO THE SHIPS FUEL SYSTE M PRIOR TO THE FUEL REACHING THE ENGINE DRIVEN FUEL PUMP. INSTALLING A NEW GASCOLATOR RESOLVED THE PROBLEM. (K) 1 L 7 1 3O 3 O RT 2A3 E3SO 2005072600224 20050726 00224 SO 2005 7 26 2005FA0001045 1 20050708 G 7810 654326E COLLECTOR RING PIPER PA46 PA46310P 7104605 SO CONT O520 TSIO520BE 17040 SO ENGINE DEFECTIVE B ZKGR O OTHER O OTHER NR NOT REPORTED 1 NE 05 802SL 468508087 273841R THIS IS THE COLLECTOR THAT MOUNTS TO THE TOP OF THE LT TURBO. FOUND HOLES ON BOTH SIDES OF WELDS ON THE AFT END NEAR TH E SMALL BALANCE TUBE. (K) 1 L 7 1 3O 3 O RT A25SO E8CE 2005072600241 20050726 00241 SO 2005 7 26 2005FA0001046 2 20050705 G 7414 4301 MAGNETO CESSNA 140 140A 2071604 CE CONT C90 C9014F 17009 SO ENGINE DEFECTIVE C O OTHER O OTHER NR NOT REPORTED 1 NM 01 5380C 475 15513 BOTH MAGS REMOVED FOR SB, 500 HOUR INSPECTION. MFG DEFECT NOTED. ROTATING MAGNET AND BEARING ASSY NOT PRESSED (FAR ENO UGH) INTO FRONT MAG HOUSING . MAGS PURCHASED NEW 1/9/98. UNEVEN WAR NOTED THROUGHOUT WITH FINE BRONZE POWDER COATING I NTERNAL PARTS. OD (GREEN) IN COLOR. MORE CAREFUL ASSEMBLY OF MAG COMPONENTS AT FACTORY. (NOTE) MAG SN 14 UNITS APART. (K) 1 H 7 1 3O 3 O 5A2 E252 2005072600242 20050726 00242 GL 2005 7 26 2005FA0001047 1 20050707 G 3243 SHUTTLE VALVE AMTR KITFOX KITFOX 05613LZ GL ROTAX ROTAX* EU MASTER CYLINDER LOCKED G O OTHER O OTHER NR NOT REPORTED 1 NM 07 316R 1561 FULL STOP LANDING, BRAKES LOCKED UP AND AIRCRAFT NOSED OVER, DAMAGING THE PROPELLER AND LOWER ENGINE COWLING. MFG HAS I SSUED SL NR 23 RE: SIMILAR OR SAME PROBLEM. SOLUTION: RESTRICT BRAKE USE TO PILOT OR CO-PILOT ONLY OR REMOVE THE CO-PIL OT PORTION OF THE SYSTEM URL. (NM07200506922) (K) 1 H 7 1 3I 3 I NC EXPA1H71 EXPE3I 2005072600284 20050726 00284 2005 7 26 2005FA0001048 1 20050715 G 3340 NLI707924 SOCKET BEACON MISMANUFACTURED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 2173 DEFECT IS CAUSED BY IMPROPER CLOCKING OF BASE ON BULB GLASS DURING MANFACTURE. IMPROPERLY MOUNTED BASE CAUSES INABILITY TO ACQUIRE THE CORRET FLASH RATE IN SIDE VIEW OF LAMP ASSY. (K) 2005072700053 20050727 00053 CE 2005 7 27 2005FA0001049 1 20050720 G 3220 NAS464P542 BOLT CESSNA 210 T210H 2073438 CE NLG BROKEN G O OTHER O OTHER TX TAXI/GRND HDL 1 SW 01 2234R T2100384 AIRCRAFT EXPERIENCED A NOSE GEAR FAILURE/COLLAPSE DURING TAXI IMMEDIATELY FOLLOWING LANDING. EXAMINATION OF THE AIRCRAFT AT THE SCENE REVEALED THAT THE NOSE GEAR ACTUATOR ASSEMBLY AFT ATTACHMENT BOLT HAD FAILED. THE HEAD OF THE BOLT HAD BROKEN OFF AND THE BOLT HAD SUBSEQUENTLY WORKED IT'S WAY OUT OF THE ATTACH FITTING ALLOWING THE ACTUATOR TO COME LOO SE DURING TAXI AFTER LANDING. PHYSICAL INSPECTION OF THE BOLT FOUND EVIDENCE THAT THE HEAD OF THE BOLT HAD MOST LIKELY BEEN SEPARATED FOR SOME TIME PRIOR TO THE INCIDENT. 1 H 7 1 3O 3A21 2005072700090 20050727 00090 CE 2005 7 27 2005FA0001050 1 20050707 G 3233 98820152 ACTUATOR CESSNA 172 172RG 2072438 CE LYC O360 O360F1A6 41514 EA MCAULY 2D34C B2D34C220 GL MLG CRACKED D O OTHER O OTHER NR NOT REPORTED 1 WP 21 6384V 8800 172RG0647 L2896336A 010011 MLG ACTUATOR CRACKED. (K) 1 H 7 1 3O 3 O 3A17 E286 5 C P7EA 2005072700122 20050727 00122 GL 2005 7 27 2005FA0001051 1 20050719 G 7120 RV6ADINA1KIT MOUNT AMTR VANS VANSRV6A 05610ZG GL LYC O320 O320D1A 41508 EA SNSNCH 70C 70CM7 EA ENGINE CHAFED D O OTHER O OTHER NR NOT REPORTED 1 GL 13 6YE 3315 L1902039A 314881L LOWER RT DIAGONAL ENGINE MOUNT TUBE FOUND CHAFED DO TO EXHAUST PIPE COMING INTO CONTACT WITH THE TUBE, THIS HAPPENED DO TO THE CLOSE PROXIMITY OF THE EXHAUST SYSTEM TO THE MOUNT. CORRECTED BY REPOSITIONING EXHAUST SUPPORT CLAMPS. WHILE RE PAIRING THE CHAFED TUBE IT WAS NOTED THAT A SMALL CRACK WAS DEVELOPING IN A TUBE OFF THE END OF A GUSSET ADJACENT TO THE RT LOWER SHOCK MOUNT ATTACH POINT, THIS ALSO NEEDED REPAIR BY A WELDED SLEEVE ON THE TUBE, CAUSE UNKNOWN. (GL132005089 90) (K) 1 L 7 1 3O 3 O RT EXPA1L71 E274 5 N P28NE 2005072700154 20050727 00154 WP 2005 7 27 2005FA0001052 1 20050710 G 6320 369D21500505 TRANSMISSION HUGHES 369 369D 4470706 WP MAIN ROTOR UNSERVICEABLE B EOOR O OTHER O OTHER NR NOT REPORTED 1 AL 03 CGBUY 10061 774 6110958D DURING ROTATION OF THE M/R HUB WHILE PERFORMING ROUTINE MAINTENANCE A NOTICEABLE (SQUEAK) WAS HEARD COMING FROM THE M/R TRANSMISSION. SUBSEQUENT INVESTIGATION ALLOWED FOR THE DISCOVERY OF THE INPUT PINION HAVING SIDE SLOPE AND THE SQUEAK W AS HEARD WITH A LISTENING DEVICE INSIDE THE TRANS AND LEAD TO THE DISCOVERY OF THE LOWER CHIP PLUG HAVING A LOT OF METAL YET NONE HAD MADE CONTACT. REMOVED TRANS, PULLED INPUT PINION AND IT AND THE BEVEL GEAR SPALLED. 1 G 7 1 3U H3WE 2005072700156 20050727 00156 SO 2005 7 27 2005FA0001053 1 20050715 G 5343 9564309 ATTACH BRACKET PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA HARTZL HCC3Y HCC3YR2 NE MLG CRACKED B OF1R O OTHER O OTHER NR NOT REPORTED 1 EA 17 3046U 11486 447995261 DURING INSP BOTH LT AND RT MAIN GEAR DRAG LINK ATTACH BRACKETS WERE REMOVED FOR BRG REPLACEMENT DUE TO EXCESSIVE FREEPLA Y AT DRAGLINK IB ATTACH END. UPON FURTHER CLEANING, PAINT RMVL AND INSP OF EACH, BOTH CASTINGS WERE FOUND CRACKED AROUN D MACHINED FLAT SPOT AREA IN RADIUS OF ONE WEB OF CASTING FOR THE UPPER ATTACH BOLT HOLE. ORDERED, INSPECTED AND REJECT ED 4 PAIR OF SERVICEABLE REPLACEMENT PARTS FROM MULTIPLE VENDORS AFTER CLEANING AND INSP OF EACH DUE TO SIMILAR CRACKS I N SAME AREA. PROBABLE CAUSE: FROM CYCLES AND LOADING OF COMPONENT AND INACCESSABLILITY FOR ADEQUATE INSP WHILE INSTALLE D. SUSPECT ALL THESE CASTINGS SHOULD BE REQUIRED TO BE REMOVED, CLEANED, INSPECTED AT SOME REQUIRED INTERVAL. (K) 1 L 7 2 3O 3 O A19S0 E286 5 C P25EA 2005072700187 20050727 00187 2005 7 27 2005FA0001054 4 20050414 G 3160 5900051 ANTENNA CESSNA 207 T207 2073612 CE CONT O520 GTSIO520C 17032 SO UAT INOPERATIVE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 90193 20700007 FOUND UPPER UAT ANTENNA UNSERVICEABLE. (K) 1 H 7 1 3O 3 O A16CE E7CE 2005072700186 20050727 00186 2005 7 27 2005FA0001055 4 20050423 G 3160 5900051 ANTENNA CESSNA 207 207A 2073604 CE CONT O520 IO520* 17032 SO UAT INOPERATIVE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 6207H 20700551 FOUND LOWER UAT ANTENNA UNSERVICEABLE DURING UAT UPGRADE. (K) 1 H 7 1 3O 3 O A16CE E5CE 2005072700185 20050727 00185 2005 7 27 2005FA0001056 4 20050429 G 3160 5900051 ANTENNA CESSNA 208 208B 2073701 CE PWA PT6 PT6A60A 52043 NE UAT INOPERATIVE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 1232Y 208B0566 FOUND LOWER UAT ANTENNA UNSERVICEABLE DURING UAT UPGRADE. (K) 1 H 7 1 3T 4 T A37CE E4EA 2005072700189 20050727 00189 2005 7 27 2005FA0001057 4 20050429 G 3160 5900051 ANTENNA CESSNA 207 207 2073602 CE CONT O520 IO520* 17032 SO UAT INOPERATIVE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 23CF 20700276 FOUND LOWER UAT ANTENNA UNSERVICEABLE DURING UAT UPGRADE. (K) 1 H 7 1 3O 3 O A16CE E5CE 2005072800015 20050728 00015 2005 7 28 2005FA0001058 4 20050429 G 3160 5900051 ANTENNA CESSNA 207 207 2073602 CE CONT O520 IO520* 17032 SO FUSELAGE INOPERATIVE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 23CF 20700276 FOUND UPPER UAT ANTENNA UNSERVICEABLE DURING UAT UPGRADE. (K) 1 H 7 1 3O 3 O A16CE E5CE 2005072800001 20050728 00001 2005 7 28 2005FA0001059 4 20050429 G 3160 5900051 ANTENNA DHAV DHC6 DHC6300 2802606 EA PWA PT6 PT6A45 52043 EA FUSELAGE INOPERATIVE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 302EH 576 FOUND UPPER UAT ANTENNA UNSERVICEABLE DURING UAT UPGRADE. (K) 1 H 7 2 3T 4 T RT A9EA E4EA 2005072800004 20050728 00004 2005 7 28 2005FA0001060 4 20050427 G 3160 5900051 ANTENNA PIPER PA31 PA31350 7103110 SO LYC O540 TIO540* 41532 EA FUSELAGE INOPERATIVE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 3516A 317952106 FOUND UPPER UAT ANTENNA UNSERVICEABLE DURING UAT UPGRADE. (K) 1 L 7 2 3O 3 O A20SO E14EA 2005072800005 20050728 00005 2005 7 28 2005FA0001061 4 20050428 G 3160 5900051 ANTENNA PIPER PA32 PA32301 7103207 SO LYC O540 IO540* 41532 EA FUSELAGE INOPERATIVE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 8374T 328106058 FOUND LOWER UAT ANTENNA UNSERVICEABLE DURING UAT UPGRADE. (K) 1 L 7 1 3O 3 O A3SO 1E4 2005072800006 20050728 00006 2005 7 28 2005FA0001062 4 20050427 G 3160 5900051 ANTENNA CESSNA 207 207A 2073604 CE CONT O520 IO520* 17032 SO FUSELAGE INOPERATIVE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 9736M 20700722 FOUND UPPER UAT ANTENNA UNSERVICEABLE DURING UAT UPGRADE. (K) 1 H 7 1 3O 3 O A16CE E5CE 2005072800016 20050728 00016 2005 7 28 2005FA0001063 4 20050421 G 3160 5900051 ANTENNA CESSNA 207 207A 2073604 CE CONT O520 IO520* 17032 SO FUSELAGE INOPERATIVE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 7605U 20700443 FOUND UPPER UAT ANTENNA UNSERVICEABLE DURIN UAT UPGRADE. (K) 1 H 7 1 3O 3 O A16CE E5CE 2005072800002 20050728 00002 2005 7 28 2005FA0001064 4 20050505 G 3160 5900051 ANTENNA CESSNA 172 172M 2072418 CE LYC O320 O320* 41508 EA FUSELAGE INOPERATIVE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 20109 17261017 FOUND UPPER UAT ANTENNA UNSERVICEABLE DURING UAT UPGRADE. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2005072800007 20050728 00007 2005 7 28 2005FA0001065 4 20050414 G 3160 5900051 ANTENNA CESSNA 207 T207 2073612 CE CONT O520 GTSIO520* 17032 SO FUSELAGE INOPERATIVE B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 90193 20700007 FOUND UPPER UAT ANTENNA UNSERVICEABLE. (K) 1 H 7 1 3O 3 O A16CE E7CE 2005072800024 20050728 00024 2005 7 28 2005FA0001066 1 20050728 G 2140 94E42 PRESSURE SWITCH HEATER FAILED B O OTHER L NO TEST NR NOT REPORTED 1 SW 99 DURING COMBUSTION HEATER PRESSURE DECAY TEST IAW AD2004-21-05, WE STILL TEST THE COMBUSTION AIR PRESSURE SWITCH WITH P/N 94E42, AND FOUND THAT MOST OF THE TIMES THE SWITCH FAILED OR NEEDED ADJUSTMENT 2005072800028 20050728 00028 2005 7 28 2005FA0001067 1 20050728 G 2140 94E42 PRESSURE SWITCH HEATER FAILED B O OTHER L NO TEST NR NOT REPORTED 1 SW 99 DURING COMBUSTION HEATER PRESSURE DECAY TEST IAW AD2004-21-05, WE STILL TEST THE COMBUSTION AIR PRESSURE SWITCH WITH P/N 94E42, AND FOUND THAT MOST OF THE TIMES THE SWITCH FAILED OR NEEDED ADJUSTMENT. 2005072800029 20050728 00029 2005 7 28 2005FA0001068 1 20050728 G 2140 94E42 PRESSURE SWITCH HEATER FAILED B O OTHER L NO TEST NR NOT REPORTED 1 SW 99 DURING COMBUSTION HEATER PRESSURE DECAY TEST I.A.W. AD2004-21-05, WE STILL TEST THE COMBUSTION AIR PRESSURE SWITCH WITH P/N 94E42, AND FOUND THAT MOST OF THE TIMES THE SWITCH FAILED OR NEEDED ADJUSTMENT. 2005072900073 20050729 00073 CE 2005 7 29 2005FA0001070 1 20050623 G 7160 1250839 DOOR CESSNA 210 T210F 2073422 CE CONT O520 TSIO520C 17040 SO INDUCTION AIRBOX FAILED B KO2R O OTHER O OTHER NR NOT REPORTED 1 CE 01 6129R 121 T2100029 178109R INVESTIGATION OF LOW MANIFOLD PRESSURE BY TECH RVEALED THE STEEL TAB RIVETED TO ALTERNATE AIR DOOR FOR MAGNETIC CLOSURE HAD FALLEN OFF AND ENTERED TURBOCHARGER. THE RIVETS USED TO FASTEN TAB TO DOOR WERE MISSING ALONG WITH THE TAB. THE RI VET HOLES LOOKED ELONGATED AND WERE POSSIBLY TOO LARGE AT TIME OF MFG. THE TURBOCHARGER COMPRESSOR WHEEL WAS DESTROYED AND METAL FROM TURBO ENTRED INDUCTION SYSTEM OF ENGINE. OIL FILTER REMOVED AND WAS FOUND TO BE HIGHLY CONTAMINATED WITH METAL. ENGINE WAS REMOVED FOR REPAIR ALONG WITH TURBO. SUGGEST ALTERNATE AIRDOOR SYSTEM BE INSPECTED EVERY 25 HOURS. (K) 1 H 7 1 3O 3 O 3A21 E8CE 2005072900119 20050729 00119 EA 2005 7 29 2005FA0001071 1 20050619 G 3244 256K433 TIRE CNDAIR CL600 CL6002B16 1900305 EA GE CF34 CF343A 30015 NE NR 4 MAIN WHEEL SEPARATED B BTVR A UNSCHED LANDING E VIBRATION/BUFFET CL CLIMB 1 GL 23 241FB 1284 108 MAY910366 5102 (REF: PA05002) VIBRATION NOTED AT ROTATION SPEED. FLIGHT CREW RETURNED TO POINT OF ORIGIN AND LANDED UNEVENTFULLY. NR 4 TIRE TREAD SEPARATED. THE NR 4 MAIN WHEEL AND TIRE ASSY WERE CHANGED IAW MM. THE AC WAS THEN FERRIED TO A MAINTENANC E BASE TO REPAIR THE DAMAGE FROM THE TIRE FAILURE. (K) 2 L 7 2 4F 4 F RT A21EA E15NE 2005072900114 20050729 00114 2005 7 29 2005FA0001072 4 20050608 G 2565 101630305 SLIDE LT OVERWING LEAKING D USAA K NONE O OTHER IN INSP/MAINT 1 EA 19 28011 357 (SHOP) IN THE SHOP, UPON RECEIPT FROM THE VENDOR, A LT OVERWING SLIDE FOR A 767 AIRCRAFT WAS GIVEN A RETENTION TEST. TH E TEST FAILED. THE SLIDE WAS REPACKED AND RETURNED TO SERVICE. (K) 2005072900130 20050729 00130 CE 2005 7 29 2005FA0001073 1 20050720 G 3240 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO DYNAMIC BREAKER INTERMITTENT B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 1570A CE1333 PILOT REPORTED AFTER PUTTING THE GEAR SELECTOR IN THE UP POSITION THE GEAR WOULDN`T RETRACT, AFTER A FEW SECONDS THE GEA R CAME UP ON ITS OWN. ON TROUBLESHOOTING THE MECHANIC FOUND THE RELAY WAS INTERMITTENT, PROBABLE CAUSE AT THIS TIME UNK NOWN. INSTALLED NEW AND IMPROVED RELAY IAW DATE CODE. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005072900136 20050729 00136 CE 2005 7 29 2005FA0001074 1 20050720 G 3240 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO DYNAMIC BREAKER INTERMITTENT B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 1563A 263 CE1320 PILOT REPORTED AFTER PUTTING THE GEAR SELECTOR IN THE UP POSITION THE GEAR WOULD NOT RETRACT. ON TROUBLESHOOTING THE ME CHANIC FOUND THE RELAY WAS INTERMITTENT, PROBABLE CAUSE AT THIS TIME UNKNOWN. INSTALLED NEW AND IMPROVED RELAY IAW DATE CODE. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005072900135 20050729 00135 EA 2005 7 29 2005FA0001075 2 20050729 G 8520 76333 BUSHING BELL 47 47G5A 1181034 SW LYC O435 TVO435B1A 41516 EA ENGINE WORN G O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 GL 27 715BH 230 25105 MAGNETO IDLER GEAR SHAFT BROKE, THE BREAK WAS CAUSED BY A WORN BUSHING ON THE GEAR/SHAFT P/N'S 76091 & 76283 THAT DRIVES IT. THIS IS THE SECOND TIME THIS SHAFT BROKE. TOTAL TIME SINCE OVERHAUL 230 HOURS. 1 G 7 1 3O 3 O 2H3 1E13 2005080100026 20050801 00026 GL 2005 8 1 2005FA0001076 1 20050729 G 5544 2055450000 SUPPORT DIAMON DA20 DA20C1 2990001 GL RUDDER CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 03 1166 C0181 RUDDER SUPPORT BRACKET ON RUDDER TOWER FACING PART AS INSTALLED ON AIRCRAFT, BOTTOM RIGHT LEG CRACKED, OUTSIDE AND INSID E, AT BASE ABOVE THE WELD. CRACK WAS VISIBLE WITH SMALL MIRROR AND FLASHLIGHT WITH THE RUDDER OFF. 1 L 7 1 3O NT TA4CH 2005080200004 20050802 00004 NE 2005 8 2 2005FA0001077 2 20050724 G 8500 ENGINE BOEING 75 PT13D 1380122 CE PWA R985 R985* 52008 NE SEIZED D O OTHER O OTHER NR NOT REPORTED 1 GL 11 808RB 755055 JP207375 ENGINE SEIZED, UNKNOWN CAUSE. (GL11200513505) (K) 1 Q 7 1 3R 3 R A743 5E1 2005080200012 20050802 00012 CE 2005 8 2 2005FA0001078 1 20050702 G 3222 1243400202 PISTON CESSNA 210 210C 2073412 CE CONT O470 IO470* 17026 SO NLG FORK ASSY SHEARED C O OTHER E VIBRATION/BUFFET LD LANDING 1 GL 23 3717Y 21058217 ON LANDING, THE PILOT FELT A NOSE WHEEL VIBRATION. TOWARD THE END OF THE ROLL OUT THE NOSE DROPPED DOWN, STRIKING THE R UNWAY. INSPECTION FOUND THE NOSE WHEEL FORK ASSY SHEARED OFF THE SHOCK STRUT ASSY. (K) 1 H 7 1 3O 3 O 3A21 E1CE 2005080200134 20050802 00134 SO 2005 8 2 2005FA0001079 2 20050801 G 7414 6310 MAGNETO CESSNA 185 A185F 2072821 CE CONT O520 IO520D 17032 SO LEFT DAMAGED D D RETURN TO BLOCK R PARTIAL RPM/PWR LOSS TX TAXI/GRND HDL 1 NM 07 61423 1537 18504180 821801R PERFORMED MAGNETO CHECK AND FOUND LT MAGNETO DROPPED 500 RPM. REMOVED MAG AND FOUND IMPULSE COUPLING RIVETS SHEARED, DRI VE GEAR BUMPER RETAINER BROKEN AND BUMPERS DAMAGED. REMOVED OIL FILTER AND FOUND METAL SHAVINGS. 1 H 7 1 3O 3 O 3A24 E5CE 2005080300001 20050803 00001 CE 2005 8 3 2005FA0001080 1 20050715 G 2434 649306 ALTERNATOR BEECH 36 B36TC 1151609 CE CONT O520 TSIO520* 17040 SO ENGINE FAILED D GMZR O OTHER O OTHER NR NOT REPORTED 1 SW 01 3042V 709 EA622 AIRCRAFT ENGINE RUNNING AND ALTERNATOR SWITCH SELECTED TO (ON) POSITION, ALTERNATOR RED ANNUCIATOR LIGHT (ON) AND LOAD M ETER SHOWING ZERO LOAD BEING CARRIED BY ALTERANTOR. AC OIL TEMP AND OIL PRESSURE INDICATIONS DROPPED TO ZERO IN FLIGHT AS BATTERY VOLTAGE DROPPED WELL BELOW 24. AC LANDING GEAR AND FLAPS SELECTED TO DOWN POSITION PRIOR TO LANDING, DID NOT OPERATE DUE TO LOW BATTERY VOLTAGE AND ALTERNATOR INOPERATIVE. AC LANDED GEAR UP. FOLLOWED POH PROCEDURES. (SW012005 05015) (K) 1 L 7 1 3O 3 O 3A15 E8CE 2005080300008 20050803 00008 CE 2005 8 3 2005FA0001082 1 20050628 G 3233 98820152 ACTUATOR CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA RT MLG CRACKED B BNZR O OTHER O OTHER NR NOT REPORTED 1 GL 19 5319V 2893 172RG0505 PILOT REPORTED SIDE LOAD ON LANDING. ON SUBSEQUENT TAKEOFF RT MAIN LANDING GEAR WOULD NOT FULLY RETRACT. FOUND RT ACTU ATOR CRACKED AT FORWARD BOLT HOLE. (K) 1 H 7 1 3O 3 O 3A17 E286 2005080300005 20050803 00005 CE 2005 8 3 2005FA0001083 1 20050610 G 3233 98820152 ACTUATOR CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA LT MLG CRACKED B BNZR O OTHER O OTHER NR NOT REPORTED 1 GL 19 9543B 172RG0868 FOUND UPPER FORWARD BOLT SHEARED AND ACTUATOR CACKED AT 100 HOUR INSPECTION. (GL19200504416) (K) 1 H 7 1 3O 3 O 3A17 E286 2005080300011 20050803 00011 CE 2005 8 3 2005FA0001084 1 20050410 G 2730 0510105391 CONTROL CABLE CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA ELEVATOR BROKEN B BNZR O OTHER O OTHER NR NOT REPORTED 1 GL 19 5327V 694 17281151 ELEVATOR CABLE, BROKEN STRANDS, 2 FT FROM AFT END. FOUND DURING 100 HOUR INSPECTION. (GL19200504415) (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005080300009 20050803 00009 CE 2005 8 3 2005FA0001085 1 20050525 G 2730 0510105391 CONTROL CABLE CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA ELEVATOR BROKEN B BNZR O OTHER O OTHER NR NOT REPORTED 1 GL 19 5353R 886 17281157 ELEVATOR CABLE, BROKEN STRANDS, 2 FT FROM AFT END. FOUND DURING 100 HOUR INSPECTION. (GL19200504414) (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005080300002 20050803 00002 CE 2005 8 3 2005FA0001086 1 20050710 G 2730 0510105391 CONTROL CABLE CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA ELEVATOR BROKEN B BNZR O OTHER O OTHER NR NOT REPORTED 1 GL 19 5335G 886 17281158 ELEVATOR CABLE, BROKEN STRANDS, 2 FT FROM AFT END. FOUND DURING 100 HOUR INSPECTION. (GL19200504419) (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005080300010 20050803 00010 EA 2005 8 3 2005FA0001087 2 20050730 G 7200 PT6A41 ENGINE BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCD4N3 HCD4N3A GL RIGHT DAMAGED B MZ2R A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 GL 13 432FA 6768 BB592 PCE81340 FY1144 AIRCRAFT PROCEEDED WITH A NORMAL TAKEOFF IN VFR CONDITIONS. FOLLOWING ROTATION, AND AT APPROXIMATELY 50 TO 100 FT AGL, THE RT ENGINE LOST POWER, THE PILOT LEVELED OFF. THE AC WOULD NOT MAINTAIN ALTITUDE, PILOT CHOSE TO LAND IMMEDIATELY, WITH ADEQUATE RUNWAY AHEAD. THE AC LANDED HARD AND WITH LANDING GEAR RETRACTED, CAUSING SUBSTANTIAL DAMAGE TO THE AC. NO INJURIES WERE INVOLVED. UPON INSPECTION OF AIRCRAFT, RIGHT PROPELLER WAS FOUND UNFEATHERED, WHEN THE AIRCRAFT WAS HO ISTED FOR SECURING, LANDING GEAR WAS SUCCESSFULLY EXTENDED BY USE OF THE EMERGENCY EXTENSION SYSTEM, AND LOCKED IN THE D OWN POSITION. CAUSE OF THE ENGINE POWER LOSS IS UNKNOWN AT THIS TIME. (K) 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2005080300007 20050803 00007 2005 8 3 2005FA0001088 4 20050513 G 2562 MN1300 BATTERY ACK CIRRUS SR SR22 2130001 GL CONT O550 IO550* SO ELT CORRODED G O OTHER O OTHER NR NOT REPORTED 1 GL 13 825CD 041121 0189 SECOND ELT FOUND WITH BATTERIES IN THIS CORRODED CONDITION. (K) 1 L 7 1 3O 3 O NT A00009CH E3SO 2005080300137 20050803 00137 SO 2005 8 3 2005FA0001089 1 20050802 G 1430 MS210426 NUT PIPER PA34 PA34200T 7103406 SO COVER CRACKED G K NONE O OTHER IN INSP/MAINT 1 NM 05 36049 4800 347870287 REPAIR STATION WAS REPAIRING AIRCRAFT HYD LEAK. WHEN REMOVING LOWER FORWARD WING ATTACH BOLT COVERS FOUND 10 OF THE 16 MS21042-6 NUTS CRACKED. PIPER P/N 404-532. 1 L 7 2 3O A7SO 2005080300152 20050803 00152 CE 2005 8 3 2005FA0001090 1 20050721 G 3610 AA3216CW PUMP BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO ENGINE VIBRATES B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 1569P 320 CE1300 PILOT REPORTED WHINING NOISE COMING FROM ENGINE AND FELT A VIBRATION COMING THROUGH THE MIXTURE CONTROL CABLE. TROUBLES HOOTING, THE MECHANIC FOUND THE AIR PUMP WAS VIBRATING. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005080300154 20050803 00154 SO 2005 8 3 2005FA0001091 1 20050726 G 5313 LONGERON AYRES S2T STRT34 0970106 SO PWA PT6 PT6A34AG 52053 NE FUSELAGE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 SW 03 4020Q 4368 T34265 BOTH UPPER LONGERON WAS CRACKED APPROXIMATELY 54 INCHES AFT OF DATUM. THE AREA IS DIFFICULT TO INSPECT AS IT IS 75 PERC ENT COVERED BY THE HOPPER. THIS IS A VERY UNUSUAL AREA TO FIND SUCH A DEFECT. THE AC HAS NO DAMAGE HISTORY AND HAS NO T BEEN ABUSED. (K) 1 L 7 1 3T 4 T A3SW E4EA 2005080300151 20050803 00151 2005 8 3 2005FA0001092 1 20050729 G 8011 MHB6016 STARTER CRACKED B F8ZR O OTHER O OTHER NR NOT REPORTED 1 WP 07 DRIVE HOUSING ASSY CRACKED ON MOUNTING PLATE. THIS IS THE 5TH CRACKED HOUSING IN A 2 MONTH PERIOD. THERE IS A MAJOR PR OBLEM. (K) 2005080900054 20050809 00054 SO 2005 8 9 2005FA0001093 1 20050725 G 2420 4111810R ALTERNATOR PIPER PA28 PA28161 7102803 SO LYC O320 O320* 41508 EA ROTOR,INTERNAL FAILED D K NONE O OTHER IN INSP/MAINT 1 NE 03 9284A 288616041 AFTER 46.9 HOURS OF OPERATION OF A NEWLY OVERHAULED ALTERNATOR, OUTPUT CEASED. HAD UNIT TESTED AND FOUND THE ROTOR OPEN , NO CURRENT FLOW THROUGH ROTOR. BRUSHES WERE GOOD. (K) 1 L 7 1 3O 3 O 2A13 E274 2005080900048 20050809 00048 CE 2005 8 9 2005FA0001094 1 20050808 G 2910 6317003136 LINE CESSNA 525 525 2076601 CE WILINT FJ44 FJ441A GL HYDRAULIC SYS SCORED B O OTHER K FLUID LOSS CR CRUISE 1 GL 09 247CW 2999 5250247 DURING FLIGHT, THE LT AND RT HYDRAULIC LOW LEVEL LIGHTS ILLUMINATED ALONG WITH A MASTER CAUTION LIGHT. AFTER A SAFE LAN DING, THE ENTIRE TAIL OF THE AIRCRAFT WAS FOUND TO BE SOAKED WITH HYDRAULIC FLUID. FURTHER INVESTIGATION FOUND THAT HYD RAULIC LINE HAD RUPTURED AT ONE OF THE BENDS. IT APPEARS THAT THE RUPTURE POINT WAS AT A SCORE MARK THAT WAS LEFT WHEN THE LINE WAS FABRICATED. EACH END OF THIS LINE IS BENT AT NEARLY A 90 DEGREE ANGLE. EACH END DISPLAYED THE SAME TYPE O F SCORE MARKS. LINE WAS REPLACED WITH NEW. SUGGEST A ONE TIME INSPECTION OF THIS LINE. IF IT IS DETERMINED THAT ANY S CORE MARKS SEEM EXCESSIVE, RECOMMEND REPLACEMENT OF THE LINE. PROCUREMENT OF NEW LINES SHOULD BE INSPECTED FOR THE SAME 1 L 7 2 4F 4 F RT A1WI E3GL 2005080900049 20050809 00049 CE 2005 8 9 2005FA0001095 1 20050808 G 2910 6317003136 LINE CESSNA 525 525 2076601 CE WILINT FJ44 FJ441A GL HYDRAULIC SYS LEAKING B K NONE K FLUID LOSS IN INSP/MAINT 1 GL 09 247CW 2999 5250247 DURING FLIGHT, THE LT AND RT HYDRAULIC LOW LEVEL LIGHTS ILLUMINATED ALONG WITH A MASTER CAUTION LIGHT. AFTER A SAFE LAND ING, THE ENTIRE TAIL OF THE AIRCRAFT WAS FOUND TO BE SOAKED WITH HYDRAULIC FLUID. FURTHER INVESTIGATION FOUND THAT HYDR AULIC LINE HAD RUPTURED AT ONE OF THE BENDS. IT APPEARS THAT THE RUPTURE POINT WAS AT A SCORE MARK THAT WAS LEFT WHEN T HE LINE WAS FABRICATED. EACH END OF THIS LINE IS BENT AT NEARLY A 90 DEGREE ANGLE. EACH END DISPLAYED THE SAME TYPE OF SCORE MARKS. LINE WAS REPLACED WITH NEW. SUGGEST A ONE TIME INSPECTION OF THIS LINE. IF IT IS DETERMINED THAT ANY SC ORE MARKS SEEM EXCESSIVE, RECOMMEND REPLACEMENT OF THE LINE. PROCUREMENT OF NEW LINES SHOULD BE INSPECTED FOR THE SAME. 1 L 7 2 4F 4 F RT A1WI E3GL 2005080900062 20050809 00062 CE 2005 8 9 2005FA0001096 1 20050804 G 3220 MS203922C17 PIN CESSNA CESSNA 210 210 2073402 CE CONT O470 IO470E 17026 SO MCAULY 2A34C D2A34C58 GL NLG MISSING C O OTHER O OTHER LD LANDING 1 SW 09 6521X 38 57521 CS931732E 786931 NOSE GEAR UPLOCK PIN FELL OUT AFTER RETAINING COTTER PIN FAILED, NOT ALLOWING UPLOCK ACTUATOR TO RELEASE GEAR RESLULTING IN NOSE GEAR UP LANDING, ALSO FOUND NOSE GEAR UPLOCK SPRING ATTACH BRACKETT SEVERLY WORN. (SW09200511362) 1 H 7 1 3O 3 O RT 3A21 3E1 5 C P3EA 2005080900091 20050809 00091 CE 2005 8 9 2005FA0001097 1 20050721 G 2910 MS21902J4 UNION CESSNA 750 750 2076810 CE ALLSN AE3007 AE3007C GL HYD SYS LOOSE B CNQ3 K NONE O OTHER IN INSP/MAINT 1 GL 13 970SK 7500186 HYD UNION WAS FOUND TO BE LOOSE ALLOWING O-RING TO FAIL OVER TIME. O-RING WAS REPLACED AND FITTING TORQUED. (K) 2 L 7 2 4J 4 F RT T00007WI TE6CH 2005080900092 20050809 00092 SW 2005 8 9 2005FA0001098 1 20050714 G 6320 407040035101 BEVEL GEAR BELL BELL 407 407 1182206 SW ALLSN 250C 250C47B GL GEAR TOOTH BROKEN B ULXR O OTHER O OTHER NR NOT REPORTED 1 WP 01 701WP 1425 A575 53542 HELICOPTER RECEIVED 2 TRANSMISSION CHIP CAUTION LIGHTS IN 2.9 HOURS. MAIN INPUT GUILL WAS REMOVED FOR INSPECTION OF THE BEVEL GEAR. THE BEVEL GEAR INSPECTION REVEALED 1 MISSING GEAR TOOTH AND AN ADJACENT TOOTH CRACKED. TRANSMISSION SENT TO MFG FOR EVALUATION AND OVERHAUL. NO RECOMMENDATION TO PREVENT RECURRENCE. 1 G 7 1 3U 3 U O H2SW E1GL 2005080900093 20050809 00093 GL 2005 8 9 2005FA0001099 1 20050727 G 2420 BC4101 MOUNT CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO MOUNT, FLANGE BROKEN D O OTHER K FLUID LOSS NR NOT REPORTED 1 NM 09 841CD 0336 686398 ALTERNATOR MOUNT BROKEN AND OIL LEAK. (THE ALTERNATOR CASE MOUNT FLANGE BROKEN) DRIVESHAFT IN ALTERNATOR SHEARED. THE ENGINE DRIVE SHAFT HUB HAS NO DAMAGE. (K) 1 L 7 1 3O 3 O NT A00009CH E3SO 2005080900137 20050809 00137 EA 2005 8 9 2005FA0001100 2 20050808 G 7322 30800 FLOAT PREAIR HA6 CESSNA 182 R182 2072734 CE LYC O540 O540J3C5 41532 EA CARBURATOR SATURATED G E ENGINE SHUTDOWN R PARTIAL RPM/PWR LOSS TX TAXI/GRND HDL 1 SW 19 576 576 DG111046 ENGINE RUNNING EXCESSIVELY RICH AT LOW POWER SETTINGS / TAXI.RAW FUEL RUNNING OUT OF INTAKE BOX AND EXHAUST STACKS.EXAMI NATION OF CARBURATOR DISCLOSED FLOAT HAD FLOODED AND SANK. 1 H 7 1 3O 3 O RT 3A13 E295 2005081500199 20050815 00199 2005 8 15 2005FA0001101 4 20050809 G 6122 SNAP RING HARTZL F624L PIPER PA31 PA31350 7103110 SO GOVERNOR BROKEN B O OTHER O OTHER NR NOT REPORTED 1 GL 25 3534Y D2545TJ 317952195 PROP GOVERNOR DRIVE GEAR FOUND BROKEN. FOUND BROKEN SNAP RING. DAMAGED COUPLING. NO METAL IN GOVERNOR. GEAR AND FLY WEIGHTS ROTATED FREELY. 1 L 7 2 3O A20SO 2005081000318 20050810 00318 CE 2005 8 10 2005FA0001107 1 20050720 G 5210 530323 SOLENOID RAYTHN 390 390 7150030 CE WILINT FJ44 FJ44 66000 GL DOOR SEAL SEIZED D K NONE O OTHER IN INSP/MAINT 1 GL 03 112CM 116 RB123 REF: (PT1838110) DOOR SOLENOID FAILED IN OPEN POSITION. WITH EITHER ENGINE RUNNING, THE DOOR COULD NOT BE OPENED/CLOSE D DUE TO INFLATED SEAL. SOLENOID REPLACED, OPERATIONAL CHECK GOOD. (K) 1 7 2 3F 4 F RT A00010WI E3GL 2005081000350 20050810 00350 CE 2005 8 10 2005FA0001108 1 20050708 G 2700 0510105365 CONTROL CABLE CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA RBL102 WORN B CTUR O OTHER O OTHER NR NOT REPORTED 1 GL 21 53289 1198 172S9331 CABLES WORN BEYOND LIMITS AT A CABLE RUB STRIP IN RT WING BY AUTOPILOT SERVO AT STATION RBL 102. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005081100089 20050811 00089 CE 2005 8 11 2005FA0001109 1 20050708 G 2710 0510105362 CONTROL CABLE CESSNA CESSNA 182 182P 2075816 CE LYC IO360 IO360L2A EA RT WING, RBL 102 WORN B CTUR K NONE O OTHER IN INSP/MAINT 1 GL 21 52389 1198 18262572 CABLES WORN BEYOND LIMITS AT A CABLE RUB STRIP IN RT WING BY AUTOPILOT SERVO AT STA RBL 102. (K) 1 H 7 1 3O 3 O NT TA13 1E10 2005081100097 20050811 00097 CE 2005 8 11 2005FA0001110 1 20050401 G 5343 ATTACH ANGLE CESSNA 310 310G 2074218 CE CONT O470 IO470* 17026 SO MLG DAMAGED D O OTHER O OTHER NR NOT REPORTED 1 NM 11 414X 310G0091 AT ANNUAL INSPECTION, FOUND 3 RIVETS AND 1 BOLT SHEARED AT RT FWD MLG TRUNNION ATTACH ANGLE. RIVETS WERE UPPER 2 ROWS O F 4 ROWS. REMAINING RIVETS SHOWED SIGNS OF (SMILE) FROM INSTALLATION. SHEARED BOLT WAS IN UPPER FWD POSITION OF FWD AN GLE. SHEARED FASTENERS WERE VISIBLE THROUGH INSPECTION PANEL AT OB CENTER OF GEAR. NO VISIBLE STRUCTURAL DAMAGE WAS NO TED. OWNER WAS NOTIFIED AND AC WAS DEEMED UN-AIRWORTHY. (K) 1 L 7 2 3O 3 O 3A10 E1CE 2005081100092 20050811 00092 CE 2005 8 11 2005FA0001111 1 20050723 G 2810 55000105 FUEL TANK BEECH 36 A36 1151604 CE CONT O550 IO550* SO WING TIO PLUGGED B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 8140G E2635 RT AUXILIARY FUEL TIP TANK IMPLODED. DETERMINED PROBABLE CAUSE WAS A PLUGGED VENT. GUIDANCE SUGGEST: WHEN PARKED, KEEP VENT CAPPED LIKE A PITOT COVER. DURING PREFLIGHT, TO OPEN GAS CAP AND BLOW OR AFFIX A TUBE TO THE .2500 INCH VENT AND BLOW TO VERIFY VENT NOT TO BE PLUGGED. IF VENT IS FOUND PLUGGED, REMOVE RESTRICTION BEFORE FLIGHT. (GL03200513894) (K) 1 L 7 1 3O 3 O 3A15 E3SO 2005081100090 20050811 00090 CE 2005 8 11 2005FA0001112 1 20050721 G 5330 SKIN CESSNA 206 U206F 2073333 CE CONT O520 IO520* 17032 SO FUSELAGE CORRODED B R2JR O OTHER O OTHER NR NOT REPORTED 1 EA 21 5VA 5757 U20603223 AC WAS UNDERGOING AN EXTENSIVE AVIONICS UPGRADE INSTALLATION AND DURING ANTENNA INSTALLATIONS, TECH NOTICED CORROSION UN DER FACTORY INSTALED DAMPENING/INSULATION MATERIAL. CORROSION WAS TO LOWER FUSELAGE SKINS UNDER THIS MATERIAL. THE COR ROSION WAS FOUND UNDER THE PIECES FOUND COMING LOOSE. INTACT PIECES DID NOT SEEM CORRODED UNDERNEATH. CLEANED CORROSIO N AND MINOR PITTING, TREATED AND PRIMERED AREAS AFTER REMOVING MATERIAL. SUGGEST CLOSE INSPECTION THIS AREA, ALL AIRCRA FT. PROBLEM MORE THAN LIKELY CAUSED BY AGE AND MOISTURE ACCUMULATION. FSDO THINKS IT MAY BE GLUE USED. (K) 1 H 7 1 3O 3 O A4CE E5CE 2005081100096 20050811 00096 CE 2005 8 11 2005FA0001113 1 20050726 G 2510 551900922 SEAT CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE COCKPIT CRACKED D O OTHER O OTHER NR NOT REPORTED 1 CE 05 123VP 5500111 UPPER CHAIR BASE ASSEMBLY CRACKED AT CHAIR BACK ATTACH POINTS. STRESS ON CHAIR BACK AND METAL FATIGUE PROBABLE CAUSE. CHAIR WAS REPAIRED IAW STC ST01042WI STRUCTURAL SEAT REPAIR. (K) 1 L 7 2 4F 4 F A22CE E1NE 2005081100069 20050811 00069 SO 2005 8 11 2005FA0001114 1 20050804 G 5541 SPAR AYRES S2 S2RT660 0970112 SO PWA PT6 PT6A65AG 52043 NE RUDDER BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SW 11 4121G 289 T660105 THE UPPER RUDDER SPAR WAS BROKEN 12.5 INCHES ABOVE THE UPPER HINGE. IN ADDITION, THE SPAR CRACKED UNDER THE UPPER HINGE FITTINGS. THIS CAUSED THE RUDDER COUNTER BALANCE TO BE LOOSE RESULTING IN RUDDER FLUTTER. FURTHER FLIGHT COULD HAVE R ESULTED IN LOSS OF RUDDER CONTROL. THE SPAR WEB IS MADE OF .040 INCH ALUMINUM CHANNEL WITH VERY LITTLE IN THE WAY OF ST IFFNERS. THE SPAR NEEDS TO BE BEEFED UP. (K) 1 L 7 1 4 T E4EA 2005081100054 20050811 00054 CE 2005 8 11 2005FA0001115 1 20050727 G 2916 511700712 TUBE CESSNA CESSNA 402 402C 207590R CE HYD SYSTEM SPLIT E A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 SO 17 78FC 402C0496 EIGHT MILES NORTH EAST OF KFLL, PILOT NOTICED A HYDRAULIC SMELL IN THE COCKPIT DURING CLIMB-OUT. THERE WERE NO ABNORMAL ITIES NOTED. PILOT DECLARED AN EMERGENCY AT KPMP. PILOT LANDED AIRCRAFT AT KPMP WITHOUT INCIDENT. POST FLIGHT REVEALE D HYDRAULIC SITE TUBE ON HYDRAULIC RESERVOIR HAD FAILED CAUSING AN ATOMIZED LEAK FROM THE HYDRAULIC SITE TUBE. 1 L 7 2 3O A7CE 2005081700006 20050817 00006 2005 8 17 2005FA0001116 1 20050810 G 3610 REGULATOR VALVE CONT O360 LTSIO360EB 17025 SO RT NACELLE RUPTURED P K NONE O OTHER IN INSP/MAINT 1 SO 01 803G 2390 2390 UPON RUN UP, PILOT CYCLED BOOTS. BOOT CYCLE STATUS LIGHT CAME ON BUT EXTINGUISHED BEFORE 6 SECOND INFLATION CYCLE TIMED OUT. (PRESS TO TEST SHOWED LAMP OK). BOOTS REMAINED PARTIALLY INFLATED AND WOULD NOT DE-FLATE. PILOT SPOOLED ENGINES DO WN AND BOOTS DE-FLATED. INSPECTION DISCLOSED THAT DIAPHRAGM ON LOW PRESSURE REGULATOR OF THE ASSEMBLY HAD FAILED AROUND ENTIRE CIRCUMFERENCE. FAILED DISK SPALLED THE BELL SHAPED PORTION OF REGULATOR RUINING THE REGULATOR AND RENDERING 2H22 -16 PART UNFIT FOR OVERHAUL. 3 O E9CE 2005081700007 20050817 00007 2005 8 17 2005FA0001117 1 20050810 G 3610 REGULATOR VALVE CONT O360 LTSIO360EB 17025 SO DE ICE SYS RUPTURED P D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 SO 01 803G 2390 2390 UPON RUN UP, PILOT CYCLED BOOTS. BOOT CYCLE STATUS LIGHT CAME ON BUT EXTINGUISHED BEFORE 6 SECOND INFLATION CYCLE TIMED OUT. (PRESS TO TEST SHOWED LAMP OK) BOOTS REMAINED PARTIALLY INFLATED AND WOULD NOT DE-FLATE. PILOT SPOOLED ENGINES DOW N AND BOOTS DE-INFLATED. INSPECTION DISCLOSED THAT DIAPHRAGM ON LOW PRESSURE REGULATOR OF THE AIRBORNE 2H22-16 ASSEMBLY HAD FAILED AROUND ENTIRE CIRCUMFERENCE. FAILED DISK SPALLED THE BELL SHAPED PORTION OF REGULATOR RUINING THE REGULATOR AND RENDERING 2H22-16 PART UNFIT FOR OVERHAUL. 3 O E9CE 2005081700172 20050817 00172 GL 2005 8 17 2005FA0001128 1 20050808 G 5210 DOOR CIRRUS SR SR22 2130001 GL CONT O550 IO550* SO CABIN FAILED C O OTHER O OTHER NR NOT REPORTED 1 SW 15 369SE 0846 BOTH DOORS WILL (POP) OPEN IN FLIGHT, CAUSING A SAFETY DISTRACTION TO THE PILOT AND WIND NOISE THAT KEEPS THE PILOT FROM HEARING AT INSTRUCTIONS. THIS STILL HAPPENS AFTER SEVER TRIPS TO MFG REPAIR STATION AND BACK TO FACTORY FOR REPAIRS. MFG RESPONSE IS THAT THE DOORS ARE WITHIN SPECS AND SHOULD NOT COME OPEN. HAVE HEARD FROM OTHER OWNERS THAT THEY HAVE S AME PROBLEM WITH THE NEW DOOR DESIGN. (K) 1 L 7 1 3O 3 O NT A00009CH E3SO 2005081600212 20050816 00212 2005 8 16 2005FA0001129 4 20050726 G 2200 4006719906 DRIVE ASSY CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE AUTOPILOT SERVO INOPERATIVE D O OTHER O OTHER NR NOT REPORTED 1 NM 13 5408G 5500666 THE PILOT REPORTED THAT THE CONTROLS WHERE STIFF IN THE ROLL AXIS. THE AUTOPILOT WAS TURNED OFF AND THE C/B WAS CYCLED WITH NO CHANGE IN THE CONDITION. AFTER LANDING WITHOUT INCIDENT, TECHS ARRIVED AND TROUBLESHOT THE A/P SYSTEM. THEY DI SCOVERED THE AILERON AUTOPILOT SERVO DRIVE CLUTCH WAS NOT FULLY DISENGAGING, CAUSING THE EXCESSIVE FORCE REQUIRED TO ROL L THE AIRCRAFT. AILERON AUTOPILOT SERVO DRIVE WAS REMOVED AND REPLACED. BOTH GROUND AND IN-FLIGHT OPERATIONAL CHECKS W ERE PERFORMED WITH NO DEFECTS NOTED. (NM13200503639) (K) 1 L 7 2 4F 4 F A22CE E1NE 2005081700059 20050817 00059 SO 2005 8 17 2005FA0001131 1 20050809 G 5210 553876 CAM PIPER PA34 PA34200T 7103406 SO PAX DOOR SHEARED D O OTHER O OTHER NR NOT REPORTED 1 SO 07 75 CAM IS THE UPPER LATCH ON THE REAR DOOR IN THE AIRCRAFT. THE INNER AND OUTER STEMS HOLD THE INNER AND OUTER DOOR LATCH HANDLES. PILOTS AND/OR PASSENGERS APPLY TOO MUCH PRESSURE OR TWIST THE HANDLES TOO FAR, SHEARING THE PART. THE PART IS MADE OF A PLASTIC OR NYLON FORMED IN ONE PART WITH THE LOCKING CAM BETWEEN THE SQUARE ENDS. HANDLES ARE ATTACHED TOT H E ENDS BY SCREWS. (K) 1 L 7 2 3O A7SO 2005081700064 20050817 00064 SW 2005 8 17 2005FA0001132 1 20050804 G 6710 222310465001 BEARING BELL 230 230 1182149 SW ALLSN 250C 250C30 03013 GL COLLECTIVE LEVER VIBRATION D O OTHER O OTHER NR NOT REPORTED 1 SW 15 870SF 2324 23018 LT COLLECTIVE LEVER SUPPORT BEARING FAILED CAUSING MAIN ROTOR VERT VIBRATION AND LOWER COLLECTIVE LEVER IDLER ELASTROMER IC BEARINGS TO FAIL AND SOME WERE IN MAIN TRANSMISSION UPPER LUGS/ATTACHMENT POINT TO WEAR. DISCUSSED WITH MFG PAODUCT SUPPORT. 1 G 7 2 3U 3 U NC H9SW E1GL 2005081700065 20050817 00065 SO 2005 8 17 2005FA0001133 2 20050719 G 8530 EC649358CN CYLINDER HEAD CESSNA 210 T210N 2073456 CE CONT O520 TSIO520R 17040 SO ENGINE DAMAGED G O OTHER O OTHER NR NOT REPORTED 1 WP 11 50QH 212 21064150 293513R DURING CRUISE FLIGHT, A LOUD BANG FROM THE ENGINE COMPARTMENT WAS FOLLOWED BY LOSS OF POWER AND SIGNIFICANT ENGINE VIBRA TION. THE PILOT MADE AN EMERGENCY LANDING ON A DIRT ROAD WITH NO DAMAGE TO THE AIRCRAFT. THE NR 1 CYLINDER HEAD HAD FR ACTURED COMPLETELY THROUGH, JUST ABOVE THE CYLINDER BARREL THREADS, LEAVING A .5 INCH GAP BETWEEN HEAD FINS 6 AND 7. TH E CYLINDER HAD BEEN REPAIRED 212 HOURS PRIOR TO FAILURE AND HAD BEEN BORED TO .010 OVERSIZE. A SERVICEABLE TAG HAD BEEN PROVIDED BY THE REPAIR STATION THAT PERFORMED THE WORK. (K) 1 H 7 1 3O 3 O 3A21 E8CE 2005081700095 20050817 00095 CE 2005 8 17 2005FA0001134 1 20050728 G 5342 12320132F FITTING CESSNA 207 T207A 2073614 CE CONT O520 TSIO520M 17040 SO HORIZONTAL STAB BROKEN B WIWR K NONE O OTHER IN INSP/MAINT 1 WP 07 9482M 14703 20700698 PILOT FOUND VERTICAL STABILIZER LOOSE ON PREFLIGHT. MAINTENANCE INSPECTED AND FOUND RT FWD ATTACHMENT FITTING BROKEN. REPLACED BOTH FWD FITTINGS WITH NEW PARTS. (K) 1 H 7 1 3O 3 O A16CE E8CE 2005081700181 20050817 00181 CE 2005 8 17 2005FA0001135 1 20050807 G 3230 S13771 SWITCH CESSNA 210 P210N 2073454 CE CONT O520 TSIO520P 17040 SO MCAULY D3A34 D3A34C402 GL MLG BROKEN C E ENGINE SHUTDOWN J WARNING INDICATION AP APPROACH 1 NE 05 152BT 3440 210000486 NO CONFIRMATION OF LANDING GEAR DOWN AND LOCKED. NO GREEN LIGHTS. GEAR APPEARED DOWN VISUALLY. ON INSPECTION ONCE ON THE GROUND IT WAS DOWN AND PROPERLY LOCK. MALFUNCTION WAS THE GEAR INDICATOR POSITION MICRO SWITCH ON THE LT MAIN BROK EN WIRE AT THE SWITCH. NEW SWITCH PN: S1377-1 FIXED THE PROBLEM. NO SIGN OF STRAIN ON WIRE, JUST AGE AND NORMAL FLEXIN G. 1 H 7 1 3O 3 O 3A21 E8CE 5 C P47GL 2005081700171 20050817 00171 SO 2005 8 17 2005FA0001136 1 20050816 G 4920 36150861 CAP GULSTM G1159 GIV 3980115 SO APU COMBUSTOR CRACKED C K NONE O OTHER IN INSP/MAINT 1 WP 23 569CW 820 820 1145 APU COMBUSTOR CAP HAD A CRACKED WELD. THE CRACKED WELD WAS ADJACENT TO THE HEAT DEFLECTOR. UNIT HAD 820 TT SINCE NEW. 2 L 7 2 4F RT A12EA 2005081800091 20050818 00091 SW 2005 8 18 2005FA0001137 1 20050811 G 5711 SPAR BBAVIA 7 7AC 2110102 SW CONT C85 C85* 17008 SO RT WING CRACKED D O OTHER O OTHER NR NOT REPORTED 1 GL 13 84286 7AC2980 AFT RT SPAR HAS LONGITUDINAL CRACK ON LOWER END. CRACK OCATED AT STRUT ATTACH POINT. SPAR ALSO SHOWS SIGNS OF ROTTING IB OF CRACK AREA. (K) 1 H 7 1 3O 3 O A759 E233 2005081800095 20050818 00095 CE 2005 8 18 2005FA0001138 1 20050801 G 2841 45AS48008003 PRESSURE SWITCH BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE FUEL SYSTEM FAILED B E81R O OTHER J WARNING INDICATION CR CRUISE 1 GL 03 432CW RK32 RT WING OVERPRESSURE ANNUNCIATOR LIGHT ILLUMINATED IN FLIGHT. FOUND S128 PRESSURE SWITCH TO HAVE CONTINUITY WITH NO PRE SSURE SWITCH TO HAVE CONTINUITY WITH NO PRESSURE APPLIED. REPLACED SWITCH ASSY WITH NEW UNIT IAW MM, OPERATIONS NORMAL. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2005081800096 20050818 00096 NE 2005 8 18 2005FA0001139 2 20050808 G 7261 209062028001 FITTING BELL 212 212 1181420 SW PWA PT6T PT6T3B 52045 NE VALVE DETACHED B IGAR O OTHER O OTHER NR NOT REPORTED 1 WP 01 212AH 30959 DURING FLIGHT FITTING BECAME DETACHED CAUSING LOSS OF OIL. FOUND FITTING MADE OF ALUMINUM. NEW FITTING MADE OF STEEL. (K) 1 G 7 1 4U 4 U H4SW E22EA 2005081800107 20050818 00107 CE 2005 8 18 2005FA0001140 1 20050729 G 3310 11693 MOUNT BEECH 1900 1900D 1154162 CE PWA PT6 PT6A6 52043 EA INDIRECT LIGHT FAULTY B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 842E 5802 UE336 TRANSISTOR MOUNT, INSTRUMENT PANEL INDIRECT LISHTS OPERATE AT FULL BRIGHT REGARDLESS OF POTENTIATOR POSITION. TROUBLESH OOTING FOUND THAT TRANSISTOR MOUNT WAS INSTALLED BEHIND LOCATION CALLED OUT AS COPILOTS FLIGHT INSTRUMENTS. IDENTIFYING FAULTY TRANSISTOR COULD NOT BE ACCOMPLISHED UNTIL MIS-ROUTED TRANSISTOR SOCKET WAS FOUND. NO MAINTENANCE WAS LOGGED IN THIS AREA SINCE NEW. (K) 2 L 7 2 4T 3 T RT A24CE E4EA 2005082200058 20050822 00058 2005 8 22 2005FA0001190 1 20050819 G 6120 C299506B0104 CONTROL CABLE PROPELLER DEFECTIVE C O OTHER O OTHER NR NOT REPORTED 1 NE 01 PROPELLER CONTROL CABLE CAME DEFECTIVE FROM MANUFACTURER. ORDERED A TOTAL OF THREE (3)ALL THREE DEFECTIVE. APPEARS CAB LES ARE MANUFACTURED BY NEW VENDOR AS ONE OF THEM WAS IDENTIFIED AS "FIRST ARTICLE SAMPLE. CONTROLS JAM AND PRODUCE BRA SS FILINGS DURING ROTATION OF VERNIER CONTROL. VERNIER CONTROL MACHINES GROVES INTO SURFACE OF SHAFT. DIGITAL PICTURES TAKEN AND CESSNA ENGINEERING CONTACTED 2005082200060 20050822 00060 SO 2005 8 22 2005FA0001192 2 20050819 G 7260 640756A6 ADAPTER CONT 360KB32 PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360KB 17025 SO MCAULY 3AF32C 3AF32C508 GL ENGINE CRACKED C K NONE O OTHER IN INSP/MAINT 1 GL 09 321AK 190 190 811403R 3447021 811403R 961314 STARTER ASSEMBLY BOLT HOLE FLANGE CRACKED AT THE 10 O'CLOCK BOLT POSITION. MANUFACTURER DESIGN FLAW. ONGOING NUMEROUS REOCCURENCES WITH THESE ADAPTER ASSEMBLY ACCESSORY DRIVE HOUSINGS, LEFT SIDE ONLY, IN FLEET AIRCRAFT. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2005082200061 20050822 00061 SO 2005 8 22 2005FA0001193 2 20050819 G 7260 640756A6 ADAPTER CONT 360KB32 PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360KB 17025 SO MCAULY 3AF32C 3AF32C508 GL ENGINE CRACKED C K NONE O OTHER IN INSP/MAINT 1 GL 09 321AK 190 190 811403R 3447021 811403R 961314 STARTER ASSEMBLY BOLT HOLE FLANGE CRACKED AT THE 10 O'CLOCK BOLT POSITION. MANUFACTURER DESIGN FLAW. ONGOING NUMEROUS REOCCURENCES WITH THESE ADAPTER ASSEMBLY ACCESSORY DRIVE HOUSINGS, LEFT SIDE ONLY, IN FLEET AIRCRAFT. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2005082200062 20050822 00062 SW 2005 8 22 2005FA0001194 1 20050821 G 5711 SPAR BBAVIA 7 7GCAA 21101N8 SW RT WING CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 09 8305V 2778 98 TWO COMPRESSION CRACKS ON RIGHT WING REAR SPAR, ONE ON EITHER SIDE OF PLYWOOD DOUBLER AT STRUT ATTACH POINT. OUT BOARD C RACK EXTENDS APPROX ONE THIRD DEPTH OF SPAR, EXTENT OF INBOARD CRACK AS YET UNKNOWN, MAY GO BEHIND DOUBLER, CRACKS FOUND DURING INSPECTION REQUIRED BY AD 2000-25-02. 1 H 7 1 3O A759 2005082200063 20050822 00063 SO 2005 8 22 2005FA0001195 2 20050817 G 7314 TF1900 PUMP BEECH 35 C35BEECH 1151508 CE CONT E225 E225* 17015 SO ENGINE FUEL WORN G A UNSCHED LANDING R Y J PARTIAL RPM/PWR LOSS ENGINE STOPPAGE WARNING INDICATION CL CLIMB 1 WP 09 709D 148 148 D2981 40009D THE ENGINE FUEL PUMP DRIVE WAS FOUND WORN TO THE POINT WHERE IT WOULD NO LONGER DRIVE THE PUMP, CAUSING AND ENGINE FAILU RE. THE PUMP HAD 148 HOURS ON IT SINCE OVERHAUL. IT HAS NOT BEEN DETERMINED IF THE LOCATOR PIN WAS INSTALLED IN THE DR IVE. 1 L 7 1 3O 3 O A777 E267 2005082500125 20050825 00125 SO 2005 8 25 2005FA0001196 1 20050806 G 3222 8628003 DRAG BRACE PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA MLG FAILED D O OTHER O OTHER NR NOT REPORTED 1 CE 01 3104C 251 4496190 UPON LANDING AND NOSE GEAR TOUCHING DOWN PILOTS HEARD LOUD BANG FROM THE NOSE AREA. NOSE GEAR HALF COLLAPSED (DRAG LINK JAMMED AGAINST THE NOSE STRUT TRUNION) AND AC WENT TO THE RT INTO GRASS AREA THEN SPUN TO RT TURNED 180 DEGREES IN A L ARGE ARC, CROSSED BACK ACROSS TO LT SIDE OF THE RUNWAY COMING TO REST ON LT SIDE OF RUNWAY. RECOVERED ONE CRESCENT SHAP ED FRAGMENT. APPEARS TO BE ANOTHER PIECE UNACCOUNTED FOR. PROBABLE CAUSE; DEFECTIVE DRAG LINK, BUSHING OR BOLT AT CONN ECTION POINT. (K) 1 L 7 2 3O 3 O A19S0 E286 2005082400100 20050824 00100 NM 2005 8 24 2005FA0001197 1 20050805 G 2710 3170121 ROD END BOEING 747 747SP21 1384802 NM PWA JT8 JT8D7A 52053 NE LT IB PCU BROKEN B LWXR K NONE O OTHER IN INSP/MAINT 1 SW 19 145UA 21441 ON AUGUST 5TH, DURING THE FLIGHT CONTROL RIGGING OPERATION, THE LT AILERON IB PCU ROD END WAS FOUND BROKEN. THIS ROD EN D IS PART OF THE BENDIX PCU PN 317012-1 ASSEMBLY. EVIDENCE OF CORROSION IS APPARENT AT CRACKED LOCATION. UNKNOWN TIME. 2 L 7 4 4F 4 F A20WE E2EA 2005082500126 20050825 00126 CE 2005 8 25 2005FA0001198 1 20050709 G 7603 WEDGE CESSNA 210 210E 2073416 CE CONT O520 IO520A 17032 SO THROTTLE CABLE BROKEN D O OTHER O OTHER NR NOT REPORTED 1 CE 07 4933U 21058633 CABLE BROKE AT THE S3 WEDGE WHERE THE BARREL END CONNECTS TO THE INTERNAL CABLE. THIS AREA IS NOT VISIBLE AS THERE IS A N INTERNAL SLEEVE THAT COVERS THE CABLE IN THIS AREA. ( CE07200516270) (K) 1 H 7 1 3O 3 O 3A21 E5CE 2005090100023 20050901 00023 2005 9 1 2005FA0001199 4 20050806 G 6113 BULKHEAD CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA PROP SPINNER CRACKED B WIWR O OTHER O OTHER NR NOT REPORTED 1 WP 07 121CW 194 172S8975 DURING ANNUAL/ 100 HOUR INSPECTION, FOUND SPINNER FWD BULKHEAD CRACKED AROUND 2 HOLES OF THE MOUNTING BOLTS. BOLTS PULL ING EDGES OF BULKHEAD HOLES INTO CHAMFER OF THE PROP HOLES, CREATING STRESS AROUND THESE BULKHEAD HOLES LEADING TO CRACK S. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005082400097 20050824 00097 EU 2005 8 24 2005FA0001200 1 20050628 G 6520 4639310062 BEVEL GEAR BOLKMS 117 BK117B2 5626013 EU LYC LTS101 LTS101* NE T/R GEARBOX CRACKED B K NONE O OTHER IN INSP/MAINT 1 SW 05 117BK 3544 469 7229 CASE CRUSHING OR SPALLING WITH CRACKS. COMPONENT COMING DUE 3600 HR TBO. SUBMITTED FOR ROUTINE OVERHAUL. DEFECTS FOUN D DURING NORMAL DETAIL BENCH INSPECTION. COMPONENT HAS A 10,800 HOUR SERVICE LIFE LIMIT. (K) 1 G 7 2 3U 3 U NC H13EU E5NE 2005090100019 20050901 00019 CE 2005 9 1 2005FA0001201 1 20050813 G 2421 DOFF10300F ROTOR SHAFT FORD CESSNA 150 150L 2071826 CE CONT O200 O200* 17020 SO ALTERNATOR SHEARED D O OTHER O OTHER NR NOT REPORTED 1 GL 15 18583 900 C041218 15073961 ALTERNATOR SHAFT SHEARED AT BEARING LOCATION. DRIVE GEAR, BUSHINGS, RETAINER AND COUPLING ASSEMBLY ROLLED BETWEEN ENGIN E ACCESSORY CASE AND DRIVE GEAR. THE SHAFT HAD BEEN PREVIOUSLY CRACKED OVER 50 PERCENT PRIOR TO FAILURE. (K) 1 H 7 1 3O 3 O 3A19 E252 2005090100024 20050901 00024 SW 2005 9 1 2005FA0001202 1 20050817 G 8011 75622CG STARTER GULSTM 680 680E 0141604 SW ENGINE FAILED B MV1R O OTHER O OTHER TX TAXI/GRND HDL 1 EA 17 50 13 680E81862 ON START UP FOR SECOND FLIGHT OF THE DAY, AC STARTER WOULD NOT ENGAGE AND TURN ENGINE. SEVERAL ATTEMPS WERE MADE TO STA RT THE ENGINE. STARTER WOULD TURN BUT WOULD NOT ENGAGE AND TURN OVER ENGINE. THIS STARTER WAS INSTALLED ON THIS AIRCRA FT ON THE SAME ENGINE AND REMOVED FOR THE SAME REASON IN 10/17/01. (K) 1 H 7 2 3O 2A4 2005090100022 20050901 00022 EU 2005 9 1 2005FA0001203 1 20050705 G 2810 ATTACH BRACKET ISRAEL 1125 ASTRASPX 4500205 EU GARRTT TFE731 TFE731* 01518 WP FUEL CELL LEAKING B JGVR O OTHER O OTHER NR NOT REPORTED 1 CE 09 610SM 101 FUEL LEAKING INTO CABIN. CUSTOMER SQKD FUEL SMELL INSIDE CABIN. REMOVED INTERIOR AND FLOOR PANELS AND FOUND ATTACHMENT BRACKETS MOUNTED INTO WING TANK (INCLUDING COLLECTOR BOX) FASTENERS LEAKING BADLY. DURING BOOST PUMP OPERATION, FUEL L EAK INCREASED TO COVER CENTER ISLE WITH FUEL. RESEALED FASTENERS IN CABIN AND INNER TANK. (K) 2 L 7 2 4F 4 F RT A16NM E6WE 2005082400095 20050824 00095 CE 2005 8 24 2005FA0001204 1 20050823 G 2434 F424R ALTERNATOR CESSNA 210 T210N 2073456 CE CONT O550 IO550* SO MCAULY D3A34 D3A34C402 GL ENGINE SEIZED D E ENGINE SHUTDOWN B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 SW 15 5416U 77 21064890 289136R 972424 AIRCRAFT WAS RUN UP PRIOR TO 50 HOUR INSPECTION AND NO DEFECTS WERE FOUND DURING RUN UP. AFTER INSPECTION, PERFORMED POS T INSPECTION RUN AND NOTICED A LOUD SQUEALING NOISE AND SMOKE COMING FROM ENGINE COMPARTMENT. ENGINE WAS SHUTDOWN AND IN SPECTION REVEALED THAT ALTERNATOR BELT WAS SLIPPING AROUND PULLEYS. ALTERNATOR WAS FOUND TO BE SEIZED UP. INSPECTED ALT ERNATOR WITH BORESCOPE INSIDE OF BLAST TUBE BUT DID NOT FIND REASON FOR SEIZURE. ALTERNATOR WAS SENT BACK FOR WARRANTY C ONSIDERATION. CAUSE OF SEIZURE AT THIS TIME IS UNKNOWN. 1 H 7 1 3O 3 O 3A21 E3SO 5 C P47GL 2005082400098 20050824 00098 NM 2005 8 24 2005FA0001206 1 20050823 G 3250 2880000000 VALVE GULSTM 200 200 4500308 NM NLG STEERING BYPASSING C D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 EA 07 402LM 082 WHEN THE THRUST REVERSERS WERE DEPLOYED ON THE AIRCRAFT, A VERY LOUD SQUEALING NOISE CAME FROM THE NOSE LANDING GEAR STE ERING CONTROL VALVE. 2 L 7 2 4F RT A53NM 2005082400099 20050824 00099 NM 2005 8 24 2005FA0001207 1 20050823 G 3250 2880000000 VALVE GULSTM 200 200 4500308 NM NLG STEERING LEAKING D K NONE O OTHER IN INSP/MAINT 1 EA 07 402LM 1148 082 THE NOSE WHEEL STEERING VALVE WAS LEAKING BEYOND LIMITS. 2 L 7 2 4F RT A53NM 2005082400109 20050824 00109 CE 2005 8 24 2005FA0001208 1 20050822 G 5230 1014301403 STRUCTURE BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCD4N3 HCD4N3A GL CARGO DOOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 WP 23 677BC 8000 BB86 THE AIRSTAIR DOOR OF THIS AIRCRAFT CLOSES INTO THE CARGO DOOR. CRACKS WERE FOUND IN THE CARGO DOOR IN THE JAMB AGAINST WHICH THE AIRSTAIR CLOSES AND SEALS. THE CARGO DOOR IS A BONDED ASSEMBLY AND THE JAMB IS A PART OF THIS BOND ASSEMBLY. THREE CRACKS WERE FOUND IN THE JAMB, ONE IN EACH UPPER CORNER AND ONE IN THE LOWER AFTER CORNER. THIS DOOR, WHILE IT I S A STANDARD MFG PART WAS INSTALLED IN THIS AIRCRAFT BY STC AT ABOUT 5130 HOURS AIRCRAFT TOTAL TIME. TOTAL TIME ON THE DOOR TODAY IS APPROX. 8000 HOURS. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2005082400110 20050824 00110 CE 2005 8 24 2005FA0001209 1 20050822 G 5230 1014301403 STRUCTURE BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCD4N3 HCD4N3A GL CARGO DOOR CRACKED C K NONE O OTHER IN INSP/MAINT 1 WP 23 677BC 8000 BB86 THE AIRSTAIR DOOR OF THIS AIRCRAFT CLOSES INTO THE CARGO DOOR. CRACKS WERE FOUND IN THE CARGO DOOR IN THE JAMB AGAINST WHICH THE AIRSTAIR CLOSES AND SEALS. THE CARGO DOOR IS A BONDED ASSEMBLY P/N 101-430140-3 AND THE JAMB IS A PART OF THI S BOND ASSEMBLY. THREE CRACKS WERE FOUND IN THE JAMB, ONE IN EACH UPPER CORNER AND ONE IN THE LOWER AFTER CORNER. THIS DOOR, WHILE IT IS A STANDARD MFG PART WAS INSTALLED IN THIS AIRCRAFT BY STC AT ABOUT 5130 HOURS AIRCRAFT TOTAL TIME. T OTAL TIME ON THE DOOR TODAY IS APPROX. 8000 HOURS 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2005082500124 20050825 00124 CE 2005 8 25 2005FA0001210 1 20050811 G 2750 C1452501S MOTOR BEECH 58 58P 1152744 CE CONT O520 TSIO520* 17040 SO TE FLAP FAILED D WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 80LM 253 TJ216 FLAP CIRCUIT BREAKER POPS WHEN RETRACTING FLAPS. FOUND FLAPS GOING OVER TRAVEL IN DOWN DIRECTION, PROBABLY OVERLOADING CAUSING OVERLOADING OF FLAP MOTOR. FOUND MOTOR COILS SHOW SIGNS OF OVERHEATING. MFG HAS SUPERSEDED MOTOR TO NEW MOTOR. (K) 1 L 7 2 3O 3 O A23CE E8CE 2005090100036 20050901 00036 GL 2005 9 1 2005FA0001211 3 20050808 G 6110 7503503AF O-RING PIPER PA42 PA421000 7104225 SO GARRTT TPE331 TPE33114 01514 NE ROTOL R339 R3394123F8 GL PROP DOME CUT B GW1R K NONE B SMOKE/FUMES/ODORS/SPARKS AP APPROACH 1 EA 03 901MT 425527011 P52012 AT THE OUTER MARKER ON APPROACH, THE PILOT NOTICED AN OIL ODOR IN THE ENVIRONMENTAL SYSTEM. THE AIRCRAFT LANDED WITHOUT INCIDENT. POST FLIGHT WALK AROUND REVEALED OIL LEAK AT THE RT PROPELLER. MAINTENANCE WAS DISPATCHED AND INVESTIGATION REVEALED THE RT PROPELLER DOME PISTON O-RING WAS CUT/ROLLED. THE O-RING WAS REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE. (K) 1 L 7 2 4T 4 T RT A23SO E18NE 6 C P8NE 2005082500123 20050825 00123 CE 2005 8 25 2005FA0001212 1 20050816 G 2510 551900922 ATTACH BRACKET CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE SEAT CRACKED B O OTHER O OTHER NR NOT REPORTED 1 CE 05 120Q 5500332 UPPER CHAIR BASE ASSEMBLY CRACKED AT CHAIR BACK ATTACH POINTS. ALSO, PREVIOUS INAPPROPRIATE REPAIR. CHAIR WAS REPAIRED IAW STC SEAT REPAIR. (K) 1 L 7 2 4F 4 F A22CE E1NE 2005090100018 20050901 00018 SO 2005 9 1 2005FA0001214 1 20050808 G 5552 HINGE BRACKET PIPER PA28 PA28140 7102802 SO ROTAX 582 ROTAX582 55555 EU ELEVATOR CRACKED G O OTHER O OTHER NR NOT REPORTED 1 AL 01 4243J 2822598 DURING INSPECTION, IT WAS NOTED THAT THE ELEVTOR FORWARD HINGE ATTACH BRACKET WAS CRACKED AT THE AFT BEND IN THE RADIUS NEAR THE AFT ATTACH RIVET. THE OWNER STATED THAT THIS WAS A COMMON OCCURANCE ON THESE MODEL AC AND THAT 2 OTHERS WERE K NOWN. (K) 1 L 7 1 3O 3 I 2A13 EXPE3I 2005082500122 20050825 00122 SO 2005 8 25 2005FA0001215 1 20050808 G 5540 HINGE BRACKET PIPER PA28 PA28140 7102802 SO ROTAX 582 ROTAX582 55555 EU RUDDER UNSERVICEABLE G O OTHER O OTHER NR NOT REPORTED 1 AL 01 4243J 2822598 DURING INSPECTION IT WAS NOTED THAT THE RUDDER LOWER HINGE ATTACH FITTING HAD THE AFT 2 ATTACH RIVETS PULLIN OUT OF THE REINFORCING CHANNELS. IT SHOULD BE NOTED THAT THE RUDDER IS ALSO THE VERTICAL FIN ON THIS AIRCRAFT. RECOMMEND THAT THE REST OF THESE (POP-RIVET) FASTENERS BE REMOVED AND AC HARDWARE BE INSTALLED EITHER BOLTS OR STRUCTURAL MS SCREWS. AC O WNERS SHOULD ALSO CONSIDER INSTALLING DOUBLER CHANNEL ON THE BOTTOM SIDE OF THIS ATTACH POINT. (K) 1 L 7 1 3O 3 I 2A13 EXPE3I 2005090200053 20050902 00053 SO 2005 9 2 2005FA0001216 1 20050805 G 3230 2572000 TRANSMISSION PIPER PA24 PA24 7102402 SO LYC O360 O360* 41514 EA MLG FAILED D O OTHER O OTHER NR NOT REPORTED 1 SO 15 180ML 242609 LANDING GEAR RETRACT SYS WOULD NOT EXTEND GEAR TO A DOWN AND LOCKED POSITION. SEVERAL ATTEMPTS TO CYCLE GEAR POPPED GEA R MOTOR CIRCUIT BREAKER. TRANSMISSION DECOUPLER RELEASED WHEN EMERGENCY GEAR EXTENSION WAS ATTEMPTED, GEAR WOULD NOT GO TO DOWN AND LOCKED POSITION. PILOTS ATTEMPT TO RECYCLE GEAR TO THE RETRACTED POSITION AND THEN TO EXTENDED POSITION AF TER EMERGENCY GEAR EXTENSION WAS ACTUATED, ADDED TO PROBLEM, TRANSMSN DECOUPLER WAS IN DIRECT CONTACT WITH GEAR THROUGH BOLT, MAKING EXTENSION IMPROBABLE. SITUATION MAKES POSSIBILITY OF GEAR EXTENSION NEARLY IMPOSSIBLE BECAUSE THE THROUGH BOLT CANNOT TRAVEL FAR ENOUGH BACK TO GET DOWN AND LOCKED CONDITION. 1 L 7 1 3O 3 O 1A15 E286 2005082500116 20050825 00116 NM 2005 8 25 2005FA0001217 1 20050824 G 3250 2880000000 CONTROL VALVE GULSTM 200 200 4500308 NM NLG STEERING BYPASSING D H DEACTIVATE SYST/CIRCUITS O OTHER IN INSP/MAINT 1 EA 07 402LM 082 WHEN THE THRUST REVERSERS WERE DEPLOYED ON THE AIRCRAFT. A VERY LOUD SQUEALING NOISE CAME FROM THE NOSE LANDING GEAR STE ERING CONTROL VALVE. THIS IS THE 4TH REPLACEMENT UNIT INSTALLED ON THE AIRCRAFT. THE 5TH UNIT SERIAL NO. IL0138 RESOLVED THE PROBLEM. AND THE AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 2 4F RT A53NM 2005082500117 20050825 00117 NM 2005 8 25 2005FA0001218 1 20050823 G 3250 2880000000 CONTROL VALVE GULSTM 200 200 4500308 NM NLG STEERING BYPASSING D K NONE O OTHER IN INSP/MAINT 1 EA 07 402LM 082 WHEN THE THRUST REVERSERS WERE DEPLOYED ON THE AIRCRAFT, A VERY LOUD SQUEALING NOISE CAME FROM THE NOSE LANDING GEAR STE ERING CONTROL VALVE. 2 L 7 2 4F RT A53NM 2005082500118 20050825 00118 NM 2005 8 25 2005FA0001219 1 20050824 G 3250 2880000000 CONTROL VALVE GULSTM 200 200 4500308 NM NLG STEERING BYPASSING D K NONE O OTHER IN INSP/MAINT 1 EA 07 402LM 082 WHEN THRUST REVERSERS WERE DEPLOYED ON THE AIRCRAFT, A VERY LOUD SQUEALING NOISE CAME FROM THE NOSE LANDING GEAR STEERIN G CONTROL VALVE. 2 L 7 2 4F RT A53NM 2005082500120 20050825 00120 SO 2005 8 25 2005FA0001220 1 20050728 G 2810 FUEL TANK PIPER PA18 PA18180 7101880 SO LYC O360 O360* 41514 EA LT WING MISMANUFACTURED P O OTHER O OTHER NR NOT REPORTED 1 AL 05 44TC 157 9941CC LT WING TANK AT 157 HRS SEAM WELD BROKE OPEN WHILE SITTING ON GROUND CAUSING FUEL LEAK INTO WING. WELDS EVALUATED FOUND TO BE THIN AND OF POOR QUALITY. 1 H 7 1 3O 3 O 1A2 E286 2005082500121 20050825 00121 SO 2005 8 25 2005FA0001221 1 20050728 G 2810 FUEL TANK PIPER PA18 PA18180 7101880 SO LYC O360 O360* 41514 EA LT WING MISMANUFACTURED P O OTHER O OTHER NR NOT REPORTED 1 AL 05 44TC 157 9941CC LT WING TANK AT 157 HRS SEAM WELD BROKE OPEN WHILE SITTING ON GROUND CAUSING FUEL LEAK INTO WING. WELDS EVALUATED FOUND TO BE THIN AND OF POOR QUALITY. 1 H 7 1 3O 3 O 1A2 E286 2005082500048 20050825 00048 SO 2005 8 25 2005FA0001222 1 20050825 G 2497 7814039 CABLE PIPER PA28 PA28181 7102807 SO LYC O360 O360* 41514 EA BATTERY CHAFED B K NONE O OTHER IN INSP/MAINT 1 NE 01 284HP 1795 2843372 DURING ROUTINE MAINTENANCE FOUND BATTERY POSITIVE CABLE BEING CHAFED ON CONTROL CABLE TURNBUCKLE IT CAME IN CONTACT WITH . THE SAWING MOTION OF THE TURNBUCKLE ALMOST WORE THROUGH THE BATTERY CABLE INSULATION JACKET. THE CABLE WAS REROUTED (R EPOSITIONED) AT LAST 100 HOUR FOR THE SAME REASON. APPARENTLY THE CABLE HAS TAKEN A SET AND KEEPS RETURNING TO ITS ORIGI NAL BEND CONFIGURATION. RECOMMEND SHORTENING THE CABLE AND CRIMPING THE TERMINAL ENDS 90 DEGREES TO THE LAY OF THE CABLE . 1 L 7 1 3O 3 O 2A13 E286 2005090100112 20050901 00112 SO 2005 9 1 2005FA0001223 1 20050805 G 1100 PLACARD PIPER PA24 PA24260 7102406 SO LYC O540 TIO540* 41532 EA SWITCH MISINSTALLED D K NONE O OTHER IN INSP/MAINT 1 SO 05 8955P 244412 WHEN DOING OPERATIONAL CHECK AFTER INSTALLATION OF SVS VI UPGRADE KIT ON SVA IA SYSTEM, (AD 2005-11-05). THE ON/OFF PLA CARD ON ON/OFF LEVER WAS CONFUSING. WHEN LEVER VALVE WAS ON OR OPEN, IT LOOKED AS IF IT WERE (OFF) OR CLOSED ON THE PLA CARD. (K) 1 L 7 1 3O 3 O 1A15 E14EA 2005090100105 20050901 00105 EU 2005 9 1 2005FA0001224 1 20050811 G 2530 200146901 COVER AMD FALC90 FALCON900EX 2730009 EU MICROWAVE OVEN MELTED H O OTHER O OTHER NR NOT REPORTED 1 EA 21 MICROWAVE OVEN, PN 400-1338-02-L, INSTALLED, EXPERIENCED A (SMOKE EVENT) WHILE FLYING OVER TURKEY. REP EXAMINED THE UNI T ON 8/12/2005. THE MOISTURE COVER HAD OVERHEATED DURING OPERATION WITH A LIGHT LOAD. SB-MW-02, DATED 4/25/01 TO REPLA CED MOISTURE COVER WAS NOT INSTALLED. RECURRENCE COULD BE PREVENTED BY INSTALLING SB-MW-02. (K) 2 L 7 3 4F RT A46EU 2005083000101 20050830 00101 EU 2005 8 30 2005FA0001225 1 20050329 G 3610 FGFB721535200B1 DUCT AMD FALC90 FALCON900B 2730171 EU GARRTT TFE731 TFE7315BR WP LT BLEED AIR CRACKED B BG5Y O OTHER O OTHER NR NOT REPORTED 1 EA 33 103DT 3844 142 DURING INVESTIGATION OF OIL PRESSURE TRANSMITTER ENGINE NR 1 FOUND HOT AIR LEAK FROM PYLON. AFTER REMOVAL OF PYLON DOOR FOUND BLEED AIR DUCT PROBE TEMPERATURE SUPPORT CRACKED. NO SIGNIFICANT DAMMAGE FOUND AROUND THE DUCT. REPLACED BLEED AIR DUCT. (K) 2 L 7 3 4F 4 F RT E6WE 2005083000142 20050830 00142 SO 2005 8 30 2005FA0001226 1 20050824 G 5220 86676212 ROD PIPER PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA EMERGENCY EXIT DEPARTED D A UNSCHED LANDING D INFLIGHT SEPARATION CL CLIMB 1 SO 05 2079N 9493 447995214 FORWARD EMERGENCY LATCH DID NOT FULLY ENGAGE ALLOWING EMERGENCY EXIT TO DEPART IN FLIGHT. PROBLEM IS CAUSED BY THE CON TROLLING ROD BEING TOO SMALL OF DIAMETER TO ENGAGE FORWARD LATCH. ROD BENDS EASILY FEELING LIKE IT FORCED THE FORWARD LA TCH TO THE ENGAGED POSITION. THERE IS NO WITNESS HOLE TO VIEW ENGAGEMENT OF THE FORWARD LATCH. IN THIS CASE, A WITNESS HOLE WAS MADE IN THE INTERIOR PLASTIC TRIM ON THE LT SIDE OF THE AIRCRAFT AND PAINTED THE LATCH RED SO THAT IT COULD BE VIEWED WITHOUT DISMANTLING THE INTERIOR. THE MM DOES NOT MENTION A METHOD TO ENSURE ENGAGEMENT OF THE FORWARD LATCH. 1 L 7 2 3O 3 O A19S0 E286 2005083000143 20050830 00143 SO 2005 8 30 2005FA0001227 1 20050826 G 3213 40247000 BEARING PIPER PIPER PA31T PA31T 7103124 SO PWA PT6 PT6A11 52043 NE MLG STRUT DETACHED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 09 195AA 180 180 31T7904001 FOUND UPPER BRGS SEPARATED FROM PISTON TUBES DUE TO PINS MIGRATING INTO PISTON TUBE, TURNING UPPER BRG LOOSE, PINS THEN BACKED OUT AND FELL OUTSIDE PISTON TUBE, LOCKED UP MAIN GEAR SHOCK STRUT TRAVEL. CAUSE OF PINS MIGRATING, TURNING UPPER BRGS LOOSE WAS THAT PISTON TUBE WAS DRILLED FOR OVERSIZED MAIN GEAR UPPER BRG RETAINER PINS, WHEN UPPER BRGS WERE REPLAC ED AT O/H THEY WERE NOT REFITTED FOR OVERSIZE PINS, STANDARD PINS WERE USED WHICH ARE SMALLER IN DIAMETER THAN OVERSIZED HOLES IN PISTON TUBES ALLOWING THEM TO FALL INTO TUBE AND TURN BRG LOOSE. SUGGEST THAT PISTON TUBES BE PERMANENTLY MAR KED TO INDICATE IF OVERSIZED PINS ARE NECESSARY, A WARNING BANNER BE ADDED TO SB779B. 1 L 7 2 3T 3 T A8EA E4EA 2005083000103 20050830 00103 CE 2005 8 30 2005FA0001228 1 20050829 G 7602 CONTROL CABLE BEECH 23 23 1151202 CE LYC O320 O320* 41508 EA MIXTURE FRACTURED H B EMER. DESCENT Y ENGINE STOPPAGE CL CLIMB 1 WP 23 2388Q M469 THE PILOT LOST ENGINE POWER DURING TAKEOFF. EXAM FOUND MIXTURE CONTROL CABLE FRACTURED AT 90-DEGREE ANGLE NEAR SET SCRE W TO CARBURETOR. FATIGUE ON CABLE INDICATES INSTALLATION ERROR. FRACTURE COULD NOT BE SEEN DUE TO OUTER SHEATH ON MIXT URE CONTROL CABLE. 1 L 7 1 3O 3 O RT A1CE E274 2005090600103 20050906 00103 SW 2005 9 6 2005FA0001229 1 20050803 G 1420 MS251822 CONNECTOR GULSTM 690TP 690C 7630517 SW GARRTT TPE331 TPE3315 01514 WP ROTOL R306 R306382F7 GL BATTERIES WORN C K NONE O OTHER IN INSP/MAINT 1 SW 01 835CC 1000 93 11730 PILOT REPORTED INABILITY OF "SERIES" START WITH A/C. UPON INSPECTION FOUND + PIN OF RH BATTERY BROKEN OFF IN BATTERY CO NNECTOR. INSPECTED LH BATTERY FOUND + PIN WITH PARTIAL BURN INDICATION. REMOVED TOPS OF BOTH BATTERIES AND NOTED INDICA TION OF HIGH HEAT ABOVE CONNECTOR TERMINAL AREA. CONTACTED FSI MAINT TRAINING INSTRUCTOR, INDICATED SIMILAR CONDITION F OUND RECENTLY ON SAME TYPE PLANE AT EAGLE AVIATION. BATTERY CONNECTOR FOUND TO HAVE LOST TENSION ON CONNECTOR PINS. PR EVIOUSLY DISCUSSED SIMILAR PROBLEM WITH GILL MANUFACTURING. TECHNICIAN SAID WITH LOOSE PINS IN CONNECTOR, CREATES HIGH RESISTANCE, WITH HIGH TEMP ON CONNECTOR AREA AND WILL CAUSE AREA TO CRACK DUE TO HEAT. REPLACED BOTH G-6381E BATTERI 1 H 7 2 3T 4 T 2A4 E4WE 6 C P8EU 2005090100089 20050901 00089 EA 2005 9 1 2005FA0001230 2 20050818 G 7322 75107922 CARBURETOR CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA SNSNCH 72C 72CK EA ENGINE FAILED G O OTHER O OTHER NR NOT REPORTED 1 NM 07 714VV 509 15279475 L1507315 K7833 WHILE IN THE PATTERN DOING LANDINGS. THE ENGINE QUIT WHEN THE POWER WAS REDUCED ON BASE LEG TO LAND. AN UNEVENTFUL LAN DING WAS MADE, AND AFTER CLIMBING OUT OF AIRCRAFT, FUEL WAS COMING OUT OF THE COWLING. UPON FURTHER INVESTIGATION FOUND 1 OF THE FUEL BOWL FLOATS TO BE .7500 FULL OF FUEL AND THE OTHER WAS .2500 FULL. CAUSING THE FLOAT TO SINK AND CAUSING THE FUEL AIR MIXTURE TO BE TOO RICH AT REDUCED POWER SETTINGS. CAUSING THE ENGINE TO FLOOD OUT AND QUIT ON THE APPROAC H TO LAND. (K) 1 H 7 1 3O 3 O NT 3A19 E223 5 N P9045 2005090100127 20050901 00127 SO 2005 9 1 2005FA0001231 1 20050808 G 2497 7814039 CABLE PIPER PA28 PA28181 7102807 SO LYC O360 O360* 41514 EA BATTERY CHAFED B C85R O OTHER O OTHER NR NOT REPORTED 1 NE 01 284HP 1794 2843372 DURING ROUTINE MAINTENANCE, FOUND BATTERY POS CABLE BEING CHAFED ON CONTROL CABLE TURNBUCKLE IT CAME IN CONTACT WITH. T HE SAWING MOTION OF THE TURNBUCKLE ALMOST WORE THRU THE BATTERY CABLE INSULATION JACKET. THE CABLE WAS REROUTED (REPOSI TIONED) AT LAST 100 HR FOR THE SAME REASON. THE CABLE HAS TAKEN A SET AND KEEPS RETURNING TO ITS ORIGINAL BEND CONFIGU RATION. RECOMMEND SHORTENING THE CABLE AND CRIMPING THE TERMINAL ENDS 90 DEGREES TO THE LAY OF THE CABLE. (K) 1 L 7 1 3O 3 O 2A13 E286 2005090100131 20050901 00131 GL 2005 9 1 2005FA0001232 1 20050819 G 2820 11443004 LINE CIRRUS SR SR22 2130001 GL CONT O550 IO550* SO FUEL SYS CHAFED G O OTHER O OTHER NR NOT REPORTED 1 GL 21 2354B 750 0077 MAIN FUEL SUPPLY LINE FROM FUEL SELECTOR TO FIREWALL HAD HOLE CHAFED IN IT. THE WIRE BUNDLE TO THE CB PANEL WAS CHAFING LINE. (K) 1 L 7 1 3O 3 O NT A00009CH E3SO 2005090200002 20050902 00002 SO 2005 9 2 2005FA0001237 2 20050830 G 8520 CONNECTING ROD CESSNA 175 175 2072502 CE CONT O300 GO300* 17022 SO ENGINE BROKEN D A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 NM 04 7600M 848 55900 62099A NR 3 CONNECTING ROD PENETRATED CASE. ENGINE TSO 848 HRS. LAST ENGINE O/H 06/10/1964 OR 41 YEARS AGO. MANUFACTURER RECOM MENDS 12 YEARS IAW SIL 98-9. 1 H 7 1 3O 3 O NT 3A17 E298 2005090200025 20050902 00025 CE 2005 9 2 2005FA0001238 1 20050829 G 2731 S26376Z11 PIN CESSNA CESSNA 210 T210N 2073456 CE CONT O520 TSIO520* 17040 SO ACTUATOR BACKED OUT D A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 GL 07 6239Y 92 92 21063131 21064304 THE PIN THAT HOLDS THE DRIVE GEAR ONTO THE ACTUATOR DRUM HAD FALLEN OUT WHEN THE AIRCRAFT WAS TRIMMED NOSE UP. THE PILOT HAD TO PUSH ON THE YOKE WITH GREAT FORCE TO PITCH THE AIRCRAFT DOWN. AFTER EXAMINING THE ACTUATOR, NOTICED THAT THE HO LE FOR THE PIN WAS ELONGATED AND WOULD NOT HOLD A NEW PIN. RECOMMEND SOME SORT OF CLAMP BE INSTALLED TO INSURE THE PIN COULD NOT BACK OUT. 1 H 7 1 3O 3 O 3A21 E8CE 2005090600108 20050906 00108 CE 2005 9 6 2005FA0001242 1 20050829 G 2731 S26376Z11 PIN CESSNA CESSNA 210 T210N 2073456 CE ZONE 300 BACKED OUT D A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 SW 99 6239Y 92 92 21063131 21064304 THE PIN THAT HOLDS THE DRIVE GEAR ONTO THE ACTUATOR DRUM HAD FALLEN OUT WHEN THE AIRCRAFT WAS TRIMMED NOSE UP. THE PILOT HAD TO PUSH ON THE YOKE WITH GREAT FORCE TO PITCH THE AIRCRAFT DOWN. AFTER EXAMINING THE ACTUATOR I NOTICED THAT THE HO LE FOR THE PIN WAS ELONGATED AND WOULD NOT HOLD A NEW PIN. I WOULD RECOMMEND SOME SORT OF CLAMP BE INSTALLED TO INSURE T HE PIN COULD NOT BACK OUT. 1 H 7 1 3O 3A21 2005090200054 20050902 00054 CE 2005 9 2 2005FA0001244 1 20050516 G 5341 08112763 ATTACH FITTING CESSNA 310 310J 2074226 CE CONT O470 IO470U 17026 SO MCAULY 3AF32C D3AF32C80 GL WING TO BODY CORRODED D K NONE O OTHER IN INSP/MAINT 1 NE 05 700MA 310J0181 115658511 681031 DURING THE ANNUAL INSPECTION, THE WING FITTING WAS FOUND TO BE CORRODED SO SEVERE THAT IT WAS ALMOST .2500 OF THE WAY TH RU THE FITTING. PICTURES ENCLOSED THAT SHOW DAMAGE. FITTING WAS LOCATED ON THE LT SIDE, AFT TOP FITTING. (K) 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 2005090200102 20050902 00102 2005 9 2 2005FA0001245 1 20050818 G 2140 94E423 SWITCH HEATER ASSY SHORTED B IS4R K NONE O OTHER IN INSP/MAINT 1 SO 09 FOUND COMBUSTION AIR PRESSURE SWITCH (PN 94E42-3) CLOSED AT ALL TIMES (HAS CONTINUITY). THIS IS A NORMALLY OPEN (N.O.) SWITCH AND CLOSES WHEN IT SENSES AIR PRESSURE AT THE HIGH PRESSURE PORT. WITH IT CLOSED AT ALL TIMES, THIS SAFETY DEVIC E WILL TELL THE HEATER THAT IT HAS COMBUSTION AIR, WHETHER ITS THERE OR NOT. NOT GOOD IF THE COMBUSTION AIR BLOWER FAIL S. THIS 94E42 SERIES SWITCH DOES NOT REQUIRE INSPECTION IAW AD AT THIS TIME. TO PREVENT REOCCURRENCE, RECOMMEND TESTIN G THESE COMBUSTION AIR PRESSURE SWITCHES IN CONJUNCTION WITH THE PRESSURE DECAY TEST MANDATED BY AD. 2005090200104 20050902 00104 2005 9 2 2005FA0001246 4 20050815 G 3497 3446J1B CONNECTOR BEECH MU300 400A 1155402 CE WIRE BUNDLE LOOSE B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 36997 514 RK397 INVESTIGATED IN-FLIGHT (GPWS), (TERR), AND (WINDSHEAR) FAILE INDICATIONS. SYSTEM FAILURES CONFIRMED ON GROUND. FOUND A IRFRAME WIRING CONNECTOR (3446J1B UNSEATED FROM EGPWS UNIT CONNECTOR DUE TO TENSION ON WIRING BUNDLE. RESEATED CONNECTO R PINS AND RESECURED WIRING BUNDLE AS REQUIRED TO RELIEVE TENSION. REINSTALLED CONNECTOR TO EGPWS UNIT, OPS CHECK OK. (K) 2 H 7 2 4F RT A16SW 2005090200103 20050902 00103 SO 2005 9 2 2005FA0001247 1 20050729 G 2821 FILTER PIPER PA24 PA24260 7102406 SO LYC O540 TIO540* 41532 EA FUEL SYSTEM CONTAMINATED B R2JR O OTHER O OTHER NR NOT REPORTED 1 EA 21 8788P 244240 THIS STATION RECEIVED REQUEST FROM REGULAR CUSTOMER, THAT WAS FERRYING AIRCRAFT. AIRCRAFT ENGINE FAILED TO MAKE FULL PO WER THEN QUIT ON GROUND. CREW WAS SENT TO REMOTE AIRFIELD TO TROUBLESHOOT. AFTER EXTENSIVE TROUBLESHOOTING, FOUND FUEL INJECTORS CLOGGED BY DIRT. FUEL FILTER SCREEN AND FILTER REMOVED AND FOUND BADLY CONTAMINATED. (PHOTO) AIRCRAFT HAD J UST RECEIVED A FRESH ANNUAL INSP. FILTRS AND NOZZLES WERE CLEANED, FUEL LINES PURGED AND ENGINE RUN MADE FULL POWER. F ILTERS THEN CHECKED AGAIN AND WERE CLEAN AT THIS TIME. POOR MAINT AND INSP DETERMINED TO MAJOR FACTOR CONTRIBUTING TO M ALFUNCTION. EXPERIENCED PILOT RECONIZED PROBLEM ENGINE COULD HAVE FAILED WHILE AIRBORNE. (K) 1 L 7 1 3O 3 O 1A15 E14EA 2005090200106 20050902 00106 SO 2005 9 2 2005FA0001249 2 20050117 G 8500 GTSIO520L ENGINE CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO HARTZL HCC3Y HCC3YN GL RIGHT SEIZED G O OTHER O OTHER NR NOT REPORTED 1 EA 21 112AL 30 421C0697 610449 DG675B OIL PRESSURE NEVER CAME UP AFTER PILOT STARTED ENGINE AND ENGINE SEIZED. TIME ON ENGINE: 03.3. ENGINE WAS REMOVED AND ANOTHER ENGINE WAS PROVIDED, UNDER WARRANTY TO TAKE ITS PLACE. PN: GTSIO520L/ SN: 292065R 1 L 7 2 3O 3 O A7CE E7CE 5 C P25EA 2005090200105 20050902 00105 SO 2005 9 2 2005FA0001250 2 20050805 G 8500 GTSIO520L ENGINE CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO HARTZL HCC3Y HCC3YN GL RIGHT FAILED G O OTHER O OTHER NR NOT REPORTED 1 EA 21 112AL 31 421C0697 292065R DG675B DURING MAINTENANCE CHECK, RUNNING THE RT ENGINE AT 1200 RPM, ENGINE LOST OIL PRESSURE AND SHUT DOWN. THIS IS THE 2ND EN GINE THAT HAS FAILED WITHIN 30 HOURS OF INSTALLATION. BOTH ENGINE HAVE BEEN FROM SAME FACILITY. 1 L 7 2 3O 3 O A7CE E7CE 5 C P25EA 2005090200107 20050902 00107 CE 2005 9 2 2005FA0001251 1 20050314 G 8120 S19211 CLAMP CESSNA CESSNA 337 T337G 2075726 CE CONT IO360 IO360* 17025 CE TURBOCHARGER SEPARATED G O OTHER O OTHER NR NOT REPORTED 1 EA 21 289 P3370233 EXHAUST PIPE TO TURBOCHARGER CLAMP FOR FRONT ENGINE CRACKED AT SPOT-WELD AND SEPARATED ON TAKEOFF. WHEN THIS HAPPENED, THE EXHAUST PIPE DEPARTED THE AIRCRAFT AND THE EXHAUST SCORCHED THE ENGINE COWLING AND FIREWALL. (K) 1 H 7 2 3O 3 O A6CE E1CE 2005090600124 20050906 00124 CE 2005 9 6 2005FA0001252 1 20050621 G 7160 AM106735 AIR FILTER AIRESRCH CESSNA 320 320E 2074514 CE CONT O520 TSIO520E 17040 SO TURBO CHARGER FAILED G E ENGINE SHUTDOWN C Y F.O.D. ENGINE STOPPAGE TO TAKEOFF 1 NM 05 3438Q YE024103 320E0038 1828000R ACCIDENT INVESTIGATION FOUND RIGHT TURBO CHARGER COMPRESSOR INGESTED PAPER AND JAMMED. IT WAS DETERMINED THAT THE PAPER WAS THE INSTRUCTIONS AND APPLICATION CHART FOR THE FILTER. A CHECK OF A NEW REPLACEMENT DONALDSON (FAA/PMA FOR CESSNA FILTERS) FILTER REVEALED THAT THE INSTRUCTIONS AND A STICKER WERE INSERTED INSIDE THE CANISTER TYPE FILTER. THE INSTRUC TIONS (FOLDED INTO A QUARTER SHEET) WERE LAYING (MOLDED) ON THE COURSE INSIDE SCREEN OF THE FILTER. IN-STOCK FILTERS SHO ULD BE INSPECTED AND INSTRUCTIONS PLACE ON THE OUTSIDE OF THE FILTER. 1 L 7 2 3O 3 O 3A25 E8CE 2005090600126 20050906 00126 SO 2005 9 6 2005FA0001253 1 20050829 G 8010 MX6220 STARTER PIPER PA44 PA44180 7104402 SO LYC O360 O360A1H 41514 EA RT ENGINE BROKEN B E ENGINE SHUTDOWN O OTHER TX TAXI/GRND HDL 1 GL 21 191ND 60 60 4495003 L71871A PILOT ATTEMPTED START BUT STARTER WOULD NOT CRANK. UPON VISUAL INSP OF STARTER FOUND BENDIX HAD STUCK IN THE EXTENDED PO SITION ON THE PREVIOS START CAUSINING THE GEAR TO BREAK AND BREAKING 2 MOUNTING PADS OF THE BENDIX HOUSING. DAMAGE WAS A LSO NOTED ON THE ENGINE RING GEAR. STARTER AND RING GEAR REPLACED AND AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 3O 3 O A19S0 E286 2005091200185 20050912 00185 EU 2005 9 12 2005FA0001255 1 20050714 G 2913 41222 SHAFT AMD FALC10 FALCON10 2730101 EU GARRTT TFE731 TFE731* 01518 WP DRIVE SHEARED B UO2R O OTHER O OTHER NR NOT REPORTED 1 GL 19 401JW AH49775 46 WHILE PERFORMING AN ENGINE GROUND OPERATION THE HYDRAULIC PUMP OUTPUT CEASED. A SHEARED PUMP EXTERNAL DRIVE SHAFT WAS D ISCOVERED. SYSTEM REGULATION AND RETURN FILTERS AND PUMP HOSES SHOW NO INDICATIONS OF METAL CONTAMINATES. THE PUP STUB SHAFT STILL TURNS BY HAND. REMOVED PUMP ASSEMBLY FROM SERVICE AND INSTALLED AN OVERHAULED PUMP. (K) 2 L 7 2 4F 4 F A33EU E6WE 2005092000074 20050920 00074 SO 2005 9 20 2005FA0001256 1 20050812 G 3000 1H2418 VALVE PIPER PA46 PA46350P 7104602 SO LYC O540 TIO540* 41532 EA DE-ICE SYSTEM DEFECTIVE B BNGR K NONE O OTHER IN INSP/MAINT 1 GL 19 772DS 534 4636338 DE-ICE PRESSURE MANIFOLD VALVE DEFECTIVE IAW SL. (K) 1 L 7 1 3O 3 O RT A25SO E14EA 2005103100113 20051031 00113 CE 2005 10 31 2005FA0001257 1 20050718 G 2910 NAS16126 O-RING CESSNA 750 750 2076810 CE ALLSN AE3007 AE3007C GL A-HYD MANIFOLD FAILED D O OTHER K FLUID LOSS NR NOT REPORTED 1 GL 19 15RL 1003 0255 7500165 NAS1612-6, O-RING LOCATED ON AN814-6K, PLUG INSTALLED IN (A) HYDRAULIC SYSTEM MANIFOLD, PN 6717277-3 FAILED, CAUSING LOS S OF SYSTEM (A) HYDRAULIC FLUID AND SUBSEQUENT PILOT SHUTDOWN OF (A) HYDRAULIC SYSTEM. FOUND TORQUE ON PLUG TO BE LESS THAN 30 INCH POUNDS ALLOWING HYDRAULIC FLUID UNDER PRESSURE TO DAMAGE O-RING. NO PROVISIONS FOR SAFTEYING THE PLUG ARE PROVIDED. RECOMMEND A DRILLED HEAD PLUG BE INSTALLED AND PROPERLY SAFETIED TO PREVENT LOSS OF TORQUE ON PLUG. (K) 2 L 7 2 4J 4 F RT T00007WI TE6CH 2005103100109 20051031 00109 NE 2005 10 31 2005FA0001258 2 20050806 G 8530 399359 CYLINDER SCWZER G164 G164A 3952704 EA PWA R1340 R134053 52016 NE NR 8 FAILED G HFTG O OTHER O OTHER NR NOT REPORTED 1 GL 19 9041M 1026 1703 2P100353 FOUND NR 8 CYLINDER TO HAVE RUPTURED OUTWARD DURING CRASH INVESTIGATION. ENGINE WAS BEING INSPECTED IAW AD. PERHAPS TH IS AD NEEDS TO BE RE-VISITED AS THIS PROBLEM IS TOO COMMON. (GL19299504540) (K) 1 Q 7 1 3R 3 R 1A16 5E2 2005091500123 20050915 00123 CE 2005 9 15 2005FA0001259 1 20050901 G 8011 643259 ADAPTER CESSNA 421 421C 2076016 CE CONT O520 GTSIO520* 17032 SO STARTER DAMAGED B VA1R O OTHER O OTHER NR NOT REPORTED 1 SW 19 617CC 800 421C0897 808298R METAL IN ENGINE. STARTER ADAPTER, CRANK GEAR HAD TEETH MISSING. SB WAS NEVER C/W. (K) 1 L 7 2 3O 3 O A7CE E7CE 2005092000220 20050920 00220 EA 2005 9 20 2005FA0001260 2 20050822 G 8550 B-NUT BBAVIA 7 7KCAB 21101P3 CE LYC O320 IO320* 41508 EA CRANKCASE LOOSE G O OTHER K FLUID LOSS NR NOT REPORTED 1 NM 13 7546F 28770 L453055A ENGINE OIL PRESSURE LINE B-NUT AT GEAR CASE LOST TORQUE AND THE ENGINE LOST ALL OIL. LACK OF LUBRICATION CAUSED FAILURE OF THE NR2 CONNECTING ROD BEARING. (K) 1 H 7 1 3O 3 O A759 1E12 2005092600183 20050926 00183 CE 2005 9 26 2005FA0001261 1 20050810 G 3231 LINE CESSNA 210 210 2073402 CE CONT O470 IO470E 17026 SO NLG DOOR MISMANUFACTURED D LX2R O OTHER O OTHER NR NOT REPORTED 1 GL 27 9408T 57208 8867871ER FERRULE ON NLG DOOR OPEN LINE CRACKED ALONG STRESS RISER CREATED BY FLARING TOOL VISE. RESULTED IN LOSS OF HYDRAULIC FL UID TO OPERATE LANDING GEAR. AIRCRAFT LANDED WITH MAIN LANDING GEAR UP. (K) 1 H 7 1 3O 3 O RT 3A21 3E1 2005103100064 20051031 00064 SO 2005 10 31 2005FA0001262 1 20050727 G 3233 8360004 BOLT PIPER PA46 PA46350P 7104602 SO LYC O540 TIO540* 41532 EA ACTUATOR BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SO 05 527TB 4636166 ON PERFORMING A ROUTINE TIRE CHANGE, I NOTICED THE RT MAIN ACTUATOR BOLT HAD BROKEN THE SAFETY WIRE TO THE TRUNION AND H AD BACKED OUT UNTIL THERE WERE NO THREAD ENGAGEMENT TO TRUNION. ROD END SEIZED ON ACUTATOR OR FAILED TORQUE ON MAINTEN ANCE. RECOMMEND PREFLIGHT CHECKLIST. (K) 1 L 7 1 3O 3 O RT A25SO E14EA 2005092000043 20050920 00043 CE 2005 9 20 2005FA0001263 1 20050805 G 5610 66004047 WINDSHIELD LEAR 55 55LEAR 5170702 CE GARRTT TFE731 TFE7313A 01518 WP COCKPIT DELAMINATED B DELR O OTHER O OTHER NR NOT REPORTED 1 CE 03 32KJ 93 WINDSHIELD HAS CONSIDERABLE DELAMINATIONS AT AREA BELOW DEFOG NOZZLE. DIMENSIONS OF AREA 3.5 INCH X 2 INCH. DEPTH OF D ELAMINATIONS UP TO .125. THIS IS NOT THE FIRST WINDSHIELD FOUND IN THIS CONDITION. PROBABLE CAUSE IS ALCOHOL GETTING B ETWEEN THE WINDSHIELD AND DEFOG ASSEMBLY. (K) 2 L 7 2 4F 4 F A10CE E6WE 2005103100103 20051031 00103 CE 2005 10 31 2005FA0001264 1 20050822 G 3297 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO DYNAMIC BREAKER INTERMITTENT B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 8240T 121 CE1542 ON ROUTINE GEAR INSPECTION, THE MECHANIC NOTICED THE GEAR WAS VERY SLOW ON RETRACTION. ON TROUBLESHOOTING THE MECHANIC FOUND THE RELAY WAS INTERMITTENT, PROBABLE CAUSE AT THIS TIME UNKNOWN. INSTALLED NEW AND IMPROVED RELAY IAW DATE CODE. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005091500017 20050915 00017 SO 2005 9 15 2005FA0001265 2 20050823 G 7313 627335D13A NOZZLE BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO ENGINE FUEL BROKEN B VJ3R K NONE O OTHER IN INSP/MAINT 1 WP 07 8268T 1433 CE1547 825913R ON ROUTINE PHASE INSPECTION THE FUEL INJECTOR NOZZLES WERE REMOVED FOR CLEANING, AT THIS TIME THE MECHANIC DIDN’T NOTICE ANY DEFECTS. THE NOZZLES WERE THEN PLACED IN A CLEANING TANK AND AFTER REMOVING THEM FROM THE TANK THE MECHANIC NOTICE D THE RING THAT THE FUEL INJECTOR LINE SEATS TO WAS BROKEN AWAY FROM THE NOZZLE, RECOMMENDATION AT THIS TIME IS TO DO A THROUGH INSPECTION OF THE NOZZLES WHEN THEY ARE REMOVED FOR CLEANING. 1 L 7 1 3O 3 O 3A15 E5CE 2005090800130 20050908 00130 EU 2005 9 8 2005FA0001266 1 20050825 G 2510 5110023000 SEAT ISRAEL 1125 ASTRASPX 4500205 EU GARRTT TFE731 TFE731* 01518 WP BACKREST FRAME BROKEN B JGVR O OTHER O OTHER NR NOT REPORTED 1 CE 09 882GA 2360 082 DURING REUPHOLSTERY OF PILOT SEAT, FOUND BACKREST FRAME BROKEN. CONTACTED MFG AND WAS GIVEN REPAIR TO ADD WELDED DOUBLE RS. (CE09200505050) (K) 2 L 7 2 4F 4 F RT A16NM E6WE 2005090800025 20050908 00025 CE 2005 9 8 2005FA0001267 1 20050825 G 7120 71 MOUNT BEECH 77 77 1153007 CE LYC O235 O235L2C 41505 EA SNSNCH 72C 72CK EA ENGINE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 WP 25 38026 WA202 L2127315 K3278 THE UPGRADED ENGINE MOUNT WAS FOUND CRACKED. A PLUG USED TO RELIEVE WELDING PRESSURE AND ADD ADD LINSEED OIL APPEARS TO THE THE PROBLEM (STRESS RISER? ETC) THE LINSEED OIL ESCAPED AND MADE A PERFECT CRACK INDICATION WITHOUT USE OF DYE PENE TRANT. THE OLDER STYLE, -1 MOTOR MOUNT DOES NOT HAVE PLUGS IN THIS AREA. (K) 1 L 7 1 3O 3 O A30CE E223 5 N P9045 2005091500014 20050915 00014 SO 2005 9 15 2005FA0001272 2 20050825 G 8520 639468 CRANKCASE CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO ENGINE CRACKED G A UNSCHED LANDING K FLUID LOSS CR CRUISE 1 EA 21 711TX 3459 514 421C0165 241213R OPERATOR COMPLAINT OF SMALL OIL LEAKS IN CRUISE FLIGHT. CLEANED ENGINE AND RAN, TO INSPECT FOR OIL LEAKS. AFTER EXTENS IVE VISUAL INSPECTION AND DYE PENETRANT INSPECTIONS (3) CRACKS IN THE CRANKCASE WERE DISCOVERED. (2) CRACKS WERE NOTED EXTENDING FROM TOP FORWARD CASE HALF BOLT HOLES. (1) CRACK WAS NOTED ON THE TOP LEFT CASE UNDER THE MAGNETO AREA. (K) 1 L 7 2 3O 3 O A7CE E7CE 2005103100148 20051031 00148 EU 2005 10 31 2005FA0001274 1 20050907 G 6720 704A3413023 CONTROL CABLE SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE TAIL ROTOR FAILED D A UNSCHED LANDING F J FLT CONT AFFECTED WARNING INDICATION NR NOT REPORTED 1 WP 07 353FB 303 3926 IN FORWARD FLIGHT, TAIL ROTOR CONTROL DEVELOPED SEVERE BINDING. FOUND CONTROL CABLE TO HAVE INTERNAL FAILURE. ALIGNMEN T OF CABLE THROUGH THE REAR BULKHEAD TO THE BELLCRANK CAUSING SIDE PRESSURE ON THE INTERNAL SHAFT IN THE CABLE POSSIBLY CAUSING THE BINDING. (K) 1 G 7 1 3U 3 U H9EU E00054EN 2005092600091 20050926 00091 2005 9 26 2005FA0001276 1 20050831 G 8011 ES6462751 STARTER ENGINE DAMAGED B WS9R K NONE O OTHER IN INSP/MAINT 1 NM 07 STARTER NEW OUT OF BOX, TOO TIGHT. 8130-3 STATES ONLY APPLICABLE FOR MFG SRS, BUT IS APPLICABLE TO MANY OTHER MFG ENGIN ES. 2005091500008 20050915 00008 NM 2005 9 15 2005FA0001279 1 20050824 G 3820 ES71183206400DK WATER HEATER BOEING 767 7672AX 1387000 NM GE CF6 CF680 30025 NE GALLEY FAILED B K NONE O OTHER IN INSP/MAINT 1 SW 05 767A 33685 FA COMPLAINED ABOUT NO HOT WATER AT GALLEY SINK SHORTLY BEFORE LANDING. ONCE ON GROUND, MAINTENANCE EXPOSED WATER HEATE R, GOT HEAVY BURNED SMELL. REMOVED FALSE PANEL COVERING WATER HEATER, NOTED THAT NO CB EITHER ON UNIT OR ON GALLEY CB P ANEL HAD TRIPPED. DECIDED TO LOOK AT INSIDE OF INSTALLED UNIT TO SEE IF THERE WAS SOMETHING THAT COULD BE REPAIRED. LO OKED AS THOUGH THERE WAS A FIRE INSIDE OF UNIT. IT BURNED ITSELF OUT, NO EXTERNAL DAMAGE WAS DONE. PRIOR TO OPENING AR EA WHERE HEATER IS INSTALLED, THERE WAS NO SMELL ANYWHERE IN GALLEY FROM THE FIRE, NO CB TRIPPED. UNIT WAS REMOVED FROM AC AND SENT TO THE MFG. NO REASON OR CAUSE HAS BEEN FOUND AT THIS TIME. (SW05200511531) (K) 2 L 7 2 4F 4 F RT A1NM E13NE 2005092000073 20050920 00073 EU 2005 9 20 2005FA0001280 1 20050829 G 2120 14632112 SHUTOFF VALVE AMD FALC20 FALCONF 2720306 EU GE CF700 CF700* 30010 NE P3 INTERMITTENT D K NONE O OTHER IN INSP/MAINT 1 SW 15 312K 324 INSTALLED O/H VALVE. PERFORMED LEAK CHECKS OF VALVE WITH NO DEFECTS NOTED. AC NOTED LOW AIRFLOW ON GROUND. OPS CHECKE D PRESSURIZATION ON GROUND AND FOUND THAT AC WOULD NOT PRESSURIZE. TROUBLESHOT VALVE AND DETERMINED THAT THE VALVE INST ALLED WAS MALFUNCTIONING. VALVE WOULD ONLY MOVE INTERMITTENTLY. FURTHER REVIEW FOUND THAT THE VALVE WAS PREVIOUSLY O/H DUE TO SAME REASON. NO RECOMMENDATIONS FOR PREVENTING RECURRANCE EXCEPT FOR METHODS AND STANDARDS REVIEW OF THE REPAIR STATION THAT OVERHAULED THE PART. (K) 2 L 7 2 4F 4 F A7EU E7EA 2005091500005 20050915 00005 SO 2005 9 15 2005FA0001281 1 20050823 G 5270 587817 SWITCH PIPER PA31 PA31P 7103120 SO LYC O541 TIGO541* 41539 EA CABIN DOOR OPEN B E81R K NONE N FALSE WARNING IN INSP/MAINT 1 GL 03 527CB 31P7730001 CONFIRMED REPORT OF CABIN DOOR UNSAFE ANNUNCIATOR REMAINING ILLUMINATED W/DOOR CLOSED. FOUND UPPER CENTER BAYONET RECEP TACLE SWITCH TO HAVE OPEN CONTINUITY IN ANY POSITION. FOUND WIRE L11T PREVIOUSLY JUMPERED TO DOOR SEAL PRESSURE SWITCH GROUND AND DOOR WARNING RELAY JUMPERED AROUND FROM L11T CONNECTION TO GROUND CONNECTION BY PERSONS OR FACILITY UNKNOWN. NO RECORDS IN US AC LOGBOOKS OF REPAIRS IN THIS AREA. REPLACED BAYONET SWITCH W/NEW SWITCH AND REPAIRED/CORRECTED SYST EM WIRING TO AS SHOWN IN SRM WIRING DIAGRAMS. DOOR WARNING ANNUNCIATOR OPERATIONAL CHECKS NOW NORMAL. (K) 1 L 7 2 3O 3 O A8EA E19EA 2005091500010 20050915 00010 CE 2005 9 15 2005FA0001282 1 20050817 G 3260 5EN16 SWITCH BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE NLG FAILED B E81R O OTHER N FALSE WARNING LD LANDING 1 GL 03 430CW RK30 LANDING GEAR SYS RED (GEAR UNSAFE) WARNING LIGHT REMAINED ILLUMINATED FOLLOWING GEAR EXTENSION WHILE LANDING. ALL (3) G REEN LANDING GEAR DOWN AND LOCKED POSITION INDICATING LIGHTS ILLUMINATED. AC FERRIED FOR REPAIRS. FOUND LT MLG DOOR PO SITION SWITCH S097 FAILED INTERNALLY. REPLACED S097 SWITCH ASSY WITH SERVICEABLE UNIT, LANDING GEAR RETRACT/EXTENSION S YSTEM TESTS NORMAL. TRANSIENT AIRCRAFT, UNABLE TO DETERMINE TT ON FAILED SWITCH. SUGGEST THAT LG POSITION INDICATING S WITCHES BE SCHEDULED REPLACEMENT ITEMS. PROBABLY IN CONJUNCTION WITH LANDING GEAR 7400 HR/5000 CYCLE INSPECTIONS. SUGG EST REPLACING POSITION SWITCHES WITH IMPROVED HERMETICALLY SEALED TYPE SWITCHES AS THEY REQUIRE REPLACEMENT. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2005092600084 20050926 00084 SO 2005 9 26 2005FA0001283 2 20050907 G 7322 MA3SPA CARBURETOR CESSNA 150 150G 2071816 CE CONT O200 O200A 17020 SO ENGINE MISMANUFACTURED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 SW 99 1996739A ENGINE HAD BAD HESITATION ON TAKEOFF ACCELERATION. SURGING OCCURRED DURING CLIMB WITH RPM FLUCTUATIONS OF +/- 50-75 RPM . AIRCRAFT AND ENGINE FUEL SCREENS WERE REMOVED AND INSPECTED 3 TIMES IN THE LAST 50 HOURS WITH NO EVIDENCE OF CONTAMIN ATION. FUEL LINE TO CARBURETOR WAS REPLACED. NONE OF THESE ACTIONS WERE OF HELP. CARBURETOR WAS REMOVED AND SENT BACK TO FACTORY SERVICE CENTER. THEY REPORTED ORANGE PARTICLES IN THE BOWL AND AN ORANGE BUILDUP IN THE VENTURI AREA. SINC E NO CONTAMINATION WAS FOUND IN EITHER THE CARB OR AIRCRAFT SCREENS OR THE FUEL SAMPLES; THE SUBMITTER SUSPECTS CONTAMIN ATION DURING ASSEMBLY BY EITHER PRESERVATIVE OR SOME OTHER SUBSTANCE. CARB HAD 101 HOURS SINCE RECONDITIONING. (K) 1 H 7 1 3O 3 O 3A19 E252 2005091900029 20050919 00029 SO 2005 9 19 2005FA0001284 1 20050908 G 2497 PF1416 WIRE PRESTOLITE PIPER PA23 PA23250 7102308 SO LYC O540 TIO540* 41532 EA ALTERNATOR CHAFED G H DEACTIVATE SYST/CIRCUITS H ELECT. POWER LOSS-50 PC TO TAKEOFF 1 NE 01 2548Z VARIOUS 278054047 LT ALT NR1 FAILED. REPAIRED WIRING CONNECTIONS, REPLACED ALT AND REG. LT ALT NR 2 FAILED ON T/O. FOUND FIELD WIRE SEG I NNER INSULATION CRACKED, BARE UNDER SHIELDING. HEATSHRINK TUBING ADDED TO MAKE INSTALLATION NEATER, FORCED SHIELDING INT O CONTACT WITH PRIMARY CONDUCTOR BRINGING FIELD TO GROUND. SPLICED IN NEW WIRE SEG. LT ALT NR3 FAILED AFTER 2 FLIGHTS. F OUND FIELD WIRE SEG PF-14-16 AT WING CNTR LAYING ON BELLY SKIN AND CHAFED THROUGH. WING CNTR DID NOT HAVE STRAIN RELIE F BACKSHELL INSTALLED,WAS NOT SECURED AWAY FROM SKIN. CHAFED AREA WAS 2 INCHES OF CONNECTOR. SPLICED NEW WIRE SEG, SECU RED WIRE BUNDLE CLEAR OF SKIN. REPLACED ALT (INSTALLED NR 4) AND REG. FIELD WIRE IS NOT PROTECTED BY A FUSE OR CB. 1 L 7 2 3O 3 O 1A10 E14EA 2005092600064 20050926 00064 SW 2005 9 26 2005FA0001285 1 20050827 G 5210 269A475511 HINGE HUGHES 269 269C1 8059504 SW LYC O360 HIO360* 41514 EA PAX DOOR FAILED B HA4R K NONE O OTHER IN INSP/MAINT 1 SO 15 1542D 367 0198 THE DOOR PIN PORTION OF THE HINGE, WHICH IS RESPONSIBLE RETAINING THE DOOR, FAILED. THIS LEAVES THE DOOR CONNECTED AT O NLY ONE POINT AND AN IN-FLIGHT FAILURE COULD POTENTIALLY ALLOW THE DOOR SEPARATE FROM THE AIRCRAFT. (K) 1 G 7 1 3O 3 O O 4H12 1E10 2005092600065 20050926 00065 SW 2005 9 26 2005FA0001286 1 20050830 G 5343 269A475511 HINGE HUGHES 269 269C1 8059504 SW LYC O360 HIO360* 41514 EA PAX DOOR BROKEN B HA4R O OTHER O OTHER CR CRUISE 1 SO 15 1567C 304 0203 THE DOOR PIN PORTION OF THE HINGE, WHICH IS RESPONSIBLE RETAINING THE DOOR, BROKE IN FLIGHT AND THE DOOR WAS UNSECURED A T THE LOWER CONNECTING POINT. THE FLIGHT CREW LANDED, THE DOOR WAS SECURED TEMPORARILY AND THE AIRCRAFT RETURNED TO THE MAINTENANCE FACILITY. (K) 1 G 7 1 3O 3 O O 4H12 1E10 2005103100105 20051031 00105 SW 2005 10 31 2005FA0001287 1 20050829 G 2497 WIRE HARNESS MOONEY M20 M20R 5870225 SW CONT O550 IO550* SO CONTROL PANEL BURNED B MPYR O OTHER O OTHER NR NOT REPORTED 1 SW 17 366GJ 170 290366 WHEN TROUBLESHOOTING, THE SQUAWK (RECOGNITION LIGHTS ON ALL THE TIME) WE FOUND CARRED WIRE INSULATION IN THE WIRE HARNES S FEEDING THE OVERHEAD BANK OF SWITCHES THAT CONTROL THE SHIPS EXTERIOR LIGHTING. WE TRACED THE CHARRED INSULATION TO A N OVERHEATED CONDITION IN THE RECOGNITION LIGHT CIRCUIT. A SUBSTANDARD CRIMP ON A WIRE TERMINAL WAS REPAIRED AND THE OV ERHEATED CONDITION WAS NOT NOTED AFTER THAT. THE (LIGHTS ON ALL THE TIME) SQUAWK WAS DUE TO THE CHARRED INSULATION ALLO WING POWER DIRECTLY TO THE RECOG LIGHTS, CIRCUMVENTING THE SWITCH. (K) 1 L 7 1 3O 3 O RT 2A3 E3SO 2005092000075 20050920 00075 SW 2005 9 20 2005FA0001288 1 20050829 G 2497 WIRE HARNESS MOONEY M20 M20R 5870225 SW CONT O550 IO550* SO COCKPIT BURNED B MPYR K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 SW 17 366GJ 170 290366 WHEN TROUBLESHOOTING THE SQUAWK (RECOGNITION LIGHTS ON ALL THE TIME), FOUND CHARED WIRE INSULATION IN THE WIRE HARNESS F EEDING THE OVERHEAD BANK OF SWITCHES THAT CONTROL THE SHIPS EXTERIOR LIGHTING. TRACED THE CHARRED INSULATION TO AN OVER HEATED CONDITION IN THE RECOGNITION LIGHT CIRCUIT. A SUBSTANDARD CRIMP ON A WIRE TERMINAL WAS REPAIRED AND THE OVERHEAT ED CONDITION WAS NOT NOTED AFTER THAT. THE (LIGHTS ON ALL THE TIME) SQUAWK WAS DUE TO THE CHARRED INSULATION ALLOWING P OWER DIRECTLY TO THE RECOG LIGHTS, CIRCUMVENTING THE SWITCH. (K) 1 L 7 1 3O 3 O RT 2A3 E3SO 2005103100116 20051031 00116 NE 2005 10 31 2005FA0001289 2 20050621 G 7261 1710M83P05 SEAL BOEING 777 777* UTILUSE NM GE GE90 GE9090B NE HPT ROTOR FAILED B QEMY K NONE K FLUID LOSS IN INSP/MAINT 1 EA 35 11468 M900188 HZAKA1 DURING ENGINE O/H UPON EXPOSURE OF THE HPT ROTOR, EVIDENCE OF HEAT DISTRESS WAS NOTED AT THE AFT SEAL LOCATION. THE HPT R AFT SEAL SUMP SEAL TEETH AND OIL SLING PRESENTED PLASTIC DEFORMATION AND HEAT DISTRESS. THE COMPONENT WAS RETURNED TO OEM FOR INVESTIGATION. (K) 2 L 7 2 4F 4 F RT T00001SE E00049EN 2005091900049 20050919 00049 EA 2005 9 19 2005FA0001290 2 20050915 G 7261 AA48111 OIL FILTER CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA ENGINE LEAKING D K NONE K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 SO 15 431ER 21 172S9165 L3042351A INSPECTION OF AIRCRAFT FOLLOWING PILOTS COMPLAINT OF BURNING SMELL IN COCKPIT, AND OIL ON LOWER PART OF AIRCRAFT, REVEAL ED OIL LEAKING FROM THE BASE SEAM OF THE OIL FILTER. THE OIL LEVEL HAD GONE DOWN ONE HALF QUART IN THE ONE HOUR FLIGHT. THE LEAK WAS NOT FROM THE FILTERS BASE SEAL AND HAD BEEN PROPERLY TORQUED AND SAFETY WIRED IN PLACE. NO DAMAGE WAS VIS IBLE ON THE FILTER. 1 H 7 1 3O 3 O NT 3A12 1E10 2005091900050 20050919 00050 CE 2005 9 19 2005FA0001291 1 20050902 G 2750 CONTROL TUBE CESSNA 140 140 2071602 CE CONT O240 IO240A SO FLAP SYSTEM CORRODED H K NONE O OTHER IN INSP/MAINT 1 WP 23 89671 8719 THE IB RT FLAP AND SECTION OF THE FLAP CONTROL TUBE WERE EXAMINED. THE CONTROL TORQUE TUBE WELD CONTAINED SURFACE CORRO SION AND A FATIGUE CRACK WAS NOTED. 1 H 7 1 3O 3 O NC A768 E7SO 2005091900074 20050919 00074 EA 2005 9 19 2005FA0001292 2 20050909 G 8530 LW12988 CYLINDER BEECH 18 E18S 1151006 CE LYC O540 IO540* 41532 EA NR 1 DAMAGED D K NONE O OTHER IN INSP/MAINT 1 NM 08 700W BA54 RL283761A DURING ANNUAL INSPECTION, IT WAS DISCOVERED DURING A DIFFERENTIAL COMPRESSION CHECK THAT THE NR 1 CYLINDER ON THIS ENGIN E HAD ALMOST NO COMPRESSION. IT WAS DISCOVERED THAT THE EXHAUST VALVE GUIDE WAS BAD. ALSO, THE EXHAUST VALVE AND INTAKE VALVE HAD TO BE REPLACED. THIS CYLINDER WAS ON AN ENGINE THAT HAD BEEN RECALLED FOR THE CRANKSHAFT REPLACEMENT AD AND HA D ALL CYLINDERS REPLACED AT THAT TIME. THE CYLINDER HAD 149 HOURS IN SERVICE SINCE NEW. MFG WAS NOTIFIED OF THIS PROBLEM BUT WAS NOT INTERESTED. THE CYLINDER WAS REPAIRED. 1 L 7 2 3R 3 O A765 1E4 2005091900119 20050919 00119 CE 2005 9 19 2005FA0001294 1 20050915 G 5520 BOLT BBAVIA 8 8KCAB 2110612 CE LYC O360 AEIO360* EA ELEVATOR MISINSTALLED B K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 28 912MA 9482004 DURING PREFLIGHT THE PILOT FOUND EXCESSIVE MOVEMENT IN THE LT OB ELEVATOR HINGE PIN. MAINTENANCE REMOVED BOTH ELEVATORS AND THE RUDDER AND FOUND LONGITUDINAL SCORING ON ALL THE HINGE BOLTS (AN23-40) APPARENTLY CAUSED DURING MFG OF THE AIRC RAFT. THE LONGITUDINAL SCORING WAS CAUSED BY THE CENTER NEEDLE BEARING (PN B34PS) ON THE ELEVATOR AND RUDDER. CIRCUMFE RENTIAL SCORING WAS ALSO PRESENT ON ALL BOLTS APPARENTLY CAUSED BY IMPROPERLY ALIGNED AND REAMED BUSHINGS (PN 1-3737-1) ON THE HORIZONTAL AND VERTICAL STABILIZER HINGES. THE MFG WAS CONTACTED CONCERNING THE PROBLEM. THE SAME CONDITION IS PRESENT IN SN 943-2004. 1 H 7 1 3O 3 O A21CE 1E10 2005102600205 20051026 00205 EA 2005 10 26 2005FA0001295 2 20050909 G 8530 VALVE GUIDE LYC PIPER PA60 PA60602P 7106015 NM LYC O540 TIO540U2A 41532 EA CYLINDER BURNED C K NONE O OTHER IN INSP/MAINT 1 NM 08 149 62P088681650 RL283761A DURING ANNUAL INSPECTION, IT WAS DISCOVERED DURING A DIFFERENTIAL COMPRESSION CHECK THAT NR 1CYLINDER ON THIS ENGINE HAD ALMOST NO COMPRESSION. THE CYLINDER WAS REMOVED AND SENT, IT WAS DISCOVERED THAT THE EXHAUST VALVE GUIDE WAS BAD. THE G UIDE WAS REPLACED ALONG WITH THE INTAKE AND EXHAUST VALVES UNDER WORK ORDER NR 21110. THIS CYLINDER WAS ON AN ENGINE TH AT HAD BEEN RECALLED BY THE AD FOR THE CRANKSHAFT AND ALL CYLINDERS WERE REPLACED AT THAT TIME. THE CYLINDER HAD 149 HOU RS IN SERVICE SINCE NEW. MFG WAS CONTACTED REGARDING THIS PROBLEM AND WAS NOT EVEN INTERESTED IN DISCUSSING IT. 1 M 7 2 3O 3 O RT A17WE E14EA 2005102600209 20051026 00209 EA 2005 10 26 2005FA0001296 2 20050909 G 8530 VALVE GUIDE LYC PIPER PA60 PA60602P 7106015 NM LYC O540 TIO540U2A 41532 EA CYLINDER BURNED D K NONE O OTHER IN INSP/MAINT 1 NM 08 700WG 149 62P088681650 RL283761A DURING ANNUAL INSPECTION, IT WAS DISCOVERED DURING A DIFFERENTIAL COMPRESSION CHECK THAT THE NR 1 CYLINDER ON THIS ENGIN E HAD ALMOST NO COMPRESSION. THE CYLINDER WAS REMOVED AND SENT AND WAS DISCOVERED THAT THE EXHAUST VALVE GUIDE WAS BAD. THE GUIDE WAS REPLACED ALONG WITH THE INTAKE AND EXHAUST VALVES UNDER WORK ORDER NR 21110. THIS CYLINDER WAS ON AN ENGI NE THAT HAD BEEN RECALLED BY THE AD FOR THE CRANKSHAFT AND ALL CYLINDERS WERE REPLACED AT THAT TIME. THE CYLINDER HAD 14 9 HOURS IN SERVICE SINCE NEW. MFG WAS CONTACTED REGARDING THIS PROBLEM AND WAS NOT EVEN INTERESTED IN DISCUSSING IT. 1 M 7 2 3O 3 O RT A17WE E14EA 2005092600202 20050926 00202 SO 2005 9 26 2005FA0001297 1 20050809 G 3210 LANDING GEAR AMRGEN AA5 AA5A 3960106 SO LYC O320 O320* 41508 EA MLG NOISY D O OTHER O OTHER NR NOT REPORTED 1 EA 31 9920U AA5A0320 FOUND THAT WHEN MOVING THE PILOT SEAT THERE WAS A SCRATCHING NOISE AS PLASTIC SLIPPING OVER EACH OTHER. FOUND CRACK IN PART OF THE LANDING GEAR. 1 L 7 1 3O 3 O A16EA E274 2005092000080 20050920 00080 SO 2005 9 20 2005FA0001299 2 20050915 G 7414 ROTOR SHAFT CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA MAGNETO SHEARED C O OTHER O OTHER TX TAXI/GRND HDL 1 WP 25 293D 768 250 03090897 824561R AF3178 UNSCHEDULED FAILURE OF THE LT ENGINE MAGNETO DURING ENGINE START. FOUND MAGNETO ROTOR SHAFT SHEARED AT POINTS CAM DRIVE END. 3 O E7SO 5 N TA4CH 2005092600062 20050926 00062 EA 2005 9 26 2005FA0001300 2 20050909 G 8530 72897 VALVE GUIDE PARTEN P68 P68C 6780105 EU LYC O360 IO360A1B6 41514 EA EXHAUST VALVE STUCK B IGAR O OTHER O OTHER LD LANDING 1 WP 01 300LF 842 295 DURING LANDING, RT POSITION ENGINE EXPERIENCED ROUGHNESS. FOUND CYLINDER NR 2 EXHAUST VALVE STUCK. VALVE GUIDE INSPECT IONS ARE DUE AT 1000 HOURS. ENGINE ONLY HAD 842.6 HRS. (K) 1 H 7 2 3O 3 O A31EU 1E10 2005092600060 20050926 00060 EA 2005 9 26 2005FA0001301 2 20050909 G 8520 72877 LIFTER PARTEN P68 P68C 6780105 EU LYC O360 IO360A1B6 41514 EA ENGINE BROKEN B IGAR K NONE O OTHER IN INSP/MAINT 1 WP 01 300LF 842 295 RL2071451A UPON COMPLYING WITH SB, VALVE GUIDE INSPECTION, FOUND LIFTER BODY PN 72877 BROKEN. VALVE GUIDE REVEALED NO SIGNS OF STI CKING. (K) 1 H 7 2 3O 3 O A31EU 1E10 2005092600058 20050926 00058 CE 2005 9 26 2005FA0001302 1 20050913 G 5410 J744442 MOUNT CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA COWLING TORN B DYTR K NONE O OTHER IN INSP/MAINT 1 SO 15 5027X 100 172S8966 DURING THE COURSE OF A ROUTINE 100 HOUR INSPECTION, 3 OF THE RUBBER (LORD) COWLING MOUNTS WERE FOUND TORN. THIS HAS BEE N A COMMON OCCURRENCE SEEN WHILE MAINTAINING A FLEET OF THIS MODEL AC OPERATED BY A FLIGHT SCHOOL. IF NOT ADDRESSED THI S COULD LEAD TO A LOSS OF THE ENGINE COWLING IN FLIGHT. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005092600063 20050926 00063 SW 2005 9 26 2005FA0001303 1 20050907 G 2497 430076506109 WIRE BELL 430 430 1182150 SW ALLSN 250C 250C40B 03032 NE BATTERY FAILED B NYXR K NONE O OTHER IN INSP/MAINT 1 EA 01 430SP 1137 49083 A LOOSE CONNECTION AT THE RING TERMINAL ON THE AIRCRAFT BATTERY CONNECTOR CAUSED SUFFICIENT HEAT BUILDUP TO MELT THE SEC URING NUT AND WASHER AND CHAR THE WIRING. THE PROBLEM WAS COMPOUNDED BY THE AIRCRAFT MFG USE OF IMPROPERLY SIZED RING T ERMINALS AT THIS CONNECTION. THE MS25036-127 TERMINAL ENDS SPECIFIED BY THE MFG, UTILIZE A (.4375 INCH) HOLE IN CONJUNC TION WITH (.2500 INCH) STUDS ON THE BATTERY CONNECTOR PN MS25182-2. THIS IS CONTRADICTORY TO STANDARD PRACTICE AS SPECI FIED IN AC. (K) 1 G 7 2 3U 3 U RT H9SW E1GL 2005103100055 20051031 00055 CE 2005 10 31 2005FA0001304 1 20050912 G 5410 J744442 MOUNT CESSNA 172 172R 2072401 CE COWLING TORN B DYTR O OTHER O OTHER NR NOT REPORTED 1 SO 15 78JA 100 17280622 THE RUBBER (LORD) MOUNTS USED TO ATTACH THE ENGINE COWLING TO THE AIRFRAME ARE FAILING AT A RATE OF ABOUT 3 MOUNTS EVERY 100 HOURS. MAINTAIN A FLEET OF THESE MODEL AIRCRAFT USED IN A FLIGHT SCHOOL ENVIRONMENT AND SEE THIS REGULARLY ON THES E AIRCRAFT. IF NOT CORRECTED THIS COULD CAUSE A LOSS OF THE ENGINE COWLING IN FLIGHT. (K) 1 H 7 1 3O NT 3A12 2005103100097 20051031 00097 CE 2005 10 31 2005FA0001305 1 20050830 G 2797 WIRE BEECH MU300 400A 1155402 CE PWA JT15 JT15* 52060 NE CONTROL WHEEL DAMAGED B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 494CW RK4 INVESTIGATED REPORT OF HORIZONTAL STABILIZER TRIM INOPERATIVE AND SYSTEM CIRCUIT BREAKER TRIPPING WHEN TRIM ACTUATED ON LANDING. CREW REPORTED NORMAL TRIM OPERATIONS SLOW JUST PRIOR TO FAILURE. FOUND BARE WIRING IN COPILOTS CONTROL WHEEL AT PITCH TRIM SWITCH. REPAIRED WIRING AS REQUIRED. HORIZONTAL STABILIZER TRIM OPERATIONS NORMAL AFTER REPAIRS. SUGGES T WIRING IN THIS AREA HAVE BEETER STRAIN RELIEF/CHAFE PROTECTION. (K) 2 H 7 2 4F 4 T RT A16SW E1NE 2005092600079 20050926 00079 CE 2005 9 26 2005FA0001306 1 20050908 G 2460 4TP110 SWITCH RAYTHN DH125 HAWKER800XP 7150012 CE GARRTT TFE731 TFE731* 01518 WP CONTROL PANEL FAILED B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 934RD 258296 INVESTIGATED BATTERY POWER NOT CONNECTING TO AIRCRAFT BUSSES. FOUND OVERHEAD PANEL BATTERY POWER SELECT SWITCH (IDENTIF IER (EN)) FAILED. REPLACED SWITCH ASSY, BATTERY POWER, ENGINE START OPERATIONS NORMAL. (K) 2 L 7 2 4F 4 F RT A3EU E6WE 2005103100104 20051031 00104 CE 2005 10 31 2005FA0001307 1 20050908 G 8097 CONNECTOR RAYTHN DH125 HAWKER800XP 7150012 CE GARRTT TFE731 TFE731* 01518 WP ENGINE STARTER LOOSE B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 934RD 258296 INVESTIGATED ENGINE NR 1 AND ENGINE NR 2 STARTERS NOT ROTATING WHEN START SEQUENCE INITIATED. FOUND WIRING CONNECTORS L OOSE ON PANEL ZL INTERNAL START CONTACTOR (U) TERMINALS (CONTACTOR, PN A84MAS). RETORQUED WIRING TERMINALS, ENGINE STAR T OPERATIONS, NORMAL. (K) 2 L 7 2 4F 4 F RT A3EU E6WE 2005103100112 20051031 00112 CE 2005 10 31 2005FA0001308 1 20050902 G 5510 FASTENER BEECH BEECH MU300 400A 1155402 CE PWA JT15 JT15* 52060 NE VERTICAL STAB LOOSE B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 907JE RK107 RK107 DURING SCHEDULED 1ST (D) INSPECTION FOUND HI-LOK PIN COLLAR LOOSE (UPPER HEX SECTION STILL INTACT) FOR (1) FASTENER (OF 3) ATTACHING PN 454A23202-3 LT VERTICAL STABILIZER PIVOT PLATE TO VERTICAL STABILIZER AFT SPAR, UPPER LT SIDE. AREA IS JUST BELOW WHERE PN 45A61505-11 ELEVATOR CONTROL ATTACH BRACKET IS INSTALLED. HI-LOK PIN FOUND STILL SECURE, COLLAR TOR QUED DOWN AND SNAPPED OFF NORMALLY WHEN TIGHTENED. SUSPECT COLLAR STARTED BUT NOT TORQUED DOWN AT MFG OR DURING SUBSEQU ENT POSSIBLE UNDOCUMENTED REPAIRS THIS AREA. AREA SHOULD BE VISIBLE DURING NORMAL (C) CHECKS OR WHEN AFT VERTICAL STABI LIZER/ HORIZONTAL STABILIZER FAIRING IS REMOVED. (K) 2 H 7 2 4F 4 T RT A16SW E1NE 2005103100106 20051031 00106 SW 2005 10 31 2005FA0001309 1 20050903 G 6200 047120252011 GRIP BELL 47 47G3B1 1181028 SW LYC O435 TVO435* 41516 EA MAIN ROTOR CRACKED B QH5R O OTHER O OTHER NR NOT REPORTED 1 NM 07 8554F 6508 MAIN ROTOR GRIP, CRACK IN THREADS. (K) 1 G 7 1 3O 3 O 2H3 1E13 2005103100022 20051031 00022 CE 2005 10 31 2005FA0001310 1 20050909 G 2497 CV7313 DIODE RAYTHN DH125 HAWKER800XP 7150012 CE GARRTT TFE731 TFE731* 01518 WP LOOSE FAILED B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 934RD 258296 INVESTIGATED LOSS OF BATTERY POWER AFTER AIRCRAFT DC BUSSES POWERED-UP FOR 4 TO 5 MINUTES. FOUND COLD-SOLDIER JOINT ON EQUIPMENT PANEL ZL DIODE (P) WIRING CONNECTIONS. REPAIRED SOLDIER CONNECTIONS AS REQUIRED, OPS CHECK NORMAL. (K) 2 L 7 2 4F 4 F RT A3EU E6WE 2005103100110 20051031 00110 CE 2005 10 31 2005FA0001311 2 20050909 G 8500 ENGINE CESSNA 337 P337H 2075731 CE CONT IO360 IO360* 17025 CE LT AND RT STOPPED D A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CR CRUISE 1 GL 03 37E P3370127 DURING CRUISE CLIMB, PILOT REPORTED BOTH ENGINES QUIT RUNNING AND DEVERTED. DURING DECENT ENGINES CAME BACK TO LIFE. S UMPED 1 PINT EACH FROM FRONT, BACK FUEL STRAINERS, LT AND RT WING DRAINS. FUEL APPEARED NORMAL COLOR BLUE AND NO CONTAM INATES FOUND. (K) 1 H 7 2 3O 3 O A6CE E1CE 2005092600175 20050926 00175 EU 2005 9 26 2005FA0001312 1 20050809 G 2150 451400003 DRIVE BELT SNIAS 350 AS350B1 8680811 EU TMECA ARRIEL ARRIEL1D1 NE AIR CONDITIONER FAILED B CDBR O OTHER O OTHER NR NOT REPORTED 1 EA 05 311SJ 3583 9818 AIR CONDITIONER DRIVE BELT FOUND SHREDDED ON ENGINE DECK, FAILED SEVERAL TIME IN HISTORY OF AC. REPLACED AC COMPRESSOR AND DRYER ASSY THINKING COMPRESSOR SEIZURE WHEN HOT. BELT REQUIRED, MM SHOWS 30 LBS TENSION REQUIRED. BELT INSTALLED TO SPECS WAS OPERATED FOR A LENGTH OF TIME ON GROUND, THEN AS THE MM SPECIFIES, TURNED OFF FOR TAKEOFF. WHEN THE AC WAS R E-ACTIVATED IN FLIGHT, PILOT REPORTS A BURNING SMELL AND THE AIR TEMP CAME OUT WARM. AC WAS RETURNED TO HELIPORT WHERE THE BELT WAS AGAIN FOUND SHREDDED. MFG STATES THAT DRIVE BELT AND TENSIONING LISTED IN MM IS NOT CORRECT BELT OR TENSIO N. REQUIREMENT TO DEACTIVATE AC FOR TAKE-OFF REMOVED. MFG PARTS MANUAL, TO REQUIRE NOTICE OF STC`D PARTS. (K) 1 G 7 1 3U 3 U H9EU E19EU 2005092300093 20050923 00093 CE 2005 9 23 2005FA0001313 1 20050919 G 3251 59420011 BELLCRANK CESSNA 421 421C 2076016 CE CONT O520 GTSIO520* 17032 SO NLG STEERING CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 01 2740B 421C1249 PILOT SAID PRESSURE REQUIRED TO MOVE RUDDER PEDALS WAS NOT NORMAL ON PREFLIGHT INSPECTION. NOSE GEAR STEERING BELLCRANK WAS CRACKED THROUGH AND BROKEN APART ON THE LT SIDE OF THE CENTER MOUNTING RADIUS. THE RT SIDE OF THIS RADIUS ALSO IS CRACKED. 1 L 7 2 3O 3 O A7CE E7CE 2005092300094 20050923 00094 CE 2005 9 23 2005FA0001314 1 20050919 G 3251 59420011 BELLCRANK CESSNA 421 421C 2076016 CE CONT O520 GTSIO520* 17032 SO NLG STEERING CRACKED D K NONE O OTHER IN INSP/MAINT 1 CE 01 2740B 421C1249 PILOT SAID PRESSURE REQUIRED TO MOVE RUDDER PEDALS WAS NOT NORMAL ON PREFLIGHT INSPECTION. NOSE GEAR STEERING BELLCRANK WAS CRACKED THROUGH AND BROKEN APART ON THE LT SIDE OF THE CENTER MOUNTING RADIUS. THE RT SIDE OF THIS RADIUS ALSO IS CRACKED. 1 L 7 2 3O 3 O A7CE E7CE 2005092300149 20050923 00149 CE 2005 9 23 2005FA0001315 1 20050923 G 3260 DOWNLOCK SWITCH BEECH 90 C90 1152913 CE PWA PT6 PT6A21 52043 EA RT MLG OUT OF ADJUST E A UNSCHED LANDING J WARNING INDICATION AP APPROACH 1 GL 21 502SE LJ740 ON APPROACH THERE WAS NO RT MAIN GEAR INDICATION. CHECKED GEAR RIGGING AND ADJUSTED RT DOWNLOCK SWITCH IAW M/M. 1 L 7 2 3T 4 T 3A20 E4EA 2005092300153 20050923 00153 SO 2005 9 23 2005FA0001316 2 20050921 G 8530 SA10200 CYLINDER CONT O300 O300D 17022 SO ENGINE BROKEN C E ENGINE SHUTDOWN Y ENGINE STOPPAGE CR CRUISE 1 EA 03 1388 34897D6D ENGINE CYLINDER NR 6, CRACKED CIRCUMFERENTIALLY AND FULLY SEPARATED BETWEEN THE 12TH AND 13TH COOLING FINS AS COUNTED FR OM THE BASE OF THE CYLINDER CAUSING A COMPLETE LOSS OF ENGINE POWER. 3 O E253 2005102700088 20051027 00088 SO 2005 10 27 2005FA0001317 1 20050920 G 2810 BLADDER PIPER PA25 PA25235 7102504 SO LYC O540 O540* 41532 EA FUEL TANK COLLAPSED G A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 GL 21 4827Y 254618 FOUND AC TO HAVE DAMAGE TO L G BUNGEE, LT BOOM OB ATTACH POINT AT AFT WING CLOSEOUT. NO FUEL IN TANK, VERIFIED BY REMOVA L OF FUEL LINE AT FUEL VALVE ON BOTTOM OF TANK. FILLED TANK TO OVERFLOW CONDITION. WAS ONLY ABLE TO GET 23.2 OF 38 GAL LONS INTO TANK. FUEL BLAD PARTIALLY COLLAPSED, UNABLE TO BLOW AIR THROUGH FUEL VENT. LINE WAS PARTIALLY BLOCKED WHICH COULD HAVE CAUSED FUEL CONSUMPTION TO COLLAPSE BLAD UNHOOKING UPPER SNAPS. SB INSTALLS BOLT, WIDE AREA WASHER IN BOTTO M OF TANK DIRECTLY BELOW FUEL GAGE/FLOAT TO HOLD BLADDER IN PLACE. TANK/BLADDER TO BE INSP DURING AC REPAIR TO DETERMIN E IF BLOCKED VENT CAUSED UPPER BLADDER SNAPS TO UNHOOK COLLAPSING TANK, PREVENTING FULL USABLE FUEL CAPACITY. 1 L 7 1 3O 3 O 2A10 E295 2005103100131 20051031 00131 EU 2005 10 31 2005FA0001318 1 20050730 G 2612 9583820090 PROBE SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE FIRE DETECTION FAULTY B HXSR O OTHER J WARNING INDICATION NR NOT REPORTED 1 AL 05 6094E 2750 4035 PILOT REPORTED THAT HIS FIRE INDICATION LIGHT HAD FLICKERED A COUPLE OF TIMES BUT THEN WENT AWAY. LIGHT WOULD NOT FLICK ER ON THE GROUND WHILE NOT RUNNING. MECHANIC COULD NOT FIND THE FAULT. CLEANED THE CONNECTIONS AND FIRE DETECTION PROB ES AND TRIED A RUN UP. FIRE LIGHT AGAIN FLICKERED A COUPLE OF TIMES THEN WENT OUT. TROUBLESHOOTING AGAIN FOUND A FIRE DETECTION PROBE TO BE PROBABLE. CHANGED THE PROBE AND AGAIN RAN UP THE AC. THIS TIME THE FIRE SYSTEM WORKED IAW THE MM . TOOK THE AC FOR A FLIGHT TO DETERMINE PROPER FUNCTION UNDER FLIGHT LOADS AND AGAIN THE SYSTEM WORKS IAW MM. RETURNED THE AC TO SERVICE. (K) 1 G 7 1 3U 3 U NC H9EU E19EU 2005092600193 20050926 00193 EU 2005 9 26 2005FA0001319 1 20050723 G 2913 704A34310006 PUMP SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE HYDRAULIC SYS FAILED E HXSA O OTHER O OTHER NR NOT REPORTED 1 AL 05 6080R 2685 PILOT WAS ON HIS INTENDED ROUTE AND NOTIFIED OPERATIONS BASE THAT HE WAS TURNING AROUND AND THAT HAD LOST HYDRAULIC ASSI ST TO FLIGHT CONTROLS. RETURNED TO BASE AND LANDED WITH NO INCIDENT. MAINT FOUND THAT THE HYDRAULIC PUMP SPLINES HAD F AILED AND REMOVED AND REPLACED WITH A SERVICEABLE PUMP. AC HAS BEEN RETURNED TO SERVICE. (K) 1 G 7 1 3U 3 U NC H9EU E19EU 2005092600176 20050926 00176 GL 2005 9 26 2005FA0001320 2 20050825 G 7200 23034787 BEARING HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE FAILED B HXSR O OTHER O OTHER NR NOT REPORTED 1 AL 05 8357F 1265 170069D 832729 ENGINE CHIP LIGHTS FOLLOWED BY ENGINE NOISE. (K) 1 G 7 1 3U 3 U H3WE E4CE 2005103100092 20051031 00092 CE 2005 10 31 2005FA0001321 1 20050912 G 3240 LINE BEECH MU300 400A 1155402 CE PWA JT15 JT15D1 52060 NE HYD SYSTEM DAMAGED B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 907JE RK107 DURING COMPLIANCE WITH INSPECTION PORTION OF SB NOTED CHAFE DAMAGE TO PN 128580101-1 NOTED CHAFE DAMAGE TO PN 128-580101 -1 HYDRAULIC BRAKE LINE FROM ADJACENT FLOORBOARD ATTACH SCREW. DAMAGE FOUND LESS THAN 10 PERCENT OF TUBING WALL THICKN ESS. RECOMMEND THAT THIS SB BE MADE AT LEAST A MANDATORY COMPLIANCE ITEM. SEVERAL OF THE AFFECTED AC INSPECTED AT THI S FACILITY HAVE SHOWN EVIDENCE OF DAMAGE IN THIS AREA. (K) 2 H 7 2 4F 4 F RT A16SW E1NE 2005103100026 20051031 00026 EA 2005 10 31 2005FA0001322 2 20050901 G 7414 M3548 ROTOR PIPER PA28 PA28181 7102807 SO LYC O360 O360* 41514 EA MAGNETO CRACKED B UC2R O OTHER O OTHER NR NOT REPORTED 1 GL 19 4145A 482 99121536 2843150 L3620536A DURING A ROUTINE 500 HR INSPECTION, THE ROTOR SHAFT WAS FOUND CRACKED AT THE BOTTOM OF THE CAM SLOT. THE CAUSE IS UNKNO WN. THIS IS THE THIRD SUCH DEFECT FOUND IN THIS SERIES OF MAGNETOS IN A YEAR. (K) 1 L 7 1 3O 3 O 2A13 E286 2005103100027 20051031 00027 EA 2005 10 31 2005FA0001323 2 20050901 G 8520 CRANKSHAFT PIPER PA44 PA44180 7104402 SO LYC O360 LO360A1G6 41514 EA ENGINE FAILED D O OTHER O OTHER NR NOT REPORTED 1 SO 15 239AT 4496038 L62571A APPARENT CRANKSHAFT FAILURE: JUST AFTER TAKEOFF ENGINE STARTED VIBRATING VIOLENTLY. SHUTDOWN AND LANDED SAFETLY. ENGI NE WAS SPLIT IN HALF. PROP WAS ANGLED DOWN AS FRONT HALF OF ENGINE WAS ANGLED DOWN. (K) 1 L 7 2 3O 3 O A19S0 1E10 2005103100100 20051031 00100 CE 2005 10 31 2005FA0001325 1 20050916 G 2750 C3010020110 MOTOR CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA TE FLAP MALFUNCTIONED B MYNR O OTHER O OTHER NR NOT REPORTED 1 GL 11 915MA 1500 172S8260 FOUND FLAP MOTOR LOOSE ON TRANSMISSION, CAUSING STATIC IN RADIOS WHEN FLAPS IN TRANSIT TIGHTENED MOTOR ALL OPS GOOD. (K ) 1 H 7 1 3O 3 O NT 3A12 1E10 2005103100197 20051031 00197 CE 2005 10 31 2005FA0001326 1 20050914 G 2710 05232333 CONTROL CABLE CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA LT WING AILERON WORN B WIWR O OTHER O OTHER NR NOT REPORTED 1 WP 07 5275S 172S9203 DURING 100 HOUR INSPECTION, WHILE INSPECTING AILERON CABLES, FOUND FLAT SPOT ON THE LT AILERON CROSSOVER CABLE AT THE AI LERON CABLE ABRASION STRIP ATTACHED TO A RIB ASSEMBLY LOCATED AT WING STATION 71.19. FURTHER INVESTIGATION FOUND THE CA BLE BEGINNING TO FRAY. THE CAUSE IS THE CABLE WEARING ON THE ABRASION STRIP. TO SOLVE THIS PROBLEM , THE ABRASION STRI P BE LOWERED OR A PULLEY BE INSTALLED. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005102800132 20051028 00132 CE 2005 10 28 2005FA0001327 1 20050914 G 5720 05232333 STRIP CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA LT WING UNSERVICEABLE B WIWR O OTHER O OTHER NR NOT REPORTED 1 WP 07 141CW 172S9389 DURING 100 HOUR INSPECTION, WHILE INSPECTING THE AILERON CABLES, FOUND A FLAT SPOT ON THE LT AILERON CROSSOVER CABLE AT THE AILERON CABLE ABRASION STRIP ATTACHED TO A RIB ASSEMBLY LOCATED AT WING STATION 71.19. FURTHER INVESTIGATION FOUND THE CABLE BEGINNING TO FRAY. THE CAUSE IS THE CABLE WEARING ON THE ABRASION STRIP. TO SOLVE THIS PROBLEM, THE ABRASIO N STRIP BE LOWERED OR A PULLEY BE INSTALLED. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005103100229 20051031 00229 CE 2005 10 31 2005FA0001328 1 20050914 G 5720 05232333 STRIP CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA LT WING UNSERVICEABLE B WIWR O OTHER O OTHER NR NOT REPORTED 1 WP 07 2134M 172S9552 WHILE INSPECTING FOR STORM DAMAGE, DURING THE INSPECTION OF THE AILERON CABLES, FOUND A FLAT SPOT ON THE LT AILERON CROS SOVER CABLE AT THE AILERON CABLE ABRASION STRIP ATTACHED TO A RIB ASSEMBLY LOCATED AT WING STATION 71.19. FURTHER INVES TIGATION FOUND THE CABLE BEGINNING TO FRAY. THE CAUSE IS THE CABLE WEARING ON THE ABRASION STRIP. TO SOLVE THIS PROBLE M, THE ABRASION STRIP BE LOWERED OR A PULLEY BE INSTALLED. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005092900016 20050929 00016 CE 2005 9 29 2005FA0001329 1 20050821 G 7931 83278 PRESSURE SWITCH CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA OIL SYSTEM BLOWN H B EMER. DESCENT K J FLUID LOSS WARNING INDICATION CR CRUISE 1 SW 07 93AF 5321 17280073 RL211751A ORIGINAL OIL PRESSURE SWITCH HAD BEEN REPLACED PER SB SB00-79-01. THE REPLACEMENT SWITCH P/N 83278 FAILED ALLOWING ENGI NE OIL TO PASS THROUGH SWITCH AND VENT OVERBOARD. NTSB ACCIDENT NUMBER IS DFW05CA219. 1 H 7 1 3O 3 O NT 3A12 1E10 2005092900017 20050929 00017 CE 2005 9 29 2005FA0001331 1 20050821 G 7931 83278 PRESSURE SWITCH CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA OIL SYSTEM BLOWN H B EMER. DESCENT K J FLUID LOSS WARNING INDICATION CR CRUISE 1 SW 07 93AF 5321 17280073 RL211751A ORIGINAL OIL PRESSURE SWITCH HAD BEEN REPLACED PER SB SB00-79-01. THE REPLACEMENT SWITCH P/N 83278 FAILED ALLOWING ENGI NE OIL TO PASS THROUGH SWITCH AND VENT OVERBOARD. NTSB ACCIDENT NUMBER IS DFW05CA219. 1 H 7 1 3O 3 O NT 3A12 1E10 2005101300033 20051013 00033 SO 2005 10 13 2005FA0001332 2 20050724 G 7261 CH481091 OIL FILTER AMTR LANCAR LANCAIR 05616TS GL CONT O550 TSIO550E 17043 SO ENGINE FAILED C A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CE 03 619SJ 1 357 CHANGED OIL AND OIL FILTER PRIOR TO FLIGHT. WHILE IN CRUISE FLIGHT, OIL PRESSURE BEGAN DECLINING TO < 10PSI. NO RISE IN OIL TEMPERATURE. DECLARED EMERGENCY, LANDED UNEVENTFULLY. EXTENSIVE TROUBLESHOOTING REVEALED NEW OIL FILTER TO BE CAUSE OF DECLINING PRESSURE PROBLEM (<10 PSI). PILOT EXPERIENCED SAME PROBLEM (LOSS OF OIL PRESSURE (0 PSI) ABOUT ONE HOUR INT O FLIGHT) ON SIMILAR AIRCRAFT/ENGINE TWO MONTHS LATER FOLLOWING REPLACEMENT OF CH48109 OIL FILTER. REPLACEMENT OF THAT O IL FILTER FIXED LOW OIL PRESSURE PROBLEM. WILL SUBMIT REPORT SEPARATELY ON THAT INCIDENT. HOLDING OIL FILTERS FOR INSPEC TION. 1 L 7 1 3O 3 O RT EXPA1L71 E5SO 2005101700212 20051017 00212 EU 2005 10 17 2005FA0001334 1 20050927 G 3240 AHO89881 BRAKE ASSY BRAERO DH125 BAE125800A 1500285 EU GARRTT TFE731 TFE731* 01518 WP LT MLG OVERHEATED C O OTHER M OVER TEMP NR NOT REPORTED 1 GL 07 466AE 54 54 NA0466 PILOT NOTICED LT OB TIRE WAS FLAT. MAINT FLEW TO AIRPORT AND CHANGED BOTH LT MAIN GEAR WHEEL AND TIRE ASSYS. AC WAS THE N FLOWN BACK. UPON INSPECTION OF FLAT TIRE IT WAS FOUND THAT ALL 3 FUSIBLE PLUGS HAD MELTED. INSPECTED THE LT OB BRAKE AND FOUND IT HAD OVERHEATED. DURING DISASSEMBLY OF BRAKE HEAT PACK IT WAS NOTED THAT BACKING PLATE WAS BADLY WARPED AND WEAR PADS WERE FLAKING AWAY. RIVETS HOLDING WEAR PADS IN PLACE HAD TURNED BLUE FROM HEAT. IB WHEEL ON THIS AXLE WAS UNAF FECTED BY HEAT, TIRES HAD NOT BEEN FLAT SPOTTED OR SKIDDED WHICH WOULD INDICATE EXCESSIVE BRAKING WAS NOT USED. APPEARS BRAKE MATERIAL WAS DEFECTIVE. NORMALLY WE SEE SERVICE AND LANDING OF ABOUT 400 HOURS ON EACH HEAT PACK. 2 L 7 2 4F 4 F RT A3EU E6WE 2005101800178 20051018 00178 CE 2005 10 18 2005FA0001335 1 20050921 G 2435 80603201 STARTER GEN BEECH 50 B50 1152506 CE GARRTT TFE731 TFE73131C 01518 NE NR 1 ENGINE FAILED E XORA A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 NE 03 100E 790 CH14 UNIT SUSTAINED A MAIN BEARING ARMATURE DRIVE SHAFT FAILURE DURING FLIGHT. THE NR1 MAIN GENERATOR WARNING LIGHT ENUNCIATO R ILLUMINATED THE ARMATURE, DRIVE BALL DRIVESHAFT, AND BEARING FLANGE ARE NON-SERVICEABLE. THE ORIGINAL OVERHAUL PERIOD (TBO), FOR THIS UNIT IS 900 FLIGHT HOURS. THE AIR OPERATOR HAS NOW ELECTED TO REDUCE THE TBO OF THE UNIT TO 600 HRS. 1 L 7 2 3O 4 F 5A4 E6WE 2005110800324 20051108 00324 GL 2005 11 8 2005FA0001336 2 20050815 G 7323 252476914 GOVERNOR HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE STIFF B EOOR O OTHER O OTHER NR NOT REPORTED 1 AL 03 CGPHC 2746 1158 180257D CAE832057 ON INSPECTION THE GOV LOOKED TO BE OUT OF RIG. WHEN THE ARM WAS REMOVED IT WAS DISCOVERED THAT THE SHAFT WAS EXTREMELY STIFF. REPLACED GOVERNOR. (K) 1 G 7 1 3U 3 U H3WE E4CE 2005110800317 20051108 00317 WP 2005 11 8 2005FA0001337 1 20050813 G 6700 369A717111 MOTOR HUGHES 369 369A 4470503 WP ALLSN 250C 250C20B 03013 GL FLIGHT CONTROLS INOPERATIVE B EOOR O OTHER O OTHER NR NOT REPORTED 1 AL 03 C6BU4 610958D CAE833793 ON APPROACH TO LANDING THE LONG TRIM MOTOR QUIT WORKING. REPLACED UNIT. (K) 1 G 7 1 3U 3 U H3WE E4CE 2005110800309 20051108 00309 GL 2005 11 8 2005FA0001338 2 20050809 G 7323 369A20023 MOTOR HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL GOVERNOR TRIM INOPERATIVE B EOOR O OTHER O OTHER NR NOT REPORTED 1 AL 03 C6PNC 1800257D PILOT BEEPED THE N2 UP AND WAS UNABLE TO BEAP DOWN, THEN LATER GOT IT DOWN WITH NUMEROUS ATTEMPTS AND FLEW IT BACK. UNI T WAS CHANGED. (K) 1 G 7 1 3U 3 U H3WE E4CE 2005110800308 20051108 00308 WP 2005 11 8 2005FA0001339 1 20050807 G 6220 369D21200501 HUB HUGHES 369 369D 4470706 WP ALLSN 250C 250C20 03013 GL MAIN ROTOR DAMAGED B EOOR O OTHER O OTHER NR NOT REPORTED 1 AL 03 5074R 7035 2620 1151D FOUND THE UPPER M/R P/C LINK BEARING HAD WORN INTO THE ATTACH HUB OF THE PITCH HOUSING ABOUT .130 INCH UNTIL THE SPHERIC AL PART OF THE BEARING CONTACTED, PREVENTING FURTHER PROGRESSION. (K) 1 G 7 1 3U 3 U H3WE E4CE 2005103100194 20051031 00194 SO 2005 10 31 2005FA0001340 1 20050922 G 5500 28321RL TIP CAP PIPER PA28 PA28180 7102808 SO LYC O360 O360* 41514 EA STABILATOR TIPS DAMAGED G O OTHER O OTHER NR NOT REPORTED 1 EA 07 9467J 1 283581 OWNER REMOVED ORIGINAL HORIZONTAL STABILATOR TIPS AND INSTALLED AMR, D, STC SA520CH. OWNER COMPLAINED THAT THE CONTROL FORCES HAD CHANGED CONSIDERABLY. THE CONTROL FORCES WERE HEAVY ON TAKEOFF CAUSING THE OWNER TO OVER ROTATE. OWNER REVE RTED BACK TO ORIGINAL STYLE STABILATOR TIPS. (NO MORE PROBLEMS) THE OWNER THINKS THAT THE HOLDER OF THE STC SHOULD INFO RM PEOPLE INTERESTED IN THESE TIPS THAT THERE WILL BE CHANGES IN THE CONTROL FORCES WHEN THE TIPS ARE INSTALLED. THE OW NER TALKED TO THE STC HOLDER WHO SAID THAT THERE WOULD BE CHANGES. THE OWNER THINKS HE SHOULD HAVE BEEN INFORMED BEFORE HE BOUGHT THEM AND NOT BE SURPRISED WHEN HE FLEW THE AIRCRAFT. (K) 1 L 7 1 3O 3 O 2A13 E286 2005103100192 20051031 00192 EA 2005 10 31 2005FA0001341 2 20050920 G 7322 HA6106019 THROTTLE PRECISION AMRGEN AG5B AG5B 3990100 SO LYC O360 O360A4K 41514 EA CARBURETOR STIFF B IG8R K NONE O OTHER IN INSP/MAINT 1 EA 07 938TE 223 10217 L3842436A ANNUAL INSP, IT WAS DISCOVERED THA THE THROTTLE WOULD NOT REACH THE FULL THROTTLE STOP. THE THROTTLE CABLE WAS DISCONNE CTED AND THE THROTTLE ARM WAS MOVED BY HAND. THE THROTTLE WOULD BECOME STIFF AT HALF TRAVEL AND VIRTUALLY IMPOSSIBLE TO MOVE BEFORE REACHING THE WIDE OPEN THROTTLE STOP. THE CARBUETOR WAS REMOVED AND SENT FOR REPAIR. THIS CARB WAS PREVIO USLY RETURNED TO MFG FOR REPAIR OF THE SAME CONDITION AT 199.1 HOURS TIME IN SERVICE. ENCOUNTERED CONDITION WAS CAUSED B Y A FAULY ACCELERATOR PUMP DISCHARGE CHECK VALVE, WHICH CREATED A HYDRAULIC LOCK IN THE ACCELERATOR PUMP, RESTRICTING FW D THROTTLE TRAVEL. (K) 1 L 7 1 3O 3 O NT 1L71 E286 2005103100174 20051031 00174 CE 2005 10 31 2005FA0001342 1 20050923 G 5410 J744442 MOUNT CESSNA 172 172R 2072401 CE LYC O360 IO360A1A 41514 EA COWLING TORN B DYTR O OTHER O OTHER NR NOT REPORTED 1 SO 15 7265B 100 17280749 DURING A ROUTINE 100 HOUR INSPECTION, 2 OF THE (LORD) COWLING MOUNTS THAT SECURING THE LOWER ENGINE COWLING TO THE AIRFR AME WERE FOUND TORN IN HALF. THIS IS A RECURRING PROBLEM ON ALL C AND S MODEL AC OPERATED BY A LOCAL FLIGHT SCHOOL. IF NOT CORRECTED THIS COULD LEAD TO A LOSS OF THE ENGINE COWLING IN FLIGHT. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005103100175 20051031 00175 2005 10 31 2005FA0001343 4 20050830 G 3417 702490031304 ADC LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE731* 01518 WP COCKPIT INOPERATIVE B BSYA O OTHER O OTHER NR NOT REPORTED 1 GL 07 701AS 047 ON 5/28/2005, THE PILOTS ALTIMETER INDICATOR AGAIN WAS REPORTED TO SHOW ONLY DASHES INTERMITTENTLY IN FLIGHT, IAW PILOT. THE ADC WAS REPLACED AND THE SYSTEM WAS TESTED AND INSPECTED, AND FOUND TO COMPLY WITH FAR, AND TO REMAIN RVSM COMPLAI NT. THERE HAD BEEN ONE PRIOR REPORT OF PROBLEMS WITH THIS SYSTEM ON 5/25/2005. (K) 2 L 7 2 4F 4 F A10CE E6WE 2005103100179 20051031 00179 2005 10 31 2005FA0001344 4 20050829 G 3416 70310N01D01 INDICATOR LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE731* 01518 WP PILOT ALTIMETER INTERMITTENT B BSYR O OTHER O OTHER NR NOT REPORTED 1 GL 07 701AS 047 ON 5/25/2005, THE PILOTS ALTIMETER INDICATOR SHOWED ALL DASHES INTERMITTENTLY IN FLIGHT, IAW PILOT REPORT. THE PILOTS A LTIMETER INDICATOR WAS REPLACED AND THE SYSTEM WAS TESTED AND INSPECTED IAW ICA AND FOUND TO REMAIN RVSM COMPLAINT. THE RE HAVE BEEN NO PRIOR REPOARTS OF PROBLEMS WITH THIS SYSTEM. (K) 2 L 7 2 4F 4 F A10CE E6WE 2005103100177 20051031 00177 NE 2005 10 31 2005FA0001345 2 20050920 G 7240 1968M63G11 LINER CFMINT CFM56 CFM565A3 NE FUEL NOZZLE DESTROYED B QEMY O OTHER O OTHER NR NOT REPORTED 1 EA 35 19566 3031 42X31412 731433 THE CORE MAJOR MODULE 02 X 31733 WAS REMOVED FROM ESN 731433 FOR COMBUSTOR DISTRESS. THIS WAS CONFIRMED ON EXPOSURE AT REPAIR STATION, WHERE SIGNIFICANT BURNING AND BURN THROUGH ON THE OUTER LINER WAS SEEN IN LINE WITH FUEL NOZZLE N-DEGREE 15. THE COMBUSTION CHAMBER WAS PERVIOUSLY REPAIRED AND IS WITH MFG FOR INVESTIGATION. (K) 4 F E29NE 2005101300032 20051013 00032 EU 2005 10 13 2005FA0001346 1 20051004 G 3213 350A41107620 LEAF SPRING SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE RT SKID BROKEN B A UNSCHED LANDING O OTHER CL CLIMB 1 SW 15 186AE 3872 22484 WHEN HELICOPTER TOOK OFF, PILOT NOTICED AN OBJECT ON THE GROUND WHERE HELICOPTER WAS SITTING. HE SET THE AIRCRAFT BACK D OWN AND RETRIEVED THE OBJECT. HE THEN NOTICED THAT A 3 INCH AFT SECTION OF THE RT SKID LEAF SPRING HAD SNAPPED OFF. THE LEAF SPRING WAS JUST INSTALLED ON THE HELICOPTER PRIOR TO THE FLIGHT. THE LEAF SPRING HAD BEEN REPAIRED AND CAME WITH AN 8130-3. INSPECTION OF THE PART REVEALED RUST IN THE AREA OF THE BREAK WHICH WOULD INDICATE THAT THE PART HAD BEEN CRACK ED FOR SOME TIME. PART WAS SENT BACK TO REPAIRER FOR WARRANTY. 1 G 7 1 3U 3 U H9EU E00054EN 2005101300077 20051013 00077 CE 2005 10 13 2005FA0001347 1 20050928 G 2510 MM201057 CYLINDER CESSNA 172 172R 2072401 CE LYC O360 IO360A1A 41514 EA SEAT BACK LOCK BROKEN D O OTHER O OTHER NR NOT REPORTED 1 CE 07 826KS 2823 41 17280792 CREW SEAT BACK LOCK CYLINDER FAILED AND MOUNTING BOLT SHEARED DURING FLIGHT TRAINING, SPIN RECOVERY. PIC SEAT BACK WENT TO HORIZONTAL POSITION. FLIGHT INSTRUCTOR GAINED CONTROL OF AIRCRAFT. UNEVENTFUL LANDING. THIS FACILITY HAS REPLACED 12 OF THESE ASSEMBLIES IN PAST 6 MONTHS AFTER INSPECTION IAW MF SB04-25-02. 1 H 7 1 3O 3 O NT 3A12 1E10 2005101300198 20051013 00198 2005 10 13 2005FA0001348 2 20051004 G 7414 ES10357426 DISTRIBUTOR BLK CONT MAGNETO CRACKED B O OTHER O OTHER NR NOT REPORTED 1 SO 17 300 THREE MAGNETOS IN SHOP FOR 500HR INSPECTION. FOUND ALL THREE BLOCKS CRACKED AT FELT WASHER BORE, EXTENDING IN 2 CASES UP INTO TOWER. THESE THREE BLOCKS ARE AFTERMARKET MANUFACTURE 2005101700215 20051017 00215 CE 2005 10 17 2005FA0001349 1 20051004 G 5711 SPAR CAP BEECH 90 E90 1152914 CE PWA PT6 PT6A60A 52043 NE RT WING CRACKED B K NONE O OTHER IN INSP/MAINT 1 GL 21 300MT LW143 DURING COMPLIANCE WITH AD 89-25-10, 1,000 HOUR INTERVAL EDDY CURRENT INSPECTION, THE SPAR CAP WAS FOUND TO BE CRACKED 3 INCHES OB OF BATHTUB AT RT WING LOWER FORWARD SPAR ATTACH POINT. 1 L 7 2 3T 4 T 3A20 E4EA 2005120200087 20051202 00087 2005 12 2 2005FA0001350 1 20051004 G 5610 CANOPY COCKPIT SEPARATED C O OTHER O OTHER NR NOT REPORTED 1 SW 99 CANOPY GLASS SEPARATING FROM FRAME. THIS A TEST. 2005101800190 20051018 00190 EA 2005 10 18 2005FA0001351 2 20050927 G 7322 BOWL PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA CARBURETOR LOOSE B K NONE O OTHER IN INSP/MAINT 1 GL 21 447ND 139 75877713 2842247 L2000739A ENGINE WAS REPORTED TO NOT SHUTDOWN USING MIXTURE CONTROL. INSPECTED AND FOUND CARBURETOR BOWL LOOSE ON CARBURETOR. AL L SAFETY CLIPS ON ATTACHING HARDWARE WERE INSTALLED AND INTACT. 1 L 7 1 3O 3 O 2A13 E274 2005101800191 20051018 00191 EA 2005 10 18 2005FA0001352 2 20050927 G 7322 BOWL PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA CARBURETOR LOOSE B K NONE O OTHER IN INSP/MAINT 1 GL 21 447ND 139 75877713 2842247 L2000739A ENGINE WAS REPORTED TO NOT SHUTDOWN USING MIXTURE CONTROL. INSPECTED AND FOUND CARBURETOR BOWL LOOSE ON CARBURETOR. AL L SAFETY CLIPS ON ATTACHING HARDWARE WERE INSTALLED AND INTACT. 1 L 7 1 3O 3 O 2A13 E274 2005102500150 20051025 00150 2005 10 25 2005FA0001353 2 20051004 G 7414 ES10357426 DISTRIBUTOR BLK CONT MAGNETO CRACKED B K NONE O OTHER IN INSP/MAINT 1 SO 17 300 THREE MAGNETOS IN SHOP FOR 500HR INSPECTION. FOUND ALL THREE BLOCKS CRACKED AT FELT WASHER BORE, EXTENDING IN 2 CASES U P INTO TOWER. THESE THREE BLOCKS ARE AFTERMARKET MANUFACTURE. 2005103100193 20051031 00193 2005 10 31 2005FA0001354 4 20050726 G 2210 4006719906 DRIVE ASSY CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE AUTOPILOT STIFF G O OTHER O OTHER NR NOT REPORTED 1 NM 13 5408G 5500666 THE PILOT REPORTED THAT THE CONTROLS WERE STIFF IN THE ROLL AXIS. THE AUTOPILOT WAS TURNED OFF AND THE CB WAS CYCLED WI TH NO CHANGE IN THE CONDITION. AFTER LANDING, WITHOUT INCIDENT, TECHNICIANS ARRIVED AND TROUBLESHOOT THE A/P SYSTEM. T HEY DISCOVERED THE AILERON AUTOPILOT SERVO DRIVE CLUTCH WAS NOT FULLY DISENGAGING, CAUSING THE EXCESSIVE FORCE REQUIRED TO ROLL THE AIRCRAFT. THE AILERON AUTOPILOT SERVO DRIVE WAS REMOVED AND REPLACED. BOTH GROUND AND INFLIGHT OPERATIONAL CHECKS WERE PERFORMED WITH NO DEFECTS NOTED. (K) 1 L 7 2 4F 4 F A22CE E1NE 2005101300059 20051013 00059 EU 2005 10 13 2005FA0001355 1 20050816 G 3320 61213 BALLAST BRAERO DH125 HS125700A 4230170 EU GARRTT TFE731 TFE731* 01518 WP VALANCE LIGHT UNSERVICEABLE B RO3R O OTHER O OTHER NR NOT REPORTED 1 CE 03 727TA NA0202 AC WAS DISASSEMBLED FOR INSP. GROUNDING STRAPS ON VALENCE LIGHTS BROKEN. REPAIRED GROUNDING STRAPS. AC WAS REASSEMBLE D, PWR WAS APPLIED TO AC FOR CHECKOUT. PWR WAS ON AC FOR HOURS. INSPECTING OVERHEAD LIGHTING, NOTICED A SPARK. DROPPE D VALENCE TO INVESTIGATE, WHILE VALENCE WAS DROPPED, PWR SUPPLY BLEW UP. NOTICED BECAUSE OF OVERLAPPING OF VALENCE LIGH T, THAT SILICONE WAS USED TO KEEP GROUNDING STRAPS FROM RUBBING ON LAMP HOLDERS. LAMP HOLDER WAS RUBBED DOWN, GROUNDING STRAP WAS TOUCHING, CAUSING A SHORT AND PWR SUPPLY TO OVERHEAT AND BLOW UP. RE-ADJUSTED GROUNDING STRAPS TO KEEP THEM AWAY FROM LAMP HOLDERS. PWR SUPPLY WAS SUPPOSED TO SHUT LIGHTS OFF IN CASE OF A SHORT BUT THIS ONE DID NOT. 2 L 7 2 4F 4 F A3EU E6WE 2005101300069 20051013 00069 SW 2005 10 13 2005FA0001356 1 20050922 G 5711 SPAR BBAVIA 7 7GCBC 1220601 SW LYC O320 O320* 41508 EA WING CRACKED D O OTHER O OTHER NR NOT REPORTED 1 GL 07 5033V 107079 CRACKED SPAR PLATE AT WING STRUT ATTACHMENT LT WING. APPEARS THAT SOME ONE HAS ATTEMPTED TO ADD GLUE TO PLATE FROM A HO LE CUT INTO FABRIC ON TOP WING. IN OTHER WORDS, THIS CRACK HAS BEEN THERE FOR SOME TIME. COULD NOT DETERMINE IF MAIN S PAR CRACKED OR SPLIT. TALKED WITH LAST INSPECTOR AND SAID WING WAS INSPECTED BY PROBE WITH CAMERA ATTACHMENT AND WAS DE TERMINED AIRWORTHY AT THAT TIME. (K) 1 H 7 1 3O 3 O NC A759 E274 2005110800301 20051108 00301 CE 2005 11 8 2005FA0001357 1 20050923 G 2150 HE812933 MOTOR CESSNA 414 414A 2075907 CE CONT O520 TSIO520* 17040 SO BLOWER MALFUNCTIONED D O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 EA 09 414AK 414A0321 RT AIR CONDITIONER BLOWER MOTOR LOCATED UNDER CO-PILOTS SEAT MALFUNCTIONED AND PRODUCED SMOKE WHICH WAS DRAWN THROUGH TH E RT SIDE VENTILATION DUCTS. PILOT FOLLOWED EMERGENCY PROCEDURES AND LANDED SAFELY. (EA09200505819) (K) 1 L 7 2 3O 3 O A7CE E8CE 2005103100056 20051031 00056 CE 2005 10 31 2005FA0001358 1 20050919 G 2450 CV7313 DIODE RAYTHN DH125 HAWKER800XP 7150012 CE GARRTT TFE731 TFE731* 01518 WP INTERNAL OPEN B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 934RD 258296 INVESTIGATED BATTERY NOT CONNECTING TO AIRCRAFT DC BUSSES. REPLACED OPEN DIODE (DA) ON GG EQUIPMENT PANEL. DC POWER OP ERATIONS NORMAL. (K) 2 L 7 2 4F 4 F RT A3EU E6WE 2005103100057 20051031 00057 SO 2005 10 31 2005FA0001359 1 20050910 G 5330 62061002 SKIN PIPER PA28 PA28R201 7102816 SO FUSELAGE CRACKED B BIIR O OTHER O OTHER NR NOT REPORTED 1 EA 21 2221M 4753 28R7837071 AT CABIN ENTRANCE WING WALK, FOUND SUPPORT PANEL UNDER WING WALK CRACKED. FAILURE DUE TO REPEATED WALKING. FACTORY USE OF THICKER SHEET METAL MAY HELP. (K) 1 L 7 1 3O 2A13 2005110800305 20051108 00305 SO 2005 11 8 2005FA0001360 1 20050914 G 5330 62061002 SKIN PIPER PA28 PA28R200 7102811 SO LYC O360 IO360A1A 41514 EA FUSELAGE CRACKED B BIIR O OTHER O OTHER NR NOT REPORTED 1 EA 21 75340 9286 28R7635292 AT CABIN ENTRANCE, WING WALK, FOUND SUPPORT PANEL UNDER WING WALK CRACKED. FAILURE DUE TO REPEATED WALKING ON. IF FACT ORY STAMPED SUPPORT OUT OF HEAVIER, THICKER PANEL, MAY HELP PROLONG FAILURE. (EA21200507814) (K) 1 L 7 1 3O 3 O 2A13 1E10 2005110800306 20051108 00306 SW 2005 11 8 2005FA0001361 1 20050528 G 3233 COUPLING MOONEY M20 M20E 5870212 SW LYC O360 IO360A1A 41514 EA MLG FAILED G O OTHER O OTHER NR NOT REPORTED 1 WP 21 9362V 700011 SUFFERED A GEAR UP LANDING DUE TO A FAILURE OF THE COUPLING BETWEEN THE ACTUATOR AND GEARBOX. (K) 1 L 7 1 3O 3 O 2A3 1E10 2005103100028 20051031 00028 EU 2005 10 31 2005FA0001362 1 20050926 G 6100 B15892 SPRING BNORM BN2 BN2A8 1520209 EU LYC O540 O540E4C5 41532 EA HARTZL HCC2Y HCC2YK2 GL PROPELLER FAILED B LT4R O OTHER O OTHER NR NOT REPORTED 1 SO 19 296TA AU10273B 384 L2450040A AU10273B PROPELLER WAS INSTALLED ON RT SIDE OF AC, THE PROP WENT FEATHER, UNCOMMANDED ON ENGINE SHUTDOWN. PROPELLER WAS REMOVED FROM AC FOR INSPECTION AND WAS RECEIVED WITH THE BLADES IN FEATHER, LOGBOOK WAS NOT SUPPLIED. ALL INFO VIA PHONE. PROP CYLINDER WAS REMOVED AND THE SPRING KIT ASSY WAS CONTAINED. AFTER DISASSEMBLY, SPRING KIT INSP. PROP WAS VISUALLY INSP ECTED, SPRING KIT REBUILT WITH REPLACEMENT PARTS, CYLINDER REINSTALLED AND BLADE ANGLES ADJUSTED. PROP ASSY RETURNED TO SERVICE. ALL WORK/ INSP ACCOMPLISHED IAW MFG MM. SCREWS, SPRING RETAINER, START WEIGHT LOCK(2 HALVES) AND START LOCK H SG SENT TO MFG SERVICE CENTER. (K) 1 H 7 2 3O 3 O A17EU E295 5 C P920 2005103100050 20051031 00050 NE 2005 10 31 2005FA0001363 2 20050901 G 7210 350A32314306 GEAR SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D NE RGB FAILED B FF6R O OTHER O OTHER NR NOT REPORTED 1 NM 11 GEAR SET, REQUEST WARRENTY ON GEAR SET TOOTH FAILURE OR PINION. (K) 1 G 7 1 3U 3 U H9EU E19EU 2005101700213 20051017 00213 CE 2005 10 17 2005FA0001364 1 20050928 G 5711 00011001316 SPAR CAP BEECH 95 95B55 1152729 CE CONT O470 IO470L 17026 SO HARTZL HCC2Y BHCC2YF2 GL WINGS CORRODED B L3CR O OTHER O OTHER NR NOT REPORTED 1 SO 19 1071T TC2002 232180H AN2647R DURING AN ANNUAL INSPECTION, SOME CORROSION WAS FOUND IN THE AREA OF THE RT WING TIE DOWN ASSY, UPON FURTHER INVESTIGATI ON AN AREA OF APPROXIMATELY 8 INCHES IN LENGTH WITH SEVERE INTERGRANULAR CORROSION WAS DISCOVERED ON THE LOWER SPAR CAP POSSIBLY CAUSED BY DISSIMILAR METAL OF THE TIE DOWN ASSY AND THE LOWER SPAR CAP. THIS AC HAD SUFFERED THE SAME TYPE OF CORROSION ON THE LT WING AT EXACTLY THE SAME LOCATION. (K) 1 L 7 2 3O 3 O RT 3A16 3E1 5 C P920 2005103100155 20051031 00155 CE 2005 10 31 2005FA0001365 1 20050927 G 2701 05131663 YOKE CESSNA 172 172B 2072406 CE CONT O360 IO360D 17025 SO LT COCKPIT BROKEN D O OTHER O OTHER NR NOT REPORTED 1 NM 13 6950X 17247850 551105D UPON THE FLAIR ON LANDING AT NORMAL WEIGHTS THE CONTROL YOLK BROKE AT THE OUTSIDE LT RADIUS. THIS CAUSED THE NOSE WHEEL OF THE AC TO DROP AT A GREATER SPEED THAN NORMAL AND SHIMMY WAS EXPERIENCED THE MAIN GEAR HAD JUST TOUCHED DOWN WHEN TH E FAILURE OCCURRED. PART OF THE YOLK WAS STILL ATTACHED TO THE ASSEMBLY SO AILERON CONTROL WAS MAINTAINED. (NM13200504 343) (K) 1 H 7 1 3O 3 O NT 3A12 E1CE 2005103100181 20051031 00181 GL 2005 10 31 2005FA0001366 1 20050930 G 7820 14836001 MUFFLER CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO EXHAUST MISSING B QRQR O OTHER D INFLIGHT SEPARATION NR NOT REPORTED 1 SW 05 7171X 0838 917100 REPLACED MUFFLERS ON AC DUE TO THE DETERIORATED CONDITION OF THE SPARK ARRESTERS INSIDE OF THE MUFFLERS. THE SPARK ARRE STER IN THE LT MUFFLER WAS GONE. IT HAD COME LOOSE AND FALLEN OUT OF THE MUFFLER SOMEWHERE. THE SPARK ARRESTER IN THE RT MUFFLER HAD MELTED AND BOWED TO THE LT (IB). RECOMMEND MANDATORY REPLACEMENT AT A SPECIFIED TIME OR REDESIGN OF ARRE STERS. 1 L 7 1 3O 3 O NT A00009CH E3SO 2005103100199 20051031 00199 EA 2005 10 31 2005FA0001368 2 20050908 G 8520 SL18840 CAMSHAFT PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA SNSNCH 76E 76EM8S5 EA ENGINE WORN D O OTHER O OTHER NR NOT REPORTED 1 NE 02 8946C 800 287690171 L2201436A 15374K AT ANNUAL INSPECTION METAL WAS FOUND IN OIL FILTER. ENGINE WAS TORNDOWN, CAMSHAFT AND LIFTER BODIES WERE DAMAGED. CAMS HAFT AND LIGTER BODIES WERE PURCHASED FROM VENDOR, 1/4/93 AND INSTALLED IN ENGINE 4/8/93 IAW 2000 HOUR TBO. FAILURE OCC URED, TSO 800 HR. IT APPEAR FAILURE WAS CAUSED BY MFG DEFECT. (K) 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 2005103100065 20051031 00065 CE 2005 10 31 2005FA0001369 1 20050923 G 3220 55421029 TORQUE TUBE CESSNA 500 560CESSNA 2076750 CE PWA JT15 JT15D1 52060 NE NLG CRACKED B PAZR O OTHER O OTHER NR NOT REPORTED 1 CE 03 561JS 5600413 NOSE LANDING GEAR DOORS WERE OBSERVED TO BE DROOPING SLIGHTLY. NOSE GEAR RETRACT LINKAGE WAS INSPECTED AND TORQUE TUBE WAS OBSERVED TO HAVE A BROKEN WELD AT ONE END CAP. RECOMMEND INSPECTING WELDS CAREFULLY DURING PERIODIC INSPECTIONS. ( K) 2 L 7 2 4F 4 F RT A22CE E1NE 2005103100213 20051031 00213 NE 2005 10 31 2005FA0001370 2 20051003 G 7230 797706 COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 2997 P673117NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2997.3 HOURS. THE FOLLOWING PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. SUSPECT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. ENGINE SN: P673117NB (TSO: 2997.3 HOURS). (K) 4 J 1E9 2005103100223 20051031 00223 NE 2005 10 31 2005FA0001371 2 20051003 G 7230 725008 COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 4132 2997 P673117NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2997.3 HOURS. THE FOLLOWING PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION I S THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (K) 4 J 1E9 2005103100225 20051031 00225 NE 2005 10 31 2005FA0001372 2 20051003 G 7230 797309 COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 2997 2997 P673117NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2997.3 HOURS. THE FOLLOWING PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION I S THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (K) 4 J 1E9 2005103100226 20051031 00226 NE 2005 10 31 2005FA0001373 2 20051003 G 7230 701106 COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2998.9 HOURS. THE FOLLOWING PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION I S THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (K) 4 J 1E9 2005103100220 20051031 00220 NE 2005 10 31 2005FA0001374 2 20051003 G 7230 797309 COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 P673346NB THES PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2998.9 HOURS. THE FOLLOWING PART (COMPRESSOR DISKS) WERE DEEMED S CRAP DUE TO NOT BE ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (K) 4 J 1E9 2005103100221 20051031 00221 NE 2005 10 31 2005FA0001375 2 20051003 G 7230 701505F COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 5358 2407 P673094NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2407.9 HOURS (PRIOR TO THE ENGINE TBO OF 3000 HOURS). THE FOLLOW ING PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (K) 4 J 1E9 2005103100209 20051031 00209 NE 2005 10 31 2005FA0001376 2 20051003 G 7230 701106C COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 2407 P673094NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2407.9 HOURS (PRIOR TO THE ENGINE TBO OF 3000 HOURS). THE FOLLOW ING PARTS (COMPSRSSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (K) 4 J 1E9 2005103100210 20051031 00210 NE 2005 10 31 2005FA0001377 2 20051003 G 7230 725008F COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 5845 2407 P673094NB THESE PART WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2407.9 HOURS (PRIOR TO THE ENGINE TBO OF 3000 HOURS). THE FOLLOWI NG PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (K) 4 J 1E9 2005103100227 20051031 00227 NE 2005 10 31 2005FA0001378 2 20051003 G 7230 797309 COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 2407 P673094NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2407.9 HOURS (PRIOR TO THE ENGINE TBO OF 3000 HOURS). THE FOLLOW ING PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. WE SUSP ECT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (K) 4 J 1E9 2005103100224 20051031 00224 NE 2005 10 31 2005FA0001379 2 20051003 G 7230 701106 COMPRESSOR PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 5823 2824 P673173NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2824.2 HOURS. THE FOLLOWING PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION I S THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (K) 4 J 1E9 2005103100215 20051031 00215 NE 2005 10 31 2005FA0001380 2 20051003 G 7230 803108 COMPRESSOR PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 2824 P6733173NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2824.2 HOURS. THE FOLLOWING PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION I S THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (K) 4 J 1E9 2005103100228 20051031 00228 NE 2005 10 31 2005FA0001381 2 20051003 G 7230 797309 COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 2824 P673173NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2824.2 HOURS. THE FOLLOWING PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION I S THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (K) 4 J 1E9 2005103100138 20051031 00138 NE 2005 10 31 2005FA0001382 2 20051003 G 7230 496705L COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 2954 1493 P672774NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 1493.7 HOURS (PRIOR TO THE ENGINE TBO OF 3000 HOURS). THE FOLLOW ING PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (NOTE: DUE TO PN AND SN OF PART S BEING NOT LEGIBLE, THE PN AND SN WERE OBTAINED FROM PREVIOUS RECORDS/ DISK SHEETS). (K) 4 J 1E9 2005110900055 20051109 00055 NE 2005 11 9 2005FA0001383 2 20051003 G 7230 701106E COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 4275 1493 P672774NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 1493.7 HOURS (PRIOR TO THE ENGINE TBO OF 3000 HOURS). THE FOLLOW ING PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. WE SUSP ECT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (NOTE: DUE TO PN AND SN OF P ARTS BEING NOT LEGIBLE, THE PN AND SN WERE OBTAINED FROM PREVIOUS RECORDS/DISK SHEETS). (K) 4 J 1E9 2005110900024 20051109 00024 NE 2005 11 9 2005FA0001384 2 20051003 G 7230 725008F COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 4502 1493 P672774NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 1493.7 HOURS (PRIOR TO THE ENGINE TBO OF 3000 HOURS). THE FOLLOW ING PARTS (COMPRESSOR DISK) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. WE SUSPE CT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (NOTE: DUE TO PN AND SN OF PA RTS BEING NOT LEGIBLE, THE PN AND SN WERE OBTAINED FROM PREVIOUS RECORDS/DISK SHEETS). (K) 4 J 1E9 2005102800135 20051028 00135 NE 2005 10 28 2005FA0001385 2 20051003 G 7230 797309B COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 1493 P672774NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 1493.7 HOURS (PRIOR TO THE ENGINE TBO OF 3000 HOURS). THE FOLLOW ING PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. WE SUSP ECT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (NOTE: DUE TO PN AND SN OF P ARTS BEING NOT LEGIBLE, THE PN AND SN WERE OBTAINED FROM PREVIOUS RECORDS/DISK SHEETS). (K) 4 J 1E9 2005103100127 20051031 00127 CE 2005 10 31 2005FA0001386 1 20050914 G 5610 PAS660011510 WINDOW LEAR 35 35A 5170602 CE GARRTT TFE731 TFE731* 01518 WP COCKPIT CORRODED B N38R O OTHER O OTHER NR NOT REPORTED 1 EA 05 630SJ 344 ABOUR 1 INCH IN FROM THE OUTER EDGE OF THE WINDOW IT LOOKS LIKE THERE HAS BEEN A CHEMICAL REACTION WERE THE OUTER AND IN NER WINDOW WAS PUT TOGETHER. THIS WAS FOUND ON FOUR OTHER WINDOWS ON THE SAME AIRCRAFT. (K) 2 L 7 2 4F 4 F A10CE E6WE 2005103100020 20051031 00020 NE 2005 10 31 2005FA0001387 2 20051003 G 7230 701505 COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 5891 2998 P637881NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2824.2 HOURS. THE FOLLOWING PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION I S THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (NOTE: DUE TO PN AND SN OF PARTS BEING NOT LEGIBLE, THE PN AND SN WERE OBTAINED FROM PREVIOUS RECORDS/DISK SHEETS). (K) 4 J 1E9 2005110900054 20051109 00054 NE 2005 11 9 2005FA0001388 2 20051003 G 7230 496706 COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 5129 2998 THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2824.2 HOURS. THE FOLLOWING PARTS (COMPRESSOR DISK) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (NOTE: DUE TO PN AND SN OF PARTS BE NOT LEGIBLE, THE PN AND SN WERE OBTA INED FROM PREVIOUS RECORDS/DISK SHEETS). (K) 4 J 1E9 2005110800289 20051108 00289 NE 2005 11 8 2005FA0001389 2 20051003 G 7230 725008 COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 5859 2998 P637881NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2824.2 HOURS. THE FOLLOWING PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. WE SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSIO N IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (NOTE: DUE TO PN AND SN OF PARTS BEING NOT LEGIBLE, THE PN AND SN WE RE OBTAINED FROM PREVIOUS RECORDS/DISK SHEETS). (K) 4 J 1E9 2005110800290 20051108 00290 NE 2005 11 8 2005FA0001390 2 20051003 G 7230 701409 COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 5545 2998 P637881NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2824.2 HOURS. THE FOLLOWING PARTS (COMPRESSOR DISK) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. WE SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (NOTE: DUE TO PN AND SN OF PARTS BEING NOT LEGIBLE, THE PN AND SN WE RE OBTAINED FROM PREVIOUS RECORDS/DISK SHEETS). (K) 4 J 1E9 2005110800291 20051108 00291 NE 2005 11 8 2005FA0001391 2 20051003 G 7230 725008 COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 2898 160 P673349NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 160.5 HOURS (PRIOR TO THE ENGINE TBO OF 3000 HOURS). THE FOLLOWI NG PARTS (COMPRESSOR DISK) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. SUSPECT T HAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (NOTE: DUE TO PN AND SN OF PARTS BEING NOT LEGIBLE, THE PN AND SN WERE OBTAINED FROM PREVIOUS RECORDS/DISK SHEETS). (K) 4 J 1E9 2005103100091 20051031 00091 NE 2005 10 31 2005FA0001392 2 20051003 G 7230 701409 COMPRESSOR WHEEL PWA JT12 JT12* 52042 NE ENGINE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 CE 03 160 P673349NB THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 160.5 HOURS (PRIOR TO THE ENGINE TBO OF 3000 HOURS). THE FOLLOWI NG PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. WE SUSPE CT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (NOTE: DUE TO PN AND SN OF PA RT BEING NOT LEGIBLE, THE PN AND SN WERE OBTAINED FROM PREVIOUS RECORDS/DISK SHEETS). (K) 4 J 1E9 2005102800137 20051028 00137 SO 2005 10 28 2005FA0001393 1 20050919 G 3213 40081 STRUT MAULE M6 M6235 5460160 SO LYC O540 IO540* 41532 EA LT MLG FAILED C O OTHER O OTHER NR NOT REPORTED 1 SO 11 5648P 1698 7426C UPON LANDING, LT MLG OLEO STRUT FOLDED UPWARDS ALLOWING PROP TO CONTACT GROUND. INVESTIGATION REVEALED MODERATE CORROSI ON THROUGHOUT STRUT LOWER MOUNT AND BOLT HOLE. SUGGEST INSPECTING AND CLEANING LOWER ATTACH POINTS EVERY 100 HOURS. AP PLY CORROSION INHIBITOR AND CONSIDER SEALING LOWER STRUT OPENING. (SO11200516668) (K) 1 H 7 1 3O 3 O 3A23 1E4 2005102800138 20051028 00138 2005 10 28 2005FA0001394 4 20050718 G 2562 AK450 ELT PIPER PA12 PA12 7101202 SO LYC O360 IO360A1A 41514 EA CABIN WEAK D O OTHER O OTHER NR NOT REPORTED 1 AL 03 7689H 190 12579 ELT TRANSMISSION WAS VERY WEAK. INSTALLED IN AC FOR LESS THAN 3 YEARS. INSTALLED 10/18/01. REMOVED 09/10/04. (K) 1 H 7 1 3O 3 O A780 1E10 2005110800292 20051108 00292 SO 2005 11 8 2005FA0001395 2 20050822 G 8530 654004 CYLINDER CESSNA 175 175 2072502 CE CONT O300 GO300A 17022 SO EXHAUST VALVE FAILED B CY4R O OTHER O OTHER NR NOT REPORTED 1 AL 03 7218M 55518 53018A CYLINDER WAS REBUILT 5/12/05 USING CURRENT PRODUCTION MFG EXHAUST VALVE AND GUIDE. THE EXHAUST VALVE STRUCK (17 HOURS I N SERVICE) RESULTING IN A BROKEN EXHAUST ROCKER ARM, AS A RESULT AN EMERGENCY LANDING WAS SUCCESSFULLY MADE. (K) 1 H 7 1 3O 3 O NT 3A17 E298 2005110800318 20051108 00318 SO 2005 11 8 2005FA0001396 2 20050705 G 8530 1691111 CYLINDER HEAD CONT O520 IO520BA 17032 SO ENGINE CRACKED B CY4R O OTHER O OTHER NR NOT REPORTED 1 AL 03 865 CYLINDER 16911-11 BLEW A HOLE IN THE SIDE. CYLINDER 16757-25 CRACKED. TSN 71.2 ACA CYLINDERS. (K) 3 O E5CE 2005110800335 20051108 00335 CE 2005 11 8 2005FA0001398 1 20050416 G 5524 12346251 ATTACH BRACKET CESSNA 206 U206G 2073356 CE CONT O520 IO520* 17032 SO LT ELEVATOR CRACKED B FE4R O OTHER O OTHER NR NOT REPORTED 1 AL 03 7367C U20603905 DURING AN ANNUAL INSPECTION, THE LT ELEVATOR OB ATTACH HINGE WAS FOUND TO BE CRACKED AT WELD. UPON FURTHER INSPECTION, IT WAS NOTED THAT WELD WAS IN FACT ONLY A SPOT WELD. THIS PART IS SUPPOSED TO BE WELDED THE FULL LENGTH OF THE HINGE. PART APPEARS TO BE THE ORIGINAL FACTORY INSTALLED PART. (K) 1 H 7 1 3O 3 O A4CE E5CE 2005103100159 20051031 00159 SO 2005 10 31 2005FA0001399 2 20050706 G 8530 AEC631397ST712A CYLINDER HEAD CONT O520 IO520F 17032 SO ENGINE CRACKED B CY4R O OTHER O OTHER NR NOT REPORTED 1 AL 03 991 ENGINE CYLINDER HEAD CRACKED. (K) 3 O E5CE 2005110800321 20051108 00321 CE 2005 11 8 2005FA0001400 1 20050913 G 5712 57222061 RIB CESSNA 441 441 2076020 CE GARRTT TPE331 TPE331* 01514 WP WINGS CRACKED B EATR O OTHER O OTHER NR NOT REPORTED 1 GL 09 385GH 4410066 WHILE ACCOMPLISHING MFG CQB 03-1 EDDY CURRENT INSPECTION THE CANTED RIB CAPS WERE FOUND CRACKED ON THE LT AND RT WINGS. THE AIRCRAFT WILL REQUIRE SERVICE KIT SK441-110-1 REPAIR KIT IAW CQB 03-1 BEFORE FURTHER FLIGHT. (K) 1 L 7 2 3T 3 T RT A28CE E2WE 2005103100212 20051031 00212 CE 2005 10 31 2005FA0001401 1 20050124 G 2910 6556600020 LINE CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE HYDRAULIC SYS DAMAGED B MNGR O OTHER O OTHER NR NOT REPORTED 1 SW 05 511TH 900 5600561 HYDRAULIC LINE, PN 6556000-20, ON LT ENGINE IS MAKING CONTACT WITH FUEL LINE PN 3042937-01. THIS CAUSED CHAFFING IN EXC ESS OF 20 PERCENT OF THE WALL THICKNESS ON THE HYDRAULIC LINE AND 10 PERCENT TO 15 PERCENT WALL THICKNESS ON THE FUEL LI NE. BOTH LINES WERE REPLACED WITH FACTORY NEW PARTS. AFTER PART REPLACEMENT CONTACT WAS STILL BEING MADE AND REQUIRED THAT SLIGHT ADJUSTMENTS TO THE BENDS ON THE LINES WERE REQUIRED TO MAINTAIN ADEQUATE CLEARANCE. (K) 2 L 7 2 4F 4 F RT A22CE E00053EN 2005110900018 20051109 00018 CE 2005 11 9 2005FA0001402 1 20050124 G 2910 OA553191 CONTROL VALVE CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE HYD SYSTEM SHORTED B MNGR O OTHER O OTHER NR NOT REPORTED 1 SW 05 511TH 900 5600561 FLAP CONTROL VALVE PN 2710970 TO BE MAKING CONTACT WITH DUMP VALVE PN OA55319-1 CAUSING WAS SUBSTIALLY DAMAGE. BY SHORT ING THE STAND OFF ON THE BOTTOM SIDE OF THE DUMP VALVE BY APROX .1250 OF AN INCH A CLEARANCE OF APROX .0625 OF AN INCH W AS OBTAINED. (K) 2 L 7 2 4F 4 F RT A22CE E00053EN 2005110900010 20051109 00010 EA 2005 11 9 2005FA0001403 2 20050920 G 8530 CYLINDER HEAD PIPER PA28 PA28180 7102808 SO LYC O360 O360A4A 41514 EA ENGINE FAILED D O OTHER O OTHER NR NOT REPORTED 1 EA 17 6494J 284925 L1938736A NR 3 CYLINDER PRODUCED CRACK FROM LOWER SPARK PLUG TO EXHAUST PORT, ENGINE LOST POWER DURING CLIMB OUT AT APPROX 700 FT ATTEMPT TO RETURN FOR LANDING WAS UNSUCESSFUL, FAILED. CYCLINDER INSTALLED 1/12/00 RECONDITION CYLINDER TIME UNKNOWN - TIME IN SERVICE, APPROX 1300. (K) 1 L 7 1 3O 3 O 2A13 E286 2005110800337 20051108 00337 SO 2005 11 8 2005FA0001405 1 20050922 G 5730 62061002 SKIN PIPER PA28 PA28161 7102803 SO GE CFM56 CFM567B24 NE WING CRACKED B BIIR O OTHER O OTHER NR NOT REPORTED 1 EA 21 9089N 9942 2816003 WING WALK STIFFENER PANEL CRACKED UNDER UPPER WING SKIN, YEARS OF WALKING ON PANEL. STIFFENER PANEL SHOULD BE HEAVER GA UGE METAL. (K) 1 L 7 1 3O 4 F 2A13 E00055EN 2005103100198 20051031 00198 SO 2005 10 31 2005FA0001406 1 20050716 G 5540 6339500 DOUBLER PIPER PA32 PA32300 7103212 SO LYC O540 TIO540* 41532 EA RUDDER HINGE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 AL 03 9304K 327640076 CRACKS WERE FOUND AT THE TOP OF THE RUDDER SPAR HINGE DOUBLER. CRACKING WAS ON BOTH SIDES OF THE DOUBLER IN THE BEND RA DIUS`S. ACCESS FOR INSPECTION NECCESSITATES REMOVING THE RUDDERS TIP/COUNTERWEIGHT. RECURRENCE MAY BE PREVENTED BY FAB RICATING AND INSTALLING AN ADDITIONAL SIMILAR DOUBLER ON THE AFT SIDE OF THE SPAR OPPOSITE THE EXISTING DOUBLER. HOWEVE R, THAT MAY EFFECT FLEXIBILITY AND CAUSE THE RUDDER SPAR TO RECEIVE EXTRA STRESS. (AL03200519295) (K) 1 L 7 1 3O 3 O A3SO E14EA 2005103100069 20051031 00069 CE 2005 10 31 2005FA0001407 1 20051010 G 3233 908200151 NUT BEECH 200 200T 1152928 CE NLG ACTUATOR FAILED C NBFR O OTHER O OTHER NR NOT REPORTED 1 EA 27 44U 89 BT14 THE LANDING GEAR WAS BEING OPS CHECKED DURING A SHEDULED COMPLETE INSPECTION. WITH THE AC ON JACKS, THE LANDING GEAR WA S BEING RETRACTED WHEN THE ACTUATOR FAILED BEFORE THE GEAR WAS COMPLETELY RETRACTED. THE NUT ASSY FAILED JUST BELOW THE THREADED SECTION WHICH CAUSES THE NLG TO FALL DOWN BUT UNLOCKED WITH NO MEANS TO RETRACT OR LOCK THE GEAR DOWN. THIS F AILURE IS VERY SIMILAR TO THE MLG ACTUATOR FAILURE ADDRESSED IN SB 32-3433. (K) 1 L 7 2 4T A24CE 2005103100070 20051031 00070 SW 2005 10 31 2005FA0001408 1 20051002 G 2197 CONNECTOR MOONEY M20 M20J 5870219 SW LYC O360 IO360A1A 41514 EA AUTOPILOT SYS DISCONNECTED H O OTHER O OTHER NR NOT REPORTED 1 WP 01 4171H 240653 CONNECTOR CAME LOOSE FROM SLAVE CONTROLLER WHILE ON THE GROUND. HSI WAS NOW IN FREE GYRO (UNSLAVED) MODEL BUT THERE WAS NO (HDG) FLAG, HENCE GYRO SLOWLY DRIFTED WITHOUT WARNING TO PILOT. (K) 1 L 7 1 3O 3 O 2A3 1E10 2005110800310 20051108 00310 CE 2005 11 8 2005FA0001409 1 20051005 G 5520 1016100195 TORQUE TUBE BEECH 200 B200 1152922 CE PWA PT6 PT6* 52043 EA LT ELEVATOR FAILED D O OTHER O OTHER NR NOT REPORTED 1 EA 21 6182A 3808 BB1484 FOUND LT ELEVATOR TORQUE TUBE MOUNTING FLANGE FROM TUBE ASSY TO ELEVATOR RIVETS WORKING LOOSE, ALLOWING THE LT ELEVATOR TO HAVE 1.5 INCHES OF PLAY. THIS WAS FOUND DURING A 400 HOUR LUBRICATION AND INSPECTION. RECOMMENDATION TO PREVENT REC URRENCE, USE SOLID RIVET NOT BLIND RIVET. (K) 1 L 7 2 4T 3 T A24CE E2NE 2005103100083 20051031 00083 2005 10 31 2005FA0001410 1 20050927 G 8011 ES6462382 STARTER ENGINE INOPERATIVE B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 NEW STARTER DOES NOT TURN FREELY BY HAND. (K) 2005103100071 20051031 00071 2005 10 31 2005FA0001411 2 20050927 G 7322 104404 CARBURETOR ENGINE OUT OF ADJUST B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 CARBURETOR RUNS LEAN IN THE MID RANGE. (K) 2005103100084 20051031 00084 2005 10 31 2005FA0001412 2 20050927 G 7322 105009 CARBURETOR ENGINE INOPERATIVE B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 CARBURETOR, MIXTURE SHUT OFF IS BAD. (K) 2005102500168 20051025 00168 2005 10 25 2005FA0001413 1 20050912 G 8011 6462751 STARTER ENGINE INOPERATIVE B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 STARTER, CUSTOMER REPORTS AFTER 7.7 HOURS OF OPERATION STARTER SEEPING WAX FROM REAR OF STARTER. (K) 2005103100042 20051031 00042 2005 10 31 2005FA0001414 1 20050919 G 8011 ES6462751 STARTER ENGINE INOPERATIVE B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 STARTER, UNABLE TO TURN FREELY BY HAND. (K) 2005103100043 20051031 00043 2005 10 31 2005FA0001416 1 20050919 G 8011 ES6462751 STARTER ENGINE INOPERATIVE B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 STARTER, UNABLE TO TURN FREELY BY HAND. (K) 2005103100080 20051031 00080 2005 10 31 2005FA0001417 1 20050919 G 8011 ES6462751 STARTER ENGINE INOPERATIVE B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 STARTER, UNABLE TO TURN FREELY BY HAND. (K) 2005103100081 20051031 00081 2005 10 31 2005FA0001421 1 20050927 G 8011 ES6462751 STARTER ENGINE INOPERATIVE B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 NEW STARTER DOES NOT TURN FREELY BY HAND. (K) 2005103100188 20051031 00188 2005 10 31 2005FA0001422 1 20050927 G 8011 ES6462751 STARTER ENGINE INOPERATIVE B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 NEW STARTER DOES NOT TURN FREELY BY HAND. (K) 2005103100094 20051031 00094 2005 10 31 2005FA0001423 1 20051007 G 8011 ES6462751 STARTER ENGINE INOPERATIVE B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 STARTER DOES NOT TURN FREELY BY HAND. (K) 2005103100095 20051031 00095 2005 10 31 2005FA0001424 1 20050928 G 8011 ES6462751 STARTER ENGINE INOPERATIVE B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 STARTER, WAX SEEPING OUT OF END PLATES. (K) 2005103100189 20051031 00189 2005 10 31 2005FA0001425 2 20050928 G 7322 1048931 CARBURETOR ENGINE INOPERATIVE B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 CARBURETOR, THIS CARBURETOR WOULD NOT RUN, NEEDLE AND SEAT OVERFLOWS. (K) 2005103100165 20051031 00165 CE 2005 10 31 2005FA0001426 1 20051012 G 5544 10164001423 HINGE BEECH 200 B200 1152922 CE RUDDER CORRODED B MGOR O OTHER O OTHER NR NOT REPORTED 1 CE 09 585CE 6720 BB1194 DURING SCHEDULED PHASE 2 INSPECTION OF AIRCRAFT, FOUND THE CENTER RUDDER HINGE ASSY HAVING INTERGRANULAR CORROSION AROUN D THE HARDWARE ATTACHING TEE TO THE HINGE ASSY. THIS TYPE OF CORROSION IS PROBABLY DUE TO THE LOCATION OF THE PART AND THE AGE OF THE AIRCRAFT. (CE09200601298) (K) 1 L 7 2 4T A24CE 2005103100167 20051031 00167 NE 2005 10 31 2005FA0001427 2 20051010 G 7230 26580471 PLENUM CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL ENGINE DAMAGED B L3CR O OTHER O OTHER NR NOT REPORTED 1 SO 19 701SE 208B0701 PCEPC0425 960408 WHILE REMOVING THE ENGINE FOR A SCHEDULED OVERHAUL, WE NOTICED 5 RIVETS SHEARED OFF THE TOP HALF OF THE INDUCTION AIR PL ENUM BAND ASSEMBLY. A SHEARED RIVET HEAD CAN EASILY FIT THRU THE ENGINE INLET SCREEN AND COULD BE INGESTED BY THE ENGIN E CAUSING GREAT DAMAGE OR TOTAL ENGINE FAILURE. (K) 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2005102800134 20051028 00134 NE 2005 10 28 2005FA0001428 2 20051010 G 7230 36580472 PLENUM CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL ENGINE CORRODED B L3CR O OTHER O OTHER NR NOT REPORTED 1 WP 19 701SE 208B0701 PCEPC0425 960408 WHILE REMOVING THE ENGINE FOR A SCHEDULED OVERHAUL, WE NOTICED 5 RIVETS SHEARED OF THE TOP HALF OF THE INDUCTION AIR PLE NUM BAND ASSY. A SHEARED RIVET HEAD CAN EASILY FIT THRU THE ENGINE INLET SCREEN AND COULD BE INGESTED BY THE ENGINE CAU SING GREAT DAMAGE OR TOTAL ENGINE FAILURE. (K) 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2005110800302 20051108 00302 2005 11 8 2005FA0001429 4 20050706 G 3497 WIRE CESSNA 182 182T 2072703 CE LYC O540 IO540* 41532 EA TRANSPONDER CHAFED D F7HS O OTHER O OTHER NR NOT REPORTED 1 WP 13 861SF 18281438 L2971748 TRANSPONDER CIRCUIT BREAKER POPPED AND PILOTS NOTED SMOKE IN CABIN. FLIGHT WAS DISCONTINUED AND DISCREPENCY WAS NOTED. AFTER INSPECTION, CHAFFED WIRE WAS FOUND NEAR THE AVIONICS RACK THAT HAD SHORTED ON THE AIRFRAME. THE WIRES WERE REPAI RED IAW MFG RECOMMENDATION. MFG ALSO RECOMMENDED ANTI-CHAFE BE INSTALLED ON AIRFRAME AT THE LOCATION OF CHAFFING. (WP1 3200510948) (K) 1 H 7 1 3O 3 O NT 3A13 1E4 2005110800323 20051108 00323 WP 2005 11 8 2005FA0001430 2 20050915 G 7200 31018303 DUCT MTSBSI MU2 MU2B40 5780440 CE GARRTT TPE331 TPE33110 01514 WP ENGINE FAILED B R2JR O OTHER O OTHER NR NOT REPORTED 1 EA 21 361MA 4055 429SA P36200 ENGINE EGT SUDDENLY ROSE IN FLIGHT AND POWER HAD TO BE REDUCED. SAFE LANDING ACCOMPLISHED AT HOME BASE. TROUBLESHOOTIN G REVEALED THE COMPRESSOR CROSSOVER DUCT (DIFFUSER) HAD FAILED, CAUSING LOW COMPRESSOR PERFORMANCE. A VANE HAD BROKEN O FF AND LODGED, PREVENTING CATASTROPHIC FAILURE OF COMPONENTS DOWNSTREAM. INVESTIGATION REVEALED THIS PART WAS REQUIRED TO BE REPLACED WITH AN UPGRADED DUCT LESS PRONE TO FAILURE AT THE ENTINE TBO EXTENSION, WHICHC WAS RECORDED IN MAINTENAN CE RECORDS AS HAVING BEEN ACCOMPLISHED AT AN EARLIER TIME, AND THE ENGINE CERTIFIED TO MEET THE 5400 HOUR TBO. (K) 1 H 7 2 3T 4 T RT A10SW E4WE 2005110900007 20051109 00007 WP 2005 11 9 2005FA0001431 2 20050915 G 7220 31018303 DUCT MTSBSI MU2 MU2B40 5780440 CE GARRTT TPE331 TPE331* 01514 WP ENGINE LOOSE B R2JR O OTHER O OTHER NR NOT REPORTED 1 EA 21 361MA 4055 429SA P36199 ENGINE WAS TORN DOWN, BY AN APPROVED ENGINE SERVICE CENTER, FOR AN AUDIT OF ITS SB AND TBO CONFIGURATION, DUE TO CROSSOV ER DUCT/DIFFUSER FAILURE OF ITS SISTER ENGINE ON THE SAME AIRCRAFT. IT WAS FOUND THE MAINTENANCE RECORDS CONCERNING SB STATUS AND TBO STATUS WERE IN ERROR ON THIS ENGINE ALSO AND INSPECTION OF THE CROSSOVER DUCT ASSY IN THIS ENGINE WAS FOU ND VERY LOOSE, BUT NOT YET FAILED. FAILURE OF THIS PART WAS IMINENTNENT AND SEALS IN THIS DUCT WERE MOSTLY FAILED, AFFE CTING COMPRESSOR AND ENGINE POWER. COMPRESSOR CROSSOVER DUCT/ DIFFUSER POOR CONDITION FOR ENGINE. (K) 1 H 7 2 3T 3 T RT A10SW E2WE 2005102000109 20051020 00109 NE 2005 10 20 2005FA0001432 2 20050920 G 7240 1968M63G11 LINER CFMINT CFM56 CFM565A3 NE COMBUSTION CHAM BURNED B CT5Y O OTHER O OTHER NR NOT REPORTED 1 EA 33 19566 3031 42X31412 731433 THE CORE MAJOR MODULE 02X31733 FOR COMBUSTOR DISTRESS. THIS WAS CONFIRMED ON EXPOSURE, WHERE SIDNIFICANT BURNING AND BU RN-THROUGH ON THE OUTER LINER WAS SEEN IN LINE WITH FUEL NOZZLE NR 15. THE COMBUSTION CHAMBER WAS PREVIOUSLY REPAIRED A ND IS WITH MFG FOR INVESTIGATION. (K) 4 F E29NE 2005102000114 20051020 00114 NE 2005 10 20 2005FA0001433 2 20051009 G 7200 0292005310 ENGINE SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1 60030 NE NR 2 FLAMED OUT C B A EMER. DESCENT UNSCHED LANDING X J ENGINE FLAMEOUT WARNING INDICATION CR CRUISE 1 EA 17 88CP 2393 79 760500 WHILE IN CRUISE, WE WERE VMC ON TOP OF A CLOUD DECK, EXPERIENCED A NR 2 ENGINE CHIP LIGHT. IMMEDIATELY, NR 2 ENGINE SHU TDOWN. NR 1 AUTOPILOT ALSO DROPPED OFF LINE. EMERGENCY WAS DECLARED AND SINGLE ENGINE INSTRUMENT ILS APPROACH WAS ACCO MPLISHED. WEATHER AT THE TIME WAS ABOUT 700 FT OVC WITH 5 MILES VISUAL. INSPECTION REVEALED CONTAINED ENGINE FAILURE WI TH A SIGNIFICANT AMOUNT OF METAL DEBRIS ON ACCY GB MECHANICAL CHIP PLUG. THIS ENGINE HAD ONLY 79 HOURS ON IT SINCE RETU RN FROM MFG FOR REPAIR DUE TO METAL CHIPS. NR 1 ENGINE EXPERIENCED A 30 SEC POWER EXCURSION DURING ENGINE FAILURE, REQU IRING IT'S REMOVAL AS WELL. SPECULATION WOULD INDICATE A FAULTY REPAIR. 1 G 7 2 3U 3 U NC H1NE E19EU 2005102400097 20051024 00097 SW 2005 10 24 2005FA0001434 1 20051014 G 5320 407010105101 STOP BELL 407 407 1182206 SW FUSELAGE CRACKED C O OTHER O OTHER NR NOT REPORTED 1 SW 99 2500 DROOP STOP STUDS HAD CRACK INDICATIONS IN RADIUS DURING FLUORESCENT PENETRATE CHECK. NEW STYLE STOPS INSTALLED. 1 G 7 1 3U O H2SW 2005102000163 20051020 00163 CE 2005 10 20 2005FA0001435 1 20051014 G 3250 0024100397 BELLCRANK BEECH 58 58 1152740 CE CONT O550 IO550* SO STEERING FRACTURED B O OTHER O OTHER TX TAXI/GRND HDL 1 GL 21 555ND TH1750 THE CO-PILOTS RUDDER/STEERING BELLCRANK FRACTURED AT THE CENTER CONNECTING POINT CAUSING A LACK OF NOSE WHEEL STEERING O N THE CO-PILOTS SIDE. 1 L 7 2 3O 3 O 3A16 E3SO 2005102000169 20051020 00169 NE 2005 10 20 2005FA0001436 2 20051015 G 8530 EXHAUST VALVE DOUG DC6 DC6B 3021712 WP PWA R2800 R2800CB16 52026 NE ENGINE STICKING I Z5QB O OTHER O OTHER NR NOT REPORTED 1 EA 29 996DM 180 45563 ENGINE EXHAUST VALVE STICKING (5 TIMES) MOST LIKELY CAUSED BY OIL. THE MFG ADDITIVE IN CONTACT WITH LEAD ON THE VALVE ST EM CAUSES EXCESSIVE PHOSPHOR BUILDUP AND THE VALVE TO STICK. MFG IS AWARE OF THIS PROBLEM. 2 L 7 4 4R 4 R 6A4 5E8 2005102400158 20051024 00158 CE 2005 10 24 2005FA0001437 1 20051017 G 5410 11420247 STUD CESSNA 172 172R 2072401 CE LYC O320 IO320* 41508 EA ENGINE COWLING COLLAPSED D K NONE O OTHER IN INSP/MAINT 1 NM 01 THE STUD SPRINGS ARE COLLAPSING UPON INSTALLATION. SUSPECT POOR HEAT-TREATING OF THE SPRINGS. NOTICED EXCESSIVE CHAFFIN G (SMOKING) FROM THE ENGINE COWLING SINCE AIRCRAFTS WERE NEW. AT ABOUT 300TT THE RECEPTACLES FOR THE STUDS STARTED TO F AIL. WHEN NEW STUDS AND RECEPTACLES WERE INSTALLED, NOTICED THE SPRINGS COLLAPSED AND DID NOT RETURN TO THEIR BEFORE HEI GHT. THIS CONDITION ALLOWS THE ENGINE COWLING TO FIT LOOSELY AND VIBRATE ENOUGH TO CAUSE THE (SMOKING) AND TO WEAR OUT T HE RECEPTACLES. 1 H 7 1 3O 3 O NT 3A12 1E12 2005110800297 20051108 00297 SO 2005 11 8 2005FA0001438 1 20050622 G 8011 GEAR PIPER PA23 PA23250 7102308 SO LYC O540 IO540* 41532 EA STARTER BROKEN D O OTHER O OTHER NR NOT REPORTED 1 GL 09 63954 85022809 277854085 ON RESTART IN THE AIR THE STARTER DRIVE GEAR BROKE. THE PILOT WAS UNABLE TO START THE ENGINE. THE GEAR ALSO DAMAGED TH E RING GEAR ON THE ENGINE. (K) 1 L 7 2 3O 3 O 1A10 1E4 2005103100214 20051031 00214 CE 2005 10 31 2005FA0001439 1 20051004 G 3230 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520BB 17032 SO CABIN INTERMITTENT B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 5581T 134 CE1350 825982R GEAR WOULD NOT RETRACT MADE NO NOISE AT ALL. MAINTENANCE TECH TROUBLESHOOT GEAR SYSTEM AND FOUND THAT THE DYNAMIC RELAY WAS INTERMITTENT. NO RECOMMENDATION AT THIS TIME. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005110800298 20051108 00298 CE 2005 11 8 2005FA0001440 1 20051006 G 3297 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO DYNAMIC BREAKER INTERFERENCE B VJ3R O OTHER O OTHER NR NOT REPORTED 1 WP 07 1556A 26 CE1318 PILOT REPORTED AFTER PUTTING THE GEAR SELECTOR IN THE DOWN POSITION, THE GEAR WOULD NOT EXTEND, AFTER CYCLING GEAR SELEC TOR GEAR WENT DOWN, AC RETURNED TO BASE. ON TROUBLESHOOTING, THE MECHANIC SELECTED DOWN AND IT FAILED TO EXTEND, AFTER TAPPING ON TOP OF RELAY THE GEAR WENT DOWN. PROBABLE CAUSE AT THIS TIME IS UNKNOWN. INSTALLED NEW AND IMPROVED RELAY I AW DATE CODE. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005102500072 20051025 00072 EU 2005 10 25 2005FA0001441 1 20051021 G 2720 A740255N CONTROL CABLE LET L23 L23 1360308 EU RUDDER FRAYED B K NONE O OTHER IN INSP/MAINT 1 NM 03 410BA 160 029005 RT RUDDER CABLE FOUND FRAYED AT FORWARD NR 1 PULLEY. 1 K 0 0 RC G24EU 2005103100205 20051031 00205 SW 2005 10 31 2005FA0001442 1 20050930 G 2720 12364 CONTROL CABLE BBAVIA 7 7GCBC 1220601 SW LYC O320 O320* 41508 EA RUDDER BROKEN G O OTHER O OTHER LD LANDING 1 NM 03 113AW 5888 88876 LT RUDDER CABLE BROKE NEAR REAR SEAT BACK HINGE PIVOT BOLT. NO EVIDENCE OF CABLE CHAFFING ON REAR SEAT FRAME, PULLEY AR EA, CABLE GUIDE OR SIDE PANEL UPHOLSTERY. OPTIONAL WIDE REAR SEAT. NTSB SENT CABLE TO LAB FOR ANALYSIS. RESULTS PENDI NG. AC HAD MADE 3 LANDINGS ON THIS FLIGHT. ON 4TH LANDING, AIRCRAFT STARTED TO DRIFT RT, PILOT APPLIED CORRECTIVE LT P EDAL AND CABLE BROKE RESULTING IN A GROUND LOOP AND SUBSTANTIAL DAMAGE TO AIRCRAFT. (NM03200513237) (K) 1 H 7 1 3O 3 O NC A759 E274 2005103100204 20051031 00204 CE 2005 10 31 2005FA0001443 1 20050805 G 3230 GEARBOX CESSNA 414 414 2075908 CE CONT O520 TSIO520* 17040 SO MCAULY 3AF32C 3AF32C93 GL MLG WORN G O OTHER O OTHER NR NOT REPORTED 1 SW 17 414RJ 7468 4140632 NOSE LANDING GEAR COLLAPSED ON LANDING ROLL-OUT. UNABLE TO FIND A BROKEN PART, HOWEVER, LINKAGE WAS WORN INCLUDING PART S IN GEARBOX. CONDITION COULD LEAK TO INSUFFICENT OVER-CENTER TENSION ON DOWN LOCK LINKAGE. (SW17200508357) (K) 1 L 7 2 3O 3 O RT A7CE E8CE 5 C P22EA 2005110800346 20051108 00346 GL 2005 11 8 2005FA0001444 1 20051005 G 5610 2056000101 CANOPY DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240A SO COCKPIT SEPARATED D O OTHER O OTHER NR NOT REPORTED 1 EA 07 644DC 754 C0144 GLASS SEPARATING FROM FRAME. (EA07200505548) (K) 1 L 7 1 3O 3 O NT TA4CH E7SO 2005103100141 20051031 00141 GL 2005 10 31 2005FA0001445 1 20051005 G 5610 2056000101 CANOPY DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240A SO COCKPIT SEPARATED D O OTHER O OTHER NR NOT REPORTED 1 EA 07 542DC 1164 C0142 CANOPY GLASS SEPARATING FROM FRAME. (EA07200505547) (K) 1 L 7 1 3O 3 O NT TA4CH E7SO 2005103100142 20051031 00142 SO 2005 10 31 2005FA0001446 1 20051010 G 2910 50157001 LINE PIPER PA31T PA31T 7103124 SO HYDRAULIC SYS CHAFED B GW1R K NONE K FLUID LOSS IN INSP/MAINT 1 EA 03 78CA 5144 31T7920062 CUSTOMER REPORTED RED FLUID SEEP AT TOP IB OF RT WING. RT IB LEADING EDGES WERE REMOVED. IT WAS DETERMINED THAT A LEAD ING EDGE RETAINING SCREW HAD CHAFED THE RT HYDRAULIC PRESSURE LINE AND SUBSEQUENTLY CAUSED A HYDRAULIC LEAK. THE LINE W AS REPLACED AND THE AC WAS RETURNED TO SERVICE. THIS AREA IS NOT NORMALLY ACCESSED DURING PERIODIC INSPECTIONS. IT IS SUGGESTED THA THE AREA BE INSPECTED AT 800 HOUR INTERVALS. (EA03200602866) (K) 1 L 7 2 3T A8EA 2005103100047 20051031 00047 SO 2005 10 31 2005FA0001447 1 20050930 G 5730 89640826 SKIN PIPER PA46 PA46500TP 7104622 SO PWA PT6 PT6A42 52043 NE WING ROOT WRINKLED B ECWR O OTHER O OTHER NR NOT REPORTED 1 SO 15 53516 619 4697132 PCERM0140 DURING ANNUAL INSPECTION NOTED WING ROOTS, BOTH LT AND RT WRINKLED. AREA OF DEFECT IS FORWARD OF MAIN CARRY THRU SPAR. A SERIES OF 3 WAVES EXTENDING APPROXIMATELY 6-8 INCHES LONG. PROBABLE CAUSE: SEVERE TURBULENCE OR OVER CONTROL OF AIRC RAFT EXCEEDING (G) LIMITATIONS. WING REMOVED AND REPLACED. (K) 1 L 7 1 3O 4 T RT A25SO E4EA 2005103100016 20051031 00016 2005 10 31 2005FA0001448 1 20051012 G 8011 MCL6501 STARTER ENGINE FAILED B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 STARTER DOES NOT TURN FREELY BY HAND. (K) 2005103100130 20051031 00130 SO 2005 10 31 2005FA0001449 1 20051017 G 8011 BUSHING PIPER PA28 PA28161 7102803 SO STARTER FAILED B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 5336S 302 E123293 2842133 STARTER BENDIX, FRONT BUSHING FAILURE. (K) 1 L 7 1 3O 2A13 2005110900036 20051109 00036 NE 2005 11 9 2005FA0001450 2 20051012 G 7313 SEAL PWA JT8 JT8D15 52051 NE FUEL NOZZLE WRONG PART B Z3EY O OTHER W INADEQUATE Q C NR NOT REPORTED 1 WP 03 709210 INCORRECT SEAL INSTALLED ON PRE-ASB6169 FUEL NOZZLES, PT NR 809137-01, SEAL NR 814352 INSTALLED, CORRECT SEAL FOR PRE A SB6169 IS NR 775723. (K) 4 F E2EA 2005102800136 20051028 00136 SO 2005 10 28 2005FA0001451 2 20051021 G 8500 ENGINE CESSNA 421 421B 2076014 CE CONT O520 GTSIO520D 17032 SO MAKING METAL D O OTHER O OTHER NR NOT REPORTED 1 GL 09 6675Q 421B0442 219277R AT INITIAL 10 HR OIL CHANGE, A LARGE AMOUNT OF WHAT APPEARS TO BE BEARING MATERIAL WAS FOUND IN THE DRAIN OIL, DRAIN PLU G, AND ON FURTHER EXAMINATION, THE OIL FILTER. ENGINE WAS REMOVED FROM SERVICE AT THIS TIME AND SENT BACK TO OVERHAUL F ACILITY FOR FURTHER EXAMINATION. (K) 1 L 7 2 3O 3 O A7CE E7CE 2005103100201 20051031 00201 WP 2005 10 31 2005FA0001452 2 20050729 G 7230 18114PMA BEARING GARRTT TPE331 TPE33110 01514 WP COMPRESSOR FLAKING B DSCR O OTHER O OTHER NR NOT REPORTED 1 GL 25 112 P31201 PN 18114 IS PMA REPLACEMENT FOR PN 31014051. THIS BEARING WAS REMOVED WITH SEVERE FLAKING/ PEELING OF THE SILVER PLATIN G THAT RESULTED IN CONTAMINATION OF THE ENGINE OIL. (K) 4 T E4WE 2005103100049 20051031 00049 EU 2005 10 31 2005FA0001453 1 20050502 G 7160 350A108004 INTAKE SNIAS 350 AS350* EU ENGINE CRACKED B A7RR O OTHER O OTHER NR NOT REPORTED 1 SW 19 CRACKS IN BASE METAL AND PITTING. ENGINE VIBRATION EXPOSURE TO ENVIRONMENT. (K) 1 G 7 1 3U H9EU 2005103100086 20051031 00086 EU 2005 10 31 2005FA0001454 1 20051014 G 7160 350A54108004 INTAKE SNIAS 350 AS350* EU NACELLE CRACKED B A7RR O OTHER O OTHER NR NOT REPORTED 1 SW 19 CRACK IN BASE METAL FROM ENGINE VIBRATION. (K) 1 G 7 1 3U H9EU 2005103100087 20051031 00087 EU 2005 10 31 2005FA0001455 1 20051014 G 7810 117651121 EXHAUST PIPE BOLKMS 117 BK117A1 5626010 EU ENGINE CRACKED B A7RR O OTHER O OTHER NR NOT REPORTED 1 SW 19 EXHAUST PIPE, CRACKED IN BASE METAL FROM ENGINE VIBRATION. (K) 1 G 7 2 3U H13EU 2005103100099 20051031 00099 WP 2005 10 31 2005FA0001456 2 20050909 G 7250 TURBINE CESSNA 650 650 2076802 CE GARRTT TFE731 TFE7314R 01518 WP ENGINE FAILED B CNQ3 A UNSCHED LANDING E X J VIBRATION/BUFFET ENGINE FLAMEOUT WARNING INDICATION CR CRUISE 1 GL 13 175DP 1302 6507116 102348 AIRCRAFT WAS LEVEL AT 38,000 FT AND THE CREW REPORTED THEY HEARD AN AUDIBLE THUD. UPON SCANNING THE COCKPIT INSTRUMENTS THE LT ENGINE WAS OBSERVED TO BE SHUTTING DOWN NON-COMMANDED. AIRCRAFT LANDED WITHOUT INCIDENT. INITIAL INSPECTION RE VEALED THE LT ENGINE EXPERIENCED A NON-CONTAINED FAILURE IN THE AREA OF THE TURBINE SECTION. FAILED ENGINE WAS REMOVED FROM AIRCRAFT AND SHIPPED TO MFG FOR INVESTIGATIVE TEARDOWN. (K) 2 L 7 2 4F 4 F A9NM E6WE 2005110800288 20051108 00288 CE 2005 11 8 2005FA0001457 1 20051010 G 2750 TRANSMITTER BEECH MU300 400A 1155402 CE PWA JT15 JT15D1 52060 NE TE FLAPS OUT OF ADJUST B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 419CW RK19 FLAP ASYMMETRY ANNUNCIATOR ILLUMINATED DURING APPROACH. FOUND MIDBOARD ASYMMETRY DETECTOR READING 5.7 VOLTS. FOUND IB ASYMMETRY DETECTOR READING 7.8 VOLTS. ADJUSTED LT AND RT FLAP POSITION TRANSMITTERS AS REQUIRED IAW MM TO BRING VOLTAGE S TO 5.8 VOLTS +/- 0.2 VOLTS. FLAP SYSTEM FUNCTIONAL CHECKS SATISFACTORY, NO ASYMMETRY FAULTS INDICATED AFTER 20 CYCLES . (K) 2 H 7 2 4F 4 F RT A16SW E1NE 2005102700018 20051027 00018 EU 2005 10 27 2005FA0001458 1 20050428 G 7810 M10DE0104 EXHAUST STACK AEROSP ATR42 ATR42* 8680900 EU ENGINE CRACKED B A7RR O OTHER O OTHER NR NOT REPORTED 1 SW 19 CRACKING IN EXHAUST DUCT BASE METAL, ENGINE VIBRATION. (K) 2 H 7 2 4T RT A53EU 2005102700020 20051027 00020 EU 2005 10 27 2005FA0001459 1 20050430 G 7810 7811200000200 EXHAUST PIPE AEROSP ATR42 ATR42* 8680900 EU ENGINE CRACKED B A7RR O OTHER O OTHER NR NOT REPORTED 1 SW 19 CRACKS IN BASE METAL NEAR FLANGE. ENGINE VIBRATION. (K) 2 H 7 2 4T RT A53EU 2005102700021 20051027 00021 EA 2005 10 27 2005FA0001460 1 20050421 G 3210 C6UM11107 LANDING GEAR DHAV DHC6 DHC6 2802606 EA MAIN CRACKED B A7RR O OTHER O OTHER NR NOT REPORTED 1 SW 19 LANDING GEAR, CRACK IN WELD, CAUSED BY CYCLIC STRESS DUE TO LANDING LOADS. (K) 1 H 7 2 3T RT A9EA 2005110800303 20051108 00303 EU 2005 11 8 2005FA0001461 1 20051005 G 5412 L713M2072104 FIREWALL UROCOP EC135 EC135P1 8680990 EU FUSELAGE CRACKED B A7RR O OTHER O OTHER NR NOT REPORTED 1 SW 19 FIREWALL, CRACK IN BASE METAL DUE TO ENGINE VIBRATION. (K) 1 G 7 2 3U O H88EU 2005110800287 20051108 00287 EU 2005 11 8 2005FA0001462 1 20051011 G 7810 S7811200000200 PIPE AEROSP ATR72 ATR72 EU ENGINE CRACKED B A7RR O OTHER O OTHER NR NOT REPORTED 1 SW 19 JET PIPE, CRACK IN BASE METAL PARALLEL TO ATTACH FLANGE, FROM VIBRATION. (K) 2 H 7 2 4T RT 2005103100018 20051031 00018 CE 2005 10 31 2005FA0001463 1 20051004 G 2721 6226717104 SERVO BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE RUDDER BOOST INTERMITTENT B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 480LX RK398 INVESTIGATED PILOT REPORT OF INTERMITTENT (RUDDER BOOST FAIL) ANNUNCIATOR LIGHT DURING TAKEOFF, CRUISE, AND CLIMB SEGMEN TS. FOUND RUDDER SERVO WOULD SPIKE HIGH VOLTAGE BUT YAW DAMPER WOULD STAY ENGAGED. REPLACED RUDDER BOOST SERVO W/OVERH AULED REPLACEMENT UNIT, SYSTEM FUNCTIONAL TESTS SATISFACTORY. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2005110800342 20051108 00342 SO 2005 11 8 2005FA0001464 1 20051012 G 3244 304K632 TIRE EMB 135 EMB135BJ 3260306 SO MLG LEAKING B WC7R O OTHER O OTHER NR NOT REPORTED 1 GL 25 DURING LEAK CHECK OF A NEW TIRE, IT WAS DISCOVERED THAT THE SIDEWALL WEEP HOLES WERE LEAKING, THIS CONDITION WAS NOTICED AFTER THE TIRE HAD COMPLETED A 12 HOUR LEAK CHECK. (K) 2 L 7 2 4F RT 2005103100051 20051031 00051 2005 10 31 2005FA0001465 4 20051003 G 3418 07133481 STALL WARNING CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA RT WING INOPERATIVE D O OTHER P NO WARNING INDICATION NR NOT REPORTED 1 EA 07 5352A 587 172S9382 DURING STUDENTS STALL PRACTICE THE WARNING HORN FAILED TO OPERATE THROUGH FULL STALL, CFI HALTED MANEUVER. TROUBLESHOOT ING CONFIRMED THAT WARNING HORN ASSY, PN 07133481 WAS DEFECTIVE. UNIT WAS REPLACED WITH NEW. THIS IS THE 7TH HORN REPL ACED IN THIS FLIGHT SCHOOL IN CAUSE IS THE CHEAP GRADE OF PLASTIC USED TO MFG THE REED IN THIS ITEM. 1 H 7 1 3O 3 O NT 3A12 1E10 2005102800065 20051028 00065 CE 2005 10 28 2005FA0001466 1 20051021 G 7603 1065240159 LINKAGE BEECH 58 58 1152740 CE THROTTLE JAMMED B O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION LD LANDING 1 WP 27 879JN 849 TH2066 DURING POWER APPLICATION FOR TOUCH AND GO, UNABLE TO ADVANCE THROTTLE ON RT ENGINE. FOUND THE LOWER NUT WHICH SECURES T HE PHENOLIC BLOCK FOR THE ANTI-RETRACT CAM TO THE THROTTLE LINKAGE ROD HAD COME OFF, ALLOWING THE BLOCK TO SEPARATE FROM THE LINKAGE ROD. DURING ATTEMPTED POWER-UP, THE NOW UNATTACHED LINKAGE ROD JAMMED AGAINST THE AIRCRAFT STRUCTURE. THE PHENOLIC BLOCK IS ATTACHED TO THE ROD WITH AN315 NUTS AND SECURED WITH A SPLIT LOCK-WASHER. RECOMMEND THAT THE LOWER NUT ESPECIALLY BE REPLACED WITH A MS21044N3 NUT, OR BETTER YET A NAS1291-3 NUT, WHICH IS EASIER TO INSTALL. 1 L 7 2 3O 3A16 2005103100107 20051031 00107 2005 10 31 2005FA0001467 1 20051012 G 8011 MCL6501 STARTER ENGINE FAILED B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 STARTER DOES NOT TURN FREELY BY HAND. (K) 2005103100118 20051031 00118 CE 2005 10 31 2005FA0001468 1 20051002 G 2810 20344 FUEL CELL BEECH 58 58 1152740 CE CONT O520 IO520* 17032 SO RT WING IB FAILED B EA4R A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION NR NOT REPORTED 1 SO 09 92DD 504 TH1167 WHILE ENROUTE, PILOT EXPERIENCED TOTAL LOSS OF REMAINING FUEL IN RT WING. DURING FLIGHT WITHOUT WARNING. SUBSEQUENTLY RT ENGINE EXPERIENCED UNCOMMANDED SHUTDOWN DUE TO FUEL STARVATION. LARGE QUANTITY OF FUEL LOST IN SHORT TIME. PILOT LA NDED, TROUBLESHOT AC AND FOUND RT IB FUEL CELL LEAKING. FUEL CELL REMOVED AND INSPECTED. INSPECTION REVEALED INTERCONN ECT PORTION OF FUEL CELL HAD DEBONDED FROM CELL. RECOMMEND FAA INSPECT SUBJECT CELL AND DETERMINE REASON FOR PREMATURE FAILURE. DUE TO LOCATION OF FAILURE, REGULAR INSPECT OF FAILURE POINT IS NOT OPTION. 1 L 7 2 3O 3 O 3A16 E5CE 2005110100001 20051101 00001 EU 2005 11 1 2005FA0001469 1 20051027 G 3210 A751305N DAMPER LET L23 L23 1360308 EU MLG CRACKED B O OTHER O OTHER NR NOT REPORTED 1 NM 03 437BA 1135 029015 UPPER HINGE ARM OF GEAR STRUT CRACKED AT WELDS. 1 K 0 0 RC G24EU 2005110700175 20051107 00175 EA 2005 11 7 2005FA0001470 2 20051028 G 7497 P-LEAD PIPER PA22 PA22150 7102210 SO LYC O320 O320* 41508 EA LT MAGNETO DETERIORATED D K NONE O OTHER IN INSP/MAINT 1 GL 13 7721D 2309 2309 225395 DURING RUNUP AFTER ANNUAL INSPECTION, LT MAG WAS NOT WORKING. FOUND INSULATION ON P-LEAD WIRE WAS DETERIORATING AND SHO RTING TO SHIELDING CAUSING MAG TO BE CONTINUOUSLY GROUNDED NO MATTER WHAT SWITCH POSITION WAS. REPLACED SECTION OF P-LE AD AS REQUIRED. THIS WIRING IS DIRECTLY ABOVE EXHAUST AND DETERIORATION WAS PROBABLY CAUSED BY HEAT OF EXHAUST SYSTEM O VER TIME. 1 H 7 1 3O 3 O 1A6 E274 2005110700176 20051107 00176 EA 2005 11 7 2005FA0001471 2 20051028 G 7497 P-LEAD PIPER PA22 PA22150 7102210 SO LYC O320 O320* 41508 EA MAGNETO DETERIORATED D K NONE O OTHER IN INSP/MAINT 1 GL 13 7721D 2309 2309 225395 DURING RUNUP AFTER ANNUAL INSPECTION, LT MAG WAS NOT WORKING. FOUND INSULATION ON P-LEAD WIRE WAS DETERIORATING AND SH ORTING TO SHIELDING CAUSING MAG TO BE CONTINUOUSLY GROUNDED NO MATTER WHAT SWITCH POSITION WAS. REPLACED SECTION OF P-L EAD AS REQUIRED. THIS WIRING IS DIRECTLY ABOVE EXHAUST AND DETERIORATION WAS PROBABLY CAUSED BY HEAT OF EXHAUST SYSTEM OVER TIME. 1 H 7 1 3O 3 O 1A6 E274 2005110700177 20051107 00177 EA 2005 11 7 2005FA0001472 2 20051028 G 7497 P-LEAD PIPER PA22 PA22150 7102210 SO LYC O320 O320* 41508 EA MAGNETO DETERIORATED D K NONE O OTHER IN INSP/MAINT 1 GL 13 7721D 2309 2309 225395 DURING RUNUP AFTER ANNUAL INSPECTION, LEFT MAG WAS NOT WORKING. FOUND INSULATION ON P-LEAD WIRE WAS DETERIORATING AND SHORTING TO SHIELDING CAUSING MAG TO BE CONTINUOUSLY GROUNDED NO MATTER WHAT SWITCH POSITION WAS. REPLACED SECTION OF P- LEAD AS REQUIRED. THIS WIRING IS DIRECTLY ABOVE EXHAUST AND DETERIORATION WAS PROBABLY CAUSED BY HEAT OF EXHAUST SYSTEM OVER TIME. 1 H 7 1 3O 3 O 1A6 E274 2005110700178 20051107 00178 EA 2005 11 7 2005FA0001473 2 20051028 G 7497 P-LEAD PIPER PA22 PA22150 7102210 SO LYC O320 O320* 41508 EA MAGNETO DETERIORATED D K NONE O OTHER IN INSP/MAINT 1 GL 13 7721D 2309 2309 225395 DURING RUNUP AFTER ANNUAL INSPECTION, LEFT MAG WAS NOT WORKING. FOUND INSULATION ON P-LEAD WIRE WAS DETERIORATING AND SHORTING TO SHIELDING CAUSING MAG TO BE CONTINUOUSLY GROUNDED NO MATTER WHAT SWITCH POSITION WAS. REPLACED SECTION OF P- LEAD AS REQUIRED. THIS WIRING IS DIRECTLY ABOVE EXHAUST AND DETERIORATION WAS PROBABLY CAUSED BY HEAT OF EXHAUST SYSTEM OVER TIME. 1 H 7 1 3O 3 O 1A6 E274 2005110900058 20051109 00058 EU 2005 11 9 2005FA0001474 1 20051012 G 3320 6335110 BULB BRAERO DH125 BAE125800A 1500285 EU GARRTT TFE731 TFE731* 01518 WP CABIN LIGHTING IMPROPER PART B JGVR O OTHER W INADEQUATE Q C NR NOT REPORTED 1 CE 09 803JL 258160 A SELA FLORESCENT BULB WAS FOUND IN THE CABIN LIGHTING SYSTEM. THIS SYSTEM IS AN ALC SYSTEM. THE SELA BULB HAD IMPROPE R CONNECTORS ON IT AS WELL. WE CHANGED OUT THE SELA BULB WITH AN ALC BULB AND USED THE PROPER CONNECTORS WHEN INSTALLIN G IAW AD 95-22-01 AND IB 90-001. (K) 2 L 7 2 4F 4 F RT A3EU E6WE 2005110800281 20051108 00281 EA 2005 11 8 2005FA0001475 2 20051025 G 7200 ENGINE DHAV DHC7 DHC7102 2802708 EA PWA PT6 PT6A50 52043 EA SEIZED B K08R O OTHER O OTHER NR NOT REPORTED 1 SW 01 34HG 34 86183 ENGINE INSTALLED ON AIRCRAFT AFTER RETURN FROM REPAIR FACILITY. DURING INITIAL GROUND RUN OF ENGINE THE POWER LEVER SEI ZED AND VERY HARD TO MOVE. ENGINE TEMPERATURE AND PRESSURE WERE NORMAL. FEATHERED THE PROPELLER AND SHUTDOWN ENGINE. POST INSPECTION SHOWED NO LEAKS WITH THE PROPELLER VERY HARD TO TURN AND BETA REVERSING LEVER SEIZED. (K) 2 H 7 4 4T 4 T A20EA E4EA 2005110900090 20051109 00090 SO 2005 11 9 2005FA0001476 1 20050911 G 2910 NAS161210A O-RING GULSTM G1159 GIV 3980115 SO RROYCE SPEY SPEY5118 54523 EU HYD SHUTOFF VLVE LEAKING B EBVR O OTHER K FLUID LOSS NR NOT REPORTED 1 CE 09 165ST 3 1053 HYD LINE WAS REPLACED DUE TO CRACK IN FLARE AT TEE FITTING. REPLACEMENT OF LINE REQUIRED INSTALL OF NEW O-RING, WHERE T EE FITTING ATTACHES TO FLIGHT CTRL HYD SHUT OFF VALVE. AFTER INSTALL OF HYD LINE AND O-RING, A LEAK CHECK WAS PERFORMED . NO LEAKS WERE NOTED. AC WAS APPROVED FOR RETURN TO SERVICE. AFTER 2.6 HOURS, O-RING FAILED CAUSING LEAKAGE OF HYD F LUID FROM COMBINED HYD SYS. AC MADE PRECAUTIONARY LANDING. MAINT REPLACED DEFECTIVE O-RING AND SERVICED HYDR SYS. LEA K CHECK WAS PERFORMED AND NO DEFECTS WERE NOTED. DEFECTIVE O-RING WAS INSPECTED AND FOUND TO BE CUT. DETERMINATION ALSO COULD NOT BE MADE AS TO WHY O-RING FAILED 2.6 HOURS AFTER INSTALLATION, INITIAL LEAK CHECK SHOWED NO DEFECTS. 2 L 7 2 4F 4 F RT A12EA E2EU 2005110700171 20051107 00171 CE 2005 11 7 2005FA0001477 1 20051010 G 5740 SUPPORT BRACKET CESSNA 182 182P 2075816 CE CONT O470 O470* 17026 SO BEND RADIUS CRACKED D O OTHER O OTHER NR NOT REPORTED 1 NM 02 888SR 8872 18261455 WING T/E SKIN SUPPT BRKT CRACKED CAUSED FLAP INTERFERENCE AND FAILURE. BRKT IS ATTACHED TO EACH FLAP TRACK RIB INSIDE T /E OF WING, SUPPT T/E WING SKIN IN FLAP BAY. PART CRACKED, ALLOWED FLAP SUPPT TO GET CAUGHT DURING FLAP RETRACTION, BIN DING FLAP. FLAP STRUCTURE FAILED BEFORE FLAP MOTOR CAUSED CB TO TRIP. RESULTING CONFIGURATION OF FLAP CAUSED YAW IN FL T. VERY LITTLE CLEARANCE BTWN THESE BRKTS AND/OR CRACKED WING SKINS AT BRKT ATTACH POINT, FLAP SUPPT RAILS BY DESIGN. BRKTS REST FIRMLY AGAINST UPPER PORTION OF FLAP SUPPT RAILS WHEN FLAPS ARE FULLY RETRACTED, PROPERLY RIGGED. BRKT APPEA RS TO BE A SUB-PART OF WHOLE RIB ASSY. IRREGULARITY OF RIVET HOLES IN BRKTS, FLAP TRACK RIB, HAND DRILLED AT FACTORY. 1 H 7 1 3O 3 O NT TA13 E273 2005110700169 20051107 00169 SO 2005 11 7 2005FA0001478 1 20051010 G 3210 67040012 FITTING PIPER PA34 PA34200 7103405 SO LYC O360 IO360A1A 41514 EA MLG UNSERVICEABLE D O OTHER O OTHER NR NOT REPORTED 1 NM 02 2871T 5966 347250178 MLG PIVOT CASTING (FWD TRUNNION FITTING ASSY) ATTACH HARDWARE CONTINUALLY COMES LOOSE ALLOWING CHAFFING BETWEEN CASTING, WING SPAR, ENLARGING ATTACH BOLT HOLES IN CASTING AND SPAR. AFFECTED LT CASTING HAD BEEN PREVIOUSLY REMOVED, INSPECTED AND INSTALLED IAW MM FOR THIS REASON ONLY 100 HRS PRIOR TO THIS REOCCURENCE. CONDITION HAD BEEN NOTED ON RT CASTING AT SAME INSPECTION HAD BEEN CORRECTED BY REPLACING CASTING WITH NEW, REAMING ATTACH HOLES IN CASTING, SPAR (UTILIZING APPR OVED DATA) TO ACCEPT BOLTS. NUTPLATES ON THE FWD SIDE OF WING SPAR, NOT ADEQUATE TO ACCEPT STRESSES IMPOSED ON THEM, L EADING FACTOR IN CONTINUAL LOOSENING OF FWD PIVOT CASTING ATTACH HARDWARE. 1 L 7 2 3O 3 O A7SO 1E10 2005110800312 20051108 00312 NM 2005 11 8 2005FA0001479 1 20051026 G 2997 WIRE BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE CONTROL VALVE CROSSED B MEDY O OTHER O OTHER NR NOT REPORTED 1 SW 15 977RY 32740 DURING TROUBLESHOOTING FOLLOWING PTU TEST FIRE, THE PTU CONTROL VALUE AS FOUND FAILED IN CLOSED POSITION WITH 28 VDC ON PIN: 2 OF VALVE CONNECTOR. AN INVESTIGATION REVEALED WIRES WERE CROSSED AT MFG. WIRING REMADE IAW WDM2911 AND NEW VAL VE FIT. (SW15200606366) (K) 2 L 7 2 4F 4 F RT A16WE E2GL 2005110900115 20051109 00115 CE 2005 11 9 2005FA0001480 1 20051018 G 3610 CLAMP BEECH 58 58P 1152744 CE CONT O520 TSIO520WB 17040 SO INTERCOOLER DUCT LOOSE B VT3R O OTHER O OTHER NR NOT REPORTED 1 WP 09 6677L TJ209 518463 IN CRUISE FLIGHT, 2500 RPM, 35 HG, PILOT NOTED L/ENGINE LOST POWER. PILOT FEATHERED PROPELLER AND POWERED ENGINE. MAIN T NOTED INTERCOOLER DUCT, PN 102-389003-3 LOOSE AT DUCT SERV CLAMP WAS LOOSE, DUCT WAS PARTIALLY DETACHED. REPLACED DUC T, RUNUP OK. (K) 1 L 7 2 3O 3 O A23CE E8CE 2005110900104 20051109 00104 EU 2005 11 9 2005FA0001481 1 20051004 G 2913 259SF3325 DRAIN BRAERO 1000 BAE1251000A 1500104 EU PWA 305 PW305 NE HYD PUMP CHAFED B JGVR O OTHER O OTHER NR NOT REPORTED 1 CE 09 503QS 259003 RT HYDRAULIC PUMP CASE DRAIN HYDRAULIC LINE RUPTURED IN FLIGHT, DRAINING HYDRAULIC FLUID FROM THE AIRCRAFT SYSTEM. FOUN D RT HYDRAULIC PUMP CASE DRAIN LINE CRACKED WHERE LINE HAS BEEN CHAFING. INSPECTED AIRCRAFT AND FOUND SIMULAR CHAFE IN SAME LINE IN SAME LOCATION IN AFT EQUIPMENT BAY. THIS APPEARS TO BE A COMMON PROBLEM IN THE 1000 SERIES AIRCRAFT WITH T HE PROXIMITY OF THE AFT BAY HYDRAULIC LINE RUNS. (K) 2 L 7 2 4F 4 F RT A3EU E35NE 2005110800328 20051108 00328 SO 2005 11 8 2005FA0001482 2 20051014 G 8520 633620 CRANKSHAFT BEECH 50 50 1152502 CE CONT O470 IO470* 17026 SO ENGINE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 EA 21 9057Q 591 TC1366 215778R CRANKSHAFT DEVELOPED CRACK BEHIND PROP FLANGE .3333 - .5 AROUND SHAFT IN FLIGHT, LEAKED OIL STEADY ON GROUND RUN. (EA212 00603317) (K) 1 L 7 2 3O 3 O 5A4 E1CE 2005110900060 20051109 00060 GL 2005 11 9 2005FA0001483 1 20051005 G 5344 HINGE DIAMON DA40 DA40 2990002 GL CONT IO360 IO360* 17025 CE AFT CABIN DOOR FAILED B XR0R O OTHER O OTHER NR NOT REPORTED 1 SW 05 541DS 041 UPON INSTALLATION OF A NEW AFT CABIN DOOR SUPPORT STRUT, THE DOOR WAS CLOSED, AND THE AFT CABIN DOOR HINGE FAILED. UPON FURTHER INSPECTION, THE DOOR HINGE WAS FOUND TO HAVE BEEN DELAMINATED WHICH COULD NOT WITHSTAND THE PRESSURE OF THE NEW SUPPORT STUT. THE DOOR HINGE IS BONDED TO THE DOOR ASSY, AND IS NOT REPLACEABLE IN THE FIELD. (SW05200512642) (K) 1 L 7 1 3O 3 O NT A47CE E1CE 2005110900008 20051109 00008 EA 2005 11 9 2005FA0001484 2 20051019 G 7322 NEEDLE VALVE AMTR GLASTR GLASTAR 05605M8 GL LYC O320 O320* 41508 EA CARBURETOR FAILED G O OTHER O OTHER NR NOT REPORTED 1 EA 09 722W 44 5207 L466827A DURING CRUISE FLIGHT ENGINE QUIT SUDDENLY. PILOT APPLIED CARBURETOR HEAT, CHECKED HIS FUEL GAUGE, WHICH SHOWED 5 PSI A ND TURNED ON THE ELECTRIC FUEL PUMP AND SWITCHED TO ANOTHER FUEL TANK. ALL HAD NO EFFECT. PILOT WAS ABLE TO MAINTAIN 2 000 RPM ON ENGINE BY PUMPING THE PRIMER HANDLE IN AND OUT. PILOT LANDED THE AIRCRAFT AND WAS UNABLE TO STOP THE AIRCRAF T, IT FLIPPED OVER. CARBURETOR WAS DISASSEMBLED AND THE FLOAT ACTUATED AND RELEASED, NEEDLE VALVE STUCK IN THE CLOSED P OSITION. BLACK PARTICLES WERE FOUND IN THE FLOAT BOWL. ACTUATION OF THE NEEDLE SEVERAL TIMES APPEARED TO CORRECT THE P ROBLEM. IT IS STILL A LITTLE STICKY BUT DOES NOT REMAIN CLOSED WHEN THE FLOAT IS RELEASED. (K) 1 H 7 1 3O 3 O NC EXPA1H71 E274 2005110700094 20051107 00094 EU 2005 11 7 2005FA0001485 1 20050923 G 2497 FEEDER CABLE AEROSP ATR72 ATR72202 8680940 EU RT CABIN AREA CHAFED B G78R O OTHER O OTHER NR NOT REPORTED 1 SW 17 EIFXG 29863 224 DURING INDUCTION INSPECTION FOR PASSENGER TO FREIGHTER CONVERSION MODIFICATION, INSPECTION REVEALED 2 AREAS OF SEVERE CH AFING RESULTING IN EXPOSURE OF CONDUCTOR WIRES FOR AC WILD FEEDERS AT RT SIDE CABIN AREA BETWEEN FRAMES 15-17 APPROXIMAT ELY STRINGER 5R. (K) 2 H 7 2 4T RT A53EU 2005110700095 20051107 00095 EU 2005 11 7 2005FA0001486 1 20050923 G 2497 FEEDER CABLE AEROSP ATR72 ATR72212 8680945 EU RT CABIN AREA CHAFED B G78R O OTHER O OTHER NR NOT REPORTED 1 SW 17 812FX 23020 404 DURING INDUCTION INSPECTION FOR PASSENGER TO FREIGHTER CONVERSION MODIFICATION, INSPECTION REVEALED 2 AREAS OF SEVERE CH AFING RESULTING IN EXPOSURE OF CONDUCTOR WIRES FOR AC WILD FEEDERS AT RT SIDE CABIN AREA BETWEEN FRAMES 15-17 APPROXIMAT ELY STINGER 5R. (SW17200603842) (K) 2 H 7 2 4T RT A53EU 2005110900039 20051109 00039 CE 2005 11 9 2005FA0001487 1 20051025 G 2752 3903814020020 ACTUATOR RAYTHN 390 390 7150030 CE TE FLAPS FAILED B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 322BJ 336 RB93 INSTALLED .0 TIME SINCE FACTORY MODIFIED NR 2R FLAP ACTUATOR AS PART OF COMPLIANCE WITH MFG MSB. (FLAP FAIL) ANNUNCIATO R ILLUMINATED AFTER INSTALLATION. FLAP SYSTEM TROUBLESHOOTING SHOWED FAULT CODES 3, 8 AND THEN 1,3, 8. ANNUNCIATOR NOT ILLUMINATED AFTER REINSTALLING ORIGINAL ACTUATOR. REPLACED ACTUATOR WITH MODIFIED ACTUATOR, NO ADDITIONAL (FLAP FAIL) ANNUNCIATOR INDICATIONS NOTED. (K) 1 7 2 3F RT A00010WI 2005110900063 20051109 00063 CE 2005 11 9 2005FA0001488 1 20051025 G 2752 3903814020018 ACTUATOR RAYTHN 390 390 7150030 CE TE FLAP FAILED B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 322BJ RB93 INSTALLED .0 TIME SINCE FACTORY, MODIFIED NR 1L FLAP ACTUATOR AS PART OF COMPLIANCE WITH MFG MSB. (FLAP FAIL) ANNUNCIAT OR ILLUMINATED AFTER INSTALLATION. FLAP SYSTEM TROUBLESHOOTING SHOWED FAULT CODES 2,8 AND THEN 1,2, 8. ANNUNCIATOR NOT ILLUMINATED AFTER REINSTALLING ORIGINAL ACTUATOR. REPLACED ACTUATOR WITH MODIFIED ACTUATOR, NO ADDITIONAL (FLAP FAIL) ANNUNCIATOR INDICATIONS NOTED. (K) 1 7 2 3F RT A00010WI 2005110800304 20051108 00304 SO 2005 11 8 2005FA0001489 1 20051006 G 7603 455350 THROTTLE CABLE PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA ENGINE BROKEN D O OTHER O OTHER NR NOT REPORTED 1 NE 01 8285B 9670 288116066 L1191039A THE THROTTLE CABLE BROKE IN HALF, INSIDE THE THROTTLE CABLE HOUSING. WHEN THE THROTTLE CABLE BROKE, IT CREATED FREYED E NDS THAT CAUGHT IN THE CABLE HOUSING WHICH RESULTED IN THE THROTTLE BECOMING (STUCK) IN THE FULL POSITION WHICH ENDED IN THE PILOT PULLING THE MIXTURE TO FULL LEAN POSITION AND LANDING (DEAD STICK) AT OTIS ANG BASE. (NE01200505868) (K) 1 L 7 1 3O 3 O 2A13 E274 2005110900075 20051109 00075 2005 11 9 2005FA0001490 4 20050929 G 3497 CONNECTOR LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE731* 01518 WP ADC LOOSE B BSYR O OTHER O OTHER NR NOT REPORTED 1 GL 07 130F 044 THE PILOTS ALTIMETER FLAGGED WHILE ENROUTE. THE FLIGHT CREW NOTIFIED ATC. SEVERAL MINUTES LATER THE ALTIMETER BEGAN WO RKING NORMALLY. THE CONNECTIONS WERE CHECKED AND A BITE TEST WAS PERFORMED ON THE ADC WITH NO DEFECTS NOTED. AC WAS RE TURNED TO SERVICE AND CONTINUED FLIGHT. WHILE ON THE GROUND, THE ALTIMETER AND ADC CONNECTIONS WERE RECHECKED. BOTH PR IMARY ALTIMETERY SYSTEMS WERE RUN TO ALTITUDE USING A DPS 500 AND NO DEFECTS WERE NOTED. THERE HAVE BEEN NO PRIOR REPOR TS OF ALTIMETERY ERRORS ON THE AIRCRAFT. (K) 2 L 7 2 4F 4 F A10CE E6WE 2005110900074 20051109 00074 2005 11 9 2005FA0001491 1 20050901 G 5514 EX405RC BEARING AMD HORIZONTAL STAB CORRODED B SE2R O OTHER O OTHER NR NOT REPORTED 1 CE 03 TAILPLANE ACTUATOR EXCEEDED SCREW CASING END PLAY LIMIT OF 0.25 MM AS LISTED IN MM. DISASSEMBLED UNIT AND FOUND PRESENC E OF WATER CONTAMINATION AND INTERNAL BALL BEARINGS RUSTED. DATE DISCOVERED 17 AUG 2005. UNIT SHOULD BE CHECKED INTERN ALLY FOR CONDITION OF BALL BEARINGS AND PROPER LUBRICATION. AT PRESENT, MFG MM PROVIDE NO SCHECULED INTERVALS TO MONITO R BEARING CONDITIONS. (K) 2005110900077 20051109 00077 2005 11 9 2005FA0001492 1 20051101 G 2742 3661RSP5 BEARING HORIZ STAB ACT CORRODED B SE2R O OTHER O OTHER NR NOT REPORTED 1 CE 03 TAILPLANE ACTUATOR EXCEEDED SCREW/CASING END PLAY LIMIT OF 0.25 MM AS LISTED IN MM. DISASSEMBLED UNIT AND FOUND PRESENC E OF WATER CONTAMINATION AND INTERNAL BALL BEARINGS RUSTED. DATE DISCOVERED 17 AUG 2005. UNIT SHOULD BE CHECKED INTERN ALLY FOR CONDITION OF BALL BEARINGS AND PROPER LUBRICATION. AT PRESENT MM PROVIDES NO SCHEDULED INTERVALS TO MONITOR BE ARING CONDITIONS. (K) 2005110900073 20051109 00073 SW 2005 11 9 2005FA0001493 1 20051020 G 5711 450001 SPAR AIRTRC AT400 AT402 0390205 SW PWA PT6 PT6A15AG 52043 NE WING SEPARATED B AXTR O OTHER O OTHER NR NOT REPORTED 1 SW 19 2116 THE MAIN SPARS (PN 4500-01 AND 4500-02, RT AND LT) WERE BROKEN AWAY FROM THE WINGLET. WINGLETS AND SPAR ARE PART OF STC INSTALLATION. SPAR IS ATTACHED TO INSIDE WINGLET WITH FIBERGLASS CLOTH. CLOTH WAS TORN AND DELAMINATED. SPAR WAS COM PLETELY SEPARATED FROM WINGLET ON RT SIDE AND MOSTLY SEPARATED ON THE LT SIDE. DISCOVERED DURING INSPECTION. 1 L 7 1 3T 4 T NC A17SW E4EA 2005110900080 20051109 00080 2005 11 9 2005FA0001494 1 20051021 G 5520 AN5158R26 SCREW CESSNA CESSNA TRIM TAB CORRODED B AK6R O OTHER O OTHER NR NOT REPORTED 1 SW 19 THERE ARE 4 SCREWS WHICH HOLD THE ELEVATOR TRIM TAB HORN TO THE TRIM TAB. HAVE STARTED TO REMOVE THESE SCREWS ON EVERY ANNUAL WE DO ON 300/400 SERIES. HAVE FOUND NUMEROUS SCREWS CORRODED ALMOST IN HALF. THERE IS NOT A WAY TO INSPECT THESE SCREWS WITHOUT REMOVAL. DUE TO THE CRITICAL NATURE OF THESE SCREWS AND THE AGEING FLEET. RECOMMEND MANDITORY REMOVAL AND INSPECTION AT EACH ANNUAL INSPECTION. (K) 2005110900092 20051109 00092 SO 2005 11 9 2005FA0001495 1 20051018 G 7120 6711957 MOUNT PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA MCAULY 2D34C B2D34C213 GL ENGINE BROKEN B OG5R K NONE O OTHER IN INSP/MAINT 1 GL 21 283ND 4437 2844025 L2713851A 00906 DURING ROUTING SCHEDULED MAINTENANCE INSPECTION NOTED ENG MOUNT WAS CRACKED JUST ABOVE WELD ON RT LOWER SIDE OF ENGINE M OUNT. JUST ABOVE AFT DRAGLINK MOUNT POINT. ALSO, UPON FURTHER INSPECTION THE LOWER HORIZONTAL TUBE MOST OB WAS ALSO BE NT. MOS NOTED TOWARD THE FRONT PART OF THE MOUNT BY THE LANDING GEAR ATTACH POINT. NO HARD LANDING HAD BEEN REPORTED. (K) 1 L 7 1 3O 3 O 2A13 1E10 5 C P7EA 2005110900109 20051109 00109 CE 2005 11 9 2005FA0001496 1 20051020 G 3233 98820152 ACTUATOR CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA MLG DOOR CRACKED B BX4R O OTHER O OTHER NR NOT REPORTED 1 NM 03 5136R 172RG0040 COMPLYING WITH SB, FOUND BFE BORE CRACKED IAW ILLUSTRATION OF ACCOMPLISHEMENT OF INSTRUCTION OF SEB. (K) 1 H 7 1 3O 3 O 3A17 E286 2005110900113 20051109 00113 SW 2005 11 9 2005FA0001497 1 20050915 G 5311 SPAR GULSTM 112 112A 7630302 SW LYC O360 TO360A1A6 41514 EA FUSELAGE DAMAGED B BX4R O OTHER O OTHER NR NOT REPORTED 1 NM 03 100PP 412 FOUND LT AND RT MAIN SPAR WEBS DAMAGED FROM STATION 50 TO 63. EACH WEB HAD DIAGONAL WRINKLES FROM TOP OF SPAR, JUST IB OF LANDING GEAR ATTACH AREA, DOWN AND IB TO JUST OB OF DRAG BRACE BRACKET AND REINFORCEMENTS. AIRCRAFT HAS BEEN FOUND T O BE IN COMPLIANCE WITH AD. BY REINFORCEMENT KIT INSTALLED IAW SB. NO CRACKS DETECTED ATH THIS DATE. (K) 1 L 7 1 3O 3 O A12SO E26EA 2005110900006 20051109 00006 2005 11 9 2005FA0001498 4 20051020 G 3416 ENCODER CESSNA 185 A185F 2072821 CE ALTITUDE FAILED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 6590E 18504058 FOLLOWING INSTALLATION OF A NEW GNS480, DURING INITIAL POWER CHECKS, FOUND THE FOLLOWING FAILURE FLAGS DISPLAYED: COM CO MUNICATION FAILURE, NAV COMMUNICATION FAILURE, ALTITUDE ENCODER COMMUNICATION FAILURE. INSTALLATION OF ANOTHER UNIT RES OLVED THE PROBLEMS. (K) 1 H 7 1 3O 3A24 2005110900005 20051109 00005 CE 2005 11 9 2005FA0001499 1 20051005 G 2840 MOUNT CESSNA 206 U206F 2073333 CE CONT O520 IO520* 17032 SO FUEL TRANSDUCER CRACKED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 206Q 377 U20603259 DURING A ROUTINE INSPECTION FOUND THE FUEL FLOW TRANSDUCER MOUNT BRACKET CRACKED. (K) 1 H 7 1 3O 3 O A4CE E5CE 2005110900001 20051109 00001 2005 11 9 2005FA0001500 4 20051001 G 3417 612826 MOUNT DHAV DHC2 DHC2* 2800108 EA ADC CRACKED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 37756 906 1456 DURING ANNUAL INSPECTION FOUND THE ADC TRAY CRACKED COMPLETELY ACROSS ONE END. (K) 1 H 7 1 3R A806 2005110900305 20051109 00305 SO 2005 11 9 2005FA0001501 1 20051026 G 3397 394A1J1 CONNECTOR GULSTM GV GULFSTREAMGV 3980116 SO RROYCE BR700 BR700710A110 NE CABIN LIGHTS DISCONNECTED B GR4R O OTHER O OTHER NR NOT REPORTED 1 SO 11 508QS 4733 631 DURING SCHEDULED MAINTENANCE, CREW NOTED SEVERAL CABIN LIGHTS WENT INOPERATIVE. WIRE PX601A8 AT CONNECTOR 394A1J1/369A1 P1 BEHIND AUX CB PANEL AT RT RADIO RACK WAS FOUND WITH EVIDENCE OF OVERHEATING AND ARCING. SOLDERED CONNECTION TO CORRE SPONDING PIN HAD FAILED. CB DID NOT TRIP. REPLACED CONNECTOR, TRIMMED DAMAGED WIRE, INSTALLED NEW PIN. REPLACED 50 AM P CB. INTERNALLY INSPECTED POWER DISTRIBUTION BOX FOR EVIDENCE OF OVERHEATING. TESTED REPAIRED CIRCUIT. (K) 2 L 7 2 4F 4 F RT A12EA E00057EN 2005110900302 20051109 00302 SO 2005 11 9 2005FA0001502 1 20051026 G 3397 394A1P1 CONNECTOR GULSTM GV GULFSTREAMGV 3980116 SO RROYCE BR700 BR700710A110 NE CABIN LIGHTS DISCONNECTED B GR4R O OTHER O OTHER NR NOT REPORTED 1 SO 11 508QS 4733 631 DURING SCHEDULED MAINTENANCE, CREW NOTED SEVERAL CABIN LIGHTS WENT INOPERATIVE. WIRE PX601A8 AT CONNECTORS 394A1J1/394A 1P1 BEHIND AUX CB PANEL AT RT RADIO RACK WAS FOUND WITH EVIDENCE OF OVERHEATING AND ARCING. SOLDERED CONNECTION TO CORR ESPONDING PIN HAD FAILED. CB DID NOT TRIP. REPLACED CONNECTOR 394A1J1/394A1P1, TRIMMED DAMAGED WIRE, INSTALLED NEW PIN . REPLACED 50 AMP CB. INTERNALLY INSPECTED POWER DISTRIBUTION BOX FOR EVIDENCE OF OVERHEATING. TESTED REPAIRED CIRCUIT. (K) 2 L 7 2 4F 4 F RT A12EA E00057EN 2005110900304 20051109 00304 SO 2005 11 9 2005FA0001503 1 20051019 G 5610 6971203 WINDOW PIPER PA32 PA32RT300 7103215 SO LYC O540 IO540* 41532 EA COCKPIT CRACKED B EL6R O OTHER O OTHER NR NOT REPORTED 1 EA 23 39503 3760 32R7885224 LT FORWARD SIDE WINDOW. CRACKED AND BROKEN 2 PLACES AROUND SIDE VENT WINDOW CAUSING LARGE SECTION TO BECOME LOOSE. (K ) 1 L 7 1 3O 3 O A3SO 1E4 2005110900303 20051109 00303 SW 2005 11 9 2005FA0001504 1 20051102 G 5302 206020113223 SKIN BELL 407 407 1182206 SW ALLSN 250C 250C47B GL VERTICIAL FIN DEBONDED B KKQR O OTHER O OTHER NR NOT REPORTED 1 GL 11 113TV 53242 LESS THAN 10 HOURS FLIGHT TIME AFTER REPAIR FOR LEADING EEDGE DISBONDING THE BONDING FAILED AND TAIL ROTOR WASH DISPLACE D THE LEADING EDGE. (K) 1 G 7 1 3U 3 U O H2SW E1GL 2005111000107 20051110 00107 GL 2005 11 10 2005FA0001505 1 20051019 G 7810 15074001 EXHAUST HEADER CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO ENGINE CRACKED B QRQR O OTHER O OTHER NR NOT REPORTED 1 SW 05 495CD 1605 917847 NR 5 EXHAUST HEADER CRACKED AT CYLINDER JUST BELOW FLANGE ONE HALF THE WAY AROUND HEADER UNDER NORMAL USE. HEADER NEEDS REDESIGN OR SOME SORT OF SUPPORT. IT IS OVER CANTILEVERED FOR STRESSES IMPOSED ON IT. NR 6 HEADER CRACKED THRU THE FL ANGE FOR A DISTANCE OF ABOUT 1.5 INCHES RADIUSING OUT ALONG THE FLANGE WELD. AIRFRAME AND EXHAUST HOURS: 25.6 (K) 1 L 7 1 3O 3 O NT A00009CH E3SO 2005111000109 20051110 00109 GL 2005 11 10 2005FA0001506 1 20051019 G 7810 15070001 EXHAUST HEADER CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO NR 5 CRACKED B QRQR O OTHER O OTHER NR NOT REPORTED 1 SW 05 495CD 25 1605 917847 NR 5 EXHAUST HEADER CRACKED AT CYLINDER JUST BELOW FLANGE HALF THE WAY AROUND HEADER UNDER NORMAL USE. HEADER NEEDS RED ESIGN OR SOME SORT OF SUPPORT. IT IS OVER CANTILEVERED FOR STRESSES IMPOSED ON IT. NR 6 EXHAUST HEADER CRACKED THRU TH E FLANGE FOR A DISTANCE OF ABOUT 1.5 INCHES RADIUSING OUT ALONG THE FLANGE WELD. (K) 1 L 7 1 3O 3 O NT A00009CH E3SO 2005111000105 20051110 00105 GL 2005 11 10 2005FA0001507 1 20051019 G 7810 15070001 EXHAUST HEADER CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO NR 5 CRACKED B QRQR O OTHER O OTHER NR NOT REPORTED 1 SW 05 99OP 0945 917219 NR 5 EXHAUST HEADER CRACKED AT CYLINDER FLANGE JUST BELOW WELD UNDER NORMAL USE. HEADER NEEDS REDESIGN OR SOME SORT OF SUPPORT. IT IS OVER CANTILEVERED FOR STRESSES IMPOSED ON IT. AIRFRAME AND EXHAUST HOURS. 1 L 7 1 3O 3 O NT A00009CH E3SO 2005111000106 20051110 00106 GL 2005 11 10 2005FA0001508 1 20051019 G 7810 15070001 EXHAUST HEADER CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO ENGINE CRACKED B QRQR O OTHER O OTHER NR NOT REPORTED 1 SW 05 613MM 33 1497 NR 5 EXHAUST HEADER CRACKED AT CYLINDER FLANGE JUST BELOW WELD UNDER NORMAL USE. HEADER NEEDS REDESIGN OR SOME SORT OF SUPPORT. IT IS OVER CANTILEVERED FOR STRESSES IMPOSED ON IT. AIRFRAME ADN EXHAUST HOURS: 33.7 1 L 7 1 3O 3 O NT A00009CH E3SO 2005111000111 20051110 00111 SO 2005 11 10 2005FA0001509 1 20051025 G 5730 62061002 SKIN PIPER PA28 PA28161 7102803 SO LYC O320 O320* 41508 EA WING CRACKED B BIIR O OTHER O OTHER NR NOT REPORTED 1 EA 21 35705 2557 288016207 FORWARD WING WALK DOUBLER CRACKED. DOUBLER SHOULD BE HEAVIER GAUGE METAL. (K) 1 L 7 1 3O 3 O 2A13 E274 2005111000113 20051110 00113 NE 2005 11 10 2005FA0001510 1 20050810 G 2497 WIRE SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1 60030 NE STARTER GEN CORRODED D O OTHER O OTHER NR NOT REPORTED 1 EA 17 88CP 760500 THE TERMINALS ON THE GENERATOR ARE DESIGNATED A8 TERMINAL D WHICH HAS 2 WIRES. WIRE NR P257A16 GOES TO P708 PIN -3 AND THIS WIRE WAS FOUND TO HAVE BUBBLED UP INSULATION CAUSED BY WIRE CORROSION AND HEAT. THE OTHER WIRE ON TERMINAL D IS P2 56A16 WHICH GOES TO P708 PIN 4 WHICH THAT WAS PULLED AND IT ALSO WAS FOUND TO HAVE RED CORROSION STARTING ON WIRE SURFAC E. THIS WIRE AS WELL AS THE OTHERS SHOWED STARTING SIGNS OF CORROSION. MAINTENANCE HAS REPLACED ALL THE ABOVE CORRODED WIRES. (EA17200603551) (K) 1 G 7 2 3U 3 U NC H1NE E19EU 2005111000112 20051110 00112 CE 2005 11 10 2005FA0001511 1 20050818 G 5280 A103TGS NUT RAYTHN DH125 HAWKER800XP 7150012 CE GARRTT TFE731 TFE731* 01518 WP MLG DOOR BACKED OUT B AK6R O OTHER O OTHER NR NOT REPORTED 1 CE 05 804BH 594 258596 RT OB GEAR DOOR. FOUND THE DOOR TO GEAR STRUT ATTACHMENT BOLT BACKING OUT AND LOOSE. AFTER REMOVING COVER WAS FOUND TH AT NUT WAS TO SECURE THE BOLT WAS NOT SAFETIED AND HAD BACKED OFF ABOUT 3 TURNS. THIS HAD COM OFF THE DOOR AND WOULD HA VE DROPPED INTO THE SLIP STREAM. (K) 2 L 7 2 4F 4 F RT A3EU E6WE 2005111000069 20051110 00069 SO 2005 11 10 2005FA0001512 1 20051104 G 3260 LIGHT PIPER PA28 PA28R201 7102816 SO MLG INDCATOR MISINSTALLED D O OTHER W N INADEQUATE Q C FALSE WARNING LD LANDING 1 SW 99 D-EPV 2844117 DURING TRAINING FLIGHT IN APPROACH, PILOT NOTICED, THAT LT LANDING GEAR GREEN LIGHT WAS NOT ON, RED LANDING GEAR UNSAFE LIGHT WAS ON HYD PUMP WAS RUNNING CONSTANTLY. PROBLEM CONTINUED EVEN AFTER EMERGENCY EXTENSION. AFTER FLYBY, ABOVE CONTR OL TOWER, GROUND CONTROL SAW LANDING GEAR WAS DOWN, PILOT PROCEEDED WITH SAFE LANDING. TROUBLESHOOTING WAS PERFORMED WI TH FOLLOWING RESULTS: THE MLG WARNING LIGHTS WHERE INVERTED. LT MAIN GEAR MICROSWITCH OPERATED RT MAIN GEAR GREEN LIGHT, RT MAIN GEAR MICROSWITCH OPERATED LT MAIN GEAR GREEN LIGHT. RT MAIN GEAR MICROSWITCH POSITION WAS ADJUSTED IAW MM, WIR ES WERE INSTALLED CORRECT WAY. GEAR SWING WAS PERFORMED WITH SATISFACTORY RESULT. 1 L 7 1 3O 2A13 2005111000055 20051110 00055 CE 2005 11 10 2005FA0001513 1 20051108 G 5312 17121042 BULKHEAD CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA BS 263 CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 04 8050G 2000 177RG0050 BULKHEAD CRACKED AROUND BOTH VERTICAL FIN FORWARD ATTACH BOLTS. 1 H 7 1 3O 3 O A20CE 1E10 2005111000070 20051110 00070 CE 2005 11 10 2005FA0001514 1 20051108 G 5312 17121042 BULKHEAD CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B 41514 EA ZONE 200 CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 04 8050G 2000 177RG0050 BULKHEAD CRACKED AROUND BOTH VERTICAL FIN FORWARD ATTACH BOLTS. 1 H 7 1 3O 3 O A20CE 1E10 2005111000110 20051110 00110 EU 2005 11 10 2005FA0001515 1 20051018 G 5321 3652100590501 FLOOR PANEL AEROSP SA365 SA365N1 8680668 EU TMECA ARRIEL ARRIEL1 60030 NE COCKPIT CORRODED B UOHR O OTHER O OTHER NR NOT REPORTED 1 GL 13 97SV 6298 DURING A PRE-BUY INSPECTION, THE LONCOIN RUBBER MATS WERE PULLED UP FROM THE COCKPIT FLOORS. UNDER THE PILOTS SIDE OF T HE MATS, MAJOR CORROSION ACCUMULATION WAS DISCOVERED. THESE MATS WERE STILL DAMP UNDERNEATH WHICH SHOWED WHY THIS CORRO SION EXISTED. SUSPECT THAT SALT LADEN WATER FROM THE PILOTS FEET DURING WINTER OPERATIONAS CONTRIBUTED TO THIS CORROSIO N. THE RUBBER MATS ALLOWED THE MOISTURE TO PENETRATE BUT WOULD NOT LET IT DRY. THIS FLOOR PANEL IS COMPLETELY DESTROYE D AND MUST BE REPLACED. MORE STRIGENT CLEANING AND INSPECTION PRACTICES MUST BE PRACTICED IN ENVIROMENTS SUCH AS THIS. (K) 1 G 7 2 3U 3 U H10EU E19EU 2005122000161 20051220 00161 EA 2005 12 20 2005FA0001516 2 20050920 G 8520 LW16711 BEARING LYC IO360 IO360L2A EA ENGINE DEFECTIVE B NX4R K NONE O OTHER IN INSP/MAINT 1 SO 15 2102 L2779051A DURING ENGINE DISASSEMBLY FOR ROUTINE OVERHAUL, IT WAS NOTED THAT SOME NR 3 MAIN BEARING SURFACE MATERIAL HAD RELEASED F ROM THE BEARING SHELL. NO OTHER DEFECTS WERE NOTED RELATIVE TO THIS OCCURRENCE. (K) 3 O 1E10 2006011700329 20060117 00329 SO 2006 1 17 2005FA0001517 1 20051107 G 7120 LW38275 BOLT LYC O360E1A6D PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA RT ENGINE BROKEN D K NONE G MULTIPLE FAILURE IN INSP/MAINT 1 SO 05 120RH 1650 FOUR BOLTS FOUND BROKEN ON LT SIDE OF RT ENGINE MOUNT DURING INSPECTION. LT SIDE OF MOUNT HAD 2 LOOSE BOLTS. 1 L 7 2 3O 3 O A19S0 E286 2005120200143 20051202 00143 2005 12 2 2005FA0001518 4 20051031 G 2562 MN1300 BATTERY E01 PIPER PA28 PA28180 7102808 SO LYC O360 O360* 41514 EA ELT LEAKING D K NONE O OTHER IN INSP/MAINT 1 GL 15 8806J 015652 282756 ELT BATTERIES FOUND LEAKING AT ANNUAL INSPECTION. ELT IS MODEL E-01 WHICH USES 8 EA. MN1300 (D) CELL BATTERIES. THE BA TTERIES WERE DATED MAR 2010 (DATE OF INSTALLATION UNKNOWN), AND THE ELT WAS LABELED AND MAINTENANCE ENTRIES NOTED FOR (E LT BATTERY DUE JUNE 2005). BATTERY LEAKAGE HAD CONTAMINATED THE ELT CASE AND CAUSED CORROSION OF THE MOUNTING TRAY. TH IS WAS THIRD INSTANCE OF DISCOVERING LEAKING BATTERIES IN AN ELT WHERE THE SHELF LIFE DATE PRINTED ON THE BATTERY WAS ST ILL MANY YEARS INTO THE FUTURE. 1 L 7 1 3O 3 O 2A13 E286 2005111600170 20051116 00170 CE 2005 11 16 2005FA0001519 1 20051101 G 8011 COMMUTATOR LAMAR CESSNA 172 172R 2072401 CE LYC O320 IO320* 41508 EA STARTER DESTROYED B MS2R O OTHER O OTHER NR NOT REPORTED 1 CE 09 9918F 80116408 17280194 2723451A A SEGMENT OF THE COMMUTATOR CAME OFF DURING STARTING, COMPLETELY DISTROYING THE BRUSES AND THE INSIDE OF THE STARTER. (K ) 1 H 7 1 3O 3 O NT 3A12 1E12 2005111600172 20051116 00172 CE 2005 11 16 2005FA0001520 1 20051101 G 5321 FLOORBOARD CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA FUSELAGE CRACKED B MS2R O OTHER O OTHER NR NOT REPORTED 1 CE 09 6394M 15284706 L1856515 FOUND FLOORBOARD SKIN ABOVE THE LT AND RT GEAR BOXES, CRACKED AT THE INSPECTION HOLES. CRACKS RAN FROM THE EDGE OF THE HOLE TO THE SCREW HOLE FOR THE INSPECTION PLATE. INSTALLED A REINFORCEMENT UNDER THE DOUBLER AND STOP DRILLED THE CRACK S. (K) 1 H 7 1 3O 3 O NT 3A19 E223 2005111600175 20051116 00175 GL 2005 11 16 2005FA0001521 1 20051104 G 2810 2228610000 FUEL TANK DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240A SO CRACKED B SL5R O OTHER O OTHER NR NOT REPORTED 1 NE 03 517JT 134 C0275 DURING OUTER MAINTENANCE FOUND FUEL TANK CRACKED IN NP SURFACE AT CENTERAL APT SPOT WELD FOR INTERNAL BAFFEL. INSTALLED NEW FUEL TANK TO CORRECT PROBLEM. (K) 1 L 7 1 3O 3 O NT TA4CH E7SO 2005111600174 20051116 00174 CE 2005 11 16 2005FA0001522 1 20051024 G 5751 67240204 HINGE BRACKET CESSNA 750 750 2076810 CE ALLSN AE3007 AE3007C GL OB AILERON CORRODED B JGVR O OTHER O OTHER NR NOT REPORTED 1 CE 09 936QS 7500036 DURING RECENT INSPECTION CORRODED HARDWARE WAS FOUND ON AILERON. AFTER AILERON WAS REMOVED HEAVY GALLING WAS FOUND ON O UTBOARD HINGE SUPPORT AND AILERON FITTING. SEVERAL OTHER AIRCRAFT WERE INSPECTED AND 3 OTHERS AND IDENTICAL GALLING. M FG WAS NOTIFIED AND REPAIRS MADE,, INCLUDING BLENDING AND NDT. AILERON ARE NOT REMOVED DURALAY INSPECTIONS. BUT CLOSE VISUAL INSPECTIONS SHOULD FIND DEFECTS. AIRCRAFT ARE DAMAGE TOLERANT AND PART IS CONSIDERED. PSE. (K) 2 L 7 2 4J 4 F RT T00007WI TE6CH 2005111600164 20051116 00164 GL 2005 11 16 2005FA0001523 2 20050926 G 7230 STUD HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL COMPRESSOR BROKEN B EOOR O OTHER O OTHER NR NOT REPORTED 1 AL 03 511SB 12792 1090592D CAE834299 FOUND THE LOWER RT COMPRESSOR STUD BROKEN OFF. DURING INSPECTION PROCESS FOR COMPRESSOR CASE HALVES. IT WAS NOTICED TH AT THE RT LOWER COMPRESSOR STUD WAS MISSING (THAT IS THE NUT AND STUD WERE NOT VISABLE ON THE COMPRESSOR FLANGE). REPLA CED UNIT. (K) 1 G 7 1 3U 3 U H3WE E4CE 2005111600168 20051116 00168 WP 2005 11 16 2005FA0001524 1 20050904 G 3246 369D2921143 SKID HUGHES 369 369D 4470706 WP MLG CRACKED B EOOR O OTHER O OTHER NR NOT REPORTED 1 AL 03 CGPHC 1802570 UPON LANDING THE MECHANIC SAW THE FORWARD LT SKID TUBE WAS ANGLED UP SEVERAL DEGREES. IT WAS DISCOVERED THAT THE TUBE W AS CRACKED UNDER THE FORWARD FOOT AND SKID PLATE. REPLACED UNIT. (K) 1 G 7 1 3U H3WE 2005111600162 20051116 00162 WP 2005 11 16 2005FA0001525 1 20051002 G 5320 369D256273 BRACKET HUGHES 369 369D 4470706 WP FUSELAGE MISMANUFACTURED B EOOR O OTHER O OTHER NR NOT REPORTED 1 AL 03 RECEIVED A BLOWN BRACKET FROM THE VENDOR AND FOUND IT IS NOT BUILT TO THE LATEST SPECS, IT WAS BUILT IN 2002 AND REQUIRE S MODIFICATIONS CALLED OUT IN AN SB. (K) 1 G 7 1 3U H3WE 2005122000165 20051220 00165 SO 2005 12 20 2005FA0001526 1 20051103 G 5610 S2C503 CANOPY AYRES S2 S2C 0143006 SO LYC O540 AEIO540* EA COCKPIT DEPARTED B ZL6R O OTHER D INFLIGHT SEPARATION CR CRUISE 1 NM 03 114RM 532 6030 CANOPY ASSEMBLY PN S2C503, DEPARTED AIRCRAFT DURING NORMAL FLIGHT ATTITUDE AND CRUISE SPEED. NO APPARENT COMPONENT FAIL URE NOTED ON AIRCRAFT COCKPIT STRUCTURE OR CANOPY RETAINING COMPONENTS. SINCE CANOPY ASSEMBLY WAS NOT RECOVERED. NO PR OBABLE CAUSE FOR SEPARATION COULD BE FOUND. (K) 1 L 7 1 3R 3 O 2A7 1E4 2005111600163 20051116 00163 EA 2005 11 16 2005FA0001527 2 20051103 G 7414 M3984 CAPACITOR SLICK CESSNA 188 A188B 2073005 CE LYC O540 TIO540A1A 41532 EA MAGNETO INOPERATIVE B EATR K NONE O OTHER IN INSP/MAINT 1 GL 09 53255 281 01031727 18801716 OPENED PRESSURIZED MAGNETO TO INSPECT FOR CORROSION DURING ANNUAL INSPECTION. DETECTED A LARGE AMOUNT OF OIL IN AFT CAS E OF MAGNETO. FURTHER INVESTIGATION REVEALED THAT IT IS DIELECTRIC FLUID FROM CAPACITOR. TESTED CAPACITOR WITH A SIMPS ON METER AND WAS FOUND TO HAVE FAILED. SUBMITTER FEELS THAT MAGNETO FAILURE WAS EMINENT DUE TO OIL CONTAMINATION TO POI NTS AND DISTRIBUTOR. SUBMITTER SUGGESTS INSPECTION OF ALL MAGNETOS CONTAINING THS PN CONDENSOR BEFORE FURTHER FLIGHT. (K) 1 L 7 1 3O 3 O A9CE E14EA 2005111600167 20051116 00167 EU 2005 11 16 2005FA0001528 1 20051108 G 2622 C352TS EXTINGUISHER BRAERO 1000 HAWKER1000 7450005 EU PWA 305 PW305 NE COCKPIT INCORRECT B YK1R O OTHER W INADEQUATE Q C NR NOT REPORTED 1 SW 11 551QS 7085 259051 REMOVING HAND HELD FIRE EXTINGUISHER FROM THE COCKPIT FOR ROUTINE INSPECTION IT WAS NOTED THAT THE HANDLE DID NOT APPEAR TO BE CORRECT. FURTHER INSPECTION SHOWED THAT THERE ARE TABS ON THE LOWER HANDLE THAT WOULD HAVE PREVENTED THE EXTINGU ISHER FROM DISCHARGING. NUMEROUS ATTEMPTS AT DISCHARGING FAILED. IT APPEARS THAT AN INCORRECT HEAD WAS INSTALLED. SUB JECT FIRE EXTINGUISHER WAS REMOVED FROM SERVICE. (K) 2 L 7 2 4F 4 F RT A3EU E35NE 2005122000150 20051220 00150 SO 2005 12 20 2005FA0001529 1 20051102 G 3244 304K632 TIRE EMB 135 EMB135BJ 3260306 SO ALLSN AE300 AE3007A GL LANDING GEAR LEAKING D O OTHER O OTHER NR NOT REPORTED 1 GL 25 780SG 145780 THE TIRE WAS REMOVED FROM THE AIRCRAFT FOR A SLOW LEAK. THE WEEP HOLES IN THE SIDEWALL OF THE TIRE WERE BUBBLING WHEN C HECKED WITH LEAK DETECTOR FLUID. (K) 2 L 7 2 4F 4 F RT TE6CH 2005111600173 20051116 00173 SO 2005 11 16 2005FA0001530 1 20051102 G 3244 304K632 TIRE EMB 135 EMB135BJ 3260306 SO MLG LEAKING D O OTHER O OTHER NR NOT REPORTED 1 GL 25 AFTER COMPLETING THE SPECIFIED LEAK CHECK TIME, THE WEEP HOLES IN THE SIDE WALL OF THE TIRE WERE STILL BUBBLING WHEN CHE CKED WITH LEAK DETECTOR FLUID. 2 L 7 2 4F RT 2005112800176 20051128 00176 SW 2005 11 28 2005FA0001531 1 20051012 G 2120 3136171 SOLENOID BELL 430 430 1182150 SW DIVERTER VALVE STUCK C K NONE O OTHER NR NOT REPORTED 1 EA 01 9SP 1166 49086 SOLENOID FAILED IN ENERGIZED POSITION. THIS UNIT IS IN THE DUCTING DIVERTER VALVE MAKING IT SUBJECT TO MOISTURE. THIS CO RRODES THE UNIT OVER TIME. IT FAILED ON, THUS DIVERTING AIR IN THE WRONG DIRECTION. HEAT WILL COME OUT OF OVERHEAD CABIN DUCTS. 1 G 7 2 3U RT H9SW 2005120200031 20051202 00031 GL 2005 12 2 2005FA0001532 1 20051110 G 3220 LANDING GEAR DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240A SO NOSE UNLOCKED D K NONE O OTHER IN INSP/MAINT 1 NM 03 932AF C0198 ROLL PIN LOCKING THE NOSE STRUT ELECTROMETRIC SPRING PLATE (PN 20-3220-05-02) TO THE SHOCK ABSORBER ROD (PN 20-3220-05-0 1) HAD WORKED OUT UNLOCKING THE ASSY. 1 L 7 1 3O 3 O NT TA4CH E7SO 2005120200032 20051202 00032 CE 2005 12 2 2005FA0001533 1 20051111 G 5210 S31948 SPRING CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE PAX DOOR BROKEN D K NONE O OTHER IN INSP/MAINT 1 NE 03 102FS 1147 560XL5318 THE AIRCRAFT RETURNED FROM A FLIGHT WITH NO DEFECTS NOTED. AIRCRAFT WAS MOVED INTO THE HANGAR AND APPROXIMATELY 20 MINUT ES LATER A LOUD BANG WAS HERD. THE AIRCRAFT WAS STATIC WITH THE DOOR CLOSED. THE LOUD BANG WAS THE CABIN ENTRY DOOR FORW ARD COUNTERBALANCE SPRING BREAKING IN THE SECOND COIL. 2 L 7 2 4F 4 F RT A22CE E00059EN 2005122800092 20051228 00092 SW 2005 12 28 2005FA0001534 1 20050926 G 5320 1159BM502161 BRACKET GULSTM 111 111RKWELL 0144601 SW CONT O520 TSIO520* 17040 SO BS 169 CRACKED B VZGR O OTHER O OTHER NR NOT REPORTED 1 SW 05 444GA 301 MED ACTUATING CYLINDER UPPER BRACKET FAILED ALONG A ROW OF LOCK FASTENERS HOLES CAUSING MAJOR DAMAGE TO SKIN AND STRINGE RS. ACTUATING CYLINDER REPLACED AS PRECAUTIONARY MEASURE. NEW BRACKET, SKINS, STRINGERS AND DOUBLERS. (K) 1 L 7 1 3O 3 O A11SO E8CE 2005120200037 20051202 00037 EA 2005 12 2 2005FA0001535 2 20051017 G 8500 LW18837 CAMSHAFT PIPER PA28 PA28140 7102802 SO LYC O320 O320E3D 41508 EA ENGINE MAKING METAL B EASR K NONE O OTHER IN INSP/MAINT 1 EA 23 5563U 928 2826882 L1738227A DURING ANNUAL INSPECTION, FERROUS FLAKES OF METAL WERE FOUND IN OIL FILTER, ALSO, SEVERAL PIECES FOR FERROUS METAL WERE FOUND IN THE FINGER STRAINER. THE OIL FILTER AND THE PIECES FOUND IN THE FINGER STRAINER WERE SENT TO MFG FOR ANALYSIS. IT WAS REPORTED THAT THE FERROUS METAL CAME FROM THE CAMSHAFT AND TAPPET BODIES. THE ENGINE IS BEING REMOVED FOR OVER HAUL, TIME SINCE OVERHAUL IS 2092.9. CAMSHAFT WAS REPLACED AT 1164.4 HRS SINCE OVERHAUL. THE AVERAGE OIL CHANGE INTERVA L SINCE OVERHAUL IS 91 HOURS. RECOMMEND THAT THE 50 HOUR OIL CHANGE INTERVAL RECOMMENDED BY MFG BE STRICTLY ADHERED TO. 1 L 7 1 3O 3 O 2A13 E274 2005122100174 20051221 00174 CE 2005 12 21 2005FA0001536 1 20051103 G 3244 184F135 TIRE BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE NLG DEBONDED B E81R O OTHER E VIBRATION/BUFFET TO TAKEOFF 1 GL 03 400MV RK286 OPERATOR STATED, RT FROM INSTALL AT ANOTHER FACILITY, THE AIRCRAFT EXPERIENCED NOSE VIBRATION ON TAKE OFF. DISASSEMBLED WHEEL ASSY AND FOUND INNER CASING OF TIRE DEBONDING. (K) 2 H 7 2 4F 4 F RT A16SW E25EA 2005122100176 20051221 00176 SO 2005 12 21 2005FA0001537 1 20051107 G 8011 MHB2399S ARMATURE ELECTROSYS PIPER PA28 PA28181 7102807 SO LYC O360 O360A4A 41514 EA STARTER BROKEN B UC2R O OTHER O OTHER NR NOT REPORTED 1 GL 19 4147K 40 8021149 2843169 PILOT REPORTED GRINDING NOISE FROM ENGINE COMPARTMENT WHEN STARTER WAS ENGAGED. STARTER WAS REMOVED ARMATURE WAS FOUND WITH 2 SPLINES SHEARED OFF. INTERMEDIATE GEAR WAS MISSING 2 TEETH. CAUSE UNKNOWN. THIS IS THE THIRD ARMATURE IN THE P AST 6 MONTHS WITH THE SAME DEFECT. (K) 1 L 7 1 3O 3 O 2A13 E286 2005122000151 20051220 00151 CE 2005 12 20 2005FA0001538 1 20051116 G 7931 83278 PRESSURE SENSOR CESSNA 172 172S 2072439 CE LYC O540 IO540* 41532 EA OIL SYSTEM LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 NM 01 24ME 1581 172S8463 DURING A 100 HR INSPECTION AN OIL LEAK WAS DETERMINED TO BE ORIGNATING FROM THE HOBBS METER SENSOR AT THE SWEDGED FLANGE . AD CALLS FOR THE REPLACMENT OF SENSOR. JUST THOUGHT IT IRONIC AN AD CALLS FOR HE REPLACEMENT OF ONE LEAKING SENSOR F OR ANOTHER LEAKING SENSOR. (K) 1 H 7 1 3O 3 O NT 3A12 1E4 2005122000152 20051220 00152 CE 2005 12 20 2005FA0001539 1 20051027 G 3230 50410016 BELLCRANK CESSNA 402 402B 207590P CE CONT O520 TSIO520* 17040 SO RT MLG FRACTURED D O OTHER O OTHER LD LANDING 1 NM 13 402CA 10938 402B0842 RT LANDING GEAR COLLAPSED DURING A NORMAL LANDING. (K) 1 L 7 2 3O 3 O A7CE E8CE 2005120100183 20051201 00183 SO 2005 12 1 2005FA0001540 1 20051121 G 3230 GEARBOX PIPER PA30 PA30 7103002 SO MLG FRACTURED H O OTHER O OTHER LD LANDING 1 WP 23 23RD 30469 THE GEARBOX CASTING WHICH SUPPORTS THE MOTOR AND GEARBOX FRACTURED. VISUAL EXAMINATION INDICATES FATIGUE. DUE TO THIS FAILURE, THE LANDING GEAR WOULD NOT EXTEND DURING LANDING. 1 L 7 2 3O A1EA 2005120200033 20051202 00033 SO 2005 12 2 2005FA0001541 1 20051117 G 3230 89291004 SWITCH PIPER PA44 PA44180 7104402 SO LYC O360 O360* 41514 EA MLG BROKEN B A UNSCHED LANDING O OTHER CL CLIMB 1 WP 07 572ER 2237 46 4496148 DURING TRAINING TOUCH AND GO THE GEAR FAILED TO RETRACT AFTER TAKEOFF. AIRCRAFT RETURNED TO AIRPORT AND MADE UNEVENTFUL LANDING. MAINTENANCE FOUND THE LT GEAR SWITCH ASSEMBLY HAD 3 BROKEN WIRES AT THE SWITCH. SWITCH WAS REPLACED AND GEAR SWING PERFORMED. 1 L 7 2 3O 3 O A19S0 E286 2005120200050 20051202 00050 GL 2005 12 2 2005FA0001542 1 20051116 G 3220 ROLL PIN DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240B 17063 SO SNSNCH W69EK W69EK63 EA NLG BACKED OUT C K NONE O OTHER IN INSP/MAINT 1 NM 03 N924AF ROLL PIN LOCKING THE NOSE STRUT ELECTROMETRIC SPRING PLATE (PN 20-3220-05-02) TO THE SHOCK ABSORBER ROD (PN 20-3220-05-0 1) HAD WORKED OUT UNLOCKING THE ASSY. 1 L 7 1 3O 3 O NT TA4CH E7SO 5 N TA4CH 2005120200065 20051202 00065 SO 2005 12 2 2005FA0001543 2 20051116 G 7414 6320 MAGNETO CONT O520 TSIO520NB 17040 SO LT ENGINE CORRODED B O OTHER R PARTIAL RPM/PWR LOSS TX TAXI/GRND HDL 1 SO 05 311K 400 400 PILOT REPORTED NO MAG DROP ON LT ENGINE. UPON INSPECTION OF MAGNETOS FOUND POINTS BROKEN. INSPECTED OTHER MAGNETOS AND FOUND ONE OTHER MAGNETO EXCESSIVELY BURNED AND DAMAGED INTERNALLY. PICTURES WERE TAKEN OF MAGNETOS IF ANY ADDITIONAL IN FORMATION IS NEEDED. MAGNETOS WERE REPLACED AND AC WAS RETURNED TO SERVICE. 3 O E8CE 2005120200066 20051202 00066 SO 2005 12 2 2005FA0001544 2 20051116 G 7414 6320 MAGNETO CONT O520 TSIO520NB 17040 SO LT ENGINE CORRODED B K NONE R PARTIAL RPM/PWR LOSS TX TAXI/GRND HDL 1 SO 05 311K 400 400 PILOT REPORTED NO MAG DROP ON LT ENGINE. UPON INSPECTION OF MAGNETOS FOUND POINTS BROKEN. INSPECTED OTHER MAGNETOS AND F OUND ONE OTHER MAGNETO EXCESSIVELY BURNED AND DAMAGED INTERNALLY. PICTURES WERE TAKEN OF MAGNETOS IF ANY ADDITIONAL INF ORMATION IS NEEDED. MAGNETOS WERE REPLACED AND AC WAS RETURNED TO SERVICE. 3 O E8CE 2005120200072 20051202 00072 2005 12 2 2005FA0001545 1 20051116 G 7810 86202004R RISER EXHAUST CRACKED B K NONE O OTHER IN INSP/MAINT 1 WP 07 WHILE INSTALLING REPAIRED EXHAUST ON ENGINE NOTICED A 1.5 INCH CRACK IN THE WELD AT THE EXHAUST RISER FLANGE. THIS UNIT WAS RECENTLY REPAIRED AND RECERTIFIED. RISER TO BE RETURNED TO REPAIR FACILITY. 2005120200104 20051202 00104 CE 2005 12 2 2005FA0001546 1 20051114 G 5753 052323124 SUPPORT BRACKET CESSNA 172 172S 2072439 CE LYC O360 IO360B1E 41514 EA TE FLAPS BROKEN G B EMER. DESCENT F FLT CONT AFFECTED LD LANDING 1 WP 23 967SP 3015 172S8169 DURING APPROACH TO LANDING LT FLAP RETRACTED WHILE RT FLAP REMAINED EXTENDED. AN ASYMMETRICAL FLAP LANDING WAS MADE WIT H MUCH DIFFICULTY BUT WITHOUT INCIDENT. INVESTIGATION REVEALED THAT A FLAP SUPPORT BRACKET PN 0523231-24 LOCATED WITHIN THE WING HAD FAILED ALLOWING THE FLAP CABLE TO LOOSE TENSION. IT APPEARS THAT PRELOAD ROM T/E SKIN POSSIBLE CAUSED THE FAILURE OF THE BRACKET. 1 H 7 1 3O 3 O NT 3A12 1E10 2005120200105 20051202 00105 CE 2005 12 2 2005FA0001547 1 20051111 G 5210 S31948 SPRING CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE PAX DOOR BROKEN D O OTHER O OTHER NR NOT REPORTED 1 NE 03 102FS 1147 560XL5318 THE AIRCRAFT RETURNED FROM A FLIGHT WITH NO DEFECTS NOTED. AIRCRAFT WAS MOVED INTO THE HANGAR AND APPROXIMATELY 20 MINUT ES LATER A LOUD BANG WAS HEARD. THE AIRCRAFT WAS STATIC WITH THE DOOR CLOSED. THE LOUD BANG WAS THE CABIN ENTRY DOOR FOR WARD COUNTER BALANCE SPRING BREAKING IN THE SECOND COIL. 2 L 7 2 4F 4 F RT A22CE E00059EN 2005120200106 20051202 00106 CE 2005 12 2 2005FA0001548 1 20051109 G 2560 1013030 HARNESS BBAVIA 8 8KCAB 2110612 CE LYC O360 AEIO360* EA LATCH BROKEN B O OTHER O OTHER NR NOT REPORTED 1 WP 07 912MA 359 28 9482004 JUST PRIOR TO INITIATING AEROBATICS THE PILOT ATTEMPTED TO RATCHET DOWN HIS AEROBATIC HARNESS. THE HANDLE FOR THE RATCH ET BROKE ALLOWING THE RATCHET LOCK TO FALL OUT OF THE ASSEMBLY. FLIGHT WAS TERMINATED. HARNESS REPLACED WITH NEW ASSEM BLY. 1 H 7 1 3O 3 O A21CE 1E10 2005120200144 20051202 00144 2005 12 2 2005FA0001549 4 20051031 G 2562 MN1300 BATTERY ACK E01 PIPER PA28 PA28180 7102808 SO LYC O360 O360* 41514 EA ELT LEAKING D K NONE O OTHER IN INSP/MAINT 1 GL 15 8806J 015652 282756 ELT BATTERIES FOUND LEAKING AT ANNUAL INSPECTION. ELT IS MODEL E-01 WHICH USES 8 EA. MN1300 (D) CELL BATTERIES. THE B ATTERIES WERE DATED MAR 2010 (DATE OF INSTALLATION UNKNOWN), AND THE ELT WAS LABELED AND MAINTENANCE ENTRIES NOTED FOR ( ELT BATTERY DUE JUNE 2005). BATTERY LEAKAGE HAD CONTAMINATED THE ELT CASE AND CAUSED CORROSION OF THE MOUNTING TRAY. T HIS WAS THIRD INSTANCE OF DISCOVERING LEAKING BATTERIES IN AN ELT WHERE THE SHELF LIFE DATE PRINTED ON THE BATTERY WAS S TILL MANY YEARS INTO THE FUTURE. 1 L 7 1 3O 3 O 2A13 E286 2005120200145 20051202 00145 SO 2005 12 2 2005FA0001550 1 20051109 G 5410 COWL DOOR GULSTM GV GULFSTREAMGV 3980116 SO RROYCE BR700 BR700710A110 NE LT NACELLE CRACKED C O OTHER O OTHER TX TAXI/GRND HDL 1 WP 01 888CW 3661 545 DURING ROUTINE INSP, FOUND 25 INCH CRACK, SEVERE DELAMINATION WITHIN THE LT ENG LOWER COWL DOOR. AFFECTED AREA IS LOCAT ED JUST AFT OF FWD SIDE, BETWEEN THE 4 & 8 O'CLOCK POSITION. INITIAL INSPECTION REVEALS DEBOND ON CARBON FIBER SKIN TO CORE AT 375 SQUARE INCHES. EXTERNAL CARBON FIBER SKIN DEBOUND TO CORE AT 247 SQUARE INCHES. FOUND CRACK AND DELAMINAT ED AREA TO HAVE MUCH MOISTURE. INSP OF AFFECTED AREA REVEALS NO IN SERVICE DAMAGE NOR WEAR THAT WOULD HAVE ALLOWED MOIS TURE TO EGRESS COMPOSITE MATERIAL. CAUSE OF DELAMINATION IS YET TO BE DETERMINED; CAUSE OF MOISTURE EGRESS IS UNKNOWN. FAILURE OF COWL DOOR COULD HAVE CAUSED UNUSUAL FLT CHARACTERISTICS. COMPONENT IS BEING SENT FOR FURTHER INVESTIGATION. 2 L 7 2 4F 4 F RT A12EA E00057EN 2005122100193 20051221 00193 EA 2005 12 21 2005FA0001551 2 20050908 G 7322 MA3PA105267 CARBURETOR CESSNA 150 152 2071835 CE LYC O235 O235N2C 41505 EA ENGINE FAILED D JU8S A UNSCHED LANDING R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 GL 25 95475 367 15285902 L1927815 PILOT REPORTED PARTIAL LOSS OF POWER. EXECUTED PRECAUTIONARY OFF FIELD LANDING. NO DAMAGE TO AIRCRAFT. TEARDOWN OF CA RBURETOR REVEALED METAL SHAVINGS IN ACCELERATOR PUMP CIRCUIT. SUSPECT METAL ORIGIN FROM ACCELERATOR PUMP STEM RUBBING O N HOUSING. 1 H 7 1 3O 3 O NT 3A19 E223 2005120100150 20051201 00150 EA 2005 12 1 2005FA0001552 2 20050930 G 8520 LW11750 CONNECTING ROD AMRGEN AA5 AA5B 3960105 SO LYC O360 O360A4K 41514 EA SNSNCH 76E 76EM8 EA ENGINE BROKEN D A UNSCHED LANDING O OTHER CL CLIMB 1 GL 05 23JK 2043 2043 AA5B0022 L1974036A CONNECTING ROD TO CRANKSHAFT BEARING FAILED RESULTING IN ROD DISCONNECTING FROM CRANKSHAFT AND SUBSEQUENT CASE PENETRATI ON AND ENGINE STOPPAGE. 1 L 7 1 3O 3 O A16EA E286 5 N P4EA 2005120200045 20051202 00045 NE 2005 12 2 2005FA0001553 2 20050914 G 7230 804581 STATOR SKRSKY S64 S64F 8142610 NE PWA JFTD12 JFTD12A4A 52047 NE COMPRESSOR SHEARED D JYDR K NONE O OTHER IN INSP/MAINT 1 NM 09 179AC 827 64091 677776 (REF NR MDR05-080) INSPECTION WAS PERFORMED ON 1ST STAGE STATOR AND SHOWED SIGNS OF FOD. UPON FURTHER INSPECTION IST WA S DETERMINED THAT TWO RIVETS (MFG HEAD) HAD SHEARED ON STIFFENER RING OF THE 1ST STATOR AND WERE INGESTED CAUSING MINOR DAMAGE TO THE LATER STAGES OF THE ENGINE. THE ENGINE WAS FULLY DISASSEMBLED, INSPECTION AND REPAIRED. PARTS THAT WERE R EPLACED DUE TO EXCESSIVE DAMAGE ARE AS FOLLOWS; COMP BLADES 2ND STAGE, 5 EACH, 3RD STAGE, 2 EA, 4TH STAGE, 10 EACH, 5TH STAGE, 4 EACH, 7TH STAGE, 8EA, 9TH STAGE, 6 EA, COMP STATORS 1ST, 3RD, 4TH, 7TH, AND 8TH. PROBABLE CAUSE UNKNOWN. RECO MMENDATIONS TO PREVENT RECURRENCE: CONTINUE TO PERFORM 100 PERCENT RIVET REPLACEMENT TO ALL STATORS AT OVERHAUL. (K) 2 G 7 2 4U 4 U H6EA E15EA 2005122100197 20051221 00197 NE 2005 12 21 2005FA0001554 2 20051104 G 7200 5124T96P01 PLATE GE CT58 CT581401 30011 NE ENGINE CRACKED B CHIR O OTHER O OTHER NR NOT REPORTED 1 NM 09 1078 295273 DURING MAJOR INSPECTION THE NR 1 COOLING PLATE WAS FOUND TO HAVE CRACKS IN (SURFACE M). THERE ARE 6 EA CRACKS APPROXIM ATELY .250 IN LENGTH. THE OVERALL GOOD, AND THERE WAS NO EVIDENCE OF AN OVERTEMPATURE ON ANY PARTS. (K) 4 U 1E3 2005122000146 20051220 00146 CE 2005 12 20 2005FA0001555 1 20051114 G 3230 08412259 BELLCRANK CESSNA 310 310I 2074224 CE CONT O470 IO470* 17026 SO LT MLG BROKEN G K NONE O OTHER LD LANDING 1 SW 11 8119M 310I0119 PILOT HAD INTERMITTENT GEAR LIGHT , HAD OBTAINED GREEN LIGHT WHEN HE LANDED. UPON 1000 FT ROLL OUT THE LT MAIN GEAR COL LAPSED CAUSING THE AC TO VEER LEFT 75 FT TO 100 FT. UPON INSPECTION, FOUND LT MAIN LANDING GEAR, BELLCRANK ASSY HAD BRO KEN. (K) 1 L 7 2 3O 3 O 3A10 E1CE 2005122100199 20051221 00199 CE 2005 12 21 2005FA0001556 1 20051010 G 3233 991013990H ROD END CESSNA 421 421C 2076016 CE CONT O520 GTSIO520* 17032 SO NLG ACTUATOR FAILED B NF2D O OTHER O OTHER LD LANDING 1 CE 03 923CP 421C1009 ROD END ON NOSE GEAR ACTUATOR FAILED DURING ROLLOUT CAUSING THE NOSE GEAR TO COLLAPSE. (K) 1 L 7 2 3O 3 O A7CE E7CE 2005122800102 20051228 00102 CE 2005 12 28 2005FA0001557 1 20051109 G 2910 3905800370001 TUBE RAYTHN 390 390 7150030 CE HYD SYSTEM CHAFED B E81R O OTHER K FLUID LOSS NR NOT REPORTED 1 GL 03 322BJ 342 RB93 INVESTIGATED HYDRAULIC FLUID LEAKAGE FROM RT ENGINE AREA. FOUND RT ENGINE HYDRAULIC PUMP TO DAMPER TUBING ASSY CHAFED B Y ADJACENT CLAMP AND SEEPING FLUID. REPLACED TUBE AND SECURED AS REQUIRED KIT INSTALLED 5.9 HRS PREVIOUS FOR COMPLIANCE WITH AD. (K) 1 7 2 3F RT A00010WI 2005122800043 20051228 00043 CE 2005 12 28 2005FA0001558 1 20051116 G 5523 906100105 BUSHING BEECH 90 C90A 1152911 CE PWA PT6 PT6* 52043 EA LT ELEVATOR TAB SEIZED B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 439PW 1160 LJ1589 DURING COMPLIANCE WITH ELEVATOR TAB TO ACTUATOR PUSHROD INSP FOR SAFETY NR 243 FOUND ELEVATOR TAB HORN BUSHING SEIZED. REPLACED TAB HORN BUSHING AND ACTUATOR PUSHROD TO HORN ATTACH BOLT BUSHING VERIFIED TAB HORN TO ACTUATOR PUSHROD OPERATI ONS NORMAL IAW SAFETY NR 243. HAVE FOUND THIS CONDITION ON SEVERAL AC INSPECTED. RECOMMEND THIS BE A RECURRING MANDATO RY SB OR CONNECTION REDESIGNED. HAVE FOUND THIS CONNECTION OVERTIGHTENED DURING INSPECTION, SUSPECT AS A (QUICK FIX) FO R AN EXCESSIVELY LOOSE TAB FREEPLAY CONDITION. (K) 1 L 7 2 3T 3 T RT 3A20 E2NE 2005122000066 20051220 00066 CE 2005 12 20 2005FA0001559 1 20051116 G 5521 906100105 BUSHING BEECH 90 C90A 1152911 CE PWA PT6 PT6* 52043 EA ELEVATOR TAB SEIZED B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 439PW LJ1589 DURING COMPLIANCE WITH ELEVATOR TAB TO ACTUATOR PUSHROD INSPECTION FOR SAFETY NR 243, FOUND ELEVATOR TAB HORN BUSHING SE IZED. REPLACED TAB HORN BUSHING AND ACTUATOR PUSHROD TO HORN ATTACH BOLT BUSHING, VERIFIED TAB HORN TO ACTUATOR PUSHROD OPERATIONS NORMAL IAW SAFETY COMMUNIQUE NR 243. HAVE FOUND THIS CONDITION ON SEVERAL AC INSPECTED. RECOMMEND THIS BE A RECURRING MANDATORY SB OR CONNECTION REDESIGNED. HAVE FOUND THIS CONNECTION OVERTIGHTENED DURING INSPECTION, SUSPECT AS A (QUICK FIX) FOR AN EXCESSIVELY LOOSE TAB FREEPLAY CONDITION. (K) 1 L 7 2 3T 3 T RT 3A20 E2NE 2005122000067 20051220 00067 CE 2005 12 20 2005FA0001560 1 20051116 G 3210 508102503 BRACE BEECH BEECH 90 C90A 1152911 CE PWA PT6 PT6* 52043 EA MLG STRUT CORRODED B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 439PW 1160 LJ1589 LJ1589 DURING INITIAL 6-YEAR/8000 CYCLE INSPECTION OF MAIN GEAR ASSY FOUND INTERNAL SURFACE OF UPPER BRACE PITTED AND CORRODED AT AREA IN CONTACT WITH UPPER MAIN GEAR STRUT. CORROSION APPEARS UNUSUAL FOR A CLEAN, NEWER, LOW-TIME AIRCRAFT THAT IS HANGARED IN A NON SALT-AIR TYPE ENVIRONMENT. UPPER BRACE ASSY SHOULD BE ASSEMBLED TO STRUT CYCLINDER WITH CORROSION PRE VENTION COMPOUND AT ASSEMBLY IAW COMPONENT MM SUSPECT CORROSION PREVENTION COMPOUND NOT ADEQUATELY APPLIED AT INITIAL AS SEMBLY. (K) 1 L 7 2 3T 3 T RT 3A20 E2NE 2005120100186 20051201 00186 NE 2005 12 1 2005FA0001561 2 20051130 G 7230 BRR19918 BLADES GULSTM GV GULFSTREAMGV 3980116 SO RROYCE BR700 BR700710A110 NE ENGINE FAN DEBONDED C K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 WP 01 888CW 260 545 11196 DURING ROUTINE ENGINE A-CHECK INSPECTION, FOUND 15 OUT OF 24 (CHOCKING PADS) ON BASE OF ENGINE FAN BLADE TO HAVE MIGRATE D AFT OF NORMAL POSITION DUE TO DEBONDING OF (CHOCKING PAD). THIS CONDITION WAS CAUSING ABNORMAL ENGINE VIBRATION DURIN G ENGINE GROUND OPERATIONAL CHECK. THE EMM 72-31-02-300-802 ALLOWS TWO METHODS OF ATTACHING THE (CHOCKING PAD) TO THE F AN BLADE. ONE METHOD IS THE USE OF PERMABOND F241 ADHESIVE. THE SECOND METHOD IS THE USE OF 3M-9473 DOUBLE SIDED TAPE. NONE OF THE (CHOCKING PADS) THAT WERE ATTACHED WITH THE PERMABOND F241 FAILED; ONLY THE (CHOCKING PADS) ATTACHED WITH 3M 9473 DOUBLE SIDED TAPE FAILED. 2 L 7 2 4F 4 F RT A12EA E00057EN 2005122000062 20051220 00062 EA 2005 12 20 2005FA0001562 2 20051117 G 8530 LW12966 VALVE SEAT PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA CYLINDER SEPARATED D O OTHER O OTHER NR NOT REPORTED 1 NM 03 66906 338 317405197 L220768A VALVE SEAT SEPARATED FROM CYLINDER. (K) 1 L 7 2 3O 3 O A20SO E14EA 2005122800094 20051228 00094 SW 2005 12 28 2005FA0001563 1 20050908 G 7603 THROTTLE CABLE MOONEY M20 M20C 5870208 SW LYC O360 O360* 41514 EA THROTTLE ARM DISCONNECTED B AW4R O OTHER O OTHER NR NOT REPORTED 1 WP 11 6821V 200003 PILOT REPORTED THAT ON RUNUP, HE WAS UNABLE TO CONTROL RPM. INVESTIGATION DETRMINED THAT THE THROTTLE CABLE HAD COME DI SCONNECTED FROM THE CARBURETOR THROTTLE ARM. BOLT WAS PRESENT, BUT NUT AND COTTER PIN WERE MISSING INSTALLED PROPER HAR DWARE AND FUNCTIONAL CHECKED, OK. (K) 1 L 7 1 3O 3 O 2A3 E286 2005122000155 20051220 00155 EA 2005 12 20 2005FA0001564 1 20051114 G 2160 6279622 SWITCH CNDAIR CL600 CL6002B16 1900305 EA GE CF34 CF34* NE AIR CONDITIONING FAILED D O OTHER O OTHER NR NOT REPORTED 1 SO 25 779AZ 2795 5176 AIR CONDITIONING WOULD INTERMITTENTLY GO UNCONTROLLABLY FULL HOT. IN THE HANGAR, FOLLOWING MAINTENANCE MANUAL TROUBLESH OOTING FLOW CHART WOULD NOT REVEAL AND DISCREPANCIES. AFTER RUNNING SYSTEM ON RAMP AND GETTING SYSTEM TO FAIL. LT AIR CONDITIONING SYSTEM LOW LIMIT TEMPERATURE CONTROL SWITCH WAS FOUND OPEN. REMOVED SWITCH FROM AIRCRAFT AND COOLED IN SHO P, CHECKED AGAIN AND SWITCH CHECKED GOOD. HEATED WITH HEAT GUN AND SWITCH OPENED. REPLACED WITH NEW UNIT. OPS CHECKED GOOD. (K) 2 L 7 2 4F 4 F RT A21EA E15NE 2005122700200 20051227 00200 2005 12 27 2005FA0001565 1 20051201 G 5100 GEAR UNKNOWN UNKNOWN C O OTHER O OTHER NR NOT REPORTED 1 SW 99 234HM GEAR 2005122800213 20051228 00213 NE 2005 12 28 2005FA0001566 2 20051130 G 7230 BRR19918 BLADE GULSTM GV GULFSTREAMGV 3980116 SO RROYCE BR700 BR700710A110 NE COMPRESSOR DEBONDED C E ENGINE SHUTDOWN E VIBRATION/BUFFET TX TAXI/GRND HDL 1 WP 01 888CW 260 545 11197 DURING ROUTINE ENGINE A-CHECK INSPECTION, FOUND 15 OUT OF 24 (CHOCKING PADS) ON BASE OF ENGINE FAN BLADE TO HAVE MIGRATE D AFT OF NORMAL POSITION DUE TO DEBONDING OF (CHOCKING PAD). THIS CONDITION WAS CAUSING ABNORMAL ENGINE VIBRATION DURIN G ENGINE GROUND OPERATIONAL CHECK. THE EMM 72-31-02-300-802 ALLOWS 2 METHODS OF ATTACHING THE (CHOCKING PAD) TO THE FAN BLADE. NR 1 METHOD IS THE USE OF PERMABOND F241 ADHESIVE. NR 2 METHOD IS THE USE OF 3M-9473 DOUBLE SIDED TAPE. NONE O F THE (CHOCKING PADS) THAT WERE ATTACHED WITH THE PERMABOND F241 FAILED; ONLY THE (CHOCKING PADS) ATTACHED WITH 3M 9473 DOUBLE SIDED TAPE FAILED. 2 L 7 2 4F 4 F RT A12EA E00057EN 2005122800207 20051228 00207 EA 2005 12 28 2005FA0001567 1 20051130 G 6210 269A1002 BLADES SCWZER 269 269D 8059501 EA ALLSN 250C 250C20 03013 GL MAIN ROTOR VIBRATES B O OTHER E VIBRATION/BUFFET HO HOVERING 1 SW 17 277DT 3801 0028 CAE845057 HAVE BEEN EXPERIENCING PROBLEMS KEEPING THE M/R BLADES IN ACCEPTABLE TRACK AND BALANCE ON ALL 333/269D CONFIG A AIRCRAFT THAT WE MAINTAIN. ALSO HAVE BEEN FINDING MUCH MORE RAPID DETERIORATION OF THE M/R DAMPERS, FLAPPING HINGE BEARINGS, AND VERTICAL HINGE BEARINGS COMPARED TO THE PREVIOUS AIRCRAFT WITH THE P/N 269A1185-5 M/R BLADE ASSEMBLIES. THE NEW BLADES WITH THE EXTENDED NOSE SECTION WILL NOT STAY IN TRACK OR BALANCE FOR ANY ADEQUATE PERIOD OF TIME. SUGGEST THAT MFG DESIG N A NEW BLADE WITH A CONSTANT CHORD AND SOON. 1 G 7 1 3U 3 U 0 4H12 E4CE 2006010500256 20060105 00256 NM 2006 1 5 2005FA0001568 1 20051203 G 2810 VENT LINE CHRIS HUSKY A1 221020X NM LYC O360 O360C1G 41514 EA HARTZL HCC2Y HCC2Y* GL FUEL SYSTEM BLOCKED P K NONE O OTHER TX TAXI/GRND HDL 1 AL 05 9622V 1154 L3258536A H72509 ENGINE STOPPED DUE TO BLOCKED FUEL VENT LINE. THIS OCCURRED ON THE GROUND DURING TAXIING. NO DAMAGE TO PLANE. PROBABLE CAUSE WAS SNOW BUILD UP ON THE WING EXTENDING OVER THE ENDS OF THE VENT LINES FOLLOWED BY FREEZING. 1 H 7 1 3O 3 O NC A22NM E286 5 C P920 2005122800066 20051228 00066 CE 2005 12 28 2005FA0001569 1 20051128 G 6100 IA103TCM PROPELLER CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL OUT OF LIMITS B W59R O OTHER O OTHER NR NOT REPORTED 1 WP 07 757QH 15279916 773931 PROPELLER SUBMITTED FOR INSPECTION IAW AD 03-12-05. DURING SB RESEARCH IT WAS DISCOVERED THAT AD WAS DUE AS SN IS LISTE D IN AD. DURING INSPECTION FOR AD, THE PROPELLER WAS FOUND UNDER MINIMUM WIDTH. PROPELLER IS SCRAP. (K) 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2005122800040 20051228 00040 CE 2005 12 28 2005FA0001570 1 20051121 G 2697 WIRE PYROTECTOR BEECH 99 99 1154002 CE PWA PT6 PT6A28 EA FIRE DETECTOR CHAFED B HI1R O OTHER N FALSE WARNING NR NOT REPORTED 1 NE 05 192WA U152 PCE50587 AC EXPERIENCED A FALSE FIRE WARNING ON THE LT ENGINE ENROUTE. WHILE FLYING THROUGH HEAVY PRECIPITATION. THE PILOT VISU ALLY CHECKED THE ENGINE AND MONITORED ALL RELATED INSTRUMENTS AND SYSTEMS TO VERIFY NORMAL INDICATIONS THUS CONCLUDING T HE INDICATION WAS FALSE. THE PILOT NOTIFIED MAINT UPON ARRIVAL. MAINT EXAMINED THE FIRE DETECTOR SYSTEM AND FOUND 2 WI RES CHAFING AT THE LT NACELLE AFT UPPER DETECTOR. THE MECHANIC REPOSITIONED AND REPAIRED THE WIRES IAW STANDARD MAINT P RACTICES AND OPERATIONALLY CHECKED THE SYSTEM. NO DEFECTS WERE NOTED. THE MECHANIC ALSO INSPECTED THE ENGINE FOR VISIB LE SIGNS OF FIRE. NONE NOTED. (K) 1 L 7 2 3T 4 T A14CE E4EA 2005122800037 20051228 00037 CE 2005 12 28 2005FA0001571 1 20051011 G 5751 11561001065 RIB BEECH 99 99 1154002 CE PWA PT6 PT6A27 52043 EA LT ELEVATOR CRACKED B TIMA O OTHER O OTHER NR NOT REPORTED 1 NM 07 95WA 39157 U6 LT ELEVATOR WAS FOUND CRACKED BEHIND ELEVATOR BALANCE WEIGHT AT THE OB END OF THE ELEVATOR. UPON FURTHER INVESTIGATION IT WAS DISCOVERED THAT THE BALANCE WEIGHT WAS MODIFIED TO INCREASE THE WEIGHT. THE ADDED WEIGHT WAS DETERMINED TO BE IN STALLED BECAUSE THE ELEVATOR HAD BEEN SKINNED WITH ALUMINUM AND WAS PREVIOUSLY SKINNED WITH MAGNESIUM. THE ADDED WEIGHT OF THE ALUMINUM SKIN REQUIRED ADDED WEIGHT FOR BALANCING THE ELEVATOR. THIS ADDED WEIGHT CAUSED THE RIB TO CRACK. ELE VATOR WAS REPLACED WITH AN ALUMINUM ELEVATOR. ALUMINUM ELEVATOR HAS AN ADDITIONAL BALANCE WEIGHT INSTALLED FOR BALANCIN G PURPOSES. KIT 99-4018S WAS INSTALLED IN THE HORIZ STAB TO PROVIDE AN OPENING FOR THE ADDITIONAL BALANCE WEIGHT. (K) 1 L 7 2 3T 4 T A14CE E4EA 2005122000147 20051220 00147 CE 2005 12 20 2005FA0001572 1 20051123 G 3610 PNEUMATIC SYSTEM BEECH 58 58 1152740 CE CONT O550 IO550* SO CONTAMINATED D K NONE O OTHER UK UNKNOWN 1 EA 05 3267N TH1767 DURING PROLONGED PERIODS OF OPERATION IN HEAVY PRECIPITATION CONSIDERABLE AMOUNTS OF WATER ENTER INTO THE PNEUMATIC SYST EM. INSP OF PNEUMATIC SYS REVEALED LG AMOUNTS OF WATER BEING PASSED THROUGH DEICE BOOT EJECTOR, FURTHER DISASSEMBLY INS P REVEALED SEVERAL OUNCES OF WATER REMAINING IN SYS. SYS WAS PURGED OF ALL WATER AND DRIED. AC WAS RETURNED TO SERVICE . FLIGHT CREW REPORTED AC AGAIN WAS OPERATED FOR AN EXTENDED PERIOD OF TIME IN HEAVY PRECIPITATION. THIS AC HAS A HIST ORY OF PREMATURE FLIGHT COMMAND INDICATOR FAILURES CAUSED BY RUST AND WATER CONTAMINATION. RELOCATE THE PNEUMATIC SYS F ILTER TO AN AREA BEHIND THE ENGINE BAFFLE ASSEMBLY WHERE IT WILL NOT BE SUBJECT TO IMPACT WATER. (K) 1 L 7 2 3O 3 O 3A16 E3SO 2005122000071 20051220 00071 CE 2005 12 20 2005FA0001573 1 20051123 G 3610 PNEUMATIC SYSTEM BEECH 58 58 1152740 CE CONT O550 IO550* SO CONTAMINATED D O OTHER O OTHER NR NOT REPORTED 1 EA 05 1065B TH1765 DURING PROLONGED PERIODS OF OPERATION IN HEAVY PRECIPITATION CONSIDERABLE AMOUNTS OF WATER ENTER INTO THE PNEUMATIC SYST EM. INSP OF PNEUMATIC SYS REVEALED LARGE AMOUNTS OF WATER BEING PASSED THROUGH DEICE BOOT EJECTOR, FURTHER DISASSEMBLY INSP REVEALED SEVERAL OUNCES OF WATER REMAINING IN SYS. SYS WAS PURGED OF ALL WATER AND DRIED. AC WAS RETURNED TO SERV ICE. FLIGHT CREW REPORTED AC AGAIN WAS OPERATED FOR AN EXTENDED PERIOD OF TIME IN HEAVY PRECIPITATION. THIS AC HAS A H ISTORY OF PREMATURE FLIGHT COMMAND INDICATOR FAILURES CAUSED BY RUST AND WATER CONTAMINATION. RELOCATE THE PNEUMATIC SY S FILTER TO AN AREA BEHIND THE ENGINE BAFFLE ASSEMBLY WHERE IT WILL NOT BE SUBJECT TO IMPACT WATER. (K) 1 L 7 2 3O 3 O 3A16 E3SO 2005122000149 20051220 00149 CE 2005 12 20 2005FA0001574 1 20051123 G 3610 PNEUMATIC SYSTEM BEECH 58 58 1152740 CE CONT O550 IO550* SO CONTAMINATED D K NONE O OTHER UK UNKNOWN 1 EA 05 3214H TH1731 DURING PROLONGED PERIODS OF OPERATION IN HEAVY PRECIPITATION CONSIDERABLE AMOUNTS OF WATER INTO THE PNEUMATIC SYSTEM. I NSP OF PNEUMATIC SYS REVEALED LARGE AMOUNTS OF WATER BEING PASSED THROUGH DEICE BOOT EJECTOR, FURTHER DISASSEMBLY INSP R EVEALED SEVERAL OUNCES OF WATER REMAINING IN SYS. SYS WAS PURGED OF ALL WATER AND DRIED. AC WAS RETURNED TO SERVICE. FLIGHT CREW REPORTED AC AGAIN WAS OPERATED FOR AN EXTENDED PERIOD OF TIME IN HEAVY PRECIPITATION. THIS AC HAS A HISTORY OF PREMATURE FLIGHT COMMAND INDICATOR FAILURES CAUSED BY RUST AND WATER CONTAMINATION. RELOCATE THE PNEUMATIC SYS FILTE R TO AN AREA BEHIND THE ENGINE BAFFLE ASSEMBLY WHERE IT WILL NOT BE SUBJECT TO IMPACT WATER. (K) 1 L 7 2 3O 3 O 3A16 E3SO 2005122000153 20051220 00153 EA 2005 12 20 2005FA0001575 2 20051207 G 7320 312310001 SENSE LINE BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA ENGINE WORN G O OTHER O OTHER NR NOT REPORTED 1 EA 09 1114Z LJ1514 RR0030 P3 AIR LINE CONNECTS COMP TO P3 AIR FLTR. LINE ATTACHES TO GAS OPER CASE AT 5:00 POS LOOKING FWD, CONNECTS TO IS FITTIN G AT REAR FIREWALL. ENG INSTALLED, LINE RESTS FIRMLY ON ENG TRUSS. SUB ENG HAVE BEEN INSTALLED ON THIS AC FOR 300 HRS. P3 LINE IS ALREADY FRETTED THROUGH INSULATION THAT IS WRAPPED ON LINE. BOTH P3 LINE, ENG TRUSS SHOW SIGNS OF FRETTING WEAR IN PARENT MATL. P3 LINE SUPPLIES P3 AIR TO P3 AIR FLTR. P3 AIR CONTINUES THROUGH FLTR TO FCU. IF THIS LINE WAS TO RUPTURE. (FRETTING THROUGH OUTER WALL OF TUBE), P3 AIR SUPPLY TO FCU WILL BE LOST. FCU DROPS OFF TO MIN FLOW (40 PER CENT) WHEN P3 AIR IS LOST. PROP OF AFFECTED ENG WILL NOT REVERSE EFFECTIVELY. LOSS OF P3 AIR SUPPLY THE FCU WOULD RESU 1 L 7 2 3T 4 T RT 3A20 E4EA 2005122800034 20051228 00034 CE 2005 12 28 2005FA0001576 1 20051207 G 5100 MANUAL BEECH 90 C90A 1152911 CE PWA PT6 PT6* 52043 EA INCORRECT G O OTHER O OTHER NR NOT REPORTED 1 EA 09 1114Z LJ1514 RR0030 THIS ENG MODEL HAS BEEN INSTALLED ON THIS AC. FG OAW TRAD STC SA02238AT. THIS STC HAS NO REFERENCES FOR A GROUND PWR AS SURANCE RUNS. NO GRAPHS ARE AVAILABLE THROUGH STC TO CHART ENG PARAMETERS FOR ACCEPTABLE GROUND PERFORMANCE DATA ON THI S INSTALLATION. IT CAN NOT BE VERIFIED THAT THIS ENG ON THIS INSTALLATION IS OPERATING WITHIN REQUIRED ENG PARAMETERS. UNABLE TO RETURN THIS AC TO SERVICE WITHOUT SUCH DATA. CHART DATA FOR THIS ENG HAS BEEN USED IN PAST TO ACCEPT THIS EN G AT GROUND PERFORMANCE. HOW IS IT POSSIBLE TO ACCEPT AN ENG/AC USING A DIFFERENT MODEL CHART? STC HOLDER MUST BE RESP ONSIBLE FOR SUPPLYING ALL REQUIRED DATA FOR GROUND PERFORMANCE. HOW DID STC INSTALL GET APPROVED WITHOUT THIS INFO? 1 L 7 2 3T 3 T RT 3A20 E2NE 2006010500255 20060105 00255 NM 2006 1 5 2005FA0001577 1 20051203 G 2810 VENT LINE CHRIS HUSKY A1 221020X NM LYC O360 O360C1G 41514 EA HARTZL HCC2Y HCC2Y* GL FUEL SYSTEM BLOCKED P K NONE O OTHER TX TAXI/GRND HDL 1 AL 01 9622V 1154 L3258536A H72509 ENGINE STOPPED DUE TO BLOCKED FUEL VENT LINE. THIS OCCURRED ON THE GROUND DURING TAXIING. NO DAMAGE TO PLANE. PROBABLE CAUSE WAS SNOW BUILD UP ON THE WING EXTENDING OVER THE ENDS OF THE VENT LINES FOLLOWED BY FREEZING. 1 H 7 1 3O 3 O NC A22NM E286 5 C P920 2006010500247 20060105 00247 SO 2006 1 5 2005FA0001578 1 20050415 G 5310 TUBE MAULE M5 M5235C 5460135 SO LYC O540 O540* 41532 EA FUSELAGE CORRODED C K NONE O OTHER IN INSP/MAINT 1 AL 05 56395 1350 7335C ANNUAL INSPECTION DISCOVERED WIDESPREAD CORROSION OF 4130 STEEL FUSELAGE STRUCTURE. LOWER DOOR POST TUBES WERE CORRODED NEARLY THROUGH, RENDERING AIRPLANE UNAIRWORTHY. SIGNIFICANT PORTIONS OF APPARENT ORIGINAL YELLOW FIBERGLASS INSTALLATIO N WERE WET. AIRCRAFT WAS KEPT OUTSIDE. MOISTURE MIGHT HAVE ENTERED THROUGH WING ROOT, WITH PROBLEM POSSIBLY COMPOUNDED BY HEADLINER BEING FACTORY SALINE-IMPREGNATED (FOR FIRE RESISTANCE), AND BY WICKING OF MOISTURE BY FIBERGLASS INSULATIO N. THE MOST SIGNIFICANT CORROSION WAS NOT VISIBLE WITHOUT TEARING OUT INTERIOR THAT IS NOT TYPICALLY AND CONVENIENTLY R EMOVABLE. AC HAD BEEN FLOATPLANE, SEASONALLY, SINCE 1999. 1 H 7 1 3O 3 O 3A23 E295 2006012400124 20060124 00124 EU 2006 1 24 2005FA0001579 1 20051214 G 5313 LONGERON RHNFLU EXT300 EA300L 70218DG EU LYC O540 AEIO540* EA FUSELAGE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 15 78EX 078 DURING ROUTINE 1,000 HR INSPECTION CRACKS WERE FOUND IN THE UPPER LONGERON AT THE HORIZONTAL STABILIZER ATTACHMENT, THES E WERE VERIFIED USING A FLUORESCENT DYE CHECK PENETRANT METHOD, CRACKS WERE ALSO FOUND IN THE VERTICAL TUBE SUPPORTING F ORCES FROM THE TAIL LANDING GEAR FORWARD ATTACH POINT. 1 M 7 1 3O 3 O NC EA67U 1E4 2005122800032 20051228 00032 2005 12 28 2005FA0001580 1 20051007 G 8011 MZ4222 STARTER HOUSING FAILED B WS9R O OTHER O OTHER NR NOT REPORTED 1 NM 07 124 UPON INSPECTION OF STARTER MOTOR, IT APPEARS AS THOUGHT THE THRU-BOLTS THAT ATTACH THE MOTOR TO THE BENDIX FAILED IN FLI GHT. (K) 2005122000154 20051220 00154 CE 2005 12 20 2005FA0001581 1 20051215 G 8011 MZ298 BEARING PRESTOLITE CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA STARTER LOOSE B K NONE O OTHER IN INSP/MAINT 1 NE 05 73827 123 150043 17267703 AIRCRAFT CAME IN FOR AN OIL CHANGE, OWNER NOTICED BENDIX DRIVE SHAFT BEARING LYING IN THE COWLING. STARTER WAS O/H. TH E BEARING WAS A SLIP FIT TO THE HOUSING. I WOULD RECOMMEND BETTER TOLERANCE CONTROL AT OVERHAUL, AND REMIND ALL MECHANI CS TO PERFORM SOME SORT OF INCOMING PARTS INSPECTION. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2005122000157 20051220 00157 CE 2005 12 20 2005FA0001582 1 20051130 G 3610 PNEUMATIC SYSTEM BEECH 58 58 1152740 CE CONT O550 IO550* SO CONTAMINATED D O OTHER O OTHER NR NOT REPORTED 1 EA 05 202P TH1875 PNEUMATIC SYSTEM INSPECTED AND TRACES OF WATER WERE FOUND IN THE EJECTOR VALVE AND AREA BELOW THE VALVE. FURTHER INSPEC TION REVEALED WATER IN THE PNEUMATIC MANIFOLD VALVE AND ASSOCIATED PLUMBING. APPROXIMATELY .5 OZ OF WATER WAS REMOVED F ROM THE SYSTEM. THE PNEUMATIC SYSTEM INLET FILTER WERE INSPECTED AND SHOWED SIGNS OF WATER INGESTION. THERE WERE NO SI GNS OF WATER OR MOISTURE OR WATERE INT THE INSTRUMENTS AND THE PILOT HAD NO INDICATION OF ANY CONTAMINATION. RELOCATE T HE PNEUMATIC SYSTEM FILTER TO AN AREA WHERE IT WILL NOT BE SUBJECT TO WATER INGESTION. (K) 1 L 7 2 3O 3 O 3A16 E3SO 2005122000158 20051220 00158 SO 2005 12 20 2005FA0001583 1 20051205 G 2810 VENT LINE AMRGEN AA5 AA5A 3960106 SO LYC O320 O320* 41508 EA RT WING TANK PLUGGED D O OTHER O OTHER CR CRUISE 1 NE 03 26403 AA5A0566 RT WING FUEL TANK COLLAPSED DURING FLIGHT. SAFE LANDING WAS MADE. FOUND FUEL TANK VENT LINE PLUGGED WITH INSECT DEBRIS . PERIODICALLY CHECK FUEL VENTS FOR OBSTRUCTIONS, ESPECIALLY WHEN TIED DOWN ON GRASS. (K) 1 L 7 1 3O 3 O A16EA E274 2005122800103 20051228 00103 GL 2005 12 28 2005FA0001584 2 20051121 G 7310 A91941 HOSE RAYTHN 390 390 7150030 CE WILINT FJ44 FJ442A GL LT ENG FUEL CHAFED B E81R O OTHER K FLUID LOSS NR NOT REPORTED 1 GL 03 112CM 198 RB123 105143 DURING INITIAL 200 HOUR INSPECTION FOUND LT ENGINE MOTIVE FLOW FUEL LINE HOSE ASSY CHAFED BY ADJACENT COWL LATCH. REPLA CED HOSE ASSY. AND REROUTED, SECURED AS REQUIRED FOR CLEARANCE. AIRCRAFT ABOVE SN RANGE OF AD AND MSB. (K) 1 7 2 3F 4 F RT A00010WI E3GL 2005122800062 20051228 00062 CE 2005 12 28 2005FA0001585 1 20051121 G 2820 S14956R221605 LINE CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA FUEL SYSTEM LEAKING B L6QR O OTHER K J FLUID LOSS WARNING INDICATION NR NOT REPORTED 1 EA 05 544SP 949 172S8399 PILOT REPORTED FUEL LEAKING FROM THE IB WING ROOT AREA AFTER AIRCRAFT WAS FUELED. UPON INSPECTION, RUBBER FUEL HOSES AT WING ROOT WERE FOUND TO BE HARD, SPLIT LENGTHWISE AND LEAKING THROUGH WALL OF HOSE. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005122000156 20051220 00156 CE 2005 12 20 2005FA0001586 1 20050424 G 3233 ACTUATOR CESSNA 210 210C 2073412 CE CONT O470 IO470* 17026 SO MLG FAILED G O OTHER K FLUID LOSS NR NOT REPORTED 1 NM 09 9794X 21058094 MAIN GEAR ROTORY ACTUATOR SEALS FAILED. HYD FLUID LEVEL WENT TO ZERO AND GEAR FAILED TO EXTEND AND LOCK. (K) 1 H 7 1 3O 3 O 3A21 E1CE 2005122800065 20051228 00065 CE 2005 12 28 2005FA0001587 1 20051128 G 2730 12600747 ACTUATOR CESSNA 182 182T 2072703 CE LYC O540 IO540AB1A5 EA MCAULY 3D36C B3D36C431 GL ELEVATOR TRIM MISDRILLED B FU2R O OTHER W INADEQUATE Q C NR NOT REPORTED 1 SW 03 521AF 1000 18281194 L2865648A MFG MANDATES THE REMOVAL DISASSEMBLY, AND INSPECTION OF THE ELEVATOR TRIM ACTUATOR AT 1000 HRS TT OR 6 YEARS. UPON REMO VAL OF THIS ACTUATOR, FOUND THAT THE GROOVED PIN HOLES IN HOUSING WERE MISDRILLED. THIS CAUSED THE PIN TO WEAR INTO TH E ACTUATOR HOUSING. OPERATE 18 AIRCRAFT WITH THE SAME ACTUATOR IN THEM. AS ACTUATORS ARE REMOVED, WILL ADVISE. PICTU RES ARE AVAILABLE OF THE HOUSING IN QUESTION IF NEEDED FOR YOUR CONSIDERATION. INSTALLING A NEW ACTUATOR IN THIS AIRCRA FT. (K) 1 H 7 1 3O 3 O NT 3A13 1E4 5 C 2005122800095 20051228 00095 NE 2005 12 28 2005FA0001588 2 20051130 G 7250 3037313 TURBINE WHEEL PIAGIO P180 P180 6960204 EU PWA PT6 PT6A66 52043 NE HARTZL HCE5N HCE5N3 GL LT ENGINE DAMAGED B VIBR A UNSCHED LANDING Y E ENGINE STOPPAGE VIBRATION/BUFFET CL CLIMB 1 SO 13 137SL 1102 RK01510 KV55 AIRCRAFT WAS CLIMBING FROM 26,000 TO 28,000 WHEN THE PILOT HEARD A LOUD BANG. THE LT ENGINE TEMPERATURE PEGED. THE PIL OT IMMEDIATELY PULLED THE LT ENGINE TO FLIGHT IDLE. AFTER LANDING AND SHUTDOWN, VISUAL INSPECTION OF THE LT ENGINE SHOW ED SEVERE DAMAGE TO THE TURBINE DISC AND ALL BLADES OF THE LT PROPELLER. (K) 1 H 7 2 3O 4 T RT A59EU E26NE 5 C PZONE 2005122800033 20051228 00033 CE 2005 12 28 2005FA0001589 1 20051129 G 3297 WIRE BEECH 90 C90A 1152911 CE PWA PT6 PT6A11 52043 NE MLG CHAFED B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 5641X 5527 LJ1241 INVESTIGATED REPEATED INTERMITTENT LANDING GEAR RETRACT/ EXTENSION SYSTEM FAULTS. FOUND WIRES G45F22 AND G10L22 FOR NOS E LANDING GEAR DOWNLOCK SWITCH CHAFING ON ENVIRONMENTAL AIR CROSS-OVER DUCT IN LOWER RT NOSE KEEL AREA. REPAIRED DAMAGE D WIRING AS REQUIRED AND SECURED. ALSO REPAIRED ADJACENT AIR CONDITIONING SYSTEM WIRING CHAFING IN SAME AREA. RECOMMEN D THAT THIS AREA AND OTHER SIMILAR SELDOM INSPECTED AREAS BE INSPECTED FOR GENERAL WIRING CONDITION AND OTHER FAULTS AFT ER THE AIRCRAFT HAS ACCUMULATED 5000 HRS OR IS PAST TEN YEARS OLD. (K) 1 L 7 2 3T 3 T RT 3A20 E4EA 2005122000049 20051220 00049 CE 2005 12 20 2005FA0001590 1 20051122 G 5610 10138402521 WINDSHIELD BEECH 200 B200 1152922 CE PWA PT6 PT6* 52043 EA COCKPIT CRACKED G O OTHER O OTHER NR NOT REPORTED 1 EA 03 946CE 1609 BB1728 AT 27,000 FT THE PILOT SIDE WINDSHIELD SHATTERED. THE PILOTS VIEW WAS TOTALLY OBSTRUCTED. THE COPILOT WAS ABLE TO LAND THE AIRCRAFT SAFELY. AFTER REMOVAL, THE OUTSIDE PANEL WAS NOT DAMAGED. THE INSIDE PANEL WAS STILL IN TACT BUT COMPLET ELY SHATTERED. THE LARGEST PIECE WAS ONLY .5 INCH IN DIAMETER. AFTER TALKING TO MFG, IT WAS REVEALED THAT THIS WAS A C OMMON PROBLEM AND AN NEW STYLE WINDSHIELD WAS BEING USED. (K) 1 L 7 2 4T 3 T A24CE E2NE 2005122000053 20051220 00053 CE 2005 12 20 2005FA0001591 1 20051128 G 3230 1153800025 MOTOR BEECH 99 B99 1154004 CE PWA PT6 PT6A28 EA HARTZL HCB3T HCB3TN3 GL LANDING GEAR INOPERATIVE B HI1R A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 NE 05 199WA U154 PCE42154 BUA29207 AFTER DEPARTING, PILOT, SELECTING GEAR UP. AFTER THIS THE PILOT NOTED A STRONG ELECTRICAL BURNING SMELL. THE PILOT ELE CTED TO RETURN TO DEPARTURE. ON VERY SHORT FINAL APPROACH, THE PILOT NOTED THE GEAR WAS NOT FULLY LOCKED INTHE DOWN POS ITION AS INDICATED BY THE GEAR HANDLE LIGHTS AND INITIATED A GO AROUND AND DECLARED AN EMERGENCY. BY THAT TIME THE BURN ING SMELL HAS DISIPATED SOMEWHAT. THE PILOT THEN HAND-PUMPED THE GEAR DOWN AND LANDED WITHOUT INCIDENT. A MAINTENANCE EVALUATION REVEALED THE HYDRAULIC MOTOR THAT DRIVEWS THE GEAR HAD FAILED RESULTING IN THE BURNING SMELL. THE MOTOR WAS R EPLACED AND THE AIRCRAFT HAS BEEN PLACED BACK IN SERVICE. (K) 1 L 7 2 3T 4 T A14CE E4EA 6 C P15EA 2005122000057 20051220 00057 GL 2005 12 20 2005FA0001592 3 20051121 G 6110 SNAP RING MCAULY 3AF32C 3AF32C* GL PROPELLER MISSING B PS4R O OTHER O OTHER NR NOT REPORTED 1 SO 05 050019 THIS PROPELLER CAME INTO OUR SHOP FOR STC BLADE ANGLE CHANGE ON A NEW PROPELLER. ON OUR FIRST CHECK OF THE BLADE ANGLE WE GOT 4 DEGREES AND KENW SOMETHING WAS WRONG. SO WE PULLED TH DOEM AND THE PISTON SNAP RING HAD NOT BEEN INSTALLED FRO M THE FACTORY. (K) 5 C P22EA 2005122000055 20051220 00055 CE 2005 12 20 2005FA0001593 1 20051206 G 2140 CD21186 PUMP CESSNA 421 421B 2076014 CE CONT O520 GTSIO520H 17032 SO MCAULY 3AF34C 3AF34C92 GL CABIN HEATER INOPERATIVE D O OTHER O OTHER NR NOT REPORTED 1 NE 05 421KS 521 421B0507 267301R 735052 THE PILOT REPORTED THE HEATER HAD STOPPED DURING FLIGHT. AFTER RETURNING TO THE MAINTENANCE SHOP THE HEATER WAS TROUBLE SHOT AND INSPECTED. FOUND THE HEATER FUEL PUMP HAD MALFUNCTIONED AND HAD CAUGHT ON FIRE FOR A TIME. WERE ABLE TO SAY I T WAS ON FIRE BECAUSE OF THE BURN MARKS ON THE OUTSIDE OF THE PUMP HOUSING. HAVE ENCLOSED 2 PHOTOS TO SHOW THIS. HAVE TALKED WITH PUMP MFG TO DESIGN A NEW PUMP . PROBLEM IS WITH FUEL REGULATOR ING THE WINGS. THE REGULATORS SEEM TO NOT A LLOW ENOUGH FUEL TO GO THRU THEM TO KEEP THE PUMPS OPERATING CORRECTLY WHICH ALLOWS THEM TO OVERHEAT AND FAIL. (K) 1 L 7 2 3O 3 O A7CE E7CE 5 C P22EA 2005122000077 20051220 00077 CE 2005 12 20 2005FA0001594 1 20051206 G 3220 HMXLTFG ROD END BEECH 55 E55 1152732 CE CONT O520 IO520* 17032 SO NLG P/P TUBE BROKEN B VL1R A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 SW 01 1748W TE887 AFTER TAKEOFF, LANDING GEAR WAS RETRACTED AND A BANGING NOISE WAS HEARD BY THE PILOT. IT BECAME APPARENT THE NOSE GEAR RETRACT MECHANISM HAD BROKEN AND THAT THE NOSE GEAR DID NOT RETRACT PROPERLY. THE AIRCRAFT WAS FLOWN TO ITS DESTINATION AIRPORT WHERE NOSE GEAR COLLAPSED ON LANDING AS EXPECTED. INVESTIGATION OF THE MECHANISM REVEALED A LANDING GEAR TRANS MISSION CONNECTED TO THE NOSE LANDING GEAR PUSH/PULL TUBE. PROBABLE CAUSE SUSPECT TO BE OUT OF RIG CONDITION THAT CAUSE D FAILURE. NO EVIDENCE OF FOREIGN OBJECTS WERE EVIDENT. SPECIAL INSPECTIONS OF RIGGING AT REGULAR INTERVALS IS RECOMME NDED TO AVOID RECURRANCE OF THIS INCIDENT. (K) 1 L 7 2 3O 3 O 3A16 E5CE 2005122000408 20051220 00408 CE 2005 12 20 2005FA0001595 1 20051209 G 2710 CONTROL CABLE BEECH 55 95B55A CE CONT O470 IO470L 17026 SO HARTZL HCC2Y BHCC2YF2 GL AILERON DAMAGED D K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 NE 01 602FC 3050 TC1624 AILERON CABLE RUNNING FROM LT WHEEL WELL AREA LOWER REAR SPAR THRU CABIN UNDER FLOOR TO PEDESTAL AND CONTROL SPROCKET WA S FOUND SEVERELY RUSTED AND ABOUT HALF THE WIRE STRANDS HAD FAILED IN THE AREA WHERE THE CABLE MET THE SWAGED TERMINAL E ND. AREA IS VERY HARD TO INSPECT, AC MUST BE ON JACKS WITH GEAR PARTIALLY RETRACTED AND INNER GEAR DOORS OPEN TO SEE, A ND STILL DIFFICULT TO SEE. 1 L 7 2 3O 3 O 3A16 3E1 5 C P920 2005122000409 20051220 00409 CE 2005 12 20 2005FA0001596 1 20051209 G 2710 CONTROL CABLE BEECH 55 95B55A CE CONT O470 IO470L 17026 SO HARTZL HCC2Y BHCC2YF2 GL AILERON FAILED D K NONE O OTHER IN INSP/MAINT 1 NE 01 602FC 3050 TC1624 AILERON CABLE RUNNING FROM LT WHEEL WELL AREA LOWER REAR SPAR THRU CABIN UNDER FLOOR TO PEDESTAL AND CONTROL SPROCKET WA S FOUND SEVERELY RUSTED AND ABOUT HALF THE WIRE STRANDS HAD FAILED IN THE AREA WHERE THE CABLE MET THE SWAGED TERMINAL E ND. AREA IS VERY HARD TO INSPECT, AC MUST BE ON JACKS WITH GEAR PARTIALLY RETRACTED AND INNER GEAR DOORS OPEN TO SEE, AN D STILL DIFFICULT TO SEE. 1 L 7 2 3O 3 O 3A16 3E1 5 C P920 2005122000410 20051220 00410 EA 2005 12 20 2005FA0001597 2 20051210 G 8500 ENGINE AMTR VANS RV8 GL LYC O360 O360A1A 41514 EA MALFUNCTIONED G A UNSCHED LANDING Y ENGINE STOPPAGE CL CLIMB 1 EA 21 20EA 007 FORCED LANDING, DUE TO ENG FAIL DURING TAKEOFF. DAMAGE TO AC INCLUDED LT MLG WAS BROKEN, LT WING TIP SKIN DENTED, LWR E NG COWLING DAMAGED. DAMAGE TO AC WAS CONSIDERED TO BE MINOR. INSP OF AC REVEALED LT FUEL TANK WAS FULL OF FUEL; FUEL Q TY IN RT FUEL TANK COULD NOT BE DETERMINED. ENG OIL LEVEL WAS AT 6 QUARTS. CONTINUITY OF ENG CONTROLS, THROTTLE, MIXTUR E, AND CARBURETOR HEAT WAS ESTABLISHED FROM COCKPIT TO ENG. ENG FUEL SYS LINES WERE DISCONNECTED FROM CARBURETOR, FUEL SAMPLE REVEALED CLEAN BLUE AVIATION FUEL. EXT INSP OF ENG REVEALED NO MECH ANOMALIES. ENG FUEL STRAINER COULD NOT BE D RAINED WITH ENG COWLINGS INSTALLED ON AC, THEREFORE FUEL STRAINER WAS NOT BEING DRAINED DURING PILOT'S PREFLIGHT INSP. 1 L 7 1 3O 3 O NT EXPA1L71 E286 2005122000411 20051220 00411 CE 2005 12 20 2005FA0001598 1 20051209 G 2710 CONTROL CABLE BEECH 55 95B55A CE CONT O470 IO470L 17026 SO HARTZL HCC2Y BHCC2YF2 GL AILERON FAILED D K NONE O OTHER IN INSP/MAINT 1 NE 01 602FC 3050 TC1624 AILERON CABLE RUNNING FROM LT WHEEL WELL AREA LOWER REAR SPAR THRU CABIN UNDERFLOOR TO PEDESTAL AND CONTROL SPROCKET WAS FOUND SEVERELY RUSTED AND ABOUT HALF THE WIRE STRANDS HAD FAILED IN THE AREA WHERE THE CABLE MET THE SWAGED TERMINAL EN D. AREA IS VERY HARD TO INSPECT, AC MUST BE ON JACKS WITH GEAR PARTIALLY RETRACTED AND INNER GEAR DOORS OPEN TO SEE, AND STILL DIFFICULT TO SEE. 1 L 7 2 3O 3 O 3A16 3E1 5 C P920 2005122000407 20051220 00407 GL 2005 12 20 2005FA0001599 1 20051219 G 7820 19148410 MUFFLER BLANCA 17 1730A 1220433 GL CONT O520 IO520* 17032 SO RT ENGINE BROKEN G A UNSCHED LANDING A FLAME/FIRE NR NOT REPORTED 1 SO 13 910EJ 8 30405 RT SIDE MUFFLER, REAR TAIL-PIPE OUTLET, CRACKED OFF OF THE MUFFLER ALLOWING HOT GASES TO BLOW ONTO FIREWALL AND SURROUND ING COMPONENTS. AN ENGINE FIRE OCCURRED AND AIRCRAFT MADE EMERGENCY LANDING. THE TAIL PIPE BALL JOINT FOUND TO BE STIL L INTACT WITH THE (V) BAND INSTALLED, TIGHT AND SAFETY WIRED. 1 L 7 1 3O 3 O A18CE E5CE 2005122800099 20051228 00099 SO 2005 12 28 2005FA0001600 1 20050523 G 7602 3020508 CABLE PIPER PA23 PA23250 7102308 SO LYC O540 TIO540* 41532 EA MIXTURE CONTROL BROKEN D O OTHER O OTHER NR NOT REPORTED 1 NM 01 63790 4782 277754117 MIXTURE CABLE BROKE AT CONTROL LEVER END. 7 STRAND INNER CABLE PARTED .7500 INCH FROM PUSH/PULL SLIDER CABLE END. CABL E STRANDS APPEAR TO HAVE BEEN BALLONED FROM OVER COMPRESSION, OVER TRAVEL. CABLE PARTED AT ENGINE SHUT DOWN. THE REPLA CEMENT CABLE IS PN 454-204 AND MAY AVE BEEN IMPROVED OVER THE ORIGINAL. (K) 1 L 7 2 3O 3 O 1A10 E14EA 2005122800097 20051228 00097 SO 2005 12 28 2005FA0001601 1 20050818 G 3210 402427 BOLT PIPER PIPER PA23 PA23250 7102308 SO LYC O540 TIO540* 41532 EA LINK BROKEN D O OTHER O OTHER LD LANDING 1 NM 01 63790 4898 277754117 PN 400-111 BOLT BROKE ON LANDING. BOLT IS IN LINK, PN 16240-5. GEAR FOLDED AFT AND MAIN TIRE RODE ON RT FLAP. (NM0120 0510571) (K) 1 L 7 2 3O 3 O 1A10 E14EA 2005122800068 20051228 00068 CE 2005 12 28 2005FA0001602 1 20051207 G 5330 04102362 SKIN CESSNA 150 152 2071835 CE LYC O235 O235* 41505 EA FUSELAGE CRACKED B V36R O OTHER O OTHER NR NOT REPORTED 1 SO 13 65407 15281533 THE SKIN SUPPORTING THE COPILOTS IB SEAT RAIL WAS FOUND CRACKED. THE CRACK WAS APPROX 2.5 INCH LONG AND WAS PERPENDICUL AR TO THE SEAT RAIL. THE CRACK WAS LOCATED AT THE AFT END OF THE SEAT RAIL. DURING THE REPAIR, WE FOUND THE STIFFENER UNDERNEATH THE FLOOR, PN 04102362 CRACKED IN THE WEB. THIS STIFFENER WAS REPLACED. THE AC HAD 9500 HOURS TT AND HAS BE EN USED EXCLUSIVELY AS A TRAINER. THE CRACK WAS FOUND DURING A 100 HOUR INSPECTION. (K) 1 H 7 1 3O 3 O NT 3A19 E223 2005122800069 20051228 00069 SO 2005 12 28 2005FA0001603 2 20051123 G 8530 64193110 BOLT CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO NR 2 CYLINDER BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SO 05 4837A 828 414A0101 519028 WHILE CHECKING RT ENGINE OVER FOR OIL LEAKS, FOUND NUT AND PART OF BOLT FROM TOP FORWARD NR 2 CYLINDER THRU BOLT LODGE B Y OIL FILLER TUBE. BREAK ON BOLT APPEARS TO BE OLD BY THE DARK COLOR. REMOVAL OF CYLINDER NECESSARY TO REPLACE BOLT. (K) 1 L 7 2 3O 3 O A7CE E8CE 2005122800098 20051228 00098 SO 2005 12 28 2005FA0001604 1 20051201 G 3213 4531405 CYLINDER PIPER PA31 PA31350 7103110 SO NLG MISMANUFACTURED B K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 05 PURCHASED 2 NEW NOSE LANDING GEAR CYLINDER ASSEMBLYS WITH INCORRECTLY MACHINED CENTER BORE. THE BORE OF THE CYLINDERS I S TOO SMALL AT THE TOP WHICH DOESN`T ALLOW UPPER GEARINGS FULL TRAVEL TO TOP OF CYLINDER. THE COULD CAUSE BEARING TO FA M IN BORE AND LANDING GEAR TO MALFUNCTION ON RETRACTION/ EXTENSION. (K) 1 L 7 2 3O A20SO 2005122800022 20051228 00022 EA 2005 12 28 2005FA0001605 2 20051129 G 7414 GEAR PIPER PA28 PA28236 7102815 SO LYC O540 O540J3A5 41532 EA MAGNETO BROKEN B OLKR O OTHER O OTHER NR NOT REPORTED 1 GL 19 451X G03DA023 287911129 L2340940A ONE MAGNETO DIST. GEAR HAD 1 TOOTH BROKEN OFF THE OTHER DIST YEAR HAD A 13 TOOTH SECTION BROKEN OFF. SUSPECT THE ONE TO OTH BROKE AND TOOK OUT SECOND GEAR TEETH, LT MAG STOPPED WORKING ON TAKEOFF AND PILOT RETURNED TO AIRPORT. RT MAG WORKED WITH 1 TOOTH MISSING. CARBURETOR MAY HAVE CAUSED BACKFIRE. CARB SENT IN FOR OVERHAUL AND CHECKED FOR LEAN MIXTURE. (K ) 1 L 7 1 3O 3 O 2A13 E295 2005122800100 20051228 00100 SO 2005 12 28 2005FA0001606 1 20050429 G 3230 1904300 DRAG LINK PIPER PA23 PA23160 7102304 SO LYC O320 O320* 41508 EA LT MLG CRACKED D O OTHER O OTHER NR NOT REPORTED 1 NM 09 4001P 5545 231476 DUE TO PREVIOUS FAILURE OF RT DRAG LINK, LT MAIN LANDING GEAR DRAG LINK WAS REMOVED, PAINT STRIPED AND INSPECTED WITH ZY GLOW. A SMALL CRACK WAS NOTED EXTENDING INTO A WELD IN THE SAME AREA THAT THE OTHER (RT MLG LINK) HAD BROKEN. DRAG LIN K WAS REPLACED WITH A NEW OEM PART AND GEAR SYSTEM CHECKED FOR RIG AND PROPER OPERATION. THE AC HAD BEEN PAINTED RECEIN TLY AND DETECTING A CRACK IN THIS AREA WOULD HAVE BEEN IMPOSSIBLE UNLESS THE LINK WAS STRIPPED AND ZYGLOW INSPECTED. (K ) 1 L 7 2 3O 3 O 1A10 E274 2005122800101 20051228 00101 SO 2005 12 28 2005FA0001608 1 20050523 G 5100 40233 BOLT PIPER PIPER PA23 PA23250 7102308 SO LYC O540 TIO540* 41532 EA LINK ASSY BROKEN D O OTHER O OTHER NR NOT REPORTED 1 SW 99 63790 4782 277754117 BOLT BROKEN. (K) 1 L 7 2 3O 3 O 1A10 E14EA 2005122800042 20051228 00042 EA 2005 12 28 2005FA0001609 2 20051202 G 7250 310427901 HOUSING BEECH 90 C90 1152913 CE PWA PT6 PT6A20 52043 EA POWER TURBINE FAILED B UTBR O OTHER O OTHER NR NOT REPORTED 1 GL 11 108KU LJ568 PCE24127 POWER TURBINE SHAFT HOUSING CRACKED AND BROKEN, PN 310427901. (K) 1 L 7 2 3T 3 T 3A20 E4EA 2005122800001 20051228 00001 EU 2005 12 28 2005FA0001610 2 20050808 G 7200 ENGINE GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6118 EU RIGHT MAKING METAL C K NONE O OTHER IN INSP/MAINT 1 CE 03 515PL 1092 16309 INTERMITTENT FUEL QUANTITY INDICATION DISCREPANCY, IT WAS ALSO ELECTED TO HAVE TERMINATING ACTION OF AD COMPLIED WITH B Y SB (REPLACEMENT OF FUEL TUBES). MAINT REMOVED TUBES FOR REPLACEMENT, THEY DISCOVERED SUBSTANTIAL AMOUNTS OF METAL SHA VINGS HAD ACCUMULATED AGAINST THE INLET SCREENS OF THE HIGH-PRESSURE FUEL PUMPS ON BOTH ENGINE. ALL FINDINGS WERE IMMED IATELY FORWARDED TO MFG GUIDANCE. FWD SAMPLE OF METAL TO TEST LAB FOR ANALYZE, JUDGEMENT ON WHERE METAL ORIGINATED, MET AL WAS FROM AIRFRAME. MFG RECOMMEND FUEL SYS COMPONENTS OF ENGINES DOWNSTREAM OF LOW PRESS FUEL FILTERS INSP AND OR REP AIRED AS NECESSARY. 2 L 7 2 4F 4 F RT A12EA E25NE 2005122800002 20051228 00002 EU 2005 12 28 2005FA0001611 2 20050808 G 7200 ENGINE GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6118 EU MAKING METAL C K NONE O OTHER IN INSP/MAINT 1 CE 03 515PL 1092 16308 AN INTERMITTENT FUEL QUANTITY INDICATION DISCREPANCY, IT WAS ALSO ELECTED TO HAVE THE TERMINATING ACTION OF AD COMPLIED WITH BY INCORPORATING SB, (REPLACEMENT OF FUEL TUBES). WHEN REMOVED TUBES FOR REPLACEMENT THEY DISCOVERED SUBSTANTIAL A MOUNTS OF METAL SHAVINGS HAD ACCUMULATED AGAINST THE INLET SCREENS OF HIGH PRESS FUEL PUMPS ON BOTH ENGINES. FINDINGS W ERE FWD TO MFG AND SAMPLE TO TEST LAB INDICATED METAL WAS CONSISTENT WITH AIRFRAME. MFG RECOMMEND TO HAVE FUEL SYS COMP ONENTS DOWNSTREAM OF LOW PRESSURE FUEL FILTERS INSPECTED AND OR REPAIRED AS NECESSARY. REPAIRED ENGINE AND REINSTALLED. (K) 2 L 7 2 4F 4 F RT A12EA E25NE 2006010400088 20060104 00088 GL 2006 1 4 2005FA0001612 2 20051220 G 7230 E23051119 DIFFUSER ALLSN C30P ALLSN 250C 250C30P 03013 GL COMPRESSOR SEPARATED B O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 SW 07 449 449 CAC90492 CAC90492 COMPRESSOR REPORTED STALLING. VERIFIED ON TEST CELL. UPON DISASSEMBLY DIFFUSER VANE RING WAS FOUND TO HAVE THE AFT STUD BAND (RING) SEPARATED FROM THE DIFFUSER ASSEMBLY BODY. DIFFUSER INSTALLED NEW AT LAST OVERHAUL 449.3 HOURS PRIOR. 3 U E1GL 2006010500311 20060105 00311 CE 2006 1 5 2005FA0001613 1 20051209 G 2710 CONTROL CABLE BEECH 55 95B55A CE CONT O470 IO470L 17026 SO HARTZL HCC2Y BHCC2YF2 GL AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 NE 01 602FC 3050 TC1624 AILERON CABLE RUNNING FROM LT WHEEL WELL AREA LOWER REAR SPAR THRU CABIN UNDER FLOOR TO PEDESTAL AND CONTROL SPROCKET WA S FOUND SEVERELY RUSTED AND ABOUT HALF THE WIRE STRANDS HAD FAILED IN THE AREA WHERE THE CABLE MET THE SWAGED TERMINAL E ND. AREA IS VERY HARD TO INSPECT, AC MUST BE ON JACKS WITH GEAR PARTIALLY RETRACTED AND INNER GEAR DOORS OPEN TO SEE, AN D STILL DIFFICULT TO SEE. 1 L 7 2 3O 3 O 3A16 3E1 5 C P920 2006010500312 20060105 00312 CE 2006 1 5 2005FA0001614 1 20051209 G 2710 CONTROL CABLE BEECH 55 95B55A CE CONT O470 IO470L 17026 SO HARTZL HCC2Y BHCC2YF2 GL AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 NE 01 602FC 3050 TC1624 AILERON CABLE RUNNING FROM LT WHEEL WELL AREA LOWER REAR SPAR THRU CABIN UNDER FLOOR TO PEDESTAL AND CONTROL SPROCKET WA S FOUND SEVERELY RUSTED AND ABOUT HALF THE WIRE STRANDS HAD FAILED IN THE AREA WHERE THE CABLE MET THE SWAGED TERMINAL E ND. AREA IS VERY HARD TO INSPECT, A/C MUST BE ON JACKS WITH GEAR PARTIALLY RETRACTED AND INNER GEAR DOORS OPEN TO SEE, A ND STILL DIFFICULT TO SEE. 1 L 7 2 3O 3 O 3A16 3E1 5 C P920 2006010500313 20060105 00313 CE 2006 1 5 2005FA0001615 1 20051209 G 2710 CONTROL CABLE BEECH 55 95B55A CE CONT O470 IO470L 17026 SO HARTZL HCC2Y BHCC2YF2 GL AILERON CORRODED D K NONE O OTHER IN INSP/MAINT 1 NE 01 602FC 3050 TC1624 AILERON CABLE RUNNING FROM LT WHEEL WELL AREA LOWER REAR SPAR THRU CABIN UNDER FLOOR TO PEDESTAL AND CONTROL SPROCKET WA S FOUND SEVERELY RUSTED AND ABOUT HALF THE WIRE STRANDS HAD FAILED IN THE AREA WHERE THE CABLE MET THE SWAGED TERMINAL E ND. AREA IS VERY HARD TO INSPECT, A/C MUST BE ON JACKS WITH GEAR PARTIALLY RETRACTED AND INNER GEAR DOORS OPEN TO SEE, A ND STILL DIFFICULT TO SEE. 1 L 7 2 3O 3 O 3A16 3E1 5 C P920 2005122800030 20051228 00030 CE 2005 12 28 2005FA0001616 1 20051209 G 3297 SM50D7 RELAY BEECH 33 F33A 1151425 CE CONT O520 IO520* 17032 SO MLG INTERMITTENT D VJ3R A UNSCHED LANDING F FLT CONT AFFECTED NR NOT REPORTED 1 WP 07 1565A 171 CE1331 PILOT REPORTED AFTER PUTTING THE GEAR SELECTOR IN THE DOWN POSITION THE GEAR WOULDN`T EXTEND, AFTER CYCLING GEAR SELECTO R GEAR WENT DOWN, AC RETURNED TO BASE. ON TROUBLESHOOTING THE MECHANIC SELECTED DOWN AND IT FAILED TO EXTEND, AFTER TAP PING ON TOP OF RELAY THE GEAR WENT DOWN. PROBABLE CAUSE AT THIS TIME UNKNOWN. INSTALLED NEW AND IMPROVED RELAY IAW DAT E CODE. (K) 1 L 7 1 3O 3 O 3A15 E5CE 2005122800024 20051228 00024 SO 2005 12 28 2005FA0001617 1 20051216 G 5343 NUT PLATE PIPER PIPER PA28 PA28R200 7102811 SO LYC O360 IO360A1A 41514 EA HARTZL HCC3Y HCC3YR GL MLG TRUNNION CRACKED D O OTHER O OTHER NR NOT REPORTED 1 CE 05 191BC 28R7435088 RL895251A DY3439A AFTER REMOVING THE RT FUEL TANK FOR REPAIR, IT WAS DISCOVERED THAT ALL 4 NUTPLATES THAT HOLD THE FWD MLG TRUNNION BOLTS WERE CRACKED. THE LOWER IB NUTPLATE WAS CRACKED VERTICALLY DOWN THE THREADS. THE REMAINING 3 NUTPLATES WERE CRACKED IN THE RIVET TABS. THE AC IS A TRAINING AC THAT SEES ITS SHARE OF HARD LANDINGS. PROBABLE CAUSE IS FATIGUE FROM REPEATED NOT SO SOFT LANDINGS. THE LT FUEL TANK WAS REMOVED AS WELL TO INSPECT THE LT MAIN LANDING GEAR TRUNNION NUTPLATES. NO CRACKS WERE FOUND ON THE LT SIDE. PERIODIC INSPECTIONS MAY BE REQUIRED TO ENSURE THE NUTPLATES ARE SERVICEABLE. (K) 1 L 7 1 3O 3 O 2A13 1E10 5 C P25EA 2006010600091 20060106 00091 SO 2006 1 6 2005FA0001618 2 20051215 G 7414 DISTRIBUTOR GEAR BENDIX DHAV DHC2 DHC2* 2800108 EA CONT O520 GTSIO520N 17032 SO MAGNETO DISINTEGRATED D O OTHER E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 SW 99 2740 109 F081746 579 DURING CRUISE LT ENGINE BEGAN TO RUN ROUGH. MAINTENANCE TRACED PROBLEM TO LT MAG. UPON OPENING THE MAGNETO, DISCOVERED THE DISTRIBUTOR GEAR MISSING 98 PERCENT OF ITS TEETH WITH MANY BROKEN PIECES AND SHAVINGS INSIDE THE MAG. THE DISTRIBU TOR GEAR BUSHING IS LOOSE INSIDE THE DISTRIBUTOR BLOCK. THIS MAGNETO OVERHAULED. 1 H 7 1 3R 3 O A806 E7CE 2005122700187 20051227 00187 SO 2005 12 27 2005FA0001619 2 20051222 G 8520 653129 CRANKSHAFT CONT O360 IO360ES SO ENGINE CRACKED C K NONE O OTHER IN INSP/MAINT 1 EA 23 357267 ENGINE HAD A PROPELLER STRIKE INSPECTION WITH NO DAMAGE FOUND TO CRANKSHAFT. ENGINE WAS PUT BACK INTO SERVICE, CRANKSHA FT DEVELOPED A CRACK IN THE PROPELLER FLANGE. CRACK PROPAGATED FROM A SUBSURFACE DEFECT THAT WAS UNDECTED BY MAGNETIC P ARTICLE INSPECTION. 3 O E1CE 2005122800031 20051228 00031 CE 2005 12 28 2005FA0001620 1 20051202 G 2820 00292000049 TUBE BEECH 58 58 1152740 CE FUEL SYSTEM CHAFED B E81R O OTHER O OTHER IN INSP/MAINT 1 GL 03 200KH TH2102 WHILE RETRACTING AND EXTUENDING LANDING GEAR FOR ADJUSTMENT OF DROOPING IB MAIN WHEEL DOOR NOTED ABNORMAL NOISE AND VIBR ATION DURING APPROXIAMTE MID-TRAVEL. INVESTIGATED FURTHER, FOUND RT MLG RETRACT ROD ASSY. CHAFING ON PN 002-920000-49 AND PN 002-920000-51 RT WHEEL WELL FUEL CROSSFEED TUBES. VISUALLY INSPECTED FUEL TUBE ASSY. FOUND CHAFING ON EXTERIOR N EGLIGIBLE. REPOSITIONED AND SECURED FUEL TUBES AS REQUIRED FOR CLEARANCE WITH RETRACT ROD DURING RETRACT/EXTENSION OPER ATIONS. RECOMMEND 1-TIME INSP OF AREA; IF NOT NOTICED EARLY COULD RESULT IN CHAF-THROUGH AND SUBSEQUENT FUEL LEAKAGE. (K) 1 L 7 2 3O 3A16 2005122800035 20051228 00035 CE 2005 12 28 2005FA0001621 1 20051201 G 2700 CONTROL CABLE BEECH 200 B200 1152922 CE FLT CONTROLS OUT OF RIG B E81R K NONE O OTHER IN INSP/MAINT 1 GL 03 351CB BB1889 DURING INSPECTION OF FLIGHT CONTROL SYSTEM, DURING INITIAL 200 HOUR PHASE 1 INSPECTION, IAW SAFETY COMMUNIQUE NR 265, FO UND RUDDER CABLE TENSIONS, RUDDER TAB CABLE TENSIONS, AND ELEVATOR TAB CABLE TENSIONS BELOW APPLICABLE MM SERVICE LIMITS . NO OTHER FAULTS NOTED. A MANDATORY SB IS IN THE PROCESS OF BEING ISSUED ON THIS SUBJECT IAW THE TEXT OF SAFETY COMMU NIQUE NR 265. (K) 1 L 7 2 4T A24CE 2005122800023 20051228 00023 SO 2005 12 28 2005FA0001622 1 20051122 G 3260 451848 DOWNLOCK SWITCH PIPER PA32 PA32RT300 7103215 SO LYC O540 IO540* 41532 EA NLG BROKEN B EL6R O OTHER O OTHER NR NOT REPORTED 1 EA 23 39503 32R7885224 UPON ARRIVING AT DESTINATION GEAR WAS SELECTED DOWN. NOSE GEAR GREEN LIGHT DID NOT ILLUMINATE AND IN TRANSIT LIGHT STA YED ON. INSPECTED AND FOUND NOSE GEAR DOWNLOCK SWITCH ACTUATING ARM BROKEN OFF. DETERMINED CAUSE OF BREAKING WAS TIME IN SERVICE AND WORK HARDING OF METAL ARM, SUGGEST TIME LIMITED INTERVAL FOR REPLACING. (K) 1 L 7 1 3O 3 O A3SO 1E4 2005122800067 20051228 00067 CE 2005 12 28 2005FA0001623 1 20051107 G 5343 20130035 BRACKET CESSNA 177 177RG 2073709 CE LYC O360 IO360A1B6 41514 EA NLG ACTUATOR CRACKED D O OTHER O OTHER NR NOT REPORTED 1 GL 25 7557V 3675 177RG0853 WHILE ATTEMPTING TO RIGG THE NOSE GEAR AFTER DOING AN ENGINE AND MOUNT OVERHAUL, IT WAS IMPOSSIBLE TO MAINTAIN THE PROPE R CLEARANCES AND THE LOCK WOULD NOT SNAP OVER CENTER ON THE DOWN CYCLE. WHILE WATCHING THE ACTUATOR IT SEEMED THE MOVE. UPON FURTHER INSPECTION AT THE UPPER ATTACH POINT (USING A BRIGHT LIGHT) THE BRACKET ASSY WAS FOUND TO BE SEVERLY CRAC KED. WOULD RECOMMEND CLOSE VISUAL INSPECTION AT EACH ANNUAL. (K) 1 H 7 1 3O 3 O A20CE 1E10 2006010300198 20060103 00198 CE 2006 1 3 2005FA0001624 1 20051027 G 3230 13137825CL LINK BEECH 200 200BEECH 1152920 CE MLG BROKEN D O OTHER O OTHER NR NOT REPORTED 1 CE 07 71RG BB443 LINK IN LANDING GEAR EXTENSION CHAIN WAS FOUND BROKEN AND IN THE BELLY OF THE AIRCRAFT. THIS BRAKAGE PREVENTED THE EXTE NSION OF THE NOSE GEAR. (K) 1 L 7 2 4T A24CE 2006010300186 20060103 00186 CE 2006 1 3 2005FA0001625 1 20051123 G 2435 230801902 BRUSHES BEECH MU300 400A 1155402 CE PWA JT15 JT15D4 52112 NE STARTER GEN WORN B BUER K NONE O OTHER IN INSP/MAINT 1 GL 23 53MS 365 YO1230 RK64 1,000 HOUR OVERHAUL OF BOTH STARTER-GENERATORS BRUSHES WORN. REINSTALLED AFTER OVERHAUL. (K) 2 H 7 2 4F 4 F RT A16SW E1NE 2006010300195 20060103 00195 CE 2006 1 3 2005FA0001626 1 20051123 G 2435 230801902 BRUSHES LUCAS BEECH MU300 400A 1155402 CE PWA JT15 JT15D4 52112 NE STARTER GEN WORN B BUER O OTHER O OTHER NR NOT REPORTED 1 GL 23 53MS 365 Y01231 RK64 1000 HOUR OVERHAUL OF BOTH STARTER-GENERATORS, REINSTALLED AFTER OVERHAUL. (K) 2 H 7 2 4F 4 F RT A16SW E1NE 2006010300187 20060103 00187 SW 2006 1 3 2005FA0001627 1 20051206 G 5100 474502524 LINK BELL 47 47G5 1181032 SW ALLSN 250B 250B* GL UNKNOWN CRACKED B E5WR O OTHER O OTHER NR NOT REPORTED 1 GL 21 2251W 7965 CRACK INDICATION REVEALED TRANSVERSE BETWEEN HOLES. INSPECTION METHOD: FLOURESCENT PENETRANT. (K) 1 G 7 1 3O 3 T 2H3 E10CE 2006010300190 20060103 00190 SW 2006 1 3 2005FA0001628 1 20051206 G 6700 TTB21032 SLEEVE BELL 47 47G5 1181032 SW ALLSN 250B 250B* GL COLLECTIVE PITCH CRACKED B E5WR O OTHER O OTHER NR NOT REPORTED 1 GL 21 2251W 7965 CRACK INDICATION REVEALED AT WELD TO TUBE SLEEVE. INSPECTION METHOD: FLUORESCENT MAGNETIC PARTICLE. (K) 1 G 7 1 3O 3 T 2H3 E10CE 2006010300191 20060103 00191 SW 2006 1 3 2005FA0001629 1 20051206 G 5100 471202523 GRIP BELL 47 47G5 1181032 SW ALLSN 250B 250B* GL UNKNOWN CRACKED B E5WR O OTHER O OTHER NR NOT REPORTED 1 GL 21 2251W 7965 CRACK INDICATION REVEALED AT THE 8TH THREAD IB FROM END. INSPECTION METHOD: EDDY CURRENT. (K) 1 G 7 1 3O 3 T 2H3 E10CE 2006010300185 20060103 00185 SO 2006 1 3 2005FA0001630 1 20051107 G 2810 DC1084924G32L FUEL TANK PIPER PA18 PA18150 7101828 SO LYC O320 O320* 41508 EA LEFT LEAKING B WWKR O OTHER K FLUID LOSS NR NOT REPORTED 1 AL 03 2880P 613 184477 LT FUEL TANK WAS LEAKING. PILOT ADVISED US OF LEAK. WE DRAINED BOTH TANKS AND TURNED THEM INTO REP. THEY ADVISED US T HERE WAS AS/L ON BOTH TANKS. WERE REMOVED AND SENT IN TO MFG FOR REPAIR AND APPROVAL. (K) 1 H 7 1 3O 3 O 1A2 E274 2006010300189 20060103 00189 CE 2006 1 3 2005FA0001631 1 20051014 G 5720 052323124 SUPPORT BRACKET CESSNA 172 172P 2072436 CE LYC O320 O320* 41508 EA WING TE CRACKED D O OTHER O OTHER NR NOT REPORTED 1 NM 13 54844 11427 17275065 WING T/E SKIN SUPPT BRACKET CRACKED IN BEND RADIUS. LOCATION OF CRACKED PART IS IB SIDE OF RT FLAP TRACK RIB AT STA 39. PART HAS .2500 INCH CRACK FROM L/E OF TAB AFT, ANOTHER CRACK IN SAME BEND RADIUS .7500 INCH FROM T/E OF TAB FWD. BEND RADIUS CRACK IS UNDER EXCESSIVE STRESSES. DEFLECTED DOWN AS VIEW FROM FRONT OF AC FACING AFT, T/E WING SKIN MAKES A SI GNIFICANT INCREASE IN ITS CURVE AFT OF LAST TAB ATTACHING RIVET AS VIEW FROM OB EDGE OF SKIN LOOKING THROUGH FLAP TRACK SLOT. VERY LITTLE CLEARANCE BETWEEN THESE BRACKETS AND FLAP SUPPT RAILS. CRACK IN OR EXCESSIVE DEFORMATION CAN CAUSE T HE FLAP SUPPT RAILS TO GRAB BRACKET UPON RETRACTION, RESULTING IN FAILURE OF FLAP, POSSIBLE LOSS OF CONTROL OF AC. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2006010300209 20060103 00209 SO 2006 1 3 2005FA0001632 1 20050831 G 3220 3200 TAIL WHEEL PIPER PA22 PA22150 7102210 SO LYC O320 O320* 41508 EA MLG WORN G O OTHER O OTHER NR NOT REPORTED 1 NM 13 1829P 222609 PILOT REPORTED SEVERE TAILWHEEL SHIMMY DURING LANDING ROLLOUT LEADING TO LOSS OF CONTROL AND GROUND LOOP WITH SIGNIFICAN T DAMAGE TO AIRCRAFT. POST ACCIDENT INSP FOUND PLAY IN THE ALUMINUM SPACER BETWEEN THE TAILWHEEL ASSY AND THE TAILWHEEL SPRING. ALSO, THERE WAS LITTLE RESISTANCE TO TURNING THE WHEEL OUT OF THE STRAIGHT FORWARD POSITION. SOME EXTERNAL DA MAGE HAD OCCURRED TO THE TAILWHEEL ASSY DURINT THE GROUND LOOP. RECOMMENDED THAT WEIGHT BE REMOVED FROM THE TAILWHEEL A SSY DURING INSPECTIONS TO DETERMINE THE TRUE INTERNAL CONDITION AS WELL AS THE MOUNTING ADAPTER CONDITION AND THE TAILWH EEL PIVOT AXIS GEOMETRY BE INSPECTED IAW MM. (K) 1 H 7 1 3O 3 O 1A6 E274 2006010300203 20060103 00203 EA 2006 1 3 2005FA0001633 1 20051115 G 5340 612826 MOUNT DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985* 52008 NE ADC CRACKED B HJBR O OTHER O OTHER NR NOT REPORTED 1 AL 05 60077 1861 1419 DURING THE REPLACEMENT OF THE AIR DATA COMPUTER. FOUND THE MOUNTING TRAY ASSY CRACKED COMPLETELY ACROSS ON THE OPPOSITE END OF THE THUMBSCREW. AIRCRAFT IS CONFIGURED ON AMPHIBIAN FLOATS. (K) 1 H 7 1 3R 3 R A806 5E1 2006010400087 20060104 00087 SO 2006 1 4 2005FA0001634 2 20051222 G 8520 653129 CRANKSHAFT CONT O360 IO360ES SO ENGINE CRACKED C K NONE O OTHER IN INSP/MAINT 1 EA 23 357267 ENGINE WAS INVOLVED IN A PROPELLER STRIKE, NO CRANKSHAFT DAMAGE WAS FOUND AT THAT TIME. ENGINE WAS RETURNED TO SERVICE AND A CRACK DEVELOPED IN THE CRANKSHAFT FLANGE, CRANKSHAFT WAS REMOVED FROM THE ENGINE. THE CRACK MOST LIKELY ORIGINATED FROM A SUBSURFACE DEFECT THAT WAS NOT DETECTIBLE WITH MAG PARTICLE INSPECTION. 3 O E1CE 2006010500151 20060105 00151 SO 2006 1 5 2005FA0001635 2 20051220 G 8520 IO520F CRANKCASE CONT O520 IO520F 17032 SO ENGINE FAILED B O3OR O OTHER O OTHER NR NOT REPORTED 1 AL 03 1798 814752 LT CRANKCASE MAIN BEARING SADDLE FAILURE. THIS ENGINE MADE IT TO TBO BUT WASN`T GOING TO GO VERY MUCH LONGER. (K) 3 O E5CE 2006010500159 20060105 00159 CE 2006 1 5 2005FA0001636 1 20051216 G 7160 CPE1173 FILTER CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA INDUCTION FAILED B DYTR O OTHER O OTHER NR NOT REPORTED 1 SO 15 78JA 293 17280622 L2997051A THIS IS AN INDUCTION AIR FILTER BEARING. REMOVED 5 OF THESE FILTERS FROM SERVICE IN ADDITION TO THE ONE IN THIS REPORT WITH THE SAME DAMAGE SIMILAR TIME IN SERVICE. THE WIRE MESH THAT ENCLOSES THE COTTON FIBER FILTER MATERIAL IS TEARING A ND EXPOSING THE FILTER MIATERIAL.. SOME OF THE WIRE MESH AND FILTER MATERIAL IS MISSING, ASSUMED TO HAVE BEEN INGESTED B Y THE ENGINE. MFG FILTERS CURRENTLY ELIMINATE THE REQUIREMENTS SET FORTH IN AD84-26-02 DEALING WITH INGESTION OF PAPER AIR FILTERS. JUDGING BY THE RESULTS SEEN FROM THIS AND THE OTHER FILTERS REMOVED FROM SERVICE, THESE FILTERS POSE A GRE ATER RISK OF INGESTION AND ENGINE FAILURE THAN PAPER FILTERS. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2006010400103 20060104 00103 GL 2006 1 4 2005FA0001637 2 20051116 G 7261 206061505109 OIL TANK BELL 206 206L1 1182107 SW ALLSN 250C 250C28 03013 GL ENGINE LEAKING C K NONE K FLUID LOSS IN INSP/MAINT 1 SO 01 2009C 3541 45678 206-061-505-109 ENGINE OIL RESERVOIR BEGAN TO LEAK ENGINE OIL. 1 G 7 1 3U 3 U H2SW E1GL 2006010400104 20060104 00104 GL 2006 1 4 2005FA0001638 2 20051116 G 7261 206061505109 OIL TANK BELL 206 206L1 1182107 SW ALLSN 250C 250C28 03013 GL ZONE 200 LEAKING C K NONE K FLUID LOSS IN INSP/MAINT 1 SO 01 2009C 3541 45678 206-061-505-109 ENGINE OIL RESERVOIR BEGAN TO LEAK ENGINE OIL 1 G 7 1 3U 3 U H2SW E1GL 2006010600058 20060106 00058 EA 2006 1 6 2005FA0001639 2 20050806 G 7421 REM40E SPARK PLUG PIPER PA18 PA18A150 7101837 SO LYC O320 O320* 41508 EA ENGINE DEFECTIVE G O OTHER R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 GL 15 6983B 185105 AIRCRAFT LOST POWER WHILE TAKING OFF WITH GLIDER IN TOW. GLIDER WAS RELEASED AND WAS DAMAGED DURING LANDING IN PASTURE. AIRCRAFT RETURNED TO AIRPORT AND LANDED. TWO SPARK PLUGS ON NR 2 CYLINDER WERE COLD. ALL EIGHT SPARK PLUGS WERE REPLACED . 1 H 7 1 3O 3 O 1A2 E274 2006012400201 20060124 00201 NE 2006 1 24 2005FA0001640 2 20051229 G 7321 0164248850 FCU TMECA ARRIEL1D1 SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE ENGINE UNCONTROLLABLE B E ENGINE SHUTDOWN O OTHER TO TAKEOFF 1 SW 01 6098U 2230 2230 9280 2718 9280 FCU WOULD NOT GOVERN ENGINE FROM START. 1 G 7 1 3U 3 U H9EU E19EU 2006012500002 20060125 00002 NE 2006 1 25 2005FA0001641 2 20051229 G 7321 0164248850 FCU TMECA ARRIEL1D1 SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE ENGINE UNCONTROLLABLE B E ENGINE SHUTDOWN O OTHER TO TAKEOFF 1 SW 01 6103X 4669 969 9442 2723 9442 FCU WOULD NOT GOVERN ENGINE AT GROUND IDLE. 1 G 7 1 3U 3 U H9EU E19EU 2006020300126 20060203 00126 CE 2006 2 3 2005FA0001642 1 20051208 G 8011 MZ4218 STARTER BEECH 23 A23 1151204 CE LYC O320 IO320A2B EA ENGINE FAILED C K NONE O S OTHER AFFECT SYSTEMS IN INSP/MAINT 1 EA 23 L518951A STARTER BENDIX FAILED, DAMAGED STARTER SHAFT, DAMAGED TEETH ON RING GEAR SUPPORT. 1 L 7 1 3O 3 O A1CE 1E12 2006010500173 20060105 00173 CE 2006 1 5 2005FA0001643 1 20051206 G 2150 JBS2402 RESISTOR CESSNA 500 S550 2076607 CE BLOWER ASSY BURNED B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 22HP S5500103 PILOT REPORTED FREON AIR CONDITIONING SYSTEM CIRCUIT BREAKER TRIPPED WHEN SYSTEM TURNED ON. FOUND AFT EVAPORATOR BLOWER INOPERATIVE IN LOW POSITION, EXCESSIVELY NOISY IN HIGH POSITION. REMOVED FLOORBOARD FOR INVESTIGATION, FOUND BLOWER MO TOR RESISTOR ASSY. BURNED AND ADJACENT PLASTIC BLOWER MOTOR HOUSING MELTED. FREON AIR CONDITIONING SYSTEM INSTALLED UN DER STC SA2698SW, 809.7 HOURS PREVIOUSLY, NO RECORD OF COMPONENT REPLACEMENTS SINCE INSTALLED. REPLACED BLOWER ASSY AND RESISTOR, OPS CHECKS SATISFACTORY. (K) 1 L 7 2 4F RT A22CE 2006010500172 20060105 00172 CE 2006 1 5 2005FA0001644 1 20051207 G 2720 1015240174 SUPPORT BEECH 200 B200 1152922 CE RUDDER MISINSTALLED B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 912JS 369 BB1845 OPERATOR NOTED (2) NON-STANDARD RIVETS INSTALLED ATTACHING THE PN 101-524017-4 RT RUDDER MECHANISM SUPPORT BRACKET ANGLE TO THE FS 437.234 CANTED BULKHEAD. DURING RIVET REPLACEMENT FOUND THAT IB RIVET HAD FORMED A SHOP HEAD BETWEEN THE BUL KHEAD AND SUPPORT ANGLE DUE TO A MOUNTING GAP. (K) 1 L 7 2 4T A24CE 2006012400200 20060124 00200 CE 2006 1 24 2005FA0001645 1 20051229 G 7700 400510 PROBE EDM800C CESSNA 210 T210M 2073451 CE AIR TEMP PROBE FAILED D K NONE O OTHER TX TAXI/GRND HDL 1 SW 15 25 22386 21061879 OUTSIDE AIR TEMP PROBE FAILED SELF TEST INDICATING OPEN. 1 H 7 1 3O 3A21 2006011300173 20060113 00173 GL 2006 1 13 2005FA0001646 1 20051220 G 3220 ROLL PIN DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240A SO NOSE STRUT LOOSE D K NONE O OTHER IN INSP/MAINT 1 NM 03 922AF C0179 ROLL PIN LOCKING THE NOSE STRUT ELECTROMETRIC SPRING PLATE (PN 20-3220-05-02) TO THE SHOCK ABSORBER ROD (PN 20-3220-05-0 1) HAD WORKED OUT UNLOCKING THE ASSY. 1 L 7 1 3O 3 O NT TA4CH E7SO 2006011300174 20060113 00174 GL 2006 1 13 2005FA0001647 1 20051220 G 3220 ROLL PIN DIAMON DA20 DA20C1 2990001 GL CONT O240 IO240A SO NOSE GEAR LOOSE D K NONE O OTHER IN INSP/MAINT 1 NM 03 915AF C0149 ROLL PIN LOCKING THE NOSE STRUT ELECTROMETRIC SPRING PLATE (PN 20-3220-05-02) TO THE SHOCK ABSORBER ROD (PN 20-3220-05-0 1) HAD WORKED OUT UNLOCKING THE ASSY. 1 L 7 1 3O 3 O NT TA4CH E7SO 2006012400199 20060124 00199 EU 2006 1 24 2005FA0001648 1 20051229 G 5711 14101B1 SPAR CAP PARTEN PARTEN P68 P68CTC 6780106 EU LYC O360 TO360A1A6 41514 EA RT WING CORRODED B O OTHER O OTHER IN INSP/MAINT 1 SO 15 775MW 2414 20801 SEVERE INTERGRANULAR CORROSION OF MAIN WING SPAR WEB AND UPPER SPAR CAP AFT OF ENGINE FIREWALL. REQUIRES REMOVAL OF ENG INE, ENGINE MOUNT, FIREWALL. SUSPECT SOURCE OF CORROSION TO BE FIRE SHEATH INSTALLED OVER FUEL LINES BEHIND FIREWALL. SB 61 ADDRESSES INSPECTION OF FUEL LINES AND REMOVAL OF FIRE SHEATHING, WITH CORRESPONDING INSPECTION FOR SPAR CORROSION . BULLETIN IS MISLEADING, DOES NOT PLACE EMPHASIS ON SPAR. WING SPAR IS UNAIRWORTHY, FACTORY AND DER CONTACTED FOR POSS IBLE REPAIR. RECOMMEND AD FOR THIS CONDITION. 1 H 7 2 3O 3 O A31EU E26EA 2006010600096 20060106 00096 CE 2006 1 6 2005FA0001649 1 20051219 G 3242 1013800961 BRAKE BEECH BEECH B300 B300 1159232 CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL MLG DRAGGING C C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 GL 19 981LL 286 286 769B99 FL265 ON TAKEOFF ROLL, BRAKES APPEARED TO BE DRAGGING. CREW DECIDED TO ABORT TAKEOFF W/O INCIDENT AND TAXIED BACK TO GATE. MA INT JACKED AC AND CHECKED BRAKES. BRAKES APPEARED TO BE DRAGGING AND NOT RELEASING ALL THE WAY. THESE ARE UNMODIFIED BR AKES (W/O STAINLESS STEEL SLEEVES) CHANGED ALL BRAKES AND THE AC IS BACK ON FLIGHT LINE. SUSPECT THAT REASON FOR BRAKES DRAGGING ARE UNMODIFIED BRAKES. THESE WILL BE SENT OUT FOR O/H AND MODIFICATION. THIS PROCESS IS RECOMMENDED BY MFG FOR CORROSION IN THE PUCK AREA. IN THE PROCESS OF CHANGING ALL OF THE BRAKES FLEET WIDE TO THE MODIFIED BRAKES TO HELP ELI MINATE THIS PROBLEM. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2005092300150 20050923 00150 CE 2005 9 23 2005FAA09001 1 20050922 G 2434 ALV9510R ALTERNATOR CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO MCAULY 3FF32 3FF32C501 GL ENGINE DISLODGED D K NONE H ELECT. POWER LOSS-50 PC CL CLIMB 1 NM 11 404B 21 0676 608093 880921 THE ALTERNATOR, OVERHAULED UNIT, WAS IN PIECES WHEN THE AIRCRAFT LANDED. THE BACK HALF OF THE ALTERNATOR WAS OFF, THE S TATOR WAS CHEWED UP. THE END BEARINGS WERE IN PLACE AND TURNED LIKE A NEW BEARING WITH GREASE IN THEM. 1 L 7 2 3O 3 O A7CE E7CE 5 C P45GL 2005070600041 20050706 00041 2005 7 6 2005R0124 4 20050628 G 3416 066306403 ALTIMETER CESSNA 210 T210M 2073451 CE COCKPIT BINDS B K NONE O OTHER IN INSP/MAINT 1 SW 01 732XE 61850 ALTIMETER HANDS ARE BENT & INTERFERE WITH EACH OTHER. 1 H 7 1 3O 3A21 2005120200115 20051202 00115 EA 2005 12 2 2005WP09I021 2 20050718 G 8530 CYLINDER HEAD PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA ENGINE CRACKED G A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION AP APPROACH 1 WP 09 2525Y 1100 288516075 RL1763939A DURING APPROACH FOR LANDING (TOUCH AND GO'S), ONE OF THE CYLINDER HEADS BLEW OFF AND THERE WAS A SUDDEN REDUCTION OF POW ER. THE AIRCRAFT LANDED SAFELY WITHOUT DAMAGE OR INJURIES. THE CYLINDER WAS A NEW PMA CYLINDER WITH APPROX. 1100 HOURS TIME IN SERVICE. THE CAUSE OF THE FAILURE IS CURRENTLY UNDER INVESTIGATION BY THE NTSB. 1 L 7 1 3O 3 O 2A13 E274 2006010500204 20060105 00204 CE 2006 1 5 2006FA0000000 1 20051221 G 3244 184F135 TIRE BEECH MU300 400A 1155402 CE PWA JT15 JT15D1 52060 NE MLG LEAKING D O OTHER O OTHER NR NOT REPORTED 1 SW 03 94LH 28 RK112 REPLACED THE FRONT TIRE, WITH THIS NEW TIRE AND HAVE HAD A SLOW LEAK EVER SINCE. TOOK THE TIRE BACK OFF AND SUBMERGED T HE TIRE AND WHEEL UNDER WATER, FOUND 10 VERY SMALL PINHOLES IN THE TIRE SIDEWALL CLOSE TO THE RIM EQUALLY SPACED AROUND THE SIDEWALL, THE PINHOLES WERE IN THE TIRE FROM THE FACTORY AND NOT DUE TO ANY DAMAGE INSTALLING IT OR WHILE ON THE AIR CRAFT. SIZE OF TIRE IS 18 X 4.4, LOAD RATING 3550 LBS, 10 PLY. (K) 2 H 7 2 4F 4 F RT A16SW E1NE 2006010500128 20060105 00128 SO 2006 1 5 2006FA0000001 2 20051220 G 8530 ROCKER CESSNA 150 150K 2071822 CE CONT O200 O200A 17020 SO ENG CYLINDER BROKEN G A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 CE 07 6424G 3509 883 15071924 72KABNA48 AIRCRAFT IN CRUISE FLIGHT AT 2200 FT, ENGINE BEGAN TO RUN ROUGH. PILOT DECLARED AND EMERGENCY AND LANDED AT AIRPORT. A FTER LANDING THE VALVE COVER WAS REMOVED FROM THE NR 2 CYLINDER AND IT WAS DISCOVERED THAT ALL 3 BOSSES FOR THE VALVE RO CKER SHAFTS HAD BROKEN. (K) 1 H 7 1 3O 3 O 3A19 E252 2006012400135 20060124 00135 2006 1 24 2006FA0000005 4 20051214 G 6113 05522311 BULKHEAD CESSNA 172 172R 2072401 CE LYC O360 IO360A1A 41514 EA SPINNER CRACKED B WIWR K NONE O OTHER IN INSP/MAINT 1 WP 07 24322 197 17280866 DURING 100 HR INSPECTION, THE FORWARD SPINNER BULKHEAD WAS FOUND TO BE CRACKED AROUND 3 OF THE 6 BOLT HOLES. CAUSE OF T HE PROBLEM IS THAT WHEN THE PROP MOUNTING BOLTS ARE TORQUED TO THE LIMITS GIVEN IN THE SRM THAT THE FWD BULKHEAD GETS PU LLED DOWN SLIGHTLY INTO THE CHAMFER OF THE PROP BOLT HOLES AND THIS IN TURN STRESSES THE PART LEADING EDGE TO CRACKING. TO SOLVE THIS PROBLEM, THE TORQUE OF THE MOUNTING BOLTS AND THE DESIGN OF THE BULKHEAD NEED TO BE EVALUATED AND CHANGES MADE. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2006012400126 20060124 00126 CE 2006 1 24 2006FA0000006 1 20051208 G 5100 583801091 VALVE BEECH 58 58 1152740 CE CONT O550 IO550* SO UNKNOWN OUT OF RIG D O OTHER O OTHER NR NOT REPORTED 1 WP 07 2347G TH1867 THE NEW VALVE RECEIVED FROM THE MFG WAS INTERNALLY CLOCKED INCORRECTLY. AFTER INSTALLATION, NO FUEL WAS AVAILABLE FROM EITHER THE ON OR CROSSFEED PORTS. AFTER MALVE REMOVAL, IT WAS CONFIRMED THAT THE VALVE REMAINED IN THE OFF POSITION REG ARDLESS OF MOVMENT TO ANY OF THE 3 AVAILABLE POSITIONS. A NEW VALVE WAS ORDERED AND IT WORKED CORRECTLY. (K) 1 L 7 2 3O 3 O 3A16 E3SO 2006013100218 20060131 00218 CE 2006 1 31 2006FA0000007 1 20051212 G 3060 P6592SW BOOT MCAULY CESSNA 414 414A 2075907 CE CONT O520 TSIO520* 17040 SO NR 3 BLADE FAILED B LT4R O OTHER D INFLIGHT SEPARATION NR NOT REPORTED 1 SO 19 414SH 393 950618 414A0470 BOOT PN P6592SW DEPARTED PROPELLER BLADE IN FLIGHT. CUSTOMER LANDED, REMOVED OTHER BOOTS AND CONTINUED TRIP TO HOME STA TION. BOOTS HAVE 393.6 HOURS SINCE INSTALLATION. AD NOTE 2005-18-20 INSPECTION WAS ACCOMPLISHED WITH NO DEFECTS NOTED. (K) 1 L 7 2 3O 3 O A7CE E8CE 2006012400134 20060124 00134 SO 2006 1 24 2006FA0000008 2 20051221 G 8530 EXHAUST VALVE CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO ENGINE STUCK B O3OR O OTHER O OTHER NR NOT REPORTED 1 AL 03 4676U 376 U20604352 812282R THE EXHAUST VALVE GUIDE HAD .0035 INCH OF BUILD UP MATERIAL, CAUSING THE VALVE TO STICK OPEN, WHERE IT STRUCK THE PISTON . POSSIBLY DUE TO RICH MIXTURE. (K) 1 H 7 1 3O 3 O A4CE E5CE 2006012400165 20060124 00165 CE 2006 1 24 2006FA0000009 1 20051213 G 5700 05232333 STRIP CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA LT WING UNSERVICEABLE B WIWR O OTHER O OTHER NR NOT REPORTED 1 WP 07 2173Z 937 17281216 DURING ANNUAL INSPECTION, WHILE INSPECTING THE AILERON CABLES, FOUND A FLAT SPOT ON THE LT AILERON CROSSOVER CABLE AT TH E AILERON CABLE ABRASION STRIP ATTACHED TO A RIB ASSY LOCATED AT WING STA 71.19. FURTHER INVESTIGATION FOUND THE CABLE BEGINING TO FRAY. THE CAUSE IS THE CABLE WEARING ON THE ABRASION STRIP. TO SOLVE THIS PROBLEM, THE ABRASION STRIP BE LOWERED OR A PULLEY INSTALLED. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2006012400140 20060124 00140 CE 2006 1 24 2006FA0000010 1 20051213 G 2810 FITTING CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA RESERVOIR LEAKING D O OTHER K FLUID LOSS NR NOT REPORTED 1 NM 01 686SP 1226 337836 172S8097 DURING AN ANNUAL INSPECTION, FUEL STAINING WAS NOTED AT AND BELOW THE WELD TO THE INLET FITTING. THE UNIT WAS REMOVED F ROM AIRCRAFT AND INSPECTED. A LEAK WAS LOCATED IN THE WELD. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2006012400141 20060124 00141 2006 1 24 2006FA0000011 1 20051115 G 2820 23056E60 VALVE FUEL CROSSFEED LEAKING D PRZR O OTHER K FLUID LOSS NR NOT REPORTED 1 SO 11 PART WAS RECEIVED TO REPLACE EXISTING PART DUE TIME CHANGE. WHEN PART WAS INSTALLED, PART FUNCTIONED FINE. WHEN FUEL W AS INTRODUCED TO SYSTEM FOR LEAK CHECK, UNIT WAS FOUND TO NOT HOLD SEAL. THIS IS THE FIRST OF 2 VALVES FROM THE SAME FA CILITY THAT HAVE LEAKED WHEN INSTALLED ON AIRCRAFT. FUEL CROSSFEED VALVE. (K) 2006012300230 20060123 00230 CE 2006 1 23 2006FA0000012 1 20051110 G 5511 SPAR CESSNA 150 152 2071835 CE LYC O235 O235* 41505 EA STABILIZER CRACKED D M9OR K NONE O OTHER IN INSP/MAINT 1 GL 09 24831 8207 15280403 ON ROUTING 100 HR INSPECTION FOUND CRACK ON HORIZONTAL STABILIZER FRONT APEK, LOWER ANGLE PN 0432001-37 AND REINFORCEMEN T PLATE PN 0432001-44, 1 LOWER SKIN RIVET SEAM FRETTED AND LOOSE. UPON REMOVAL AND DISASSEMBLY DISCOVERED CRACKED SKIN (PN 0432001-55) AND CRACKED SPAR PN 0432001-56. NOTE: THIS IS AN EARLIER SN AC WHICH APPARENTLY DID NOT HAVE REINFORCEM ENT ANGLE PN 0432007-3 AS INSTALLED ON LATER SN`S. THIS AC ALSO HAS A CONVERSION TO TAILWHEEL AND HAS SPENT A PORTION O F ITS TT AS A TAILWHEEL. (K) 1 H 7 1 3O 3 O NT 3A19 E223 2006012500124 20060125 00124 EA 2006 1 25 2006FA0000013 2 20051228 G 7414 M3163 IMPULSE COUPLING SLICK CESSNA 172 172N 2072434 CE LYC O320 O320* 41508 EA MAGNETO LOOSE B O OTHER O OTHER NR NOT REPORTED 1 GL 15 739XK 17270887 DURING 500 HOUR MAG AND IMPULSE COUPLING INSPECTION FOUND ONE IMPULSE COUPLING PAWL RETAINING RIVET VERY LOOSE IN IMPULS E HOUSING. NO DAMAGE NOTED. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2006012300227 20060123 00227 CE 2006 1 23 2006FA0000014 1 20051112 G 3700 215CC EXHAUST PIPE BEECH 23 C24R 1151254 CE LYC O360 IO360A1A 41514 EA VACUUM PUMP CORRODED D K NONE D S INFLIGHT SEPARATION AFFECT SYSTEMS CR CRUISE 1 SO 07 18993 281 MC550 EXHAUST PORT OF DRY AIR PUMP FELL OFF DURING FLIGHT AND LODGED IN LANDING GEAR RETRACTION SYSTEM. AC HAD TO LAND NOSE G EAR UP. PIPE THREADS IN ALUMINUM PUMP HOUSING WERE WORN AND CORRODED. SUGGESTED THAT FITTINGS BE INSPECTED FOR SECURIT Y MORE FREQ THAN 100 HOUR/ANNUAL. ALSO INDUSTRY SHOULD ALLOW PIPE DOPE COMPOUND ON EXHAUST FITTINGS SINCE INGESTION OF FOD WOULD NOT BE A FACTOR ON THE EXIT PORT. (K) 1 L 7 1 3O 3 O A1CE 1E10 2006012400123 20060124 00123 2006 1 24 2006FA0000016 1 20051228 G 2900 FLANGE DUNLOP SERVO ACTUATOR CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 99 FJ383 CRACK DETECTED ON LOWER LEE PLUG FLANGE. (K) 2006012400122 20060124 00122 2006 1 24 2006FA0000017 1 20050620 G 2824 23056EGD VALVE CROSSFEED FAILED B PRZR K NONE K FLUID LOSS IN INSP/MAINT 1 SO 11 PART WAS RECEIVED TO REPLACE EXISTING PART DUE TIME CHANGE. WHEN PART WAS INSTALLED, PART FUNCTIONED FINE. WHEN FUEL W AS INTRODUCED TO THE SYSTEM FOR A LEAK CHECK, UNIT WAS FOUND TO NOT HOLD A SEAL. THIS IS THE SECOND UNIT FROM SAME FACI LITY THAT HAD THE SAME PROBLEM. FUEL CROSSFEED VALVE. WO NR 44103345 (K) 2006012400163 20060124 00163 SO 2006 1 24 2006FA0000020 1 20051221 G 2840 50954000 CONDUIT PIPER PA31T PA31T 7103124 SO PWA PT6 PT6A60A 52043 NE FUEL SYSTEM LEAKING G K NONE O OTHER IN INSP/MAINT 1 GL 21 234K 6359 31T7520001 LT NACELLE TANK SENDER WAS LEAKING OUT OF TOP OF NACELLE. SENDER SCREWS HAD BEEN TIGHTENED AND GASKETS REPLACED BUT STIL L LEAKED. TECH FOUND ALUMINUM CONDUIT THAT SENDER WIRING IS ROUTED THROUGH IN TANK TO HAVE APPROX 10-15 PINHOLES IN IT F ROM CORRODING FROM THE INSIDE OF ALUMINUM CONDUIT. FUEL LEAKS INTO CONDUIT AND UP TO TOP OF SENDER THEN WOULD LEAK OUT T OP AND DOWN/AFT ON NACELLE. 1 L 7 2 3T 4 T A8EA E4EA 2006011800207 20060118 00207 CE 2006 1 18 2006FA0000024 1 20051103 G 2730 7627302026001 CABLE LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP ELEV CNTRL CABLE DAMAGED B WVER K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 EA 09 423FX 134 DURING THE INITIAL 5,000 HOUR CABLE INSPECTIONON THIS AIRCRAFT NOTED EXTENSIVE DAMAGE TO THE LOWER LEFT AFT ELEVATOR CON TROL CABLE AND PRESSURIZATION SYSTEM VACUUM LINE WAS FOUND MISROUTED CAUSING DAMAGE TO THE ELEVATOR CONTROL CABLE AND VA CCUM LINE. ENGINEERING EVALUATE THE NEED FOR A ONE-TIME INSPECTION OF THIS AREA ON ALL LIKE AIRCRAFT WITH LESS THAN 5,0 00 ACCLUMATED FLIGHT HOURS. (K) 2 L 7 2 4F 4 F RT T00008WI E6WE 2006011800206 20060118 00206 CE 2006 1 18 2006FA0000025 1 20050930 G 2720 ANGLE LEAR 60 60LEAR 5170707 CE PWA 305 PW305A 52128 NE RUDDER STOP CRACKED B WVER K NONE O OTHER IN INSP/MAINT 1 EA 09 251FX 195 UPON REMOVAL OF RUDDER, TO REPAIR SKIN DAMAGE AT HINGE POINTS FOUND RUDDER SUPPORT STIFFENER ANGLE (PN 5412481-004) CRAC KED UNDER RUDDER PRIMARY TRAVEL STOP AT FRAME STATION 48. RUDDER OVER TRAVELING WHEN GUST LOCK NOT INSTALLED AND WHEN P ARKED OUTSIDE IN WINDY CONDITIONS. ENSURE FLIGHT CONTROL GUST LOCKS ARE INSTALLED WHEN PARKED OUTSIDE. (EA09200600885) (K) 2 L 7 2 4F 4 F RT A10CE E35NE 2006011800205 20060118 00205 CE 2006 1 18 2006FA0000026 1 20051018 G 2720 4555401134009 TORQUE TUBE LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP RUDDER CORRODED B WVER K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 EA 09 418FX 120 DURING 5,000 HOUR INSPECTION, THE RUDDER WAS REMOVED FOR S/B (REPAIR OF RUDDER TORQUE TUBE ASSY BONDING JUMPERS) FOUND C ORROSION ON TORQUE TUBE INTERNAL AND EXTERNAL. ON FURTHER INVESTIGATION (EDDY CURRENT INSP) A CRACK INDICATION WAS NOTE D .020 INCH DEEP BY 1 INCH LONG. TORQUE TUBE WAS REMOVED AND REPLACED. PROBABLE CAUSE: MOISTURE INGRESSION THROUGH WIR E BUNDLE HOLE. ENGINEERING EVALUATE FOR POSSIBLE INTERNAL INSPECTION CRITERIA OF TORQUE TUBE AND ENVIRONMENTAL SEALING AS REQUIRED. (K) 2 L 7 2 4F 4 F RT T00008WI E6WE 2006011800204 20060118 00204 CE 2006 1 18 2006FA0000027 1 20051031 G 2720 4555401134009 TORQUE TUBE LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP RUDDER CORRODED B WVER K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 EA 09 423FX 134 DURING 5,000 HR INSPECTION, THE RUDDER WAS REMOVED FOR SB, REPAIR OF (RUDDER TORQUE TUBE ASSY BONDING JUMPERS) FOUND COR ROSION ON TORQUE TUBE INTERNAL AND EXTERNAL. MOISTURE INGRESSION THROUGH WIRE BUNDLE HOLE. ENGINEERING EVALUATE FOR PO SSIBLE INTERNAL INSPECTION CRITERIA OF TORQUE TUBE AND ENVIRONMENTAL SEALING AS REQUIRED. (EA09200600887) (K) 2 L 7 2 4F 4 F RT T00008WI E6WE 2006011800202 20060118 00202 CE 2006 1 18 2006FA0000028 1 20051031 G 2720 4555401134009 TORQUE TUBE LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP RUDDER CORRODED B WVER K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 EA 09 422FX 135 DURING 5,000 HOUR INSPECTION, THE RUDDER WAS REMOVED FOR SB (REPAIR OF RUDDER TORQUE TUBE ASSY BONDING JUMPERS) FOUND CO RROSION ON TORQUE TUBE INTERNAL AND EXTERNAL. MOISTURE INGRESSION THROUGH WIRE BUNDLE HOLE. ENGINEERING EVALUATE FOR P OSSIBLE INTERNAL INSPECTION CRITERIA OF TORQUE TUBE AND ENVIRONMENTA SEALING AS REQUIRED. (EA09200600888) (K) 2 L 7 2 4F 4 F RT T00008WI E6WE 2006011800201 20060118 00201 SO 2006 1 18 2006FA0000029 2 20051206 G 7414 DISTRIBUTOR GEAR CESSNA 421 421C 2076016 CE CONT O520 GTSIO520* 17032 SO LT MAGNETO STRIPPED B WC7R O OTHER E VIBRATION/BUFFET UK UNKNOWN 1 GL 25 421CQ BL349460 421C1218 PILOT REPORTED LT ENGINE RUNNING ROUGH. TROUBLESHOT PROBLEM TO LT MAGNETO. FOUND TEETH ON DISTRIBUTOR GEAR IN LT MAGNE TO STRIPPED AND NOT TURNING PROPERLY. (GL25200605792) (K) 1 L 7 2 3O 3 O A7CE E7CE 2006012600100 20060126 00100 EA 2006 1 26 2006FA0000048 2 20051230 G 8520 PLUG MOONEY M20 M20M 5870222 SW LYC O540 TIO540A1B 41532 EA MCAULY 3D32C B3D32C417 GL CRANKSHAFT DISLODGED B RF1R O OTHER O OTHER NR NOT REPORTED 1 SW 01 22320 270297 L1054861A 001085 DURING PROP REMOVAL FOR A GROUND STRIKE, FOUND CRANKSHAFT WELSH PLUG LOGGED IN THE PROP HOUSING, RESTRICTING OIL FLOW TO PROP. ENGINE HAD BEEN INSTALLED 30 DAYS EARLIER, 4 HOURS SINCE INSTALL. (K) 1 L 7 1 3O 3 O RT 2A3 E14EA 5 C P58GL 2006012600092 20060126 00092 EU 2006 1 26 2006FA0000049 1 20051220 G 6320 109062087101 OIL COOLER AGUSTA A109 A119 0261102 EU PWA PT6 PT6* 52043 EA TRANSMISSION CRACKED D O OTHER O OTHER NR NOT REPORTED 1 EA 17 318PD 14039 OIL COOLER, TRANSMISSION SIDE OF COOLER CRACKED AND SPRAYED OIL BELOW ENGINE DECK. (K) 1 G 7 2 3U 3 T H7EU E2NE 2006012600101 20060126 00101 GL 2006 1 26 2006FA0000052 3 20051123 G 6111 S90AT8 BLADE CESSNA 206 P206 2073304 CE CONT O520 IO520D 17032 SO MCAULY 2A34C E2A34C73 GL PROPELLER FRACTURED D A UNSCHED LANDING E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 WP 07 2653X 1233 P2060153 175293H 725446 PILOT TOOKOFF, DURING CRUISE FLIGHT, SEVERE VIBRATION OCCURRED FROM ENGINE. ENGINE PULLS BACK TO IDLE AND EMERGENCY LAN DING MADE ON ROAD . UPON INSPECTION IT WAS DISCOVERED THERE WAS 7.5 INCHES OF BLADE TIP MISSING. SERIAL NR OF BLADE IS NOT ACCESSIBLE AT THIS TIME, MUST DISASSEMBLE PROP. BLADE SN IS EITHER K46513YS OR K64839S ACCORDING TO PROP LOG. (K) 1 H 7 1 3O 3 O A4CE E5CE 5 C P3EA9 2006012600085 20060126 00085 EU 2006 1 26 2006FA0000054 1 20051215 G 3610 SBJ33057401 DUCT AMD FALC50 FALCON50MYST 2730106 EU GARRTT TFE731 TFE73140 29001 NE HP BLEED AIR CRACKED D K NONE O OTHER IN INSP/MAINT 1 NM 01 39WP 3051 294 DURING SCHEDULED NR 2 ENGINE CHANGE INSPECTION NOTICED HP BLEED AIR DUCT WAS CRACKED AT CENTER BLEED AIR TAP. CRACK APP EARED TO ORIGINALS AT THE WELD AND PROGRESSED RADIALLY, APPROX 2.25 INCH TOWARDS THE BRAIDED FLEX COUPLING. NEW DUCT WA S ORDERED AND INSTALLED. CRACKED DUCT WILL BE SENT TO MFG FOR ENGINEERING EVALUATION. THIS IS THE SECOND HP BLEED AIR DUCT FOUND CRACKED DURING RECENT ENGINE CHANGES. THE FIRST DUCT FOUND CRACKED WAS ON NR 3 ENGINE. PN SBJ33055-401 WITH SOME DIFFERENCE IN CONFIGURATION BUT SAME APPLICATION. THE ABOVE DUCT WAS ALSO REPLACED WITH NEW PART FROM MFG. (K) 2 L 7 3 4F 4 F A46EU E1NM 2006012600093 20060126 00093 SW 2006 1 26 2006FA0000059 1 20051220 G 6210 430310101107 RESTRAINT BELL 430 430 1182150 SW ALLSN 250C 250C40B 03032 NE M/R BLADE FAILED D O OTHER O OTHER NR NOT REPORTED 1 NM 09 430LF 1523 49096 PILOT REPORTED SEVERE VIBRATION AFTER INSPECTION FOUND ORANGE BLADE SHEAR RESTRAINT AT MAIN ROTOR SYSTEM FAILED. CNETER BUSHING HAD BECOME DEBONDED FROM ELASTOMERIC. VISUAL INSPECTION DIFFICULT BECAUSE OF ORIENTATION AT INSTALLATION. (K) 1 G 7 2 3U 3 U RT H9SW E1GL 2006012600090 20060126 00090 CE 2006 1 26 2006FA0000061 1 20051221 G 8011 EBB131A DRIVE ASSY CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA STARTER FAILED D YYBR O OTHER O OTHER NR NOT REPORTED 1 GL 03 75716 229 C080744 17267897 RL193576T (.7500) OF THE DRIVE TEETH ON THE BENDIX DRIVE WERE COMPLETELY SHEARED DURING AN ENGINE START-UP. NO PROBABLE CAUSE OR RECOMMENDATIONS TO MAKE. (K) 1 H 7 1 3O 3 O NT 3A12 E274 2006013000038 20060130 00038 2006 1 30 2006FA0000062 4 20051209 G 6122 89365120 GOVERNOR MTSBSI MU2 MU2B25 5780409 CE GARRTT TPE331 TPE33110 01514 WP PROPELLER DEFECTIVE B IZ2R O OTHER O OTHER NR NOT REPORTED 1 SW 15 50K 277 305 P106013 ENGINE/PROPELLER RPM WAS UNSTABLE AND PROP GOVERNOR HIGH SETTING WOULD DECREASE FROM 100 PERCENT RPM TO 98 PERCENT RPM W ITH NO INPUT BY THE PILOT. INSPECTION OF THE PROP GOVERNOR REVEALED THAT THE BUSHING IN THE IDLER GEAR HAD EXCESSIVE WE AR WITH .139 INCH GAP BETWEEN THE BUSHING AND SHAFT. NOTE: EARLIER MODELS OF THIS PROP GOVERNOR HAD EARLIER MODELS OF THIS PROP GOVERNOR HAD NEEDLE BEARINGS INSTEAD OF A BUSHING IN THIS LOCATION. THE DEFECTIVE PROP GOVERNOR WAS REPLACED. (K) 1 H 7 2 3T 4 T A2PC E4WE 2006013000089 20060130 00089 GL 2006 1 30 2006FA0000063 1 20051224 G 2730 PUSHROD AVIAT A1 A1A 2210405 GL LYC O360 O360A1D 41514 EA ELEVATOR DISCONNECTED D O OTHER F FLT CONT AFFECTED AP APPROACH 1 EA 05 8XC 1382 REPORTED LOSS OF ELEV CNTRL ON FINAL APROACH. BOOT AROUND REAR CNTRL STICK WAS REMOVED, ELEV PUSH ROD WAS NO LONGER CON NECTED, NO NUT WAS FOUND. ROD ENDS WERE INSP, FOUND THAT SELFLOCKING NUT, BOLT FOR AFT INTERCONNECT PUSH ROD WAS LOOSE. HARDWARE WAS NOT REINSTALLED, IT WAS LOOSE ON INSP. 2 EA NEW WERE INSTALLED, BOLT, WASHERS, CASTLE NUT AND COTTER PIN IN REAR CNTRL STICK ROD END CONNT POINTS. REPAIR OF FLT CNTRLS, DETERMINED AIRWORTHY. ADVISED MFG SERV CTR INSPECT AC AND MAKE REPAIRS IAW MM. PROBABLE CAUSE, REUSE OF HARDWARE OR INCORRECT TORQUE APPLIED TO NUT AND BOLT. CASTLE NUT, C OTTER PIN WAS INSTALLED IN PLACE OF SELFLOCKING TO ENSURE A PROVEN METHOD OF SAFETY WAS USED ON AIRFRAME CNTRLS. (K) 1 H 7 1 3O 3 O NC A22NM E286 2006012400182 20060124 00182 2006 1 24 2006FA0000070 4 20050922 G 2565 BACK12BU9B CHAIN BOEING 727 72725C 138400H NM PWA JT8 JT8D5 52046 NE FWD DOOR SLIDE DETACHED B NP1Y O OTHER O OTHER NR NOT REPORTED 1 EA 33 932UP 19856 DURING C-CHECK, INSPECTION OF FWD DOOR EMERGENCY ESCAPE SLIDE BUSTLE LATCH CHAIN WAS FOUND DETACHED FROM THE SPLIT RING. THE SPLIT RING HAD BECOME ELONGATED AND THE RING COILS HAD SEPARATED THUS ALLOWING THE CHAIN TO DETACH. THE SLIDE WOU LD NOT HAVE INFLATED IF REQUIRED. THE CHAIN AND RING ASSY WILL BE REPLACED. (K) 2 L 7 3 4F 4 F A3WE E2EA 2006012400170 20060124 00170 EA 2006 1 24 2006FA0000072 1 20051015 G 5597 WIRE CNDAIR CL601 CL6013A 8070802 EA CONT O200 O200* 17020 SO VERT STABILIZER SHORTED B RO3R O OTHER O OTHER NR NOT REPORTED 1 CE 03 601KF 5175 WHILE TROUBLESHOOTING INTERMITTENT UPPER BEACON CIRCUIT BREAKER FAULT, DISCOVERED LT ELEVATOR CONTROL CABLE HAD TORN THR OUGH WIRING CONDUIT IN VERTICAL STABILIZER. THE CABLE WORE THROUGH THE CONDUIT AND SHORTED OUT THE WIRING FOR THE UPPER BEACON. REPAIRED WIRING CONDUIT, REPLACED WIRING AND REPLACED CONTROL CABLE IAW MFG INSTRUCTIONS. REPAIR OF CONDUIT A LLOWED SUFFICIENT CLEARANCE BETWEEN CABLE AND CONDUIT. UNCLEAR IF CONDUIT WAS INSTALLED AT FACTORY OR AT TIME OF COMPLE TION. SUGGEST INSPECTION OF THIS AREA ON OTHER SIMILAR AIRCRAFT. DEFECT DIFFICULT TO NOTICE DUE TO ACCESSIBILITY OF AR EA IN TAIL. (K) 2 L 7 2 4F 3 O RT A21EA E252 2006012400168 20060124 00168 CE 2006 1 24 2006FA0000073 1 20051020 G 2500 551900912 SEAT CESSNA 501 501 2076603 CE CRACKED B GVRR O OTHER O OTHER NR NOT REPORTED 1 CE 05 7700T 5010248 UPPER CHAIR BASE ASSEMBLY CRACKED AT CHAIR BACK ATTACH POINTS. STRESS ON CHAIR BACK AND METAL FATIGUE PROBABLE CAUSE. CHAIR WAS REPAIRED IAW STC. STRUCTURAL SEAT REPAIR. (K) 1 L 7 2 4F A27CE 2006013000092 20060130 00092 NM 2006 1 30 2006FA0000074 1 20051118 G 3213 40005401 CYLINDER PIPER PA60 PA60600A 7106002 NM LYC O540 TIO540* 41532 EA MLG MISMANUFACTURED D O OTHER W INADEQUATE Q C NR NOT REPORTED 1 SO 15 7411S 3968 60001627 COLLAR SEPARATING FROM TUBE DUE TO INSUFFICIENT PENETRATION WHEN PART WAS FURNACE BRAZED OR SILVER SOLDERED TOGETHER-WOR KING COLLAR CAUSED PART TO WORK AND CRACK BOSS. RECOMMEND INSPECTION OF COLLAR AT BOTTOM OF GEAR STRUT FOR ANY MOVEMENT OR WORKING BETWEEN COLLAR AND THE STRUT CYLINDER ASSY. DYE CHECK COLLAR WHERE PART IS MACHINED FOR CLEARANCE ON TORQUE LINKS. (K) 1 M 7 2 3O 3 O RT A17WE E14EA 2006012400169 20060124 00169 2006 1 24 2006FA0000075 1 20051118 G 3213 40005401 CYLINDER SMITH STC STC600 LYC O540 TIO540* 41532 EA ENGINE MISMANUFACTURED D O OTHER W INADEQUATE Q C NR NOT REPORTED 1 SO 15 7411S 3968 600016 COLLAR SEPARATING FROM TUBE DUE TO INSUFFICIENT PENETRATION WHEN PART WAS FURNACE BAZED OR SILVER SOLDERED TOGETHER-WORK ING COLLAR CAUSED PART TO WORK AND CRACK BOSS. RECOMMEND INSPECTION OF COLLAR AT BOTTOM OF GEAR STRUT FOR ANY MOVEMENT OR WORKING BETWEEN COLLAR AND THE STRUT CYLINDER ASSY- DYE CHECK COLLAR WHERE PART IS MACHINED FOR CLEARANCE ON TORQUE L INKS. (K) 1 M 7 2 3O 3 O A17WE E14EA 2006013100170 20060131 00170 SW 2006 1 31 2006FA0000085 1 20051013 G 2436 800397503 VOLT REGULATOR MOONEY M20 M20M 5870222 SW LYC O540 TIO540* 41532 EA FAILED G O OTHER O OTHER NR NOT REPORTED 1 CE 07 9145X 270095 COMBINATION VOLTAGE AND OVERVOLTAGE REGULATOR FAILED. THIS FAILURE CAUSED A VOLTAGE SPIKE IN THE ELECTRICAL SYSTEM WHIC H IN TURN DAMAGED ALL OF THE COM AND NAV RADIOS, THE ANNUNCIATOR PANEL, AND NUMEROUS COMPUTER RELATED AVIONICS ITEMS. M ULTIPLE LIGHT BULBS IN THE AIRCRAFT WERE ALSO REPLACED. THE REASON FOR THE REGULATOR FAILURE IS STILL UNCLEAR AT THIS T IME. 1 L 7 1 3O 3 O RT 2A3 E14EA 2006013100163 20060131 00163 EA 2006 1 31 2006FA0000089 2 20051230 G 7310 LW120980210 FUEL LINE CESSNA 182 T182T 2072738 CE LYC O540 TIO540* 41532 EA ENGINE WORN B RF1R O OTHER O OTHER NR NOT REPORTED 1 SW 01 542LB 101 T18208402 FOUND FUEL INJECTION LINE RUBBING CYLINDER COOLING FINS. CAUSING WEAR TO THE LINE. IF WORN CAN CAUSE FUEL LEAK ON TO T HE TURBO CHARGER. AD WAS IN COMPLIANCE BUT THE CLAMP WAS LOOSE ALLOWING FUEL LINE TO ROTATE. (SW01200603311) (K) 1 H 7 1 3O 3 O NT 3A13 E14EA 2006013100168 20060131 00168 CE 2006 1 31 2006FA0000091 1 20051115 G 3210 3730FLOATS LANDING GEAR CESSNA 185 A185F 2072821 CE CONT O520 IO520* 17032 SO RIGHT LACK OF LUBE B KL2R O OTHER W INADEQUATE Q C NR NOT REPORTED 1 GL 23 800TA 18502901 RT MAIN GEAR, NO GREEN GEARDOWN LIGHT. GEAR CYCLED SEVERAL TIMES, RT MAIN GEAR COLLAPSED AFTER LANDING. REMOVED GEAR A SSY FOUND LACK OF LUBE THE PROBLEM. REPLACED PARTS, BENT WHEN GEAR COLLAPSED. LUBED, REINSTALLED. OPS OK. LUBE GEAR M ORE OFTEN. (K) 1 H 7 1 3O 3 O 3A24 E5CE 2006013100207 20060131 00207 2006 1 31 2006FA0000095 4 20051029 G 2562 AK450 TRANSMITTER MOONEY M20 M20J 5870219 SW LYC O360 IO360A1A 41514 EA ELT INOPERATIVE B NT3R K NONE O OTHER IN INSP/MAINT 1 WP 25 201VE 240395 ELT TRANSMITTER WAS REMOVED DURING ANNUAL FOR BATTERY REPLACEMENT AND TESTING. UPON REMOVAL THE ELT WENT OFF WHEN TURNE D UPSIDE DOWN. PIECES CAN BE HEARD RATTLING AROUNG INSIDE UNIT. SUSPECT G-SWITCH CAME LOOSE. THIS IS OUT 2ND EXPERIEN CE OF SAME CONDITION. LOOSE COMPONENT INSIDE RATTLING AROUND. FIRST UNIT, ELT DID NOT ACTIVATE. UNIT IS APPROXIMATELY 4 YEARS OLD. TREND OF FAILURES ON THIS MAKE AND MODEL OF ELT. SUSPECT INTERNAL DETERIORATION OF COMPONENT SECURITY. (K) 1 L 7 1 3O 3 O 2A3 1E10 2006013100198 20060131 00198 CE 2006 1 31 2006FA0000097 1 20051228 G 2720 08602073 CONTROL CABLE CESSNA 310 310N 2074234 CE CONT O470 IO470* 17026 SO LT RUDDER BROKEN D O OTHER O OTHER NR NOT REPORTED 1 GL 05 4110Q 6986 310N0010 THE LT RUDDER CABLE BROKE AT THE CLEVIS THAT ATTACHES IT TO THE RUDDER TORQUE TUBE ARM. UNDER NORMAL OPERATING CONDITIO NS, DURING THE 37 YEARS AND HOURS THAT THE AIRCRAFT HAS BEEN IN SERVICE. THE RT RUDDER CABLE HAD ABOUT 25 PERCENT OF TH E STRANDS BROKEN. THE BOLT FOR THE CLEVIS WAS SO TIGHT THAT THE CLEVIS COULD NOT PIVOT ON THE BOLT ATTACHING IT TO THE RUDDER TORQUE TUBE ARM. THE CONSTANT UP AND DOWN PULL ON THE CABLE BALL SWEDGE SEEMS TO HAVE BROKEN THE STRANDS OF THE CABLE A FEW AT A TIME. THE CLEVISES NEED TO BE INSPECTED FOR FREEDOM OF MOVEMENT ON THE BOLTS THAT ATTACH THEM TO ARMS. (K) 1 L 7 2 3O 3 O 3A10 E1CE 2006020200150 20060202 00150 SO 2006 2 2 2006FA0000105 1 20051127 G 2910 GAC1159SCH2463A SHUTOFF VALVE GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6118 EU HYD SYSTEM CRACKED G O OTHER O OTHER NR NOT REPORTED 1 EA 25 250VC 1043 1495 AIRCRAFT WAS ON A POSITION FLIGHT, ON DEPARTURE THE CREW RECEIVED A (CK HYD QUANTITY) EICAS CAUTION LIGHT. COCKPIT INDI CATIONS REVEALED A LOSS OF COMBINED HYDRAULIC FLUID. THE FLIGHT CREW DECLARED AN EMERGENCY AND RETURNED TO DEPARTURE. MAINT INVESTIGATION REVEALED THE FLIGHT POWER SHUTOFF VALVE ASSY HOUSING WAS CRACKED. THIS IS THE SECOND INCIDENT OF A CRACKED HOUSING WITHIN OUR FLEET. AN UPGRADED 5 ASSY WAS PROCURED FROM MFG AND AC WAS RETURNED TO SERVICE. HAVE COMMUN ICATED OUR CONCERNS TO AC MFG AND ENCOURAGED A PROACTIVE RESOLUTION TO A RATHER SEVERE SITUATION. (EA25200605366) (K) 2 L 7 2 4F 4 F RT A12EA E25NE 2006020200167 20060202 00167 NE 2006 2 2 2006FA0000112 2 20051001 G 7200 ARRIEL1D1 ENGINE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE FUSELAGE MAKING METAL B EOOR O OTHER J WARNING INDICATION CR CRUISE 1 AL 03 CGLNH 956 1230 9999 DURING FLIGHT, THE CHIP LIGHT ILLUMINATED, CHIPS WERE FOUND AND BEFORE 30 MINUTE GROUND RUN WAS COMPLETED ANOTHER LIGHT OCCURRED. CHIPS WERE OF SUFFICIENT SIZE THAT REQUIRED REMOVING THE ENGINE. (K) 1 G 7 1 3U 3 U H9EU E19EU 2006020300081 20060203 00081 GL 2006 2 3 2006FA0000113 2 20051005 G 7200 LINE HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL LEAKING B EOOR O OTHER K FLUID LOSS LD LANDING 1 AL 03 CFMAL 611010D CAE834272 PILOT SAW TORQUE PRESS FLUCTUATE. TORQUE PRESS LINE TO GAUGE LEAKED AND ENGINE WAS STARVED OF OIL. THE AIRCRAFT HAD MA DE A NORMAL LANDING AND SHUTOFF ENGINE SEIZED UP ON COASTDOWN, REPLACED ENGINE. (K) 1 G 7 1 3U 3 U H3WE E4CE 2006020200104 20060202 00104 WP 2006 2 2 2006FA0000114 1 20050928 G 5330 SKIN HUGHES 369 369E 4470707 WP FUSELAGE CRACKED B EOOR O OTHER O OTHER NR NOT REPORTED 1 AL 03 CGREP 10728 0242E FOUND A CRACK ON THE (TURTLE BACK) SKIN ABOVE THE ENGINE BETWEENT THE ATTACHMENT STRINGERS OF THE TAILBOOM FARRING AND B ETWEEN THE RIBS AT STA 146.62 AND STA 155.75 CRACK IS LOCATED ON THE RT SIDE AND RUNNING FROM STA 146.62 AFT 7.25 INCHES . REPAIRED CRACK WITH PATCH. (K) 1 G 7 1 3U H3WE 2006020200168 20060202 00168 GL 2006 2 2 2006FA0000115 2 20051006 G 7240 6870992 COMBUST CHAMBER HUGHES 500N 500N 3027374 SW ALLSN 250C 250C20B 03013 GL ENGINE CRACKED B EOOR K NONE M OVER TEMP IN INSP/MAINT 1 AL 03 CGBUY CAE833577 DURING AN INSPECTION FOR HIGH TOT THE OUTER COMBUSTION CAN WAS FOUND TO BE CRACKED IN THE LEFT (ARM PIT). (K) 1 G 7 1 3U 3 U NC H3WE E4CE 2006020300105 20060203 00105 EU 2006 2 3 2006FA0000116 1 20051111 G 6400 355A2700720001 BELLCRANK SNIAS 350 AS350B2 8680813 EU T/R CONTROLS ELONGATED B EOOR K NONE O OTHER IN INSP/MAINT 1 AL 03 CFYUU 518 1384 DURING 500 HOUR INSPECTION AND REMOVAL OF T/R SERVO OVERCENTERING MECHANISM, IT WAS DISCOVERED THAT THE MAIN SUPPORT BO LT AND THE BELLCRANK PIVOT BOLT WERE VERY DIFFICULT TO REMOVE. THE BELLCRANK PIVOT BOLT WAS OBVIOUSLY HAMMERED IN BY E VIDENCE OF THE RAISED METAL AND ELONGATED HOLE. REPLACED BELLCRANK AND BOTH BOLTS. (K) 1 G 7 1 3U H9EU 2006020200110 20060202 00110 CE 2006 2 2 2006FA0000120 1 20050617 G 2130 STATIC LINE LEAR 25 25B 5170511 CE GE CJ610 CJ6106 30006 NE EQUIPMENT BAY LOOSE C CYOG A UNSCHED LANDING O OTHER CR CRUISE 1 SW 05 8005Y 121 241C287A WHILE ENROUTE, CABIN ALTITUDE EXCEEDED 10,000 FT. THE FLIGHT CREW FOLLOWED EMERGENCY PROCEDURES BUT WAS UNABLE TO RETUR N THE CABIN PRESSURIZATION WITHIN NORMAL PIRAMETERS. THE FLIGHT CREW DECIDED TO DIVERTED AND LANDED WITHOUT FURTHER INC IDENT. UPON INSPECTION MAINTENANCE CREW FOUDN A LINE LOOSE ON THE PRESSURIZATION JET PUMP. (K) 2 L 7 2 4J 4 J A10CE 1E16 2006021400163 20060214 00163 2006 2 14 2006FA0000122 4 20051215 G 3160 4306081100000 TRANSCEIVER DHAV DHC2 DHC2MK1 2800102 EA PWA R985 R985* 52008 NE COCKPIT MALFUNCTIONED B HJBR K NONE O OTHER IN INSP/MAINT 1 AL 05 5160G 236 DURING POST INSTALLATION CHECKS, FOUND THE GDL90 UAT REPORTING CONTINUOUS EXTERNAL FAULT ERROR. NO EXTERNAL FAULTS FOUN D. REPLACEMENT OF THE UNIT CORRECTED THE ERROR. (K) 1 H 7 1 3R 3 R A806 5E1 2006020600237 20060206 00237 2006 2 6 2006FA0000124 4 20051226 G 3160 4306081100000 TRANSCEIVER CESSNA 207 207A 2073604 CE CONT O520 IO520* 17032 SO COCKPIT MALFUNCTIONED B HJBR K NONE O OTHER IN INSP/MAINT 1 AL 05 96AK 20700782 DURING POST INSTALLATION CHECKS, FOUND THE GDL90 UAT REPORTING CONTINUOUS GPS FAILURE. REPLACEMENT OF THE UNIT CORRECTE D THE ERROR. (K) 1 H 7 1 3O 3 O A16CE E5CE 2006021700094 20060217 00094 CE 2006 2 17 2006FA0000137 1 20051215 G 5100 MS21042L3 NUT BEECH 200 200BEECH 1152920 CE LT WING ROOT FAILED B AHDR O OTHER O OTHER NR NOT REPORTED 1 EA 13 561SS BB464 NUT, PN MS21042L3 (PN130909N29) FAILED AND TAPERED PIN PN AN 38629A CAME OUT OF ADAPTER NP 1158110473 IN LT WING ROOT. THE ADAPTER DISENGAGED FROM THE TORQUE TUBE SHAFT PN 1018100211, THE LT MAIN GEAR COULD NOT LOCK DOWN. THE NUT HAD ONLY 160.4 HOURS ON IT FROM NEW. THE NUT IS EXPOSED TO HIGH TENSION LOADS DUE TO THE CENTRIFUGAL FORCE FROM THE TORQUE TUB E SPINNING. (K) 1 L 7 2 4T A24CE 2006021700008 20060217 00008 CE 2006 2 17 2006FA0000147 1 20051026 G 2810 1002268815 SEAL RAYTHN DH125 HAWKER800XP 7150012 CE GARRTT TFE731 TFE731* 01518 WP FUEL LINE TORN B E81R O OTHER K FLUID LOSS TX TAXI/GRND HDL 1 GL 03 815TA 5129 258534 DURING REFUELING OF RT WING, FUEL WOULD EXIT OUT OF NACA VENT BEFORE TANK TOPPED OFF. RT FUEL QUANTITY INDICATION WOULD SHOW TANKS NOT FULL YET. FOUND VENT SYSTEM INTERCONNECTING TUBING SEALS TORN/MISSING BETWEEN SURGE TANK AND NACA SCOOP . REPLACED SEALS AS REQUIRED AND REASSEMBLED VENT SYSTEM INTERCONNECTING TUBING. NO FAULTS NOTED ON REFUELING. (K) 2 L 7 2 4F 4 F RT A3EU E6WE 2006021700032 20060217 00032 2006 2 17 2006FA0000148 4 20051027 G 2297 CONNECTOR RAYTHN DH125 HAWKER800XP 7150012 CE GARRTT TFE731 TFE731* 01518 WP AUTOPILOT DIRTY B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 815TA 258534 PILOTS REPORT AIRCRAFT (PORPOISING) IN LEVEL FLIGHT AT FL 380 WITH AUTOPILOT ENGAGED. TROUBLESHOT IAW COMMUNIQUE NR 22- 07; FOUND HIGH RESISTANCE AT AUTOPILOT FLAP COMPENSATOR TRANSMITTER (FT) CONNECTOR FT-1B. CLEANED AND REINSTALLED CONNE CTOR, CHECKED RESISTANCES NOW WITHIN COMMUNIQUE NR22-07 SERVICE LIMITS. RECOMMEND INVESTIGATION OF POSSIBLE REPLACEMENT AP FLAP COMPENSATOR TRANSMITTER CONNECTOR OR INSTALLATION WITH IMPROVED ENVIRONMENTAL SEALING CHARACTERISTICS. (K) 2 L 7 2 4F 4 F RT A3EU E6WE 2006021700011 20060217 00011 CE 2006 2 17 2006FA0000149 1 20050207 G 5310 1294000339 STRUCTURE BEECH 1900 1900D 1154162 CE PWA PT6 PT6* 52043 EA FUSELAGE CORRODED D O OTHER O OTHER NR NOT REPORTED 1 GL 03 891SK 26259 UE89 AIR STAIR DOOR LOWER CLOSURE, MFG FROM 4130 STEEL, WAS CORRODED THRU UNDER FOLDING STEP. THIS CLOSURE HAD BEEN PREVIOUS LY REPAIRED BY REMOVING CORROSION, TREATING AND A DOUBLER INSTALLED. REMOVED CLOSURE DUE TO CORROSION AND DISBOND FROM DOOR CORE MATERIAL. INSTALLED FACTORY NEW ALUMINUM REPLACEMENT CLOSURE. RECOMMEND FREQUENT INSPECTIONS OF THIS AREAS, ESPECIALLY AFTER OPERATIONS IN WET CONDITIONS, AND IMMEDIATE TREATEMENT OF CORROSION. (K) 2 L 7 2 4T 3 T RT A24CE E2NE 2006021700009 20060217 00009 SO 2006 2 17 2006FA0000150 2 20050126 G 8520 LIFTER BEECH 58 58 1152740 CE CONT O550 IO550C SO ENGINE SPALLED B YYBR O OTHER O OTHER NR NOT REPORTED 1 GL 03 584LL 509 TH1931 684339 METAL FOUND IN OIL FILTER DURING INSP WAS LATER DETERMINED TO BE FROM FAILED LIFTERS. CONDITION WAS STARTING TO DAMAGE CAM LOBES. SID 05-1 STATES THAT MINOR IMPERFECTIONS CAN (HEAL OVER) BUT WE HAVE NOT FOUND THIS TO BE CASE, JUST OPPOSIT E IS TRUE. ONCE LIFTER BEGINS TO SPALL IT CREATES A (CHEESE GRATER) EFFECT BETWEEN CAM AND LIFTER. W/O PROPER METALLUR GICAL LAB, CAUSE CANNOT BE DETERMINED. SPECULATED THAT MATERIAL IS EITHER IMPROPERLY HEAT TREATED OR SUBSTANDARD MATERI AL IS USED. TO PREVENT THIS FROM RECURRING MFG SHOULD INSPECT ALL LIFTER BODIES BEFORE INSTALLATION FOR GRANULAR DEFEC TS OF METAL. THIS CAN BE ACCOMPLISHED USING X-RAY EXAM, NDT WHICH WOULD INCLUDE USE OF A SPECIAL MICROSCOPE. (K) 1 L 7 2 3O 3 O 3A16 E3SO 2006021700007 20060217 00007 CE 2006 2 17 2006FA0000151 1 20050124 G 5220 115430100661A SKIN BEECH 200 B200 1152922 CE PWA PT6 PT6* 52043 EA EMERGENCY EXIT CRACKED B CGHR O OTHER O OTHER NR NOT REPORTED 1 GL 03 1568E BB1488 DURING PHASE 1-4 INSPECTION, EMERGENCY EXIT HATCH OUTER SKIN WAS FOUND CRACKED AT THE IB SURFACE, THROUGH THE ENTIRE 90 DEGREES RADIUS OF THE LOWER AFT CORNER OF SKIN ASSY 115430100-661A. CRACK LENGTH APPROX 6 INCHES. (K) 1 L 7 2 4T 3 T A24CE E2NE 2006021600268 20060216 00268 CE 2006 2 16 2006FA0000152 1 20050124 G 5532 SKIN BEECH 1900 1900D 1154162 CE PWA PT6 PT6* 52043 EA VENTRAL FIN DELAMINATED B E81R O OTHER O OTHER NR NOT REPORTED 1 GL 03 843E 6068 UE339 BOTH LT AND RT VENTRAL FINS SHOWED AREAS OF DELAMINATION ON FWD TOP CORNERS. DELAMINATION WAS BEYOND REPAIR LIMITS IAW SRM AND REQUIRED DER APPROVAL. FOUND INNER CORE MATERIAL WET DAMAGE WAS APPARENTLY CAUSED BY FREEZE CYCLES. WATER WAS FOUND ALONG TOP OF FIN BETWEEN FIN AND FUSELAGE ATTACH ANGLES. AC HAD BEEN RECENTLY REPAINTED. REPLACED SEALANT AT LEA DING AND TRAILING EDGES OF FIN TO PRECLUDED WATER INGRESS. SUGGEST CLOSE VISUAL INSPECTION OF FIN/FUSELAGE FOR BREAKS I N SEALING AT AFT FUSELAGE DETAILED INSPECTION AND AFTER STRIPPING/ PAINTING HAS BEEN ACCOMPLISHED. AREA OF DISBOND WAS MAPPED OUT USING TAP TESTING HOWEVER ADDITIONAL CORE MATERIAL WAS REMOVED DUE TO ENTRAPPED WATER. (K) 2 L 7 2 4T 3 T RT A24CE E2NE 2006021700082 20060217 00082 NE 2006 2 17 2006FA0000153 2 20050120 G 7261 CHIP DETECTOR UROCOP EC130 EC130B4 8680989 EU TMECA ARRIEL ARRIEL2B NE ENGINE OIL FALSE INDICATION C A UNSCHED LANDING N FALSE WARNING NR NOT REPORTED 1 WP 13 11QL 3738 PRECAUTIONARY LANDING, DUE TO ENG OIL CHIP LIGHT ANNUNCIATION IN FLT. UNEVENTFUL LANDING. MAINT INVESTIGATED, FOUND ONE SMALL HAIR LIKE DARK CHIP. PLUG WAS CLEANED, ENG WAS TEST RUN FOR 10 MIN. ENG RUN-DOWN TIME WAS CHECKED. NO ADDITION AL CHIPS FOUND. RUN DOWN TIMES WERE NML. AC WAS FLOWN EMPTY BACK TO MAINT BASE. CHIP PLUG WAS RE-INSPECTED FOR ADDITI ONAL CHIPS. NO CHIPS NOTED AT THAT TIME. IAW MFG INSTRUCTION, PLUG IS TO BE REINSPECTED AFTER FIRST FLIGHT OF DAY FOR NEXT 25 HOURS. CHIP DETECTOR, SUPPORTING SYS WORKED PROPERLY, ALERTING PILOT OF A POTENTIAL PROBLEM. FALSE INDICATION BECAUSE OF CHIP DETECTORS INABILITY TO DIFFERENTIATE 1 VERSES CHIPS . 1 G 7 2 3U 3 U H9EU E00054EN 2006021700099 20060217 00099 EA 2006 2 17 2006FA0000154 2 20050126 G 7314 A1005B PUMP CESSNA 206 T206H 2073303 CE LYC O540 TIO540* 41532 EA AUX FUEL PUMP FAILED D O OTHER O OTHER NR NOT REPORTED 1 NE 02 65556 112 T20608496 THIS FUEL PUMP IS LOCATED UNDERT HE PILOTS SIDE FLOORBOARDS AND IS AN ELECTRICLY DRIVE AUX FUEL PUMP. THE AC ORIGINAL F UEL PUMP A10055B FAILED AFTER 53 HOURS IN SERVICE ON MARCH OF 2005. IT FAILED IN A WAY TO ALLOW FUEL TO ENTER THE ELECT RIC SIDE OF THE MOTOR. THAT WAS A MAJOR FIRE HAZZARD. THE PUMP THAT REPLACED WAS A LIKE PN, SN 111810 WHICH IS THE ONE FILED IN THIS REPORT, LASTED 112.3 HOURS IN SERVICE WHEN IT BEGAN TO MAKE HIGH PITCHED NOISES ON SHUTDOWN. IT SOUNDED AS IF A BEARING WAS RUNNING DRY. (K) 1 H 7 1 3O 3 O RT A4CE E14EA 2006021700105 20060217 00105 SW 2006 2 17 2006FA0000155 1 20050131 G 3220 LANDING GEAR GULSTM 114 114TC 0145002 SW LYC O540 TIO540* 41532 EA MCAULY 3D32C B3D32C417 GL NOSE COLLAPSED B CB5Y O OTHER O OTHER TX TAXI/GRND HDL 1 EA 35 115TB 20031 L1061461A 000408 FIRST FLT AFTER ENG REFITMENT NLG FAILED TO EXTEND TO LANDING POS. ON FIRST FLT, GREEN NOSE WHEEL INDICATOR WOULD NOT I LLUMINATE. NLG WAS PARTIALLY EXTENDED TO ANGLE OF SOME 45 DEGREES. EMERGENCY EXTENSION PRECEDURES CARRIED OUT BY PILOT STILL FAILED TO EXTEND NLG BEYOND 45 DEGREES. PWROFF LANDING WAS EXECUTED WHERE UPON NLG COLLAPSED AND AC CAME TO REST ON 2 OF 3 PROP BLADES NOSE WHEEL BAY DOORS. AC NOSE WAS LIFTED. LANDING HAD PUSHED NLG BACK TOWARD RETRACTED POSITION BUT WITH PART OF TIRE PROTRUDING THROUGH PARTIALLY OPEN NOSE BAY DOORS. PIN ATTACHING NOSE GEAR ACT TO NOSE LEG WAS REM OVED. ENGINEERING INVESTIGATION IS BEING CARRIED OUT WHICH AT THIS TIME HAS FAILED TO DETERMINE CAUSE OF FAILURE. (K) 1 L 7 1 3O 3 O RT A12SO E14EA 5 C P58GL 2006022800035 20060228 00035 EA 2006 2 28 2006FA0000177 2 20050314 G 8520 75072 IDLER GEAR MOONEY M20 M20C 5870208 SW LYC O360 O360A1D 41514 EA ENGINE DAMAGED D O OTHER O OTHER NR NOT REPORTED 1 SO 08 1202X 3560 1639 2605 L636336 ENGINE FAILED IN FLIGHT PRELIMINARY INSPECTION REVEALED CAMSHAFT AND ASSOCIATED CRANKSHAFT IDLER GEAR WAS SEPARATED FROM CRANKSHAFT DRIVE GEAR IDLER GEAR SLOWS EVIDENCE OF DAMAGE TO DRIVE TEETH. UNABLE TO DETERMINE AT THIS TIME WHETHER THE CAMSHAFT OR LT MAGNETO DRIVE WAS RESPONSIBLE FOR IDLER GEAR DAMAGE AND ENGINE FAILURE. (K) 1 L 7 1 3O 3 O 2A3 E286 2006022800064 20060228 00064 EU 2006 2 28 2006FA0000178 1 20050124 G 2910 MY20751107 LINE AMD FALC20 FALCON 2720302 EU GE CF700 CF700* 30010 NE HYDRAULIC SYS CHAFED B QY5R O OTHER O OTHER NR NOT REPORTED 1 NE 01 20NY 61 WHILE COMPLAYING WITH SB, FOUND 2 HYDRAULIC LINES PN MY20751107 AND MY20751207 CHAFED 20 PERCENT OF WALL THICKNESS LINES REPLACED. (K) 2 L 7 2 4F 4 F A7EU E7EA 2006022800036 20060228 00036 EU 2006 2 28 2006FA0000179 1 20050124 G 2910 MY20751207 LINE AMD FALC20 FALCON 2720302 EU GE CF700 CF700* 30010 NE HYDRAULIC SYS CHAFED B QY5R O OTHER O OTHER NR NOT REPORTED 1 NE 01 20NY 8548 61 WHILE COMPLYING WITH SB, FOUND 2 HYDRAULIC LINES PN MY20751107 AND MY20751207 CHAFED 20 PERCENT OF WALL THICHNESS LINES REPLACED. (K) 2 L 7 2 4F 4 F A7EU E7EA 2006022800007 20060228 00007 2006 2 28 2006FA0000180 4 20050210 G 2562 EBC302V ELT PIPER PA28 PA28180 7102808 SO LYC O360 O360* 41514 EA CABIN INOPERATIVE B ZKGR O OTHER O OTHER NR NOT REPORTED 1 NE 05 7967N 285383 ELT WENT OFF WITH AIRCRAFT SETTING ON RAMP, NO WIND AIRCRAFT HAS NOT FLOWN IN A NUMBER OF DAYS. UNHOOKED BATTERY OVERNI GHT. REHOOKED BATTERY IN MORNING, UNIT STILL ACTIVATED. UNHOOKED BATTERY AND TAG UNIT AS INOPERATIVE AND REMOVED FROM AIRCRAFT. (K) 1 L 7 1 3O 3 O 2A13 E286 2006022800023 20060228 00023 CE 2006 2 28 2006FA0000181 1 20050213 G 7797 CONNECTOR CESSNA 182 T182T 2072738 CE LYC O540 TIO540* 41532 EA TRANSDUCER DISCONNECTED B EHHR O OTHER W INADEQUATE Q C NR NOT REPORTED 1 EA 17 36TP T18208387 PLASTIC CONNECTOR THAT CONNECTS TO TACHOMETER TRANSDUCER HAS NO LOCKING DEVICE, THIS TYPE OF CONNECTOR SHOULD HAVE A SNA P LOCK AT THE END OF IT THREAD TRAVEL. FOUND THIS SAME SIMILAR PROBLEM ON 2 OTHER SINGLE ENGINE AIRCRAFT WITH THE SAME TRANSDUCERE. ALSO HAVING PLASTIC CONNECTORS IN ENGINE COMPARTMENT IS A BIT OF CONCERN. ON FIRST AC, AFTER TIGHTENING TH E CONNECTOR, IT HAD UNSCREWED AND FELL OFF IN FLIGHT. REINSTALLED THE CONNECTOR AND APPLIED RTV SEALANT TO THE OUTSIDE OF THE CONNECTOR AND TRANSDUCER. (K) 1 H 7 1 3O 3 O NT 3A13 E14EA 2006022800024 20060228 00024 EA 2006 2 28 2006FA0000182 2 20050203 G 7414 4370 MAGNETO PIPER PA28 PA28161 7102803 SO LYC O320 O320* 41508 EA ENGINE FAILED B TVMR O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION NR NOT REPORTED 1 EA 05 42997 622 288316062 RLK58339A EXPERIENCED IN-FLIGHT FAILURE OF RT MAGNETO. (K) 1 L 7 1 3O 3 O 2A13 E274 2006022800025 20060228 00025 EU 2006 2 28 2006FA0000184 1 20051219 G 2823 503CA90 SELECTOR BNORM BN2 BN2A 1520204 EU LYC O540 O540* 41532 EA FUEL INOPERATIVE D O OTHER O OTHER NR NOT REPORTED 1 GL 09 80KM 80 RT FUEL PRESSURE WOULD OCCASIONALLY DROP OFF TO BOTTOM OF GREEN RANGE AFTER AIRCRAFT IN CRUISE CONFIGURATION, (ELECTRIC PUMPS OFF) AFTER EXTENDED TROUBLESHOOTING IT WAS FOUND THAT THE RT FUEL COCK HAS VACUUM LEAK AT THE SHAFT AT HIGHER MANI FOLD PRESSURE 23-24 INCH MP, FUEL PRESSURES RETURNED TO NORMAL BELOW 23 INCHES MP OR WHEN ELECTRIC PUMPS ACTIVATED NO FU EL LEAKS OR STAINS FOUND. REPLACED VALVE WITH OVERHAULED UNIT, OPS TEST SATISFACTORY RETURNED TO SERVICE. (K) 1 H 7 2 3O 3 O A17EU E295 2006032300143 20060323 00143 CE 2006 3 23 2006FA0000263 1 20051028 G 2697 WIRE HARNESS CESSNA 750 750 2076810 CE APU FIRE BOTTLE DISCONNECTED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 11 69SB 7500212 DURING THE CONDUCT OF THE RECURRING INSPECTION REQUIRED BY AD2005-09-01 AND PHASE 30, THE WIRING BUNDLE FOR THE APU FIRE BOTTLE WAS FOUND WRAPPED AROUND THE APU FUEL TUBE JUST FORWARD OF THE FIRE BOTTLE. THIS WIRE BUNDLE HAS BOTH AN ACTIVA TION CIRCUIT (NORMALLY UNPOWERED) AND A BOTTLE PRESSURE SENSING CIRCUIT WHICH IS POWERED WHENEVER BATTERY POWER IS SELEC TED. THE CONNECTOR WAS UNPLUGGED AT THE FIRE BOTTLE AND UNWRAPPED FROM THE FUEL TUBE, THEN TIED UP OUT OF THE WAY AND S PIRAL WRAP APPLIED TO WIRING HARNESS. 2 L 7 2 4J RT T00007WI 2006040500223 20060405 00223 SO 2006 4 5 2006FA0000287 2 20050822 G 8530 TIST712BCA CYLINDER CONT O520 TSIO520M 17040 SO ENGINE CRACKED B CY4R K NONE O OTHER IN INSP/MAINT 1 AL 03 4395 511157 5 OF 6 CYLINDERS CRACKED: ( SN 11501-23, 11501-11, 11556-01, 10644-18 CRACKED EXHAUST SIDE) (11909-27 CRACKED INTAKE SID E) AT 439.5 HOURS. (K) 3 O E8CE 2006040500230 20060405 00230 SO 2006 4 5 2006FA0000288 2 20050822 G 8530 TIST712BCA CYLINDER CONT O520 TSIO520M 17040 SO ENGI NE CRACKED B CY4R K NONE O OTHER IN INSP/MAINT 1 AL 03 439 511157 5 OF 6 CYLINDERS CRACKED, (SN NR 11501-23, 11501-11, 11556-01, 10644-18 CRACKED EXHAUST SIDE) (SN NR 11901-27 CRACKED IN TAKE SIDE) CRACKED AT 439.5 HOURS. (K) 3 O E8CE 2006040600155 20060406 00155 SO 2006 4 6 2006FA0000289 2 20050822 G 8530 TIST712BCA CYLINDER CONT O520 TSIO520M 17040 SO ENGINE CRACKED B CY4R K NONE O OTHER IN INSP/MAINT 1 AL 03 511157 5 OF 6 CYLINDERS CRACKED. (SN NR 11501-23, 11501-11, 11556-01, 10644-18, 11909-27 CRACKED EXHAUST SIDE) (SN NR 11909-27 CRACKED INTAKESIDE) CRACKED AT 439.5 HOURS. (K) 3 O E8CE 2006040500232 20060405 00232 SO 2006 4 5 2006FA0000290 2 20050822 G 8530 TIST712BCA CYLINDER CONT O520 TSIO520M 17040 SO ENGINE CRACKED B CY4R K NONE O OTHER IN INSP/MAINT 1 AL 03 511157 5 OF 6 CYLINDERS CRACKED. (S/N 11501-23, 11501-11, 11556-01, 10644-18 CRACKED AT EXHAUST SIDE) ( S/N 11909-27 CRACKED A T INTAKE SIDE) CRACKED AT 439.5 HOURS. (K) 3 O E8CE 2006040500233 20060405 00233 SO 2006 4 5 2006FA0000291 2 20050822 G 8530 TIST712BCA CYLINDER CONT O520 TSIO520M 17040 SO ENGINE CRACKED B CY4R K NONE O OTHER IN INSP/MAINT 1 AL 03 511157 5 OF 6 CYLINDERS CRACKED (S/N 11501-23, 11501-11, 11556-01, 10644-18 CRACKED EXHAUST SIDE) (S/N 11909-27 CRACKED ON INTA KE SIDE) CRACKED AT 439.5 HOURS. (K) 3 O E8CE 2006040500244 20060405 00244 SO 2006 4 5 2006FA0000292 2 20050822 G 8530 934215 CYLINDER CONT O520 IO520F 17032 SO ENGINE CRACKED B CY4R K NONE O OTHER IN INSP/MAINT 1 AL 03 570865 CYLINDER CRACKED AT 480 HOURS. (K) 3 O E5CE 2006040500229 20060405 00229 SO 2006 4 5 2006FA0000293 2 20050822 G 8530 TISN712ACA CYLINDER CONT O520 IO520F 17032 SO ENGINE CRACKED B CY4R K NONE O OTHER IN INSP/MAINT 1 AL 03 670 826501R 6 OF 6 CYLINDERS CRACKED AT 670 HOURS. (S/N 12094-7, 12208-27, 13248-8, 13890-9, 13890-25, 14841-10) (K) 3 O E5CE 2006040500224 20060405 00224 SO 2006 4 5 2006FA0000294 2 20050822 G 8530 TISN712ACA CYLINDER CONT O520 IO520F 17032 SO ENGINE CRACKED B CY4R K NONE O OTHER IN INSP/MAINT 1 AL 03 826501R 5 OF 6 CYLINDERS CRACKED AT 670 HOURS. (S/N 12094-7, 1220827, 13248-8, 13890-9, 13890-25, 14841-10) (K) 3 O E5CE 2006040500237 20060405 00237 SO 2006 4 5 2006FA0000295 2 20050822 G 8530 TISN712ACA CYLINDER CONT O520 IO520F 17032 SO ENGINE CRACKED B CY4R K NONE O OTHER IN INSP/MAINT 1 AL 03 670 826501R CYLINDER CRACKED AT 670 HOURS. (K) 3 O E5CE 2006040500238 20060405 00238 SO 2006 4 5 2006FA0000296 2 20050822 G 8530 TISN712ACA CYLINDER CONT O520 IO520F 17032 SO ENGINE CRACKED B CY4R K NONE O OTHER IN INSP/MAINT 1 AL 03 670 826501R CYLINDER CRACKED AT 670 HOURS. (K) 3 O E5CE 2006040500239 20060405 00239 SO 2006 4 5 2006FA0000297 2 20050822 G 8530 TISN712ACA CYLINDER CONT O520 IO520F 17032 SO ENGINE CRACKED B CY4R K NONE O OTHER IN INSP/MAINT 1 AL 03 826501R CYLINDERS CRACKED AT 670 HOURS. (K) 3 O E5CE 2006040500240 20060405 00240 SO 2006 4 5 2006FA0000298 2 20050822 G 8530 TISN712ACA CYLINDER CONT O520 IO520F 17032 SO ENGINE CRACKED B CY4R K NONE O OTHER IN INSP/MAINT 1 AL 03 670 826501R CYLINDERS CRACKED AT 670 HOURS. (K) 3 O E5CE 2006041100057 20060411 00057 GL 2006 4 11 2006FA0000322 1 20050926 G 3800 FAUCET BOMBDR BD700 BD7001A10 1390006 GL UNKNOWN C A UNSCHED LANDING G MULTIPLE FAILURE CL CLIMB 1 GL 03 18WY 1806 1806 9057 THE FOWARD FAUCET WAS BUMPED OPEN ALLOWING WATER TO FLOW INTO THE SINK, OVERFILLING THE SINK, GOING INTO LOWER EQUIPMENT BAY. ALL THE CRITICIAL FLIGHT COMPONENTS ARE LOCATED THERE AND AFTER TAKEOFF THE CREW HAD TO RETURN BACK TO HOMEBASE DU E ALL THE FAILED SYSTEMS. 2 L 7 2 4F RT T00003NY 2006041200041 20060412 00041 CE 2006 4 12 2006FA0000329 1 20051026 G 3010 BOOT LEAR 60 60LEAR 5170707 CE WINGS DAMAGED B EPDR K NONE O OTHER IN INSP/MAINT 1 NM 13 647TS 3368 047 INADVERRTENT ACTIVATION OF ANTI-ICE SYSTEM ON GROUND, RESULTING IN DAMAGE TO ANTI-ICE BOOTS WAS CAUSED BY AN INTERMITTEN T GROUND OF CIRCUIT THAT IS NORMALLY OPEN. THE WIRE NR H255A20 RUNS FROM THE CONTROLLER TO THE REMOTE CIRCUIT BREAKER. (K) 2 L 7 2 4F RT A10CE 2006041900209 20060419 00209 NM 2006 4 19 2006FA0000341 1 20050603 G 5753 6546434139 FLAP BOEING 737 7373G7 1384595 NM WINGS WRONG PART B LH6Y K NONE O OTHER IN INSP/MAINT 1 EA 35 370WL 24011 (ATC0660) DURING ROUTINE MAINTENANCE IT WAS NOTICED THAT THE LT IB AFT FLAP APPEARED TO BE OF THE WRONG TYPE FOR THIS SE RIAL OF AIRCRAFT. THE AIRCRAFT IPC WAS CONSULTED AND THIS CONFIRMED THAT TIME 139, AFT FLAP ASSY IS NOT EFFECTIVE FOR T HIS AIRCRAFT. A SURVEY WAS CARRIED OUT ON THE OTMGR T/E FLAP ASSEMBLED AND IT WAS DISCOVERED THAT THE RT IB AFT FLAP WA S ALSO NOT OF THE CORRECT AFFECTIVITY. FOR THIS AIRCRAFT (-140). ALL OF THE OTHER FLAP ASSEMBLED WERE FOUND TO BE CORR ECT. WE SUSPECT THAT THESE AFT FLAP ASSEMBLIES ARE FOR AIRCRAFT. (K) 2 L 7 2 4F RT A16WE 2006042400230 20060424 00230 SO 2006 4 24 2006FA0000396 1 20050808 G 3230 HYDRAULIC SYSTEM PIPER PA28 PA28R180 7102809 SO MLG CONTAMINATED C O OTHER O OTHER TO TAKEOFF 1 WP 11 3872T 1661 28R30196 ON TAKEOFF ROLL, EXPERIENCED A LT MAIN GEAR DOWN LOCK DISENGAGEMENT, RESULTING IN MINOR DAMAGE TO THE UNDERSIDE OF THE L T WING SKIN, SHUTTLE VALVE IN THE POWER PACK WAS STICKY, CAUSED BY THE SEDIMENTS IN LWR PARTS OF FLUID RESERVOIR. HYDRA ULIC CYLINDERS WERE TESTED AND FOUND TO HAVE EXCESSIVE INTERNAL LEAKAGE IN THE GEAR DOWN POSITION; THE PISTON SEALS WERE NOTED TO BE VISIBLY WORN. THE BACKUP EXTENDER/OVERRIDE VALVE WAS TESTED AND FOUND TO HAVE INTERNAL LEAKAGE. THE PROBA BLE CAUSE OF THE LT MAIN GEAR DOWN LOCK DISENGAGEMENT APPEARS TO BE RELATED TO SEDIMENT WITHIN THE HYDRAULIC POWER PACK RESERVOIR. (K) 1 L 7 1 3O 2A13 2006051200041 20060512 00041 NE 2006 5 12 2006FA0000424 1 20051014 G 6230 K77461221 ROTOR SHAFT KAMAN K600 H43A 4800702 NE MAIN ROTOR CRACKED B MINR K NONE O OTHER NR NOT REPORTED 1 NM 05 DURING MAGNETIC PARTICAL INSPECTION, THE SHAFT WAS FOUND CRACKED AT THE UPPER END WHERE THE ROTOR HUB ATTACHES TO THE SH AFT. THE CRACK IS APPROXIMATELY 1 INCH LONG AND LOCATED IN THE LOWER RADIUS OF THE RETANGLE CUTOUT. (K) 1 G 7 1 3O AR27 2006051900230 20060519 00230 NE 2006 5 19 2006FA0000505 2 20050909 G 7200 3053519050 BEARING AIRBUS A340 A340* EU GE CFM56 CFM56* 13802 NE POS 5,ROLLER BRG WORN B X3NY K NONE O OTHER IN INSP/MAINT 1 EA 33 740278 BEARING IS FROM SNR PRODUCTION. ROLLER BEARING WAS SENT FOR AN INSPECTION. WE COULD ONLY PERFORM A LEVEL 1 INSPECTION, WITHOUT DISASSEMBLING THE INNER RING, CAGE AND ROLLERS. DURING THE INSPECTION OF THE BEARING, NOTICED SOME HEAVY WEAR TRACES AND MARKS ON THE CIRCUMFERENCE OF DIFFERENT ROLLER. THE DIAMETER OF ONE ROLLER SHOWS AN IMPORTANT NOTCH WITH RAI SED METAL ON ITS DIAMETER PARALLEL TO ITS ROTATION AXIS. ON EACH SIDE OF THE NOTCH THE DEFECT IS FOLLOWED BY A CRACK. THE TOTAL LENGTH OF THE NOTCH PLUS THE CRACK ON EACH SIDE IS ABOUT ONE THIRD OF THE ROLLER LENGTH. 2 L 7 4 4F 4 F RT A197 E2GL 2006052200186 20060522 00186 SO 2006 5 22 2006FA0000520 2 20050716 G 8530 TISN712BCA221 CYLINDER CESSNA 414 414A 2075907 CE CONT O520 TSIO520NB 17040 SO ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SW 13 6822U 414A0808 290903 418.6 HRS SINCE COMPLIANCE W19TH AD2004-08-10 ON ECI CYLINDERS. LT ENG NR2 AND RT ENG NR 4 CYLINDERS FOUND CRACKED THRO UGH FROM UPPER PLUG HOLE TO EXHAUST VALVE. BOTH CYLINDERS HAVE IDENTICAL CRACKS ON RELATIVELY NEW HEADS. (K) 1 L 7 2 3O 3 O A7CE E8CE 2006061200218 20060612 00218 2006 6 12 2006FA0000565 4 20051005 G 6113 100738005 BULKHEAD PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360* 17025 SO MCAULY 3AF32C 3AF32C* GL SPINNER CRACKED D O OTHER O OTHER NR NOT REPORTED 1 GL 13 344HP 165 3449244 THIS AC WAS NEW IN 3/3/2002. LT AND RT SPINNER BULKHEADS HAVE HAD TO BE REPLACED TWICE. FIRST SET OF SPINNER BULKHEADS WERE REPLACED 12/28/2004, WITH 563.3 HOURS ON THEM. PROPS WERE BALANCED TO PREVENT FURTHER PROBLEMS. SECOND SET OF SP INNER BULKHEADS WERE REPLACED 8/26/05 WITH 165.9 HOURS ON THEM. FINDING CRACKS CAN BE DIFFICULT BECAUSE BULKHEAD IS SAN DWICHED BETWEEN 2 SHIMS. FIRST SUSPECTED THAT THERE WAS ONLY 1 CRACK ON EACH BULKHEAD BUT AFTER REMOVING BULKHEAD AND T HE SHIMS, NOTICED THAT EVERY HOLE HAD A CRACK COMING FROM IT. PROBABLE CAUSE COULD BE IMPROPER INSTALLATION OF PROPELLE R MOUNTING BOLTS OR DEFECTIVE MATERIAL. RECOMMEND TAKING CLOSE LOOK EACH 100 HR, IF POSSIBLE LOOKING UNDER SHIMS. (K) 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2006061400240 20060614 00240 CE 2006 6 14 2006FA0000578 1 20050710 G 3233 12810013 ACTUATOR CESSNA 172 172RG 2072438 CE LYC O360 O360* 41514 EA LT MLG CRACKED B PVCR K NONE O OTHER AP APPROACH 1 NM 01 9775B 7005 172RG1029 DURING FLIGHT, LT MLG FAILED TO EXTEND BUT TRAILED, DISCONNECTED FROM HYD SYS. PILOT WAS ABLE TO ROCK LT MLG INTO DOWN AND LOCKED POSITION, MADE SAFE LANDING. DETERMINED, ACTUATOR BODY HAD CRACKED THROUGH FWD ATTACH HOLE, HALF THROUGH AFT ATTACH HOLE, WHICH CAUSED ACT TO SEPARATE WHEN HYD PRESS WAS APPLIED THUS SEPARATING ACTUATOR PISTON GEAR SHAFT FROM SE CTOR GEAR MOUNTED TO PIVOT. ACT ATTACH BOLTS WERE FOUND TIGHT, SAFETY WIRE UNDISTURBED. ACTUATOR BODY WAS REPLACED, A CTUATOR WAS RESEALED, REASSEMBLED, REINSTALLED AND TORQUED IAW SRM. SUSPECT FAILURE OF ACTUATOR BODY MAY BE SHEAR STR ESS ON ACTUATOR ATTACH BOLT HOLES DUE TO HIGH NR OF GEAR CYCLES. INSP OF RT GEAR ACT BODY, NO CRACKS OR DEFECTS. (K) 1 H 7 1 3O 3 O 3A17 E286 2006070500006 20060705 00006 EA 2006 7 5 2006FA0000633 2 20051213 G 7310 LW120980170 LINE PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA FUEL INJECTOR BROKEN D K NONE O OTHER IN INSP/MAINT 1 CE 05 331FC 980 277554024 THIS PART BROKE ON THE WELDED AREA NEXT TO B-NUT. ALL CLAMPS WERE PROPERLY LOCATED AND TIGHT. THIS FAILURE COULD HAVE BEEN FROM FATIGUE CAUSED BY OVERTORQUING B-NUT TO FUEL NOZZLE. SUGGEST PAYING ATTENTION TO PROPER TORQUE VALVES. (K) 1 L 7 2 3O 3 O 1A10 1E4 2006071900007 20060719 00007 NM 2006 7 19 2006FA0000645 1 20051108 G 2620 511000 CONTROL VALVE BOEING 727 72730C 1384009 NM PWA JT8 JT8D5 52046 NE FIRE EXTINGUISH FAILED B NP1Y K NONE O OTHER IN INSP/MAINT 1 EA 33 918UP 19008 NR 2 ENGINE FIRE EXTINGUISHING SELECTOR CONTROL VALVE FAILED TO OPEN DURING ROUTINE TESTING IAW UPS ROUTINE TASK CARD TC 2-221-12. THE VALVE SOLENOID HOUSING WAS NOTED AS BEING CORRODED. (K) 2 L 7 3 4F 4 F A3WE E2EA 2006080800075 20060808 00075 CE 2006 8 8 2006FA0000746 1 20051123 G 3411 7024900 ADC LEAR 35 35A 5170602 CE GARRTT TFE731 TFE731* 01518 WP LT AVIONICS BAY DEFECTIVE B BSYR K NONE O OTHER IN INSP/MAINT 1 GL 07 813AS 167 THE PILOTS ALTIMETER AND ALTITUDE ALERTER WERE FLAGGED AND THE OVERSPEED HORN WAS GOING OFF. THE ADC WAS FOUND TO BE DE FECTIVE AND REPLACED. THE SYSTEM WAS TESTED AND INSPECTED IAW MFG AND FOUND TO COMPLY WTH FAR 91 AND TO REMAIN RVSM CO MPLIANT. THERE HAS BEEN ONE PRIOR REPORT OF THE ADC FALLING ON THIS AIRCRAFT. (K) 2 L 7 2 4F 4 F A10CE E6WE 2006081000126 20060810 00126 2006 8 10 2006FA0000754 4 20051121 G 3417 ADC LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE73122B 01518 WP DEFECTIVE B BSYR O OTHER O OTHER NR NOT REPORTED 1 GL 07 900JC 178 THE PILOTS ALTIMETER AND ALTITUDE ALERTER WERE FLAGGED AND THE OVERSPEED WARNINGS WERE GOING OFF WHILE ON THE GROUND. T HE ADC WAS FOUND TO BE DEFECTIVE AND REPLACED. THE SYSTEM WAS TESTED AND INSPECTED AND FOUND TO COMPLY AND TO REMAIN RV SM COMPLIANT. THERE HAVE BEEN NO PRIOR REPORTS OF PROBLEMS WITH THIS SYSTEM IN THIS AIRCRAFT. (K) 2 L 7 2 4F 4 F A10CE E6WE 2006081600301 20060816 00301 EA 2006 8 16 2006FA0000771 2 20051115 G 8520 CRANKSHAFT LYC O540 IO540E1B5 41532 EA NR 5 ROD JOURNAL FAILED H O OTHER O OTHER DE DESCENT 1 SW 99 J8VAY L1151845 APPROX 5 MILES INTO FLIGHT, FELT A SURGE FROM RT ENG, AC STARTS YAWING TO RT. PROCEEDED TO FEATHER PROP WHICH WAS SUCCE SSFUL AT THIS TIME, NOTICED ENGINE STOPPED TURNING. ADVISED PASSENGERS OF SITUATION IN PREP FOR AN EMERGENCY LANDING. ON GROUND MAINT WAS ADVISED OF INCIDENT. PROP WAS DIFFICULT TO ROTATE BY HAND. SPARK PLUGS WERE REMOVED FOR INTERNAL IN SP OF CYL. NR 6 CYL PISTON WAS FOUND STUCK IN BDC POSITION AND WAS INOPERATIVE ON ROTATION OF THE PROPELLER WHILE THE O THER WAS OPERATIVE. NO PHYSICAL EXTERNAL DAMAGE OR SIGNIFICANT OIL LEAK WERE NOTED. SUSPECT POSSIBLE NR 6 CONNECTING R OD OR CRANKSHAFT DAMAGE. THE ENGINES WILL BE REMOVED AND RETURNED TO OVERHAULER FOR FURTHER EVALUATION. (K) 3 O 1E4 2006081800151 20060818 00151 NE 2006 8 18 2006FA0000813 2 20050519 G 7200 70BMO35420 MODULE SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE ENGINE UNKNOWN B ULXR O OTHER O OTHER NR NOT REPORTED 1 WP 01 228LA 3316 9708 MO2 AND MO3 WERE REPLACED. GROUND RUNS WERE PERFORMED. OIL FLOW AT REAR BRG WAS MEASURED AT 180 MI. NO FUEL OR OIL LE AKS NOTED. DURING PWR CHECK, AT APPROX 1000 FT AGL, (ENG CHIP) LIGHT ILLUMINATED, AFTER PILOT INITIATED LANDING. DURIN G DESCENT, BURNING ODOR WAS NOTED IN COCKPIT, AT APPROX 70 FT AGL (FIRE) CAUTION LIGHT ILLUMINATED. PILOT EXITED AC WIT H FIRE EXTING, SMOKE WAS COMING FROM ENG COWLING, NO INDICATIONS OF FLAMES OR FIRE. INSP PRIOR TO TEARDOWN REVEALED OIL WAS EVIDENT AT REAR BRG AREA, ON OUTSIDE OF MO4. NOISE CAME FROM REAR BRG AREA. METAL CHIPS FOUND AT REAR BRG SCAVENG E CHIP DETECTOR, IN SCREEN. TEARDOWN COULD NOT BE COMPLETED BECAUSE REAR BRG HSG COULD NOT BE SEPARATED FROM MO3. (K) 1 G 7 1 3U 3 U H9EU E19EU 2006082100062 20060821 00062 NM 2006 8 21 2006FA0000814 1 20050111 G 5311 65176626 FRAME BOEING 727 72721 1384003 NM PWA JT8 JT8D1 52044 NE BS 950 S9-10R DAMAGED B K NONE O OTHER IN INSP/MAINT 1 SO 17 727PX 19261 DURING SCHEDULE INSP REQUIRED BY AD, FOUND 8.5 WEB SEPARATION AT FUSELAGE BS 950, RT BETWEEN STRINGER S-9 AND S-10. PAR TIAL FRAME REPLACEMENT BETWEEN S-9 AND S-12 WAS ACCOMPLISHED. INSTALLED KIT NR 65C35283-2. ALL WORK DONE IAW DWG, SRM, SB, AND AD. (K) 2 L 7 3 4F 4 F A3WE E2EA 2006091300202 20060913 00202 CE 2006 9 13 2006FA0000873 1 20050325 G 8011 STARTER CESSNA 172 172S 2072439 CE ENGINE FAILED D O OTHER O OTHER NR NOT REPORTED 1 NM 01 3555L 172S8865 PINION GEAR IN PIECES AND RING GEAR TEETH BROKEN. (K) 1 H 7 1 3O NT 3A12 2006091300203 20060913 00203 CE 2006 9 13 2006FA0000875 1 20050506 G 8011 GEAR CESSNA 172 172S 2072439 CE STARTER FAILED D O OTHER O OTHER NR NOT REPORTED 1 NM 01 3555L 172S8865 PINION GEAR SHATTERED AND RING GEAR TEETH BROKEN. (K) 1 H 7 1 3O NT 3A12 2006092700006 20060927 00006 CE 2006 9 27 2006FA0000876 1 20050916 G 8011 SHAFT CESSNA 172 172S 2072439 CE STARTER FAILED D O OTHER O OTHER NR NOT REPORTED 1 NM 01 3555L 172S8865 PINION GEAR SHAFT WEARING AND GEAR NOT RETRACTING. (K) 1 H 7 1 3O NT 3A12 2006092600131 20060926 00131 CE 2006 9 26 2006FA0000956 1 20050816 G 7713 656219B CONTROL ARM BEECH 36 A36 1151604 CE CONT O550 IO550B SO ENGINE SLIPPED P E ENGINE SHUTDOWN O OTHER DE DESCENT 1 GL 19 64793 43 43 E2057 688427 NOTICED WHILE DESCENDING THROUGH 5,000 FEET, THE MP WAS INCREASING AND NOT RESPONDING TO THROTTLE BACK. MP REMAINED AT 2 8 INCHES TO AIRPORT WITH THROTTLE SETTING AT IDLE. SHUTOFF ENGINE AND LANDED. FOUND THE NUT THAT HOLDS THE THROTTLE CO NTROL ARM TO AIR/FUEL MIXTURE DEVICE WAS LOOSE AND THE SPLINES WERE SLIPPING. ENGINE IS SPRING LOADED SO TO STAY AT PAR TIAL POWER IN CASE THIS HAPPENS. MINE FOR SOME REASON WENT TO FULL POWER. 1 L 7 1 3O 3 O 3A15 E3SO 2006020300127 20060203 00127 CE 2006 2 3 2006RC02001 1 20051012 G 5312 9744001967 BULKHEAD BEECH B200 BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL FUSELAGE CRACKED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA 18354 BB1309 (CAN) PRESSURIZATION ERRATIC IN THE AIR. THE AIRCRAFT WAS TESTED ON THE GROUND AND LEAK WAS DETECTED WITH A 6 INCH CRAC K LT OF THE OUTFLOW VALVE. A REPAIR DESIGN WAS CARRIED OUT. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2007030900043 20070309 00043 SO 2007 3 9 2007FA0000212 2 20051221 G 8540 SUMP CONT O300D CESSNA 172 172H 2072424 CE CONT O300 O300D 17022 SO ENGINE LEAKING D K NONE K FLUID LOSS IN INSP/MAINT 1 EA 17 8848Z 64805D6D 17255498 64805D6D DURING NEWLY OVERHAULED ENGINE INSTALLATION AN OIL LEAK WAS DISCOVERED. WHEN BREAK-IN OIL WAS ADDED TO OIL SUMP FOR INI TIAL ENGINE RUN, OIL WAS OBSERVED LEAKING ONTO NOSE TIRE. FURTHER EXAMINATION REVEALED OIL LEAK WAS ORIGINATING FROM LE FT REAR OF ENGINE WHERE THE OIL SUMP AND ACCESSORY HOUSING MATE TOGETHER. CAUSE OF LEAK WAS IMPROPER SEALING OF OIL SUM P AND ACCESSORY HOUSING DURING ASSEMBLY. 1 H 7 1 3O 3 O NT 3A12 E253 2007061300223 20070613 00223 CE 2007 6 13 2007FA0000408 1 20050326 G 7810 02R3022406 EXHAUST DUCT BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 12898 2845 WHILE PREFORMING SCHEDULED MAINTENANCE,REMOVED EXHAUST STACKS TO FACILTATE INSPECTING THE EXHAUST DUCT.A CRACK WAS FOUND IN THE SKI SLOPE.POWER SECTION WAS REMOVED FOR REPAIR. 1 L 7 2 4T 4 T A24CE E4EA 2007061300217 20070613 00217 CE 2007 6 13 2007FA0000422 1 20050501 G 7810 02R3022406 EXHAUST DUCT BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 11150 154 WHILE PREFORMING SCHEDULED MAINTENANCE,REMOVED EXHAUST STACKS TO FACILTATE INSPECTING THE EXHAUST DUCT.A CRACK WAS FOUND IN THE SKI SLOPE.POWER SECTION WAS REMOVED FOR REPAIR. 1 L 7 2 4T 4 T A24CE E4EA 2007061300218 20070613 00218 CE 2007 6 13 2007FA0000423 1 20050917 G 7810 02R3022406 EXHAUST DUCT BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 13079 90 WHILE PREFORMING SCHEDULED MAINTENANCE,REMOVED EXHAUST STACKS TO FACILTATE INSPECTING THE EXHAUST DUCT.A CRACK WAS FOUND IN THE SKI SLOPE.POWER SECTION WAS REMOVED FOR REPAIR. 1 L 7 2 4T 4 T A24CE E4EA 2007061300212 20070613 00212 CE 2007 6 13 2007FA0000431 1 20050518 G 7810 02R3022406 EXHAUST DUCT BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 11322 1519 WHILE PREFORMING SCHEDULED MAINTENANCE,REMOVED EXHAUST STACKS TO FACILTATE INSPECTING THE EXHAUST DUCT.A CRACK WAS FOUND IN THE SKI SLOPE.THE EXHAUST DUCT SB 3380 HAD NOT BEEN COMPLIED WITH.POWER SECTION WAS REMOVED FOR REPAIR. 1 L 7 2 4T 4 T A24CE E4EA 2007061300211 20070613 00211 CE 2007 6 13 2007FA0000438 1 20050405 G 7810 02R3022406 EXHAUST DUCT BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 11060 442 WHILE PREFORMING SCHEDULED MAINTENANCE,REMOVED EXHAUST STACKS TO FACILTATE INSPECTING THE EXHAUST DUCT.A CRACK WAS FOUND IN THE SKI SLOPE.THE EXHAUST HAD NOT HED SB 3380 COMPLIED WITH.POWER SECTION WAS REMOVED FOR REPAIR. 1 L 7 2 4T 4 T A24CE E4EA 2007061300227 20070613 00227 CE 2007 6 13 2007FA0000442 1 20050523 G 7810 02R3022406 EXHAUST DUCT BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA ENGINE CRACKED D K NONE O OTHER IN INSP/MAINT 1 SO 09 1423 495 WHILE PREFORMING SCHEDULED MAINTENANCE,REMOVED EXHAUST STACKS TO FACILTATE INSPECTING THE EXHAUST DUCT.A CRACK WAS FOUND IN THE SKI SLOPE. EXHAUST DUCT SB HAD BEEN COMPLIED WITH 495 HOURS PRIOR. POWER SECTION WAS REMOVED FOR REPAIR. 1 L 7 2 4T 4 T A24CE E4EA 2005041400102 20050414 00102 CE 2005 4 14 2120003 1 20050114 G 3246 NUT DUNLOP RAYTHN DH125 HAWKER800XP 7150012 CE WHEEL BACKED OUT B O OTHER O OTHER TX TAXI/GRND HDL 1 WP 27 305SC 069BN061BP 258662 DURING TAXI FOR TAKEOFF, BOTH RIGHT MAIN GEAR TIRES CAME OFF OF THE WHEELS AND THE AIRCRAFT SETTLED ON THE WHEELS. BOTH WHEELS WERE DESTROYED. ALL WHEEL HALF BOLTS WERE LOOSE, NONE HAD NUTS INSTALLED, AND ONLY TWO NUTS COULD BE LOCATED. WHI LE THE WHEELS ROTATED, THE LOOSE BOLTS DRAGGED ON THE BRAKE BACKING PLATES DAMAGING THEM. THE INBOARD WHEEL, INBOARD WHE EL HALF, DEPARTED UNDER PRESSURE STRIKING THE KEELBEAM FAIRING JUST AFT OF THE ROTATING BEACON AND CONTINUED, STRIKING T HE LEFT GEAR INBOARD WHEEL HUBCAP. THE HUBCAP AND ANTI SKID ADAPTER SLEEVE WERE BOTH DAMAGED. ONLY ONE TIRE WAS RECOVERE D. 2 L 7 2 4F RT A3EU 2006012400203 20060124 00203 CE 2006 1 24 2552 1 20051207 G 1210 FUEL CESSNA 500 560CESSNA 2076750 CE PWA JT15 JT15D5 52112 NE FUEL TANKS CONTAMINATED C D RETURN TO BLOCK X ENGINE FLAMEOUT TX TAXI/GRND HDL 1 SW 15 64LV 5600345 UNK AC WAS LT OUTSIDE DURING COLD PERIOD, OAT 10F, ENGINES WERE STARTED, IDLED FOR 15-20 MIN TO WARM UP. UPON TAXI OUT, RT E NGINE HAD UNCOMMANDED SHUTDOWN. MAINT CHECKED BOTH ENGINES AND AIRFRAME FUEL FILTERS WITH NO WATER OR CONTAMINATION FOU ND. FURTHER TESTING OF THE FUEL REVEALED A PRIST LEVEL OF .21. NORMAL LEVEL SHOULD BE .10 TO .15. FUEL TANKS WERE DRAINE D, NEW FUEL ADDED, RUN-UP AND LEAK CHECK PERFORMED OK. AC WAS RETURNED TO SERVICE. NOTIFIED LAST 4 FBOS OF POSSIBLE FUE L PROBLEMS WITH THEIR FUEL. 3 OF THE FBO'S TESTED THEIR FUEL RIGHT AWAY WITH GOOD READINGS, LAST FBO WHERE FUELED CLAIM ED THEY COULD NOT TEST THEIR FUEL. 1 WEEK LATER THAT FBO INFORMED ME THAT THEY TESTED THEIR FUEL AND IT WAS OK. 2 L 7 2 4F 4 F RT A22CE E25EA 2005071200066 20050712 00066 SO 2005 7 12 386506171 1 20050701 G 2750 1763400 TORQUE TUBE PIPER PA23 PA23250 7102308 SO LYC O540 IO540C4B5 41532 EA RUDDER CUT D O OTHER O OTHER NR NOT REPORTED 1 GL 15 1100 273645 PERFORMING AD 2003-09-13, FOUND TORQUE TUBE WORE/CUT BY LEFT RUDDER CABLE, 2 INCH LONG AND THRU TUBE WALL. TUBE HAS BEE N INSTALLED SINCE 1996 1100 HRS AGO. 1 L 7 2 3O 3 O 1A10 1E4 2005042700093 20050427 00093 SO 2005 4 27 4253620 1 20050323 G 2560 554204 CABLE PIPER PA28 PA28181 7102807 SO SEAT BELT CUT B K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 09 4161P 734 2843309 TWO OF THE REAR SEAT BELT ATTACH CABLES HAD BEEN CUT AT MANUFACTURE. 1 L 7 1 3O 2A13 2006012400206 20060124 00206 SO 2006 1 24 43881 2 20051213 G 7310 FUEL LINE PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360* 17025 SO RT ENGINE CHAFED B K NONE O OTHER IN INSP/MAINT 1 GL 09 1130D 3449311 THE FUEL INJECTOR LINE FROM THE FLOW DIVIDER TO THE NR3 CYLINDER ON THE RT ENGINE WAS ROUTED UNDER A COWL LATCH FOR THE COWLING NOSE BOWL WHICH CAUSED SEVER CHAFING IN A LOCALIZED AREA. THIS WAS ORIGINAL FACTORY ROUTING. NO FAILURE OCCURR ED, PART WAS REPLACED AND DIGITAL PHOTO'S WERE PROVIDED TO MFG TECH SERVICES. 1 L 7 2 3O 3 O A7SO E9CE 2005072000164 20050720 00164 NM 2005 7 20 471082 1 20050715 G 4920 38222516 TURBINE ALIDSG GTCP280 DOUG MD80 MD83 3023681 NM APU FAILED B ZN3R O OTHER R PARTIAL RPM/PWR LOSS NR NOT REPORTED 1 WP 07 P80389 RECEIVED SUBJECT APU WITH A BURST IMPELLER. THE OEM HAS BEEN NOTIFIED AND IS CURRENTLY UNDER INVESTIGATION FROM HONEYWEL L OEM. ONCE THE INVESTIGATION IS COMPLETE AN OFFICAL REPORT WILL BE SUBMITTED TO THE CUSTOMER FROM REPAIR & OVERHAUL AND OEM ENGINEERING. 2 L 7 2 4F RT 2005050300260 20050503 00260 SW 2005 5 3 5322 1 20050411 G 2197 WIRE MOONEY M20 M20M 5870222 SW AVIONICS BLOWER OVERHEATED B O OTHER O OTHER CR CRUISE 1 CE 03 21816 270277 AVIONICS BLOWER AND COWL FLAP BREAKER POPPED IN FLIGHT, UNABLE TO RESET. LANDING AND TAXI CIRCUITS DRAW 18 AMPS EACH AND WERE ROUTED THROUGH CIRCUIT BREAKER DISCONNECT WITH CONTACT RATING OF 13 AMPS EACH. THE OVERHEATED CONNECTION MELTED IN SULATION ON SURROUNDING WIRES SHORTING LANDING AND TAXI LIGHT CIRCUIT TO AVIONICS BLOWER AND COWL FLAP ACTUATOR CIRCUIT. CORRECTIVE ACTION WAS TO REMOVE DAMAGED WIRES AND CONTACT, THEN ROUTE LANDING AND TAXI LIGHT CIRCUITS THROUGH MULTIPLE CONTACTS TO INCREASE CURRENT CAPABILITY. 1 L 7 1 3O RT 2A3 2005052400296 20050524 00296 CE 2005 5 24 5330 1 20050509 G 5340 965630045 BRACKET CESSNA 500 550 2076604 CE NLG WW CRACKED B K NONE O OTHER IN INSP/MAINT 1 CE 03 52RF 7908 5500021 AVIONICS SHELF BRACKET CRACKED, LOCATED IN NOSE AVIONICS COMPARTMENT ON RT SIDE OF NOSE WHEEL WELL, FRAME STA 50. REPLA CED BROKEN ANGLE BRACKET WITH NEW BRACKET FROM THE MFG. METHOD OF PREVENTION IS UNKNOWN. 1 L 7 2 4F A22CE 2005120200149 20051202 00149 SO 2005 12 2 77865 1 20051102 G 6120 C4503 FORK HARTZL HCC4YR2 PIPER PA31 PA31350 7103110 SO HARTZL HCC4Y HCC4YR2 GL PITCH CHANGE CRACKED B EY2R K NONE O OTHER IN INSP/MAINT 1 GL 03 1687 FH804 FH804 DURING OVERHAUL THE C4503 WAS FOUND TO BE CRACKED AFTER BEING MAGNAFLUXED. 1 L 7 2 3O A20SO 5 C P52GL 2005111000058 20051110 00058 SO 2005 11 10 77866 1 20051102 G 6120 C4503L FORK PIPER PA31 PA31350 7103110 SO HARTZL HCC4Y HCC4YR2 GL PITCH CHANGE CRACKED B EY2R O OTHER O OTHER NR NOT REPORTED 1 GL 03 1687 FH892 PITCH CHANGE FORK CRACK FOUND DURING MAG-PARTICLE CHECK AT OVERHAUL (OH). 1 L 7 2 3O A20SO 5 C P52GL 2005051600101 20050516 00101 NM 2005 5 16 78 1 20050426 G 5330 SKIN BOEING 737 737300 1384610 NM FUSELAGE DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 312FL 24569 DENTS AND GOUGES STA 770 - 827 STR 26 - 27 RT BELOW AFT PIT DOOR. 2 L 7 2 4F RT A16WE 2005052300287 20050523 00287 NM 2005 5 23 80 1 20050502 G 5330 SKIN BOEING 737 7373L9 1384470 NM CFMINT CFM56 CFM563B2 13802 EU FUSELAGE GOUGED B K NONE O OTHER IN INSP/MAINT 1 SO 15 312FL 24569 AIRCRAFT DAMAGE BELOW AFT PIT FROM BELT LOADER BS 755-790, S-25R. LOG PAGE ITEM NR1 PG. 158526,S/O 109001, N/R 22583. 2 L 7 2 4F 4 F RT A16WE E21EU 2005052300137 20050523 00137 NM 2005 5 23 81 1 20050502 G 5311 FRAME BOEING 737 7373L9 1384470 NM FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 312FL 24569 LOWER FWD SIDE OF FRAME AT STA 616 S-16R CRACKED AT LOWER FASTENER. 2 L 7 2 4F RT A16WE 2005052300138 20050523 00138 NM 2005 5 23 82 1 20050502 G 5322 SHEAR TIE BOEING 737 7373L9 1384470 NM FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 312FL 24569 CABIN UPPER LOBE SHEAR TIE CRACKED AT BS 639 S-4L. 2 L 7 2 4F RT A16WE 2005052300139 20050523 00139 NM 2005 5 23 83 1 20050502 G 5310 CREASE BEAM BOEING 737 7373L9 1384470 NM FUSELAGE CORRODED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 312FL 24569 R-1 SERVICE DOOR INNER CHORD CREASE BEAM HAS CORROSION THRU OUT THE BEAM. 2 L 7 2 4F RT A16WE 2005052300140 20050523 00140 NM 2005 5 23 84 1 20050502 G 5311 FRAME BOEING 737 7373L9 1384470 NM FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 312FL 24569 CRACKED FRAME AT BS 294.5, WL 208.1 FWD GALLEY DOOR. 2 L 7 2 4F RT A16WE 2005052300142 20050523 00142 NM 2005 5 23 85 1 20050502 G 5315 FLOORBEAM BOEING 737 7373L9 1384470 NM FUSELAGE CORRODED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 312FL 24569 CORRODED AFT CABIN FLOORBEAM UPPER SKIN FROM BS 987 LBL 48.0. 2 L 7 2 4F RT A16WE 2005012400049 20050124 00049 WP 2005 1 24 872SJ009 1 20050107 G 5320 FLOOR SUPPORT DOUG DC8 DC871F 302199D WP FUSELAGE CORRODED B GKZR O OTHER O OTHER NR NOT REPORTED 1 SW 11 872SJ 46040 LT W/W UPPER LT SIDE FWD AND AFT OF SIXTH FLOOR SUPPORT HAS CORROSION. GBAMC NR 4178 CLEANED, CHECKED FOUND TO BE OUT O F LIMITS IAW DC-8 SRM 53-2-0. REMOVED LT W/W, L/H SIDE AFT FLOOR SUPPORT AT STA 960.00 AND REPLACED FLOOR SUPPORT FITTI NG AT STA 960.00 IAW DC-8 SRM 53-2-0.-CLOSED- 2 L 7 4 4F RT 4A25 2005091500003 20050915 00003 GL 2005 9 15 9132005 1 20050914 G 5100 314 STEP AMTR LANCAR LANCAIR 05616TS GL LT SIDE DAMAGED G O OTHER O OTHER LD LANDING 1 GL 03 1QB 3 3 319 RETRACTABLE STEP ASSEMBLY MECHANISM IS ATTACHED TO THE LANDING GEAR STRUT BY A STEEL BRAIDED CABLE WITH METAL CLAMP. CL AMP AROUND STRUT ROTATED ALLOWING EXCESSIVE SLACK IN THE CABLE. WHEN THE LT LANDING GEAR WAS EXTENDED IT CAME IN CONTAC T WITH THE RETRACTABLE STEP ASSEMBLY AND WOULD NOT ALLOW THE LANDING GEAR TO LOCK IN THE DOWN POSITION. 1 L 7 1 3O RT EXPA1L71 2005050500008 20050505 00008 EA 2005 5 5 A6WA200540124 1 20050325 G 5330 SKIN CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE FUSELAGE SCRATCHED A A6WA K NONE O OTHER IN INSP/MAINT 1 GL 31 415AW 7593 2 SCRATCHES IN FUSELAGE AT CARGO DOOR CUT-OUT, (APPROX 1 INCH LONG AND .5 INCH LONG.) PERFORMED A MAJOR REPAIR AT FS 549 , STR 14-16 IAW EO. (K) 2 L 7 2 4F 4 F RT A21EA E15NE 2005051100256 20050511 00256 GL 2005 5 11 AHDR051179 1 20050418 G 3110 70000004002 DISPLAY CIRRUS SR SR22 2130001 GL INSTRUMENT PANEL SMOKE B AHDR O OTHER B S SMOKE/FUMES/ODORS/SPARKS AFFECT SYSTEMS CR CRUISE 1 EA 13 816CD 217 0150 PILOT REPORTED SMOKE COMING FROM INSTRUMENT PANEL ABOVE MFD. DISPLAY WENT BLANK AND SMOKE CONDITION ENDED. AIRCRAFT WA S NEARING DESTINATION SO PILOT CONTINUED TO LANDING. ON SHORT FINAL MFD CAME BACK ON. UNIT REMOVED AND RETURNED TO MFG FOR INSPECTION AND REPAIR. MFG DID NOT PROVIDE DETAILS OF FINDINGS. 1 L 7 1 3O NT A00009CH 2006022100170 20060221 00170 SW 2006 2 21 ALGA106654 1 20051029 G 6220 406310 PITCH LINK BELL 407 407 1182206 SW MAIN ROTOR BINDING B ALGA O OTHER O OTHER NR NOT REPORTED 1 SW 03 527AL 596 53211 BINDING AND AXIAL PLAY BEYOND MAX. / REPLACED BY FIELD MAINTENANCE. 1 G 7 1 3U O H2SW 2005042000043 20050420 00043 SO 2005 4 20 AMCR200500001 1 20050315 G 5755 1159CS55403102 PANEL GULSTM GV GULFSTREAMGV 3980116 SO SPOILER DAMAGED B AMCR K NONE O OTHER IN INSP/MAINT 1 GL 09 250DV 1008 691 DURING MAINTENANCE WITH HYDRAULIC MULE RUNNING, MAINTENANCE PERSONNEL NOTICED THE RIGHT WING FLIGHT SPOILERS EXCESSIVELY SUCKED DOWN, CAUSING OIL CANNING WHICH CAUSED THE AFT TIPS OF THE BOARDS TO CURL UP. MANUFACTURER WAS CALLED AND CREW WAS SENT TO INVESTIGATE. AILERON SYSTEM WAS IN RIG, HOWEVER DURING FLIGHT SPOILER RIGGING CHECK, THE INPUT SHAFT RIG PI NS WOULD NOT INSERT. FOUND INPUT SHAFT OUT OF RIG AND SPOILER CONNECTING RODS OUT OF ADJUSTMENT. NO DAMAGE TO BOARDS O CCURRED. INVESTIGATION REVEALED SYSTEM WAS RECENTLY RIGGED BY MANUFACTURER'S SERVICE CENTER AFTER FLIGHT SPOILER ACTUAT OR WAS REMOVED AND REPLACED. 2 L 7 2 4F RT A12EA 2005050300214 20050503 00214 EU 2005 5 3 AMCR200500002 1 20050331 G 4930 MOTOR BRAERO DH125 BAE125800A 1500285 EU BOOST PUMP OVERHEATED B AMCR C F E ABORTED TAKEOFF ACTIVATE FIRE EXT. ENGINE SHUTDOWN J WARNING INDICATION TO TAKEOFF 1 GL 09 527AC 1445 258104 ON TAKE-OFF ROLL, CREW GOT AN APU FIRE IND, BOTH BELL, ANNUNCIATION. WITH APU MASTER SWITCH ALREADY OFF, FIRED EXTINGUIS HER, EXITED RUNWAY, STOPPED. WITH FIRE ANNUN STILL ILLUMINATED AN EVAC TOOK PLACE. CLEARED AC, BATTERY PWR WAS TURNED ON , FIRE ANNUNCIATION WAS GONE. NO IND THAT ACTUAL FIRE TOOK PLACE. AC WAS TOWED BACK TO HANGAR. AFTER THOROUGH INVESTIGAT ION, MAINT FOUND THAT APU FUEL BOOST PUMP MOTOR HAD OVERHEATED. WITH MOTOR COVER REMOVED, REAR BRG/BRUSH AREA WAS MILDLY CHARRED. EVIDENCE OF POSSIBLE FUEL MIGRATION INTO MOTOR. CHECKS OF ALL APPLICABLE COMPONENTS, AC WAS OPERATED, TEST-FL OWN WITH NO FURTHER PROBLEMS. ESTIMATED TIME FIRE WARNING TOOK PLACE AFTER APU WAS SHUTDOWN WAS ABOUT 4 MINUTES. 2 L 7 2 4F RT A3EU 2005052500205 20050525 00205 SO 2005 5 25 AMCR200500004 1 20050510 G 3340 3019941 STROBE GULSTM G1159 GIV 3980115 SO LT WING ARCED B AMCR K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 GL 09 523AC 431 1528 AN OPERATIONAL CHECK FOUND LT WING STROBE INOP. TROUBLESHOOTING FOUND STROBE LAMP UNIT TO BE ARCING INSIDE OF CASE. 2 L 7 2 4F RT A12EA 2005061400026 20050614 00026 SO 2005 6 14 AMCR200500005 1 20050526 G 2752 1159SCC21216 JACKSCREW GULSTM G1159 GIV 3980115 SO TE FLAPS SHEARED B AMCR O OTHER J WARNING INDICATION CL CLIMB 1 GL 09 523AC 469 1528 AFTER TAKEOFF, CREW RECEIVED A FLAP ASYMMETRY MESSAGE DURING FLAP RETRACTION FROM 10 DEG TO 0 DEG. MAINTENANCE FOUND TH E RIGHT-OUTBOARD FLAP ACTUATOR TO HAVE THE SMALL SHAFT THAT DRIVES THE ASYMMETRY SWITCH SHEARED. NO INDICATION WHY SHAF T SHEARED, SINCE ROTARY SWITCH SEEMS TO OPERATE OK. ACTUATOR AND SWITCH WAS REPLACED. 2 L 7 2 4F RT A12EA 2005072500022 20050725 00022 EU 2005 7 25 AMCR200500006 1 20050721 G 5610 24016335 WINDSHIELD BRAERO DH125 BAE125800A 1500285 EU COCKPIT FAILED B AMCR O OTHER J WARNING INDICATION CR CRUISE 1 GL 09 526AC 2036 258169 CREW GOT A WINDSHIELD OVERHEAT INDICATION. UPON RETURN, CONTINUITY CHECK FOUND LEFT WINDSCREEN'S NORMAL SENSOR OPEN. REP LACED WINDSHIELD. 2 L 7 2 4F RT A3EU 2005090200011 20050902 00011 NE 2005 9 2 AMCR200500007 1 20050829 G 5344 7620902019045 ATTACH FITTING SKRSKY S76 S76B 8143007 NE PWA PT6 PT6* 52043 EA MLG DOOR BROKEN B AMCR O OTHER O OTHER LD LANDING 1 GL 09 520AC 2027 760380 AFTER LANDING, CREW FOUND RT MAIN GEAR DOOR RESTING ON LANDING GEAR. FOUND DOOR ATTACH BRACKET BROKEN. 1 G 7 2 4U 3 T H1NE E2NE 2005092600053 20050926 00053 2005 9 26 AMCR200500008 4 20050915 G 2210 6014303 SWITCH GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6118 EU AUTOPILOT SEPARATED B AMCR O OTHER F FLT CONT AFFECTED CL CLIMB 1 GL 09 522AC 670 1524 DURING CLIMB, CREW COULD NOT ENGAGE AUTOPILOT. DURING HAND FLYING, CREW GOT SEVERAL UNCOMMANDED GO-AROUND COMMANDS IN WH ICH COMMAND BARS WOULD POP-UP AND THROTTLES WOULD ADVANCE TO FULL POWER. MX FOUND THE BODY OF GO-AROUND SWITCH HAD SEP ARATED WHICH CAUSED SWITCH TO RECESS A BIT INTO THE YOKE. BECAUSE SWITCH POSTS DID NOT HAVE HEAT SHRINK ON THEM, THEY WE RE SHORTING OUT CAUSING THE UNCOMMANDED GO-AROUND SCENERIO. MX ENSURED SHRINK TUBE WAS INSTALLED ON NEW SWITCH. 2 L 7 2 4F 4 F RT A12EA E25NE 2005101300173 20051013 00173 CE 2005 10 13 AMCR200500009 1 20051003 G 2121 125021124 FAN CESSNA 525 525A 2076615 CE WILINT FJ44 FJ44 66000 GL AFT CABIN CLOGGED B AMCR H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 GL 09 179DV 382 525A0172 WHILE THE AIR CONDITIONER WAS RUNNING, THE CREW REPORTED INADEQUATE COOLING AND A FAINT ODOR OF SOMETHING BURNING. MAINT ENANCE FOUND THE AFT EVAPORATOR FAN WAS BARELY RUNNING. AFTER REPLACING THE FAN, THE OLD FAN'S COVER WAS REMOVED AND A BIG PILE OF BRUSH DUST POURED OUT. 1 L 7 1 4F 4 F RT A1WI E3GL 2005120100154 20051201 00154 SO 2005 12 1 AMCR200500010 1 20051129 G 5230 1159SCB2021 SEAL GULSTM G1159 GIV 3980115 SO RROYCE TAY TAY6118 EU CARGO DOOR CHAFED B AMCR O OTHER J WARNING INDICATION CR CRUISE 1 GL 09 522AC 804 1524 CREW NOTED A WHISTLE FROM BAGGAGE DOOR AREA. MAINTENANCE FOUND THE BAGGAGE DOOR SEAL TORN IN THE 12 O'CLOCK POSITION. IT APPEARS THAT THE TOP BAYONET LATCH PLATE ON THE FUSELAGE HAD EXCESS SEALANT ON THE IB SIDE, CAUSING THE DOOR SEAL TO RU B HARD AGAINST IT DURING DOOR CLOSING. DOOR SEAL REPLACED AND EXCESS SEALANT REMOVED FROM BAYONET PLATE. OTHER AIRCRAFT IN FLEET WERE INSPECTED AND NO EXCESS SEALANT WAS FOUND ON THOSE PLATES. 2 L 7 2 4F 4 F RT A12EA E25NE 2005121900181 20051219 00181 GL 2005 12 19 AMSA10280502 1 20051028 G 5210 12545001 ACTUATOR CIRRUS SR SR22 2130001 GL ZONE 800 BROKEN D D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 GL 31 0920 PILOT SIDE DOOR PISTON, THAT GOT DISCONNECTED, JAMMED PILOT'S CONTROL STICK. THERE IS NO WAY, THAT AC COULD BE FLOWN IN THIS CONDITION. IN ORDER TO FREE CONTROLS DOOR, UPHOLSTERY HAD TO BE REMOVED PISTON ON DOOR SIDE HAD TO BE DISCONNECTED , DOOR HAD TO BE OPENED, THEN PISTON THAT WAS CAUGHT IN CONTROL STICK COULD BE REMOVED. AFTER REMOVAL, PLASTIC ROD END OF THE PISTON HAD BROKEN AND PISTON ROD HAD BENT. AFTER INVESTIGATION, DISCOVERED, THAT PISTON PLASTIC ROD END OF BOTH LT AND RT DOORS HAD BEEN DAMAGED AND WERE NOT FULLY LOCKING IN POSITION. 1 L 7 1 3O NT A00009CH 2005102800029 20051028 00029 WP 2005 10 28 AOC05001 1 20050418 G 6230 369D27609501 SWASHPLATE HUGHES 369 369D 4470706 WP MAIN ROTOR MISINSTALLED B R29R O OTHER O OTHER NR NOT REPORTED 1 SW 19 484 870177D WHEN REPLACING THE SWASHPLATE ASSEMBLY. IT WAS NOTED THAT MASTINOX WAS USED INSTEAD OF MIL-P-85582 AS REQUIRED BY THE MA NUFACTURES MAINTENANCE MANUAL. USE OF MASTINOX WILL ALLOW THE UNIBALL TO ROTATE IN THE SWASHPLATE. WHEN THE MAINTENANC E FACILITY WAS CONTACTED (PRISM HELICOPTERS LTD, 12-11465 BAYNES ROAD NORTH, PITT MEADOWS AIRPORT, PITT MEADOWS, BC, AIR AGENCY CERTIFICATE V3Y 2B3) HAD NO APPROVED PROCEDURE TO USE MASTINOX. HIGHLY RECOMMEND THAT ANY SWASHPLATE ASSEMBLY O VERHAULED OR PURCHASED FROM THIS FACILITY BE INSPECTED FOR PROPER ASSEMBLY. USE OF MASTINOX WAS PRIMARY CAUSE OF THIS D EFECT. 1 G 7 1 3U H3WE 2005102800042 20051028 00042 GL 2005 10 28 AOC05002 2 20051025 G 7250 E23062750 NOZZLE HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL ENGINE DEPARTED B R29R O OTHER O OTHER NR NOT REPORTED 1 SW 19 541 435 711023D CAE830651 UPON INSPECTION OF THE TURBINE ASSEMBLY, THE NOZZLE SHIELD DOME WAS FOUND TO BE COMPLETELY DETACHED FROM THE NOZZLE ASSE MBLY. APPEARS THAT NOZZLE SHIELD WAS NOT PROPERLY BRAZED IN PLACE AT MANUFACTURE. THIS NOZZLE ASSEMBLY NOT INCLUDED IN CEB-A-1370R2, WHICH ADDRESSES THIS PROBLEM. 1 G 7 1 3U 3 U H3WE E4CE 2006010400116 20060104 00116 SW 2006 1 4 AOC05003 1 20051213 G 6210 407015001129 BLADE BELL 407 407 1182206 SW MAIN ROTOR CRACKED B R29R K NONE O OTHER IN INSP/MAINT 1 SW 19 2869F 291 53623 DURING A 300 HR INSPECTION, A 1.2500 INCH CRACK WAS DISCOVERED ON THE LEADING EDGE ABRASION STRIP AT APPROXIMATLEY BLADE STATION 133.5. BLADE SENT TO BHTI FOR REPAIR. 1 G 7 1 3U O H2SW 2006012400208 20060124 00208 SW 2006 1 24 AOC05004 1 20051213 G 6220 407310104105 SPRING BELL 407 407 1182206 SW ALLSN 250C 250C47B GL ROTOR HEAD BROKEN B R29R K NONE O OTHER IN INSP/MAINT 1 SW 19 2869F 291 53623 DURING A 300 HR INSPECTION, A LEAD/LAG DAMPER SPRING WAS FOUND BROKEN IN 2 PLACES. JUDGING FROM THE BREAK LINES, THE SPR ING HAD BEEN CRACKED FOR SOME TIME. 1 G 7 1 3U 3 U O H2SW E1GL 2005080900063 20050809 00063 EU 2005 8 9 AS350B2BELCRK 1 20050808 G 6710 350A27145300 BELLCRANK SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1 60030 NE TRANS DECK GOUGED B K NONE O OTHER IN INSP/MAINT 1 SW 15 4059W 2545 2933 WE HAVE FOUND THIS PART TO HAVE MAINTENANCE INDUCED DAMAGE FROM DISCONNECTING THE LT FORWARD INPUT ROD AT THE PRIMARY FL IGHT CONTROL SERVO AND ALLOWING THE ROD TO FALL FORWARD. THIS ACTION ALLOWS THE LOWER JAM NUT TO CONTACT THE BELLCRANK, CAUSING DAMAGE. THE MANUFACTURER STATES THAT THERE IS NO ALLOWABLE DAMAGE TO THIS PART. THE OPERATOR OF THIS AIRCRAFT HA S A FLEET WITH THIS TYPE OF DAMAGE FOUND ON AT LEAST 5 OTHER AIRCRAFT. 1 G 7 1 3U 3 U H9EU E19EU 2005040400088 20050404 00088 WP 2005 4 4 ASAA0580104 1 20050215 G 5321 98391951 FLOOR PANEL DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE CABIN DAMAGED A ASAA K NONE O OTHER IN INSP/MAINT 1 NM 02 943AS 53018 OKC C-CHECK- PAX CABIN FLOOR PANEL PEELED. FIBERGLASS BOND REPAIRED. (K) 2 L 7 2 4F 4 F RT A6WE E9NE 2005072200097 20050722 00097 SW 2005 7 22 ASI200501 1 20050715 G 6220 204012104005 PIN BELL BELL 204 UH1H 1181407 SW ROTOR HEAD FAILED B U1DM O OTHER O OTHER NR NOT REPORTED 1 WP 07 2767X 1085 1085 ADA6239 696664 DURING 1200 OVERHAUL OUTBOARD FITTING/STRAP PIN WAS FOUND BROKEN IN HALF. PIN HAD 1085.1 HOURS SINCE NEW. DISCOLORATION AND CONDITION OF BREAK INDICATES THE BREAK WAS NOT RECENT. FITTING DAMAGE BEYOND USE. STRAP ALTHOUGH DUE RETIREMENT HAS NO SIGNIFICANT DAMAGE. PIN WAS MISSING TWO WASHERS P/N AN816L AND SEALANT ON THE ENDS. PIN HAS A LIFE LIMIT OF 2400 HOUR S. 1 G 7 1 4U EXPA1G71 2005072000040 20050720 00040 SW 2005 7 20 ASI200501A 1 20050715 G 6220 204012104005 PIN BELL BELL 204 UH1H 1181407 SW M/R HEAD FAILED B U1DM K NONE O OTHER IN INSP/MAINT 1 WP 07 2767X 1085 1085 ADA6239 696664 DURING 1200 OVERHAUL OUTBOARD FITTING/STRAP PIN P/N 204-012-104-005, S/N DIFS12334 WAS FOUND BROKEN IN HALF. PIN HAD 108 5.1 HOURS SINCE NEW. DISCOLORATION AND CONDITION OF BREAK INDICATES THE BREAK WAS NOT RECENT. FITTING DAMAGE BEYOND USE. STRAP ALTHOUGH DUE RETIREMENT HAS NO SIGNIFICANT DAMAGE. PIN WAS MISSING TWO WASHERS P/N AN816L AND SEALANT ON THE ENDS . PIN HAS A LIFE LIMIT OF 2400 HOURS. 1 G 7 1 4U EXPA1G71 2006060700001 20060607 00001 2006 6 7 AU510001434 4 20050906 G 3417 4040831901 SENSOR HONEYWELL DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE DADC OUT OF LIMITS W K NONE O OTHER IN INSP/MAINT 1 AU S 94096350 (AUS) DIGITAL AIR DATA COMPUTER (DADC) PS AND PT SENSORS OUT OF TOLERANCE.(AD/SB DESC: AD/RAD/43 AMDT 5, PART 1 ) (OTHER CAUSE: CALIBRATION SHIFT ) (CASA# 510001434) 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006060700003 20060607 00003 CE 2006 6 7 AU510001435 1 20050206 G 5740 24300259 FITTING BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO MCAULY 3AF34C 3AF34C502 GL WING SPAR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 12224 (AUS) UPPER LH REAR SPAR FITTING CRACKED. (OTHER CAUSE: MATERIAL ) (CASA# 510001435) 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 2006060700005 20060607 00005 NM 2006 6 7 AU510001436 1 20050906 G 2170 23404061 WATER SEPARATOR BOEING 737 737800* NM GE CFM56 CFM567B24 NE CABIN CLIMATE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AIR CONDITIONING SYSTEM FORWARD WATER SEPARATOR CRACKED ALONG INBOARD WELDED SEAM. CRACK LENGTH APPROXIMATELY 50.8 MM (2IN).(OTHER CAUSE: CRACKED ALONG THE WELDED SEAM ) (CASA# 510001436) 2 L 7 2 4F 4 F RT A16WE E00055EN 2006060700006 20060607 00006 NM 2006 6 7 AU510001437 1 20050906 G 3097 TERMINAL DHAV DHC8 DHC8103 1386005 NM PWA PW121 PW121 52124 NE HAMSTD 14SF 14SF7 NE WINDSHIELD LOOSE W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) LT FRONT WINDSHIELD ANTI-ICE SYSTEM TERMINAL L1 LOOSE AND SHOWING SIGNS OF OVERHEATING. (OTHER CAUSE: VIBRATION ) (CASA# 510001437) 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006060700009 20060607 00009 EU 2006 6 7 AU510001438 1 20050806 G 2422 M401D4F003 RELAY FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE INVERTER FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) EMERGENCY INVERTER SYSTEM TRANSFER RELAY FAILED.(OTHER CAUSE: MATERIAL ) (CASA# 510001438) 2 L 7 2 4F 4 F RT E25NE 2006060700013 20060607 00013 2006 6 7 AU510001439 4 20051212 G 2350 63333007 MICROPHONE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE COCKPIT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HAND MICROPHONE SWITCH STICKING.(OTHER CAUSE: STICKY SWITCH - MATERIAL ) (CASA# 510001439) 2 L 7 2 4F 4 F RT E25NE 2006060700017 20060607 00017 CE 2006 6 7 AU510001440 1 20050706 G 3230 SM50D7 RELAY BEECH 58 58 1152740 CE CONT O550 IO550* SO MCAULY 3AF32C 3AF32C512 GL DYNAMIC RELAY FAILED W O OTHER O OTHER DE DESCENT 1 AU S 592 (AUS) LANDING GEAR RETRACTION SYSTEM DYNAMIC RELAY FAULTY.(OTHER CAUSE: HIGH HOURS ) (CASA# 510001440) 1 L 7 2 3O 3 O 3A16 E3SO 5 C P22EA 2006060700019 20060607 00019 2006 6 7 AU510001441 4 20050506 G 2310 ANTENNA REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL HF SYSTEM FAILED W O OTHER D INFLIGHT SEPARATION CR CRUISE 1 AU S (AUS) NR 2 HF ANTENNA BROKE AT EMPENNAGE ATTACHMENT POINT. 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2006060700021 20060607 00021 WP 2006 6 7 AU510001442 1 20050606 G 7820 C16932 MUFFLER ROBSIN R44 R44 7640120 WP LYC O540 IO540AE1A5 41530 NE EXHAUST UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MUFFLER ASSEMBLY DEFORMED AROUND EXHAUST PIPE.(OTHER CAUSE: MATERIAL - POSS CHANGE IN MATL. THICKNESS ) (CASA# 510 001442) 1 G 7 1 3O 3 O H11NM 1E4 2006060700024 20060607 00024 CE 2006 6 7 AU510001443 1 20051212 G 5753 SKIN CESSNA 182 182D 2072710 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL TE FLAP CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LH AND RH WING FLAP SKINS CRACKED. WHEN THE SKINS WERE REMOVED FOR REPLACEMENT, INTERNAL CORROSION WAS ALSO FOUND. (OTHER CAUSE: AGE ) (CASA# 510001443) 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 2006060700028 20060607 00028 SO 2006 6 7 AU510001444 1 20051006 G 7922 53E22144A BYPASS VALVE PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA ENGINE OIL TEMP DISINTEGRATED W K NONE O OTHER IN INSP/MAINT 1 AU S 138 (AUS) RH ENGINE OIL BYPASS VALVE (VERNATHERM) BREAKING UP IN AREA OF CIRCLIP RING. METAL CONTAMINATION OF OIL SYSTEM. (O THER CAUSE: MATERIAL ) (CASA# 510001444) 1 L 7 2 3O 3 O A20SO E14EA 2006060700031 20060607 00031 SW 2006 6 7 AU510001445 1 20050906 G 3213 2751501XX CYLINDER SWRNGN SA227 SA227* SW MLG FAILED W O OTHER O OTHER LD LANDING 1 AU S 17019 17019 (AUS) RH MAIN LANDING GEAR STRUT CYLINDER FAILED IN AREA OF LOWER YOKE/PISTON RETAINING RING GROOVE. STRUT COLLAPSED DUR ING LANDING. SEE ATTACHMENTS FOR PHOTOGRAPHS OF DEFECT. (OTHER CAUSE: UNKNOWN ) (CASA# 510001445) 2 L 7 2 4T RT A5SW 2006060700053 20060607 00053 NM 2006 6 7 AU510001446 1 20051206 G 3610 RING BOEING 737 737800* NM GE CFM56 CFM567B24 NE NR 1 ENGINE DISLODGED W C ABORTED TAKEOFF R J PARTIAL RPM/PWR LOSS WARNING INDICATION TO TAKEOFF 1 AU S (AUS) NR 1 ENGINE BLEED AIR SYSTEM HIGH STAGE VALVE GATE SEALING RING DISLODGED, PREVENTING VALVE FROM FULLY CLOSING. IN VESTIGATION FOUND THE HIGH STAGE VALVE BUTTERFLY PLATE SEALING RING CLIP FAILED ALLOWING THE SEALING RING TO JAM THE THE VALVE IN THE SLIGHTLY OPEN POSITION ALLOWING AIR TO BYPASS PLATE AND ACTIVATE OVERPRESSURE SWITCH WHEN THE ENGINE ACCEL LERATED. 2 L 7 2 4F 4 F RT A16WE E00055EN 2006060700054 20060607 00054 SO 2006 6 7 AU510001447 2 20051212 G 8520 655961 BOLT CESSNA 404 404 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL ENGINE BROKEN W O OTHER O OTHER TO TAKEOFF 1 AU S 288 288 (AUS) ENGINE INTERNAL DAMAGE. SUSPECT CAUSED BY FAILURE OF NR 5 CONNECTING ROD BOLT OR CONNECTING ROD. INVESTIGATION CON TINUING. 1 L 7 2 3O 3 O RT A25CE E7CE 5 C P45GL 2006060700056 20060607 00056 CE 2006 6 7 AU510001448 1 20051212 G 5751 4019008 SPAR PIPER PA23 PA23150 7102303 CE LYC O540 TIO540J2BD 41532 EA AILERONS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 14635 (AUS) LT AILERON SPAR AND DOUBLER LOCATED BEHIND THE HINGE ATTACHMENT AND CONTROL INPUT HINGE CRACKED IN TWO PLACES. SPA R HAD BEEN PREVIOUSLY REPAIRED. SUSPECT REPAIR WAS POORLY DESIGNED AND NOT STRONG ENOUGH. AILERON HAD BEEN REMOVED FOR A BEARING REPLACEMENT. (AD/SB DESC: AD/PA31/118 ) (OTHER CAUSE: HIGH HOURS - DEFICIENT REPAIR ) (CASA# 510001448) 1 L 7 2 3O 3 O RT 1A10 E14EA 2006060700057 20060607 00057 SO 2006 6 7 AU510001449 1 20050605 G 3230 40336000 LINK PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NOSE LANDING GEAR DOWN LINK CRACKED. FOUND DURING INSPECTION IAW PIPER SL 1088. (AD/SB DESC: PIPER SL 1088 ) (OTHE R CAUSE: MATERIAL - AGE - HIGH HOURS ) (CASA 510001449) 1 L 7 2 3O 3 O A20SO E14EA 2006060700058 20060607 00058 EU 2006 6 7 AU510001450 1 20050406 G 2120 ODOR REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL CABIN DETECTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) ELECTRICAL BURNING ODOR IN CABIN. INVESTIGATION CONTINUING. (OTHER CAUSE: PENDING FINAL REPORT ) (CASA 510001450) 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2006060700060 20060607 00060 SO 2006 6 7 AU510001451 1 20051212 G 7110 SCREW LYC PIPER PA28 PA28RT201 7102818 SO LYC O360 IO360C1C 41514 EA MCAULY 2D34C B2D34C213 GL COWLING BROKEN W O OTHER P NO WARNING INDICATION DE DESCENT 1 AU S (AUS) ENGINE COWL SUPPORT BRACKET ATTACHMENT SCREW BROKEN ALLOWING SUPPORT BRACKET TO INTERFERE WITH THE NOSE LANDING GE AR DOWN MICROSWITCH STRIKER PLATE.(OTHER CAUSE: MATERIAL ) (CASA# 510001451) 1 L 7 1 3O 3 O 2A13 1E10 5 C P7EA 2006060700062 20060607 00062 SO 2006 6 7 AU510001452 1 20050606 G 3230 4033600 LINK PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NOSE LANDING GEAR LINK ASSEMBLY CRACKED IN LUG AREA. FOUND DURING INSPECTION IAW PIPER SL 1088. (AD/SB DESC: PIPER SL1088 ) (OTHER CAUSE: HIGH HOURS ) (CASA# 510001452) 1 L 7 2 3O 3 O A20SO E14EA 2006060700063 20060607 00063 NE 2006 6 7 AU510001454 2 20050406 G 7210 PT6T3B6 GEARBOX BELL 212 212 1181420 SW PWA PT6T PT6T3B 52045 NE COMBINING MAKING METAL W K NONE O OTHER IN INSP/MAINT 1 AU S 9000 2249 (AUS) COMBINING GEARBOX METAL CONTAMINATION. (CASA# 510001454) 1 G 7 1 4U 4 U H4SW E22EA 2006060700066 20060607 00066 NM 2006 6 7 AU510001455 1 20051212 G 2170 M01AC0101091 SEAL BOEING 747 747438 NM MOTOR FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S 27618 9683 0 (AUS) SMOKE ODOR ON FLIGHT DECK. ODOR DISAPPEARED WHEN THE HUMIDIFIER WAS TURNED OFF. WORKSHOP INVESTIGATION FOUND THAT BOTH BALL BEARINGS IN THE HUMIDIFIER ELECTRIC MOTOR ASSEMBLY PNO M01AB0101-101 HAD COLLAPSED. THIS RESULTED IN THE MOTOR ROTOR RUBBING ONTO THE MOTOR STATOR LEADING TO THE HEATING UP OF THE WINDINGS RESULTING IN THE ODOR. THE CAUSE OF THE C OLLAPSED BEARINGS HAS BEEN ATTRIBUTED TO A FAULTY ROTATING LIP SEAL PNO M01AC0101-091 WHICH ALLOWED THE INGRESS OF WATER INTO THE UPPER AND LOWER BEARING LOCATION. SEE ATTACHMENT FOR INVESTIGATION DETAILS.(OTHER CAUSE: MATERIAL ) (CASA# 510 001455) 2 L 7 4 4F RT A20WE 2006060700069 20060607 00069 NM 2006 6 7 AU510001456 1 20051212 G 2710 550030017 ACTUATOR BOEING 737 737300 1384610 NM AILERONS FAILED W O OTHER F FLT CONT AFFECTED CR CRUISE 1 AU S (AUS) RT OUTBOARD AILERON LOCKOUT ACTUATOR FAILED IN PARTLY EXTENDED POSITION. WORKSHOP INVESTIGATION OF THE ACTUATOR FO UND INTERNAL CORROSION. SEE ATTACHMENT FOR INVESTIGATION DETAILS. (OTHER CAUSE: MATERIAL - AGE - ENVIRONMENT ) (CASA# 51 0001456) 2 L 7 2 4F RT A16WE 2006060700070 20060607 00070 2006 6 7 AU510001457 4 20051006 G 2216 AR6460M2 SERVO BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU AUTOPILOT TRIM FAILED W O OTHER F FLT CONT AFFECTED CL CLIMB 1 AU S 50690 14046 (AUS) AUTOPILOT STABILISER TRIM SERVO FAILED. WORKSHOP INVESTIGATION FOUND ROTOR GEAR STRIPPED AND ROTOR BEARING JOURNAL WORN. (OTHER CAUSE: AGE ) (CASA# 510001457) 2 L 7 2 4F 4 F RT A16WE E21EU 2006060700072 20060607 00072 CE 2006 6 7 AU510001458 1 20051212 G 5751 STRUCTURE BEECH BEECH 76 76 1153005 CE AILERONS CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 12673 (AUS) LT AND RT AILERONS PNO 105-130000-1 (LT) AND PN 105-130000-2 (RT) SPARS AND DOUBLER BRACKETS CRACKED AT PUSHROD SU PPORT BRACKETS. FLEET INSPECTION FOUND SIMILAR CRACKING ON FOUR OF SEVEN AIRCRAFT. (CASA# 510001458) 1 L 7 2 3O A29CE 2006060700074 20060607 00074 NM 2006 6 7 AU510001459 1 20050706 G 6310 A1902 DRIVE BELT ROBSIN R22 R22BETA 7640110 NM LYC O320 O320B2C 41508 EA ENG TO XMSN DISTORTED W C ABORTED TAKEOFF R PARTIAL RPM/PWR LOSS TO TAKEOFF 1 AU S 270 (AUS) ENGINE TO TRANSMISSION DRIVE SYSTEM `V` BELTS STRETCHED.(OTHER CAUSE: MATERIAL ) (CASA 510001459) 1 G 7 1 3O 3 O H10WE E274 2006060700076 20060607 00076 CE 2006 6 7 AU510001460 1 20051212 G 5751 SPAR BEECH 76 76 1153005 CE AILERON CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 10236 (AUS) LT AND RT AILERONS PNO 105-130000-1 (LT) AND PN 105-130000-2 (RT) SPARS AND DOUBLER BRACKETS CRACKED AT PUSHROD SU PPORT BRACKETS. (CASA# 510001460) 1 L 7 2 3O A29CE 2006060700077 20060607 00077 NM 2006 6 7 AU510001461 1 20051006 G 2910 651784961 LINE BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE HYDRAULIC SYS DAMAGED W O OTHER K FLUID LOSS CR CRUISE 1 AU S 54177 0 (AUS) HYDRAULIC PIPES PNO 65-17849-61 AND PNO 65-17849-4014 RUBBING TOGETHER CAUSING ONE PIPE TO BE HOLED. LOSS OF HYDRA ULIC FLUID. INVESTIGATION FOUND A FAILED `P` CLIP ON ONE OF THE PIPES WHICH ALLOWED THE PIPES TO RUB TOGETHER.(OTHER CAU SE: AGE ) (CASA# 510001461) 2 L 7 3 4F 4 F RT A3WE E2EA 2006060700078 20060607 00078 NM 2006 6 7 AU510001462 1 20051212 G 2120 ODOR BOEING 737 7377Q8 1384418 NM CABIN DETECTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS DE DESCENT 1 AU S (AUS) FAINT BURNING INSULATION ODOR. INVESTIGATIONS COULD FIND NO SOURCE OF THE ODOURS. (OTHER CAUSE: UNABLE TO FIND A NY FAULT ) (CASA 510001462) 2 L 7 2 4F RT A16WE 2006060800001 20060608 00001 WP 2006 6 8 AU510001463 2 20050206 G 7230 31020224 SHROUD SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL ENGINE DISLODGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE SECOND STAGE IMPELLER SHROUD MOVED FORWARD OPENING UP THE SECOND STAGE COMPRESSOR CLEARANCE AND DRAGGING TH E OUTER TRNSITION LINER PNO 3102102-3 ONTO THE REAR FACE OF THE SECOND STAGE IMPELLER PNO 893482-5 DAMAGING BOTH PARTS. (AD/SB DESC: PILOT REPORTED PROBLEM TO ENGINEERING ) (OTHER CAUSE: PROCESS MISSED DURING O/H OF THE PART ) (CASA# 510001 463) 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 2006060800002 20060608 00002 EU 2006 6 8 AU510001464 1 20050906 G 3200 201138002 PIN BAC 146 146100A 1500260 EU LYC ALF502 ALF502R5 41580 NE NLG INSTALLED W A UNSCHED LANDING W INADEQUATE Q C CL CLIMB 1 AU S (AUS) NOSE LANDING GEAR FAILED TO RETRACT. INVESTIGATION FOUND NLG PIN STILL INSTALLED. PERSONNEL/MAINTENANCE ERROR. (CA SA# 510001464) 2 H 7 4 4F 4 F RT A49EU E6NE 2006060800004 20060608 00004 NE 2006 6 8 AU510001465 2 20051212 G 7250 O-RING BOEING 737 737800* NM GE CFM56 CFM567B24 NE GASKET DETERIORATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ENGINE TURBINE REAR FRAME OIL COVER GASKET PNO 340-179-401-0 AND O-RING SEAL PNO 649-393-271-0 DETERIORATED AND LE AKING. SEE ATTACHMENT FOR INVESTIGATION DETAILS. (CASA# 510001465) 2 L 7 2 4F 4 F RT A16WE E00055EN 2006060800006 20060608 00006 NM 2006 6 8 AU510001466 1 20050706 G 2822 6098976 PUMP BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE FUEL BOOST FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 33465 24529 (AUS) NO4 MAIN FUEL BOOST PUMP FAILED RESISTANCE CHECK AS PER AD/B747/173. (CASA# 510001466) 2 L 7 4 4F 4 F RT A20WE E30NE 2006060800009 20060608 00009 2006 6 8 AU510001467 4 20051206 G 2210 6355B000103 ACTUATOR BOEING 737 737800* NM AUTOPILOT FAILED W O OTHER F FLT CONT AFFECTED CL CLIMB 1 AU S (AUS) AUTOPILOT STABILISER TRIM ACTUATOR MOTOR FAILED. (CASA# 510001467) 2 L 7 2 4F RT A16WE 2006060800011 20060608 00011 NM 2006 6 8 AU510001468 1 20051106 G 2742 AR7077M3 ACTUATOR BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU STAB FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 48216 9327 (AUS) STABILISER ELECTRIC TRIM ACTUATOR FAILED. CAUSED BY WORN AND STICKING CLUTCH. (OTHER CAUSE: STICKING CLUTCH PLATE S ) (CASA# 510001468) 2 L 7 2 4F 4 F RT A16WE E21EU 2006060800012 20060608 00012 CE 2006 6 8 AU510001469 1 20051212 G 5751 1051300001 BRACKET BEECH 76 76 1153005 CE AILERON CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 10554 (AUS) LH AND RH AILERONS PNO 105-130000-1 (LH) AND PNO 105-130000-2 (RH) SPARS AND DOUBLER BRACKETS CRACKED AT PUSHROD S UPPORT BRACKETS. (CASA# 510001469) 1 L 7 2 3O A29CE 2006060800013 20060608 00013 EU 2006 6 8 AU510001470 1 20051206 G 2780 CH251040 SOLENOID VALVE AIRBUS A330 A330* EU SLAT CONTROL SHORTED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RH SLAT SOLENOID (34CW) SHORT CIRCUITING TO CHASSIS. (OTHER CAUSE: MATERIAL ) (CASA# 510001470) 2 L 7 2 4F RT A46NM 2006060800015 20060608 00015 NM 2006 6 8 AU510001471 1 20051212 G 2897 WIRE HARNESS BOEING 747 747438 NM FUEL INDICATOR DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CENTRE WING TANK DAISY CHAIN HARNESS DAMAGED. HARNESS CONTAINED A SUBSTANTIAL GASH ON THE OUTER INSULATION AND INT O THE SHIELD. THE HARNESS HAD ALSO BEEN SHARPLY KINKED AND WEAKENED IN TWO OTHER LOCATIONS. SUSPECT HARNESS DAMAGED DURI NG PREVIOUS TANK ENTRY. (CASA# 510001471) 2 L 7 4 4F RT A20WE 2006060800018 20060608 00018 NM 2006 6 8 AU510001472 1 20051206 G 2613 WARNING SYSTEM BOEING 737 7377Q8 1384418 NM OVERHEAT FAULTY W O OTHER N FALSE WARNING TX TAXI/GRND HDL 1 AU S (AUS) LT WING TO BODY OVERHEAT LIGHT ILLUMINATED FOLLOWING NR 2 ENGINE START. INVESTIGATION FOUND CODE 10 (LOOP 1A SHORT ED) IN ALARM MEMORY. CODES CLEARED AND UNIT FUNCTIONED NORMALLY. (OTHER CAUSE: UNABLE TO ESTABLISH THE CAUSE ) (CASA# 51 0001472) 2 L 7 2 4F RT A16WE 2006060800020 20060608 00020 NM 2006 6 8 AU510001473 1 20051212 G 2613 M1761 DETECTOR BOEING 737 7377Q8 1384418 NM OVERHEAT FAULTY W K NONE N FALSE WARNING IN INSP/MAINT 1 AU S (AUS) NR 1 WING TO BODY OVERHEAT LIGHT ILLUMINATED. INVESTIGATION FOUND DETECTOR M1761. (OTHER CAUSE: NOT KNOWN AT THIS STAGE ) (CASA# 510001473) 2 L 7 2 4F RT A16WE 2006060800023 20060608 00023 2006 6 8 AU510001474 4 20051212 G 3421 40023344 LIGHT HONEYWELL INDICATOR OPEN W K NONE O OTHER IN INSP/MAINT 1 AU S 95068116 (AUS) ATTITUDE INDICATOR PANEL LAMPS ON BEZEL BLOWN. FOUND DURING INSPECTION IAW AD/RAD/043.(AD/SB DESC: AD/RAD/O43 ) (C ASA# 510001474) 2006060800026 20060608 00026 NE 2006 6 8 AU510001475 2 20051212 G 7230 6497823000 PIN GE BOEING 737 737800* NM GE CFM56 CFM567B24 NE COMPRESSOR LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) DURING FAN LUBE INSPECTION OF THE FAN HUB FOUR (4) FORWARD BOOSTER SPOOL PINS WERE FOUND TO BE VISIBLY LOOSE. AFTE R A TORQUE CHECK OF THE REMAINDER, A FURTHER FIVE (5) PINS WERE FOUND TO BE LOOSE. TOTAL NUMBER OF UNDERTORQUED PINS NIN E (9). (OTHER CAUSE: UNABLE TO ESTABLISH THE CAUSE ) (CASA 510001475) 2 L 7 2 4F 4 F RT A16WE E00055EN 2006060800029 20060608 00029 SW 2006 6 8 AU510001476 1 20050406 G 2910 27810322682 LINE SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE HYD SYSTEM WORN W O OTHER K FLUID LOSS CR CRUISE 1 AU S (AUS) LH ENGINE DRIVEN HYDRAULIC PUMP PRESSURE LINE CHAFED AND HOLED BY OIL TANK UNION. LOSS OF HYDRAULIC PRESSURE RESUL TED IN AN EMERGENCY LANDING. DUE TO NO HYDRAULIC PRESSURE, THE ANTISKID WAS NOT AVAILABLE AND THE BRAKES LOCKED UP. NO1, NO2 AND NO3 TYRES WERE FLATSPOTTED AND NO2 TYRE BLEW OUT. (CASA# 510001476) 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2006060800031 20060608 00031 EA 2006 6 8 AU510001477 2 20050106 G 8520 6930100 ELBOW PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA ENGINE OIL CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S L4382627A (AUS) RH ENGINE ACCESSORY CASE OIL INDICATOR PORT SCREW-IN ELBOW FAILED. SEE ATTACHMENT FOR PHOTOGRAPH OF FAILED ITEM. ( CASA# 510001477) 1 L 7 1 3O 3 O 2A13 E274 2006060800035 20060608 00035 NM 2006 6 8 AU510001478 1 20051212 G 3010 8510237002 BOOT DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE HORIZONTAL STAB DAMAGED W O OTHER O OTHER CL CLIMB 1 AU S 9271 (AUS) RT OUTER TAILPLANE RUDDER BOOT TORN AND LIFTING IN AREA LOCATED IN FRONT OF THE ELEVATOR HORN. (OTHER CAUSE: MATE RIAL - ENVIRONMENT ) (CASA# 510001478) 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006060800037 20060608 00037 2006 6 8 AU510001479 4 20051212 G 3413 INDICATOR REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL COCKPIT FAULTED W O OTHER O OTHER CL CLIMB 1 AU S (AUS) LH VERTICAL SPEED INDICATOR (VSI) NEEDLE FLUCTUATING. GROUND TEST COULD FIND NO FAULTS WITH THE SYSTEM. NO FURTHER REPORTS OF PROBLEMS. (OTHER CAUSE: UNKNOWN ) (CASA# 510001479) 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2006060800038 20060608 00038 EU 2006 6 8 AU510001480 1 20050405 G 2150 11341041 MOTOR REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL A/C PACK FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S 651 (AUS) REAR AIR CONDITIONING SYSTEM ELECTRIC MOTOR FAILED. (CASA# 510001480) 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2006060800040 20060608 00040 EU 2006 6 8 AU510001481 1 20051212 G 5753 3019 NIPPLE MENASCO FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE TE FLAPS MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S MC001 (AUS) FLAP BALL NUT GREASE NIPPLE MISSING.(OTHER CAUSE: UNKNOWN ) (CASA# 510001481) 2 L 7 2 4F 4 F RT E25NE 2006060800061 20060608 00061 CE 2006 6 8 AU510001482 1 20051212 G 5751 1051300002 SPAR BEECH 76 76 1153005 CE AILERON CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 9707 (AUS) RT AILERON UPPER DOUBLER AND SPAR CRACKED. CRACK LENGTHS 10MM (0.39IN) IN DOUBLER AND 5MM (0.196IN) IN SPAR. (CASA # 510001482) 1 L 7 2 3O A29CE 2006060800063 20060608 00063 GL 2006 6 8 AU510001483 3 20050906 G 6111 BLADE GIPPLD GA8 GA8 3900102 EU LYC O540 IO540K1A5 41532 EA HARTZL HCC2Y HCC2YR1 GL PROPELLER FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) PROPELLER BLADE TIP SEPARATED IN FLIGHT. APPROXIMATELY 228.6 (9IN) OF BLADE SEPARATED. SEVERE VIBRATION CAUSED ENG INE TO SEIZE DURING EMERGENCY LANDING. AIRCRAFT IS REGISTERED AND OPERATING IN CANADA. (CASA# 510001483) 1 H 7 1 3O 3 O NT 1E4 5 C P920 2006060800064 20060608 00064 NM 2006 6 8 AU510001484 1 20051212 G 2910 HYDRAULIC SYSTEM BOEING 737 737800* NM B SYSTEM LOW PRESSURE W O OTHER K FLUID LOSS CR CRUISE 1 AU S (AUS) HYDRAULIC B-SYSTEM LOW PRESSURE. INVESTIGATION CONTINUING. (CASA# 510001484) 2 L 7 2 4F RT A16WE 2006060800065 20060608 00065 NM 2006 6 8 AU510001485 1 20051212 G 2170 HUMIDIFIER BOEING 747 747400 NM CABIN CLIMATE FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) SMOKE ON FLIGHT DECK WHEN HUMIDIFIER ACTIVATED. SMOKE STOPPED WHEN HUMIDIFIER SWITCHED OFF. AIRCRAFT IS FOREIGN RE GISTERED. (OTHER CAUSE: UNKNOWN ) (CASA# 510001485) 2 L 7 4 4F RT A20WE 2006060800066 20060608 00066 SO 2006 6 8 AU510001486 2 20051212 G 8520 CRANKCASE CESSNA 210 T210L 2073449 CE CONT O520 TSIO520H 17040 SO MCAULY 2A34C E2A34C70 GL ENGINE DAMAGED W O OTHER R PARTIAL RPM/PWR LOSS CL CLIMB 1 AU S (AUS) CRANKCASE HOLED. LOSS OF POWER IN NR 4 AND NR 6 CYLINDERS. (CASA# 510001486) 1 H 7 1 3O 3 O 3A21 E8CE 5 C P3EA 2006060800067 20060608 00067 GL 2006 6 8 AU510001487 3 20051006 G 6111 BLADE CESSNA 208 208 2073702 CE PWA PT6 PT6A114 52043 NE MCAULY 3AF34C 3GFR34C703 GL PROPELLER CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 986 218 983124 (AUS) PROPELLER BLADE CRACKED SPANWISE ON THE LEADING EDGE APPROXIMATELY 140MM (5.5IN) FROM BLADE TIP. FURTHER INVESTIGA TION FOUND SEVERE INTERNAL EXFOLITAION CORROSION. THE SAME PROPELLER HAD A SIMILAR DEFECT APPROXIMATELY 50 HOURS PREVIOU S. (CASA# 510001487) 1 H 7 1 3T 3 T NT A37CE E4EA 5 C P60GL 2006060800074 20060608 00074 SO 2006 6 8 AU510001488 2 20051212 G 8530 AEC631397 CYLINDER CESSNA 206 U206F 2073333 CE CONT O550 IO550F 17042 SO ENGINE SEPARATED W A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 AU S 89 (AUS) ENGINE CYLINDER HEAD SEPARATED FROM BARREL. SUSPECT DEFECTIVE CASTING. (OTHER CAUSE: IT`S FAIRLY OBVIOUS THAT CAST ING WAS DEFECTIVE ) (CASA# 510001488) 1 H 7 1 3O 3 O A4CE E3SO 2006071900075 20060719 00075 SO 2006 7 19 AU510001489 2 20051212 G 8520 643503 BEARING CESSNA 404 404 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 1206 272465 (AUS) ENGINE METAL CONTAMINATION. WORKSHOP STRIP AND INVESTIGATION FOUND NR 2 AND NR 3 MAIN BEARINGS FAILED. BEARING SHE LLS BROKE UP CAUSING DAMAGE TO CRANKCASE AND SEVERE DAMAGE TO CRANKSHAFT WITH CRACKING ON JOURNALS. (CASA NR 510001489) 1 L 7 2 3O 3 O RT A25CE E7CE 5 C P45GL 2006071900076 20060719 00076 SW 2006 7 19 AU510001490 1 20051212 G 3310 271911583 PANEL SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL COCKPIT BURNED OUT W O OTHER B SMOKE/FUMES/ODORS/SPARKS DE DESCENT 1 AU S (AUS) NON-ESSENTIAL BUSS PANEL BACKLIGHTING SHORT CIRCUITED INTERNALLY DUE TO CORROSION CAUSED BY MOISTURE INGRESS. HEAT BUILDUP IN PANEL CAUSED OVERHEATING AND SMOKE IN COCKPIT. (CASA NR 510001490) 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 2006060700083 20060607 00083 SW 2006 6 7 AU510001491 1 20051212 G 5610 262113E19 WINDSHIELD SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL COCKPIT CRACKED W K NONE O OTHER DE DESCENT 1 CA LT WINDSHIELD SEVERELY CRACKED. RT WINDSHIELD SEVERELY DELAMINATED. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 2006060800076 20060608 00076 NM 2006 6 8 AU510001492 1 20051212 G 5330 SKIN BOEING 727 7272J4 1384006 NM PWA JT8 JT8D17 52049 NE BS 822 CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 0 CABIN WING CENTER SECTION UPPER SKIN PANEL CORRODED. PANEL IS LOCATED AT FS 822 RBL12. 2 L 7 3 4F 4 F RT A3WE E2EA 2006060800077 20060608 00077 NE 2006 6 8 AU510001493 2 20051212 G 7261 ENGINE BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3A NE OIL SYSTEM LOW PRESSURE W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S PCEPS114292 RT ENGINE LOST OIL PRESSURE. ENGINE SHUT DOWN WHEN OIL PRESSURE DROPPED TO 60 PSI. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2006060800079 20060608 00079 2006 6 8 AU510001494 4 20051212 G 2215 65000560059 ACTUATOR PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL AUTOPILOT FAULTY W O OTHER F FLT CONT AFFECTED CR CRUISE 1 AU S 39 AUTOPILOT PITCH ACTUATOR INCORRECT OPERATION. ACTUATOR HAD BEEN MODIFIED IAW HONEYWELL SB KSA372-M1 TO COMPLY WITH PILA TUS SB 22-004 AND AD/PC12/39A1. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2006060800080 20060608 00080 EU 2006 6 8 AU510001495 1 20051212 G 3234 643500100 SELECTOR BAG BAE146 BAE146300A 1500267 EU MLG FAILED W O OTHER O OTHER CL CLIMB 1 AU S LANDING GEAR SELECTOR LEVER WOULD NOT MOVE TO THE `UP` POSITION. 2 H 7 4 4F RT A49EU 2006060800081 20060608 00081 NM 2006 6 8 AU510001496 1 20051212 G 2781 189929 SENSOR BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU SLATS FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S NR 3 LEADING EDGE FLAP RETRACTION SENSOR FAULTY. 2 L 7 2 4F 4 F RT A16WE E21EU 2006060800082 20060608 00082 EU 2006 6 8 AU510001497 1 20051212 G 3213 201072013 STRUT FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE MLG FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S LT MAIN LANDING GEAR STRUT INTERNAL SLEEVE MIGRATED OUT OF POSITION AND BLOCKED BLEED PLUG HOLE, FOUND DURING INSPECTION IAW AD/F100/64. 2 L 7 2 4F 4 F RT E25NE 2006060800083 20060608 00083 EU 2006 6 8 AU510001498 1 20051212 G 3213 STRUT FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S RT MAIN LANDING GEAR STRUT BLEED PORT CRACKED, FOUND DURING INSPECTION IAW AD/F100/64. 2 L 7 2 4F 4 F RT E25NE 2006060800138 20060608 00138 NM 2006 6 8 AU510001499 1 20051212 G 2822 PUMP BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE FUEL BOOST CAVITATES W K NONE O OTHER IN INSP/MAINT 1 AU S CENTER FUEL TANK PUMPS CAVITATES. 2 L 7 2 4F 4 F RT A16WE E2GL 2006060800139 20060608 00139 NM 2006 6 8 AU510001500 1 20051212 G 5620 657676510 SEAL BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE WINDOW LEAKING W K NONE O OTHER IN INSP/MAINT 1 AU S FOUND CABIN WINDOW 15A INNER AND OUTER PANES TOUCHING AND FULL OF WATER. INVESTIGATION FOUND SEAL LEAKING. 2 L 7 2 4F 4 F RT A16WE E2GL 2006060800141 20060608 00141 NM 2006 6 8 AU510001501 1 20051212 G 2897 WIRE BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE FUEL SYSTEM DAMAGED W O OTHER O OTHER DE DESCENT 1 AU S NR 2 AFT FUEL PUMP LOW PRESSURE LIGHT ILLUMINATED AND CIRCUIT BREAKER TRIPPED. INVESTIGATION FOUND FUEL PUMP WIRING BAD LY BURNT AT EARTH PIG TAIL FERRULE. IT APPEARS THAT WHEN THE WIRING HARNESS WAS MANUFACTURED, ONE OR ALL THREE PHASE PO WER WIRES TO THE PUMP WERE CUT DURING THE CRIMP PREPARATION. WHEN THE EARTH PIG TAIL FERRULE FOR THE METAL SHEATH OVER THE TOP OF THE THREE PHASE WIRES WAS CRIMPED, IT PROVIDED A PATH TO SHORT THE THREE PHASE WIRES TO EARTH. SUSPECT MANUF ACTURING ERROR. 2 L 7 2 4F 4 F RT A16WE E2GL 2006060800142 20060608 00142 NM 2006 6 8 AU510001502 1 20051212 G 5320 145T252422 STRAP BOEING 767 767277 1385128 NM GE CF6 CF680A 30025 NE BULKHEAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 51129 11383 REAR SPAR BULKHEAD SIDE FITTING RT FAIL/SAFE STRAP CRACKED. STRAP IS LOCATED AT SECTION 45 STN 955. FOUND DURING INSPE CTION IAW AD/B767/201, BOEING ALERT SB 767-53A0100 AND AAES AD ER B76-53-10-39A. FURTHER INVESTIGATION ALSO FOUND CORRO SION ON THE RT LONGERON CHORD, PRESSURE DECK CLOSEOUT `T` FITTING. THE AIRCRAFT SKIN AND THE FACE OF THE FAIL/SAFE STRA P ABUTTING THE SKIN, TO ASSESS THE EXTENT OF CORROSION ON THE FACE OF THE FAIL/SAFE STRAP. THE RT WING REAR SPAR UPPER KICK FITTING WAS REMOVED. ON REMOVAL CORROSION WAS ALSO FOUND ON THE ABUTTING FACE OF THE KICK FITTING. 2 L 7 2 4F 4 F RT A1NM E13NE 2006061900174 20060619 00174 EA 2006 6 19 AU510001503 2 20050606 G 7310 6158124A LINE GULSTM 500 500S 0141107 SW LYC O540 IO540E1B5 41532 EA HARTZL HCC3Y HCC3YR2 NE FUEL SYS BROKEN W O OTHER J WARNING INDICATION CR CRUISE 1 AU S 252 (AUS) RT ENGINE NR 2 CYLINDER FUEL INJECTOR LINE BROKEN AT NIPPLE. (CASA NR 510001503). 1 H 7 2 3O 3 O 6A1 1E4 5 C P25EA 2006060800143 20060608 00143 SO 2006 6 8 AU510001504 1 20051212 G 5280 110272407 DOOR EMB 110 EMB110P1 3260122 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL MLG MISSING W O OTHER D INFLIGHT SEPARATION LD LANDING 1 AU S 22242 RT MAIN LANDING GEAR INBOARD DOOR MISSING. HINGES AND DOOR OPERATING RODS BROKEN. 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 2006060800146 20060608 00146 NM 2006 6 8 AU510001505 1 20051212 G 3810 288237 COMPRESSOR BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL POTABLE WATER OVERHEATED W K NONE M OVER TEMP IN INSP/MAINT 1 AU S 4178 4178 FUMES IN CABIN PRIOR TO BOARDING. INVESTIGATION FOUND POTABLE WATER COMPRESSOR EXTREMELY HOT. INVESTIGATION FOUND THAT ON REMOVAL OF THE CAPS AND COVER BOTH STAGES HAD WATER IN BELLOWS AND VALVES. THE SECOND STATE (HIGH-PRESSURE) REED WAS FRACTURED AT THE OUTPUT AND THE DRIVE SLIPS OFF THE CAMS. THE OVER-PRESSURE BALL VALVE WAS STAINED FROM WATER AND HAD MULTIPLE SET MARKS INDICATING THAT THE UNIT HAD BEEN OVER PRESSURIZED. THE MOTOR STATOR AND ROTOR WAS BURNT WHICH WOULD HAVE CAUSED THE BURNING SMELL IN THE CABIN. THE UNIT HAD INGESTED WATER AND WAS DAMAGED BEYOND ECONOMICAL REPAIR. 2 L 7 2 4F 4 F RT A1NM E23EA 2006060800333 20060608 00333 NM 2006 6 8 AU510001506 1 20050306 G 3520 PIN BOEING 767 767300 1385204 NM RROYCE RB211 RB211524* NE PAX OXYGEN MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S PASSENGER OXYGEN GENERATOR BAND CLAMP PIN LOCKS MISSING. 2 L 7 2 4F 4 F RT A1NM E12EU 2006060800338 20060608 00338 NM 2006 6 8 AU510001507 1 20051006 G 3610 2780539103 VALVE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL PNEUMATIC DIST FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 43664 7035 LT BLEED ISOLATION VALVE FAULTY. WORKSHOP INVESTIGATION FOUND THE FAILURE WAS DUE TO AN WORN AND INOPERATIVE MOTOR ASSE MBLY. 2 L 7 2 4F 4 F RT A1NM E23EA 2006060800339 20060608 00339 NM 2006 6 8 AU510001508 1 20051206 G 2822 5006003C PUMP BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL FUEL BOOST FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 61686 2132 RT FORWARD BOOST PUMP TRIPPED CIRCUIT BREAKER WHEN PUMP SWITCHED `ON`. INVESTIGATION FOUND THE BOOST PUMP FAILED. WORK SHOP INSPECTION FOUND THAT THE IMPELLER FINS HAD EXCESSIVE WEAR FROM RUBBING IN THE PUMP HOUSING. THE HOUSING ALSO HAD SEVERE EROSION ON THE STRUT AREAS AND EXCESSIVE WEAR IN THE IMPELLER BORE INSIDE DIAMETER. THE PUSH ROD, INSTALLED EXTE RNALLY, WAS ALSO FOUND TO BE BENT. 2 L 7 2 4F 4 F RT A1NM E23EA 2006060800340 20060608 00340 CE 2006 6 8 AU510001509 1 20051212 G 2721 1015240895 CABLE BEECH 200 200CBEECH 1152926 CE PWA PT6 PT642A NE RUDDER TAB FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 1020 RUDDER TAB CONTROL CABLE OVERRAN RUDDER TAB ACTUATOR CABLE DRUM. INVESTIGATION FOUND THE CABLE RIGGING WAS OUT OF ADJUS TMENT. 1 L 7 2 4T 4 T A24CE E4EA 2006060800373 20060608 00373 CE 2006 6 8 AU510001510 1 20051212 G 5415 10598000023 BRACKET BEECH 76 76 1153005 CE LYC O360 O360A1G 41514 EA RT NACELLE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S RT ENGINE FIREWALL BRACKET CRACKED ON BOTH SIDES OF ANCHOR NUT. FOUND DURING INSPECTION IAW AD/BEECH76/10-2. 1 L 7 2 3O 3 O A29CE E286 2006062100002 20060621 00002 NE 2006 6 21 AU510001511 2 20051212 G 8530 25717 MANIFOLD CVAC PBY6 PBY6ABABB 2421302 WP PWA R1830 R183092 52020 NE HAMSTD 23E 23E51 NE CYLINDER SEPARATED W O OTHER E VIBRATION/BUFFET DE DESCENT 1 AU S (AUS) RT ENGINE NR 9 CYLINDER INDUCTION MANIFOLD SEPARATED FROM CYLINDER AND WAS FOUND LAYING IN THE LOWER COWL FLAP ARE A. INVESTIGATION FOUND THE MANIFOLD ATTACHMENT NUT HAD BACKED OFF ALLOWING THE MANIFOLD TO PULL OUT OF THE CYLINDER AND REAR CASE. (CASA NR 510001511) 2 H 7 2 4R 4 R AR22 5E4 6 C P603 2006060800374 20060608 00374 EU 2006 6 8 AU510001512 1 20050106 G 7830 SOLENOID FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE THRUST REVERSER STICKING W K NONE O OTHER IN INSP/MAINT 1 AU S NR 2 ENGINE THRUST REVERSER SECONDARY LOCK SOLENOID BINDING IN LAST 2MM (0.078IN) OF TRAVEL. 2 L 7 2 4F 4 F RT E25NE 2006060800375 20060608 00375 2006 6 8 AU510001513 4 20050406 G 2210 TRIM SWITCH FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE AUTOPILOT SYS FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S NR 2 TRIM SWITCH FAULTY. 2 L 7 2 4F 4 F RT E25NE 2006060800376 20060608 00376 2006 6 8 AU510001514 4 20050106 G 3160 DISPLAY FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE COCKPIT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S MULTI FUNCTION DISPLAY UNIT (MFDU) FAULTY. 2 L 7 2 4F 4 F RT E25NE 2006060800377 20060608 00377 EU 2006 6 8 AU510001515 1 20050806 G 5330 SKIN FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE FUSELAGE LIGHTNING STRIKE W K NONE O OTHER IN INSP/MAINT 1 AU S 0 LIGHTNING STRIKE ON FUSELAGE WITH EXIT HOLE FOUND IN RT ELEVATOR TRAILING EDGE. 2 L 7 2 4F 4 F RT E25NE 2006060800378 20060608 00378 EU 2006 6 8 AU510001516 1 20050806 G 7830 RELAY FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE THRUST REVERSER FAULTY W O OTHER O OTHER LD LANDING 1 AU S NR 2 THRUST REVERSER RELAY FAULTY. 2 L 7 2 4F 4 F RT E25NE 2006061300048 20060613 00048 EU 2006 6 13 AU510001517 1 20050806 G 3260 858202 PSEU FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S PROXIMITY SYSTEM ELECTRONIC UNIT (PSEU) INTERMITTENT OPERATION. 2 L 7 2 4F 4 F RT E25NE 2006061300049 20060613 00049 2006 6 13 AU510001518 4 20051106 G 2211 COMPUTER FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE AUTOPILOT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S AUTOPILOT COMPUTER INTERMITTENT FAULT. 2 L 7 2 4F 4 F RT E25NE 2006061300052 20060613 00052 NM 2006 6 13 AU510001519 1 20051212 G 5310 DOOR FRAME BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 54209 NR 3 CARGO DOOR LOWER FORWARD FRAME RADIUS AND `T` FRAME CRACKED THROUGH THREE FASTENER HOLES. FOUND DURING INSPECTION IAW SB 727-52-0149. 2 L 7 3 4F 4 F RT A3WE E2EA 2006061300054 20060613 00054 CE 2006 6 13 AU510001520 1 20051212 G 2612 356043255 WIRE LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE731* 01518 WP FIRE DECTECTOR UNSERVICEABLE W K NONE N FALSE WARNING IN INSP/MAINT 1 AU S E36 FIRE WIRE ELEMENT LOCATED IN FORWARD WING TO FUSELAGE AREA UNSERVICEABLE. NO PHYSICAL DAMAGE COULD BE FOUND. 2 L 7 2 4F 4 F RT T00008WI E6WE 2006061300055 20060613 00055 EU 2006 6 13 AU510001521 1 20051212 G 4940 CH34313 IGNITER FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE APU FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S APU IGNITER PLUG FAILED. WORKSHOP INVESTIGATION FOUND THAT ONLY APPARENT FAULT WAS SLIGHT SOILING ON THE CERAMIC INSIDE OF THE CONNECTOR END OF THE IGNITER. THERE WAS NO OBVIOUS SIGN OF ARCING ACROSS THE CERAMIC SURFACE. WHEN THE IGNITER WAS CLEANED, THERE WAS NO OTHER SIGNS OF A DEFECT. THE IGNITER WAS CONNECTED TO THE LEAD ON AN OPERATIONAL APU AND RUN THROUGH THE START CYCLE WITH THE APU FUEL TURNED OFF. THE IGNITER FIRED CORRECTLY AND WITHOUT ANY SIGN OF FAILURE FOR T HE ENTIRE CYCLE. 2 L 7 2 4F 4 F RT E25NE 2006061300225 20060613 00225 EU 2006 6 13 AU510001522 1 20051212 G 5270 893301 PROXIMITY SENSOR AIRBUS A330 A330* EU GE CF6 CF680 30025 NE CARGO DOOR FALSE INDICATION W O OTHER N FALSE WARNING CL CLIMB 1 AU S AFT CARGO DOOR OPEN INDICATION. INSPECTION FOUND THE DOOR SECURE. SUSPECT FAULTY SENSOR. 2 L 7 2 4F 4 F RT A46NM E13NE 2006061300264 20060613 00264 NM 2006 6 13 AU510001523 1 20051212 G 2913 21830 BEARING BOEING 737 7377Q8 1384418 NM GE CFM56 CFM56* 13802 NE HYDRAULIC PUMP FAILED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S 13168 0 HYDRAULIC SYSTEM `A` ELECTRIC PUMP FAILED. INVESTIGATION FOUND THE FAILURE WAS CAUSED BY FAILURE OF THE PRE-MOD SB 5718 6-29-291 TRUNNION NEEDLE BEARING. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061300265 20060613 00265 NM 2006 6 13 AU510001524 1 20051212 G 2424 948F4583 GCU BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU AC SYSTEM FAILED W K NONE H ELECT. POWER LOSS-50 PC IN INSP/MAINT 1 AU S 53507 5861 NR 1 GENERATOR CONTROL UNIT (GCU) FAILED. 2 L 7 2 4F 4 F RT A16WE E21EU 2006061300266 20060613 00266 NE 2006 6 13 AU510001525 2 20051212 G 7320 1853M56P09 HMU BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE NR 1 ENGINE FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 6798 NR 1 ENGINE HYDROMECHANICAL UNIT (HMU) FAULTY. INVESTIGATION FOUND THE DEFECT WAS CAUSED BY FAILURE OF THE FMV RESOLVER BODY ASSEMBLY. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061300267 20060613 00267 NM 2006 6 13 AU510001526 1 20051212 G 3246 101376 WHEEL BFGOODRICH BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S MAIN WHEEL INNER HUB CRACKED APPROXIMATELY 35MM (1.377IN) BELOW THE MATING FACE AND EXTENDING THROUGH TO THE OUTSIDE OF THE HUB AT THE TIE BOLT HOLE SEAT RADIUS. CRACK LENGTH 18MM (0.708IN). CRACK IS LOCATED OUTSIDE OF AREAS LAID DOWN IN THE MAINTENANCE MANUAL. FOUND USING EDDY CURRENT INSPECTION. 2 L 7 3 4F 4 F RT A3WE E2EA 2006061300269 20060613 00269 NM 2006 6 13 AU510001527 1 20051212 G 5312 PRESSURE PANEL BOEING 727 7272J4 1384006 NM PWA JT8 JT8D17 52049 NE FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 0 FUSELAGE STRUCTURE PRESSURE WEB CORRODED. WEB IS LOCATED AT FS 46 IN THE MAIN LANDING GEAR WHEEL WELL. 2 L 7 3 4F 4 F RT A3WE E2EA 2006061300270 20060613 00270 NM 2006 6 13 AU510001528 1 20051212 G 5330 BEAR STRAP BOEING 727 7272J4 1384006 NM PWA JT8 JT8D17 52049 NE NR 3 CARGO DOOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 0 NR 3 CARGO DOOR BEAR STRAP INNER SURFACE CORRODED. 2 L 7 3 4F 4 F RT A3WE E2EA 2006061300271 20060613 00271 CE 2006 6 13 AU510001529 1 20050906 G 3260 UPLOCK SWITCH CESSNA 404 404 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL MLG DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 417 LT MAIN LANDING GEAR MICROSWITCH DAMAGED INTERNALLY. 1 L 7 2 3O 3 O RT A25CE E7CE 5 C P45GL 2006061300272 20060613 00272 CE 2006 6 13 AU510001530 1 20051212 G 3260 602EN556B UPLOCK SWITCH CESSNA CESSNA 404 404 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL MLG FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 14 LT MAIN LANDING GEAR UPLOCK MICROSWITCH FAULTY. 1 L 7 2 3O 3 O RT A25CE E7CE 5 C P45GL 2006061400100 20060614 00100 CE 2006 6 14 AU510001531 1 20051212 G 2150 4764HD COMPRESSOR CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL A/C PACK FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S CABIN AIRCONDITIONING COMPRESSOR FAILED. FLUID LEAKING FROM REAR CASE AND ALL COVER BOLTS LOOSE. REAR COVER WAS REMOVE D AND INTERNAL DAMAGE FOUND. SUSPECT DAMAGE CAUSED BY INCORRECT ROTATION OF COMPRESSOR DUE TO THIS MODEL OF COMPRESSOR NOT BEING MANUFACTURED TO ROTATE IN A COUNTERCLOCKWISE DIRECTION. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2006061400127 20060614 00127 EU 2006 6 14 AU510001532 1 20051212 G 5320 PLATE BAG JETSTM JETSTM3107 1500215 EU GARRTT TPE331 TPE33110U 01514 WP ROTOL R333 R333482F12 GL BS 223 CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 32241 PASSENGER CUTOUT INTERCOSTAL UPPER JOINT PLATE LOCATED AT FS 223 LT CRACKED. FOUND DURING INSPECTION IAW AD/JETSTREAM/9 8 AND SB51-JA030544 R1. 2 L 7 2 4T 4 T RT BA15CAA E4WE 6 C P61GL 2006061400128 20060614 00128 EU 2006 6 14 AU510001533 1 20050107 G 2760 A16160431 PUSHROD FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE SPOILER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S NR 1 RT INBOARD LIFT DUMPER BELLCRANK PUSHROD CRACKED IN TWO PLACES. 2 L 7 2 4F 4 F RT E25NE 2006061400130 20060614 00130 EU 2006 6 14 AU510001534 1 20051212 G 7797 CONNECTOR FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE ENGINE LOOSE W O OTHER N FALSE WARNING CR CRUISE 1 AU S ENGINE INDICATION SYSTEM PRESSURE BULKHEAD CONNECTOR P2874 LOOSE. 2 L 7 2 4F 4 F RT E25NE 2006061400132 20060614 00132 GL 2006 6 14 AU510001535 1 20051212 G 5740 ATTACH FITTING NAMER T6 T6G 6400432 GL PWA R1340 R1340AN1 52016 NE HAMSTD 12D 12D40 NE WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S EDDY CURRENT INSPECTION OF WING ATTACHMENT FITTINGS FOUND CRACK INDICATIONS. FURTHER TESTING USING FLUORESCENT PENETRAT ION FAILED TO DETECT THE CRACK. FOUND DURING INSPECTION IAW AD/AT-6/1. 1 L 7 1 3R 3 R A2575 5E2 5 C P257 2006061400136 20060614 00136 GL 2006 6 14 AU510001536 1 20051212 G 5740 ATTACH FITTING NAMER T6 AT6 6400402 GL FITTING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S EDDY CURRENT INSPECTION OF WING ATTACHMENT FITTINGS FOUND CRACK INDICATIONS. FURTHER TESTING USING FLUORESCENT PENETRAT ION FAILED TO DETECT THE CRACK. FOUND DURING INSPECTION IAW AD/AT-6/1. 1 L 7 1 3R A2575 2006061400137 20060614 00137 EU 2006 6 14 AU510001537 1 20051212 G 5270 893301 PROXIMITY SENSOR AIRBUS A330 A330* EU GE CF6 CF680 30025 NE CARGO DOOR FAULTY W O OTHER N FALSE WARNING CL CLIMB 1 AU S AFT CARGO DOOR WARNING. INVESTIGATION FOUND THE DOOR CLOSED AND LOCKING MECHANISM SERVICEABLE. SUSPECT CAUSED BY FAULT Y SENSOR. 2 L 7 2 4F 4 F RT A46NM E13NE 2006061400139 20060614 00139 2006 6 14 AU510001538 4 20051212 G 2310 5ARM3006LV3 TENSIONER CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL HF ANTENNA SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S HF ANTENNA SUPPORT AND TENSION UNIT SNAPPED AT ANTENNA CONNECTION TO VERTICAL STABILIZER. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2006061400141 20060614 00141 EA 2006 6 14 AU510001539 2 20050504 G 8530 LW12966 CYLINDER PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA ENGINE FAILED W O OTHER E VIBRATION/BUFFET CL CLIMB 1 AU S 1584 1584 L866461A RT ENGINE METAL CONTAMINATION. INSPECTION FOUND NR 3 CYLINDER AND PISTON DAMAGED. SUSPECT CAUSED BY DETONATION. 1 L 7 2 3O 3 O A20SO E14EA 2006061400144 20060614 00144 EU 2006 6 14 AU510001540 1 20051212 G 7332 1453PGCP115 PRESSURE SWITCH FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE ENGINE FUEL FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 0 RT ENGINE LP FUEL PRESSURE SWITCH FAULTY. 2 L 7 2 4F 4 F RT E25NE 2006061500029 20060615 00029 EU 2006 6 15 AU510001541 1 20050107 G 3260 TARGET FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE MLG DEBONDED W K NONE O OTHER IN INSP/MAINT 1 AU S RT MLG LWR TOGGLE TARGET PARTIALLY DISBONDED. LANDING GEAR WAS BEING FITTED TO A/C AFTER BEING IN STORAGE FOR SEVERAL Y EARS. 2 L 7 2 4F 4 F RT E25NE 2006061500030 20060615 00030 2006 6 15 AU510001542 4 20050307 G 3140 6220847541 DISPLAY FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE MULTFUNCTION FAULTY W O OTHER O OTHER CR CRUISE 1 AU S MULTI FUNCTION DISPLAY UNIT (MFDU) SUSPECT FAULTY. 2 L 7 2 4F 4 F RT E25NE 2006061500031 20060615 00031 EU 2006 6 15 AU510001544 1 20050407 G 5610 D20543405 WINDSHIELD FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE WINDSHIELD CRACKED W O OTHER O OTHER CR CRUISE 1 AU S 4186 NR 1 WINDSHIELD CRACKED. CRACK ORIGINATES NEAR ELEMENT. 2 L 7 2 4F 4 F RT E25NE 2006061500032 20060615 00032 NM 2006 6 15 AU510001545 1 20050407 G 3020 65222723 DUCT BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE NR 2 ENGINE BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S NR 2 ENGINE INLET ANTI-ICE DUCT FLANGE COUPLING LIP FRACTURED AND SEPARATED. EVIDENCE OF A PRE-EXISTING CRACK. 2 L 7 3 4F 4 F RT A3WE E2EA 2006061500076 20060615 00076 2006 6 15 AU510001546 4 20050207 G 2310 RADIO BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE HF SYSTEM FAILED W O OTHER O OTHER CR CRUISE 1 AU S NR 2 HF RADIO NOT TRANSMITTING. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061500078 20060615 00078 2006 6 15 AU510001547 4 20050107 G 2220 AR6460M2 ACTUATOR BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU AUTOPILOT FAILED W O OTHER O OTHER CL CLIMB 1 AU S 45395 22270 AUTOPILOT STABILIZER TRIM ACTUATOR FAILED DUE TO STRIPPED ROTOR GEAR AND WORN ROTOR BEARING JOURNAL. 2 L 7 2 4F 4 F RT A16WE E21EU 2006061500079 20060615 00079 NM 2006 6 15 AU510001548 1 20050507 G 2913 21830 BEARING BOEING 737 7377Q8 1384418 NM GE CFM56 CFM56* 13802 NE HYDRAULIC PUMP FAILED W O OTHER K FLUID LOSS NR NOT REPORTED 1 AU S HYDRAULIC SYSTEM `B` NR 1 ELECTRIC HYDRAULIC PUMP FAILED. NIL PRESSURE AND METAL CONTAMINATION. INVESTIGATION FOUND TH E FAILURE WAS DUE TO FAILURE OF THE PRE-MOD SB 57186-29-291 TRUNNION NEEDLE BEARING P/N 21830. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061500081 20060615 00081 EU 2006 6 15 AU510001549 1 20050107 G 2760 FON62125R06K BEARING FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE SPOILERS WORN W K NONE O OTHER IN INSP/MAINT 1 AU S LIFT DUMPER ACTUATOR RODEND BEARING WORN. 2 L 7 2 4F 4 F RT E25NE 2006061500082 20060615 00082 NM 2006 6 15 AU510001550 1 20051212 G 5754 256T2800112 TORQUE TUBE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL LE SLAT CONTROL SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S INBOARD LEADING EDGE DRIVE SHAFT/TORQUE TUBE SHEARED. DRIVE SHAFT SHOWED SIGNS OF SEVERE CHAFING DAMAGE DUE TO WATER SU PPLY LINE AND ADJACENT CLAMP. TORQUE TUBE HAD BEEN WORN THROUGH BY MORE THAN 50 PERCENT OF THICKNESS PRIOR TO FAILURE D URING MAINTENANCE. 2 L 7 2 4F 4 F RT A1NM E23EA 2006061500205 20060615 00205 NM 2006 6 15 AU510001551 1 20051212 G 5100 SCREW BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL COVER MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S LT THRUST REVERSE LEVER COULD BE LIFTED WITH FORWARD THRUST LEVER OFF IDLE. THE THRUST LEVER TOP COVERS WERE REMOVED AN D IT WAS FOUND THAT THE AFT TWO FASTENERS OF THE LEFT THRUST LEVER BAULK RAIL INSTALLATION WERE MISSING. THIS ALLOWED T HE LEFT THRUST REVERSE SELECTION BY THE BAULK PIN ON THE LEFT LEVER PUSHING THE RAIL OUT OF THE WAY. WITH THE FORWARD T HRUST LEVER OFF IDLE, THE RAIL SHOULD HAVE STOPPED THE THRUST REVERSE LEVER FROM BEING LIFTED. 2 L 7 2 4F 4 F RT A1NM E23EA 2006061600110 20060616 00110 2006 6 16 AU510001552 4 20050307 G 2397 COUPLER BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU HF RADIO FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S NR 2 HF SYSTEM FAILED. NEW TRANSMITTER FITTED BUT PROBLEM REMAINED. SUSPECT FAULTY COUPLER. 2 L 7 2 4F 4 F RT A16WE E21EU 2006061600111 20060616 00111 NM 2006 6 16 AU510001553 1 20051212 G 2782 7321861001 ACTUATOR BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL LE FLAPS FAULTY W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 AU S LEADING EDGE SLAT DISAGEE MESSAGE. INVESTIGATION FOUND THAT THE INBOARD LEADING EDGE SLAT BYPASS VALVE ROTARY ACTUATOR WAS INTERMITTENT IN OPERATION. 2 L 7 2 4F 4 F RT A1NM E23EA 2006061600112 20060616 00112 NM 2006 6 16 AU510001554 1 20050207 G 3610 79275515 CONTROLLER BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL PNEUMATIC DIST FAILED W O OTHER J WARNING INDICATION CL CLIMB 1 AU S 24462 719 LT ENGINE PNEUMATIC SYSTEM PRESSURE REDUCING VALVE (PRC) CONTROLLER FAILED. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT A1NM E23EA 2006061600114 20060616 00114 GL 2006 6 16 AU510001555 2 20050207 G 7200 CF680C2B6 ENGINE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL RIGHT BIRD INGESTION W A UNSCHED LANDING C J F.O.D. WARNING INDICATION CL CLIMB 1 AU S RT ENGINE BIRDSTRIKE. THREE FAN BLADES DAMAGED BEYOND LIMITS LAID DOWN IN MAINTENANCE MANUAL. 2 L 7 2 4F 4 F RT A1NM E23EA 2006061600133 20060616 00133 2006 6 16 AU510001556 4 20050107 G 2562 ELP362D BEACON BOEING 747 747438 NM RROYCE RB211 RB211524* NE UNDERWATER LOCAT NO TEST W K NONE O OTHER IN INSP/MAINT 1 AU S UNDERWATER LOCATION BEACON (ULB) FAILED TEST IAW EI 744-023-0182R04 AND AD/REC/1. 2 L 7 4 4F 4 F RT A20WE E12EU 2006061600135 20060616 00135 NM 2006 6 16 AU510001557 1 20050607 G 5210 BACW10BP4CD BOLT BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE L1 DOOR DISLODGED W K NONE O OTHER IN INSP/MAINT 1 AU S DOOR L1 UPPER GATE STUCK IN LOCKED POSITION DUE TO LOWER ROD ASSEMBLY BOLT DISLODGED IN THE TORQUE BOX ASSEMBLY. SUSPEC T BOLT INSUFFICIENTLY TORQUED. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061600137 20060616 00137 NE 2006 6 16 AU510001558 2 20050507 G 7230 COMPRESSOR WHEEL BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE ENGINE WRONG PART W O OTHER E W VIBRATION/BUFFET INADEQUATE Q C CL CLIMB 1 AU S NR 2 ENGINE FAN BLADE PLATFORMS NR 1 AND NR 4 LOCATED OPPOSITE NR 13 AND NR 16 FAN BLADES WERE NOT CHANGED WHEN NR 13 AN D NR 16 FAN BLADE PLATFORMS WERE CHANGED AS DIRECTED BY SB CFM56-7B-0353. NR 13 AND NR 16 FAN BLADE PLATFORMS WERE CHAN GED TO P/N 340-001-814-0. NR 1 AND NR 4 PLATFORMS WERE P/N 340-001-809-0. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061600138 20060616 00138 CE 2006 6 16 AU510001559 1 20051212 G 3233 99101363 ACTUATOR CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP RT MLG FAULTY W O OTHER J WARNING INDICATION LD LANDING 1 AU S RT MAIN LANDING GEAR NIL DOWN INDICATION. 1 L 7 2 3T 4 T RT A28CE E4WE 2006061600139 20060616 00139 2006 6 16 AU510001560 4 20050507 G 3100 DISPLAY SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R390 R3904123F27 NE MFDU FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 AU S AVIONICS SMOKE WARNING AND HOT ODOR IN COCKPIT. AVIONICS MPU RERACKED. SMOKE DETECTOR REMOVED FOR CLEANING DURING MAIN TENANCE. MULTIPLE PRINTED CIRCUIT BOARDS REMOVED AND DUST DISTURBED DURING TAWS INSTALLATION. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P31NE 2006061600140 20060616 00140 NM 2006 6 16 AU510001561 1 20051212 G 3244 TIRE BOEING 747 747438 NM RROYCE RB211 RB211524* NE MLG FAILED W O OTHER D INFLIGHT SEPARATION CR CRUISE 1 AU S LT BODY GEAR NR 6 MAIN WHEEL TIRE TREAD SEPARATED. LOSS OF TIRE PRESSURE. 2 L 7 4 4F 4 F RT A20WE E12EU 2006061900259 20060619 00259 EU 2006 6 19 AU510001562 1 20051212 G 2700 LA2K2B100D80000 COMPUTER AIRBUS A330 A330* EU GE CF6 CF680 30025 NE FLT CONTROL FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 4913 4913 FLIGHT CONTROL PRIMARY COMPUTER (FCPC) FAILED. FCPC REMOVED AND SENT FOR TEST AND REPAIR. INVESTIGATION FOUND THE POWE R SUPPLY FAULTY. 2 L 7 2 4F 4 F RT A46NM E13NE 2006062100091 20060621 00091 NM 2006 6 21 AU510001563 1 20051212 G 2421 AM739515B IDG BOEING 767 767* NM GE CF6 CF680C2* GL AC FAILED W O OTHER H J ELECT. POWER LOSS-50 PC WARNING INDICATION CR CRUISE 1 AU S 28771 15314 (AUS) RT INTEGRATED DRIVE GENERATOR (IDG) FAILED. INVESTIGATION FOUND PUMP AND MOTOR ASSEMBLY CYLINDER BLOCKS WORN BEYO ND LIMITS AT VARIOUS PISTON AND SLIPPER BORES. NUMEROUS OTHER COMPONENTS ALSO SEVERELY WORN. SUSPECT CAUSED BY OIL CONTA MINATION. IDG SCAVENGE FILTER CONTAMINATED. SEE ATTACHMENT FOR INVESTIGATION DETAILS. (CASA NR 510001563) 2 L 7 2 4F 4 F RT A1NM E23EA 2006062100092 20060621 00092 NM 2006 6 21 AU510001564 1 20051212 G 5414 313U23162 PANEL BOEING 747 747* NM GE CF6 CF680C2* GL NR 2 NACELLE SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 2 ENGINE IB SAILBOAT FAIRING HYDRAULIC VALVE ACCESS PANEL MISSING. SUSPECT PANEL INCORRECTLY SECURED. IMPACT DA MAGE CAUSED TO LEADING EDGE OF LT HORIZONTAL STABILIZER. 2 L 7 4 4F 4 F RT A20WE E23EA 2006062100093 20060621 00093 NM 2006 6 21 AU510001565 1 20051212 G 2750 113T24015 ROD END BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL TE FLAPS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) IB AFT FLAP DEFLECTION CONTROL ROD PULLED OUT OF IB RODEND. INSPECTION FOUND RODEND BADLY CORRODED AND THREAD STRI PPED. 2 L 7 2 4F 4 F RT A1NM E23EA 2006062100094 20060621 00094 NM 2006 6 21 AU510001566 1 20051006 G 2530 137884E13 LIGHT BOEING 737 7377BX 13844D2 NM GE CFM56 CFM567B24 NE GALLEY ARCED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) REAR GALLEY POWER NR 2 INDICATOR LIGHT DAMAGED AND WIRES W315-61-16A AND W315-62-16N DAMAGED FROM ARCING. 2 L 7 2 4F 4 F RT A16WE E00055EN 2006062100095 20060621 00095 2006 6 21 AU510001567 4 20050707 G 3497 W6491001620 WIRE BOEING 737 737800* NM GE CFM56 CFM567B24 NE WX RADAR SYS SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WEATHER RADAR SYSTEM WIRES PN W6491-0016-20 AND PN W6491-0065-24 FOUND PULLED OUT OF TERMINAL BLOCK GD383. SUSPECT WIRES DISTURBED DURING AIRCRAFT MODIFICATION. SEE ATTACHMENT FOR INVESTIGATION DETAILS.(OTHER CAUSE: WIRES FOUND PULLED OUT OF TERMINAL BLOCK ) (CASA NR 510001567) 2 L 7 2 4F 4 F RT A16WE E00055EN 2006062100096 20060621 00096 2006 6 21 AU510001568 4 20050807 G 3100 40023344 LAMP HONEYWELL DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE INDICATOR FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 89105755 (AUS) PANEL LIGHTS FOR ATTITUDE INDICATOR BLOWN. (OTHER CAUSE: MATERIAL ) (CASA NR 510001568) 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006062100097 20060621 00097 2006 6 21 AU510001569 4 20050807 G 3442 6225132633 TRANSCEIVER BOEING 737 7377BX 13844D2 NM GE CFM56 CFM567B24 NE WX RADAR SYS CONTAMINATED W O OTHER O OTHER CR CRUISE 1 AU S (AUS) WEATHER RADAR TRANSCEIVER CONTAMINATED WITH WATER FROM FORWARD TOILET HAND BASIN OVERFLOW. 2 L 7 2 4F 4 F RT A16WE E00055EN 2006062100099 20060621 00099 2006 6 21 AU510001570 4 20050606 G 2340 285A178010 CONTROLLER BOEING 737 737* NM GE CFM56 CFM567B24 NE INTERPHONE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FLIGHT ATTENDANT HANDSET CONTROLLER FAILED. (CASA NR 510001570) 2 L 7 2 4F 4 F RT A16WE E00055EN 2006062200072 20060622 00072 2006 6 22 AU510001571 4 20050507 G 2565 D31591478 SLIDE BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 40151 88 DOOR L1 ESCAPE SLIDE PRESSURE OUTSIDE OF OPERATING RANGE. 2 L 7 2 4F 4 F RT A16WE E21EU 2006062200073 20060622 00073 SO 2006 6 22 AU510001572 2 20051212 G 8530 EXHAUST VALVE CESSNA 182 182P 2075816 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C201 GL NR 3 CYLINDER WORN W K NONE O OTHER IN INSP/MAINT 1 AU S NR 3 CYLINDER EXHAUST VALVE STEM WORN EXCESSIVELY. WEAR WAS APPROXIMATELY 3.175MM (0.125IN). SUSPECT INCORRECT VALVE G UIDE/VALVE COMBINATION. 1 H 7 1 3O 3 O NT TA13 E273 5 C P3EA 2006062200075 20060622 00075 NM 2006 6 22 AU510001573 1 20050707 G 2822 SWITCH BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE FUEL BOOST PUMP FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S CENTER FUEL TANK RT BOOST PUMP RUNNING WHEN SWITCH `OFF`. SUSPECT FUEL PANEL CONTROL SWITCH. 2 L 7 2 4F 4 F RT A16WE E2GL 2006062200076 20060622 00076 SW 2006 6 22 AU510001574 1 20051007 G 5711 SPAR SWRNGN SA227 SA227* SW GARRTT TPE331 TPE3312 01514 WP MCAULY 4HFR34 4HFR34C652 NE WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S WING SPAR INNER WEB CUTOUT CRACKED IN THREE PLACES. THREE CRACKS WERE FOUND IN THE STARBOARD INNER WEB STRINGER 13 CUTO UT MEASURING 12.7MM (0.5IN), 3.175MM (0.125IN) AND 9.525MM (0.375IN). FOUND DURING INSPECTION IAW AD/SWSA226/86. SEE A TTACHMENTS FOR FURTHER INFORMATION AND DIAGRAMS. 2 L 7 2 4T 3 T RT A5SW E3WE 6 C 3PNE 2006062200077 20060622 00077 2006 6 22 AU510001575 4 20051212 G 2215 7002260903 SERVO BEECH 200 B200C 1152924 CE PWA PT6 PT642A NE YAW DAMPER FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S RUDDER AUTOPILOT SERVO/YAW DAMPER FAULTY, OTHER CAUSE: FAILURE OF INTERNAL MECHANISM. 1 L 7 2 4T 4 T A24CE E4EA 2006062200079 20060622 00079 WP 2006 6 22 AU510001576 1 20051212 G 6230 A2041 ARM ROBSIN ROBSIN R22 R22 7640102 WP LYC O320 O320B2C 41508 EA SWASHPLATE WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 45 45 2825 MAIN ROTOR UPPER SCISSOR ARM WORN IN AREA OF SWASHPLATE BEARING ATTACHMENT. BOLT ALSO WORN. 1 G 7 1 3O 3 O H10WE E274 2006062700284 20060627 00284 SW 2006 6 27 AU510001577 1 20050806 G 6520 476452051 SHAFT BELL 47 47G3B1 1181028 SW LYC O435 TVO435B1A 41516 EA TAIL ROTOR WRONG PART W K NONE O OTHER IN INSP/MAINT 1 AU S 1200 TAIL ROTOR GEARBOX PINION SHAFT WORN AND INCORRECT PART. BELL 47 SI 428 CALLED FOR REPLACEMENT OF P/N 47-645-205-1 WITH P/N 47-645-205-3 SHAFT. 1 G 7 1 3O 3 O 2H3 1E13 2006062300099 20060623 00099 CE 2006 6 23 AU510001578 1 20051212 G 8011 GEAR MHB6016 CESSNA 172 172N 2072434 CE LYC O360 O360A4M 41514 EA MCAULY 1B90 1B90* GL STATER BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 91 E122519 (AUS) ENGINE STARTER MOTOR DRIVE GEAR DISINTEGRATED DURING START. STARTER MOTOR FRONT HOUSING DAMAGED. (CASA NR 51000157 8) 1 H 7 1 3O 3 O NT 3A12 E286 5 N P842 2006062300100 20060623 00100 EU 2006 6 23 AU510001579 1 20051207 G 3610 3925308 SHUTOFF VALVE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE PNEUMATIC SYS FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 1535 (AUS) PNEUMATIC SYSTEM PRESSURE REGULATING SHUTOFF VALVE (PRSOV) FAULTY. (CASA NR 510001579) 2 L 7 2 4F 4 F RT E25NE 2006062300101 20060623 00101 CE 2006 6 23 AU510001580 1 20051207 G 5711 P1756021 FRAME BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO HARTZL HCJ3Y PHCJ3YF2 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 7099 (AUS) FUSELAGE FRAMES PN P1756-02/1 AND PN P1756-01/1 LOCATED IN WING FORWARD SPAR CARRY THROUGH SECTION CRACKED. FOUND DURING INSPECTION IAW AD. (CASA NR 510001580) 1 L 7 2 3O 3 O 3A16 E5CE 5 C P36EA 2006062300102 20060623 00102 EU 2006 6 23 AU510001581 1 20051212 G 2911 9603001291 ACCUMULATOR PILATS PC12 PC12 7090550 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL HYD SYSTEM LEAKING W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 AU S 10686 (AUS) HYDRAULIC ACCUMULATOR LEAKING.(OTHER CAUSE: HIGH CYCLES ) (CASA NR 510001581) 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2006062300103 20060623 00103 NM 2006 6 23 AU510001582 1 20050807 G 3244 TIRE BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE MLG LOW PRESSURE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 3 MAIN LANDING GEAR TIRE PRESSURE LOW. FOD FOUND IN TREAD. (OTHER CAUSE: MATERIAL - ENVIRONMENT ) (CASA NR 510 001582) 2 L 7 4 4F 4 F RT A20WE E30NE 2006062300133 20060623 00133 NM 2006 6 23 AU510001583 1 20050107 G 3397 WIRE HARNESS BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE LIGHTS SHORTED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LIGHTING WIRING SHORT CIRCUIT. INVESTIGATION FOUND DAMAGED INSULATION ON WIRE W4003-575-22R LOCATED ABOVE THE COPI LOT`S PFD. SEE ATTACHMENT FOR INVESTIGATION DETAILS. (CASA NR 510001583) 2 L 7 4 4F 4 F RT A20WE E30NE 2006062300134 20060623 00134 NM 2006 6 23 AU510001584 1 20050807 G 2497 WIRE BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU BURNED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WIRE LOCATED ON THE BACK OF PLUG D4001P LOCATED BEHIND THE E I RACK BURNED DUE TO CONTACT WITH TRAY DISCONNECT BRA CKET. (OTHER CAUSE: MATERIAL ) (CASA NR 510001584) 2 L 7 2 4F 4 F RT A16WE E21EU 2006062300191 20060623 00191 CE 2006 6 23 AU510001585 1 20051212 G 8011 6462382 STARTER CESSNA 206 U206F 2073333 CE CONT O550 IO550F 17042 SO MCAULY 3A32C D3A32C90 GL ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 515 515 (AUS) ENGINE STARTER MOTOR FAILED TO TURN OVER. INVESTIGATION FOUND A FAILED BRUSH SPRING JAMMED BETWEEN THE BRUSH AND C OMMUTATOR. (CASA NR 510001585) 1 H 7 1 3O 3 O A4CE E3SO 5 C P21EA 2006062300192 20060623 00192 NM 2006 6 23 AU510001586 1 20050307 G 2761 85770012003 ACTUATOR DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE LT SPOILER FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 15639 (AUS) LT IB ROLL SPOILER ACTUATOR FAILED. (CASA NR 510001586) 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006062300194 20060623 00194 2006 6 23 AU510001587 4 20051207 G 2211 6227476411 COMPUTER FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE AUTOPILOT FAULTY W O OTHER O OTHER CL CLIMB 1 AU S (AUS) AUTOPILOT COMPUTER SUSPECT FAULTY. (CASA NR 510001587) 2 L 7 2 4F 4 F RT E25NE 2006062300196 20060623 00196 2006 6 23 AU510001588 4 20051207 G 2565 D31841101 SLIDE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE RIGHT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT ESCAPE SLIDE FAILED TO DEPLOY CORRECTLY. FOLLOWING MANUAL OPERATION THE SLIDE INFLATED BUT WAS NOT CORRECTLY OR IENTATED TO THE DOOR OPENING. SUSPECT CAUSED BY FAULTY PACKING OF THE SLIDE AT THE LAST OVERHAUL. (CASA NR 510001588) 2 L 7 2 4F 4 F RT E25NE 2006062300197 20060623 00197 NE 2006 6 23 AU510001589 2 20051203 G 7261 WF331451 FILTER EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE ENGINE OIL UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 AU S 360 (AUS) ENGINE OIL FILTER BULGED OUT ON BOTTOM SURFACE. (CASA NR 510001589) 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 2006062300198 20060623 00198 SO 2006 6 23 AU510001590 1 20051107 G 2912 BOWL PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA HARTZL HCE2Y HCE2YR2 GL HYD SYS FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT HYDRAULIC FILTER BOWL FAILED ALLOWING LOSS OF FLUID TO THE LEVEL OF THE ENGINE DRIVEN PUMP STANDPIPE. (CASA N R 510001590) 1 L 7 2 3O 3 O A20SO E14EA 5 C P9EA 2006062300199 20060623 00199 2006 6 23 AU510001591 4 20051207 G 2340 9506747 CIRCUIT BOARD DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE INTERPHONE UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 AU S 1806 (AUS) PASSENGER SERVICE UNITS (PSU) FAULTY. INVESTIGATION FOUND PSU CONTROL CIRCUIT BOARDS HAD BEEN HEAT DAMAGED. INVES TIGATION INTO THE CAUSE OF THE CIRCUIT BOARDS DAMAGE REVEALED THAT THE WIRE ON THE OUTLET SIDE OF ALL OF THE PSU CONTROL CIRCUIT BOARDS HAD CHAFED INSULATION ALLOWING SHORT CIRCUIT TO GROUND. THIS UNCONTROLLED SHORT CIRCUIT RESULTED IN THE OUTLET TRANSISTOR BURNING OUT ON ALL PSU CONTROL CIRCUIT BOARDS.(CASA NR 510001591) 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006062300200 20060623 00200 NM 2006 6 23 AU510001592 1 20050907 G 2760 10AT3041 SWITCH BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL DRAG CONTROL SY FAULTY W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 AU S (AUS) SPOILER WARNING ON TAKEOFF. SUSPECT FAULTY POSITION SWITCH. (CASA NR510001592) 2 L 7 2 4F 4 F RT A1NM E23EA 2006062300201 20060623 00201 NM 2006 6 23 AU510001593 1 20051212 G 2133 7786863 SHUTOFF VALVE DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE LT BLEED SYS FAILED W O OTHER O OTHER CR CRUISE 1 AU S 9655 (AUS) LT BLEED AIR HIGH PRESSURE SHUTOFF VALVE (HPSOV) FAILED. (CASA NR 510001593) 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006070500046 20060705 00046 SO 2006 7 5 AU510001594 2 20051212 G 7310 560010960 LINE CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO MCAULY 3AF32C 3AF32C93 GL FUEL SYSTEM WORN W K NONE K J FLUID LOSS WARNING INDICATION IN INSP/MAINT 1 AU S (AUS) RT ENGINE FUEL SUPPLY LINE LOCATED BETWEEN FUEL BOWL AND NACELLE CHAFED THROUGH ON WING STRUCTURE LIGHTENING HOLE. FUEL LEAKING INTO WING. (CASA NR 510001594) 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 2006070300018 20060703 00018 NM 2006 7 3 AU510001595 1 20051207 G 3244 TIRE BOEING 747 747338 NM RROYCE RB211 RB211524* NE MLG DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S NR 3 REAR TIRE ASSEMBLY CONTAINED A DEEP CUT. INVESTIGATION FOUND CUT TO BE OUT OF LIMITS. 2 L 7 2 4F 4 F RT A20WE E12EU 2006070300019 20060703 00019 NM 2006 7 3 AU510001596 1 20051207 G 3097 CONNECTOR BOEING 747 747438 NM RROYCE RB211 RB211524* NE WINDOW HEAT LOOSE W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S CAPTAIN`S WINDOW HEAT BOTTOM LT CONNECTION LOOSE AND ARCING. 2 L 7 4 4F 4 F RT A20WE E12EU 2006070300020 20060703 00020 NM 2006 7 3 AU510001597 1 20051007 G 2530 BEARING BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL CHILLER FAN COLLAPSED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 AU S 30155 11929 NR 1 AFT GALLEY CHILLER FAULTY. WORKSHOP INVESTIGATION FOUND THE FAN BLOWER MOTOR BEARINGS COLLAPSED. 2 L 7 2 4F 4 F RT A1NM E23EA 2006070300021 20060703 00021 NM 2006 7 3 AU510001598 1 20051212 G 5312 STA18095 FRAME BOEING 767 767277 1385128 NM GE CF6 CF680A 30025 NE BULKHEAD CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S FUSELAGE-BODY STATION 1809.5 BULKHEAD RT FORWARD OUTER CHORD CRACKED IN LOWER FORWARD HOLE. FOUND DURING INSPECTION IAW AD/B767/146 AMDT2 AND AAES AD ER NO B76-53-36F. 2 L 7 2 4F 4 F RT A1NM E13NE 2006070300022 20060703 00022 NM 2006 7 3 AU510001599 1 20051212 G 3220 LANDING GEAR DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE NOSE LOCKED W O OTHER J WARNING INDICATION CL CLIMB 1 AU S NOSE LANDING GEAR FAILED TO RETRACT. INVESTIGATION FOUND THE LANDING GEAR GROUND LOCK STILL FITTED. GROUND LOCK HAD NO T BEEN STOWED FOLLOWING PUSHBACK. PERSONNEL/MAINTENANCE ERROR. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006070300023 20060703 00023 EU 2006 7 3 AU510001600 1 20050907 G 2823 HTE900212 VALVE AIRBUS A330 A330* EU GE CF6 CF680 30025 NE FUEL SELECTOR LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 8215 8215 LOW PRESSURE FUEL VALVE LEAKING. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT A46NM E13NE 2006070300024 20060703 00024 2006 7 3 AU510001601 4 20051107 G 2565 ASPIRATOR AIRBUS A330 A330* EU GE CF6 CF680 30025 NE ESCAPE SLIDE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S SLIDERAFT FAILED FLAT FIRE TEST. INSPECTION OF THE INFLATABLE ASSEMBLY FOUND THREE HOLES AND ONE INDENTATION COMMON TO THE LOWER INFLATION TUBE. THIS SLIDERAFT ASSEMBLY WAS FITTED WITH P/N 4A3791-3 PLASTIC PRESSURE RELIEF VALVES (PRV) ON BOTH THE UPPER AND LOWER TUBES, WHICH ACCOUNTED FOR LEAKAGE FAILURE OF THE UPPER TUBE. ADDITIONALLY, THE PN 5A3265-1 AS PIRATOR WAS FOUND TO BE SIGNIFICANTLY DISTORTED. INITIAL INDICATIONS SHOW THAT THE ASPIRATOR BODY TRACE LINE MATCHES TH E APPROXIMATE LOCATION OF THE HOLES. 2 L 7 2 4F 4 F RT A46NM E13NE 2006070300025 20060703 00025 NM 2006 7 3 AU510001602 1 20051007 G 3010 2780537104 ANTI-ICE VALVE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL RT WING FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S RT WING ANTI-ICE MESSAGE. THERMAL ANTI-ICE VALVE FAULTY. 2 L 7 2 4F 4 F RT A1NM E23EA 2006070300060 20060703 00060 NM 2006 7 3 AU510001603 1 20051212 G 5753 113T22036 SEAL BOEING 767 767300 1385204 NM RROYCE RB211 RB211524* NE TE FLAP FAILED W O OTHER D INFLIGHT SEPARATION TO TAKEOFF 1 AU S LT WING LT INBOARD FLAP OUTBOARD UPPER SEAL SEPARATED DURING TAKEOFF. 2 L 7 2 4F 4 F RT A1NM E12EU 2006070300101 20060703 00101 EA 2006 7 3 AU510001604 1 20050306 G 3110 PANEL DHAV DHC6 DHC6200 2802620 EA PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL INSTRUMENT PANEL MISMARKED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S NO LABELS ON DUAL RADIOS/INDICATORS AND ADVISORY LABELS AS REQUIRED BY ANO 108.34 SECTION 6.2. 1 H 7 2 3T 4 T RT A9EA E4EA 6 C P15EA 2006070300102 20060703 00102 EA 2006 7 3 AU510001605 1 20051107 G 2800 FUEL SYS DHAV DHC6 DHC6200 2802620 EA PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL FAULTY W O OTHER O OTHER CR CRUISE 1 AU S FUEL SYSTEM SUSPECT FAULTY. LIMITED INFORMATION PROVIDED. 1 H 7 2 3T 4 T RT A9EA E4EA 6 C P15EA 2006070300103 20060703 00103 EU 2006 7 3 AU510001606 2 20051212 G 7314 7086005 PUMP BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU ENGINE FUEL FAULTY W O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION NR NOT REPORTED 1 AU S 17788 17788 NR 2 ENGINE HAS A HISTORY OF STARTING DIFFICULTIES AND FLUCTUATING PARAMETERS. INVESTIGATION FOUND FUEL PUMP HAD NO FLO W AT LOW SPEED AND WAS WELL BELOW LIMIT OF FLOW AT HIGHER SPEED. THE PUMP GEARS WERE FOUND SCORED. THIS CAUSED DAMAGE TO THE BEARINGS AND THE `O` RING WHERE THE BEARINGS ARE SEATED IN THE HOUSING ALLOWING SOME FUEL TO BYPASS AND CAUSE LOW F UEL FLOW FROM THIS PUMP. 2 L 7 2 4F 4 F RT A16WE E21EU 2006070300104 20060703 00104 SO 2006 7 3 AU510001607 1 20050107 G 3210 LANDING GEAR PIPER PA32 PA32RT300 7103215 SO LYC O540 IO540K1G5 41532 EA HARTZL HCC2Y HCC2YK1 GL COLLAPSED W O OTHER O OTHER LD LANDING 1 AU S LT MAIN LANDING GEAR COLLAPSED. AIRCRAFT AND LANDING GEAR DAMAGED. 1 L 7 1 3O 3 O A3SO 1E4 5 C P920 2006070300105 20060703 00105 CE 2006 7 3 AU510001608 1 20051212 G 2820 520010785 LINE CESSNA 402 402C 207590R CE CONT O520 TSIO520VB 17040 SO MCAULY 3AF32C 3AF32C505 GL FUEL DIST CRACKED W O OTHER K FLUID LOSS CL CLIMB 1 AU S LINE LOCATED IN RT WING ROOT CRACKED. LIMITED INFORMATION PROVIDED. 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 2006070300106 20060703 00106 CE 2006 7 3 AU510001610 1 20050606 G 3220 LANDING GEAR BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO MCAULY 3AF34C 3AF34C502 GL NOSE OUT OF ADJUST W K NONE O OTHER IN INSP/MAINT 1 AU S NOSE LANDING GEAR RETRACTION SYSTEM MISRIGGED. NLG FAILED TO FULLY RETRACT INTO THE WHEEL WELL, LEAVING THE DOORS WIDE OPEN AND THE NOSEWHEEL HANGING OUT BY APPROXIMATELY 127MM TO 152.4MM (5IN TO 6IN). NLG WAS CORRECTLY RIGGED IN THE DOWN POSITION. 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 2006070300107 20060703 00107 CE 2006 7 3 AU510001611 1 20050606 G 3260 CAM BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO MCAULY 3AF34C 3AF34C502 GL WARNING SYS MISSING W K NONE P NO WARNING INDICATION IN INSP/MAINT 1 AU S LANDING GEAR WARNING HORN FAILED TO OPERATE WHEN THROTTLES CLOSED. INVESTIGATION FOUND NO SWITCHES, BRACKETS OR ROLLERS IN WARNING SYSTEM. LT ENGINE FCU WARNING SYSTEM ACTIVATING CAM MISSING. NO WIRING FITTED FORWARD OF THE FIREWALL. PE RSONNEL/MAINTENANCE ERROR. 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 2006070500085 20060705 00085 SO 2006 7 5 AU510001613 1 20050406 G 2710 AILERON PIPER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL AILERON SYSTEM FOD W K NONE O OTHER IN INSP/MAINT 1 AU S 317305070 (AUS) RAG LODGED BETWEEN LT OB AILERON BALANCE CABLE PULLEY AND CABLE LOCATED BELOW CABIN FLOOR. FOD. PERSONNEL/MAINTENA NCE ERROR. (CASA NR 510001613) 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2006070500086 20060705 00086 SO 2006 7 5 AU510001614 1 20050406 G 7810 AEA40111729801 TAILPIPE PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA HARTZL HCE3Y HCE3YR2 GL TURBOCHARGER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT ENGINE TURBOCHARGER TAILPIPE CRACKED FOR APPROX 90 PERCENT OF CIRCUMFERENCE. TAILPIPE ALSO CONTAINED 3 HOLES RA NGING IN DIAMETER FROM 12.7 MM TO 25.4MM (0.5IN TO 1IN). (CASA NR 510001614) 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2006070500087 20060705 00087 SO 2006 7 5 AU510001615 1 20050406 G 7120 MOUNT PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL ENGINE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT ENGINE IB UPPER ENGINE MOUNT BRACKET RIVETS (3OFF) SHEARED AND BRACKET SEPARATED FROM STRUCTURE BY APPROXIMATEL Y 3.175MM (0.125IN). CORROSION FOUND BETWEEN BRACKET AND AIRCRAFT STRUCTURE. (CASA NR 510001615) 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2006070500088 20060705 00088 SO 2006 7 5 AU510001616 1 20050406 G 3222 752731 PLUG PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NOSE LANDING GEAR AXLE PLUGS CRACKED DUE TO OVERTORQUING. AXLE BOLT BADLY CORRODED. (CASA NR 510001616) 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2006070500089 20060705 00089 SO 2006 7 5 AU510001617 1 20050406 G 7602 89307000 ROD END PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL MIXTURE CONTROL LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT ENGINE MIXTURE CONTROL RODEND LOOSE. BALL WAS ONLY RETAINED BY SECONDARY RETAINER CLIP. FINGER PRESSURE COULD D ISCONNECT RODEND FROM FCU. (CASA NR 510001617) 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2006070500090 20060705 00090 SO 2006 7 5 AU510001618 1 20050406 G 3211 RETAINER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL MLG LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT MAIN LANDING GEAR FORWARD TRUNNION BOLT RETAINER HAD 1 OF 2 RIVETS SHEARED ALLOWING TRUNNION BOLT TO PIVOT IN S PAR INSTEAD OF IN TRUNNION BUSH. (CASA NR 510001618) 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2006070500091 20060705 00091 CE 2006 7 5 AU510001619 1 20051212 G 2140 8259JR2 HEATER CESSNA 404 404 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL CABIN FAULTY W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 AU S (AUS) CABIN HEATER FAULTY. SMOKE IN CABIN. INVESTIGATION FOUND THE FORWARD VENT BLOWER INOPERATIVE DUE MOTOR BRUSH HANGU P. INSPECTION OF THE HEATER FOUND DISCOLORATION ON THE HEATER OUTER SHROUD. INTERNAL INSPECTION FOUND THE PAINT ON THE I NSIDE OF THE HEATER SHROUD HAD CAUGHT FIRE RESULTING IN THE SMOKE IN THE CABIN. DUCT OVERTEMP SWITCH ALSO TRIPPED. (CAS A NR 510001619) 1 L 7 2 3O 3 O RT A25CE E7CE 5 C P45GL 2006070500120 20060705 00120 SO 2006 7 5 AU510001620 1 20050406 G 3110 475109 SHOCK MOUNT PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA INSTRUMENT PANEL BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S PILOT`S INSTRUMENT PANEL ONLY SECURED BY TWO OF FOUR SHOCK MOUNTS. COPILOT`S PANEL HAD ALL FOUR SHOCK MOUNTS BROKEN. P ANEL WAS HELD IN PLACE BY PLUMBING AND WIRING. 1 L 7 2 3O 3 O A20SO E14EA 2006070500121 20060705 00121 SO 2006 7 5 AU510001621 1 20050406 G 3230 UPLOCK ROLLER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA LT & RT MLG SEIZED W K NONE O OTHER IN INSP/MAINT 1 AU S LT AND RT MAIN LANDING GEAR UPLOCK ROLLERS SEIZED. 1 L 7 2 3O 3 O A20SO E14EA 2006070500229 20060705 00229 EA 2006 7 5 AU510001622 2 20050406 G 8530 VALVE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL OUT OF LIMITS W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT AND RT ENGINES BOTH OVERDUE FOR 400 HOUR VALVE INSPECTION. NO RECORD OF INSPECTION BEING CARRIED OUT. (CASA NR 510001622) 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2006070500230 20060705 00230 SO 2006 7 5 AU510001623 1 20050406 G 2730 71056003 SPRING PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL ELEVATOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 476 (AUS) ELEVATOR DOWN SPRING SEVERELY CORRODED. (CASA NR 510001623) 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2006070500231 20060705 00231 SO 2006 7 5 AU510001625 1 20050406 G 5712 RIB PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL CENTER WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RIB LOCATED IN CENTER OF RT WHEEL WELL CRACKED. (CASA NR 510001625) 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2006070500232 20060705 00232 SO 2006 7 5 AU510001626 1 20050406 G 2823 CABLE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL FUEL SHUTOFF SEIZED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT FUEL SHUTOFF CABLE SEIZED. (CASA NR 510001626) 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2006070500233 20060705 00233 NM 2006 7 5 AU510001627 1 20051212 G 4920 SEAL BOEING 737 737800* NM GE CFM56 CFM567B24 NE APU LEAKING W O OTHER K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S P6537 (AUS) APU LEAKING OIL INTO AIR DUCTING. STRONG OIL SMELL IN COCKPIT. INVESTIGATION FOUND THE APU LOAD COMPRESSOR SEAL FA ILED AND LEAKING. SEE ATTACHMENT FOR INVESTIGATION DETAILS. (OTHER CAUSE: LOAD COMP SEAL LEAKAGE ) (CASA NR 510001627) 2 L 7 2 4F 4 F RT A16WE E00055EN 2006070500234 20060705 00234 CE 2006 7 5 AU510001628 1 20051212 G 5311 FRAME BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCD4N3 HCD4N3A GL FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 10743 (AUS) FUSELAGE FRAME LOCATED AT FS226.875 UNDER THE RT SEAT ROW CORRODED IN AREA BETWEEN 2 STRINGERS. CORROSION EXTENDED UP THE FRAME WEB. FOUND DURING INSPECTION IAW AD/B200/21 AMDT 11.(AD/SB DESC: AD/B200/21 AMDT 11 ) (CASA NR 510001628) 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2006070500235 20060705 00235 CE 2006 7 5 AU510001629 1 20051212 G 5320 RIVET BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCD4N3 HCD4N3A GL WINDSHIELD SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S 10713 (AUS) LT WINDSHIELD UPPER OB CORNER DOUBLER HAD 4 SHEARED RIVETS. FOUND DURING INSPECTION IAW AD/B200/21 AMDT 11.(AD/SB DESC: AD/B200/21 AMDT 11 ) (OTHER CAUSE: MATERIAL ) (CASA NR 510001629) 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2006071100142 20060711 00142 CE 2006 7 11 AU510001630 1 20051212 G 5314 KEELBEAM BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCD4N3 HCD4N3A GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 10743 KEEL WEB LOCATED IN NOSE WHEEL WELL CRACKED IN AREA OF AIR CONDITIONING PIPE P-CLAMP ATTACHMENT. FOUND DURING INSPECTIO N IAW AD/B200/21 AMDT 11. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2006071100143 20060711 00143 SO 2006 7 11 AU510001631 1 20051207 G 3310 484498 RESISTOR PIPER PIPER PA44 PA44180 7104402 SO LYC O360 O360E1A6 41514 EA HARTZL HCC2Y HCC2YR2 GL DIMMER BURNED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S 9407 INSTRUMENT PANEL LIGHTING DIMMER 22 OHM RESISTOR BURNED. 1 L 7 2 3O 3 O A19S0 E286 5 C P920 2006071100144 20060711 00144 CE 2006 7 11 AU510001632 1 20051212 G 5210 1295140591 CABLE BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3A NE PAX DOOR FAILED W O OTHER D INFLIGHT SEPARATION CR CRUISE 1 AU S 0 CABIN DOOR TOP FORWARD LATCHING CABLE SNAPPED ALLOWING TOP FORWARD LOCK TO UNLATCH. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2006071100145 20060711 00145 EA 2006 7 11 AU510001633 2 20050107 G 7310 LINE BEECH 76 76 1153005 CE LYC O360 O360A1G 41514 EA HARTZL HCM2Y HCM2YR GL FUEL SYSTEM CHAFED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S ENGINE FUEL LINE CHAFED AND WORN BY THROTTLE CABLE. LOSS OF APPROXIMATELY 5 GALLONS OF FUEL. THROTTLE CABLE HAD BEEN R ECENTLY REPLACED. 1 L 7 2 3O 3 O A29CE E286 5 C P43GL 2006071100146 20060711 00146 SO 2006 7 11 AU510001634 1 20050707 G 7713 193F0004D0330 HOSE PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA HARTZL HCE3Y HCE3YR2 GL RT ENGINE FRACTURED W O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 AU S 1007 RT ENGINE SUMP TO DIFFERENTIAL PRESSURE CONTROLLER FAILED. HOSE IS MANUFACTURED FROM 306 RUBBER AND IT IS SUSPECTED THA T THE MATERIAL IS INCAPABLE OF WITHSTANDING HIGH TEMPERATURES. ORIGINAL PIPER HOSE P/N 39999-14. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2006071100147 20060711 00147 SW 2006 7 11 AU510001635 1 20051212 G 2897 2782015810 WIRE HARNESS SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE3313UW 01514 WP HARTZL HCB3T HCB3TN5 GL FUEL SYSTEM DETERIORATED W K NONE O OTHER IN INSP/MAINT 1 AU S 27268 FUEL BOOST PUMP WIRING HARNESSES PN 27-82015-810 AND PN 27-82015-811 DETERIORATED. FOUND DURING INSPECTION IAW AD/SWA22 6/51 AND SB226-28-011. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P15EA 2006071100148 20060711 00148 NM 2006 7 11 AU510001636 1 20051212 G 4930 MANIFOLD BOEING 737 7377Q8 1384418 NM GE CFM56 CFM56* 13802 NE APU LEAKING W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 AU S 9521 987 APU FUEL MANIFOLD LEAKING. 2 L 7 2 4F 4 F RT A16WE E2GL 2006071100149 20060711 00149 NE 2006 7 11 AU510001637 2 20051212 G 7230 SPACER BOEING 737 737* NM GE CFM56 CFM56* 13802 NE COMPRESSOR INCORRECT W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 2 ENGINE FAN BLADE SPACERS WERE INCORRECT PART. FAN BLADES NR 9, NR 10, NR 17, NR 18, NR 19 AND NR 20 WERE AFFE CTED. INCORRECT PN 340-001-261-0 SPACERS FITTED. CORRECT PNO 340-001-215-0. INCORRECT PART. PERSONNEL/MAINTENANCE ERROR . (CASA NR 510001637) 2 L 7 2 4F 4 F RT A16WE E2GL 2006071100167 20060711 00167 NM 2006 7 11 AU510001638 1 20051212 G 2750 FLAP SYSTEM BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU FLAP CONTROL STICKING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT FLAP STOPPED. FLAP ASSYMETRY. INVESTIGATION CONTINUING. (CASA NR 510001638) 2 L 7 2 4F 4 F RT A16WE E21EU 2006071100171 20060711 00171 NM 2006 7 11 AU510001639 1 20051212 G 5311 FRAME BOEING 747 747338 NM RROYCE RB211 RB211524D419 54555 NE BULKHEAD SCRATCHED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FORWARD PRESSURE BULKHEAD AFT FACE OUTER CHORD SCRATCHED IN BEND RADIUS LOCATED AT LBL46/WL235 AND RBL24/WL268. SU SPECT A SHARP OBJECT WAS USED TO REMOVE SEALANT. FOUND DURING INSPECTION IAW AD/B747/159. SEE ATTACHMENT FOR INVESTIGAT ION DETAILS. (CASA NR 510001639) 2 L 7 2 4F 4 F RT A20WE E12EU 2006071100172 20060711 00172 WP 2006 7 11 AU510001640 1 20051212 G 7820 C16932 MUFFLER ROBSIN R44 R44 7640120 WP LYC O540 IO540AE1A5 41530 NE ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 677 (AUS) MUFFLER CRACKED AND DISTORTED IN AREA OF TAILPIPE ATTACHMENT. (OTHER CAUSE: MATERIAL ) (CASA NR 510001640) 1 G 7 1 3O 3 O H11NM 1E4 2006071100173 20060711 00173 WP 2006 7 11 AU510001641 1 20050704 G 3340 A470A402A469A STROBE HUGHES 369 369A 4470503 WP ALLSN 250C 250C18 03011 GL EXTERIOR WRONG PART W O OTHER D INFLIGHT SEPARATION LD LANDING 1 AU S (AUS) INCORRECT STROBE LIGHT FITTED. THE INCORRECT LIGHT WAS APPROXIMATELY 50MM (1.96IN) HIGHER THAN THE ORIGINAL LIGHT. THIS EXTRA HEIGHT BROUGHT THE LIGHT INTO THE TRACKING AREA OF THE MAIN ROTOR BLADES WHICH CONSEQUENTLY IMPACTED ON THE LIGHT CAUSING UNREPAIRABLE DAMAGE TO ALL FOUR MAIN ROTOR BLADES. INCORRECT PART. PERSONNEL/MAINTENANCE ERROR. (OTHER CAU SE: INCORRECT STROBE FITTED) (CASA NR 510001641) 1 G 7 1 3U 3 U H3WE E4CE 2006071100174 20060711 00174 EA 2006 7 11 AU510001642 2 20051212 G 8520 AEL74241PL PISTON RING SOCATA TB10 TB10TOBAGO 8680696 EU LYC O360 O360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL ENGINE DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S 1269 (AUS) ENGINE CYLINDERS (4OFF) HAD TOP PISTON RINGS DELAMINATING. PLASMA FACE SECTION COMING AWAY FROM BASE MATERIAL. ALL 4 CYLINDERS ALSO HAD EXCESSIVELY WORN EXHAUST VALVE GUIDES AND 2 EXHAUST VALVES REQUIRED REPLACEMENT. (CASA NR 5100016 42) 1 L 7 1 3O 3 O RT A51EU E286 5 C P920 2006071100175 20060711 00175 EU 2006 7 11 AU510001643 1 20051212 G 6510 365A34103301 COUPLING AEROSP AS365 AS365N2 8680815 EU TMECA ARRIEL ARRIEL1C 60030 NE T/R DRIVE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 91 91 (AUS) TAIL ROTOR DRIVESHAFT FORWARD FLEXIBLE COUPLING CRACKED. INVESTIGATION FOUND MECHANICAL DAMAGE ON THE EDGE OF THE COUPLING AT ONE END OF THE CRACK. (OTHER CAUSE: MATERIAL - IMPACT DAMAGE ) (CASA NR 510001643) 1 G 7 2 3U 3 U RT H10EU E19EU 2006071100176 20060711 00176 2006 7 11 AU510001644 4 20051212 G 3417 4040831901 CONVERTER HONEYWELL AZ810 DADC OUT OF LIMITS W K NONE O OTHER IN INSP/MAINT 1 AU S 86011359 (AUS) DIGITAL AIR DATA COMPUTER (DADC) PRESSURE CONVERTER FAILED MANUFACTURER`S TEST. FOUND DURING INSPECTION IAW AD/RAD /43.(AD/SB DESC: AD/RAD/43 (FAR 43, APP. E) ) (OTHER CAUSE: MATERIAL ) (CASA NR 510001644) 2006071900021 20060719 00021 NE 2006 7 19 AU510001645 2 20051212 G 7313 NOZZLE PWA PT6 PT642A NE FUEL INJECTOR WRONG PART W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) INCORRECT FUEL NOZZLE SHEATHS FITTED AT ENGINE OVERHAUL. FUEL NOZZLES WERE PRE SB3250 AND SHEATHS WERE POST SB3250 . INCORRECT PART. PERSONNEL/MAINTENANCE ERROR. (CASA NR 510001645) 4 T E4EA 2006071100177 20060711 00177 NM 2006 7 11 AU510001646 1 20051212 G 5514 69144105 HINGE PIN BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 53856 (AUS) LT HORIZONTAL STABILIZER OUTER HINGE PIN CRACKED IN AREA OF THREAD ROOT ADJACENT TO SPLIT PIN HOLES. FOUND DURING MAGNETIC PARTICLE INSPECTION IAW SB727-55A0090R1 PART 4 AND AD/B727/173.(AD/SB DESC: AD/B727/173, SB727-55A0090R1 ) (CAS A# 510001646) 2 L 7 3 4F 4 F RT A3WE E2EA 2006061600126 20060616 00126 NM 2006 6 16 AU510001647 1 20051212 G 3320 LIGHT BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL CABIN FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S STRONG BURNING ODOR IN CABIN FORWARD GALLEY AREA. INSPECTION FOUND A BURNT FLUORESCENT TUBE ABOVE SEAT 2JK. 2 L 7 2 4F 4 F RT A1NM E23EA 2006061600127 20060616 00127 EU 2006 6 16 AU510001648 1 20051212 G 3411 8538R PITOT HEAD FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE PITOT SYSTEM FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S NR 3 PITOT HEAD HEATING SYSTEM FAILED. 2 L 7 2 4F 4 F RT E25NE 2006060800084 20060608 00084 NM 2006 6 8 AU510001649 1 20051212 G 3020 2790583108 ANTI-ICE VALVE BOEING 767 767338 1385151 NM GE CF6 CF680C GL AIR INTAKE FAILED W O OTHER O OTHER CR CRUISE 1 AU S 22405 LT ENGINE ANTI-ICE VALVE FAILED. 2 L 7 2 4F 4 F RT A1NM E23EA 2006060800085 20060608 00085 NM 2006 6 8 AU510001650 1 20051212 G 2761 15425001 ACTUATOR BOEING 767 767338 1385151 NM GE CF6 CF680C GL DRAG CONTROL LEAKING W O OTHER K FLUID LOSS CR CRUISE 1 AU S 39707 RT HYDRAULIC SYSTEM QUANTITY DECREASING. INVESTIGATION FOUND RT NO7 SPOILER ACTUATOR FILTER CAP PNO 1542615 LEAKING. 2 L 7 2 4F 4 F RT A1NM E23EA 2006060800086 20060608 00086 2006 6 8 AU510001651 4 20050507 G 3400 DISPLAY AIRBUS A330 A330* EU GE CF6 CF680 30025 NE NAVIGATION FAILED W O OTHER O OTHER CR CRUISE 1 AU S CAPTAIN`S LT AND FIRST OFFICER`S DISPLAY UNITS READ `DATA INVALID` FOR APPROXIMATELY 20 SECONDS AND THEN RETURNED TO NOR MAL DISPLAY. 2 L 7 2 4F 4 F RT A46NM E13NE 2006061900167 20060619 00167 WP 2006 6 19 AU510001652 1 20050707 G 3230 369H600131 LEG ASSY HUGHES 369 369E 4470707 WP ALLSN 250C 250C20B 03013 GL MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 6764 (AUS) LT REAR LANDING GEAR LEG CRACKED FROM CROSS BRACE LOWER BOLT HOLE. CRACK LENGTH APPROXIMATELY 9.525MM (0.375IN). S EE ATTACHMENT FOR IPC REFERENCE. (OTHER CAUSE: AGE, MATERIAL, OPERATES ON FIXED FLOATS ) (CASA NR 510001652) 1 G 7 1 3U 3 U H3WE E4CE 2006060800087 20060608 00087 CE 2006 6 8 AU510001653 1 20051212 G 2820 6017001079 VENT LINE BEECH 58 58 1152740 CE CONT O550 IO550* SO MCAULY 3AF32C 3AF32C512 GL RT FUEL VENT LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 12584 RT FUEL VENT LEAKING. INVESTIGATION FOUND THAT THE SEALANT AROUND THE VENT TUBE IN THE RT WET WING FUEL TANK HAD DETERI ORATED ALLOWING FUEL TO LEAK INTO THE VENT LINE. 1 L 7 2 3O 3 O 3A16 E3SO 5 C P22EA 2006060800089 20060608 00089 NE 2006 6 8 AU510001654 2 20051212 G 7220 UP60336 BEARING RROYCE TAY65015 FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE INLET GUIDE VANE WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 0 LT ENGINE INLET GUIDE VANE BEARINGS PNO UP60336 (1OFF) AND PNO EU61711 (2OFF) WORN. FOUND DURING INSPECTION IAW SB TAY- 75-1655. 2 L 7 2 4F 4 F RT E25NE 2006060800090 20060608 00090 EU 2006 6 8 AU510001655 1 20051212 G 3510 CONNECTOR FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE PILOT O2 SYS LEAKING W K NONE O OTHER IN INSP/MAINT 1 AU S CREW OXYGEN MASK BOX ASSEMBLY CONNECTOR LEAKING. LOSS OF OXYGEN. 2 L 7 2 4F 4 F RT E25NE 2006060800091 20060608 00091 CE 2006 6 8 AU510001656 1 20051212 G 2820 292000017 LINE BEECH 58 58 1152740 CE CONT O550 IO550C SO MCAULY 3AF32C 3AF32C512 GL FUEL SYSTEM LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 10279 MAIN FUEL LINE LOCATED IN RT NACELLE LEAKING IN AREA ABOVE THE ELECTRIC FUEL PUMP. INVESTIGATION FOUND LINE CORRODED. 1 L 7 2 3O 3 O 3A16 E3SO 5 C P22EA 2006060800294 20060608 00294 SO 2006 6 8 AU510001658 2 20051212 G 8530 TIST712BCA CYLINDER CESSNA 210 P210N 2073454 CE CONT O520 TSIO520P 17040 SO MCAULY D3A34 D3A34C402 GL ENGINE FAILED W A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 AU S 190 NR 2 CYLINDER HEAD SEPARATED FROM BARREL. FURTHER INVESTIGATION FOUND THAT ALL CYLINDERS (6OFF) SHOULD HAVE BEEN REPLAC ED IN JULY 2004 IAW ECI SB 04-1. 1 H 7 1 3O 3 O 3A21 E8CE 5 C P47GL 2006060800148 20060608 00148 NE 2006 6 8 AU510001659 2 20051212 G 7314 5008269H PUMP DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE ENGINE FUEL FAILED W A UNSCHED LANDING X J ENGINE FLAMEOUT WARNING INDICATION CL CLIMB 1 AU S 3390 3390 NR 2 ENGINE FUEL PUMP INPUT SHAFT SHEARED. PUMP TURNED FREELY. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006060800149 20060608 00149 NM 2006 6 8 AU510001660 1 20051212 G 5330 SKIN BOEING B727200GROUP BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE BS 480-720B CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 53856 22641 FUSELAGE SKIN LAP JOINTS CRACKED. JOINTS WERE LOCATED AT STRINGER 4R BETWEEN BS 480 AND BS 720B AND AT STRINGER 26L BET WEEN STN 560 AND STN 580. FOUND DURING MEDIUM FREQUENCY EDDY CURRENT (MFEC) INSPECTION IAW AD/B727/160 AND SB727-53AO22 2. 2 L 7 3 4F 4 F RT A3WE E2EA 2006060800150 20060608 00150 NM 2006 6 8 AU510001661 1 20051212 G 2760 CABLE BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE DRAG CONTROL BROKEN W O OTHER F FLT CONT AFFECTED LD LANDING 1 AU S GROUND SPOILER INTERLOCK CABLE BROKEN. INVESTIGATION FOUND VERY STIFF BEARING OPERATION DUE TO MOISTURE INGRESS INTO TH E BEARING LINER LEAD TO FATIGUE AND ULTIMATELY FAILURE OF THE CABLE RODEND. 2 L 7 2 4F 4 F RT A16WE E2GL 2006060800151 20060608 00151 NM 2006 6 8 AU510001662 1 20051212 G 2820 MODULE BOEING 737 7377Q8 1384418 NM GE CFM56 CFM56* 13802 NE FUEL SYSTEM FAULTY W O OTHER O OTHER CL CLIMB 1 AU S P5-2 FUEL SYSTEM FLIGHT DECK MODULE FAULTY. 2 L 7 2 4F 4 F RT A16WE E2GL 2006060800168 20060608 00168 NM 2006 6 8 AU510001663 1 20051212 G 2760 SPOILER BOEING 737 7377Q8 1384418 NM GE CFM56 CFM56* 13802 NE OUT OF ADJUST W O OTHER F FLT CONT AFFECTED DE DESCENT 1 AU S FLIGHT SPOILER OPERATION FAULTY. INVESTIGATION FOUND SPOILER ADJUSTMENT OUT OF LIMITS. 2 L 7 2 4F 4 F RT A16WE E2GL 2006060800170 20060608 00170 EU 2006 6 8 AU510001664 1 20050208 G 5280 HC528B0039002 HINGE BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE RT MLG DOOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S RT MAIN LANDING GEAR DOOR HINGE FITTINGS CORRODED IN BORES. BEARING HOUSINGS ALSO CONTAINED PITTING AND RUST DEPOSITS O N THE OUTER SURFACES. FOUND DURING INSPECTION IAW BAE SYSTEMS ISB 52-113 REV 1 AND AAES AD ER BA6-32-10-43B AND UK CAA AD G-2005-0017. 2 H 7 4 4F 4 F RT A49EU E6NE 2006060800172 20060608 00172 NM 2006 6 8 AU510001665 1 20051212 G 3244 TIRE BOEING 747 747438 NM RROYCE RB211 RB211524* NE MLG DEFLATED W K NONE O OTHER IN INSP/MAINT 1 AU S NR 10 MAIN LANDING GEAR TIRE DEFLATED. 2 L 7 4 4F 4 F RT A20WE E12EU 2006060800173 20060608 00173 EU 2006 6 8 AU510001666 1 20051212 G 3244 TIRE AIRBUS A330 A330* EU GE CF6 CF680 30025 NE NLG LOW PRESSURE W O OTHER O OTHER LD LANDING 1 AU S LEFT NOSE WHEEL TIRE LOW PRESSURE. NOSE SHIMMY ALSO EVIDENT. 2 L 7 2 4F 4 F RT A46NM E13NE 2006060800175 20060608 00175 EU 2006 6 8 AU510001667 1 20051212 G 2611 SMOKE DETECTOR FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE LAVATORY FAULTY W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 AU S REPORT OF CIGARETTE SMOKE SMELL IN CABIN. TOILET SMOKE DETECTOR DID NOT ACTIVATE ALARM. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT E25NE 2006060800335 20060608 00335 SO 2006 6 8 AU510001668 1 20051212 G 3233 762554 ROD END PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA MLG ACTUATOR FAILED W O OTHER O OTHER LD LANDING 1 AU S 0 RT MAIN LANDING GEAR ACTUATOR RODEND FAILED. RT MAIN LANDING GEAR WOULD NOT EXTEND AND THE AIRCRAFT MADE A WHEELS UP LA NDING. 1 L 7 2 3O 3 O A20SO E14EA 2006062100011 20060621 00011 EU 2006 6 21 AU510001669 1 20050108 G 3246 313721 WHEEL REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 10133 (AUS) LT MLG WHEEL ASSEMBLY HAD 2 SECTIONS OF THE BEAD MISSING. TIRE DEFLATED DURING LANDING ROLL. (CASA NR 510001669) 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2006061200319 20060612 00319 CE 2006 6 12 AU510001670 1 20051212 G 2720 5052432651 ARM BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO MCAULY 3AF34C 3AF34C502 GL RUDDER CONTROL SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S PILOT`S LT RUDDER PEDAL ARM SHEARED. 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 2006061200321 20060612 00321 SO 2006 6 12 AU510001671 1 20050108 G 3230 4550429 DOWNLOCK PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA RT MLG STICKING W O OTHER J WARNING INDICATION DE DESCENT 1 AU S 10988 318152142 RT MAIN LANDING GEAR FAILED TO EXTEND. INVESTIGATION FOUND THE RT MAIN LANDING GEAR DOWNLOCK WAS STUCK DUE TO CARBON BU ILDUP FROM EXHAUST AND ALSO LUBRICATION DRYING OUT. 1 L 7 2 3O 3 O A20SO E14EA 2006061200322 20060612 00322 NM 2006 6 12 AU510001672 1 20051212 G 5754 1060779124A BEARING BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU LE SLAT FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S LT WING OUTBOARD KRUGER FLAP NOSE LINK EYE END SHEARED. 2 L 7 2 4F 4 F RT A16WE E21EU 2006061200324 20060612 00324 CE 2006 6 12 AU510001673 1 20051212 G 5313 STRINGER BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCD4N3 HCD4N3A GL BS 190 CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 10743 0 FUSELAGE CLEATS AND STRINGERS CRACKED AND CORRODED IN THE FOLLOWING AREAS, CLEAT AT LOWER LONGERON LT SIDE CRACKED AT FR AME ATTACHMENT FS 216.125 2 LT SIDE STRINGER CORRODED ON END AT FS 190.6 3. CLEAT AT STRINGER 6 LT HAS RIVETS MISSING A T FS 227. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2006061200325 20060612 00325 CE 2006 6 12 AU510001674 1 20051007 G 2410 DRIVE BELT CESSNA 180 180K 2072624 CE CONT O470 O470U 17026 SO MCAULY 2A34C C2A34C204 GL ALTERNATOR LOOSE W O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 AU S ALTERNATOR DRIVE BELT LOOSE. LOSS OF ELECTRICAL POWER. 1 H 7 1 3O 3 O 5A6 E273 5 C P3EA 2006062100012 20060621 00012 EA 2006 6 21 AU510001675 2 20051212 G 8520 BOLT NEWZE FU24 FU24954 6280102 WP LYC O720 IO720A1B 41546 EA HARTZL HCC3Y HCC3YR GL CONNECTING ROD SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S 1639 (AUS) NR 2 CYLINDER CONNECTING ROD BIG END BOLT FAILED WITH OTHER BIG END BOLT BENT. NR 2 CYLINDER SEPARATED FROM CRANKC ASE. (OTHER CAUSE: MATERIAL - HIGH HOURS ) (CASA NR 510001675) 1 L 7 1 3O 3 O A9PC 1E15 5 C P25EA 2006061200326 20060612 00326 CE 2006 6 12 AU510001676 1 20051212 G 8011 2005001 GEAR LAMAR CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY IC235 IC235LFA7570 EA STARTER BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 247 85007343 (AUS) STARTER MOTOR DRIVE GEAR DISINTEGRATED DURING ENGINE CRANKING. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2006061200327 20060612 00327 WP 2006 6 12 AU510001677 2 20051212 G 7200 ENGINE SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UA 01514 WP MCAULY 4HFR34 4HFR34C652 NE LEFT FLUCTUATES W O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 AU S (AUS) LT ENGINE EGT, TORQUE AND FUEL FLOW FLUCTUATING. LT FUEL BYPASS VALVE AND LT EGT SHORT LEAD CHANGED. GROUND RUNS AND TEST FLIGHT CARRIED OUT WITH NIL DEFECTS EVIDENT. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2006061300092 20060613 00092 WP 2006 6 13 AU510001678 2 20051212 G 7321 89778016 FCU SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UA 01514 WP MCAULY 4HFR34 4HFR34C652 NE ENGINE FAULTY W A UNSCHED LANDING X J ENGINE FLAMEOUT WARNING INDICATION CL CLIMB 1 AU S 5805 LT ENGINE EGT, TORQUE AND FUEL FLOW FLUCTUATING. FUEL CONTROL UNIT CHANGED. GROUND RUN AND TEST FLIGHT CARRIED OUT SER VICEABLE. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2006061300094 20060613 00094 EA 2006 6 13 AU510001679 2 20051212 G 8520 AEL74241PL PISTON RING SOCATA TB10 TB10TOBAGO 8680696 EU LYC O360 O360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL ENGINE DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S 588 TOP COMPRESSION RINGS ON ALL PISTONS DELAMINATING. 1 L 7 1 3O 3 O RT A51EU E286 5 C P920 2006061300096 20060613 00096 GL 2006 6 13 AU510001680 1 20050408 G 3710 216CWRWIP PUMP AMTR LANCAR LC41550FG 5150001 GL VACUUM SYS FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S EXCESSIVE AMOUNT OF VACUUM PUMPS FAILING EITHER ON FITMENT OR SHORTLY AFTER. THESE PUMPS ARE PURCHASED FROM AERO ACCESS ORIES INC. 1 L 7 1 3O RT EXPA1L71 2006061300097 20060613 00097 CE 2006 6 13 AU510001681 1 20050207 G 7603 ROD END CESSNA 177 177B 2073708 CE LYC O360 O360A1F 41514 EA MCAULY 1A170 1A170FFA GL POWER LEVER SEPARATED W O OTHER F FLT CONT AFFECTED LD LANDING 1 AU S CARBURETOR THROTTLE ARM DISCONNECTED FROM RODEND DUE TO USE OF INCORRECT HARDWARE. LIMITED INFORMATION PROVIDED. PERSO NNEL/MAINTENANCE ERROR. 1 H 7 1 3O 3 O A13CE E286 5 N P857 2006061300099 20060613 00099 2006 6 13 AU510001682 4 20051212 G 3497 WIRE HARNESS BOEING 747 747438 NM RROYCE RB211 RB211524* NE ADC WORN W K NONE O OTHER IN INSP/MAINT 1 AU S UNABLE TO RESET LEFT ADC POWER CIRCUIT BREAKER. INVESTIGATION FOUND TRANSFORMER T131 IN P6 INOPERATIVE. FURTHER INVEST IGATION FOUND P7 WIRING LOOM CHAFING ON `AOA ALT L` CICUIT BREAKER (A13). `L ADC PWR` CIRCUIT BREAKER WIRE W007-131-22 FOUND BURNT AND BROKEN. `LEFT VOR/MAX RCVR` CIRCUIT BREAKER WIRE W007-162-22 FOUND CHAFED AND `AOA L` AND `ALTN L` CIRC UIT BREAKER WIRING AND LUGS FOUND BURNT (W007-587-22). 2 L 7 4 4F 4 F RT A20WE E12EU 2006061300100 20060613 00100 NM 2006 6 13 AU510001683 1 20050408 G 2520 BOLT BOEING 767 767300 1385204 NM RROYCE RB211 RB211524* NE SEAT BACK BROKEN W O OTHER O OTHER NR NOT REPORTED 1 AU S SEAT 3E SEAT BACK INBOARD ATTACHMENT BOLTS SHEARED. 2 L 7 2 4F 4 F RT A1NM E12EU 2006061300101 20060613 00101 NM 2006 6 13 AU510001684 1 20050108 G 2910 AS11708K0165 HOSE BOEING 767 767300 1385204 NM RROYCE RB211 RB211524* NE HYD SYSTEM FAILED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S RT HYDRAULIC PUMP PRESSURE LINE FAILED. LOSS OF HYDRAULIC FLUID. SUSPECT CAUSED BY FATIGUE TO TO PRESSURE SPIKES CAUSE D BY PUMP ACTIVATION. 2 L 7 2 4F 4 F RT A1NM E12EU 2006061300226 20060613 00226 NM 2006 6 13 AU510001685 1 20050108 G 2823 MA20A10011 ACTUATOR BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE FUEL SELECTOR FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 255 255 NR 2 ENGINE SPAR VALVE ACTUATOR FAILED. NR 2 ENGINE FAILED TO START. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061300273 20060613 00273 2006 6 13 AU510001686 4 20050108 G 3400 WARNING SYSTEM BOEING 777 777 UTILUSE NM MULTIPLE FAIL W A UNSCHED LANDING G J MULTIPLE FAILURE WARNING INDICATION CR CRUISE 1 AU S AIR TURN BACK DUE EICAS LOW AIRSPEED WARNING/AUTO THROTTLE UNRELIABLE/ AUTOPILOT NOT FLYING TO CORRECT COMMANDS/HARD OVE R SLIP INDICATION. AIRCRAFT IS FOREIGN REGISTERED. FOR INFORMATION ONLY. 2 L 7 2 4F RT T00001SE 2006061300274 20060613 00274 NM 2006 6 13 AU510001687 1 20051212 G 2133 7110033 OUTFLOW VALVE BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU CABIN PRESSURE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 37637 8998 PRESSURIZATION SYSTEM AFT OUTFLOW VALVE FAILED TO OPEN. INVESTIGATION FOUND A DEFECTIVE AC MOTOR AND AC POTENTIOMETER. 2 L 7 2 4F 4 F RT A16WE E21EU 2006061300275 20060613 00275 NM 2006 6 13 AU510001688 1 20051212 G 2822 KDAE4F RELAY BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE FUEL BOOST PUMP FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S CENTER FUEL TANK RT BOOST PUMP CONTROL RELAY R55 FAILED. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061300276 20060613 00276 NM 2006 6 13 AU510001689 1 20050808 G 4920 SEAL BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE APU FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS DE DESCENT 1 AU S 3998 APU BLEED VALVE AND DUCTS CONTAMINATED WITH OIL. INVESTIGATION FOUND THE APU LOAD COMPRESSOR SEAL FAILED. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061300277 20060613 00277 2006 6 13 AU510001690 4 20050308 G 3140 8221033100 COMPUTER BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL EICAS FAULTY W K NONE G J MULTIPLE FAILURE WARNING INDICATION IN INSP/MAINT 1 AU S 18014 LT ENGINE INDICATION AND CREW ALERT SYSTEM (EICAS) COMPUTER FAULTY. 2 L 7 2 4F 4 F RT A1NM E23EA 2006061300278 20060613 00278 GL 2006 6 13 AU510001691 1 20051212 G 2820 20139001 LINE CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO FUEL SYSTEM LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 155 155 FUEL SUPPLY PIPE P/N 20139-001 AND FUEL RETURN PIPE P/N 20138-001 LEAKING AT `TEE` FITTING. `TEE` FITTINGS ARE PART OF T HE FERRY TANK SYSTEM AND SHOULD BE REMOVED WHEN THE FERRY TANK IS REMOVED. PIPE FLARES WERE POORLY MANUFACTURED. INCOR RECT PART. 1 L 7 1 3O 3 O NT A00009CH E3SO 2006071800169 20060718 00169 2006 7 18 AU510001692 1 20050907 G 5102 SUPPORT BALLOON BASKET BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 1405 BA125 (AUS) BALLOON NYLON SUPPORT POLES CRACKED AND BROKEN. (OTHER CAUSE: GROUND HANDLING OF BASKET ) (CASA NR 510001692) 2006061300279 20060613 00279 EA 2006 6 13 AU510001693 2 20051212 G 7314 DIAPHRAGM PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA FUEL PUMP LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 648 D7073 LT ENGINE FUEL PUMP DIAPHRAGM LEAKING. 1 L 7 2 3O 3 O A20SO E14EA 2006061300280 20060613 00280 SO 2006 6 13 AU510001694 1 20051212 G 3240 BOLT PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA BRAKE ASSY LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S LT AND RT MAIN WHEEL BRAKE BACKING PLATE ATTACHMENT BOLTS LOOSE. 1 L 7 2 3O 3 O A20SO E14EA 2006061400147 20060614 00147 SO 2006 6 14 AU510001695 2 20051212 G 8520 634503M010 BEARING LYC CESSNA 404 404 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL CRANKSHAFT DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 412 0 ENGINE METAL CONTAMINATION. BULK STRIP FOUND THAT THE TWO REARMOST MAIN BEARINGS WERE DAMAGED. INSPECTION OF THE CRANK SHAFT IN THE VICINITY OF THE TWO REARMOST JOURNALS FOUND CRACKS RUNNING LONGITUDINALLY ACROSS JOURNALS TO THE CRANK. 1 L 7 2 3O 3 O RT A25CE E7CE 5 C P45GL 2006061400150 20060614 00150 EA 2006 6 14 AU510001696 2 20050707 G 7414 1052945 SHAFT ROBSIN R22 R22BETA 7640110 NM LYC O360 O360J2A 41514 EA MAGNETO BROKEN W O OTHER R PARTIAL RPM/PWR LOSS CR CRUISE 1 AU S 1667 EO3HA055 MAGNETO SHAFT SHEARED BETWEEN BEARING P/N 10-81806 AND BEARING SLEEVE PNO 10-357078. FRACTURE LINES EVIDENT AT BREAK PO INT. 1 G 7 1 3O 3 O H10WE E286 2006061400153 20060614 00153 WP 2006 6 14 AU510001697 1 20051212 G 7820 C16932 MUFFLER ROBSIN R44 R44 7640120 WP LYC O540 IO540AE1A5 41530 NE ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 700 MUFFLER CRACKED AND DISTORTED IN AREA OF TAILPIPE ATTACHMENT WELD. 1 G 7 1 3O 3 O H11NM 1E4 2006061400154 20060614 00154 WP 2006 6 14 AU510001698 1 20051107 G 7820 C1693 MUFFLER ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA LEFT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 1197 MUFFLER CRACKED ON LT SIDE. LT COLLECTOR ALSO CRACKED. 1 G 7 1 3O 3 O H11NM E295 2006061400165 20060614 00165 EA 2006 6 14 AU510001699 2 20051107 G 7414 10353060 BEARING PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA MAGNETO FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S D071103 LT ENGINE RT MAGNETO FAILED. INVESTIGATION FOUND THE MAGNETO BEARING HAD COLLAPSED. HEAT GENERATED DISCOLORED THE CAM ASSEMBLY AND MELTED THE PLASTIC BLOCK ON THE CONTACT ASSEMBLY CAUSING THE CONTACTS TO STAY CLOSED. SUSPECT CAUSED BY IN CORRECT LUBRICATION OF BEARING. 1 L 7 2 3O 3 O A20SO E14EA 2006061400166 20060614 00166 WP 2006 6 14 AU510001700 1 20050107 G 3240 BRAKE DOUG DC3 DC3CS1C3G 3021458 WP PWA R1830 R183092 52020 NE HAMSTD 23E 23E51 NE MLG FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S RT BRAKE GRABBED CAUSING LT MAIN LANDING GEAR TO RUN OFF TAXIWAY AND BECOME BOGGED. INVESTIGATION COULD FIND NO FAULT W ITH THE BRAKE SYSTEM EXCEPT FOR A LARGER THAN USUAL AMOUNT OF DUST WHICH WAS ATTRIBUTED TO OPERATING IN THE OUTBACK. 2 L 7 2 4R 4 R A669 5E4 6 C P603 2006061400167 20060614 00167 CE 2006 6 14 AU510001701 1 20051007 G 2697 MS3450KT3685 CONNECTOR BEECH 200 200BEECH 1152920 CE PWA PT6 PT642A NE HARTZL HCD4N3 HCD4N3A GL FIRE DETECTION DAMAGED W O OTHER O OTHER LD LANDING 1 AU S 7961 LT ENGINE SUFFERED FROM FALSE FIRE WARNING INDICATIONS. INVESTIGATION FOUND LOW INSULATING RESISTANCE IN FIREWALL CONNE CTOR J102. CONNECTOR WAS SECTIONIZED AND EVIDENCE OF INTERNAL CRACKING AND TRACKING WAS FOUND. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2006061400169 20060614 00169 NE 2006 6 14 AU510001702 2 20051212 G 7261 OIL SYSTEM EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE ENGINE LOW PRESSURE W O OTHER K J FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S ENGINE OIL SYSTEM PRESSURE FLUCTUATING. INSPECTION FOUND LOW OIL LEVEL BUT NO EVIDENCE OF LEAKS. OIL TOPPED UP WITH NO FAULTS SINCE. 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 2006061400170 20060614 00170 CE 2006 6 14 AU510001703 1 20051212 G 3220 CESSNA BELLCRANK CESSNA 310 310Q 2074242 CE CONT O470 IO470V 17026 SO MCAULY 3AF32C 3AF32C87 GL NLG SHEARED W O OTHER O OTHER CL CLIMB 1 AU S NOSE LANDING GEAR IDLER BELLCRANK SHEARED AT THE TWO BOLT HOLES FOR THE FORWARD AND AFT PUSH-PULL TUBES. SUSPECT CAUSED BY WORN UPLOCK. 1 L 7 2 3O 3 O 3A10 3E1 5 C P22EA 2006061500084 20060615 00084 CE 2006 6 15 AU510001704 1 20051001 G 7160 642232 ELBOW CESSNA 414 414A 2075907 CE CONT O520 TSIO520N 17040 SO MCAULY 3AF32C 3AF32C505 GL AIR INDUCTION WORN W O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 AU S 1185 0 RT ENGINE AIR INDUCTION HOSE FLEXIBLE ELBOW TORN ON INSIDE RADIUS. 1 L 7 2 3O 3 O A7CE E8CE 5 C P22EA 2006061500085 20060615 00085 SO 2006 6 15 AU510001705 1 20051212 G 5751 SPAR PIPER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA AILEON CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S RT AILERON ASSEMBLY SPAR CRACKED IN AREA UNDER THE AILERON PUSH-PULL ROD ATTACHMENT BRACKET. FOUND USING COLOR CONTRAST DYE PENETRANT INSPECTION IAW AD/PA31/118 AMDT1. 1 L 7 2 3O 3 O A20SO E14EA 2006061500086 20060615 00086 SO 2006 6 15 AU510001706 1 20051212 G 5751 SPAR PIPER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2 GL AILERON CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 0 LT AILERON ASSEMBLY SPAR CRACKED IN AREA UNDER THE AILERON PUSH-PULL ROD ATTACHMENT BRACKET. FOUND USING COLOR CONTRAST DYE PENETRANT INSPECTION IAW AD/PA31/118 AMDT1. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2006061500090 20060615 00090 2006 6 15 AU510001707 4 20051208 G 3417 4040831901 CONVERTER HONEYWELL DADC OUT OF TOLERANCE W K NONE O OTHER IN INSP/MAINT 1 AU S 85071123 DIGITAL AIR DATA COMPUTER (DADC) PRESSURE CONVERTER PS AND PT SENSORS OUT OF TOLERANCE. FOUND DURING INSPECTION IAW AD/ RAD/43 AMDT5 PART1. 2006061500091 20060615 00091 EU 2006 6 15 AU510001708 1 20051208 G 4900 APU FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE INOPERATIVE W K NONE O OTHER IN INSP/MAINT 1 AU S APU FAILED TO START. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT E25NE 2006061500093 20060615 00093 EU 2006 6 15 AU510001709 1 20051008 G 2897 WIRE BAG BAE146 BAE146300A 1500267 EU FUEL SYSTEM SHORTED W O OTHER O OTHER CR CRUISE 1 AU S RT INNER FUEL BOOST PUMP PRESSURE SWITCH TO PRINTED CIRCUIT BOARD WIRE SHORT CIRCUITED. 2 H 7 4 4F RT A49EU 2006061500094 20060615 00094 EU 2006 6 15 AU510001710 1 20051008 G 5311 FRAME BAG BAE146 BAE146100A 1500260 EU LYC ALF502 ALF502R5 41580 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S FUSELAGE FRAME 15 AND FRAME 41 CRACKED. FOUND DURING INSPECTION IAW AD/BAE146/116. 2 H 7 4 4F 4 F RT A49EU E6NE 2006061500095 20060615 00095 EA 2006 6 15 AU510001711 2 20051212 G 8520 AEL74241PL PISTON RING SOCATA TB10 TB10TOBAGO 8680696 EU LYC O360 O360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL ENGINE DETERIORATED W K NONE O OTHER IN INSP/MAINT 1 AU S 773 NR 2 CYLINDER PISTON TOP COMPRESSION RING PLASMA COATING DELAMINATING. TOP RINGS ON ALL OTHER PISTONS SHOWING SIGNS OF DELAMINATION BEGINNING TO OCCUR. 1 L 7 1 3O 3 O RT A51EU E286 5 C P920 2006061500097 20060615 00097 NM 2006 6 15 AU510001712 1 20051008 G 3233 ACTUATOR BOEING 747 747400 NM MLG LEAKING W O OTHER K FLUID LOSS CR CRUISE 1 AU S LOSS OF NR 1 HYDRAULIC SYSTEM FLUID. INVESTIGATION FOUND THE RT BODY GEAR POSITIONING ACTUATOR HYDRAULIC FUSE LOWER `B` NUT LOOSE AND LEAKING. AIRCRAFT IS FOREIGN REGISTERED. 2 L 7 4 4F RT A20WE 2006061500206 20060615 00206 2006 6 15 AU510001713 4 20050408 G 3421 H321BTM GYRO BOEING 747 747438 NM RROYCE RB211 RB211524* NE ATTITUDE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 41553 210 STANDBY ATTITUDE INDICATOR TOPPLED. 2 L 7 4 4F 4 F RT A20WE E12EU 2006061600064 20060616 00064 2006 6 16 AU510001714 4 20051212 G 3421 H321BTM INDICATOR BOEING 747 747438 NM RROYCE RB211 RB211524* NE ATTITUDE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 16249 STANDBY ATTITUDE INDICATOR TOPPLED. 2 L 7 4 4F 4 F RT A20WE E12EU 2006061600065 20060616 00065 NM 2006 6 16 AU510001715 1 20051008 G 3232 1U11986 ACTUATOR BOEING 747 747438 NM RROYCE RB211 RB211524* NE MLG DOOR FAILED W O OTHER J WARNING INDICATION CL CLIMB 1 AU S NOSE LANDING GEAR DOOR ACTUATOR FAILED. INVESTIGATION OF THE ACTUATOR IN THE WORKSHOP FOUND A FAILURE OF THE DOOR ACTUA TOR INTERNAL LOCKING MECHANISM. PART OF THE LOCKING RAM AND PISTON LOCK KEYWAY HAD FRACTURED. 2 L 7 4 4F 4 F RT A20WE E12EU 2006061600066 20060616 00066 NM 2006 6 16 AU510001716 1 20050808 G 5712 65B1086366 RIB BOEING 747 747438 NM RROYCE RB211 RB211524* NE WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S RT WING FIXED TRAILING EDGE RIB AT LOCATED AT WBL 432.65 SEVERED APPROXIMATELY 457.2MM (18IN) FORWARD OF THE TRAILING ED GE. 2 L 7 4 4F 4 F RT A20WE E12EU 2006061600068 20060616 00068 NM 2006 6 16 AU510001717 1 20051212 G 3211 65B143012 TRUNNION BOEING 747 747338 NM RROYCE RB211 RB211524* NE MLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S RT WING LANDING GEAR AFT TRUNNION CRACKED ON INTERNAL SURFACE OF THE SPIGOT BORE LOCATED APPROX 241.3MM (9.5IN) FORWARD OF THE AFT FACE BETWEEN THE 6 O`CLOCK AND 9 O`CLOCK POSITIONS. CRACK CONFIRMED USING HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION. FOUND DURING INSPECTION IAW AD/B747/81 AND EI 747-32-48. FOLLOWING REMOVAL OF PAINT AND CADMIUM PLATING, THE TRUNNION WAS AGAIN INSPECTED USING FLUORESCENT PENETRANT INSPECTION (FPI) AND MEDIUM AND HIGH FREQUENCY EDDY CURRENT INSPECTION. THESE INSPECTIONS AS WELL AS VISUAL INSPECTION COULD NOT VERIFY THE CRACKING. SUSPECT CRACK INDICATION OR IGINATED IN THE PLATING AND NOT THE BASE METAL. 2 L 7 2 4F 4 F RT A20WE E12EU 2006061600070 20060616 00070 CE 2006 6 16 AU510001718 1 20051212 G 3244 184F102 TIRE LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP NLG FAILED W C ABORTED TAKEOFF E VIBRATION/BUFFET TO TAKEOFF 1 AU S NOSE WHEEL TIRE SHREDDED ON FIRST TAKEOFF FOLLOWING FITMENT. TIRE FRAGMENTS BROKE THE LENS ON THE LOWER ANTI-COLLISION BEACON AND ENTERED THE RT ENGINE CAUSING DAMAGE TO THE INLET DUCT AND A NUMBER OF FAN BLADES. SUSPECT MANUFACTURING FAU LT. 2 L 7 2 4F 4 F A10CE E6WE 2006061600080 20060616 00080 NM 2006 6 16 AU510001719 1 20051212 G 2612 473054 SMOKE DETECTOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE CARGO BAY FAULTY W O OTHER N FALSE WARNING DE DESCENT 1 AU S 3134 REAR BAGGAGE LOCKER SMOKE DETECTOR FAULTY. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006061600082 20060616 00082 NM 2006 6 16 AU510001720 1 20050608 G 5610 58935734 WINDOW BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE COCKPIT FAILED W O OTHER O OTHER CR CRUISE 1 AU S 12904 NR 4 RT FLIGHT COMPARTMENT WINDOW INNER PANE SHATTERED. WINDOW HEAT SYSTEM WAS FOUND TO BE SERVICEABLE. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061600141 20060616 00141 EU 2006 6 16 AU510001721 1 20051212 G 2611 FON1390606 HOSE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE SMOKE DETECTOR FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S LT TOILET SMOKE DETECTOR TO AIR EJECTOR HOSE SPLIT AT EJECTOR END. RT SMOKE DETECTOR TO AIR EJECTOR TUBE SIDEWALL COLLA PSED. HOSES ALLOW FOR AIRFLOW THROUGH SMOKE DETECTORS. 2 L 7 2 4F 4 F RT E25NE 2006061600142 20060616 00142 NM 2006 6 16 AU510001722 1 20050908 G 2730 EAL4 CABLE BOEING 737 7377Q8 1384418 NM GE CFM56 CFM56* 13802 NE ELEVATOR MISROUTED W O OTHER W INADEQUATE Q C CR CRUISE 1 AU S LT LOWER ELEVATOR CONTROL CABLE INCORRECTLY ROUTED AT FUSELAGE FRAME LOCATED AT BS 1138. CABLE IS ROUTED OVER FRAME INS TEAD OF THROUGH LIGHTENEING HOLE. CABLE HAS CAUSED DAMAGE TO FRAME. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061600143 20060616 00143 SO 2006 6 16 AU510001723 1 20050408 G 8120 SHAFT PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA HARTZL HCE3Y HCE3YR2 GL TURBOCHARGER BROKEN W O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 AU S GGR00460 RT ENGINE TURBOCHARGER MAIN SHAFT BROKEN. ENGINE HAD JUST BEEN FITTED FOLLOWING OVERHAUL AND AIRCRAFT WAS ON ACCEPTANCE FLIGHT. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2006061600144 20060616 00144 CE 2006 6 16 AU510001724 1 20051212 G 5520 RIVET CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S ELEVATOR LT OUTBOARD HINGE BRACKET ATTACHMENT RIVET HEAD CRACKED. FOUND DURING INSPECTION IAW AD/C400/102 AMDT3. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2006061600145 20060616 00145 NE 2006 6 16 AU510001725 2 20050508 G 7323 430121205 GOVERNOR BOLKMS 117 BK117B1 5626012 EU LYC LTS101 LTS101750B1 41560 NE LT ENGINE FAULTY W O OTHER X J ENGINE FLAMEOUT WARNING INDICATION NR NOT REPORTED 1 AU S 1517 LT ENGINE POWER TURBINE GOVERNOR FAULTY. ENGINE OVERSPED TO 110.9%. OVERSPEED INSPECTION FOUND NIL DEFECTS. 1 G 7 2 3U 3 U H13EU E5NE10 2006061900002 20060619 00002 EU 2006 6 19 AU510001726 1 20051212 G 2910 PIPE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE HYDRAULIC SYS FRACTURED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 0 HYDRAULIC PIPE LOCATED ON THE FORWARD WALL OF THE REAR CARGO HOLD LEAKING. INVESTIGATION FOUND A FRACTURED FLARE. PIPE WAS A -4 STAINLESS STEEL TYPE. 2 L 7 2 4F 4 F RT E25NE 2006061900003 20060619 00003 NM 2006 6 19 AU510001727 1 20051208 G 5610 5893543135 WINDOW BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU COCKPIT DAMAGED W O OTHER O OTHER CR CRUISE 1 AU S CAPTAIN`S NR 1 WINDOW CRACKED DUE TO ARCING. 2 L 7 2 4F 4 F RT A16WE E21EU 2006061900004 20060619 00004 2006 6 19 AU510001728 4 20051208 G 2565 737M25651013 SLIDE BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU R1 DOOR NO TEST W K NONE O OTHER IN INSP/MAINT 1 AU S 8793 1535 DOOR 1R ESCAPE SLIDE FAILED TO DEPLOY NORMALLY DURING TEST. SLIDE CONTACTED EDGE OF DOOR DURING OPENING CAUSING IT TO T WIST SIDEWAYS. 2 L 7 2 4F 4 F RT A16WE E21EU 2006061900005 20060619 00005 NM 2006 6 19 AU510001729 1 20050708 G 2121 732591D COOLING FAN BOEING 747 747* NM GE CF6 CF680C2B2 30025 NE CABIN AIR FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S 46387 12410 UPPER RECIRCULATION FAN FAILED. CIRCUIT BREAKER `OHD RECIRC FAN PWR 2` R7 ON P415 TRIPPED. INVESTIGATION FOUND FAN BEA RINGS HAD FAILED. 2 L 7 4 4F 4 F RT A20WE E13NE 2006061900103 20060619 00103 CE 2006 6 19 AU510001730 1 20051212 G 2434 BEARING PRESTOLITE CESSNA 404 404 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL ALTERNATOR COLLAPSED W K NONE O OTHER IN INSP/MAINT 1 AU S 6101531 RT ENG DRIVEN ALT FAILED. ALT DRIVE COUPLING SHEARED AND ALT FRONT BEARING COLLAPSED. RED ELASTOMER MAT`L FROM ALT DRI VE COUPLING AND MINOR METALLIC PARTICLES VISIBLE INTERNALLY THRU ALT ATTACHMENT PORT. ALT DISASSEMBLED AND INSPECTED. FRONT BEARING SERIOUSLY DETERIORATED. SEVERAL BALL BEARINGS MISSING, 2 SEVERELY DEFORMED AND REMAINDER SHOWING SIGNS OF DISTRESS. FRONT BEARING SEAL DEFORMED BY MIGRATION OF MISSING BALL BEARINGS THROUGH SEAL INTO ENG. ROTOR LOOSE DUE TO FRONT BEARING FAILURE AND HAD CONTACTED STATOR. A MIXTURE OF GREASE AND OIL WAS FOUND ADHERING TO INTERNAL SURFACE OF FRONT ALT HOUSING. GREASE/OIL MIXTURE EXHIBITED A PATTERN CONSISTENT WITH BEING FLUNG OUT OF ALT FRONT BEARING. 1 L 7 2 3O 3 O RT A25CE E7CE 5 C P45GL 2006062100100 20060621 00100 SO 2006 6 21 AU510001731 1 20050303 G 3220 40336000 LINK PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LINKAGE CRACKED. FOUND DURING INSPECTION IAW MFG SL 1088. (AD/SB DESC: MFG SL 1088 ) (CASA NR 510001731). 1 L 7 2 3O 3 O A20SO E14EA 2006062100101 20060621 00101 CE 2006 6 21 AU510001732 1 20050208 G 5312 12134071 BULKHEAD CESSNA 210 2105 2073404 CE CONT O470 IO470S 17026 SO HARTZL HCA2X HCA2XF1 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 11766 (AUS) FUSELAGE DOORPOST BULKHEAD CRACKED. FOUND DURING INSPECTION IAW AD/C205/21. (AD/SB DESC: AD/C205/21 ) (CASA NR 510 001732) 1 H 7 1 3O 3 O 3A21 3E1 5 C P908 2006062100103 20060621 00103 SW 2006 6 21 AU510001733 1 20051212 G 2150 20475546 ACM SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE CABIN COOLING SEIZED W O OTHER B SMOKE/FUMES/ODORS/SPARKS LD LANDING 1 AU S 2900 2900 (AUS) LT AIRCYCLE MACHINE COOLING TURBINE SEIZED. ( MATERIAL ) (CASA NR 510001733) 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2006062100104 20060621 00104 CE 2006 6 21 AU510001734 1 20051212 G 5740 7133661 FITTING CESSNA 182 182S 2072701 CE LYC O540 IO540AB1A5 EA MCAULY 3D36C B3D36C431 GL WING STRUT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT FORWARD DOORPOST WING STRUT ATTACHMENT FITTING MISSING 2 RIVETS PN MS20470AD6. FITTING AND SURROUNDING STRUCTU RE SHOW EVIDENCE OF REWORK DURING MFG.(MANUFACTURING QUALITY CONTROL ISSUE ) (CASA NR 510001734) 1 H 7 1 3O 3 O NT 3A13 1E4 5 C 2006062100105 20060621 00105 CE 2006 6 21 AU510001735 1 20051212 G 5312 7606931 SCREW CESSNA 182 182S 2072701 CE LYC O540 IO540AB1A5 EA MCAULY 3D36C B3D36C431 GL FIREWALL DEFECTIVE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CONTROL COLUMN/ELEVATOR BELLCRANK TORQUE TUBE SUPPORT SCREWS PNO MS35206-228 (2OFF3) DEFECTIVE. SCREWS APPEAR TO H AVE BEEN OVERTORQUED DURING ASSEMBLY. (OTHER CAUSE: MANUFACTURING QUALITY CONTROL ISSUE ) (CASA NR 510001735) 1 H 7 1 3O 3 O NT 3A13 1E4 5 C 2006062100107 20060621 00107 CE 2006 6 21 AU510001736 1 20050408 G 2730 3652400023 CONTROL CABLE BEECH 36 A36 1151604 CE CONT O520 IO520BA 17032 SO MCAULY 2A36C 2A36C23 GL ELEVATOR FRAYED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ELEVATOR CONTROL CABLE FRAYED. INSPECTION FOUND AT LEAST 4 STRANDS BROKEN INTERNALLY. (CASA NR 510001736) 1 L 7 1 3O 3 O 3A15 E5CE 5 C P880 2006062100108 20060621 00108 CE 2006 6 21 AU510001737 1 20050208 G 5510 26320208 SUPPORT CESSNA 208 208 2073702 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL HORIZONTAL STAB CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT HORIZONTAL STABILIZER OUTER HINGE FITTING CONTAINED SEVERE EXFOLIATION CORROSION. AIRCRAFT OPERATES AS A SEAPLA NE IN A SALTWATER ENVIRONMENT. SEE ATTACHMENTS FOR PHOTOGRAPHS OF DEFECT.(OTHER CAUSE: ENVIRONMENT ) (CASA NR 510001737) 1 H 7 1 3T 3 T NT A37CE E4EA 5 C P60GL 2006062100113 20060621 00113 NM 2006 6 21 AU510001738 1 20051212 G 5730 STITCHING CHILD S2 S2APITTS 0110201 NM LYC O360 AEIO360A1A 41514 EA HARTZL HCC2Y HCC2YK4 GL WING SKIN LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S 0 (AUS) TOP WING FABRIC RIB STITCHING LOOSE AND BROKEN. INSPECTION FOUND UNAPPROVED KNOTS IN THE STITCHING WHICH SLIPPED W HEN PULLED. SEE ATTACHMENT FOR PHOTOGRAPHS. (CASA NR 510001738) 1 Q 7 1 3O 3 O A8SO 1E10 5 C P920 2006062000110 20060620 00110 NE 2006 6 20 AU510001739 2 20051212 G 7200 ENGINE SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1 60030 NE NR 2 MALFUNCTIONED W K NONE J O O WARNING INDICATION OTHER OTHER CR CRUISE 1 AU S 0 NR 2 ENGINE CHIP DETECTOR MAGNETIC PLUGS (3OFF) CONTAMINATED WITH TYPE 3 FUZZ. PREVIOUS SOAP ANALYSIS NORMAL. ENGINE R EMOVED FOR REPAIR AND INVESTIGATION. 1 G 7 2 3U 3 U NC H1NE E19EU 2006062200082 20060622 00082 EU 2006 6 22 AU510001740 1 20051212 G 4940 105160001 EXCITER GTCP36150R FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE APU FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S P228 APU IGNITION EXCITER UNIT FAULTY. 2 L 7 2 4F 4 F RT E25NE 2006062200084 20060622 00084 NM 2006 6 22 AU510001741 1 20051212 G 2700 7321870018 SHUTOFF VALVE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL FLIGHT CONTROL FAILED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S FLAP/SLAT SHUTOFF VLV LOCATED IN RT W/W LEAKING. INSPECTION FOUND CAP P/N 732-18718 HAD AN OPEN CRACK AT LAST/OUTERMOST THREAD RUNNING 270 DEGREES AROUND ITS CIRCUMFERENCE (CRACKED THROUGH). HEX-NUT END OF ALUMINUM CAP HAD LIFTED BY 0.1 I NCHES UNDER HYD PRESS. CRACK WAS LOCATED ON PRESSURE SIDE OF `O` RING SEAL. CLOSE EXAM OF FRACTURE SURFACE SHOWED THAT CRACK STARTED AT ROOT OF LAST THREAD, PROPAGATED 0.050` AXIALLY (TOWARD THE SHUT-OFF VALVE MODULE), TRAVELED 75% OF WAY AROUND CAP’S OUTSIDE DIAMETER BEFORE FAILING RADIALLY WITH ONE FRACTURE PLANE. NO BEACH MARKS WERE EVIDENT ON FINAL FRA CTURE PLANE, INDICATING SUDDEN FAILURE. CRACK COULD HAVE INITIALIZED DUE TO OVER-TORQUING DURING ASSY, OR FROM SUBSTAND 2 L 7 2 4F 4 F RT A1NM E23EA 2006062200086 20060622 00086 CE 2006 6 22 AU510001742 1 20051212 G 2710 510105365 CONTROL CABLE CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY IC235 IC235LFA7570 EA AILERON WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 599 RT AILERON CARRY THROUGH CABLE WORN TO LIMITS. CABLE WAS WORN BY THE PHENOLIC RUB BLOCK LOCATED AT WS 71.125. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2006062200088 20060622 00088 NM 2006 6 22 AU510001743 1 20051212 G 2150 AS13806NO130L HOSE BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE LT ACM LEAKING W O OTHER O OTHER NR NOT REPORTED 1 AU S LT AIR CONDITIONING PACK AIRCYCLE MACHINE SENSE LINE LEAKING. HOSE APPEARS TOO LONG CAUSING TO TIGHT A CURVE RAD. 2 L 7 2 4F 4 F RT A16WE E2GL 2006062200089 20060622 00089 NM 2006 6 22 AU510001744 1 20051008 G 2760 BEARING BOEING 727 7272J4 1384006 NM PWA JT8 JT8D17 52049 NE DRAG CONTROL COLLAPSED W O OTHER F FLT CONT AFFECTED LD LANDING 1 AU S 0 GROUND SPOILER QUADRANT UPPER AND LOWER BEARINGS COLLAPSED. SPOILER DIFFERENTIAL MIXER P/N 10-60841-8 ROUGH IN OPERATIO N. 2 L 7 3 4F 4 F RT A3WE E2EA 2006062200091 20060622 00091 2006 6 22 AU510001745 4 20050908 G 3417 ADC BOEING 737 737* NM FAILED W O OTHER O OTHER CR CRUISE 1 AU S AIR DATA COMPUTER FAILED. AIRCRAFT IS FOREIGN REGISTERED. 2 L 7 2 4F RT A16WE 2006062100114 20060621 00114 2006 6 21 AU510001746 4 20051212 G 2565 737M25651013 GIRT BAR BOEING 737 737376 NM GE CFM56 CFM563B1 13802 NE SLIDE FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 45165 588 (AUS) DOOR R1 ESCAPE SLIDE GIRT BAR CONTACTING DOOR FRAME. 2 L 7 2 4F 4 F RT A16WE E2GL 2006062100115 20060621 00115 NM 2006 6 21 AU510001747 1 20051212 G 2822 PUMP BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL FUEL BOOST FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT FWD BOOST PUMP SUSPECT FAULTY. CB POPPED. ON DISASSEMBLY INVESTIGATION FOUND SEVERE SCORING WAS ON PUMP HSG IMP ELLER BORE INSIDE DIAMETER, SHAFT AND ROTOR ASSY WAS SCORED ON BRG JOURNAL AREA. SEVERE SCORING COULD BE CAUSED BY FOD P ASSING THROUGH PUMP. EVIDENCE OF FOD WAS NOT FOUND DURING DISMANTLE INDICATING THAT IT HAD PASSED THROUGH. ABNORMAL WEAR ON SHAFT BRG JOURNAL, POSSIBLY CAUSED BY FOD, HSG CARBON BRG AREA CAUSED IMPELLER TO RUB ON HSG IMPELLER BORE RESULTING IN AN EXCESSIVE AMPERAGE DRAW,CAUSED CB TO TRIP. (CASA NR 510001747) 2 L 7 2 4F 4 F RT A1NM E23EA 2006062300042 20060623 00042 NM 2006 6 23 AU510001748 1 20051212 G 2530 8653020000 OVEN BOEING 767 767* NM RROYCE RB211 RB211524* NE GALLEY FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 AU S 1429 1032 (AUS) NR 5 REAR GALLEY OVEN FAULTY. SMOKE AND FUMES IN CABIN. SUSPECT CAUSED BY SHORTED/BURNED OVEN FAN MOTOR. (CASA NR 510001748) 2 L 7 2 4F 4 F RT A1NM E12EU 2006062300068 20060623 00068 NM 2006 6 23 AU510001749 1 20051212 G 3242 AS11506K0264 HOSE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL BRAKE SYS WORN W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) LOSS OF RT HYDRAULIC SYSTEM FLUID. INVESTIGATION FOUND NR 3 BRAKE HYDRAULIC HOSE CHAFED THOUGH. (CASA NR 510001749 ) 2 L 7 2 4F 4 F RT A1NM E23EA 2006062300069 20060623 00069 EU 2006 6 23 AU510001750 1 20051212 G 3270 INDICATOR BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502* 41580 EA TAIL STRIKE DAMAGED W O OTHER D INFLIGHT SEPARATION LD LANDING 1 AU S (AUS) AIRCRAFT EXPERIENCED A HIGH SINK RATE DURING LANDING. INVESTIGATION FOUND THAT THE MAIN LANDING GEAR AND TAILSKID CONTACTED THE GROUND CAUSING DAMAGE TO THE TAIL STRIKE INDICATOR. (CASA NR 510001750) 2 H 7 4 4F 4 F RT A49EU E6NE 2006062300070 20060623 00070 EU 2006 6 23 AU510001751 1 20051212 G 4930 38828405 FUEL CONTROL FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE APU FAILED W O OTHER J WARNING INDICATION CR CRUISE 1 AU S (AUS) APU AUTO-SHUTDOWN IN FLIGHT. INVESTIGATION FOUND A FAULTY FUEL CONTROL UNIT. (CASA NR 510001751) 2 L 7 2 4F 4 F RT E25NE 2006062300071 20060623 00071 EU 2006 6 23 AU510001752 1 20051212 G 2611 RAI2811M0103 CONTROL UNIT AIRBUS 330 A330300 EU GE CF6 CF680 30025 NE SMOKE DETECTOR FAULTY W O OTHER O OTHER CR CRUISE 1 AU S (AUS) CARGO COMPARTMENT SMOKE WARNINGS. FORWARD CARGO FIRE BOTTLES DISCHARGED. EMERGENCY LANDING CARRIED OUT. LOCAL AUTH ORITIES REPORTED A (WHITE POWDER) IN THE WHEEL WELL AREA. DURING EMERGENCY EVACUATION, DOOR 1L ESCAPE SLIDE FAILED TO DE PLOY. ALL OTHER SLIDES DEPLOYED SUCCESSFULLY. INVESTIGATION FOUND THE FALSE SMOKE WARNING WAS CAUSED BY A DESIGN DEFICIE NCY IN THE SMOKE DETECTOR CONTROL UNIT (SDCU). NOTE: FAILURE OF THE SLIDERAFT TO DEPLOY IS COVERED BY SDR 510001917. (CA SA NR 510001752) 2 L 7 2 4F 4 F RT E13NE 2006062300072 20060623 00072 NM 2006 6 23 AU510001753 1 20051212 G 3233 B-NUT BOEING 747 747400 NM NR 1 HYD SYSTEM LOOSE W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) NR 1 HYDRAULIC SYSTEM LEAKING. INVESTIGATION FOUND A LOOSE B-NUT ON THE LANDING GEAR TRUCK POSITIONING ACTUATOR FU SE LOCATED ON THE AFT WHEEL WELL AT STN 1440. AIRCRAFT IS FOREIGN REGISTERED. (CASA NR 510001753) 2 L 7 4 4F RT A20WE 2006062300073 20060623 00073 EA 2006 6 23 AU510001754 2 20050708 G 7414 M3975 COIL SLICK CESSNA 172 172P 2072436 CE LYC O320 O320* 41508 EA MAGNETO FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 3030784 (AUS) MAGNETO COIL FAULTY. INVESTIGATION FOUND THE SECONDARY WINDINGS OPEN CIRCUITED. (CASA NR 510001754) 1 H 7 1 3O 3 O NT 3A12 E274 2006062300074 20060623 00074 EA 2006 6 23 AU510001756 2 20051212 G 8530 AEL74241PL PISTON RING BEECH 76 76 1153005 CE LYC O360 O360A1G6D EA ENGINE DETERIORATED W K NONE O OTHER IN INSP/MAINT 1 AU S 785 (AUS) ENGINE OIL FOUND TO BE VERY BLACK. INSPECTION FOUND THE PLASMA COATING ON THE TOP PISTON RINGS ON ALL FOUR CYLINDE RS FRACTURED. (CASA NR 510001756) 1 L 7 2 3O 3 O A29CE E286 2006062300075 20060623 00075 NM 2006 6 23 AU510001757 1 20051212 G 2761 A44700009 ACTUATOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE SPOILERS FAILED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 12639 (AUS) RT IB ROLL SPOILER ACTUATOR BODY FAILED ALLOWING LOSS OF HYDRAULIC FLUID. (OTHER CAUSE: MATERIAL ) (CASA NR 510001 757) 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006062300076 20060623 00076 NM 2006 6 23 AU510001758 1 20051212 G 3230 LOCK DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE NLG INCORRECT W O OTHER W INADEQUATE Q C CL CLIMB 1 AU S (AUS) NOSE LANDING GEAR WOULD NOT RETRACT. INVESTIGATION FOUND THE NOSE LANDING GEAR GROUND LOCK (ENGAGED). PERSONNEL/M AINTENANCE ERROR. (CASA NR 510001758) 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006062300215 20060623 00215 GL 2006 6 23 AU510001759 1 20050306 G 8010 687181A24VVN1113 SOLENOID CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL STARTER FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 346 346 (AUS) STARTER SOLENOID FAILED. SUSPECT CAUSED BY FAILURE AND CRACKING OF END CAP WHICH ALLOWED COPPER DUST TO LEAK OUT. (CASA NR 510001759) 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2006062300216 20060623 00216 GL 2006 6 23 AU510001760 1 20051212 G 8010 PN687181A24VVN11 SOLENOID CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL STARTER FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 451 451 (AUS) STARTER SOLENOID FAILED. SUSPECT CAUSED BY FAILURE AND CRACKING OF END CAP WHICH ALLOWED COPPER DUST TO LEAK OUT. (CASA# 510001760) 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2006062300217 20060623 00217 NM 2006 6 23 AU510001761 1 20051212 G 3246 314353 WHEEL DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE MLG MISINSTALLED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 13 (AUS) LT IB MAIN WHEEL ASSY INCORRECTLY FITTED. INVESTIGATION FOUND THAT DURING INSTALLATION INNER WHEEL HALF BRAKE ROT OR DRIVE KEYS HAD NOT BEEN ENGAGED WITH THE ROTOR SLOTS. THIS RESULTED IN THE WHEEL HALF DRIVE KEYS DRIVING THE BRAKE RO TORS VIA THEIR CHAMFERED EDGES. IN ADDITION SOME DAMAGE TO THE BRAKE ROTOR WAS FOUND. PERSONNEL/MAINTENANCE ERROR. (CASA NR510001761) 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006062300218 20060623 00218 GL 2006 6 23 AU510001762 1 20051212 G 2434 ES4024LP ALTERNATOR CIRRUS SR SR20 05628AJ GL CONT O360 IO360E 17025 SO HARTZL HCJ3Y PHCJ3YF1 GL ENGINE FAILED W O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 AU S 199 (AUS) ALTERNATOR FAILED. INVESTIGATION FOUND STATOR TO DIODE FEEDER WIRES CHAFING ON HOUSING AND SHORTED. BRUSH WIRE TAI L FOUND TO BE RUNNING ON STATOR BRUSH RING. (CASA NR 510001762) 1 L 7 1 3O 3 O NT A00009CH E1CE 5 C P36EA 2006062300220 20060623 00220 GL 2006 6 23 AU510001764 1 20051212 G 2432 G243 BATTERY CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL MASTER FAULTY W O OTHER H J ELECT. POWER LOSS-50 PC WARNING INDICATION CL CLIMB 1 AU S 155 (AUS) AIRCRAFT BATTERY INTERNAL FAULT. BATTERY HAD HIGH CURRENT DRAW CAUSING LOSS OF ELECTRICAL POWER. (CASA# 510001764 ) 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2006062300221 20060623 00221 GL 2006 6 23 AU510001765 1 20050408 G 3710 216CWWIP PUMP AMTR LANCAR LC41550FG 5150001 GL VACUUM SYS FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) VACUUM PUMPS FAILED. (OTHER CAUSE: MATERIAL - DEBRIS REMAINING AFTER FAILURE ) (CASA NR 510001765) 1 L 7 1 3O RT EXPA1L71 2006062300222 20060623 00222 EU 2006 6 23 AU510001766 1 20051212 G 5100 D9251015520000 HINGE PIN AIRBUS 320 A320232 3930326 EU IAE V2527 V2527A5 NE BATTERY BOX LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S 3942 (AUS) 103VU PANEL HINGE PIN LOOSE. NO CONTACT WITH ADJACENT ELECTRICAL HARNESS. FOUND DURING INSPECTION IAW AD/A320/175. (AD/SB DESC: AD/A320/175 ) (CASA NR 510001766) 2 L 7 2 4F 4 F RT A28NM E40NE 2006062300223 20060623 00223 CE 2006 6 23 AU510001767 1 20051212 G 5712 57222062 CAP CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL RT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 20514 (AUS) RT WING CANTED RIB CAP CRACKED. CRACK LENGTH APPROXIMATELY 40MM (1.574IN). CRACK WAS LOCATED IN THE RADIUS OF THE UPPER CAP AND TRAVELLED REARWARDS FROM THE AUXILIARY SPAR. FOUND DURING NDI IAW SB CQB03-01 PART B REV 1. (AD/SB DESC: S B CQB03-01 PART B REV 1 ) (CASA NR 510001767) 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2006070500047 20060705 00047 CE 2006 7 5 AU510001768 1 20051212 G 5520 58321672 BRACKET CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT ELEVATOR OB HINGE ASSY IB ATTACHMENT BRACKET CRACKED IN LOWER FORWARD RADIUS. FOUND DURING INSPECTION IAW AD/C4 00/102 AMDT 3 PART 3. BOTH LT AND RT ELEVATOR OB BRGS STIFF IN OPERATION. (AD/SB DESC: AD/C400/102 AMDT 3 PART 3 ) (CAS A NR 510001768) 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2006070500048 20060705 00048 CE 2006 7 5 AU510001769 1 20051212 G 3260 MS25237327 BULB CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL MLG INDICATOR BURNED OUT W O OTHER P NO WARNING INDICATION DE DESCENT 1 AU S (AUS) RT MAIN LANDING GEAR POSITION INDICATOR LIGHT BULB BLOWN. (CASA NR 510001769) 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2006070300010 20060703 00010 CE 2006 7 3 AU510001770 1 20051212 G 7921 GASKET BEECH 80 65B80 1152812 CE LYC O720 IO720A1B 41546 EA HARTZL HCB3Z HCB3Z302 GL OIL COOLER FAILED W O OTHER K FLUID LOSS NR NOT REPORTED 1 AU S RT ENGINE OIL COOLER LOWER FITTING GASKET FAILED. LOSS OF ENGINE OIL. 1 L 7 2 3O 3 O 3A20 1E15 5 C P907 2006070500049 20060705 00049 CE 2006 7 5 AU510001771 1 20051212 G 3260 444EN3R SQUAT SWITCH LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP RT MLG FAILED W O OTHER N FALSE WARNING CL CLIMB 1 AU S 3664 (AUS) RT MAIN LANDING GEAR IB SQUAT SWITCH FAILED. (OTHER CAUSE: AGE ) (CASA NR 510001771) 2 L 7 2 4F 4 F RT T00008WI E6WE 2006070500050 20060705 00050 EU 2006 7 5 AU510001772 2 20051212 G 7200 TURBINE BLADES BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU ENGINE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 1 ENGINE MAKING (POPPING) SOUNDS. SOUNDS INCREASED WHEN THRUST LEVER INCREASED AND DECREASED WHEN THRUST LEVER RETARDED. BORESCOPE INSPECTION FOUND HPC BLADES DAMAGED BEYOND LIMITS. INVESTIGATION CONTINUING. (CASA NR 510001772) 2 L 7 2 4F 4 F RT A16WE E21EU 2006070500051 20060705 00051 NM 2006 7 5 AU510001773 1 20051212 G 7830 UL27562 FAIRING BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE THRUST REVERSER SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 3 ENGINE THRUST REVERSER BLOCKER DOOR DAMAGED. INVESTIGATION FOUND THE RT INNER (A) FRAME FAIRING FAILED AND A PIECE WEDGED UNDER THE BLOCKER DOOR. SEE ATTACHMENT FOR INVESTIGATION DETAILS. (CASA NR 510001773) 2 L 7 4 4F 4 F RT A20WE E30NE 2006070500052 20060705 00052 NM 2006 7 5 AU510001774 1 20051008 G 2421 766088B IDG BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL GENERATOR FAILED W O OTHER H J ELECT. POWER LOSS-50 PC WARNING INDICATION CR CRUISE 1 AU S 7255 969 (AUS) RT INTEGRATED DRIVE GENERATOR (IDG) FAILED. INITIAL INVESTIGATION FOUND BENT PINS 2, 9 AND 10 ON ELECTRICAL CONN ECTOR (B). STRIP AND INVESTIGATION FOUND THE LT AND RT FIXED END CYLINDER BLOCKS TO PORT PLATES MATING FACES WERE SCORE D. THE CONTROL CYLINDER`S CONTROL ROD WAS FOUND TO BE VERY NOTCHY IN OPERATION. (CASA NR 510001774) 2 L 7 2 4F 4 F RT A1NM E23EA 2006070500053 20060705 00053 WP 2006 7 5 AU510001775 2 20051212 G 7261 LINE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL LT ENGINE OIL LOOSE W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S (AUS) LT ENGINE MAIN OIL PRESSURE LINE TO BETA MANIFOLD LOOSE AND LEAKING. LOSS OF ENGINE OIL. (OTHER CAUSE: UNKNOWN ) ( CASA NR 510001775) 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 2006070300061 20060703 00061 CE 2006 7 3 AU510001776 1 20051212 G 5712 57222061 RIB CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL LT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 17021 LT WING ROOT CANTED RIB UPPER CAP LOCATED AT CWS 26.85 CRACKED. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2006070300062 20060703 00062 CE 2006 7 3 AU510001777 1 20051212 G 5711 LH10810000023RH1 SPAR BEECH 77 77 1153007 CE LYC O235 O235L2C 41505 EA SNSNCH 72C 72CK EA WINGS FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 7374 LT AND RT WING REAR SPARS PNO 108-100000-23 (LT) AND P/N 108-100000-24 (RT) FAULTY. EVIDENCE OF WING MOVEMENT AT SKIN I NTERSECTIONS ON TOP OF EACH WING. 1 L 7 1 3O 3 O A30CE E223 5 N P9045 2006070300063 20060703 00063 SO 2006 7 3 AU510001778 1 20050808 G 3213 AN7 BOLT MAULE MT7235 MT7235 5470209 SO LYC O540 IO540W1A5 41532 NE MLG WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 745 0 MAIN LANDING GEAR BOLT INCORRECT PART. BOLT IS AN AN7-24 TYPE ITEM. 1 H 7 1 3O 3 O NC 3A23 1E4 2006070300064 20060703 00064 SO 2006 7 3 AU510001779 1 20051212 G 2434 ALX9525B ALTERNATOR PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360KB 17025 SO HARTZL HCC3Y PHCC3YF2 GL ENGINE FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 12 12 LT AND RT ALTERNATORS REMOVED FROM AIRCRAFT FOR INTERNAL INSPECTION FOLLOWING PURCHASE OF AIRCRAFT. BOTH ALTERNATORS WE RE FOUND TO CONTAIN NUMEROUS DEFECTS. ALTERNATORS HAD ONLY 12 HOURS TSO. ALTERNATORS WERE `KELLY AEROSPACE` ITEMS. 1 L 7 2 3O 3 O A7SO E9CE 5 C P25EA 2006070300065 20060703 00065 SO 2006 7 3 AU510001780 2 20051212 G 8530 AEC631397 CYLINDER CESSNA 206 U206F 2073333 CE CONT O550 IO550F 17042 SO ENGINE DETERIORATED W K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 AU S 86 ENGINE CYLINDER NICKEL CARBIDE CYLINDER WALL COATING SEPARATED FROM BARREL. AREA OF MISSING COATING WAS APPROXIMATELY 1 0MM BY 35MM (0.39IN BY 1.37IN) LOCATED AT THE TOP OF THE BORE NEAR THE TOP SPARK PLUG HOLE. 1 H 7 1 3O 3 O A4CE E3SO 2006070300066 20060703 00066 SO 2006 7 3 AU510001781 2 20050407 G 8540 643109 SPRING CONT CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO STARTER ADAPTER BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 1061 ENGINE STARTER ADAPTER SPRING END TANG BROKEN OFF. 1 H 7 1 3O 3 O A4CE E5CE 2006070300067 20060703 00067 NM 2006 7 3 AU510001782 1 20051108 G 2820 FUEL SYS BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL FAULTY W O OTHER J WARNING INDICATION CR CRUISE 1 AU S UNCOMMANDED INFLIGHT FUEL TRANSFER. INVESTIGATION COULD NOT FIND ANY MECHANICAL CAUSE FOR THE DEFECT. 2 L 7 2 4F 4 F RT A1NM E23EA 2006070300068 20060703 00068 2006 7 3 AU510001783 2 20051008 G 7261 BOLT BOEING 747 747400 NM ENGINE LOOSE W O OTHER K Y J FLUID LOSS ENGINE STOPPAGE WARNING INDICATION CR CRUISE 1 AU S NR 3 ENGINE INFLIGHT SHUTDOWN DUE TO OIL LOSS. INVESTIGATION FOUND LOOSE BOLTS (2OFF) ON THE TRANSFER DRIVE LOWER FITTI NG. AIRCRAFT IS FOREIGN REGISTERED. 2 L 7 4 4F RT A20WE 2006070300069 20060703 00069 CE 2006 7 3 AU510001784 1 20050908 G 8011 EBB131A GEAR CESSNA 172 172P 2072436 CE LYC O360 O360A4M 41514 EA MCAULY 1A170 1A170FFA GL STARTER DISINTEGRATED W K NONE O OTHER IN INSP/MAINT 1 AU S 196 EO94821 ENGINE STARTER MOTOR DRIVE GEAR DISINTEGRATED. ENGINE RING GEAR DAMAGED. 1 H 7 1 3O 3 O NT 3A12 E286 5 N P857 2006070300070 20060703 00070 SO 2006 7 3 AU510001785 1 20051212 G 3222 4033600 LINK PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S NOSE LANDING GEAR LINK ASSEMBLY CRACKED AS REFERENCED IN PIPER SL 1088. 1 L 7 2 3O 3 O A20SO E14EA 2006070500124 20060705 00124 2006 7 5 AU510001786 4 20050307 G 2310 8220987003 COUPLER BOEING 737 737800* NM GE CFM56 CFM567B24 NE HF COMMS FAILED W O OTHER O OTHER CR CRUISE 1 AU S (AUS) NR 1 HF SYSTEM ANTENNA COUPLER FAILED. (CASA NR 510001786) 2 L 7 2 4F 4 F RT A16WE E00055EN 2006070500125 20060705 00125 CE 2006 7 5 AU510001787 1 20051212 G 5753 16916000520 RIB BEECH 23 C24R 1151254 CE LYC O360 IO360A1B6 41514 EA HARTZL HCM2Y HCM2YR GL TE FLAPS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 3361 (AUS) LT FLAP IB HINGE BRACKET ATTACHMENT RIB SEVERELY CORRODED. FOUND DURING INSPECTION IAW AD/23/43.(AD/SB DESC: AD/ 23/43 ) (CASA NR 510001787) 1 L 7 1 3O 3 O A1CE 1E10 5 C P43GL 2006070500127 20060705 00127 EU 2006 7 5 AU510001788 1 20051212 G 2822 41400017RX PUMP GIPPLD GA8 GA8 3900102 EU LYC O540 IO540K1A5 41532 EA HARTZL HCC2Y HCC2YR1 GL FUEL BOOST FAILED W O OTHER J WARNING INDICATION CR CRUISE 1 AU S 783 783 (AUS) AUXILIARY FUEL PUMP DRIVE SHEARED. PUMP IS LOCATED BENEATH COPILOT SEAT.(OTHER CAUSE: MATERIAL ) (CASA NR 51000178 8) 1 H 7 1 3O 3 O NT 1E4 5 C P920 2006070500128 20060705 00128 EA 2006 7 5 AU510001789 2 20051208 G 7314 RG17980DM PUMP GIPPLD GA8 GA8 3900102 EU LYC O540 IO540K1A5 41532 EA HARTZL HCC2Y HCC2YR1 GL FUEL SYS FAILED W O OTHER E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 AU S 762 762 (AUS) ENGINE DRIVEN FUEL PUMP FAILED. (CASA NR 510001789) 1 H 7 1 3O 3 O NT 1E4 5 C P920 2006070500129 20060705 00129 NM 2006 7 5 AU510001790 1 20051212 G 3320 79341 BALLAST BOEING 737 737 UTILSYS NM CABIN LIGHTS FAILED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 AU S 6308 (AUS) ELECTRICAL BURNING SMELL IN CABIN. INVESTIGATION FOUND EVIDENCE OF OVERHEATED FLUORESCENT CABIN LIGHTING BALLAST. AIRCRAFT IS FOREIGN REGISTERED. (CASA NR 510001790) 2 L 7 2 4F RT A16WE 2006070500130 20060705 00130 2006 7 5 AU510001791 4 20051212 G 3417 7006988975 CIRCUIT CARD ADC FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) DIGITAL AIR DATA COMPUTER (DADC) CIRCUIT CARD ASSEMBLY (CCA) INTERNAL FAULT. FOUND DURING INSPECTION IAW AD/INST/ 9 AND FAR43E.(AD/SB DESC: AD INST 9 FAR43E ) (OTHER CAUSE: MATERIAL ) (CASA NR 510001791) 2006070500139 20060705 00139 EA 2006 7 5 AU510001792 2 20051212 G 8520 AEL74241PL PISTON RING BEECH 76 76 1153005 CE LYC O360 O360A1G6D EA HARTZL HCM2Y HCM2YR GL ENGINE DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S 717 (AUS) ENGINE PISTON TOP COMPRESSION RINGS EXHIBITED SLIGHT SIGNS OF DELAMINATION. ENGINE OIL VERY DIRTY. PREMATURE WEAR ALSO FOUND ON EXHAUST VALVE ROTATING CAPS. (CASA NR 510001792) 1 L 7 2 3O 3 O A29CE E286 5 C P43GL 2006070500140 20060705 00140 2006 7 5 AU510001793 4 20051212 G 2340 5145142 AUDIO PANEL BOEING 737 737800* NM GE CFM56 CFM567B24 NE COCKPIT FAULTY W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 AU S (AUS) SMOKE AND FUMES IN IN COCKPIT. INVESTIGATION FOUND CAPTAIN`S INTERPHONE SYSTEM AUDIO SELECTOR PANEL FAULTY WITH TH E MIC SELECTOR SWITCH STUCK AND THE LED NOT WORKING. SUSPECT CAUSED BY FLUID SPILLAGE CAUSING CORROSION. (CASA NR 51000 1793) 2 L 7 2 4F 4 F RT A16WE E00055EN 2006070500215 20060705 00215 CE 2006 7 5 AU510001794 1 20051212 G 2752 C1444881 ACTUATOR LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP TE FLAPS UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 AU S 4885 (AUS) RT OB FLAP ACTUATOR WORN EXCESSIVELY IN GIMBAL TO SCREWJACK ATTACHMENT AREA. FURTHER INVESTIGATION FOUND THE ACTUA TOR GIMBAL LOWER PIN MISSING. UPPER GIMBAL PIN RETAINING CLIP CORRODED. (OTHER CAUSE: MATERIAL - AGE ) (CASA NR 5100017 94) 2 L 7 2 4F 4 F RT T00008WI E6WE 2006070500123 20060705 00123 NE 2006 7 5 AU510001795 2 20051212 G 8500 ENGINE DOUG DC3 DC3CS1C3G 3021458 WP PWA R1830 R183092 52020 NE HAMSTD 23E 23E51 NE MALFUNCTIONED W K NONE E VIBRATION/BUFFET CR CRUISE 1 AU S 9118 713 7043 ENGINE SHUT DOWN DUE TO ROUGH RUNNING. INVESTIGATION CONTINUING. 2 L 7 2 4R 4 R A669 5E4 6 C P603 2006070500236 20060705 00236 NM 2006 7 5 AU510001796 1 20051212 G 5610 141A481018 WINDOW BOEING 737 737* NM GE CFM56 CFM567B24 NE COCKPIT FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) F/O NR 2 SLIDING WINDOW SHATTERED. (CASA NR 510001796) 2 L 7 2 4F 4 F RT A16WE E00055EN 2006070500237 20060705 00237 EU 2006 7 5 AU510001797 1 20051212 G 2761 P308450102 JACKSHAFT BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE LIFT SPOILER CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 31055 8406 (AUS) LT CENTER AND RT OB LIFT SPOILER JACKS CORRODED BEYOND LIMITS IN PISTON THREADS FOR EYE ENDS. FOUND DURING INSPECT ION IAW AAES ER BA6-27-60-23B AND BAE SYSTEMS SB 27-176. (CASA NR 510001797) 2 H 7 4 4F 4 F RT A49EU E6NE 2006070500126 20060705 00126 CE 2006 7 5 AU510001798 1 20051212 G 2731 332X375TYPE3 SHEAR PIN CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO ELEVATOR FAILED W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 AU S ELEVATOR ACTUATOR DRIVE SHEAR PINS FAILED. 1 L 7 2 3O 3 O 3A10 E5CE 2006070500238 20060705 00238 CE 2006 7 5 AU510001799 1 20051212 G 3260 602EN556B SWITCH CESSNA 404 404 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL GEAR UPLOCK UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT MAIN LANDING GEAR UPLOCK MICROSWITCH FAILED. SWITCH HAD ONLY 54.5 HOURS OPERATION SINCE REPLACEMENT. (CASA NR 5 10001799) 1 L 7 2 3O 3 O RT A25CE E7CE 5 C P45GL 2006070500239 20060705 00239 CE 2006 7 5 AU510001800 1 20051212 G 5320 4118991 STIFFENER CESSNA 150 150H 2071818 CE CONT O200 O200A 17020 SO MCAULY 1A101 1A101DCM GL FUSELAGE CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 2482 (AUS) LT LANDING GEAR GEAR ATTACHMENT SADDLE (STIFFENER) CORRODED IN AFT LOWER SECTION. EVIDENCE OF DELAMINATION THROUG H THE FULL HEIGHT OF THE LOWER SECTION. SEE ATTACHMENT FOR PHOTOGRAPHS OF DEFECT. (CASA NR 510001800) 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2006071000109 20060710 00109 EU 2006 7 10 AU510001802 1 20051212 G 4940 51895411 MOTOR HONEYWELL FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE STARTER SHEARED W O OTHER O OTHER DE DESCENT 1 AU S 1511 P228 APU STARTER MOTOR DRIVE SHAFT SHEARED. 2 L 7 2 4F 4 F RT E25NE 2006071000112 20060710 00112 EU 2006 7 10 AU510001803 1 20051212 G 3233 AIR864101 ACTUATOR SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE RT MLG SLUGGISH W O OTHER J WARNING INDICATION DE DESCENT 1 AU S RT MAIN LANDING GEAR RETRACTION ACTUATOR SLUGGISH IN OPERATION. INVESTIGATION CONTINUING. 2 L 7 2 4T 4 T RT A52EU E8NE 2006071000113 20060710 00113 EU 2006 7 10 AU510001804 1 20051212 G 3246 BOLT FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE MAIN WHEEL ASSY BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 25764 456 OCT940013 NR 2 MAIN WHEEL TIE BOLT BROKEN. BOLT HEAD MISSING. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT E25NE 2006071000114 20060710 00114 2006 7 10 AU510001805 4 20051212 G 3441 HG1050AD04 IRU FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE FAILED W O OTHER O OTHER NR NOT REPORTED 1 AU S 41061 NR 2 INERTIAL REFERENCE UNIT (IRU) INTERMITTENTLY FAILS CODE 2. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT E25NE 2006071000115 20060710 00115 NE 2006 7 10 AU510001806 2 20051212 G 7297 C821805 POWER CABLE SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A2 30030 NE ROTOL R354 R3544123F13 NE LT ENGINE SEPARATED W K NONE O OTHER IN INSP/MAINT 1 AU S 30326 LT ENGINE POWER CABLE SEPARATED IN AREA LOCATED BETWEEN WHEEL WELL AND CABLE TERMINAL PULLEY SECTOR. 2 L 7 2 4T 4 T RT A52EU E8NE6 6 C P61GL 2006071000116 20060710 00116 2006 7 10 AU510001807 4 20050109 G 3421 H301BAM INDICATOR FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE ART HORIZ FAULTY W K NONE N FALSE WARNING IN INSP/MAINT 1 AU S 18009 STANDBY ARTIFICIAL HORIZON (AH) FAULTY. AH HAS A SLIGHT TILT TO THE LEFT. 2 L 7 2 4F 4 F RT E25NE 2006071000117 20060710 00117 EU 2006 7 10 AU510001808 1 20051212 G 5751 SKIN BAC BAC 146 146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE AILERON CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S LT AILERON PN HC576C0077-000 CRACKED AT THE SECOND OUTBOARD AILERON HINGE FOR THE OUTBOARD TAB. RT AILERON PN HC576C007 7-001 ALSO CRACKED AT THE OUTBOARD TAB HINGE. 2 H 7 4 4F 4 F RT A49EU E6NE 2006071000118 20060710 00118 CE 2006 7 10 AU510001809 1 20050209 G 5712 5720013S RIB CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL LT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 17021 LT WING UPPER FORWARD PN 572001-3S AND AFT PN 572001-5S DRAG ANGLES CRACKED. FOUND DURING EDDY CURRENT INSPECTION IAW C QB03-1 REV 1. EDDY CURRENT INSPECTION REVEALED A TOTAL OF NINE CRACKS ALL AROUND 5MM (0.196IN) IN LENGTH. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2006071000119 20060710 00119 SO 2006 7 10 AU510001810 1 20050208 G 8120 4091709001 TURBOCHARGER PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA RT ENGINE FAILED W C ABORTED TAKEOFF B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION TO TAKEOFF 1 AU S 1495 1495 RT ENGINE TURBOCHARGER FAILED. 1 L 7 2 3O 3 O A20SO E14EA 2006071100162 20060711 00162 SO 2006 7 11 AU510001811 1 20051212 G 3246 MS2125005016 BOLT BFGOODRICH 314461 EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE MGL WHEEL BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 434 2447 (AUS) LT OB MAIN WHEEL TIE BOLTS BROKEN. INVESTIGATION CONTINUING. (CASA NR 510001811) 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 2006071100163 20060711 00163 NM 2006 7 11 AU510001812 1 20051212 G 7830 BLOCKER DOOR RROYCE BOEING 767 767300 1385204 NM RROYCE RB211 RB211524* NE THRUST REVERSER DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RT ENGINE THRUST REVERSER BLOCKER DOORS (3OFF) DAMAGED. INVESTIGATION ALSO FOUND RT ENGINE GAS GENERATOR FAIRING A T RT SIDE (A) FRAME DAMAGED. RT ENGINE GAS GENERATOR FAIRING (A) FRAME FAIRING LOWER HALF DAMAGED. RT ENGINE GAS GENERAT OR FAIRING (A) FRAME FAIRING TOP HALF MISSING. DURING GAS GENERATOR FAIRING REPLACEMENT FORWARD ATTACHMENT BRACKETS (4OF F) FOUND DAMAGED. SEE ATTACHMENT FOR INVESTIGATION DETAILS. (CASA NR 510001812) 2 L 7 2 4F 4 F RT A1NM E12EU 2006071100168 20060711 00168 2006 7 11 AU510001813 4 20051212 G 3452 G699010 CONTROL PANEL BOEING 737 737800* NM GE CFM56 CFM567B24 NE ATC TRANSPONDER FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) ATC TRANSPONDER CONTROL PANEL FAILED. (CASA NR 510001813) 2 L 7 2 4F 4 F RT A16WE E00055EN 2006071100169 20060711 00169 GL 2006 7 11 AU510001814 3 20051212 G 6111 C5022 SPRING MCAULY CESSNA 441 441 2076020 CE GARRTT TPE331 TPE331* 01514 WP MCAULY 3G34C6 3GFR34C601 GL PROPELLER BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 816212 (AUS) PROPELLER FEATHERING AND UNREVERSING SPRING FAILED. (CASA# 510001814) 1 L 7 2 3T 3 T RT A28CE E2WE 6 C P54GL 2006060800093 20060608 00093 NM 2006 6 8 AU510001815 1 20051212 G 2620 CIRCUIT BREAKER BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE APU FIRE EXTING TRIPPED W K NONE O OTHER IN INSP/MAINT 1 AU S APU FIRE EXTINGUISHING SYSTEM CIRCUIT BREAKER PULLED AND RED COLLARED. CIRCUIT BREAKER RESET AND SYSTEM TESTED SERVICEA BLE. SUSPECT CIRCUIT BREAKER PULLED WHEN MEL APPLIED AND NOT RESET WHEN MEL CLEARED. 2 L 7 2 4F 4 F RT A16WE E2GL 2006060800094 20060608 00094 SO 2006 6 8 AU510001816 2 20051212 G 8520 6461402 STUD CESSNA 404 404 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL NR 5 CYLINDER BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 981 276339R RT ENGINE NR 5 CYLINDER HOLD-DOWN STUDS (2OFF) BROKEN OFF FLUSH WITH THE CYLINDER BASE. 1 L 7 2 3O 3 O RT A25CE E7CE 5 C P45GL 2006060800095 20060608 00095 CE 2006 6 8 AU510001817 1 20050109 G 3710 SHAFT CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO VACUUM PUMP SHEARED W O OTHER J WARNING INDICATION CR CRUISE 1 AU S 36914 VACUUM PUMP DRIVE SHAFT SHEARED DUE TO INTERNAL PUMP FAILURE. 1 H 7 1 3O 3 O A4CE E5CE 2006060800096 20060608 00096 WP 2006 6 8 AU510001818 2 20051212 G 7261 30719496 PUMP LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP RT ENGINE OIL FAULTY W O OTHER K FLUID LOSS CR CRUISE 1 AU S P74668 RT ENGINE OIL LUBRICATION PUMP FAULTY. OIL WAS NOT SCAVENGED FROM NR 6 BEARING AREA AND WAS LEAKING OUT THROUGH THE BEA RING SEAL. 2 L 7 2 4F 4 F A10CE E6WE 2006060800097 20060608 00097 WP 2006 6 8 AU510001819 2 20051212 G 7260 SHAFT LEAR 35 35A 5170602 CE GARRTT TFE731 TFE73122B 01518 WP ENGINE FAILED W O OTHER Y ENGINE STOPPAGE CR CRUISE 1 AU S P74668 ENGINE CHIP DETECTOR CONTAMINATED WITH METAL PARTICLE. SUSPECT ACCESSORY SECTION TOWER SHAFT OR POWER SHAFT FAILED. IN VESTIGATION CONTINUING. 2 L 7 2 4F 4 F A10CE E6WE 2006060800298 20060608 00298 SW 2006 6 8 AU510001820 1 20050109 G 5711 SPAR MOONEY M20 M20C 5870208 SW LYC O360 O360A1D 41514 EA HARTZL HCC2Y HCC2YK1 GL WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S DURING MOD REPAIR, NUMEROUS DEFECTS FOUND RELATING MAINLY TO CORROSION IN WING & ATTACH STRUCTURE. FOLLOWING DEFECTS FO UND, EXFOLIATION OF EXTRUSIONS ON REAR SPAR CAPS IN BOTH W/W. CNTR SECTION OF 1 PIECE WING OPENED UP FOR INSPECT & REV EALED OLD FIBERGLASS TYPE INSULATION & 2 DEAD RATS. CLEANING THIS AREA REVEALED SEVERE EXFOLIATION OF EXTRUSIONS AROUND LT MAIN SPAR ATTACHMENT FITTING. REMOVAL OF WING TO FURTHER ASSESS VIABILITY OR REPAIR & REVEALED MORE CORROSION OF ST EEL FRAME AT WING ATTACHMENT FITTINGS AND FUSELAGE STR`S EXFOLIATING AT ATTACHMENT TO STEEL TUBE FRAME. WING ATTACHMENT BOLTS SEVERELY RUSTED & BOLTS AND LOCKWIRE WERE STILL PAINTED BLUE FROM PREVIOUS PAINT JOB TO A/C SOME YEARS PRIOR. 1 L 7 1 3O 3 O 2A3 E286 5 C P920 2006060800098 20060608 00098 2006 6 8 AU510001821 4 20050209 G 3442 MI585353 ANTENNA DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE WX RADAR SYS FAILED W O OTHER O OTHER CR CRUISE 1 AU S WEATHER RADAR ANTENNA FAILED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006060800099 20060608 00099 NM 2006 6 8 AU510001822 1 20050109 G 6120 CONTROL ROD DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE LT PROPELLER FOULED W K NONE O OTHER IN INSP/MAINT 1 AU S LT PROPELLER CONTROL ROD ATTACHMENT BOLT SPLIT PIN TAIL FOULING ON POWER LEVER CONTROL ROD RODEND LOCKNUT LOCKWIRING. T HIS CAUSED THE LT PROPELLER CONTROL LEVER TO STICK AND THE LT POWER LEVER TO MOVE THE PROPELLER CONTROL LEVER WAS MOVED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006060800178 20060608 00178 EU 2006 6 8 AU510001823 1 20051212 G 5540 TB10310000 HINGE SOCATA TB10 TB10TOBAGO 8680696 EU LYC O360 O360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL RUDDER CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 2966 0 FOUND TOP RUDDER HINGE CORRODED. 1 L 7 1 3O 3 O RT A51EU E286 5 C P920 2006060800180 20060608 00180 EU 2006 6 8 AU510001824 1 20051212 G 7120 TB1050001000 MOUNT SOCATA TB10 TB10TOBAGO 8680696 EU LYC O360 O360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 2966 ENGINE MOUNT CRACKED. FOUND DURING INSPECTION IAW AD/TB10/8 AND TBSB NO 16/1. 1 L 7 1 3O 3 O RT A51EU E286 5 C P920 2006060800182 20060608 00182 EU 2006 6 8 AU510001825 1 20051212 G 5520 TB1034020001 HINGE SOCATA TB10 TB10TOBAGO 8680696 EU LYC O360 O360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL ELEVATOR TAB CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 2966 RT STABILATOR HINGE CORRODED, AD/SB DESC: CASA SCHEDULE 5. 1 L 7 1 3O 3 O RT A51EU E286 5 C P920 2006060800184 20060608 00184 NM 2006 6 8 AU510001826 1 20051212 G 2997 DP1204 CONNECTOR BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE HYD PUMP BROKEN W A UNSCHED LANDING K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 AU S 7044 7044 LOSS OF SYSTEM `A` HYDRAULIC PRESSURE AND QUANTITY. INVESTIGATION FOUND THE NR 1 ENGINE DRIVEN HYDRAULIC PUMP CONNECTOR DP1204 HARD PLASTIC INSERT BROKEN. METAL CONTAMINATION OF HYDRAULIC FILTER. BURNING SMELL DURING TAKEOFF SUSPECTED TO BE HYDRAULIC PUMP OIL RESIDUE. 2 L 7 2 4F 4 F RT A16WE E2GL 2006060800187 20060608 00187 SW 2006 6 8 AU510001827 1 20050509 G 2150 20475546 ACM SWRNGN SA227 SA227* SW GARRTT TPE331 TPE3311 01514 WP MCAULY 4HFR34 4HFR34C652 NE CABIN COOLING FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS LD LANDING 1 AU S 1035 RT AIRCYCLE MACHINE (ACM) FAILED. SMOKE AND FUMES IN AIRCRAFT. 2 L 7 2 4T 3 T RT A5SW E3WE 6 C 3PNE 2006060800189 20060608 00189 CE 2006 6 8 AU510001828 1 20050209 G 8011 MMU4001R MOTOR CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL STARTER SHORTED W K NONE O OTHER IN INSP/MAINT 1 AU S 45 ENGINE STARTER MOTOR INTERNAL SHORT CIRCUIT. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2006060800336 20060608 00336 NM 2006 6 8 AU510001829 1 20051212 G 5320 85CH70020A INTERCOSTAL BOEING 747 747338 NM RROYCE RB211 RB211524* NE BS 140 CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S INTERCOSTAL CRACKED. CRACK LOCATED AT FORWARD FACE OF BS 140 FPB AT LBL 20 AT 2 O`CLOCK POSITION LOOKING AFT. FOUND DU RING INSPECTION IAW AD/B747/159 AND EI 747-053-0215. 2 L 7 2 4F 4 F RT A20WE E12EU 2006060800396 20060608 00396 NM 2006 6 8 AU510001830 1 20051212 G 5311 141U10423 FRAME BOEING BOEING 747 747338 NM RROYCE RB211 RB211524* NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S FOUND FUSELAGE INNER CHORD RING CRACKED. CRACK LOCATED AT FASTENER HOLE LBL 33.5 AND WL 153 BS 140 FPB (REAR FACE). FO UND DURING INSPECTION IAW AD/B747/159 AND EI 747-053-0215. 2 L 7 2 4F 4 F RT A20WE E12EU 2006060800399 20060608 00399 NM 2006 6 8 AU510001832 1 20050609 G 3246 277A6000204 WHEEL BOEING 737 7377BX 13844D2 NM GE CFM56 CFM56* 13802 NE MLG WRONG PART W O OTHER O OTHER LD LANDING 1 AU S INCORRECT PART NUMBER MAIN WHEEL FITTED TO LT MAIN LANDING GEAR NR 2 POSITION. WHEEL FITTED WAS PNO 277A6000-204 WHICH IS FOR FITMENT TO 737-800 SERIES AIRCRAFT. THE CORRECT P/N 277A6000-206 IS FITTED TO 737-700 SERIES. THE INCORRECT WHE EL IS A HIGH GROSS WEIGHT (HGW) MAIN WHEEL WITH A TIRE DIAMETER 25.4MM (1IN) GREATER THAN THE CORRECT LOW GROSS WEIGHT ( LGW) MAINWHEEL. INCORRECT PART PERSONNEL/MAINTENANCE ERROR. 2 L 7 2 4F 4 F RT A16WE E2GL 2006060800400 20060608 00400 NE 2006 6 8 AU510001833 2 20050909 G 7230 FAN BLADE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE ENGINE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S ENGINE LP FAN BLADE CONTAINED NICKS IN THE LEADING EDGE. THE DAMAGE WAS BLENDED OUT AND AN EDDY CURRENT INSPECTION IS D UE WITHIN 50 HOURS. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT E25NE 2006060800401 20060608 00401 NE 2006 6 8 AU510001834 2 20050809 G 7310 PUMP FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE EJECTOR OBSTRUCTED W K NONE O OTHER IN INSP/MAINT 1 AU S RT ENGINE ENVIRONMENTAL DRAIN TANK EJECTOR PUMP BLOCKED. 2 L 7 2 4F 4 F RT E25NE 2006060800402 20060608 00402 NM 2006 6 8 AU510001835 1 20050809 G 5410 HA2261 LATCH BOEING 737 7377Q8 1384418 NM GE CFM56 CFM56* 13802 NE NACELLE DOOR BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S ENGINE CORE COWL NR 6 LATCH BROKEN. FURTHER INVESTIGATION FOUND NR 1, NR 3, NR 4 AND NR 5 LATCHES CRACKED. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061300102 20060613 00102 EU 2006 6 13 AU510001836 1 20051009 G 2910 O-RING BAC 146 146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE HYDRAULIC SYS FAILED W O OTHER K FLUID LOSS CR CRUISE 1 AU S LOSS OF HYDRAULIC FLUID. INVESTIGATION FOUND A FAILED O-RING SEAL AT THE PIPE CONNECTOR ON NR 2 HIGH PRESSURE MANIFOLD. THIS PIPE SUPPLIES GREEN SYSTEM HIGH PRESSURE FLUID THROUGH THE STANDBY GENERATOR ISOLATION VALVE. 2 H 7 4 4F 4 F A49EU E6NE 2006061300103 20060613 00103 SO 2006 6 13 AU510001837 1 20051109 G 3250 110P241020 STEERING SYS EMB 110 EMB110P2 3260124 SO PWA PT6 PT6A34 52043 EA HARTZL HCB3T HCB3TN3 GL NLG UNSERVICEABLE W O OTHER O OTHER LD LANDING 1 AU S NOSE WHEEL STEERING SYSTEM FAULTY. STEERING SYSTEM TRAVEL WAS RESTRICTED. LT MAIN LANDING GEAR AND NOSE GEAR RAN OFF R UNWAY AND BECAME BOGGED IN THE SOFT SURFACE AT THE SIDE OF THE RUNWAY. 1 L 7 2 4T 4 T A21SO E4EA 6 C P15EA 2006061300104 20060613 00104 NM 2006 6 13 AU510001838 1 20050909 G 2910 1550121221 HOSE BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE HYDRAULIC SYS LEAKING W O OTHER K FLUID LOSS LD LANDING 1 AU S (AUS) RT ENGINE DRIVEN HYDRAULIC PUMP TO PYLON QUICK DISCONNECT PRESSURE HOSE LEAKING. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061300105 20060613 00105 2006 6 13 AU510001839 4 20050909 G 3442 6225136203 DRIVE ASSY BOEING 747 747438 NM RROYCE RB211 RB211524* NE WX RADAR SYS FAULTY W O OTHER O OTHER CR CRUISE 1 AU S 33097 5139 WEATHER RADAR ANTENNA DRIVE PEDESTAL FAULTY. 2 L 7 4 4F 4 F RT A20WE E12EU 2006061300107 20060613 00107 NM 2006 6 13 AU510001840 1 20050608 G 2131 71211997101AC CONTROLLER BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE CABIN PRESSURE FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 10902 10902 NR 2 CABIN PRESSURE CONTROLLER FAULTY. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061300108 20060613 00108 NM 2006 6 13 AU510001841 1 20050809 G 2121 732591D FAN BOEING 767 767300 1385204 NM GE CF6 CF680C2* GL EXHAUST FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S 58337 19354 ELECTRICAL BURNING SMELL ON FLIGHT DECK. INVESTIGATION FOUND THE FORWARD EQUIPMENT EXHAUST FAN FAILED. FAN BEARINGS CO LLAPSED AND ROTOR WORN OUT. 2 L 7 2 4F 4 F RT A1NM E23EA 2006061300109 20060613 00109 NM 2006 6 13 AU510001842 1 20050209 G 3610 REGULATOR BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE PNEUMATIC SYS FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S LT BLEED AIR FAILURE. BLEED AIR REGULATOR AND PRECOOLER CONTROL VALVE REPLACED. INVESTIGATION FOUND PRECOOLER CONTROL VALVE FAULTY. POPPET SET AND ADAPTER PLATE WORN. SIGNIFICANT CONTAMINATION INSIDE VALVE. BLEED AIR REGULATOR ALSO FAI LED SHOP TEST. RELIEF VALVE AND POPPET WORN. PRECOOLER CONTROL VALVE AND BLEED AIR REGULATOR DEFECTS CONSIDERED TO ADVE RSELY AFFECT PRECOOLER OPERATION WITH THE BLEED OVER TEMPERATURE SWITCH ACTIVATING THE BLEED TRIP LIGHTS. THESE DEFECTS CONSIDERED TO BE DUE TO ENGINE VIBRATION. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061300110 20060613 00110 2006 6 13 AU510001843 4 20051212 G 2340 INTERPHONE BOEING 747 747338 NM RROYCE RB211 RB211524* NE CABIN UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 AU S CABIN INTERPHONE SYSTEM FAULTY. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT A20WE E12EU 2006061300111 20060613 00111 NM 2006 6 13 AU510001844 1 20050509 G 3150 285N04329 CIRCUIT CARD BOEING 767 767338 1385151 NM GE CF6 CF680C GL CENTRAL WARNING FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S EICAS SIGNAL CONSOLIDATION CARD (SCC) FAILED. 2 L 7 2 4F 4 F RT A1NM E23EA 2006061300227 20060613 00227 2006 6 13 AU510001845 4 20050209 G 3197 W105201322 WIRE BOEING 767 767300 1385204 NM RROYCE RB211 RB211524* NE WARNING SWITCH WORN W O OTHER B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 AU S SMOKE IN COCKPIT EMANATING FROM NEAR TO CAPTAIN`S GLARE SHIELD. INVESTIGATION FOUND A CHAFED WIRE AT PIN 13 OF THE CAPT AIN`S CAUTION/WARNING SWITCH ASSEMBLY ON THE GLARE SHIELD. 2 L 7 2 4F 4 F RT A1NM E12EU 2006061300228 20060613 00228 NE 2006 6 13 AU510001846 2 20051209 G 7321 2042M67P02 EEC BOEING 737 737* NM GE CFM56 CFM56* 13802 NE NR 1 ENGINE FAULTY W O OTHER F J FLT CONT AFFECTED WARNING INDICATION CL CLIMB 1 AU S 384 NR 1 ENGINE ELECTRONIC CONTROL (EEC) FAULTY. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061300230 20060613 00230 EU 2006 6 13 AU510001847 1 20050209 G 7603 C822249 CONTROL CABLE SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A 30030 NE ROTOL R354 R3544123F13 NE POWER LEVER BROKEN W O OTHER F FLT CONT AFFECTED CL CLIMB 1 AU S RT ENGINE POWER LEVER CABLE BROKEN AT END FITTING WHERE IT ATTACHES TO THE HYDROMECHANICAL UNIT (HMU). 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P61GL 2006061300231 20060613 00231 NM 2006 6 13 AU510001848 1 20051209 G 3244 TIRE HONEYWELL BOEING 737 737* NM GE CFM56 CFM56* 13802 NE MLG DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S B4852 NR 4 MAIN WHEEL TIRE TREAD DELAMINATED AT INBOARD SIDEWALL. TIRE HAS A RETREAD DATE R1 505. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061300232 20060613 00232 NM 2006 6 13 AU510001849 1 20050909 G 5210 232U212220B SOLENOID BOEING 747 747438 NM RROYCE RB211 RB211524* NE PAX DOOR LATCH FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 AU S STRONG ODOR ON FLIGHT DECK. INVESTIGATION FOUND THE FLIGHT DECK DOOR CIRCUIT BREAKER P6-3 D21 TRIPPED. FLIGHT DECK DOO R EMERGENCY PANEL INOPERATIVE AND DOOR LATCH WAS WARM. INVESTIGATION FOUND THE COCKPIT DOOR LOCK SOLENOID HAD FAILED. 2 L 7 4 4F 4 F RT A20WE E12EU 2006061300233 20060613 00233 2006 6 13 AU510001850 4 20051109 G 2211 4051601937 CONTROL PANEL BOEING 737 737400 138449A NM CFMINT CFM56 CFM563C 13802 EU AUTOPILOT FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS DE DESCENT 1 AU S 36869 7253 AUTOPILOT MODE CONTROL PANEL (MCP) FAILED. 2 L 7 2 4F 4 F RT A16WE E21EU 2006071800172 20060718 00172 EU 2006 7 18 AU510001853 1 20051109 G 2701 936401312 CONTROL COLUMN REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL COCKPIT STICKING W O OTHER F FLT CONT AFFECTED CR CRUISE 1 AU S 10005 (AUS) CONTROL YOKE STICKING DURING ROLL INPUT. INVESTIGATION FOUND THE CONTROL YOKE CONTACTING THE LT DEFOG VENT. FURTH ER INVESTIGATION FOUND THE BOLT HOLES CONTAINED WITHIN THE CONTROL COLUMN YOKE WERE ELONGATED. (CASA NR 510001853) 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2006061400176 20060614 00176 SO 2006 6 14 AU510001854 1 20050509 G 5751 4020043 ATTACH BRACKET PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA HARTZL HCE3Y HCE3YR2A GL RT AILERON CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S RT AILERON CRACKED IN AREA OF CONTROL ROD/SPAR ATTACHMENT BRACKET. FOUND DURING COLOR CONTRAST DYE PENETRANT INSPECTION IAW AD/PA31/118. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2006061400178 20060614 00178 SO 2006 6 14 AU510001855 1 20050609 G 5551 40024T008 ROD END AYRES S2 S2RT15RESTD SO PWA PT6 PT6A15AG 52043 NE HARTZL HCB3T HCB3TN3 GL HORIZONTAL STAB BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S LT HORIZONTAL STABILIZER ATTACHMENT BOLT BROKEN AT TOP OF THREADED AREA UNDER CLEVIS. FOUND WHEN STABILIZER REMOVED FOR PAINTING. INSPECTION FOUND ALL OTHER ATTACHMENT BOLTS RUSTED AND PITTED IN THE SAME AREA. 1 L 7 1 3T 4 T A4SW E4EA 6 C P15EA 2006061500098 20060615 00098 CE 2006 6 15 AU510001856 1 20050306 G 8010 99100791 SWITCH CESSNA 404 404 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL STARTER FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 219 LT ENGINE STARTER SWITCH FAILED. SWITCH REMAINED ENGAGED. 1 L 7 2 3O 3 O RT A25CE E7CE 5 C P45GL 2006061500110 20060615 00110 CE 2006 6 15 AU510001857 1 20050104 G 8011 643109 SPRING CONT CESSNA 210 210N 2073453 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL STARTER ADAPTER BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S ENGINE STARTER ADAPTER CLUTCH SPRING TANG BROKEN OFF. 1 H 7 1 3O 3 O 3A21 E5CE 5 C P47GL 2006061500111 20060615 00111 CE 2006 6 15 AU510001858 1 20051212 G 8011 643109 CLUTCH SPRING CONT CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO STARTER ADAPTER BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 6193 0 ENGINE STARTER ADAPTER CLUTCH SPRING TANG BROKEN OFF. 1 H 7 1 3O 3 O A4CE E5CE 2006061500112 20060615 00112 CE 2006 6 15 AU510001859 1 20051212 G 2434 ALE2045BS BRUSH BLOCK CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL ALTERNATOR DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 200 200 E112870E0604 ALTERNATOR HAD HIGH RESISTANCE IN BOTH BRUSH BLOCK CONNECTIONS. 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 2006061500133 20060615 00133 CE 2006 6 15 AU510001860 1 20051212 G 2497 WIRE LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE731* 01518 WP BUSS BAR SHORTED W K NONE O OTHER IN INSP/MAINT 1 AU S 3741 BUSS BAR CABLE SHORT CIRCUITED TO RT CIRCUIT BREAKER PANEL. FURTHER INVESTIGATION FOUND A LOOSE CONNECTING SCREW ON THE ICE DETECTION CIRCUIT BREAKER WHICH HAD BURNT OUT. 2 L 7 2 4F 4 F RT T00008WI E6WE 2006061500134 20060615 00134 EU 2006 6 15 AU510001861 1 20051209 G 2760 FON21185V46 BOLT FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY62015 04564 NE SPOILER SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S RT LIFT DUMPER SYSTEM NR 1 BELLCRANK INBOARD UPPER ATTACHMENT BOLT SHEARED. 2 L 7 2 4F 4 F RT E25NE 2006061500135 20060615 00135 EU 2006 6 15 AU510001862 1 20051209 G 2760 MS212306 BEARING FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY62015 04564 NE SPOILER LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S RT LIFT DUMPER NR 3 BELLCRANK HORIZONTAL ROD ATTACHMENT BEARING MIGRATED OF POSITION. 2 L 7 2 4F 4 F RT E25NE 2006061500136 20060615 00136 SO 2006 6 15 AU510001863 2 20050809 G 8520 PN649134ASSY CRANKSHAFT CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO MCAULY D3A34 D3A34C404 GL ENGINE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 1691 ENGINE CRANKSHAFT COUNTERWEIGHT HANGER BLADE HOLES OUT OF ROUND. 1 H 7 1 3O 3 O A4CE E5CE 5 C P47GL 2006061500138 20060615 00138 EU 2006 6 15 AU510001864 1 20051209 G 2760 A16084003 ROD FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY62015 04564 NE SPOILER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S RH LIFT DUMPER SYSTEM VERTICAL ROD CRACKED. 2 L 7 2 4F 4 F RT E25NE 2006061500140 20060615 00140 SO 2006 6 15 AU510001865 2 20050709 G 8530 AEC631397 CYLINDER CESSNA 206 U206G 2073356 CE CONT O550 IO550F 17042 SO MCAULY D3A34 D3A34C401 GL ENGINE UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 AU S 186 284957R ENGINE CYLINDER DAMAGED. A PIECE OF THE NICKEL CARBIDE BORE COATING MISSING FROM THE TOP AREA OF THE CYLINDER BORE. SI ZE OF MISSING PIECE APPROXIMATELY 20MM BY 5MM BY 0.254MM DEEP (0.78IN BY 0.19IN BY 0.010IN DEEP). THE SECOND COMPRESSIO N RING WAS ALSO FOUND BROKEN IN TWO PLACES APPROXIMATELY 40MM (1.57IN) APART. THE FLOATING PIECE WAS JAMMED IN THE PIST ON RING GROOVE AND WAS STARTING TO BREAK UP. 1 H 7 1 3O 3 O A4CE E3SO 5 C P47GL 2006061500207 20060615 00207 EU 2006 6 15 AU510001866 1 20051212 G 2760 BOLT FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY62015 04564 NE SPOILER LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S NR 1 LT LIFT DUMPER SYSTEM BELLCRANK SPIGOT ATTACHMENT BOLTS LOOSE. 2 L 7 2 4F 4 F RT E25NE 2006061500235 20060615 00235 EU 2006 6 15 AU510001867 1 20051209 G 5753 MS1410414 BEARING FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY62015 04564 NE LT WING FLAP WORN W K NONE O OTHER IN INSP/MAINT 1 AU S LT WING TRAILING EDGE FLAP TRACK FORWARD SUPPORT BEARING WORN. 2 L 7 2 4F 4 F RT E25NE 2006061500236 20060615 00236 EU 2006 6 15 AU510001868 1 20051209 G 5753 MS1410414 BEARING FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY62015 04564 NE RT WING TE FLAP WORN W K NONE O OTHER IN INSP/MAINT 1 AU S RT WING FLAP TRACK BEAM ASSEMBLY FORWARD SUPPORT BEARING WORN. 2 L 7 2 4F 4 F RT E25NE 2006061500245 20060615 00245 2006 6 15 AU510001869 4 20051212 G 3416 70007641 POTENTIOMETER DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE ALTIMETER FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S ALTIMETER POTENTIOMETER NON-LINEAR IN OPERATION. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006061600001 20060616 00001 NM 2006 6 16 AU510001870 1 20051212 G 5414 311T245013 SKIN BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL RT NACELLE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 0 RT ENGINE STRUT INBOARD SKIN CRACKED FROM UPPER AFT RADIUS OF 442AL ACCESS PANEL CUTOUT THROUGH RIVET HOLE. CRACK IS LO CATED IN INTERNAL DOUBLER AS WELL. CRACK WAS CONFIRMED USING NDT. CRACK LENGTH APPROXIMATELY 63.5MM (2.5IN). 2 L 7 2 4F 4 F RT A1NM E23EA 2006061600002 20060616 00002 NM 2006 6 16 AU510001871 1 20050209 G 5414 311T245025 SKIN BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL RT NACELLE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S RT ENGINE STRUT INBOARD SKIN CRACKED FROM UPPER AFT RADIUS OF 442AL ACCESS PANEL CUTOUT AND THROUGH RIVET HOLE. CRACK C ONFIRMED USING NDT. CRACK LENGTH APPROXIMATELY 58.4MM (2.3IN). CRACK ALSO EXISTS IN INTERNAL DOUBLER AS WELL. 2 L 7 2 4F 4 F RT A1NM E23EA 2006071100110 20060711 00110 EU 2006 7 11 AU510001872 1 20051212 G 7722 9550124240 PROBE AEROSP AS355 AS355N 8680818 EU TMECA ARRIEL ARRIEL1C 60030 NE ENGINE TEMP FAILED W O OTHER D INFLIGHT SEPARATION CR CRUISE 1 AU S 1676 1676 (AUS) NR 1 ENGINE T4 TEMPERATURE PROBE SEPARATED FROM ENGINE. LOCKING NUT STILL FIRMLY ATTACHED TO MOUNTING POINT. (CASA NR 510001872) 1 G 7 2 3U 3 U RT H11GU E19EU 2006061600003 20060616 00003 SW 2006 6 16 AU510001873 1 20051212 G 3010 LINE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL ANTI-ICE SYS BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S BLEED AIR DE-ICE LINE BROKEN AT OUTBOARD EDGE OF RIGHT AILERON. LINE HAD FALLEN TO THE UNDERSIDE OF THE AILERON AND JAM MED BETWEEN THE WING LOWER CLOSEOUT PANEL AND THE AILERON LOWER LEADING EDGE WITH THE `B` NUT FITTING ON THE LINE INHIBI TING AILERON TRAVEL. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 2006061600005 20060616 00005 NM 2006 6 16 AU510001874 1 20051207 G 5415 SUPPORT FITTING BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 53856 LT AND RT ENGINE FORWARD SUPPORT FITTING ASSEMBLIES CRACKED. LT PYLON FITTING CRACKED AT HOLE `F`. RT PYLON FITTING CR ACKED AT HOLE `P`. FOUND DURING INSPECTION IAW AD/B727/151 AND BOEING SB 727-54A0010. 2 L 7 3 4F 4 F RT A3WE E2EA 2006061600009 20060616 00009 2006 6 16 AU510001875 4 20051212 G 3417 4040831901 SENSOR HONEYWELL AZ810 DADC OUT OF LIMITS W K NONE O OTHER IN INSP/MAINT 1 AU S 93035792 DIGITAL AIR DATA COMPUTER (DADC) PRESSURE CONVERTER (PS AND PT SENSOR) OUT OF TOLERANCE. 2006061900006 20060619 00006 SO 2006 6 19 AU510001876 2 20051212 G 8530 PISTON BEECH 33 3533 1151402 CE CONT O470 IO470J 17026 SO HARTZL HC92Z BHC92Z* GL ENGINE BROKEN W O OTHER Y J ENGINE STOPPAGE WARNING INDICATION CL CLIMB 1 AU S 636 636 852710J NR 6 CYLINDER PISTON BROKEN AT GUDGEON. CONNECTING ROD BIG END CAP BROKEN OFF. 1 L 7 1 3O 3 O 3A15 3E1 5 C P892 2006061900007 20060619 00007 NE 2006 6 19 AU510001877 2 20051212 G 7261 ENGINE BOLKMS 117 BK117B2 5626013 EU LYC LTS101 LTS101750B1 41560 NE NR 1 MAKING METAL W K NONE O OTHER IN INSP/MAINT 1 AU S LE48195AEF NR 1 ENGINE CHIP DETECTOR LIGHT ILLUMINATED. INSPECTION FOUND A FINE HAIRLIKE METAL SLIVER. ENGINE INSPECTED IAW MAINT ENANCE MANUAL AND DECLARED SERVICEABLE. 1 G 7 2 3U 3 U NC H13EU E5NE10 2006061900009 20060619 00009 NM 2006 6 19 AU510001878 1 20051212 G 2761 NAS16126A O-RING DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE ROLL SPOILER DAMAGED W O OTHER K FLUID LOSS CL CLIMB 1 AU S 99999 99999 RT INBOARD ROLL SPOILER ACTUATOR BULKHEAD UNION FITTING SLIGHTLY LOOSE IN ACTUATOR BODY CAUSING FAILURE OF THE UNION O-R ING SEAL AND LOSS OF HYDRAULIC FLUID. SPOILER ACTUATOR HAD BEEN REPLACED AT LAST MAINTENANCE CHECK AND IT IS SUSPECTED THAT EITHER THE RIGID LINE CONNECTION OR THE BULKHEAD FITTING HAD NOT BEEN CORRECTLY RETORQUED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006061900011 20060619 00011 SO 2006 6 19 AU510001879 1 20051212 G 3233 762554 ROD END OZONE PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA HARTZL HCF3Y HCF3YR2 GL ACTUATOR BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 398 LT MAIN LANDING GEAR RETRACTION ACTUATOR ROD END BROKEN. FURTHER INVESTIGATION OF THE NOSE LANDING GEAR AND RT MAIN LAN DING GEAR ACTUATOR ROD ENDS FOUND SLIGHT BENDING IN THE THREADED AREA OF THE NLG ROD END. 1 L 7 2 3O 3 O A20SO E14EA 5 C P31EA 2006061900012 20060619 00012 EU 2006 6 19 AU510001880 1 20050509 G 5311 FRAME BAG BAE146 BAE146100A 1500260 EU LYC ALF502 ALF502R5 41580 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 0 FUSELAGE FRAMES 15 AND 18 CRACKED, FOUND DURING INSPECTION IAW AD/BAE146/116. 2 H 7 4 4F 4 F RT A49EU E6NE 2006061900014 20060619 00014 SW 2006 6 19 AU510001881 1 20051212 G 2701 917010507 CONTROL WHEEL MOONEY M20 M20G 5870316 SW LYC O360 O360A1D 41514 EA HARTZL HCC2Y HCC2YK1 GL COCKPIT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S CONTROL WHEEL CRACKED FROM TOP BOLT HOLE. 1 L 7 1 3O 3 O 2A3 E286 5 C P920 2006061900016 20060619 00016 GL 2006 6 19 AU510001882 3 20051212 G 6114 D220117 HUB HARTZL PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA HARTZL HCC2Y HCC2YK1 GL PROPELLER DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 183 CH19462E CH19462E PROPELLER HUB DAMAGED. SUSPECT CAUSED BY GROUND STRIKE. FOUND DURING INSPECTION IAW AD/PHZL/77 AMDT2. 1 L 7 1 3O 3 O A3SO 1E4 5 C P920 2006061900017 20060619 00017 NM 2006 6 19 AU510001883 1 20051212 G 3242 26123011 BRAKE BOEING 737 7377Q8 1384418 NM GE CFM56 CFM56* 13802 NE NR 2 BINDING W O OTHER O OTHER CL CLIMB 1 AU S MAIN LANDING GEAR NR 2 BRAKE BINDING. INVESTIGATION FOUND FOD TO ROTOR AND STATOR ASSEMBLIES. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061900018 20060619 00018 CE 2006 6 19 AU510001884 1 20051212 G 5730 NAS22112 SCREW BEECH 300 300BEECH 1152930 CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL WING SKIN LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S OUTER WING FORWARD UPPER BATHTUB FITTING TO UPPER SKIN PANEL ATTACHMENT SCREWS LOOSE. SUSPECT SCREWS INCORRECTLY TORQUE D DURING MANUFACTURE. 2 L 7 2 4T 4 T A24CE E4EA 6 C P56GL 2006061900104 20060619 00104 CE 2006 6 19 AU510001885 1 20051212 G 5712 57222062 RIB CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL RT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 17021 0 RT CANTED RIB CAP CRACKED BENEATH REPAIR. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2006061900105 20060619 00105 CE 2006 6 19 AU510001886 1 20051212 G 5712 57200014S RIB CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL RT WING CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 17021 RT CANTED RIB CAP FORWARD PN 5720001-4S AND AFT PN 5720001-6S ANGLES CRACKED, FOUND DURING EDDY CURRENT INSPECTION. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2006061900106 20060619 00106 EU 2006 6 19 AU510001887 1 20051212 G 3020 SWITCH FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE ENGINE ANTI ICE FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S NR 1 ENGINE ANTI-ICE SWITCH FAULTY. 2 L 7 2 4F 4 F RT E25NE 2006061900107 20060619 00107 SO 2006 6 19 AU510001888 1 20051212 G 2434 411810 ALTERNATOR PIPER PA28 PA28181 7102807 SO LYC O360 IO360A1A 41514 EA HARTZL HCC2Y HCC2YK1 GL ENGINE FAILED W O OTHER H J ELECT. POWER LOSS-50 PC WARNING INDICATION CR CRUISE 1 AU S ALTERNATOR FAILED. FOLLOWING REMOVAL IT WAS NOTICED THAT THE ALTERNATOR DID NOT HAVE A DATA PLATE ATTACHED IDENTIFYING EITHER SERIAL NUMBER OR PART NUMBER. 1 L 7 1 3O 3 O 2A13 1E10 5 C P920 2006061900108 20060619 00108 SO 2006 6 19 AU510001889 1 20051007 G 3233 762554 ROD END OZONE PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA HARTZL HCE3Y HCE3YR2 GL ACTUATOR FAILED W O OTHER J WARNING INDICATION LD LANDING 1 AU S RT MAIN LANDING GEAR ACTUATOR ROD END FAILED. FOLLOWING REPLACEMENT OF THE RODEND, THE RT MAIN LANDING GEAR COULD NOT B E RIGGED DUE TO EXCESSIVE WEAR IN THE DRAG LINK BUSHES AND BOLTS AND THE DOWNLOCK HOOK AND PIN. GEAR WAS RERIGGED FOLLO WING REPLACEMENT OF THE WORN PARTS. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2006061900109 20060619 00109 CE 2006 6 19 AU510001890 1 20051212 G 5740 NAS22112 SCREW BEECH 300 300BEECH 1152930 CE PWA PT6 PT6A60A 52043 NE WING FITTING LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S OUTER WING FORWARD UPPER BATHTUB FITTING TO UPPER SKIN PANEL ATTACHMENT SCREWS LOOSE. SUSPECT SCREWS INCORRECTLY TORQUE D DURING MANUFACTURE. 2 L 7 2 4T 4 T A24CE E4EA 2006061900110 20060619 00110 NM 2006 6 19 AU510001891 1 20051212 G 5210 232U212220B LOCK BOEING 747 747438 NM PAX DOOR FAULTY W O OTHER M B OVER TEMP SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 AU S ELECTRICAL BURNING ODOR ON FLIGHT DECK AND IN UPPER DECK CABIN. INVESTIGATION FOUND FLIGHT DECK DOOR LOCK HOT. FURTHER INVESTIGATION FOUND THE FLIGHT DECK DOOR ELECTRIC STRIKER ASSEMBLY HAD FAILED. 2 L 7 4 4F RT A20WE 2006061900111 20060619 00111 CE 2006 6 19 AU510001892 1 20051212 G 3260 444EN496 SQUAT SWITCH BEECH 200 200CBEECH 1152926 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL MLG OUT OF ADJUST W O OTHER N FALSE WARNING CL CLIMB 1 AU S RT MAIN LANDING GEAR SQUAT SWITCH ADJUSTED TO MINIMUM TOLERANCE PREVENTING RETRACTION OF THE LANDING GEAR. SWITCH ADJUS TED AND LANDING GEAR RETRACTION WAS NORMAL. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2006061900112 20060619 00112 NM 2006 6 19 AU510001893 1 20051212 G 2912 271T00424 FILTER BOEING 767 767300 1385204 NM RROYCE RB211 RB211524* NE HYDRAULIC SYS FAILED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S CENTER NR 1 HYDRAULIC SYSTEM PRESSURE FILTER BOWL FAILED. LOSS OF HYDRAULIC FLUID. 2 L 7 2 4F 4 F RT A1NM E12EU 2006061900292 20060619 00292 NM 2006 6 19 AU510001894 1 20051009 G 2120 ODOR BOEING 737 737 UTILSYS NM COCKPIT DETECTED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 AU S BURNING SMELL ON FLIGHT DECK. SMELL TRACED TO FAULTY P5-9 PANEL. AIRCRAFT IS FOREIGN REGISTERED. 2 L 7 2 4F RT A16WE 2006061900293 20060619 00293 NM 2006 6 19 AU510001895 1 20051212 G 2121 COOLING FAN BOEING 747 747438 NM GE CF6 CF680C2* GL FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S SMOKE AND FUMES IN COCKPIT. INVESTIGATION FOUND THE CHILLER BOOST FAN CIRCUIT BREAKER TRIPPED. INVESTIGATION FOUND THE FAN FORWARD BEARING HAD COLLAPSED ALLOWING THE IMPELLER BLADES TO RUB ON THE CASE AND THE FAN MOTOR ROTOR AND STATOR TO RUB. 2 L 7 4 4F 4 F RT A20WE E23EA 2006061900294 20060619 00294 EU 2006 6 19 AU510001896 1 20051212 G 5520 NB31B133 SPACER BNORM EQUIPMENT BNORM BN2 BN2B26 1520350 EU LYC O540 O540E4B5 41532 EA HARTZL HCC2Y HCC2YK2 GL ELEVATOR WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 10136 LT OB ELEVATOR SPACER (DISTANCE PIECE) WORN BEYOND LIMITS. AS A RESULT THE ELEVATOR SUPPORT STRUCTURE WAS CRACKED TO TH E POINT OF NEAR SEPARATION. 1 H 7 2 3O 3 O RT A17EU E295 5 C P920 2006062300022 20060623 00022 EU 2006 6 23 AU510001897 1 20051212 G 2121 3133759 COOLING FAN REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL AVIONICS ODOR W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S (AUS) ODOR IN COCKPIT. INVESTIGATION FOUND ODOR ONLY BECAME PRESENT WHEN THE AIR CONDITIONING SYSTEM WAS SELECTED OFF. F URTHER INVESTIGATION FOUND THE ODOR CAME FROM RECENTLY INSTALLED AVIONICS INSTRUMENT COOLING FANS. FANS WERE CHECKED SER VICEABLE. FANS HAD BEEN FITTED IAW EO F406-21-416 ISSUE1. (OTHER CAUSE: ENVIRONMENT ) (CASA NR 510001897) 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2006061900148 20060619 00148 SO 2006 6 19 AU510001898 1 20051212 G 2140 A23D0475 REGULATOR PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA HARTZL HCE3Y HCE3YR2 GL HEATING SYSTEM LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S CABIN HEATER FUEL PRESSURE REGULATOR LEAKING FUEL FROM DIAPHRAGM. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2006061900295 20060619 00295 EU 2006 6 19 AU510001899 1 20051212 G 3310 LIGHT AIRBUS A330 A330* EU GE CF6 CF680 30025 NE COCKPIT FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S FO READING LIGHT FAILED. SMOKE AND FUMES IN COCKPIT. INVESTIGATION FOUND SWARF MATERIAL IN THE LENS ASSEMBLY FOLLOWING REMOVAL OF THE COVER. 2 L 7 2 4F 4 F RT A46NM E13NE 2006061900296 20060619 00296 CE 2006 6 19 AU510001900 1 20051212 G 3710 COUPLING 216CW BEECH 58 58 1152740 CE CONT O550 IO550B SO MCAULY 3AF34C 3AF34C502 GL VACUUM PUMP SHEARED W O OTHER J WARNING INDICATION CR CRUISE 1 AU S 29 35967 RT VACUUM PUMP FAILED. INVESTIGATION FOUND THE PUMP JAMMED AND FULL OF CARBON VANE DEBRIS. DRIVE SHAFT FAILED AT SHEA R POINT. PUMP IS OUTSIDE OF THE SN RANGE AS INDICATED IN TEMPEST SB-003. 1 L 7 2 3O 3 O 3A16 E3SO 5 C P22EA 2006062100161 20060621 00161 CE 2006 6 21 AU510001901 1 20051212 G 3710 DRIVE SHAFT AERO BEECH 33 F33A 1151425 CE CONT O520 IO520B 17032 SO MCAULY 2A36C 2A36C23 GL VACUUM PUMP SHEARED W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 AU S 38343 (AUS) VACUUM PUMP FAILED. INVESTIGATION FOUND THE PUMP JAMMED AND FULL OF CARBON VANE DEBRIS. DRIVE SHAFT FAILED AT SPLI NED SECTION AND NOT AT SHEAR POINT AS DESIGNED. PUMP IS OUTSIDE OF THE SN RANGE AS INDICATED IN TEMPEST SB-003. (AD/SB DESC: TEMPEST SB-003 ) (OTHER CAUSE: MATERIAL ) (CASA NR 510001901) 1 L 7 1 3O 3 O 3A15 E5CE 5 C P880 2006062100164 20060621 00164 SO 2006 6 21 AU510001902 1 20051212 G 3710 COUPLING 215CC PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA VACUUM PUMP SHEARED W O OTHER O OTHER CR CRUISE 1 AU S 41 41 38552 (AUS) VACUUM PUMP FAILED. INVESTIGATION FOUND THE PUMP JAMMED AND FULL OF CARBON VANE DEBRIS. DRIVE SHAFT FAILED AT SHE AR POINT. PUMP IS OUTSIDE OF THE SN RANGE AS INDICATED IN TEMPEST SB-003. (OTHER CAUSE: MATERIAL ) (CASA NR 510001902) 1 L 7 1 3O 3 O 2A13 E274 2006062100165 20060621 00165 EU 2006 6 21 AU510001903 1 20051212 G 4940 DRIVE SHAFT FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE STARTER SHEARED W O OTHER O OTHER DE DESCENT 1 AU S (AUS) APU STARTER MOTOR DRIVESHAFT SHEARED. INVESTIGATION FOUND THAT THE BROKEN END WAS JAMMED IN THE CLUTCH ASSEMBLY. (CASA NR 510001903) 2 L 7 2 4F 4 F RT E25NE 2006062100167 20060621 00167 NM 2006 6 21 AU510001904 1 20051212 G 7603 CLUTCH BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL POWER LEVER FAULTY W C ABORTED TAKEOFF F FLT CONT AFFECTED TO TAKEOFF 1 AU S (AUS) NR 1 ENGINE AUTO THROTTLE CLUTCH PACK FAULTY. INVESTIGATION FOUND THE TORQUE LIMITER FAILED TO JUMP TO THE NEXT P OSITION AT THE FORCE OF 49 POUNDS TO 60 POUNDS FOR BOTH CLUTCHES. (CASA NR 510001904) 2 L 7 2 4F 4 F RT A1NM E23EA 2006062100170 20060621 00170 SO 2006 6 21 AU510001905 1 20051212 G 3232 AE1011469EO122 HOSE EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE MLG DOOR ACT FAILED W O OTHER K J FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S (AUS) LT MAIN LANDING GEAR IB DOOR ACTUATOR CLOSE HYDRAULIC HOSE FAILED. LOSS OF HYDRAULIC FLUID. INVESTIGATION ALSO FO UND THAT THE HOSE PN WAS INCORRECT IAW THE IPC. SUSPECT INCORRECT PN HOSE WAS FITTED BY A PREVIOUS OPERATOR. (CASA NR 5 10001905) 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 2006062100171 20060621 00171 WP 2006 6 21 AU510001906 1 20051009 G 6210 A0164 BLADE ROBSIN R22 R22ALPHA 7640104 WP LYC O320 O320B2C 41508 EA MAIN ROTOR DISTORTED W K NONE O OTHER IN INSP/MAINT 1 AU S 399 399 (AUS) MAIN ROTOR BLADE BENT. BEND LOCATED IN AREA APPROXIMATELY 200MM (7.8IN) OB OF THE BLADE DOUBLER AND RUNNING ALONG THE CHORDWISE AXIS. A STRINGLINE WAS RUN DOWN THE LEADING EDGE OF THE BLADE AND THE DEVIATION FROM THIS AT THE BEND WAS 19MM TO 20MM (0.74IN TO 0.78 IN) DOWNWARD. FOUND DURING BLADE REMOVAL AND REPLACEMENT. (CASA NR 510001906) 1 G 7 1 3O 3 O H10WE E274 2006062100173 20060621 00173 NM 2006 6 21 AU510001907 1 20051212 G 5750 2061141 INDICATOR BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU TE FLAPS FAULTY W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 AU S 27444 27444 (AUS) TRAILING EDGE FLAP ASSYMETRY. FLAPS RECYCLED AND OPERATED NORMALLY. INVESTIGATION CONTINUING. (CASA NR 510001907 ) 2 L 7 2 4F 4 F RT A16WE E21EU 2006062300028 20060623 00028 EA 2006 6 23 AU510001908 2 20051212 G 8520 72877R CAM FOLLOWER LYC O540 TIO540J2BD 41532 EA ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 53 (AUS) ECI PNO 72877R CAM FOLLOWERS FAULTY. LIFTERS ARE BADLY WORN AND CAMSHAFT LOBES DAMAGED. ENGINES FITTED WITH THIS P N LIFTERS INCLUDE MFG TIO540J2BD AND O320D2J MODELS. (MATERIAL - ORGANIZATIONAL ) (CASA NR 510001908) 3 O E14EA 2006062300030 20060623 00030 NE 2006 6 23 AU510001909 2 20050309 G 7250 70BM037330 MODULE SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE ENGINE SEIZED W K NONE O OTHER IN INSP/MAINT 1 AU S 15129 (AUS) NR 1 ENGINE, NR 2 AND NR 3 MODULES SEIZED. INVESTIGATION CONTINUING. (CASA NR 510001909). 1 G 7 2 3U 3 U NC H1NE E19EU 2006062300138 20060623 00138 NM 2006 6 23 AU510001910 1 20051212 G 3610 PRESSURE VALVE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL BLEED AIR SYS FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) RT ENGINE BLEED AIR SYSTEM PRESSURE REGULATING VALVE (PRV) FAILED. INVESTIGATION FOUND EXCESSIVE BUTTERFLY SHAFT P LAY DUE TO WORN CARBON SHAFT BUSHINGS. (CASA NR 510001910) 2 L 7 2 4F 4 F RT A1NM E23EA 2006062300140 20060623 00140 SO 2006 6 23 AU510001911 2 20051212 G 8520 537432 GEAR CESSNA 421 421C 2076016 CE CONT O520 GTSIO520N 17032 SO MCAULY 3FF32 3FF32C501 GL CRANKSHAFT DAMAGED W O OTHER O OTHER DE DESCENT 1 AU S 1516 (AUS) ENGINE CRANKSHAFT GEAR MISSING TEETH. SUSPECT CAUSED BY A PIECE OF METAL FROM THE STARTER ADAPTER GEAR JAMMING IN THE GEAR TEETH. METAL CONTAMINATION OF ENGINE. (CASA NR 510001911) 1 L 7 2 3O 3 O A7CE E7CE 5 C P45GL 2006062300141 20060623 00141 GL 2006 6 23 AU510001912 1 20051212 G 3244 252752 TIRE AMTR LANCAR LC41550FG 5150001 GL LYC O540 IO540N1A5 41532 EA HARTZL HCF3Y HCF3YR1 GL NLG DISINTEGRATED W O OTHER O OTHER NR NOT REPORTED 1 AU S UNKNOWN (AUS) NOSE WHEEL TYRE DISINTEGRATED CIRCUMFERENTIALLY. INVESTIGATION FOUND EXCESSIVELY LONG NOSEWHEEL SPAT ATTACHMENT S CREWS WHICH CUT INTO THE TYRE AS IT ROTATED. INCORRECT PART. (CASA NR 510001912) 1 L 7 1 3O 3 O RT EXPA1L71 1E4 5 C P31EA 2006062300142 20060623 00142 NM 2006 6 23 AU510001913 1 20051212 G 2751 1817389 TRANSMITTER BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU TE FLAPS FAULTY W K NONE N FALSE WARNING IN INSP/MAINT 1 AU S 39668 39668 (AUS) LT FLAP POSITION TRANSMITTER FAULTY. (CASA NR 510001913) 2 L 7 2 4F 4 F RT A16WE E21EU 2006062300144 20060623 00144 EU 2006 6 23 AU510001914 1 20051212 G 5751 NOTKNOWN BOLT FOKKER FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE AILERON LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT AILERON TAB OB HINGE BRACKET ATTACHMENT BOLTS LOOSE. BOLTS WERE THREADBOUND IN ANCHOR NUTS. INVESTIGATION FOU ND INCORRECT BOLTS WERE FITTED BY A PREVIOUS OPERATOR IN THE US. (CASA NR 510001914) 2 L 7 2 4F 4 F RT E25NE 2006062300146 20060623 00146 EU 2006 6 23 AU510001915 1 20051212 G 2750 CONTROL CABLE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE TE FLAPS MISRIGGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CONTROL CABLES FOR FLAPS ( F1 AND F2) WERE FOUND TO BE 43LB LOW IN TENSION. THE LT AILERON WING CABLE WAS 30LB LOW . THE LT AND RT AILERON UPFLOAT CABLES WERE 45LB LOW. (CASA NR 510001915) 2 L 7 2 4F 4 F RT E25NE 2006062300148 20060623 00148 NM 2006 6 23 AU510001916 1 20051212 G 2611 30326E11 AMPLIFIER DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE SMOKE DETECTOR UNSERVICEABLE W O OTHER N FALSE WARNING DE DESCENT 1 AU S (AUS) BAGGAGE COMPARTMENT SMOKE DETECTOR CONTROL AMPLIFIER FAILED.(OTHER CAUSE: SHIFT IN DESIGN PROPERTIES. ) (CASA NR 5 10001916) 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006062300150 20060623 00150 2006 6 23 AU510001917 4 20051212 G 2565 SLIDE AIRBUS A330 A330* EU GE CF6 CF680 30025 NE L1 DOOR FAILED W O OTHER O OTHER CR CRUISE 1 AU S (AUS) DURING EMER EVAC FOR FIRE WARNING, DOOR 1L SLIDE FAILED TO DEPLOY. DOOR OPENING HANDLE HAD BEEN MOVED TO FULL UP P OSITION, DOOR WAS FOUND TO HAVE OPENED APPROX 3 INCHES, JAMMED IN THAT POSITION. DOOR ARMING HANDLE HAD BEEN MOVED FROM ARMED POSITION TO DISARMED POSITION. SLIDE GIRT BAR WAS STILL ATTACHED TO DOOR FRAME FLOOR FITTINGS, SLIDE WAS STILL WI THIN DOOR COVER. FILLING VALVE NUT ON DOOR ASSIST ACT WAS LOOSENED TO RELEASE REMAINING PRESS IN ACT. AFTER SLIGHT RELEA SE OF PRESS, DOOR OPENED AUTOMATICALLY, SLIDE DEPLOYED NORMALLY. DETERMINED DOOR HAD BECOME JAMMED BECAUSE PRESS FROM D OOR ASSIST ACT FORCED DOOR AGAINST DOOR FRAME, PREVENTED DOOR FROM BEING MOVED TO CLOSED POSITION. (CASA NR 510001917) 2 L 7 2 4F 4 F RT A46NM E13NE 2006061900297 20060619 00297 CE 2006 6 19 AU510001918 1 20050809 G 5514 4320049 BRACKET CESSNA 150 A152 2071836 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 2813 HORIZONTAL STABILIZER UPPER PLATE CRACKED IN AREA ADJACENT TO VERTICAL STABILIZER BRACKET ATTACHMENT. CRACK LENGTH 5MM (0.196IN). 1 H 7 1 3O 3 O 3A19 E223 5 N P50GL 2006070500054 20060705 00054 CE 2006 7 5 AU510001919 1 20050909 G 5511 4320049 BRACKET CESSNA 150 A152 2071836 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) HORIZONTAL STABILIZER UPPER PLATE CRACKED IN AREA ADJACENT TO VERTICAL STABILIZER BRACKET ATTACHMENT. CRACK LENGTH 7MM (0.275IN). (AD/SB DESC: SEB 03-6 ) (CASA NR 510001919) 1 H 7 1 3O 3 O 3A19 E223 5 N P50GL 2006070500055 20060705 00055 NM 2006 7 5 AU510001920 1 20051212 G 2782 272A165154 LINE BOEING 737 73776N 13844CH NM GE CFM56 CFM567B24 NE SLAT HYD SYS CHAFED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) LT WING NR 2 LEADING EDGE SLAT ACTUATOR HYDRAULIC PIPE CHAFED AND LEAKING DUE TO INSUFFICIENT CLEARANCE BETWEEN TH E PIPE AND THE ACTUATOR. LOSS OF HYDRAULIC FLUID. (CASA NR 510001920) 2 L 7 2 4F 4 F RT A16WE E00055EN 2006070500056 20060705 00056 NM 2006 7 5 AU510001921 1 20051212 G 2130 CABIN PRESSURE BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU FAULTY W O OTHER J WARNING INDICATION LD LANDING 1 AU S (AUS) AIRCRAFT PRESSURISED ON LANDING. NUMEROUS COMPONENTS CHANGED. INVESTIGATION CONTINUING. (CASA NR 510001921) 2 L 7 2 4F 4 F RT A16WE E21EU 2006070500057 20060705 00057 GL 2006 7 5 AU510001922 1 20051212 G 5740 66130131 ANGLE NAMER T6 SNJ4 6400414 GL PWA R1340 R1340AN1 52016 NE HAMSTD 3D 3D40 NE LT WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) WING LT UPPER ANGLE CORRODED IN 2 BOLT HOLES. FOUND DURING INSPECTION IAW WS-622-REV1.0.(OTHER CAUSE: AGE ) (CASA NR 510001922) 1 L 7 1 3R 3 R A2575 5E2 6 C A815 2006070500058 20060705 00058 EU 2006 7 5 AU510001923 1 20051212 G 2121 6451101 COOLING FAN FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE AVIONICS FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 20824 (AUS) AVIONICS COOLING FAN NOISY IN OPERATION. 2 L 7 2 4F 4 F RT E25NE 2006070500059 20060705 00059 NM 2006 7 5 AU510001924 1 20051212 G 5350 85350966 FAIRING DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE RT WING ROOT BIRD STRIKE W O OTHER O OTHER LD LANDING 1 AU S 2338 (AUS) RT WING ROOT FAIRING SUFFERED A FRUIT BAT STRIKE DURING LANDING. THE BAT CAUSED A HOLE IN THE KEVLAR FAIRING BUT D ID NOT PENETRATE. THE HOLE SIZE WAS APPROXIMATELY 180MM (7.08IN). (OTHER CAUSE: BIRDSTRIKE ) (CASA NR 510001924) 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006070500060 20060705 00060 SW 2006 7 5 AU510001925 1 20051212 G 2840 INDICATION SYS SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL FUEL QUANTITY FAULTY W O OTHER Y N ENGINE STOPPAGE FALSE WARNING DE DESCENT 1 AU S (AUS) NO1 ENGINE SHUT DOWN DUE TO FUEL STARVATION. INVESTIGATION FOUND THE FUEL GAUGE INDICATION WAS 400LBS FUEL QUANTIT Y LHS AND 250LBS FUEL QUANTITY RHS. THE MAGNETIC STICKS SHOWED NIL LHS AND NIL RHS. ACTUAL FUEL EMPTIED FROM TANKS INTO CONTAINERS AT WAS 2 LITRES LHS AND 28 LITRES RHS. SUSPECT FAULTY FUEL INDICATING SYSTEM. INVESTIGATION CONTINUING.(OTHER CAUSE: UNDER INVESTIGATION ) (CASA# 510001925) 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 2006070500061 20060705 00061 SW 2006 7 5 AU510001926 1 20051212 G 6420 206012E11 TRUNNION BELL 205 205B SW ALLSN 250C 250C20J 03013 GL TAIL ROTOR HUB CRACKED W K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 AU S (AUS) TAIL ROTOR HUB ASSEMBLY TRUNNION CRACKED ON INNER BEARING RACE. (OTHER CAUSE: MATERIAL ) (CASA NR 510001926) 1 G 7 1 4U 3 U H1SW E4CE 2006070500062 20060705 00062 SO 2006 7 5 AU510001927 1 20051212 G 3242 SPACER CLEVELAND PIPER PA28 PA28181 7102807 SO LYC O360 O360A4M 41514 EA SNSNCH 76E 76EM8S5 EA BRAKE CALIPER INCORRECT W O OTHER W INADEQUATE Q C LD LANDING 1 AU S (AUS) RT MAIN LANDING GEAR BRAKE CALIPER SPACER INCORRECTLY FITTED ON THE WRONG SIDE ALLOWING THE CALIPER TO FALL OUT OF THE GUIDES. MAINTENANCE ERROR. (OTHER CAUSE: WHEEL SPACER PLACED ON INCORRECT SIDE OF WHEEL ) (CASA NR 510001927) 1 L 7 1 3O 3 O 2A13 E286 5 N P4EA 2006070300071 20060703 00071 CE 2006 7 3 AU510001928 1 20051212 G 7830 20200081 ARM BEECH MU300 400A 1155402 CE PWA JT15 JT15D5 52112 NE IDLER BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 2414 3426 LT ENGINE THRUST REVERSER INBOARD LOWER IDLER ARM BROKEN AT BEARING END BATWING ATTACHMENT POINT. DURING INVESTIGATION CRACKS WERE ALSO FOUND IN THE UPPER THRUST REVERSER SKIN THROUGH A ROW OF NINE RIVETS. 2 H 7 2 4F 4 F RT A16SW E25EA 2006070300072 20060703 00072 SO 2006 7 3 AU510001929 1 20051212 G 2701 12006325007 CONTROL WHEEL EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE COCKPIT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 31549 CAPTAIN`S CONTROL WHEEL CRACKED AT BEND APEX. 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 2006070300073 20060703 00073 CE 2006 7 3 AU510001930 1 20051212 G 2720 LOCK NUT BEECH 300 300BEECH 1152930 CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL RUDDER PEDAL MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S 95 (AUS) RUDDER PEDAL INTERCONNECT TUBE DISCONNECTED AT PILOT`S RUDDER PEDAL BELLCRANK. INVESTIGATION FOUND THE ATTACHING B OLT PNO 130909B81 AND WASHER ON THE FLOOR AND THE NUT ON TOP OF THE BELLCRANK. NIL EVIDENCE OF A SPLIT PIN WAS FOUND. TH E NYLOC NUT WAS INSPECTED AND NIL EVIDENCE OF THREAD CUT INTO THE NYLOC WAS FOUND. SUSPECT THE NUT HAD BEEN ONLY SCREWED ON BY THREE OR FOUR THREADS AND HAD NOT LOCKED. PERSONNEL/MAINTENANCE ERROR MANUFACTURING ERROR. AIRCRAFT IS OPERATED B Y THE AUSTRALIAN MILITARY AND HAS ONLY OPERATED FOR APPROXIMATELY 95 HOURS SINCE NEW. SEE ATTACHMENT FOR FURTHER INFORMA TION. (OTHER CAUSE: NUT NOT FITTED & LOCKED AT MANUFACTURE ) (CASA# 510001930) 2 L 7 2 4T 4 T A24CE E4EA 6 C P56GL 2006070300074 20060703 00074 NM 2006 7 3 AU510001931 1 20051212 G 7931 APT761000100DW TRANSMITTER DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE OIL PRESSURE FAILED W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S 99999 99999 LT ENGINE OIL PRESSURE TRANSMITTER FAILED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006070300075 20060703 00075 SW 2006 7 3 AU510001932 1 20051212 G 6220 206011E11 PITCH HORN BELL 206 206B1 1181503 SW ALLSN 250C 250C20J 03013 GL MAIN ROTOR HUB DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) MAIN ROTOR HEAD PITCH HORN DAMAGED BEYOND REPAIR. INVESTIGATION FOUND THAT AN INDENTATION IN THE PITCH HORN UPPER SURFACE WAS PREVIOUS DAMAGE THAT HAD BEEN BLENDED AND PAINTED OVER. FOLLOWING REMOVAL OF THE PAINT IT WAS FOUND THAT THE DAMAGE WAS BEYOND THE ALLOWABLE LIMITS SET OUT IN THE REPAIR AND OVERHAUL MANUAL. FURTHER INVESTIGATION FOUND THAT THE DAMAGE TOLERANCES HAD BEEN AMENDED BY THE MANUFACTURER AND THE DAMAGE WAS NOW WITHIN ACCEPTABLE LIMITS. NIL DEFECT. (OTH ER CAUSE: INCORRECT DAMAGE CRITERION USED ) (CASA# 510001932) 1 G 7 1 3U 3 U H2SW E4CE 2006070300076 20060703 00076 NM 2006 7 3 AU510001933 1 20051212 G 2913 GENM29501013 PUMP BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU HYDRAULIC SYS FAILED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 44252 3242 HYDRAULIC SYSTEM `B` HYDRAULIC PUMP FAILED. 2 L 7 2 4F 4 F RT A16WE E21EU 2006070300077 20060703 00077 NM 2006 7 3 AU510001934 1 20050509 G 5311 FRAME BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S FUSELAGE FRAMES CONTAINED 28 CRACKS AT PASSENGER SERVICE UNIT (PSU) ATTACHMENT POINTS. FOUND DURING EDDY CURRENT INSPEC TION IAW EI 737-53-68R3 AND B737 NTM PT6 51-00-00 FIG 4 AND FIG 16. 2 L 7 2 4F 4 F RT A16WE E21EU 2006070300078 20060703 00078 EU 2006 7 3 AU510001935 1 20051212 G 5313 STRINGER FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE BS 13851 CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S NR 3 LT STRINGER LOCATED AT STN 13851 IN THE FORWARD CARGO COMPARTMENT CORRODED. 2 L 7 2 4F 4 F RT E25NE 2006070300079 20060703 00079 GL 2006 7 3 AU510001936 3 20051212 G 6111 BLADE MCAULY CESSNA 208 208 2073702 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL PROPELLER CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 981258 PROPELLER BLADE CRACKED AT 40` STATION. FURTHER INVESTIGATION OPENED UP THE CRACK AND FOUND A LARGE AREA OF CORROSION. 1 H 7 1 3T 3 T NT A37CE E4EA 5 C P60GL 2006070500144 20060705 00144 WP 2006 7 5 AU510001937 2 20051212 G 7200 TPE33112UH ENGINE SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE RIGHT FLUCTUATES W A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 AU S (AUS) RT ENGINE EXPERIENCED 20 PERCENT TO 30 PERCENT TORQUE DROP WITH ASSOCIATED EGT FLUCTUATIONS. MAINTENANCE INVESTIG ATION COULD NOT FIND ANY FAULTS AND ENGINE PARAMETERS WERE NORMAL. AIRCRAFT RETURNED TO SERVICE. (CASA NR 510001937) 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2006070500145 20060705 00145 NM 2006 7 5 AU510001938 1 20051212 G 2530 GENM2585013 OVEN BOEING 737 737* NM CFMINT CFM56 CFM563C 13802 EU GALLEY FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S 31451 2739 (AUS) SMOKE AND FUMES IN FORWARD GALLEY. INVESTIGATION FOUND GALLEY OVEN C206 CIRCUIT BOARD DIODE BURNED. INVESTIGATIO N ALSO FOUND A BURNED RESISTOR R429 ON THE POWER SWITCH BOARD PNO LK25-85-4B. (OTHER CAUSE: MATERIAL ) (CASA NR 5100019 38) 2 L 7 2 4F 4 F RT A16WE E21EU 2006070500147 20060705 00147 NM 2006 7 5 AU510001939 1 20051212 G 5210 232U212220B STRIKER BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE COCKPIT DOOR FAILED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 AU S (AUS) COCKPIT DOOR LOCK ELECTRICAL STRIKER ASSEMBLY OVERHEATED AND FAILED. SEE ATTACHMENT FOR INVESTIGATION DETAILS. (CA SA NR510001939) 2 L 7 4 4F 4 F RT A20WE E30NE 2006070500148 20060705 00148 EU 2006 7 5 AU510001940 1 20051212 G 5311 FRAME BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FRAME 43 CRACKED. FOUND DURING INSPECTION IAW AD/BAE146/116. (OTHER CAUSE: MATERIAL ) (CASA NR 510001940 ) 2 H 7 4 4F 4 F RT A49EU E6NE 2006070500149 20060705 00149 EU 2006 7 5 AU510001941 1 20051212 G 5311 FRAME BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) FUSELAGE FRAME 41 AND FRAME 43 CRACKED. FOUND DURING INSPECTION IAW AD/BAE146/116. (OTHER CAUSE: MATERIAL ) (CASA NR 510001941) 2 H 7 4 4F 4 F RT A49EU E6NE 2006070500151 20060705 00151 NE 2006 7 5 AU510001942 2 20051212 G 7250 3030252 RING BEECH 200 B200C 1152924 CE PWA PT6 PT642A NE HARTZL HCD4N3 HCD4N3A GL STATOR VANE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) POWER TURBINE STATOR VANE RING CRACKED AND SEPARATED AT THE ROOT ENDS WITH CURLING OF THE TIPS. (OTHER CAUSE: NOT KNOWN AT THIS STAGE ) (CASA# 510001942) 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2006070500152 20060705 00152 EA 2006 7 5 AU510001943 2 20051212 G 7322 70148001 SERVO CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY IC235 IC235LFA7570 EA FUEL CONTAMINATED W A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION DE DESCENT 1 AU S 1868 (AUS) FUEL SERVO CONTAMINATED WITH OILY RESIDUE LOCATED BEHIND THE VENTURI. CONTAMINATION WAS CONSISTANT WITH PRECISION SIL RS-40.(OTHER CAUSE: ENVIRONMENT ) (CASA NR 510001943) 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2006070500153 20060705 00153 2006 7 5 AU510001944 4 20051212 G 6122 8971604 GOVERNOR CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCE4N HCE4N3 NE PROPELLER FAULTY W O OTHER F FLT CONT AFFECTED CL CLIMB 1 AU S 3442 (AUS) RT ENGINE PROPELLER GOVERNOR FAULTY. INVESTIGATION CONTINUING. (CASA NR 510001944) 1 L 7 2 3T 4 T RT A28CE E4WE 5 C P10NE 2006070500155 20060705 00155 CE 2006 7 5 AU510001945 1 20051212 G 2750 LEAD CESSNA 500 560CESSNA 2076750 CE PWA JT15 JT15D5 52112 NE FLAP SELECTOR BROKEN W O OTHER F FLT CONT AFFECTED LD LANDING 1 AU S 3732 (AUS) FLAP SELECTOR MICROSWITCH POWER WIRE OPEN CIRCUIT. (CASA NR 510001945) 2 L 7 2 4F 4 F RT A22CE E25EA 2006070500217 20060705 00217 EU 2006 7 5 AU510001946 1 20051212 G 3397 WIRE AIRBUS 330 A330300 EU GE CF6 CF680 30025 NE EMERGENCY LIGHT FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) DOOR 3 EMERGENCY EXIT LIGHTS (2OFF) FAILED. SUSPECT WIRING DEFECT. (CASA NR 510001946) 2 L 7 2 4F 4 F RT E13NE 2006071000087 20060710 00087 EU 2006 7 10 AU510001947 1 20051212 G 3020 40E183SNGWD03086 SHUTOFF VALVE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE ENG ANTI-ICE SYS FAILED W O OTHER K J FLUID LOSS WARNING INDICATION DE DESCENT 1 AU S LT ENGINE ANTI-ICE PRESSURE REGULATING AND SHUTOFF VALVE (PRSOV) FAILED. 2 L 7 2 4F 4 F RT E25NE 2006071000088 20060710 00088 EU 2006 7 10 AU510001948 1 20051212 G 2824 9401037 MOTOR FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE XFLOW VALVE FAULTY W O OTHER J WARNING INDICATION CR CRUISE 1 AU S FUEL SYSTEM RT CROSS FLOW VALVE MOTOR FAULTY. VALVE STUCK IN CLOSED POSITION. 2 L 7 2 4F 4 F RT E25NE 2006071000089 20060710 00089 EU 2006 7 10 AU510001949 1 20051212 G 5330 SKIN FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY62015 04564 NE FUSELAGE LIGHTNING STRIKE W K NONE O OTHER IN INSP/MAINT 1 AU S EVIDENCE OF LIGHTNING STRIKE ON FUSELAGE AT STN 9305, STN 9805 AND STN 10253. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT E25NE 2006070500371 20060705 00371 NM 2006 7 5 AU510001950 1 20050210 G 3411 0851HT1 PROBE BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE ADC BLOCKED W C ABORTED TAKEOFF N FALSE WARNING TO TAKEOFF 1 AU S AIRCRAFT SUFFERED MOTH STRIKES DURING TAKEOFF. CAPTAIN`S PITOT PROBE BLOCKED BY MOTH FOD. 2 L 7 2 4F 4 F RT A16WE E2GL 2006070600001 20060706 00001 NM 2006 7 6 AU510001951 1 20050210 G 7830 BOLT BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE BLOCKER DOOR LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S 714185001 NR 2 ENGINE THRUST REVERSER BLOCKER DOOR DRAG LINK/DOOR ATTACHMENT BOLT NUT AND WASHER MISSING ALLOWING BOLT TO DROP DOW N AND GOUGE AND DAMAGE DOOR BEYOND LIMITS. 2 L 7 2 4F 4 F RT A16WE E2GL 2006071000090 20060710 00090 NE 2006 7 10 AU510001952 2 20051212 G 7200 ENGINE SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE LEFT FAILED W A UNSCHED LANDING F X J FLT CONT AFFECTED ENGINE FLAMEOUT WARNING INDICATION CL CLIMB 1 AU S PASSENGER REPORTED `FLAMES OF RED METAL COMING FROM LEFT ENGINE 3-4 METRES BACK` AND AN EMERGENCY LANDING WAS CARRIED OU T. ENGINEERING INSPECTION THE IGV`S, FIRST STAGE COMPRESSOR, AFT FACE OF POWER TURBINE ASSEMBLY FOUND NIL DAMAGE. A GR OUND POWER ASSURANCE RUN WAS CARRIED OUT. TAKEOFF MARGIN WAS 33.2 DEGREES C. SHIFT FROM LAST GPA RUN MINIMAL. AIRCRAF T HAS OPERATED SERVICEABLE SINCE. 2 L 7 2 4T 4 T RT A52EU E8NE 2006071000091 20060710 00091 EU 2006 7 10 AU510001953 1 20050510 G 2424 740514C GCU FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE NR 2 GENERATOR FAILED W K NONE H J ELECT. POWER LOSS-50 PC WARNING INDICATION IN INSP/MAINT 1 AU S NR 2 GENERATOR CONTROL UNIT (GCU) FAILED. NR 2 GENERATOR TRIPPED OFF LINE. 2 L 7 2 4F 4 F RT E25NE 2006071000092 20060710 00092 NE 2006 7 10 AU510001954 2 20051212 G 7230 848101 COMPRESSOR BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE NR 3 ENGINE MISREPAIRED W K NONE O OTHER IN INSP/MAINT 1 AU S NR 3 ENGINE FIRST STAGE COMPRESSOR BLADE BLENDED BEYOND LIMITS IN MAINTENANCE MANUAL. RECORDS GAVE NO INDICATION OF BLE ND REPAIR BEING CARRIED OUT. 2 L 7 3 4F 4 F RT A3WE E2EA 2006071100178 20060711 00178 WP 2006 7 11 AU510001955 1 20051209 G 6320 269A5154 SHAFT HUGHES 269A517537 HUGHES 269 269C 4470504 WP CONT O360 IO360G 17025 SO M/R GEARBOX LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S 736 S0124 (AUS) LATERAL CYCLIC CONTROL BELLCRANK LOOSE. DISASSEMBLY AND INVESTIGATION OF THE TRANSMISSION FOUND THAT THE BELLCRANK MOUNTING SHAFT ATTACHED TO THE TRANSMISSION HAD NO SPLIT PIN WHICH ALLOWED THE NUT TO WORK LOOSE AND COME OFF THE SHAFT . THE NUT AND WASHER WERE FOUND SITTING IN THE RING GEAR CARRIER. THE RING GEAR CARRIER HAD GROOVES WORN INTO IT BY THE LOOSE NUT AND/OR WASHER MAKING IT AND THE TRANSMISSION UNSERVICEABLE. THE NUT/WASHER/SPLIT PIN ARE FITTED INTERNALLY IN THE TRANSMISSION. PERSONNEL/MANUFACTURING ERROR. (CASA NR 510001955) 1 G 7 1 3O 3 O 4H12 E1CE 2006071100179 20060711 00179 NM 2006 7 11 AU510001956 1 20050410 G 2701 82710081 CONTROL COLUMN DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE COCKPIT LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S 2410 (AUS) RT CONTROL COLUMN LOWER ATTACHMENT RIVETS LOOSE. CONTROL COLUMN HAD APPROXIMATELY 5MM (0.196IN) FORE AND AFT MOVEM ENT WHEN LOCKED. (CASA NR 510001956) 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006071100180 20060711 00180 SW 2006 7 11 AU510001957 1 20050510 G 5751 STRUCTURE SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UA 01514 WP MCAULY 4HFR34 4HFR34C652 NE AILERON DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) DURING CONTROL CHECKS AILERONS FELT STRANGE WHEN MOVED IN LT DIRECTION. INVESTIGATION FOUND THE RT AILERON HAD SUF FERED INTERFERENCE DAMAGE WITH THE WING LOWER TRAILING EDGE CAUSING THE AILERON SKIN TO BIND WITH THE WING SKIN AND JAM. FURTHER INVESTIGATION FOUND EVIDENCE OF A FOREIGN OBJECT COMING INTO CONTACT WITH THE WING/AILERON SKIN (WITNESS MARKS) AT THE INBOARD EDGE OF THE AILERON AND THE WING LOWER TRAILING EDGE AT THE SAME LOCATION.(OTHER CAUSE: FOREIGN OBJECT D AMAGE ) (CASA NR 510001957) 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2006071100181 20060711 00181 NE 2006 7 11 AU510001958 2 20050410 G 7200 ENGINE SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A2 30030 NE ROTOL R390 R3904123F27 NE RIGHT SHUTDOWN W O OTHER Y J ENGINE STOPPAGE WARNING INDICATION LD LANDING 1 AU S (AUS) RT ENGINE PARAMETERS DECREASED AND ENGINE SHUTDOWN. EXTENSIVE INVESTIGATION COULD FIND NO CAUSE FOR THE SHUTDOWN. THE AIRCRAFT WAS RETURNED TO SERVICE AND HAS OPERATED WITHOUT FURTHER INCIDENT. (OTHER CAUSE: UNKNOWN ) (CASA NR 5100019 58) 2 L 7 2 4T 4 T RT A52EU E8NE6 6 C P31NE 2006071100182 20060711 00182 EU 2006 7 11 AU510001959 1 20050510 G 2761 BOLT FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE SPOILER INCORRECT W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT LIFT DUMPER ACTUATOR NR 3 AND NR 4 ATTACHMENT BOLTS NOT LOCKWIRED. PERSONNEL/MAINTENANCE ERROR. (CASA NR 510001 959) 2 L 7 2 4F 4 F RT E25NE 2006071100183 20060711 00183 NM 2006 7 11 AU510001960 1 20050210 G 7603 448774 NUT PWA JT8D15 BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE POWER LEVER SEPARATED W O OTHER O OTHER CL CLIMB 1 AU S 0 (AUS) NR 2 ENGINE POWER CONTROL LEVER CONTROL CRANK RETAINING NUT LOCATED ON THE MAIN ACCESSORY GEARBOX CROSS SHAFT ADRI FT. THE CRANK MOVED OFF THE CROSS SHAFT AND POWER LEVER CONTROL WAS LOST. THE RESULT OF THE UNCONTROLLED POWER LEVER ALL OWED AN UNCOMMANDED INCREASE IN FUEL FLOW RESULTING IN A RISE IN EGT. THE START LEVER BECAME JAMMED AT 50 PERCENT TRAVEL DUE TO INTERFERENCE OF THE POWER LEVER CONTROL RODS HAVING MOVED OFF THE MAIN ACCESSORY GEARBOX CROSS SHAFT. INVESTIGA TION FOUND THAT THE LOCKWIRE ON THE CROSS SHAFT POWER LEVER CRANK RETAINING NUT HAD BROKEN. THIS ALLOWED THE RETAINING N UT TO EVENTUALLY BACK OFF WITH THE RESULTING CONSEQUENCES. (CASA NR 510001960) 2 L 7 3 4F 4 F RT A3WE E2EA 2006071100184 20060711 00184 EU 2006 7 11 AU510001961 1 20050710 G 8011 DRIVE SHAFT FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE STARTER SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 2 ENGINE AIR STARTER DRIVESHAFT SHEARED. (OTHER CAUSE: AWAITING STRIP REPORT ) (CASA NR 510001961) 2 L 7 2 4F 4 F RT E25NE 2006071000093 20060710 00093 GL 2006 7 10 AU510001962 2 20050410 G 7310 AC9227F1740 FILTER BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL RT ENGINE FUEL CONTAMINATED W O OTHER J WARNING INDICATION CL CLIMB 1 AU S RT ENGINE FUEL FILTER CONTAMINATED. 2 L 7 2 4F 4 F RT A1NM E23EA 2006071000094 20060710 00094 EU 2006 7 10 AU510001963 1 20050710 G 8011 DRIVE SHAFT FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE STARTER SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S NR 2 ENGINE AIR STARTER DRIVE SHAFT SHEARED. 2 L 7 2 4F 4 F RT E25NE 2006060800107 20060608 00107 CE 2006 6 8 AU510001964 1 20050710 G 5511 432001E15 RIB CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 5247 HORIZONTAL STABILIZER INBOARD LEADING EDGE RIBS CRACKED. REMOVAL OF HORIZONTAL STABILIZER INBOARD RIBS REVEALED ONE PIE CE 0.5 SQ INCH OF FLANGE COMPLETELY CRACKED AWAY STARTING FROM APEX RELIEF HOLE. THIS AREA IS NOT NORMALLY VISIBLE FOR INSPECTION. ONE OTHER FLANGE CRACK EXTENDED 12.7MM (0.5IN) FURTHER UNDER SKINS. THIS AREA IS ALSO NOT NORMALLY VISIBLE FOR INSPECTION. IN TOTAL, FOUR CRACKS (THREE RT AND ONE LT) WERE FOUND MAKING THE STABILIZER UNSERVICEABLE. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2006060800108 20060608 00108 NE 2006 6 8 AU510001965 2 20050410 G 7200 JT8D15 ENGINE BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE BIRD INGESTION W O OTHER C F.O.D. LD LANDING 1 AU S NR 1 ENGINE BIRDSTRIKE. INVESTIGATION FOUND THE REMAINS OF THREE FLYING FOXES. THOROUGH INSPECTION OF THE ENGINE FOUND NO OBVIOUS DEFECTS. A WATER WASH WAS CARRIED OUT AND THE AIRCRAFT RELEASED TO SERVICE. 2 L 7 3 4F 4 F RT A3WE E2EA 2006060800110 20060608 00110 2006 6 8 AU510001966 4 20050710 G 6122 8971609 GOVERNOR CESSNA 441 441 2076020 CE GARRTT TPE331 TPE331* 01514 WP HARTZL HCB3T HCB3TN5 GL PROPELLER FAULTY W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 AU S 4796 LT ENGINE PROPELLER GOVERNOR FAULTY. 1 L 7 2 3T 3 T RT A28CE E2WE 6 C P15EA 2006060800111 20060608 00111 EU 2006 6 8 AU510001967 1 20050610 G 5711 HLT912AP109 BOLT BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE WING SPAR SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S CENTER FUEL TANK WING SPAR ATTACHMENT BOLTS (4OFF) HAD SHEAR BOLT HEADS. FUEL LEAKING FROM CENTER TANK AT RT FRONT CORN ER ABOVE THE WING TO FUSELAGE ATTACHMENT LINK AT FRAME 26 RIB 2. 2 H 7 4 4F 4 F RT A49EU E6NE 2006060800113 20060608 00113 GL 2006 6 8 AU510001968 3 20051212 G 6114 D65591 HUB HARTZL HCF2Y HCF2YR1 GL PROPELLER DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S CM1093A CHECK OF PROPELLER HUB BEFORE FITMENT TO AIRCRAFT FOUND UNACCEPTABLE DAMAGE IN BLADE/HUB SOCKET RADIUS. THIS IS A CRITI CAL AREA AND THE MANUFACTURER ADVISED THAT THE HUB BE SCRAPPED. 5 C P27EA 2006060800114 20060608 00114 GL 2006 6 8 AU510001969 3 20051212 G 6114 D65591 HUB GROB G115 G115C 1660303 EU LYC O360 O360A1F6 41514 EA HARTZL HCF2Y HCF2YR1 GL PROPELLER CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S CM1014A PROPELLER HUB CORRODED BEYOND LIMITS INTERNALLY IN AREA LOCATED AROUND LOWER CONTROL ROD BORE BOSS. 1 L 7 1 3O 3 O NT A57EU E286 5 C P27EA 2006060800115 20060608 00115 GL 2006 6 8 AU510001970 3 20051212 G 6114 C501 HUB CESSNA 404 404 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL PROPELLER CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S PROPELLER HUB CORRODED BEYOND LIMITS IN BLADE SOCKET AREA. 1 L 7 2 3O 3 O RT A25CE E7CE 5 C P45GL 2006060800116 20060608 00116 EU 2006 6 8 AU510001971 1 20050710 G 2613 1734362450 DETECTOR SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R390 R3904123F27 NE OVERHEAT SYS FAULTY W O OTHER N FALSE WARNING CL CLIMB 1 AU S LT ENGINE TAILPIPE OVERHEAT DETECTOR FAULTY. SUSPECT CAUSED BY WATER INGRESS DUE TO HEAVY RAIN. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P31NE 2006060800117 20060608 00117 EU 2006 6 8 AU510001972 1 20050810 G 8011 DRIVE SHAFT FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE STARTER SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S NR 1 ENGINE STARTER DRIVESHAFT SHEARED. SUSPECT CAUSED BY ERRATIC PRESSURE PULSES FROM APU AIR SUPPLY. 2 L 7 2 4F 4 F RT E25NE 2006060800191 20060608 00191 EU 2006 6 8 AU510001973 1 20050810 G 4970 38760033 THERMOCOUPLE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE BLEED AIR SYS BROKEN W K NONE X ENGINE FLAMEOUT IN INSP/MAINT 1 AU S APU AIR SUPPLY ERRATIC WITH PULSES CAUSING FAILURE OF THREE AIRSTARTERS. INVESTIGATION FOUND APU THERMOCOUPLE BREAKING DOWN. 2 L 7 2 4F 4 F RT E25NE 2006060800193 20060608 00193 EU 2006 6 8 AU510001974 1 20050310 G 2741 FON9126422 TRIM SWITCH FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE STAB FAULTY W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 AU S STABILIZER TRIM SWITCH INTERMITTENT DUE TO FAULTY WIRE TERMINATION. 2 L 7 2 4F 4 F RT E25NE 2006060800195 20060608 00195 NM 2006 6 8 AU510001975 1 20050710 G 3230 LANDING GEAR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE MALFUNCTIONED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 AU S WHEN THE LANDING GEAR WAS SELECTED `UP` THE NOSE LANDING GEAR DOORS FAILED TO CLOSE. THE GEAR WAS RECYCLED AND THE NLG DOORS INDICATED `CLOSED`. THOROUGH TESTING AND INVESTIGATION IAW MAINTENANCE MANUAL FAILED TO FIND A CAUSE FOR THE DEFE CT AND THE AIRCRAFT WAS RETURNED TO SERVICE WITH NO FURTHER INCIDENTS. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006061300002 20060613 00002 GL 2006 6 13 AU510001976 3 20051212 G 6110 CYLINDER HARTZL CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO HARTZL HCJ3Y PHCJ3YF1 GL PROPELLER UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 AU S FP1026A DURING STRIP IT WAS FOUND THAT THE PROPELLER CYLINDER HAD BEEN OVERTORQUED WHEN LAST FITTED. FURTHER INVESTIGATION FOUN D THAT THE NUT HOLDING THE PISTON UNIT TO THE CONTROL ROD WAS LOOSE AND THE SPLIT PIN WAS SHEARED. THE REMAINS OF THE S PLIT PIN WERE FOUND IN THE PROPELLER ON EITHER SIDE OF THE PISTON. DAMAGE TO THE UNDERSIDE OF THE PISTON HAD BEEN DRESS ED OUT. SUSPECT THAT THE CYLINDER AND PISTON HAD BEEN REMOVED AND REFITTED WITHOUT USING THE CORRECT TECHNIQUES OR TOOL S. 1 H 7 1 3O 3 O A4CE E5CE 5 C P36EA 2006060800304 20060608 00304 CE 2006 6 8 AU510001977 1 20051212 G 5711 4224076 SPAR CESSNA 150 A152 2071836 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL RT WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 9645 RT WING SPAR STRAP CONTAINED AREAS OF HEAVY CORROSION BETWEEN THE MATING FACES OF THE SPAR ANGLE AND SPAR STRAP LOCATED MAINLY IN THE TANK BAY AREA. 1 H 7 1 3O 3 O 3A19 E223 5 N P50GL 2006060800305 20060608 00305 CE 2006 6 8 AU510001978 1 20051212 G 5711 4224152 ANGLE CESSNA 150 A152 2071836 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL RT WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 9645 0 RT WING SPAR ANGLE CONTAINED AREAS OF HEAVY CORROSION BETWEEN THE MATING FACES OF THE ANGLE AND SPAR CHANNEL AND THE ANG LE AND THE SPAR STRAP. CORROSION WAS MAINLY LOCATED IN THE AREA OF THE TANK BAY. 1 H 7 1 3O 3 O 3A19 E223 5 N P50GL 2006060800306 20060608 00306 CE 2006 6 8 AU510001979 1 20051212 G 5711 4224056 SPAR CESSNA 150 A152 2071836 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL RT WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 9645 RT WING SPAR CHANNEL HEAVILY CORRODED IN AREAS ON THE MATING FACE BETWEEN THE CHANNEL AND THE SPAR ANGLE. 1 H 7 1 3O 3 O 3A19 E223 5 N P50GL 2006060800337 20060608 00337 EA 2006 6 8 AU510001982 2 20051212 G 8530 LW18852 CYLINDER PIPER PA31 PA31 7103102 SO LYC O540 TIO540V2AD 41532 EA ENGINE CRACKED W A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 AU S 602 L848461A LT ENGINE NR 5 CYLINDER CRACKED AROUND TOP. 1 L 7 2 3O 3 O A20SO E14EA 2006060800403 20060608 00403 SO 2006 6 8 AU510001983 1 20051212 G 5312 62444005 BULKHEAD PIPER PA28 PA28151 7102805 SO LYC O320 O320E3D 41508 EA SNSNCH 74D 74DM EA FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 10762 REAR FUSELAGE BULKHEAD CRACKED. FOUND FOLLOWING REMOVAL OF STEEL FORWARD FIN ATTACHMENT FITTING. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2006060800404 20060608 00404 SW 2006 6 8 AU510001984 1 20051212 G 2820 NUT BELL 412 412 1182202 SW PWA PT6T PT6T3 52045 EA FUEL HOSE CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 721 0 FUEL SYSTEM HOSE ASSEMBLY NUT CRACKED ON FLARE FITTING. FUEL LEAKING. 1 G 7 2 4U 4 U H4SW E22EA 2006060800405 20060608 00405 NM 2006 6 8 AU510001985 1 20051212 G 5521 651693541 SPAR BOEING 657278411 BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE LT ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 53629 0 LT ELEVATOR REAR SPAR CRACKED. FOUND DURING INSPECTION IAW AD/B727/100. 2 L 7 3 4F 4 F RT A3WE E2EA 2006062300007 20060623 00007 NE 2006 6 23 AU510001986 2 20051010 G 7200 3029300 ENGINE REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL RIGHT FAILED W O OTHER X J ENGINE FLAMEOUT WARNING INDICATION LD LANDING 1 AU S (AUS) RT ENGINE FAILED DURING LANDING ROLL WHEN REVERSE THRUST WAS DE-SELECTED. THOROUGH INVESTIGATION COULD FIND NO CA USE FOR THE DEFECT. SUSPECT THE FUEL FLOW MAY HAVE DROPPED TOO FAR WHILE REDUCING NEGATIVE THRUST TO A POINT THAT THE EN GINE FLAMED OUT. THE AIRCRAFT HAS RETURNED TO SERVICE WITH NO FURTHER ISSUES NOTED. (CASA NR 510001986) 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2006061200274 20060612 00274 NE 2006 6 12 AU510001987 2 20051210 G 7421 Y1836 IGNITER FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE NR 1 ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S NR 1 ENGINE IGNITER PLUG FAILED. 2 L 7 2 4F 4 F RT E25NE 2006061200276 20060612 00276 EU 2006 6 12 AU510001988 1 20051210 G 4920 APU FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE APU BAY FAILED W O OTHER O OTHER CR CRUISE 1 AU S APU AUTO SHUTDOWN. INVESTIGATION COULD FIND NO FAULTS. DURING TEST FLIGHT THE APU AGAIN SHUT DOWN. INVESTIGATION CONT INUING. 2 L 7 2 4F 4 F RT E25NE 2006061200277 20060612 00277 EU 2006 6 12 AU510001989 1 20051110 G 2923 PUMP FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE HYDRAULIC SYS FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S NR 2 SYSTEM HYDRAULIC PUMP FAILED. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT E25NE 2006061200279 20060612 00279 SO 2006 6 12 AU510001990 1 20051212 G 5311 FRAME PIPER PA28 PA28161 7102803 SO LYC O320 O320D3G 41508 EA SNSNCH 74D 74DM EA FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 10107 REAR FUSELAGE FRAME AND DOUBLER CRACKED AND CORRODED. SUSPECT MATING SURFACES NOT PRIMED DURING MANUFACTURE. 1 L 7 1 3O 3 O 2A13 E274 5 N P88614 2006061200310 20060612 00310 SO 2006 6 12 AU510001991 1 20051212 G 5312 62404003 BULKHEAD PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA HARTZL HCC2Y HCC2YK1 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 8144 REAR FUSELAGE BULKHEAD CRACKED. FOUND FOLLOWING REMOVAL OF FORWARD FIN ATTACHMENT FITTING. 1 L 7 1 3O 3 O A3SO 1E4 5 C P920 2006061300112 20060613 00112 SW 2006 6 13 AU510001992 1 20050710 G 7603 74390420 CONTROL CABLE GARRETTLTD SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL POWER LEVER BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S LT ENGINE POWER CONTROL CABLE BROKEN BETWEEN POWER LEVER AND CABLE JOINT. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 2006061300113 20060613 00113 2006 6 13 AU510001993 4 20051212 G 3416 433006228 ALTIMETER CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL COCKPIT FAILED W O OTHER O OTHER CR CRUISE 1 AU S ENCODING ALTIMETER FAILED. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2006061300114 20060613 00114 EU 2006 6 13 AU510001994 1 20050601 G 5751 68530171 FITTING PARTEN P68 P68B 6780104 EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL AILERONS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S TORQUE TUBE ATTACHMENT FITTING CORRODED. LIMITED INFORMATION PROVIDED. 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 2006061300116 20060613 00116 EA 2006 6 13 AU510001995 2 20051212 G 8520 19341 CAMSHAFT PIPER PA31 PA31350 7103110 SO LYC O540 LTIO540J2BD 41533 EA ENGINE WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 568 RT ENGINE METAL CONTAMINATION. INVESTIGATION FOUND CAMSHAFT LOBE FOR INLET VALVE ON NR 5 AND NR 6 CYLINDERS FAILED/WORN . 1 L 7 2 3O 3 O A20SO E14EA 2006061300118 20060613 00118 SO 2006 6 13 AU510001996 1 20051212 G 5280 4752932 HINGE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA MLG DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S MAIN LANDING GEAR INBOARD DOOR HINGE ASSEMBLY CRACKED IN ATTACHMENT ANGLES. 1 L 7 2 3O 3 O A20SO E14EA 2006061300119 20060613 00119 CE 2006 6 13 AU510001997 1 20051212 G 5312 BULKHEAD BEECH 200 200BEECH 1152920 CE PWA PT6 PT642A NE HARTZL HCD4N3 HCD4N3A GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S REAR PRESSURE BULKHEAD EXTENDER NR 7 CLEAT CRACKED. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2006061300121 20060613 00121 SO 2006 6 13 AU510001998 2 20051010 G 8530 ROCKER CESSNA 182 182F 2072714 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL ENGINE DETERIORATED W K NONE O OTHER IN INSP/MAINT 1 AU S ROCKER ARMS (2OFF) HAD HARD FACING FAILURE. FOUND DURING INSPECTION IAW AD/ENG/4 AMDT9. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 2006061300239 20060613 00239 GL 2006 6 13 AU510001999 2 20050510 G 7310 FILTER BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL RT ENGINE FUEL CONTAMINATED W A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION TO TAKEOFF 1 AU S RT ENGINE FUEL FILTER CONTAMINATED WITH BLACK SOOTY DEPOSITS. FURTHER INVESTIGATION FOUND A LESSER DEGREE OF THE SAME D EPOSITS IN THE LT ENGINE FUEL FILTER. EXTENSIVE FUEL DRAINS FOUND TO BE CLEAR. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT A1NM E23EA 2006061300242 20060613 00242 EA 2006 6 13 AU510002000 2 20050510 G 8530 C36001D CYLINDER GIPPLD GA200 GA200 3900100 EU LYC O540 O540A1D5 41532 EA MCAULY 1A200 1A200FA GL ENGINE CRACKED W O OTHER O OTHER NR NOT REPORTED 1 AU S 1638 792 0 ENGINE CYLINDERS (2OFF) CRACKED IN CYLINDER HEAD AREA. 1 L 7 1 3O 3 O NC A00001LA E295 5 N P874 2006061300244 20060613 00244 CE 2006 6 13 AU510002001 1 20050610 G 2710 AN16132LL FORK CESSNA 172 172F 2072414 CE CONT O300 O300C 17022 SO MCAULY 1C172 1C172EM GL AILERONS CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 7309 0 RT AILERON BELLCRANK FORK CORRODED. FOUND DURING INSPECTION IAW AWB 27-1. AIRCRAFT HAS SPENT MOST OF ITS LIFE OUTDOORS . 1 H 7 1 3O 3 O NT 3A12 E253 5 N P910 2006061300246 20060613 00246 NE 2006 6 13 AU510002002 2 20051210 G 7321 324476812 FUEL CONTROL BEECH 200 200CBEECH 1152926 CE PWA PT6 PT642A NE ENGINE FAILED W A UNSCHED LANDING X J ENGINE FLAMEOUT WARNING INDICATION CR CRUISE 1 AU S 4171 2832 0 ENGINE FUEL CONTROL UNIT FAILED. FORWARD BEARING COLLAPSED. BEARING WAS OLD PRE-MOD TYPE. 1 L 7 2 4T 4 T A24CE E4EA 2006061300247 20060613 00247 CE 2006 6 13 AU510002003 1 20050610 G 3320 334977E14 INVERTER BEECH 200 200BEECH 1152920 CE PWA PT6 PT642A NE CABIN LIGHTS FAILED W O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 AU S 3177 FLUORESCENT CABIN LIGHTING SYSTEM COLD CATHODE INVERTER FAILED INTERNALLY. 1 L 7 2 4T 4 T A24CE E4EA 2006061300249 20060613 00249 NM 2006 6 13 AU510002006 1 20051212 G 3230 DOOR DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE ALT MLG EXTEND OPEN W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 AU S 99999 99999 LANDING GEAR FAILED TO RETRACT. INVESTIGATION FOUND THAT THE ALTERNATE GEAR EXTENSION DOOR IN THE FLIGHT DECK FLOOR WAS OPEN. WITH THIS DOOR OPEN THE LANDING GEAR CYCLE WILL NOT COMMENCE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006061400179 20060614 00179 SO 2006 6 14 AU510002007 2 20051212 G 8540 DRIVE SHAFT BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO MCAULY 3AF34C 3AF34C502 GL CSU FAILED W O OTHER Y J ENGINE STOPPAGE WARNING INDICATION CR CRUISE 1 AU S CSU DRIVE ASSEMBLY FAILED. INVESTIGATION CONTINUING. 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 2006061400180 20060614 00180 NM 2006 6 14 AU510002008 1 20051212 G 5610 WINDSHIELD BOEING 737 737800* NM COCKPIT FAILED W O OTHER O OTHER CR CRUISE 1 AU S CAPTAIN`S NR 2 WINDSHIELD OUTER PANE SHATTERED. 2 L 7 2 4F RT A16WE 2006061400182 20060614 00182 2006 6 14 AU510002009 4 20050610 G 3420 6229436100 SYMBOL GENERATOR BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU ATTITUDE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S CAPTAIN`S SYMBOL GENERATOR FAILED. 2 L 7 2 4F 4 F RT A16WE E21EU 2006061400183 20060614 00183 SW 2006 6 14 AU510002010 1 20051205 G 2910 LINE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL HYD SYSTEM DETERIORATED W K NONE O OTHER IN INSP/MAINT 1 AU S NUMEROUS RIGID HYDRAULIC AND FUEL PIPES DETERIORATED. PIPES WERE CRACKED, CORRODED AND CHAFED. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 2006061400184 20060614 00184 2006 6 14 AU510002011 4 20051210 G 3421 6226342022 EADI EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE COCKPIT FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS DE DESCENT 1 AU S CAPTAIN`S ELECTRONIC ATTITUDE DIRECTION INDICATOR (EADI) FAILED. 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 2006061400185 20060614 00185 EU 2006 6 14 AU510002012 1 20051212 G 7500 WARNING SYSTEM SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE BLEED AIR SYS FAULTY W O OTHER J WARNING INDICATION CR CRUISE 1 AU S RT ENGINE BLEED AIR LEAK LIGHT ILLUMINATED. INVESTIGATION CONTINUING. 2 L 7 2 4T 4 T RT A52EU E8NE 2006061400189 20060614 00189 NM 2006 6 14 AU510002013 1 20051212 G 3244 TIRE BOEING 747 747438 NM RROYCE RB211 RB211524* NE MLG DEFLATED W K NONE O OTHER IN INSP/MAINT 1 AU S 21872 384 NR 12 MAIN WHEEL TIRE PRESSURE REDUCING STEADILY. INVESTIGATION FOUND THAT THE TIRE CARCASS HAD BEEN PUNCTURED BY FOD. 2 L 7 4 4F 4 F RT A20WE E12EU 2006061400190 20060614 00190 2006 6 14 AU510002014 4 20051212 G 3421 HG1050AD04 IRU BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU ATTITUDE GYRO FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 20332 6251 NR 1 INERTIAL REFERENCE UNIT (IRU) FAILED. 2 L 7 2 4F 4 F RT A16WE E21EU 2006061400191 20060614 00191 NM 2006 6 14 AU510002015 1 20050310 G 5414 UL37842 PANEL RROYCE BOEING 747 747438 NM RROYCE RB211 RB211524* NE ENGINE COWLING DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S NR 1 ENGINE LT FORWARD LOWER CARBON FIBER PANEL P/N UL37842 DAMAGED. FORWARD SUPPORT BRACKETS (2OFF) P/N UL24084A FOUND SHEARED/CRACKED TO COMPRESSOR CASING. CORE PANEL SUPPORT BRACKETS (3OFF) UNSERVICEABLE. LT LOWER `A` FRAME TO CORE CU FF PANELS DAMAGED/MISSING. LOWER CUFF PANEL P/N UL27564 AND UPPER CUFF PANEL P/N UL27563 MISSING. 2 L 7 4 4F 4 F RT A20WE E12EU 2006061500099 20060615 00099 NE 2006 6 15 AU510002016 2 20050310 G 7314 PAC102MK4S PUMP BOEING 747 747338 NM RROYCE RB211 RB211524* NE FUEL SYSTEM FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 6504 6504 NR 3 ENGINE FUEL PUMP LOW PRESSURE IMPELLER SHEARED. INVESTIGATION FOUND THE FAILURE OF THE PUMP WAS CAUSED BY VIBRATIO NS THAT WERE INTRODUCED BY THE INTERACTION OF THE IMPELLER SYMMETRICAL SUPPORT PINS WITH THE SPACER TUBE. THESE VIBRATI ONS CAUSED A LOSS OF TORQUE ON THE SCREWED PLUG P/N 77083508 WHICH ALLOWED THE IMPELLER P/N 77085495 TO MOVE ON THE GEAR SHAFT P/ N 77086297. THIS MOVEMENT CAUSED THE IMPELLER TO LOCK ON THE IMPELLER BACK PLATE AND INSERT ASSEMBLY RESULTIN G IN THE SHEARED QUILL SHAFT. 2 L 7 2 4F 4 F RT A20WE E12EU 2006061500101 20060615 00101 NE 2006 6 15 AU510002018 2 20051212 G 7421 Y1836 IGNITER FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE NR 2 ENGINE WORN W K NONE O OTHER IN INSP/MAINT 1 AU S NR 2 ENGINE IGNITER WORN. 2 L 7 2 4F 4 F RT E25NE 2006061500102 20060615 00102 EU 2006 6 15 AU510002019 1 20051212 G 7830 1159SCP4081 SOLENOID RROYCE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE THRUST REVERSER FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S NR 2 ENGINE THRUST REVERSER INTERMITTENT WARNING. INVESTIGATION FOUND THE SECONDARY LOCK SOLENOID HAD A FAULTY INTERNAL SWITCH. 2 L 7 2 4F 4 F RT E25NE 2006061500104 20060615 00104 EA 2006 6 15 AU510002020 2 20050610 G 8530 TISN41 CYLINDER PIPER PA28 PA28140 7102802 SO LYC O320 O320D3G 41508 EA NR 2 DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 39 NR 2 CYLINDER BORE COATING MISSING, PISTON RINGS WORN AND SCORING ON PISTON SKIRT. 1 L 7 1 3O 3 O 2A13 E274 2006061500105 20060615 00105 SW 2006 6 15 AU510002021 1 20051110 G 3241 60064911 CONTROL VALVE SWRNGN SA227 SA227* SW GARRTT TPE331 TPE331* 01514 WP MCAULY 4HFR34 4HFR34C652 NE ANTI SKID SYS FAILED W O OTHER J WARNING INDICATION LD LANDING 1 AU S 10519 RT MAIN LANDING GEAR NR 2 WHEEL LOCKED UP ON LANDING CAUSING THE TIRE TO BURST. INVESTIGATION FOUND THE RT MAIN LANDING GEAR AXLE HAD WATER INGRESS AND THE ANTI-SKID WIRING HAD HIGH RESISTANCE. THE WIRING WAS REPLACED BUT THE ANTI-SKID SY STEM WAS STILL INOPERATIVE. FURTHER INVESTIGATION FOUND THE OUTBOARD ANTI-SKID CONTROL VALVE FAILED. 2 L 7 2 4T 3 T RT A5SW E2WE 6 C 3PNE 2006061500106 20060615 00106 CE 2006 6 15 AU510002022 2 20051212 G 7314 SHAFT PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360RB 17025 CE MCAULY 3AF32C 3AF32C* GL FUEL PUMP WORN W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 1066 ENGINE DRIVEN FUEL PUMP LEAKING. THE PUMP WAS DISMANTLED AND THE FOLLOWING DEFECTS WERE FOUND, ROTOR SHAFT FOUND WITH E XCESSIVE WEAR AND EXTREME SCORING, DEEP SCORING IN SHAFT BEARING (BUSHING), LOWER FACE OF ROTOR SHAFT HAS CONTACTED AND DAMAGED LOWER THRUST PLATE. THE WEAR ON PARTS HAS ALLOWED THE ROTOR TO BE LOADED TO ONE SIDE CAUSING WEAR ON LINER WAL L 5. ROTOR SHAFT (AT VANE SEGMENTS) SHOWS SIGNS OF BEING SUBJECT TO EXTREME HEAT. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2006061500107 20060615 00107 NM 2006 6 15 AU510002023 1 20051212 G 3220 LANDING GEAR BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE NOSE MALFUNCTIONED W O OTHER J WARNING INDICATION CL CLIMB 1 AU S AFTER TAKEOFF, NOSE LANDING GEAR EXTENDED WHEN LANDING GEAR LEVER WAS SELECTED TO `OFF`. NLG WAS NOT OVERSPED. INVESTI GATION COULD FIND NO FAULTS WITH THE EXTENSION/RETRACTION SYSTEM. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061500108 20060615 00108 EU 2006 6 15 AU510002024 1 20051212 G 7810 FAIRING FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE EXHAUST CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S ENGINE EXHAUST SPOKE FAIRING CRACKED IN TWO PLACES AT THE 7:30 O`CLOCK AND 9 O`CLOCK POSITIONS. 2 L 7 2 4F 4 F RT E25NE 2006061500109 20060615 00109 NM 2006 6 15 AU510002025 1 20051212 G 6120 8148291 TRANSFER TUBE DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE PROPELLER FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S RT PROPELLER TRANSFER TUBE DRIVE PIN LOOSE. DURING TEST FOR AXIAL RETENTION OF THE DRIVE PIN, IT WAS FOUND TO MOVE WITH LESS THAN THE REQUIRED 25-30 POUNDS FORCE. FOUND DURING INSPECTION IAW AD/PHS/22. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006061500233 20060615 00233 WP 2006 6 15 AU510002026 2 20051212 G 7200 ENGINE CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL RIGHT SEIZED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 AU S RT ENGINE SEIZED. INVESTIGATION CONTINUING. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2006061600010 20060616 00010 CE 2006 6 16 AU510002027 1 20051010 G 5540 4310074 HORN CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL RUDDER CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S RUDDER HORN CORRODED IN AREA OF CABLE ATTACHMENT. 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2006061600011 20060616 00011 CE 2006 6 16 AU510002028 1 20051212 G 7430 L2925010105 IGNITION SWITCH CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO COCKPIT WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 0 IGNITION SWITCH INTERNAL CONTACTS WORN WITH EVIDENCE OF ARCING. FOUND DURING INSPECTION IAW AD/ELEC/59. 1 H 7 1 3O 3 O A4CE E5CE 2006061600012 20060616 00012 CE 2006 6 16 AU510002029 1 20051212 G 5511 53200198 SPAR CESSNA CESSNA 172 172M 2072418 CE LYC O320 O320E2D 41508 EA MCAULY 1C160 1C160DTM GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 4149 17263115 HORIZONTAL STABILIZER FRONT SPAR CRACKED. FOUND DURING INSPECTION IAW AD/CESSNA170/59. 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2006061600013 20060616 00013 WP 2006 6 16 AU510002030 1 20051212 G 7820 C1693 MUFFLER ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 985 MUFFLER ASSEMBLY COLLAPSED AROUND TAILPIPE IN AREA LOCATED UNDER THE HEATER SHROUD. 1 G 7 1 3O 3 O H11NM E295 2006061600014 20060616 00014 NM 2006 6 16 AU510002031 1 20051212 G 5302 A02323 TAIL BOOM ROBSIN R22 R22BETA 7640110 NM LYC O360 O360J2A 41514 EA DISTORTED W K NONE O OTHER IN INSP/MAINT 1 AU S 814 TAILBOOM DISTORTED IN FIRST BAY. FOUND DURING INSPECTION FOLLOWING HARD LANDING. 1 G 7 1 3O 3 O H10WE E286 2006061600016 20060616 00016 SO 2006 6 16 AU510002032 1 20051212 G 2434 ALE1003K BEARING ELECTROSYS PIPER PA30 PA39 7103902 SO LYC O320 IO320B1A 41508 EA HARTZL HCE2Y HCE2YL2 GL ALTERNATOR LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S 691 B030341 LT ENGINE ALTERNATOR DRIVE END BEARING SPINNING IN HOUSING. ALTERNATOR ROTOR RUBBING ON STATOR. LOSS OF BEARING GREASE . 1 L 7 2 3O 3 O A1EA 1E12 5 C P9EA 2006061600017 20060616 00017 EA 2006 6 16 AU510002033 2 20051212 G 8520 68484 TUBE LYC LYC O360 O360A1F6 41514 EA CRANKSHAFT LOOSE W K NONE O OTHER IN INSP/MAINT 1 AU S OIL TRANSFER TUBE LOOSE IN CRANKSHAFT. SUSPECT POOR QUALITY OF FLARING. INVESTIGATION FOUND TWO OTHER CRANKSHAFTS WITH THE SAME PROBLEM. 3 O E286 2006061600018 20060616 00018 NM 2006 6 16 AU510002034 1 20051212 G 6120 8148291 TUBE HAMSTD DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE PROPELLER UNSERVICEABLE W K NONE O OTHER IN INSP/MAINT 1 AU S LT PROPELLER TRANSFER TUBE DRIVE PIN LOOSE. DURING TEST FOR AXIAL RETENTION OF THE DRIVE PIN, IT WAS FOUND TO MOVE WITH LESS THAN THE REQUIRED 25-30 POUNDS FORCE. FOUND DURING INSPECTION IAW AD/PHS/22. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006061600020 20060616 00020 GL 2006 6 16 AU510002035 3 20051212 G 6114 C7361 HUB PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA MCAULY 3DF36C B3DF36C526 GL PROPELLER LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 0 RED DYE LEAKING FROM PROPELLER HUB. INSPECTION FOUND THE CYLINDER SCREWS TIGHT AND LOCKWIRED. SUSPECT FAULTY MANUFACTU RE OF GASKET P/N C7361. 1 L 7 2 3O 3 O A20SO E14EA 5 C 2006061900019 20060619 00019 NM 2006 6 19 AU510002036 1 20050710 G 2780 256T280014 TORQUE TUBE BOEING 767 767300 1385204 NM RROYCE RB211 RB211524* NE LE SLAT CONTROL WORN W K NONE O OTHER IN INSP/MAINT 1 AU S LEADING EDGE SLAT TORQUE TUBE COUPLING SPLINES WORN AT NR 5 LEADING EDGE SLAT GEARBOX. INVESTIGATION ON REMOVAL FOUND T HAT THE SPLINES (SPLINE FITTING P/N 256T2806-1 WERE COMPLETELY MISSING FROM THE TORQUE TUBE FITTING. THE TORQUE TUBE CO UPLING P/N 256T2801-1 APPEARS IN SATISFACTORY CONDITION WITH ONLY A SMALL AMOUNT OF WEAR EVIDENT. 2 L 7 2 4F 4 F RT A1NM E12EU 2006061900021 20060619 00021 NM 2006 6 19 AU510002037 1 20051212 G 3242 S160T400510 ROTOR BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL NR 6 BRAKE DISINTEGRATED W K NONE O OTHER IN INSP/MAINT 1 AU S MAIN LANDING GEAR NR 6 BRAKE ROTOR DISINTEGRATED. 2 L 7 2 4F 4 F RT A1NM E23EA 2006061900024 20060619 00024 NM 2006 6 19 AU510002038 1 20051212 G 5244 DOOR BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU LAVATORY MISREPAIRED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S PAPER AND LINEN WASTE RECEPTACLE DOORS IN TOILETS NOT SEALING. INVESTIGATION FOUND LAV A (FWD) TO BE LATCHING SECURELY BUT NOT SEALING. INVESTIGATION REVEALED EXTRA STRIKER PLATE BONDED OVER EXISTING STRIKER PLATE CAUSING DOOR TO SIT OUT FURTHER THAN REQUIRED. EXTRA PLATE REMOVED. DOOR IS NOW SEALING. LAV B (MID) HINGE REQUIRED TO BE ADJUSTED IN SO THAT THE WASTE COMPARTMENT INNER DOOR COULD SEAL ADEQUATELY. PAINT REMOVED FROM STRIKER PLATE TO ENSURE MAGNETIC LATCH OPER ATION. WASTE CONTAINER OUTER DOOR FOULS INNER DOOR HINGE AREA WHEN CLOSED CAUSING A SLIGHTLY PRE-LOADED CONDITION ON TH E OUTER DOOR LATCH ASSEMBLY. FOUND DURING INSPECTION IAW AD/GENERAL/48 AND EI 734-25-2R9. 2 L 7 2 4F 4 F RT A16WE E21EU 2006061900028 20060619 00028 NM 2006 6 19 AU510002039 1 20050810 G 2997 CONNECTOR BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE HYDRAULIC PUMP DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S HYDRAULIC PUMP CONNECTOR AND MATING RECEPTACLE CONTAMINATED WITH HYDRAULIC FLUID AND BADLY BURNT. ONE OF THE CONNECTOR SOCKETS WAS WELDED ONTO THE PUMP CONNECTOR PINS. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061900029 20060619 00029 NM 2006 6 19 AU510002040 1 20050510 G 2131 1305026 CONTROLLER BOEING 767 767300 1385204 NM RROYCE RB211 RB211524* NE CABIN PRESSURE FAULTY W O OTHER J WARNING INDICATION DE DESCENT 1 AU S 18593 NR 2 CABIN PRESSURE CONTROLLER FAULTY. 2 L 7 2 4F 4 F RT A1NM E12EU 2006061900031 20060619 00031 NM 2006 6 19 AU510002041 1 20051110 G 3610 PNEUMATIC SYSTEM BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL LT ENGINE FAULTY W O OTHER J WARNING INDICATION CL CLIMB 1 AU S LT ENGINE PRV WARNING WHEN TAKEOFF THRUST SET. MESSAGE CLEARS WHEN THRUST REDUCED. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT A1NM E23EA 2006061900032 20060619 00032 NM 2006 6 19 AU510002042 1 20051210 G 2750 113A93061 CONTROL ROD BOEING 767 767* NM GE CFM56 CFM56* 13802 NE TE FLAP CONTROL SEPARATED W O OTHER F FLT CONT AFFECTED CR CRUISE 1 AU S RT INBOARD FLAP OUTBOARD FAIRING ATTACHMENT ROD SEPARATED. INVESTIGATION FOUND THE CONTROL ROD FROM FLAP LOWER SURFACE TO THE AFT LINKAGE OF THE FAIRING HAD BECOME DETACHED AND THE LOWER BEARING HAD PULLED OUT OF THE ROD. 2 L 7 2 4F 4 F RT A1NM E2GL 2006061900034 20060619 00034 2006 6 19 AU510002043 4 20051212 G 3442 6225136203 RADAR BOEING 747 747438 NM RROYCE RB211 RB211524* NE WX SYS FAULTY W O OTHER O OTHER CR CRUISE 1 AU S 39707 WEATHER RADAR FAULTY. 2 L 7 4 4F 4 F RT A20WE E12EU 2006061900036 20060619 00036 NM 2006 6 19 AU510002044 1 20051212 G 2910 65445101378 PIPE BOEING 737 737200 1384453 NM PWA JT8 JT8D7 52053 NE HYDRAULIC SYS LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S HYDRAULIC PIPE LOCATED IN NR 2 ENGINE NACELLE LEAKING. 2 L 7 2 4F 4 F A16WE E2EA 2006061900144 20060619 00144 NM 2006 6 19 AU510002045 1 20051212 G 5714 VAPOR BARRIER BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE WING OUT OF LIMITS W K NONE O OTHER IN INSP/MAINT 1 AU S WING CENTER SECTION FUEL VAPOR BARRIER UNDER LIMITS IN THE FOLLOWING SIX AREAS ON THE TRIANGLE POCKET-FRONT SPAR/SIDE OF BODY, TP3-R THICKNESS 1.7 2. TP3-L 2.2, TP6-L 5.9 4. TP9-L 2.0 SHEAR FITTING, FRONT SPAR CORNER WITH TOP PANEL 5. SF4- R 6.3 6. SF5-R 5.8 FOUND DURING INSPECTION IAW AD/B737/245 AND SB 737-57-1250. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061900298 20060619 00298 NM 2006 6 19 AU510002046 1 20051212 G 3244 TIRE DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE MLG DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S NR 4 MAIN WHEEL TIRE DEFLATED. INSPECTION FOUND A 100MM (4IN) CUT IN THE SIDEWALL. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006061900299 20060619 00299 2006 6 19 AU510002047 4 20051212 G 3420 DG1035AB03 ADAPTER BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU DAA FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 43748 43748 RT INERTIAL REFERENCE SYSTEM (IRS) FAILED. CAUSED BY FAULTY RT DIGITAL ANALOGUE ADAPTER (DAA). 2 L 7 2 4F 4 F RT A16WE E21EU 2006061900300 20060619 00300 2006 6 19 AU510002048 4 20051212 G 3417 4040800906 ADC BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL COCKPIT FAILED W O OTHER O OTHER NR NOT REPORTED 1 AU S AIR DATA COMPUTER (ADC) FAILED. 2 L 7 2 4F 4 F RT A1NM E23EA 2006061900301 20060619 00301 NM 2006 6 19 AU510002049 1 20051212 G 3350 LIGHT BOEING 747 747438 NM RROYCE RB211 RB211524* NE R1 DOOR OVERHEATED W O OTHER M B OVER TEMP SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S ENHANCED CABIN LIGHTING SYSTEM LOCATED ABOVE DOOR 1R OVERHEATED. FIRE AND SMOKE IN CABIN. BCF FIRE EXTINGUISHER DISCHA RGED. 2 L 7 4 4F 4 F RT A20WE E12EU 2006061900302 20060619 00302 2006 6 19 AU510002050 4 20051212 G 2330 CONTROL SYSTEM BOEING 747 747438 NM RROYCE RB211 RB211524* NE VIDEO SYS FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S PASSENGER ENTERTAINMENT SYSTEM VIDEO CONTROL CENTER FAULTY. 2 L 7 4 4F 4 F RT A20WE E12EU 2006061900304 20060619 00304 NM 2006 6 19 AU510002051 1 20051212 G 2781 189929 PROXIMITY SENSOR BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE NR 6 SLAT FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S NR 6 LEADING EDGE SLAT POSITION PROXIMITY SENSOR FAULTY. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061900309 20060619 00309 2006 6 19 AU510002052 4 20051212 G 3442 6225135002 DISPLAY BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE WX RADAR SYS FAILED W O OTHER O OTHER CR CRUISE 1 AU S 45912 92 WEATHER RADAR PEDESTAL FAILED. 2 L 7 2 4F 4 F RT A16WE E2GL 2006062100163 20060621 00163 NM 2006 6 21 AU510002053 1 20051212 G 2710 BACP30M1A PULLEY BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE AILERON CONTROL SEIZED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) AILERON SYSTEM SLIGHTLY STIFF. LT TRIM ACTUATOR CHANGED BUT DEFECT REMAINED. INVESTIGATION FOUND A SEIZED PULLEY IN AILERON CONTROL SYSTEM. PULLEY LOCATED AT LT AB CABLE RUN AT STN 380 WL 283. (CASA NR 510002053) 2 L 7 4 4F 4 F RT A20WE E30NE 2006062300077 20060623 00077 2006 6 23 AU510002054 4 20051212 G 3442 8221710001 TRANSMITTER BOEING 737 737800* NM GE CFM56 CFM567B24 NE WX RADAR SYS FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 978 978 (AUS) WEATHER RADAR TRANSMITTER/RECEIVER FAILED. (CASA NR 510002054) 2 L 7 2 4F 4 F RT A16WE E00055EN 2006062300078 20060623 00078 2006 6 23 AU510002055 4 20051212 G 6122 4060575 COVER GROB G115 G115C 1660303 EU LYC O360 O360A1F6 41514 EA HARTZL HCF2Y HCF2YR1 GL GOVERNOR CRACKED W O OTHER F FLT CONT AFFECTED CL CLIMB 1 AU S 842 2488029 (AUS) PROPELLER GOVERNOR CONTROL HEAD BROKEN AWAY IN AREA LOCATED BELOW THE LEVER RETURN SPRING. LOSS OF APPROXIMATELY 2 QUARTS OF OIL. (CASA NR 510002055) 1 L 7 1 3O 3 O NT A57EU E286 5 C P27EA 2006062300079 20060623 00079 EU 2006 6 23 AU510002056 1 20051212 G 2550 AFGO326925 CABLE BOLKMS 117 BK117B2 5626013 EU LYC LTS101 LTS101750B1 41560 NE CARGO HOOKS DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 374 (AUS) BAMBI BUCKET FULL OF WATER CARRIED BELOW AIRCRAFT ON CARGO HOOK FELL OFF WHEN HOOK INADVERTENTLY RELEASED. INVESTI GATION OF THE CARGO HOOK MANUAL RELEASE CABLE FOUND IT TO BE DAMAGED. FURTHER INVESTIGATION FOUND THAT THE OUTER SHEATH HAD BEEN DAMAGED PREVIOUSLY AND CORROSION AND BROKEN WIRE STRANDS HAD BEEN COVERED WITH TAPE. THE DAMAGED OUTER SHEATH H AD CAUSED THE INNER CABLE TO KINK AND ALLOW THE MANUAL CABLE RELEASE MECHANISM TO OPERATED WHEN A FULL BUCKET LOAD WAS A TTACHED. SUSPECT CABLE DAMAGE HAD OCCURRED BEFORE THE AIRCRAFT WAS PURCHASED BY THE PRESENT OWNER. PERSONNEL/MAINTENANCE ERROR. ILLEGAL REPAIR. (CASA NR 510002056) 1 G 7 2 3U 3 U NC H13EU E5NE10 2006062300080 20060623 00080 SO 2006 6 23 AU510002057 2 20051212 G 7414 6314653271 MAGNETO CIRRUS SR SR20 05628AJ GL CONT O360 IO360E 17025 SO ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 422 (AUS) LT AND RT MAGNETOS PREMATURELY WORN. LT MAGNETO, HIGH VOLT CONTACT TERMINALS IN DIST BLOCK/CAP ARE ERODED/ARCED. HIGH VOLT DIST ARM TIP HAS ERODED CENTER WIPER ELECTRODE, ARCED END W/PITTING, MATERIAL BREAK DOWN. POINTS SHOW SIGNS OF PITTING WITHIN SERVICE LIMITS. CONDENSER MEASURED .35. RT MAGNETO, DIST SHAFT CARBON BRUSH/SPRING ASSY WORN BEYOND LIMITS, CARBON BRUSH AND SPRING BURNED AWAY. SPRING LEAF ON COIL HAS BEEN BURNED BY ARCING. HIGH VOLT CONTACT TERMINA LS IN DIST BLOCK/CAP ARE ERODED/ARCED. HIGH VOLT DIST ARM TIP HAS ERODED CENTER WIPER ELECTRODE, ARCED END WITH PITTING , MATERIAL BREAK DOWN. POINTS SHOW SIGNS OF PITTING WITHIN SERVICE LIMITS. CONDENSER MEASURED .35. (CASA NR 510002057) 1 L 7 1 3O 3 O NT A00009CH E1CE 2006062100090 20060621 00090 NM 2006 6 21 AU510002058 1 20051212 G 5414 UL37842 PANEL BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE NR 4 NACELLE MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR4 ENGINE LOWER (A) FRAME SEALING FAIRING UPPER PANEL MISSING AND LOWER FAIRING SLIGHTLY DAMAGED ON THE AFT CORNE R. SEE ATTACHMENT FOR INVESTIGATION DETAILS. (CASA NR 510002058) 2 L 7 4 4F 4 F RT A20WE E30NE 2006070500063 20060705 00063 EU 2006 7 5 AU510002059 1 20051212 G 5534 F535760800020 LUG AIRBUS A330 A330* EU GE CF6 CF680 30025 NE VERTICAL STAB BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) VERTICAL STABILIZER ACCESS LADDER UPPER ATTACHMENT LUGS BROKEN. SUSPECT CAUSED BY POOR SHIMMING OF THE UPPER ATTAC HMENT FITTINGS. SEE ATTACHMENT FOR INVESTIGATION DETAILS. (CASA NR 510002059) 2 L 7 2 4F 4 F RT A46NM E13NE 2006070500064 20060705 00064 EU 2006 7 5 AU510002060 2 20051212 G 7250 SHROUD BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU TURBINE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 42120 42120 (AUS) LT ENGINE FAILED TO START. INVESTIGATION FOUND ENGINE SEIZED AND A SMALL AMOUNT OF DEBRIS IN THE TAILPIPE. BOROS COPE INSPECTION FOUND DAMAGE TO HIGH PRESSURE TURBINE (HPT). INVESTIGATION FOUND THE HPT SHOUD HAD FAILED AND LODGED BE TWEEN THE HPT BLADES AND THE FIRST STAGE LPT NOZZLE GUIDE VANE CAUSING THE N2 TO SEIZE. FURTHER INVESTIGATION CONTINUIN G. (CASA NR 510002060) 2 L 7 2 4F 4 F RT A16WE E21EU 2006070500065 20060705 00065 NE 2006 7 5 AU510002061 2 20051212 G 7200 CFM567B24 ENGINE BOEING 737 737* NM GE CFM56 CFM567B24 NE CONTAMINATED W A UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 AU S (AUS) OILY FUMES IN COCKPIT AND CABIN. AIRCRAFT TURNED BACK AND OVERWEIGHT LANDING WAS CARRIED OUT. OVERWEIGHT LANDING I NSPECTION CARRIED OUT WITH NIL FAULTS. SUSPECT FUMES CAUSED BY INHIBITING FLUID REMAINING IN ENGINE FOLLOWING ENGINE CHA NGE. INVESTIGATION CONTINUING. (CASA NR 510002061) 2 L 7 2 4F 4 F RT A16WE E00055EN 2006071900012 20060719 00012 EU 2006 7 19 AU510002062 1 20051212 G 3244 TIRE REIMS 406 F406 7535723 EU PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL MLG DEFLATED W O OTHER O OTHER LD LANDING 1 AU S 685 (AUS) RT MAIN LANDING GEAR TIRE DEFLATED. SUSPECT TIRE DAMAGED BY FOD.(OTHER CAUSE: MATERIAL ) (CASA NR 510002062) 1 L 7 2 3T 3 T RT A54EU E4EA 5 C P60GL 2006070500066 20060705 00066 EA 2006 7 5 AU510002063 2 20051212 G 8530 LW12416PO10 EXHAUST VALVE PIPER PA28 PA28151 7102805 SO LYC O320 O320D3G 41508 EA NR 3 CYLINDER SEIZED W O OTHER E VIBRATION/BUFFET CR CRUISE 1 AU S 1412 L927839A (AUS) NR 3 CYLINDER EXHAUST VALVE SEIZED IN VALVE GUIDE. 1 L 7 1 3O 3 O 2A13 E274 2006070500067 20060705 00067 GL 2006 7 5 AU510002064 1 20051212 G 2434 S4024LP ALTERNATOR CIRRUS SR SR20 05628AJ GL CONT O360 IO360E 17025 SO HARTZL HCJ3Y PHCJ3YF1 GL FAILED W O OTHER H ELECT. POWER LOSS-50 PC CR CRUISE 1 AU S 26 (AUS) ALTERNATOR FAILED. INVESTIGATION FOUND DEFECTIVE INSULATORS AND BATTERY POST TO ALTERNATOR BODY ARCING. (CASA NR 510002064) 1 L 7 1 3O 3 O NT A00009CH E1CE 5 C P36EA 2006070500068 20060705 00068 SO 2006 7 5 AU510002065 1 20051212 G 3211 AN6H14A BOLT PIPER PA38 PA38112 7103812 SO LYC O235 O235L2C 41505 EA MCAULY 1B90 1B90* GL LT MLG SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S 6130 (AUS) LT MAIN LANDING GEAR ATTACHMENT BOLT SHEARED. LT MAIN LANDING GEAR COLLAPSED. (OTHER CAUSE: MATERIAL - ENVIRONMEN T ) (CASA NR 510002065) 1 L 7 1 3O 3 O A18SO E223 5 N P842 2006070500069 20060705 00069 WP 2006 7 5 AU510002066 1 20051212 G 6420 HS1551238 WASHER HUGHES 369 369E 4470707 WP ALLSN 250C 250C20B 03013 GL TAIL ROTOR FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 425 (AUS) TAIL ROTOR FORK ASSEMBLY NUT TABWASHER FAILED ALLOWING THE NUT TO WORK LOOSE. AIRCRAFT THEN SUFFERED A LOSS OF TA IL ROTOR CONTROL WHICH RESULTED IN A FORCED LANDING WITH MINOR AIRCRAFT DAMAGE. INVESTIGATION FOUND A BROKEN INTERNAL TA B ON THE TABWASHER.(OTHER CAUSE: UNKNOWN ) (CASA NR 510002066) 1 G 7 1 3U 3 U H3WE E4CE 2006070300011 20060703 00011 EA 2006 7 3 AU510002067 2 20051212 G 7313 47739 METERING JET LYC O360 O360A1F6 41514 EA CARBURETOR MISMANUFACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S CARBURETOR JET INCORRECTLY MANUFACTURED. METERING HOLE MACHINED OUT OF ROUND. JET IS A NEW ITEM REMOVED FROM OVERHAUL KIT P/N 286-1670-F. 3 O E286 2006070300080 20060703 00080 SO 2006 7 3 AU510002068 1 20051212 G 5311 62444005 FRAME PIPER PA28 PA28R201 7102816 SO LYC O360 IO360C1C6 41514 EA MCAULY 2D34C B2D34C213 GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 6859 REAR FUSELAGE FRAME P/N 62444-005 AND DOUBLER P/N 79272-000 CRACKED AND CORRODED. 1 L 7 1 3O 3 O 2A13 1E10 5 C P7EA 2006070300081 20060703 00081 CE 2006 7 3 AU510002069 1 20051212 G 8011 C12ST21S MOTOR CESSNA 150 A150L 2071828 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL STARTER MISMANUFACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S 81 (AUS) ENGINE STARTER MOTOR HAD NO DRAIN HOLE DRILLED. THIS ALLOWED OIL TO ACCUMULATE IN THE PINION AREA AND LEAK PAST T HE ADAPTER PLATE GASKET. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2006070300082 20060703 00082 EU 2006 7 3 AU510002070 1 20051212 G 3241 ANTI-SKID SYS BAG BAE146 BAE146200A 1500266 EU LYC ALF502 ALF502R5 41580 NE MLG FAULTY W O OTHER O OTHER LD LANDING 1 AU S FOLLOWING TWO BURST TIRES ON NR 1 MAIN WHEEL, MAINTENANCE CHANGED THE GREEN SYSTEM ANTI-SKID VALVE FOR NR 1 WHEEL POSITI ON. INVESTIGATION CONTINUING. 2 H 7 4 4F 4 F RT A49EU E6NE 2006070300083 20060703 00083 NM 2006 7 3 AU510002071 1 20051212 G 5714 VAPOR BARRIER BOEING 737 7377Q8 1384418 NM GE CFM56 CFM56* 13802 NE WING FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S FUEL VAPOR BARRIER LOCATED IN CENTER WING BOX WAS FOUND TO BE BELOW MINIMUM THICKNESS AND LIFTING. FOUND DURING INSPECT ION IAW AD/737/245 AND BOEING SB 737-57-1250. 2 L 7 2 4F 4 F RT A16WE E2GL 2006070300084 20060703 00084 GL 2006 7 3 AU510002072 3 20051212 G 6111 A22131 SPRING GROB G115 G115C 1660303 EU LYC O360 O360A1F6 41514 EA HARTZL HCF2Y HCF2YR1 GL PROPELLER WORN W K NONE O OTHER IN INSP/MAINT 1 AU S PROPELLER COARSE PITCH STOP P/N A2420-30 AND SPRING P/N A2213-1 WORN. SPRING WAS PREVENTED FROM RETURNING THE BLADES TO THE FINE PITCH POSITION AFTER SHUTDOWN. 1 L 7 1 3O 3 O NT A57EU E286 5 C P27EA 2006070500080 20060705 00080 EA 2006 7 5 AU510002073 2 20051212 G 8520 13F27727 CRANKSHAFT GIPPLD GA8 GA8 3900102 EU LYC O540 IO540K1A5 41532 EA HARTZL HCC2Y HCC2YR1 GL ENGINE FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 2193 145 (AUS) CRANKSHAFT REMOVED AND REPLACED DUE TO APPLICABILITY WITH AD AND SB 566. (AD/SB DESC: SB 566 AND AD/LYC/112 ) (CAS A NR 510002073) 1 H 7 1 3O 3 O NT 1E4 5 C P920 2006070300085 20060703 00085 EA 2006 7 3 AU510002074 2 20051212 G 7414 10382585 POINTS CONT BEECH 76 76 1153005 CE LYC O360 O360A1G 41514 EA HARTZL HCM2Y HCM2YR GL MAGNETO UNSERVICEABLE W K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 AU S 13 G04JA140R RT MAGNETO CONTACT BREAKER POINT LOOSE ON SPRING ASSEMBLY. CONTACTS HAD BEEN REPLACED APPROXIMATELY 13 HOURS PREVIOUSLY . SUSPECT BREAKER INCORRECTLY SWAGED ONTO SPRING. 1 L 7 2 3O 3 O A29CE E286 5 C P43GL 2006070500156 20060705 00156 NM 2006 7 5 AU510002075 1 20051212 G 2150 1828203 HEAT EXCHANGER BOEING 737 737800* NM GE CFM56 CFM567B24 NE A/C PACK CRACKED W O OTHER O OTHER NR NOT REPORTED 1 AU S (AUS) LT AND RT AIR CONDITIONING PACK SECONDARY HEAT EXCHANGERS CRACKED. 2 L 7 2 4F 4 F RT A16WE E00055EN 2006070500157 20060705 00157 NM 2006 7 5 AU510002076 1 20050111 G 5714 VAPOR BARRIER BOEING 737 7377Q8 1384418 NM CFMINT CFM567 CFM567B2US 13802 NE FUME BARRIER OUT OF LIMITS W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) SECONDARY FUEL VAPOUR BARRIER OUT OF LIMITS IN THE FOLLOWING AREAS:- TP3-R 0.001, TP3-L 0.001, TP6-R 0.001, TP6-L 0.001, TP9-R 0.001, TP9-L 0.003, SF2-R 0.005, SF1-L 0.003, SF2-L 0.002. SF3-R 0.002, SF4-R 0.004, SF3-L 0.002, SF4-L 0.0 06 FOUND DURING INSPECTION IAW AD/737/245 AND SB 737-57-1250. (AD/SB DESC: AD/B737-245 ) (CASA NR 510002076) 2 L 7 2 4F 4 F RT A16WE E2GL 2006070500160 20060705 00160 NE 2006 7 5 AU510002077 2 20051212 G 7250 GUIDE VANE BOEING 727 727277 138408S NM PWA JT8 JT8D15 52051 NE 1ST STAGE NOZZLE FRACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S 687588 (AUS) NR 1 ENGINE FIRST STAGE NOZZLE GUIDE VANE (NGV) BURNED THROUGH. NGV WAS LOCATED ADJACENT TO NR 9 COMBUSTION CHAMB ER. SUSPECT CAUSED BY CRACKING ON THE LEADING EDGE ALLOWING HOT AIR TO PENETRATE THE NGV. FOUND DURING INSPECTION OF TH E COMBUSTION CHAMBERS IAW AD/JT8D/20 (PW SB5639). (OTHER CAUSE: MATERIAL ) (CASA NR 510002077) 2 L 7 3 4F 4 F RT A3WE E2EA 2006070500161 20060705 00161 EU 2006 7 5 AU510002078 1 20051111 G 2910 D71281649 LINE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE HYD SYSTEM CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S (AUS) HYDRAULIC PIPE CRACKED AND LEAKING. LOSS OF HYDRAULIC FLUID. (CASA NR 510002078) 2 L 7 2 4F 4 F RT E25NE 2006070500162 20060705 00162 NE 2006 7 5 AU510002079 2 20050911 G 7230 PANEL BOEING 747 747438 NM RROYCE RB211 RB211524* NE COMPRESSOR MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) SMALL TITANIUM PANEL MISSING FROM ENGINE COMPRESSOR SECTION. (CASA# 510002079) 2 L 7 4 4F 4 F RT A20WE E12EU 2006070500163 20060705 00163 NM 2006 7 5 AU510002080 1 20051011 G 3242 26123121 BRAKE BOEING 737 737* NM GE CFM56 CFM567B24 NE NR 1 LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 7198 1654 (AUS) NR 1 MAIN LANDING GEAR BRAKE ASSEMBLY LOWER PISTON WET WITH HYDRAULIC FLUID. LARGE PUDDLE OF HYDRAULIC FLUID FOUN D. BRAKE CHANGED. INVESTIGATION CONTINUING AS TO EXACT SOURCE OF LEAK FROM BRAKE. (CASA NR 510002080) 2 L 7 2 4F 4 F RT A16WE E00055EN 2006070500219 20060705 00219 CE 2006 7 5 AU510002081 1 20050911 G 2761 66276E12 ACTUATOR LEAR 45 45LEAR 5170805 CE GARRTT TFE731 TFE7312 01518 WP SPOILERS LEAKING W A UNSCHED LANDING K FLUID LOSS CR CRUISE 1 AU S 1675 (AUS) RT WING SPOILER ACTUATOR LEAKING. LOSS OF HYDRAULIC FLUID.(OTHER CAUSE: MATERIAL ) (CASA NR 510002081) 2 L 7 2 4F 4 F RT T00008WI E6WE 2006071000095 20060710 00095 2006 7 10 AU510002082 4 20050811 G 3457 CIRCUIT CARD CESSNA 404 404 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL GPS FAILED W O OTHER O OTHER CR CRUISE 1 AU S GPS DATA CARD FAILED. 1 L 7 2 3O 3 O RT A25CE E7CE 5 C P45GL 2006071000096 20060710 00096 SW 2006 7 10 AU510002083 1 20051011 G 3297 WIRE SWRNGN SA227 SA227* SW GARRTT TPE331 TPE331* 01514 WP MCAULY 4HFR34 4HFR34C652 NE CONTROL VALVE WORN W O OTHER O OTHER DE DESCENT 1 AU S LANDING GEAR CONTROL VALVE CONNECTOR PLUG WIRE WORN AND SHORT CIRCUITING TO PIN `B`. 2 L 7 2 4T 3 T RT A5SW E2WE 6 C 3PNE 2006071000097 20060710 00097 NE 2006 7 10 AU510002084 3 20051011 G 6111 4HFR34C652 BLADE SWRNGN SA227 SA227* SW GARRTT TPE331 TPE331* 01514 WP MCAULY 4HFR34 4HFR34C652 NE PROPELLER LIGHTNING STRIKE W O OTHER O OTHER CR CRUISE 1 AU S LIGHTNING STRIKE ON AIRCRAFT EXITED THROUGH LT PROPELLER BLADE. UNKNOWN POINT OF ENTRY. ENGINE AND PROPELLER REMOVED F OR LIGHTNING STRIKE INSPECTION. 2 L 7 2 4T 3 T RT A5SW E2WE 6 C 3PNE 2006071000098 20060710 00098 SO 2006 7 10 AU510002085 2 20051212 G 8530 AEC631397A CYLINDER CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO NR 2 CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 1044 NR 2 CYLINDER CRACKED AND LEAKING IN AREA LOCATED BETWEEN THE SECOND AND THIRD FINS BACK FROM THE TOP SPARK PLUG HOLE. CRACKS ALSO FOUND UNDER THE TOP SPARK PLUG HOLE, BETWEEN THE SPARK PLUG AND EXHAUST VALVE SEAT INSIDE THE CYLINDER AND I NSIDE THE EXHAUST PORT FROM THE EXHAUST VALVE SEAT HEADING TOWARDS THE LOWER SIDE OF THE CYLINDER. CYLINDER FALLS OUTSI DE THE RANGE COVERED BY ECI SB SI04-1. 1 H 7 1 3O 3 O A4CE E5CE 2006071000099 20060710 00099 EU 2006 7 10 AU510002086 1 20050911 G 2421 740508 IDG FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE AC GENERATOR FAULTY W K NONE H ELECT. POWER LOSS-50 PC IN INSP/MAINT 1 AU S 11874 LT ENGINE INTEGRATED DRIVE GENERATOR (IDG) FAULTY. LT GENERATOR LINE CONTACTOR P/N S6002206 ALSO CHANGED. 2 L 7 2 4F 4 F RT E25NE 2006071000100 20060710 00100 EU 2006 7 10 AU510002087 1 20051011 G 2844 PRESSURE SWITCH FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE FUEL SYSTEM FAULTY W A UNSCHED LANDING O OTHER CR CRUISE 1 AU S FUEL TRANSFER PUMP PRESSURE SWITCH FAULTY. 2 L 7 2 4F 4 F RT E25NE 2006071000101 20060710 00101 NM 2006 7 10 AU510002088 1 20050911 G 2133 OUTFLOW VALVE BOEING 737 7377Q8 1384418 NM GE CFM56 CFM56* 13802 NE CABIN PRESSURE FAULTY W O OTHER J WARNING INDICATION CR CRUISE 1 AU S PRESSURIZATION SYSTEM PROBLEMS. INVESTIGATION FOUND INBOARD AND OUTBOARD POSITIVE PRESSURE RELIEF VALVES TO BE UNSERVIC EABLE. BOTH VALVES REPLACED. OUTBOARD VALVE CURRENTLY CONSIDERED TO BE THE PRIMARY CAUSE OF THE CABIN DEPRESSURIZATION EVENT. 2 L 7 2 4F 4 F RT A16WE E2GL 2006071100123 20060711 00123 CE 2006 7 11 AU510002089 1 20051011 G 5414 57544104 SKIN CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL RT NACELLE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S 17109 UPPER AFT RT NACELLE SKIN CRACKED AND CORRODED. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2006071100132 20060711 00132 2006 7 11 AU510002090 4 20050311 G 6122 F624 GOVERNOR HARTZL PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA HARTZL HCE3Y HCE3YR2 GL PROPELLER FAILED W O OTHER O OTHER CL CLIMB 1 AU S 186 RT ENGINE PROPELLER GOVERNOR COUPLING GEAR PNO A-3181 DRIVE TEETH (8OFF) SHEARED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2006071100133 20060711 00133 NE 2006 7 11 AU510002091 2 20051212 G 7200 6053T87G01 ENGINE SAAB SF340 SF340A 7850100 EU GE CT7TP CT75A 30030 NE ROTOL R389 R3894123F25 NE LEFT MAKING METAL W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 AU S LT ENGINE OIL SYSTEM CHIP DETECTOR CONTAMINATED WITH METAL FUZZ. ANALYSIS FOUND THE METAL TO BE BEARING MATERIAL. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P30NE 2006071100134 20060711 00134 CE 2006 7 11 AU510002092 1 20050911 G 3020 65525026 BELLOWS CESSNA 500 560CESSNA 2076750 CE PWA JT15 JT15D5 52112 NE AIR INTAKE BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 3778 LT ENGINE AIR INTAKE ANTI-ICE SYSTEM BELLOWS BROKEN AT WELD. 2 L 7 2 4F 4 F RT A22CE E25EA 2006060800118 20060608 00118 2006 6 8 AU510002093 4 20051212 G 3416 433006228 ENCODER CESSNA 441 441 2076020 CE GARRTT TPE331 TPE331* 01514 WP HARTZL HCB3T HCB3TN5 GL ALTIMETER FAILED W O OTHER N FALSE WARNING CR CRUISE 1 AU S ALTIMETER ENCODER OUTPUT FAILED GIVING FALSE READINGS. 1 L 7 2 3T 3 T RT A28CE E2WE 6 C P15EA 2006060800119 20060608 00119 SO 2006 6 8 AU510002094 2 20050510 G 8530 AEC642068STA CYLINDER CESSNA 182 182H 2072718 CE CONT O470 O470R 17026 SO MCAULY 2A34C 2A34C66 GL ENGINE FAULTY W O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 AU S 396 396 288427R PISTON RINGS PREMATURELY WORN AND DETERIORATED CAUSING HIGH OIL CONSUMPTION AND POWER LOSS. CYLINDER VALVE GUIDES WORN AND EXHAUST VALVE REPLACED. 1 H 7 1 3O 3 O NT 3A13 E273 5 C P3EA 2006060800121 20060608 00121 NM 2006 6 8 AU510002095 1 20050811 G 6310 A9661 SEAL ROBSIN ROBSIN R22 R22BETA 7640110 NM LYC O360 O360J2A 41514 EA CLUTCH ASSY DISLODGED W K NONE O OTHER IN INSP/MAINT 1 AU S 7048 ENGINE/TRANSMISSION CLUTCH ASSEMBLY FORWARD AND AFT SEALS DISLODGED IN HOUSING. NO OIL LOSS WAS NOTICED. SUSPECT SEALS ARE BEING HYDRAULICALLY PRESSED OUT DUE TO THE EXCESS OIL IN THE CLUTCH BEING UNABLE TO BLEED BACK TO THE RESERVOIR. 1 G 7 1 3O 3 O H10WE E286 2006060800124 20060608 00124 SO 2006 6 8 AU510002096 1 20050710 G 2410 PULLEY PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA ALTERNATOR LOOSE W O OTHER H ELECT. POWER LOSS-50 PC DE DESCENT 1 AU S D02131 ALTERNATOR DRIVE PULLEY CAME LOOSE AND DAMAGED ALTERNATOR COOLING FAN. A PIECE OF THE COOLING FAN CAME OFF AND ENTERED THE ALTERNATOR CAUSING AN INTERNAL SHORT CIRCUIT. 1 L 7 2 3O 3 O A20SO E14EA 2006060800126 20060608 00126 NM 2006 6 8 AU510002097 1 20050611 G 4930 PUMP BOEING 737 7377Q8 1384418 NM GE CFM56 CFM56* 13802 NE APU FUEL SYS LEAKING W K NONE O OTHER IN INSP/MAINT 1 AU S APU FUEL PUMP LEAKING BEYOND LIMITS. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061900169 20060619 00169 WP 2006 6 19 AU510002099 1 20050610 G 6410 500P3100101 BLADE HUGHES 369 369E 4470707 WP ALLSN 25OC 250C20R GL TAIL ROTOR DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S 2582 842 (AUS) TAIL ROTOR BLADE DELAMINATED. AREA OF DELAMINATION APPROXIMATELY 38.1MM LONG BY 9.525MM WIDE (1.5IN BY 0.375IN). SEE ATTACHMENT FOR PHOTOGRAPHS. (OTHER CAUSE: VOID DEVELOPED FROM POOR PREP WHEN REPAIRED BY HTC ) (CASA 510002099) 1 G 7 1 3U 3 U H3WE E4CE 2006060800127 20060608 00127 2006 6 8 AU510002100 4 20050511 G 2312 1010524 ANTENNA BOEING 737 73776N 13844CH NM GE CFM56 CFM56* 13802 NE VHF SYSTEM BROKEN W O OTHER D INFLIGHT SEPARATION CR CRUISE 1 AU S NR 2 VHF ANTENNA BROKEN IN HALF. BROKEN SECTION MISSING. SUSPECT CAUSED BY FOD. 2 L 7 2 4F 4 F RT A16WE E2GL 2006060800130 20060608 00130 NM 2006 6 8 AU510002101 1 20050611 G 2120 ODOR BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE CABIN DETECTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS CL CLIMB 1 AU S ELECTRICAL BURNING ODOR IN CABIN IN AREA OF ROW 18. EXTENSIVE INVESTIGATION COULD FIND NO CAUSE FOR THE ODOR. 2 L 7 2 4F 4 F RT A16WE E2GL 2006060800309 20060608 00309 EU 2006 6 8 AU510002102 1 20050411 G 3260 858202 PSEU FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE MLG FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S PROXIMITY SENSING ELECTRONIC UNIT (PSEU) FAULTY. 2 L 7 2 4F 4 F RT E25NE 2006060800310 20060608 00310 2006 6 8 AU510002103 4 20051212 G 3442 8221710001 TRANSCEIVER BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE WX RADAR FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 1573 1573 WEATHER RADAR TRANSCEIVER FAILED. 2 L 7 2 4F 4 F RT A16WE E2GL 2006060800311 20060608 00311 NM 2006 6 8 AU510002104 1 20051212 G 3244 TIRE BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU MLG DEBONDED W K NONE O OTHER IN INSP/MAINT 1 AU S 23523 304 NR 3 MAIN WHEEL TIRE TREAD DEBONDED. 2 L 7 2 4F 4 F RT A16WE E21EU 2006060800312 20060608 00312 NM 2006 6 8 AU510002105 1 20051212 G 3230 654492532 ACTUATOR BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU MLG FAULTY W O OTHER O OTHER CL CLIMB 1 AU S LT MAIN LANDING GEAR ACTUATOR FAULTY. LT MAIN LANDING GEAR NOT FULLY RETRACTED. 2 L 7 2 4F 4 F RT A16WE E21EU 2006060800323 20060608 00323 EU 2006 6 8 AU510002106 1 20050211 G 2822 PUMP FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE FUEL BOOST LOW PRESSURE W K NONE O OTHER IN INSP/MAINT 1 AU S NR 1 CENTER WING TANK BOOST PUMP LOW PRESSURE. 2 L 7 2 4F 4 F RT E25NE 2006060800325 20060608 00325 EU 2006 6 8 AU510002107 1 20051212 G 3610 3925308 SHUTOFF VALVE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE BLEED AIR SYS FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S RT BLEED AIR PRESSURE REGULATING AND SHUTOFF VALVE (PRSOV) FAULTY. 2 L 7 2 4F 4 F RT E25NE 2006060800329 20060608 00329 CE 2006 6 8 AU510002108 1 20051212 G 3260 1CH16 SWITCH CESSNA 441 441 2076020 CE GARRTT TPE331 TPE33110 01514 WP NLG ACTUATOR SHORTED W K NONE O OTHER IN INSP/MAINT 1 AU S NOSE LANDING GEAR ACTUATOR DOWNLOCK SWITCH SHORT CIRCUIT. 1 L 7 2 3T 4 T RT A28CE E4WE 2006060800330 20060608 00330 NM 2006 6 8 AU510002109 1 20051212 G 2760 SPOILER BOEING 747 747438 NM GE CF6 CF680C2* GL FAULTY W K NONE F FLT CONT AFFECTED DE DESCENT 1 AU S SPOILER SYSTEM FAULTY. AIRCRAFT ROLLED TO THE RIGHT WHEN SPEEDBRAKE DEPLOYED. INVESTIGATION CONTINUING. 2 L 7 4 4F 4 F RT A20WE E23EA 2006060800331 20060608 00331 NM 2006 6 8 AU510002110 1 20051212 G 3230 SOLENOID 1387T1005 BOEING 747 747338 NM RROYCE RB211 RB211524* NE UPLOCK ACTUATOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 0 LT WING LANDING GEAR UPLOCK ACTUATOR SOLENOID CORRODED. A CORROSION LIKE SUBSTANCE WAS FOUND AROUND THE CANNON PLUG AND PART OF THE OPERATING SOLENOID OUTER CASE WAS CORRODED AWAY. 2 L 7 2 4F 4 F RT A20WE E12EU 2006061200269 20060612 00269 GL 2006 6 12 AU510002111 2 20050211 G 7321 8061865 MEC GE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL LT ENGINE LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S LT ENGINE MAIN ENGINE CONTROL (MEC) LEAKING AT THE FORWARD ATTACHMENT FLANGE. 2 L 7 2 4F 4 F RT A1NM E23EA 2006061200313 20060612 00313 2006 6 12 AU510002112 4 20051212 G 3452 75178E11 TRANSPONDER FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE ATC FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S NR 2 ATC TRANSPONDER FAILED. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT E25NE 2006061200314 20060612 00314 NM 2006 6 12 AU510002113 1 20051212 G 3230 AS11706K0280 HOSE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL RT MLG CYLINDER LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S RT MAIN LANDING GEAR RETRACTION CYLINDER DOWN LINE HOSE LEAKING. LOSS OF HYDRAULIC FLUID. 2 L 7 2 4F 4 F RT A1NM E23EA 2006061200316 20060612 00316 NM 2006 6 12 AU510002115 1 20051212 G 5753 113T2271Y44 FITTING BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL TE FLAPS SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S LT INBOARD TRAILING EDGE FLAP OUTBOARD HINGE FITTING OUTBOARD LUG SHEARED. FOUND DURING INSPECTION IAW AD/B767/188 (EI 767-57-073). 2 L 7 2 4F 4 F RT A1NM E23EA 2006061200317 20060612 00317 2006 6 12 AU510002116 4 20051212 G 3452 G699035 CONTROL PANEL HONEYWELL FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE TRANSPONDER FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S 2285 NR 2 ATC TRANSPONDER SYSTEM CONTROL PANEL DISPLAY DIGITS NOT VISIBLE. 2 L 7 2 4F 4 F RT E25NE 2006061300145 20060613 00145 GL 2006 6 13 AU510002117 3 20051212 G 6111 CLAMP D4170 CESSNA 310 310K 2074228 CE CONT O470 IO470V 17026 SO MCAULY 2AF34C D2AF34C81 GL PROPELLER FAILED W O OTHER F FLT CONT AFFECTED DE DESCENT 1 AU S 528 0 NR 2 PROPELLER BLADE COUNTERWEIGHT CLAMP FAILED. 1 L 7 2 3O 3 O 3A10 3E1 5 C P5EA 2006061300146 20060613 00146 NM 2006 6 13 AU510002118 1 20051111 G 2530 OVEN BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE GALLEY FAILED W O OTHER B SMOKE/FUMES/ODORS/SPARKS LD LANDING 1 AU S SPARKS AND ELECTRICAL FUMES EMANATING FROM REAR GALLEY AREA. INSPECTION COULD FIND NO FAULTS BUT THE OVEN WAS REPLACED AS A PRECAUTION. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061300147 20060613 00147 SW 2006 6 13 AU510002119 1 20050811 G 7603 477271611 SHAFT BELL 47 47G2 1181008 SW LYC O435 VO435A1F 41516 EA THROTTLE CRACKED W O OTHER F FLT CONT AFFECTED CR CRUISE 1 AU S 11475 THROTTLE/COLLECTIVE CONTROL SHAFT CRACKED IN AREA HIDDEN BY GEAR. 1 G 7 1 3O 3 O H1 E279 2006061300148 20060613 00148 NM 2006 6 13 AU510002120 1 20050911 G 2910 DSC252B40124 LINE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE HYD SYSTEM FAILED W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S NOSE LANDING GEAR ACTUATOR FLEXIBLE HYDRAULIC LINE RUPTURED. LOSS OF NR 2 SYSTEM HYDRAULIC FLUID. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006061300150 20060613 00150 NE 2006 6 13 AU510002121 1 20050311 G 2612 CONNECTOR SKRSKY S76 S76C 8143008 NE TMECA ARRIEL ARRIEL1S 60030 NE FIRE DETECTOR CONTAMINATED W K NONE N FALSE WARNING IN INSP/MAINT 1 AU S NR 1 ENGINE FIRE WARNING SYSTEM GAVE FALSE INDICATIONS. SUSPECT CONNECTOR CONTAMINATED. 1 G 7 2 3U 3 U NC H1NE E19EU 2006061300152 20060613 00152 CE 2006 6 13 AU510002122 1 20050711 G 8011 2005001 GEAR LAMAR CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA STARTER BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 179 85013017 ENGINE STARTER DRIVE GEAR DISINTEGRATED. 1 H 7 1 3O 3 O NT 3A12 1E10 2006061300153 20060613 00153 GL 2006 6 13 AU510002123 1 20051212 G 3213 HF5000 FORK DHAV DH82 DH82 2801000 GL DHAVXX GIPSY GIPSYMAJOR1 20004 WP RT MLG BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 5419 RT MAIN LANDING GEAR COMPRESSION LEG LOWER FORK END FITTING FAILED. LOWER END OF LEG CONTACTED THE GROUND. 1 Q 7 1 3I 3 I EXPA1Q71 A8EU 2006061300156 20060613 00156 EU 2006 6 13 AU510002124 1 20051111 G 5220 68260411 DOOR PARTEN P68 P68B 6780104 EU LYC O360 IO360A1B6 41514 EA HARTZL HCC2Y HCC2YK2 GL EMERGENCY EXIT SEPARATED W A UNSCHED LANDING D INFLIGHT SEPARATION CL CLIMB 1 AU S 7584 RT SIDE EMERGENCY EXIT POPPED OUT ON TAKEOFF. INVESTIGATION COULD FIND NO FAULTS. SUSPECT CAUSED BY PREVIOUS PASSENGER INTERFERENCE WITH LOCKING LEVER. 1 H 7 2 3O 3 O A31EU 1E10 5 C P920 2006061300159 20060613 00159 NM 2006 6 13 AU510002125 1 20051111 G 3610 BACC1DU400ABE CLAMP BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE APU BLEED AIR FRACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) APU BLEED AIR DUCT FRACTURED. BLEED AIR SUPPLY DUCT SEPARATED IN HORIZONTAL STABILISER COMPARTMENT. (CASA# 5100021 25) 2 L 7 2 4F 4 F RT A16WE E2GL 2006061300251 20060613 00251 EU 2006 6 13 AU510002126 1 20051011 G 2930 6607P98D PRESSURE SWITCH FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE HYD SYS FAILED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S LT AND RT HYDRAULIC PRESSURE SWITCHES FOR THE NR 2 STABILIZER SYSTEM FAULTY. 2 L 7 2 4F 4 F RT E25NE 2006061300253 20060613 00253 EU 2006 6 13 AU510002127 1 20051011 G 2840 0106KIP02018 TOTALIZER FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE FUEL INDICATION FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S FUEL INDICATING SYSTEM COMBINED PROCESSOR TOTALIZER UNIT (CPT) FAULTY. 2 L 7 2 4F 4 F RT E25NE 2006061300254 20060613 00254 NM 2006 6 13 AU510002128 1 20051212 G 4990 OIL SYSTEM BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL APU LOW W O OTHER J WARNING INDICATION CR CRUISE 1 AU S APU OIL QUANTITY LOW. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT A1NM E23EA 2006061300255 20060613 00255 CE 2006 6 13 AU510002129 1 20051111 G 3260 DOWNLOCK CESSNA 310 310R 2074245 CE CONT O520 IO520M 17032 SO MCAULY 3AF32C 3AF32C87 GL MLG FAULTY W O OTHER J WARNING INDICATION LD LANDING 1 AU S LT AND RT MAIN LANDING GEAR DOWNLOCKS FOUND TO BE IN AN UNSAFE CONDITION. 1 L 7 2 3O 3 O 3A10 E5CE 5 C P22EA 2006061300256 20060613 00256 EU 2006 6 13 AU510002130 1 20051212 G 3510 176225 OXYGEN BOTTLE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE CREW SYSTEM LEAKING W O OTHER O OTHER CR CRUISE 1 AU S COCKPIT OXYGEN BOTTLE LEAKING FROM VALVE. 2 L 7 2 4F 4 F RT E25NE 2006061300258 20060613 00258 SO 2006 6 13 AU510002131 1 20051212 G 2120 SMOKE EMB 120 EMB120 3260201 SO PWA 118 PW118A NE HAMSTD 14RF 14RF9 NE CABIN DETECTED W O OTHER B SMOKE/FUMES/ODORS/SPARKS DE DESCENT 1 AU S MODERATE AMOUNT OF SMOKE IN COCKPIT CAUSED OXYGEN MASKS TO BE FITTED. FLIGHT ATTENDANTS ALSO ADVISED OF SMOKE IN THE CA BIN AND PASSENGER OXYGEN WAS ALSO DEPLOYED. INVESTIGATION IN PROGRESS TO FIND THE CAUSE OF THE SMOKE. 2 L 7 2 4T 4 T RT A31SO E20NE 6 C P11NE 2006061300260 20060613 00260 SO 2006 6 13 AU510002132 1 20051212 G 5711 RIVET PIPER PA24 PA24250 7102404 SO LYC O540 O540A1D5 41532 EA WING SPAR MISSING W K NONE W INADEQUATE Q C IN INSP/MAINT 1 AU S 6730 0 WING REAR SPAR ATTACHMENT PLATE RIVETS (7OFF) MISSING. INVESTIGATION CONTINUING. 1 L 7 1 3O 3 O 1A15 E295 2006062100023 20060621 00023 EU 2006 6 21 AU510002133 1 20051212 G 2731 TRIM SYSTEM GIPPLD GA8 GA8 3900102 EU ELEVATOR FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) RUNAWAY ELEVATOR TRIM SYSTEM. AIRCRAFT IS FOREIGN REGISTERED. (CASA NR 510002133) 1 H 7 1 3O NT 2006061300261 20060613 00261 CE 2006 6 13 AU510002134 2 20051212 G 7314 654351 PUMP PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360RB 17025 CE MCAULY 3AF32C 3AF32C* GL LT ENGINE FUEL CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S 731 LT ENGINE DRIVEN FUEL PUMP CONTAMINATED AND WORN INTERNALLY. SUSPECT CAUSED BY CONTAMINATION FROM ELECTRIC FUEL PUMP VA NES AND/OR BRUSH MATERIAL. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2006061400192 20060614 00192 SO 2006 6 14 AU510002135 2 20051212 G 7314 6543511A1 PUMP PIPER PA34 PA34220T 7103420 SO CONT O360 LTSIO360RB SO MCAULY 3AF32C 3AF32C* GL FUEL SYSTEM CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S 126 RT ENGINE DRIVEN FUEL PUMP CONTAMINATED AND WORN INTERNALLY. SUSPECT CAUSED BY CONTAMINATION FROM ELECTRIC FUEL PUMP VA NES AND/OR BRUSH MATERIAL. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2006061400193 20060614 00193 SO 2006 6 14 AU510002136 2 20051212 G 7314 6543511A1 PUMP PIPER PA34 PA34220T 7103420 SO CONT O360 LTSIO360RB SO MCAULY 3AF32C 3AF32C* GL FUEL SYS CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S RT ENGINE DRIVEN FUEL PUMP CONTAMINATED AND WORN INTERNALLY. SUSPECT CAUSED BY CONTAMINATION FROM ELECTRIC FUEL PUMP VA NES AND/OR BRUSH MATERIAL. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2006061400194 20060614 00194 CE 2006 6 14 AU510002137 2 20051212 G 7314 6543513A1 PUMP PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360RB 17025 CE MCAULY 3AF32C 3AF32C* GL FUEL SYS CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S RT ENGINE DRIVEN FUEL PUMP CONTAMINATED AND WORN INTERNALLY. SUSPECT CAUSED BY CONTAMINATION FROM ELECTRIC FUEL PUMP VA NES AND/OR BRUSH MATERIAL. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2006061400195 20060614 00195 CE 2006 6 14 AU510002138 2 20051212 G 7314 6543511A1 PUMP PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360RB 17025 CE MCAULY 3AF32C 3AF32C* GL FUEL SYS CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S RT ENGINE DRIVEN FUEL PUMP CONTAMINATED AND WORN INTERNALLY. SUSPECT CAUSED BY CONTAMINATION FROM ELECTRIC FUEL PUMP VA NES AND/OR BRUSH MATERIAL. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2006061400196 20060614 00196 CE 2006 6 14 AU510002139 2 20051212 G 7314 6543512 PUMP PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360RB 17025 CE MCAULY 3AF32C 3AF32C* GL FUEL SYS CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S LT ENGINE DRIVEN FUEL PUMP CONTAMINATED AND WORN INTERNALLY. SUSPECT CAUSED BY CONTAMINATION FROM ELECTRIC FUEL PUMP VA NES AND/OR BRUSH MATERIAL. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2006061400197 20060614 00197 CE 2006 6 14 AU510002140 2 20051212 G 7314 6543514A1 PUMP PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360RB 17025 CE MCAULY 3AF32C 3AF32C* GL FUEL SYS CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S LT ENGINE DRIVEN FUEL PUMP CONTAMINATED AND WORN INTERNALLY. SUSPECT CAUSED BY CONTAMINATION FROM ELECTRIC FUEL PUMP VA NES AND/OR BRUSH MATERIAL. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2006061400198 20060614 00198 SO 2006 6 14 AU510002141 2 20051212 G 7314 6543511 PUMP PIPER PA34 PA34220T 7103420 SO CONT O360 LTSIO360RB SO MCAULY 3AF32C 3AF32C* GL FUEL SYS CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S 2651 872 RT ENGINE DRIVEN FUEL PUMP CONTAMINATED AND WORN INTERNALLY. SUSPECT CAUSED BY CONTAMINATION FROM ELECTRIC FUEL PUMP VA NES AND/OR BRUSH MATERIAL. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2006061500147 20060615 00147 CE 2006 6 15 AU510002142 2 20051212 G 7314 6543514A1 PUMP PIPER PA34 PA34220T 7103420 SO CONT O360 TSIO360RB 17025 CE MCAULY 3AF32C 3AF32C* GL FUEL SYSTEM CONTAMINATED W K NONE O OTHER IN INSP/MAINT 1 AU S LT ENGINE DRIVEN FUEL PUMP CONTAMINATED AND WORN INTERNALLY. SUSPECT CAUSED BY CONTAMINATION FROM ELECTRIC FUEL PUMP VA NES AND/OR BRUSH MATERIAL. 1 L 7 2 3O 3 O A7SO E9CE 5 C P22EA 2006061500149 20060615 00149 SW 2006 6 15 AU510002143 1 20051212 G 6410 47642117105 BLADE BELL 47 47 1180602 SW TAIL ROTOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 1581 TAIL ROTOR BLADE CORRODED AND DELAMINATED. DELAMINATION IS LOCATED AT THE OUTBOARD TIP OF THE LEADING EDGE ABRASION STR IP. 1 G 7 1 3O H1 2006061900240 20060619 00240 WP 2006 6 19 AU510002144 1 20051212 G 6520 369D25434 GEARBOX HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL TAIL ROTOR MAKING METAL W K NONE O OTHER IN INSP/MAINT 1 AU S 7461 4261 (AUS) TAIL ROTOR GEARBOX METAL CONTAMINATION. INVESTIGATION FOUND THE INPUT SHAFT REAR BEARING PN 369D25417 TO BE UNSERV ICEABLE. INPUT SHAFT PN 369D25434 CRACKED IN AREA UNDER BEARING. (CASA NR 510002144) 1 G 7 1 3U 3 U H3WE E4CE 2006061500150 20060615 00150 SO 2006 6 15 AU510002145 2 20050311 G 7414 10400309 IMPULSE COUPLING BENDIX 103493505 CESSNA 210 210R 2073458 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL MAGNETO DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S B119701FR MAGNETO IMPULSE COUPLING CAM FLYWEIGHT TIP BROKEN OFF. RETURN SPRING MISSING FROM UNDER FLYWEIGHT. FOUND DURING INSPEC TION IAW AD/ELECT/75. 1 H 7 1 3O 3 O RT 3A21 E5CE 5 C P47GL 2006061500151 20060615 00151 SO 2006 6 15 AU510002146 1 20051212 G 5540 95539000 HINGE PIPER PA34 PA34200T 7103406 SO CONT O360 TSIO360E 17025 SO HARTZL HCC2Y BHCC2YF2 GL RUDDER CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 2751 0 RUDDER HINGE BRACKET CORRODED. 1 L 7 2 3O 3 O A7SO E9CE 5 C P920 2006061500153 20060615 00153 SO 2006 6 15 AU510002147 1 20051212 G 5720 SUPPORT PIPER PA32 PA32300 7103212 SO LYC O540 IO540K1A5 41532 EA HARTZL HCC2Y HCC2YK1 GL LT WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S LT WING REAR SUPPORT CORRODED. FOUND DURING INSPECTION IAW AD/PA32/27 AMDT2. 1 L 7 1 3O 3 O A3SO 1E4 5 C P920 2006061500155 20060615 00155 NM 2006 6 15 AU510002148 1 20051211 G 5532 PANEL BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU VERTICAL STAB MISINSTALLED W O OTHER E VIBRATION/BUFFET CL CLIMB 1 AU S VERTICAL STABILIZER RT LOWER PANEL INCORRECTLY FITTED BETWEEN FORWARD AND AFT ATTACHMENT POINTS. 2 L 7 2 4F 4 F RT A16WE E21EU 2006061500156 20060615 00156 SO 2006 6 15 AU510002149 2 20051212 G 8520 PISTON CIRRUS SR SR20 05628AJ GL CONT O360 IO360E 17025 SO ENGINE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 400 NR 3 CYLINDER SEVERELY DAMAGED. INVESTIGATION CONTINUING. 1 L 7 1 3O 3 O NT A00009CH E1CE 2006061600021 20060616 00021 NM 2006 6 16 AU510002150 1 20051212 G 5551 PIN BOEING 737 7377BX 13844D2 NM GE CFM56 CFM56* 13802 NE HORIZONTAL STAB WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 0 HORIZONTAL STABILIZER REAR SPAR PINS (3OFFLH AND 3OFFRH) WORN BEYOND LIMITS. FORWARD SPAR RT LOWER BOLT WORN BEYOND LIM ITS. FOUND DURING INSPECTION IAW AD/B737/224. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061600022 20060616 00022 WP 2006 6 16 AU510002151 2 20051212 G 7260 BEARING SWRNGN SA227 SA227AT 8780610 SW GARRTT TPE331 TPE33111U 01514 WP ROTOL R321 R321482F8 GL ENGINE FAILED W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S P44378 RT ENGINE GEARBOX FUEL PUMP DRIVE BEARING FAILED. 2 L 7 2 4T 4 T RT A5SW E4WE 6 C P61GL 2006061600023 20060616 00023 NM 2006 6 16 AU510002152 1 20051212 G 2730 6933691 SPRING BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU ELEVATOR FAILED W O OTHER F FLT CONT AFFECTED CR CRUISE 1 AU S ELEVATOR FEEL SPRING BROKEN. 2 L 7 2 4F 4 F RT A16WE E21EU 2006061600026 20060616 00026 2006 6 16 AU510002153 4 20051212 G 3441 HG1050AD04 IRU BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU LEFT FAILED W O OTHER O OTHER LD LANDING 1 AU S 52981 10646 LT INERTIAL REFERENCE UNIT (IRU) FAILED. 2 L 7 2 4F 4 F RT A16WE E21EU 2006061600027 20060616 00027 CE 2006 6 16 AU510002154 1 20050111 G 2720 4330222 TUBE CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA MCAULY IC235 IC235LFA7570 EA RUDDER CONTROL WORN W K NONE O OTHER IN INSP/MAINT 1 AU S 5601 RUDDER TO NOSE WHEEL STEERING TUBE WORN. TUBE IS A SEALED UNIT BUT WHEN IT WAS CUT OPEN FOR INVESTIGATION IF WAS FOUND THAT THE STEERING RODEND FITTING HAD ALMOST PULLED THROUGH THE WASHER THAT TRANSFERS THE LOAD TO THE SPRING. IF THE ROD PULLED COMPLETELY THROUGH THE WASHER THE RODEND COULD PICK UP ON THE SPRING AND CAUSE RUDDER CONTROL PROBLEMS. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P12EA 2006061600028 20060616 00028 EA 2006 6 16 AU510002155 2 20050911 G 8520 75038 CRANKSHAFT LYC O540 IO540E1B5 41532 EA ENGINE BROKEN W O OTHER E VIBRATION/BUFFET CR CRUISE 1 AU S 774 CRANKSHAFT BROKEN COMPLETELY THROUGH AT NR 1 CRANKPIN JOURNAL. 3 O 1E4 2006061600030 20060616 00030 CE 2006 6 16 AU510002156 1 20051212 G 5230 521309126 DOOR CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP HARTZL HCB3T HCB3TN5 GL CARGO BAY SEPARATED W O OTHER D INFLIGHT SEPARATION DE DESCENT 1 AU S 22647 LT FORWARD NOSE LOCKER SEPARATED FROM AIRCRAFT SEVERING BOTH HINGES. ONE BAG LOST OVERBOARD. DOOR STRUCK PROPELLER CAU SING A TORQUE SHIFT IN THE ENGINE. LT ENGINE, PROPELLER AND LT WING INBOARD LEADING EDGE DAMAGED. INVESTIGATION CONTIN UING. 1 L 7 2 3T 4 T RT A28CE E4WE 6 C P15EA 2006061600031 20060616 00031 NM 2006 6 16 AU510002157 1 20051212 G 5610 58935734 WINDOW BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE COCKPIT CRACKED W O OTHER O OTHER DE DESCENT 1 AU S 11271 COCKPIT NR 4 (EYEBROW) WINDOW INNER PANE SHATTERED. 2 L 7 2 4F 4 F RT A16WE E2GL 2006061900038 20060619 00038 NE 2006 6 19 AU510002158 2 20051212 G 7310 UL37981 PIPE BOEING 747 747438 NM RROYCE RB211 RB211524* NE ENGINE FUEL BROKEN W O OTHER K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S 0 NR 3 ENGINE MANIFOLD FUEL DRAIN LINE BROKEN AND LEAKING AT WELDED JOINT LOCATED BETWEEN THE FUEL DRAIL TUBE AND THE END FITTING AT THE MANIFOLD END OF THE ASSEMBLY. 2 L 7 4 4F 4 F RT A20WE E12EU 2006061900039 20060619 00039 NE 2006 6 19 AU510002159 2 20051212 G 7310 UL37981 PIPE BOEING 747 747438 NM RROYCE RB211 RB211524* NE ENGINE FUEL LEAKING W O OTHER K FLUID LOSS CR CRUISE 1 AU S FUEL LEAKING FROM NR 3 ENGINE. ENGINE CHANGED. INVESTIGATION FOUND THE FUEL MANIFOLD DRAIN TUBE FRACTURED IN THE TUBE BORE AT THE EDGE OF THE WELD. 2 L 7 4 4F 4 F RT A20WE E12EU 2006061900041 20060619 00041 CE 2006 6 19 AU510002160 1 20050111 G 7603 5038901219 CABLE BEECH 55 D55 1152730 CE CONT O520 IO520C 17032 SO MCAULY 2AF34C 2AF34C55 GL POWER LEVER FAILED W C ABORTED TAKEOFF F FLT CONT AFFECTED TO TAKEOFF 1 AU S LH ENGINE THROTTLE CABLE FAILED IN AREA UNDER SHEATH. 1 L 7 2 3O 3 O 3A16 E5CE 5 C P5EA 2006061900044 20060619 00044 NE 2006 6 19 AU510002161 2 20051212 G 7310 SEAL BEECH 200 200BEECH 1152920 CE PWA PT6 PT642A NE MCAULY 4HFR34 4HFR34C754 NE FUEL FILTER DAMAGED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S LT ENGINE FUEL FILTER BOWL SEAL DISPLACED AND FUEL LEAKING. FILTER BOWL WAS CORRECTLY LOCKWIRED. 1 L 7 2 4T 4 T A24CE E4EA 6 C 3PNE 2006061900045 20060619 00045 NM 2006 6 19 AU510002162 1 20051212 G 3610 VALVE BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL PNEUMATIC DIST FAULTY W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 AU S RT ENGINE PRESSURE REDUCING VALVE (PRV) SUSPECT FAULTY. 2 L 7 2 4F 4 F RT A1NM E23EA 2006062100033 20060621 00033 NM 2006 6 21 AU510002163 1 20051212 G 5414 311U2060177 PANEL BOEING 747 74748E 2FOR NM GE CF6 CF680C2* GL NACELLE MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S NR 3 ENGINE IB STRUT ACCESS PANEL MISSING. 2 L 7 2 4F 4 F RT A20WE E23EA 2006062100034 20060621 00034 NM 2006 6 21 AU510002164 1 20051212 G 2742 6355B000103 MOTOR BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE STAB FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 16380 STABILIZER TRIM MOTOR FAILED. CIRCUIT BREAKER TRIPPED. 2 L 7 2 4F 4 F RT A16WE E2GL 2006062100035 20060621 00035 CE 2006 6 21 AU510002165 1 20051011 G 5551 S346161 BOLT CESSNA 208 208B 2073701 CE HORIZONTAL STAB SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S 12084 HORIZONTAL STABILIZER FORWARD LT ATTACHMENT BOLT SHEARED. AIRCRAFT IS PNG REGISTERED. 1 H 7 1 3T A37CE 2006062100036 20060621 00036 NM 2006 6 21 AU510002166 1 20051212 G 3810 INSULATION BOEING 737 737* NM HOT WATER LINE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S HEATED POTABLE HOT WATER PIPE INSULATION AND ATTACHING CLAMPS HEAT DAMAGED. SUSPECT WATER IN PIPE IS NOT THERMOSTATICAL LY CONTROLLED. PIPE SUPPLIES HOT WATER TO VIP SUITE. AIRCRAFT IS RAAF VIP. 2 L 7 2 4F RT A16WE 2006062100039 20060621 00039 WP 2006 6 21 AU510002167 2 20050711 G 7210 8937396 BULL GEAR GARRTT TPE331 TPE33110 01514 WP ENGINE BROKEN W K NONE J O O WARNING INDICATION OTHER OTHER IN INSP/MAINT 1 AU S 749 P36412 CHIP LIGHT ON IN FLIGHT. STRIP INSPECTION FOUND THAT THE ENGINE BULL GEAR HAD BROKEN TEETH. 4 T E4WE 2006062100041 20060621 00041 GL 2006 6 21 AU510002168 1 20050211 G 3246 13889 BEARING AMTR LANCAR LC41550FG 5150001 GL WHEEL MISMANUFACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S NEW WHEEL BEARING HAD TWO ROLLERS MISSING. FAULTY MFG. 1 L 7 1 3O RT EXPA1L71 2006062100042 20060621 00042 SO 2006 6 21 AU510002169 2 20050711 G 8550 633412 SUMP CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO MCAULY 3A32C D3A32C* GL ENGINE WORN W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 690 OIL DIPSTICK WORE A HOLE IN THE SUMP. OIL LEAKING. 1 H 7 1 3O 3 O A4CE E5CE 5 C P21EA 2006062100067 20060621 00067 SW 2006 6 21 AU510002170 1 20051212 G 3213 SEAL GULSTM 500 500S 0141107 SW LYC O540 IO540E1B5 41532 EA HARTZL HCC3Y HCC3YR2 NE CYLINDER ASSY WORN W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 AU S 3251 RT MAIN LANDING GEAR RAM SEALS WORN AND LEAKING. LOSS OF HYDRAULIC FLUID. 1 H 7 2 3O 3 O 6A1 1E4 5 C P25EA 2006062300044 20060623 00044 NE 2006 6 23 AU510002171 2 20051212 G 7314 PAG102MK1 PUMP BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE FUEL SYSTEM FAULTY W O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 AU S 32454 7885 (AUS) NR 1 ENGINE DRIVEN FUEL PUMP SUSPECT FAULTY. INVESTIGATION CONTINUING. (CASA NR 510002171) 2 L 7 4 4F 4 F RT A20WE E30NE 2006062300081 20060623 00081 EA 2006 6 23 AU510002172 2 20051111 G 8550 ES48108 FILTER ROBSIN R22 R22ALPHA 7640104 WP LYC O320 O320B2C 41508 EA ENGINE OIL MISMANUFACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S 27 (AUS) ENGINE OIL FILTER ELEMENT INCORRECTLY BONDED. CARDBOARD FILTER SEAM WAS ONLY JUST HOLDING TOGETHER. (CASA NR 51000 2172) 1 G 7 1 3O 3 O H10WE E274 2006062300093 20060623 00093 CE 2006 6 23 AU510002173 1 20051212 G 2133 47061RX OUTFLOW VALVE CESSNA 441 441 2076020 CE GARRTT TPE331 TPE331* 01514 WP HARTZL HCB3T HCB3TN5 GL CABIN PRESSURE FAULTY W O OTHER B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 AU S 1414 (AUS) CABIN EMERGENCY PRESSURIZATION VALVE HAD UNCOMMANDED ACTUATION. (CASA NR 510002173) 1 L 7 2 3T 3 T RT A28CE E2WE 6 C P15EA 2006062300094 20060623 00094 SW 2006 6 23 AU510002174 1 20051212 G 6410 47642117105 BLADE BELL 47 47 1180602 SW TAIL ROTOR CORRODED W K NONE O OTHER IN INSP/MAINT 1 AU S 1581 (AUS) TAIL ROTOR BLADE CORRODED AND DELAMINATED IN AREA UNDER OB TIP OF ABRASION STRIP. (CASA NR 510002174) 1 G 7 1 3O H1 2006062300096 20060623 00096 GL 2006 6 23 AU510002175 1 20051210 G 2820 11443005 LINE CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO FUEL SYSTEM DAMAGED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 499 (AUS) FUEL PIPES LEAKING. FUEL WAS FOUND TO HAVE BEEN LEAKING FROM THE BLANKED T-FITTINGS THAT WERE INSTALLED IN THE FU EL SELECTOR TO FIREWALL SUPPLY LINE PN 11443-005 AND THE RETURN LINE PN 11444-005. ON REMOVAL THE FUEL LINES WERE FOUND TO HAVE VERY POOR/DAMAGED FLARES AT THE T-FITTING ENDS. FITTINGS ARE INSTALLED AS PART OF THE FERRY TANK INSTALLATION. (CASA NR 510002175) 1 L 7 1 3O 3 O NT A00009CH E3SO 2006062300097 20060623 00097 CE 2006 6 23 AU510002176 1 20051212 G 3297 CONNECTOR CESSNA 404 404 2075901 CE CONT O520 GTSIO520M 17032 SO MCAULY 3FF32 3FF32C501 GL MLG FAULTY W O OTHER O OTHER DE DESCENT 1 AU S (AUS) RT MAIN LANDING GEAR DOWN MICROSWITCH WIRE CONNECTOR FAULTY. SUSPECT CONNECTOR WAS NOT AN APPROVED ITEM. (OTHER CA USE: MAINTENANCE CONTROL ISSUE ) (CASA NR 510002176) 1 L 7 2 3O 3 O RT A25CE E7CE 5 C P45GL 2006061600083 20060616 00083 NM 2006 6 16 AU510002177 1 20051111 G 5311 FRAME BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S FUSELAGE FRAMES (21OFF) CRACKED AT PASSENGER SERVICE UNIT (PSU) ATTACHMENT POINTS. FOUND DURING EDDY CURRENT INSPECTION IAW EI 737-53-68R3 AND NDT TECHNIQUES E-13 AND E-18. 2 L 7 2 4F 4 F RT A16WE E21EU 2006070500070 20060705 00070 NM 2006 7 5 AU510002178 1 20051212 G 5414 PANEL BOEING 747 747338 NM RROYCE RB211 RB211524D419 54555 NE NACELLE MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 4 ENGINE VIGV ACCESS PANEL MISSING. INVESTIGATION ALSO FOUND THE LP COMPRESSOR ACOUSTIC LINING DAMAGED AT THE 6 O`CLOCK POSITION WITH A HOLE APPROXIMATELY 150MM BY 100MM (6IN BY 4IN) IN THE SKIN. VIGV CONTROLLER PANEL SUPPORT STRUC TURE ALSO DAMAGED. (CASA NR 510002178) 2 L 7 2 4F 4 F RT A20WE E12EU 2006070500071 20060705 00071 NM 2006 7 5 AU510002179 1 20051212 G 5414 UL27562 FAIRING BOEING 747 747438 NM RROYCE RB211 RB211524G19 NE NACELLE MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) NR 2 ENGINE UPPER LT (A) FRAME FAIRINGS PN UL27562 AND PN UL27561 DAMAGED/MISSING. UPPER HALF DAMAGED AND LOWER H ALF MISSING. (CASA NR 510002179) 2 L 7 4 4F 4 F RT A20WE E30NE 2006070500072 20060705 00072 EA 2006 7 5 AU510002180 2 20051212 G 7322 242528 VALVE LYC O540 O540E4C5 41532 EA CARBURETOR MISMANUFACTURED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) CARBURRETOR MIXTURE VALVE FAULTY MANUFACTURE. INSPECTION FOUND THE BRASS VALVE END OF THE MIXTURE VALVE ASSEMBLY HAD NOT BEEN CORRECTLY SWAGED CAUSING THE BRASS END TO TURN ON THE CABLE. (CASA NR 510002180) 3 O E295 2006070300012 20060703 00012 CE 2006 7 3 AU510002181 1 20051212 G 2150 73838416 ACM CESSNA 441 441 2076020 CE GARRTT TPE331 TPE3318 01514 WP FAILED W O OTHER O OTHER CL CLIMB 1 AU S 6911 AIR CYCLE MACHINE (ACM) FAILED AND EMERGENCY PRESSURISATION VALVE AUTOMATICALLY OPENED. 1 L 7 2 3T 4 T RT A28CE E4WE 2006070500073 20060705 00073 NE 2006 7 5 AU510002182 2 20051212 G 7321 METERING VALVE HONEYWELL BOEING 737 737800* NM GE CFM56 CFM567B24 NE HMU FAULTY W O OTHER O OTHER NR NOT REPORTED 1 AU S BECW3455 (AUS) NR 2 ENGINE HYDROMECHANICAL UNIT (HMU) FUEL METERING VALVE FAULTY. (CASA NR 510002182) 2 L 7 2 4F 4 F RT A16WE E00055EN 2006070500074 20060705 00074 GL 2006 7 5 AU510002183 1 20051212 G 2820 11443005 LINE CIRRUS SR SR20 05628AJ GL CONT O360 IO360E 17025 SO HARTZL HCJ3Y PHCJ3YF1 GL FUEL SYS DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 498 (AUS) FUEL PIPES PN 11443-005 AND PN 11444-005 CRACKED/DAMAGED ON FLARES AT THE (T) FITTING ENDS. SWARF WAS ALSO FOUND O N THE FLARES. (CASA NR 510002183) 1 L 7 1 3O 3 O NT A00009CH E1CE 5 C P36EA 2006070300013 20060703 00013 NM 2006 7 3 AU510002184 1 20051111 G 5310 DOOR FRAME BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S FORWARD CARGO DOOR CUTOUT AFT FRAME WEB CRACKED. CRACK LENGTH APPROXIMATELY 17.78MM (0.700IN). FOUND DURING EDDY CURRE NT INSPECTION IAW AD/737/242 AND BOEING SB 737-53A1228. 2 L 7 2 4F 4 F RT A16WE E21EU 2006070300014 20060703 00014 NM 2006 7 3 AU510002185 1 20051212 G 2824 737M28500011 VALVE BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU NR 2 ENGINE STICKING W K NONE O OTHER IN INSP/MAINT 1 AU S 52514 14042 NR 2 ENGINE SPAR VALVE FAULTY. 2 L 7 2 4F 4 F RT A16WE E21EU 2006070300015 20060703 00015 NM 2006 7 3 AU510002186 1 20051212 G 3411 BACT16AS060406D TEE FITTING BOEING 737 737200 1384453 NM PWA JT8 JT8D7 52053 NE AIRSPEED PITOT CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S AIRSPEED SWITCH PITOT TEE FITTING CRACKED AND LEAKING ON SMALL DIAMETER END. 2 L 7 2 4F 4 F A16WE E2EA 2006070300086 20060703 00086 EA 2006 7 3 AU510002187 1 20051212 G 6100 AS3217146 RETAINING RING DHAV DHC6 DHC6300 2802606 EA PWA PT6 PT6A27 52043 EA PROPELLER SHAFT MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S ENGINE PROPELLER SHAFT ADAPTER PLUG RETAINING RING MISSING. ADAPTER PLUG P/N 3013146 DISLODGED AND LOOSE IN THE PROPELL ER SHAFT INTERNAL BORE. RETAINING RING COULD NOT BE FOUND. SUSPECT RETAINING RING HAD NOT BEEN INSTALLED. PERSONNEL/M AINTENANCE ERROR. AIRCRAFT IS REGISTERED IN PNG. 1 H 7 2 3T 4 T RT A9EA E4EA 2006070300087 20060703 00087 SO 2006 7 3 AU510002188 2 20051212 G 8520 536379 BOLT BEECH 58 58 1152740 CE CONT O520 IO520C 17032 SO MCAULY 3AF34C 3AF34C502 GL CRANKSHAFT SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S 936 CRANKSHAFT GEAR RETAINING BOLTS SHEARED. LOSS OF DRIVE TO GOVERNOR. 1 L 7 2 3O 3 O 3A16 E5CE 5 C P22EA 2006070300088 20060703 00088 NM 2006 7 3 AU510002189 1 20051212 G 2421 IDG BOEING 767 767338 1385151 NM GE CF6 CF680C2* GL AC GEN FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S RT ENGINE INTEGRATED DRIVE GENERATOR (IDG) FAILED. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT A1NM E23EA 2006070300089 20060703 00089 NM 2006 7 3 AU510002190 1 20051212 G 5410 FAIRING BOEING 747 747438 NM RROYCE RB211 RB211524* NE NR 3 NACELLE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S NR 3 ENGINE LOWER RT COMPRESSOR FAIRING DAMAGED WITH A PIECE MISSING. 2 L 7 4 4F 4 F RT A20WE E12EU 2006070300090 20060703 00090 NM 2006 7 3 AU510002191 1 20051212 G 2750 FSEU BOEING 767 767300 1385204 NM RROYCE RB211 RB211524* NE TE FLAP CONTROL FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S TRAILING EDGE FLAP ASYMMETRY MESSAGE. FLAP/SLAT ELECTRONIC UNIT (FSEU) RERACKED AND MESSAGE CLEARED. 2 L 7 2 4F 4 F RT A1NM E12EU 2006070300091 20060703 00091 NM 2006 7 3 AU510002192 1 20051212 G 3350 BATTERY BOEING 747 747438 NM GE CF6 CF680C2* GL EMERGENCY LIGHT DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S DOOR 5 CREW REST CEILING EMERGENCY LIGHTING PACK DAMAGED. EVIDENCE OF FIRE TO THE UNIT AND DAMAGE TO THE SURROUNDING AR EA. 2 L 7 4 4F 4 F RT A20WE E23EA 2006070300092 20060703 00092 NM 2006 7 3 AU510002193 1 20051212 G 5313 STRINGER BOEING 737 737476 NM CFMINT CFM56 CFM563C 13802 EU FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S FUSELAGE STRINGER SPLICE CRACKED. CRACK LENGTH APPROXIMATELY 5MM (0.200IN). UPON REMOVAL OF THE SPLICE THERE WAS EVIDEN CE OF MULTI-SITE CRACKING ON OUTBOARD SURFACE OF SPLICE (TWO HOLES). FOUND DURING EDDY CURRENT INSPECTION OF FUSELAGE U PPER LOBE FASTENER HOLE LOCATED AT STRINGER 4L, BS 907. 2 L 7 2 4F 4 F RT A16WE E21EU 2006070300093 20060703 00093 NE 2006 7 3 AU510002194 2 20051212 G 7230 3400010260 FAN BLADE BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE ENGINE BIRD STRIKE W A UNSCHED LANDING C E J F.O.D. VIBRATION/BUFFET WARNING INDICATION CL CLIMB 1 AU S NR 2 ENGINE FAN BLADES (4OFF) DAMAGED BY BIRDSTRIKE. 2 L 7 2 4F 4 F RT A16WE E2GL 2006070300094 20060703 00094 NM 2006 7 3 AU510002195 1 20051212 G 5330 SKIN BOEING 737 737300 1384610 NM RROYCE RB211 RB211524* NE FUSELAGE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S FUSELAGE SKIN TORN ACROSS RIVET ON STRINGER 39L FRAME 1197 AND 132 LOCATED JUST OUTBOARD OF PREVIOUS PATCH. A SLIGHT BU LGE IN THE SKIN WAS NOTED. 2 L 7 2 4F 4 F RT A16WE E12EU 2006070500165 20060705 00165 NM 2006 7 5 AU510002196 1 20051212 G 4900 762904E APU BOEING 717 717200 1383700 NM RROYCE BR700 BR700715A130 NE FAILED W K NONE H ELECT. POWER LOSS-50 PC IN INSP/MAINT 1 AU S (AUS) APU AUXILIARY POWER CONVERSION AND DISTRIBUTION UNIT FAILED. SEE ATTACHMENT FOR INVESTIGATION DETAILS.(OTHER CAUSE : AGE ) (CASA NR 510002196) 2 L 7 2 4F 4 F TR A6WE E00061EN 2006070500166 20060705 00166 SW 2006 7 5 AU510002198 1 20051212 G 3230 NAS660421 BOLT SWRNGN SA227 SA227* SW GARRTT TPE331 TPE33112UHR WP MCAULY 4HFR34 4HFR34C652 NE LT MLG SHEARED W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) LT MAIN LANDING GEAR UPLOCK ROLLER BOLT SHEARED. (CASA NR 510002198) 2 L 7 2 4T 4 T RT A5SW E4WE 6 C 3PNE 2006070500167 20060705 00167 SW 2006 7 5 AU510002199 1 20051212 G 2910 2781032777 LINE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE HYDRAULIC SYS WORN W O OTHER K J FLUID LOSS WARNING INDICATION DE DESCENT 1 AU S (AUS) HYDRAULIC PIPES LOCATED IN LT ENGINE BAY CHAFING TOGETHER. ONE PIPE WORN THROUGH AND LEAKING. LOSS OF HYDRAULIC FL UID. (CASA NR 510002199) 2 L 7 2 4T 4 T RT A8SW E4WE 6 C 3PNE 2006070500168 20060705 00168 EU 2006 7 5 AU510002200 1 20051212 G 7810 EXHAUST PIPE BNORM BN2 BN2A8 1520209 EU LYC O540 O540E4C5 41532 EA HARTZL HCC2Y HCC2YK2 GL LT ENGINE MISSING W K NONE O OTHER IN INSP/MAINT 1 AU S (AUS) APPROXIMATELY 457.2MM (18IN) OF LT ENGINE RT TAILPIPE BANK AND CLAMP MISSING. FURTHER INVESTIGATION ALSO FOUND CRA CKING ON NR 3 AND NR 5 CYLINDER EXHAUST RISERS. ENGINE LOWER COWL ALSO SUFFERED SCORCHING DAMAGE. (CASA NR 510002200) 1 H 7 2 3O 3 O A17EU E295 5 C P920 2006070500169 20060705 00169 EU 2006 7 5 AU510002201 1 20051212 G 3230 683702 VALVE SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R375 R3754123F21 NE MLG SEIZED W K NONE O OTHER IN INSP/MAINT 1 AU S 23403 (AUS) LANDING GEAR EMERGENCY UPLOCK VALVE SEIZED. (OTHER CAUSE: INDETERMINABLE ) (CASA NR 510002201) 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P17NE 2006070500171 20060705 00171 CE 2006 7 5 AU510002202 1 20051212 G 3233 A2176B PLUG GARKENYON BEECH 76 76 1153005 CE LYC O360 O360A1G6D EA HARTZL HCM2Y HCM2YR GL NLG ACTUATOR CRACKED W O OTHER N FALSE WARNING CR CRUISE 1 AU S 867 222 (AUS) NOSE LANDING GEAR ACTUATOR END PLUG CRACKED IN AREA OF SPANNER FLATS. LOSS OF HYDRAULIC FLUID. (CASA NR 510002202) 1 L 7 2 3O 3 O A29CE E286 5 C P43GL 2006070500172 20060705 00172 EU 2006 7 5 AU510002203 1 20050212 G 2910 CLAMP BAG JETSTM JETSTM3107 1500215 EU GARRTT TPE331 TPE33110U 01514 WP ROTOL R333 R333482F12 GL HYDRAULIC SYS BROKEN W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S 32594 (AUS) HYDRAULIC PIPES PN 1379007D441 AND PN 1379007D443 LOCATED IN LT WING LEADING EDGE RUBBING TOGETHER DUE TO A BROKEN CLAMP. ONE PIPE WAS WORN THROUGH. LOSS OF HYDRAULIC FLUID. (OTHER CAUSE: BROKEN CLAMP ) (CASA NR 510002203) 2 L 7 2 4T 4 T RT BA15CAA E4WE 6 C P61GL 2006070500174 20060705 00174 CE 2006 7 5 AU510002204 1 20050212 G 3230 574122214 UPLOCK HOOK CESSNA 441 441 2076020 CE GARRTT TPE331 TPE331* 01514 WP HARTZL HCB3T HCB3TN5 GL LANDING GEAR CRACKED W A UNSCHED LANDING O OTHER CL CLIMB 1 AU S 17180 (AUS) RT MAIN LANDING GEAR UPLOCK HOOK CRACKED. (CASA NR 510002204) 1 L 7 2 3T 3 T RT A28CE E2WE 6 C P15EA 2006071000086 20060710 00086 EU 2006 7 10 AU510002205 1 20051212 G 3230 SA7670006127 HOSE BAG BAE146 BAE146300A 1500267 EU LYC ALF502 ALF502R5 41580 NE NLG FAILED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 AU S NOSE LANDING GEAR RETRACTION ACTUATOR FLEXIBLE HYDRAULIC HOSE RUPTURED. LOSS OF GREEN SYSTEM HYDRAULIC FLUID. 2 H 7 4 4F 4 F RT A49EU E6NE 2006070500370 20060705 00370 NM 2006 7 5 AU510002206 1 20050112 G 3244 DR29620T TIRE BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE MLG FAILED W C ABORTED TAKEOFF O OTHER TO TAKEOFF 1 AU S NR 2 MAIN WHEEL TIRE TREAD SEPARATED. TIRE WAS RETREAD LEVEL R2. DAMAGE WAS CAUSED TO THE LT INBOARD TRAILING EDGE FLA P AND LT INBOARD LOWER WING FIXED TRAILING EDGE PANEL. 2 L 7 2 4F 4 F RT A16WE E2GL 2006071100124 20060711 00124 NM 2006 7 11 AU510002207 1 20051212 G 3230 DSC252B40124 HOSE DHAV DHC8 DHC8315 2809010 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE NR 2 HYD SYS RUPTURED W O OTHER K FLUID LOSS CL CLIMB 1 AU S 10711 NOSE LANDING GEAR DRAG STRUT RETRACTION ACTUATOR FLEXIBLE HOSE RUPTURED. LOSS OF NR 2 HYDRAULIC SYSTEM FLUID. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006071100125 20060711 00125 2006 7 11 AU510002208 4 20051212 G 2310 RADIO BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE HF SYSTEM FAILED W O OTHER O OTHER CR CRUISE 1 AU S BOTH HF RADIO SYSTEMS FAILED TO TUNE. A WEAK BACKGROUND HASH COULD BE HEARD ON NR 2 HF SYSTEM ONLY. INVESTIGATION CONT INUING. 2 L 7 2 4F 4 F RT A16WE E2GL 2006071100126 20060711 00126 2006 7 11 AU510002209 4 20051212 G 3442 8221710001 TRANSCEIVER BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE WX RADAR FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S WEATHER RADAR TRANSCEIVER FAULTY. 2 L 7 2 4F 4 F RT A16WE E2GL 2006071100127 20060711 00127 NM 2006 7 11 AU510002210 1 20051212 G 2913 887477 PUMP BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE HYDRAULIC SYS FAILED W K NONE K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 AU S HYDRAULIC PUMP FAILED. CIRCUIT BREAKER TRIPPED AND PUMP ELECTRIC MOTOR HAD A BURNED ODOR. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT A16WE E2GL 2006071100128 20060711 00128 SO 2006 7 11 AU510002211 2 20050311 G 8520 SA642720 BEARING CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 AU S 1429 CRANKSHAFT NR 2 MAIN BEARING SHELL PROTRUDING MORE THAN NORMAL OUTSIDE OF THE CRANKCASE SADDLE. WHEN THE ENGINE WAS STR IPPED DOWN THE NR 2 BEARING SHELL LOCATED IN THE LT CRANKCASE FELL APART INTO AT LEAST FIVE PIECES. DAMAGE TO THE CRANK CASE WAS ALSO FOUND DUE TO THE FORE AND AFT MOVEMENT OF THE BEARING. SEVERE WEAR IN THE TANG LOCATING AREA. 1 H 7 1 3O 3 O A4CE E5CE 2006071100129 20060711 00129 SO 2006 7 11 AU510002212 2 20051212 G 8520 631716 CRANKSHAFT CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO ENGINE DAMAGED W K NONE O OTHER IN INSP/MAINT 1 AU S 1429 CRANKSHAFT DAMAGED. MAGNETIC PARTICLE INSPECTION OF CRANKSHAFT FOLLOWING NR 2 MAIN BEARING FAILURE (SEE SDR510002211) F OUND INDICATIONS OF HEAT CRACKS ON THE RADIUS OF NR 2 MAIN JOURNAL. CRANKSHAFT WAS REJECTED. 1 H 7 1 3O 3 O A4CE E5CE 2006071100130 20060711 00130 CE 2006 7 11 AU510002213 1 20051212 G 8011 643109 SPRING CONT CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO STARTER ADAPTER BROKEN W K NONE O OTHER IN INSP/MAINT 1 AU S 1044 STARTER ADAPTER SPRING BROKEN IN HALF. 1 H 7 1 3O 3 O A4CE E5CE 2006071100131 20060711 00131 NE 2006 7 11 AU510002214 2 20051212 G 7314 5008269H PUMP DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE FUEL FAILED W O OTHER X J ENGINE FLAMEOUT WARNING INDICATION CL CLIMB 1 AU S 3390 3390 NR 2 ENGINE DRIVEN FUEL PUMP INPUT SHAFT SHEARED. FUEL PUMP COULD TURN FREELY. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006070300098 20060703 00098 NM 2006 7 3 AU510002215 1 20050212 G 2700 65448616 ACTUATOR BOEING 737 737200 1384453 NM PWA JT8 JT8D7 52053 NE FLIGHT CONTROL LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S ACTUATOR LOCATED IN LT WING LEAKING. LIMITED INFORMATION PROVIDED. 2 L 7 2 4F 4 F A16WE E2EA 2006070300099 20060703 00099 NM 2006 7 3 AU510002216 1 20050312 G 2150 A/C PACK BOEING 737 7377BX 13844D2 NM GE CFM56 CFM56* 13802 NE CONTAMINATED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 AU S STRONG OIL SMELL IN COCKPIT AND CABIN. INVESTIGATION FOUND OIL CONTAMINATION OF THE AIR CONDITIONING AND PNEUMATIC SYST EMS. 2 L 7 2 4F 4 F RT A16WE E2GL 2006070300100 20060703 00100 NM 2006 7 3 AU510002217 1 20050212 G 2781 WARNING MESSAGE BOEING 767 767277 1385128 NM GE CF6 CF680A 30025 NE SLAT ACTIVATED W O OTHER J WARNING INDICATION CL CLIMB 1 AU S SLAT ASYMMETRY WARNING. INVESTIGATION CONTINUING. 2 L 7 2 4F 4 F RT A1NM E13NE 2006060800131 20060608 00131 NM 2006 6 8 AU510002218 1 20050412 G 5610 WINDSHIELD BOEING 777 777 UTILUSE NM COCKPIT CRACKED W O OTHER O OTHER CR CRUISE 1 AU S CAPTAIN`S WINDSCREEN CRACKED. AIRCRAFT IS REGISTERED IN NEW ZEALAND. 2 L 7 2 4F RT T00001SE 2006060800132 20060608 00132 EU 2006 6 8 AU510002219 1 20050512 G 2730 CONTROL SYSTEM FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE ELEVATOR FAULTY W K NONE O OTHER IN INSP/MAINT 1 AU S ELEVATOR CONTROL SYSTEM MESSAGE ON MULTI FUNCTION DISPLAY UNIT (MFDU). 2 L 7 2 4F 4 F RT E25NE 2006060800133 20060608 00133 EU 2006 6 8 AU510002220 1 20051212 G 3610 6730010000 VALVE AIRBUS 320 A320232 3930326 EU IAE V2527 V2527A5 NE PNEUMATIC SYS FAULTY W O OTHER J WARNING INDICATION CL CLIMB 1 AU S 4787 NR 2 ENGINE BLEED SYSTEM FAN AIR VALVE SUSPECT FAULTY. 2 L 7 2 4F 4 F RT A28NM E40NE 2006060800135 20060608 00135 WP 2006 6 8 AU510002221 2 20050812 G 7310 8945682 LINE SWRNGN SA227 SA227* SW GARRTT TPE331 TPE3312 01514 WP MCAULY 4HFR34 4HFR34C652 NE LT ENG FUEL CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 AU S LT ENGINE FUEL PIPE LOCATED BETWEEN THE START PRESSURE REGULATOR AND THE FUEL FLOW TRANSMITTER CRACKED AND LEAKING. 2 L 7 2 4T 3 T RT A5SW E3WE 6 C 3PNE 2006060800137 20060608 00137 NM 2006 6 8 AU510002222 1 20050712 G 2150 1828203 HEAT EXCHANGER BOEING 737 737800* NM GE CFM56 CFM56* 13802 NE A/C PACK CRACKED W K NONE O OTHER IN INSP/MAINT 1 AU S RT AIR CONDITIONING PACK HEAT EXCHANGER CRACKED AND LEAKING. 2 L 7 2 4F 4 F RT A16WE E2GL 2005122800220 20051228 00220 NM 2005 12 28 AUCR200500001 1 20051201 G 5730 9255011 PANEL LKHEED P3A P3A 5260103 NM ALLSN T56 T56A10 03004 GL LT WING CRACKED B AUCR K NONE O OTHER IN INSP/MAINT 1 WP 25 917AU 15178 150510 LOCATED LOWER WING PLANK RISER FRACTURE 7 INCHES IN LENGTH LT WING STA. 167. FRACTURE EMANATED ALONG BASE OF RISER EXTEN DING IB AND OB SPANWISE. FRACTURE WAS VISUALLY DETECTED DURING SCHEDULED INSPECTION. FRACTURE WAS PROPAGATED BY THE MAIN LANDING GEAR TRUSS RIB ATTACHING STIFFENER AT THE FORWARD SPAR ATTACHMENT. MANUFACTURING PROCESSES ENTAILED THE VERTICA L LEG TO BE CUT BACK AT THE RISER INTERSECTION; FAILURE TO DO SO ENCROACHED THE RISER AT THE VERTICAL STIFFENER PRELOADI NG THE NR 1 RISER. THIS INCIDENT IS TO BE CONSIDERED AN ISOLATED MFG PROCESS FAILURE. SPECIFICATIONS CLEARLY SHOW THE ST IFFENER TO BE TRIMMED AT THE INTERFACE WITH THE RISER. 2 L 7 4 4T 4 T RT A32NM E282 2005122800223 20051228 00223 NM 2005 12 28 AUCR200500002 1 20051201 G 5711 9010622 SPAR CAP LKHEED P3A P3A 5260103 NM LT WING CORRODED B AUCR K NONE O OTHER IN INSP/MAINT 1 WP 25 917AU 15178 150510 LT WING UPPER REAR SPAR CAP WS178, AT NACELLE AFT ATTACH PLATE. DISSIMILAR METAL CORROSION ATTACK UPPER CROWN AND VERTIC AL LEG. CORROSION WAS VISUALLY DETECTED AT DEPOT LEVEL SCHEDULED INSPECTION. CORROSION WAS FOUND TO EXCEED NEGLIGIBLE D AMAGE LIMITS. 2 L 7 4 4T RT A32NM 2005122800224 20051228 00224 NM 2005 12 28 AUCR200500003 1 20051201 G 5711 9010622 SPAR CAP LKHEED P3A P3A 5260103 NM RT WING CORRODED B AUCR K NONE O OTHER IN INSP/MAINT 1 WP 25 917AU 15178 150510 RT WING REAR SPAR UPPER CAP WS178 AT NACELLE AFT ATTACH PLATE. DISSIMILAR METAL CORROSION ATTACKING UPPER CROWN AND AND VETICAL LEG OF THE SPAR CAP. CORROSION WAS VISUALLY DETECTED AT SCHEDULED DEPOT LEVEL INSPECTION. CORROSION EXCEEDED MAX IMUM NEGLIGIBLE LIMITS. 2 L 7 4 4T RT A32NM 2005122700209 20051227 00209 NM 2005 12 27 AUCR200500004 1 20051201 G 5711 9010552 SPAR CAP LKHEED P3A P3A 5260103 NM RT WING CORRODED B AUCR K NONE O OTHER IN INSP/MAINT 1 WP 25 917AU 15178 150510 RT WING UPPER FORWARD SPAR CAP W.S.73 (PREVIOUS PROCESSING BY PARTY UNKNOWN) OF THE FORWARD FLANGE HAS EXCEEDED MAXIMUM NEGLIGIBLE LIMITS FOR DAMAGE LOCATION. DUE TO THE RELATIVE LOCATION OF THE WING ATTACH CORNER FITTING THIS DAMAGE CANNOT BE REPAIRED AND WILL REQUIRE A SPAR CAP INSERTION. 2 L 7 4 4T RT A32NM 2006010500186 20060105 00186 NM 2006 1 5 AUCR200500005 1 20051202 G 5730 9006072 SKIN PANEL LKHEED P3A P3A 5260103 NM RT WING CORRODED B NASA K NONE K FLUID LOSS IN INSP/MAINT 1 WP 25 426NA 18057 152735 RT WING LOWER SKIN PANEL NR 7 AT BUTT LINE 65 INTERNAL INTERGRANULAR CORROSION. THE DEFECTIVE PANEL WAS FIRST DETECTED B Y A FUEL LEAK AT BUTT LINE 65. FURTHER INVESTIGATION REVEALED EXFOLIATION FROM INTERGRANULAR CORROSION. THE CORROSION WA S CONCEALED BY LAYERS OF FUEL TANK BARRIER SEALANT. 2 L 7 4 4T RT A32NM 2005031000089 20050310 00089 CE 2005 3 10 B30R20050105 1 20050103 G 2731 511523128 ACTUATOR CESSNA 500 550 2076604 CE ELEVATOR TRIM MALFUNCTIONED B B30R K NONE O OTHER IN INSP/MAINT 1 SW 03 26496 5500607 DURING PREFLIGHT OF AIRCRAFT, PILOT HEARD A NOISE IN WHILE OPERATING ELEVATOR ELECTRIC TRIM. TROUBLESHOOTING REVEALED THAT THE TRIM CABLES IN THE ELEVATOR ELECTRIC TRIM ACTUATOR HAD CROSSED. A REPLACEMENT ELECTRIC TRIM ACTUATOR WAS ORDER ED. UPON RECEIPT OF THE ACTUATOR IT WAS DISCOVERED THAT ONE OF THE CABLES HAD BEEN BENT OVER AND PINCHED. FURTHER INSP ECTION REVEALED A BROKEN WIRE IN THE CABLE AT THE PINCHED AREA. THE ACTUATOR WAS RETURNED TO THE VENDOR AS UNSERVICABLE , AND ANOTHER ORDERED. 1 L 7 2 4F A22CE 2005041100203 20050411 00203 CE 2005 4 11 B30R20050405 1 20050204 G 3240 302 MOTOR ELECTROMECH CESSNA 500 550 2076604 CE POWER PACK INOPERATIVE B B30R D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 SW 03 26496 NA 5500607 AFTER LANDING DURING TAXI BACK TO THE RAMP, PILOT EXPERIENCED POWER BRAKE FAILURE. WAS ABLE TO CONTROL THE AIRCRAFT AND RETURN IT TO THE PARKING RAMP SAFELY. MECHANIC'S TROUBLESHOOTING REVEALED THAT THE POWER PACK PUMP MOTOR HAD FAILED. THE POWER PACK ASSEMBLY WAS REMOVED AND THE MOTOR WAS REPLACED. THE POWER PACK ASSEMBLY WAS REINSTALLED AND THE BRAKE S YSTEM WAS BLED. BRAKE SYSTEM RESUMED NORMAL OPERATION. THE AIRCRAFT WAS RELEASED FROM MAINTENANCE AND RETURNED TO SERV ICE. 1 L 7 2 4F A22CE 2005031000091 20050310 00091 CE 2005 3 10 B3OR20050105 1 20050104 G 2731 511523128 TRIM MOTOR CESSNA 500 550 2076604 CE ELEVATOR JAMMED B B3OR O OTHER O OTHER NR NOT REPORTED 1 SW 03 26496 5500607 AIRCRAFT WAS AOG FOR ELEVATOR ELECTRIC TRIM ACTUATOR. WHEN PART WAS RECIEVED FROM VENDOR IT WAS DISCOVERED THAT THE AFT TRIM CABLE WAS ROUTED BETWEEN THE CABLE DRUM AND THE CLUTCH ASSEMBLY JAMMING THE CLUTCH ASSEMBLY. THE CABLE DRUM CLUTCH COULD NOT DISENGAGE TO ALLOW ROTATION OF THE CABLE DRUM. DUE TO THE JAMMED CONDITION OF CLUTCH ASSEMBLY, THE PART COULD NOT BE USED AND A REPLACEMENT WAS ORDERED. THE TRIM ACTUATOR S/N:0313-28, WAS AN OVERHAULED UNIT AND THE WORK WAS DONE B Y CESSNA. 1 L 7 2 4F A22CE 2005031000092 20050310 00092 CE 2005 3 10 B3OR20050205 1 20050104 G 2731 511523128 TRIM MOTOR CESSNA 500 550 2076604 CE ELEVATOR JAMMED B B3OR O OTHER O OTHER NR NOT REPORTED 1 SW 03 26496 5500607 AIRCRAFT WAS AOG FOR ELEVATOR ELECTRIC TRIM ACTUATOR. WHEN PART WAS RECIEVED FROM VENDOR IT WAS DISCOVERED THAT THE AFT TRIM CABLE WAS ROUTED BETWEEN THE CABLE DRUM AND THE CLUTCH ASSEMBLY JAMMING THE CLUTCH ASSEMBLY. THE CABLE DRUM CLUTCH COULD NOT DISENGAGE TO ALLOW ROTATION OF THE CABLE DRUM. DUE TO THE JAMMED CONDITION OF CLUTCH ASSEMBLY, THE PART COULD NOT BE USED AND A REPLACEMENT WAS ORDERED. THE TRIM ACTUATOR S/N:0313-28, WAS AN OVERHAULED UNIT AND THE WORK WAS DONE B Y CESSNA. 1 L 7 2 4F A22CE 2005050400100 20050504 00100 2005 5 4 B3OR20050505 4 20050413 G 6113 1250419K200 SPINNER CESSNA 210 210N 2073453 CE CONT O550 IO550* SO MCAULY D3A34 D3A34C402 GL PROPELLER CRACKED B B3OR K NONE O OTHER IN INSP/MAINT 1 SW 03 5515Y 5239 35 21064233 289125R 941015 PROPELLER SPINNER WAS INSPECTED DURING A PRE-FLIGHT INSPECTION AND FOUND TO HAVE A CRACK. THE CRACK WAS FROM A SCREW HOL E AND EXTENDED TO BLADE CUT-OUT. THE SPINNER WAS REPLACED AND INSPECTED AFTER ITS FIRST FLIGHT, NO CRACKS WERE FOUND OR NOTED ON THE REPLACED SPINNER. SUSPECT OVER TORQUEING OF SPINNER ATTACH SCREWS AS CAUSE OF CRACK 1 H 7 1 3O 3 O 3A21 E3SO 5 C P47GL 2005061500139 20050615 00139 CE 2005 6 15 B3OR20050614 1 20050613 G 3240 PUMP CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE BRAKES SEIZED B B3OR O OTHER J WARNING INDICATION LD LANDING 1 SW 03 26496 5500607 DURING APPROACH, WHILE LOWERING GEAR, PILOT IN COMMAND NOTICED "ANTI SKID INOP" LIGHT ILLUMINATED. PILOTS FOLLOWED EMERG ENCY CHECKLIST PROCEDURES & MADE AN UNEVENTFUL LANDING AT HOME FIED. HOWEVER, EMERGENCY BRAKE SYS HAD TO BE USED TO BRIN G ACFT TO A STOP. MX STARTED TROUBLESHOOTING PROCEDURES & DISCOVERED POWER BRAKE PUMP SEIZED, CAUSING MOTOR TO TRIP CIRC UIT BREAKER. MOTOR ITSELF TESTED ON A BENCH & FOUND TO BE WORKING IAW MM. AT TIME OF WRITING, POWER BRAKE PUMP AND MOTOR ASSY HAVE BEEN SENT OUT FOR REPAIR/OVERHAUL. SINCE CESSNA DOES NOT HAVE A TBO ON EITHER THE MOTOR OR THE PUMP, IT IS SU GGESTED THAT A TBO OF 500 TO 600 LANDINGS BE APPLIED TO THESE COMPONENTS. 1 L 7 2 4F 4 F A22CE E1NE 2005071200135 20050712 00135 SO 2005 7 12 B3OR20050627 2 20050627 G 7310 6464336P MANIFOLD CESSNA 210 210N 2073453 CE CONT O520 TSIO520* 17040 SO HARTZL HCJ3Y PHCJ3YF1 GL FUEL SYSTEM CONTAMINATED B B3OR O OTHER R J PARTIAL RPM/PWR LOSS WARNING INDICATION TX TAXI/GRND HDL 1 SW 03 6621A 21063559 821022R FP1513B TAXI, ENG RUNS ROUGH. FUEL INJECTOR LINES DISCONNECTED, NR 5 CYL FUEL INJECTOR NOT FLOWING CORRECTLY. PROBLEM FUEL DIS TRIBUTOR MANIFOLD OR SPIDER. FILTER SCREEN IN SPIDER REMOVED, 9 PARTICLES FOUND. LARGEST 7CM LONG & 1MM WIDE. MANIFOL D DISASSEMBLED & 2 PARTICLES FOUND NEAR OUTLET NR 5 CYL. LARGEST 1CM WIDE BY 1CM LONG. TWO PARTICLES HAD GOTTEN PAST F ILTER SCREEN. AFTER FILTER SCREEN & DISTRIBUTION MANIFOLD CLEANED & REASSEMBLED. FLOW PATTERN NR 5 CYL NORMAL. FUEL S CREEN ON FUEL DISTRIBUTION MANIFOLD IS NOT LISTED FOR PERIODIC INSP OR CLEANING. ENG HAS INTERMITTENT PROBLEM OF ROUGH RUNNING, 1ST TIME INDICATION OF DEBRIS IN FUEL DISTRIBUTION MANIFOLD. IO550P OPERATORS SHOULD BE MADE AWARE OF PROBLEM. 1 H 7 1 3O 3 O 3A21 E8CE 5 C P36EA 2005072000109 20050720 00109 CE 2005 7 20 B3OR20050718 1 20050718 G 7160 646205 INTAKE PIPE CESSNA 210 210N 2073453 CE CONT O550 IO550* SO HARTZL HCJ3Y PHCJ3YF1 GL NR 4 CYLINDER CRACKED B B3OR K NONE O OTHER IN INSP/MAINT 1 SW 03 6621A 934 934 21063559 821022R FP1513B WHILE REMOVING LT MAGNETO FOR TBO, THE NR 4 CYLINDER INTAKE PIPE HAD TO BE REMOVED FOR ACCESS TO THE MAGNETO. REMOVAL OF THE INTAKE PIPE REVEALED THAT THE INTAKE PIPE HAD A CRACK IN THE FLARE END THAT IS SECURED TO THE CYLINDER INTAKE PORT. FURTHER INVESTIGATION REVEALED THAT THE NR 4 INTAKE PIPE WAS THE ONLY PIPE FOUND IN THIS CONDITION. THIS ENGINE HAD AN INTERMITTENT PROBLEM OF RUNNING ROUGH FOR A FEW MOMENTS THEN BACK TO RUNNING NORMALLY. ALL IO-550P OPERATORS SHOULD BE M ADE AWARE OF THIS PROBLEM. 1 H 7 1 3O 3 O 3A21 E3SO 5 C P36EA 2005102700134 20051027 00134 CE 2005 10 27 BG001 1 20051006 G 2910 S217840102 LINE CESSNA 182 TR182 2072735 CE LYC O540 O540* 41532 EA HYDRAULIC SYS FAILED G B EMER. DESCENT K J FLUID LOSS WARNING INDICATION CL CLIMB 1 SW 09 2426S R18201339 DOWN HYDRAULIC PRESSURE LINE FAILED AT ACTUATOR. LINE PULLED OUT OF SWAGED END FITTING. 1 H 7 1 3O 3 O 3A13 E295 2005120200146 20051202 00146 SO 2005 12 2 BNG0002 1 20051106 G 2460 PS5012012 CIRCUIT BREAKER PIPER PA28 PA28RT201 7102818 SO UNKNOWN FAILED G O OTHER S AFFECT SYSTEMS LD LANDING 1 SW 09 3023K 28R7918022 CIRCUIT BREAKER FAILED. 1 L 7 1 3O 2A13 2005042500038 20050425 00038 WP 2005 4 25 CA050103002 1 20050102 G 8012 39279621 START VALVE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE NR 1 ENGINE MALFUNCTIONED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) NR 1 ENGINE, THE LT START VALVEOPEN LIGHT CAME ON IN CLIMB. THE AIRCRAFT LEVELED OFF, WHEN THE POWER REDUCED, THE LIGHT WENT OUT. WHEN CLIMB POWER INITIATED AGAIN, THE LIGHT CAME BACK ON. THE AIRCRAFT CAME BACK TO PLACE OF DEPARTURE. THE AIRCRAFT WAS RELEASED UNDER MEL 80-1.2. THE STARTER VALVE (PN ON OFF, 392796-2-1, SN OFF 3938, SN ON 3624) WAS LATE R REPLACED IAW AMM 80-10-02. OPERATIONAL CHECK C/OUT PER AMM 71-00-00. 2 L 7 2 4F 4 F RT A6WE E9NE 2005042500039 20050425 00039 EU 2005 4 25 CA050104001 1 20050103 G 2910 PACKING RV99199 FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE THERMAL RELIEF FAILED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA 1011927 (CAN) HYDRAULIC SYSTEM NR 1 FAILED IN FLT (AFTER TAKE OFF), LOW QUANTITY. THE FLIGHT CREW DECLARED AN EMERGENCY AND RETU RNED TO PLACE OF DEPARTURE. MAINTENANCE FOUND THAT THE HYDRAULIC SYSTEM FAILURE WAS CAUSED BY A PACKING FAILURE OF THE T HERMAL RELIEF VALVE ON THE PRESSURE MANIFOLD ASSY, THE VALVE WAS REPLACED (PN OFF ON: RV99-199, SN OFF 1011927, SN ON 04 -0916528) IAW AMM 32-44-13. THE SYSTEM WAS REPLENISHED AND TESTED SERVICEABLE. 2 L 7 2 4F 4 F RT E25NE 2005042500040 20050425 00040 NE 2005 4 25 CA050104002 2 20050104 G 7310 3033736 LINE PWA PT6 PT6A42 52043 NE FUEL SYSTEM WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) DURING VISUAL INSPECTION AT PWC, WE HAVE IDENTIFIED THAT ONE FUEL PRESSURE HOSE WAS NOT GENUINE BUT WAS FITTED TO THE ENGINE S/N 42372 WHERE THE HOSE P/N 3033736 SHOULD BE FITTED. THIS HOSE IS BUILT IN 3 PIECES, A FLEXIBLE STEEL HOSE COVERED WITH AN ORANGE RUBBER HOSE WHICH IS CONNECTED AT EACH END WITH A FEMALE 90 DEG. CONNECTOR. THE PART ITSELF IS ID ENTIFIED AS LEAVENS 10-943 LAM, 090 E4181G0070, AICOI PT BEB01, TEFLON 3 008SI, TSO 075A TYPE D NOC PART WAS REMOVED FRO M THE ENGINE AND WILL BE KEPT IN QUARANTINE FOR 21 DAYS BEFORE BEING MUTILATED. THIS IS THE SECOND OCCURENCE IN THE PAST MONTH. 4 T E4EA 2005031400053 20050314 00053 NE 2005 3 14 CA050105005 1 20050104 G 7810 EXHAUST DUCT SKRSKY S76 S76A 8143006 NE ALLSN 250C 250C30S 03013 GL NR 2 EGINE CRACKED W A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 CA CAE890793S (CAN) PILOT REPORTED, NO N2 INDICATION FOR NR 2 ENGINE. UPON INSPECTION, WHEN N2 PICKUP WAS REMOVED FROM THE ACCY GEARBO X, IT WAS OBSERVED THAT THE NR 5 BEARING NUT HAD BACKED OFF ON THE PT OUTER SHAFT TRAVELING AWAY FROM THE N2 PICKUP, HEN CE 'NO N2 INDICATION'. IT WAS OBSERVED THAT THE 12 O'CLOCK MOUNTING STRUT ON THE EXHAUST COLLECTOR HAS DEVELOPED SEVERA L CRACKS. THE LOCK WASHER APPEARED TO HAVE BEEN DEFORMED IN TWO PLACES AT SOME POINT AND TIME, HOWEVER, THE DEFORMATIONS WERE EITHER WERE NOT SUFFICIENT TO PREVENT THE NR 5 NUT FROM BACKING OFF, OR THE NUT HAS NOT BEEN TORQUED CORRECTLY TO BEGIN WITH. TURBINE HAS BEEN REPLACED AND TEARDOWN REPORT REQUESTED FROM THE AUTHORIZED MAINTENANCE CENTER. 1 G 7 2 3U 3 U H1NE E1GL 2005031400031 20050314 00031 EU 2005 3 14 CA050105009 1 20050105 G 2435 524321215 GENERATOR PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL NR 2 DIRTY W O OTHER J WARNING INDICATION CR CRUISE 1 CA (CAN) DURING CRUISE FLIGHT, GEN 2 TRIPPED OFF LINE. PILOT TRIED TO RESET WITH NO SUCCESS, AND THEN RETURNED TO BASE. IN VESTIGATION REVEALED THE ARMATURE TO BE VERY DIRTY. ARMATURE CLEANED, AIRCRAFT GROUND RUN AND FUNCTION TEST PREFORMED SATISFACTORY. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005042500043 20050425 00043 SO 2005 4 25 CA050105014 1 20050105 G 2800 5379700 ADAPTER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL FUEL CAP INCORRECT W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) THE INNER RING ON THE FUEL CAP HOUSING IS HELD IN PLACE BY LOCKING TABS. THE FUEL CAP LOCKS ONTO THIS RING. THE LO CKING TABS THAT HOLD THE RING IN PLACE SLOWLY, OVER TIME OF CONSTANT USE RELEASED THE RING TO LET THE CAP COME OUT OF TH E HOUSING. CHECKING OUR OTHER A/C AND THE PILOTS HAVE ALL BEEN INFORMED ON HOW TO DETERMINE IF THERE IS A PROBLEM WITH THE CAP. MAINTENANCE ALSO IS PAINTING LINES ON THE CAP AND HOLDER TO SHOW A VISIBLE INDICATION OF THE CAP NOT BEING IN T HE PROPER PLACE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005032400037 20050324 00037 SW 2005 3 24 CA050105015 1 20050104 G 7920 8941172 ADAPTER SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP OIL FILTER CRACKED W E ENGINE SHUTDOWN K J Y FLUID LOSS WARNING INDICATION ENGINE STOPPAGE CR CRUISE 1 CA P54108 DURING CRUISE, RT ENG OIL PRESS WARNING LIGHT ILLUM ON ANNUNCIATOR. UPON LOOKING AT RT OIL PRESS IND FLT CREW NOTICED O IL PRESS DECREASING THROUGH 40 PSI. CREW ELECTED TO SHUTDOWN RT ENG AS A PRECAUTION. A/C CONTINUED IT'S FLIGHT TO YWG WHERE IS LANDED W/O FURTHER INCIDENT WITH EMERGENCY SERVICES STANDING BY. UPON INSPECTION BY MX OF RT ENG, OIL FILTER H OUSING ADAPTER FOUND CRACKED AT MOUNTING FLANGE WHICH PROPAGATED TO ADAPTERS O-RING GROOVE, WHICH CAUSED LOSS OF OIL. 3 OF 8 US QUARTS OF ENGINE OIL SYS LOST DUE TO LEAKING ADAPTER. ENG OIL PRESS ONLY DROPPED TO 40 PSI BEFORE ENG SHUTDOWN . OIL FILTER ADAPTER CHANGED & LEAK CHECKS PERFORMED. 2 L 7 2 4T 4 T RT A8SW E4WE 2005032400038 20050324 00038 SO 2005 3 24 CA050106001 1 20050105 G 5753 CB17663 BEARING LKHEED 282 C130A 5262502 SO FLAP CARRIAGE MISMANUFACTURED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA TECHS FOUND DIFFICULTY WHILE ATTEMPING TO GREASE NEWLY INSTALLED FLAP CARRIAGE BEARINGS. BEARINGS WOULD NOT ACCEPT GREA SE AS DIRECTED BY THE MM. A RECALL & INSPECT OF ALL INVENTORIED BEARINGS CARRIED OUT AT SPAR QUALITY DEPARTMENT. BEARIN GS IN QUESTION WERE ACQUIRED AS NEW PARTS ACCOMPANIED BY PROPER PART CERTIFICATIONS. BEARINGS WERE MANUFACT UNDER P/N C B17663. ALL INSPECTED & RECALLED BEARINGS WERE FROM PRODUCTION LOTS 64598, 61262, 61077. A TOTAL OF 120 BEARINGS EXAMIN ED. A FAILURE RATE PER LOT FROM 25-50 PERCENT. OBSERVED THAT WHEN GREASE APPLIED THROUGH APPROPRIATE NEEDLE ZERK, THE ORFICE BALL FORCED TO BOTTOM OF THE GREASE ORFICE BLOCKING THE ENTRY OF GREASE TO THE BEARING SURFACE. 2 H 7 4 4T A31NM 2005032400032 20050324 00032 EU 2005 3 24 CA050107002 1 20050104 G 3211 5321012077 BOLT PILATS PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A67B 52043 NE HARTZL HCE4A HCE4A3D GL MLG BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA VLG018 LOWER LANDING GEAR ACTUATOR BOLT ON LEFT GEAR LEG MISSING BOLT HEAD. 1 L 7 1 3T 4 T RT A78EU E26NE 5 C P210NE 2005042500045 20050425 00045 GL 2005 4 25 CA050107003 2 20050129 G 7230 COMPRESSOR EMB 135 EMB135ER 3260203 SO ALLSN AE300 AE3007A GL RT ENGINE SEIZED W B A EMER. DESCENT UNSCHED LANDING E Y VIBRATION/BUFFET ENGINE STOPPAGE CL CLIMB 1 CA CAE31171 (CAN) UNCOMMANDED IN FLIGHT SHUTDOWN DURING CLIMBOUT AT APPROXIMATELY 25,000 FT. PILOT HEARD A LOUD BANG FOLLOWED BY A UNCOMMANDED SPOOL DOWN TO THE RT ENGINE. AN EMERGENCY WAS DECLARED AND A/C RETURNED TO FIELD ACCOMPLISHING A UNEVENTFUL SINGLE ENGINE LANDING. GROUND CHECK REVEALED THAT COMPRESSOR ROTOR COULD NOT BE ROTATED. ENGINE ENROUTE TO ROLLS-ROYCE CANADA FOR INVESTIGATION. RRC HAS BEEN ADVISED THAT THE FAA WILL BE ON SITE FOR THE INVESTIGATION. 2 L 7 2 4F 4 F RT T00011AT TE6CH 2005041200039 20050412 00039 SW 2005 4 12 CA050107004 1 20050105 G 6320 168459 HOUSING BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL OIL FILTER LEAKING W B EMER. DESCENT J WARNING INDICATION CL CLIMB 1 CA B12177 (CAN) DURING A TEST FLIGHT FOLLOWING AN OPS NR4 INSPECTION, THE TRANSMISSION OIL PRESSURE LIGHT ILLUMINATED AND THE OIL PRESSURE DROPPED SLIGHTLY BELOW THE RED LINE. AN IMMEDIATE DECENT WAS CONDUCTED AND UPON LANDING A MAJOR OIL LEAK WAS D ISCOVERED. THE SOURCE OF THE LEAK WAS THE MAIN TRANSMISSION FILTER HOUSING. THE FILTER WAS REMOVED AND THE O-RING WAS FO UND NICKED APPROXIMATELY .1250 INCH WIDE. THE AIRCRAFT HAD COMPLETED A 30-MINUTE POST INSPECTION GROUND RUN TWO WEEKS E ARLIER WITH NO LEAKS DETECTED. 1 G 7 1 3U 3 U H2SW E4CE 2005042500046 20050425 00046 NM 2005 4 25 CA050107005 1 20050106 G 2450 SM601BA20A1 RCCB DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE RT NACELLE ARCED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) WHILE INSPECTING NR 2 AC CONTACTOR BOX IN THE RT NACELLE DURING A HEAVY MX CHECK, DISCOVERED THAT HARDWARE THAT HO LDS WIRES ONTO THE REMOTE CONTROL CIRCUIT BREAKER (RCCB) HAD COME OFF AT 3 OF 6 ATTACH STUDS. RCCB IS FOR NR 1 ENG STAN DBY HYD PUMP. HARDWARE FOR LOAD A2 & LOAD B2 WERE LAYING ON INSIDE BOTTOM OF CONTACTOR BOX AND HARDWARE FOR LOAD C2 HAD BACKED OFF APPROX HALF WAY ON STUD. ALL 3 STUDS SHOWED SIGNS OF ARCING DAMAGE WITH GROOVES BURNED INTO STUDS FROM CURR ENT. TERMINAL ENDS ON WIRE 10006A18C-1 AT LOAD C2 ALL SHOWED SIGNS OF ARCING AND WERE BURNED AT THE POINT OF CONTACT WIT H THE STUDS. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005042500049 20050425 00049 EA 2005 4 25 CA050110002 1 20050106 G 3210 17002110 LANDING GEAR CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343A1 30015 NE RIGHT COLLAPSED W O OTHER D INFLIGHT SEPARATION LD LANDING 1 CA 12490 (CAN) FOLLOWING A REPOSITIONING FLIGHT (FERRY FLIGHT WITH NO PAX), THE RT MLG COLLAPSED ON LANDING. NOBODY WAS INJURED DURING THE INCIDENT. THE INVESTIGATION IS STILL IN PROGRESS 2 L 7 2 4F 4 F RT A21EA E15NE 2005041200040 20050412 00040 SW 2005 4 12 CA050110003 1 20050105 G 6310 212040687001 COUPLING BELL BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA INPUT DRIVE CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA A2000991 (CAN) DURING SCHEDULED INSPECTION PITTING CORROSION IN EXCESS OF .005 INCH HAS BEEN DISCOVERED. THE PATTERN AND LOCATIO N OF CORROSION PITTING CONFORMS TO PROCESS STAMP IMPRESSION (186). IT IS LIKELY THAT IMPROPER INK HAS BEEN USED DURING SHAFT OVERHAUL. OVERHAUL SHOP(S) HAVE BEEN ADVISED. THE ORIGIN OF THE STAMP IMPRESSION IS YET TO BE ESTABLISHED. 1 G 7 1 4U 4 U H4SW E22EA 2005042500050 20050425 00050 NM 2005 4 25 CA050110005 1 20050103 G 2721 82760050005 SPRING DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE RUDDER OUT OF ADJUST W O OTHER E VIBRATION/BUFFET CR CRUISE 1 CA 33343 33343 (CAN) AIRCRAFT VIBRATION REPORTED WHEN LEVEL AT 12,000 FT. SHAKING STOPPED AT POWER SETTING LESS THAN 40 PERCENT AND S PEED BELOW 150KTS. AIRCRAFT INSPECTED ON ARRIVAL AND NOFAULTS FOUND. AIRCRAFT RELEASED SUBJECT TO SATISFACTORY TEST FLI GHT, VIBRATION STILL PRESENT. RUDDER ACTUATORS, BEARINGS AND LINKAGE INSPECTED, NO FAULTS FOU ND. WHEN RUN ON EITHE R NR 1 OR 2 HYDRAULIC SYSTEM RUDDER HAD 4 PERCENT SPLIT. SPRING STRUTS ADJUSTED AS PER MM27-20-00. AIRCRAFT RELEASED FO R TEST FLIGHT, TEST FLIGHTSTISFACTORY. AIRCRAFT RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005042500052 20050425 00052 EA 2005 4 25 CA050110009 1 20050109 G 5270 864202 SENSOR DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE EMERGENCY EXIT OUT OF ADJUST W A UNSCHED LANDING N FALSE WARNING CR CRUISE 1 CA 32430 32430 (CAN) AT 20,000 FT AT MAX DIFFERENTIAL , FORWARD EMERGENCY EXIT DOOR WARNING LIGHT FLICKERED ON/ OFF , THEN CAME ON STEA DY. WHEN CABIN DIFFERENTIAL BELOW 4.5 PSI WARNING LIGHT EXTINGUISHED. AIRCRAFT RETURNED TOORIGINATING AIRPORT. MAINTENAN CE INSPECTION FOUND FORWARD EMERG EXIT DOOR SENSOR RIGGING EXCEDED MAX ALLOWABLE , GAP ADJUSTED AS PER MM. AIRCRAFT RETU RNED TO SERVICE. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005021400184 20050214 00184 NM 2005 2 14 CA050111001 1 20050105 G 3221 654581945 GUSSET BOEING 737 7372Q9 138448M NM PWA JT8 JT8D9A 52048 NE NLG CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A ROUTINE PHASE 3 CHECK (137.5 HRS.), A 2.75 INCH CRACK WAS FOUND ON THE NOSE LANDING GEAR GUSSET WHILE CAR RYING OUT SERVICE DIFFICULTY ALERT AL-2002-03.RETRACT ACTUATOR SUPPORT FITTING GUSSET REPLACED IAW SRM 51-30-2 FIG II. T IMES. 61981.7 CYCLES. 52905. 2 L 7 2 4F 4 F A16WE E2EA 2005021500004 20050215 00004 EU 2005 2 15 CA050111002 1 20050111 G 2760 SERVO AIRBUS 320 A320211 3930320 EU CFMINT CFM56 CFM565A1 NE SPOILER INTERMITTENT W O OTHER F FLT CONT AFFECTED TO TAKEOFF 1 CA 38898 14851 (CAN) FAULT: JUST PRIOR TAKE-OFF, FLIGHT RECEIVED A FLT CTL SPOILER 1 FAULT. CREW TAXIED ONTO A TAXIWAY AND PERFORMED A SUCCESSFUL RESET. HOWEVER, AT 3000 FT/210 KNOTS ON CLIMB, THE FAULT RETURNED AGAIN. FURTHER INTO THE FLIGHT IN CRUISE SLAT SYSTEM. ACTION: ACFT OUT OF SERVICE FOR INVESTIGATION. 2 L 7 2 4F 4 F RT A28NM E29NE 2005021500005 20050215 00005 NM 2005 2 15 CA050111003 1 20050111 G 2530 6253190003 OVEN BOEING 767 767375 1385217 NM GE CF6 CF680C2B6F 30025 NE MID GALLEY FIRE W F ACTIVATE FIRE EXT. A FLAME/FIRE CR CRUISE 1 CA (CAN) FAULT: JUST PRIOR TO DESCENT, SOMETHING WAS BEING COOKED IN THE MID CABIN GALLEY. AS THE F/A WAS ABOUT TO REMOVE IT, A FIRE WAS FOUND AT THE BACK OF THE OVEN. 3 FIRE EXT. WERE USED TO DOUSE THE FIRE. NO EMERGENCY WAS DECLARED, NO A DVERSE PAX REACTION. AIRCRAFT REMOVED FROM SERVICE, WIRING INSPECTION U/WAY. 2 L 7 2 4F 4 F RT A1NM E13NE 2005031400045 20050314 00045 NM 2005 3 14 CA050111004 1 20050105 G 2932 106055410 TRANSMITTER BOEING 727 727223 1384074 NM PWA JT8 JT8D15A 52051 NE HYD SYSTEM STICKING W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA 56659 56659 (CAN) 'A' SYSTEM LOW LEVEL LIGHT ILLUMINATED, 'A' SYSTEM QUANTITY DOWN TO 2 GALLONS AFTER GEAR RETRACTION. CREW RETURNED TO DEPARTURE WITHOUT FURTHER INCIDENT. MAINTENANCE ARRIVED AND INSPECTED AIRCRAFT AND FOUND 3 GALLONS INDICATING. FOUND SMALL LEAK ON B-NUT ON TAIL SKID ACTUATOR. ALSO FOUND HYDRAULIC QUANTITY TRANSMITTER STICKING ON 'A' SYSTEM RESERVOIR, INDICATION FLUCTUATED +/- 1.5 GALLONS BY TAPPING ON TRANSMITTER. TRANSMITTER REPLACED ENGINE RUNS CARRIED OUT WITH NO FU RTHER LEAKS FOUND AND INDICATION WORKING CORRECTLY. 2 L 7 3 4F 4 F A3WE E2EA 2005042500053 20050425 00053 EA 2005 4 25 CA050111005 2 20050109 G 7323 210631 GOVERNOR BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA HARTZL HCD4N3 HCD4N3A GL OVERSPEED FAILED W E ENGINE SHUTDOWN E VIBRATION/BUFFET AP APPROACH 1 CA (CAN) ON APPROACH, WHEN THE CREW TRIED TO THROTTLE BACK, THE LT ENGINE WOULD NOT GO BELOW 1000 LB. OF TORQUE. THE CREW M OVED THE THROTTLE FORE AND AFT SEVERAL TIMES BUT NO CHANGE. THE CREW DECLARED AN EMERGENCY AND SHUT DOWN THE LT ENGINE ON FINAL APPROACH. UPON INVESTIGATION BY MAINTENANCE IT WAS FOUND THAT THE OVERSPEED GOVERNOR HAD FAILED INTERNALLY. T HE OVERSPEED GOVERNOR WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 3T 4 T A14CE E4EA 5 C STC 2005042500054 20050425 00054 EU 2005 4 25 CA050112001 1 20050105 G 5610 350A25900000 WINDSCREEN UROCOP EC130 EC130B4 8680989 EU TMECA ARRIEL ARRIEL2B NE COCKPIT CRACKED W O OTHER O OTHER LD LANDING 1 CA (CAN) AFTER LANDING THE PILOT NOTICED A CRACK IN THE UPPER RT CORNER OF THE COPILOTS WINDSCREEN. THE CRACK WAS WITHIN A LLOWABLE LIMITS TO STOP DRILL AND TAPE IAW ECC MANUALS. (12CM LONG) AIRCRAFT WAS RETURNED TO SERVICE. TEMPERATURE AT T IME OF THE CRACK WAS -30C. 1 G 7 2 3U 3 U H9EU E00054EN 2005042500055 20050425 00055 CE 2005 4 25 CA050112002 1 20050110 G 5610 5042006936 WINDSHIELD BEECH 100 100BEECH 1152916 CE PWA PT6 PT6A28 EA HARTZL HCD4N3 HCD4N3A GL COCKPIT CRACKED W B EMER. DESCENT O OTHER CR CRUISE 1 CA (CAN) IN CRUISE PILOT HEARD LOUD BANG, NOTICED CO-PILOTS INNER PANE SHATTERED. STARTED DECENT TO 130000 ASL, BROUGHT C ABIN PRESSURE DOWN TO 2 PSI. LANDED AT DESIGNATION. 1 L 7 2 3T 4 T A14CE E4EA 5 C STC 2005041200036 20050412 00036 EU 2005 4 12 CA050112003 1 20050106 G 5630 SPSEC130811 WINDOW UROCOP UROCOP EC130 EC130B4 8680989 EU TMECA ARRIEL ARRIEL2B NE SLIDING DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 3759 (CAN) THE HELICOPTER PARKED OVERNIGHT OUTSIDE, WAS BEING PREPARED FOR FLIGHT, COVERS REMOVED AND DI COMPLETED. ALL WIND OWS WERE INSPECTED FOR CRACKS BECAUSE THE DAY BEFORE THE CO PILOTS WINDOW HAD CRACKED. PASSENGERS WERE LOADED AND HELIC OPTER WAS STARTED. AFTER START, PASSENGER NOTICED A 16CM LONG CRACK IN THE UPPER LT CORNER OF THE SLIDING DOOR WINDOW. AC WAS SHUT DOWN AND MFG WAS CONTACTED. THIS CRACK WAS BEYOND THE ALLOWABLE LIMIT FOR OPERATION SO THE CRACK WAS STOP DRILLED, TAPED AND THE HELICOPTER WAS RETURNED TO BASE. DOOR HAS BEEN SENT TO MFG FOR WINDOW REPLACEMENT. TEMPERATURE WAS -22C AT TIME OF THE CRACK.(THE DAY BEFORE WHEN THE CO PILOTS WINDSCREEN CRACKED THE TEMP WAS -30C.) 1 G 7 2 3U 3 U H9EU E00054EN 2005041200037 20050412 00037 CE 2005 4 12 CA050112004 1 20050103 G 2820 1009200423 TUBE BEECH 200 200BEECH 1152920 CE PWA PT6 PT6A41 52043 EA HARTZL HCB3T HCB3TN3 GL FUEL SYSTEM CHAFED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) UPON INSPECTION OF THE FUEL TRANSFER PRESSURE SWITCH, IT WAS NOTICED THAT ONE OF THE ENGINE CONTROLS WAS RUBBING A GAINST THE MAIN FEED LINE TO THE RT NAC TANK. REPLACED TUBE ASSY AND TIED BACK TELEFLEX CABLES TO PREVENT FURTHER RUBBI NG. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2005032400034 20050324 00034 NE 2005 3 24 CA050112005 2 20050109 G 7250 ENGINE AGUSTA A109 A109 0260109 EU PWC PW206C PW206C NE MALFUNCTIONED W E ENGINE SHUTDOWN R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 CA BC0368 THE ENGINE EXPERIENCED A RAPID, UNCOMMANDED DECREASE IN TORQUE IN FLIGHT, ACCOMPANIED BY AN INCREASE IN OTHER ENGINE PAR AMETERS. THE ENGINE WAS SHUT DOWN AND THE AIRCRAFT RETURNED TO BASE. SUBSEQUENT INSPECTION REVEALED POWER TURBINE BLAD E DAMAGE. PWC WILL INVESTIGATE THE INCIDEMT AND SUPPLEMENT THIS REPORT TO PROVIDE ROOT CAUSE, ONCE DETERMINED. 1 G 7 2 3U 3 U H7EU E42NE 2005042500056 20050425 00056 SW 2005 4 25 CA050112006 1 20050107 G 3610 3017393 LINE BELL 212 212 1181420 SW PWA PT6T PT6T3B 52045 NE PNEUMATIC SYS FRACTURED W E ENGINE SHUTDOWN O OTHER CR CRUISE 1 CA (CAN) THE ENGINE NO.2 POWER-SECTION EXPERIENCED AN UNCOMMANDED POWER REDUCTION IN CRUISE, FALLING BELOW GROUND IDLE.THE POWER-SECTION WAS SHUTDOWN IN FLIGHT AND THE AIRCRAFT RETURNED TO BASE. SUBSEQUENT INSPECTION REVEALED A FRACTURED P3 PN EUMATIC TUBE LEADING TO THE FUEL CONTROL (AFCU). 1 G 7 1 4U 4 U H4SW E22EA 2005042500057 20050425 00057 EA 2005 4 25 CA050112007 1 20050112 G 2163 7546911 SENSOR CNDAIR CL600 CL6002B19 1900309 EA CABIN AIR SEPARATED W K NONE O OTHER IN INSP/MAINT 1 CA NA (CAN) DURING ROUTINE PERIODIC INSPECTION, DUCT WAS DISSASEMBLED AND TEMP PROBE SCREEN WAS FOUND TRAPPED IN DUCT CHECK VA LVE, HOLDING IT OPEN. LOOSE SCREEN REMOVED. VALVE INSPECTED AND FOUND SERVICEABLE. UPSTREAM INVESTIGATION OF MOST LI KELY SOURCE SHOWS PART CORRECTLY INSTALLED. SUSPECT PRIOR FAILURE AND SUBSEQUENT PART REPLACEMENT. NO FURTHER ACTION T AKEN. 2 L 7 2 4F RT A21EA 2005042500058 20050425 00058 NM 2005 4 25 CA050113001 1 20050107 G 1430 BOLT BOEING 737 737522 138449F NM CFMINT CFM56 CFM563C 13802 EU WING SPAR LOOSE W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A POST FLT WALKAROUND MX DISCOVERED DAMAGE ON LT OUTBOARD WING LOWER SPAR CAP, AFT OF THE NR 6 LEADING EDG E SLAT. FURTHER INSPECTION REVEALED A LOOSE UNATTACHED BOLT PRESENT IN THE AREA. THIS BOLT CREATED FOD DAMAGE TO THE S PAR WHEN THE NR 6 SLAT ACTUATOR RETRACTED AND EXTENDED. THIS BOLT IS THE SAME PART AS THE ACTUATOR ATTACHMENT BOLT AND IS SUSPECTED TO HAVE BEEN LOST AND LEFT IN THE AREA DURING THE RECENT HEAVY MX CHECK COMPLETED AT TIMCO AVIATION BEFORE ACRFT DELIVERY TO CANADA. THE DAMAGE AND REPAIRS ARE CURRENTLY BEING ASSESSED AND AN INVESTIGATION TO THE CAUSE IS STIL L UNDERWAY. THIS SDR WILL BE UPDATED AS MORE INFORMATION BECOMES AVAILABLE. 2 L 7 2 4F 4 F RT A16WE E21EU 2005021400185 20050214 00185 NM 2005 2 14 CA050113002 1 20050109 G 2913 6617302 PUMP BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU NR 1 HYD SYSTEM MAKING METAL W A UNSCHED LANDING J WARNING INDICATION AP APPROACH 1 CA (CAN) DURING APPROACH TO BASE, NR 1 HYD ISO VLV AND NR 1 ENG HYD PUMP CAUTION LIGHT ILLUMINATED. NR 1 SYSTEM PRESSURE 0 PSI. STBY PRESS NORMAL AFTER SPU SELECTED ON. EMERGENCY LANDING DECLARED. AIRCRAFT STOPPED ON RUNWAY AND WAS TOWED IN. NR1 PROP COULD NOT BE ROTATED BY HAND. METAL FOUND IN CASE DRAIN AND PRESSURE FILTERS. REPLACED NR 1 EDP. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2005021500008 20050215 00008 NM 2005 2 15 CA050113003 1 20050110 G 2913 6617302 PUMP BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU HYD SYSTEM CRACKED W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA (CAN) NR2 HYDRAULIC SYSTEM FAILED DURING CLIMBOUT FROM BASE. PILOTS COMPLETED CHECKLIST AND PERFORMED AIR TURNBACK WITH UNEVENTFUL LANDING . PUMP HOUSING CRACKED WITH SUBSEQUENT FLUID LOSS INTO NACELLE. ENGINE DRIVEN PUMP REPLACED. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2005031100009 20050311 00009 NM 2005 3 11 CA050113004 1 20050112 G 2910 AN81510D UNION DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE NR 1 HYD SYS FRACTURED W O OTHER K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) DURING CRUISE, THE NR 1 HYDRAULIC SYSTEM SUFFERED A TOTAL HYDRAULIC SYSTEM FLUID LOSS. A FULL EMERGENCY LANDING W AS DECLARED INTO BASE, WHICH WAS CARRIED OUT WITHOUT FURTHER INCIDENT. UPON INSPECTION BY ENGINEERING IT WAS DISCOVERED THAT THE NR 1 HYDRAULIC PRESSURE MANIFOLD HAD SUFFERED A FAILURE OF THE AN815-10D UNION. THE AIRCRAFT MFG HAS PREVIOUS LY IDENTIFIED THIS DEFECT, AND A SYD 8-29-002 WAS ISSUED THAT PERMITS THE REPLACEMENT OF THE ALLOY UNION WITH A CORROSIO N RESISTANT STEEL UNION. AS A RESULT OF THIS INCIDENT, ALL DASH 8 / 315 SERIES AIRCRAFT OPERATED THIS AIRLINE HAVE HAD SYD 8-29-002 INCORPORATED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005031100010 20050311 00010 EU 2005 3 11 CA050113005 1 20050111 G 3220 LANDING GEAR SAAB SF340 340B 7860101 EU GE CT7TP CT79B 30030 NE ROTOL R390 R3904123F27 NE NOSE FAILED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) AFTER A NORMAL LANDING, THE AIRCRAFT TAXIED OFF THE RUNWAY AND STOPPED IN FRONT OF THE AIRPORT TERMINAL. THE ENGIN ES WERE SHUT DOWN AND THE CREW COMPLETED THEIR COCKPIT CHECKS. WHEN THE ELECTRICAL MASTER SWITCH WAS TURNED TO OFF THE NOSE UNDERCARRIAGE RETRACTED, DROPPING THE NOSE OF THE AIRCRAFT ONTO THE TARMAC. A SHORT WHILE LATER, AS THE GROUND CR EW WERE POSITIONING A TEMPORARY TAIL SUPPORT, THE MAIN UNDERCARRIAGE STARTED TO RETRACT.THE AIRCRAFT WAS RECOVERED TO A MAINTENANCE HANGAR FOR INVESTIGATION. 2 L 7 2 4T 4 T RT A52EU E8NE 6 C P31NE 2005031400046 20050314 00046 NE 2005 3 14 CA050113006 3 20050111 G 6111 BLADE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE PROPELLER TIP BROKEN W C ABORTED TAKEOFF D INFLIGHT SEPARATION TO TAKEOFF 1 CA 011390 (CAN) DURING TAKE OFF ROLL OUT, THE LT PROP STRUCK DEBRIS ON RUNWAY AND A 3 INCH PORTION OF THE TIP OF THE PROP BROKE OF F AND WENT THROUGH THE FUSELAGE JUST BEHIND AND BELOW THE AIRSTAIR DOOR. A 2 -3 INCH HOLE IN RT PROP SPINNER WAS ALSO D ISCOVERED AT THE SAME TIME. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C 3PNE 2005042500059 20050425 00059 SW 2005 4 25 CA050113007 1 20050109 G 5610 2419441004 WINDSHIELD SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE COCKPIT FAILED W O OTHER O OTHER CR CRUISE 1 CA (CAN) OUTER PANE SHATTERED IN FLIGHT ON ITS WAY TO FINAL DESTINATION. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C 3PNE 2005041200038 20050412 00038 EU 2005 4 12 CA050113008 1 20050112 G 5610 SP350110 WINDOW SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE COCKPIT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING THE BLF THE MAIN WINDOW WAS FOUND TO BE CRACKED. THE OAT WAS -34 DEGREES. IT APPEARS TO HAVE BEEN INSTALLE D WITH IMPROPER TORQUE AS THE CRACK ORIGINATED FROM THE TOP SCREW OF THE SLIP INDICATOR. 1 G 7 1 3U 3 U H9EU E19EU 2005042500060 20050425 00060 EA 2005 4 25 CA050114001 1 20050106 G 3320 BR900022 BALLAST CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE LIGHT BURNED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 CA (CAN) BURNING SMELL PRESENT IN CABIN DURING TURNAROUND. FOUND TOILET LIGHTS NOT WORKING AND SMELL CAUSED BY TOILET BALLA ST UNIT. BALLAST UNIT REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4F 4 F RT A21EA E15NE 2005042500061 20050425 00061 NE 2005 4 25 CA050114002 2 20050109 G 7200 ENGINE CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE RIGHT MALFUNCTIONED W A UNSCHED LANDING Y J ENGINE STOPPAGE WARNING INDICATION CL CLIMB 1 CA GEE873446 (CAN) ON INITIAL CLIMB, HEARD A SUDDEN AND LOUD NOISE BETWEEN 4000 AND 4500 FT AND THE RT ENGINE SHUTDOWN ITSELF IN FLT. AFTER ASSESSING THE SITUATION AND FOLLOWING QRH AND MEMORY ITEMS, THE CREW NOTIFIED THE FLT ATTENDANT, PAX AND MX OF TH E SITUATION. AN EMERGENCY WAS DECLARED AND THE CREW PROCEEDED TO DIVERT BACK TO PLACE OF DEPARTURE. AN UNEVENTFUL LAND ING FOLLOWED. MX REPLACED THE RT ENGINE. 2 L 7 2 4F 4 F RT A21EA E15NE 2005021400186 20050214 00186 NM 2005 2 14 CA050114003 1 20050112 G 2910 887087 MOTOR BOEING 757 75728A 1384976 NM RROYCE RB211 RB211535E437 54555 NE HYD ACTUATOR LEAKING W A UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA (CAN) A/C DEPARTED AND TURNED AROUND AFTER NOTICING SLOW STEADY DECLINE IN CENTER SYSTEM QUANTITY. MAINTENANCE FOUND FLU ID LEAKING FROM FUSELAGE DRAIN HOLES IN THS COMPARTMENT. UPON INVESTIGATION MAINTENANCE FOUND CENTER SYSTEM HYD MOTOR ON THIS GEARBOX LEAKING FLUID OUT MOTOR DRAIN LINE BUT MOST WAS COMING OUT THS GEAR BOX VENT HOLE ON FWD SIDE OF GEARBOX P OSSIBLY DUE TO A PARTIALLY BLOCKED MOTOR DRAIN LINE. MFG INDICATED THAT WE WILL HAVE TO REPLACE THE THS ACTUATOR DUE TO THE HYDRAULIC FLUID LEAKAGE CONTAMINATING THE ACTUATOR GEAR BOX. 2 L 7 2 4F 4 F RT A2NM E12EU 2005042000086 20050420 00086 EA 2005 4 20 CA050114004 2 20050106 G 7320 A23D047 REGULATOR PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL FUEL SYSTEM LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 317405143 (CAN) DURING AN INSPECTION NECESSARY BY AD 2004-25-16 THE FUEL REGULATOR WAS FOUND TO BE LEAKING AROUND THE SEAM. IT WA S NOT LEAKING ENOUGH TO RUN OUT THE DRAIN FOR THE PROTECTIVE COVER. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005042000087 20050420 00087 EU 2005 4 20 CA050114005 1 20050114 G 5310 350A38101891 CROSSBEAM SNIAS 350 AS350B2 8680813 EU TMECA ARRIEL ARRIEL1D1 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AN ENGINEER WAS DOING A 30 HOUR INSPECTION IAW AWD 96-156-071(B) R1 PART 1.1.THE ENGINEER DISCOVERED A BLACK LINE IN THE REGION THAT IS TO BE INSPECTED, A CLOSER LOOK, IT WAS DETERMINED THAT IT WAS CRACKED. THE TSO IS ACTUALLY TSI SI NCE THE LAST (NDT LIQUID DYE PENETRENT) INSPECTION IAW AWD. 1 G 7 1 3U 3 U H9EU E19EU 2005031100016 20050311 00016 EA 2005 3 11 CA050115001 1 20050111 G 2420 755469D IDG CNDAIR CL600 CL6002B19 1900309 EA GE CF34 CF343B1 NE GENERATOR INOPERATIVE W O OTHER H ELECT. POWER LOSS-50 PC AP APPROACH 1 CA 16558 (CAN) LOSS OF BOTH IDGS ON APPROACH FOLLOWED BY AN ADG DEPLOYMENT. NO PROBLEM WAS REPORTED WITH THE ADG. FLIGHT CREW D ECIDED TO ABORT THE APPROACH. EMERGENCY WAS DECLARED. THE CREW DECIDED TO START DE APU TO POWER THE AIRCRAFT BUSES. THE AIRCRAFT LANDED. THE IDG 2 WAS INSPECTED. OIL LEVEL WAS LOW. ANS REPORTS 2 LITERS WERE ADDED. IDG 1 OIL LEVEL WAS OK . GROUND RUNS COULD NOT DUPLICATE THE SNAG. BOTH IDG'S AND BOTH GCUS WERE REPLACED. WIRING INSPECTION INCLUDING ENGINE S AND PYLONS WITH NO ANOMALY FOUND. 2 L 7 2 4F 4 F RT A21EA E15NE 2005042000088 20050420 00088 CE 2005 4 20 CA050117001 1 20050113 G 5411 FRAME BEECH 200 B200C 1152924 CE PWA PT6 PT6A42 52043 NE HARTZL HCD4N3 HCD4N3A GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 20570 (CAN) DURING A ROUTINE INSPECTION A CRACK WAS FOUND PROPAGATING FROM THE OVAL HOLE IN THE RT FRAME AT STATION 207.125 (H ALF WAY BETWEEN THE FLOOR AND THE WINDOW). THE CRACK WAS APPROXIMATELY 1 = INCH LONG AND EXTENDED FROM THE 11 O`CLOCK P OSITION OF THE LIGHTNING HOLE TO A RIVET ON THE REINFORCEMENT PLATE. 1 L 7 2 4T 4 T A24CE E4EA 5 C STC 2005031100017 20050311 00017 CE 2005 3 11 CA050117002 1 20050106 G 3233 91929 SWITCH CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE LT MLG ACTUATOR FAILED W O OTHER J WARNING INDICATION DE DESCENT 1 CA 3248 (CAN) WHILE CARRYING OUT NIGHT LANDINGS ON A LOCAL TRAINING FLIGHT, THE LT MAIN GEAR DOWNLOCK INDICATION FAILED TO ILLUM INATE ON THE NINTH LANDING APPROACH. THE CREW CARRIED OUT AN EMERGENCY EXTENSION PROCEDURE AND LANDED SAFELY. MAINTENANC E CREW SERVICED THE LANDING GEAR IAW THE MM AND REPLACED THE LT MAIN GEAR ACTUATOR P/N 9912053-21. THE GEAR DOWNLOCK SWI TCH WHICH FAILED IS INTEGRAL TO THE ACTUATOR. A SUCCESSFUL LANDING GEAR EXTENSION AND RETRACTION TEST WAS CARRIED OUT A ND THE AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 4F 4 F A22CE E1NE 2005031100018 20050311 00018 NM 2005 3 11 CA050117003 1 20050117 G 7120 9604209 MOUNT BOMBDR DHC8 DHC8400 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU NR 1 ENGINE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING INSPECTION OF THE NR1 ENGINE MOUNT PN 96042-09, A CRACK WAS FOUND ON THE CORE ASSY PN. 19-9495-01. MFG IS I NVESTIGATING THE ISSUE. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2005031400047 20050314 00047 WP 2005 3 14 CA050117004 1 20050116 G 3244 95502675 TIRE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE NLG OVERSERVICED W C ABORTED TAKEOFF W D INADEQUATE Q C INFLIGHT SEPARATION TO TAKEOFF 1 CA (CAN) DURING TAKE-OFF ROLL, A NOSE WHEEL SHIMMY WAS FELT AND REJECTED TAKE-OFF WAS CARRIED OUT. THE AIRCRAFT RETURNED T O THE GATE WITHOUT INCIDENT. UPON INVESTIGATION, IT WAS OBSERVED THAT THE NR2 NOSE WHEEL TIRE WAS OVER-SERVICED. THE N OSE WHEEL TIRE WAS SERVICED CORRECTLY IAW MM 12-00-00. NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2 L 7 2 4F 4 F RT A6WE E9NE 2005042500062 20050425 00062 WP 2005 4 25 CA050117005 2 20050113 G 7261 8941172 ADAPTER SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP OIL FILTER CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA P54259 (CAN) A SPECIAL INSPECTION WAS CARRIED OUT TO FLEET AIRCRAFT OF SUSPECTED CRACKING OIL FILTER ADAPTERS. EDDY CURRENT ME THOD WAS USED TO DISCOVER THIS CRACKED ADAPTER . ALTHOUGH VISIBLE WITH THE NAKED EYE, INITIAL DETECTION MAY BE DIFFICUL T DUE TO THE ADAPTER LOCATION. FLEET INSPECTION IS STILL UNDERWAY.THIS ADAPTER SHOWS THE SAME PATTERN OF CRACKING AS THE ADAPTER DISCUSSED IN SDR20050105015. 2 L 7 2 4T 4 T RT A8SW E4WE 2005042500063 20050425 00063 WP 2005 4 25 CA050117006 1 20050115 G 3213 528039 AXLE CVAC 340 340CVAC 242270A WP ALLSN 501D 501D13D 03004 GL NR 1 MLG FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) UPON TAXI TO PARKING, GROUND CREWS NOTICED THE NR 1 MAIN WHEEL WAS MISSING. UPON FURTHER INVESTIGATION, IT WAS DIS COVERED THAT THE NR 1 AXLE HAD SHEARED OFF, ALLOWING THE WHEEL TO DEPART THE A/C. THE WHEEL WAS FOUND JUST OFF OF THE TA XIWAY STILL ATTACHED TO THE BROKEN PIECE OF AXLE. THE CREW WAS UNAWARE OF A PROBLEM UNTIL THEY SHUTDOWN THE AIRCRAFT AND DEPLANED. THE LOWER SHOCK STRUT ASSEMBLY WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4R 4 T 6A6 E282 2005042500064 20050425 00064 WP 2005 4 25 CA050117007 2 20050115 G 7261 8941172 ADAPTER SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP OIL FILTER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA P54090 (CAN) DURING ROUTINE ENGINE MAINTENANCE AN AME NOTICED THE LT ENGINE OIL FILTER ADAPTER WAS CRACKED AT THE MOUNTING FLAN GE. THE OIL FILTER ADAPTER WAS REPLACED. THIS OIL FILTER ADAPTER CRACKED IN THE SAME AREA AS THE ADAPTER DISCUSSED IN SD R20050105015 AND SDR20050117005. 2 L 7 2 4T 4 T RT A8SW E4WE 2005031100019 20050311 00019 NE 2005 3 11 CA050117008 2 20050111 G 7321 5001T39G39G29 FCU AMD FALCON FALCON20 2730103 EU GE CF700 CF7002D2 30010 NE ENGINE FAILED W O OTHER X J ENGINE FLAMEOUT WARNING INDICATION CR CRUISE 1 CA 304415B (CAN) AC WAS DISPATCHED FOR A TEST FLIGHT DUE TO DUAL ENGINE CHANGE. AT FL370 MAX ACCELERATION CHECK COMPLETED, WITHOUT INCIDENT. ON RETURN, ENGINE FLAMED OUT, ENGINE RELIGHT AT FL180. ENGINE FCU RIGGING, BLEED VALVES RIGGING AND AIR SE NSOR LINES WERE INSPECTED, NOTHING UNUSUAL FOUND. SECOND TEST FLIGHT WAS CONDUCTED ON 13 JAN 05. ENGINE WAS INTENTIONA LLY SHUTDOWN AT FL250 AND A RELIGHT ATTEMPTED WITH PARTIAL SUCCESS. ENGINE WOULD NOT ACCELERATE PAST 40 PERCENT N2 UNTI L AC HAD DESCENDED TO FL180. AC RETURNED WITHOUT INCIDENT AND THE AC WAS GROUNDED PENDING THE REPLACEMENT OF THE FCU CH ANGE, WHICH IS CURRENTLY IN PROCESS. 2 L 7 2 4F 4 F RT A7EU E7EA 2005031100020 20050311 00020 EU 2005 3 11 CA050117009 1 20050116 G 7603 POWER LEVER AMD FALC50 FALCON900 2700160 EU GARRTT TFE731 TFE7315BR WP ENGINE FROZEN W E ENGINE SHUTDOWN E VIBRATION/BUFFET CR CRUISE 1 CA (CAN) DURING CRUISE FLIGHT, NOTICED BY CREW THAT THE NR1 ENGINE POWER LEVER WAS FROZEN IN POSITION. THE ENGINE WAS SHUTD OWN AND AN UNEVENTFUL LANDING WAS COMPLETED. WITH WARMER TEMPERATURES, POWER LEVER WAS ABLE TO MOVE FREELY THROUGH ITS FULL RANGE OF TRAVEL. FLIGHT WAS CONDUCTED WITH NO FAULTS NOTED. ON THE 3RD FLIGHT, WHILE IN CRUISE, IT WAS NOTED THAT POWER LEVER BECAME DIFFICULT TO MOVE. ENGINE POWER WAS REDUCED TO IDLE, SCHEDULED LANDING. REVEALED WATER LEAK FROM LAV SINK SUPPLY LINE MIGRATED BELOW FLOOR ONTO NR 1 ENGINE PWR LEVER BELLCRANK, ICE ACCUMULATION WAS EVIDENT IN AREA. LEAK WAS REPAIRED, CONTAMINATED AREAS WERE CLEANED, DRIED AND LUBRICATED. ENGINE PWR LEVER FUNCTION CHECKED SERVICEABLE. 2 L 7 3 4F 4 F RT A46EU E6WE 2005021400187 20050214 00187 NE 2005 2 14 CA050117011 2 20050113 G 7210 TURBINE BLADES AEROSP ATR42 ATR42* 8680900 EU PWA 120 PW120 NE ENGINE DAMAGED W E ENGINE SHUTDOWN B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) DURING CRUISE THE PILOT REPORTED A (PUFF) FROM THE ENGINE ACCOMPANIED BY A LOSS OF TORQUE. POWER LEVER ADVANCEMEN T RESULTED IN ENGINE TEMPERATURE INCREASE AND AN OIL SMELL AND SMOKE IN THE CABIN. THE ENGINE WAS SHUT DOWN, AN EMERGEN CY DECLARED AND THE FLIGHT DIVERTED. SUBSEQUENT INSPECTION REVEALED DAMAGED TURBINE BLADES. MFG WILL INVESTIGATE THE IN CIDENT AND SUPPLEMENT THIS REPORT TO PROVIDE ROOT CAUSE, ONCE ESTABLISHED. 2 H 7 2 4T 4 T RT A53EU E20NE 2005031400048 20050314 00048 EA 2005 3 14 CA050118002 2 20050112 G 7414 10382971 BEARING CONT PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL LT MAGNETO SEIZED W A UNSCHED LANDING E R VIBRATION/BUFFET PARTIAL RPM/PWR LOSS CR CRUISE 1 CA C139805GR (CAN) AFTER TAKEOFF, IN CRUISE FLIGHT, THE PILOT NOTICED THE LT ENGINE TACHOMETER NEEDLE FLUCTUATING. SHORTLY AFTER, TH E ENGINE STARTED SURGING AND A NOTICEABLE VIBRATION WAS FELT. THE AIRCRAFT RETURNED, AN INVESTIGATION REVEALED THE LT E NGINE MAGNETO, UPPER BEARING, P/N 10-382971, HAD SEIZED IN THE DISTRIBUTOR BLOCK P/N 10 -682058. THIS IS THE FIRST INCID ENT OF THIS NATURE AND WITH OVER 15,000 HOURS ON THIS ENGINE TYPE, FEEL NOTHING COULD HAVE PREVENTED THIS OCCURRENCE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005032400133 20050324 00133 GL 2005 3 24 CA050118003 3 20050112 G 6114 A1851T BEARING RACE HARTZL HCB3T HCB3TN3 GL PROPELLER HUB CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA DURING THE NDT PROCESS OF THE PROPELLER OVERHAUL, ONE BEARING RACE, INBOARD RACE WAS DISCOVERED CRACKED. 6 C P15EA 2005042500065 20050425 00065 CE 2005 4 25 CA050118004 1 20050113 G 2160 7547512 BYPASS VALVE CESSNA 441 441 2076020 CE ACM FAILED W A UNSCHED LANDING B J SMOKE/FUMES/ODORS/SPARKS WARNING INDICATION CL CLIMB 1 CA (CAN) AFTER DEPARTURE THE DUCT OVERHEAT WARNING CAME ON.EMERGENCY CHECKLIST CARRIED OUT. SMOKE BEGAN TO EMIT FROM FLOOR INTO CABIN AND COCKPIT. AIRCRAFT RETURNED AND SHUTDOWN AS PER FIRE CHECKLIST. AIRCRAFT EVACUATED.UPON INVESTIGATION TH E AIR CONDITIONING BYPASS VALVE WAS FOUND FAILED IN THE OPEN POSITION. INSPECTION OF DUCTS AND MANIFOLDS FOUND NO FAULT S. BYPASS VALVE REPLACED AND AIRCRAFT RELEASED. 1 L 7 2 3T RT A28CE 2005021400206 20050214 00206 CE 2005 2 14 CA050118005 1 20050117 G 3211 LANDING GEAR CESSNA 421 421C 2076016 CE CONT O520 GTSIO520L 17032 SO MCAULY 3FF32 3FF32C501 GL RIGHT COLLAPSED W O OTHER O OTHER AP APPROACH 1 CA (CAN) RT LANDING GEAR COLLAPSED ON LANDING, THIS IS A PRELIMINARY REPORT MORE INFORMATION WILL FOLLOW. 1 L 7 2 3O 3 O A7CE E7CE 5 C P45GL 2005021400188 20050214 00188 EA 2005 2 14 CA050119001 1 20050117 G 3000 601970975 VALVE CNDAIR CL601 CL6012A12 1900303 EA ANTI-ICE VLV IMPROPER PART W O OTHER W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) FOLLOWING AN FAA, SUSPECTED UNAPPROVED PART REPORT, FOR A COWL ANTI-ICE VALVE PN 300013000-002, SN 1596, THREE (3) ADDITIONAL VALVES WERE FOUND TO HAVE BEEN REPAIRED AND CERTIFIED WITHOUT THE USE OF PROPER CMM. THE VALVES INVOLVED ARE S/N: 133R, 867, 691. 2 L 7 2 4F RT A21AE 2005021400203 20050214 00203 EA 2005 2 14 CA050119002 1 20050118 G 5330 6003303913 ACCESS PANEL CNDAIR CL601 CL6012A12 1900303 EA GE CF34 CF34* NE FUSELAGE DISTORTED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AC REMOVED FROM HEATED HANGAR (20 DEG C) TO RAMP (-27 DEG C) T/E OF UPPER ELEC BAY ACCESS PANEL DEFLECTED .345 FRO M AIRFRAME. FURTHER INVESTIGATION SHOWED DISTORTION THROUGHOUT PANEL WITH GREATEST DISTORTION AT CORNERS RANGING FROM . 100IN TO .345 IN. SIMILAR DISTORTION WAS FOUND ON LT DOOR. WHEN AC WAS RETURNED TO HEATED HANGAR DOORS RETURNED TO NORM AL AS THE AIRFRAME WARMED. AC 144615,144616 WERE TESTED UNDER SAME CONDITIONS, AGAIN SIMILAR RESULTS WERE NOTED. DISCU SSIONS WITH MFG THROUGH SRPSA WERE CONDUCTED WITH RECOMMENDATION THAT AC NOT BE FLOWN UNTIL DOORS IN QUESTION COULD BE REPLACED. COMPLETE LIST OF MEASURMENTS FOR 144614,144615,144616 ARE ON FILE WITH OPERATOR. 2 L 7 2 4F 4 F RT A21AE E15NE 2005021400204 20050214 00204 NM 2005 2 14 CA050119003 1 20050119 G 3260 H1010153 SWITCH BOEING 727 727233 138408A NM PWA JT8 JT8D15 52051 NE NLG INTERMITTENT W O OTHER N FALSE WARNING AP APPROACH 1 CA (CAN) ON APPROACH, LANDING GEAR CYCLED DOWN FOR LANDING. THE NOSE LANDING GEAR RED INDICATOR STAYED ILLUMINATED AND NO G REEN INDICATION WAS SEEN. GEAR WAS RE-CYCLED AND THE GEAR WAS EXTENDED WITH PROPER INDICATION. MAINTENANCE LUBED THE NOS E GEAR AND JACKED THE GEAR AND CYCLED THE GEAR NUMEROUS TIMES, NO FAULTS FOUND. THE AIRCRAFT WAS DISPATCHED, NO FAULT ON LANDING THERE. THIS IS THE SECOND OCCURENCE AND SECOND SDR FOR THE SAME AIRCRAFT AND SNAG. DUE TO ITS HISTORY, NOSE GEA R DOWN POSITION SWITCH S93 AND THE NOSE GEAR LOCKED SWITCH S96 ARETO BE REPLACED BEFORE THE AIRCRAFT WILL BEDISPATCHED.P OSSIBLE INTERNAL INTERMITTENT FAILURE TO ONE OF THE SWITCHES AND AT THE SAME TIME ALL WIRING WILL BE INSPECTED. 2 L 7 3 4F 4 F RT A3WE E2EA 2005021400205 20050214 00205 2005 2 14 CA050119005 4 20050117 G 3425 800610350 COMPUTER FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE FLT DIRECTOR FAILED W A UNSCHED LANDING H J ELECT. POWER LOSS-50 PC WARNING INDICATION CL CLIMB 1 CA (CAN) DURING CLIMB, IT WAS OBSERVED THAT THE MFDS FAILED. FLIGHT WARNING COMPUTER WAS SUSPECTED. AIRCRAFT RETURNED TO BASE AND LANDED WITHOUT INCIDENT. THE FLT WARNING COMPUTER WAS REPLACED AND CHECKED SERVICEABLE IAW MM 31-51-00. THERE WAS NO PROBLEM WITH THIS SYSTEM DURING THE SUBSEQUENT FLIGHT. 2 L 7 2 4F 4 F RT E25NE 2005031400049 20050314 00049 2005 3 14 CA050119006 4 20050117 G 3425 6228047541 DISPLAY FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE COCKPIT FAILED W A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CL CLIMB 1 CA (CAN) DURING CLIMB, IT WAS OBSERVED THAT THE NR1 AND NR2 EMUX SINGLE CHANNELS FAILED. THE AIRCRAFT RETURNED TO BASE AND LANDED WITHOUT INCIDENT. THE NR1 AND NR2 MAIN FLIGHT DISPLAY UNITS WERE REPLACED AND CHECKED SERVICEABLE IAW MM 31-61- 01. NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2 L 7 2 4F 4 F RT E25NE 2005021400207 20050214 00207 EU 2005 2 14 CA050119007 1 20050105 G 3211 LANDING GEAR BRAERO 748 HS7482B 1500248 EU RROYCE DART DART5342 EU ROTOL R4304 R2124304 EU UNKNOWN W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) ON TAKEOFF, THE LANDING GEAR WOULD NOT RETRACT AFTER BEING SELECTED. THE AIRCRAFT RETURNED TO POINT OF DEPARTURE A ND LANDED NORMALLY. THE AIRCRAFT WAS HANGARED AND A GEAR SWING CARRIED OUT, THE FAULT COULD NOT BE DUPLICATED. THE AIRCR AFT WAS RETURNED TO SERVICE. 2 L 7 2 3T 4 T A24EU A196 6 C P899 2005021400208 20050214 00208 2005 2 14 CA050119008 4 20050103 G 3418 PROBE AEROSP ATR42 ATR42300 8680920 EU PWA 120 PW120 NE HAMSTD 14SF 14SF5 NE ANGLE OF ATTACH STICKING W A UNSCHED LANDING N FALSE WARNING CL CLIMB 1 CA (CAN) AFTER DEPARTING, THE CREW OBSERVED A STICK SPURRIOUS SHAKER WARNING. THE AIRCRAFT RETURNED TO POINT OF DEPARTURE. THE ANGLE OF ATTACK PROBE WAS FOUND TO BE STICKING, MAINTENANCE LURICATED THE PROBE AND THE SYSTEM WAS CHECKED SERVICEAB LE. THE AIRCRAFT WAS RETURNED TO SERVICE. 2 H 7 2 4T 4 T RT A53EU E20NE 6 C P7NE 2005021400210 20050214 00210 EU 2005 2 14 CA050119009 1 20050112 G 2140 S200 HEATER BRAERO 748 HS7482B 1500248 EU RROYCE DART DART5342 EU ROTOL R4304 R2124304 EU CABIN FAILED W A UNSCHED LANDING O OTHER CL CLIMB 1 CA (CAN) SHORTLY AFTER DEPARTING, THE CABIN HEATER FAILED. THE CREW RETURNED THE AIRCRAFT TO POINT OF DEPARTURE. THE HEATER UNIT WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 3T 4 T A24EU A196 6 C P899 2005042500066 20050425 00066 SO 2005 4 25 CA050119010 1 20050117 G 2810 461713 VENT LINE PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL FUEL CELL LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 20174 317552099 (CAN) DURING INSPECTION, FUEL WAS NOTICED LEAKING FROM THE LT WING. THERE WAS A FUEL STAIN AROUND THE VENT TUBE. WHEN THE TUBE WAS MOVED IT BROKE OFF AT THE TANK END OF THE TUBE. BOTH IB AND OB TANKS WERE REMOVED FOR INSPECTION. THEY B OTH SHOWED SIGNS OF DETERIORATION OF THE FUEL TANK MATERIAL. IT WAS STILL HOWEVER, PLIABLE AND NOT SHOWING ANY LEAKING ELSEWHERE. THE MFG 2 YEAR INSPECTION OF THE FUEL CELLS WAS CARRIED OUT IN AUGUST OF 2003 WITH NO FAULTS FOUND. THE TA NKS WERE SHOWING A BUILD DATE OF 1974. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005042500067 20050425 00067 NM 2005 4 25 CA050119011 1 20050116 G 5620 58935734 WINDOW BOEING 737 737200 1384453 NM PWA JT8 JT8D* NE CABIN CRACKED W A UNSCHED LANDING O OTHER CR CRUISE 1 CA (CAN) RT WINDOW NR 4 PANE CRACKED, APPEARS TO BE OUTER PANE. AIRCRAFT RETURNED TO BASE. WINDOW REPLACED, AIRCRAFT RET URNED TO SERVICE. 2 L 7 2 4F 4 F A16WE E2EA 2005021400211 20050214 00211 EA 2005 2 14 CA050120003 1 20050120 G 2720 215T2429080 FITTING CNDAIR CL215 CL2156B11415 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF* NE RUDDER BROKEN W K NONE F FLT CONT AFFECTED IN INSP/MAINT 1 CA (CAN) THE RUDDER GEAR/TRIM TAB UPPER FITTING FOUND BROKEN ON A VISUAL INSPECTION. A/C 1655, HOURS 1054, CYCLES 7200 DROP S. 2 H 7 2 4T 4 T RT A14EA E20NE 6 C P7NE 2005042000090 20050420 00090 2005 4 20 CA050120004 4 20050119 G 2340 25091 CIRCUIT BOARD TEMP SENSOR FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) VIBRATION TESTING REVEALED THAT MODEL 251 UNITS MFG WITH SPRAY CONFORMAL COATING ARE NON-COMPLIANT WITH DO-160C V IBRATION CATEGORY SPECIFIED IN TSO APPROVAL. FAILURE OF UNITS COULD RESULT IN LOSS OF OUTPUT TO PASSENGER ADDRESS SPEAKE RS. TYPICAL APPLICATIONS INCLUDE PROVISION OF SEAT BELT AND NO SMOKING CHIME TONES, CABIN PAGER AUDIO, AND MUSIC AUDIO T O PASSENGER CABIN. FAILURE OF UNIT WILL BE OBVIOUS TO CREW AND/OR PASSENGERS, FAILED UNITS WILL BE REPLACED. FAILURES WILL NOT POSE THREAT TO SAFETY OF AIRCRAFT, COULD IMPACT SAFETY OF OCCUPANTS IF FAILURE OCCURS PRIOR TO OR DURING EMERGE NCY FLT CONDITION, WHERE EMERGENCY INSTRUCTIONS TO OCCUPANTS OVER CABIN PAGING SYSTEM ARE NECESSARY FOR THEIR SAFETY. 2005021400212 20050214 00212 EA 2005 2 14 CA050120005 1 20050118 G 3220 16700109 STRUT MENASCO DHAV DHC7 DHC7102 2802708 EA NLG BROKEN W O OTHER D INFLIGHT SEPARATION LD LANDING 1 CA (CAN) NLG HAD SEVERE SHIMMY, STEERING SYSTEM FAILURE UNCONTROLLED. B- MAINTENANCE FINDINGS: THE STEERIN G ACTUATOR MOUNTING PIN INTEGRATED ON THE INNER CYLINDER BODY FOUND COMPLETELY SHEARED OR RUPTURED. THE STEERING ACTUAT OR FOUND LEAKING . THE AC DID NOT EXPERIENCE AN OVERSTEER, THE OVER TRAVEL MECHANICAL STOP, FOUND IN GOOD CONDITION . C -MAINTENANCE ACTION : NLG SHOCK STRUT P/N: 16100 -43 , S/N MC-113 REPLACED, S/N MC 117 OF SAME P/N INSTALLED. STEERING ACT P/N 16700-109 , S/N MC-152 REPLACED , A SERVICEABLE ONE INSTALLED. 2 H 7 4 4T A20EA 2005042000091 20050420 00091 CE 2005 4 20 CA050120006 1 20050109 G 2910 661705213 LINE CESSNA 560 560XL 2076702 CE PWA 545 PW545A NE LT HYD SYS CRACKED W A UNSCHED LANDING K FLUID LOSS CL CLIMB 1 CA (CAN) AIRCRAFT DEPARTED. AS THE AIRCRAFT ACCELERATED THE CREW BECAME CONCERNED DUE TO A VIBRATION. THE AIRCRAFT WAS DIV ERTED TO INTERNATIONAL AIRPORT. INVESTIGATION FOUND A CRACK IN THE HYDRAULIC LINE FROM THE LT ENGINE DRIVEN HYDRAULIC P UMP WHERE IT CONNECTS TO THE INPUT PORT OF THE LT PRESSURE FILTER. A NEW LINE WAS INSTALLED. THE HYDRAULIC SYSTEM WAS SERVICED AND GROUND FUNCTION TESTS WERE COMPLETED. THE AIRCRAFT WAS RELEASED TO SERVICE. 2 L 7 2 4F 4 F RT A22CE E00059EN 2005042000092 20050420 00092 CE 2005 4 20 CA050120007 1 20050117 G 5610 10138402523 WINDSHIELD BEECH 90 C90A 1152911 CE PWA PT6 PT6A21 52043 EA HARTZL HCB3T HCB3TN3 GL COCKPIT BROKEN W B EMER. DESCENT D INFLIGHT SEPARATION CR CRUISE 1 CA (CAN) ENROUTE IN CRUISE FLIGHT AT 16000 MSL, OAT -38C THE LT WINDSHEILD SHATTERED. THE WINDSHIELD HEAT WAS OFF AND HAD N OT BEEN USED DURING THE FLIGHT. THE DEFOG AIR WAS ALSO OFF. THE CREW DECLARED AN EMERGENCY AND REQUESTED CLEARENCE AND IMMEDIATE DECENT TO 8000 MSL. THE AIRCRAFT LANDED WITHOUT FURTHER INCIDENT. THE WINDSHIELD INNER PLY WAS FOUND SHATTERE D. THE WINDSHIELD WILL BE REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. 1 L 7 2 3T 4 T RT 3A20 E4EA 6 C P15EA 2005021400213 20050214 00213 EA 2005 2 14 CA050120008 1 20050120 G 3000 601970975 ANTI-ICE VALVE CNDAIR CL601 CL6012A12 1900303 EA FAILED W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) FOLLOWING AN FAA, SUSPECTED UNAPPROVED PART REPORT, FOR A COWL ANTI ICE VALVE P/N: 300013000-002 S/N: 1596, MFG P/ N: 601-97097-5, AN ADDITIONAL VALVE S/N:691, WAS FOUND TO HAVE BEEN REPAIRED AND CERTIFIED WITHOUT THE USE OF A PROPER C MM. 2 L 7 2 4F RT A21AE 2005021500002 20050215 00002 EA 2005 2 15 CA050120010 1 20050116 G 3250 DSC167 LIMIT SWITCH DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE NLG STEERING CORRODED W K NONE O OTHER TX TAXI/GRND HDL 1 CA (CAN) ON TAXI TO GATE NOSE WHEEL STEERING FAILED CAUSING OVER STEER CONDITION. MAINTENANCE FOUND STEERING ACTUATOR LINKA GES DAMAGED. DURING TROUBLESHOOTING / REPAIRS, LIMIT SWITCH WAS FOUND WITH CONNECTOR PINS CORRODED AND BROKEN OFF. STEE RING ACTUATOR, TRANSFER TUBE, LIMIT SWITCH AND CONNECTOR REPLACED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005032400051 20050324 00051 CE 2005 3 24 CA050120011 1 20050118 G 3397 1303640448 WIRE HARNESS BEECH B300 B300B350C CE PWA PT6 PT6A60A 52043 NE HARTZL HCB4M HCB4MP3 GL LIGHTS BURNED W K NONE B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA ACFT POWERED UP FOR DAILY INSPECT IN HANGER. CABIN INDIRECT LIGHTING TURNED ON, SOON AFTER, SMOKE NOTED COMING FROM AFT HEADLINER ASSY, OUT OF CABIN DOOR. HEADLINER REMOVED & CONNECTER W2J4 WAS BURNED, & WIRING DAMAGED. IT SHOULD BE NOTE D THAT WIRING IN CLOSE PROXIMITY TO OXYGEN LINES. SYS DISABLED UNTIL FURTHER INVESTIGATION COMPLETED. FOLLOWING DAY AF T PORTION OF LIGHTING DISCONNECTED & DEFERRED FOR PARTS AVAILABILITY, FRONT PORTION REMAINS OPERATIONAL. CONSULTED WITH RAYTHEON WHO ADVISED THAT SYS HAD 3000 VOLTS, & THAT CONNECTOR DAMAGE COMMON WHEN CONNECTERS ARE MISHANDLED DURING ASSY . 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2005042000093 20050420 00093 CE 2005 4 20 CA050120012 1 20050118 G 2752 C1450046 ACTUATOR CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL TE FLAP WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) FLAP ACTUATOR MAKING NOISE DURING FLAP OPERATION. PRIMARY FLAP MOTOR LOADING THROUGH PARTIAL TRAVEL OF FLAPS. SE CONARDY FLAP SYSTEM WOULD NOT EXTEND OR RETRACED FLAPS BUT MOTOR STILL RUNNING. FLAP ACTUATOR/MOTOR ASSEMBLY REMOVED AN D UPON INSPECTION FOUND DRIVE GEARS WORN AND SECONARDARY MOTOR DRIVE SHEARED. SUPECT WORN GEARS BINDING AND LOAD STRESS ON FLAP MOTORS. NEW FLAP MOTOR ASSEMBLY INSTALLED, TESTED SERVICABLE AND AIRCRAFT RETURNED TO SERVICE. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2005042000094 20050420 00094 EU 2005 4 20 CA050120013 1 20050112 G 6230 350A37118101 SWASHPLATE SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE MAIN ROTOR WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A DAILY INSPECTION, WITH THE COLLECTIVE CONTROL RAISED, AME NOTICED THAT PROTECTIVE TEFLON TAPE WAS MISSING ON THE SWASHPLATE GUIDE (SEVERAL SQUARE INCHES IN AREA, FROM 7:30 O'CLOCK TO 2:00 O'CLOCK). CORRESPONDING WEAR STEP O F APPROXIMATELY .040 INCH HAS BEEN FOUND ON GUIDE'S SURFACE. THE WEAR HAS BEEN CAUSED BY THE BALL RING (UNIBALL) RUBBIN G ON BEAR SURFACE OF THE GUIDE. THE SWASHPLATE GUIDE HAS BEEN REPLACED AND A/C RETURNED TO SERVICE. 1 G 7 1 3U 3 U NC H9EU E19EU 2005042000095 20050420 00095 CE 2005 4 20 CA050121001 1 20050120 G 3397 CONNECTOR CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE LANDING LIGHT BURNED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) RT LND LIGHT WOULD NOT EXTING. (RELAY STUCK (ON)). RELAY WAS REPLACED, FAULT STILL PERSISTED, (SHORT) DISCOVERED TO X2. (COIL GROUND) TERM OF RELAY. BETWEEN RT GEAR WHEELWELL CNTR P/J 64 PIN W, RELAY TERM X2. WHEN P/J 62 WAS DISCON TD PIN SMALL (E) AND WIRE L590C16 SHOWED SIGNS OF OVERHEAT. PIN WAS HEAT TO PREVENT EXTRACT FROM CONN, WIRE WAS DISCOLO RED ABOUT 8 IN FROM CONN. RELAY CONTACTS REMAINED CLOSED (RELAY ENERGISED)TO PERMIT FLOW OF DC PWR TO LIGHT IS STILL ON -GOING. PIN WAS OVERHEAT COULD BE RELATED TO EXT ILLUMN OF LDNG LIGHT. NOT AN INTERNAL (SHORT) IN CONN. COIL (GROUND S EEKING) WIRE USES PIN H OF THIS CONN , SMALL (E) PWR PIN. RELAY AND LAND LIGHT ON/OFF SWITCH (S2) HAVE BEEN REPLACED. 1 L 7 2 4F 4 F A22CE E1NE 2005042000096 20050420 00096 WP 2005 4 20 CA050121002 1 20050119 G 3040 DISPLAY DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE FLIGHT SCREEN INOPERATIVE W D RETURN TO BLOCK H ELECT. POWER LOSS-50 PC TX TAXI/GRND HDL 1 CA (CAN) DURING TAXI, IT WAS OBSERVED THAT THE PRIMARY FLIGHT DISPLAY SCREEN WENT BLANK. A BURNING SMELL WAS SENSED. THE A IRCRAFT RETURNED TO THE GATE WITHOUT INCIDENT . THE PFD UNIT WAS REPLACED AND THE AIRCRAFT WAS RELEASED. DURING TAXI, THE PFD SCREEN WENT BLANK AGAIN. THE AIRCRAFT RETURNED TO THE GATE. UPON FURTHER INVESTIGATION, WATER AND MOISTURE WAS FOUND WHICH CAUSED THE UNIT TO BECOME UNSERVICEABLE. A LEAK WAS FOUND COMING FROM THE WIPER MOTOR AREA AND THE SEALANT HAD DETERIORATED. THE AREA WAS CLEANED OF ALL THE OLD SEALANT AND REPLACED. A SERVICEABLE PFD WAS INSTALLED. THE AIRC RAFT WAS RELEASED WITH NO FURTHER INCIDENT DURING SUBSQUENT FLIGHT. 2 L 7 2 4F 4 F RT A6WE E9NE 2005042500068 20050425 00068 NM 2005 4 25 CA050121003 1 20050114 G 3411 QUICK DISCONNECT BOEING 737 737242C 1384478 NM PWA JT8 JT8D9A 52048 NE PITOT LINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AC ENCOUNTERED AUTOPILOT, STATIC AIR TEMP INDICATION ANOMALIES. AUTOPILOT PITCH, ROLL COMPUTERS ALONG WITH 3 AIR DATA COMPUTERS (ADC). FOUND PITOT LINE QUICK DISCONNECT TO ADC HAD FAILED. INTERNAL BARREL THAT OPENS PITOT LINE TO ADC HAD FAILED. LINE SEALED, WOULD NOT ALLOW PITOT PRESS TO ENTER THE ADC. RESULTS WAS PITOT INFO USED BY ADC FOR AUTOPILO T GAIN CNTRL, SAT CALCULATION WAS NOT AVAILABLE. FIT NOTED THAT AIRSPEED PROBLEMS WERE NOT RECORDED AS MACH AIRSPEED IN D WAS STRICTLY PNEUMATIC. NOT INPUT OR SERVO FROM ADC FOR AIRSPEED INFO. SNAG MANIFESTED ITSELF AS AUTOPILOT, SAT RELA TED ALONE. PITOT STATIC CKS DID NOT SHOW PRBLM FOR LEAKAGE OR AIRSPEED INFO. LINE WAS REPLACED, AC OPERATED NORMALLY. 2 L 7 2 4F 4 F A16WE E2EA 2005042500069 20050425 00069 CE 2005 4 25 CA050121004 1 20050121 G 2730 0510105308 CONTROL CABLE CESSNA 172 172S 2072439 CE LYC IO360 IO360L2A EA MCAULY 1A170 1A170E GL ELEVATOR BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) UNDER A ROUTINE INSPECTION, IT WAS FOUND THAT THE FORWARD STAINLESS STEEL LOWER ELEVATOR CABLE PN 0510105-308 WAS WEARING ON THE BULKHEAD FAIRLEAD UNDER THE FLOOR AT FUSELAGE STATION 65.33, WITH A FLAT SPOT ON THE CABLE, AND WEAR THRO UGH 4 STRANDS. MM PN 172RMM08, CHAPTER 27-00-01 PAGE 201 STATES THAT FOR THIS ELEVATOR CABLE, THERE SHOULD BE NO MORE T HAN 6 BROKEN STRANDS IN A 10 INCH CABLE LENGTH. THOUGH STILL WITHIN LIMITS, THE CABLE WAS REPLACED. 1 H 7 1 3O 3 O NT 3A12 1E10 5 N P857 2005042500072 20050425 00072 SW 2005 4 25 CA050121006 1 20050118 G 6310 206040106001 SPRING BELL BELL 206 206L 1181522 SW ALLSN 250C 250C20B 03013 GL M/R DRIVE SHAFT BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA AMN10072 (CAN) DURING A 600 HRS/ 12 MONTHS INSPECTION AND LUBRICATION, OVERHAUL TECH DISCOVERED THAT IN ONE OF THE DRIVE SHAFT CO UPLINGS, A SPRING P/N 206-040-106-001 WAS BROKEN INTO THREE PIECES. BROKEN SPRING PIECES WORE HEAVILY INTO PARENT MATER IAL OF ALUMINIUM PLATE AS WELL AS INNER COUPLING. 1 G 7 1 3U 3 U H2SW E4CE 2005041200008 20050412 00008 NM 2005 4 12 CA050121007 1 20050107 G 2710 BEARING BOMBDR DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE LT AIL PULLEY WORN W K NONE O OTHER IN INSP/MAINT 1 CA 35199 35199 (CAN) DURING MAINTENANCE INSPECTION, LT AILERON CABLE PULLEY BEARING FOUND WORN AT WINGSPAR CENTER SECTION. PULLEYS REP LACED , CABLES RE-RIGGED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005042000097 20050420 00097 SO 2005 4 20 CA050121008 1 20050120 G 2421 ALU8421R ALTERNATOR PIPER PA31 PA31 7103102 SO LYC O540 IO540M1A5 41532 EA HARTZL HCE2Y HCE2YR2 GL ENGINE SHORTED W A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CR CRUISE 1 CA (CAN) AN INTERNAL SHORT IN THE ALTERNATOR CAUSED THE VOLTAGE REGULATER CIRCUIT BREAKER TO POP. DUE TO THE DESIGN OF THE SYSTEM, THE FAILURE WAS NOT ISOLATED TO THE FAILED SIDE. THE PILOT TURNED OFF ALL ELECTRIC DEVICES AND LANDED AT THE N EAREST AIRPORT. THE AIRCRAFT WAS FERRIED TO ANOTHER AIRPORT WERE THE ALTERNATOR WAS REPLACED. 1 L 7 2 3O 3 O A20SO 1E4 5 C P9EA 2005042000098 20050420 00098 NE 2005 4 20 CA050121009 2 20050116 G 7320 7898426009 ECU DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE ENGINE CORRODED W D RETURN TO BLOCK J WARNING INDICATION NR NOT REPORTED 1 CA 42014 42014 (CAN) NR1 ENGINE, ENGINE CONTROL UNIT WOULD NOT INDICATE (ON). MAINTENANCE FOUND CORROSION INSIDE AND OUTSIDE CONNECTOR J1. ECU REPLACED. (NOTE: TIMES ARE AIRCRAFT TOTAL TIME NOT ACTUAL PART TIME) 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005042000099 20050420 00099 EA 2005 4 20 CA050121010 1 20050117 G 3297 324612CC225 WIRE HARNESS DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE MLG SHORTED W O OTHER J WARNING INDICATION AP APPROACH 1 CA 30671 30671 (CAN) DURING APPROACH, WHEN GEAR SELECTED DOWN, OB ANTISKID CAUTION LIGHT ILLUMINATED. MAINTENANCE FOUND WIRE 32-46-12C C22-5 SHORTED TO SHIELD BETWEEEN 9811-P59 AND 9811-1J177 (PIN K). WIRING REPAIRED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005042000100 20050420 00100 CE 2005 4 20 CA050124001 1 20050117 G 3233 23271004 ACTUATOR LEAR 35 35LEAR 5170600 CE GARRTT TFE731 TFE73122B 01518 WP MLG INOPERATIVE W O OTHER J WARNING INDICATION AP APPROACH 1 CA (CAN) DURING APPROACH CREW SELECTED GEAR DOWN. THE LT MLG WOULD NOT EXTENDED. LT MLG RED GEAR UNSAFE LIGHT CAME ON. GE AR EMERGENCY AIR SYSTEM ACTIVATED, RED LIGHT STAYS ON. ALTERNATE MEANS USED TO CONFIRM GEAR WERE DOWN AND LOCK. AIRCRA FT LANDED AND MAINTENANCE REPLACED THE LT MLG ACTUATOR. 2 L 7 2 4F 4 F A10CE E6WE 2005042500073 20050425 00073 EU 2005 4 25 CA050124003 1 20050120 G 2730 MOTOR FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE ELEVATOR CONTAMINATED W A UNSCHED LANDING F FLT CONT AFFECTED CL CLIMB 1 CA (CAN) DURING CLIMB, IT WAS REPORTED BY THE CREW THAT ELEVATOR PITCH CONTROL WAS VERY HARD TO OPERATE. THE AUTO PILOT WA S DISENGAGED AND IN MANUAL OPERATION IT WAS STILL VERY HARD TO OPERATE. AN EMERGENCY WAS DECLARED AND THE AIRCRAFT LAND ED WITHOUT INCIDENT. FURTHER INVESTIGATION FOUND THAT THE SERVO MOTOR AND THE CONTROL CABLES HAD EXCESSIVE BUILD UP OF GREASE AND MOISTURE. THE AFFECTED AREA WAS CLEANED AND RELUBRICATED IAW SL 273 AND MM 22-11-00. THE AIRCRAFT WAS DISPAT CHED AND NO FURTHER PROBLEM DURING SUBSEQUENT FLIGHT. 2 L 7 2 4F 4 F RT E25NE 2005042500074 20050425 00074 WP 2005 4 25 CA050124004 1 20050121 G 5280 DOOR DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE MLG SEPARATED W O OTHER D INFLIGHT SEPARATION TX TAXI/GRND HDL 1 CA (CAN) UPON ARRIVAL AT GATE, THE AIRCRAFT WAS BEING INSPECTED DURING THE TURN. IT WAS OBSERVED THAT THE LT OUTER GEAR DO OR WAS MISSING. NR2 BRAKE LINE LEAKING. LOWER SIDE OF TRAILING EDGE FLAPS (F/H) DAMAGED. BROKEN HOSE SUPPORT LINK LT GEAR. BUNGEE EXTENSION SPRINGS AND BRACKETS DAMAGED. FUSELAGE SCRATCHED BELOW L2 DOOR. TSB WERE INVOLVED WITH THIS IN CIDENT. PRELIMINARY FINDINGS ARE THE AIRCRAFT DID NOT LINE UP PROPERLY WITH THE RUNWAY. PMI INFORMED ON INCIDENT. THE INVESTIGATION IS STILL UNDERWAY. 2 L 7 2 4F 4 F RT A6WE E9NE 2005042500075 20050425 00075 SW 2005 4 25 CA050124005 1 20050120 G 6410 222016001131 BLADE BELL 430 430 1182150 SW ALLSN 250C 250C40B 03032 NE TAIL ROTOR DEBONDED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) TAIL ROTOR BLADE DOUBLER DEBOND ON APPROX. 6.5 IN. FROM THE TIP OF THE DOUBLER. 1 G 7 2 3U 3 U RT H9SW E1GL 2005042500076 20050425 00076 2005 4 25 CA050124006 4 20050122 G 2370 RDAV400111 RECORDER AIRBUS 320 A320232 3930326 EU IAE V2527 V2527A5 NE CABIN BURNED W O OTHER B SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 CA (CAN) TROUBLE SHOOTING THE AFT VIDEO MONITOR NOT EXTENDING REVEALED THAT THE TAPEING UNIT WAS SHOWING SIGNS OF SMOKE DAM AGE. CLOSER INVESTIGATION REVEALED THAT THE TAPEING UNIT HAD GIVEN OF SUFFICIENT HEAT TO CAUSE BURNING OF THE INSULATION BLANKET DIRECTLY ABOVE. THIS IS THE SECOND SUCH OCCURRENCE ON THIS AIRCRAFT (REF SDR 20040223001) SB 613-996-9178 DEALS WITH THIS PARTICULAR ISSUE BUT THE SUPPLY OF THE MODIFIED UNITS HAS BEEN SLOW. ONLY 7 UNITS HAVE BEEN MADE AVAILABLE ON AN EXCHANGE BASIS TO DATE WHICH IS HALF THE QUANTITY REQUIRED FOR THE AIRCRAFT. NO COMPLAINTS FROM PASSENGERS REGARDING SMOKE AND NO CIRCUIT BREAKERS POPPED. 2 L 7 2 4F 4 F RT A28NM E40NE 2005042500077 20050425 00077 EU 2005 4 25 CA050124007 1 20050121 G 7500 30748451 TRANSFER TUBE AMD FALC50 FALCON900 2700160 EU GARRTT TFE731 TFE7315BR WP BLEED AIR SYS SEPARATED W K NONE O OTHER IN INSP/MAINT 1 CA P101120C (CAN) TUBE FOUND SEPARATED AND PROTRUDING FROM BEHIND PANEL AT BOTTOM OF BYPASS DUCT. PIPE HAD CRACKED/FATIGUED AND SEPA RATED AT ONE END AND IN THE MIDDLE OF AN UNSUPPORTED SECTION. THE OPEN TUBE RESULTED IN A LOW PRESSURE COMPRESSOR BLEED AIR LEAK THAT COULD BE SEEN IN LOSS OF TEMPERATURE MARGIN BETWEEN LAST TWO PERFORMANCE PLOTS IN ENGINE LOG BOOK. IT IS SUSPECTED THE TUBE SEPARATED MORE THAN 300 HOURS PREVIOUSLY. ENGINE WAS NOT TEMPERATURE LIMITED. ENGINE WAS BEING REMO VED FOR CORE OIL CARBON SEAL FAILURE. TUBE FAILURE IS NOT CONSIDERED TO HAVE BEEN A CONTRIBUTORY FACTOR. A VIBRATION IN SPECTION WAS REQUESTED BY MFG, IN ADDITION TO THE REPAIR THE ENGINE WAS REMOVED FOR. ENGINE FORWARDED TO O/H FACILITY . 2 L 7 3 4F 4 F RT A46EU E6WE 2005041200017 20050412 00017 2005 4 12 CA050124008 4 20050118 G 3422 40001728513 HSI PIPER PA31 PA31325 7103105 SO LYC O540 TIO540F2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL COCKPIT STUCK W O OTHER I FLT. ATTITUDE INST. AP APPROACH 1 CA (CAN) NR1 HSI NEEDLE STUCK ON NORTHERN HEADING. NR1 ENGINE STARTED TO SURGE. ENGINE DROPPED TO 20 INCHES OF MANIFOLD P RESSURE. AIRCRAFT RETURNED TO BASE SAFELY. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005042000101 20050420 00101 WP 2005 4 20 CA050124009 1 20050122 G 3260 WARNING LIGHT DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE NLG ILLUMINATED W O OTHER N FALSE WARNING CR CRUISE 1 CA (CAN) CREW OBSERVED NOSE GEAR LIGHT ILLUMINATED WITH THE GEAR HANDLE IN THE UP POSITION. HEARD A GRINDING NOISE WITH VI BRATION FELT. THE AIRCRAFT CONTINUED AND LANDING WITHOUT INCIDENT. NUMEROUS NOSE WHEEL RETRACTIONS/EXTENSIONS WERE CAR RIED SUCCESSFULLY. THE NOSE GEAR TRUNNION WAS LUBRICATED AND THE NOSE GEAR WAS FOUND SERVICEABLE IAW MM 32-30-00. NO F URTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2 L 7 2 4F 4 F RT A6WE E9NE 2005042000103 20050420 00103 EA 2005 4 20 CA050124011 2 20050109 G 7323 GOVERNOR BEECH 100 A100 1152915 CE PWA PT6 PT6A28 EA HARTZL HCD4N3 HCD4N3A GL OVERSPEED DEFECTIVE W E A ENGINE SHUTDOWN UNSCHED LANDING E VIBRATION/BUFFET DE DESCENT 1 CA 50153 (CAN) DURING DESCENT, ENGINE POWER COULD NOT BE REDUCED BELOW 1000 LBS TORQUE. THE AIRCRAFT DIVERTED TO BASE AND THE PI LOT SHUT THE ENGINE DOWN IN FLIGHT AND ACCOMPLISHED A SINGLE ENGINE LANDING. SUBSEQUENT INSPECTION DETERMINED A DEFECTI VE OVERSPEED GOVERNOR AS THE SOURCE OF THE PROBLEM. 1 L 7 2 3T 4 T A14CE E4EA 5 C STC 2005042100001 20050421 00001 EA 2005 4 21 CA050124012 2 20050114 G 7230 304865101 BLADE PWC BOMBDR DHC8 DHC8402 1390042 NM PWC 150 PW150A EA ROTOL R408 CR4086123F17 EU COMPRESSOR BENT W O OTHER D INFLIGHT SEPARATION DE DESCENT 1 CA FA0160 (CAN) PILOT NOTICED AN UNUSUAL NOISE SUSPECTING A FWD CARGO DOOR SEAL PROBLEM. ALL A/C AND ENGINE PARAMETER SEEM NORMAL . NOISE THEN DISAPPEARED TO CAME BACK DURING DESCENT, WITH STILL NO AIRCRAFT OR ENGINE PARAMETER VARIATION. PILOT LANDE D A/C NORMALLY. AFTER INVESTIGATION RT ENGINE FOUND WITH ONE FIRST STAGE COMPRESSOR ROTOR BLADE BENT. SOFT FOD INSPECTIO N C/OUT IAW AMM. DAMAGE SUSPECTED CAUSED BY ICE DUE ICE FOUND IN NACELLE LOWER COWL. DAMAGE FOUND WITHIN AMM, UNUSUAL COMPRESSOR NOISE NOT PERMITTED. IAW MFG SL AND SPECIAL FLIGHT PERMIT AUTHORIZATION AC WAS FERRIED BACK TO MAINT BASE F OR RT ENGINE CHANGE. 2 H 7 2 4T 4 T RT A13NM E00062EN 6 C P17BO 2005042000104 20050420 00104 SW 2005 4 20 CA050124013 1 20050117 G 3244 TIRE SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE MLG DISINTEGRATED W C ABORTED TAKEOFF D INFLIGHT SEPARATION TO TAKEOFF 1 CA (CAN) UPON ROTATION IN APPROXIMATELY -35 DEGREE CELSIUS THE RT GEAR TIRES BLEW UP CAUSING VIBRATION AND A PULL OF THE RT . PILOT ABORTED TAKE OFF AND AIRCRAFT WAS TOWED OFF RUNWAY. THE CAUSE IS LEANING TO THE BELIEF THAT THE MFG (RETREAD) TIRES HAVE A STIFFER SIDEWALL AND THAT AIR PRESSURES WERE NOT MAINTAINED FOR THE ENVIRONMENT THAT THEY WERE FLYING TO IN STEAD OF THE ENVIRONMENT THAT THEY WERE LEAVING FROM. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C 3PNE 2005021500003 20050215 00003 NM 2005 2 15 CA050125000 1 20050123 G 2915 1849 PRESSURE VALVE DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE MANIFOLD FAULTY W A UNSCHED LANDING M J OVER TEMP WARNING INDICATION CL CLIMB 1 CA O409A (CAN) THE CREW REPORTED , AFTER GEAR UP SELECTION , LOST NR 2 MAIN AND STANDBY PRESSURE (SPU ON). AFTER APPROXIMATELY 3 MINUTES THEY RECEIVED NR 2 STANDBY PUMP HOT LIGHT. ON SHORT FINAL NR 2 MAIN PRESSURE RETURNED BUT NR 2 STANDBY HOT LIGH T REMAINED ON EVEN THOUGH NR 2 STANDBY PUMP CIRCUIT BREAKER WAS PULLED . IT ONLY WENT OUT WHEN BOTH ENGINES FEATHERED A FTER APPROXIMATELY 2 MINUTES. THE MAINTENANCE CREW AFTER TROUBLESHOOTING DETERMINED THE PRESSURE RELIEF VALVE TO BE AT F AULT AND REPLACED . 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005042500078 20050425 00078 SW 2005 4 25 CA050125001 1 20050121 G 7712 206075739125 INDICATOR BELL 206 206B 1181511 SW ALLSN 250C 250C20B 03013 GL TORQUE MALFUNCTIONED W O OTHER O OTHER CL CLIMB 1 CA (CAN) AFTER THE AIRCRAFT WAS COLD SOAKED FOR OVER AN HOUR, THE GUAGE RESPONSE WAS VERY SLOW WHILE THE ENGINE OIL TEMP WA S ALLOWED TO STABILIZE AT 60 DEG. 1 G 7 1 3U 3 U H2SW E4CE 2005042500079 20050425 00079 SW 2005 4 25 CA050125002 1 20050121 G 7712 206075739123 INDICATOR BELL 206 206L4 1182110 SW TORQUE INOPERATIVE W O OTHER O OTHER CL CLIMB 1 CA (CAN) AFTER THE AIRCRAFT WAS COLD SOAKED FOR OVER AN HOUR, THE GAGE RESPONSE WAS VERY SLOW WHILE THE ENGINE OIL TEMP WAS ALLOWED TO STABALIZE AT 60 DEG. 1 G 7 1 3U NC H2SW 2005042000105 20050420 00105 EU 2005 4 20 CA050125004 1 20050123 G 3810 LINE FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE GALLEY BURST W D RETURN TO BLOCK O OTHER TX TAXI/GRND HDL 1 CA (CAN) IT WAS OBSERVED BY THE FLIGHT ATTENDANTS THAT A WATER LEAK WAS FOUND COMING FROM THE FWD GALLEY AREA. THE MANUAL SHUT-OFF VALVE WAS CLOSED BUT THE LEAK WAS STILL OBSERVED. THE AIRCRAFT RETURNED TO THE GATE AND A WATER LINE UNDER THE FWD GALLEY HAD BURST. THE LINE WAS REPLACED AND NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2 L 7 2 4F 4 F RT E25NE 2005042000106 20050420 00106 EU 2005 4 20 CA050125005 1 20050124 G 4950 APU FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE APU BAY SMOKE W D RETURN TO BLOCK B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) AFTER START SEQUENCE AND COMMENCE TAXI, THE CABIN CREW OBSERVED A LIGHT SMOKE COMING THROUGH THE AIR VENT. THE AP U WAS SHUTDOWN WHICH SEEMED TO DISSAPATE THE SMOKE. AS A PRECAUTION THE AIRCRAFT RETURNED TO THE GATE AND PASSENGERS DI SEMBARKED. MAINTENANCE STARTED THE AIRCRAFT USING A GROUND START UNIT. NO SMOKE WAS OBSERVED AFTER START UP. THE AIRC RAFT WAS RELEASED AND NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2 L 7 2 4F 4 F RT E25NE 2005042000107 20050420 00107 CE 2005 4 20 CA050125006 1 20050114 G 3213 57411405 LINK CESSNA 441 441 2076020 CE GARRTT TPE331 TPE33110 01514 WP LT MLG WRONG PART W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) MLG WAS REMOVED FOR MODIFICATION IAW STC. NR SA00487SE. ON RE-INSTALLATION THE MLG TRAILING LINK P/N 5741140-5 - L T WAS INSTALLED ON THE RT MLG, AND P/N 5741140-6 RT WAS INSTALLED ON THE LT MLG. THIS ERROR WAS NOT OBVIOUS DURING LANDI NG GEAR FUNCTIONAL RETRACTION AND EXTENSION TESTING. THE GEAR RETRACTED AND LOCKED UP NORMALLY, EXTENDED AND LOCKED DOWN NORMALLY. THE AIRCRAFT FLEW WITH NO LOSS OF AIRSPEED OR ANY INDICATION OF AIRFRAME BUFFET DUE TO THE TRAILING LINKS HAN GING BELOW THE WHEEL WELLS. THIS CONFIGURATION WAS REVERSED AND THE AIRCRAFT RETURNED TO SERVICE. IT IS VERY EASY TO MA KE THIS ASSEMBLY ERROR, WHICH RESULTS IN A LANDING GEAR CONFIGURATION MOST TECHNICIANS WOULD THINK (COULD NOT HAPPEN). 1 L 7 2 3T 4 T RT A28CE E4WE 2005042000108 20050420 00108 NM 2005 4 20 CA050125007 1 20050121 G 5330 SKIN BOEING 737 737296 1384486 NM PWA JT8 JT8D9A 52048 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AN OUTER FUSELAGE CRACK WAS FOUND DURING A PHASE EIGHT CHECK AT STRINGER 16L, STATION 727+14.5 APPROXIMATELY 1.5 I NCHES IN LENGTH. FUSELAGE CRACK REPAIRED IAW REO-L00889 REV 1R TIMES - 59761:05 HOURS AND 54470 CYCLES 2 L 7 2 4F 4 F RT A16WE E2EA 2005042000109 20050420 00109 EA 2005 4 20 CA050125008 1 20050119 G 5242 6003303913 ACCESS DOOR CNDAIR CL601 CL6012A12 1900303 EA GE CF34 CF341A NE E/E BAY DISTORTED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THIS AIRCRAFT WAS INSPECTED AND TESTED AND FOUND TO EXHIBIT UNACCEPTABLE NOSE AVIONICS ACCESS DOOR DEFORMATION IN EXTREME COLD CONDITIONS. THE DEGREE OF DOOR CORNER CURLING EXCEEDS THE MANUFACTURERS LIMITS FOR SKIN WAVINESS FOR RVSM C ERTIFICATION. (THIS CONDITION WAS PREVIOUSLY IDENTIFIED SDR 20050119002) 2 L 7 2 4F 4 F RT A21AE E15NE 2005042000110 20050420 00110 EA 2005 4 20 CA050125009 1 20050119 G 5242 6003303913 ACCESS DOOR CNDAIR CL601 CL6012A12 1900303 EA E/E BAY DISTORTED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THIS AIRCRAFT WAS INSPECTED AND TESTED AND FOUND TO EXHIBIT UNACCEPTABLE NOSE AVIONICS ACCESS DOOR DEFORMATION IN EXTREME COLD CONDITIONS. THE DEGREE OF DOOR CORNER CURLING EXCEEDS THE MANUFACTURERS LIMIT FOR SKIN WAVINESS FOR RVSM CE RTIFICATION. THIS CONDITION WAS PREVIOUSLY IDENTIFIED (SDR 20050119002). 2 L 7 2 4F RT A21AE 2005042500080 20050425 00080 NM 2005 4 25 CA050125010 1 20050122 G 5330 SKIN BOEING 737 7372Q9 138448M NM PWA JT8 JT8D9A 52048 NE FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) AN OUTER FUSELAGE CRACK WAS DISCOVERED AT STRINGER S-18R, STATION 750, APPROXIMATELY 1.125 INCHES LONG. THE CRACK WAS REPAIRED IAW SRM 53-30-3 FIGURE 48, DETAIL IX AND DETAIL XIX. 2 L 7 2 4F 4 F A16WE E2EA 2005042500081 20050425 00081 EA 2005 4 25 CA050125011 1 20050119 G 5242 6003303913 DOOR CNDAIR CL600 CL600* EA LYC ALF502 ALF502* 41580 EA E/E BAY DEFORMED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) THIS AIRCRAFT WAS INSPECTED, TESTED AND FOUND TO EXHIBIT UNACCEPTABLE NOSE AVIONICS ACCESS DOOR DEFORMATION IN EXT REME COLD CONDITIONS. THE DEGREE OF DOOR CORNER CURLING EXCEEDS THE MFG LIMIT FOR SKIN WAVINESS FOR RVSM CERTIFICATION. THIS CONDITION WAS PREVIOUSLY IDENTIFIED ON AIRCRAFT 144614, (SDR 20050119002). 2 L 7 2 4F 4 F RT A21EA E6NE 2005042500082 20050425 00082 CE 2005 4 25 CA050125012 1 20050121 G 3246 1368520629 BEARING BFGOODRICH BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL WHEEL ASSY FAILED W O OTHER D INFLIGHT SEPARATION TX TAXI/GRND HDL 1 CA APR921876 (CAN) AIRCRAFT DEPARTED ENROUTE AT TEMPERATURE AT 5 DEG C. AIRCRAFT ARRIVED WITHOUT ANY INCIDENT, WHEN AIRCRAFT WAS AT THE PAX TERMINAL IT WAS NOTICED THAT THE RT OB MAIN WHEEL ASSEMBLY WAS MISSING. INSPECTION REVEALED THAT THE WHEEL BEA RINGS HAD DISINTEGRATED AND ALLOWED THE WHEEL ASSEMBLY TO FALL OFF THE WHEEL AXLE. THE WHEEL ASSEMBLY WAS FOUND ON THE RUNWAY AT ORIGINATING AIRPORT. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2005042500083 20050425 00083 CE 2005 4 25 CA050125013 1 20050120 G 8011 535539 BEARING CAGE CESSNA 421 421B 2076014 CE CONT O520 GTSIO520H 17032 SO MCAULY 3AF34C 3AF34C92 GL STARTER ADAPTER DISINTEGRATED W E ENGINE SHUTDOWN E K VIBRATION/BUFFET FLUID LOSS IN INSP/MAINT 1 CA (CAN) ATTEMPT TO START RT ENGINE AT EXTREME COLD TEMP. ENGINE BACKFIRED, STARTER ADAPTER SHAFT BRG CAGE DISINTEGRATED, SHAFT OIL SEAL BLEW. 1 L 7 2 3O 3 O A7CE E7CE 5 C P22EA 2005042500084 20050425 00084 WP 2005 4 25 CA050125014 1 20050111 G 5250 AM767BA LATCH DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE LAVATORY DOOR BROKEN W O OTHER O OTHER CR CRUISE 1 CA (CAN) WHILE IN FLT, A PERSON WENT TO THE FWD LAVATORY, ONCE INSIDE, WAS UNABLE TO OPEN DOOR. DOOR HANDLE WOULD TURN, BU T DOOR REMAINED CLOSED. PERSON WAS BASICALLY STUCK INSIDE. CAPTAIN AUTHORIZED CABIN CREW TO USE CRASH AXE IN ORDER OPEN THE DOOR. FORWARD LAVATORY WAS PUT ON MEL. LATER, MAINTENANCE REMOVED THE DOOR AND REMOVED THE DOOR HANDLE MECHANISM. I T WAS FOUND THAT THE DOOR LOCK SLIDER PLATE WAS BROKEN, MAKING IT POSSIBLE FOR THE DOOR LOCK SLIDER LEVER TO COME OUT OF THE SLIDER LOCK PLATE, THE DOOR BEING IN THE CLOSED POSITION (SLIDER LOCK PLATE ENGAGED IN THE DOOR FRAME RECEPTACLE) M AKING IT IMPOSSIBLE TO OPEN THE DOOR BY ROTATING THE DOOR HANDLE. MX REPLACED THE DOOR ASSY. 2 L 7 2 4F 4 F RT A6WE E9NE 2005042000111 20050420 00111 EA 2005 4 20 CA050125016 1 20050122 G 5730 8711802005 PANEL DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE HAMSTD 14SF 14SF15 NE WING LOOSE W K NONE P NO WARNING INDICATION IN INSP/MAINT 1 CA 31794 (CAN) DURING ROUTINE MAINTENANCE INSPECTION VISUALLY NOTICED SCREW HEADS PROTRUDING ABOVE WING SURFACE ON WING STRESS PA NEL (DRYBAY ACCESS). APPROXIMATELY 50 PERCENT OF THE ATTACH SCREWS (CSP318-5) WERE FOUND LOOSE ON ACESS PANEL NR 522AT, ALSO SOME LOOSE SCREWS FOUND ON DRYBAY/WING CENTER BOX ACESS PANELS 521AT AND 622AT. AIRCRAFT HAS APPROX. 1980-2372 CYC LES SINCE PREVIOUS RE-TORQUE OF THESE SCREWS AFTER MAINTENANCE ACCESS. ALL SCREWS ON THESE PANELS RE-TORQUED. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005042000112 20050420 00112 SW 2005 4 20 CA050125017 1 20050125 G 6710 212001181001 COLLECTIVE STICK BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA THROTTLE GRIPS BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 28648 (CAN) THE ENGINEER WAS ABOUT TO GREASE THE SWASHPLATE. TO GREASE SOME OF THE ZERK FITTINGS IT IS EASIER TO LIFT THE COLL ECTIVE CONTROL STICK UP. THE ENGINEER WAS MOVING THE COLLECTIVE CONTROL STICK UP WHEN THE RIDGED TUBE BENT AND BROKE IN TWO. THE BREAKAGE OCCURED BETWEEN THE TWO THROTTLE GRIPS WHERE THERE IS A SLOT IN THE TUBE FOR THE THROTTLE CONTROL. 1 G 7 1 4U 4 U H4SW E22EA 2005042000113 20050420 00113 NE 2005 4 20 CA050126001 2 20050112 G 7200 ENGINE AIRTRC AT400 AT402A 0390206 SW PWA PT6 PT6A11AG 52043 NE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING A SPRAYING RUN, THE ENGINE EXPERIENCED AN UNCOMMANDED POWER REDUCTION. THE AIRCRAFT CLIPPED TREES AND IMPA CTED THE GROUND. MFG WILL PARTICIPATE IN THE INVESTIGATION OF THE INCIDENT AND WILL SUPPLEMENT THIS REPORT TO PROVIDE R OOT CAUSE, ONCE ESTABLISHED. 1 L 7 1 3T 3 T NC A17SW E4EA 2005042000114 20050420 00114 GL 2005 4 20 CA050126002 1 20050125 G 2910 9555805 PUMP BOMBDR BD700 BD7001A10 1390006 GL HYD SYSTEM FAILED W O OTHER O OTHER DE DESCENT 1 CA (CAN) FOR THE RELIGHT PROCEDURES FOR THE RT ENGINE, THE RT HYD DCMP HAD BEEN TURNED ON PRIOR SHUTDOWN. AFTER 5 MINUTES OF DRIFT DOWN AT 185 KTS, AROUND 40000 FT, AP SYNC WAS PRESSED AND ACCELERATED TO 250. SOMEWHERE AROUND THAT TIME, THE LT GEN DROPPED OFF LINE AND WE WERE LEFT WITH ESSENTIAL POWER ONLY (ALSO LOSS OF YAW DAMPER). THE PNF WENT THRU THE QRH AND RESET THE LT GEN, THEN POWER WAS RESTORED, LEAVING A CYAN ELECTRICAL FAULT MSG. ALSO THE RT HYD DCMP HAD FAILED FO R GOOD. A/C LANDED WITHOUT FURTHER INCIDENT. 2 L 7 2 4F RT T00003NY 2005042000115 20050420 00115 SO 2005 4 20 CA050126003 2 20050125 G 8530 654004 EXHAUST VALVE CESSNA 150 150L 2071826 CE CONT O200 O200A 17020 SO MCAULY 1A102 1A102OCM GL ENGINE CORRODED W A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CL CLIMB 1 CA 635636A (CAN) POOR ACCELERATION AND SLUGGISH PERFORMANCE DURING POWER UP AND DIFFERENT POWER SETTINGS. WHEN APPLYING POWER, ENGI NE STUMBLED. INITIALLY SUSPECTED CARB ICING BUT GROUND CHECK RESULTED IN SAME FAILURE TO PRODUCE POWER. PRELIMINARY D/P CHECK SHOWED LOW POWER ON 3 OF 4 CYLINDERS (42-52 PSI) CYLINDERS DISMANTLED AND FOUND EXHAUST VALVES CORRODED AND DETER IORATED REF: SB M90-13. THIS SB SUGGESTS THAT VALVE STEMS, AT TIME OF OVERHAUL, SHOULD REQUIRE 100% REPLACEMENT. THIS IS THE SECOND FIELD EXPERIENCE OF SEVERE CORROSION 400+ HOURS PRIOR TO OVERHAUL. 1 H 7 1 3O 3 O 3A19 E252 5 N P918 2005042000116 20050420 00116 NE 2005 4 20 CA050126004 2 20050117 G 7321 81850012 FCU CESSNA 500 550 2076604 CE PWA 530 PW530A NE ENGINE MALFUNCTIONED W O OTHER X J ENGINE FLAMEOUT WARNING INDICATION DE DESCENT 1 CA (CAN) THE ENGINE EXPERIENCED AN UNCOMMANDED INFLIGHT SHUTDOWN FOLLOWING POWER REDUCTION FOR DESCENT. A RELIGHT ATTEMPT WAS UNSUCCESSFUL. SUBSEQUENT INSPECTION REVEALED A MALFUNCTIONING FUEL CONTROL UNIT. MFG WILL INVESTIGATE THE INCIDENT AND WILL SUPPLIMENT THIS REPORT TO REFLECT ROOT CAUSE, ONCE ESTABLISHED. 1 L 7 2 4F 4 F A22CE E00053EN 2005042500085 20050425 00085 NE 2005 4 25 CA050126005 2 20050114 G 7200 BLADES PWA PT6 PT6A114A 52043 NE ENGINE DAMAGED W O OTHER O OTHER LD LANDING 1 CA PC0592 (CAN) ON LANDING ENGINE TEMPERATURE WAS SEEN TO INCREASE, FOLLOWED BY AN UNCOMMANDED REDUCTION IN POWER. SUBSEQUENT IN SPECTION REVEALED COMPRESSOR TURBINE AND POWER TURBINE BLADE DAMAGE. MFG WILL MONITOR THE INVESTIGATION OF THE INCIDENT AND WILL SUPPLIMENT THIS REPORT TO PROVIDE ROOT CAUSE, ONCE DETERMINED. 3 T E4EA 2005042500086 20050425 00086 NM 2005 4 25 CA050126006 1 20050119 G 7600 87620130101 SPRING STRUT DHAV DHC8 DHC8201 2809001 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE NR 1 ENGINE BROKEN W E D ENGINE SHUTDOWN RETURN TO BLOCK E Y VIBRATION/BUFFET ENGINE STOPPAGE TX TAXI/GRND HDL 1 CA 14368 (CAN) NR 1 ENGINE SHUTDOWN ON GROUND RUN DUE TO BROKEN CONTROL SPRING STRUT. UNABLE TO CONTROL THE ENGINE, SHUTDOWN BY THE TEE HANDLE. MFG IS INVESTIGATING THE EVENT. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005042500087 20050425 00087 NE 2005 4 25 CA050126007 2 20050119 G 7200 ENGINE AEROSP ATR42 ATR42* 8680900 EU PWA PW121 PW121 52124 NE FLUCTUATES W E A ENGINE SHUTDOWN UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 CA 120602 (CAN) THE ENGINE EXPERIENCED TORQUE FLUCTUATIONS IN CRUISE FOLLOWED BY AN UNCOMMANDED REDUCTION IN PROPELLER SPEED TO 12 PERCENT. THE PILOT SHUT THE ENGINE DOWN AND DIVERTED THE FLIGHT. MFG WILL MONITOR THE INVESTIGATION OF THE INCIDENT A ND WILL SUPPLIMENT THIS REPORT TO PROVIDE ROOT CAUSE, ONCE ESTABLISHED. 2 H 7 2 4T 4 T RT A53EU E20NE 2005041200022 20050412 00022 CE 2005 4 12 CA050126008 1 20050122 G 3297 MS3126F1210P CONNECTOR BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE MLG CORRODED W O OTHER J WARNING INDICATION AP APPROACH 1 CA (CAN) DURING APPROACH CREW SELECTED GEAR DOWN HOWEVER, THE GEAR CONTROL C/B OPENED AND WOULD NOT RESET. MANUAL EXTENSIO N COMPLETED. MAINTENANCE FOUND THE CONNECTOR BEWTEEN THE NOSE GEAR ACTUATOR AND THE FRAME INTERNALLY CORRODED. THE CONN ECTOR WAS REPLACED, GEAR SWUNG AND THE AIRCRAFT RELEASED. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005042000117 20050420 00117 NE 2005 4 20 CA050126009 2 20050124 G 7200 ENGINE LEAR 60 60LEAR 5170707 CE PWA 305 PW305A 52128 NE LEAKING W E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION CR CRUISE 1 CA CA0319 (CAN) IN CRUISE, THE ENGINE OIL PRESSURE REDUCED ACCOMPANIED BY A LOW OIL PRESSURE INDICATION. THE PILOT SHUT THE ENGIN E DOWN, DECLARED AN EMERGENCY AND DIVERTED THE FLIGHT. SUBSEQUENT INSPECTION REVEALED EXTERNAL OIL LEAKAGE. MFG WILL IN VESTIGATE THE EVENT AND WILL SUPPLEMENT THIS REPORT TO PROVIDE ROOT CAUSE, ONCE ESTABLISHED. 2 L 7 2 4F 4 F RT A10CE E35NE 2005042000118 20050420 00118 NE 2005 4 20 CA050126010 2 20050120 G 7200 CF7002D2 ENGINE AMD FALCON FALCON20 2730103 EU GE CF700 CF7002D2 30010 NE NR 1 FOD W K NONE C F.O.D. IN INSP/MAINT 1 CA 304415B (CAN) WHILE DOING THE DAILY INSPECTION, TECHNICIAN NOTICED SUBSTANTIAL FOREIGN OBJECT DAMAGE TO THE BYPASS FAN AND THE F IRST STAGE COMPRESSOR BLADES OF THE ENGINE INSTALLED IN POSITION NR 1. AIRCRAFT HAD JUST COMPLETED 9.6 HOURS OF FLYING WITHOUT ANY INDICATION OF POWER LOSS. AIRCRAFT LANDED, THE FREIGHT WAS OFF LOADED AT THE FACILITY. AIRCRAFT ENGINES WE RE STARTED AND THE AIRCRAFT WAS TAXIED BACK TO THE HANGAR FOR ROUTINE MAINTENANCE. ENGINE WAS REMOVED AND RETURNED FOR INVESTIGATION AND REPAIR. 2 L 7 2 4F 4 F RT A7EU E7EA 2005042000119 20050420 00119 CE 2005 4 20 CA050126011 1 20050120 G 3233 11238002223 ACTUATOR BEECH 1900 1900C 1154161 CE PWA PT6 PT6A65B 52043 EA HARTZL HCB4M HCB4MP3 GL NLG LEAKING W O OTHER J WARNING INDICATION LD LANDING 1 CA (CAN) NOSE LANDING GEAR WOULD NOT EXTEND UPON DESCENT INTO AIRPORT. EMERGENCY GEAR EXTENSION PROCEDURE COMPLETED AND TH E AIRCRAFT LANDED SAFELY. NOSE LANDING GEAR ACTUATOR WAS REPLACED, FOLLOWED BY SEVERALGEAR SWINGS IN NORMAL AND EMERGEN CY MODES. GEAR GROUND CHECKED SERVICEABLE AND AIRCRAFT WAS RETURNED TO SERVICE. 2 L 7 2 4T 4 T RT A24CE E4EA 6 C P56GL 2005042000120 20050420 00120 EU 2005 4 20 CA050127001 1 20050127 G 2150 ODOR AIRBUS A340 A340* EU RROYCE RB211 RB211* 54555 NE AIR CONDITIONING DETECTED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) IN CRUISE LOUD GRINDING NOISE HEARD MID GALLEY, AFT J CLASS. AIRCRAFT FILLED WITH ACRID SMELL. AFT AND MID CA BINS FILLED WITH SMOKE. SMELL AND SMOKE LASTED ONE TO TWO MINUTES. ALL SYSTEMS INDICATED NORMAL. PACK FLOW SET TO HIG H FOR 15 MINS. SMELL FOUND COMING FROM MID GALLEY AIR COOLER. CHILLER DE-ACT AND AIRCRAFT DISPATCHED UNDER MEL. NOTE: FURTHER INFO WILL FOLLOW AS AVAILABLE. 2 L 7 4 4F 4 F RT A197 A12EU 2005042500088 20050425 00088 CE 2005 4 25 CA050127002 1 20050124 G 5520 956100054 CONTROL HORN BEECH 95 D95A 1153408 CE LYC O360 IO360B1B 41514 EA HARTZL HCC2Y HCC2YK2 GL ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING SHEET METAL REPAIR OF THE RT ELEVATOR ASSY IT WAS NOTED THAT THE ELEVATOR SKIN AT THE CONTROL HORN ATTACH P OINT WAS CRACKED. FURTHER INSPECTION OF THE CONTROL HORN ASSY REVEALED A LARGE CRACK PROGRESSSING FROM 1 OF 4 ELEVATOR T O CONTROL HORN MOUNTING BOLTS. CRACK LENGTH WAS APPROXIMATLY 1 INCH. THE ELEVATOR CONTROL FITTING WAS REPLACED. A FLE ET INSPECTION WAS CARRIED OUT USING VISUAL AND EDDY CURRENT INSPECTION AND NO FURTHER DEFECTS WERE FOUND ON ANY AIRCRAFT . 1 L 7 2 3O 3 O 3A16 1E10 5 C P920 2005042500089 20050425 00089 NE 2005 4 25 CA050127003 2 20050117 G 7261 310047001 ELBOW BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE ENG OIL LINE FRACTURED W E ENGINE SHUTDOWN K J FLUID LOSS WARNING INDICATION DE DESCENT 1 CA 12780 PS0218 (CAN) IMMEDIATELY AFTER STARING DESCENT, CREW NOTED OIL PRESSURE DROPPING FOLLOWED BY WARNING ANNUCIATORS ON LT POSITION . ENGINE CONTINUED TO LOSE OIL PRESSURE AND ENGINE WAS SHUTDOWN AND FEATHERED. MAINT FOUND OIL BOSS (ELBOW) FOR REDUCT ION GEAR CASE RETURN OIL LINE HAD FRACTURED THROUGH 1 OF 2 ATTACHING BOLT HOLES AND HEAD OF 1 BOLT WAS DETACHED FROM STU D PORTION. HEAD WAS RETAINED BY SAFETY WIRE. IT WAS UNCERTAIN AS TO WHY THE BOSS HAD FRACTURED SO ENGINE WAS REPLACED F OR PRECAUTIONARY REASONS. ENGINE HAS SINCE BEEN CHECKED AND IS IN NORMAL OPERATING CONDITION LEADING TO DETERMINATION THAT BOSS AND/OR ATTACHING BOLTS SIMPLY FAILED AND WAS NOT CAUSED BY OIL PRESSURE SPIKES OR. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005042500090 20050425 00090 EA 2005 4 25 CA050127004 1 20050126 G 3320 AL1235T490 LAMP CNDAIR CL604 CL604 1900301 EA GE CF34 CF343B1 NE GALLEY LIGHT BURNED W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) UPON LANDING THE CREW WHILE WORKING IN THE GALLEY AREA CLEANING UP NOTICED A BURNING ODOR. AFTER OPENING A SLIDIN G DOOR IN THE GALLEY THE FUMES BECAME STRONGER. MAINTENANCE REMOVED THE LIGHT COVER AND FOUND THE END OF THE BULB HAD B ECOME HOT AND DISCOLORED. NO SMOKE WAS SEEN DURING THE PROBLEM. THE BULB DOES HAVE A MELT SPOT ON THE GLASS THAT MAY BE FROM MANUFACTURING BUT AM UNSURE. CHECKED POWER SUPPLY AND INSTALLED NEW LAMP, AND SYSTEM OPERATED NORMALY WITH NO FURTH ER PROBLEMS. 2 L 7 2 4F 4 F RT A21EA E15NE 2005042500091 20050425 00091 NE 2005 4 25 CA050127005 2 20050120 G 7200 SEAL PWA JD15 JT15D1A NE ENGINE LEAKING W O OTHER K B FLUID LOSS SMOKE/FUMES/ODORS/SPARKS NR NOT REPORTED 1 CA 76094 (CAN) CAUSE OF SMOKE ODOR IN CABIN DUE TO OIL CONTAM OF GAS PATH AIRFLOW DUE TO A LARGE NR OF AIR/OIL SEALS HAD EXCESSI VE CLEARANCES, ALLOWING OIL TO ENTER SECONDARY AIR SYS. ENG DID HAVE A SIGNIFICANT AMOUNT OF FRETTING DAMAGE ON COMBUSIO N COMPONENTS, WHICH INDICATED THAT ENG OPERATED WITH VIBRATION FOR SOME TIME. RETURNED ENG TO SERVICE, ALL WORN AIR SEA LS WILL BE REPAIRED/REPLACED BACK TO THE O/H MANUAL LIMITS. NR 4 BEARING HOUSING WILL HAVE ALL PACKINGS & GASKETS CHANG ED TO ENSURE NO FURTHER LEAK. FIT BETWEEN LOW COMPRESSOR SHAFT & LOW TURBINE SHAFT WILL BE RESTORED TO AVOID TO POSSIBIL ITY OF VIBRATION PROBLEMS. ENG WILL BE TESTED. 4 F E25EA 2005042500092 20050425 00092 CE 2005 4 25 CA050127006 1 20050127 G 2121 09040022 BLADES CESSNA 425 425 2076018 CE PWA PT6 PT6A112 52043 NE MCAULY 3G34C7 3GFR34C701 GL BLOWER FAILED W H DEACTIVATE SYST/CIRCUITS D INFLIGHT SEPARATION CL CLIMB 1 CA 0252 (CAN) FAN BLADE FAILURE, BLADE BROKEN OFF FROM SPINNER, OCCURRED 3 TIMES. (TSN 4904 HOURS METAL BLADE) (TSN 657 HO URS PLASTIC BLADE) (TSN 258 HOURS PLASTIC BLADE) 1 L 7 2 3T 3 T RT A7CE E4EA 5 C P60GL 2005041200023 20050412 00023 CE 2005 4 12 CA050127007 1 20050125 G 2910 1015800241 LINE BEECH 200 B200 1152922 CE PWA PT6 PT6A42 52043 NE HARTZL HCB3T HCB3TN3 GL LT WING UNSERVICEABLE W K NONE K FLUID LOSS IN INSP/MAINT 1 CA (CAN) HYDRAULIC FLUID LEAKING OUT OF THE LT IB L/E. L/E REMOVED AND FOUND RIGID HYDRAULIC BRAKE LINE CHAFFED THROUGH BY ENGINE CONTROL CABLES ABOVE HEAT EXCHANGER. REPLACED LINE. ALL COMPANY AIRCRAFT USING THIS HYDRAULIC LINE VISUALLY INSP ECTED AND FOUND DAMAGE ON ALL RANGING FROM MINOR TO MAJOR. BOTH LT P/N 101-580024-1 AND RT P/N 101-580025-1 LINES EFFECT ED. 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2005042000121 20050420 00121 NE 2005 4 20 CA050128001 2 20050127 G 7200 ENGINE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE NR 2 MALFUNCTIONED W C ABORTED TAKEOFF H ELECT. POWER LOSS-50 PC TO TAKEOFF 1 CA (CAN) DURING TAKE-OFF, THE CREW OBSERVED NR 2 ENGINE EPR GAUGE NOT WORKING. TAKE-OFF WAS REJECTED AND AIRCRAFT RETURNED TO THE GATE. NR 2 ENGINE EPR DEFERRED IAW MEL 77-1 AND DMI NR 10956 RAISED. ALL OTHER ENGINES PARAMETERS NORMAL. AIR CRAFT RELEASED AND NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT. 2 L 7 2 4F 4 F RT A6WE E9NE 2005042000122 20050420 00122 NM 2005 4 20 CA050128002 1 20050128 G 3340 2401 CONTROL UNIT DHAV DHC8 DHC8202 2809007 NM PWA 120 PW123D 52152 NE HAMSTD 14SF 14SF23 NE PULSE LIGHT MALFUNCTIONED W K NONE M B OVER TEMP SMOKE/FUMES/ODORS/SPARKS IN INSP/MAINT 1 CA (CAN) THE TECH WAS WORKING ON A DEICE PROBLEM AND WHILE STANDING OUTSIDE THE AC SUDDENLY SAW THE PULSELITE START WORKING ON THERE OWN. HE WENT IN THE AC AND SAW THAT THE PULSELITE SWITCH WAS NOT TO THE ON POSITION. HE CLOSED THE POWER TO T HE AC. HE WENT TO THE PULSELITE CONTROL UNIT AND NOTICED A BURNED ODOR. HE WENT TO TOUCH THE PULSELITE CONTROL BOX BU T IT WAS VERY HOT AND COULD NOT TOUCH IT. NOTE: THE TECHNICIAN HAD REMOVED THE GROUND WIRE AND THE PULSELITE CONTROL BOX TO GAIN ACCESS TO ANOTHER BOX ON A SYSTEM THAT HE WAS WORKING ON. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005042000123 20050420 00123 SO 2005 4 20 CA050128003 1 20050118 G 5320 4070200 CHANNEL PIPER PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 317852128 (CAN) CHANNEL FOUND CRACKED AT FWD DOOR HINGE ATTACH POINT. A 2.5 INCH CRACK RUNNING PARALELL WITH THE CHANNEL UPPER RAD IUS ABOVE HINGE PLATE AIRFRAME PORTION. CHANNEL REPLACED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005042000124 20050420 00124 NE 2005 4 20 CA050128004 2 20050124 G 7230 ENGINE BOEING 737 737210C 1384459 NM PWA JT8 JT8D9A 52048 NE NR 2 FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA 666056 (CAN) DEPARTING, THE NR2 ENGINE PERAMETERS BECAME ERRATIC ASSOCIATED WITH A LOUD REPORT, BELIEVED TO BE A COMPRESSOR STA LL. THE AIRCRAFT LANDED WITHOUT INCIDENT AT POINT OF DEPARTURE. MAINTENANCE FOUND THE NR2 ENGINE TO HAVE SUFFERED SEVER E INTERNAL DAMAGE TO THE TURBINE SECTION. 2 L 7 2 4F 4 F A16WE E2EA 2005042000125 20050420 00125 NM 2005 4 20 CA050128005 1 20050128 G 2121 731376 COOLING FAN BOEING 757 757236 1384971 NM RROYCE RB211 RB211535E437 54555 NE E/E BAY BINDING W H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS DE DESCENT 1 CA (CAN) CREW NOTICED A BURNING SMELL THROUGHOUT AIRCRAFT AND THEN HAD AN EICAS MESSAGE (EQUIPMENT OVERHEAT) . MAINTENANCE CONFIRMED FWD EQUIPMENT COOLING FAN BINDING AND A BURNT SMELL COMING FROM UNIT. 2 L 7 2 4F 4 F RT A2NM E12EU 2005042000127 20050420 00127 SW 2005 4 20 CA050128008 1 20050125 G 2612 17343450F FIRE DETECTOR SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE33111U 01514 WP MCAULY 4HFR34 4HFR34C652 NE LT NACELLE INTERMITTENT W O OTHER N FALSE WARNING AP APPROACH 1 CA (CAN) PILOT CALLED AND NOTIFIED MAINTENANCE THAT ON APPROACH THE LT FIRE WARNING LIGHT CAME ON. LIGHT WENT OUT WHEN INL ET HEAT WAS TURNED OFF. MAINTENACE INSPECTED AIRCRAFT AND FOUND NO SIGNS OF HEAT DISTRESS. TOP FIRE DETECTOR WAS REPLAC ED AND GROUND CHECKED SERVICIBLE. NO OTHER REPORTED INCIDENTS SINCE THEN. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C 3PNE 2005021500007 20050215 00007 NM 2005 2 15 CA050128009 1 20050127 G 3242 DISK DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE BRAKE ASSY SEIZED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA 14693 0410 (CAN) AFTER STARTED AIRCRAFT, RELEASED PARK BRAKE AND TAXIED NORMALLY , BRAKING AS REQUIRED, DUE TO LONG LINE UP AWAITIN G TAKEOFF PARK BRAKE WAS APPLIED. WHEN PART BRAKE WAS RELEASED AIRCRAFT UNABLE TO TAXI. MAINTENANCE INSPECTION FOUND BR AKE PISTONS WERE RELEASING USING TOE BRAKES OR PARK BRAKE, BUT BRAKE DISKS ON THE NR3 AND NR4 BRAKES WERE SEIZED AND WOU LD NOT ROTATE. BOTH NR3 AND NR4 BRAKE ASSEMBLIES REPLACED. NR3 BRAKE S/N 0410 HAD 88CY SINCE OVERHAUL (BUILD NR1) CARR IED OUT. NR4 BRAKE S/N 3120P HAD 208CY SINCE OVERHAUL (BUILD NR1) CARRIED OUT. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005042500093 20050425 00093 SO 2005 4 25 CA050130001 1 20050125 G 3220 AN17413 BOLT PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2C 41532 EA HARTZL HCE3Y HCE3YR2A GL NLG FAILED W O OTHER D INFLIGHT SEPARATION LD LANDING 1 CA (CAN) WHEN THE NOSE WAS LOWERED DURING LANDING, A SEVERE VIBRATION DEVELOPED WHEN THE NOSE TIRE TOUCHED THE RUNWAY. STE ERING WAS NOT AVAILABLE BUT DIRECTIONAL CONTROL WAS MAINTAINED WITH RUDDER. AS THE AIRCRAFT SLOWED, THE VIBRATION EASED UP. TURNING TO EXIT THE RUNWAY WAS ACCOMPLISHED BY DIFFERENTIAL ENGINE POWER. WHEN THE AIRCRAFT WAS SHUTDOWN IT WAS DI SCOVERED THE BOLT HOLDING THE UPPER AND LOWER NOSE SCISSOR LINKS TOGETHER WAS MISSING AND THE LINKS WERE OPEN. SINCE TH E PARTS WERE NOT FOUND IT COULD NOT BE DETERMINED WHICH PART FAILED, THE BOLT, THE NUT OR THE LOCKING PIN. DAMAGE WAS L IMITED TO THE TIRE. NEW HARDWARE WAS INSTALLED. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005042500094 20050425 00094 SW 2005 4 25 CA050130002 1 20050130 G 6720 DW4 BEARING BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL TAIL ROTOR SEIZED W K NONE O OTHER IN INSP/MAINT 1 CA 13427 (CAN) UPON INSPECTION OF THE LONG TAIL ROTOR PITCH CHANGE TUBE THE WALKING BEAM WAS OBSERVED TO BE A LITTLE RATCHETY TO ROTATE EVEN THOUGH IT ONLY ROTATES ABOUT 30 DEGREES OF TRAVEL. UPON THIS INSPECTION THE PART WAS REMOVED AND FURTHER IN SPECTED. THE BEARING WAS ROTATED IN ORDER TO FREE IT UP AND AS MOVEMENT PROGRESSED IT GOT TIGHTER AND FINALLY SEIZED. TOOK THE WALKING BEAM TO A MFG SERVICE CENTER FOR BEARING REPLACEMENT AND EVEN THOUGH MFG SHOWS THE PART IN THE IPC. THE BEARING IS NOT A REPLACEABLE ITEM. A NEW WALKING BEAM WAS ORDERED AND WILL BE INSTALLED. 1 G 7 1 3U 3 U H2SW E4CE 2005042500095 20050425 00095 SW 2005 4 25 CA050131001 1 20050128 G 2612 1734361450 FIRE DETECTOR SWRNGN SA227 SA227AC 8780603 SW GARRTT TPE331 TPE3311U 01514 WP MCAULY 4HFR34 4HFR34C652 NE LT ENGINE FAULTY W F E C ACTIVATE FIRE EXT. ENGINE SHUTDOWN ABORTED TAKEOFF N FALSE WARNING TO TAKEOFF 1 CA (CAN) PILOT HAD A LT FIRE LIGHT COME ON SHORTLY AFTER TAKEOFF. LT ENGINE WAS SHUTDOWN AND FIRE BOTTLE WAS ACTIVATED. A IRCRAFT THEN RETURNED TO AIRPORT. MAINTENANCE INSPECTED FIRE DETECTION SYSTEM AND FOUND THE FIREWALL FIRE DETECTOR FAUL TY. FIRE DETECTOR WAS REPLACED AND AIRCRAFT RETURNED TO SERVICE. 2 L 7 2 4T 3 T RT A8SW E3WE 6 C 3PNE 2005042500096 20050425 00096 SO 2005 4 25 CA050131002 1 20050127 G 3230 4179702 UPLOCK HOOK PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL MLG SEIZED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) FLIGHT CREW INDICATED LANDING GEAR INTRANSIT LIGHT. THE GEAR WAS CYCLED ONE MORE TIME WITH FAILED ATTEMPT. FLIGH T CREW RETURNED AND LANDED. MAINTENANCE WAS DISPATCHED AND FOUND THE NOSE GEAR UPLOCK HOOK STUCK IN DOWN POSITION. WHE N NOSE GEAR RETRACTED, THE UPLOCK ROLLER BENT THE UPLOCK HOOK AND TUBE ASSY, UNABLING IT TO LOCK UP AND SECURE. NEW TU BE IDLER ASSY WITH UPLOCK HOOK ASSY REPLACED. NUMEROUS GEAR SWING C/W. ALL CHECKED SERVICEABLE. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005042500097 20050425 00097 SO 2005 4 25 CA050131003 1 20050127 G 3230 4179703 UPLOCK HOOK PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL LT MLG SEIZED W A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CA (CAN) FLIGHT CREW WAS UNABLE TO SECURE LANDING GEAR IN UP POSITION. THE FLIGHT RETURNED FOR SAFE LANDING. MAINTENANCE W AS DISPATCHED AND FOUND THE LT GEAR UP LOCK HOOK STUCK AND FROZEN IN THE UP POSITION. ASSY WAS DISASSEMBLED, MOISTURE REMOVED, CLEANED AND LUBED AND REASSEMBLED. NUMEROUS GEAR SWINGS PERFORMED, ALL CHECK SVC. 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2005041200025 20050412 00025 EU 2005 4 12 CA050131004 1 20050115 G 2435 23079009 STARTER GEN BAG JETSTM JETSTM3212 1500217 EU GARRTT TPE331 TPE33110UG 01514 WP MCAULY 4HFR34 4HFR34C652 NE ENGINE FAILED W O OTHER H B ELECT. POWER LOSS-50 PC SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CA (CAN) GENERATOR WENT OFF LINE, SMOKE AND OIL VISUAL ON COWLING. 2 L 7 2 4T 4 T RT BA15CAA E4WE 6 C 3PNE 2005042000128 20050420 00128 NE 2005 4 20 CA050131005 2 20050122 G 7313 PACKING EMB 120 EMB120 3260201 SO PWA 118 PW118A NE FUEL NOZZLE DAMAGED W E A ENGINE SHUTDOWN UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION CR CRUISE 1 CA AA0031 (CAN) DURING CRUISE, THE ENGINE EXPERIENCED AN UNCOMMANDED REDUCTION IN POWER. THE PILOT SHUT THE ENGINE DOWN IN FLIGHT . SUBSEQUENT INVESTIGATION REVEALED A DAMAGED FUEL NOZZLE TUBE PACKING. 2 L 7 2 4T 4 T RT A31SO E20NE 2005042000129 20050420 00129 WP 2005 4 20 CA050131006 2 20050119 G 7200 ENGINE BAG JETSTM JETSTM3212 1500217 EU GARRTT TPE331 TPE33110UG 01514 WP ROTOL R333 R333482F12 GL FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING Y ENGINE STOPPAGE CR CRUISE 1 CA P63145 (CAN) ENGINE FAILED IN FLIGHT, AIRCRAFT HAD JUST EXITED ICING CONDITIONS, CONTINUOUS IGNITION WAS TURNED OFF A FEW MINUT ES PRIOR TO ENGINE FAILURE. AIRCRAFT RETURNED TO BASE AND ENGINE WAS INSPECTED FOR ANY CAUSE OF THE FAILURE, NOTHING WAS FOUND. GROUND/POWER RUNS WERE CARRIED OUT AND FOUND SERVICEABLE, CONDITIONAL MAINTENANCE RELEASE WAS SIGNED FOR A TEST FLIGHT. TEST FLIGHT WAS CARRIED OUT AND AIRCRAFT RETURNED TO BASE WITH ALL ENGINE PARAMETERS WITHIN LIMITS. 2 L 7 2 4T 4 T RT BA15CAA E4WE 6 C P61GL 2005042000130 20050420 00130 EU 2005 4 20 CA050131007 1 20050111 G 7900 ENGINE BAG JETSTM JETSTM3212 1500217 EU GARRTT TPE331 TPE33110UG 01514 WP MCAULY 4HFR34 4HFR34C652 NE FAILED W O OTHER O OTHER IN INSP/MAINT 1 CA P63243 (CAN) SOAP SAMPLE INDICATED MAJOR ALUMINIUM IN THE OIL SYSTEM, 2ND SOAP SAMPLE TAKEN AND FOUND MAGNESIUM AND CARBON STEE L PARTICLES IN THE SAMPLE. ENGINE REMOVED AND SENT FOR EVALUATION, AMO 50-04. 2 L 7 2 4T 4 T RT BA15CAA E4WE 6 C 3PNE 2005042000131 20050420 00131 EU 2005 4 20 CA050131008 1 20050131 G 3246 FN22A524 NUT BRAERO DH125 BAE125800A 1500285 EU GARRTT TFE731 TFE7315R 01518 WP MLG WHEEL MISSING W K NONE O OTHER IN INSP/MAINT 1 CA KR083 (CAN) AFTER ARRIVAL TO BASE OF OPERATIONS DURING A POST FLIGHT INSPECTION NR 2 MAIN WHEEL ASSY. A WHEEL TIE BOLT NUT WA S FOUND MISSING AND ANOTHER 180 DEGREES APART WAS FOUND SPLIT. WHEEL WAS CHANGED. THESE NUTS WERE INSTALLED NEW AS THA T IS OUR POLICY. MFG HAS BEEN NOTIFIED AS THE NUTS WERE PURCHASED FROM THEM. 2 L 7 2 4F 4 F RT A3EU E6WE 2005042000132 20050420 00132 NE 2005 4 20 CA050131009 2 20050122 G 7200 ENGINE DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE SHUTDOWN W O E OTHER ENGINE SHUTDOWN O OTHER CR CRUISE 1 CA 123145 (CAN) THE ENGINE EXPERIENCED AN UNCOMMANDED POWER ROLL-BACK IN CRUISE (ZERO TORQUE INDICATED).THE PILOT DECLARED AN EMER GENCY AND SHUT THE ENGINE DOWN IN FLIGHT. MFG WILL MONITOR INVESTIGATION OF THE EVENT AND WILL SUPPLEMENT THIS REPORT T O PROVIDE ROOT CAUSE, ONCE ESTABLISHED. 2 H 7 2 4T 4 T RT A13NM E20NE 2005042500098 20050425 00098 NE 2005 4 25 CA050201001 2 20050126 G 7250 TURBINE PWA JD15 JT15D1A NE ENGINE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 76492 (CAN) ENGINE WAS FOUND TO HAVE SUSTAINED A MAJOR INTERNAL FAILURE WITH EXTENSIVE DAMAGE TO THE IMPELLER AND THE ENTIRE T URBINE SECTION OF THE ENGINE. EVIDENCE OF A FAILED NR 2 BEARING, AN HP VANE ASSEMBLY WITH EXTENSIVE BURNING AND LOSS OF MATERIAL, AN HP TURBINE WITH FRACTURED AIRFOILS, AND AN LP TURBINE MISSING ALL OF THE FIRST STAGE ROTOR BLADES, THE PRI MARY FAILURE IS NOT IMMEDIATELY OBVIOUS AND THE POSSIBILITY OF COINCIDENTAL FAILURES EXISTS. THE ENGINE WILL BE CANNABA LIZED TO SALVAGE ANY UNDAMAGED COMPONENTS FOR POSSIBLE RE-SALE. ALL ENGINE BEARINGS WILL BE SCRAPPED REGARDLESS OF COND ITION DUE TO THE AMOUNT OF METAL CONTAMINATION AND CONDITION OF THE ENGINE. 4 F E25EA 2005042500099 20050425 00099 CE 2005 4 25 CA050201002 1 20050201 G 7120 265102215 COLLAR CESSNA 208 208B 2073701 CE PWA PT6 PT6A114A 52043 NE MCAULY 3AF34C 3GFR34C703 GL ENGINE MOUNT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING ROUTINE MAINTENANCE THE ENGINE MOUNT RING (HORSE COLLAR) WAS FOUND CRACKED AT 2 OF THE 4 CORNERS, INSIDE JO INT. DUE TO THIS BEING A KNOWN PROBLEM, AN ADDITIONAL TASK CARD TO CHECK FOR THIS CONDITION, INITIATED IN 1999, WAS ADD ED TO OUR MAINTENANCE SCHEDULE EVERY 100 HOURS. AS A RESULT, WE HAVE DISCOVERED THE CONDITION ON 12 SEPARATE COLLARS. TH E COLLAR WAS REPLACED AND THE AIRCRAFT REL EASED. 1 H 7 1 3T 3 T A37CE E4EA 5 C P60GL 2005042500101 20050425 00101 NM 2005 4 25 CA050201003 1 20050108 G 2435 03600923 BEARING LUCAS DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE STARTER GEN FAILED W O OTHER J WARNING INDICATION TX TAXI/GRND HDL 1 CA 1464 (CAN) GENERATOR CAUTION LIGHT ILLUMINATED AND ELECTRICAL LOAD WENT TO (0) SUSPECT STARTER BEARING FAILURE DUE TO HEAVY V IBRATION IN THROTTLE HANDLE. STARTER GEN INSPECTED IN SHOP, WO NR182352, BEARING FAILURE NOTED ON DRIVE END (03-6009-23 ). 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2005042500102 20050425 00102 NE 2005 4 25 CA050201004 2 20050130 G 7261 ENGINE BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE LEFT FAILED W E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA PS0051 (CAN) AC HAD DEPARTED, LT LOW OIL PRESSURE LIGHT ILLUMINATED, GAUGE ALSO CONFIRMED PRESSURE AT 50-55. ENG WAS SHUTDOWN AND SECURED. EMERGENCY WAS DECLARED, AC DIVERTED TO NEAREST AIRPORT, LANDED UNEVENTFULLY. MAINT FOUND ENGINE LOW BY 3 LITERS. OIL WAS NOTED ON LT LANDING GEAR BUT INSP OF ENG DID NOT REVEAL LOCATION OF LEAK. AC WAS GROUND RUN, INSPECTED WITH ALL PARAMETERS NORMAL, NO LEAKAGE. AC FOUND FIT TO RETURN TO INTENDED DESTINATION. TAKEOFF WAS NORMAL, HALFWAY INT O FLIGHT OIL PRESSURE STARTED TO DROP. ENG WAS SHUTDOWN AND SECURED, LANDING AT DESTINATION WAS UNEVENTFULL. INVEST OF ENG REVEALED INTRNL LEAKAGE OF OIL. IT WILL BE REMOVED AND FOLLOW UP REPORT WILL BE SUPPLIED. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005042500103 20050425 00103 WP 2005 4 25 CA050201005 1 20050129 G 3150 WARNING HORN DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE COCKPIT ACTIVATED W C ABORTED TAKEOFF J WARNING INDICATION TO TAKEOFF 1 CA (CAN) DURING TAKEOFF, AN AUDIBLE WARNING WAS HEARD FROM THE TAKEOFF WARNING COMPUTER. THE TAKEOFF WAS ABORTED SUCCESSFU LLY WITHOUT INCIDENT. THE AIRCRAFT RETURNED TO THE GATE WHERE THE FLIGHT CREW ADJUSTED THEIR SETTINGS. THE AIRCRAFT DE PARTED WITHOUT INCIDENT AND NO FURTHER PROBLEM DURING SUBSEQUENT FLIGHT. 2 L 7 2 4F 4 F RT A6WE E9NE 2005041200028 20050412 00028 EU 2005 4 12 CA050201006 1 20050130 G 5610 D20543406 WINDSHIELD FOKKER F28 F28MK0100 4990807 EU RROYCE TAY TAY65015 54557 NE COCKPIT CRACKED W K NONE O OTHER CR CRUISE 1 CA (CAN) DURING FLIGHT IT WAS OBSERVED THE RT WINDSHIELD OUTER PANE WAS CRACKED. CREW INITIATED QRH PROCEDURES AND FLIGHT WAS CONTINUED. AIRCRAFT LANDED WITHOUT INCIDENT. RT WINDSHIELD WAS REPLACED IAW MM 56-11-00. NO FURTHER INCIDENT DURI NG SUBSEQUENT FLIGHT. 2 L 7 2 4F 4 F RT E25NE 2005042000133 20050420 00133 EA 2005 4 20 CA050202001 1 20050201 G 2100 GG67095009 ACM CNDAIR CL600 CL6002C10 1390015 EA GE CF34 CF348C1 NE RT A/C PACK SEIZED W D RETURN TO BLOCK B SMOKE/FUMES/ODORS/SPARKS TX TAXI/GRND HDL 1 CA (CAN) RT PACK AUTOFAIL MESSAGE ON EICAS WITH RT PACK FAILING AFTER START OF ENGINE NR1. MANUAL TEMP SELECTED WHICH RESU LTED WITH THE LAV SMOKE DETECTOR ACTIVATING AND SMOKE ENTERING THE AFT CABIN. PACK TEMP OBSERVED AT 98 DEGREES JUST BEF ORE AUTOFAIL. THE AIR CYCLE MACHINE (ACM) WAS REPLACED. 2 L 7 2 4F 4 F RT A21EA EOOO63EN 2005042000134 20050420 00134 NE 2005 4 20 CA050202002 2 20050201 G 7532 0301007860 SCREEN SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE BLEED VALVE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 895 (CAN) WIRE BROKEN ON SCREEN THAT IS ATTACHED TO BLEED VALVE. 1 G 7 1 3U 3 U NC H9EU E19EU 2005042000135 20050420 00135 CE 2005 4 20 CA050202003 1 20050201 G 3297 MS24171D1 RELAY BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3I NE MLG BURNED W O OTHER O OTHER AP APPROACH 1 CA (CAN) DURING APPROACH, FLIGHT CREW SELECTED GEAR DOWN BUT THE CONTROL CB OPENED AND WOULD NOT RESET. THE LANDING GEAR WA S MANUALLY EXDENDED WITH 3 GREENS. MAINTENANCE FOUND THE LANDING GEAR RELAY WAS BURNED AT THE CONTACTS AREA AND THE REL AY WAS REPLACED. THIS OPERATOR HAS HARDTIME, THE RELAY AT 5000 HOURS PREVIOUSLY TO PREVENT THESE TYPES OF OCCURENCES. TO DATE, THIS NUMBER HAS BEEN SUCCESSFUL BUT THIS FAILURE OCCURRED APPROX 3600 HOURS SINCE INSTALLATION. AS A RESULT, THE COMPANY HARDTIME ON THIS RELAY HAS BEEN LOWERED TO 3000 HOURS. 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005042000136 20050420 00136 CE 2005 4 20 CA050202004 1 20050125 G 5511 053200198 SPAR CESSNA 172 172N 2072434 CE LYC O360 O360A4A 41514 EA SNSNCH 76E 76EM8 EA HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 12402 (CAN) DURING THE 200 HOUR INSPECTION CRACKS WERE FOUND STARTING FROM THE CENTRAL LIGHTENING HOLE IN THE FORWARD HORIZONT AL STABILIZER SPAR. THE CRACKS WERE STOP DRILLED AND REINFORCEMENT P/N 0531037-1 AND SKIN P/N 0523001-25 WERE INSTALLED IAW SEB94-8. 1 H 7 1 3O 3 O NT 3A12 E286 5 N P4EA 2005042000137 20050420 00137 CE 2005 4 20 CA050202005 1 20050201 G 2435 03601018 BEARING LUCAS CESSNA 500 550 2076604 CE PWA JT15 JT15D4 52112 NE COMMUTATOR DESTROYED W O OTHER D E H INFLIGHT SEPARATION VIBRATION/BUFFET ELECT. POWER LOSS-50 PC CR CRUISE 1 CA 7128 (CAN) WHILE IN CRUISE BACK TO BASE, CREW ENCOUNTERED AIRFRAME VIBRATION FROM THE AFT CABIN, FOLLOWED BY THE RT GENERATOR FAIL LIGHT 10 MINUTES LATER. CREW CONFIRMED LOSS OF RT GENERATOR, AND DECLARED AN EMERGENCY DUE TO THE INTENSITY OF VIB RATION. A/C LANDED WITHOUT INCIDENT. ON DISASSEMBLY OF UNIT, DISCOVERED CUMMUTATOR BEARING DESTROYED. CAUSE OF FAILURE IS UNDER INVESTIGATION. THERE WAS ONLY 406 HRS ON THE BEARING SINCE REPLACEMENT. 1 L 7 2 4F 4 F A22CE E1NE 2005042000138 20050420 00138 GL 2005 4 20 CA050202006 1 20050131 G 2730 10146005 CONTROL UNIT CIRRUS SR SR22 2130001 GL CONT O550 IO550N 17042 SO HARTZL HCJ3Y PHCJ3YF1 GL ELEVATOR RESTRICTED W O OTHER F FLT CONT AFFECTED AP APPROACH 1 CA (CAN) PILOT NOTICED ELEVATOR CONTROL WAS STIFFER THAN USUAL ON APPROACH. UPON LANDING, FOUND THE LT ELEVATOR BALANCE WE IGHT HORN IS RUBBING AGAINST THE HORZIONTAL STABILIZER. FOUND THE ELEVATOR WILL NOT RUB ONCE THE AIRCRAFT IS WARMED UP. THE ELEVATOR TIP FAIRING MOUNTING SCREWS WERE LOOSENED AND THE ELEVATOR HORN WAS REPOSITIONED TO PROVIDE THE NECESSARY CLEARANCE. 1 L 7 1 3O 3 O NT A00009CH E3SO 5 C P36EA 2005042500104 20050425 00104 NE 2005 4 25 CA050203001 2 20050106 G 7210 547344P3 STUD PWA BOEING 727 727217 1384061 NM PWA JT8 JT8D17 52049 NE GEARBOX LOOSE W E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CL CLIMB 1 CA 688797 (CAN) DURING CLIMBOUT, CREW OBSERVED DECREASING OIL QUANTITY NR 3 ENGINE. PRECAUTIONARY ENGINE SHUTDOWN COMPLETED. LAND ED WITHOUT INCIDENT. 2 L 7 3 4F 4 F RT A3WE E2EA 2005042500105 20050425 00105 NM 2005 4 25 CA050203002 1 20050128 G 5513 653120043 PLATE BOEING 727 727217 1384061 NM PWA JT8 JT8D17 52049 NE HORIZONTAL STAB FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) RT HORIZONTAL STABILIZER TO FIN SEAL SEPARATED FROM AIRCRAFT. UNABLE TO DETERMINE EXACT CAUSE. ALL AFFECTED PART S REPLACED. REMAINING FLEET CHECKED, SERVICEABLE. 2 L 7 3 4F 4 F RT A3WE E2EA 2005042500106 20050425 00106 SO 2005 4 25 CA050203003 2 20050127 G 7414 SGRN1225 HOUSING BENDIX CESSNA 185 A185F 2072821 CE CONT O550 IO550D 17042 SO HARTZL HCC3Y PHCC3YF1 GL MAGNETO CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 653290R (CAN) DURING ROUTINE 500 HOURS INSPECTION, BOTH MAGNETO HOUSINGS WERE FOUND CRACKED IAW FIGURE 716 OF MFG MASTER SERVICE MANUAL X40000. 900 DEG CELSIUS, TOGETHER WITH ENGINE VIBRATION. N1 STARTED TO SPOOL DOWN AND FLUCTUATING N2 WAS SEEN. CREW SHUTDOWN THE ENGINE AND RETURNED TO DEPARTURE. SUCCESSFUL SINGLE ENGINE LA NDING WAS PERFORMED. FAN AND TURBINE LOOKED NORMAL AND TURNED NORMALLY. GEARBOX TURNED AND ALSO SEEMS NORMAL. CHIP DETEC TOR FOUND CLEAN. OIL FILTER SHOWED A SMALL AMOUNT OF CHIPS. OIL IN GEARBOX LOOKED NORMAL. FOUND IN EXHAUST A LOT OF MET AL CHIPS. BORESCOPE INSPECTION OF THE AIRFLOW SECTION SHOWED DAMAGED COMPRESSOR ROTOR BLADES STAGE 10 THROUGH 14. (TC NR 20060211004) 2 L 7 2 4F 4 F RT A21EA E15NE 2006071900035 20060719 00035 EA 2006 7 19 CA060213005 2 20051220 G 7414 LW14227 BEARING HUGHES 269 269C1 8059504 SW LYC O360 HO360C1A 41514 EA MAGNETO BROKEN W K NONE O OTHER IN INSP/MAINT 1 CA 1005 (CAN) SMALL METAL FRAGMENT DISCOVERED WHILE CHANGING ENGINE OIL. FOUND TO BE PART OF A BEARING KEEPER IN RT MAGNETO ADAP TER BEARINGS. THIS IS THE SECOND TIME THIS PROBLEM HAS OCCURRED ON THIS AIRCRAFT. (TC NR 20060213005) 1 G 7 1 3O 3 O O 4H12 E286 2006060700249 20060607 00249 EA 2006 6 7 CA060216007 1 20051225 G 7120 73512562 MOUNT BARRYCTRLS 73512562 DHAV DHC6 DHC6300 2802606 EA ENGINE MOUNT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA DURING EDDY CURRENT INSPECTION PER MULDIVES AD CAD/2005/1, A CRACK INDICATION WAS FOUND IN THE RADIUS OF THE TOP ENGINE VIBRATION ISOLATOR MOUNT. 1 H 7 2 3T RT A9EA 2006060700250 20060607 00250 EA 2006 6 7 CA060216008 1 20051005 G 7120 73512562 MOUNT BARRYCTRLS 73507217 DHAV DHC6 DHC6300 2802606 EA PWA PT6 PT6A34 52043 EA ENGINE MOUNT CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA TOP, ENGINE VIBRATION ISOLATOR MOUNT (RIGHT ENGINE) WAS FOUND CRACKED DURING INSPECTION. 1 H 7 2 3T 4 T RT A9EA E4EA 2006060800203 20060608 00203 NM 2006 6 8 CA060219002 1 20050908 G 3010 38962E REGULATOR DHAV DHC8 DHC8102 2809003 NM PWA 120 PW120A NE HAMSTD 14SF 14SF7 NE DE ICE SYSTEM MALFUNCTIONED W K NONE O OTHER IN INSP/MAINT 1 CA NR 2 ENGINE FORWARD DE-ICE VALVE P/N 28E96-2D WAS FOUND DAMAGED DURING 3 MONTH LUMP INSPECTION WHILE PERFORMING ZONAL TA SK CARD 422 (PANEL 422DT) THERE DC FEED CABLES WERE POSITIONED WRONG AND HAD CHAFED THROUGH RUBBER COATING OF TERMINAL A ND HAD SHORTED AGAINST FORWARD DE-ICE VALVE, THERE WAS SUBSTANTIAL DAMAGE TO THE VALVE, RESULTING IN AN UNRESTRICTED BLE ED AIR LEAK FROM THE BOTTOM OF THE VALVE. VALVE WAS REMOVED, THE CABLES WERE INSPECTED WITH NO DAMAGE NOTED THEN REPOSI TIONED AND THE TERMINAL COVERS WERE REPLACED. THE SURROUNDING AREA WAS ALSO INSPECTED WITH NO DAMAGED NOTED. THE VALVE WAS REPLACED, LEAK AND FUNCTION CHECKED SERVICEABLE, PANEL 422DT WAS RESEALED WITH PRC 1422 B1/2. 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006061500192 20060615 00192 SO 2006 6 15 CA060228010 2 20050621 G 7414 BL3493108 MAGNETO CESSNA 210 2105 2073404 CE CONT O470 IO470S 17026 SO ENGINE FAILED W D RETURN TO BLOCK J WARNING INDICATION TX TAXI/GRND HDL 1 CA 171 ROUGHNESS ON STARTUP OF LT MAGNETO. 1 H 7 1 3O 3 O 3A21 3E1 2006061500193 20060615 00193 SO 2006 6 15 CA060228011 2 20051205 G 7414 BL3493108 MAGNETO CESSNA 210 2105 2073404 CE CONT O470 IO470S 17026 SO ENGINE FAILED W D RETURN TO BLOCK J WARNING INDICATION TX TAXI/GRND HDL 1 CA 134 NR 1 CYLINDER NOT FIRING. TRACED BACK TO INTERNAL PROBLEM WITH MAGNETO, RETURNED FOR WARRANTY. 1 H 7 1 3O 3 O 3A21 3E1 2006061500194 20060615 00194 CE 2006 6 15 CA060228012 1 20050702 G 7921 654593 OIL COOLER CESSNA 210 2105 2073404 CE CONT O470 IO470S 17026 SO ENGINE OIL CRACKED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 211 OIL LEAK FROM OIL COOLER. 1 H 7 1 3O 3 O 3A21 3E1 2006061600039 20060616 00039 NE 2006 6 16 CA060228020 2 20051028 G 7314 B8187B PUMP ROBSIN R44 R44RAVENII 7640122 WP LYC O540 IO540AE1A5 41530 NE FUEL SYSTEM FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 1346 DURING START UP PILOT COULD NOT PRIME AIRCRAFT. FURTHER INVESTIGATION FOUND PUMP HAD FAILED. PUMP REPLACED AND NO FURT HER DEFECTS WERE NOTED. 1 G 7 1 3O 3 O H11NM 1E4 2006061600041 20060616 00041 NE 2006 6 16 CA060228022 2 20050422 G 7314 B8187B PUMP ROBSIN R44 R44RAVENII 7640122 WP LYC O540 IO540AE1A5 41530 NE FUEL SYSTEM SEIZED W K NONE O OTHER IN INSP/MAINT 1 CA 1190 DURING AN ATTEMPTED START, THE AUX FUEL PUMP LIGHT ILLUMINATED. SYSTEM WOULD NOT FUNCTION. FURTHER INVESTIGATION FOUND PUMP SEIZED. PUMP REPLACED AND NO FURTHER DEFECTS WERE NOTED. 1 G 7 1 3O 3 O H11NM 1E4 2006061600042 20060616 00042 CE 2006 6 16 CA060301001 1 20050225 G 2435 S24431 CONTACTOR CONT CESSNA 210 210R 2073458 CE CONT O520 IO520L 17032 SO MCAULY D3A34 D3A34C404 GL STARTER ENG ARCED W D RETURN TO BLOCK H ELECT. POWER LOSS-50 PC TX TAXI/GRND HDL 1 CA 789 0179 DURING TAXI TO POSITION, PILOT HEARD UNUSUAL STATIC ON HEADSET AND A LARGER THAN NORMAL AMPS DRAW. RETURNED TO CHOCKS; WHILE STILL RUNNING CHECKED SYSTEM AND SUDDENLY ALL APPEARED NORMAL. ENGINE WAS SHUT DOWN, MAINTENANCE WAS CONTACTED. A RESTART WAS TRIED BUT NO STARTER ENGAGEMENT. STARTER AND CONTACTOR WAS CHANGED. UPON INVESTIGATION, APPEARS STARTER REMAINED ENERGIZED DUE TO FAULTY CONTACTOR. THIS FRIED THE STARTER. 1 H 7 1 3O 3 O RT 3A21 E5CE 5 C P47GL 2006061900097 20060619 00097 CE 2006 6 19 CA060303004 1 20050531 G 3243 211111 SHUTTLE VALVE CESSNA 500 560CESSNA 2076750 CE PWA 530 PW535A NE BRAKE ASSEMBLY LEAKING W K NONE K FLUID LOSS IN INSP/MAINT 1 CA BRAKE SHUTTLE VALVE LEAKING HYDRAULIC FLUID (SKYDROL) INTO PNEUMATIC EMERGENCY BRAKE CONTROL SYSTEM NECESSITATING THE RE PLACEMENT OF THE EMERGENCY BRAKE CONTROL VALVE P/N 895232-0875. SHUTTLE VALVE REPLACED SYSTEM CHECK SERVICEABLE. 2 L 7 2 4F 4 F RT A22CE E00053EN 2006061900150 20060619 00150 WP 2006 6 19 CA060303016 1 20051125 G 2842 VALVE HUGHES 269 269C 4470504 WP LYC O360 HIO360D1A 41514 EA FUEL SYSTEM INCORRECT W K NONE O OTHER IN INSP/MAINT 1 CA FUEL SYSTEM SENDER INCORRECT VALVE. REPLACED SENDER. 1 G 7 1 3O 3 O 4H12 1E10 2006062100072 20060621 00072 GL 2006 6 21 CA060303017 2 20050604 G 7421 CH34168 IGNITER BELL 206 206L 1181522 SW ALLSN 25OC 250C20R GL ENGINE FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA NO IGNITION. REPLACED IGNITER. 1 G 7 1 3U 3 U H2SW E4CE 2006062100073 20060621 00073 SW 2006 6 21 CA060303018 1 20050719 G 2424 206075447007 VOLT REGULATOR BELL 206 206L 1181522 SW ALLSN 25OC 250C20R GL FAILED W O OTHER O OTHER NR NOT REPORTED 1 CA AT START UP NO CHARGE. REPLACED VOLTAGE REGULATOR. 1 G 7 1 3U 3 U H2SW E4CE 2006062100136 20060621 00136 WP 2006 6 21 CA060306001 1 20051001 G 2740 C0559 MOTOR ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA LATERAL TRIM FAILED W A UNSCHED LANDING F FLT CONT AFFECTED HO HOVERING 1 CA (CAN) TRIM MOTOR NOT OPERATING. REPLACED TRIM. (TC NR 20060306001) 1 G 7 1 3O 3 O H11NM E295 2006062100137 20060621 00137 WP 2006 6 21 CA060306002 1 20051015 G 2740 D1402 CONTROL BOX ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA TRIM FAILED W A UNSCHED LANDING F FLT CONT AFFECTED HO HOVERING 1 CA (CAN) LONGITUDINAL TRIM NOT WORKING. REPLACED TRIM BOX. (TC NR 20060306002) 1 G 7 1 3O 3 O H11NM E295 2006062100138 20060621 00138 WP 2006 6 21 CA060306003 1 20051121 G 7810 C1692 SHROUD ROBSIN R44 R44 7640120 WP LYC O540 O540F1B5 41532 EA EXHAUST PIPE WORN W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WORN AT END OVER ENGINE EXHAUST PIPE DUE TO LOOSENESS. REPLACED PART. (TC NR 20060306003) 1 G 7 1 3O 3 O H11NM E295 2006062300165 20060623 00165 EU 2006 6 23 CA060306010 1 20050629 G 7931 704A37642043 TRANSMITTER SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE OIL PRESSURE FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) NO OIL PRESSURE INDICATION. REPLACED PRESSURE GENDER. (TC NR 20060306010) 1 G 7 1 3U 3 U NC H9EU E19EU 2006062300167 20060623 00167 EU 2006 6 23 CA060306011 1 20051014 G 2435 ARMATURE SNIAS 350 AS350BA 8680817 EU TMECA ARRIEL ARRIEL1B 6OO30 NE STARTER GEN FAILED W K NONE O OTHER IN INSP/MAINT 1 CA 401 53570 (CAN) START UP SPARK/SMOKE FROM STARTER. REPLACED STARTER. (TC NR 20060306011) 1 G 7 1 3U 3 U NC H9EU E19EU 2006062300168 20060623 00168 SW 2006 6 23 CA060306012 1 20051118 G 5320 269A8598 BRACKET HUGHES 269 269C1 8059504 SW LYC O360 HO360C1A 41514 EA FUSELAGE CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) BRACKET CRACKED. REPLACED BRACKET. (TC NR 20060306012) 1 G 7 1 3O 3 O O 4H12 E286 2006062300170 20060623 00170 2006 6 23 CA060306014 4 20051028 G 2340 B2272 SWITCH ROBSIN R22 R22BETA 7640110 NM LYC O320 O320B2C 41508 EA INTERCOM FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) TRIM INTERMITTENT. REPLACED SWITCH. (TC NR 20060306014) 1 G 7 1 3O 3 O H10WE E274 2006062300171 20060623 00171 SW 2006 6 23 CA060306015 1 20051021 G 2424 15891F VOLT REGULATOR BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL FAILED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) NO CHARGE. REPLACED VOLTAGE REGULATOR. (TC NR 20060306015) 1 G 7 1 3U 3 U H2SW E4CE 2006062300189 20060623 00189 SW 2006 6 23 CA060306016 1 20051028 G 6240 D22A690 TACHOMETER BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL MAIN ROTOR FAILED W K NONE N FALSE WARNING IN INSP/MAINT 1 CA (CAN) NO ROTOR TACH INDICATION. REPLACED TACH. (TC NR 20060306016) 1 G 7 1 3U 3 U H2SW E4CE 2006070500096 20060705 00096 CE 2006 7 5 CA060317005 1 20050907 G 2422 CIRCUIT BOARD BEECH 200 B200 1152922 CE PWA PT6 PT642A NE HARTZL HCB3T HCB3TN3 GL STATIC INVERTER CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) STATIC INVERTER BOARD CRACKED AND MOISTURE SHORTED BOARD. (TC NR 20060317005) 1 L 7 2 4T 4 T A24CE E4EA 6 C P15EA 2006070500209 20060705 00209 EA 2006 7 5 CA060321010 2 20050920 G 7322 S123017 CONTROL CABLE CESSNA 172 172N 2072434 CE LYC O320 O320H2AD 41508 EA MCAULY 1C160 1C160DTM GL CARB HEAT WORN W K NONE O OTHER IN INSP/MAINT 1 CA 2249 (CAN) THIS REPORT HAS BEEN RESUBMITTED. THE INTERNAL PART OF THE BOUDEN CABLE WAS FOUND TO BE EXCESSIVELY WORN DURING I NSPECTION. SEE ATTACHED PHOTO (TC NR 20060321010) 1 H 7 1 3O 3 O NT 3A12 E274 5 N P910 2006070500150 20060705 00150 EA 2006 7 5 CA060321015 1 20051215 G 2810 C3PT315 FUEL CELL DHAV DHC3 DHC3 2800202 EA PWA R1340 R134059 52016 NE WING DAMAGED W K NONE K FLUID LOSS IN INSP/MAINT 1 CA 23509 ALL OF THE BLADDER STYLE FUEL CELLS REQUIRED EXTENSIVE WORK OR REPLACEMENT, PN# C3PT31-5, C3PT32-5, C3PT33-5, C3PT34-5 T HE FUEL CELLS WERE REPLACED AS REQUIRED. THE AVERAGE DATE OF THE TANK MANUFACTURE WAS NOTED TO BE 1956. 1 H 7 1 3R 3 R A815 5E2 2006070500173 20060705 00173 GL 2006 7 5 CA060322005 2 20050810 G 7314 1132431 SPLINE CHNDLREVANS 11331002A1 BELL 206 206L4 1182110 SW ALLSN 250C 250C30P 03013 GL FUEL PUMP WORN W R A AUTOROTATION UNSCHED LANDING X ENGINE FLAMEOUT CR CRUISE 1 CA 1288 J6AKW0079 THE ENGINE LOST POWER BECAUSE THE ENGINE DRIVEN FUEL PUMP FAILED. THE CAUSE OF THE PUMP FAILURE WAS DISENGAGEMENT OF TH E DRIVE SHAFT SPLINES FROM THE DRIVER GEAR SPLINES DUE TO EXCESSIVE WEAR. 1 G 7 1 3U 3 U NC H2SW E1GL 2006062600099 20060626 00099 SO 2006 6 26 CA060328003 1 20051015 G 5730 40659002 SKIN PIPER PA31 PA31 7103102 SO LYC O540 TIO540A2B 41532 EA HARTZL HCE2Y HCE2YR2 GL LT WING CORRODED W K NONE O OTHER IN INSP/MAINT 1 CA 11280 ON DE-ICER BOOT REPLACEMENT DUE TO WEAR AND CONDITION FOUND LT WING AND LT HORIZONTAL STAB LEADING EDGE SKINS CORRODED. THERE WERE HOLES THROUGH THE METAL. SKINS WERE BEYOND REPAIR AND HAD TO BE REPLACED. RT SIDE WAS FOUND OK. 1 L 7 2 3O 3 O A20SO E14EA 5 C P9EA 2006062600104 20060626 00104 SW 2006 6 26 CA060329003 1 20050730 G 6320 204040353023 CASE BELL 212040001123 BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA TRANSMISSION BROKEN W A UNSCHED LANDING E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 CA ABW270 WHILE IN CRUISE, A LOUD BANG WAS HEARD AND AC SHUDDERED. AC SETTLED OUT AND CREW DIVERTED TO AIRPORT. INSPECTION OF AC REVEALED MAIN TRANSMISSIOM SUPPORT CASE BROKEN AT DRAG LINK ATTACHMENT POINT. AC GROUNDED AND MAIN TRANSMISSION REPLAC ED. AC RELEASED BACK TO SERVICE. 1 G 7 1 4U 4 U H4SW E22EA 2006062600106 20060626 00106 EA 2006 6 26 CA060329005 2 20050801 G 7230 ENGINE BELL 212 212 1181420 SW PWA PT6T PT6T3 52045 EA NR 2 FAILED W A UNSCHED LANDING E J VIBRATION/BUFFET WARNING INDICATION CR CRUISE 1 CA 3971 CPPS61680 WHILE IN CRUISE, A LOUD BANG WAS HEARD FOLLOWED BY AIRFRAME SHUDDER. AN EMERGENCY WAS DECLARED AND AIRCRAFT STARTED LAN DING PROCEDURES. NR 2 ENGINE INDICATING FAILURE AND ROLLED BACK. AIRCRAFT SUCCESSFULLY LANDED IN A FIELD. POWER RECOV ERY OF NR 2 ENGINE ABORTED DUE TO COMPRESSOR STALL. AC WAS SHUTDOWN AND GROUNDED UNTIL POWER SECTION COULD BE REPLACED. 1 G 7 1 4U 4 U H4SW E22EA 2006062600122 20060626 00122 SO 2006 6 26 CA060405007 1 20051125 G 2133 7331802 OUTFLOW VALVE PIPER PA42 PA42720 7104212 SO PWA PT6 PT6A61 52043 EA HARTZL HCB3T HCB3T* GL CABIN PRESSURE MALFUNCTIONED W O OTHER O OTHER NR NOT REPORTED 1 CA 0161 DURING AN EVENT, NR 2 INSPECTION OF THE EMERGENCY PRESSURIZATION SYSTEM, VALVE ASSY (BY-PASS) P/N 73318-00-1) WAS REMOVE D FROM RT WING ROOT AREA, FURTHER INSPECTION FOUND EXTENSIVE CORROSION IN THIS VALVE AND REDUCER P/N: 584-124 (A55-16-12 ). SYSTEM CLEANED. BENCH TESTED VALVE, FOUND U/S. SUSPECT MOISTURE RESTING IN VALVE AND REDUCER OVER A LONG PERIOD OF TIME CAUSED VALVE FAILURE. 1 L 7 2 4T 4 T A23SO E4EA 6 C P15EA 2006061300291 20060613 00291 SW 2006 6 13 CA060407009 1 20050427 G 5210 2720063907 RECEPTACLE SWRNGN SA226 SA226TC 8780404 SW GARRTT TPE331 TPE33110UA 01514 WP ROTOL R321 R321482F8 GL PAX DOOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA 29489 WHEN COMPLYING WITH SERVICE LETTER 226-SL-027, WHICH DEALS WITH INSPECTION OF THE DOOR CLICK CLACK RECEPTACLES, TWO WERE FOUND CRACKED ON THE PASSENGER DOOR. THIS IS THE FIRST TWO PASSENGER DOOR RECEPTACLES THIS OPERATOR HAS FOUND CRACKED. ONE WAS BROKEN IN HALF WHEN IT WAS REMOVED. 2 L 7 2 4T 4 T RT A8SW E4WE 6 C P61GL 2006062600064 20060626 00064 NM 2006 6 26 CA060502007 1 20050506 G 7830 HEAT SHIELD BOEING 757 75728A 1384976 NM RROYCE RB211 RB211535E437 54555 NE THRUST REVERSER DELAMINATED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) NR 1 ENG RT THRUST REVERSER COWL AFT HEAT SHIELD DAMAGED (DISBONDED). REPAIR FOR HEATSHIELD IN OEM MANUAL. (TC NR 20060502007) 2 L 7 2 4F 4 F RT A2NM E12EU 2006071100117 20060711 00117 WP 2006 7 11 CA060503005 2 20051220 G 7230 8939735 PLENUM MTSBSI MU2 MU2B36 5780412 CE GARRTT TPE331 TPE3316 01514 WP HARTZL HCB3T HCB3TN5 GL ENGINE CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA CFTWO P20362C (CAN) AC TOOK OFF, AC CRASHED, POST-CRASH FIRE OCCURRED. AC WAS DESTROYED. BOTH PILOTS FATALLY INJURED. DURING TEAR-DOWN OF RT ENG (WHICH WAS FOUND TO BE OPERATING AT HIGH POWER ON IMPACT) P3, BLEED AIR BOSS WELDS WERE EXAMINED BY FPI USING A 2X POWER MAGNIFYING GLASS WITH NO CRACKS NOTED. LOCATION BETWEEN P3, BLEED AIR BOSSES WAS THEN SECTIONED. A SMALL CRA CK ABOUT .5 MM DEEP AND 3.5 MM LONG WAS VISUALLY DETECTED ALONG TOE OF P3 BOSS WELD. CRACK OPENED FOLLOWING RELEASE OF R ESIDUAL STRESSES WHEN CUT. CRACK WAS EXAMINED, FOUND TO BE FATIGUE IN NATURE, ORIGINATING FROM OUTER SURFACE. NO FLUORES CENT PENETRANT RESIDUE WAS NOTED ON SURFACES OF CRACK, INDICATING PENETRANT HAD NOT PENETRATED CRACK. 1 H 7 2 3T 4 T RT A10SW E4WE 6 C P15EA 2006071900014 20060719 00014 WP 2006 7 19 CA060503006 2 20051220 G 7230 8939735 PLENUM MTSBSI MU2 MU2B36 5780412 CE GARRTT TPE331 TPE3316 01514 WP HARTZL HCB3T HCB3TN5 GL ENGINE CRACKED W O OTHER O OTHER NR NOT REPORTED 1 CA P20190C (CAN) AIRCRAFT TOOK OFF FROM AIRPORT RUNWAY 15 OR A COURIER FLIGHT. THE AIRCRAFT CRASHED ABOUT 500 METERS EAST OF, AND A PPROXIMATELY ABEAM, THE SOUTH END OF RUNWAY 15, ABOUT 300 METERS BEYOND THE AIRPORT PERIMETER. A POST-CRASH FIRE OCCURRE D. THE AIRCRAFT WAS DESTROYED. THE TWO PILOTS WERE FATALLY INJURED. A TEAR-DOWN OF THE TWO ENGINES HAS DETERMINED THAT THE LT ENGINE FAILED AS A RESULT OF THE COMBUSTION CASE ASSEMBLY (PLENUM) RUPTURING ALONG ITS ENTIRE LENGTH AND MUCH OF ITS CIRCUMFERENCE. THE ORIGIN OF THE RUPTURE WAS FOUND TO BE A FATIGUE CRACK IN A REINFORCING WELD BETWEEN THE P3 AND BL EED AIR BOSSES. (TC NR 20060503006) 1 H 7 2 3T 4 T RT A10SW E4WE 6 C P15EA 2006070500222 20060705 00222 CE 2006 7 5 CA060509005 1 20050517 G 2910 105932B POWERPACK BEECH 76 76 1153005 CE LYC O360 O360A1G6D EA HARTZL HCM2Y HCM2YR GL HYD SYS FAILED W O OTHER O OTHER DE DESCENT 1 CA (CAN) LANDING GEAR FAILED TO EXTEND. CREW ACTIVATED EMERGENCY EXTENSION. STILL NO INDICATION ON RT GEAR POSITION. SWI TCHED BULBS ON GEAR INDICATOR AND DISCOVERED ONE BULB U/S. LANDING CARRIED OUT NORMALLY. FOUND HYDRAULIC POWER PUMP MO TOR BRUSHES WORN. REPLACED WITH OVERHAULED UNIT, REPLACED CONTROL RELAY AS WELL. RECORDS RESEARCH DISCOVERED AVERAGE LIFE IS APPROX. 1700 HOURS BETWEEN FAILURES, WE HAVE ELECTED TO PLACE THIS PART ON A 1500 HOUR REPLACEMENT. (TC NR 20060 509005) 1 L 7 2 3O 3 O A29CE E286 5 C P43GL 2006091300052 20060913 00052 GL 2006 9 13 CA060803002 2 20050811 G 7261 03807205 FILTER BELL 206 206B 1181511 SW ALLSN 250C 250C20 03013 GL SCAVENGE OIL WRONG PART W K NONE W INADEQUATE Q C IN INSP/MAINT 1 CA (CAN) WHILE CARRYING OUT A SCAVENGE OIL FILTER REPLACEMENT IAW INSPECTION PROGRAM IT WAS NOTED THAT THE FILTER WAS DIFFE RENT THAN THE REPLACEMENT FILTER. THE CORRECT FILTER FOR THE SCAVENGE OIL FILTER IS P/N 038088-08, WHAT WAS FOUND IN THE SCAVENGE OIL FILTER HOUSING WAS AN P/N 038072-05 FILTER. WE ARE INVESTIGATING HOW THIS OCCURRED. (TC NR 20060803002) 1 G 7 1 3U 3 U H2SW E4CE 2006120800056 20061208 00056 WP 2006 12 8 CA061002008 1 20050915 G 6320 369D25146 BEARING HUGHES 369 369D 4470706 WP ALLSN 250C 250C20B 03013 GL TRANSMISSION SPALLED W O OTHER J WARNING INDICATION CR CRUISE 1 CA 3097 1810 (CAN) M/R TRANSMISSION CHIP DETECTOR FOUND TO HAVE A LARGE AMOUNT OF METAL. SOURCE FOUND TO BE THE T/R O/P PINION ROLLE R BEARING INNER RACE. THE INNER RACE WAS FOUND TO HAVE HEAVY SPALLING IN A LARGE AREA. (APPROXIMATELY .550 INCH X .200 INCH) (TC NR 20061002008) 1 G 7 1 3U 3 U H3WE E4CE 2006120800075 20061208 00075 EU 2006 12 8 CA061004002 1 20051028 G 5620 M1052330115 WINDOW BOLKMS 105 BO105S 5626006 EU ALLSN 250C 250C20B 03013 GL DOOR SEPARATED W A UNSCHED LANDING D INFLIGHT SEPARATION CR CRUISE 1 CA (CAN) AIRCRAFT HAD DEPARTED FROM HELICOPTER PAD AND WAS TRANSITING TO WEST COAST. SHORTLY AFTER TAKE-OFF AND ALMOST IN CRUISE, THE PASSENGER SITTING IN THE LT CREW SEAT HEARD A NOISE. AT THAT TIME HE NOTICED THAT THE WIND DEFLECTOR HAD BE COME SEPARATED AT THE LOWER POINT OF THE WINDOW. THE PASSENGER MANAGED TO OPEN THE SLIDING WINDOW AND SECURE THE REMAIN ING PORTION OF THE DEFLECTOR IN HIS HAND. THE PILOT AT THAT POINT ELECTED TO RETURN THE AIRCRAFT TO THE POINT OF DEPART URE. UPON ARRIVAL BACK AT POINT OF DEPARTURE, THE REMAINING PORTION OF THE WIND DEFLECTOR WAS REMOVED, AIRCRAFT INSPECT ED FOR ANY DAMAGE CAUSED BY FOD, AND THEN RETURNED TO SERVICE. (TC NR 20061004002) 1 G 7 2 3U 3 U H3EU E4CE 2006120800104 20061208 00104 NM 2006 12 8 CA061005008 1 20051021 G 5610 8SC0043007 WINDSHIELD DHAV DHC8 DHC8301 1386003 NM PWA PW120 PW123 NE HAMSTD 14SF 14SF23 NE COCKPIT FAILED W O OTHER O OTHER CR CRUISE 1 CA (CAN) APPROXIMATELY 53 MINUTES INTO FLIGHT, SOON AFTER LEAVING FL 190, CREW HEARD A LONG (BANG) FOLLOWED BY THE OBSERVAT ION OF THE CAPTAIN’S MAIN WINDSHIELD SHATTERING, CREW CONTINUED DESCENT TO FL 100 AT RESTRICTED AIRSPEED OF 188 KNOTS AN D MAINTAINED A CABIN DIFFERENTIAL OF 2.6PSI IAW QRH. ENGINEERING CHANGED THE AIRCRAFT WINDSHIELD IAW MM 56-10-11. AIRCR AFT RETURNED TO SERVICE. (TC NR 20061005008) 2 H 7 2 4T 4 T RT A13NM E20NE 6 C P7NE 2006121100365 20061211 00365 2006 12 11 CA061107006 4 20051215 G 8300 311433701 GEARBOX PILATS PC12 PC1245 7090551 EU PWA PT6 PT6A6 52043 EA ENGINE DAMAGED W O OTHER J WARNING INDICATION CR CRUISE 1 CA 937 (CAN) THE ENGINE LOST OIL PRESSURE IN FLIGHT RESULTING IN LOSS OF THE AIRCRAFT. SUBSEQUENT INVESTIGATION REVEALED THAT A PROTECTIVE COATING HAD BEEN IMPROPERLY APPLIED TO THE AGB HOUSING AT THE PRIOR ENGINE OVERHAUL. THE COATING DEBONDED AND BLOCKED THE OIL PUMP INLET RESULTING IN LOSS OF OIL PRESSURE. IT WAS FURTHER DETERMINED THAT RECOMMENDED PERIODIC VI SUAL INSPECTIONS OF THE PUMP INLET HAD NOT BEEN PERFORMED BY THE OPERATOR. (TC NR 20061107006) 1 L 7 1 3T 3 T RT A78EU E4EA 2006121300081 20061213 00081 EA 2006 12 13 CA061201005 1 20051228 G 5521 C6TE1064 RIB DHAV DHAV DHC6 DHC6200 2802620 EA PWA PT6 PT6A27 52043 EA HARTZL HCB3T HCB3TN3 GL ELEVATOR CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) WHILE PERFORMING AD CF-82-21 R1 USING A BORESCOPE, CRACKS WERE FOUND AT THE ATTACHMENT POINT OF THE TORQUE TUBE TO THE ELEVATOR RIB. SEE PHOTOS AND DAMAGE REPORT. (TC NR 20061201005) 1 H 7 2 3T 4 T RT A9EA E4EA 6 C P15EA 2007050700119 20070507 00119 SO 2007 5 7 CA061219008 1 20051212 G 7714 INDICATOR PIPER PA31 PA31350 7103110 SO LYC O540 TIO540J2BD 41532 EA HARTZL HCE3Y HCE3YR2A GL ENGINE RPM FAILED W O OTHER O OTHER TX TAXI/GRND HDL 1 CA (CAN) TACH CABLE FAILED WHILE ON TAXI CAUSING NO RPM INDICATION. (TC NR 20061219008) 1 L 7 2 3O 3 O A20SO E14EA 5 C P33EA 2007080800139 20070808 00139 CE 2007 8 8 CA070214003 1 20051118 G 5511 043200156 SPAR CESSNA 150 152 2071835 CE LYC O235 O235L2C 41505 EA MCAULY 1A103 1A103TCM GL HORIZONTAL STAB CRACKED W K NONE O OTHER IN INSP/MAINT 1 CA (CAN) DURING 100 HOUR INSPECTION, VERIFICATION OF AD 80-11-04, THE TECHNICIAN FOUND A CRACKED BRACKET. CLOSER INSPECTIO N INDICATED THAT THE SPAR WAS ALSO CRACKED. (TC NR 20070214003) 1 H 7 1 3O 3 O NT 3A19 E223 5 N P50GL 2005062200039 20050622 00039 CE 2005 6 22 CAR110 1 20050604 G 2130 310112 MIXING VALVE RKWELL NA265 NA26560 7630106 CE E/E BAY NOT BONDED B A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 CE 03 XCJDC 306145 HOT AIR MIXING VALVE WAS OVERHAULED BY ROCKER, 1-25-05, REF WO 56559. INSTALLED IN AIRCRAFT FROM STOCK ON 6-4-05. DURI NG FUNCTIONAL TEST FLIGHT FOR PRESSURIZATION PROBLEM, THE UP STREAM FLANGE SEPARATED FROM VALVE HOUSING. RELEASING BLEE D AIR INTO AFT EQUIPMENT BAY. AFT FUSELAGE HOT LIGHTS ILLUMINATED. FLIGHT ABORTED. RED RUBBERIZED INSULATION MELTED/B URNED AWAY NEAR LEAK. POST FLIGHT EVALUATION REVEALED FLANGE NOT WELDED/BRAZED TO HOUSING. 2 L 7 2 4J RT A2WE 2005030800276 20050308 00276 WP 2005 3 8 COOSDR05003 1 20050125 G 5310 DOOR FRAME DOUG DC9 DC915F 3022037 WP PWA JT8 JT8D* NE FUSELAGE CRACKED B EE4Y K NONE O OTHER IN INSP/MAINT 1 SO 23 785TW 47015 FWD CARGO COMPARTMENT, DOOR JAMB, STUB BEAM, PN 5921718-1, SHORT FLANGES CRACKED. (K) 2 L 7 2 4F 4 F A6WE E2EA 2006031500036 20060315 00036 CE 2006 3 15 CQWR20005006 1 20050805 G 2820 651631155 LINE CESSNA 500 560CESSNA 2076750 CE FUEL SYSTEM DAMAGED B DXTA K NONE O OTHER IN INSP/MAINT 1 GL 05 808Q 2048 5600619 DURING PHASE 1 THRU 5 INSPECTION, FOUND REFUEL/DEFUEL FLOW LINE ASSY (P/N 6516311-55) SAWED BY THE FORWARD FLAP CROSS-OV ER CABLE. THIS LINE ASSY HAD BEEN DAMAGED MORE THAN 50 PERCENT OF THE WALL THICKNESS, AND IS LOCATED IN THE LEFT WING R OOT DRY BAY AREA FORWARD OF THE FLAP WELL. THE LINE ASSY IS SUPPORTED BY TWO ADEL CLAMPS. A DESCRIPTION OF THIS REPORT AND PICTURES HAVE BEEN SUBMIT TO CESSNA/CIATION VIA SERVICE CONDITION REPORT NR 200470. 2 L 7 2 4F RT A22CE 2005041100025 20050411 00025 CE 2005 4 11 CWQR20050001 1 20050126 G 3010 66212812930 HEAT SHIELD CESSNA 560 560XL 2076702 CE WINGS CRACKED B DXTA K NONE O OTHER IN INSP/MAINT 1 GL 05 697QS 3352 5605197 DURING INSPECTION FOUND THE LEADING EDGE HEAT SHIELD FLANGE CRACKED ON BOTH LEFT AND RIGHT WINGS. SUBMITTED CESSNS/CITA TION SERVICE CONDITION REPORT 181187 WITH PICTURES. 2 L 7 2 4F RT A22CE 2005041100026 20050411 00026 CE 2005 4 11 CWQR20050002 1 20050128 G 2731 MS21044N3 NUT CESSNA 560 560XL 2076702 CE ELEVATOR TRIM WRONG PART B DXTA K NONE O OTHER IN INSP/MAINT 1 GL 05 688Q 5605188 PILOT FOUND ELEVATOR TRIM OUT OF RIG. TECHICIAN FOUND EXCESSIVE PLAY IN TRIM WHEEL, ALLOWING TRIM INDICATOR POINTER TO JUMP GROOVE IN TRIM WHEEL. FOUND TRIM WHEEL BOLT (P/N AN3-57) NOT TO HAVE NUT (P/N MS21044N3) INSTALLED. NUT WAS FOUND IN AIRCRAFT BELLY. BOLT IS DRILLED FOR COTTER PIN, AND FIBER LOCK NUT WAS INSTALLED. CHECKED IPC, FOUND PROPER HARDWA RE WAS INSTALLED. SUGGEST CASTELLATED NUT BE INSTALLED. SUBMITTED CITATION SERVICE CONDITION REPORT 181391. 2 L 7 2 4F RT A22CE 2005041100024 20050411 00024 CE 2005 4 11 CWQR20050003 1 20050406 G 2842 99144272 SENSOR CESSNA 560 560XL 2076702 CE LOW FUEL ARCED B DXTA K NONE L NO TEST IN INSP/MAINT 1 GL 05 671Q 4538 5605071 DURING INSPECTION FOUND LOW LEVEL FUEL SWITCH INOP AND THE APPEARANCE OF MISSING MATERIAL AND ARCING BETWEEN FLOAT AND S WITCH BODY WHEN FLOAT WAS IN THE UP POSITION. THIS SWITCH HAS BEEN SENT TO CESSNA FOR EVALUATION AND SUBMITTED CITATION SERVICE CONDITION REPORT 187403. 2 L 7 2 4F RT A22CE 2005050300276 20050503 00276 CE 2005 5 3 CWQR20050004 1 20050411 G 7830 64ND784093 SUPPORT BRACKET CESSNA 560 560XL 2076702 CE THRUST REVERSER MISINSTALLED B DXTA K NONE W INADEQUATE Q C IN INSP/MAINT 1 GL 05 626QS 4261 5605293 DURING PHASE 1-4 INSPECTION FOUND LOWER OUTBOARD BARREL SUPPORT BRACKETS INSTALLED INCORRECTLY DURING MANUFACTURE. 2 L 7 2 4F RT A22CE 2005071100068 20050711 00068 CE 2005 7 11 CWQR2005005 1 20050622 G 2810 68C48 DRAIN CESSNA 560 560XL 2076702 CE FUEL SYS POPPED B DXTA K NONE O OTHER IN INSP/MAINT 1 GL 05 609QS 566 5605522 FORWARD RT FUSELAGE STATIC DRAIN VALVE NOT FLUSH. NEW UNIT ORDERED AND INSTALLED, LEAK CHECKED. DURING REMOVAL OF SUSP ECTED BAD PART, ENTIRE CORE POPPED OUT, CONDITION WOULD HAVE DIRECTLY OPENED STATIC SYSTEM. CORE OF UNIT APPEARS TO BE PRESSED AND GLUED INTO PLACE, VERY LITTLE GLUE RESIDUE APPEARED ON CORE OR BASE. THIS IS A RVSM A/C. ALSO, THE VERBIAGE IN THE IPC REFERS TO IT AS A FUEL DRAIN NOT A STATIC DRAIN. 2 L 7 2 4F RT A22CE 20081128 NM 2008 11 28 DL757081592 1 20051027 G 5210 SKIN BOEING 757 757232 1384965 NM L1 DOOR CRACKED C DALA K NONE O OTHER IN INSP/MAINT 1 SO 27 610DL 22817 SUPPLEMENTAL SDR FUSELAGE/SKIN L-1 DOOR CUTOUT/UPPER FWD CORNER-CRACK IAW ERA 090914-14. C/W ERA 090914-14. 2 L 7 2 4F RT A2NM 2005071200063 20050712 00063 NM 2005 7 12 DU4R00507139 1 20050701 G 5754 SKIN BOEING 737 737522 138449F NM NR 4 SLAT GOUGED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 954UA 26739 RIGHT WING NR 4 SLAT HAS SKIN CHAFED THRU AT T/E LOWER INBOARD SKIN SURFACE. 2 L 7 2 4F RT A16WE 2005062400050 20050624 00050 NM 2005 6 24 DU4R0506031 1 20050603 G 5321 FLOORBOARD DOUG MD88 MD88 3023688 NM CABIN DAMAGED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 12FQ 49766 PAX CABIN FLOORBOARD BETWEEN L/S SEAT TRACK AT FS 389 - 465 HAS A VERY SOFT AND VOIDED AREA. 2 L 7 2 4F RT A6WE 2005062700042 20050627 00042 NM 2005 6 27 DU4R05060310 1 20050603 G 5300 PANEL DOUG MD88 MD88 3023688 NM FUSELAGE PUNCTURED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 12FQ 49766 RT CABIN STA 693 PANEL D9 IS PUNCTURED. 2 L 7 2 4F RT A6WE 2005062700043 20050627 00043 NM 2005 6 27 DU4R05060311 1 20050603 G 5300 PANEL DOUG MD88 MD88 3023688 NM FUSELAGE PUNCTURED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 12FQ 49766 RT CABIN STA 350.5 PANEL D2 IS PUNCTURED. 2 L 7 2 4F RT A6WE 2005062700044 20050627 00044 NM 2005 6 27 DU4R05060312 1 20050603 G 5300 PANEL DOUG MD88 MD88 3023688 NM FUSELAGE PUNCTURED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 12FQ 49766 R/H CABIN STA. 335 PANEL B2 IS PUNCTURED. 2 L 7 2 4F RT A6WE 2005062700045 20050627 00045 NM 2005 6 27 DU4R05060313 1 20050603 G 5300 PANEL DOUG MD88 MD88 3023688 NM FUSELAGE PUNCTURED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 12FQ 49766 RT CABIN STA. 655 AND 674 PANEL B8 HAS PUNCTURES. 2 L 7 2 4F RT A6WE 2005062400051 20050624 00051 NM 2005 6 24 DU4R0506032 1 20050603 G 5347 SEAT TRACK DOUG MD88 MD88 3023688 NM FWD CABIN CORRODED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 12FQ 49766 FWD CABIN 256 LBL 24 SEAT TRACK LOWER LEG IS CORRODED. 2 L 7 2 4F RT A6WE 2005062400057 20050624 00057 NM 2005 6 24 DU4R0506033 1 20050603 G 5321 FLOOR PANEL DOUG MD88 MD88 3023688 NM CABIN DAMAGED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 12FQ 49766 CABIN FLOOR PANEL AT FS 875 - 864 HAS A SOFT SPOT LT OVER FUEL ACCESS PANEL. 2 L 7 2 4F RT A6WE 2005062400061 20050624 00061 NM 2005 6 24 DU4R0506034 1 20050603 G 5321 FLOORBOARD DOUG MD88 MD88 3023688 NM CABIN DAMAGED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 12FQ 49766 FLOORBOARD AT R/S SEAT TRACK STA 1193-1250 HAS SOFT SPOTS. 2 L 7 2 4F RT A6WE 2005062400062 20050624 00062 NM 2005 6 24 DU4R0506035 1 20050603 G 5321 FLOOR PANEL DOUG MD88 MD88 3023688 NM CABIN DELAMINATED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 12FQ 49766 LT FLOOR PANEL FS 866 BL 44.5 TO 24.5 DELAMINATED AND SOFT SPOTS. 2 L 7 2 4F RT A6WE 2005062400063 20050624 00063 NM 2005 6 24 DU4R0506036 1 20050603 G 5320 THRESHOLD DOUG MD88 MD88 3023688 NM AFT CARGO BAY CORRODED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 12FQ 49766 AFT CARGO DOOR THRESHOLD HAS CORROSION AROUND FASTENER HOLES AT L-28R. 2 L 7 2 4F RT A6WE 2005062400064 20050624 00064 NM 2005 6 24 DU4R0506037 1 20050603 G 5320 FLOOR SUPPORT DOUG MD88 MD88 3023688 NM FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 12FQ 49766 CENTER FLOORBOARD AT FS 807 TO 886 HAS CRACKED SUPPORT ANGLE. 2 L 7 2 4F RT A6WE 2005062400065 20050624 00065 NM 2005 6 24 DU4R0506038 1 20050603 G 5330 SKIN DOUG MD88 MD88 3023688 NM FUSELAGE DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 12FQ 49766 FUSELAGE SKIN AT FS 224 L-19L 1.2 BY 1.9 IN. DENT 0.043 IN. DEPTH D/X 27.9. 2 L 7 2 4F RT A6WE 2005062700041 20050627 00041 NM 2005 6 27 DU4R0506039 1 20050603 G 5330 SKIN DOUG MD88 MD88 3023688 NM FUSELAGE DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 12FQ 49766 DENT AT FS 237 LEFT LONGERON 17 AND 18L .021 BY .750 IN D/X 35.7. 2 L 7 2 4F RT A6WE 2005070700014 20050707 00014 NM 2005 7 7 DU4R0507002 1 20050701 G 5754 SKIN BOEING 737 737522 138449F NM GE CFM56 CFM56* 13802 NE NR 3 SLAT CHAFED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 954UA 26739 LT WING NR 3 SLAT HAS SKIN CHAFED THRU AT T/E LOWER IB SKIN SURFACE. S/O 269008, OPS NR 24936 2 L 7 2 4F 4 F RT A16WE E2GL 2005070700020 20050707 00020 NM 2005 7 7 DU4R0507003 1 20050630 G 5330 SKIN BOEING 737 737 UTILSYS NM GE CFM56 CFM56* 13802 NE FUSELAGE DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 387UA 24662 DENT AND CREASE IN LOWER FUSELAGE SKIN AT BS 907 BETWEEN S-25R - S-26R. 2 L 7 2 4F 4 F RT A16WE E2GL 2005071200086 20050712 00086 NM 2005 7 12 DU4R0507126 1 20050630 G 5313 STRINGER BOEING 737 737522 138449F NM FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 387UA 24662 CABIN S-15L CRACKED, ALSO END FITTING. 2 L 7 2 4F RT A16WE 2005070700022 20050707 00022 NM 2005 7 7 DU4R0507128 1 20050630 G 5330 SKIN BOEING 737 737 UTILSYS NM GE CFM56 CFM56* 13802 NE FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 387UA 24662 DL/H UPPER FUSELAGE SKIN S-7L HAS 1 EA. CHERRY MAX RIVET FS 420. S/O NR 134005, OPS NR 20347. 2 L 7 2 4F 4 F RT A16WE E2GL 2005071200069 20050712 00069 NM 2005 7 12 DU4R0507133 1 20050630 G 5330 SKIN BOEING 737 7373S1 138447S NM FUELAGE DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 311FL 24856 DENT IN LEFT FUSELAGE EXTERIOR SKIN BS 935 S-26L. 2 L 7 2 4F RT A16WE 2005071200070 20050712 00070 NM 2005 7 12 DU4R0507134 1 20050630 G 5330 SKIN BOEING 737 7373S1 138447S NM FUSELAGE DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 311FL 24856 CREASES IN DENTS AND ON TOP OF STRINGER 27R AT BS 951 - 952 A/Y = 24.7 A/Y 1.875 X .076. 2 L 7 2 4F RT A16WE 2005071100177 20050711 00177 NM 2005 7 11 DU4R0507135 1 20050630 G 5330 SKIN BOEING 737 7373S1 138447S NM CFMINT CFM56 CFM563B2 13802 EU FUSELAGE DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 311FL 24856 CREASE IN DENT AT BS 971 BETWEEN S-24L-25L 2 INCHES X .86 A/Y = 23.3. S/O NR 109002, OPS NR 25863. 2 L 7 2 4F 4 F RT A16WE E21EU 2005071200087 20050712 00087 NM 2005 7 12 DU4R0507137 1 20050701 G 5330 SKIN BOEING 737 737500 138449E NM FUSELAGE DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 954UA FOUND DENT WITH OLD YELLOW DOTS 20 INCHES AFT OF DOOR 2L. 2 L 7 2 4F RT A16WE 2005071200064 20050712 00064 NM 2005 7 12 DU4R0507141 1 20050701 G 5753 SKIN BOEING 737 737522 138449F NM TE FLAP DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 954UA 26739 RIGHT WING INBOARD FORE FLAP LOWER SKIN SURFACE HAS NUMEROUS DENTS. 2 L 7 2 4F RT A16WE 2005071200065 20050712 00065 NM 2005 7 12 DU4R0507143 1 20050701 G 5753 SKIN BOEING 737 737522 138449F NM TE FLAP DELAMINATED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 954UA 26739 RIGHT WING INBOARD MID FLAP WEDGE LOWER T/E SKIN SURFACE DELAMINATED AND DENTED. 2 L 7 2 4F RT A16WE 2005071100157 20050711 00157 NM 2005 7 11 DU4R0507144 1 20050706 G 5311 FRAME BOEING 737 7373S1 138447S NM CFMINT CFM56 CFM563B2 13802 EU BULKHEAD CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 311FL 24856 BS 178 BULKHEAD RT SIDE AFT SIDE FRAME HAS EVIDENCE OF CRACK ABOVE AND BELOW WL 207. 2 L 7 2 4F 4 F RT A16WE E21EU 2005071100154 20050711 00154 NM 2005 7 11 DU4R0507145 1 20050706 G 5312 BULKHEAD BOEING 737 7373S1 138447S NM CFMINT CFM56 CFM563B2 13802 EU FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 311FL 24856 CRACK APPROX. 5.5 INCHES BELOW WL 207 IB SIDE LBL 5.7 APPROX. 1.2 INCH IN LENGTH AT BS 178 BULKHEAD. 2 L 7 2 4F 4 F RT A16WE E21EU 2005071500021 20050715 00021 NM 2005 7 15 DU4R0507146 1 20050706 G 5312 BULKHEAD BOEING 737 7373S1 138447S NM FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 311FL 24856 CRACK APPROX 8 IN BELOW WL 207 INBD SIDE RBL 5.7 APPROX 1.5" IN LENGTH AT BS 178 BULKHEAD. 2 L 7 2 4F RT A16WE 2005071500022 20050715 00022 NM 2005 7 15 DU4R0507147 1 20050706 G 5330 SKIN BOEING 737 7373S1 138447S NM FUSELAGE DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 311FL 24856 DENT 3 IN DIAMETER, DEPTH .015 INCHES FUSELAGE S 1070 S-14L FRONTIER DENT TALLY ITEM NR 3. 2 L 7 2 4F RT A16WE 2005071100155 20050711 00155 NM 2005 7 11 DU4R0507148 1 20050706 G 5330 SKIN BOEING 737 7373S1 138447S NM CFMINT CFM56 CFM563B2 13802 EU FUSELAGE DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 311FL 24856 DENT AT RT EXTERNAL FUSELAGE SKIN AT BS 391.5 BETWEEN S-22R AND S-23R. 2 L 7 2 4F 4 F RT A16WE E21EU 2005071500023 20050715 00023 NM 2005 7 15 DU4R0507149 1 20050706 G 5330 SKIN BOEING 737 7373S1 138447S NM FUSELAGE DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 311FL 24856 DENT AT LT EXTERNAL FUSELAGE SKIN AT BS 997.5 BETWEEN S-13L AND S-14L. 2 L 7 2 4F RT A16WE 2005071500029 20050715 00029 NM 2005 7 15 DU4R0507150 1 20050706 G 5330 SKIN BOEING 737 7373S1 138447S NM FUSELAGE DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 311FL 24856 DENT AT RT EXTERNAL FUSELAGE SKIN AT BS 876 S-21R AND S-22R. 2 L 7 2 4F RT A16WE 2005071100140 20050711 00140 NM 2005 7 11 DU4R0507153 1 20050707 G 5330 SKIN BOEING 737 7373S1 138447S NM CFMINT CFM56 CFM563B2 13802 EU FUSELAGE DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 311FL 24856 FUSELAGE SKIN HAS DENT AT BS 480 S-26R - S-28R. 2 L 7 2 4F 4 F RT A16WE E21EU 2005071400009 20050714 00009 NM 2005 7 14 DU4R0507155 1 20050707 G 5313 STRINGER BOEING 737 7373S1 138447S NM FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 311FL 24856 STRINGER 27R CRACKED. 2 L 7 2 4F RT A16WE 2005071400010 20050714 00010 NM 2005 7 14 DU4R0507156 1 20050707 G 5330 SKIN BOEING 737 7373S1 138447S NM FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 311FL 24856 FUSELAGE EXTERNAL SKIN CRACKED AT S-24R BETWEEN BS 727D - 727E. 2 L 7 2 4F RT A16WE 2005071400011 20050714 00011 NM 2005 7 14 DU4R0507157 1 20050707 G 5330 SKIN BOEING 737 7373S1 138447S NM FUSELAGE DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 311FL 24856 DENT AT RT EXTERNAL FUSELAGE AT BS 871 BETWEEN S-22R AND S-23R. 2 L 7 2 4F RT A16WE 2005072900045 20050729 00045 NM 2005 7 29 DU4R0507159 1 20050728 G 5311 FRAME BOEING 757 757232 1384965 NM FUSELAGE DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 624DL 22914 AFT CARGO BAY LT BS 1340 AT S-25L MAIN FRAME HAS DENT. 2 L 7 2 4F RT A2NM 2005072900046 20050729 00046 NM 2005 7 29 DU4R0507160 1 20050728 G 5311 FRAME BOEING 757 757232 1384965 NM FUSELAGE DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 624DL 22914 AFT CARGO BAY LT BS 1480 AT S-25L MAIN FRAME HAS DENTS. 2 L 7 2 4F RT A2NM 2005072900067 20050729 00067 NM 2005 7 29 DU4R0507161 1 20050728 G 5311 FRAME BOEING 757 757232 1384965 NM FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 624DL 22914 AFT BAG PIT LT BS 1500 AT S-26L MAIN FRAME HAS DENT/CRACK. 2 L 7 2 4F RT A2NM 2005072900051 20050729 00051 NM 2005 7 29 DU4R0507165 1 20050728 G 5320 SHEAR WEB BOEING 757 757232 1384965 NM FUSELAGE CORRODED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 624DL 22914 CORROSION IN SHEAR WEB SURFACE FROM BS 1681.8 - 1720 BL 0 - BL 60R INCLUDING FASTENERS. 2 L 7 2 4F RT A2NM 2005072900065 20050729 00065 NM 2005 7 29 DU4R0507166 1 20050728 G 5310 CREASE BEAM BOEING 757 757232 1384965 NM FUSELAGE CORRODED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 624DL 22914 CORROSION ON CREASE BEAM AT 364 - 371 RBL 65. 2 L 7 2 4F RT A2NM 2005072900072 20050729 00072 NM 2005 7 29 DU4R0507168 1 20050728 G 5320 SUPPORT BOEING 757 757232 1384965 NM FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 624DL 22914 CRACKED/TORN METAL SUPPORT IN CABIN FUSELAGE AT BS 1040 - 1060 JUST AFT OF FLOORBOARD 1020A. 2 L 7 2 4F RT A2NM 2005072900106 20050729 00106 NM 2005 7 29 DU4R0507170 1 20050728 G 5210 DOOR FRAME BOEING 757 757232 1384965 NM PAX DOOR CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 624DL 22914 RT NR 2 DOOR ON FRAME 27 IS CRACKED. 2 L 7 2 4F RT A2NM 2005072900074 20050729 00074 NM 2005 7 29 DU4R0507171 1 20050728 G 5210 DOOR BOEING 757 757232 1384965 NM R4 DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 624DL 22914 R-4 DOOR IS DENTED ON THE LOWER AFT CORNER. 2 L 7 2 4F RT A2NM 2005051700195 20050517 00195 NM 2005 5 17 DU4R20050428 1 20050428 G 5320 FLOOR SUPPORT BOEING 737 7373L9 1384470 NM FUSELAGE CORRODED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 312FL 24569 CORROSION AT FLOORBOARD ANGLE SUPPORT FROM BS 947 - 1000 LBL 68. 2 L 7 2 4F RT A16WE 2005042000066 20050420 00066 SO 2005 4 20 DUKESPUMPMPG 2 20050405 G 7314 41400015RX PUMP CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO FUEL SYSTEM LEAKING D O OTHER K FLUID LOSS NR NOT REPORTED 1 WP 21 PKMPG 321 U20606585 PUMP IS LEAKING AT THE SEAL AT THE BASE OF THE PUMP, NEAR DRAIN PIPE. 1 H 7 1 3O 3 O A4CE E8CE 2005042000065 20050420 00065 SO 2005 4 20 DUKESPUMPPKMP 2 20050405 G 7314 41400015RX PUMP CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO FUEL SYSTEM LEAKING D K NONE O OTHER IN INSP/MAINT 1 WP 21 PKMPG 321 U20606585 PUMP IS LEAKING AT THE SEAL AT THE BASE OF THE PUMP-NEAR/AT DRAIN PIPE. 1 H 7 1 3O 3 O A4CE E8CE 2005072600314 20050726 00314 CE 2005 7 26 DYCR200532202 1 20050726 G 3240 90C897001 BRAKE ASSY CESSNA 500 550 2076604 CE ZONE 700 DAMAGED B DYCR C ABORTED TAKEOFF E VIBRATION/BUFFET TO TAKEOFF 1 GL 07 550KA 171 5500279 BRAKE IS PART OF MTOW STC BY NEWFLIGHT. BRAKE AND WHEEL ASSEMBLY FIT FINE, HOWEVER AFTER SEVERAL FLIGHT HOURS THE BRAKE LUGS ON THE INNER WHEEL HALF RUB THE PIN IN THE LOWER TORQUE LINK DAMAGING THE WHEEL HALF AND THE TORQUE LINK. AXLE NUT IS TORQUED AT INITIAL INTALL, BUT IT WAS NOTED UPON THIS DISCREPANCY THAT THE NUT WAS NOW ONLY FINGER TIGHT. LOCK SCREWS AND SAFETY WIRE WERE STILL IN PLACE. 1 L 7 2 4F A22CE 2005042600010 20050426 00010 GL 2005 4 26 EAHR200500001 1 20050308 G 6520 28135079 SPACER ENSTRM ENSTRM F28 280FX 3300506 GL LYC O360 HIO360F1AD 41514 EA T/R GEARBOX CRACKED B K NONE O OTHER IN INSP/MAINT 1 GL 09 1200 1200 2551794T 2079 CRACK ON ID OF SPACER OF TAIL ROTOR GEARBOX. 1 G 7 1 3O 3 O H1CE 1E10 2005102400170 20051024 00170 GL 2005 10 24 EAHR200500002 1 20050930 G 8120 037360115 ADAPTER ENSTRM F28 F28F 3300412 GL LYC O360 HIO360F1AD 41514 EA TURBOCHARGER BROKEN B K NONE O OTHER IN INSP/MAINT 1 GL 09 8095 4039 10 754 L2516051A WELD BROKEN AT TURBO-CHARGER FLANGE. 1 G 7 1 3O 3 O H1CE 1E10 2005110700168 20051107 00168 GL 2005 11 7 EAHR200500003 1 20051101 G 2430 VR152811B GCU ENSTRM F28 ENSTROM480 GL ALLSN 250C 250C20 03013 GL DC SYSTEM MALFUNCTIONED B K NONE O OTHER IN INSP/MAINT 1 GL 09 735 5025 CAE845049 GENERATOR CONTROL UNIT CAUSES GENERATOR RELAY TO CYCLE ON AND OFF. 1 G 7 1 3O 3 U NC H1CE E4CE 2006010500268 20060105 00268 SO 2006 1 5 EC3R20050001 1 20051121 G 3230 LANDING GEAR AID GULSTM GV GULFSTREAMGV 3980116 SO RT MLG MALFUNCTIONED B EC3R A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 WP 09 225GV 672 RT MAIN LANDING GEAR STUCK IN TRANSIT. WOULD NOT FULLY RETRACT OR EXTEND. EVENTUALLY WAS ABLE TO GET GEAR DOWN AND LOC KED, UNEVENTFUL LANDING. 2 L 7 2 4F RT A12EA 2005072000116 20050720 00116 CE 2005 7 20 ERYR682D 1 20050715 G 2750 45A6103511 CABLE BEECH MU300 400A 1155402 CE ZONE 500 BROKEN B K NONE L NO TEST IN INSP/MAINT 1 SO 11 746TA 6580 RK146 FLAP FOLLOW-UP CABLE WAS DISCOVERED CORRODED AND BROKEN IN HALF DURING AN INSPECTION. 2 H 7 2 4F RT A16SW 2005102800047 20051028 00047 GL 2005 10 28 EY2R77637 3 20051011 G 6114 2A34C203 HUB MCAULY 2A34C203 CESSNA 172 R172K 2072431 CE MCAULY 2A34C 2A34C203 GL PROPELLER CORRODED B EY2R O OTHER O OTHER NR NOT REPORTED 1 GL 03 776084 776084 PITTING CORROSION ON INTERNAL SURFACES OF PROPELLER HUB. 1 H 7 1 3O 3A17 5 C P3EA 2005062800150 20050628 00150 SO 2005 6 28 F8ZR871Y 1 20050606 G 8011 MOUNT PIPER PA28 PA28181 7102807 SO LYC O360 O360* 41514 EA STARTER CRACKED B F8ZR O OTHER O OTHER NR NOT REPORTED 1 WP 07 429PA E101996 2843487 MOUNTING PLATE STRESSED CRACKED. IDENTICAL TO OTHER FAILURES. CRACKS ON BOTH UNITS WERE 2 INCHES LONG. (K) 1 L 7 1 3O 3 O 2A13 E286 2005071800222 20050718 00222 CE 2005 7 18 FAA0507001 1 20050707 G 3213 2500404511 STRUT HELIO H250 H250 4300302 CE MLG FAILED C O OTHER O OTHER TX TAXI/GRND HDL 1 AL 05 7004 2530 RIGHT LANDING GEAR FAILED DURING TAXI. 1 H 7 1 3O 1A8 2005060100021 20050601 00021 2005 6 1 FAAAL01002 1 20050512 G 2710 TURNBUCKLE AILERON CRACKED G K NONE O OTHER IN INSP/MAINT 1 AL 01 FSDO SENT INFO LETTER TO ALL IA`S IN DISTRICT REGARDING TURNBUCKLES CRACKING AT ENDS THUS LOOSING STRUCTURAL INTEGRITY O F TURNBUCKLE ON PRIMARY FLT CONTROLS AS A RESULT OF SURVEILIANCE CONDUCTED IN DISTRICT, DISCOVERING PROBLEM. AS A RESUL T OF LETTER MECHANIC GAVE OFFICE AFTER OFFICE SENT OUT LETTER REGARDING TURNBUCKLES AND AFTER AC WAS INSPECTED. TURNBUCK LE WAS INSTALLED ON AN AILERON CONTROL CABLE. THIS TURNBUCKLE HAS NO V NOTCH ALLOWING FOR CLIPS TO BE USED. RECOMMEND AD BE IMPLEMENTED MANDATING REPLACEMENT OF ALL TURNBUCKLES THAT DO NOT HAVE A DATE ON THEM. DOCUMENT RECOMMENDS THE ACT ION OF NOT REUSING TURNBUCKLES W/DATE OF 1978 OR PRIOR. MS21251M AND PHOTO OF TURNBUCKLE MFG IN APPROX 1952.(K) 2005092600081 20050926 00081 CE 2005 9 26 FCPR200500020 1 20050812 G 3250 50820042601 BARREL BEECH 300 300BEECH 1152930 CE PWA PT6 PT6A60A 52043 NE NLG STEERING BROKEN B FCPR O OTHER O OTHER TX TAXI/GRND HDL 1 NM 09 544PS 8140 FA90 SHARP TAXI TURN, NOSE WHEEL STEERING BARREL BROKE AT RETAINER AREA. C/W SB 220 TO PREVENT RECURRENCE. (K) 2 L 7 2 4T 4 T A24CE E4EA 2005080200138 20050802 00138 EU 2005 8 2 GQRR082005 1 20050802 G 3232 D52177 HOLDER MESSIER AMD FALC20 FALCON200 2730150 EU ACTUATOR PACKING BROKEN B GQRA O OTHER K FLUID LOSS DE DESCENT 1 SW 05 064 THE PACKING HOLDER P/N D52177 INSIDE OF THE MAIN GEAR ACTUATOR BROKE APART IN TWO PIECES.THIS CAUSED LOSS OF HYDRAULIC F LUID TO THE AIRCRAFT. THIS PART HAD NOT BEEN MODIFIED IAW SB TO PREVENT THIS PART FROM BREAKING. THIS IS THE 3RD PACKIN G HOLDER FOUND TO BE CRACKED OR BROKEN, WHERE MODIFIED OR NOT. 2 L 7 2 4F RT A7EU 2005050500088 20050505 00088 EU 2005 5 5 HDS0315051 1 20050316 G 5531 109037301 FRAME AGUSTA A109 A119 0261102 EU PWA PT6 PT6* 52043 EA VERT STABILIZER CRACKED B VK1R K NONE O OTHER IN INSP/MAINT 1 SW 19 521RC 14019 THIS IS TO REPORT CRACKS IN THE FRAMES ON THE VERTICAL FIN, IN THE AREAS AT WL 2145.0 AND 2520.0. THESE CRACKS ARE OCCU RRING APPROXIMATELY BETWEEN FS 9350.0 TO 9850.0. (SW19200508005) (K) 1 G 7 2 3U 3 T H7EU E2NE 2005050400034 20050504 00034 EU 2005 5 4 HE89099847 1 20050317 G 2435 150SG117Q STARTER GEN AEROSP AS355 AS355F1 8680810 EU ALLSN 250C 250C20F 03013 GL ENGINE UNSERVICEABLE Z O OTHER O OTHER TX TAXI/GRND HDL 1 SW 03 ZKHDG 5212 CAE840557 STARTER WOULDN'T START ENGINE 1 G 7 2 3U 3 U H11EU E4CE 2005072600265 20050726 00265 SO 2005 7 26 IAD05LA064 1 20050726 G 7820 6690602 MUFFLER PIPER PA28 PA28140 7102802 SO EXHAUST BLOCKED G O OTHER R PARTIAL RPM/PWR LOSS CL CLIMB 1 EA 17 55165 287325336 MUFFLER INTERNAL BAFFLE CAME LOOSE. TAILPIPE SAFETY RODS DID NOT PROTRUDE FAR ENOUGH INTO MUFFER TO PREVENT BLOCKAGE. 1 L 7 1 3O 2A13 2005102600219 20051026 00219 CE 2005 10 26 IGL1520050080 1 20050915 G 7820 15006 MUFFLER CESSNA 175 175 2072502 CE LYC O360 O360* 41514 EA HARTZL HCC2Y HCC2Y* GL EXHAUST DETERIORATED G A UNSCHED LANDING O OTHER CR CRUISE 1 GL 15 7219M 800 7 55519 L1881136A CH13441 EXHAUST MUFFLER CRACKED AND DETERIORATED AND WAS NOT DETECTED DUE TO LOCATION UNDER HEAT SHROUD. MUFFLER IS PART OF ENG INE CONVERSION STC NR SA777CE, KIT NR 740. 1 H 7 1 3O 3 O NT 3A17 E286 5 C P920 2005072600198 20050726 00198 CE 2005 7 26 IS4R200500002 1 20050513 G 2140 45C40 TUBE BEECH 95 95B55 1152729 CE CONT O470 IO470* 17026 SO COMBUSTION CRACKED B IS4R O OTHER O OTHER NR NOT REPORTED 1 SO 09 560X 7650187 TC968 HEATER COR RECEIVED FROM CUSTOMER. COMBUSTION TUBE FOUND CRACKED AT CROSSOVER PART WHICH CONNECTS THE INNER COMBUSTION TUBE TO THE OUTER COMBUSTION TUBE. MALFUNCTION FOUND USING A PRESSURE DECAY TEST, EVEN THOUGH THIS TEST IS NOT REQUIRED ON THE D83A28 HEATER ASSY. THE SERIAL NUMBER ON THE COMBUSION TUBE INDICATES IT WAS MFG IN AUG 1995. RECOMMEND PRESSU RE DECAY TESTS ON THESES HEATER ASSEMBLIES. AD DOES NOT APPLY TO THESE HEATERS. (K) 1 L 7 2 3O 3 O RT 3A16 E1CE 2005072600160 20050726 00160 CE 2005 7 26 IS4R200500003 1 20050513 G 2140 51A45 COMBUSTION HEAD BEECH 95 95B55 1152729 CE CONT O470 IO470* 17026 SO HEATER WORN B IS4R O OTHER O OTHER NR NOT REPORTED 1 SO 09 560X 7650187 TC968 HEATER CORE RECEIVED FROM CUSTOMER. UPON TEARDOWN, FOUND INTERIOR OF THE COMBUSTION HEAD SEVERELY WORN FROM FLAME EROSI ON. PREVIOUS INSPECTIONS BY THIS REPAIR STATION HAVE FOUND SMALL HOLES APPEARING IN THE WALL OF THE COMBUSTION HEAD. F ROM THE OUTSIDE, THE COMBUSION HEAD APPEARS GOOD INTERNALLY, THIS COMBUSTION HEAD IS UNAIRWORTHY. BY FOLLOWING THE MFG AND MM THESE CONDITIONS WOULD HAVE BEEN FOUND EARLIER. TBO TIME IS EVERY 500 HOURS OF HEATER OPERATION OR EVERY ENGINE OVERHAUL, WHICHEVER OCCURS FIRST. (K) 1 L 7 2 3O 3 O RT 3A16 E1CE 2005050600089 20050506 00089 2005 5 6 JGVR2005P7YFA 4 20050415 G 3420 2300626020 MOTOR COLLINS ADI85A ADI INTERMITTENT B JGVR O OTHER O OTHER NR NOT REPORTED 1 CE 09 822 INTERMITTENT MOTOR CAUSED STICKING FLIGHT DIRECTOR COMMAND FUNCTION. THIS CAUSED THE COMMAND FLAG TO BE INTERMITTENTLY DISPLAYED. INSPECTION REVEALED THE MOTOR TO HAVE HIGH RESISTANCE. THIS MOTOR WAS INSTALLED NEW IN AUGUST 2004. DATE C ODE ON THE MOTOR IS 0424. 2006012400202 20060124 00202 CE 2006 1 24 JK1205 1 20050820 G 7920 AE7013002H0194 LINE CESSNA 441 441 2076020 CE GARRTT TPE331 TPE33110 01514 WP OIL SYSTEM LEAKING D E A ENGINE SHUTDOWN UNSCHED LANDING K J Y FLUID LOSS WARNING INDICATION ENGINE STOPPAGE CR CRUISE 1 NM 07 441DD 4410341 P77719 THE ENGINE OIL LINE SUPPLYING OIL TO THE OIL COOLER BEGAN TO LEAK RAPIDLY INFLIGHT. OIL PRESSURE WAS LOST, THE ENGINE W AS SHUTDOWN AND AN UNSCHEDULED LANDING WAS ACCOMPLISHED WITHOUT DAMAGE. INSPECTION REVEALED THAT THE LOSS WAS FROM THE P/N AE7013002H0194 OIL HOSE, THE INTERNAL LINING APPEARED TO HAVE BEEN SOFTENED AND RIPPED SUCH AS POSSIBLY A COMPOUND T HAT WAS NOT COMPATIBLE WITH THE 2380 ENGINE OIL. 1 L 7 2 3T 4 T RT A28CE E4WE 2006010400121 20060104 00121 WP 2006 1 4 JKWS1205 2 20050820 G 7261 AE7013002H0194 HOSE CESSNA 441 441 2076020 CE ALIDSG TPE331 TPE331201A 0517 WP ZONE 400 LEAKING D E A ENGINE SHUTDOWN UNSCHED LANDING K J FLUID LOSS WARNING INDICATION CR CRUISE 1 NM 07 441DD 4410341 P77719 THE ENGINE OIL LINE SUPPLYING OIL TO THE OIL COOLER BEGAN TO LEAK RAPIDLY IN-FLIGHT. OIL PRESSURE WAS LOST, THE ENGINE WAS SHUTDOWN AND AN UNSCHEDULED LANDING WAS ACCOMPLISHED WITHOUT DAMAGE. INSPECTION REVEALED THAT THE LOSS WAS FROM THE P/N AE7013002H0194 OIL HOSE, THE INTERNAL LINING APPEARED TO HAVE BEEN SOFTENED AND RIPPED SUCH AS POSSIBLY A COMPOUND THAT WAS NOT COMPATIBLE WITH THE 2380 ENGINE OIL. FAILURE OCCURRED. 1 L 7 2 3T 3 T RT A28CE AEXJ STC 2005032800075 20050328 00075 SO 2005 3 28 KBUY5052 1 20050216 G 3220 36742016 SWITCH PIPER PA32 PA32R301 7103218 SO NLG OPEN D O OTHER J WARNING INDICATION AP APPROACH 1 SO 05 61KD 3336 175 3213065 PILOT REPORTED UNSAFE NLG ON FINAL. CYCLED AND INDICATION WAS SAFE. JACKED AC, RAN GEAR THROUGH RIG AND OPS CK. FOUND NL G DOWN LIMIT SWITCH WOULD NOT ACTIVATE PUMP IF IT WAS NOT DOWN AND LOCKED. REPLACED SWITCH AND OPS CK SYSTEM THROUGH 5 N ORMAL AND 3 EMERGENCY CYCLES. AC RETURNED TO SERVICE. BENCH CHECK OF SWITCH REVEALED OPEN CONDITION WHEN IT SHOULD BE CL OSED. 1 L 7 1 3O A3SO 2005082200057 20050822 00057 GL 2005 8 22 KESE0508001 2 20050816 G 7314 PUMP AMTR SUBURU SUBURU GL FUEL SYS SEIZED C A UNSCHED LANDING R J PARTIAL RPM/PWR LOSS WARNING INDICATION AP APPROACH 1 EA 23 18GK 226 ELECTRIC FUEL PUMP FAILED UPON THROTTLE RETARDATION WHILE TURNING BASE LEG TO FINAL FOR LANDING. ENGINE SHUT OFF AND SU CCESSFUL DEAD STICK APPROACH AND LANDING EXECUTED. NO DAMAGE OR INJURIES. PUMP PISTON FOUND TO BE SIEZED AND WAS BROKE N FREE WITH FORCE. CORROSION EVIDENT ON BARREL WHICH LOOKED TO BE BRASS. THIS INSTALLATION HAS NO ENGINE DRIVEN FUEL PU MP AND FAILED UNIT IS RELIED UPON AT LOW POWER SETTINGS. SUGGEST ROUTINE LUBRICATION AND REPLACEMENT. 3 O EXPE3O 2005120200089 20051202 00089 2005 12 2 L3WSA 4 20051118 G 2216 6565001197 CONTROL CABLE HONEYWELL CESSNA 500 550 2076604 CE AUTOPILOT SERVO FRAYED B K NONE O OTHER IN INSP/MAINT 1 SW 17 2663Y 7495 5500602 WE HAVE FOUND THE ELEVATOR AUTOPILOT SERVO LT CABLE WITH BROKEN STRANDS ON 3 SUCCESSIVE AIRCRAFT THAT WERE UNDERGOING A PHASE 5 INSPECTION. ON CABLE HAD 50 PERCENT FRAYING. THE FRAYING WAS FOUND WHERE THE CABLE PASSES THROUGH A DOUBLE CABLE JOGGLE AT FUSELAGE STA 428.50 AND CAN BE DIFFICULT TO DETECT. THE 3 SUBJECT AIRCRAFT HAD 7495, 8856 AND 13393 HOURS TOT AL TIME. THE IPC REFERENCE FOR THE CABLE IS 22-10-00, FIGURE 1, PAGE 3, ITEM 85. 1 L 7 2 4F A22CE 2005041400106 20050414 00106 WP 2005 4 14 LCQ20050120 1 20050120 G 5321 FLOOR PANEL DOUG DC9 DC932 3022066 WP FUSELAGE CRACKED B K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 MAIN CABIN FLOOR PANEL NR 85 HAS HALF SECTION CRACKED OUT. S/O 152051, OPS 29532, ZONE 6C-127. 2 L 7 2 4F A6WE 2005041400107 20050414 00107 WP 2005 4 14 LCQ20050120A 1 20050120 G 5320 CHANNEL DOUG DC9 DC932 3022066 WP FUSELAGE CRACKED B K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 LT CENTER FS 606 TO 680 HAS SURFACE CORROSION ON CHANNELS, CRACKED OUT ON ENDS AND CENTER AREAS. S/O 152051, OPS 29568, ZONE 6C-145. 2 L 7 2 4F A6WE 2005031500034 20050315 00034 WP 2005 3 15 LCQ29 1 20050119 G 5330 SKIN DOUG DC9 DC932 3022066 WP FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 SKIN CRACKED AT FS 996 STRINGER 23L. S/O 152051, OPS 29033, ZONE 1A-16. 2 L 7 2 4F A6WE 2005031100037 20050311 00037 WP 2005 3 11 LCQ30 1 20050119 G 5330 SKIN DOUG DC9 DC932 3022066 WP PWA JT8 JT8D9A 52048 NE FUSELAGE LIGHTNING STRIKE C K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 AIRCRAFT NOSE RT STA 69, APPROX. 15 INCHES ABOVE FLOOR REFERENCE PLANE HAS A LIGHTNING STRIKE. S/O 152051, OPS 29036, Z ONE 1A-18 2 L 7 2 4F 4 F A6WE E2EA 2005031500038 20050315 00038 WP 2005 3 15 LCQ31 1 20050119 G 5330 SKIN DOUG DC9 DC932 3022066 WP FUSELAGE LIGHTNING STRIKE B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 FOUND LIGHTNING STRIKE INDICATION AT L-4R BS 659. S/O 152051, OPS 29677, ZONE 1A-54. 2 L 7 2 4F A6WE 2005031500039 20050315 00039 WP 2005 3 15 LCQ32 1 20050119 G 5330 SKIN DOUG DC9 DC932 3022066 WP FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 FS 64.150 SKIN IS CRACKED AROUND FASTENER, 10TH FASTENER DOWN FROM CUSP LINE. S/O 152051, OPS 29845, ZONE 1A-67. 2 L 7 2 4F A6WE 2005031500040 20050315 00040 WP 2005 3 15 LCQ33 1 20050119 G 5330 SKIN DOUG DC9 DC932 3022066 WP FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 SKIN CRACKED ON RT SIDE OF FUSELAGE CANTED FRAME STA 1155.225 MID WAY BETWEEN RIVETS 2 INCH LENGTH. S/O 152051, OPS 298 66, ZONE 1A-69. 2 L 7 2 4F A6WE 2005031500041 20050315 00041 WP 2005 3 15 LCQ34 1 20050119 G 5313 LONGERON DOUG DC9 DC932 3022066 WP FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 L-23L CRACKED AT FRAME ATTACH FASTENERS FS 200 E&E COMPARTMENT. S/O 152051, OPS 29808, ZONE 1C-16. 2 L 7 2 4F A6WE 2005031500042 20050315 00042 WP 2005 3 15 LCQ35 1 20050119 G 5313 LONGERON DOUG DC9 DC932 3022066 WP FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 L-25L CRACKED AT FRAME ATTACH FASTENER (UPPER AND LOWER FASTENERS) FS 160 E&E COMPARTMENT. S/O 152051, OPS 29807, ZONE 1C-17. 2 L 7 2 4F A6WE 2005031500043 20050315 00043 WP 2005 3 15 LCQ36 1 20050119 G 5514 FITTING DOUG DC9 DC932 3022066 WP HORIZ STAB CORRODED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 HORIZONTAL STABILIZER LT MOUNT LUG FITTING FOR PIVOT BEARING O/B FACE HAS CORROSION. S/O 152051, OPS 29688, ZONE 2A-24. 2 L 7 2 4F A6WE 2005031100061 20050311 00061 WP 2005 3 11 LCQ37 1 20050119 G 5310 DOOR FRAME DOUG DC9 DC932 3022066 WP PWA JT8 JT8D9A 52048 NE FUSELAGE CORRODED C K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 STA. 908.5, AFT CARGO DOOR FRAME WEB HAS CORROSION ON VERTICAL SUPPORT, FOUR CORNERS FWD SIDE. S/O 152051, OPS 29258, ZO NE 1E-3 2 L 7 2 4F 4 F A6WE E2EA 2005031500044 20050315 00044 WP 2005 3 15 LCQ39 1 20050119 G 5543 DOUBLER DOUG DC9 DC932 3022066 WP RUDDER TAB DEBONDED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 RUDDER TRIM TAB REPAIR DOUBLER DISBONDED ON RT SIDE. S/O 152051, OPS 29865, ZONE 2B-3. 2 L 7 2 4F A6WE 2005031500045 20050315 00045 WP 2005 3 15 LCQ40 1 20050119 G 5347 SEAT TRACK DOUG DC9 DC932 3022066 WP FUSELAGE BROKEN B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 CAPTAIN'S O/B SEAT TRACK HAS THE END PIECE BROKEN OFF. S/O 152051, OPS 29443, ZONE 6A-24. 2 L 7 2 4F A6WE 2005031500046 20050315 00046 WP 2005 3 15 LCQ41 1 20050119 G 5321 FLOOR PANEL DOUG DC9 DC932 3022066 WP FUSELAGE CORRODED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 MAIN CABIN FLOOR PANEL NR 7 HAS SURFACE CORROSION THRU OUT TOP AND BOTTOM. S/O 152051, OPS 29210, ZONE 6C-24. 2 L 7 2 4F A6WE 2005031500049 20050315 00049 WP 2005 3 15 LCQ42 1 20050119 G 5321 FLOOR PANEL DOUG DC9 DC932 3022066 WP FUSELAGE CORRODED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 MAIN CABIN FLOOR PANEL NR 4 HAS SURFACE CORROSION THROUGH OUT TOP AND BOTTOM. S/O 152051, OPS 29208, ZONE 6C-26. 2 L 7 2 4F A6WE 2005031500050 20050315 00050 WP 2005 3 15 LCQ43 1 20050119 G 5321 FLOOR PANEL DOUG DC9 DC932 3022066 WP FUSELAGE CORRODED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 MAIN CABIN FLOOR PANEL 2A IS CORRODED. S/O 152051, OPS 29207, ZONE 6C-27. 2 L 7 2 4F A6WE 2005031500053 20050315 00053 WP 2005 3 15 LCQ44 1 20050119 G 5320 PAN DOUG DC9 DC932 3022066 WP FUSELAGE CHAFED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 CABIN FLOOR PAN HAS CHAFED THRU AREA STA 237 RBL 3 FROM THE CENTER. S/O 152051, OPS 29425, ZONE 6C-85. 2 L 7 2 4F A6WE 2005031500058 20050315 00058 WP 2005 3 15 LCQ45 1 20050119 G 5321 FLOOR PANEL DOUG DC9 DC932 3022066 WP FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 CABIN FLOOR PANEL HAS GOUGE AND CRACK FWD OF FS 237 I/B OF LEFT O/B SEAT TRACK. S/O 152051, OPS 29423, ZONE 6C-87. 2 L 7 2 4F A6WE 2005031500060 20050315 00060 WP 2005 3 15 LCQ46 1 20050119 G 5321 FLOOR PANEL DOUG DC9 DC932 3022066 WP FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 CABIN FLOOR PANEL HAS 3 EACH AREAS WORN AND CRACKED AT FS 237 LBL 7 FROM CENTER. S/O 152051, OPS 29422, ZONE 6C-88. 2 L 7 2 4F A6WE 2005031500062 20050315 00062 WP 2005 3 15 LCQ47 1 20050119 G 5321 FLOOR PANEL DOUG DC9 DC932 3022066 WP FUSELAGE DAMAGED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 CABIN FLOOR PANEL 73 LT CENTER HAS HOLES ON THE EDGE TORN OUT. S/O 152051, OPS 29524, ZONE 6C-119. 2 L 7 2 4F A6WE 2005031500066 20050315 00066 WP 2005 3 15 LCQ48 1 20050119 G 5321 FLOOR PANEL DOUG DC9 DC932 3022066 WP FUSELAGE CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 MAIN CABIN FLOOR PANEL FS 120 - 160 HAS CRACKS ON TOP SKIN AND CORROSION. TOP AND BOTTOM SIDE HAS HOLES DRILLED IN HALF SECTION. S/O 152051, OPS 29528, ZONE 6C-123. 2 L 7 2 4F A6WE 2005031100032 20050311 00032 WP 2005 3 11 LCQ49 1 20050120 G 5321 FLOOR PANEL DOUG DC9 DC932 3022066 WP PWA JT8 JT8D9A 52048 NE MAIN CABIN CORRODED C K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 MAIN CABIN FLOOR PANEL NR 83 HAS SURFACE CORROSION AND A PUNCTURE. S/O 152051, OPS 29530, ZONE 6C-125 2 L 7 2 4F 4 F A6WE E2EA 2005020100003 20050201 00003 WP 2005 2 1 LCQ50 1 20050120 G 5321 FLOOR PANEL DOUG DC9 DC932 3022066 WP FUSELAGE CRACKED C K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 MAIN CABIN FLOOR PANEL NR 80 HAS SECTION CRACKED OUT IN THE CENTER AND TOP SKIN CRACKED OUT ON EDGES. S/O 152051, OPS 2 9531, ZONE 6C-126. 2 L 7 2 4F A6WE 2005020100009 20050201 00009 WP 2005 2 1 LCQ52 1 20050120 G 5321 FLOOR PANEL DOUG DC9 DC932 3022066 WP FUSELAGE CRACKED C K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 MAIN CABIN FLOOR PANEL NR 92 HAS CORNERS BROKEN OUT OF TOP SKIN, HALF SECTION IS CRACKED AND HAS SURFACE CORROSION. S/O 152051, OPS 29535, ZONE 6C-130. 2 L 7 2 4F A6WE 2005020100010 20050201 00010 WP 2005 2 1 LCQ53 1 20050120 G 5321 FLOOR PANEL DOUG DC9 DC932 3022066 WP FUSELAGE CRACKED C K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 MAIN CABIN FLOOR PANEL NR 95 HAS SKIN TORN ON END AND SURFACE CORROSION ON BOTTOM CHANNELS. S/O 152051, OPS 29564, ZONE 6C-141. 2 L 7 2 4F A6WE 2005031100003 20050311 00003 WP 2005 3 11 LCQ54 1 20050120 G 5320 PANEL DOUG DC9 DC932 3022066 WP PWA JT8 JT8D9A 52048 NE CABIN ELONGATED C K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 MAIN CABIN PANEL E5-3 HAS ELONGATED HOLES ON THE END OF PANEL. S/O 152051, OPS 29566, ZONE 6C-143 2 L 7 2 4F 4 F A6WE E2EA 2005031100034 20050311 00034 WP 2005 3 11 LCQ56 1 20050120 G 5320 CHANNEL DOUG DC9 DC932 3022066 WP PWA JT8 JT8D9A 52048 NE FUSELAGE CRACKED C K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 MAIN CABIN PANEL NR 75 HAS CHANNELS CRACKED OUT AND SURFACE CORROSION. S/O 152051, OPS 29569, ZONE 6C-146 2 L 7 2 4F 4 F A6WE E2EA 2005031100012 20050311 00012 WP 2005 3 11 LCQ57 1 20050120 G 5320 CHANNEL DOUG DC9 DC932 3022066 WP PWA JT8 JT8D9A 52048 NE FUSELAGE CRACKED B K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 MAIN CABIN PANEL, NR A53 HAS CHANNELS CRACKED. S/O 152051, OPS 29572, ZONE 6C-149 2 L 7 2 4F 4 F A6WE E2EA 2005031100035 20050311 00035 WP 2005 3 11 LCQ61 1 20050120 G 5321 FLOOR PANEL DOUG DC9 DC932 3022066 WP PWA JT8 JT8D9A 52048 NE FUSELAGE BROKEN C K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 MAIN CABIN FLOOR PANEL NR 76 RT CENTER FS 680 - 760 IB HAS HOLES BROKEN OUT ON THE END. S/O 152051, OPS NR 29576, ZONE 6C-153 2 L 7 2 4F 4 F A6WE E2EA 2005031100036 20050311 00036 WP 2005 3 11 LCQ62 1 20050120 G 5321 FLOOR PANEL DOUG DC9 DC932 3022066 WP PWA JT8 JT8D9A 52048 NE FUSELAGE CRACKED C K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 MAIN CABIN FLOOR PANEL NR 81 HAS CRACKS AROUND RIVETS, 2 EACH PUNCTURES AND SURFACE CORROSION. S/O 152051, OPS NR 29583 , ZONE 6C-156 2 L 7 2 4F 4 F A6WE E2EA 2005021700137 20050217 00137 WP 2005 2 17 LCQ63 1 20050120 G 5321 FLOOR PANEL DOUG DC9 DC932 3022066 WP FUSELAGE CORRODED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 MAIN CABIN FLOOR PANEL NR 83 HAS CORROSION. S/O 152051, OPS 29582, ZONE 6C-157. 2 L 7 2 4F A6WE 2005020100001 20050201 00001 WP 2005 2 1 LCQ66 1 20050120 G 5320 FLOOR SUPPORT DOUG DC9 DC932 3022066 WP FUSELAGE CRACKED C K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 CABIN LT FLOORBOARD OB SUPPORT CRACKED FS 617 TO 658 ABOVE FLOOR WEB. S/O 152051,OPS NR 29661, ZONE 6C-180. 2 L 7 2 4F A6WE 2005020100013 20050201 00013 WP 2005 2 1 LCQ67 1 20050120 G 5320 FLOOR SUPPORT DOUG DC9 DC932 3022066 WP FUSELAGE MISLOCATED C K NONE W INADEQUATE Q C IN INSP/MAINT 1 SO 15 867AT 47170 CABIN FLOOR AREA FS 680 FLOORBOARD SUPPORT MISDRILLED 36 INCHES RT OF CENTER. S/O 152051, OPS NR 29665, ZONE 6C-183. 2 L 7 2 4F A6WE 2005031500074 20050315 00074 WP 2005 3 15 LCQ68 1 20050120 G 5321 FLOOR PANEL DOUG DC9 DC932 3022066 WP FUSELAGE CORRODED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 L-1 FLOOR PANEL COVER HAS CORROSION UPPER AND LOWER SURFACE. S/O 152051, OPS 29737, ZONE 6C-201. 2 L 7 2 4F A6WE 2005031500075 20050315 00075 WP 2005 3 15 LCQ69 1 20050120 G 5240 PAN DOUG DC9 DC932 3022066 WP SERVICE DOOR CRACKED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 867AT 47170 RIGHT SERVICE DOOR PAN CRACKED IN 4 EA PLACES AND INNER STRAP CRACKED AT FWD LOWER CORNER. S/O 152051, OPS 29879, ZONE 6C-206. 2 L 7 2 4F A6WE 2005031500147 20050315 00147 NM 2005 3 15 LCQ73 1 20050224 G 5543 TAB BOEING 737 737522 138449F NM RUDDER BROKEN B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 948UA 26691 COMPOSITE TAB ON L/E SPAR OF RUDDER BROKEN OFF. S/O 269004, N/R 24993. 2 L 7 2 4F RT A16WE 2005031500148 20050315 00148 NM 2005 3 15 LCQ74 1 20050224 G 5330 SKIN BOEING 737 737522 138449F NM FUSELAGE GOUGED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 948UA 26691 GOUGE BETWEEN S-27L - S-28L BS 420. S/O 269004, N/R 24710. 2 L 7 2 4F RT A16WE 2005031500149 20050315 00149 NM 2005 3 15 LCQ75 1 20050224 G 5330 SKIN BOEING 737 737522 138449F NM FUSELAGE DENTED B DU4R K NONE O OTHER IN INSP/MAINT 1 SO 15 948UA 26691 DENT IN EXTERIOR FUSELAGE SKIN AT FS 412 S-18R. S/O 269004, N/R 24964. 2 L 7 2 4F RT A16WE 2005041500127 20050415 00127 EU 2005 4 15 LEGR200500001 1 20050218 G 5280 25W261201452 DOOR ISRAEL 1125 ASTRASPX 4500205 EU ZONE 700 CRACKED B LEGR K NONE O OTHER IN INSP/MAINT 1 NE 03 108C 108 DURING ACCOMPLISHMENT OF AD 2004-13-18 FOUND RT MLG DOOR TO BE CRACKED AFTER REMOVAL OF DOOR HINGE. DOOR HINGE IS NOT R EQUIRED TO BE REMOVED UNLESS THE AFT DOOR GAP IS LESS THAN 0.25 INCH PER AD AND REFERENCED SERVICE BULLETIN. 2 L 7 2 4F RT A16NM 2005052500116 20050525 00116 GL 2005 5 25 LU4R12482 3 20050421 G 6110 B5020 SPRING CESSNA 208 208 2073702 CE MCAULY 3AF34C 3GFR34C703 GL PROPELLER STRETCHED B LU4R K NONE O OTHER IN INSP/MAINT 1 SO 17 208JB 20800362 020561 SPRING ASSY STRETCHED TOO LARGE. (K) 1 H 7 1 3T NT A37CE 5 C P60GL 2005091200031 20050912 00031 SO 2005 9 12 M1555 2 20050902 G 7261 BRACKET CIRRUS SR SR22 2130001 GL CONT O550 IO550* SO OIL FILTER SPLIT B PAI5 K NONE O OTHER IN INSP/MAINT 1 SO 05 763C 0431 DURING SCHEDULED ENGINE OIL CHANGE, FOUND BRACKET INDUCTION AIR FILTER SPLIT AT MANUFACTURED SEAM. SUSPECT ADHESIVE USE D AT MANUFACTURE OF THE FOAM TYPE FILTER IS INADEQUATE FOR THE TASK. 1 L 7 1 3O 3 O NT A00009CH E3SO 2005042000060 20050420 00060 CE 2005 4 20 MAFALT1 1 20050404 G 2430 DOFF10300BR ALTERNATOR CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO ENGINE OPEN D A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 WP 21 575 OPEN FIELD WINDING. 1 H 7 1 3O 3 O A4CE E8CE 2005042000061 20050420 00061 CE 2005 4 20 MAFALT2 1 20050404 G 2430 DOFF10300BR ALTERNATOR CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO ENGINE OPEN D A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 WP 21 279 OPEN FIELD WINDING AT SLIP RING (WIRE BROKEN AT SOLDER JOINT). 1 H 7 1 3O 3 O A4CE E8CE 2005042000062 20050420 00062 CE 2005 4 20 MAFALT3 1 20050404 G 2497 WIRE CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO ENGINE OPEN D A UNSCHED LANDING J WARNING INDICATION CR CRUISE 1 WP 21 327 ES4145 OPEN FIELD WINDING AT SLIP RING (WIRE BROKEN AT SOLDER JOINT). 1 H 7 1 3O 3 O A4CE E8CE 2005091200086 20050912 00086 CE 2005 9 12 MAFALT4 1 20050902 G 2420 C6FF10335B ROTOR ELECTROSYS CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO ALTERNATOR FAILED D A UNSCHED LANDING H ELECT. POWER LOSS-50 PC CR CRUISE 1 WP 21 188 B110413 ELECTROSYSTEM WOES CONTINUE, WITH ANOTHER ROTOR GOING BAD. DETAILS: M/N DOFF10300BR S/N B110413 WITH A TS0 :1095.1 ON T HE ALTERNATOR. THE ROTOR WAS CHANGED 3 DIFFERENT TIMES ON THIS ALTERNATOR AND IT RAN ON FOUR DIFFERENT A/C IN IT'S LIFE HERE. THIS LAST ROTOR RAN FOR 188.1 HRS. TIS, AND PREVIOUS ROTORS ONLY RAN 18.9HRS AND 1 HR. MORE IN-DEPTH INSPECTIO N OF THE ALTERNATOR FOR A REOCURRING FAULT HAS TURN UP NOTHING, AS TO A CAUSE FOR ROTORS CONTINUING TO FAIL. SINCE A RE CENT RASH OF ROTOR FAILURES ON OTHER ALTERNATORS, POSSIBLY AN ISSUE WITH THE MANUFACTURE, ELECTORSYSTEMS AND THE QUALITY OF ROTORS. 1 H 7 1 3O 3 O A4CE E8CE 2005110800311 20051108 00311 SW 2005 11 8 MDR01KH2005 1 20051010 G 6220 200571045D BOLT BELL 222 222 1182122 SW M/R CONTROLS SHEARED C O OTHER O OTHER NR NOT REPORTED 1 WP 25 29KH 47053 UPON INSPECTION AND MAINTENANCE OF MAIN ROTOR CONTROLS, INSPECTION REVEALED SHEARED BOLT (PN 20-057-10-45D) AT BOLT HEAD AT THE M/R SWASH PLATE COLLECTIVE LEVER IDLER LINK. (ATTACH BOLTS) MFG A- NR 28 BOLT, MFG U-NR 28 BOLT. THIS CONDITI ON HAS BEEN REPORTED TO MFG FOR INVESTIGATION ADN ANALYSIS OF CAUSE. ALL REMAINING COMPANY HELICOPTERS HAVE BEEN INSPEC TED FOR LIKE CONDITION AND FOUND AIRWORTHY. (K) 1 G 7 2 3U H9SW 2005110800285 20051108 00285 2005 11 8 MDR02BO2005 1 20050110 G 6220 10514104119 NUT MAIN ROTOR HEAD CRACKED B O OTHER O OTHER NR NOT REPORTED 1 WP 25 674 2033 UPON INSPECTION AND MAINTENANCE OF MAIN ROTOR HEAD ASSY, SUBCOMPONENT (UPPER QUAD NUT) WAS SENT TO VENDOR FOR MAG PARTIC LE INSPECTION AND SUBSEQUENTLY WAS REJECTED. THIS CONDITION HAS BEEN REPORTED TO MFG FOR INVESTIGATION AND ANALYSIS OF CAUSE. (K) 2005081700163 20050817 00163 EU 2005 8 17 MFSDR0501 1 20050811 G 7797 AWG22TG2 WIRE EXTRA EA400 EA400 7021804 EU CONT O550 TSIOL550C SO BURNED B K NONE P NO WARNING INDICATION UK UNKNOWN 1 SW 99 400YY 159 019 603272 TACHOMETER FULL SCALE DEFLECTION ON ANALOG NEEDLE WHEN POWER SELECTED AND LOW ANALOG READING ON EGT. PROBLEM TRACED TO R OUTING OF BOTH CABLES THROUGH A FIRESLEEVE OVER THE TURBOCHARGER. THE FIRESLEEVE HAS BUNED AWAY, LOSING ITS FIRE RESISTA NT QUALITIES AND CAUSING BOTH TACHO AND EGT CABLES TO MELT. PROBABLY SATISFACORY ON AN AIR COOLED ENGINE, BUT NOT ON A C LOSE COWLED, WATER COOLED ENGINE. 1 H 7 1 3O 3 O RT A43CE E4SO 2005032400150 20050324 00150 SO 2005 3 24 MN3525 2 20050224 G 8500 IO520F ENGINE CESSNA 206 U206G 2073356 CE CONT O520 IO520F 17032 SO MCAULY D3A34 D3A34C404 GL MAKING METAL B K NONE O OTHER IN INSP/MAINT 1 CE 03 9938Z 2508 872 U20606757 112700R 010968 DURING AIRCRAFT 50 HOUR INSPECTION, FOUND METAL IN THE OIL FILTER. TOOK OIL SAMPLE DURING ENGINE OIL CHANGE. RECOMMEND ED TO OWNER TO CHANGE ENGINE. REPLACED ENGINE AFTER OWNER APPROVAL. 1 H 7 1 3O 3 O A4CE E5CE 5 C P47GL 2006010400107 20060104 00107 CE 2006 1 4 MPFACTUATOR1 1 20051213 G 2750 99105863RX ACTUATOR CESSNA 208 208B 2073701 CE PWA PT6 PT6A114 52043 NE TE FLAPS INOPERATIVE D K NONE O OTHER IN INSP/MAINT 1 WP 21 PK-MP 885 507 208B0989 PCEPC1004 BOTH PRIMARY AND STAND-BY FLAP ACTUATOR WAS INOPERATIVE. ACTIVATION OF EITHER SYSTEM WOULD CAUSE THE RESPECTIVE CIRCUIT BREAKER TO OPEN. DISASSASEMBLY OF THE ACTUATOR REVEALED A SHEARED ROLL PIN AND ROUGH WORM SHAFT BEARING. 1 H 7 1 3T 3 T A37CE E4EA 2005062300130 20050623 00130 NM 2005 6 23 MTF2351 1 20050616 G 3340 65445543 MOUNT BRACKET BOEING 727 727223 1384074 NM STROBE LIGHT DETERIORATED B K NONE O OTHER IN INSP/MAINT 1 WP 23 289MT 53426 1463 22467 STROBELIGHT MOUNT BRACKET, SHOCK MOUNTS DETERIORED AND UNIT HELD IN PLACE BY ONE SHOCK MOUNT, ALL SHOCK MOUNT ATTACH HOL ES IN BRACKET WORN/ELONGATED, SO MOUNTS WERE NOT ABLE TO REMAIN ATTACHED. INSPECTION OF THIS AREA WAS BY REMOVING ACCES S PANEL 9715 PREVIOUS LISTED IN BOEING 727 MPD D6-8766-2 REV H DATED 3/78, PER -D- CHECK 6-55-12. D-CHECK REQUIREMENT. REQUIREMENT REVISED TO C-CHECK LEVEL PER REVISION TO MPD D6-8766-2 REV K DATED 4/80 OF BOEING 727 AND ACCESS PANEL 9715 REQUIREMENT TO REMOVE HAS BEEN DELETED THEREFORE NOT PRESENTING AVAILABILITY TO INSPECT MOUNT/BRACKET ATTACHMENT. 2 L 7 3 4F A3WE 2005052000061 20050520 00061 EA 2005 5 20 MYNR748KA 2 20050105 G 8530 EXHAUST VALVE CESSNA 172 172R 2072401 CE LYC IO360 IO360L2A EA NR 3 CYLINDER STUCK B MYNR K NONE O OTHER IN INSP/MAINT 1 GL 11 4190P 350 17280620 L2779651A NR 3 CYLINDER EXHAUST VALVE STUCK AT 300.1 HRS. NR 2 CYLINDER EXHAUST VALVE STUCK AT 351.1 HRS. REMOVED NR 1 AND NR 4 FOR EVALUATION, CYLINDER SHOP FOUND PROBLEMS WITH THERE EXHAUST VALVES. THESE WERE NEW SUPERIOR MILLENNIUM CYLINDER ASS EMBLIES INSTALLED AT ENGINE OVERHAUL 351.0 TSMOH. (K) 1 H 7 1 3O 3 O NT 3A12 1E10 2005081700125 20050817 00125 SO 2005 8 17 NEFSDO03 1 20050711 G 3210 ROLL PIN PIPER PA24 PA24260 7102406 SO RROYCE RB211 RB211535E4 54555 NE LT MLG MISSING G O OTHER O OTHER TX TAXI/GRND HDL 1 NE 03 9167P 244655 APPROXIMATELY 2149 Z PILOT ADVISED HE BELIEVED THE AIRCRAFT LT MAIN GEAR COLLAPSED. THE SAFETY DEVICE (ROLL PIN) WAS NOT INSTALLED. THIS ALLOWED THE NUT TO ROTATE ALLOWING THE STUD TO BACK OUT OF THE CASTING. THIS CAUSED THE LT MAIN LANDING GEAR TO COLLAPSE. AD97-01-01R1 TO PREVENT MAIN LANDING GEAR (MLG) COLLAPSE CAUSED BY MAIN GEAR SIDE BRACE STUD CRACKED . ANNUAL INSPECTION C/W FEB 1, 2005. 1 L 7 1 3O 4 F 1A15 E12EU 2006042700217 20060427 00217 CE 2006 4 27 OMKR200600001 1 20050425 G 5511 45A21104642 RIB BEECH MU300 400A 1155402 CE HORIZ STAB CRACKED B K NONE O OTHER IN INSP/MAINT 1 NM 03 743TA RK271 ROLLER RIB AT INBOARD END CRACKED (ASSY P/N 45A21104-642) IN THREE PLACES. RIB, AND BOTH CLIPS. CRACKING IS FROM RIB M ATERIAL BEING TOO THIN, IMPROPER RIGGING, OR EXCESSIVE WEAR OF HORIZONTAL STABILIZER HINGE POINTS. SUSPECT RIB MATERIAL IS JUST TOO THIN TO CARRY LOAD FROM ROLLER BRACKET. 2 H 7 2 4F RT A16SW 2006051000234 20060510 00234 CE 2006 5 10 PAI5200503774 1 20051019 G 3231 354100779 BRACKET BEECH BEECH 36 A36 1151604 CE ZONE 700 CRACKED B PAI5 K NONE O OTHER IN INSP/MAINT 1 SO 05 4489S 6516 E706 DURING ANNUAL INSPECTION, FOUND LT NOSE GEAR DOOR RETRACT BRACKET CRACKED COMPLETELY THROUGH ON ONE SIDE. NOSE GEAR RET RACT ROD ATTACHES TO THIS BRACKET, WHICH IS RIVETED TO THE NOSE GEAR DOOR. 1 L 7 1 3O 3A15 2005102500026 20051025 00026 EU 2005 10 25 PAZR200550249 1 20051017 G 3320 CIRCUIT BOARD AMD FALC50 FALCON50MYST 2730106 EU CABIN LIGHTS BURNED B PAZR H DEACTIVATE SYST/CIRCUITS B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 CE 03 980S 29939408 249 PASSENGER NOTICED A SPARK AND SMOKE IN THE UPPER FWD AREA OF THE CABIN HEADLINER. PILOT WAS NOTIFIED AND PILOT DISENGAGE D CIRCUIT BREAKER FOR THE LIGHTS. AIRCRAFT LANDED WITHOUT INCIDENT. UPON REMOVAL OF HEADLINER AND LIGHT STRIPS, VISUALLY INSPECTED AND FOUND LIGHT STRIP CIRCUIT BOARD WAS BURNED AND CHARRED DUE TO EXCESSIVE HEAT, LIGHT TRACK WAS DEFORMED, T HERMAL PLASTIC AT ENDS OF LIGHTS WERE MELTED, AND ONE OF THE 28VDC POWER LEAD WIRES WAS PULLED OUT OF THE CIRCUIT BOARD. 2 L 7 3 4F A46EU 2005092100060 20050921 00060 NE 2005 9 21 R017794 3 20050920 G 6110 D7745 BEARING HARTZL HCE4A3J BEECH 1900 1900D 1154162 CE PWA PT6 PT6A67D NE HARTZL HCE4A HCE4A3A NE PROPELLER HUB BROKEN B SJ3R K NONE E VIBRATION/BUFFET TX TAXI/GRND HDL 1 GL 05 SJ3R 3791 HJ1634 HJ1634 PROP WAS REMOVED FOR LOOSE BLADE. PROP WAS OVERHAULED BY MFG SERVICE CENTER ON 10/7/03 AND INSTALLED NEW D-7745 BEARINGS AT THAT TIME. HUB SIDE BEARINGS ON BLADES 2 AND 3 ARE CRACKED CIRCUMFERENTIALLY. HUB SIDE BEARING ON BLADE 4 IS BROKEN . 2 L 7 2 4T 4 T RT A24CE E26NE 5 C P10NE 2005080900070 20050809 00070 EU 2005 8 9 RX8R2005002 1 20050802 G 2120 050143 MOTOR 35000031HP SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE BLOWER INOPERATIVE B RX8R K NONE O OTHER IN INSP/MAINT 1 SO 15 578AE 401 401 3716 22318 AIR CONDITIONING CONDENSER BLOWER FAILED AFTER 401.4 OPERATING HOURS. 1 G 7 1 3U 3 U H9EU E00054EN 2005080900059 20050809 00059 EU 2005 8 9 RX8R2005003 1 20050803 G 2120 050085 MOTOR 35000031HP SNIAS 350 AS350B3 8680954 EU TMECA ARRIEL ARRIEL2B NE A/C BLOWER INOPERATIVE B RX8R K NONE O OTHER IN INSP/MAINT 1 SO 15 578AE 2 2 3716 22318 AIR CONDITIONING CONDENSER BLOWER FAILED AFTER 2 OPERATING HOURS. 1 G 7 1 3U 3 U H9EU E00054EN 2005061700137 20050617 00137 CE 2005 6 17 S002368 1 20050608 G 2435 6762751R STARTER BEECH 58 58 1152740 CE ENGINE SEIZED D E ENGINE SHUTDOWN O OTHER TX TAXI/GRND HDL 1 SO 06 3101B TH1901 THIS STARTER SIEZED DURING START CAUSING SIEZURE AND SEVERE DAMAGE TO THE ENGINE ACCESSORY GEARBOX STATER ADAPTER. 1 L 7 2 3O 3A16 2005083000149 20050830 00149 CE 2005 8 30 S3692 1 20050825 G 3246 C1630040102 WHEEL CESSNA 210 210M 2073450 CE PWA PT6 PT6* 52043 EA MLG SEPARATED B O OTHER O OTHER LD LANDING 1 SO 05 761K 5265 21062316 TWO BOLTS IN RT MAIN WHEEL INNER FLANGE, BROKE ON LANDING, CAUSING WHEEL INNER FLANGE AND BRAKE DISC TO PARTIALLY SEPARA TE FROM WHEEL HUB AND RUB INTO MAIN GEAR AXLE FITTING. MOUNTING BOLT HOLES IN BRAKE DISC SHOW SOME ELONGATION, POSSIBLY DUE TO LOOSE BOLTS BEFORE BOLT FAILURE. REPLACED WHEELS AND BRAKES WITH CONVERSION KIT, AND REPLACED RT MAIN GEAR AXLE FITTING. 1 H 7 1 3O 3 T 3A21 E2NE 2005060900089 20050609 00089 SO 2005 6 9 SO11200516386 1 20050428 G 3250 485615 ARM PIPER PA20 PA20 7102002 SO LYC O290 O290* 41506 EA TAIL STEERING BROKEN G O OTHER O OTHER LD LANDING 1 SO 11 7053K 1632 6 20160 UPON LANDING, PILOT REPORTED NO CONTROL OF TAIL WHEEL STEERING AND SUBSEQUENT LOSS OF CONTROL. VISUAL INSPECTION REVEAL ED RUDDER TO TAIL WHEEL STEERING ARM HAD BROKEN JUST OB OF A PREVIOUS WELD/BRAZE REPAIR. 1 H 7 1 3O 3 O 1A4 E229 2005040700302 20050407 00302 NM 2005 4 7 SROM200500001 1 20050119 G 3350 21131A BATTERY PACK BOEING 737 737205 1384456 NM CABIN DISCHARGED C SROM K NONE L NO TEST IN INSP/MAINT 1 AL 03 733PA 11 23466 AFT GALLEY DOOR EMERGENCY LIGHT INOP. REMOVED AND REPLACED BATTERY PACK IAW B737 NN 3351-71, OPS CHECKED GOOD. 2 L 7 2 4F RT A16WE 2005041400115 20050414 00115 NM 2005 4 14 SROM200500002 1 20050129 G 3397 58791 POWER CABLE BOEING 737 737205 1384456 NM EMERGENCY LIGHT OPEN C SROM K NONE L NO TEST IN INSP/MAINT 1 AL 03 733PA 6 23466 FLOOR PROXIMITY EMERGENCY ESCAPE PATH LIGHTING INOP BETWEEN ROWS 9 TO 15. TROUBLESHOT, REMOVED AND REPLACED FLOOR PROXI MITY ESCAPE PATH LIGHTING CABLE LEAD ASSEMBLY IAW B737 MM 33-51-191, OPS CHECK GOOD. 2 L 7 2 4F RT A16WE 2005041400116 20050414 00116 NM 2005 4 14 SROM200500003 1 20050128 G 3350 582212 BATTERY PACK BOEING 737 737205 1384456 NM EMERGENCY LIGHT INOPERATIVE C SROM K NONE L NO TEST IN INSP/MAINT 1 AL 03 733PA 6 23466 EMERGENCY ESCAPE FLOOR LIGHTING FROM ROWS 16 TO 19 INOP AND L2 DOOR INTERIOR EMERGENCY EXIT LIGHTS INOP. CLEANED CONNEC TOR ON EMERGENCY ESCAPE FLOOR LIGHT STRIP AT ROW 18 AND REMOVED AND REPLACED R2 DOOR EMERGENCY EXIT LIGHTS BATTERY PACK IAW B737MM 33-51-191, OPS CHECK GOOD. 2 L 7 2 4F RT A16WE 2005041500044 20050415 00044 NM 2005 4 15 SROM200500004 1 20050203 G 3397 58791 WIRE BOEING 737 737205 1384456 NM EMERGENCY LIGHT BROKEN C SROM K NONE L NO TEST IN INSP/MAINT 1 AL 03 733PA 6 23466 FWD SECTION EMERGENCY FLOOR LIGHTS INOPERATIVE ROWS 1 - 3. REPLACED BROKEN FLOOR LIGHT STRIP IAW MM 33-51-191. OPS CHE CK NORMAL. 2 L 7 2 4F RT A16WE 2005041500045 20050415 00045 NM 2005 4 15 SROM200500005 1 20050204 G 3350 582212 BATTERY PACK BOEING 737 737205 1384456 NM EMERGENCY LIGHT INOPERATIVE C SROM K NONE L NO TEST IN INSP/MAINT 1 AL 03 733PA 32 23466 EMERGENCY ESCAPE FLOOR LIGHTING INOP FROM ROWS 15 TO 18. REPLACED BATTERY PACK, ESCAPE LIGHTING OPS CHECK GOOD IAW CPA AMM SUPPLEMENT 33-51-191. 2 L 7 2 4F RT A16WE 2005042000047 20050420 00047 NM 2005 4 20 SROM200500006 1 20050310 G 3350 582212 BATTERY PACK BOEING 737 737205 1384456 NM EMERGENCY LIGHT INOPERATIVE C SROM K NONE L NO TEST IN INSP/MAINT 1 AL 03 733PA 6 23466 EMERGENCY EGRESS AFT FLOOR LIGHTING VERY DIM, THEN WENT INOP ON OPS CHECK. REMOVED AND REPLACED EMERGENCY EGRESS AFT BA TTERY PACK IAW B737MM 33-51-93, OPS CHECK GOOD. 2 L 7 2 4F RT A16WE 2005071500184 20050715 00184 NM 2005 7 15 SROM200500008 1 20050710 G 3350 582212 POWER SUPPLY BOEING 737 737205 1384456 NM EMERGENCY LIGHTS DISCHARGED C SROM O OTHER L NO TEST IN INSP/MAINT 1 AL 03 733PA 23466 RT FLOOR LEVEL EMERGENCY EXIT DOOR LIGHT INOP. REMOVED AND REPLACED RT EMERGENCY EXIT POWER SUPPLY P/N 5822-12, CABLE LE AD AND 1 EL LAMP STRIP. OPS CHECKED GOOD PER AMM 33-51-191. 2 L 7 2 4F RT A16WE 2005081000224 20050810 00224 NM 2005 8 10 SROM200500011 1 20050729 G 5330 SKIN BOEING 737 737205 1384456 NM PWA JT8 JT8D17A 52049 NE STA910,STR16 GOUGED I SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 736BP 23465 DURING 24 MONTH INSPECTION FOUND GOUGE IN SKIN AT STA 910, STR 16 TO BE OUT OF LIMITS DUE TO SKIN THICKNESS AFTER BLENDI NG. REPAIRED GOUGE IN SKIN AT STA 910, STR 16 IAW B737 SRM 53-30-3 FIG. 18. 2 L 7 2 4F 4 F RT A16WE E2EA 2005081000225 20050810 00225 NM 2005 8 10 SROM200500012 1 20050802 G 5320 FLOOR SUPPORT BOEING 737 737205 1384456 NM PWA JT8 JT8D17A 52049 NE STA797,STR 8R DAMAGED A SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 736BP 23465 DURING 24 MONTH INSPECTION FOUND DAMAGE TO CARGO FLOOR SUPPORT STRUCTURE AT STA 797 STR 8R. ALLOWABLE DAMAGE .090 IAW S RM 63-10-1 FIG 5, DAMAGE - .340. REPAIRED DAMAGE IAW SRM 53-10-5, FIG 6. 2 L 7 2 4F 4 F RT A16WE E2EA 2005082300060 20050823 00060 NM 2005 8 23 SROM200500013 1 20050815 G 3230 SENSOR BOEING 737 737205 1384456 NM MLG OUT OF ADJUST C SROM A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 AL 03 736BP 5 23465 AFTER TAKEOFF THE LANDING GEAR LEVER WOULD NOT MOVE TO THE GEAR UP POSITION. GEAR WAS LEFT DOWN AND AIRCRAFT RETURNED T O DEPARTURE AIRPORT AND MADE A UNEVENTFUL OVERWEIGHT LANDING. TROUBLE SHOOTING FOUND NO FAULTS WITH THE WIRING HARNESS ASSOCIATED WITH THE LANDING GEAR CONTROL SYSTEM. FOUND GROUND SAFETY SENSOR ACTUATOR GAP OUT OF ADJUSTMENT. ADJUSTED G AP, GROUND SPOILER INTERLOCK. OPS CHECKED SAFETY SENSOR, GROUND SPOILER AND LANDING GEAR EXTENSION & RETRACTION SYSTEMS IAW B737 AMM. 2 L 7 2 4F RT A16WE 2005082500115 20050825 00115 NM 2005 8 25 SROM200500014 1 20050821 G 5330 SKIN BOEING 737 737201 1384454 NM PWA JT8 JT8D15 52051 NE BS1036,STR8L GOUGED I SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 245US 22751 DURING ROUTINE INSPECTION FOUND A GOUGE IN THE SKIN AT BS 1036.5, STR 8L. REPAIRED IAW MFG MESSAGE 1-115922448-4 AND SR M 53-30-3, FIG. 50. BLENDED, REMOVED DAMAGE, EDDY CURRENT INSPECTED FOR CRACKS AND INSTALLED AN EXTERNAL DOUBLER IAW ME SSAGE AND SRM REFERENCED. 2 L 7 2 4F 4 F A16WE E2EA 2005101800168 20051018 00168 NM 2005 10 18 SROM200500015 1 20050926 G 3230 69355004 ACTUATOR BOEING 737 737205 1384456 NM LT MLG UPLOCK BYPASSING C SROM A UNSCHED LANDING J WARNING INDICATION CL CLIMB 1 AL 03 736BP 23465 AFTER TAKE-OFF FROM ANC, GEAR WAS SELECTED UP, LT MAIN WOULD NOT INDICATE UP AND LOCKED. AIRCRAFT RETURNED FOR AN UNEVE NTFUL LANDING. DETERMINED LT UPLOCK ACTUATOR WAS BYPASSING FLUID. REPLACED UPLOCK ACTUATOR. SUBSEQUENT GEAR SWING AND FL IGHT CHECK WERE SATISFACTORY. 2 L 7 2 4F RT A16WE 2006010600074 20060106 00074 NM 2006 1 6 SROM200500016 1 20051212 G 5330 SKIN BOEING 737 737201 1384454 NM PWA JT8 JT8D17 52049 NE FUSELAGE CRACKED A SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 245US 22751 DURING ROUTINE MAINTENANCE FOUND A 3 INCH CRACK IN THE FUSELAGE SKIN AT BS 973, STR 21L. INSTALLED TEMPORARY REPAIR DOU BLER IAW 8110-3 APPROVED REPAIR, REFERENCE DWG 33-05565-1. 2 L 7 2 4F 4 F A16WE E2EA 2006010600077 20060106 00077 NM 2006 1 6 SROM200500017 1 20051212 G 5753 654648175 SPINDLE BOEING 737 737201 1384454 NM PWA JT8 JT8D17 52049 NE FLAP CARRIAGE CRACKED C SROM K NONE O OTHER IN INSP/MAINT 1 AL 03 245US 9319 22751 DURING ROUTINE NDT INSPECTION OF OB FLAP SPINDLE IAW AD 2003-24-08 AND SB 737-57A1277 FOUND A FLAP CARRIAGE SPINDLE CRAC KED 40 PERCENT AT THE RADIUS OF THE YOKE TO THE FIRST BEARING LAND. FLAP CARRIAGE ASSEMBLY REPLACED WITH A NEW UNIT. RE CORDS INDICATE 5221 CYCLES SINCE OVERHAUL. 2 L 7 2 4F 4 F A16WE E2EA 2005071800218 20050718 00218 NM 2005 7 18 SROM20050009 1 20050712 G 3350 362624 LIGHT BOEING 737 737205 1384456 NM EMERGENCY LIGHTS INOPERATIVE C SROM K NONE L NO TEST IN INSP/MAINT 1 AL 03 736BP 23465 EMERGENCY TRACK LIGHTING AT ROW 17 AFT AND L2 GROUND LEVEL EXIT LIGHT INOP. REMOVED AND REPLACED ILLUMINATION AISLE STR IP AT ROW 19 IAW 33-51-191. OPERATIONAL CHECK GOOD. 2 L 7 2 4F RT A16WE 2005071800217 20050718 00217 NM 2005 7 18 SROM20050010 1 20050713 G 3350 582039 LIGHT BOEING 737 737205 1384456 NM EMERGENCY LIGHTS INOPERATIVE C SROM K NONE L NO TEST IN INSP/MAINT 1 AL 03 733PA 23466 AFT EMERGENCY EXIT LIGHT UNDER AFT F/A SEAT INOP. REMOVED AND REPLACED EMERGENCY EXIT LIGHT ASSEMBLY IAW B737MM 33-51-1 91. 2 L 7 2 4F RT A16WE 2005062900089 20050629 00089 NE 2005 6 29 T48R20050013 2 20050621 G 7250 798404 BLADE DOUG DC9 DC983 3022083 WP PWA JT8 JT8D219 52053 NE ENGINE FRACTURED B GTIA E A ENGINE SHUTDOWN UNSCHED LANDING T ENGINE CASE PENETRATION CR CRUISE 1 GL 09 834NK 4500 4500 49847 718055 ENGINE WAS REMOVED FROM N834NK NR 2 POSITION FOR IN FLIGHT SHUTDOWN. VISUAL INSPECTION REVEALED THE T-4 BLADES FRACTURE D/MISSING AT THE BASE OF THE BLADE ROOT WITH PENETRATION OF THE CONTAINMENT AND OUTER ENGINE CASINGS. 2 L 7 2 4F 4 F RT A6WE E9NE 2005052500068 20050525 00068 GL 2005 5 25 T7419 3 20050509 G 6114 D7582 BULKHEAD MOONEY M20 M20R 5870225 SW CONT O550 TSIO550B 17043 SO MCAULY 2A34C 2A34C201 GL PROPELLOR CRACKED B K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 GL 11 1016C 145 290297 685018 00296 SPINNER BULKHEAD CRACKING AT 50HRS TKS WAS INSTALLED BY AIRCRAFT FACTORY. 1ST BULKHEAD REPLACED AT 104 HRS, 2CD BULKHEA D REPLACED AT 249.5 HRS. COULD NOT DETERMINE IF THE PROPELLER EVER HAD A PROP BALANCE. FOUND OIL COOLER MOUNTING ANGLE CRACKED ALSO AT 249.5 HRS 1 L 7 1 3O 3 O RT 2A3 E5SO 5 C P3EA 2005032800046 20050328 00046 SO 2005 3 28 TCMMAQ1 2 20050125 G 7414 103493504 MAGNETO CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO MCAULY D3A34 D3A34C402 GL ENGINE DEFORMED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 21 PKMAB 509 U20606806 532226 COIL WEDGES OVERDRIVEN TO THE POINT OF CONTACT WITH COIL, CRACKING THE INSULATION. 1 H 7 1 3O 3 O A4CE E8CE 5 C P47GL 2005032800047 20050328 00047 SO 2005 3 28 TCMMAQ2 2 20050125 G 7414 103493505 MAGNETO CESSNA 206 TU206G 2073357 CE CONT O520 TSIO520M 17040 SO MCAULY D3A34 D3A34C402 GL ENGINE DEFORMED D K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 21 PKMAB 509 U20606806 532226 COIL WEDGES OVERDRIVEN TO THE POINT OF CONTACT WITH COIL, CRACKING THE INSULATION. 1 H 7 1 3O 3 O A4CE E8CE 5 C P47GL 2005020100012 20050201 00012 EU 2005 2 1 TL9R200500001 1 20050120 G 3242 C200601004 BRAKE AIRBUS 330 A300* EU MLG MAKING METAL B TL9R K NONE O OTHER IN INSP/MAINT 1 GL 13 OUR REPAIR SHOP REPORTS THAT THE ROTORS IN THIS BRAKE PN HAVE A HISTORY OF FALLING APART. WHEN THIS HAPPENS, DAMAGE TO THE TORQUE TUBE CAN OCCUR WHICH WILL SEVERELY DEGRADE THE PERFORMANCE OF THE BRAKE. 2 L 7 2 4F RT A26NM 2005020100011 20050201 00011 EU 2005 2 1 TL9R200500002 1 20050120 G 3242 C200601004 BRAKE AIRBUS 330 A300* EU MLG MAKING METAL B TL9R K NONE O OTHER IN INSP/MAINT 1 GL 13 OUR REPAIR SHOP REPORTS THAT THE ROTORS IN THIS BRAKE PN HAVE A HISTORY OF FALLING APART. WHEN THIS HAPPENS, DAMAGE TO THE TORQUE TUBE CAN OCCUR WHICH WILL SEVERELY DEGRADE THE PERFORMANCE OF THE BRAKE. 2 L 7 2 4F RT A26NM 2005031400008 20050314 00008 EU 2005 3 14 TXER099315 1 20050120 G 2400 51455Y2 RELAY UROCOP EC155 EC155B 8681000 EU TMECA ARRIEL ARRIEL2B NE UNKNOWN FAILED B TXER O OTHER O OTHER NR NOT REPORTED 1 SW 09 155EW 6660 RELAY FAILED. 1 G 7 2 3U 3 U H10EU E00054EN 2005062200220 20050622 00220 NE 2005 6 22 UIA0506 2 20050614 G 7320 ST3367009WE PACKING DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE NR 1 ENGINE BROKEN Z K NONE K FLUID LOSS IN INSP/MAINT 1 TW 00 15225 405 123131 TRANSIT CHECK FOUND FUEL LEAKING FROM NR 1 ENG. DETAILED INSPECTION FOUND FUEL MANIFOLD PACKING BROKEN IAW AMM 71-01-40 . REPLACED NEW ONE AND IAW AMM 71-00-00 ENG RUNUP CHECK CONDITION NORMAL, NO FUEL LEAK FIND. 2 H 7 2 4T 4 T RT A13NM E20NE 2005072000166 20050720 00166 EA 2005 7 20 UIA0507001 1 20050704 G 3231 83232013003 BELLCRANK DHAV DHC8 DHC8311 1386006 EA NLG DOOR BROKEN Z O OTHER S AFFECT SYSTEMS AP APPROACH 1 TW 00 15233 402 NOSE LANDING GEAR DOOR MAFUNCTION IN FLIGHT,AFTER LANDING CHECK FOUND NOSE LANDING GEAR FRONT DOOR BELLCRANK BOLT HOLE B ROKEN.IAW AMM32-20-26 REPLACED NEW BELLCRANK ASSY AND BOLT.AND IAW AMM FUNCTION CHECK CONDCTION NORMAL. 2 H 7 2 4T RT A13NM 2005102800080 20051028 00080 NE 2005 10 28 UIA200509 2 20051025 G 7200 ENGINE DHAV DHC8 DHC8311 1386006 EA PWA PW120 PW123 NE LEFT MAKING METAL Z A UNSCHED LANDING R PARTIAL RPM/PWR LOSS CL CLIMB 1 SW 99 15227 18273 5118 406 123250 AC LT ENGINE LOW OIL PRESS WARNING LIGHT ON, PILOT SHUT DOWN LT ENGINE IN-FLIGHT, THEN SINGLE ENGINE LANDING. GROUND IN SPECTION RESULTS, FOUND ENGINE CONDITION PANEL TOTAL 7 FLAG, ONLY OIL TANK, RED FLAG SHOW ON, REMOVED OIL TANK CHIP DETE CTOR FOUND MINOR METAL CHIP, FOUND OIL WETTING ON EXTERNAL AREA, OIL QTY DROP TO LOWER LEVEL. 2 H 7 2 4T 4 T RT A13NM E20NE 2005041500084 20050415 00084 2005 4 15 VW3R20050004 4 20050208 G 2565 D29601103 GIRT BAR AIRCRUISERS AIRBUS 330 A300* EU ESCAPE SLIDE DEFECTIVE B VW3R K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 09 ALL 0412 ALL GIRT EXTENSION DOES NOT FIT PROPERLY ON GIRT BAR. GIRT EXTENSION PADS RIDE UP ON CAVITY RIDGE OF GIRT BAR. PLEASE NOTE THIS EVACUATION SLIDE IS ALSO USED ON A310 AIRCRAFT. 2 L 7 2 4F RT A26NM 2006020300119 20060203 00119 2006 2 3 YHLR200500001 4 20051123 G 3457 0100013911 GPS PIPER PA28 PA28181 7102807 SO LYC O360 O360* 41514 EA COCKPIT INOPERATIVE B K NONE O OTHER IN INSP/MAINT 1 SO 15 2668Q 287790414 CUSTOMER STATED THAT THE GNS-430 DISPLAY WAS NO LONGER WORKING AND THAT THE CDI WAS PEGGED LT AT ALL TIMES. SENT UNIT OU T FOR REPAIR. ALSO FOUND UPON INSPECTION OF THE GNS-430 INSTALLATION, IT WAS NOTED THAT REPAIR STATION HAD NOT INSTALLED AN AVIONICS COOLING FAN IAW THE INSTALLATION MANUAL. AN AVIONICS COOLING FAN WAS INSTALLED UPON RECEIVING THE GNS-430 B ACK FROM REPAIR. THE PROBLEM WITH THE GNS-430 WOULD HAVE BEEN PREVENTED IF AN AVIONICS FAN HAD BEEN INSTALLED IAW THE RE QUIREMENTS FOR COOLING AS STATED IN THE INSTALLATION MANUAL. 1 L 7 1 3O 3 O 2A13 E286 2006022100160 20060221 00160 SW 2006 2 21 YTRR106607 1 20051104 G 6710 412310400105 BEARING BELL 412 412 1182202 SW ROD END WORN B YTRR K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 SW 03 4125C 760 33103 BEARING WORN. REPLACED ROD-END BEARING ASSEMBLY. 1 G 7 2 4U H4SW 2006022100161 20060221 00161 SW 2006 2 21 YTRR106608 1 20051101 G 6710 412310400103 BEARING BELL 412 412 1182202 SW ROD END WORN B YTRR K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 SW 03 4125C 760 33103 BEARING FOUND WORN. REPLACED ROD END ASSY. 1 G 7 2 4U H4SW 2006022100162 20060221 00162 SW 2006 2 21 YTRR106609 1 20051101 G 6710 412310400103 BEARING BELL 412 412 1182202 SW ROD END WORN B YTRR K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 SW 03 4125C 760 33103 ROD END BEARING FOUND WORN. REPLACED ASSEMBLY. 1 G 7 2 4U H4SW 2006022100163 20060221 00163 SW 2006 2 21 YTRR106610 1 20051101 G 6710 412310400103 BEARING BELL 412 412 1182202 SW ROD END WORN B YTRR K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 SW 03 4125C 760 33103 ROD END BEARING FOUND WORN. REPLACED ASSEMBLY. 1 G 7 2 4U H4SW 2006022100164 20060221 00164 SW 2006 2 21 YTRR106621 1 20050916 G 6710 BEARING BELL 407 407 1182206 SW UNIVERSAL JOINT WORN B YTRR K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 SW 03 407HX 259 RXFS8590 53092 UNIVERSAL BEARING ASSEMBLY FOUND WORN. REPLACED BEARING ASSY. 1 G 7 1 3U O H2SW 2006022100165 20060221 00165 SW 2006 2 21 YTRR106622 1 20050916 G 6710 BEARING BELL 407 407 1182206 SW UNIVERSAL JOINT WORN B YTRR K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 SW 03 407HX 259 RXFS8058 53092 UNIVERSAL BEARING ASSEMBLY FOUND WORN. REPLACED BEARING ASSY. 1 G 7 1 3U O H2SW 2006022100166 20060221 00166 SW 2006 2 21 YTRR106624 1 20051014 G 6710 BEARING BELL 407 407 1182206 SW UNIVERSAL JOINT WORN B YTRR K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 SW 03 595RL 856 RXFS9719 53595 UNIVERSAL BEARING ASSEMBLY FOUND WORN. REPLACED PART. 1 G 7 1 3U O H2SW 2006022100167 20060221 00167 SW 2006 2 21 YTRR106625 1 20051015 G 6710 406310405101 BEARING BELL 407 407 1182206 SW MAIN ROTOR WORN B YTRR K NONE O OTHER IN INSP/MAINT 1 SW 03 594RL 1031 53594 M/R PC LINK BEARING AXIAL AND RADIAL MOVEMENT BEYOND LIMITS 1 G 7 1 3U O H2SW 2006022100168 20060221 00168 SW 2006 2 21 YTRR106626 1 20051006 G 5302 206031417007005 SUPPORT FITTING BELL 206 206B3 1181506 SW VERTICAL FIN BROKEN B YTRR K NONE O OTHER IN INSP/MAINT 1 SW 03 2043B 3355 FOUND BOTH SUPPORTS FOR VERTICAL FIN ASSEMBLY BROKEN THROUGH LOWER MOUNTING HOLES. 1 G 7 1 3U H2SW 2006022100169 20060221 00169 GL 2006 2 21 YTRR106627 2 20051103 G 7320 23057344 FUEL CONTROL BELL 206 206B3 1181506 SW ALLSN 250C 250C20B 03013 GL ENGINE HOT START B YTRR O OTHER O OTHER NR NOT REPORTED 1 SW 03 2043B 203 3355 FUEL CONTROL FAILED TO HIGH-SIDE DURING LIGHT OFF. REPLACED FUEL CONTROL ASSEMBLY. 1 G 7 1 3U 3 U H2SW E4CE 2005051100221 20050511 00221 SO 2005 5 11 ZB0R200500001 1 20050418 G 2720 TRIM SYSTEM PIPER PA28 PA28180 7102808 SO ZONE 300 OUT OF RIG B ZB0R K NONE O OTHER IN INSP/MAINT 1 SO 05 643MT 4902 45 285646 FOUND RUDDER CONTROL AND RUDDER TRIM CONTROL SYSTEMS OUT OF RIG. CABLES WERE LOOSE AND IMPROPERLY ADJUSTED. RIGGED RUD DER AND RUDDER TRIM SYSTEM PER PA28-180 SERVICE MANUAL. 1 L 7 1 3O 2A13 2005051600100 20050516 00100 SO 2005 5 16 ZB0R200500002 1 20050425 G 8011 MZ6222 STARTER PIPER PA28 PA28R200 7102811 SO LYC O360 IO360C1C 41514 EA ENGINE BROKEN B ZB0R E C ENGINE SHUTDOWN ABORTED TAKEOFF E VIBRATION/BUFFET TX TAXI/GRND HDL 1 SO 05 15143 140 140 28R7335027 L958451A ON START, PILOT HEARD GRINDING NOISE. ABORTED START PROCEDURE AND PERFORMED VISUAL INSP OF VISIBLE STARTER COMPONENTS. F OUND STARTER BENDIX SEVERELY DAMAGED. MAINT INSPECTION REVEALED DAMAGE TO STARTER RING GEAR. BOTH COMPONENTS (GEAR AND S TARTER) REPLACED. NO FURTHER PROBLEMS DETECTED. 1 L 7 1 3O 3 O 2A13 1E10 2005071100167 20050711 00167 CE 2005 7 11 ZB0R200500003 1 20050706 G 3340 CM358910 CIRCUIT BREAKER CESSNA 172 172S 2072439 CE LYC O360 IO360A1A 41514 EA LANDING LIGHT SHORTED B ZB0R H A DEACTIVATE SYST/CIRCUITS UNSCHED LANDING B SMOKE/FUMES/ODORS/SPARKS CR CRUISE 1 SO 05 963AC 2735 2 172S8259 DURING TRAINING FLIGHT, INSTRUCTOR AND STUDENT NOTICED SMOKE COMING FROM LANDING LIGHT SWITCH. INSTRUCTOR IMMEDIATELY TU RNED MASTER SWITCH OFF AND PROCEEDED BACK TO BASE. INSPECTION IN MAINTENANCE REVEALED LANDING LIGHT BREAKER SWITCH INOPE RATIVE. REPLACED WITH NEW P/N CM3589-10. SYSTEM OPS CK OK. NO EXTERNAL OR WIRING DAMAGE. 1 H 7 1 3O 3 O NT 3A12 1E10 2005071100166 20050711 00166 SO 2005 7 11 ZB0R200500004 1 20050701 G 2731 481640 PULLEY PIPER PA28 PA28R200 7102811 SO LYC O360 IO360A1A 41514 EA STABILIZER BROKEN B ZB0R K NONE O OTHER IN INSP/MAINT 1 SO 05 15143 99 28R7335027 DURING ANNUAL INSPECTION, FOUND STABILIZER TRIM AFT CABLE UPPER RT PULLEY, P/N 481-640, BROKEN IN HALF. REPLACED WITH NE W PART. RIG AND OPS CKS OK. 1 L 7 1 3O 3 O 2A13 1E10 2005071100168 20050711 00168 SO 2005 7 11 ZB0R200500005 1 20050701 G 3110 67435002 POTENTIOMETER PIPER PA28 PA28R200 7102811 SO LYC O360 IO360A1A 41514 EA PANEL LIGHTS MALFUNCTIONED B ZB0R K NONE L NO TEST IN INSP/MAINT 1 SO 05 15143 99 28R7335027 DURING ANNUAL INSPECTION, FOUND PANEL LIGHTS POTENTIOMETER DIMMING INOP. SWITCH WILL COME ON BRIGHT, BUT WILL NOT DIM. A LSO, LANDING GEAR LIGHTING WILL NOT DIM CORRECTLY WHEN POTENTIOMETER IS ON. REPLACED WITH NEW P/N 67435-002. OPS CK OK. 1 L 7 1 3O 3 O 2A13 1E10 2005081600216 20050816 00216 SO 2005 8 16 ZB0R200500006 1 20050811 G 3210 67031002 FITTING PIPER PA28 PA28R200 7102811 SO MLG CRACKED B ZB0R K NONE O OTHER IN INSP/MAINT 1 SO 05 41331 56 28R7435169 DURING REPAIR OF LT MLG DRAG BRACE KNEE JOINT, WE FOUND THE RETRACT FITTING CRACKED. REPLACED WITH NEW LIKE PART. 1 L 7 1 3O 2A13 2005120200098 20051202 00098 EU 2005 12 2 ZN3R030M 1 20051122 G 7921 1601562 OIL COOLER AMD FALC20 FALCON 2720302 EU GARRTT ATF3 ATF36A4 29002 WP ENGINE MISREPAIRED B K NONE W INADEQUATE Q C IN INSP/MAINT 1 WP 07 ZN3R 5177 P21108 OIL COOLER 160156-2, SN 23-610C SERIES 2 HAS POSSIBLE UNAPPROVED REPAIR CONSISTING OF A PLUG WELD IN THE MIDDLE OF THE O IL COOLER FINS AND WALL COMPLETELY THRU. CHIEF INSPECTOR NOTIFIED AT REPAIR STATION AND REQUESTED SUP TO BE COMPLETED O N 11/22/05. 2 L 7 2 4F 4 F A7EU E7WE 2005052300321 20050523 00321 WP 2005 5 23 ZN3R425038 2 20050401 G 7200 30729202 BEARING ISRAEL 1124 1124 4500102 EU GARRTT TFE731 TFE731* 01518 WP ENGINE FRACTURED B ZN3R K NONE O OTHER IN INSP/MAINT 1 WP 07 1052 P77111C ENGINE RETURNED TO SERVICE CENTER FOLLOWING COMMANDED SHUTDOWN IN FLIGHT DUE TO LOW OIL PRESSURE. DURING INSPECTION A F RACTURED CAGE AND OUTER RACE WAS FOUND ON A FORWARD PLANETARY ROLLER BEARING. 2 M 7 2 4F 4 F A2SW E6WE 2005072200056 20050722 00056 WP 2005 7 22 ZN3R475888 2 20050719 G 7250 30607881 TURBINE BLADES RAYTHN DH125 HAWKER800XP 7150012 CE GARRTT TFE731 TFE7315BR WP SEPARATED B ZN3R K NONE E VIBRATION/BUFFET IN INSP/MAINT 1 WP 07 959 N864QS P107672 ENGINE RETURNED TO SERVICE CENTER FOLLOWING COMMANDED SHUTDOWN IN FLIGHT DUE TO EXCESSIVE VIBRATION. DURING INSPECTION, SEPARATED 3RD LPT BLADES (QTY. 3) WERE FOUND. SEPARATED BLADES WERE RETURNED TO ENGINE OEM (HONEYWELL) FOR EVALUATION. CAUSE OF BLADE SEPARATION IS UNKNOWN AT THIS TIME. 2 L 7 2 4F 4 F RT A3EU E6WE