United States Department of Transportation / Federal Aviation Administration logo

AFS-600 Regulatory Support Division logo

 

ADVISORY CIRCULAR

43-16A

 

 

AVIATION MAINTENANCE ALERTS

 

 

flag of the United States of America

 

ALERT

NUMBER

389

bald eagle watching over three eggs

DECEMBER

2010

 


CONTENTS

AIRPLANES

BEECH......................................................................................................................................... 1

BOEING...................................................................................................................................... 2

CESSNA...................................................................................................................................... 3

FAIRCHILD................................................................................................................................. 7

 

POWERPLANTS

ROTAX...................................................................................................................................... 10

 

ACCESSORIES

GOODRICH.............................................................................................................................. 12

SLICK MAGNETO................................................................................................................... 12

AIR NOTES

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE................................... 14

IF YOU WANT TO CONTACT US......................................................................................... 16

AVIATION SERVICE DIFFICULTY REPORTS...................................................................... 16

 


U.S. DEPARTMENT OF TRANSPORTATION
FEDERAL AVIATION ADMINISTRATION
WASHINGTON, DC 20590

AVIATION MAINTENANCE ALERTS

The Aviation Maintenance Alerts provides the aviation community with an economical means to exchange service experiences and to assist the FAA in improving aeronautical product durability, reliability, and safety.  We prepare this publication from information operators and maintenance personnel who maintain civil aeronautical products pertaining to significant events or items of interest.  At the time we prepared this document, we have not fully evaluated the material.  As we identify additional facts such as cause and corrective action, we may publish additional data in subsequent issues of the Alerts.  This procedure gives Alerts’ readers prompt notice of conditions reported to the FAA Service Difficulty Reporting System (SDRS).  We welcome your participation, comments, and suggestions for improvement.  Send to:  FAA; ATTN: Aviation Data Systems Branch (AFS-620); P.O. Box 25082; Oklahoma City, OK 73125-5029.

(Editor’s notes are provided for editorial clarification and enhancement within an article. They will always be recognized as italicized words bordered by parentheses.)

 

AIRPLANES

Beech:  95B-55; Corroded Fuel Pressure Line; ATA 2820

A general aviation submission states, "I was (motivated) to access and closely inspect the right fuel-flow, pressure gauge line where it crosses the CEET type defrost duct because it looked like they may be contacting each other.  I was concerned about chafing or corrosion.  The upper right side area behind the instrument panel is very difficult to inspect.  It is not accessible from above, or at arm's length from below.  The line crosses above the duct.  (I) almost gave up inspecting (this area) closely, but ultimately I found extensive corrosion at the point of contact.  After the line was removed, slight bending pressure cracked the area wide open and it was seen that the corrosion had actually penetrated to the inside of the line, yet the line was not leaking up to this point (in time).  If a leak started, the only way to stop it would be to shut down the right engine.  I strongly recommend careful, intense inspection of the lines in the vicinity of any CAT or CEET type duct—(these) are notorious for causing corrosion or chafing.  This particular instance is, of course, model specific (and is sufficiently serious) to demand attention.  This (particular) aircraft has very little corrosion overall, (but this fuel line defect) was definitely caused by the ducting."


 

A) PHOTO OF CORRODED FUEL LINE BROKEN IN HALF.

(This is a great catch and an excellent story.  You can work on my garage-Fox any day—Ed.)

Part Total Time:  3,000 hours

 

Boeing:  747-409; Arcing Lamp Holders; ATA 3320

A foreign repair station submitter writes, "The cabin log records the first class galley, number one work light as 'inoperative'.  (We) removed this light and found the light assembly lamp holders had arced.  The galley ceiling was checked (for water leakage)—none was found.  This light assembly was replaced."


A) PHOTO OF BURNED LAMP PARTS; TWO VIEWS IN ONE PICTURE.

(Component P/N: BD10007001; manufacturer’s name “Bruce.”   You got my attention!  Thank-you for this submission—Ed.)

Part Total Time:  (unknown)

 

Cessna:  182R; Failed Fuel Injection Intake Tube; ATA 3710

"A significant problem occurred in the fuel induction system," says this aircraft owner, "where a rubber intake tube connects the intake manifold to the fuel induction rail.  Shortly after a flight where an entirely normal operation was experienced, engine restart could not be accomplished.  The rubber tube was found to be fully separated from the intake manifold, causing a large vacuum leak (downstream of the carburetor) and rendering the engine inoperable.

"The probable cause is incorrect installation of the rubber tube at engine overhaul, 262 hours previously.  The failed connection was between the Y-shaped intake manifold and the fuel rail on the right side.  This could result from 1) failing to force the rubber tube far enough onto the manifold tube, or 2)  failing to seat the hose clamp far enough (in) from the end of the manifold tube.  (Another) possible cause is the clamp or hose worked loose in normal operation.

      "To prevent recurrence, I suggest the following:

            a)  The rubber connecting tube on the intake manifold must be installed to achieve maximum depth on both the intake manifold and fuel rail.

            b)  The clamp position is critical to maintain the position of the rubber tube on the manifold, since there is no enlargement bead at the end of the manifold tube.

            c)  Use correct torque on clamps and consider safety wire to prevent loosening.

            d)  Consider preparation of the surface; (for example), removing paint and lubricants at assembly time.

"The consequences of this failure would have been much more serious if the separation had occurred in flight—causing a complete power loss."

Part Total Time:  262 hours.

 


Cessna:  182T; Cracked Firewall Doubler; ATA 5412

"A crack was discovered in a firewall doubler (forward side)," says this submitter.  "The crack is located behind the right hand 'cowl exit ramp' (P/N 0752732-2; see manufacturer's IPC 53-10-00, revision 19; item 241).  The longest section of the crack is six inches.  There is also a secondary crack (3/4 inch long) radiating out from the rivet hole at the center of the six inch crack.  Another small crack (3/4 inch) was found just outboard of the 6 inch crack during rivet removal (in preparation for repair).  This area is very difficult to inspect with the lower cowling removed on a P2 (100 hour inspection) or P3 (Annual inspection)—but it is accessible.  There was (also) substantial dirt and oil build-up in the area behind the cowl exit ramp, making the area harder to inspect."

 

A) VIEW OF A CRACKED FIREWALL DOUBLER.

(Doubler P/N:  075360024.  The SDRS database provides four examples of this crack.  See also the next report.)

Part Total Time:  (unknown)

 

Cessna:  182T; Cracked Firewall Doubler; ATA 5412

A few days pass when the above submitter again writes, "A 1.5 inch long crack was discovered in a doubler on the forward side of the firewall.  The crack location can be found by locating the 'bracket-parking brake control' aft of the firewall (see Cessna 182T IPC Revision 19, Chapter 32-32-02, figure 01, item 38; P/N 0713070-20).  Translate this location to the forward side of the firewall.  The crack was centered around the top rivet attaching the 'bracket-parking brake control' to the firewall and firewall doubler.


"When the parking brake handle is pulled, this area of the firewall and firewall doubler flex a little.  It is very probable this flexing action has caused the crack in the firewall doubler.  Two small dents can be seen in the firewall from the 'bracket-parking brake control'."  (Doubler P/N:  075360024.  See last month's Alerts for another of these cracked doublers.)

 

A) VIEW OF A CRACKED FIREWALL DOUBLER.


 

B) A CLOSEUP VIEW OF A CRACKED FIREWALL DOUBLER.

Part Total Time:  2,991 hours

 

Cessna:  510; Loose Aileron Trim Actuator; ATA 2711

A quality manager for a repair station says, "During maintenance on (this aircraft) and while carrying out Mustang SB510-27-01 (service bulletin), a loud rattle was noticed from inside the LH aileron prior to refit.  The noise sounded like multiple loose items toward the inboard end of the aileron.  On removal of the aileron trim actuator access panel (532EB), it was discovered that the noise was being caused by two AN3-3A bolts and matching washers (P/N NAS1149F0363P) inside the compartment where the trim actuator is located.  Further investigation revealed the two bolts had fallen out of the aileron trim actuator mounting points and had dropped inside the aileron.  The two remaining bolts which secure the actuator in position were very loose—(these) also in process of falling out."

Part Total Time:  502.2 hours

 


Fairchild:  SA227-DC; Cracked Spar Web; ATA 5711

"During an NDT (non-destructive testing) inspection," says this air carrier submitter, "a crack was visually identified at stringer number 14 on the wing spar shear web.  Photos of the defect have been provided.  (We) are currently in contact (with the manufacturer) for a repair disposition."

 

A) DRAWING OF A SPAR SECTION.


 

B) PHOTO OF THE SPAR LOCATION IN THE FLOOR.


C) CLOSEUP OF THE SPAR LOCATION IN THE FLOOR.

 

D) VIEW OF THE BOLT-HOLE OBSERVATION POINT.


 

E) A BORE-SCOPE CAMERA SHOT.

 

(No part numbers were provided.  Take a second look at the above, last photo:  taken through the bolt-hole!  Thank-you for sharing such trick photography—Ed.)

Part Total Time:  29,756 hours

 

POWERPLANTS

Rotax:  912ULS; Failed Crankshaft Connecting Rod; ATA 8520

A repair station submission says, "The number three crankshaft rod failed in flight—knocking a hole in the crankcase.  The engine remained running and the pilot was able to return the aircraft to the airport.  One quart of oil was remaining in the oil tank.  (A supplier/repair station) performed a tear-down inspection and was unable to (determine) a conclusive cause for this engine failure" (P/N:  888164).


 

A) PHOTO OF A BROKEN PISTON CONNECTING ROD.

Part Total Time:  607 hours

 


ACCESSORIES

Goodrich: Water Heater; Failed Thermostat; ATA 3820

(The following description references a Bombardier BD1001A10.)

"The 'Lavatory Water' circuit breaker popped," says this writer.  "(We) found the water heater to be at fault.  We removed the plastic cover on the heater and found the thermostat body had separated (from a poor solder joint) which exposed the contacts and shorted-out the unit.  The heater was manufactured in May of 2008."  (Goodrich Water Heater P/N:  4E31762.  Klixon Thermostat P/N:  4391S1471.)

 

PHOTO OF THE HEATER AND ITS THERMOSTAT.

 

Part Total Time:  563 hours

 

Slick Magneto:  4330; Broken Impulse Coupling; ATA 7414

A general aviation submission states, "The L/H magneto on the R/H engine cut out while running the engine.  After removing the magneto, (we) noticed the impulse coupling hub spacer had (pulled) away from the rivets and split into two pieces."  (Component number M3068.  Next photo vertically compressed—Ed.)


 

A) PHOTO OF THE MAGNETO SHAFT AND THE BROKEN SPACER.


 

B) CLOSEUP PHOTO OF THE BROKEN SPACER.

Part Total Time:  977.0 hours

 

AIR NOTES

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE

The Federal Aviation Administration (FAA) Internet Service Difficulty Reporting (iSDR) web site is the front-end for the Service Difficulty Reporting System (SDRS) database that is maintained by the Aviation Data Systems Branch, AFS-620, in Oklahoma City, Oklahoma. The iSDR web site supports the Flight Standards Service (AFS), Service Difficulty Program by providing the aviation community with a voluntary and electronic means to conveniently submit in-service reports of failures, malfunctions, or defects on aeronautical products. The objective of the Service Difficulty Program is to achieve prompt correction of conditions adversely affecting continued airworthiness of aeronautical products. To accomplish this, Malfunction or Defect Reports (M or Ds) or Service Difficulty Reports (SDRs) as they are commonly called, are collected, converted into a common SDR format, stored, and made available to the appropriate segments of the FAA, the aviation community, and the general public for review and analysis. SDR data is accessible through the “Query SDR data” feature on the iSDR web site at: http://av-info.faa.gov/sdrx/Query.aspx.


In the past, the last two pages of the Alerts contained a paper copy of FAA Form 8010-4, Malfunction or Defect Report. To meet the requirements of *Section 508, this form will no longer be published in the Alerts; however, the form is available on the Internet at: http://forms.faa.gov/forms/faa8010‑4.pdf. You can still download and complete the form as you have in the past.

*Section 508 was enacted to eliminate barriers in information technology, to make available new opportunities for people with disabilities, and to encourage development of technologies that will help achieve these goals.

A report should be filed whenever a system, component, or part of an aircraft, powerplant, propeller, or appliance fails to function in a normal or usual manner. In addition, if a system, component, or part of an aircraft, powerplant, propeller, or appliance has a flaw or imperfection, which impairs or may impair its future function, it is considered defective and should be reported under the Service Difficulty Program.

The collection, collation, analysis of data, and the rapid dissemination of mechanical discrepancies, alerts, and trend information to the appropriate segments of the FAA and the aviation community provides an effective and economical method of ensuring future aviation safety.

The FAA analyzes SDR data for safety implications and reviews the data to identify possible trends that may not be apparent regionally or to individual operators. As a result, the FAA may disseminate safety information to a particular section of the aviation community. The FAA also may adopt new regulations or issue airworthiness directives (ADs) to address a specific problem.

The iSDR web site provides an electronic means for the general aviation community to voluntarily submit reports, and may serve as an alternative means for operators and air agencies to comply with the reporting requirements of 14 Title of the Code of Federal Regulations (CFR) Section 121.703, 125.409, 135.415, and 145.221, if accepted by their certificate-holding district office. FAA Aviation Safety Inspectors may also report service difficulty information when they conduct routine aircraft maintenance surveillance as well as accident and incident investigations.

The SDRS database contains records dating back to 1974. At the current time, we are receiving approximately 40,000 records per year. Reports may be submitted to the iSDR web site on active data entry form or submitted hardcopy to the following address.

The SDRS and iSDR web site point of contact is:

Pennie Thompson
Service Difficulty Reporting System, Program Manager
Aviation Data Systems Branch, AFS-620
P.O. Box 25082
Oklahoma City, OK 73125
Telephone: (405) 954-5313
SDRS Program Manager e-mail address: 9‑AMC‑SDR‑ProgMgr@faa.gov

 

 


IF YOU WANT TO CONTACT US

We welcome your comments, suggestions, and questions. You may use any of the following means of communication to submit reports concerning aviation-related occurrences.

Editor:  Daniel Roller (405) 954-3646
FAX:    (405) 954-4570 or (405) 954-4655

E-mail address:   Daniel.Roller@faa.gov

Mailing address: FAA, ATTN: AFS-620 ALERTS, P.O. Box 25082 , Oklahoma City, OK 73125-5029

You can access current and back issues of this publication from the internet at:
http://av‑info.faa.gov/. Select the General Aviation Airworthiness Alerts heading.

 

AVIATION SERVICE DIFFICULTY REPORTS

The following are abbreviated reports processed for the previous month, which have been entered into the FAA Service Difficulty Reporting System (SDRS) database. This is not an all-inclusive listing of Service Difficulty Reports. For more information, contact the FAA, Regulatory Support Division, Aviation Data Systems Branch, AFS-620, located in Oklahoma City, Oklahoma. The mailing address is:

FAA
Aviation Data Systems Branch, AFS-620
PO Box 25082
Oklahoma City, OK 73125

To retrieve the complete report, click on the Control Number located in each report. These reports contain raw data that has not been edited. Also, because these reports contain raw data, the pages containing the raw data are not numbered.

If you require further detail please contact AFS-620 at the address above.


 

 

Federal Aviation Administration

Service Difficulty Report Data

 

Sorted by aircraft make and model then engine make and model. This report derives from unverified information submitted by the aviation community without FAA review for accuracy.

Control Number

Aircraft Make

Engine Make

Component Make

Part Name

Part Condition

Difficulty Date

Aircraft Model

Engine Model

Component Model

Part Number

Part Location

2010FA0001104

 

 

BENDIX

BREAKER POINTS

MISALIGNED

10/11/2010

 

 

 

ES382585

MAGNETO

RECEIVED 2 NEW SETS OF CONTACT BREAKER POINTS. INITIAL VISUAL INSPECTION SHOWS SIGNIFICANT ANGULAR MISALIGNMENT OF POINT FACES ON EACH SET.

2010FA0001134

 

 

 

TUBE

MISMANUFACTURED

8/17/2010

 

 

 

AEL75767

OIL FILL

(WS9R) THREAD SIZE IN CAPSIDE IS INCORRECT.

2010FA0001137

 

 

 

HOUSING

CRACKED

8/20/2010

 

 

 

 

T/R SERVO

(QH5R) SERVO BODY CRACKED.

2010FA0001133

 

 

 

CYLINDER

MISMANUFACTURED

8/5/2010

 

 

 

AEC631397

ENGINE

(WS9R) UPON REDCEIVING THE CYLINDER INTAKE ROCKER BUSHING BORE NOT CUT SQUARE.

2010FA0001121

 

CONT

 

TAPPET

CHIPPED

10/18/2010

 

TSIO520R

 

658077FG

ENGINE

NEW TAPPET BODY WAS CHIPPED AT THE EDGE OF THE TAPPET BODY FACE.

2010FA0001120

 

LYC  

 

TAPPET

DEFECTIVE

10/18/2010

 

O320H2AD

 

15B26090

ENGINE

NEW HYD LIFTER BODY WILL NOT BLEED DOWN OR COLLAPSE TO ALLOW FOR PROPER DRY TAPPET CLEARANCE AT ENGINE O/H.

2010F00231

AEROSP

PWA  

 

SPAR

CORRODED

11/4/2010

ATR72212

PW120

 

 

LT WING

LEFT WING FRONT SPAR LOWER FLANGE AT RIB 31 HAS SMALL AREA OF DELAMINATED. REPAIRED DAMAGE IAW STRUCTURAL REPAIR INSTRUCTION DO/TS-3386/10-13712 ISSUE A DATED JUNE 28, 2010. OK TO PAINT. RESTORED TOPCOAT IAW SRM 51-21-27, PP 1-25, REV 77 FEB 01/10. SRI DO/TS-3386/10-13712 ACCOMPLISHED IAW SRAS DO/TS-3386/10...5878. *NOTE: PERFORMED STEP 8 OF ABOVE SRI NO DEFECTS NOTED.

2010F00232

AEROSP

PWA  

 

STRINGER

CORRODED

11/4/2010

ATR72212

PW120

 

 

ZONE 100

(COER) FLT DECK, FRAME 12 FWD, AFT SIDE FROM STRINGER 20L-20R HAS CORROSION. REMOVED CORROSION IAW SRM 51-21-42, REV 77. MATERIAL LOSS FOUND TO BE OUT OF LIMITS IAW SRM 53-11-00, FIG 301 & 53-11-40, FIG 112, REV 77. ALL PARTS INSTALLED IAW SRM 51-25-01, 51-25-02, 51-25-03, 51-25-04 AND 53-11-40, REV 77. APPLIED ALODINE PRIMER AND PAINT TO OUTER SKIN AS REQUIRED IAW SRM 51-21-17 AND 51-21-27 REV 77.

2010F00233

AEROSP

PWA  

 

STRINGER

CORRODED

11/4/2010

ATR72212

PW120

 

 

ZONE 100

(COER) FLIGHT DECK, STRINGER 21L JUST AFT OF FRAME 12 HAS SURFACE CORROSION. (LEVEL II) REMOVED RIVETS TO FOM CORROSION REMOVAL IAW SRM 51-25-01, REV 77. REMOVED CORROSION IAW SRM 51-21-42, REV 77. FOUND TO BE OUT OF LIMITS IAW SRM 51-10-10, REV 77. REMOVED STRINGER END TIE IAW SRM 51-25-01, REV 77. INSTALLED NEW STR END TIE IAW SRM 51-25-01 AND 53-31-26, FIG 101, REV 77.

2010F00234

AEROSP

PWA  

 

STRINGER

CORRODED

11/4/2010

ATR72212

PW120

 

 

ZONE 100

(COER) FLIGHT DECK, STR 21R END TIE JUST AFT OF FRAME 12 HAS SURFACE CORROSION. (LEVEL II) REMOVED CORROSION IAW SRM 51-21-42, REV 77. FOUND TO BE OUT OF LIMITS IAW SRM 51-10-10, REV 77. REMOVED STRINGER END TIE IAW SRM 51-25-01, REV 77. INSTALLED NEW STR END TIE IAW SRM 51-25-01 AND 53-31-26, FIG 101, REV 77.

EE4Y100446

AIRBUS

IAE  

 

BEAM

CORRODED

11/4/2010

A319132

V2524A5

 

D53472193200

ZONE 200

UPPER REAR FUSELAGE, PAX CABIN, AFT SERVICE AREA FROM STA 2800 TO STA 2884, -Y765 BEAM CORRODED (FLOOR STRUCTURE BEAM PN: D53472193200). NOTE: THE CORROSION REQUIRES A MAJOR REPAIR.

EE4Y100474

AIRBUS

IAE  

 

PANEL

CORRODED

11/5/2010

A319132

V2524A5

 

D54530052203

NR 2 PYLON

ENGINE NR2, PYLON LT LATERAL PANEL, BETWEEN STA 829 AND STA 928, SKIN PANEL WITH EROSION (PANEL PN: D54530052203). THE EROSION REQUIRES A MAJOR REPAIR.

2010FA0001159

AIRBUS

 

 

FITTING

CORRODED

11/8/2010

A320232

 

 

D5347026920000

FLOORBEAM

CORROSION ON AFT CARGO COMPARTMENT FLOOR SUPPORT FITTING FR 56 LBL 15. NO CORROSION REMOVAL LIMITS AVAILABLE IN SRM. FITTING IS LISTED AS PRIMARY STRUCTURE. R & R FITTING IAW SRM 51-42-11.

2010FA0001160

AIRBUS

 

 

SUPPORT

CORRODED

11/8/2010

A320232

 

 

D47112320300

FUSELAGE

CORROSION ON FRAME SUPPORT FR 69-70 RBL 50. NO CORROSION REMOVAL LIMITS AVAILABLE IN SRM. SUPPORT IS LISTED AS PRIMARY STRUCTURE. R & R FITTING IAW SRM 51-42-11.

2010FA0001161

AIRBUS

 

 

FLOOR SUPPORT

CORRODED

11/8/2010

A320232

 

 

D53974840002

FUSELAGE

CORROSION ON AFT CARGO COMPARTMENT FLOOR SUPPORT PROFILE FR 56, LBL24 - RBL12. NO CORROSION REMOVAL LIMITS AVAILABLE IN SRM. PROFILE IS LISTED AS PRIMARY STRUCTURE. R & R PROFILE IAW SRM 51-42-11.

2010FA0001145

AIRBUS

 

 

FLOOR SUPPORT

CORRODED

11/1/2010

A320232

 

 

D5392059220000

CARGO BAY  

CORROSION ON FWD CARGO COMPARTMENT FLOOR SUPPORT PROFILE FR 24 - 28, Y765. NO CORROSION REMOVAL LIMITS AVAILABLE IN SRM. PROFILE IS LISTED AS PRIMARY STRUCTURE. R & R PROFILE IAW SRM 51-42-11.

2010FA0001129

AIRBUS

 

 

FITTING

CRACKED

10/22/2010

A320232

 

 

D534714220090

FLOORBEAM

FITTING CRACKED ON AFT CABIN FLOORBEAM. R & R FITTING IAW SRM 51-42-11.

2010FA0001108

AIRTRC

PWA  

 

MOUNT

CRACKED

10/14/2010

AT502B

PT6*

 

 

WING TO BODY

DURING WING REMOVAL THE LT FUSELAGE TUBING WAS FOUND CRACKED AT THE TOP WING ATTACH BUSHING MOUNT. THE CRACK APPEARS TO BE ALMOST COMPLETE CRACKING FAILURE OF THE FUSELAGE VERTICAL TUBE AND GOES THROUGH THE DIAMOND PLATE GUSSET.

2010FA0001125

AMRGEN

LYC  

 

DIODE

BROKEN

10/6/2010

AA5  

IO320*

 

 

ZONE 400

MASTER SWITCH TURNED ON TO START ENGINE FOR FLT RESULTING IN VISIBLE SMOKE & ODOR IN CABIN. RETURNED TO HANGAR & FOUND IMPROPER RESPONSE & FUNCTION OF MASTER SWITCH. INVESTIGATION REVEALED THE MASTER CONTACTOR CONTROL WIRE FROM AIRFRAME GROUND POINT BEHIND INSTRUMENT PANEL TO THE MASTER SIDE OF THE MASTER/ALTERNATOR SWITCH AND ON TO THE CONTROL POST OF MASTER CONTACTOR HAD BEEN SHORTED RESULTING IN ENOUGH HEAT TO DESTROY THE INSULATION ON THE WIRE. MASTER CONTACTOR WAS FOUND TO FUNCTION NORMALLY. THE CLAMPING DIODE BETWEEN THE MASTER CONTACTOR CONTROL POST AND THE BATTERY TERMINAL OF THE MASTER CONTACTOR APPARENTLY HAD PHYSICALLY FAILED ALLOWING THE ANODE/CATHODE WIRES OF THE DIODE TO MAKE PHYSICAL CONTACT. THIS RESULTS IN AN UNPROTECTED SHORT TO GROUND WHEN THE MASTER SWITCH IS TURNED ON. DIODES OF THE TYPE AND PURPOSE ARE COMMON IN GENERAL AVIATION AIRCRAFT. THEY ARE USUALLY ENCASED IN SHRINK TUBE MAKING AN INSPECTION OF THE ACTUAL DIODE IMPRACTICAL. THIS PARTICULAR DIODE IS LOCATED ON THE ENGINE SIDE OF FIREWALL WITH EXPOSURE TO HEAD AND VIBRATION.

2010FA0001082

AMTR

 

 

TUBE

FAILED

9/10/2010

SPITFIRE

 

 

12200

LT MLG TIRE

LT MAIN TIRE WAS FLAT ON LANDING. PILOT FELT SHIMMY ON TAKEOFF ROLL JUST AT ROTATION. SUSPECT TUBE FAILURE ON TAKEOFF. TIRE WAS NOT DAMAGED BUT WHEEL WAS DESTROYED.

V0DR967YA

BEECH

 

 

SPACER

MISMANUFACTURED

8/11/2010

1900D

 

 

50124041

BRAKE ASSY

A SPACER (PN: 5012404-1) WAS INSTALLED NEW FROM STOCK INTO A BRAKE ASSY (PN: 5006749-5R). DURING THE TESTING PROCESS, THE MECHANIC WAS UNABLE TO ACHIEVE THE DESIRABLE SPACING BETWEEN BRAKE PARTS. THE SPACER (PN 5012404-1) WAS REMOVED AND INSPECTED IN REFERENCE TO COMPONENT MM(CMM). THE SPACER WAS FOUND TO BE UNSERVICEABLE IAW CMM. ALL SPACERS IN STOCK HAVE BEEN REMOVED FROM SERVICE AND QUARANTINED.

V0DR967YB

BEECH

 

HARTZL

JAM-NUT

DEFECTIVE

8/11/2010

1900D

 

 

B3368

PROPELLER

(V0DR) DURING ASSY OF A PROPELLER ASSY, THE JAM-NUTS (PN B-3368) WERE INSTALLED AND THE BETA RING RUN-OUT TOLERANCE COULD NOT BE MAINTAINED. FURTHER TROUBLESHOOTING IDENTIFIED THE JAM-NUTS (PN B-3368) WERE MFG WITH THE THREADS NOT TRUE. CAUSING THE RUN-OUT TO BECOME EXCESSIVE WHEN THE JAM-NUT WAS TIGHTENED.

2010FA0001150

BEECH

CONT

BEECH

THRUST WASHER

MISOVERHAULED

11/2/2010

58  

IO550*

 

105090CR0324E

MLG ACTUATOR

THE LANDING GEAR ACTUATOR AND MOTOR ASSY WAS R & R WITH LANDING GEAR ACTUATOR PN 95-810017-23 DURING MX WITH AN O/H UNIT. DURING LANDING GEAR RIGGING, MOTOR SOUNDED OK AS THE GEAR WAS BROUGHT UP. WHEN GEAR WAS SELECTED DOWN, ACTUATOR AND MOTOR MADE A SLOW, DEEP GRINDING NOISE. MOTOR WAS REMOVED FOR INSP. IT WAS NOTICED THAT THE WASHER PN 105090CR032-4E, IPC 32-30-00-04, IN BETWEEN MOTOR AND GEAR, WAS MISSING. MOTOR HAD SIGNS OF RUBBING BY THE PINION GEAR. FURTHER INVESTIGATION REVEALED THAT THE WASHER WAS MISPLACED BETWEEN THE GEAR ACTUATOR HSG AND SPUR AND PINION GEAR PN 35-810135. IF THE UNITS ARE ASSEMBLED IAW THE MM THE NARRATIVE NEVER TELLS YOU TO INSTALL THE PN 105090CR032-4E WASHER, AND FIG 202- "LANDING GEAR ACTUATOR ASSY" DOES NOT DEPICT THE WASHER. THE IPC 32-30-00-04 FIG 2 OF 2 DOES SHOW THE WASHER (ITEM 320) IN ITS PROPER LOCATION. THIS IS CONFUSING AND MISLEADING.

2010FA0001103

BEECH

CONT

BEECH

CONTROL CABLE

DETACHED

9/20/2010

95B55

IO470L

 

503891021

MIXTURE CABLE

DURING FLIGHT, THE RT ENGINE MIXTURE CONTROL FAILED AND THE ENGINE QUIT. AFTER LANDING, FOUND THE SWAGGED END OF THE MIXTURE CONTROL CABLE (PN 50-389010-21) HAD SEPARATED AT THE FUEL CONTROL UNIT.

JDWA147SF1

BEECH

PWA  

 

SWITCH

OUT OF ADJUST

10/26/2010

99  

PT6*

 

 

PAX DOOR

ON TAKEOFF ROLL, CABIN DOOR LIGHT CAME ON BEFORE LIFTOFF. PILOT ABORTED TAKEOFF AND WENT BACK TO RUN UP PAD. CHECKED DOOR AND TRIED ANOTHER TAKEOFF, DOOR LIGHT CAME ON BEFORE ACFT LT THE GROUND. RETURNED TO RAMP, MECHANIC RESET DOOR LIGHT SWITCH. SYS FUNCTION CHECKED SATISFACTORY.

2010FA0001151

BEECH

CONT

 

BAFFLE

CHAFED

10/26/2010

A36  

IO550B

 

244112Z

ENGINE

THE FRONT 2 PRODUCTS CENTER AND LT BAFFLES WERE FOUND CHAFED THROUGH THE INNER NOSE BOWL AND CAUSED A HOLE APPROX 7 INCHES LONG AND .2500 INCH WIDE. THE BAFFLES ENDED UP TOO LONG OVER TIME AS THE ENGINE MOUNTS STARTED TO SAG.

2010FA0001152

BEECH

CONT

 

BAFFLE

CHAFED

10/26/2010

A36  

IO550B

 

244103Z

ENGINE

THE FRONT 2 PRODUCTS CENTER AND LT BAFFLES WERE FOUND CHAFED THROUGH THE INNER NOSE BOWL AND CAUSED A HOLE APPROX 7 INCHES LONG AND .2500 INCH WIDE. THE BAFFLES ENDED UP TOO LONG OVER TIME AS THE ENGINE MOUNTS STARTED TO SAG. HAVE HEARD OF SEVERAL OTHER REPORTS SIMILAR TO THIS ONE.

2010FA0001109

BEECH

PWA  

 

SEAL RING

DISINTEGRATED

10/15/2010

B200

PT6A60A

 

311821701

ENGINE CASE

ENGINE ACCESSORY CASE INPUT SHAFT TEFLON WASHER (SEAL RING), PN 3118217-01, DISINTEGRATED AND WAS FOUND IN THE OIL SCAVENGE PUMP SCREEN DURING A SCHEDULED INSP. ACCESSORY CASE REMOVAL REQUIRED FOR WASHER REPLACEMENT.

2010FA0001153

BEECH

CONT

 

WHEEL HALF

SEPARATED

10/17/2010

E55  

IO520*

 

16203600

NLG 

NOSE WHEEL EXPERIENCE A CIRCUMFRENCIAL CRACK AT THE BEAD FLANGE ALLOWING THE FLANGE TO SEPARATE FROM HUB ON LANDING AND THEREBY ALLOWING TIRE TO DEPART THE WHEEL.

2010FA0001089

BEECH

PWA  

 

FIRE WARNING

FALSE ACTIVATION

10/6/2010

E90  

PT6A135A

 

 

ZONE 400

FIRE WARNING ON RT ENGINE WITH NO SUPPORTING EVEDENCE OF ACTUAL FIRE. CHECK LIST COMPLIED WITH AND PRECAUTIONARY LANDING ACCOMPLISHED. INSPECTED AND TROUBLESHOT FIRE DETECTION SYS IAW MM 26-10-00 CHART 101, PROBLEM NR4. NO DEFECT NOTED CLEANED AND DRIED ELECTRICAL CONNECTORS IN THE FIRE DETECTION SYS COULD NOT DUPLICATE THE RT FIRE INDICATION ON THE GROUND. R & R RT FIRE EXTINGUISHER SUPPLY CYLINDER IAW MM 26-20-00 PAGE 203 PN 861-006. HYDRO STATIC TESTED 10/2010.

2010FA0001085

BEECH

PWA  

 

FIRE WARNING

FALSE ACTIVATION

10/6/2010

E90  

PT6A27

 

 

RT NACELLE

FIRE WARNING ON RT ENGINE WITH NO SUPPORTING EVIDENCE OF ACTUAL FIRE. CHECKLIST COMPLIED WITH AND PRECAUTIONARY LANDING ACCOMPLISHED.

2010FA0001080

BEECH

CONT

 

CIRCUIT BREAKER

UNSERVICEABLE

10/5/2010

F33A

IO520BB

 

35380132103

STROBE LIGHTS

PILOT REPORTED STROBE LIGHTS INOP. ON TROUBLESHOOTING, TECH FOUND CIRCUIT BREAKER/SWITCH TO BE AT FAULT, A.D. 2008-13-17 HAD BEEN COMPLETED 1997 HOURS PRIOR. NOTICED NEW CIRCUIT BREAKER/SWITCHES. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

2010FA0001144

BEECH

CONT

 

CIRCUIT BREAKER

FAILED

10/31/2010

F33A

IO520BB

 

35380132103

LANDING LIGHT

PILOT REPORTED LANDING LIGHT INOP. ON TROUBLESHOOTING, TECH FOUND CIRCUIT BREAKER/ SWITCH TO BE AT FAULT. AD 2008-13-17 HAD BEEN COMPLETED 1770 FLIGHT HOURS PRIOR AND ESTIMATED CYCLES 7080. NOTICED NEW CIRCUIT BREAKER MFG. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

2010FA0001130

BEECH

CONT

 

SWITCH

FAILED

10/22/2010

F33A

IO520BB

 

35380132103

TAXI LIGHT

PILOT REPORTED TAXI LIGHT INOP. WHEN TROUBLESHOOTING THE TECH FOUND C/B SWITCH HAD FAILED INTERNALLY.

2010FA0001158

BEECH

CONT

 

LIGHT

INOPERATIVE

11/7/2010

F33A

IO520BB

 

 

BEACON

PILOT REPORTED BEACON LIGHT INOP. ON TROUBLESHOOTING, TECH FOUND CIRCUIT BREAKER /SWITCH TO BE AT FAULT. AD 2008-13-17 HAD BEEN COMPLETED 1799 FLIGHT HOURS PRIOR.

QMLDMR0254

BELL  

 

 

SKIN

CRACKED

10/26/2010

412  

 

 

212030099071

TAIL BOOM

CRACK IN TAIL BOOM SKIN AND DOUBLER AT RT TAIL ROTOR FLOOD LIGHT. TAIL ROTOR FLOOD LIGHTS WERE INSTALLED ON FAA FORM 337, DATED 6 APRIL 1988.

R29R2010003

BELL  

PWA  

 

DAMPER

DEBONDED

10/12/2010

412EP

PT6T3

 

412310146103

MAIN ROTOR HEAD

(R29R) FOUND ONE DAMPER SET DEBONDED AND THE REMAINING 3 SETS SHOWING SIGNS OF DEBONDING. ACFT GROUNDED UNTIL REPLACEMENT DAMPERS ARE INSTALLED. SECOND DISCOVERY OF THIS PROBLEM IN THE CUSTOMERS FLEET.

R29R2010002

BELL  

PWA  

 

DAMPER

DEBONDED

10/8/2010

412EP

PT6T3

 

412310146103

MAIN ROTOR HEAD

(R29R) FOUND 3 OUT OF 4 DAMPER HALF SETS HAD DEBONDED THE ELASTOMERS FROM THE METAL MOUNT PADS. IT APPEARS AS THOUGH THERE WAS A LACK OF ADHESIVE BETWEEN THE 2 SURFACES. THE VIBRATION LEVEL MEASURES 4.0 IPS AT THE BEGINNING OF THE TRACK AND BALANCE PROCESS. THE MAIN TRANSMISSION MOUNTS, FRICTION DAMPERS, YOKE AND SPINDLE ASSEMBLIES INCURRED DAMAGE DUE TO THE VIBRATION LEVELS AND HAD TO BE REPLACED.

FOTR201728764

BOEING

 

 

SEAT TRACK

DAMAGED

10/25/2010

727200

 

 

UNK 

ZONE 200

SEAT TRACK STA. 720-740 LBL24 DAMAGED. REPAIRED ON NR 8764 FASI W/O 20172

FOTR201728739

BOEING

 

 

SEAT TRACK

CORRODED

10/25/2010

727227

 

 

 

BS 540-580

SEAT TRACK PITTING STA. 540-580 RBL.45. REPAIRED ON NR 8739 FASI W/O 20172.

FOTR201728741

BOEING

 

 

SEAT TRACK

CORRODED

10/25/2010

727227

 

 

UNK 

ZONE 200

SEAT TRACK PITTING STA. 480-460 RBL.24. REPAIRED ON NR 8741 FASI W/O 20172.

FOTR201728786

BOEING

 

 

SEAT TRACK

CORRODED

10/25/2010

727227

 

 

UNK 

ZONE 200

SEAT TRACK PITTING STA. 970 LBL.45. REPAIRED ON NR 8786 FASI W/O 20172.

FOTR201728788

BOEING

 

 

SEAT TRACK

CORRODED

10/25/2010

727227

 

 

UNK 

ZONE 200

SEAT TRACK PITTING STA. 1030-1110 LBL.24. REPAIRED ON NR 8788 FSAI W/O 20172

FOTR201728768

BOEING

 

 

SEAT TRACK

CORRODED

10/25/2010

727227

 

 

UNK 

ZONE 200

SEAT TRACK PITTING STA. 760-848 LBL.24. REPAIRED ON NR 8768 W/O 20172.

FOTR201728312

BOEING

 

 

SKIN

DELAMINATED

10/25/2010

727227

 

 

 

NR 9 SPOILER

RIGHT WING NR 9 SPOILER UPPER SURFACE DELAMINATED. REPAIRED ON NR 8312 FASI W/O 20172.

FOTR201728716

BOEING

 

 

SEAT TRACK

CORRODED

10/27/2010

727227

 

 

 

ZONE 200

SEAT TRACK PITTING STA. 990 RBL24. REPAIRED ON NR 8716 FASI W/O 20172.

FOTR201728724

BOEING

 

 

SEAT TRACK

CORRODED

10/27/2010

727227

 

 

 

ZONE 200

SEAT TRACK PITTING STA. 880-910 RBL 24. REPAIRED ON NR 8724 FASI W/O 20172.

FOTR201728871

BOEING

 

 

FLOORBEAM

CORRODED

10/25/2010

727227

 

 

 

ZONE 200

MAIN CABIN FLOORBEAM AT STA 1130 LBL 24 IS CORRODED. REPAIRED ON NR 8871 W/O 20172

FOTR201728707

BOEING

 

 

SEAT TRACK

CORRODED

10/25/2010

727227

 

 

 

ZONE 200

SEAT TRACK STA. 360 RBL 20 CORRODED. REPAIRED ON NR 8707 FASI W/O 20172.

FOTR201728792

BOEING

 

 

PAN  

CORRODED

10/29/2010

727227

 

 

 

ZONE 200

LEFT AFT FLOOR PAN CORRODED STA 1183-1146. REPAIRED ON NR 8792 FASI W/O 20172.

FOTR201728861

BOEING

 

 

FLOORBEAM

DAMAGED

10/25/2010

727227

 

 

 

ZONE 200

STA 360 FLOORBEAM FASTENER HOLE ELONGATED RBL.55. REPAIRED ON NR 8861 FASI W/O 20172.

FOTR201728753

BOEING

 

 

SEAT TRACK

CORRODED

10/25/2010

727227

 

 

 

ZONE 200

SEAT TRACK PITTING STA. 680-700 LBL 45.

FOTR201728745

BOEING

 

 

STRUCTURE

CORRODED

10/29/2010

727227

 

 

 

ZONE 200

SURFACE COROSSION ON CHORD AT STA.1183 LEFT SIDE. REPAIRED ON NR# 8745 FASI W/O# 20172.

FOTR201728712

BOEING

 

 

SEAT TRACK

CORRODED

10/27/2010

727227

 

 

UNK 

ZONE 200

SEAT TRACK CORRODED STA 1070-1030 RBL 45. REPAIRED ON NR 8712 FASI W/O 20172.

FOTR201728769

BOEING

 

 

SEAT TRACK

CORRODED

10/27/2010

727227

 

 

 

ZONE 200

SEAT TRACK PITTING STA 876 LBL 24. REPAIRED ON NR 8769 FASI W/O 20172.

FOTR201728790

BOEING

 

 

SEAT TRACK

DAMAGED

10/27/2010

727227

 

 

 

ZONE 200

SEAT TRACK 2 HOLES DRILLED IN TRACK STA 1120 LBL 24. REPAIRED ON NR 8790 FASI W/O 20172.

FOTR201728791

BOEING

 

 

SEAT TRACK

DAMAGED

10/27/2010

727227

 

 

 

BS 1110

SEAT TRACK 2 HOLES DRILLED IN TRACK STA 1110 LBL 45. REPAIRED ON NR 8791 FASI W/O 20172.

FOTR201728911

BOEING

 

 

FRAME

CRACKED

10/27/2010

727227

 

 

 

ZONE 200

FRAME CRACKED AT STA 312 BETWEEN S13-14R. REPAIRED ON NR 8911 FASI W/O 20172.

FOTR201728912

BOEING

 

 

FRAME

CRACKED

10/27/2010

727227

 

 

 

ZONE 200

FRAME CRACKED AT STA 328 BETWEEN S13-14R. REPAIRED ON NR 8912 W/O 20172.

FOTR201728708

BOEING

 

 

SEAT TRACK

CORRODED

10/25/2010

727227

 

 

 

ZONE 200

SEAT TRACK CORRODED STA. 360 RBL.55. REPAIRED ON NR 8708 FASI W/O 20172.

ERKR201000316

BOEING

 

 

BOTTLE

DISCHARGED

10/18/2010

747446

 

 

 

ESCAPE SLIDE

(ERKR) RT UPPER DECK SLIDE INFLATION BOTTLE DISCHARGED WHILE SITTING IN SHIPPING AREA. SLIDE WAS REMOVED FOR SHIPMENT TO O/H, ALL SAFETY PRECAUTIONS WERE OBSERVED AND IN PLACE. OUTSIDE AMBIENT TEMPERATURE WAS 50-85 DEGREES FAHRENHEIT AND SUNNY. 1 DAY AFTER REMOVAL FROM ACFT A LOUD NOISE WAS HEARD AND THE BOTTLE PRESSURE WAS "0". THE BOTTLE WAS INSPECTED AFTER OCCURRENCE AND NO VISIBLE SIGNS OF DISTRESS OR MALFUNCTION. LAST INSPECTED JULY 5, 2010

2010F00228

BOEING

RROYCE

 

BATTERY PACK

DISCHARGED

10/26/2010

757223

RB211*

 

P4010049

EMERGENCY LIGHTS

FIRST CLASS SEATS MOUNTED EMERGENCY LIGHTS DIM ON TEST. LIGHT SYS TESTED GOOD AFTER REPLACED BATTERY PACK CPN NR BAT5016.

2PSASDR7671010

BOEING

PWA  

 

O-RING

FAILED

10/10/2010

767238

JT9D7R4D

 

M832481216

HYDRAULIC PUMP

DURING CRUISE FLIGHT, AT APPROX 3:22 AFTER TAKEOFF, OBSERVED NR2 ENGINE OIL QTY STARTED TO SHOW A POSSIBLE LOSS OF OIL AT A RATE OF 1 QT EVERY 3 MINUTES. WHEN QTY REACHED 3 QTS, ENGINE BROUGHT BACK TO IDLE & SHUTDOWN INITIATED. ACFT LANDED WITH A TOTAL FLIGHT TIME OF 6.1 HOURS. RT ENGINE COWLING OPENED AND EVIDENCE OF OIL LEAKAGE DISCOVERED. DURING MOTORING OF ENGINE, WITNESSED OIL LEAKING FROM BETWEEN ENGINE DRIVEN HYD PUMP & PUMP MOUNTING FLANGE ON GEARBOX. PUMP REMOVED & SPLINE SHAFT O-RING REPLACED. PUMP REINSTALLED IAW AMM 29-11-05. ENGINE MOTORED, NO LEAK DETECTED. ENGINE OPERATED FOR FURTHER INSP & NO LEAKS NOTED. NOTE: O-RING REPLACED 23.3 FLT HOURS EARLIER FOR EVIDENCE OF OIL LEAKING IN SAME AREA. ACFT OPERATED FOR 11.5 HOURS, SMALL AMOUNT OF OIL WITNESSED AT THE BOTTOM OF COWLING & ENGINE GEARBOX WAS AGAIN INSPECTED TO INSURE OIL WAS RESIDUAL FROM PREVIOUS OIL LOSS. THE QTY HAD DROPPED 1 QT IN 11.5 HOURS.

AMCR201010

BOMBDR

 

 

ACTUATOR VALVE

FAULTY

10/28/2010

BD1001A10

 

 

4485253

CABIN PRESSURE

DURING DESCENT, PASSING THROUGH FL410, CABIN OXYGEN MASKS DEPLOYED. THERE WAS NO WARNING OR INDICATION. CABIN PRESSURE WAS FINE. AFTER MASKS DEPLOYED, CREW GOT THE NORMAL INDICATION WHICH WAS A CAS MSG THAT "PAX OXY ON". REPLACED ELECTRO-PNEUMATIC ACTUATING VALVE (EPAV) AND TESTED SYS WITH ALL NORMAL OPERATION. BUT, THE REPLACEMENT VALVE'S 'SHOP FINDING REPORT' FROM STATED THE VALVE WAS INSPECTED AND TESTED WITH 'NO FAULT FOUND' AND HAD A HISTORY STATING THE PREVIOUS REASON FOR REMOVAL WAS AN INTERNAL OXYGEN LEAK INTO THE PAX SYS CAUSING DEPLOY MODE. NO CONFIDENCE IN REPLACEMENT VALVE (SN 218) SO ANOTHER REPLACEMENT TO BE INSTALLED.

2010F00224

BRAERO

GARRTT

 

PUMP

FAILED

6/17/2010

BAE125800A

TFE7315BR

 

307085057

FUEL SYSTEM

(TM2R) CREW REPORTED THE "ENG NR1 FUEL" ANNUNCIATOR ILLUMINATED DURING FLIGHT.

2010F00225

BRAERO

GARRTT

 

ANNUNCIATOR

ACTIVATED

10/20/2010

BAE125800A

TFE7315R

 

 

NR 1 ENG FUEL

CREW REPORTED THE "ENG 1 FUEL" ANNUNCIATOR ILLUMINATED DURNING FLIGHT.

2010FA0001124

CESSNA

CONT

 

ROD END

BROKEN

10/8/2010

150F

O200*

 

S11073

NLG STEERING

ON TAKEOFF ROLL, LT FWD NOSE STEERING ROD END FAILED ALLOWING NOSE GEAR TO TURN FULL LT RESULTING IN LOSS OF CONTROL OF ACFT. ACFT DEPARTED RUNWAY EDGE AND FLIPPED OVER CAUSING SUBSTANTIAL DAMAGE.

ZB0R201000007

CESSNA

LYC  

 

CASE HALF

CRACKED

10/27/2010

152  

O235*

 

LW13282

ENGINE

DURING ENGINE TEAR DOWN INSP FOR PROPELLER STRIKE, TECH FOUND LT CASE HALF CRACKED IN 2 PLACES AT THE NR2 CYL OPENING. THE DAMAGE CAN BE TOTALLY ATTRIBUTED TO THE PROP STRIKE. CASE WAS REPLACED WITH AN O/H UNIT.

2010FA0001111

CESSNA

LYC  

 

CONNECTOR

ARCED

10/15/2010

172RG

O360*

 

 

HYD POWER PACK

INSTRUCTOR PILOT ACTING AS STUDENT FOR CFI TRAINING WAS AT THE CONTROLS AND WAS APPROX 4 MILES WEST OF AIRPORT (RVS). WITHIN A FEW SECONDS OF PLACING THE GEAR HANDLE IN THE DOWN POSITION FLAMES CONSUMED THE AREA OF THE RUDDER PEDALS. AN EMERGENCY WAS DECLARED AND A DESCENT WAS INITIATED TO A FIELD BELOW. CABIN WAS FILLED WITH SMOKE AND PILOT PLACED HIS HEAD OUT THE WINDOW FOR VISUAL REF ACFT LANDED IN THE FIELD. BOTH PILOTS EXITED THE ACFT AND WITHIN APPROX 30 SECONDS THE ACFT WAS ENGULFED IN FLAMES. HYD POWER PACK ELECTRICAL CONNECTION SHOWED EVIDENCE OF ARCING TO CASE.

2010FA0001162

CESSNA

 

 

CONTROL CABLE

FRAYED

11/9/2010

172S

 

 

0510105362365

RT AILERON

(U72S) DURING PHASE III INSP FOUND RT AILERON CONTROL CABLES FRAYED AGAINST PN 0522647-10 FAIRLEAD ASSY, FWD OF AILERON AUTOPILOT SERVO. BOTH CABLES PN 0510105-362 AND 0510105-365 EFFECTED.

2010FA0001154

CESSNA

CONT

 

PISTON

CRACKED

10/19/2010

182L

O470R

 

SA640518

NR 5 CYLINDER

ACFT WAS IN CRUISE FLIGHT AND EXPERIENCED AN ENGINE FAILURE. THE CASE WAS CRACKED ABOVE THE NR5 CYLINDER AND INSP THROUGH THE OIL FILLER TUBE REVEALED TNE NR5 PISTON WAS COMPLETELY DESTROYED. THIS ENGINE WAS O/H 17 YEARS AGO. INSP REVEALED THE ACFT IS CURRENTLY BURNING 100LL, HOWEVER THE ACFT DOES HAVE AN AUTO FUEL STC. PROBABLE CONTRIBUTING CAUSES FOR THE FAILURE IS THE AGE OF THE PART COMBINED WITH AN UNKNOWN AMOUNT OF TIME AND CONDITIONS OPERATING ON AUTO FUEL. COMPLIANCE WITH THE MFG RECOMMENDED O/H TIME AND PROCEDURES COULD HELP PREVENT THIS TYPE OF FAILURE. BURNING ONLY THE MFG RECOMMENDED FUEL COULD ALSO HELP PREVENT THIS TYPE OF FAILURE.

2010FA0001081

CESSNA

LYC  

 

DISPLAY

FAILED

10/5/2010

182T

IO540*

 

G1000

RIGHT

THE MFD (RT SEAT) WOULD NOT ALLOW FOR FREQUENCY CHANGES ON BOTH THE NAV AND COM. THE PFD (LT SEAT) CONTINUED TO WORK FINE. ONCE THE NEW FREQUENCIES WERE TUNED IN ON THE LT, THE RT WOULD THEN WORK AND ALLOW FOR FREQUENCY CHANGES. THE G1000 WAS 4 YEARS OLD, WARRANTY IS 2 YEARS. UNIT WAS SHIPPED TO MFG FOR REPAIR AT OWNER'S EXPENSE. LOCAL AVIONICS TECH SAID HE HAS SEEN THIS SEVERAL TIMES IN THE TUNING KNOBS ON G1000 DISPLAYS.

2010FA0001157

CESSNA

CONT

 

CYLINDER HEAD

CRACKED

10/21/2010

210M

IO520L

 

TIST714

ENGINE

DURING AN ANNUAL/100HR INSP FOUND 4 OUT OF THE 6 CYLINDER HEADS CRACKED, THEY ARE ECI CYLINDERS WITH PN TIST71.4, SN'S 38519-08, 38542-17, 38947-18, 38947-30.

2010FA0001155

CESSNA

CONT

 

NUT  

MISSING

9/20/2010

210M

IO550L

 

351124S36

ALTERNATOR

THIS ALTERNATOR, O/H WAS INSTALLED. TEST RUN-UP SHOWED NORMAL OPERATION. CHARGING SYS PROBLEMS WERE ENCOUNTERED AGAIN ON THE NEXT FLIGHT. UPON LANDING IT WAS DISCOVERED THAT THE HEX NUT ON THE ROTOR SHAFT WAS MISSING, INDICATING IMPROPER TORQUE AT UNIT O/H. BOTH THE FAN PULLEY AND ROTOR SHAFT WERE FOUND TO BE UNSERVICEABLE.

2010FA0001135

CESSNA

CONT

 

CYLINDER

CRACKED

8/18/2010

310R

IO520*

 

AEC631397

NR 4 

(WS9R) CYLINDER CRACKED FROM INJECTOR PORT TO SPARK PLUG BOSS.

2010FA0001147

CESSNA

CONT

 

SHAFT

CRACKED

9/16/2010

421B

GTSIO520H

 

633908

RT PROPELLER

PILOT HAD A ROUGH RUNNING ENGINE AND DIFFICULTY CONTROLLING THE ENGINE RPM'S. PILOT SHUTDOWN AND FEATHERED THE RT ENGINE AND LANDED SAFELY. MX PERFORM REPAIR ON PROPELLER CONTROL CABLE AND PROCEEDED TO PERFORM ENGINE RUN. HOWEVER, THE ENGINE WOULD NOT DEVELOP ENOUGH RPM TO UNFEATHER THE PROPELLER. THE MECHANIC BOARDED THE ACFT TO OBSERVE THE GAUGES AT WHICH TIME THE PROPELLER SEPARATED FROM THE ENGINE. IT HAS BEEN DETERMINE BY METALLURGICAL THAT THE PROPELLER SHAFT FAILED BY FATIGUE CRACKS FROM INITIATING CRACK FOLLOWED BY OVER FRACTURE. THE FATIGUE CRACKS GREW OVER SOME PERIOD OF TIME.

2010FA0001149

CESSNA

CONT

 

BOSS

CRACKED

11/1/2010

421B

GTSIO520H

 

633400

LT ENGINE

DURING VISUAL INSP OF THE ENGINE DISCOVERED INTERCOOLER AFT MOUNTING BOSS TO BE CRACKED 3/4 OF THE WAY AROUND.

2010FA0001110

CIRRUS

CONT

 

TUBE

SPLIT  

8/31/2010

SR22

IO550N

 

302013400

NLG TIRE

UPON LANDING, NOSE TIRE WAS FLAT. SUBSEQUENT INSPECTION REVEALED A .2500" SPLIT IN TUBE AT A LOCATION CORRESPONDING TO SIDEWALL OF TIRE. NO PUNCTURE OF THE TIRE HAD OCCURED.

V0XR413Y102710002

CNDAIR

GE  

 

ANGLE

CORRODED

10/27/2010

CL6002C10

CF34*

 

 

SILL 

SERVICE DOOR ANGLE PN SM670-31996-3 UNDER SILL PLATE HAD SURFACE CORROSION OUT OF LIMITS. R & R SERVICE DOOR ANGLE. IAW SRM 51-10-06 & SRM 51-21-23.

V0XR413Y102710003

CNDAIR

GE  

 

BULKHEAD

CORRODED

10/27/2010

CL6002C10

CF34*

 

 

BS 280

BULKHEAD LOWER WEB PN 670-53-11-052-1 AND -2 CORRODED, SURFACE, BEYOND LIMITS ABOVE 280 BEAM. REMOVED AND REPLACED LT AND RT SIDE OF LOWER FWD BULKHEAD AT FS 280 IAW REO NR 670-53-11-052. W/C 2113.

V0XR413Y102710006

CNDAIR

GE  

 

FLOORBEAM

CORRODED

10/27/2010

CL6002C10

CF34*

 

 

ZONE 100

280 BEAM HAD EXFOLIATION CORROSION ACROSS TOP. R & R 280 BEAM IAW REO 670-53-11-047.

2010FA0001073

DHAV

 

 

PUSHROD

FRACTURED

6/13/2010

DHC7*

 

 

72760272001

RT ELEVATOR

DURING DESCENT FOR LANDING, THE PILOT PUT THE AUTO PILOT MODE TO VS. THE ACFT PITCHED DOWN WITH STRONG VIBRATIONS AND BUFFETING. DISCONNECTED THE AUTO PILOT AND PUT THE ENGINES TO IDLE POWER AND SLOWED THE ACFT, VIBATION DISAPPEARED. ELEVATOR TRIM PUSH ROD ASSY FOUND FRACTURED AT AFT END BEFORE CLEVIS.

V0XR201011020003

DHAV

PWA  

 

CONNECTOR

MISINSTALLED

11/2/2010

DHC8102

PW120

 

 

NLG WOW

(V0XR) NLG WON'T EXTEND DURING TEST FLIGHT. GEAR WAS EXTENDED USING EMERGENCY EXTENSION PROCEDURES. NLG WOW SENSOR CONNECTOR PLUGS WERE RECONNECTED CORRECTLY.

V0XR201011020001

DHAV

 

 

FRAME

CORRODED

11/2/2010

DHC8103

 

 

85330073109

ZONE 100

(V0XR) RT SIDE FRAME AT STA 510 IS CORRODED. R & R SPLICE IAW RD8-53-11498.

V0XR201010290001

DHAV

 

 

FRAME

CORRODED

10/29/2010

DHC8103

 

 

85330274109

BS 531 S30R-32L

(V0XR) CORROSION ON FRAME STR 32L-30R AND STR 31R-30R AT STN 531.

V0XR201010290002

DHAV

 

 

FRAME

CORRODED

10/29/2010

DHC8103

 

 

2024T3040

ZONE 100

(V0XR) CORROSION ON FRAME FLANGE AND WEB AT STN 467.0 FROM STR 32L - 30R. REMOVED AND REPAIRED FRAME FLANGE. W/C 1100

V0XR201010290003

DHAV

 

 

STRINGER

CORRODED

10/29/2010

DHC8103

 

 

N1268109

BS 470-500 S33

(V0XR) CORROSION ON STRINGER AT STN 470.0 - 500.0 AT STR 33. REMOVED AND REPAIRED STRINGER. W/C 1103

V0XR201010290004

DHAV

 

 

STRINGER

CORRODED

10/29/2010

DHC8103

 

 

N1268109

BS 500-533

(V0XR) CORROSION ON STRINGER AT STN 500.0 - 533 AT STR 33. REMOVED AND REPAIRED STRINGER. W/C 1105

V0XR201010290005

DHAV

 

 

STRINGER

CORRODED

10/29/2010

DHC8103

 

 

85300130101

BS 525 S32R

(V0XR) CORROSION ON STRINGER AT STN 525.0 AT STR 32R. REMOVED AND REPAIRED STRINGER. W/C 1107

V0XR201010220005

DHAV

CONT

 

FRAME

CORRODED

10/22/2010

DHC8103

IO550C

 

2024T3040

BS 488.5 S32-33

(V0XR) FRAME FLANGE STN 488.5 BETWEEN 33 & 32 IS CORRODED BEYOND LIMITS. FABRICATED REPAIR FLANGE.

V0XR201010290007

DHAV

PWA  

 

FITTING

CORRODED

10/29/2010

DHC8103

PW120A

 

85330513105

BS 531.5

(V0XR) JOINT FITTING AFT KEEL AT LT FRAME STN 531.5. R & R FITTING.

V0XR201010220004

DHAV

PWA  

 

SKIN

CORRODED

10/22/2010

DHC8103

PW120A

 

2024T3040

BS 488-510 S33R

(V0XR) TCAS ANTENNA DOUBLER BETWEEN STN 488 TO 510 AT STR 33R IS CORRODED BEYOND LIMITS. FABRICATED NEW SHEET METAL.

V0XR201011020002

DHAV

PWA  

 

STRUT

CORRODED

11/2/2010

DHC8103

PW120A

 

85330908S117

ZONE 100

(V0XR) STRUT AT STR 31P, STA 531.5 IS CORRODED. R & R STRUT.

U43R2010AF0000203

DIAMON

LYC  

 

PUMP

FAILED

11/5/2010

DA40

IO360M1A

 

5100009

FUEL SYSTEM

ELECTRIC FUEL PUMP FAILED DURING THE 3RD PREFLIGHT OF THE DAY. R & R FUEL PUMP. LIFE TIME ON THIS FUEL PUMP WAS 231.7 HOURS.

U43R2010AF0000202

DIAMON

LYC  

 

PUMP

FAILED

10/15/2010

DA40

IO360M1A

 

5100009

ZONE 100

WHILE TAXING FOR TAKEOFF THE CIRCUIT BREAKER POPPED. CREW RESET IT AND CONTIUNED THE FLIGHT. ABOUT 1 HOUR INTO THE FLIGHT THE CIRCUIT BREAKER POPPED AGAIN THE CREW RETURN TO THE AIRFIELD AND TERMINATED THE FLIGHT. THE TECH CHECKED THE WIRING WITH A VOLTAGE REGULATOR AND FOUND THE WIRING WAS FINE. REPLACED THE ELECTRIC FUEL PUMP.

NX4R0004BB

DIAMON

 

 

CONTROL CABLE

FRAYED

10/27/2010

DA42

 

 

SF12579

RUDDER

DURING A ROUTINE INSPECTION, THE RUDDER CABLE, PILOT'S SIDE, JUST AFT OF THE RUDDER PEDAL WAS FOUND FRAYED, WITH BROKEN STRANDS. THIS CABLE(P/N-SF12579STRECHED)IS EXPOSED JUST FORWARD OF WHERE IT ENTERS THE UPHOLSTERY. THERE IS NO DISSASSEMBLY REQUIRED TO SEE THIS.

NX4R0006

DIAMON

 

 

CONTROL CABLE

FRAYED

10/28/2010

DA42

 

 

SF12579

RUDDER

THIS ACFT UTILIZES AN "S" TUBE METHOD OF ADJUSTING THE RUDDER PEDAL DISTANCE FROM THE PILOT/CO-PILOT SEATS, SINCE THE SEAT FORE/AFT POSITION IF FIXED AND NON ADJUSTABLE. THE RUDDER CABLES EXIT THE "S" TUBE SYS ABOUT 4 INCHES AFT OF THE RUDDER CABLES. THE CABLES, PN-SF12579 ARE VISIBLE FOR ABOUT 8IN OF SPAN BEFORE THEY ENTER THE UPHOLSTERY ON EITHER SIDE OF THE CABIN. ABOUT MIDWAY OF THIS SPAN, THE CABLES HAD FRAYED BROKEN STRANDS LOCATED AT THE 6 O'CLOCK ANGLE OF THE CABLE. SO FAR, ONLY THE PILOT'S SIDE CABLES HAVE BEEN FOUND FRAYED. THERE HAVE NO INSTANCES ON THE CO-PILOT'S SIDE.

NX4R0004AA

DIAMON

LYC  

 

FUEL TANK

CRACKED

10/5/2010

DA42

IO360A1A

 

D6028141200

ZONE 600

DURING A PREFLIGHT INSP, A WET FUEL STAIN WAS OBSERVED BELOW THE RT AUX FUEL TANK. THE FUEL TANK WAS FOUND TO BE CRACKED ALONG THE ROW OF SPOT WELDS. THE FUEL TANK WAS REPLACED WITH PN-D60-2814-12-00.

EE4Y1010444

DOUG

 

 

SKIN PANEL

CRACKED

10/30/2010

DC982

 

 

 

HORIZ STAB

DURING STRUCTURAL INSPECTION COOPESA REPORTED AT EMPENNAGE RT HORIZONTAL STABILIZER UPPER AFT SKIN PANEL WITH CRACK AT STATION XH -8.7 AFT INBOARD CORNER.

EE4Y1105451

DOUG

 

 

FRAME

CORRODED

11/5/2010

DC982

 

 

 

FUSELAGE

DURING STRUCTURAL INSPECTION COOPESA REPORTED AT LOWER FUSELAGE AFT CARGO COMPARMENT FRAME WITH CORROSION AT STA Y 1309 BETWEEN LONGERON 21 AND 2 RIGHT SIDE.

EE4Y1112490

DOUG

 

 

SPAR CAP

CRACKED

11/12/2010

DC982

 

 

5911301505

LT WING

DURING STRUCTURAL INSPECTION COOPESA REPORTED LT WING REAR SPAR LOWER CAP AFT FLANGE WITH CORROSION AND CRACKED AT STA XRS 172.

FOTR2016911140

DOUG

 

 

SEAT TRACK

CORRODED

10/29/2010

MD83

 

 

 

ZONE 200

SEAT TRACK STA 1098 LBL 45 CORRODED. REPAIRED ON NR 11140 FASI W/O 20169.

FOTR2016911059

DOUG

 

 

FLOORBEAM

CORRODED

10/29/2010

MD83

 

 

 

ZONE 200

FLOORBEAM SUPPORT ANGLES CORRODED STA 148- 200 BETWEEN LBL 60 AND RBL 60. REPAIRED ON NR 11059 FASI W/O 20169.

FOTR2016911216

DOUG

 

 

CUSP WEB

CORRODED

10/27/2010

MD83

 

 

 

ZONE 200

CUSP WEB STA 351- 411 CORRODED RBL 57. REPAIRED ON NR 11216 FASI W/O 20169.

FOTR1016911209

DOUG

 

 

CREASE BEAM

CORRODED

10/27/2010

MD83

 

 

 

ZONE 200

CREASE WEB STA 1140-1174 LBL 58 IS CORRODED. REPAIRED ON NR 11209 FASI W/O 20169.

FOTR2016910867

DOUG

 

 

SKIN

CORRODED

10/27/2010

MD83

 

 

 

LT WING TE FLAPS

LEFT WING O/B FLAP UPPER SURFACE XW 138-342 IS CORRODED. REPAIRED ON NR 10867 FASI W/O 20169.

FOTR2016910975

DOUG

 

 

DOOR FRAME

CORRODED

11/10/2010

MD83

 

 

 

ZONE 100

AFT LOWER CARGO COMPARTMENT DOOR JAMB HAS CORROSION. REPAIRED ON NR 10975 FASI W/O 20169.

FOTR2016911107

DOUG

 

 

FLOORBEAM

CORRODED

11/10/2010

MD83

 

 

 

ZONE 100

AFT CARGO BAY FLOORBEAM BS 1183 IS CORRODED AT LBL 16- RBL 3. REPAIRED ON NR 11107 FASI W/O 20169.

FOTR2016911104

DOUG

 

 

FLOOR SUPPORT

CORRODED

11/10/2010

MD83

 

 

 

ZONE 100

AFT CARGO LEFT FLOOR SUPPORT AT LBL 18 FROM BS. 1174- 1231. REPAIRED NR11104 FASI W/O 20169.

FOTR2016911163

DOUG

 

 

LONGERON

CORRODED

10/18/2010

MD83

 

 

 

ZONE 200

STA 1474 RT SIDE 5TH LONGERON FROM TOP HAS EXFOLIATED CORROSION. NR 11163, WO 20169 FASI.

FOTR2016910976

DOUG

 

 

DOOR FRAME

CORRODED

11/3/2010

MD83

 

 

 

ZONE 100

FWD LOWER CARGO DOOR JAMB HAS CORROSION, STA. 408- 427. REPAIRED ON NR 10976 FASI W/O 20169.

FOTR2016911132

DOUG

 

 

FLOORBEAM

CORRODED

11/3/2010

MD83

 

 

 

ZONE 100

AFT CARGO COMPARTMENT, BS. 1309 CABIN FLOORBEAM IS CORRODED ON BOTTOM SURFACE LBL.16 TO RBL.16. REPAIRED ON NR 11132 FASI W/O 20169.

FOTR2016911134

DOUG

 

 

FLOORBEAM

CORRODED

11/3/2010

MD83

 

 

 

BS 1309

AFT CARGO CABIN FLOORBEAM AT STA. 1309 IS CORRODED AT RBL 20. REPAIRED ON NR 11134 FASI WO 20169.

FOTR2016911083

DOUG

 

 

DOOR FRAME

CORRODED

11/3/2010

MD83

 

 

 

ZONE 100

CENTER CARGO DOOR LOWER FRAMES AT STA. 621- 658. REPAIRED ON NR# 11083 FASI W/O# 20169.

FOTR2016911082

DOUG

 

 

DOOR FRAME

CORRODED

10/18/2010

MD83

 

 

 

ZONE 100

CORROSION ON FWD CARGO LOWER FRAME BETWEEN STA 370 TO 435. NR11082 WO20169.

FOTR2016911012

DOUG

 

 

FRAME

CORRODED

10/18/2010

MD83

 

 

 

ZONE 200

CORROSION AT LEFT CANT FRAME 1431 NR6 ANGLE STIFFENER FROM BOTTOM. NR 11012, WO20169 FASI.

FOTR2016911293

DOUG

 

 

CUSP WEB

CRACKED

10/27/2010

MD83

 

 

 

ZONE 200

MAIN CABIN RIGHT CUSP WEB STA. 1265 RBL58. REPAIRED ON NR 11293 FASI W/O 20169.

FOTR2016911299

DOUG

 

 

SEAT TRACK

CORRODED

10/27/2010

MD83

 

 

UNK 

ZONE 200

SEAT TRACK FROM STA. 790-1036 RBL.55 IS CORRODED. REPAIRED ON NR 11299 FASI W/O 20169.

FOTR2016911300

DOUG

 

 

SEAT TRACK

CORRODED

10/27/2010

MD83

 

 

 

ZONE 200

SEAT TRACK FROM STA. 1036-1309 RBL. 55 IS CORRODRD. REPAIRED ON NR 11300 FASI W/O 20169.

FOTR2016911019

DOUG

 

 

FRAME

CORRODED

10/27/2010

MD83

 

 

 

ZONE 200

FRAME STA. 1485 RT VERTICAL STIFFNER CORRODED. REPAIRED NR 11019 FASI W/0 20169.

FOTR2016911287

DOUG

 

 

FLOOR SUPPORT

CRACKED

10/18/2010

MD83

 

 

 

ZONE 200

FLOOR SUPPORT TEE ANGLE CRACKED AT STA 927 AND RBL 54.

FOTR/20169/11121

DOUG

 

 

FRAME

CORRODED

10/18/2010

MD83

 

 

 

ZONE 100

AFT CARGO FRAME STA 1250 BETWEEN STR 29L-29R. NR11121, WO20169 FASI

FOTR2016911218

DOUG

 

 

LONGERON

CORRODED

10/18/2010

MD83

 

 

 

ZONE 100

CORROSION AT FUESLAGE STA 1007, LONGERON 23L, NR 11218, WO 20169 FASI.

FOTR2016911266

DOUG

 

 

CUSP WEB

CRACKED

10/18/2010

MD83

 

 

 

ZONE 200

RT CUSP WEB AT STA 1309 HAS 2 CRACKS. NR 11266, WO 20169 FASI.

FOTR2016911254

DOUG

 

 

CUSP WEB

CRACKED

10/18/2010

MD83

 

 

 

ZONE 200

LEFT CUSP WEB HAS CRACK STA 787, NR 11254, WO 20169 FASI.

FOTR2016911211

DOUG

 

 

FLOOR SUPPORT

CORRODED

10/18/2010

MD83

 

 

 

ZONE 200

FLOOR FRAME STA 1287, LBL 60 HAS CORROSION. NR 11211, WO 20169 FASI.

FOTR2016911228

DOUG

 

 

INTERCOSTAL

CORRODED

10/18/2010

MD83

 

 

9936718U4

BS 1309 S27R

BS 1309, L27R INTERCOSTAL IS CORRODED. REPAIRED ON NR11228, WO 20169 FASI.

FOTR2016910820

DOUG

 

 

SKIN

DENTED

10/18/2010

MD83

 

 

 

ZONE 200

DENT FUSEALGE AT STA 230, L17. NR10820, WO20169 FASI.

FOTR2016911261

DOUG

 

 

FLOORBEAM

CORRODED

10/18/2010

MD83

 

 

 

ZONE 200

FLOORBEAM CORRODED AROUND NUT PLATES AT STA 1338 LT. NR11261, WO 20169 FASI.

FOTR2016911194

DOUG

 

 

LONGERON

CRACKED

10/18/2010

MD83

 

 

 

ZONE 200

LONGERON 2 LT, CRACKED AT BS 1418 AFT AIRSTAIR. NR11194, WO20169 FASI.

FOTR20169FLOOR

DOUG

 

 

FLOORBOARD

DAMAGED

10/18/2010

MD83

 

 

 

ZONE 200

FLOORBOARD DAMAGED FROM STA 148-1361 APROX.

FOTR2016911264

DOUG

 

 

WEB  

CRACKED

10/18/2010

MD83

 

 

 

ZONE 100

WEB CRACKED AT CANTED FRAME STA 1463, NR11264, WO 20169 FASI.

FOTR2016911268

DOUG

 

 

CUSP WEB

CRACKED

10/18/2010

MD83

 

 

 

ZONE 200

RIGHT CUSP WEB HAS CRACK AT STA 780-800. NR 11268, WO 20169 FASI.

FOTR2016911267

DOUG

 

 

CUSP WEB

CRACKED

10/18/2010

MD83

 

 

 

ZONE 200

RIGHT CUSP WEB HAS CRACK AT STA 866, NR 11267, WO 20169 FASI.

FOTR2016911271

DOUG

 

 

CUSP WEB

CORRODED

10/18/2010

MD83

 

 

 

ZONE 200

CUSP WEB AT STA.927 RT IS CORRODED. NR 11271, WO 20169 FASI.

FOTR2017211141

DOUG

 

 

SEAT TRACK

CORRODED

10/27/2010

MD83

 

 

 

ZONE 200

SEAT TRACK HAS CORROSION BS 1110 LBL 22. REPAIRED ON NR 11141 FASI W/O 20169.

FOTR2016910869

DOUG

 

 

SKIN

CORRODED

10/27/2010

MD83

 

 

 

LT WING TE FLAP

LEFT WING OUTBOARD FORE FLAP LOWER SURFACE HAS SURFACE CORROSION IN SEVERAL SPOTS XW 138-342.

FOTR2016911284

DOUG

 

 

SEAT TRACK

CRACKED

10/27/2010

MD83

 

 

 

ZONE 200

SEAT TRACK CLIP CRACKED AT STA.886 RBL 54. REPAIRED ON NR 11284 FASI W/O 20169.

FOTR2016911285

DOUG

 

 

ATTACH ANGLE

CRACKED

10/27/2010

MD83

 

 

 

SEAT TRACK

SEAT TRACK CLIP CRACKED AT STA. 905 RBL.54. REPAIRED ON NR 11285 FASI W/O 20169.

FOTR2016911251

DOUG

 

 

CUSP WEB

DAMAGED

10/27/2010

MD83

 

 

 

ZONE 200

RIGHT CUSP WEB STA 1079-1098 HOLES DRILLED IN WEB. REPAIRED ON NR 11251 FASI W/O 20169.

FOTR2016911258

DOUG

 

 

FRAME

CORRODED

10/18/2010

MD83

 

 

 

ZONE 100

CORROSION ON AFT SIDE OF FRAME STA 1231, LOG 28L-29R, NR11258, WO 20169 FASI.

FOTR2016911253

DOUG

 

 

INTERCOSTAL

CORRODED

10/18/2010

MD83

 

 

 

ZONE 100

AFT PIT LEFT INTERCOSTAL STA 1022-1041 AT LT 22 IS CORRODED. NR 11253, WO20169 FASI.

FOTR2016911198

DOUG

 

 

LONGERON

CORRODED

10/18/2010

MD83

 

 

 

ZONE 100

CORROSION AT FUSELAGE STA 1007, R24. NR 11198 WO 20169 FASI.

FOTR2016911222

DOUG

 

 

LONGERON

CORRODED

10/5/2010

MD83

 

 

 

BS 1022 L22L

AFT PIT LT SIDE LONGERON 22 STA 1022 IS CORRODED.

V0XR210111050003

EMB  

 

 

SILL

CORRODED

11/5/2010

EMB145LR

 

 

14521725001

ZONE 100

(V0XR) LEFT SILL BETWEEN FRAMES 19-23 IS CORRODED BEYOND LIMITS. R & R LT SILL.

V0XR210111050004

EMB  

RROYCE

 

FLOOR SUPPORT

CORRODED

11/5/2010

EMB145LR

AE3007A1

 

14522459003

ZONE 100

(V0XR) SUPPORT BETWEEN FRAMES 19-20 ON OMEGA BEAM IS CORRODED BEYOND LIMITS. R & R SUPPORT.

V0XR210111050006

EMB  

RROYCE

 

SILL

CORRODED

11/5/2010

EMB145LR

AE3007A1

 

14525422001

ZONE 100

(V0XR) LT SILL BETWEEN FRAMES 61-65 IS CORRODED BEYOND LIMITS. R & R LT SILL. W/C 2084

V0XR210111050001

EMB  

RROYCE

 

FLOOR SUPPORT

CORRODED

11/5/2010

EMB145LR

AE3007A1

 

14521713605

ZONE 100

(V0XR) CTR OMEGA BEAM BETWEEN FRAMES 19-23 IS CORRODED BEYOND LIMITS. R & R CTR OMEGA BEAM.

V0XR210111050002

EMB  

RROYCE

 

FLOOR SUPPORT

CORRODED

11/5/2010

EMB145LR

AE3007A1

 

14521713005

ZONE 100

(V0XR) RT OMEGA BEAM BETWEEN FRAMES 19-23 IS CORRODED BEYOND LIMITS. R & R RT OMEGA BEAM.

V0XR2010110900015

EMB  

RROYCE

 

SEAT TRACK

WORN

11/9/2010

EMB145LR

AE3007A12

 

14533669003

ZONE 100

(V0XR) (CORRECTION) PILOT AND CO-PILOT SEAT TRACK WORN BEYOND LIMITS. REMOVED AND REPLACED PILOT AND CO-PILOT SEAT TRACKS. W/C 2113

2010FA0001088

FRCHLD

 

 

GOVERNOR

MALFUNCTIONED

10/7/2010

SA227DC

 

 

 

PROPELLER

RIGHT PROPELLER GOVENOR WILL NOT MAINTAIN CRUISE RPM. RMOVED AND REPLACED R/H PROPELLER GOVENOR WITH A REPAIRED UNIT. MAINTENANCE OPERATION CHECK OK.

2010FA0001100

GULSTM

 

 

PULLEY

CHAFED

10/8/2010

690B

 

 

 

TE FLAP

FLAP PULLEY AND CLIP CHAFE FLAP BRACKET - ADDRESSED PREVIOUSLY IN BOTH AD98-07-17 AND SB226.

2010FA0001101

GULSTM

 

 

PULLEY

CHAFED

10/8/2010

690B

 

 

 

LT WING TE FLAP

FLAP PULLEY CHAFES FLAP BRACKET - PREVIOUSLY ADDRESSED IN AD98-07-17 AND SB226.

2010FA0001102

GULSTM

GARRTT

 

PULLEY

CHAFED

10/8/2010

690C

TPE331*

 

 

TE FLAPS

FLAP PULLEY CHAFES FLAP BRACKET - PREVIOUSLY ADDRESSED IN BOTH AD 98-07-17 AND SB 226.

2010FA0001084

HUGHES

ALLSN

 

CONNECTOR

DIRTY

10/5/2010

369E

250C20B

 

MS3106E8S1S

ENGINE OIL SYS

ON APPROACH TO LANDING THE PILOT HAD A CHIP LIGHT EVENT. MX REMOVED BOTH ENGINE CHIP PLUGS AND FOUND NO DEBRIS. IT WAS DETERMINED THAT THE LOWER CHIP PLUG CONNECTOR PLUG WAS SHORTED INTERNALLY AND CAUSING THE LIGHT. THE CONNECTOR WAS REPLACED.

2010FA0001083

HUGHES

ALLSN

 

WARNING LIGHT

FALSE ACTIVATION

10/5/2010

369E

250C20B

 

 

CHIP DETECTOR

ON APPROACH TO LANDING THE PILOT HAD AN ENGINE CHIP LIGHT EVENT. THE LIGHT REMAINED ON DURING SHUTDOWN BUT WHEN MX ARRIVED THE LIGHT WAS OUT. BOTH ENGINE CHIP PLUGS WERE PULLED AND WERE FOUND TO BE CLEAN OF DEBRIS. THE LIGHT EVENT COULD NOT BE DUPLICATED.

2010FA0001143

HUGHES

ALLSN

 

TURBINE

DAMAGED

10/27/2010

369E

250C20B

 

23038241

ENGINE

AT ENGINE SHUTDOWN AFTER LAST FLIGHT OF THE DAY THE MECHANIC HEARD A TURBINE RUB NOISE IN THE ENGINE ASSY. ACFT WAS REMOVED FROM SERVICE FOR MX.

2010FA0001107

HUGHES

ALLSN

 

SEAL

MISSING

9/24/2010

369HS

250C20B

 

 

POPPET VALVE

ON 5/7/2010, INSTALLED A NEW ANTI-ICE VALVE PN 23053192 AT ACTT 14805.1. DURING A ROUTINE 100 HR INSP OF THE ACFT ON 9/24/2010 AT ACTT 14904.8. REMOVED AND INSPECTED THE VALVE AND DISCOVERED THAT THE POPPET SEAT SEAL WAS MISSING FROM THE POPPET. POPPET SEAT RETAINING SCREW WAS STILL INSTALLED. SINCE THIS VALVE WAS UNSERVICEABLE WE REPLACED IT WITH A NEW VALVE AND SUBMITTED THE DEFECTIVE VALVE BACK TO VIA OUR PARTS SUPPLIER UNDER A WARRANTY CLAIM SINCE THE VALVE ONLY HAD 99.7 HRS ON IT TIME IN SERVICE. ACCORDING TO THE 8130-3 FORM THAT ACCOMPANIED THE PART THE PART WAS MFG UNDER WO 902802, CASE 2579757 BY MFG.

2010FA0001141

LET  

 

 

HINGE

BENT

10/27/2010

L13ACBLANIK

 

 

 

RT AILERON

RT AILERON HINGE ASSY BENT, HINGE BEARING RACE ALSO BENT. SUSPECT DISCREPENCY OCCURED DURING AEROBATIC FLIGHT. DISCOVERED ON 2 ACFT.

2010FA0001146

MOONEY

CONT

 

HOUSING

CRACKED

10/21/2010

M20K

TSIO360LB

 

60051004

TURBOCHARGER

DURING INSP OF AD82-27-03, THERE IS A .5 INCH CRACK IN THE INTERNAL AREA OF THE HOUSING THAT DOES NOT PENETRATE THE OUTER WALL. IT WAS DETERMINED THAT THIS AD NO LONGER APPLIES, BECAUSE THE PN OF THIS HOUSING WAS FOUND TO BE 600510-04 (SEE PARA J) OF THIS AD.

2010FA0001140

PIAGIO

PWA  

 

FIRE WARNING

FALSE ACTIVATION

10/24/2010

P180

PT6A66

 

 

RT NACELLE

RT ENGINE FIRE LIGHT CAME ON IN FLIGHT, FIRE BOTTLE DISCHARGED AND ENGINE SHUTDOWN, NO EVIDENCE OF FIRE NOTED ON GROUND.

2010FA0001148

PIAGIO

PWA  

 

WARNING LIGHT

FALSE ACTIVATION

11/1/2010

P180

PT6A66

 

 

CARGO DOOR

BAG DOOR LIGHT IN FLIGHT, SECURED ENGINE, LANDED, DOOR WAS NOT OPEN.

5APR577Y44

PILATS

PWA  

 

BRAKE DISC

CRACKED

10/7/2010

PC1245

PT6A67B

 

244759C

BRAKE ASSY

(5APR) RT BRAKE OUTER DISK FOUND CRACKED DURING LINE CHECK INSP.

5APR577Y43

PILATS

PWA  

 

BRAKE DISC

CRACKED

10/5/2010

PC1247

PT6A67B

 

244759C

BRAKE ASSY

(5APR) DURING A 100 HR INSP FOUND THE LT MAIN BRAKE OUTER DISK CRACKED. REMOVED BOTH LT AND RT MAIN BRAKE AND WHEEL ASSEMBLIES AND INSTALLED BRAKE AND WHEEL CONVERSION STC SA01376CH IAW STC INSTRUCTIONS.

5APR577Y45

PILATS

PWA  

 

SKIN

DENTED

10/18/2010

PC1247

PT6A67B

 

5572012334

ZONE 600

(5APR) RT WING AND DE-ICE BOOT DAMAGE FROM BIRDSTRIKE NOTICED AFTER POST FLIGHT INSPECTION.

2010FA0001123

PIPER

LYC  

 

DIPSTICK

BROKEN

10/19/2010

PA18150

O360C2A

 

 

OIL SYSTEM

OIL DIP STICK BROKE AND DROPPED INTO CRANKCASE. DIP STICK TUBE EXTENSION IS INSTALLED AND DIP STICK ANCHORED END FITS INTO CAP CASTING AND IS SECURED BY A ROLL PIN. ANCHORED END OF DIP STICK FRACTURED AND SEPARATED AT LOWER HALF OF HOLE THAT ROLL PIN PENETRATES THUS LETTING THE STAINLESS MEASURING DIP STICK DROP INTO ENGINE. IT APPEARS THAT DUE TO THE LENGTH OF THE DIP STICK AND ENGINE VIBRATION, THE ANCHOR POINT IN THE CAP ALLOWS THE STAINLESS MEASURING ROD TO FATIGUE.

2010FA0001128

PIPER

LYC  

 

D-RING

CORRODED

10/21/2010

PA28140

O320*

 

010816811

SEAT BELT

DISCOVERED VERY HEAVY EXFOLIATION CORROSION ON ALUMINUM SEAT BELT ATTACH "D" RING AT FUSELAGE ATTACH POINT. CORROSION WAS HIDDEN UNDERNEATH BELT WEBBING. AREA IS PRONE TO DAMPNESS AND IS HIDDEN FROM VIEW. CAN ONLY BE SEEN BY PUSHING SEWN AREA OF BELT BACK WHERE IT ATTACHES TO RING. BELT DEPARTED AIRFRAME WHEN SUBJECTED TO A SHARP PULL. FOUND 2 BELT ENDS LIKE THIS. SUGGEST STEEL ATTACH RINGS VICE ALUMINUM. AND PRYING BACK BELT TO INSPECT "HIDDEN" AREA WHERE SEWN LOOP OF BELT JOINS ATTACH RING.

F0TR20100001122

PIPER

LYC  

LYC  

RETAINER

BROKEN

10/18/2010

PA28181

O360*

 

SL14995

CYLINDER

SHROUD TUBES FOUND LOOSE IN CYLINDERS/CRANKCASE. SHROUD TUBE RETAINERS BROKEN (FOUND UNDER ROCKER BOX COVERS). SHROUD TUBES WERE LEAKING OIL.

2010FA0001131

PIPER

LYC  

GARMIN INTL

ANTENNA

FAILED

10/22/2010

PA28235

O540*

GNS430W

0130023500

GPS 

THE GNS 430W INDICATED NO SATELLITE COVERAGE WHILE IN FLIGHT. AN ADDITIONAL PORTABLE GPS ALSO INDICATED A LOSS OF SATELLITE COVERAGE. ATC INDICATED THAT THERE WERE NO OTHER REPORTS OF GPS PROBLEMS. LANDED AND TURNED OFF ALL OTHER ELECTRICAL DEVICES EXCEPT FOR THE 430W. THE LOSS OF SATELLITE COVERAGE WAS STILL SHOWN ON THE 430W AND THE HAND-HELD GPS. WHEN I TURNED OFF THE 430W, THE HAND-HELD GPS IMMEDIATELY STARTED SHOWING GPS COVERAGE. TURNING THE 430W BACK ON CAUSED THE HAND-HELD TO LOOSE COVERAGE AGAIN. WOULD HAVE TO MOVE THE HAND-HELD GPS APPROXIMATELY 20' FROM THE ANTENNA ON THE 430W BEFORE IT WOULD REQUIRE GPS COVERAGE AGAIN. REPLACING THE ANTENNA SOLVED THE PROBLEM. GARMIN INDICATED THAT MOST LIKELY THE ANTENNA HAD FAILED AND WAS OSCILLATING THEREFORE JAMMING THE OTHER GPS RECEIVERS. IN THIS FAILURE SCENARIO, IF I HAD 2 IFR GPS RECEIVERS IN THE ACFT, BOTH GPS RECEIVERS WOULD HAVE LOST GPS SATELLITE COVERAGE UNLESS THE OFFENDING UNIT WAS TURNED OFF.

2010FA0001156

PIPER

LYC  

 

VALVE SPRING

WEAK

11/5/2010

PA32R300

IO540K1G5D

 

 

ENGINE CYLINDER

PARTIAL POWER FAILURE ON TAKEOFF.

2010FA0001105

PIPER

LYC  

 

LANDING GEAR

DISTORTED

4/18/2010

PA32R301T

TIO540AH1A

 

 

NOSE 

DAMAGE OCCURRED TO NLG SUPPORT STRUCTURE DURING THE RETRACT CYCLE OF MLG AFTER TAKEOFF. FULL (OR CLOSE TO FULL) RUDDER CONTROL IMPUTED DURING THIS CYCLE. A LOUD BANG WAS HEARD DURING CYCLE. GEAR UP & SUBSEQUENT GEAR EXTENSION CYCLE NORMAL. UPON INSPECTION OF NLG IT WAS EVIDENT THAT THE STRUCTURE SUSTAINED MAJOR DAMAGE DURING THE RETRACT CYCLE. DURING THE INSP OF THE DAMAGE, IT WAS APPARENT THAT THE DAMAGE WAS A RESULT OF A JAMMING OF THE NLG DURING THE RETRACT MODE. THE GEAR WAS MANUALLY SWUNG TO VERIFY PROPER RIGGING. THE TEST SHOWED THAT IF FULL RUDDER CONTROL WAS INPUT DURING THE RETRACT CYCLE THAT THE NLG ALIGNMENT FITTING WOULD CAUSE A MOMENTARY JAMMING OF THE NLG. THIS CAUSED THE NLG ACTUATOR AND ITS ATTACHMENT BRACKET TO DAMAGE THE WHEEL WELL STRUCTURE. ONCE THE RUDDER INPUT WAS RELEASED, THE GEAR FULLY RETRACTED TO THE UP AND LOCKED POSITION. THE EXTEND CYCLE WORKED NORMALLY. THE NLG RIGGING WAS WITHIN TOLERANCES IAW THE MM, AND THE NLG WOULD ONLY JAM WHEN FULL OR NEARLY FULL INPUT WAS MADE DURING THE RETRACT CYCLE.

2010FA0001078

QUEST

PWA  

 

FCU  

LEAKING

3/24/2010

KODIAK100

PT6A34

 

307191501

ENGINE

FUEL PUMP SEAL LEAKAGE THAT LED TO FCU BRG GREASE WASHOUT. DISCOVERED BY OBSERVING BLUE DYE COMING FROM WITNESS HOLE IN BOTTOM OF FCU.

2010FA0001079

QUEST

PWA  

 

FCU  

LEAKING

10/4/2010

KODIAK100

PT6A34

 

307191501

ENGINE

FUEL PUMP SEAL LEAKAGE THAT LED TO FCU BRG GREASE WASHOUT. DISCOVERED BY OBSERVING BLUE DYE COMING FROM WITNESS HOLE IN BOTTOM OF FCU.

EVGR20101005

QUEST

PWA  

 

PUMP

LEAKING

10/5/2010

KODIAK100

PT6A34

 

307105701

FUEL SYS

(EGVR) FUEL PUMP SEAL FAILED, WASHING OUT BLUE DYE FROM THE BEARING. DYE WAS FOUND COMING OUT THE FUEL PUMP /FCU DRAIN LINE.

EVGR20101006

QUEST

PWA  

 

FCU  

LEAKING

10/5/2010

KODIAK100

PT6A34

 

307191501

ENGINE

BRG GREASE WAS WASHED OUT DUE TO FUEL PUMP SEAL FAILURE. BLUE DYE WAS FOUND IN THE DRAIN BETWEEN THE FUEL PUMP AND FUEL CONTROL UNIT.

2010FA0001076

QUEST

PWA  

 

PUMP

LEAKING

3/24/2010

KODIAK100

PT6A34

 

307105701

ENGINE FUEL

FUEL PUMP SEAL LEAKAGE THAT LED TO FCU BRG GREASE WASHOUT. DISCOVERED BY OBSERVING BLUE DYE COMING FROM WITNESS HOLE IN BOTTOM OF FCU.

2010FA0001077

QUEST

PWA  

 

SEAL

LEAKING

3/24/2010

KODIAK100

PT6A34

 

 

FUEL PUMP

FUEL PUMP SEAL LEAKAGE THAT LED TO FCU BEARING GREASE WASHOUT. DISCOVERED BY OBSERVING BLUE DYE COMING FROM WITNESS HOLE IN BOTTOM OF FCU.

2010FA0001074

QUEST

PWA  

 

PUMP

LEAKING

10/4/2010

KODIAK100

PT6A34

 

307105701

ENGINE FUEL

FUEL PUMP SEAL LEAKAGE THAT LED TO FCU BEARING GREASE WASHOUT. DISCOVERED BY OBSERVING BLUE DYE COMING FROM WITNESS HOLE IN BOTTOM OF FCU.

2010FA0001075

QUEST

PWA  

 

PUMP

LEAKING

6/15/2010

KODIAK100

PT6A34

 

307105701

ENGINE FUEL

FUEL PUMP SEAL LEAKAGE THAT LED TO FCU BRG GREASE WASHOUT. DISCOVERED BY OBSERVING BLUE DYE COMING FROM WITNESS HOLE IN BOTTOM OF FCU.

E81RAW301008

RAYTHN

WILINT

 

DISPLAY

MALFUNCTIONED

10/25/2010

390  

FJ44

 

8221084014

COCKPIT

FLIGHT CREW REPORTED PILOT'S PRIMARY FLIGHT DISPLAY TURNED GREEN FOR APPROX 2 MINUTES DURING FLIGHT, THEN RETURNED TO NORMAL.

2010F00226

RAYTHN

GARRTT

 

ANNUNCIATOR

ACTIVATED

8/7/2010

HAWKER800

TFE7315R

 

 

NR 2 ENGINE FUEL

CREW REPORTED THE "ENG 2 FUEL" ANNUNCIATOR ILLUMINATED DURING FLIGHT.