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

312

bald eagle watching over three eggs

JULY

2004

 


CONTENTS

AIRPLANES

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

CESSNA...................................................................................................................................... 1

ROCKWELL INTERNATIONAL............................................................................................... 2

POWERPLANTS AND PROPELLERS

McCAULEY................................................................................................................................ 2

PRATT AND WHITNEY............................................................................................................. 3

AIR NOTES

AIRCRAFT ACCIDENTS AND INCIDENTS – A REVIEW OF 2003
     AS PRINTED IN THE IOWA AVIATION BULLETIN, SPRING 2004 EDITION............... 3

ELECTRONIC VERSION OF FAA FORM 8010-4,
     MALFUNCTION OR DEFECT REPORT.............................................................................. 4

PAPER COPY OF FAA FORM 8010-4, MALFUNCTION OR DEFECT REPORT................. 4

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE..................................... 4

IF YOU WANT TO CONTACT US........................................................................................... 5

AVIATION SERVICE DIFFICULTY REPORTS........................................................................ 6

 


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

AVIATION MAINTENANCE ALERTS

The Aviation Maintenance Alerts provide a common communication channel through which the aviation community can economically interchange service experience and thereby cooperate in the improvement of aeronautical product durability, reliability, and safety. This publication is prepared from information submitted by those who operate and maintain civil aeronautical products. The contents include items that have been reported as significant, but have not been evaluated fully by the time the material went to press. As additional facts such as cause and corrective action are identified, the data will be published in subsequent issues of the Alerts. This procedure gives Alerts’ readers prompt notice of conditions reported via Malfunction or Defect Reports. Your comments and suggestions for improvement are always welcome. Send to: FAA; ATTN: Aviation Data Systems Branch (AFS-620); P.O. Box 25082; Oklahoma City, OK 73125-5029.

 

AIRPLANES

BEECH

Beech; Model 58; Baron; Cracked Heater Combustion Tube; ATA 2140

During an annual inspection, the technician performed a heater decay test. The heater failed the test and was removed from the aircraft.

The technician conducted a subsequent bench pressure test and discovered two large cracks at the weld joints between the inner combustion tube (P/N 45C40) and two of the crossover ports.

A search of the FAA Service Difficulty Reporting System data base revealed two additional reports concerning cracked combustion tubes.

Part total time: unknown.

Time since overhaul: approximately 80 hours.

 

CESSNA

Cessna; Model 172S; Fuel Servo Inoperative; ATA 7320

The submitter of this report stated, “The engine dies at idle speed, excessively rich mixture. Black smoke emitted from the exhaust.” The idle speed and mixture could not be adjusted IAW AD 2001-06-17 instructions Ref: (d), (l), and (i).

A search of the FAA Service Difficulty Reporting System data base revealed 26 additional reports with similar submissions.

Part total time: unknown.

Time since overhaul: 248.2 hours.

 


Cessna; Model 190/195/LC126A; Aileron Hinge Bracket Cracking and Corrosion; ATA 5751

The technician inspected the inboard aileron hinge brackets, and discovered the original magnesium brackets displayed some or all of the following conditions:

     1.   Severely corroded bracket body around mount and bearing boss.

     2.   Cracks spanning completely across the bearing boss and/or mounting feet.

     3.   Primer and/or body filler obstructing inspection of brackets where cracks were located (this condition was found on two different sets of these brackets).

The submitter reported a large percentage of the original brackets were unairworthy due to corrosion, cracks, or a combination of both.

A search of the FAA Service Difficulty Reporting System data base revealed 82 additional reports with similar submissions.

Part total time: unknown.

 

ROCKWELL INTERNATIONAL

Rockwell; Model 690B; Twin Commander; Cracked Aileron Spar; ATA 5751

The technician was complying with Twin Commander SB 236 Aileron Spar Inboard Hinge Inspection and Reinforcement, dated March 9, 2004, part 1, and discovered both aileron inboard spar webs (P/N250000-375) were cracked at the inboard hinge area. The aft and forward ribs also displayed cracks.

While complying with the needed repairs required by SB 236 (part III), the technician found a crack on the center spar just outboard of the center hinge upper attach bolt area. After removing the center spar web, he found a crack generating at each bolt hole.

A search of the FAA Service Difficulty Reporting System data base revealed four additional reports concerning cracked aileron spars.

Part total time: 5936.6 hours.

 

POWERPLANTS AND PROPELLERS

MCCAULEY

McCauley Propeller; Model D2AF34C30; Counterweight Separation; ATA 6111

During flight, the counterweight (P/N D-4170-1) separated from the propeller, and damaged the blade and the spinner assemblies.

A search of the FAA Service Difficulty Reporting System data base revealed four additional reports concerning damaged counterweights and attaching hardware.

Time since overhaul: 272.3 hours.

 


PRATT AND WHITNEY

Pratt and Whitney; PT6A114A; Compressor Turbine (CT) Vane Attachment; ATA 7250

The technician reported the CT vane segment slipped and rubbed into the CT disk, and caused abnormally hot engine operation.

After the technician installed a new hot section, all operating temperatures were normal.

The first time this problem occurred was in November 2003. At that time, the technician thought it was just a fluke since this engine had been operating a long time and never had this problem before. In May 2004, the problem occurred again when the CT vane segment slipped and rubbed into the CT disk and caused abnormally hot engine operation.

A search of the FAA Service Difficulty Reporting System data base revealed two additional reports concerning similar submissions.

Part total time: 231.2.

 

AIR NOTES

AIRCRAFT ACCIDENTS AND INCIDENTS - A REVIEW OF 2003

This article is was reprinted from the Iowa Aviation Bulletin, Spring 2004 edition. (This article is printed as the article appeared in the Iowa Aviation Bulletin.)

Iowa Accidents
For the 15+ years that I have been the FAA’s safety program manager for Iowa, this is the first time I can remember the total number of accidents exceeding incidents. As a review, if the occurrence resulted in a serious injury or fatality and/or at least substantial damage to the aircraft, it is considered an accident. If the occurrence resulted in less than substantial damage and injuries less than serious, it is considered an incident. In 2003 there were a total of 19 accidents in the state of Iowa that included 11 fatalities and four serious injuries. Looking at the accident category, Iowa follows the national trend with the majority of accidents (79 percent) falling in the personal/pleasure category.  That usually happens every year and is easy to understand because that’s where most of the activity is. There were also two accidents involving aerial application, one sightseeing, one instructional, and one cargo operation involved in an accident.

What were the casual factors in the accidents?
Again, we followed the national trend with the majority of the accidents in the landing/takeoff phase (42 percent), including factors such as loss of control in a crosswind, hitting objects on takeoff, and impacting the ground on approach, probably due to a stall condition. The next highest causal factor was related to mechanical problems; e.g., engine malfunction and landing gear problems. Fuel problems continue to appear yearly with three accidents in 2003 attributed to some kind of fuel exhaustion/mismanagement. Other accident causal factors were uncontrolled descent and a taxi accident. 

When we consider all the casual factors, approximately 72 percent would be related to some kind of “pilot error.”  Sound familiar?

Iowa Incidents
In 2003 there were a total of 13 incidents in the state of Iowa.

Again, personal/pleasure was the highest category of incidents with 84 percent. Additionally, there was one aerial application and one other incident. The leading cause of incidents, like accidents, was in the landing/takeoff phase with similar types of problems such as striking objects on approach and during takeoff, and the loss of control attributed to cross wind conditions. Fuel problems exceeded the accident figures with four incidents attributed to


fuel exhaustion or mismanagement. Two incidents were due to mechanical problems, again related to power loss and landing gear malfunctions. One gear-up incident occurred during 2003 in Iowa. This is a situation related to pilot error when the pilot forgot to put the landing gear down.

It has been a busy year in Iowa trying to keep up with investigation of these accidents and incidents and trying to determine causal factors.

Until next time, have a safe flight.

Roger “N” Clark
Safety Program Manager
Des Moines Flight Standards District Office

 

ELECTRONIC VERSION OF FAA FORM 8010-4, MALFUNCTION OR DEFECT REPORT

One of the recent improvements to the Flight Standards Service Aviation Information Internet web site is the inclusion of FAA Form 8010-4, Malfunction or Defect Report. This web site is still under construction and further changes will be made; however, the site is now active, usable, and contains a great deal of information.

Various electronic versions of this form have been used in the past; however, this new electronic version is more user friendly and replaces all other versions. You can complete the form online and submit the information electronically. The form is used for all aircraft except certificated air carriers who are provided a different electronic form. The Internet address is: http://forms.faa.gov/forms/faa8010-4.pdf

When the page opens, select “M or D Submission Form” and, when complete, use the “Add Service Difficulty Report” button at the top left to send the form. Many of you have inquired about this service. It is now available, and we encourage everyone to use this format when submitting aviation, service-related information.

 

PAPER COPY OF FAA FORM 8010-4, MALFUNCTION OR DEFECT REPORT

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.

 

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) data base 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, Mechanical Reliability Reports (MRRs), Malfunction or Defect Reports (M or Ds), Maintenance Difficulty Reports (MDRs), 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.

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 data base contains records dating back to 1974. At the current time, we are receiving approximately 45,000 records per year. Reports may be submitted to the iSDR web site on active data entry form or submitted hardcopy to the address below.

The SDRS and iSDR web site point of contact is:

John Jackson
Service Difficulty Reporting System, Program Manager
Aviation Data Systems Branch, AFS-620
P.O. Box 25082
Oklahoma City, OK 73125
Telephone: (405) 954-6486
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: John Jackson (405) 954-6486
FAX: (405) 954-4570 or (405) 954-4655
Technical support provided by: Aero Tech Service Associates

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 submitted between May 21, 2004, and June 22, 2004, which have been entered into the FAA Service Difficulty Reporting (SDR) System data base. 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

2004FA0000419

 

CONT

 

CYLINDER

CRACKED

4/6/2004

 

GTSIO520*

 

655474

ENGINE

RAM AIRCRAFT HAS FOUND NUMEROUS CYLINDERS WITH LOW HOURS CRACKED IN AN AREA EXTENDING FROM FUEL INJECTOR BOSS AREA TO THE SPARK PLUG HOLE. IN THIS AREA IS A MACHINED AREA WITHOUT SUFFICIENT RADIUS. SUGGEST RADIUS OF THIS AREA TO PREVENT CRACKING.

2004FA0000409

 

GARRTT

 

GASKET

FAILED

5/24/2004

 

TPE33110

 

8687466

PLENUM

PLENUM FUEL NOZZLE BOSS BLANK-OFF COVER GASKET PN 868746-6 (BLEW OUT) ON 5 OF 5 BOSSES. GASKET FAILURE ALLOWS HOT COMPRESSOR GAS LEAKING. GASKETS WERE ALL REPLACED AND ENGINE WAS TEST RUN. 3 OF 5 NEW GASKETS (BLEW OUT) DURING TEST RUN.

2004FA0000410

 

GARRTT

 

GASKET

FAILED

5/24/2004

 

TPE33110

 

8687466

PLENUM

PLENUM FUEL NOZZLE BOSS BLANK-OFF COVER GASKET PN 868746-6 (BLEW OUT) ON 5 OF 5 BOSSES. GASKET FAILURE ALLOWS HOT COMPRESSOR GAS LEAKING. GASKETS WERE ALL REPLACED AND ENGINE WAS TEST RUN. 3 OF 5 NEW GASKETS (BLEW OUT) DURING TEST RUN.

CA040426006

 

LYC  

 

BOLT

FAILED

3/17/2004

 

TIO540*

 

SL75060

CONNECTING ROD

(CAN) DURING ASSEMBLY OF ENGINE, A NEW SUPERIOR CONNECTING ROD BOLT, P/N SL75060 AND LOT NR 574065 WAS BEING USED. FOUND THAT THIS BOLTS MACHINING WAS INADEQUATE AND ALREADY WITHIN THE STRETCH LIMITS OF 2.255 - 2.256 INCHES WITHOUT A LOAD ON BOLT.

CA040402005

 

PWA  

 

RETAINING RING

COLLAPSED

3/25/2004

 

PT6A114A

 

3020159

ENGINE

(CAN) THE HOT SECTION WAS GIVEN A SCHEDULED HOT SECTION INSPECTION. A FEW CT SHROUD SEGMENTS HAD SHIFTED SLIGHTLY AND WERE RUBBED. THE RETAINING RING HAD NO END GAP AND WAS STARTING TO COME OUT OF THE GROOVE. THIS PROBLEM HAS BEEN DOCUMENTED ON OTHER ENGINES. PWA HAS ISSUED P/N 3110741-02 RETAINING RING ON SB 13121 (60A, 61, 62, 65 SERIES) AND SB 3248 (41/42, 45 SERIES) TO PREVENT THE COLLAPSE OF THE RETAINING RING. THE LATTER SB HAS NOT BEEN ISSUED ON SMALLER ENGINE MODELS SUCH AS THE 114A ENGINE MODEL TO ALLOW THE MORE ROBUST RETAINING RING TO BE USED.

109052704

AGUSTA

 

 

RELAY

FAILED

5/27/2004

A109

 

 

MS24166D

HYD SYSTEM

DURING ROUTINE SCHEDULED MAINTENANCE, IT WAS NOTED THAT THE HYDRAULIC UTILITY POWER PACK WOULD NOT SHUT OFF AFTER REACHING OPERATING PRESSURE. THE PROBLEM WAS TRACED TO AN ELECTRICAL RELAY. THE CONTACT POINTS WERE WORN AND HAD INDICATIONS OF METAL TRANSFER. THE RELAY WAS REPLACED AND SUBSEQUENT FUNCTIONAL TESTS OF THE SYSTEM WERE WITHOUT FAULT. AS A PRECAUTIONARY MEASURE, WE ARE TAKING STEPS TO REPLACE THIS RELAY THROUGHOUT OUR FLEET.

2004FA0000422

AMRGEN

LYC  

 

MOUNT

CRACKED

3/1/2004

AA5B

O360*

 

5501111501

ENGINE

DURING ANNUAL INSP, A CRACK WAS NOTED IN THE LOWER HORIZONTAL CROSSPIECE OF THE ENGINE MOUNT. THE CRACK IS APPROX .5000 INCH AWAY FROM THE PILOT SIDE END OF THIS TUBE, NEAR THE WELD THAT ATTACHES THIS TUBE TO THE DIAGONAL TUBE THAT ATTACHES TO THE FIREWALL LOWER PILOT SIDE SUPPORT BRACKET. THIS SAME CRACK LOCATION HAS BEEN SEEN IN SEVERAL AIRCRAFT. APPEARS TO BE A POINT OF HIGH VIBRATION INDUCED STRESS, AS THERE IS LITTLE LOAD ON THE PART DURING OPERATION.

AUS20040206

AMTR

AMTR

 

BOLT

SHEARED

3/18/2004

JABIRUSK

CHEVYV8

 

AN442

NLG 

(AUS) NOSE LANDING GEAR TRAILING LINK PIVOT BOLT FAILED AT LT PIVOT POINT.

2004FA0000428

BALWKS

 

 

LINE

INADEQUATE

4/28/2004

FIREFLY11

 

 

231311

FUEL DIST

UPON INSPECTION OF VALVE LINE SEVERAL LOCATIONS WERE FOUND WHERE THE INNER KEVLAR LINE HAS BUNCHED UP AND BECAME EXPOSED THROUGH THE OUTER PROTECTIVE NYLON COVER. THIS WAS FOUND IN VARIOUS PLACES ALONG LENGTH OF LINE. EACH OF THE PEA SIZED EXPOSED AREAS HAVE ABRASION ON THE EXPOSED KEVLAR. THIS LINE WAS REMOVED FROM SERVICE.

AUS20040105

BBAVIA

LYC  

 

SPAR

CRACKED

1/22/2004

7EC  

O235C1

 

129579

RT WING

(AUS) RT WING FRONT AND REAR SPARS CRACKED. CRACKS APPEAR TO ALIGN WITH THE ATTACHMENT FITTING BOLT HOLES. SPARS ARE CONSTRUCTED FROM TIMBER. FOUND DURING INSPECTION IAW AD/CHA/23 AMDT4.

2004F00121

BBAVIA

LYC  

 

LEG ASSY

BROKEN

3/26/2004

7GCBC

O320A2B

 

71404

MLG 

UPON LANDING, GEAR RT MLG, BROKE FLUSH AT FUSELAGE. AIRCRAFT HAD SADDLE BLOCKS INSTALLED BY STC437SWP. THE LANDING GEAR BREAK, SHOW SIGNS OF INTERGRANULAR CORROSION.

AUS20040145

BEECH

PWA  

 

LINK

MISINSTALLED

2/23/2004

200BEECH

PT6A41

 

131378252CL

NLG 

(AUS) NOSE WHEEL RETRACTION CHAIN CONNECTING LINK INCORRECTLY FITTED. PERSONNEL/MAINTENANCE ERROR.

AUS20040150

BEECH

PWA  

 

FIRE DETECTOR

FAULTY

2/18/2004

200BEECH

PT6A41

 

473275

LT ENGINE

(AUS) LT ENGINE FORWARD UPPER FIRE DETECTOR SUSPECT FAULTY.

AUS20040197

BEECH

PWA  

 

BLADE

LIGHTNING STRIKE

3/13/2004

200BEECH

PT6A41

 

 

PROPELLER

(AUS) LT PROPELLER BLADE EXHIBITED LIGHTNING EXIT MARKS. FURTHER INVESTIGATION FOUND BOTH LT AND RT PROPELLERS MAGNETISED BEYOND LIMITS. LT ENGINE POWER SECTION MAGNETISM BEYOND LIMITS. LIGHTNING EXIT MARKS FOUND ON LT ELEVATOR OB TRAILING EDGE.

AUS20040120

BEECH

PWA  

 

STRUCTURE

CRACKED

2/2/2004

200BEECH

PT6A42

 

8050 

BULKHEAD

(AUS) REAR PRESSURE BULKHEAD CLEAT LOCATED AT STRINGER 7L AND BULKHEAD BEAM AT STRINGER 6L CRACKED. FOUND DURING INSPECTION IAW AD.

AUS20040308

BEECH

PWA  

 

ENGINE

SURGES

4/14/2004

200BEECH

PT6A42

 

 

NR 2 

(AUS) NR 2 ENGINE POWER SURGE. DURING GROUND RUN TORQUE BLED OFF. INVESTIGATION FAILED TO FIND ANY CAUSE AND THE ENGINE WAS REMOVED.

AUS20040102

BEECH

PWA  

 

SHROUD

DAMAGED

2/11/2004

200BEECH

PT6A42

 

3053094CL

TURBINE SECTION

(AUS) RT ENGINE TURBINE SHROUD AND BLADES DAMAGED.

AUS20040096

BEECH

PWA  

 

FRAME

CRACKED

2/6/2004

200BEECH

PT6A42

 

 

FUSELAGE

(AUS) FUSELAGE FRAME LOCATED AT RF 265-760 CRACKED IN AREA ADJACENT TO FLOORBEAM. FOUND DURING INSPECTION IAW AD/BEECH200/65.

AUS20040092

BEECH

PWA  

 

SKIN

DELAMINATED

2/3/2004

200BEECH

PT6A42

 

8135105

LT WING

(AUS) LT WING INNER LEADING EDGE SKIN DELAMINATING IN AREA LOCATED ABOVE THE BYPASS DUCT.

AUS20040093

BEECH

PWA  

 

CIRCUIT BREAKER

TRIPPED

2/5/2004

200BEECH

PT6A42

 

 

MLG 

(AUS) RT MAIN LANDING GEAR WOULD NOT EXTEND. CIRCUIT BREAKER (60AMP)FOUND TRIPPED. CB RESET AND RETRACTION TESTS CARRIED OUT WITH NO REOCCURANCE.

AUS20040252

BEECH

PWA  

 

PUSHROD

CORRODED

3/31/2004

200BEECH

PT6A42

 

1015242653

RUDDER CONTROL

(AUS) RUDDER PUSHROD CONTAMINATED WITH WATER CAUSING CORROSION OF THE INTERNAL BORE.

AUS20040239

BEECH

PWA  

 

FRAME

CRACKED

3/2/2004

200BEECH

PT6A42

 

 

FUSELAGE

(AUS) FUSELAGE FRAMES CRACKED. CRACKS FOUND IN THE FOLLOWING AREAS:-1. INTERCOSTAL CRACKED AT STRINGER NR 72. FUSELAGE FRAME CRACKED AT STATION 326.75, STRINGER NO8 AND NO9 3. FUSELAGE FRAME CRACKED AT STATION 337.75, AT STRINGER NR 9, NR 10 AND NR 114. LT STRINGER NR 9 CRACKED AT REAR PRESSURE BULKHEAD 5. ATIGUE CRACKS TO SKIN AND STRINGERS AT FUSELAGE STATION 326.75 TO 337.75 AND STRINGER NR 9, REAR PRESSURE BULKHEAD 6. MULTIPLE CRACKS IN FUSELAGE SKIN LT SIDE LOWER FRAME STATION 337.5.

AUS20040246

BEECH

CONT

 

STRUT

CRACKED

3/29/2004

58  

IO550*

 

358152607

MLG 

(AUS) MAIN LANDING GEAR STRUT SLIDING MEMBER CRACKED CIRCUMFERENTIALLYAROUND THE LOWER SECTION.

AUS20040064

BEECH

LYC  

 

CONNECTOR

CONTAMINATED

2/3/2004

76  

O360A1G

 

606171

ENGINE

(AUS) RT ENGINE INSTRUMENT CLUSTER CONNECTOR CONTAMINATED.

AUS20040056

BEECH

LYC  

 

DAMPER

FAULTY

1/23/2004

76  

O360A1G6D

 

35825145

NLG 

(AUS) NOSE WHEEL SHIMMY DAMPER END CAP RETAINING CIRCLIP MISSING.

CA040510007

BEECH

PWA  

 

DOOR FRAME

CRACKED

5/6/2004

A100

PT6A28

 

50430043867

PAX DOOR

(CAN) DURING A PHASE INSPECTION A CRACK WAS FOUND ON THE CABIN DOOR FRAME, WHICH EXTENDED FROM THE CUT-OUT FOR THE UPPER FWD BAYONETTE TO THE BAYONETTE SUPPORT BRACKET SCREW HOLE.

WK1

BEECH

 

 

MOTOR

FAILED

5/13/2004

A200

 

 

50041

CABIN

SHORTLY AFTER TAKEOFF SMOKE WAS OBSERVED IN THE COCKPIT WITH ELECTRICAL ODOR. FORWARD CABIN VENT BLOWER WAS DISABLED AND THE SMOKE CLEARED. VENT BLOWER HAD FAILED INTERNALLY.

CA040426003

BEECH

PWA  

 

WINDOW

WARPED

3/30/2004

B200

PT6A42

 

1014301835

COCKPIT

(CAN) DURING A ROUTINE DAILY INSPECTION IT WAS NOTED THE RT AFT CABIN WINDOW HAD A INWARD CONCAVE APPEARANCE ACROSS THE CENTER FROM TOP TO BOTTOM. UPON REMOVAL WITH THE USE OF A STRAIGHT EDGE IT WAS WARPED ACROSS THIS AREA. NO FURTHER DEFECTS IN THE FORM OF CRACKING OR CRAZING WERE NOTED. INTEGRITY OF WINDOW PANE APPEARED NORMAL. THE WINDOW AND SEAL WEAR REPLACED WITH NEW IAW B200 MM. NO FURTHER DEFECTS HAVE BEEN NOTED.

CA040423006

BEECH

PWA  

 

SWITCH

SHORTED

4/22/2004

B200

PT6A42

 

1013646283

STALL WARNING

(CAN) PILOT REPORTED THAT THE STALL HEAT APPEARED TO BE ON (HIGH) MODE ON THE GROUND WHEN A WALK-AROUND WAS CONDUCTED. MAINTENANCE CONFIRMED BY RESEARCHING WIRING DIAGRAM AND SYSTEM OPERATION. TROUBLESHOT AND FOUND LT MAIN GEAR SAFETY SWITCH P/N 101-364628-3 HAD HIGH RESISTANCE THROUGH THE CONTACTS ON SWITCH WHEN AIRCRAFT WAS ON GROUND. THE SWITCH WAS GIVING FALSE INFORMATION TO STALL HEAT PANEL MAK ING IT THINK THE AIRCRAFT WAS IN FLIGHT AND GIVING MAXIMUM VOLTAGE FOR MAXIMUM HEAT. SWITCH WAS REPLACED AND OPERATION FOUND NORMAL.

AUS20040222

BEECH

PWA  

 

SHAFT

FAILED

3/23/2004

B200C

PT6A41

 

1018100211

MLG 

(AUS) LT MAIN LANDING GEAR RETRACTION DRIVE TUBE FAILED DUE TO INTERFERENCE WITH PNEUMATIC DUCTING CLAMP.

AUS20040115

BEECH

PWA  

 

FRAME

CRACKED

2/18/2004

B200C

PT6A41

 

10144009133

FUSELAGE

(AUS) FUSELAGE FRAMES (3OFF) LOCATED AT STN 285.188, STN 278.5 AND STN291.875 CRACKED. FRAME PART NUMBERS PN 101-440091-33, PN 101-440090-27 AND PN 101-440092-31. FOUND DURING INSPECTION IAW AD.

AUS20040176

BEECH

PWA  

 

CHECK VALVE

FAULTY

3/7/2004

B200C

PT6A42

 

10138901157

FUEL DIST

(AUS) FUEL SYSTEM CHECK VALVE SUSPECT FAULTY.

AUS20040151

BEECH

PWA  

 

ENGINE

FLUCTUATES

3/1/2004

B200C

PT6A42

 

PT6A42

LEFT 

(AUS) LT ENGINE FUEL FLOW AND ENGINE TORQUE FLUCTUATING BEFORE ENGINE STARTED TO ROLLBACK. INVESTIGATION COULD FIND NO CAUSE FOR THE DEFECT. THE ENGINE WAS GROUND RUN AND THEN TEST FLOWN WITH NO FURTHER REOCCURRENCE.

AUS20040213

BEECH

PWA  

 

VALVE

FAULTY

3/12/2004

B200C

PT6A42

 

10138901157

FUEL TRANSFER

(AUS) DEFECT REPORT NR WAS CREATED IN LIEU OF DATA BEING ATTACHED TO MDR 04/0176. CANCELLED, DATED 25TH MARCH 2004.

AUS20040107

BELL  

ALLSN

 

SKIN

CRACKED

1/2/2004

206B

250C20B

 

 

TAILBOOM

(AUS) TAILBOOM CRACKED IN LOWER SKIN TO UPPER SKIN ATTACHMENT RIVET LINE LOCATED ON AFT RT SIDE.

AUS20040166

BELL  

ALLSN

 

FITTING

SEPARATED

3/8/2004

206B3

250C20B

 

AN8334J

ENG OIL PRESS

(AUS) ENGINE TURBINE OIL PRESSURE FITTING PN AN833-4J SEPARATED FROM GEARBOX COVER PN 6898569 ALLOWING ENGINE OIL TO BE PUMPED OVERBOARD. SUSPECT CAUSED BY B NUT VIBRATING LOOSE ALLOWING THE FITTING TO FRET IN THE COVER. REDUCED OIL FLOW (AND COOLING) TO THE TURBINE DAMAGED THE TURBINE BEARINGS. BEARING DEBRIS COLLECTED ON THE FORWARD CHIP PLUG.

AUS20040289

BELL  

ALLSN

 

BEARING

LACK OF LUBE

4/16/2004

206B3

250C20B

 

B542DD

MAIN ROTOR

(AUS) COLLECTIVE JACKSHAFT SUPPORT BEARING FAULTY. INVESTIGATION FOUND THAT THE BEARING LUBRICANT HAD DRIED OUT.

AUS20040052

BELL  

PWA  

 

HOSE

LEAKING

1/25/2004

412  

PT6T3B

 

70061L275W210A

MAIN ROTOR GB

(AUS) MAIN TRANSMISSION OIL HOSE LEAKING. FURTHER INVESTIGATION FOUND THE HOSE WAS CHAFING IN THE AREA UNDER THE IDENTIFICATION TAG.

AUS20040155

BELL  

PWA  

 

OIL COOLER

LEAKING

3/3/2004

412  

PT6T3B

 

8538100

ENGINE

(AUS) ENGINE/TRANSMISSION OIL COOLER INTERNAL LEAK. THE LEAK ALLOWED TRANSMISSION OIL TO ENTER THE COMBINING GEARBOX OIL SYSTEM UNDERPRESSURE AND OVERFILL THE COMBINING GEARBOX WHICH THEN VENTED THROUGH THE BREATHER.

AUS20040143

BELL  

PWA  

 

GEARBOX

CONTAMINATED

3/1/2004

412  

PT6T3B

 

CPGB1384

ENGINE

(AUS) COMBINING GEARBOX CHIP DETECTOR METAL CONTAMINATION.

AUS20040185

BELL  

LYC  

 

CLAMP

CRACKED

3/14/2004

47G5A

VO435B1A

 

471401341

MAIN ROTOR HEAD

(AUS) MAIN ROTOR STABILIZER BAR CLAMP CRACKED.

AUS20040292

BNORM

LYC  

 

CONTROLLER

FAULTY

2/17/2004

BN2B20

IO540K1B5

 

0119244TF

AUTOPILOT

(AUS) AUTOPILOT BURNED OUT. ROLL SERVO ALSO BURNED OUT.

2004FA0000413

CESSNA

LYC  

 

VALVE

INOPERATIVE

5/6/2004

150J

IO720A1B

 

53E22144

OIL COOLER

PILOT REPORTED HIGH OIL TEMPERATURE 220-225 DEGREES, REMOVED VALVE AND TESTED SIDE BY SIDE WITH NEW VALVE, OLD VALVE DID NOT CLOSE AT THE SAME RATE AS NEW VALVE, INSTALLED NEW VALVE AND OIL TEMP DECREASED TOO.

CA040511002

CESSNA

LYC  

 

SUPPORT BRACKET

CRACKED

5/10/2004

172K

O320E2D

 

05411212

MLG 

(CAN) RT MAIN LANDING GEAR OB SUPPORT BRACKET CRACKED AT U BOLT FORWARD HOLE.

2004FA0000429

CESSNA

LYC  

 

CONTROL CABLE

BROKEN

5/27/2004

172M

O320*

 

0510105291

ELEVATOR

ANNUAL INSPECTION FOUND UPPER ELEVATOR CABLE WITH SOME BROKEN STRANDS. REPLACED BOTH CABLES BOTH AIRCRAFT HAVE A LITTLE OVER 5000.0 HOURS ON THEM.

2004FA0000424

CESSNA

 

 

DOUBLER

CORRODED

5/29/2004

172N

 

 

051310929, 56

FIREWALL

DURING ANNUAL INSPECTION FOUND POPPED RIVET HEADS IN FIREWALL DOUBLERS, REMOVED DOUBLERS FOUND EXFOLIATION EXCEEDING 40 PERCENT THICKNESS ON BACK SIDE OF DOUBLERS, REPLACED DOUBLER, RECOMMEND CLOSE INSPECTION OF RIVET HEADS IN THIS AREA.

AUS20040073

CESSNA

LYC  

 

ARM  

CORRODED

2/10/2004

172N

O320H2AD

 

052390114

TE FLAP

(AUS) FLAP SUPPORT ARM TO FLAP SUPPORT ARM RIB RIVETS MISSING DUE TO CORROSION.

CA040426007

CESSNA

LYC  

 

WIRE

BURNED

4/2/2004

172N

O320H2AD

 

 

ALTERNATOR

(CAN) WHILE IN CRUISE FLIGHT, THE ALTERNATOR FIELD CIRCUIT BREAKER POPPED. THE PILOT PUSHED IN THE BREAKER SEVERAL TIMES UNTIL THE BREAKER STAYED IN. SMOKE THEN APPEARED AND THE PILOT LANDED SAFELY. THE MAIN POWER WIRE AT THE BACK OF THE ALTERNATOR WAS FOUND WORN. THE WIRE SHORTED OUT AGAINST THE ALTERNATOR CASE. THE FIELD BREAKER GOT SO HOT THAT IT STAYED CONTACTED. THE WIRES FROM THE BREAKER TO THE MASTER SWITCH TO THE VOLTAGE REGULATOR WERE FOUND BURNED. THE WIRES WERE REPLACED AS REQUIRED. THE 5 AMP ALTERNATOR FIELD CB, MASTER SWITCH, ALTERNATOR BRUSHES, AND VOLTAGE REGULATOR WERE ALL REPLACED.

2004FA0000430

CESSNA

 

 

CONTROL CABLE

BROKEN

5/27/2004

172P

 

 

0510105291

ELEVATOR

ANNUAL INSPECTION FOUND UPPER ELEVATOR CABLE WITH SOME BROKEN STRANDS. REPLACED BOTH CABLES. AIRCRAFT HAS A LITTLE OVER 5000.0 HOURS.

AUS20040159

CESSNA

LYC  

LYC  

GEAR

BROKEN

3/2/2004

172P

O320D2J

 

D104103

ENGINE STARTER

(AUS) STARTER BENDIX DRIVE GEAR DISINTEGRATED DURING ENGINE START.

AUS20040265

CESSNA

LYC  

 

ALTERNATOR

FAILED

4/11/2004

172P

O320D2J

 

10300B

DC SYSTEM

(AUS) ALTERNATOR FAILED IN FLIGHT.

AUS20040264

CESSNA

LYC  

LYC  

SERVO

FAULTY

4/6/2004

172R

IO360L2A

 

70274603

FUEL CONTROL

(AUS) FUEL CONTROL UNIT AIR CHAMBER CONTAMINATED WITH FUEL.

AUS20040306

CESSNA

LYC  

 

RIB  

CRACKED

4/28/2004

172R

IO360L2A

 

053200199

HORIZONTAL STAB

(AUS) HORIZONTAL STABILIZER RIB CRACKED AROUND CIRCUMFERENCE OF AFT ATTACHMENT HOLES.

AUS20040116

CESSNA

LYC  

LYC  

MOTOR

FAILED

2/16/2004

172R

IO360L2A

 

PM2401H

ENGINE STARTER

(AUS) ENGINE STARTER MOTOR BENDIX DRIVE WOULD NOT ENGAGE.

AUS20040218

CESSNA

LYC  

LAMAR

GEAR

BROKEN

3/22/2004

172R

IO360L2A

 

85073009

ENGINE STARTER

(AUS) STARTER MOTOR BENDIX DRIVE GEAR DISINTEGRATED.

CA040423010

CESSNA

LYC  

 

WIRE

CHAFED

4/21/2004

172R

IO360L2A

 

 

AUTOPILOT SYS

(CAN) PILOT REPORTED THAT FLIGHT CONTROLS WERE (STIFF AND VERY HARD TO MOVE). DURING RUN-UP PRIOR TO DEPARTURE. PILOT ELECTED TO RETURN TO BASE. AMO FOUND THAT WIRE HARNESS BEHIND RADIO PANEL WAS CHAFING ON THROTTLE MOUNT CAUSING SHORT TO GROUND. THIS CAUSED THE AUTOPILOT SERVO TO ENGAGE UNCOMMANDED.

AUS20040262

CESSNA

LYC  

LYC  

GEAR

DISINTEGRATED

4/8/2004

172RG

O360F1A6

 

D112530

ENGINE STARTER

(AUS) STARTER BENDIX DRIVE GEAR DISINTEGRATED ON START.

2004FA0000417

CESSNA

LYC  

 

SPAR

DAMAGED

5/4/2004

172S

IO360A1A

 

053200196

HORIZONTAL STAB

WHILE PERFORMING THE INSPECTIONS REQUIRED BY MFG SB04-55-01, FOUND THE RT SIDE HOLE IN THE HORIZONTAL STABILIZER AFT SPAR ELONGATED. THIS ELONGATION OPENED THE HOLE APPROX. .040 TO .050 INCHES IN THE 5 O`CLOCK DIRECTION (VIEWING THE HOLE FROM THE ACCESS IN THE TIO STABILIZER SKIN, LOOKING AFT). ELONGATION DID NOT APPEAR TO EXTEND INTO THE PN 0531006-113 HORSESHOE FITTING ON THE VERTICAL STABILIZER OR INTO THE PN 05121595 AFT BULKHEAD. ADDITIONALLY, THE BOLT DID NOT APPEAR TO BE WORN. IAW MFG TECH SUPPORT, HOLE WILL BE ENLARGED TO NEXT BOLT SIZE AND APPROPRIATE SIZE BOLT WILL BE INSTALLED. CONDITION SB IS INSPECTING FOR WAS NOT FOUND.

2004FA0000407

CESSNA

CONT

 

CARBURETOR

WORN

5/20/2004

180  

O470*

 

45A10396512

ENGINE

CARBURETOR STICKING AT FULL THROTTLE DUE TO WEAR OF THE FULL THROTTLE STOP. IT WAS ACTUALLY GOING PAST FULL THROTTLE. THE PUMP LEVER ASSEMBLY WOULD TURN PAST THE AIR METERING PIN AND HANG UP THE THROTTLE SHAFT IN WIDE OPEN POSITION.

CA040512001

CESSNA

CONT

 

CONTROL CABLE

FRAYED

3/30/2004

180C

O470K

 

051010516

AILERON

(CAN) CABLE FRAYED AT PULLEY, PULLEY NOT SEIZED.

AUS20040257

CESSNA

CONT

 

RIVET

CORRODED

4/7/2004

182P

O470R

 

MS20470AD3

FUSELAGE

(AUS) FUSELAGE SKIN RIVET HEADS CORRODED AND MISSING. RIVETS ARE LOCATED IN THE AREA UNDER THE BELLY OF THE AIRCRAFT AND ATTACH THE MAIN LANDING GEAR CASTINGS PNO 0741627-1 AND PNO 0741627-2 TO THE FUSELAGE BELLY SKIN.

2004FA0000462

CESSNA

CONT

 

HINGE BRACKET

CORRODED

5/25/2004

190  

W670*

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS).

2004FA0000472

CESSNA

 

 

HINGE BRACKET

CORRODED

5/25/2004

195  

 

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS).

2004FA0000438

CESSNA

 

 

HINGE BRACKET

CORRODED

5/25/2004

195  

 

 

0322709, 1

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORHTY DUE TO CORROSION, 35 PERCENT ARE CRACKED.

2004FA0000447

CESSNA

 

 

HINGE BRACKET

CORRODED

5/25/2004

195  

 

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED.

2004FA0000437

CESSNA

 

 

HINGE BRACKET

CRACKED

5/25/2004

195  

 

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESES BRACKETS). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED.

2004FA0000454

CESSNA

CONT

 

HINGE BRACKET

CORRODED

5/25/2004

195  

W670*

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS) WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED.

2004FA0000470

CESSNA

JACOBP

 

HINGE BRACKET

CORRODED

5/25/2004

195  

R755A1

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/ OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS).

2004FA0000451

CESSNA

JACOBP

 

HINGE BRACKET

CORRODED

5/25/2004

195  

R755A1

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED.

2004FA0000450

CESSNA

JACOBP

 

HINGE BRACKET

CORRODED

5/25/2004

195  

R755A1

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS) WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED.

2004FA0000452

CESSNA

JACOBP

 

HINGE BRACKET

CORRODED

5/25/2004

195  

R755A1

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS.

2004FA0000449

CESSNA

JACOBP

 

HINGE BRACKET

CORRODED

5/25/2004

195  

R755A1

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED.

2004FA0000469

CESSNA

JACOBP

 

HINGE BRACKET

CORRODED

5/25/2004

195  

R755A1

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE SETS OF THESE BRACKETS).

2004FA0000478

CESSNA

JACOBP

 

HINGE BRACKET

CORRODED

5/25/2004

195  

R755B1

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS).

2004FA0000435

CESSNA

JACOBS

 

HINGE BRACKET

CRACKED

5/25/2004

195  

L4*  

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS) WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED.

2004FA0000436

CESSNA

JACOBS

 

HINGE BRACKET

CRACKED

5/25/2004

195  

R7557

 

0322709

AILERON

INSPECTED ORIGINAL MAGENSIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED.

2004FA0000487

CESSNA

RROYCE

 

HINGE BRACKET

CORRODED

5/25/2004

195  

VIPER522

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS).

2004FA0000474

CESSNA

JACOBP

 

HINGE BRACKET

CORRODED

5/25/2004

195A

R755A1

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESES BRACKETS).

2004FA0000457

CESSNA

JACOBP

 

HINGE BRACKET

CORRODED

5/25/2004

195A

R755A1

 

 

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS).

2004FA0000458

CESSNA

JACOBP

 

HINGE BRACKET

CORRODED

5/25/2004

195A

R755A1

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM INBOARD AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS).

2004FA0000455

CESSNA

JACOBS

 

HINGE BRACKET

CORRODED

5/25/2004

195A

R7557

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED.

2004FA0000439

CESSNA

JACOBS

 

HINGE BRACKET

CORRODED

5/25/2004

195A

R7557

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR AL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESES BRACKETS). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED.

2004FA0000444

CESSNA

 

 

HINGE BRACKET

CORRODED

5/25/2004

195B

 

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED.

2004FA0000446

CESSNA

 

 

HINGE BRACKET

CORRODED

5/25/2004

195B

 

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM INBOARD AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS ( THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED.

2004FA0000448

CESSNA

 

 

HINGE BRACKET

CORRODED

5/25/2004

195B

 

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS) WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED.

2004FA0000486

CESSNA

JACOBP

 

HINGE BRACKET

CORRODED

5/25/2004

195B

R755A1

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS).

2004FA0000456

CESSNA

JACOBP

 

HINGE BRACKET

CORRODED

5/25/2004

195B

R755B1

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS).

2004FA0000482

CESSNA

JACOBP

 

HINGE BRACKET

CORRODED

5/25/2004

195B

R755B1

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS).

2004FA0000481

CESSNA

JACOBP

 

HINGE BRACKET

CORRODED

5/25/2004

195B

R755B1

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS).

2004FA0000442

CESSNA

JACOBP

 

HINGE BRACKET

CORRODED

5/25/2004

195B

R755B1

 

0322709

AILERON

INSPECTED ORIGINAL MAGNESIUM IB AILERON HINGE BRACKETS AND FOUND SOME OR ALL OF THE FOLLOWING CONDITIONS: SEVERELY CORRODED BRACKET BODY AROUND MOUNT AND BEARING BOSS. CRACKS SPANNING COMPLETELY ACROSS THE BEARING BOSS AND/OR MOUNTING FEET. PRIMER AND/OR BODY FILLER TO HIDE CRACKING OF BRACKETS (THIS CONDITION FOUND ON TWO DIFFERENT SETS OF THESE BRACKETS). WE ARE FINDING 85 PERCENT OF THE ORIGINAL BRACKETS UNAIRWORTHY DUE TO CORROSION, 35 PERCENT ARE CRACKED.

CA040210005

CESSNA

PWA  

CESSNA

HINGE

TORN

2/10/2004

208B

PT6A114A

 

26012053

CARGO POD DOOR

(CAN) ON SHORT FINAL THE PILOT HEARD A LOUD BANG AT THE BEGINNING OF THE FLARE. THE PILOT TAXIED THE AIRCRAFT TO THE CARGO RAMP. AFTER THE PILOT GOT OUT OF THE COCKPIT HE NOTICED THAT THE FWD LOWER POD CARGO DOOR WAS MISSING. THE CARGO DOOR WAS FOUND ON TOP OF THE SNOW 50 FEET FORM THE THRESHOLD OF THE RUNWAY. THERE WAS NO DAMAGE TO THE AIRCRAFT OR THE DOOR. THE ONLY DAMAGE WAS THE TORN HINGE WHERE IT HAD SEPARATED FROM THE DOOR. THE DOOR LATCHING SYSTEM WAS FOUND TO BE OPERATING NORMALLY WITH NO DAMAGE OR WEAR TO THE DOOR OR POD ASSY. SUSPECT THAT THE DOOR WAS NOT LATCHED CORRECTLY BEFORE DEPARTURE.

2004FA0000427

CESSNA

CONT

 

BEARING

FAILED

5/6/2004

210L

IO520L

 

643840

ALTERNATOR

BEARING AT PULLEY END, PN 643840, FAILED, ALLOWING BELT TO BECOME OUT OF ALIGNMENT. BELT CAME OFF OF PULLEY CAUSING ALTERNATOR TO BECOME INOPERATIVE.

AUS20040062

CESSNA

CONT

 

HOSE

FAILED

1/16/2004

210M

IO520L

 

S217840095A

MLG DOOR ACT

(AUS) NOSE LANDING GEAR DOOR ACTUATOR HOSE FAILED. LOSS OF HYDRAULIC FLUID.

AUS20040077

CESSNA

CONT

 

WIRE HARNESS

BURNED

2/5/2004

210M

IO520L

 

 

DC POWER DISTRIB

(AUS) WIRING LOOM CHAFED AND BURNED BY ELEVATOR COUNTERWEIGHT.

AUS20040169

CESSNA

CONT

 

TUNNEL WALL

CRACKED

3/9/2004

210N

IO520L

 

12131842

FUSELAGE

(AUS) RT SIDE NOSE LANDING GEAR TUNNEL WALL CRACKED IN AREA NEAR RT NOSE LANDING GEAR TORQUE TUBE STIFFENER PN 1213801-2. AREA HAD BEEN MODIFIED IAW STC NO SA00796AT. CRACKING WAS FOUND DURING INSPECTION FOLLOWING DISCOVERY OF SIMILAR CRACKING AS REPORTED IN MDR 04/0168.

AUS20040168

CESSNA

CONT

 

TUNNEL WALL

CRACKED

3/9/2004

210R

IO520L

 

12131842

FUSELAGE

(AUS) RT SIDE NOSE LANDING GEAR TUNNEL WALL CRACKED IN AREA NEAR RT NOSE LANDING GEAR TORQUE TUBE STIFFENER PN 1213801-2. FURTHER INVESTIGATION OF THE STRUCTURE FOUND CRACKS IN THE LT AND RT NOSE GEAR TUNNEL WALLS LOCATED AT THE LOWER END OF THE FORWARD ENGINE SHOCK MOUNT ASSEMBLY CHANNEL. CRACKS WERE ALSO FOUND IN THE STIFFENERS PN 1213195-1 AND PN 1213195-2). AREA HAD BEEN MODIFIED IAW STC NO SA00796AT.

AUS20040134

CESSNA

CONT

 

TORQUE TUBE

BROKEN

1/14/2004

310Q

IO470V

 

50450107

MLG 

(AUS) LT MAIN LANDING GEAR TORQUE TUBE BROKEN.

AUS20040125

CESSNA

CONT

 

WIRE

MISROUTED

2/19/2004

310R

IO520M

 

 

LT WING

(AUS) WIRING IN BOTH LT AND RT WINGS CONTACTING FUEL VENT LINES LOCATED AT WS 145. PERSONNEL/MAINTENANCE ERROR.

AUS20040154

CESSNA

CONT

 

TRUNNION

CRACKED

3/3/2004

310R

IO520M

 

5842000213

NLG 

(AUS) NOSE LANDING GEAR TRUNNION CRACKED IN RADIUS LOCATED ON LOWER SIDE OF THE LT ATTACHMENT LUG. CRACK LENGTH APPROXIMATELY 12MM(0.472IN). THE TRUNNION WAS THE EARLIER PN 5842000-213 WITH SMALLER DIAMETER ATTACHMENT LUGS. FOUND DURING INSPECTION IAW MFG SB MEB 88-5 REV2.

AUS20040243

CESSNA

CONT

 

WIRE

BROKEN

3/27/2004

340CESSNA

TSIO520K

 

 

DOWNLOCK SWITCH

(AUS) RT MAIN LANDING GEAR DOWNLOCK SWITCH WIRE BROKEN IN AREA APPROXIMATELY 763MM (3IN) FROM SWITCH.

AUS20040191

CESSNA

CONT

 

WIRE

FAULTY

2/25/2004

402B

TSIO520VB

 

 

ATC TRANSPONDER

(AUS) TRANSPONDER WIRING SUSPECT FAULTY. TRANSPONDER AND GPS WIRING PARALLEL WHICH CAN CAUSE INACCURATE ALTITUDE READINGS.

AUS20040215

CESSNA

CONT

 

FITTING

CORRODED

3/22/2004

402C

TSIO520VB

 

50110242

WING 

(AUS) LT WING AFT LOWER ATTACHMENT FITTING PN 5011024-2, LT WING AFT UPPER ATTACHMENT FITTING PN 5011023-1, RT WING AFT LOWER FITTING PN 5011024-2 AND RT WING AFT UPPER FITTING PN 5011023-1 ALL CONTAINED INTERGRANNULAR CORROSION.

AUS20040221

CESSNA

CONT

MCAULY

LATCH

FAILED

3/24/2004

404CESSNA

GTSIO520M

 

891286

PROPELLER BLADE

(AUS) PROPELLER EXPERIENCED UNCOMMANDED FEATHER FOLLOWING GROUND RUN. SUSPECT CAUSED BY FAILURE OF THE LOW PITCH STOP LATCH PINS.

AUS20040183

CESSNA

GARRTT

 

PIPE

CRACKED

3/8/2004

441  

TPE3318

 

572700223

HYDRAULIC SYS

(AUS) HYDRAULIC PIPE CRACKED AND LEAKING. LOSS OF HYDRAULIC FLUID. PIPE IS LOCATED IN RT WING LEADING EDGE. INVESTIGATION FOUND TOOLING MARKS ON THE PIPE IN THE AREA OF THE PIPE BEND.

AUS20040128

CESSNA

GARRTT

 

SWITCH

OUT OF ADJUST

2/24/2004

441  

TPE3318

 

 

MLG 

(AUS) LT MAIN LANDING GEAR UPLOCK SWITCH OUT OF ADJUSTMENT. MICROSWITCH WAS SWITCHING OFF LOADING VALVE BUT NOT THE IN TRANSIT LIGHT. INVESTIGATION FOUND SOME WEAR IN THE SWITCH WHICH AFFECTED ADJUSTMENT.

AUS20040076

CESSNA

GARRTT

 

SPAR

DEBONDED

2/11/2004

441  

TPE3318

 

 

LT WING

(AUS) LT WING SPAR WEB DISBONDED IN AREA LOCATED AT CWS 57.

W592004F00000

CESSNA

CONT

 

SPACER

CRACKED

1/27/2004

A150L

O200A

 

C4513

PROPELLER

PROPELLER SPACER WAS FOUND CRACKED FROM DOWEL PIN HOLES. ONE CRACK PROGRESSED COMPLETELY THROUGH SPACEER, THE SECOND WAS 90 PERCENT THROUGH SPACER. PROPELLER DOWEL PIN HOLES ARE ELONGATED AND OVERSIZE, PROPELLER WAS BENT SEVERELY AT ONE TIME AND IMPROPERY REPAIRED. ANGLES WERE WELL OUT OF SPEC, SOME AS MUCH AS 1 DEGREE. PROPELLER WAS OUT OF BALANCE TRACK AND ANGLES. SUSPECT SEVERE VIBRATION FROM PROPELLER OR PREVIOUS IMPACT DAMAGE CAUSED SPACER TO CRACK. PROPELLER AND SPACER ARE SCRAP.

AUS20040074

CESSNA

LYC  

 

DRIVE GEAR

STRIPPED

1/5/2004

A152

O235L2C

 

 

ENGINE STARTER

(AUS) ENGINE STARTER MOTOR DRIVE GEAR TEETH STRIPPED.

AUS20040075

CESSNA

LYC  

 

CARBURETOR

FAULTY

2/5/2004

A152

O235L2C

 

105267

FUEL CONTROL

(AUS) CARBURETOR FAULTY.

AUS20040082

CESSNA

LYC  

 

ALTERNATOR

FAILED

2/3/2004

A152

O235L2C

 

DOFF10300B

DC SYSTEM

(AUS) ALTERNAOR FAILED.

AUS20040207

CESSNA

LYC  

 

BRACKET

CRACKED

3/17/2004

A152

O235L2C

 

04320049

HORIZONTAL STAB

(AUS) HORIZONTAL STABILIZER STEEL BRACKET CRACKED. CRACK LENGTH 10MM(0.393IN).

AUS20040114

CESSNA

LYC  

LYC  

GEAR

BROKEN

2/13/2004

A152

O235L2C

 

D083645

ENGINE STARTER

(AUS) STARTER MOTOR BENDIX DRIVE GEAR DISINTEGRATED. ENGINE RING GEAR TEETH DAMAGED.

AUS20040126

CESSNA

LYC  

LYC  

VALVE

SEPARATED

2/24/2004

R182

O540J3C5

O540J3C5

105235

FUEL CONTROL

(AUS) CARBURETOR ACCELERATOR PUMP DISCHARGE CHECK VALVE LOOSE AND SEPARATED.

2004FA0000434

CESSNA

 

 

FLAP TRACK

MISINSTALLED

6/9/2004

T206H

 

 

 

WING 

MECHANIC HEARD (POPPING) NOISE WHEN FLAPS WERE EXTENDED OR RETRACTED. FOUND THE UPPER FLAP TRACK HARDWARE WAS HITTING THE FLAP WELL CUT OUTS. THE BOLTS WERE INSTALLED FACING OB AT THE FACTORY. REVERSED HARDWARE AND PROBLEM WENT AWAY.

2004FA0000432

CESSNA

CONT

 

PUMP

INOPERATIVE

5/21/2004

T210L

TSIO520H

 

6467682

ENGINE

ENGINE DRIVEN FUEL PUMP NO METERED OR UN METERED FUEL PRESSURE WHILE ENGINE RUNNING. FUEL PUMP RECENTLY INSTALLED HAD 2.7 HOURS ON IT, AFTER OVERHAUL. INSTALLED NEWLY OVERHAULD PUMP. OPS CHECK GOOD. PROBABLE CAUSE OF PUMP FAILURE, UNKNOWN.

AUS20040069

CESSNA

CONT

 

FITTING

IMPROPER PART

1/13/2004

U206A

IO520F

 

 

PITOT/STATIC SYS

(AUS) STATIC SYSTEM T FITTING UNAPPROVED PART. FITTING WAS A COMMERCIAL PRODUCT. PERSONNEL/MAINTENANCE ERROR. UNAPPROVED PART.

AUS20040078

CESSNA

CONT

 

LANDING GEAR

COLLAPSED

2/11/2004

U206G

IO520F

 

12411171

MAINS

(AUS) LT MAIN LANDING GEAR LEG COLLAPSED. THE LEG WAS A NEWLY FITTED ITEM AND FAILED 530MM (20.8IN) FROM THE IB TIP OF THE LEG. AIRCRAFT TAILPLANE, ELEVATOR, WINGTIP AND POD DAMAGED.

AUS20040090

CESSNA

CONT

CONT

SPRING

BROKEN

1/2/2004

U206G

IO520F

 

643109

ENGINE STARTER

(AUS) ENGINE STARTER ADAPTER CLUTCH SPRING TANG BROKEN OFF CAUSING SPRING TO SLIP ON GEAR. BROKEN PIECE OF SPRING FOUND IN BASE OF STARTER ADAPTER.

AUS20040298

CONAER

LYC  

 

ROD END

FAILED

3/18/2004

LA4200

IO360A1B

 

 

RUDDER CONTROL

(AUS) RUDDER CONTROL ROD BALL JOINT SEIZED AND ROD END FAILED. THE SEIZED BALL JOINT ALLOWED THE CONTROL ROD END TO BEND UP AND DOWN DURING RUDDER APPLICATIONS UNTIL FINAL FAILURE.

CA040511003

DHAV

PWA  

PWA  

CASTING

CORRODED

4/22/2004

DHC3

S3H1G

 

399359

VALVE GUIDE

(CAN) THE ALUMINUM CASTING IN WHICH THE VALVE GUIDE SLIDES HAD DISINTEGRATED DUE TO CORROSION INSIDE THE EXHAUST PORT. IT WAS PROBABLY A POOR QUALITY PART THAT WAS INSTALLED DURING THE LAST OVERHAUL.

AUS20040146

FLTCHR

LYC  

 

BOLT

FAILED

3/1/2004

FU24AAIRPTS

IO720A1B

245109

AN626

MLG 

(AUS) RT MAIN LANDING GEAR TOP TORQUE LINK BOLT FAILED.

AUS20040161

GULSTM

LYC  

 

CYLINDER

WORN

2/28/2004

STCAA5

O320E2G

 

LW12416

ENGINE

(AUS) NR 1 CYCLINDER WORN. PISTON, RING, & BARREL CLEARANCES EXCESSIVE.

AUS20040084

HUGHES

LYC  

 

SEAL

WORN

2/7/2004

269C

HIO360C1A

 

LW11997

CRANKSHAFT

(AUS) ENGINE CRANKSHAFT SEAL LEAKING. INVESTIGATION FOUND SEAL HAD DISINTEGRATED AROUND THE SEALING LIP.

AUS20040085

HUGHES

LYC  

 

SEAL

WORN

2/8/2004

269C

HIO360D1A

 

LW11997

CRANKSHAFT

(AUS) ENGINE CRANKSHAFT SEAL LEAKING. INVESTIGATION FOUND SEAL HAD DISINTEGRATED AROUND THE SEALING LIP. THIS IS A REPLACEMENT SEAL AFTER THE SEAL FAILURE IN MDR 04/0084.

AUS20040136

HUGHES

LYC  

 

FUEL CONTROL

FAULTY

2/27/2004

269C

HIO360D1A

 

252434710

ENGINE

(AUS) ENGINE FUEL CONTROL UNIT FAULTY. INVESTIGATION FOUND PRESSURE ON THE MIXTURE ARM CHANGED THE FUEL FLOW RATE CAUSING THE ENGINE TO STOP.

AUS20040236

HUGHES

ALLSN

BENDIX

SHAFT

WORN

3/17/2004

369D

250C20B

 

22397

TURBINE GOVERNOR

(AUS) POWER TURBINE GOVERNOR DRIVESHAFT FAILED. INVESTIGATION FOUND THE DRIVESHAFT COUPLING SPINNING FREELY ON THE DRIVESHAFT.

AUS20040050

HUGHES

ALLSN

ALLSN

SHIELD

CRACKED

1/29/2004

369E

250C20R

250C20R

6890040

TURBINE SECTION

(AUS) FIRST STAGE TURBINE NOZZLE SHIELD CRACKED AROUND 90 PERCENT OF RADIUS. ONE PIECE OF SHIELD ABOUT THE SIZE OF A 50 CENT PIECE DISLODGED AND WAS FOUND SITTING IN THE BOTTOM OF THE COMBUSTION LINER.

2004FA0000423

KAMAN

LYC  

 

PIN  

UNSERVICEABLE

3/25/2004

K1200

T5317A

 

K910005007

LT ROTOR HUB

THE LEADING EDGE OF THE LT SIDE TEETER PIN WAS DAMAGED (MUSHROOMED). FURTHER INSPECTION SHOWED THAT THE HEAD SIDE OF THE INSIDE DIAMETER OF THE LINER THAT THE TEETER PIN SITS IN IS ALSO DAMAGED. THE LINER IS DEFORMED AND PROTRUDES IN AN IRREGULAR MANNER ON THE LEADING EDGE. THE TEETER PIN SHOWS CROSS-CORNER WEAR. THE TEETER THRUST WASHER ON THE HEAD SIDE WAS ALSO MISSING. THERE WAS RESIDUE OF THE COATING ON THE ID OF THE LINER. THE DAMAGES EXCEED THE INSPECT LIMITS ON THE TEETER PIN NON-CRITICAL AREA IAW THE CRITERIA ON THE ROTOR HUB ASSY INSP. RESIDUE WAS FOUND ON THE HEAD SIDE OF THE RIGHT TEETER PIN. PLAY GREATER THAN .015 ON THE TEETER PIN ALLOWABLE PLAY LIMITS WAS ALSO NOTED.

AUS20040188

MUDRY

LYC  

 

FCU  

CONTAMINATED

3/16/2004

CAP10B

AEIO360B2F

 

252429111

ENGINE

(AUS) FUEL CONTROL UNIT FINGER FILTER CONTAMINATED. WORKSHOP INSPECTION FOUND A FINE HAIR LIKE SUBSTANCE.

AUS20040063

NEWZE

LYC  

 

EXHAUST VALVE

STICKING

1/28/2004

FU24954

IO720A1B

 

 

ENGINE

(AUS) NR 2 CYLINDER REAR PUSHROD COVER BENT AND LEAKING OIL. SUSPECT CAUSED BY STICKING EXHAUST VALVE.

AUS20040267

PARTEN

LYC  

 

INJECTOR

CONTAMINATED

3/26/2004

P68B

IO360A1B6

 

252405411

FUEL SYSTEM

(AUS) RT ENGINE FUEL INJECTORS CONTAMINATED BY SMALL FERROUS (RUST) PARTICLES.

AUS20040276

PARTEN

LYC  

 

INJECTOR

FAULTY

4/16/2004

P68B

IO360A1B6

 

252405411

RT ENGINE

(AUS) RT ENGINE FUEL INJECTOR FLOW ERRATIC.

AUS20040118

PARTEN

LYC  

LYC  

NOZZLE

BLOCKED

2/20/2004

P68B

IO360A1B6

 

73772

FUEL INJECTOR

(AUS) NR 4 CYLINDER FUEL INJECTOR NOZZLE BLOCKED.

AUS20040133

PARTEN

LYC  

 

SPAR CAP

CRACKED

2/6/2004

P68B

IO360A1G6

 

 

LT WING

(AUS) REAR WING SPAR BOTTOM SPAR CAP CRACKED IN AREA OF LT SIDE WING ATTACHMENT. CRACK LENGTH 6MM (0.236IN). FOUND DURING EDDY CURRENT INSPECTION.

AUS20040067

PARTEN

LYC  

 

HOSE

DISTORTED

2/2/2004

P68B

IO360A1G6

 

687751710

VACUUM DIST

(AUS) VACUUM HOSE KINKED. DISTORTION WAS LOCATED ON FRAME F AT THE TOP FRONT LT DOOR FRAME AND WAS CAUSED BY THE BEND RADIUS BEING TOO SMALL AFTER PASSING OVER THE FRAME. PERSONNEL/MAINTENANCE ERROR.

AUS20040088

PILATS

PWA  

CLEVELAND  

ROTOR

BROKEN

2/11/2004

PC12

PT6A67B

 

1597400

BRAKE

(AUS) RT BRAKE ROTOR BROKEN INTO TWO PIECES WITH ONE PIECE LODGING BETWEEN THE BRAKE ASSEMBLY AND WHEEL. ON DISASSEMBLY IT WAS NOTED THAT THE ROTOR HAD BEEN BROKEN FOR SOME TIME.

AUS20040106

PILATS

PWA  

 

DRIVE SHAFT

WORN

2/17/2004

PC12

PT6A67B

 

5243212137

DC GENERATOR

(AUS) NR 2 GENERATOR DRIVESHAFT WORN AT INNER (FORWARD) BEARING AREA.

AUS20040270

PILATS

PWA  

 

DRIVE SHAFT

SHEARED

4/8/2004

PC12

PT6A67B

 

5243212137

DC GENERATOR

(AUS) NR 2 GENERATOR DRIVESHAFT SHEARED.

AUS20040271

PILATS

PWA  

 

SERVO

FAULTY

4/14/2004

PC12

PT6A67B

 

065005656

AUTOPILOT SYS

(AUS) AUTOPILOT ROLL SERVO FAULTY. INVESTIGATION FOUND THAT THE SCREWS HOLDING THE CLUTCH HAD LOOSENED ALLOWING THE CLUTCH TO REMAIN ENGAGED WHEN THE AUTOPILOT WAS DISENGAGED.

AUS20040302

PILATS

PWA  

CLEVELAND  

PAD  

SEPARATED

4/24/2004

PC12

PT6A67B

 

1090300

BRAKE

(AUS) BRAKE ASSEMBLY WEAR PAD SEPARATED FROM BRAKE DISC ROTOR AND DAMAGED FOUR MORE PADS CAUSING THE BRAKE UNIT TO LOCK UP.

AUS20040256

PILATS

PWA  

 

SEAT

CRACKED

3/25/2004

PC12

PT6A67B

 

959300111

COCKPIT

(AUS) PILOTS SEAT BACKREST ASSEMBLY CRACKED IN TWO PLACES.

AUS20040251

PILATS

PWA  

GOODYEAR

BALANCE WEIGHT

SEPARATED

3/29/2004

PC12

PT6A67B

 

12480131

TIRE 

(AUS) RT MAIN LANDING GEAR TIRE BALANCE WEIGHT SEPARATED.

AUS20040203

PILATS

PWA  

 

RING

WORN

3/5/2004

PC12

PT6A67B

 

 

NLG 

(AUS) NOSE LANDING GEAR OVEREXTENDED. INVESTIGATION FOUND THE OLEO GUIDE RING WORN AND DAMAGED ALLOWING THE RETAINING PINS TO MIGRATE OUT DISCONNECTING THE GUIDE TUBE FROM THE NOSE FORK.

CA040401006

PILATS

PWA  

PILATS

ACTUATOR

FAILED

3/26/2004

PC1245

PT6A67B

 

1291110002

PITCH TRIM

(CAN) AUTO-PILOT TEST FAILED. ALTERNATE TRIM WAS SELECTED AND TESTED AND FOUND TO BE INTERMITTENT. PITCH TRIM ACTUATOR WAS REPLACED. NO FURTHER ACTION REQUIRED. PITCHTRIM FAILED TO MAKE OVERHAUL LIFE.

AUS20040138

PIPER

LYC  

 

LONGERON

CRACKED

2/22/2004

PA18150

O320A2B

 

 

FUSELAGE

(AUS) UPPER LT LONGERON TUBE CRACKED IN AREA BETWEEN FORWARD WELD OF LT REAR STABILIZER SUPPORT AND FORWARD WELD OF CROSS BRACE TUBE.

2004FA0000414

PIPER

LYC  

 

WIRE

BURNED

5/14/2004

PA23250

IO540*

 

 

FAN 

COCKPIT BEGAN TO FILL WITH SMOKE WHILE TAXIING FOR TAKE-OFF. AIRCRAFT WAS SHUTDOWN AND UPON INSPECTION FOUND AVIONIOCS FAN TO BE BURNT ON CORNER WHERE WIRES ENTER FAN ASSEMBLY. THE DATE STAMPED ON FAN IS NOV. 1979. SUSPECT THE AGE AND TIME IN SERVICE WOULD BE THE CAUSE OF DEFECT. THESE ELECTRICAL PARTS SHOULD BE INSPECTED CLOSELY FOR ANY SIGNS OF MELTING OR DISCOLORED PLASTIC.

2004FA0000412

PIPER

LYC  

 

SEAT FRAME

CRACKED

12/6/2003

PA28140

O320E3D

 

6956800

CABIN

PILOTS TUBULAR SEAT FRAME (UPPER TUBULAR AT FWD CONNECTING BRACKETS) FOUND CRACKED AT LEAST 270 DEGREES CIRCUMFERENCE BOTH SIDES. THIS DISCREPANCY COULD RESULT IN SEPARATION OF THE SEAT FRAME RESULTING IN PILOTS LOSS OF CONTROL OF THE AC ESPECIALLY DURING FINAL LANDING APPROACH OR DURING TAKEOFF. REPLACEMENT OF SEAT FRAME OR WELDING OF FRAME TUBULAR WITH 30 DEGREE TUBULAR SPLICE PATCHES WOULD RESOLVE THIS DISCREPANCY. THIS DISCREPANCY WAS ALSO FOUND BOTH SIDES ON UPPER TUBULAR OF NON-ARTICULATING FWD RT SEAT. NOTE: THESE DISCREPANCIES WERE FOUND DUE TO AN INTERIOR REPLACEMENT AND SEAT RE-UPHOLSTERY. NORMAL MAINTENANCE INSPECTIONS WOULD PROBABLY NOT DETECT THESE CRACKS AS THEY ARE HIDDEN BY THE SEAT MATERIAL.

AUS20040081

PIPER

LYC  

LYC  

CARBURETOR

ICED

2/10/2004

PA28151

O320D3G

 

MA4SPA

FUEL CONTROL

(AUS) ENGINE FAILED DURING LANDING. SUSPECT CAUSED BY CARBURETOR ICING.

AUS20040103

PIPER

LYC  

 

BULKHEAD

CORRODED

2/5/2004

PA28161

O320D3G

 

62444005

FUSELAGE

(AUS) FUSELAGE BULKHEAD CORRODED IN AREA BENEATH VERTICAL FIN FRONT ATTACHMENT PLATE AND STRINGER HAT ASSEMBLY ATTACHMENT AREA.

AUS20040104

PIPER

LYC  

 

FORK

CORRODED

2/5/2004

PA28161

O320D3G

 

35123002

NLG 

(AUS) NOSE LANDING GEAR FORK CONTAINED INTERGRANNULAR CORROSION IN ATTACHMENT AREA.

AUS20040180

PIPER

LYC  

SLICK

IMPULSE COUPLING

LOOSE

3/15/2004

PA28161

O320D3G

 

6089188

MAGNETO

(AUS) LT MAGNETO IMPULSE COUPLING LOOSE ON SHAFT. FURTHER INVESTIGATION FOUND THE IMPULSE COUPLING LOCATION KEY SHEARED.

AUS20040202

PIPER

LYC  

 

SPAR

CORRODED

3/16/2004

PA28R200

IO360C1C

 

67069003

WING 

(AUS) WING SPAR CORRODED. FOUND FOLLOWING REMOVAL OF FUEL TANK FOR STRUCTURAL DEFECT REPAIR. CORROSION WAS SEVERE ENOUGH TO HAVE COMPROMISED STRUCTURAL INTEGRITY.

CA040426004

PIPER

LYC  

 

PUMP

INOPERATIVE

4/21/2004

PA31

TIO540A2C

 

RG9080J4AM

FUEL SYSTEM

(CAN) PUMP WAS RECENTLY MODIFIED/OVERHAULED. IT WAS DISCOVERED THAT ENGINE DRIVEN FUEL PUMP OUTPUT PRESSURE DROPPED RIGHT OFF AT IDLE POWER BUT WAS FINE AT HIGH POWER SETTINGS. ENGINE DID NOT GIVE ANY INDICATION OF PUMP PRESSURE DIFFICULTIES, ROUGH RUNNING, QUITTING,ETC. PUMP WAS REMOVED AND REPLACED WITH A SERVICEABLE UNIT. SUSPECTED INTERNAL RELIEF VALVE AT FAULT. PUMP IS PRESENTLY AT COMPONENT SHOP. TEARDOWN REPORT RECEIVED FROM AND FINDINGS WERE AS FOLLOWS: RELIEF VALVE POPPET SEATING AREA UNEVENLY WORN AND NICKED CAUSING POOR SEATING ON RELIEF VALVE HSG. LOCK RING. ADJUSTMENT SCREW CAME OFF AND WAS LODGED BETWEEN SPRING AND SPRING SEAT. DRIVE SEAL NUT LOCK SCREW WRONG.

AUS20040217

PIPER

LYC  

 

GEAR

FAILED

3/19/2004

PA31350

LTIO540J2BD

 

LW10292

ENGINE

(AUS) CRANKSHAFT IDLER GEAR FRACTURED. DAMAGE CAUSED TO SHAFT SUPPORT HOLE IN CRANKCASE. METAL CONTAMINATION OF OIL SYSTEM.

AUS20040216

PIPER

LYC  

 

SPARK PLUG

CRACKED

3/23/2004

PA31350

TIO540J2BD

 

URHB32E

ENGINE

(AUS) SPARK PLUG CRACKED IN AREA BETWEEN HEXAGONAL BODY AND FLANGE AT UPPER THREADED AREA.

AUS20040164

PIPER

LYC  

 

CAMSHAFT

SPALLED

2/24/2004

PA31350

TIO540J2BD

 

LW13908

LT ENGINE

(AUS) LT ENGINE CAMSHAFT LOBE NR 2 BADLY SPALLED. METAL CONTAMINATION OF OIL SYSTEM.

AUS20040156

PIPER

LYC  

 

FUEL TANK

CONTAMINATED

2/20/2004

PA31350

TIO540J2BD

 

 

RT ENGINE

(AUS) RT ENGINE MISFIRING IN FLIGHT. INVESTIGATION FOUND CONTAMINATION IN THE LT FUEL TANK. A HAIR LIKE FIBER WAS FOUND IN THE FUEL FILTERS AND INJECTOR NOZZLES.

CA040401009

PIPER

LYC  

 

CYLINDER

CONTAMINATED

3/29/2004

PA31350

TIO540J2BD

 

 

NR 2 

(CAN) SMALL PIECE OF RUBBER FOUND FLOATING IN AIR SIDE OF NR 2 CYLINDER INJECTOR. THE PIECE APPEARED TO BE VERY DRY AND HARD O-RING MATERIAL, MOST LIKELY FROM THE BANJO FITTING SEALS. NO OTHER FAULTS FOUND ON OTHER BANJO FITTINGS. REMOVAL OF CONTAMINATION AND NEW SPARK PLUGS FOR THIS CYLINDER RETURNED THE AIRCRAFT TO NORMAL OPERATION.

CA040511007

PIPER

LYC  

 

MAGNETO

MALFUNCTIONED

5/10/2004

PA31350

TIO540J2BD

 

1068291013

LT ENGINE

(CAN) ON LT ENGINE RUN UP, MAGNETO TEST FOUND RPM DROP BY 400 RPM. DURING TROUBLESHOOTING FOUND FAULTY MAGNETO, REPAIRED ON MAY 3/ 2002, 460.1 HRS IN SERVICE SINCE REPAIR.

AUS20040135

PIPER

LYC  

 

ARM  

CRACKED

2/28/2004

PA32300

IO540K1A5

 

6345703

RUDDER TAB

(AUS) RUDDER TRIM ARM ASSEMBLY SEPARATED FROM RUDDER PEDAL BAR.

AUS20040204

PIPER

CONT

 

TUBE

WORN

2/25/2004

PA34200T

TSIO360E

 

8623853

MLG 

(AUS) NOSE LANDING GEAR EXTENSION HYDRAULIC PIPE WORN THROUGH BY CONTACT WITH THE NLG BRAKE FLUID COVER ASSEMBLY. LOSS OF HYDRAULIC FLUID.

AUS20040254

PIPER

CONT

CONT

SERVO

CONTAMINATED

4/1/2004

PA34220T

LTSIO360RB

 

25765407

FUEL CONTROL

(AUS) RT ENGINE FCU REGULATOR AIR SECTION CONTAMINATED WITH OIL.

AUS20040255

PIPER

CONT

CONT

SERVO

LEAKING

3/22/2004

PA34220T

TSIO360RB

 

25765407

FUEL CONTROL

(AUS) ENGINE FCU SERVO STEM SEAL LEAKING FUEL. FURTHER INVESTIGATION FOUND THAT THERE WERE MANY SMALL PARTS OF BLUE RUBBER THROUGH OUT THE UNIT. THESE RUBBER PARTS HAD COME FROM A POSSIBLE DAMAGED O RING SEAL DURING ASSEMBLY. ON TOTAL STRIP OF THE UNIT NONE OF THE O RINGS SHOWED SIGNS OF DAMAGE INDICATING THAT THE DAMAGED ORING MAY HAVE BEEN CHANGED BUT THE RUBBER NOT REMOVED.

AUS20040227

PIPER

CONT

CONT

BEARING

FAILED

3/22/2004

PA34220T

TSIO360RB

 

 

ENGINE FUEL PUMP

(AUS) ENGINE DRIVEN FUEL PUMP FAULTY. PUMP CONTAMINATED WITH A BLACK CARBON POWDER TYPE SUBSTANCE. POOR PUMP LUBRICATION CAUSED EXCESSIVE BEARING WEAR.

AUS20040238

PIPER

CONT

 

PUMP

CONTAMINATED

3/22/2004

PA34220T

TSIO360RB

 

6543511

ENGINE FUEL

(AUS) INSPECTION OF ENGINE DRIVEN FUEL PUMP FOLLOWING STRIP FOR OVERHAUL. THE PUMP WAS FOUND TO CONTAMINATED WITH WHAT APPEARS TO BE CARBON POWDER. PUMP SHAFT BUSHING CONTAMINATED, CAUSING PUMP ROTATION TO BE RESTRICTED.

AUS20040223

PIPER

LYC  

 

BLADE

CORRODED

3/19/2004

PA38112

O235L2C

 

72CK056

PROPELLER

(AUS) PROPELLER BLADES CONTAINED SEVERE INTERGRANNULAR CORROSION.

AUS20040189

PIPER

LYC  

 

BLADE

CORRODED

3/12/2004

PA38112

O235L2C

 

72CK056

PROPELLER

(AUS) PROPELLER BLADES CONTAINED SEVERE INTERGRANNULAR CORROSION.

AUS20040190

PIPER

LYC  

 

BLADE

CORRODED

3/15/2004

PA38112

O235L2C

 

72CK056

PROPELLER

(AUS) PROPELLER BLADES CONTAINED SEVERE INTERGRANNULAR CORROSION.

AUS20040083

PIPER

LYC  

PIPER

FITTING

LOOSE

2/4/2004

PA44180

O360E1A6

 

3866003

AILERON CONTROL

(AUS) LT AND RT AILERON CONTROL ROD ATTACHMENT FITTINGS, LOOSE.

AUS20040174

PIPER

LYC  

 

BELLCRANK

BROKEN

3/9/2004

PA60601P

IO540S1A5

 

4000894E

RT MLG DOOR

(AUS) RT MAIN LANDING GEAR DOOR BELLCRANK LUG BROKEN.

AUS20040277

ROBSIN

LYC  

 

DRIVE BELT

DAMAGED

4/20/2004

R22ALPHA

O320B2C

 

A1902

ENGINE/XMSN

(AUS) ENGINE TO TRANSMISSION DRIVE BELTS STRETCHED AND WORN.

AUS20040278

ROBSIN

LYC  

CONT

DISTRIBUTOR BLK

LOOSE

4/20/2004

R22BETA

HO360*

 

E02HA23B

MAGNETO

(AUS) LT MAGNETO DISTRIBUTOR BLOCK LOOSE IN HOUSING.

AUS20040286

ROBSIN

LYC  

 

GASCOLATOR

CONTAMINATED

4/8/2004

R22BETA

O320B2C

 

 

FUEL SYS

(AUS) ENGINE FAILED. INVESTIGATION FOUND WATER AND RUST IN THE AIRCRAFT FUEL FILTER GASCOLATOR AND CARBURETOR.

AUS20040119

ROBSIN

LYC  

 

DRIVE BELT

DISTORTED

2/24/2004

R22BETA

O320B2C

 

A1902

ENGINE/XMSN

(AUS) ENGINE TO TRANSMISSION DRIVE BELTS STRETCHED.

AUS20040307

ROBSIN

LYC  

 

BOLT

MISSING

4/22/2004

R44  

O540F1B5

 

STD1419

ENGINE

(AUS) CRANKCASE BOLT MISSING. OIL LEAKING FROM CRANKCASE. ENGINE HAD JUST BEEN FITTED AND AIRCRAFT WAS ON TEST FLIGHT. PERSONNEL/MAINTENANCE ERROR.

AUS20040110

ROBSIN

LYC  

 

DRIVE BELT

FAULTY

2/10/2004

R44RAVENII

IO540AE2A

 

A1903

ENGINE/XMSN

(AUS) ENGINE TO TRANSMISSION DRIVE V BELTS HAD AN ABNORMAL BUMP ON THE INSIDE OF THE BELTS WHICH CAUSED A VIBRATION.

AUS20040263

SKRSKY

TMECA

 

FIRE DETECTOR

FAULTY

4/14/2004

S76C

ARRIEL1S

 

7630607902103

NR 2 ENGINE

(AUS) NR 2 ENGINE FLAME DETECTOR FAULTY.

AUS20040130

SKRSKY

TMECA

 

DRAIN VALVE

LEAKING

2/25/2004

S76C

ARRIEL1S

 

0174078010

ENGINE

(AUS) ENGINE START DRAIN VALVE LEAKING DUE TO ORING SEAL FAILURE.

AUS20040315

SNIAS

TMECA

 

NUT  

MISMANUFACTURED

4/29/2004

AS332L

MAKILA1A

 

332BF6

NR 1 ENG FLANGE

(AUS) NR 1 ENGINE OUTPUT DRIVESHAFT TO OUTPUT FLANGE ATTACHMENT NUTS FAULTY. MATING SURFACE OF NUTS MISALIGNED. NUTS ARE PART OF BOLT SET PN 332BF6. SUSPECT MANUFACTURING ERROR.

AUS20040113

SNIAS

TMECA

 

SERVO

FAULTY

2/19/2004

AS350B

ARRIEL1D

 

SC5072

TAIL ROTOR

(AUS) TAIL ROTOR SERVO FAULTY. INVESTIGATION FOUND ALTHOUGH FULL TAIL ROTOR PEDAL CONTROL WAS AVAILABLE, THE ACTUATOR GAVE LIMITED OUTPUT.

CA040401007

SNIAS

TMECA

 

BLADE

CRACKED

3/29/2004

AS350B3

ARRIEL2B

 

355A12005004

TAIL ROTOR

(CAN) DURING DAILY INSPECTION AND DAILY COMPLIANCE WITH AD 2001-640-089(A), A CHORDWISE CRACK WAS DETECTED APPROXIMATELY 3 INCHES IB OF THE BLADE-TIP.

AUS20040142

SOCATA

LYC  

CONT

BEARING

FAILED

3/2/2004

TB10TOBAGO

O360A1A

 

10400553

MAGNETO

(AUS) MAGNETO DRIVE SHAFT OUTER BEARING COMPLETELY DESTROYED. BEARING HAD BEEN RUNNING DRY FOR SOME TIME. SUSPECT MAGNETO ASSEMBLED WITHOUT GREASE IN THE BEARING. PERSONNEL/MAINTENANCE ERROR.

2004FA0000418

YAKLEV

 

 

CONTROL CABLE

MISINSTALLED

5/3/2004

YAK50

 

 

 

RUDDER

UPON CONDITIONAL INSPECTION, WHILE AIRCRAFT PARKED ON RAMP. FOUND AFT RT RUDDER CABLE PULLEY OUT OF TERMINAL END. SENT TO REPAIR SHOP AND WAS TOLD TERMINAL END WAS NOT SWAGED PROPERLY DURING ASSY. INSPECTED AND REPLACED ALL CABLE CONTROLS AS PRECAUTIONARY MEASURES.

END OF REPORTS