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AFS-600 Regulatory Support Division logo

 

ADVISORY CIRCULAR

43-16A

 

 

AVIATION MAINTENANCE ALERTS

 

 

flag of the United States of America

 

ALERT

NUMBER

384

bald eagle watching over three eggs

JULY

2010

 


CONTENTS

AIRPLANES

BOMBARDIER............................................................................................................................ 1

CASA........................................................................................................................................... 6

CESSNA.................................................................................................................................... 10

DIAMOND................................................................................................................................ 15

POWERPLANTS

CONTINENTAL....................................................................................................................... 17

AIR NOTES

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE................................... 20

IF YOU WANT TO CONTACT US......................................................................................... 21

AVIATION SERVICE DIFFICULTY REPORTS...................................................................... 21

 


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

Bombardier:  BD100-1A10; Sheared Generator Spline Shaft; ATA 2421

About this aircraft an unidentified technician states, "The APU (auxiliary power unit) goes off line as soon as it is loaded.  The APU generator spline shaft (was found) sheared off."

PHOTO OF THE DC  POWER GENERATOR.


 

VIEW OF SHEARED DRIVE SHAFT.

 

CLOSEUP VIEW OF THE DATA PLATE.

(The SDRS database reflects seven of these units.)

Part Total Time:  1,492.0 hours

 


Bombardier:  CL600; Engine Cowl Support Rod; ATA (N/A)

(The following Service Advisory comes from our sister organization, Transport Canada.)

TRANSPORT CANADA SERVICE ADVISORY.


 

TRANSPORT CANADA SERVICE DIFFICULTY ADVISORY.


 

AIR TRANSPORT CANADA SERVICE DIFFICULTY ADVISORY.


 

AIR TRANSPORT CANADA SERVICE DIFFICULTY ADVISORY.

Part Total Time:  (N/A)

 

CASA:  C212CC; Corroded Longeron; ATA 5313

An air carrier submission says, "The longeron that connects the left fuselage sidewall and belly has one spot of corrosion between frames 3 and 4 at approximate station 4100.  The longeron is 3.2 MM thick, and is formed as an angle.  The corrosion damage extends at least halfway into the beam (thickness) and moves into the bend radius.  This (corrosion spot) is about 0.50 inches in diameter."

PHOTO OF A TECHNICIAN LOOKING UNDERNEATH THE AIRCRAFT'S FLOORBOARDS.


 

VIEW OF THE CORRODED LONGERON FROM APPROXIMATELY 36 INCHES.

 

(Part number for this longeron:  21221000541.  This airplane has more issues; see the next entry—Ed.)

Part Total Time:  16,761.0 hours

 


CASA:  C212CC; Cracked Horz. Stabilizer Attach Fittings; ATA 5551

The previously reported aircraft has another defect.  The submission states, "Three each horizontal stabilizer attach fittings (fuselage side) were found to be cracked, and three others were found with intergranular corrosion.  Six of the eight (fittings) are beyond limits (P/N 2122415XX)."

 

VIEW 1 OF CRACKED ATTACH FITTING.


VIEW 2 OF CRACKED ATTACH FITTING.

 

VIEW 3 OF CRACKED ATTACH FITTING.

Part Total Time:  16,761.0 hours

 


Cessna:  172S; Frayed Aileron Cable; ATA 2710

"During a routine inspection," says a flight school submission, " the aileron cable (P/N 0510105-364) was found shiny (worn) where it passes through the ceiling pulley cluster.  When it was viewed through a strong magnifying glass many broken strands could be seen."

 

VIEW 1 OF FRAYED AILERON CABLE.


 

VIEW 2 OF FRAYED AILERON CABLE.


 

VIEW 3 OF FRAYED AILERON CABLE.

 

(This part number hits 14 times in the SDRS database.  Thank-you for the photo effort—Ed.)

Part Total Time:  2,311.0 hours

 


Cessna:  680; Cracked Diffuser Ducts; ATA 3010

A repair station technician describes a heat duct defect.  "We have found these wing bleed air heated leading edge diffusers cracked or deformed on numerous aircraft.  This (particular) discrepancy was found while performing A301001 Wing/Horizontal Stabilizer Bleed Air Anti-Ice System Detailed Inspection.  Task 30-10-00-220 is part of Inspection Document nine—a 48 month inspection.  This discrepancy was likely caused by thermal expansion and flight vibrations of the wing leading edge, anti-ice piccolo tube.  The piccolo tube is hard mounted to the diffuser with no vibration dampeners or means to compensate for thermal expansion.  The material for the diffusers is thin and bends easily.  We have also found the piccolo tubes chafing on the diffusers.  We recommend the diffusers be built with a heavier material and the piccolo tube mounting to be redesigned.  This occurrence was corrected by replacement of the effected parts."  (Diffuser P/N's 6922520-53, -54, -55, and -56.)


VIEW 1 AND 2 OF CRACKED DUCT.

Part Total Time:  3,042.3 hours

 


Diamond:  DA42; Cracked Fuel Tanks; ATA 2810

A flight school reports, "During a routine inspection a fuel stain was noted in the left auxiliary tank area.  The tank was removed and inspected.  There were cracks found at several of the weld points where an internal baffle is welded to the bottom panel of the tank.  A new tank (P/N D6028141100) was installed."

 

VIEW 1 OF CRACKED FUEL TANK.

 

VIEW 1 OF CRACKED FUEL TANK.

 

Part Total Time:  625.0 hours

 


Diamond:  DA42; Chafed Rudder Cable; ATA 2720

An unidentified submitter states, "During a routine inspection, the rudder cable (P/N CA13190) was found worn with broken strands where it exits the (guide) tube (P/N 157727) about two inches forward of the rudder bell crank.  This is approximately on the rudder hinge line.  Once the cable was removed, additional wear was found 33 inches inside the tube.  Since both ends of the cable are swaged, this cable would never be removed to inspect for that wear (occurring) midway in the protective tube."

 

PARTS DRAWING FOR THE RUDDER CABLE INSTALLATION.

 

CLOSEUP VIEW OF THE WORN CABLE.

 

Part Total Time:  1,313.0 hours

 


POWERPLANTS

Continental:  IO550C; Leaking Dipstick Housing; ATA 8550

A technician states, "During a routine oil change a puddle of oil was observed in the bottom of the cowling.  No oil was spilled while filling the crankcase.  Having seen this problem several times in the past, the mechanic immediately knew to look at the dipstick tube (P/N 6494061) in the chafed area.  As in all the previous situations, the hole is located at the first inside bend below the filler opening.  Even though the OEM says they are not aware of the problem, most of our in-service engines show some sign of chafing which can be observed by looking down the oil fill opening on the crank case side of the tube.  Fortunately, once the dipstick is in place, it tends to fill the chafed opening and very little oil can escape through the hole.  The attached photos show the dipstick through the chafed hole—it actually creates a decent seal."

 

PHOTO OF THE DIP-STICK GUIDE TUBE AND ITS ENGINE MOUNT.

 

CLOSEUP VIEW OF THE CHAFED DIP-STICK.


CLOSEUP VIEW OF THE HOLE CHAFED IN THE GUIDE TUBE.

 

CLOSEUP VIEW OF THE GUIDE TUBE HOLE WITH DIP-STICK INSTALLED.

Part Total Time:  1,209.0 hours

 

Continental:  IO470N; Failed Oil Cooler Gasket; ATA 7921

(The following short report references a Beech V35 aircraft.  The photograph is excellent.  Unfortunately, how or why the gasket failed is not included.)

A technician for an aviation company says, "The oil cooler gasket failed."


 

PHOTO OF THE BROKEN GASKET STILL ON THE ENGINE CASE.

Part Total Time:  160.0 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 address below.


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

2010F00130

AIRBUS

 

 

VENT

ICED

6/2/2010

A330*

 

 

 

CABIN AIR

WHILE AT CRUSING ALTITUDE 39,000 FT, THERE WERE A SERIES OF LOUD AND PROLONGED CRACKLING/CRUNCHING NOISES COMING FROM THE AIRVENTS. THE CRACKLING NOISES WERE THEN FOLLOWED IN SEQUENCE BY A SLIDING NOISES (E.G. SMALL PEBBLES OR CHIPS GOING DOWN A METAL OR PLASTIC CHILDREN'S OUTDOOR SLIDE). THIS SEQUENCE WAS LOUD ENOUGHT THAT IT COULD BE HEARD VERY CLEARLY NOT WITHSTANDING THE FACT THAT WE WERE WATCHING IN IN-FLIGHT MOVE WITH HEADPHONES ON. IT WAS SO LOUD, THAT MANY OTHER PASSENGERS TOOK OFF THEIR EARPHONES TO FIGURE OUT WHERE THE NOISE WAS COMING FROM. I HAD THE EXACT SAME EXPERIENCE ON ANOTHER A330 ABOUT TWO YEARS AGO AND WAS TOLD BY THE FLIGHT CREW CHIEF THAT THE NOISE WAS THE THAWING/BREAKING OF ICE INSIDE THE AIRVENTS. IN REALITY, THAT'S EXACTLY WHAT IT SOUNDED LIKE. EVEN SO, THIS EXPLANATION SEEMS VERY UNSATISFACTORY TO ME, GIVEN THAT I'VE NEVER HEARD IT ON ANY OTHER PLANE BEFORE, AND I DON'T SEE HOW A PLANE CAN TAKE ON THAT MUCH ICE, WITH NOWHERE FOR IT GO, OVER THE COURSE OF A LONG FLIGHT. IN THE FIRST INSTANCE, IT WAS 10 HOURS, AND LAST WEEK, IT WAS 3 HOURS. PLEASE ADVISE WHETHER THIS IS SOME DESIGN FLAW OR OTHER MALFUNCTION.

2010FA0000528

AMTR

 

 

FITTING

BROKEN

6/1/2010

GLASAIRIISRG

 

 

MS20822

MLG 

OWNER/PILOT OF THIS ACFT WAS PERFORMING TOUCH & GOES WHEN PREPARING FOR 2ND LANDING, NOTICED DID NOT HAVE A GREEN MLG DOWN LIGHT FOR THE LT MLG. FLEW PAST TOWER & VERIFIED THIS FACT. NOTED ALSO DIDN`T HAVE HYD PRESSURE. A SAFE LANDING WAS MADE WITH MINOR DAMAGE TO THE ACFT AND NO INJURIES TO PILOT. UPON EXAMINATION OF ACFT, IT WAS DETERMINED THAT ONE OF THE LT MLG ACTUATOR HYD FITTINGS HAD BROKEN OFF OF THE ACTUATOR. ALLOWING THE HYD SYS TO LOOSE A SUBSTANTIAL AMOUNT OF FLUID THAT WOULD NOT RETRACT OR EXTEND THE MLG COMPLETELY. EXAMINATION OF BROKEN FITTING SHOWS THAT IT FAILED AT A POINT FLUSH WITH ACTUATOR HSG. 90 DEGREE ELBOW PORTION REMAINED ATTACHED TO FLEXIBLE HOSE ASSY. EXAMINATION OF MLG WELL & GENERAL LAYOUT OF MLG COMPONENTS SHOWS FLEX HOSE MAY HAVE BEEN STRESS LOADED WHILE GEAR LEG WAS UP. THIS MAY HAVE PUT UNDUE STRESS ON HOSE ASSY & FOCUSED HIGH LOADS ON HOSE ELBOW AT ACTUATOR HSG. IT ALSO APPEARED THE GEAR ACTUATOR MAY ALSO BE RUBBING AGAINST TOP OF WHEEL WELL.

2010FA0000516

BEECH

 

 

WINDSHIELD

CRACKED

5/28/2010

2000

 

 

10138402518

COCKPIT

RT WINDSHIELD CRACKED.

2010FA0000515

BEECH

CONT

 

ROTOR SHAFT

SHEARED

5/28/2010

35C33A

IO520*

 

 

ALTERNATOR

ALTERNATOR FAILED IN FLIGHT. THIS IS THE 3RD FAILURE IN LESS THAN 100 HRS (18HRS, 17HRS, & 36HRS) THE PREVIOUS (2) WERE REPLACED UNDER WARRANTY. ALL (3) HAVE HAD IDENTICAL ROTOR SHAFT TORSIONAL FAILURE JUST INTERNAL TO THE ALTERNATOR BETWEEN THE FAN AND THE INBD BEARING.

2010FA0000524

BEECH

CONT

 

RELAY

FAILED

6/4/2010

F33A

IO520BB

 

SM50D7

MLG 

((VJ3R)) ON ROUTINE PHASE INSP, MECHANIC FOUND THE DYNAMIC BREAKER FAILED ON RELAY. PROBABLE CAUSE AT THIS TIME UNKNOWN. RECOMMENDATION IS TO REPLACE RELAY UNTIL MFG DESIGNS A BETTER RELAY.

2010FA0000523

BEECH

CONT

 

CIRCUIT BREAKER

INOPERATIVE

6/4/2010

F33A

IO520BB

 

35380132103

TAXI LIGHT

PILOT REPORTED TAXI LIGHT INOP. ON TROUBLESHOOTING , TECH FOUND CIRCUIT BREAKER/ SWITCH TO BE AT FAULT. AD 2008-13-17 HAD BEEN COMPLETED 1516 FLIGHT HOURS PRIOR AND ESTIMATED CYCLES 6064. NOTICED NEW CIRCUIT BREAKER, NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

2010FA0000514

BELL  

ALLSN

 

TACH GENERATOR

MALFUNCTIONED

5/24/2010

206L3

250C30

 

2060733731

MAIN ROTOR

HYD PRESSURE FAILURE IN FLIGHT, ACCOMPANIED BY LOSS OF ROTOR TACH NEEDLE (WENT TO ZERO) AND LOW ROTOR RPM CAUTION LIGHT ILLUMINATION.

2010FA0000525

BELL  

ALLSN

BELL  

BEVEL GEAR

CRACKED

6/7/2010

407  

250C47B

 

407040035101

M/R TRANSMISSION

MAIN ROTOR TRANSMISSION WAS MAKING VERY SMALL AMOUNTS OF METAL, BUT ENOUGH TO KEEP SETTING OFF THE CHIP DETECTOR. STRAINED OIL AND FILTER LOOKED NORMAL. TEAR DOWN INSPECTION, FOUND BEVEL GEAR COMPLETELY CRACKED THROUGH. THERE WHERE NO OVER TORQUE INDICATIONS. UNKNOWN IF GEAR HAS MFG DEFECT? (IMPROPER HEAT TREATMENT?) THIS GEAR SHOULD NOT CRACK CLEAR THROUGH. NO MATTER HOW CLEAN YOUR FILTER BOWEL LOOKS OR HOW SMALL THE AMOUNT OF METAL FOUND, HEED YOUR MULTIPLE CHIP DETECTOR INDICATIONS AND INSPECT YOUR TRANSMISSION.

EE4Y100209

BOEING

 

 

STRINGER

CORRODED

6/9/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE E & E COMPARTMENT FROM BS 352 TO BS 360, STR 22 LT WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 177).

EE4Y100203

BOEING

 

 

FLOORBEAM

CORRODED

6/8/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT AT BS 860, RBL 3 CARGO FLOORBEAM WITH CORROSION. ( W/O Y10122, SUB JOB 1, ITEM 220).

EE4Y100204

BOEING

 

 

SUPPORT

CRACKED

6/8/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT AT BS 794 BETWEEN STR 22R AND STR 23R SUPPORT WITH CRACK. (W/O Y10122, SUB JOB 1, ITEM 227).

EE4Y100186

BOEING

 

 

INTERCOSTAL

CRACKED

6/2/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE CARGO CABIN BS 294.5 INTERCOSTAL CRACKED AT STRINGER 11 LT. (WO Y10122, SUB JOS 2, ITEM 97).

EE4Y100184

BOEING

 

 

INTERCOSTAL

CRACKED

6/2/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE CARGO CABIN BS 294.5 INTERCOSTAL CARCKED AT STRINGER 12 LT. (WO Y10122, SUB JOB 2, ITEM 97).

EE4Y100205

BOEING

 

 

INTERCOSTAL

CRACKED

6/8/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT AT BS 817 BETWEEN STR 24R AND 25R INTERCOSTAL WITH CRACK. (W/O Y10122, SUB JOB 1, ITEM 228).

EE4Y100212

BOEING

 

 

STRINGER

CORRODED

6/9/2010

7372X6C

 

 

 

BS 892 S26R

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT BS 892, STRINGER 26RT WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 210).

EE4Y100213

BOEING

 

 

FLOORBEAM

CORRODED

6/9/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT BS 727B BETWEEN RBL 25 AND LBL 25 FLOORBEAM UPPER CHORD UPPER SURFACE WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 212).

EE4Y100214

BOEING

 

 

FLOORBEAM

CORRODED

6/9/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE FWD CARGO COMPARTMENT BS 500B AT LBL 55 FLOORBEAM UPPER CHORD LOWER SURFACE WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 214).

EE4Y100215

BOEING

 

 

FLOORBEAM

CORRODED

6/9/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CABIN FLOORBEAM UPPER CHORD AT B STA 947.6 BETWEEN BL 0 TO LBL 45 WITH CORROSION AT SEVERAL PLACES. (W/O Y10122, SUB JOB 2, ITEM 142).

EE4Y100202

BOEING

 

 

STIFFENER

CRACKED

6/8/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE FWD CARGO COMPARTMENT AT BS 500B BL STIFFENER WITH CRACK. (W/O Y10122, SUB JOB 1, ITEM 216).

EE4Y100216

BOEING

 

 

FLOOR SUPPORT

CORRODED

6/9/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE PAX CABIN FLOORBEAM UPPER SKIN WITH CORROSION BETWEEN STA 480-520, LBL 45-65. (W/O Y10122, SUB JOB 2, ITEM 144).

EE4Y100217

BOEING

 

 

FLOORBEAM

CORRODED

6/9/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE PAX CABIN FLOORBEAM WITH CORROSION AT STA 500A BETWEEN LBL 25 & LBL 40. (W/O Y10122, SUB JOB 2, ITEM 145).

EE4Y100218

BOEING

 

 

WEB  

CORRODED

6/9/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE PAX CABIN FLOOR WEB WITH CORROSION BETWEEN STA 420 & 440, LBL 40 TO LBL 65. (W/O Y10122, SUB JOB 2, ITEM 154).

EE4Y100195

BOEING

 

 

FLOORBEAM

CORRODED

6/5/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT FLOORBEAM AT BS 847 FROM RBL 30 TO RBL 55 FLOORBEAM LOWER CHORD WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 94).

EE4Y100197

BOEING

 

 

STRINGER

CRACKED

6/5/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) MAIN CARGO CABIN AT BS 500B+3 AND BS 500B+13,5 AT SCANNING LIGHT AREA STRINGER 16 RT WITH CRACK. (W/O Y10122, SUB JOB 2, ITEM 134).

EE4Y100201

BOEING

 

 

PAN  

CRACKED

6/5/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) PAX CABIN MAIN CARGO DOOR LOWER PAN AT STA 475 AND STA 405 WITH CRACK. (W/O Y10122, SUB JOB 2, ITEM 135).

EE4Y100199

BOEING

 

 

SKIN

CRACKED

6/5/2010

7372X6C

 

 

 

CARGO DOOR

((EE4Y)) UPPER FUSELAGE MAIN CARGO DOOR, AT BS 460 LOWER FRAME SKIN WITH CRACK. (W/O Y10122, SUB JOB 2, ITEM 116).

EE4Y100200

BOEING

 

 

VERTICAL BEAM

CRACKED

6/5/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT BS 727+4 LBL 17, WL 156 BULKHEAD VERTICAL BEAM FLANGE WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 207).

EE4Y100227

BOEING

 

 

FLOORBEAM

CORRODED

6/11/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE FWD CARGO COMPARTMENT BS 500A, BTWN LBL 25 AND RBL 25 FLOORBEAM UPPER CHORD WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 208).

EE4Y100112

BOEING

 

 

DUCT

CRACKED

5/28/2010

7372X6C

 

 

 

ZONE 100

LOWER FUSELAGE LT AIR CONDITIONING BAY, PRIMARY HEAT EXCHANGER EXHAUST DUCT CRACKED.

EE4Y100170

BOEING

 

 

SPAR

CORRODED

5/31/2010

7372X6C

 

 

 

ZONE 500

((EE4Y)) LT WING FRONT SPAR LOWER CHORD FLANGE WITH CORROSION AT W STA 520. (W/O Y10122, SUB JOB 5, ITEM 1).

EE4Y100171

BOEING

 

 

SPAR

CORRODED

5/31/2010

7372X6C

 

 

 

ZONE 500

((EE4Y)) LT WING FRONT SPAR LOWER CHORD FLANGE WITH CORROSION AT W STA 602. (W/O Y10122, SUB JOB 5, ITEM 3).

EE4Y100193

BOEING

 

 

FLOORBEAM

CORRODED

6/4/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT AT BSTA 867 FROM RBL 60 TO LBL 60 FLOORBEAM LOWER CHORD WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 112).

EE4Y100194

BOEING

 

 

CARGO TRACK

CORRODED

6/4/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT FROM BSTA 716 TO 727B CARGO TRACK WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 77).

EE4Y100187

BOEING

 

 

HINGE PIN

CORRODED

6/2/2010

7372X6C

 

 

6937451502

ZONE 300

DURING THE ACCOMPLISHMENT OF ECO 3472R4, RELATED TO AD 2004-19-10 (SB737-55A1077) WAS FOUND THE HORIZONTAL STABILIZER PIVOT HINGE INNER PIN WITH CORROSION ON ITS SHANK. ( WO Y10122, SUB JOB 9, ITEM 24).

EE4Y100207

BOEING

 

 

FLOORBEAM

CORRODED

6/9/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE FWD CARGO COMPARTMENT AT BS 500B, LBL 39, WL 200 FLOORBEAM LOWER FLANGE WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 170).

EE4Y100229

BOEING

 

 

STRINGER

CORRODED

6/11/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE CARGO COMPARTMENT AT BS 865.5, STR 27R WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 229).

EE4Y100230

BOEING

 

 

BEAR STRAP

CRACKED

6/11/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT BS 844 BETWEEN STRINGERS 23 & 24RH, BEAR STRAP DOUBLER WITH CRACK. (W/O Y10122, SUB JOB 1, ITEM 230).

EE4Y100110

BOEING

 

 

SUPPORT ANGLE

CRACKED

5/28/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE AT B/S 535.5 WL 144 LBL 45, WING TO BODY SUPPORT ANGLE WITH CRACK.

EE4Y100228

BOEING

 

 

HINGE PIN

CORRODED

6/11/2010

7372X6C

 

 

 

ZONE 300

((EE4Y)) HORIZONTAL STABILIZER PIVOT HINGE IAW ECO 3472 PART II. (W/O Y10122, SUB JOB 2, ITEM 94).

EE4Y100111

BOEING

 

 

SKIN

DELAMINATED

5/28/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE LT AIR CONDITIONING BAY DOOR INNER SKIN DELAMINATED AT STA 138.

EE4Y100119

BOEING

 

BOEING

ATTACH FITTING

CORRODED

5/29/2010

7372X6C

 

 

69353646

BS 867 FRAME

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT AT BSTA 867 LSTR 20 CLIP WITH CORROSION.

EE4Y100100121

BOEING

 

BOEING

ATTACH FITTING

CRACKED

5/29/2010

7372X6C

 

 

69353521

BS 727A FRAME

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT AT BS 727A, S25L WITH CRACK.

EE4Y100120

BOEING

 

BOEING

ATTACH FITTING

CORRODED

5/29/2010

7372X6C

 

 

69353523

BS 867 FRAME

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT AT BS 867, S26L CLIP WITH CORROSION.

EE4Y100123

BOEING

 

 

STRINGER CLIP

CRACKED

5/29/2010

7372X6C

 

 

 

BS 400 S4R

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 400 STR 4R AND STR 10R STRINGER TIE CLIPS WITH CRACK.

EE4Y100130

BOEING

 

 

STRINGER CLIP

CRACKED

5/29/2010

7372X6C

 

 

 

BS 400 S10R

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AL B/S 400 STR 10R, STRINGER TIE CLIP WITH CRACK.

EE4Y100124

BOEING

 

 

STRINGER CLIP

CRACKED

5/29/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSALAGE MAIN CARGO CABIN AT B/S 420 STR 5R, STRINGER TIE CLIPS WITH CRACK.

EE4Y100185

BOEING

 

 

INTERCOSTAL

CRACKED

6/2/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE CARGO CABIN BS 294.5 STR, 8 LT INTERCOSTAL WITH CRACK. (WO Y10122, SUB JOB 2, ITEM 96).

EE4Y100208

BOEING

 

 

FLOORBEAM

CORRODED

6/9/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE FWD CARGO COMPARTMENT AT BS 500A, RBL 25, WL 207 FLOORBEAM UPPER FLANGE LOWER FACE WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 1736).

EE4Y100188

BOEING

 

 

FLOOR SUPPORT

CORRODED

6/2/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE FWD CARGO COMPARTMENT FROM BS 460 TO BS 520, BL 0, WL 200 FLOOR SUPPORT UPPER AND LOWER FLANGE WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 174).

EE4Y100206

BOEING

 

 

FLOORBEAM

CORRODED

6/9/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE FWD CARGO COMPARTMENT AT BS 500, LBL 22, WL 200 FLOORBEAM LOWER FLANGE WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 169).

EE4Y100192

BOEING

 

 

FRAME

CORRODED

6/4/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT AT BSTA 1006, STR 20L, FRAME WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 136).

EE4Y100113

BOEING

 

 

CONNECTOR

BROKEN

5/28/2010

7372X6C

 

 

 

POWER SUPPLY

LOWER FUSELAGE FWD CARGO COMPARTMENT BATTERY POWER SUPPLY GROUND CONNECTION BROKEN.

EE4Y100114

BOEING

 

 

SKIN

CANNING

5/28/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER EXTERNAL FUSELAGE AT B/S 360.5 BETWEEN STRINGERS 22R AND 23R SKIN WITH OIL CAN.

EE4Y100115

BOEING

 

 

INTERCOSTAL

CRACKED

5/28/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE CARGO CABIN B/S 294.5 INTERCOSTALS CRACKED (2EA) AT STRINGER 11 AND 12 LT.

EE4Y100116

BOEING

 

 

INTERCOSTAL

CRACKED

5/28/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE CARGO CABIN B/S 294.5 STRINGER 8 LT INTERCOSTAL ANGLE CRACKED.

EE4Y100118

BOEING

 

 

INTERCOSTAL

CRACKED

5/28/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE CARGO CABIN B/S 360 STR 14 LT INTERCOSTAL WEB CRACKED.

EE4Y100131

BOEING

 

 

STRINGER CLIP

CRACKED

5/29/2010

7372X6C

 

 

 

BS 420

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 420 STR 10, STRINGER TIE CLIP WITH CRACK.

EE4Y100125

BOEING

 

 

STRINGER CLIP

CRACKED

5/29/2010

7372X6C

 

 

 

BS 440 S3R

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 440 STR 3, STRINGER TIE CLIPS WITH CRACKS.

EE4Y100132

BOEING

 

 

STRINGER CLIP

CRACKED

5/29/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 440 STR 4R, STRINGER TIE CLIP WITH CRACK.

EE4Y100133

BOEING

 

 

STRINGER CLIP

CRACKED

5/29/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN B/S 440 STR 10R, STRINGER TIE CLIP WITH CRACK.

EE4Y100126

BOEING

 

 

STRINGER CLIP

CRACKED

5/29/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 460 STR 4R STRINGER TIE CLIP WITH CRACK. WORK ORDER Y10122, SUBJOB 2, ITEM 65.

EE4Y100127

BOEING

 

 

STRINGER CLIP

CRACKED

5/29/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 616 STR 3R STRINGER TIE CLIP WITH CRACK. W/O Y10122, SUB JOB 2, ITEM 66.

EE4Y100128

BOEING

 

 

STRINGER CLIP

CRACKED

5/29/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 685 STR 4R STRINGER TIE CLIP WITH CRACK. WORK ORDER Y10122, SUB JOB 2, ITEM 67.

EE4Y100129

BOEING

 

 

STRINGER CLIP

CRACKED

5/29/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 706 STR 10L STRINGER TIE CLIP CRACK. WORK ORDER Y10122, SUB JOB 2, ITEM 68.

EE4Y100134

BOEING

 

 

STRINGER CLIP

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 727A STR 7R STRINGER TIE CLIP WITH CRACK. WO Y10122, SUB JOB 2, ITEM 69.

EE4Y100135

BOEING

 

 

STRINGER CLIP

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 200

((EE4Y) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 727B STR 5R, STRINGER TIE CLIP WITH CRACK. W/O Y10122, SUB JOB 2, ITEM 70.

EE4Y100136

BOEING

 

 

STRINGER CLIP

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 727B STR 7R, STRINGER TIE CLIP WITH CRACK. WORK ORDER Y10122, SUB JOB 2, ITEM 70.

EE4Y100137

BOEING

 

 

STRINGER CLIP

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 747 STR 8L, STRINGER TIE CLIP WITH CRACK. W/O Y10122, SUB JOB 2, ITEM 71.

EE4Y100138

BOEING

 

 

STRINGER CLIP

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 747 STR 5L, STRINGER TIE CLIP WITH CRACK. WORK ORDER Y10122, SUB JOB 2, ITEM 71.

EE4Y100139

BOEING

 

 

STRINGER CLIP

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 747 STR 5R, STRINGER TIE CLIP WITH CRACK. W/O Y10122, SUB JOB 2, ITEM 71.

EE4Y100140

BOEING

 

 

STRINGER CLIP

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 767 STR 6L, STRINGER TIE CLIP WITH CRACK. W/O Y10122, SUB JOB 2, ITEM 72.

EE4Y100141

BOEING

 

 

STRINGER CLIP

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 767 STR 5R, STRINGER TIE CLIP WITH CRACK. W/O Y10122, SUB JOB 2, ITEM 72.

EE4Y100142

BOEING

 

 

STRINGER CLIP

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 787 STR 3R, STRINGER TIE CLIP WITH CRACK. W/O Y10122, SUB JOB 2, ITEM 73.

EE4Y100143

BOEING

 

 

STRINGER CLIP

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 787 STR 5R, STRINGER TIE CLIP WITH CRACK. W/O Y10122, SUB JOB 2, ITEM 73.

EE4Y100144

BOEING

 

 

STRINGER CLIP

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 787 STR 6R, STRINGER TIE CLIP WITH CRACKED. W/O Y10122, SUB JOB 2, ITEM 73.

EE4Y100146

BOEING

 

 

SKIN

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 500

LT WING L/E SKIN WITH CRACK AT WBL 384. (W/O Y10122, SUB JOB 5, ITEM 9).

EE4Y100147

BOEING

 

 

SKIN

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 600

((EE4Y)) RT WING FRONT SPAR SECTION LEADING EDGE SKIN WITH CRACK AT WBL 405. (WORK ORDER Y10122, SUB JOB 6, ITEM 12).

EE4Y100148

BOEING

 

 

SKIN

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 600

((EE4Y)) RT WING FRONT SPAR SECTION, LEADING EDGE SKIN WITH CRACK AT WBL STA 280.76. ( W/O Y10122, SUB JOB 6, ITEM 16).

EE4Y100150

BOEING

 

 

STRINGER CLIP

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 100

((EE4Y) LOWER FUSELAGE AFT CARGO COMPARTMENT BSTA 727A STR 25L WITH CLIP CRACKED. (W/O Y10122, SUB JOB 1, ITEM 71).

EE4Y100149

BOEING

 

 

SKIN

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE FWD CARGO COMPARTMENT DOOR INNER SKIN AT BS 440 BETWEEN BEAM 2,3 WITH CRACK. (W/O Y10122, SUB JOB 1, ITEM 67).

EE4Y100151

BOEING

 

 

SUPPORT

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE AFT CARGO DOOR CUT-OUT AT BSTA 793 FROM STR 22R TO 25R STOP FITTING INNER SUPPORT CRACKED. (WORK ORDER Y10122, SUB JOB 1, ITEM 84).

EE4Y100152

BOEING

 

 

SKIN

CRACKED

5/30/2010

7372X6C

 

 

 

CARGO DOOR

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT DOOR INNER SKIN CRACKED. (W/O Y 10122, SUB JOB 1, ITEM 95).

EE4Y100153

BOEING

 

 

CHANNEL

CRACKED

5/30/2010

7372X6C

 

 

 

BS 874

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT AT BSTA 847 STR 19R CHANNEL CRACKED. (W/O Y10122, SUB JOB 1, ITEM 135).

EE4Y100154

BOEING

 

 

FLOORBEAM

CORRODED

5/30/2010

7372X6C

 

 

 

ZONE 200

UPPER FUSELAGE MAIN CARGO CABIN AT B/S 986.5 FLOORBEAM UPPER CHORD WITH CORROSION BETWEEN LBL 16 AND RBL 45. (W/O Y10122, SUB JOB 2, ITEM 100).

EE4Y100155

BOEING

 

 

CROSSBEAM

CORRODED

5/30/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT BL 0 BETWEEN B/ 986.5 AND B/S 1006, CROSS BEAM UPPER CHORD WITH CORROSION. (W/O Y10122, SUB JOB 2, ITEM 102).

EE4Y100156

BOEING

 

 

FLOOR SUPPORT

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE PAX AT BSTA 328 BL 30L FLOOR ANGLE WITH CRACK. (W/O Y10122, SUB JOB 2, ITEM 107).

EE4Y100158

BOEING

 

 

FLOORBEAM

CORRODED

5/30/2010

7372X6C

 

 

 

ZONE 200

UPPER FUSELAGE PAX CABIN AT BSTA 294 FLOORBEAM UPPER FLANGE WITH CORROSION BETWEEN BL 12R TO BL 55R. ( W/O Y10122, SUB JOB 2, ITEM 111).

EE4Y100157

BOEING

 

 

FLOORBEAM

CORRODED

5/30/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE PAX CABIN AT BSTA 328 BETWEEN BL 12R TO BL 55R, FLOOR BEAM UPPER FLANGE WITH CORROSION. (W/O Y10122, SUB JOB 2, ITEM 109).

EE4Y100159

BOEING

 

 

FLOOR SUPPORT

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE PAX CABIN AT BSTA 328 BL 35R FLOOR ANGLE WITH CRACK. (W/O Y10122, SUB JOB 2, ITEM 112).

EE4Y100160

BOEING

 

 

SKIN

CRACKED

5/30/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) EXTERNAL UPPER FUSELAGE AT B/S 533 STR 16R FUSELAGE SKIN WITH CRACK. (W/O Y10122, SUB JOB 2, ITEM 115).

EE4Y100163

BOEING

 

 

FLOORBEAM

CORRODED

5/31/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE AFT CRAGO COMPARTMENT AT BSTA 787 FROM BL 0 TO BL 60L FLOORBEAM LOWER CHORD WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 82).

EE4Y100162

BOEING

 

 

FLOORBEAM

CORRODED

5/31/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE FWD CARGO COMPARTMENT AT BS 500A, BL 50R, WL 200 FLOORBEAM LOWER FLANGE WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 68).

EE4Y100161

BOEING

 

 

SKIN

BULGED

5/31/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER EXTERNAL FUSELAGE AT STRINGER 26L B/S 874.5 WITH BULDGED SKIN. (WORK ORDER Y10122, SUB JOB 1, ITEM 5).

EE4Y100164

BOEING

 

 

STRINGER

CORRODED

5/31/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT AT BSTA 877 STR 26L WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 117).

EE4Y100165

BOEING

 

 

FLOORBEAM

CORRODED

5/31/2010

7372X6C

 

 

 

ZONE 100

((EE4Y)) LOWER FUSELAGE AFT CARGO COMPARTMENT AT BSTA 887 BL 30L TO BL 60L FLOOR BEAM UPPER CHORD WITH CORROSION. (W/O Y10122, SUB JOB 1, ITEM 125).

EE4Y100166

BOEING

 

 

SKIN

DENTED

5/31/2010

7372X6C

 

 

 

ZONE 200

((EE4Y) UPPER EXTERNAL FUSELAGE AT B/S 959.5 BETWEEN STRINGER 4R AND 5R SKIN WITH DENT. (W/O Y10122, SUB JOB 2, ITEM 59).

EE4Y100167

BOEING

 

 

STRINGER CLIP

CRACKED

5/31/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 616 STR 3L STRINGER TIE CLIP WITH CRACK. (W/O Y10122, SUB JOB 2, ITEM 66).

EE4Y100168

BOEING

 

 

FLOORBEAM

CORRODED

5/31/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE MAIN CARGO CABIN AT B/S 1016 FLOORBEAM UPPER FLANGE WITH CORROSION FROM BL 45R TO BL 45L. (W/O Y10122, SUB JOB 2, ITEM 98).

EE4Y100169

BOEING

 

 

STRAP

CORRODED

5/31/2010

7372X6C

 

 

 

ZONE 200

((EE4Y)) UPPER FUSELAGE PAX CABIN FROM BSTA 340 TO BSTA 310 BL 45L FLOOR STRAP WITH CORROSION. (W/O Y10122, SUB JOB 2, ITEM 105).

EE4Y100179

BOEING

PWA  

 

SPAR

CORRODED

6/1/2010

7372X6C

JT8D17

 

 

LWS 460

((EE4Y)) LT WING FRONT SPAR LOWER CHORD FLANGE WITH CORROSION AT W STA 460. (WO Y10122, SUB JOB 5, ITEM 1).

EE4Y100108

BOEING

PWA  

 

STRINGER

CRACKED

5/28/2010

7372X6C

JT8D17

 

 

ZONE 300

EMPENNAGE TAIL COMPARTMENT FWD CORNER OF THE HORIZ STABILIZER CUTOUT AT THE UPPER HORIZ BEAM STRINGER S-5A RT CRACKED FROM BS 1138 TO BS 1142.

EE4Y100109

BOEING

PWA  

 

STRINGER

CORRODED

5/28/2010

7372X6C

JT8D17

 

 

ZONE 100

LWR FUSELAGE AFT CARGO COMPARTMENT AT B STA 767, STR 20L WITH CORROSION.

EE4Y100180

BOEING

PWA  

 

ANGLE

CORRODED

6/1/2010

7372X6C

JT8D17A

 

65495647

ZONE 500

((EE4Y)) LT WING NR 2 SLAT OTBD MAIN TRACK AREA LOWER ANGLE WITH CORROSION. (W/O Y10122, SUB JOB 5, ITEM 18).

VGQY2010052000010

BOEING

 

 

SKIN

CRACKED

5/20/2010

747243B

 

 

 

ZONE 500

DRWS NR:0381, LT WING UPPER SKIN SURFACE FRONT SPAR AT APPROX WS420 FOUND SKIN CRACKED. REPAIR CARRIED OUT PER SRM 51-40-14 REV. 116

VGQY2010051900008

BOEING

 

 

MOUNT

CORRODED

5/19/2010

747243B

 

 

65B943491

NR 3 ENGINE

CORROSION PRODUCTS (RUST) NR 3 ENGINE - PYLON / AFT UPPER MOUNT / MATING SURFACE. COMPLIED WITH EN 1090-10, NR 3 & NR 4 STRUT NAC WL 131 LWR AFT SPAR NAC STA 286 FILLER DOUBLER 65B94115-7 FOUND WITH SURFACE RUST.

VGQY2010061100030

BOEING

 

 

RIB  

CRACKED

6/11/2010

747243B

 

 

65B10945

LT WING

LT WING SURGE TANK WS 1516.6 RIB / LOWER CHORD FOUND CRACKED / ACCESS FROM TANK PANEL 555AB.

VGQY2010051800005

BOEING

 

 

MOUNT

CORRODED

5/18/2010

747281F

 

 

65B943503

NR 3 ENGINE

DRWS NR 0020, NR 3 ENGINE AFT. UPPER MOUNT FOUND RUST. REMOVED AND REPROTECTED PER OHM CMM 71-20-02. MATERIAL REMOVED = 0.008", FOUND WITHIN LIMITS PER OHM CMM 71-20-02.

2010F00119

BOEING

 

 

SKIN

DELAMINATED

6/2/2010

7472F6B

 

 

 

ZONE 400

PYLON NR 2, SKIN PYLON NR 2 DELAMINATION ( RT INNER SIDE )BETWEEN NAC STA 201.4 TO NAC STA 286,00.

WGFY2010FA0765013

BOEING

 

 

SKIN

CORRODED

6/3/2010

7472F6B

 

 

65B144523

ZONE 500

((WGFY)) THERE IS GAP L=2.73 INCH. W=0.78 INCH .T=0.029 BETWEEN LT LOWER SURFACE AND UNDER WING FUSE PIN FITTING PYLON NR 1 WING STA 116.8. PERFORMED A DETAIL VISUAL INSPECTION OF THE REPAIR ZONE, C-CHECK PERFORMED REPEAT DVI INSPECTION OF THE SUBJECT AREA IAW SB 747-54A2182 R2. REQUIREMENT AT 1200 FLIGHT CYCLES INTERVAL NOT TO EXCEED 24 MONTHS.

WGFY2010FA0765014

BOEING

 

 

SKIN

DELAMINATED

6/3/2010

7472F6B

 

 

 

ZONE 400

((WGFY)) PYLON NR 3 LT INNER SKIN DELAMINATION (BETWEEN NAC STA 201.60 TO 240.00) PERFORMED DVI OF THE REPAIR ZONE AT THE REPEAT "C" CHECK, PERFORM REPEAT DVI INSPECTION PER SB 747 54A2182R2 REQUIREMENT AT 1200 FLIGHT CYCLE INTERVAL NOT TO EXCEED 24 MOUNTHS

WGFY2010FA0765011

BOEING

 

 

SKIN

DELAMINATED

6/2/2010

7472F6B

 

 

65B940511

NR 2 PYLON

((WGFY)) PYLON NR 2, SKIN PYLON NR 2 DELAMINATION (RT INNER SIDE ) BETWEEN NAC 201,4 TO NAC STA 286,00. PERFORM A REPEATED DVI OF THE SUBJECT REPAIRED AREAS AT EVERY "C" CHECK OR 18 MONTHS, WHICH EVER OCCURS FIRST.

2010F00120

BOEING

GE  

 

SKIN

DELAMINATED

6/2/2010

7472F6B

CF650*

 

65B940511

NR 2 PYLON

PYLON NR2, SKIN PYLON NR2 DELAMINATION ( RT INNER SIDE ) BETWEEN NAC STA 201.4 TO NAC STA 286,00.

WGFY2010FA0000495

BOEING

GE  

 

STIFFENER

CRACKED

5/25/2010

7472F6B

CF650E2

 

65B100984

BS 980

FUSELAGE RT SIDE VERTICAL STIFFENER STA 980, RBL 11,33 WAS CRACKED AND PERFORM HFEC INSPECTION METHOD TO ENSURE CRACK :+/- 20MM. REPLACED VERTICAL STIFFENER IAW SRM 51-30-02 PART 116.

2010F00118

BOEING

 

MOOG

HOUSING

CRACKED

5/28/2010

757*

 

 

33217771

FLIGHT SPOILER

THIS COMPONENT HAS AN AD (92-17-10) AGAINST IT. THIS AD REQUIRED, WITHIN 48 MONTHS AFTER THE EFFECTIVE DATE OF THIS AD, REPLACE THE PCA'S ON ALL INBD SPOILERS (POSITIONS 4, 5, 6, 7, 8, AND 9), IAW ALERT SB 757-27A0105, DATED DECEMBER 5, 1991. ALERT SB 757-27A0105 CALLED FOR THE INSTALLATION OF PCU'S THAT HAVE CHANGES TO THE BLOCKING AND RELIEF VALVE HSG AND TRUNNION ROD SEALS WILL PREVENT THE SPOILER FLOAT CAUSED BY THE INTERNAL LEAKAGE. OLD PCU’S COULD BE UPDATED IAW THE SB 3321480-27-07 TO INCORPORATE THE NEW HSG. THE NEW HSG (PN 3321777-1) ARE ANODIZED BLUE FOR IDENTIFICATION PURPOSES. THE UNIT NOTED ABOVE WAS RECEIVED. DURING NDT INSPECTION IT WAS NOTED THAT THE BLOCKING AND RELIEF VALVE HOUSING IS CRACKED. THE HSG IS BLUE AND HAS THE PN 3321777-1 ON IT. THAT MEANS THAT IT IS IN COMPLIANCE WITH THE AD BUT IT STILL CRACKED.

IPXA10560070

BOEING

PWA  

 

FLOOR PANEL

BROKEN

5/21/2010

75724APF

PW2040

 

 

BS 720-820

INSPECTION TYPE:C3, MCB FLOOR PANEL BROKEN AT 2 EA INSERT LOCATIONS, BS 720-820 LBL 45-60 WL 208. DAMAGE BEYOND REPAIRABLE LIMITS. FABRICATED REPLACEMENT PANEL.

AMCR201003

BOMBDR

 

 

TIRE

BULGED

6/1/2010

BD1001A10

 

 

269K431

ZONE 700

(AMCR) WHILE ACFT WAS AT A SERVICE CTR FOR MX, MX FOUND A BULGE ON THE LT INBD MAIN TIRE. BULGE WAS GOLFBALL SIZE, PROTRUDED ABOUT .7500", AND WAS LOCATED ON SIDEWALL NEAR WHERE THE SIDEWALL AND TREAD CAP MEET. THIS WAS THE ORIGINAL TIRE SINCE ACFT WAS NEW.

ZB0R20100002

CESSNA

CONT

 

MASTER SWITCH

BURNED

5/31/2010

172S

IO360*

 

S344311

INSTRUMENT PANEL

((ZB0R)) PILOT REPORTED BURNING SMELL AND FAILURE OF AVIONICS BUSS NR 2 ON RUN-UP. ACFT REPORTED TO MX. TROUBLESHOOTING REVEALED AVIONICS MASTER SWITCH RT SIDE (BUSS 2) ARCING INTERNALLY. REPLACED AVIONICS SWITCH AND OPS CK OK.

2010FA0000513

CESSNA

LYC  

SLICK

BRUSHES

WORN

5/27/2010

182T

IO540AB1A5

6351

M3215

MAGNETO DISTRIBU

UPON DISASSEMBLY OF THE RT MAGNETO FOR RECOMMENDED 500 HR. MAGNETO INSPECTION, FOUND THE DISTRIBUTOR BRUSH BADLY WORN. WEAR IS EXACTLY AS DESCRIBED IN SB3-08A FIG 1, ALTHOUGH MORE EXTREME. THIS MAGNETO SN AND MFG DATE ARE WELL OUTSIDE OF THE AFFECTED APPLICABILITY RANGE AS LISTED BY THE SB AND THE INSTALLED BRUSH HAD NEVER BEEN REPLACED SINCE MFG, ALTHOUGH IT HAD BEEN INSPECTED AT THE LAST 500 HR. MAGNETO INSPECTION, 469.6 HRS. AGO WITH NO DEFECTS NOTED. THE OTHER MAGNETO ON THIS SAME ENGINE EXIBITED MORE EXTREME WEAR SIGNS AND WAS ALSO UNAFFECTED ACCORDING TO THE SB. THE MFG HAS PREVIOUSLY BEEN CONTACTED IN REGARDS TO ABNORMAL BRUSH WEAR IN OTHER MAGNETOS OUTSIDE THE SB AFFECTIVITY RANGE, AND APPARENTLY IS NOT CONCERNED.

2010FA0000512

CESSNA

LYC  

SLICK

BRUSHES

WORN

5/27/2010

182T

IO540AB1A5

6351

M3215

DISTRIBUTOR BLK

UPON DISASSEMBLY OF THE LT MAGNETO FOR RECOMMENDED SLICK 500 HR. MAGNETO INSP, FOUND THE DISTRIBUTOR BRUSH BADLY WORN AND ABOUT TO BREAK OFF. WEAR IS EXACTLY AS DESCRIBED IN SB3-08A FIG 1, ALTHOUGH MUCH MORE EXTREME. THIS MAGNETO SN AND MFG DATE ARE WELL OUTSIDE OF THE AFFECTED APPLICABILITY RANGE AS LISTED BY THE SB AND THE INSTALLED BRUSH HAD NEVER BEEN REPLACED SINCE MFG, ALTHOUGH IT HAD BEEN INSPECTED AT THE LAST 500 HR MAGNETO INSP, 469.6 HRS. AGO WITH NO DEFECTS NOTED. THE OTHER MAGNETO ON THIS SAME ENGINE EXHIBITED SIMILAR WEAR SIGNS AND WAS ALSO UNAFFECTED ACCORDING TO THE SB. THE MFG HAS PREVIOUSLY BEEN CONTACTED IN REGARDS TO ABNORMAL BRUSH WEAR IN OTHER MAGNETOS OUTSIDE THE SB AFFECTIVITY RANGE, AND APPARENTLY DOES NOT CARE.

DD2RW900000

CESSNA

CONT

 

CLUTCH SPRING

OVERHEATED

4/8/2010

340A

TSIO520NB

 

AS539800M30

STARTER

((DD2R)) NEWLY O/H STARTER ADAPTER FAILED 1.4 HOURS AFTER INSTALLATION. DISASSLY AND FAILURE ANALYSIS OF UNIT REVEALED OVERHEATED AND MANGLED CLUTCH SPRING. SPRING HAD A COLLAPSED COIL THAT HAD WOUND AROUND THE SHAFT GEAR MINOR DIAMETER BETWEEN CLUTCH DRUM AND INTEGRAL SPUR GEAR. THE COLLAPSED COIL HAD OVERHEATED SHAFTGEAR SO SEVERELY THAT IT TWISTED IN TWO. MANGLED CLUTCH SPRINGS AND SEPARATED SHAFTGEARS MAKE IN-FLIGHT ENGINE RE-START IMPOSSIBLE. BOTH CAUSE SIGNIFICANT OIL CONTAMINATION. SHAFTGEAR SEPARATION STOPS OPERATION OF TURBOCHARGER SCAVENGE PUMP, COULD CAUSE LOSS OF OIL PAST TURBOCHARGER SEALS, POSSIBLE ENGINE OIL STARVATION. A SEPARATED SHAFTGEAR COULD DAMAGE CRANKCASE PILOT BRG AND CAM/CRANK GEAR TEETH, POSSIBLE ENGINE POWER LOSS. STRONGLY SUSPECT STARTER MOTOR RUN-ON AFTER ENGINE START. STARTER RUN-ON CAN ONLY BE CAUSED BY A FAULTY ACFT STARTER SWITCH OR RELAY. MOST STARTER RELAYS ARE AIRFRAME PARTS NOT REPLACED AT O/H OR REPAIR OF ENGINE AND STARTER. IF STARTER ADAPTER FAILURE OCCURS, RECOMMEND TROUBLESHOOTING AND FAILURE ANALYSIS OF ENTIRE ACFT STARTING SYS TO DETERMINE THE ROOT CAUSE(S) IN ORDER TO PREVENT RECURRENCE OF THE FAILURE. RECOMMEND ACFT STARTER RELAY REPLACEMENT EVERY 10 YEARS OR 3,000 HOURS OR EVERY SECOND ENGINE CHANGE, WHICHEVER COMES FIRST, AND WHENEVER STARTER ADAPTER FAILURE OR STARTER MOTOR FAILURE OCCUR. RELAY INSP CRITERIA SHOULD INCLUDE MINIMUM LIMITS FOR SPRING FORCE AND CONTACT GAP.

DD2RW900001

CESSNA

CONT

CONT

CLUTCH SPRING

OVERHEATED

4/29/2010

340A

TSIO520NB

 

AS539800M30

STARTER

((DD2R)) NEWLY O/H'D STARTER ADAPTER FAILED APPROX 5 HOURS AFTER INSTALLATION. DISASSEMBLY & FAILURE ANALYSIS OF UNIT REVEALED OVERHEATED AND MANGLED CLUTCH SPRING. SPRING HAD A COLLAPSED COIL THAT HAD WOUND AROUND THE SHAFTGEAR MINOR DIAMETER BETWEEN CLUTCH DRUM AND INTEGRAL SPUR GEAR. COLLAPSED COIL HAD OVERHEATED THE SHAFTGEAR SO SEVERELY THAT IT TWISTED IN TWO. MANGLED CLUTCH SPRINGS AND SEPARATED SHAFTGEARS MAKE IN-FLIGHT ENGINE RE-START IMPOSSIBLE. BOTH CAUSE SIGNIFICANT OIL CONTAMINATION. SHAFTGEAR SEPARATION STOPS OPERATION OF TURBOCHARGER SCAVENGE PUMP, COULD CAUSE LOSS OF OIL PAST TURBOCHARGER SEALS, POSSIBLE ENGINE OIL STARVATION. A SEPARATED SHAFTGEAR COULD DAMAGE CRANKCASE PILOT BRG AND CAM/CRANK GEAR TEETH, POSSIBLE ENGINE POWER LOSS. STRONGLY SUSPECT STARTER MOTOR RUN-ON AFTER ENGINE START. STARTER RUN-ON CAN ONLY BE CAUSED BY A FAULTY ACFT STARTER SWITCH OR RELAY. MOST STARTER RELAYS ARE AIRFRAME PARTS NOT REPLACED AT O/H OR REPAIR OF ENG AND STARTER. IF STARTER ADAPTER FAILURE OCCURS, WE RECOMMEND TROUBLESHOOTING AND FAILURE ANALYSIS OF ENTIRE ACFT STARTING SYS TO DETERMINE THE ROOT CAUSE(S) IN ORDER TO PREVENT RECURRENCE OF THE FAILURE. RECOMMEND THAT THE ACFT STARTER RELAY BE REPLACED EVERY 10 YEARS OR 3,000 HOURS OR EVERY SECOND ENGINE CHANGE AND WHENEVER STARTER ADAPTER FAILURE OR STARTER MOTOR FAILURE OCCUR. RELAY SERVICE INFO SHOULD INCLUDE MINIMUM SPRING FORCE AND CONTACT GAP. THIS IS FOURTH SUCH FAILURE SEEN.

UVVR2010060900012

CESSNA

 

 

SKIN

CORRODED

6/9/2010

425  

 

 

591200017S26

ZONE 100

(UVVR) EXTERIOR SIDE OF FUSELAGE BOTTOM SKINS CORRODED FS 307.94 - FS 316.94, BL2L TO BL3R. FOUND UPON REMOVAL OF STORMSCOPE ANTENNA, MM, ZONE 311 &N 312.

UVVR2010060900013

CESSNA

 

 

SKIN

CORRODED

6/9/2010

425  

 

 

511130358

ZONE 200

(UVVR) EXTERIOR SIDE OF OF FUESELAGE, TOP SKIN CORRODED FS 200.75 TO FS 212.87, BL6R TO BL9.5R. FOUND UPON REMOVAL OF VHF COMMUNICATIONS ANTENNA, MM, ZONE 252.

UVVR2010060700009

CESSNA

PWA  

 

FITTING

CRACKED

6/7/2010

425  

PT6A60

 

59510483

ENGINE MOUNT

RT ENGINE INBD ENGINE MOUNT FITTING WAS FOUND CRACKED APPROX .30 INCHES IN LENGTH DURING INSPECTION.

UVVR2010060700010

CESSNA

PWA  

 

FITTING

CRACKED

6/7/2010

425  

PT6A60A

 

59510482

ENGINE MOUNT

RT ENGINE OTBD ENGINE MOUNT FITTING WAS FOUND CRACKED APPROX .20 INCHES IN LENGTH DURING INSPECTION.

UVVR2010060800011

CESSNA

PWA  

CESSNA

FORK

CRACKED

6/7/2010

425  

PT6A60A

 

58420005

NLG STRUT

((UVVR)) WHILE PERFORMING SUPPLEMENTARY INSPECTION DOCUMENT NR 32-20-02 A .25" CRACK WAS FOUND IN THE RT AXLE BORE OF THE NLG FORK ASSY.

UVVR2010060200008

CESSNA

PWA  

 

SKIN

CORRODED

6/2/2010

425  

PT6A60A

 

51220032AND59221

ZONE 600

((UVVR)) RT OTBD WING L/E SKIN CORRODED UNDER AERODYNAMIC FILLER AT SKIN SPLICE SEAM JUST OTBD OF NACELLE STRUCTURE. CORROSION IS AT LEVEL 3. IT APPEARS THAT MOISTURE HAS SEEPED UNDER DEICE BOOT AT SKIN SPLICE SEAM WHERE THE 2 SECTIONS OF L/E ARE SPLICED TOGETHER.

2010FA0000520

CESSNA

CONT

 

STARTER

BROKEN

6/1/2010

A185F

IO520*

 

C12ST3

ENGINE

STARTER HAS A PARTIAL SEPARATION BETWEEN THE HOUSING THAT ATTACHES TO THE STARTER ADAPTER AND THE MAIN STARTER HSG. EXTERIOR BOLTS THAT SECURE THE HSGS TOGETHER ARE INTACT AND TIGHT. PILOT REPORTED STARTING DIFFICULTY. PROBLEM WAS VISIBLY OBVIOUS. STARTER WAS REPLACED.

V0XR201006090001

DHAV

 

 

THRESHOLD

CORRODED

6/9/2010

DHC8106

 

 

8532686101

ZONE 100

(V0XR) PASSENGER DOOR SILL THRESHOLD IS CORRODED BEYOND LIMITS. R & R THRESHOLD. W/C 8031

V0XR201006030001

DHAV

 

 

FLOOR SUPPORT

CORRODED

6/3/2010

DHC8106

 

 

85330217007

ZONE 100

(V0XR) LT FLOOR TRACK AT STA 589.5. CORRODED BEYOND LIMITS. R & R FLOOR TRACK. W/C 1086

V0XR201006030002

DHAV

 

 

FLOOR SUPPORT

CORRODED

6/3/2010

DHC8106

 

 

85330217007

ZONE 100

(V0XR) LT FLOOR TRACK AT STA 589.5. IS CORRODED BEYOND LIMITS. R & R FLOOR TRACK. W/C 1086

V0XR20100607001

DHAV

PWA  

 

DOOR FRAME

CRACKED

6/8/2010

DHC8311

PW123

 

85330272103

BS 607

(V0XR) FWD LOWER CARGO DOOR FRAME X.607.00 CRACKED. R & R LOWER CARGO FRAME.

U43R2010AF0000189

DIAMON

LYC  

 

PUMP

FAILED

6/7/2010

DA40

IO360M1A

 

5100009

FUEL BOOST

2ND PREFLIGHT OF THE MORNING, CREW PREFORMED A FUNCTION CHECK OF THE ELECTRIC FUEL PUMP. INTERNAL FAILURE OF THE FUEL PUMP WAS THE CAUSE.

U43R2010FA0000188

DIAMON

LYC  

 

STARTER

FAILED

6/2/2010

DA40

IO360M1A

 

14924LS

ENGINE

STARTER HAD WORKED FOR 2 STARTS EARLIER IN THE DAY. THE 3RD FLIGHT ATTEMPT, THE STARTER DIDN'T WORK AT ALL. CHECKED CONNECTIONS THEY WERE TIGHT. HAD PLENTY OF VOLTAGE INDICATED. PROBLEM APPEARS TO BE IN THE STARTER. ITS UNDER WARRANTY RETURNED TO THE MFG. REPLACEMENT STARTER WORKED FINE.

U43R2010AF0000187

DIAMON

LYC  

 

PUMP

FAILED

5/20/2010

DA40

IO360M1A

 

5100009

FUEL SYSTEM

(U43R) DURRING 1ST PRE-FLIGHT OF THE DAY. CREW PERFORMED A FUNCTION CHECK OF THE FUEL PUMP, NO INDICATION OF ANY OPERATION AT ALL ON THE MFD OR ANY SOUND OF OPERATION.

2010FA0000598

GULSTM

LYC  

 

CAMSHAFT

BROKEN

5/15/2010

112  

IO360C1D6

 

AEL18840

ENGINE

PILOT STATED THE ENGINE BECAME ROUGH AFTER TAKEOFF. RETURNED TO AIRPORT & LANDED. FOUND NR 1 CYLINDER TO BE COLDER THAN REST. PULLED ROCKER COVER & NOTED THE VALVES WERE NOT MOVING WHEN ROTATING ENGINE. PULLED ROCKER ARMS & PUSHRODS BUT FOUND NO PROBLEMS. REMOVED ENGINE FROM ACFT & BROUGHT TO REPAIR STATION. REMOVED A CYLINDER & FOUND CAMSHAFT BROKEN. DISASSEMBLED REMAINDER OF ENGINE. VALVES MOVED FREELY IN GUIDES & NO OTHER UNUSUAL PROBLEMS NOTED WITH ENGINE. CAMSHAFT INSTALLED NEW 236.48 HOURS PREVIOUSLY WITH NEW 72877 LIFTERS. CAMSHAFT IS BROKEN ABOUT 3 3/4" FROM FORWARD END. THE FRACTURE APPEARS TO ORIGINATE AT THE BASE OF LETTERS E AND L OF THE METAL STAMPED PART NUMBER, FORWARD OF THE NR 1 & 2 INTAKE LOBE. RECOMMEND THAT THE PART NUMBER BE APPLIED TO THE PART BY A METHOD OTHER THAN METAL STAMPING.

2010F00131

GULSTM

LYC  

LYC  

CYLINDER

SEPARATED

6/2/2010

680FL

IGSO540B1A

 

O5K21269

NR 5 

FAILURE OF LOWER UNIT CYL NR 5, SEPARATED FROM CRANKCASE.

AMCR201002

GULSTM

 

 

TIRE

BULGED

5/26/2010

GIV  

 

 

217K221

NLG 

(AMCR) DURING POSTFLIGHT INSPECTION, MX FOUND A BULGE ON THE LT NOSE TIRE. THE BULGE WAS ABOUT 1 INCH DIAMETER AND EXTENDED OUT .2500 INCH. THE BULGE WAS LOCATED ON THE SIDEWALL JUST BELOW THE TREAD CAP.

AMCR201005

GULSTM

 

 

ELBOW

CRACKED

6/10/2010

GIVG400

 

 

MS21908D6

FUEL SYSTEM

DURING PILOT'S POST-FUELING WALKAROUND INSPECTION, FUEL WAS OBSERVED DRIPPING FROM THE WHEEL WELL KEEL BEAM AREA. MX FOUND A CRACKED ALUMINUM ELBOW ON THE APU FUEL SHUTOFF VALVE LOCATED IN THE WHEEL WELL. CRACK WAS LOCATED ON THE SHORT LEG OF THE ELBOW EXTENDING FROM THE END OF THE OPENING DOWN TO INNER SHOULDER. THIS WAS AN ORIGINAL FACTORY INSTALLATION. RECOMMEND MFG USE STEEL FITTINGS FOR FLAMMABLE FLUID LINES.

AMCR201004

GULSTM

 

 

TIRE

OUT OF ROUND

6/3/2010

GV  

 

 

217K221

ZONE 700

(AMCR) DURING TAKEOFF AND LANDING, CREW REPORTED A NOSE GEAR SHIMMY. MX FOUND THE LT NOSE TIRE TO BE OBLONG-OUT OF ROUND. THERE WAS NO UNUSUAL WEAR OR FLAT SPOTS ON TIRE. MX REPLACED WHEEL ASSY.

EVGR060210

HELIO

LYC  

 

FIRE DETECTOR

CHAFED

6/2/2010

H295

GO480G1D6

 

 

ZONE 400

(EVGR) THE FIRE DETECTION LOOP IN THE ENGINE COMPARTMENT CHAFED AGAINST SCAT TUBE CAUSING INTERMITTENT ALARM. THE UNIT IS FIRE DETECTION SYSTEM INSTALLED UNDER STC SA1586SO.

2010FA0000519

HUGHES

ALLSN

 

WARNING LIGHT

FALSE ACTIVATION

5/29/2010

369E

250C20B

 

 

ENG CHIP DETECT

PILOT EXPERIENCED AN ENGINE CHIP LIGHT DURING A TOUR FLIGHT AND PROCEEDED TO LAND AT AN OFFSITE AIRPORT. MX ARRIVED ON SCENE AND FOUND THAT THE LIGHT WAS NO LONGER ON. THE MECHANIC INSPECTED UPPER AND LOWER ENGINE CHIP DETECTORS AND FOUND NO EVIDENCE OF METAL. WIRING AND CONNECTOR PLUGS WERE INSPECTED BUT PROBLEM COULD NOT BE DUPLICATED. ACFT WAS RETURNED TO SERVICE

2010FA0000518

LKHEED

WRIGHT

 

ARM  

BROKEN

5/15/2010

P2V7

R3350*

 

428409

SPOILERS

((NI6R)) FOUND THAT AT FULL AILERON DEFLECTION AND DESCENT SPOILERS DEPLOYED, WHEN ROLLING AILERONS OUT OF FULL TRAVEL BINDING OCCURED BETWEEN PN 428409 AND PN 428414, CAUSING FAILURE OF PN'S 428409 AND 428410. THIS RENDERS THE ROLL AND DESCENT SPOILERS INOPERATIVE AND DOES NOT EFFECT AILERON TRAVEL. THIS PROBLEM WAS DISCOVERED FOLLOWING ANNUAL MX, UPON INVESTIGATION DISCOVERED THAT THE PROBLEM WAS CAUSED BY THE LACK OF CLEARANCE BETWEEN THE PREVIOUSLY MENTION PARTS AT THE FULL TRAVEL LIMITS. DESCENT SPOILER SYS WAS INSTALLED BY 337 IN 2004 AND PROVIDES A MEANS OF DEPLOYING THE ROLL SPOILERS SIMULTANEOUSLY TO AID IN SLOWING THE ACFT. DEVELOPED AND INSTALLED A SIMILAR SYS IN 2002 AND FOUND THIS PROBLEM AND CORRECTED BY MEANS OF A MOD TO PN 428409 THAT ALLOWS FOR CLEARANCE BETWEEN THE 2 PARTS AT FULL TRAVEL. WE HAVE DISSABLED THE DESCENT SPOILER SYS BY PULLING AND LOCKING OUT THE CONTROL CIRCUIT BREAKERS FOR THE DESCENT SPOILER SYS. THIS LEAVES THE ROLL CONTROL SPOILERS FULLY OPERATIONAL. WE HAVE SUBMITTED PAPERWORK TO THE DENVER ACO TO REFIT THIS ACFT WITH THE DESCENT SPOILER SYS.

2010FA0000517

LKHEED

WRIGHT

 

SPOILER SYS

BROKEN

5/15/2010

P2V7

R3350*

 

428409

ZONE 600

((NI6R)) FOUND THAT AT FULL AILERON DEFLECTION AND DESCENT SPOILERS DEPLOYED, WHEN ROLLING AILERONS OUT OF FULL TRAVEL BINDING OCCURRED BETWEEN P/N 428409 AND P/N 428414, CAUSING FAILURE OF PN'S 428409 AND 428410. THIS RENDERS THE ROLL AND DESCENT SPOILERS INOPERATIVE AND DOES NOT EFFECT AILERON TRAVEL. THIS PROBLEM WAS DISCOVERED FOLLOWING ANNUAL MX, UPON INVESTIGATION DISCOVERED THAT THE PROBLEM WAS CAUSED BY THE LACK OF CLEARANCE BETWEEN THE PREVIOUSLY MENTION PARTS AT THE FULL TRAVEL LIMITS. THE DESCENT SPOILER SYS WAS INSTALLED BY 337 IN 2004 AND PROVIDES A MEANS OF DEPLOYING THE ROLL SPOILERS SIMULTANEOUSLY TO AID IN SLOWING THE ACFT. OPERATOR DEVELOPED AND INSTALLED A SIMILAR SYSTEM IN 2002 AND FOUND THIS PROBLEM AND CORRECTED BY MEANS OF A MOD TO PN 428409 THAT ALLOWS FOR CLEARANCE BETWEEN THE 2 PARTS AT FULL TRAVEL. WE HAVE DISABLED THE DESCENT SPOILER SYS BY PULLING AND LOCKING OUT THE CONTROL CIRCUIT BREAKERS FOR THE DESCENT SPOILER SYS. THIS LEAVES THE ROLL CONTROL SPOILERS FULLY OPERATIONAL. WE HAVE SUBMITTED PAPERWORK TO THE DENVER ACO TO REFIT THIS ACFT WITH THIS OPERATORS’ DESCENT SPOILER SYSTEM.

5APR577Y38

PILATS

PWA  

 

SKIN

CRACKED

5/25/2010

PC1247

PT6A67B

 

5553012038

VERTICAL STAB

DURING AN ANNUAL INSPECTION, DISCOVERED A 46MM LONG CRACK IN THE SKIN ON THE RT SIDE OF THE VERTICAL STABILIZER. THE CRACK IS ROUGHLY 55MM FROM THE TOP OF THE SKIN AND 250MM FWD OF THE REAR END OF THE SKIN. SUBMITTED A DEFECT REPORT TO THE MFG AND RECEIVED AN EASA APPROVED REPAIR MEMO TO REMOVE THE SECTION OF CRACKED SKIN AND INSTALL A DOUBLERS.

5APR577Y39

PILATS

PWA  

 

BRAKE DISC

BROKEN

6/1/2010

PC1247

PT6A67B

 

244759C

ZONE 700

((5APR)) DURING A LINE CHECK THE LT BRAKE OTBD BRAKE DISC WAS DISCOVERED BROKEN INTO 4 PIECES. REMOVED DEFECTIVE BRAKE AND INSTALLED (CLEVELAND) MAIN WHEEL AND BRAKE CONVERSION KIT 199-241 ON BOTH MAIN GEAR IAW STC SA01376CH.

2010FA0000521

PIPER

CONT

 

CONTROL CABLE

BROKEN

6/2/2010

J3C*

O200A

 

 

ZONE 400

ACFT MADE AN EMERGENCY LANDING DUE TO POWER LOSS DURING FLIGHT. WEATHER WAS CONDUCIVE TO CARBURETOR ICING.

2010FA0000529

PIPER

LYC  

 

TORQUE LINK

BROKEN

6/8/2010

PA28180

O360*

 

633066

LT MLG

LT MLG TORQUE LINK BROKE ABOUT 1" BELOW UPPER MOUNT AFTER LANDING. TORQUE LINK WAS SENT TO NTSB FOR TESTING WITH THE FOLLOWING REPORT. THE FATIGUE ORIGIN AREAS CONTAINED NO EVIDENCE OF GOUGE DAMAGE OR CORROSION DAMAGE. ON ONE SIDE OF THE LINK THE FATIGUE CRACK EXTENDED APPROX THROUGH 40 PERCENT OF THE WALL AND ON THE OTHER SIDE THE FATIGUE CRACK EXTENDED THROUGH APPROX 30 PERCENT OF THE WALL.

2010FA0000526

PIPER

LYC  

 

OIL COOLER

FAILED

6/7/2010

PA28236

O540*

 

8000074

ENGINE

NEW OIL COOLER INSTALLED FAILED WITH ONLY A TOTAL OF 29 CUMMLATIVE HOURS AT THE BRAZE WELD OF THE CASING.

2010FA0000527

SOCATA

 

 

BRACKET

CRACKED

6/7/2010

TBM700

 

 

 

FUSELAGE

ATTEMPTING TO START USING A GPU, GPU WAS WORKING NORMAL AND HAD LIGHT OFF OF THE FUEL, ELECTRIC SYS WENT DEAD. THEN IT CAME BACK ON, CONTINUING TO TURN THE STARTER. QUICKLY TURNED OFF THE IGNITION SWITCH AND FUEL CUTOFF. NO HOT START, TEMPS GOT UP HIGH 300'S. ASSUMED THE FBO'S GPU DIED. HOOKED UP ANOTHER GPU. 2ND GPU STILL NOTHING, DID A NORMAL BATTERY START AND GOT TO OUR DESTINATION. ON OUR NEXT FLT, GPU HOOKED UP TO START, IT WOULD NOT POWER SHIP. JIGGLED GPU POWER CABLE AND PUSHED IT IN TO MAKE SURE IT HAD GOOD CONTACT AND POWER CAME UP. GPU WORKED FINE UP UNTIL THE STARTER MOTOR ON, AND NO POWER. A BROKEN GROUNDING STRAP THAT CONNECTS TO FIREWALL, BRACKET ATTACHED TO THE FIREWALL CRACKED AND ARCED ELECTRICITY FROM GPU, THROUGH STRAP. VIBRATION MAY HAVE CRACKED THE BRACKET.