3/26/03

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
2005FA0000035				LIFE VEST	FAILED
12/16/2004				GA12P0201	CABIN
INDIVIDUAL FLOAT DEVICE FAILED CELL PRESSURE TEST DUE TO INFLATION VALVE RUPTURE. DOM: NOV 1981.
CA040629002		ALLSN		BEARING	FAILED
6/29/2004		AE3007C			NR 4
(CAN) DURING CRUISE AT 43,000 FT, CREW RECEIVED CHIP DETECTOR MESSAGE, FOLLOWED BY AN OIL FILTER BYPASS MESSAGE ON THE RT ENGINE. A/C WAS BEING FLOWN FOR MAINTENANCE VISIT TO THE MFG SERVICE CENTER. CREW ELECTED TO CONTINUE F LIGHT AFTER RECEIVING THE ABOVE MESSAGES. 15 MINUTES AFTER RECEIVING THE OIL FILTER BYPASS MESSAGE, OIL PRESSURE BEGAN TO DROP AND THE CREW ELECTED TO SHUTDOWN THE ENGINE. CREW ELECTED TO CONTINUE SINGLE ENGINE FLIGHT TO DESTINATION. INITIAL INVESTIGATION INDICATES A NR 4 BEARING FAILURE. ENGINE SENT TO FOR REPAIR, FURTHER DETAIL WILL BE SUBMITTED UPON DISASSEMBLY OF ENGINE.
C7GR861J		LYC	HONEYWELL	MANIFOLD	MISINSTALLED
8/20/2004		LTS101750B1		419110003	PT MODULE
LTS101-750B-1 ENGINE, SN: LE-48166BEF WAS RECEIVED BY THIS REPAIR STATION (CRS NR C7GR861J) FOR ROUTINE MAINTENANCE. SINCE WE HAD RECEIVED SOME NEW MANIFOLD ASSEMBLIES WITH IMPROPERLY TORQUED BOLTS (16 EA) THAT SECURE EIGHT COVERS ON THE INJECTOR BLOCKS, DECIDED TO PERFORM A TORQUE CHECK ON THIS FUEL MANIFOLD (TSN = 900 HRS). BREAKAWAY TORQUES AS LOW AS 18 IN/LB WAS OBSERVED. THE PROPER TORQUE IS 40-45 IN/LB. THIS CONDITION HAS BEEN REPORTED TO HONEYWELL, PHOENIX FOR PROPER INVESTIGATION AND RESOLUTION.
CA040415006		PWA		ENGINE	DAMAGED
4/2/2004		PT6A28
ENG REMOVED AFTER A/C DRIFTED TO LT SIDE OF RWY & HIT A 4 FT SNOWBANK. NLG COLLAPSED & ENG HIT BANK AT MAX PWR. EXHAUST DUCT & GG CASE HAD OUTER SKIN BUCKLING. 2ND STAGE REDUCTION PLANET GEAR CARRIER BENT, PT RUB DAMAGE ON BLADE TIPS. COMP BLADES, STATORS & IMPELLER RUB DAMAGE. PT DISK DISPLACED, COMPRESSOR RUB DAMAGE GG CASE. RGB OIL PRESS XFER TUBE BENT & CONNECTING ELBOW BROKEN. IN TEST CELL, DURING TEST FOUND ENG PERFORMANCE ACCEPTABLE, BUT A LOUD RUB NOISE HEARD ON RUNDOWN, TRACED TO WORN SPLINES ON RGB HOUSING. CHANGED HOUSING. REMOVED FROM CELL TO INVEST 2ND STAGE GEARING, FOUND REAR FACE OF 2ND STAGE CARRIER DISTORTED. CARRIER CHANGED, ENG TESTED. NO ADVERSE NOISES ON SHUTDOWN, ENG DECLARED SERVICEABLE.
TXER096384	AEROSP			SERVO	BINDING
7/13/2004	AS355*			SC5072	TAIL ROTOR
TAIL ROTOR SERVO IS BINDING.
I05R098769	AEROSP			PRESSURE SWITCH	FAILED
8/25/2004	AS355*			MA12401	HYD SYSTEM
PRESSURE SWITCH FAILED IN 3 HRS OF OPERATION. REPLACED PART.
CA040811008	AEROSP	ALLSN		BLOWER	DAMAGED
8/5/2004	AS355F1	250C20F		355A340109	OIL COOLER
(CAN) DURING OPERATION A NOISE WAS HEARD FROM THE BACK OF THE AIRCRAFT, AIRCRAFT WAS LANDED AND DURING INSPECTION TO DETERMINE THE ORIGIN OF THE SOUND IT WAS NOTED THAT THE OIL COOLER BLOWER ASSY WAS DAMAGED AND HAD SEVERAL PIECES MISSING. THE AIRCRAFT WAS RETURNED TO BASE BY ROAD AND WAS DISASSEMBLED TO THE EXTENT REQUIRED TO INSPECT FOR OTHER DAMAGE. ONCE THE BLOWER WAS REMOVED IT WAS NOTED THAT THE FIRST STAGE OF THE ASSY HAD 2 SMALL NICKS ON 2 OF THE ROTATING BLADES. THE FIRST STAGE STATOR CASE, THE SECOND STAGE ROTATING AND STATIONARY COMPONENTS HAD EXTENSIVE DAMAGE AND WERE FOUND IN SEVERAL PIECES. SUSPECT DAMAGE COULD HAVE BEEN CAUSED BY FOD.
CA050117011	AEROSP	PWA		TURBINE BLADES	DAMAGED
1/13/2005	ATR42*	PW120			ENGINE
(CAN) DURING CRUISE THE PILOT REPORTED A (PUFF) FROM THE ENGINE ACCOMPANIED BY A LOSS OF TORQUE. POWER LEVER ADVANCEMENT RESULTED IN ENGINE TEMPERATURE INCREASE AND AN OIL SMELL AND SMOKE IN THE CABIN. THE ENGINE WAS SHUT DOWN, AN EMERGENCY DECLARED AND THE FLIGHT DIVERTED. SUBSEQUENT INSPECTION REVEALED DAMAGED TURBINE BLADES. MFG WILL INVESTIGATE THE INCIDENT AND SUPPLEMENT THIS REPORT TO PROVIDE ROOT CAUSE, ONCE ESTABLISHED.
CA040810003	AEROSP	PWA		O-RING	FAILED
8/7/2004	ATR42300	PW120			HYD SYSTEM
(CAN) ENROUTE, (GREEN SYS) LOW LEVEL PRESS INDICATION OBSERVED. THE CREW ACCOMPLISHED THE CHECK LIST AND CONTINUED TO YZF. THE AIRCRAFT LANDED WITHOUT INCIDENT AND WAS TOWED FROM THE RUNWAY. THE O-RING AND BACK-UP RING AT THE ACCUMULATOR FITTING WERE REPLACED, THE AIRCRAFT WAS LEAK CHECKED AND RETURNED TO SERVICE.
CA050119008	AEROSP	PWA		PROBE	STICKING
1/3/2005	ATR42300	PW120			ANGLE OF ATTACH
(CAN) AFTER DEPARTING, THE CREW OBSERVED A STICK SPURRIOUS SHAKER WARNING. THE AIRCRAFT RETURNED TO POINT OF DEPARTURE. THE ANGLE OF ATTACK PROBE WAS FOUND TO BE STICKING, MAINTENANCE LURICATED THE PROBE AND THE SYSTEM WAS CHECKED SERVICEABLE. THE AIRCRAFT WAS RETURNED TO SERVICE.
CA041124011	AEROSP	PWA		DRIVE ASSY	FRACTURED
11/10/2004	ATR72	PW124B			GEARBOX
(CAN) DURING CRUISE, ENGINE OIL PRESSURE DROPPED TO ZERO FOLLOWED BY AN UNCOMMANDED ENGINE SHUTDOWN. A SINGLE ENGINE LANDING WAS CARRIED OUT AT DESTINATION. SUBSEQUENT INVESTIGATION HAS EVIDENCED A FRACTURED (ACCESSORY GEARBOX DRIVE) TOWERSHAFT. PWA WILL INVESTIGATE THE EVENT AND REVISE THIS REPORT TO REFLECT ROOT CAUSE, ONCE DETERMINED.
CA041122014	AEROSP	PWA		ENGINE	FAILED
10/26/2004	ATR72	PW124B			LEFT
(CAN) DURING CRUISE, PROPELLER SPEED DECREASED ACCOMPANIED BY MASTER WARNING AND CCAS+LOW ALERTS. THE CREW SECURED THE ENGINE, DECLARED PAN PAN AND COMPLETED A SING LT ENGINE LANDING AT DESTINATION. MFG WILL MONITOR THE INVESTIGATION AND AMEND THIS REPORT TO REFLECT ROOT CAUSE ONCE DETERMINED.
TL9R200500002	AIRBUS			BRAKE	MAKING METAL
1/20/2005	A300*			C200601004	MLG
OUR REPAIR SHOP REPORTS THAT THE ROTORS IN THIS BRAKE PN HAVE A HISTORY OF FALLING APART. WHEN THIS HAPPENS, DAMAGE TO THE TORQUE TUBE CAN OCCUR WHICH WILL SEVERELY DEGRADE THE PERFORMANCE OF THE BRAKE.
TL9R200500001	AIRBUS			BRAKE	MAKING METAL
1/20/2005	A300*			C200601004	MLG
OUR REPAIR SHOP REPORTS THAT THE ROTORS IN THIS BRAKE PN HAVE A HISTORY OF FALLING APART. WHEN THIS HAPPENS, DAMAGE TO THE TORQUE TUBE CAN OCCUR WHICH WILL SEVERELY DEGRADE THE PERFORMANCE OF THE BRAKE.
CA040630005	AIRBUS	GE		FITTING	LOOSE
6/29/2004	A310304	CF680C2*		A5784365500400	PRESSURE LINE
(CAN) ON FINAL APPROACH, WHEN FLAP/SLAT WERE EXTENDED, THE HYDRAULIC RESERVOIR LOW LEVEL ECAM WARNING CAME ON. AIRCRAFT OVERSHOT AND CHECKLIST PROCEDURE INDICATE A FAILURE OF GREEN HYDRAULIC SYSTEM. ALTERNATE GEAR EXTENSION PERFORMED. DURING INVESTIGATION, FOUND THE GREEN SYSTEM PRESSURE LINE FITTING LOOSE ON THE RT KRUGER FLAP ACTUATOR. LINE TIGHTENED AND SYSTEM WAS VERIFIED SERVICEABLE IAW THE MM.
CA041202002	AIRBUS	CFMINT		SELECTOR VALVE	FAILED
12/2/2004	A319114	CFM565A1		114079016	MLG
(CAN) FAULT: AFTER T/O AND GEAR UP, NR 1 LGCIU ECAM MSG ON. ALSO DURING A GO-AROUND AFTER GEAR SELECTED UP, MASTER (RED) WARNING CAME ON WITH MSG. (GEAR DISAGREEMENT) DURING APROX. 10 SEC.ACTION: MLG DOOR SEL VALVE REPLACED IAW MM 32-31-34. FUNCTIONAL CHECK CARRIED OUT OK, LEAK CHECK C/OUT SERVICE.
CA041203002	AIRBUS	GE		CONTROL VALVE	INOPERATIVE
12/3/2004	A319114	CFM565A		C24736001	NLG STEERING
(CAN) IN CRUISE, WHEEL NOSE WHEEL STEERING FAULT . TRIED RESET ANTI-SKID /NW STEERING SWNO FIX. NO NW STEERING ON LANDING. TOWED TO GATE. TESTED BSCU 1 AND 2 FAULTED NLG STEERING SERVO FTN 6GC. IAW TSM AND AMM REPLACED NLG STEERING SERVO FTN 6GC. OPERATION TEST PERFORMED BSCU 1 AND 2 TESTED, NO FAULTS.
CA040615001	AIRBUS	CFMINT		CONTROL UNIT	FAILED
6/15/2004	A320211	CFM565A1			TE FLAPS
(CAN) FAULT: ON FINAL APPROACH, WHEN FLAP 1 SELECTED, ONLY SLATS CAME OUT. NO FLAPS, RECYCLED TWICE NOJOY. SLATS ONLY LANDING CARRIED OUT. ACFT OUT OF SERVICE FOR INVESTIGATION. COMMENTS: FURTHER INFO WILL FOLLOW.
CA050111002	AIRBUS	CFMINT		SERVO	INTERMITTENT
1/11/2005	A320211	CFM565A1			SPOILER
(CAN) FAULT: JUST PRIOR TAKE-OFF, FLIGHT RECEIVED A FLT CTL SPOILER 1 FAULT. CREW TAXIED ONTO A TAXIWAY AND PERFORMED A SUCCESSFUL RESET. HOWEVER, AT 3000 FT/210 KNOTS ON CLIMB, THE FAULT RETURNED AGAIN. FURTHER INTO THE FLIGHT IN CRUISE SLAT SYSTEM. ACTION: ACFT OUT OF SERVICE FOR INVESTIGATION.
CA040412006	AIRBUS	CFMINT		ENGINE	BIRD INGESTION
4/12/2004	A320211	CFM565A1			NR 1
(CAN) FAULT: HIT 2 GEESE ON T/O HIGH SPEED REJECTED RETURNED TO GATE. FOUND EVIDENCE OF BIRD INGESTION AT NR 1 ENG. SEVERAL DAMAGED BLADES, A/C ROUTED TO HANGAR FOR ENGINE BOROSCOPE.
CA040812004	AIRBUS	CFMINT	BFGOODRICH	BOLT	BROKEN
6/20/2004	A320214	CFM565B4	31530	431304	MLG WHEEL
(CAN) ON WALK AROUND PILOT FOUND 2 TIE BOLTS (P/N 43-1304) BROKEN ON THE NR 1 MAINWHEEL ASSY, TOTAL CYCLES ON MAIN WHEEL ASSY SINCE LAST RE-FURB 427, TOTAL TIME ON TIE BOLTS UNKN.
CA041102001	AIRBUS	RROYCE		BOLT	SHEARED
11/2/2004	A330*	RB211TRENT77		NAS6605D136	RT MLG
(CAN) MSN 419 WAS UNDERGOING A C2 CHECK IN YUL. IN PREP FOR DOING A SEAL CHANGE ON RT MLG MAINT DISCOVERED SM9 PIN MIGRATED APPROX. 1INCH OUT IN THE IB DIRECTION. GEAR WAS SPLIT,AND IT WAS DISCOVERED THAT THE SM9 PIN RETENTION BOLT (NAS6605D136) HAD SHEARED AT THE HEAD. THE BOLT RETAINS THE PIN END CAPS. CAMPAIGN NR 9-0066 WAS LAUNCHED ON NOV 1 2004 TO INSPECT ALL ACFT IN FLEET A330/A340.
2004FA0000908	AMD	GARRTT		HOSE	COLLAPSED
10/14/2004	FALCON10	TFE73121C		FAL1005D	ANTI-ICE SYS
DURING ENGINE RUN-UP, PHYSICALLY CHECKED LEADING EDGE FOR HEAT AND FOUND COLD. RT IB ANTI-ICE FLEXHOSE WAS REMOVED AND VISUALLY INSPECTED. FOUND THE INNER LINING HAD COLLAPSED, BLOCKING AIRFLOW THROUGH HOSE. HOSE WAS REPLACED WITH NEW. FAULTY HOSE WAS MARKED "3Q01". THIS FLEXHOSE, P/N FAL1005D, IS REFERENCED IN DASSAULT SERVICE BULLETIN F10-A246. THIS HOSE WAS LAST REPLACED ON 4/22/2003 AT 6213.2 HRS TTAF AND 5458 TOTAL LANDINGS BY CRS# BONR551C.
2005FA0000072	AMD	GARRTT		AUDIO CONTROL	INOPERATIVE
7/15/2004	FALCON50MYST	TFE73140		9903333142	COCKPIT
FLIGHT CREW REPORTED ACRID SMELL IN THE COCKPIT ON APPROACH TO LANDING. NR 2 VHF COMM NOT FUNCTION REPORTED BY FLIGHTCREW. INSPECTION DID CONFIRM NR 2 COMM TRANSCEIVER WAS INOPERATIVE. REMOVED AND REPLACED WITH SERVICEABLE UNIT. ADDITIONAL TROUBLESHOOTING AND INSPECTION TO AIRFRAME AND AVIONICS RELATED COMPONENTS DID REVEAL THE AUDIO CONTROL PANEL (PN990-3333-142) NR 2 VHF COMM TRANSCEIVER. AUDIO CONTROL PANEL RETURNED FOR INSPECTION, REPAIR AND RETURNED TO SERVICE. (NM01200501124) (K)
2004FA0000888	AMRGEN	LYC		CABLE	WORN
7/13/2004	AG5B	O360*		A9200410	THROTTLE
SWEDGED-IN PORTION OF THE CABLE GUIDE DISPLAYED .110 INCH FORE AND AFT PLAY INDICATING IMPENDING FAILURE OF THE SWIVEL JOINT. CABLE WAS REMOVED AND GIVEN FOR EVALUATION. THIS CONDITION WAS APPARENTLY CAUSED BY DIRT CONTAMINATION. (THE PROTECTIVE RUBBER BOOT OVER THE SWIVEL JOINT HAD CRACKED, ALLOWING DIRT CONTAMINATION OF THE JOINT.) THIS SUBMITTER RECOMMENDS THAT THE THROTTLE CABLE SWIVEL JOINT AND ITS RUBBER BOOT BE CLOSELY INSPECTED AT EACH 100 HOUR AND/OR ANNUAL INSPECTION TO PREVENT EXCESSIVE WARE AND SUBSEQUENT FAILURE OF THE THROTTLE CABLE. (EA07NEL200405197)
2004FA0000600	AMTR			FORK	BROKEN
6/14/2004	AEROSTARBIRD				NLG
THE PILOT REPORTED THAT WHILE TAXING AFTER A LANDING, THE NOSE GEAR GAVE WAY AND THE AIRCRAFT CAME TO REST ON THE PROPELLER SPINNER. THIS IS AN AMATEUR BUILT AIRCRAFT. THE AIRCRAFT BUILDER MADE THE NOSE WHEEL FORK THAT BROKE. THEREBY LOSING THE NOSE WHEEL AND CAUSING THE NOSE GEAR LEG TO FOLD BACK AND PUTTING THE PROPELLER SPINNER ON THE PAVEMENT. SINCE THIS PART IS INSTALLED ON AN EXPERIMENTAL AIRCRAFT THERE ARE NO STANDARDS FOR THE AIRCRAFT OR ANY OF THE PARTS. PREVENTION/SOLUTION, THE PRESENT OWNER HAS RELATED THE OLD PART WAS MADE UP OF ONE QUARTER INCH 2024 T3 ALUMINUM AND THE NEW PART WILL BE ONE EIGHTH INCH 4130 STEEL, BENT TO SHAPE AND THEN HARDENED TO A HARDNESS OF 135-145.
2005FA0000029	AMTR	LYC		ROD	BENT
1/7/2005	COZY	O320*			RT BRAKE CYL ACT
RT BRAKE CYLINDER ACTUATING ROD, LOCATED BEHIND RT RUDDER PEDAL, WAS SLIGHTLY BENT AFT. THIS CONDITION CAUSED INSUFFICIENT BRAKE CYLINDER PISTON TRAVEL AND MAKING THE RT BRAKE INOPERATIVE.
2004FA0000401	AMTR			PAD	BINDING
5/13/2004	VM1			DP600	BRAKES
PILOT WAS IN PROCESS OF TAKEOFF ROLL, PILOT REPORTED A/C VEERED TO LT HITTING A RUNWAY LIGHT, WENT OVER SOME TERRAIN AND ENDED PARTIALLY SUBMERGED IN A BODY OF WATER. AN EXAMINATION OF THE A/C WAS CONDUCTED. THE A/C CONFIG INCLUDES A FREE CASTORING NOSE WHEEL AND BRAKES ARE OF A MOTO-GUZZI MOTORCYCLE. LT BRAKE FOUND TO BE DRAGGING SUBSTANTIALLY, AFFECTING THE SMOOTH ROTATION OF THE LT MAIN GEAR WHEEL. THE RT WHEEL AND BRAKE WERE SATISFACTORY. THE BRAKE WAS REMOVED. IT WAS FOUND THE DESIGN OF WIRE LOOP USED AS A MEANS TO HOLD BRAKE PADS ALIGNED, APPLIES CONSTANT RESISTANCE ON THE BRAKE PADS. THIS CONSTANT RESISTANCE PREVENTS THE BRAKE PADS FROM FLOATING AT ALL, THERE IS MINIMAL CLEARANCE, FROM THE BRAKE DISC.
2004FA0000878	AMTR	ROTAX		AXLE	SEPARATED
10/8/2004	ZENITHCH701	ROTAX912UL			WHEEL ASSEMBLY
LEFT MAIN AXLE SEPARATED FROM BACKING PLATE AT LANDING CAUSING MAIN SPRING TO DIG IN, WHICH CAUSED THE PLANE TO NOSE OVER. INSPECTION OF THE AXLE ASSEMBLY REVEALED VERY LITTLE WELD PENETRATION AND THE WHOLE DESIGN WAS VERY INADEQUATE FOR THE TYPE OF OPERATIONS THAT THIS GEAR ASSEMBLY MARKETED TO.
2004FA0000931	AMTR	ROTAX		STRUT	BROKEN
12/16/2004	ZODIAC	ROTAX912S2			LT MLG
THE LT MAIN GEAR STRUT FAILED AT THE LOWER WELDMENT WHERE THE STRUT ATTACHES TO THE FORK. THIS DAMAGE HAD PROGRESSED AROUND THE ATTACHMENT IN THE FORM OF A CRACK UNTIL WEEKEND TO THE POINT OF FAILURE. THIS PART HAD BEEN FABRICATED BY THE KIT MANUFACTURER.
CA040610014	BAC	LYC		SPRING	FAILED
6/7/2004	146200A	ALF502R5		HC323L0001000	NLG
(CAN) UPON DEPARTURE, THE CREW REPORTED LOUD CLUNK NOISE UNDER FLIGHT DECK DURING GEAR RETRACTION. MAINTENANCE INSPECTED AIRCRAFT AND FOUND LT NLG ASSIST SPRING ASSEMBLY HAD FAILED AND CAUSED A 12 X 8 HOLE IN UPPER NOSE WELL. ASSISTOR SPRING WAS REPLACED AND HOLE WAS REPAIRED IAW THE PRINCIPALS OF RIL HC537H9252 AT ISSUE 1 IN REFERENCE TO BARA/AVR/6774/04-DC. GEAR SWINGS WERE CARRIED OUT AS SERVICEABLE AND AIRCRAFT WAS RETURNED TO SERVICE. TIMES FOR THIS PART ARE LISTED AS AIRCRAFT TIMES.
CA040505001	BAC	LYC		WHEEL	CRACKED
5/1/2004	146200A	ALF502R5		AHA1481	MLG
A/C IN HEAVY MX IN YHZ AND HAD JUST BEEN TAKEN OFF THE JACKS WHEN ENGINEERS NOTED THAT NR 3 MAIN WHEEL WAS FLAT. THE WHEEL WAS REPLACED ALONG WITH ITS MATE AS PER COMPANY POLICY, THE WHEEL WAS ROUTED TO WHEEL/BRAKE SHOP AND WENT THROUGH A BUILD (22) INSPECTION. NDT FOUND THE INNER WHEEL HALF HAD CRACK EMANATING FROM ONE OF THE THREE-FUSE PLUGHOLE.THE INNER WHEEL HALF P/N AHA1481 IS FOUND IN THE DUNLOP CMM IPL 32-42-59 FIG 1 ITEM 280.THIS WHEEL WAS ON BUILD 21 AND HAD BEEN NDT AT THAT TIME WITH NO DEFECTS NOTED AT THE TIME. THIS MATTER HAS BEEN BROUGHT TO THE ATTN OF THE MANUF AND WE HAVE ASKED WHAT HAS BEEN THE OCCURRENCE ON THIS TYPE OF FAILURE AND HAVE ASKED WHETHER OR NOT THEY WOULD LIKE TO SEE THE COMPONENT FOR ANALYSIS. WILL FOLLOW-UP ON THE INCIDENT ONCE WE HEAR BACK FROM THE MANUF WITH THEIR RECOMMENDATIONS.
2005FA0000014	BBAVIA	CONT		SPAR	CRACKED
1/21/2005	7AC	A65*			WING
DURING PRE-PURCHASE, COMPLIED WITH INSPECTION. BOTH SPARS IN BOTH WINGS WERE FOUND TO HAVE LOOSE AND MISSING NAILS THAT HOLD RIBS OT THE SPARS. SEVERAL LONGITUDINAL CRACKS WERE FOUND. RECOMMENDATION TO OWNER WAS TO REPLACE ALL WOOD SPARS, WITH STC METAL SPARS.
2005FA0000038	BBAVIA	LYC		BOLT	IMPROPER PART
11/2/2004	7KCAB	IO320*		NAS	MLG ATTACH
DURING ANNUAL INSPECTION, IT WAS FOUND THAT ONE OF THE NAS BOLTS HOLDING THE IB END OF THE LANDING GEAR WAS TOO SHORT AND DID NOT GO ALL THE WAY THROUGH THE NAS NUT. THESE BOLTS WERE INSTALLED AT THE FACTORY, DURING A REPAIR IN 2001. FAILURE WOULD RESULT IN ONE LANDING GEAR LEG COLLAPSING. (EA17200504802)
CA040504004	BEECH	PWA		SUPPORT BRACKET	CRACKED
4/29/2004	100BEECH	PT6A28		11552405813	ELEV BELLCRANK
(CAN) DURING AIRCRAFT INSPECTION, IT WAS NOTED THE AFT RT ELEVATOR BELLCRANK SUPPORT BRACKET P/N 115-524058-13 WAS CRACKED. THE CRACK EXTENDED APPROX. 1.5 INCHES VERTICALLY AROUND THE BELLCRANK PIVOT BOLT ATTACHMENT.
CA040810004	BEECH	PWA		LINE	WORN
8/6/2004	1900C	PT6A65B		11492000023	ENGINE FUEL
(CAN) WHEN INSTALLING INSPECTION PANEL ON LT OB NACELLE FOUND FUEL LINE FROM FUEL BOWL FORWARD TO ENGINE WAS CHAFING ON BULKHEAD IN SIDE OF NACELLE. THE LINE WAS WORN ABOUT A QUARTER OF ITS WALL THICKNESS.
CA041004003	BEECH	PWA		DISC	FRACTURED
9/26/2004	1900C	PT6A65B		114800817	BRAKES
(CAN) ON PUSH BACK INTO THE HANGAR AN UNUSUAL NOISE WAS HEARD FROM NR 2 MAINWHEEL. ON REMOVING THE MAIN WHEEL, A SECTION OF THE STATIONARY DISC FELL OUT OF THE BRAKE ASSEMBLY. WHEN THE BRAKE ASSY WAS REMOVED THE REST OF THE STATIONARY DISC WAS REMOVED WITHOUT DISSAMBLY OF THE BRAKE. THE INNER HALF OF THE MAIN WHEEL WAS SCORED BY THE BRAKE DISC AND WAS REPLACED ALONG WITH THE BRAKE ASSEMBLY. WHEN THE BRAKE WAS LAST REPAIRED THE DISC WAS EXAMINED AND FOUND TO BE SERVICABLE TO CONTINUE IN SERVICE WITHOUT REPLACING THE PADS. THEREFORE NDT WAS NOT REQUIRED. THE BRAKE HAD COMPLETED 963.2 HRS AND 851 CYCLES DURING THIS INSTALLATION.
CA041109003	BEECH	PWA	PPG	GROUND WIRE	BURNED
11/1/2004	1900D	PT6A67D		MS250852BB5	WINDSHIELD HEAT
(CAN) DURING CRUISE FLT AT FL210, THE FLIGHT CREW DETECTED AND ODOR FOLLOWED BY SMOKE EMANATING FROM THE DASH AREA. THEY DONNED MASKS AND REQUESTED PRIORITY LANDING . THEY RAN THRU THEIR EMERGENCY PROCEDURES AND AFTER THE WINDSHIELD HEAT WAS SELECTED OFF THE SMOKE DISSIPATED. AN UNEVENTFUL LANDING WAS COMPLETED AND AIRCRAFT BROUGHT TO MAINTENANCE. MAINTENANCE FOUND THAT THE GROUND WIRE HAD CONTACTED THE DASHBOARD EYEBROW AND THE HEAT HAD CAUSED IT TO SMOLDER. THE WIRE WAS REPLACED AND ROUTED TO ENSURE NO CONTACT CAN BE MADE WITH ANYTHING. A FLEETWIDE INSPECTION IS BEING CARRIED OUT AT THIS TIME AND WILL LEAVE SDR OPEN UNTIL TOTAL RESULTS.
CA040810002	BEECH	PWA		FIRE LOOP	BROKEN
8/4/2004	1900D	PT6A67D		24412886	RT ENGINE
(CAN) CREW NOTED THAT THE RT FIRE LOOP WOULD NOT TEST. MAINTENANCE FOUND THE FWD FIRE WIRE LOOP PARTIALLY BROKEN PREVENTING CONTINUITY. THE WIRE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE.
CA040713008	BEECH	PWA		SEAL	TORN
7/12/2004	1900D	PT6A67D		1294000371	PAX DOOR
(CAN) DURING CRUISE FLIGHT THE CREW NOTED AN INCREASED NOISE FROM THE MAIN DOOR AND WAS UNABLE TO MAINTAIN CABIN PRESSURE APPROPRIATE FOR 170 ALTITUDE. THE AIRCRAFT WAS DESCENDED TO 100 AND THE FLIGHT CONTINUED TO DESTINATION. MAINTENANCE WAS DISPATCHED AND FOUND THE MAIN DOOR PRESSURE SEAL HAD TORN ALLOWING THE SEAL TO COLLAPSE. DEBRIS IN THE FORM OF GRAVEL WAS FOUND, WHICH MAY HAVE CONTRIBUTED TO THE SEAL FAILURE. THE SEAL WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE.
CA040629009	BEECH	PWA		BOLT	UNDERTORQUED
6/28/2004	1900D	PT6A67D			VERTICAL STAB
(CAN) IN REFERENCE TO AN MAINTENANCE ALERT, AN INSPECTION WAS CARRIED OUT TO THE VERTICAL STABILIZER FRONT SPAR ATTACHMENT BOLTS FOR SECURITY AND TORQUE OF AIRCRAFT. ONE AIRCRAFT WAS FOUND WITH BOLT TORQUE UNDER THE SPECIFIED TORQUE ON THE RT SIDE UPPER AND LT SIDE LOWER. THE BOLTS WERE RE-TORQUED AND A CONTINUING INSPECTION WAS SET UP TO THE FLEET AT 1000 HOUR INTERVALS.
CA040927002	BEECH	PWA		CROSS TIE	CRACKED
9/21/2004	200BEECH	PT6A41		97430000115	FUSLEAGE
(CAN) DURING MAINTENANCE, A CRACK WAS DISCOVERED IN A FUSELAGE CROSS TIE FOR THE UPPER RT FUSELAGE, IMMEDIATELY AFT OF THE EMERGENCY EXIT WINDOW. NEW PART HAS BEEN ORDERED AND WILL BE INSTALLED TO RECTIFY THIS DEFECT.
CA040422007	BEECH	PWA		RECEPTACLE	BURNED
4/21/2004	200BEECH	PT6A41		2062071	CABIN
(CAN) WHEN THE CABIN CENTER HEADLINER WAS REMOVED DURING ROUTINE MX, RADIANT HEAT RECEPTACLES/SOCKETS WERE FOUND CHARRED AND MELTED WITH THE WIRE CONNECTERS INSIDE THE SOCKET LOOSE AND BURNT, PROBABLY FROM THE AMOUNT OF CURRENT BEING DRAWN THROUGH THE WIRES WHEN RADIANT HEAT WAS ON FOR LONG PERIODS OF TIME OVER THE YEARS OF OPERATION. RECEPTACLES, SOCKETS, AND CONNECTERS WERE REPLACED NEW ON BOTH THE FRONT AND BACK OF THE CABIN CENTER HEADLINER, AND FUNCTION TESTED SERVICEABLE. ALL OTHER KA 200 S OPERATED BY THE COMPANY WERE INSPECTED AND FOUND TO HAVE SIMILAR DAMAGE, TO SOME DEGREE ON THE RADIANT HEAT CONNECTERS. ALL PARTS WERE REPLACED NEW AND SYSTEMS CHECKED SERVICEABLE.
CA040423002	BEECH	PWA		BULKHEAD	CORRODED
3/5/2003	200BEECH	PT6A41			FUSELAGE
DURING A SCHEDULED INSPECTION OF THE REAR PRESSURE BULKHEAD A LOCALIZED AREA OF PITTING CORROSION WAS DISCOVERED AROUND THE BULKHEAD FITTING FOR THE RELIEF TUBE CONNECTION. THE AREA WAS CLEANED AND INSPECTED AND AN APPROVED DOUBLER REPAIR CARRIED OUT. THE BULKHEAD FITTING ASSEMBLY WAS REPLACED WITH NEW TO PREVENT THE POSSIBILITY OF ANY FURTHER LEAKAGE. ALL OTHER AIRCRAFT IN THE FLEET WERE INSPECTED WITH NO DEFECTS NOTED.
2005FA0000031	BEECH	PWA		CABLE	BROKEN
10/12/2004	400A	JT15D5			LT MLG
DURING SCHEDULED INSPECTION FOUND LT MAIN GEAR UPLOCK EMERGENCY EXTENSION CABLE BROKEN NEAR OB END. REPLACED CABLE WITH NEW PN128-380021-55 CABLE ASSEMBLY AND RIGGED IAW BE 400/400A, MM 32-30-00. ORIGINAL PN, PART TT NOT SUPPLIED, POSSIBLY ORIGINAL. ASSEMBLY PN FOR THIS SN RANGE AIRCRAFT HAS BEEN SUPERSEDED TWICE IAW CURRENT BE 400/400A IPC. APPEARS TO HAVE FAILED FROM AGE/TIME IN SERVICE. RECOMMEND ESTABLISHING A LIFE-LIMIT ON THIS CABLE ALSO, OR ISSUE A SB REQUIRING IMPROVED PN CABLE INSTALLATION. TTAF: 5397.4 HRS.
CA041115004	BEECH	PWA		GENERATOR	INTERMITTENT
11/11/2004	99	PT6A20			ELECTRICAL
(CAN) ON CLIMB OUT THE PILOT OBSERVED THAT ONLY ONE GENERATOR WAS ACCEPTING LOAD. DECIDED TO RETURN TO DEPARTURE AERODROME WITHOUT CARRYING OUT ANY CONFIRMATION CHECKS. A SUBSEQUENT MAINTENANCE INSPECTION DETERMINED THAT AT LIGHT ELECTRICAL LOADS BOTH GENERATORS DO NOT ALWAYS STAY ON LINE. BOTH GENERATORS WERE CONFIRMED TO BE WORKING. BOTH GENERATOR INDICATING SYSTEMS WERE CONFIRMED TO BE FUNCTIONAL.
CA040927007	BEECH	PWA		DOOR	INOPERATIVE
9/24/2004	99	PT6A20		50430043663	LT AFT FUSELAGE
(CAN) ON APPROACH, AT 20 MILES OUT AND 2500 FT ASL THE CABIN DOOR OPENED. FLIGHT SERVICES WAS INFORMED AND THE AIRCRAFT LANDED UNEVENTFULLY. THE COPILOT CLOSED THE DOOR AFTER LANDING. THE DOOR AND SURROUND WERE INSPECTED NO DAMAGE FOUND.
CA041122004	BEECH	PWA		TIRE	BLISTERED
11/17/2004	A100	PT6A28		185F035	MLG
(CAN) AFTER A PILOT REPORTED THAT THE NR 3 TIRE WAS FLAT, MAINTENANCE REPLACED THE WHEEL ASSY. DURING THE REMOVAL IT WAS NOTICED THAT THE IB SIDEWALL HAD A LARGE BLISTER. IT APPEARS THAT AN AREA (3 INCHES IN DIAMETER) OF THE OUTSIDE LAYER OF RUBBER (.0625 IF AN INCH THICK) WAS DISBONDED FROM THE REST OF THE TIRE, THE AIR PRESSURE CAUSED THIS TO INFLATE CREATING A LARGE BLISTER. THIS BLISTER EVENTUALLY RUBBED ON THE BRAKE CALLIPER CAUSING THE BLISTER TO BURST, DEFLATING THE TIRE.
CA040510006	BEECH	PWA		FITTING	CRACKED
5/6/2004	A100	PT6A28		11561001S1	ELEVATOR TORQUE
(CAN) DURING A PHASE INSPECTION THE TAIL CONE WAS BEING REINSTALLED WHEN A CRACK WAS NOTICED ON THE LT TORQUE TUBE. THE CRACK EXTENDS FROM THE TAPER PIN HOLE TO THE EDGE OF THE FITTING. THESE FITTINGS ARE NDT EVERY 1000 HRS AND THIS TUBE WAS DONE AT 142.5 HRS.
CA041122011	BEECH	PWA		O-RING	DISPLACED
11/16/2004	A100	PT6A28			FCU FUEL BOWL
(CAN) FUEL LEAK ON LT ENGINE IN FLIGHT. CAUSE BEING, DISPLACED O-RING ON FCU FUEL BOWL. VARIFIED BOWL HAD BEEN TORQUED TO SPECS IAW MM, CHAPTER 73-10-02 FOR ARGO-TECH PUMPS.
CA041130012	BEECH	PWA		STARTER GEN	FAILED
11/29/2004	A100	PT6A28		23048018	LEFT
(CAN) DURING CRUISE FLIGHT AT 12000 FEET THE PILOTS NOTICED THE LT GENERATOR FAIL LIGHT CAME ON. ALSO A PASSENGER INDICATED THAT HE NOTICED SPARKS COMING FROM THE ENGINE. THE GENERATOR WAS SELECTED OFF AND AIRCRAFT RETURNED TO BASE FOR INSPECTION. MAINTENANCE INSPECTED THE AIRCRAFT AND NOTICED THAT THE REAR BEARING IN THE STARTER GENERATOR HAD FAILED CAUSING IT TO SELF-DESTRUCT. THE GENERATOR WAS REPLACED, ENGINE WAS INSPECTED FOR DAMAGED AND AIRCRAFT WAS RETURNED TO SERVICE.
2004FA0000935	BEECH			SKIN	DELAMINATED
12/20/2004	B200			10140453S	LT WING
SKIN DELAMINATION ON LT WING CENTER SECTION UPPER SURFACE AFT OF THE SPAR NOTICED BY MAINTENANCE CREW, WHILE MAINTENANCE WAS BEING COMPLETED ON A NON-RELATED MATTER.
2004FA0000928	BEECH			STRINGER	CRACKED
12/21/2004	B200			1014400311	FUSELAGE
STRINGER NR 9 ON THE LT SIDE FOUND CRACKED DURING NON-RELATED MAINTENANCE.
2005FA0000025	BEECH	PWA		BLOWER	ARCED
1/10/2005	B200	PT6*		1013841763	COCKPIT
PILOT REPORTED AN ELECTRICAL SMELL DURING FLIGHT AND THEN THE FORWARD VENTILATION BLOWER WENT INOPERATIVE. FOUND THE BRUSHES WORN OUT AND ARCING ON THE ARMATURE. REPLACED WITH OVERHAULED UNIT AND FUNCTIONAL CHECK OK.
CA040628008	BEECH	PWA		SKIN	CRACKED
6/28/2004	B200	PT6A42			FUSELAGE
(CAN) COMBINATION VHF/GPS ANTENNA DOUBLER AND FUSELAGE SKIN CRACKED UNDER ANTENNA WHICH WAS ENGINEERED AND INSTALLED IAW LSTC NR C-LSA01-625/D. FUSELAGE REPAIRED AND ANTENNA REMOVED. NEW REPAIR DOUBLER INSTALLED.
CA040628009	BEECH	PWA		SKIN	CRACKED
6/28/2004	B200	PT6A42			FUSELAGE
(CAN) COMBINATION VHF/GPS ANTENNA DOUBLER AND FUSELAGE SKIN CRACKED UNDER COMANT ANTENNA WHICH WAS ENGINEERED AND INSTALLED IAW LSTC NR C-LSA01-625/D. FUSELAGE REPAIRED AND ANTENNA REMOVED. NEW REPAIR DOUBLER INSTALLED.
2005FA0000034	BEECH	PWA		RELAY	FAILED
10/19/2004	B200C	PT6A42		SM50D7	TE FLAPS
WHILE THE AIRCRAFT WAS IN FLIGHT, THE FLAPS FAILED TO EXTEND TO THE SELELCTED APPROACH POSITION. THE PILOT CYCLED THE FLAP SELECT SWITCH TO UP AD BACK TO APPROACH AND THE FLAPS EXTENDED. MAINTENANCE INVESTIGATED THE REPORTED PROBLEM AND WAS ABLE TO DUPLICATE THE PROBLEM ON THE GROUND. WHEN THE FLAPS WERE SELECTED TO APPROACH THE FLAPS MOVED APPROXIMATELY 5 DEGREES AND QUIT MOVING. AFTER ACCESS WAS GAINED TO THE FLAP MOTOR/GEARBOX AND RELAY, A TAP ON THE RELAY RETURNED THE FLAPS TO NORMAL SELECTOR SWITCH RESPONSE OPERATION. INSTALLATION OF A REPLACEMENT RELAY SOLVED THE PROBLEM. THE (FAILED ) RELAY HAD 69.0 HOURS. (WP19200503541)
AOC04006	BEECH			COMPRESSOR	DAMAGED
8/18/2004	B300C			1015552119	AIR CONDITIONER
PILOT REPORTED FREON AIR CONDITIONING SYSTEM INOPERATIVE FOLLOWING A FLIGHT. FOUND COMPRESSOR CLUTCH PLATE HAS SEPARATED FROM THE COMPRESSOR AND WAS FOUND IN THE LOWER ENGINE COWL. FIRE SLEEVE ON OIL LINE FROM THE OIL COOLER HAD IMPACT DAMAGE (SLEEVE CUT) BUT NO DAMAGE TO THE OIL LINE. NO OTHER DAMAGE NOTED.
CA041123001	BEECH	PWA		PIN	MISSING
11/19/2004	C90A	PT6A21		NAS427K6	ELEVATOR CONTROL
(CAN) THE PRIMARY CABLE FOR THE ELEVATOR CONTROL HAD JUMPED OUT OF THE PULLEY. THE (SPRING PIN) THAT PREVENTS THIS FROM HAPPENING WAS OUT OF POSITION (UNABLE TO STOP THE CABLE FROM LEAVING THE PULLEY). ABRASION OF THE ELEVATOR CABLE AT THE PULLEY AND ON SUPPORTING STRUCTURE A SHORT DISTANCE FROM WHERE THE ELEVATOR CABLE, EMERGES FROM THE PRESSURE VESSEL AS IT TRAVELS AFT TO THE BELLCRANK.
CA040713001	BEECH	PWA		SHUTOFF VALVE	FAILED
7/12/2004	C90A	PT6A21		1013890253	FUEL SELECTOR
(CAN) FAILED FUNTIONAL TEST IAW PILOTS CHECK LIST. REPLACED
2005FA0000033	BEECH	CONT		RELAY	INTERMITTENT
11/5/2004	F33A	IO520*		SM50D7	DYNAMIC BREAKER
PILOT SELECTED GEAR DOWN AND NOTHING HAPPENED, SELECTED GEAR DOWN AGAIN AND GEAR CAME DOWN. ON FURTHER TROUBLESHOOTING FOUND RELAY WAS INTERMITTNET, PROBABLE CAUSE AT THIS TIME UNKNOWN, THIS IS SUPPOSE TO BE AN IMPROVED RELAY SO THERE IS NO RECOMMENDATIONS AT THIS TIME.
CA040811009	BELL	ALLSN		CLAMP	MISSING
7/26/2004	206B	250C20			TAIL ROTOR PEDAL
(CAN) ON DECENT PILOT FELT A TAP ON THE TAIL ROTOR PEDALS, AND LOOKED INTO HIS SLINGING MIRROR AND DETERMINED THAT THE LT BEAR PAW WAS MISSING. AFTER LANDING HE NOTICED DAMAGE TO TAIL ROTOR BLADES, AND VERTICLE FIN. ON INSPECTION, IT WAS FOUND THAT A CLAMP THAT WOULD PREVENT THE BEAR PAW FROM SLIPPING OFF WAS MISSING FROM THE INSTALLATION.
CA041223005	BELL	ALLSN		PITCH LINK	CRACKED
8/21/2004	206B	250C20B		206010355009	MAIN ROTOR
(CAN) DURING A SCHEDULED 100-HOUR INSPECTION TWO (2) VERTICAL CRACKS WERE FOUND ON A MAIN ROTOR PITCH LINK. THE CRACKS (APPROX. .180)
CA040615002	BELL			PIN	IMPROPER PART
6/11/2004	206B1			206031620101	DOOR HANDLE
(CAN) CREW AND PASSENGER, INTERIOR (D) SHAPED DOOR HANDLES FOUND TO HAVE LOCKING (SPRING PINS) TOO SHORT INSTALLED BY THE MANUFACTURER. MS171525 (.438 INCH LONG) INSTALLED INSTEAD OF MS171526 (.500 INCH LONG).
CA041007004	BELL	ALLSN		GEAR	WORN
9/27/2004	206BELL	250C18		3579501200	OIL PUMP
(CAN) THIS IS THE OIL PUMP GEAR THAT DRIVES THE HYDRAULIC PUMP ON THE AC, GREASING INTERVAL IS 300 HRS. THIS SHAFT WAS GREASED EVERY 100 HRS AND HAS TOTALLY WORN OUT. THIS SHAFT ALSO WEARS OUT THE COUPLING IT ATTACHES TO, AS WELL.
CA041124009	BELL	ALLSN		DISC PACK	CRACKED
11/8/2004	206L	250C20R		327211	TAIL ROTOR DRIVE
(CAN) DISC PACK, 1 DISC CRACKED.
CA041123010	BELL	ALLSN		BYPASS SWITCH	CORRODED
11/3/2004	206L	250C20R			FILTER ASSY HEAD
(CAN) FILTER LIGHT CAME ON UPON LANDING. REMOVED FILTER AND INSPECTED. NO CONTAMINATION FOUND AND TEST LIGHT CIRCUIT. A LIGHT CAME ON AGAIN AND UPON INVESTIGATION, IT WAS FOUND THAT THE SWITCH WAS CORRODED. A NEW FILTER ASSY. WAS INSTALLED AND TESTED. IT FUNCTIONS CORRECTLY. INCIDENT HAPPENED 35 HOURS AFTER 300 HR INSP, WHICH INCLUDED FILTER CHANGE.
ALGA095160	BELL			BLADE	CORRODED
6/7/2004	206L1			206015001119	MAIN ROTOR
DURING ROUTINE A/F INSPECTION, CORROSION AND SEPARATION WAS NOTED ON LOWER SURFACE SKIN/SPAR INTERFACE IMMEDIATELY O/B OF GRIPFINGER. REPLACED W/SERVICABLE PART.
PG9R97953	BELL	ALLSN		FUEL NOZZLE	CRACKED
11/5/2004	206L1	250C28		6899001	ENGINE
FUEL NOZZLE SPRAY SHROUD CRACKED. A NEW MATERIAL SHOULD BE USED FOR THE SPRAY SHROUD. (K)
HEEA095226	BELL	ALLSN		ENGINE	STALLED
5/8/2004	206L3	250C30P		23004545
COMPRESSOR STALL WHILE HOVERING FOR TAKE OFF.
CA041007008	BELL	PWA		CONTROL TUBE	CRACKED
10/7/2004	212	PT6T3		212076101001	MAIN ROTOR
(CAN) WE ARE PRESENTLY DOING A 3000 HOUR AIRFRAME INSPECTION. THIS VERTICAL UPPER SERVO CONTROL TUBE WAS SENT TO A NDT SHOP FOR INSPECTION. THE NDT SHOP STATED THAT THEIR WAS A LONGDITUDANAL CRACK ON THE UPPER END OF CONTROL TUBE. SINCE THE LAST INSPECTION THE TUBE HAS 2617 HOURS ON IT. THE AIRFRAME TIME IS 28,644 HOURS.
CA040812003	BELL	PWA		BULKHEAD	CRACKED
7/19/2004	212	PT6T3		212030156047	TAILBOOM
(CAN) BULKHEAD FRAME CRACKED ADJACENT TO RT UPPER TAILBOOM ATTACH BOLT. FRAME REPLACED.
CA040407011	BELL	PWA		TAPE	IMPROPER PART
4/7/2004	212	PT6T3			GYROS
(CAN) ADHESIVE BACKED LEAD TAPE HAD BEEN USED TO BALANCE THE PITCH ERECTION VANES. IAW MANUFACTURER'S SERVICE ADVISORY NR 75, DATED JANUARY 25, 1985, LEAD TAPE SHOULD NOT BE USED TO BALANCE AIM GYROS AS IT CAN FALL OFF AND CAUSE THE GYRO TO BECOME INOPERATIVE.
CA040422004	BELL	PWA		GRIP	BROKEN
4/18/2004	212	PT6T3		2050010461	CYCLIC STICK
(CAN) DURING ROUTINE GREASING AND SERVICING OF MAIN ROTOR COMPONENTS AME ATTEMPTED TO MOVE THE PILOT'S CYCLIC STICK. AS THE MOVEMENT WAS ATTEMPTED, THE GRIP BROKE INTO TWO PIECES. THE FRACTURE OCCURRED BETWEEN THE FORCE TRIM RELEASE SWITCH AND CARGO RELEASE SWITCH. NEW GRIP WAS REWIRED AND INSTALLED. A/C RETURNED TO SERVICE.
ALGA098260	BELL			UNIVERSAL	WORN
12/6/2004	407			406310405101	M/R DRIVE
UNIVERSAL BEARING HAS AXIAL PLAY BEYOND LIMITS. REPLACED WITH NEW BY FIELD MAINTENANCE.
ALGA098261	BELL			UNIVERSAL	WORN
12/6/2004	407			406310405101	M/R DRIVE
UNIVERSAL HAS AXIAL PLAY BEYOND LIMITS. REPLACED WITH NEW BY FIELD MAINTENANCE.
CA041005004	BELL			HUB	OVERSIZED
9/23/2004	407			406012102109	TAIL ROTOR HEAD
(CAN) T/R HUB FOUND TO HAVE 1.6255 - 1.6260, INTERNAL DIAMETER FOR ELASTOMERIC FLAPPING BEARING INSTALL, OVERSIZE FROM .0002 TO .0007.
CA041104005	BNORM	LYC		WHEEL	CRACKED
11/2/2004	BN2A	O540E4C5		16104700	MLG
(CAN) CREW FELT LOSS OF BRAKE PRESSURE ON RT SIDE. RETURN TO RAMP. MAINT FOUND NR 3 IB WHEEL HALF BROKEN CAUSING BRAKE UNIT TO DETACH FROM BRAKE DISK. BRAKE UNIT FOUND ON TAXIWAY BY AIRPORT OPS. GIVEN TO TC OUTSIDE OF THEIR SOPS. LOCAL TC OFFICE, RETAINED POSSESSION OF BRAKE UNIT AND WILL NOT RETURN UNIT, DESPITE ENDEAVORS TO RETRIEVE FOR OWNER. THEREFORE UNABLE TO DETERMINE ORIGINAL CAUSE OF FAILURE WHETHER WHEEL HALF OR BRAKE UNIT FAILED FIRST.
CA040928001	BOEING	RROYCE		ENGINE	FAILED
9/12/2004	717200	BR700715A130
(CAN) IN FLIGHT SHUT DOWN AND AIR TURN BACK. IN CLIMB LOUD BANG AND TGT INCREASED TO 1000 DEG C. PILOT SHUT DOWN ENGINE AND RETURNED TO ORIGIN. ON GROUND, DEBRIS FOUND IN TAIL PIPE. ENGINE WILL BE INDUCTED IN OCTOBER. SUSPECT ED HPT BLADE FAILURE, FURTHER INFO WILL BE PROVIDED AT ENGINE STRIP.
CA040611005	BOEING	PWA		SWITCH	INOPERATIVE
6/8/2004	727225	JT8D15A		10608197	KRUEGER FLAP
(CAN) AFTER TAKE OFF AND DURING CLIMB IT WAS OBSERVED THAT THE LT OB KRUGER FLAP WAS NOT RETRACTED. BOTH INDICATIONS SHOWED THE KRUGER WAS STILL EXTENDED. THE AIRCRAFT MADE AN UNSCHEDULED LANDING WITHOUT INCIDENT. JUMPER ASSY WAS INSTALLED IAW B727-27-80-02, L/E FLAP JUMPER CABLE INSTALLATION, AND CHECKED SERVICEABLE. THE AIRCRAFT WAS RELEASED FOR SERVICE. NO FURTHER PROBLEMS DURING SUBSEQUENT FLIGHT.
CA041123004	BOEING	PWA	BOEING	HINGE	DAMAGED
11/22/2004	727233	JT8D15		69222825	DOOR HALF
(CAN) HYDRAULIC BAY DOOR SEPARATED FROM AIRCRAFT. AIRCRAFT WAS BEING POSITIONED FROM THE MAIN MAINTENANCE BASE ON THE MORNING OF NOVEMBER 22, 2004. DURING SERVICE CHECK BY MAINTENANCE, IT WAS NOTICED THAT THE HYDRAULIC BAY DOOR WAS MISSING. MAINTENANCE SUSPECT DOOR HINGE FAILURE. THE HYDRAULIC BAY STRUCTURE WAS INSPECTED FOR SECONDARY STRUCTURE DAMAGE. SERVICEABLE DOOR AND DOOR HINGE ASSY WAS INSTALLED AND AIRCRAFT WAS RETURNED TO SERVICE.
CA050119003	BOEING	PWA		SWITCH	INTERMITTENT
1/19/2005	727233	JT8D15		H1010153	NLG
(CAN) ON APPROACH, LANDING GEAR CYCLED DOWN FOR LANDING. THE NOSE LANDING GEAR RED INDICATOR STAYED ILLUMINATED AND NO GREEN INDICATION WAS SEEN. GEAR WAS RE-CYCLED AND THE GEAR WAS EXTENDED WITH PROPER INDICATION. MAINTENANCE LUBED THE NOSE GEAR AND JACKED THE GEAR AND CYCLED THE GEAR NUMEROUS TIMES, NO FAULTS FOUND. THE AIRCRAFT WAS DISPATCHED, NO FAULT ON LANDING THERE. THIS IS THE SECOND OCCURENCE AND SECOND SDR FOR THE SAME AIRCRAFT AND SNAG. DUE TO ITS HISTORY, NOSE GEAR DOWN POSITION SWITCH S93 AND THE NOSE GEAR LOCKED SWITCH S96 ARETO BE REPLACED BEFORE THE AIRCRAFT WILL BEDISPATCHED.POSSIBLE INTERNAL INTERMITTENT FAILURE TO ONE OF THE SWITCHES AND AT THE SAME TIME ALL WIRING WILL BE INSPECTED.
CA040812001	BOEING	PWA		B-NUT	CRACKED
7/29/2004	727243	JT8D15		65178444440	HYDRAULIC LINE
(CAN) CREW REPORTED 'A' SYSTEM HYDRAULIC FLUID LOSS IN FLIGHT. MAINTENANCE FOUND LEAK AT B-NUT END FITTING AT 'A' SYSTEM MODULE. LINE REPLACED.
CA041001004	BOEING	CFMINT		ENGINE	FAILED
9/29/2004	737*	CFM567B22			NR 1
(CAN) AIRCRAFT REPORTED STRONG ODOR THROUGHOUT THE CABIN AND FLIGHT DECK IN CLIMB. NO SMOKE VISIBLE. CREW RAN AIR CONDITIONING IN MANUAL/AIR MIX VALVES COLD, SMELL DISSIPATED. AIRCRAFT RETURNED TO DEPARTURE AND LANDED WITHOUT INCIDENT. NO EMERGENCY WAS DECLARED. MAINTENANCE CONDUCTED ENGINE RUNS ON BOTH ENGINES AT 70 PERCENT N2 FOR 10 MINUTES WITH EACH CORRESPONDING PACK RUNNING IN HOTMODE. ODOR DISSIPATED GRADUALLY. SYSTEM CHECKED SERVICEABLE. AIRCRAFT RETURNED TO SERVICE WITH NO FURTHER INCIDENTS TO REPORT. NOTE: PREVIOUS NIGHT MAINTENANCE INCLUDED NR 1 ENGINE FAN BLADE LUBE/INSPECTION TASK NR 95-072-00-01.
CA040412001	BOEING		ROSEMOUNT	PITOT LINE	LEAKING
4/6/2004	737200				PITOT TUBE ASSY
(CAN) B737-200 PITOT TUBE ASSEMBLY FAILED BENCH CHECK WITH A PITOT LEAK IN EXCESS OF 200 KTS/MIN. THE LEAK WAS DETERMINED TO BE ORIGINATING WHERE THE PITOT TUBE AIRFRAME ATTACHMENT CONNECTS TO THE BASE OF THE PITOT TUBE ASSEMBLY. THE COMPONENT WAS A USED PART ACQUIRED FROM A DISTRIBUTOR, QWEST AIR PARTS INC, IN MEMPHIS TN. THE PITOT TUBE HAD BEEN BENCH CHECKED SERVICEABLE BY CROSS-CHECK AVIATION, FAA REPAIR STATION XK8R253Y LOCATED IN RENO, NEVADA.
CA040412002	BOEING		ROSEMOUNT	PITOT LINE	LEAKING
4/6/2004	737200				PITOT TUBE ASSY
(CAN) B737-200 PITOT TUBE ASSEMBLY FAILED BENCH CHECK WITH A PITOT LEAK IN EXCESS OF 350 KTS/MIN. THE LEAK WAS DETERMINED TO BE ORIGINATING WHERE THE PITOT TUBE AIRFRAME ATTACHMENT CONNECTS TO THE BASE OF THE PITOT TUBE ASSEMBLY. THE COMPONENT WAS A USED PART ACQUIRED FROM A DISTRIBUTOR, QWEST AIR PARTS INC, IN MEMPHIS TN. THE PITOT TUBE HAD BEEN BENCH CHECKED SERVICEABLE BY CROSS-CHECK AVIATION, FAA REPAIR STATION NR XK8R253Y LOCATED IN RENO, NEVADA.
CA040412003	BOEING		ROSEMOUNT	PITOT LINE	LEAKING
4/8/2004	737200				PITOT TUBE ASSY
(CAN) B737-200 PITOT TUBE ASSEMBLY FAILED BENCH CHECK WITH A PITOT LEAK IN EXCESS OF 350 KTS/MIN. THE LEAK WAS DETERMINED TO BE ORIGINATING WHERE THE PITOT TUBE AIRFRAME ATTACHMENT CONNECTS TO THE BASE OF THE PITOT TUBE ASSEMBLY. THE COMPONENT WAS A USED PART ACQUIRED FROM A DISTRIBUTOR, QWEST AIR PARTS INC, IN MEMPHIS TN. THE PITOT TUBE HAD BEEN BENCH CHECKED SERVICEABLE BY CROSS-CHECK AVIATION, FAA REPAIR STATION NR XK8R253Y LOCATED IN RENO, NEVADA.
CA040412005	BOEING		ROSEMOUNT	PITOT LINE	LEAKING
4/8/2004	737200				PITOT TUBE ASSY
(CAN) B737-200 PITOT TUBE ASSEMBLY FAILED BENCH CHECK WITH A PITOT LEAK IN EXCESS OF 10 KTS/MIN. THE LEAK WAS DETERMINED TO BE ORIGINATING WHERE THE PITOT TUBE AIRFRAME ATTACHMENT CONNECTS TO THE BASE OF THE PITOT TUBE ASSEMBLY. THE COMPONENT WAS A USED PART ACQUIRED FROM A DISTRIBUTOR, QWEST AIR PARTS INC, IN MEMPHIS TN. THE PITOT TUBE HAD BEEN BENCH CHECKED SERVICEABLE BY CROSS-CHECK AVIATION, FAA REPAIR STATION # XK8R253Y LOCATED IN RENO, NEVADA.REF SDRS20040412001, 2004041202, AND 2004041203.
CA041110001	BOEING	PWA		PROXIMITY SENSOR	FAILED
11/8/2004	737200	JT8D15			LE SLAT
(CAN) UPON SELECTION OF FLAPS 15 ON LANDING CHECKLIST THE L/E FLAP TRANSIT REMAINED ILLUMINATED AND THE NR 4 SLAT INDICATOR WAS SHOWING IN TRANSIT. REPLACED AND ADJUSTED NR 4 SLAT PROX SENSOR IAW MM 27-88-11. NR 4 SLAT FOUND DENTED ON UPPER SURFACE, REPLACED NR 4 SLAT IAW MM 27-81-21. RII CARRIED OUT. UPON FURTHER INVESTIGATION IT WAS FOUND THAT DAMAGE FROM A PREVIOUS BIRD STRIKE WAS FOUND TO THE SLAT CURTAINS WHICH CAUSED THE DAMAGE TO THE PROX SENSOR. THIS DAMAGE WAS NOT VISIBLE WITHOUT REMOVING L/E PANELS.
SROM200400056	BOEING			LIGHT	CORRODED
8/4/2004	737201			30043231	EXTERIOR
L2 DOOR EXTERIOR LIGHT INOP. REMOVED AND REPLACED L2 EXTERIOR EMERGENCY LIGHT IAW B737 M/M 33-51-61 - OPS CH'D GOOD.
CA041122013	BOEING	PWA		SKIN	CRACKED
11/18/2004	737201	JT8D15			FUSELAGE
(CAN) A 4 INCH CRACK WAS FOUND ON THE OUTER FUSELAGE SKIN JUST AFT OF THE WING TO BODY FAIRING RT SIDE. CRACK LOCATED ON STR 15R (2) TWO INCHES AFT OF STA.727A. CRACK REPAIRED IAW SRM 53-30-3 FIG48 DETAIL XI TIMES 53851.20 CYCLES 46695.
SROM200400055	BOEING			BATTERY PACK	INOPERATIVE
6/20/2004	737205			20131A	EMERGENCY LIGHT
L2 DOOR EMERGENCY LIGHT INOP. CHANGED OUT BATTERY PACK. OPS CHECKED GOOD.
CA040510004	BOEING	PWA		RING	DAMAGED
5/7/2004	737217	JT8D17		MS905820	FUEL FLOW TRANS
HAVE HAD SEVERAL OCCURRENCES OF FUEL LEAKS FROM THE JT8D FUEL FLOW TRANSMITTERS. THE LEAKS ARE EVIDENT AT VERY HIGH POWER SETTINGS. A FLEET CAMPAIGN HAS BEEN COMPLETED WHICH CHECKED ALL ENGINES FOR LEAKS AND RECTIFIED DEFECTS. AN EXTENSIVE INVESTIGATION IS BEING CONDUCTED BY OUR MAINTENANCE PROVIDER AND PRELIMINARY RESULTS SHOW THE CAUSE TO BE DEFECTIVE TEFLON BACK-UP RINGS MS9058-20. ALL STOCK OF THE SUSPECT PART HAS BEEN INSPECTED AND ANY DEFECTIVE BACK-UP RINGS FOUND HAVE BEEN QUARANTINED. OUR MAINTENANCE PROVIDER HAS CONTACTED THEIR SUPPLIER OF THE PART WITH THE FINDING. ADDITIONALLY THEY ARE CHECKING FOR OTHER APPLICATIONS FOR THE PART WITHIN THEIR VARIOUS FLEETS. A FULL REPORT WILL BE ISSUED AND I WILL UPDATE THIS SDR WITH ALL ADDITIONAL INFO WHEN THE REPORT IS AVAILABLE.
CA041105003	BOEING	PWA		FIRE LOOP	INOPERATIVE
11/4/2004	737281	JT8D17		894093	NR 1 ENGINE
(CAN) ENGINE NR 1 FIRE WARNING AT 8000 ASL ON APPROACH. FIRE BOTTLES AND SQUIBS REPLACED IAW MM. NR 1 LOWER FIRE LOOP REPLACED AND CONNECTOR D1098 IAW MM. SYSTEM TESTED SERVICEABLE.
CA041201004	BOEING	PWA		SKIN	CRACKED
11/29/2003	737296	JT8D9A			FUSELAGE
(CAN) TWO INCH CRACK WAS FOUND ON OUTER FUSELAGE BETWEEN STA 727A, 727B AT STR. 16L. FUSELAGE CRACK REPAIRED IAW SRM 53-30-3 FIG.48 SHEET 34 DETAIL XII. TIMES- 59472:22 CYCLES- 54285.
CA050111001	BOEING	PWA		GUSSET	CRACKED
1/5/2005	7372Q9	JT8D9A		654581945	NLG
(CAN) DURING A ROUTINE PHASE 3 CHECK (137.5 HRS.), A 2.75 INCH CRACK WAS FOUND ON THE NOSE LANDING GEAR GUSSET WHILE CARRYING OUT SERVICE DIFFICULTY ALERT AL-2002-03.RETRACT ACTUATOR SUPPORT FITTING GUSSET REPLACED IAW SRM 51-30-2 FIG II. TIMES. 61981.7 CYCLES. 52905.
CA040629006	BOEING	RROYCE		IDG	FAILED
6/26/2004	757*	RB211535E437		73664E	RT GENERATOR
(CAN) RT GEN FAILED ON CLIMBOUT. COULD NOT RESET, QRH CARRIED OUT. AIRCRAFT RETURNED TO DEPARTURE. ETOPS DOWNGRADED TO 120MIN. OPERATE IAW MEL 24-00-1.
CA050114003	BOEING	RROYCE		MOTOR	LEAKING
1/12/2005	75728A	RB211535E437		887087	HYD ACTUATOR
(CAN) A/C DEPARTED AND TURNED AROUND AFTER NOTICING SLOW STEADY DECLINE IN CENTER SYSTEM QUANTITY. MAINTENANCE FOUND FLUID LEAKING FROM FUSELAGE DRAIN HOLES IN THS COMPARTMENT. UPON INVESTIGATION MAINTENANCE FOUND CENTER SYSTEM HYD MOTOR ON THIS GEARBOX LEAKING FLUID OUT MOTOR DRAIN LINE BUT MOST WAS COMING OUT THS GEAR BOX VENT HOLE ON FWD SIDE OF GEARBOX POSSIBLY DUE TO A PARTIALLY BLOCKED MOTOR DRAIN LINE. MFG INDICATED THAT WE WILL HAVE TO REPLACE THE THS ACTUATOR DUE TO THE HYDRAULIC FLUID LEAKAGE CONTAMINATING THE ACTUATOR GEAR BOX.
CA040920001	BOEING	PWA		ACTUATOR	CORRODED
6/17/2004	767233	JT9D7R4D		251T43101	STABILIZER TRIM
(CAN) WATER INGRESS INTO GEAR BOX CAUSED EXTENSIVE CORROSION, INVESTIGATION ON GOING WITH MFG (STAB TRIM ACTUATOR).
2104	BOEING	GE		ENGINE	VIBRATION
10/15/2004	767300	CF680C2B7			NR 1
NR 1 ENGINE SHUT DOWN DURING FLIGHT DUE TO VIBRATION.
CA050111003	BOEING	GE		OVEN	FIRE
1/11/2005	767375	CF680C2B6F		6253190003	MID GALLEY
(CAN) FAULT: JUST PRIOR TO DESCENT, SOMETHING WAS BEING COOKED IN THE MID CABIN GALLEY. AS THE F/A WAS ABOUT TO REMOVE IT, A FIRE WAS FOUND AT THE BACK OF THE OVEN. 3 FIRE EXT. WERE USED TO DOUSE THE FIRE. NO EMERGENCY WAS DECLARED, NO ADVERSE PAX REACTION. AIRCRAFT REMOVED FROM SERVICE, WIRING INSPECTION U/WAY.
CA050113003	BOMBDR	PWC		PUMP	CRACKED
1/10/2005	DHC8400	PW150A		6617302	HYD SYSTEM
(CAN) NR2 HYDRAULIC SYSTEM FAILED DURING CLIMBOUT FROM BASE. PILOTS COMPLETED CHECKLIST AND PERFORMED AIR TURNBACK WITH UNEVENTFUL LANDING . PUMP HOUSING CRACKED WITH SUBSEQUENT FLUID LOSS INTO NACELLE. ENGINE DRIVEN PUMP REPLACED.
CA050113002	BOMBDR	PWC		PUMP	MAKING METAL
1/9/2005	DHC8400	PW150A		6617302	NR 1 HYD SYSTEM
(CAN) DURING APPROACH TO BASE, NR 1 HYD ISO VLV AND NR 1 ENG HYD PUMP CAUTION LIGHT ILLUMINATED. NR 1 SYSTEM PRESSURE 0 PSI. STBY PRESS NORMAL AFTER SPU SELECTED ON. EMERGENCY LANDING DECLARED. AIRCRAFT STOPPED ON RUNWAY AND WAS TOWED IN. NR1 PROP COULD NOT BE ROTATED BY HAND. METAL FOUND IN CASE DRAIN AND PRESSURE FILTERS. REPLACED NR 1 EDP.
CA041125003	BOMBDR	PWC		ECU	FAILED
9/3/2004	DHC8400	PW150A		699018002	PROPELLLER
(CAN) AUTO FEATHER SYSTEM FAILED TO ARMED WHEN TAKE-OFF POWER WAS APPLIED. ABORTED TAKE-OFF. FAULT CODE 794 WAS LOGGED IN THE CENTRAL DIAGNOSTIC SYSTEM (CDS) DURING THE FOLLOWING OVERSPEED GOVERNOR TEST. A FUNCTIONAL TEST OF THE PEC AND CALIBRATION PROCEDURE WAS THEN PERFORMED IAW AMM TASK 61-20-36-720-801. FAULT CODE 238 REMAINED LOGGED IN THE CDS AS WELL AS PEC CAUTION LIGHT AND POWERPLANT MESSAGE ON THE ED AND FINALLY THE LT PROPELLER ELECTRONIC CONTROL UNIT (PEC) WAS REPLACED IAW AMM TASK 61-20-36.
CA040611001	BOMBDR	PWC		SWITCH	BURNED
6/7/2004	DHC8400	PW150A		RV4NBYSD502A	READING LIGHT
(CAN) PILOT REPORTED BURNING SMELL IN THE COCKPIT. MAINTENANCE FOUND THE DIMMER SWITCH OF THE CO-PILOTS READING LIGHT BURNED THE SWITCH PN RV4NBYSD502A WAS REPLACED AND A FUNCTION CHECK CARRIED OUT. NO FURTHER PROBLEMS.
CA040610009	BOMBDR	PWC		PUMP	FAILED
6/6/2004	DHC8400	PW150A		661732	NR 2 HYD SYSTEM
(CAN) DURING CLIMB FROM AIRPORT, NR 2 ENG HYD PUMP AND ASSOCIATED FLIGHT CONTROL CAUTION LIGHTS ALL ON HYD QTY 75 PERCENT. ACTIVATED PTU, THEN PRESSURE RETURNED TO NORMAL. AFTER LDG AND FLAPS SELECTED FOR LANDING, HYD QTY DECREASED TO 30 PERCENT. FLIGHT CONTROL C/LS ILLUMINATED AGAIN. CONTINUED LANDING WITHOUT FURTHER INCIDENT. STOPPED ON TAXIWAY FOR TOWING TO GATE, AT THAT TIME HYD QTY WAS 0 PERCENT. FOUND NR 2 EDP HANGER TRUNNION SCREWS, 1 MISSING AND 3LOOSE AND PACKING BLOWN OUT. REPLACED EDP.
CA040610006	BOMBDR	PWC		BLADE	DEPARTED
6/9/2004	DHC8400	PW150A			COMPRESSOR
(CAN) AN AIRCRAFT CARRIED AN EMERGENCY LANDING AFTER EXPERIENCING A NR 2 ENGINE FIRE INDICATION. PRELIMINARY INFORMATION ADVISES LPC BLADE DEPARTURE AND COMPRESSOR SEIZURE. OIL WAS FOUND IN AND AROUND THE ENGINE AND NACELLE AREA AND HEAT DAMAGE WAS ALSO FOUND ON THE WIRING HARNESSES. FIRE BELIEVED TO HAVE BEEN CONTAINED WITHIN ENGINE. MFG INVESTIGATING THE ISSUE.
CA041124010	BOMBDR	PWC		ACTUATOR	FAILED
8/30/2004	DHC8400	PW150A		3994001009	ELEV PITCH TRIM
(CAN) DURING DECENT INBOUND TO BASE, THE PITCH TRIM CAUTION LIGHT CAME ON, QRH PERFORMED AND IT BECAME APPARENT THAT WE HAD A FAILURE OF THE PITCH TRIM. ATC NOTIFIED AND THE APPROACH PLANNED WITH HIGH SPEED FOR AS LONG AS POSSIBLE. DURING SPEED REDUCTION STICK FORCES INCREASED SIGNIFICANTLY AS DESCRIBED IN QRH. STICK FORCES LIGHTENED ON SELECTION OF FLAP 5, AND INCREASED AGAIN WITH SPEED REDUCTION. ALTHOUGH QUITE HEAVY TO HOLD, THE APPROACH AND LANDING WERE PERFORMED WITHOUT PROBLEMS. ELEVATOR PITCH TRIM ACTUATOR WAS REPLACED IAW AMM TASK 27-32-06.
CA041125002	BOMBDR	PWC		PROXIMITY SENSOR	FAULTY
11/10/2004	DHC8400	PW150A		82410888011	NLG
(CAN) DURING DECENT TO BASE WITH LANDING GEAR RETRACTED, NOSE (GREEN), NOSE (RED) AND HANDLE (AMBER) LIGHT ILLUMINATED FOR ABOUT 3 MINUTES. EXTENSION, LANDING AND TAXI NORMAL. PSEU FAULT HISTORY INDICATED NGDN1 UNREASONABLE NEAR FAULT. REPLACED NGDN1 PROXIMITY SENSOR IAW AMM 32-61-06.
CA040422005	BOMBDR	PWC		ACTUATOR	LEAKING
2/11/2004	DHC8400	PW150A		46455109	LT MLG
(CAN) AFTER GEAR DOWN SELECTION, NR 2 HYD ISO VALVE' CAUTION CAME ON AND DURING THE WHOLE APPROACH TO LANDING, 'OUTBOARD ROLL SPOILER CAUTION LIGHT' CAME ON INTERMITTENTLY. THIS WAS DUE TO, LOW QUANTITY IN NR 2 HYD SYSTEM. MADE A GO AROUND, AND KEPT GEAR DOWN WITH FLAPS 5. PERFORMED SYSTEM FAILURE CHECKLISTS AND DECIDED TO COMPLETE ALTERNATE GEAR EXTENSION PROCEDURE AS WELL. A NORMAL LANDING COMPLETED. INVESTIGATION/ACTION, EXTENSION HOSE FOR LT MAIN LANDING GEAR EXTENSION/RETRACTION ACTUATOR FOUND LEAKING. EXTENSION HOSE REPLACED ACCORDING AMM 32-31-11.
CA040422006	BOMBDR	PWC		WIRE	SHORTED
2/17/2004	DHC8400	PW150A			NLG PROX SENSOR
GEAR OUT INDICATION AFTER TAKEOFF, NOSE GEAR DOWN, NOSE GEAR UNSAFE AND GEAR IN TRANSIT LIGHT REMAINED ON. DURING DESCENT, THE LIGHTS WENT OUT AND ON FOUR TIMES. INVESTIGATION/ACTION, THE PROXIMITY SENSOR ELECTRONIC UNIT INTERROGATED FOR FAULTS, PSEU FAULT NR 1. THE NOSE GEAR DOWN SENSOR WIRING WERE FOUND SHORTED. SENSOR REPLACED ACCORDING AMM 32-61-06.
CA041124006	BOMBDR	PWC		PUMP	INOPERATIVE
11/23/2004	DHC8402	PW150A		6617302	HYD SYSTEM
(CAN) DURING CLIMB, 10 MIN. AFTER TAKE OFF, CLOSE TO 25 000 FT, PILOT NOTICED NR 2 ENGINE HYD PUMP CAUTION LIGHT FOLLOWED BY A LOSS OF NR 2 HYD FLUID QTY ON COCKPIT GAUGE. PILOT FOLLOWED Q400 QUICK REF HANDBOOK PROCEDURE NR 12.5. PTU HAS BEEN MANUALLY SELECTED ON WITH NO PRESSURE INCREASE IN NR 2 SYST DUE NO HYD FLUID, PTU SELECTED OFF, NR 2 HYD ISOLATION VALVE SELECTED ON. AC RETURNED AND ALTERNATE LANDING GEAR EXTENSION PROCEDURE USED. NR 2 ENGINE DRIVE HYD PUMP R & R IAW AMM. NR 2 HYD SYS BLEED IAW AMM AND NR 2 HYD SYS SERVICE IAW AMM. AC RETURN TO MAINT BASE. ENGINE DRIVE HYD PUMP DETAIL FINDING REPORT WILL FOLLOW.
2005FA0000010	BRAERO	GARRTT		CLAMP	CRACKED
12/7/2004	HS125700A	TFE7315R		FIOA5SCP2013	TAIL PIPE
THE DEFECT IS A FATIGUE CRACK, CAUSED BY BEING OVERSTRESSED DUE TO LOAD LIMITS, POSSIBLE OVERTORQUED. MAYBE THIS PART SHOULD BE MADE STRONGER, TO HANDLE THE STRESS. THIS DEFECT WAS FOUND BY A PENETRANT INSPECTION. THE LOCKING NUT NEEDS TO BE REMOVED, IN THIS CASE THE DEFECT WOULD NOT HAVE BEEN NOTICED IF THE LOCKING NUT HAD NOT BEEN REMOVED. (CE09200501913) (K)
CA040611007	BRAERO	RROYCE		DEICE SYSTEM	INOPERATIVE
5/30/2004	HS7482A	DART5342			RIGHT
(CAN) RT ENGINE DE-ICE FOUND INOPERATIVE, RETURNED TO DEPARTURE, STA NR 2 RELAY P/N CZ105648-2 REPLACED ENGINE INLET DE-ICE RING COWL REPLACED. HARNESS, P/N 6V10659 REPLACED FUNCTION TEST, SERVICEABLE
CA041202006	BRAERO	RROYCE		ENGINE	FAILED
12/2/2004	HS7482A	DART5342			RIGHT
(CAN) AC WAS ENROUTE, WHILE IN CRUISE THE AC YAWED TO THE RT AND THE STBD ENGINE SPOOLED DOWN. IN-FLIGHT SHUTDOWN PROCEDURE WAS CARRIED OUT AND THE AC RETURNED, WHERE AN UNEVENTFULL LANDING WAS MADE. UNTIL THE ENGINE SHUT DOWN, OPERATING INDICATION WERE NORMAL. MAINTENANCE INSPECTION REVEALED HEAVY STEEL CONTAMINATION OF THE OIL FILTERS, INCLUDING A COMPLETE CROWN FROM A GEAR WHEEL. INITIAL INVESTIGATION INDICATES THE PROPELLER GEAR BOX FAILED.THIS ENGINE IS DUE FOR OVERHAUL AND THE ENSUING STRIP REPORT WILL FURNISH A MORE IN DEPTH REPORT.
CA040803001	BRAERO	RROYCE		BATTERY	INOPERATIVE
7/23/2004	HS7482A	DART5342			MASTER
(CAN) AFTER DEPARTURE, THE CREW OBSERVED THAT THE STBD CHARGE RATE WAS NOT DECLINING BELOW 10 AMPS. THE AIRCRAFT RETURNED TO POINT OF DEPARTURE. MAINTENANCE REPLACED THE STBD BATTERIES AND THE AIRCRAFT WAS RETURNED TO SERVICE.
CA050119007	BRAERO	RROYCE		LANDING GEAR	UNKNOWN
1/5/2005	HS7482B	DART5342
(CAN) ON TAKEOFF, THE LANDING GEAR WOULD NOT RETRACT AFTER BEING SELECTED. THE AIRCRAFT RETURNED TO POINT OF DEPARTURE AND LANDED NORMALLY. THE AIRCRAFT WAS HANGARED AND A GEAR SWING CARRIED OUT, THE FAULT COULD NOT BE DUPLICATED. THE AIRCRAFT WAS RETURNED TO SERVICE.
CA050119009	BRAERO	RROYCE		HEATER	FAILED
1/12/2005	HS7482B	DART5342		S200	CABIN
(CAN) SHORTLY AFTER DEPARTING, THE CABIN HEATER FAILED. THE CREW RETURNED THE AIRCRAFT TO POINT OF DEPARTURE. THE HEATER UNIT WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE.
CA041130004	CESSNA	CONT		LINE	WORN
11/16/2004	150L	O200A		040031178	OIL PRESS
(CAN) THE OIL PRESSURE LINE UNDER THE INSTRUMENT PANEL WAS CHAFED AGAINST THE CABIN HEATER CONTROL CABLE. WE REPLACED THE PRESSURE LINE AND INSTALLED IT CORRECTLY.
CA040610010	CESSNA	CONT		LINE	CORRODED
6/10/2004	150M	O200A		040031158	FUEL SYSTEM
(CAN) FUEL LINE ASSEMBLY LOCATION/LOCATED UNDER FLOOR AND UNDER CENTER CONSOLE. THIS LINE IS DIRECTLY FORWARD OF THE BELLY DRAIN. IT IS UP STREAM FROM THE GASCOLATOR AND DOWN STREAM OF THE FUEL SHUT-OFF. FUEL SMELL WAS DETECTED. FUEL STAINING WAS PRESENT. THE LINE PASSES THROUGH A BULKHEAD. THE LINE IS PROTECTED BY A GROMMET WHICH WAS INTACT. THE LINE HAD BECOME CORRODED AND PITTED AROUND THE GROMMET AREA AND DEVELOPED A PIN HOLE LEAK. LINE WAS REPLACED.
CA040422003	CESSNA	LYC		MOUNT	CRACKED
4/22/2004	152	O235L2C		045100336	ENGINE
(CAN) AT INSPECTION THE ENGINE MOUNT WHICH ALSO HAS PROVISION FOR MOUNTING THE NOSE LANDING GEAR WAS FOUND DAMAGED. TWO TUBES WERE CRACKED, THREE OTHERS WERE SLIGHTLY BENT. ALL EVIDENCE POINTS TO A UNREPORTED HARD LANDING. AIRCRAFT HAS BEEN THOROUGHLY INSPECTED FOR FURTHER DAMAGE. NONE FOUND.
2005FA0000026	CESSNA	CONT		CONTROL PANEL	WORN
1/13/2005	172	O300*			PITCH CONTROL
AIRCRAFT WAS SUBSTANTIALLY DAMAGED DURING A LANDING ACCIDENT. PILOT WAS UNABLE TO FLARE AIRPLANE. DURING A POST ACCIDENT INSPECTION BY FAA INSPECTORS, IT WAS DISCOVERED THAT THE AIRPLANE'S CONTROL TEE PULLEYS FOR THE AILERON SYSTEM WOULD GET (HUNG UP) ON THE RADIO TRAY ASSEMBLY, WHEN THE CONTROL WHEEL TUBE WOULD REACH HALF TRAVEL. THE CONTROL TEE PIVOT AND THE LEFT INSTRUMENT PANEL CONTROL TUBE BALL SOCKET, EXHIBITED WEAR, AND THE CONTROL TEE COULD BE MOVED LATERALLY ALONG A PORTION OF THE CONTROL TEE PIVOT BOLT. ADDITIONALLY, THE RADIO-MOUNTING TRAY DID NOT INCLUDE THE INSTALLATION OF A VERTICAL SUPPORT TO HELP ASSURE PROPER CLEARANCE BETWEEN THE TRAY AND THE CONTROL TEE ASSEMBLY.
CA040506003	CESSNA	LYC		TORQUE LINK	CRACKED
2/6/2004	172K	O320E2D		04425061	NLG
(CAN) DURING INSPECTION, IT WAS DISCOVERED THE UPPER TORQUE LINK PART NUMBER 0442506-1WAS CRACKED. NEW PART WAS INSTALLED.
CA041103005	CESSNA	LYC		PUSHROD	BROKEN
10/25/2004	172M	O320E2D		05170281	LT DOOR LATCH
(CAN) LT DOOR WOULD NOT OPEN AND CLOSE PROPERLY.
CA041122003	CESSNA	LYC		GASKET	SPLIT
11/19/2004	172M	O320E2D		71973	INTAKE FLANGE
(CAN) INTAKE FLANGE GASKET SPLIT THROUGH CIRCUMFERENCE RESULTING IN MINOR VACUUM LEAK. THE GASKET MATERIAL IS HARD AND BRITTLE, AND APPEARS TO BE ERODING ON THE INNER EDGE. THIS IS THE FOURTH GASKET FOUND SPLIT IN THE LAST FEW WEEKS. THREE ON THIS ENGINE (1164 HOURS) AND ONE ON ANOTHER AT 700 HOURS. BOTH MGF FACTORY REMANUFACTURES. SUSPECT DEFICIENCY IN MATERIAL.
4356	CESSNA	LYC		STARTER	DESTROYED
12/21/2004	172P	O320D2J		EBB131A	ENGINE
ON ENGINE START, STARTER BENDIX DID NOT DISENGAGE. ALL BENDIX DRIVE ENGAGEMENT TEETH SHEARED AND DAMAGED ENGINE STARTER RING GEAR. TIME SINCE OVERHAUL BY KELLY AEROSPACE 195.0
CA041129011	CESSNA	LYC	CESSNA	COUPLING	BROKEN
11/27/2004	172P	O320D2J		C3010020211	ACTUATOR
(CAN) STUDENT AND INSTRUCTOR WERE PERFORMING A WALK AROUND OF THE AIRCRAFT BEFORE GOING FOR A LESSON. STUDENT SELECTED FLAPS DOWN THEY STARTED TO GO DOWN THEN THE FLAPS STOPPED MOVING BUT THE MOTOR KEPT RUNNING. FLAP MOTOR WAS REMOVED AND IT WAS FOUND THAT THE COUPLING BETWEEN THE MOTOR AND THE ACTUATOR HAD BROKEN. NEW COUPLING WAS INSTALLED AND THE FLAPS WORKED CORRECTLY.
CA041130011	CESSNA	LYC		CONTROL UNIT	FAILED
11/22/2004	172R	IO360L2A		AC2101	ALTERNATOR
(CAN) ALTERNATOR FIELD C/B TRIPPED WHEN ALTERNATOR TURNED ON. ZERO VOLTS FOUND AT ALT FIELD TERMINAL. REPLACED ALTERNATOR CONTROL RELAY, NO CHANGE. REPLACED ALTERNATOR CONTROL UNIT, VOLTAGE AT FIELD TERMINAL OF ALTERNATOR. ALTERNATOR FUNCTIONING NORMALLY DURING GROUND RUNUP.
CA040629007	CESSNA	LYC	AERO	CAPACITOR	CHAFED
6/25/2004	172R	IO360L2A		S19151	ALTERNATOR
(CAN) INTERMITTANT OCCURRENCE OF ALTERNATOR FAILING TO STAY ON LINE. INCORRECT POSITIONING OF CAPACITOR ALLOWED UNIT TO CHAFE AGAINST ENGINE BAFFLING UNTIL INTERNAL PORTION WAS EXPOSED CAUSED INTERMITTENT SHORT.
2005FA0000099	CESSNA			BULKHEAD	CRACKED
12/15/2004	172S			05522311	SPINNER
DURING A 100 HR INSPECTION THE FORWARD SPINNER BULKHEAD WAS FOUND TO BE CRACKED AROUND 4 OF THE 6 BOLT HOLES. THINK THAT THE CAUSE OF THE PROBLEM IS THAT THE TORQUE OF THE PROP WAS RAISED AND THE NEW TORQUE IS NOT ENOUGH TO CAUSE THE BULKHEAD AROUND THE BOLT HOLES TO BE PULLED INTO THE CHAMFERED AREA OF THE PROPELLER BOLT HOLES. THIS STRESSES THE BULKHEAD AND ALLOWS CRACKS TO START. TO PREVENT THIS PROBLEM POSSIBLY CONSIDER MAKING THE BULKHEAD OF THICKER MATERIAL OR REDESIGNING THE PART SO THAT WHEN IT IS TORQUED THERE IS STRESS RELIEF AROUND THE BOLT HOLES SO THAT THE BULKHEAD SITS FLAT. (K)
2005FA0000032	CESSNA	LYC		BULKHEAD	CRACKED
12/1/2004	172S	IO360B1E		05522311	SPINNER
DURING 100 HRS INSPECTION, FOUND FWD BULKHEAD OF THE SPINNER CRACKED 4 PLACES AROUND PROPELLER BOLT HOLES. RECOMMENDATION: BULKHEAD MATERIAL STRONGER OR THICKER. (WP07200507539)
CA040610008	CESSNA	LYC	CESSNA	BULKHEAD	BROKEN
6/9/2004	172S	IO360L2A		055032111	PROP SPINNER
(CAN) THE CORNER SECTION OF SPINNER AT LEADING EDGE OF PROPELLER BLADE CUT-OUT BADLY BENT (PEELED BACK) BY CENTRIFUGAL FORCE. THIS WAS CAUSED BY THE ADJACENT CORNER SECTION OF THE BACKPLATE (AROUND ANCHOR NUT) BREAKING OFF DURING OPERATION. NEW BACKPLATE DESIGN USED. (MOST CURRENT PN 0550321-12)
CA040615004	CESSNA	CONT	CONT	ROCKER BOSS	BROKEN
6/10/2004	180	O470K			CYLINDER EXHAUST
(CAN) ROCKER BOSSES BROKE OFF, FOR ROCKER SHAFT ON EXHAUST VALVE.
CA041108005	CESSNA	CONT		SKIN	CORRODED
11/1/2004	180C	O470L		07310041	VERTICAL STAB
(CAN) VERTICAL STABILIZER REMOVED TO ACCESS FUSELAGE SIDE SKIN REPLACEMENT (COSMETIC) WITH STABILIZER ON WORKBENCH, VISIBLE ACCESS TO INTERNAL STRUCTURE REVEALED CONSIDERABLE SURFACE CORROSION EVERY WHERE INTERNALLY. EXTERNAL UNIT LOOKS FINE. RECOMMEND REMOVAL OF VERTICAL AND HORIZONTAL STABILIZERS ON A REGULAR BASIS. IE. 400 HRS/5 YEARS.
CA040730007	CESSNA	CONT		TRIM SYSTEM	CONTAMINATED
7/27/2004	180H	O470R			ELEV TRIM WHEEL
(CAN) ELEVATOR TRIM WHEEL WOULD ONLY MOVE .5 INCH. FOUND DEBRIS CONSISTING OF GRASS, PEANUT SHELLS ETC. A SQUIRRELS NEST JAMMING THE CHAIN (CABLE ATTACHED TO CHAIN) ON THE GEAR WHICH ACTIVATES THE WORM GEAR TO MOVE THE ELEVATOR UP AND DOWN. BECAUSE OF THE LOCATION UNDER THE CENTER OF THE ELEVATOR, BETWEEN TWO BULKHEADS. IT WAS DIFFICULT TO REMOVE. IT WAS COMPLETELY (ALL) REMOVED, USING MIRRORS, VACUUM CLEANER. ALL PARTS WHERE IN EXCELLENT CONDITION.
CA040506002	CESSNA	CONT	EDOAIREXXXXX	BAR	CRACKED
4/19/2004	180H	O470R		3665710	FLOATS
DURING A ROUTINE, CHANGE OVER FROM SKIS TO FLOATS, IT WAS DISCOVERED THAT THE FORWARD SPREADER BAR ASSEMBLY PART NUMBER 36657-10 WAS BADLY CORRODED AND CRACKED. THE SPREADER BAR ASSEMBLY WAS REMOVED FROM EDO 249-2870 FLOATS. NEW PART NUMBER 26-32096 INSTALLED IN ACCORDANCE WITH STC SA00066SE AND INSTALLATION GUIDE FORAEROCET 26-32096 SPREADER BAR REPLACEMENT DOCUMENTA-10013.
2005FA0000101	CESSNA	LYC		EXHAUST VALVE	SEIZED
7/12/2004	182T	IO540AB1A5		LW19001	NR 3 CYLINDER
UPON TAKEOFF, PILOT REPORTED POWER LOSS AND ROUGH RUNNING ENGINE. INVESTIGATION FOUND NR 3 CYLINDERS EXHAUST VALVE SEIZED. THIS WAS 4TH OCCURENCE SINCE NEW (1999). INSTITUTED 300 HOUR VALVE GUIDE REAM AND 25 HOUR OIL CHANGE. MFG DENIED REQUEST TO INCREASE VALVE GUIDE CLEARANCE.
CA040421003	CESSNA	PWA	CESSNA	CARD	BROKEN
4/20/2004	208	PT6A114A			DIRECTIONAL GYRO
(CAN) THE CO-PILOT'S DIRECTIONAL GYRO WAS RECENTLY REPLACED WITH THE ABOVE MENTIONED OVERHAULED INSTRUMENT. UPON COMPLAINT FROM PILOT, THE INSTRUMENT WAS HARD TO SET, A FUNCTIONAL TEST WAS COMPLETED. IT WAS FOUND THAT PUSHING THE KNOB IN AND TURNING IT DID NOT ROTATE THE CARD WITH EASE. FOUND THAT IT TOOK ABNORMALLY GREAT AMOUNT OF INWARD PRESSURE WHILE TURNING THE KNOB TO GET ANY MOVEMENT OF THE CARD ESPECIALLY IN THE CLOCKWISE ROTATION. THE INSTRUMENT HAS ONLY 37.6 HOURS AND 34 CYCLES SINCE OVERHAUL.
CA040810005	CESSNA	PWA		SHIMMY DAMPENER	BROKEN
7/19/2004	208B	PT6A114A		26430096	MLG
(CAN) SHIMMY DAMPENER BARREL END ENTIRELY BROKE OFF AT CIRCLIP GROOVE. ALL FLUID LOST,CIRCLIP MISSING, BROKEN PIECE MISSING. NO EVIDENCE OF PRIOR OVERSTEER.
CA040614004	CESSNA	PWA		BELLCRANK	MISMANUFACTURED
6/10/2004	208B	PT6A114A		262400724	AILERON
(CAN) DURING COMPLETION OF MFG BULLETIN CAB03-4 ONE WELD WAS FOUND TO BE MISSING. THE MISSING WELD WAS ON THE LOWER ARM INNER SURFACE DESCRIBED AS ITEM 6 IN FIGURE 1 OF CAB03-4. ALL OTHER WELDS WERE PRESENT AND THE BELLCRANK SHOWED NO OBVIOUS DAMAGE OR DISTORTION CAUSED BY THE MISSING WELD.
CA040423003	CESSNA	CONT		SPRING	SEIZED
4/23/2004	210L	IO520L		12416432	MLG DOWNLOCK
DOWNLOCK SPRING ASSY SLIDING ACTION WAS RESTRICTED BY ACCUMULATION OF DIRT AND DEBRIS. DOWNLOCK WAS UNABLE TO FULLY ENGAGE RESULTING IN AN 'UNSAFE' GEAR IND. INSPECT REVEALED WET LUBRICATION ATTRACTED DEBRIS AND DIRT IN THE SPRING ASSY CONCENTRIC SLEEVE AND SPRING. CESSNA INSPECTION MANUAL SECTION 2 IS VAGUE REGARDING LUBRICATION TYPE AND APPLICABILITY AND STATES IN PART - 'AND ANY OTHER FRICTION POINT OBVIOUSLY REQUIRING LUBRICATION'. CONFUSION MAY ARISE IN THIS EXAMPLE. SUBMITTER RECOMMENDS A DRY LUBRICATION IN THIS AREA, AND INCREASED AWARENESS IN INDIVIDUAL INSPECTION PROGRAMS FOR A/C OPERATING IN 'OFF AIRPORT' LOCATIONS, GRAVEL AND DUSTY STRIPS. SUBMITTER'S A/C IS MODIFIED BY STC SA 5737SW NO DOOR KIT. AT LEAST 5 OTHER EXAMPLES EXIST IN A 14 YEAR SDR DATABASE SEARCH. SUBMITTER HAS INCLUDED ADDITIONAL TRAINING FOR FLIGHT AND GROUND PERSONNEL OPERATING AND MAINTAINING THIS A/C AND INCORPORATED ADDITIONAL DOCUMENTATION AND TRAINING DOCUMENTATION REFLECTING THIS CONDITION.
CA040423004	CESSNA	CONT		CYLINDER	CRACKED
4/23/2004	210L	IO520L		653446	ENGINE
CYLINDER CRACKED THROUGH 75 PERCENT OF CIRCUMFERENCE AT CYLINDER CROWN FROM A POINT BEYOND THE UPPER SPARK PLUG HOLE, AROUND THE EXHAUST VALVE, AND TERMINATING AT A POINT BEYOND THE LOWER SPARK PLUG HOLE (BUT NOT TRANSECTING THE HOLE).
CA040730005	CESSNA	CONT		CRANKCASE	CRACKED
5/23/2004	337D	IO360C			ENGINE
(CAN) ENGINE OIL LEAK DETECTED ON REAR ENGINE SUCTION INSPECTED FOUND 1.5 INCH LONG CRACK IN CASE BETWEEN NR 3 AND NR 5 CYLINDER. NO OTHER REPORTED DAMAGE. ENGINE REMOVED.
CA040930006	CESSNA			PAD	MISSING
9/24/2004	402B			P5855BSW	PROP DEICE
(CAN) AFTER FLIGHT, PILOT SAW ON RT PROPELLER, ONE PROP DE-ICE PAD MISSING ON ONE BLADE. AFTER INSPECTION OF THE DEFECT, WE SAW THE GLUE WAS NOT HARD. THE DE-ICE PAD WAS INSTALLED AT O/H SHOP WITH NEW KIND OF GLUE. WE REMOVED THE OLD GLUE AND REINSTALLED A NEW DE-ICE PAD WITH CONTACT GLUE (3M 1300L). AIRCRAFT RETURNED TO SERVICE AFTER REPAIR.NOTE: IT'S NOT THE FIRST TIME THIS PROBLEM APPEAR DUE TO THIS NEW KIND OF GLUE.
CA041006005	CESSNA	CONT		LINE	CORRODED
9/22/2004	414	TSIO520N		5100106236	LT ENG OIL
(CAN) PILOT AND AME FLYING HOME TO BASE OBSERVED THE LT ENGINE OIL PRESSURE DECREASING AT A SLOW RATE, UNTIL DECISION MADE TO SHUT DOWN THE ENGINE AND LAND AT THE NEAREST AIRFIELD. INVESTIGATION ON THE GROUND REVEALED OIL TO BE LEAKING FROM THIS LINE. LINE REPLACED AND CONDITIONS RETURNED TO NORMAL. CONTINUED ON HOME. NO FURTHER ACTION REQUIRED.
2004FA0000914	CESSNA	CONT	CONT	ROCKER	BROKEN
10/22/2004	421	GTSIO520D		6399576	NR 3 CYLINDER
ANNUAL PRE-INSPECTION RUN-UP RAN GOOD. POST INSPECTION RUN-UP RAN ROUGH. SUSPECTED A STICKING VALVE. FURTHER INVESTIGATION REVEALED A BROKEN EXHAUST ROCKER ARM AND STUCK VALVE FOR NR 3 CYLINDER ON THE LEFT ENGINE. ALSO, NOTED IS AN APPARENT INCLUSION IN THE BROKEN ROCKER ARM.
1538T001	CESSNA			TABLE	MISINSTALLED
11/26/2004	421B			863422	CABIN
INSPECTED RIGHT HAND CABIN EXECUTIVE TABLE AT THE RECOMMENDATION OF ANOTHER MAINTENANCE FACILITY MAINTAINING SAME TYPE OF AIRCRAFT. FOUND A LEFT HAND TABLE INSTALLED. FORWARD CUP HOLDER WAS SCREWED TO THE TABLE MAKING EMERGENCY EXIT REMOVAL DIFFICULT. EMERGENCY EXIT CHECKED AT LAST TWO ANNUAL INSPECTIONS WITH THE INTERIOR REMOVED.
2004FA0000927	CESSNA	CONT		BRACKET	MISINSTALLED
12/21/2004	421B	GTSIO520C		51310103	ZONE 300
COMPLIED WITH MFG MEB 00-4 RUDDER BEARING INSPECTION/REPLACEMENT. FOUND RUDDER LOWER HINGE BEARING BRACKET INSTALLED UPSIDE DOWN FROM FACTORY. REPLACEMENT PROCEDURE DESCRIBED IN MEB FOUND ERRONEOUS AND INADEQUATE TO COMPLETE SATISFACTORY REPLACEMENT OF BRACKET. MS 2047AD4-11 AND AD 5-11 RIVETS CALLED OUT IN MEB ARE OF THE INADEQUATE LENGTH. THIS WILL REQUIRE -12 OR -13 LENGTH RIVETS. REPLACEMENT PN 5131010-3 IS NOT SAME SIZE AS ORIGINAL AND DOES NOT APPEAR TO HAVE ADEQUATE EDGE DISTANCE FROM RIVET HOLES AS WELL AS CAUSING BULGING OF VERTICAL STABILIZER SKINS BECAUSE IT IS SLIGHTLY TOO WIDE. A MAJOR RE-WRITE OF THIS MEB AND ITS COMPLIANCE INSTRUCTIONS IS NEEDED.
CA050118005	CESSNA	CONT		LANDING GEAR	COLLAPSED
1/17/2005	421C	GTSIO520L			RIGHT
(CAN) RT LANDING GEAR COLLAPSED ON LANDING, THIS IS A PRELIMINARY REPORT MORE INFORMATION WILL FOLLOW.
CA041110019	CESSNA	GARRTT		SUPPORT BRACKET	CRACKED
11/8/2004	441	TPE33110		57150021	BELLCRANK
(CAN) AILERON BELLCRANK SUPPORT BRACKET WAS DISCOVERED TO BE CRACKED. PART WAS REPLACED WITH A NEW BRACKET AND THE AIRCRAFT RETURNED TO SERVICE.
2005FA0000098	CESSNA	PWA	GOODYEAR	HEAT SHIELD	DAMAGED
11/7/2004	500CESSNA	JT15D1		5004549E	LT MLG TIRE
PILOT REPORTED, HE HAD HIT AN OBJECT ON RUNWAY DUE TO IMPACT SOUND HEARD ON LT SIDE OF AC AND BRAKE ANTI-SKID FAIL INDICATION. INVESTIGATED LT WHEEL AREA AND DISCOVERED THAT TIRE HEAT SHIELD HAD PARTIALLY DISLOGED FROM WHEEL ASSY. INSPECTED AREA AND FOUND PART OF HEAT SHIELD HAD TORN AWAY CUTTING BRAKE ANTI-SKID WIRE HARNESS, BENDING GEAR DOOR ROD, AND DENTING IB AREA OF LT LANDING LIGHT HSG. INSPECTED RT TIRE HEAT SHIELD AND FOUND IT LOOSE ALSO. INSP FOUND RT SHIELD TO BE INSTALLED CORRECTLY IAW MFG MM. DECISION WAS MADE TO REPLACE RT SHIELD. TIRE HEAT SHIELD HAS NOT HARD MOUNT ATTACHMENT TO WHEEL ASSY. UPGRADING AC TO NEW STYLE WHEEL/BRAKE ASSY IS THE ONLY VIABLE FIX TO PREVENT THIS FROM HAPPENING.
CA040810007	CESSNA	PWA	BFGOODRICH	DISK	BROKEN
8/6/2004	550	JT15D4		1338932	BRAKE STATOR
(CAN) WHILE PUSHING THE AIRCRAFT WITH A TUG THE LT BRAKE LOCKED UP. ON INSPECTION IT WAS DISCOVERED THAT ONE OF THE STATOR DISKS HAD BROKEN AND JAMMED THE BRAKE. THE BRAKE WAS REPLACED WITH AN OVERHAULED UNIT. AD2004-09-05 WHICH ADDRESSES MFG BRAKE STATORS BREAKING HAD BEEN ACCOMPLISHED RECENTLY AND PASSED THE INSPECTION AS CALLED OUT. BOTH STATORS ARE STAMPED 'CHANGE D', SO NO FURTHER ACTION WAS REQUIRED. IN LIGHT OF THIS INCIDENT THE REPLACEMENT CRITERIA SHOULD POSSIBLY BE CHANGED.
CA040730004	CESSNA	PWA	BFGOODRICH	STATOR	CRACKED
7/27/2004	550	JT15D4		1338931	BRAKE SYSTEM
(CAN) DURING TAXI PILOT NOTICED MORE THRUST THAN NORMAL WAS NEEDED TO TAXI AND AIRCRAFT WAS DIFFICULT TO TURN TO THE RT. MAINTENANCE INSPECTION DISCOVERED CRACKED STATOR WHICH WARPED CAUSING BRAKE TO BIND UP.
CA041130001	CESSNA	PWA		COUPLER	DISCONNECTED
11/28/2004	550	JT15D4		CM357024	CABIN PRESSURE
(CAN) COUPLING DISCONNECTED WHEN AIRCRAFT WAS AT FLIGHT LEVEL AND AIRCRAFT AT A OPERATING CABIN PRESSURE ALTITUDE. AIRCRAFT CABIN LOST PRESSURIZATION.
2004FA0000871	CESSNA			BRIDAL CABLE	FRAYED
8/1/2004	560CESSNA			6565007197CR	ELEVATOR
ELEVATOR AUTO PILOT BRIDAL CABLE FRAYED TO THE POINT OF LOCKING UP CONTROL. DURING LOCATING CONTROL BLOCKAGE CABLE BROKE COMPLETELY INTO AT THE SUPPORT GUIDE PULLEYS. PRE-SB 560-27-07.
CA041007006	CESSNA	PWA		SLEEVE	WORN
9/22/2004	560CESSNA	JT15D5		7423461	THROTTLE CABLE
(CAN) DURING GROUND RUN OPERATIONS CHECK AFTER STARTER GENERATOR CHANGE THROTTLE WAS ADVANCED TO 70 PERCENT THEN RETARDED TO IDLE QUICKLY (1 SEC.). ENGINE FLAMED OUT. ENGINE RIGGING WAS CHECKED, THEN THE INNER CABLE OF THE AFT THROTTLE CABLE WAS REMOVED AND INSPECTED. FOUND THAT THE OUTSIDE SLEEVE ASSEMBLY COULD BE REMOVED EVEN WITH THE LOCK BOLT TIGHT AND THAT THE INNER CABLE WAS BEING PULLED OUT WHEN THE THROTTLE WAS QUICKLY RETARDED TO IDLE.
CA041126001	CESSNA	PWA		CABLE	BROKEN
11/22/2004	560CESSNA	PW535A		656014131	TE FLAPS
(CAN) AC DEPARTED, DURING CLIMB THE PILOTS NOTICED THAT THE FLAP INDICATOR DID NOT MATCH FLAP SELECTOR HANDLE. FLAP POSITION WAS VERIFIED VISUALLY BY CO-PILOT PRIOR TO RETURNING TO BASE. UPON MAINTENANCE INVESTIGATION IT WAS FOUND THAT THE FWD FLAP FOLLOW-UP CABLE WAS BROKEN AT THE PULLEY SWEDGED BALL. SL560-27-11 (SWEDGED BALL INSPECTION) WAS ACCOMPLISHED APRIL26/04 AT 573.1 A/F HOURS 411 LDGS. THIS SB WAS NEXT DUE AT 873.1 HRS. AIRCRAFT TT AT FAILURE WAS 846.3 HRS (-26.8 HRS TO NEXT INSPECTION) THE CABLE WAS REPLACED, RIGGED IAW MM, DUAL INSPECTION C/W AND RETURNED TO SERVICE.
CA040830006	CESSNA	PWA		PLUG	LEAKING
7/9/2004	560CESSNA	PW535A		49330	MAIN WHEEL
(CAN) MAIN WHEEL/TIRE ASSEMBLY LEAKING AIR 2-4 PSI PER DAY. REPLACED THERMAL RELIEF PLUG ASSEMBLY. THIS IS THE SECOND PLUG ASSEMBLY TO BE REPLACED ON THIS WHEEL (THERE ARE THREE PLUGS PER WHEEL ASSEMBLY).
CA040830004	CESSNA	PWA		PANEL	INOPERATIVE
8/3/2004	560CESSNA	PW535A		7511001915	AUDIO CONTROL
(CAN) FRONT PANEL OF AUDIO CONTROL UNIT DOES NOT ILLUMINATE ON NIGHT SETTING.
2004FA0000872	CESSNA			BRAKE	OUT OF ADJUST
8/9/2004	650			6242020519	MLG
ON DEPARTURE FROM MKE, CREW NOTED A SHIMMY IN THE NOSE WHEEL AND ABORTED TAKEOFF. INSPECTION FOUND NOSE GEAR FRICTION BRAKE DRAG LOW. ADJUSTED FRICTION BRAKE PER CE650 MM. COMPLETED HIGH SPEED (100 KTS) TAXI CHECK WITH NO SHIMMY EVIDENT. RELEASED AIRCRAFT FOR SERVICE. (M)
CA040629008	CESSNA	LYC		PLUG	WORN
6/17/2004	A152	O235L2C		LW11625	PISTON PIN
(CAN) A FEW PIECES OF NON-FERROUS MATERIAL WERE FOUND AT 1375.8 HOURS. FILTER RE-INSPECT SCHEDULED. SUBSEQUENT FILTER INSPECTION SHOWED HEAVY CONTAMINATION. ALL CYLINDERS REMOVED, FOUND PISTON PINS AND PLUGS NOT FLOATING. TWO PLUGS WERE WORN EXTENSIVELY. ALL PISTONS REMOVED FOR INSPECTION AND CLEANING, NO DAMAGE NOTED TO CYLINDER WALLS. PISTONS RE-INSTALLED WITH NEW PLUGS. ACCESSORY DRIVE COVER AND SUMP REMOVED FOR INSPECTION AND CLEANING. NO FURTHER EVIDENCE OF CONTAMINATION FOUND. NO FURTHER DAMAGE FOUND.
CA041001011	CESSNA	CONT		MAGNETO	ARCED
9/13/2004	A185F	IO520D		6310	RIGHT
(CAN) PILOT REPORTED A 200 RPM DROP ON RT MAGNETO. TROUBLESHOOTING REVEALED THAT TOP IGNITION WIRE ON NR 5 CYLINDER WAS UNSERVICEABLE. WHEN HARNESS WAS REMOVED FROM MAGNETO, EVIDENCE OF HEAVY ARCING WAS NOTED IN THE NR 5 LEAD OUTLET AREA OF THE DISTRIBUTOR BLOCK.
CA040506001	CESSNA	CONT		SPAR	CRACKED
11/21/2003	A185F	IO520D		07326031	HORIZONTAL STAB
REMOVED HORIZONTAL STABILIZER. REAR SPAR REINFORCEMENT PART NUMBER 0732603-1 CHANGED. AFT ATTACHEMNT POINT REINFORCEMENT BRACKET RT PART NUMBER 0732101-4 REPLACED WITH NEW. ADJACENT RIVETS REPLACED. SERVICE KIT SK185-27 INSTALLED TO FACILITATE SCREW JACK REMOVAL. LT TRIM JACK REMOVED. NEW SCREW PART NUMBER 0712500-11 INSTALLED. TRIM JACK REINSTALLED. RIGGED AND SAFETIED AS PER CESSNA MANUAL.
CA040421004	CESSNA	CONT		PAN	CORRODED
4/21/2004	A185F	IO550D		07520144	COWL FLAP
(CAN) DURING RIGHT COWL FLAP HINGE REPLACEMENT, FOUND COWL FLAP PAN ASSEMBLY HAS SEVERE CORROSION UNDER HINGE HALF. THIS AREA IS ONLY VISIBLE AFTER REMOVING THE HINGE.
2005FA0000024	CESSNA	CONT		BOLT	LOOSE
1/17/2005	T210M	TSIO520R			WASTEGATE VALVE
3 OF THE 4 BOLTS THAT ATTACH THE METAL PLATE THAT THE ACTUATOR IS MOUNTED ON TO THE WASTEGATE BODY WERE MISSING. FOURTH BOLT WAS BACKED OUT ABOUT HALF WAY. ALL THREE BOLTS FOUND LOOSE IN ENGINE COMPARTMENT. WASTEGATE ASSEMBLY ONLY 287 FROM OVERHAUL BY MAIN TURBO.THESE BOLTS ARE NOT EASILY OBSERVABLE AND REQUIRE A MIRROR TO SEE. RECOMMEND INSPECTION AT EACH OIL CHANGE AND TIGHTEN AS NEEDED.
CA040930002	CESSNA	CONT		SKIN	CRACKED
9/29/2004	T337G	TSIO360CB		14220006	LT WING
(CAN) DURING INSPECTION, CRACKS WERE DISCOVERED AT THE IB END OF THE LT AND RT UPPER OB WING SKINS WHERE THEY UNDERLAP THE FUEL TANK BAY COVERS. THE CRACKS ARE LOCATED IN THE RADIUS OF CUTOUT AREAS IN THE SKINS WHERE THE STINGERS JOIN AT WING STATION 150.0. THE AIRCRAFT IS EQUIPPED WITH FLINT WING TIP FUEL TANKS THAT WERE INSTALLED APPROXIMATELY 800 HOURS AGO. IT IS NOT KNOWN IF THIS IS A CONTRIBUTING FACTOR.
CA040927008	CESSNA	LYC	CESSNA	PIVOT ASSY	CRACKED
9/27/2004	TR182	O540L3C5		224110213	MLG
(CAN) RT BRAKE CONTINUALLY LOOSING FLUID. CENTER SECTION AT GEAR PIVOTS ALWAYS WET. BRAKE SWIVEL NOT LEAKING. PIVOT ASSEMBLY REMOVED AND CHECKED BY DYE PENETRATE INSPECTION FOUND TO BE CRACKED. INSTALLED NEW PIVOT ASSEMBLY IAW MAINTENANCE MANUAL.
CA040823BB	CESSNA			FITTING	CRACKED
8/20/2004	U206B			1216012	FUSELAGE
(CAN) DURING THE 100 HOUR INSPECTION THE RH MAIN GEAR OUTBOARD FITTING WAS FOUND CRACKED AT THE UPPER AFT RADIUS OF THE FITTING OPENING.THE FITTING WAS REPLACED IN ACCORDANCE WITH CESSNA'S RECOMMENDATIONS (OBTAINED FROM CESSNA) WITH A USED SERVICEABLE CUSTOMER SUPPLIED UNIT AFTER NDT INSPECTION.
CA041125004	CESSNA	CONT	CESSNA	BOLT	SHEARED
10/25/2004	U206C	IO520F		NAS464P5A42	NLG STRUT
(CAN) BOLT SHEARED ON LANDING CAUSING NOSE GEAR TO PIVOT FORWARD. NOTE: THIS BOLT WAS LAST CHANGED SEPTEMBER 9/94 AT 2875 I.T.T. (AIRCRAFT PRESENT TT IS 6238.7 HOURS) THIS AIRCRAFT HAS OPERATED ON SKIS (SUSPECT THAT BOLT WAS OVERSTRESSED IN THIS CONFIGURATION). THIS BOLT WAS CRACKED PRIOR TO FAILURE AS HALF OF FRACTURE IS BLACK AND TOTAL FAILURE IS WHITE. SOME DAMAGE TO AIRFRAME WAS ENCOUNTERED. IT SHOULD BE NOTED THAT INSPECTION OF THIS BOLT IS NOT REPLACED IN INSPECTION SCHEDULE.
CA040630002	CESSNA	CONT		CRANKCASE	CRACKED
6/30/2004	U206G	IO520F			ENGINE
(CAN) DURING UNSCHEDULED MAINTENANCE 3 CRACKS WERE NOTICED ON CRANKSHAFT NEAR PROP FLANGE. TWO CRACKS WERE APPROXIMATELY 2 INCHES IN LENGTH PARALLEL TO EACH OTHER WITH SMALLER CRACKS EXTENDING. ONE CRACK IS ALSO APPROXIMATELY 2 INCHES IN LENGTH AND ABOUT 1 INCH FROM THE OTHER TWO CRACKS. THESE CRACKS RUN ALONG THE CIRCUMFERANCE OF THE CRANKSHAFT.
CA040924007	CESSNA	CONT		TUBE	CRACKED
9/13/2004	U206G	IO520F		537296	PUSHROD
(CAN) NR 5 CYLINDER PUSH ROD TUBE HOUSINGS FOUND 1 CRACKED, AT CYLINDER HEAD END, THE OTHER WAS BENT AT OB END OF SPRING RETAINER.
24331	CIRRUS			BOLT	CHAFED
11/2/2004	SR22			AN334	ALT AIR DOOR
THE BOLT (P/N AN3-34) THAT SERVES AS THE PIVOT FOR THE ALTERNATE AIR DOOR IN THE INDUCTION DUCT ASSEMBLY (P/N 15708-001) IS BEING CHAFFED BY THE INDUCTION DUCT SUPPORT BRACKET (P/N 15671-002). IN ADDITION TO THE CHAFFED BOLT THE INDUCTION DUCT ASSY IS SUSCEPTIBLE TO CRACKING. ALSO INSPECTED 14 OTHER AIRCRAFT WITH COMPARABLE TIME OR LESS AND FOUND SIGNS OF CHAFFING AND/OR INDUCTION DUCT CRACKING REQUIRING REPLACEMENT OF THE INDUCTION DUCT ASSY. THIS CONDITION IS VERY DIFFICULT TO INSPECT WITHOUT REMOVING THE INDUCTION DUCT ASSY.
2005FA0000018	CIRRUS	CONT		OIL COOLER	CRACKED
11/11/2004	SR22	IO550N		654585	ENGINE OIL
THIS AIRCRAFT HAS HAD AN OIL COOLER REPLACED FOR THE SAME DEFECT AT
2201092004	CIRRUS	CONT	CIRRUS	BOLT	CHAFED
10/4/2004	SR22	IO550N		AN334	INDUCTION DUCT
DURING REMOVAL AND REPLACEMENT OF THE P/N 15708-001 INDUCTION DUCT ASSY IT WAS NOTED THAT DUCT WAS CRACKED IN THE AREA OF THE AN3-34 BOLT THAT SERVES AS THE HINGE POINT FOR THE ALTERNATE AIR DOOR. AFTER REMOVING THE BOLT IT WAS FOUND TO BE CHAFFED ALL THE WAY AROUND THE SHANK (360 DEGREES). IT APPEARS THE INDUCTION DUCT SUPPORT BRACKET P/N 15671-002, MADE OF STAINLESS STEEL, IS WEARING IT'S WAY INTO THE BOLT SHANK. SEVERAL OTHER AIRCRAFT WERE INSPECTED AND WERE FOUND TO HAVE BOLT WEAR AND/OR CRACKING OF THE DUCT IN THE SAME AREA. THE CRACKING OF THE DUCT IS VERY DIFFICULT TO SEE WITHOUT REMOVING THE ASSY AND THE CHAFFING OF THE BOLT CANNOT BE SEEN WITHOUT REMOVING IT.
CA040510002	CNDAIR			FRAME	CRACKED
5/3/2004	CL2151A10			21531036212	WING TO BODY
WHILE PERFORMING AD CF-1997-07R2 A CRACK WAS DISCOVERED BY EDDY CURRENT ABOUT ONE AND A HALF INCHES LONG ON THE OUTBOARD RT REAR WING TO FUSELAGE FRAME ANGLE. THE CRACK BECAME VISUALLY APPARENT AFTER BEING DETECTED BY NDT. THE CRACK STARTED AT THE TOP OF FRAME P/N 215-31036-212 AND EXTENDED PASS THE FIRST HIGH LOCK AND ON TOWARDS THE SECOND. THE AD WAS PERFORMED AT AIRFRAME TIME 1984.2 AND TOTAL WATER DROPS 6843 WHICH IS PRIOR TO THE COMPLIANCE REQUIREMENTS OF AD CF-1997-07R.
CA040630007	CNDAIR	PWA		INDICATOR	DEFECTIVE
6/28/2004	CL2151A10	CA3		21550724	PRESS TRANSMITER
(CAN) AFTER TAKE-OFF, THE RT FUEL PRESSURE INDICATOR WAS 1 PSI LOWER THAN PREVIOUS FLIGHTS. THE CREW ELECTED TO PROCEED FOR MAINTENANCE. AFTER CRUSING FOR AWHILE THEY NOTICED ANOTHER DROP IN FUEL PRESSURE AND ELECTED TO SHUT DOWN THE RT ENGINE. THEY LANDED SAFELY FOR MAINTENANCE. MAINTENANCE CHECKED THE RT FUEL SYSTEM FOR LEAKS AND NONE WERE FOUND. THE FUEL PRESSURE INDICATING SYSTEM WAS CHECKED AND THE TRANSMITTER WAS FOUND DEFECTIVE. THE TRANSMITTER WAS REPLACED AND GROUND CHECKED SERVICABLE. THE A/C WAS RETURNED TO SERVICE.
CA040825006	CNDAIR	PWA		CASE	LEAKING
8/11/2004	CL2151A10	CA3		177770	RT ENGINE
(CAN) AFTER A DROP DURING FIRE BOMBING OPERATIONS, THE CAPTAIN AND FO PERFORMED ENGINE VISUAL CONDITION CHECK. THE FO NOTED A LARGE AMOUNT OF OIL LEAKING FROM THE RT ENGINE. OIL TEMPERATURE, PRESSURE AND QUANTITY WERE CLOSELY MONITORED ON THE 20 MIN. FLIGHT BACK TO THE MAINTENANCE BASE. MAINTENANCE FOUND OIL LEAKING FROM AN INSERT ON THE FRONT NOSE CASE. THE NOSE CASE WAS REPLACED AND THE A/C RETURNED TO SERVICE.
CA040629010	CNDAIR	PWA		MAIN BEARING	FAILED
6/29/2004	CL2151A10	CA3			RT ENGINE
(CAN) WHILE CLIMBING AWAY FROM A WATER SCOOP, THE CREW NOTICED THAT THE RT ENGINE WAS BECOMING UNCONTROLLABLE, ROUGH RUNNING AND LOSING POWER. THE CREW DROPPED THE LOAD AND SHUTDOWN THE RT ENGINE AND FEATHERED THE PROPELLER. THE AIRCRAFT MADE THE SINGLE ENGINE LANDING WITHOUT INCIDENT, AND THE AIRCRAFT RETURNED TO THE HANGER FOR INVESTIGATION.
CA040510003	CNDAIR	PWA		CONTROL CABLE	CORRODED
5/3/2004	CL2151A10	R2800*		215903812	RUDDER CONTROL
DURING A STRUCTURAL REPAIR TO THE RT REAR WING-TO-FUSELAGE FRAME ANGLE A PANEL AT WS 60.80, ADJACENT TO REAR SPAR, HAD TO BE DRILLED OFF TO FACILITATE THE REPAIR. IT WAS AT THIS TIME CORROSION WAS DISCOVERED ON THE RUDDER/AILERON INTERCONNECT CABLE P/N 215-90381-2 WHICH LIES DIRECTLY UNDER THIS PANEL. THE CORROSION WAS REMOVED AND UPON A CLOSER INSPECTION SEVERAL BROKEN STRANDS WERE NOTICED. THE MM WAS CONSULTED AND IT WAS DETERMINED THAT THE CABLE WAS BEYOND LIMITS. THE CABLE WAS REMOVED AND REPLACED WITH A SERVICEABLE UNIT AND THE WING PANEL WAS SEALED WITH AN APPROVED SEALANT. ITS WORTH NOTING THAT THE DAMAGE WOULD BE IMPOSSIBLE TO SPOT HAD IT NOT BEEN FOR THE REMOVAL OF THE RIVETED PANEL. THIS IS AN AREA NORMALLY INACCESSIBLE.
CA050120003	CNDAIR	PWA		FITTING	BROKEN
1/20/2005	CL2156B11415	PW123		215T2429080	RUDDER
(CAN) THE RUDDER GEAR/TRIM TAB UPPER FITTING FOUND BROKEN ON A VISUAL INSPECTION. A/C 1655, HOURS 1054, CYCLES 7200 DROPS.
CA040507003	CNDAIR			HEATER	SMOKE
4/30/2004	CL6002B19				WINDSHIELD
DURING CRUISE, SMOKE FROM LEFT WINDOW HEATER. WHEN LT WINDSHIELD HEAT WAS TURNEDOFF, SMOKE STOP. DIVERTED FLIGHT. FOUND LOOSE SCREW AND DAMAGED TERMINAL LUG ON LEFT WINDSHIELD HEAT ELEMENT. LUG REPLACED AND SCREW TIGHTENED.
2004FA0000870	CNDAIR			ANGLE	CRACKED
7/30/2004	CL6002B19			601R35031239	FUSELAGE
FLOOR SUPPORT ANGLE AT FS 621, WL 73 OUTBOARD OF LBL AND RBL 27 CRACKED. REPAIR IAW BOMBARDIER AEROSPACE EO NR 601R-53-61-117.
CA040811002	CNDAIR	GE		CONTROL UNIT	FAILED
7/29/2004	CL6002B19	CF343A1		47259701	NR 1 ENGINE
(CAN) FLT DIVERTED, EMERGENCY DECLARED. ON CLIMBOUT RECEIVED NUMEROUS FIRE FAIL MSGS., CAUTION MSG, THEY ALL DISAPPEARED. WE THEN RECEIVED A LH ENG FIRE WARNING AND WE SHUT DOWN NR 1 ENGINE. ON APPROACH WE RECEIVED A RH ENGINE FIRE WARNING MSG, ON LANDING WE RECEIVED A APU FAIL MSG, WHICH DISCHARGED THE BOTTLE. MTCE R/R THE FIREX CONTROLLER AND APU FIRE BOTTLE.
CA041129014	CNDAIR	GE		PUMP	CRACKED
11/29/2004	CL6002B19	CF343A1		848847	HYDRAULIC SYS
(CAN) FAULT: ON CLIMB OUT MSP, CREW RECEIVED PAX DR HANDLE LATCH MSG, FOLLOWED BY HYD SYS 3 LOW PRESS. MSG FOLLOWED BY PAX DR WARNING MSG. ON AIR RETURN, ON APPROACH FLT, RECEIVED GEAR DISAGREE MSG AND CARRIED OUT MNL EXTENSION. FOUND LINE LEAKING ON PUMP 3B. FOUND CASE CRACKED ON PUMP 3A. REPLACED BOTH 3A AND 3B HYD. PUMP REPLACED PRESS/RETURN AND CASE DRAIN FILTERS SYS. 3. REPLACED HYD. LINE ON PULSE DAMPENER PUMP 3B. HYD SYST. SERVICED.
CA040613001	CNDAIR	GE		IDG	INOPERATIVE
6/11/2004	CL6002B19	CF343B1		755469D	NR 1
(CAN) NR 1 IDG CAUTION MESSAGE CAME ON DURING TAKEOFF ROLL AND CREW ELECTED TO REJECT TAKEOFF. ON WEEK PRIOR OR(JUNE 5), THE CREW RECEIVED A CAUTION MESSAGE (DURING CRUISE AT 31000 FEET) ON EICAS FOR APPROX 30 SECONDS WITH SYNOPTIC CHANGING FROM GREEN TO YELLOW WHILE THE OUTPUT VOLTAGE REMAINED STEADY. MAINTENANCE CARRIED OUT A VISUAL INSPECTION AND THEN AS THE SNAG REOCCURRED, INITIALLY THE SYSTEM WAS DEFERRED IAW AS MEL PROCEDURE AND IDG WAS REPLACED AT THE SAME NIGHT HOURS SINCE INSTALLATION OF IDG. TT 2555.34 AND 1576 CYCLES ON A 381 DAY PERIOD.
CA040811003	CNDAIR	GE		NOSE COWL	DAMAGED
7/25/2004	CL6002B19	CF343B1		22850080158	NACELLE
(CAN) PILOT REPORTED LOUD NOISE AND SOME LOSS OF ENGINE POWER ON THE RT ENGINE AT CRUISE. UPON LANDING, THE TOWER INFORMED THE AIRCRAFT THAT A COWLING FELL OFF AT LANDING. ENGINE LOWER NOSE COWLING PANEL WAS RECOVERED.MTC LOOKED AT THE AIRCRAFT AND FOUND THE RT ENGINE UPPER AND LOWER NOSE COWLINGS MISSING. LOWER WAS RECOVERED FROM THE RUNWAY. UPPER WHERE ABOUTS STILL UNKNOWN. MANY OF THE CAM LOCK FASTENERS ARE STILL IN PLACE. SOME ARE MISSING AND 1 OR 2 FEMALE SOCKETS ARE NOT DAMAGED.
CA040929001	CNDAIR	GE		ENGINE	INOPERATIVE
9/24/2004	CL6002B19	CF343B1			NR 2
(CAN) AT 500 FT THERE WAS A LOUD BANG AND THE NR 2 ENGINE SHUT DOWN, DECLARED AN EMERGENCY. LANDED WITHOUT INCIDENT. ENGINE REPLACED. OVERWEIGHT LANDING INSPECTION ALSO REQUIRED.
CA040615008	CNDAIR	GE		TIRE	SEPARATED
5/27/2004	CL6002B19	CF343B1		H29X901516	MLG
(CAN) NR 2 MLG TIRE SEPARATION/ RUPTURE ENGINE VIBRATION (N1) WAS DEPICTED ON EICAS AND FELT THROUGHOUT THE AIRCRAFT. THE FLIGHT CREW RETARDED THE POWER LEVERS TO REDUCE N1 VIB. TO WITHIN LIMITS. (FYI:AT 42 PERCENT N1 = 3.9 MILS). A/C DIVERTED. FLIGHT CREW POST FLIGHT CHECK WITNESSED 3 FAN BLADES SEVERELY DAMAGED INDUCED BYTHE NR 2 TIRE SEPARATION AND RUPTURE. THE IB FLAP SURFACE HAS SUSTAINED DAMAGE AS WELL. FYI: THIS IS THE SIXTH OCCURRENCE SINCE MAY 11TH, 2004, ASSOCIATED WITH THIS MFG TIRE SEPARATION.
CA040615009	CNDAIR	GE		TIRE	SEPARATED
5/13/2004	CL6002B19	CF343B1		H29X901516	MLG
(CAN) DURING PASSENGER DEPLANING, A RAMPER REPORTED THE LT IB TIRE SHOWN TIRE SEPARATION (TREAD MISSING) AND THE CORD SECTION WAS SHREDDED AND THE TIRE HAD POPED OUT IN SEVERAL AREAS. UPON A CLOSURE LOOK, THE FLIGHT CREW NOTICED THE LT IB FLAP SURFACE HAD SUSTAINED DAMAGED AS WELL. LT NR 1 AND NR 2 TIRES REPLACED. FLAP SURFACE PN 601R14002-1, SN SB/RJ/777 REPLACED. LT ENGINE INSPECTED AND NO DAMAGE WAS FOUND.
CA040802001	CNDAIR	GE		SKIN	LIGHTNING STRIKE
7/30/2004	CL6002B19	CF343B1			HORIZ STAB
(CAN) THE FLIGHT CERW REPORTED A POSSIBLE LIGHTINING STRIKE , UPON INSPECTION BY MAINTENANCE IT WAS FOUND THAT THERE WAS DAMAGE TO NR 2 DME ANTENNA , NR 2 COMM ANTENNA AND NR 1 AND 2 ATC ANTENNES WHICH WERE REPLACED AND TESTED . ALSO FOUND STRUCTURAL DAMAGE ON RT HORIZONTAL STABLILIZER WHICH WAS REPAIRED IAW MFG EO 601R-55-11-129.
CA040811001	CNDAIR	GE		WINDSHIELD	CRACKED
7/27/2004	CL6002B19	CF343B1		NP13932111	COCKPIT
(CAN) CAPTAINS WINDSHIELD SHATTERED, OCCURRED AT FL330, CREW DESCENDED TO FL100, W/S HEAT ON LOW, MFG P: 7.2 WHEN WINDOW SHATTERED. WINDSHIELD REPLACED. (SEE ALSO: US NR 2004081200104)
CA041129001	CNDAIR	GE		WINDOW	CRACKED
11/28/2004	CL6002B19	CF343B1		NP1393225	COCKPIT
(CAN) THE LT SIDE WINDOW CRACKED WHILE IN APPROACH. VSB CSB-NP-139322 WAS PERORMED ON NOV 2003. WINDOW WAS REPLACED IAW AMM.
CA040420007	CNDAIR	GE		O-RING	LEAKING
4/15/2004	CL6002B19	CF343B1		MS29513326	FUEL COUPLING
(CAN) DURING ROUTINE WALK AROUND , MAINTENANCE DISCOVERED FUEL LEAK AROUND RT WING DRYBAY DRAIN. DRY BAY PANELS WERE REMOVED AND DRY BAY FOUND TO HAVE SMALL AMOUNT OF FUEL PRESENT. THE COUPLING THAT ATTACHES THE AIR SCOOP TO THE FUEL TANK VENTLINES ON THE RT WING WAS FOUND TO BE LEAKING INTO THE DRY BAY. COUPLING PACKINGS WERE REPLACED AND LEAK CHECK WAS COMPLETED WITH NO LEAKS FOUND. AIRCRAFT WAS RETURNED TO SERVICE. AIRCRAFT HOURS WERE 11178:51 AIRCRAFT CYCLES WERE 9107
CA040507002	CNDAIR	GE		SERVO	FAILED
4/23/2004	CL6002B19	CF343B1		8220260001	ELEVATOR
DURING CRUISE FLIGHT, AP TRIM IS RWD POSTED ON AND OFF EVERY FEW SECONDS. AUTO-PILOT DISCONNECTED. NOTICED THAT AILERON IS EXTREMELY HARD TO MOVE ALMOST BLOCKED. IN DESCENT WITHOUT AUTO-PILOT, WE NOTICED THAT THE ELEVATOR ALSO COULD NOT BE MOVED (FL310-300 / SAT -50 C). AROUND FL290 AND AFTER APPLYING STRONG INPUT, THE AILERON CAME FREE WITH A JERK. AROUND FL130 (TAT 0C), ELEVATOR FREE AGAIN. APPROACH AND LANDING NORMAL. AILERON AND ELEVATOR SERVO MOUNT CHANGED. OPERATIONAL TESTS ON A/P SERVOS SUCCESSFULLY PERFORMED. AILERON SERVO CYCLE 18126/ HOURS 23075 ELEVATOR SERVO CYCLE 19592/ HOURS 24455.
CA040507001	CNDAIR	LYC		ACTUATOR


		ADVISORY CIRCULAR 43-16A
	AVIATION MAINTENANCE ALERTS

ALERT NUMBER 320			MARCH 2005

ADVISORY CIRCULAR

AVIATION MAINTENANCE ALERTS