United States Department of Transportation / Federal Aviation Administration logo

AFS-600 Regulatory Support Division logo

 

ADVISORY CIRCULAR

43‑16A

 

 

AVIATION MAINTENANCE ALERTS

 

 

flag of the United States of America

 

ALERT

NUMBER

406

bald eagle watching over three eggs

MAY

2012

 


CONTENTS

AIRPLANES

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

PIPER........................................................................................................................................... 6

AGUSTA...................................................................................................................................... 8

 

POWERPLANTS

CONTINENTAL....................................................................................................................... 11

TURBOMECA........................................................................................................................... 11

 

ACCESSORIES

AUXILEX GENERATOR.......................................................................................................... 16

CESSNA ALTERNATOR......................................................................................................... 17

 

AIR NOTES

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE................................... 19

IF YOU WANT TO CONTACT US......................................................................................... 20

AVIATION SERVICE DIFFICULTY REPORTS...................................................................... 20

 


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

Cessna:  182G; Cracked Main Landing Gear Attach Casting; ATA 5343

A general aviation submission states, "A casting crack was found (visually) during the course of an Annual Inspection.  The crack is located on the forward end of the support casting (P/N 07416031), (starting) 0.25 inches from the outboard mount holes and (ends) within 0.25 inches of the mount holes on the inboard side of the casting."

CASTING BLOCK SHOWN WITH CRACK.


CASTING BLOCK SHOWN WITH CRACK.

Part Total Time:  2,690.0 hours

 

Cessna:  208B; Cracked Inertial Vane Shaft; ATA 7160

"Bypass door loose—will not close all the way," states this report from a Part 135 operator.  "Upon investigation, (we) found the shaft cracked on the forward inertial vane assembly (P/N 200803511002).  The mechanic also noticed the inlet splitter (P/N 200803511002) was cracked at (its two ends, and one attach angle was broken)."  (Reader minder:  the italicized parenthetical expressions are my insertions—Ed.)

 

END VIEW OF TORQUE TUBE.


TOP VIEW OF TORQUE TUBE SHOWING CRACKS.

 

SPLITTER ANGLE - SHOWING CRACKS AT BOTH ENDS.


SPLITTER ANGLE - SHOWING BROKEN MOUNT CLIP.

Part Total Time:  140.0 hours

 

Cessna:  208B; Rudder Torque Tube Corrosion; ATA 5540

A repair station technician states, "This Hawaiian based aircraft arrived at our (facility) for maintenance.  The rudder was removed from the aircraft, and its skin (then removed) to allow access to the rudder torque tube (P/N 263066‑3).  (This torque tube...) was scheduled to be replaced due to elongated holes in the bell crank.  Severe corrosion was found on the upper part of the torque tube which is located under the skin—(this area) is not visible to any scheduled maintenance.  The corrosion had reached the stage of 'blistered rust', and the 'L' angle on one side was easily separated with (minor) force (about 11 pounds; and wiggled twice)."  "By design the rudder is not sealed on the top.  The (torque tube top attach) bracket is located about a foot from the bottom—this cross member seems to pool water running down from inside the rudder (even though) there are drain holes in the design.  Hawaii is listed as a 'moderate' corrosion environment.

"The operator had no way to inspect this location.  A borescope would need to be used to (even) get an idea of the health of this part—(but still) it is better to remove and disassemble the (rudder).  I would suggest a rudder inspection (hole be designed and implemented) so maintenance can easily inspect the torque tube for corrosion."


RUDDER AND ITS TORQUE TUBE.

TORQUE TUBE AND THE BOTTOM RIB - REMOVED.


TOP OF THE TORQUE TUBE MOUNT SHOWING SEVERE CORROSION.

(Okay—that IS UGLY!  Ed.)

Part Total Time:  12,563.6 hours

 

Piper:  PA28R200; Cracked Aileron Pulley Brackets; ATA 2710

A General Aviation submission states, "During an Annual Inspection, both the L/H and R/H lower support aileron pulley brackets were (found) cracked in the forward inboard radius mount (flange) at each wing rib.  A piece of one of these pulley brackets was detached."  (Pulley bracket P/N: 67550000.)


BRACKETS AND CRACK LOCATIONS.

BRACKETS AND CRACK LOCATIONS.


NEW BRACKET.

 

NEW BRACKET.

Part Total Time:  (unknown)

 

Agusta:  A119; Cracked Gleason Crown Gear; ATA 6320

A quality control supervisor for this repair facility says, "During a 4800 hour overhaul inspection, the Gleason Crown gear was found to have a crack."


CLOSEUP OF CRACKED GEAR.

CLOSEUP OF CRACKED GEAR.


CLOEUP OF CRACKED GEAR.

CLOSEUP OF CRACKED GEAR.

(Gleason Crown gear P/N:  109040307103; Main Gear Box component P/N:  109040005103.  A second such gear report is found in the SDRS database.  Thanks for the photos—Ed.)

Part Total Time:  4,854.0 hours

 


POWERPLANTS

Continental:  IO520C; Cracked Crankshaft; ATA 8520

"The crankshaft cracked in the propeller flange at the radius," writes a technician.  "The crack (appeared) in a 'V' shape.  On one side the (crack) line was about four inches long, and the other about three inches."  (Crankshaft P/N:  649859.)

CLOSEUP OF CRANKSHAFT PROPELLER FLANGE AND ITS CRACK.

Part Total Time:  4,531.0 hours

 

Turbomeca:  Arriel 2B1; Cracked Turbine Guide Vane; ATA 7250

An AS350B3 helicopter operator writes, "While disassembling the engine to perform modification TU166, (I) found the power turbine nozzle guide vane cracked (P/N 0292517060).  The 'Module 3' (P/N  70BM032020) must be returned to the manufacturer for repair."


CLOSEUP OF CRACKED GUIDE VANE.

Part Total Time:  2,590.0 hours

 

Turbomeca:  Arrius 2B2; Cracked Guide Vane(s); ATA 7250

A technician for a corporate operation says, "While performing disassembly of this engine for a rear bearing oil pipe leak, (I) found damage to the following components, including:  a PT nozzle guide vane cracked (HP segment, assembly P/N 0319217910); an HP nozzle guide vane cracked (P/N 0319218310); the flame tube cracked (P/N 031917850); Diffuser with FOD (P/N 0319210050; and the T‑4 harness broken.  All of these parts are being replaced."  (Additional listed parts:  Module 2 P/N: 70EM027070 with cracked guide vane P/N 1319411580.)


CLOSEUP OF CRACKED GUIDE VANE.


CLOSEUP OF CRACKED GUIDE VANE.

CLOSEUP OF CRACKED FLAME TUBE.


CLOSEUP OF CRACKED FLAME TUBE.


CLOSEUP OF CRACKED FOD DIFFUSER.

 

Part(s) Total Time:  4,763.0 hours

 

ACCESSORIES

Auxilec Generator: (P/N) A3579101; Failed Bearing; ATA 2434

(This report references a Bombardier BD1001‑A10 aircraft with Honeywell AS90711A engines.)

A technician for a corporate operation says, "The generator rear bearing (opposite drive shaft) failed on the right engine.  (Its) mounting pad sheared and the generator split apart.  The crew received a 'Generator Fail' CAS (Crew Alerting System) message."  There are six of these P/Ns in the SDRS database.)


GENERATOR SEPARATED FROM ITS MOUNT.

Part Total Time:  1,397.0 hours

 

Cessna Alternator:  (P/N) 99105923; Brush Failure; ATA 2434

(This report references a Cessna T206H aircraft with a Lycoming TIO540AJ1A engine.)

"The alternator field circuit breaker tripped intermittently over the last 25 hours, (causing) various instances of radio noise," states this mechanic.  "The alternator remained functional.  (I) suspected possible brush failure, and elected to replace the alternator during an Annual Inspection. 

"The alternator was disassembled—found the ground brush (to be) 0.375 inches long.  The field brush was completely disintegrated, with the spring contacting the slip ring.  This alternator is only available from the manufacturer.  There are no known third party overhaul facilities.  The aircraft manufacturer service documents provide no service or parts data.  There are no aircraft manufacturer inspection protocols beyond external security checks.  Brush and/or slip ring inspection can only be accomplished by disassembly of the case. 

"I suggest a re‑design to permit proper periodic inspection the brushes, make service and overhaul data available, and/or improve quality.  Neither 'operation to failure' or 'periodic mandatory alternator replacement' is (acceptable)."


BRUSH SPRINGS IN ALTERNATOR HOUSING END.

DAMAGED SLIP RING ON ARMATURE.

Part Total Time:  645.0 hours

 


AIR NOTES

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE

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

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

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

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

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

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

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

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

 


The SDRS and iSDR web site point of contact is:

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

 

IF YOU WANT TO CONTACT US

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

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

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

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

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

 

AVIATION SERVICE DIFFICULTY REPORTS

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

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

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

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


Federal Aviation Administration

Service Difficulty Report Data

 

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

Control Number

Aircraft Make

Engine Make

Component Make

Part Name

Part Condition

Difficulty Date

Aircraft Model

Engine Model

Component Model

Part Number

Part Location

2012FA0000149

 

 

 

LIFE VEST 

DAMAGED 

3/10/2012

 

 

 

S512506300

CABIN

LIFE VEST HAS SEVERE RUST ON HARDWARE AND RUST STAINS ON ATTACHMENT STRAPS.

2012FA0000164

 

 

 

RING 

BROKEN 

3/22/2012

 

 

 

3037251

TURBINE VANE

BORESCOPE EVALUATION OF THE ENGINE PRIOR TO REMOVAL OF THE CT VANE RING SHOWED RUB ON THE L/E OF THE CT BLADES. ON THE CT VANE RING, ONE OF AIRFOILS SHOWED A "THUMBNAIL" TYPE INSERT ON THE T/E OF ONE AIRFOIL WHICH WAS PARTIALLY LIBERATED AND FOLDED BACK INTO THE GAS PATH. THE INSERT IN FOLDING BACK IMPINGED ON THE L/E OF THE CT BLADES AND RESULTED IN HEAVY RUB. VISUAL EXAMINATION OF THE REST OF THE VANE RING SHOWED THE REMAINING 13 AIRFOILS ALL HAVE HAD A THUMBNAIL TYPE INSERT SIMILAR TO THE FAILED AIRFOIL. THE INSERT EXTENDS BACK FROM THE TRAILING EDGE APPROXIMATELY 1.25" WITH A WIDTH OF .700". THE INSERT EXISTS IN BOTH THE CONVEX AND CONCAVE AIRFOILS WITH A DISTINCT LINE BETWEEN THE INSERT AND THE VANE RING. IT APPEARS THAT SINCE A DISTINCT LINE EXISTS THAT THE INSERT WAS NOT WELDED IN PLACE BUT RATHER BRAZED. THE INSERT APPEARS TO HAVE BEEN MFG FROM 2 PIECES OF FLAT STOCK WELDED ON ONE EDGE TO FORM THE T/E OF THE VANE.

AG2R2012040532747

 

LYC 

 

TRANSFER TUBE 

LEAKING 

4/5/2012

 

IO360L2A 

 

131327120

ENGINE OIL

LEAK FOUND ON CENTER MAIN OIL TRANSFER TUBE ON CRANKSHAFT, SN .

2012FA0000158

AGUSTA 

PWC 

 

SUPPORT 

WORN 

3/13/2012

A109E 

PW206C 

 

109060547

ENGINE MOUNT

DURING ACCOMPLISHMENT OF 109EP-112, ENGINE MOUNT INSTALLATION INSPECTION AND RT AND LT V-SHAPED SUPPORTS AND REAR SUPPORT LEGS REPLACEMENT. NR 2 ENGINE INBD MOUNT V-SHAPED SUPPORT, FORWARD LEG HAD LATERAL PLAY. UPON REMOVAL OF MOUNT, MOUNT BOLT WAS FOUND WORN THRU ABOUT 90 PERCENT OF BOLT THICKNESS. V-SHAPED SUPPORT MOUNT HOLD WAS FOUND ELONGATED. SHEARING OF THE BOLT WOULD HAVE CAUSED LATERAL SHIFTING OF ENGINE AND SHEARING OF ENGINE TO MAIN TRANSMISSION DRIVESHAFT. ENGINE OR MOUNT HAS NOT HAD A HISTORY OF REMOVAL OR REPLACEMENT FROM THE ACFT SINCE FACTORY. SUGGEST SHORTENING COMPLIANCE TIME OF TB 109EP-112 OR FLEET WIDE SPECIFIC INSPECTION.

DT1R2012041204

AGUSTA 

PWA 

AGUSTA 

GEAR 

CRACKED 

4/12/2012

A119 

PT6B37A 

 

109040307103

M/R GEARBOX

DURING 4800 HR O/H INSPECTION, SUBJECT GLEASON CROWN GEAR WAS FOUND TO HAVE A CRACK.

EE4Y20120329155

AIRBUS 

 

 

FLOOR SUPPORT 

CORRODED 

3/29/2012

A319132 

 

 

D5347219220000

ZONE 200

UPPER FUSELAGE PAX CABIN AFT GALLEY AREA FLOOR SUPPORT WITH CORROSION BETWEEN FR68 AND FR69, STRINGER Y765. DAMAGED PARTS WAS REPLACED IAW THE SRM 51-72-11. UNDER THE NON ROUTINE ITEM: WO A1A079, SUB JOB 2, ITEM 45.

EE4Y20120326148

AIRBUS 

 

 

TUBE 

SCRATCHED 

3/29/2012

A319132 

 

 

201371304

ZONE 700

LOWER FUSELAGE RT MLG SLIDING TUBE EXTERNAL SURFACE WITH SCRATCH AT 9 O`CLOCK POSITION. DAMAGED PART WAS REPAIRED IAW REPAIR GUIDELINES, UNDER THE NON ROUTINE ITEM: WO A1A079, SUB JOB 1, ITEM 93.

EE4Y20120326149

AIRBUS 

 

 

SKIN 

DAMAGED 

3/26/2012

A319132 

 

 

 

ZONE 300

VERTICAL STABILIZER RT SIDE BETWEEN RIB 3 AND RIB 4 SKIN WITH LIGHTNING STRIKE. DAMAGED AREA WAS REPAIRED IAW REPAIR GUIDELINES 70560175/006, UNDER THE NON ROUTINE ITEM: WO A1A079, SUB JOB 3, ITEM 11.

EE4Y20120326150

AIRBUS 

 

 

SKIN 

DAMAGED 

3/26/2012

A319132 

 

 

D5547100400000

RUDDER

VERTICAL STABILIZER RUDDER RT SIDE AT STA 80 AND 25" OF THE T/E SKIN WITH LIGHTNING STRIKE. DAMAGED AREA WAS REPAIRED IAW REPAIR GUIDELINES 70560169/008, UNDER THE NON ROUTINE ITEM: WO A1A079, SUB JOB 3, ITEM 12.

EE4Y20120326151

AIRBUS 

 

 

SKIN 

DAMAGED 

3/26/2012

A319132 

 

 

D5547100400000

ZONE 300

EMPENNAGE VERTICAL STABILIZER RUDDER SIDE PANEL HOISTING POINT NR 3 LT WITH TRAPPED FLUID. DAMAGED AREA WAS REPAIRED IAW REPAIR GUIDELINES 70560165/006, UNDER THE NON ROUTINE ITEM: WO A1A079, SUB JOB 3, ITEM 20.

EE4Y20120329152

AIRBUS 

 

 

FLOOR SUPPORT 

CORRODED 

3/29/2012

A319132 

 

 

D5367423920000

ZONE 100

LOWER FUSELAGE AFT CARGO COMPARTMENT BETWEEN FR58-FR59 LT FLOOR SUPPORT WITH CORROSION. DAMAGED PART WAS REPLACED IAW SRM 51-72-11, PARA 4, 5 AND 6. UNDER TO NON ROUTINE ITEM: WO A1A079, SUB JOB 1, ITEM 145.

EE4Y20120329153

AIRBUS 

 

 

PROFILE 

CORRODED 

3/29/2012

A319132 

 

 

D5347646000000

ZONE 100

LOWER FUSELAGE AFT CARGO COMPARTMENT FROM FR53 TO FR55 -Y28 PROFILE WITH CORROSION. DAMAGED PART WAS REPLACED IN ACCORDANCE WITH THE A319 SRM 51-72-11 PARAGRAPH 4, 5 AND 6. UNDER THE NON ROUTINE ITEM: WO A1A079, SUBJOB 1, ITEM 125.

EE4Y20120326144

AIRBUS 

 

 

FITTING 

CORRODED 

3/26/2012

A319132 

 

 

D57259162000

ZONE 100

LOWER FUSELAGE LT MLG RETRACTION JACK ANCHORAGE FITTING LOWER FACE AND BORE WITH CORROSION PITS. THE DAMAGED AREA WAS REPAIRED FOLLOWING REPAIR GUIDELINES 70560297/009. UNDER THE NON ROUTINE ITEM: WO A1A079. SUBJOB 1, ITEM 103.

EE4Y20120329154

AIRBUS 

 

 

PROFILE 

CORRODED 

3/29/2012

A319132 

 

 

D534704752600

ZONE 100

LOWER FUSELAGE AFT CARGO COMPARTMENT FROM FR53 TO FR55 +Y28 PROFILE WITH CORROSION. DAMAGED PART WAS REPLACED IAW THE SRM A319 51-72-11, PARA 4, 5 AND 6. UNDER THE NON ROUTINE ITEM: WO: A1A079, SUB JOB 1, ITEM 126.

EE4Y20120326145

AIRBUS 

 

 

ANCHOR FITTING 

CORRODED 

3/26/2012

A319132 

 

 

D57259162001

ZONE 100

LOWER FUSELAGE RT MLG RETRACTION ANCHORAGE FITTING LOWER FACE AND BORE WITH CORROSION. DAMAGED PART WAS REPAIR IAW REPAIR GUIDELINES, UNDER THE NON ROUTINE ITEM: WO A1A079, SUBJOB 1, ITEM 104.

VQIA2012FA0000120

AIRBUS 

 

 

FLOOR SUPPORT 

CORRODED 

1/23/2012

A320214 

 

 

D5347220924500

CABIN

FLOOR SUPPORT AT FRAME 68-69 AREAS OF CORROSION 50" TO THE RT OF CENTERLINE. LENGTH 1" X WITTH 1.2" X DEPTH .050".

VQIA2012FA0000121

AIRBUS 

 

 

FLOOR SUPPORT 

CORRODED 

1/14/2012

A320214 

 

 

D53448004320701

CABIN

TOP FLOOR SUPPORT , FURTHEST OTBD ON RT SIDE BETWEEN FRAMES 62 AND 66 HAS AN AREA OF CORROSION. LENGTH 2" X 2.5" WIDTH X DEPTH .050".

2012FA0000026

AIRBUS 

ENGALL 

 

DISK 

DAMAGED 

1/3/2012

A380861 

GP7270 

 

3821005050

HPC STG 6

THE HPC MODULE COM320015 WAS REMOVED FROM ENGINE PROPULSOR, P550135 AND DISPATCHED FOR INSPECTION AND REPAIR. THE REASON FOR ENGINE REMOVAL WAS HPC AND HPT DAMAGE. MISSING MATERIAL WAS NOTED ON THE BAFFLE PLATE OF THE HPC STAGE 6 DISK DURING INSPECTION OF THE HPC ROTOR MODULE. THE OEM HAS BEEN INFORMED. THE DEFECT HAS BEEN COMFIRMED BY ADDITIONAL BORESCOPE INSP AND THE INVESTIGATION IS IN PROGRESS.

2012FA0000181

AMD 

 

 

SEAT TRACK 

WORN 

4/2/2012

FALCON50MYST 

 

 

MY20212608811

COCKPIT

PILOT SEAT SLID AFT AFTER TAKEOFF. PILOT NOTED A CLICK AS SEAT LATCH PIN ENGAGED. DISASSEMBLY REVEALED BOTH SEAT TRACKS HAD WEAR MARKS BETWEEN HOLES DOWN CENTERLINE OF TRACK AND LATCH PINS HAD BEEN GROUND TO A CONICAL TAPER. NEW PINS ARE CYLINDRICAL WITH NO TAPER OTHER THAN A SLIGHTLY ROUND END. INSTALLATION INSTRUCTIONS DO NOT ALLOW MODIFICATION OF PINS. WHEN NEW PINS WERE INSTALLED ONLY ONE WOULD ENGAGE AT A TIME. SEAT WAS CHECKED FOR SQUARE AND ALSO TRIED IN OTHER AIRCRAFT TO CONFIRM IT WAS NOT RELATED TO PROBLEM. SEAT TRACKS WERE 1/2 HOLE OUT OF ALIGNMENT FROM SQUARE. NEW TRACKS WERE INSTALLED WITH PROPER ALIGNMENT TO SEAT TRACK PINS. ACFT RECORDS RESEARCH AND WEAR OF ALL PARTS INDICATED THIS WAS ORIGINAL FACTORY INSTALLATION.

2012FA0000162

AMTR 

 

 

GUSSET 

CRACKED 

3/19/2012

VELOCITYXL 

 

 

 

NLG

THE NOSE GEAR SPRING STRUT APPEARED TO HAVE FAILED AT THE END OF THE GUSSET. THERE APPEARED TO BE A PREVIOUSLY UNDETECTED CRACK IN THE LOWER END OF THE GUSSET WELD.

2012FA0000192

BEECH 

 

 

TUBE 

DEFLATED 

4/8/2012

35B33 

 

 

092315

MLG TIRE

HAVE EXPERIENCED MULTIPLE FAILURES OF SUBJECT INNER TUBES SINCE DEC 06. FIRST FAILURE OCCURRED ON LANDING SEPT 08; 21 MO. TIS, 70 HRS. ALL SUBSEQUENT FAILURES OCCURRED WHILE ACFT WAS PARKED. SECOND FAILURE NOV 09; 14 MO. TIS, 55 HRS. THIRD FAILURE APR 12; 24 MO. TIS, 62 HRS. CAUSE OF FAILURE ON LANDING WAS INDETERMINATE DUE TO EXTENT OF DAMAGE (STEM WAS NOT RECOVERED). OTHER FAILURES WERE THE RESULT OF A FRACTURE IN THE RUBBER AT THE BASE OF THE STEM. MFG WAS CONTACTED IN NOV 09. THE SECOND TUBE TO FAIL WAS PROVIDED TO THEM FOR ANALYSIS AT THEIR REQUEST. 2 REPLACEMENT TUBES WERE PROVIDED GRATIS, 1 OF WHICH WAS THE LAST TO FAIL. THE AIRCRAFT HAS NOT BEEN SUBJECTED TO COLD WEATHER OPERATIONS. TIRE PRESSURES HAVE BEEN MAINTAINED IAW ACFT MFG SPECIFICATIONS. TIRES ARE SERVICED WITH AMBIENT AIR (VICE NITROGEN). NO HISTORY OF SIMILAR FAILURES WITH OTHER MFG PRODUCTS OVER THE PAST 29 YEARS OWNING AND OPERATING THIS ACFT.

2012FA0000155

BEECH 

 

 

UPLOCK SWITCH 

SHORTED 

3/15/2012

400A 

 

 

1EN6

MLG

ACFT EXPERIENCED A LANDING GEAR UNSAFE LIGHT (RED HANDLE) IN FLIGHT, PILOT ATTEMPTED AND WAS ABLE TO CYCLE LANDING GEAR NUMEROUS TIMES, LIGHT WOULD NOT EXTINGUISH. PILOT VARIED GEAR DOWN AND LOCKED, LANDED ACFT.

2012FA0000178

BEECH 

CONT 

 

ROD END 

BROKEN 

4/4/2012

A45 

O470* 

 

HMY5FG

NLG

ACFT LANDED AND AFTER NORMAL TOUCHDOWN NOSE GEAR COLLAPSED. INSPECTION REVEALED THAT THE RETRACT ROD END HAD SEPARATED AND FAILED TO LOCK NOSE GEAR.

J8UR20120326002

BEECH 

 

 

HANDPUMP 

MALFUNCTIONED 

3/23/2012

B300C 

 

 

207006

 

DURING EMERGENCY LANDING GEAR OPERATIONAL AND FUNCTIONAL (GROUND) CHECK, EMERGENCY HANDPUMP HANDLE SEPERATED FROM PUMP HOUSING. (SNAP-RING THAT HOLDS PISTON ASSEMBLY INTO THE HAND PUMP ASSEMBLY DISENGAGED, CAUSING HAND PUMP ASSY TO COME APART DURING OPERATION).

2012FA0000176

BEECH 

PWA 

 

TRANSDUCER 

FAILED 

3/24/2012

C90 

PT6A135A 

 

1013890237

RT OIL PRESSURE

RT ENGINE OIL PRESSURE TRANDUCER QUIT WORKING DURING CLIMB OUT.

2012FA0000154

BEECH 

 

 

CIRCUIT BREAKER 

WRONG PART 

3/15/2012

F33A 

 

 

35380132XX

 

AD 2008-13-17 APPLIES TO THE ACFT DISCRIBED. WHILE ADMIRING THE AIRPLANE, NOTICED THE CIRCUIT BREAKERS DID NOT HAVE THE SAME APPEARANCE OF THE CORRECT BREAKERS. THE PERSON THAT COMPLIED WITH AD 2008-13-17 USED CIRCUIT BREAKERS THAT WERE NOT CALLED OUT IN SB 3735. THERE WAS NO AMOC IN PLACE FOR THE INSTALLED BREAKERS. THE AD IS STILL OUTSTANDING.

2012FA0000160

BEECH 

CONT 

 

CIRCUIT BREAKER 

FAILED 

3/13/2012

F33A 

IO520BB 

 

35380132101

ZONE 100

PILOT REPORTED NAVAGATION LIGHTS INOPERATIVE. ON TROUBLESHOOTING, THE TECH FOUND THE CIRCUIT BREAKER AT FAULT. INSTALLED NEW CIRCUIT BREAKER. OPS CHECKED OK. CIRCUIT BREAKER THAT FAILED WAS INSTALLED TO COMPLY WITH AD 2008-13-17.

3HCR03222012

BELL 

ALLSN 

 

BUSHING 

MISINSTALLED 

3/22/2012

206L1 

250C28 

ALAD1 

2526146

GOVERNOR

GOVERNOR ALLOWS ENGINE TO OVERSPEED. FAILED SHOP TEST. DIASSEMBLED AND FOUND UNIT IMPROPERLY ASSEMBLED. SPOOL BUSHING ANTI-ROTATION TANG WAS ENGAGED IN LEVER SLOT.

2012FA0000185

BELL 

ALLSN 

 

MAST 

BROKEN 

2/10/2012

OH58A 

T63A720 

 

206010332121

MAIN ROTOR

ACFT LANDED ON LOAD TRUCK. ACFT RECEIVED FUEL AND LOAD. PILOT FELT VIBRATION AND SHUTDOWN ACFT AND FOUND MAST POLE BROKEN.

FOTR0409201227183

BOEING 

 

 

VANE 

DEBONDED 

3/29/2012

717200 

 

 

 

LT WING TE FLAP

LEFT WING AFT MOVABLE FLAP VANE LOWER SKIN HAS A SMALL AREA OF DISBOND.

FOTR040920012

BOEING 

 

 

SKIN 

DENTED 

4/5/2012

717200 

 

 

 

ZONE 100

FOUND DENT ON THE LT SIDE OF FUSELAGE AT STA 215 JUST BELOW FLOORLINE AT L-18. REPAIRED ON FAS WO22051 NR 28247 WITH CONTINUED NR 28462.

FOTR0312201226588

BOEING 

 

 

DOOR FRAME 

CORRODED 

3/6/2012

717200 

 

 

 

ZONE 100

MULTIPLE AREAS OF CORROSION ALONG C1 DOOR FRAME (LOWER).

FOTR0312201227966

BOEING 

 

 

SKIN 

DAMAGED 

3/13/2012

717200 

 

 

 

ZONE 100

HOLE IN FUSELAGE SKIN AT BS 140 L-24 RIGHT. REPAIRED ON FAS WO 22031, NR 27966.

FOTR0301201225306

BOEING 

 

 

STIFFENER 

CRACKED 

3/1/2012

72731 

 

 

 

ZONE 600

RIGHT WING FRONT SPAR VERTICAL STIFFENER CRACKED, WS 200.

FOTR0301201225522

BOEING 

 

 

STRUCTURE 

CORRODED 

2/6/2012

72731 

 

 

 

ZONE 300

RT HORIZ STABILIZER- LOWER CHORD BETWEEN ELEVATOR STA 50.50 AND 66.50 ON AFT SPAR CORRODED.

FOTR0301201225523

BOEING 

 

 

STRUCTURE 

CORRODED 

2/1/2012

72731 

 

 

 

ZONE 300

RT HORIZ STABILIZER- VERTICAL STIFFENER AT ELEVATOR STA 53.91 AT AFT SPAR IS CORRODED.

7AHR201204132381

BOEING 

 

 

FLOOR SUPPORT 

CORRODED 

4/13/2012

7372X6C 

 

 

 

BS 663

CORROSION ON FLOOR SUPPORT AT STA 663 NEAR RBL 45. REMOVED CORROSION FROM FOUND SUPPORT, CORROSION FOUND TO BE OUT OF LIMITS. R & R FLOOR SUPPORT IAW CURRENT SRM.

7AHR201204132155

BOEING 

 

 

SKIN 

CORRODED 

4/13/2012

7372X6C 

 

 

 

RT WING

CORROSION RT WING UPPER SURFACE UNDER WING WALKWAY PAINT AT WING STA 765.9 AT WBL 92.5. BLENDED CORROSION, AFTER CORROSION REMOVAL IT WAS DETERMIND THE MATERIAL LOSS WAS OUT OF LIMITS. AFTER REVIEWING THE CURRENT SRM IT WAS DETERMIND THERE WAS NOT REPAIR IN THE SRM. THE DISCREPANCY WAS REFERED TO A DER, FLIGHT VEHICLES CONSULTING. A REPAIR SCHEME WAS DEVELOPED AND PROVIDED. ALL REPAIRS WERE ACCOMPLISHED UNDER THE INSTRUCTIONS PROVIDED BY THE EO FROM FLIGHT VEHICLES CONSULTING ON EO 57-12102-1.

7AHR201204092588

BOEING 

 

 

RIB 

CORRODED 

4/9/2012

7372X6C 

 

 

 

LT MLG DOOR

CORROSION ON AFT RIB OF LT MLG INNER DOOR. FOUND RIB ON INNER DOOR FOR LT MLG CORROSION BEYOND LIMITS. R & R RIB IAW SRM.

7AHR201204092598

BOEING 

 

 

RIB 

CRACKED 

4/9/2012

7372X6C 

 

 

69378551

L/E FLAP

LEFT FORE FLAP WBL 355 INBD SIDE OF RIB HAS A CRACK IN FITTING. R & R IAW SRM.

7AHR201204112562

BOEING 

 

 

FRAME 

CRACKED 

4/11/2012

7372X6C 

 

 

 

BS 380

CRACK AT INTERNAL FRAME, STRINGER 5R BODY STATION 380. REMOVED 2 EA STRINGER CLIPS 5R AT BODY STATION 380, REMOVED DAMAGED INTERIOR FRAME, FABRICATED REPAIR PARTS AND INSTALLED ALL REPAIR PARTS IAW SRM.

7AHR201204112597

BOEING 

 

 

RIB 

CRACKED 

4/11/2012

7372X6C 

 

 

 

NR 2 NACELLE

NR 2 ENGINE FIXED FAN COWL HAS CRACKED RIB. REMOVED CRACKED RIB AND FABRICATED REPAIR PARTS AND INSTALLED REPAIR PARTS IAW CURRENT SRM.

7AHR201204112459

BOEING 

 

 

FLOORBEAM 

CORRODED 

4/11/2012

7372X6C 

 

 

 

BS 706

CORROSION ON FLOORBEAMS AT BS 706 AT RBL 45. REMOVED CORROSION FROM FLOORBEAM BS 706. CORROSION FOUND TO BE OUT OF LIMITS. FABRICATED REPAIR PARTS FOR FLOORBEAM AND INSTALLED ALL REPAIR PARTS IAW CURRENT SRM.

7AHR201204112458

BOEING 

 

 

FLOORBEAM 

CORRODED 

4/11/2012

7372X6C 

 

 

 

BS 767

CORROSION ON FLOORBEAM AT BS 767 AT RBL 45. REMOVED CORROSION, AFTER CORROSION REMOVAL, DAMAGE FOUND TO BE OUT OF LIMITS. REMOVED CORRODED FLOORBEAM, AND FABRICATED REPAIR STRAPS AND INSTALLED STRAPS IAW CURRENT SRM.

7AHR35012D2219

BOEING 

 

 

STRINGER SPLICE 

CORRODED 

4/13/2012

7372X6C 

 

 

 

BS 1016

CORROSION AT FUSELAGE BULKHEAD BS 1016 AT STRINGER 25R. REMOVED CORROSION, AFTER CORROSION REMOVAL, AREA FOUND TO BE OUT OF LIMITS AT STRINGER 25R FROM STA 1016 TO 1026. FABRICATED REPAIR SPLICE AND INSTALLED REPAIR COMPOENENTS IAW SRM.

7AHR201204132167

BOEING 

 

 

SKIN 

CORRODED 

4/13/2012

7372X6C 

 

 

 

BS 1016

EXFOLIATION CORROSION AT STA 1016 AT STRINGER 26R TO 27R IN AREA OF OUTER WASTE DRAIN PAN. REMOVED CORROSION, AFTER REMOVAL OF CORROSION IT WAS DETERMIND THAT THERE WAS EXCESSIVE MATERIAL LOSS, WHICH DETERMIND THE AREA TO BE OUT OF LIMITS. AFTER EVALUATION IS WAS DETERMIND THAT THE REPAIR WAS NOT A STANDARD SRM REPAIR. CONTACTED ENGINEERING FIRM FLIGHT VEHICLE CONSULTING (FVC). A REPAIR SCHEME WAS DEVELOPED AND SUBMITTED. A REPAIR EO WAS PROVIDED AND THE ACFT WAS REPAIRED IAW WITH FLIGHT VEHICLE CONSULTING EO 53-12090-1.

2012F00072

BOEING 

 

 

SKIN 

CORRODED 

4/5/2012

7372X6C 

 

 

 

WING

CORROSION ON INTERNAL SKIN AND LONGERON BETWEEN WING STA 557.0 AND WBL 583.0. REMOVED CORROSION, ALODINE, AND PRIMED STRUCTURE IAW CURRENT SRM.

7AHR201204092258

BOEING 

 

 

ACCESS PANEL 

CORRODED 

4/9/2012

7372X6C 

 

 

 

ZONE 500

CORROSION AT LT WING FWD LOWER SPAR AT ACCESS PANEL MATING SURFACE FROM WBL 227.0 TO WBL 522.0. REMOVE ALL CORROSION FROM PANEL MATING SURFACE. MATERIAL LOSS FOUND TO OUT OF LIMITS AT WBL 291.82 AND WBL 314.76. DAMAGE FOUND TO BE OUTSIDE OF THE PARAMETER OUTLINED IN SRM. A REPAIR SCHEME WAS DEVELOPED AND PROVIDED. ALL REPAIR PARTS AND INSTALLATION WAS PERFORMED AS OUTLINED DWG 57-12094-1. AREAS THAT WERE WITH-IN LIMITS WERE TREATED AND PRIMED IAW INSTRUCTIONS OUTLINED IN CURRENT SRM.

7AHR201204052467

BOEING 

 

 

SKIN 

CORRODED 

4/5/2012

7372X6C 

 

 

 

ZONE 500

CORROSION ON LEFT WING INTERNAL SURFACE AND LONGERON BETWEEN WING STA 557.0 AND WBL 583.0. REMOVED CORROSION, ALODINE AND PRIMED IAW CURRENT SRM.

7AHR201204052466

BOEING 

 

 

SKIN 

CORRODED 

4/5/2012

7372X6C 

 

 

 

ZONE 600

CORROSION ON INTERNAL SKIN AND LONGERON BETWEEN WING STA 557.0 AND WBL 583.0. REMOVED CORROSION, MATERIAL LOSS WITHIN LIMITS. ALODINED AND PRIMED STRUCTURE IAW CURRENT SRM.

7AHR2012040635012

BOEING 

 

 

SPAR 

CORRODED 

4/6/2012

7372X6C 

 

 

 

RT WING

CORROSION AT LOWER RT WING L/E FWD SPAR AT WBL 227.0 TO WBL 522.0. REMOVED CORROSION, FABRICATED 2 REPAIR STRAPS AND INSTALLED IAW CURRENT SRM.

7AHR201204062375

BOEING 

 

 

SEAT TRACK 

CORRODED 

4/6/2012

7372X6C 

 

 

 

BS 663-747

CORROSION ON SEAT TRACK AT BS 663 TO 747 AT RBL 24.75. R & R SEAT TRACK IAW SRM.

7AHR201204062390

BOEING 

 

 

SEAT TRACK 

CORRODED 

4/6/2012

7372X6C 

 

 

 

ZONE 200

CORROSION ON SEAT TRACK AT BS 616 RBL 46. CORROSION FOUND TO BE OUT OF LIMITS, R & R SEAT TRACK IAW SRM.

7AHR201204062366

BOEING 

 

 

FLOORBEAM 

CORRODED 

4/6/2012

7372X6C 

 

 

 

ZONE 200

CORROSION ON FLOORBEAM AT BS 967 AND RBL 12. CORROSION FOUND TO BE OUT OF LIMITS. PERFORMED A SPLICE REPAIR TO THE FLOORBEAM IAW CURRENT SRM.

7AHR201204062357

BOEING 

 

 

FLOORBEAM 

CORRODED 

4/6/2012

7372X6C 

 

 

 

ZONE 200

CORROSION ON FLOORBEAM AT BS 727B AND RBL 24. REMOVED CORROSION, FLOORBEAM FOUND TO BE OUT OF LIMITS, FABRICATED REPAIR STRAP AND INSTALLED ALL REPAIR PARTS IAW SRM.

7AHR201204062365

BOEING 

 

 

FLOORBEAM 

CORRODED 

4/6/2012

7372X6C 

 

 

 

ZONE 200

CORROSION ON FLOORBEAM CAP AT STA 727B AND APPROX LBL 40. AFTER CORROSION REMOVAL FLOORBEAM FOUND TO BE OUT OF LIMITS. FABRICATED A REPAIR STRAP AND INSTALLED IAW CURRENT SRM.

7AHR201204062580

BOEING 

 

 

SEAT TRACK 

CORRODED 

4/6/2012

7372X6C 

 

 

 

ZONE 200

CORROSION ON SEAT TRACK AT STATION 540 AND RBL 64. AFTER CORROSION REMOVAL, SEAT TRACK FOUND TO BE OUT OF LIMITS. REPLACED SEAT TRACK IAW SRM.

7AHR201204062581

BOEING 

 

 

FLOORBEAM 

CORRODED 

4/6/2012

7372X6C 

 

 

 

BS 540

CORROSION ON FLOORBEAM AT BS 540 AND LBL 24. REMOVED CORROSION, FLOOR SUPPORT FOUND TO BE OUT OF LIMITS. FABRICATED REPAIR STRAP AND INSTALLED REPAIR PARTS IAW SRM.

7AHR201204062571

BOEING 

 

 

BRACKET 

CRACKED 

4/6/2012

7372X6C 

 

 

 

ZONE 500

LEFT INBD MID FLAP - OTBD CARRIAGE ASSY PULLEY SUPPORT BRACKET CRACKED. R & R PULLEY SUPPORT BRACKET IAW WITH MM 27-51-21.

7AHR201204032220

BOEING 

 

 

STRINGER 

CORRODED 

4/3/2012

7372X6C 

 

 

 

ZONE 100

CORROSION AT AFT FUSELAGE BULKHEAD AT BS 1016, STRINGER 17L. CUT OUT DAMAGED STRINGER 17L FROM 1016 TO 1026 TO ACCESS STRINGER TIE FITTING. FABRICATED REPAIR PART AND INSTALLED IAW SRM.

7AHR201204062296

BOEING 

 

 

ANGLE 

CRACKED 

4/6/2012

7372X6C 

 

 

 

ZONE 100

AFT CARGO BAY LEFT TRANSITION PANEL ANGLE CRACKED BETWEEN STATION 907 AND 927. REMOVED CRACKED ANGLE AND FABRICATED REPLACE PARTS IAW SRM.

7AHR201204072417

BOEING 

 

 

FLOORBEAM 

CORRODED 

4/7/2012

7372X6C 

 

 

 

ZONE 200

CORROSION ON FLOORBEAM AT STA 312 AT RBL 12. REMOVED CORROSION, FLOORBEAM FOUND TO BE OUT OF LIMITS. CUT OUT TEE CAP EXTRUSION, FABRICATED REPAIR PARTS AND INSTALLED REPAIR PARTS IAW SRM.

7AHR201204072138

BOEING 

 

 

RETAINER SEAL 

CORRODED 

4/7/2012

7372X6C 

 

 

 

NR 5 SLAT

CORROSION ON RT NR 5 L/E SLAT LOWER SEAL RETAINER. REMOVED CORROSION, SEAL RETAINER FOUND TO BE OUT OF LIMITS. FABRICATED NEW SEAL REATINER AND INSTALLED IAW WITH CURRENT SRM.

7AHR201204072456

BOEING 

 

 

SEAT TRACK 

CORRODED 

4/7/2012

7372X6C 

 

 

 

ZONE 200

CORROSION ON SEAT TRACK AT STA 540 TO 578 AT LBL 24.75. REMOVED CORROSION, SEAT TRACK FOUND TO BE OUT OF LIMITS. FABRICATED REPAIR PARTS AND INSTALLED IAW SRM.

7AHR201204072391

BOEING 

 

 

STRINGER SPLICE 

CRACKED 

4/7/2012

7372X6C 

 

 

 

ZONE 100

STRINGER SPLICE CRACKED AT S4L AT BS 908. REMOVED CRACKED STRINGER SPLICE, FABRICATED REPAIR PARTS AND INSTALLED REPAIR PARTS IAW SRM.

7AHR201204072657

BOEING 

 

 

STRINGER 

CORRODED 

4/7/2012

7372X6C 

 

 

 

ZONE 100

CORROSION AT BS 1004, AT STRINGER 27L. CUT OUT CORRODED SECTION OF STRINGER. FABRICATED REPAIR PARTS AND INSTALLED REPAIR PARTS IAW SRM.

7AHR201204092154

BOEING 

 

 

SKIN 

CORRODED 

4/9/2012

7372X6C 

 

 

 

ZONE 500

CORROSION ON TOP OF LT WING UNDER WALKWAY PAINT. BLENDED CORROSION, AFTER CORROSION REMOVAL FROM WING SKIN, MATERIAL LOSS FOUND TO BE OUT OF LIMITS. REPAIR REQUIREMENTS FOUND TO BE OUTSIDE OF STANDARD SRM REPAIR. FABRICATED REPAIR PARTS AND INSTALLED ALL REPAIR PARTS AS OUTLINED BY EO 57-12101-1.

Z6WR20120316004

BOEING 

 

BOEING 

SKIN 

MISREPAIRED 

3/14/2012

73776N 

 

737700 

315A2502102

THRUST REVERSER

A REPAIR LOCATED ON THE AFT END MOVES FORWARD APPROX 18" AND APPROX 25" FROM THE UPPER EDGE MOVING DOWNWARD ON THE 315A2502-102 INNER WALL BONDED PANEL, HAS AN AREA OF BLOCKAGE (PERF SKIN TO CORE) THAT MEASURES APPROX 15" X 15" C/T THE 315A2501-16 ACOUSTIC PANEL INSTALLATION. ULTRASONIC INSP IAW NDT MANUAL REVEALS AN AREA OF DISBOND 1.8" X 12.7" LOCATED WITHIN THE REPAIR AREA. REPAIR APPEARES TO HAVE BEEN ACCOMPLISHED FROM THE OML SIDE, BUT PERF HOLES DIDN'T GET RETICULATED CAUSING A BLOCKAGE OF THE PERF THAT MEASURES 17" X 24". AFTER REMOVING DEBONDED PERF SKIN, THE CORE PLUG FOR THE REPAIR WAS FOUND TO HAVE A 1.0" GAP. ALSO AN UNKNOWN RED SUBSTANCE IS CURED INTO THE REPAIR.

FOTR0301201233124

BOEING 

 

 

SKIN 

DENTED 

1/5/2012

75728A 

 

 

 

ZONE 200

EXT FUSELAGE BS 1963-1992, 11:00 POSITION IS DENTED.

FOTR0301201233119

BOEING 

 

 

SKIN 

DENTED 

1/24/2012

75728A 

 

 

 

ZONE 100

EXTERNAL FUSELAGE SKIN HAS 2 DENTS AT STA 1630 STR 18L AND STA 1650 STR 19L.

FOTR2107117411

BOEING 

 

 

SEAT TRACK 

GOUGED 

3/29/2012

7572Q8 

 

 

 

ZONE 200

MAIN CABIN SEAT TRACK GOUGED ON UPPER SURFACE, LBL 24, BS 460 TO BS 640. FOUND SEAT TRACK OUT OF LIMITS IAW SRM 53-40-52. REMOVED SEAT TRACK BS 460 TO BS 640 LBL 24, DRILLED AND LOCATED NEW SEAT TRACK AND INSTALLED NEW SEAT TRACK BS 460 TO BS 640, LBL 24 IAW SRM 53-30-52, 53-00-52 FIG 201, AND 51-40-02.

FOTR2012032117114

BOEING 

 

 

SKIN 

DENTED 

3/21/2012

7572Q8 

 

 

 

CARGO DOOR

FWD CARGO DOOR SKIN HAS A DENT AT B.S. 618 BETWEEN STRINGERS 18R AND 19R. REPAIRED BY CUTTING OUT DAMAGE, FABRICATING AND INSTALLING EXTERNAL DOUBLER IAW SRM 52-30-01 FIG 201 REPAIR 4. W/O 21071 N/R 17114

FOTR0307201217239

BOEING 

 

 

FLOOR SUPPORT 

CRACKED 

1/27/2012

7572Q8 

 

 

 

ZONE 200

MAIN CABIN FLOORBEAM INTERCOSTAL AT BS 1520 - 1540, BL 0 HAS CRACKED UPPER ANGLE.

FOTR0307201217238

BOEING 

 

 

FLOOR SUPPORT 

CRACKED 

1/27/2012

7572Q8 

 

 

 

ZONE 200

MAIN CABIN FLOORBEAM INTERCOSTAL AT BS 1620-1640, BL-0- HAS CRACKED UPPER ANGLE. REPAIRED ON FAS WO 21071, NR 17238.

FOTR0307201217257

BOEING 

 

 

SEAT TRACK 

CORRODED 

2/17/2012

7572Q8 

 

 

 

ZONE 200

MAIN CABIN SEAT TRACK AT BS 1320 RBL 24 HAS AREA OF CORROSION ON UPPER SURFACE. REPAIRED ON FASI WO 21071 NR 17257.

FOTR0307201217237

BOEING 

 

 

FLOORBEAM 

CORRODED 

1/31/2012

7572Q8 

 

 

 

ZONE 300

MAIN CABIN, BS 1320 FLOORBEAM HAS AREAS OF CORROSION OF UPPER SURFACE BETWEEN RBL 48 AND RBL 58. REPAIRED ON FAS WO 21071 NR 17237.

2012F00074

BOEING 

 

 

ASPIRATOR 

WRONG PART 

4/10/2012

767300 

 

767300 

119000103

ESCAPE SLIDE

DURING PRELIMINARY INSPECTION OF EVACUATION SLIDE/RAFT THE FOLLOWING DISCREPANCY WAS NOTED. ASPIRATOR, INSTALLED IN EVACUATION SLIDE/RAFT IS NOT IN COMPLIANCE WITH FAA AD 90-22-04. THERE IS NO EVIDENCE OF MODIFICATION OF ASPIRATOR AS REQUIRED BY THE AD. MARKINGS ON THE GIRT INDICATE THAT THIS EVACUATION SLIDE/RAFT WAS LAST SERVICED (OVERHAULED) IN MARCH OF 2011.

ABXR2012033100038

BOEING 

 

 

SKIN 

CORRODED 

3/31/2012

767338 

 

 

112T4701

ZONE 500

LEFT WING LOWER SURFACE CORRODED IN SEVERAL SPOTS BETWEEN WS 375 AND WS 992. REPAIRED IAW SRM AND AMES REA 46938REA10.

ABXR2012033100039

BOEING 

 

 

SKIN 

CORRODED 

3/31/2012

767338 

 

 

112T3301

ZONE 600

RIGHT WING UPPER SURFACE CORRODED IN SEVERAL SPOTS BETWEEN WS 350 AND WS 1021. REPAIRED IAW SRM AND REA 46938REA13.

ABXR2012033100040

BOEING 

 

 

FAILSAFE 

CORRODED 

3/31/2012

767338 

 

 

145T2524623

ZONE 100

FAILSAFE AREA CORRODED AT BS 955 S23-26L. REPAIRED IAW AMES REA 46938REA05.

ABXR2012033100028

BOEING 

 

 

STRUCTURE 

CRACKED 

3/31/2012

767338 

 

 

015T10594

ZONE 200

BS 1809 RT/FWD UPPER CHORD CRACKED AT LWR/FWD FASTENER HOLE. R & R CHORD IAW AMES REA 46938REA19.

ABXR2012033100030

BOEING 

 

 

SKIN 

CORRODED 

3/31/2012

767338 

 

 

145T252423

ZONE 100

FUSELAGE SKIN EXPOSED BY LT FAILSAFE STRAP CORRODED. REPAIRED IAW SRM AND REA 46938REA06.

ABXR2012033100029

BOEING 

 

 

SKIN 

CHAFED 

3/31/2012

767338 

 

 

148T31212

ZONE 100

FUSELAGE SKIN DAMAGED AT STA 1809, S12R. REPAIRED IAW SRM.

ABXR2012033100041

BOEING 

 

 

SKIN 

CRACKED 

3/31/2012

767338 

 

 

148T322212

ZONE 100

FUSELAGE SKIN CRACKED AT STA 1726. REPAIRED IAW SRM.

ABXR2012033100031

BOEING 

 

 

HOUSING 

DEBONDED 

3/31/2012

767338 

 

 

112T33012

ZONE 600

RIGHT OVERWING FILL HOUSING DID NOT BOND CHECK PROPERLY. REPAIRED IAW AMES REA 46938REA15.

ABXR2012033100032

BOEING 

 

 

FITTING 

CORRODED 

3/31/2012

767338 

 

 

112T10289

ZONE 100

LEFT KICK FITTING CORRODED. R & R KICK FITTING IAW REA 46938REA21.

ABXR2012033100033

BOEING 

 

 

FITTING 

CRACKED 

3/31/2012

767338 

 

 

148T25126

ZONE 100

RIGHT BS 1809 FWD SPLICE FITTING HAS CRACK INDICATION. R & R SPLICE FITTING IAW REA 46938REA28.

ABXR2012033100034

BOEING 

 

 

FITTING 

DAMAGED 

3/31/2012

767338 

 

 

148T904402

ZONE 100

BS 1809 RT LOWER CHORD TENSION FITTING HAS HOLE DAMAGE. R & R TENSION FITTING IAW REA 46938REA22.

ABXR2012033100036

BOEING 

 

 

SKIN 

DAMAGED 

3/31/2012

767338 

 

 

112T4702

ZONE 600

RT WING LOWER SURFACE HAS DAMAGE TO SEVERAL FASTENER HOLES BETWEEN WS 375 AND WS 1067. REPAIRED IAW SRM AND REA'S 46938REA11, 46938REA20, AND 46938REA26.

ABXR2012033100035

BOEING 

 

 

SKIN 

CORRODED 

3/31/2012

767338 

 

 

112T4703

ZONE 600

RIGHT WING LOWER SURFACE CORRODED IN SEVERAL SPOTS BETWEEN WS 375 AND WS 1067. REPAIRED IAW SRM AND REA'S 46938REA11 AND 46938REA16.

ABXR2012033100037

BOEING 

 

 

SKIN 

CORRODED 

3/31/2012

767338 

 

 

112T3302

ZONE 500

LEFT WING UPPER SURFACE CORRODED IN SEVERAL SPOTS BETWEEN WS 344 AND WS 916. REPAIRED IAW SRM AND REA'S 46938REA09, 46938REA12, AND 46938REA24.

QMLD2012041103961

BOLKMS 

 

 

RING 

LOOSE 

4/11/2012

BK117C2 

 

 

11211418206

ROTOR HEAD

BOLTS SECURING RINGS TO MAIN ROTOR HEAD INNER SLEEVES LOOSE.

AMCR2012033003

BOMBDR 

 

 

TIRE 

BULGED 

3/28/2012

BD1001A10 

 

 

269K432

ZONE 700

AFTER FLIGHT, MX DISCOVERED MULTIPLE BULGES ON THE INBD SIDE OF THE NR 3 TIRE SIDEWALL, NEAR THE CROWN EDGE OF THE TIRE.

QLFR20120309001

CAMRON 

 

 

VALVE 

FAILED 

3/8/2012

A315 

 

 

F8612

BURNER

THE BLAST VALVE (MAIN BURNER VALVE) NO LONGER FUNCTIONED. UPON DISASSEMBLING THE BLAST VALVE FROM BURNER SN:1221 THE SHUTTER VALVE WAS VISUALLY INSPECTED. THE VISUAL INSPECTION FOUND THE ADHESIVE COMPOUND BONDING THE BRASS TO THE RUBBER RING HAD FAILED. THE AMOUNT OF ADHESIVE BONDING THE TWO PIECES ALSO SEEMS TO BE INADEQUATELY OR UNEVENLY APPLIED. THE RUBBER RING SEPARATING FROM THE BRASS HOUSING RESULTED IN COMPLETE BLOCKAGE OF FUEL (PROPANE) TO THE BURNER COILS WHICH ULTIMATELY RESULTED IN FAILURE OF THE BLAST VALVE.

SROM2011011

CASA 

 

 

WIRE HARNESS 

CHAFED 

9/25/2011

C212DF 

 

 

 

COCKPIT

MULTIPLE CIRCUIT BREAKERS ON OVERHEAD PANEL POPPED IN FLIGHT. FLIGHT CREW CONTINUED TO DESTINATION AND LANDED WITHOUT INCIDENT. BREAKERS THAT TRIPPED INSTRUMENT LIGHT, ANTI SKID AND TEST, RADIO POWER AND NR 2 INVERTER OUTPUT 26 VAC AND 115 VAC. DETERMINED THE WIRING CHAFED AT ANTI-SKID CONTROL SWITCH AREA. FOR CORRECTION ACTION PERMANENT REPAIRS AND RE-ROUTING OF WIRING BUNDLE WERE ACCOMPLISHED.

2012FA0000175

CESSNA 

LYC 

 

BOLT 

BROKEN 

3/6/2012

152 

O235L2C 

 

78027

ROD

IN CRUISE FLIGHT PILOT REPORTED LOSS OF ENGINE OIL PRESSURE. ACFT LANDED IN A FIELD. VISUAL EXTERNAL EXAMINATION OF THE ENGINE REVEALED AN 8" SQUARE AREA OF THE BOTTOM OF THE CRANKCASE MISSING BY THE NR 1 AND NR 2 CYLINDERS. THE CONNECTING ROD FOR THE NR 1 CYLINDER WAS NOT CONNECTED, THE ROD CONNECTION BOLTS WERE IN PLACE BUT BROKEN. THE CRANKSHAFT JOURNAL DID NOT SHOW EVIDENCE OF DAMAGE. 1 OF THE NR 2 CYLINDER PUSH RODS WAS BENT.

NX4R2012031200028

CESSNA 

 

 

CONTROL CABLE 

FRAYED 

3/12/2012

172S 

 

 

0510105364

AILERON

DURING A ROUTINE INSPECTION, THE AILERON CABLE, FOUND FRAYED WITH BROKEN STRANDS. THE WEAR IS AT WS: 65.33

NX4R2012031501028

CESSNA 

 

 

CONTROL CABLE 

FRAYED 

3/15/2012

172S 

 

 

0510105391

ZONE 100

DURING A ROUTINE INSPECTION, THE TOP ELEVATOR CABLE AT THE PULLEY PNS-378-3, F/S-205.81 WAS FOUND TO BE FRAYED WITH SEVERAL BROKEN STRANDS. THERE WAS NO ABNORMAL WEAR ON THE PULLEY AND THE CABLE WAS NOT WORN. THE STRANDS APPEARED TO BE BROKEN DUE TO A TENSION FAILURE. THE CABLE TENSIONS WERE CHECKED PRIOR TO THIS FINDING AND WERE WITHIN PUBLISHED SPECIFICATIONS.

2012FA0000161

CESSNA 

 

 

WIRE 

MISINSTALLED 

3/19/2012

172S 

 

 

 

ELECTRIAL

WHILE CONDUCTING THE ESSENTIAL AND CROSSFEED BUSS DIODES INSPECTION AS CALLED OUT IN MM 5-10-01 AND 24-61-01, 2 WIRES SLIPPED OUT OF BUSS 1 AND BUSS 2 CONNECTOR ON MALE END. WIRES APPEARED TO HAVE INCORRECT CRIMP CAUSING WIRES TO PULL OUT CREATING POWER LOSS.

NX4R2012031200025

CESSNA 

 

 

CONTROL CABLE 

FRAYED 

3/12/2012

172S 

 

 

201201500

ELEVATOR

DURING A PHASE INSPECTION THE UPPER, AFT ELEVATOR CABLE P/N-2012-01500 HAD BROKEN STRANDS AT FS 205.81 AT PULLEY P/N-378-3.

NX4R2012031200026

CESSNA 

 

 

CONTROL CABLE 

FRAYED 

3/12/2012

172S 

 

 

0510105391

ELEVATOR

DURING A PHASE INSPECTION THE UPPER, AFT ELEVATOR CABLE PN-0510105-391 HAD BROKEN STRANDS AT FS 205.81 AT PULLEY PN-378-3.

NX4R2012031200027

CESSNA 

 

 

CONTROL CABLE 

FRAYED 

3/12/2012

172S 

 

 

0510105308

ELEVATOR

DURING A PHASE INSPECTION, THE UPPER, AFT ELEVATOR CABLE PN-0510105-308, HAD BROKEN STRANDS AT FS 205.81 AT PULLEY PN-378-3.

NX4R2012030800029

CESSNA 

 

 

CONTROL CABLE 

FRAYED 

3/8/2012

172S 

 

 

0510105360

AILERONS

DURING A ROUTINE INSP, THE AILERON CABLE PN-01510105 AT WS 65.33 WAS FOUND FRAYED WITH BROKEN STRANDS.

NX4R2012031900031

CESSNA 

 

 

SHAFT 

WORN 

3/19/2012

172S 

 

 

05600595

CONTROL COLUMN

DURING A ROUTINE INSPECTION, CONTROL COLUMN SHAFT WAS SIGNIFICANTLY WORN AT THE 6 O'CLOCK POSITION WHERE IT EXITS THE INSTRUMENT PANEL. IT RIDES ON A BUSHED SURFACE.

2012FA0000152

CESSNA 

LYC 

 

LINE 

OUT OF POSITION 

2/18/2012

172S 

IO360L2A 

 

050042500

FUEL SYSTEM

FUEL LINE, TOUCHING UPPER LIP OF LOWER FUSELAGE FORMER. THIS IS THE 3RD ACFT SEEN WITH THIS PROBLEM.

2012FA0000165

CESSNA 

LYC 

 

CABLE 

BROKEN 

3/15/2012

172S 

IO360L2A 

 

161102101R

COCKPIT SEAT

ONE OF TWO ATTACHING CABLES FOR THE SEAT TRACK LOCK PINS, FOUND BROKEN AT THE SWEDGE POINT, LEAVING THE CABLE FLAPPING LOOSE AND ONLY ONE PIN LOCKED IN SEAT TRACK. PULLING ON TEE HANDLE ONLY RELEASED PIN ON ONE SIDE. R & R CABLE ASSY. OPS CHECKED GOOD. CABLE ASSY BELIEVED TO BE ORIGINAL SINCE NEW.

2012FA0000174

CESSNA 

LYC 

 

RIB 

CORRODED 

4/3/2012

177RG 

IO360A1B6 

 

17130533

ZONE 200

DURING ANNUAL INSPECTION, HEADLINER WAS REMOVED FOR REPLACEMENT. FOUND CORROSION THAT WAS HIDDEN BY INSULATION MATERIAL. CORROSION WAS ON BOTH LT AND RT FUSELAGE ROOT RIB AND CORROSION ON RT DOOR OUTER JAMB (PN 1711030-4). CORROSION CONCENTRATED IN AREA WHERE FRESH AIR SCAT DUCTING ROUTES THROUGH ROOT RIBS. SCAT TUBING HAD DETERIORATED LETTING MOISTURE INTO CABIN ROOT RIB AREA. ALL PARTS WERE REPLACED WITH NEW FACTORY PARTS.

EVGR20120326001

CESSNA 

 

 

SKIN 

CORRODED 

3/26/2012

182P 

 

 

 

ZONE 100

CORROSION WAS FOUND UNDER THE BLACK SOUND DEADENING PATCHES ON THE INSIDE OF THE ACFT SKIN, AND WAS NOT DETECTED UNTIL THE PATCHES WERE REMOVED.

2012FA0000186

CESSNA 

LYC 

 

HUB 

CRACKED 

2/1/2012

182S 

IO540* 

 

D7298C431

NR2 BLADE SOCKET

LIQUID PENETRANT INDICATION ON THE EXTERNAL SOCKET ON NR 2 BLADE AT 4 O`CLOCK. THIS IS NOT A RADIAL INDICATION. THIS CRACK INDICATION WAS DISCOVERED DURING O/H. THE PART IS UNAIRWORTHY. HUB WAS SENT TO MFG FOR DESTRUCTIVE TESTING.

2012FA0000167

CESSNA 

PWA 

 

BRACKET 

WORN 

3/26/2012

208B 

PT6* 

 

26221102

FLAP BELLCRANK

THE PILOT COMPLAINED OF EXCESSIVE ROLL DURING LANDING WITH FULL FLAPS, INSPECTION FOUND THE RT AND LT INBD AFT FLAP BELLCRANKS TO HAVE EXCESSIVE PLAY IN ITS ATTACH BRACKETS. DURING DISASSEMBLY A TORQUE CHECK WAS DONE ON THE CENTER STUD AND FOUND TO BE UNDER THE TORQUE VALUE OF 35"LBS WHICH IN TURN WAS A .2500 TURN OF THE STUD. AFTER COMPLETE DISASSEMBLY OF BOTH INBD BELLCRANKS IT WAS FOUND THAT BOTH RT AND LT UPPER BRACKETS HAD EXCESSIVE WEAR IN THE CENTER HOLE. REPLACED UPPER ATTACH BRACKETS AND VERIFIED FLAP RIGGING.

2012FA0000168

CESSNA 

PWA 

 

BRACKET 

WORN 

3/26/2012

208B 

PT6* 

 

26221101

TE FLAP

DURING A ROUTINE INSPECTION, FOUND RT AND LT INBD AFT FLAP BELLCRANKS TO HAVE EXCESSIVE PLAY IN ATTACH BRACKETS. DURING DISASSEMBLY A TORQUE CHECK WAS DONE ON THE CENTER STUD AND FOUND TO BE UNDER THE TORQUE VALUE OF 35"LB WHICH IN TURN WAS A .2500 TURN OF THE STUD. AFTER COMPLETE DISASSEMBLY OF BOTH INBD BELLCRANKS IT WAS FOUND THAT BOTH RT AND LT UPPER BRACKETS HAD EXCESSIVE WEAR IN THE CENTER HOLE. REPLACED UPPER ATTACH BRACKETS AND VERIFIED FLAP RIGGING.

2012FA0000197

CESSNA 

 

BENDIX 

BEARING 

WORN 

4/7/2012

310N 

 

 

 

MAGNETO

PILOT DECLARED EMERGENCY AND PERFORMED UNSCHEDULED LANDING DUE TO LT ENGINE LT MAGNETO FAILURE. FAILURE APPEARS TO HAVE BEEN CAUSED BY A BAD BEARING IN THE MAGNETO.

2012FA0000172

CESSNA 

WILINT 

 

PADDLE 

MISSING 

3/29/2012

525 

FJ441A 

 

635405179

THRUST ATTEN

PILOT REPORTED THAT THAT THE NR 1 (LT) THRUST ATTENUATOR PADDLE WAS NOT PRESENT WHEN HE PERFORMED HIS POST FLIGHT INSPECTION. INSPECTION BY MX REVEALED THAT THE THRUST ATTENUATOR PADDLE HAD BROKEN OFF IN A CIRCUMFERENCE SURROUNDING THE ATTACHMENT FASTENERS. ALL FASTENERS ARE PRESENT AND APPEAR TO BE INTACT. THE ENTIRE TAIL PORTION OF THE ACFT HAS BEEN INSPECTED FOR IMPACT OR CONTACT DAMAGE RESULTANT FROM THE DEPARTING PADDLE AND NONE WAS FOUND. THE THRUST ATTENUATOR ON THE RT SIDE WAS INSPECTED FOR DEFECTS AND NONE WERE FOUND. A NEW PN 6354051-79 THRUST ATTENUATOR PADDLE ASSY HAS BEEN ORDERED FROM MFG AND WILL BE INSTALLED IAW AMM 78-30-00.

WI5R201203010001

CESSNA 

WILINT 

 

BOLT 

IMPROPER PART 

2/29/2012

525A 

FJ443A 

FJ443A 

MS955804

ENGINE DIFFUSER

DURING ON-WING REPLACEMENT OF A DIFFUSER ON ENGINE 216014, THE INCORRECT CONFIGURATION BOLT WAS FOUND INSTALLED IN THE SERVICE ISLAND OF THE DIFFUSER BEING REMOVED. INSTEAD OF THE PN MS9558-04, PLUG BOLT, THAT IS REQUIRED FOR THE THIS ENGINE, A PN 45947, SPECIAL HOLLOW BOLT, WAS INSTALLED. THE PN 45947 BOLT IS USED ON OTHER ENGINES TO GIVE CDP FEEDBACK TO THE FUEL CONTROL, AND THE TIP OF THE BOLT FITS THROUGH A HOLE IN THE DIFFUSER INNER FLOW PATH SKIRT. BECAUSE THE -3 DIFFUSER DOES NOT HAVE THIS HOLE, THE PN 45947, BOLT INSTALLED ON THIS -3 DIFFUSER CONTACTED THE INNER FLOWPATH SKIRT, PN 73185 AND DEFORMED IT AS THE BOLT WAS TORQUED DOWN. THERE ARE NO RECORDS OF PERFORMANCE ISSUES WITH THE ENGINE RELATED TO THE HOLLOW BOLT LEAKING CDP AIR INTO THE BYPASS AIR, ALTHOUGH THE TIP OF THE BOLT WAS GROUND INTO THE INNER FLOWPATH SKIRT AND MAY HAVE REDUCED THE AMOUNT OF LEAKAGE.

2012FA0000198

CESSNA 

WILINT 

 

BEARING 

FAILED 

3/18/2012

525B 

FJ443A 

 

 

NR 2

ON DESCENDING FROM FL 360 FT, A SMALL VIBRATION WAS FELT. ALL INDICATIONS NORMAL AND PILOT REPORTED THE VIBRATION WAS COMING FROM THE LT ENGINE. AT FL100 FT A MORE STEADY VIBRATION FELT. ALL ENGINE PARAMETERS REMAINED GREEN (NORMAL). NOTICED RT OIL PRESSURE LOWER THAN LT. RT OIL PRESSURE WAS 58 PSI & LT 78 PSI. ABOUT 20 MILES OUT, CABIN FILLED WITH SMOKE. OXYGEN MASKS WERE PUT ON BY PILOTS & AN EMERGENCY WAS DECLARED. LANDED UNEVENTFULLY. ALL ENGINE PARAMETERS REMAINED IN GREEN THROUGHOUT FLIGHT. SHUTDOWN ENGINES AFTER TAXI. POST-FLIGHT INSPECTION FOUND THE NO OIL IN SIGHT GLASS OF RT ENGINE. INSPECTION OF CHIP DETECTORS FOUND ALL 3 CHIP DETECTORS CONTAMINATED WITH METAL. ENGINE REMOVED. FOUND WEAR OF THE NR 2 BEARING THE ROOT CAUSE OF ANOMALY.

2012FA0000190

CESSNA 

 

 

TORQUE TUBE 

CRACKED 

2/9/2012

560CESSNA 

 

 

55421029

NLG DOOR

DURING A SCHEDULED LANDING GEAR INSPECTION, NOTICED LT BOLT SECURING NLG TORQUE TUBE SHEARED AND NUT AND COTTER PIN MISSING. ON REMOVAL OF ORIGINAL BROKEN BOLT, NOTICED THE BOLT WAS INCORRECT. THE MARKING ON THE BOLT WAS A STANDARD TOLERANCE BOLT (AN4-10D), REQUIRED IS A HIGH SHEAR, CLOSE TOLERANCE BOLT ( NAS4204-10D). BOTH LT AND RT NLG TORQUE TUBE BOLTS WERE CHANGED AT THE SAME TIME SINCE AN INSPECTION REVEALED THAT THE OPPOSITE SIDE BOLT WAS AN AN4-10D ALSO. DURING REPLACEMENT, NOTICED CRACKS AT WELDED END PLATES OF NOSE GEAR DOOR TORQUE TUBE. TORQUE TUBE ASSY WAS REPLACED AT THE SAME TIME.

2012FA0000188

CESSNA 

 

 

INLET GUIDE VANE 

DISCONNECTED 

2/1/2012

560CESSNA 

 

 

60525009

APU

DURING A ROUTINE MX CHECK, FOUND THE INLET AIR GUIDE DISCONNECTED AND LOOSE IN THE UPPER TAILCONE AREA. THE APU AIR INLET GUIDE AND "FIRE PROTECTION" FLANGE WAS LOOSE AND PARTIALLY COVERING THE AIR INLET TO THE APU. OPERATION OF THE APU BEFORE THE INSPECTION, GAVE NO INDICATION THAT THE INLET WAS PARTIALLY BLOCKED. THESE 2 PIECES APPEARS TO BE MADE FROM STAINLESS STEEL, AND BEING LOOSE IN THIS AREA, COULD CAUSE CHAFING INTO THE TAILCONE STRUCTURE. THE ATTACHMENT OF THESE PARTS ARE A FRICTION FIT TOT THE AIR INLET ADAPTER ( THE ADAPTER IS MECHANICALLY SECURED TO THE ACTUAL INLET ON THE APU). THESE PART ARE DIFFICULT TO INSTALL AND VISUALLY CONFIRM PROPER INSTALLATION DUE TO THE LIMITED ACCESS TO THIS AREA. THERE ARE FORMED "NUBS" ON THE AIR INLET GUIDE MATCH UP WITH CORRESPONDING SPOTS IN THE AIR INLET ADAPTER. AGAIN , DIFFICULT TO VERIFY PROPER INSTALLATION. COULD NOT FIND ANY INFORMATION ON THE PROPER INSTALLATION OF THE PARTS LISTED ABOVE IN THE MM.

CWQR20120306012

CESSNA 

 

 

TRANSFER TUBE 

CHAFED 

3/6/2012

560CESSNA 

 

 

65264807

ZONE 600

WHILE WORKING SL560-28-09, FOUND FUEL TRANSFER TUBE CHAFED BY CLAMP ASSY BEYOND ALLOWABLE LIMITS. FOUND A NR OF THESE TUBES CHAFED BECAUSE OF MISALIGNMENT. A NEW TUBE WAS INSTALLED IAW ACFT MM.

CWQR20120306011

CESSNA 

 

 

TRANSFER TUBE 

CHAFED 

3/6/2012

560CESSNA 

 

 

652640011

ZONE 600

WHILE WORKING SL560-28-09, FOUND FUEL TRANSFER TUBE CHAFED BY CLAMP ASSY BEYOND ALLOWABLE LIMITS. FOUND A NR OF THESE TUBES CHAFED BECAUSE OF MISALIGNMENT. A NEW TUBE WAS INSTALLED IAW ACFT MM.

CWQR20120306013

CESSNA 

 

 

TRANSFER TUBE 

CHAFED 

3/6/2012

560CESSNA 

 

 

65264807

FUEL SYSTEM

FOUND FUEL TRANSFER TUBE CHAFED BY THE CLAMP ASSY BEYOND ALLOWABLE LIMITS. HAVE FOUND A NUMBER OF THESE TUBES CHAFED BECAUSE OF MISALINEMENT. A NEW TUBE WAS INSTALLED IAW ACFT MM.

CWQR2012040225

CESSNA 

 

 

SUPPORT CHANNEL 

CRACKED 

4/2/2012

560XL 

 

 

66120692

CARGO DOOR

DURING A SCHEDULED INSPECTION OF THE TAIL BAGGAGE DOOR HINGE, FOUND THE LOWER FORWARD HINGE SUPPORT CHANNELS CRACKED, SB560XL-52-13 HAD BEEN COMPLIED WITH AT THE FACTORY. BUT BOTH THE 66120692 AND THE 6612069-11 CHANNELS WERE CRACKED IN 2 PLACES. THE CRACKS EXTEND FROM THE END OF THE PART PAST THE FIRST LOCK FASTNER TOWARDS THE SECOND.

CWQR2012040224

CESSNA 

 

 

CONTROL CABLE 

FRAYED 

4/2/2012

560XL 

 

 

66600031

ELEVATOR TRIM

DURING A SCHEDULED INSPECTION THE ELEVATOR TRIM CABLE WAS FOUND TO BE FRAYED BEYOND LIMITS. THIS CABLE ASSY IS LOCATED WHERE THE CABLE TRANSITIONS FROM A VERTICAL RUN TO THE HORIZ AT A PULLEY LOCATED IN THE HORIZ STABILIZER. WE HAVE SEEN NUMEROUS THIS SAME CONDITION. THE FRAYED CABLE ASSY AND A SERVICE CONDITION REPORT HAS BEEN SENT UNDER NR 613899.

CWQR2012040326

CESSNA 

 

 

HUB 

CRACKED 

4/3/2012

560XL 

 

 

62112975

CABIN DOOR

DURING A SCHEDULED INSPECTION OF THE CABIN DOOR, FOUND THE FORWARD CABIN DOOR COUNTERBALANCE SPRING REEL HUB TO BE CRACKED WHERE THE ROLL PIN GOES THROUGH THE HUB. PICTURES AND A SERVICE CONDITION REPORT HAS BEEN SENT TO MFG UNDER SDR 614143.

CWQR20120330020

CESSNA 

 

 

CONTROL CABLE 

FRAYED 

3/30/2012

560XL 

 

 

66600031

ELEVATOR TRIM

DURING A SCHEDULED INSPECTION THE ELEVATOR TRIM CABLE WAS FOUND TO BE FRAYED BEYOND LIMITS. THIS CABLE ASSY IS LOCATED WHERE THE CABLE TRANSITIONS FROM A VERTICAL RUN TO THE HORIZ AT A PULLEY LOCATED IN THE HORIZ STABILIZER. HAVE SEEN NUMEROUS WITH THIS SAME CONDITION. A SERVICE CONDITION REPORT HAS BEEN SENT TO MFG UNDER NR 613657.

CWQR20120320016

CESSNA 

 

 

HINGE 

CRACKED 

3/20/2012

560XL 

 

 

67113311

PAX DOOR

DURING A SCHEDULED INSPECTION, FOUND AN AREA OF CORRISION ON THE FWD MAIN CABIN DOOR HINGE, THAT IS ATTACHED TO THE DOOR FRAME. FOUND THE CORRISION ON THE FWD EDGE OF THE HINGE, PREFORMED A DYE-PEN CHECK AND FOUND THE HINGE TO BE CRACKED. THIS IS THE THIRD HINGE FOUND CORRODED AND CRACKED.

CWQR20120330023

CESSNA 

 

 

CONTROL CABLE 

FRAYED 

3/30/2012

560XL 

 

 

66600031

ELEVATOR TRIM

DURING A SCHEDULED INSPECTION, THE ELEVATOR TRIM CABLE WAS FOUND TO BE FRAYED BEYOND LIMITS. THIS CABLE ASSY IS LOCATED WHERE THE CABLE TRANSITIONS FROM A VERTICAL RUN TO THE HORIZONTAL AT A PULLEY LOCATED IN THE HORIZONTAL STABILIZER.

CWQR20120330022

CESSNA 

 

 

CONTROL CABLE 

FRAYED 

3/30/2012

560XL 

 

 

66600031

ELEVATOR TRIM

DURING A SCHEDULED INSPECTION, THE ELEVATOR TRIM CABLE WAS FOUND TO BE FRAYED BEYOND LIMITS. THIS CABLE ASSY IS LOCATED WHERE THE CABLE TRANSITIONS FROM A VERTICAL RUN TO THE HORIZ AT A PULLEY LOCATED IN THE HORIZ STABILIZER.

CWQR20120323017

CESSNA 

 

 

HINGE BRACKET 

CRACKED 

3/23/2012

560XL 

 

 

663400359

ELEVATOR

DURING A SCHEDULED INSPECTION, FOUND A CRACK ON THE ELEVATOR RT INBD HINGE THAT ATTACHES TO THE STABILIZER. VERIFIED CRACK WITH NDT, R & R HINGE.

CWQR20120330021

CESSNA 

 

 

CONTROL CABLE 

FRAYED 

3/30/2012

560XL 

 

 

66600031

ELEVATOR TRIM

DURING A SCHEDULED INSPECTION, THE ELEVATOR TRIM CABLE WAS FOUND TO BE FRAYED BEYOND LIMITS. THIS CABLE ASSY IS LOCATED WHERE THE CABLE TRANSITIONS FROM A VERTICAL RUN TO THE HORIZONTAL AT A PULLEY LOCATED IN THE HORIZONTAL STABILIZER.

CWQR20120327019

CESSNA 

 

 

HINGE BRACKET 

CRACKED 

3/27/2012

560XL 

 

 

663400359

ELEVATOR

DURING A SCHEDULED INSPECTION, FOUND RT ELEVATOR INBD HINGE CRACKED, VERIFIED WITH NDT, R & R HINGE ASSY.

CWQR20120323018

CESSNA 

 

 

HINGE BRACKET 

CRACKED 

3/23/2012

560XL 

 

 

663400361

ELEVATOR

DURING A SCHEDULED INSPECTION, FOUND RT ELEVATOR OTBD HINGE CRACKED, VERIFIED WITH NDT, R & R HINGE.

DXTR20120322002

CESSNA 

 

 

DRIP TRAY 

DEBONDED 

3/22/2012

560XL 

 

 

6213021661310766

ZONE 100

DURING ACCOMPLISHMENT OF SB-53-13, 1 AREA OF BOND SEPARATION NOTED ON RT SIDE AT FS 90.20, FROM LOWER EDGE OF NOSE COMPARTMENT DOOR OPENING UP TO 14". C/W SB-53-13 R1-- FUSELAGE NOSE DRIP CAP REPAIR OF MARKED AREA IAW SB-53-13 R1.

DXTR20120302001

CESSNA 

 

 

HINGE FITTING 

CORRODED 

3/2/2012

560XL 

 

 

67113311

ZONE 100

CABIN DOOR AFT LOWER HINGE AIRFRAME SIDE, UPPER FORWARD CORNER CORRODED.

DXTR20120322001

CESSNA 

 

 

WEB 

CRACKED 

3/22/2012

560XL 

 

 

6611268

PAX DOOR

WEB HAS 3 CRACKS AT DOOR HANDLE ATTACH POINT. REMOVED DAMAGE AS REQUIRED AND INSTALLED NEW STIFFENER IAW SRM 51-40-03 AND 51-40-06 AND SB-52-14.

EMWC2012F00070

CESSNA 

CONT 

 

CABLE 

DAMAGED 

11/26/2011

A185F 

GTSIO520D 

 

C3600

ZONE 700

DURING CRUISE FLIGHT, AFT SKI CABLE ATTACH CLEVIS PIN CAME LOOSE. CLEVIS PIN AND DIAPER PIN HOLDING CLEVIS DEPARTED ACFT. AFT SKI CABLE CAME LOOSE AND SKI FLIPPED FORWARD AND STRUCK WING LIFT STRUT, DENTING THE STRUT. PILOT MADE A SAFE LANDING. LIFT STRUT, AND SKI CHECK CABLE WERE REPLACED. SKI WAS REPAIRED. UPON FURTHER INVESTIGATION IT WAS DETERMINED THAT A SECOND HOLE IN THE AFT SKI CABLE ATTACH FITTING ON THE ACFT NEEDED A SECOND HOLE. A SECOND HOLE WAS DRILLED AND REAMED. THIS SECOND HOLE ALLOWS FOR THE REAR SKI CABLE AND REAR CHECK CABLE TO BE ATTACHED AT SEPARATE PLACES ON THE FITTING RATHER THAN ONE POINT AT BEFORE. ALSO THE CABLES WERE REATTACHED WITH AN BOLTS AND LOW PROFILE NUTS TO PROVIDE A MORE POSITIVE CONNECTION THAN THE PREVIOUS HARDWARE. AIRCRAFT WAS RETURNED TO SERVICE.

2012FA0000184

CESSNA 

CONT 

 

HUB 

CRACKED 

2/10/2012

A185F 

IO520* 

 

D5856

PROPELLER

PROP ASSY WAS SUBMITTED FOR O/H AND OIL LEAK FROM CRACK. CRACK EXTENDS FROM BLADE NR 1 PORTAL THROUGH THE CYL MOUNTING SURFACE.

YN8R2012041013834

CESSNA 

LYC 

 

HOSE 

LEAKING 

4/10/2012

T182T 

TIO540AK1A 

 

AE3663161G0174

FUEL SYSTEM

ON COMPLIANCE WITH SB 599, FUEL PUMP REPLACEMENT, IT WAS DISCOVERED THAT THE ENGINE DRIVEN FUEL PUMP INLET HOSE HAD INDICATIONS OF OUTER FIRESLEEVE DETERIORATION AND BULGING INDICATIVE OF THE FUEL HOSE LEAKING FUEL FROM CRIMPED AREA OF FITTING/HOSE. REPLACED HOSE WITH NEW PART. DEFECTIVE HOSE MAY HAVE BEEN ASSEMBLED INCORRECTLY OR NOT BEEN PRESSURE CHECKED DURING MFG.

2012FA0000182

CESSNA 

LYC 

CESSNA 

BRUSHES 

DISINTEGRATED 

4/5/2012

T206H 

TIO540AJ1A 

 

 

ALTERNATOR

ALTERNATOR FIELD CIRCUIT BREAKER TRIPPED INTERMITTENTLY OVER LAST 25 HRS WITH VARIOUS INSTANCES OF RADIO NOISE. ALTERNATOR REMAINED FUNCTIONAL. SUSPECT POSSIBLE BRUSH FAILURE AND ELECTED TO REPLACE THE ALTERNATOR DURING AN ANNUAL INSPECTION. ALTERNATOR WAS DISASSEMBLED. FOUND GROUND BRUSH .3750" LONG. THE FIELD BRUSH WAS COMPLETELY DISINTEGRATED WITH SPRING CONTACTING THE SLIP RING. THIS ALTERNATOR IS ONLY AVAILABLE FROM MFG. THERE ARE NO KNOWN THIRD PARTY O/H FACILITIES. ACFT MFG SERVICE DOCUMENTS PROVIDE NO SERVICE OR PARTS DATA. THERE ARE NO ACFT MFG INSP PROTOCOLS BEYOND EXTERNAL SECURITY CHECKS. BRUSH AND/OR SLIP RING INSPECTION CAN ONLY BE ACCOMPLISHED BY DISASSEMBLY OF THE CASE. SUGGEST RE-DESIGN TO

T22R2012032858301

CESSNA 

LYC 

LYC 

RETAINER 

BROKEN 

3/28/2012

T206H 

TIO540AJ1A 

 

LW16475

ENGINE CYLINDER

ENGINE STARTED TO RUN ROUGH WITH POWER LOSS ON TAKEOFF CLIMB. RETURNED TO AIRPORT AND LANDED SAFELY. UPPER VALVE SPRING RETAINER BROKE APART WHICH ALLOWED EXHAUST VALVE TO DROP INTO CYLINDER COMBUSTION CHAMBER ON A NEW CYLINDER WITH 8.0 HOURS ON IT. EXHAUST VALVE HEAD WAS BROKEN INTO MULTIPLE PIECES WITH THE MAIN SECTION LODGED INTO PISTON HEAD. EXHAUST VALVE STEM WAS FOUND IN EXHAUST SIDE OF TURBO IMPELLERS. METAL FOUND IN OIL FILTER. CYLINDER COMBUSTION CHAMBER AND PISTON DAMAGED.

2012FA0000170

CESSNA 

LYC 

 

CARBURETOR 

FAILED 

3/25/2012

TR182 

O540L3C5 

 

105243

ENGINE

INSTALLED O/H HA-6 CARBURETOR, ON GROUND RUNS NOTED ENGINE EXTREMLY ROUGH AT POWER SETTING ABOVE 1400 RPM, STRONG ODOR OF FUEL AND BLACK SMOKE FROM EXHAUST. USE OF MIXTURE CONTROL AT 1400 RPM GAVE 200 RPM RISE AND CLEARED CONDITION. UNABLE TO REACH TAKEOFF RPM AT 41" MANIFOLD PRESSURE WITHOUT LEANING AT FIELD ELEVATION OF APPROX 700 FT UNLESS MIXTURE USED. IDLE AND IDLE MIXTURE WERE WITHIN LIMITS. UNIT RETURNED FOR INSPECTION AND REPAIR. CARBURETOR WAS INSTALLED DUE TO PREVIOUS UNITS MIXTURE UNABLE TO SHUTDOWN CLEAN. MIXTURE CONTROL WAS FOUND TO BE WORN AND LEAKING FROM BODY OF UNIT. NO OTHER ENGINE PERFORMANCE ISSUES NOTED PRIOR TO ITS REMOVAL.

2012FA0000157

CESSNA 

CONT 

 

BOLT 

LOOSE 

2/16/2012

TU206G 

TSIO520M 

 

 

RECTIFIER BRIDGE

DURING TROUBLESHOOTING FOR ALTERNATOR NOISE, INSPECTED ALTERNATOR AND FOUND BOLT LOOSE INSIDE ALTERNATOR CASE. REMOVED ALTERNATOR AND DISASSEMBLED, FOUND DIODE RECTIFIER BRIDGE BOLT HAD BACKED OUT AND HAD CONTACTED THE ROTOR, BENDING THE BOLT AND ELONGATING THE MOUNTING HOLE ON THE RECTIFIER BRIDGE.

2012FA0000177

CIRRUS 

CONT 

 

FUEL LINE 

SPLIT 

4/4/2012

SR20 

IO360ES 

 

649101

ENGINE

ON TAKEOFF ROLL, NOTICED AN EXCESSIVE FUEL FLOW INDICATION AND ABORTED TAKEOFF. ON INSPECTION OF THE DISCREPANCY THE MECHANIC WAS ABLE TO DUPLICATE THE HIGH FUEL FLOW READING. AFTER SHUTTING DOWN THE ENGINE AND REMOVING THE ENGINE COWL, A SPLIT IN THE NR 1 CYLINDER FUEL INJECTION LINE WAS NOTED AND WAS DUMPING RAW FUEL IN THE ENGINE COMPARTMENT CAUSING THE HIGH FUEL FLOW INDICATION.

2012FA0000196

CIRRUS 

CONT 

 

ATTACH BOLT 

WORN 

4/5/2012

SR22 

IO550N 

 

AN334

ENGINE INTAKE

FOUND ALTERNATE AIR FLAPPER BOLT THREADS STRIPPED FROM VIBRATION. FOUND AS A RESULT OF PREVIOUS INCIDENT.

IVLA2012FA0000194

CIRRUS 

CONT 

 

ATTACH BOLT 

BACKED OUT 

4/4/2012

SR22 

IO550N 

 

AN334

ENGINE AIR INTAK

BOLT AND ALTERNATE AIR FLAPPER HINGE FAILURE POSSIBLY DUE TO VIBRATION OVER TIME, WHICH CAUSED ONE OR MORE BUSHINGS TO ENTER THROUGH AN INTAKE VALVES. SYMPTOMS WERE SIMILAR TO A FOULED PLUG; THE PILOT REPORTED THAT HIS EGT ON CYLINDER NR 1 HAD INITIALLY DECREASED AND SUBSEQUENTLY DISCONTINUED THE TAKEOFF AS SOON AS POWER WAS APPLIED. ALSO STATED WAS ABLE TO "BURN IT OFF" AS THERE MAY HAVE BEEN SMALL METAL PIECES CLOGGING THE SPARK PLUGS THAT WERE DISPLACED. AFTER CONTINUED ROUGH OPERATION ON THE GROUND AFTER A HIGH POWER RUN-UP, GROUNDED ACFT IAW DISCREPANCY PROCEDURES. AFTER BORESCOPE INSPECTION, DAMAGE FOUND IN CYLINDERS.

2012FA0000169

CNDAIR 

 

 

CARBON SEAL 

DEFECTIVE 

3/12/2012

CL6001A11 

 

 

 

NR 2 IDG

AFTER PERFORMING SEVERAL PREFLIGHTS, IT WAS NOTED THAT THE NR 2 INTEGRATED DRIVE GENERATOR HAD AN INCREASE IN THE FREQUENCY AND QUANITY OF OIL SERVICING. AFTER INVESTAGATING THE CAUSE, IT WAS DETERMINED THAT THE DRIVE END CARBON SEAL WAS LEAKING, ALLOWING PRESSURIZED OIL TO TRANSFER INTO THE NR 2 ENG SYS. A NEW CARBON SEAL WAS INSTALLED IAW THE CMM AND THE ACFT RETURNED TO SERVICE. AFTER THE NEXT FLIGHT, THE NR 2 IDG OIL LEVEL WAS NOTED TO BE LOW AGAIN. THE IDG WAS THEN REPLACED WITH AN O/H RENTAL UNIT. PERFORMED ENGINE GROUND RUN FOR LEAK AND OP'S CHECK WITH NO DEFECTS NOTED. THE ACFT WAS RETURNED TO SERVICE.

UE5R201203280001

DHAV 

 

 

PLANETARY GEAR 

MISALIGNED 

3/26/2012

DHC6 

 

 

E310145502

REDUCTION GEAR

IN THE PROCESS OF REPLACING 1ST STAGE SUNGEAR AND PLANET GEAR SET, A DEFECT IN THE BEARING INSTALLED IN ALL 3 PLANET GEARS WAS FOUND. THE BRONZE SLEEVE PORTION OF THE BEARINGS HAD ROTATED CAUSING MISALIGNMENT OF BEARING SCALLOPS. THE BRONZE SLEEVE SHOULD NOT MOVE DURING A TYPICAL SERVICE LIFE OF A 1ST STAGE PLANET GEAR. SUNGEAR AND PLANET GEAR SET WERE BEING REPLACED TO COMPLY WITH AD2011-25-15. REF SB-804, REV B. THIS IS THE 5TH INSTANCE OF BRONZE SLEEVE ROTATION WE HAVE SEEN FOR THIS PART.

V0XR201203220001

DHAV 

 

 

RIB 

CRACKED 

3/22/2012

DHC8102 

 

 

85520268105

LT ELEVATOR

CRACKED RIB AT YH 6.00 ON LT ELEVATOR. R & R CRACKED RIB AT YH 6.00 ON LT ELEVATOR IAW DWG 85520268.

V0XR2012031500001

DHAV 

 

 

STRINGER 

CORRODED 

3/15/2012

DHC8103 

 

 

85530192190

S9

CORROSION OUT OF LIMITS ON STR 9S BELOW APU EXHAUST HOLE ON STR UNDER HOLE. REPAIRED STRINGER WITH SPLICE REPAIR IAW DASH 8/100 SRM 53-10-21.

V0XR201203090001

DHAV 

 

 

SKIN 

DENTED 

3/9/2012

DHC8103 

 

 

85320251

ZONE 100

SKIN DENT APPROX X302.0 LT SIDE ABOVE STRINGER 23P. REPAIRED DAMAGED AREA IAW RD 8-53-10295.

V0XR201203090002

DHAV 

 

 

MOUNT 

DAMAGED 

3/9/2012

DHC8103 

 

 

85530231

ZONE 300

RIVETS PULLED THROUGH ON ELEVATOR HORN HEAT MX SWITCH BRACKET IN AFT ACCESS DOOR. REPAIRED CONDENSOR MIXER MOUNTING STRUCTURE AND ELEVATOR HORN HEAT MX SWITCH BRACKET IAW RD 8-55-2394, PERMANENT REPAIR INSTRUCTION FOR DAMAGED HOLES IN CONDENSOR MIXER MOUNTING STRUCTURE ASSY.

V0XR201203090003

DHAV 

 

 

TRIM TAB 

DAMAGED 

3/9/2012

DHC8103 

 

 

85520213

RT ELEVATOR

RIGHT ELEVATOR TRIM TAB T/E DAMAGED. REMOVED ELEVATOR TRIM TAB FOR REPAIR, REPAIRED TRIM TAB IAW RD 8-55-061, SPLICE REPAIR TO ELEVATOR TRIM TAB SKIN, REINSTALLED ELEVATOR IAW AMM 27-36-21, BALANCED TRIM TAB IAW SRM 55-20-61.

V0XR201203090004

DHAV 

 

 

FRAME 

CORRODED 

3/9/2012

DHC8103 

 

 

85410318

NACELLE

ACCOMPLISHED RD 8-54-1178, GENERIC REPAIR FOR LIGHT CORROSION AND FRETTING DAMAGE ON AFT FACE OF MLG FRAME TO BOTH LEFT AND RIGHT MLG. ACCOMPLISHED MLG RETRACTION AND EXTENSION OPS CHECK IAW AMM 32-30-00.

V0XR201203090005

DHAV 

 

 

SKIN 

DAMAGED 

3/9/2012

DHC8103 

 

 

854106278

LT NACELLE

LEFT NACELLE FWD/OTBD CORNER CUT OUT FOR MLG DOOR DAMAGED. REPAIRED DAMAGE ON FWD/OTBD CORNER MLG DOOR CUT OUT ON LT NACELLE IAW RD 8-54-874, PERMANENT REPAIR FOR CRACK DAMAGE AT FWD UPPER CORNERS OF MLG DOOR OPENING.

V0XR201203090006

DHAV 

 

 

DOOR 

DAMAGED 

3/9/2012

DHC8103 

 

 

85420006001

LT MLG

LEFT MLG GEAR DOOR DAMAGED. REPAIRED LEFT FWD MLG DOOR COMPOSITE DAMAGE IAW RD 8-54-554, REPAIR TO EDGE DAMAGE ON FWD MLG DOOR ASSY.

GR4D20120321020

GULSTM 

 

 

FLAP TRACK 

CORRODED 

3/19/2012

GIV 

 

 

1159WM200524

ZONE 600

FLAP TRACK CORRODED, ULTRA SONIC NDT INSPECTION COMPLIED WITH. AFTER ENGINEERING EVALUATION, REMAINING THICKNESS WAS UNACCEPTABLE. REF B/P SE05811901, REV D. REF CMP GIV MESSAGE 3575111 FOR INSPECTION.

LD2R20120403001

GULSTM 

RROYCE 

 

ADAPTER 

BACKED OUT 

4/3/2012

GV 

BR700710A110 

 

39500221

FUEL PUMP

WHILE PERFORMING A SERVICE BULLITIN TO REPLACE THE FUEL PUMP SPLINE ADAPTER, WE FOUND THE ENGINE DRIVEN FUEL PUMP DRIVE SHAFT TO BE MIGRATING OUT OF THE FUEL PUMP AND INTO THE ACCESSORY GEAR CASE. UPON INSPECTION OF THE GEAR CASE WE FOUND A RETAINING PLUG IN THE GEAR CASE SPLINE TO BE PUSHING INTO THE GEAR CASE ALLOWING THE FUEL PUMP DRIVE SHAFT TO MIGRATE OUT OF THE FUEL PUMP.

2012FA0000173

LEAR 

 

 

WINDSHIELD 

CRACKED 

4/3/2012

45LEAR 

 

 

4556100001V16001

ZONE 200

OUTER PLY OF WINDSHIELD (PILOT SIDE) CRACKED IN FLIGHT DURING TAKEOFF.

2012FA0000199

MOONEY 

LYC 

 

AUTOPILOT SYS 

MALFUNCTIONED 

4/11/2012

M20C 

O360* 

 

STEC50

 

DISCONNECTED AUTOPILOT AND HAND FLEW ACFT FOR SEVERAL MINUTES. SHORTLY AFTER INITIATING DESCENT TO LAND, AILERONS BEGAN TO "SEIZE." ELEVATOR STILL HAD FULL MOVEMENT, THEN IT ALSO BEGAN TO SEIZE. IT TOOK ABOUT FIVE TO TEN SECONDS TO LOSE AILERON AUTHORITY, THEN ELEVATOR AUTHORITY. STILL HAD FULL RUDDER AUTHORITY. HAD TO MAKE EMERGENCY LANDING WITH ONLY A FEW DEGREES OF OPERABLE AILERON AND ELEVATOR. CONTROLLED AIRPLANE WITH RUDDER AND THROTTLE. LANDED WITHOUT DAMAGE OR INJURY. DISCOVERED ON THE GROUND THAT A/P HAD RE-ENGAGED AND THAT SERVO CLUTCHES HAD "FROZEN." DID NOT ATTEMPT TO DISCONNECT A/P IN FLIGHT BECAUSE DIDN'T KNOW IT WAS ON.

2012FA0000189

MOONEY 

LYC 

 

FUEL TANK 

LEAKING 

2/15/2012

M20J 

IO360A1B6 

 

240319

 

THIS ACFT HAS BEEN REPEATEDLY REPAIRED TO CORRECT FUEL LEAKS. EVERY DRAIN HOLE HAS BEEN COVERED UP ALLOWING WATER AND FUEL TO BE TRAPPED IN THE OTBD BAYS. ALSO THE DRAIN VALVE RECEPTACLE DRAIN HOLES WERE COVERED WITH SEALANT CAUSING WATER TO COLLECT UP TO .5" BEFORE IT COULD BE REMOVED OVER THE TOP OF THE RECEPTACLE, INSTEAD OF THE BOTTOM. THIS ACFT EXPERIENCED A ROUGH RUNNING ENGINE ON TAKEOFF. MOST LIKELY WATER INGESTION. UPON OPENING THE TANKS, A LARGE AMOUNT OF WATER WAS FOUND STILL IN THE TANKS, A LARGE AMOUNT OF WATER WAS FOUND STILL IN THE TANKS EVEN AFTER COMPLETE DRAINING. A LARGE AMOUNT OF FUEL WAS STILL TRAPPED IN THE MIDDLE FUEL BAY. HAVE SEEN THIS HAPPEN VERY OFTEN.

5APR20120307110

PILATS 

PWA 

 

EFIS 

FAULTY 

3/7/2012

PC1245 

PT6A67B 

 

066031252500

ZONE 200

PILOT REPORTS LEFT EHSI INTERMITTENT, HAS A BLURRY SCREEN. THE LEFT EHSI, WAS FOUND TO BE FAULTY. R & R WITH A SERVICEABLE UNIT IAW AMM 12-A-34-26-02-00A-920A-A AND TESTED GOOD IAW 2-A-34-26-00-00A-903A-A.

5APR20120327113

PILATS 

PWA 

 

ATTACH FITTING 

OUT OF ALIGNMENT 

3/27/2012

PC1247 

PT6A67 

 

5551012150

HORIZONTAL STAB

THE HORIZONTAL STABILIZER ATTACHMENT FITTING, WHERE THE PITCH TRIM ACTUATOR IS SECURED TO THE STABILIZER. EACH SIDE OF THE ATTACHMENT FITTING HAS 2 LUGS. ON THE LT SIDE, THESE 2 LUGS ARE SEPARATING. THE GAP WAS MEASURED WITH A FEELER GUAGE, AND FOUND TO BE .018". THERE IS NO EVIDENCE OF DAMAGE TO THE STABILIZER. THE BRACKET PN IS 555.10.12.150, ANGLE FITTING LT. THE ACFT WAS REPAIRED USING TEMPORARY REV 55-01 OF THE PC-12/47E SRM 12-B-55-00-00-00A-904A-A.

5APR20120325112

PILATS 

PWA 

 

DISPLAY 

FAULTY 

3/25/2012

PC1247 

PT6A67B 

 

066031252500

ZONE 200

PILOT REPORTS"EADI ON LT SIDE ZOOMS IN AND OUT GOING BLACK ON OCCASION." THE LT EADI PN 066-03125-2500 WAS FOUND TO BE FAULTY. IT WAS R & R WITH A SERVICEABLE UNIT OF THE SAME PN, IAW THE AMM 12-A-34-26-03-00A-920A-A AND TESTED GOOD IAW 12-A-34-26-00-00A-903B-A.

5APR20120224109

PILATS 

PWA 

 

DISPLAY 

FAULTY 

2/24/2012

PC1247 

PT6A67B 

 

066031252500

EADI

DURING ROUTINE MX THE PILOTS EADI WAS FOUND TO BE FUZZY. THE EADI DISPLAY PN 066-03125-2500 WAS R & R WITH A SERVICEABLE UNIT OF THE SAME PN IAW MM 12-A-34-26-03-00A-920A-A, AND OPS CHECKED GOOD IAW 12-A-34-26-00-00A-903A-A.

5APR20120310111

PILATS 

PWA 

 

EFIS 

FAULTY 

3/10/2012

PC1247 

PT6A67B 

 

066031252500

LEFT

PILOT REPORTS "LT EHSI DISPLAY UNIT IS FUZZY/HARD TO READ." THE LT EHSI PN 066-03125-2500 WAS FOUND TO BE FAULTY. IT WAS R & R WITH A SERVICEABLE UNIT OF THE SAME PN, IAW THE AMM DMC-12-A-34-26-02-00A-920A-A AND TESTED GOOD IAW DMC-12-A-34-26-00-00A-903A-A.

C41R201204050001

PILATS 

PWA 

 

BRAKE DISC 

FAILED 

4/5/2012

PC1247 

PT6A67B 

 

260926

MLG

ACFT WAS UNDERGOING A 100 HR INSPECTION. REMOVED LT & RT MLG WHEEL ASSEMBLIES TO COMPLETE NDT AND UPON WHEEL REMOVAL ONE OF THE WHEEL BRAKE DISC ASSEMBLIES FELL ONTO FLOOR IN 2 SEPARATE PIECES. THE LT AND RT BRAKE ASSEMBLIES BOTH SHOWED SEPARATED BRAKE DISCS. THE BRAKE DISC ASSEMBLIES WERE NOT THE ORIGINAL BRAKE ASSEMBLIES. THE AFFECTED BRAKE ASSEMBLIES WERE INSTALLED AT AN EARLY DATE AND TAGGED AS REMOVED FROM ANOTHER ACFT. THE OPERATOR DID NOT NOTICE ANY ABNORMAL SOUNDS OR CONDITIONS DURING ACFT OPERATIONS. THE TECH DID NOT NOTICE ANY ABNORMAL SOUNDS OR CONDITIONS DURING RUN UP OPS AND THE WEAR GUIDE PINS SHOWED NORMAL. SYS FUNCTIONED PROPERLY.

2012FA0000166

PIPER 

 

 

STRUT 

SEPARATED 

3/22/2012

J5A 

 

 

 

MLG

LEFT MLG COLLAPSED DURING LANDING. SUBSEQUENT EXAMINATION REVEALED THAT BOTH OF THE UPPER LANDING GEAR STRUTS HAD SEPARATED AT THE AXLE KNUCKLE, JUST ABOVE THE AXLE JOINT. BLACK DUST AND RESIDUE WAS PRESENT AROUND THE FRACTURE SURFACE OF THE AFT STRUT, INDICATIVE OF A PRE-EXISTING FAILURE. THE AREA OF FAILURE WAS OBSCURED BY FABRIC COVERING MATERIAL, AND THEREFORE COULD NOT BE DETECTED DURING PREFLIGHT. SEE NTSB REPORT WPR11LA370.

FQAR201203050001

PIPER 

LYC 

 

ELBOW 

LEAKING 

3/5/2012

PA28181 

O360A4M 

 

68778000

ENGINE OIL SYS

UPON INSTALLATION OF A NEW OIL PRESSURE HOSE ELBOW A DEFECT WAS FOUND IN THE PART. THIS IS AN ORIFICED FITTING, IT APPEARS THAT WHEN THE ORIFICE HOLE WAS MACHINED IT WAS DRILLED TO FAR AND THE HOLE CONTINUES OUT THE SIDE OF THE FITTING. THIS WOULD HAVE CAUSED OIL LOSS ONTO THE ENGINE WHEN STARTED.

2012FA0000171

PIPER 

 

 

BRACKET 

CRACKED 

3/28/2012

PA28R200 

 

 

67550000

AILERON PULLEY

DURING AN ANNUAL INSPECTION, IT WAS NOTED THAT BOTH LT AND RT LOWER SUPPORT AILERON PULLEY BRACKETS WERE CRACKED AT THE FWD INBD RADIUS MOUNT AT EACH WING RIB. A PIECE OF 1 OF THE BRACKETS WAS DETACHED.

2012FA0000159

PIPER 

 

 

LINK 

WORN 

3/18/2012

PA31350 

 

 

56981002

ELEVATOR

DURING REPLACEMENT OF THE ELEVATOR BUNGEE SPRING, PN 71056-003, THE FORWARD ATTACHMENT LINK, WAS FOUND APPROX 30 PERCENT OF THE MATERIAL. THIS PART IS NOT REQUIRED TO BE REPLACED IAW AD 98-08-18 OR SB626C. THIS PARTICULAR PART WAS HOWEVER REPLACED DURING THE LAST BUNGEE SPRING REPLACEMENT 1000 HOURS PREVIOUS. THIS IS ALSO THE SECOND LINK WE HAVE DISCOVERED IN THIS CONDITION. RECOMMEND THAT THIS PART BE INSPECTED OR REPLACED DURING EACH REPLACEMENT OF THE BUNGEE SPRING.

2012FA0000163

PIPER 

 

 

CONTROL CABLE 

FAILED 

3/21/2012

PA32R300 

 

 

6270140

STABILIZER

DURING APPROACH AND ON LANDING, PILOT NOTICED NO RESPONCES TO STABILIZER CONTROL. DURING INSPECTION, FOUND THE LOWER CONTROL CABLE HAD SHEARED OR BROKE AT THE TURNBUCKLE. CAUSE OF FAILURE IS DUE TO INTERNAL CORROSION INSIDE THE SHEATHING.

ECPR20120310466

PIPER 

LYC 

 

THROTTLE CABLE 

STUCK 

3/10/2012

PA44180 

O360A1H6 

 

554546

LEFT

AFTER PRACTICING INSTRUMENT APPROACH AND GO AROUND, THE LT ENGINE THROTTLE LEVER STUCK AT 25" MAINFOLD PRESSURE AND 2500 RPM. AFTER DEPARTURE FROM AIRPORT CONTROL AREA, INSTRUCTOR PILOT WAS ABLE TO REDUCE LT THROTTLE DOWN TO 16-18" MANIFOLD PRESSURE AT 2500 RPM. AFTER DISCUSSION WITH FLIGHT DEPARTMENT PERSONELL IT WAS DESCIDED THE BEST COURSE OF ACTION WAS TO SHUTDOWN THE LT ENGINE AND PERFORM A SINGLE ENGINE APPROACH AND LANDING. AN EMERGENCY DECLARED AND LANDED UNEVENTFULLY. SINCE PREVIOUS INSTANCES OF PROBLEMS WITH ENGINE CONTROL CABLES IN THIS PARTICULAR MAKE AND MODEL AIRCRAFT, THE LT ENGINE THROTTLE CABLE WAS REPLACED AS PART OF A SCHEDULED PROGRESSIVE INSPECTION.

E81R2012032900001

RAYTHN 

 

 

WEB 

CRACKED 

3/29/2012

HAWKER800XP 

 

 

25FN486771

FUSELAGE

DURING SCHEDULED AIRFRAME "F" 24-MONTH AND "G" 48-MONTH INSPECTIONS, NOTED CRACK IN WEB OF FORWARD AND AFT RUNNING UNDER FLOORBEAM UNDER COPILOT'S SEAT AREA.

2012FA0000183

RAYTHN 

 

MEGGITT 

TIE BOLT 

MISSING 

2/15/2012

HAWKER800XP 

 

 

EWB22516

NR 3 MAIN WHEEL

DURING A SCHEDULED INSPECTION, FOUND ONE TIE BOLT NUT AND BOLT MISSING AS WELL AS SEVERAL OTHER LOOSE ON THE MLG WHEEL.

2012FA0000187

RAYTHN 

 

 

HYDRAULIC LINE 

LEAKING 

1/10/2012

HAWKER800XP 

 

 

HS783500115

RT PYLON

THRUST REVERSER DEPLOY LINE FLARE CRACKED RT SIDE DURING NORMAL OPERATION. THIS CAUSED HYD LEAK. POSSIBLE CAUSE DUE TO REPEATED REMOVAL AND INSTALLATION AND/OR OVER TORQUING DURING INSTALLATION.

KI2R20120323001

RAYTHN 

 

 

ROD END 

FAILED 

3/21/2012

HAWKER800XP 

 

 

CN635MESP56

ELEVATOR TAB

DURING A MX PRE-FLIGHT INSPECTION, NOTICED RUST STAINING COMING FROM AFT ROD ENDS OF ELEVATOR TRIM TAB ROD ON BOTH LT & RT ELEVATOR TRIM TABS. FURTHER INSPECTION REVEALED THE GREASE SEAL ON ONE ROD END, HAD COME OFF & BALL BEARINGS WERE MOSTLY MISSING. OTHER ROD END STILL INTACT, RUST STAINING WAS ALSO OBSERVED COMING THROUGH GREASE SEALS. DURING REPLACEMENT OF ROD ENDS, NOTICED DE-ICING FLUID HAD PENETRATED INTO HOLLOW INNER PORTION OF TRIM TAB CONTROL ROD, NO EVIDENCE OF CORROSION EXISTED.

LC1R20120306005

SOCATA 

LYC 

LYC 

PLUG 

LOOSE 

3/6/2012

TB20TRINIDAD 

IO540C4D5 

 

71640

CRANKSHAFT

DURING RUN UP OF A NEWLY FACTORY REBUILT ENGINE, THE PROPELLER DID NOT CYCLE. IT WAS DISCOVERED THAT THE PLUG, BEHIND THE OIL SUPPLY TUBE HAD COME LOOSE AND WAS ALLOWING PRESSURIZED OIL FROM THE GOVERNOR TO FLOW BACK THROUGH THE CRANKSHAFT AND NOT ACTUATE THE PROP.

2012FA0000191

UROCOP 

TMECA 

 

CONTROL PANEL 

UNSERVICEABLE 

3/24/2012

EC130B4 

ARRIEL2B1 

 

704A46580119

COCKPIT

ON OTBD FLIGHT 30 ALPHA PANEL PRODUCED AN ELECTRICAL CHEMICAL SMELL, PERFORMED INSP ON PANEL, SN PO29433 AND FOUND ANTI-COLLISION CIRCUIT INOPERTIVE. REPLACED 30 ALPHA PANEL WITH SN PO15420.

QMLD2012022310212

UROCOP 

 

 

ROTOR 

DAMAGED 

2/23/2012

EC135P2 

 

 

L642A0101052

TAIL

A TAIL ROTOR IS IN THE SHOP FOR A 36 MONTH INSPECTION. ON BEGINNING THE INSPECTION, HAVE WHAT SEEMS TO BE A LIGHTNING STRIKE. AFFECTED ARE THE SPLINED FLANGE, PN L642A2019201, LAMINATED TORSION BAR, PN 350A33318000, AND 1 OF THE SLIDING RING BUSHINGS, PN L642A2035201. THE HUB BODY PN L642A2003102, HAS AN ANOMALY THAT IS NOT CONSISTENT WITH WHAT HAS NORMALLY BEEN FOUND DURING INSPECTIONS.

2012FA0000151

ZINAIR 

 

 

WHEEL 

BROKEN 

3/6/2012

CH2000 

 

 

20L41

MLG

DURING LANDING, THE PILOT TOUCHED DOWN ON THE MAIN GEAR AND THE THE PILOT LOWERED THE NOSE TO THE GROUND, UPON GROUND CONTACT, THE NOSE WHEEL SEPARATION FROM NOSE WHEEL STRUT. THE NOSE WHEEL MOUNTING BRACKET SUPPORT BROKE AWAY FROM THE VERTICAL STRUT TUBE. THE PILOT COMPLETED LANDING ON THE NOSE WHEEL STRUT TUBE. AFTER INSP, NO DAMAGE WAS FOUND ON ANY PART THE NOSE GEAR ASSY EXCEPT FOR THE THE WELD THAT ATTACHES THE WHEEL MOUNTING PLATE TO THE VERTICAL TUBE. AN EXISTING CRACK WAS ALSO DETECTED ON THE REAR WARD SIDE OF THE SAME WELD. NO SECONDARY DAMAGE TO THE ACFT OR INJURY TO THE PILOTS OCCURRED.