AC 43-16A, Aviation Maintenance Alert for December 2011

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
CA110530009				ROD	INOPERATIVE
5/25/2011				M20201892007	SEAT
CABIN CHAIR ASSY. SOLENOID SENSOR ACTUATING RODS BECOME MAGNETIZED FROM CONTINUOUS USE AND KEPT SEAT LOCKS FROM DROPPING. P/N M20201-892-007, CMM 25-24-38
CA110706002				IMPELLER	MISMANUFACTURED
7/5/2011				2660162401	COMPRESSOR
NEW IMPELLER FROM MFG HAD DAMAGE (DEEP NICK) ON IMPELLER VANE. SENT BACK TO MFG. DAMAGE OCCURED AT MFG, AS DAMAGE WAS PRIMERED OVER.
CA110712004				IMPELLER	MISMANUFACTURED
7/12/2011				2660162401	COMPRESSOR
NEW FROM MFG, IMPELLER, PN 2660-1624-01, TOP EDGE OF IMPELLER RUBS ON BOTTOM OF STATOR HOUSING. IMPELLER SUSPECTED OF BEING DIMENSIONALLY INCORRECT. SENT BACK TO MFG FOR WARRANTY. THIS IS OUR SECOND OCCURANCE.
CA110715003				CONNECTOR	CRACKED
7/12/2011					CABIN LIGHTS
CRACKED CONNECTOR DIRECTLY BELOW THE SCREW HEADS WAS FOUND ON MULTIPLE CONNECTORS. THIS PARTICULAR UNIT SHOWS VISIBLE SIGNS OF ARCING. BOTH CONNECTOR PNS HAVE SAME TYPE OF CRACKING, PN BV5-01258 AND BV5-01261 ARE THE CONNECTORS. THIS IS ONE EXAMPLE OF SEVEN UNITS THAT WERE SENT TO THE SHOP, THESE WERE ALL FOUND IN THE SHOP PROCESS.
CA110721006				CONTROL UNIT	MISOVERHAULED
7/21/2011					SPOILERS
SPOILER ELECTRONIC CONTROL UNIT REMOVED FROM ACFT FOR UN-COMMANDED DEPLOYMENT OF FLIGHT SPOILER IN FLIGHT. INITIAL TEST PERFORMED UPON RECEIVING THE SECU CONSISTED OF CAPTURING THE FAILURES LOGGED FORM THE NVM AND SYSTEM FUNCTIONALITY TEST USING THE DIAGNOSTIC TEST FIXTURE. REPRODUCED FAILURE, CAUSED BY A DEFECTIVE POWER SUPPLY MODULE. A VISUAL INSPECTION HAS REVEALED THAT SOME FITTED COMPONENTS INSTALLED DURING PREVIOUS MX ACTIVITIES ARE NOT APPROVED OR SPECIFIED BY THE ORIGINAL MFG IN THEIR CMM FOR THIS EQUIPMENT.
CA110726006				CARBURETOR	FAILED
7/25/2011
DURING INSTALLATION OF FUEL ECONOMZER KIT PN 666-814 FOUND, PN 49-267 TO BE WAY OFF SETTING THE NYLON LOCK STRIP WAS INEFFECTIVE AND PN 261-501 SAFTEY RACHET ASSY (AIR METERING JET) WAS, BURIED TOO DEEP IN ITS BORE TO ENGAGE AND PREVENT ROTATION. THREADS IN PN 227-1443 THROTTLE BODY WAS RUINED. BODY REPLACED WITH SERVICABLE USING KIT 666-814 AND ALL OTHER SERVICABLE PARTS. CARB IS NOW 10-3965-12-1.
CA110726012			ARTEX	G SWITCH	FAILED
7/26/2011					ELT
ON A ROUTINE SHOP VISIT IT WAS DETERMINED THAT THE G-SWITCH HAD FAILED WHILE IN SERVICE. AN INVESTIGATION WAS PERFORMED AND ALSO DISCUSSED WITH LOCAL SERVICE CENTER WHERE THE UNITS WERE SENT FOR REPAIR. IT WAS DETERMINED THAT THIS IS NOT AN ISOLATED INCIDENT.
CA110726013			ARTEX	CASE	BROKEN
7/26/2011					ELT
DURING INVESTIGATION OF RECURRING DEFECTS FOR ELTS, SEVERAL INSTANCES OF BROKEN CASES AND SEALS WERE NOTED.
CA110729011				ELT	INOPERATIVE
7/29/2011				AK450	CABIN
WHEN TESTING ELT FOR COMPLIANCE WITH CAR 571 APPENDIX G, ELT OPERATED FOR ABOUT 2 MINUTES THEN THE MODULATION WENT TO ZERO. UNIT REMOVED FROM SERVICE.
2011FA0000589				SMOKE GENERATOR	INOPERATIVE
9/14/2011					ZONE 600
CIRCUIT BREAKER POPPED DURING SMOKE GENERATOR ACTIVATION.
2011FA0000607				REGULATOR	OUT OF ADJUST
9/19/2011				5A302380	SLIDE
MFG RECEIVED AN EVACUATION SLIDE, PN 7A1509-119, SN AD0693, FROM OPERATOR. THIS SLIDE WAS LAST O/H ON 4/10. DURING THE FLAT FIRE FUNCTIONAL TEST THE ASPIRATOR'S CROSS MEMBER BROKE OFF FROM INSIDE THE ASPIRATOR BODY AND THE NOZZLE ASSY CAME OFF CAUSING THE TEST TO FAIL. THE SLIDE DID NOT INFLATE IAW THE CMM 25-62-14. THE CYLINDER ASSY WAS ROUTED TO THE VALVE SHOP FOR FURTHER INVESTIGATION. THE CYLINDER ASSY WAS RECHARGED AND AN OVER PRESSURE TRACE TEST WAS PERFORMED IAW CMM 25-62-19. THE TESTING REVEALED THAT THE ADJUSTER, PN 2A1855-1 ON THE REGULATOR, PN 5A3023-80, SN N-0805 WAS FOUND TO BE IMPROPERLY ADJUSTED AND THE OVER PRESSURE TRACE TEST WAS 1455.56 PSI. THE CMM 25-62-19 STATES THE OVER PRESSURE TRACE TEST SHOULD BE 395 TO 425 PSI. THE DIFFERENCE IN THE OVER PRESSURE TRACE TEST IS OVER 1045 PSI. NOT HAVING THE REGULATOR PROPERLY ADJUSTED AND TESTED CAUSED THE ASPIRATOR TO COME APART AND CAUSE THE FUNCTIONAL TEST FAILURE.
2011FA0000652				PAD	CRACKED
9/21/2011					ROTOR BRAKE
ROTOR BRAKE PAD EDGES CRACKED OR CHIPPED FROM NEW. WHEN INSTALLING ON DISK PAD COMES APART AT EDGE. VIBRATION OF RIVET GUN CAUSES FURTHER CRACKING OR CHIPPING AT EDGE WHEN INSTALLING ON THE DISK. PROBABLE CAUSE BAD BATCH OF ROTOR BRAKE PADS. MFG F0210 CODE.
HEEA20111019326				SKIN	CORRODED
10/19/2011					TAILBOOM
TAILBOOM SKIN FOUND CORRODED, COMMON TO PREVIOUSLY INSTALLED LARSON ANTENNA PROVISIONS. THE TAILBOOM WILL THEN BE REPAIRED IAW THE FAA-APPROVED REPAIR DATA.
CA110624006			ROTAX	HOUSING	STRIPPED
6/7/2011			810809	810809	GOVERNOR OUTPUT
GOVERNOR OIL LINE REMOVED FOR UNRELATED MX. THE INSIDE THREADS STRIPPED FROM THE OIL PUMP HSG FOR THE GOVERNOR OIL FEED LINE BEFORE THE PROPER TORQUE (105 IN/LB) WAS REACHED. THIS PROBLEM HAS OCCURRED AND HAS BEEN REPORTED PREVIOUSLY: THE FIRST EVENT WAS BLAMED ON MECHANIC ERROR. THE SECOND EVENT WAS CAUSED AFTER THE MM REVISION LOWERED THE TORQUE VALUE FROM 150 IN/LB TO 105 IN/LB. THE THIRD EVENT IS NOW BLAMED ON THE THREADS OF THE OIL PUMP HOUSING.
CA110803027		LYC		IMPULSE COUPLING	WORN
8/1/2011		AEIO360A1B6	4370	M3100	MAGNETO
IMPULSE COUPLING SHOWED WORN RIVET AND EXCESSIVE PAWL GAP AFTER ONLY 200 HRS TIME IN SERVICE. THIS SHOP PERFORMS SLICK SB 1-86 EVERY 100 HRS INSTEAD OF THE RECOMMENDED 500 DUE TO PREVIOUS EXPERIENCE. THIS IMPULSE COUPLING WOULD NOT HAVE LASTED ANOTHER 300 HRS IN AME`S OPINION.
CA110704002		PWA		TURBINE BLADES	FAILED
6/28/2011		JT15D4			ENGINE
EIR JT15D 2011-008 O/H SHOP WAS ABLE TO CONFIRM THE OPERATORS REPORT OF HAVING AN HP TURBINE BLADE FAILURE IN ENGINE 70351. 2 OF THE HP TURBINE BLADES (PN 3028601) WERE MISSING THE TOP, OF THE AIRFOILS. THE LIBERATED MATERIAL FROM THE 2 HP TURBINE BLADES CAUSED HEAVY IMPACT DAMAGE TO MANY OF THE REMAINING HP TURBINE BLADES AND SCATTERED IMPACT DAMAGE TO THE HP TURBINE STATOR AND COMPONENTS DOWNSTREAM OF THE HP TURBINE DISK ASSY. THE IMPACT DAMAGE ON THE 2ND AND 3RD STAGE LP TURBINE BLADES WAS SUFFICIENT TO REQUIRE THE LP TURBINES ASSEMBLIES TO REQUIRE DISASSEMBLY FOR FURTHER INSP WHICH WILL RESULT IN MANY OF THE LP TURBINE BLADES BEING SCRAP. THE LIGHT O/H SECTION OF THE O/H MANUAL REQUIRES THAT THE NR 3 BEARING BE ACCESSED AND REPLACED FOR ANY HPT BLADE DISTRESS, MORE OF THE AIRFOIL IS MISSING ON 1 OR MORE BLADES. THE BEARINGS RELATED TO THE HP ROTOR (NR 2 BEARING (PN 3119579-01, SN FA0223156), NR3 BEARING (PN 3107493-01, SN FC122110) & NR 3 BEARING (PN 3101648-01, SN FA0217673)) WERE ALL PRECAUTIONARY SCRAPPED DUE TO THE DAMAGE FOUND AND POSSIBLE FORCES/LOADS SUFFERED FROM THE HP ROTOR IMBALANCE.
CA110704003		PWA		HOUSING	CORRODED
6/27/2011		PT642A			RGB
EIR PT6A 2011-072, O/H SHOP WAS ABLE TO CONFIRM THE OPERATORS REPORT OF EXCESSIVE OIL LEAKAGE. THE EXHAUST DUCT HAD SHINY OIL WETNESS DURING RECEIVING INSPECTION. THE RGB REAR HSG WAS HEAVILY CORRODED AND HAD 2 THROUGH GOING HOLES ON THE OUTER CONICAL SECTION. THE EXTERNAL OIL SCAVENGE PUMPS WERE ACCESSED AND FOUND TO BE IN EXCELLENT CONDITION. THE ENGINE WAS RECEIVED AT O/H SHOP. THE POWER SECTION WAS DISASSEMBLED AS REQUIRED TO ACCESS AND REMOVE THE RGB REAR HSG. THE GAS GENERATOR SECTION WAS DISASSEMBLED AS REQUIRED TO ACCESS AND REMOVE THE EXTERNAL SCAVENGE PUMPS. THE ENGINE WILL BE RE-BUILT AND TESTED FOR LEAKS AND VIBRATIONS PRIOR TO RETURN TO SERVICE.
CA110606001		PWA		DRIVE SHAFT	WORN
5/18/2011		PT642A			FUEL PUMP
ACCIDENT WAS REPORTED THAT THE CREW OF 2 HAD TO EJECT DURING A TRAINING MISSION. ACFT EXPERIENCED A SUSPECTED ENGINE FAILURE AND CRASHED APPROX 1.5 KM IN FRONT OF THE RUNWAY. AS A PRECAUTION, ALL RAAF PC-9 FLYING OPS HAVE BEEN TEMPORARILY SUSPENDED. DIRECTORATE OF DEFENSE AVIATION AND AIR FORCE SAFETY (DDAAFS), SUPPORTED BY THE REGULATOR (DGTA) IS COORDINATING THE INVESTIGATION. ENGINE HAS BEEN RECOVERED AND SENT TO MFG FOR EXAMINATION. INVESTIGATION REVEALED A ENGINE FUEL PUMP DRIVESHAFT SPLINE AND INPUT COUPLING DISPLAYED INDICATIONS OF SIGNIFICANT WEAR AND WAS DETERMINED TO BE THE CAUSE OF THE ENGINE POWER LOSS.
CA110715005		PWA		JOURNAL	LOOSE
7/15/2011		PT6A21		ASABOVE	NR 5 BEARING
DURING DETAIL INSPECTION, OF THE 2ND STAGE REDUCTION CARRIER AT ENGINE O/H, IT WAS NOTED THAT THE NR 5 BEARING JOURNAL HAD PREVIOUSLY BEEN SLEEVE REPAIRED, AND A 0.046" GAP WAS MEASURED BETWEEN THE SLEEVE AND THE CARRIER SHOULDER. MM PN 3013243, 72-11-00, PAGE 323, PARA L. STATES: L. SECOND-STAGE REDUCTION GEAR CARRIER (10, FIG. 308) CAUTION: ALL CARRIERS WITH PREVIOUS SLEEVE REPAIR MUST BE INSPECTED FOR THE FOLLOWING MARKING, 3Z433 REV1. PARTS IDENTIFIED WITH CAGE CODE 3Z433 ONLY MUST BE SENT FOR REPAIR. NOTE: CARRIERS NOT IN COMPLIANCE WITH THE ABOVE MUST BE SENT FOR REPAIR. THIS PARTICULAR 2ND STAGE CARRIER IS IDENTIFIED WITH MARKING 3Z433, REV 1, AND IAW THE OHM SHOULD NOT HAVE REQUIRED REPAIR.
CA110705002		PWA		OIL FILTER	MISMANUFACTURED
7/3/2011		PT6A27		7579522AM
(CAN) OIL FILTER PMA, PN-7579522AM EQUIVALENT TO P/N-3024084 OR 3033315 FROM THE COMPANIES STORES DEPARTMENT, NOTICED THE FINE CONE SHAPED SCREEN WAS MISSING FROM END OF FILTER THAT IS FIRST INSERTED INTO THE OIL FILTER HOUSING.
CA110711016		PWA		FCU	INOPERATIVE
6/30/2011		PT6A67D		8063005	RT ENGINE
RIGHT ENGINE N1 AND TORQUE ACCELERATED UNCONTROLLED WHEN POWER WAS APPLIED ON TAKEOFF.
CA110525010		PWA		TURBINE BLADES	FAILED
5/25/2011		PT6A67R		310830301	ENGINE
ENGINE WAS REMOVED SUBSEQUENT TO A CATASTROPHIC FAILURE DURING TAKEOFF ROLL. THE PILOT REPORTED "ENGINE FAILED ON TAKEOFF ROLL, AUDIBLE NOISE, METAL EXITING EXHAUST DUCT, ENGINE WENT TO MIN FLOW AND TAKEOFF ABORTED". DURING DISMANTLE INVESTIGATION, THE ENGINE WAS SPLIT AND THE POWER AS WELL AS GAS GENERATOR SECTIONS WERE COMPLETELY DISMANTLED. THE POWER SECTION WAS FOUND EXCESSIVELY DAMAGED AND IT APPEARED THAT THE FAILURE OCCURRED IN POWER TURBINE AREA, WHERE ALL THE 1ST STAGE PT BLADES WERE FOUND BROKEN CLOSE TO THE PLATFORM AREAS, THE FRACTURE SURFACE EXHIBIT ROUGH APPEARANCE WITH TEXTURES OF BRITTLE OVERLOADING FRACTURE. THE 2ND STAGE PT BLADES WERE FOUND BROKEN, BREAKAGE VARYING FROM BELOW SHROUDED BLADE TIP TO ABOVE BLADE PLATFORM. QTY 1, PT 2 BLADE WAS FOUND BROKEN CLOSE TO THE PLATFORM WITH SIGNS OF FATIGUE FAILURE. THE SB 14369 WAS RELEASED TO ADDRESS A PREMATURE FAILURE ISSUE AND SB 14003 PROVIDES RELEVANT LIFE LIMIT RECOMMENDATIONS FOR PRE SB 14369 2ND STAGE PT BLADES. IN THIS CASE, THE PT 2 BLADES PN 3108303-01, LIFE LIMIT IS NOT ADDRESSED IN SB 14369 OR 14003.
CA110613001		PWA		BEARING	FAILED
6/10/2011		PW127			RGB
ENGINEERING INVESTIGATION REPORT EIR PW100 2011-040. CONFIRMED THE OPERATORS REPORT OF METAL CONTAMINATION OF THE RGB OIL SYS. THE SOURCE OF THE METAL CONTAMINATION WAS DETERMINED TO BE THE NR 15 BEARING WHICH HAD A CRACK AND SPALLED INNER RACE. THE CAUSE OF THE NR 15 BEARING FAILURE COULD NOT BE DETERMINED.
CA110726002		PWA		TURBINE BLADES	FAILED
7/25/2011		PW127			TURBINE SECTION
ENGINEERING INVESTIGATION REPORT EIR PW100 2011-046. THE ENGINE WAS DISASSEMBLED TO INVESTIGATE THE FIRST STAGE PT BLADE FAILURE. ACCESS OF THE 1ST STAGE PT DISK REVEALED 5 OF THE 1ST STAGE PT BLADES HAD FAILED. OF THE 5 BLADES THAT FAILED, 4 WERE LOCATED CONSECUTIVELY IN THE DISK. REVIEW OF THE 1ST STAGE PT BLADE HISTORY REVEALED OF THE 4 BLADES LOCATED CONSECUTIVELY IN THE DISK, 1 ACCUMULATED 16,319.3 HRS SINCE NEW, 2 ACCUMULATED 16,901.2 HOURS SINCE NEW AND 1 ACCUMULATED 8,408.6 HRS SINCE NEW. THE 5TH BLADE ACCUMULATED 16,319.3 HRS SINCE NEW. THE SET OF BLADES WERE PN 3120983-01 WHICH IS POST SB 21419. SB 21419 BLADES HAVE AN IMPROVED PROTECTIVE COATING AS WELL AS COATING PROTECTION IN THE INTERNAL CAVITY TO PREVENT THE BLADES FROM CRACKING ABOVE THE ROOT PLATFORM. DAMAGE WHICH IS CONSIDERED SECONDARY TO THE 1ST STAGE PT BLADE FAILURE WAS THE IMPACT DAMAGE SUSTAINED BY THE FIRST STAGE PT BLADES AND ALL COMPONENTS DOWNSTREAM OF THE FIRST STAGE PT DISK. TO INVESTIGATE FOR SECONDARY DAMAGE WHICH MAY HAVE RESULTED FROM UNBALANCE ON THE PT ROTOR, THE PT SHAFT WAS ACCESSED TO DETERMINE IF INTER-SHAFT RUBBING OCCURRED - NO EVIDENCE OF INTER-SHAFT RUBBING WAS PRESENT. LAST ACCESS OF THE ENGINE WAS A REPAIR 441.5 HRS AGO FOR HP VANE DAMAGE AND BLENDING OF THE LP IMPELLER. AT THAT VISIT THE PT DISK WAS INSPECTED AS AN ASSY WITH NO DEFECTS NOTED. THE LAST ACCESS OF THE ENGINE PRIOR TO THE REPAIR WAS AN O/H 1229.6 HRS AGO. MICROSTRUCTURE ANALYSIS OF 2 HP AND 2 LP BLADES WAS CARRIED OUT TO DETERMINE WHETHER AN OVERTEMPERATURE INCIDENT OCCURRED. THE ANALYSIS DETERMINED NEITHER OF THE BLADES WERE SOLUTIONED AND THEREFORE IT WAS DETERMINED AN OVERTEMPERATURE INCIDENT DID NOT OCCUR. THE CAUSE OF THE 1ST STAGE PT BLADE FAILURE COULD NOT BE DETERMINED.
CA110810001		PWA		ENGINE	FIRE
8/8/2011		PW127			NR 2
IFSD, WHILE IN CLIMB, NR 2 ENGINE SUFFERED ENGINE FIRE. PILOTS SECURED THE ENGINE AND PERFORMED AN UNEVENTFUL SINGLE ENGINE LANDING. INVESTIGATION ONGOING. MFG WILL INVESTIGATE TO ESTABLISH ROOT CAUSE AND SUPPLEMENT THE REPORT ONCE THE INFORMATION IS AVAILABLE.
CA110803002		PWA		FUEL CONTROL	INOPERATIVE
7/18/2011		PW127			ENGINE
DURING INITIAL CLIMB, 50 TO 100 FT OF THE GROUND, THE ENGINE LOST POWER AND FLAMED OUT. THE CREW APPLIED PROCEDURES FOR OEI AND CLIMBED TO FL40 BEFORE RETURNING TO THE DEPARTURE AIRPORT WHERE AN UNEVENTFUL SINGLE ENGINE LANDING WAS MADE. POST FLIGHT INSP FOUND THE P2.8/P3 BLEED AIR LINE FROM THE ENGINE TO NACELLE WAS FRACTURED & DISCONNECTED AT THE FLEXIBLE JOINT. FURTHER TROUBLESHOOTING FOUND THAT THE ENGINE ACTUALLY HAD AN UNCOMMANDED AUTOFEATHER FOR WHICH THE FUEL CONTROL WILL BE REPLACED.
CA110803013		PWA		BOLT	LOOSE
7/23/2011		PW127			PROPELLER
DURING A LAYOVER, MX FOUND AN OIL LEAK AROUND THE PROPELLER SHAFT. FURTHER INSP REVEALED THAT ALL 16 BOLTS RETAINING THE PROPELLER TO THE PROPELLER SHAFT WERE LOOSE. THE PROPELLER SHAFT FLANGE WAS FOUND CRACKED AROUND THE DOWEL PINS. THE ENGINE WILL BE FORWARDED FOR REPAIRS AND THE PROPELLER SHAFT AND ASSOCIATED HARDWARE WILL BE RETURNED TO MFG FOR INVESTIGATION.
CA110720001		PWA		PUMP	FAULTY
7/15/2011		PW545A			OIL SYSTEM
LOW OIL PRESSURE/IFSD AFTER T/O, THE PILOT REPORTED A LOSS OF OIL PRESSURE INDICATION AND LOW OIL PRESSURE ON THE EICAS. THE ENGINE WAS SHUTDOWN AND THE ACFT RETURNED TO THE POINT OF DEPARTURE WHERE AN UNEVENTFUL SINGLE ENGINE LANDING WAS ACCOMPLISHED, POST FLIGHT INSP FOUND THE BOTTOM SIDE OF THE ENGINE COVERED WITH OIL. TROUBLESHOOTING LED TO THE REPLACEMENT OF A FAULTY OIL PUMP. MFG WILL INVESTIGATE TO ESTABLISH ROOT CAUSE AND SUPPLEMENT THE REPORT ONCE THE INFORMATION IS AVAILABLE.
CA110812002		PWA		MAIN BEARING	DAMAGED
8/3/2011		R985*		232291	ENGINE
ON INSPECTION OF THE OIL SCREEN IT WAS NOTICED THAT THERE WAS FOREIGN MATERIAL IN THE OIL SCREEN. THIS MATERIAL WAS TAKEN TO AN O/H SHOP FOR ANALYSIS. WE WERE INSTRUCTED TO PULL 1 CYLINDER AND LOOK AT THE THE MAIN BEARING AND NOTICED THAT A PIECE OF IT WAS MISSING. THE ENGINE WAS PULLED AND REPLACED.
EE4Y20111005097	AIRBUS			ANCHOR FITTING	CORRODED
10/29/2011	A319132			D57259162000	ZONE 500
LT WING, INNER SPAR BETWEEN RIB 2 AND RIB 3, MLG RETRACTION JACK ANCHORAGE FITTING'S BORE, LOWER & UPPER SURFACE WITH CORROSION. NOTE: THE FITTING'S CORROSION/REWORKS REQUIRES A MAJOR REPAIR IAW ENGINEERING GUIDELINES.
EE4Y20111005098	AIRBUS			ANCHOR FITTING	CORRODED
10/29/2011	A319132			D57259162001	ZONE 600
RT WING, INNER SPAR BETWEEN RIB 2 AND RIB 3, MLG RETRACTION JACK ANCHORAGE FITTING'S BORE, LOWER & UPPER SURFACE WITH CORROSION. THE FITTING'S CORROSION/REWORKS REQUIRES A MAJOR REPAIR IAW ENGINEERING GUIDELINES.
EE4Y20111005099	AIRBUS			SKIN PANEL	CORRODED
10/29/2011	A319132			D54530052202	ZONE 400
ENGINE NR 2, PYLON AFT FIXED FAIRING, OTBD AND INBD LATERAL SKIN PANEL WITH CORROSION. NOTE: THE FAIRING SKIN PANEL REQUIRES A MAJOR REPAIR IAW SRM GUIDELINES.
EE4Y2011029600	AIRBUS			SKIN PANEL	CORRODED
10/29/2011	A319132			D54530052202	ZONE 400
ENGINE NR 1, PYLON AFT FIXED FAIRING, OTBD AND INBD LATERAL SKIN PANEL WITH CORROSION. NOTE: THE FAIRING SKIN PANEL REQUIRES A MAJOR REPAIR IAW SRM GUIDELINES.
EE4Y20111029601	AIRBUS			FLOOR SUPPORT	CORRODED
10/29/2011	A319132			D5347219620000	ZONE 200
PAX CABIN, (SECTION 18) UPPER REAR FUSELAGE BETWEEN FR69 TO FR70 Y160 FLOOR SUPPORT BEAM LONGITUDINAL WITH CORROSION. NOTE: THE FLOOR SUPPORT BEAM REQUIRES A MAJOR REPAIR IAW SRM GUIDELINES.
EE4Y20111005051	AIRBUS			SKIN	CRACKED
10/5/2011	A319132			D574500482207	ZONE 600
RT WING, W STA 8744 L/E SKIN WITH CRACK. NOTE: THE L/E SKIN REQUIRES A MAJOR REPAIR IAW SRM GUIDELINES.
EE4Y20110554	AIRBUS			SEAT TRACK	CORRODED
10/8/2011	A319132			D5347213320200	ZONE 200
UPPER FUSELAGE PAX CABIN, FROM FR66 TO FR66+5, -Y30", SEAT TRACK WITH CORROSION. REPLACED PAX CABIN SEAT TRACK IAW SRM 51-72-11.
EE4Y201110555	AIRBUS			FLOOR SUPPORT	CORRODED
10/8/2011	A319132			D5347217220500	ZONE 200
UPPER FUSELAGE PAX CABIN, FROM FR66+5 INCHES TO FR68, -Y50 INCHES FLOOR SUPPORT WITH CORROSION. REPLACED PAX CABIN FLOOR SUPPORT IAW SRM 51-72-11.
EE4Y201110556	AIRBUS			FLOOR SUPPORT	CORRODED
10/8/2011	A319132			D5347219620000	ZONE 200
UPPER FUSELAGE PAX CABIN, FROM FR68 TO FR70, +Y6 INCHES FLOOR SUPPORT WITH CORROSION. REPLACED PAX CABIN FLOOR SUPPORT IAW SRM 51-72-11.
EE4Y20111001538	AIRBUS			SEAT TRACK	CORRODED
10/1/2011	A319132			D53472133202	ZONE 200
PAX CABIN, UPPER REAR FUSELAGE BETWEEN FR64 TO FR66 -Y765 SEAT TRACK WITH CORROSION. SEAT TRACK REQUIRES A MAJOR REPAIR IAW SRM GUIDELINES.
EE4Y20111001539	AIRBUS			FLOOR SUPPORT	CORRODED
10/1/2011	A319132			D534721722005	ZONE 200
PAX CABIN, UPPER REAR FUSELAGE BETWEEN FR66 TO FR68 -Y1292 FLOOR SUPPORT WITH CORROSION. FLOOR SUPPORT REQUIRES A MAJOR REPAIR IAW SRM GUIDELINES.
EE4Y20111001540	AIRBUS			FLOOR SUPPORT	CORRODED
10/1/2011	A319132			D53472193200	ZONE 200
PAX CABIN, UPPER REAR FUSELAGE BETWEEN FR67 TO FR70 -Y765 FLOOR SUPPORT WITH CORROSION. FLOOR SUPPORT REQUIRES A MAJOR REPAIR IAW SRM GUIDELINES.
EE4Y20110542	AIRBUS			SHEAR PLATE	CORRODED
10/1/2011	A319132			D53471124202	ZONE 200
PAX CABIN, UPPER REAR FUSELAGE BETWEEN FR69 TO FR70, STRINGER 23 LEVEL SHEAR PLATE WITH CORROSION. SHEAR PLATE REQUIRES A MAJOR REPAIR IAW SRM GUIDELINES.
EE4Y20110543	AIRBUS			FLOOR SUPPORT	CORRODED
10/1/2011	A319132			D53472196200	ZONE 200
PAX CABIN, UPPER REAR FUSELAGE BETWEEN FR68 TO FR70 Y254 FLOOR SUPPORT WITH CORROSION. FLOOR SUPPORT REQUIRES A MAJOR REPAIR SRM GUIDELINES.
EE4Y20111001544	AIRBUS			ANCHOR FITTING	CORRODED
10/1/2011	A319132			D57259162000	ZONE 600
RT WING, INNER SPAR BETWEEN RIB 2 AND RIB 3, MLG RETRACTION JACK ANCHORAGE FITTING'S BORE, LOWER & UPPER SURFACE WITH CORROSION. FITTING REQUIRES A MAJOR REPAIR IAW ENGINEERING GUIDELINES.
EE4Y20111001545	AIRBUS			ANCHOR FITTING	CORRODED
10/1/2011	A319132			D57259162001	ZONE 500
LT WING, INNER SPAR BETWEEN RIB 2 AND RIB 3, MLG RETRACTION JACK ANCHORAGE FITTING'S BORE, LOWER & UPPER SURFACE WITH CORROSION. FITTING REQUIRES A MAJOR REPAIR IAW MFG ENGINEERING GUIDELINES.
EE4Y20111001546	AIRBUS			SKIN	DEBONDED
10/1/2011	A319132				RUDDER
VERTICAL STABILIZER, RUDDER LT & RT SIDE PANELS WITH WATER INGRESS AROUND INSIDE HONEYCOMB CORE AROUND HOISTING POINT NR 2. RUDDER PANELS REQUIRE A MAJOR REPAIR IAW MFG ENGINEERING GUIDELINES.
EE4Y201110560	AIRBUS			ANCHOR FITTING	CORRODED
10/10/2011	A319132			D57259162000	ZONE 500
LT WING, INNER SPAR BETWEEN RIB 2 AND RIB 3, MLG RETRACTION JACK ANCHORAGE FITTING'S BORE, LOWER & UPPER SURFACE WITH CORROSION. NOTE: THE FITTING'S CORROSION/REWORKS REQUIRES A MAJOR REPAIR IAW ENGINEERING GUIDELINES.
EE4Y201110561	AIRBUS			ANCHOR FITTING	CORRODED
10/10/2011	A319132			D57259162001	ZONE 600
RT WING, INNER SPAR BETWEEN RIB 2 AND RIB 3, MLG RETRACTION JACK ANCHORAGE FITTING'S BORE, LOWER & UPPER SURFACE WITH CORROSION. NOTE: THE FITTING'S CORROSION/REWORKS REQUIRES A MAJOR REPAIR IAW ENGINEERING GUIDELINES.
EE4Y201110562	AIRBUS			FLOOR SUPPORT	CORRODED
10/10/2011	A319132			D53111460202	ZONE 200
PAX CABIN, UPPER REAR FUSELAGE BETWEEN FR19 TO FR20 Y-254 FLOOR SUPPORT WITH CORROSION. MAJOR REPAIR.
EE4Y201110563	AIRBUS			PROFILE	CORRODED
10/10/2011	A319132			D53470479204	ZONE 100
AFT CARGO COMPARTMENT FLOOR STRUCTURE, BETWEEN FR59 TO FR60 AT STRINGER 38LT LEVEL, PROFILE-CORNER WITH CORROSION.
EE4Y201110564	AIRBUS			FLOOR SUPPORT	CORRODED
10/10/2011	A319132			D53476460000	ZONE 100
AFT CARGO COMPARTMENT BETWEEN FR47/51 TO FR55A AT STRINGER 38RT LEVEL, FLOOR STRUCTURE, PROFILE-CORNER WITH CORROSION.
EE4Y201110565	AIRBUS			SEAT TRACK	CORRODED
10/10/2011	A319132			D5347213320700	ZONE 100
PAX CABIN FROM FR 66 TO FR 66+5, -Y50 WITH SEAT TRACK CORRODED. THE SEAT TRACK DAMAGED WAS REPLACED IAW SRM 51-72-11.
EE4Y201110566	AIRBUS			FLOOR SUPPORT	CORRODED
10/10/2011	A319132			D5311145020201	ZONE 100
PAX CABIN, FROM FR 19 TO FR 20, -Y10 WITH FLOOR SUPPORT CORRODED. THE FLOOR SUPPORT DAMAGED WAS REPLACED IAW SRM 51-72-11.
EE4Y201110567	AIRBUS			FLOOR SUPPORT	CORRODED
10/11/2011	A319132			D5347217220500	ZONE 100
UPPER FUSELAGE PAX CABIN FROM STA 2801 TO 2869 -Y 1292 FLOOR SUPPORT CORRODED. REPLACED FLOOR SUPPORT IAW SRM 51-72-11 PARAGRAPH 4 AND 6.
EE4Y201110568	AIRBUS			FLOOR SUPPORT	CORRODED
10/11/2011	A319132			D5347217220400	ZONE 100
UPPER FUSELAGE PAX CABIN FROM STA 2801 TO STA 2869 +Y 1292 FLOOR SUPPORT CORRODED. REPLACED FLOOR SUPPORT IAW SRM 51-72-11, PARAGRAPH 4 AND 6.
EE4Y201110571	AIRBUS			FLOOR SUPPORT	CORRODED
10/11/2011	A319132			D5347213320600	ZONE 100
UPPER FUSELAGE PAX CABIN STA 2791 +Y 1292 FLOOR SUPPORT CORRODED. REPLACED FLOOR SUPPORT TRACK IAW SRM 51-72-11, PARAGRAPH 4 AND 6.
EE4Y201110572	AIRBUS			FLOOR SUPPORT	CORRODED
10/11/2011	A319132			D5347218920400	ZONE 100
UPPER FUSELAGE PAX CABIN STA 2884 -Y 1162 FLOOR SUPPORT CORRODED. REPLACED FLOOR SUPPORT IAW SRM 51-72-11, PARAGRAPH 4 AND 6.
EE4Y201110573	AIRBUS			FLOOR SUPPORT	CORRODED
10/11/2011	A319132			D5347218820400	ZONE 100
UPPER FUSELAGE PAX CABIN STA 2884 +Y 1162 FLOOR SUPPORT CORRODED. REPLACED FLOOR SUPPORT IAW SRM 51-72-11, PARAGRAPH 4 AND 6.
EE4Y20110574	AIRBUS			FLOOR SUPPORT	CORRODED
10/11/2011	A319132			D5347219620000	ZONE 100
UPPER FUSELAGE PAX CABIN AFT ENTRANCE AREA FROM STA 2884 TO STA 2992, +Y 16, FLOOR SUPPORT WITH CORROSION. REPLACED FLOOR SUPPORT IAW SRM 51-72-11, PARAGRAPH 4 AND 6.
EE4Y201110570	AIRBUS			SKIN	CORRODED
10/11/2011	A319132			D54530052200201	NR 1 NACELLE
ENGINE NR 1 PYLON SECTION INBD AND OTBD AFT FIXED PANELS WITH CORROSION. REPLACED ENGINE NR 1 PYLON AFT FAIRING SECTION INBD AND OTBD SKIN PANEL IAW SRM 51-72-11 PARAGRAPH 4 AND 6.
EE4Y20111001547	AIRBUS	IAE		PAN	CRACKED
10/1/2011	A319132	V2524A5		74010912	ENGINE NOZZLE
ENGINE NR 2, COMMON NOZZLE ASSY, PAN WITH CRACK. NOTE: THE PAN CRACKED REQUIRE A MAJOR REPAIR IAW SRM GUIDELINES.
EE4Y20111001548	AIRBUS	IAE		PAN	CRACKED
10/1/2011	A319132	V2524A5		74010911	ENGINE NOZZLE
ENGINE NR 1, COMMON NOZZLE ASSY, PAN WITH CRACK. PAN CRACKED REQUIRES A MAJOR REPAIR IAW SRM GUIDELINES.
EE4Y20111001541	AIRBUS	IAE		SEAT TRACK	CORRODED
10/1/2011	A319132	V2524A5		D53472133207	ZONE 200
PAX CABIN, (SECTION 18) UPPER REAR FUSELAGE BETWEEN FR64 TO FR66 -Y1292 SEAT TRACK WITH CORROSION. SEAT TRACK REQUIRES A MAJOR REPAIR IAW SRM GUIDELINES.
EE4Y201110557	AIRBUS	IAE		SKIN	CORRODED
10/10/2011	A319132	V2524A5		D54530052202	NR 1 NACELLE
ENGINE NR1, PYLON AFT FIXED FAIRING, OTBD AND INBD LATERAL SKIN PANEL WITH CORROSION. THE FAIRING SKIN PANEL REQUIRES A MAJOR REPAIR IAW SRM GUIDELINES.
EE4Y201110558	AIRBUS	IAE		SKIN	CORRODED
10/10/2011	A319132	V2524A5		D54530052203	NR 2 NACELLE
ENGINE NR 2, PYLON AFT FIXED FAIRING, OTBD AND INBD LATERAL SKIN PANEL WITH CORROSION. THE FAIRING SKIN PANEL REQUIRES A MAJOR REPAIR IAW SRM GUIDELINES.
EE4Y201110559	AIRBUS	IAE		SKIN	CORRODED
10/10/2011	A319132	V2524A5		7400515799	THRUST REVERSER
ENGINE NR 2, LEFT C-DUCT LOWER BIFURCATION OUTER SKIN WITH CORROSION, LOCATED JUST ABOVE THE 740-0420 FAIRING AT 6 O'CLOCK POSITION. NOTE: THE C-DUCT OUTER SKIN REQUIRES A MAJOR REPAIR IAW ENGINEERING GUIDELINES.
EE4Y20111005549	AIRBUS	IAE		SKIN PANEL	CORRODED
10/5/2011	A319132	V2524A5		D54530052203	NR 2 NACELLE
ENGINE NR 2, PYLON AFT FIXED FAIRING, OTBD AND INBD LATERAL SKIN PANEL WITH CORROSION. FAIRING SKIN PANEL REQUIRES A MAJOR REPAIR IAW SRM GUIDELINES.
EE4Y20111005050	AIRBUS	IAE		SKIN PANEL	CORRODED
10/5/2011	A319132	V2524A5		D54530052202	ZONE 400
ENGINE NR 1, PYLON AFT FIXED FAIRING, OTBD AND INBD LATERAL SKIN PANEL WITH CORROSION. FAIRING SKIN PANEL REQUIRES A MAJOR REPAIR IAW SRM GUIDELINES.
EE4Y201111060593	AIRBUS			ANCHOR FITTING	CORRODED
11/6/2011	A321231			UNK	ZONE 100
LOWER FUSELAGE, OUTER WING REAR SPAR AFT FACE, LT RETRACTION ANCHOR JACK FITTING WITH CORROSION. THE ANCHOR JACK FITTING REQUIRED A MAJOR REPAIR IAW MFG.
EE4Y201111070594	AIRBUS			FLOORBEAM	CORRODED
11/7/2011	A321231				ZONE 100
DURING THE INSPECTION FOUND THE UPPER FUSELAGE PAX CABIN STA FR 66 Y STA 1292 FLOORBEAM WITH COROSION.
EE4Y20110595	AIRBUS			FLOORBEAM	CORRODED
11/7/2011	A321231				ZONE 100
DURING THE INSPECTION, FOUND THE UPPER FUSELAGE PAX CABIN FR21, YSTA 254 FLOORBEAM WITH COROSION.
EE4Y201111070596	AIRBUS			SKIN	CORRODED
11/7/2011	A321231				ZONE 500
1-DURING THE ACFT MX SERVICE, FOUND LT WING, TOP SKIN, UPPER SURFACES WITH CORROSION AROUND FASTENERS HEAD NR 483, 493, 496 AND 497 IAW R572-45006 (WING SKIN BOLT LOCATION DIAGRAM A321-200). THEY ARE LOCATED BETWEEN RIB 4 AND RIB 5 ON INNER REAR SPAR AREA. MFG PROVIDED REPAIR INSTRUCTIONS
EE4Y201111070615	AIRBUS			DOOR FRAME	CORRODED
11/7/2011	A321231				ZONE 100
1-DURING THE ACFT MX SERVICE, FOUND THE LOWER FUSELAGE AFT CARGO COMPARMENT DOOR JAMB SUPPORT UPPER SURFACE WITH COROSION FROM FR 59 AND FR 56. REPLACED WEB AT AFT CARGO COMPARTMENT FROM FR55A TO FR59 IAW SRM 51-72-11PA 4 AND 6.
EE4Y201111070616	AIRBUS			FLOORBEAM	CORRODED
11/7/2011	A321231				ZONE 200
DURING THE ACFT MX SERVICE, FOUND THE UPPER FUSELAGE PAX CABIN STA FR21- Y254 FLOORBEAM WITH CORROSION. REPLACED FLOORBEAM, UPPER FUSELAGE PAX CABIN YSTA 254-FR21 IAW SRM 51-72-11.
EE4Y20110592	AIRBUS			ANCHOR FITTING	CORRODED
11/6/2011	A321231				ZONE 100
LOWER FUSELAGE, OUTER WING REAR SPAR AFT FACE, RT RETRACTION ANCHOR JACK FITTING WITH CORROSION. THE ANCHORAGE JACK FITTING REQUIRED A MAJOR REPAIR IAW MFG.
B62R20110714001	AIRBUS			CONTROL PANEL	MALFUNCTIONED
7/14/2011	A340212			817535128140001	MEDICAL O2
MEDICAL OXYGEN CYLINDER LEAKED OUT AND DEPLETED. PROBLEM HAS BEEN ISOLATED TO CONTROL CIRCUITRY FOR THE OXYGEN PULSE LATCHING VALVE. MFR REPORTED THAT A CONTINUOUS ON POWER SIGNAL WOULD CAUSE THE VALVE TO CHATTER, RELEASING OXYGEN SLOWLY FROM THE CYLINDER UPSTREAM OF THE VALVE.
2011FA0000637	AIRTRC	PWA	PWA	EXHAUST VALVE	STUCK
7/29/2011	AT401	R1340*			CYLINDER
ACFT DEVELOPED HEAVY VIBRATION DUE TO A STUCK EXHAUST VALVE IN THE CYLINDER ASSY.
CA110727011	AIRTRC	PWC		ANTENNA	CRACKED
7/24/2011	AT802	PT6A67AG		0145621	ELT
ACFT SKIN AT BASE OF ELT ANTENNA CRACKED. POSSIBLE LOSS OF ELT ANTENNA AND FURTHER DAMAGE IN NEXT FEW FLIGHT HOURS.
CA110811004	AIRTRC	PWC		SEAL	CUT
8/9/2011	AT802A	PT6A67AG			SOILENOID VALVE
LT AND RT WATER PICK UP PROBES STUCK DOWN DURING PRAC SCOOP CHECK. PILOT RETURNED TO BASE, FOUND SOLENOID UNLOCK POSITION JAMMED WITH DISPLACED/CUT SEAL. SOLENOID VALVE ASSY REPLACED-FUNCTION CHECKED AND SERVICABLE. MODEL PN DG4V-3-2AL-MFPBWL-H7-60.
CA110720002	AIRTRC	PWC		FUEL CONTROL	FAULTY
7/15/2011	AT802A	PT6A67AG			ENGINE
ACFT WAS COMING IN FOR LANDING WHEN PILOT NOTICED ENGINE POWER LOSS. LANDED SAFELY AND WHEN THE ACFT CAME TO A STOP, THE COMPRESSOR SPEED (NG) HAD DROPPED DOWN TO 10 PERCENT. TROUBLESHOOTING LEAD TO A FAULTY FUEL CONTROL UNIT WHICH WILL BE REPLACED BEFORE THE ACFT IS RETURNED TO SERVICE. RECOMMENDS THE SDR BE CLOSED ON THE BASIS OF THE FOLLOWING INFORMATION.
CA110629002	AIRTRC	PWC		BUSHING	LOOSE
6/26/2011	AT802A	PT6A67AG			MLG
FOUND INBD, LT AND OTBD, RT WHEEL BRAKE TORQUE PLATES WITH MIGRATING BUSHINGS (1 EACH) FOR CALIPER SLIDE PINS. TORQUE PLATES REPLACED IAW MP 5-1.
2011FA0000671	AMRGEN	LYC		ALTERNATOR	LOOSE
8/7/2011	AA5B	O360A4K
ALTERNATOR CASE BOLTS WORKED LOOSE, SAFETY WIRE BROKEN. CATASTROPHIC FAILURE AT 152 HRS SINCE O/H. THE ORIGINAL MFG HISTORICALLY LAST MUCH LONGER. ADVISE SELF LOCKING BOLTS AND LOCK TABS AS THE ORIGINAL, AND EXTREME CLEANING OF MATING SURFACES PRIOR TO ASSY.
2011FA0000597	BBAVIA			BOLT	LOOSE
9/6/2011	7GCB			AN622A	TAIL WHEEL
AN AN6-22A BOLT WITH AN AN365 NUT WAS USED TO HOLD THE FWD END OF THE TAIL WHEEL SPRING. THE NUT BACKED OFF ALLOWING THE TAIL WHEEL SPRING TO SIDE AFT IN THE TAIL POST SADDLE. SUGGEST THE INSTALLATION BE DONE USING AN AN6-22 BOLT WITH AN 310 NUT AND A COTTER PIN. THE TAIL POST BOLTS SHOULD ALSO BE CHANGED TO DRILLED BOLTS, CASTELLATED NUTS AND COTTER PINS AS THESE ALSO COME LOOSE.
CA110629004	BBAVIA	LYC		CYLINDER	CRACKED
6/23/2011	8GCBC	O360C2E		LW12427	NR 4
DURING THE 100HR INSPECTION, A .5" TO 1" CRACK WAS DISCOVERED COMMING FROM THE LOWER SPARK PLUG HOLE ON NR 4 CYLINDER. CYLINDER WAS REPLACED. THIS ENGINE IS USED FOR GLIDER TOWING AND IS O/H EVERY 2000 HRS.
2011F00201	BEECH	PWA		ENGINE	MAKING METAL
9/13/2011	400A	JT15D5		JT15D5
DURING ENGINE MINOR INSP, SENT OIL FILTER TO LAB FOR ROUTINE ANALYSIS, LAB REPORTED METAL IN OIL. CONTACTED MFG FOR EVALUATION, MFG INSTRUCTED TO INSTALL NEW OIL AND FILTER, PERFORM GROUND RUN FOR 1 HOUR, AND SEND FILTER OUT FOR REPEAT ANALYSIS. SECOND ANALYSIS FOUND MORE METAL (BEARING MATERIAL) IN OIL FILTER. MFG RECOMMENDED ENGINE REPLACEMENT. ENGINE HAS 958.2 HOURS SINCE O/H.
2011FA0000587	BEECH		CONT	IMPULSE COUPLING	FAILED
9/13/2011	58			1076232	MAGNETO
THE SPRINGS IN THE IMMPULSE COUPLING FAILED. THE PAWS TO ENGAGE THE MAGNETO WOULD NOT EXTEND. IT WAS NOTED THAT THE IMPLUSE COUPLING WAS NOT SNAPPING DURRING A 100 HR INSPECTION. MAGNETO WAS R/R'D TO CORRECT DISCREPANCY.
C41R201110060105	BEECH			CIRCUIT BREAKER	SHORTED
10/5/2011	A36				COCKPIT LIGHTS
ACFT IN ANNUAL INSPECTION. ELECTROLUMINESCENT PANEL LIGHTING INOPERATIVE. TROUBLESHOT SYS AND FOUND MAIN CIRCUIT BREAKER PANEL, CENTER ROW STRIP PANEL TO BE INTERNALLY SHORTED. REMOVED PANEL FROM CIRCUIT AND ALL OTHER STRIP PANELS LIGHT OK. SENT OUT BAD PANEL FOR REPAIR.
C41R201110030104	BEECH			ANNUNCIATOR	BURNED OUT
10/3/2011	A36			065005801KA185	AUTOPILOT
DURING PRE-INSPECTION RUN-UP, TECH FOUND "FD" LIGHT INOP ON AUTOPILOT ANNUNCIATOR. UNIT REMOVED FOR REPAIR.
C41R201110030103	BEECH	CONT		INDICATOR	INTERMITTENT
10/3/2011	A36	IO550*		1023800143	OIL TEMP
DURING PRE-INSPECTION RUN-UP, TECH FOUND OIL TEMPERATURE AND OIL PRESSURE NEEDLES (DUAL GAUGE) INTERMITTENTLY PEG FULL SCALE. REMOVED GAUGE AND FOUND SMALL PIECES/PARTS RATTLING AROUND INSIDE UNIT. ALSO, GAUGE CORE MOVES FORE AND AFT (REAR SCREWS MISSING). SENT OUT FOR REPAIR.
CA110712002	BEECH	GARRTT		FIREWALL	CRACKED
7/1/2011	B100	TPE3316252B			ENGINE BAY
DURING ROUTINE INSP, A CRACK HAS BEEN FOUND ON THE RT INBD WALL OF THE COLLECTOR TANK IN THE FIREWALL FUEL SHUTOFF REGION. REPAIR HAS BEEN DONE IAW THE MM.
CA110719008	BEECH	PWA		TRANSDUCER	FAILED
6/6/2011	B200	PT642A		1013890235	LT ENGINE
DURING FLIGHT, THE CREW NOTICED THE LT ENGINE OIL PRESSURE DECREASING. IAW THE SOP`S THE ENGINE WAS SHUTDOWN IN FLIGHT AND A SAFE LANDING WAS MADE. TROUBLESHOOTING WAS CARRIED OUT AND FOUND THAT THE OIL PRESSURE TRANSDUCER HAD FAILED GIVING THE LOW READING.
CA110627019	BEECH	PWA		VALVE	BENT
6/24/2011	B200	PT642A		10192006137	ANTI SIPHON
DURING POST-FLIGHT INSPECTION, ANTI-SIPHON VALVE IN RT OTBD WING FUEL FILLER WAS FOUND FORCED OUT AT FLAPPER SEAL AREA AND CRACKED UP TO ATTACH FLANGE. VALVE WAS REPLACED WITH NEW PART, SAME PN. DAMAGE WAS CAUSED BY FUELLER`S FORCING FUEL NOZZLE IN FILLER AND TWISTING AND IS AN ONGOING ISSUE. FUEL STAFF SHOWN DAMAGED PARTS AND PROBLEM EXPLAINED AGAIN AS THEY PROVIDE 80 PERCENT OF OUR FUEL!
2011FA0000655	BEECH	CONT		CIRCUIT BREAKER	FAILED
10/3/2011	F33A	IO520*		35380132103	LANDING LIGHT
PILOT REPORTED LANDING LIGHT INOP. ON TROUBLESHOOTING THE TECH FOUND THE CIRCUIT BREAKER AT FAULT. INSTALLED NEW CIRCUIT BREAKER. OPS CHECKED OK.
2011FA0000654	BEECH	CONT		CIRCUIT BREAKER	FAILED
10/2/2011	F33A	IO520BB		35380132103	LANDING LIGHT
PILOT REPORTED LANDING LIGHT INOPERATIVE. ON TROUBLESHOOTING THE TECH FOUND THE CIRCUIT BREAKER AT FAULT. INSTALLED NEW CIRCUIT BREAKER. OPS CHECKED OK.
2011FA0000586	BEECH	CONT		SWITCH	FAILED
9/11/2011	F33A	IO520BB		35380132101	NAVIGATION LIGHT
PILOT REPORTED NAV LIGHTS INOP. ON TROUBLESHOOTING, TECH FOUND CIRCUIT BREAKER/SWITCH TO BE AT FAULT. THIS BEING THE SECOND NAV LIGHT CIRCUIT BREAKER/SWITCH BEING REPLACED IN THIS ACFT SINCE AD 2008-13-17 WAS COMPLETED.
2011FA0000610	BEECH	CONT		CIRCUIT BREAKER	FAILED
9/20/2011	F33A	IO520BB		35380132103	LANDING LIGHT
PILOT REPORTED LANDING LIGHT INOP. ON TROUBLESHOOTING, TECH FOUND CIRCUIT BREAKER/ SWITCH TO BE AT FAULT. AD 2008-13-17 HAD BEEN COMPLETED 2301.4 FLIGHT HOURS PRIOR AND ESTIMATED CYCLES 9205.6. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.
2011FA0000635	BEECH	CONT		CIRCUIT BREAKER	FAILED
9/28/2011	F33A	IO520BB		35380132103	LANDING LIGHT
PILOT REPORTED LANDING LIGHT INOP. ON TROUBLESHOOTING, TECH FOUND CIRCUIT BREAKER TO BE AT FAULT. AD 2008-13-17 HAD BEEN COMPLETED 1898.9 FLIGHT HOURS PRIOR AND ESTIMATED CYCLES 7595.6. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.
2011FA0000599	BELL	ALLSN	BELL	COUNTERWEIGHT	DEPARTED
8/31/2011	206B	250C20B			TAIL ROTOR
AT APPROXIMATELY 21:15 THE EVENING OF 31 AUG 2011, DEPARTED THE COUNTY RAMP IN FOR A NIGHT VISION GOGGLE TRAINING MISSION WITH A CONTRACT INSTRUCTOR PILOT. WEATHER AT THE TIME WAS VFR. ALL PRE-FLIGHT CHECKS WERE NORMAL, AS WAS TAKEOFF AND CLIMB HEADING SOUTHEAST FROM THE AIRPORT TO A CRUISE ALITUDE OF 700 FT. APPROX 5 TO 6 MINUTES AFTER TAKEOFF, EXPERIENCED A SEVERE VIBRATION LASTING AN EXTIMATED 10 TO 20 SECONDS. THE INSTRUCTOR INITIATED A RAPID DECENT TO AN OPEN FIELD FOR A PRECAUTIONARY LANDING. AFTER LANDING AND ENGINE SHUTDOWN IT WAS DISCOVERED THAT A COUNTER WEIGHT HAD DEPARTED 1 TAIL ROTOR BLADE FOR UNKNOWN REASONS CAUSING THE VIBRATION. IT WAS ALSO DISCOVERED AFTER LANDING AND INSPECTION OF THE TAIL ROTOR THAT THE VIBRATION HAD CAUSED 3 OF THE 4 ATTACHMENT STUDS HOLDING THE TAIL ROTOR GEAR BOX TO SHEAR.
CA110215010	BELL	ALLSN		FCU	MALFUNCTIONED
2/12/2011	206B	250C20B		23070606	ENGINE
OCCASIONAL DELAYED LIGHT OFF AFTER THROTTLE IS CRACKED OPEN TO DETENT ON GROUND RUN. REPLACED FCU.
CA110511006	BELL	ALLSN		TRANSPONDER	INTERMITTENT
4/30/2011	206B	250C20B		066106200	ATC
ATC TRANSPONDER INTERMITTENTLY TRANSMITTING WRONG MODE A CODE. MODE A CODE SELECTOR SWITCHES INTERMITTENT. TRANSPONDER IN SERVICE FOR 5 DAYS SINCE LAST RECERTIFICATION. TRANSPONDER REPLACED.
CA110516012	BELL	ALLSN		BRUSHES	WORN
5/13/2011	206B	250C20B		23032018	STARTER GEN
THIS STARTER/GENERATOR WAS INSTALLED ON THE ACFT AT THE TIME OF PURCHASE. STARTER BRUSHES WORN.
CA110603003	BELL	ALLSN		ELT	CRACKED
5/11/2011	206B	250C20B		S182250202	CABIN
DURING ANNUAL ELT INSPECTION, UNIT WAS FOUND TO HAVE 28 CRACKS IN THE HOUSING. THE UNIT WAS FOUND TO HAVE SOME OIL CONTAMINATION ON THE HOUSING. ALL CRACKS WERE FOUND NEAR THE COVER SCREWS SUGGESTING THAT THE SCREWS MAY HAVE BEEN OVER-TORQUED. THE COVER SCREWS HAD NOT BEEN REMOVED SINCE THE ELT CAME FROM THE MFR.
3HCR20110928001	BELL	ALLSN	HONEYWELL	BEARING	MISSING
9/28/2011	206B3	250C20B	ALAD2	2523237	GOVERNOR
REMOVED GOVERNOR FOR ENGINE SURGING. TESTED AS RECEIVED. FAILED TEST POINT 4.020-4.050. INSPECTED AND FOUND BEARING NOT INSTALLED ON CAM FOLLOWER LEVER.
3HCR20110927001	BELL	ALLSN		FUEL CONTROL	FAILED
9/27/2011	206L3	250C30		2549092823087146	FUEL
AIRCRAFT FAILED TO LIGHT OFF. INSPECTED AND FOUND CUT-OFF UNSERVICABLE.
3HCR20110927002	BELL	ALLSN	HONEYWELL	SHAFT	CRACKED
9/27/2011	206L3	250C30	DPV1	2541924	FUEL CONTROL
UNIT FAILED TO LIGHT OFF. INSPECTED AND FOUND TORSION SHAFT LEAKING.
2011FA0000653	BELL	ALLSN		BEARING	FAILED
9/30/2011	407	250C47B		M25010121	ENGINE
WHILE IN CRUISE FLIGHT, ENGINE CHIP LIGHT ILLUMINATED, PILOT LANDED IN FIELD. INSP OF BOTH ENGINE CHIP DETECTORS REVEALED MULTIPLE CHIPS. THE SOURCE OF THE METAL WAS DUE TO FAILURE OF THE PTO BEARING, PN (M250-10121) THE ENGINE GEARBOX IS AN "ON CONDITION" ITEM AND ACCORDING TO THE REPAIR FACILITY FAILURE OF THIS BEARING IS ONLY SEEN IN HIGH TIME ENGINES.
2011FA0000663	BELL	ALLSN		DRIVE SHAFT	BROKEN
9/27/2009	OH58A	250C20		SKCP234085	MAIN ROTOR
HELICOPTER WAS TOOK OFF EMPTY FROM LANDING PAD TO SURVEY AREA. DURING TAKEOFF A "POPPING" SOUND WAS HEARD BY PILOT AND GROUND CREW AND THE ACFT WOULD NOT DEVELOP SUFFICIENT ENGINE TORQUE TO CLEAR TERRAIN. FOLLOW UP TO ACCIDENT FOUND ENGINE DRIVE SHAFT HAD SEVERED COMPLETELY APART INTO SEVERAL PIECES AND HAD ROTATED MANY TIMES IN A DAMAGED CONDITION. DRIVESHAFT SENT TO NTSB LAB FOR ANALYSIS, BUT LAB COULD NOT DETERMINE DEFINITIVELY WHETHER DAMAGE TO DRIVESHAFT CAUSED THE ACCIDENT OR WAS CAUSED BY THE ACCIDENT. NO FURTHER ACTION POSSIBLE.
2011FA0000657	BELL		BELL	BLADE	CRACKED
10/3/2011	UH1H			204011250113	M/R HUB
PILOT NOTED A VERTICAL VIBRATION DURING FLIGHT. UPON VISUAL INSPECTION, IT WAS FOUND THAT MAIN ROTOR BLADE HAD CRACKED 90 INCHES FROM BLADE TIP THROUGH THE T/E TO THE SPAR AND 7" TOWARDS THE BLADE ROOT ALONG THE SPAR, ON UPPER AND LOWER SURFACES OF THE BLADE.
7AHR201192030	BOEING			FRAME	CRACKED
10/16/2011	737282C				BS 907
AFT PIT CRACKED, FRAME LOWER CHORD AT BS 907 AND STRINGER 26R.
7AHR2011092019	BOEING			THRESHOLD	CORRODED
9/23/2011	737282C				ZONE 100
FORWARD FUSELAGE FLOOR STRUCTURE AT L1 DOOR CENTER THRESHOLD AREA HAS LIGHT CORROSION ON UPPER SURFACE STRUCTURE AND UNDER NUTPLATES
7AHR2011092020	BOEING			INTERCOSTAL	CORRODED
9/23/2011	737282C				ZONE 100
AFT BAGGAGE COMPARTMENT INTERCOSTAL UPPER FLANGE CORRODED OUT OF LIMITS BETWEEN BODY STATION 767 AND 787 AT STRINGER 25R
7AHR2011092022	BOEING			SKIN	CORRODED
9/23/2011	737282C				ZONE 100
AFT FUISELAGE BODY STA 976.6 AT STRINGER 25L, EDGE OF WATER SERVICING DOOR HAS EVIDENCE OF CORROSION.
7AHR2011092023	BOEING			TRANSITION PANEL	CORRODED
9/23/2011	737282C				ZONE 100
AFT PIT TRANSITION PANEL CORRODED JUST AFT OF CARGO DOOR ON THE RT SIDE AT BODY STATION 887.
7AHR2011092024	BOEING			FLOOR SUPPORT	CORRODED
9/23/2011	737282C				ZONE 100
AFT BAGAGGE COMPARTMENT FLOOR SUPPORTS AT BODY STATION 770 AT SPLICE STRAP ATTACHED HAS SIGNS OF CORROSION
7AHR2011092026	BOEING			SKIN	CORRODED
9/23/2011	737282C				ZONE 100
AFT FUSELAGE HAS EVIDENCE PILLOWING (CORROSION) AT BODY STA 1016 AT STR 25L AND 24L AROUND FASTENERS.
7AHR2011092027	BOEING			BEAM	ELONGATED
9/23/2011	737282C				ZONE 700
DURING THE ACCOMPLISHMENT OF ECO 3731 SB 737-57A-1266 INSPECTION OF THE MAIN LANDING GEAR BEAM TO WING ATTACH FITTINGS IT WAS DISCOVERED THAT THE MLG BEAM PIN RETAINER LOCK BOLT FITTING IS ELONGATED ON BOTH LT AND RT MLG BEAM.
7AHR2011092002	BOEING			ACCESS PANEL	CORRODED
9/21/2011	737282C				ZONE 100
AFT FUSELAGE AT POTABLE WATER SERVICING PANEL HAS EVIDENCE OF CORROSION AROUND PANEL.
7AHR2011092004	BOEING			SKIN	CORRODED
9/22/2011	737282C				ZONE 100
PILLOWING CORROSION AROUND FASTENERS AT BODY STA 787, STRINGER 27R.
7AHR2011092005	BOEING			ANGLE	CORRODED
9/22/2011	737282C				ZONE 900
AFT FUSELAGE FLOOR STRUCTURE AT AFT LAVATORY FORWARD WALL AS CORROSION AT ATTACH ANGLE AT INBD FASTENER HOLE.
7AHR2011092006	BOEING			FLOOR SUPPORT	CORRODED
9/22/2011	737282C				ZONE 100
AFT PIT FLOOR SUPPORT AT BODY STATION 770 HAS CORROSION AND WAS FOUND TO BE OUT OF LIMITS AT SPLICE STRAP
7AHR2011092008	BOEING			FLOOR SUPPORT	CORRODED
9/22/2011	737282C				ZONE 100
AFT BAGGAGE COMPARTMENT FLOOR SUPORT AT RBL 8" HAS CORROSION THAT IS OUT OF LIMITS AT SPLICE STRAP BODY STA 770.
7AHR2011092003	BOEING			STRUCTURE	CORRODED
9/22/2011	737282C				BS 464
CORROSION UNDER FLOORBOARD SPLICE AT STA 464 BETWEEN STRINGER 27R AND 26R IN FORWARD PIT.
7AHR2011092011	BOEING			SKIN	CRACKED
9/23/2011	737282C				FUSELAGE
DURING THE ACCOMPLISHMENT OF ECO 3735, FORWARD ENTRY AND FORWARD GALLEY SERVICE DOORWAY UPPER AND LOWER HINGE CUTOUT INSPECTION, IT WAS DETERMINED THAT THE FORWARD ENTRY DOOR, LOWER HINGE CUTOUT HAS 1 EACH CRACKED FASTENER HOLE. CRACK IS IN THE LOWER B-5 HOLE, DETERMINED BY EDDY CURRENT.
7AHR2011092012	BOEING			FLOORBEAM	CORRODED
9/23/2011	737282C				ZONE 100
FORWARD CABIN FLOOR STRUCTURE (FRAME) HAS CORROSION AT BODY STA 312 BETWEEN RBL 24 AND RBL 45.
7AHR2011092013	BOEING			SILL	CORRODED
9/23/2011	737282C				ZONE 900
FORWARD CABIN FLOOR STURCTURE AT BODY STATION 312 TO 344 AT MOP SILL HAS CORROSION AROUND FASTNER HOLES.
7AHR2011092014	BOEING			FLOOR SUPPORT	CORRODED
9/23/2011	737282C				ZONE 900
AFT FUSELAGE FLOOR STRUCTURE AT LT LAVATORY WALL, FLOOR IS CORRODED AT BODY STATION 947 TO 967.
7AHR2011092015	BOEING			FLOORBEAM	CORRODED
9/23/2011	737282C				ZONE 100
AFT FUSELAGE FLOOR STRUCTURE HAS CORROSION AT FLOOR SUPPORT BODY STA 957 BETWEEN RT SIDE OF SEAT TRACKS AT RBL 24 AND 45.
7AHR2011092016	BOEING			FLOOR SUPPORT	CORRODED
9/23/2011	737282C				ZONE 100
CORROSION UNDER TIE DOWN AT STRINGER 26R AT SHEAR TIE FLOORBOARD SUPPORT AT BODY STATION 384.
7AHR2011092017	BOEING			FLOOR SUPPORT	CORRODED
9/23/2011	737282C				ZONE 100
AFT BAGGAGE COMPARTMENT FLOOR SUPPORT SPLICE PLATE HAS SIGNS OF CORROSION ON BOTTOM SIDE AT BODY STA 770.
7AHR2011092018	BOEING			FLOOR SUPPORT	CORRODED
9/23/2011	737282C				ZONE 200
FORWARD CABIN FLOOR STRUCTURE HAS CORROSION ON FLOOR SUPPORT AT LBL 6 BETWEEN BODY STATION 294.5 AND 312.0.
TX9Y20110914001	BOEING			INTERCOSTAL	CRACKED
9/11/2011	747200F			65B1236840	FUSELAGE
RT SIDE STATION 1220 OVERWING INTERCOSTAL WEB WAS FOUND HAVING CRACKS AND NEED TO BE REPLACED IN ACCORDANCE WITH PARAGRAPH 3B, WORK INSTRUCTIONS OF SB-747-53A2750. FOUND 2EA CRACKS ON STA 1220 INTERCOSTAL LOWER CHORD. THE INTERCOSTAL LOWER CHORD WAS REPLACED WITH A NEW PART THAT WAS LOCALLY MANUFACTURED PER DRAWING 65B12368 (-40) REV B AND SRM 51-00-06. THE DEVIATION WAS APPROVED UNDER BOEING SERVICE REQUEST 1-1966232700 ON ODA-300064-NM FAA FORM 8100-9 DATED SEPTEMBER 2, 2011 AS AN ALTERNATIVE METHOD OF COMPLIANCE TO PARAGRAPH (I) OF AD 2010-14-17 AND FOUND TO MEET THE TYPE CERTIFICATE BASIS.
ABXR201109300041	BOEING			STRUCTURE	CRACKED
9/30/2011	767231			114T293815	ZONE 100
NWW LT STA 287 CHORD CRACKED APPROX 11" FROM TOP OF CHORD. REPAIRED CHORD AT STA 287 LT IAW SRM.
ABXR201109300042	BOEING			CHANNEL	CRACKED
9/30/2011	767231			313T3380181	ZONE 400
CHANNEL CRACKED INSIDE NR 1 STRUT DOOR 437AR. REPAIRED NR1 PYLON CHANNEL IAW SRM.
ABXR201109300043	BOEING			STIFFENER	CORRODED
9/30/2011	767231			112T12307	ZONE 500
LT WING T/E STIFFNER CORRODED AT WS 430. R & R STIFFNER IAW SRM.
ABXR201109300044	BOEING			BEAM	CRACKED
9/30/2011	767231			313T3380372	ZONE 400
NR 2 PYLON OTBD LONGITUDINAL BEAM CRACKED. R & R BEAM IAW SRM.
ABXR201109300045	BOEING			SKIN	CORRODED
9/30/2011	767231			140T26405	CARGO DOOR
CORROSION AROUND NUTPLATE HOLES FOR DOOR LINER OF FLC DOOR. REPAIRED IAW SRM.
QMLA20111010002	BOLKMS			PANEL	CORRODED
10/10/2011	BK117B2			1172336151	ENGINE BAY DOOR
CORROSION FOUND COMING FROM UNDER PROTECTIVE PLATE ON EXTERIOR OF PANEL ASSY. (LT ENGINE DOOR) PANEL WAS REMOVED AND SENT TO VENDOR FOR REPAIR.
2011FA0000757	BOMBDR		BOMBDR	SENSOR	CORRODED
10/22/2011	BD7001A10			2F7851	ZONE 100
AT FL 430 4 HOURS INTO FLIGHT CREW DETECTED ELECTRICAL BURNING ODOR FROM CREW REST AREA. SMOKE EMERGENCY PROCEDURES WERE INIATED. AFTER PULLING GALLEY CB'S AND TURNING RECIRCULATION FANS OFF ODOR DISSIPATED AND THEN RETURNED. EMERGENCY DECLARED AND DIVERTED WITHOUT FURTHER INCIDENT. MAINTENANCE DISCOVERED FAILED FORWARD WATER TANK LEVEL SENSORS WHICH WERE CHANGED AND THE AIRCRAFT RETURNED TO SERVICE. MANUFACTURER NOTIFIED OF OCCURRENCE FOR DISPOSITION.
CA110630003	CESSNA	LYC		CYLINDER	SCORED
6/30/2011	152	O235L2C		05K23037
OIL FILTER INSPECTION SHOWED CONTAMINATION. PISTON PIN FWD PLUG WEARING/SCORING BOTTOM OF 2 FRONT CYLINDERS. TIME IS FROM REPLACEMENT DUE SAME ISSUE.
CA110811006	CESSNA	LYC		CONTROL CABLE	SEPARATED
8/8/2011	152	O235L2C		S123019	CARB HEAT
(CAN) THE ACFT WAS ON APPROACH AFTER A ROUTINE PIPELINE PATROL WHEN THE PILOT PULLED THE CARBURETOR HEAT CONTROL TOWARDS THE "ON" POSITION. THE PILOT REALIZED THAT THE CONTROL FELT LOOSE AS HE CONTINUED TO PULL IT OUT OF THE PANEL. THE INNER CONTROL CABLE HAD SEPARATED ABOUT 6 INCHES FROM THE CONTROL KNOB. THE PILOT CONTINUED THE DESCENT AND LANDED THE ACFT WITHOUT INCIDENT. THE CONTROL WAS REPLACED AND THE ACFT RETURNED TO SERVICE.)
CA110804001	CESSNA	LYC	SLICK	DISTRIBUTOR GEAR	LOOSE
8/3/2011	152	O235L2C	4381	K3008	MAGNETO
AT ROUTINE 500 HR MAGNETO INSP, THE DISTRIBUTOR FINGER OF THE DISTRIBUTOR GEAR WAS FOUND TO BE LOOSE - DISTRIBUTOR GEAR REPLACED.
CA110729005	CESSNA	LYC		FUEL LINE	CHAFED
7/6/2011	172L	O320E2D		0500118117
RIGID ALUMINIUM FUEL LINE, FOUND CHAFED THRU APPROX HALF OF WALL THICKNESS. LOCATION - RT AFT DOOR FRAME LOWER CORNER AT BEND WHERE LINE IS ROUTED THRU FLOOR BULKHEAD AND CONTINUES THRU INSIDE OF LOWER DOOR FRAME.
CA110810007	CESSNA	LYC		SWITCH	FAILED
8/8/2011	172N	O320D2J		S21605	LANDING LIGHT
THE LANDING LIGHT SWITCH WAS REPORTED TO BE STUCK IN THE "ON" POSITION DURING A PRE-FLIGHT INSPECTION OF THE ACFT. THE SWITCH WAS REPLACED AND THE ASSOCIATED WIRING CHECKED FOR CONDITION. GROUND TEST CHECKED SERVICEABLE. THIS TYPE OF SWITCH IS SUBJECT TO A SB REQUIRING REPLACEMENT EVERY 5 YEARS. THIS SWITCH WAS DOCUMENTED AS BEING DUE FOR REPLACEMENT AUG. 24, 2011.
CA110531009	CESSNA	LYC	MCAULY	RETAINER	FAILED
5/31/2011	172N	O320H2AD			WHEEL BEARING
DURING A WALKAROUND THE PILOT NOTICED AN ODD NOSEWHEEL WOBBLE. UPON INSP BY THE AMO, IT WAS DISCOVERED THAT THE INNER BEARING RACE RETAINER ON 1 OF THE WHEEL HALVES HAD CRACKED FREE, ALLOWING THE RACE, BEARING, SEALS AND RINGS TO FALL INTO THE INTERIOR OF THE WHEEL. THIS ALLOWED THE WHEEL TO ROTATE AROUND THE AXLE STILL, BUT WITH NO BEARING. AFTER CLEANING THE WHEEL FOR FURTHER INSPECTION, PITTING UNDER THE BEARING RACE WAS NOTED.
CA110810006	CESSNA	LYC		SWITCH	STUCK
8/4/2011	172P	O360A4M		TTGCTA201TWB	LANDING LIGHT
THE LANDING LIGHT SWITCH WAS REPORTED TO BE STUCK IN THE "ON" POSITION DURING A PRE-FLIGHT INSP. THE SWITCH WAS REPLACED AND THE ASSOCIATED WIRING INSPECTED FOR CONDITION. THE REPLACEMENT SWITCH GROUND CHECKED SERVICEABLE. THIS TYPE OF SWITCH IS SUBJECT TO A RECURRING SB REQUIRING SWITCH REPLACEMENT EVERY 5 YEARS. THE FAULTY SWITCH HAD BEEN INSTALLED AUGUST 29, 2009.
2011FA0000641	CESSNA			PIN	SHEARED
9/29/2011	172S				NLG STRUT
NLG PINS SHEARED ON INNER STRUT TUBE.
2011FA0000642	CESSNA			TUBE	DAMAGED
9/28/2011	172S			07436311	NLG STRUT
NLG STRUT TUBE HAS PIN HOLES ELONGATED.
2011FA0000643	CESSNA			TUBE	DAMAGED
9/29/2011	172S			07436311	NLG STRUT
NLG INNER TUBE SEPARATED.
2011FA0000644	CESSNA			PIN	SHEARED
9/29/2011	172S				NLG STRUT
NLG STRUT HAS PINS SHEARED INTERNALLY.
2011FA0000645	CESSNA			PIN	SHEARED
9/29/2011	172S				NLG STRUT
NLG STRUT PINS SHEARED.
2011FA0000646	CESSNA			TUBE	SEPARATED
9/14/2011	172S			07436311	NLG STRUT
NLG STRUT INNER TUBE SEPARATING.
2011FA0000647	CESSNA		CESSNA	PIN	MISSING
9/27/2011	172S				NLG STRUT
PINS MISSING.
2011FA0000648	CESSNA			TUBE	SEPARATED
9/15/2011	172S			07436311	NLG STRUT
INNER TUBE SEPARATED.
2011FA0000649	CESSNA			PIN	BROKEN
9/27/2011	172S				STRUT TUBE
NLG STRUT TUBE HAS A BROKEN PIN.
2011FA0000601	CESSNA		CESSNA	STRUT	SEPARATED
9/16/2011	172S			07436311	NLG
DURING INSP, NOSE GEAR INNER STRUT TUBE WAS FOUND TO BE SEPARATED AT CAP AND TUBE CONNECTION. NO LEAKS WERE NOTED BUT A SPONGY STRUT WAS REPORTED DURING PRE-INSPECTION RUN-UP.
2011FA0000602	CESSNA			PIN	LOOSE
9/16/2011	172S			07436311	NLG STRUT
DURING HARD LANDING INSPECTION, INNER STRUT TUBE CAP PINS WERE FOUND TO BE LOOSE AND ELONGATING. THIS HAS BEEN FOUND IN NUMEROUS ACFT IN OUR FLEET OF 62 ACFT RANGING FROM LOOSE PINS TO PIN DISPLACEMENT CAUSING CAP AND TUBE SEPERATION. MFG AND LOCAL FSDO HAVE BEEN NOTIFIED.
2011FA0000603	CESSNA		CESSNA	STRUT	SEPARATED
9/16/2011	172S			07436311	NLG
INNER STRUT TUBE FOUND SEPARATED DURING SPECIAL INSPECTION. OTHER ACFT IN FLEET HAVE BEEN FOUND. MFG AND LOCAL FSDO HAVE BEEN MADE AWARE OF ISSUE.
2011FA0000604	CESSNA		CESSNA	SHIM	DAMAGED
9/16/2011	172S				NLG
DURING PHASE INSP NOSE GEAR SHIMS WERE FOUND TO BE TORN AND COMPRESSED. INTERIOR INSP OF STRUT FOUND THE INNER STRUT TUBE CAP WAS SEPARATED FROM THE METERING TUBE. UPON DISASSEMBLY THE 4 PIN HOLES WERE FOUND TO BE ELONGATED AND THE SECURING PINS WERE FOUND IN THE INTERIOR OF THE METERING TUBE. NO EXTERIOR EVIDENCE OF LEAKAGE OF FLUID OR NITRIGEN WERE NOTED. OTHER ACFT WERE BORESCOPE INSPECTED AND ALL HAD CAP SEPARATION. MFG WAS CONTACTED AND LOCAL FSDO HAS BEEN INFORMED. WE WILL BE INSPECTING THE REST OF OUR FLEET FOR FURTHER DEFECTS.
2011FA0000605	CESSNA		CESSNA	STRUT	SEPARATED
9/16/2011	172S			07436311	NLG
INNER STRUT TUBE FOUND SEPARATED AT CAP AND TUBE CONNECTION.
2011FA0000606	CESSNA		CESSNA	STRUT	SEPARATED
9/16/2011	172S			07436311	NLG
DURING SPECIAL INSPECTION INNER STRUT TUBE FOUND SEPARATED AT CAP AND TUBE CONNECTION.
NX4R20110930001	CESSNA			CONTROL CABLE	FRAYED
9/30/2011	172S			0510105360	ZONE 200
DURING A ROUTINE INSPECTION, THIS CABLE WAS FOUND WORN AND FRAYED WHERE IT CONTACTS THE 3 NYLON PULLEYS IN THE CABIN CEILING.
2011FA0000658	CESSNA			PIN	MIGRATED
10/3/2011	172S				NLG STRUT
DURING SPECIAL INSPECTION, ALL 4 LOCKING PINS WERE FOUND EXHIBITING MOVEMENT AND ABOUT TO FALL OUT.
2011FA0000639	CESSNA		CESSNA	TUBE	SEPARATED
9/21/2011	172S			07436311	NLG STRUT
NLG INNER STRUT TUBE PIN MIGRATING LOOSE.
2011FA0000640	CESSNA	LYC	CESSNA	TUBE	SEPARATED
9/29/2011	172S	IO360L2A		07436311	NLG STRUT
NLG STRUT TUBE SEPARATED.
2011FA0000633	CESSNA	LYC		TUBE	LEAKING
9/12/2011	172S	IO360L2A		302246401	MLG
TUBE FAILED DUE TO AN INTERNAL DEFECT, THIS IS ONE OF NUMEROUS TUBE FAILURES (OVER 20 IN THE LAST 12 MONTHS) THE FAILURES CAUSE THE TUBE TO START LEAKING AND GO FLAT WITH NO WARNING. THIS HAS CAUSED DAMAGE TO THE WHEEL FAIRINGS ON NUMEROUS OCCASIONS AS THE FAILURE OCCURS AT ANYTIME INCLUDING DURING TAKEOFF, LANDING, TAXI, OF WHILE PARKED. THE INTERNAL DEFECT HAS BEEN FOUND IN NEW TUBES IN STOCK AND IS LOCATED 180 DEGREES FROM THE VALVE STEM AND ON THE OPPOSITE SIDE OF THE TUBE, WITH THE TUBE INFLATED, A THIN AREA ABOUT A.2500 INCH WIDE BY 2 OR MORE INCHES LONG CAN BE FELT. ALL OF THE FAILURES HAVE OCCURRED ALONG 1 OF THE OUTER EDGES OF THIS DEFECT. ATTACHING 2 PICTURES, 1 TAKEN OF THE FAILURE OF THE TUBE AND ANOTHER SHOWING THE DEFECT FROM THE INSIDE OF THE TUBE.
CA110526001	CESSNA	LYC		TRANSMITTER	MALFUNCTIONED
5/25/2011	172S	IO360L2A		S3852	FUEL SYSTEM
WE HAVE HAD SEVERAL REPORTS OF LOW FUEL LIGHTS COMING ON OR FLICKERING WHEN THE FUEL TANKS ARE FILLED TO THE MAX. THE FIX IS USUALLY REMOVING A FEW GALLONS OF FUEL FROM THE TANK. WE HAVE HAD SEVERAL PROBLEMS WITH THESE FUEL TRANSMITTERS OVER THE YEARS BUT MFG HAS NOT COME UP WITH A BETTER TRANSMITTER. S3852-1 AND -2
CA110713002	CESSNA	LYC		STARTER	BURNED
7/11/2011	172S	IO360L2A		149NLEC
SHORTLY AFTER START UP, THE PILOT NOTICED ONCE TAXIING, THAT AN ELECTRICAL SMOKE ODOR WAS PRESENT. THE PILOT QUICKLY SHUTDOWN THE ENGINE AND THE AIRCRAFT WAS TOWED BACK TO THE HANGAR FOR MAINTENANCE. IT WAS FOUND THAT THE STARTER WAS NOT FUNCTIONAL AND THAT AN ELECTRICAL BURNING SMELL WAS COMING FROM INSIDE THE STARTER. THE STARTER WAS REPLACED AND THE STARTING SYSTEM WAS TESTED AND FOUND TO BE FUNCTIONAL.
CA110719010	CESSNA	LYC		SERVO	LEAKING
7/10/2011	172S	IO360L2A		25765362	FUEL SYSTEM
FUEL SERVO FOUND TO BE LEAKING DURING 100 HR INSP. FUEL SERVO REPLACED.
2011FA0000600	CESSNA	CONT	CONT	BUSHING	DEFECTIVE
9/16/2011	182Q	O470U		SA638172	MAG DRIVE
DEFECTIVE MAGENTO DRIVE BUSHINGS INSTALLED AT ENGINE O/H. CONTINUE HIS VFR FLIGHT BACK TO WHERE THE ACFT IS BASED. UPON REMOVAL OF THE VACUUM PUMP IT WAS NOTED THAT THE DRIVE SHAFT HAD MELTED/BURNED AWAY. REMOVED ACCESSORY DRIVE PAD AND NOTED THAT THE ACCESSORY DRIVE SHAFT/GEAR HAD OVERHEATED, THE THRUST BEARING/BUSHING WAS GALLED, AND THE TOP OF HOUSING UNDER THE THRUST BEARING WAS BELLED OUT FROM EXCESS HEAT. REMOVED THE RT ACCESSORY PAD (NO ACCESSORY INSTALLED) AND NOTED SIMILAR ISSUES. NEW ACCESSORY DRIVE PAD ASSEMBLIES, NEW MAGNETO DRIVE BUSHINGS AND CUPS, AND AN O/H VACUUM PUMP WERE INSTALLED. MAGNETOS WERE UNAFFECTED. THE ENGINE OIL AND FILTER WERE REPLACED. NO METALS WERE NOTED IN THE FILTER MATERIAL. NOTE: MFG HAS BEEN NOTIFIED AND HAS SUPPLIED THE REPLACEMENT PARTS.
2011FA0000591	CESSNA	CONT		CYLINDER HEAD	SEPARATED
9/14/2011	182R	IO470*		TISN703ACA	NR 6 CYLINDER
CYLINDER HEAD SEPARATION.
2011FA0000669	CESSNA	LYC		CONNECTING ROD	FAILED
8/28/2011	182S	IO540AB1A5		LW13865S	ENGINE
INSTALLED CRANKSHAFT KIT 05K23580 TO C/W AD 06-02-09 CRANKSHAFT RETIREMENT. KIT INCLUDES NEW CRANK, NEW BEARINGS, ROD BOLTS AND NUTS. NEW PISTON RINGS, SEAL AND GASKET SET. ENGINE TEST RAN AND TEST FLOWN. ENGINE RAN FOR APPROX 40 HRS OF TROUBLE FREE OPERATION. TOOK OFF FROM AIRPORT, AFTER REACHING PATTERN ALTITUDE AND REDUCING POWER, ENGINE STARTED VIBRATING VIOLENTLY. PILOT MADE A 180 DEGREE TURN AND RETURNED TO AIRPORT. REMOVED ENGINE. FOUND THAT NR 5 ROD CAP HAD COME OFF AND WENT THROUGH THE CASE BELOW NR1 AND NR2 CYLINDERS.
2011FA0000593	CESSNA	LYC		PISTON PIN	MISSING
9/7/2011	206H	IO540AC1A5		72198	ENGINE
BOTH PISTON PIN PLUGS WERE OMITTED FROM A CYLINDER DURING ENGINE ASSEMBLY AT THE FACTORY. DURING AN ANNUAL INSPECTION, THE COMPRESSION TEST INDICATED NO PRESSURE BEING HELD IN NR 4 CYLINDER. WHEN THE CYLINDER WAS REMOVED FOR REPAIR, THE PISTON PIN PLUGS WERE DISCOVERED TO BE MISSING. THE ENDS OF THE PISTON PIN WERE WORN TO THE CONTOUR OF THE CYLINDER AND CYLINDER WALLS HAD 2 DEEP SCORE LINES ON EACH SIDE, WHERE THE PIN HAD BEEN RIDING. ENGINE LOG BOOK RESEARCH INDICATED THAT THE CYLINDER HAD NOT BEEN REMOVED SINCE THE AIRPLANE AND ENGINE WERE NEW. THE REMAINING CYLINDERS WERE REMOVED TO VERIFY THE INSTALLATION OF THE PLUGS. ALL OTHER PLUGS WERE FOUND INSTALLED. ENGINE OPERATION APPEARED TO BE NORMAL.
2011FA0000585	CESSNA	CONT		CRANKSHAFT	BROKEN
7/27/2011	310R	IO520M			ENGINE
ACFT LANDED AT AIRPORT WITH RT PROPELLER FEATHERED. PILOT STATED ENGINE QUIT SUDDENLY ABOUT 15 MILES NORTH OF AIRPORT. PILOT AUTHORIZED INSP TO DETERMINE PROBLEM. GROUND PERSONEL COULD NOT TURN ENGINE OVER WITH PROPELLER. OIL DRAINED AND FILTER INSPECTED. OIL CONTAINED SMALL PARTICLES OF METAL AND FILTER ELEMENT CONTAINED MORE METAL. REMOVED STARTER ADAPTER AND ALTERNATOR TO GAIN VISUAL ACCESS TO ENGINE, NO DETERMINATION AT THIS POINT. OWNER ADVISED. GAVE PERMISSION TO PULL ENGINE/OIL PAN. REMOVED OIL PAN AND FOUND LARGE QUANTITIES OF METAL (STEEL AND ALUMINUM). PULLED CYLINDERS NR3 AND NR5 (COULD NOT REMOVE CYL NR1) NOTED PISTON NR3 'AT AN ANGLE' TO CASE. INSPECTED REAR GEAR TRAIN AND NOTED GEARS NOT ALIGNED. DETERMINED PROBABLE CRANKSHAFT FAILURE. FAA/OWNER NOTIFIED.
2011FA0000742	CESSNA			CONTROL CABLE	FRAYED
11/12/2011	337D			1460100307	TE FLAPS
REMOVED LT & RT INBD FLAP EXTEND CABLES FROM BOTH INBD FLAP BELLCRANKS TO INSPECT FOR WEAR OR DAMAGEDURING 100HR, ANNUAL INSPECTON PROCESS. FOUND APPROX 1" BEHIND CABLE END THREADED FITTINGS BOTH CABLES HAD SIGNIFICANT BROKEN WIRE STRANDS WHICH UNDETECTED, WOULD HAVE LEAD TO EVENTUAL FAILURE. CABLES ARE STEEL TYPE WITH 3795.4 HRS (ORGINIAL CABLES SINCE NEW). ALL FLAP CABLES REPLACED WITH NEW & FLAP SYSTEM RIGGED PER SERVICE MANUAL. SUGGEST THESE CABLES BE REMOVED AND INSPECTED ON 500HR MIN BASIS AS THIS IS BECOMING AN ISSUE ON THIS TYPE ACFT, FLEET WIDE. THESE CABLES MUST BE REMOVED FROM THE BELLCRANK FOR PROPER INSPECTION. THESE CABLES LOOKED FINE WHEN INSTALLED BUT WERE OBVIOUSLY NOT AIRWORTHY.
2011FA0000660	CESSNA	CONT		EXHAUST ROCKER	BROKEN
10/4/2011	421C	GTSIO520L		16542	LT ENGINE
PILOT STATED HE WAS IN NORMAL CRUISE, WHEN HE SUDDENLY LOST POWER AND NOTICED A VIBRATION FROM THE LT ENGINE. HE IMMEDIATELY FEATHERED THE LT ENGINE AND LANDED. INSP REVEALED THE NR 2 CYL EXHAUST ROCKER WAS SHEARED DUE TO A SUSPECTED CASTING DEFECT.
2011FA0000590	CIRRUS	CONT	CONT	CYLINDER HEAD	CRACKED
9/14/2011	SR22	IO550N	IO550N	655465A5	ENGINE
DURING INSP OF ENGINE WHILE TROUBLESHOOTING A NR 2 ALTERNATOR PROBLEM, FOUND EACH ENGINE CYL (6 EA) WITH CRACKS FROM FUEL INJECTION NOZZLE BOSS TO SPARK PLUG HOLE BOSS. COMFIRMED CRACKS BY EDDY CURRENT.
2011FA0000634	CIRRUS	CONT		SPARK PLUG	CRACKED
9/23/2011	SR22	IO550N		RHB32S	ZONE 400
DURING ROUTINE ANNUAL INSP FOUND 1 EACH RHB32S CHAMPION SPARK PLUG TO BE MISSING HALF OF THE CERAMIC INSERT THAT SURROUNDS THE CENTER ELECTRODE. FURTHER CLEANING AND INVESTIGATION REVEALED 3 OTHER SPARK PLUGS WITH CRACKS IN THE CERAMIC. IT ALSO APPEARED THAT THE POOR CYLINDER DIFFERENTIAL COMPRESSION RESULTS ON THE CYLINDER THAT HAD THE SPARK PLUG MISSING HALF OF THE CERAMIC COULD HAVE BEEN THE RESULT OF THE LOOSE CERAMIC GETTING CAUGHT BETWEEN THE VALVE AND THE VALVE SEAT. WE HAVE SEEN A LARGE AMOUNT OF LIKE DEFECTS ON SAME TYPE OF SPARK PLUGS IN SAME TYPE OF ENGINE.
2011F00192	CNDAIR			ACTUATOR	WORN
10/4/2011	CL6002B16			60093000113	LT WING TE FLAP
FLAP ACTUATOR FAILED END PLAY CHECK.
JR2R2011092900452	CNDAIR	GE		INTERCOSTAL	CHAFED
10/2/2011	CL6002D24	CF34*		MM67036537012	ZONE 200
INTERCOSTAL CHAFED AT STRINGER 9R BETWEEN FRAMES AT FS 1144 AND 1162. REPAIRED INTERCOSTAL IAW RO CRJ9-53-0809.
2011FA0000668	CUBCFT			ELT	FAILED
9/26/2011	CC18180			ME406
WHEN THE ACFT FLIPPED OVER ON ITS BACK, THE ELT FAILED TO ACTIVATE. THE VERTICAL MOTION OF THE ACFT COMING TO REST INVERTED DID NOT PROVIDE ENOUGH FWD MOTION TO ACTIVATE THE ELT. POST ACCIDENT GROUND TEST OF THE ELT SHOWED THAT THE UNIT WAS FUNCTIONAL WHEN ACTIVED AS DIRECTED IN THE UNITS DESCRIPTION, OPERATION, INSTALLATION AND MM.
5ASR2011929003	DHAV			ADC	FALSE INDICATION
9/29/2011	DHC2*			962831A1S8
ALTITUDE OUT OF TOLERANCE. FAILED BIENNIAL INSPECTION.
V0XR201110200001	DHAV			DOUBLER	CORRODED
10/20/2011	DHC8102				ZONE 800
AIRSTAIR DOUBLER AT THE FWD SIDE OF TOP STEP IS CORRODED. R & R DOUBLER IAW AMM 52-10-00-02 AND SRM 51-10-00.
V0XR2011102000002	DHAV			ANGLE	CORRODED
10/20/2011	DHC8102				ZONE 100
CORROSION FOUND ON CLIP ANGLES THAT TIE FRAME X = 488.5 TO STRINGER 23L, FWD AND AFT SIDE. AFTER FURTHER INVESTIGATION FOUND CLIP ANGLES THAT TIE FRAME X = 488.5 TO STRINGER 23L FWD AND AFT SIDE TO BE OUT OF LIMITS. FABRICATED NEW ANGLES OF 0.032 IN 2024-T3, AND INSTALLED IAW SRM 51-10-00, 51-40-11, 53-00-16, DWG 8533050 AND 85330051.
CA110718001	DIAMON	CONT		VALVE SEAT	MISSING
7/7/2011	DA20C1	IO240B			OIL RELIEF VALVE
ACFT WAS SNAGGED FOR LOW OIL PRESSURE, AFTER INSPECTION, NOTICED THAT THERE WAS A SMALL CHIP ON THE OIL PRESSURE RELIEF VALVE SEAT THAT WAS MISSING. O/H REAR ACCESSORY CASE WAS INSTALLED AND OIL PRESSURE FOUND TO BE WITHIN MFG LIMITS.
CA110630001	DIAMON	LYC		PITOT HEAD	OBSTRUCTED
6/29/2011	DA40	IO360M1A
AUTOPILOT ALTITUDE HOLD FUNCTION WAS NOT WORKING PROPERLY. FOUND BOTH KAP 140 EXTERNAL STATIC PORTS BLOCKED. CLEANED PORTS IAW WI-0SB-40-050, STEP 9 USING A 1.5 MM DRILL BIT THROUGH FUSELAGE SHELL FROM INSIDE TO OUTSIDE (BOTH STATIC PORTS). ALSO FOUND ORFICE PN D60-3413-01-00 PLUGGED, CLEANED PLUG AND RAMP TESTED SERVICEABLE. CUSTOMER REPORTED THAT FLIGHT CHECK WAS PERFORMED SATISFACTORY.
CA110708013	DIAMON	LYC		PIN	LOOSE
7/5/2011	DA40	IO360M1A		DA452107300	CANOPY
DURING CRUISE, THE INSTRUCTOR NOTICED THAT THE CANOPY WAS LOOSE (VISIBLE DAYLIGHT ON RT SIDE), ACFT RETURNED AND LANDED WITH NO PROBLEMS. AFTER A VISUAL INSP, FOUND THAT THE RT DOOR LATCH PIN HAD A GUIDE SLEEVE THAT WAS LOOSE, PART WAS RETRIEVED AND RE-INSTALLED IAW MFG INSTRUCTION WITH RETAINING COMPOUND.
CA110727008	DIAMON	THIELT		FUEL LINE	CHAFED
7/27/2011	DA42	TAE1250299		057313K003105	ENGINE COMPARTME
(CAN) THIS FUEL RETURN LINE IS PART OF THE HIGH PRESSURE FUEL INJECTION COMMON RAIL P/N 05-7313-K006801 AND THE ELBOW AT THE END OF THE HOSE CHAFFED ON A HOSE CLAMP FOR THE COOLANT SYSTEM. AN ELBOW FOR THE COOLANT SYSTEM WAS REORIENTED TO PROVIDE MORE CLEARANCE.
2011FA0000588	DOUG			NUT	UNSAFETIED
8/26/2011	DC3				FLIGHT CONTROL
AFTER TAKEOFF, AILERON WOULD NOT TRAVEL RT VERY FAR. STOP FELT IN YOKE. CONTROL CHECK WAS DONE PRIOR TO FLIGHT, ALL WAS NORMAL. AUTOPILOT WAS TURNED OFF TO ELIMINATE ANY INTERFERENCE WITH FLIGHT CONTROLS. RETURNED TO DEPARTING AIRPORT FOR UNEVENTFUL APPROACH AND LANDING. DISCOVERED LOOSE NUT ON BOLT LOCATED ON PILOT’S CONTROL WHEEL SPACER. THIS ALLOWED BOLT TO MOVE, CAUSING INTERFERENCE WITH CONTROL WHEEL, OBSTRUCTING AILERON COMMANDS FROM THE PILOT. ALL NUTS ON SPACER BOLTS WERE OF THE NON-LOCKING VARIETY. TIGHTENED PILOT’S CONTROL WHEEL SPACER BOLT. INSPECTED CONTROL WHEEL SPACER BOLTS ON PILOT AND CO-PILOT SIDE FOR SECURITY AND PROPER INSTALLATION.
USMS20110907001	DOUG	PWA		CONTROLLER	NO TEST
9/7/2011	DC983	JT8D219		21184901	CABIN PRESSURE
DURING CRUISE, HEARD A LOUD POP, FOLLOWED BY RAPID DECOMPRESSION OF CABIN. R & R OUTFLOW VALVE ACTUATOR, IAW AMM, OPS CHECKED GOOD. R & R CABIN PRESSURE SELECTOR IAW AMM FOUND NR1 CABIN PRESSURE CONTROLLER FAILED BITE TEST. SWAPPED NR1 & NR2 PRESSURE CONTROLLERS PROBLEM FOLLOWED. R & R NR 2 PRESSURE CONTROLLER IAW AMM. PRESSURIZED CABIN TO VERIFY INTERGITY AND FOUND NO LEAKS IAW AMM.
2011FA0000594	ECLIPS			JOINT	FAILED
9/8/2011	ECLIPSEEA500			271058221003	LT AILERON
SB 500-27-004, REV B AILERON JOINT ASSY INSP AND REPLACEMENT. THIS SB HAS PROCEDURES FOR INSPECTING/TESTING BOTH WINGS, AILERONS JOINT ASSEMBLIES. REPLACING THE AILERON JOINT ASSY, WHENEVER THE AILERON FAILS A "FRICTION" TEST. THE ASSY FAILS TESTING WHEN THE BELLCRANK IS CORRODED AND FROZEN IN THE BEARING OF THE FITTING ASSY. THIS IS DUE TO CORROSION FROM DISSIMILAR METALS. SINCE THIS IS JUST A SB, SUGGEST THIS INSP BE UPGRADED TO AN AD TO PREVENT POSSIBLE AILERON MALFUNCTIONS FROM ACFT NOT COMPLYING WITH THE SB.
2011FA0000595	ECLIPS			BELLCRANK	FAILED
9/8/2011	ECLIPSEEA500			271058201002	LT AILERON
SB 500-27-004, REV B, AILERON JOINT ASSY INSP AND REPLACEMENT. THIS SB HAS PROCEDURES FOR INSPECTING/TESTING BOTH WINGS, AILERONS JOINT ASSEMBLIES. REPLACING THE AILERON JOINT ASSY, WHENEVER THE AILERON FAILS A "FRICTION" TEST. THE ASSY FAILS TESTING WHEN THE BELLCRANK IS CORRODED AND FROZEN IN THE BEARING OF THE FITTING ASSY. THIS IS DUE TO CORROSION FROM DISSIMILAR METALS. SINCE THIS IS JUST A SB, SUGGEST THIS INSP BE UPGRADED TO AN AD TO PREVENT POSSIBLE AILERON MALFUNCTIONS FROM ACFT NOT COMPLYING WITH THE SB.
CA110707007	FOUND	LYC		BEARING	FAILED
7/7/2011	FBA2C1	IO540L1A5	40418	13889	MLG WHEEL
BEARING FAILED, LEADING TO OUTER COTTER PIN SHEARING OFF. NUT TIGHTENING WITH TIRE ROTATION, AND WHEEL + TIRE SEIZING COMPLETELY. APPROX 2 HR SPENT ON RUNWAY TO GET WHEEL UNSEIZED AND ACFT CLEAR OF RUNWAY.
CA110812005	GROB	LYC		PUMP	FAILED
8/12/2011	G120A	AEIO540D4D5		RG9570K1M	FUEL SYSTEM
FUEL PUMP WAS INSTALLED TO REPLACE ANOTHER PUMP WITH LOW IDLE PRESSURE. ON STARTUP FOR GROUND TEST, IT WAS NOTICED THAT THE PUMP HAD ZERO OUTPUT. ON REMOVAL FOR REPLACEMENT, IT WAS NOTED THAT THE DRIVE SHAFT WAS SHEARED. IT WAS THEN NOTICED THAT THE FITTING ON THE OUTPUT PORT HAD MADE CONTACT WITH A SHOULDER INSIDE THE PUMP. WHILE IT WAS NOT INTERFERING WITH THE OPERATION OF THE PUMP, THE FITTING HAD BEEN DAMAGED AND SOME PARTICLES HAD JAMMED THE PUMP CAUSING THE SHAFT TO SHEAR. THE OUTLET PORT WAS MEASURED AT 0.610" DIA VS THE INLET PORT AT 0.582" DIA. THIS DIFFERENCE COULD POSSIBLY ALLOW THE PIPE THREADED FITTING TO GO IN FURTHER AND CONTACT WITH THE BOTTOM OF THE PUMP HOUSING. THE DIFFERENCE IN PORT SIZES COULD POSSIBLY BE DUE TO SOME WEAR CAUSED BY REPEATED THREADING OF THE FITTINGS INTO THE PUMP SINCE THE PUMP HAD BEEN IN FOR OVERHAUL QUITE OFTEN. ANOTHER POSSIBLE CAUSE IS DUE TO THE FITTING ON THE OUTPUT SIDE HAVING THREADS THAT ARE LONGER THAN THE DEPTH OF THE HSG, ALLOWING THE FITTING TO GO IN TOO DEEPLY. THE THREADS ON THE INLET SIDE FITTING HAVE A SHOULDER THAT MAY STOP IT BEFORE IT BOTTOMS IN THE PUMP. PART AFFECTED: ENGINE DRIVEN FUEL PUMP TSN: 1749 TSO 505.3 MANUFACTURER: LEAR ROMEC PN: RG9570K1/M SN: B4696
CA110811007	GROB	LYC		PUMP	MALFUNCTIONED
8/11/2011	G120A	AEIO540D4D5		RG9570K1M	FUEL
FUEL PUMP WAS INSTALLED TO REPLACE ANOTHER PUMP WITH LOW IDLE PRESSURE. ON STARTUP FOR GROUND TEST, IT WAS NOTICED THAT THE PUMP HAD ZERO OUTPUT. ON REMOVAL FOR REPLACEMENT, IT WAS NOTED THAT THE DRIVE SHAFT WAS SHEARED. IT WAS THEN NOTICED THAT THE FITTING ON THE OUTPUT PORT HAD MADE CONTACT WITH A SHOULDER INSIDE THE PUMP. WHILE IT WAS NOT INTERFERING WITH THE OPERATION OF THE PUMP, THE FITTING HAD BEEN DAMAGED AND SOME PARTICLES HAD JAMMED THE PUMP CAUSING THE SHAFT TO SHEAR. THE OUTLET PORT WAS MEASURED AT 0.610" DIA VS THE INLET PORT AT 0.582" DIA. THIS DIFFERENCE COULD POSSIBLY ALLOW THE PIPE THREADED FITTING TO GO IN FURTHER AND CONTACT WITH THE BOTTOM OF THE PUMP HOUSING. THE DIFFERENCE IN PORT SIZES COULD POSSIBLY BE DUE TO SOME WEAR CAUSED BY REPEATED THREADING OF THE FITTINGS INTO THE PUMP SINCE THE PUMP HAD BEEN IN FOR O/H QUITE OFTEN. ANOTHER POSSIBLE CAUSE IS DUE TO THE FITTING ON THE OUTPUT SIDE HAVING THREADS THAT ARE LONGER THAN THE DEPTH OF THE HOUSING, ALLOWING THE FITTING TO GO IN TOO DEEPLY. THE THREADS ON THE INLET SIDE FITTING HAVE A SHOULDER THAT MAY STOP IT BEFORE IT BOTTOMS IN THE PUMP.
2011FA0000598	GULSTM			BUSHING	UNSERVICEABLE
9/12/2011	690A			31035921	TORQUE SENSOR
BUSHING, PN 31035921, SEPARATED FROM THE TORQUE SENSOR MAIN HOUSING PN 3103583-2 ALLOWING THE INTERMEDIATE BEARING AND DRIVE GEAR ASSY TO SHIFT FWD IN THE HSG. SPUR GEAR PN 3103406-2 CONTACTED THE MAIN HOUSING. SPUR GEAR, PN 3103406-2 CONTACTED THE MAIN HOUSING DUE TO THE SHIFT AND SUBSEQUENTLY FAILED, 2 GEAR TEETH BROKEN FREE FROM THE GEAR AND BECAME JAMMED IN THE MAIN DRIVE GEAR, PN 896884-1, CAUSING THE GEAR TO FRACTURE AND SEPARATE FROM THE DRIVE SHAFT. THIS SEPARATION CAUSED THE FUEL CONTROL DRIVE TRAIN TO "UNCOUPLE" AND THE ENGINE TO SHUTDOWN DUE TO LOSS OF DRIVE TO THE ENGINE DRIVEN FUEL PUMP.
2011FA0000636	GULSTM	RROYCE		PANEL	DAMAGED
9/28/2011	GV	BR700710A110		FW32280	BYPASS DUCT
APPROX 4" DIAMETER HOLE IN INNER BYPASS DUCT PANEL OVER NR1 IGNITOR OF RT ENGINE.
2011FA0000628	HUGHES			DRIVE GEAR	CRACKED
9/22/2011	369A			369A5256	M/R TRANSMISSION
DURING MAGNETIC PARTICLE INSPECTION, A CRACK WAS FOUND ON THE GEAR.
CA110810011	HUGHES	ALLSN		BEARING	SPALLED
8/10/2011	369D	250C20B		369D25146	M/R TRANSMISSION
M/R TRANSMISSION CHIP LIGHT ILLUMINATED DURING FLIGHT. EVIDENCE OF METAL FOUND ON CHIP PLUGS. DURING TRANSMISSION DISASSEMBLY, REASON FOR METAL GENERATION WAS FOUND TO BE T/R O/P PINION ROLLER BEARING INNER RACE WHICH WAS CRACKED AND BADLY SPALLED.
BKEA20111009 1	LEAR			HEATER	SMOKE
10/9/2011	35A				CABIN
WHITE SMOKE AND FUMES FROM AFT RT PASSENGER OVERHEAD VENT. IMMEDIATELY RETURNED AND UNEVENTFUL LANDING AT DEPARTURE. FOUND AUX HEAT HEATER ODOR, PLACARDED AUX HEAT SWITCH INOPERATIVE IAW MEL 21-20.
2011FA0000627	MOONEY	LYC		CYLINDER BORE	PEELING
9/21/2011	M20F	AEIO360A1A		ECLW12995CN	ENGINE
CLIMBING THROUGH 7000 FELT A SLIGHT SHUDDER. WHILE LEVELING AT 9500, NOTICED OIL PRESSURE GOING DOWN. PROP WENT TO FLAT PITCH. OIL PRESSURE NOW IN YELLOW ARC. DECLARED AN EMERGENCY. PULLED ENGINE TO IDLE AND BEGAN A DESCENT TO AIRPORT. LANDED LONG AND BLEW MAIN TIRES WHILE BRAKING HEAVILY. STOPPED SHORT OF OVERRUN. INSPECTION FOUND A SECTION OF CYLINDER WALL HAD DELAMINATED AND PASSED THROUGH THE ENGINE.
5APR20110922001	PILATS	PWA		MOTOR	FAULTY
9/22/2011	PC1245	PT6A67B		9599022126	COOLING UNIT
THE COOLING UNIT CB KEEPS POPPING. THE COOLING UNIT MOTOR, PN 959.90.22.126 WAS REMOVED, AND A SERVICEABLE UNIT OF THE SAME PN WAS INSTALLED IAW ENVIRO SYSTEMS CMM 21-00-23, THE COOLING SYS WAS TESTED AND FOUND TO OPERATE NORMALLY IAW AMM 12-A-21-50-01-00A-920B-A.
5APR577Y87	PILATS	PWA		SENSOR	FAULTY
9/10/2011	PC1245	PT6A67B		5245212720	BATTERY CURRENT
PILOT REPORTS OVERHEAD PANEL DISPLAY READS 570 AMP CURRENT DRAW UPON TURNING ON NR1 BATTERY SWITCH. R & R BATTERY NR 1 CURRENT SENSOR PN 524.52.12.720 IAW AMM DMC-12-A-24-30-08-00A-920A-A. OPS CHECK NORMAL.
5APR20111005094	PILATS	PWA		FCU	FAULTY
10/5/2011	PC1245	PT6A67B		8063044	ENGINE
PILOT REPORTS PCL BINDING. THE FCU WAS FOUND TO BE AT FAULT. THE FCU WAS R & R WITH A SERVICEABLE UNIT IAW AMM 12-A-73-20-01-00A-920A-A AND THE EMM 73-20-00, ALL REQUIRED TEST WERE ACCOMPLISHED WITH NO FURTHER DEFECTS NOTED.
5APR20110930093	PILATS	PWA		FITTING	OUT OF ALIGNMENT
9/30/2011	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 GAUGE, AND FOUND TO BE .406MM. THERE IS NO EVIDENCE OF DAMAGE TO THE STABILIZER. THE BRACKET PN IS 555.10.12.150, ANGLE FITTING LT. RESOLUTION: THE ACFT MFG ISSUED A REPAIR MEMO WITH STATEMENT OF APPROVED DESIGN DATA (ECC-12-RM-11-220) WITH THE FOLLOWING INSTRUCTIONS. CHECK THE LUGGED FACE OF THE LT BRACKET PN 555.10.12.150 (ANGLE FITTING LT ) FOR STRAIGHTNESS. IF WITHIN LIMITS, COMPLETE A VISUAL AND NDT INSPECTION (DYE PENETRANT OR EDDY CURRENT) OF THE ANGLE FITTING AND THE BOLTS. IF NO CRACKS OR DEFECTS NOTED, REINSTALL THE FITTING AND HARDWARE USING SEALANT.
5APR20110927001	PILATS	PWA		MOTOR	FAULTY
9/27/2011	PC1247	PT6A67B		9599022126	ZONE 100
THE VCCS SYS WAS REPORTED AS INOP. THE VCCS DRIVE MOTOR, PN 959.90.22.126 WAS FOUND FAULTY. IT WAS R & R WITH A SERVICEABLE UNIT OF THE SAME PN IAW AMM 12-A-21-50-03-00A-313A-A AND CMM 21-00-23. OPS CHECK NORMAL.
5APR20110916001	PILATS	PWA		EFIS	DEFECTIVE
9/16/2011	PC1247	PT6A67B		066031252500	ZONE 200
PILOT REPORTED: CO-PILOTS EADI FLASHING AND INTERMITTENT. THE NR 2 EADI, PN 066-03125-2500 WAS R & R WITH A SERVICEABLE UNIT OF THE SAME PN IAW AMM DMC-12-A-34-26-03-00A-920A-A, OPS CHECK GOOD IAW AMM DMC-12-A-34-26-00-00A-903A-A.
5APR20110915001	PILATS	PWA		EFIS	DEFECTIVE
9/15/2011	PC1247	PT6A67B		066031252500	ZONE 200
PILOT REPORTED COPILOTS EADI IS INOP. REMOVED ED462, PN 066-03125-2500, INSTALLED SERVICEABLE EXCHANGE ED462 UNIT OF THE SAME PN, SYS OPS CHECK GOOD IAW AMM CH 12-A-34-26-03-00A-920A-A.
5APR577Y88	PILATS	PWA		SENSOR	FAULTY
9/11/2011	PC1247	PT6A67B		5245212720	ZONE 100
PILOT REPORTS THAT BATTERY NR1 INDICATES CONTINUOUS 457 AMP DISCHARGE WITH NO DEPLEATION OF VOLTAGE. THE BATTERY NR 1 CURRENT SENSOR PN 524.52.12.720 WAS R & R IAW AMM 12-A-24-30-08-00A-920A-A.
2011FA0000631	PIPER	LYC		TIRE	FLAT
9/20/2011	PA28181	O360A4M		FLTSPII	MLG
EXPERIENCING PROBLEMS WITH BOTH NEW AND DESSERTIRE RECAPPED TIRES. HAVE HAD MULTIPLE TIRES RANDOMLY GO FLAT AND UPON INSP HAVE FOUND THAT THE INTERIOR SEAM OF THE TIRE IS PUNCTURING THE TUBE. AT FIRST THIS WAS THOUGHT TO BE A RANDOM OCCURANCE BUT NOW WE ARE HAVING THIS OCCUR ON ALMOST A WEEKLY BASIS. WE ARE KEEPING ALL TIRES AND TUBES THAT HAVE FAILED FOR INSPECTION.
2011FA0000656	PIPER		PIPER	BEARING	DISINTEGRATED
10/3/2011	PA28236			DW4K2	STAB
PILOT NOTED STABILATOR LOOSE DURING PREFLIGHT. MX FOUND BEARING HAD FAILED IN LT STABILATOR HINGE. ROLLERS HAD DISINTEGRATED IN THE BEARING. ALSO REPLACED RT STABILATOR HINGE BEARING AS PRECAUTIONARY MEASURE.
2011FA0000650	PIPER	LYC		TRUNNION	CRACKED
9/28/2011	PA28R180	IO360C1C		67054803	NLG
THIS ACFT HAS HAD 2 NOSE GEAR TRUNNION ASSY CRACKED AT THE BOTTOM OF THE TRUNNION. THE CRACKS ACCRUE AT THE PART THAT THE SHIMMY DAMPNER ATTACHES TO THE TRUNNION AND TUBE ASSY.
2011FA0000632	PIPER	LYC		TAPPET	DAMAGED
8/15/2011	PA28R201	IO360C1C6		26064	ENGINE
AFTER FINDING MAGNETIC METAL FLAKES IN OIL FILTER AT ANNUAL INSP, ENGINE WAS REMOVED FROM SERVICE AND DISASSEMBLED. INSP REVEALED SEVERE FLAKING AND SPALLING OF 2 EA TAPPET FACES AND DAMAGE TO THE CORRESPONDING CAM LOBES. NONE AT THIS TIME. SUSPECT MFG PROBLEM. THIS IS THE 2ND TAPPET FAILURE WITH LESS THAN 200 HR SINCE NEW IN ACFT FLEET.
2011FA0000661	PIPER	LYC		BOLT	FAILED
9/17/2011	PA28RT201	IO360C1C6		AN440A	MLG
AFTER LANDING, WHILE TURNING, LT WING SAGGED. CONTINUED TAXI, LT MLG COLLAPSED. BOLT HOLDING REAR TRUNNION FRACTURED AT THE HEAD DUE TO CORROSION. ALL THE LOAD WAS TRANSFERRED TO THE FRONT TRUNNION WHICH FRACTURED AT THE END OF THE MACHINED MAIN TRUNNION STUB DUE TO OVERSTRESS, CAUSING THE RETENTION BOLT (AN4-20A) TO FAIL IN TENSION ALLOWING THE WING TO DROP OVER THE LANDING GEAR ASSY. THE GEAR STRUT PIERCED THE UPPER WING SKIN. THE BOLT HEAD REMAINED IN THE TRUNNION SLEEVE (67502-00) WHICH WAS FOUND IN THE WELL BEHIND THE REAR SPAR. THERE IS SEVERE CORROSION ON THE SHAFT OF THE BOLT FOR SEVERAL INCHES FROM THE HEAD. THE BOLT SHAFT, APPROX 1.5 INCHES FROM THE HEAD END WAS BENT AT 90 DEGREES TO THE THREAD END SHAFT APPARENTLY WHEN THE WING DROPPED OVER THE GEAR. THE RT SIDE BOLT WAS REMOVED AND HAD NO EVIDENCE OF SUCH SEVERE CORROSION. THE ANNUAL INSPECTION FOR THIS BOLT IS TO CHECK FOR THE PRESENCE OF THE HEAD. THERE IS NO REQUIREMENT TO CHECK THE TORQUE ON THE BOLT DURING THE ANNUAL INSPECTION.
2011FA0000638	PIPER			AUTOPILOT SYS	MALFUNCTIONED
9/29/2011	PA31350			91000013001	ZONE 100
AUTOPILOT. COUPLED APPROACHES RESULT ERRATIC ROLL HUNTING AND/OR OVERCORRECTION AND PITCH UNSTABILITY.
2011FA0000609	PIPER			SPAR	CORRODED
9/20/2011	PA44180			86152000	ZONE 500
AT APPROX LT WING STA 56.0, THE UPPER OTBD QUADRANT OF AN ELECTRICAL WIRE PASS THROUGH HOLE IN THE WING SPAR WEB WAS FOUND TO HAVE EXFOLIATION CORROSION. THE PASS THROUGH HOLE, WHICH IS IN THE LANDING GEAR WHEEL WELL AREA, HAD A CATERPILLAR GROMMET INSTALLED TO PREVENT THE WIRES FROM CHAFING. THE GROMMET WAS REMOVED TO FACILITATE CORROSION DETECTION. AFTER REMOVING THE CORROSION, THE SERVICES OF A DESIGNATED ENGINEERING REPRESENTATIVE WAS REQUIRED TO PROVIDE A REPAIR PROCEDURE IN ORDER TO RETURN THE ACFT TO SERVICE. THE CORROSION STARTED AT THE EDGE OF THE HOLE AND PROGRESSED INSIDE THE METAL.
2011FA0000596	PIPER			DRAG LINK	BROKEN
9/4/2011	PA44180			86280003	NLG
NOSE GEAR DRAG LEG BROKEN AT FWD ATTACH POINT BREAKING THROUGH BOLT HOLE. THIS FAILURE LEAD TO THE ACFT INDICATING THAT ALL GEARS WERE DOWN AND LOCKED. DURING LANDING THE NOSE GEAR FOLDED FWD CAUSING DAMAGE TO THE FWD BULKHEAD AND CAUSING 2 PROP STRIKES. IF THIS FWD ATTACH POINT WERE BUILT UP MORE WHICH THERE IS ROOM, THAT WOULD HELP WITH THIS ISSUE.
2011FA0000608	PIPER	LYC		SPAR	CORRODED
2/26/2011	PA44180	O360*		86152000	ZONE 500
AT APPROX LT WING STA 56.0, THE UPPER OTBD QUADRANT OF AN ELECTRICAL WIRE PASS THROUGH HOLE IN THE WING SPAR WEB WAS FOUND TO HAVE EXFOLIATION CORROSION. THE PASS THROUGH HOLE, WHICH IS IN THE LANDING GEAR WHEEL WELL AREA, HAD A CATERPILLAR GROMMET INSTALLED TO PREVENT THE WIRES FROM CHAFING. THE GROMMET HAD BEEN REMOVED TO FACILITATE CORROSION INSP. AFTER REMOVING THE CORROSION, THE SERVICES OF A DESIGNATED ENGINEERING REPRESENTATIVE WAS REQUIRED TO PROVIDE A REPAIR PROCEDURE IN ORDER TO RETURN THE ACFT TO SERVICE. IT IS APPARENT THAT THE CORROSION STARTED AT THE EDGE OF THE HOLE AND PROGRESSED INSIDE THE METAL.
2011FA0000680	PIPER	LYC		BAFFLE	DAMAGED
8/25/2011	PA46350P	TIO540AE2A		LW13383	OIL SYSTEM
OIL BAFFLE HAD 1 RIVET HEAD MISSING, NOTED THAT AROUND 3 OF THE 6 ATTACHING HOLES THAT CIRCULAR CRACKS WERE EMINATING FROM UNDER WASHER.
2011FA0000670	RAYTHN	PWA		EXHAUST DUCT	BROKEN
9/4/2011	B300RAYTHEON	PT6A60A		11791007035	LT ENGINE
DURING SCHEDULED INSP, THE LT INBD EXHAUST DUCT THAT CONNECTS THE LT ENG COWLING`S INTAKE HEATED LIP TO THE EXHAUST PORT OF THE LT ENGINE`S INBD EXHAUST STACK WAS FOUND TO BE BROKEN AND DETACHED FROM ITS MATING FLANGE. THIS, IN TURN, WAS ALLOWING EXHAUST GASES TO FILL THE LT ENGINE`S COWLING. THE DUCT WAS R & R WITH A NEW PART.
2011FA0000630	RAYTHN	CONT		AUTOPILOT SYS	FAILED
9/12/2011	G36	IO550B		010G100000
AUTOPILOT FAILED TO DISENGAGE ON COUPLED APPROACH.
OWFR20110921001	SAAB			RIB	CRACKED
9/20/2011	SF340A			7257800010	RT WING TE FLAP
DURING A ROUTINE INSPECTION IAW JOB CARD 0600-541-01I, A CRACK HAS BEEN FOUND IN THE LOWER BEND RADIUS OF THE RT FLAP RIB NR5 LOCATED APPROX AT STA WS202.
CA110503007	SCHLER			SPAR	CRACKED
4/14/2011	ASW19			442119	LT ELEVATOR
LT OTBD ELEVATOR SPAR FOUND CRACKED AFTER INSP, COMPLETED REF AD2011-07-13.
2011FA0000629	SNIAS	TMECA		STRUCTURE	CRACKED
9/22/2011	AS350B2	ARRIEL1D1			TAILBOOM
CRACK IN TAIL BOOM.
2011FA0000651	SNIAS	LYC		DAMPER	CRACKED
9/26/2011	AS350BA	LTS101600A3		366A54108800	ENGINE
PART FOUND CRACKED AT INSPECTION. CRACK RUNS ALONG WITH METAL GRAIN ALONG THE INBD SECTION NEXT TO WELDED NIPPLE. FAILURE OF THIS PART WILL CAUSE ENGINE FAILURE.
DATR001632	STBROS	PWA	PWA	BOLT	FAILED
9/17/2011	SD360	PT6A67R	PT6A67R	MS949034	ENGINE
RT SIDE ENGINE EXPERIENCED A LOW OIL PRESSURE LIGHT 1.5 HOURS INTO MISSION AND SUBSEQUENT PRESSURE LOSS. ENGINE WAS SHUTDOWN IN FLIGHT AND ACFT DIVERTED. THE ENGINE WAS RECEIVED AT THIS FACILITY FOR INVESTIGATION. THE PROPELLER SHAFT WAS HARD TO TURN AND A GRINDING NOISE WAS HEARD. THE CHIP DETECTOR WAS REMOVED AND FOUND IT WAS COMPLETELY ENCASED IN METAL CHIPS. THE POWER SECTION WAS REMOVED AND DISASSEMBLED. UPON REMOVAL OF THE 1ST STAGE CARRIER IT WAS DISCOVERED THAT THE HEAD WAS MISSING FROM ONE OF THE 6 INSTALLED MS 9490-34 BOLTS THAT HOLD THE SPLINE ADAPTER PLATE TO THE CARRIER. THE SUBJECT BOLTS AND FAILURES ARE ADDRESSED IN SB 14444 AND WAS ALSO INVESTIGATED BY THE TRANSPORT SAFETY BUREAU, AO-2010-006.
G78R20111006002	STBROS	PWA		ENGINE	SHUTDOWN
8/9/2011	SD360SHERPA	PT6A65AR		PT6A65AR	RIGHT
AFTER TAKEOFF CLIMB, AT 6,000 FT, THE CREW PULLED BACK THE POWER TO CRUISE. ON THE RT ENGINE, THE TORQUE DROPPED AND LOW OIL PRESSURE LIGHT ILLUMINATED. PROPELLER FEATHERED AND THE RT ENGINE SHUTDOWN UNCOMMANDED. THE CREW STATED ALL SYSTEMS WERE NORMAL BEFORE INCIDENT. THE ACFT LANDED SAFELY AT THEIR OCONUS BASE. POST FLIGHT INSP REVEALED RT PROPELLER AND POWER SECTION WERE LOCKED UP. THERE WERE NO SIGNS OF OIL LEAKAGE. BRASS AND METAL SHAVINGS WERE DISCOVERED IN OIL FILTER, CHIP DETECTOR, AND POWER SECTION FILTER.
G78R20111006001	STBROS	PWC		ENGINE	FAILED
5/29/2011	SD360SHERPA	PT6A67AG		PT6A65AR	RIGHT
THE RT ENGINE HAD AN IN-FLIGHT ENGINE FAILURE. THE ENGINE EXPERIENCED A DROP IN OIL PRESSURE AND A RISE IN OIL TEMPERATURE. THE CREW SHUT THE ENGINE DOWN AND DECLARED AN EMERGENCY AND RETURNED TO THEIR BASE. THE MECHANIC CHECKED AND FOUND THE RT COWLING SOAKED WITH OIL, THE EXHAUST STACKS FILLED WITH OIL, AND THE PROPELLER WAS DIFFICULT TO TURN. LARGE AMOUNTS OF METAL WERE DISCOVERED IN THE OIL STRAINER SCREEN AND THE CHIP DETECTOR. CHIPS WERE ALSO DISCOVERED IN THE 2 QUARTS OF OIL THAT WERE DRAINED FROM UNDER THE TURBINE SECTION.
2011FA0000662	STNSON			LANDING GEAR	COLLAPSED
9/3/2011	V77
ACFT WAS TAXIING OUT FOR TAKEOFF WHEN GUST OF WIND FROM LT REAR AT ABOUT 15 KNOTS CAUGHT TAIL AND SPUN AIRPLANE IN HARD GROUND LOOP TO LT. RT LANDING GEAR COLLAPSED COMPLETELY CAUSING SUBSTANTIAL DAMAGE TO ACFT. FOLLOW UP TO ACCIDENT FOUND WELDED STEEL TUBING NEAR RT GEAR ATTACH POINTS WAS HEAVILY CORRODED AND TUBING CLUSTER WELDS BROKE CLEANLY AT WELD LINES WITH LITTLE SIGNS OF BENDING OR STRESS. RT GEAR PIVOT BUSHING MADE OF STEEL TUBING ALSO CRACKED LONGITUDINALLY AND SPLIT CLEANLY IN HALF ALLOWING GEAR LEG TO SEPARATE FROM AIRPLANE. EVIDENCE OF CORROSION AND CRACKS NOTED IN RT GEAR PIVOT BUSHING. UNABLE TO DETERMINE FROM VISUAL INSP WHY TUBING FAILED. SUSPECTED CAUSES ARE: PRIOR CORROSION, PREEXISTING UNREPAIRED DAMAGE, AND /OR POOR WELDING FROM ORIGINAL CONSTRUCTION OR A LATER WELDED REPAIR. THE STRUCTURAL SECTION OF THE FUSELAGE THAT FAILED IS ALSO THE LOWER WING STRUT ATTACH POINT, RAISING CONCERNS ABOUT POTENTIAL IN-FLIGHT WING FAILURE. FOLLOW UP LAB ANALYSIS OF FAILED STEEL TUBING SECTIONS RECOMMENDED TO NTSB IIC IN ORDER TO DETERMINE CAUSE OF ACCIDENT AND GEAR FAILURE.
HKGR20111006226	SWRNGN			UPLOCK	DIRTY
10/6/2011	SA227AC				MLG
ON CLIMB OUT, RETRACTED GEAR AND THE RT MLG WOULD NOT LOCK IN THE UP POSITION, WOULD EXTEND AND RE-CYCLE. EXTENDED GEAR NORMALLY AND HAD NORMAL GEAR EXTENSION AND DOWN AND LOCKED INDICATION. LANDED AT DEPARTURE AIRPORT WITHOUT INCIDENT. FOUND LANDING GEAR UPLOCK TO BE DIRTY AND STIFF, CLEANED AND LUBRICATED SAME, OPS CHECK SATISFACTORY FOR RETURN TO SERVICE.
M36R20110927003	SWRNGN	GARRTT		LEAD	BROKEN
9/22/2011	SA227AC	TPE33111U		SMR23692	PROP DEICE
FOUND 3 DEFECTIVE LEADS ON RT PROP. ALL 3 FAILED AT THE GROUND WIRE AT THE SAME LOCATION AS PREVIOUS FAILED LEADS.
2011FA0000664	UNIVAR			ATTACH FITTING	CORRODED
10/5/2011	415C			22017	ELEVATOR
DURING RESTORATION OF THIS AIRPLANE THE ATTACH POINT FOR THE ELEVATOR CONTROL WITHIN THE ELEVATOR ITSELF WAS FOUND TO BE LOOSE. THE ELEVATOR WAS REMOVED FROM THE ACFT AND TAKEN APART. THE ELEVATOR CONTROL ATTACH BRACKET WAS FOUND TO HAVE SEVERE CORROSION AND HOLDING THE ELEVATOR CONTROL ATTACH BRACKET AT ONLY 1 POINT AS OPPOSED TO 4. THE BRACKET HAD FAILED DUE TO SEVERE CORROSION. THERE IS NO WAY TO EXTERNALLY INSPECT THIS INTERNAL PART OF THE ELEVATOR MAKING IT IMPOSSIBLE TO DETECT SUCH INTERNAL DAMAGE UNTIL LOOSENESS BEGINS TO OCCUR. THE SUBJECT ELEVATOR ON THIS ACFT WILL BE COMPLETELY REBUILT THUS RECTIFYING THE PROBLEM. INSP PORTS WILL ALSO BE INSTALLED TO FACILITATE INSP FOP CONTINUED AIRWORTHINESS. THE EXTERNAL APPEARANCE OF THE ELEVATOR WAS UNREMARKABLE. THE CORROSION OF THE CENTER PART OF THE ELEVATOR INCLUDING THE SUBJECT BRACKET, 2 STIFFENERS, AND THE CENTER BOTTOM SKIN WERE SUBSTANTIALLY CORRODED BEYOND REASONABLE REPAIR. NEW PARTS TO O/H THE EXISTING ELEVATOR ARE BEING FABRICATED AS SAME ARE NOT COMMERCIALLY AVAILABLE. THIS FORM OF UNDETECTABLE DAMAGE AND DETERIORATION RAISES THE ISSUE OF EXCHANGING THE ELEVATOR FOR A SEEMINGLY SERVICEABLE PART AS THE SAME INTERNAL DAMAGE COULD BE WELL CONCEALED REGARDING THE EXTERNAL APPEARANCE OF THE ELEVATOR.
2011FA0000673	UROCOP			BEARING	FAILED
9/13/2011	AS365N3			704A33652044	T/R GEARBOX
FAILURE OF INPUT PINION TAPERED ROLLER BEARING OF TAIL ROTOR GEARBOX. FAILURE OCCURRED DURING GROUND RUN AFTER MX. REPLACEMENT OF TAIL ROTOR GEARBOX. TAIL ROTOR GEARBOX INPUT CASING DISCOLORED DUE TO OVERHEATING OF FAILED BEARING. INPUT PINION SEIZED.
2011FA0000672	UROCOP	TMECA		LOCKWASHER	MISINSTALLED
9/21/2011	AS365N3	ARRIEL2C		LN9023B51	M/R SHAFT
INCORRECT APPLICATION OF LOCKING WASHERS ON ROTOR SHAFT NUT RETAINER LOCK (117-12118-01). INCORRECT APPLICATION OCCURRED DURING INSTALLATION OF REPLACEMENT ROTOR SHAFT. DISCOVERED WHILE PERFORMING MAIN GEARBOX LOWER CASING REPAIR. (REMOVAL OF ROTOR SHAFT REQUIRED). SECURITY OF ROTOR SHAFT RETAINER LOCK IS NOT ASSURED.
QMLD20111192662	UROCOP			MAST	CORRODED
11/9/2011	BK117C1EURO			4639205016	ZONE 200
THE MAIN ROTOR SHAFT HAS CORROSION ON THE TOP OF THE FLANGE WHERE IT COMES INTO CONTACT WITH THE SILVER SHIM AND THE MAIN ROTOR HEAD. THE CORROSION IS BEYOND LIMITS.
CA110610009	UROCOP	TMECA		FREQ ADAPTER	FAILED
6/9/2011	EC120B	ARRIU2F		C622A4002102	MAIN ROTOR
DURING A MAJOR INSPECTION, DISCOVERED THE FREQUENCY ADAPTER WAS INCORRECT (TOO LONG). PILOT HAD JUST REPORTED A SERIOUS VIBRATION ON THE GROUND. REMOVED THE FREQUECY ADAPTER AND FOUND THAT 1 OF THEM HAD STRETCHED AND REQUIRED A COMPLETE TURN IN ON THE ROD END TO FALL BACK INTO RIGGING SPECICATIONS.


		ADVISORY CIRCULAR 43-16A
	AVIATION MAINTENANCE ALERTS

ALERT NUMBER 401			DECEMBER 2011

ADVISORY CIRCULAR

AVIATION MAINTENANCE ALERTS