CitabriaScout · Decathlon

Parts most often named Spar (65) · Spar Cap (1)

RIGHT WING MAIN SPAR CRACKED IN TWO LOCATIONS, ADJACENT TO THE DOUBLER FOR THE WING STRUT ATTACH FITTING. TOP EDGE OF SPAR CRACKED AT INBOARD AND OUTBOARD ENDS OF DOUBLER PLATES. LAMINATED SPAR, COMPRESSION CRACKS STOPPED AT GLUE JOINT OF TOP LAMINATION, ABOUT 1.5 INCHES THICK.

SPAR BUTT CRACKS, AFT SPARS, BOTH WINGS, NOTED AT ANNUAL INSPECTION, ALL SPARS, BOTH WINGS REPLACED REF FAA FORM 337 DATED APRIL 10, 2019.

(CAN) ROUTINE INSPECTION BEFORE A/C WAS DEPARTING ON LONG CONTRACT AWAY BASE. CRACKS EMANATING FROM NAIL HOLES ON SPAR DOUBLER. (TC# 20190718001)

Parts most often named Control Cable (24) · Pulley (5) · Handle (3) · Cable (2)

(CAN) FLAP HANDLE MATERIAL FAILED JUST FWD OF CABLE ATTACHMENT. THIS IS OUR 3RD FAILURE OF THIS PART ALONG WITH 1 CRACKED AND REMOVED FROM [S/N removed].

(CAN) CABLE FOUND FRAYED AT FWD END WHERE CABLE BENDS HARD OFF OF HANDLE TRACK TO FWD CABLE ATTACH POINT. (TC NR 20061220001)

(CAN) CABLE FOUND FRAYED AT THE PULLEY PN 1-2395.THE AREA TENDS TO BE A HIGH WEAR BECAUSE OF THE SIZE OF PULLEY AND IS MONITORED CLOSELY AT ALL INSPECTIONS. FAILURES HAVE OCCURED IN THE PAST WITH THIS COMPANY.

Parts most often named Control Cable (11) · Pedal (5) · Rudder Pedal (3) · Cable (3)

(CAN) THE FRONT RT RUDDER PEDAL BROKE INTO 2 PEICES. THIS RESULTED IN THE REAR PILOT TO BE UNABLE TO ACTIVATE THE RT BRAKE.

RIGHT RUDDER CABLE SEPARATED AT RUDDER BELLCRANK DURING RECOVERY OF INTENTIONAL LEFT SPIN. CABLE APPARENTLY PULLED OUT OF NICOPRESS SLEEVE. AIRPLANE WAS LANDED AT KCHA, WITHOUT INCIDENT, AFTER DECLARING AN EMERGENCY.

(CAN) DURING THE COMPANY STRUCTURAL INSPECTION AND REPAIR PROGRAM (SIRP), THE AIRCRAFT RUDDER PEDALS WERE SENT FOR NDT INSPECTION WHERE IT WAS DISCOVERED THAT BOTH LT AND RT REAR RUDDER PEDALS WERE CRACKED. THESE PEDALS ARE AN OLDER STYLE PEDAL AND ARE NO LONGER AVAILABLE FROM MFG. (TC NR 20060124002)

Parts most often named Fuel Tank (9) · Tank (5) · Structure (2) · Vent Line (1)

(CAN) FUEL WAS NOTED DRIPPING FROM SUMP DRAIN BOSS WHEN TANK WAS FULL. DRAIN VALVE WAS REPLACED BUT DRIP CONTINUED. INVESTIGATION NOTED FUEL STAINING ON TANK INSIDE WING, OPENING OF FABRIC REVEALED A CRACK AT THE INBOARD END OF THE TOP FORWARD STIFFENING BEAD PRESSED INTO THE ALUMINUM OF THE TANK, WHERE THE COMPOUND CURVE FORMED DURING THE MANUFACTURING PROCESS CREATES A STRETCHED AND WORK-HARDENED AREA.

(CAN) DURING THE IN HOUSE REQUIRED 10 YEAR STRUCTURAL INSPECTION & REPAIR PROGRAM, SIRP, THE FABRIC WAS REMOVED FROM THE WINGS & A CRACK APPROX 1 1/4" LONG WAS DISCOVERED ON THE TOP OF THE INBD FUEL TANK. THE FABRIC HAD LAST BEEN REMOVED OVER THE WINTER OF 2000 - 01. AT THAT TIME THE FUEL TANKS WERE REMOVED FROM THE ACFT & INSPECTED [S/N removed]. THE WINGS HAVE BEEN REPLACED WITH NEW WINGS FROM MFG WITH THE NEW METAL SPARS IN THE PAST.

(CAN) GAS FUMES WERE DETECTED AROUND AC. WHEN RT OB FUEL TANK WAS REMOVED A CRACK WAS FOUND ON A REPAIRED RADIUS OF THE LATERAL RE-ENFORCEMENT INDENT OF THE TANK. 720 HOURS SINCE THE TANK WAS REPAIRED. (TC NR 20080123007)

Parts most often named Crankshaft (14) · Camshaft (3) · Cylinder Head (1) · Transfer Tube (1)

(CAN) DURING A 100 HR INSPECTION, METAL FILINGS WERE DISCOVERED IN THE OIL FILTER. CYLINDER 2 AND CYL NR 4 WERE REMOVED AND THE CAMSHAFT INSPECTED. MISSING METAL WAS DISCOVERED ON THE NR 2 CYL EXHAUST LOBE. IN ADDITION WERE AND PITTING HAVE BEEN OBSERVED ON THE HYD TAPPET FACE. ENGINE IS BEING REMOVED FROM [S/N removed] FOR OVERHAUL.

(CAN) A COMPANY DIRECTED 2 YEAR INSPECTION OF THE ID OF THE CRANKSHAFT IAW SB 505B WAS COMPLETED AND PITTING WAS DISCOVERED. THE ID IS NOW AT MAX LIMITS AND PITTING REMAINS AND AN NDT INSPECTION WAS COMPLETED AND WILL BE COMPLETED EVERY 100 HRS AS REQUIRED IAW SB 505B. THE OPTIONAL REAR PLUG HAS BEEN INSTALLED AS DESCRIBED IN WSDR 20110222004.

(CAN) DURING A COMPANY DIRECTED 2 YEAR INSPECTION OF THE ID OF THE CRANKSHAFT IAW SB 505B, PITTING WAS DISCOVERED AND FOUND TO BE 0.082" DEEP. CRANKSHAFT HAS BEEN INSPECTED AND PITTING REMOVED AND STILL FOUND TO BE IN LIMITS. THE OPTIONAL REAR PLUG HAS BEEN INSTALLED AS DESCRIBED IN WSDR 20110222004.

Parts most often named Magneto (7) · Distributor Gear (2) · Brushes (1) · Impulse Coupling (1)

DURING FLIGHT, ACFT HAD AN ENGINE POWER LOSS. DISCOVERED THE MAGNETO TO HAVE A LOOSE DISTRIBUTOR ARM, WHICH CAUSED THE MAGNETO TO FAIL.

DURING FLT, ACFT HAD AN ENGINE POWER LOSS. DISCOVERED THE MAGNETO TO HAVE A LOOSE DISTRIBUTOR ARM, WHICH CAUSED THE MAGNETO TO FAIL.

FAA-PMA PART AM-3215 CARBON BRUSH AND SPRING WAS FOUND BROKEN OFF FLUSH WITH THE SPRING AND FELL INTO THE MAGNETO. CONTACT WAS MAINTAINED BY THE REMAINING PART OF THE BROKEN BRUSH. DURING THE PREINSPECTION RUN UP, THERE WERE NO INDICATIONS OF A PROBLEM. THE BROKEN OFF PARTS OF THE CARBON BRUSH WAS LOCATED DOWN BY THE COIL AND WAS DISLOGED BY TILTING THE MAGNETO UPSIDE DOWN AND SHAKING THE MAGNETO.

Parts most often named Elt (4) · Switch (2) · Remote Switch (2) · G Switch (1)

(CAN) ELT REMOTE SWITCH FAILED TO ACTIVATE THE ELT WHEN SWITCHED TO THE ON POSITION. THE SWITCH WAS RETURNED TO THE ARMED POSITION AND TRIED AGAIN WITH NO ACTIVATION. THIS WAS REPEATED A THIRD TIME WITH THE SAME RESULTS. A NEW SWITCH WAS INSTALLED AND THE SYS RESPONDED CORRECTLY.

(CAN) DURING THE ANNUAL INSPECTION OF THE ELT, IT WAS DISCOVERED THAT THE BATTERIES WERE TIME-EXPIRED AND VERY LOW VOLTAGE (LESS THAN 1 VOLT FOR 3 OUT OF 4 BATTERIES). THE ELT WAS MARKED ON THE OUTSIDE WITH A STICKER INDICATING THAT THE BATTERIES WERE NEXT DUE IN 2017. (TC# 20140925006)

(CAN) DURING THE TROUBLESHOOTING OF ANOTER ELT SYSTEM. IT WAS DISCOVERED THAT THE ELT REMOTE SWITCH WOULD TURN THE ELT ON PROPERLY BUT WOULD NOT RESET THE SYSTEM WHEN SWITCHED BACK TO "ARM". THE REPLACEMENT OF THE ORIGINAL PROBLEM SWITCH WITH A NEW ONE IDENTIFIED THE SWITCH TO BE THE PROBLEM. FURTHER TESTING CONFIRMED THAT THIS SWITCH WAS DEFECTIVE. THE SWITCH IS BEING RETURNED TO THE MANUFACTURE FOR TESTING.

Parts most often named Control Cable (6) · Guard (1) · Nut (1) · Cable (1)

UP ELEVATOR CABLE PART NUMBER 3-1072 HAD MULTIPLE BROKEN/FRAYED WIRE STRANDS AT AFT MOST PULLEY LOCATION (APPROX FUSELAGE STATION 167.50, JUST AFT OF THE FRONT STABILIZER ATTACH POINT) AND MID PULLEY (APPROX LOCATION UNDER REAR SEAT). DOWN ELEVATOR CABLE PART NUMBER 2-1534 HAD BROKEN/FRAYED STRAND OF WIRE AT MID PULLEY (APPROX LOCATION UNDER REAR SEAT).

DURING PRE-FLIGHT INSPECTION. PILOT OBSERVED THAT THE LEFT ELEVATOR TORQUE TUBE JUST OTBD OF THE BELLCRANK ATTACH FITTING HAD A SPIRAL CRACK AFFECTING APPROX 80 PERCENT OF THE TUBE.

THE CABLE GUIDE ON THE AFT PULLEY (BEFORE ATTACHING TO THE ELEVATOR BELLCRANK) WAS INSTALLED AT AN ANGLE WHICH ALLOWED THE CABLE TO WEAR AGAINST THE GUIDE. TWO OF THE SEVEN STRANDS ON THE 7 X 19 CABLE WERE FOUND WORN THROUGH ON AN ANNUAL INSPECTION.

Parts most often named Line (5) · Fuel Line (3) · Clamp (1) · Fitting (1)

IN COMPLIANCE WITH MFG SL NR 419. FOUND FUEL LINE CHAFED OVER .5000 WAY THROUGH TUBE WALL. CAUSED BY FLAP ACTUATOR. CHAFE WAS NOT VISIBLE. FOUND BY FEELING. RECOMMEND MFG RUN LINE STRAIGHT THROUGH FUSELAGE WALL THEN ROUTE AFT. ALSO RECOMMEND MAKING INTO AN AD.

AIRCRAFT FORMED FUEL LEAKS WITHIN 28.8 HOURS OF [S/N removed]. THIS AIRCRAFT WAS BROUGHT IN FOR [S/N removed] WHEN THE PILOT REPORTED FUEL LEAKING FROM THE INVERTED FUEL SYSTEM HEADER TANK ONTO HIS LEGS AND FEET. PERFORMING A VISUAL INSPECTION OF THE SYSTEM SIX FUEL LEAKS AND IMPROPER FLARING ON THE INVERTED FUEL SYSTEM .3750 ALUMINUM LINES.

BOTH FUEL TANK AFT OUTLET LINES (P/N 7-14761-1 LT, AND P/N 7-1476-3 RT) CHAFED BY FLAP BELLCRANK CABLE GUARD P/N 1-2573 IN EACH WING ROOT. THE RT LINE ALSO CHAFED BY THE AILERON CABLE PULLEY P/N 1-10365.

Parts most often named Axle (3) · Strut (2) · Bolt (1) · Lock Nut (1)

(CAN) THE LT MLG OLEO ASSY DETACHED FROM THE AXLE STRUT ASSY. THE OLEO CYLINDER HAD UNTHREADED FROM THE CAP ON THE AXLE STRUT, THE LOCK NUT WAS STILL ATTACHED TO THE CYLINDER BUT DID NOT PREVENT THE CYLINDER FROM UNTHREADING.

DURING LANDING THE RT OLEO PN 3-665 SPRING AND SHAFT POPPED AND CAUSED OLEO TO OVSR EXTEND AND BEND REARWARD. THIS ALLOWED THE WHEEL AND BRACE TO COLLAPSE.

LOCK NUT THREADS FAILED, MLG STRUT EXTENDED ON TAKEOFF ALLOWING MLG TO SWING FREE. DURING LANDING, MLG WAS UNDER FUSELAGE CAUSING DAMAGE TO LOWER LONGERONS, CONDITION OF THREADS CANNOT BE DETERMINED WITHOUT DISASSEMBLING THE MLG STRUT ASSY. THEREFORE, THE THREADS MAY DETERIORATE SIGNIFICANTLY WITHOUT DETECTION. SUGGEST SPECIAL EMPHASIS INSPECTION ROUTINE AT (5) YEAR INTERVALS TO INCLUDE DISASSEMBLY OF MLG STRUT ASSY. (K)