35/33/36Bonanza · Debonair

Parts most often named Cylinder (79) · Cylinder Head (21) · Valve (5) · Piston (4)

THE INTAKE VALVE HAS MATERIAL MISSING IN I LOCATIONS AROUND THE PERIMETER OF THE VALVE HEAD SEAT AREA, LT APPEARS TO BE VALVE FAILURE AND NOT FOD, (OTHER INFO FOUND ON VALVE WFAA PMA719077QITALY),

DURING ANNUAL INSPECTION FOUND NUT MISSING FROM NR 6 CYLINDER THROUGH STUD, UPPER FORWARD STUD. FOUND NUT IN BOTTOM OF COWLING. NUT WAS SPLIT. REMOVED ENGINE FOR INTERNAL INSPECTION DUE TO LOSS OF CRANKSHAFT BEARING PRELOAD. 42.9 HOURS SINCE LAST ANNUAL.

DURING ANNUAL INSPECTION, FOUND NUT MISSING FROM NR 6 CYLINDER THROUGH STUD, UPPER FORWARD STUD. FOUND NUT IN BOTTOM OF COWLING. NUT WAS SPLIT. REMOVED ENGINE FOR INTERNAL INSPECTION DUE TO LOSS OF CRANKSHAFT BEARING PRELOAD. 42.9 HOURS SINCE LAST ANNUAL.

Parts most often named Circuit Breaker (83) · Switch (16) · Light (2) · Power Supply (1)

PILOT REPORTED THAT THE STROBE LIGHT WAS INOPERATIVE. THE TECH TROUBLESHOT THE SYSTEM AND DISCOVERED THE STROBE LIGHT FAILED. THE TECH REPLACED THE CIRCUIT BREAKER SWITCH. NO CAUSE OR RECOMMENDATION AT THIS TIME.

PILOT REPORTED THAT THE TAXI LIGHT WAS INOP. THE TECHNICIAN TROUBLESHOT THE SYSTEM AND DISCOVERED THE TAXI LIGHT FAILED. THE TECHNICIAN REPLACED THE CIRCUIT BREAKER SWITCH. NO CAUSE OR RECOMMENDATION AT THIS TIME.

PILOT REPORTED THAT THE LANDING LIGHT WAS INOP. THE TECHNICIAN TROUBLESHOT THE SYSTEM AND DISCOVERED THE LANDING LIGHT FAILED. THE TECHNICIAN REPLACED THE CIRCUIT BREAKER SWITCH. NO CAUSE OR RECOMMENDATION AT THIS TIME.

Parts most often named Relay (43) · Rod End (10) · Motor (7) · Bracket (5)

RIGHT GEAR RETRACT ROD BENT, ON A WET WINTER DAY THE PILOT PUT THE GEAR HANDLE DOWN AND THE BREAKER POPPED. HE MANUALLY EXTENDED THE GEAR WITH THE HAND CRANK AND GOT 2 GREEN LIGHTS. 3 GEAR COULD BE SEEN FROM THE GROUND AND HE LANDED. LANDING WAS OK, BUT ON ROLL OUT THE RIGHT GEAR COLLAPSED. LIKELY CAUSE IS UPLOCK CABLE FREEZING AND PREVENTING THE SPRING FROM RELEASING THE HOOK WHICH TURNED FREELY ON INSPECTION AFTER THE FACT.

ON DOWNWIND, GEAR HORN SOUNDED AND OBSERVED NO GREEN GEAR INDICATION, CYCLED GEAR, NO HELP. PERFORMED MANUAL GEAR EXTENSION PROCEDURES, NO HELP. FELT A BINDING OR PREMATURE STOP WHILE CRANKING DOWN GEAR FOR MANUAL EXTENSION. GEAR HORN AND UNSAFE INDICATION REMAINED. PERFORMED A FLY-BY, AND WAS ADVISED THAT THE GEAR APPEARED TO BE DOWN. SET UP FOR THE APPROACH AND CUT OFF ENGINE OVER THE THRESHOLD. ON TOUCHDOWN, THE AIRCRAFT SETTLED ON THE GEAR DOORS AND SKIDDED TO A STOP ON CENTER LINE.

PILOT REPORTED SMOKE IN THE COCKPIT AFTER THE LANDING GEAR WAS FULLY EXTENDED. LANDED SAFELY. DISCOVERD THAT THE DYAMIC BRAKE RELAY DID NOT TURN OFF THE LANDING GEAR ACTUATOR WHEN THE GEAR WAS FULLY EXTENDED CAUSING THE GEAR MOTOR TO OVERHEAT AND SMOKE.

Parts most often named Brushes (16) · Distributor Blk (14) · Impulse Coupling (14) · Magneto (12)

ELECTRIC MAGNETO FAILED. TROUBLESHOOT FOUND MAGNETIC PIC-UP CIRCUIT OPEN. REPLACED WITH NEW AND RUN CHECK SATISFACTORY. REMOVED PART APPEARS TO HAVE DEBONDED FROM CYLINDER AND THERE IS EVEDENCE THAT IT CONTACTED THE CRANK TRIGGER. OAT TEMPERATURE WAS JUST BELOW FREEZING.

IMPULSE COUPLING FOUND TO BE CRACKED AT ADVANCE STOP NOTCHES OF BASE PLATE. DEFECT WAS DISCOVERED USING MAGNETIC PARTICLE INSPECTION OF PART DURING PERFORMANCE OF MANUFACTURERS RECOMMENDED-500 HOUR INSPECTION. WE HAVE SEEN THIS SAME DEFECT ON A VERY LARGE PERCENTAGE OF IMPULSE COUPLINGS USED ON THESE 6 CYLINDER ENGINES.

DURING A 500 HOUR INSPECTION OF MAGNETOS, IMPULSE COUPLING ON EACH MAG WAS FOUND TO HAVE CRACKS IN THE HUB BASE PLATE, LOCATED AT THE FULL ADVANCE STOP NOTCH. CRACKS RADIATE FROM THE SHARP-CORNERED FEATURE OF THE NOTCH OF THE PLATE. DEFECT DETECTED USING MAGNETIC PARTICLE NDT TESTING.

Parts most often named Circuit Breaker (48) · Wire (5) · Rib (1)

PILOT REPORTED THAT THE NAVIGATION LIGHTS WERE INOPERATIVE. THE TECH TROUBLESHOT THE SYS AND DISCOVERED THE NAVIGATION LIGHTS FAILED. THE TECH REPLACED THE CIRCUIT BREAKER SWITCH. NO CAUSE OR RECOMMENDATION AT THIS TIME.

PILOT REPORTED THAT THE LANDING LIGHT WAS INOPERATIVE. THE TECH TROUBLESHOT THE SYSTEM AND DISCOVERED THE LANDING LIGHT CIRCUIT BREAKER FAILED. THE TECH REPLACED THE CIRCUIT BREAKER SWITCH. NO CAUSE OR RECOMMENDATION AT THIS TIME.

PILOT REPORTED THAT THE ANTI-COLLISION LIGHT WAS INOPERATIVE. THE TECH TROUBLESHOT THE SYS AND DISCOVERED THE ANTI-COLLISION LIGHT FAILED. THE TECH REPLACED THE CIRCUIT BREAKER SWITCH. NO CAUSE OR RECOMMENDATION AT THIS TIME.

Parts most often named Pump (37) · Pneumatic System (3) · Shaft (2) · Vanes (1)

PILOT REPORTED INSTRUMENT AIR PRESSURE WAS LOW AT 1700 RPM. UP ON TROUBLESHOOTING THE MECHANIC NOTICED ON INITIAL RUN UP PRESSURES WERE WITHIN LIMITS, AFTER ENGINE STARTED TO WARM UP THE PRESSURE STARTED TO DROP BELOW LIMITS. ON INSP THE VANES SHOW SOME WEAR. INSTALLED NEW PUMP, SYS WORKED NORMAL. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

AIR PUMP WILL NOT SUSTAIN REQUIRED PRESSURE WHEN ENGINE BECOMES HOT. UPON TROUBLESHOOTING THE MECHANIC NOTICED ON INITIAL RUN UP PRESSURES WERE WITHIN LIMITS, AFTER ENGINE STARTED TO WARM UP THE PRESSURE STARTED TO DROP BELOW LIMITS. REPLACED AIR PUMP WITH A NEW UNIT. PERFORMED AN OPS CHECK AND FOUND TO BE NORMAL. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

PILOT REPORTED ON RUN UP, THERE WAS NO INSTRUMENT AIR PRESSURE. UP ON TROUBLESHOOTING THE MECHANIC FOUND THE SHAFT SHEARED. INSTALLED NEW PUMP, SYS WORKED NORMAL. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

Parts most often named Crankcase (9) · Camshaft (5) · Piston (5) · Crankshaft (4)

(CAN) OWNER OF AIRCRAFT REPORTED AN OIL LEAK. UPON INSPECTING FOR THE OIL LEAK A CRACK WAS FOUND. CRACK WAS APPROXIMATELY 6 INCH LONG IN THE CASE HALF ABOVE THE THE #2 CYLINDER BORE INTERSECTING WITH TOP REAR CYLINDER BASE STUD. ENGINE WAS REMOVED AND SENT FOR REPAIR. (TC# 20190823007)

DURING CLIMB OUT, PIC HEARD ENGINE NOISE. AT 6000 AGL ENGINE SHUTDOWN AND PILOT LANDED AT NEAREST AIRPORT. A SUBSEQUENT ENGINE TEARDOWN REVEALED APPROXIMATELY 12 CAM GEAR TEETH DAMAGED ON PN 655516A.

DURING REMOVAL OF CYLINDER ASSEMBLIES FOR TOP O/H, FOUND SEVERAL LIFTERS SPALLED AND EXCESSIVE CAM LOBE WEAR. RECOMMEND THAT AD 2010-11-04 AND TCM MSB098A BE REVISED TO INCLUDE ENGINE MFG EARLIER THAN SPECIFIED IN THE AD. THIS ENGINE WAS BUILT IN 2005.

Parts most often named Hub (30) · Collar (2) · Low Pitch Stop (1) · Pin (1)

PROPELLER SUBMITTED FOR OIL LEAK. DURING REPAIR, THE HUB WAS MAGNETIC PARTICLE INSPECTED IAW AD 62-17-01. HUB WAS FOUND CRACKED IN THE WELD AREA, WHICH IS THE SUBJECT OF AN AD.

ROLL PIN BROKE ALLOWING SLIP RING TO MOVE OUT OF POSITION CAUSING A HYDRAULIC LOCK IN PROPELLER OPERATION. PROPELLER REMAINED IN LOW PITCH, HIGH RPM. REASON FOR PIN FAILURE UNKNOWN.

GUIDE COLLAR CRACKED DUE TO VIBRATION FROM PROPELLER. BOTH BLADES SLIPPED IN CLAMP CREATING A SPLIT IN ANGLES. THIS CAUSED VIBRATION.

Parts most often named Alternator (11) · Circuit Breaker (3) · Rotor (2) · Stator (2)

ALTERNATOR FAILED IN FLIGHT CAUSING AN UNSCHEDULED LANDING AT HERITAGE AVIATION IN BURLINGTON, VT. ALTERNATOR WAS A FAIRLY NEW INSTALLATION ACCORDING TO CUSTOMER.

ALTERNATOR WOULD INTERMITTENTLY GO OFF-LINE. ULTIMATELY HIGH FIELD RESISTANCE WAS DETERMINED TO BE A FACTOR....VOLTAGE REGULATOR AND ALTERNATOR WERE REPLACED. CONTINENTAL SB23-4 WAS COMPLIED WITH IN CONJUNCTION

THE ALTERNATOR WAS INSTALLED AND PRODUCED A TOTAL MECHANICAL FAILURE WITH ONLY 144.7 HOURS. REPLACED THAT UNIT, WHICH ALSO PRODUCED A TOTAL MECHANICAL FAILURE WITH ONLY 41.8 HOURS. OBSERVATION SUGGESTS THAT THE ALTERNATOR CASE HARDWARE WAS NOT PROPERLY TORQUED AND/OR DID NOT USE A FORM OF LOCK FLUID. IN EACH SCENARIO THE ACFT WAS IN NEAR IMC CONDITIONS.

Parts most often named Blade (21) · Bearing (1) · Rod End Bearing (1) · Blades (1)

BLADE FOUND CRACKED IN THE SECOND RETENTION THREAD DURING PENETRANT INSPECTION PERFORMED AT OVERHAUL. NO RED DYE LEAKAGE REPORTED. NO ABNORMAL VIBRATION REPORTED.

PROPELLER SUBMITTAL FOR AD 97-18-02 INITIAL INSPECTIONS. [S/N removed] (BLADE NR 1) FOUND CRACKED IN AREA OF A/O?????? USING EDDY CURRENT INSPECTION EQUIPMENT. NOTE: A/O??????WAS OVERDUE. SUBMITTER STATED SHOULD HAVE BEEN COMPLETED NO LONGER THAN SEPT, 1999. (X)

(CAN) FOUND CORROSION ON THE BLADE THREADS DURING THE CORROSIION INSPECTION. BLADES REPLACED WITH USED [S/N removed]. IN ACCORDANCE WITH MCCAULEY MANUAL 720415.