19/​23/​24Musketeer · Sundowner · Sierra

Parts most often named Cylinder (5) · Valve (2) · Pin Plug (1) · Piston (1)

AFTER TAKE OFF, PILOT HEARD A LOUD BANG FROM THE ENGINE FOLLOWED BY VIBRATION AND LOSS OF POWER. SUCCESSFULLY RETURNED TO THE AIRPORT AND LANDED WITHOUT INCIDENT. INSPECTION OF THE ENGINE REVEALED THE NR 1 CYLINDER HAD CRACKED APPROXIMATLY 75% OF THE CIRCUMFERENCE WHERE THE HEAD AND BARREL MEET. RECORDS INDICATE THE CYLINDER HAD BEEN OVERHAULED ON 10/20/2011. THE CYLINDER WAS INSTALLED ON 6/19/2014. THE CYLINDER ACCUMULATED 73.1 HOURS BEFORE THE FAILURE.

(CAN) LORS D`UN INSPECTION DE 100 HRS, LE TECHNICIEN D`ENTRETIEN A DECOUVERT DU METAL (BRASSE) DANS LE FILTRE A L`HUILE. APRES INVESTIGATION, UNE "PUSH ROD TUBE" DE LA VALVE D`ADMISSION A ETE TROUVE DEFORME. APRES ANALYSE, LE RESSORT INTERIEUR DE LA VALVE A ETE TROUVE CASSE EN PLUSIEURS MORCEAUX CE QUI A PROVOQUE LE BLOCAGE DE LA SOUPPAPE D`ADMISSION CAUSANT AINSI LA DEFORMATION DE LA "PUSH ROD TUBE". (TC# 20101117001)

(AUS) ENGINE CYLINDERS (4OFF) SEVERELY ERODED ON EXHAUST FLANGES. GASKETS LEAKING AND CAUSING BLOW-BY. ENGINE, ENGINE COMPONENTS AND FIREWALL CORRODED DUE TO EXHAUST GAS CONTAMINATION. AIRCRAFT HAD COMPLETED 20.7 HOURS SINCE LAST PERIODIC INSPECTION.

Parts most often named Switch (1) · Swivel Rod (1) · Brush Set (1) · Side Brace (1)

THE RT MLG UP-LOCK ACTUATOR FAILED AND WOULD NOT RELEASE THE LANDING GEAR UP-LOCK HOOK, PREVENTING THE RT MLG FROM EXTENDING.

THE AIRCRAFT TOUCHED DOWN UNEVENTFUL. DURING ROLLOUT, THE NOSE GEAR COLLAPSED ABOUT 1500 FT AFTER TOUCHDOWN. THE DRAG BRACE FAILED AT THE YOKE WHERE IT ATTACHES TO THE NOSE GEAR. (K)

DURING AN ANNUAL INSPECTION, A CRACK WAS DISCOVERED ON THE MLG UPPER SIDE BRACE WELD ASSEMBLY NEAR THE AFT ATTACH POINT.

Parts most often named Valve (9) · Bypass Valve (2)

WHILE COMPLYING WITH LYCOMING SB 518A, FOUND CRIMP NUT LOOSE AS SHOWN IN STEP 2 OF BULLETIN. ALSO, FOUND THERMO BELLOWS DAMAGED. CRIMP NUT LOOSE DUE TO POOR DESIGN.

WHILE COMPLYING WITH LYCOMING SB 518, FOUND CRIMP NUT LOOSE AS SHOWN IN STEP 2 OF BULLETIN. SUBMITTER SUGGESTS CRIMP NUT LOOSE DUE TO POOR DESIGN.

WHILE COMPLYING WITH LYCOMING SB 518A FOUND CRIMP NUT LOOSE AS SHOWN IN STEP 2 OF BULLETIN. SUBMITTER SUGGESTS CRIMP NUT LOOSE DUE TO POOR DESIGN.

Parts most often named Rod Bearing (2) · Crankcase (2) · Camshaft (1) · Piston Ring (1)

IN-FLIGHT CATASTROPHIC FAILURE, DURING INITIAL CLIMB, ENGINE RAN ROUGH, QUIT PRODUCING POWER AND STOPPED. ACFT LANDED IN A FIELD. NO DAMAGE INCURRED.

OPERATOR COMPLAINED OF ENGINE SURGING 25 RPM OF 2400 RPM. STATED THAT THE NR 4 CYL WAS 70 DEGREES COLDER THAN THE OTHER CYLINDERS. LANDED AND CHECKED OIL. FOUND OIL ON TOP OF THE ENGINE, SUSPECTED TO COME FROM THE SPLIT CASE. FOUND NO DAMAGE TO EXTERIOR OF ENGINE. FOUND OIL BLACK JUST AFTER BEING CHANGED 7 HRS BEFORE. OIL HAD A STRONG ODOR OF COMBUSTION. BOTH SPARK PLUGS WAS OIL FOULED. REMOVAL OF THE NR 4 CYL REVEALED THE OIL SCRAPPER RING AND SECOND COMPRESSION RING HAD BROKEN. CAUSE UNKNOWN.

556 HOURS SINCE MAJOR OVERHAUL, CAMSHAFT AND LIFTERS SPALLED AND CORROSION IS EVIDENT. ENGINE HAS BEEN OPERATED ON PHILLIPS XC 20W50 OIL.

Parts most often named Hinge (2) · Spar (2) · Stabilator (2) · Bolt (2)

UPON REMOVAL OF THE HORIZONTAL STABILATOR FOR BEARING REPLACEMENT, A CRACK WAS NOTED COMING OUT FROM UNDER THE LEFT HINGE BRACKET THAT IS RIVETED TO THE SPAR OF THE HORIZONTAL STABILATOR. (K)

THE PAINT WAS CRACKED AROUND THE HINGE PLATE ON THE RT SIDE. A FINGERNAIL WOULD GO UNDER A COUPLE OF THE RIVETS. WHEN THE RIVETS WERE DRILLED OUT, SEVERAL SPUN AND BROKE BEFORE THE BIT WENT THROUGH. THE BACK SIDE OF THE HINGE PLATES WAS RUSTED AND BLACK GALLING APPEARED ON THE ALUMINUM UNDERNEATH INDICATING MOVEMENT. SUBMITTER STATED THIS IS A 25-HOUR AD INSPECTION THAT IS DIFFICULT TO ASSESS UNTIL REMOVED. (X)

(CAN) UPON REMOVAL OF STABILATOR ACTUATING TUBE BALANCE WEIGHT, IMPACT DAMAGE TO THE ATTACHMENT BOLT WAS FOUND. DAMAGE APPEARED TO BE CAUSED BY REPETITIVE IMPACT RESULTING FROM BALANCE WEIGHT STRIKING THE MICARTA STOP BLOCK. AIRCRAFT TT: 2,033 HOURS.

Parts most often named Blade (7) · Block (1) · Propeller (1)

(AUS) PROPELLER PITCH CHANGE BLOCKS CRACKED. PITCH CONTROL FORK WORNEXCESSIVELY. HUB PRELOAD PLATE DAMAGED DUE TO PREVIOUS FOREIGN OBJECT STRIKE.

(CAN) DIMENSIONAL CHECK, FOUND PROPELLER TO BE JUST UNDER MINIMUM ALLOWABLE THICKNESS AT THE 34.20 INCH STATION. PROPELLER RETIRED FROM [S/N removed].

(CAN) DUE TO CORROSION OF THE PROPELLER BLADES, CAMBER AND FACE GRINDING IN ACCORDANCE WITH THE SENSENICH MAINTENANCE MANUAL WAS CARRIED OUT.

Parts most often named Frame Angle (8) · Channel (1)

FOUND COROSION AT FORWARD ATTACH POINT OF CHANNEL 169, 520000-91, AT FS 132 WHERE AIR DUCT COMES THROUGH CHANNEL - ATTACH POINT COMPLETELY GONE. ALSO, FOUND CORROSION AT VARIOUS POINTS ON FUSELAGE (WHERE FRESH AIR DUCT TOUCHES FUSELAGE).

INSPECTION FOUND CRACKING IN FRAME ANGLE WHICH MOUNTS INSTRUMENT PANEL TO FUSELAGE AND CRACKS IN ADJACENT CHANNEL AND FUSELAGE SKIN. SUSPECT CRACKING BECAUSE OF LANDINGS MADE IN TRAIING AIRCRAFT. SUBMITER SUGGESTED CLOSE INSPECTION OF STRUCTURE MOUNTING INSTRUMENT PANEL EVERY 100 HOURS OR ANNUALLY.

Parts most often named Rotor (3) · Magneto (2) · Housing (1) · Coil (1)

(CAN) DURING A FLIGHT AIRCRAFT LOST THE USE OF A MAGNETO. AFTER OPENING THE ENGINE COVER, THE TECHNICIAN NOTICED THAT THE FLANGE OF THE MAGNETO WAS HANGING. A LARGE QUANTITY OF METAL FILINGS HAS BEEN FOUND IN THE OIL FILTER. (TC# 20180808017)

(CAN) AFTER STARTING THE ENGINES, A CHECK OF THE MAGNETOS REVEALED THE RIGHT HAND MAGNETO WAS DEAD. THE AIRCRAFT WAS TAKEN TO MAINTENANCE AND THE TECHNICIAN FOUND THE CAM BROKEN.

DISASSEMBLED RT MAGNETO. FOUND EXCESSIVE CARBON RESIDUE IN COIL AREA. FURTHER INVESTIGATION REVEALED THE ROTOR ARM ON GEAR ASSY HAD BECOME LOOSE ALLOWING APPROXIMATELY 30 DEGREE MOVEMENT SIDE TO SIDE. SUBMITTER RECOMMENDS 500-HOUR INSPECTION OF BLOCK AND GEAR ASSY IN FAA SAFETY RECOMMENDATION.

Parts most often named Alternator (3) · Fan (1) · Rotor Coil (1) · Generator (1)

ALTERNATOR FAILED WHILE ACFT WAS IMC, VFR CONDITIONS ENCOUNTERED. AIRCRAFT LANDED WITHOUT INCIDENT. INVESTIGATION REVEALED ROTATING FIELD WAS ELECTRICALLY OPEN DOWN. STREAM OF SUD RINGS. PART TSO WAS ONLY 52 HOURS SINCE OVERHAULED. (X)

ALTERNATOR FAILED IN IMC. AIRCRAFT WAS LANDED GEAR UP. SUBSTANTIAL DAMAGE. NO INJURIES. INSTALLED NEW ALTERNATOR. OPS CHECKED OK. FAILED ALTERNATOR OVERHAUL. ON 11-15-96. INSTALLED 5-19-97.

GENERATOR WENT 'OFF LINE'. DISASSEMBLY FOUND BRUSH LEADS CUT AND FRAYED BY BRUSH HOLDERS. REAR BEARING FOUND LOOSE IN REAR HOUSING CAUSING ROTATIONAL VIBRATION WHICH CAUSED BRUSH LEADS TO HIT BRUSH HOLDERS.

Parts most often named Bulkhead (6) · Spinner (1)

(AUS) PROPELLER SPINNER CRACKED IN SEVERAL PLACES. SPINNER APPEARS TO HAVE BEEN REPAIRED BY WELDING. THE QUALITY OF THE WELD REPAIRS IS VERY POOR WITH CRACKS EMANATING FROM THE WELDS. LAST PERIODIC INSPECTION 20.7 HOURS PREVIOUS. PERSONNEL/MAINTENANCE ERROR.

(AUS) PROPELLER SPINNER FORWARD BULKHEAD CRACKED IN SEVERAL PLACES. BULKHEAD APPEARS TO HAVE BEEN REPAIRED BY WELDING WITH THEQUALITY OF WELDS VERY POOR. CRACKS EMANATING FROM THE WELDS.AIRCRAFT HAD OPERATED FOR 20.7 HOURS SINCE THE LAST PERIODICINSPECTION. PERSONNEL/MAINTENANCE ERROR.

DURING PROPELLER REMOVAL, FOUND CRACKS AT EACH BOLT HOLE. BULKHEAD WAS INSTALLED WITH NEW A-4227-1 SHOULDER WASHERS AT INITIAL INSTALLATION 72 HOURS PRIOR. SUSPECT CRACKS DUE TO POOR DESIGN AND POOR MANUFACTURING.