150/152Commuter

Parts most often named Cylinder (70) · Exhaust Valve (27) · Valve (22) · Piston (15)

AFER TAKING ON FUEL AT BAF, THE AIRCRAFT DEPARTED FOR 47N. WHILE CLIMBING OUT THROUGH 2500 MSL, THE AIRCRAFT ENGINE SUFFERED CATASTROPHIC FAILURE OF CYLINDER NUMBER 4. THE UPPER SECTION OF THE CYLINDER BARREL SEPERATED FROM THE LOWER SECTION APPROXIMATELY FOUR INCHES ABOVE THE CYLINDER FLANGE.

ALUMINUM SHAVINGS WERE FOUND IN THE OIL FILTER DURING 100HR INSPECTION. FOUND THIS TO BE A RESULT OF ALL PISTON PIN PLUGS BEING WORN ON ALL OF THE CYLINDERS AND THE CYLINDER WALLS HAVING A “RIDGE” AT THE BOTTOM OF THE RING TRAVEL.

ENGINE ROUGH RUNNING DURING TAKE OFF RUN UP. COMPRESSION TEST FOUND #4 CYLINDER LOW. REMOVED CYLINDER FOUND EXHAUST VALVE STUCK OPEN. REMOVED VALVE, CLEANED GUIDE OF CARBON BUILDUP, RE-ASSEMBLED, RE-INSTALLED, OPERATES SATISFACTORY.

Parts most often named Carburetor (32) · Float (10) · Shaft (4) · Venturi (3)

DURING TRAINING, FLIGHT, INSTRUCTOR AND STUDENT PILOT NOTICED LOSS OF POWER. THEY DID PRECAUTIONARY LANDING ON I-75 HIGHWAY.

ENGINE QUIT AT 300 FT DURING TAKEOFF. ACFT RETURNED TO AIRPORT SAFELY. ENGINE INTERMITTENTLY ROUGH DURING RUN UP AFTER LANDING, TAXI TO RAMP DID FULL POWER RUN UP RAN SMOOTH AND DID MAGNETO CHECK EVERYTHING OK. RAN FOR TEN MINUTES NO ISSUES. SUSPECT CARBURETOR NEEDLE VALVE OR FLOAT STUCK CLOSED. R & R WITH FACTORY O/H UNIT. OPS CHECK OK, TEST FLIGHT OK, RETURNED TO [S/N removed].

(CAN) IAW PILOT " THROTTLE LEVER JAMMING AT APPROXIMATELY 2000 RPM AFTER IDLE FOR ABOUT 20S. THROTTLE TENSION WAS FULL LOOSE." UPON INVESTIGATION BY MAINTENANCE, THE CARB WAS FOUND VERY STIFF TO MOVE WHEN DISCONNECTED FROM THE AIRFRAME THROTTLE CONTROL. ON THE BENCH, THE CARB THROTTLE CONTROL WAS INTERMITTENTLY SEIZING. THE PROBLEM WAS THEN ISOLATED TO THE ACCELERATOR PUMP PART OF THE CARB.

Parts most often named Crankcase (10) · Crankshaft (10) · Plug (8) · Piston (7)

WHILE COMPLYING WITH LYCOMING SB667A, ONE WRIST PIN PLUG ON CYLINDER #2 WAS FOUND EXCESSIVELY WORN WITH A HOLE IN THE CENTER OF THE PLUG

AIRCRAFT IN FOR ANNUAL INSPECTION, REMOVED SPINNER TO CHECK PROP HUB, S/N, MODEL. NOTICED CRANKSHAFT OIL PLUG MISSING, LOOKED INSIDE CRANKSHAFT BORED HOLE I NOTICE A 1/2" CRACK AT BOTTOM OF BORED HOLE CRACK STARTS AT CENTER OF CRANKSHAFT AND RADIATES OUTWARD.

(CAN) AIRCRAFT SUFFERED ENGINE LOSS. THE DOWEL AT THE REAR OF THE CRANKSHAFT BROKE CAUSING THE CAMSHAFT AND MAGNETOS NOT TO TURN. PILOT DID FORCED LANDING. NO INJURIES TO PILOT OR AIRCRAFT. SEE TSB REPORT A19P0068 (TC# 20190617026)

Parts most often named Magneto (22) · Coil (11) · Distributor Gear (6) · Impulse Coupling (4)

LARGE MAG DROP ON RUNUP THAT WAS SIGNIFICANT ENOUGH TO ALMOST SHUT DOWN THE ENGINE. MAGNETO HAD 568.9 HOURS SINCE INSTALLATION ON THE ENGINE, AND WAS INSTALLED 10 MONTHS AGO.

PILOT EXPERIENCED A TOTAL ENGINE FAILURE. UPON INSPECTION IT WAS FOUND THAT THE RH MAGNETO WAS ASSEMBLED INCORRECTLY, CAUSING THE DISTRIBUTOR GEAR BRUSH TO ARC TO THE COIL TAB, RESULTING IN A FAILED MAGNETO.

AIRCRAFT EXPERIENCED A TOTAL LOSS OF ENGINE POWER RESULTING IN AN UNSCHEDULED LANDING. AFTER THE RH MAGNETO WAS CHANGED IN THE FIELD THE AIRCRAFT RETURNED TO HOME BASE. UPON FURTHER INVESTIGATION THE LH MAGNETO WAS REMOVED AND INSPECTED, IT WAS FOUND THAT THE MAGNETO WAS ASSEMBLED INCORRECTLY WITH THE DISTRIBUTOR GEAR BRUSH HOLDER CONTACTING THE COIL TAB.

Parts most often named Control Cable (9) · Spring (8) · Rudder Bar (6) · Bar (5)

AIRCRAFT DUE FOR ROUTINE 100 HOUR / ANNUAL INSPECTION. FOUND RIGHT HAND RUDDER FAIRLEAD TO BE INSTALLED UPSIDE DOWN AT FUSELAGE STATION 95, FUSELAGE FORMER WAS NEARLY COMPLETELY SEVERED DUE TO WEAR FROM RUDDER CABLE.

PILOT WAS STARTED TO TAXI AND RELEASED PARKING BREAK WHEN HE HEARD SNAP SOUND FROM RUDDER PEDALS AND RIGHT SIDE RUDDER PEDAL FEEL STRANGE. PILOT STOPED TAXING AND TURN ENGINE OFF AND STARTED TO DO TROUBLE SHOOTING WHEN HE FOUND THAT RT RUDDER PEDAL WAS COMPLETELY CRACKED. PHOTOS OF CRACKED RUDDER BAR ARE AVAILABLE IF NEEDED.

PILOTS LEFT "RUDDER BAR WELD ASSEMBLY (CESSNA IPC DESCRIPTION)" BROKE (CRACKED) ALLOWING THE VERTICAL RUDDER PEDAL POST TO SEPARATE FROM THE HORIZONTAL CROSS OVER TUBE. THE BREAK WAS LOCATED ON THE HORIZONTAL PORTION BELOW THE VERTICAL POST.

Parts most often named Hub (41) · Propeller (2) · Bolt (2) · Flange (1)

REMOVED FOR AD 2010-04-05, FOUND HUB CRACK IN THE PROCESS OF COMPLYING WITH AD. FLIGHT SCHOOL, PROPELLER WAS INSTALLED ON MULTIPLE AIRCRAFT, TOTAL TIME UNKNOWN.

(IT6R) PROPELLER SENT FOR AD 2010-04-05. PROPELLER TT 5379.2. PROPELLER HAS A CRACK DOWN THE L/E BOLT HOLE AND CLEAR AROUND THE HUB FACE DOWN THE SIDE OF THE HUB VISUALLY ABOUT 1.5 INCHES. CRACK CAN BE SEEN VISUALLY ABOUT .5" DOWN THE BOLT HOLE.

(CAN) DURING INSP, IAW AD 2003-12-05, CORROSION WAS FOUND IN THE HUB BORE. UPON DIMENSIONAL INSP OF BORE AND CONSULTATION WITH THE MFG IT WAS DETERMINED THAT THE BORE WAS OVERSIZE BY 0.230 INCH.

Parts most often named Rib (30) · Spar (9) · Bracket (2) · Stab Spar (1)

HORIZONTAL STABILIZER LT & RT INSIDE L/E NOSE RIB ASSY, PN: RT 0432001-6, LT 0432001-46 WAS FOUND CRACKED DURING A 100HR/ ANNUAL INSPECTION. THE FAILURE WAS FOUND BY GENTLY LIFTING UP ON EITHER THE LT OR RT SIDES OF THE HORIZONTAL STABILIZER NOTING THE DEFLECTION OF ATTACHMENT AND LISTENING FOR NOTICEABLE ABNORMAL CREEKS AND POPS. AFTER CAREFUL INSPECTION THE CRACKING WAS FOUND COMMON TO THE HORIZONTAL STABILIZER FORWARD SPAR INSIDE NOSE RIB ATTACH POINT.

(CAN) A SLIGHT BUCKLE IN THE STABILIZER TOP SKIN JUST AHEAD OF THE FORWARD SPAR WAS NOTICED AS ACFT WAS PUSHED INTO HANGAR. UPON FURTHER INVESTIGATION IT WAS FOUND THAT THE NOSE RIB INSIDE THE L/E WAS CRACKED. STABILIZER REMOVED FOR REPAIR AND REINSTALLED AFTER REPAIR.

DURING COMPLIANCE OF CESSNA SEB03-6 VERTICAL TAIL ATTACH BRACKET & AFT HORIZONTAL STABILIZER SPAR INSPECTION, CRACKS WERE FOUND IN THE UPPER RADIUS AREA OF BOTH AFT HORIZONTAL STABILIZER SPARS (PART NO. 0432001-56) AND REINFORCEMENT (P/N 0432001-15). CRACKS WERE FOUND BY VISUAL AND/OR FLUORESCENT PENETRANT INSPECTION PER SEB03-6. REINFORCEMENT REMOVAL WAS REQUIRED TO FIND THE SPAR CRACKS. SEB03-6 REQUIRES REINFORCEMENT REMOVAL WHEN CRACKS ARE FOUND TO FACILITATE INSPECTION OF THE SPARS.

Parts most often named Starter (18) · Clutch (5) · Drive Gear (2) · Screw (2)

DURING CESSNA 152 AIRCRAFT SCHEDULED MAINTENANCE TECHNICIAN FOUND THAT THREE OF THE FOUR SCREWS BETWEEN STARTER AND ELECTRIC MOTOR WERE LOST. PHOTOS OF STARTER MOTOR IS AVAILABLE.

(CAN) STARTER FWD BOLTS BECAME LOOSE AND DEPARTED FROM STARTER. STARTER FWD HOUSING CAME OFF CAUSING STARTER GEAR TO CONTACT FLYWHEEL RING GEAR. (TC# 20180529016)

WHILE IN PATTERN, COMMUNICATION WAS LOST BETWEEN ACFT AND TOWER. ACFT WAS CLEARED TO LAND USING LIGHT GUN SIGNALS. LANDING WAS UNEVENTFUL. MAINTENANCE FOUND STARTER SOLENOID HAD AN INTERNAL SHORT THAT DEPLETED ELECTRICAL POWER.

Parts most often named Bracket (19) · Rib (3) · Structure (2) · Fitting (1)

DURING A 100-HOUR INSPECTION, THE MECHANIC DISCOVERED A SIGNIFICANT CRACK/BREAK OF THE AIRCRAFT'S HORIZONTAL STABILIZER 'BRACKET ASSEMBLY,' P/N 0432004-9, THAT SEVERELY COMPROMISES THE INTEGRITY OF THE AIRCRAFT VERTICAL FIN MOUNT. THE NUTPLATES WITHIN THE SUBJECT PART ARE SUBJECT TO AD 80-11-04.

FOUND CRACK IN BRACKET APPROX 3 IN LONG, TOP RT CORNER BROKE OUT AROUND NUTPLATES. ALSO FOUND CRACKS IN REINFORCEMENT 0432001-15 & 0432001-56, APPROX 2 IN LONG, BELIVED TO HAVE BEEN CAUSED BY MOVEMENT AS RESULT FROM CRACKED BRACKET. CRACKS FOUND WHILE PERFORMING INSPECTION PER AD 80-11-84.

3 CRACKS WHERE FOUND ON THE TOP RT OB BOLT HOLE AND ONE CRACK IN WELD JUST AFT OF SAME BOLT HOLE, (NUT PLATES HAD BEEN PREVIOUSLY REMOVED). UNKNOWN CAUSE, AD SHOULD BE REVISED TO REFER FURTHER INSPECTION OF COMPLETE BRACKET ASSY. (K)

Parts most often named Mount (18) · Bracket (2) · Clamp (1) · Bolt (1)

FOUND UPPER LT ENGINE MOUNT BOLT SHEARED. BOLT SHEARED ABOUT .75" FROM HEAD. THIS BOLT ATTACHES THE ENGINE TO THE MOUNT.

(CAN) UPON LANDING THE PILOT NOTICED A NOSE GEAR SHIMMY. UPON INVESTIGATING, THE ENGINE MOUNT WAS FOUND TO BE CRACKED AT THE LOWER NOSE GEAR ATTACH. MOUNT WAS REPAIRED AND ACFT WAS PLACED BACK IN [S/N removed].

(CAN) ENGINE MOUNT TUBE CRACKED AT NOSE GEAR OLEO UPPER ATTACH POINT- RT SIDE DIAGONAL TUBE FROM RT LOWER ENGINE MOUNT, TOO UPPER NOSE GEAR ATTACH POINT, AND LT LOWER DIAGONAL TUBE FROM LOWER LT FIRE WALL ATTACH POINT TO LOWER NOSE GEAR ATTACH POINT. (CRACKED IS AT NOSE GEAR ATTACH POINT).