180/​185Skywagon

Parts most often named Cylinder (29) · Cylinder Head (9) · Lifter (3) · Piston (2)

SUPERIOR PISTON ASSY PART # SA640518 INSTALLED. WITHIN 40 HOURS OF INSTALLATION PISTON DISINTEGRATED RESULTING IN EXTREME VIBRATION. ENGINE WAS SHUTDOWN AND LANDING MADE IN FIELD WITHOUT INCIDENT.

WHILE ON A FLIGHT, ACFT AT CRUISE, 4500 VMC, PILOT FELT A SUDDEN POWER LOSS AND A VIBRATION. PILOT LANDED AND PERFORMED AN INSPECTION WITH A MECHANIC. ONCE IN THE ENGINE, THEY FOUND A BROKEN ROCKER ARM. REPLACED SAME AND RETURNED THE ACFT TO [S/N removed].

THE SURFACE OF THE LIFTERS WHICH CONTACT THE CAMSHAFT HAVE BEGUN TO SPALL AND PIT. THERE IS ONLY 268.2 HOURS SINCE THE ENGINE WAS REPAIRED AND THE LIFTERS WERE REPLACED DUE TO A SIMILAR ISSUE WITH THE OLD LIFTERS. THIS APPEARS TO BE A CHRONIC PROBLEM AS IT HAS HAPPENED TO 3 OTHER ENGINES ON DIFFERENT AIRCRAFT IN OUR FLEET. PICTURES OF DAMAGE ARE AVAILABLE UPON REQUEST.

Parts most often named Lifter (17) · Crankshaft (12) · Connecting Rod (5) · Camshaft (4)

(CAN) WHEN THE LIFTER WAS REMOVED FOR BLEEDING AFTER A CYLINDER , IT WAS FOUND TO HAVE A SIGNIFICANT SIZE CHUNK MISSING FROM THE LIFTER FACE. THE ASSOCIATED CAM LOBE WAS INSPECTED AND FOUND TO BE IN [S/N removed] CONDITION, THE LIFTER WAS REPLACED AND THE ENGINE RETURNED TO [S/N removed].

AT OIL CHANGE, FOUND ALUMINUM CONTAMINATION IN OIL FILTER ELEMENT. INVESTIGATION FOUND BROKEN PISTON SKIRT AND RING PARTS IN OIL PAN FROM NR 4 CYLINDER. NR 4 PISTON SKIRT WAS BROKEN AT LOWEST RING, AT BOTTOM OF PISTON HALF, TOTAL SKIRT WAS BROKEN OFF THIS PISTON , FOUND 5/27/2008. (K)

(CAN) IN REMOVING NR 1 CYLINDER TO BE CHANGED OUT THE LIFTERS WERE REMOVED TO BE BLEED DOWN, LIFTERS WERE SPAWLED. THE AME INSPECTED THE CAM AND THE EXHAUST LOBE WAS ALSO SPALLED. THE ENGINE WAS REMOVED AND PREPARED FOR SHIPMENT TO A REPAIR SHOP. UNDER FURTHER INVESTIGATION WE FOUND OTHER LOBES AND LIFTERS WITH SPALLING. OUR HYPOTHESIS IS LACK OF ENGINE USE CAUSING INTERNAL CORROSION/RUST WICH LEAD TO FAILURE (TC NRIN 20070522003)

Parts most often named Hub (33) · Cylinder (2) · Bearing (2) · Block (1)

PROP ASSY WAS SUBMITTED FOR O/H AND OIL LEAK FROM CRACK. CRACK EXTENDS FROM BLADE NR 1 PORTAL THROUGH THE CYL MOUNTING SURFACE.

DUE TO SUSPECTED PROPELLER STRIKE OR ABNORMAL LOADS, THE PROPELLER HUB CRACKED NEAR THE BLADE RETENTION RADIUS. AS A RESULT OF THIS, INTERNAL PARTS WERE DAMAGED INCLUDING ONE BLADE THRUST WASHER. PROPELLER TO BE O/HD.

(CAN) EXCESSIVE RED DYE LEAKAGE NOTED IN SPINNER AREA DURING INSPECTION. PROPELLER INSPECTED AS PER OWNERS MANUAL NR MPC-11. OIL LEAKAGE BEYOND LIMITS. PROPELLER REMOVED FOR INSPECTION BY O/H FACILITY. O/H FACILITY FOUND 2 SLOT BLOCKS PN NR CAB 4746 CRACKED AT FLANGES. PROPELLER REPAIRED AND RETURNED TO [S/N removed].

Parts most often named Blade (26) · Nut (4) · Prop Blade (2) · Ferrule (2)

(CAN) PROPELLER RECEIVED FOR OVERHAUL AT 10 YEARS CALENDAR TIME, AT THAT TIME THE PROPELLER HAD BEEN INSPECTED PER AIRWORTHINESS MANUAL PART VI APPENDIX C (4). THE LAST OVERHAUL COMPLETED WAS OCTOBER 1991. FOUND BOTH BLADE THREADS CRACKED. FAA AD 91-15-04 APPLIED TO THIS PROPELLER FOR INITIAL INSPECTION AND MODIFICATION WHICH HAD BEEN ACCOMPLISHED. (TC NR 20070528006)

PROPELLER D2A34C58, [S/N removed] NR 705814, WORK ORDER NR T68807, C-FYJJ. PROPELLER RECEIVED FOR 10 YEAR OVERHAUL. LAST OVERHAUL MARCH 1996, NOW 800.5 HOURS SINCE OVERHAUL. FOUND BLADE S-90AT-4, [S/N removed] NR C75151YS, CRACKED IN BLADE THREADS, FOUND WITH EDDY CURRENT.

(CAN) PROPELLER, W/O T 64571, RECEIVED FOR 10 YEAR OVERHAUL. LAST OVERHAUL MAY 1996. NOW 667.9 HOUR SINCE OVERHAUL. FOUND BLADE S-90AT-2, [S/N removed], CRACKED IN BLADE THREADS, FOUND WITH EDDY CURRENT.

Parts most often named Spreader Bar (2) · Bracket (2) · Wheel (2) · Retain Arm (1)

(CAN) DURING A TRAINING FLIGHT, THE PILOTS NOTICED THAT THE WATER RUDDERS WERE NOT RESPONDING. THE ACFT FLEW TO THE MX FACILITY WHERE THEY LANDED UNEVENTFULLY & RECEIVED A TOW TO THE DOCK. THE MX ENGINEER FOUND THAT THE WATER RUDDER DIRECT CABLE WAS FOUND ADRIFT AT THE CONTROL SPRING. THE CABLE WAS SECURED & A FUNCTION CHECK WAS CARRIED OUT TO RECTIFY THE DEFECT.

(CAN) DURING A SCHEDULED INSPECTION, THE RT AND LT NLG SLIDE BRACKETS WERE FOUND CORRODED AND DEFORMED CAUSING EXCESSIVE PLAY IN BOTH NLG LEG ASSEMBLIES. THE GEAR WAS DISASSEMBLED AND THE SLIDE BRACKETS, P/N 35A-42022L AND PN 35A-42022R WERE REPLACED WITH NEW PARTS TO RECTIFY THE DEFECTS. THE GEAR WAS RE ASSEMBLED, AND FUNCTION CHECKS WERE CARRIED OUT.

(CAN) DURING REPLACEMENT OF THE NOSE GEAR SLIDE BRACKETS, THE RT AND LT SLIDE TRUCKS WERE FOUND CORRODED AT THE SLIDE PIVOT AS WELL AS CRACKS WERE FOUND AT THE OTBD EDGES. THE SLIDE TRUCKS WERE REPLACED WITH NEW, PN 35A-42124 TO RECTIFY THE DEFECTS.

Parts most often named Mount (17) · Tube (2) · Engine Mount (1) · Bolt (1)

CRACKS VISUALLY IDENTIFIED IN 3 LOCATIONS ON ENGINE MOUNT, 0751003-31. MOUNT IS APPROVED BY MFG FOR INSTALLATION WITH 2 BLADE PROP ONLY. ACFT IS APPROVED BY STC FOR INSTALLATION OF ENGINE AND 3 BLADE PROP WITH THIS MOUNT.

(CAN) THE RT FORWARD ENGINE MOUNT LEG BROKE INTO 2 PIECES. THE PIECES REMAINED ATTACHED TO THE ENGINE AND THE ENGINE MOUNT.

(CAN) DURING ROUTINE INSPECTION, IT WAS DISCOVERED THAT THE FWD LT MOUNT PAD WAS CRACKED. THIS ENGINE MOUNT WAS INSTALLED 44.8 HRS AGO. REPLACED ENGINE MOUNT WITH [S/N removed] P/N 075-1003-31, AIRCRAFT WAS RETURNED TO [S/N removed]. (TC NR 20060717003)

Parts most often named Magneto (10) · Contact (2) · Capacitor (2) · Housing (2)

DURING ROUTINE ENGINE RUNUP, ENGINE DIED WHEN SWITCHED TO LT MAGNETO. REMOVED LT MAGNETO. OPENED TO INVESTIGATE, AND FOUND CONTACT ASSY BROKEN IN 2 PIECES. NO OTHER. DAMAGE FOUND. INSTALLED NEW CONTACT ASSY PN M3081. REINSTALLED MAGNETO. FUNCTIONAL, TEST GOOD. THERE WAS NO APPARENT REASON FOR THE COMPONENT FAILURE. TTSN 3.9.

ROUGH MAG IN FLIGHT. FOUND THAT CAPACITOR LEAD WAS INSTALLED ON POINTS BACKWARDS ALLOWING LEAD TO CONTACT MAIN DRIVE GEAR. GEAR HAD EATEN THROUGH INSULATION AND ALL BUT 2 STRANDS OF THE WIRE. MAG WAS NEARING COMPLETE FAILURE.

PERFORMED MAGNETO CHECK AND FOUND LT MAGNETO DROPPED 500 RPM. REMOVED MAG AND FOUND IMPULSE COUPLING RIVETS SHEARED, DRIVE GEAR BUMPER RETAINER BROKEN AND BUMPERS DAMAGED. REMOVED OIL FILTER AND FOUND METAL SHAVINGS.

Parts most often named Reinforcement (6) · Bracket (4) · Channel (3) · Hinge (2)

(CAN) DURING INSPECTION OF HORIZONTAL STABILIZER TRIM TAB ACTUATORS, 1000 HRS OR 3 YEARS, IT WAS FOUND THAT THE TAILCONE REINFORCING LT ANGLE ASSY, PN 0712048-7 HAD A CRACK AT THE HORIZONTAL STABILIZER PIVOT POINT BOLT HOLE. CRACK RUNNING FROM TOP OF ANGLE, DOWN AROUND THE BOTTOM OF THE BOLT HOLE.

DURING THE REPAIR OF THE STABILIZER WHILE REPLACING THE BRACKETS DUE TO CRACKS, IT WAS ALSO FOUND THAT THE CHANNEL WAS CRACKED (PN 0723603-1), BRACKETS AND CHANNEL REPLACED.

(CAN) REPAIRED HORIZONTAL STABILIZER. AFT ATTACHMENT POINT REINFORCEMENT BRACKET PN 07321014 REPLACED WITH NEW. ADJACENT RIVETS REPLACED. TAIL REASSEMBLED. INDEPENDENT CONTROL CHECK CARRIED OUT.

Parts most often named Line (12) · Fuel Line (2) · Fitting (2) · Tee (1)

IN PREPARING FOR A ENGINE CHANGE THE INSPECTOR WAS CHECKING ALL FITTINGS LOCATED ON THE FIREWALL. THE FUEL CONTROL, FUEL RETURN LINE BULKHEAD FITTING AN833-4D WAS NOTED TO BE LOOSE. WHEN THE FITTING WAS REMOVED IT WAS DISCOVERED TO BE CUT ALMOST IN HALF, DUE TO THE STAINLESS MATERIAL OF THE FIREWALL CUTTING INTO THE FITTING WHILE THE FITTING WAS LOOSE.

FLAP CABLE WEARING INTO FUEL LINE. FUEL LINE WAS INCORRECTLY ASSEMBLED. VISUAL INSPECTION OF AREA AT ANNUAL OR 100 HR INSPECTIONS. (K)

(2) AILERON CABLES, (1) FLAP CABLE AND THE FUEL LINE ARE ALL ROUTED THROUGH THE LT LOWER AFT DOOR POST AREA. THE FUEL LINE IS PROTECTED BY A PLASTIC SLEEVE BUT THE CABLE WORE THROUGH THE SLEEVE AND WAS WEARING INTO THE FUEL LINE. THE LINE IS APPROX 20 INCHES LONG WITH (4) BENDS. SUGGEST A (1) TIME INSPECTION IN CASE OTHER AC MIGHT HAVE THIS PROBLEM. (K)

Parts most often named Bellcrank (5) · Control Cable (4) · Rudder Bar (2) · Bracket (2)

(CAN) WHILE PERFORMING A SCHEDULED INSPECTION, A CRACK WAS NOTICED ON THE RUDDER TORQUE TUBE ATTACHMENT ARM, THE ARM WHICH CONNECTS THE RUDDER CABLE TO THE RUDDER TQ TUBE. THE ATTACHMENT ARM WAS CRACKED WHERE IT IS WELDED TO THE RUDDER TORQUE TUBE, THE RUDDER TQ TUBE ASSEMBLY WAS REMOVED, WELD REPAIRED, INSPECTED POST WELD AND REINSTALLED. ALL CONTROLS RECONNECTED AND SAFETIED. ALL WORK WAS PERFORMED IAW THE APPLICABLE MAINTENANCE PUBLICATIONS. (TC# 20190730023)

(CAN) RUDDER BAR ASSY CRACKED AT SPIGOT ATTACH POINT WHERE RUDDER PEDAL STUB SHAFT (PN 0411307) CONNECTS TO RUDDER BAR ASSY. PILOTS REPORTED A SOFT PEDAL ON WATER OPERATIONS, INVESTIGATION REVEALED A SPHERICAL CRACK ON THE RUDDER PEDAL TORQUE TUBE. (TC NR 20071213004)

(CAN) THE BOLT THAT ATTACHES THE LT FORWARD RUDDER CABLE TO THE RUDDER PEDAL SETUP WAS ORIGINALLY TOO TIGHTLY DONE UP. THE CABLE ATTACHMENT FORK WAS NOT ABLE TO MOVE FREELY ON END, IN THE FORK, AND BREAK UNDER LOAD. (TC NR 20070502013)