402401 · 404 Titan · 411

Parts most often named Exhaust Valve (219) · Cylinder (131) · Cylinder Head (18) · Lifter (8)

THE PILOT REPORTED ENGINE SURGING AND MANIFOLD PRESSURE DROP IN FLIGHT, AND THEN SHUT DOWN ENGINE IN-FLIGHT ACCORDING TO THE QRH. DURING THE INITIAL INSPECTION, FOUND SHINY PARTICLES IN THE OIL FILTER, AND SPARK PLUG DAMAGED, AND PARTICLES IN THE PROPELLER GOVERNOR. MAINTENANCE CONFIRMED PREIGNITION OCCURRED ON THE NUMBER LEFT ENGINE #6 CYLINDER. ENGINE CHANGE IN PROGRESS.

PILOT REPORTED ROUGH RUNNING RIGHT ENGINE ON CLIMB OUT. MAINTENANCE INSPECTED AND FOUND THE NUMBER 6 CYLINDER EXHAUST VALVE TO BE BROKEN AND THE NUMBER 4 CYLINDER DAMAGED. REPLACED BOTH CYLINDERS AND RELEASED TO [S/N removed].

PILOT REPORTED RIGHT ENGINE MAP FLUCTUATED IN FLIGHT. MAINTENANCE INSPECTED AND FOUND TURBOCHARGER IMPELLER HARD TO MOVE AS WELL AS LOW COMPRESSION ON THE NUMBER 4 & 6 CYLINDERS. TURBO AND CYLINDERS WERE REPLACED AND THE AIRCRAFT WAS RELEASED TO [S/N removed].

Parts most often named Drag Brace (149) · Torque Tube (13) · Bellcrank (8) · Uplock Hook (6)

PILOT REPORTED THE LANDING GEAR EXTENDED BY ITSELF WITH GEAR HANDLE IN UP POSITION. MAINTENANCE INSPECTED LANDING GEAR SELECTOR SWITCH, NO DEFECTS FOUND. THE SWITCH WAS REPLACED AS A PRECAUTION, WITH NO FURTHER DEFECTS NOTED.

DURING APPROACH THE NOSE LANDING GEAR WOULD NOT EXTEND. AIRCRAFT LANDED WITH NOSE GEAR RETRACTED. NO INJURIES. INSPECTION FOUND THE NOSE GEAR DOOR RETURN SPRING TO BE BROKEN, WHICH CAUSED THE NOSE GEAR DOOR RETRACT BELLCRANK TO BECOME OUT POSITION JAMMING THE NOSE GEAR DOORS CLOSED AND UNABLE TO EXTEND.

PILOT REPORTED THE LEFT MAIN GEAR WOULD NOT RETRACT. MAINTENANCE INSPECTED AND FOUND THE LEFT MAIN LANDING GEAR UPLOCK HOOK BROKEN. THE PART WAS REPLACED WITH NO FURTHER DEFECTS NOTED.

Parts most often named Crankcase (25) · Connecting Rod (24) · Bolt (10) · Nut (9)

DURING ROUTINE INSPECTION AND REPLACEMENT OF THE RIGHT ENGINE CYLINDER #6 IT WAS DISCOVERED THAT THE CONNECTING ROD BUSHING OF THE #6 CYLINDER WAS FOUND TO BE LOOSE AND MIGRATING. THE CONNECTING ROD AND CYLINDER WILL BE REPLACED.

PILOT REPORTED STEADILY DECREASING OIL PRESSURE AT LT ENGINE. CREW INTENTIONALLY CAGED LT ENGINE WHEN ‘MECHANICAL’ NOISES WERE HEARD AND SAFELY LANDED. INITIAL INSPECTION FOUND MULTIPLE CRANKCASE BREACHES AND INDICATIONS OF POSSIBLE OIL STARVATION. ADDITIONAL DETAILS WILL BE AVAILABLE UPON ENGINE TEARDOWN INSPECTION.

PILOT REPORTED THE LEFT ENGINE RUNNING ROUGH IN FLIGHT AND OIL PRESSURE WENT TO ZERO PSI. PRELIMINARY INSPECTION FOUND METAL CONTAMINATION IN OIL FILTER, #4 CYLINDER INTAKE PUSH ROD BROKEN AND A LARGE GAP AT THE EXHAUST ROCKER ARM. THE ENGINE IS BEING REPLACED AND SENT TO CMI FOR FURTHER ANALYSIS. FURTHER INFORMATION ON THIS EVENT CAN BE PROVIDED BY THE OEM.

Parts most often named Pump (13) · Switch (10) · Blower (9) · Heater (7)

PILOT REPORTED A FUEL SMELL IN THE CABIN. MAINTENANCE INSPECTED AND FOUND THE HEATER FUEL PUMP LEAKING. THE FUEL PUMP WAS REPLACED WITH NO FURTHER DEFECTS NOTED.

PILOT REPORTED STRONG SMELL OF FUEL IN THE CABIN WITH THE HEATER ON. MAINTENANCE INSPECTED AND FOUND THE HEATER FUEL PUMP TO BE LEAKING. THE PUMP WAS REPLACED WITH NO FURTHER DEFECTS NOTED.

PILOT REPORTED BURNING SMELL IN CABIN, THEY TURNED THE HEATER OFF AND SMELL DISSIPATED. MAINTENANCE INSPECTED AND FOUND THE COMBUSTION BLOWER INOPERATIVE. MAINTENANCE REPLACED THE COMBUSTION BLOWER WITH NO FURTHER DEFECTS NOTED.

Parts most often named Spar Cap (44) · Spar (17) · Strap (3) · Support (1)

DURING MAINTENANCE AN AREA OF CORROSION WAS VISUALLY IDENTIFIED ON THE RH AFT LOWER OUTBOARD SPAR CAP, OEM P/N: 5122041-24. THIS CORROSION IS LOCATED ON THE FORWARD FACE OF THE VERTICAL LEG AT APPROXIMATE RWS 229.71. THIS CORROSION MEASURES APPROXIMATELY .020 AT ITS DEEPEST WHICH IS EXCESS OF ALLOWABLE LIMITS FOR REMOVAL PER CESSNA MEB 95-11R1 SECTION 3. THIS CAP WILL BE REMOVED AND REPLACED USING FACTORY NEW PARTS.

DURING MAINTENANCE A CRACK WAS VISUALLY IDENTIFIED ON THE RH UPPER FWD SPAR CAP PN: 5122031-6. THIS CRACK IS LOCATED NEAR THE FORWARD RADIUS OF THE SPAR CAP AT APPROXIMATE RWS 70.94. THIS CRACK WAS CONFIRMED BY SURFACE EDDY CURRENT, MEASURES APPROXIMATELY 1 INCH LONG, AND IS CONSISTENT WITH OTHER CRACKS VISUALLY IDENTIFIED IN THIS AREA. THE CAP WILL BE REMOVED AND REPLACED USING NEW PARTS.

DURING MAINTENANCE, INTERGRANULAR CORROSION WAS VISUALLY DISCOVERED ON THE RIGHT HAND SPAR STRAP OF [tail no. removed] AS PART OF SK402-47B (P/N: 5292029-2). THIS CORROSION IS LOCATED AT APPROXIMATE RIGHT WING STATION 106.79 NEAR THE OUTBOARD ENGINE BEAM NACELLE FITTING, AND IS OUTSIDE ALLOWABLE LIMITS FOR REPAIR PER SID 57-10-16 INSTRUCTIONS. THIS STRAP WILL BE REPLACED USING NEW PARTS.

Parts most often named Beam (33) · Fitting (12) · Crossbeam (9) · Channel (1)

DURING MAINTENANCE A CRACK WAS VISUALLY IDENTIFIED ON THE AFT SIDE OF THE LEFT NACELLE CROSSOVER BEAM (P/N: 5654104-11). THIS CRACK MEASURES APPROXIMATELY 1.25 INCHES IN LENGTH, AND BEGINS AT THE TOP INBOARD TURBO BRACKET MOUNTING HOLE ON THE AFT FACE OF THE BEAM. THIS CRACK IS CONSISTENT WITH OTHERS FOUND IN THIS AREA AND IS NOT VISIBLE WITH THE TURBO MOUNTING BRACKET INSTALLED. THIS BEAM WILL BE REMOVED AND REPLACED USING NEW PARTS.

DURING MAINTENANCE A CRACK WAS VISUALLY IDENTIFIED ON THE RIGHT HAND CROSSOVER BEAM. THIS CRACK IS LOCATED ON THE AFT FACE OF THE BEAM, COMMON TO THE TOP OUTBOARD BOLT HOLE FOR THE TURBOCHARGER SUPPORT BRACKET. THIS CRACK MEASURES APPROXIMATELY .875 INCHES LONG TRAVELING LONGITUDINALLY ACROSS THE FASTENER LOCATION. IT IS CONSISTENT WITH OTHER CRACKS VISUALLY IDENTIFIED IN THIS AREA. THIS BEAM WILL BE REMOVED AND REPLACED.

DURING MAINTENANCE A CRACK WAS VISUALLY DISCOVERED ON THE INBOARD FACE OF THE RIGHT HAND INBOARD ENGINE BEAM IN THE AREA OF THE VERTICAL ATTACH CHANNELS FOR THE CROSSOVER BEAM. THIS CRACK WAS DISCOVERED AFTER CHANGING THE CROSSOVER BEAM VERTICAL ATTACH BRACKET P/N: 5654107-15 AND THEREFORE NOT VISIBLE UNTIL THE BRACKET WAS REMOVED. THE CRACK MEASURES APPROXIMATELY 1.210 INCHES LONG, AND IS CONSISTENT WITH OTHERS FOUND IN THIS AREA USING A DETAILED VISUAL INSPECTION. THIS BEAM HAS BEEN REPLACED USING NEW PARTS.

Parts most often named Switch (23) · Uplock Switch (10) · Downlock Switch (8) · Squat Switch (2)

PILOT REPORTED "RIGHT LANDING GEAR LIGHT BURNT OUT. REPLACED WITH BULB AND WHEN REPLACED, 3 GREEN APPEARED BUT THEN SPARKED AND WENT OUT." MAINTENANCE INSPECTED AND DETERMINE THE LANDING GEAR INDICATOR BLOCK TO BE AT FAULT. THE LANDING GEAR INDICATOR BLOCK WAS REPLACED.

PILOT REPORTED NOSE GEAR COLLAPSED ON LANDING. INITIAL INSPECTION AND TESTING INDICATES A FAULTY ACTUATOR SWITCH FALSELY INDICATED GEAR WAS DOWN AND LOCKED.

CREW REPORTED DURING CRUISE FLIGHT, GEAR UNLOCK LIGHT ILLUMINATED. GEAR WAS CYCLED ONCE WITH SAME INDICATION. GEAR WAS SELCTED DOWN, THREE GREEN DOWN AND LOCK LIGHTS ILLUMINATED BUT GEAR UNLOCK LIGHT REMAINED ILLUMINATED. AIRCRFT RETURNED TO KBOS WHERE MAINTENANCE INSPECTED AIRCRAFT AND RELEASED AIRCRAFT FOR SPECIAL FERRY FLIGHT SO THAT RETRACTION AND EXTENSION CHECKS COULD BE PERFORMED. MAINTENANCE FOUND NOES GEAR UPLOCK SWITCH HAD FAILED. SWITCH TO BE REPLACED AFTER OTHER MAINTENANCE IS PERFORMED.

Parts most often named Hub (45) · Latch (1) · Screw (1) · Propeller (1)

(CAN) PROPELLER WOULD NOT CYCLE AND MOVED INTO FEATHER. CYLINDER HAS SWOLLEN SIGNIFICANTLY AND HAS SPLIT. RED DYED OIL PRESENT BETWEEN CYLINDER AND HUB.

(CAN) UPON VISUAL INSP OF HUB PARTS THE HUB WAS FOUND TO BE UNSERVICABLE DUE TO EXPANSION PLUG HOLES WERE DRILLED IN THE CRITICAL AREA. THE HUB WAS RETURNED TO THE CUSTOMER AND NO OTHER ACTION WAS TAKEN.

UPON DISASSEMBLY OF PROPELLER, FOUND CORROSION IN HUB BEYOND LIMITS, FOUND HUB HAD BEEN REPAIRED IN AN AREA WHERE NO REPAIR ALLOWED.

Parts most often named Fitting (46) · Attach Fitting (1) · Channel (1)

DURING MAINTENANCE, A CRACK WAS IDENTIFIED ON THE INBD LEG OF THE RT INBD NACELLE FITTING, THIS CRACK MEASURES APPROXIMATELY .144 INCHES LONG AND WAS DISCOVERED USING THE LIGHTED BORESCOPE INSPECTION PROCEDURE AS OUTLINED IN MEL-54-02R2 TO SATISFY AD2017-10-09. THIS CRACK IS CONSISTENT WITH OTHERS THAT HAVE BEEN IDENTIFIED USING THE SAME INSPECTION PROCEDURE. THIS FITTING WILL BE REPLACED USING NEW PARTS.

DURING NDT INSPECTION AS NOTED IN SID 57-10-16, A CRACK WAS DISCOVERED ON THE LEFT HAND INBOARD NACELLE FITTING. (P/N: 5292029-21) THIS CRACK MEASURES APPROXIMATELY .100 INCHES LONG ON THE INBOARD LOWER LEG OF THE FITTING, AND IS CONSISTENT WITH OTHER CRACKS FOUND USING THE LIGHTED BORESCOPE INSPECTION TECHNIQUE (TEXTRON MEL54-02R2) TO SATISFY REQUIREMENT OF AD2017-10-09. THIS FITTING WILL BE REPLACED USING NEW PARTS.

WHILE PERFORMING THE LIGHTED BORESCOPE PROCEDURE AS OUTLINED IN TEXTRON MEL-54-02 R2 TO SATISFY AS2017-10-19, A CRACK WAS IDENTIFIED ON THE OUTBOARD SIDE OF THE RIGHT HAND OUTBOARD NACELLE FITTING. THIS CRACK MEASURES .0799 IN LENGTH AND ITS LOCATION IS CONSISTENT WITH OTHERS FOUND USING THE SAME METHOD. THIS FITTING WILL BE REPLACED WITH A FACTORY NEW PART.

Parts most often named Engine (34) · Bolt (3) · Case (2) · Bearing (1)

ON APPROACH PILOT NOTICED A SUDDEN "BANG" ACCOMPANIED BY SLIGHT POWER & RPM LOSS ON THE LEFT ENGINE. SMOKE AND OIL BEGAN COMING FROM LEFT ENGINE. OIL PRESSURE DROPPED AND PILOT SECURED THE ENGINE PER COMPANY PROCEDURES. INITIAL INSPECTION FOUND THE NUMBER 6 CYLINDER TO HAVE SEPARATED FROM THE ENGINE BUT STILL REMAINED WITHIN THE COWLING, AND THE ENGINE CRANK CASE TO BE DAMAGED. THE ENGINE HAS BEEN REPLACED AND WILL BE SENT TO CONTINENTAL FOR ANALYSIS.

THE PILOT REPORTED THE LEFT ENGINE HAD A LOSS OF POWER IN AND THE OIL PRESSURE FELL TO ZERO. MAINTENANCE INSPECTED AND FOUND METAL PARTICLES IN THE OIL FILTER. AN ENGINE HAS BEEN ORDERED TO REPLACE THIS ENGINE. FURTHER DETAILS ARE TO BE PROVIDED UPON ENGINE TEARDOWN INVESTIGATION.

ENGINE FAILED IN FLIGHT. NUMBER 1 CONNECTING ROD AND (CRANK END) PROTRUDING THROUGH TOP OF ENGINE CASE. RIGHT MAGNETO BROKEN OFF ITS MOUNT. THE ENGINE HAS BEEN IN [S/N removed] SINCE 05/2017. IT IS A FACTORY REBUILT ENGINE. THIS IS THE SECOND ENGINE IN OUR FLEET TO HAVE THIS TYPE OF FAILURE.