PA-25Pawnee

Parts most often named Impulse Coupling (3) · Contact Points (2) · Capacitor (2) · Bearing Cage (2)

(CAN) MAGNETO RECEIVED FOR OVERHAUL. DEFECT FOUND DURING DISASSEMBLY. MOUNTING TAB SPOT WELDS DETACHED FROM CAPACITOR HOUSING.

MAGNETO WAS REMOVED FROM ENGINE FOR ROUTINE MAINTENANCE INSPECTION. THREADS ON MAGNETO SHAFT AND NUT WERE COMPLETELY STRIPPED. SLOT IN SHAFT FOR WOODRUFF KEY WAS WALLOWED OUT. COTTER KEY WHICH RETAINED NUT TO SHAFT WAS STILL IN PLACE. AT TIME OF REMOVAL ENGINE WAS OPERATING NORMALLY. ONLY THE MAG BUSHINGS AND RETAINER WERE HOLDING THE IMPULSE COUPLING IN PLACE. THE DRIVE SHAFT AND OR THE WOODRUFF WERE DEFECTIVE AT THE TIME OF MANUFACTURE. THIS CONDITION IF UNDETECTED WILL LEAD TO COMPLETE ENGINE FAILURE. (K)

MAG FAILED IN FLIGHT, UPON INSPECTION POINTS WERE FOUND TO BE BROKEN WITH 44 HOURS TT ON THE POINTS. THE SPRING PORTION WAS BROKEN DUE TO A DEFECT IN THE STAMPING WHICH SET UP A STRESS POINT AT THE ATTACH SCREW. RECOMMEND MFG CONTACT ASSY BE INSPECTED FOR PROPER BENDING OF THE PARTS AND REMOVE FROM [S/N removed] THAT DO NOT HAVE PROPER FORMING OF THE SPRING. (K)

Parts most often named Cylinder Head (1) · Cylinder (1) · Piston (1) · Engine (1)

THIS WAS A NEW CYLINDER INSTALLED APRIL 05, AT ENGINE OVERHAUL. THE CYLINDER COMPLETELY SEPARATED BETWEEN THE HEAD AND BARREL, IN FLIGHT. THE AIRCRAFT WAS SAFELY LANDED AT HOME AIRPORT. PN STAMPED ON CLY BASE: AEL65102, SN12.0F. (K)

LYCOMING CYLINDER PN LW12429 WITH A CERMINILL COATING FROM ECI DELAMINATED. THE AREA WAS ABOUT 1.5 INCHES IN LENGTH AND ABOUT .250 WIDE AT THE TOP OF THE CYLINDER BORE, ABOVE THE PISTON RING TRAVEL. THE PROBABLE CAUSE WAS CORROSION UNDER THE CERMINILL COATING. THIS IS A PLATING DEFECT. THE ECI BATCH NUMBER ON THE CYLINDERS ARE 46463-3, 46463-10, 40739-3D, AND 40739-6D.

DURING ASSEMBLY OF THIS ENGINE, 6 SHROUD TUBE SPRINGS WERE INSTALLED, 3 BROKE WHEN THE NUT WAS TIGHTENED. THESE SPRINGS WERE SUPPLIED AS PART OF A PACKET SET FROM SUPERIOR AIR PARTS.

Parts most often named Rod Bolt (1) · Dowel (1) · Crankcase (1) · Bolt (1)

(CAN) CONNECTING RODS REMOVED FROM ENGINE AT 192.0HRS DUE TO PROP STRIKE. RODS INSPECTED IAW SB439A, AND ALL 6 RODS HAD FRETTING AND GALLING ON THE CONNECTING ROD BEARING BORE SURFACE. THE RODS WERE REPAIRED AND RETURNED TO [S/N removed]. THE PREVIOUS OVERHAUL RECORDS HAD NOT INDICATED COMPLIANCE WITH SB439A. (TC NR 20060427002)

(CAN) WITH THE MAGS REMOVED, MAG DRIVE IDLER WAS FOUND LOOSE. IT WAS NOTED UPON REMOVAL THAT THE CAST BOSS IN THE AFT END OF THE LEFT CRANKCASE WAS FOUND WORN TO THE POINT THAT THE BEARING FAILED AND WAS MISSING. SUBMITTER SUGGESTED NOT TO RUN ENGINE PAST TBO IF ENGINE ON CONDITIONAL MAINTENANCE SCHEDULE.

(AUS) RH CRANKCASE NO3 DOWEL SHEARED ALLOWING MOVEMENT OF THE MAINBEARINGS - WEAR ALSO TO CRANKCASE TUNNEL AND SCORING OF THE CRANKCASE JOURNAL - DOWEL WAS SUPERCEDED (STEPPED) TYPE

Parts most often named Engine (3) · Washer (1) · Tube (1)

DURING BANNER TOW OPERATIONS, IN CRUISE FLIGHT AT APPROX 600' AGL, THE PILOT REPORTED THAT THE ENGINE STARTED TO SHUTTER VIOLENTLY AND SUBSEQUENTLY BEGAN TO RAPIDLY LOSE POWER. CARBURETOR HEAT WAS APPLIED WITH NO EFFECT. THE PILOT WAS FORCED TO PERFORM EMERGENCY DITCHING PROCEDURES.

COUNTER WEIGHT RETAINING WASHER P/N 71907 CRACKED AND BROKE. THIS ALLOWED THE COUNTER WEIGHT RETAINING PIN TO FALL OUT. ENGINE SEIZED.

(AUS) ENGINE STOPPED. INITIAL INVESTIGATION FOUND THE LH MAGNETO DRIVE GEAR TO BE DAMAGED AND THE SUPPORT BEARING FAILED. ROTATING THE PROPELLER DID NOT CAUSE THE REAR CASE GEAR TRAIN TO OPERATE.

Parts most often named Bladder (2) · Fuel (1)

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

INSPECTED AIRCRAFT FOR NDT-UTT PER AD 95-12-01, RIGHT FORWARD WING SPAR ATTACH. PRELIMINARY INSPECTION SHOWED VISIBLE POCKET INBETWEEN THE STEEL PLATES. WHEN TESTING UTT, A LOW READING WAS DETECTED IN THIS AREA WHICH WAS BELOW THE MINIMUM THICKNESS ALLOWED. THE EAR HAD BEEN WELDED AT ONE TIME TO REPAIR WHAT LOOKED LIKE IT COULD HAVE BEEN A CRACK.

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

(AUS) LT AND RT WING/FUSELAGE ATTACHMENT FITTING CLUSTERS CRACKED IN THE FOLLOWING LOCATIONS: LT FORWARD CLUSTER CONTAINED ONE 3MM (0.118 INCH) CRACK IN THE FORWARD LUG LOWER SURFACE AND ONE 7MM (0.275 INCH) CRACK IN THE AFT LUG LOWER SURFACE. RT FORWARD CLUSTER CONTAINED ONE 7MM (0.275 INCH) CRACK IN THE AFT LUG LOWER SURFACE.

Parts most often named Axle (1) · Strut (1)

ON MAKING A SLIP TO A LANDING, THE LT GEAR COLLAPSED. IT WAS FOUND THAT THE (VEE ASSEMBLY) PULLED OUT OF THE FITTING ASSEMBLY OF THE SHOCK STRUT. I RECOMMEND THAT THIS BECOME AN INSPECTION POINT FOR POSSIBLE CRACKS. THESE AIRCRAFT MAKE HUNDREDS OF LANDINGS THAT PLACE HIGH SIDE LOADS AT THIS POINT.

Parts most often named Air Box (1) · Gasket (1)

DURING FLIGHT, POWER LOSS FROM ENGINE. SUCCESSFUL OFF FIELD LANDING WAS MADE. INSPECTION REVEALED A BAFFLE INSIDE THE CARBURETOR AIR BOX, CAME LOOSE STARTVING THE CARB OF AIR CAUSING ENGINE TO LOOSE POWER.

THIS AIRCRAFT HAS THE SAME AIR FILTER AND LANDING LIGHT ASSY AS THE PA28140 150-150 WITH BAD GASKETS. SUBMITTER FEELS AD96-10-01-R1 SHOULD APPLY. (X)

Parts most often named Bolt (1) · U Bolt (1)

DURING THE RELOCATION OF THE ACFT, THE RT MLG ATTACH "U" BOLT FAILED WITH A SUBSEQUENT GEAR COLLAPSE. THE "U" IS SPECIFIC TO THE SPRING STEEL GEAR INSTALLATION IAW STC SA441SW.

RIGHT FORWARD LANDING GEAR BOLT WAS FOUND WITH HEAD SHEARED COMPLETELY OFF DURING ANNUAL INSPECTION OF WING ATTACH FITTINGS. RECOMMEND GOOD INSPECTION OF GEAR ATTACH AREA.