PA-32Cherokee Six · Lance · Saratoga

Parts most often named Magneto (36) · Impulse Coupling (23) · Gear (12) · Capacitor (3)

THE MAGNETO IMPULSE COUPLER LOCKED UP AND BROKE THE GEARS INSIDE THE BACK OF THE ENGINE. THIS SHEARED THE DOWEL PIN IN THE BACK OF THE CRANKSHAFT CAUSING ENGINE STOPPAGE.

LEFT MAGNETO IMPULSE COUPLING FAILED. . AD 99-04-04 APPLIES TO THIS MAGNETO ENGINE COMBINATION. INTERVAL FOR REPETITIVE INSPECTIONS IS 250 HRS. MAGNETO HAD BEEN RECENTLY REPLACED WITH A REBUILT UNIT AND HAS A NEW IMPULSE COUPLING. THE IMPULSE COUPLING SHEARED INTERNAL RIVETS CAUSING MAGNETO TO BIND WHICH CAUSED TWO TEETH TO BREAK OFF OF THE DRIVE GEAR AND DAMAGED ACCESSORIES DRIVE SYSTEM.

THE AIRCRAFT WOULD NOT START. TROUBLESHOT THE SYSTEM AND FOUND THE MAGNETO IMPULSE COUPLING HAD BROKEN AND THAT THE PROP WOULD NO LONGER TURN THE ACCESSORY GEARS ON THE BACK OF THE ENGINE.

Parts most often named Intake Valve (5) · Rocker Cover (4) · Valve (4) · Valve Guide (3)

ENGINE LOST POWER ON TAKEOFF ROLL AND TAKE OFF WAS SAFELY ABORTED. FOUND NO COMPRESSION ON CYLINDER #6 AND DETERMINED THE ENTIRE INTAKE VALVE WAS MISSING. FOUND VALVE IN THREE PIECES IN INTAKE PLENUM. VALVE STEM TIP HAD SEPARATED FROM THE VALVE STEM AT THE KEEPER GROOVE AND WAS STILL IN THE ROTATOR CAP. LIFTER, PUSH ROD ENDS, ROCKER, VALVE SPRING RETAINER AND KEEPERS WERE STILL IN PLACE AND UNREMARKABLE. PARTS SENT TO LYCOMING FOR EVALUATION.

DURING A SCHEDULED VISUAL INSPECTION OF THE ENGINE, EVIDENCE OF OIL SEEPING FROM THE CYLINDER ROCKER BOX COVER AREA WAS DISCOVERED ON TWO CYLINDERS. USING SOAP BUBBLES AND AIR, OIL SEEP WAS ISOLATED TO SEVERAL SMALL PIN HOLES AROUND THE RAISED STAMPED AREA ON THE ROCKER BOX COVER WHERE "LYCOMING" IS STAMPED. FURTHER INSPECTION WITH A 10X MAGNIFYING GLASS CONFIRMED THE STAMPED AREA TO HAVE SMALL HOLES/CRACKS DIRECTLY AROUND THE EDGES OF THE STAMPED LETTERING.

DURING A SCHEDULED MAINTENANCE INSPECTION OF THE ENGINE ROCKER BOX COVERS, EVIDENCE OF OIL SEEPING FROM THE CYLINDER #5 ROCKER BOX COVER AREA WAS DISCOVERED ON RAISED "LYCOMING" STAMPED. FURTHER INSPECTION WITH A 10X MAGNIFYING GLASS CONFIRMED THE STAMPED AREA TO HAVE SMALL HOLES/CRACKS DIRECTLY AROUND THE EDGES OF THE STAMPED LETTERING.

Parts most often named Crankcase (6) · Connecting Rod (4) · Bolt (4) · Crankshaft (4)

THIS ENGINE HAS BEEN REMOVED FROM [S/N removed] DUE TO A CRACK ON THE RT SIDE OF THE CASE BELOW THE NR 3 CYLINDER AT THE FORWARD LOWER CYLINDER HOLD DOWN NUT. CRACK STARTS FROM THE FORWARD LOWER CYLINDER HOLD DOWN NUT AND CONTINUES ABOUT 3 INCHES. ENGINE REMOVED FROM AIRCRAFT REFERENCING PA-32-301 MAINTENANCE MANUAL SECTION 71-00-04.

PILOT REPORTED, ENGINE MADE A LOUD NOISE THEN LOST POWER AND STOPPED TURNING. AIRCRAFT WAS FORCED TO MAKE A LANDING IN SEMI-FROZEN TUNDRA AND FOLDED THE NOSE GEAR, FOLDED RIGHT HAND MAIN LANDING GEAR, AND BROKE LEFT HAND MAIN LANDING GEAR AXLE. ENGINE TEAR DOWN INSPECTION SHOWED THAT THE CRANKSHAFT HAD BROKE AT NUMBER THREE MAIN BEARING JOURNAL.

PRIOR TO EVENT FLIGHT PILOT REPORTED AN UNUSUAL SOUND WHILE ON APPROACH TO LAND. THE ENGINE FAILED 35 MINUTES INTO A 40 MINUTE FLIGHT. THE PILOT PULLED THE THROTTLE IMMEDIATELY ONCE THE ENGINE BEGAN TO VIBRATE AND CONTINUED TO SECURE THE ENGINE AND ACFT FOR AN OFF FIELD LANDING.

Parts most often named Gasket (3) · Baffle (3) · Seal (2) · Drain Tube (2)

THE OIL RELIEF SPRING WAS DEFORMED AND THE FILTER WAS OFF THE SEAL ALLOWING OIL TO BYPASS THE FILTER. THE ENGINE WAS PROBABLY STARTED WITH COLD OIL CAUSING THE FILTER TO COME OFF THE SEAT AND DEFORM THE SPRING. THE FILTER WAS NOT CLOGGED WITH ONLY 23 HOURS ON THE OIL.

ON CLIMBOUT TO 9000 FT OIL TEMP WENT TO 240 DEGREES F AT 7500 FT. REDUCED POWER TO 20MAP AND TEMP KEPT CLIMBING TO 270. MADE A PRECAUTIONARY LANDING. GROUND TEMP 21 DEGREE F AIR TEMP AT 7500 FT 0 DEGREE F

(CAN) IN FLIGHT FAILURE OF ENGINE DURING CRUISE. ENGINE DISASSEMBLY AND ASSESSMENT FOUND INCORRECT PROPELLER GOVERNOR GEAR SHAFT SET SCREW P AND INCORRECT SAFTEING PROCEDURE USED FOR PEENING OF THE SET SCREW. SET SCREW CAME LOOSE INSIDE OF ENGINE CAUSING THE JAMMING AND FAILURE OF THE ENGINE NR 1/NR 2 INTAKE VALVE HYDRAULIC TAPPET BODY. DEBRIS IN THE ENGINE WHILE RUNNING CAUSED MULTIPLE FAILURES OF THE ENGINE COMPONENTS.

Parts most often named Downlock (4) · Bolt (3) · Bearing (2) · Fitting (2)

NOSE GEAR COLLAPSED ON LANDING ROLL OUT, PLACED AIRCRAFT ON JACKS TO TROUBLE SHOOT AND FOUND NOSE GEAR DOWN LOCK TO HAVE A CRACKED DOWN LOCK CASTING THAT FAILED,(PART WHEN REMOVED SHOWED SIGN OF AN OLD CRACK NOT VISIBLE WITH OUT REMOVAL). REPLACED DOWN LOCK ASSY. WITH NEW PART P/N 38078-02. ADJUSTED DOWN LOCKS, PERFORMED NUMEROUS RETRACTION BOTH MANUAL AND EMERGENCY AS PER PIPER PA32R-300 MAINTENANCE MANUAL, OPERATIONAL CHECK GOOD.

PILOT REPORTED NOSE GEAR PARTIALLY DROPPED IN FLIGHT WITH GEAR LEVER IN UP POSITION. NOSE GEAR WOULD NOT EXTEND OF RETRACT. PILOT CYCLED GEAR AND RECEIVED THREE GREEN GEAR INDICATION AND LANDED WITHOUT INCIDENT. UPON INITIAL VISUAL INSPECTION OF LANDING GEAR FOUND THE AFT ATTACHMENT BROKEN ON THE NOSE LANDING GEAR ACTUATOR. PILOT REPORTED LANDING GEAR ACTUATOR WAS REPLACED TWO WEEKS PRIOR TO INCIDENT.

NOSE GEAR EXTENDED SUDDENLY AND UNCOMMANDED IN FLIGHT, EXAMINED AND FOUND CYLINDER ROD END TO NOSE GEAR RETRACT ASSY WAS BROKEN.

Parts most often named Blade (21) · Bearing (1)

((ZY2R)) LOSS OF BLADE TIP IN-FLIGHT. IN FLIGHT, PILOT EXPERIENCED SUDDEN VIBRATION. AS HE WAS OVER AN AIRPORT, IMMEDATELY POWERED BACK AND LANDED THE ACFT APPROX 9 MINUTES LATER. AFTER GO AROUND ACFT INSP PILOT DISCOVERED 1 TIP MISSING FROM THE 3-BLADED PROP. ROCK, STONE OR OTHER FOD AT THE L/E OF THE BLADE, CAUSING STRESS RISER, BENDING AND TWISTING AND LOADS IN THIS AREA LEADING TO BLADE FAILURE.

(CAN) PROPELLER RECEIVED FOR 6 YEAR CORROSION INSPECTION. THE PAINT WAS REMOVED FROM THE BLADES AND INSPECTION FOUND CORROSION ON THE CAMBER AND THRUST FACE OF THE BLADES. EXTRA WORK WAS REQUIRED TO REMOVE THE CORROSION.

(CAN) PAINT REMOVED FROM PROPELLER BLADES FOR INSPECTION. CORROSION WAS FOUND AND EXTRA WORK WAS REQUIRED TO REMOVE THE CORROSION PER HARTZELL MANUAL 133C.

Parts most often named Alternator (12) · Brush (1) · Belt (1) · Shaft (1)

ENROUTE, CLOSE TO DESTINATION THE PILOT HAD A NEGATIVE RATE OF CHARGE AND WAS ON BATTERY POWER ALONE DUE TO ALTERNATOR FAILURE.

4 SCREWS THAT HOLD THE RECTIFIER PLATE INTO THE BACK CASE OF ALTERNATOR CAME LOOSE AND CONTACTED THE ROTOR, DESTROYED ALTERNATOR. (K)

EN ROUTE TO AKN FROM PDB AIRCRAFT HAD AN ALTERNATOR FAILURE AND LOSS RADIOS. PILOT TRIED TO GET LIGHT SIGNAL FROM AKN TOWER WITH NO SUCCESS AND DIVERTED TO 5NK AND CONTACTED AKN MAINTENACE. MAINTENANCE CHANGED OUT THE FAILED ALTERNATOR AND BATTERY. FLIGHT CONTINUED TO AKN.

Parts most often named Doubler (6) · Rib (5) · Bracket (2) · Hinge (1)

(CAN) DURING THE REMOVAL OF THE RT SIDE AILERON FOR PAINTING, THE AME DISCOVERED SEVERE CORROSION ON THE INSIDE HINGE. THE CORROSION REDUCES THE HINGE BRACKET THICKNESS TO ABOUT 60 PERCENT -70 PERCENT OF IT`S ORIGINAL SIZE. CORROSION WAS ALSO FOUND ON THE LT AILERON HINGE BRACKET. THE AME REMOVED ALL 4 HINGE BRACKETS OF BOTH THE AILERONS AND REPLACED THEM FOR 4 NEW HINGE BRACKETS, 2 X 86392-02 AND 2 X 86392-03.

WHILE PERFORMING MANDATORY SB 1216A OF AILERON RIB INSP, THE MECHANIC FOUND A CRACK ON THE RT OTBD L/E AT COUNTER WEIGHT ATTACH POINT.

OUTBOARD DOUBLER HOLDING AILERON TO WING (REINFORCES MOUNT) HAS CRACKS. FOUND ON THREE CONSECUTIVE AIRCRAFT DURING ANNUAL INSPECTION. THREE RIGHT OUTBOARD AND ONE LEFT OUTBOARD. SUBMITTER SUGGESTS COUNTERWEIGHTS FOR THE AILERON MAY BE CAUSING STRESS FRACTURES. SUGGEST AN ADDITIONAL PRE-FLIGHT CARD ITEM SHOULD BE ADDED TO PRE-FLIGHT CHECK LIST. CAN BE READILY SEEN IF LOOKED FOR.

Parts most often named Control Cable (9) · Turnbuckle (5) · Cable (1) · Trim Pulley (1)

ELEVATOR CONTROL CABLE BROKE DUE TO CORROSION AT THE CABLE CONNECTOR FOR THE TURNBUCKLE. RECOMMEND AN INSPECTION WITH A 10 POWER MAGNIFYING GLASS TO DETECT ANY CRACKS AT THE CABLE TURNBUCKLES ATTACHMENTS.

ELEVATOR CONTROL CABLE INSPECTION IAW SB1245A, FOUND ALL SWAGGED AREAS OF TURNBUCKLES CRACKED. INSTALLED NEW CABLE ASSEMBLIES AND BARRELS.

AFT FUSELAGE ELEVATOR CABLE TURNBUCKLE END, CRACKED AND BROKE OFF AT THE BARREL SIDE IN THE SHANK PART, .6250" BACK FROM THE THREADED PORTION OF THE TURNBUCKLE END, JUST AT THE THICKER PART WHERE THE SAFETY WIRE HOLE IS, OPPOSITE THE SWEDGED END. THERE WAS EVIDENCE OF SOME CORROSION ON BOTH.

Parts most often named Pump (12) · Diaphragm (1) · Housing (1) · Fuel Pump (1)

PRE-FLIGHT RUN-UP DISCOVERED LACK OF TAKE OFF POWER AND ENGINE VIBRATION. THE AIRCRAFT FLIGHT WAS ABORTED AND THE AIRCRAFT RETURNED TO THE HANGER. THE ENGINE WAS TROUBLESHOT AND THE ENGINE DRIVEN FUEL PUMP WAS DISCOVERED TO HAVE MULTIPLE DEFECTS IN ITS LOWER DIAPHRAGM. THIS DEFECT ALLOWED FUEL TO ENTER THE INTAKE SYSTEM WITH THE MIXTURE IN CUT-OFF AND THE THROTTLE RETARDED WITH THE AIRFRAME ELECTRIC PUMP RUNNING. THE PUMP HAD 228 HOURS SINCE INSTALLATION AND NO ABNORMAL OPERATING PRACTICES WERE NOTED.

AFTER TAKEOFF PILOT SHUT THE FUEL BOOST PUMP (ELECTRIC) AND NOTICED AN IMMEDIATE FUEL FLOW REDUCTION, AND ENGINE BEGAN TO SHUT DOWN. PILOT TURNED BOOST PUMP BACK ON AND POWER WAS RESTORED FULLY. PILOT MADE A UNEVENTFUL LANDING AT THE DEPARTURE AIRPORT. MAINTENANCE FOUND THE MECHANICAL ENGINE DRIVEN FUEL PUMP HAD FAILED. PUMP WAS REPLACED AND SYSTEM OPERATED NORMALLY.

UPON TAKE-OFF, THE ENGINE FALTURED AND STUTTERED, THE PILOT EXITED THE RUNWAY AND UNLOADED PASSENGERS AND FREIGHT. THE AIRCRAFT WAS BROUGHT TO THE SHOP WHERE IT WAS DISCOVERED THAT THE FUEL PRESSURE WAS LOW. THE MECHANICS REPLACED THE ENGINE DRIVEN FULE PUMP, AIRCRAFT WAS TEST FLOWN AND THEN RETURNED TO [S/N removed]. (AL05200402659) (K)