PA-36Pawnee Brave

Parts most often named Nozzle (1) · Oil Sump (1) · Adapter (1) · Oil Filter (1)

OIL FILTER ADAPTER CRACKED ACROSS THE UPPER LT CORNER DURING FLIGHT, CAUSING LARGE LOSS OF OIL IN APPROX 10 MINUTES OF OPERATION. PART HAS NOT BEEN DISTURBED ON THE ENGINE SINCE THE ENGINE WAS REBUILT BY MFG 573 HRS AGO IN JULY OF 2011. THE ADAPTER IS ETCHED WITH 77852-85 AND HAS WHAT APPEARS TO BE A DATE CODE OF 06-28-05.

INSTALLED NEW OIL FILTER AND FOUND THE OIL FILTER WAS FAULTY AND CAUSED THE ENGINE TO PUMP ALL OF THE OIL OUT OF THE ENGINE. OIL FILTER MOUNTING STUD WAS ONLY THREADED TO A LENGTH OF APPROXIMATELY .2500.

PILOT STATED AFTER ENGINE SHUT DOWN, THAT OIL WAS DRAINING FROM INTAKE SYSTEM. UPON FURTHER INVESTIGATION, FOUND THE NR 3 CYLINDER INTAKE EXTENSION PIPE HAD FALLEN OUT OF ITS SWAGED RECEPTACLE AND CHAFED A HOLE IN THE BOTTOM OF THE OIL SUMP. AFTER REMOVAL OF OIL SUMP, FOUND THE PROBLEM HAD OCCURRED BEFORE BECAUSE THERE WAS A WELD AT THE SAME SPOT. ALSO, AFTER REMOVAL OF THE OIL SUMP, THE SUMP SWASHPLATE WAS FOUND WITH TWO BREAKS AT ATTACH POINTS, AND MULTIPLE CRACKS AT ATTACH POINTS.

Parts most often named Bushing (2) · Wedge (1)

BRONZE CENTER BUSHING IN DISTRIBUTOR BLOCK IS LOOSE IN THE PLASTIC ALLOWING THE ROTOR ARM TO MAKE CONTACT WITH THE DISTRIBUTOR BLOCK. SECOND OCCURRANCE OF THIS HAPPENING TO THIS [S/N removed] MAGNETO. OTHER OCCURANCE HAPPENED TO A MAGNETO VERY CLOSE IN SN TO THIS ONE.

A COIL WEDGE WAS NOT INSTALLED CORRECTLY FROM THE FACTORY, THE WEDGE BECAME LOOSE INSIDE THE MAGNETO AND PASSED BETWEEN THE 2 GEARS, DESTROYING THE PLASTIC ROTOR, CAUSING A MISSFIRE.

CENTER BUSHING OF DISTRIBUTOR BLOCK FOUND LOOSE IN THE PLASTIC OF THE DISTRIBUTOR BLOCK, ROTOR ARM WAS CONTACTING DISTRIBUTOR BLOCK BECAUSE OF THE BUSHING BEING LOOSE.

Parts most often named Attach Fitting (2) · Fitting (1)

LEFT WING FORWARD ATTACH FITTING OF FUSELAGE CRACKED. CRACK LOCATED AT THE TOP OF BEND AREA OF THE FRONT AND REAR GUSSETS THAT SANDWICH THE ATTACH PLATE. CRACK IS THROUGH ALL 3 LAYERS OF METAL (FRONT GUSSET, ATTACH PLATE, REAR GUSSET) AND EXTENDS .3750" VERTICALLY.

LEFT WING FORWARD ATTACH FITTING CRACKED AND SEPARATED FROM FUSELAGE. RT WING FORWARD ATTACH FITTING FOUND CRACKED AT BEND RADIUS OF GUSSETS THAT SANDWICH THE ATTACH FITTING.

Parts most often named Crankcase (1) · Tappet Body (1) · Crankshaft (1)

(AUS) ENGINE CRANKSHAFT BROKEN IN WEB LOCATED FORWARD OF MAIN BEARING JOURNAL BETWEEN NO5/NO6 AND NO7/NO8 CYLINDER BANKS. ONE CONNECTING ROD CRACKED.

(CAN) ENGINE WAS REMOVED DUE TO METAL CONTAMINATION. #1 EXHAUST LOBE WAS WORN. TAPPET BODY WAS SPALLED, PITTED AND DEFORMED. CAMSHAFT LOBE WAS PITTED AND WORN DUE TO CONTACT BETWEEN LOBE AND LIFTER BODY (TAPPET). LOBE DISTRESS IS SECONDARY AND BEGINS AFTER LIFTERS BECOME SPALLED BECAUSE OF INSUFFICIENT LUBRICATION FROM EITHER COLD STARTS OR RUNUPS DURING COLD WEATHER. LYCOMING RECOMMENDS AN OIL ADDITIVE LW16702 ANTI-SCUFFING AGENT TO REDUCE WEAR AS PER LYCOMING SB 1409.

WHILE ASSISTING THE OWNER/OPERATOR WITH A PREVENTIVE MAINTENANCE OPERATION, A CRACK WAS DISCOVERED ON THE FRONT SIDE OF THE NR 1 CYLINDER MOUNT PAD AREA. THE CRACK, ALTHOUGH CLEARLY VISIBLE, WAS CONFIRMED WITH DYE PENETRANT. THE CRACK DID NOT APPEAR TO BE LEAKING OIL. THE CAUSE IS UNKNOWN AT THIS TIME.

Parts most often named Carburetor (1) · Adjust Spring (1)

CARBURETOR LISTED IN NR 6 WAS REPAIRED AND TESTED. 23.1 HOURS AFTER INSTALLATION OF THIS CARBURETOR, ENGINE WOULD ONLY PRODUCE 2,000 RPM. TEAR DOWN OF CARBURETOR REVEALED NEEDLE VALVE AND SEAT WORN, FLOAT LEVEL SET TOO HIGH, AND A THUMB SIZED BALL OF LINE IN BOWL.

MIXTURE ARM ADJUSTMENT RETAINING SPRING BROKEN DUE TO ATTACHMENT END BEING WORN. WHEN SPRING BROKE, IT ALLOWED MIXTURE SETTING TO CHANGE WHICH CAUSED ENGINE TO RUN ROUGH AND LOST POWER. SUBMITTER RECOMMENDED A MORE SUBSTANTIAL SPRING THAT IS LESS SUSCEPTIBLE TO WEAR OR TO PROVIDE A MEANS OF SAFETYTING THE ADJUSTMENT ONCE THE PROPER MIXTURE SETTING IS OBTAINED AND IS MADE AVAILABLE.

Parts most often named Spar (2)

(AUS) FIN STRUCTURE EXTENSIVELY CORRODED. FORWARD ATTACHMENT POINT, REAR SPAR AND LOWER RIB AS WELL AS THE INNER SKIN AND UPPER FIN STRUCTURE CORRODED.

Parts most often named Fitting (2)

(AUS) RT FRONT SPAR ATTACHMENT FITTING ON FUSELAGE LOCATED AT RT STN 124.250 CRACKED IN REAR LAMINATE. CRACK LENGTH 10MM (0.39IN).

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

Parts most often named Hub (1) · Propeller (1)

(AUS) PROPELLER HUB WAS PREVIOUSLY INSPECTED AT THE 50HR INTERVAL IAW HARTZELL SB164C AND FOUND SATISFACTORY. WHEN INSPECTED AT THE 100 HOURLY, A PARTICULARLY LARGE CRACK WAS FOUND IN THE REAR HALF OF THE RADIUS AT THE BLADE ROOT.

Parts most often named Bracket (1)

(AUS) ENGINE GAS GENERATOR OUTER CASE BRACKET BROKE OF THE CASE LEAVING TWO HOLES OF APPROXIMATELY 9.525MM (0.375IN) IN THE CASE. THE BRACKET IS WELDED TO THE GAS GENERATOR CASE AND IS USED TOSUPPORT THE FORWARD FIRESEAL BULKHEAD ASSEMBLY.