O-235Lycoming O-235

Parts most often named Cylinder (51) · Pushrod (17) · Plug (15) · Piston (12)

ALUMINUM SHAVINGS WERE FOUND IN THE OIL FILTER DURING 100HR INSPECTION. FOUND THIS TO BE A RESULT OF ALL PISTON PIN PLUGS BEING WORN ON ALL OF THE CYLINDERS AND THE CYLINDER WALLS HAVING A “RIDGE” AT THE BOTTOM OF THE RING TRAVEL.

PILOT EXPERIENCED POWER LOSS SHORTLY AFTER TAKE OFF AND LANDED AS SOON AS POSSIBLE. UPON REMOVAL OF SPARK PLUGS THERE WAS UNUSUAL FOULING ON CYLINDER #1 BOTTOM SPARK PLUG, LOOKING THROUGH THE SPARK PLUG HOLE OF CYLINDER #1 REVEALED A HOLE BLOWN THROUGH THE PISTON.

(CAN) SOON AFTER TAKEOFF ENGINE STARTED VIBRATING ABNORMALLY, VIBRATIONS GOT WORST AND PILOT DECLARED AN EMERGENCY AND LANDED SAFELY ON AIRPORT RUNWAY. PRIMARY INVESTIGATION SHOWS CYLINDER #3 NOT SECURED TO CRANKCASE. EFFECT OF VIBRATIONS SHOWS BROKEN EXHAUST, LOOSE INTAKE TUBE, LOOSE OIL RETURN LINE AND OTHER MINOR DAMAGES. ENGINE WILL BE SENT TO ENGINE REPAIR SHOP FOR INVESTIGATION TO FIND THE CAUSE OF THE PROBLEM. (TC# 20190509011)

Parts most often named Crankshaft (15) · Plug (9) · Crankcase (8) · Piston (6)

WHILE COMPLYING WITH LYCOMING SB667A, ONE WRIST PIN PLUG ON CYLINDER #2 WAS FOUND EXCESSIVELY WORN WITH A HOLE IN THE CENTER OF THE PLUG

(CAN) AIRCRAFT SUFFERED ENGINE LOSS. THE DOWEL AT THE REAR OF THE CRANKSHAFT BROKE CAUSING THE CAMSHAFT AND MAGNETOS NOT TO TURN. PILOT DID FORCED LANDING. NO INJURIES TO PILOT OR AIRCRAFT. SEE TSB REPORT A19P0068 (TC# 20190617026)

(CAN) PILOT AND INSTRUCTOR EXPERIENCED AND ENGINE FAILURE ON FINAL. UPON INVESTIGATION NR 2 CYLINDER STUDS BROKE OFF THE CYLINDER WHERE THE CYLINDER MOUNTS ON TO THE ENGINE CASE. THE PISTON SKIRT WAS FOUND BROKEN AND THE CYLINDER SEPARATED FROM THE ENGINE. THE CAUSE OF THE DAMAGE AT THIS POINT IS UNKNOWN.

Parts most often named Carburetor (29) · Float (13) · Shaft (2) · Carburettor (2)

DURING TRAINING, FLIGHT, INSTRUCTOR AND STUDENT PILOT NOTICED LOSS OF POWER. THEY DID PRECAUTIONARY LANDING ON I-75 HIGHWAY.

ENGINE QUIT AT 300 FT DURING TAKEOFF. ACFT RETURNED TO AIRPORT SAFELY. ENGINE INTERMITTENTLY ROUGH DURING RUN UP AFTER LANDING, TAXI TO RAMP DID FULL POWER RUN UP RAN SMOOTH AND DID MAGNETO CHECK EVERYTHING OK. RAN FOR TEN MINUTES NO ISSUES. SUSPECT CARBURETOR NEEDLE VALVE OR FLOAT STUCK CLOSED. R & R WITH FACTORY O/H UNIT. OPS CHECK OK, TEST FLIGHT OK, RETURNED TO [S/N removed].

(CAN) IAW PILOT " THROTTLE LEVER JAMMING AT APPROXIMATELY 2000 RPM AFTER IDLE FOR ABOUT 20S. THROTTLE TENSION WAS FULL LOOSE." UPON INVESTIGATION BY MAINTENANCE, THE CARB WAS FOUND VERY STIFF TO MOVE WHEN DISCONNECTED FROM THE AIRFRAME THROTTLE CONTROL. ON THE BENCH, THE CARB THROTTLE CONTROL WAS INTERMITTENTLY SEIZING. THE PROBLEM WAS THEN ISOLATED TO THE ACCELERATOR PUMP PART OF THE CARB.

Parts most often named Magneto (16) · Coil (9) · Distributor Gear (8) · Impulse Coupling (4)

PILOT EXPERIENCED A TOTAL ENGINE FAILURE. UPON INSPECTION IT WAS FOUND THAT THE RH MAGNETO WAS ASSEMBLED INCORRECTLY, CAUSING THE DISTRIBUTOR GEAR BRUSH TO ARC TO THE COIL TAB, RESULTING IN A FAILED MAGNETO.

AIRCRAFT EXPERIENCED A TOTAL LOSS OF ENGINE POWER RESULTING IN AN UNSCHEDULED LANDING. AFTER THE RH MAGNETO WAS CHANGED IN THE FIELD THE AIRCRAFT RETURNED TO HOME BASE. UPON FURTHER INVESTIGATION THE LH MAGNETO WAS REMOVED AND INSPECTED, IT WAS FOUND THAT THE MAGNETO WAS ASSEMBLED INCORRECTLY WITH THE DISTRIBUTOR GEAR BRUSH HOLDER CONTACTING THE COIL TAB.

CAM GEAR WAS IMPROPERLY INSTALLED/SEATED DURING MANUFACTURE, WHICH CAUSED EXCESSIVE WEAR AND DAMAGE TO THE CAM GEAR DURING ROTATION AGAINST THE DISTRIBUTOR GEAR. THIS WAS THE FIRST 500HR INSPECTION SINCE THE MAGNETO WAS MANUFACTURED.

Parts most often named Starter (14) · Drive Gear (2) · Screw (2) · Motor (1)

DURING CESSNA 152 AIRCRAFT SCHEDULED MAINTENANCE TECHNICIAN FOUND THAT THREE OF THE FOUR SCREWS BETWEEN STARTER AND ELECTRIC MOTOR WERE LOST. PHOTOS OF STARTER MOTOR IS AVAILABLE.

(CAN) STARTER FWD BOLTS BECAME LOOSE AND DEPARTED FROM STARTER. STARTER FWD HOUSING CAME OFF CAUSING STARTER GEAR TO CONTACT FLYWHEEL RING GEAR. (TC# 20180529016)

DURING ENGINE START, PILOT NOTICED STARTER WOULD NOT ENGAGE FLYWHEEL. ACFT REPORTED TO MX WHERE IT WAS DISCOVERED THE STARTER MOTOR WAS INOPERATIVE. STARTER WAS REMOVED AND INSPECTION REVEALED THE MOTOR AREA HAS 2 SPOTS BURNED THROUGH THE CASING. THIS IS THE 2ND OCCURANCE OF THIS PROBLEM IN THE PAST 12 MONTHS DISCOVERED BY THIS MX SHOP. THE STARTER WAS REPLACED AND OPS CK OK.

Parts most often named Seal (3) · Tube (3) · Breather (2) · Oil Filter (2)

OIL THERMAL BYPASS VALVE WAS FOUND TO NOT MAINTAIN SPECIFIC OPERATING TEMPERATURES, VALVE WAS REPLACED WITH A [S/N removed] UNIT WITH NO FURTHER ISSUES NOTED.

FOUND CRANKSHAFT SEAL PUSHED FREE FROM ITS MOUNTING AREA. SEAL APPEARED DRY ROTTED AND INSTALLED WITH INSUFFICIENT SEALANT. INSTALLED NEW SEAS IAW SRM. INSPECTED OIL SCREEN AND TOOK OIL SAMPLE. NO METAL FOUND SEAL SHOULD BE INSPECTED FOR PROPER MOUNTING EVERY 100 HOURS.

(CAN) AFTER DRAINING ENGINE OIL DURING A 100 HOUR INSPECTION, THE VALVE WAS CLOSED. UPON CLOSING THE VALVE, IT CAME APART. NO ABNORMAL AMOUNT OF FORCE WAS APPLIED. THE VALVE IS SPRING LOADED CLOSED. IF THIS WERE TO HAPPEN IN FLIGHT ALL OIL COULDBE LOST AT A RAPID RATE. THE VALVE WAS REPLACED WITH A DIFFERENT STYLE OF UNIT. ALL THESE VALVES SHOULD BE REMOVED FROM [S/N removed].

Parts most often named Mount (10) · Bracket (1) · Clamp (1)

(CAN) UPON LANDING THE PILOT NOTICED A NOSE GEAR SHIMMY. UPON INVESTIGATING, THE ENGINE MOUNT WAS FOUND TO BE CRACKED AT THE LOWER NOSE GEAR ATTACH. MOUNT WAS REPAIRED AND ACFT WAS PLACED BACK IN [S/N removed].

THE UPGRADED ENGINE MOUNT WAS FOUND CRACKED. A PLUG USED TO RELIEVE WELDING PRESSURE AND ADD ADD LINSEED OIL APPEARS TO THE THE PROBLEM (STRESS RISER? ETC) THE LINSEED OIL ESCAPED AND MADE A PERFECT CRACK INDICATION WITHOUT USE OF DYE PENETRANT. THE OLDER STYLE, -1 MOTOR MOUNT DOES NOT HAVE PLUGS IN THIS AREA. (K)

(CAN) AT INSPECTION THE ENGINE MOUNT WHICH ALSO HAS PROVISION FOR MOUNTING THE NOSE LANDING GEAR WAS FOUND DAMAGED. TWO TUBES WERE CRACKED, THREE OTHERS WERE SLIGHTLY BENT. ALL EVIDENCE POINTS TO A UNREPORTED HARD LANDING. AIRCRAFT HAS BEEN THOROUGHLY INSPECTED FOR FURTHER DAMAGE. NONE FOUND.

Parts most often named Engine (9)

(CAN) SHORT AFTER TAKE OFF PILOT REPORTED ENGINE VIBRATIONS. PILOT RETURNED TO AIRPORT AND LANDED SAFELY. MAINTENANCE PERSONNEL INSPECTED ENGINE AND FOUND SOME POTENTIAL MAJOR INTERNAL DAMAGES. ENGINE HAS BEEN REMOVED AND SENT TO ENGINE SHOP FOR INVESTIGATION. FOLLOW UP INFORMATIONS WILL BE PROVIDED UPON ENGINE SHOP INVESTIGATION REPORT IS PRODUCED. (TC# 20190503019)

(CAN) LARGE AMOUNT OF METAL DISCOVERED IN ENGINE OIL FILTER DURING INP. ENGINE IS BEING SENT OUT TO ENGINE AMO TO INSPECT FOR DEFECTS AND REPAIR. TSO: 551 HRS. ENGINE IS ON A TC APPROVED MX SCHEDULE AND APPROVED TO BE ON-CONDITION. DISCOVERED DURING "ON CONDITION" INSPECTION.

(CAN) FORCED LANDING AFTER ENGINE FAILURES. MAJOR DAMAGE TO AIRCRAFT RIGHT WING, PROPELLER, RIGHT SIDE FUSELAGE, NOSE LANDING GEAR. LIMITED DAMAGE LEFT WING. ACFT REMAINED UPRIGHT, STRUCK TREES. WHEN REMOVING BATTERY TO SECURE ACFT IT WAS OBSERVED THAT THE ENGINE CRANKCASE IS BROKEN/SPLIT BETWEEN CYLINDERS 2 AND 4 AND THAT THE PROPELLER ROTATES FREELY THROUGH A LIMITED ARC (ABOUT 80° LEST). CRANKSHAFT FAILURE SUSPECTED.

Parts most often named Spark Plug (9)

A LOSS OF ENGINE POWER DURING FLIGHT. EXAMINATION OF ENGINE FOUND THAT THERE WAS A CATASTROPHIC FRACTURE AT THE FLANGE OF THE SPARK PLUG LEAVING THE COPPER GASKET WASHER STILL HELD IN PLACE ALONG WITH THE THREAD FROM THE SPARK PLUG BUT THE PLUG WAS COMPLETELY OUT OF THE CYLINDER WITH THE ELECTRODE AND CERAMIC INSULATOR STILL ATTCHED. UPON FURTHER INSPECTION, IT APPEARED THAT THE PLUG FAILED FROM FRACTURE ALL AT ONE TIME, AS IT DID NOT APPEAR THAT THERE WERE ANY PREVIOUS CRACKS.

RECENTLY INSTALLED SPARK PLUGS. RETURNING HOME, NOTICED ODOR OF FUEL VAPOR, ENGINE STARTED RUNNING VERY ROUGH & WOULD ONLY DEVELOP ABOUT 2000 RPM. MADE LANDING AND FOUND SPARK PLUG BROKEN AND THAT THE PART WITH THE CABLE WAS LAYING ON THE ENGINE AND WHAT WAS LEFT WAS STILL SCREWED INTO THE CYLINDER.

(CAN) DURING TAKEOFF, PILOT NOTICED ROUGH RUNNING ENGINE AND POWER LOSS. THREE OF THE FOUR LOWER SPARK PLUGS WHERE LEAD CONTAMINATED. NR 2 SPARK PLUG ELECTRODES WERE (WELDED) OVER WITH LEAD.

Parts most often named Propeller (4) · Blade (1) · Bolt (1) · Flange (1)

THIS PROP WAS PURCHASED NEW AND INSTALLED, IT HAS BEEN OVERSPEEDING BY 25-50 RPM. SENT IT TO BE REPITCHED AND THAT CORRECTED THE ISSUE. RECORDS INDICATE THAT IT SHOULD BE AN APPROPRIATE PROP FOR THIS ENGINE/ AIRCRAFT.

(W59R) PROPELLER SUBMITTED FOR INSPECTION AND COMPLIANCE WITH AD 10-04-05. PROPELLER WAS CRACKED ALONG L/E BOLT HOLES BEYOND REPAIR LIMITS.

(CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION IAW AD 2003-12-05. A SMALL CRACK WAS LOCATED RADIALLY AT THE EDGE OF ONE MOUNTING BOLT HOLE. TIME SINCE LAST INSPECTED FOR AD 2003-12-05 WAS 409.2 HOURS. (TC NR 20071212026)