21 November-20 December 2019

327
AIRCRAFT BELOW 5700kg
CESSNA 404 – ATA 2913 HYDRAULIC PUMP, (ELECTRIC/ENGINE), MAIN – PUMP – SHEARED. DR 611954453
Shortly after take-off, left hydraulic flow annunciator light came on and remained illuminated.

Root cause: LH engine hydraulic pump shaft sheared. Pump removed, engine accessory pad inspected for defects and freedom of rotation with nil defects noted.

Rectifications:  Pump replaced with serviceable unit IAW Cessna 404 SM 11-02. Operational test completed with nil further defects.

NORTH AMERICAN T6 IV – ATA 2710 AILERON CONTROL SYSTEM – TERMINAL – CORRODED. DR 611954456
Small (1mm diameter approx.) instance of pitting corrosion on surface of swaged stainless steel cable end fitting.
Cable replaced.
PIPER PA31 – ATA 7120 ENGINE MOUNT SECTION – MOUNT – DISCONNECTED. DR 611954463
RH Engine frame top inboard attachment at nacelle found detached.

Suspect excessively aged engine mount rubbers have caused excessive vibration/ shock loads through structure over a period causing the rivets to shear on the chrome moly doubler behind the firewall. Doubler was found completely detached from structure and weight of engine was only supported by outboard upper attach point.  Engine was at serious risk of departing the aircraft.

Chrome moly doubler removed from structure, cleaned inspected and painted.  All other mounting points and structure inspected for damage. Doubler will be re-installed as per AMM.  Replacement engine frame to be installed and aircraft awaiting overhauled engines and other repairs.

PIPER PA31 – ATA 5312 FUSELAGE MAIN, BULKHEAD – BULKHEAD – INCORRECT REPAIR. DR 611954465
Upon carrying out first 100-hour inspection, many rivet holes attaching a doubler to the rear bulkhead were found to be elongated or drilled in the wrong place.

Rivets were redrilled with not properly knocked down. There are now many extra and oversize holes in the structure that have been drilled incorrectly.

 
PIPER PA31 – ATA 5730 WING, PLATES/SKIN – SKIN – Detached. DR 611954466
While carrying out first 100 hourly inspection, RH and LH wing lower skins behind engines were discovered to be badly chafed and approximately 1.2 metres of wing skin on each wing was no longer attached properly to the main spars.  Many rivets have pulled right through skins.

Rivets have been left working for so long, drenched in oil from engine oil leaks that they have worn right through the skins in some areas.  The deteriorated engine mount rubbers and excessive oil leaks could likely be a contributor to the excessive wear and tear.
Repairs planned.

CESSNA 208 B – ATA 2520 PASSENGER STATION EQUIPMENT SYSTEM  – SEAT BELT – JAMMED. DR 611954475
Sear 2A seat belt stuck. Freed passenger by unbolting seat belt from the seat.

Root cause: Broken/missing fascia on the seatbelt buckle assy.

Investigation Results

Broken fascia has allowed the passenger to insert the latch plate into the base of the buckle instead of the correct receptacle area.  Once inserted, latch plate cannot be released by the mechanism.

CESSNA 152 – ATA 5530 VERTICAL STABILIZER STRUCTURE  – BRACKET – CRACKED. DR 611954482
Visual inspection of tail bracket per AD/C150/31 Amd4.  Visual crack indications and deterioration required further investigation.

Unknown factors resulted in observed accelerated deterioration since last SIDs inspection. Bracket substituted with a replacement assembly.  SID’s inspection and reassembly of empennage completed.

 
PIPER PA44 180 – ATA 3230 LANDING GEAR RETRACT/EXTENSION SYSTEM – POWER PACK – UNSERVICEABLE. DR 611954518
Gear failed to extend following gear unsafe warning light in flight.
Root cause: Electric motor in the undercarriage hydraulic pump assembly (power pack) had failed spontaneously.
Replacement of hydraulic power pack required.
 
CESSNA 208 B – ATA 2710 AILERON CONTROL SYSTEM – BOLT – SERVICEABLE. DR 611954533
While carrying out scheduled inspection, Bolt item number 152 & 164 of IPC 27-10-02 Fig 01 P/N AN3-7 and P/N AN4-7 did not physically match bolts removed from the aircraft. Bolts found were having PN of AN3-10 and AN4-10.

Cessna Tech rep advised the following:

1. P/N in the IPC and the Engineering drawings match
2.The production line has factory build allowance to increase or decrease most fastener lengths by a size depending on tolerances.
3. Cessna Tech rep advised to use bigger size bolts on our aircraft.

 
BEECH 35 A36 – ATA 2710 AILERON CONTROL SYSTEM – TERMINAL – CORRODED. DR 611954455
Severe corrosion, pitting and cracking of primary aileron control cable terminal fittings found during AD/BEECH36/2019-21-08 compliance. Also found cracking on unrelated cable end on L/H side.
All new aileron cables to be installed.
 

 

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