N290CA

Part: AXLE — CRACKED (LT MLG) · airframe 31,526 hrs · 18,171 cycles

DURING SCHEDULED NDT INSPECTION A CRACK WAS FOUND ON THE LEFT MAIN LANDING GEAR AXLE. THE LOWER LEG AND AXLE WERE REPLACED WITH NO FURTHER DEFECTS NOTED.

Part: ENGINE — FAILED (LEFT) · airframe 31,440 hrs · 18,052 cycles

ON APPROACH PILOT NOTICED A SUDDEN "BANG" ACCOMPANIED BY SLIGHT POWER & RPM LOSS ON THE LEFT ENGINE. SMOKE AND OIL BEGAN COMING FROM LEFT ENGINE. OIL PRESSURE DROPPED AND PILOT SECURED THE ENGINE PER COMPANY PROCEDURES. INITIAL INSPECTION FOUND THE NUMBER 6 CYLINDER TO HAVE SEPARATED FROM THE ENGINE BUT STILL REMAINED WITHIN THE COWLING, AND THE ENGINE CRANK CASE TO BE DAMAGED. THE ENGINE HAS BEEN REPLACED AND WILL BE SENT TO CONTINENTAL FOR ANALYSIS.

Part: BEAM — CRACKED (ZONE 400) · airframe 29,567 hrs · 15,440 cycles

DURING MAINTENANCE A CRACK WAS VISUALLY IDENTIFIED ON THE RIGHT HAND OUTBOARD ENGINE BEAM (P/N: 5654109-8) IN THE AREA UNDERNEATH THE FORWARD ENGINE MOUNT DOUBLER. THIS CRACK TRAVELS LEFT TO RIGHT ACROSS THE TOP FACE OF THE BEAM AND PARTIALLY DOWN THE OUTBOARD FACE WITH AN APPROXIMATE LENGTH OF 1.153" ACROSS THE TOP FACE, AND EXTENDS DOWN THE OUTBOARD VERTICAL FACE APPROXIMATELY .336". ULTRASONIC INSPECTION PER AVENGER AEROSPACE AAS-ALS-002 REV. B PART 2 PG. 1-13 PER CAPE AIR REFERENCE 1 AMOC TO SATISFY AD 2015-07-03 WAS PERFORMED ON THIS BEAM AT TAT 29023.8. THIS BEAM WILL BE REPLACED USING NEW PARTS.

Part: WINDSHIELD — FAILED (COCKPIT) · airframe 27,205 hrs

DURING CLIMB OUT PIC TURNED ON WINDSHIELD HEAT. UPON REACHING CRUISE, BURNING SMELL AND SMOKE NOTICED FROM LOWER LEFT SIDE OF WINDSHILED. PIC TURNED OFF HEAT AND SMELL/SMOKE DISAPPEARED AND STOPPED.THE WINDSHIELD WAS TESTED AND CONTINUITY FOUND BAD. THE WINDSHIELD WAS PLACED ON MEL AND WILL BE REPLACED.

Part: CONTROL CABLE — BROKEN (RUDDER) · airframe 26,476 hrs

PILOT REPORTED THE LEFT RUDDER DOES NOT MOVE, A SNAP WAS HEARD WHEN MAKING A LEFT TURN. MAINTENANCE INSPECTED AND FOUND THE FORWARD LEFT RUDDER CABLE BROKEN NEAR THE FORWARD PULLEY. LAST VISUAL INSPECTION OF AREA OCCURRED 134.8 HOURS PRIOR TO FAILURE. CABLE WAS REPLACED WITH NO FURTHER DEFECTS NOTED.

Part: PISTON — DAMAGED (NR 5 CYLINDER) · airframe 25,836 hrs · 10,106 cycles

PILOT REPORTED ON CLIMB OUT, RIGHT ENGINE MANIFOLD PRESSURE DROPPED, COINCIDED WITH ROUGHNESS FOLLOWED SHORTLY AFTER BY ENGINE FAILURE. THE AIRCRAFT LANDED SAFELY WITH NO INJURIES. INSPECTION OF RT ENGINE REVEALED A PRE-IGNITION EVENT WITHIN THE NR 5 CYLINDER CAUSING THE PISTON TO BREAK APART WHICH RESULTED IN SIGNIFICANT METAL CONTAMINATION THROUGHOUT THE ENGINE. WE SUSPECT SPARK PLUG INSULATOR FAILURE. THE ENGINE IS BEING REPLACED; FURTHER DETAILS WILL BE PROVIDED UPON RECEIPT OF ENGINE TEAR-DOWN RESULTS.

Part: EXHAUST VALVE — DAMAGED (NR 5 CYLINDER) · airframe 25,656 hrs

CYLINDER REMOVED DUE TO LOW COMPRESSION AT INSPECTION. EXHAUST VALVE DISPLAYS EVIDENCE OF HEAT DAMAGE.

Part: EXHAUST VALVE — DAMAGED (NR 4 CYLINDER) · airframe 25,593 hrs

CYLINDER REMOVED DUE TO LOW COMPRESSION AT INSPECTION, EXHAUST VALVE DISPLAYS EVIDENCE OF HEAT DAMAGE.

Part: TRANSISTOR — FAILED (INSTRUMENT PANEL) · airframe 25,493 hrs · 9,631 cycles

PILOT REPORTED INSTRUMENT PANEL LIGHT DIMMER SWITCH FOR ENGINE INSTRUMENTS SMOKED, DIMMER DOES NOT WORK. MAINTENANCE TROUBLESHOT AND FOUND DIMMABLE PANEL TRANSISTOR AND HEAT SINK FAILED. REPLACED THE DIMMABLE PANEL TRANSISTOR AND HEAT SINK ASSEMBLY, AND REPLACED THE DIMMER ASSEMBLY IAW MM 33-40-02.

Part: EXHAUST VALVE — DAMAGED (NR 3 CYLINDER) · airframe 25,477 hrs

CYLINDER REMOVED DUE TO LOW COMPRESSION AT INSPECTION. EXHAUST VALVE DISPLAYS EVIDENCE OF HEAT DAMAGE.

Part: CALIPER — DEFECTIVE (MLG BRAKE) · airframe 23,489 hrs · 6,772 cycles

RIGHT BRAKE PEDAL INEFFECTIVE. PEDAL GOES TO FLOOR & DOES NOT HOLD ACFT DURING RUN-UP. R & R THE RT BRAKE CALIPER & BRAKE PADS.

Part: BEAM — CRACKED (RT NACELLE) · airframe 22,607 hrs

DURING ROUTINE SCHEDULED INSPECTION, THE RT NACELLE INBD ENG BEAM WAS FOUND TO BE CRACKED AT INBD AFT FACE. CORRECTIVE ACTION WILL BE TO REMOVE & INSTALL NEW RT NACELLE INBD ENG BEAM IN ITS ENTIRETY. A SUPPLEMENT TO THIS SDR HAS BEEN SUBMITTED TO FURTHER OUTLINE DAMAGE POINT LOCATION & DETAILS.

Part: BEAM — CRACKED (RT NACELLE) · airframe 22,607 hrs

DURING ROUTINE SCHEDULED INSPECTION, THE RT NACELLE CROSSOVER BEAM WAS FOUND TO BE CRACKED AT LWR U CHANNEL. CORRECTIVE ACTION WILL BE TO REMOVE & INSTALL RT NACELLE CROSSOVER BEAM IN ITS ENTIRETY. A SUPPLEMENT TO THIS SDR HAS BEEN SUBMITTED TO FURTHER OUTLINE DAMAGE POINT LOCATION & DETAILS.

Part: SPAR — DAMAGED (ZONE 100) · airframe 21,531 hrs

DAMAGE WAS DISCOVERED ON THE FRONT UPPER SPAR CAP. OPEN

Part: SPAR CAP — CRACKED (ZONE 100) · airframe 21,531 hrs

DURING A SCHEDULED MX EVENT CRACKS FOUND ON THE REAR SPAR WEB CRACKS AT FLOOR SUPPORT LOCATIONS. THERE WERE ALSO 5 MISS DRILLS IN THE TOP OF THE REAR SPAR THAT WERE NOTED. AFTER REVIEWING ENGINEERING REPAIR OPTIONS, THE DECISION WAS MADE TO REPLACE REAR SPAR CAP. REPAIRS ARE CURRENTLY BEING WORKED.

Part: DRAG BRACE — CRACKED (NLG) · airframe 20,660 hrs

AT SCHEDULED INSPECTION, NLG DRAG BRACE, PN 5142002-5, WAS FOUND TO BE CRACKED IN THE AREA OF NLG ACTUATOR ATTACH POINT. METHOD OF INSPECTION WAS DYE PENETRANT. THIS CRACK WAS FOUND TO BE BEYOND LIMIT ALLOWABLE OF MEB91-11R1. THIS UNIT HAS BEEN SCRAPPED & A REPLACEMENT DRAG BRACE HAS BEEN INSTALLED IN ACFT.

Part: FLEX DUCT — DETERIORATED (CABIN FLOOR DUCT)

DURING C-CHECK, BY ACCESS OF FUSELAGE REPAIR, IT WAS FOUND THAT FLEXIBLE AIR CONDITIONING DUCTS WERE BADLY DETERIORATED. FOAM ON INSIDE OF DUCTS WERE COMING LOOSE AND SOME OF DUCTS WERE COLLAPSED. THESE DUCTS ARE JUST PLAIN OLD. MFG TIME LIMITS DO NOT COVER THESE DUCTS AND DURING 800 HOUR C-CHECK AIRFRAME INSP THERE IS NOT A REQUIREMENT TO INSPECT INSIDE OF DUCTS FOR BLOCKAGE OR COLLAPSED DUCTS. FLEX DUCTS CONNECT BELOW THE BLOW AND RUN UP SIDE OF THE FUSELAGE TO LWR AIR CONDITIONING VENTS. THESE ARE NOT HOT AIR DUCTS, UNDER A UNFORSEEN CIRCUMSTANCE, POSES A POSSIBLE FIRE HAZARD IF DUCT TEMPERATURES GET HOT. CALLED MFG TO GET FLEX DUCTS, PN CROSSED TO A NEW STYLE DUCT (PN BWT103080360A.) (K)

Part: POSITION SWITCH — FAULTY (MLG)

UPON APPROACH INTO OMA, LANDING GEAR WAS EXTENDED, RIGHT MAIN GEAR DOWN/LOCKED LIGHT FAILED TO ILLUMINATE. COCKPIT LIGHT TESTED GOOD. EMERGENCY GEAR EXTENSION WAS PERFORMED IAW WITH CHECKLIST. RIGHT GEAR DOWNLOCKED WAS STILL NOT ESTABLISHED. EMERGENCY LANDING WAS PERFORMED. AIRCRAFT THEN ACCOMPLISHED FERRIED FLIGHT TO DUNCAN AVIATION AT LINCOLN. DUNCAN FOUND DOWNLOCKED INDICATION. REPLACED FAULTY SWITCH. (M)

Part: HYDRAULIC LINE — BURST (HYD SYSTEM)

NR 2 ENGINE HYDRAULIC PUMP LINE BURST.