N401TJ

Part: EXHAUST VALVE — FAILED (NR 5 CYLINDER) · airframe 24,884 hrs · 34,018 cycles

PILOT REPORTED "LEFT ENGINE RUNNING ROUGH AND WON'T IDLE BELOW 500 RPM". UPON INSPECTION MAINTENANCE FOUND THE NR 5 CYLINDER WAS READING ZERO COMPRESSION DUE TO AN EXHAUST VALVE CRACKED IN HALF. MAINTENANCE REPLACED THE CYLINDER AND PISTON ASSEMBLY WITH NO FURTHER DEFECTS NOTED.

Part: TORQUE TUBE — BROKEN (BRAKE PEDAL) · airframe 24,820 hrs · 33,876 cycles

PILOT REPORTED THE BRAKES FAILED PRIOR TO DEPARTURE. DURING INSPECTION, MAINTENANCE FOUND THE BRAKE PEDAL TORQUE TUBE CRACKED & BROKEN, REMOVED AND REPLACED TORQUE TUBE ASSEMBLY. NO FURTHER DEFECTS WERE NOTED.

Part: EXHAUST VALVE — DAMAGED (NR 2 CYLINDER) · airframe 24,688 hrs

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

Part: DOOR — OPEN · airframe 23,975 hrs · 32,207 cycles

PILOT REPORTED CREW DOOR IN FLIGHT UNLATCHED & CAME OPEN. INSPECTED THE DOOR LATCH MECHANISM WITH NO DEFECTS NOTED. DAMAGE NOTED AT FWD HINGE & REPAIRED AS NECESSARY. CREW WAS UNABLE TO VERIFY IF THE DOOR WARNING LIGHT HAD ILLUMINATED DURING FLIGHT.

Part: WIRE HARNESS — CHAFED (RT ENGINE) · airframe 23,402 hrs · 31,059 cycles

PILOT REPORTED SEEING SMOKE FROM RT ENG ON SHUT DOWN. FURTHER INVESTIGATION FOUND CHAFED WIRE HARNESS IN RT ENG BAY. ACFT IS CURRENTLY IN MX REPAIRING & REPLACING AFFECTED WIRING.

Part: CONTROL CABLE — FRAYED (RT ELEVATOR) · airframe 22,691 hrs · 29,491 cycles

DURING A PRE-FLIGHT INSPECTION THE PILOT REPORTED CAPTAINS CONTROL YOKE HAS A SPONGY FEEL WHEN PULLED AFT. MAINTENANCE INSPECTED & FOUND THE RT ELEVATOR CABLE, PN 5200008-31CR, FRAYED AT FS 112.07, ALONG WITH DAMAGE TO THE AILERON CABLE GUARD PIN PN NAS427K22. THE RT ELEVATOR CABLE WAS REPLACED IAW MM CHAPTER 27-30-01 & THE AILERON TRIM CABLE GUARD WAS REPLACED IAW MM CHAPTER 27-10-00. ANTI-CHAFE MATERIAL WAS PLACED AROUND THE STRUCTURE ROUTING HOLE IAW MM CHAPTER 5-20-01.

Part: DRAG BRACE — CRACKED (NLG) · airframe 19,833 hrs

AT SCHEDULED INSPECTION, NLG DRAG BRACE OEM 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 WITHIN ALLOWABLE LIMIT. THIS UNIT HAS BEEN REPAIRED IAW PROCEDURE OUTLINED IN CESSNA MEB941-11R1 & RETURNED TO SERVICE.

Part: DRAG BRACE — CRACKED (NLG) · airframe 19,684 hrs

AT SCHEDULED INSPECTION, NLG DRAG BRACE OEM 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 WITHIN ALLOWABLE LIMIT. THIS UNIT HAS BEEN REPAIRED IAW PROCEDURE OUTLINED IN MEB941-11R1 & RETURNED TO SERVICE.

Part: GYRO — UNRELIABLE (FWD AVIONICS BAY) · airframe 17,941 hrs

IFR CONDITIONS, CREW REPORTED HORIZONTAL SITUATION INDICATOR UNRELABLE IN SLAVE AND UN-SLAVE MODE. CREW ELECTED TO RETURN, DECLARED EMERGENCY, LANDED WITHOUT INCIDENT.

Part: GYRO — UNRELIABLE (DIRECTIONAL)

IFR CONDITION, CREW REPORTED HORIZONTAL SITUATION INDICATOR UNRELIABLE IN SLAVE AND UN-SLAVED MODE. CREW ELECTED TO RETURN, LANDED WITHOUT INCIDENT. MAINTENANCE REMOVED AND REPLACED KG-102 REMOTE GYRO. SYSTEM CHECKED OK. RELEASED BACK TO SERVICE.

Part: RELAY — BURNED (ZONE 500) · airframe 17,448 hrs · 18,089 cycles

SMOKE COMING OUT OFF THE COCKPIT. MAINTENANCE INSPECTED FOUND RIGHT ENGINE'S STARTER RELAY HAD FAILED. MAINTENANCE REMOVED AND REPLACED RELAY RETURNED AIRCRAFT TO SERVICE.

Part: CIRCUIT BREAKER — DEFECTIVE (AVIONICS)

CREW REPORTED AVIONICS MASTER SWITCH INOP. MX CHANGED CIRCUIT BREAKER SWITCH.

Part: FITTING — CORRODED (WING SPAR)

AFT SPAR REAR TOP WING ATTACH FITTING CORRODED. INSTALLED NEW FITTING.