N406GA

Part: BLOWER — INOPERATIVE · airframe 38,419 hrs · 38,650 cycles

THE PILOT NOTED A BURNING SMELL IN FLIGHT, CABIN FAN CIRCUIT BREAKER POPPED. MAINTENANCE INSPECTED AND DETERMINED TO BE HEATER FAN INOPERATIVE, SYSTEM WAS DISABLED AND PLACED ON MEL, ADDITIONAL DETAILS CAN BE PROVIDED AFTER RECEIPT OF TEARDOWN INSPECTION REPORT.

Part: SPAR CAP — CORRODED (RT WING) · airframe 35,963 hrs · 35,220 cycles

CORROSION WAS DISCOVERED ON THE AFT LOWER OUTBOARD SPAR CAP. CORROSION WAS FOUND AT RWS 107.21 TO 111.781 ON THE BOTTOM OF THE HORIZONTAL LEG OF THE CAP. DEEPER THAN THE ALLOWABLE LIMITS IAW MEB 91-11 R1, SECTION 3, ITEM B. THE SPAR CAP WAS REPLACED.

Part: RIB — CRACKED (CLOSE OUT) · airframe 35,963 hrs · 35,220 cycles

DURING A ROUTINE INSPECTION, A CRACK WAS IDENTIFIED IN THE RT CLOSE OUT RIB. THE CRACK WAS FOUND FROM THE FORWARD ROW OF LOCK FASTENERS IN THE AFT TRUNNION SUPPORT TO THE AFT SIGNAL CONDITIONER MOUNTING UPRIGHT. THE CRACKED MEASURED OUT TO 2.60 INCHES IN LENGTH. ALL TRUNNION SUPPORT HOLES ARE WITHIN TOLERANCE. THE CLOSE-OUT RIB WAS REPLACED WITH NEW.

Part: INDICATOR — FAILED (COCKPIT) · airframe 35,733 hrs · 34,940 cycles

PILOT REPORTED BURNING SMELL FROM WEATHER RADAR WHEN TURNED ON. MAINTENANCE INSPECTED AND FOUND THE SOURCE TO BE A FAULTY INDICATOR. THE SYSTEM WAS PLACED OM MEL UNTIL SCHEDULED MAINTENANCE VISIT.

Part: WIRE — DAMAGED (VENT FAN) · airframe 35,008 hrs · 33,935 cycles

PASSENGER REPORTED BURNING ODOR OUT OF REAR OF AIRCRAFT. MAINTENANCE INSPECTED ALL AFT COMPARTMENT WIRING FOUND POWER WIRES FOR CABIN VENT FAN TO BE BEGINNING TO OVERHEAT DUE TO LACK OF INSULATION INTEGRITY. CUT BAD PORTIONS OF SPLICE ON THE POSITIVE AND NEGATIVE LINES. RE-SPLICED PROPERLY AND INSTALLED HEAT RESISTANT INSULATION AT BOTH POINTS. OPERATIONALLY CHECKED VENT FAN GOOD, WITH NO REMAINING BURNING ODOR IAW MM AND WIRING DIAGRAM MAINTENANCE MANUAL 21-20-00.

Part: EXHAUST VALVE — DAMAGED (NR 5 CYLINDER) · airframe 34,762 hrs

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

Part: EXHAUST VALVE — DAMAGED (NR 3 CYLINDER) · airframe 34,762 hrs

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

Part: GASKET — DEFECTIVE (HEATER) · airframe 34,059 hrs · 32,326 cycles

PILOT REPORTED STRONG SMELL OF FUEL, WHEN COCKPIT WITH THE HEATER RUNNING. R & R THE HEATER FUEL FILTER GASKET & PUMP OUTLET FITTING. OPERATIONALLY CHECKED GOOD.

Part: BEAM — CRACKED (RT NACELLE) · airframe 33,266 hrs

THE RT NACELLE CROSSOVER BEAM ASSEMBLY WAS FOUND TO BE CRACKED AT AFT FACE IN AREA OF TURBOCHARGER MOUNT BRACKET HOLE LOCATIONS DURING DISASSEMBLY OF TURBOCHARGER ASSEMBLY TO FACILITATE OTHER MAINTENANCE. CRACK LOCATED ADJACENT TO OTBD MOST TURBOCHARGER BRACKET HOLE LOCATION. REMOVE CROSSOVER BEAM ASSEMBLY, PERFORM DETAILED VISUAL INSPECTION OF SURROUNDING STRUCTURE & INSTALL NEW BEAM ASSEMBLY. A SUPPLEMENT ILLUSTRATING DAMAGE POINT WILL BE SUBMITTED ALONG WITH SDR.

Part: BEAM — CRACKED (RT NACELLE) · airframe 33,266 hrs

THE RT NACELLE INBD ENG BEAM WAS FOUND TO BE CRACKED JUST AFT OF AFT ENG MOUNT, TRANSVERSE TO LENGTH OF BEAM, ACROSS UPPER FACE OF BEAM, DURING NDT PRESCRIBED WITHIN MEL-54-01. REMOVE BEAM ASSEMBLY FROM NACELLE, PERFORM DETAILED VISUAL INSPECTION OF SURROUNDING STRUCTURE & INSTALL NEW BEAM ASSEMBLY. A SUPPLEMENT TO THIS SDR WILL BE SUBMITTED ILLUSTRATING RESULT OF X-RAY INSPECTION.

Part: SKIN — CORRODED (LT WING) · airframe 33,248 hrs · 31,163 cycles

DURING INSPECTION A LOWER WING FUEL LEAK WAS DISCOVERED. THE REPAIR TO THE LOWER WING CONSTITUTES A MAJOR REPAIR. REPAIRED THE LOWER WING ASSEMBLY, OEM PN 5122011-21, AT WING STATION 137.2 CTR IAW MEB95-11R1 & AMM D2527-10-13 AS REVISED CHAPTER 51, STRUCTURAL REPAIR, & AC43.13-1B SECTION 4. WEIGHT & BALANCE NOT AFFECTED BY THIS REPAIR.

Part: UNKNOWN — MALFUNCTIONED (LANDING GEAR) · airframe 32,650 hrs · 30,363 cycles

RIGHT MLG FAILED TO EXTEND. ACFT LANDED WITH THE RT MAIN GEAR UP. FURTHER INVESTIGATION REQUIRED TO DETERMINE CAUSE OF FAILURE.

Part: UNKNOWN — MALFUNCTIONED (FUEL SYSTEM) · airframe 32,122 hrs · 29,507 cycles

PILOT REPORTED LT ENG FUEL FLOW FLUCTUATES AROUND 100 PPH DURING CLIMB WITH FUEL PUMP, AUXILIARY, OFF. REPLACED LT ENG DRIVEN FUEL PUMP IAW CMI MANUAL & RELEASED FOR A FCF. THE FCF WAS UNSATISFACTORY. THE ACFT IS STILL IN MAINTENANCE. THIS REPORT WILL BE AMENDED AFTER FINAL REPAIRS ARE ACCOMPLISHED & SATISFACTORY. THIS SDR REMAINS OPEN AT THIS TIME.

Part: DRAG BRACE — CRACKED (NLG) · airframe 31,349 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 BEYOND LIMIT ALLOWABLE. THIS UNIT HAS BEEN SCRAPPED & A REPLACEMENT DRAG BRACE HAS BEEN INSTALLED IN ACFT.

Part: MASTER CYLINDER — LOW (ZONE 700) · airframe 30,274 hrs

ON LANDING, PILOT NOTICED THAT THERE WAS LITTLE TO NO PRESSURE WHEN APPLYING RIGHT BRAKE. LANDED AIRCRAFT SAFELY AND MAINTAINED DIRECTIONAL CONTROL. ON MAINTENANCE INSPECTION, SERVICED THE BRAKE MASTER CYLINDER, AND BLED THE SYSTEM IAW MM 32-40.

Part: BEAM — CHAFED (LT NACELLE) · airframe 30,174 hrs

DURING A SCHEDULED MX, INSPECTION OF THE LEFT NACELLE INBD ENGINE BEAM REVEALED A CHAFE. R & R BEAM WITH NEW PART.

Part: CROSSBEAM — CRACKED (LT NACELLE) · airframe 30,174 hrs

DURING A REGULARLY SCHEDULED MX, DAMAGE WAS NOTICED TO THE LT NACELLE CROSSOVER BEAM. UPON ARRIVAL IN FACILITY, CROSSOVER BEAM WAS FOUND CRACKED. R & R BEAM WITH NEW PART.

Part: DRAG BRACE — CRACKED (NLG) · airframe 27,159 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: O-RING — SPLIT (MLG STRUT) · airframe 26,232 hrs

CREW REPORTED THAT GEAR RETRACTION, LANDING GEAR WARNING HORN SOUNDED AND ALL THREE GEAR DOWN ANDM LOCKED LIGHTS REMAINED ILLUMINATED. TOWER FLY-BY REVEALED THAT GEAR DID NOT LOOK "NORMAL". CREW PERFORMED "GEAR WILL NOT EXTEND HYDRAULICALLY" PROCEDURE USING EMERGENCY EXTENSION SYSTEM. SECONG FLY-BY REVEALED GEAR STILL DID NOT LOOK " NORMAL". CREW DECLARED EMERGENCY, LANDIND WAS UNEVENTFUL. MAINTENANCE FOUND LEFT MAIN LANDING GEAR STRUT FLAT. MAINTENANCE REMOVED REPLACED UPPER TRUNNION O-RING. SERVICED STRUT, PERFORMED GEAR RETRACTION AND EXTENSION TEST, SYSTEM CHECKED OK. AIRCRAFT RELEASED BACK TO SERVICE.

Part: CIRCUIT BREAKER — UNSERVICEABLE (AVIONICS) · airframe 26,141 hrs

CREW REPORTED AVIONICS MASTER SWITCH INOPERATIVE. MX R & R CIRCUIT BREAKER SWITCH. SYS CHECKS OK. ACFT RELEASED BACK TO SERVICE.

Part: BEAM — CRACKED (LT NACELLE)

DURING ENGINE NACELLE INSPECTION, FOUND 1.5 INCH CRACK ON TOP REAR RADIUS OF CROSSOVER BEAM. REMOVED BEAN AND INSTALLED NEW BEAM IAW MFG MM. (NE01200502852) (K)

Part: MASTER SWITCH — INOPERATIVE (LT SWITCH PANEL)

ON PREFLIGHT, CREW REPORTED AVIONICS MASTER SWITCH, INOPERATIVE. MAINTENANCE REMOVED AND REPLACED THE SWITCH AND RETURNED THE AIRCRAFT TO SERVICE.

Part: BOLT — SHEARED (CRANKSHAFT)

RIGHT ENGINE WOULD NOT START. FORWARD DRIVE GEAR FOR STARTER ADAPTOR LOOSE IN ACCESSORY CASE. ALL 6 BOLTS SHEARED OFF CRANKSHAFT END.

Part: AXLE — CRACKED (RT MLG)

PILOT HAD DIFFICULTY DURING TAXI, RT WHEEL BINDING. MAINTENANCE FOUND BRAKE DISC CONTACTING LOWER BARREL OF STRUT. FOUND AXLE CRACKED UPON TIRE AND WHEEL REMOVAL.