N409BK

Part: PACKING — LEAKING (FUEL SYSTEM) · airframe 28,782 hrs · 19,625 cycles

THE PILOT REPORTED A FUEL SMELL IN COCKPIT. MAINTENANCE INSPECTED AND FOUND THE CABIN HEATER FUEL FILTER BOWL LEAKING. REMOVED AND REPLACED THE BOWL SEAL WITH NO FURTHER DEFECTS NOTED.

Part: SPAR CAP — CORRODED (VERTICAL STAB) · airframe 28,673 hrs · 19,430 cycles

DURING MAINTENANCE TWO SPOTS OF CORROSION WERE VISUALLY IDENTIFIED ON THE AFT LEFT HAND VERTICAL SPAR CAP (P/N: 5131007-5) OF THE  VERTICAL STABILIZER. THESE SPOTS EXIST AT APPROXIMATE W.L 156.52 AND W.L. 167.52, AND HAVE A MAXIMUM DEPTH OF .033 INCHES. THIS DEPTH IS IN EXCESS OF BLENDING LIMITS OUTLINED IN CESSNA AIRCRAFT COMPANY'S SUPPLEMENTAL INSPECTION NUMBER 55-30-01. THIS CAP WILL BE REMOVED AND REPLACED USING NEW PARTS.

Part: SPAR CAP — CRACKED (WING) · airframe 27,433 hrs · 17,751 cycles

A CRACK WAS IDENTIFIED AT THE LT SIDE OF LWR FWD CARRYTHROUGH SPAR CAP, IB MOST AFT FASTENER HOLE WHILE PERFORMING NDT PROCEDURE AS AMOC FOR AD2018-03-03R1. THE CRACK WAS CONFIRMED WITH BOLT HOLE EDDY CURRENT AFTER THE FASTENER WAS REMOVED. WE BELIEVE THIS SPAR CAP/WING JOINT FITTING ASSEMBLY TO BE UNTOUCHED SINCE ORIGINAL ASSEMBLY BASED ON THE FASTENER STYLE INSTALLED, AFTT, AND RECORDS REVIEW. THE CRACK IS NOT DETECTABLE WITH MAGNIFIED VISUAL INSPECTION. THE SPAR CAP WILL BE REPLACED.

Part: ATTACH FITTING — CORRODED (RT WING) · airframe 27,426 hrs · 17,506 cycles

DURING MAINTENANCE CORROSION WAS DISCOVERED ON THE RIGHT HAND UPPER AFT WING FITTING (P/N: 0822550-46) IN THE WHEEL WELL. THIS FITTING WILL BE REMOVED AND REPLACED WITH A NEW PART. A PICTURE HAS BEEN ATTACHED TO THIS SDR FOR FURTHER DETAILS AND CLARITY.

Part: GASKET — TORN (HEATER) · airframe 27,231 hrs

PILOT REPORTED A FUEL SMELL WHEN TURNING ON CABIN HEAT. MAINTENANCE INSPECTED AND FOUND THE HEATER FUEL FILTER GASKET IN NEED OF REPLACEMENT, THE GASKET WAS REPLACED WITH NO FURTHER DEFECTS NOTED.

Part: SPARK PLUG — FAILED (ENGINE) · airframe 25,175 hrs · 14,654 cycles

PILOT REPORTED THE LEFT ENGINE WOULD NOT DEVELOP FULL POWER, STOPPED AT 26 INCHES MAP AND VIBRATION. INSPECTION OF THE LEFT ENGINE REVEALED A PREIGNITION EVENT IN THE NR 3 CYLINDER WHICH CAUSED SIGNIFICANT DAMAGE TO THE PISTON HEAD. THE CYLINDER IS IN THE PROCESS OF BEING REPLACED. SUSPECT SPARK PLUG INSULATOR FAILURE TO BE THE CAUSE OF THIS EVENT. FURTHER DETAILS WILL BE PROVIDED UPON DETERMINATION OF THE SPARK PLUG PERFORMANCE.

Part: EXHAUST VALVE — DAMAGED (NR 4 CYLINDER) · airframe 24,770 hrs

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

Part: TRANSISTOR — FAILED (COCKPIT) · airframe 23,778 hrs · 12,496 cycles

PILOT REPORTED SMOKE COMING FROM PANEL LIGHT RESISTOR. R & R THE DIMMER ASSEMBLY FOR INSTRUMENT LIGHTS. REPLACED Q7 TRANSISTOR FOR DIMMER SWITCH IAW MM 33-10-105 & WDM 33-10-00.

Part: ENGINE — FAILED (LEFT) · airframe 21,948 hrs

OPERATING FLIGHT 1821 ALB TO MSS RETURNED TO ALB IMMEDIATELY AFTER TAKEOFF & LANDED SAFELY WITH 3 PAX ON BOARD. PILOT NOTED DECREASING LT ENG OIL PRESS & HEARD A LOUD BANG FROM LT ENG AFTER ROTATION. LT ENG MAGNETO SEPARATED FROM ACCESSORY DRIVE & CONNECTING ROD PENETRATING CASE. SIGNIFICANT DAMAGE TO UPPER LT ENG COWLING. CORRECTIVE ACTION WILL BE TO REPLACE ENGINE ASSEMBLY, REPLACE ALL ENG DRIVEN ACCESSORIES, REPLACE PROPELLER, FLUSH & INSPECT ALL FLUID CARRYING LINES & HOSES PRIOR TO RELEASE. ENG ASSEMBLY WILL BE ROUTED TO OEM ANALYTICAL DEPARTMENT FOR COMPLETE TEARDOWN INSPECTION, REPORT OF FINDINGS & WARRANTY CONSIDERATION. PROPELLER WILL BE SHIPPED TO PROPELLER REPAIR STATION FOR DISASSEMBLY & INSPECTION AS A PRECAUTION FOR POSSIBLE METAL CONTAMINATION. AFFECTED ACCESSORIES WILL BE ROUTED TO APPROPRIATE VENDORS FOR DISASSEMBLY & INSPECTION AS A PRECAUTION FOR POTENTIAL METAL CONTAMINATION. LT NACELLE UPPER COWLING WILL BE REPLACED.

Part: GOVERNOR — INOPERATIVE (PROPELLER) · airframe 20,786 hrs

PILOT REPORTED THAT WHEN REDUCING POWER WHILE TRANSITIONING FROM CLIMB TO CRUISE, THE LT ENGINE PROPELLER RPM STAYED AT FULL RPM AND WOULD NOT REDUCE. THE PILOT ELECTED TO RETURN TO THE DEPARTURE AIRPORT. AFTER MX INSPECTION, THE DISCREPANCY WAS UNABLE TO BE DUPLICATED. AS A PRECAUTION, THE PROP GOVERNOR WAS R & R AND THE ACFT WAS RETURNED TO SERVICE.

Part: LATCH — OUT OF ADJUST (EMERGENCY EXIT) · airframe 20,698 hrs

PILOT REPORTED THAT AFTER TAKEOFF, DURING CLIMB, EMERGENCY EXIT DOOR LOCATED ON THE RT SIDE OF THE AFT, OPENED UNCOMMANDED. SAFELY RETURNED TO THE DEPARTURE. DURING INSPECTION, DOOR LATCHES WERE FOUND TO BE OUT OF ADJUSTMENT. LATCHES WERE ADJUSTED IAW MM.

Part: DOUBLER — CRACKED (FUSELAGE) · airframe 20,534 hrs

DURING A ROUTINE SCHEDULED MX EVENT, A CRACK WAS DISCOVERED IN THE RT FORWARD NLG TUNNEL WEB 00DOUBLER AT FS 44.00 IN THE AREA OF THE RT NLG TRUNNION BEARING BLOCK FORWARD MOUNT HOLE LOCATIONS. DETERMINED TO BE A REMOVAL AND REPLACEMENT OF OWNER PRODUCED WEB DOUBLER.

Part: DRAG BRACE — CRACKED (NLG)

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: DRAG BRACE — CRACKED (NLG) · airframe 20,174 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: SWITCH — SHORTED (CABIN HEAT) · airframe 18,170 hrs

CREW REPORTED, ON DESCENT, NOTICED AN ODOR AND SAW SMOKE COMING FROM CABIN HEAT SWITCH. EMERGENCY WAS DECLARED, DEACTIVATED ALL ELECTRICAL SYS AND SMOKE STOPPED. TURNED ON SELECTIVE ELECTRICAL EQUIPMENT ON TO FINISH APPROACH, LANDING WAS UNEVENTFUL. MX FOUND CABIN HEAT SWITCH SHORTED. R & R SWITCH, SYS CHECKS OK. ACFT RELEASED BACK TO SERVICE.