N5074R

Part: HUB — DAMAGED (MAIN ROTOR)

FOUND THE UPPER M/R P/C LINK BEARING HAD WORN INTO THE ATTACH HUB OF THE PITCH HOUSING ABOUT .130 INCH UNTIL THE SPHERICAL PART OF THE BEARING CONTACTED, PREVENTING FURTHER PROGRESSION. (K)

Part: ADAPTER — WORN (DRIVE SPLINE)

DURING TURBINE REMOVAL IT WAS DISCOVERED THAT THE EPOXY WAS MISSING FROM THE GOVERNOR DRIVE ADAPTOR AND THAT THERE IS EXCESSIVE SPLINE WEAR BETWEEN THE ADAPTOR AND THE GOVERNOR DRIVE SHAFT. THE EPOXY PIECE WAS RECOVERED FROM THE ENGINE GEARBOX GOVERNOR DRIVE GEAR. GOVERNOR WAS REPLACED.

Part: BEARING — FAILED (M/R HUB)

369A1306-3 BEARING FOUND WITH TEFLON LINER FAILED. MDNC SOR NR 300194 AND MAINTENANCE DISCREPANCY REPORT DATED 02 OCT 2003.

Part: SEAL — LEAKING (FUEL PUMP)

AFTER OIL SEAL REPLACEMENT, AND REINSTALLATION OF FUEL PUMP, THE PUMP SHAFT SEAL WAS DISCOVERED LEAKING. DURING BOOST PUMP OPERATION FOR BLEEDING , FUEL SYSTEM ABOUT 50/60 + PER MINUTE DROP LATE. REPLACED PUMP

Part: BLEED VALVE — ERRATIC (ENGINE)

DURING FLIGHT THE COMPRESSOR STALLED A COUPLE OF TIMES. BOTH DURING A POWER CHANGE AND IN A STABLE POWER SETTING. REMOVED BLEED VALVE AND REPLACED WITH A SERVICEABLE UNIT AND THE PROBLEM WAS CORRECTED.

Part: GUIDE — BROKEN (MLG)

DURING 100/300 ROUTINE INSPECTION THE GUIDE TUBE FOR THE SPRING LOADED FILLETS WERE FOUND BROKEN ON (3) THREE LANDING GEAR.

Part: BEARING — INOPERATIVE (MLG)

FOUND LEFT FRONT MAIN LANDING GEAR KEEL BEARING AND RETAINER BACKED OUT OF KEEL FITTING. IT IS NORMALLY RETAINED WITH A CIRCLIP BUT IT WAS NOT ENGAGED BUT IT WAS CAPTURED BY THE BOLT. THE LIMIT OF REMOVAL WAS DEFINED BY THE FORK ON THE END OF THE LANDING GEAR LEG. THE ID OF THE BORE IN THE KEEL FITTING WAS WITHIN LIMITS AND A NEW RETAINER AND BEARING WERE INSTALLED WITH A NEW CIRCUP.

Part: IGNITION LEAD — CHAFED (ENGINE)

DURING POST-FLIGHT, IGNITION LEAD WAS FOUND CHAFING ON THE LOWER B-NUT OF THE PC AIR REFERENCE LINE ON THE GOVERNOR. FURTHER INSPECTION REVEALED THE ADEL CLAMPS FOR THE LEAD AND LINE, AT THAT POINT, WERE MISSING. REPLACED MISSING CLAMPS. (X)

Part: CLAMP — WRONG PART (TOT HARNESS)

DURING INSPECTION, THE ADEL CLAMP ON THE TOT LEAD AT THE EXHAUST CLAMP WAS FOUND TO BE THE WRONG PART NUMBER AND SUBSEQUENTLY THE CUSHION WAS UNABLE TO SURVIVE THE TEMPERATURES. REPLACED WITH PROPER PART NUMBER CLAMP. (X)

Part: SWASHPLATE — LACK OF LUBE (TAIL ROTOR)

DURING INSPECTION, THE TAIL ROTOR SWASHPLATE WAS FOUND LOW ON GREASE. FURTHER INSPECTION REVEALED NO DEFECTS AND UNIT WAS RE-GREASED AND RETURNED TO SERVICE. (X)

Part: FITTING — LOOSE (FUEL SYSTEM)

DURING INSPECTION, DISCOVERED THE FIREWALL FUEL FITTING (BULKHEAD FITTING) WAS LOOSE IN THE FIREWALL. RE-TORQUED JAM NUT. (X)

Part: SEAL — LEAKING (T/R TRANSMISSION)

DURING INSPECTION, FOUND THE TAIL ROTOR OUTPUT SEAL LEAKING. REPLACED SEAL. (X)

Part: SEAL — DELAMINATED (GEARBOX)

DURING REMOVAL OF TURBINE SECTION, A PREVIOUSLY REPAIRED AREA AROUND THE TURBINE SEAL BOSS ON THE GEARBOX COVER HAD DELAMINATED. REPLACED GEARBOX.

Part: COMBUSTION LINER — CRACKED (ENGINE)

DURING REPLACEMENT OF TURBINE, THE COMBUSTION LINER WAS FOUND CRACKED AT THE EXPANSION SLOTS AT THE DOUBLE LIP AND THE FUEL NOZZLE FERRULE HAS A DEEP STEP WORN AT THE 6 O'CLOCK POSITION.

Part: BLEED VALVE — INOPERATIVE (ENGINE)

PILOT ENCOUNTERED NUMEROUS RAPID COMPRESSOR STALLS IN A HIGH POWER SITUATION. FOUND SIDE SLOP ON BLEED VALVE POPPET AND A RATCHETY FEEL DURING MANUAL ACTUATION. REPLACED BLEED VALVE.

Part: DAMPER PIN — LOOSE (M/R HUB)

DURING POST-FLIGHT, THE 'GREEN' MAIN ROTOR DAMPER PIN WAS FOUND LOOSE. IT HAD WORKED UP TO A POINT WHERE THE BALE WAS CONTACTING THE DAMPER CLEVIS ALTHOUGH IT WAS STILL ENGAGED ON THE PIN.

Part: BLEED VALVE — INOPERATIVE (ENGINE)

DURING THROTTLE ROLL-ON DURING POWER RECOVERY FROM PRACTICE AUTOROTATION, THE PILOT EXPERIENCED A COMPRESSOR STALL. REPLACED BLEED VALVE.

Part: IGNITION LEAD — DAMAGED (ENGINE IGNITION)

(ALLISON EQUIVALENT P/N 6870855) ON INSPECTION, THE CONTACT SLEEVE AT THE 16NOTOR END WS FOUND TO BE MISSING THE CIRCLIP RETAINER AND THE CONTACT SLEEVE HAD SLIPPED BACK INTO THE INSULATOR.

Part: DAMPER PIN — LOOSE (M/R HUB)

DURING 100-HOUR INSPECTION, THE MAIN ROTOR DAMPER PINS WERE FOUND LOOSE AND ONE, THE 'BALE', WAS NOT ENGAGED PROPERLY. (THE PIN HAVING RISEN SO HIGH AS TO FORCE THE BALE OFF OF THE INDEX). INSPECTED, ADJUSTED, AND RE-INSTALLED TWO EACH (RED AND YELLOW).

Part: BUNGEE SOCKET — LOOSE (COLLECTIVE)

PILOT COMPLAINED OF A STIFF COLLECTIVE. FOUND COLLECTIVE BUNGEE BRACKET DEFLECTING EXCESSIVELY DURING CONTROL MOVEMENT. FOUND THE BUNGEE PLUNGER 369A 7372-5 DRAGGING WITHIN BUNGEE SOCKET 369A 7371-7. CLEANED OUT DRIED OUT MOLYBOENUM DISULPHIDE GREASE AND RE-LUBED.

Part: DAMPERS — WEAK (MLG)

BOTH DAMPERS WERE FOUND WEAK WITH FLUID SHOWING AROUND SEALS, SN 3244 AND SN 0887. REPLACED SEALS AND RE-SERVICED.

Part: BULB — FAILED (STROBE)

ON POST-FLIGHT, BOTH STROBES WERE FOUND INOPERABLE. THIS IS THE SECOND SET IN 73.6 HOURS. SUBSEQUENT INSPECTION FOUND THE WIRES AT THE LIGHT JUNCTIONS MIS-MARKED. REWIRED AND REPLACED BULBS.

Part: DAMPER PIN — LOOSE (M/R HUB)

DURING A 100-HOUR INSPECTION, THE DAMPER PIN WAS FOUND UNCOUPLED FROM THE PIN ADJUSTMENT NUT. INSPECTED, RE-TORQUED, AND RE-INSTALLED.

Part: TIME DELAY — MALFUNCTIONED (FUEL FILTER)

DURING A 100-HOUR INSPECTION OF ANTI-ICE FUEL FILTER ASSEMBLY, DISCOVERED THE TIME DELAY FOR THE BYPASS INDICATOR PRESS-TO-TEST WAS NOT DELAYING THE SIGNAL. REPLACED TIME DELAY.

Part: VENT — MISINSTALLED (FUEL TANK)

THE AIRCRAFT HAD FUEL DRIPPING FROM THE BELLY. FOUND FORWARD FUEL VENT WAS MIS-SHIMMED AT INSTALLATION. RE-SHIMMED AND REPLACED SEALS.

Part: TRANSCEIVER — MALFUNCTIONED (COCKPIT)

UPON TRANSMIT (INTERMITTENTLY), THE EPO SYSTEM WOULD BE ENERGIZED AS WELL AS THE FREQUENCY DISPLAY WOULD BLINK OUT. REMOVED AND REPLACED RADIO AND ALL WAS CURED.

Part: LIGHT — CONTAMINATED (HORIZONTAL STAB)

DURING INSPECTION, THE AFT TAIL LIGHT WAS FOUND INOPERABLE. FURTHER INSPECTION REVEALED TAIL LIGHT LENS WAS HALF FILLED WITH WATER. THE INSTALLATION OF THIS LIGHT ASSEMBLY LENDS ITSELF TO THIS TYPE OF DAMAGE DURING OPERATION IN RAINY WEATHER. (X)

Part: COVER PLATE — LOOSE (FUEL CELL)

DURING AN ANNUAL INSPECTION, A FUEL LEAK FROM THE AIRCRAFT BELLY WAS NOTED. SUBSEQUENT INSPECTION FOUND THE RIGHT HAND FUEL CELL COVER BOLTS (THUS THE COVER) WERE LOOSE. INSPECTED SEAL AND RETORQUED.

Part: PULLEY GUARD — WORN (OIL COOLER FAN)

DURING AN ANNUAL INSPECTION, THE OIL COOLER BLOWER PULLEY GUARD ON THE M/R TRANSMISSION WAS FOUND TO BE SEVERELY WORN IN THE AREA OF THE BLOWER BELT. NO EVIDENCE OF BELT DAMAGE. REPLACED PULLEY GUARD.

Part: SWITCH — FAILED (COMM TRANSMIT)

PILOT COMPLAINED THE TRANSMIT SWITCH WOULD STICK PERIODICALLY. REPLACED SWITCH.

Part: PIVOT PIN — WORN (M/R HUB)

DURING AN ANNUAL INSPECTION OF THE MAIN ROTOR, ALL PIVOT BEARINGS WERE FOUND WORN BEYOND LIMITS AND ONE FAR ENOUGH TO WEAR INTO AND SCRAPPING ONE OF THE PIVOT PINS. REPLACED AFFECTED PARTS.

Part: CONNECTOR — DEFECTIVE (N2 TACH GEN)

DURING AN ANNUAL INSPECTION, THE N2 TACHOMETER GENERATOR PLUG WAS FOUND TO HAVE BUT ONE STRAND REMAINING ON ONE OF THE WIRES. REPAIRED WIRE/PLUG.

Part: BEARING — WORN (M/R HUB)

DURING AN ANNUAL INSPECTION OF THE MAIN ROTOR, ALL PIVOT BEARINGS WERE FOUND WORN BEYOND LIMITS AND ONE FAR ENOUGH TO WEAR INTO AND SCRAPPING ONE OF THE PIVOT PINS. REPLACED AFFECTED PARTS.

Part: SPRING — BROKEN (EXH CLAMP)

DURING AN ANNUAL INSPECTION, THE AFT EXHAUST CLAMP RETAINING SPRING WAS FOUND BROKEN. REPLACED SPRING.

Part: EXHAUST — CRACKED (RT STACK)

DURING AN ANNUAL INSPECTION, THE RIGHT HAND EXHAUST STACK WAS FOUND CRACKED ON THE INSIDE DIAMETER OF THE ELBOW FOR ABOUT 5 INCHES FORWARD AND INTO THE FLANGE THAT CONTACTS THE ENGINE EXHAUST COLLECTOR. REPLACED STACK.

Part: CYCLIC STICK — LOOSE (FLT CONTROL)

DURING AN ANNUAL INSPECTION WHILE PERFORMING THE CYCLIC STICK SLACK INSPECTION, THE LATERAL PIVOT BOLT WAS FOUND LOOSE CAUSING FORE AND AFT SLACK. REPLACED BEARINGS AND RETORQUED THE BOLT.

Part: ACTUATOR — FAILED (ENGINE ANTI-ICE)

DURING AN ANNUAL INSPECTION OF THE ENGINE ANTI-ICE VALVE SYSTEM, FOUND THE ACTUATOR ERRATIC (THIS AIRCRAFT HAS BEEN MODIFIED, BY FIELD APPROVAL, FOR INSTALLATION OF THE BELL HELICOPTER 206B ENGINE ANTI-ICE ACTUATOR SYSTEM). REPLACED ACTUATOR.

Part: TURBINE — SMOKING (EXH COLLECTOR)

19.4 HOURS AFTER A REPAIR TO THE TURBINE PT SUPPORT, THE TURBINE STARTED SMOKING HEAVILY ON SHUT DOWN. AFTER THE ENGINE COOLED, A VISUAL INSPECTION FOUND OIL PUDDLING IN THE TURBINE EXHAUST COLLECTOR. UNIT SENT BACK FOR REPAIR.

Part: LINE — CHAFED (ENGINE FCU)

DURING RE-ASSEMBLY OF THE ENGINE, IT WAS FOUND THAT THE FUEL LINE FROM FCU TO THE CHECK VALVE WAS CONTACTING ANOTHER LINE. NORMALLY, THIS INDICATES IT IS INSTALLED BACKWARDS, BUT IN THIS CASE, IT HIT BOTH WAYS. NO PART NUMBER WAS FOUND ON THE TUBE, AND A NEW TUBE RECTIFIED THE PROBLEM. SUSPECT IT HAD BEEN A 'FIELD FIX' SOME TIME PAST.

Part: BREAKER — FAILED (CARGO HOOK)

CARGO HOOK DID NOT FUNCTION. FOUND CIRCUIT BREAKER WAS INOPERATIVE. AFTER REMOVING CIRCUIT BREAKER COULD HEAR A RATTLE WHEN SHAKING.

Part: BELL MOUNT — DETERIORATED (ENGINE INLET)

FOUND ON REMOVAL OF THE ENGINE THAT THE INLET BELL MOUNT WAS NO LONGER PLIABLE, BUT RIGID AND BRITTLE. REPLACED WITH NEW PART.

Part: ACTUATOR — DEFECTIVE (GOV)

DURING RUN-UP IT WAS DISCOVERED THE GOV NEEDED CONSTANT ADJUSTMENT UP AND DOWN WITH THE TRIM MOTOR. IT WAS FOUND THAT THE TRIM MOTOR HAS SOME INTERNAL SLOP. REPLACED TRIM MOTOR.

Part: PANEL — CRACKED (XMSN SUPPORT)

SUBMITTER STATED THIS IS NOT AN UNCOMMON PROBLEM. THIS PANEL IS ATTACHED TO THE AFT BOTTOM OF THE TRANSMISSION SUPPORT STRUCTURE AND ALSO ATTACHES TO THE REAR DOOR FRAME AS IT COMES UP TO THE TRANS SUPPORT. IT WAS FOUND CRACKED BETWEEN 3 RIVET HOLES WHERE IT ATTACHES TO THE SUPPORT. THE SUPPORT IS STAINLESS STEEL AND THE PANEL IS ALUMINUM AND THE ATTACHING RIVETS ARE DASH 5 MODELS. I BELIEVE THE ACT OF INSTALLING THESE HARD RIVETS AIDS IN THE FAILURE OF THESE PANELS.

Part: HARNESS — CHAFED (SCAV AIR SYSTEM)

FOUND SCAV AIR SOLENOID WIRE HARNESS WAS CHAFING ON THE COOLING DUCT FOR THE TRANS OIL COOLER. REPLACED HARNESS.

Part: RING GEAR — SPALLED (M/R XMSN)

OPENED TRANSMISSION TO INSPECT FOR WEAR AND FOUND M/R OUTPUT SHAFT RING GEAR 369D25127-11, S/N 005570-1089, AND PINION 369D25125-13, S/N 005570-0437, SPALLED IN SEVERAL PLACES. REPLACED TRANSMISSION. SENT THIS ONE IN FOR OVERHAUL.

Part: TURBINE — CRACKED (PT SUPPORT)

DURING REPLACMENT OF THE NR 1 NOZZLE, A CRACK WAS FOUND IN THE P/T SUPPORT BODY JUST AFT OF THE 6 AND 7 BEARING. SUMP BOSS UNIT WAS SENT IN FOR REWORK.

Part: BEARING — SPALLED (ENG GEARBOX)

PILOT HAD JUST RUN THE ENGINE UP TO FLIGHT IDLE IN PREPARATION FOR TAKEOFF WHEN THE ENGINE CHIP LIGHT ILLUMINATED. A LARGE CHIP .0937 INCH BY .0625 INCH WAS FOUND ON THE UPPER CHIP PLUG AND SUBSEQUENT INSPECTION FOUND 2 ROLLERS WITH DEEPLY SPALLED AREAS ON THE WORKING SURFACES.

Part: CASE HALF — CRACKED (COMP)

DURING ANNUAL INSPECTION THE ENG COMPRESSOR CASE HALVES WERE INSPECTED AND FOUND TO BE CRACKED AND LIFTING. REPLACED CASE HALVES.

Part: NOZZLE — BENT (XMSN OIL)

DURING OVERHAUL OIL NOZZLE WAS FOUND BENT - PART WAS REPLACED.

Part: SEAL — LEAKING (MR XMSN TACH GEN)

M/R TRANSMISSION WAS LEAKING AND SUBSEQUENT INSPECTION FOUND THE TACHOMETER GENERATOR SEAL WAS LEAKING. THE SEAL EDGE SEEMED TO BE ROUGH AND BURNT LOOKING. REPLACED SEAL.

Part: DRAIN VALVE — CRACKED (M/R XMSN)

DURING OVERHAUL, FOUND THE M/R TRANS DRAIN PLUGS CRACKED AT THE FLANGE COMPLETELY AROUND, BUT NOT YET ALL THE WAY THROUGH THE WALL. REPLACED PART.

Part: SHAFT — DAMAGED (T/R O/P)

DURING OVERHAUL INSPECTION OF M/R TRANS, THE T/R OUTPUT PINION SHAFT WAS FOUND DAMAGED BEYOND LIMITS FROM A BROKEN BEARING RACE GOUGING THE BEARING LAND AND RETAINING RING LIP.

Part: GOVERNOR — ERRATIC (ENGINE)

PILOT COMPLAINED OF ERRATIC OPERATION AND CONSTANT BEEP ADJUSTMENT. UNIT IS 344.6 HOURS SINCE REPAIR. THIS IS ANOTHER OF NUMEROUS GOVERNOR PROBLEMS.

Part: FCU — FAILED (ENGINE)

FCU CAUSED DELAYED LIGHT-OFF WHEN AT AMBIENT TEMP. UNITS REPLACED, STARTS NORMAL.

Part: HOUSING — DAMAGED (M/R XMSN)

DURING OVERHAUL INSPECTION OF M/R TRANSMISSION, A DEEP GOUGE .137 INCH WAS FOUND IN THE HOUSING COVER IN THE FWD T/R O/P PINION BEARING BOX CAUSED BY THE BEARING FAILURE.

Part: BEARING — FAILED (M/R XMSN)

DURING INSPECTION OF M/R TRANSMISSION AFTER CHIP LIGHT, THE FORWARD INPUT PINION BEARING WAS FOUND CONTAMINATED WITH IMPREGNATED METAL.

Part: BEARING — DEFECTIVE (M/R XMSN)

DURING INSPECTION OF MAIN ROTOR TRANSMISSION AFTER CHIP LIGHT, FOUND 369D25149 OUTPUT SHAFT BALL BEARING TO BE SEVERELY ETCHED ON ONE BALL.

Part: BEARING — CRACKED (MR GRBOX)

DISASSEMBLED MAIN ROTOR TRANSMISSION AFTER CHIP LIGHT. FOUND THE FORWARD SUPPORT BEARING FOR THE TAIL ROTOR O/P SHAFT HAD A CRACKED INNER RACE AND THAT IT HAD FORCED THE SNAP RING OFF OF THE END OF THE SHAFT AND THEN THE INNER RACE GOUGED INTO THE COVER ASSEMBLY ABOUT .125 INCH DEEP.

Part: TRANSMISSION — LEAKING (M/R)

REMOVED MAIN ROTOR TRANSMISSION FOR LEAKY INPUT SEAL. THIS IS THE SECOND TIME IN 102.8 HOURS THIS HAS BEEN DONE. SUBMITTER STATED THIS IS NOT AN ISOLATED INCIDENT EITHER.

Part: GOVERNOR — ERRATIC (ENGINE)

THIS IS THE SECOND TIME THIS UNIT HAS BEEN REMOVED FOR ERRATIC CONDITION. PILOT MUST MAKE CONSTANT ADJUSTMENTS TO THE GOVERNOR 'BEEP' WITH EVERY POWER CHANGE.

Part: GOVERNOR — ERRATIC (ENGINE)

PILOT COMPLAINED MANUAL BEEPING WAS REQUIRED FOR TAKEOFF, POWER CHANGES, AND LANDING. GOVERNOR UNIT REPLACED AND SENT IN FOR REPAIR.

Part: SHIELD — WARPED (NR 1 TURB NOZZLE)

DURING REPLACEMENT OF NR 1 TURBINE NOZZLE, THE NOZZLE SHIELD WAS FOUND WARPED OUT OF SHAPE. PART SENT IN FOR OVERHAUL.

Part: NOZZLE — BURNED (NR 1)

NR 1 NOZZLE WAS REPLACED DUE TO EROSION AND CRACKING BEYOND LIMITS. NOZZLE SENT IN FOR OVERHAUL.

Part: TRANSMISSION — MAKING METAL (M/R)

PILOT GOT A FLICKER ON M/R TRANSMISSION CHIP LIGHT, THEN IT STAYED OUT. PILOT CHECKED CHIP PLUG ON LANDING WITH THE LIGHT STILL OFF AND FOUND SEVERAL LARGE CHIPS ON BOTH PLUGS. UNIT REMOVED AND RETURNED FOR REPAIR.

Part: HARNESS — FAILED (TURB TOT)

TURBINE REMOVED FROM AIRCRAFT EARLIER AND REPLACED. DURING INSPECTION, TOT HARNESS FOUND CRACKED AT ONE OF THE PROBES (2:30 O'CLOCK POSITION). PART WAS SCRAPPED.

Part: CASE HALF — ERODED (COMPRESSOR)

DURING ANNUAL INSPECTION, THE COMPRESSOR CASE HALVES WERE FOUND ERODED BEYOND LIMITS. CASE HALVES WERE REMOVED AND SENT IN FOR OVERHAUL.

Part: GOVERNOR — ERRATIC (ENGINE)

DURING RUN-UP, PILOT WAS ADJUSTING ENGINE 'BEEP' AND THE GOVERNOR HESITATED, BUT WHEN AN INCREASE WAS NOTED, IT JUMPED UP 3 PERCENT TO 4 PERCENT AND WAS NOT A SMOOTH TRANSITION. PART SENT IN FOR REPAIR.

Part: BEARING — SPALLED (M/R XMSN)

MAIN ROTOR TRANSMISSION DISASSEMBLED AFTER CHIPS DISCOVERED ON THE CHIP DETECTOR. BEARING, 369D25140, FOUND HEAVILY SPALLED. REPLACED BEARING.

Part: TRANSMISSION — MAKING METAL (M/R)

DURING ANNUAL INSPECTION, CHIPS FOUND ON UPPER CHIP PLUG. UNIT REMOVED AND SENT FOR REPAIR.

Part: SUMP — WARPED (NR 6-7 BEARING)

DURING ANNUAL INSPECTION, NR 6 AND NR 7 BEARING SUMP ON THE TURBINE FOUND LEAKING AT THE MATING SURFACE. SUBSEQUENT INSPECTION REVEALED FLANGE WAS WARPED.

Part: TUBE — CRACKED (SCAVENGE AIR)

DURING INSPECTION OF SCAVENGE AIR SYSTEM, THE AIR TUBE WAS FOUND CRACKED ABOUT 4 INCHES ABOVE THE SOLENOID. IT APPEARS TO HAVE HAD WATER FROZEN AT THAT POINT AS THE TUBE IS EXPANDED ALONG THE CRACKED AREA AND RECENT TEMPERATURES HAVE BEEN SUB-ZERO.

Part: HOSE — LEAKING (SCAVENGE OIL)

DURING ENGINE REMOVAL, THE SCAVENGE OIL HOSE FOUND SET WITH OIL. SUBSEQUENT INSPECTION FOUND IT WAS LEAKING. REPLACED HOSE.

Part: SWITCH — INOPERATIVE (FUEL BYPASS)

DURING ENGINE REMOVAL, THE FUEL BYPASS SWITCH WAS REMOVED AND CHECKED, FOUND INOPERATIVE.

Part: CHIP PLUG — LEAKING (COMPRESSOR)

DURING REMOVAL OF COMPRESSOR, CHIP PLUG FOUND LEAKING PAST THE INSULATOR. REPLACED CHIP PLUG.

Part: PANEL — CRACKED (AIRFRAME)

DURING REMOVAL OF ENGINE, A CRACK WAS FOUND STARTING FROM THE RELIEF HOLE ON PANEL FORWARD .50 INCH AND .3750 INCH. REPAIR PANEL WITH A PATCH. IT APPEARS THE CLEARANCE BETWEEN THE RELIEF HOLE AND THE 369D23007-5 ANGLE WERE TOO TIGHT.

Part: PULLEY — SEIZED (ALT AIR DOOR)

DURING DAILY INSPECTION, ONE OF THE PULLEYS FOR THE ALTERNATE AIR DOOR CABLE WAS FOUND SEIZED. REPLACED THE PULLEY.

Part: SENSOR — OUT OF CALIB (ENG OIL)

PILOT COMPLAINED THE ENGINE OIL TEMP WAS TOO LOW. SUBSEQUENT INSPECTION FOUND TEMP BULB RESISTANCE TOO HIGH AND IT READ LOW ON FUNCTIONAL BENCH CHECK. REPLACED TEMP BULB.

Part: TRANSMISSION — LEAKING (M/R)

DURING INSPECTION, A LEAKY SEAL WAS DISCOVERED ON THE INPUT SHAFT OF THE TRANSMISSION. REPLACED TRANSMISSION.

Part: VALVE — LEAKING (ENGINE ANTI-ICE)

ANTI-ICE VALVE WAS LEAKING. FOUND THE PLUNGER WAS WORN ON ONE SIDE ALLOWING THE VALVE TO BE COCKED OFF ITS SEAT. REPLACED PART.

Part: COMBUSTION LINER — BURNED (ENGINE)

WHILE REMOVING TURBINE, THE COMBUSTION LINER WAS FOUND BURNED, WARPED, AND CRACKED. PART REPLACED.

Part: SWASHPLATE — DEFECTIVE (M/R)

PILOT COMPLAINED THAT FORE/AFT CYCLIC WAS A 'LITTLE NOTCHEY'. SUBSEQUENT INSPECTION FOUND THE UNIBAL LINER IN THE OUTER RACE WAS CONTAMINATED WITH GREASE OR OIL AND WAS ROUGH. REPLACED SWASHPLATE AND SENT THE OTHER IN FOR OVERHAUL.

Part: PIN — EXCESS WEAR (M/R BLADE)

WHILE REMOVING BLADES FOR M/R SWASHPLATE REPLACEMENT, ONE OF THE BLADE PINS WAS FOUND WITH ABNORMAL WEAR IN THE CAM HANDLE PIVOT BOSS. PIN RETURNED TO MDHC ON SOR NR 300165.

Part: UNILOCK — DEFECTIVE (CYCLIC)

PILOT COMPLAINED THE CYCLIC WOULD DRIFT AFT EVEN WITH TRIM SET. REPLACED UNILOCK, CURED THE PROBLEM. UNIT SENT IN FOR OVERHAUL.

Part: PIN — BROKEN (M/R HUB)

ON POST-FLIGHT, FOUND M/R BLADE PIN BROKEN AT THE END WHERE THE THREADS STOP. THIS IS THE SAME SERIAL NUMBERED PREFIX OF 2 OTHER BROKEN BLADE PINS IN THE LAST 12 MONTHS.

Part: HOUSING — WORN (COLLECTIVE)

PILOT REPORTED THE IDLE WAS TOO LOW AT LIGHT OFF AND TOO HIGH AFTER ROLL-DOWN FROM FLIGHT IDLE. AFTER A LENGTHY PROCESS OF POKING, RIGGING, AND PRODDING, DISCOVERED THE SWITCH HOUSING AT THE END OF THE COLLECTIVE WAS WORN AT ITS INTERNAL STOPS. REPLACED UNIT AND RIGGED THE THROTTLE SYSTEM.

Part: GYRO — DEFECTIVE (COCKPIT HORIZ)

PILOT COULD NOT ADJUST THE GYRO WITH THE CAGING KNOB. REMOVED AND REPLACED UNIT AND SENT IN FOR REPAIR.

Part: BEARING — DEFECTIVE (M/R TRANSMISSION)

DURING REPAIR OF M/R TRANSMISSION AFTER THE RING GEAR HAD FAILED, THE TRANSMISSION OUTPUT SHAFT DUPLEX BEARING ASSEMBLY WAS FOUND WITH A 'CLICK' IN IT AS IT ROTATED. BEARING WAS REMOVED AND SENT IN FOR OVERHAUL.

Part: COMPRESSOR — STALLS (ENGINE)

COMPRESSOR STALLS WITH SLIGHT BUT RAPID POWER CHANGES. NOTE: THIS ENGINE WAS REMOVED FROM ANOTHER A/C WITH THESE SYMPTOMS AND ANOTHER ENGINE INSTALLED SO IT COULD START A JOB. THIS COMPRESSOR WAS INSTALLED FOR TROUBLESHOOTING WHEN THIS ENGINE WAS INSTALLED IN 5074R. *(PREVIOUS MDR FOR THE SAME PROBLEM WAS FILLED OUT ON THIS ENGINE WHEN IT WAS INSTALLED ON N3115Y). BOTH COMPRESSORS HAVE BEEN SENT IN FOR REPAIR.

Part: STARTER — MALFUNCTION (ENGINE)

AIRCRAFT HAS HAD INTERMITTENT STARTER MOTORING PROBLEMS. ALL SYSTEMS WORKING, BUT IT WOULD NOT MOTOR WHEN START BUTTON WAS DEPRESSED AND NEXT TIME IT WOULD OPERATE FOR SEVERAL DAYS. FINAL REPLACEMENT OF STARTER SEEMS TO HAVE REMEDIED THE PROBLEM. UNIT SENT IN FOR REPAIR.

Part: GEAR TOOTH — FAILED (M/R XMSN)

PILOT REPORTED A M/R TRANS CHIP LIGHT. INITIAL INSPECTION FOUND A DOT SIZED CHIP. THE AIRCRAFT WAS RUN UP AND AT 108 PERCENT FLIGHT IDLE A LOUD KNOCKING NOISE WAS HEARD FROM THE TRANSMISSION. REMOVAL AND SUBSEQUENT DISASSEMBLY FOUND A 1 INCH SECTION OF A TOOTH MISSING FROM THE RING GEAR. THIS TOOTH DAMAGED THE REST OF THE GEARS IN THE TRANSMISSION.

Part: SUPPORT — DEFECTIVE (M/R HUB FAIRING)

ON PRE-FLIGHT, PILOT NOTICED A 'DIMPLE' AROUND AN ATTACHMENT SCREW ON THE MAIN ROTOR HUB FAIRING. SUBSEQUENT INSPECTION REVEALED THE TIP OF THE 'STAR' LEG WAS BENT CHANGING ITS ANGLE AND THE SCREW WOULD DIMPLE THE FAIRING IN AS IT WAS TORQUED. REPLACED FAIRING SUPPORT.

Part: AMPLIFIER BOX — FAILED (INTERCOM SYSTEM)

PILOT WOULD KEY HIS ICS AND THE ENTIRE SYSTEM WENT HOT AND WOULD STAY HOT UNTIL THE PILOT DEPRESSED THE RADIO TRANSMIT SWITCH. REPLACED ICS AMP BOX.