N5632C

Part: DIAPHRAGM — LEAKING (FUEL PUMP)

MAINTENANCE REPLACED THE LOW PRESSURE FUEL PUMP DUE FUEL LEAKING FROM PRESSURE RELIEF PUMP DUE FUEL LEAKING FROM PRESSURE RELIEF CRANE SB. 101SB023 CONCERNING RELIEF COVER SCREW TORQUES AND LEAKS. POST REMOVAL TEARDOWN REVEALED A RUPTURED CONTROL DIAPHRAGM. THE PUMP HAD BEEN IN SERVICE FOR 9 MONTHS.(K)

Part: PUMP — LEAKING (LT ENGINE)

PILOT REPORTED FUEL LEAKING FROM LEFT COWLING AFTER SHUT DOWN ON THE RAMP, MAINTENANCE REPLACED THE LOW PRESSURE FUEL PUMP DUE FUEL LEAKING FROM PRESSURE RELIEF COVER GASKET. THIS PUMP WAS IN COMPLIANCE WITH CRANE SB. CONCERNING RELIEF COVER SCREW TORQUES AND LEAKS.

Part: BOLT — LACK OF LUBE (MLG)

AT CAMP INSPECTION, WHILE PERFORMING A SPECIAL INSPECTION AS DIRECTED BY MFG. FOUND RT MLG DRAG BRACE CENTER BOLT TO BE MISSING GREASE PASSAGES. THIS IS THE EXACT CONDITION THAT REQUIRED THE SPECIAL INSPECTION. REPLACED THE (PN 1018100903) BOLT WITH A NEW INSPECTED BOLT OF THE SAME PART NUMBER. THIS IS THE FIRST DEFECTIVE BOLT LOCATED OUT OF FOUR INSPECTED.

Part: VALVE — MISMANUFACTURED (DRAIN)

ON ROUTINE INSPECTION, FOUND ENGINE FORWARD AND AFT COMBUSTION CASE DRAIN VALVE LINES OVERHEATED. REMOVED DRAIN VALVES AND INSPECTED FOR CONDITION. DETERMINED THAT BOTH DRAIN VALVES HAD BEEN PREVIOUSLY INSTALLED WITH MISSING INTERNAL COMPONENTS. A TOTAL OF 118.6 HOURS HAD BEEN ACCUMULATED ON THE ENGINE SINCE INSTALLATION OF THE VALVES. REPLACED BOTH VALVES WITH COMPLETE ASSEMBLIES, REPLACED DRAIN LINES. A REVIEW OF THE ENGINE IPC DOES NOT SHOW AN ASSY PN FOR THE ENTIRE VALVE ALL INDIVIDUAL COMPONENTS (FOUR PARTS TOTAL) MUST BE PROCURED AND ASSEMBLED PRIOR TO VALVE INSTALLATION.

Part: LIGHT — BROKEN (MLG INDICATOR)

UPON LANDING GEAR RETRACTION AFTER TAKEOFF, LANDING GEAR DOWN AND LOCK GREEN LIGHTS REMAINED ILLUMINATED. GEAR WARNING HANDLE LIGHTS CONTINUED TO WORK CORRECTLY. AIRCRAFT MADE UNEVENTFUL LANDING IN ANCHORAGE AND MAINTENANCE REPLACED THE DEFECTIVE LAMP MODULE.

Part: GAS GENERATOR — SEIZED (RT ENGINE)

AC DEPARTED AND GOING THROUGH 5,000 FT THE COPILOT REPORTED SEEING AN ORANGE FLASH FROM THE RT ENGINE, THEN LOUD NOISE AND FLASH OF FIRE FROM THE NR 2 ENG EXHAUST, PILOT REPORTED THAT ENGINE SEIZED AND WAS SECURED. NO FIRE WARNING WAS RECEIVED AND THE FIRE EXTINGUISHING BOTTLE WAS NOT DISCHARGED. THE AC RETURNED AND MADE AN UNEVENTFUL LANDING. THE OIL FILTER HAS BEEN INSPECTED AND FOUND CLEAN, THE COMPRESSOR IS SEIZED AND HAS HEAVY RUB/BLADE FAILURE ON THE FIRST STAGE COMPRESSOR AND ON THE COMPRESSOR TURBINE BLADES. ENGINE IS REMOVED FOR MAJOR REPAIR.

Part: OIL COOLER — CRACKED (NR 2 ENGINE)

FLIGHT CREW PERFORMED IN-FLIGHT SHUTDOWN OF THE NR 2 ENGINE ONE HALF HOUR PRIOR TO REACHING THE DESTINATION AIRPORT, DUE TO LOW ENGINE OIL PRESSURE INDICATION. UNEVENTFUL LANDING. A SUSPECTED OIL LEAK WAS REPAIRED AND THE AIRCRAFT DEPARTED AND AGAIN THE NR 2 ENGINE WAS SECURED PRIOR TO ARRIVAL AT DESTINATION. AN UNEVENTFUL LANDING WAS PERFORMED. AGAIN, A SUSPECTED OIL LEAK WAS REPAIRED AND AIRCRAFT RETURNED.

Part: SPRING — BROKEN (PROPELLER)

FLIGHT CREW REPORTED PROPELLER NOT GOING INTO FULL FEATHER AT ENGINE SHUT DOWN. INSPECTION REVEALED THAT ALL PROP BLADES WERE FREE TO TWIST 45 DEG.+ BY HAND. THERE WERE NO EXTERNAL FAULTS VISIBLE AND THE DOME MOVED FREELY WITH THE BLADES. DETAILED INSPECTION REVEALED THAT THE FEATHER SPRING HAD SHATTERED IN MANY LOCATIONS. CAUSE OF FAILURE HAS NOT BEEN DETERMINED.

Part: ENCODER — FAILED (COCKPIT)

ALTIMETER QUIT AT 950 FEET. ENCODING FUNCTION ALSO QUIT. FLAG DROPPED AND STAYED IN VIEW. UNIT BENCH CHECKED AS INOPERABLE. SUBMITTER STATED THIS IS THE SECOND UNIT, OF THIS PART NUMBER, IN A WEEK TO FAIL. (X)

Part: SWITCH — OUT OF ADJUST (NLG)

NOSE GEAR DOWN AND LOCKED LIGHTS FAILED TO ILLUMINATE WITH LANDING GEAR SELECTED DOWN FOR LANDING AT NOME, ALASKA. AN UNEVENTFUL LANDING WAS PERFORMED AT NOME. THE PILOT VISUALLY INSPECTED THE GEAR AFTER LANDING AND AFTER WIGGLING THE NOSE GEAR DOWN AND LOCKED SWITCH, GOT DOWN AND LOCKED INDICATION. AIRCRAFT RETURNED TO ANCHORAGE AND MAINTENANCE ADJUSTED THE DOWNLOCK SWITCH. SYSTEM OPERATION CHECKED GOOD.

Part: COOLER — CRACKED (ENGINE OIL)

MECHANICS NOTICED OIL LEAKING FROM NR 1 ENGINE LOWER CHIN COWLING. REMOVED COWLING AND FOUND OIL COOLER LEAKING AT EDGE WELD. REPLACED OIL COOLER WITH 0 TSN UNIT. SERVICED OIL RESERVOIR WITH 2 QUARTS. THIS IS THE SECOND OIL COOLER TO FAIL ON THIS AIRCRAFTS NR 1 POSITION WITHIN ONE WEEK. BOTH UNITS WERE 0 TIME SINCE OVERHAUL FROM SOUTHWEST COOLER SERVICE, INC AT TIME OF INSTALLATION. BOTH UNITS CRACKED OUT AN EDGE WELD IN THE SAME PLACE. (M)

Part: COOLER — CRACKED (NR 1 ENGINE OIL)

TWENTY MINUTES SOUTH OF BARROW, AK, LOST OIL PRESSURE ON NR 1 ENGINE AND LOW OIL PRESSURE LIGHT CAME ON. ENGINE SECURED AND AN UNEVENTFUL LANDING WAS EXECUTED. VERIFIED LOW OIL LEVEL. VERIFIED CRACKED OIL COOLER. REPLACED OIL COOLER AND COMPLIED WITH OIL FILTER INSPECTION. (M)

Part: FUEL HEATER — CRACKED (ENGINE)

LOWER BOTTOM PLADE CRACKED AT EDGE WELD. LARGE QUANTITY OF OIL LOST. THIS IS THE SECOND FAILURE, CRACK, ON THIS FUEL HEATER IN 40.8 HOURS. SUSPECT IMPROPER/POOR REPAIR AND TEST PROCEDURES AT OVERHAUL BY VENDOR.

Part: FUEL CELL — CONTAMINATED (WS 171-183)

THE WING IS CONSTRUCTED IN A WAY THAT TRAPPED WATER CANNOT BE DRAINED FROM THE TRAILING EDGE OF THE FUEL STORAGE AREA BETWEEN WS 171.29 AND WS 183.07. THE SAME PROBLEM IS IN BOTH WINGS. A DRAIN PATH NEEDS TO BE PROVIDED.

Part: SPAR — CORRODED (RT WING)

FOUND MAIN SPAR LOWER CAP SEVERELY CORRODED. THIS CORROSION WAS FOUND WHERE MAIN SPAR PASSES THROUGH FUSELAGE BENEATH AIR CONDITIONER LOCATION. SUSPECT MOISTURE FROM AIR CONDITIONER COLLECTED ON SPAR CAUSING CORROSION. LOCATION FURTHER IDENTIFIED AS FS 288.0, FROM WS 0.0 TO RT WS 27.0.

Part: SPAR CAP — CORRODED (CENTER SECTION)

FOUND CORROSION ON FORWARD SIDE OF MAIN WING SPAR LOWER CAP BOND ASSEMBLY. THE AFFECTED AREA IS UNDER THE CABIN FLOOR IN THE CABIN. CORROSION DAMAGE FOUND TO REQUIRE REPLACEMENT OF THE SPAR CAP BOND ASSEMBLY.

Part: NUT — MISSING (HANDLE ARM)

THREE UPPER AIRSTAIR DOOR LATCHES FAILED TO PROPERLY LATCH AND CAUSED DOOR FRAME TO FAIL WHILE IN PRESSURIZED FLIGHT. AIRCRAFT DE-PRESSURIZED AND THE PILOT RETURNED TO THE POINT OF DEPARTURE WITHOUT FURTHER INCIDENT. SUSPECT FAILURE OF LATCHING MECHANISM PUSH ROD ATTACHMENT HARDWARE THAT PREVENTED ALL LATCH CAMS FROM FULLY ROTATING AND CAPTURING DOOR FRAME LUGS.

Part: WIRE — CHAFED (WS 69)

EN ROUTE TO BRW, FLIGHT CREW HEARD STATIC IN HEADSET, SAW LOADMETER 'SPIKE' AND THE LANDING GEAR CONTROL CIRCUIT BREAKER TRIPPED. FLIGHT CREW RESET CIRCUIT BREAKER AND DESCENDED TO BRW. UPON SELECTING LANDING GEAR DOWN, GEAR WOULD NOT EXTEND. MANUALLY EXTENDED GEAR AND LANDED WITHOUT INCIDENT. FERRIED AIRCRAFT TO ANC WITH GEAR EXTENDED. LANDING GEAR WORKS CORRECTLY DURING HANGAR TESTS. TROUBLESHOOTING CONTINUING. FOUND CHAFED WIRE BUNDLE UNDER FLIGHT CABIN FLOOR.

Part: TRANSMITTER — FAILED (RT ENGINE)

DURING CLIMB FROM ANC, RIGHT ENGINE OIL PRESSURE DROPPED TO 30 PSI, LOW PRESSURE WARNING LIGHT DID NOT ILLUMINATE, AIRCRAFT RETURNED TO ANC. RESET CANNON PLUG ON OIL PRESSURE TRANSMITTER. GROUND RAN ENGINE, OIL PRESSURE INDICATION NORMAL. AIRCRAFT RETURNED TO SERVICE. 12 MINUTES AFTER TAKEOFF FROM ANC, RIGHT ENGINE OIL PRESSURE DROPPED TO 30 PSI, LOW OIL PRESSURE LIGHT DID NOT COME ON. MAINTENANCE REPLACED OIL PRESSURE TRANSMITTER. OPS CHECKED NORMAL, AIRCRAFT RETURNED TO SERVICE. (M)

Part: ENGINE — FAILED (NR 2)

FLT 1463 - AIR RETURN ANC, NR 2 ENGINE HAD TO BE SHUT DOWN DUE TO INTERNAL FAILURE. THE AIRCRAFT LANDED ANC WITHOUT INCIDENT. MAINTENANCE REMOVED AND REPLACED THE ENGINE AND RETURNED THE AIRCRAFT TO SERVICE. (W)

Part: CONTROL CABLE — BINDING (RT TE FLAPS)

KSM - FLT 5691 - ON DESCENT, THE WING FLAPS BECAME STUCK IN THE APPROACH POSITION. A LANDING WAS MADE WITHOUT INCIDENCE. THE AIRCRAFT WAS THEN REPOSITIONED TO ANC ON A SPECIAL FLIGHT PERMIT. AFTER TROUBLESHOOTING THE WING FLAP SYSTEM, MAINTENANCE REMOVED AND REPLACED THE LEFT INBOARD AND THE RIGHT OUTBOARD FLAP DRIVE CABLES. THE AIRCRAFT WAS THEN RETURNED TO SERVICE. REFERENCE CONTROL NR HERA9504.

Part: CONTROL CABLE — BINDING (LT TE FLAPS)

KSM - FLT 5691 - ON DESCENT, THE WING FLAPS BECAME STUCK IN THE APPROACH POSITION. A LANDING WAS MADE WITHOUT INCIDENCE. THE AIRCRAFT WAS THEN REPOSITIONED TO ANC ON A SPECIAL FLIGHT PERMIT. AFTER TROUBLESHOOTING THE WING FLAP SYSTEM, MAINTENANCE REMOVED AND REPLACED THE LEFT INBOARD AND THE RIGHT OUTBOARD FLAP DRIVE CABLES. THE AIRCRAFT WAS THEN RETURNED TO SERVICE. REFERENCE CONTROL NR 95ZZZX922. (X)