N68391

Part: CYLINDER — DAMAGED (NR 6) · airframe 36,677 hrs · 34,473 cycles

THE PILOT REPORTED ENGINE SURGING AND MANIFOLD PRESSURE DROP IN FLIGHT, AND THEN SHUT DOWN ENGINE IN-FLIGHT ACCORDING TO THE QRH. DURING THE INITIAL INSPECTION, FOUND SHINY PARTICLES IN THE OIL FILTER, AND SPARK PLUG DAMAGED, AND PARTICLES IN THE PROPELLER GOVERNOR. MAINTENANCE CONFIRMED PREIGNITION OCCURRED ON THE NUMBER LEFT ENGINE #6 CYLINDER. ENGINE CHANGE IN PROGRESS.

Part: DOOR FRAME — CORRODED (FUSELAGE) · airframe 35,207 hrs · 31,696 cycles

WHILE CONDUCTING OTHER MAINTENANCE, AN AREA OF CORROSION WAS NOTED ON THE FUSELAGE FRAME ASSEMBLY AT FS 214.00, JUST ABOVE THE 501110-12 STRIKER PLATE FOR THE LOWER PASSENGER DOOR PIN. THE 501110-12 STRIKER PLATE WAS REMOVED FOR FURTHER INSPECTION. UPON REMOVAL OF THE STRIKER PLATE, MORE CORROSION WAS DISCOVERED. THIS AREA OF CORROSION WAS MEASURED AT 1.5" HIGH BY 1" WIDE. THE FUSELAGE FRAME AND STRIKER PLATE WILL BE REPLACED WITH NEW PARTS.

Part: ENGINE — MAKING METAL (LEFT) · airframe 15,574 hrs

PILOT REPORTED LT ENGINE HAD PARTIAL POWER, THEN NOTICED OIL COMING FORM COWLING UNDER THE TURBO. MAINTENANCE INSPECTED AND FOUND METAL CONTAMINATION IN ENGINE OIL FILTER AND THE #5 CYLINDER SHOWING SIGNS OF PRE-IGNITION. THE ENGINE IS TO BE REPLACED.

Part: CYLINDER — DAMAGED (NR 5) · airframe 34,845 hrs

PILOT REPORTED THE LEFT ENGINE STARTED TO RUN ROUGH DURING FLIGHT AND THE OIL PRESSURE SLOWLY DROPPED. AFTER LANDING, THE CREW REPORTED OIL DRIPPING OFF THE COWL. MAINTENANCE INSPECTED AND FOUND METAL CONTAMINATION IN ENGINE OIL SYSTEM AND THE NR 5 CYLINDER SHOWING SIGNS OF PRE-IGNITION. THE ENGINE WAS REPLACED.

Part: CABLE — BROKEN (TE FLAPS) · airframe 31,433 hrs · 29,769 cycles

PILOT REPORTED ON LOWERING THE FLAPS AFTER THE FIFTEEN DEGREE POINT, HEARD A LOUD SNAP/BANG AND THE PLANE ABRUPTLY ROLLED TO THE RIGHT FOR A SPLIT SECOND BUT THEN STRAIGHTENED OUT. LANDED AS SOON AS POSSIBLE. MAINTENANCE INSPECTED AND FOUND THAT THE UPPER RT FLAP CABLE (5000008-63) HAD BROKEN. ALL CABLES AS WELL AS THE FLAP GEAR BOX HAVE BEEN INSTALLED SINCE OCTOBER 2013. THE OEM DIRECTS THESE ARE ON CONDITION ITEMS, BUT AS GOOD PRACTICE HYANNIS AIR SERVICE REPLACES BOTH THE FLAP CABLES AND THE FLAP GEAR BOX ON A 48 CALENDAR MONTH BASIS.

Part: UNKNOWN — ODOR (CABIN) · airframe 34,055 hrs · 29,619 cycles

PILOT REPORTED A BURNING ODOR IN THE CABIN WITH THE HEATER ON, AFTER LANDING NOTICED CABIN VENT FAN CIRCUIT BREAKER TRIPPED. OPEN

Part: DRAG BRACE — CRACKED (NLG) · airframe 30,531 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: DRAG BRACE — CRACKED (ZONE 700) · airframe 29,186 hrs

AT SCHEDULED INSPECTION, NLG DRAG BRACE 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 OF MEB91-11R1. THIS UNIT HAS BEEN REPAIRED IAW PROCEDURE OUTLINED IN MEB941-11R1 & RETURNED TO SERVICE.

Part: DRAG BRACE — CRACKED (NLG) · airframe 29,186 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 WITHIN ALLOWABLE LIMIT OF MEB91-11R1. THIS UNIT HAS BEEN REPAIRED IAW PROCEDURE OUTLINED IN MEB941-11R1 & RETURNED TO SERVICE.

Part: DRAG BRACE — CRACKED (NLG) · airframe 28,636 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: CIRCUIT BREAKER — FAILED

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

Part: LINE — CHAFED (ENGINE OIL)

CREW FOUND LT ENGINE OIL LEAK ON PORT FLIGHT INSPECTION. MECHANIC FOUND INTAKE BALANCE TUBE FLEX HOSE DATA TAG CHAFING ON OIL PAN. MECHANIC REMOVED AND REPLACED OIL PAN AND FLEX HOSE AND RETURNED AIRCRAFT TO SERVICE. FLEX LINE LENGTH WAS SHORTENED BY MANUFACTURER, CAUSING INADEQUATE CLEARANCE WHEN ROUTING HOSE. SUGGEST RETURNING TO ORIGINAL LENGTH HOSE FOR PROPER CLEARANCE.

Part: MASTER SWITCH — FAILED (INST PANEL)

ON PREFLIGHT INSPECTION AVIONICS MASTER SWITCH AND RETURNED AIRCRAFT TO SERVICE.

Part: MASTER SWITCH — FAILED (LT SWITCH PANEL)

ON PRE-FLIGHT INSPECTION AVIONICS MASTER SWITCH FAILED. MAINTENANCE REPLACED SWITCH AND RETURNED AIRCRAFT TO SERVICE.

Part: CAM — DAMAGED (RUDDER)

AFTER T/O CREW EXPERIENCED RUDDER LOCK. THROUGH MANIPULATION OF THE ELEVATOR. CONTROLLED RUDDER GUST LOCK RELEASE AND BY WORKING THE RUDDER PEDALS, THE SYSTEM WAS UNLOCKED. MECHANIC FOUND RUDDER GUST LOCK RELEASE CAM DISFIGURED, CAUSING THE RELEASE MECHANISM TO BE INEFFECTIVE WELL BEYOND NORMAL RELEASE RANGE. FOUND THAT IF AN APPLIED SIDE LOAD (IE TRYING TO RELEASE THE RUDDER LOCK W/PEDALS HARDOVER IN TAXI CAUSED EXCESS PRESSURE ON THE RELEASE CAM BENDING IT OUT OF RIG RENDERING THE LOCK INEFFECTIVE. SUGGEST RELEASING PRIOR TO TAXI OR DURING PRE-FLIGHT.

Part: VALVE — DETERIORATED (WASTEGATE)

PILOT ABORTED TAKEOFF DUE TO ENGINE OVERBOOST. FOUND TOP SECTION OF BUTTERFLY VALVE WARPED DUE TO HEAT. FOUND THAT ON WASTEGATES OVERHAULED USING CONTINUED TIME VALVES, THIS OFTEN HAPPENS ALONG WITH VARING MANIFOLD PRESSURE. ON COMPONENTS WITH NEW VALVES INSTALLED AT OVERHAUL, NO PROBLEMS ARE NOTED THROUGH THE LIFE OF THE COMPONENT - 2100 HRS.