N991AA

Part: CYLINDER — FAILED (NR 3) · airframe 36,423 hrs

PILOT REPORTED RIGHT ENGINE SURGING AFTER TAKEOFF. MAINTENANCE INSPECTED AND FOUND THE #3 CYLINDER TO BE AT FAULT. THE #3 CYLINDER WAS REPLACED WITH NO FURTHER DEFECTS NOTED.

Part: FITTING — CRACKED (NACELLE) · airframe 35,234 hrs · 38,856 cycles

WHILE PREPPING FOR A SID 57-10-16 INSPECTION OF THE SPAR STRAP AND NACELLE FITTINGS, A CRACK WAS FOUND ON THE OUTBOARD SIDE OF THE RIGHT OUTBOARD FITTING, JUST FORWARD OF THE SPAR STRAP.

Part: FITTING — CRACKED (RT NACELLE) · airframe 33,971 hrs · 37,163 cycles

DURING A ROUTINE INSPECTION, A CRACK WAS FOUND IN THE RT INBOARD NACELLE FITTING. THE CRACK WAS FOUND ON THE INBOARD SIDE OF THE FITTING, JUST FORWARD OF THE SPAR STRAP. THE CRACK MEASURED .049 IN LENGTH.

Part: MOTOR — BURNED OUT (HEATER BLOWER) · airframe 33,968 hrs · 37,160 cycles

THE PILOT REPORTED "BURNING ODOR WHEN CABIN HEATING SYSTEM IN USE DURING FLIGHT AND BLOWER NOT BLOWING ON GROUND." AFTER INSPECTING, MAINTENANCE FOUND THE HEATER BLOWER MOTOR BURNED OUT. THE HEATER BLOWER WAS REMOVED AND REPLACED AND OPS CHECKED GOOD.

Part: COIL — FRACTURED (EXHAUST VALVE)

DURING EXAMINATION OF ENGINE CORE FOR OVERHAUL, THE NR 5 CYLINDER EXHAUST VALVE ROTOCOIL WAS FOUND TO BE FRACTURED. THE TOP CIRCUMFERENCE OF THE ROTOCOIL STRUCTURE HAD FRACTURED FROM THE ROTOCOIL ASSEMBLY AND REMAINED CAPTURED BY THE EXHAUST ROCKER ARM WHERE IT EXPERIENCED WEAR AND CONTACT WITH THE ROCKER ARM, ROCKER SHAFT BOSS AND ROCKER COVER.

Part: EXHAUST VALVE — DAMAGED (NR 4 CYLINDER) · airframe 33,634 hrs

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

Part: EXHAUST VALVE — DAMAGED (NR 5 CYLINDER) · airframe 33,634 hrs

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

Part: EXHAUST VALVE — DAMAGED (NR 2 CYLINDER) · airframe 33,634 hrs

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

Part: LIFTER — DAMAGED (RT ENGINE) · airframe 33,539 hrs · 36,629 cycles

PILOT REPORTED DURING RUN-UP, RT ENGINE RPM OSCILLATES, 100 RPM. MAINTENANCE INSPECTED AND FOUND THE NR 3 CYLINDER EXHAUST LIFTER PITTED, THE NR 3 INTAKE LIFTER COLLAPSED AND THE NR 5 CYLINDER INTAKE LIFTER COLLAPSED. MAINTENANCE R & R THE LIFTERS IAW O/H MANUAL, CH 72-20-18.

Part: LIFTER — COLLAPSED (RT ENGINE) · airframe 33,539 hrs · 36,629 cycles

PILOT REPORTED DURING RUN-UP, RT ENGINE RPM OSCILLATES 100 RPM. MAINTENANCE INSPECTED AND FOUND THE NR 3 CYLINDER EXHAUST LIFTER PITTED, THE NR 3 INTAKE LIFTER COLLAPSED AND THE NR 5 CYLINDER INTAKE LIFTER COLLAPSED. MAINTENANCE R & R THE LIFTERS IAW O/H MANUAL CH 72-20-18.

Part: LIFTER — COLLAPSED (NR 1 CYLINDER) · airframe 33,460 hrs · 36,464 cycles

PILOT REPORTED THE RIGHT ENGINE MANIFOLD PRESSURE & RPM SURGE AT TAKE-OFF POWER. MAINTENANCE INSPECTED INTAKE SYSTEM, TURBO SYSTEM, INDEXED FUEL SELECTOR & REPLACED THE RIGHT ENGINE NR 1 CYLINDER EXHAUST LIFTER IAW OH MM 72.

Part: RELAY — FAILED (STARTER) · airframe 33,446 hrs · 36,440 cycles

PILOT REPORTED "RIGHT STARTER STAYS ENGAGED" MAINTENANCE FOUND RIGHT STARTER RELAY FAILED. REMOVED AND REPLACED RT STARTER RELAY, RAN STARTER AND ENGINE- ALL OPERATION GOOD.

Part: O-RING — DAMAGED (MASTER CYLINDER) · airframe 32,325 hrs · 34,897 cycles

PILOT REPORTED LT BRAKE FAILED UPON LANDING. R & R O RING ON PISTON IN LT MASTER CYLINDER, SERVICED WITH HYD FLUID. OPERATIONAL & LEAK CHECKED GOOD.

Part: DRAG BRACE — CRACKED (NLG) · airframe 29,717 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: UPLOCK SWITCH — FAILED (NLG) · airframe 27,369 hrs

CREW REPORTED DURING CRUISE FLIGHT, GEAR UNLOCK LIGHT ILLUMINATED. GEAR WAS CYCLED ONCE WITH SAME INDICATION. GEAR WAS SELCTED DOWN, THREE GREEN DOWN AND LOCK LIGHTS ILLUMINATED BUT GEAR UNLOCK LIGHT REMAINED ILLUMINATED. AIRCRFT RETURNED TO KBOS WHERE MAINTENANCE INSPECTED AIRCRAFT AND RELEASED AIRCRAFT FOR SPECIAL FERRY FLIGHT SO THAT RETRACTION AND EXTENSION CHECKS COULD BE PERFORMED. MAINTENANCE FOUND NOES GEAR UPLOCK SWITCH HAD FAILED. SWITCH TO BE REPLACED AFTER OTHER MAINTENANCE IS PERFORMED.

Part: DRAG BRACE — CRACKED (NLG) · airframe 27,294 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: HEATER — BURNED (WINDSHIELD) · airframe 26,974 hrs

CREW REPORTED, ON CLIMB OUT, STARTED SMELLING ELECTRICAL TYPE BURNING. NOTIFIED ATC, DECLARED AN EMERGENCY, AND ELECTED TO RETURN. PERFORMED CHECKLIST AND WHILE TRYING TO LOCATE THE SOURCE OF THE ODOR, NOTICED ELECTRIC HEATING GRID ON WINDSHIELD DISTORTED. LANDED UNEVENTFUL. MAINTENANCE INSPECTED AIRCRAFT, FOUND WINDSHIELD HEATING GRID SHORTED, AND AVIONICS STATIC DISCHARGE SUPPRESSORS BURNT. WINDSHIELD HEAT DEFFERED PER MEL 30-13. AIRCRAFT RELEASED FOR SERVICE. MAINTENANCE LATER REMOVED AND REPLACED HEATED WINDSHIELD, AVIONICS STATIC DISCHARGE SUPPRESSORS, AND AS A PRECAUTIONARY MEASURE, REMOVED AND REPLACED WINDSHIELD HEAT INVERTER.

Part: FAN — ODOR (HEATER) · airframe 26,944 hrs

CREW REPORTED, DURING CRUISE FLIGHT, WITH CABIN HEATER VENTILATING FAN ON HIGH, THE FAN CIRCUIT BREAKER TRIPPED. RESET BREAKER, HAD BURNING SMELL AND BREAKER TRIPPED AGAIN. MX INSPECTED ACFT HEATING SYS, R & R CABIN HEATER VENTILATING FAN. SYS CHECKED OK.

Part: DRAG BRACE — CRACKED (NLG) · airframe 26,851 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: MASTER SWITCH — UNSERVICEABLE (AVIONICS)

CREW REPORTED AVIONICS MASTER SWITCH INOPERATIVE. MAINTENANCE REMOVED AND REPLACED SWITCH.

Part: MOTOR — FAILED (HEATER BLOWER) · airframe 24,271 hrs · 60,000 cycles

IN CRUISE FLIGHT, NOXIOUS FUMES FILLED CABIN. CREW SUSPECTED HEATER AND TURNED OFF HEATER SWITCH. FUMES DISSIPATED. TURNED HEATER BACK ON AND FUMES RETURNED. RETURNED FOR UNEVENTFUL LANDING. MAINTENANCE INSPECTED HEATER AND FOUND COMBUSTION BLOWER INOPERATIVE. REMOVED AND REPLACED COMBUSTION BLOWER ASSEMBLY.

Part: DIPSTICK — UNKNOWN (LT ENGINE)

DURING CLIMB-OUT, PILOT NOTED LT ENGINE MANIFOLD PRESSURE INCREASE FOLLOWED BY INCREASE IN OIL PRESSURE. PILOT TURNED BACK AND SECURED LT ENGINE AS A PRECAUTIONARY MEASURE. WHITE SMOKE WAS NOTED COMING FROM LT ENGINE. ACFT LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED ENGINE FOR CONDITION AND COMPRESSION, DEGREASED ENGINE AND REPLACED DIPSTICK, PERFORMED RUN UP AND RELEASED AIRCRAFT RETURN TO SERVICE.