Stark Airways, LLC

Part: ENGINE — FAILED · airframe 4,550 hrs · 4,455 cycles

DURING CLIMBOUT, NOTICED A MASTER CAUTION LIGHT FLASH. THEN A FEW SECONDS LATER IT DID IT AGAIN, LOOKED ALL AROUND AND SAW NOTHING. THEN IT CAME ON AND STAYED ON AND IT WAS THE RT OIL PRESSURE LIGHT. LOOKED AT THE GAUGE AND THE NEEDLE WAS IN THE RED. WENT TO THE CHECK LIST AND REDUCED POWER ON ENGINE. NO CHANGE ON THE GAUGE AND THE LIGHT WAS STILL ON. SO THE NEXT STEP WAS TO DO A PRECAUTIONARY ENGINE SHUTDOWN. RETURNED & LANDED WITH NO PROBLEMS. MX PERSONNEL CAME OUT TO LOOK AT THE ENGINE AND THERE WAS OIL ALL OVER THE ENGINE COWL. TESTS ARE BEING DONE TO SEE WHAT HAPPENED, BUT ON FIRST GLANCE THERE WAS METAL PIECES IN THE OIL FILTER AND OIL.

Part: VALVE — LEAKING (MLG)

ON TAKEOFF, LANDING GEAR WOULD NOT RETRACT. AIRCRAFT LANDED UNEVENTFULLY. TROUBLESHOOTING REVEALED VALVE ON EMERGENCY PNEUMATIC RESERVOIR (BLOW DOWN BOTTLE) LEAKED, PRESSURIZING DOWN SIDE OF LANDING GEAR RETRACTION SYSTEM. ASSEMBLY WAS REMOVED AND SHIPPED OUT FOR REPAIR.

Part: ENGINE — MALFUNCTIONED (RT NACELLE)

PILOT REPORTED HOT OIL SMELL COMING FROM OVERHEAD VENTS DURING POSITIONING FLIGHT FOR MAINTENANCE. TROUBLESHOOTING SHOWED SMELL COMING FROM RIGHT ENGINE.

Part: GROMMET ASSY — BROKEN (COMB LINER)

RIGHT IGNITER WAS EXTREMELY DIFFICULT TO REMOVE. WHEN REMOVED PARTS WERE HEARD TO FALL INSIDE COMBUSTION CHAMBER. BORESCOPE INSPECTION REVEALED PORTIONS OF BOTH LEFT AND RIGHT GROMMET ASSEMBLIES LYING IN COMBUSTION CHAMBER. ENGINE HAS BEEN DISASSEMBLED TO HSI LEVEL AND REPAIRS ARE PENDING.

Part: SWITCH — STUCK (HYD PRESS)

ON TAKEOFF, 'HYD PRESS ON'. LIGHT STAYED ON AFTER LANDING GEAR RETRACTION. PILOT RAN CHECKLIST ITEMS AND DIVERTED TO FJJ. TROUBLESHOOTING REVEALED SWITCH S89 STUCK. SWITCH WAS REPLACED AND FUNCTIONAL TEST COMPLETED SATISFACTORILY.

Part: WINDOW — CRACKED (COCKPIT RT SIDE)

DURING PRISM INSPECTION OF CO-PILOT'S WINDOW, FOUND 4 FASTENER HOLES CRACKED AT UPPER FORWARD. CRACK CONNECTS CENTER 2 FASTENERS. WINDOW IS TO BE REPLACED.

Part: PERISEAL — BROKEN (LT ENG BLEED)

PILOT REPORTED FIRE WARNING LIGHT CAME ON IN-FLIGHT. THROTTLE WAS REDUCED AND LIGHT WENT OUT. TROUBLESHOT SYSTEM AND FOUND BROKEN PERI-SEAL ON INBOARD SIDE OF LEFT ENGINE ALLOWED BLEED AIR TO BLOW ON FIRE LOOP. NO ADDITIONAL PROBLEM FOUND. REPLACED 2 PERI-SEALS AND OPS TESTED OK.

Part: WINDSHIELD — MISMANUFACTURED (COCKPIT LT)

DURING PRE-PURCHASE INSPECTION, WINDSHIELDS MEASURED UNDER MINIMUM THICKNESS SPECIFICED BY CESSNA AIRCRAFT. THESE ARE ORIGINAL EQUIPMENT AND MAINTENANCE RECORDS REFLECT NO REPAIRS. ITS IS SUSPECTED UNDER SPEC UNITS WERE INSTALLED NEW AT FACTORY. THIS AIRCRAFT WAS PURCHASED USED FROM CESSNA IN 1989 AND NO REPAIRS WERE ACCOMPLISHED TO UNITS SINCE. RECOMMEND AD NOTE BE ISSUED REQUIRING ONE TIME INSPECTION OF WINDSHIELDS FOR MINIMUM THICKNESS ON ALL 500 SERIES CESSNAS.

Part: WINDHSIELD — MISMANUFACTURED (COCKPIT RT)

DURING PRE-PURCHASE INSPECTION, BOTH WINDSHIELDS WERE MEASURED UNDER MINIMUM THICKNESS SPECIFIED BY CESSNA AIRCRAFT. THESE ARE ORIGINAL UNITS AND MAINTENANCE RECORDS REFLECT NO REPAIRS SINCE NEW. IT IS SUSPECTED UNDER SPEC UNITS WERE INSTALLED NEW AT FACTORY. THIS AIRCRAFT WAS PURCHASED USED FROM CESSNA AND NO REPAIRS WERE ACCOMPLISHED. SUBMITTER RECOMMENDS AN AD NOTE BE ISSUED REQUIRING ONE TIME INSPECTION OF ALL WINDSHIELDS FOR THICKNESS IN ALL 500 SERIES CESSNAS.

Part: PUMP — FAILED (RT BOOST)

DURING POST-FLIGHT INSPECTION, A FUEL LOAD MISBALANCE WAS NOTED. ACTIVATED CROSS-FEED SYSTEM TO BALANCE LOAD. RIGHT BOOST PUMP RAN, BUT LOW FUEL WARNING. NO EVIDENCE OF CROSS-FEED WAS NOTED. TROUBLESHOOTING REVEALED RIGHT PUMP RUNNING, BUT NO FUEL FLOW. REPLACED RIGHT BOOST PUMP.

Part: TIRE — DEFECTIVE (BALANCE PATCH)

WHILE MOVING AIRCRAFT INTO HANGAR, NOSE TIRE MADE ODD NOISE. DISASSEMBLY REVEALED BALANCE PATCH INSIDE TIRE HAD COME LOOSE. PATCH WAS FREE TO CHANGE POSITION. SUBMITTER SUSPECTS POOR QUALITY OF ADHESIVE. MANUFACTURER WAS NOTIFIED OF PROBLEM. LANDINGS, 41.