POLARIS AVIATION SOLUTIONS, LLC

AUTOBRAKE FAIL-FAULTS POWER AB - CA: AS A FOLLOW-UP WE WERE ABLE TO CORRECT THE PROBLEM BY TAKING THE BBJ TO ALOFT AEROARCHITECTS WHO DISCOVERED THAT THE AUTO-BRAKE DISARM RELAY (R1) MOUNTED ON THE BACK OF THE AUTO-BRAKE CONTROL PANEL ON THE INSTRUMENT PANEL WAS INSTALLED BACKWARDS. WE BELIEVE THIS OCCURRED DURING EARLY TROUBLESHOOTING AT A 2ND MRO. THE POINT IS IT SHOULD BE IMPOSSIBLE TO INSTALL THIS RELAY BACKWARDS BUT THERE'S NO KEY WAY AND NO GUIDE PIN TO PREVENT THIS ERROR (NOT MURPHY PROOF). THAT'S A POOR DESIGN AND SHOULD BE CORRECTED AS SOON AS POSSIBLE. IN THE INTERIM THERE SHOULD BE A NOTICE TO OPERATORS THAT THIS UNSAFE CONDITION EXISTS. WE SPENT A WEEK OF TROUBLESHOOTING AND THEN HAD TO FLY IT TO ALOFT WHEN WE WERE GOING TO RUN INTO FLIGHT SCHEDULE CONFLICT PROBLEMS IF WE DIDN'T FIX IT FAST. ALOFT WAS ABLE TO COMPARE THE INSTALLATION TO OTHER AIRCRAFT AND FINALLY FIGURE OUT THE RELAY WAS INSTALLED BACKWARDS.

# 1 LEFT OUTBOARD BRAKE OUTBOARD DISK CRACK IN NUMEROUS PLACES.FOUND WHILE PERFORMING ITEM # 21.19 CMP 321003.P/N 1159SCL504-5 S/N 5231EP.INSTALLED NEW BRAKE ASSEMBLY P/N 1159SCL504-5, S/N 5050LA IAW CMP 324105.

HORIZONTAL STABILIZER LH LOWER SKIN ASSEMBLY (1159CS52003-403) DISBONDS UNDERNEATH THE RIB 8 AFT MOST RIB FOOT PER SE55502113-1 REV -. THIS IS A MAJOR REPAIR.

HORIZONTAL STABILIZER RH LOWER SKIN ASSEMBLY (1159CS52003-404) DISBOND COMMON TO THE STGR 14R FORWARD FLANGE BETWEEN RIB 1R AND RIB 2R. THIS IS A MAJOR REPAIR.

LH AND RH HORIZ STAB TRAILING EDGE FLANGE HAS NUMEROUS AREAS OF CORROSION AROUND TOP AND BOTTOM OF SCREW HOLES.

FRAME 500A RT HAS GOUGES BEHIND "EXO GRID" AT APPROX WL 230. GOUGES ARE 0.003" AND 0.015" DEEP X 0.200" WIDE.

TAKEOFF & 0:30 CREW OBSERVED LT ENG OIL QTY DECREASING ABNORMALLY. ENG WAS SHUT DOWN & ACFT RETURNED. DISCOVERED A FAILED FACE SEAL AT THE FUEL PUMP DRIVE PAD ON THE ACCESSORY GEAR BOX. A GVI OF THE SEAL WAS COMPLIED WITH PRIOR TO THE PUMP INSTALLATION THE DAY PRIOR & NO LEAKS WERE DETECTED ON THE GND RUNS FOR THE PUMP REPLACEMENT.

BRAKE ROTOR TABS TORE, BROKEN OFF SEVERAL ROTORS ON ALL 4 BRAKE ASSEMBLIES. PN 1159SCL504-5, LT OTBD SN 5231EP, LT INBD SN 5010EM, RT INBD 5011EM, RT OTBD SN 5013EM. LT INBD, RT INBD & RT OTBD BRAKES ARE ORIGINAL EQUIPMENT FROM BUILD. LT OTBD WAS INSTALLED AT ACFT TT 2783.3, LDGS 935, CONDITION AT TIME INSTALLED UNKNOWN.

DURING ROUTINE CHAPTER 5, 500 HOUR, ROOT END SPAR BORESCOPE INSPECTION, NOTICED SHADED AREA. CONFIRMED SHADED AREA AS A CRACK THROUGH INDEPENDENT NDT EDDY CURRENT INSPECTION. CRACK ORIGINATES ON THE INSIDE BORE OF THE SPAR, AT THE TE OTBD BLADE BOLT HOLE. NOTIFIED ENGINEERING, REF ATTACHED SIMPLE DRAWING.

DURING CRUISE FLIGHT, AT APPROX 3:22 AFTER TAKEOFF, OBSERVED NR2 ENGINE OIL QTY STARTED TO SHOW A POSSIBLE LOSS OF OIL AT A RATE OF 1 QT EVERY 3 MINUTES. WHEN QTY REACHED 3 QTS, ENGINE BROUGHT BACK TO IDLE & SHUTDOWN INITIATED. ACFT LANDED WITH A TOTAL FLIGHT TIME OF 6.1 HOURS. RT ENGINE COWLING OPENED AND EVIDENCE OF OIL LEAKAGE DISCOVERED. DURING MOTORING OF ENGINE, WITNESSED OIL LEAKING FROM BETWEEN ENGINE DRIVEN HYD PUMP & PUMP MOUNTING FLANGE ON GEARBOX. PUMP REMOVED & SPLINE SHAFT O-RING REPLACED. PUMP REINSTALLED IAW AMM 29-11-05. ENGINE MOTORED, NO LEAK DETECTED. ENGINE OPERATED FOR FURTHER INSP & NO LEAKS NOTED. NOTE: O-RING REPLACED 23.3 FLT HOURS EARLIER FOR EVIDENCE OF OIL LEAKING IN SAME AREA. ACFT OPERATED FOR 11.5 HOURS, SMALL AMOUNT OF OIL WITNESSED AT THE BOTTOM OF COWLING & ENGINE GEARBOX WAS AGAIN INSPECTED TO INSURE OIL WAS RESIDUAL FROM PREVIOUS OIL LOSS. THE QTY HAD DROPPED 1 QT IN 11.5 HOURS.