40 MILE AIR LTD

Operated by 40 MILE AIR LTD. — On-demand air taxi (135) Operator Does Business As: (per NTSB report)

PILOT REPORTED THAT HE WAS NOT GETTING A DOWN AND LOCK INDICATION ON LEFT MAIN. AFTER HE WAS ON GROUND, INSPECTION REVEALED THAT THE LEFT RETRACT ARM PN 42042-000 WAS CRACKED AND SEPARATED SUFFICIENTLY ENOUGH TO PREVENT THE DOWN LOCK SWITCH FROM CLOSING. REPLACED RETRACT ARMS ON BOTH SIDES OF ACFT, AFTER LEARNING OF PIPER SL 1092C.

DURING A 100 HOUR INSPECTION, A CRACK WAS FOUND ON THE REAR ATTACH BRACKET OF THE HORIZONTAL STAB.

AIRCRAFT CAME IN FOR A 50 HR INSPECTION. WHEN ENGINE OIL SCREEN WAS PULLED, IT WAS FOUND TO HAVE A LARGE AMOUNT OF METAL IN IT. UPON INVESTIGATION IT WAS FOUND THAT THE NR 2 CYLINDER CONNECTING ROD BUSHING, PN 530658 WAS SIDINGRATING. NOTE: AT FIRST OIL CHANGE AFTER ENGINE INSTALLATION, THERE WAS FOUND TO BE A NOTABLE AMOUNT OF METAL. THIS AT THE TIME WAS THOUGHT TO BE ONLY A LITTLE BEYOND NORMAL FOR A FIRST OIL CHANGE. AFTER THAT METAL LEVELS WERE NOTED TO GO UP AND DOWN BOTH THROUGH OBSERVATION OF SCREENS AND OIL ANALYSIS. WE HAD TRIED CHANGING STARTER DRIVES, ANOTHER CYLINDER WITH NO REAL SOLUTIONS. WITH THIS INCIDENT THE DECISION WAS MADE TO PULL THE ENGINE FROM SERICE AND SEND IT TO O/H FACILITY.

PRECOOLER VALVE FAILED OPS CHECK, DURING NR 2 ENG HEALTH CHECK (BLEED SYS). REMOVED & REPLACED NR 2 ENGINE PRE-COOLER VALVE AS PER AMM 36-12-02, OPS CHECKED OK. NO LEAKS NOTED AT THIS TIME.

ETOPS SIGNIFICANT SYSTEM: ON RECALL ALL THREE ZONE TEMP LTS ILLUMINATED. PERFORMED PACK/ZONE TEMP CONT BITE TEST IAW AMM 21-61-00-700-806-002. TRIM VALVE FAULT STORED. PERFORMED T/S PER FIM 21-62-TASK 848. FAULT INTERMITTENT AND CLEARED. PERFORMED BITE TEST. BITE TEST PASSED IAW AMM 21-62-00-700-806-002, NO FAULTS.

CONT CAB ZONE TEMP LIGHT ILLUMINATED DURING FLIGHT DECK RECALL. PERFORMED PACK/ZONE TEMP CONTROLLER BITE PROCEDURES IAW FIM 21-62 TASK 801, NO FAULTS NOTED.

ETOPS SIGNIFICANT SYSTEM: ZONE TEMP LIGHT ILLUMINATES ON RECALL. F/M ADVICED CONTROLLER 1 HAD THE LIGHTS ILLUMINATED. REMOVED AND REPLACED PACK/ZONE TEMP CONTROLLER NR 1 AND OPS TEST OK IAW AMM 21-61-20.

ETOPS SIGNIFICANT SYSTEM: ALL THREE ZONE TEMP LIGHTS ILLUMINATE ON RECALL. PERFORMED BITE TO BOTH ZONE TEMP CONTROLLERS, TRIM VALVE, F/T DCK AND ZONE LIGHTS ON. ABLE TO RESET LIGHTS AND VERIFY IAW FIM 21-62 TASK 801. SYSTEM OPS CHECK OK. NO LIGHTS ON RECALL.

ETOPS SIGNIFICANT SYSTEM: ON TAKE-OFF CLIMB R DUCT PRESSURE AT 80. PERFORMED HEALTH CHECK ON NR 2 ENGINE, BLEED AIR REGULATOR FAILED AS PER AMM 36-11-00. REMOVED AND REPLACED NR 2 ENG BAR AND OPS OK AS PER AMM 36-11-03, PERFORMED TAKEOFF POWER CHECK AS PER AMM 71-00-00 NO FAULTS NOTED AT THIS TIME.

ETOPS SIGNIFICANT SYSTEM: DUCT SPLIT L=40PSI-AT FL 380 R=20PSI. REMOVED AND REPLACED NR 2 ENGINE BLEED AIR REGULATOR IAW B737-800 M/M 36-11-03 OPS CHECK NORMAL.

ETOPS SIGNIFICANT SYSTEM: ALL THREE ZONE TEMP LIGHTS ILLUMINATE ON RECALL EXTINGUISH WHEN SYSTEM IS RESET FAULT CODE 216 224-00. C/W ZONE TEMP CONTROL ADJUSTMENT TEST NO DEFECTS NOTED AT THIS TIME IAW AMM 21-61-00.

ETOPS SIGNIFICANT SYSTEM: ALL 3 ZONE TEMP LIGHTS ILLUMINATE ON RECALL AFTER ENGINE START. FOUND CABIN TEMP SENSOR FILTERS DIRTY. CLEAN ALL 3 ZONES CABIN TEMP SENSOR FILTERS AS PER B737 AMM 21-61-06, OPS CHECK NORMAL.

ETOPS SIGNIFICANT SYSTEM: BLEED TRIP OFF LIGHT ON EN ROUTE ENG NR 1. REMOVED AND REPLACED PRE-COOLER CONTROL VALVE IAW AMM 36-12-02. RAN ENG NO BLEED TRIP AT 80 PERCENT. NO DISCREPANCIES NOTED.

ETOPS SIGNIFICANT SYSTEM: BLEED TRIP OFF LIGHT ON, EN ROUTE ENG NR 1. REMOVED AND REPLACED PRE-COOLER CONTROL VALVE IAW AMM 36-12-02. RAN ENG. NO BLEED TRIP AT 80 PERCENT. NO DISCREPANCIES NOTED.

ETOPS SIGNIFICANT SYSTEM: NR 1 ENG BLEED TRIP DURING CRUISE. FOUND LOOSE CONNECTOR ON BLEED SENSE LINE. RE-TIGHTENED AND SAFETIED, RAN ENG 1. NO DISCREPANCIES NOTED IAW 36-10-00.

ETOPS SIGNIFICANT SYSTEM: NR 1 ENG BLEED AIR TRIP. PERFORMED NR 1 ENG BLEED HEALTH CHECK IAW TASK 36-11-00-700-801. FOUND HP FAILED AND PCV KISS BAD. RE-ACTIVATED HIGH PRESS VALVE PER MEL 36-9. REMOVED AND REPLACED HIGH STAGE VALVE IAW 36-11-06-800. REMOVED AND RE-INSTALLED PCV. REPLACED KISS SEAL IAW 36-12-02. REPLACED 390 DEGREE THERMOSTAT IAW 36-11-05-400-801.

ETOPS SIGNIFICANT SYSTEM: FWD RIGHT WINDOW HEAT INOP. ACCOMPLISHED BITE OF FWD RIGHT WINDOW CONTROLLER IAW 737-800 FIM 30-41 TASK 801 FAULTS CLEARED FOUND NR 1 SENSOR AT FAULT SWAPPED SENSOR IAW 30-41 TASK 811-812, OPS CHECK OK.

ETOPS SIGNIFICANT SYSTEM: ENG NR 2 "COWL ANTI ICE" LIGHT COMES ON AT HIGH THRUST SETTING AND GOES OFF AT REDUCED THRUST. CHECKED & CLEANED CONNECTORS ON OVERPRESSURE SWITCH & COWL ANTI ICE VALVE IAW AMM 30-21-11. CHECK GOOD. RAN NR 2 ENG AT PWR 3 TIMES COULD NOT DUPLICATE DISCREPANCY WITH NR 2 COWL ANTI ICE IAW FIM 30-21 TASK 809. INTERMITTENT FAULT.

ETOPS SIGNIFICANT SYSTEM: LEFT FORWARD WINDOW OVERHEAT LIGHT ILLUMINATED. RESET BITE TESTED WINDOW HEAT CONTROL UNIT. NO FAULTS DETECTED RESET CIRCUIT BREAKER IAW 737-800 FIM 30-41 TASK 801, OPS CHECK NORMAL.

ETOPS SIGNIFICANT ITEM: APU FAULT LIGHT ILLUMINATED DURING TAXI IN. REMOVED AND REPLACED APU IGN UNIT, IGNITOR PLUG, & IGNITOR PLUG LEAD IAW AMM 49-41-31, 49-41-51 & 49-41-52. OPS CHECK OK.

ETOPS SIGNIFICANT SYSTEM: BLEED TRIP OFF LIGHT ILLUMINATED SHORTLY AFTER TOP OF DESCENT. C/W AMM TASK 36-11-00-700-802 (ENG BLEED AIR SYS LEAK CHECK WITH APU) FOUND NO LEAKS, FOUND HS VALVE WILL NOT CLOSE COMPLETELY. REPLACED NR 2 ENGINE HIGH STAGE VALVE, OPS CHECK NORMAL.

ETOPS SIGNIFICANT SYSTEM: EXCESSIVE DUCT SPLIT (20PSI) THROUGHOUT CLIMB. REPLACED NR 2 ENGINE HIGH STAGE VALVE SYSTEM, OPS NORMAL.

ETOPS SIGNIFICANT SYSTEM: EXCESSIVE DUCT SPLIT (20PSI) THROUGHOUT CLIMB. REPLACED NR 2 ENGINE HIGH STAGE VALVE. SYSTEM OPS CHECK NORMAL.

ETOPS SIGNIFICANT SYSTEM: NR 1 ENGINE STARTER START CUTOUT EARLY, SECOND ATTEMPT NO START. CLEANED CONNECTOR ON NR 1 ENGINE START VALVE RESCURED AND OPS CHECK NORMAL AS PER AMM 80-11-00 & 71-00-00 NO DEFECTS NOTED.

ETOPS SIGNIFICANT SYSTEM: NR 2 ENG START VAVLE STUCK CLOSED FAULT CODE 800 080 52. REMOVED AND REPLACED NR 2 ENGINE START VALVE IAW AMM 80-11-03 OPS & LEAK CHECK OK. THIS CLEARS MDDR # 8336. PLACARD REMOVED A/C IS UPGRADED TO ETOPS.

ETOPS SIGNIFICANT SYSTEM: AFTER TAKEOFF DUCT PRESSURE SPLIT GREATER THAN 16 PSI, L-23, R-40. DUCT PRESSURE SPLIT WITHIN LIMITS IAW FIM 36-10 PAGE 315. DUCT PRESSURE IS NOT LESS THAN 18 PSI.

ETOPS SIGNIFICANT SYSTEM: IN CLIMB (30,000) RIGHT DUCT PRESSURE SHOWS 45 PSI LEFT DUCT PRESSURE SHOWS 25 PSI. INSPECTED NR 1 ENG BLEED AIR SYSTEM IAW AMM 36-11-00. FOUND NO DEFECTS. PERFORMED ENGINE POWER RUN UP IAW AMM 71-00-00. NO DEFECTS NOTED.

ETOPS SIGNIFICANT SYSTEM: AIRCRAFT WOULD NOT PRESSURIZE LOUD NOISE AT L1 DOOR. FOUND DOOR BARRIER STRAP IN DOOR SEAL NOT PROPERLY STOWED. PROPERLY STOWED STRAP. PRESSURIZED A/C IAW TASK 052/51/9 AND OPS CHECKED DOOR IAW 55-11-00 PAGE 601. A/C PRESSURIZED NO FURTHER ISSUES OK FOR SERVICE.

ETOPS SIGNIFICANT SYSTEM: NR 1 BLEED LIGHT ILLUMINATES IN FLIGHT. REMOVED AND REPLACED NR 1 450 DEGREE TEMP SENSOR IAW B-737-800 MM REF 36-11-05, CHECKS GOOD.

ETOPS SIGNIFICANT SYSTEM: PASSENGER CABIN IS WARM WITH PACKS ON AUTO AND MANUAL COOL. CLEANED CABIN TEMPERATURE SENSOR & FILTER IAW AMM 21-61-06. PERFORMED BITE TEST OF PACK/ZONE TEMP CONT IAW AMM 21-61-00. OPS CHECK OK. NO FAULTS.

ETOPS SIGNIFCANT SYSTEM: CABIN ALT WARNING SOUNDED WHILE CLIMBING OUT OF FL250. CABIN ALT WAS APPROX 13,000FT PUT PRESSURIZATION MODE CONTROL PANEL TO MANUAL AND OUT FLOW VALVE TO CLOSE AND STARTED A DESCENT AT FL200 CABIN ALT WAS AT 9000 AND STOPPED THE DESCENT. CABIN ALT SLOWLY RETURNED TO NORMAL FOR FL200 AND CONTINUED FLIGHT TO DESTINATION. PERFORMED BITE CHECK ON DPCU 1 & 2 SYSTEM OK NO FAULTS FOUND AT THIS TIME IAW FIM 21-31 TASK 801.

ETOPS SIGNIFICANT SYSTEM: CARGO FIRE WARNING FWD COMPARTMENT LOOP-B IS INOP. REMOVED AND REPLACED B2 FWD CARGO SMOKE DETECTOR IAW AMM 26-16-01. PERFORMED TEST IAW AMM 26-16-00 TEST NORMAL.

ETOPS SIGNIFICANT SYSTEM: CAL POSITION ON RADAR SHOWS RADAR RETURNS ON ECLECTICALLY ACTIVE THUNDERSTORMS AS LIGHT RAIN, MANUAL POSITIONS FUNCTION NORMALLY. FOUND WX RADAR RT FILTER DIRTY. CLEANED IAW B737-800 AMM 34-43-09 PG 701, OPS CHECKED GOOD IAW B737-800 AMM 34-43-00 PG 501. NO DEFECTS NOTED.

ETOPS SIGNIFICANT SYSTEM: LEFT FWD WINDOW HEAT LIGHT SHOWS "OVERHEAT" WHEN POWER APPLIED SAME INDICATION ON PWR TEST FAULT CODE 304-010-41. PERFORMED FIM 30-41 TASK 806 FOUND P6-11 C/B POPPED OPS SYSTEM CHECKED NORMAL.

ETOPS SIGNIFICANT SYS: PRECAUTIONARY SHUTDOWN OF NR 2 ENGINE DUE TO LOW OIL PRESSURE AND ZERO OIL QUANTITY. REPLACED #2 ENGINE.

EMERGENCY EXIT LIGHTS AT THE PAX COMPARTMENT BIN LOCATIONS 7-10DEF, 15-23 DEF AND 16-22 ABC ARE INOP. REPLACED BATTERY PACKS. SYSTEM OPS NORMAL.

ETOPS SIGNIFICANT SYSTEM: ENGINE NR 1 SWITCHED TO ALT EEC SHORTLY AFTER T/O.

ETOPS SIGNIFICANT SYSTEM: APU FAULT LIGHT ILLUMINATED MAINTENANCE MSG 49-41011 NO FLAME SHUTDOWN. REMOVED AND REPLACED APU IGNITION UNIT IAW MM 49-41-31. OPS CHECKED NORMAL.

ETOPS SIGNIFICANT SYSTEM: ON RECALL PRIOR TO TAXI, AIR COND LIGHT AND 3 ZONE TEMP LIGHTS REMAINED ILLUMINATED AND WOULD NOT CLEAR USING QRH PROCEDURE. PERFORMED BITE CHECK OF BOTH PACK CONTROLLERS AND FOUND INTERMITTENT. BITE CHECKED PASSED AND FAULT CLEARED. OPS CHECK NORMAL.

ETOPS SIGNIFICANT SYSTEM: NR 1 ENGINE IDG DRIVE LIGHT ILLUMINATED AFTER START.

ETOPS SIGNIFICANT SYSTEM: NR 1 ENGINE ANTI-ICE LIGHT ILLUMINATES AT HIGH THRUST SETTINGS.

ETOPS SIGNIFICANT SYSTEM: AFT CARGO FIRE DETECTION LOOP A INOP.

ETOPS SIGNIFICANT SYSTEM: ABORTED TAKEOFF DUE TO CONFIGURATION WARNING HORN.

ETOPS SIGNIFICANT SYSTEM: AIRSPEED AND ALTITUDE DISAGREE AND NR 2 ENGINE WENT TO SOFT ALTERNATE MODE.

ETOPS SIGNIFICANT SYSTEM: AFT CARGO B LOOP WOULD NOT TEST.

ETOPS SIGNIFICANT SYSTEM - AUTO TEMP CONTROL DOES NOT OPERATE.

ETOPS SIGNIFICANT SYSTEM - AIR CONDITIONING COOLING INSUFFICIENT.

ETOPS SIGNIFICANT SYSTEM - LT PACK ONLY WORKS IN HIGH.

ETOPS SIGNIFICANT ITEM - "DISCHARGE" CARGO FIRE BOTTLE LIGHT ILLUMINATED DURING PREFLIGHT.

ETOPS SIGNIFICANT ITEM - "DISCHARGE" CARGO FIRE BOTTLE LIGHT ILLUMINATED DURING PREFLIGHT.