Airtec, Inc.

WHILE INSTALLING KIT MK172-25-10C TO COMPLY WITH SB 04-25-01 R4 AND AD 2007-05-10, ONE OF THE PARTS IN THE KIT WAS MACHINED IMPROPERLY. THE HEIGHT ADJUSTING NUT HAD THE THRU HOLE FOR THE ULTRALOC WITH MIS FORMED THREADS. THE MINOR DIAMETER OF THE THREAD WAS GREATER THAN THE MAJOR DIAMETER OF THE THREADS ON THE ULTRALOC. THE CROSS HOLE FOR MOUNTING WAS INCORRECTLY LOCATED WITH INSUFFICIENT EDGE DISTANCE, AND THE PILOT HOLE WAS OFFSET GIVING AN EGG SHAPED HOLE.

WHILE INSTALLING KIT MK172-25-10C TO COMPLY WITH SB 04-25-01 R4 AND AD 2007-05-10, ONE OF THE PARTS IN THE KIT WAS MACHINED IMPROPERLY. THE HEIGHT ADJUSTING NUT HAD THE THRU HOLE FOR THE ULTRALOC WITH MALFORMED THREADS. THE MINOR DIAMETER OF THE THREAD WAS GREATER THAN THE MAJOR DIAMETER OF THE THREADS ON THE ULTRALOC. THE CROSS HOLE FOR MOUNTING WAS INCORRECTLY LOCATED WITH INSUFFICIENT EDGE DISTANCE, AND THE PILOT HOLE WAS OFFSET GIVING AN EGG SHAPED HOLE.

DURING PHASE 1 INSPECTION, MAINTENANCE FOUND AFT PROPELLER SPINNER BULKHEAD CRACKED AT ONE FLANGE BY THE PROPELLER BLADE CUT OUT ON ONE SIDE. REPLACED PROPELLER AFT SPINNER BULKHEAD & REINSTALLED PROPELLER.

SECOND FLIGHT OF THE DAY, TEMP 89F, DA 9444. ENGINE START WAS DIFFICULT, TAXI AND ENGINE RUN UP NORMAL. AIRCRAFT TOOK THE RUN WAY FOR TAKE OFF. WHEN THROTTLE WAS OPENED TO FULL POWER, ENGINE HAD POPPING NOISE AND WOULD ONLY DEVELOP 2000 RPM. TAKE OFF WAS ABORTED FOR LOW POWER. A CLEAR LINE WAS INSTALLED FROM THE FUEL INJECTION SERVO TO THE FLOW DIVIDER IAW PRECISION AIRMOTIVE TROUBLE SHOOTING MANUAL AND EXCESSIVE VAPOR IN THE LINE WAS DISPLACING THE FUEL WHEN THE ENGINE WAS RUN. THE ENGINE WAS ALLOWED TO COOL COMPLETELY AND RESTARTED, NO VAPOR WAS DETECTED AND ALL OPERATION WAS NORMAL INCLUDING FUEL FLOW WITH THE ENGINE DEVELOPING FULL POWER. AIRCRAFT TEST FLOWN AND RELEASED.

ENGINE RSA-5AD1 FUEL SERVO WILL NOT MEET SPECIFICATIONS. FUEL FLOW BELOW 1700 RPM IS TOO HIGH. IDLE SPEED AND MIXTURE CAN NOT BE SET TO MFG SPECIFICATIONS WITH SATISFACTORY ENGINE OPERATION. FUEL SERVO REMOVED, SENT FOR REPAIRS. MAJOR REPAIRS ACCOMPLISHED AND SERVO REFLOWED TO PRECISION FLOW SHEET 30075-02 DATED 5 JAN 00. REINSTALLED FUEL SERVO, ADJUSTED IAW MFG SPECIFICATIONS, OPERATIONAL AND FLIGHT CHECKED SATISFACTORY.

PILOT REPORTED HIS SEAT LOCK PINS WOULD NOT RELEASE. MAINTENANCE FOUND THE PILOTS SEAT LOCK CONTROL WAS BROKEN. THIS SAME CONTROL WAS REPLACED 431.0 HOURS PRIOR FOR THE SAME PROBLEM. BOTH CONTROL ASSEMBLYS HAVE PN 1611020-05 REPLACE CONTROL ASSEMBLY, OPERATIONAL CHECK SATISFACTORY.

PILOT ATTEMPTED ENGINE START, STARTER WOULD NOT ROTATE. MAINTENANCE FOUND STARTER HAD TWO TERMINALS MELTED WHERE THAT ATTACH TO COMMUTATOR BRUSHES. REPLACED STARTER, OPERATIONAL CHECKED SAT.

PILOT ATTEMPTED ENGINE START. FIRST FLIGHT OF THE DAY, STARTER WOULD NOT ROTATE. MAINTENANCE FOUND STARTER HAD TWO TERMINALS MELTED WHERE THEY ATTACH TO COMMUTATOR BRUSHES. REPLACED STARTER, OPERATIONAL CHECKED SAT.

DURING PHASE 2 INSPECTION, PARKING BRAKE CROSSOVER CABLE, BELLCRANK BOLT WAS BACKED OUT AND RESTRICTING PILOT''S R-RUDDER PEDAL, FWD TRAVEL. WITH THE BOLT BACKED OUT OF THE BELLCRANK, PARKING BRAKE INOP. THE FIBERLOCK NUT WAS FOUND DOWN UNDER THE RUDDER PEDALS AND THE BOLT WAS BENT SLIGHTLY. NO PREVIOUS WORK ACCOMPLISHED ON PARKING BRAKE OR RUDDER PEDALS. IT IS ASSUMED THE NUT WAS NOT TIGHTENED ON INSTALL. THE ONLY WRITE-UP ON ACFT ENTERING PHASE INSPECT WAS PARKING BRAKE INOP. SUBMITTER RECOMMENDED THE AN3-13A BOLT SECURING THE PARKING BRAKE CROSSOVER CABLE BELLCRANK PN 0713070-9 BE INSTALLED FROM RT TO LT INSTEAD OF PRESENT INSTALL LT TO RT. (X)

DURING PHASE 2 INSPECTION, FOUND 4 LOWER COWL ATTACH SHOCK MOUNTS TORN AT THE BASE. LOCATED AT THE 2, 3, AND 4 O'CLOCK POSITIONS AND THE LOWER L. REPLACED SHOCK MOUNTS.

DURING PHASE 2 INSPECTION, FOUND LOWER COWL SHOCK MOUNT BRACKET CRACKED AT THE 4 O'CLOCK POSITION. THE OTHER HALF OF THE SHOCK MOUNT BRACKET WAS ALSO CRACKED, P/N 045303-3. REPLACED BOTH BRACKETS.

DURING PHASE 2 INSPECTION, FOUND LOWER COWL SHOCK MOUNT BRACKET CRACKED AT THE 4 O'CLOCK POSITION. THE OTHER HALF OF THE SHOCK MOUNT BRACKET WAS ALSO CRACKED, P/N 045303-3. REPLACED BOTH BRACKETS.

NEW 172S CONDUCTING FLIGHT TRAINING AT AIRFIELD ABOVE 6,000 FEET WITH DENSITY ALTITUDE AT 9,000 FEET AND AMBIENT TEMP APPROXIMATELY 89 DEGREES FAHRENHEIT. TAXI AND RUN-UP CHECKS SATISFACTORY. ON TAKEOFF ROLL, PILOT REPORTED POWER LOSS AND REJECTED TAKEOFF. AIRCRAFT RETURNED TO MAINT AND SHUT DOWN. APPROX 20 MINUTES LATER, MAINT ATTEMPTED TO START ENGINE, WITH BOOST PUMP ON, MIXT AND THROTTLE FULL OPEN. NO FUEL FLOW COULD BE ATTAINED DUE TO FUEL VAPORIZATION. AFTER ALLOWING ENGINE TO COOL SUFFICIENTLY, ENGINE START AND RUN-UP WERE NORMAL.

NEW CESSNA WITH 97.4 HOURS SINCE NEW. DURING FIRST PHASE 2 INSPECTION, FOUND PILOT'S AND COPILOT'S RUDDER PEDALS WERE NOT ALIGNED PARALLEL TO ONE ANOTHER. THE PILOT'S 'R' AND COPILOT'S 'L' RUDDER PEDAL MOUNT ARMS WERE MISDRILLED WHERE THEY MOUNT TO THE RUDDER PEDAL CROSS-OVER SHAFT. REPLACED BOTH ARMS WITH CORRECTELY DRILLED PARTS FROM CESSNA AND ALIGNMENT IS NOW CORRECT.