MIDWEST FLYING SERVICE, INC.

LEFT INNER GEAR DOOR ACTUATOR WOULD NOT OPEN DUE TO INTERNAL MALFUNCTION RESULTING IN NOT LETTING THE LEFT GEAR LEAVE THE GEAR WELL. THE AIRCRAFT MADE A GEAR UP LANDING. THE ACTUATOR IS AN OZONE P/N 2924-3, PIPER P/N 455-946. THE ACTUATOR WAS INSTALLED 12-95 AND HAD 3086 HOURS SINCE INSTALLED.

ON AUG 6, 2009 AT 6:45 AM, DURING TAKEOFF, THE NR 2 ENGINE FAILED WITH A REPORTED "LOUD SHARP BANG" RESULTING IN THE ACFT`S "YAWING". THERE WERE NO INDICATIONS OF FIRE/SMOKE, HOWEVER, AN EMERGENCY WAS DECLARED AND ACFT RETURNED TO DEPARTURE AIRPORT AND LANDED UNEVENTFULLY. POST FLIGHT INSPECTION REVEALED THE N1 SPOOL HAD LOCKED UP AND VISUAL INSPECTION OF THE EXHAUST DUCT REVEALED LPT3 BLADE MID SPAN BLADE SEPARATIONS WITH SUBSEQUENT DOWN STREAM OBJECT DAMAGE IN THE FORM OF IMPACT DAMAGE (DENTS). THE ENGINE WAS RETURNED TO MFG FOR ENGINEERING INVESTIGATION. DISASSEMBLY FINDINGS AND MATERIAL ANALYSIS OF THE HPT ROTOR ASSY REVEALED ONE BLADE EXHIBITED A FLAT AREA INDICATIVE OF FATIGUE AND WAS OBSERVED ON THE FRACTURE SURFACE AND APPEARED TO EMANATE FROM THE L/E OF THE BLADE. HEAVY OXIDATION OBSCURED THE FINER FEATURES ON THE FRACTURE SURFACE. THE REMAINING FRACTURE SURFACES OF THE SEPARATIONS ON THE REMAINING HPT BLADES WERE INDICATIVE OF OVERLOAD AND DID NOT EXHIBIT ANY FEATURES RELATED TO FATIGUE. (K)

AFTER INSTALLING REBUILT MAGS, TEST RAN AND WAS KNOCKING. REMOVED NR 1 CYLINDER AND FOUND CRANKSHAFT BROKEN AT THE JOURNAL. I FEEL THE CRANK MAY BE BROKEN IN ANOTHER SPOT. MFG IS AWARE OF THIS AND A REPLACEMENT ENGINE HAS BEEN SENT. PILOT WAS FLYING AT 7000 FT AND THE ENGINE QUIT. MADE A SAFE LANDING. (CE01200502280)

PILOT WAS FLYING AT 7000 FT AND LOST POWER. ENGINE WENT TO IDLE. MADE A SAFE LANDING. AFTER COMING TO A STOP THE ENGINE WS NOT RUNNING. FOUND THE MAGS BOTH LT AND RT HAVE NO SPARK. REMOVED P LEADS AND STILL NO SPARK. REPLACED CONDENSORS AND STILL NO SPARK. REMOVED MAGS FROM ENGINE AND BENCH CHECKED AND NO SPARK. THE LT MAG HAS SN LISTED ABOVE AND RT MAG SN DO4DA208R. AFTER TALKING WITH MFG CAN NOT FIND CAUSE OF THE PROBLEM. ENGINE WAS FROM FACTORY AND INSTALLED AT 6/23/04, AND THE MAGS FAILED ON 11-13-04 WITH 35.14 HOURS SINCE OVERHAUL. (CE01200502044)

PILOT WAS FLYING AT 7000 FT AND LOST POWER. HE SAID ENGINE WENT TO IDLE. HE MADE A SAFE LANDING. AFTER COMING TO A STOP THE ENGINE WAS NOT RUNNING. FOUND THE MAGS BOTH LT AND RT HAVE NO SPARK. REMOVED P LEADS AND STILL NO SPARK. REPLACED CONDENSERS AND STILL NO SPARK. REMOVED MAGS FROM ENGINE AND BENCH CHECKED AND NO SPARK. THE LT MAG HAS SN LISTED ABOVE AND RT MAGS SN D04DA208R. AFTER TALKING WITH MFG AND IS WARRANTY ISSUE, CANNOT FIND CAUSE OF PROBLEM. ENGINE WAS FROM FACTORY AND INSTALLED AT 6/23/2004, AND THE MAG FAILED ON 11/13/2004 WITH 35.14 HOURS SINCE OVERHAUL. (K)

ON A PART 91 FLIGHT THE GEAR DID NOT GET A LT DOWN LIGHT AND THE GEAR SELECTOR DID NOT COME BACK TO CENTER. AFTER A SAFE LANDING FOUND THE SWITCH NOT OPENING ALL THE WAY. CLEANED SWITCH AND BELIEVE THAT THE INTERNAL SPRING IS BROKEN AND ONLY ALLOWING HALF TRAVEL OUT AND NOT DISENGAGING SWITCH.

CYLINDER WAS INSTALLED USING NEW RINGS AND GASKET SET FROM ECI ALSO. REMOVED CYLINDER DUE TO LOW COMPRESSION AND EXHAUST STAINS AROUND THE EXHAUST AREA. FOUND THAT HEAD WAS CRACKED BETWEEN BOTH SPARK PLUG HOLES AND BY THE EXHAUST SEAT, WHICH IN RETURN BURNED A HOLE NEXT THE EXHAUST FLANGE.

REMOVED HEATER FROM AIRCRAFT, 12 VOLT STYTEM AND FOUND (PN 45D70-1A) 24 VOLT. NO ENTRY IN THE AIRCRAFT LOG BOOK OF HEATER REPLACED. AFTER TALKING TO OVERHAUL SHOP, THEY ARE THE SAME HEATER EXCEPT ONE IS A 12 VOLT AND THE OTHER 24 VOLT ON THE COMPONENTS. HEATER WAS REPLACED WITH CORRECT UNIT FOR SERIAL NUMBER OF AIRCRAFT. PROBABLE CAUSE: FIELD OVERHAUL AND TRYING TO MAKE A GOOD HEATER OUT OF SEVERAL JUNK HEATERS.

AIRCRAFT ON 135 FLIGHT, PILOT NOTICED BLUE FLAME IN COWLING, RIGHT ENGINE. LANDED AT COLUMBIA, MO ON A SCHEDULED STOP. FOUND NR 5 CYLINDER HAD EXHAUST HOLE BURNED THROUGH CYLINDER FORWARD SIDE, .25 INCH BY 1 INCH. HOLE STARTED ON INSIDE EXHAUST PART BY EXHAUST SEAT AND WORKED OR BURNED FORWARD FRONT OF ENGINE. CRACKS WERE NOTED FROM BOTH SPARKPLUG HOLES TO BURNED HOLE. THE CYLINDERS WERE NEW, ECI INSTALLED 2-18-99 AND HAD 974.6 HOURS ON CYLINDER, OCCURRED 11-20-00. (X)