CASTLE AVIATION INC

Operated by Castle Aviation (per NTSB report)

Operated by CASTLE AVIATION INC (per NTSB report)

FOUND CRACK IN WEB OF WEB OF NOSE LANDING GEAR ATTACH FITTING LOCATED ON LOWER FIREWALL. REPLACED FITTING WITH NEW PART. THIS AIRCRAFT WAS INVOLVED IN A HARD LANDING CAUSING NOSE LANDING GEAR DAMAGE IN 2003 WHICH MAY HAVE CONTRIBUTED TO THIS FINDING.

PILOT REPORTS “L SIDE EADI WENT BLANK FOLLOWED BY STRONG, VISIBLE SMOKE IN THE COCKPIT. NO CB'S POPPED AT TIME OF FAILURE. DPU1 IN AVIONICS BAY FOUND TO BE THE ISSUE. REMOVED AND REPLACED DPU1. OPS CHECKS GOOD AT THIS TIME. PART REMOVED:P/N 622-7713-004, S/N 3042.

PILOT REPORTS “L SIDE EADI WENT BLANK FOLLOWED BY STRONG, VISIBLE SMOKE IN THE COCKPIT. NO CB'S POPPED AT TIME OF FAILURE. DPU1 IN AVIONICS BAY FOUND TO BE THE ISSUE. REMOVED & REPLACED DPU1. OPS CHECKS GOOD AT THIS TIME.

DURING TAKEOFF ROLL OUT OF DPA, PILOTS AIRSPEED INDICATOR INOPERATIVE. PILOT ABORTED TAKEOFF AND RETURNED TO RAMP. AVIONICS SHOP REPLACED DEFECTIVE AIRSPEED INDICATOR, OPERATIONAL CHECK NORMAL.

EN ROUTE FROM LCK TO DPA PILOT NOTICED DOOR FRAME NEXT TO WINDSHIELD WAS HOT TO THE TOUCH, THEN DIVERTED TO FWA. REMOVED AND REPLACED DEFECTIVE BLEED AIR REGULATOR OPS CHECKS GOOD.

DURING A HMBV INSPECTION, THE SEAT TRACK AT BL 0.0 WAS FOUND TO BE CORRODED BETWEEN FS 297 TO FS 314. REMOVED 31 OF SEAT 31 OF SEAT TRACK FROM FS 297 TO FS 328. POSITIONED SPLICE SECTION P/N 7253799-381 AND U-BEAM REPAIR PIECE. TREATED AND INSTALLED IAW SAAB SRM (72LKS 3079 REV 50) CHAPTER 53-70-60. AIRCRAFT RETURNED TO SERVICE.

ON FLIGHT 3006, CREW REPORTED DURING CRUISE AT 9000 FEET, THAT THEY WERE STRUCK BY LIGHTNING. CREW LOST BOTH EFIS SYSTEM, AUTOPILOT, AND MOST OF THE ALERTING SYSTEM. AFTER RESETTING BOTH GENERATORS CREW GOT ALL INDICATIONS BACK EXCEPT THE RT FUEL QUANTITY GAUGE. CREW DECLARED EMERGENCY. AIRCRAFT LANDED SAFELY AND TAXIED TO THE GATE WITHOUT FURTHER INCIDENT.

ON FLIGHT 3062 CREW REPORTED EMERGENCY EXIT LIGHTS DO NOT COME ON WITH SWITCH IN ON POSITION. AIRCRAFT REMOVED FROM SERVICE. REMOVED AND REPLACED EMERGENCY POWER SUPPLY AT LOCATION 20LN IAW SAAB AMM 33-50-10. OPERATIONAL CHECK GOOD AT THIS TIME IAW SAAB AMM 33-50-00 AIRCRAFT RETURNED TO SERVICE.

WITH OR WITHOUT A/P, A/C EXPERIENCES LEFT TO RIGHT LATERAL VIBRATIONS AT HIGHER SPEEDS (NOT TURBULENCE) OVER-200 KTS. NO RELATIONSHIP TO POWER LEVER SETTINGS. COMPLIED WITH INFLIGHT VIBRATION INSPECTION IAW AE WC NR 05-02133 PART 1. DURING INSPECTION FOUND RUDDER DAMPENER LT SIDE BOLT BROKEN AND DAMPENER OUT OF ADJUSTMENT (LEVER). REMOVED AND REPLACED DAMPENER LEFT BOLT AND ADJUSTED DAMPENER IN REFERENCE TO SAAB MM 27-22-35. AIRCRAFT RETURNED TO SERVICE.

AVIONIC SMOKE LIGHT INFLIGHT, WENT OUT AFTER 10 MINUTES FOLLOWING LEFT AND RIGHT AVIONIC SWITCHES SELECTED TO OFF. EMERGENCY DECLARED, RETURNED TO LAX. REMOVED AND REPLACED AVIONIC SMOKE DETECTOR IAW SAAB AMM 26-13-05. OPERATIONAL CHECK GOOD, RETURNED AIRCRAFT TO SERVICE.

EMERGENCY FLOOR LIGHTING INOPERATIVE. REMOVED AND REPLACED 20LN EMERGENCY POWER SUPPLY IAW SAAB AMM. OPERATIONAL CHECK GOOD. RETURNED AIRCRAFT TO SERVICE.

EMERGENCY PROXIMITY FLOOR LIGHT AT ROW 8 INOPERATIVE. REMOVED AND REPLACED POWER SUPPLY AT POSITION 24LN IAW SAAB AMM 33-50-10. OPERATIONAL CHECK GOOD, RETURNED BACK TO SERVICE.

CREW REPORTED AN ELECTRICAL BURNING SMELL IN THE COCKPIT. REPLACED NR 2 DPU IAW AMM. OPERATIONAL CHECK GOOD. AC RETURNED TO SERVICE. (SW21200600453) (K)

SEAT TRACK BL0 WAS FOUND TO BE CORRODED BETWEEN STA 339 AND 363. BLENDED THE SEAT TRACKS TO REMOVE THE CORROSION. CUT A SECTION FROM U-BEAM FOR REPAIR. CLEANED TREATED AND INSTALLED U-BEAM IN SEAT TRACK. REPAIR DONE IAW SRM. (K)

PILOT REPORTED THAT IN LEVEL CRUISE FLIGHT AFTER ENCOUTERING TURBULENCE THE CABIN DOOR OPEN LIGHT ILLUMINATED. IMMEDIATELY FOLLOWING THE LIGHT THE UPPER CABIN DOOR OPENED AND DEPARTED THE AIRCRAFT. THE PILOT EXECUTED AN EMERGENCY LANDING WITH NO FURTHER INCIDENT. THE AIRCRAFT WAS INSPECTED AND THE FORWARD AND AFT DOOR LATCH MICROSWITCHES AND THE DOOR OPEN LIGHT WERE FOUND TO BE OPERATIONAL. THE DOOR WAS RETREIVED AND THE LATCHING MECHANISM WAS FOUND INTACT AND OPERATIONAL. (EA13200501883) (EA13200501865)

AT 11,000 RT ENGINE MADE A LOUD BANG. OIL PRESSURE LIGHT CAME ON AS OIL PRESSURE DROPPED. ITT EXCEEDED 1200C AND INCREASING RAPIDLY, ENGINE SHUT DOWN PERFORMED. SUP-MAINTENANCE REMOVED AND REPLACED THE RIGHT ENGINE IAW WORK CARD. OPERATIONAL AND LEAK CHECKS WERE GOOD AND AIRCRAFT WAS RETURNED TO SERVICE. (PTRS NR: SW21200305091)

LAX - FLT 3269 - CREW REPORTED THE AVIONICS SMOKE LIGHT CAME ON DURING TAKEOFF. TAKEOFF WAS ABORTED AND AIRCRAFT WAS RETURNED TO GATE. MAINTENANCE CLEANED THE AVIONICS SMOKE DETECTOR. OPS CHECK WAS GOOD AND AIRCRAFT WAS RETURNED TO SERVICE. (M)

SAN - FLT 3212 - CREW REPORTED THE EMERGENCY OVERHEAD LIGHTS AT SEATS 9A, AND 11A, EMERGENCY EXIT LIGHT OVER SEAT 8A, AND FLOOR PROXIMITY LIGHTS AT 8BC AND 10BC TO BE INOPERATIVE. MAINTENANCE REMOVED AND REPLACED THE EMERGENCY POWER SUPPLY UNIT BATTERY AT POSITION 8BC. OPERATIONAL CHECK WAS GOOD AND AIRCRAFT WAS RETURNED TO SERVICE. (M)

BOS - FLT 4933 - CREW REPORTED INTERIOR EMERGENCY LIGHTS AT SEATS 12BC AND 14AB TO BE INOPERATIVE. MAINTENANCE REMOVED AND REPLACED POWER SUPPLY UNIT 24LN. OPERATIONAL CHECK WAS GOOD AND AIRCRAFT WAS RETURNED TO SERVICE. (M)

SBP - FOUND CABIN EMERGENCY EXIT LIGHTS OUT. REMOVED AND REPLACED EMERGENCY BATTERY ASSEMBLY IAW SAAB AMM 33-50-00. (M)

SBA - FLT 3037 - ON TAKEOFF ROLL, LEFT ENGINE APR DID NOT ARM. ABORTED TAKEOFF. ISSUED MEL 76-02. (M)

FLT 3003 - SAN - CREW REPORTED THE EMERGENCY LIGHTS FAIL AFTER 15 SECONDS. AIRCRAFT WAS FERRIED TO LAX FOR MAINTENANCE. MAINTENANCE REMOVED AND REPLACED BATTERY PACKS (S/N 18484, 17509) AT 141AL AND 141CZ. OPS CHECK WAS GOOD AND AIRCRAFT WAS RETURNED TO SERVICE. (M)

MHT - FLT 4460 - EMERGENCY FLOOR PROXIMITY LIGHTS AT 6, 7, 8BC AND OVERHEAD LIGHTS AT 7A, 8, 10BC, INOPERATIVE. MAINTENANCE REMOVED AND REPLACED EMERGENCY POWER SUPPLY UNIT 22LN. OPERATIONAL CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (X)

MHT - FLT 4460 - EMERGENCY FLOOR PROXIMITY LIGHTS AT 6, 7, 8BC AND OVERHEAD LIGHTS AT 7A, 8, 10BC, INOPERATIVE. MAINTENANCE REMOVED AND REPLACED EMERGENCY POWER SUPPLY UNIT 22LN. OPERATIONAL CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (X)

JFK - FLIGHT 5019 - CREW REPORTED AUTO TRIM LIGHT ILLUMINATED AFTER LANDING GEAR RETRACTION. UNABLE TO EXTINGUISH LIGHT FOLLOWING CHECKLIST PROCEDURES. CREW RETURNED TO JFK. MAINTENANCE PERFORMED OPERATIONAL CHECK OF AUTOPILOT AUTO TRIM IAW SAAB MM 22-10-00 PROCEDURE 8. NO DEFECTS WERE NOTED AND AIRCRAFT WAS RETURNED TO SERVICE. (M)

SBP - DURING 5000 HOUR INSPECTION, FOUND CORROSION ON THE ENTRY WAY KICK PLATE AT FS 294. REPLACED ENTRY WAY KICK PLATE IAW SAAB AMM 51-40-21 AND 51-20-50. (M)

SBP - DURING 500 HOUR INSPECTION, FOUND CORROSION ON FORWARD END OF 18.3 BL LEFT SEAT TRACK. CUT SEAT TRACK AT FS 325.8 AND INSTALLED NEW SECTION OF REPAIR TRACK AND U-BEAM IAW SAAB SRM 53-70-60. (M)

SBP - DURING 5000 HOUR INSPECTION, FOUND CORROSON ON LOWER FUSELAGE RIVET HEADS BETWEEN STATION 518 AND 535 AT BL 0.0. REPLACED 43 RIVETS IAW SAAB SRM 51-40-21. (M)

SBP - DURING 5000 HOUR INSPECTION, FOUND CORROSION ON FUSELAGE INTERCOSTAL AND ANGLE BETWEEN FS 272 AND FS 288 IN CABIN ENTRY AREA. REPLACED INTERCOSTAL P/N 7253720-319 AND ANGLE P/N 7253720-337 IAW SAAB SRM 51-40-00. (M)

SBP - DURING 5000 HOUR INSPECTION, FOUND CORROSION ON FUSELAGE CABIN BOTTOM FRAME AT STATION 272 AT BL 0 BETWEEN BLR 15 AND BLR 24. REPAIRED FRAME BY INSERTION OF SPLICE AND DOUBLER IAW SAAB STRUCTURAL REPAIR STATEMENT NR 72SDS2633. (M)

DURING 5000 HOUR INSPECTION, FOUND SEAT TRACK BL 15.8 AND ATTACHMENT PROFILE FROM STATION 216-272 IN LAVATORY AREA CORRODED. REPLACED LAVATORY TRACK PART NR 7253721-459 AND PROFILE PART NR 7253721-495 FROM STATION 216-272 PART NR 7253721-495. (M)

DURING 5000 HOUR INSPECTION, FOUND CORROSION ON THE UPPER AFT FACING FLANGE OF CABIN BOTTOM FRAME UPPER FLANGE AT STATION 258 BETWEEN BL10 AND RBL 10.0. CUT OUT THE CORROSION AND INSTALLED REINFORCEMENT ANGLES IAW SAAB STRUCTURAL REPAIR STATEMENT. (M)

SBP - DURING 5000 HOUR INSPECTIN, FOUND CORROSION ON ANGLE PART NUMBER 7253722-001 AT FUSELAGE STATION 258 IN CABIN ENTRANCE AREA. REPLACED ANGLE IAW SAAB STRUCTURAL REPAIR STATEMENT PROCEDURES. (M)

SBP - DURING 5000 HOUR INSPECTION, FOUND FUSELAGE INTERCOSTAL UNDER FLOORBOARD IN FORWARD ENTRANCE AREA BETWEEN STATIONS 236.5 AND 258 CORRODED. REPLACED INTERCOSTAL. (M)

SBP - DURING 5000 HOUR INSPECTION, FOUND FUSELAGE ANGLE UNDER FLOORBOARD IN FORWARD ENTRANCE AREA BETWEEN STATIONS 236.5 AND 258 CORRODED. REPLACED ANGLE. (M)

SBP - FOUND DURING 5000 HOUR INSPECTION, FOUND AIRSTAIRS TRACK CORRODED. REPLACED AIRSTAIRS TRACK. (M)

SBP - DURING 5000 HOUR INSPECTION, FOUND LAVATORY TRACK 15, 8 AND ATTACHMENT PROFILE CORRODED. REPLACED LAVATORY TRACK RBL 15, 8 AND PROFILE, P/N 7253721-495. (M)

SBP - DURING 5000 HOUR INSPECTION, FOUND INTERCOSTAL IN CABIN ENTRANCE AREA BETWEEN STATION 272 AND 288 CORRODED. REMOVED AND REPLACED INTERCOSTAL. (M)

DFW - FLT 3330 - NR 2 OIL CWP WARNING ON IN FLIGHT. SHUT DOWN NR 2 AS PRECAUTION. OIL PRESSURE FLUCTUATED PLUS MINUS 15-20 PSI AV. 20-25 PSI IN YELLOW AND RED AREAS. REMOVED AND REPALCED BB AXIS SEAL KIT ON NR 2 ENGINE IAW GE MM 72-61-00. OPS CHECK GOOD. (M)

JFK - ALL CABIN EMERGENCY LIGHTS INOPERATIVE. MAINTENANCE REMOVED AND REPLACED ALL EMERGENCY LIGHT BATTERY PACKS IAW WORK CARD. OPS CHECK GOOD. (M)

JFK - ALL CABIN EMERGENCY LIGHTS INOPERATIVE. MAINTENANCE REMOVED AND REPLACED ALL EMERGENCY LIGHT BATTERY PACKS IAW WORK CARD. OPS CHECKS GOOD. (M)

JFK - ALL CABIN EMERGENCY LIGHTS INOPERATIVE. MAINTENANCE REMOVED AND REPLACED ALL EMERGENCY LIGHT BATTERY PACKS IAW WORK CARD. OPS CHECK GOOD. (M)

JFK - FOUND ALL CABIN EMERGENCY LIGHTS INOPERATIVE. MAINTENANCE REMOVED AND REPLACED ALL EMERGENCY LIGHT BATTERY PACKS IAW WORK CARD. OPS CHECK GOOD. (M)

DURING ACCOMPLISHMENT OF AD 96-19-05, ULTRASONIC INSPECTION OF MAIN LANDING GEAR YOKES, THE FOLLOWING DEFECT INDICATIONS WERE NOTED. THE INBOARD SIDE OF THE RT MLG YOKE HAD A CRACK INDICATION .500 INCH IN LENGTH BELOW THE FILL VALVE/RETAINING PIN HOLE. THE OUTBOARD SIDE HAD A .500 INCH CRACK INDICATION BELOW THE FILL VALVE/RETAINING PIN HOLE. ADDITIONAL INDICATIONS WERE FOUND IN THE LEFT MLG YOKE. (X)

DURING ACCOMPLISHMENT OF AD 96-19-05, ULTRASONIC INSPECTION OF MAIN LANDING GEAR YOKES, THE FOLLOWING DEFECT INDICATIONS WERE NOTED. THE INBOARD SIDE OF THE LT MLG YOKE HAD 3 CRACK INDICATIONS. NR 1, A .250 INCH CRACK INDICATION ABOVE FILL VALVE/RETAINING PIN HOLE. NR 2 AND NR 3, .250 INCH CRACK INDICATIONS BELOW THE FILL VALVE/RETAINING PIN HOLE. OTBD SIDE HAD A .500 INCH CRACK INDICATION ABOVE FILL VALVE/RETAINING PIN HOLE. ADD''L INDICATIONS FOUND IN RT MLG YOKE. (X)

JFK - FLT 5051 - AFTER TAKEOFF, AIRCRAFT ROLLED 15 TO 20 DEGREES TO LEFT. ON CLIMB, AIRCRAFT YAW RIGHT AND LEFT THEN PITCHED DOWN 5 DEGREES TO APPROX LEVEL. AIRCRAFT RETURNED WITH NO INCIDENT. REMOVED AND REPLACED FLIGHT CONTROL COMPUTER, OPS CHECK AND FCF OF AIRCRAFT GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

SBA - FLT 3208 - SEAT 9A EMERGENCY OVERHEAD LIGHT DOES NOT ILLUMINATE. REMOVED AND REPLACED OVERHEAD EMERGENCY LIGHT BULB. OPERATIONAL CHECK GOOD. AIRCRAFT RETURNED TO SERVICE. (M)

DFW - FLT 5026 - SEVERAL FLOOR PROXIMITY LIGHTS DO NOT ILLUMINATE. REMOVED AND REPLACED FLOOR PROXIMITY LIGHTS BULBS. OPERATINOAL CHECK GOOD. (M)

FLT 5055 - CREW FOUND EMERGENCY LIGHT SWITCH WAS LEFT IN THE ARM POSITION, ALL AIRCRAFT EMERGENCY LIGHTS DO NOT ILLUMINATE. REMOVED AND REPLACED ALL EMERGENCY LIGHT POWER SUPPLY'S . OPERATIONAL CHECK GOOD. (M)

LAX - FLT 3386 - UNCOMMANDED PITCH MOVEMENTS IN-FLIGHT WITH OR WITHOUT AUTOPILOT. VERIFIED THE FLAPS DID NOT APPEAR TO BE MOVING. REMOVED AND REPLACED THE FLIGHT CONTROL COMPUTER. OPERATIONAL CHECK AND TEST FLIGHT PERFORMED WITH NO FURTHER PROBLEMS NOTED. AIRCRAFT RETURNED TO SERVICE. (X)