Lycoming IO-540-K1G5

Service difficulty reports · 163

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duckdb -csv -c "SELECT sdr_id, difficulty_date, n_number, aircraft_make, aircraft_model, part_name, part_condition, jasc_code, discrepancy
  FROM 'https://openairdocs.org/data/latest/faa_service_difficulty_report.parquet'
  WHERE engine_model_key = 'IO540K1G5'
  ORDER BY difficulty_date DESC"

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SDR 8TNC202609060001Case · crackedTHIS ENGINE HAS BEEN REMOVED FROM SERVICE DUE TO A CRACK ON THE RT SIDE OF THE CASE BELOW THE NR 3 CYLINDER AT THE FORWARD LOWER CYLINDER HOLD DOWN NUT. CRACK STARTS FROM THE FORWARD LOWER CYLINDER HOLD DOWN NUT AND CONTINUES ABOUT 3 INCHES. ENGINE REMOVED FSep 6, 2026 · N81052 · Piper PA32301 · Reciprocating Engine Power SectionSDR 2024FA0000727Cylinder · damagedALL CYLINDERS WERE FOUND TIGHTLY INSTALLED TO THE ENGINE CASE AND REMOVED FOR EXAMINATION. CYLINDERS NUMBER 1, 2, AND 6 WERE REMOVED WITH MINOR RESISTANCE ONCE ATTACHING HARDWARE WAS REMOVED. CYLINDERS 3, 4, AND 5 WERE MET WITH RESISTANCE DURING THE REMOVAL PRSep 19, 2024 · N651E · Reciprocating Engine Cylinder SectionSDR 2022FA0000288Landing Gear · noneON 12/3/2021 ON TAKE-OFF ROLL, THE NOSE LANDING GEAR SUDDENLY RETRACTED CAUSING THE AIRCRAFT TO SUFFER A PROP STRIKE AND OTHER NON-STRUCTURAL DAMAGE. THE CAUSE WAS BELIEVED TO BE A WORN HYDRAULIC ACTUATOR. REPAIRS WERE UNDERTAKEN AND THE AIRCRAFT RETURNED TO SDec 3, 2021 · Piper PA32R300 · Fuselage Structure (General)SDR 2021F00275Magneto · malfunctionedWHILE IN CRUISE FLIGHT EXPERIENCED ABNORMAL ENGINE NOISES AND SURGES. SUSPECTED MAG ISSUE DUE TO JUST INSTALLED SUREFLY ELECTRONIC MAG. DECLARED AN EMERGENCY AND LANDED ON AIRPORT. SUREFLY CONFIRMED KNOWN PROBLEM WITH 28 VOLT SYSTEMS WHERE UNIT OVERVOLTAGE Aug 17, 2021 · N529PE · Piper PA32R301 · Magneto/DistributorSDR 2018FA0000447Impulse Coupling · malfunctionedAPPEARS TO HAVE BEEN CAUSED BY IMPULSE COUPLER FAILURE. MAG CAUSED GEAR PN 71652 AND BEARING PN67542 TO FAIL.Oct 25, 2018 · N39771 · Piper PA32300 · Magneto/DistributorSDR D1NR201709200001Trunnion · failedDURING LANDING ROLL-OUT, THE NOSE LANDING GEAR COLLAPSED. DURING INSPECTION, IT WAS DETERMINED THE TRUNNION ASSEMBLY WAS FOUND TO HAVE FAILED NEAR THE NOSE GEAR DOWN-LOCK LINK ATTACH POINT. AFTER THAT AREA OF THE TRUNNION FAILED IT CAUSED THE RIGHT TRUNNION ATAug 22, 2017 · N8800E · Piper PA32R300 · Fuselage, Landing Gear Attach FittingsSDR DSFA2016041100097Impulse Coupling · defectiveREMOVED MAGNETO MODEL 6351 FOR THE 250 HOUR IMPULSE INSPECTION REQUIRED BY AD 99-04-04. THE MAGNETO IMPULSE COUPLING FAILED THE INSPECTION SO WE INSTALLED A SERVICEABLE IMPULSE COUPLING. THE MAGNETO HAD 198.8 HOURS SINCE NEW. 16 HOURS LATER THE MAGNETO MODEL Apr 11, 2016 · N428S · Piper PA32301 · Magneto/DistributorSDR P9KA2014122201Intake Valve · leakingDURING A ROUTINE 100 HOUR INSPECTION, THE NR 2 CYLINDER WAS FOUND TO HAVE COMPRESSION OF 30/80 WITH LEAKAGE OUT THE INTAKE VLV. THIS IS THE THIRD OCCURRENCE OF THE SAME PROBLEM ON THIS FACTORY OVERHAULED ENG IN LESS THAN 500 HOURS SINCE OVERHAUL. THE FIRST TDec 22, 2014 · N8216T · Piper PA32301 · Reciprocating Engine Cylinder SectionSDR CY4R201309050001Nozzle · missingDURING CRUISE FLIGHT, A LOUD NOISE WAS HEARD COMING FROM THE ENGINE COMPARTMENT. FOLLOWED BY AN AIRFRAME VIBRATION, WHICH WAS FOLLOWED BY AN ENGINE SHUT DOWN. AFTER LANDING A LARGE HOLE WAS FOUND IN THE ENGINE CRANKCASE ABOVE THE NR 5 CYLINDER. DURING THE TApr 4, 2013 · N8374T · Piper PA32301 · Reciprocating Engine Cylinder SectionSDR 2012F00133Crankcase · crackedCRACK WAS DISCOVERED IN THE FORWARD LEFT CASE HALF PROPAGATING OUT FROM NR 2 CYLINDER BASE. DAMAGE FOUND DURING ROUTINE 100 HOUR INSPECTION. ENGINE GROUND RUN CONFIRMED CRACK WAS LEAKING OIL.Jul 10, 2012 · N8216T · Piper PA32301 · Reciprocating Engine Power SectionSDR 2011FA0000519Control Arm · brokenTHE PILOT REPORTED THAT THE RUDDER TRIM WAS WEAK. INVESTIGATION LED TO FINDING THE ARM ATTACH POINT ON THE RUDDER CONTROL ARM ASSY (63457-003) HAD BROKEN OFF. THE RUDDER PEDAL ASSY WAS REMOVED FROM THE ACFT AND SUBSEQUENT INSPECTION FOUND THAT THE CENTER SUPAug 5, 2011 · N645BC · Piper PA32300 · Rudder Control SystemSDR 2011FA0000279Control Cable · failedDURING TOUCH AND GO`S, AFTER COMPLETING THE SECOND TOUCH AND GO, AND WITH FULL POWER IN A CLIMB AT AN ALTITUDE OF APPROX 15 FEET, THE NOSE OF THE ACFT PITCHED DOWN ABRUPTLY. THE ACFT NOSE GEAR CONTACTED THE RUNWAY VERY HARD, FOLLOWED IMMEDIATELY BY THE MAIN Apr 7, 2011 · N31407 · Piper PA32300 · Elevator Control SystemSDR 2010FA0001266Control Cable · brokenLOWER FWD STABILATOR CONTROL CABLE, THREADED ROD END BROKE AT THE SAFETY WIRE WRAP WHERE IT THREADS INTO THE TURNBUCKLE THE ONLY THING HOLDING CABLE TOGETHER WAS A SINGLE STRAND OF .041 SAFETY WIRE.Dec 29, 2010 · N2155H · Piper PA32300 · Stabilizer Control SystemSDR 2010FA0000725Spline · shearedFUEL PUMP RECEIVED WITH A SHEARED OFF SPLINE COUPLING. A TEARDOWN ANALYSIS, INSP REPORT EVALUATION, ORIGINAL SALES AND CERTIFICATION DOCUMENTS, APPLICABLE PAGES FROM THE MM AND SB AND PICTURES ARE INCLUDED IN A SEPARATE E-MAIL.Jul 15, 2010 · Fuel Injector NozzleSDR 2010FA0000583Blade · failed((ZY2R)) LOSS OF BLADE TIP IN-FLIGHT. IN FLIGHT, PILOT EXPERIENCED SUDDEN VIBRATION. AS HE WAS OVER AN AIRPORT, IMMEDATELY POWERED BACK AND LANDED THE ACFT APPROX 9 MINUTES LATER. AFTER GO AROUND ACFT INSP PILOT DISCOVERED 1 TIP MISSING FROM THE 3-BLADED PMay 14, 2010 · N83KL · Piper PA32R301 · Propeller Blade SectionSDR 2009FA0000469Cylinder Head · separatedTHIS CYLINDER HAS ONE (1) HOUR OF TEST CELL TIME. THE DEFECT WAS DISCOVERED AND BELIEVED TO BE HEAD BARREL SEPARATION. PERFORMED A COMPRESSION TEST WITH SOAP AND WATER TO CONFIRM OUR FINDING. THE CYLINDER WAS PURCHASED 2/17/2009 AND INSTALLED ON THIS NEWLY OMar 22, 2009 · Reciprocating Engine Cylinder SectionSDR 2009FA0000470Cylinder Head · separatedTHIS CYLINDER HAS ONE (1) HOUR OF TEST CELL TIME. THE DEFECT WAS DISCOVERED AND BELIEVED TO BE HEAD BARREL SEPARATION. PERFORMED A COMPRESSION TEST WITH SOAP AND WATER TO CONFIRM OUR FINDING. THE CYLINDER WAS PURCHASED 2/17/2009 AND INSTALLED ON THIS NEWLY OMar 22, 2009 · Reciprocating Engine Cylinder SectionSDR 2009FA0000471Cylinder Head · separatedTHIS CYLINDER HAS ONE (1) HOUR OF TEST CELL TIME. THE DEFECT WAS DISCOVERED AND BELIEVED TO BE HEAD BARREL SEPARATION. PERFORMED A COMPRESSION TEST WITH SOAP AND WATER TO CONFIRM OUR FINDING. THE CYLINDER WAS PURCHASED 2/17/2009 AND INSTALLED ON THIS NEWLY OMar 22, 2009 · Reciprocating Engine Cylinder SectionSDR 2009FA0000472Cylinder Head · separatedTHIS CYLINDER HAS ONE (1) HOUR OF TEST CELL TIME. THE DEFECT WAS DISCOVERED AND BELIEVED TO BE HEAD BARREL SEPARATION. PERFORMED A COMPRESSION TEST WITH SOAP AND WATER TO CONFIRM OUR FINDING. THE CYLINDER WAS PURCHASED 2/17/2009 AND INSTALLED ON THIS NEWLY OMar 22, 2009 · Reciprocating Engine Cylinder SectionSDR 2009FA0000473Cylinder Head · separatedTHIS CYLINDER HAS ONE (1) HOUR OF TEST CELL TIME. THE DEFECT WAS DISCOVERED AND BELIEVED TO BE HEAD BARREL SEPARATION. PERFORMED A COMPRESSION TEST WITH SOAP AND WATER TO CONFIRM OUR FINDING. THE CYLINDER WAS PURCHASED 2/17/2009 AND INSTALLED ON THIS NEWLY OMar 22, 2009 · Reciprocating Engine Cylinder SectionSDR 2009FA0000474Cylinder Head · separatedTHIS CYLINDER HAS ONE (1) HOUR OF TEST CELL TIME. THE DEFECT WAS DISCOVERED AND BELIEVED TO BE HEAD BARREL SEPARATION. PERFORMED A COMPRESSION TEST WITH SOAP AND WATER TO CONFIRM OUR FINDING. THE CYLINDER WAS PURCHASED 2/17/2009 AND INSTALLED ON THIS NEWLY OMar 22, 2009 · Reciprocating Engine Cylinder SectionSDR FFKA01272008001Pump · failedPILOT REPORTED A VACUUM FAILURE WHILE EN ROUTE TO KCAE.Jan 27, 2009 · N38305 · Piper PA32R300 · Vacuum Distribution SystemSDR PNSA110804Pump · failedAFTER TAKEOFF PILOT SHUT THE FUEL BOOST PUMP (ELECTRIC) AND NOTICED AN IMMEDIATE FUEL FLOW REDUCTION, AND ENGINE BEGAN TO SHUT DOWN. PILOT TURNED BOOST PUMP BACK ON AND POWER WAS RESTORED FULLY. PILOT MADE A UNEVENTFUL LANDING AT THE DEPARTURE AIRPORT. MAINNov 21, 2008 · N8259V · Piper PA32301 · Engine Fuel PumpSDR 2008FA0000409Alternator · damaged4 SCREWS THAT HOLD THE RECTIFIER PLATE INTO THE BACK CASE OF ALTERNATOR CAME LOOSE AND CONTACTED THE ROTOR, DESTROYED ALTERNATOR. (K)Jun 7, 2008 · N30969 · Piper PA32R301 · DC Generator-AlternatorSDR 2008FA0000263Cylinder · crackedNR 2 CYL CRACKED FROM UPPER SPARK PLUG HOLE TO THE EXHAUST VALVE SEAT. CRACK IN HEAD LED TO FAILURE OF EXHAUST PUSHROD HOUSING, AND DEFORMATION OF THE EXHAUST PUSHROD. AC LANDED WITHOUT INCIDENT. (K)Apr 3, 2008 · N8200M · Piper PA32301 · Reciprocating Engine Cylinder SectionSDR 2008F00002Muffler · brokenON CLIMB AFTER TAKEOFF, PILOT HEARD BANG IN ENGINE COMPARTMENT, SMOKE AND FLAMES ENTERED CABIN AT PILOT'S FEET. AFTER LANDING AIRCRAFT, AIRCRAFT BURN, TOTAL LOSS. MUFFLER FOUND CRACKED/BROKEN EMITTING HEAT, FLAME, ETC. THROUGH HEATER MUFF INTO CABIN.Jun 11, 2007 · N6117J · Piper PA32300 · Engine Noise SuppressorSDR PNSA070505Pump · malfunctionedLOW FUEL FLOW. REMOVED AND REPLACED FUEL PUMP.May 19, 2007 · N8259V · Piper PA32301 · Engine Fuel PumpSDR PNSA070401Fuel Nozzle · malfunctionedON TAKEOFF ENGINE BEGIN RUNNING ROUGH LANDED AND CALLED MX. REMOVED AND REPLACED FUEL NOZZLES.Apr 13, 2007 · N4327P · Piper PA32301 · Fuel Injector NozzleSDR FFKA114Gear · damagedPILOT REPORTED THAT THE ENGINE IS RUNNING ROUGH DURING TAXI AND HAD A BAD MAGNETO DROP. MAINTENANCE INVESTIGATED AND FOUND THE GEAR TEETH P/N 10-682016 BROKEN OFF OF BOTH THE LEFT AND RIGHT GEAR ASSEMBLIES. AFTER FURTHER INVESTIGATION OF THE MAGNETO, IT WAS Feb 26, 2007 · N5454F · Piper PA32R300 · Magneto/DistributorSDR PNSA070105Line · looseWHILE EN ROUTE FROM AKN TO DLG, THE PILOT NOTICED OIL PRESSURE WAS ON THE LOW REDLINE AND THE OIL ANNUNCIATOR WAS ON. AIRCRAFT LANDED NORMALLY IN DLG AND PILOT FOUND EXCESSIVE OIL ON BELLY AND THE OIL LEVEL REMAINING WAS 2 QUARTS. MAINTENANCE FOUND THE OIL VAJan 30, 2007 · N82455 · Piper PA32301 · Reciprocating Engine Oil SystemSDR YAX2006F00000Bolt · brokenFOUND BOLT BROKEN AT NR 1 CYLINDER BASE. NUT AND SPACER FROM OPPOSITE SIDE MISSING AT TIME OF INSPECTION. (K)Dec 12, 2006 · N8200M · Piper PA32301 · Reciprocating Engine Cylinder SectionSDR 2006FA0001179Connecting Rod · failedINTERNAL ENGINE FAILURE, CYLINDERS 2 AND 4 CONNECTING RODS FAILED. ENGINE WAS ORIGINAL TO THE AIRCRAFT (1979).Dec 5, 2006 · N2148N · Piper PA32RT300 · Reciprocating Engine Cylinder SectionSDR GQ72006F00000Trunnion · crackedUPON INSPECTION OF THE NOSE GEAR. A 4.5 INCH CRACK WAS FOUND IN THE TUBULAR AREA OF THE LANDING GEAR TRUNNION. CAUSE IS UNKNOWN, BUT SUSPECT HARD LANDING, OR NOSE WHEEL TURNED BEYOND LIMITS. (K)Mar 7, 2006 · N196SQ · Piper PA32R300 · Nose/Tail Landing Gear Attach SectionSDR 2006FA0000230Trunnion · crackedUPON INSPECTION OF THE NOSE GEAR. A 4.5 INCH CRACK WAS FOUND IN THE TUBULAR AREA OF THE LANDING GEAR TRUNNION CAUSE IS UNKNOWN, BUT SUSPECT HARD LANDING OR NOSE WHEEL TURNED BEYOND LIMITS. (K)Feb 23, 2006 · N196SQ · Piper PA32R300 · Nose/Tail Landing Gear Attach SectionSDR LGD2005F00000Landing Gear · collapsedGEAR BROKE ON LANDING ROLLOUT EST. 700 HOURS ON 3600 FLUIDINE SKIS, EST 7,000 HRS ON WHEEL ADAPTERS WITH 8:50 X 10 TIRES. RECOMMEND INSPECTIONS OR LIFE LIMITED PART, BROKE OFF AT TOP BOLT HOLES. (K)Nov 17, 2005 · N771X · Cessna A185E · Main Landing GearSDR PNSA051103Axle · brokenAIRCRAFT WAS DEPARTING WITH QUARTERING CROSSWIND JUST AS THE AIRCRAFT WAS ROTATING PILOT FELT AND HEARD A (THUD) ON THE RT SIDE OF AIRPLANE. AIRCRAFT RETURNED TO ITS MAINTENANCE BASE AND A FLYBY WAS MADE AND IT WAS DISCOVERED THAT THE RAT WHEEL AND AXLE ASSEMBNov 16, 2005 · N81052 · Piper PA32301 · Hydraulic System, MainSDR PNSA060502Fuel Control · unknownPILOT WAS TAKING OFF AND JUST AS HE ROTATED THE ENGINE BEGAN TO RUN ROUGH, THE PILOT HAVING RUNAWAY LEFT LANDED AND SHUT DOWN ENGINE. MX STARTED THE ENGINE AFTER SOME DIFFICULTY THEN REPLACED FUEL SERVO, CLEANED FUEL NOZZLES, SUMPED A VERY SMALL AMOUNT OFF WAJun 22, 2005 · N4327P · Piper PA32301 · Fuel Control/Turbine EnginesSDR 2005FA0000445Rack · dislodgedDURING ANNUAL INSPECTION, FOUND ELT LAYING ON THE CONTROL CABLES IN AFT FUSELAGE. LATCH AHD FAILED ON ELT RACK. (EA21200505230) (K)Mar 7, 2005 · N8310H · Piper PA32301 · Emergency Locator BeaconSDR AU510001607Landing Gear · collapsedLT MAIN LANDING GEAR COLLAPSED. AIRCRAFT AND LANDING GEAR DAMAGED.Jan 7, 2005 · Piper PA32RT300 · Main Landing GearSDR LAB2004F00001Probe · inoperativeOAT (OUTSIDE AIR TEMPERATURE) PROBE INSTALLED IN CONJUNCTION WITH EFIS-SV SYSTEM FAILED. REPLACED PROBE WITH NEW AND CORRECTED PROBLEM.Sep 29, 2004 · N666EB · Piper PA32300 · Outside Air Temperature Indicator/SensorSDR BJ3R200400002Alternator · defectivePREVIOUSLY INSTALLED OVERHAULED ALTERNATOR FAILED AFTER APPROXIMATELY 27 HOURS OF OPERATION. THE ALTERNATOR WAS MANUFACTURED BY KELLY AEROSPACE/ELECTROSYSTEMS. THERE WAS EXCESSIVE BINDING OF THE ALTERNATOR SHAFT AND PULLEY. IN ADDITION, TWO EACH OF THE COOLSep 27, 2004 · N75143 · Piper PA32R300 · Alternator-Generator DriveSDR LAB2004F00002Ahrs · malfunctionedAHRS (ALTITUDE HEADING REF SYSTEM) INSTALLED IAW EFIS-SV SYSTEM UNDER STC NR SA02203AK FAILED TO REPORT HEADING INDICATION.Sep 21, 2004 · N54KA · Piper PA32300 · Integrated Flight SystemSDR 2005FA0000441Display · inoperativeTHE INSTRUMENT DISPLAY UNIT (IDU) PRIMARY FLIGHT DISPLAY INSTALLED AS PART OF FLIGHT SYSTEM, INC EFIS-SV SYSTEM FAILED. DURING BOOT-UP, THE DISPLAY SHOWED VERTICAL LINES ACROSS THE SCREEN. (K)Sep 15, 2004 · N8127Q · Piper PA32300 · Instrument PanelSDR 2004FA0000942Adc · malfunctionedUNIT REPORTING ERRONEOUS ALTITUDE READINGS UP TO 1000 FEET OFF. (AL05200401238)Sep 14, 2004 · N31589 · Piper PA32300 · Air Data ComputerSDR YAX2004F00000Adc · malfunctionedADC REPORTING TO IDU VARIED ALTITUDE OF +800 FEET. CROSSWIND COMPONENT ERRONEOUS AT TIMES. UNIT INSTALLED AS PART OF EFIS-SV SYSTEM.Jul 13, 2004 · N8200M · Piper PA32301 · Air Data ComputerSDR PNSA040701Line · looseDURING CLIMB WHEN POWER WAS REDUCED ENGINE FUEL PRESSURE DROPPED AND ENGINE POWER WAS PARTIALLY LOSS. AIRCRAFT RETURNED TO AIRPORT AND MAINTENANCE FOUND FUEL INJECTOR LINE HAD COME LOOSE. THIS WAS FIRST FLIGHT AFTER FUEL INJECTOR MAINTENANCE.Jul 9, 2004 · N8470Y · Piper PA32301 · Fuel Injector NozzleSDR 2004FA0000550Exhaust Valve · brokenTHE PILOT REPORTED A LOSS OF POWER AND LOSING ALTITUDE TO AIR TRAFFIC. AN EMERGENCY LANDING WAS ACCOMPLISHED AT A PUBIC AIRPORT. MAINTENANCE PERSONNEL FOUND THE NR 2 CYLINDER HAD A BROKEN EXHAUST VALVE, WITH THE PISTON AND CYLINDER DAMAGED DUE TO THE HEAD OF TJul 7, 2004 · N9SA · Piper PA32R300 · Reciprocating Engine Cylinder SectionSDR 2005FA0000438Ahrs · malfunctionedAHRS REPORTING TO IDU WANDERING HEADING AND ERRONEOUS ACCELL/DECELERATION. UNIT INSTALLED AS PART OF FLIGHT SYSTEMS, INC EFIS-SV SYSTEM. (K)Jun 16, 2004 · N8200M · Piper PA32301 · Attitude and Direction Data SystemSDR AUS20040441Trunnion · cracked(AUS) RT MAIN LANDING GEAR TRUNNION CRACKED.May 21, 2004 · Piper PA32R301 · Main Landing Gear Attach SectionSDR 2004F00146Points · failedINVESTIGATION OF MAGNETO FAILURE FOUND THAT THE CONTACT ARM OF THE PRIMARY POINT SET HAD SNAPPED OFF. THE BREAK OCCURED AT THE AREA WHERE THE STIFFENER FLANGES FLATEN OUT. JUST AT THE EDGE OF THE NYLON BLOCK. UNABLE TO DETERMINE CAUSE OF FAILURE. (AL0520040May 17, 2004 · N8127K · Piper PA32300 · Magneto/Distributor
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