# Service difficulty reports: Lycoming IO-540-K1G5D

A list on [Lycoming IO-540-K1G5D](https://openairdocs.org/engine/lycoming-io-540-k1g5d.md).

Newest first. General aviation reporting is voluntary.

- [SDR 2025FA0000207](https://openairdocs.org/sdr/2025FA0000207.md): Intake Duct · incorrect · Oct 17, 2024 · N81481 · Piper PA32R301 · Engine Air Intake System
  > AIRCRAFT DEPARTED AIRPORT AND AFTER APPROXIMATELY 10 MINUTES INTO FLIGHT, AIRCRAFT HAD LEVELED OUT AT CRUISE ALTITUDE OF 7,000 FEET. AIRCRAFT EXPERIENCED A LOSS OF POWER WHICH RESULTED IN THE AIRCRAFT IMPACTING THE GROUND ON ITS BELLY AND SLIDING SIDEWAYS INTO
- [SDR 2023FA0000789](https://openairdocs.org/sdr/2023FA0000789.md): Hub · leaking · Nov 27, 2023 · Piper PA32R300 · Propeller Hub Section
  > PROPELLER MODEL B3D34C433-C, RED DYED OIL COMING FROM BLADE HUB, ON COWLING, WIND SCREEN AND PUDDLE ON HANGER FLOOR. PROP OVERHAUL DATE 12/ 2018 T.T. 604 HRS, DISASSEMBLED AND RESEALED 3/2022 T.T. 900 HRS, LEAKAGE REAPPEARED ON 11/2023 T.T. 1150.0 HRS.
- [SDR 2022FA0000290](https://openairdocs.org/sdr/2022FA0000290.md): None · bypassing · Jun 13, 2022 · N8415H · Piper PA32R301 · Fuselage Structure (General)
  > THIS AIRCRAFT MADE AN EMERGENCY LANDING AT FORT LAUDERDALE EXECUTIVE AIRPORT AFTER SEVERAL ATTEMPTS THE RIGHT MAIN WOULD NOT FREEFALL, THE AIRCRAFT WAS BROUGHT TO US FOR MAINTENANCE AND TROUBLESHOOT AFTER THIS INCIDENT. WE FOUND THAT THE POWER PACK P/N HYC5005
- [SDR 1MYR20210701001](https://openairdocs.org/sdr/1MYR20210701001.md): Attach Fitting · corroded · Jul 1, 2021 · N8186F · Piper PA32R300 · Fuselage, Wing Attach Fittings
  > FUSELAGE FRAME STATION 73 LEFT AND RIGHT WING ATTACH FITTING SEVERELY CORRODED DUE TO DISSIMILAR METAL CORROSION STEEL/ALUMINUM. PART IS CORRODED BEYOND ECONOMICAL REPAIR. REPLACEMENT IS REQUIRED. THIS IS FOLLOWING UP ON SPECIAL AIRWORTHINESS INFORMATIONAL BUL
- [SDR 2017FA0000413](https://openairdocs.org/sdr/2017FA0000413.md): Tube · failed · Aug 10, 2017 · N377SM · Piper PA32R300 · Tire Tube
  > NOSE WHEEL TIRE WENT FLAT UPON A SMOOTH LANDING. ABLE TO TAXI OFF OF MAIN RUNWAY. THE INNER TUBE WAS INSTALLED ON MARCH 28, 2009 TACH TIME OF 3718.57 HRS. THE FLAT OCCURRED ON SEPT 29, 2016 TACH TIME 4630.15 HRS. THE NOSE WHEEL TIRE TREAD WAS IN GOOD COND
- [SDR CA130423007](https://openairdocs.org/sdr/CA130423007.md): Control Cable · cracked · Apr 17, 2013 · Piper PA32R300 · Stabilizer Control System
  > (CAN) INSPECTED IAW AD 2013-02-13 FOUND THE FOLLOWING CABLED HAD MICRO CRACKING IN THE SWAGING FOR THE TURN BARREL CONNECTION, PN 62701-13, 62701-39, 62701-40. OWNER HAS REQUESTED ALL 4 STABLIATOR CONTROL CABLES BE REPLACED.
- [SDR CA121114001](https://openairdocs.org/sdr/CA121114001.md): Hinge Bracket · corroded · Nov 13, 2012 · Piper PA32R301 · Ailerons
  > (CAN) DURING THE REMOVAL OF THE RT SIDE AILERON FOR PAINTING, THE AME DISCOVERED SEVERE CORROSION ON THE INSIDE HINGE. THE CORROSION REDUCES THE HINGE BRACKET THICKNESS TO ABOUT 60 PERCENT -70 PERCENT OF IT`S ORIGINAL SIZE. CORROSION WAS ALSO FOUND ON THE LT
- [SDR CA111209002](https://openairdocs.org/sdr/CA111209002.md): Tube · broken · Nov 30, 2011 · Piper PA32R300 · Rudder Structure
  > (CAN) RUDDER TRIM ARM CRACKED AT WELD AND TORN SECTION OF TUBE ASSEMBLY ON CONTROL ARM THAT ALSO CONTROLS RT RUDDER CABLE ATTACHMENT TO RUDDER PEDEL ASSEMBLY. CRACK APPEARS TO HAVE POSIBLY STARTED AT FWD EDGE OF WELD.
- [SDR 2010FA0001156](https://openairdocs.org/sdr/2010FA0001156.md): Valve Spring · weak · Nov 5, 2010 · N3402Q · Piper PA32R300 · Reciprocating Engine Cylinder Section
  > PARTIAL POWER FAILURE ON TAKEOFF.
- [SDR 2010FA0000002](https://openairdocs.org/sdr/2010FA0000002.md): Vernatherm · distorted · Jan 7, 2010 · N82EB · Piper PA32RT300 · Engine Oil Cooler
  > AFTER REMOVING THE LT OIL COOLER SUPPLY HOSE AT THE CASE FOR ACCESS TO MAGNETO, IT WAS NOTICED THAT THE NUT OFF THE END OF THE VERNATHERM WAS STUCK IN THE FITTING STICKING OUT OF THE CASE. VERNATHERM WAS REMOVED AND REMAINING PARTS LOCATED. INSPECTED SEAT AR
- [SDR FFKA140](https://openairdocs.org/sdr/FFKA140.md): Ring · broken · Jul 20, 2009 · N169BW · Piper PA32RT300 · Reciprocating Engine Power Section
  > SHORTLY AFTER TAKEOFF, WHILE CLIMBING THROUGH ABOUT 3000 FT, ENGINE LOST ABOUT 200 - 300 RPM MOMENTARILY AND THEN RECOVERED. IT DID THIS 2 TIMES AND THEN WENT BACK TO NORMAL. NOT LONG AFTER THIS NOTICED THAT THE OIL PRESSURE HAD DIPPED INTO THE YELLOW. MX C
- [SDR 2009FA0000828](https://openairdocs.org/sdr/2009FA0000828.md): Air Filter · split · Jul 2, 2009 · N23585 · Piper PA32R300 · Engine Air Intake System
  > THE FILTER IS SEPARATING AT MFG SEAM. THIS IS THE 3RD FILTER FOUND IN THIS CONDITION.
- [SDR FFKA20081217001](https://openairdocs.org/sdr/FFKA20081217001.md): Pump · inoperative · Dec 17, 2008 · N8954C · Piper PA32R300 · Engine Fuel Pump
  > ABOUT 40 OR SO MILES FROM AIRPORT, THE ENGINE DRIVEN FUEL PUMP DIED. WHEN THE FUEL PRESSURE STARTED DROPPING THE PILOT WENT THROUGH THE "HAIL MARY" MANEUVER (SWITCH TANKS, MIXTURE RICH, CHECK THE MAGNETOS, ELECTRICAL FUEL PUMP ON). AS SOON AS HE HIT THE ELEC
- [SDR CA081024001](https://openairdocs.org/sdr/CA081024001.md): Trunnion · cracked · Oct 24, 2008 · Piper PA32R300 · Fuselage, Landing Gear Attach Fittings
  > (CAN) FOUND GREASE LEAKING FROM TOP PORTION OF THE LWR BRG SUPPORT. CLEANED AREA AND RE GREASED TRUNNION. GREASE WAS FOUND COMING OUT OF CRACK. THE CRACK IS APPROXIMATELY ONE INCH LONG, HORIZONTAL. THIS CRACK INDICATION DOES APPEAR TO BE CAUSED BY IMPROPER GRO
- [SDR 2008FA0000530](https://openairdocs.org/sdr/2008FA0000530.md): Stator · shorted · Jul 14, 2008 · N2125V · Piper PA32R300 · AC Generation System
  > THE AC SUFFERED LOSS OF ELECTRICAL POWER WHILE IN CONTACT WITH ATC WHEN LOST RADIO CONTACT. CONTACTED BKP VIA CELL PHONE AND STATED HIS PROBLEM AND REQUESTED RUNWAY LIGHT AND WHEN THEY WERE TURNED ON HE WAS WITHIN SIGHT OF THE RUNWAY AND USED EMERGENCY RELEA
- [SDR 2007F00068](https://openairdocs.org/sdr/2007F00068.md): Gear · failed · Dec 11, 2007 · N8493C · Piper PA32R300 · Magneto/Distributor
  > PILOT REPORTED PARTIAL POWER/ROUGH-RUNNING ENGINE PRIOR TO TAKEOFF, RETURNED TO MAINTENANCE HANGAR. MAINTENANCE PERSONNEL REMOVED D6LN-3000 DUAL MAGNETO AND DISCOVERED SEVERAL DOZEN TEETH MISSING BOTH DISTRIBUTOR GEARS. MAGNETO INSTALLED NEW ON 28 MAY, 2007.
- [SDR FFKA119](https://openairdocs.org/sdr/FFKA119.md): Governor · malfunctioned · Nov 23, 2007 · N6291J · Piper PA32R300 · Propeller Governor
  > PILOT REPORTED THAT THE TACHOMETER WAS INDICATING 100 RPMS HIGHER THEN RECOMMENDED BY THE ENGINE MANUFACTURE AFTER TAKEOFF BUT STILL HAD CONTROL OF THE PROPELLER GOVERNOR. REMOVED GOVERNOR FROM SERVICE AND SENT OFF FOR EVALUATION, THIS EVALUATION DETERMINED T
- [SDR FFKA115](https://openairdocs.org/sdr/FFKA115.md): Gear · damaged · Mar 6, 2007 · N333TG · Piper PA32R300 · Magneto/Distributor
  > PILOT REPORTED THAT THE ENGINE IS RUNNING ROUGH DURING TAXI AND HAD A BAD MAGNETO DROP. MAINTENANCE INVESTIGATED THE PROBLEM AND DETERMINED THAT THE MAGNETO P/N 10-682560-13 NEEDED TO BE REPLACED. UPON FURTHER INVESTIGATION OF THE MAGNETO, FOUND THAT 2 EACH
- [SDR 2006FA0000604](https://openairdocs.org/sdr/2006FA0000604.md): Control Cable · separated · Jun 14, 2006 · N31709 · Piper PA32RT300 · Elevator Control System
  > CABLE TURNBUCKLE MALE END SEPARATED AT FITTING DURING ROLLOUT AFTER LANDING. FITTING SEEMS TO HAVE CORRODED FROM THE SHANK CORE AND PROGRESSED OUTWARD TO THE SURFACE OVER TIME. (K)
- [SDR 2006FA0000608](https://openairdocs.org/sdr/2006FA0000608.md): Control Cable · separated · Jun 12, 2006 · N31709 · Piper PA32RT300 · Elevator Control System
  > UP ELEVATOR CABLE SEPARATED IN LANDING FLARE.
- [SDR 2006FA0000609](https://openairdocs.org/sdr/2006FA0000609.md): Control Cable · separated · Jun 12, 2006 · N31709 · Piper PA32RT300 · Elevator Control System
  > UP ELEVATOR CABLE SEPARATED DURING LANDING FLARE.
- [SDR 2006FA0000610](https://openairdocs.org/sdr/2006FA0000610.md): Control Cable · separated · Jun 12, 2006 · N31709 · Piper PA32RT300 · Elevator Control System
  > UP ELEVATOR CABLE SEPARATED DURING LANDING FLARE.
- [SDR 2006FA0000611](https://openairdocs.org/sdr/2006FA0000611.md): Control Cable · separated · Jun 12, 2006 · N31709 · Piper PA32RT300 · Elevator Control System
  > UP ELEVATOR CABLE SEPARATED DURING LANDING FLARE.
- [SDR FFKA2006108](https://openairdocs.org/sdr/FFKA2006108.md): Magneto · broken · Jan 6, 2006 · N333TG · Piper PA32R300 · Magneto/Distributor
  > AFTER AN EMERGENCY LANDING, MAINTENANCE INSPECTED ENGINE AND FOUND THE DUEL MAGNETO HAD BROKEN OFF THE ENGINE ACCESSORY CASE. AFTER A RECORD SEARCH OF THE AIRCRAFT IT WAS FOUND TO HAVE TWO OTHER MAGNETOS INSTALLED IN THE PAST TWO YEARS. THERE MIGHT BE A PROBL
- [SDR FFKA2005107](https://openairdocs.org/sdr/FFKA2005107.md): Magneto · inoperative · Dec 21, 2005 · N8954C · Piper PA32R300 · Magneto/Distributor
  > PILOT REPORTED A DEAD LEFT MAGNETO ON ENGINE GROUND RUN. MAINTENANCE REMOVED MAGNETO AND FOUND NEEDLE BEARINGS FROM THE LEFT HAND SIDE OF MAGNETO DRIVE GEAR IN MAGNETO HOUSING. MAINTENANCE REPLACED MAGNETO AND GROUND RUN WAS NORMAL.
- [SDR 2005FA0000620](https://openairdocs.org/sdr/2005FA0000620.md): Gasket · missing · Apr 13, 2005 · N2430Y · Piper PA32R301 · Reciprocating Engine Oil System
  > ON INITIAL GROUND RUN, AFTER INSTALLING FACTORY REMFG, OIL WAS LEAKING FROM ACCY CASE UNDER FUEL PUMP. WHEN FUEL PUMP WAS REMOVED TO REPLACE GASKET, IT WAS FOUND THAT THERE WAS NO GASKET INSTALLED. INSTALLED NEW GASKET, LEAK CHECK GOOD. PROBABLE CAUSE: COMP
- [SDR 2005FA0000021](https://openairdocs.org/sdr/2005FA0000021.md): Magneto · cracked · Dec 24, 2004 · N333TG · Piper PA32R300 · Magneto/Distributor
  > WHEN PERFORMING A VISUAL INSPECTION OF THE ENGINE COMPARTMENT EXCESSIVE OIL WAS FOUND IN THE ENGINE COMPARTMENT. FOUND THE DUEL MAGNETO MOUNTING FLANGE CRACKED. REMOVED MAGNETO, CRACKED MOUNTING FLANGE PIECE FELL OFF OF MAGNETO HOUSING.
- [SDR DD52005F00000](https://openairdocs.org/sdr/DD52005F00000.md): Gear · broken · Nov 12, 2004 · N6249J · Piper PA32R300 · Reciprocating Engine Oil System
  > THE DRIVEN OIL PUMP GEAR (PN 61298) WHICH WAS ALUMINUM AND WAS NOT CHANGED AT OVERHAUL LOST A TOOTH. THE BROKEN TOOTH JAMED INTO THE DRIVE GEAR (PN 61297) WHICH BROKE 2 TEETH OFF THE OIL PUMP DRIVE (PN LW 10318) THIS IS THE ONLY PART INVOLVED THAT WAS REPLAC
- [SDR DD52002F00000](https://openairdocs.org/sdr/DD52002F00000.md): Skin · cracked · Apr 8, 2002 · N6249J · Piper PA32R300 · Rudder, Plate/Skin
  > CRACKS ON TRAILING EDGE SKIN OF RUDDER. CRACKS IN AREA OF STIFFENER BEADS.
- [SDR 2001FA0000220](https://openairdocs.org/sdr/2001FA0000220.md): Muffler · split · Aug 6, 2001 · N3516M · Piper PA32RT300 · Engine Noise Suppressor
  > THE CENTER MUFFLER HOUSING SPLIT OPEN AT THE UPPER WELD SEAM ALLOWING EXHAUST TO DAMAGE THE UPPER ALUMINUM MUFFLER ASSEMBLY SHROUD AND THE ENGINE INDUCTION COVER. SUGGEST THAT A VERY CLOSE INSPECTION BE DONE BY BOTH VISUAL AND PRESSURE CHECK METHODS OF ALL MU
- [SDR 2001FA0000101](https://openairdocs.org/sdr/2001FA0000101.md): Muffler · cracked · Jun 28, 2001 · N9265B · Piper PA32R301 · Engine Noise Suppressor
  > UPON REMOVAL OF HEATING SHROUDS FOR INSPECTION, FOUND SIGNIFICANT DISTORTION OF MUFFLER CAN. THE MUFFLER WAS CRACKED AT UPPER LEADING EDGE WELD.
- [SDR 2001FA0000099](https://openairdocs.org/sdr/2001FA0000099.md): Muffler · cracked · Jun 8, 2001 · N9265B · Piper PA32R301 · Engine Noise Suppressor
  > UPON REMOVAL OF HEATING SHROUDS FOR INSPECTION, FOUND SIDNIFICANT DISTORTION OF MUFFLER WAS CRACKED AT UPPER LEADING EDGE WELD.
- [SDR FFK2001F00000](https://openairdocs.org/sdr/FFK2001F00000.md): Magneto · damaged · May 30, 2001 · N4451X · Piper PA32R300 · Magneto/Distributor
  > PILOT REPORTED DEAG MAGNETO. INSPECTED MAGNETO TO BE MISSING INTERNAL GEAR TEETH. REMOVED AND REPLACED MAGNETO WITH SERVICEABLE PART.
- [SDR 2001FA0000154](https://openairdocs.org/sdr/2001FA0000154.md): Gear · broken · Apr 26, 2001 · N39503 · Piper PA32RT300 · Magneto/Distributor
  > AFTER TAKE OFF AT APPROX 500FT AGL, THE ENGINE STOPPED RUNNING. AIRCRAFT MADE EMERGENCY LANDING IN A FIELD WITH NO DAMAGE OR INJURIES. INSPECTION OF MAGNETO REVEALED THAT BOTH DISTRIBUTOR GEARS HAD FAILED. MAGNETO WAS REBUILT BY TCM 04/07/2000 AND INSTALLED
- [SDR 2001FA0000141](https://openairdocs.org/sdr/2001FA0000141.md): Gear · broken · Apr 26, 2001 · N39503 · Piper PA32RT300 · Magneto/Distributor
  > ON TAKE OFF AT APPROXIMATLEY 500 FEET THE ENGINE FAILED. THE AIRCRAFT LANDED IN GRASS AT END OF RUNWAY WITHOUT INCIDENT. INSPECTION SHOWED THAT BOTH DISTRIBUTOR GEARS HAD FAILED, TEETH MISSING.
- [SDR 20001019SH007](https://openairdocs.org/sdr/20001019SH007.md): Seal · failed · Sep 1, 2000 · N28WC · Piper PA32RT300 · Reciprocating Engine Oil System
  > SEAL SOFTENED, SWELLED, RUPTURED. NIGHT, PART 135 FLIGHT LOST OIL, ENGINE SEIZED. SEAL MATERIAL NOT OIL PROOF. SUBMITTER SUGGESTED RETURNING TO ORIGINAL MATERIAL. (X)
- [SDR 20000831SH015](https://openairdocs.org/sdr/20000831SH015.md): Engine · failed · Aug 31, 2000 · N165R · Piper PA32RT300 · Engine (Reciprocating)
  > AIRCRAFT WAS IN-FLIGHT WHEN ENGINE LOST ALL OIL PRESSURE, AND HAD A CATASTROPHIC FAILURE. AIRCRAFT WAS ABLE TO MAKE A SAFE OFF-FIELD LANDING WITH NO STRUCTURAL DAMAGE. ENGINE WAS OVERHAULED ENGINE FROM LYCOMING. ENGINE SHOPPED TO LYC FOR INSPECTION. (X)
- [SDR 20000911SH024](https://openairdocs.org/sdr/20000911SH024.md): Oil Cooler · leaking · Aug 12, 2000 · N38984 · Piper PA32R300 · Engine Oil Cooler
  > PILOT DEPARTED AIRPORT. DURING CLIMB APPROXIMATELY 2 MINUTES INTO FLIGHT, NOTICED NO OIL PRESSURE INDICATION. QUICKLY RETURNED TO DEPARTURE AIRPORT. ENGINE FAILED ON FINAL DUE TO OIL STARVATION. A SAFE LANDING WAS MADE. ENGINE SEIZED AND THREW PARTS THROU
- [SDR 20000831SH003](https://openairdocs.org/sdr/20000831SH003.md): Intake Valve · fractured · May 12, 2000 · N5633V · Piper PA32R300 · Reciprocating Engine Cylinder Section
  > DURING FLIGHT, ENGINE BEGAN TO RUN ROUGH. PILOT POWERED BACK AND MADE PRECAUTIONARY LANDING. INSPECTION REVEALED FAILURE OF THE VALVE STEM ON NR 2 CYLINDER INTAKE VALVE. THE FRACTURE IS LOCATED APPROXIMATELY.6250 INCH FROM THE TOP OF THE VALVE STEM NEAR TH
- [SDR 20000920SH010](https://openairdocs.org/sdr/20000920SH010.md): Intake Valve · fractured · May 12, 2000 · N5633V · Piper PA32R300 · Reciprocating Engine Cylinder Section
  > DURING FLIGHT, ENGINE BEGAN TO RUN ROUGH. PILOT POWERED BACK AND MADE PRECAUTIONARY LANDING. INSPECTION REVEALED FAILURE OF THE VALVE STEM ON NR 2 CYLINDER INTAKE VALVE. THE FRACTURE IS LOCATED APPROXIMATELY.6250 INCH FROM THE TOP OF THE VALVE STEM NEAR TH
- [SDR FWRA002](https://openairdocs.org/sdr/FWRA002.md): Gear · damaged · Apr 19, 2000 · N4375B · Piper PA32R301 · Magneto/Distributor
  > BROKEN DISTRIBUTOR GEAR TEETH ON RT HAND GEAR CAUSING INTERMITTENT RUNNING ON RIGHT MAGNETO. PART NUMBER ON GEAR 10-682016. (X)
- [SDR 20000417SH017](https://openairdocs.org/sdr/20000417SH017.md): Gasket · failed · Feb 29, 2000 · N6925J · Piper PA32R300 · Reciprocating Engine Oil System
  > ENGINE LOST OIL ON START-UP DUE TO EXCESSIVE OIL PRESSURE WHICH BENT PLATE ON OIL FILLER KIT CAUSING GASKET TO BLOW OUT. (X)

## The whole list in SQL

Runs in DuckDB 1.2 or later on the release's Parquet files over HTTPS:

```sql
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 = 'IO540K1G5D'
ORDER BY difficulty_date DESC
```

This list as a web page: https://openairdocs.org/engine/lycoming-io-540-k1g5d/reports

---
OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain.