# Service difficulty reports: Lycoming IO-540-S1A5 A list on [Lycoming IO-540-S1A5](https://openairdocs.org/engine/lycoming-io-540-s1a5.md). Newest first. General aviation reporting is voluntary. - [SDR HX1R2016041230269](https://openairdocs.org/sdr/HX1R2016041230269.md): Stud · broken · Mar 10, 2016 · N601HB · Piper PA60601P · Reciprocating Engine Cylinder Section > DURING INSPECTION, SAW NR 3 CYLINDER WITH ALL OF THE HOLDDOWN STUDS BROKEN OFF. THE CYLINDER MOVED IN AND OUT AND BROKE CONNECTION ROD, PUSH ROD TUBES, FUEL INJECTOR LINE, EXHAUST RISES, INDUCTION TUBES. 1 OF THE BROKEN STUDS HAVE A FILM OF RUST ON IT. THIS - [SDR 2015FA0000173](https://openairdocs.org/sdr/2015FA0000173.md): Engine · failed · Apr 27, 2015 · N221CA · Piper PA60601P · Engine (Reciprocating) > PILOT REPORTED THAT IN FLIGHT, ENGINE MADE SOME NOISES FOLLOWED BY LOSS OF ENGINE POWER, LT ENGINE. PROP WENT TO UN-COMMANDED FEATHER WITH A SUDDEN INCREASE IN RPM BEFORE ENGINE STOPPED RUNNING. INVESTIGATION ON THE GROUND REVEALED NO MOVEMENT OF THE PISTONS I - [SDR TZRA200600001](https://openairdocs.org/sdr/TZRA200600001.md): Rocker Cover · broken · Mar 10, 2006 · N600TE · Piper PA60601 · Reciprocating Engine Cylinder Section > LT ENG BEGAN TO RUN ROUGH & LEAK OIL ONTO COWLING INBD SIDE. ENG CONTINUED TO MAKE PWR & OIL PRESS REMAINED NORM, DEACTIVATED TURBOS AS PRECAUTION. EXAM REVEALED NR 3 CYL INTAKE PUSHROD BENT & PUSHROD TUBE BROKEN IN MIDDLE. FUEL INJ LINE ALSO BROKEN & ROCKE - [SDR AUS20040174](https://openairdocs.org/sdr/AUS20040174.md): Bellcrank · broken · Mar 9, 2004 · Piper PA60601P · Landing Gear Door Retract Section > (AUS) RT MAIN LANDING GEAR DOOR BELLCRANK LUG BROKEN. - [SDR TZR2004F00003](https://openairdocs.org/sdr/TZR2004F00003.md): Crankcase · cracked · Dec 10, 2003 · N601TE · Piper PA60601 · Reciprocating Engine Power Section > PILOT REPORTED A HARD DOWNDRAFT (REPORTED THAT HE HIT HIS HEAD ON CEILING) APPROX 20 SECONDS LATER NR 2 ENGINE LOST POWER AND HE SHUT THE ENGINE DOWN. HE LANDED WITHOUT INCIDENT. INSPECTION OF THE ENGINE IN HANGAR REVEALED A CRACKED CASE UPPER SIDE BY NR 5 C - [SDR 2003FA0000823](https://openairdocs.org/sdr/2003FA0000823.md): Strut · broken · Jul 29, 2003 · N600TE · Piper PA60601 · Main Landing Gear Strut/Axle/Truck > TORQUE LINK ATTACH POINT ON THE RIGHT STRUT BROKE AT LANDING. THIS ALLOWED THE RIGHT MLG TIRE TO ROTATE AND PULL THE AIRCRAFT OFF THE RUNWAY. THE RESULTING SIDE LOAD ON THE MLG CAUSED THE OVER CENTER LINK PN 400084-001, AND THE STRUT CYLINDER 400054-001, TO BR - [SDR TZR2004F00001](https://openairdocs.org/sdr/TZR2004F00001.md): Torque Link · broken · Jul 29, 2003 · N600TE · Piper PA60601 · Main Landing Gear > TORQUE LINK ATTACH POINT ON THE RT STRUT BROKE AT LANDING. THIS ALLOWED THE RT MLG TIRE TO ROTATE AND PULL THE AIRCRAFT OFF THE RUNWAY. THE RESULTING SIDE LOAD ON THE MLG CAUSED THE OVER CENTER LINK, AND THE STRUT CYLINDER, TO BREAK. ALSO, BOTH RT SIDE MLG - [SDR GH62003F00000](https://openairdocs.org/sdr/GH62003F00000.md): Window · failed · May 2, 2003 · N663W · Piper PA60601P · Flight Compartment Windows > WHILE CLIMBING OUT AFTER TAKEOFF, AT APPROX 20,000 FT, CO-PILOT WINDOW EXPERIENCED A CATASTROPHIC FAILURE. WINDOW SHARDS CONTACTED RT PROPELLER. PARTIALLY RIPPING HOT PROP BOOTS. PILOT RETURNED FOR INSPECTION AND REPAIR. CAUSE UNKNOWN/ SUSPECT CRACKS IN A - [SDR AUS20020664](https://openairdocs.org/sdr/AUS20020664.md): Downlock Switch · contaminated · Jul 1, 2002 · Piper PA60601B · Landing Gear Position and Warning > (AUS) NOSE LANDING GEAR DOWNLOCK MICROSWITCH CONTACTS DIRTY. - [SDR CA020228016](https://openairdocs.org/sdr/CA020228016.md): Hose · ruptured · Feb 2, 2002 · Piper PA60601P · Engine Oil Distribution (Airframe Furnished) > (CAN) TURBO OIL SUPPLY HOSE FROM OPTIONAL FILTER P/N 300180-501 TO WAISTGATE ACTUATOR ROUTED IN CLOSE PROXIMITY TO EXHAUST PIPES WITH SHARP BENDS DUE TO EXTREMITY TIGHT ROUTING. ADDITIONALLY THIS HOSE IS DISTURBED EVERY 50 HOURS DUE TO REMOVAL AND CLEANING OF - [SDR 2002FA0000204](https://openairdocs.org/sdr/2002FA0000204.md): Crankcase · cracked · Jan 16, 2002 · N502SB · Piper PA60601P · Reciprocating Engine Power Section > CRANKCASE FAILED NEAR NR 2 CYLINDER, CRACKED FROM IN FRONT OF CYLINDER RADIALLY BELOW AND AROUND TO THE REAR OF THE CYLINDER. CRACK EXTENDS MORE THAN 180 DEGREES, ALL 3 UPPER CYLINDER BASE STUDS AND UPPER CRANKCASE THRU BOLT WERE ALL BROKEN. THE ONLY THING - [SDR MHJ2001F00001](https://openairdocs.org/sdr/MHJ2001F00001.md): Main Bearing · delaminated · Nov 1, 2001 · N601PJ · Piper PA60601 · Reciprocating Engine Power Section > FOUND NONFERROUS METAL IN SUCTION OIL SCREEN, CUT OPEN OIL FILTER AND FOUND NONFERROUS METAL IN OIL FILTER, DISASSEMBLED ENGINE, FOUND NR 2 AND NR 4 MAIN BEARINGS TO BE DELAMINATING. OIL ANALYSES SHOWS METAL TO BE CONSISTENT WITH BEARING MATERIAL. - [SDR AUS20011043](https://openairdocs.org/sdr/AUS20011043.md): Tailpipe · cracked · Jul 5, 2001 · Piper PA60601 · Engine Collector/Tailpipe/Nozzle > (AUS) RH ENGINE TAILPIPE CRACKED ALLOWING HOT EXHAUST GAS TO ACTIVATE FIRE WARNING SYSTEM. - [SDR CA010219004](https://openairdocs.org/sdr/CA010219004.md): Spark Plug · separated · Dec 22, 2000 · Piper PA60601P · Spark Plug/Igniter > (CAN) THIS ENGINE HAD APPROXIMATELY 16 MINUTES AFTER ENGINE OVERHAUL. THIS WAS ON NR 2 ENGINE THAT THE SPARK PLUG SEPARATED. WE THEN REMOVED ALL SPARK PLUGS IN NR 2 & NR 1 ENGINES AND REPLACED WITH CHAMPION, AND WHEN REMOVING SPARK PLUGS ON NR 1 ENGINE ANOTHER - [SDR AU000679](https://openairdocs.org/sdr/AU000679.md): Brace · cracked · Sep 1, 2000 · Piper PA60601 · Landing Gear Retraction/Extension System > (AUS) LEFT MAIN LANDING GEAR LOWER SIDE BRACE CRACKED. FOUND DURING INSPECTION IAW TSA-SB600-134A. (X) - [SDR 99ZZZX3309](https://openairdocs.org/sdr/99ZZZX3309.md): Cam Follower · loose · Aug 2, 1999 · N564RA · Piper PA60601P · Magneto/Distributor > PILOT REPORTED DEAD MAGNETO ON SECOND LEG OF TRIP. MAGNETO REMOVED AND BREAKER COMPARTMENT INSPECTED REVEALING THE CAM FOLLOWER ON THE CONTACT POINTS WAS NO LONGER SECURED TO THE SPRING BY THE TWO SMALL STAINLESS STEEL RIVETS. REPLACED CONTACT BREAKER POINTS - [SDR AU990707](https://openairdocs.org/sdr/AU990707.md): Collar · cracked · Jun 17, 1999 · Piper PA60601P · Landing Gear Steering System > (AUS) NOSE LANDING GEAR STEERING COLLAR FAILED AT THE STEERING ACTUATING MECHANISM ATTACHMENT LUG. INVESTIGATION FOUND THAT THE CRACK HAD EXISTED FOR SOME TIME FINALLY FAILING DUE TO OVERLOAD. THE COLLAR HAD GENERAL PITTING CORROSION. FURTHER INVESTIGATION - [SDR AU980916](https://openairdocs.org/sdr/AU980916.md): Pushrod · loose · Jul 28, 1998 · Piper PA60601P · Aileron Control System > (AUS) AILERON CONTROL SYSTEM PUSHROD LOWER END FITTING RIVETS LOOSE. - [SDR CA981013013](https://openairdocs.org/sdr/CA981013013.md): Brace · cracked · Jul 28, 1998 · Piper PA60601P · Main Landing Gear > (CAN) ON LANDING ROLL-OUT AT ABOUT 40 KNOTS, THE WARNING HORN SOUNDED AND THE LEFT WING STARTED TO DROP. LEFT ENGINE SHUTDOWN, A/C STAYED ON RUNWAY. LEFT GEAR COLLAPSED DAMAGING WING, AND GEAR DOOR. SUBMITTER STATED CAUSED BY FAILURE OF LEFT LOWER SIDE BRA - [SDR 98ZZZX1716](https://openairdocs.org/sdr/98ZZZX1716.md): Pump · loose · Apr 1, 1998 · N30004 · Piper PA32300 · Engine Fuel Pump > UPON VISUAL INSPECTION OF NEWLY OVERHAULED ENGINE, FOUND ALL OF THE BOLTS SECURING THE BOTTOM DIAPHRAGM PLATE TO THE FUEL PUMP BODY WERE LOOSE, AT LEAST.0312 INCH OF SPACE COULD BE SEEN UNDER BOLT HEAD. THIS WAS A NEW PUMP INSTALLED BY ENGINE SHOP. SUBMITTE - [SDR 98ZZZX773](https://openairdocs.org/sdr/98ZZZX773.md): Crankshaft · failed · Jan 24, 1998 · Piper PA60601P · Reciprocating Engine Power Section > PILOT (OWNER) DEPARTING FROM AIRPORT AND CLIMBING THROUGH 4,000 FEET NOTED LOUD BANG AND SEVERE VIBRATION FROM LT ENGINE. ENGINE SHUT DOWN AND SECURED AND SAFE LANDING MADE. DISASSEMBLY OF ENGINE REVEALED CRANKSHAFT BROKEN. BREAK OCCURRED AT THE REAR CHEEK - [SDR 98ZZZX909](https://openairdocs.org/sdr/98ZZZX909.md): Crankshaft · failed · Jan 24, 1998 · Piper PA60601P · Reciprocating Engine Power Section > PILOT (OWNER) DEPARTING FROM AIRPORT AND CLIMBING THROUGH 4,000 FEET NOTED LOUD BANG AND SEVERE VIBRATION FROM LT ENGINE. ENGINE SHUT DOWN AND SECURED AND SAFE LANDING MADE. DISASSEMBLY OF ENGINE REVEALED CRANKSHAFT BROKEN. BREAK OCCURRED AT THE REAR CHEEK - [SDR GXPA97011](https://openairdocs.org/sdr/GXPA97011.md): Magneto · seized · May 8, 1997 · N160GA · Piper PA60601 · Magneto/Distributor > ACFT'S RT ENG FAILED IN-FLIGHT. ACFT LANDED AT FDY. NLG COLLA PSED ON LANDING.INSP AND TEAR DOWN OF ENG NOTED THAT RT MAG WAS S EIZED. CRANKSHAFT DRIVE GEAR HAD 6 TEETH MISSING. PARTIAL DISASSEMBLY OF MAG FOUND ROTATING MAGNETS RUBBING THE COIL POLES CAUSI - [SDR 96ZZZX6020](https://openairdocs.org/sdr/96ZZZX6020.md): Piston · hole in side · Nov 20, 1996 · N771LB · Piper PA60601P · Reciprocating Engine Cylinder Section > DURING TEST FLIGHT, A LARGE STREAM OF OIL, FROM OIL DOOR OF RIGHT ENGINE WAS NOTICED. SUBSEQUENTLY, ENGINE SHUT DOWN WAS PERFORMED AND AN UNEVENTFUL LANDING WAS MADE. TROUBLESHOOTING REVEALED A DIME SIZE HOLE IN NR 2 CYLINDER PISTON AND SIGNS OF SEVER DETONA - [SDR 96ZZZX6155](https://openairdocs.org/sdr/96ZZZX6155.md): Injector Servo · failed · Nov 20, 1996 · N3646N · Piper PA60601P · Fuel Control/Reciprocating Engines > INJECTOR SERVO 'SHUT DOWN' DURING ACTUAL FUEL FLOW TEST', ALLOWING ONLY A DRIBBLE OF FUEL THROUGH WITH FULL THROTTLE AND FULL MIXTURE AND FUEL PUMP ON. HAD THIS HAPPENED IN-FLIGHT, ENGINE WOULD HAVE STOPPED. - [SDR AU961150](https://openairdocs.org/sdr/AU961150.md): Propeller · ground strike · Jul 30, 1996 · Piper PA60601 · Propeller Assembly > (AUS) RH ENGINE SUFFERED A PROPELLER STRIKE - ALL THREE BLADES DAMAGED IN AREA APPROXIMATELY 50.8MM (2IN) FROM TIP - [SDR AU960740](https://openairdocs.org/sdr/AU960740.md): Duct · cracked · May 17, 1996 · Piper PA60600A · Heating System > (AUS) CABIN HEATER DUCTING CRACKED - HOT AIR CAUSED FREIGHT TO SMOULDER - [SDR 95ZZZX3643](https://openairdocs.org/sdr/95ZZZX3643.md): Hose · loose · Jul 11, 1995 · N601GA · Piper PA60601P · Reciprocating Engine Oil System > AN OIL RETURN HOSE FROM THE TURBOS CAME LOOSE SPRAYING OIL ONTO THE FIRE DETECTION PROBES. THIS CAUSED THE FIRE WARNING TO ACTIVATE, AND THE PILOT WENT INTO THE CLOSEST AIRPORT. THERE WAS NO DEFECT FOUND WITH THE HOSE OR 'AN' FITTING IT ATTACHED TO. THE HOS - [SDR 95ZZZX2618](https://openairdocs.org/sdr/95ZZZX2618.md): Crankcase · cracked · May 15, 1995 · N901RG · Piper PA60601P · Reciprocating Engine Power Section > FOUND ENGINE CASE CRACKED FROM NR 2 CYLINDER RETAINING STUD HOLE (LOWER, FORWARD LARGE BOLT). - [SDR 95ZZZX1799](https://openairdocs.org/sdr/95ZZZX1799.md): Cylinder · base nut failed · Mar 25, 1995 · N6902T · Piper PA60602P · Reciprocating Engine Power Section > ON TAKEOFF, RT ENGINE FIRE LIGHT, LOSS OF POWER. PILOT SHUT DOWN, RETURNED TO AIRPORT. FOUND NR 4 CYLINDER HELD ON BY ONE BASE NUT. EXAMINED CYLINDER/PISTON, FOUND NO DISCREPANCIES. SUSPECT NUTS OVER/UNDERTORQUED. - [SDR 95ZZZX1274](https://openairdocs.org/sdr/95ZZZX1274.md): Engine · failed · Feb 8, 1995 · N8248J · Piper PA60601 · Engine (Reciprocating) > LEFT ENGINE SHUT DOWN IN-FLIGHT, ACFT LANDED. REMOVED AND REPLACED ENGINE, CAUSE FOR FAILURE UNKNOWN AT THIS TIME. ## 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 = 'IO540S1A5' ORDER BY difficulty_date DESC ``` This list as a web page: https://openairdocs.org/engine/lycoming-io-540-s1a5/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.