Lycoming O-540-E4B5
Service difficulty reports · 39
Newest first. General aviation reporting is voluntary.
Query with SQL
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 = 'O540E4B5' ORDER BY difficulty_date DESC"
Prints the whole list as CSV. It reads the release’s Parquet files over HTTPS, so there’s nothing to download first. Install DuckDB to run it.
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 = 'O540E4B5' ORDER BY difficulty_date DESC
Run it at the DuckDB prompt, or in any tool that reads Parquet over HTTPS. More ways to query the release are on Use the data.
SDR 2025F00056Magneto · failedRUN UP ENGINE WENT DOWN WHEN TESTING.SDR 2020FA0000179Points · bentSLIGHTLY LESS THAN 500 HOURS AGO (AUGUST 2016), THE AIRPLANE WAS APPROPRIATELY MODIFIED WITH THE INSTALLATION OF A SLICK START SYSTEM WHICH INCLUDED THE INSTALLATION OF SLICK MAGNETO M/N 6393, S/N 07052122/E-08075 IN THE LEFT MAGNETO POSITION. UPON RECEIVING TSDR 2014FA0000096Valve · stickingELECTRIC FUEL PUMP WILL NOT PUMP FUEL. DISASSEMBLY OF PART INDICATES STUCK OR STICKING VALVE INTERNALLY WHICH WOULD NOT ALLOW FUEL FLOW THROUGH SYSTEM TO ENGINE RESULTING IN ENGINE SHUTDOWN IN FLIGHT. RECOMMEND REPLACE ELECTRIC FUEL PUMP.SDR 2011FA0000774B-Nut · backed outPILOT REPORTED SMOKE IN THE COCKPIT AFTER LANDING. AFTER AN INSPECTION OF THE ENGINE, IT WAS FOUND THAT NR4 CYLINDER HEAD OIL RETURN LINE "B" NUT HAD BACKED OFF CAUSING OIL TO DRIP ONTO THE EXHAUST STACK WHICH CAUSED THE SMOKE IN THE COCKPIT. THE MECHANIC INSDR 2011FA0000770Crankshaft · brokenCRANKSHAFT BROKE IN FLIGHT. CONTINUED TO RUN BUT PILOT REPORTED KNOCKING NOISE IN ENGINE AND LANDED. ENGINE WAS REMOVED FROM AIRCRAFT AND SHIPPED TO SHOP FOR PARTIAL TEAR DOWN. FOUND METAL IN OIL SUMP AND A CRACK IN COUNTERBALANCE SECTION OF CRANKSHAFT.SDR CA091102001Transmitter · failed(CAN) THE FLOAT, WHICH IS ATTACHED TO THE WIPER ARM OF THE FUEL SENDER, HAD DETERIORATED TO THE POINT OF FALLING OFF OF THE ARM.SDR AU510001896Spacer · wornLT OB ELEVATOR SPACER (DISTANCE PIECE) WORN BEYOND LIMITS. AS A RESULT THE ELEVATOR SUPPORT STRUCTURE WAS CRACKED TO THE POINT OF NEAR SEPARATION.SDR 2005FA0000144Gear Shaft · brokenAT AIRCRAFT 100 HOUR ENGINE WAS FOUND WITH TIGHT SPOT. REMOVED ENGINE ACCYS AND FOUND GOVERNOR SHAFT NOT TURNING DISASSEMBLED ENGINE. FOUND GOVERNOR IDLER GEAR SHAFT (PN 70384) BROKEN IN 3 PARTS; ALL GOV GEARS HAD RG TEETH, 1 OF 2 KNOWN FAILURES, ON SHAFT (SDR 2004FA0000880Crankcase · damagedWHILE CLIMBING OUT FROM RAWLINS, WY ON A FLIGHT TO HOLLISTER, CA., THE ENGINE STARTED TO RUN ROUGH AND THE PILOT NOTICED THAT THE OIL TEMPERATURE WAS RED LINED. THE PILOT RETURNED TO THE AIRPORT FOR EMERGENCY LANDING UNDER PARTIAL ENGINE POWER. THE AIRCRAFT SDR 2004FA0000305Rod Bearing · delaminatedENGINE EXPERIENCED FAILURE OF CONNECTING ROD BOLT, PN 74644 OR DELAMINATION OF CONNECTING ROD BEARING, PN SL 13521 IN NR 6 CONNECTING ROD POSITION. NOT SURE WHICH CAUSED THE FAILURE OF THE ENGINE. A ROD BEARING HALF WAS FOUND IN THE SUMP, MANGLED BUT INTACTSDR 2004FA0000278Connecting Rod · brokenWHILE IN CRUISE FLIGHT, ENGINE STARTED TO RUN ROUGH, CATASTROPHIC ENGINE FAILURE OCCURED. PILOT MADE AN EMERGENCY LANDING, MINOR DAMAGE TO AIRCRAFT. INSPECTION OF FAILED ENGINE REVIELD A BROKEN NR 1, (ONE) CONNECTING ROD.SDR O3O2004F00000Shaft · brokenDISMANTLED THIS ENGINE DUE TO FUEL CONTAMINATION, FOUND THE PROP GOVERNOR IDLER SHAFT BROKEN AT THE KEYWAY AREA. ALSO THE IDLER GEAR SHAFT BOSS IN THE CRANKCASE WAS BROKEN.SDR 2003FA0001233Muffler · detachedEXHAUST TUBE ON MUFFLER, BECAME DETACHED FROM MUFFLER AND DEPARTED AIRCRAFT DURING NORMAL FLIGHT UNDER NORMAL CONDITIONS. RECOMMENDATIONS: CHANGE MUFFLER AT MFG RECOMMEND TIME OF 1000 HOURS OF USE.SDR IKR2003F00000Intake · wornAT ANNUAL INSPECTION, FOUND NR 1 INTAKE TUBE PN 71699 AT NR 1 INTAKE LOCATION EXCESSIVELY LOOSE, MOVEMENT, IN AND OUT, AND SIDEWAYS. MASSIVE AIR LEAKAGE INTO INDUCTION SYSTEM. PN 71699 IS SWEDGED (AIRTIGHT) INTO SUMP ASSY. PN LW-13901 AT 6 EA LOCATIONS. ENSDR AUS20021269Spar · corroded(AUS) LH WING REAR SPAR CONTAINS SEVERE EXFOLIATION CORROSION BETWEEN THE SPAR AND ATTACHMENT PLATE.SDR 2003FA0000996Main Bearing · failedNEW FRONT MAIN BEARING PN LW13884M010 (6-99 ML-KS) INSTALLED AT ENGINE MAJOR OVERHAUL ON 5/15/00. ENGINE REMOVED THIS DATE FOR METAL CONTAMINATION DV SCREEN AND FILTER. METAL SOURCE IS FROM MAIN BEARING DELAMINATION. THIS IS A MANUFACTURING PROBLEM. FURTHESDR HO1R15248Spar · corrodedDURING ANNUAL INSPECTION THE RIGHT WING AFT ATTACH FITTING OUTBOARD OF THE FUSELAGE AND AFT WING SPAR WERE FOUND TO EXHIBIT DISSIMILAR METAL CORROSION BETWEEN THE STEEL ATTACH FITTING AND THE REAR SPAR. THE AFT SPAR WAS CORRODED TO THE POINT WHERE A CRACK HADSDR AUS20010743Bolt · failed(AUS) LH MAIN LANDING GEARLOWER LEG SEPARATED FROM UPPER LEG. SUSPECT CAUSED BY FAILURE OF THE CENTRE TORQUE LINK BOLT. LOWER LEG HOLED LH FLAP DURING SEPARATION.SDR 20010501CW002Stud · misinstalledDURING ENGINE INSTALLATION AFTER OVERHAUL, FOUND ALL 4 GOVERNOR HOLD DOWN STUDS NOT SCREWED FAR ENOUGH INTO CASE. STUDS HAD TO BE TURNED IN .2500 FURTHER TO ALLOW GOVERNOR TO MATE WITH ENGINE.SDR 20000412SH027Carburetor · separatedCARBURETOR SEPARATED AT PARTING SURFACE CAUSING BOTTOM HALF OF CARBURETOR TO ALMOST FALL OFF. LOCKING TABS WERE LOCKED, BOLTS WERE LOOSE. SUBMITTER STATED THIS IS THE 3RD CARBURETOR TO HAVE THIS TYPE FAULT. (X)SDR 99ZZZX1744Inpulse Coupling · mismanufacturedPER AD 99-4-4, FOUND THE IMPULSE COUPLING TO BE MISSING ONE OF THE FLY-WEIGHT SPRINGS AND EXCESSIVE PLAY AT THE RIVETS.SDR AU980807Muffler · separated(AUS) MUFFLER EXHAUST OUTLET PIPE SEPARATED FROM THE MUFFLER.SDR CA980513007Dist Block · cracked(CAN) AFTER MAGNETO FAILURE, THE FOLLOWING DEFECTS WERE FOUND. THE DISTRIBUTOR BLOCK WAS CRACKED AND THERE WERE TEETH MISSING FROM THE DISTRIBUTOR GEAR.SDR 97ZZZX4762Impulse Coupling · brokenACFT IN CRUISE AT 4,000 FEET ON IFR FLIGHT PLAN WHEN ENGINE SUDDENLY LOST POWER. ALL ATTEMPTS MADE BY PILOT TO RESTART THE ENGINE UNSUCCESSFUL. PILOT WAS ABLE TO MAKE A FORCED LANDING IN A COW POSTURE. INVESTIGATION AND ENG TEAR DOWN REVEALED LT MAG HAD SEISDR 97ZZZX4184Shroud Tube · fracturedAFTER RUN-UP, OIL FILM NOTED ON LEFT SIDE OF ENGINE. OIL CAME FROM DENT IN PUSH ROD SHROUD TUBE WHICH WAS FOUND COMPLETELY FRACTURED AT DENT LOCATION. PUSH ROD HAD APPARENTLY RUBBED SHROUD AND CAUSED THE FRACTURE. DENT WAS ABOUT .0937 INCH DEEP. OTHER SHROSDR 97ZZZX4185Drain Tube · chafedNR 2 CYLINDER 71737 ROCKER DRAIN TUBE CHAFED THROUGH ABOUT 90 PERCENT OF WALL THICKNESS BY BOTTLE RETAINER (PIN EASILY PENETRATED 'PAPER-THIN' WALL') 68761 TUBES (3 OF EACH) HAD SUBSTANTIAL WEAR MARKS, AGAIN, TRIM BOTTLE RETAINER. NOTE: TY WRAPS ARE NOT A GOOSDR 97ZZZX4186Drain Tube · chafedNR 2 CYLINDER 71737 ROCKER DRAIN TUBE CHAFED THROUGH ABOUT 90 PERCENT OF WALL THICKNESS BY BOTTLE RETAINER (PIN EASILY PENETRATED 'PAPER-THIN' WALL') 68761 TUBES (3 OF EACH) HAD SUBSTANTIAL WEAR MARKS, AGAIN, TRIM BOTTLE RETAINER. NOTE: TY WRAPS ARE NOT A GOOSDR 97ZZZX4187Valve · seal missingSEALING FELT ON AIR BOX VALVE MISSING FROM OUTER EDGES EXCEPT FOR A 1 INCH SECTION THAT WAS 'HANGING ON'. THE FELT MATERIAL IS SANDWICHED BETWEEN 2 METAL PLATES WITH SOME FELT PROTRUDING TO PROVIDE SEAL. THE PROTRUDING PART WAS ALMOST ALL MISSING. THE POTENTSDR AU971541Valve Seat · separated(AUS) EXHAUST VALVE SEAT SEPARATED FROM CYLINDER HEAD.SDR 97ZZZX3488Screen · required changeREMOVED ENGINE FOR OVERHAUL WITH APPROXIMATELY 2,100 HOURS SINCE LAST OVERHAUL. OIL SUCTION SCREEN SAFETY WIRE WAS PAINTED WITH ENGINE PAINT. ENGINE LAST OVERHAUL WAS 10-71. MANY ANNUALS AND OIL CHANGES WITHOUT THIS SCREEN BEING PULLED. VERY POOR MAINTENANSDR 97ZZZX3691Hose · defectiveFUEL HOSE AT LEFT SIDE OF FIREWALL TO ENGINE DRIVEN FUEL PUMP DEVELOPS LOSS OF FUEL PRESSURE ON TAKEOFF. HOSE SUCKS IN AIR WHICH DOES NOT LET FUEL FLOW. SUBMITTER RECOMMENDS THESE FUEL HOSES BE PRESSURE CHECKED AT EVERY ANNUAL OR WHEN THIS TYPE OF PROBLEM OCSDR CA970106005Hub · corroded(CAN) DURING CALENDAR TIME INSPECTION THE PROPELLER HUB WAS FOUND CORRODED IN THE #2 SOCKET. IN ACCORDANCE WITH HARTZELL MANUAL NO CORROSION IS PERMITTED.SDR 96ZZZX3008Fuel Pump · failedPILOT REPORTED LOSS OF ENGINE POWER ON TAKEOFF AND ELECTED TO LAND ON GOLF COURSE. DURING INVESTIGATION, ENGINE WAS OPERATED AND ENGINE DRIVEN FUEL PUMP FOUND INOPERATIVE.SDR CA960103532Valve Seat · wrong depth(CAN)AFTER THE ENGINE WAS OVERHAULED, WITH SIX (6) NEW CYLINDERS FROM CONTINENTAL, THE ENGINE FAILED TO ACHIEVE FULL POWER ON THE POST INSPECTION/OVERHAUL RUN-UP. THE MAXIMUM RPM WAS 2700, INSTEAD OF THE REQUIRED 2850 RPM. TROUBLESHOOTING REVEALED THAT ONE OF SDR CA960103533Woodruff Key · broken(CAN)THE OWNER REPORTED THAT #5 CYLINDER PISTON ROD MOVED ABNORMALLY AND THERE WAS A LOT OF METAL IN THE OIL FILTER. INTERNAL INSPECTION REVEALED THE ENGINE HAD LACKED OIL BECAUSE THE OIL PUMP DRIVE KEY (W OODRUFF KEY) HAD BROKEN. THE OIL PUMP AND THE ENGINE WSDR 95ZZZX3210Crankshaft · crackedAIRCRAFT MADE AN OFF-FIELD LANDING 200 YARDS SHORT OF THE AIRPORT. A COMPLETE LOSS OF OIL OCCURRED EXITING A HOLE IN THE CRANKCASE ADJACENT TO THE NR 2 CYLINDER. THE NR 1 AND NR 2 CYLINDER CAM FOLLOWER LIFTER BODY HEADS WERE SEPARATED ON THE INTAKE AND EXHAUSDR 95ZZZX2883Venturi · corrodedFOUND CORROSION IS OCCURRING BELOW THE SURFACE OF THE CASTING CAUSING THE SURFACE TO BUBBLE UP, CHANGING THE SHAPE OF THE VENTURI. IF THIS PART IS PLATED, CAN THE PLATING BE ELIMINATED?SDR BIER9501AMagneto · malfunctionedAT 100 HR INSP NOTICED LEFT MAG TIMEING INCORRECT. AFTER DISSASEMBLY FOUND PT.S COATED AND IMPULSE COUPLING PAST 500 HR LIMITS, VARIOUS OTHER PARTS WERE WORN WORSE THAN THE ENG REBUILDER'S CLAIMED TIME IN SERVICE OF MAG WOULD DICTATE (350 HR.S SINCE NEW). BOSDR 95ZZZX687Valve · brokenTHE AIRCRAFT RETURNED SHORTLY AFTER TAKEOFF WITH A ROUGH RUNNING ENGINE. THE EXHAUST VALVE, THE UPPER VALVE SPRING SEAT, PN LW-16475, AND THE VALVE STEM CAP, PN 17C19386, WERE FOUND BROKEN.
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