# Service difficulty reports: Lycoming O-540-E4B5

A list on [Lycoming O-540-E4B5](https://openairdocs.org/engine/lycoming-o-540-e4b5.md).

Newest first. General aviation reporting is voluntary.

- [SDR 2025F00056](https://openairdocs.org/sdr/2025F00056.md): Magneto · failed · Mar 1, 2025 · N852VL · Piper PA32260 · Magneto/Distributor
  > RUN UP ENGINE WENT DOWN WHEN TESTING.
- [SDR 2020FA0000179](https://openairdocs.org/sdr/2020FA0000179.md): Points · bent · Feb 25, 2020 · Piper PA32260 · Magneto/Distributor
  > SLIGHTLY 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 T
- [SDR 2014FA0000096](https://openairdocs.org/sdr/2014FA0000096.md): Valve · sticking · Feb 17, 2014 · N7122J · Piper PA32260 · Fuel Boost Pump
  > ELECTRIC 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 2011FA0000774](https://openairdocs.org/sdr/2011FA0000774.md): B-Nut · backed out · Dec 2, 2011 · N3941W · Piper PA32260 · Reciprocating Engine Oil System
  > PILOT 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 IN
- [SDR 2011FA0000770](https://openairdocs.org/sdr/2011FA0000770.md): Crankshaft · broken · Nov 3, 2011 · N7748J · Piper PA32260 · Reciprocating Engine Power Section
  > CRANKSHAFT 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 CA091102001](https://openairdocs.org/sdr/CA091102001.md): Transmitter · failed · Oct 28, 2009 · Piper PA32260 · Fuel Quantity Sensor
  > (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 AU510001896](https://openairdocs.org/sdr/AU510001896.md): Spacer · worn · Dec 12, 2005 · Bnorm BN2B26 · Elevator Structure
  > LT OB ELEVATOR SPACER (DISTANCE PIECE) WORN BEYOND LIMITS. AS A RESULT THE ELEVATOR SUPPORT STRUCTURE WAS CRACKED TO THE POINT OF NEAR SEPARATION.
- [SDR 2005FA0000144](https://openairdocs.org/sdr/2005FA0000144.md): Gear Shaft · broken · Aug 14, 2004 · Reciprocating Engine Rear Section
  > AT 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 2004FA0000880](https://openairdocs.org/sdr/2004FA0000880.md): Crankcase · damaged · Aug 2, 2004 · N3542W · Piper PA32260 · Reciprocating Engine Power Section
  > WHILE 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 2004FA0000305](https://openairdocs.org/sdr/2004FA0000305.md): Rod Bearing · delaminated · Apr 7, 2004 · Piper PA32260 · Reciprocating Engine Power Section
  > ENGINE 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 INTACT
- [SDR 2004FA0000278](https://openairdocs.org/sdr/2004FA0000278.md): Connecting Rod · broken · Feb 23, 2004 · N3370W · Piper PA32260 · Reciprocating Engine Power Section
  > WHILE 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 O3O2004F00000](https://openairdocs.org/sdr/O3O2004F00000.md): Shaft · broken · Jan 9, 2004 · N4798S · Piper PA32260 · Reciprocating Engine Front Section
  > DISMANTLED 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 2003FA0001233](https://openairdocs.org/sdr/2003FA0001233.md): Muffler · detached · Nov 12, 2003 · N3580W · Piper PA32260 · Engine Noise Suppressor
  > EXHAUST 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 IKR2003F00000](https://openairdocs.org/sdr/IKR2003F00000.md): Intake · worn · Oct 16, 2003 · N998MM · Piper PA32260 · Reciprocating Engine Cylinder Section
  > AT 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. EN
- [SDR AUS20021269](https://openairdocs.org/sdr/AUS20021269.md): Spar · corroded · Oct 30, 2002 · Piper PA32260 · Wing Spar
  > (AUS) LH WING REAR SPAR CONTAINS SEVERE EXFOLIATION CORROSION BETWEEN THE SPAR AND ATTACHMENT PLATE.
- [SDR 2003FA0000996](https://openairdocs.org/sdr/2003FA0000996.md): Main Bearing · failed · Oct 7, 2002 · N3450W · Piper PA32260 · Reciprocating Engine Power Section
  > NEW 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. FURTHE
- [SDR HO1R15248](https://openairdocs.org/sdr/HO1R15248.md): Spar · corroded · Jan 19, 2002 · N7728J · Piper PA32260 · Wing Spar
  > DURING 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 HAD
- [SDR AUS20010743](https://openairdocs.org/sdr/AUS20010743.md): Bolt · failed · May 19, 2001 · Piper PA32260 · Main Landing Gear Strut/Axle/Truck
  > (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 20010501CW002](https://openairdocs.org/sdr/20010501CW002.md): Stud · misinstalled · Apr 9, 2001 · N4803S · Piper PA32260 · Engine (Reciprocating)
  > DURING 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 20000412SH027](https://openairdocs.org/sdr/20000412SH027.md): Carburetor · separated · Mar 18, 2000 · N6YB · Piper PA32260 · Fuel Control/Reciprocating Engines
  > CARBURETOR 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 99ZZZX1744](https://openairdocs.org/sdr/99ZZZX1744.md): Inpulse Coupling · mismanufactured · Mar 2, 1999 · N4830S · Piper PA32260 · Magneto/Distributor
  > PER AD 99-4-4, FOUND THE IMPULSE COUPLING TO BE MISSING ONE OF THE FLY-WEIGHT SPRINGS AND EXCESSIVE PLAY AT THE RIVETS.
- [SDR AU980807](https://openairdocs.org/sdr/AU980807.md): Muffler · separated · Jul 18, 1998 · Piper PA32260 · Engine Noise Suppressor
  > (AUS) MUFFLER EXHAUST OUTLET PIPE SEPARATED FROM THE MUFFLER.
- [SDR CA980513007](https://openairdocs.org/sdr/CA980513007.md): Dist Block · cracked · Apr 3, 1998 · Piper PA32260 · Magneto/Distributor
  > (CAN) AFTER MAGNETO FAILURE, THE FOLLOWING DEFECTS WERE FOUND. THE DISTRIBUTOR BLOCK WAS CRACKED AND THERE WERE TEETH MISSING FROM THE DISTRIBUTOR GEAR.
- [SDR 97ZZZX4762](https://openairdocs.org/sdr/97ZZZX4762.md): Impulse Coupling · broken · Oct 15, 1997 · N7748J · Piper PA32260 · Magneto/Distributor
  > ACFT 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 SEI
- [SDR 97ZZZX4184](https://openairdocs.org/sdr/97ZZZX4184.md): Shroud Tube · fractured · Aug 25, 1997 · N4365T · Piper PA32260 · Reciprocating Engine Cylinder Section
  > AFTER 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 SHRO
- [SDR 97ZZZX4185](https://openairdocs.org/sdr/97ZZZX4185.md): Drain Tube · chafed · Aug 25, 1997 · N4365T · Piper PA32260 · Reciprocating Engine Oil System
  > NR 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 GOO
- [SDR 97ZZZX4186](https://openairdocs.org/sdr/97ZZZX4186.md): Drain Tube · chafed · Aug 25, 1997 · N4365T · Piper PA32260 · Reciprocating Engine Oil System
  > NR 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 GOO
- [SDR 97ZZZX4187](https://openairdocs.org/sdr/97ZZZX4187.md): Valve · seal missing · Aug 25, 1997 · N4365T · Piper PA32260 · Engine Air Intake System
  > SEALING 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 POTENT
- [SDR AU971541](https://openairdocs.org/sdr/AU971541.md): Valve Seat · separated · Jul 21, 1997 · Bnorm BN2B26 · Reciprocating Engine Cylinder Section
  > (AUS) EXHAUST VALVE SEAT SEPARATED FROM CYLINDER HEAD.
- [SDR 97ZZZX3488](https://openairdocs.org/sdr/97ZZZX3488.md): Screen · required change · Jul 11, 1997 · N3669W · Piper PA32260 · Reciprocating Engine Oil System
  > REMOVED 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 MAINTENAN
- [SDR 97ZZZX3691](https://openairdocs.org/sdr/97ZZZX3691.md): Hose · defective · Jul 3, 1997 · N33831 · Piper PA32260 · Engine Fuel Distribution
  > FUEL 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 OC
- [SDR CA970106005](https://openairdocs.org/sdr/CA970106005.md): Hub · corroded · Nov 21, 1996 · Piper PA32260 · Propeller Hub Section
  > (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 96ZZZX3008](https://openairdocs.org/sdr/96ZZZX3008.md): Fuel Pump · failed · May 25, 1996 · N40933 · Piper PA32260 · Engine Fuel Pump
  > PILOT 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 CA960103532](https://openairdocs.org/sdr/CA960103532.md): Valve Seat · wrong depth · Nov 24, 1995 · Reciprocating Engine Cylinder Section
  > (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 CA960103533](https://openairdocs.org/sdr/CA960103533.md): Woodruff Key · broken · Nov 24, 1995 · Reciprocating Engine Oil System
  > (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 W
- [SDR 95ZZZX3210](https://openairdocs.org/sdr/95ZZZX3210.md): Crankshaft · cracked · May 31, 1995 · N16354 · Piper PA32260 · Reciprocating Engine Power Section
  > AIRCRAFT 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 EXHAU
- [SDR 95ZZZX2883](https://openairdocs.org/sdr/95ZZZX2883.md): Venturi · corroded · May 1, 1995 · N4315T · Piper PA32260 · Fuel Control/Reciprocating Engines
  > FOUND 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 BIER9501A](https://openairdocs.org/sdr/BIER9501A.md): Magneto · malfunctioned · Jan 27, 1995 · N33058 · Piper PA32260 · Magneto/Distributor
  > AT 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). BO
- [SDR 95ZZZX687](https://openairdocs.org/sdr/95ZZZX687.md): Valve · broken · Jan 18, 1995 · N4803S · Piper PA32260 · Reciprocating Engine Cylinder Section
  > THE 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.

## 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 = 'O540E4B5'
ORDER BY difficulty_date DESC
```

This list as a web page: https://openairdocs.org/engine/lycoming-o-540-e4b5/reports

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