Lycoming TIO-540-AJ1A
Service difficulty reports · 102
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 = 'TIO540AJ1A' 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 = 'TIO540AJ1A' 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 2026FA0000797Attach Bracket · crackedALTERNATOR ATTACH BRACKET P/N: 07A22214 FOUND TO BE CRACKED COMPLETELY THROUGH AT THE AFT ATTACH BOLT DURING THE 1ST 100 HOUR INSPECTION OF THE AIRCRAFT.SDR 2025FA0000196Connecting Rod · damagedENGINE WAS RECEIVED BY EJ1R FOR SUDDEN STOPPAGE INSPECTION RESULTING FROM PRECAUTIONARY OFF FIELD LANDING DUE TO BROKEN EXHAUST VALVE ON CYLINDER #5. DURING SUDDEN STOPPAGE TEARDOWN INSPECTION WHILE CLEANING AND VISUALLY INSPECTING CONNECTING RODS, #1 CONNECTISDR 2024FA0000197Coupling · loosePILOT REPORTED MANIFOLD PRESSURE SPIKE AND ENGINE SURGE. FOUND A LOOSE EXHAUST V-BAND COUPLING AND MISSING THE V-BAND COUPLING GASKET. FOUND THE MISSING GASKET LODGED IN THE TURBOCHARGER AND DESTROYED THE TURBINE BLADES. PLEASE CONTACT ME FOR PICTURES AND VIDSDR 2023FA0000394Alternator · seizedDC ALTERNATOR FAILED DURING GROUND RUN. UPON REMOVAL FOUND THE ALTERNATOR TO HAVE SEIZED. ALTERNATOR WAS SENT TO HARTZELL WITH AN RMA # 13301. PRODUCT WAS REPLACED WITH A NEW ALTERNATOR. NO REPORT WAS PROVIDED TO US ON WHY THE UNIT FAILED, ALTHOUGH WE HAVE SDR IKBR2021061600027Line · gougedWHILE PERFORMING AD 2015-19-07 WE CAME ACROSS 3 INJECTOR LINES THAT WERE GOUGED BY THE HOSE CLAMPS ON THE ADJACENT MANIFOLD LINES. ALL THREE ARE BEING REPLACED PER THE AD INSTRUCTIONS AND PICTURES WILL BE SENT IN TO SUPPLEMENT THIS REPORT. THE CLAMPS HAVE BESDR 2021FA0000161Exhaust Riser · crackedDURING A 50 HOUR ENGINE INSPECTION THE TECHNICIAN DISCOVERED A CRACK IN THE #5 CYLINDER EXHAUST TO CYLINDER RISERSDR 2021FA0000160Exhaust Riser · crackedDURING A 100 HOUR INSPECTION OF THE ENGINE, THE TECHNICIAN DISCOVERED A CRACK IN THE #5 CYLINDER EXHAUST TO RISER WELD.SDR IKBR2021030100023Exhaust Pipe · crackedWHILE PERFORMING AN OIL CHANGE AND AD 17-11-10, WE DISCOVERED A CRACK IN THE WELD ASSEMBLY P/N 12509927 FOUND JUST AFTER THE WASTE GATE. INSTALLED NEW EXHAUST WELD ASSY P/N 1250992-7 (8130-3) GASKET P/N 24096-225N (8130-3) AND COUPLING P/N S3262-6 IAW CESSNA SDR 2021FA0000023Governor · misrepairedENGINE RPM FOLLOWS MANIFOLD PRESSURE IN ALL FLIGHT ENVELOPES. REMOVED PROPELLER GOVERNOR AFTER 218.4HRS TIS AFTER OVERHAUL BY SOUTH COAST PROPELLER SERVICE INC. SEE SPECIFIC PART BELOW FOR DETAILS.SDR 2020FA0000563Exhaust Pipe · crackedDEFECTIVE PART IS CRACKED AT A WELD AND HAD TO BE REPLACED UNDER WARRANTY. THE DEFECTIVE PART IS PART OF A KIT, PART NUMBER 05J2883. THE KIT WAS INSTALLED APPROXIMATELY 60 HOURS AGO AS A TERMINATING ACTION TO AD 17-11-10.SDR R29R2020091509003Boot · disconnectedMCCAULEY PROPELLER INSTALLED ON CESSNA T2065H HAD PROPELLER DEICE CONNECTORS BREAK OFF THE ATTACHMENT LUGS LOCATED ON THE PROPELLER BACKING PLATE AFTER 44 HOURS OF OPERATION. ASSOCIATED WIRING HAS RUBBER COATING THAT EXTENDS ALL THE WAY DOWN TO THE WIRING CONSDR R29R2020091509002Boot · disconnectedMCCAULEY PROPELLER INSTALLED ON CESSNA T206H HAD PROPELLER DEICE BOOT WIRING CONNECTORS BREAK OFF THE ATTACHMENT LUGS LOCATED ON THE BACKING PLATE AFTER 72 HOURS OF OPERATION. ASSOCIATED WIRING HAS RUBBER COATING THAT EXTENDS ALL THE WAY DOWN TO THE WIRING COSDR 2020FA0000244Control Cable · stretchedTHE FACTORY INSTALLED FLAP "RETRACT" CABLE WAS FOUND TO BE 5/32". PER THE S/N OF THE AIRCRAFT ALL CABLES, 4 EA. SHOULD BE 1/8". THE CORRECT P/N CABLES ARE: 2 EA. 0510105-192 & 2 EA. 0510105-359. ALSO THE IPC 27-50-00 FIG ITEM 229 LISTS THE BARREL-TURNBUCKLE ASSDR 2019FA0000354Bearing · looseAIRCRAFT HAD RUDDER PEDDLES SQUAWK FOR CLICKING. FOUND RUDDER PEDAL BEARING HALF BOLTS LOOSE. REF MODEL 206 MM 27-21-00-001 ITEMS 19, 22. THIS IS THE SECOND OCCURRENCE OF RUDDER PEDAL HARDWARE COMING LOSE. FIRST
OCCURRENCE WAS ON 10-15-2019 AT 200.4 T.T. SVC-SDR 2020FA0000065Tube · mismanufacturedTHIS IS THE BY-PASS FROM THE EXIT OF THE WASTE GATE TO THE EXHAUST PIPE. THIS IS THE SECOND TUBE SUPPLIED BY TEXTRON THAT WAS FOUND DEFECTIVE FROM THE MFG. THE FIRST TUBE HAD THE FLARE AT THE INCORRECT END OF THE TUBE. THIS TUBE WAS POORLY FORMED AT ITS FLASDR 2018FA0000055Exhaust Stack · mismanufacturedRECEIVED NEW EXHAUST COLLECTOR FROM THE MANUFACTURE. DURING RECEIVING INSPECTION, A LEAK CHECK WAS PERFORMED, REVEALING PIN HOLES IN THE WELD AREA AT THE HEEL OF THE BEND JUST AFT OF THE TURBO FLANGE CONNECTION.SDR 2017FA0000325Pump · leakingAFTER SHUTDOWN, A SLOW STEADY FUEL LEAK WAS OBSERVED. LEAK WAS TRACED TO FUEL PUMP.SDR 2017FA0000263Coil · out of toleranceRIGHT MAGNETO FAILED DUE TO BAD COIL M3975. RIGHT MAGNETO WAS REPLACED WITH NEW TTAF 2595.6SDR 2017FA0000350Pump · leakingPILOT REPORTED A FUEL LEAK FROM THE ENGINE DRIVEN FUEL PUMP AFTER FLIGHT. INSPECTED PUMP, REMOVED DRAIN LINE FROM BOTTOM OF PUMP, VERIFIED LEAK. PERFORMED GROUND RUN FOR OPERATIONAL LEAK CHECK, COULD NOT DUPLICATE. CONTACTED TECH SUPPORT, AND WAS ADVISED TOSDR 2017FA0000343Pump · leakingFUEL WAS LEAKING ONTO THE GROUND FROM THE RUBBER DRAIN TUBE OUT OF THE LOWER COWL AND WOULD NOT STOP UNTIL FUEL SELECTOR WAS TURNED TO THE OFF POSITION. REMOVED RUBBER DRAIN HOSE FROM PUMP AND FUEL WAS VISIBLY DRIPPING FROM PUMP DRAIN WHEN FUEL SELECTOR WAS TSDR 2017FA0000104Pushrod · scoredDURING THE INSPECTION OF THE PUSHRODS, FOUND THE NR 2 PUSHROD AND ROCKER ARM SCORED BEYOND LIMITS. REPLACED PUSHROD AND ROCKER ARM WITH NEW.SDR 2017FA0000094Pushrod · scoredDURING INSPECTION OF PUSHRODS, FOUND NR 5 EXHAUST PUSHROD SCORED AND REQUIRED REPLACEMENT PER SA-167A.SDR 2017FA0000089Shaft · scoredDURING THE SA-167A INSPECTION, MAINTENANCE FOUND SCORING ON THE VALVE ROCKER SHAFT. REPLACED ALL 12 IN THE ENGINE.SDR 2017FA0000055Pushrod · scoredNR 2 EXHAUST, PUSHROD AND ROCKER REPLACED DUE TO BEING OUT OF LIMITS.SDR PCPR201701031Stud · backed outDURING SCHEDULED INSPECTION TECHNICIAN DISCOVERED EXHAUST STUD BACKED OUT OF NR 2 CYLINDER ASSEMBLY.SDR 2017FA0000042Pushrod · scoredNR 2 EXHAUST PUSHROD AND ROCKER SCORED AND REPLACED PER THE SA-167A.SDR 2017FA0000034Shaft · scoredDURING THE INSPECTION OF THE PUSHRODS IAW SA-167A. FOUND SCORING ON THE ROCKER ARM SHAFTS ON ALL 6 CYLINDERS AND REPLACED ACCORDINGLY.SDR 2016FA0000635Pushrod · scoredNR 2 AND 4 EXHAUST CYLINDER PUSHROD AND ROCKER SCORED BEYOND LIMITS OF THE SA-167A. REPLACED BOTH PUSHRODS AND ROCKER ASSEMBLIES IAW SA-167A.SDR 2016FA0000628Pushrod · scoredFOUR PUSHRODS WERE SCORED AND 4 ROCKER ARMS WERE SCORED, THESE WERE MATING PARTS. IAW SA-167A PARTS WERE REPLACED DUE TO UNACCEPTABLE LIMITS.SDR 2016FA0000594Pushrod · scoredPUSHROD SCORING VISIBLE ON THE NR 2, 3, 4, AND 5 EXHAUST PUSHRODS AND ROCKERS ARMS. REPLACING COMPONENTS IAW SA-167A.SDR PCPR2016093001Switch · burnedNUMBER 2 BUSS FOUND INOPERATIVE AT START UP. ROCKER SWITCH DETERMINED TO BE FAULTY. OPENED SWITCH AND FOUND PLASTIC CONTACT ACTUATOR BURNT.SDR CA160223001Gasket · damaged(CAN) DURING OPERATION NR 1 INSPECTION OF ENGINE PORTION OF CHECK NOTICED INTAKE PIPE AT CYLINDER GASKET HAD BLUE STAINING FROM FUEL LEAK. GASKET APPEARED COMPRESSED AND UNABLE TO SEAL ,ALSO GASKET WAS SLIGHTLY OFF SET. REPLACED GASKET WITH NEW NO MORE LEAK.SDR PCPR201510131Cylinder · defectiveDURING SCHEDULED INSPECTION, TECH DISCOVERED EXHAUST STUDS PULLED OUT OF NR 2 CYLINDER ASSEMBLY CAUSING SEPARATION OF EXHAUST RISER FLANGE FROM CYLINDER EXHAUST PORT AND ESCAPE OF EXHAUST GASSES. CYLINDER ASSEMBLY REQUIRED REPLACEMENT.SDR PCPR201510132Cylinder · defectiveDURING SCHEDULED INSPECTION, TECH DISCOVERED EXHAUST STUDS PULLED OUT OF NR 3 CYLINDER ASSEMBLY, CAUSING SEPARATION OF EXHAUST RISER FLANGE FROM CYLINDER EXHAUST PORT AND ESCAPE OF EXHAUST GASSES. CYLINDER ASSEMBLY REQUIRED REPLACEMENT.SDR 2015FA0000470Exhaust Pipe · detachedOVERBOARD EXHAUST ELBOW, BETWEEN THE WASTEGATE AND THE TAILPIPE DISENGAGED BY THE SLIP-JOINT FROM WASTEGATE FLANGE, PN 1250992-4. NO CLAMP FAILURE WAS EVIDENT.SDR 2015FA0000347Line · chafedUPON ACCOMPLISHING AD 2011-26-04 IT WAS DISCOVERED THAT THE FUEL INJECTION LINE, PN LW-12098-0-140 FOR THE NR 3 CYLINDER WAS RUBBING ON THE BAFFLING, PN 1255115-36 FOR THE NR 3 CYLINDER. THE LINE WAS BENT TO MAKE THE RECOMMENDED CLEARANCE IAW SB342G.SDR 2015FA0000377Line · brokenA STRONG VIBRATION IN THE ENGINE AT 60 NM FROM THE AIRPORT WAS PRESENTED, TO 40 NM THIS IS ACCOMPANIED BY NOISE UNABLE TO CORRECT BY REDUCING THE RPM THE ENGINE "COUGHED" LIKE A LACK OF FUEL, CONTINUED FAILURE TO REPORT THE EMERGENCY TO 10NM FROM THE AIRPORT. SDR CA150606001Sprocket · failed(CAN) TRIM SPROCKET FAILURE. COMPLETE SHEAR OF SPROCKET FROM ACTUATOR ASSY. ACFT WAS ON THE GROUND AND FAILED ON DI INSPECTION TEST OF TRIM SYS. THIS IS THE SECOND FAILURE FOR THIS, PN ON THIS ACFT.SDR 2015FA0000145Pump · faultyREMOVED DEFECTIVE ENGINE DRIVEN FUEL PUMP RG9080J9A/M, SN E3394 AND INSTALLED "DEFECTIVE" NEWLY O/H FUEL PUMP, PN RG9080J8A/M, SN E-1186 THE FUEL PUMP WOULD NOT MAINTAIN PROPER FUEL PUMP AT IDLE RPM. WE OBTAINED ANOTHER NEWLY O/H FUEL PUMP RG9080J8A/M, SN D-1SDR CA141114005Oil Filter · cracked(CAN) AFTER LANDING FOR FUEL PILOT NOTED A LARGE AMOUNT OF OIL WAS VISIBLE LONG THE ENTIRE LENGTH OF THE BOTTOM OF THE FUSELAGE. AN INVESTIGATION LED MAINTENANCE TO THE COOLING SHROUD ASSEMBLY FOR VACUUM PUMP. THE SHROUD HAD LOOSENED AND ROTATED COMING IN CONTSDR CA140130014Pump · erratic(CAN) FUEL PUMP OUTPUT PRESSURE ERRATIC CAUSING A ROUGH ENGINE IDLE BETWEEN 700-1000 RPM.SDR CA140123004Timer · failed(CAN) PROP DE-ICE TIMER UNSERVICABLE. CUSTOMER HAS RARELY USED THIS SYSTEM ON THE ACFT SINCE NEW.SDR CA140124003Pump · malfunctioned(CAN) ENGINE DRIVEN FUEL PUMP HAS INCONSISTENT OUTPUT PRESSURE CAUSING A ROUGH IDLE.SDR CA131205005Control Cable · worn(CAN) AILERON CARRY THROUGH CABLES 1260505-154 AND -160, WORN OR CHAFED TO BETWEEN 40 AND 50 PERCENT OF THE OUTER WIRES. THE AILERON CABLES WERE WORN AT THE PULLEYS AT WS94 IN BOTH LT AND RT WINGS,SDR CA131204004Selector Valve · leaking(CAN) PILOTS REPORTED THAT FUEL TRANSFERS BETWEEN FUEL TANKS WITH THE FUEL SELECTOR IN OFF POSITION. DISCOVERED WHEN LOOKING FOR A FUEL LOAD THAT SOMETIMES ONE TANK HAD MORE FUEL THAN OTHER. SEALS BYPASSING FUEL INTERNALLY. FUEL SELECTOR REPLACED WITH NEW.SDR 2013FA0000502Magneto · malfunctionedLT AND RT MAGNETOS EXPERIENCING REPEATED INTERNAL TIMING DRIFT DURING SHORT PERIODS OF OPERATION. ACFT ARE ON A 50 HOUR PHASE INSPECTION CYCLE. PILOTS REPORT DIFFICULTY STARTING ACFT, INSP RESULTS DETERMINE THAT MAGNETOS ARE CAUSE. REMOVAL OF MAGNETOS, DISASDR 2013FA0000452Magneto · inoperative8540.2 HOURS, MAGNETO INSTALLED. 8597.3 HOURS ENGINE HARD TO START, FOUND MAGNETO INTERNAL TIMING INCORRECT.SDR 2013FA0000453Magneto · inoperative8372.5 HRS, MAGENTO INSTALLED. ENGINE BECAME HARD TO START. RESET MAGNETO TO ENGINE TIMING AND REPLACED SPARK PLUGS. ENGINE STILL HARD TO START. REMOVED MAGNETO AND SENT FOR EVALUATION. INTERNAL TIMING FOUND TO BE INCORRECT.SDR 2013FA0000454Magneto · inoperative8372.5 HRS MAGNETO INSTALLED. 8509.9 HRS ENGINE BECAME HARD TO START. RESET MAGNETO TO ENGINE TIMING AND REPLACED SPARK PLUGS. 8540.2 HRS ENGINE STILL HARD TO START. REMOVED MAGNETO AND SENT FOR EVALUATION. INTERNAL TIMING FOUND TO BE INCORRECT.SDR 2013FA0000455Magneto · inoperativeMAGNETO INSTALLED 337.4 HRS LATER BECAME ENGINE HARD TO START. TIMING TO ENGINE OK. REMOVED AND SENT FOR EVALUATION AND FOUND INTERNAL TIMING OUT OF SPEC.
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