ATL96TA047

The flight departed Kissimmee, Florida, on a forest fire spotting mission. The engine began to run rough and lost power. The airplane landed in an orange grove, striking a tree. An engine examination revealed that improper connecting rod bolts had been used in the engine. The bolts in two connecting rods failed, resulting in the failure of the engine. Investigation determined that the bolts were manufactured in the '80s and became available in the U.S. market in February 1994. The bolts were obtained by a repair station on June 1994 and installed in connecting rod assemblies that were in storage. The overhaul date on the work order for the stored rod assemblies was not changed at that time, and it continued to indicate an overhaul date of 2/9/94. The stored rod assemblies were then installed in the engine during an overhaul in October 1994. In March 1995, an AD was issued to inspect engines with connecting rod bolts installed on or since 2/15/94. The AD was not complied with on the engine because the repair station certified that the rod assemblies had been overhauled on 2/9/94, before the effective date of the AD.

On February 13, 1996, about 1304 eastern standard time, a Piper PA-32-300, N8951N, collided with a tree during a forced landing at Windermere, Florida. The aircraft was operated by the Florida Department of Agriculture under the provisions of Title 14 CFR Part 91 and visual flight rules. A flight plan was not filed for the public use flight, and visual meteorological conditions prevailed. The commercial pilot sustained minor injuries; the aircraft was substantially damaged. The aircraft departed Kissimmee Airport, Kissimmee, Florida, at 1100 on the same day.

The pilot stated that while in cruise flight on a forest fire spotting mission, the engine began to run roughly, vibrating the entire aircraft. Oil started spraying from the engine onto the windscreen, then the engine quit. The pilot executed an emergency landing, touching down in an orange grove, and collided with a tree.

An engine examination revealed that bogus connecting rod bolts had been used in the engine. The bolts in two connecting rods failed, resulting in the failure of the engine. Investigation determined that the bolts were manufactured in the 1980s, and became available in the Unites States market on February 15, 1994. The bolts were obtained by the repair station in June, 1994, and installed in connecting rod assemblies that were in storage. The overhaul date on the work order for the stored rod assemblies was not changed at that time, and continued to indicate an overhaul date of February 9, 1994. The stored rod assemblies were then installed in the engine during an overhaul in October 28, 1994. On March 17, 1995, Airworthiness Directive (AD) 95-07-01 was issued to inspect engines with connecting rod bolts installed on or since February 15, 1994. The AD was not complied with on the engine because the repair station certified that the rod assemblies had been overhauled on February 9, 1994, before the effective date of the AD.

The FAA conducted an investigation to locate and remove from the system all defective connecting rod bolts from the original manufacturer.