Service difficulty report · Exhaust Header · Diamon DA40

Difficulty date
September 7, 2004
Submitted
September 9, 2004
Operation
General aviation
Aircraft
N858PA
Make and model
Diamon DA40
Aircraft serial
40258
Aircraft time
454 hours
Engine
Lyc IO360A1A
Engine time
454 hours
Part
Exhaust Header
Part number
DA403REVB
Part serial
16G850017
Condition
Broken
Location
Engine
Part time
454 hours
Stage of operation
IN
How discovered
V
Nature of condition
O
Precautionary procedure
K

As reported to the FAA. Reports are unverified, and codes are left as the FAA publishes them.

What was found

ON INSTALLATION OF NEW NR 4 EXHAUST PIPE, THE FLANGE WELD BEGAN TO CRACK. THIS WAS WITH LITTLE TORQUE APPLIED THE FLANGE. SUBMITTED REPORT TO MFG AND DISCUSSED WHAT MAY POSSIBLY BE CAUSING THIS PROBLEM. THEY SEEMED TO THINK IT WAS THE USE OF MFG EXHAUST GASKET WITH THE ASBESTOS CENTER CAUSING THE PROBLEMS, THIS IS THE SAME GASKET THAT IS CALLED FOR IN THEIR PARTS MANUAL. THEY RECOMMENDED USING TWO THIN COPPER GASKETS INSTEAD OF THE SINGLE THICKER ASBESTOS/COPPER GASKET.

More about the Diamon DA 40