Service difficulty report · Aileron · Piper PA44180

Difficulty date
February 23, 2007
Submitted
February 23, 2007
Operation
General aviation
Aircraft
N577ER
Make and model
Piper PA44180
Aircraft serial
4496153
Aircraft time
3,881 hours
Engine
Lyc O320*
System (JASC)
5751 · Ailerons
Part
Aileron
Part number
86562025
Condition
Misrepaired
Location
Wing
Part time
3,881 hours
Stage of operation
CR
How discovered
O
Nature of condition
W, F
Precautionary procedure
O

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

What was found

DURING POWER OFF (CLEAN CONFIGURATION) STALLS, THE AIRCRAFT WOULD SUDDENLY BREAK LT AND IF NOT IMMEDIATELY STOPPED COULD LEAD TO A SPIN. AFTER RERIGGING ALL FLIGHT CONTROLS, CHECKING THE AIRCRAFT ALIGNMENT WITH A LASER AND SEVERAL TEST FLIGHTS BOTH BY COMPANY PILOTS AND MFG FACTORY TEST PILOT, IT WAS DETERMINED THAT WE HAD (FAT) AILERONS ON OUR FLEET. MFG HAS A HISTORY OF AILERON SKIN CRACKING. (FOR US, IT HAS JUST BEEN THE RT AILERON THAT HAS HAD THE CRACKING PROBLEM.) ONCE THE CRACK IS PAST A CERTAIN POINT YOU EITHER HAVE TO REPLACE THE AFFECTED SKIN OR REPLACE THE AILERON. DURING SKIN REPLACEMENT, IF THE PREFORMED FACTORY SKIN IS SPREAD APART EVEN A LITTLE THE TRAILING EDGE TAKES ON A (FAT) CONDITION.

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