Service difficulty report · Housing · Diamon DA40

Difficulty date
February 8, 2010
Submitted
February 25, 2010
Operation
General aviation
Aircraft
N342AF
Make and model
Diamon DA40
Aircraft serial
401040
Engine
Lyc IO360M1A
Propeller
Hartzl HCC2YR1
Part
Housing
Part number
D4171662030
Condition
Damaged
Location
Alt Air Valve
Part time
147 hours
Stage of operation
IN
How discovered
9
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

AFTER 150 HOURS ON ACFT DURING SCHEDULED MAINTENANCE THE FIRST ONE OF THE TYPE OF PROBLEM WAS FOUND. MECHANICS ARE FINDING THE ALTERNATE AIR VALVE BODY CONTROL CABLE (PN NR DAI-9076-00-04) LOOSE OR COMPLETELY DISCONNECTED AND HANGING NEXT TO THE PRIMARY/ALTERNATE AIR VALVE BODY (PN D41-7166-20-30). THEN WHEN THEY TRY TO REINSTALL THE CABLE THEY ARE FINDING THAT THE THREADS ARE STRIPPED OUT ON THE ALTERNATE AIR VALVE BODY. THIS PROBLEM HAS NOW OCCURRED ON 14 DIFFERENT ACFT IN OUR FLEET ALL BETWEEN 150 TO 350 HOURS TTSN. MY CONCERN IS THAT THE OPERATOR OF THE ACFT (IF THE CABLE HAS BECOME DISCONNECTED) MAY NOT KNOW IF THE ENGINE IS GETTING FILTERED OR UNFILTERED AIR. THE FIX MIGHT BE THAT THE MANUFACTURE MAKES THE VALVE BODY THICKER (MORE THREADS), PUT IN A STEEL HELICOIL, OR MAYBE SPOT WELD A NUT ON THE OUTSIDE OF THE VALVE BODY.

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