What was found
UPON INSPECTION AFTER MAJOR ENGINE OVERHAUL, IT WAS DISCOVERED THAT THE ROCKER SHAFT THRUST BUTTONS HAD EITHER PARTIALLY OR COMPLETELY MELTED, ONLY ONE CYLINDER HAD BOTH THRUST BUTTONS COMPLETELY INTACT. MELTED PLASTIC DEBRIS WAS FOUND IN THE ROCKER COVERS AND OIL SUMP SCREEN. DEFECTIVE THRUST BUTTONS WERE REMOVED AND REPLACED WITH LYCOMING THRUST BUTTONS P/N LW-12892. DEBRIS WAS REMOVED, ENGINE OIL AND FILTER CHANGED AND GROUND RUN FOR 2 HOURS, THEN CHANGED AGAIN BY CUSTOMER AND RETURNED TO SERVICE. INFORMATION THAT WE RECEIVED STATED THAT FAULTY THRUST BUTTONS WILL FLOAT IN WATER AND GOOD PARTS WILL SINK. WE PERFORMED THIS TEST ON EVERY LOT NUMBER IN OUR INVENTORY AND FOUND SEVERAL LOT NUMBER BATCHES THAT FLOAT. WE THEN CONTACTED ANY CUSTOMERS WITH THE SUSPECT LOT NUMBER THRUST BUTTONS INSTALLED IN THEIR ENGINES TO INFORM THEM OFOUR FINDINGS AND TO REMOVE THE PARTS FROM SERVICE. SUSPECT LOT NUMBERS IN OUR INVENTORY WERE QUARANTINED.