Ouch! Another Lycoming AD

bmurrish · Post by **bmurrish** » Thu May 18, 2006 10:26 pm

I got this from aero-web

When It Rains, It Pours... Another Lycoming AD

[Docket No. FAA-2005-21331; Directorate Identifier 2005-NE-07-AD; Amendment
39-14605; AD 2006-10-21]
ANN is looking over yet another Lycoming AD that was just published to the
Federal Register, affecting a number of Lycoming 360 and 540 series engines,
using ECi connecting rods.

According to the FAA, it is "adopting a new airworthiness directive (AD) for
certain Lycoming Engines (formerly Textron Lycoming) 360 and 540 series
reciprocating engines with ECi connecting rods, part number (P/N) AEL11750,
installed. The Airmotive Engineering Corp, Division of Engine Components
Incorporated (ECi), holds the Parts Manufacturer Approval (PMA) for the
affected parts, and markets the parts as ECi parts."

"This AD requires replacing certain lot and serial numbered connecting rods,
P/N AEL11750, having forging part number AEL11488. This AD would also
prohibit installing certain ECi connecting rods, P/N AEL11750, into any
Lycoming 360 or 540 series reciprocating engines. This AD results from
reports of connecting rods with excessive variation in circularity of the
journal bores. We are issuing this AD to prevent fatigue failure of the
connecting rod and a possible uncommanded shutdown of the engine."

The AD becomes effective June 22, 2006.

In its final ruling, the FAA also addresses the comments made by many pilots
that such an airworthiness directive is not needed, based on the relatively
few incidents reported.

"Several commenters question the need for the connecting rod AD," the FAA
stated. "We disagree. We confirmed that a manufacturing defect existed in
the ECi connecting rods. The FAA has determined that this defect was the
most probable cause of an engine shutdown and forced landing incident."

"ECi identified the manufacturing process deficiencies that were responsible
for the defective condition and took specific actions to correct these
deficiencies. We also determined that the subject ECi connecting rods in
service could possess these manufacturing defects and could, therefore, fail
during operation."

FMI: http://dms.dot.gov, AD 2006-10-21
aero-news.net

jim_geo · Post by **jim_geo** » Fri May 19, 2006 12:38 am

Isn't that just the way it goes! I just put my connecting rods on the crank today. Did I measure the circularity? NO! Guess what I'll be doing tomorrow? The machining on their parts is just so nice it's hard to believe there's a problem.

I just read the AD and I am definetly taking a close look and asking some questions in the morning. Thanks for the heads up.

captain_john · Post by **captain_john** » Fri May 19, 2006 5:45 am

Jim, do the part numbers jive with yours?

CJ

Wicked Stick · Post by **Wicked Stick** » Fri May 19, 2006 3:18 pm

"This AD requires replacing certain lot and serial numbered connecting rods,
P/N AEL11750, having forging part number AEL11488. This AD would also
prohibit installing certain ECi connecting rods, P/N AEL11750, into any
Lycoming 360 or 540 series reciprocating engines. This AD results from
reports of connecting rods with excessive variation in circularity of the
journal bores. We are issuing this AD to prevent fatigue failure of the
connecting rod and a possible uncommanded shutdown of the engine."

The AD becomes effective June 22, 2006.

Mahlon, if you listening, is there a way to find out if my Superior I0-360 with ECI cylinders (built by Mattituck) has paperwork that shows what connecting rod part numbers are in it ?

Dave Rogers

jim_geo · Post by **jim_geo** » Fri May 19, 2006 8:47 pm

Well here is what I've found today. This AD applies to P.N. AEL11750 Forging Number 11488 and Lot numbers 1 to 54. Basically any part number AEL11750 is going to have a forging number 11488 the only variation will be in the lot number. Anyone interested in this AD already knows that some connecting rods made by ECI were over tolerance out of round on their large bore end. Evidence showed that the out of round caused a wash board effect on the bearing leading to a failure.
Yesterday I installed three of the four connecting rods on their crank. I had not installed the forth because I wanted to do a photo journal of it's assembly and I had left my camera at home. When I got home I read the original post of this thread. This morning I took the uninstalled connecting rod to a trusted engine rebuilder and had them check the bore for out of round.

It was checked and rechecked and was found to be WELL within tolerance. Based on the fact that this connecting rod was found to be "very" round I decided to forgo checking the others. The lot numbers for all of the connecting rods I have are in the 80's and 90's. It should be noted that from what I was able to gather this AD was based on one failure and that Lycoming was the tear down inspector. Also it seems to me not insignificant that Lycoming was the driving force behind an AD against ECI. This AD covers in a small way (not a lot of detail) a list of the insufficiencies of a piece of equipment at ECI specifically the tool used to grind the large bore end of the connecting rods. Apparently judging from my experience this morning those insufficiencies have been addressed. All in all it would have been a smart move to have checked all of the connecting rods before charging ahead.

As I assemble this engine I have been keeping track of part numbers and serial numbers for it's log book and as I move further along with assembly will be including position information. Looks like I'm going to be including lot numbers in its log book also.

Mahlon · Post by **Mahlon** » Sun May 21, 2006 6:08 am

Dave,
The rods in question were made by ECI not Superior, so you engine couldn't be affected. We do maintain all the build records, for all of our engines. Yes there is a parts list for your engine on record with us.
Good Luck,
Mahlon
"The opinions and information provided in this and all of my posts are hopefully helpful to you. Please use the information provided responsibly and at you own risk."

Mahlon · Post by **Mahlon** » Sun May 21, 2006 6:08 am

Dave,
The rods in question were made by ECI not Superior, so you engine couldn't be affected. We do maintain all the build records, for all of our engines. Yes there is a parts list for your engine on record with us.
Good Luck,
Mahlon
"The opinions and information provided in this and all of my posts are hopefully helpful to you. Please use the information provided responsibly and at you own risk."

Wicked Stick · Post by **Wicked Stick** » Mon May 22, 2006 8:34 am

Mahlon wrote:Dave,
The rods in question were made by ECI not Superior, so you engine couldn't be affected. We do maintain all the build records, for all of our engines. Yes there is a parts list for your engine on record with us.
Good Luck,
Mahlon
"The opinions and information provided in this and all of my posts are hopefully helpful to you. Please use the information provided responsibly and at you own risk."

Could I get a copy of the parts list ? I didn't see one in the folder that came with my engine.

Thanks,
Dave R.