Critical Details & Aircraft Engine Consequences

Ever wonder what happen’s if the incorrect bushings are installed and how that might affect your next flight?

Read on.

This engine came to us with 40 hours on it since the last overhaul by a different engine shop. The owner reported a suspected issue and our team went to diagnosing.

We uncovered that the incorrect bushings had been installed in the rocker arms.

While this might not be seen at first glance to the untrained eye- it was quickly disastrous to the valve train. The rocker arm bushings act as funnels to cycle oil from the pushrods through the valves, springs, and rotators. Without this critical lubrication, all of the guides and valves seized.

These cylinders will all need to be overhauled, and although we hope additional damage to the oil pump and camshaft did not occur, that will be uncovered in disassembly.

The next course of action is to fix the damage- overhauling the cylinders, magnetic particle inspect the rocker arms and install new bushings- correcting the problem. We would monitor this client closely over their next 25 hours; close attention to operational parameters, lubrication, and checking oil filter for contamination.

Every. Single. Detail. Matters.

Even the “pros” of our industry admit they need to be reminded from time to time of the basics of General Aviation Maintenance and the importance of attention to detail.

Inspections at annuals and intervals, daily pre-flights, following Airworthiness Directives and Service Bulletins, keeping up with preventative and progressive maintenance, conducting test flights after any repairs or alterations - all are opportunities to find inconsistencies, and maximize your engine. Aircraft maintenance engineers play a critical role in ensuring that aircraft are maintained in accordance with the above regulations and standards extending your aircrafts operating life, and in turn keeping you safe.

An engine overhaul is one of the biggest and most expensive aircraft repair and maintenance tasks that owners have to face. Make sure you are taking it somewhere you can trust.

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