Heating And Cooling

A mechanic found the same problem on two identical aircraft:, "The carburetor heat control arm (p/n: D4F-7326-12-00-1) broke off the carburetor air box, causing uncontrolled selection of carburetor heat versus ram (cold) air intake." The mechanic recommends installing thicker material on the carburetor heat control arm lever, or a different welding/heat treating process, or a different attachment provision altogether.

Key Takeaways:

• Diamond DA40F aircraft experienced recurring failures, including early breakage of carburetor heat control arms and electrical fuel pumps, with inadequate cooling suggested as a cause for the latter.
• Other significant mechanical issues included persistently loose exhaust stacks on Lycoming TIO-540-AJ1A engines and cracked spinner bulkheads on Sensenich propellers used in Maule aircraft.
• An inaccurate fuel gauge was reported on a Mooney M20D, consistently indicating more fuel than present in the tank.

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