Mufflers

While carrying out Canadian AD CF90-03-R2, large leaks were found in the area surrounding the muffler tail pipe area under the structure for supporting the heat muff shroud. No defects were noticed in a visual inspection of this area. No data tag was on the muffler, so its assumed it is an original unit. The operators logs dont show it ever being changed.

Key Takeaways:

• Aircraft exhaust systems, particularly mufflers, are susceptible to diverse failures including leaks, structural separations (e.g., failed spot welds, internal detachment), and internal blockages.
• These defects often pose inspection challenges, being difficult to detect visually or missed during routine maintenance, and can lead to serious risks like carbon monoxide exposure.
• Failures occur across various aircraft models and part lifespans, sometimes originating from repair welds, highlighting the need for thorough inspections.

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