Corrosion And leaks

Upon investigating a loose rudder pedal, the controls were disassembled. We found the shaft had been double-drilled with the holes overlapping. This aircraft is a relatively new aircraft, having been certificated in January 2002. Pilots rudder pedal assembly: p/n 002-524040. Left rudder pedal shaft: p/n 002-524016-5.

Key Takeaways:

• Aircraft are experiencing diverse mechanical issues, including manufacturing defects (e.g., double-drilled rudder pedal shaft) and material degradation (e.g., brittle hydraulic sight glass, severe wing spar corrosion).
• Corrosion, often due to moisture exposure, is a recurring problem affecting critical components like wing spars and elevator torque tubes, with some issues prompting airworthiness bulletins.
• Reported failures, such as a leaking hydraulic sight glass causing smoke in the cockpit and a cracked primer line due to vibration, underscore the importance of regular inspections, preventative maintenance, and timely part replacement.

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