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 carburetor heat control arms breaking off at very low hours and electrical fuel pumps failing frequently due to suspected inadequate cooling.
• Lycoming TIO-540-AJ1A engines had issues with exhaust stacks repeatedly coming loose and leaking, even after repairs with oversized studs.
• Multiple Sensenich propeller spinner bulkheads were found cracked through mount bolt holes on several Maule aircraft.
• A Mooney M20D reported an inaccurate fuel gauge consistently indicating 2.5-3.0 gallons higher than the actual fuel in the tank.

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