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 issues with very early failures of carburetor heat control arms and multiple electrical fuel pump failures, likely due to inadequate cooling.
• Lycoming TIO-540-AJ1A engines repeatedly suffered from loose exhaust stacks, attributed to undertorqued studs and persistent sealing challenges.
• Multiple Sensenich propeller spinner assemblies (S76EM and S74DM models) developed cracks through the forward bulkhead mount bolt holes on several Maule aircraft.

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