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‘Improper Installation’

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Key Takeaways:

  • The FAA issued Airworthiness Directive (AD 2023–04–08) for Continental engines manufactured between June 2021 and February 2023 due to improperly seated crankshaft counterweight retaining rings, a defect that could cause catastrophic engine failure.
  • This AD affects 2,176 crankshaft assemblies (1,632 on U.S. aircraft) with less than 200 operating hours, requiring inspections and potential cylinder removal for compliance.
  • The FAASTeam and GAJSC highlighted that a lack of formal transition training for general aviation pilots switching aircraft types is a significant causal factor in accidents, making the initial 50-100 hours in a new aircraft particularly hazardous.
  • Effective transition training should include thorough study of the new aircraft's systems and limitations, instruction from a qualified expert, and extensive practical experience, including simulator use and altitude maneuvering.
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The FAA on February 23, 2023 published a new, final airworthiness directive (AD 2023–04–08) highlighting a problem with new Continental engines manufactured between June 1, 2021, and Feb. 7, 2023. According to the agency, “The manufacturer has notified the FAA that 2,176 crankshaft assemblies are subject to the unsafe condition. The FAA estimates that of those 2,176 crankshaft assemblies, 1,632 are installed on aircraft of U.S. registry. The FAA estimates that 544 engines will need to remove one cylinder, 544 engines will need to remove two cylinders, and 544 engines will need to remove three cylinders for compliance with this AD.”

The new AD is based on Continental’s Mandatory Service Bulletin MSB23–01, Revision A, dated February 16, 2023. According to the bulletin, “It is possible one or more counterweight retaining rings were not properly seated in the crankshaft counterweight groove. This condition could allow the counterweight to depart from the crankshaft during engine operation resulting in catastrophic engine damage.”

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