AIRWORTHINESS DIRECTIVE

For the reasons set out in the background section, the CASA delegate whose signature appears below revokes Airworthiness Directive AD/CON/81 and issues the following AD under subregulation 39.1 (1) of CAR 1998. The AD requires that the action set out in the requirement section (being action that the delegate considers necessary to correct the unsafe condition) be taken in relation to the aircraft or aeronautical product mentioned in the applicability section: (a) in the circumstances mentioned in the requirement section; and (b) in accordance with the instructions set out in the requirement section; and (c) at the time mentioned in the compliance section.

Teledyne Continental Motors Piston Engines

AD/CON/81

Amdt 1

Unison Industries (Slick) Magnetos 9/2002

DM

Applicability: Teledyne Continental Motors (TCM) C-125, C145, O-300 series, IO-360 series, TSIO-360 series, and LTSIO-520-AE series reciprocating engines with Unison Industries (Slick) Magnetos, models 6314, 6324, and 6364, with magneto serial numbers of 99110001 through 99129999 inclusive.

Note 1: These engines are used on, but not limited to, Cessna 170, 170A, 170B, 172, 172A through 172H, 172XP, 336, 337, and T303, Beagle B242-C, Cirrus SR20 and SR22, Globe Swift GC-1A and GC-1B, Maule M4, Piper PA-28R-201T and PA-34, and Reims (Cessna) FA172, F337, and FR172.

Note 2: A cross-reference for part numbers (P/N's) for Unison magneto model 6314 (TCM P/N 653271), model 6324 (TCM P/N 653292), and model 6364 (TCM P/N

649696) can be found in TCM Mandatory Service Bulletin 00-6A, dated June 8, 2000.

Note 3: The magneto serial number (S/N) can be found in logbooks or other maintenance records. If the magneto was installed, or if the engine was assembled new, rebuilt, or overhauled before 31 October 1999, it is likely that a suspect magneto is not installed on the engine.

Requirement: 1. If not accomplished in accordance with the original issue of this Directive - Replace any magneto that has a S/N of 99110001 through 99129999, inclusive, with a magneto that does not have a serial number in that range.

2.    Inspect each removed magneto to verify that the impulse coupling stop pin is present. If the pin is missing, accomplish the following:

a.    For C-125, C145, O-300, IO-360 and TSIO-360 engines:

1. Remove magnetos, alternator or generator, and starter adapter from the accessory case.

ii.        Remove the accessory case from the crankcase and oil sump.

iii.     Visually inspect the entire engine gear train for damaged or broken gears and gear teeth.

Teledyne Continental Motors Piston Engines

AD/CON/81 Amdt 1 (continued)

iv.      Inspect visible portions of the engine crankcase and accessory case for damage due to the stop pin becoming lodged between the engine gear train and the crankcase or accessory case.

v.        If the accessory case is damaged, repair or replace the accessory case.

vi.      If the engine crankcase is damaged, disassemble the engine, and repair or replace the crankcase.

vii.    Inspect the oil pump drive gear teeth and inner cam gear teeth for damage. Replace any engine drive train component that has been damaged.

viii. Replace any damaged gear, and magnaflux the mating gears using the applicable engine overhaul manual.

b.    For LTSIO-520-AE series engines:

1. Remove the starter adapter, fuel pump, vacuum pumps, accessory drive pads, and both magnetos.

ii.        Visually inspect the entire engine gear train for damaged or broken gears and gear teeth.

iii.     If any damage has occurred, remove the engine from the aeroplane, disassemble the engine, and inspect it for damage. If any damage is found, repair as necessary.

iv.      Replace any damaged gear, and magnaflux the mating gears using the applicable engine overhaul manual.

v.        Inspect the interior portions of the engine crank case for damage due to the stop pin becoming lodged between the gear train and the crankcase. If the crankcase is damaged, repair or replace the crankcase.

3.    Unison Industries (Slick) magnetos, model 6314, 6324, or 6364 that have a S/N of 99110001 through 99129999 inclusive, may not be installed on any engine.

Note 4: FAA Emergency AD 2000-11-51 and AD 2002-13-04 Amdt 39-12792 refer.

Compliance: For Requirement 1 - Within ten hours time in service from the effective date of this Amendment.

For Requirement 2 - Before further flight after the magneto is removed from the engine.

For Requirement 3 - As of the effective date of this Amendment.

Teledyne Continental Motors Piston Engines

AD/CON/81 Amdt 1 (continued)

This Amendment becomes effective on 12 July 2002.

Background: The Federal Aviation Administration (FAA) received reports of engine failures on certain Teledyne Continental Motors (TCM) reciprocating engines. On 26 April 2000, the FAA was notified of an in- flight engine failure in a Cirrus SR20 aeroplane with a TCM IO-360 engine. The FAA also received two reports of engine failures on the ground. The FAA determined that migration of the magneto impulse coupling stop pin out of the magneto frame and into the gear train of the engine caused damage to the gear train and, ultimately, engine failure. The specific cause for the migration of the impulse coupling stop pin is still undetermined, but data indicate that it is due to a manufacturing problem limited to a specific range of magneto models and serial numbers that were produced during the months of November 1999 and December 1999. This condition, if not corrected, could result in engine failure and subsequent loss of control of the aeroplane.

Since an unsafe condition has been identified that is likely to exist or develop on other engines of this same type design, this original issue of this Directive required replacement of the magneto if it falls within the specified serial number range; and, if it is replaced, an inspection of the ma gneto to verify that the stop pin is still in place. Additionally, if the stop pin is not in place, the Directive required an inspection of the engine gear train.

This amendment is issued following the FAA identifying two further engines series that may be affected. The amendment also includes two new explanatory notes identifying known aeroplanes with the affected engine series and providing a cross reference of Unison and TCM magneto P/Ns.

Note 5: The Direct Mail version of this amendment has only been forwarded to the Certificate of Registration holder of aeroplanes with C-125 and C145 engines fitted.

The original issue of this Airworthiness Directive became effective on 14 June 2000.

Eugene Paul Holzapfel

Delegate of the Civil Aviation Safe ty Authority 3 July 2002

The above AD is notified in the Commonwealth of Australia Gazette on 10 July 2002.