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Technician with inspection authority reported an alternate starter caused an oil leak due to insufficient clearance between the oil cooler and starter power terminal. This caused an oil leak and air turn back and emergency landing.
| Attributes | |
| ACN | 1749972 |
| Time | |
| Date | 202007 |
| Place | |
| Locale Reference | ZZZ.Airport |
| State Reference | US |
| Environment | |
| Flight Conditions | VMC |
| Light | Daylight |
| Aircraft 1 | |
| Make Model Name | PA-28 Cherokee/Archer/Dakota/Pillan/Warrior |
| Operating Under FAR Part | Part 91 |
| Flight Phase | Cruise |
| Route In Use | None |
| Flight Plan | None |
| Component | |
| Aircraft Component | Engine Electric Starter |
| Person 1 | |
| Function | Inspector |
| Qualification | Maintenance Airframe Maintenance Powerplant Maintenance Inspection Authority |
| Experience | Maintenance Inspector 2 Maintenance Technician 10 |
| Events | |
| Anomaly | Aircraft Equipment Problem Critical Deviation - Procedural Maintenance Deviation - Procedural FAR Deviation - Procedural Published Material / Policy |
Narrative:
The installation instructions for the pma (parts manufacturer approval) approved sky-tec 122NL starter does not address the lack of clearance between the oil cooler and the starter wire terminal. The terminal chaffed a hole in the oil cooler; causing an oil leak in flight followed by smoke in the cockpit and an immediate return to the airport. There were no injuries or damage to the aircraft other than the oil cooler. This starter is not a direct replacement for the PA-28-140 as listed in the pma and is also listed this way with [the] parts seller. Neither the piper maintenance manual nor the manufacurers instructions address this issue.
Original NASA ASRS Text
Title: Technician with inspection authority reported an alternate starter caused an oil leak due to insufficient clearance between the oil cooler and starter power terminal. This caused an oil leak and air turn back and emergency landing.
Narrative: The installation instructions for the PMA (Parts Manufacturer Approval) approved Sky-Tec 122NL starter does not address the lack of clearance between the oil cooler and the starter wire terminal. The terminal chaffed a hole in the oil cooler; causing an oil leak in flight followed by smoke in the cockpit and an immediate return to the airport. There were no injuries or damage to the aircraft other than the oil cooler. This starter is not a direct replacement for the PA-28-140 as listed in the PMA and is also listed this way with [the] parts seller. Neither the Piper maintenance manual nor the manufacurers instructions address this issue.
Data retrieved from NASA's ASRS site and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.