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Date: Tue, 16 May 2006 23:22:35 -0400
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From: "Clark Baker" <bakercdb@gmail.com>
Subject: Lycoming 360 A1A durability question - piston pin plug wear
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When I purchased my Lancair 360, it had 15hrs TTAF and SMOH and a know issu=
e
with excessive oil consumption.  We attributed this to the chrome cylinders
never properly seating (not a rare problem).  When it did not improve after
about 50hrs, my mechanic suggested trying new rings and glaze breaking the
cylinders (I was still in the post-purchase checkbook phase).

Not surprisingly, this did not accomplish much and the engine (with
150hrs SMOH) went in for new cylinders at one of the oldest and most
established engine shops in the North East . However, the shop discovered a
spun bearing and so I opted for the 1st class overhaul with dynamic
balancing, etc.  I spoke to the small Florida shop that did the original
overhaul and they would not cover any of their work since it had been
several years.

Last week, at 370hrs SMOH (the second one) I discovered material amounts of
aluminum material in the filter.  I discovered that I had excessive piston
pin plug wear.  It turns out Lycoming issued Service Instruction 1492C,
which addressed problems with excessive piston pin plug wear.  Lycoming
addressed this by extending the warranty for Lycoming new or Lycoming
factory rebuilt engines from 1year to 3.

I spoke to my Engine shop manager and they said "it is just one of those
things" and they don't have a good answer.  I spoke to Lycoming and the
technician could not offer any advice other than replace the parts and try
again.

Obviously I am not thrilled pulling my cylinders off at 370hrs , previously
believing these early top end problems were the domain of the IV(P) people
running boosted engines at high altitudes/power/temps.

My questions and comments are:
-what exactly happened (bad part? bad install?, maintenance? operation)?
-as the owner/operator, what can I do to help prevent this?  I believe I
have always followed a conservative maintenance and operating policy.
-I am disappointed (but not surprised at the support).  Lycoming
acknowledges that there is a problem, but extending the warranty to 3 years
and only to New and Lycoming factory rebuilt engines is not much support fo=
r
an engine with a typical design TBOH of say 15 years (non commercial
applications) or to those that had someone other than Lycoming (ie, most
people) perform the overhaul.

Regards,
Clark Baker

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<div>When I purchased my Lancair 360, it had 15hrs TTAF and SMOH and a know=
 issue with excessive oil consumption.&nbsp; We attributed this to the&nbsp=
;chrome cylinders never properly seating (not a rare problem).&nbsp; When i=
t did not improve after about 50hrs, my mechanic suggested trying new rings=
 and glaze breaking the cylinders (I was still&nbsp;in the post-purchase ch=
eckbook phase).&nbsp;=20
</div>
<div>&nbsp;</div>
<div>Not surprisingly, this did not accomplish much and the engine (with 15=
0hrs&nbsp;SMOH)&nbsp;went in for new cylinders at one of the oldest and mos=
t established engine shops in the North East .&nbsp;However, the shop disco=
vered a spun bearing and so I opted for the 1st class overhaul with dynamic=
 balancing, etc.&nbsp; I spoke to the small Florida shop that did the origi=
nal overhaul and they would not cover any of their work since it had been s=
everal years.
</div>
<div>&nbsp;</div>
<div>Last week, at 370hrs SMOH (the second one) I discovered material amoun=
ts of aluminum material in the filter.&nbsp; I discovered that I had excess=
ive piston pin plug wear.&nbsp; It turns out Lycoming issued Service Instru=
ction 1492C, which addressed problems with excessive piston pin plug wear.&=
nbsp; Lycoming addressed this by extending the warranty for Lycoming new or=
 Lycoming factory rebuilt engines from 1year to 3.
</div>
<div>&nbsp;</div>
<div>I spoke to my Engine shop&nbsp;manager&nbsp;and they said &quot;it is =
just one of those things&quot; and they don't have a good answer.&nbsp; I s=
poke to Lycoming and the technician could not offer any advice other than r=
eplace the parts and try again.
</div>
<div>&nbsp;</div>
<div>Obviously I am not thrilled pulling my cylinders off at 370hrs , previ=
ously believing these early top end problems were the domain of the IV(P) p=
eople running boosted engines at high altitudes/power/temps.&nbsp; </div>
<div>&nbsp;</div>
<div>My questions and comments are:</div>
<div>-what exactly happened (bad part? bad install?, maintenance? operation=
)?</div>
<div>-as the owner/operator, what can I do to help prevent this?&nbsp; I be=
lieve I have always followed a conservative maintenance and operating polic=
y.</div>
<div>-I am disappointed (but not surprised at the support).&nbsp; Lycoming =
acknowledges that there is a problem, but extending the warranty to 3 years=
 and only to New and Lycoming factory rebuilt engines is not much support f=
or an engine with a typical design TBOH of say 15 years (non commercial app=
lications) or to those that had someone other than Lycoming (ie, most peopl=
e) perform the overhaul.
</div>
<div>&nbsp;</div>
<div>Regards,</div>
<div>Clark Baker</div>
<div>&nbsp;</div>
<div>&nbsp;</div>
<div>&nbsp;</div>
<div>&nbsp;</div>

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