FAA unapproved PARTs notification

No. 2001-00274 issued June 17, 2001

AFFECTED PARTS

Turbochargers.

PURPOSE

The purpose of this notification is to advise all aircraft owners, operators, manufacturers, maintenance organizations, parts suppliers, and distributors regarding improper maintenance performed on Garrett and RayJay/Roto-Master turbochargers.

BACKGROUND

A joint suspected unapproved parts investigation conducted by the Federal Aviation Administration (FAA), Department of Transportation - Office of Inspector General , and the Federal Bureau of Investigation revealed that Thunderbird Accessories, Inc. (Thunderbird), improperly maintained and approved for return to service Garrett and RayJay/Roto-Master turbochargers. Thunderbird, located at 5406 N. Rockwell, Bethany, OK 73008, previously held Air Agency Certificate No. IC2R893K.

Evidence revealed that Thunderbird had failed to accomplish maintenance in accordance with the manufacturers' maintenance manuals; Instructions for Continued Airworthiness; or other methods, techniques, and practices acceptable to the FAA. Discrepancies noted included stop-drilling beyond allowable limits on exhaust housings, and the installation of unapproved bolts and bearings that were not designed for extreme heat applications. The FAA has been unable to determine all models and serial numbers affected; therefore, all turbochargers approved for return to service by Thunderbird should be considered suspect.

RECOMMENDATIONS

Regulations require that type-certificated products conform to their type design. Aircraft owners, operators, maintenance organizations, parts suppliers, and distributors should inspect their aircraft, aircraft records, and/or parts inventories for turbochargers approved for return to service by Thunderbird. Suspect turbochargers installed on aircraft should be inspected for conformity to type design. If any are found in existing stock, it is recommended that the turbochargers be quarantined to prevent installation until a determination can be made regarding each part's eligibility for installation.

FURTHER INFORMATION

Further information concerning this investigation and guidance regarding the above-referenced turbochargers may be obtained from the FAA Flight Standards District Office (FSDO) given below. In addition to the above recommendations, the FAA would appreciate any information concerning the discovery of the turbochargers, the means used to identify the source, and the action taken to remove any turbocharger from service. This notice originated from the Oklahoma City FSDO, 1300 S. Meridian Blvd., Suite 601, Oklahoma City, OK 73108, telephone (405) 951-4200, fax (405) 951-4282; and was published through the FAA Suspected Unapproved Parts Program Office, AVR-20, telephone (703) 668-3720, fax (703) 481-3002, web: http://www1.faa.gov/avr/sups/upn.cfm.