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  1. My two cents. I have no particular expertise in this area but suspect the cotter pins broke from fatigue. If the head of the pin wasn't peened close to the nut face and/or the prong wasn't tightly wrapped against the bolt end, it would flex as the rod reversed directions during rotation. (see the figure Pilot64 posted). I guess after one prong broke off inertial forces could cause the other prong to straighten as the pin was pulled out. Of course using the wrong size pin or the wrong material could cause this as well. I would definitely want a full explanation from the shop on why this happened and how they plan to fix it. Good luck going forward - I know this has to be disappointing.
  2. I agree with Yetti about the lugs. Solenoids can intermittently make good contact. Are you confident you had a good ground during the voltage drop test? Also Aircraft Spruce sells Sky-Tec/Lamar FAA-PMA approved main (continuous duty) and starter relays for around $75.
  3. On my 1964 M20E the starter solenoid is located on the firewall -pilot side.
  4. According to Wikipedia the B6 has impulse coupled magnetos and crankshaft counterweights. I have no idea if these can be installed in an "E"
  5. I use a homemade closed loop dehumidifier. This morning the RH in the hangar was 67% at 50 degrees F. The air in the crankcase was 34%. Hopefully this improves my odds - who knows for sure.
  6. If the plane is in trim and flys hands off, I would try cleaning and re-seating the electrical connectors. I read somewhere that the left/right course and HDG deviations provide a voltage differential. A dirty connector can bias the voltage. Take all this with a grain of salt - I'm no expert. Just telling you what I would try.
  7. I agree with all the above comments. The same thing happened to mine several years ago. Altitude hold got intermittent and would often oscillate. As a last ditch effort I sprayed the pitch servo with electrical contact cleaner (sprayed the end with the brushes). Its been working just fine since then. I read somewhere that the brushes wear and all the dust causes problems.