Engine and prop OH issues, solutions and shop PIREP

[1964-M20E]

This year I did a field OH on a spare IO-360A1A engine.  I was able to work with the mechanic and complete the OH turning the wrenches myself.  The existing engine on my plane was leaking more and more oil and was becoming an issue.  It was time.

I installed the engine and completed the initial test flight in early June.  Everything was fine until August when I was returning home from Florida.  The prop became unresponsive and would not control engine RPM.  I was running 14” MP to keep from over speeding the engine.  I only had about 31 hours on the engine and prop at this point.  I drained the oil checked the finger screen and the oil filter and both were clean.  I suspected the governor, a PCU-5000, installed last year about 130 hours) and removed it.  During the OH I sent the governor to APS for IRAN so that it would be back to factory standards when I started  with my new engine.  After removing the governor I sent it back APS and they were great.  They did not find anything wrong with the governor and only charged me shipping and it was a quick turnaround.

I then proceeded to do a pressure test on the prop and found the issue.  The prop was hydraulicly locked.  I pulled the grease fitting revealed engine oil in the hub.  When doing the OH I sent the prop to Stallings Propeller for IRAN.  I removed the prop and again sent it to Cody Stallings. Upon disassembly and inspection Cody suspected there was an issue with the piston since the O-ring was fine.  Cody installed a serviceable newer style piston, tested the prop and sent it back to me quickly.  Cody was absolutely great.  Even though I offered he would not charge me for the piston, shipping or dressing out one of the blades that had damage caused by my packaging.  I reinstalled the prop, did a test flight and everything went well.

 

Again thanks to APS and Stallings for standing behind their work.

[jaylw314]

Dang it @Cody Stallings, why do you have to be on the wrong side of the country?? 

[1964-M20E]

2 hours ago, jaylw314 said:

Dang it @Cody Stallings, why do you have to be on the wrong side of the country?? 

A freight truck will carry your props anywhere you want.    Besides he's in the middle side of the country.

[carusoam]

Great pireps for Cody Stallings and APS!

Great pirep for John doing an engine OH!    (that’s a @Raptor05121 like project!)

Thanks for sharing the details John!

Best regards,

-a-

[jaylw314]

2 hours ago, 1964-M20E said:

A freight truck will carry your props anywhere you want.    Besides he's in the middle side of the country.

No! I want him within a 5 minute drive!!! 

[Ragsf15e]

16 hours ago, jaylw314 said:

No! I want him within a 5 minute drive!!! 

Me too! And m20doc and agl and…

 

[Raptor05121]

On 10/20/2021 at 7:36 PM, carusoam said:

 

Great pirep for John doing an engine OH!    (that’s a @Raptor05121 like project!)

 

I can barely afford to keep Ramen noodles in my hotel. Maybe in 10 years I can afford the overhaul

 

 

manual

Edited October 23, 2021 by Raptor05121

[EricJ]

27 minutes ago, Raptor05121 said:

I can barely afford to keep Ramen noodles in my hotel. Maybe in 10 years I can afford the overhaul

 

 

manual

Wait...I thought you were in the Big Time now making the bux by good timing in the pilot shortage?

 

[Raptor05121]

2 hours ago, EricJ said:

Wait...I thought you were in the Big Time now making the bux by good timing in the pilot shortage?

 

Year 1 FO pay isn't really Big Time. But I digress, I don't want to derail OPs thread.

Any pics of the field overhaul?
 

[Cody Stallings]

On 10/20/2021 at 2:59 PM, 1964-M20E said:

This year I did a field OH on a spare IO-360A1A engine.  I was able to work with the mechanic and complete the OH turning the wrenches myself.  The existing engine on my plane was leaking more and more oil and was becoming an issue.  It was time.

I installed the engine and completed the initial test flight in early June.  Everything was fine until August when I was returning home from Florida.  The prop became unresponsive and would not control engine RPM.  I was running 14” MP to keep from over speeding the engine.  I only had about 31 hours on the engine and prop at this point.  I drained the oil checked the finger screen and the oil filter and both were clean.  I suspected the governor, a PCU-5000, installed last year about 130 hours) and removed it.  During the OH I sent the governor to APS for IRAN so that it would be back to factory standards when I started  with my new engine.  After removing the governor I sent it back APS and they were great.  They did not find anything wrong with the governor and only charged me shipping and it was a quick turnaround.

I then proceeded to do a pressure test on the prop and found the issue.  The prop was hydraulicly locked.  I pulled the grease fitting revealed engine oil in the hub.  When doing the OH I sent the prop to Stallings Propeller for IRAN.  I removed the prop and again sent it to Cody Stallings. Upon disassembly and inspection Cody suspected there was an issue with the piston since the O-ring was fine.  Cody installed a serviceable newer style piston, tested the prop and sent it back to me quickly.  Cody was absolutely great.  Even though I offered he would not charge me for the piston, shipping or dressing out one of the blades that had damage caused by my packaging.  I reinstalled the prop, did a test flight and everything went well.

 

Again thanks to APS and Stallings for standing behind their work.

Normally we don’t have issues with props fresh out of the shop, Very humbling an somewhat embarrassing.

However it’s those instances when you have to step up to the microphone an make good on the deal.

Appreciate your patience while the situation was Handled.