Lycoming SB 632 7/17/2017

[jwilbur]

Anybody see this ST-531 tool yet?

[KJBSouth]

The S/B tool was at the OSH Lyc. booth yesterday. Was told they are making ~40 per day.

Also, that Lyc. will send me a crate for my never run 360-M1B and pay freight both ways if I wish. The engine is currently mounted on the airframe with all sensors and ascessories connected. I'll first see if a local shop will send a mechanic and do the job in my hangar and for the allowed hours.

I talked to two engine shops at OSH today and both thought the job could be done in the warranty allowed hours.

[jwilbur]

I saw it too.

I was surprised to receive the tool in the mail yesterday from Lycoming along with the top overhaul gasket kit. I expected it to take a lot longer given the high demand. I'm planning to have a local A&P do the work for me while I watch.

[bruceflys]

I spoke separately with a tech rep and the head of product support at Oshkosh about SB 632. The connecting rod bushings from an outside supplier assembled properly. Only when field failures occurred did the company realize that some did not meet specs. The failure modes are 1) making metal, 2) loose piston pins and plugs banging around in the cylinder and 3) connecting rod breaking. The company showed pix of broken connecting rods that failed IN FLIGHT.

I asked about operating with frequent oil analysis and filter cuts to early detect an impending failure. Both said no, as some failures occurred less than 25 hours after clean oil changes.

As mentioned above, a demonstration showed that the test with their tool is quick and simple. Exposing the connecting rods is not. Lycoming's policy is to re-hone and re-ring a cylinder if the piston is ever removed, even on new engines with only test cell time. The reps stressed pulling the cylinder only enough to remove the piston pin and caps, leaving most of the piston and the rings in the cylinder.

For those of us who bought engines through Vans, that company is our dealer and the conduit for warranty reimbursement. I hope that we will hear something about procedures once Vans' product support persons return from Wisconsin.

FWIW, both had a chagrined attitude and said that Lycoming wanted to make things right.

[jwilbur]

Originally Posted by bruceflys

For those of us who bought engines through Vans, that company is our dealer and the conduit for warranty reimbursement. I hope that we will hear something about procedures once Vans' product support persons return from Wisconsin.

I don't think you need to go through Van's. I bought my engine and prop through Van's about 16 months ago. When the SB was first released I spoke with Lycoming and they told me I could work with any Lycoming distributor. I contacted Triad and they are handling all the warranty claims for me. In fact, it was less than a week from when I contacted them to when I had the tool and top overhaul gasket kit in hand. As mentioned in a previous post, I was very pleasantly surprised how quickly they responded. Because I'm just a single experimental customer whose not even flying yet, I was anticipating a long wait for the tool.

Obviously I wish I didn't have to deal with tearing down a bran new engine that's only run for 0.6 hours on my airplane. But stuff happens. And so far my experience with Lycoming and Triad has been surprisingly very positive.

[ctennis]

Originally Posted by jwilbur

In fact, it was less than a week from when I contacted them to when I had the tool and top overhaul gasket kit in hand.

I wish I had the same experience.

When the SB came out, I started calling distributors. The first I called I left a message, which they never returned. The next I called said they didn't want to talk to me, they wanted to talk to a mechanic who would be doing the work (on an non-certificated engine??). I had an A&P call them back, but he got nowhere.

Finally I found a company where I could speak to a reasonable person, and got the tool and gasket kit ordered last Friday. I called back again this past Friday (a week later) to find out they still haven't received ANY of the tools yet for the people who were even ahead of me in line for them. I asked if Lycoming was preferring one distributor over another, since I've heard of others already getting the tool. He was very doubtful, and said he if found out that was happening there would be some major repercussions.

I just got my RV-8 airworthiness certificate 3 days ago. At this point, no clue when I'll actually be able to go flying though. However, I'm also at peace with the ordeal knowing that I'm glad I wasn't one of the unlucky ones who found out about the bad bushings the hard way.

[jwilbur]

When I'm finished with the tool I'll post here (hopefully early this week). I'll send it to anyone still waiting. Then they can send it to someone else, etc.

[tturner]

I order the tool and gasket kit from Aircraft Spruce the Friday before OSH. It arrived Last Friday. I removed the cylinders today performed the inspection and reassembled the engine. All my rod bushings are fine ( IO-360-M1B ). I had already removed the baffling last week. The first cylinder took about 2 hours ( this does not count time to remove and replace exhaust, intake runners and oil drain lines ), after that they were about an hour each. It is real touchy trying to keep from exposing the rings. I laid a piece of carpet under the engine in case I dropped anything and it save a lifter and one pin button. I removed and replaced the cylinders one at a time which negates the need for the torque plates. I think I spend more time assembling the documentation and lubricants needed then it took to do the work. I received my engine June 2016 and I have not run it. The date code on the connecting rods was 12/15/15.

[BGS]

I also have a brand new 540 in the crate that was purchased through Vans. Called and spoke to Lycoming and they are covering all costs to send the engine back, inspect, fix, return. Luckily it is not installed on the plan yet and still in the box. Still a pain but nearly as bad as some I would suppose.

[bruceflys]

As instructed by Lycoming, I contacted Vans as my engine distributor asking how to obtain the tool and gasket kit and for instructions about later submitting a warranty claim. My email to Support, which explained that I was referred by Lycoming, was answered by Fedosia in the Parts Dept with this statement, "If your engine is on the list for the service bulletin contact Lycoming for questions."

That is hardy the response I expected after giving Vans $47,000 for a new engine. Has anyone else gotten better info as to how Vans will handle this situation?

Meanwhile I sent my questions to Support and Fedosia again.