PA-28 Cherokee/Archer/Dakota/Pillan/Warrior
Maintenance Airframe; Maintenance Powerplant; Maintenance Inspection Authority
Maintenance Inspector 2; Maintenance Technician 10
Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural Published Material / Policy; Deviation / Discrepancy - Procedural Maintenance; Deviation / Discrepancy - Procedural FAR
Air Traffic Control Provided Assistance; Flight Crew Returned To Departure Airport; Flight Crew Landed in Emergency Condition; General Flight Cancelled / Delayed; General Maintenance Action
Aircraft; Chart Or Publication; Procedure; Incorrect / Not Installed / Unavailable Part; Manuals
The installation instructions for the PMA (Parts Manufacturer Approval) approved Sky-Tec 122NL starter does not address the lack of clearance between the oil cooler and the starter wire terminal. The terminal chaffed a hole in the oil cooler; causing an oil leak in flight followed by smoke in the cockpit and an immediate return to the airport. There were no injuries or damage to the aircraft other than the oil cooler. This starter is not a direct replacement for the PA-28-140 as listed in the PMA and is also listed this way with [the] parts seller. Neither the Piper maintenance manual nor the manufacurers instructions address this issue.
Technician with inspection authority reported an alternate starter caused an oil leak due to insufficient clearance between the oil cooler and starter power terminal. This caused an oil leak and air turn back and emergency landing.