PA-28R Cherokee Arrow All Series
Maintenance Powerplant; Maintenance Inspection Authority; Maintenance Airframe
Maintenance Inspector 6; Maintenance Technician 9
Training / Qualification; Situational Awareness
Aircraft Equipment Problem Critical; Ground Event / Encounter Gear Up Landing
Aircraft Aircraft Damaged; Flight Crew Landed in Emergency Condition
Aircraft; Incorrect / Not Installed / Unavailable Part
A privately-owned/flown ZZZ-based aircraft used solely by the owner; was brought to us by the owner in late 2015 to conduct some extensive maintenance; including an engine overhaul. The aircraft flew without incident after overhaul. During its annual inspection earlier this year; the owner requested a modification to the engine to replace the existing oil drain plug to a quick drain valve. The mechanic who was trying to find the quick drain valve was unable to locate the part number in our FAA-approved illustrated parts catalog for the Piper Arrow. I instructed him to give an Aviation Parts Center a call because they had been great at helping us find part numbers that are difficult to locate. When the mechanic called he gave him the aircraft tail number; make; model; engine model; and serial number. I overheard the call/conversation by the mechanic. After he got off the phone; he said they are shipping it ground. We received the quick drain valve; but due to work load at the time; we elected not to install the quick drain valve before returning the aircraft to service from the annual inspection. We decided to wait until the first oil change since we were going to change the oil and oil filter after 20 hours of flight since the engine had just been installed on the aircraft after having an overhaul. In March 2016; the owner flew the aircraft and had just returned from his flight and told me that the aircraft had just reached the 20 hour mark and was ready for its oil change. The mechanic apprentice and I conducted the oil change; cut filter for inspection; installed the quick drain; test ran aircraft on the ground; and returned to service. At the time when the aircraft was returned to service; I believed that the work was done to standard and that the aircraft was safe for flight. The aircraft departed on a local owner-flown flight in March. After departure and near cruising altitude; the aircraft engine quit and the pilot landed on a local highway. The pilot was not injured but the airframe sustained damage due to the gear-up landing.Based on the on-site inspections by the FAA and additional research conducted by our shop; we believe there were several factors involved in the engine quitting. While we procured the correct quick drain valve based on aircraft/engine make/model/SN; the incorrect valve was shipped and installed in the aircraft. The Aviation Parts Center nor I caught the error. Although the ground run showed no leaks after the new valve was installed; the gear retraction (in flight) may have triggered the loss of oil and the engine quitting. We would strongly recommend that Piper Mandatory Service Bulletin 965 be converted to an Airworthiness Directive.
A Piper Arrow made a gear-up landing on a highway due to an engine failure. The engine failed due to loss of oil because of an incorrect 'quick drain' oil plug installed.