The Annual Inspection for a Piper Archer (PA-28-181, and other legacy PA-28 models) is a comprehensive, mandated inspection that ensures the aircraft’s continued airworthiness. Unlike a 100-hour inspection, an Annual Inspection can only be performed by an A&P mechanic holding an Inspection Authorization (IA). This inspection is far more detailed than a pre-flight or a 100-hour check, involving extensive disassembly, cleaning, lubrication, and detailed examination of virtually every system and component. For Piper Archer owners in California, Arizona, and Nevada, a thorough annual inspection by a trusted maintenance provider like The Aero Center is essential for safety, compliance, and long-term aircraft health.
At The Aero Center, our experienced IA mechanics meticulously follow Piper’s prescribed maintenance procedures and all applicable Airworthiness Directives (ADs) for legacy Archer models. Our 24/7 service ensures efficient and thorough inspections, minimizing your aircraft’s downtime. We exemplify Authority, with our certified professionals performing inspections to the highest FAA standards, providing unparalleled peace of mind to our clients.
GENERAL REQUIREMENTS FOR AN ANNUAL INSPECTION
Before any detailed inspection, the aircraft must be thoroughly cleaned, and all necessary inspection plates, access doors, fairings, and cowlings must be removed or opened. This provides the mechanic with complete access to all components.
The inspection typically follows a systematic approach, often divided into major sections of the aircraft. While the Piper Archer Maintenance Manual (e.g., P/N 761-679 for Archer II/III) contains the definitive and most detailed inspection checklist and instructions, a general overview of key areas includes:
PIPER ARCHER ANNUAL INSPECTION CHECKLIST (LEGACY ARCHERS)
I. OPERATIONAL CHECKS (Pre-Inspection Run-Up & Cockpit Checks)
- Documentation: Verify current airworthiness certificate, registration, operating limitations, weight and balance. Review aircraft logbooks, AD compliance, and current status of all mandatory inspections.
- Engine Run-Up:
- Start engine IAW Owner’s Manual.
- Check engine oil pressure and temperature within limits.
- Perform magneto check (R/L drops within limits, no excessive RPM drop).
- Check carburetor heat operation (RPM drop).
- Verify throttle and mixture control operation (smooth, full travel, idle cut-off).
- Check propeller operation (if constant speed).
- Static RPM check within limits.
- Check suction gauge/vacuum pump operation (if applicable).
- Check alternator/generator warning light and voltage output.
- Verify operation of all engine instruments, fuel flow (if installed).
- Listen for any unusual engine noises.
- Cockpit/Cabin:
- Inspect seats, seat belts, and harnesses for condition, security, and proper operation.
- Check windows and windshield for deterioration, cracks, or crazing.
- Verify operation and security of all flight and engine controls (full, free, correct travel, no binding or excessive play).
- Inspect instruments for condition, mounting, markings, and (where practical) proper operation.
- Check all lights (interior, exterior, nav, strobe, landing, taxi) for operation.
- Verify stall warning system operation.
- Check pitot-static system drains and function.
- Inspect battery and battery box for proper installation, security, and charge.
- Verify ELT operation and battery expiration date.
- Check cabin heater, defroster, and ventilation systems.
- Inspect baggage compartment and door for security, latch operation, and condition.
II. ENGINE COMPARTMENT (After Engine Run-Up & Cooldown)
- Overall Engine: Inspect for excessive oil, fuel, or hydraulic leaks. Check cleanliness.
- Mounts: Inspect engine mount for cracks, corrosion, dents, bends, evidence of overheating, and looseness. Check flexible vibration dampeners for deterioration.
- Cylinders: Perform cylinder compression check. Inspect cylinders for broken fins, cracks, and security of cylinder base nuts.
- Crankcase/Oil System: Inspect crankcase, oil pan, and accessory section for security, oil leaks, and safetying. Drain engine oil, remove and examine oil filter/suction screen for metal particles. Check oil cooler for leaks and security.
- Ignition System: Remove, clean, gap, and inspect spark plugs (replace as needed). Inspect ignition leads, magnetos for proper installation, security, corrosion, and vent obstruction. Check magneto internal timing.
- Fuel System: Inspect all fuel lines, hoses, and fittings for leaks, security, chafing, and deterioration. Inspect fuel pumps (engine-driven and electric), fuel strainer, and fuel selector valve for leaks and proper operation. Check fuel drains for proper operation and security. Inspect fuel vents for obstruction.
- Exhaust System: Inspect exhaust stacks, muffler, and heat exchange for cracks, leaks, burned-out spots, security, and proper attachment. This is a critical item due to CO poisoning risk.
- Intake System: Inspect intake manifold and hoses for security, leaks, and deterioration.
- Propeller (Constant Speed or Fixed Pitch):
- Inspect blades for nicks, cracks, corrosion, bends, and dents. Dress minor nicks as per maintenance manual.
- Inspect propeller mounting bolts for proper torquing and safetying.
- Inspect hub for cracks, corrosion, and oil leaks (constant speed).
- For constant speed props, inspect propeller governor for security, safetying, cracks, and oil leaks; check control rigging.
- Inspect spinner and spinner backplate for cracks, dents, alignment, and security. (Refer to previous blog on spinner backplates).
- Accessories: Inspect alternator, starter, vacuum pump, and other engine accessories for security, oil leaks, and safetying. Check drive belts for condition and tension.
III. FUSELAGE AND EMPENNAGE
- Fuselage Skin: Inspect for deterioration, distortion, cracks, loose rivets, and evidence of failure.
- Control Cables: Inspect all control cables (rudder, stabilator trim, stabilator, flap) for damage, chafing, corrosion, and proper tension. Inspect all pulleys and bellcranks for excessive wear, cracks, and proper lubrication.
- Tail Cone: Remove tail cone and inspect internal structures, control cables, and the stabilator jackscrew assembly for lubrication, wear, and security.
- Stabilator: Inspect stabilator surface for damage. Inspect hinges, attachments, and horn for damage, excessive wear, and operation. Check stabilator control stops.
- Rudder: Inspect rudder surface for damage. Inspect hinges, horn, and attachments. Check rudder control stops.
- Antennas: Inspect all antennas for security, corrosion, and proper wiring.
IV. WINGS
- Wing Skin: Inspect for deterioration, distortion, cracks, loose rivets, and evidence of failure.
- Fuel Tanks: Inspect fuel tanks, lines, and fittings for leaks (internal and external), signs of water, or contamination. Verify fuel tanks are correctly marked for capacity and minimum octane.
- Wing Attachment Points: Crucially, inspect wing attachment bolts and fittings for corrosion, cracks, and security. **Pay special attention to current Airworthiness Directives (ADs) related to wing spar inspections (e.g., AD 2020-26-16 regarding eddy current inspections for fatigue cracking in the lower main wing spar bolt holes, and more recent ADs regarding aft wing spar attachment fittings for double-drilled holes)**⁴. Compliance with these ADs is mandatory and often requires specialized inspection techniques.
- Ailerons: Inspect aileron surfaces for damage. Inspect hinges, attachments, and control stops.
- Flaps: Inspect flap surfaces for damage. Inspect hinges and attachments for damage, excessive wear, and operation. Lubricate as per manual.
- Pitot/Static System: Inspect pitot tube and static ports for obstructions and damage.
V. LANDING GEAR
- Struts: Inspect oleo struts for proper extension and oleo fluid level (if applicable).
- Linkages: Inspect linkages, trusses, and members for undue wear, fatigue, and distortion.
- Wheels: Inspect wheels for cracks, defects, and bearing condition.
- Tires: Inspect tires for wear, cuts, and proper inflation.
- Brakes: Inspect brake pads for wear, rotors for condition, and hydraulic lines for leaks. Check brake adjustment.
- Nose Gear: Inspect nose gear strut, shimmy damper, steering linkages, and tire for condition and operation.
VI. MISCELLANEOUS
- Overall Aircraft: Check for general cleanliness and condition of the entire aircraft.
- Fairings & Cowlings: Inspect all fairings, cowlings, and access panels for cracks, security, and proper installation.
- Fire Extinguisher: Check expiration date and charge (if installed).
- First Aid Kit: Check contents and expiration (if installed).
AIRWORTHINESS DIRECTIVES (ADS)
ADs are legally binding requirements issued by the FAA to address unsafe conditions. During an Annual Inspection, compliance with all applicable Airworthiness Directives for the specific Piper Archer model and serial number is mandatory. Recent ADs impacting Piper PA-28 series aircraft include:
- Wing Spar ADs (e.g., AD 2020-26-16 and subsequent revisions/related ADs): These are critical and require calculating “factored service hours” for the wing spars. Depending on these calculations and/or specific airplane conditions, eddy current inspections for cracks in the main wing spar bolt holes may be required. There are also new ADs regarding inspecting aft wing spar attachment fittings for manufacturing defects (e.g., double-drilled holes) that can significantly impact structural integrity³.
- Rudder Post ADs: Depending on the model year, there have been ADs requiring inspection or replacement of rudder posts due to fatigue cracking.
- Fuel System ADs: Various ADs may exist for fuel system components, including fuel selector valves or fuel quantity senders.
An IA mechanic will have access to the most current AD list for your aircraft and ensure all are complied with.
For Piper Archer owners in California, Arizona, and Nevada, the Annual Inspection is more than just a regulatory hurdle; it’s a vital health check for your aircraft. The Aero Center’s commitment to 24/7 service and experienced IA mechanics means your Annual Inspection will be comprehensive, efficient, and ensure the highest level of safety for your legacy Archer.
The Aero Center is located at William J. Fox Airfield KWJF | Lancaster, CA. Contact us at 209.885.6950 for questions or appointments.
Footnotes:
- Piper Aircraft Corporation. PA-28-181 Archer II/III Maintenance Manual. (Specific Part Number and latest revision is critical).
- Federal Aviation Administration (FAA). 14 CFR Part 43, Appendix D – Scope and Detail of Items to be Included in Annual and 100-Hour Inspections.
- Federal Register. “Airworthiness Directives; Piper Aircraft, Inc. Airplanes (AD 2020-26-16).” January 15, 2021.
- Piper Flyer Association. “Piper Airworthiness Directive 2024-10-04 mandates an immediate inspection for double-drilled holes at the rear wing spar attachment fittings.” October 4, 2024.