What Federal Agencies Should Know About Lycoming Engine Rebuilds

There is no other way of putting this: aircraft power is expensive. When you need to service, repair, or replace engines, it is going to cost. A lot.

But, there are solutions to help reduce costs while getting a replacement Lycoming factory engine. Rather than buying a factory new engine, you can buy a factory certified rebuilt engines that are guaranteed to perform as new, and are certified as zero time engines at a much lower price point.

Let's walk through this process together and talk about the benefits of an engine overhaul for your Lycoming powered fleet

Understanding Engine Overhaul

All aircraft engines have a finite amount of time before they need to either be rebuilt or a replacement is made. Turbines have a substantially higher time between overhaul (TBO) over any piston engines, which makes sense. 

While it seems like turbines are more complex, they really aren't. There are only a handful of moving parts on a turbine engine, whereas a piston engine has hundreds of moving parts, many under high stress throughout the duration of operation.

Unlike an automotive piston engine, which are only operating at 10-15% of capacity at any given time, piston aircraft engines constantly operate at 75% and up. As a rule of thumb, and all engines are different and have technical data for each specific application from the Lycoming factory, the TBO is 2,000 hours or 12 years for piston engines. Specifics for their line of engines are in Service Instruction No. 1009 BE, so make sure to have your maintenance team familiarize themselves with the service schedules for your engines.

A Lycoming engine overhaul is a cost-effective alternative to buying a new engine, offering a like-model complete operating engine with current features and parts. Generally, and this is always subjecting to a lot of factors, a factory certified rebuilt Lycoming engine is about 35% less than a factory new engine. 

This is a bargain because Lycoming rebuilds them to a zero-time standard, meaning for all practical purposes you get a brand new engine.

The overhaul process involves exchanging your old engine for a new one, with the old engine’s core value being returned to you. This applies a few thousand dollars back to your budget for other repair items.

The FAA regulates engine overhauls under Title 14 of the Code of Federal Regulations (14 CFR) Part 145. Manufacturers are responsible for creating the technical details of the overhaul process which applies to third party MROs and repair facilities and their own in-house rebuild centers.

Lycoming Factory Engine Overhaul

Lycoming has a licensed repair facility where they inspect and overhaul engines. The overhaul process includes replacing the camshaft and lifters with new ones, as well as the magnetos with new ones if Slick.

The overhaul process also includes a new logbook, engine run with calibrated gauges, and dynamic balancing of the engine and propeller. In short, the engine is a brand new engine that is guaranteed as a zero-time engine.

Lycoming factory engine overhauls are backed by a Lycoming warranty, providing peace of mind for flight operations.

Engine Overhaul Costs and Budgeting

Overhauls are not cheap, but with a GSA Advantage purchase, government agencies know exactly how much they have to budget for either a rebuilt or a new engine; the price we list the engine for on GSA Advantage is exactly what your agency pays for it.

The cost of a Lycoming engine overhaul can vary depending on the type of engine and the extent of the overhaul. But instead of getting pulled into overhaul costs that can start with one number and end with something completely different (and higher), just buy a factory certified rebuild through Greenwood Aerospace and you will know exactly how much it will be. The listed price is the price.

A complete overhaul can include replacing all required parts, and including a new logbook and dynamic balancing. Basically, the case is kept and given a thorough inspection, then new cylinders, pistons, cam and crankshaft are installed, along with a laundry list of other parts.

Budgeting for engine overhaul costs should include consideration of the cost of replacement parts and labor. But there is more to it than that: time. An overhaul can take months to complete, and lots of shop have wait times in the months or even years.

A factory rebuilt engine, on the other hand, is available in inventory. You order it from GSA Advantage, the order is processed, and we (or our third party vendor) send an engine through freight.

Airworthiness Directives and Compliance

ADs are a part of life for aircraft and engines. When a core is brought in for overhaul, all applicable ADs are addressed while the engine is being rebuilt.

The FAA issues airworthiness directives (ADs) to address safety concerns with Lycoming engines (don't worry, this is not Lycoming factory specific or anything; it happens to all manufacturers).

ADs may require repetitive oil inspections for bronze metal particulates and additional inspections of the connecting rod bushings for damage, proper fit, movement, and wear.

Compliance with ADs is mandatory for maintaining airworthiness, and again, they are complied with while the engine is being rebuilt as part of becoming a zero-hour engine. Repair stations must have a system in place for tracking and complying with ADs, which includes the Lycoming factory.

Engine Maintenance and Inspection

Having zero-time engines is great, but it means nothing if your maintenance plan doesn't keep them in good condition.

  • Regular maintenance and inspection are critical for ensuring the airworthiness of Lycoming engines. This should go without saying, but regular maintenance is the determining factor that will take your engine to that 2,000 hour mark.
  • Maintenance should include oil changes, filter replacements, and inspections of the engine and propeller. Regular inspect of the cylinder jugs, fins, flywheel, intake manifold, exhaust manifold, wiring harnesses, and more.
  • Inspection should include checking for signs of wear, damage, or corrosion. Feeling the oil for grit is a great indicator of the overall health of the engine.
  • Maintenance and inspection records should be kept up to date and available for review. There has to be total transparency in aircraft maintenance records. If there is any confusion or question about the validity of the records, it needs to be thoroughly investigated.

Choosing the Right Overhaul Option

If you've decided to go for an overhaul vice new engine for your engine, you have a few options. First, you can have a dedicated third party overhaul shop or MRO handle it. These are usually certified through the Lycoming factory to provide an extremely high quality rebuild.

A factory rebuild by Lycoming is a fantastic option because it gives you essentially a brand-new engine. In the eyes of Lycoming and the FAA, it is brand new but without the price tag. 

Also, you can procure a factory rebuild on GSA Advantage through Greenwood Aerospace, giving you a simple purchase option for your aircraft.

Choosing the right overhaul option depends on the condition of the engine, the budget, and the desired level of performance. A certified factory rebuild is the best blend of cost savings and performance, and again, since they are rebuilt and put into inventory, you won't have to worry about the insane lead times to get your engine in for overhaul.

Parting Thoughts

Lycoming is an industry leader in piston aircraft engines, powering thousands of aircraft around the world every single day. The company has been around for decades and makes a wonderful product. Moreover, they rebuild a wonderful product.

Greenwood Aerospace is your trusted partner in federal, state, local, and even tribal procurement, and you can find our catalog of Lycoming engines on GSA Advantage. 

Questions? Give us a call at (580) 762-2580, or email us at contact@governmentprocurement.com. We'll walk you through our catalog, our process, and anything else you need to know!