Parts for Aircraft Annual Inspection
The Part 91 annual inspection (or the 100-hour equivalent for Part 135 and flight-school operators) is the most predictable spend on your aircraft. Everything below is a consumable or a typical replacement item that you can stage in the hangar a week before the inspection opens, turning a two-week annual into a four-day annual.
Engine consumables
- Oil filter — Champion CH48110, Tempest AA48108, or the equivalent for your engine.
- Spark plugs — often rotated at annual even when not replaced. A full set spare is cheap insurance on a cross-country trip.
- Induction air filter — Brackett foam or the dry paper element per your airframe.
- Fuel strainer / gascolator gasket — almost always disturbed during inspection and replaced on reassembly.
- Exhaust gaskets / crush rings — replace every time the exhaust is separated.
- Oil cooler hoses — Teflon has a 10-year limit; rubber has a 5-year limit. Check the stamp.
- Magneto 500-hr kit — impulse coupling springs, distributor block, points where applicable.
Landing gear and brakes
- Brake linings and rivets — Cleveland or Rapco.
- Brake discs if worn past minimum.
- Tire (if tread is questionable) and tube.
- Wheel bearings and grease.
Electrical and lights
- Landing / taxi light (LED drops in beautifully for most steady filament bulbs).
- Nav and strobe bulbs — LED Whelen/Aveo retrofits are popular.
- Battery — Concorde RG sealed typically runs 3–5 years.
- ELT battery — check expiration on the label. Replacement interval is fixed by the regulation regardless of use.
Fuel system and pneumatics
- Fuel hoses — follow the 5- or 10-year replacement per TSO-C53 fire sleeve hose.
- Vacuum filter (if equipped) and central air filter.
- Vacuum pump — Rapco or Tempest, replace at 500 hours or at suspicion.
- Instrument air check valve.
Buy once, inspect twice
Shop your parts list against the AAP catalog in a single order. Overnight shipping from our warehouse keeps annuals on track. Questions on eligibility by serial number? Email us with your aircraft data and we will cross-check.
