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. Each product page lists eligibility and fitment, and the Aircraft Finder filters the catalog to the parts that fit your make and model.

Stock these for annual

The three categories that drive most annual-inspection part orders: ignition consumables, induction-side wear items, and top-end. Start with our spark plug buyer guide for fine-wire vs. massive-electrode picks per engine type, then check the magneto guide for 500-hour inspection intervals and IRAN options, and finish with the cylinders guide if your IA found compression below acceptance limits during the borescope.