Spent 6 hours chasing a ghost in a King Air and it was a $12 relay the whole time
Last Tuesday I pulled a nav rack twice, swapped two LRUs, and rang out half the harness before I found a corroded relay behind the panel in N431TW. Cost the customer 6 hours of my labor for a 12 dollar part, and I still think the manual's troubleshooting tree sent me down the wrong path on purpose. Anybody else feel like the flowchart always points at the expensive box first?
Read a AOPA article last year about how avionics troubleshooting trees get written by the people who sell the boxes. One shop owner said he started checking grounds and relays first no matter what the flow chart says, and his comeback rate dropped way down. Six hours stings but at least you found it before you sold the customer a new GPS. That corroded relay behind the panel stuff gets missed because nobody wants to pull the panel.