History of Flight
On January 22, 2009, about 1910 eastern standard time, a Cessna 402C, N2615G, operated by Cape Air as Continental Connection Flight 9399, experienced a total loss of engine power from both engines and was not damaged during a forced landing at Naples Municipal Airport (APF), Naples, Florida. Visual meteorological conditions prevailed and an instrument flight rules flight plan was filed for the scheduled domestic passenger flight from Key West International Airport (EYW) to Southwest Florida International Airport (RSW). The airline transport-certificated pilot and six passengers were not injured. The flight originated about 1828 from EYW.
The incident flight was the pilot’s fourth leg that day. Prior to the first flight, 90 pounds of fuel were added to each main tank, with fuel quantity gauges indicating 500 pounds total after fueling. The 55-minute flight to EYW was uneventful. After landing at EYW, 90 pounds of fuel were added to each main tank. The second flight from EYW to RSW was uneventful, flown at 6,000 feet for about 55 minutes. After landing at RSW, 180 pounds were added to each main tank, with gauges showing 350 pounds left and 300 pounds right.
The third flight from RSW to EYW departed with a 50-pound fuel imbalance. During cruise, the pilot crossfed from the right to the left tank for 15 to 20 minutes to balance the fuel. No fuel was added at EYW. For the fourth flight, the pilot did not visually inspect fuel tanks before departure. Pre-takeoff gauges showed left 300 pounds, right 200 pounds. During climb to 6,000 feet, a slight right-wing-heavy condition was noted. In cruise, left fuel indicated 280 pounds, right 160 pounds. About halfway, the pilot crossfed from left to right for 15 minutes, after which left indicated 300 pounds, right between 100 and 90 pounds.
When approaching Marco Island, left fuel indicated 300 pounds, right 50 pounds. The pilot became concerned. Near Naples, instructed to descend to 4,000 feet, left still 300 pounds, right below 50 pounds. The pilot thought the difference might be an indication issue. All engine instruments were normal. Past Naples at 4,000 feet, the right engine began surging; right fuel gauge indicated 0. The pilot moved the right fuel selector to the left tank (crossfeed), restoring power. The left engine then began surging, followed by the right. Unable to maintain altitude, he declared an emergency and was cleared to APF. He performed a 180-degree turn, feathered propellers, landed with full flaps on runway 14, rolled to the end, and stopped. The airplane was towed to a hangar; no fuel was added after landing.
Aircraft Information
The airplane was a 1979 Cessna 402C, serial number 402C0101, powered by two Teledyne Continental TSIO-520-VB engines with McCauley constant speed propellers. The fuel system includes integral wing tanks and two fuel selector handles mechanically linked to valves. Crossfeed allows supplying both engines from one tank. Maintenance followed an FAA-approved inspection program. Post-incident inspection revealed no damage; left main tank contained 275 pounds of fuel indicated, right main tank was drained and contained about 13 gallons. The left fuel selector handle appeared in left main position, but the valve was between left and right main positions. Operational testing showed no flow for the left engine in that position; after moving to detent, flow resumed. The left selector lacked a positive detent feel due to insufficient lubrication. The right selector had positive detents.
Pilot Information
The 63-year-old pilot held an airline transport pilot certificate and flight instructor certificate, with a first-class medical certificate. He had approximately 25,000 total flight hours, 20,000 in type. He was employed by Cape Air since 1993 and passed a proficiency check on November 21, 2008.
Meteorological and Airport Information
Weather at APF at 1853: wind 330 degrees at 3 knots, visibility 10 statute miles, clear skies, temperature 13°C, dew point 3°C, altimeter 30.26 inHg. Naples Municipal Airport has two runways; runway 14/32 is 5,000 feet long and 75 feet wide.
Post-Incident Examination
Examination revealed the left fuel selector cable and gearbox lacked specified grease; light lubricant was present at the valve piston. The right cable also lacked specified grease but had red-brown grease at the gearbox. Testing showed the left selector's detent was not felt in the cockpit; after lubrication, the detent became positive. Fuel quantity gauges were accurate. The operator later replaced the left fuel selector valve control cable and valve. No water contamination was found in fuel samples.