3 Sep 2015: CESSNA R172 K — USCG Auxiliary

3 Sep 2015: CESSNA R172 K (N758DK) — USCG Auxiliary

No fatalities • Cresskill, NJ, United States

Probable cause

Maintenance personnel’s failure to apply proper torque to the cylinder flange nuts and through bolts during installation of the engine cylinders, which resulted in the loosening of the components, loss of lubrication, failure of the crankshaft, and the subsequent total loss of engine power.

— NTSB Determination

Accident narrative

On September 3, 2015, about 1710 eastern daylight time (EDT), a Cessna R172K, N758DK, was destroyed by collision with terrain during a forced landing following a total loss of engine power near Cresskill, New Jersey. The private pilot and pilot-rated observer were seriously injured. The flight departed Republic Airport (FRG), Farmingdale, New York, about 1400. Visual meteorological conditions prevailed, and no flight plan was filed for the public use flight.According to the United Stated Coast Guard (USCG), the flight was conducted as a USCG Auxiliary Maritime Observation Mission.

Federal Aviation Administration (FAA) inspectors interviewed the pilot in the hospital the day after the accident. Due to his injuries, the inspectors conducted only a brief interview. According to the pilot, he departed Lincoln Park, New Jersey (N07) about 1300 and flew to Farmingdale, New York (FRG) to pick up the observer for the flight. They then departed FRG, and flew to the Albany, New York area where they reversed course and flew south along the Hudson River. While in cruise flight about 2,000 feet mean sea level (msl), the airplane's engine stopped producing power.

During the subsequent descent, the pilot selected a large open area adjacent to a community center that contained several athletic fields for the forced landing. As the airplane approached, the pilot observed that the fields were in use, and that only a small space was available for landing which would allow separation from people on the ground. The resultant hard landing destroyed the airplane and required first responders to affect the egress of the airplane's occupants.

According to FAA and USCG records, the pilot held a private pilot certificate with a rating for airplane single engine land. His most recent FAA third-class medical certificate was issued on April 20, 2015. The pilot updated a USCG Pilot/Aircrew Qualification form on April 30, 2015, and reported 510 total hours of flight experience on that date. According to the FAA, the pilot reported he had 648 total hours of flight experience, of which 382 were in the accident airplane make and model.

The four-seat, single-engine, high-wing, retractable-gear airplane was manufactured in 1978 and was equipped with a Continental Motors 210-horsepower reciprocating engine. According to the FAA, the airplane's maintenance records showed the most recent annual inspection was completed on July 17, 2015, at 2,194 total aircraft hours. The hobbs meter indicated 2,281 total aircraft hours at the accident site.

Review of engine maintenance records revealed the #3 and #4 cylinders had been removed and reinstalled for maintenance on May 11, 2012. The engine accrued approximately 231.5 hours of operation prior to the accident.

Examination of photographs revealed the accident site was located in a hedgerow on the perimeter of an athletic field about 41 feet elevation. The wreckage path was approximately 36 feet long, oriented about 130 degrees magnetic. The tail section and empennage appeared intact, but the roof and wingbox structure appeared collapsed into the cockpit and cabin areas. The airplane came to rest in about a 30-degree, right wing-down attitude. The right wing was visible, and remained intact from the cabin to about mid-span, where it wrinkled and curled upwards towards the tip.

The airplane was removed from the accident site, and the engine was shipped to the manufacturer for a detailed examination at a later date.

The engine was examined at the manufacturer's facility under the supervision of an FAA aviation safety inspector. Examination revealed impact damage to the fuel pump housing, and the right magneto, which had a broken mount flange and was hanging loose from the engine. The right front engine mount was broken and several ignition harness leads were severed.

The cylinder flange nuts were checked for security and breakaway torque, and the #2 and #3 cylinders' through bolts nuts and perimeter nuts were below factory specifications. The #2 cylinder through bolts breakaway torque was 236/365 in. lbs. respectively. The #3 cylinder through bolts breakaway was 286/351 in. lbs. respectively. The manufacturer's specification was 590-610 in lbs.

Removal of the engine oil pan revealed metal fragments and bearing material in the sump. Disassembly of the crankcase revealed damage to the #1 and #2 main bearings and bearing journals consistent with a loss of lubrication, high heat, and fatigue.

Fretting was noted around the #1, #2, and #3 through bolt bosses as well as the #2 and #3 cylinder deck pads.

The crankshaft was fractured through the #4 throw.

Contributing factors

  • cause Incorrect service/maintenance
  • cause Damaged/degraded
  • cause Maintenance personnel
  • cause Maintenance personnel

Conditions

Weather
VMC, wind 020/06kt, vis 10sm

Loading the flight search…

What you can do on Flight Finder

  • Search flights between any two airports with live fares.
  • By aircraft — pick a plane model (e.g. Boeing 787, Airbus A350) and see every route it flies from your origin.
  • Route map — click any airport worldwide to explore its destinations, or draw a radius to find nearby airports.
  • Global aviation safety — aviation accident database, 5,200+ records since 1980, with map and rankings by aircraft and operator.
  • NTSB safety feed — recent U.S. aviation accidents and incidents from the official NTSB CAROL database, updated daily.

Frequently asked questions

How do I search flights by aircraft type on FlightFinder?

Pick an aircraft model — Boeing 737, Airbus A320, A380, Boeing 787 Dreamliner and more — enter your origin airport, and FlightFinder shows every route that plane flies from there with live fares.

Which aircraft types can I filter by?

We support Boeing 737/747/757/767/777/787, the full Airbus A220/A319/A320/A321/A330/A340/A350/A380 family, Embraer E170/E175/E190/E195, Bombardier CRJ and Dash 8, and the ATR 42/72 turboprops.

Is FlightFinder free to use?

Search and schedules are free. Pro ($4.99/month, $39/year, or $99 one-time lifetime) unlocks the enriched flight card — on-time stats, CO₂ per passenger, amenities, live gate & weather — plus My Trips with push alerts.

Where does the route data come from?

Live schedules come from Amadeus, AeroDataBox and Travelpayouts. Observed routes (which aircraft actually flew a given city pair) are crowdsourced from adsb.lol ADS-B data under the Open Database License.