Accident Details
On May 18, 2024, at 2115 eastern daylight time, a Cessna 177, registration N3268T, sustained substantial damage during an accident near Selma, Alabama. The commercial pilot, the sole occupant, was seriously injured. The flight was conducted under Title 14 Code of Federal Regulations Part 91 as a personal cross-country flight.
The pilot reported completing pre-flight checks, including verifying the oil level at 7 quarts, before departure. While cruising at 3,500 feet, the pilot observed a sudden drop in oil pressure to approximately 30 psi. He declared an emergency with air traffic control and requested a diversion to Vaiden Field Airport (A08) in Marion, Alabama.
During descent, the engine began running roughly, and the pilot noticed oil leaking into the cabin near the rudder pedals. Approaching A08, he attempted to activate the runway lights via the common traffic advisory frequency, but the lights did not illuminate. Due to darkness and low ceilings, he could not visually identify the airport and initiated a go-around.
Air traffic control then provided vectors to Craig Field (SEM) in Selma, Alabama. However, the engine lost total power about 7 miles west of SEM, and the airplane impacted terrain approximately 2.5 miles from the runway.
Damage and Examination
An FAA inspector reported crush damage to the cockpit and cabin, with buckling on both wings. Examination of the engine revealed the No. 4 piston was seized within its cylinder, and the corresponding connecting rod had fractured from the crankshaft. The engine oil pump showed no signs of malfunction, abnormal wear, or blockage. Cylinder Nos. 1 and 2 exhibited glazing, and the crankcase halves displayed fretting with a large crack adjacent to the No. 4 cylinder. The crankshaft No. 4 throw bearing and connecting rod exhibited extreme heat damage consistent with oil starvation. Portions of the connecting rod cap, bolts, and other components were found melted into the engine case. The Nos. 2 and 3 main bearing surfaces showed oil starvation signatures, and the camshaft was broken in half. Spark plugs were normal in color with no damage.
The engine oil sump was punctured consistent with ground impact. An unquantified amount of oil was present within the sump. Residual oil was observed in the engine cowling area and on various components. Dirt and debris extended along the fuselage underside from forward to aft, with an undetermined amount of oil within the debris.
Maintenance History
A review of the airplane's maintenance logbooks revealed that the engine had been overhauled approximately 180 flight hours before the accident. The logbooks did not contain an entry indicating that a break-in inspection had been performed, a standard procedure following engine overhaul to prevent premature wear or damage. The pilot stated he purchased the airplane in September 2022 with an engine time of 75 hours since overhaul.
The maintenance facility that performed the overhaul had provided the previous owner with detailed instructions for the engine break-in procedure, including warnings about noncompliance consequences. The instructions stated a warranty requirement of an inspection after 15 to 18 flight hours following overhaul. Records show the overhauled engine was installed on May 22, 2018, at 0 hours since overhaul, with an annual inspection that same day. The next annual inspection on April 12, 2019, at 10.2 hours since overhaul noted that engine oil was drained and refilled with 8 quarts of Aeroshell 100 (mineral oil), consistent with instructions to use mineral oil during the first 25 hours of operation, but did not mention other inspection items from the 15- to 18-hour inspection. Subsequent annual inspections occurred in April 2020 and April 2021 at 29 hours and 67.2 hours since overhaul, with no entries indicating the 15- to 18-hour inspection was performed.