Passenger Killed After Aileron Control Loss and Crash Landing in Caribbean Sea (N604SS)

Incident Summary

Shortly after takeoff, while executing a left turn, the flight crew lost aileron control. The aircraft exhibited uncorrectable left turning tendencies and subsequently crash-landed in the Caribbean Sea. One passenger was killed, and the other 14 occupants were rescued.

Investigation Findings

Post-crash inspection revealed that the left aileron control cable had become trapped within a bundle of electrical wires and cables. This entrapment occurred when an electrical cable connecting a reverse current relay in the right wing to the main junction box in the left cabin area at the center wing was changed and secured. The aileron cable chafed through the protective cover of the large electrical cable. Upon contact with the metal electrical cable, the aileron cable experienced arcing at several points and separated completely at two locations, resulting in a total loss of aileron control.

Probable Cause

The official probable cause is documented as a sequence of occurrences:

• Occurrence #1 (Airframe/component/system failure/malfunction during climb): Findings include: electrical system wiring incorrect; maintenance improper by company maintenance personnel; electrical wiring chafed; electrical wiring arcing; aileron control separation; aileron control total loss.

• Occurrence #2 (Loss of control in flight during climb): Finding: aircraft handling not possible by pilot.

• Occurrence #3 (Forced landing during descent): No specific findings beyond forced landing.

• Occurrence #4 (In-flight collision with terrain/water during landing flare/touchdown): Finding: terrain condition water rough.