Pilot Debrief

CESSNA 172N near Genoa City, WI — 2010-02-14

Final reportCEN10LA123
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Date
2010-02-14
Location
Genoa City, WI, USA
Aircraft
CESSNA 172N
Registration
N24CV
Category
Airplane
Highest injury
Minor
Fatalities
0
Phase of flight
Cruise

Probable cause

A total loss of engine power due to the failure of the bolts that held in place the connecting rods to the engine's No. 3 and No. 4 cylinders as a result of the engine overhaul facility's improper installation of the bolts during a recent overhaul.

NTSB narrative

The pilot stated that during cruise flight he heard a “loud metallic clicking” sound, followed by a “bang” and a vibration. A few seconds later there was another “bang” and the propeller stopped rotating. He subsequently executed a forced landing to a corn field, where the airplane sustained damage to the firewall, nose landing gear, and wings. A postaccident examination on the engine revealed that the No. 3 and No. 4 engine connecting rod bolts had failed. Metallurgical examination determined that the bolts failed as a result of overstress fractures. No evidence of a fatigue fracture was observed. The teardown examination of the engine revealed that the nuts installed on the No. 1 and No. 2 connecting rod bolts were not tightened to the engine manufacturer’s specifications. Maintenance records indicated that the engine had been overhauled and the airplane returned to service about two weeks prior to the accident. At the time of the accident, the engine had been operated about 68 hours since the overhaul. The lack of proper torque on the intact rod bolts/nuts and the overstress failure of the remaining bolts indicates that the connecting rods were not installed properly during the overhaul procedure.

Analysis

Primary failure mode
Mechanical failure
First missed decision gate
Proper torque of connecting rod bolts during engine overhaul could have prevented failure.

NTSB coding

Evidence available

  • 8 docket documents
View NTSB final reportView NTSB docket

Docket documents8

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