Failed, Broken, Leaking

The pilot observed smoke in the cockpit, declared an emergency and landed normally. On inspection, the muffler’s aft wall was missing and exhaust was directed onto the battery box, which melted the battery and battery contactor, clock fuse holder, both battery cables and boots. Also, the gascolator push/pull control knob was melted and all wiring into the engine compartment was destroyed. The owner recalls the engine backfiring when a student performed ignition test at high rpm.

Editorial Staff

Friday, May 24, 2013 at 12:00 AM ET

Verified

Key Takeaways:

Multiple incidents involved smoke in the cockpit due to failures such as a damaged muffler, an overheated landing gear motor relay, or a leaking crankshaft seal, all requiring immediate pilot action.
Significant mechanical failures, including a broken fuel injector causing engine roughness and a failed nose gear rod end leading to collapse upon landing, created critical operational emergencies.
The reports highlight a range of component failures from low operating hours (e.g., fuel injector at 23 hours) to high-time parts (e.g., corroded flap ribs, failed muffler), emphasizing the broad scope of maintenance vigilance required across aircraft systems.

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Cessna 150E
Failed Muffler
The pilot observed smoke in the cockpit, declared an emergency and landed normally. On inspection, the muffler’s aft wall was missing and exhaust was directed onto the battery box, which melted the battery and battery contactor, clock fuse holder, both battery cables and boots. Also, the gascolator push/pull control knob was melted and all wiring into the engine compartment was destroyed. The owner recalls the engine backfiring when a student performed ignition test at high rpm.
Part Total Time: 3228 hours