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Fuel Cap Failures

The following is derived from maintenance facility submissions to the FAA’s Service Difficulty Reports database.

Gemini Sparkle

Key Takeaways:

  • Fuel caps can malfunction due to a variety of reasons, including wear and tear, deteriorated gaskets, manufacturing flaws, broken components, or improper securing of the cap or lanyard.
  • These malfunctions frequently lead to fuel leaks, siphoning, and significant fuel loss, which can result in critical operational issues like engine performance degradation or in-flight engine failure.
  • The reported incidents underscore the crucial importance of regular inspection, proper maintenance, and secure closure of fuel caps to ensure aviation safety.
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Beech C90A King Air
Worn Fuel Cap

The crew noticed fuel leaking from the right hand outboard fuel cap. Aircraft returned and the fuel cap was replaced with a new one. The aircraft has since flown 4.9 hours with no defects noted.

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