Propeller Problems

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

Aviation Safety

Monday, March 03, 2025 at 05:00 AM ET

Verified

Key Takeaways:

Propeller systems are susceptible to diverse failures, including worn internal components (e.g., hub pistons, governors) and structural integrity issues (e.g., hub cracks, blade separation).
These malfunctions can lead to critical in-flight emergencies such as engine overspeed and destruction, severe vibrations, unresponsive controls, and forced emergency landings.
Incidents occurred across various aircraft types and at different component lifespans, highlighting the necessity of thorough pre-flight inspections and diligent maintenance of propeller assemblies.

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Cessna R182 Skylane RG

Worn Hub Piston

Propeller was leaking oil, so it was removed and sent it off to be resealed. Prop shop discovered the piston had worn out of spec. Scoring was found on the inside of the piston where it rides on the guide. Wear marks were 180 degrees apart on the front and back. The piston was cocked while moving on the guide rod. Part replaced and prop was resealed.