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:

The article details multiple instances of diverse aircraft component failures, encompassing engine, exhaust, landing gear, and airframe systems across various aircraft models.
These malfunctions frequently led to critical safety incidents, including smoke in the cockpit, engine roughness, or landing gear collapse, often necessitating emergency landings.
Reported issues range from mechanical failures like broken fuel injectors and rod ends to material degradation such as corroded flap ribs and a failed muffler, occurring at varied component total times.

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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