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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:

  • Various fuel cap defects, including wear, deteriorated gaskets, manufacturing flaws, or unsecured components, frequently lead to significant fuel leaks or siphoning.
  • These fuel cap issues can cause critical operational problems, such as substantial fuel loss, engine performance degradation, or even engine failure.
  • Incidents highlight the importance of proper fuel cap maintenance, design integrity, and correct securing procedures to prevent serious aviation safety concerns.
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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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