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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:

  • Aircraft fuel caps are prone to various defects, including wear, deteriorated gaskets, broken components, or manufacturing flaws, often resulting in fuel leaks or siphoning.
  • Improperly secured or missing fuel caps present significant safety hazards, capable of causing substantial fuel loss and leading to engine failure in flight.
  • Problems with fuel cap ventilation, such as plugged vents, can lead to fuel siphoning and negatively impact engine performance during operation.
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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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