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‘Improper Installation’

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Key Takeaways:

  • A new FAA Airworthiness Directive (AD 2023–04–08) targets Continental engines manufactured between June 2021 and February 2023 due to a defect where improperly seated crankshaft counterweight retaining rings could lead to catastrophic engine failure, affecting over 2,000 units globally.
  • The FAASTeam and General Aviation Joint Steering Committee highlight the critical importance of formal transition training for pilots moving to different aircraft types, citing its absence as a frequent causal factor in accidents, particularly during the first 50 to 100 flight hours in a new aircraft.
  • Recommended transition training includes thorough study of the new aircraft's systems and limitations, instruction from a qualified pilot experienced in that type, and extensive practice, including simulator use and slow-speed maneuvering at altitude.
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The FAA on February 23, 2023 published a new, final airworthiness directive (AD 2023–04–08) highlighting a problem with new Continental engines manufactured between June 1, 2021, and Feb. 7, 2023. According to the agency, “The manufacturer has notified the FAA that 2,176 crankshaft assemblies are subject to the unsafe condition. The FAA estimates that of those 2,176 crankshaft assemblies, 1,632 are installed on aircraft of U.S. registry. The FAA estimates that 544 engines will need to remove one cylinder, 544 engines will need to remove two cylinders, and 544 engines will need to remove three cylinders for compliance with this AD.”

The new AD is based on Continental’s Mandatory Service Bulletin MSB23–01, Revision A, dated February 16, 2023. According to the bulletin, “It is possible one or more counterweight retaining rings were not properly seated in the crankshaft counterweight groove. This condition could allow the counterweight to depart from the crankshaft during engine operation resulting in catastrophic engine damage.”

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