Oil Cooler Failures

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

Aviation Safety

Friday, August 23, 2024 at 05:45 AM ET

Verified

Edited By: Omar Filipovic

Key Takeaways:

Aircraft oil coolers frequently experience various failure modes, including leaks from cracks, weld voids, or pleats, and issues like vapor lock.
These failures can occur across a wide range of operational times, from newly installed components with as little as 8 hours of use to units with hundreds of hours.
Consequences of oil cooler failure range from significant oil loss, often discovered during pre- or post-flight inspections, to critical engine stoppage and emergency landings.
Some failures may not provide immediate warning indications on cockpit instruments, as the oil cooler can be downstream of the oil pressure gauge, emphasizing the need for thorough visual checks.

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Cessna 177 Cardinal

New Oil Cooler Failure

Sometime after engine start, the eight-hour-old oil cooler developed a leak, resulting in engine stoppage approximately two minutes into the flight. The result was an emergency descent and off-airport landing. According to the technician, because the oil cooler is downstream of the oil pressure gauge, there were no warning indications on instruments.