Propeller Problems

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

Aviation Safety

Monday, March 03, 2025 at 05:00 AM ET

Verified

Key Takeaways:

Aircraft propellers experienced a range of mechanical failures, including worn internal hub pistons, cracks in the propeller hub, and broken blades or missing tips.
Control system malfunctions, such as a governor failure, led to severe engine overspeed (6000 rpm), resulting in critical engine damage and emergency landings.
These propeller issues frequently occurred during critical flight phases like initial climb or level-off, causing significant vibration, loss of control, and necessitating emergency procedures and landings.

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Cessna R182 Skylane RG

Worn Hub Piston

Propeller was leaking oil, so it was removed and sent it off to be resealed. Prop shop discovered the piston had worn out of spec. Scoring was found on the inside of the piston where it rides on the guide. Wear marks were 180 degrees apart on the front and back. The piston was cocked while moving on the guide rod. Part replaced and prop was resealed.