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Aviation safety reports, made easier to study

NTSB Reports is an independent research and search tool for public aviation accident and incident records. It brings NTSB aviation reports, structured fields, docket files, extracted figures, photos, videos, and update history into one searchable interface.

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October 9, 1999 · Cessna 150G · N3603J

El Reno, OK

Overview

Report Status
Final with probable cause
Event Type
Accident
Date
October 9, 1999
Injury Outcomes
1 injury (1 minor injury), 1 uninjured
Location
El Reno, OK
Aircraft
Cessna 150G
Tail Number
N3603J
Operator
Sunshine Aviation
Injuries
Minor
Aircraft Damage
Substantial
NTSB Number
FTW00LA009

A total loss of engine power occurred during a dual cross-county instructional flight. During the ensuing forced landing in soft terrain, the nose landing gear collapsed. Examination of the Continental O-200-A engine, revealed that the intake rocker arm on the #4 cylinder was separated. Metallurgical examination indicated that a fatigue fracture initiated on the push rod side of the rocker arm. There was no evidence of machining defects or mechanical deformation associated with the fatigue crack propagation. The #4 cylinder had accumulated 76 hours of operation since new at the time of the rocker arm failure. No maintenance records were found for any repair, overhaul, or replacement of the rocker arm for the #4 cylinder. Total time on the engine was 3,198 hours.

NTSB Probable Cause

The total loss of engine power resulting from a fatigue failure of the intake rocker arm for the #4 cylinder. A factor was the soft terrain encountered during the forced landing.

Full Narrative

On October 9, 1999, at 1500 central daylight time, a Cessna 150G airplane, N3603J, sustained substantial damage during the forced landing following a loss of engine power near El Reno, Oklahoma. The airplane, owned by Timeless Images, Inc., of Edmond, Oklahoma, was operated by Sunshine Aviation, of Guthrie, Oklahoma, under 14 Code of Federal Regulations Part 91. The commercial pilot/flight instructor received minor injuries, and the student pilot was not injured. Visual meteorological conditions prevailed for the cross-country instructional flight, and a flight plan was not filed. The flight departed Guthrie, Oklahoma, at 1430, with a planned destination of Hobart, Oklahoma. Local authorities, the operator and the pilots reported to the FAA inspectors that a total loss of engine power occurred during cruise flight at 3,500 feet msl, approximately 6 miles west of the El Reno Municipal Airport. The flight diverted toward the airport; however, the airplane landed approximately 3 miles west of the El Reno Municipal Airport. During the landing flare/touchdown in the soft field, the nose landing gear collapsed and the aircraft spun around. The wings and empennage received structural damage. The nose landing gear and propeller were damaged. On October 20, 1999, the FAA inspector and the manufacturer representative examined the Continental O-200-A engine, serial number 64599-6-A. During the examination, the #4 cylinder intake rocker arm was found separated at the point where it attaches to the valve rocker shaft. The #4 cylinder components were forwarded to the NTSB Materials Laboratory for metallurgical examination. The metallurgical examination of the rocker arm indicated that a fatigue fracture initiated on the push rod side of the rocker arm. Optical and SEM examination of the surface of the rocker arm in the vicinity of the origin area revealed no evidence of machining defects or mechanical deformation associated with the origin. A portion of the contact surface of the valve side of the rocker arm had a smooth, metallic appearance, indicating off-center contact with the valve stem. See the enclosed metallurgist's report for additional details. The FAA inspector reported that a new #4 cylinder was installed on November 13, 1998. The FAA inspector reported the cylinder had been manufactured by [Aircraft] Engine Components, Inc., at San Antonio, Texas. This cylinder had accumulated 76 hours at the time of the rocker arm failure. There were no maintenance entries for repair, overhaul, or replacement of the rocker arm. Total time on the engine was 3,198 hours. See the enclosed maintenance records for additional information. The NTSB IIC examined the #4 cylinder components in March 2000 at Arlington, Texas. Vibro peened on the cylinder were the following numbers: head part number AEC65315D; casting number 67333-22; and PMA part number AEC65314-D FAA-PMA. According to personnel at Engine Components, Inc., the FAA Form 8130-3 with work order number 01118354 was for the #4 cylinder (part number AEC65314-A, serial number 67333-22H).

Flight

Event TypeAccident
Event Time15:00 CDT
Nearest Airport0nm
Runway0
Flight Plan FiledNone
Aircraft FireNo
Aircraft ExplosionNo

Aircraft

AircraftCessna 150G
Tail NumberN3603J
Aircraft CategoryAir
DamageSubstantial
OperatorSunshine Aviation
Operating RulePart 91
Engines1
Engine TypeReciprocating
Engine DetailsContinental · O-200-A · Reciprocating · 100
Seats2

People & Injuries

Injury Summary1 injury (1 minor injury), 1 uninjured
Fatal0
Serious0
Minor1
Uninjured1
Total2
Crew 1Age 30 · Second Class

Conditions

ConditionsVMC
LightDaylight
WindCalm
Visibility10 sm
CeilingNone
Temperature / Dew Point0 C / 0 C
Altimeter0
Weather SourcePILO

Appendix: Source Data