NTSB Reveals Incorrectly Installed Engine Parts Caused American Airlines Plane Fire
NTSB reports American Airlines flight fire caused by loose parts misinstallation and fuel leaks.
An American Airlines flight departing from Denver International Airport in March experienced a dramatic engine fire shortly after takeoff, with a newly released preliminary report revealing critical maintenance failures were at the heart of the incident. The report, issued by the National Transportation Safety Board (NTSB) on Thursday, details a series of errors—including several parts installed incorrectly and ongoing fuel leaks—that placed passengers and crew in immediate danger.
The Dallas-bound plane’s trouble began almost as soon as it was airborne. According to the NTSB, the right engine contained a loose component that was installed in the wrong direction. Additionally, investigators found evidence of leaking fuel from a fitting connected to another part that had also been fastened improperly. Moments into the flight, the cockpit crew detected “high engine vibration indications for the right engine” and quickly engaged in discussions about whether an emergency diversion was necessary.
Despite the concerning signs, the crew was able to land the aircraft safely back in Denver. However, the situation escalated after the plane reached a gate. Smoke and fire began to fill the cabin, prompting urgent efforts by both passengers and the flight crew to evacuate the aircraft. Videos from the scene captured anxious travelers standing atop the plane’s wings after fleeing the smoke-filled fuselage, reflecting the gravity of the emergency.
Efforts to alert the pilots were described in the report, with one flight attendant attempting to call the cockpit while another resorted to knocking on the door to convey the urgency. Outside, visible streaks on the engine’s exterior marked the path of leaking fuel, and subsequent examination in a hangar confirmed that severe heat, smoke, and burn damage had marred multiple sections of the plane, including the right engine nacelle, wing, main landing gear, and wheel well.
Technical inspections further uncovered that the lockwire on a fuel fitting for the variable stator vane—a critical part regulating airflow through the engine—was both loose and improperly installed. Notably, a fan blade platform inside the engine was found fractured, and another turbine component was not securely fastened, creating conditions for sustained fuel leakage and the subsequent fire hazard.
At the time of the incident, 172 passengers and six crew members were aboard. Although all survived, a total of 18 people sustained minor injuries during the evacuation procedures. The aircraft itself suffered what the NTSB characterized as "substantial damage."
This alarming incident has intensified scrutiny over maintenance and inspection protocols across the airline industry. As investigations continue, the focus remains on ensuring stricter adherence to safety regulations to prevent similar situations in the future.
