Maintenance: The Overdue Inspection That Almost Cost a Life

In 2021, a Bonanza A36 owner in Florida scheduled a “quick flight” to visit family 200 miles away. The aircraft was due for its annual inspection in three weeks, but since it had flown reliably for years with few issues, the pilot decided to make the trip without addressing a subtle vibration he had noticed on his last two flights.

Shortly after departure, while climbing through 3,500 feet, the pilot noticed a sudden drop in oil pressure and increased engine roughness. He declared an emergency and returned to the departure airport, landing safely but shaken. Mechanics discovered a severely worn crankshaft bearing and small metal particles in the oil filter—clear signs of a developing failure that could have led to engine seizure in flight.

Further inspection showed that the aircraft’s oil analysis reports had been showing elevated metal levels for months, but no action had been taken. The owner admitted he had delayed dealing with the issue due to cost concerns and a belief that “it would probably be fine for another few flights.” The engine was removed and sent for overhaul—costing nearly $30,000.

The incident was used in a 2022 AOPA maintenance webinar to emphasize the dangers of pushing maintenance past recommended intervals. Experts pointed out that even seemingly minor symptoms—vibrations, slow starts, oil pressure fluctuations—can be early signs of serious engine trouble.

Since the incident, the owner has implemented a much more aggressive maintenance tracking process, including digital logs, regular borescope inspections, and sending oil samples to a lab after every oil change. “Cutting corners nearly ended my flying career—or worse,” he said. “Now, I treat maintenance as part of the cost of safe aviation.”