DA40Diamond Star
diamondEffective Sep 28, 2026Timetable 2002–2025
What mechanics have reported to the FAA on the Diamond DA40 Diamond Star, the airworthiness directives in force, and the NTSB accident record, on one sheet. DA40, DA40 F, DA40 NG (Austro diesel) and DA40 D (Thielert diesel).
Top six of ten systems. Counts reflect who reports, not how reliable the airplane is.
- Registered
- 1,016 in the U.S., FAA registry Sep 28, 2026
- Reports on file
- 299 since 2002
- 2016–2025
- 115, about 11.3 a year per 1,000 registered
- ADs in force
- 57 (15 airframe, 42 engine)
- Accidents
- 67 since 1995, 11 fatal
Airworthiness directives
57 in force · 19 superseded not shown
From Federal Register final rules since 1995. Whether an AD applies to a particular airplane depends on its serial number, engine and installed equipment; confirm against the FAA’s Dynamic Regulatory System.
AD2026-06-03Effective Apr 30, 2026Diamond Aircraft Industries Inc. AirplanesOne-time
Rubber material has detached from fuel tank connection hoses on certain Diamond Aircraft airplanes, creating a potential fuel system hazard. Operators must replace affected parts, inspect fuel tank chambers, remove detached rubber material, and follow updated service instructions for DA 40 NG models.
Read the AD in the Federal RegisterAD2024-19-08Effective Nov 29, 2024Diamond Aircraft Industries Inc. (Type Certificate Previously Held by Diamond Aircraft Industries GmbH) AirplanesRepetitive
Nose landing gear legs on certain Diamond Aircraft have cracked pivot axles, creating a potential landing gear failure risk. This AD requires repetitive detailed inspections of the NLG leg pivot axle for cracks, replacement of cracked parts, and eventual replacement of all NLG legs with affected part numbers.
Read the AD in the Federal RegisterAD2022-13-06Effective Aug 11, 2022Diamond Aircraft Industries Inc. AirplanesOne-time
Some baggage nets have defective buckles that may fail to restrain baggage or cargo during an emergency landing, potentially injuring occupants. This AD requires identifying and replacing affected baggage nets.
Read the AD in the Federal RegisterAD2020-16-08Effective Aug 17, 2020Aspen Avionics, Inc.One-time
Aspen EFD1000 flight display systems with software version 2.10 or 2.10.1 and no independent backup instruments may lose attitude, altitude, and airspeed information. This AD requires installing a software update to address the display failure condition.
Read the AD in the Federal RegisterAD2019-01-02Effective Feb 7, 2019Aspen Avionics, Inc., Evolution Flight Display UnitsOne-time
Certain Aspen Avionics Evolution Flight Display units repetitively reset when equipped with specific software and options, creating a potential flight safety hazard. The AD requires disabling the ADS-B In function and revising the Airplane Flight Manual Supplement.
Read the AD in the Federal RegisterAD2016-23-03Effective Nov 29, 2016Diamond Aircraft Industries GmbH AirplanesOne-time
A manufacturing quality deficiency in V-clamps used on these airplanes can cause them to crack and fail, potentially resulting in loss of engine power and emergency landing. This AD requires identification and correction of the unsafe condition caused by the defective V-clamps.
Read the AD in the Federal RegisterAD2016-22-06Effective Nov 16, 2016Diamond Aircraft Industries GmbH AirplanesOne-time
Autopilot bridle cable clamps may crack, potentially affecting autopilot operation. This AD requires identification and correction of cracked autopilot bridle cable clamps.
Read the AD in the Federal RegisterAD2014-13-08Effective Aug 27, 2014Diamond Aircraft Industries GmbH AirplanesOne-time
The aft main spar on certain DA 40 and DA 40 F airplanes may not have unlimited lifetime structural integrity due to fatigue strength concerns. This AD requires actions to address the unsafe structural condition.
Read the AD in the Federal RegisterShow 7 older
AD2013-08-21Effective May 21, 2013Diamond Aircraft Industries AirplanesOne-time
Charge air tubing may chafe against the engine firewall, creating a hole that causes loss of charged air pressure and engine power. This AD requires inspection and correction of the charge air tubing routing and installation.
Read the AD in the Federal RegisterAD2012-26-13Effective Feb 13, 2013Thielert Aircraft Engines GmbH Reciprocating EnginesOne-time
Thielert TAE 125 engines may experience power loss or in-flight shutdown due to incorrect FADEC software versions. This AD requires removing all software mapping versions prior to 292, 301, or 302.
Read the AD in the Federal RegisterAD2011-21-10Effective Nov 16, 2011Diamond Aircraft Industries GmbH Airplanes With Supplemental Type Certificate (STC) SA03674ATOne-time
Damage has been found around vapor cycle system compressor mounting areas on DA 40 airplanes equipped with cabin air conditioning. This AD requires deactivating and removing the VCS compressor and bracket, then revising the airplane weight and balance.
Read the AD in the Federal RegisterAD2010-25-01Effective Jan 11, 2011Diamond Aircraft Industries GmbH Models DA 40 and DA 40F AirplanesOne-time
Several rear passenger doors have departed aircraft in flight. The AD requires changing the emergency door opening procedure via flight manual revision and replacing the passenger door retaining bracket with an improved design on certain aircraft.
Read the AD in the Federal RegisterAD2009-07-14Effective May 11, 2009Diamond Aircraft Industries GmbH Model DA 40 and DA 40F AirplanesOne-time
An unsafe condition has been identified on Diamond Aircraft DA 40 and DA 40F airplanes that requires corrective action. The AD adopts mandatory continuing airworthiness information to identify and correct this condition.
Read the AD in the Federal RegisterAD2007-11-21Effective Jul 9, 2007Diamond Aircraft Industries GmbH Model DA 40 AirplanesOne-time
An unsafe condition has been identified on Diamond Aircraft Industries GmbH Model DA 40 airplanes. This AD requires inspections and/or corrective actions as mandated by continuing airworthiness information from an aviation authority.
Read the AD in the Federal RegisterAD2006-23-04Effective Nov 28, 2006Diamond Aircraft Industries GmbH Model DA 40 AirplanesEmergency AD
Some DA 40 airplanes equipped with the Garmin G1000 supplemental type certificate may have fuel system indicating system components contaminated with manufacturing particles. This AD requires inspection and cleaning of affected fuel system components.
Read the AD in the Federal RegisterAD2026-04-11Effective Apr 8, 2026Lycoming EnginesRepetitive
Certain connecting rod assemblies and bushings installed in Lycoming engines may fail due to inadequate design, potentially causing engine failure. This AD requires repetitive oil inspections for bronze particulates and replacement of affected connecting rod bushings with eligible parts.
Engine models named IO-360 series
Read the AD in the Federal RegisterAD2025-20-18Effective Oct 30, 2025Continental Aerospace Technologies GmbH EnginesOne-time
Cracks in cylinder heads can cause engine coolant to leak into the combustion chamber. This AD requires a one-time inspection of engine coolant for contamination, replacement of coolant and cylinder heads if needed, and prohibits installation of non-serviceable cylinder heads.
Engine models named TAE 125-02-125
Read the AD in the Federal RegisterAD2025-02-12Effective Apr 1, 2025Austro Engine GmbH EnginesRepetitive
Certain Austro Engine GmbH E4 and E4P engines may have excessive piston and crankcase wear due to aluminum content in engine oil exceeding acceptable limits. This AD requires repetitive engine oil analysis and replacement of affected components or the engine core if necessary.
Engine models named E4, E4P
Read the AD in the Federal RegisterAD2024-19-10Effective Oct 9, 2024Austro Engine GmbH EnginesEmergency AD
Cracks have been discovered on pistons in certain Austro engines, which can lead to engine failure. The AD requires repetitive borescope inspections for piston cracks, replacement of cracked pistons, fuel sample analysis for water contamination, and replacement of fuel system components if contamination is found.
Engine models named E4, E4P
Read the AD in the Federal RegisterAD2024-05-01Effective Mar 11, 2024Austro Engine GmbH EnginesOne-time
Certain cap screws installed on inner main bearing positions of these engines were manufactured below material strength tolerance, causing engine failures. This AD requires replacing affected cap screws with approved parts, prohibits installation of certain cap screws and engine cores, and requires compliance with service bulletin MSB-E4-042.
Engine models named E4, E4P
Read the AD in the Federal RegisterShow 37 older
AD2023-01-08Effective Mar 9, 2023Continental Aerospace Technologies GmbH Reciprocating EnginesOne-time
Certain Continental Aerospace Technologies GmbH TAE 125 engines may have fractured main bearing studs, which could lead to engine failure. This AD requires removal and replacement of affected main bearing studs.
Engine models named TAE 125-02-114, TAE 125-02-99
Read the AD in the Federal RegisterAD2022-16-03Effective Aug 15, 2022Continental Aerospace Technologies, Inc., Lycoming Engines, and Textron Lycoming/Subsidiary of Textron, Inc. Reciprocating EnginesOne-time
Improperly lubricated roller bearings in certain S-1200 series magnetos may cause overheating and magneto seizure. This AD requires replacement of affected magnetos or inspection and component replacement if no white grease is detected.
Engine models named IO-360
Read the AD in the Federal RegisterAD2022-03-03Effective Feb 14, 2022Austro Engine GmbH EnginesOne-time
Certain Austro Engine E4 and E4P diesel engines may have high-pressure pump driving gears that were damaged during assembly or by incompatible cylinder head combinations, which could lead to gear failure. This AD requires inspection and replacement of the HPP driving gear before further flight, with possible replacement of additional components based on inspection findings.
Engine models named E4, E4P
Read the AD in the Federal RegisterAD2021-24-10Effective Dec 27, 2021Austro Engine GmbH EnginesOne-time
Oil pump blockage has been reported on E4 model diesel piston engines, creating a risk of engine failure. This AD requires replacing the oil pump, oil filter, and engine oil on all E4 and E4P engines.
Engine models named E4, E4P
Read the AD in the Federal RegisterAD2021-17-01Effective Aug 23, 2021Austro Engine GmbH EnginesEmergency AD
Oil pressure loss has occurred on E4 model diesel engines due to a defective oil pump. This AD requires removal of the affected oil pump and replacement with an eligible part.
Engine models named E4, E4P
Read the AD in the Federal RegisterAD2020-25-12Effective Jan 15, 2021Superior Air Parts, Inc. Engines and Lycoming Engines Reciprocating Engines With a Certain SAP Crankshaft AssemblyOne-time
Three crankshaft assembly failures resulted in loss of engine power and emergency landings. This AD requires immediate removal from service of all affected SAP crankshaft assemblies.
Engine models named IO-360-B1A, IO-360-B1B, IO-360-B1D, IO-360-B1E, IO-360-B1F, IO-360-B2F, IO-360-L2A, IO-360-M1A
Read the AD in the Federal RegisterAD2020-26-06Effective Dec 29, 2020Technify Motors GmbH (Type Certificate Previously Held by Thielert Aircraft Engines GmbH) Reciprocating EnginesOne-time
A defective turbocharger hose was discovered on certain TAE 125 engines during pre-flight inspection. This AD requires removal and replacement of the affected turbocharger hose on specific engine serial numbers.
Engine models named TAE 125-02-114, TAE 125-02-99
Read the AD in the Federal RegisterAD2020-22-14Effective Dec 10, 2020Austro Engine GmbH EnginesOne-time
Waste gate controller and circlip failures can occur on these diesel engines. This AD requires installing a modified waste gate control rod with a fail-safe bridge and spring-loaded circlip to eliminate the need for repetitive replacements.
Engine models named E4, E4P
Read the AD in the Federal RegisterAD2020-15-05Effective Aug 31, 2020Austro Engine GmbH EnginesOne-time
Considerable wear has been observed on timing chains in certain Austro Engine GmbH model E4 and E4P engines. This AD requires amendment of airplane flight manuals to limit windmill restart usage and removes the previous timing chain replacement requirement.
Engine models named E4, E4P
Read the AD in the Federal RegisterAD2020-14-07Effective Aug 25, 2020Austro Engine GmbH EnginesOne-time
Austro Engine GmbH model E4 and E4P diesel engines may experience timing chain wear and fuel injector failures. This AD requires replacement of the timing chain and fuel injectors.
Engine models named E4, E4P
Read the AD in the Federal RegisterAD2017-19-15Effective Oct 31, 2017Technify Motors GmbH Reciprocating EnginesOne-time
Oil leakage from the gearbox radial shaft sealing ring can contaminate the clutch and cause loss of engine power in flight. This AD requires replacement of the clutch with a dual mass flywheel on affected engines.
Engine models named TAE 125-02-114, TAE 125-02-99
Read the AD in the Federal RegisterAD2016-07-19Effective May 9, 2016Technify Motors GmbH Reciprocating EnginesOne-time
Fuel feed pumps on certain Technify Motors GmbH TAE 125-02 engines can fail in flight, causing engine shutdown and damage. The AD requires removal of affected fuel feed pumps.
Engine models named TAE 125-02-114, TAE 125-02-99
Read the AD in the Federal RegisterAD2015-21-01Effective Nov 27, 2015Technify Motors GmbH Reciprocating EnginesOne-time
Gearbox drive shafts can break during engine starting or restarting, potentially causing engine failure and loss of aircraft control. This AD requires installation of a start phase monitoring system with specified software.
Engine models named TAE 125-02
Read the AD in the Federal RegisterAD2015-19-07Effective Nov 3, 2015Lycoming Engines Fuel Injected Reciprocating EnginesRepetitive
Externally mounted fuel injector fuel lines on certain Lycoming fuel injected engines can fail, potentially causing uncontrolled engine fires and damage. This AD requires inspection and replacement if necessary of fuel injector fuel lines with proper clamping.
Engine models named IO-360-A1A, IO-360-A1B, IO-360-A1B6, IO-360-A1B6D, IO-360-A1C, IO-360-A1D, IO-360-A1D6, IO-360-A2A, IO-360-A2B, IO-360-A3B6, IO-360-A3B6D, IO-360-B1B
Read the AD in the Federal RegisterAD2015-02-01Effective Feb 13, 2015Technify Motors GmbH (Type Certificate Previously Held by Thielert Aircraft Engines GmbH) Reciprocating EnginesOne-time
Clutch assemblies in TAE 125 engines may fail due to disk springs that received nonconforming heat treatment, potentially causing engine failure and in-flight shutdown. This AD requires replacement of affected clutch assemblies identified by part number and serial number.
Engine models named TAE 125-01, TAE 125-02-99
Read the AD in the Federal RegisterAD2014-17-03Effective Oct 2, 2014Technify Motors GmbH Reciprocating EnginesOne-time
High-pressure fuel pumps on certain Technify Motors engines have experienced in-flight shutdowns that can damage the engine and airplane. The AD requires removal of the HP fuel pump before 300 flight hours in service or within 55 flight hours after the AD's effective date, whichever is later.
Engine models named TAE 125-02-114, TAE 125-02-99
Read the AD in the Federal RegisterAD2014-08-10Effective Jun 3, 2014Austro Engine GmbH EnginesOne-time
Waste gate controller levers on certain Austro Engine GmbH model E4 engines have fractured, causing power loss and loss of thrust control. This AD requires removing affected waste gate controllers from service.
Engine models named E4
Read the AD in the Federal RegisterAD2013-24-06Effective Dec 30, 2013Thielert Aircraft Engines GmbH Reciprocating EnginesOne-time
Engine clutch housing openings can allow coolant contamination, causing in-flight power loss. This AD requires applying sealant to close the engine clutch housing opening.
Engine models named TAE 125-01
Read the AD in the Federal RegisterAD2012-26-12Effective Feb 13, 2013Thielert Aircraft Engines GmbH Reciprocating EnginesRepetitive
Engine oil filler plug vent holes can become blocked with debris, causing engine in-flight shutdown or power loss. Inspect the vent hole at the next scheduled maintenance or within 110 flight hours, and perform corrective action if blockage is found.
Engine models named TAE 125-02-114, TAE 125-02-99
Read the AD in the Federal RegisterAD2010-11-09Effective Apr 11, 2012Thielert Aircraft Engines GmbH (TAE) Reciprocating EnginesRepetitive
Thielert reciprocating engines may experience in-flight shutdown due to proportional pressure reducing valve failure. This AD relaxes the repetitive replacement interval for the PPRV on TAE 125-02-99 engines from 300 hours to 600 hours.
Engine models named TAE 125-01, TAE 125-02-99
Read the AD in the Federal RegisterAD2012-02-05Effective Mar 2, 2012Thielert Aircraft Engines GmbH Reciprocating EnginesOne-time
In-flight engine shutdown has been reported on these engines. The AD requires corrective action to prevent engine shutdown and potential loss of aircraft control.
Engine models named TAE 125-02-114, TAE 125-02-99
Read the AD in the Federal RegisterAD2010-06-12Effective Feb 3, 2012Thielert Aircraft Engines GmbH Reciprocating EnginesOne-time
Engine in-flight shutdown due to rail pressure control valve failure can reduce aircraft control. This AD requires replacement of the existing rail pressure control valve with an improved valve.
Engine models named TAE 125-01, TAE 125-02-99
Read the AD in the Federal RegisterAD2011-18-19Effective Oct 6, 2011Austro Engine GmbH Model E4 Diesel Piston EnginesRepetitive
High-pressure fuel pumps in Austro Engine E4 diesel engines can fail due to damaging pressure oscillations, risking engine power loss or in-flight shutdown. The AD requires initial and repetitive fuel pressure inspections, with mandatory installation of replacement HP fuel pump part number E4A-30-200-000 to terminate the inspection requirement.
Engine models named E4
Read the AD in the Federal RegisterAD2011-05-06Effective Mar 30, 2011Thielert Aircraft Engines GmbH Models TAE 125-02-99 and TAE 125-02-114 Reciprocating EnginesOne-time
An unsafe condition has been identified on Thielert reciprocating engines that requires corrective action. The FAA is adopting an airworthiness directive based on mandatory continuing airworthiness information from another aviation authority.
Engine models named TAE 125-02-114, TAE 125-02-99
Read the AD in the Federal RegisterAD2010-26-04Effective Feb 1, 2011Piper Aircraft, Inc. Model PA-28-161 AirplanesOne-time
Some Piper PA-28-161 aircraft equipped with Thielert TAE-125-01 engines have experienced in-flight engine shutdowns due to momentary loss of electrical power to the FADEC. The AD requires installing a FADEC backup battery, replacing the engine supplement pilot's operating handbook and FAA-approved flight manual, and revising the supplement maintenance manual.
Engine models named TAE-125-01
Read the AD in the Federal RegisterAD2010-14-21Effective Aug 17, 2010Thielert Aircraft Engines GmbH Model TAE 125-01 Reciprocating EnginesOne-time
An unsafe condition has been identified on Thielert TAE 125-01 engines that requires corrective action. The AD adopts measures from mandatory continuing airworthiness information to identify and correct this condition.
Engine models named TAE 125-01
Read the AD in the Federal RegisterAD2010-04-06Effective Mar 30, 2010Thielert Aircraft Engines GmbH (TAE) Model TAE 125-01 Reciprocating EnginesOne-time
An unsafe condition has been identified on TAE 125-01 reciprocating engines that requires corrective action. This AD adopts mandatory continuing airworthiness information to address and correct the unsafe condition.
Engine models named TAE 125-01
Read the AD in the Federal RegisterAD2009-24-10Effective Jan 4, 2010Thielert Aircraft Engines GmbH (TAE) Model TAE 125-01 Reciprocating EnginesOne-time
An unsafe condition has been identified on Thielert Aircraft Engines GmbH TAE 125-01 reciprocating engines that requires corrective action. This AD mandates the necessary steps to identify and correct the unsafe condition as identified in mandatory continuing airworthiness information from another aviation authority.
Engine models named TAE 125-01
Read the AD in the Federal RegisterAD2009-22-03Effective Nov 12, 2009Hartzell Propeller Inc. ()HC-()2Y(K,R)-() Series PropellersRepetitive
Hartzell propeller hubs may crack, causing blade separation and loss of aircraft control. The AD requires initial and repetitive eddy current inspections of the front cylinder half for cracks, removal of cracked hubs from service, or installation of improved design hub (suffix SN A or B) as terminating action.
Engine models named IO-360 series
Read the AD in the Federal RegisterAD2008-22-23Effective Nov 4, 2008Thielert Aircraft Engines GmbH (TAE) Model TAE 125-02-99 Reciprocating EnginesOne-time
An unsafe condition has been identified in Thielert TAE 125-02-99 reciprocating engines. This AD requires operators to inspect and correct the identified condition per mandatory continuing airworthiness information.
Engine models named TAE 125-02-99
Read the AD in the Federal RegisterAD2008-06-52Effective Apr 30, 2008Thielert Aircraft Engines GmbH (TAE) Model TAE 125-02-99 EnginesEmergency AD
Thielert TAE 125-02-99 engines are experiencing in-flight shutdowns and fire risk due to cracked high-pressure fuel lines. The AD requires replacing the high-pressure fuel line and installing a high-pressure fuel line support before further flight.
Engine models named TAE 125-02-99
Read the AD in the Federal RegisterAD2006-06-16Effective Apr 27, 2006Lycoming Engines (Formerly Textron Lycoming) AEIO-360, IO-360, O-360, LIO-360, and LO-360 Series Reciprocating EnginesOne-time
Certain crankshafts in Lycoming AEIO-360, IO-360, O-360, LIO-360, and LO-360 series engines can fail, causing total engine power loss and possible aircraft loss. This AD requires replacement of affected crankshafts.
Engine models named IO-360
Read the AD in the Federal RegisterAD2005-19-11Effective Oct 21, 2005Lycoming Engines (Formerly Textron Lycoming) AEIO-360, IO-360, O-360, LIO-360, LO-360, AEIO-540, IO-540, O-540, and TIO-540 Series Reciprocating EnginesOne-time
Certain Lycoming 360 and 540 series engines have experienced crankshaft failures that could cause total engine power loss and in-flight engine failure. This AD requires replacement of affected crankshafts.
Engine models named IO-360
Read the AD in the Federal RegisterAD2003-14-03Effective Aug 14, 2003Textron Lycoming Fuel Injected Reciprocating EnginesRepetitive
Certain Textron Lycoming fuel-injected engines equipped with Crane/Lear Romec rotary fuel pumps are prone to fuel leakage from the pump relief valve, which could cause engine failure or fire. Owners must inspect pump relief valve attaching screws for proper torque and replace the affected fuel pump at or before engine overhaul with a new design pump having enhanced leak resistance.
Engine models named IO-360
Read the AD in the Federal RegisterAD2002-12-07Effective Jul 3, 2002Textron Lycoming Reciprocating EnginesEmergency AD
Oil can leak between the converter plate and accessory housing on certain Lycoming engines, potentially causing complete engine oil loss, engine seizure, and fire. This AD requires replacement of the oil filter converter plate gasket or kit, inspection of the oil filter base for leakage, and eventually installation of an improved gasket or kit to eliminate the need for repetitive replacements.
Engine models named IO-360-A1B6D, IO-360-A1D6D, IO-360-A3B6D, IO-360-A3D6D, IO-360-C1E6D, IO-360-J1A6D, IO-360-J1AD
Read the AD in the Federal RegisterAD97-15-11Effective Aug 12, 1997Avco Lycoming and Textron Lycoming Reciprocating EnginesOne-time
Certain Lycoming reciprocal engines may have defective piston pins that could fail and cause engine failure. Affected engines must be removed from service and replaced with serviceable parts according to the referenced service bulletin.
Engine models named IO-360
Read the AD in the Federal RegisterAD95-07-01Effective Apr 12, 1995Textron Lycoming O-360, LO-360, HO-360, HIO-360, TIO-360, LIO-360, AEIO-360, O-540, IO-540, TIO-540, LTIO-540, IVO-540, AEIO-540, TIO-541, and IO-720 Series Reciprocating EnginesOne-time
Unapproved connecting rod bolts sourced from Superior Air Parts, Inc., have failed in certain Textron Lycoming engines, potentially causing engine failure. The AD requires removing all suspect connecting rod bolts prior to further flight and replacing them with serviceable bolts.
Engine models named IO-360-A1A, IO-360-A1B, IO-360-A1B6, IO-360-A1B6D, IO-360-A1C, IO-360-A1D, IO-360-A1D6, IO-360-A2A, IO-360-A2B, IO-360-A3B6D, IO-360-B1A, IO-360-B1B
Read the AD in the Federal RegisterEngine ADs name an engine model family used on some DA40s; check the exact model and serial. 4 more apply by part number only and are not listed.
Accident history
67 U.S. accidents involving the DA40 since 1995, 11 of them fatal, with 20 fatalities. Homebuilt aircraft excluded. Counts, not rates: they follow fleet size, hours flown and how the airplane is used.
- Ground61
- Takeoff and climb100
- Cruise103
- Maneuvering75
- Approach and descent92
- Landing250
Phase of the event the NTSB recorded as defining the accident.
- 2000–200431
- 2005–2009112
- 2010–201473
- 2015–2019171
- 2020–2024224
- 2025–202670
2026 is year to date. Investigations can take a year or more to reach the data.
NTSB cause findings, 2008–2026 · share of 58 accidents with findings
- 40% Personnel issues
- 38% Aircraft performance and control
- 14% Environmental issues
- 5.2% Aircraft systems, powerplant and structure
Most frequent cause findings
- Aircraft controlPersonnel issues17
- Directional control: not attained/maintainedAircraft performance and control10
- Decision making/judgmentPersonnel issues4
- Incorrect action performancePersonnel issues3
- Surface speed/braking: not attained/maintainedAircraft performance and control2
- Dark: effect on personnelEnvironmental issues2
- Landing gear (fitting on wing): damaged/degradedAircraft systems, powerplant and structure1
- Crosswind: response/compensationEnvironmental issues1
- Lateral/bank control: not attained/maintainedAircraft performance and control1
- Altitude: not attained/maintainedAircraft performance and control1
Findings about systems and powerplant
- Landing gear (fitting on wing): damaged/degradedWing structure1
- Brake: inoperativeLanding gear system1
- Brake: incorrect use/operationLanding gear system1
Wording is the NTSB’s. An accident can carry findings in several categories. Read individual investigations in the NTSB’s CAROL database.
What gets written up
299 reports · 2002–2025
The ten systems with the most service difficulty reports, by FAA system code (JASC). Fewer than 200 reports were filed on the DA40 in 2016–2025, so read these as long-run patterns.
52Passenger/Crew Doors217.0%4
Parts most often named Door (10) · Hinge (4) · Latch (3) · Spring (1)
(CAN) REPORT OF PASSENGER DOOR DETACHMENT ON A DA40NG (S/N 40.[tail no. removed]) WHILE IN FLIGHT. PILOT DECLARED EMERGENCY AND LANDED UNEVENTFULLY. (TC# 20190313014)
GAS COMPRESSION SPRING FAILED TO MAINTAIN THE DOOR LATCH IN A CLOSED POSITION. DURING CRUISE THE DOOR UNLATCHED. AFTER SHORT TIME IN FLIGHT SAFETY CATCH FAILED CAUSING THE DOOR TO OPEN. WHEN THE DOOR OPENED BOTH HINGES FAILED, CAUSING THE DOOR TO FULLY SEPARATE FROM THE AIRCRAFT.
THE PASSENGER DOOR DEPARTED ACFT MID-FLIGHT. THE ACFT LANDED AT THE NEAREST AIRPORT WITH NO INCIDENTS. THE DOOR WAS NOT RECOVERED. THE REAR DOOR RETAINING BRACKET, AD2010-25-01 WAS INSTALLED. DOOR NOT PROPERLY SECURED BEFORE FLIGHT AND CAME LOOSE SOMETIME DURING 50 MINUTE FLIGHT.
32Nose/Tail Landing Gear175.7%11
Parts most often named Fork (7) · Bearing Shaft (2) · Rod (2) · Bushing (2)
DURING 100 HOUR INSPECTION FOUND NLG DAMPER ROD P/N D41-3223-20-33B CHAFFED 1.2 INCHES FROM THE BOTTOM TO 3.1 INCHES FROM THE BOTTOM OF THE ROD. CHAFFED AREA REDUCED DIAMETER OF ROD BY 25 PERCENT. FAILURE OF THIS ROD WOULD RESULT IN NLG LEG COMING LOOSE FROM ATTACHMENT POINT AND POSSIBLY FALLING DOWN UPON TAKEOFF.
100 HRS. INSPECTION REVEALED CRACK IN NLG. THIS PART WAS INSTALLED LESS THAN 300 HRS AGO TO REPLACE A BROKEN NLG THAT RESULTED IN A PROP STRIKE. THIS PART IS NOT PART OF THE CURRENT AD (THE PREVIOUS PART WAS).
CRACK IN THE NOSE GEAR FORK ASSY ON BOTH SIDES. CRACKS WERE ABOUT 1/2INCH-3/4INCH STARTING FROM THE OUTSIDE OF THE FORK AND MOVING TOWARD THE INSIDE.
28Fuel Storage165.3%8
Parts most often named Hose (4) · Fuel Cap (4) · Cap (3) · Fuel Tank (2)
(CAN) FUEL TANK INTER-CONNECT HOSE IS DEGRADING/DELAMINATING, INNER LAYER OF MULTI-LAYER HOSE IS COMING AWAY FROM OTHER LAYERS AND CONTAMINATING FUEL TANK. (TC# 20190529016)
(CAN) FUEL TANK INTERCONNECT HOSE FOUND FAILING IN LH MAIN FUEL TANK ASSEMBLY OF LH WING, INNER LAYERS OF RUBBER APPEAR TO BE SEPARATING. INSPECTION OF RH TANK FOUND NO DEFECTS. (TC# 20190531012)
(CAN) DURING FIRST ANNUAL INSPECTION OF THIS AIRCRAFT IN DIAMOND CANADA AMO, THE FUEL WAS SUMPED AND FINE BLACK DEBRIS WAS NOTED. UPON INSPECTION OF THE FUEL TANKS IT WAS DISCOVERED THAT LH & RH FUEL INTERCONNECT HOSES WERE COLLAPSING. (TC# 20190711002)
28Fuel Boost Pump144.7%0
Parts most often named Pump (14)
ENGINE DRIVEN FUEL PUMP FAILED AFTER 80.9 HOURS, TOTAL TIME AND 6 WEEKS. THE PILOT NOTED THAT THE ENGINE RAN ROUGH DURING TAXI FOR DEPARTURE BUT CLEARED UP PRIOR TO RUN-UP. AFTER THE FLIGHT THE PUMP WAS TESTED BY PRESSURIZING THE SYSTEM WITH THE BOOST PUMP AND SHOWED SIGNS OF INTERNAL LEAKAGE. THE DIAPHRAGM FAILED ALLOWING FUEL TO LEAK OUT THE DRAIN. ALTHOUGH THIS PUMP IS IDENTIFIED AS HAVING COMPLIED WITH SB 615, IT HAD THE SAME FAILURE MODE AS PUMPS AFFECTED BY THIS SB.
3ND FLIGHT OF THE DAY, DURING PRE-FLIGHT INSPECTION. CREW DID A FUNCTION CHECK OF THE ELECTRIC FUEL PUMP, IT WAS NOT EVEN MAKING SOUNDS.
(U43R) DURRING 1ST PRE-FLIGHT OF THE DAY. CREW PERFORMED A FUNCTION CHECK OF THE FUEL PUMP, NO INDICATION OF ANY OPERATION AT ALL ON THE MFD OR ANY SOUND OF OPERATION.
74Magneto/Distributor124.0%1
Parts most often named Arm (5) · Magneto (3) · Coil (1) · Seal (1)
WHILE PERFORMING MAGNETO 500 HOUR INSPECTION, I WENT TO REPLACE THE SECONDARY POINTS WITH NEW CHAMPION M3637 CONTACT POINT KIT AND THE POINTS ARM DID NOT TOUCH THE CAM WHEN THE SCREWS WERE TORQUED DOWN. THIS CAUSED THE POINTS CONTACTS TO NOT OPEN. TRIED MULTIPLE LOCATIONS FOR THE POINTS AND THE CAM WOULD NOT TOUCH THE ARM. GRABBED ANOTHER NEW POINT SET AND THEY WORKED AND TIMED CORRECTLY PER SLICK/UNISON/CHAMPION L-1363C MANUAL
FOLLOWING A SCHEDULED INSPECTION THE AIRCRAFT WAS RUN AND HAD A BAD MAGNETO CHECK. WHEN THE MAGNETO WAS REMOVED FROM THE ENGINE AND TURNED VERTICALLY TO CLEAR THE ENGINE MOUNT OIL POURED OUT OF THE MAGNETO. THE MAGNETO WAS OPENED TO SEE IF THE OIL SEAL WAS THE ONLY FAILURE. THE DISTRIBUTOR CAP WAS REMOVED AND THE ELECTRODE FINGER WAS FOUND TO BE LOOSE. THIS MAGNETO IS OUTSIDE OF THE [S/N removed] COVERED BY MFG [S/N removed] BULLETIN SB1-15 THAT ADDRESSES THE ELECTRODE FINGER PROBLEM. THIS MAGNETO IS JUST OVER 2 YEARS OLD.
DISTRIBUTOR ARM COMING LOOSE FORM THE GEAR. WHEN THE ARM COMES LOOSE, IT CAUSES WEAR ON THE ARM CTR AND AS THE CTR WEARS TO A LARGER DIAMETER HOLE, THE ARM FLIES OUT CLOSING THE GAP AND GRINDS INTO THE CONTACTS OF THE DISTRIBUTOR BLOCK. THE MAG RAN NORMAL AND WAS FOUND DURING AN INSPECTION.
24Electrical Power System Wiring113.7%0
Parts most often named Wire (4) · Suppressor (3) · Jumper (1) · Terminal (1)
ALTERNATOR OUTPUT WIRE, SHORTED BETWEEN THE INNER CABLE AND OUTER SHIELDING, CAUSING FAILURE OF THE TIE BUSS CIRCUIT BREAKERS AND DAMAGE TO ASSOCIATED WIRES IN HARNESS. DAMAGE TO HARNESS CAUSED SHORT TO ENGINE DATA UNIT AND COMPLETE FAILURE OF THE ENGINE INSTRUMENTS.
DURING CRUISE FLIGHT, NOTICED STRONG SMOKE JODOR IN COCKPIT. TURNED OFF ELECTRICAL SYSTEM AND LANDED. EXAMINATION SHOWED THAT THE ESSENTIAL BUSS EMERGENCY BATTERY PACK UNDER CO PILOT PANEL WAS BURNED. FOUND A VERY SMALL SCREW HAD FALLEN FROM SOMEWHERE IN PANEL AND LANDED ON THE CONNECTOR TERMINAL TO THE PACK, SHORTING OUT THE BATTERY PACK. COULD NOT FIND ANY MISSING SCREWS BEHIND PANEL. NOT SURE WHERE THIS CAME FROM.
JUMPER WIRE FROM 70 AMP ALTERNATOR BREAKER TO BUSS BAR WAS BURNED AND DISCOLORED CAUSING INFLIGHT ALTERNATOR FAILURES AS WELL AS AVIONICS INTERFERENCE AND FAILURE. SMOKE IN CABIN WAS ALSO REPORTED. UPON INSPECTION FOUND JUMPER TERMINALS WERE NEVER CRIMPED AT FACTORY CAUSING HIGH RESISTANCE AND BURNING OF THE WIRE. MFG REPS ADVISED OF OTHER FAILURES ON ACFT IN THIS [S/N removed]. RECOMMEND IMMEDIATE GROUNDING OF THESE EFFECTED [S/N removed] UNITL THESE JUMPERS ARE REPLACED WITH [S/N removed] PARTS. (K)
28Fuel Selector/Shut-Off Valve113.7%2
Parts most often named Shaft (5) · Selector Valve (3) · Pad (2) · Selector (1)
THE RT DETENT PAD P/N DP2 CAME LOOSE FROM THE FUEL SELECOR BASE P/N DA4-2738-11-50 AND JAMMED THE FUEL SELECTOR HANDLE FROM BEING ABLE TO SELECT THE RT FUEL TANK.
THE RT DETENT PAD P/N DP2 CAME LOOSE FROM THE FUEL SELECTOR BASE P/N DA4-2738-11-50 AND JAMMED THE FUEL SELECTOR HANDLE FROM BEING ABLE TO SELECT THE RT FUEL TANK.
THIS FLEET OPERATOR OPERATES 10 DA40 AIRCRAFT. THERE WAS A PILOT REPORT OF THE FUEL SELECTOR NOT FUNCTIONING PROPERLY, AND NOT ALLOWING THE PILOT TO SELECT THE OTHER TANK. A FLEET INSPECTION WAS INITIATED, AND THIS AIRCRAFT WAS FOUND TO HAVE THE SELECTOR SHAFT UNIVERSAL JOINTS WITH LOOSE OR MISSING ATTACH PINS.
80Engine Starter113.7%2
Parts most often named Starter (8) · Drive Gear (1) · Shear Pin (1) · Casting (1)
1ST FLIGHT OF THE DAY, CREW TRIED TO START THE AIRPLANE AND IT WOULD NOT START. REPLACED STARTER, AIRCRAFT WAS RETURNED TO [S/N removed].
PERIODICALLY STARTER WOULD NOT ENGAGE ON FIRST ATTEMPT. REMOVED FOR TROUBLESHOOTING PURPOSES, ACFT HAS HAD NO STARTING ISSUES SINCE INSTALL OF NEW STARTER.
(U43R) WHILE ATTEMPTING TO START THE AIRPLANE, THE STARTER TURNED THE ENGINE VERY SLOWLY. THIS WAS TO BE THE 2ND FLIGHT OF THE DAY, THE AIRPLANE HAD THE PROPER VOLTAGE SUPPLIED TO THE STARTER. R & R THE STARTER, ACFT WAS RETURNED TO [S/N removed].
71Engine Air Intake System103.3%0
Parts most often named Control Arm (2) · Air Box (2) · Housing (2) · Screen (1)
(CAN) DA 40F`S HAVE HAD A HISTORY OF CARB-HEAT DOORS CRACKING. THERE HAVE BEEN MULTIPLE FAILURES OF THE DOORS REPORTED. FIELD REPAIRS HAVE BEEN CARRIED OUT, BUT A REVIEW OF THE DESIGN AND MATERIALS IS BEING INVESTIGATED AT THIS TIME.
(CAN) THE RUBBER SECTION OF THE INDUCTION AIR FILTER NEAR WHERE THE WORM CLAMP HOLDS THE FILTER TO THE INDUCTION HOUSING SHEARED NEAR THE OUTER RIM.
(U43R) DURING SCHEDULED INSP, A&P MECHANIC FOUND THAT THE ALTERNATE AIR VALVE CONTROL LINE WAS LOOSE. FURTHER INSP FOUND THAT THE "EYE" BOLT HAD STRIPPED THE THREADS IN THE VALVE BODY HSG. THE BODY HSG IS MADE FROM ALUMINUM, THE "EYE" BOLT FROM STEEL. THE "EYE" BOLT CANNOT BE TIGHTENED COMPLETELY BECAUSE THE OPENING WILL FACE THE WRONG WAY, NOT ALLOWING INSTALLATION OF THE CONTROL CABLE. WITH THE VIBRATION FROM THE ENGINE, THIS CAUSES THE "EYE" BOLT TO WEAR ON/IN THE VALVE BODY HSG.
81Exhaust Turbocharger93.0%9
Parts most often named Actuator (5) · Turbocharger (2) · Hose (1) · Impeller (1)
ON TAKE OFF. DUAL ECU FAILURE NOTED ON PDF. PILOT LANDED SAFELY. MX INSPECTED AND FOUND WASTEGATE ACTUATOR INOP. REPLACED ACTUATOR, GROUND RUN AND DATA DOWNLOAD GOOD. NO ISSUES ON NEXT FLIGHTS. I AM NOTING THIS TO MAKE THE FAA AWARE THAT THIS SAME ISSUE HAS OCCURRED ON MULTIPLE OF OUR DA40NGS. THE ACTUATORS DO NOT APPEAR TO LAST LONGER THAN 100-300 TACH HOURS. WOULD LIKE TO SEE A BETTER PART RELEASED TO RESOLVED THESE ONGOING ISSUES.
ON TAKEOFF, DUAL ECU FAILURES NOTED ON PDF. ABORTED TAKEOFF. MX INSPECTED AND FOUND WASTEGATE ACTUATOR INOP. REPLACED ACTUATOR, GROUND RUN, AND DATA DOWNLOAD GOOD PER MECHANIC. NO ISSUE ON ALL SUBSEQUENT FLIGHTS. THIS SAME ISSUE HAS BEEN REPORTED REGARDING MULTIPLE OTHER DA40NGS. SEE SDR: 2020FA0000205.
WASTEGATE ACTUATOR FAILS CAUSING ECU OVERBOOST FAIL CODES. WHEN THE ACTUATOR IS PRESSURE TESTED IT IS FOUND TO LEAK AIR DUE TO A LEAKING DIAPHRAGM. ACROSS A FLEET OF NINE DA40NGS AND DA42NGS ABOUT 25 OF THESE ACTUATORS HAVE NEEDED TO BE REPLACED OVER THE PAST 2 YEARS. THEY ONLY SEEM TO LAST 100-300HRS ROUGHLY.
Open a row to read what mechanics wrote. Tail and serial numbers are removed.
At the pre-buy
My pre-buy card · DA40
0 of 7 looked at
The components written up most often since 2011. Take this to the pre-buy and ask your inspector about each one; tap a mark to record what they found. Saved on this device only.
- Nose/Tail Landing Gear
- Fuel Storage
- Exhaust Turbocharger
- Main Landing Gear
- Landing Gear Attach Fittings
- Magneto/Distributor
- Passenger/Crew Doors
A starting point for the conversation with your inspector, not maintenance advice.
What buyers get caught by
The expensive surprises on any used airplane are missing logbooks, corrosion under paint, outstanding ADs, an engine near overhaul, and the same squawk written up again and again. The card lists where the DA40 gets written up; the AD timetable below lists what the FAA requires.
Ask for the logbook entries that match each item. A repeated entry is a pattern, not a coincidence.
Alerts for the DA40
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