DA42Twin Star
diamondEffective Sep 28, 2026Timetable 2007–2026
What mechanics have reported to the FAA on the Diamond DA42 Twin Star, the airworthiness directives in force, and the NTSB accident record, on one sheet. DA42 (Thielert/Continental diesel), DA42 NG (Austro diesel) and DA42-VI.
Top six of ten systems. Counts reflect who reports, not how reliable the airplane is.
- Registered
- 261 in the U.S., FAA registry Sep 28, 2026
- Reports on file
- 313 since 2007
- 2016–2025
- 157, about 60.2 a year per 1,000 registered
- ADs in force
- 67 (26 airframe, 41 engine)
- Accidents
- 18 since 1995, 1 fatal
Airworthiness directives
67 in force · 18 superseded not shown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.
AD2026-14-08Effective Jul 20, 2026Diamond Aircraft Industries GmbHRepetitive
Cracked nose landing gear hydraulic actuator rod ends can cause uncommanded rudder deflection and potential rudder control failure. The AD requires revising the airplane flight manual, conducting repetitive inspections of the NLG hydraulic actuator rod ends for cracks and damage, and replacing affected parts as needed.
Read the AD in the Federal RegisterAD2025-24-07Effective Feb 12, 2026Diamond Aircraft Industries GmbH AirplanesRepetitive
Passenger doors have separated from the fuselage on these aircraft. The AD requires AFM revisions, airplane modifications, and repetitive inspections of door latching mechanisms and safety hooks for engagement, foreign objects, damage, and proper function.
Read the AD in the Federal RegisterAD2024-06-13Effective May 28, 2024Diamond Aircraft Industries GmbH AirplanesRepetitive
The rudder T-yoke axle and steering bracket on certain Diamond Aircraft airplanes may have unsafe conditions including edge distance issues and bolt wear. This AD requires inspecting the rudder steering bracket and T-yoke bolt, replacing affected parts, applying torque seal marks, and performing repetitive inspections of those marks.
Read the AD in the Federal RegisterAD2022-06-08Effective May 9, 2022Diamond Aircraft Industries GmbH AirplanesRepetitive
Certain flap bell cranks on Diamond DA 42 airplanes can fail due to an unsafe condition. This AD requires modification of the flap control system, repetitive inspections of the flap bell crank with replacement as necessary, and prohibits installation of certain flap bell cranks.
Read the AD in the Federal RegisterAD2022-03-01Effective Mar 17, 2022Diamond Aircraft Industries GmbH AirplanesOne-time
Dissolved or detached fuel tank hose material can enter main fuel tank chambers and restrict fuel flow, causing fuel starvation. This AD requires removing the affected fuel tank connection hoses from service and inspecting them for damage and detached rubber material.
Read the AD in the Federal RegisterAD2021-22-03Effective Dec 21, 2021Diamond Aircraft Industries GmbH AirplanesRepetitive
The nose landing gear actuator attachment lever can fail and detach from the nose landing gear leg. This AD requires repetitive inspections of the nose landing gear actuator attachment lever for cracks and damage, with corrective action as needed.
Read the AD in the Federal RegisterAD2019-14-11Effective Sep 9, 2019Diamond Aircraft Industries GmbH AirplanesOne-time
Certain Diamond DA 42 NG and DA 42 M-NG airplanes have insufficient clearance of the gust lock mounts on the pilot side rudder pedals, creating an unsafe condition. This AD requires inspection and correction of the gust lock mount clearance.
Read the AD in the Federal RegisterAD2018-10-10Effective Jun 12, 2018Diamond Aircraft Industries GmbH AirplanesOne-time
Certain DA 42 airplanes may experience uncommanded engine shutdown in flight due to failure of the propeller-regulating valve caused by hot exhaust gases from fractured engine exhaust pipes. This AD requires actions to address this unsafe condition.
Read the AD in the Federal RegisterShow 18 older
AD2017-15-09Effective Aug 1, 2017Diamond Aircraft Industries GmbH AirplanesRepetitive
Cracks in engine exhaust pipe clamps can cause propeller regulating valve failure due to hot exhaust gases escaping from fractured pipes. This AD requires installing engine exhaust pipe clamps with spring washers and repetitively inspecting clamps for cracks, replacing any found cracked.
Read the AD in the Federal RegisterAD2017-11-08Effective May 31, 2017Diamond Aircraft Industries GmbH AirplanesOne-time
Propeller regulating valves can fail due to hot exhaust gases from fractured engine exhaust pipes. This AD requires inspection and replacement of affected engine exhaust pipes.
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 RegisterAD2014-04-04Effective Apr 7, 2014Diamond Aircraft Industries GmbH AirplanesOne-time
The alternator indication system on certain Diamond Aircraft DA 42 NG and DA 42 M NG airplanes may fail to provide warning when one alternator becomes inoperative. This AD requires incorporating a modification to ensure proper alternator failure indication.
Read the AD in the Federal RegisterAD2013-19-11Effective Oct 31, 2013Diamond Aircraft Industries GmbH AirplanesOne-time
Insufficient clearance between the rod end safety washer and the nose landing gear attachment lever causes the rod end to bend during each gear retraction sequence. This AD requires actions to correct this unsafe condition.
Read the AD in the Federal RegisterAD2013-07-01Effective May 20, 2013Diamond Aircraft Industries GmbH AirplanesOne-time
Main landing gear shock absorber overextension could cause the gear to jam in the gear bay, potentially damaging the aircraft or injuring occupants. This AD requires actions to address this unsafe condition on affected Diamond Aircraft models.
Read the AD in the Federal RegisterAD2013-06-02Effective Apr 8, 2013Diamond Aircraft Industries GmbH AirplanesOne-time
The engine air inlet filter is subject to icing on certain Diamond Aircraft airplanes. This AD requires actions to identify and correct this unsafe condition.
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 RegisterAD2012-17-07Effective Oct 11, 2012Diamond Aircraft Industries GmbH AirplanesOne-time
Excessive voids in the adhesive joint between the center wing spars and upper center wing skins could cause wing failure and loss of control. This AD requires inspection and corrective actions to address the unsafe condition.
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.
Read the AD in the Federal RegisterAD2011-11-07Effective Jul 6, 2011Diamond Aircraft Industries GmbH Model DA 42 AirplanesOne-time
This AD addresses an unsafe condition identified on Diamond Aircraft DA 42 airplanes through mandatory continuing airworthiness information from another aviation authority. The AD requires corrective actions to address the identified safety issue.
Read the AD in the Federal RegisterAD2011-10-13Effective Jun 17, 2011Diamond Aircraft Industries GmbH Models DA 42, DA 42 NG, and DA 42 M-NG AirplanesOne-time
An unsafe condition has been identified on certain Diamond Aircraft models that requires corrective action. The AD mandates compliance with continuing airworthiness information to address this condition.
Read the AD in the Federal RegisterAD2008-23-08Effective Dec 22, 2008Diamond Aircraft Industries GmbH Model DA 42 AirplanesOne-time
An unsafe condition has been identified on Diamond Aircraft Industries GmbH Model DA 42 airplanes that requires corrective action. This AD mandates inspection and correction of the unsafe condition in accordance with mandatory continuing airworthiness information from another aviation authority.
Read the AD in the Federal RegisterAD2008-16-20Effective Sep 17, 2008Diamond Aircraft Industries GmbH Model DA 42 AirplanesOne-time
An unsafe condition has been identified on Diamond Aircraft DA 42 airplanes. This AD requires corrective actions to address the condition as specified by mandatory continuing airworthiness information.
Read the AD in the Federal RegisterAD2007-23-14Effective Dec 26, 2007Diamond Aircraft Industries Model DA 42 AirplanesOne-time
An unsafe condition has been identified on Diamond Aircraft Industries Model DA 42 airplanes that requires corrective action. The AD mandates compliance with mandatory continuing airworthiness information to correct this unsafe condition.
Read the AD in the Federal RegisterAD2007-13-16Effective Aug 10, 2007Diamond Aircraft Industries GmbH Model DA 42 AirplanesOne-time
An unsafe condition has been identified on Diamond Aircraft Industries GmbH Model DA 42 airplanes that requires corrective action. This AD requires operators to comply with the corrective measures specified to ensure continued airworthiness.
Read the AD in the Federal RegisterAD2007-12-24Effective Jul 19, 2007Diamond Aircraft Industries Model DA 42 AirplanesOne-time
Diamond Aircraft Industries identified an unsafe condition on Model DA 42 airplanes. This AD requires corrective actions to address the condition and restore airworthiness.
Read the AD in the Federal RegisterAD2007-12-05Effective Jul 16, 2007Diamond Aircraft Industries GmbH Model DA 42 AirplanesOne-time
A safety issue has been identified on Diamond Aircraft DA 42 airplanes through mandatory continuing airworthiness information from another aviation authority. This AD requires inspection and/or corrective action to address the unsafe condition.
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 36 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 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 DA42s; check the exact model and serial. 4 more apply by part number only and are not listed.
Accident history
18 U.S. accidents involving the DA42 since 1995, 1 of them fatal, with 1 fatalities. Homebuilt aircraft excluded. Counts, not rates: they follow fleet size, hours flown and how the airplane is used.
- Ground31
- Cruise30
- Approach and descent20
- Landing100
Phase of the event the NTSB recorded as defining the accident.
- 2005–200910
- 2010–201420
- 2015–201930
- 2020–2024111
- 2025–202610
2026 is year to date. Investigations can take a year or more to reach the data.
NTSB cause findings, 2008–2026 · share of 18 accidents with findings
- 33% Personnel issues
- 17% Aircraft performance and control
- 11% Environmental issues
Most frequent cause findings
- Aircraft controlPersonnel issues3
- Delayed actionPersonnel issues2
- Landing flare: incorrect use/operationAircraft performance and control2
- Monitoring other aircraftPersonnel issues2
- Task monitoring/vigilancePersonnel issues2
- Animal(s)/bird(s): effect on equipmentEnvironmental issues1
- Crosswind: effect on operationEnvironmental issues1
- AttentionPersonnel issues1
- Gusts: effect on operationEnvironmental issues1
- Gear extension and retract sys: not used/operatedAircraft systems, powerplant and structure1
Findings about systems and powerplant
- Gear extension and retract sys: not used/operatedLanding 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
313 reports · 2007–2026
The ten systems with the most service difficulty reports, by FAA system code (JASC). Fewer than 200 reports were filed on the DA42 in 2016–2025, so read these as long-run patterns.
78Engine Collector/Tailpipe/Nozzle4113%41
Parts most often named Exhaust Pipe (38) · Clamp (2) · Heat Shield (1)
EXHAUST HEAT SHIELD IS LOOSE ON THE EXHAUST PIPE AND THE WELDS HAVE FAILED. AD 2018-10-10 REQUIRES THE HEAT SHIELD TO BE TIGHT AND WELDED TO THE PIPE. THE ISSUE IS THE HEAT SHIELD IS CRIMPED ON THE PIPE AND THEN WELDED TO IT AND IT'S NOT WORKING. THIS PIPE FAILED WITH ONLY 23.5 TTSN
AD2018-10-10 DATED JUNE 12 2018 REQUIRES THE HEAT SHIELD TO BE TIGHT ON AND WELDED TO THE EXHAUST PIPE. THE HEAT SHIELD SPOT WELDS FAILED AND VERY LOOSE ON THE EXHAUST PIPE THE AD IS SUGGESTING THE PIPE SHOULD LAST AT LEAST 1500 HOURS BUT FAILED AT 62.8
AD2018-10-10 DATED JUNE 12 2018 REQUIRES THE HEATSHIELD TO BE TIGHT ON AND SPOT WELDED IN TWO PLACES TO THE EXHAUST PIPE. THE PROBLEM IS THE HEATSHIELD SPOT WELDS FAILED AND THE HEATSHIELD IS LOOSE ON THE EXHAUST PIPE AND HAS A HOLE IN THE EXHAUST PIPE CAUSED WHEN THE UPPER SPOT WELD FAILED THE AD MAKES IT SOUND LIKE THE EXHAUST PIPE ASSY SHOULD LAST AT LEAST 1500 HOURS BUT THIS ONE FAILED AT 167.5
61Propeller Governor3210%9
Parts most often named Governor (22) · Actuator (9) · Flywheel (1)
DURING ECU SELF-TEST, AN ERROR MESSAGE APPEARED SHOWING TIME OUT. INSPECTION REVEALED A MALFUNCTIONING GOVERNOR. IT WAS REPLACED AND OPERATION CHECK WAS NORMAL.
LT. GOVERNOR FAILED TO MOVE IN FLIGHT. USING THE MT GOVERNOR TEST TOOL, THE GOVERNOR WAS OPERATED, THE CONNECTION CLEANED AND THE OPERATION WAS NORMAL.
ON TAKE-OFF RPM REMAINED AT 2400 AND ONLY CAME DOWN WHEN POWER WAS SET TO 30%. THE GOVERNOR WAS CHANGED...THIS OPERATOR HAS HAD REPEATED SIMILAR EVENTS
28Fuel Storage185.8%4
Parts most often named Fuel Tank (12) · Fuel Cell (2) · Tank (2) · Fuel Cap (1)
FOUND FUEL PUDDLING IN L/H WING IB BULKHEAD REAR OF AFT SPAR. REMOVED WING, REMOVED FUEL TANK, FOUND SEVERAL CRACKS IN WELDS ON THE FUEL TANK IB SIDE. REPAIRED FUEL TANK AND LEAK TESTED. LEAK TEST GOOD. REINSTALLED FUEL TANK AND WING.
DURING A ROUTINE 2,000 HOUR INSPECTION, THE FUEL TANKS ARE REMOVED. THE LEFT INBOARD TANK (P/N-D64-2817-21-00 HAD EVIDENCE OF A LEAK. A SMALL CRACK WAS FOUND ALONG THE MARGIN OF ONE OF THE SPOT WELDS ON THE TANK SURFACE. THIS HAS HAPPENED ON THREE OTHER FLEET AIRCRAFT. DURING DISCUSSIONS WITH OTHER OPERATORS, THEY TOO HAD CRACKS AT THE EDGES OF THESE SPOT WELDS ON THE INBOARD TANKS.
LT AUX FUEL TANK LEAKS AT MULTIPLE SPOT WELDS. THIS IS THE FOURTH CRACKED AND LEAKING AUX TANK (LT OR RT) WE HAVE CHANGED IN OUR FLEET.
27Rudder Control System165.1%1
Parts most often named Control Cable (7) · Pedal (4) · Rudder Pedal (2) · Bracket (1)
PILOTS REPORTED: "RIGHT RUDDER PEDAL ON PILOT SIDE MOVES HALFWAY THEN AN AUDIBLE THUNK SOUND AND PEDAL FEELS LIKE IT GIVES OUT AND GOES ALL THE WAY TO THE FLOOR. MECHANIC INSPECTED RUDDER SYSTEM AND FOUND THE "T-YOKE" UNDER THE PILOT & CO-PILOT SEAT IN THE LOWER FUSELAGE TO BE EXTREMELY LOSE WITH MORE THAN 4 INCHES OF PLAY IN LATERALLY. AFTER REMOVAL OF THE "T-YOKE" & "T-YOKE AXLE" FOUND THE "BRAKET RUDDER STEERING" HOLE TO BE ELONGATED IN ALL DIRECTIONS OVER 15MM.
RUDDER CABLE, PILOTS SIDE, LT SIDE. CABLE FROM BULKHEAD TO BELL CRANK. FRAYED CABLE ABOUT A QUARTER OF AN INCH FROM THE (S) TURN WITH RUDDER PETAL ASSY ALL THE WAY AFT.
DURING PRE-FLIGHT, CREW NOTICED THAT THE RUDDER PEDAL APPEARED TO BE CROOKED, AT A DIFFERENT ANGLE RELATIVE TO THE OTHER PEDAL. MAINTENANCE PERSONNEL DISCOVERED THAT THE RUDDER PEDAL, P/N-DA4-2723-37-00 WAS CRACKED APPROXIMATELY 2 INCHES LONG WHERE THE BRAKE CYLINDER ACTUATING WEB IS WELDED TO THE HORIZONTAL TUBE. TWO OTHER AIRCRAFT IN THIS FLEET OF TEN HAD SIMILAR CRAKED PEDALS. IN TOTAL THERE WERE 4 CRACKED PEDALS.
85Engine (Reciprocating)154.8%8
Parts most often named Engine (4) · Damper (3) · Gearbox (2) · Belt (1)
LEFT ENGINE OIL LEAK ON TAKEOFF WITH WHITE SMOKE, CREW FEATHERED AND LANDED. DURING INSPECTION, A HOLE WAS FOUND IN THE CRANKCASE, AND ANOTHER LOCATION SHOWED A FRACTURED CASE. THE ENGINE WAS DISASSEMBLED, AND A CRANKSHAFT BOLT E4A-10-100-202 WAS FOUND TO HAVE FAILED. THE HEAD OF THE BOLT HAD MIGRATED THROUGH THE LOWER POWER SECTION, CAUSING DAMAGE TO THE ENGINE CASE AND INTERNAL ENGINE ITEMS. THE ENGINE WAS REPLACED.
DURING TROUBLESHOOTING FOR LOW POWER OUTPUT, THE TORSIONAL VIBRATION DAMPER WAS FOUND DAMAGED, WITH SEVERAL BROKEN PIECES MISSING FROM IT. IT WAS ALLOWING SLIPPAGE WHILE DRIVING THE PROPELLER.
DURING AN ANNUAL INSPECTION, THE LEFT TORSION VIBRATION DAMPER (TVD) P/N-E4B-73-000-000-KIT, WAS INSPECTED FOR RIVET WEAR IT WAS BELOW LIMITS. THE ASSEMBLY WAS REPLACED WITH A NEW UNIT.
81Exhaust Turbocharger134.2%12
Parts most often named Controller (5) · Turbocharger (3) · Actuator (2) · Seal (1)
TURBO EXHAUST MANIFOLD CRACKED IN TWO PLACES ONE CRACK IS 3/4 THE WAY AROUND THE MANIFOLD (OVER 5.5 INCHES LONG) AND THE OTHER CRACK IS ABOUT 2 INCHES LONG.
DURING PRE-TAKE RUN UP, THE LT ENGINE ECU INDICATED A TURBO BOOST PROBLEM. THE WASTE GATE CONTROLLER WAS REPLACED AND THE ISSUE WAS RESOLVED.
THE LEFT ENGINE ECU A&B INDICATED "BOOST PRESSURE RANGE WITH ERROR". INSPECTION REVEALED THAT THE WASTE GATE CONTROLLER WAS DEFECTIVE.
85Reciprocating Engine Power Section123.8%11
Parts most often named Piston (9) · Bolt (1) · Chain (1) · Timing Chain (1)
WHILE COMPLYING WITH AD2024-19-10 / MSB-E4-043 (RTBORESCOPE INSPECTION), THE #2 PISTON ON THE RIGHT ENGINE WAS FOUND CRACKED. THE ENGINE WAS REPLACED.
SIGNIFICANT OIL LOSS AND LOSS OF OIL PRESSURE ON TAKEOFF. FADEC SYSTEM AUTOMATICALLY SHUT DOWN ENGINE DUE TO OIL PRESSURE LOSS. PILOT LANDED SAFELY ON RUNWAY AND TAXIED OFF OF ACTIVE RUNWAY WITHOUT ISSUES. UPON VISUAL INSPECTION, FOUND THERE TO BE A 2 IN DIAMETER HOLE BLOWN IN THE THE CRANKCASE NEAR THE PISTON ARM OF CYLINDER 3. FURTHER INSPECTION HAS NOT BEEN DONE, BUT BELIEVE THE HOLE TO BE CAUSED BY A JOURNAL BEARING BOLT SHEARING.
LEFT ENGINE POWER HAD 3% & RPM(100RPM) FLUCTUATION. VISIBLE ENGINE OIL LEAKING OUT OF AIR OUTLETS. DIVERTED TO XXXX ON THE GROUND, POWER 10%FLUCTUATION RPM. INVESTIGATION REVEALED THAT THE #3 PISTON WAS CRACKED AND A HOLE HAD DEVELOPED AT THE 3 O'CLOCK POSITION. THE ENGINE WAS REMOVED AND A NEW ENGINE WAS INSTALLED.
32Main Landing Gear113.5%4
Parts most often named Housing (3) · Bushing (3) · Retaining Clip (1) · Fitting (1)
LANDING GEAR CROSS LINK JOINTS THAT WERE BONDED IN TO THE LANDING GEAR TRAILING ARM PER MSB 42-088/3 AND AD 2011-11-07 SHIFTED DURING NORMAL OPERATION. THIS RESULTED IN METAL ON METAL CONTACT BETWEEN THE LANDING GEAR CROSS LINKS AND THE TRAILING ARMS.
(CAN) DURING 100 HOUR INSP, REAR BRG HSG ON LT MLG ASSY WAS DETERMINED TO BE CRACKED UNDER MOUNTING BOLT AT 1 O`CLOCK POSITION WHEN SEEN FROM AFT TO THE FRONT. BOLT WAS REMOVED AND IT WAS OBSERVED THAT THE BOLT SHANK WAS BADLY CORRODED AND SOME WEAR MARKS WERE FOUND ON IT. BOLT PN LN9037-M8X28 REF: DA 42 IPC CHAPTER 32-10 PAGE 588 THRU 594.
(CAN) DURING 100 HOUR INSP BOTH LT AND RT MLG REAR BEARING HOUSING WERE FOUND CRACKED ALONG THE HOUSING MOUNTING BOLTS. PART IDENTIFIED IN IPC AS ITEM NR 110, CHAPTER 32-10 PAGE 588 THRU 594.
32Nose/Tail Landing Gear103.2%0
Parts most often named Shaft (6) · Tube (2) · Bolt (1) · Pin (1)
PILOT STATED THAT NOSE GEAR BULB WOULD NOT ILLUMINATE, DESPITE TEST INDICATING A FUNCTIONING BULB. CYCLED GEAR AND TWO TIMES RECEIVED NORMAL GEAR INDICATIONS. MX WAS ABLE TO DUPLICATE THE PROBLEM WHICH THE NOSE GEAR DOWN LIGHT DID NOT COME ON UNTIL AFTER MULTIPLE CYCLES. FOUND NOSE GEAR DOWN LOCK PIN NOT ROLLING AND WORN, REPLACED NOSE PIN AND INSTALLED WITH CORROSION PREVENTION COMPOUND. INSTALLED PIN ASSY IAW SB MSB-42-062/1.
THE NLG TUBULAR PIVOT ASSEMBLY SHOWS SIGNS OF FAILURE INDICATED BY THE MISALIGNMENT OF THE GUDGEON (D60-3233-82-31) WITHIN THE TUBULAR PIVOT SHAFT (D60-3233-82-32). THE MISALIGNMENT ALWAYS OCCURS ON THE LT GUDGEON AND ALWAYS OPENS TOWARD THE AFT DIRECTION WHEN THE GEAR IS DOWN AND LOCKED. FORCES ON THIS POINT ARE INDUCED BY THE NLG SPRING ASSEMBLY AND THE NLG ACTUATOR OVERDRIVING THE DOWN LOCK. REPEATED FORCES ON THE GUDGEON RESULT IN A BELLING DEFORMATION ON THE TUBULAR PIVOT SHAFT.
THE NLG PIVOT ASSEMBLY FAILED BY SHEARING OF THE LT GUDGEON WITHIN THE TUBULAR PIVOT SHAFT. THIS FAILURE WAS NOTED UPON INSPECTION DUE TO A NLG INDICATION LIGHT NOT BEING ILLUMINATED DURING TAXI OUT. UPON RETURNING TO HANGAR THE FAILURE WAS NOTED. ALSO DISCOVERED WAS COMPOSITE DAMAGE ON THE LT WALL OF THE WHEEL WELL INFLICTED BY THE NLG COMPONENT DISLOCATION.
85Reciprocating Engine Cylinder Section103.2%6
Parts most often named Cylinder Head (6) · Piston (2) · Crankcase (1) · Shield (1)
DURING TAKEOFF OFF THE #1 (LT. ) ENGINE MADE A LOUD POPPING NOISE AND WAS ROUGH. AFTER CONSULTATION WITH MANUFACTURER, THE CYLINDER HEAD ASSEMBLY WAS CHANGED. THE CONDITION DID NOT OCCUR ON POST MAINTENANCE FLIGHT ANDSUBSEQUENT FLIGHTS.
DURING TAKE OFF THE LEFT ENGINE FAILED AND WAS SHUT DOWN AND FEATHERED. OIL WAS SEEN STREAMING FROM THE COWLING. A BORE SCOPE INSPECTION REVEALED THE #1 PISTON FAILED.
DURING CLIMB-OUT, THE CREW REDUCED POWER TO 92% AND NOTICED THAT "L ECU A" AND "L ECU B" FAIL WARNINGS APPEARED, ACCOMPANIED BY A LOSS OF POWER. THE CREW CONTINUED THE CLIMB, AND BOTH "L ECU A" AND "L ECU B" FAIL WARNINGS CLEARED, ALTHOUGH OIL WAS OBSERVED LEAKING FROM THE LEFT-HAND ENGINE. THE CREW PROCEEDED TO LAND AND SHUT DOWN THE ENGINE UPON EXITING THE RUNWAY. A BORESCOPE INSPECTION REVEALED THAT THE LEFT ENGINE #4 CYLINDER HAD A HOLE BURNED THROUGH THE TOP OF THE PISTON.
Open a row to read what mechanics wrote. Tail and serial numbers are removed.
At the pre-buy
My pre-buy card · DA42
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.
- Engine Collector/Tailpipe/Nozzle
- Propeller Governor
- Exhaust Turbocharger
- Reciprocating Engine Power Section
- Rudder Control System
- Engine Fuel Pump
- Fuel Controlling System
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 DA42 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 DA42
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