The pylon flange cracked during removal - did they reach safety?
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The pylon flange cracked during removal - did they reach safety?
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The pylon flange cracked during removal - did they reach safety?
In this episode, we follow the thirty-one seconds after American Airlines Flight 191 lost an engine at rotation and the maintenance decisions that preceded it. The episode traces the chain from a combined engine-pylon removal shortcut in Tulsa to the unnoticed crack that grew over weeks - but did anyone foresee the consequence?
Date: May 25, 1979
Flight: American Airlines Flight 191
Aircraft: McDonnell Douglas DC-10, N110AA
Maintenance event: Engine and pylon removed together March 29-30, 1979
Fatalities: 273
- The airline used a combined engine-and-pylon removal method in Tulsa to save roughly 200 labor hours per aircraft.
- The combined removal stressed the pylon aft bulkhead flange in ways the procedure wasn’t designed to handle.
- During the Tulsa work, a forklift-supported engine-pylon assembly shifted and produced an undetected crack in the flange.
- The cracked flange went unnoticed through inspections and the aircraft flew nearly two months afterward.
- The left engine and pylon separated at the exact instant of rotation at O'Hare, 15:59, sending the engine onto runway 32R while the airframe continued airborne.
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