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NTSB finds maintenance lapse led Cargojet Boeing 767-300F to lose APU doors near Cincinnati

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NTSB finds maintenance lapse led Cargojet Boeing 767-300F to lose APU doors near Cincinnati
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CEO Kelly Ortberg | Boeing

The National Transportation Safety Board (NTSB) has released its final report on a 2024 incident involving a CargoJet Boeing 767-300F. The report found that a maintenance oversight caused the aircraft to lose its auxiliary power unit (APU) doors during climb from Cincinnati Northern Kentucky International Airport. According to the NTSB, the critical fasteners for the APU doors had not been properly reinstalled during prior maintenance, leading to their separation in flight.

On June 17, 2024, CargoJet flight W8 1926 was climbing through 13,000 feet when both APU doors detached and fell to the ground. The crew declared an emergency and leveled off at 25,000 feet before returning safely to Cincinnati. No injuries were reported among the crew or on the ground, and there was no property damage from falling debris.

During descent, the pilots experienced difficulty using speed brakes and noted substantial elevator damage. They reported hearing a loud "bang," feeling airframe vibrations, and receiving EICAS messages suggesting a possible onboard fire. Despite these issues, the landing was uneventful.

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The NTSB investigation attributed the probable cause of the incident to maintenance personnel failing to properly secure the APU access doors after scheduled work. Investigators found missing or incorrectly installed fasteners that weakened the panel’s structural integrity. The board emphasized that this error could have been prevented by following standard inspection checklists and maintenance manual requirements for verifying secured panels after service.

CargoJet stated it is cooperating with regulators and has implemented corrective measures in response to these findings. The airline is reviewing its maintenance training procedures and quality assurance protocols across its fleet as part of efforts to prevent similar incidents in future operations.

"CargoJet has stated that it is cooperating with regulators and has implemented corrective measures in response to the findings."

As cargo airlines often operate older aircraft requiring meticulous upkeep, incidents like this highlight ongoing challenges in balancing operational efficiency with safety standards.

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