Engine Fire
A newly released preliminary report from the National Transportation Safety Board (NTSB) has found that a fire on an American Airlines flight in March was likely caused by improperly installed engine parts. The report, released this week, highlights a series of maintenance errors that may have led to intense vibrations, a fuel leak, and ultimately, a dramatic fire that forced the aircraft to abort takeoff.
The incident occurred on March 6, 2024, aboard American Airlines Flight 1256, a Boeing 737-800, which was scheduled to fly from Denver International Airport (DEN) to Dallas-Fort Worth International Airport (DFW). The plane was taxiing to the runway when passengers and crew reported loud vibrations and strange noises coming from the right engine. Moments later, flames were seen erupting from beneath the wing, prompting an emergency response.
Airport emergency crews quickly arrived at the scene and were able to extinguish the fire without injuries. All 161 people on board, including passengers and crew, were safely evacuated or returned to the terminal.
According to the NTSB report, multiple components inside the engine — including the fuel nozzle, fan cowl doors, and associated mounting hardware — were found to be incorrectly installed during recent maintenance. These errors likely caused unstable engine vibrations, which in turn damaged internal components and allowed fuel to leak near hot engine surfaces, igniting the fire.
Maintenance Issues at the Center of Investigation
The Boeing 737-800 had recently undergone scheduled maintenance at a third-party facility not publicly named in the report. Investigators noted that the improperly installed components did not meet manufacturer specifications and had not been adequately verified after installation. While the NTSB stopped short of assigning blame in its preliminary report, it pointed to “installation errors” and “a lack of proper post-maintenance inspection” as significant contributing factors.
The NTSB is now focusing its efforts on understanding how these installation errors went unnoticed during routine checks and quality control measures. Investigators are reviewing records of the maintenance procedures, technician training documentation, and oversight from both American Airlines and its contracted repair providers.
“This event underscores the critical importance of proper maintenance practices and the need for robust inspection protocols,” the report stated.
Emergency Response and Passenger Reactions
Passengers aboard Flight 1256 described the experience as frightening. “We hadn’t even taken off yet, and suddenly there was this loud rattling noise. Then someone shouted that the engine was on fire,” said one passenger, who recorded video of the flames from his window seat. “The crew was incredibly calm, though. They got us back to the gate and off the plane quickly.”
Cell phone footage of the incident circulated widely on social media, showing bright orange flames near the right engine as the plane sat on the taxiway. Airport fire crews arrived within minutes and extinguished the fire before it spread further.
American Airlines released a brief statement after the preliminary report was made public:
“We are fully cooperating with the NTSB and FAA in their ongoing investigation. The safety of our customers and team members is our top priority. We have taken immediate steps to review our maintenance practices and third-party maintenance vendors.”
Broader Concerns Over Maintenance Oversight
This incident comes amid growing concerns over the aviation industry’s increasing reliance on third-party maintenance providers. Many U.S. airlines outsource maintenance work to external contractors, both domestically and overseas, to cut costs and improve efficiency. Critics argue that such outsourcing can introduce inconsistencies in training, oversight, and quality assurance.
Aviation safety experts say the Denver incident is a reminder that even minor lapses in installation procedures can have serious consequences.
“This is a textbook case of why every bolt, fitting, and procedure must be double-checked,” said John Cox, a former airline pilot and aviation safety consultant. “What happened in Denver could have ended very differently if the crew hadn’t acted as quickly as they did.”
The Federal Aviation Administration (FAA) is also reviewing the incident and may issue industry-wide guidance depending on the NTSB’s final findings.
What’s Next?
The NTSB emphasized that this is still a preliminary report and a full investigation is ongoing. The final report, expected later this year, will likely include a detailed timeline of events, human factors analysis, and specific safety recommendations aimed at preventing similar maintenance errors.
In the meantime, the FAA has advised airlines to conduct immediate reviews of engine installation and inspection procedures. American Airlines has reportedly initiated an internal audit of its maintenance operations and temporarily increased inspections of its Boeing 737-800 fleet.
Despite the dramatic nature of the incident, no further issues have been reported on similar aircraft in American’s fleet, and Flight 1256 passengers were rebooked on other flights the same day.
As the investigation continues, the incident is being viewed as both a close call and a wake-up call for the airline industry — a reminder of the vital role that meticulous maintenance and quality control play in keeping the skies safe.
