Cracked Engine Heads? FAA Orders Inspections for Continental Engines
Published Date: 10/15/2025
Rule
Summary
If you own or operate a Continental Aerospace Technologies TAE 125-02-125 engine, listen up! The FAA found cracks in the cylinder heads that can cause coolant leaks and engine trouble. Starting October 30, 2025, you’ll need to inspect your engine’s coolant and possibly replace the coolant and cylinder heads to keep flying safe and sound.
Analyzed Economic Effects
5 provisions identified: 0 benefits, 5 costs, 0 mixed.
Required cylinder-head replacement for certain contamination
If the coolant sample has aluminum or fluoride above the service bulletin limits, you must remove and replace the cylinder head with a serviceable part, flush the cooling system, and refill before further flight. The FAA estimated the on-condition cost to replace a cylinder head at $11,360 per engine (parts $10,000 plus 16 work-hours at $85/hour = $1,360).
Mandatory one-time coolant inspection
If you own or operate a Continental TAE 125-02-125 engine, you must do a one-time inspection (sample and analysis) of the engine coolant. For engines with 50 or more flight hours since the last coolant replacement (or since new) as of October 30, 2025, do the inspection within 5 flight hours after October 30, 2025. For engines with less than 50 flight hours since the last coolant replacement, do the inspection within 5 flight hours after you reach 50 flight hours.
Flush and refill required for other coolant contamination
If the coolant sample exceeds any acceptable range other than aluminum or fluoride, you must drain and flush the engine cooling system and refill it with new coolant before further flight. The FAA estimated the on-condition cost for drain/flush and refill at $360 per engine (4 work-hours at $85/hour plus parts).
Ban on installing non-serviceable cylinder heads
After October 30, 2025, you may not install a cylinder head on any engine unless it is a "serviceable part," defined as new (never installed) or not removed under the AD's removal rule. This prohibits installing certain used or previously removed cylinder heads.
Estimated national compliance scope and inspection cost
The FAA estimates this AD affects 30 engines on U.S.-registered airplanes and estimates the coolant inspection cost at $170 per engine (2 work-hours at $85/hour). The total estimated cost to U.S. operators for the inspection step is $5,100.
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