Top 10 Most Common Aircraft Maintenance Issues (And How We Fix Them)

In the aviation world, safety isn’t just a priority — it’s a requirement. Whether you're flying a single-engine aircraft or managing a fleet, regular maintenance is essential to keep your aircraft airworthy, efficient, and compliant with FAA regulations. At Aviotec, we’ve seen it all. Here are the top 10 most common aircraft maintenance issues we encounter — and how our expert team fixes them.

1. Oil Leaks

🔧 The Issue:

Oil leaks are among the most common problems, especially in older aircraft. They can lead to engine wear, overheating, and reduced performance.

✅ How We Fix It:

We inspect seals, gaskets, fittings, and oil lines using dye penetrant testing or borescope inspections. After pinpointing the source, we repair or replace the defective component and perform a leak test post-fix.

2. Worn or Flat Tires

🔧 The Issue:

Aircraft tires endure significant stress during takeoff and landing. Flat spots, balding, or underinflation can pose serious risks.

✅ How We Fix It:

We inspect for wear patterns, check tire pressure, and replace tires when they fall below safety standards. We also check the condition of wheel bearings and brakes during the change.

3. Battery Failures

🔧 The Issue:

Dead or weak batteries can lead to starting problems or electrical failures mid-flight.

✅ How We Fix It:

Our technicians test battery voltage and capacity using certified aviation battery testers. If needed, we replace the battery and ensure the charging system is functioning properly.

4. Brake Wear

🔧 The Issue:

Worn or overheated brakes can lead to reduced stopping power, especially during high-speed landings.

✅ How We Fix It:

We inspect discs, pads, and hydraulic systems for wear and leakage. Replacing brake linings and flushing brake fluid are common solutions.

5. Navigation and Avionics Issues

🔧 The Issue:

Faulty GPS, radios, or transponders can lead to communication and navigation problems — a serious safety concern.

✅ How We Fix It:

We use diagnostic tools to test avionics systems. Our certified technicians repair or replace faulty components and re-certify the equipment if required.

6. Corrosion

🔧 The Issue:

Aircraft are regularly exposed to moisture, salt, and pollutants — making them prone to corrosion, especially in coastal or humid environments.

✅ How We Fix It:

We perform regular corrosion inspections, remove surface corrosion using approved techniques, and apply corrosion inhibitors or protective coatings. Structural corrosion may require component replacement.

7. Landing Gear Issues

🔧 The Issue:

Hydraulic leaks, actuator failures, or alignment problems can lead to gear extension/retraction issues.

✅ How We Fix It:

We inspect the landing gear system for leaks, worn bushings, and sensor issues. Repairs may involve hydraulic line replacement, actuator overhauls, or rigging adjustments.

8. Lighting System Failures

🔧 The Issue:

Exterior and cockpit lighting are essential for safety and night operations. Burned-out bulbs or electrical issues are common maintenance tasks.

✅ How We Fix It:

We test all lighting circuits and replace bulbs with OEM or LED alternatives. We also check for shorts, fuses, and faulty switches.

9. Fuel Contamination

🔧 The Issue:

Water, debris, or microbial growth in fuel systems can lead to engine performance issues or failure.

✅ How We Fix It:

We perform fuel sampling and visual inspections. If contamination is found, we drain the tanks, clean the fuel system, and replace filters. In some cases, fuel polishing is required.

10. Loose or Missing Fasteners

🔧 The Issue:

Vibrations and wear can cause screws, bolts, or rivets to come loose — risking structural integrity.

✅ How We Fix It:

We perform regular inspections during every maintenance cycle, tighten torque-specific fasteners, and replace worn or missing hardware. Locking compounds or safety wire may be applied where necessary.

Preventive maintenance is the best defense against unexpected downtime, costly repairs, or worse — in-flight emergencies. At Aviotec, our certified technicians follow strict FAA guidelines and manufacturer recommendations to ensure every aircraft we touch is safe, compliant, and flight-ready.

Need a check-up or have a maintenance concern?

📞 Contact us today to schedule an inspection or speak to one of our technicians. 941 704 7428