Common Maintenance-Related Issues That Lead to Insurance Claims

While flying always involves some level of operational risk, many aviation insurance claims originate from issues that could have been avoided with proper maintenance. From worn-out tires to corroded components, the majority of mechanical-related insurance claims are tied to overlooked or delayed upkeep. For aircraft owners and operators, understanding the most common maintenance-related claim triggers can help prevent costly incidents, improve safety, and lower insurance premiums.

Insurance providers frequently analyze claim patterns to identify the root causes of loss. And time and time again, maintenance oversights top the list. Whether due to inconsistent inspections, deferred repairs, or failure to follow manufacturer guidance, these gaps in care can lead to incidents that are both dangerous and expensive. By addressing them proactively, aircraft owners can significantly reduce their claims exposure.

1. Engine Failures from Irregular Oil Changes

One of the most preventable causes of engine-related claims is neglecting timely oil changes. Over time, engine oil degrades, collects contaminants, and loses its ability to lubricate effectively. Ignoring manufacturer-recommended oil change intervals—or skipping oil analysis—can result in accelerated wear, component overheating, and even catastrophic failure in flight.

From an insurance perspective, if an engine seizes mid-flight and records show infrequent or outdated oil changes, the claim may be reduced or denied altogether. Routine oil sampling and documentation can help prove due diligence and may even detect early signs of engine wear before failure occurs.

2. Undetected Corrosion

Corrosion is one of aviation’s most insidious threats—often forming in hidden areas like wing spars, control linkages, or fuselage joints. If left untreated, corrosion can compromise structural integrity and lead to equipment malfunction or failure. Many insurance claims involving control loss or structural issues are later traced back to corrosion that went undetected during routine inspections.

Annual inspections should include corrosion-prone zones, especially for aircraft operating in coastal, humid, or wet environments. Keeping thorough records of anti-corrosion treatments and protective coatings can strengthen your case in the event of a related claim.

3. Brake and Tire Failures

Flat spots, worn treads, and underinflated tires are a leading cause of insurance claims during taxi, takeoff, and landing. Similarly, neglected brake systems—such as worn pads or leaking hydraulic lines—can result in runway overruns or ground collisions. These issues are frequently identified in post-incident investigations as causes that could have been mitigated with proper inspections and replacements.

Insurers expect tires to be checked before each flight and replaced on schedule. Keeping a log of tire inspections, brake fluid levels, and wear reports can show you’ve exercised due diligence if a mishap occurs on the ground.

4. Electrical System Failures

Another common source of insurance claims stems from electrical problems caused by neglected wiring, battery failure, or corroded connectors. Electrical faults can trigger in-flight emergencies, failed communications, or instrument loss—all potentially triggering expensive emergency landings or damage.

Routine avionics inspections, battery testing, and wire harness checks should be part of every annual or 100-hour maintenance plan. Claims tied to preventable electrical failures may be flagged if proper preventive actions weren’t documented.

5. Fuel System Contamination

Claims involving engine failure are often linked to water-contaminated fuel, improperly maintained fuel filters, or leaks. Even trace amounts of water in the fuel system can lead to vapor lock, misfires, or power loss during flight. Fuel caps, vents, and seals should be regularly inspected to prevent moisture intrusion.

Pilots are required to sump fuel before flights, but maintenance logs showing regular filter changes and fuel line inspections add another layer of evidence that you’re managing this risk seriously. A contaminated fuel-related claim is more likely to be paid when these records are in place.

6. Deferred AD Compliance

Ignoring or delaying compliance with FAA Airworthiness Directives (ADs) can lead directly to denial of claims if the AD pertains to the failed part or system. Insurers often review compliance history when a claim involves regulated components.

Even when ADs allow for a compliance window, exceeding that timeline without justification can raise red flags. Maintaining a clear, up-to-date log of ADs addressed, including dates, part numbers, and mechanic certifications, is essential to avoiding policy complications.

7. Incomplete or Inaccurate Maintenance Logs

Sometimes the issue isn’t the maintenance itself—it’s the lack of proof. If an owner fails to document completed inspections, replacements, or repairs, an otherwise valid claim may be challenged. Inaccurate or missing logs create doubt around airworthiness and may suggest negligence in the eyes of the insurer.

Keeping clean, complete, and chronologically organized logs helps validate your claim and provides your insurer with the confidence that maintenance-related failures weren’t the result of neglect.

Conclusion

Many insurance claims are rooted in overlooked or delayed maintenance—issues that could have been avoided through regular inspections, better documentation, or timely compliance with manufacturer and FAA guidance. By understanding the most common maintenance-related causes of insurance claims, aircraft owners can take proactive steps to improve safety, reduce risk, and preserve their policy coverage.

Ultimately, staying ahead of these issues demonstrates responsibility and builds trust with your insurer. It can also result in fewer operational disruptions, reduced long-term costs, and potentially lower premiums. Prevention always costs less than a claim—and in aviation, that principle holds especially true.