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September 19, 2025 · Diamond Aircraft DA20-C1 · N544KC

Terre Haute, IN

Overview

Report Status
Probable Cause
Event Type
Accident
Date
September 19, 2025
Injury Outcomes
No injuries (2 uninjured)
Location
Terre Haute, IN
Aircraft
Diamond Aircraft DA20-C1 (2009)
Tail Number
N544KC
Operator
Indiana State University
Injuries
None
Aircraft Damage
Substantial
NTSB Number
CEN25LA392

The flight instructor and pilot-receiving-instruction were conducting an instructional flight when the nosewheel separated from the nose landing gear strut during takeoff. The flightcrew reported that the takeoff was normal and that there was no indication that the nosewheel had separated from the airplane. However, after the nosewheel was located on the runway, the flight instructor received a phone call from the airplane operator and then via subsequent radio calls over the operator dispatch frequency it was determined that the separated nosewheel was likely from their airplane. Then the airplane operator and airport tower controller each visually confirmed that the nosewheel was indeed missing from the airplane. During the subsequent landing, the nose landing gear strut collapsed aft when it contacted the runway. The composite fuselage structure sustained multiple cracks, the nose landing gear box delaminated, and the firewall delaminated from the fuselage during the landing. The lower portion of the nose landing gear strut welded assembly terminates with a threaded stud where a castellated nut and cotter pin secure the nosewheel fork assembly to the strut pivot. A postaccident examination determined that the threaded stud fractured which allowed the nosewheel fork to separate from the strut pivot. The castellated nut and cotter pin remained installed to the threaded portion of the fractured stud. In January 2023, the airplane manufacturer issued Service Information Letter (SIL) No. SIL20C1-014 to address cracks at the top of the nose landing gear strut pivot and/or at the top of the threaded stud. Additionally, the airplane manufacturer cautioned that a single hard landing may severely reduce the service life of the nose landing gear strut, and that improper assembly of the nose landing gear could result in cracking at the threaded stud which may result in the separation of the nosewheel fork assembly. The airplane manufacturer recommended a thorough examination of the nose landing gear strut pivot and threaded stud every 100 hours in accordance with the airframe maintenance manual instructions. The airplane manufacturer further stipulated that it was imperative that “all suspected hard landings are reported and the airplane inspected.” According to a postaccident review of maintenance documentation, there were no cracks observed on the nose landing gear strut when it was last examined during a 100-hour examination completed about 30.7 flight hours before the accident flight.

NTSB Probable Cause

The failure of the nose landing gear strut and associated nosewheel separation during takeoff.

Full Narrative

The flight instructor and pilot-receiving-instruction were conducting an instructional flight when the nosewheel separated from the nose landing gear strut during takeoff. The flightcrew reported that the takeoff was normal and that there was no indication that the nosewheel had separated from the airplane. However, after the nosewheel was located on the runway, the flight instructor received a phone call from the airplane operator and then via subsequent radio calls over the operator dispatch frequency it was determined that the separated nosewheel was likely from their airplane. Then the airplane operator and airport tower controller each visually confirmed that the nosewheel was indeed missing from the airplane. During the subsequent landing, the nose landing gear strut collapsed aft when it contacted the runway. The composite fuselage structure sustained multiple cracks, the nose landing gear box delaminated, and the firewall delaminated from the fuselage during the landing. The lower portion of the nose landing gear strut welded assembly terminates with a threaded stud where a castellated nut and cotter pin secure the nosewheel fork assembly to the strut pivot. A postaccident examination determined that the threaded stud fractured which allowed the nosewheel fork to separate from the strut pivot. The castellated nut and cotter pin remained installed to the threaded portion of the fractured stud. In January 2023, the airplane manufacturer issued Service Information Letter (SIL) No. SIL20C1-014 to address cracks at the top of the nose landing gear strut pivot and/or at the top of the threaded stud. Additionally, the airplane manufacturer cautioned that a single hard landing may severely reduce the service life of the nose landing gear strut, and that improper assembly of the nose landing gear could result in cracking at the threaded stud which may result in the separation of the nosewheel fork assembly. The airplane manufacturer recommended a thorough examination of the nose landing gear strut pivot and threaded stud every 100 hours in accordance with the airframe maintenance manual instructions. The airplane manufacturer further stipulated that it was imperative that “all suspected hard landings are reported and the airplane inspected.” According to a postaccident review of maintenance documentation, there were no cracks observed on the nose landing gear strut when it was last examined during a 100-hour examination completed about 30.7 flight hours before the accident flight.

Flight

Event TypeAccident
Event Time12:56 CDT
Nearest AirportTerre Haute Regional Airport (0nm)
Runway14
Runway Length7200 ft
Runway Width150 ft
Flight Plan FiledNone
Flight Plan ActivatedNo
Aircraft FireNo
Aircraft ExplosionNo

Aircraft

AircraftDiamond Aircraft DA20-C1
Tail NumberN544KC
Aircraft CategoryAir
DamageSubstantial
OperatorIndiana State University
Operating RulePart 91
Engines1
Engine TypeReciprocating
Engine DetailsContinental · IO-240-B · Reciprocating · 125
Seats2

People & Injuries

Injury SummaryNo injuries (2 uninjured)
Fatal0
Serious0
Minor0
Uninjured2
Total2
Crew 1Age 24 · First Class · None
Crew 2Age 19 · First Class · None

Conditions

ConditionsVMC
LightDaylight
Wind160° @ 6 kt
Visibility10 sm
CeilingNone
Temperature / Dew Point59 F
Altimeter30.05 inHg
Observation Time13:53
Weather SourceWFAC

Appendix: Source Data