Flight controls
Ailerons, elevator, rudder, flaps and trim, their cables and rods, and the autopilot that moves them. A jammed or disconnected control is rare but serious, so the FAA watches this system closely.
Operators and repair shops have filed 50,142 failure reports about this system since 1995, 11,652 of them in the last ten years. The FAA has issued 2,242 airworthiness directives on it, the most recent December 1, 2026. The part most often named in the reports is the actuator. Among model families, the Boeing 737 appears most often in the last ten years; taking fleet size into account, the Boeing 767 has the highest rate among sizeable fleets, about 18.1 reports a year for every 100 aircraft.
Failure reports by year as filed with the FAA
Failure reports by year, as a table
| reports | |
|---|---|
| 95 | 1,376 |
| 96 | 1,579 |
| 97 | 1,565 |
| 98 | 1,586 |
| 99 | 1,506 |
| 00 | 1,715 |
| 01 | 2,299 |
| 02 | 1,938 |
| 03 | 1,987 |
| 04 | 2,073 |
| 05 | 2,423 |
| 06 | 3,248 |
| 07 | 1,930 |
| 08 | 1,656 |
| 09 | 1,465 |
| 10 | 1,359 |
| 11 | 1,784 |
| 12 | 1,631 |
| 13 | 1,711 |
| 14 | 1,256 |
| 15 | 1,207 |
| 16 | 1,196 |
| 17 | 1,019 |
| 18 | 1,055 |
| 19 | 1,408 |
| 20 | 891 |
| 21 | 1,271 |
| 22 | 1,396 |
| 23 | 1,440 |
| 24 | 1,158 |
| 25 | 1,153 |
| 26 | 861 |
Models most often named last ten years
Boeing 7373,961Bombardier CL-600 Challenger and CRJ1,269Boeing 7671,056Boeing 757960Airbus A320536Embraer ERJ 170 E170 and E175454Embraer EMB-145 ERJ 145449Airbus A319389Airbus A321385Embraer EMB-505 Phenom 300276Airbus A300196Boeing 747188
Model families most named, as a table
Highest rate, fleets of 500 or more reports a year per 100 aircraft registered
Boeing 767 18.1Boeing 737 13.7Bombardier CL-600 Challenger and CRJ 7.7Airbus A320 6.7Embraer ERJ 170 E170 and E175 6.0Airbus A321 4.1Embraer EMB-505 Phenom 300 4.1Cessna 680 Citation Sovereign and Latitude 1.7Cessna 560 Citation V, Ultra, Encore and Excel 1.2Bombardier BD-100 Challenger 300 and 350 0.7
Parts most often named
Actuator930Flap System638Sensor496Computer464Transmitter455Warning Message434Control Panel316Control Unit299Autothrottle Sys270Autopilot Sys245Warning System224Motor203
Parts most reported, as a table
| reports | |
|---|---|
| Actuator | 930 |
| Flap System | 638 |
| Sensor | 496 |
| Computer | 464 |
| Transmitter | 455 |
| Warning Message | 434 |
| Control Panel | 316 |
| Control Unit | 299 |
| Autothrottle Sys | 270 |
| Autopilot Sys | 245 |
| Warning System | 224 |
| Motor | 203 |
Who made the parts named last ten years, as the reports code them
The Boeing CO369Group Economique Airbus Industrie216Thales Navigation,Inc.164Cessna Aircraft CORP159Eaton CORP143Honeywell International INC (Engine)117The Bf Goodrich CO113Empresa Brasileira de Aeronautica SA97Canadair LTD Sub General Dynamics96Moog INC67
Part makers most named, as a table
| reports | |
|---|---|
| The Boeing CO | 369 |
| Group Economique Airbus Industrie | 216 |
| Thales Navigation,Inc. | 164 |
| Cessna Aircraft CORP | 159 |
| Eaton CORP | 143 |
| Honeywell International INC (Engine) | 117 |
| The Bf Goodrich CO | 113 |
| Empresa Brasileira de Aeronautica SA | 97 |
| Canadair LTD Sub General Dynamics | 96 |
| Moog INC | 67 |
What was wrong with them the condition reported
Malfunctioned1,723Failed1,618Faulted1,344Faulty878Inoperative625False Activation555Corroded545Defective308Damaged263Leaking197
Conditions most reported, as a table
| reports | |
|---|---|
| Malfunctioned | 1,723 |
| Failed | 1,618 |
| Faulted | 1,344 |
| Faulty | 878 |
| Inoperative | 625 |
| False Activation | 555 |
| Corroded | 545 |
| Defective | 308 |
| Damaged | 263 |
| Leaking | 197 |
Where in the system the FAA's codes
flaps 2,286Auto flight 1,578Flight controls 1,139Flight controls 962lift augmenting 675spoilers, drag devices 659Auto flight 586rudder and tab 557elevator and tab 552horizontal stabilizer trim 550aileron and tab 527Flight controls 463
What the NTSB found accidents and incidents since 2008 in which the NTSB's findings named this system
In 498 cases since 2008 the NTSB named flight controls as a cause (263 of them) or a contributing factor; 99 of those were fatal accidents. The part most often named is the flight control system › rudder control system. Among model families, the Cessna 172 Skyhawk appears most often. A failure report (above) is a part that failed and was fixed; an NTSB finding is a part that the investigators decided helped cause an accident. The two measure different things, and both are here.
Cases by year
Parts and problems named
Flight control system › Rudder control system113Flight control system › Elevator control system102Flight control system › TE flap control system76Flight control system › (general)67Flight control system › Aileron control system62Flight control system › Elevator tab control system41Auto flight system › Autopilot system29Flight control system › Control column section24Flight control system › Stabilizer control system16Flight control system › Gust lock or damper16
Parts the NTSB named, as a table
| cases | |
|---|---|
| Flight control system › Rudder control system | 113 |
| Flight control system › Elevator control system | 102 |
| Flight control system › TE flap control system | 76 |
| Flight control system › (general) | 67 |
| Flight control system › Aileron control system | 62 |
| Flight control system › Elevator tab control system | 41 |
| Auto flight system › Autopilot system | 29 |
| Flight control system › Control column section | 24 |
| Flight control system › Stabilizer control system | 16 |
| Flight control system › Gust lock or damper | 16 |
Models most often named
What was wrong last ten years · share of 12,848 reports that say
a warning light or message4,274 (33%)flight controls affected2,566 (20%)a false warning997 (8%)vibration or buffeting178 (1%)other systems affected114 (0.9%)smoke, fumes, odours or sparks95 (0.7%)more than one failure75 (0.6%)no warning when there should have been63 (0.5%)
As a table
| reports | share | |
|---|---|---|
| a warning light or message | 4,274 | 33% |
| flight controls affected | 2,566 | 20% |
| a false warning | 997 | 8% |
| vibration or buffeting | 178 | 1% |
| other systems affected | 114 | 0.9% |
| smoke, fumes, odours or sparks | 95 | 0.7% |
| more than one failure | 75 | 0.6% |
| no warning when there should have been | 63 | 0.5% |
When it was found last ten years · share of 12,848 reports that say
approach2,425 (19%)climb2,180 (17%)inspection or maintenance2,114 (16%)cruise1,635 (13%)descent910 (7%)take-off780 (6%)landing573 (4%)taxiing or ground handling569 (4%)
As a table
| reports | share | |
|---|---|---|
| approach | 2,425 | 19% |
| climb | 2,180 | 17% |
| inspection or maintenance | 2,114 | 16% |
| cruise | 1,635 | 13% |
| descent | 910 | 7% |
| take-off | 780 | 6% |
| landing | 573 | 4% |
| taxiing or ground handling | 569 | 4% |
What the crew did last ten years · share of 12,848 reports that say
an unscheduled landing2,968 (23%)an aborted take-off585 (5%)an emergency descent516 (4%)a return to the gate399 (3%)fuel dumped20 (0.2%)an engine shut down4 (0.0%)the cabin depressurised1 (0.0%)an autorotation1 (0.0%)
As a table
| reports | share | |
|---|---|---|
| an unscheduled landing | 2,968 | 23% |
| an aborted take-off | 585 | 5% |
| an emergency descent | 516 | 4% |
| a return to the gate | 399 | 3% |
| fuel dumped | 20 | 0.2% |
| an engine shut down | 4 | 0.0% |
| the cabin depressurised | 1 | 0.0% |
| an autorotation | 1 | 0.0% |
Who filed the report last ten years · share of 12,848 reports that say
an airline (Part 121)10,596 (82%)a charter or commuter operator (Part 135)1,254 (10%)a repair station (Part 145)368 (3%)a foreign carrier (Part 129)299 (2%)a mechanic120 (0.9%)a non-certificated international operator76 (0.6%)a private or corporate operator (Part 91)35 (0.3%)the FAA21 (0.2%)
As a table
| reports | share | |
|---|---|---|
| an airline (Part 121) | 10,596 | 82% |
| a charter or commuter operator (Part 135) | 1,254 | 10% |
| a repair station (Part 145) | 368 | 3% |
| a foreign carrier (Part 129) | 299 | 2% |
| a mechanic | 120 | 0.9% |
| a non-certificated international operator | 76 | 0.6% |
| a private or corporate operator (Part 91) | 35 | 0.3% |
| the FAA | 21 | 0.2% |
How it was found last ten years · share of 12,848 reports that say
a visual inspection2,409 (19%)a functional check197 (2%)borescope29 (0.2%)ultrasound14 (0.1%)eddy current3 (0.0%)a magnified visual inspection3 (0.0%)X-ray1 (0.0%)
As a table
| reports | share | |
|---|---|---|
| a visual inspection | 2,409 | 19% |
| a functional check | 197 | 2% |
| borescope | 29 | 0.2% |
| ultrasound | 14 | 0.1% |
| eddy current | 3 | 0.0% |
| a magnified visual inspection | 3 | 0.0% |
| X-ray | 1 | 0.0% |
FAA orders 2,242 airworthiness directives · newest first
2026-12-012026-21-13 · Elevator Tab Control System
2026-12-012026-22-02 · Flight controls
2026-10-202026-19-01 · Rotorcraft flight control
2026-10-132026-19-06 · Aileron Control System
2026-10-022026-15-12 · Cabin Equipment/Furnishings
2026-07-202026-12-05 · Flight controls
2026-07-062026-10-18 · Flight Control System
2026-07-012026-13-13 · Navigation
2026-06-182026-09-13 · Flight controls
2026-06-152026-11-04 · Stabilizers
2026-06-122026-09-04 · Flight Controls
2026-06-032026-08-07 · Stabilizers
All 2,242 orders on this system
Orders by decade
Who makes and modifies it
Companies the FAA has approved to make equipment for this system (technical standard order authorisations):
Garmin International 15Honeywell Aerospace US LLC 7Rockwell International Avionics Group 3S-Tec Corporation 3Avidyne Corporation 2Century Flight Systems, INC. 2Resurgent Aviation Solutions, LLC 2Thales Avionics S.A. 2Woodward Mpc 2Wulfsberg Electronics Division 2Bendix King 1Ge Aviation System LLC 1
Approved modifications 2,904 · the companies holding the most
Century Flight Systems INC 704S-Tec Corporation 324Brittain Industries, INC 182Honeywell International INC 149Bendix Corporation Avionics Div 79Bendix CORP 43Collins Radio Company 42Cooper Engineering Corporation 39Rockwell Collins INC 38Astronautics Corporation of America 34
Engine series most often named last ten years
Pratt & Whitney PT6A series 28Pratt & Whitney Canada PW150A 16CFM International CFM56-7B27 11CFM International CFM56-7B27E 10CFM International CFM56-5B4/3 9General Electric CF34-3B1 8Pratt & Whitney Canada PT6A-67P 7Rolls-Royce BR 700 series 7CFM International CFM56-3C1 5CFM International CFM56-5B4 5CFM International CFM56 series 5CFM International LEAP-1B28 series 5
Safety bulletins 71 · advice, not orders
2026-09-102026-16 · Elevator Control System
2026-01-212026-02 · Elevator Tab Control System
2025-12-222025-11 · RUDDER CONTROL SYSTEM
2024-04-252024-03 · Rudder Control System
2022-05-17AIR-22-09R1 · AUTOPILOT FLIGHT DIRECTOR SYSTEM: ALT HOLD Engaged on Takeoff on Boeing Model 777/787 common fleets.
2022-04-12AIR-22-09 · AUTOPILOT FLIGHT DIRECTOR SYSTEM: ALT HOLD Engaged on Takeoff on Boeing Model 777/787 common fleets.
Sources: FAA service difficulty reports (yearly files since 1995, grouped by the FAA's four-digit system code into this site's fourteen systems), airworthiness directives, supplemental type certificates, technical standard order authorisations and special conditions from the FAA's Dynamic Regulatory System. Rates per 100 aircraft use today's register as the fleet; they show reporting as much as reliability, and commercial fleets report more. Connections as data: /graph/system/flight-controls.json.