NTSB releases dramatic frame-by-frame images of engine tearing away in deadly UPS MD-11 crash

The National Transportation Safety Board has released striking new evidence from its investigation into the UPS cargo jet that crashed shortly after takeoff in Louisville earlier this month, including a six-frame sequence showing the aircraft’s left engine ripping free of its mount, vaulting over the wing, and erupting into a fireball.

According to the preliminary report, a critical structural fitting that secured the MD-11F’s left engine to its wing failed moments after the aircraft lifted off from Runway 17R at Louisville Muhammad Ali International Airport. The catastrophic separation occurred at a height of no more than 30 feet, leaving the three-engine freighter unable to climb and sending it rolling sharply left before plunging into a petroleum recycling facility and adjacent UPS warehouse.

All three pilots aboard UPS Flight 2976 and 11 people on the ground were killed. The impact carved a half-mile debris path and triggered a massive blaze visible for miles.

Fatigue cracks found in engine mounts

Investigators say the two recovered structural fittings—known as lugs—which hold the engine pylon tight to the wing, exhibited fatigue cracking and signs of “over-stressing” at their 2 o’clock and 9 o’clock positions. The failure allowed the entire engine-pylon assembly to detach cleanly, echoing the 1979 crash of American Airlines Flight 191 in Chicago, when a DC-10 lost its left engine in a nearly identical manner.

The MD-11 involved in the Louisville crash was 34 years old and already slated for retirement. The FAA has since grounded all MD-11 and MD-11F aircraft in U.S. service pending detailed inspections. UPS operates 26 additional MD-11s.

A failed climb and sudden roll

Airport surveillance footage and eyewitness accounts indicate that although takeoff speed appeared normal, the aircraft struggled to climb and quickly lost altitude. Moments later, with the left engine gone and the wing aerodynamically compromised, the jet entered an unrecoverable left roll.

The aircraft had recently undergone maintenance in San Antonio that kept it out of service for six weeks. The NTSB is reviewing all associated records.

Recorders recovered; investigation expands

Both the cockpit voice recorder and flight data recorder have been transported to NTSB labs. The CVR captured more than two hours of high-quality audio, while the FDR held 63 hours of flight data from 24 flights, including the accident sequence.

Specialists in aircraft performance, human factors, maintenance procedures, and air traffic control have been added to the probe as investigators work to establish why the engine mount failed so abruptly.

The publication of the 12-page preliminary report just over two weeks after the November 4 crash is notably faster than the NTSB’s typical 30-day timeline.

UPS, in a statement, said it “fully supports the investigation,” while Boeing—successor to McDonnell Douglas—offered condolences and pledged cooperation.

The NTSB’s final report, including a determination of probable cause and safety recommendations, is expected in 18 to 24 months.