Overview
• Operator: FedEx Federal Express
• Aircraft Model: Boeing 767-300
• Registration: N178FE
• Flight Number: FX-3609
• Route: Newark, NJ (EWR) to Indianapolis, IN (IND)
• Date: 1 March 2025
• Occupants: 3 crew members
• Casualties: None
• Nature of Incident: Bird strike leading to an engine fire on departure
Incident Summary
A FedEx Boeing 767-300 freighter, operating flight FX-3609 from Newark to Indianapolis, suffered a bird strike shortly after takeoff from Runway 22L, leading to an engine fire on the #2 (right-hand) General Electric CF6 engine.
The crew declared an emergency while still on the tower frequency, reporting the bird ingestion and engine fire. Ground observers saw large flames trailing from the right engine, and another crew on the ground mistakenly believed the engine had detached.
The aircraft stopped its climb at 2,000 feet, shut down the affected engine, and discharged both fire bottles, but the fire continued to burn visibly through the exhaust.
The aircraft returned immediately and landed safely on Runway 22L approximately 8 minutes after departure, where emergency services were already in position.
Fire crews used water to extinguish the flames, and runways 22L and 22R were closed while emergency operations continued.
Runway 29 was reopened approximately 15 minutes after the aircraft landed.
Sequence of Events
Pre-incident Conditions:
• The aircraft departed Runway 22L at Newark International Airport on schedule.
• Weather conditions and visibility were not reported as factors.
• No prior technical issues were recorded before takeoff.
Bird Strike & Engine Fire Event:
• At approximately 500 feet AGL, the crew reported hitting a flock of birds, leading to a severe ingestion into the right-hand (No. 2) engine (CF6).
• Flames erupted from the engine exhaust, visible from the ground.
• A separate flight crew on the ground mistakenly reported the engine had detached, later confirmed to be incorrect.
Emergency Response & Safe Landing:
• The crew declared an emergency and stopped their climb at 2,000 feet.
• Engine shutdown procedures were followed, and both fire suppression bottles were discharged, but the fire continued burning.
• The aircraft turned back to Newark, landing safely on Runway 22L just 8 minutes after departure.
• Emergency services confirmed the fire was still active upon landing and extinguished the flames using water.
Post-Landing Actions:
• The aircraft remained on the runway while fire crews ensured the fire was fully out.
• All runways at Newark were temporarily closed, with Runway 29 reopening 15 minutes later.
• Runways 22L and 22R remained closed for further inspection.
Investigation & Findings
Probable Cause:
The ingestion of birds into the right-hand General Electric CF6 engine resulted in a catastrophic failure, leading to a sustained engine fire.
Factors Contributing to the Fire Persistence:
• The severity of the bird ingestion likely caused severe turbine or combustor damage, allowing unburned fuel or oil to ignite.
• Despite fire suppression activation, the fire continued to burn through the exhaust, suggesting internal damage.
Ongoing Investigation & Maintenance Actions:
• The aircraft remains grounded at Newark for inspection and engine assessment.
• FAA and FedEx maintenance teams are examining the extent of the damage to determine repair viability.
• Runway inspections were conducted to assess debris from the engine.
Analysis & Safety Recommendations
For Airlines & Airport Authorities:
• Strengthen wildlife hazard management programs near airports to reduce the risk of bird strikes.
• Enhance radar detection and deterrence systems to monitor and scare birds away from active flight paths.
• Review takeoff procedures in known bird strike zones, including modifying climb-out speeds or profiles when feasible.
For Flight Crews:
• Reinforce immediate response procedures for bird strikes and post-ingestion engine failures.
• Continue strict adherence to emergency engine shutdown and fire suppression procedures.
• Enhance communication with ATC and emergency services to ensure rapid response in such events.
For Aircraft & Engine Manufacturers (Boeing & General Electric):
• Assess bird ingestion resilience for the CF6 engine series and determine if design modifications are necessary.
• Evaluate fire suppression effectiveness in cases of severe engine damage leading to persistent post-shutdown fires.
Conclusion
This severe bird strike incident at Newark highlights the ongoing risk of wildlife encounters in aviation and the importance of rapid emergency response procedures.
The FedEx crew executed the emergency effectively, shutting down the engine and returning safely in just 8 minutes.
The fire’s persistence even after engine shutdown and fire bottle discharge underscores the challenges associated with severe bird ingestion events.
This event reinforces the need for enhanced wildlife mitigation at airports, improved fire suppression effectiveness, and continued training for pilots and emergency responders.
Disclaimer
“This report is based on available information as of 2 March 2025. While every effort has been made to ensure accuracy, the completeness of the details cannot be guaranteed. If you are the rightful owner of any referenced materials and wish them removed, please email takedown@cockpitking.com.”
