A US military jet carrying Defense Secretary Pete Hegseth made an emergency landing in the United Kingdom after a crack was detected in the aircraft’s cockpit windshield during its return flight to Washington from Brussels, the Pentagon said Wednesday.
Officials said the aircraft diverted as a safety precaution, emphasizing that all passengers and crew members were safe. The United State defense plane landing occurred without incident and followed standard emergency procedures, according to the statement.
Flight tracking data indicated the aircraft began descending from cruising altitude off the southwest coast of Ireland before turning east toward British airspace. Pentagon officials said the crew acted “with full professionalism” throughout the event.
Hegseth had been returning from a NATO Defense Ministers meeting in Brussels, where discussions centered on Ukraine’s defense, European security, and allied coordination. Shortly after takeoff, pilots detected a crack forming in one of the aircraft’s windshield panels.
The crew immediately declared an emergency, transmitting a “7700” squawk code a transponder signal used globally to indicate in flight emergencies ranging from depressurization to mechanical faults.
Data from FlightRadar24 showed the aircraft, identified as a C-32 a modified Boeing 757 used for senior government officials descended to 10,000 feet, a standard altitude for managing cabin pressure issues, before diverting eastward.
“The aircraft landed based on standard safety procedures, and everyone onboard, including Secretary Hegseth, is safe,” Pentagon spokesperson Col. Marcus Lane said in a written statement.
Hegseth later posted on X formerly Twitter “All good. Thank God. Continue mission.” This marks the second incident this year involving a high level US government aircraft. In February, a plane carrying Secretary of State Marco Rubio was forced to turn back due to a similar cockpit window crack.
Aviation experts said the US defense plane landing was a textbook example of proper protocol under pressure.
“A cracked windshield is serious, but rarely catastrophic if handled promptly,” said Dr. Elaine Brooks, an aerospace engineering professor at Purdue University.
“Cockpit windshields are multi layered composites designed to withstand bird strikes and extreme pressure. Even so, a visible crack requires immediate descent and diversion to prevent possible failure.”
Capt. Ryan Mitchell, a retired US Air Force pilot, said pilots are trained to respond instantly to windshield anomalies. “If you see any structural weakness, you descend to a safe breathable altitude and divert to the nearest base,” he said. “That’s exactly what happened here.”
Experts noted that the 7700 code is not a sign of panic but a procedural alert that ensures air traffic control prioritizes the aircraft. “It means everyone along the route clears the airspace,” Mitchell added.
According to Brooks, such incidents can result from thermal stress, manufacturing imperfections, or accumulated wear. “Pressure cycles over thousands of hours can create tiny microfractures that expand suddenly during flight,” she said.
The Air Force operates a small fleet of C-32 aircraft for executive transport, each averaging more than 25 years in service. Although these planes undergo rigorous maintenance, analysts say age increases the likelihood of stress related issues.
Data from the Federal Aviation Administration (FAA) shows that less than 0.3% of reported in flight mechanical incidents involve windshield damage. Most are minor but demand immediate attention.
In 2018, a Southwest Airlines jet made an emergency landing in Cleveland after its outer windshield pane cracked at 32,000 feet.
In February 2025, Secretary Marco Rubio’s government aircraft turned back due to a cockpit window fault, marking the first high level diversion of that year.
Historical data show that commercial and military aircraft alike can safely land after windshield fractures if protocols are followed.
“These events are rare and generally well controlled,” said Mark Ellis, a former FAA safety investigator. “They demonstrate how redundant design and disciplined crews prevent a potentially dangerous situation from escalating.”
At a British airfield believed to be RAF Mildenhall, witnesses said they saw a large US jet land under tight security.
“I noticed the plane descending lower than usual and several emergency vehicles positioned near the runway,” said James O’Leary, a resident living near the base. “Later we heard it was a U.S. defense flight making an emergency stop.”
An air traffic controller who handled part of the flight’s diversion confirmed that coordination between Irish and British control zones was “smooth and immediate.”
“When the 7700 code came through, we initiated the emergency corridor procedure,” the controller said. “The pilots were calm, professional, and clearly experienced.”
Officials at the U.K. Ministry of Defence declined to specify where the aircraft landed but confirmed coordination with US personnel. “It was handled jointly under standard bilateral procedures,” a spokesperson said.
At the Pentagon, press secretary Lt. Col. Andrea Martin told reporters that Secretary Hegseth resumed communications with Washington shortly after landing and remained “in full command of his duties.”
The US defense plane landing will trigger a detailed technical investigation by the Air Force’s 89th Airlift Wing, responsible for maintaining executive aircraft.
Engineers will inspect the windshield assembly, pressure seals, and thermal protection systems to identify the source of the crack.
Preliminary assessments suggest thermal expansion during altitude transition or material fatigue may have caused the defect. Replacement of the windshield is expected before the aircraft returns to service.
Defense analysts say the incident could accelerate discussions about modernizing the Air Force’s VIP transport fleet.
“These aircraft are aging, and even minor mechanical events highlight the need for modernization,” said Sarah Nguyen, senior fellow at the Center for Strategic Studies. “Still, it’s impressive how well safety systems worked.”
The Pentagon has not indicated whether Hegseth’s travel schedule will change, though officials said his duties remain unaffected.
The safe US defense plane landing in the United Kingdom underscores the effectiveness of military flight safety protocols and the professionalism of its flight crews.
While the incident disrupted a routine return from NATO meetings, all onboard including Defense Secretary Pete Hegseth escaped unharmed.
As investigations continue, officials emphasize that the event was handled according to procedure and posed no security risk.
For now, the episode serves as a reminder that even the most advanced aircraft are subject to the realities of mechanical wear and the value of disciplined responses in aviation safety.