Originally posted by AquaShrimp
Just go to google and type "Aim-54 phoenix propellant cracks". Then take your pick.
The article I read said that Navy inspection teams found cracks in over 50% of the Aim-54C's in storage.
Considering the AIM-54 could use 2 different rocket motors, Aerojet Mk 60 or Rocketdyne Flexadyne Mk 47 long-burn-time solid-fuel rocket, if a crack was found it would be no big deal to replace the motor however, I have found no official sources stating that cracks in the solid fuel propellant was ever an issue.
There were however issues with the warhead fuse.
The AIM-54 has had a history of delays and, more recently, quality control problems. Production schedules have not been met, especially since a Department of Defense (DoD) decision in 1984 to withhold payments, a decision which closed down the line for several months. At one point, 240 of 318 AIM-54Cs delivered to the Navy under FY1982/FY1983 contracts, were in storage because of a unreliable fuze. A redesign of the FSU-10/A fuze was tested on 11 Sep 1987 and failed to explode, prompting the cancellation of further flight tests and imposing further delays in deploying a fully capable AIM-54C. The stockpile of completed, but fuzeless, missiles grew to over 500 before a new version of the FSU-10 fuze was accepted in the summer of 1988 with deliveries commencing soon afterward.
An August 1988 DOD inspector general report revealed that the Navy paid Hughes Aircraft more than 3 times the estimated cost to produce the AIM-54C. The report also criticized the selection of Raytheon as a second source and the scheduling of full competition beginning in 1989. The auditors contended that the Raytheon missile has not been adequately tested, and because testing was not scheduled to be completed until early 1990, it would be unwise to award Raytheon a portion of the 1989 contract.
Despite these concerns, the Navy awarded Raytheon more than half of the missiles to be built (208 to 195) under the 1989 contracts. The FY1990 contract, the last planned, was awarded as a block to Hughes.