Since winning the Wings Around the Globe race, Dusty Crophopper has a successful career as a racer. Unfortunately, his engine's gea...
Since winning the Wings Around the Globe race, Dusty Crophopper has a successful career as a racer. Unfortunately, his engine's gearbox becomes damaged. To make things worse, it is out of production, so he may never race again. Frustrated with mechanic Dottie's newly installed warning light to keep his engine performance low to prevent further damage, Dusty goes on a defiant flight testing his limits. Unfortunately in doing so, he has a hard landing with engine trouble at Propwash Junction's airport, causing a fire.
Although the residents put out the fire with some difficulty, the accident leads to a government inspector closing the airport due to inadequate firefighting personnel. Aggrieved at his carelessness, Dusty offers to undergo training to be certified as a firefighter to meet the necessary regulations to reopen the airport. To that end, Dusty travels to Piston Peak National Park where he meets a fire and rescue crew under the command of a helicopter named Blade Ranger. The leader of an efficient unit, Blade is initially unimpressed by the small newcomer and Dusty's training proves to be a difficult challenge.
During training, Dusty learns that Blade was formerly an actor who played a police helicopter on the TV series CHoPs. Later, Dusty is devastated by a call from his friends at Propwash Junction noting that all attempts at a replacement gearbox have failed and his racing career is over.
Depressed, Dusty's education falters to Blade's frustration and things come to a head when makes a forced landing into a river during a fire dispatch and swept through the rapids with Blade trying to extract him. Eventually, the pair make it to land, and Dusty confesses his physical disability, to which Blade advises Dusty not to give up. They must take shelter in an abandoned mine during a fire. The situation is complicated in that Blade himself is damaged from protecting Dusty in the fire is and temporarily grounded for repairs. While Blade is recuperating, Dusty learns that Blade's co-star from CHoPs was killed during a stunt gone wrong on set that Blade was helpless to stop, so he decided to become a firefighter for real.
Unfortunately, a massive forest fire breaks out due to a major opening of a local lodge and the manager, Cad Spinner, selfishly diverts all the water supply to prevent his lodge from burning and preventing the firefighters from loading fire retardant for their own duties. With only their pre-existing tank loads, the firefighters manage to help the evacuees escape the fire while Dusty is alerted that two elderly campers are trapped on a burning bridge deep in the fire zone. He races to the scene and is forced to push his engines to the maximum to reload his water tanks by going into a vertical climb up a nearby waterfall to do a necessary water drop to save the campers. In the meantime, Blade shows up and assists the campers. Dusty is successful in dropping water and extinguishes the fire, but his overstressed gearbox fails completely and he crashes.
Unconscious, Dusty is airlifted back to base where he wakes up days later to learn that not only has his structure been fully repaired, but the base mechanic has built a superior custom refurbished gearbox for his engine to allow full performance again. Impressed at Dusty's skill and heroism, Blade certifies him a firefighter. Propwash Junction is reopened with Dusty assuming his duty as a firefighter, celebrated with an aerial show with his new colleagues from Piston Peak.
During the end credits, it is shown that Cad's misconduct resulted in him being demoted and reassigned as a Death Valley park ranger.
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