N427AL

Part: PITCH HORN — CORRODED (T/R HUB)

DURING 2500 HOUR OVERHAUL, CORROSION BEYOND LIMITS ON ENTIRE SURFACE OF PARTS DUE TO POOR QUALITY OF MATERIAL AND PAINTING PROCEDURE. SCRAPPED PARTS. USE BETTER QUALITY ALUMINUM AND PAINTING PROCEDURE.

Part: LINK — CORRODED (MAIN ROTOR)

DURING PHASE INSPECTION. CORROSION BEYOND MAXIMUM LIMITS. RETURN TO 206 SERIES ALLOY USED ON LINKS AND LEVERS. BETTER ALLOY AND/OR SURFACE PROTECTION.

Part: DISC PACK — CRACKED (TAIL ROTOR)

DAILY INSPECTION OF TAILROTOR HANGER BEARINGS. CRACKED DISC NR5 AND NR6 TAILROTOR HANGER BEARINGS. ALLOW THE TAILROTOR DRIVESHAFT TO FLOAT SO DISC PACKS DO NOT FLEX AS MUCH OR AS OFTEN.

Part: DUCT — CRACKED (OIL COOLER) · airframe 4,633 hrs

DURING DAILY INSPECTION, FOUND OIL COOLER BLOWER CRACKED. (X)

Part: HOUSING — CRACKED (T/R DRIVESHAFT)

DURING DAILY INSPECTION, FOUND HOUSING CRACKED AND RIVETS MISSING DUE TO HIGH VIBRATION, HOUSING SCRAPPED. (X)

Part: FUEL CAP — LEAKING (FUEL CELL) · airframe 4,309 hrs

DURING DAILY INSPECTION, FOUND FUEL CAP LEAKING, CRACKED AT LOCKING MECHANISM. (X)

Part: PITCH HORN — CORRODED (MAIN ROTOR HUB)

DURING FIRST 2,500 HOUR OVERHAUL, FOUND CORROSION BEYOND LIMITS UNDER PLATE, POSSIBLY CAUSED BY INCOMPATIBLE ADHESTIVE PRIMER. (X)

Part: FRAME — CRACKED (TRANSMISSION)

DURING DAILY SERVICE CHECK, FOUND TRANSMISSION SIDE OF MDS, FORWARD FLEX FRAME CRACKED FROM ATTACHMENT BOLT TO OUTER EDGE OF FLEX FRAME. (X)

Part: DISC PACK — CRACKED (TAIL ROTOR)

DURING 25-HOUR AD INSPECTION, FOUND DISC PACK CRACKED IN 3 PLACES FACING AFT AND 1 CRACK FORWARD. (X)

Part: HOUSING — CRACKED (COOLER BLOWER)

DURING DAILY INSPECTION, FOUND CRACKED BLOWER HOUSING.

Part: HOUSING — CRACKED (COOLER BLOWER)

DURING DAILY INSPECTION, FOUND CRACKED BLOWER HOUSING.

Part: HOUSING — CRACKED (COOLER BLOWER)

DURING DAILY INSPECTION, FOUND CRACKED BLOWER HOUSING.

Part: HOUSING — CRACKED (COOLER BLOWER)

DURING DAILY INSPECTION, FOUND CRACKED BLOWER HOUSING.

Part: BEARING — ROUGH (T/R DRIVE)

UNIT WAS REMOVED FOR VIBRATIONS. FOUND 2 EACH 407-340-339-103 BEARINGS ROUGH. FOUND 1 EACH 206-061-432-116 HOUSING CRACKED.

Part: BEARING — ROUGH (TAIL ROTOR)

FOUND 2 EACH 407-340-339-103, BEARINGS ROUGH. FOUND 206-061-432-116 HOUSING CRACKED. FOUND 406-040-320-101 SHAFT SPLINES WORN.

Part: SHAFT — WORN (TAIL ROTOR)

FOUND 2 EACH 407-340-339-103, BEARINGS ROUGH. FOUND 206-061-432-116 HOUSING CRACKED. FOUND 406-040-320-101 SHAFT SPLINES WORN.

Part: HOUSING — CRACKED (TAIL ROTOR)

FOUND 2 EACH 407-340-339-103, BEARINGS ROUGH. FOUND 206-061-432-116 HOUSING CRACKED. FOUND 406-040-320-101 SHAFT SPLINES WORN.

Part: BEARING — WORN (LEG ASSY)

DURING INSPECTION, FOUND WORN BEARING.

Part: INPUT SHAFT — WORN (TRANSMISSION)

F/W/U REMOVED FOR 2,500-HOUR OVERHAUL. FOUND AT TEAR-DOWN INSPECTION. INPUT SPLINES WORN BEYOND LIMITS. SHAFT SCRAPPED.

Part: BEARING — WORN (TAIL ROTOR)

TAIL ROTOR ASSEMBLY WAS REMOVED FOR WORN BEARINGS. FOUND THE TWO INBOARD BEARINGS BADLY WORN. THE OUTER RACE LINERS DEBONDED. THREE T/R HUBS HAVE BEEN FOUND IN THIS CONDITION. BEARING KEPT FOR POSSIBLE EVALUATION. RECOMMEND: REMOVE T/R BLADES AND INSPECT INBOARD BEARINGS EVERY 800 HOURS. REPLACED TWO EACH BEARINGS.

Part: SUPPORT — CRACKED (TAILBOOM)

DURING ROUTINE DAILY INSPECTION FOUND RT UPPER SUPPORT FITTING, FIRST FORWARD SCREW CRACKED CRESCENT SHAPED 1 INCH TO 1.50 INCHES. THE DRAWING IS OF THE LT HAND CRACK, BUT THE RT HAND CRACK IS IN A SIMILAR LOCATION.

Part: DISC — CRACKED (T/R)

SCHEDULED INSPECTION FOUND DISC COUPLING CRACKED.

Part: DISC — CORRODED (T/R)

SCHEDULED INSPECTION FOUND CORROSION AND COUPLING (PACK) SEPARATED WHEN BOLTS ARE TORQUED.

Part: PINION GEAR — GALLED (GEARBOX)

UPON DISASSEMBLY OF GEARBOX AND INSPECTION OF PARTS DUE TO METAL, FOUND PINION GEAR HAD EXCESSIVE GALLING ON GEAR TEETH. POSSIBLY DUE TO IMPROPER MESHING OF GEARS. SECONDARY DAMAGE: T/M GEAR P/N 6893673 S/N NN143321. TT: 15,65.3 HOURS. SPALLING ON GEAR TEETH.

Part: SUPPORT — CRACKED (HORIZ STAB)

AFTER BEING NOTIFIED THAT ONE OTHER AIRCRAFT IN FLEET HAD LOST ITS SLAT, SUBMITTER C/W VISUAL INSPECTION AND FOUND THE HORIZONTAL STABILIZER SLAT SUPPORT AT THE MID-INBOARD SUPPORT CRACKED ON THE LT SLAT, ONE EACH. ONE MID-INBOARD SLAT SUPPORT CRACKED IN RADIUS AREA OF SUPPORT TO HORIZONTAL STABILIZER MOUNTING AREA.

Part: SUPPORT — CRACKED (HORIZ STAB LT)

AFTER BEING NOTIFIED THAT ONE OTHER AIRCRAFT IN FLEET HAD LOST ITS SLAT, C/W A VISUAL INSPECTION AND FOUND THE HORIZONTAL STABILIZER SLAT SUPPORT AT THE MID-INBOARD SUPPORT CRACKED ON THE LT SLAT. ONE EACH. ONE MID-INBOARD SLAT SUPPORTS CRACKED IN RADIUS AREA OF SUPPORT TO HORIZONTAL STABILIZER MOUNTING AREA.

Part: BEARING — ROUGH (NR 2 T/R DRIVE)

TWENTY-FIVE HOUR INSPECTION FOUND OIL COOLER BLOWER BEARINGS ROUGH. ALSO, SHAFT SPLINES SHOW SIGNS OF LACK OF LUBRICATION. SUBMITTER RECOMMENDED IMPROVING BEARING AND LUBRICATION ON SHAFT TO COUPLING SPLINES.

Part: BEARING — ROUGH (NR 2 T/R DRIVE)

TWENTY-FIVE HOUR INSPECTION FOUND OIL COOLER BLOWER BEARINGS ROUGH. ALSO, SHAFT SPLINES SHOW SIGNS OF LACK OF LUBRICATION. SUBMITTER RECOMMENDED IMPROVING BEARING AND LUBRICATION ON SHAFT TO COUPLING SPLINES.

Part: DISC PAC — CRACKED (NR 7 T/R DRIVE)

DURING DAILY INSPECTION, C/W MAINTENANCE NOTAM 52-97, FOUND CRACKED DISK IN DISC PACK.

Part: SPRING PIN — MISSING (TAIL SKID)

POST-FLIGHT INSPECTION FOUND TAIL SKID ASSEMBLY HAD DEPARTED THE AIRCRAFT, SPRING PIN WAS ALSO MISSING. SPRING PIN MUST HAVE FALLEN OUT, AND THEN TAIL SKID WITHOUT SPRING PIN TO HOLD IT ON FELL OFF THE AIRCRAFT DURING FLIGHT. PILOT DID NOT NOTICE ANYTHING UNUSUAL DURING FLIGHT.

Part: FUSIBLE PLUG — FAILED (RT FLOAT BOTTLE)

WHILE AIRCRAFT WAS SITTING ON MAINTENANCE RAMP, NITROGEN CAME OUT OF FUSIBLE PLUG. THE INTERNAL PLUNGER CAME LOOSE OR SHEARED.