N437AL

Part: BLADE — DEBONDED (MAIN ROTOR) · airframe 13,282 hrs

DURING DAILY SERVICE CHECK, MX FOUND PREVIOUSLY INSTALLED MAIN ROTOR BLADE REPAIR DEBONDED.

Part: LONGERON — CRACKED (FUSELAGE) · airframe 12,813 hrs

DURING ROUTINE INSP, TAILBOOM RING (FUSELAGE SIDE), SHEAR DECK/ WEB, AND LONGERON FOUND CRACKED.

Part: BEARING — BINDING (MAIN ROTOR) · airframe 6,766 hrs

BINDING, ROUGH, AND AXIAL PLAY BEYOND MAX. REPLACED W/NEW BY FLT MAINTENANCE.

Part: CONNECTOR — DIRTY (TRANS PUMP)

ON TAKE OFF, RT FUEL TRANSFER LIGHT ILLUMINATED DURING TAKE OFF. MAINTENANCE FOUND MOISTURE ON TRANSFER PUMP CONNECTOR, CLEANED AND REINSTALLED, THE OPS CHECK WAS GOOD.

Part: BEARING — BINDING (M/R BLADE) · airframe 6,380 hrs

BINDING, AXIAL WEAR BEYOUND MAX, AND ROUGH. REPLACED WITH NEW PART IN FIELD.

Part: FLANGE — ELONGATED (FREEWHEEL UNIT) · airframe 6,301 hrs

ELONGATION FOUND ON BOLT HOLES OF ADAPTER P/N: 406-040-542-107. REPLACED WITH NEW PART.

Part: INDICATOR — WILL NOT TEST (DUAL TACH)

DUAL TACH NEEDLE ON INDICATOR WILL NOT TEST.

Part: BEARING — WORN (T/R HUB) · airframe 5,726 hrs

FOUND 4 EA. TAIL ROTOR YOKE BEARINGS WORN. AXIAL PLAY.

Part: STRINGER — CRACKED (FUSELAGE)

11/11/02 IN FOR C/W ASB 407-02-54. WEIGHT OF CARBON FIBER DOORS. STRINGER, CRACK IS OCCURRING ON FORWARD LEFT STRINGER AT CLIP ANGLE AND STRINGER RIVETED LOCATION, WEIGHT OF DOORS AND VIBRATION. HEAVIER GAUGE STRINGER MATERIAL TO ACCOMMODATE WEIGHT OF DOORS.

Part: STRINGER — CRACKED (NACELLE DOOR)

IN FOR C/W ASB 4070254, WEIGHT OF CARBON FIBER DOORS. CRACK IS OCCURING ON FORWARD LEFT STRINGER AT CLIP ANGLE AND STRINGER RIVETED LOCATION, WEIGHT OF DOORS AND VIBRATION. HEAVIER GAUGE STRINGER MATERIAL TO ACCOMODATE WEIGHT OF DOORS.

Part: CROSSTUBE — CORRODED (MLG)

DAILY SERVICE CHECK, FOUND HEAVY PITTING CORROSION UNDER WEAR PADS. SCRAPPED CROSSTUBE. PROBABLE CAUSE IS WATER ENTRAPMENT. EXTENT OF CORROSION ALMOST UNDETECTABLE WITH ALL PARTS INSTALLED. RECOMMEND INSPECTION BE DONE WITH CROSSTUBE REMOVED FROM AIRCRAFT AND WEAR PADS REMOVED. INSPECTION SHOULD BE ON TIME SPECIFIC INTERVALS.

Part: DISC PACK — CRACKED (TAIL ROTOR)

DAILY INSPECTION OF TAILROTOR DRIVESHAFT BEARINGS AND FOUND CRACKED DISC PACK. THE COUPLING IS CRACKED, PROBABLE CAUSE IS EXCESSIVE RIGIDITY IN THE BEARING MOUNT SYSTEM. ALLOW TAILROTOR DRIVESHAFT TO FLOAT SO DISC PACKS DO NOT FLEX AS MUCH OR AS OFTEN. (M)

Part: BEVEL GEAR — CRACKED (TRANSMISSION)

TRANSMISSION MAKING METAL. BEVEL GEAR CRACKED FROM BOLT HOLE.

Part: BEARING — SEPARATED (TRUNNION BEARING)

OCCURED DURING DAILY. ELASTOMER SEPARATION.

Part: DISC PACK — CRACKED (NR 6)

DURING PHASE INSPECTION, VISUAL INSPECTION OF TAILROTOR DRIVESHAFT FOUND ONE SEGMENT OF DISC PACK OF NR 6 DRIVESHAFT CRACKED. FORWARD SEGMENT CRACKED ACROSS THE SPAN. (X)

Part: SUPPORT BRACKET — CRACKED (TAIL BOOM) · airframe 3,308 hrs

DURING DAILY INSPECTION, FOUND SUPPORT WITH STRESS CRACKS IN RADIUS FROM WHEN THE SUPPORT WAS MANUFACTURED. (X)

Part: BEARING — ROUGH (TAIL ROTOR DRIVE) · airframe 3,314 hrs

BEARINGS NOISEY AND ROUGH. REMOVED AND REPLACED 2 EACH BEARINGS. (X)

Part: BEARING — ROUGH (TAIL ROTOR DRIVE) · airframe 3,314 hrs

BEARINGS NOISEY AND ROUGH. REMOVED AND REPLACED 2 EACH BEARINGS. (X)

Part: DISC PACK — CRACKED (T/R DRIVE)

DURING 25-HOUR AD INSPECTION, NR 7 DISC PACK CRACKED IN ONE LOCATION ON AFT DISC.

Part: HOUSING — CRACKED (COOLER BLOWER)

DURING DAILY INSPECTION, FOUND BLOWER HOUSING CRACKED.

Part: PANEL — CRACKED (FUSELAGE)

DURING TAILROTOR DRIVESHAFT REPLACEMENT. OIL COOLER BLOWER DECK IS CRACKED AND THE OIL COOLER TRANSITION DUCT IS CRACKED.

Part: DISC PACK — CRACKED (T/R DRIVE)

DURING 25-HOUR AD INSPECTION, FOUND NR 7 TAILROTOR DISC CRACKED IN TWO PLACES.

Part: DISC PACK — CRACKED (TAIL ROTOR)

DURING 25-HOUR AD INSPECTION. 50-HOUR PMI LAST 50-HOUR INSPECTION DONE AT 2,867.5 HOURS. AFT LAMINATE OF NR 6 DISC PACK CRACKED.

Part: DISC PACK — CRACKED (T/R DRIVE)

DURING 50-HOUR INSPECTION, FOUND NR 7 DISC PACK CRACKED AT AFT DISC. IT IS CRACKED IN 3 LOCATIONS ON AFT DISC. DISC PACK WAS 76.8 HOURS TT ON AIRCRAFT.

Part: BEARING — DAMAGED (MAIN ROTOR)

DURING DAILY INSPECTION, FOUND ELASTOMERIC EXTRUSION AND SEPARATION.

Part: BEARING — DAMAGED (MAIN ROTOR)

DURING DAILY INSPECTION, FOUND ELASTOMERIC EXTRUSION AND SEPARATION.

Part: BEARING — DAMAGED (MAIN ROTOR)

DURING DAILY INSPECTION, FOUND ELASTOMERIC EXTRUSION AND SEPARATION.

Part: DISC PACK — CRACKED (T/R DRIVE)

ONE DISC ON AFT SIDE OF THE DISC PACK CRACKED IN HALF. INSTALLED DISC PACK S/N RNFS-2938, FOUND AT AIR LOGISTICS LLC, HOUMA BASE.

Part: DISC PACK — CRACKED (T/R DRIVE)

DURING PHASE INSPECTION, DISC PACK CRACKED.

Part: DISC PACK — CRACKED (T/R DRIVE)

DURING PHASE INSPECTION, DISC PACK CRACKED.

Part: SHAFT — WORN (TAIL ROTOR)

FOUND SPLINES WORN BEYOND LIMITS (406-040-320-101). FOUND HOUSING CRACKED (206-061-432-116). FOUND 2 EACH BEARINGS ROUGH (407-340-339-103). TT 4.77.4 HOURS.

Part: BEARING — GALLED (AFT SIDE OF GRBX)

ENGINE REMOVED FROM AIRCRAFT FOR CHIP LIGHT. UPON INSPECTION OF PARTS, FOUND EXCESSIVE GALLING ON T/M JOURNAL INNER RACE AND ROLLERS. EXCESSIVE GALLING ON T/M JOURNAL BEARIANG INNER RACE AND ROLLERS.

Part: NOZZLE — FAILED (COMBUSTION SECT)

TURBINE AND FUEL NOZZLE SENT TO SHOP FOR ENGINE MAKING METAL. REMOVED FUEL NOZZLE FROM COMBUSTION SECTION AND FOUND HEAVY CARBON BUILD-UP ON BOTTOM OF SHROUD HOUSING AND ALSO CARBON BUILD-UP INSIDE COMBUSTION LINER. FUEL NOZZLE WAS SHIMMED AT .341 INCH. CARBON BUILD-UP SEEMS TO BE CAUSED BY SMOKELESS LINERS.

Part: BEARING — FAILED (T/R)

SCHEDULED INSPECTION FOUND NR 2 DRIVE SHAFT BEARING ROUGH AND NOISY.

Part: DISC PACK — CRACKED (T/R)

SCHEDULED INSPECTION FOUND DISK PACK CRACKED.

Part: DISK — CRACKED (T/R DRIVE)

DURING PHASE INSPECTION AND C/W AD 97-24-17, 25-HOUR INSPECTION FOUND CRACKED DISK (9TH) FACING AFT.

Part: DISC PACK — CRACKED (T/R SHAFT NR 5)

DURING 25-HOUR INPSECTION, FOUND ONE DISC IN PACK ASSEMBLY CRACKED. IT WAS THE NR 1 DISC IN THE PACK.

Part: DISC PACK — CRACKED (T/R DRIVE SHAFT)

ON PHASE NR 1 INSPECTION WHILE DOING AD 97-24-17 100-HOUR BLOWER INSPECTION, FOUND DISC NR 1 OF 10, TOTAL, CRACKED (STARTING FRONT TO BACK).

Part: DISK PACK — CRACKED (T/R SHAFT)

DISCOVERED DURING 25 HOUR INSPECTION, T/R DRIVE SHAFT NR 5 DISK PACK CRACKED ON AFT SIDE IN 2 PLACES.

Part: DISK PACK — CRACKED (NR 5)

FOUND DURING 25 HOUR AD INSPECTION, T/R DRIVESHAFT DISK PACK NR 5 HAS CRACKED COUPLING. CRACKED ON AFT SIDE OF COUPLING. PACK CONSISTS OF 1 DISK.

Part: DISC PACK — CRACKED (T/R DRIVE)

AD 97-22-15, 25-HOUR TAIL BOOM INSPECTION FOUND CRACKED DISCS NR 2 TO NR 3, NR 1 DISC IN PACK CRACKED, NR 5 TO NR 6 LOCATION NR 10 DISC IN PACK CRACKED. SUBMITTER RECOMMENDED FLOATING DRIVESHAFTS SIMILAR TO THE BELL 206 SERIES.

Part: DISC PACK — CRACKED (T/R SHAFT)

ON 50-HOUR P.M.I., AND AD 97-22-15, FOUND NR 10 OF 10 DISC CRACKED IN 2 PLACES.

Part: DISC PACK — CRACKED (T/R SHAFT)

DURING 50-HOUR PMI AND MAINTENANCE NOTAM NR 51B-97, FOUND NR 1 DISC IN PACK ASSEMBLY OF 10 DISC TOTAL, CRACKED IN TWO PLACES.

Part: DAMPER ASSY — DETERIORATED (M/R)

DAILY INSPECTION FOUND FRAHM DAMPER ASSY RUBBER DETERIORATING AND STICKING OUT OF DAMPER.

Part: DISC PACK — CRACKED (T/R DRIVE SHAFT)

DAILY VISUAL INSPECTION OF TAILBOOM IAW NOTAM NR 51A-97, NR 5 TO NR 6 DISC PACK (T/R D/S) ASSEMBLY. ONLY ONE DISC FOUND CRACKED IN THE NR 10 POSITION OUT OF 10 DISCS. 57.8 HOURS TOTAL TIME ON DISC PACK FROM LAST CRACKED DISC.

Part: MAST NUT — LOOSE (T/R)

DAILY INSPECTION FOUND COMPLETE LOSS OF TORQUE ON T/R MAST NUT. THE NUT COULD BE REMOVED BY HAND. THE SAFETY WIRE BETWEEN THE NUT AND THE SUPPORT, (P/N 407-012-106-103) KEPT THE NUT FROM SPINNING OFF OF THE TAIL ROTOR GEARBOX OUTPUT SHAFT.

Part: SPRING PIN — BROKEN (TAIL SKID)

PIN WAS BEING REMOVED TO INSTALL AN AN4-15A BOLT IN ITS PLACE AS A PRECAUTION AFTER THE TAIL SKID OF ANOTHER 407 AIRCRAFT FELL OFF IN-FLIGHT. WHEN THE SPRING PIN WAS REMOVED, IT CAME APART IN TWO PIECES. SUBMITTER STATED INSTALL AN4 BOLT IN PLACE OF THE SPRING PIN.

Part: DISC — CRACKED (T/R DISC PACK)

SCHEDULED INSPECTION FOUND DISC CRACKED.

Part: DISC — CRACKED (T/R DRIVE)

DURING DAILY INSPECTION, FOUND T/R DRIVE DISC HAS CRACK STARTING ON INSIDE DIAMETER GOING TOWARDS OUTSIDE DIAMETER, NR 1 DISC (FIRST ON PACK).

Part: FRAHM ASSY — DETERIORATED (M/R HEAD)

LATERAL VIBRATION IN AIRCRAFT. FOUND ALL RUBBER PARTS DETERIORATED (ERASER TYPE WEAR) INSIDE FRAHM ASSEMBLY.

Part: DISC PAK — CRACKED (T/R DISC PAK)

SCHEDULED INSPECTION, T/R DRIVE DISC FOUND CRACKED AND SCRATCHED. REMOVED AND REPLACED.