N457AL

Part: VALVE — SEIZED (MLG FLOATS) · airframe 12,806 hrs

DURING 3 YR FLOAT SYS FUNCTION CHECK, PULL CABLE WAS ACTUATED AND PLUNGER CAME COMPLETELY OUT OF FLOAT VALVE BUT VALVE FAILED TO OPEN CAUSING TEST TO FAIL. MX REPLACED FLOAT BOTTLE.

Part: BEARING — UNSECURE (ANTI-DRIVE LINK) · airframe 12,112 hrs

DURING DAILY SERVICE CHECK, MECHANIC NOTICED THAT THE ANTI-DRIVE LINK UPPER BEARING HAD UNSEATED.

Part: CONNECTOR — DIRTY (XMSN PRESSURE)

IN FLIGHT, TRANSMISSION PRESSURE INDICATOR OSCILLATING BETWEEN 0-120 PSI. CLEANED CONNECTOR PLUG ON TRANSMISSION TRANSMITTER. GROUND OPERATIONAL CHECK GOOD. (K)

Part: UNIVERSAL — WORN (M/R DRIVE) · airframe 7,217 hrs

UNIVERSAL HAS AXIAL PLAY BEYOND LIMITS. REPLACED WITH NEW BY FIELD MAINTENANCE.

Part: UNIVERSAL — WORN (M/R DRIVE) · airframe 7,217 hrs

UNIVERSAL BEARING HAS AXIAL PLAY BEYOND LIMITS. REPLACED WITH NEW BY FIELD MAINTENANCE.

Part: PRESSURE SWITCH — INOPERATIVE (TRANSMISSION)

DURING BEFORE TAKEOFF CHECK, THE TRANSMISSION OIL PRESSURE LIGHT CAME ON, BUT THE GAUGE WAS READING AT A NORMAL LEVEL. LANDED AND CALLED MAINTENANCE, SHUTDOWN AND CHECK THE MEL BOOK AND THE CONNECTOR PLUGS. MAINTENANCE FLYING PART OUT. MAINTENANCE REMOVED TRANSMISSION PRESSURE SWITCH AND INSTALLED SERVICEABLE PRESSURE SWITCH IAW MM. (K)

Part: PITCH LINK — BINDING (MAIN ROTOR) · airframe 7,181 hrs

EXCESSIVE AXIAL PLAY AND BINDING. REPLACED W/NEW BY FIELD MAINTENANCE.

Part: UNIVERSAL — RATCHETING (MAIN ROTOR) · airframe 5,314 hrs

FOUND EXCESS AXIAL PLAY AND RATCHETY. UNIT REPLACED WITH NEW BY FIELD MAINT.

Part: DISC PACK — CRACKED (TAIL ROTOR) · airframe 6,204 hrs

FOUND DISC CRACKED. REMOVED AND REPLACED.

Part: CHIP DETECTOR — MALFUNCTIONED (TRANSMISSION)

DURING LANDING, TRANSMISSION LIGHT ILLUMINATED AS AIRCRAFT WAS LANDING ON EC 195, CHECKED CHIP PLUGS, FOUND NORMAL FUZZ C/W 30 MINUTE GROUND RUN, LEAK CHECKED GOOD. AIRCRAFT WAS RETURNED TO SERVICE.

Part: BEARING — SEPARATED (M/R HUB ASSY) · airframe 6,326 hrs

FOUND TOTAL SEPARATION OF ELASTROMER. REPLACED SHEAR BEARING.

Part: UNIVERSAL — DEFECTIVE (MAIN ROTOR) · airframe 5,940 hrs

UNIVERSAL STICKING, RATCHETY AND WORN. REPLACED WITH A SERVICABLE PART.

Part: WARNING LIGHT — ILLUMINATED (FUEL TRANSFER)

IN FLIGHT, FUEL TRANSFER LIGHT ILLUMINATED IN FLIGHT, FLIGHT WAS DIVERTED TO WD 70 AND DISCOVERED FUEL OF 148 LBS. THE PILOT CALLED HOUMA AND 35 GALLONS OF FUEL WAS FLOWN TO THE AIRCRAFT.

Part: HOSE — CRACKED (HYD SYSTEM)

HYDRAULIC SYSTEM, DEFECT FOUND DURING UNSCHEDULED MAINTENANCE. SOCKET CRACKED.

Part: FRAME — CRACKED (TAILBOOM)

ROUTINE INSPECTION, UPPER SECTION OF FRAME CRACKED ABOVE RIGHT ATTACHMENT CASTING. PROBABLE CAUSE: RIGHT UPPER SHIM ON TAILBOOM (407-030-810-119) NOT BURNISHED AT EDGES.

Part: COUPLER — CRACKED (TAIL ROTOR)

DAILY 25 HOUR INSPECTION FOUND NR 7 DISC PACK COUPLING CRACKED.

Part: BEARING — DISINTEGRATED (TAIL ROTOR)

AFTER 2 HOURS OF FLIGHT AIRCRAFT EXPERIENCED INTERMITTENT MEDIUM FREQUENCY VIBRATION SUBSEQUENT INSPECTION REVEALED THE BEARING FAILURE OF NR 2 TAILROTOR DRIVESHAFT. FORWARD BEARING ON SHAFT DISINTEGRATED DUE TO LOSS OF GREASE. BEARING SCRAPPED AND C/W ASB 407-01-44. (M)

Part: ADAPTER — WORN (SPLINE)

DURING PHASE 1 INSPECTION, SECTION II ITEM 2 CLEANING SPLINES ON BLOWER SHAFT AND ADAPTER. SPLINES HAVE SLIGHT STEP WORN INTO THEM AT FLANGED END OF ADAPTER. THIS SMALL STEP PREVENTS ADAPTER FROM SLIDING FREELY ON BLOWER SHAFT SPLINES WHEN SUBJECT TO TORSIONAL LOAD OF DRIVESHAFT TURNING.

Part: DISC PACK — CRACKED (T/R DRIVE)

DURING DAILY/50-HOUR INSPECTION, FOUND NR 3 DISC PACK AFT DISC CRACKED AT 4 LOCATIONS.

Part: BEARING — DEBONDED (M/R HUB)

MAIN ROTOR HUB REMOVED FOR BEARING SEPARATION. BEARING COMPLETELY DEBONDED AT 9TH CONE FROM FLANGE.

Part: GEAR — GALLED (GEARBOX)

ENGINE REMOVED FOR EXCESSIVE METAL ON BOTH PLUGS. DISASSEMBLED AND FOUND T/M GEAR TO PINION GEAR GALLING CAUSING METAL CONTAMINATION. SUBMITTER STATES IMPROPER MESHING BETWEEN T/M GEAR AND PINION GEAR WAS CAUSE FOR GALLING. SECONDARY DAMAGE - PINION GEAR P/N 6893672 S/N NN76130, TT: 1,834.7 HOURS.

Part: INSERT — LOOSE (GEARBOX)

UPON VISUAL INSPECTION OF ALL PARTS, FOUND 1 EACH INSERT PULLED OUT AND 2 EACH INSERTS LOOSE AT EXCITER BOX MATING SURFACE ON GEARBOX HOUSING. ONE EACH INSERT P/N NAS1394-3L PULLED OUT AND 2 EACH INSERTS LOOSE. POSSIBLY CAUSED BY EXCESSIVE CLEARANCE BETWEEN EXCITER BOX AND GEARBOX CAUSING BOX TO GET HUNG UP OR HIT ON ENGINE REMOVAL.

Part: BLADE — CRACKED (T/R)

POST-FLIGHT FOUND TAILROTOR BLADE CRACKED AT INBOARD RADIUS INSIDE TOWARD LEADING EDGE. POSSIBLY STARTED AT CORROSION SPOT.