N477AL

Part: UNIVERSAL — ROUGH (MAIN ROTOR) · airframe 8,132 hrs

UNIVERSAL BEARING WORN, RATCHETY, ROUGH AND BINDING. REMOVED AND REPLACED.

Part: UNIVERSAL — WORN (MAIN ROTOR) · airframe 7,997 hrs

EXCESSIVE AXIAL PLAY.

Part: BEARING — SPALLED (ACCESSORY G/B) · airframe 7,826 hrs

FOUND NR 4 BEARING SEPARATOR BROKEN IN PIECES. BEARING FAILURE CAUSED METAL IN OIL.

Part: BEARING — SPALLED (ACCESSORY G/B) · airframe 7,826 hrs

FOUND #3 BEARING SEPARATOR MISSING. BEARING FAILURE CAUSED METAL IN OIL.

Part: PINION GEAR — BROKEN (ENGINE G/B) · airframe 7,826 hrs

FOUND PINION GEARS HAD BROKEN GEAR TEETH CAUSING MASSIVE METAL IN OIL. THIS IS A REOCCURRING EVENT.

Part: FADEC — FAILED (HMU/ENGINE)

DURING FLIGHT, FIVE MILES FROM DESTINATION PLATFORM, ENGINE CHIP LIGHT ILLUMINATED, DURING FINAL APPROACH TO THE PLATFORM APPROXIMATELY 75 TO 100 FEET THE FADEC FAULT, FADEC MANUAL, FADEC FAIL, RESTART FAULT AND AUTO RELIGHT ILLUMINATED WITH FADEC FAIL AUDIO ACTIVATED - LANDING WAS COMPLETED TO THE PLATFORM WITH FADEC IN MANUAL MODE AND MAINTENANCE WAS NOTIFIED. UPON INSPECTION OF THE ENGINE, IT WAS DETERMINED THE ENGINE NEEDS TO BE REPLACED.

Part: CROSSTUBE — CORRODED (MLG)

DAILY SERVICE CHECK, FOUND PITTING CORROSION ON CROSSTUBE AT STRAP ATTACH POINT. PROBABLE CAUSE IS WATER ENTRAPMENT. SCRAP CROSSTUBE.

Part: CROSSTUBE — CORRODED (MLG)

DURING DAILY INSPECTION, FOUND PITTING CORROSION ON CROSSTUBE .2500 INCH DEEP .5000 INCH ROUND. SCRAPPED CROSSTUBE. PROBABLE CAUSE IS WATER ENTRAPMENT. ALMOST UNDETECTABLE WITH ALL PARTS INSTALLED.

Part: BEARING — SEPARATED (MAIN ROTOR HUB)

OFFSHORE PLATFORM BY PILOT. ELASTOMERIC SEPARATED FROM SPINDLE.

Part: DUCT — CRACKED (OIL COOLER)

UPON DAILY INSPECTION, CRACKS IN CORNERS CAUSED BY INHERENT VIBRATIONS. (X)

Part: PINION GEAR — GALLED (GEARBOX)

PINION GEAR HAS EXCESSIVE GALLING ON GEAR TEETH, POSSIBLY DUE TO EXCESSIVE TORQUE ON ENGINE, GEAR CANNOT SUSTAIN LOAD. (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: FRAME — CRACKED (FUSELAGE)

ROUTINE INSPECTION. FRAME AND ANGLE CRACKED BEYOND LIMITS.

Part: HOUSING — CRACKED (COOLER BLOWER)

DURING DAILY INPSECTION, FOUND CRACKED BLOWER HOUSING.

Part: HOUSING — CRACKED (TAIL ROTOR)

FOUND HOUSING 206-061-432-116 CRACKED AND WORKING RIVETS. FOUND 2 EACH BEARINGS 407-340-339-103 ROUGH.

Part: BEARING — ROUGH (TAIL ROTOR)

FOUND HOUSING 206-061-432-116 CRACKED AND WORKING RIVETS. FOUND 2 EACH BEARINGS 407-340-339-103 ROUGH.

Part: RELAY — FAILED (MLG)

DURING FIRST TURNING ON OF BATTERY IN MORNING, LANDING LIGHT UPPER WAS ON AND WOULD NOT TURN OFF BY SWITCH. THIS IS THE SECOND RELAY INSTALLED FOR THE UPPER LANDING LIGHT ON THIS AIRCRAFT. TOTAL TIME OF THE RELAY IS UNKNOWN, BUT IS ALSO A PROBLEM FOR OTHER 407'S OPERATED HERE.

Part: INPUT SHAFT — WORN (TRANSMISSION)

FREE WHEELING UNIT REMOVED FOR 2,500-HOUR OVERHAUL. FOUND AT TEAR-DOWN INSPECTION. INPUT SPLINES WORN BEYOND LIMITS. SHAFT SCRAPPED.

Part: GEAR — GALLED (GEARBOX)

DISASSEMBLED, CLEANED AND INSPECTED AND FOUND EXCESSIVE GALLING ON PINION AND T/M GEARS. PINION GEAR HAD EXCESSIVE GALLING ON GEAR TEETH POSSIBLY DUE TO IMPROPER MESHING OF T/M AND PINION GEARS. SECONDARY DAMAGE: T/M GEAR P/N 6893673 S/N NN145514, TT: 648.9 HOURS - GALLING ON GEAR TEETH.

Part: SEAL — FAILED (NR 5 BEARING)

ENGINE WAS REMOVED FOR MAKING METAL. REMOVED NR 5 BEARING AND FOUND METAL IN BEARING CAVITY. REMOVED NR 5 BEARING FOR INSPECTION AND FOUND METAL SLIVERS UNDER NR 5 BEARING NUT AND CAP LOCK WASHER.

Part: DISC — CRACKED (T/R)

SCHEDULED INSPECTION FOUND T/R DISC PACK CRACKED.

Part: PINION GEAR — GALLED (GEARBOX)

UPON DISASSEMBLY AND INSPECTION OF PARTS, FOUND EXCESSIVE GALLING ON PINION GEAR AND SPALLING ON T/M GEAR. PINION GEAR HAD EXCESSIVE GALLING ON GEAR TEETH. POSSIBLY DUE TO IMPROPER MESHING OF GEARS. SECONDARY DAMAGE. T/M GEAR PN 689367. SN NN144843, TT: 849.6 HOURS. SPALLING GEAR TEETH.

Part: ROTATING SEAL — MAKING METAL (NR 5)

ENGINE WAS REMOVED FOR MAKING METAL. REMOVED NR 5 BEARING AND FOUND METAL IN BEARING CAVITY. REMOVED NR 5 BEARING FOR INSPECTION AND FOUND METAL SLIVERS UNDER NR 5 BEARING NUT AND CAP LOCK WASHER.