N497AL

Part: PITCH LINK — LOOSE (TAIL ROTOR)

IN FLIGHT, TAIL ROTOR PRODUCED A VIBRATING NOISE. TIGHTEN T/R PC LINK CAP NUT ONE FLAT. INSPECTED SYSTEM AND CHECKED WITH VIBRATION GEAR. EVERYTHING CHECKED OK. ALL WORK IAW MM. (K)

Part: WIRE HARNESS — CHAFED (FUEL SYSTEM) · airframe 8,670 hrs

CHAFING AT AREAS WHERE CABLE COMES THROUGH TRANSFER TUBE. ADDED CHAFING PROTECTION TO CABLE ASSY OR ADELING IN ANOTHER MANNER.

Part: PITCH LINK — WORN (MAIN ROTOR) · airframe 8,272 hrs

EXCESSIVE BINDING AND AXIAL PLAY / REPLACED WITH NEW BY FIELD MAINTENANCE

Part: STUD — CRACKED (M/R HEAD) · airframe 4,958 hrs

FOUND 8 EA. STUDS CRACKED AT BASE OF THREAD SHANK IN RADIUS.

Part: INDICATOR — MALFUNCTIONED (TORQUE)

IN LEVEL FLIGHT CHECK INSTRUMENT LIGHT ILLUMINATED, TOOK POWER AWAY AND THE LIGHT WENT OUT. CHECK INSTRUMENT LIGHT ILLUMINATED AGAIN AND THE TORQUE GAUGE CYCLED FROM ZERO TO PEGGED OUT EXCEDANCE SHOWED 63 PERCENT OVER TORQUE. LOWERED TEMP TO 200 DEGREES BELOW NORMAL AND RETURNED TO INTRACOASTAL. MADE MINIMUM POWER LANDING. THE MECHANIC REPLACED TORQUE TRANSMITTER AND TORQUE INDICATORS. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: TRANSMITTER — FAILED (TORQUE)

IN LEVEL FLIGHT, CHECK INSTRUMENT LIGHT ILLUMINATED, I TOOK POWER AWAY AND THE LIGHT WENT OUT. CHECK INSTRUMENT LIGHT ILLUMINATED AGAIN AND THE TORQUE GAUGE CYCLED FROM ZERO TO PEGGED OUT. EXCEDANCE SHOWED 63 PERCENT OVER TORQUE. LOWERED TEMP TO 200 DEGREES BELOW NORMAL AND RETURNED TO INTRACOASTAL. MADE MINIMUM POWER LANDING. THE MECHANIC REPLACED TORQUE TRANSMITTER AND TORQUE INDICATORS. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: UNIVERSAL — WORN (MAIN ROTOR) · airframe 6,252 hrs

MAIN ROTOR UNIVERSAL ROUGH, WORN AND BINDING. BEARING ASSY. REPLACED BY FIELD MAINT.

Part: UNIVERSAL — STICKING (MAIN ROTOR) · airframe 5,919 hrs

UNIVERSAL STICKING, RATCHETY AND WORN. REMOVED AND REPLACED WITH SERVCIABLE PART. SUBMITTED BY: PRESTON BARZARE

Part: GEAR — SPALLED (GEARBOX) · airframe 5,732 hrs

GEARBOX WAS REMOVED FOR CORRODED STUDS, DURING INSPECTION FOUND SPALLING ON PINION GEAR TEETH.

Part: FLOOR SUPPORT — CRACKED (FUSELAGE)

DURING MAJOR INSPECTION, SEVERE CORROSION AT ALL MATING SURFACES AND ENDS OF ALL STIFFENING STRINGERS CRACKED. ALL MOUNTING FLANGES CRACKED AND CORRODED. USE PROSEAL AND PRIME THE PARTS AFTER ASSEMBLY, INSTALL DOUBLER AROUND WATER WASH FITTING TO PREVENT CRACKING.

Part: GEAR — SPALLED (GEARBOX)

GEARBOX WAS RECEIVED FOR CORRODED STUDS. UPON INITIAL VISUAL INSPECTION FOUND SPALLING PINION GEAR TEETH. EXCESSIVE SPALLING AND LIGHT GALLING ON GEAR TEETH DUE TO IMPROPER MESHING OF TM AND PINION GEARS. ASSURE PROPER MESHING OF GEAR TEETH AT FACTORY.

Part: BEARING — FAILED (GEARBOX)

UPON DISASSEMBLY OF GEARBOX DUE TO CHIP LIGHT. NR 4 BEARING FAILURE. TOOTH MISSING FROM GEAR ON PINION GEAR, AND DAMAGED GEAR TEETH ON T/M GEAR.

Part: BEARING — MISMARKED (ENGINE)

UPON VERIFICATION OF PN AND SN AFTER CHECKING OUT OF STOCK. INNER RACE AND ROLLER RETAINER BOTH HAVE 2 DIFFERENT SERIAL NUMBERS ETCHED ON THE PART. ASSURE THE PART NUMBER AND SERIAL NUMBER AT FACTORY.

Part: BEARING — WORN (MAIN ROTOR)

2500 HOUR INSPECTION, REPLACED ELASTOMER SEPARATOR. (M)

Part: BLADE — CRACKED (TAIL ROTOR)

DURING DAILY INSPECTION, BLADE CRACKED AT WEEP HOLE, ON THE INBOARD LEADING EDGE. CRACK EXTENDED AFT FOR ABOUT 1.25 INCHES. (X)

Part: STRUCTURE — CRACKED (TAIL BOOM) · airframe 3,271 hrs

DURING DAILY SERVICE CHECK AND AD 2000-06-10/ASB 407-99-29 REVISION A, FOUND CRACK IN TAILBOOM SKIN FROM UNDER THE HORIZONTAL STABILIZER SUPPORT TO THE FIRST RIVET ABOVE THE SUPPORT. LOCATION LEFT AFT OF THE HORIZONTAL STABILIZER AT THE FORMER BOOM STA 120.75. (X)

Part: BEARING — DAMAGED (MAIN ROTOR HUB)

DURING DAILY SERVICE CHECK, FOUND ELASTOMERIC SEPARATED FROM SPINDLE. (X)

Part: HOUSING — CRACKED (COOLER BLOWER)

DURING DAILY INSPECTION, FOUND CRACKED BLOWER HOUSING.

Part: CROSSTUBE — CORRODED (MLG SKID)

THE CROSSTUBE WAS REMOVED FROM SERVICE DUE TO AN INDICATION OF CORROSION IN THE AREA OF CROSS TUBE TO SKIDTUBE JUNCTURE. FURTHER INVESTIGATION REVEALED EXCESSIVE CORROSION UNDER THE SADDLES. THIS OPERATOR VIEWS THIS AS INADEQUATE MANUFACTURING AND REQUESTS SPECIAL WARRANTY CONSIDERATION. ITEM WAS REPLACED WITH NEW.

Part: SKIN — CRACKED (TAILBOOM)

DURING DAILY INSPECTION PER BELL ASB 407-99-26, FOUND CRACK IN SKIN AT LEFT FORWARD HORIZONTAL STABILIZER UPPER MOUNT. CRACK STARTS FROM UNDER RIVETED MOUNT AND EXTENDED TO FIRST RIVET.

Part: SUPPORT — MISINSTALLED (TAILBOOM)

SUPPORT MISINSTALLED.

Part: SUPPORT — CRACKED (TAILBOOM)

DAILY INSPECTION, FOUND APPROXIMATELY .8750 INCH CRACK IN RADIUS. OEM PART DOES NOT FIT PROPERLY CAUSING UNDO STRESS.

Part: ANGLE — CRACKED (HORIZ STABILIZER)

DURING DAILY INSPECTION FOUND CRACK IN BEND RADIUS.

Part: SUPPORT — CRACKED (HORIZONTAL STAB)

DURING DAILY INSPECTION, FOUND LEFT SLAT SUPPORT, SECOND FROM INBD, CRACKED. UPON FURTHER INSPECTION, FOUND SLAT POSITIONS SWAPPED ON AIRCRAFT (LEFT INSTALLED ON RIGHT SIDE AND VICE VERSA). SWAPPED SLAT POSITIONS AND REMOVED AND REPLACED CRACKED SLAT SUPPORT P/N 206-023-119-109, SECOND FROM INBD ON RIGHT SIDE.

Part: PITCH HORN — CORRODED (MAIN ROTOR)

DISSIMILAR METAL CAUSED CORROSION UNDER BUMPER PLATE AND DOWEL PIN HOLES.

Part: PITCH HORN — CORRODED (MAIN ROTOR)

DISSIMILAR METAL CAUSED CORROSION UNDER BUMPER PLATE AND DOWEL PIN HOLES.

Part: PITCH HORN — CORRODED (MAIN ROTOR)

DISSIMILAR METAL CAUSED CORROSION UNDER BUMPER PLATE AND DOWEL PIN HOLES.

Part: PITCH HORN — CORRODED (MAIN ROTOR)

DISSIMILAR METAL CAUSED CORROSION UNDER BUMPER PLATE AND DOWEL PIN HOLES.