N687AL

Part: CROSSTUBE — CORRODED (MLG) · airframe 15,597 hrs

CROSS TUBE CORRDED BEYOND LIMITS IAW AA00061 PAGE 19, FIG 2, TABLE 8.

Part: MOUNT — CORRODED (TRANSMISSION) · corrosion level 3 · airframe 15,500 hrs · 67,803 cycles

TRANSMISSION DECK, TRANSMISSION PYLON MOUNT POINT CORRISION, RT FWD

Part: MOUNT — CORRODED (TRANSMISSION) · corrosion level 3 · airframe 15,500 hrs · 67,803 cycles

TRANSMISSION DECK. TRANSMISSION PYLON MOUNT POINT CORRODED.

Part: PITCH LINK — WORN (MAIN ROTOR) · airframe 6,449 hrs

BINDING; AXIAL PLAY BEYOND LIMITS; ROUGH / REPLACED WITH NEW PART BY FIELD MAINT.

Part: BEARING — ROUGH (MAIN ROTOR) · airframe 6,252 hrs

ROUGH, BINDING AND AXIAL PLAY, REPLACED W/NEW.

Part: BEARING — ROUGH (MAIN ROTOR) · airframe 6,252 hrs

ROUGH, BINDING AND AXIAL PLAY, REPLACED W/NEW.

Part: BEARING — ROUGH (MAIN ROTOR) · airframe 6,252 hrs

ROUGH, BINDING AND AXIAL PLAY, REPLACED W/NEW.

Part: BEARING — ROUGH (MAIN ROTOR) · airframe 6,252 hrs

ROUGH, BINDING AND AXIAL PLAY, REPLACED W/NEW.

Part: BEARING — FAILED (TRANSMISSION) · airframe 4,983 hrs

TAIL ROTOR TRANSMISSION REMOVED FOR METAL IN OIL, FOUND BEARING BREAKING DOWN. SUBMITTED BY: PRESTON BARZARE

Part: HMU — LEAKING (ENGINE)

DURING REFUELING. AFTER A/C WAS REFUELED OFFSHORE AT WC-560. THE MECHANIC NOTICED A STEADY FLOW OF FUEL FROM THE OVERFLOW DRAIN LINE. HE INSPECTED THE LEAK AND FOUND THE HMU LEAKING. HE REMOVED AND REPLACED THE HMU AND COMPLIED WITH A LEAK CHECK AND AIRCRAFT WAS RETURNED TO SERVICE.

Part: SHAFT — LOOSE (T/M GEAR BEARING) · airframe 3,933 hrs

FOUND T/M GEAR, BEARING JOURNAL SHAFT AND SUPPORT LOOSE IN COVER ASSEMBLY. FOUND ALL 4 STUDS ON JOURNAL SUPPORT PULLED OUT AND 1 EACH WITH NO THREADS LEFT IN WORN BORE. THIS ALLOWED GEAR TO WEAR IN AN UNUSUAL MANNER, WHICH COULD HAVE RESULTED IN A CATASTROPHIC GEAR FAILURE.

Part: GEARSHAFT — GALLED (TORQUE METER) · airframe 3,933 hrs

DUE TO T/M JOURNAL SUPPORT STUDS BACKING OUT OF COVER AN UNUSUAL WEAR PATTERN OF SPALLING AND GALLING OCCURRED ON GEAR TEETH.

Part: COVER — WORN (GEARBOX)

ENGINE HAD CHIP LIGHTS. UPON DISASSEMBLY OF GEARBOX FOUND T/M JOURNAL SUPPORT STUDS BACKED OUT OF COVER. FOUND T/M GEAR, BEARING JOURNAL SHAFT AND SUPPORT LOOSE IN COVER ASSEMBLY. FOUND ALL 4 STUDS ON JOURNAL SUPPORT PULLED OUT AND 1 EACH WITH NO THREADS LEFT IN WORN BORE. THIS ALLOWED GEAR TO WEAR IN AN UNUSUAL MANNER, WHICH COULD HAVE RESULTED IN A CATASTROPHIC GEAR FAILURE. ASSURE GEARBOX AND ASSOCIATED ENGINE PARTS CAN WITHSTAND HIGH TORQUE. INSTALLED INSERTS AT ALL STUD AREAS INSIDE COVER ASSEMBLY.

Part: GEAR — GALLED (ENGINE)

ENGINE WAS REMOVED DUE TO CHIP LIGHTS. UPON VISUAL INSPECTION FOUND CAUSE OF METAL DUE TO GALLING T/M AND PTO GEARS. DUE TO T/M JOURNAL SUPPORT STUDS BACKING OUT OF COVER AN UNUSUAL WEAR PATTERN OF SPALLING AND GALLING OCCURRED ON GEAR TEETH. THIS COULD HAVE CAUSED A CATASTROPHIC GEAR FAILURE. ASSURE PROPER INSERTS IN THIS AREA, ALONG WITH PROPER MACHINING AND MESHING OF GEAR TEETH.

Part: SHAFT — WORN (T/R GEARBOX)

DURING REPAIR FOR LEAKING OUTPUT SEAL, FOUND SPLINES ON OUTPUT SHAFT WORN BELOW LIMITS, READING 1.3025, MIN 1.3035 (SHAFT SPLINES SOFTER METAL THAN TRUNNION SPLINES.)

Part: PITCH HORN — CORRODED (TAIL ROTOR)

AFTER DISASSEMBLY, CLEANING AND STRIPPING PAINT FOR OVERHAUL. CORROSION ON ENTIRE SURFACE BEYOND LIMITS DUE TO POOR METAL QUALITY AND POOR PRIME AND PAINT. BETTER QUALITY ALUMINUM AND PAINTING PROCEDURES RECOMMENDED.

Part: TURBINE WHEEL — CORRODED (TURBINE)

TURBINE RECEIVED FROM FIELD FOR HOWLING NOISE. REMOVED COMBUSTION SECTION AND FOUND SULFADATION ON 1ST STAGE WHEEL. THIS TURBINE HAD A ROLLS ROYCE COMBUSTION LINER. WHEEL HAS MISSING AND BROKEN BLADES DUE TO SULFADATION. (M)

Part: BLADE — MISSING (ENGINE)

TURBINE RECEIVED FROM FIELD FOR HOWLING NOISE. REMOVED COMBUSTION SECTION AND FOUND SULFADATION ON 1ST STAGE WHEEL. WHEEL HAS MISSING AND BROKEN BLADES DUE TO SULPHADATION. (M)

Part: DRIVE SHAFT — FAILED (TRANSMISSION)

IN-FLIGHT, PILOT HEARD A LOUD POP. LANDED AT THE NEAREST PLATFORM AND AFTER SHUT DOWN, FOUND FORWARD FLEXURE ON INPUT DRIVESHAFT HAD FAILED. ONE OF THE FORWARD FLEXURES FAILED AT THE BOLT HOLE AND A PORTION OF THE FLEXURE WENT THROUGH THE TRANSMISSION DECK/CABIN ROOF. (X)

Part: DISC PACK — CRACKED (TAIL ROTOR)

DURING 25-HOUR AD INSPECTION, FOUND AFT SEGMENT CRACKED ACROSS THE SPAN. (X)

Part: DISC PACK — CRACKED (TAIL ROTOR) · airframe 1,368 hrs

DURING 25-HOUR AD INSPECTION, FOUND AFT SEGMENT CRACKED IN 3 PLACES ACROSS THE SPAN. (X)

Part: BEARING — CRACKED (T/R DRIVESHAFT) · airframe 1,260 hrs

DURING REPAIR/REPLACEMENT OF CRACKED HOUSING, BEARINGS ROUGH. (X)

Part: BEARING — CRACKED (T/R DRIVESHAFT)

DURING REPAIR/REPLACEMENT OF CRACKED HOUSING, BEARINGS ROUGH. (X)

Part: GEAR — BROKEN (GEARBOX)

CHIP LIGHT WAS DETECTED ON AIRCRAFT. CHIP DETECTORS WERE PULLED AND INSPECTED. LARGE PIECE OF GEAR TOOTH WAS FOUND ON PLUG. LARGE PIECE OF GEAR TOOTH BROKE OFF DURING FLIGHT. CAUSE FOR BROKEN GEAR TOOTH WAS DUE TO EXCESSIVE GALLING EXTENDING UP TO FORWARD END OF SMALL GEAR TEETH. (X)

Part: BEARING — DAMAGED (T/R DRIVE SHAFT)

DURING RECURRING 25-HOUR INSPECTION AND BEARING LUBRICATION (PER ASB 407-00-35/AD 2000-02-12), ACCUMULATED GREASE EXPELLED FROM AROUND THE SEAL IS BLACK DETERMINING BEARING IS DAMAGED. (X)

Part: BEARING — LEAKING (T/R DRIVE SHAFT)

DURING RECURRING 25-HOUR INSPECTION AND BEARING LUBRICATION (PER ASB 407-00-35/AD 2000-02-12), ACCUMULATED GREASE EXPELLED FROM AROUND THE SEAL IS BLACK DETERMINING BEARING IS DAMAGED. (X)

Part: BEARING — DAMAGED (SHAFT HANGER)

DURING RECURRING 25-HOUR INSPECTION AND BEARING LUBRICATION (PER ASB 407-00-35/AD 2000-02-01), DURING LUBRICATION, ACCUMULATED GREASE EXPELLED FROM AROUND THE SEAL IS BLACK DETERMINING BEARING IS DAMAGED. (X)

Part: BEARING — LEAKING (SHAFT HANGER)

DURING RECURRING 25-HOUR INSPECTION AND BEARING LUBRICATION (PER ASB 407-00-35/AD 2000-02-12), DURING LUBRICATION, ACCUMULATED GREASE EXPELLED FROM AROUND THE SEAL IS BLACK DETERMINING BEARING IS DAMAGED. (X)

Part: BEARING — DAMAGED (SHAFT HANGER)

RECURRING 25-HOUR INSPECTION AND BEARING LUBRICATION (PER ASB 407-00-35 AND AD 2000-02-01), FOUND ACCUMULATED GREASE EXPELLED FROM AROUND THE SEAL IS BLACK DETERMINING BEARING IS DAMAGED. (X)

Part: HOUSING — CRACKED (COOLER BLOWER)

DURING DAILY INSPECTION, FOUND CRACKED BLOWER HOUSING.