(a) EFFECTIVE DATE
This airworthiness directive (AD) is effective November 8, 2024.
(b) AFFECTED ADS
None.
(c) APPLICABILITY
This AD applies to Bell Textron Inc. Model 204B, 205A, 205A-1, 205B,
and 210 helicopters, certificated in any category.
(d) SUBJECT
Joint Aircraft System Component (JASC) 5302, Rotorcraft Tail Boom.
(e) UNSAFE CONDITION
This AD was prompted by an accident and incidents involving failure of
the tail boom attachment structure. The FAA is issuing this AD to
address fatigue cracking of tail boom attachment fittings, cap angles,
longerons, and bolts. The unsafe condition, if not addressed, could
result in separation of the tail boom from the helicopter and
subsequent loss of control of the helicopter.
(f) COMPLIANCE
Comply with this AD within the compliance times specified, unless
already done.
(g) ALLOWABLE TORQUE VALUES (IN-LBS)
______________________________________________________________________
TAIL BOOM MODEL
ATTACHMENT POINT MODEL 204B 205A/205A-1 MODEL 205B MODEL 210
______________________________________________________________________
Upper left-hand bolt 570-610 1000-1200 1000-1200 1300-1600
Upper right-hand bolt 360-380 1000-1200 1000-1200 1000-1200
Lower left-hand bolt 360-380 400-430 400-430 400-430
Lower right-hand bolt 360-380 400-430 400-430 400-430
______________________________________________________________________
(h) REQUIRED ACTIONS
(1) Within 300 hours time-in-service (TIS) or 90 days after the effective
date of this AD, whichever occurs first, accomplish the actions
required by paragraphs (h)(1)(i), (ii), or (iii) of this AD as
applicable to your model helicopter. For purposes of this AD, the word
"new" is defined as having zero total hours TIS.
(i) For Model 204B helicopters, accomplish the actions required by para-
graphs (h)(1)(i)(A) through (C) of this AD.
(A) With the tail boom assembly removed, remove the upper left- hand (LH)
tail boom attachment bolt (bolt) from service and inspect its
associated tail boom attachment nut (nut) for mechanical damage,
corrosion, a crack, damaged threads, and wear, and to determine
whether it is a steel alloy part number (P/N) NAS679A, NAS1291, or
MS21042. If there is any mechanical damage, corrosion, a crack, a
damaged thread, or wear, or if nut P/N NAS679A, NAS1291, or MS21042 is
installed, before further flight, remove the nut from service.
(B) Visually inspect each bulkhead (FS 195.00 and FS 195.03) and the bolt
holes for mechanical damage, corrosion, and cracks; visually inspect
each attachment fitting for mechanical damage, corrosion, cracks, and
loose fasteners; determine if any of the three other nuts are a steel
alloy P/N NAS679A, NAS1291, or MS21042; and visually inspect the other
three nuts, the upper right-hand (RH) bolt, and two lower bolts for
mechanical damage, corrosion, cracks, damaged threads, and wear,
including the bolt shank and head radii of the bolts for a damaged
thread, wear, and mechanical damage.
(1) If there is any mechanical damage, corrosion, or cracks on any bulk-
head (FS 195.00 or FS 195.03), or any mechanical damage, corrosion, or
cracks on any bolt holes, or if there is any mechanical damage,
corrosion, cracks, or loose fasteners on any attachment fitting,
before further flight, repair or replace the affected bulkhead or the
affected attachment fitting, as appropriate, in accordance with FAA
-approved procedures.
(2) If there is any mechanical damage, corrosion, a crack, a damaged
thread, or wear on any nut, or if nut P/N NAS679A, NAS1291, or MS21042
is installed, before further flight, remove the affected nut from
service. If there is a crack on any nut, before further flight, also
remove its associated bolt from service.
(3) If there is any mechanical damage, corrosion, a crack, a damaged
thread, or wear on the on the upper RH bolt or two lower bolts, which
includes the bolt shank or head radii, before further flight, remove
the affected bolt from service.
(C) Apply a coating of Aeriol ThixO #2 (3810-0) or Aeriol ThixO SYN (3820
-0) aviation grease to each bolt shank only. Install the hardware set
of each tail boom attachment point (nickel alloy nut P/ N 90-132L7 or
90-132L6, as applicable to the affected tail boom attachment point,
new upper LH bolt P/N NAS627-21, upper RH and two lower bolts P/N
NAS626-20, countersunk washer, and plain washers). Torque each bolt by
using the torque value information identified in paragraph (g) of this
AD.
(ii) For Model 205A, 205A-1, and 205B helicopters, accomplish the actions
required by paragraphs (h)(1)(ii)(A) through (C) of this AD.
(A) With the tail boom assembly removed, remove the upper LH bolt from
service and inspect its associated tail boom attachment barrel nut
(barrel nut) and retainer for mechanical damage, corrosion, a crack,
damaged threads, and wear, and to determine whether it is a steel
alloy barrel nut P/N NAS577B8A. If there is any mechanical damage,
corrosion, a crack, a damaged thread, or wear, or if barrel nut P/N
NAS577B8A is installed, before further flight, remove the barrel nut
and its associated retainer from service.
(B) Visually inspect each bulkhead (BS 17.31 and FS 243.89) and the bolt
holes for mechanical damage, corrosion, and cracks; visually inspect
each attachment fitting for mechanical damage, corrosion, cracks, and
loose fasteners; determine if any of the three other barrel nuts are
steel alloy P/N NAS577B8A or P/N NAS577B6A; and visually inspect the
other three barrel nuts and the associated retainers, the upper RH
bolt, and two lower bolts for mechanical damage, corrosion, cracks,
damaged threads, and wear, including the bolt shank and head radii of
the bolts for a damaged thread, wear, and mechanical damage.
(1) If there is any mechanical damage, corrosion, or cracks on any bulk-
head (BS 17.31 or FS 243.89), or any mechanical damage, corrosion, or
cracks on any bolt holes, or if there is any mechanical damage,
corrosion, cracks, or loose fasteners on any attachment fitting,
before further flight, repair or replace the affected bulkhead or the
affected attachment fitting, as appropriate, in accordance with FAA
-approved procedures.
(2) If there is any mechanical damage, corrosion, a crack, a damaged
thread, or wear on any barrel nut or retainer, or if barrel nut P/N
NAS577B8A or NAS577B6A is installed, before further flight, remove the
affected barrel nut and retainer (as a pair) from service. If there is
a crack on any nut, before further flight, also remove its associated
bolt from service.
(3) If there is any mechanical damage, corrosion, a crack, a damaged
thread, or wear on the upper RH bolt or two lower bolts, which
includes the bolt shank or head radii, before further flight, remove
the affected bolt from service.
(C) Apply a coating of Aeriol ThixO #2 (3810-0) or Aeriol ThixO SYN (3820
-0) aviation grease to each bolt shank only. Install the hardware set
of each tail boom attachment point (nickel alloy barrel nut P/N
NAS577C6A or P/N NAS577C8A and retainer P/N NAS578C6A or P/N
NAS578C8A, as applicable to the affected tail boom attachment point,
new upper LH bolt P/N NAS628-22, upper RH and two lower bolts P/N
NAS628-22 or NAS626-18, as applicable to the affected tail boom
attachment point, countersunk washer, and plain washers). Torque each
bolt by using the torque value information identified in paragraph (g)
of this AD.
(iii) For Model 210 helicopters, accomplish the actions required by para-
graphs (h)(1)(iii)(A) through (C) of this AD.
(A) With the tail boom supported, remove the upper LH bolt, and the steel
alloy barrel nut P/N NAS577B9A, including the retainer, from service.
Remove the countersunk washer, and plain washers, and install new
nickel alloy barrel nut P/N NAS577C9A, new retainer P/N NAS578C9A,
airworthy countersunk washer, airworthy plain washers, and a new bolt
in accordance with the Accomplishment Instructions, Part I, paragraphs
5 through 7 of Bell Alert Service Bulletin (ASB) 210-21-15, Revision
A, dated February 23, 2022 (ASB 210-21-15, Rev A).
(B) Remove the upper RH bolt, steel alloy barrel nut P/N NAS577B8A,
countersunk washer, and plain washers. Visually inspect the upper RH
bolt for any corrosion, damaged threads, wear, and fatigue cracking.
If the upper RH bolt has any corrosion, damaged threads, wear, or
fatigue cracking, before further flight, remove the upper RH bolt from
service. Visually inspect the removed barrel nut for cracking. If
there is any cracking in the barrel nut, before further flight, remove
the upper RH bolt from service. Regardless of the result of the upper
RH steel alloy barrel nut inspection, replace the barrel nut with a
new nickel alloy barrel nut P/N NAS577C8A and new retainer P/N
NAS578C8A. Install a new upper RH bolt or reinstall the existing upper
RH bolt (if no cracks in the barrel nut, and no corrosion, damaged
threads, wear, or fatigue cracking in the bolt were identified), by
following the Accomplishment Instructions, part I, paragraphs 11 and
12, including the caution above paragraph 11, of ASB 210-21-15, Rev A.
(C) Remove one of the lower bolts, its lower steel alloy barrel nut P/N
NAS577B6A, countersunk washer, and plain washers. Visually inspect
that lower bolt for any corrosion, damaged threads, wear, and fatigue
cracking. If the lower bolt has any corrosion, damaged threads, wear,
or fatigue cracking, before further flight, remove the lower bolt from
service. Visually inspect the removed lower barrel nut for cracking.
If there is any cracking in the lower barrel nut, before further
flight, remove the lower bolt from service. Regardless of the result
of that lower steel alloy barrel nut inspection, replace the barrel
nut with a new nickel alloy barrel nut P/N NAS577C6A and new retainer
P/N NAS578C6A. Install a new lower bolt or reinstall the existing
lower bolt (if no cracks in the barrel nut, and no corrosion, damaged
threads, wear, or fatigue cracking in the bolt were identified), by
following the Accomplishment Instructions, part I, paragraphs 16
through 17, including the caution above paragraph 16, of ASB 210-21
-15, Rev A. Repeat the actions required by this paragraph for the
other lower attachment point.
(2) After accumulating 1 hour TIS, but not to exceed 5 hours TIS, after
accomplishing the actions required by paragraph (h)(1) of this AD,
using the torque value information identified in paragraph (g) of this
AD applicable to your model helicopter, inspect the torque applied on
each bolt. Thereafter, repeat the torque inspection of each bolt after
accumulating 1 hour TIS, but not to exceed 5 hours TIS, to determine
if the torque has stabilized. Do not exceed three torque inspections
total for each bolt and accomplish the actions required by paragraphs
(h)(2)(i) and (ii) of this AD.
(i) If the torque on a bolt is below the minimum allowable torque limit as
a result of any instance of the torque inspection or if after three
torque inspection attempts, the torque on any bolt has not stabilized,
before further flight, accomplish the actions required by paragraphs
(h)(2)(i)(A) and (B) of this AD.
(A) Remove the hardware set of one failed tail boom attachment point (nut,
bolt, countersunk washer, and plain washers for Model 204B
helicopters, and barrel nut, bolt, retainer, countersunk washer, and
plain washers for Model 205A, 205A-1, 205B, and 210 helicopters). For
Model 204B helicopters, remove the nut from service and for Model
205A, 205A-1, 205B, and 210 helicopters, remove the barrel nut and
retainer from service as applicable to the affected tail boom
attachment point. Visually inspect the removed bolt for any corrosion,
damaged threads, wear, and fatigue cracking. If the bolt has any
corrosion, a damaged thread, wear, or fatigue cracking, before further
flight, remove the bolt from service.
(B) Apply a coating of Aeriol ThixO #2 (3810-0) or Aeriol ThixO SYN (3820
-0) aviation grease to the bolt shank only. Install a new bolt or
reinstall the existing bolt (if no corrosion, damaged threads, wear,
or fatigue cracking in the bolt were identified) and the hardware set
of the affected tail boom attachment point (new nut P/N 90-132L6 or
90-132L7, countersunk washer, and plain washers for Model 204B
helicopters, and new nickel alloy barrel nut P/N NAS577C6A, NAS577C8A
or P/N NAS577C9A and new retainer P/N NAS578C6A, NAS578C8A, or P/N
NAS577C9A, countersunk washer, and plain washers for Model 205A, 205A
-1, 205B, and 210 helicopters), as applicable to the affected tail
boom attachment point. Torque the bolt by using the torque value
information identified in paragraph (g) of this AD. Repeat the actions
required by paragraphs (h)(2)(i)(A) and (B) of this AD for each failed
tail boom attachment point, one hardware set at a time. Then repeat
the actions required by paragraph (h)(2) of this AD just for each
newly installed or reinstalled bolt until the torque for all four tail
boom attachment points stabilize.
(ii) If the torque for all four tail boom attachment points has
stabilized, before further flight, apply a torque stripe to all four
bolts.
(3) Within 600 hours TIS or 12 months, whichever occurs first after
applying torque stripes to all four bolts as required by paragraph
(h)(2)(ii) of this AD, and thereafter within intervals not to exceed
600 hours TIS or 12 months, whichever occurs first, inspect the torque
applied on each bolt using the torque value information identified in
paragraph (g) of this AD, as applicable to your model helicopter. If
the torque on any bolt is below the minimum allowable torque limit,
accomplish the actions required by paragraphs (h)(3)(i) and (ii) of
this AD.
(i) Before further flight, remove the hardware set of one failed tail boom
attachment point (nut, bolt, countersunk washer, and plain washers for
Model 204B helicopters, and barrel nut, retainer, bolt, countersunk
washer, and plain washers for Model 205A, 205A-1, 205B, and 210
helicopters) and then accomplish the actions required by paragraphs
(h)(3)(i)(A), (B), or (C) of this AD as applicable to your model
helicopter.
(A) For Model 204B helicopters, visually inspect the removed nut for
cracking, corrosion, and loss of tare torque. If the nut has any
cracking, corrosion, or loss of tare toque, before further flight,
remove the nut from service and replace with a new nut P/N 90-132L7 or
90-132L6 as applicable to the tail boom attachment point. Regardless
of the result of the nut inspection, remove the bolt from service and
replace it with a new bolt by applying a coating of Aeriol ThixO #2
(3810-0) or Aeriol ThixO SYN (3820-0) aviation grease to the bolt
shank only, and install the hardware set of the tail boom attachment
point (nut, bolt, and countersunk washer, and plain washers). Torque
each bolt by using the torque value information identified in
paragraph (g) of this AD. Repeat the actions required by this
paragraph for each failed tail boom attachment point, one hardware set
at a time.
(B) For Model 205A, 205A-1, and 205B helicopters, visually inspect the
removed barrel nut for cracking, corrosion, and loss of tare torque.
If the barrel nut has any cracking, corrosion, or loss of tare toque,
before further flight, remove the barrel nut and retainer from service
and replace them with a new nickel alloy barrel nut P/N NAS577C6A, or
NAS577C8A, and new retainer P/N NAS578C6A, or NAS578C8A, with the P/N
of the new nickel alloy barrel nut and the P/N of the new retainer
being as applicable to the affected tail boom attachment point.
Regardless of the result of the barrel nut inspection, remove the bolt
from service and replace it with a new bolt. Apply a coating of Aeriol
ThixO #2 (3810-0) or Aeriol ThixO SYN (3820-0) aviation grease to each
bolt shank only. Install the hardware set of each tail boom attachment
point (nickel alloy barrel nut, retainer, bolt, countersunk washer,
and plain washers). Torque each bolt by using the torque value
information identified in paragraph (g) of this AD. Repeat the actions
required by this paragraph for each failed tail boom attachment point,
one hardware set at a time.
(C) For Model 210 helicopters, visually inspect the removed barrel nut for
cracking, corrosion, and loss of tare torque. If the barrel nut has
any cracking, corrosion, or loss of tare toque, before further flight,
remove the barrel nut and retainer from service and replace them with
a new nickel alloy barrel nut P/N NAS577C6A, NAS577C8A, or NAS577C9A,
and new retainer P/N NAS578C6A, NAS578C8A, or NAS578C9A, with the P/N
of the new nickel alloy barrel nut and the P/N of the new retainer
being as applicable to the affected tail boom attachment point.
Regardless of the result of the barrel nut inspection, remove the bolt
from service and replace it with a new bolt, apply a coating of Aeriol
ThixO #2 (3810-0) or Aeriol ThixO SYN (3820-0) aviation grease to each
bolt shank only, and torque each bolt by using the torque value
information identified in paragraph (g) of this AD. Repeat the actions
required by this paragraph for each failed tail boom attachment point,
one hardware set at a time.
(ii) After accumulating 1 hour TIS, but not to exceed 5 hours TIS after
accomplishing the actions required by paragraph (h)(3)(i) of this AD,
using the torque value information identified in paragraph (g) of
this AD as applicable to your model helicopter, inspect the torque
applied on each newly installed bolt. Thereafter, repeat the torque
inspection of those bolts after accumulating 1 hour TIS, but not to
exceed 5 hours TIS, to determine if the torque has stabilized. Do not
exceed three torque inspections total for those bolts and accomplish
the actions required by paragraphs (h)(2)(i) and (ii) of this AD.
(4) Within 5,000 hours TIS or 5 years after accomplishing the actions
required by paragraph (h)(1) of this AD, whichever occurs first, and
thereafter within intervals not to exceed 5,000 hours TIS or 5 years,
whichever occurs first, accomplish the actions required by paragraphs
(h)(4)(i) and (ii) of this AD.
(i) Accomplish the actions required by paragraphs (h)(1)(i), (ii), or
(iii) of this AD, as applicable to your model helicopter.
(ii) After accumulating 1 hour TIS, but not to exceed 5 hours TIS after
accomplishing the actions required by paragraph (h)(4)(i) of this AD,
using the torque value information identified in paragraph (g) of
this AD as applicable to your model helicopter, inspect the torque
applied on each bolt. Thereafter, repeat the torque inspection of
those bolts after accumulating 1 hour TIS, but not to exceed 5 hours
TIS, to determine if the torque has stabilized. Do not exceed three
torque inspections total for those bolts and accomplish the actions
required by paragraphs (h)(2)(i) and (ii) of this AD.
(5) As of the effective date of this AD, do not install the following
parts identified in paragraphs (h)(5)(i) and (ii) of this AD on any
helicopter.
(i) For Model 204B helicopters: steel alloy nut P/N NAS679A, NAS1291, or
MS21042.
(ii) For Model 205A, 205A-1, 205B, and 210 helicopters: steel alloy barrel
nut P/N NAS577B9A, P/N NAS577B8A, or P/N NAS577B6A.
(i) SPECIAL FLIGHT PERMIT
A one-time special flight permit may be issued in accordance with 14
CFR 21.197 and 21.199 in order to fly to a maintenance area to perform
the required actions in this AD.
(j) ALTERNATIVE METHODS OF COMPLIANCE (AMOCS)
(1) The Manager, Central Certification Branch, FAA, has the authority to
approve AMOCs for this AD, if requested using the procedures found in
14 CFR 39.19. In accordance with 14 CFR 39.19, send your request to
your principal inspector or local Flight Standards District Office, as
appropriate. If sending information directly to the manager of the
certification office, send it to the attention of the person
identified in paragraph (k) of this AD. Information may be emailed to
AMOC@faa.gov.
(2) Before using any approved AMOC, notify your appropriate principal in-
spector, or lacking a principal inspector, the manager of the local
flight standards district office/certificate holding district office.
(k) RELATED INFORMATION
For more information about this AD, contact Michael Perrin, Aviation
Safety Engineer, FAA, 1801 S Airport Road, Wichita, KS 67209; phone:
(562) 627-5362; email: Michael.j.perrin@faa.gov.
(l) MATERIAL INCORPORATED BY REFERENCE
(1) The Director of the Federal Register approved the incorporation by
reference of the material listed in this paragraph under 5 U.S.C.
552(a) and 1 CFR part 51.
(2) You must use this material as applicable to do the actions required by
this AD, unless the AD specifies otherwise.
(i) Bell Alert Service Bulletin 210-21-15, Revision A, dated February 23,
2022.
(ii) [Reserved]
(3) For Bell material identified in this AD, contact Bell Textron Inc.,
P.O. Box 482, Fort Worth, TX 76101; phone: (450) 437- 2862 or (800)
363-8023; fax: (450) 433-0272; email: productsupport@bellflight.com;
website: bellflight.com/support/contact-support.
(4) You may view this material at the FAA, Office of Regional Counsel,
Southwest Region, 10101 Hillwood Pkwy., Fort Worth, TX 76177. For
information on the availability of this material at the FAA, call:
(817) 222-5110.
(5) You may view this material at the National Archives and Records Admin-
istration (NARA). For information on the availability of this material
at NARA, visit www.archives.gov/federal-register/cfr/ibr-locations or
email fr.inspection@nara.gov.
Issued on September 27, 2024. Victor Wicklund, Deputy Director, Compliance
& Airworthiness Division, Aircraft Certification Service.
FOR FURTHER INFORMATION CONTACT: Michael Perrin, Aviation Safety Engineer,
FAA, 1801 S Airport Road, Wichita, KS 67209; phone: (562) 627-5362; email:
Michael.j.perrin@faa.gov.
|
DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. FAA-2022-0600; Project Identifier AD-2021-01160-R;
Amendment 39-22827; AD 2024-17-02]
RIN 2120-AA64
Airworthiness Directives; Bell Textron Inc. Helicopters
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Final rule.
-----------------------------------------------------------------------
SUMMARY: The FAA is adopting a new airworthiness directive (AD) for all
Bell Textron Inc. (Bell) Model 204B, 205A, 205A-1, 205B, and 210
helicopters. This AD was prompted by an accident and incidents
involving failure of the tail boom attachment structure. This AD
requires inspecting the tail boom assembly hardware, replacing tail
boom attachment hardware, greasing the bolt shanks, and inspecting
torque. This AD also prohibits installing steel alloy nuts on any
helicopter. The FAA is issuing this AD to address the unsafe condition
on these products.
DATES: This AD is effective November 8, 2024.
The Director of the Federal Register approved the incorporation by
reference of a certain publication listed in this AD as of November 8, 2024.
ADDRESSES:
AD Docket: You may examine the AD docket at regulations.gov under
Docket No. FAA-2022-0600; or in person at Docket Operations between 9
a.m. and 5 p.m., Monday through Friday, except Federal holidays. The AD
docket contains this final rule, any comments received, and other
information. The address for Docket Operations is U.S. Department of
Transportation, Docket Operations, M-30, West Building Ground Floor,
Room W12-140, 1200 New Jersey Avenue SE, Washington, DC 20590.
Material Incorporated by Reference:
For Bell material identified in this AD, contact Bell
Textron Inc., P.O. Box 482, Fort Worth, TX 76101; phone: (450) 437-2862
or (800) 363-8023; fax: (450) 433-0272; email:
productsupport@bellflight.com; website: bellflight.com/support/contact-support.
You may view this material at the FAA, Office of the
Regional Counsel, Southwest Region, 10101 Hillwood Pkwy., Room 6N-321,
Fort Worth, TX 76177. For information on the availability of this
material at the FAA, call (817) 222-5110.
Other Related Material: For other material identified in this final
rule, contact Bell Textron Inc., P.O. Box 482, Fort Worth, TX 76101;
phone: (450) 437-2862 or (800) 363-8023; fax: (450) 433-0272; email:
productsupport@bellflight.com; website: bellflight.com/support/contact-support.
FOR FURTHER INFORMATION CONTACT: Michael Perrin, Aviation Safety
Engineer, FAA, 1801 S Airport Road, Wichita, KS 67209; phone: (562)
627-5362; email: Michael.j.perrin@faa.gov.
SUPPLEMENTARY INFORMATION:
Background
The FAA issued AD 2021-15-14, Amendment 39-21661 (86 FR 39942, July
26, 2021) (AD 2021-15-14) for various restricted category helicopters.
AD 2021-15-14 was prompted by an accident involving a Model UH-1B
helicopter and two forced landings involving Model UH-1H and UH-1F
helicopters, due to tail boom attachment structure failures. Each of
the three events involved a failure of the upper left-hand (LH) tail
boom attachment fitting, which is the most heavily loaded of the four
tail boom attach points. The FAA issued AD 2021-15-14 to address
fatigue cracking of tail boom attachment fittings, cap angles,
longerons, and bolts.
Due to their similarity to Model UH-1B, UH-1H, and UH-1F
helicopters, the FAA determined that Bell Model 204B, 205A, 205A-1,
205B, and 210 helicopters are also affected by the same unsafe
condition and issued a notice of proposed rulemaking (NPRM) to propose
the same actions as those required in AD 2021-15-14. The NPRM published
in the Federal Register on June 7, 2022 (87 FR 34587) to amend 14 CFR
part 39 and would have applied to Bell Model 204B, 205A, 205A-1, 205B,
and 210 helicopters. In the NPRM, the FAA proposed to require revising
the helicopter's existing rotorcraft flight manual to incorporate pre-
flight checks; removing excess paint and sealant and cleaning certain
parts; and repetitively inspecting structural components that attach
the tail boom to the fuselage. Depending on the inspection results, the
FAA proposed to require repairing or replacing components or re-bonding
the structure.
Based on comments received on the NPRM, the FAA determined changes
to the proposed required actions were necessary. Accordingly, the FAA
issued a supplemental notice of proposed rulemaking (SNPRM) to amend 14
CFR part 39 by adding an AD that would apply to all Bell Model 204B,
205A, 205A-1, 205B, and 210 helicopters. The SNPRM published in the
Federal Register on May 8, 2024 (89 FR 38846).
In the SNPRM, for Bell Model 204B helicopters, the FAA proposed to
require, with the tail boom assembly removed, removing the upper LH
bolt from service and inspecting the bolt's associated attachment
hardware and, depending on the inspection results, removing the
associated nut from service. The FAA also proposed to require visually
inspecting each bulkhead, bolt hole, attachment fitting, the three
other nuts, the upper right-hand (RH) bolt, and two lower bolts,
including the bolt shank and head radii. Depending on inspection
results, the FAA proposed to require repairing or replacing an affected
bulkhead or affected fitting, removing certain part-numbered nuts,
removing any affected nut and its associated bolt from service, and
removing any affected bolt from service.
For Bell Model 205A, 205A-1, and 205B helicopters, the FAA proposed
to require, with the tail boom assembly removed, removing the upper LH
bolt from service and inspecting its associated barrel nut and retainer
and, depending on the inspection results, removing barrel nut and
retainer from service. The FAA also proposed to require visually
inspecting each bulkhead, bolt hole, attachment fitting, the three
other barrel nuts, associated retainers, the upper RH bolt, and two
lower bolts, including the bolt shank and head radii. Depending on
inspection results, the FAA proposed to require repairing or replacing
an affected bulkhead or affected fitting, removing certain part-
numbered barrel nuts and retainers, removing any affected barrel nuts
and its associated bolt from service, and removing any affected bolt
from service.
For Bell Model 210 helicopters, the FAA proposed to require, with
the tail boom supported, removing the upper LH steel alloy barrel nut,
retainer, and bolt from service and removing the countersunk washer and
plain washers and replacing them with a new certain part-numbered
nickel alloy barrel nut, new retainer, new bolt, an airworthy
countersunk washer, and airworthy plain washers. The FAA also proposed
to require visually inspecting the upper RH bolt and its associated
hardware and, depending on the inspection results, removing the upper
RH bolt and barrel nut from service. Additionally, the FAA proposed to
require visually inspecting the two lower bolts and the associated
barrel nuts and, depending on the inspection results, removing any
affected barrel nut and its associated
bolt from service and removing any affected bolt from service.
For all applicable helicopters, the FAA proposed to require, after
the initial inspections have been completed, applying a coating of
grease to each bolt shank only, installing the applicable hardware, and
torquing each bolt. Thereafter, the FAA proposed to require inspecting
the torque applied on each bolt to determine if the torque has
stabilized and, depending on the results, replacing and inspecting
certain tail boom attachment point hardware and repeating the torque
inspections or applying torque stripes.
Lastly, the FAA proposed to prohibit installing certain part-
numbered steel alloy nuts on Model 204B helicopters and certain part-
numbered steel alloy barrel nuts on Model 205A, 205A-1, 205B, and 210
helicopters.
Discussion of Final Airworthiness Directive
Comments
The FAA received comments on the SNPRM from Helicopter Maintenance
Corporation. The commenter requested that the FAA revise the proposed
AD to allow credit for previous compliance with the visual inspection
of the tail boom attach points and bulkhead, replacement of affected
hardware, and the recurring inspections involving removal of the tail
boom. Helicopter Maintenance Corporation stated that aircraft that are
in compliance with ASB 205-21-118 should only be obligated to comply
with any differences between the AD and the alert service bulletin.
Paragraph (f) of this AD requires compliance unless the actions
have already been done. Therefore, where this AD requires actions
without incorporating Bell Alert Service Bulletin (ASB) 210-21-15,
Revision A, dated February 23, 2022 (ASB 210-21-15, Rev A), by
reference, operators may take credit for those actions they if were
done before the effective date of this AD. Also, where this AD requires
actions in accordance with ASB 210-21-15, Rev A, operators may take
credit for those actions only if they were done before the effective
date of this AD using ASB 210-21-15, Rev A; this AD does not allow
credit for those actions if previously done using the original release
of ASB 210-21-15, (dated January 27, 2022). The FAA did not change this
AD as a result of this comment.
Conclusion
The FAA reviewed the relevant data, considered any comments
received, and determined that air safety requires adopting this AD as
proposed. Accordingly, the FAA is issuing this AD to address the unsafe
condition on these products. Except for minor editorial changes, this
AD is adopted as proposed in the SNPRM.
Material Incorporated by Reference Under 1 CFR Part 51
The FAA reviewed Bell ASB 210-21-15, Rev A. This material specifies
procedures for replacing the steel alloy barrel nuts with nickel alloy
barrel nuts, inspecting and replacing the tail boom attachment
hardware, stabilizing the tail boom attachment hardware torque,
applying torque seals, and subsequently checking the torque.
This material is reasonably available because the interested
parties have access to it through their normal course of business or by
the means identified in the ADDRESSES section.
Other Related Material
The FAA also reviewed Bell ASB 205-21-118, Bell ASB 204B-21-75, and
Bell ASB 205B-21-72, each Revision A and dated February 23, 2022. This
material specifies the same procedures as ASB 210-21-15, Rev A.
Differences Between This AD and the Related Material
The related material specifies checking torque, whereas this AD
requires inspecting torque because that action is a maintenance action
that must be performed by persons authorized under 14 CFR 43.3.
When stabilizing the tail boom attachment hardware torque, the
related material does not clearly specify actions for each time the
torque is below the minimum limit during any torque stabilization
inspection, whereas this AD requires replacing and inspecting certain
tail boom attachment point hardware, stabilizing the torque of the
replaced hardware set, and applying torque stripes.
Costs of Compliance
The FAA estimates that this AD affects 62 (five Model 204B
helicopters, fifty-three Model 205A, 205A-1, and 205B helicopters, and
four Model 210 helicopters) of U.S. registry. Labor costs are estimated
at $85 per work-hour. Based on these numbers, the FAA estimates the
following costs to comply with this AD.
For the initial requirements for Model 204B helicopters, inspecting
or replacing up to four bolts (which includes applying a coating of
grease), inspecting each bulkhead, inspecting each fitting and bolt
hole, inspecting and stabilizing the torque, and applying torque
stripes will take up to approximately 8.5 work-hours for an estimated
labor cost of up to $723. The parts cost for an upper LH bolt will be
approximately $196 and the parts cost for the other bolts will be
approximately $89 per bolt. The parts cost for four new nuts will be
approximately $680. The parts cost to apply torque stripes will be a
nominal amount. The estimated cost for these actions will be up to
approximately $1,866 per helicopter and $9,330 for the U.S. fleet.
For the initial requirements for Model 205A, 205A-1, and 205B
helicopters, replacing the four steel alloy barrel nuts with new nickel
alloy barrel nuts, inspecting or replacing up to four bolts (which
includes applying a coating of grease), inspecting each bulkhead,
inspecting and stabilizing the torque, and applying torque stripes will
take up to approximately 8.5 work-hours for an estimated labor cost of
up to $723. The parts cost for the four new nickel alloy barrel nuts
(including retainers) will be approximately $680. The parts cost for an
upper LH bolt will be approximately $196 and the parts cost for the
other bolts will be approximately $89 per bolt. The parts cost to apply
torque stripes will be a nominal amount. The estimated cost for these
actions will be up to approximately $1,866 per helicopter and $98,898
for the U.S. fleet.
For the initial requirements for Model 210 helicopters, replacing
the four steel alloy barrel nuts with new nickel alloy barrel nuts,
inspecting or replacing up to four bolts (which includes applying a
coating of grease), inspecting and stabilizing the torque, and applying
torque stripes will take up to approximately 8.5 work-hours for an
estimated labor cost of up to $723. The parts cost for the four new
nickel alloy barrel nuts (including retainers) will be approximately
$680. The parts cost for an upper LH bolt will be approximately $196
and the parts cost for the other bolts will be approximately $89 per
bolt. The parts cost to apply torque stripes will be a nominal amount.
The estimated cost for these actions will be up to approximately $1,866
per helicopter and $7,464 for the U.S. fleet.
For all applicable helicopters, inspecting the torque applied on
each bolt will take approximately 1 work-hour for an estimated cost of
$85 per helicopter and $5,270 for the U.S. fleet, per inspection cycle.
For all applicable helicopters, replacing an upper LH bolt,
stabilizing the torque, and applying a torque stripe will take up to
approximately 5 work-hours. The parts cost for an upper LH bolt will be
approximately $196 and the parts cost to apply a torque stripe will
be a nominal amount. The estimated cost for these actions will be up to
approximately $621 per helicopter and $38,502 for the U.S. fleet, per
replacement cycle. Inspecting one of the other bolts, stabilizing the
torque, and applying a torque stripe will take up to approximately 3.5
work-hours for an estimated cost of $298 per other bolt and $18,476 for
the U.S. fleet per other bolt per inspection cycle. If required,
replacing a bolt following that inspection will take a minimal amount
of additional time and the parts cost will be approximately $89.
If required as a result of failing any torque inspection required
by this AD, visually inspecting a nut or a barrel nut, replacing a
bolt, stabilizing the torque, and applying a torque stripe will take up
to approximately 5.5 work-hours per failed hardware set. The parts cost
for an upper LH bolt will be approximately $196 and the parts cost for
the other bolts will be approximately $89 per bolt. The parts cost to
apply a torque stripe will be a nominal amount. The estimated cost for
these actions will be $664 (upper LH bolt) or $557 (other bolts), per
failed hardware set. If required, replacing a nut following that
inspection will take a minimal amount of additional time and the parts
cost for a nut will be approximately $89 per nut. If required,
replacing a barrel nut following that inspection will take a minimal
amount of additional time and a parts cost of approximately $173 per
barrel nut.
The corrective action that may be needed as a result of the
bulkhead inspection could vary significantly from helicopter to
helicopter. The FAA has no data to determine the costs to accomplish
the corrective action or the number of helicopters that may require
corrective action.
Authority for This Rulemaking
Title 49 of the United States Code specifies the FAA's authority to
issue rules on aviation safety. Subtitle I, section 106, describes the
authority of the FAA Administrator. Subtitle VII: Aviation Programs,
describes in more detail the scope of the Agency's authority.
The FAA is issuing this rulemaking under the authority described in
Subtitle VII, Part A, Subpart III, Section 44701: General requirements.
Under that section, Congress charges the FAA with promoting safe flight
of civil aircraft in air commerce by prescribing regulations for
practices, methods, and procedures the Administrator finds necessary
for safety in air commerce. This regulation is within the scope of that
authority because it addresses an unsafe condition that is likely to
exist or develop on products identified in this rulemaking action.
Regulatory Findings
This AD will not have federalism implications under Executive Order
13132. This AD will not have a substantial direct effect on the States,
on the relationship between the national government and the States, or
on the distribution of power and responsibilities among the various
levels of government.
For the reasons discussed above, I certify that this AD:
(1) Is not a "significant regulatory action" under Executive
Order 12866,
(2) Will not affect intrastate aviation in Alaska, and
(3) Will not have a significant economic impact, positive or
negative, on a substantial number of small entities under the criteria
of the Regulatory Flexibility Act.
List of Subjects in 14 CFR Part 39
Air transportation, Aircraft, Aviation safety, Incorporation by
reference, Safety.
The Amendment
Accordingly, under the authority delegated to me by the
Administrator, the FAA amends 14 CFR part 39 as follows:
PART 39--AIRWORTHINESS DIRECTIVES
1. The authority citation for part 39 continues to read as follows:
Authority: 49 U.S.C. 106(g), 40113, 44701.
Sec. 39.13 [Amended]
2. The FAA amends Sec. 39.13 by adding the following new airworthiness
directive:
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