Fri, Mar 19, 2004
AD: 2004-SW-09-AD.
Applicability: Model 234 helicopters, with aft
vertical shaft assembly, part number (P/N) 234D3300, serial number
-181 or lower with a prefix of A, installed, certificated in any
category.
Compliance: Required as indicated.
The FAA has issued an Emergency AD on Boeing Defense And Space
Group Model 234 Helicopters. The Emergency AD was "prompted by the
discovery of a crack in the upper shaft extension of an aft
vertical shaft assembly (assembly). The discovery was made by an
operator who was in the process of troubleshooting a lateral
vibration and noticed a slight wobble in the assembly when the
rotors were turned by hand. The manufacturer subsequently
determined that the crack initiated at an arc burn that occurred
during the silver-plating process of the part. This is an interim
action that is necessary until an arc-burn free replacement
assembly is installed. A crack in the upper shaft extension could
result in catastrophic failure of the assembly and subsequent loss
of control of the helicopter."
The FAA has reviewed Boeing BV234 Service Bulletin No.
234-63-1055, Revision 2, dated March 16, 2004, which describes
procedures for inspecting the inside diameter surfaces of the
114D3248 upper shaft extension of the 234D3300 aft vertical shaft
for cracks. The service bulletin also describes procedures for
fabricating and installing an aluminum inspection plug. Further,
the service bulletin provides for recurring inspections. This
unsafe condition is likely to exist or develop on other helicopters
of the same type design. Therefore, this AD requires, before
further flight, inspecting the upper shaft extension for a crack
and modifying the assembly. Thereafter, this AD requires, before
the first flight of each day, inspecting the upper shaft extension
for any crack. If any crack is found during any of the inspections,
replacing the assembly with an airworthy assembly is required
before further flight.
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