Airworthiness DirectiveEASA AD CF-2021-05R3

Rotors Flight Control — Collective Controls — Failure of Pilot Collective Stick and Grip Assembly

Published: Mar 25, 2021
Effective: Apr 2, 2021
Deadline: Apr 2, 2022
Replaces: CF-2021-05R2
Replaces: CF-2021-05R1
Replaces: CF-2021-05

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What to do

Operators must immediately amend flight manuals with specified temporary revisions and inform flight crews of operational limitations. An initial fluorescent penetrant inspection of the pilot collective stick must be performed before further flight, with repetitive inspections every 25 hours air time if applicable. Within 12 months of the effective date, the pilot collective stick tube must be replaced with the redesigned part number M207-20M301-043, after which operational restrictions can be removed.

Summary

Airworthiness Directive CF-2021-05R3 addresses the failure risk of the pilot collective stick and grip assembly in Bell Textron Canada Limited model 505 helicopters, serial numbers 65011 through 65347. This directive mandates inspections and operational restrictions to detect and prevent fatigue cracking that could lead to loss of helicopter control. It also requires incorporation of a redesigned pilot collective stick tube to eliminate the root cause of the cracking.

What changed

This revision supersedes previous versions by mandating the installation of a redesigned pilot collective stick tube as terminating action. It updates inspection requirements to fluorescent penetrant inspections capable of detecting smaller cracks and introduces flight manual revisions prohibiting single pilot operations from the right crew seat until the redesign is incorporated. The directive also clarifies ferry flight provisions and limits applicability to helicopters without the redesign.

Why it matters

This directive is critical for operators and maintenance personnel to prevent potential in-flight failure of the pilot collective stick, which could result in loss of helicopter control. Compliance ensures continued airworthiness and safety of Bell 505 helicopters, while avoiding operational restrictions and minimizing risk. Maintenance teams must perform required inspections and part replacements within specified intervals to maintain regulatory compliance and safe operation.

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