ALERT SERVICE BULLETIN 407-24-134

12 February 2024

MODEL AFFECTED: 407

SUBJECT: Tailboom Attachment Hardware and Fittings,

Inspection of

HELICOPTERS AFFECTED: Serial numbers 53000 through 53900, 53911

through 53999, 54000 through 54166, 54300
through 54752, 54805 through 54999 and 56300
and subsequent.

COMPLIANCE: PART I: Within 50 flight hours or 30 days whichever

occur first, following the release of this bulletin or if
TB 407-17-125 is completed thereafter.

PART II: Within 50 flight hours or 30 days whichever

occur first and every 300 flight hours thereafter
following the release of this bulletin.

PART III: Within 50 flight hours or 30 days whichever

occur first and every 50 flight hours thereafter
following the release of this bulletin.

DESCRIPTION:

Bell has recently received a report of a fractured upper left tailboom attachment bolt.
The fractured bolt was found during a scheduled 300-hour inspection. After investigation
and review of the aircraft technical records, it was confirmed that the aft fuselage upper
left longeron assembly 206-031-314-237B had been replaced on the aircraft in
accordance with Technical Bulletin (TB) 407-12-96 which might have been a
contributing factor to the event.

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PART I of this bulletin requires to determine whether the upper left longeron was
replaced in accordance with TB 407-12-96 or TB 407-17-125 or if it is the original
longeron installed on the production line.

PART II of this bulletin mandates a recurring detailed inspection of the tailboom

attachment structure and the replacement of the upper left-hand bolt and nut. The
affected helicopters are those that had the upper left longeron assemblies 206-031-314-
237B/-237S or 407-030-067-105 installed in accordance with TB 407-12-96 or TB 407-
17-125 respectively.

PART III of this bulletin mandates a recurring detailed inspection of the tailboom
attachment structure and a torque check of the tailboom attachment hardware. The
affected helicopters are those that still have their original upper left longeron assembly
installed on the production line. Helicopters serial number 54807, 54808, 54872 and
subsequent were fitted with the 2-piece upper left longeron assembly in production and
are not affected by PART III of this ASB.

This is a temporary measure to address a safety of flight concern. The terminating

actions to the recurring inspections of PART II and PART III of this bulletin will be
provided in a future revision of the ASB.

Applicability of this bulletin to any spare part shall be determined prior to its installation.

APPROVAL:

The engineering design aspects of this bulletin are Transport Canada Civil Aviation
(TCCA) approved.

CONTACT INFO:

For any questions regarding this bulletin, please contact:

Bell Product Support Engineering

Tel: 1-450-437-2862 / 1-800-363-8023 / [email protected]

MANPOWER:

Approximately 0.5 man-hour is required to complete PART I of this bulletin.

Approximately 2.5 man-hours are required to complete PART II of this bulletin.
Approximately 2.0 man-hours are required to complete PART III of this bulletin.
This estimate is based on hands-on time and may vary with personnel and facilities
available.

WARRANTY:

There is no warranty credit applicable for parts or labor associated with this bulletin.

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MATERIAL:

Required Material:
The following material is required for the accomplishment of this bulletin and may be
obtained through your Bell Supply Center.

Part Number Nomenclature Qty NOTES

NAS626-26 BOLT 2 2
NAS627-30 BOLT 2 1, 2
42FLW-624 NUT 2 2
42FLW-720 NUT 2 1, 2
140-007-29S25E6 COUNTERSUNK WASHER 2 2, 3
140-007-25S22E6 COUNTERSUNK WASHER 2 2, 3
NAS1149G0732P FLAT WASHER 9 2, 3, 4
NAS1149G0663P FLAT WASHER 10 2, 3, 5

NOTES:

1. A minimum of one bolt NAS627-30 and one nut 42FLW-720 are required to
accomplish PART II of this bulletin.
2. Required quantity may vary depending on the result of the tailboom attachment
hardware torque check performed in accordance with PART II or PART III.
3. Required quantity may vary depending on the inspection results.
4. Quantity indicated is the maximum allowable. A maximum quantity of four (4) flat
washers can be used in the upper left position. A maximum quantity of five (5)
flat washers can be used in the upper right position.
5. Quantity indicated is the maximum allowable. A maximum quantity of five (5) flat
washers can be used in the lower left and right positions.

Consumable Material:
The following material is required to accomplish this bulletin, but may not require
ordering, depending on the operator’s consumable material stock levels. This material
may be obtained through your Bell Supply Center.

Part Number Nomenclature Qty (Note) Reference *

2010-05901-00 Corrosion Preventive Compound 6 OZ (1) C-586

* C-XXX numbers refer to the consumables list in the BHT-ALL-SPM, Standard Practices Manual

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NOTE 1: Quantity indicated is the format that the product is delivered in. Actual quantity
required to accomplish the instructions in this bulletin may be less than what has been
delivered.

SPECIAL TOOLS:

407-230-001-101 Socket (or equivalent)

WEIGHT AND BALANCE:

Not affected.

ELECTRICAL LOAD DATA:

Not affected.

REFERENCES:

407-MM Maintenance Manual

407-IPB Illustrated Part Breakdown
BHT-ALL-SPM Standard Practices Manual
Alert Service Bulletin 407-10-93 (Tailboom Attachment Hardware, Replacement Of)
Technical Bulletin 407-12-96
Technical Bulletin 407-17-125
GEN-22-154 General Information Letter, Procedure for Requesting Bell-Approved
Structural Repairs.

PUBLICATIONS AFFECTED:

None affected.

ACCOMPLISHMENT INSTRUCTIONS:

PART I: Verification of the upper left longeron assembly installation

-NOTE-

407 S/N: 53001 through 54061 did not have the 206-031-314-
237 longeron assembly installed from factory with the
‘’Caution Cold Expanded Holes’’ decal as shown in Figure 2.
If the decal “Caution Cold Expanded Holes” is present on
upper left longeron as shown in Figure 2 (Analog 407 prior to
S/N: 54062), the longeron assembly was field replaced per
the above Technical Bulletins.

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 -NOTE-

For all other aircraft serial numbers, there are no visual signs
that can confirm if a longeron assembly was field replaced.
The technical records must be reviewed. In case of doubt,
accomplish PART II of this bulletin.

1. Prepare the helicopter for maintenance.

2. Review the helicopter technical records to determine if the upper left longeron
assembly was replaced in the field in accordance with TB 407-12-96 or TB 407-17-
125 or if it is still the original that was installed in production.

3. If in doubt, accomplish PART II of this bulletin.

4. If the upper left longeron assembly was replaced in the field as per TB 407-12-96 or
TB 407-17-125 proceed with PART II.

5. If the upper left longeron assembly was installed in production, proceed with PART
III.

6. All spare longeron assemblies part numbers 206-031-314-237B and 206-031-314-

237S shall not be installed and must be sent back to Bell using the New Part Return
process.

7. Make an entry in the helicopter logbook and historical service records indicating
compliance with PART I of this Alert Service Bulletin.

PART II: Inspection of the tailboom attachment structure and replacement of the
upper left bolt and nut:

-NOTE-

Tailboom removal is not required to accomplish this check.

1. From the left side of the fuselage, using a strong light source and a feeler gauge,
inspect for a gap at the upper left attachment interface between the aft fuselage and
the tailboom. The entire tailboom forward bulkhead machined / hot bonded shim
surface must be in contact with the aft fuselage bulkhead. Figure 3 shows the
inspection area for possible gap between the machined / hot bonded shim and the

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 aft fuselage bulkhead. If a 0.003 inch (0.076 mm) feeler gauge or thicker can be
inserted in the joint up to the bolt shank, contact Product Support Engineering for
further instructions.

2. Remove tailboom access cover (1, Figure 1). Retain hardware for subsequent
installation in later step.

-NOTE-

If the existing sealant application meets the intent of the Aft

Fuselage Attachment Fittings - Sealant Removal and
Application procedure specified in DMC-407-A-53-00-00-
01A-280B-A, sealant removal is not required. If the sealant
application does not meet the intent, remove the sealant to
allow inspection of the fitting(s).

-NOTE-

Any one or more of the following visible signs is an indication

of loose fasteners and underlying damage that will require
further inspection. These include chipped or cracked paint at
the edges of parts or around rivet heads, cracked sealant and
gaps at the edges of the faying surfaces of skins, bonded
panels, and structure joints, and traces of black oxide around
rivets and fasteners.

3. Using a strong light source and a mirror, examine the following:

a. Inspect the tailboom intercostals, the tailboom forward bulkhead, and aft fuselage
bulkhead for cracks, dents, loose fasteners, security of attachment, deformation,
corrosion, and general condition.

b. Inspect the aft fuselage upper and lower longerons for cracks, loose fasteners,
security of attachment, deformation, corrosion, and general condition. Pay
particular attention to the upper left longeron fitting.

-NOTE-

Minor cadmium plating damage on the attachment bolt is not

cause for further investigation.

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c. Remove and inspect the upper left tailboom attachment bolt for signs of cracking,
fretting, wear, and corrosion. If abnormal signs of deterioration are found, send
pictures to Product Support Engineering (PSE).

d. Install a new replacement bolt and nuts at the upper left tailboom attachment
location. Refer to the 407-MM; (DMC-407-A-53-01-00-00A-720A-A) for hardware
installation procedures.

-NOTE-

The torque values of the upper and lower nuts (2 and 7, Figure
4) are different. Refer to Figure 4 for the specified torque
values.

-NOTE-

For torque check purposes, the assembly torque to be applied

is the minimum specified torque, plus the minimum
acceptable tare torque of 14 inch-pounds (1.58 Nm) for the
upper nuts and 9.5 inch-pounds (1.07 Nm) for the lower nuts
(BHT-ALL-SPM, Chapter 2, Standard Practices Manual).

e. Do a torque check of the 3 remaining tailboom to the aft fuselage attachment nuts
(2 and 7, Figure 4) (DMC-407-A-53-01-00-00A-720A-A).

(1) If a nut fails the torque check, replace the affected bolt(s) and nut(s) with new
bolt(s), nut(s), and washer(s) as applicable. Retain removed hardware for
further investigation by Product Support Engineering.

(a) Refer to (DMC-407-A-53-01-00-00A-720A-A) for hardware installation

procedures.

f. After final torque is applied, apply corrosion preventive compound (C-586) to the
head of the bolt, washers, nut, and the exposed threads.

g. After 1 to 5 flight hours, perform the Tailboom Attachment Hardware Torque

Check special inspection at every location where new hardware was installed

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 (DMC-407-A-05-40-00-00A-283A-A). Repeat torque check every 1 to 5 flight
hours until the torque has stabilized.

4. Install the tailboom access cover (1, Figure 1).

5. Make an entry in the helicopter logbook and historical service records indicating
compliance with PART II of this Alert Service Bulletin. Carry out the inspection and
hardware replacement as described in PART II of this bulletin every 300 flight hours.

PART III: Inspection of tailboom attachment structure and torque check of the
tailboom attachment hardware.

-NOTE-

Helicopters serial number 54807, 54808, 54872 and

subsequent were fitted with the 2-piece upper left longeron
assembly in production and are not affected by PART III of
this ASB.

-NOTE-

To allow flexibility, it is possible to either comply with PART III

of this bulletin every 50 flight hours which consist in complying
with the inspection requirements without part replacement or
alternatively comply with PART II every 300 flight hours which
consist in replacing the upper left longeron hardware and
complying with the inspection requirements.

-NOTE-

Tailboom removal is not required to accomplish this check.

1. Prepare the helicopter for maintenance.

2. From the left side of the fuselage, using a strong light source and a feeler gauge,
inspect for a gap at the upper left attachment interface between the aft fuselage and
the tailboom. The entire tailboom forward bulkhead machined / hot bonded shim
surface must be in contact with the aft fuselage bulkhead. Figure 3 shows the
inspection area for possible gap between the machined / hot bonded shim and the
aft fuselage bulkhead. If a 0.003 inch (0.076 mm) feeler gauge or thicker can be
inserted in the joint up to the bolt shank, contact Product Support Engineering for
further instructions.

3. Remove tailboom access cover (1, Figure 1). Retain hardware for subsequent
installation in later step.

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 -NOTE-

If the existing sealant application meets the intent of the Aft

Fuselage Attachment Fittings - Sealant Removal and
Application procedure specified in DMC-407-A-53-00-00-
01A-280B-A, sealant removal is not required. If the sealant
application does not meet the intent, remove the sealant to
allow inspection of the fitting(s).

-NOTE-

Any one or more of the following visible signs is an indication

of loose fasteners and underlying damage that will require
further inspection. These include chipped or cracked paint at
the edges of parts or around rivet heads, cracked sealant and
gaps at the edges of the faying surfaces of skins, bonded
panels, and structure joints, and traces of black oxide around
rivets and fasteners.

4. Using a strong light source and a mirror, examine the following:

a. Inspect the tailboom intercostals, the tailboom forward bulkhead, and the aft
fuselage bulkhead for cracks, dents, loose fasteners, security of attachment,
deformation, corrosion, and general condition.

b. Inspect the aft fuselage upper and lower longerons for cracks, loose fasteners,
security of attachment, deformation, corrosion, and general condition. Pay
particular attention to the upper left longeron fitting.

-NOTE-

The torque values of the upper and lower nuts (2 and 7, Figure
4) are different. Refer to Figure 4 for the specified torque
values.

-NOTE-

For torque check purposes, the assembly torque to be applied

is the minimum specified torque, plus the minimum
acceptable tare torque of 14 inch-pounds (1.58 Nm) for the
upper nuts and 9.5 inch-pounds (1.07 Nm) for the lower nuts
(BHT-ALL-SPM, Chapter 2, Standard Practices Manual).

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5. Do a torque check of the tailboom to the aft fuselage attachment nuts (2 and 7, Figure
4) (DMC-407-A-53-01-00-00A-720A-A).

a. If a nut fails the torque check, replace the affected bolt(s) and nut(s) with new
bolt(s), nut(s), and washer(s) as applicable. Retain removed hardware for further
investigation by Product Support Engineering.

(1) Refer to (DMC-407-A-53-01-00-00A-720A-A) for hardware installation

procedures.

b. Apply corrosion preventive compound (C-586) to the heads of the bolts, washers,
nuts, and the exposed thread after final torque is applied.

c. If hardware replacement is required, after 1 to 5 flight hours perform the Tailboom

Attachment Hardware Torque Check Special Inspection at every location where
new hardware was installed (DMC-407-A-05-40-00-00A-283A-A). Repeat torque
check every 1 to 5 flight hours until the torque has stabilized.

6. Install the tailboom access cover (1, Figure 1).

7. Make an entry in the helicopter logbook and historical service records indicating
compliance with PART III of this Alert Service Bulletin.

8. Repeat the inspection of the tailboom attachment as described in PART III of this
bulletin every 50 flight hours. Alternatively, PART II Inspection and hardware
replacement of the upper left longeron can be accomplished and repeated every 300
flight hours.

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Figure 1 - Tailboom Access Cover Removal/Installation

Figure 2 – Upper Left Longeron 206-031-314-237

‘’CAUTION COLD EXPANDED HOLE’’ decal

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Figure 3 - Gap check at the upper left tailboom attachment interface
with tailboom and hardware installed.

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Figure 4 Tailboom Attachment Hardware

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