Proposed Rule2025-20090
Airworthiness Directives; Bell Textron Canada Limited Helicopters
Primary source
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Published
November 18, 2025
Issuing agencies
Transportation DepartmentFederal Aviation Administration
Abstract
The FAA proposes to adopt a new airworthiness directive (AD) for certain Bell Textron Canada Limited (Bell) Model 407 helicopters. This proposed AD was prompted by a report of a fractured pilot cyclic stick tube and subsequent findings of other pilot cyclic stick tubes with fatigue cracking. This proposed AD would require repetitively inspecting the pilot cyclic stick tube assembly for a crack and, depending on the results, repairing or replacing the pilot cyclic stick tube assembly. The FAA is proposing this AD to address the unsafe condition on these products.
Full Text
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<title>Federal Register, Volume 90 Issue 220 (Tuesday, November 18, 2025)</title>
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[Federal Register Volume 90, Number 220 (Tuesday, November 18, 2025)]
[Proposed Rules]
[Pages 51602-51605]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 2025-20090]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. FAA-2025-3436; Project Identifier MCAI-2024-00314-R]
RIN 2120-AA64
Airworthiness Directives; Bell Textron Canada Limited Helicopters
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Notice of proposed rulemaking (NPRM).
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SUMMARY: The FAA proposes to adopt a new airworthiness directive (AD)
for certain Bell Textron Canada Limited (Bell) Model 407 helicopters.
This proposed AD was prompted by a report of a fractured pilot cyclic
stick tube and subsequent findings of other pilot cyclic stick tubes
with fatigue cracking. This proposed AD would require repetitively
inspecting the pilot cyclic stick tube assembly for a crack and,
depending on the results, repairing or replacing the pilot cyclic stick
tube assembly. The FAA is proposing this AD to address the unsafe
condition on these products.
DATES: The FAA must receive comments on this NPRM by January 2, 2026.
ADDRESSES: You may send comments, using the procedures found in 14 CFR
11.43 and 11.45, by any of the following methods:
<bullet> Federal eRulemaking Portal: Go to <a href="http://regulations.gov">regulations.gov</a>. Follow
the instructions for submitting comments.
<bullet> Fax: (202) 493-2251.
<bullet> Mail: U.S. Department of Transportation, Docket
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New
Jersey Avenue SE, Washington, DC 20590.
<bullet> Hand Delivery: Deliver to Mail address above between 9
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
AD Docket: You may examine the AD docket at <a href="http://regulations.gov">regulations.gov</a> under
Docket No. FAA-2025-3436; 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 NPRM, the mandatory continuing airworthiness
information (MCAI), any comments received, and other information. The
street address for Docket Operations is listed above.
Material Incorporated by Reference:
<bullet> For Transport Canada material identified in this proposed
AD, contact Transport Canada, Transport Canada National Aircraft
Certification, 159 Cleopatra Drive, Nepean, Ontario, K1A 0N5, Canada;
phone: (888) 663-3639; email: <a href="/cdn-cgi/l/email-protection#b1c5d29fd0d8c3c6dec3c5d9d8dfd4c2c2d5d8c3d4d2c5d8c7d4c29cd2dedfc2d8d6dfd4c2d5d4dfd0c7d8d6d0d3d8ddd8c5d49f8dd091d9c3d4d78c" mailto:TC@tc.gc.ca"><span class="__cf_email__" data-cfemail="94c0d7d4e0f7baf3f7baf7f5">[email protected]</span></a>">tc.airworthinessdirectives-consignesdenavigabilite.<a href="/cdn-cgi/l/email-protection#9cc8dfdce8ffb2fbffb2fffd"><span class="__cf_email__" data-cfemail="9dc9dedde9feb3fafeb3fefc">[email protected]</span></a></a>; website: tc.canada.ca/en/aviation.
You may find the Transport Canada material on the Transport Canada
website at tc.canada.ca/en/aviation.
<bullet> You may view this material at the FAA, Office of the
Regional Counsel, Southwest Region, 10101 Hillwood Parkway, Room 6N-
321, Fort Worth, TX 76177. For information on the availability of this
material at the FAA, call (817) 222-5110.
FOR FURTHER INFORMATION CONTACT: Alexis Whitaker, Aviation Safety
Engineer, FAA, 1600 Stewart Avenue, Suite 410, Westbury, NY 11590;
phone: (516) 228-7309; email: <a href="/cdn-cgi/l/email-protection#46272a233e2f35682c68312e2f32272d23340620272768212930"><span class="__cf_email__" data-cfemail="e6878a839e8f95c88cc8918e8f92878d8394a6808787c8818990">[email protected]</span></a>.
SUPPLEMENTARY INFORMATION:
Comments Invited
The FAA invites you to send any written relevant data, views, or
arguments about this proposal. Send your comments using a method listed
under the ADDRESSES section. Include ``Docket No. FAA-2025-3436;
Project Identifier MCAI-2024-00314-R'' at the beginning of your
comments. The most helpful comments reference a specific portion of the
proposal, explain the reason for any recommended change, and include
supporting data. The FAA will consider all comments received by the
closing date and may amend this proposal because of those comments.
Except for Confidential Business Information (CBI) as described in
the following paragraph, and other information as described in 14 CFR
11.35, the FAA will post all comments received, without change, to
<a href="http://regulations.gov">regulations.gov</a>, including any personal information you provide. The
agency will also post a report summarizing each substantive verbal
contact received about this NPRM.
Confidential Business Information
CBI is commercial or financial information that is both customarily
and actually treated as private by its owner. Under the Freedom of
Information Act (FOIA) (5 U.S.C. 552), CBI is exempt from public
disclosure. If your comments responsive to this NPRM contain commercial
or financial information that is customarily treated as private, that
you actually treat as private, and that is relevant or responsive to
this NPRM, it is important that you clearly designate the submitted
comments as CBI. Please mark each page of your submission containing
CBI as ``PROPIN.'' The FAA will treat such marked submissions as
confidential under the FOIA, and they will not be placed in the public
docket of this NPRM. Submissions containing CBI should be sent to
Alexis Whitaker, Aviation Safety Engineer, FAA, 1600 Stewart Avenue,
Suite 410, Westbury, NY 11590. Any commentary that the FAA receives
which is not specifically designated as CBI will be placed in the
public docket for this rulemaking.
Background
Transport Canada, which is the aviation authority for Canada, has
issued Transport Canada AD CF-2024-18, dated May 29, 2024 (Transport
Canada AD CF-2024-18) (also referred to as the MCAI), to correct an
unsafe condition on Bell Model 407 helicopters, serial numbers 53000
through 53900, 53911 through 53999, 54000 through 54166, 54300 through
54800, 54805 through 54999, 56300 through 56305, and 56311 through
56315, installed with a pilot cyclic stick tube assembly part number
(P/N) 206-001-342-101 or 206-001-342-101FM. The MCAI states that Bell
received a report that a pilot cyclic stick tube assembly having P/N
206-001-342-101 fractured at the lower end of the tube near the upper
slotted area where it is held in place in the pivot assembly.
Examination of the fractured pilot cyclic stick tube and subsequent
findings of other cracked pilot cyclic stick tubes revealed fatigue
cracking. Further investigation identified the root cause of the pilot
cyclic stick tube cracking as the application of excessive force to the
cyclic stick during the freedom of movement of the controls and cyclic
centering light operation check as part of the interior and prestart
check, which resulted in elevated stress at the slotted area and was
aggravated by the high stress concentration design feature of the upper
slotted area.
This condition, if not detected and corrected, could lead to an in-
flight
[[Page 51603]]
failure of the pilot cyclic stick tube and consequent loss of control
of the helicopter.
You may examine the MCAI in the AD docket at <a href="http://regulations.gov">regulations.gov</a> under
Docket No. FAA-2025-3436.
Material Incorporated by Reference Under 1 CFR Part 51
The FAA reviewed Transport Canada AD CF-2024-18, which specifies
procedures for revising the applicable Bell 407 rotorcraft flight
manual (RFM) Normal Procedures section to limit the allowable freedom
of movement during interior and prestart checks for certain serial-
numbered helicopters (Group 1 helicopters). Transport Canada AD CF-
2024-18 also specifies procedures for inspecting the pilot cyclic stick
tube assembly for cracks and replacing or repairing and reidentifying
any cracked pilot cyclic stick tube assembly for certain serial-
numbered helicopters (Group 2 helicopters). If, as a result of an
inspection, a pilot cyclic stick tube assembly is repaired rather than
replaced, Transport Canada AD CF-2024-18 further specifies procedures
for repetitive inspections of the repaired pilot cyclic stick tube
assembly and replacement within 24 months after the repair.
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.
FAA's Determination
These products have been approved by the civil aviation authority
(CAA) of another country and are approved for operation in the United
States. Pursuant to the FAA's bilateral agreement with this State of
Design Authority, that authority has notified the FAA of the unsafe
condition described in the MCAI referenced above. The FAA is issuing
this NPRM after determining that the unsafe condition described
previously is likely to exist or develop on other products of the same
type design.
Explanation of Required Compliance Information
In the FAA's ongoing efforts to improve the efficiency of the AD
process, the FAA developed a process to use some CAA ADs as the primary
source of information for compliance with requirements for
corresponding FAA ADs. The FAA has been coordinating this process with
manufacturers and CAAs. As a result, the FAA proposes to incorporate
Transport Canada AD CF-2024-18 by reference in the FAA final rule. This
proposed AD would, therefore, require compliance with Transport Canada
AD CF-2024-18 in its entirety through that incorporation, except for
any differences identified as exceptions in the regulatory text of this
proposed AD. Material referenced in Transport Canada AD CF-2024-18 for
compliance will be available at <a href="http://regulations.gov">regulations.gov</a> under Docket No. FAA-
2025-3436 after the FAA final rule is published.
Proposed AD Requirements in This NPRM
This proposed AD would require accomplishing the actions specified
in Transport Canada AD CF-2024-18, described previously, as
incorporated by reference, except for any differences identified as
exceptions in the regulatory text of this AD. See ``Differences Between
this Proposed AD and the MCAI'' for a discussion of the general
differences included in this proposed AD.
Differences Between This Proposed AD and the MCAI
The MCAI only applies to helicopter serial numbers 53000 through
53900, 53911 through 53999, 54000 through 54166, 54300 through 54800,
54805 through 54999, 56300 through 56305, and 56311 through 56315,
whereas this proposed AD would apply to all serial numbered Model 407
helicopters with cyclic stick tube assembly part number (P/N) 206-001-
342-101 or P/N 206-001-342-101FM installed.
The MCAI specifies procedures for revising the applicable Bell 407
RFM Normal Procedures section for certain serial-numbered helicopters
to limit the allowable freedom of movement during interior and prestart
checks, whereas this proposed AD does not because the full sweep for
freedom of movement is necessary to clear icing and detect any jamming
or binding during the pre-start check.
This proposed AD would also add a repetitive inspection for pilot
cyclic stick tube assemblies that have accumulated 3,600 or more hours
time-in-service, at intervals not to exceed every 300 hours time-in-
service or 6 months, whichever occurs first. This is from a
determination that a pilot cyclic control stick could experience high
loading during hydraulic-off training and other emergency procedure
situations. This inspection is not part of the MCAI.
Interim Action
The FAA considers that this proposed AD would be an interim action.
If final action is later identified, the FAA might consider further
rulemaking.
Costs of Compliance
The FAA estimates that this AD, if adopted as proposed, would
affect 944 helicopters of U.S. registry.
The FAA estimates the following costs to comply with this proposed
AD:
Estimated Costs
----------------------------------------------------------------------------------------------------------------
Cost per
Action Labor cost Parts cost product Cost on U.S. operators
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Inspect pilot cyclic stick tube Up to 4 work-hours x $0 $340 Up to $320,960.
assembly. $85 per hour = $340.
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The FAA estimates the following costs to do any necessary repairs
that would be required based on the results of the proposed inspection.
The agency has no way of determining the number of helicopters that
might need these repairs:
On-Condition Costs
------------------------------------------------------------------------
Cost per
Action Labor Cost Parts Cost product
------------------------------------------------------------------------
Repair pilot cyclic stick 6 work-hours x $0 $510
tube assembly. $85 per hour =
$510.
Repetitively inspect pilot 2 work-hours 0 170
cyclic stick tube assembly. (per
inspection) x
$85 per hour =
$170.
Replace pilot cyclic stick 2 work-hours x 1,544 1,714
tube assembly. $85 per hour =
$170.
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[[Page 51604]]
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
The FAA determined that this proposed AD would not have federalism
implications under Executive Order 13132. This proposed AD would 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 this proposed
regulation:
(1) Is not a ``significant regulatory action'' under Executive
Order 12866,
(2) Would not affect intrastate aviation in Alaska, and
(3) Would 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 Proposed Amendment
Accordingly, under the authority delegated to me by the
Administrator, the FAA proposes to amend 14 CFR part 39 as follows:
PART 39--AIRWORTHINESS DIRECTIVES
0
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]
0
2. The FAA amends Sec. 39.13 by adding the following new airworthiness
directive:
Bell Textron Canada Limited: Docket No. FAA-2025-3436; Project
Identifier MCAI-2024-00314-R.
(a) Comments Due Date
The FAA must receive comments on this airworthiness directive
(AD) by January 2, 2026.
(b) Affected ADs
None.
(c) Applicability
This AD applies to Bell Textron Canada Limited Model 407
helicopters, certificated in any category, with a pilot cyclic stick
tube assembly part number (P/N) 206-001-342-101 or P/N 206-001-342-
101FM installed.
(d) Subject
Joint Aircraft System Component (JASC) Code 6710, Main Rotor
Control.
(e) Unsafe Condition
This AD was prompted by a report of a fractured pilot cyclic
stick tube and subsequent findings of other pilot cyclic stick tubes
with fatigue cracking. The FAA is issuing this AD to detect and
correct a crack in the pilot cyclic stick tube which, if not
addressed, could lead to an in-flight failure of the pilot cyclic
stick tube and consequent loss of control of the helicopter.
(f) Compliance
Comply with this AD within the compliance times specified,
unless already done.
(g) Required Actions
(1) Except as specified in paragraphs (h) and (i) of this AD:
Comply with all required actions and compliance times specified in,
and in accordance with, Transport Canada AD CF-2024-18, dated May
29, 2024 (Transport Canada AD CF-2024-18).
(2) For a pilot cyclic stick tube assembly that has accumulated
3,600 or more hours time-in-service if, after complying with
paragraph (g)(1) no cracks are identified, thereafter, at intervals
not to exceed 300 hours time-in-service or 6 months, whichever
occurs first, perform a detailed inspection of the pilot cyclic
stick tube assembly in accordance with Part II paragraph A. of
Transport Canada AD CF-2024-18.
(h) Exceptions to Transport Canada AD CF-2024-18
(1) Where Transport Canada AD CF-2024-18 refers to its effective
date, this AD requires using the effective date of this AD.
(2) Where Transport Canada AD CF-2024-18 requires compliance in
terms of air time, this AD requires using hours time-in-service.
(3) This AD does not adopt Part I, Rotorcraft Flight Manual
(RFM) Revision--Applicable to Group 1 Helicopters, of Transport
Canada AD CF-2024-18.
(4) Where Transport Canada AD CF-2024-18 states ``Part II--
Inspection and Replacement or Repair of Cyclic Stick Tube Assembly--
Applicable to Group 2 Helicopters'', this AD requires replacing that
text with ``Part II--Inspection and Replacement or Repair of Cyclic
Stick Tube Assembly--All Helicopters.''
(i) No Reporting Requirement
Although the material referenced in Transport Canada AD CF-2024-
18 specifies to submit certain information to the manufacturer, this
AD does not include that requirement.
(j) Alternative Methods of Compliance (AMOCs)
(1) The Manager, International Validation 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 International Validation Branch, send
it to the attention of the person identified in paragraph (k) of
this AD and email to: <a href="/cdn-cgi/l/email-protection#d594989a9695b3b4b4fbb2baa3"><span class="__cf_email__" data-cfemail="e7a6aaa8a4a7818686c9808891">[email protected]</span></a>.
(2) Before using any approved AMOC, notify your appropriate
principal inspector, or lacking a principal inspector, the manager
of the local flight standards district office/certificate holding
district office.
(k) Additional Information
For more information about this AD, contact Alexis Whitaker,
Aviation Safety Engineer, FAA, 1600 Stewart Avenue, Suite 410,
Westbury, NY 11590; phone: (516) 228-7309; email:
<a href="/cdn-cgi/l/email-protection#72131e170a1b015c185c051a1b0613191700321413135c151d04"><span class="__cf_email__" data-cfemail="1879747d60716b3672366f70716c79737d6a587e7979367f776e">[email protected]</span></a>.
(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) Transport Canada AD CF-2024-18, dated May 29, 2024.
(ii) [Reserved]
(3) For Transport Canada material identified in this AD, contact
Transport Canada, Transport Canada National Aircraft Certification,
159 Cleopatra Drive, Nepean, Ontario, K1A 0N5, Canada; phone: (888)
663-3639; email: <a href="/cdn-cgi/l/email-protection#3e4a5d105f574c49514c4a5657505b4d4d5a574c5b5d4a57485b4d135d51504d5759505b4d5a5b505f4857595f5c5752574a5b10025f1e564c5b5803" mailto:TC@tc.gc.ca"><span class="__cf_email__" data-cfemail="b7e3f4f7c3d499d0d499d4d6">[email protected]</span></a>">tc.airworthinessdirectives-consignesdenavigabilite.<a href="/cdn-cgi/l/email-protection#386c7b784c5b165f5b165b59"><span class="__cf_email__" data-cfemail="5105121125327f36327f3230">[email protected]</span></a></a>; website: tc.canada.ca/en/
aviation. You may find the Transport Canada material on the
Transport Canada website at tc.canada.ca/en/aviation.
(4) You may view this material at the FAA, Office of the
Regional Counsel, Southwest Region, 10101 Hillwood Parkway, Room 6N-
321, 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 Administration (NARA). For information on the availability
of this material at NARA, visit <a href="http://www.archives.gov/federal-register/cfr/ibr-locations">www.archives.gov/federal-register/cfr/ibr-locations</a> or email <a href="/cdn-cgi/l/email-protection#3b5d49155255484b5e584f5254557b555a495a155c544d"><span class="__cf_email__" data-cfemail="3f594d1156514c4f5a5c4b5650517f515e4d5e11585049">[email protected]</span></a>.
[[Page 51605]]
Issued on October 17, 2025.
Christopher R. Parker,
Acting Deputy Director, Compliance & Airworthiness Division, Aircraft
Certification Service.
[FR Doc. 2025-20090 Filed 11-17-25; 8:45 am]
BILLING CODE 4910-13-P
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