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TEXT
:UNCLAS
SUBJECT - AVIATION SAFETY ACTION MESSAGE, INFORMATIONAL, RCS
CSGLD-1860(R1),ALL CH-47D, MH-47D AND MH-47E AIRCRAFT WITH
ENGINE TRANSMISSIONS UTILIZING SPECO MANUFACTURED GEARS
(CH-47-95-ASAM-03). NOTE THIS ASAM IS INFORMATIONAL ONLY NO
ACTION IS REQUIRED.
NOTE - THIS IS AN AVIATION SAFETY ACTION MESSAGE ISSUED PER
AR 95-3, CHAPTER 5 REVISION VIA MESSAGE HQ AVSCOM, AMSAV-
XSOF, 181900Z SEP 90, SUBJECT:  CHANGE TO AR 95-3, CHAPTER
5, SAFETY OF FLIGHT MESSAGES.  THIS MESSAGE HAS NOT BEEN
TRANSMITTED TO UNITS SUBORDINATE TO ADDRESSEES.  ADDRESSEES
SHOULD IMMEDIATELY RETRANSMIT THIS MESSAGE TO ALL
SUBORDINATE UNITS, ACTIVITIES OR ELEMENTS AFFECTED OR
CONCERNED.  THE RETRANSMITTAL SHALL REFERENCE THE MESSAGE.
ACTION ADDRESSES WILL IMMEDIATELY VERIFY THIS RETRANSMISSION
TO COMMANDER, ATCOM, ATTN - AMSAT-R-X (SOF COMPLIANCE
OFFICER).
1.  PRIORITY CLASSIFICATION - N/A.
2.  TASK/INSPECTION SUSPENSE DATE - N/A.
3.  REPORTING COMPLIANCE SUSPENSE DATE - N/A.
4.  SUMMARY OF PROBLEM -
   A.  TWO SAFETY-OF-FLIGHT MESSAGES (CH-47-91-01)(TB 1-1520-
240-20-55) AND (CH-47-93-03)(TB 1-1520-240-20-66) WERE
ISSUED TO IDENTIFY THE UNSERVICEABLE ENGINE TRANSMISSIONS,
P/N 145D6300-(SERIES).  THESE SOF MESSAGES WERE GENERATED BY
A 1991 OPERATION DESERT STORM INCIDENT AND BY A 1993 FT.
MEADE INCIDENT INVOLVING A CH-47D ENGINE TRANSMISSION.  THE
FAILURES WERE CAUSED BY GEARS MANUFACTURED BY SPECO
CORPORATION. SINCE THEN THE GEARS HAVE UNDERGONE A PROGRAM
OF INTENSIVE INSPECTION AND CHANGES IN MANUFACTURING
PROCESSES TO ELIMINATE THE CAUSE OF THE PROBLEM.  HOWEVER,
TWO MEMORANDUMS, ONE FROM THE DEPARTMENT OF DEFENSE
INSPECTOR GENERAL, 2 DEC 1994, NOTIFICATION OF DEFECTIVE
TRANSMISSION GEARS FOR THE BOEING CH-47, CHINOOK HELICOPTER
AND THE OTHER FROM THE 515TH MILITARY POLICE DETACHMENT
(CID), 3 JAN 95, SUBJECT: CRIMINAL ALERT NOTICE, HAVE BEEN
PUBLISHED.  THESE MESSAGES ARE INCOMPLETE AND DO NOT CONTAIN
THE MOST CURRENT INFORMATION AND MEASURES THAT HAVE BEEN PUT
IN PLACE TO SOLVE THE PROBLEM.  THEREFORE, THE CID
INFORMATION/MESSAGE DOES NOT REFLECT UPDATED INFORMATION.
ATCOM IS CONTINUING THE TECHNICAL INVESTIGATION OF THE
ALLEGATIONS. AT THIS TIME IN THE INVESTIGATION, THERE HAS
BEEN NO INDICATION OF A SAFETY PROBLEM WITH THESE GEARS.
     B.  TWO ACCIDENTS WERE CAUSED BY THE FAILED SPECO
GEARS.  ONE ACCIDENT OCCURRED IN SAUDI ARABIA IN 1991 AND
THE OTHER AT FT. MEADE IN 1993.  BOTH ACCIDENTS WERE
THOROUGHLY INVESTIGATED AND APPROPRIATE CORRECTIVE ACTIONS
WERE TAKEN.
     C.  ALL SPECO GEARS WENT THROUGH AN ADDITIONAL NON
DESTRUCTIVE INSPECTION (NDI) FOLLOWING THE SAUDI ACCIDENT.
AS A RESULT THE MANUFACTURING PROCESSES AND PLANS WERE
CHANGED TO ELIMINATE THE CAUSE OF THE CRACKS- POST
CARBURIZING GRINDING OF THE DAMPING RING GROOVES.
     D.  THE FT. MEADE FAILURE INITIATED IN AN AREA OF A NON-
AUTHORIZED REWORK FOR THE REMOVAL OF BURRS.  THE
MANUFACTURING PLAN FOR THE GEAR, BOEING P/N 145D6302-2, DID
NOT HAVE AN APPROVED PROCEDURE FOR DEBURRING OPERATION IN
THE AREA OF THE GEAR THAT FAILED.  THIS WAS THE ONLY PART
NUMBER AND THE ONLY AREA ON THE GEAR WHERE THE DEBURRING
OPERATION WAS NOT CONTROLLED.  CHANGES IN THE MANUFACTURING
PLAN WERE ADDRESSED AND ALL P/N 145D6302-2 GEARS WERE
INSPECTED AGAIN.  THE GEARS ARE USED IN THE CH-47D, MH-47D
AND MH-47E TRANSMISSIONS, P/N 145D6300 SERIES.
     E.  THE INSPECTIONS RESULTED IN SOME GEARS BEING
REJECTED.  THE DMWRS WERE REVISED TO INCLUDE MORE STRINGENT
INSPECTIONS.  THERE HAS BEEN NO REOCCURRENCE OF THESE
FAILURES IN THE THOUSANDS OF FLYING HOURS SUBSEQUENT TO THE
INSPECTIONS.
     F. FOR MANPOWER/DOWNTIME AND FUNDING IMPACTS SEE PARA
12.
     G. THE PURPOSE OF THIS MESSAGE IS TO INFORM THE USER OF
UPDATED INFORMATION WHICH IS NOT REFLECTED IN REFERENCE
13A,B OF THIS MESSAGE.
5.  END ITEMS TO BE INSPECTED - N/A.
6.  ASSEMBLY COMPONENTS TO BE INSPECTED - N/A.
7.  PARTS TO BE INSPECTED - N/A.
8.  INSPECTION PROCEDURES - N/A.
9.  CORRECTION PROCEDURES - N/A.
10.  SUPPLY/PARTS AND DISPOSITION - N/A.
11.  SPECIAL TOOLS, JIGS AND FIXTURES REQUIRED - N/A.
12.  APPLICATION - N/A.
13.  REFERENCES -
     A.  DEPARTMENT OF DEFENSE INSPECTOR GENERAL, 2 DEC
1994, NOTIFICATION OF DEFECTIVE TRANSMISSION GEARS FOR THE
BOEING CH-47D, CHINOOK HELICOPTER.
     B.  515TH MILITARY POLICE DETACHMENT (CID), 3 JAN 95,
CRIMINAL ALERT NOTICE.
     C.  SOF  CH-47-91-01 AND TB 1-1520-240-20-55.
     D.  SOF  CH-47-93-03 AND TB 1-1520-240-20-66.
14.  RECORDING AND REPORTING REQUIREMENTS - N/A.
15.  WEIGHT AND BALANCE - N/A.
16.  POINTS OF CONTACT -
     A.  TECHNICAL POINTS OF CONTACT FOR THIS MESSAGE ARE
MR. DAVID BRAUN, SAIC CONTRACTOR, OR MR. MIKE WRIGHT, AMSAT-
R-ECC, DSN 693-3820 OR COMMERCIAL 314/263-3820.
     B.  LOGISTICAL POINT OF CONTACT FOR THIS MESSAGE IS MR.
NORM HUSTON, SFAE-AV-CH-L, DSN 693-1415 OR COMMERCIAL
314/263-1415.
     C.  FORMS AND RECORDS POINT OF CONTACT FOR THIS MESSAGE
IS MS. ANN WALDECK, AMSAT-I-MDM, DSN 693-1821/1758 OR
COMMERCIAL 314/263-1821/1758.
     D.  SAFETY POINT OF CONTACT FOR THIS MESSAGE IS MR. JIM
WILKINS, AMSAT-R-X, DSN 693-2258 OR COMMERCIAL 314/263-2258.
     E.  FOREIGN MILITARY SALES (FMS) RECIPIENTS REQUIRING
CLARIFICATION OF ACTION ADVISED BY THIS MESSAGE SHOULD
CONTACT CW5 JAY NANCE/MR. RON VAN REES, AMSAT-I-IAF, DSN 693-
3826/3659 OR COMMERCIAL 314/263-3826/3659.
     F.  AFTER HOURS CONTACT ATCOM COMMAND OPERATIONS CENTER
(AOC) DSN 693-2066/7 OR COMMERCIAL 314./263-2066/7.