01 08 311827Z JAN PP PP UUUU :CDRATCOM ST LOUIS MO//AMSAT-R-X// TO :AIG 6713 :AIG 9004 :AIG 8708 :AIG 9042 :AIG 7471 :AIG 12124 :DEFAIR MATERIAL CANBERRA AS//DAAP-AF// :ARMYLMSQN OAKEY AS :AVCEN OAKEY AS//DAVN-A// :CDRUSARDSG CANBERRA AS :LOGCON OTTAWA CAN//DTHEM 6-2// :EGYPT AF FMS CAIRO EG//ED-MA// :USOMC CAIRO EG//AV// :ODC ATHENS GR//ODCSA// :CDR4THBN228THAVN SOTO CANO HO//AVN-AMO// :102DARMY SCOTT AFB IL//AFRC-AMO-ASF-IL// :CHJUSMAG SEOUL KOR//MKAR// :HQROKA TAEJON KOR//DCSLOG-AVIATION/ROKA-AVIATON// :ROK ARMY FMS PUSAN KOR//ALC-LSD-L// :CDR160TH SOAR FT CAMPBELL KY//AOAV-SI// :CDRBGAD RICHMOND KY//SDSBG-GC// :USDAO RABAT MO//AF// :CHUSAS RIYADH SA//ASAV// :ODC MADRID SP//ASM// :SPAIN ARMY FMS MADRID SP :AIT TAIPEI TW :CJUSMAG THAI BANGKOK TH//MAGTAR-FS// :CDRUSARDSG LONDON UK//AMXSN-UK-SE// :ODC LONDON UK INFO :CDRAMCCOM ROCK ISLAND IL//AMSAR-QAS-P// :CDRAMC ALEXANDRIA VA//AMCMR/AMCCS/AMCSM-WAA// XMT :USDAO DHAKA BG :USDAO RANGOON BM :USCINCPAC REP PHNOM PENH CB :USDAO COLOMBO CE :USDAO SUVA FJ :OMADP JAKARTA ID :DSA NEW DELHI IN :AMEMBASSY ANTANANARIVO MA :AMEMBASSY PORT LOUIS :SAO KUALA LUMPUR MY :AMEMBASSY KATHMANDU NP//POL-MIL// :AMEMBASSY VICTORIA :SAO SINGAPORE SN ACCT : 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.