FAA Orders Crack Checks on Bell Helicopter Control Sticks
Published Date: 11/18/2025
Proposed Rule
Summary
The FAA wants Bell Model 407 helicopter owners to regularly check the pilot cyclic stick tube for cracks because some have broken or shown signs of wear. If cracks are found, the stick tube must be fixed or replaced to keep flying safe. Comments on this plan are open until January 2, 2026, and these inspections might cost some time and money but keep pilots safe.
Analyzed Economic Effects
3 provisions identified: 0 benefits, 3 costs, 0 mixed.
Mandatory inspections and fixes for Model 407
If you own or operate a Bell Model 407 helicopter with pilot cyclic stick tube part number 206-001-342-101 or 206-001-342-101FM, the FAA would require repetitive inspections of the pilot cyclic stick tube assembly for cracks and, if cracks are found, repair or replacement before further flight. The rule incorporates Transport Canada AD CF-2024-18 by reference and applies to all serial-numbered Model 407 helicopters with those part numbers.
Recurring inspection rule for high-hours assemblies
If a pilot cyclic stick tube assembly has accumulated 3,600 or more hours time-in-service, you must perform a detailed inspection thereafter at intervals not to exceed every 300 hours time-in-service or every 6 months, whichever occurs first. The FAA added this repetitive-inspection requirement to address high loading during hydraulic-off training and emergency procedures.
Estimated compliance costs and fleet size affected
The FAA estimates this proposed AD would affect 944 Model 407 helicopters on the U.S. registry. The agency estimates an initial inspection at up to 4 work‑hours (4 × $85/hr = $340) per helicopter and gives example on‑condition costs: repair labor 6 work‑hours ($510), repetitive inspection 2 work‑hours ($170) per inspection, and full replacement estimated at $1,714 (2 work‑hours = $170 plus parts $1,544).
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