Faulty Helicopter Bolts Could Fail: FAA Demands Replacements Now
Published Date: 12/5/2025
Proposed Rule
Summary
The FAA wants all Airbus Helicopters Deutschland MBB-BK 117 D-3 helicopters to replace certain bolts on their flight controls because some bolts might crack and fail. They’re also banning the use of these risky bolts in the future to keep flights safe. Comments on this plan are open until January 20, 2026, and helicopter owners should prepare for the replacement to avoid safety issues.
Analyzed Economic Effects
2 provisions identified: 0 benefits, 2 costs, 0 mixed.
Mandatory bolt inspection and replacement
If you operate an Airbus Helicopters Deutschland Model MBB-BK 117 D-3 helicopter, you must inspect and replace certain bolts (part number D671M7051211) on the horizontal control rods that were not dye-penetrant inspected during manufacturing. The FAA would require checking serial numbers listed in Airbus Helicopters Alert Service Bulletin ASB MBB-BK117 D-3-67A-002, Revision 1, dated July 29, 2024, and replacing affected bolts; the FAA estimates 146 U.S. helicopters are affected and estimates the cost per helicopter at $441 (4 work-hours x $85/hour = $340 labor plus $101 parts), for a total U.S. cost of $64,386. Comments on the proposal are due January 20, 2026.
Prohibition on using affected bolts
The FAA would prohibit installing affected bolts (part number D671M7051211 with serial numbers listed in Airbus Helicopters ASB MBB-BK117 D-3-67A-002, Revision 1, dated July 29, 2024) on any helicopter. This ban is intended to prevent future installations of bolts that were not dye-penetrant inspected and could fail.
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