Cracked Tail Rotor Blades Prompt Another FAA Inspection Directive
Published Date: 11/9/2026
Rule
Summary
If you fly Airbus Helicopters Deutschland GmbH EC135 or EC635 models, listen up! The FAA is updating safety rules to keep your tail rotor blades crack-free by stopping one old inspection method and adding new limits. Starting December 14, 2026, you’ll need to inspect, fix, or replace parts to keep flying safe—no shortcuts allowed, and it might cost some time and money but keeps everyone safer in the sky.
Analyzed Economic Effects
5 provisions identified: 0 benefits, 5 costs, 0 mixed.
Mandatory repetitive tail-rotor inspections
If you operate an AHD Model EC135 or EC635T2+ helicopter, you must perform repetitive inspections of certain tail rotor blade (TRB) assemblies for cracks per EASA AD 2026-0032 as adopted by this AD, starting with this AD effective December 14, 2026. The FAA estimates this AD affects 359 U.S.-registered helicopters and estimates inspection labor at 3 work-hours (3 x $85/hr = $255) per affected TRB assembly.
Replacement allowed as terminating action — parts cost noted
If an inspection finds a crack, you must remove the cracked TRB assembly and replace it; replacing an affected TRB assembly is a terminating action for repetitive inspections. The AD lists an on-condition parts cost of $4,900 per TRB assembly and an example maximum on-condition cost of up to $51,550 per product.
Prohibition on installing certain TRB assemblies
The AD prohibits installing an affected TRB assembly on any helicopter unless certain requirements in EASA AD 2026-0032 (as modified by this AD) are met. The rule explicitly retains the installation prohibition language from the prior ADs and the incorporated EASA AD.
Inspection method change — Method A discontinued
The AD discontinues use of the previously approved Type II visible dye inspection Method A (dye-penetrant with increased temperature) and requires alternative inspection methods: e.g., eddy current or fluorescent penetrant in specified scenarios, with specific rules for parts previously inspected by Type II visible dye. The FAA also references SAIB CE-18-26R1 regarding risks of type II visible dye inspections.
No special flight permits allowed
The AD explicitly states that special flight permits under 14 CFR 21.197 and 21.199 are not allowed for affected helicopters. That means you cannot fly an affected helicopter under a special flight permit for maintenance or other purposes while non-compliant with this AD.
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