FAA Mandates Float Replacements on Leonardo Helicopters
Published Date: 11/20/2025
Rule
Summary
If you own or work with Leonardo AW169 helicopters, listen up! The FAA is updating safety rules that require replacing certain float parts within 24 months or during your next scheduled maintenance. This keeps the helicopters safe and flying smoothly, with no surprise costs announced yet—just a smart move to avoid bigger problems later.
Analyzed Economic Effects
6 provisions identified: 3 benefits, 3 costs, 0 mixed.
Mandatory float replacement schedule
If you operate a Leonardo AW169 helicopter, you must replace certain forward and aft float assemblies within 24 months or during the next accomplishment of maintenance task 95-24 or 95-25. This requirement is part of the FAA airworthiness directive effective December 26, 2025, and applies to all AW169 helicopters certificated in any category.
Estimated replacement cost per helicopter
The FAA estimates replacement takes 2 work‑hours per affected float and parts cost up to $38,000 for an aft float with life raft and up to $19,000 for a forward float. The agency estimates up to $114,170 per helicopter (covering up to two aft and up to two forward assemblies) and a total U.S. fleet cost of $2,625,910 for 23 affected helicopters. Labor is estimated at $85 per hour.
Prohibition on installing affected float assemblies
The AD incorporates the EASA requirement that prohibits installing an affected forward or aft float assembly on a helicopter. Operators may not reinstall or install these affected assemblies as part of maintenance.
Lower‑cost compliance alternative: EFS deactivation
As an alternative to replacement, deactivating the emergency flotation system (EFS) is an allowed compliance action. The FAA estimates deactivation takes about 1 work‑hour (at $85/hour), with an estimated cost of $85 per helicopter and $1,955 for the U.S. fleet of 23 helicopters.
No requirement to return removed floats
The FAA AD does not require operators to send removed float assemblies to Leonardo, even though the referenced EASA AD's service information specifies sending removed floats to the manufacturer. This AD also does not adopt the EASA 'Remarks' section and does not require reporting to the manufacturer.
Possible warranty coverage may reduce operator costs
The FAA notes the manufacturer has stated some of the costs of this AD may be covered under warranty, which could reduce the out-of-pocket cost for affected operators.
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