The Navy and Air Force have been cleared to resume flying their V-22 Ospreys after conducting inspections on a crucial gearbox in the tiltrotor aircraft, with some already back in the air. This decision comes after a temporary suspension of Osprey flights on December 9, 2024, following a near crash in New Mexico. The Marines quickly resumed their Osprey flights, while the Navy and Air Force remained grounded longer to investigate metal component failures.
The Naval Air Systems Command (NAVAIR) issued a bulletin instructing crews to verify the number of flight hours for each aircraft’s proprotor gearbox. Ospreys that have meet or exceeded a specific number of flight hours can resume flying under previously established limitations. NAVAIR has not disclosed the specific flight hour threshold due to operational security concerns. If gearboxes are found to have fewer flight hours, they must adhere to a new, stricter set of limitations.
The grounding was influenced by a fatal crash of an Air Force CV-22 near Japan in November 2023, attributed to a cracked gear with impurities that weakened the metal. Similar metal weaknesses may have contributed to the near crash reported in November 2024.
Osprey manufacturer Bell is collaborating with the V-22 Joint Program Office to enhance the gears by reducing the occurrence of such impurities. However, the rollout of these upgrades will take time, prompting the military to find a temporary solution to keep Ospreys operational. Air Force Special Operations Command Spokeswoman Lt. Col. Becky Heyse emphasized the importance of maintaining pilot proficiency and operational readiness while longer-term fixes are developed.
Studies indicate that gear cracks generally occur early in the life of the Osprey when impurities are present. Once these aircraft have flown a sufficient number of hours and are “broken in,” the likelihood of cracks decreases, enhancing military confidence in their safety. Until the gearboxes are upgraded or aircraft exceed the flight hour threshold, the stricter guidelines will remain in effect.
NAVAIR stated that the new inspection protocols had already been in place, with Air Force Special Operations Command inspecting certain aircraft before the latest announcements, allowing some Ospreys to resume flying. The exact number of affected Ospreys and their additional flight restrictions have not been disclosed due to security concerns.
In terms of fleet sizes, the Marine Corps possesses approximately 350 Ospreys, while the Air Force has about 52 and the Navy holds roughly 30.
Stephen Losey is the air warfare reporter for Defense News, with previous experience covering various aspects of military operations and personnel issues.
