Navy investigation finds Osprey safety issues were allowed to grow for years

“As a result, risks continue to accumulate,” the report said.

The Associated Press reported last year that the most serious types of accidents for the Osprey, which is the only aircraft to fly like a plane but convert to land like a helicopter, spiked between 2019 and 2023 and that, unlike other aircraft, the problems did not level off as the years passed.

“As the first and only military tiltrotor aircraft, it remains the most aero-mechanically complex aircraft in service and continues to face unresolved legacy material, safety, and technical challenges,” the report said.

Commissioned in 2023 by NAVAIR, the Navy command responsible for the purchase and maintenance of aircraft, the investigation reveals that the Osprey not only has the “second highest number of catastrophic risks across all Naval Aviation platforms” but that those risks have gone unresolved for an average of more than 10 years.

By contrast, the average across other aircraft in the Navy's inventory is six years.

The Navy's response

Vice Adm. John Dougherty, commander of NAVAIR, said the service is “committed to improving the V-22’s performance and safeguarding the warfighters who rely on this platform.” He offered no details on any actions taken for years of failing to address the Osprey's risks.

The command did not respond to questions about what, if any, accountability measures were taken in response to the findings.

The lack of details on accountability for missteps also came up when the Navy recently released investigations into four accidents during a U.S.-led campaign against Yemen’s Houthi rebels. A senior Navy official, who spoke to reporters on the condition of anonymity to offer more candid details, said that he didn’t believe the service had an obligation to make accountability actions public.

Risks were allowed to build up, the report says

The investigation lays much of the responsibility for the problems on the Osprey's Joint Program Office. Part of the mission for this office, which operates within NAVAIR, is making sure the aircraft can be safely flown by the Marine Corps, the Navy and the Air Force, all of which use different versions of the aircraft for different missions.

The report found that this office “did not effectively manage or address identified risks in a timely manner, allowing them to accumulate,” and it faced “challenges” in implementing safety fixes across all three services.

Two major issues involve the Osprey's complicated transmission. The aircraft has a host of gearboxes and clutches that, like a car’s transmission, are crucial to powering each propeller behind the Osprey’s unique tilting capability. The system also helps connect the two sides of the aircraft to keep it flying in the event of engine failure.

One problem is an issue in which the transmission system essentially shreds itself from the inside due to a power imbalance in the engines. That brought down a Marine Corps Osprey, killing five Marines in California in 2022.

The other issue is a manufacturing defect in the gears within the transmission that renders them more brittle and prone to failure. That was behind the crash of an Air Force Osprey off the coast of Japan in November 2023 that killed eight service members.

The report reveals that this manufacturing issue went back to 2006 but the Osprey’s Joint Program Office did not formally assess or accept this risk until March 2024.

Besides these mechanical issues, the report found that the program office failed to ensure uniform maintenance standards for the aircraft, while determining that 81% of all the accidents that the Ospreys have had on the ground were due to human error.

Recommendations for the issues revealed

The report offers a series of recommendations for each of the issues it uncovered. They range from rudimentary suggestions like consolidating best maintenance practices across all the services to more systemic fixes like developing a new, midlife upgrade program for the Osprey.

While fixes for both mechanical issues are also in the report, it seems that it will take until 2034 and 2033 for the military to fully deal with both, respectively.

Naval Air Systems Command did not reply when asked if it had a message for troops who will fly in the aircraft in the meantime.

Watchdog also releases Osprey report

The Government Accountability Office, an independent watchdog serving Congress, made similar conclusions and recommendations in a separate report released Friday.

The GAO blamed most Osprey accidents on part failures and human error while service members flew or maintained the aircraft. It determined that the military hasn’t fully “identified, analyzed, or responded” to all of the Osprey’s safety risks.

The GAO said the Pentagon should improve its process for addressing those risks, while adding more oversight to ensure they are resolved. Another recommendation is for the Navy, Air Force and Marines to routinely share information on hazards and accidents to help prevent mishaps.

Associated Press writer Ben Finley contributed to this report.