V-22 "Osprey" will be in service until 2055. The US military adds 14 suppliers to replace new gears to solve the crash crisis

The picture shows the U.S. Marine Corps MV-22 transport helicopter. (DVIDS)

[Reporter Wu Zheyu/Comprehensive Report] The US military's V-22 "Osprey" tilt-rotor aircraft has suffered a series of fatal crashes in recent years. Gearbox failures and flight restrictions have also seriously affected the availability of the fleet. To ensure that this military aircraft can continue to be in service beyond 2055, the U.S. Navy's V-22 Joint Program Office (PMA-275) and manufacturer Bell Boeing are expanding the supply chain, recently announcing the addition of 14 new partners, and accelerating the improvement of component reliability and fleet modernization.

The military news website "Defence Blog" reported that the V-22 Office recently held an "Osprey Team Working Group" meeting with Bell Boeing, attracting about 200 representatives from 6 allies, 7 U.S. government agencies, and more than 35 defense and manufacturing companies to discuss how to improve parts supply, enhance component reliability, and enhance fleet logistics maintenance capabilities. However, the US military did not announce the list of new suppliers and allies participating in the meeting.

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Colonel Robert Hurst, V-22 program manager, said that by coordinating the global supply chain and introducing new technologies, parts supply capabilities on the flight line can be improved to ensure that deployed troops can maintain rapid transportation and logistics flexibility in high-threat environments.

The biggest feature of the V-22 is that it combines the vertical take-off and landing capabilities of a helicopter with the high-speed cruising capabilities of a fixed-wing aircraft. It can tilt the rotors on both sides forward to achieve a speed and range superior to traditional helicopters. The U.S. Marine Corps uses the MV-22 to transport troops and supplies, the U.S. Air Force CV-22 is responsible for the infiltration and evacuation of special forces, and the Navy CMV-22 performs aircraft carrier personnel and supply transportation tasks, and has fully replaced the C-2 Greyhound transport aircraft that was retired this year.

However, the V-22 has long been plagued by transmission system problems. Since 2022, there have been four crashes, killing 20 US officers and soldiers. Some of the accidents were related to propeller gearbox failures and the "hard clutch engagement" phenomenon in which the clutch suddenly re-engages.

Among them, a CV-22 crashed off the coast of Japan in November 2023, killing eight people, resulting in the complete grounding of all V-22 fleets in the US military. Flights will not be gradually resumed until March 2024, but they are still subject to range and other operational restrictions, affecting actual deployment capabilities.

In order to solve related problems, the US military has begun to receive redesigned gearboxes from January 2026, using higher-strength triple-melted steel components. Currently, about 12 sets are delivered every month. According to the Marine Corps aviation plan, unrestricted operational use of the fleet is expected to resume in December 2027.

As for the complete completion of the gearbox upgrade, the U.S. Navy and Air Force are expected to complete it in 2029, while the Marine Corps will have to wait until 2033. The U.S. military hopes to reduce long-term maintenance burdens by expanding suppliers and improving the life of key parts, ensuring that the V-22 can maintain its expeditionary transportation and special operations capabilities for decades to come.