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Congress Confronts Osprey Safety Gaps as GAO Reports Higher Mishap Rates, Low Readiness

Program leaders pointed to gearbox fixes plus a 2027 redesign as the route to restoring availability.

Overview

  • GAO testified that Marine Corps and Air Force V-22 Class A/B mishap rates in fiscal 2023–2024 exceeded broader fleet averages and warned of weak cross‑service safety oversight.
  • Program officials told lawmakers that mission‑capable rates stand at roughly 50 percent for Marine squadrons and about 40 percent for Navy aircraft.
  • NAVAIR reported zero hard‑clutch engagements since services imposed life limits on the input quill assembly in February 2023.
  • The Marine‑led program is delivering improved gearboxes at a rate of 12 per month, a step officials say will help remove airworthiness controls in place since March 2024.
  • Leaders outlined a modernization path that includes qualifying a new gearbox for late‑2027 fielding, targeting full fleet transition by 2033, and pursuing a broader mid‑life upgrade.