Sikorsky unveils S-92 Phase IV main gearbox

Sikorsky, a Lockheed Martin company, unveiled the highly anticipated S-92 Phase IV main gearbox, a transformative innovation that sets a new benchmark for reliability, performance and safety in the commercial helicopter industry.

The S-92 Phase IV main gearbox features an auxiliary lubrication system that automatically engages in the event of primary oil pressure loss, eliminating the need for immediate landing and allowing operators to safely reach their destination. This revolutionary solution has been validated through more than 800 hours of rigorous testing, and Federal Aviation Administration (FAA) certification is anticipated in 2025. Four gearboxes have been completed at the company’s Stratford headquarters, and customers are already vying to become first adopters.

“The Phase IV main gearbox builds upon its predecessor’s reputation as one of the best and most reliable gearboxes in the industry, and is yet another example of Sikorsky's continued investment in the S-92 platform,” said Leon Silva, vice president of Global Commercial and Military Systems at Sikorsky. "We have spent more than a decade designing, testing and optimizing the Phase IV main gearbox for exceptional performance, and we are thrilled to see it become a new industry standard."

Sikorsky invested more than $100 million into developing the gearbox, enabling customers to meet future mission requirements and underscoring the company’s commitment to enhancing the S-92 platform. The S-92 helicopter is the workhorse of the offshore energy industry, and a trusted choice for search and rescue, head of state transportation and other critical missions around the world.

Unveiling the Phase IV main gearbox represents a major milestone in Sikorsky's ongoing effort to enhance the capability and safety of the S-92 fleet. With a lifetime availability average over 90%, many S-92 aircraft servicing the demanding offshore energy industry achieve more than 1,500 flight hours per year on average. As the offshore energy industry continues to evolve, the S-92 Phase IV main gearbox is well-positioned to support the increasing demands of deepwater operations, providing a safe and reliable means of transporting personnel, equipment and supplies to remote locations.

Sikorsky has announced several enhancements to the S-92 helicopter in recent months, including increased scheduled inspection intervals and a one-time life extension for specific main gearbox housings. These enhancements will eliminate more than a full year of downtime caused by inspections and allow operators to safely keep their aircraft in service and generating revenues longer. The earned life credit is up to 1,200 hours / 3,600 ground-air-ground cycles, representing an additional 12 to 18 months for an average S-92 offshore oil operator and more than 24 months for others.