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New Reports Reveal Years of Unaddressed Osprey Safety Risks
DEEP DIVE — It is one of the most lauded defense developments in recent decades, providing preeminent capability to U.S. military personnel worldwide, but that prowess evidently comes with a steep cost that military leadership allowed to grow for years.
Critics have long asserted that the military failed to adequately address a mounting series of safety issues with the V-22 Osprey aircraft, even as service members died in preventable crashes. The Naval Air Systems Command review and Government Accountability Office report paint a scathing portrait of systemic failures by the Joint Program Office overseeing V-22 variants for the Air Force, Marine Corps, and Navy.
The Marine Corps operates approximately 348 MV-22s, the Air Force 52 CV-22s, and the Navy 29 CMV-22s, with the program of record at around 464 total across services. Japan operates 17 MV-22s, with deliveries complete or near-complete.
The Deadly Track Record
Some 30 U.S. Marines lost their lives in three separate crashes during the testing and development phase throughout the 1990s, giving the Osprey the nickname “The Widow Maker.” Since its introduction in 2007, at least 35 servicemembers have died in 10 fatal crashes.
“Initially, the V-22 suffered from Vortex Ring State, which produced crashes during development. The problem was diagnosed and remediated, and the loss rate went down dramatically,” John Pike, a leading defense, space and intelligence policy expert and Director of GlobalSecurity.org, tells The Cipher Brief. “Subsequent losses have been ‘normal accidents’ due to the usual mechanical and human failings.”
The GAO found that serious Osprey mishaps in 2023 and 2024 exceeded the previous eight years and generally surpassed accident rates of other Navy and Air Force aircraft. In August 2023, three Marines died in Australia. In 2022, four U.S. soldiers were killed in a NATO training mission, and five Marines were killed in California.
Unresolved Problems
The NAVAIR report revealed that “the cumulative risk posture of the V-22 platform has been growing since initial fielding,” and the program office “has not promptly implemented fixes.” Of 12 Class A mishaps in the past four years, seven involved parts failures already identified as major problems but not addressed.
Issues with hard-clutch engagement (HCE) caused the July 2022 California crash that killed five. The problem occurs when the clutch connecting the engine to the propeller gearbox slips and reengages abruptly, causing a power spike that can throw the aircraft into an uncontrolled roll.
There were eight Air Force servicemembers killed in the November 2023 crash off Yakushima Island when a catastrophic propeller gearbox failed due to cracks in the metal pinion gear, and the pilot continued flying despite multiple warnings, contributing to the crash.
This manufacturing issue dates to 2006, but the Joint Program Office didn’t formally assess the risk until March 2024 – nearly two decades later. A NAVAIR logbook review found that over 40 safety-critical components were operating beyond their airworthiness limits, and that 81 percent of ground accidents were due to human error.
A Broken System: Poor Communication Between Services
The GAO also found that the three services don’t routinely share critical safety information. Aircrews haven’t met regularly to review aircraft knowledge and emergency procedures. The services operate with significantly different maintenance standards, with three parallel review processes and no common source of material.
The GAO identified 34 unresolved safety risks, including eight potentially catastrophic risks that have remained open for a median of 10 years. The V-22 has the oldest average age of unresolved catastrophic safety risks across the Navy’s aircraft inventory.
Fixes May Take a Decade
The Navy report indicated fixes won’t be complete until 2033-2034. Officials now say the fleet won’t return to unrestricted operations until 2026 – a year later than planned. The V-22 program plans to upgrade gearboxes with triple-melted steel, reducing inclusions by 90 percent.
Under current restrictions, overwater flights are prohibited unless within 30 minutes of a safe landing spot, severely limiting their use by the Navy and Marine Corps.
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Osprey's Unmatched Capabilities
The Osprey still offers a game-changing advantage for U.S. troops, despite its troubled past, according to its supporters.
As it currently stands, the entire fleet operates under restrictions that prevent overwater flights unless within 30 minutes of a safe landing spot, significantly limiting its utility for Navy and Marine Corps missions.
In 1979 to 1980, American hostages were taken in Iran during Operation Eagle Claw, which gave rise to the Osprey. As five of the eight Navy helicopters that arrived at Desert One were inoperable, it was clear that rapid troop movement in harsh environmental conditions was urgently needed.
After development began in 1985, the Osprey entered service in 2007, replacing the Vietnam-era CH-46 Sea Knight.
Compared to fixed-wing transports, the Osprey can land troops just where they are needed. Airdrops with parachutes tend to scatter paratroops all over the place; see ‘Saving Private Ryan,’” Pike explained. “And compared with other rotary wing aircraft, the Osprey is much faster and has a much longer range.”
The Osprey shifts from helicopter to airplane mode in under 12 seconds, reaches speeds of 315 mph, has an operational range of 580 miles, and carries 10,000 pounds – or 24 troops. It’s used for missions ranging from combat operations to the occasional transport of White House staff. During a dust storm in Afghanistan in 2010, two CV-22 helicopters rescued 32 soldiers in under four hours from a distance of 800 miles.
Chronic Readiness Problems
Yet these performance advantages have been undercut by persistent readiness shortfalls.
The NAVAIR report noted that mission-capable rates between 2020 and 2024 averaged just 50 percent for the Navy and Air Force, and 60 percent for Marines. The Osprey requires 100 percent more unscheduled maintenance than the Navy averages and 22 maintenance man-hours per flight hour versus 12 for other aircraft.
In addition, Boeing settled a whistleblower lawsuit in 2023 for $8.1 million after employees accused the company of falsifying records for composite part testing. Boeing, in its defense, claimed that the parts were “non-critical” and did not impact flight safety.
Conflicting Views on Safety
“The Osprey does not have a troubled safety record. Per a recent press release, the V-22 mishap rate per 100,000 flight hours is 3.28, which is in line with helicopters with similar missions.” a government source who works closely with the Osprey fleet but is not authorized to speak on the record contended to The Cipher Brief. “Like anything measured statistically, there are periods above and below the mean. Just because humans tend to conclude because of apparent clusters doesn’t necessarily mean there is a pattern or connection – think of how some people say that ‘celebrities die in threes.’”
The source vowed that “the design issues, such as certain electrical wiring rubbing against hydraulic and oil lines, were fixed before fleet introduction.”
“The problems with the test plan were a product of pressure applied to accelerate a delayed and overbudget program and were not repeated when the aircraft was reintroduced,” the insider pointed out. “Those mishaps, combined with the distinctive nature of the V-22, mean that any subsequent incident, major or minor, is always viewed as part of the ‘dangerous V-22’ narrative. A U.S. Army Blackhawk crash in November killed five but barely made the news. A Japanese Blackhawk crash killed ten soldiers in April, but the Japanese didn’t ground their Blackhawks.”
That perception, however, has done little to quiet families who argue that known risks went unaddressed.
Amber Sax’s husband, Marine Corps Capt. John J. Sax died in the 2022 California crash caused by hard clutch engagement, a problem the Marine Corps had known about for over a decade. “Their findings confirm what we already know: More needs to be done, and more needs to be done,” Sax said. “It’s clear in the report that these risks were not properly assessed, and that failure cost my husband his life.”
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An Uncertain Future
As the military confronts those findings, the future of the Osprey fleet is not completely clear. In 2018, the Marine Corps Aviation proposal outlined a sustainability plan for the Osprey to at least 2060.
“The quality of maintenance training curricula, maturation, and standardization has not kept pace with readiness requirements,” the report stated. “Current maintenance manning levels are unable to support demands for labor. The current V-22 sustainment system cannot realize improved and sustained aircraft readiness and availability without significant change. Depot-level maintenance cannot keep up with demand.”
Despite extensive recommendations – NAVAIR underscored 32 actions to improve safety – Vice Adm. John Dougherty reaffirmed commitment to the aircraft. Pike believes it’s a matter of when, not if, the Osprey returns to full operations.
“Once the issues are fixed, everyone will resume their regular programming,” he asserted.
Officials and insiders alike expect that process to translate into tangible fixes.
“I would expect that to lead to some type of corrective action, whether it’s a new procedure or replacing a defective part,” the insider added. “After that, I would expect a long career for the aircraft in the Marine Corps, Navy, and Air Force, as it’s an irreplaceable part of all three services now and gives a unique capability to the American military.”
Whether that optimism proves warranted depends on whether military leadership finally addresses the systemic failures the latest reports have laid bare – failures that cost 20 service members their lives in just the past five years.
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