[Federal Register Volume 61, Number 216 (Wednesday, November 6, 1996)]
[Rules and Regulations]
[Pages 57301-57304]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 96-27241]


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DEPARTMENT OF TRANSPORTATION
14 CFR Part 39

[Docket No. 96-NM-24-AD; Amendment 39-9795; AD 96-22-06]
RIN 2120-AA64


Airworthiness Directives; McDonnell Douglas Model DC-10-15 
Airplanes

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule.

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SUMMARY: This amendment adopts a new airworthiness directive (AD), 
applicable to all McDonnell Douglas Model DC-10-15 airplanes, that 
requires, among other things, inspections to detect discrepancies at 
various locations of pylons 1 and 3, and correction of any discrepancy 
found. This amendment is prompted by a report of internal structural 
damage to the wing engine pylon that occurred during maintenance of a 
Model DC-10 series airplane. The actions specified by this AD are 
intended to ensure the integrity of the structure and attachment of the 
wing engine pylon.

DATES: Effective December 11, 1996.
    The incorporation by reference of certain publications listed in 
the

[[Page 57302]]

regulations is approved by the Director of the Federal Register as of 
December 11, 1996.

ADDRESSES: The service information referenced in this AD may be 
obtained from McDonnell Douglas Corporation, 3855 Lakewood Boulevard, 
Long Beach, California 90846, Attention: Technical Publications 
Business Administration, Department C1-L51 (2-60). This information may 
be examined at the Federal Aviation Administration (FAA), Transport 
Airplane Directorate, Rules Docket, 1601 Lind Avenue, SW., Renton, 
Washington; or at the FAA, Transport Airplane Directorate, Los Angeles 
Aircraft Certification Office, 3960 Paramount Boulevard, Lakewood, 
California; or at the Office of the Federal Register, 800 North Capitol 
Street, NW., suite 700, Washington, DC.

FOR FURTHER INFORMATION CONTACT: Ron Atmur, Aerospace Engineer, 
Airframe Branch, ANM-120L, FAA, Los Angeles Aircraft Certification 
Office, 3960 Paramount Boulevard, Lakewood, California 90712; telephone 
(310) 627-5224; fax (310) 627-5210.

SUPPLEMENTARY INFORMATION: A proposal to amend part 39 of the Federal 
Aviation Regulations (14 CFR part 39) to include an airworthiness 
directive (AD) that is applicable to all McDonnell Douglas Model DC-10-
15 airplanes was published in the Federal Register on June 19, 1996 (61 
FR 31059). That action proposed to require:
    1. At each pylon removal and installation, the engine and pylon 
must be removed and installed separately, and the pylon aft bulkhead 
lug must be protected from contact with certain attach bolt heads.
    2. Performance of various repetitive inspections to detect 
discrepancies at various locations of pylons 1 and 3, and correction of 
any discrepancy found.
    3. Submission of a pylon maintenance program that includes specific 
repetitive inspections at intervals of 20,000 hours time-in-service.
    Interested persons have been afforded an opportunity to participate 
in the making of this amendment. Due consideration has been given to 
the single comment received.
    The commenter supports the proposed rule.

Conclusion

    After careful review of the available data, including the comment 
noted above, the FAA has determined that air safety and the public 
interest require the adoption of the rule as proposed.

Cost Impact

    There are approximately 7 McDonnell Douglas Model DC-10-15 
airplanes of the affected design in the worldwide fleet. The FAA 
estimates that 2 airplanes of U.S. registry will be affected by this 
AD, that it will take approximately 22 work hours per airplane to 
accomplish the required actions, and that the average labor rate is $60 
per work hour. Based on these figures, the cost impact of the AD on 
U.S. operators is estimated to be $2,640, or $1,320 per airplane.
    The cost impact figure discussed above is based on assumptions that 
no operator has yet accomplished any of the requirements of this AD 
action, and that no operator would accomplish those actions in the 
future if this AD were not adopted.

Regulatory Impact

    The regulations adopted herein will not have substantial direct 
effects on the States, on the relationship between the national 
government and the States, or on the distribution of power and 
responsibilities among the various levels of government. Therefore, in 
accordance with Executive Order 12612, it is determined that this final 
rule does not have sufficient federalism implications to warrant the 
preparation of a Federalism Assessment.
    For the reasons discussed above, I certify that this action (1) is 
not a ``significant regulatory action'' under Executive Order 12866; 
(2) is not a ``significant rule'' under DOT Regulatory Policies and 
Procedures (44 FR 11034, February 26, 1979); and (3) will not have a 
significant economic impact, positive or negative, on a substantial 
number of small entities under the criteria of the Regulatory 
Flexibility Act. A final evaluation has been prepared for this action 
and it is contained in the Rules Docket. A copy of it may be obtained 
from the Rules Docket at the location provided under the caption 
ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration amends part 39 of 
the Federal Aviation Regulations (14 CFR part 39) as follows:

PART 39--AIRWORTHINESS DIRECTIVES

    1. The authority citation for part 39 continues to read as follows:

    Authority: 49 U.S.C. 106(g), 40113, 44701.


Sec. 39.13  [Amended]

    2. Section 39.13 is amended by adding the following new 
airworthiness directive:

96-22-06  McDonnell Douglas: Amendment 39-9795. Docket 96-NM-24-AD.

    Applicability: All Model DC-10-15 airplanes, certificated in any 
category.

    Note 1: This AD applies to each airplane identified in the 
preceding applicability provision, regardless of whether it has been 
modified, altered, or repaired in the area subject to the 
requirements of this AD. For airplanes that have been modified, 
altered, or repaired so that the performance of the requirements of 
this AD is affected, the owner/operator must request approval for an 
alternative method of compliance in accordance with paragraph (k) of 
this AD. The request should include an assessment of the effect of 
the modification, alteration, or repair on the unsafe condition 
addressed by this AD; and, if the unsafe condition has not been 
eliminated, the request should include specific proposed actions to 
address it.

    Compliance: Required as indicated, unless accomplished 
previously.
    To ensure the integrity of the structure and attachment of the 
wing engine pylon, accomplish the following:
    (a) At each pylon removal and installation that is accomplished 
after the effective date of this AD: The engine and pylon shall be 
removed and installed separately, unless such removal or 
installation, or both, as an assembly is accomplished in accordance 
with a method approved by the Manager, Los Angeles Aircraft 
Certification Office (ACO), FAA, Transport Airplane Directorate.
    (b) At each pylon removal and installation that is accomplished 
after the effective date of this AD: Protect the pylon aft bulkhead 
lug from contact with the clevis-to-wing attach bolt heads using 
part number (P/N) DZZ7268-1 in accordance with page 417, dated 
January 1, 1982, and page 427, dated May 1, 1985, of Chapter 54-00-
01 of the McDonnell Douglas DC-10 Maintenance Manual.
    (c) Prior to further flight following any pylon reinstallation 
that is accomplished after the effective date of this AD: Accomplish 
the requirements of paragraphs (c)(1), (c)(2), and (c)(3) of this 
AD.
    (1) Perform an inspection of the aft pylon bulkhead to detect 
cracking, in accordance with page 634, dated December 1, 1979, and 
page 634A, dated August 1, 1990, of Chapter 54-10-11 of the 
McDonnell Douglas DC-10 Nondestructive Testing Manual.
    (2) Perform a visual inspection of the pylon aft spherical 
bearing and attaching hardware to verify the security of the nut and 
bolt.
    (3) Perform a visual inspection of the torque stripe for proper 
alignment.
    (d) Perform the inspections required by paragraph (e) of this AD 
at the later of the times specified in paragraphs (d)(1) and (d)(2) 
of this AD. Thereafter, repeat these inspections at intervals not to 
exceed 3,600 hours time-in-service or 12 months, whichever occurs 
later.
    (1) Prior to the accumulation of 3,600 total hours time-in-
service.

[[Page 57303]]

    (2) Within 3,600 hours time-in-service or 12 months after the 
effective date of this AD, whichever occurs later.
    (e) Perform the inspections required by paragraphs (e)(1) 
through (e)(5) of this AD at the times indicated in paragraph (d) of 
this AD.
    (1) Perform a visual inspection to detect cracking of the 
external surfaces of the thrust link forward (pylon) and aft (wing) 
attachment lugs, in accordance with paragraph 2.C.(1) of McDonnell 
Douglas DC-10 Service Bulletin 54-74, dated December 21, 1979.
    (2) Perform a visual inspection to detect discrepancies of the 
upper surface of the pylon upper spar aft of station Yn=342.864, in 
accordance with paragraph 2.G. of McDonnell Douglas DC-10 Service 
Bulletin 54-74, dated December 21, 1979.
    (3) Perform a visual inspection to detect discrepancies of the 
center and lower (firewall) spar and spar cap angles from the aft 
bulkhead to the forward bulkhead, in accordance with paragraph 2.M. 
of McDonnell Douglas DC-10 Service Bulletin 54-74, dated December 
21, 1979.
    (4) Perform an inspection for discrepancies at the various 
locations of the wing and tail specified on pages 601, 602, 602A, 
604, 605, 606, and 608, all dated November 1, 1986; page 603, dated 
May 1, 1986; and pages 604A and 607, dated May 1, 1987; of Chapter 
05-51-08 of the McDonnell Douglas DC-10 Maintenance Manual. 
Accomplish the inspections in accordance with the procedures 
specified on those pages of the McDonnell Douglas DC-10 Maintenance 
Manual.
    (5) Perform a visual inspection of the pylon aft spherical 
bearing and attaching hardware to verify the security of the nut and 
bolt, and inspect the torque stripe for alignment.
    (f) Within 30 days after the effective date of this AD: Submit a 
pylon maintenance program, as an amendment to the maintenance 
program, to the assigned FAA Principal Maintenance Inspector for 
approval. The pylon maintenance program shall specify that, prior to 
the accumulation of 20,000 total hours time-in-service, or within 
20,000 hours time-in-service since the last inspection, whichever 
occurs later, the operator will accomplish, as a minimum, the 
actions specified in paragraphs (f)(1)through (f)(9) of this AD.
    (1) Perform a visual inspection to detect cracking of the pylon 
aft bulkhead, in accordance with paragraphs 2.E. and 2.F. of 
McDonnell Douglas DC-10 Service Bulletin 54-74, dated December 21, 
1979; and an eddy current inspection to detect cracking of the pylon 
aft bulkhead, in accordance with page 634, dated December 1, 1979, 
and page 634A, dated August 1, 1990, of Chapter 54-10-11 of the 
McDonnell Douglas DC-10 Nondestructive Testing Manual.
    (2) Perform a visual inspection to detect discrepancies of the 
front spar bulkhead, in accordance with paragraph 2.H. of McDonnell 
Douglas DC-10 Service Bulletin 54-74, dated December 21, 1979.
    (3) Perform a visual inspection to detect cracking of the 
attachment fitting-to-pylon forward bulkhead (footstool) of the wing 
front spar; perform a detailed visual inspection to detect cracking, 
and loose or missing fasteners, of the wing pylon attachment; and 
verify that the pre-load indicating (PLI) washers cannot be rotated; 
in accordance with paragraph 2.L. of McDonnell Douglas DC-10 Service 
Bulletin 54-74, dated December 21, 1979.
    (4) Perform an inspection to verify that the attach bolt PLI 
washers on the lower spherical bearing plug cannot be rotated; 
verify that no interference exists between the plug forward flange 
aft face, and the forward face of the spherical bearing; and perform 
a detailed visual inspection of the plug in situ; in accordance with 
paragraph 2.I. of McDonnell Douglas DC-10 Service Bulletin 54-74, 
dated December 21, 1979.
    (5) Perform a visual inspection to verify the condition, 
security, and torque stripe alignment of the plug assembly of the 
forward upper spherical bearing installation, in accordance with 
paragraph 2.J. of McDonnell Douglas DC-10 Service Bulletin 54-74, 
dated December 21, 1979.
    (6) Perform a visual inspection to verify proper installation of 
the thrust link bolts, nuts, and retaining washers of the thrust 
link installation, in accordance with paragraph 2.C.(2) of McDonnell 
Douglas DC-10 Service Bulletin 54-74, dated December 21, 1979.
    (7) Perform an inspection of the aft spherical bearing, as 
specified in paragraphs (f)(7)(i) through (f)(7)(iv) of this AD.
    (i) Remove the aft spherical bearing through bolt. Inspect the 
inner bore of the bushing in situ using Magnaflux bolt and visual 
inspection techniques. Perform a visual inspection using a 10x 
(power) glass (or equivalent) to detect cracks of the forward and 
aft surfaces of the spherical bearing. Reinstall the through bolt.
    (ii) Verify that the torque of the through bolt is 1,200 to 
1,300 inch-pounds.
    (iii) Inspect the clearance of the aft spherical bearing forward 
face/clevis.
    (iv) Torque stripe the nut to bolt.
    (8) Perform an ultrasonic inspection to detect cracking of the 
bulkhead lug and wing clevis-to-wing attachment, including the 
bolts, in accordance with pages 635, 636, 638, 638A, and 638B, dated 
December 1, 1979; page 637, dated September 1, 1993; page 651, dated 
February 1, 1982; and page 652, dated August 1, 1992; of Chapter 54-
10-11 of the McDonnell Douglas DC-10 Nondestructive Testing Manual.
    (9) Accomplish either paragraph (f)(9)(i) or (f)(9)(ii) of this 
AD.
    (i) Perform an X-ray inspection in situ to ensure the integrity 
of the steel thrust links, in accordance with page 632A, dated 
August 1, 1984, and page 632B, dated February 1, 1981, of the 
McDonnell Douglas DC-10 Nondestructive Testing Manual. Or
    (ii) Perform an ultrasonic inspection in situ to ensure the 
integrity of the steel thrust links, in accordance with page 632C, 
dated August 1, 1985, and page 632D, dated August 1, 1984, of the 
McDonnell Douglas DC-10 Nondestructive Testing Manual.
    (g) Prior to further flight after a pylon has been subjected to 
vertical or horizontal misalignment, or both (e.g., during 
maintenance), perform an inspection to detect cracking of the aft 
pylon bulkhead, in accordance with page 634, dated December 1, 1979, 
and page 634A, dated August 1, 1990, of Chapter 54-10-11 of the 
McDonnell Douglas DC-10 Nondestructive Testing Manual.
    (h) Prior to further flight following any event that produces 
high pylon loads: Perform an inspection of the pylon for structural 
integrity, in accordance with pages 601, 602, 602A, 604, 605, 606, 
and 608, dated November 1, 1986; page 603, dated May 1, 1986; and 
pages 604A and 607, dated May 1, 1987; of Chapter 05-51-08 of the 
McDonnell Douglas DC-10 Maintenance Manual.

    Note 2: Examples of events that produce high pylon loads, 
include, but are not limited to, the following:

     Hard or overweight landings (for the purpose of this 
AD, overweight landings are made at aircraft weights in excess of 
369,000 pounds);
     Severe turbulence encounters;
     Engine vibration that requires engine removal or 
critical engine failure, or both;
     Ground damage (work stands, etc.);
     Compressor stalls requiring engine removal; and
     Excursions from the runway of a nature that might have 
imposed loads more severe than those encountered normally on the 
runway.
    (i) Prior to further flight, correct any discrepancy found 
during any inspection required by this AD, in accordance with a 
method approved by the Manager, Los Angeles ACO; the Structural 
Repair Manual; or McDonnell Douglas DC-10 Service Bulletin 54-74, 
dated December 21, 1979; as appropriate.
    (j) Within 10 days after accomplishing the inspections required 
by this AD, report inspection results, positive or negative, to the 
FAA Principal Maintenance Inspector. The report shall include the 
information specified in paragraphs (j)(1)through (j)(5) of this AD. 
Information collection requirements contained in this regulation 
have been approved by the Office of Management and Budget (OMB) 
under the provisions of the Paperwork Reduction Act of 1980 (44 
U.S.C. 3501 et seq.) and have been assigned OMB Control Number 2120-
0056.
    (1) The ``N'' number of the airplane.
    (2) The total number of hours time-in-service accumulated on the 
airplane.
    (3) The pylon number of the airplane.
    (4) The specific paragraph (and subparagraph) of this AD that 
corresponds with the inspection results being reported.
    (5) Specific inspection results: For example, the location and 
size of cracking, specific location of discrepant fasteners, and 
part numbers.
    (k) An alternative method of compliance or adjustment of the 
compliance time that provides an acceptable level of safety may be 
used if approved by the Manager, Los Angeles ACO. Operators shall 
submit their requests through an appropriate FAA Principal 
Maintenance Inspector, who may add comments and then send it to the 
Manager, Los Angeles ACO.

    Note 3: Information concerning the existence of approved 
alternative methods of compliance with this AD, if any, may be 
obtained from the Los Angeles ACO.


[[Page 57304]]


    (l) Special flight permits may be issued in accordance with 
sections 21.197 and 21.199 of the Federal Aviation Regulations (14 
CFR 21.197 and 21.199) to operate the airplane to a location where 
the requirements of this AD can be accomplished.
    (m) Certain actions shall be done in accordance with McDonnell 
Douglas DC-10 Service Bulletin 54-74, dated December 21, 1979. This 
incorporation by reference was approved by the Director of the 
Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 
51. Copies may be obtained from McDonnell Douglas Corporation, 3855 
Lakewood Boulevard, Long Beach, California 90846, Attention: 
Technical Publications Business Administration, Department C1-L51 
(2-60). Copies may be inspected at the FAA, Transport Airplane 
Directorate, 1601 Lind Avenue, SW., Renton, Washington; or at the 
FAA, Transport Airplane Directorate, Los Angeles Aircraft 
Certification Office, 3960 Paramount Boulevard, Lakewood, 
California; or at the Office of the Federal Register, 800 North 
Capitol Street, NW., suite 700, Washington, DC.
    (n) This amendment becomes effective on December 11, 1996.

    Issued in Renton, Washington, on October 17, 1996.
Darrell M. Pederson,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 96-27241 Filed 11-5-96; 8:45 am]
BILLING CODE 4910-13-U