[Federal Register Volume 64, Number 178 (Wednesday, September 15, 1999)]
[Rules and Regulations]
[Pages 49961-49964]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 99-23125]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 99-NE-28-AD; Amendment 39-11290, AD 99-19-01]
RIN 2120-AA64


Airworthiness Directives; Teledyne Continental Motors O-470, IO-
470, TSIO-470, IO-520, TSIO-520, LTSIO-520, GTSIO-520, IO-550, TSIO-
550, and TSIOL-550 Series Reciprocating Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

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SUMMARY: This amendment adopts a new airworthiness directive (AD) that 
is applicable to Teledyne Continental Motors (TCM) O-470, IO-470, TSIO-
470, IO-520, TSIO-520, LTSIO-520, GTSIO-520, IO-550, TSIO-550, and 
TSIOL-550 series reciprocating engines. This action supersedes priority 
letter AD 99-09-17 that currently requires a one-time visual and 
ultrasonic (UT) inspection of the No. 2 and No. 5 crankshaft cheeks for 
cracks. All crankshafts found with a cracked cheek must be replaced 
with a serviceable crankshaft prior to further flight. This action adds 
to the applicability TCM GTSIO-520 series engines and additional 
engines, identified by serial numbers (S/Ns), of currently affected 
engine series; references a revised service bulletin that clarifies 
snap ring installation; increases to 500 hours time-in-service (TIS) 
the cutoff for engines that require a more immediate inspection; and 
corrects the contact telephone number for TCM. This amendment is 
prompted by inspection results from the current priority letter AD. The 
actions specified by this AD are intended to prevent crankshaft failure 
due to crankshaft cheek cracks, which could result in total engine 
power loss, in-flight engine failure, and possible forced landing.

DATES: Effective September 30, 1999 .
    The incorporation by reference of certain publications listed in 
the regulations is approved by the Director of the Federal Register as 
of September 30, 1999.
    Comments for inclusion in the Rules Docket must be received on or 
before November 15, 1999.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), New England Region, Office of the Regional 
Counsel, Attention: Rules Docket No. 99-NE-28-AD, 12 New England 
Executive Park, Burlington, MA 01803-5299. Comments may also be sent 
via the Internet using the following address: ``9-ane-
[email protected]''. Comments sent via the Internet must contain the 
docket number in the subject line.
    The service information referenced in this AD may be obtained from 
Teledyne Continental Motors, PO Box 90, Mobile, AL 36601; telephone 
toll free (888) 200-7565. This information may be examined at the FAA, 
New England Region, Office of the Regional Counsel, 12 New England 
Executive Park, Burlington, MA; or at the Office of the Federal 
Register, 800 North Capitol Street, NW, suite 700, Washington, DC.

FOR FURTHER INFORMATION CONTACT: Jerry Robinette, Aerospace Engineer, 
Atlanta Aircraft Certification Office, FAA, Small Airplane Directorate, 
One Crown Center, 1895 Phoenix Blvd., Suite 450, Atlanta, GA 30349; 
telephone (770) 703-6096, fax (770) 703-6097.

SUPPLEMENTARY INFORMATION: On April 22, 1999, the Federal Aviation 
Administration (FAA) issued priority letter airworthiness directive 
(AD) 99-09-17, applicable to Teledyne Continental Motors (TCM) O-470, 
IO-470, TSIO-470, IO-520, TSIO-520,

[[Page 49962]]

LTSIO-520, IO-550, TSIO-550 and TSIOL-550 series new and rebuilt 
reciprocating engines, manufactured between January 1, 1998, and 
December 31, 1998, inclusive, listed by serial number (S/N) in TCM 
Critical Service Bulletin (CSB) 99-3, dated April 19, 1999, and any 
other engine from the above series that has had a crankshaft installed 
that was newly manufactured or rebuilt between January 1, 1998, and 
December 31, 1998, inclusive. That priority letter AD requires a one-
time visual and ultrasonic (UT) inspection of the No. 2 and No. 5 
crankshaft cheeks for cracks. All crankshafts found with a cracked 
cheek must be replaced with a serviceable crankshaft prior to further 
flight. All inspections must be performed by TCM representatives, since 
it is a new procedure that only TCM-trained personnel are currently 
authorized to perform.

Background

    Priority letter AD 99-09-17 was prompted by reports of crankshaft 
failures. Since December 1998, the FAA obtained information regarding 
seven crankshaft failures. The investigation revealed that the 
crankshafts failed due to cracks through the No. 2 or No. 5 cheeks. 
Analysis indicated that the crankshaft failures occurred early in the 
life of a new or rebuilt crankshaft, from 80 to 175 hours time-in-
service (TIS). In addition, one crankshaft was found which had not 
failed but which had a crack initiation. TCM advised the FAA that all 
of the fractures were due to a discrepancy in the counterweight bushing 
installation process, involving a tool that can damage the nitride 
surface of the cheek sufficient to create a crack which will propagate 
through the nitride layer. The tool has been repaired. Such a crack 
will always result in failure of the crankshaft. All of the fractures 
were grouped around certain crankshaft manufacturing dates between 
January 1998 and December 1998, inclusive. Review of the manufacturing 
processes, basic metallurgy, nitride characteristics, dimensional 
characteristics, and supplier practices did not identify any other 
contributing causes. That condition, if not corrected, could result in 
crankshaft failure due to crankshaft cheek cracks, which could result 
in total engine power loss, in-flight engine failure, and possible 
forced landing.

Events Since the Priority Letter AD

    Since the issuance of that priority letter AD, the FAA received 
results from the inspections mandated by priority letter AD 99-09-17. 
One crankshaft was found with a significant crack. This crankshaft had 
340 hours TIS, which is outside the range of the previous known cracks. 
Since this crack was found outside the hours TIS range of the previous 
known cracks, the cutoff for engines that require a more immediate 
inspection has been raised to 500 hours TIS. This additional TIS range 
should not introduce a significant hardship as approximately 3,000 of 
the original 3,200 crankshafts have already been inspected.
    In addition, the FAA received a report of a TCM GTSIO-520 
crankshaft failure. The crack initiated on cheek No. 2, occurring 
within 45 hours TIS since the crankshaft was rebuilt. Based upon this 
report, the FAA determined the need to add the TCM GTSIO-520 series 
engines to the AD's applicability. The GTSIO-520 crankshaft is of a 
different design, with three cheeks that have counterweights; 
therefore, three cylinders, three connecting rods, and six 
counterweights must be removed versus two cylinders, two connecting 
rods, and four counterweights for the other engines affected. This AD 
requires inspecting crankshaft cheeks No. 2, 5, and 8 on the geared 
engines in accordance with TCM CSB 99-6A, dated July 21, 1999.
    Also, TCM has published Mandatory Service Bulletin (MSB) 99-3C 
dated July 27, 1999, that adds additional engines, identified by serial 
numbers (S/Ns), of currently affected engine series and clarifies snap 
ring installation.
    Finally, this AD corrects the contact telephone number for TCM.
    Since a situation exists that requires the immediate adoption of 
this regulation, it is found that notice and opportunity for prior 
public comment hereon are impracticable, and that good cause exists for 
making this amendment effective in less than 30 days.

Comments Invited

    Although this action is in the form of a final rule that involves 
requirements affecting flight safety and, thus, was not preceded by 
notice and an opportunity for public comment, comments are invited on 
this rule. Interested persons are invited to comment on this rule by 
submitting such written data, views, or arguments as they may desire. 
Communications should identify the Rules Docket number and be submitted 
in triplicate to the address specified under the caption ADDRESSES. All 
communications received on or before the closing date for comments will 
be considered, and this rule may be amended in light of the comments 
received. Factual information that supports the commenter's ideas and 
suggestions is extremely helpful in evaluating the effectiveness of the 
AD action and determining whether additional rulemaking action would be 
needed.
    Comments are specifically invited on the overall regulatory, 
economic, environmental, and energy aspects of the rule that might 
suggest a need to modify the rule. All comments submitted will be 
available, both before and after the closing date for comments, in the 
Rules Docket for examination by interested persons. A report that 
summarizes each FAA-public contact concerned with the substance of this 
AD will be filed in the Rules Docket.
    Commenters wishing the FAA to acknowledge receipt of their comments 
submitted in response to this notice must submit a self-addressed, 
stamped postcard on which the following statement is made: ``Comments 
to Docket Number 99-NE-28-AD.'' The postcard will be date stamped and 
returned to the commenter.
    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.
    The FAA has determined that this regulation is an emergency 
regulation that must be issued immediately to correct an unsafe 
condition in aircraft, and is not a ``significant regulatory action'' 
under Executive Order 12866. It has been determined further that this 
action involves an emergency regulation under DOT Regulatory Policies 
and Procedures (44 FR 11034, February 26, 1979). If it is determined 
that this emergency regulation otherwise would be significant under DOT 
Regulatory Policies and Procedures, a final regulatory evaluation will 
be prepared and placed in the Rules Docket. A copy of it, if filed, 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:

[[Page 49963]]

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:

99-19-01  Teledyne Continental Motors: Amendment 39-11290. Docket 
No. 99-NE-28-AD. Supersedes AD 99-09-17.
    Applicability: Teledyne Continental Motors (TCM) O-470, IO-470, 
TSIO-470, IO-520, TSIO-520, LTSIO-520, IO-550, TSIO-550, TSIOL-550, 
series new and rebuilt engines manufactured between January 1, 1998, 
and December 31, 1998, listed by serial number (S/N) in TCM 
Mandatory Service Bulletin (MSB) 99-3C, dated July 27, 1999. Also, 
GTSIO-520 series engines, listed by S/N in TCM Critical Service 
Bulletin (CSB) 99-6A dated July 21, 1999. This airworthiness 
directive (AD) is also applicable to any other TCM O-470, IO-470, 
TSIO-470, IO-520, TSIO-520, LTSIO-520, IO-550, TSIO-550, TSIOL-550, 
and GTSIO-520 series engines that were overhauled by facilities 
other than TCM, and that have had replacement crankshafts installed 
that were sold individually by TCM and were manufactured or rebuilt 
between January 1, 1998, and December 31, 1998.

    Note 1: Engine S/Ns can be found in logbooks or other 
maintenance records. For those engines that were overhauled in the 
field with factory new crankshafts, crankshaft S/Ns should be shown 
in work orders, log books or other maintenance records.

    Note 2: This AD applies to each engine 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 engines 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 (f) 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 prevent crankshaft failure due to crankshaft cheek cracks, 
which could result in total engine power loss, in-flight engine 
failure, and possible forced landing, accomplish the following:
    (a) For those engines listed by S/N on pages 3 through 12 of TCM 
MSB 99-3C, dated July 27, 1999, or on pages 2 and 3 of TCM CSB 99-
6A, dated July 21, 1999, with 500 hours or less time-in-service 
(TIS) on the effective date of this AD, perform visual and 
ultrasonic (UT) inspections of the crankshaft for cracks within 10 
hours TIS after the effective date of this AD, in accordance with 
sections A and B of TCM 99-3C, dated July 27, 1999, or for the 
GTSIO-520 series engines, in accordance with sections A and B of TCM 
CSB 99-6A dated July 21, 1999. These inspections must be performed 
by TCM representatives. Disposition the crankshaft as follows:

    Note 3: The engines and crankshafts that are the subject of this 
AD were manufactured or rebuilt by TCM during 1998. The dates that 
engines and crankshafts were delivered, however, may not coincide 
with their dates of manufacture. For the engines identified in 
paragraphs (a) and (b) of this AD, TCM has already determined which 
engines have either a new or rebuilt suspect crankshaft installed, 
and identified those engines by engine S/N. Only for those engines 
identified in paragraphs (c) and (d) of this AD does crankshaft 
serial number play a role in determining the need for visual and UT 
inspections.

    Note 4: The engine S/Ns listed in TCM MSB 99-3C and TCM CSB 99-
6A contain only the numerical portion of the S/N. Rebuilt engines 
will have the letter ``R'' at the end of the six digit numerical 
portion. This letter ``R'' should be disregarded and only the six 
digit numerical sequence should be used for determination of 
applicability. Only TCM is authorized to rebuild TCM engines and 
they have not approved any other agency to perform that function.

    (1) If a crack is found, replace the crankshaft with a 
serviceable crankshaft of the same part number (P/N) prior to 
further flight.
    (2) If no crack is found, reassemble the engine and return it to 
service.
    (3) If inspections have been previously accomplished in 
accordance with earlier revision levels of TCM MSB 99-3 (previously 
CSB 99-3) or CSB 99-6, no further action is required.
    (b) For those engines listed by S/N on pages 3 through 12 of MSB 
99-3C, dated July 27, 1999, or on pages 2 and 3 of TCM CSB 99-6A 
dated July 21, 1999, with more than 500 hours TIS on the effective 
date of this AD, perform visual and UT inspections of the crankshaft 
for cracks at the next maintenance event, or within 50 hours TIS 
after the effective date of this AD, whichever comes first, in 
accordance with sections A and B of TCM MSB 99-3C, dated July 27, 
1999, or for the GTSIO-520 series engines, in accordance with 
sections A and B of TCM CSB 99-6A, dated July 21, 1999. These 
inspections must be performed by TCM representatives. Disposition 
the crankshaft as follows:
    (1) If a crack is found, replace the crankshaft with a 
serviceable crankshaft of the same P/N prior to further flight.
    (2) If no crack is found, reassemble the engine and return it to 
service.
    (3) If inspections have been previously accomplished in 
accordance with earlier revision levels of TCM MSB 99-3 (previously 
CSB 99-3) or CSB 99-6, no further action is required.
    (c) For any other engine that was overhauled at a facility other 
than TCM, and that has a crankshaft installed that was manufactured 
or rebuilt between January 1, 1998, and December 31, 1998, with 500 
hours or less TIS on the effective date of this AD, perform visual 
and UT inspections of the crankshaft for cracks within 10 hours TIS 
after the effective date of this AD, in accordance with sections A 
and B of TCM MSB 99-3C, dated July 27, 1999, or for the GTSIO-520 
series engines, in accordance with sections A and B of TCM CSB 99-
6A, dated July 21, 1999. These inspections must be performed by TCM 
representatives. Disposition the crankshaft as follows:
    (1) If a crack is found, replace the crankshaft with a 
serviceable crankshaft of the same P/N prior to further flight.
    (2) If no crack is found, reassemble the engine and return it to 
service.
    (3) If inspections have been previously accomplished in 
accordance with earlier revision levels of TCM MSB 99-3 (previously 
CSB 99-3) or CSB 99-6, no further action is required.

    Note 5: The crankshaft manufacture date may be determined from 
the crankshaft serial number, which consists of eight characters, 
arranged as follows:

--------------------------------------------------------------------------------------------------------------------------------------------------------
                                                                                           Position
                                    --------------------------------------------------------------------------------------------------------------------
                                                1                      2,3                    4,5                    6,7                     8
--------------------------------------------------------------------------------------------------------------------------------------------------------
Content............................  Letter A-L represent-   Day of month            Year of manufacture..  Sequence number of     Always ``N''
                                      ing month of            manufactured.                                  crankshaft
                                      manufacture.                                                           manufactured on that
                                                                                                             day.
Example............................  C                       22                      98                     05                     N
--------------------------------------------------------------------------------------------------------------------------------------------------------

The example crankshaft, with a serial number of ``C229805N'', 
indicates a date of manufacture of March 22, 1998.
    (d) For any other engine that was overhauled at a facility other 
than TCM, and that has a crankshaft installed that was manufactured 
or rebuilt between January 1, 1998, and December 31, 1998, with more 
than 500 hours TIS on the effective date of this AD, perform visual 
and UT inspections of the crankshaft for cracks at the next

[[Page 49964]]

maintenance event, or within 50 hours TIS after the effective date 
of this AD, whichever comes first, in accordance with sections A and 
B of TCM MSB 99-3C, dated July 27, 1999, or for the GTSIO-520 series 
engines, in accordance with sections A and B of TCM CSB 99-6A dated 
July 21, 1999. These inspections must be performed by TCM 
representatives. Disposition the crankshaft as follows:
    (1) If a crack is found, replace the crankshaft with a 
serviceable crankshaft of the same P/N prior to further flight.
    (2) If no crack is found, reassemble the engine and return it to 
service.
    (3) If inspections have been previously accomplished in 
accordance with earlier revision levels of TCM MSB 99-3 (previously 
CSB 99-3) or CSB 99-6, no further action is required.
    (e) After the effective date of this AD, installation of a 
crankshaft that was manufactured or rebuilt between January 1, 1998, 
and December 31, 1998, is prohibited, unless it has been inspected 
and reidentified in accordance with section C of TCM MSB 99-3C, 
dated July 27, 1999, or, for the GTSIO-520 series engines, in 
accordance with section C of TCM CSB 99-6A, dated July 21, 1999. 
These inspections must be performed by TCM.
    (f) 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, Atlanta Aircraft Certification 
Office (ACO). Operators shall submit their requests through an 
appropriate FAA Principal Maintenance Inspector, who may add 
comments and then send it to the Manager, Atlanta ACO.

    Note 6: Information concerning the existence of approved 
alternative methods of compliance with this airworthiness directive, 
if any, may be obtained from the Atlanta ACO.

    (g) 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 inspection requirements of this AD can be accomplished.
    (h) The actions required by this AD shall be accomplished in 
accordance with the following TCM SBs:

------------------------------------------------------------------------
             Document No.               Page             Date
------------------------------------------------------------------------
MSB 99-3C............................   1-26  July 27, 1999.
    Total pages: 26.
CSB 99-6A............................   1-13  July 21, 1999.
    Total pages: 13.
------------------------------------------------------------------------

    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 Teledyne Continental Motors, PO 
Box 90, Mobile, AL 36601; telephone toll free (888) 200-7565. Copies 
may be inspected at the FAA, New England Region, Office of the 
Regional Counsel, 12 New England Executive Park, Burlington, MA; or 
at the Office of the Federal Register, 800 North Capitol Street, NW, 
suite 700, Washington, DC.

    (i) This amendment supersedes priority letter AD 99-09-17, 
issued April 22, 1999.
    (j) This amendment becomes effective on September 30, 1999.

    Issued in Burlington, Massachusetts, on August 30, 1999.
David A. Downey,
Assistant Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 99-23125 Filed 9-14-99; 8:45 am]
BILLING CODE 4910-13-P