[Federal Register Volume 66, Number 54 (Tuesday, March 20, 2001)]
[Proposed Rules]
[Pages 15670-15673]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 01-6789]


-----------------------------------------------------------------------

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2000-NM-361-AD]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 757 Series Airplanes

AGENCY: Federal Aviation Administration, DOT.

ACTION: Notice of proposed rulemaking (NPRM).

-----------------------------------------------------------------------

SUMMARY: This document proposes the supersedure of an existing 
airworthiness directive (AD), applicable to certain Boeing Model 757 
series airplanes. The existing AD requires repetitive freeplay checks 
of the elevator, and replacement of worn elevator power control 
actuator (PCA) reaction link rod-end bearings and the PCA rod-end 
bearing, if necessary. That AD also provides an optional terminating 
action for the repetitive checks. This action would remove the optional 
terminating action provided by the existing AD, expand the 
applicability of the existing AD, and require repetitive freeplay 
checks of the elevator at a revised repeat interval and repetitive 
lubrication of bearings of the elevator actuator load loop and hinge 
line. The actions specified by the proposed AD are intended to prevent 
unacceptable airframe vibration during flight, which could lead to 
excessive wear of bearings of the elevator PCA load loop and hinge line 
and result in reduced controllability of the airplane.

DATES: Comments must be received by May 4, 2001.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), Transport Airplane Directorate, ANM-114, 
Attention: Rules Docket No. 2000-NM-361-AD, 1601 Lind Avenue, SW., 
Renton, Washington 98055-4056. Comments may be inspected at this 
location between 9:00 a.m. and 3:00 p.m., Monday through Friday, except 
Federal holidays. Comments may be submitted via fax to (425) 227-1232. 
Comments may also be sent via the Internet using the following address: 
[email protected]. Comments sent via fax or the Internet must 
contain ``Docket No. 2000-NM-361-AD'' in the subject line and need not 
be submitted in triplicate. Comments sent via the Internet as attached 
electronic files must be formatted in Microsoft Word 97 for Windows or 
ASCII text.
    The service information referenced in the proposed rule may be 
obtained from Boeing Commercial Airplane Group, P.O. Box 3707, Seattle, 
Washington 98124-2207. This information may be examined at the FAA, 
Transport Airplane Directorate, 1601 Lind Avenue, SW., Renton, 
Washington.

FOR FURTHER INFORMATION CONTACT: Dennis Stremick, Aerospace Engineer, 
Airframe Branch, ANM-120S, FAA, Seattle Aircraft Certification Office, 
1601 Lind Avenue, SW., Renton, Washington 98055-4056; telephone (425) 
227-2776; fax (425) 227-1181.

SUPPLEMENTARY INFORMATION:

Comments Invited

    Interested persons are invited to participate in the making of the 
proposed rule by submitting such written data, views, or arguments as 
they may desire. Communications shall identify the Rules Docket number 
and be submitted in triplicate to the address specified above. All 
communications received on or before the closing date for comments, 
specified above, will be considered before taking action on the 
proposed rule. The proposals contained in this action may be changed in 
light of the comments received.
    Submit comments using the following format:
     Organize comments issue-by-issue. For example, discuss a 
request to change the compliance time and a request to change the 
service bulletin reference as two separate issues.
     For each issue, state what specific change to the proposed 
AD is being requested.
     Include justification (e.g., reasons or data) for each 
request.
    Comments are specifically invited on the overall regulatory, 
economic, environmental, and energy aspects of the proposed 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 summarizing each FAA-public contact concerned with 
the substance of this proposal will be filed in the Rules Docket.
    Commenters wishing the FAA to acknowledge receipt of their comments 
submitted in response to this action must submit a self-addressed, 
stamped postcard on which the following statement is made: ``Comments 
to Docket Number 2000-NM-361-AD.'' The postcard will be date-stamped 
and returned to the commenter.

Availability of NPRMs

    Any person may obtain a copy of this NPRM by submitting a request 
to the FAA, Transport Airplane Directorate, ANM-114, Attention: Rules 
Docket No. 2000-NM-361-AD, 1601 Lind Avenue, SW., Renton, Washington 
98055-4056.

Discussion

    On January 11, 1989, the FAA issued AD 89-03-05, amendment 39-6120 
(54 FR 3430, January 24, 1989), applicable to certain Model 757 series 
airplanes, to require periodic freeplay checks of the elevator, and 
replacement of worn elevator power control actuator (PCA) reaction link 
rod-end bearings and the PCA rod-end bearing, if necessary. That action 
was prompted by reports of

[[Page 15671]]

excessive wear of elevator PCA rod-end and reaction link rod-end 
bearings. The requirements of that AD are intended to prevent 
unacceptable airframe vibration during flight.

Actions Since Issuance of Previous Rule

    Since the issuance of that AD, there have been numerous occurrences 
of airframe vibration attributed to excessive freeplay in the bearing 
of the elevator PCA load loop. The existing AD contains an optional 
terminating action that involves replacement of the old-design PCA 
reaction link rod-end bearings with improved bearings. If this optional 
terminating action is accomplished, the modified airplane is only 
subject to freeplay checks per the Boeing Maintenance Manual (BMM). The 
FAA has determined that the freeplay check in the BMM does not 
accurately measure freeplay of the elevator.
    In addition, since the issuance of the existing AD, corrosion has 
been detected in the bearings of the elevator PCA load loop and hinge 
line. This corrosion has been attributed to inappropriate lubrication 
of the bearings. The interval at which the bearings are lubricated is 
currently specified by the Boeing Maintenance Planning Document.

Explanation of Relevant Service Information

    The FAA has reviewed and approved Boeing Service Bulletin 757-
27A0086, Revision 2, dated July 27, 1989, which describes procedures 
for repetitive freeplay checks of the elevator. The procedures in this 
service bulletin are similar to those in Boeing Service Bulletin 757-
27A0086, dated June 9, 1988, which was referenced as the appropriate 
source of service information for the repetitive freeplay checks 
required by the existing AD. Revision 2 clarifies that certain 
corrective actions need be done only if replacement of the bearing of 
the PCA reaction link rod-end does not correct excessive freeplay in 
the elevator. Accomplishment of the actions specified in the service 
bulletin is intended to adequately address the identified unsafe 
condition.

Explanation of Requirements of Proposed Rule

    Since an unsafe condition has been identified that is likely to 
exist or develop on other products of this same type design, the 
proposed AD would supersede AD 89-03-05 to continue to require 
repetitive freeplay checks of the elevator, and replacement of worn 
elevator power control actuator (PCA) reaction link rod-end bearings 
and the PCA rod-end bearing, if necessary. The proposed AD would remove 
the optional terminating action specified in the existing AD, expand 
the applicability of the existing AD, and require new repetitive 
freeplay checks of the elevator at a revised repeat interval and 
repetitive lubrication of bearings in the elevator PCA load loop and 
hinge line. The repetitive freeplay checks would be required to be done 
per Boeing Service Bulletin 757-27A0086, Revision 2, except as 
discussed below in the section called ``Differences Between Proposed 
Rule and Service Bulletin.'' The repetitive lubrication of the bearings 
in the elevator PCA load loop and hinge line would be required to be 
done per the Maintenance Planning Document.

Explanation of Revised Repetitive Interval

    For airplanes subject to the existing AD, this proposed AD would 
revise the repetitive inspection interval from an interval stated in 
flight hours to an interval stated in calendar time. The FAA finds that 
this change is appropriate because, as stated previously, the unsafe 
condition addressed by this AD is related to corrosion, which is a 
function of time rather than flight hours.

Differences Between Proposed Rule and Service Bulletin

    Although Boeing Service Bulletin 757-27A0086, Revision 2, lists an 
effectivity that includes certain Model 757 series airplanes having 
line positions 2 through 136, the requirements of this proposed AD 
would apply to all Boeing Model 757 series airplanes. As stated 
previously, the FAA has determined that the freeplay check in the BMM 
is not adequate to prevent excessive freeplay in the bearings of the 
elevator PCA load loop and hinge line and consequent unacceptable 
airframe vibration. Therefore, the FAA finds that the freeplay checks 
of the elevator proposed in this action are necessary for all Boeing 
Model 757 series airplanes.
    Boeing Service Bulletin 757-27A0086, Revision 2, specifies that the 
freeplay checks of the elevator in that bulletin should be repeated at 
each ``C'' check until improved PCA reaction link rod-end bearings are 
installed, and thereafter, the checks should be repeated at each ``2C'' 
check. The FAA finds that such intervals are inadequate to ensure that 
excessive freeplay in the bearings of the elevator PCA load loop is 
detected and corrected in a timely manner. Therefore, the proposed AD 
would require freeplay checks of the elevator to be done at intervals 
not to exceed 18 months.

Cost Impact

    There are approximately 906 airplanes of the affected design in the 
worldwide fleet.
    The cost impact for the existing AD was calculated based on an 
estimated average labor cost of $40 per work hour. Since the issuance 
of that AD, the FAA has revised the figures it has used over the past 
several years in calculating the economic impact of AD activity. In 
order to account for various inflationary costs in the airline 
industry, the FAA has determined that it is necessary to increase the 
labor rate used in these calculations from $40 per work hour to $60 per 
work hour. The cost impact information, below, has been revised to 
reflect this increase in the specified hourly labor rate.
    The actions that are currently required by AD 89-03-05 affect 
approximately 90 airplanes of U.S. registry. Those actions take 
approximately 30 work hours per airplane to accomplish, at an average 
labor rate of $60 per work hour. Based on these figures, the cost 
impact of the currently required actions on U.S. operators is estimated 
to be $162,000, or $1,800 per airplane, per check cycle.
    The FAA estimates that 598 airplanes of U.S. registry would be 
affected by this new proposed AD. The new actions that are proposed in 
this AD action would take approximately 28 work hours per airplane to 
accomplish, at an average labor rate of $60 per work hour. Based on 
these figures, the cost impact of the proposed requirements of this AD 
on U.S. operators is estimated to be $1,004,640, or $1,680 per 
airplane, per check cycle.
    The cost impact figures discussed above are based on assumptions 
that no operator has yet accomplished any of the proposed requirements 
of this AD action, and that no operator would accomplish those actions 
in the future if this proposed AD were not adopted. The cost impact 
figures discussed in AD rulemaking actions represent only the time 
necessary to perform the specific actions actually required by the AD. 
These figures typically do not include incidental costs, such as the 
time required to gain access and close up, planning time, or time 
necessitated by other administrative actions.

Regulatory Impact

    The regulations proposed herein would not have a substantial direct 
effect on the States, on the relationship between the national 
Government and

[[Page 15672]]

the States, or on the distribution of power and responsibilities among 
the various levels of government. Therefore, it is determined that this 
proposal would not have federalism implications under Executive Order 
13132.
    For the reasons discussed above, I certify that this proposed 
regulation (1) is not a ``significant regulatory action'' under 
Executive Order 12866; (2) is not a ``significant rule'' under the DOT 
Regulatory Policies and Procedures (44 FR 11034, February 26, 1979); 
and (3) if promulgated, 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 copy of the draft 
regulatory evaluation prepared for this action is contained in the 
Rules Docket. A copy of it may be obtained by contacting the Rules 
Docket at the location provided under the caption ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Safety.

The Proposed Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration proposes to amend 
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 removing amendment 39-6120 (54 FR 
3430, January 24, 1989), and by adding a new airworthiness directive 
(AD), to read as follows:

Boeing: Docket 2000-NM-361-AD. Supersedes 89-03-05, amendment 39-
6120.

    Applicability: All Model 757 series 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 (f)(1) 
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 unacceptable airframe vibration during flight, which 
could lead to excessive wear of elevator bearings and result in 
reduced controllability of the airplane, accomplish the following:

Restatement of Requirements of AD 89-03-05

Repetitive Elevator Freeplay Checks

    (a) For Boeing Model 757 series airplanes listed in Boeing Alert 
Service Bulletin 757-27A0086, dated June 9, 1988, on which the 
elevator power control actuator (PCA) rod-end and reaction link rod-
end bearings are lubricated at intervals of 1,000 flight hours or 
less, in accordance with Boeing Service Letter 757-SL-27-26, dated 
April 1, 1988, and on which paragraph (d) of AD 89-03-05 was not 
done: Within the next 90 days after March 6, 1989 (the effective 
date of AD 89-03-05, amendment 39-6120), or prior to the 
accumulation of 4,000 flight hours total time-in-service, whichever 
occurs later, and thereafter at intervals not to exceed 4,000 flight 
hours, perform an elevator freeplay check in accordance with Boeing 
Alert Service Bulletin 757-27A0086, dated June 9, 1988, or Revision 
2, dated July 27, 1989. Doing paragraph (d) of this AD ends the 
repetitive inspections required by this paragraph.
    (b) For Boeing Model 757 series airplanes listed in Boeing Alert 
Service Bulletin 757-27A0086, dated June 9, 1988, not subject to 
paragraph (a) of this AD, and on which paragraph (d) of AD 89-03-05 
was not done: Within the next 90 days after March 6, 1989, or prior 
to the accumulation of 3,000 flight hours total time-in-service, 
whichever occurs later, and thereafter at intervals not to exceed 
3,000 flight hours, perform an elevator freeplay check in accordance 
with Boeing Alert Service Bulletin 757-27A0086, dated June 9, 1988, 
or Revision 2, dated July 27, 1989. Doing paragraph (d) of this AD 
ends the repetitive inspections required by this paragraph.

Replacement

    (c) If freeplay of the elevator exceeds the limits specified in 
the service bulletin during any check per this AD: Before further 
flight, replace elevator PCA reaction link rod-end bearings and PCA 
rod-end bearings, as necessary, with new, improved bearings, in 
accordance with Boeing Alert Service Bulletin 757-27A0086, dated 
June 9, 1988, or Revision 2, dated July 27, 1989. After the 
effective date of this AD, use only Revision 2 of the service 
bulletin.

New Requirements of this AD

Repetitive Elevator Freeplay Checks

    (d) For all airplanes, do elevator freeplay checks per Boeing 
Service Bulletin 757-27A0086, Revision 2, dated July 27, 1989. 
Before further flight after the freeplay checks, lubricate the 
bearings in the elevator PCA load loop and hinge line. Do these 
actions per the schedule in Table 1 of this AD:

                                          Table 1--Compliance Schedule
----------------------------------------------------------------------------------------------------------------
                                                                   Repeat the check and       Inspection per
    For airplanes subject to...        Do the initial check and   lubrication thereafter  paragraph (d) ends the
                                            lubrication...           at least every...      requirements of...
----------------------------------------------------------------------------------------------------------------
Paragraph (a) of this AD...........  At the earlier of..........  18 months.............  Paragraph (a) of this
                                     4,000 flight hours after                              AD.
                                      the most recent inspection
                                      per paragraph (a) of AD 89-
                                      03-05.
                                         OR.....................
                                     18 months after the
                                      effective date of this AD.
Paragraph (b) of this AD...........  At the earlier of..........  18 months.............  Paragraph (b) of this
                                     Within 3,000 flight hours                             AD.
                                      after the most recent
                                      inspection per paragraph
                                      (b) of AD 89-03-05.
                                         OR.....................
                                     Within 18 months after the
                                      effective date of this AD.
Neither paragraph (a) nor (b) of     At the later of............  18 months.............  N/A.
 this AD.                            3,000 total flight hours...
                                         OR.....................
                                     90 days after the effective
                                      date of this AD.
----------------------------------------------------------------------------------------------------------------


[[Page 15673]]

Replacement

    (e) If freeplay of the elevator exceeds the limits specified in 
the service bulletin during any check per paragraph (d) of this AD: 
Before further flight, replace elevator PCA reaction link rod-end 
bearings and PCA rod-end bearings, as necessary, with new, improved 
bearings, per Boeing Alert Service Bulletin 757-27A0086, Revision 2, 
dated July 27, 1989.

Alternative Methods of Compliance

    (f)(1) 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, Seattle Aircraft Certification 
Office (ACO), FAA. Operators shall submit their requests through an 
appropriate FAA Principal Maintenance Inspector, who may add 
comments and then send it to the Manager, Seattle ACO.
    (2) Alternative methods of compliance, approved previously in 
accordance with AD 89-03-05, amendment 39-6120, are NOT considered 
to be approved as alternative methods of compliance with this AD.

    Note 2: Information concerning the existence of approved 
alternative methods of compliance with this AD, if any, may be 
obtained from the Seattle ACO.

Special Flight Permits

    (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 requirements of this AD can be accomplished.

    Issued in Renton, Washington, on March 13, 2001.
Vi L. Lipski,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 01-6789 Filed 3-19-01; 8:45 am]
BILLING CODE 4910-13-U