[Federal Register Volume 67, Number 220 (Thursday, November 14, 2002)]
[Rules and Regulations]
[Pages 68932-68934]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 02-29003]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2002-NE-31-AD; Amendment 39-12950; AD 2002-23-06]
RIN 2120-AA64


Airworthiness Directives; Textron Lycoming AEIO-540, IO-540, 
LTIO-540, O-540, and TIO-540 Series Reciprocating Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule, request for comments.

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SUMMARY: This amendment supersedes an emergency airworthiness directive 
(AD) that was sent previously to all known U.S. owners and operators of 
Textron Lycoming (T/L) AEIO-540, IO-540, LTIO-540, O-540, and TIO-540 
series reciprocating engines. That action requires replacing certain 
zinc-plated crankshaft gear retaining bolts. This action still requires 
replacing certain zinc-plated crankshaft gear retaining bolts, but 
expands the population of affected engines. This amendment is prompted 
by two recent failures of zinc-plated crankshaft gear retaining bolts, 
and a reassessment of the extent to which the suspect bolts may still 
be present in the field. The actions specified by this AD are intended 
to prevent loss of all engine power and possible forced landing.

DATES: Effective November 19, 2002. The incorporation by reference of 
certain publications listed in the regulations is approved by the 
Director of the Federal Register as of November 19, 2002.
    Comments for inclusion in the Rules Docket must be received on or 
before January 13, 2003.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), New England Region, Office of the Regional 
Counsel, Attention: Rules Docket No. 2002-NE-31-AD, 12 New England 
Executive Park, Burlington, MA 01803-5299. Comments may be inspected at 
this location, by appointment, between 8 a.m. and 4:30 p.m., Monday 
through Friday, except Federal holidays. Comments may also be sent via 
the Internet using the following address: ``[email protected]''. 
Comments sent via the Internet must contain the docket number in the 
subject line.
    The applicable service information may be obtained from Lycoming, a 
Textron Company, 652 Oliver Street, Williamsport, PA 10071; telephone 
(570) 323-6181. This information may also be obtained electronically on 
``http://www.lycoming.textron.com''. This information may be examined, 
by appointment, 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: Norm Perenson, Aerospace Engineer, New 
York Aircraft Certification Office, FAA, Engine and Propeller 
Directorate, 10 Fifth Street, 3rd floor, Valley Stream, NY 11581-1200; 
telephone (516) 256-7537; fax (516) 568-2716.

SUPPLEMENTARY INFORMATION: On October 1, 2002, the Federal Aviation 
Administration (FAA) issued emergency airworthiness directive (AD) 
2002-20-51 that applies to Textron Lycoming AEIO-540, IO-540, LTIO-540, 
O-540, and TIO-540 series reciprocating engines. AD 2002-20-51 requires 
replacing zinc-plated cranshaft gear retaining bolts, part number (P/N) 
STD-2209, with new cadmium-plated bolts P/N STD-2209. That action was 
prompted by two recent failures of zinc-plated crankshaft gear 
retaining bolts with one failure resulting in two fatalities. Since 
1999, when the FAA issued AD 99-03-05 that requires the removal of 
zinc-plated bolts from O-540-F series engines installed on Robinson R44 
helicopters, five failures have occurred on fixed-wing airplanes. That 
condition, if not corrected, could result in loss of all engine power 
and possible forced landing.
    Since that AD was issued, the manufacturer has introduced gear bolt 
replacement kit, 05K19987, for use in replacing suspect bolts, and has 
determined that some of the bolts that were recalled on November 10, 
1998, were not returned to T/L and may have been installed into engines 
after November 10, 1998. Based on that determination, the manufacturer 
has issued Lycoming Service Bulletin (SB) No. 554, Supplement 3, to 
increase the time period during which these bolts might have been 
installed in affected engines and to have maintenance facilities return 
to T/L, all crankshaft gear retaining bolts, part number STD-2209, 
except those that are included as

[[Page 68933]]

part of a gear bolt replacement kit, 05K19987.

Manufacturer's Service Information

    The FAA has reviewed and approved the technical contents of 
Lycoming SB No. 554, dated September 30, 2002, that describes 
procedures for replacing the existing crankshaft gear retaining bolt.

FAA's Determination of an Unsafe Condition and Required Actions

    Since the unsafe condition described is likely to exist or develop 
on other Textron Lycoming AEIO-540, IO-540, O-540, LTIO-540, and TIO-
540 series reciprocating engines of the same type design, the FAA 
issued emergency AD 2002-20-51 to prevent loss of all engine power and 
possible forced landing. This AD supersedes AD 2002-20-51, and requires 
replacing the crankshaft gear retaining bolt:
    [sbull] Before further flight on engines that have been overhauled 
or have had the gear retaining bolt replaced between November 27, 1996 
and November 10, 1998, and that have not complied with emergency AD 
2002-20-51 by using a bolt from the gear bolt replacement kit, 
05K19987, and
    [sbull] Within 10 hours time-in-service (TIS) or 7 days after the 
effective date of this AD, on engines that have complied with AD 2002-
20-51, but did not install a bolt from gear bolt replacement kit, 
05K19987, and
    [sbull] Within 10 hours time-in-service (TIS) or 7 days after the 
efective date of this AD, on engines that have been overhauled in the 
field, that have had the gear retaining bolt replaced in the field 
between November 10, 1998, and the effective date of this AD, or have 
been repaired by Lycoming between November 27, 1996 and November 10, 
1998.

Immediate Adoption of This AD

    Since it was found that immediate corrective action was required, 
notice and opportunity for prior public comment thereon were 
impracticable and contrary to the public interest, and good cause 
existed to make the AD effective immediately on October 1, 2002, to all 
known U.S. owners and operators of Textron Lycoming AEIO-540, IO-540, 
O-540, LTIO-540, and TIO-540 series reciprocating engines. These 
conditions still exist. 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 No. 2002-NE-31-AD.'' The postcard will be date stamped and 
returned to the commenter.

Regulatory Analysis

    This final rule does not have federalism implications, as defined 
in Executive Order 13132, because it would not have a substantial 
direct effect 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. Accordingly, 
the FAA has not consulted with state authorities prior to publication 
of this final rule.
    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:

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:

    [sbull] 2002-23-06 Textron Lycoming: Amendment 39-12950. Docket 
2002-NE-31-AD. Supersedes emergency AD 2002-20-51.

    Applicability: This airworthiness directive (AD) is applicable 
to all Textron Lycoming AEIO-540, IO-540, LTIO-540, O-540, and TIO-
540 series reciprocating engines with crankshaft gear retaining 
bolts, part number (P/N) STD-2209 installed, except O-540-F series 
engines to which AD 99-03-05 applies and on which the bolt has not 
been subsequently replaced with a bolt other than one included in 
gear bolt replacement kit 05K19987, and engines with single-drive 
dual magnetos. These engines are installed on, but not limited to 
the following aircraft:

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Aero Commander. (500), (500-B), (500-E), (500-U)
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Aero Mercantil. Gavilan.
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Aerofab. Renegade 250.
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Bellanca Aircraft. Aries T-250
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Britten-Norman. (BN-2).
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Cessna Aircraft. Skylane C-182, Stationair C-206, Turbo Skylane T182T,
 Turbo Stationair T-206
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Christen. Pitts (S-2S), (S-2B).
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Commander Aircraft. 114TC, 114B
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[[Page 68934]]

 
DeHavilland. (DH-114-2X)
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Dornier. (DO-28-B1)
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Evangel-Air.
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Extra-Flugzeugbau. Extra 300.
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Found Bros. (FBA-2C), Centennial (100)
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Gippsland. GA-200.
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Helio. Military (H-250).
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King Engineering. Angel.
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Maule. MT-7-260, M-7-260, MX-7-235, MT-7-235, M7-235, Star
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Rocket (MX-7-235), Super Rocket (M-6-235), Super Std. Rocket (M-7-235).
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Mooney Aircraft. ``TLS'' M20M.
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Moravan. Zlin-50L
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Pilatus Britten-Norman. Islander (BN-2A-26), Islander (BN-2A-27),
 Islander II (BN-2B-26), Islander (BN-2A-21), Trislander (BN-2A-Mark III-
 2), Islander (BN-2B).
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Piper Aircraft. 700P Aerostar, Aerostar 600A, Aerostar 601B, Aerostar
 601P, Apache (PA-23 ``235''), Aztec (PA-23 ``250''), Aztec (PA-23
 ``250''), Comanche (PA-24 ``250''), Comanche (PA-24 ``260''), Aztec F,
 Aztec C (PA-23 ``250''), Cherokee (PA-24 ``250''), Cherokee (PA-28
 ``235''), Cherokee Six (PA-32 ``260''), Cherokee Six (PA-32-300).
 ``LANCE'', Comanche (PA-24 ``150''), Comanche (PA-24 ``250''), Comanche
 (PA-24), Comanche (PA-24 ``260''), Comanche 260, Mirage (PA-46-350P),
 Navajo (PA-31), Navajo (PA-31-300), Navy Aztec (PA-23 ``250''), Pawnee
 (PA-24 ``235''), Pawnee (PA-25 ``260''), Saratoga (PA-32-300), Brave
 300, Sequoia 602P, T-1020, T35, Turbo Aztec (PA-23-250), Turbo Saratoga
 TC (PA-32-301T)
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S.O.C.A.T.A. Rallye 235CA., Rallye 235GT, Rallye 235C, TB-20
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    Note 1: 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 (h) 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: Compliance with this AD is required as indicated, 
unless already done.
    To prevent loss of all engine power and possible forced landing, 
do the following:

Engines That Have Complied With Emergency AD 2002-20-51

    (a) For AEIO-540, LTIO-540, IO-540, O-540, and TIO-540 series 
engines that have complied with emergency AD 2002-20-51 by 
installing a bolt included in bolt replacement kit 05K19987, no 
further action is required.
    (b) For AEIO-540, LTIO-540, IO-540, O-540, and TIO-540 series 
engines that have complied with emergency AD 2002-20-51 but did not 
install a bolt included in bolt replacement kit 05K19987, within 10 
hours time-in-service or 10 days after the effective date of this 
AD, whichever is earlier, replace the crankshaft gear retaining bolt 
with a new bolt included in gear bolt replacement kit, 05K19987, 
supplied by Textron Lycoming. Information on replacing the retaining 
bolt may be found in Lycoming SB No. 554, dated September 30, 2002.

Engines Listed by Serial Number (SN)

    (c) For AEIO-540, LTIO-540, IO-540, O-540, and TIO-540 engines 
with a single-drive dual magneto, and all O-540-F engines to which 
AD 99-03-05 applies and on which the bolt has not been subsequently 
replaced with a bolt other than one included in gear bolt 
replacement kit 05K19987, including any O-540-F engines that are 
listed by SN in Table 1 of Lycoming SB No. 554, dated September 30, 
2002, no further action is required.
    (d) Before further flight, for all other engines, replace the 
crankshaft gear retaining bolt with a new bolt included in gear bolt 
replacement kit, 05K19987, supplied by Textron Lycoming if your 
engine SN is listed in Table 1 of Lycoming SB No. 554, dated 
September 30, 2002. Information on replacing the retaining bolt may 
be found in Lycoming SB No. 554, dated September 30, 2002.

Bolts That Have Been Replaced During Field Maintenance or Field 
Overhaul

    (e) Replace the crankshaft gear retaining bolt with a new bolt 
supplied as part of gear bolt replacement kit 05K19987, supplied by 
Textron Lycoming, within 10 hours time-in-service or 7 days after 
the effective date of this AD, whichever is earlier,if:
    (1) The bolt on your O-540-F series was replaced after 
compliance with AD 99-03-05 with a bolt that was not included in 
bolt replacement kit 05K19987. Information on replacing the 
retaining bolt may be found in Lycoming SB No. 554, dated September 
30, 2002.
    (2) The bolt on your AEIO, LTIO, IO, O, or TIO-540 series engine 
was replaced during field maintenance or field overhaul between 
November 27, 1996 and the effective date of this AD, or if your 
engine was repaired between November 27, 1996 and November 10, 1998, 
at Lycoming. Information on replacing the retaining bolt may be 
found in Lycoming SB No. 554, dated September 30, 2002.

Recording Gear Bolt Replacement Kit Number

    (f) After the effective date of this AD, record the number of 
the gear bolt replacement kit, 05K19987, in the engine records when 
recording compliance with this AD.

Prohibition Against Installing Gear Retaining Bolts P/N STD-2209

    (g) After the effective date of this AD, do not install any 
crankshaft gear retaining bolt, P/N STD-2209, except one that is 
included in a Lycoming gear bolt replacement kit, 05K19987, onto any 
engine listed in this AD.

Alternative Methods of Compliance

    (h) 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, New York Aircraft Certification 
Office (NYACO). Operators must submit their requests through an 
appropriate FAA Maintenance Inspector, who may add comments and then 
send it to the Manager, NYACO.

    Note 2: Information concerning the existence of approved 
alternative methods of compliance with this airworthiness directive, 
if any, may be obtained from the NYACO.

Special Flight Permits

    (i) Special flight permits may be issued in accordance with 
Sec. Sec.  21.197 and 21.199 of the Federal Aviation Regulations (14 
CFR 21.197 and 21.199) to operate the aircraft to a location where 
the requirements of this AD can be done.

Documents That Have Been Incorporated by Reference

    (j) Engine serial numbers are listed in Table 1 of Lycoming 
Service Bulletin No. 554, dated September 30, 2002. 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 Lycoming, a Textron Company, 652 
Oliver Street, Williamsport, PA 17701; telephone (570) 323-6181. 
This information may also be obtained electronically on ``http://www.lycoming.textron.com''. 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.

Effective Date

    (k) This amendment becomes effective November 19, 2002.

    Issued in Burlington, Massachusetts, on November 8, 2002.
Francis A Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 02-29003 Filed 11-13-02; 8:45 am]
BILLING CODE 4910-13-P