[Federal Register Volume 69, Number 38 (Thursday, February 26, 2004)]
[Rules and Regulations]
[Pages 8801-8809]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 04-3798]


=======================================================================
-----------------------------------------------------------------------

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2004-NE-05-AD; Amendment 39-13488; AD 2004-04-07]
RIN 2120-AA64


Airworthiness Directives; General Electric Company (GE) CF6-80 
Series Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

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

SUMMARY: The FAA is superseding two existing airworthiness directives 
(ADs) for GE CF6-80 series turbofan engines with certain stage 1 high-
pressure turbine (HPT) rotor disks. Those ADs currently require initial 
and repetitive inspections of certain stage 1 HPT rotor disks for 
cracks in the bottom of the dovetail slot. This action retains the

[[Page 8802]]

initial inspection requirement, as a qualification for the mandatory 
rework procedures for certain disks, and continues repetitive 
inspections only for the disks for which the rework procedures are not 
yet defined. This action requires reworking certain disks before 
further flight. In addition, this AD expands the population of affected 
engines and removes certain CF6-80E1 series disks from service. This AD 
results from the manufacturer's investigation and development of a 
rework procedure that chamfers the aft breakedge of the dovetail slot 
bottom. We are issuing this AD to detect and prevent cracks in the 
bottoms of the dovetail slots that could propagate to failure of the 
disk and cause an uncontained engine failure.

DATES: Effective March 12, 2004. The Director of the Federal Register 
approved the incorporation by reference of certain publications listed 
in the regulations as of March 12, 2004.
    We must receive any comments on this AD by April 26, 2004.

ADDRESSES: Use one of the following addresses to submit comments on 
this AD:
     By mail: Federal Aviation Administration (FAA), 
New England Region, Office of the Regional Counsel, Attention: Rules 
Docket No. 2004-NE-05-AD, 12 New England Executive Park, Burlington, MA 
01803-5299.
     By fax: (781) 238-7055.
     By e-mail: [email protected]
    You can get the service information referenced in this AD from 
General Electric Company via Lockheed Martin Technology Services, 10525 
Chester Road, Suite C, Cincinnati, Ohio 45215, telephone (513) 672-
8400, fax (513) 672-8422.
    You may examine the AD docket, by appointment, at the FAA, New 
England Region, Office of the Regional Counsel, 12 New England 
Executive Park, Burlington, MA. You may examine the service 
information, 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: Anthony W. Cerra Jr., Aerospace 
Engineer, Engine Certification Office, FAA, Engine and Propeller 
Directorate, 12 New England Executive Park, Burlington, MA 01803-5299; 
telephone: (781) 238-7128, fax: (781) 238-7199.

SUPPLEMENTARY INFORMATION: On May 10, 2001, the FAA issued AD 2001-10-
07, Amendment 39-12233 (66 FR 27592, May 18, 2001). That AD requires 
initial and repetitive inspections of certain stage 1 HPT rotor disks 
installed on CF6-80C2 turbofan engines for cracks in the bottoms of the 
dovetail slots. That AD resulted from a report of an uncontained 
failure of an engine during a high-power ground run during maintenance. 
On January 2, 2003, we issued AD 2003-01-05, Amendment 39-13016 (68 FR 
1519, January 13, 2003). That AD requires initial and repetitive 
inspections of certain stage 1 HPT rotor disks installed on CF6-80A 
series turbofan engines for cracks in the bottoms of the dovetail 
slots. AD 2003-01-05 resulted from a report of an uncontained failure 
of a CF6-80A series engine during climb. The manufacturer investigated 
those two failures as well as findings of cracks on other disks to 
determine the root cause of the failures. Those investigations showed 
that the cracks started from tool marks, broach burrs, damage sustained 
from improper handling and processing, and other unknown causes. The 
manufacturer and the FAA have determined that those conditions could 
also exist on stage 1 HPT rotor disks that are installed in certain 
CF6-80E1 series turbofan engines. Those conditions, if not corrected, 
could result in cracks in the bottoms of the dovetail slots that could 
propagate to failure of the disk and cause an uncontained engine 
failure.

Actions Since AD 2001-10-07 and AD 2003-01-05 Were Issued

    Since we issued those ADs, the manufacturer developed a rework 
procedure to eliminate the root causes of the cracks. This rework 
procedure removes potentially damaged material from the breakedge and 
makes the geometry less susceptible to damage that could lead to cracks 
in the bottoms of the dovetail slots and subsequent failure. As part of 
the rework procedure, the disks are remarked with a different part 
number. The rework replaces the current requirements for initial and 
repetitive inspections on those disks for which rework is defined.
    Stage 1 HPT rotor disks, part number (P/N) 9367M45G02, are an early 
configuration, and no parts are believed to be in service. These disks 
do not have rework procedures defined. Therefore the repetitive 
inspections remain for any disks that may still be in service.
    The manufacturer developed a rework procedure for stage 1 HPT rotor 
disks, P/N 1862M23G01, to address cracks in the forward flange of the 
thermal shield by machining the profile of the slot bottom. A limited 
number of these disks were released to the field before the program was 
discontinued. These disks also do not have rework procedures defined 
because the chamfered breakedge rework machining was not developed for 
this limited number of parts.
    We are considering additional rulemaking to add eddy current 
inspections of the bottom of the CF6-80A dovetail slots and the CF6-80A 
and CF6-80C2 chamfer surfaces to the Airworthiness Limitations Section 
of the Instructions for Continued Airworthiness as part of the FAA's 
``enhanced-disk inspection initiative.''

Relevant Service Information

    We have reviewed and approved the technical contents of the 
following GE Service Bulletins (SBs) and Alert Service Bulletin (ASB) 
that describe procedures for removing, inspecting, and reworking 
certain stage 1 HPT rotor disks:
     SB No. CF6-80E1 S/B 72-0251, dated January 22, 
2004;
     SB No. CF6-80A S/B 72-0779, Revision 1, dated 
January 22, 2004;
     SB No. CF6-80A S/B 72-0788, Revision 2, dated 
December 17, 2003;
     ASB No. CF6-80C2 S/B 72-A1026, Revision 2, dated 
January 22, 2004;
     SB No. CF6-80C2 S/B 72-1089, Revision 2, dated 
December 18, 2003.

Differences Between This AD and the Service Information

    The differences between this AD and the service information are as 
follows:
     GE SB No. CF6-80A S/B 72-0779, Revision 1, dated 
January 22, 2004, applies to certain CF6-80A stage 1 HPT rotor disks 
and requires an initial inspection at next exposure. However, this AD 
requires only the stage 1 HPT rotor disks, P/N 9367M45G02, to have only 
an initial inspection at the next shop visit, subject to cycle 
limitations and subsequent repetitive inspections at each piece part 
exposure. This AD requires the other HPT rotor disks, to which the SB 
applies, to have the rework defined in SB No. CF6-80A S/B 72-0788, 
Revision 2, dated December 17, 2003. This AD also requires the 
inspection of stage 1 HPT rotor disks, P/N 9367M45G02, which have zero 
cycles-since-new (CSN) before installation into the engine. The SB does 
not.
     GE ASB No. CF6-80C2 S/B 72-A1026, Revision 2, 
dated January 22, 2004, applies to certain CF6-80C2 stage 1 HPT rotor 
disks, and requires initial inspections of the stage 1 HPT rotor disks 
at the next shop visit. However, this AD requires only the stage 1 HPT 
rotor disks, P/N 1862M23G01, to have only an initial inspection at the 
next shop visit, subject to cycle limitations,

[[Page 8803]]

and subsequent repetitive inspections at each piece-part exposure. This 
AD requires the other HPT rotor disks, to which this ASB applies, to 
have the rework defined in SB No. CF6-80C2 S/B 72-1089, Revision 2, 
dated December 18, 2003. The cycle limitations in the AD are based on 
the latest risk analysis for CF6-80A and CF6-80C2 engines where the 
ASB's cycle limitations are based on a risk analysis completed in 2001 
for only CF6-80C2 engines. This AD also requires the inspection of 
stage 1 HPT rotor disks, P/N 1862M23G01, which have zero CSN before 
installation into the engine. The ASB does not.
     There are no differences between GE SB No. CF6-
80A S/B 72-0788, Revision 2, dated December 17, 2003, and GE SB No. 
CF6-80C2 S/B 72-1089, Revision 2, dated December 18, 2003, and this AD 
except for the introduction of compliance cycle limitations.
     There are no differences between GE SB No. CF6-
80E1 S/B 72-0251, dated January 22, 2004, and this AD.

FAA's Determination and Requirements of This AD

    The unsafe condition described previously is likely to exist or 
develop on other GE CF6-80 series turbofan engines of the same type 
design. We are issuing this AD to detect and prevent cracks in the 
bottoms of the dovetail slots that could propagate to failure of the 
disk and cause an uncontained engine failure. This AD requires rework 
of the dovetail slot bottom of certain stage 1 rotor disks. The disks 
must pass an inspection to qualify for the rework. Disks for which the 
rework has not been defined must continue to receive initial and 
repetitive inspections. In addition, this AD expands the population of 
affected engines and removes from service certain CF6-80E1 series 
disks. You must use the service information described previously to 
perform the actions required by this AD.

FAA's Determination of the Effective Date

    Since an unsafe condition exists that requires the immediate 
adoption of this AD, we have found that notice and opportunity for 
public comment before issuing this AD are impracticable, and that good 
cause exists for making this amendment effective in less than 30 days.

Changes to 14 CFR Part 39--Effect on the AD

    On July 10, 2002, we issued a new version of 14 CFR part 39 (67 FR 
47998, July 22, 2002), which governs our AD system. This regulation now 
includes material that relates to special flight permits, alternative 
methods of compliance, and altered products. This material previously 
was included in each individual AD. Since this material is included in 
14 CFR part 39, we will not include it in future AD actions.

Comments Invited

    This AD is a final rule that involves requirements affecting flight 
safety and was not preceded by notice and an opportunity for public 
comment; however, we invite you to submit any written relevant data, 
views, or arguments regarding this AD. Send your comments to an address 
listed under ADDRESSES. Include ``AD Docket No. 2004-NE-05-AD'' in the 
subject line of your comments. If you want us to acknowledge receipt of 
your mailed comments, send us a self-addressed, stamped postcard with 
the docket number written on it; we will date-stamp your postcard and 
mail it back to you. We specifically invite comments on the overall 
regulatory, economic, environmental, and energy aspects of the rule 
that might suggest a need to modify it. If a person contacts us 
verbally, and that contact relates to a substantive part of this AD, we 
will summarize the contact and place the summary in the docket. We will 
consider all comments received by the closing date and may amend the AD 
in light of those comments.
    We are reviewing the writing style we currently use in regulatory 
documents. We are interested in your comments on whether the style of 
this document is clear, and your suggestions to improve the clarity of 
our communications with you. You may get more information about plain 
language at http://www.faa.gov/language and http://www.plainlanguage.gov.

Examining the AD Docket

    You may examine the AD Docket (including any comments and service 
information), by appointment, between 8:00 a.m. and 4:30 p.m., Monday 
through Friday, except Federal holidays. See ADDRESSES for the 
location.

Regulatory Findings

    We have determined that this AD will not have federalism 
implications under Executive Order 13132. This AD will 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.
    For the reasons discussed above, I certify that the 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. 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.
    We prepared a summary of the costs to comply with this AD and 
placed it in the AD Docket. You may get a copy of this summary by 
sending a request to us at the address listed under ADDRESSES. Include 
``AD Docket No. 2004-NE-05-AD'' in your request.

List of Subjects in 14 CFR Part 39

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

Adoption of the Amendment

0
Accordingly, under 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

0
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]

0
2. The FAA amends Sec.  39.13 by removing Amendment 39-12233 (66 FR 
27592, May 18, 2001), and Amendment 39-13016 (68 FR 1519, January 13, 
2003), and by adding a new airworthiness directive, Amendment 39-13488, 
to read as follows:

2004-04-07 General Electric Company: Amendment 39-13488. Docket No. 
2004-NE-05-AD. Supersedes AD 2001-10-07, Amendment 39-12233, and AD 
2003-01-05, Amendment 39-13016.

Effective Date

    (a) This airworthiness directive (AD) becomes effective March 
12, 2004.

Affected ADs

    (b) This AD supersedes AD 2001-10-07 and AD 2003-01-05.

Applicability

    (c) This AD applies to the General Electric Company (GE) CF6-80 
turbofan engine models listed in the following Table 1:

[[Page 8804]]



         Table 1.--Applicability Models, Part Numbers, Airplanes
------------------------------------------------------------------------
                                  Stage 1 high
                                pressure turbine    Engines installed on
           Models               (HPT) rotor disk     but not limited to
                                 part Nos. (PNs)
------------------------------------------------------------------------
CF6-80A, CF6-80A1, CF6-80A2,  9234M67G22/G24/G25/   Airbus A310 and
 CF6-80A3.                     G26. 9362M58G02/G06/  Boeing 767
                               G07/G09. 9367M45G02/  airplanes.
                               G04/G09.
CF6-80C2A1, CF6-80C2A2, CF6-  1862M23G01.           Airbus A300, A310,
 80C2A3, CF6-80C2A5, CF6-      9392M23G10/G12/G21.   Boeing 747, 767,
 80C2A8, CF6-80C2A5F, CF6-     1531M84G02/G06/G08/   and McDonnell
 80C2B1, CF6-80C2B2, CF6-      G10.                  Douglas MD11
 80C2B4, CF6-80C2B6, CF6-                            airplanes.
 80C2B1F, CF6-80C2B2F, CF6-
 80C2B4F, CF6-80C2B5F, CF6-
 80C2B6F, CF6-80C2B6FA, CF6-
 80C2B7F, CF6-80C2D1F.
CF6-80E1A2, CF6-80E1A4......  1639M41P04..........  Airbus A330
                                                     airplanes.
------------------------------------------------------------------------

    These engines are installed on, but not limited to, the 
airplanes listed in Table 1 of this AD.

Unsafe Condition

    (d) This AD results from the manufacturer's investigation and 
development of a rework procedure that chamfers the aft breakedge of 
the dovetail slot bottom. The actions specified in this AD are 
intended to detect and prevent cracks in the bottoms of the dovetail 
slots that could propagate to failure of the disk and cause an 
uncontained engine failure.

Compliance

    (e) You are responsible for having the actions required by this 
AD performed within the compliance times specified unless the 
actions have already been done.

CF6-80A, -80A1, -80A2, and -80A3 Engines

Stage 1 HPT Rotor Disks, P/N 9362M58G09, With Chamfered Breakedges

    (f) At the next piece-part exposure after the effective date of 
this AD, for stage 1 HPT rotor disks, P/N 9362M58G09, with SNs 
listed in Table 2 of this AD, do the following:

 Table 2.--SNs of CF6-80A Series Stage 1 HPT Rotor Disk P/N 9362M58G09--
                        With Chamfered Breakedges
 
 
 
GWN03RD7
GWN042J3
GWN04HRD
GWN04M9K
GWN03TKG
GWN04FW2
GWN04HRE
GWN04M9L
GWN03TKH
GWN04FW3
GWN04HRF
GWN04M9M
GWN03TKJ
GWN04FW4
GWN04HRG
GWN04M9R
GWN03W3M
GWN04FW5
GWN04HRH
GWN04M9T
GWN03W3N
GWN04H0M
GWN04K8N
GWN04M9W
GWN03W3R
GWN04HRA
GWN04M9J
 

    (1) Visually inspect the rotor disks for the presence of a 
chamfer on the aft breakedges of the dovetail slot bottoms. Use 
paragraph 3.A. of GE Service Bulletin (SB) No. CF6-80A S/B 72-0788, 
Revision 2, dated December 17, 2003, to do the inspection.
    (2) For disks that have the chamfered breakedges, remark, 
fluorescent penetrant inspect (FPI), and eddy current inspect (ECI) 
the rotor disk. Use paragraph 3.A.(1)(a) through 3.A.(1)(b) of the 
Accomplishment Instructions of GE SB No. CF6-80A S/B 72-0788, 
Revision 2, dated December 17, 2003, to remark and inspect the rotor 
disk and remove from service as necessary.
    (3) For disks that do not have the chamfered breakedges, 
inspect, rework and remark the rotor disk. Use paragraph 3.A(2)(a) 
through 3.A(2)(b) of the Accomplishment Instructions of GE SB No. 
CF6-80A S/B 72-0788, Revision 2, dated December 17, 2003, to 
inspect, rework, and remark the disk and remove from service as 
necessary.
    Stage 1 HPT Rotor Disks, P/Ns 9234M67G22, G24, G25, G26, 
9367M45G04, G09, 9362M58G02, G06, G07, and 9362M58G09 With SNs Not 
Listed in Table 2 of This AD
    (g) For stage 1 HPT rotor disks, P/Ns 9234M67G22, G24, G25, G26, 
9367M45G04, G09, 9362M58G02, G06, G07, and 9362M58G09 with SNs not 
listed in Table 2 of this AD, inspect, rework, and remark the disks 
using paragraphs 3.A.(2) through 3.B.(2) of Accomplishment 
Instructions of GE SB No. CF6-80A S/B 72-0788, Revision 2, dated 
December 17, 2003, at the following:
    (1) For stage 1 HPT rotor disks not installed in engines with 
both new and old hardware, inspect, rework, remark, and remove from 
service as necessary before further flight.
    (2) For stage 1 HPT rotor disks that have been inspected before 
the effective date of this AD using any version of GE SB No. CF6-80A 
S/B 72-0779, inspect, rework, remark, and remove from service as 
necessary at the next Engine Shop Visit (ESV) using the compliance 
times in the following Table 3:

 Table 3.--Compliance Times For Inspection and Rework of CF6-80A Series
  Stage 1 HPT Rotor Disks, P/Ns 9234M67G22, G24, G25, G26, 9367M45G04,
G09, 9362M58G02, G06, G07, and 9362M58G09 With SNs Not Listed in Table 2
                    of This AD--Previously Inspected
------------------------------------------------------------------------
  Stage 1 HPT rotor disk cycles-since-
     last-inspection (CSLI)  on the       Compliance time for inspection
       effective date of this AD                    and rework
------------------------------------------------------------------------
(i) More than 1,500 CSLI...............  At the next ESV after the
                                          effective date of this AD, but
                                          not to exceed 4,500 CSLI.
(ii) 1,500 CSLI or fewer...............  At the next ESV after the
                                          effective date of this AD, but
                                          not to exceed 3,500 CSLI.
------------------------------------------------------------------------

    (3) For stage 1 HPT rotor disks that have not been inspected 
before the effective date of this AD using any version of GE SB No. 
CF6-80A S/B 72-0779, inspect, rework, remark, and remove from 
service as necessary at the next ESV using the compliance times in 
the following Table 4:

[[Page 8805]]



  Table 4. Compliance Times for Inspection and Rework of CF6-80A Series
  Stage 1 HPT Rotor Disks, P/Ns 9234M67G22, G24, G25, G26, 9367M45G04,
G09, 9362M58G02, G06, G07, and 9362M58G09 With SNs Not Listed in Table 2
                  of This AD--Not Previously Inspected
------------------------------------------------------------------------
Stage 1 HPT rotor disk cycles-since-new   Compliance time for inspection
(CSN)  on the effective date of this AD             and rework
------------------------------------------------------------------------
(i) 10,000 or more CSN.................  At the next ESV or within 1,000
                                          cycles-in-service (CIS) after
                                          the effective date of this AD,
                                          whichever occurs first.
(ii) 5,000 or more CSN but fewer than    At the next ESV or within 2,400
 10,000 CSN.                              CIS after the effective date
                                          of this AD, whichever occurs
                                          first, but before accumulating
                                          11,000 CSN.
(iii) Fewer than 5,000 CSN.............  At the next ESV or within 3,500
                                          CIS after the effective date
                                          of this AD, whichever occurs
                                          first, but before accumulating
                                          7,400 CSN.
------------------------------------------------------------------------

Stage 1 HPT Rotor Disks, P/N 9367M45G02

    (h) For stage 1 HPT rotor disks, P/N 9367M45G02, inspect the 
rotor disk dovetail slot bottoms and remove the disk from service as 
necessary using paragraphs 3.A. through 3.C.(10)(i) of 
Accomplishment Instructions of GE SB No. CF6-80A S/B 72-0779, 
Revision 1, dated January 22, 2004, at the following times:
    (1) For stage 1 HPT rotor disks not installed in engines with 
both new and old hardware, inspect and remove from service as 
necessary before further flight.
    (2) For stage 1 HPT rotor disks that have been inspected before 
the effective date of this AD using any version of GE SB No. CF6-80A 
S/B 72-0779, and had more than zero CSN at the time of that 
inspection, inspect and remove from service as necessary at each 
piece-part exposure.
    (3) For stage 1 HPT rotor disks that have not been inspected, or 
were only inspected with zero CSN before the effective date of this 
AD using any version of GE SB No. CF6-80A S/B 72-0779, inspect and 
remove from service as necessary at the next ESV using the 
compliance times in the following Table 5:

 Table 5. Compliance Times for Inspection of CF6-80A Series Stage 1 HPT
          Rotor Disks, P/N 9367M45G02--Not Previously Inspected
------------------------------------------------------------------------
   Stage 1 HPT rotor disk CSN on the       Compliance time for initial
       effective date of this AD                    inspection
------------------------------------------------------------------------
(i) 10,000 or more CSN.................  At the next ESV or within 1,000
                                          CIS after the effective date
                                          of this AD, whichever occurs
                                          first.
(ii) 5,000 or more CSN but fewer than    At the next ESV or within 2,400
 10,000 CSN.                              CIS after the effective date
                                          of this AD, whichever occurs
                                          first, but before accumulating
                                          11,000 CSN.
(iii) Fewer than 5,000 CSN.............  At the next ESV or within 3,500
                                          CIS after the effective date
                                          of this AD, whichever occurs
                                          first, but before accumulating
                                          7,400 CSN.
------------------------------------------------------------------------

    (4) Thereafter, inspect at each piece-part exposure, and remove 
the rotor disk from service if necessary.

CF6-80C2 Series Engines

Stage 1 HPT Rotor Disks, P/N 1531M84G10, With Chamfered Breakedges

    (i) At the next piece-part exposure after the effective date of 
this AD, for stage 1 HPT rotor disks, P/N 1531M84G10, with SNs 
listed in Table 6 of this AD, do the following:

      Table 6.--SNs of CF6-80C2 Series Stage 1 HPT Rotor Disks, P/N
                  1531M84G10, With Chamfered Breakedges
------------------------------------------------------------------------
 
-------------------------------------------------------------------------
GWN03111
GWN0369J
GWN03K3F
GWN03RPD
GWN049JM
GWN03114
GWN036JG
GWN03K3G
GWN03RPE
GWN049M7
GWN03501
GWN036JH
GWN03K3H
GWN03RPF
GWN049M8
GWN03699
GWN036JJ
GWN03K3K
GWN03RPG
GWN049M9
GWN03752
GWN036JK
GWN03K3L
GWN0402A
GWN04AEP
GWN03753
GWN036JL
GWN03K3M
GWN0402E
GWN04AER
GWN03754
GWN036JM
GWN03K3N
GWN0402F
GWN04AET
GWN03755
GWN036JN
GWN03K3R
GWN0402G
GWN04ALR
GWN03756
GWN0375A
GWN03K3T
GWN0402H
GWN04ALT
GWN03757
GWN0375C
GWN03K3W
GWN0402J
GWN04ALW
GWN03759
GWN0375D
GWN03K40
GWN0402K
GWN04AM0
GWN03981
GWN0375E
GWN03K6J
GWN0402L
GWN04AM1
GWN03982
GWN037H2
GWN03K7R
GWN0402M
GWN04AM2
GWN03983
GWN0398A
GWN03K7T
GWN0402N
GWN04AM3
GWN03984
GWN0398C
GWN03KR1
GWN0402P
GWN04AM4
GWN03985
GWN039PF

[[Page 8806]]

 
GWN03KR2
GWN040R5
GWN04CGJ
GWN03986
GWN039PG
GWN03KR3
GWN0418A
GWN04CGL
GWN03987
GWN039PH
GWN03KR4
GWN0418C
GWN04CGN
GWN03988
GWN039PJ
GWN03KR5
GWN0418D
GWN04CGT
GWN03989
GWN039PK
GWN03KR6
GWN0418E
GWN04CGW
GWN04026
GWN039PL
GWN03KR7
GWN0418F
GWN04CH3
GWN04027
GWN039PM
GWN03KR8
GWN0418G
GWN04CH5
GWN04028
GWN039PN
GWN03KRA
GWN0418H
GWN04CH8
GWN04029
GWN03A4J
GWN03KRC
GWN0418J
GWN04CH9
GWN04189
GWN03A4K
GWN03KRD
GWN0418K
GWN04CHA
GWN04190
GWN03A4L
GWN03L2D
GWN0418L
GWN04CHC
GWN04191
GWN03A4M
GWN03L2E
GWN0418M
GWN04D52
GWN04366
GWN03A4N
GWN03L2F
GWN0418N
GWN04D54
GWN04722
GWN03A4P
GWN03LNF
GWN0418P
GWN04D55
GWN04726
GWN03A4R
GWN03LNJ
GWN0418R
GWN04D56
GWN04729
GWN03A4T
GWN03LNK
GWN0418T
GWN04D57
GWN031N2
GWN03A4W
GWN03M88
GWN0418W
GWN04D58
GWN031N3
GWN03C12
GWN03M89
GWN044DP
GWN04D59
GWN031N4
GWN03C13
GWN03M8C
GWN0454E
GWN04DPW
GWN031N5
GWN03C14
GWN03M8D
GWN0454F
GWN04DR4
GWN031N6
GWN03CA0
GWN03M8E
GWN0454G
GWN04DR9
GWN031N7
GWN03DC9
GWN03M8F
GWN0454H
GWN04DRE
GWN031N8
GWN03DCA
GWN03M8J
GWN0454J
GWN04DRJ
GWN031N9
GWN03DCC
GWN03M8K
GWN0454K
GWN04E9K
GWN031NA
GWN03DCD
GWN03NHN
GWN0454L
GWN04E9L
GWN031NC
GWN03DCE
GWN03NHP
GWN0454M
GWN04E9M
GWN032G1
GWN03DCF
GWN03NHR
GWN0454N
GWN04E9N
GWN032G2
GWN03DCG
GWN03NHT
GWN045T0
GWN04EM5
GWN032G3
GWN03DCH
GWN03R73
GWN045T1
GWN04EMA
GWN032G4
GWN03DCJ
GWN03R74
GWN045T2
GWN04EMK
GWN032G5
GWN03DCK
GWN03R75
GWN045T3
GWN04EML
GWN032G6
GWN03DCL
GWN03R76
GWN045T4
GWN04EMM
GWN032G7
GWN03DCM
GWN03R77
GWN045T5
GWN04F8N
GWN032G8
GWN03DCN
GWN03R78
GWN045T6
GWN04F8P
GWN032G9
GWN03DCP
GWN03R79
GWN045T7
GWN04FTJ
GWN032GE
GWN03DCR
GWN03R7A
GWN045T8
GWN04FTL
GWN0335P
GWN03DME
GWN03R7C
GWN045T9
GWN04FTM
GWN0335R
GWN03DMF
GWN03R7D
GWN045TA
GWN04FTN
GWN033C5
GWN03ER7
GWN03R7E
GWN045TC
GWN034KR
GWN03ER8
GWN03R7F
GWN045TD
GWN034KT
GWN03ER9
GWN03R7G
GWN045TE
GWN0350M
GWN03ERA
GWN03R7H
GWN045TF
GWN0350N
GWN03FTN
GWN03R9G
GWN045TG
GWN0350P
GWN03FTP
GWN03R9H
GWN045TH
GWN0350R

[[Page 8807]]

 
GWN03FTR
GWN03R9J
GWN046F6
GWN0350T
GWN03FTT
GWN03R9K
GWN046F7
GWN0350W
GWN03FTW
GWN03R9L
GWN046F8
GWN035M5
GWN03FW0
GWN03R9M
GWN047LG
GWN035M6
GWN03H56
GWN03R9N
GWN047LH
GWN035M7
GWN03H57
GWN03R9P
GWN047LJ
GWN035M8
GWN03H58
GWN03R9R
GWN047LK
GWN035M9
GWN03HTL
GWN03R9T
GWN047LL
GWN035MA
GWN03HTM
GWN03R9W
GWN048CD
GWN035MC
GWN03HTN
GWN03RA0
GWN048CF
GWN035MD
GWN03HTP
GWN03RA1
GWN048CG
GWN035TH
GWN03HTR
GWN03RA2
GWN048CH
GWN035TJ
GWN03HTT
GWN03RA3
GWN048CJ
GWN035TK
GWN03J8T
GWN03RA4
GWN048CK
GWN035TL
GWN03J8W
GWN03RA5
GWN048CM
GWN035TM
GWN03J90
GWN03RA6
GWN048CN
GWN0369A
GWN03J91
GWN03RA7
GWN048CP
GWN0369C
GWN03J92
GWN03RA8
GWN048CR
GWN0369D
GWN03JNN
GWN03RP7
GWN049GH
GWN0369E
GWN03JNP
GWN03RP9
GWN049GJ
GWN0369G
GWN03K3C
GWN03RPA
GWN049GK
GWN0369H
GWN03K3D
GWN03RPC
GWN049JL
------------------------------------------------------------------------

    (1) Visually inspect the rotor disks for the presence of a 
chamfer on the aft breakedges of the dovetail slot bottoms. Use 
paragraph 3.A. of GE SB No. CF6-80C2 S/B 72-1089, Revision 2, dated 
December 18, 2003, to do the inspection.
    (2) For disks that have the chamfered breakedges, remark, FPI, 
and ECI the rotor disk. Use paragraph 3.A.(1)(a) through 3.A.(1)(b) 
of the Accomplishment Instructions of GE SB No. CF6-80C2 S/B 72-
1089, Revision 2, dated December 18, 2003, to remark and inspect the 
rotor disk, and remove from service as necessary.
    (3) For disks that do not have the chamfered breakedges, 
inspect, rework and remark the rotor disk. Use paragraph 3.A.(2)(a) 
through 3.A.(2)(b) of the Accomplishment Instructions of GE SB No. 
CF6-80C2 S/B 72-1089, Revision 2, dated December 18, 2003, to 
inspect, rework and remark the disk and remove from service as 
necessary.

Stage 1 HPT Rotor Disks, P/Ns 9392M23G10, G12, G21, 1531M84G02, 
G06, G08, and 1531M84G10 With SNs Not Listed in Table 6 of This AD

    (j) For stage 1 HPT rotor disks, P/Ns 9392M23G10, G12, G21, 
1531M84G02, G06, G08, and 1531M84G10 with SNs not listed in Table 6 
of this AD, inspect, rework, and remark the disks using paragraphs 
3.A.(2) through 3.B.(2) of Accomplishment Instructions of GE SB No. 
CF6-80C2 S/B 72-1089, Revision 2, dated December 18, 2003, at the 
following:
    (1) For stage 1 HPT rotor disks not installed in engines with 
both new and old hardware, inspect, rework, remark, and remove from 
service as necessary before further flight.
    (2) For stage 1 HPT rotor disks that have been inspected before 
the effective date of this AD using GE SB No. CF6-80C2 S/B 72-A1024, 
Revision 1, dated November 3, 2000, or any version of GE ASB No. 
CF6-80C2 S/B 72-A1026, inspect, rework, remark, and remove from 
service as necessary at the next ESV using the compliance times in 
the following Table 7:

 Table 7.--Compliance Times for Inspection and Rework of CF6-80C2 Series
  Stage 1 HPT Rotor Disks, P/Ns 9392M23G10, G12, G21, 1531M84G02, G06,
     G08, and 1531M84G10 With SNs Not Listed in Table 6 of This AD--
                          Previously Inspected
------------------------------------------------------------------------
  Stage 1 HPT rotor disk cycles-since-
inspection (CSI)  on the effective date   Compliance time for inspection
               of this AD                           and rework
------------------------------------------------------------------------
(i) More than 1,500 CSLI...............  At the next ESV or within 4,500
                                          CSLI after the effective date
                                          of this AD, whichever occurs
                                          first.
(ii) 1,500 CSLI or fewer...............  At the next ESV or within 3,500
                                          CSLI after the effective date
                                          of this AD, whichever occurs
                                          first.
------------------------------------------------------------------------

    (3) For stage 1 HPT rotor disks that have not been inspected 
before the effective date of this AD using GE SB No. CF6-80C2 S/B 
72-A1024, Revision 1, dated November 3, 2000, or any version of GE 
ASB No. CF6-80C2 S/B 72-A1026, inspect, rework, remark, and remove 
from service as necessary at the next ESV using the compliance times 
in the following Table 8:

[[Page 8808]]



 Table 8.--Compliance Times for Inspection and Rework of CF6-80C2 Series
  Stage 1 HPT Rotor Disks, P/Ns 9392M23G10, G12, G21, 1531M84G02, G06,
   G08, and 1531M84G10 With SNs Not Listed in Table 6 of This AD--Not
                          Previously Inspected
------------------------------------------------------------------------
Stage 1 HPT rotor disk cycles-since-new   Compliance time for inspection
 (CSN) on the effective date of this AD             and rework
------------------------------------------------------------------------
(i) 10,000 or more CSN.................  At the next ESV or within 1,000
                                          CIS after the effective date
                                          of this AD, whichever occurs
                                          first.
(ii) 5,000 or more CSN but fewer than    At the next ESV or within 2400
 10,000 CSN.                              CIS after the effective date
                                          of this AD, whichever occurs
                                          first, but before accumulating
                                          11,000 CSN
(iii) Fewer than 5,000 CSN.............  At the next ESV or within 3,500
                                          CIS after the effective date
                                          of this AD, whichever occurs
                                          first, but before accumulating
                                          7,400 CSN.
------------------------------------------------------------------------

Stage 1 HPT Rotor Disks, P/N 1862M23G01

    (k) For stage 1 HPT rotor disk, P/N 1862M23G01, inspect the 
rotor disk dovetail slot bottoms and remove the disk from service as 
necessary using paragraphs 3.A. through 3.C.(10)(i) of 
Accomplishment Instructions of GE ASB No. CF6-80C2 S/B 72-A1026, 
Revision 2, dated January 22, 2004, at the following times:
    (1) For stage 1 HPT rotor disks not installed in engines with 
both new and old hardware, inspect and remove from service as 
necessary before further flight.
    (2) For stage 1 HPT rotor disks that have been inspected before 
the effective date of this AD using any version of GE ASB No. CF6-
80C2 S/B 72-A1026, and had more than zero CSN at the time of that 
inspection, inspect and remove from service as necessary at each 
piece-part exposure.
    (3) For stage 1 HPT rotor disks that have not been inspected, or 
were only inspected with zero CSN before the effective date of this 
AD using any version of GE ASB No. CF6-80C2 S/B 72-A1026, inspect 
and remove from service as necessary at the next ESV using the 
compliance times in the following Table 9:

Table 9.--Compliance Times for Inspection of CF6-80C2 Series Stage 1 HPT
          Rotor Disks, P/N 1862M23G01--Not Previously Inspected
------------------------------------------------------------------------
   Stage 1 HPT rotor disk CSN on the       Compliance time for initial
       effective date of this AD                    inspection
------------------------------------------------------------------------
(i) 10,000 or more CSN.................  At the next ESV or within 1,000
                                          CIS after the effective date
                                          of this AD, whichever occurs
                                          first.
(ii) 5,000 or more CSN but fewer than    At the next ESV or within 2,400
 10,000 CSN.                              CIS after the effective date
                                          of this AD, whichever occurs
                                          first, but before accumulating
                                          11,000 CSN.
(iii) Fewer than 5,000 CSN.............  At the next ESV or within 3,500
                                          CIS after the effective date
                                          of this AD, whichever occurs
                                          first, but before accumulating
                                          7,400 CSN.
------------------------------------------------------------------------

    (4) Thereafter, inspect at each piece-part exposure, and remove 
the rotor disk from service if necessary.

CF6-80E1A2, A4 Engines

Stage 1 HPT Rotor Disks, P/N 1639M41P04

    (l) For stage 1 HPT rotor disks, P/N 1639M41P04, remove the 
rotor disks from service using paragraphs 3.A.(1) through 3.A.(2) of 
Accomplishment Instructions of GE SB No. CF6-80E1 S/B 72-0251, dated 
January 22, 2004, at the following times:
    (1) For stage 1 HPT rotor disks currently in service, remove the 
disk using the compliance times in the following Table 10:

  Table 10.--Compliance Times for Removal of CF6-80E1 Stage 1 HPT Rotor
                          Disks, P/N 1639M41P04
------------------------------------------------------------------------
   Stage 1 HPT rotor disk CSN on the      Compliance time for removal of
       effective date of this AD                       disk
------------------------------------------------------------------------
(i) More than 10,000 CSN...............  At the next ESV or within 600
                                          CIS after the effective date
                                          of this AD, whichever occurs
                                          first.
(ii) More than 5,000 CSN but fewer than  At the next ESV or within 2,500
 or equal to 10,000 CSN.                  CIS after the effective date
                                          of this AD, whichever occurs
                                          first, but before accumulating
                                          10,600 CSN.
(iii) Fewer than or equal to 5,000 CSN.  At the next ESV or within 3,500
                                          CIS after the effective date
                                          of this AD, whichever occurs
                                          first, but before accumulating
                                          7,500 CSN.
------------------------------------------------------------------------

    (2) After the effective date of this AD, do not install any 
stage 1 HPT rotor disk, P/N 1639M41P04, into any engine.

Definitions

    (m) For the purpose of this AD, the following definitions apply:
    (1) An engine shop visit (ESV) is defined as the removal of an 
engine from an aircraft for maintenance in which a major engine 
flange is disassembled after the effective date of this AD. The 
following actions, either separately or in combination with each 
other, are not considered ESVs for the purpose of this AD.
    (i) The removal of the upper compressor stator case solely for 
airfoil maintenance.
    (ii) The module level inspection of the high-pressure compressor 
rotor 3-9 spool.
    (iii) The replacement of stage 5 high-pressure compressor 
variable stator vane bushings or lever arms.
    (2) Piece-part exposure is defined as when:
    (i) The stage 1 HPT rotor disk is considered completely 
disassembled according to the manufacturer's engine manual or other 
FAA-approved engine manual; and
    (ii) The disk has accumulated more than 100 cycles-in-service 
since the last piece-part inspection, provided that the part was not 
damaged or the disassembly is not related to the cause for its 
removal from the engine.

Reporting Requirements

    (n) Within five calendar days of the inspection, report the 
results of inspections that equal or exceed the reject criteria to: 
Engine Certification Office, FAA, Engine and Propeller Directorate, 
12 New England Executive park, Burlington, MA 01803-5299; telephone 
(781) 238-7128; fax (781) 238-7199. Reporting requirements have been 
approved by the Office of Management and Budget and assigned OMB 
control number

[[Page 8809]]

2120-0056. Be sure to include the following information:
    (1) Engine model in which the stage 1 HPT rotor disk was 
installed.
    (2) Part Number.
    (3) Serial Number.
    (4) Part CSN.
    (5) Part CSLI.
    (6) Date and location where inspection was done.
    (o) We recommend that you record the inspection information and 
results on GE Form 1653-1, entitled CF6-80A/80C Stage 1 HPT Disk 
Dovetail Slot Bottom Inspection. This form is available in any 
version of GE SB CF6-80A S/B 72-0779, or GE ASB CF6-80C2 S/B 72-
A1026. We also recommend that a copy of the data be sent to GE 
Airline Support Engineering, General Electric Aircraft Engines, 
Customer Support Center, 1 Neumann Way, Mail Drop RM285, Cincinnati, 
OH, 45215.

Alternative Methods of Compliance

    (p) The manager, Engine Certification Office, has the authority 
to approve alternative methods of compliance for this AD if 
requested using the procedures found in 14 CFR 39.19.

Material Incorporated by Reference

    (q) You must use the service information specified in Table 11 
to perform the actions required by this AD. The Director of the 
Federal Register approved the incorporation by reference of the 
documents listed in Table 11 of this AD in accordance with 5 U.S.C. 
552(a) and 1 CFR part 51. You can get a copy from General Electric 
Company via Lockheed Martin Technology Services, 10525 Chester Road, 
Suite C, Cincinnati, Ohio 45215, telephone (513) 672-8400, fax (513) 
672-8422. You may review copies 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. Table 11 follows:

                                      Table 11.--Incorporation by Reference
----------------------------------------------------------------------------------------------------------------
         Service bulletin no.               Page              Revision                       Date
----------------------------------------------------------------------------------------------------------------
GE SB No. CF6-80E1 S/B 72-0251.......  All...........  Original.............  January 22, 2004.
Total Pages: 4.......................
GE SB No. CF6-80A S/B 72-0779........  All...........  1....................  January 22, 2004.
Total Pages: 34......................
GE SB No. CF6-80A S/B 72-0788........  All...........  2....................  December 17, 2003.
Total Pages: 10......................
GE ASB No. CF6-80C2 S/B 72-A1026.....  All...........  2....................  January 22, 2004.
Total Pages: 38......................
GE SB No. CF6-80C2 S/B 72-1089.......  All...........  2....................  December 18, 2003.
Total Pages: 11......................
----------------------------------------------------------------------------------------------------------------

Related Information

    (r) GE SB No. CF6-80C2 S/B 72-A1024, Revision 1, dated November 
3, 2000 also pertains to the subject of this AD.

    Issued in Burlington, Massachusetts, on February 13, 2004.
Peter A. White,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 04-3798 Filed 2-25-04; 8:45 am]
BILLING CODE 4910-13-U