[Federal Register Volume 69, Number 213 (Thursday, November 4, 2004)]
[Proposed Rules]
[Pages 64263-64266]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 04-24631]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2004-19525; Directorate Identifier 2004-NM-18-AD]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 777-200, -200ER, and -300 
Series Airplanes

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The FAA proposes to adopt a new airworthiness directive (AD) 
for all Boeing Model 777-200, -200ER, and -300 series airplanes. This 
proposed AD would require inspection of the outer cylinder of the main 
landing gear (MLG) to determine the serial number; an ultrasonic 
inspection of the outer cylinder of the MLG for cracks if necessary; 
and applicable specified and corrective actions if necessary. This 
proposed AD is prompted by reports indicating that two outer cylinders 
were found fractured in the weld area. We are proposing this AD to 
detect and correct cracks or defects that could result in a fracture of 
the outer cylinder of the

[[Page 64264]]

MLG, which could lead to collapse of the MLG during landing.

DATES: We must receive comments on this proposed AD by December 20, 
2004.

ADDRESSES: Use one of the following addresses to submit comments on 
this proposed AD.
     DOT Docket Web site: Go to http://dms.dot.gov gov and follow 
the instructions for sending your comments electronically.
     Government-wide rulemaking Web site: Go to http://www.regulations.gov gov and follow the instructions for sending your comments 
electronically.
     Mail: Docket Management Facility, U.S. Department of 
Transportation, 400 Seventh Street SW., Nassif Building, room PL-401, 
Washington, DC 20590.
     By fax: (202) 493-2251.
     Hand Delivery: Room PL-401 on the plaza level of the 
Nassif Building, 400 Seventh Street SW., Washington, DC, between 9 a.m. 
and 5 p.m., Monday through Friday, except Federal holidays.
    For service information identified in this proposed AD, contact 
Boeing Commercial Airplanes, P.O. Box 3707, Seattle, Washington 98124-
2207.
    You can examine the contents of this AD docket on the Internet at 
http://dms.dot.gov gov, or in person at the Docket Management Facility, 
U.S. Department of Transportation, 400 Seventh Street SW., room PL-401, 
on the plaza level of the Nassif Building, Washington, DC.

FOR FURTHER INFORMATION CONTACT: Gary Oltman, Aerospace Engineer, 
Airframe Branch, ANM-120S, FAA, Seattle Aircraft Certification Office, 
1601 Lind Avenue, SW., Renton, Washington 98055-4056; telephone (425) 
917-6443; fax (425) 917-6590.

SUPPLEMENTARY INFORMATION:

Docket Management System (DMS)

    The FAA has implemented new procedures for maintaining AD dockets 
electronically. As of May 17, 2004, new AD actions are posted on DMS 
and assigned a docket number. We track each action and assign a 
corresponding directorate identifier. The DMS AD docket number is in 
the form ``Docket No. FAA-2004-99999.'' The Transport Airplane 
Directorate identifier is in the form ``Directorate Identifier 2004-NM-
999-AD.'' Each DMS AD docket also lists the directorate identifier 
(``Old Docket Number'') as a cross-reference for searching purposes.

Comments Invited

    We invite you to submit any written relevant data, views, or 
arguments regarding this proposed AD. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2004-19525; 
Directorate Identifier 2004-NM-18-AD'' in the subject line of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of the proposed AD. We will 
consider all comments submitted by the closing date and may amend the 
proposed AD in light of those comments.
    We will post all comments we receive, without change, to http://dms.dot.gov, including any personal information you provide. We will 
also post a report summarizing each substantive verbal contact with FAA 
personnel concerning this proposed AD. Using the search function of 
that Web site, anyone can find and read the comments in any of our 
dockets, including the name of the individual who sent the comment (or 
signed the comment on behalf of an association, business, labor union, 
etc.). You can review DOT's complete Privacy Act Statement in the 
Federal Register published on April 11, 2000 (65 FR 19477-78), or you 
can visit http://dms.dot.gov gov.
    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 that affect you. You can get more information about 
plain language at http://www.faa.gov/language gov/language and http://www.plainlanguage.gov gov.

Examining the Docket

    You can examine the AD docket on the Internet at http://dms.dot.gov, or in person at the Docket Management Facility office 
between 9 a.m. and 5 p.m., Monday through Friday, except Federal 
holidays. The Docket Management Facility office (telephone (800) 647-
5227) is located on the plaza level of the Nassif Building at the DOT 
street address stated in the ADDRESSES section. Comments will be 
available in the AD docket shortly after the DMS receives them.

Discussion

    We have received reports indicating that two outer cylinders of the 
main landing gear (MLG) were found fractured in the weld area while at 
the supplier, before delivery to Boeing for installation on Boeing 
Model 777-200 series airplanes. The outer cylinder of the MLG is a two-
piece design, which is welded together on the main barrel. 
Investigation revealed that the fractured outer cylinders were cleaned 
with an unapproved cleaning solution before welding. The cleaning 
solution that was used contained small amounts of oil that may have 
contaminated the bonding surfaces of the weld, which could cause cracks 
or defects in the weld. These conditions, if not detected and 
corrected, could result in a fracture of the outer cylinder of the MLG, 
which could lead to collapse of the MLG during landing.

Relevant Service Information

    We have reviewed Boeing Alert Service Bulletin 777-32A0038, 
Revision 1, dated February 19, 2004. The service bulletin describes 
procedures for an ultrasonic inspection for cracks or defects of the 
outer cylinder of the MLG, applicable specified actions, and corrective 
actions if necessary. Applicable specified actions may involve jacking 
up the airplane to remove the MLG, and disassembling the MLG to remove 
the outer cylinder for the ultrasonic inspection. Corrective actions 
involve replacing the outer cylinder of the MLG with a new MLG whose 
part identification numbers are not listed in the service bulletin. The 
service bulletin also recommends reporting the inspection results to 
Boeing. Accomplishing the actions specified in the service information 
is intended to adequately address the unsafe condition.

FAA's Determination and Requirements of the Proposed AD

    We have evaluated all pertinent information and identified an 
unsafe condition that is likely to exist or develop on other airplanes 
of this same type design. Therefore, we are proposing this AD, which 
would require inspection of the outer cylinder of the MLG to determine 
the serial number; an ultrasonic inspection of the outer cylinder of 
the MLG for cracks if necessary; and applicable specified and 
corrective actions as necessary. The proposed AD would require you to 
use the service information described previously to perform these 
actions, except as discussed under ``Differences Between the Proposed 
AD and the Service Bulletin.'' The proposed AD would also require that 
operators send the results of their ultrasonic inspection findings to 
the FAA only if the inspection finds any crack.

Differences Between the Proposed AD and the Service Bulletin

    Unlike the effectivity of the service bulletin, this proposed AD 
would affect Boeing Model 777-200ER and -300 series airplanes in 
addition to Model 777-200 series airplanes listed in the service 
bulletin. We have determined

[[Page 64265]]

that, because of the potential for the affected outer cylinders to be 
installed on all these models, the proposed actions must be done on all 
of these airplanes to address the identified unsafe condition.
    In addition, we have determined that the service bulletin does not 
completely address the rotability of the affected parts. Therefore, 
this proposed AD would also require a one-time inspection to determine 
if a suspect serial number of an outer cylinder may be installed on 
airplanes other than those listed in the effectivity of the service 
bulletin.
    The service bulletin specifies a compliance time of 8,000 flight 
cycles or when the outer cylinder is 6 years old, whichever occurs 
first. We have determined that a grace period of 4,000 flight cycles or 
750 days after the effective date of the AD, whichever occurs first, is 
necessary to prevent unnecessary grounding of airplanes that are over 
the threshold specified in the service bulletin.
    Operators should note that, although the Accomplishment 
Instructions of the referenced service bulletin describe procedures for 
submitting a report of all ultrasonic inspection results to the 
manufacturer, this proposed AD would require submitting the inspection 
report to the FAA only if the inspection finds any crack. We need 
further information on the extent of the quality control (QC) problem. 
When the unsafe condition addressed by an AD is likely due to a 
manufacturer's QC problem, a reporting requirement is instrumental in 
ensuring that we can gather as much information as possible regarding 
the extent and nature of the QC problem or breakdown, especially in 
cases where such data may not be available through other established 
means. This information is necessary to ensure that we can apply 
knowledge and lessons learned from these inspections to future MLG 
actions. The differences discussed in ``Differences Between the 
Proposed AD and the Service Bulletin'' have been coordinated with 
Boeing.

Costs of Compliance

    This proposed AD would affect about 463 Model 777 series airplanes 
worldwide. The following table provides the estimated costs for U.S. 
operators to comply with this proposed AD.

                                                                     Estimated Costs
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                                                          Average                                              Number of  U.S.-
              Action                    Work hours       labor rate        Parts         Cost per airplane        registered            Fleet cost
                                                          per hour                                                airplanes
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Part Number Inspection...........  1 to 229 (depending          $65  None.............  $65 to $14,885.....  133................  $8,645 to $1,979,705.
                                    on which
                                    inspection method
                                    is used).
Ultrasonic Inspection (if          6..................           65  None.............  $390 per outer       Unknown, there may   $10,140.
 necessary).                                                                             cylinder, $780 for   be up to 26
                                                                                         both outer           affected outer
                                                                                         cylinders on the     cylinders in fleet.
                                                                                         airplane.
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Regulatory Findings

    We have determined that this proposed AD would not have federalism 
implications under Executive Order 13132. This proposed AD 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.
    For the reasons discussed above, I certify that the 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. 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 regulatory evaluation of the estimated costs to 
comply with this proposed AD. See the ADDRESSES section for a location 
to examine the regulatory evaluation.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Safety.

The Proposed Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA proposes to amend 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. The FAA amends Sec.  39.13 by adding the following new 
airworthiness directive (AD):

Boeing: Docket No. FAA-2004-19525; Directorate Identifier 2004-NM-
18-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this AD action by December 20, 2004.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to all Boeing Model 777-200, -200ER, -300 
series airplanes; certificated in any category.

Unsafe Condition

    (d) This AD was prompted by reports that two outer cylinders of 
the main landing gear (MLG) were found fractured in the weld area. 
We are issuing this AD to detect and correct cracks or defects that 
could result in a fracture of the outer cylinder of the MLG, which 
could lead to collapse of the MLG during landing.

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.

Service Bulletin References

    (f) The term ``the service bulletin,'' as used in this AD, means 
the Accomplishment Instructions of Boeing Alert Service Bulletin 
777-32A0038, Revision 1, dated February 19, 2004.

Compliance Time

    (g) Perform the applicable actions specified in paragraph (h) of 
this AD at the later of the times specified in paragraphs (g)(1) and 
(g)(2) of this AD.
    (1) Within 4,000 flight cycles or 750 days after the effective 
date of this AD, whichever occurs first; or
    (2) Before accumulation of 8,000 total flight cycles on the 
outer cylinder or 72 months on the outer cylinder since new, 
whichever occurs first.

[[Page 64266]]

Part Identification Inspection, Ultrasonic Inspection, and Corrective 
Action

    (h) Inspect the outer cylinder of the MLG to determine whether 
an outer cylinder having a serial number (S/N) listed in paragraph 
1.D., ``Description,'' of the service bulletin is installed. Instead 
of an inspection of the outer cylinder of the MLG, a review of 
airplane maintenance records is acceptable if the S/N of the outer 
cylinder can be positively determined from that review.
    (1) If no S/N identified in the service bulletin is installed, 
no further action is required by this paragraph.
    (2) If any S/N identified in the service bulletin is installed, 
before further flight, do an ultrasonic inspection of the outer 
cylinder of the MLG for cracks, all applicable specified actions, 
and any corrective actions per the service bulletin. Do any 
applicable corrective action before further flight.

Reporting a Crack

    (i) Submit a report of any crack is found during the inspection 
required by paragraph (h)(2) of this AD to the Manager, Seattle 
Aircraft Certification Office (ACO), FAA, 1601 Lind Avenue, SW., 
Renton, Washington, at the applicable time specified in paragraph 
(i)(1) or (i)(2) of this AD. The report must include the inspection 
results, a description of any discrepancies found, the outer 
cylinder serial number and part number, and the number of landings 
and flight hours on the outer cylinder. Under the provisions of the 
Paperwork Reduction Act of 1980 (44 U.S.C. 3501 et seq.), the Office 
of Management and Budget (OMB) has approved the information 
collection requirements contained in this AD and has assigned OMB 
Control Number 2120-0056.
    (1) If the inspection was done after the effective date of this 
AD: Submit the report within 10 days after the inspection.
    (2) If the inspection was accomplished prior to the effective 
date of this AD: Submit the report within 10 days after the 
effective date of this AD.

Parts Installation

    (j) As of the effective date of this AD, no person may install 
an outer cylinder having a S/N listed in paragraph 1.D., 
``Description,'' of the service bulletin on any airplane unless it 
has been inspected and all specified and corrective actions are 
accomplished in accordance with paragraph (h)(2) of this AD.

Alternative Methods of Compliance (AMOCs)

    (k)(1) The Manager, Seattle Aircraft Certification Office (ACO), 
FAA, has the authority to approve AMOCs for this AD, if requested in 
accordance with the procedures found in 14 CFR 39.19.
    (2) An AMOC that provides an acceptable level of safety may be 
used for any action required by this AD, if it is approved by a 
Boeing Company Designated Engineering Representative who has been 
authorized by the Manager, Seattle ACO, to make those findings. For 
a repair method to be approved, the approval must specifically refer 
to this AD.

    Issued in Renton, Washington, on October 21, 2004.
Kalene C. Yanamura,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 04-24631 Filed 11-3-04; 8:45 am]
BILLING CODE 4910-13-P