[Federal Register Volume 70, Number 113 (Tuesday, June 14, 2005)]
[Rules and Regulations]
[Pages 34313-34316]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-11515]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-21358; Directorate Identifier 2005-NM-088-AD; 
Amendment 39-14120; AD 2005-12-04]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 757-200, -200PF, and -
200CB Series Airplanes

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Final rule; request for comments.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
certain Boeing Model 757-200, -200PF, and -200CB series airplanes. This 
AD requires repetitive inspections of the shim installation between the 
vertical flange and bulkhead. This AD is prompted by reports of cracks, 
loose and

[[Page 34314]]

broken bolts, and shim migration in the joint between the aft torque 
bulkhead and the strut-to-diagonal brace fitting. We are issuing this 
AD to detect and correct such cracks, loose and broken bolts, and shim 
migration, which could result in damage to the strut and consequent 
separation of the strut and engine from the airplane.

DATES: Effective June 29, 2005.
    The incorporation by reference of certain publications listed in 
the AD is approved by the Director of the Federal Register as of June 
29, 2005.
    We must receive comments on this AD by August 15, 2005.

ADDRESSES: Use one of the following addresses to submit comments on 
this AD.
     DOT Docket Web site: Go to http://dms.dot.gov and follow 
the instructions for sending your comments electronically.
     Government-wide Rulemaking Web site: Go to http://www.regulations.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.
     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 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, 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. This docket 
number is FAA-2005-21358; the directorate identifier for this docket is 
2005-NM-088-AD.

Examining the Dockets

    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 Docket Management System 
(DMS) receives them.

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) 
917-6450; fax (425) 917-6590.

SUPPLEMENTARY INFORMATION: Boeing advises that, since 1993, it has 
received 17 reports of cracks, loose and broken bolts, and shim 
migration in the joint between the aft torque bulkhead and the strut-
to-diagonal brace fitting on Boeing Model 757-200 series airplanes. 
Those conditions, if not corrected, could result in damage and 
consequent loss of the strut and engine from the airplane.

Other Relevant Rulemaking

    On May 25, 2004, we issued AD 2004-12-07, amendment 13666 (69 FR 
33561, June 16, 2004). That AD applies to Boeing Model 757 series 
airplanes, line numbers 1 through 735 inclusive, equipped with Rolls 
Royce RB211 engines.
    That AD requires modification of the nacelle strut and wing 
structure; and inspections for loose/missing fasteners of certain aft 
bulkhead fasteners, proper alignment of the middle gusset of the 
inboard side load fitting, cracking of certain fastener holes; and 
corrective action if necessary. That AD cites various revision levels 
of Boeing Service Bulletin 757-54-0035 as the appropriate source of 
service information for the required actions.
    That AD also mandated inspections of the 20 fasteners that are 
subject to this new AD. The threshold for those initial inspections is 
15,000 total flight cycles. We have received reports of missing or 
loose fasteners in the affected joint as low as approximately 7,500 
total flight cycles. In addition, that AD mandated inspections of the 
20 fasteners of airplanes modified in accordance with Boeing Service 
Bulletin 757-54-0035 (original), but did not mandate inspections for 
airplanes modified in accordance with Revisions 1 or 2 of that service 
bulletin or airplanes that had been modified in production. Loose or 
missing fasteners have been found on airplanes with all versions of the 
modification.
    The actions required by that AD were intended to prevent fatigue 
cracking in primary strut structure and consequent reduced structural 
integrity of the strut, but based on this service experience, we have 
concluded that the inspection requirements of that AD are not adequate.

Relevant Service Information

    We have reviewed Boeing Service Bulletin 757-54A0047, Revision 1, 
dated March 24, 2005. The service bulletin describes procedures for 
repetitive detailed inspections of the shim installation between the 
vertical flange and bulkhead. Specifically, the service bulletin 
provides procedures to:
     Inspect for damaged sealant around the shim;
     Inspect for signs of shim movement;
     Measure the horizontal and vertical movement of the shim 
from the installed position to determine the total cumulative movement 
of the shims;
     Inspect for signs of movement of the four fasteners in the 
vertical flange; and
     Detect signs of damaged paint and/or sealant or signs of 
movement of the 16 fasteners that hold the bulkhead assembly to the 
horizontal flange of the strut-to-diagonal brace fitting.
    The service bulletin also describes four different interim repairs, 
depending on the amount of shim movement revealed during the 
inspections. The various interim repair actions include doing an eddy 
current inspection of the fastener holes for cracks, for which the 
service bulletin recommends contacting the manufacturer for repair 
instructions; replacing the shims with new shims; oversizing the holes 
and replacing discrepant fasteners with oversize fasteners; and 
applying sealant/primer on the shim of the vertical flange.
    For airplanes modified in accordance with Service Bulletin 757-54-
0035, the compliance time for the initial inspection is 6,000 flight 
cycles/36 months after the modification, with a grace period of 3,000 
flight cycles/18 months. For unmodified airplanes, the compliance time 
is 90 days. The repetitive intervals range from 6,000 to 9,000 flight 
cycles/36 to 54 months. Interim repairs are due before further flight 
after a positive finding.
    Accomplishing the actions specified in the service information is 
intended to adequately address the unsafe condition.

FAA's Determination and Requirements of This AD

    The unsafe condition described previously is likely to exist or 
develop on other airplanes of the same type design. Therefore, we are 
issuing this AD to detect and correct cracks, loose and broken bolts, 
and shim migration in the joint between the aft torque bulkhead and the 
strut-to-diagonal brace fitting. These conditions could result in 
damage to the strut and consequent separation of the strut and engine 
from the airplane. This AD requires accomplishing the actions specified 
in the service information described previously, except as discussed 
below.

[[Page 34315]]

Differences Between the AD and the Service Bulletin

    The service bulletin specifies compliance times relative to the 
issue date of the service bulletin; this AD requires corresponding 
compliance times relative to the effective date of the AD.
    The service bulletin specifies that you may contact the 
manufacturer for instructions on how to repair certain conditions, but 
this proposed AD would require you to repair those conditions using 
either a method that we approve, or data that meet the certification 
basis of the airplane and have been approved by an Authorized 
Representative for the Boeing Delegation Option Authorization 
Organization whom we have authorized to make those findings.

Clarification of Certain Compliance Times

    For Group 2 airplanes, the service bulletin specifies an inspection 
threshold relative to the date of issuance of the ``original 
Airworthiness Certificate * * *'' For these same airplanes, however, 
this AD requires an inspection threshold relative to the date of 
issuance of the ``original standard airworthiness certificate * * *'' 
We find that the addition of the term ``standard'' will establish this 
date with certainty.

FAA's Determination of the Effective Date

    An unsafe condition exists that requires the immediate adoption of 
this AD; therefore, providing notice and opportunity for public comment 
before the AD is issued is impracticable, and good cause exists to make 
this AD effective in less than 30 days.

Comments Invited

    This AD is a final rule that involves requirements that affect 
flight safety and was not preceded by notice and an opportunity for 
public comment; however, we invite you to submit any relevant written 
data, views, or arguments regarding this AD. Send your comments to an 
address listed under ADDRESSES. Include ``Docket No. FAA-2005-21358; 
Directorate Identifier 2005-NM-088-AD'' at the beginning of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of the AD. We will consider 
all comments received by the closing date and may amend the 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 AD. Using the search function of our docket 
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 the 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.

Authority for This Rulemaking

    Title 49 of the United States Code specifies the FAA's authority to 
issue rules on aviation safety. Subtitle I, section 106, describes the 
authority of the FAA Administrator. Subtitle VII, Aviation Programs, 
describes in more detail the scope of the Agency's authority.
    We are issuing this rulemaking under the authority described in 
subtitle VII, part A, subpart III, section 44701, ``General 
requirements.'' Under that section, Congress charges the FAA with 
promoting safe flight of civil aircraft in air commerce by prescribing 
regulations for practices, methods, and procedures the Administrator 
finds necessary for safety in air commerce. This regulation is within 
the scope of that authority because it addresses an unsafe condition 
that is likely to exist or develop on products identified in this 
rulemaking action.

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 regulatory evaluation of the estimated costs to 
comply with this 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, Incorporation by 
reference, Safety.

PART 39--AIRWORTHINESS DIRECTIVES

Adoption of the Amendment

0
Accordingly, under the authority delegated to me by the Administrator, 
the FAA amends 14 CFR part 39 as follows:
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 adding the following new airworthiness 
directive (AD):

2005-12-04 Boeing: Amendment 39-14120. Docket No. FAA-2005-21358; 
Directorate Identifier 2005-NM-088-AD.

Effective Date

    (a) This AD becomes effective June 29, 2005.

Affected ADs

    (b) None.
    Applicability: (c) This AD applies to Boeing Model 757-200, -
200PF, and -200CB series airplanes; certificated in any category; 
line numbers 1 through 1048 inclusive; powered by Rolls Royce 
engines.

Unsafe Condition

    (d) This AD was prompted by reports of cracks, loose and broken 
bolts, and shim migration in the joint between the aft torque 
bulkhead and the strut-to-diagonal brace fitting. The FAA is issuing 
this AD to detect and correct such conditions, which could result in 
damage to the strut and consequent separation of the strut and 
engine from the airplane.
    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 Information

    (f) For purposes of this AD, ``the service bulletin'' refers to 
Boeing Service Bulletin 757-54A0047, Revision 1, dated March 24, 
2005.

Inspections

    (g) Inspect the joint between the aft torque bulkhead and the 
strut-to-diagonal brace fitting, and repair any loose shim or loose, 
missing, or damaged fastener, by doing all actions at the times 
specified in the Accomplishment Instructions of the service 
bulletin, as applicable, except as required by paragraphs (i), (j), 
and (k) of this AD.
    (h) An inspection and corrective actions done before the 
effective date of this AD in accordance with paragraph (b) or (c), 
as applicable, of AD 2004-12-07, amendment 39-13666, are acceptable 
for compliance

[[Page 34316]]

with the initial inspection requirement of paragraph (g) of this AD.

Exceptions to Service Bulletin Procedures

    (i) Where the service bulletin specifies a compliance time 
relative to the issue date of the service bulletin, this AD requires 
compliance within the corresponding specified time relative to the 
effective date of this AD.
    (j) For purposes of this AD, for Group 2 airplanes having line 
numbers 736 through 1048, the initial inspection must be done within 
the specified time after the date of issuance of the original 
standard airworthiness certificate or the date of issuance of the 
original export certificate of airworthiness. The grace period for 
these airplanes is 3,000 flights from the effective date of this AD.
    (k) If any crack is found during any inspection required by this 
AD, and the service bulletin specifies to contact Boeing for 
appropriate action: Before further flight, repair the crack 
according to a method approved by the Manager, Seattle Aircraft 
Certification Office (ACO), FAA; or according to data meeting the 
certification basis of the airplane approved by an Authorized 
Representative for the Boeing Delegation Option Authorization 
Organization 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.

Alternative Methods of Compliance (AMOCs)

    (l) The Manager, Seattle ACO, 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 repair required by this AD, if it is approved by an 
Authorized Representative for the Boeing Delegation Option 
Authorization Organization who has been authorized by the Manager, 
Seattle ACO, to make those findings. For a repair method to be 
approved, the repair must meet the certification basis of the 
airplane, and the approval must specifically refer to this AD.

Material Incorporated by Reference

    (m) You must use Boeing Service Bulletin 757-54A0047, Revision 
1, dated March 24, 2005, to perform the actions that are required by 
this AD, unless the AD specifies otherwise. The Director of the 
Federal Register approves the incorporation by reference of this 
document in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. To 
get copies of the service information, contact Boeing Commercial 
Airplanes, P.O. Box 3707, Seattle, Washington 98124-2207. To view 
the AD docket, go to the Docket Management Facility, U.S. Department 
of Transportation, 400 Seventh Street SW., room PL-401, Nassif 
Building, Washington, DC. To review copies of the service 
information, go to the National Archives and Records Administration 
(NARA). For information on the availability of this material at the 
NARA, call (202) 741-6030, or go to http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html.

    Issued in Renton, Washington, on May 26, 2005.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 05-11515 Filed 6-13-05; 8:45 am]
BILLING CODE 4910-13-P