[Federal Register Volume 70, Number 140 (Friday, July 22, 2005)]
[Proposed Rules]
[Pages 42282-42286]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-14575]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-21864; Directorate Identifier 2005-NE-29-AD]
RIN 2120-AA64


Airworthiness Directives; Lycoming Engines (Formerly Textron 
Lycoming) AEIO-360, IO-360, O-360, LIO-360, LO-360, AEIO-540, IO-540, 
O-540, and TIO-540 Series Reciprocating Engines

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

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The FAA proposes to adopt a new airworthiness directive (AD) 
for certain Lycoming Engines (formerly Textron Lycoming) AEIO-360, IO-
360, O-360, LIO-360, LO-360, AEIO-540, IO-540, O-540, and TIO-540 
series reciprocating engines rated at 300 horsepower (HP) or lower. 
This proposed AD would require replacing certain crankshafts. This 
proposed AD results from reports of 12 crankshaft failures in Lycoming 
360 and 540 series engines rated at 300 HP or lower. We are proposing 
this AD to prevent failure of the crankshaft, which could result in 
total engine power loss, in-flight engine failure, and possible loss of 
the aircraft.

DATES: We must receive any comments on this proposed AD by August 22, 
2005.

ADDRESSES: Use one of the following addresses to comment on this 
proposed 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 20590-0001.
     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.
    You can get the service information identified in this proposed AD 
from Lycoming, 652 Oliver Street, Williamsport, PA 17701; telephone 
(570) 323-6181; fax (570) 327-7101, or on the Internet at http://www.Lycoming.Textron.com.
    You may examine the comments on this proposed AD in the AD docket 
on the Internet at http://dms.dot.gov.

FOR FURTHER INFORMATION CONTACT: Norm Perenson, Aerospace Engineer, New 
York Aircraft Certification Office, FAA, Engine & Propeller 
Directorate, 1600 Stewart Avenue, Suite 410, Westbury, NY 11590; 
telephone (516) 228-7337; fax (516) 794-5531.

[[Page 42283]]


SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send us any written relevant data, views, or 
arguments regarding this proposal. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2005-21864; 
Directorate Identifier-2005-NE-29-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 received 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 the 
Docket Management System (DMS) 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 may review the DOT's 
complete Privacy Act Statement in the Federal Register published on 
April 11, 2000 (65 FR 19477-78) or you may visit http://dms.dot.gov.

Examining the AD Docket

    You may examine the docket that contains the proposal, any comments 
received and, any final disposition in person at the Docket Management 
Facility Docket Offices between 9 a.m. and 5 p.m., Monday through 
Friday, except Federal holidays. The Docket Office (telephone (800) 
647-5227) is located on the plaza level of the Department of 
Transportation Nassif Building at the street address stated in 
ADDRESSES. Comments will be available in the AD docket shortly after 
the Docket Management Facility receives them.

Discussion

    On September 16, 2002, we issued AD 2002-19-03, Amendment 39-12883 
(67 FR 59139) applicable to Textron Lycoming LTIO-540 and TIO-540 
series engines, rated at 300 HP or higher. That AD requires replacing 
certain crankshafts manufactured using a hammer-forged process with 
crankshafts manufactured using a press-forged process. AD 2002-19-03 
resulted from reports of 18 crankshaft failures in LTIO-540 and TIO-540 
engines, rated at 300 HP or higher. Our investigation into the cause of 
the crankshaft failures found that the failures result from subsurface 
metallurgical flaws. Lack of crankshaft process control caused the 
subsurface metallurgical flaws. While this proposed AD would affect 
different crankshafts than those affected by AD 2002-19-03, the 
crankshafts have the same possible unsafe condition. This proposed AD 
results from 12 reports of crankshaft failures on engines rated at 300 
HP or lower. This proposed AD would require replacing certain 
crankshafts installed in engines manufactured new or rebuilt, 
overhauled, or that had a crankshaft replaced after March 1, 1999. This 
condition, if not corrected, could result in crankshaft failure, which 
could result in total engine power loss, in-flight engine failure, and 
possible loss of the aircraft.

Relevant Service Information

    We have reviewed and approved the technical contents of Lycoming 
Mandatory Service Bulletin (MSB) No. 566, dated July 11, 2005, that 
describes procedures for replacing crankshafts listed by serial number 
in that MSB.

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 products 
of this same type design. We are proposing this AD, which would require 
replacing certain crankshafts within 50 hours time-in-service or 6 
months after the effective date of the proposed AD, whichever is 
earlier. The proposed AD would require you to use the service 
information described previously to perform these actions.

Costs of Compliance

    We estimate that this proposed AD would affect 1,128 engines 
installed on aircraft of U.S. registry. We estimate that it would take 
the following work hours to perform the inspection:

------------------------------------------------------------------------
                                                       Work-
                                                       hours   Number of
                 Type of application                    per     engines
                                                       engine   affected
------------------------------------------------------------------------
Helicopter..........................................       12        200
Constant-Speed Propeller............................        3        557
Fixed-Pitch Propeller...............................      1.5        371
------------------------------------------------------------------------

    We also estimate that it would take about 33 work hours to replace 
the crankshaft. We estimate the average labor rate is $65 per work hour 
and that required parts for each engine would cost about $16,218. Based 
on these figures, we estimate the total cost of the proposed AD to U.S. 
operators to be $18,594,724. Lycoming Engines informed us that they 
intend to supply the new parts at no charge, which would substantially 
reduce the estimated cost of this proposed AD.

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 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. Would 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

    Under the authority delegated to me by the Administrator, the 
Federal

[[Page 42284]]

Aviation Administration 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:

Lycoming Engines: Docket No. FAA-2005-21864; Directorate Identifier 
2005-NE-29-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by August 22, 
2005.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Lycoming Engines (Formerly Textron 
Lycoming) AEIO-360, IO-360, O-360, LIO-360, LO-360, AEIO-540, IO-
540, O-540, and TIO-540 series reciprocating engines, rated at 300 
horsepower or lower, manufactured new or rebuilt, overhauled, or 
that had a crankshaft installed after March 1, 1999. These engines 
are installed on, but not limited to, the following aircraft:

----------------------------------------------------------------------------------------------------------------
         Engine model                Manufacturer                            Aircraft model
----------------------------------------------------------------------------------------------------------------
IO-540-V4A5...................  A.M.F................  17-D Mushshak.
                                Aero Commander.......  500 B, S, U/Merlyn Products Conv.
IO-540-E1A5...................  Aero Commander.......  500-E.
                                Aerofab..............  LA 250 Renegade.
                                Aeronautica..........  Agricola Mexicana Quail.
IO-540-K1F5...................  Aerostar.............  600.
                                Aircraft               Mushshak.
                                 Manufacturing
                                 Factory.
O-540-E4A5....................  Aviamilano...........  F-250 Flamingo.
IO-540-C4B5...................  Avions...............  Pierre Robin HR-100/250.
LO-360-A1G6D..................  Beech................  76 Duchess.
O-360-A1G6D...................  .....................  76 Duchess.
                                                       C-24R Sierra or 200 Sierra.
                                Bellanca.............  Aircraft Aries T-250.
O-540-E4B5....................  Britten Norman.......  BN-2 Islander.
O-540-E4C5....................  .....................  BN-2A & BN-2B Islander.
IO-540-K1B5...................  .....................  BN-2A Islander.
                                Celair...............  Eagle.
O-360-A1F6....................  Cessna...............  177 Cardinal.
O-360-A1F6D...................  .....................  177 Cardinal.
O-540-J3C5D...................  .....................  182-RG Skylane.
IO-540-AB1A5..................  .....................  182-S.
O-360-F1A6....................  .....................  C-172RG Cutlass RG.
IO-540-AC1A5..................  .....................  C-206 Stationair.
                                                       R-G Cardinal.
IO-360-A1B6D..................  .....................  R-G Cardinal.
TIO-540-AK1A..................  .....................  T182T Skylane.
O-540-L3C5D...................  .....................  TR-182 Turbo Skylane.
AEIO-540-D4A5.................  Christen Pitts.......  S-2S, S-2B.
IO-540-T4B5D..................  Commander............  114.
IO-540-T4B5...................  .....................  114B.
TIO-540-AG1A..................  .....................  114TC.
                                Dornier..............  DO-28.
IO-540-K1J5D..................  Embraer..............  EMB-201 Ipanema.
O-540-B4B5....................  .....................  EMB-710 Corioca.
                                                       EMB-720 Minuano.
                                                       EMB-720 Minuano & EMB-721 Sertanejo.
                                                       EMB-721 Sertanejo.
AEIO-540-L1B5.................  Extra-Flugzeugbau....  Extra 300.
                                F.F.A................  FFA-2000 Eurotrainer.
                                H.A.L................  HPT-32.
O-540-A1A5....................  Helio Military.......  H-250.
AEIO-360-A1E6.................  Integrated Systems...  Omega.
IO-540-M1C5...................  King Engineering.....  Angel.
                                Korean Air...........  Chang Gong-91.
                                Lake.................  LA-4-200 Buccaneer.
O-540-J3A5                      Maule.                 .........................................................
                                                       MT-7-260 & M-7-260.
                                                       MX-7-235 Star Rocket.
IO-540-W1A5...................  .....................  MX-7-235, MT-7-235 & M7-235.
                                Mod Works............  Trophy 212 Conversion.
IO-360-A3B6...................  Mooney...............  201.
                                                       M-201.
IO-360-A1B6...................  .....................  M-20-J.
IO-360-A3B6D..................  .....................  M20J-201.
TIO-540-AF1B..................  .....................  M20M TLS Bravo.
                                Moravan..............  Z143L Zlin.
                                                       Z242L Zlin.
                                Partenavia...........  P-68 Series Observer.
IO-540-K1J5...................  Piper................  600-A Aerostar.

[[Page 42285]]

 
IO-540-S1A5...................  .....................  601-A, 601B & 601P Aerostar.
IO-540-AA1A5..................  .....................  602P Sequoia.
O-540-A1B5....................  .....................  PA-23-235 Aztec & PA-24-250 Comanche.
                                                       PA-23-250 Aztec.
IO-540-J4A5...................  .....................  PA-23-250 Aztec.
IO-540-C1B5...................  .....................  PA-23-250 Aztec & PA-24-250 Comanche.
TIO-540-C1A...................  .....................  PA-23-250T Turbo Aztec.
                                                       PA-24-150 Comanche.
O-540-A1C5....................  .....................  PA-24-250 Comanche.
O-540-A1D5....................  .....................  PA-24-250 Comanche.
IO-540-D4A5...................  .....................  PA-24-260 Comanche.
                                                       PA-24-260 Comanche.
O-540-B2C5....................  .....................  PA-25-235 Pawnee.
O-540-B2B5....................  .....................  PA-28-235 Cherokee.
                                                       PA-28-235 Cherokee.
IO-360-C1C6...................  .....................  PA-28R-201 Arrow.
IO-540-M1A5...................  .....................  PA-31-300 Navajo.
                                                       PA-32-260 Cherokee 6.
IO-540-K1G5...................  .....................  PA-32-300 & PA-32-301 Saratoga.
IO-540-K1A5...................  .....................  PA-32-300 Cherokee 6.
IO-540-K1A5D..................  .....................  PA-32-300 Cherokee 6.
IO-540-K1G5D..................  .....................  PA-32-300R Lance.
                                                       PA-32-301R Saratoga.
IO-360-C1E6...................  .....................  PA-34-200 Seneca I.
IO-540-K1G5...................  .....................  PA-36-300 Brave.
O-360-A1H6....................  .....................  PA-44-180.
LO-360-A1H6...................  .....................  PA-44-180 Seminole.
IO-540-K1K5...................  .....................  T-35 Pillan.
                                Robin................  R-3000/235.
O-540-F1B5....................  Robinson.............  R-44.
                                Rockwell.............  114.
                                Ruschmeyer...........  MF-85.
                                Saab.................  MFI-15 Safari or MFI-17 Supporter.
                                Scottish Avia........  Bulldog.
                                Siai Marchetti.......  S-205.
                                Siai Marchetti.......  S-208 & SF-260.
                                Siai Marchetti.......  SF-260.
                                Siai Marchetti.......  SF-260.
                                Slingsby.............  Firefly T3A.
                                Socata...............  R-235 Rallye Cuerrier.
                                                       Rallye 235CA.
IO-540-C4D5D..................  .....................  TB-20 Trinidad.
                                                       TB-200.
TIO-540-AB1AD.................  .....................  TB-21 & TB-21-TC Trinidad TC.
IO-540-AB1A5..................  Stoddard Hamilton....  Glasair.
IO-540-K1H5...................  Stoddard Hamilton....  Glasair III.
IO-540-L1C5...................  Swearingen Aircraft..  SX-300.
                                Transava.............  T-300 Skyfarmer.
AEIO-360-A1B6.................  Valmet...............  L-70 Vinka.
                                Wassmer..............  WA4-21.
                                Yoeman...............  Aviation YA-1.
----------------------------------------------------------------------------------------------------------------

Unsafe Condition

    (d) This AD results from 12 crankshaft failures in Lycoming 
model 360 and 540 series engines rated at 300 HP or lower. We are 
issuing this AD to prevent failure of the crankshaft, which could 
result in total engine power loss, in-flight engine failure, and 
possible loss of the airplane.

Compliance

    (e) You are responsible for having the actions required by this 
AD performed within 50 hours time-in-service or 6 months after the 
effective date of this AD, whichever is earlier, unless the actions 
have already been done.

Engines Manufactured Before March 1, 1999

    (f) If Lycoming Engines manufactured new, rebuilt, or overhauled 
your engine before March 1, 1999, and you haven't had the crankshaft 
replaced, no further action is required.

AEIO-540, IO-540, O-540, and TIO-540 Series Engines Manufactured New or 
Rebuilt, Overhauled, or That Had a Crankshaft Installed After March 1, 
1999

    (g) For AEIO-540, IO-540, O-540, and TIO-540 series engines 
manufactured new or rebuilt, overhauled, or that had a crankshaft 
installed after March 1, 1999, do the following:
    (1) If Table 1 or Table 2 of Lycoming Mandatory Service Bulletin 
(MSB) No. 566, dated July 11, 2005, lists your engine serial number 
(SN), use Table 4 to verify the crankshaft SN.
    (2) If Table 4 of Lycoming MSB No. 566, dated July 11, 2005, 
lists your crankshaft SN, replace the crankshaft with a crankshaft 
that is not listed in Table 4 of Lycoming MSB No. 566, dated July 
11, 2005.

AEIO-360, IO-360, O-360, LIO-360, and LO-360 Series Engines 
Manufactured New or Rebuilt, Overhauled, or That Had a Crankshaft 
Installed After March 1, 1999

    (h) For AEIO-360, IO-360, O-360, LIO-360, and LO-360 series 
engines manufactured new or rebuilt, overhauled, or that had a 
crankshaft installed after March 1, 1999, do the following:
    (1) If Table 3 of Lycoming MSB No. 566, dated July 11, 2005, 
lists your engine SN, use Table 4 to verify the crankshaft SN.
    (2) If Table 4 of Lycoming MSB No. 566, dated July 11, 2005, 
lists your crankshaft SN, replace the crankshaft with a crankshaft 
that is not listed in Table 4 of Lycoming MSB No. 566, dated July 
11, 2005.

[[Page 42286]]

Prohibition Against Installing Certain Crankshafts

    (i) After the effective date of this AD, do not install any 
crankshaft that has a SN listed in Table 4 of Lycoming MSB No. 566, 
dated July 11, 2005, into any engine.

Alternative Methods of Compliance (AMOCs)

    (j) The Manager, New York Aircraft Certification Office, has the 
authority to approve AMOCs for this AD if requested using the 
procedures found in 14 CFR 39.19.

Related Information

    (k) None.

    Issued in Burlington, Massachusetts, on July 19, 2005.
Jay J. Pardee,
Manager, Engine and Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 05-14575 Filed 7-20-05; 11:52 am]
BILLING CODE 4910-13-P