[Federal Register Volume 71, Number 29 (Monday, February 13, 2006)]
[Proposed Rules]
[Pages 7446-7449]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: E6-1944]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2006-23873; Directorate Identifier 2005-NM-110-AD]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 747-400, 747-400D, and 
747-400F Series Airplanes

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

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The FAA proposes to supersede an existing airworthiness 
directive (AD) that applies to certain Boeing Model 747-400, 747-400D, 
and 747-400F series airplanes. The existing AD currently requires 
reviewing airplane maintenance records; inspecting the yaw damper 
actuator portion of the upper and lower rudder power control modules 
(PCM) for cracking, and replacing the PCMs if necessary; and reporting 
all airplane

[[Page 7447]]

maintenance records review and inspection results to the manufacturer. 
This proposed AD would expand the applicability and discontinue certain 
requirements of the existing AD. This proposed AD would require 
repetitive inspections of the PCMs and replacement of the PCMs if 
necessary. This proposed AD results from manufacturer findings that the 
inspections required by the existing AD must be performed at regular 
intervals. We are proposing this AD to detect and correct cracking in 
the yaw damper actuator portion of the upper and lower rudder PCMs, 
which could result in an uncommanded left rudder hardover, consequent 
increased pilot workload, and possible runway departure upon landing.

DATES: We must receive comments on this proposed AD by March 30, 2006.

ADDRESSES: Use one of the following addresses to submit comments 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.
     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.

FOR FURTHER INFORMATION CONTACT: Douglas Tsuji, Aerospace Engineer, 
Systems and Equipment Branch, ANM-130S, FAA, Seattle Aircraft 
Certification Office, 1601 Lind Avenue, SW., Renton, Washington 98055-
4056; telephone (425) 917-6487; fax (425) 917-6590.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to submit any relevant written data, views, or 
arguments regarding this proposed AD. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2006-23873; 
Directorate Identifier 2005-NM-110-AD'' at the beginning 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 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.

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 Docket Management System 
(DMS) receives them.

Discussion

    On November 3, 2003, we issued AD 2003-23-01, amendment 39-13364 
(68 FR 64263, November 13, 2003), for certain Boeing Model 747-400, 
747-400D, and 747-400F series airplanes. That AD requires reviewing 
airplane maintenance records; inspecting the yaw damper actuator 
portion of the upper and lower power control modules (PCM) for 
cracking, and replacing the PCMs if necessary; and reporting airplane 
maintenance records review and inspection results to the manufacturer. 
That AD was prompted by a report that the lower rudder of a Boeing 
Model 747-400 series airplane made an uncommanded move to the full left 
position (hardover) during flight. We issued that AD to detect and 
correct cracking in the yaw damper actuator portion of the upper and 
lower rudder PCMs, which could result in an uncommanded left rudder 
hardover, consequent increased pilot workload, and possible runway 
departure upon landing.

Actions Since Existing AD Was Issued

    The preamble to AD 2003-23-01 explains that we consider the 
requirements ``interim action.'' The inspection reports required by 
that AD were intended to enable the manufacturer and the FAA to obtain 
better insight into the nature, cause, and extent of the cracking, and 
eventually to develop final action to address the unsafe condition. We 
now have determined that further rulemaking is necessary, and this 
proposed AD follows from that determination.
    Since we issued AD 2003-23-01, there have been no further reports 
of a failure of the yaw damper actuator portion of the lower rudder PCM 
manifold. Also, investigations that included inspection results 
gathered during accomplishment of the original release of Boeing Alert 
Service Bulletin 747-27A2397, dated July 24, 2003 (which is referenced 
as the appropriate source of service information for doing the actions 
required by AD 2003-23-01), did not yield any explanation as to the 
cause of the cracks in the yaw damper actuator portion of the lower 
rudder PCM manifold. However, the failure that led to the issuance of 
AD 2003-23-01 highlighted a previously unidentified single point 
failure. Without inspection of the yaw damper actuator portion of the 
lower rudder PCM manifold, a developing crack can remain latent and 
grow to the point of failure. Therefore, to ensure that no latent crack 
can develop undetected to the point of failure of the PCM manifold, it 
has been determined that regular repetition of the inspection required 
by AD 2003-23-01 is necessary for all Boeing Model 747-400, 747-400D, 
and 747-400F series airplanes.
    The compliance time for the initial inspection (for airplanes not 
previously inspected as required by AD 2003-23-01) has been revised to 
the earlier of 56,000 total flight hours or 9,000 total flight cycles, 
or, for airplanes that are close to or have exceeded that total, 24 
months after the effective date of the AD. This compliance time is 
based on the data gathered from airplanes inspected in accordance with 
AD 2003-23-01, including the fact that there have been no further 
reports of a failure of the yaw damper actuator portion of the lower 
rudder PCM manifold. We find that this initial compliance time will be 
adequate to ensure the safety of the affected airplane fleet.

Relevant Service Information

    We have reviewed Boeing Alert Service Bulletin 747-27A2397, 
Revision 1, dated March 31, 2005. The service

[[Page 7448]]

bulletin describes procedures for performing repetitive ultrasonic 
inspections for cracking of the yaw damper actuator portion of the 
upper and lower rudder PCMs; reporting the finding of any indication of 
a cracked or broken PCM to the airplane manufacturer; and returning any 
cracked or broken part to the PCM manufacturer.

FAA's Determination and Requirements of the Proposed AD

    We have evaluated all pertinent information and identified an 
unsafe condition that is likely to develop on other airplanes of the 
same type design. For this reason, we are proposing this AD, which 
would supersede AD 2003-23-01. This proposed AD would expand the 
applicability of the existing AD and require accomplishing all actions 
specified in Boeing Alert Service Bulletin 747-27A2397, Revision 1, 
described previously.

Clarification of Alternative Method of Compliance (AMOC) Paragraph

    We have revised this action to clarify the appropriate procedure 
for notifying the principal inspector before using any approved AMOC on 
any airplane to which the AMOC applies.

Costs of Compliance

    There are approximately 636 airplanes of the affected design in the 
worldwide fleet. The FAA estimates that 86 airplanes of U.S. registry 
would be affected by this proposed AD, and that it would take 
approximately 4 work hours per airplane to accomplish the ultrasonic 
inspection, at an average labor rate of $65 per work hour. Based on 
these figures, the cost impact of the inspection is estimated to be 
$22,360, or $260 per airplane, per inspection cycle.

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. 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 removing amendment 39-13364 (68 FR 
64263, November 13, 2003) and adding the following new airworthiness 
directive (AD):

Boeing: Docket No. FAA-2006-23873; Directorate Identifier 2005-NM-
110-AD.

Comments Due Date

    (a) The Federal Aviation Administration must receive comments on 
this AD action by March 30, 2006.

Affected ADs

    (b) This AD supersedes AD 2003-23-01.

Applicability

    (c) This AD applies to all Boeing Model 747-400, 747-400D, and 
747-400F series airplanes, certificated in any category.

Unsafe Condition

    (d) This AD results from manufacturer findings that the 
inspections required by AD 2003-23-01 must be performed at regular 
intervals. We are issuing this AD to detect and correct potential 
cracking in the yaw damper actuator portion of the upper and lower 
rudder power control modules (PCM), which could result in an 
uncommanded left rudder hardover, consequent increased pilot 
workload, and possible runway departure upon 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.

Verification of Rudder PCM/Main Manifold Time in Service

    (f) For any affected airplane, if it can be positively verified 
that any rudder PCM or PCM main manifold installed on that airplane 
has accumulated a different total of flight hours or flight cycles 
than the totals accumulated by that airplane, the flight cycles or 
flight hours accumulated by the rudder PCM or PCM main manifold will 
be acceptable as valid starting points for meeting the compliance 
times required by this AD.

Inspection Accomplished Prior to the Issuance of This AD

    (g) For airplanes which, prior to the effective date of this AD, 
have received an ultrasonic inspection for cracking of the yaw 
damper actuator portion of the upper and lower rudder PCM, in 
accordance with Boeing Alert Service Bulletin 747-27A2397, dated 
July 24, 2003, as required by AD 2003-23-01, do paragraphs (g)(1), 
(g)(2), (g)(3), and (g)(4) of this AD, as applicable, in accordance 
with the Accomplishment Instructions of Boeing Alert Service 
Bulletin 747-27A2397, Revision 1, dated March 31, 2005.
    (1) Perform the ultrasonic inspection described in paragraph (g) 
of this AD at the later of the times specified in paragraph 
(g)(1)(i) or (g)(1)(ii) of this AD, then do paragraph (g)(2) or 
(g)(3) of this AD, as applicable; and paragraph (g)(4) of this AD.
    (i) Within 28,000 flight hours or 4,500 flight cycles after the 
date of the prior inspection, whichever occurs first.
    (ii) Within 24 months after the effective date of this AD.
    (2) If no cracking is found during any inspection required by 
paragraph (g)(1) or (h) of this AD: Apply sealant and a torque 
stripe and install a lockwire on the rudder PCM in accordance with 
the Accomplishment Instructions and Figure 1 or Figure 2, as 
applicable, of Alert Service Bulletin 747-27A2397, Revision 1.
    (3) If any cracking is found during any inspection required by 
paragraph (g)(1) or (h) of this AD: Before further flight, replace 
the affected PCM with a new or serviceable PCM and submit the report 
required by paragraph (i) of this AD.
    (4) Repeat the ultrasonic inspection described in paragraph (g) 
of this AD at intervals not to exceed 28,000 flight hours or 4,500 
flight cycles, whichever occurs first,

[[Page 7449]]

and repeat the actions of paragraph (g)(2) or (g)(3) of this AD, as 
applicable.

Initial Inspection

    (h) For airplanes not inspected prior to the effective date of 
this AD as specified in paragraph (g) of this AD: At the later of 
the times specified in paragraph (h)(1) or (h)(2) of this AD, 
perform an ultrasonic inspection for cracking of the yaw damper 
actuator portion of the upper and lower rudder PCM main manifold; 
and the actions specified in paragraph (g)(2) or (g)(3) of this AD, 
as applicable; in accordance with the Accomplishment Instructions of 
Boeing Alert Service Bulletin 747-27A2397, Revision 1, dated March 
31, 2005. Repeat the inspection thereafter at intervals not to 
exceed 28,000 flight hours or 4,500 flight cycles, whichever occurs 
first.
    (1) Prior to the accumulation of 56,000 total flight hours or 
9,000 total flight cycles, whichever occurs first.
    (2) Within 24 months after the effective date of this AD.

Reporting Requirements and Damaged Parts Disposition

    (i) For all airplanes: At the applicable time specified in 
paragraph (i)(1) or (i)(2) of this AD, accomplish paragraph (j) of 
this AD.
    (1) If the inspection was done after the effective date of this 
AD: Submit the report and part, if applicable, within 30 days after 
the inspection.
    (2) If the inspection was done before the effective date of this 
AD: Submit the report and part, if applicable, within 30 days after 
the effective date of this AD.
    (j) At the applicable time specified in paragraph (i) of this 
AD: Do the requirements of paragraphs (j)(1) and (j)(2) of this AD. 
Information collection requirements contained in this regulation 
have been approved by the Office of Management and Budget (OMB) 
under the provisions of the Paperwork Reduction Act of 1980 (44 
U.S.C. 3501 et seq.) and have been assigned OMB Control Number 2120-
0056.
    (1) If any inspection required by this AD reveals any indication 
of a cracked or broken part, submit a report to: The Boeing Company, 
Service Engineering--Mechanical Systems. The report must contain the 
airplane and rudder PCM serial numbers, the total flight hours and 
flight cycles for each rudder PCM (and rudder PCM main manifold, if 
known), and a description of any damage found. Submission of the 
Inspection Report Form (Figure 3 of Boeing Alert Service Bulletin 
747-27A2397, Revision 1, dated March 31, 2005) is one acceptable 
method of complying with this requirement.
    (2) Send any cracked or broken PCMs to Parker Hannifin 
Corporation in accordance with the shipping instructions specified 
in Appendix A of Boeing Alert Service Bulletin 747-27A2397, Revision 
1.

Prior Accomplishment of Requirements

    (k) Actions accomplished before the effective date of this AD in 
accordance with Boeing Alert Service Bulletin 747-27A2397, dated 
July 24, 2003, shall be considered acceptable for compliance with 
the corresponding requirements of this AD.

Parts Installation

    (l) As of the effective date of this AD, no person shall install 
on any airplane a rudder PCM having part number (P/N) 332700-1003, -
1005, -1007, or -1009; or P/N 333200-1003, -1005, -1007, or -1009; 
unless the PCM has been ultrasonically inspected (either by the 
operator or the supplier) in accordance with the Accomplishment 
Instructions of Boeing Alert Service Bulletin 747-27A2397, Revision 
1, dated March 31, 2005.

Alternative Methods of Compliance (AMOCs)

    (m)(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) Before using any AMOC approved in accordance with 14 CFR 
39.19 on any airplane to which the AMOC applies, notify the 
appropriate principal inspector in the FAA Flight Standards 
Certificate Holding District Office.
    (3) AMOCs approved previously according to AD 2003-23-01, 
amendment 39-13364, are approved as AMOCs with this AD.

    Issued in Renton, Washington, on January 31, 2006.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. E6-1944 Filed 2-10-06; 8:45 am]
BILLING CODE 4910-13-P