[Federal Register Volume 71, Number 101 (Thursday, May 25, 2006)]
[Proposed Rules]
[Pages 30078-30086]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 06-4850]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2006-24785; Directorate Identifier 2006-NE-20-AD]
RIN 2120-AA64


Airworthiness Directives; Lycoming Engines (L)O-360, (L)IO-360, 
AEIO-360, O-540, IO-540, AEIO-540, (L)TIO-540, IO-580, AEIO-580, and 
IO-720 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 (L)O-360, (L)IO-360, AEIO-360, O-540, IO-
540, AEIO-540, (L)TIO-540, IO-580, AEIO-580, and IO-720 series 
reciprocating engines. This proposed AD would require replacing certain 
crankshafts. This proposed AD results from reports of 23 confirmed 
failures of similar crankshafts in Lycoming Engines 360 and 540 series 
reciprocating engines. We are proposing this AD to prevent failure of 
the crankshaft, which will 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 June 26, 
2006.

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.

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-2006-24785; 
Directorate Identifier 2006-NE-20-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 
DOT Web site, anyone can find and read the comments in any of our 
dockets. This includes 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 DOT Docket Office 
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

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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

    We determined that 23 failures of similar crankshafts in Lycoming 
360 and 540 series reciprocating engines have occurred due to 
subsurface material flaws that progress to a fatigue failure. Lycoming 
Engines issued Mandatory Service Bulletin (MSB) No. 552, MSB No. 553, 
MSB No. 566, Supplement No. 1 to MSB No. 566, MSB No. 569, and MSB No. 
569A to address the crankshaft failures. We issued AD 2002-19-03 (MSB 
No. 552 and MSB No. 553 crankshaft populations), AD 2005-19-11 (MSB No. 
566 crankshaft population), and AD 2006-06-16 (Supplement No. 1 to MSB 
No. 566 crankshaft population) to also address the crankshaft failures. 
The group of crankshafts listed in Lycoming MSB No. 569, dated February 
21, 2006, and in the revised version, Lycoming MSB No. 569A, dated 
April 11, 2006, which is referenced in this proposed AD, has been found 
to have the same material flaws as those crankshafts addressed by the 
earlier MSBs and ADs noted. We have determined that the crankshafts 
listed in Lycoming MSB No. 569 and MSB No. 569A, must be replaced 
because of the similarity in the design and manufacture with the groups 
that have previously failed. This condition, if not corrected, will 
result in total engine power loss, in-flight engine failure, and 
possible loss of the aircraft.

Relevant Service Information

    We reviewed and approved the technical contents of Lycoming MSB No. 
569A, dated April 11, 2006. That MSB describes procedures for replacing 
crankshafts listed by serial number (SN) in that MSB.
    Lycoming records indicate the engine SNs in MSB No. 569A, Tables 1, 
2, 3, and 4, may have a suspect crankshaft installed. MSB No. 569A 
Table 5 lists the crankshaft SNs that Lycoming confirmed were part of 
the suspect population. Because the engine and crankshaft populations 
are so large, they are not repeated in this proposed AD. Owner 
operators must determine applicability by comparing engine and 
crankshaft SNs listed in MSB No. 569A.
    We have also reviewed and approved the technical contents of 
Lycoming Service Instruction No. 1009AR, dated June 22, 2004, that 
specifies engine time between overhaul periods.

Differences Between the Proposed AD and the Manufacturer's Service 
Information

    Lycoming MSB No. 569A, dated April 11, 2006, requires compliance at 
the next accessibility of the crankshaft, but no later than February 
21, 2009. However, this proposed AD would require compliance at the 
next accessibility of the crankshaft, but no later than the next engine 
overhaul specified in Lycoming Service Instruction (SI) No. 1009AR, 
dated June 22, 2004. SI No. 1009AR requires engine overhaul at the 
specified hourly interval, but no later than 12 years since new, or 
since the previous engine overhaul. The AD compliance interval could be 
longer than the MSB No. 569 and MSB No. 569A intervals if the affected 
engine does not require maintenance that allows accessibility of the 
crankshaft, or if the engine accumulates hours at a low rate per 
calendar year. We are allowing this later compliance termination date 
because we determined that the unsafe condition is unrelated to 
calendar time and that crankshaft removal at overhaul will reduce the 
risk of failure to an acceptable level.
    Lycoming IO-390 and AEIO-390 engines listed in MSB No. 569A are 
experimental engines not affected by this AD. Lycoming Engines included 
these engine models in MSB No. 569A because a suspect crankshaft may 
have been installed.

FAA's Determination and Requirements of the Proposed AD

    We 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 at the next engine overhaul as specified 
in Lycoming Service Instruction No. 1009AR, dated June 22, 2004, or at 
the next separation of the crankcase, 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 3,774 engines 
installed on airplanes of U.S. registry. Because the proposed AD 
compliance interval coincides with engine overhaul or other engine 
maintenance, we estimate no additional labor hours will be needed to 
comply with this proposed AD. Parts would cost about $16,000 per 
engine. Based on these figures, we estimate the total cost of the 
proposed AD to be $60,384,000. Lycoming said it may provide the parts 
for $2,000, until February 21, 2009, but will not extend the parts 
price beyond that date.

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 Aviation Administration proposes to amend 14 CFR part 39 as 
follows:

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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 (formerly Textron Lycoming): Docket No. FAA-2006-
24785; Directorate Identifier 2006-NE-20-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by June 26, 
2006.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Lycoming Engines (L)O-360, (L)IO-360, 
AEIO-360, O-540, IO-540, AEIO-540, (L)TIO-540, IO-580, AEIO-580, and 
IO-720 series reciprocating engines. These applicable engines are 
manufactured new or rebuilt, overhauled, or had a crankshaft 
installed after March 1, 1997. These engines are installed on, but 
not limited to, the following aircraft:

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Unsafe Condition

    (d) This AD results from reports of 23 confirmed failures of 
similar crankshafts in Lycoming Engines 360 and 540 series 
reciprocating engines. We are issuing this AD to prevent failure of 
the crankshaft, which will result in total engine power loss, in-
flight engine failure, and possible loss of the aircraft.

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.

Engines Exempted From the AD

    (f) If your engine meets any of the following conditions, and 
you haven't had the crankshaft replaced since meeting the condition, 
no further action is required:
    (1) Engines that are in compliance with Lycoming Mandatory 
Service Bulletin (MSB) No. 552 (AD 2002-19-03) or MSB No. 553 (AD 
2002-19-03 Table 3 or Table 5); or
    (2) Engines that are in compliance with Lycoming MSB No. 566 AD 
(2005-19-11); or
    (3) Engines that are in compliance with Lycoming Supplement No. 
1 to MSB No. 566 (AD 2006-06-16); or
    (4) Engines that are in compliance with the original issue of 
Lycoming MSB No. 569, or MSB No. 569A.

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    (g) If Lycoming Engines manufactured new, rebuilt, overhauled, 
or repaired your engine, or replaced the crankshaft in your engine 
before March 1, 1997, and you haven't had the crankshaft replaced, 
no further action is required.
    (h) If Table 1, Table 2, Table 3, or Table 4 of Lycoming MSB No. 
569A, dated April 11, 2006, lists your engine serial number (SN), 
and Table 5 of MSB No. 569A, dated April 11, 2006, does not list 
your crankshaft SN, no further action is required.

Engines Not Exempted From the AD

    (i) If Table 1, Table 2, Table 3, or Table 4 of Lycoming MSB No. 
569A, dated April 11, 2006, lists your engine SN, and Table 5 of MSB 
No. 569A, dated April 11, 2006, lists your crankshaft SN, replace 
the affected crankshaft with a crankshaft that is not listed in 
Table 5 of MSB No. 569A at either of the following:
    (1) The next engine overhaul as specified in Lycoming Engines 
Service Instruction No. 1009AR, dated June 22, 2004; or
    (2) The next separation of the crankcase, whichever is earlier.
    (j) If Table 1, Table 2, Table 3, or Table 4 of Lycoming MSB No. 
569A, dated April 11, 2006, does not list your engine SN, and Table 
5 of MSB No. 569A does list your crankshaft SN (an affected 
crankshaft was installed as a replacement), replace the affected 
crankshaft with a crankshaft that is not listed in Table 5 of MSB 
No. 569A at either of the following:
    (1) The next engine overhaul as specified in Lycoming Engines 
Service Instruction No. 1009AR, dated June 22, 2004; or
    (2) The next separation of the crankcase, whichever is earlier.

Prohibition Against Installing Certain Crankshafts

    (k) After the effective date of this AD, do not install any 
crankshaft that has a SN listed in Table 5 of Lycoming MSB No. 569A, 
dated April 11, 2006, into any engine.

Alternative Methods of Compliance

    (l) The Manager, New York Aircraft 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.

Related Information

    (m) None.

    Issued in Burlington, Massachusetts, on May 19, 2006.
Robert J. Ganley,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 06-4850 Filed 5-24-06; 8:45 am]
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