[Federal Register Volume 90, Number 189 (Thursday, October 2, 2025)]
[Rules and Regulations]
[Pages 47546-47549]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2025-19394]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. FAA-2025-0196; Project Identifier AD-2024-00250-T;
Amendment 39-23157; AD 2025-20-04]
RIN 2120-AA64
Airworthiness Directives; The Boeing Company Airplanes
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Final rule.
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SUMMARY: The FAA is superseding Airworthiness Directive (AD) 2019-12-
13, which applied to all The Boeing Company Model 757 airplanes. AD
2019-12-13 required repetitive checks of the aileron trim actuator
bearing for free rotation, repetitive detailed inspections of the
aileron trim actuator attachment lug for damage and cracking, and
applicable on-condition actions. This AD was prompted by the
determination that a modification must be done to address the unsafe
condition. This AD retains the actions in AD 2019-12-13. This AD also
requires for certain airplanes changing the lateral control box support
assembly and installing an aileron trim actuator bracket, and for
certain other airplanes replacing the existing actuator lateral control
fitting with an aileron trim actuator bracket, which terminates the
repetitive checks and inspections. The FAA is issuing this AD to
address the unsafe condition on these products.
DATES: This AD is effective November 6, 2025.
The Director of the Federal Register approved the incorporation by
reference of certain publications listed in this AD as of November 6,
2025.
The Director of the Federal Register approved the incorporation by
reference of a certain other publication listed in this AD as of July
12, 2019 (84 FR 30577, June 27, 2019).
ADDRESSES:
AD Docket: You may examine the AD docket at regulations.gov under
Docket No. FAA-2025-0196; or in person at Docket Operations between 9
a.m. and 5 p.m., Monday through Friday, except Federal holidays. The AD
docket contains this final rule, any comments received, and other
information. The address for Docket Operations is U.S. Department of
Transportation, Docket Operations, M-30, West Building Ground Floor,
Room W12-140, 1200 New Jersey Avenue SE, Washington, DC 20590.
Material Incorporated by Reference:
For the Boeing material identified in this AD, contact
Boeing Commercial Airplanes, Attention: Contractual & Data Services
(C&DS), 2600 Westminster Blvd., MC 110-SK57, Seal Beach, CA 90740-5600;
telephone 562-797-1717; website myboeingfleet.com.
You may view this material at the FAA, Airworthiness
Products Section, Operational Safety Branch, 2200 South 216th St., Des
Moines, WA. For information on the availability of this material at the
FAA, call 206-231-3195. It is also available at regulations.gov under
Docket No. FAA-2025-0196.
FOR FURTHER INFORMATION CONTACT: Katherine Venegas, Aviation Safety
Engineer, FAA, 2200 South 216th St., Des Moines, WA 98198; phone: 562-
627-5353; email: [email protected].
SUPPLEMENTARY INFORMATION:
Background
The FAA issued a notice of proposed rulemaking (NPRM) to amend 14
CFR part 39 to supersede AD 2019-12-13, Amendment 39-19668 (84 FR
30577, June 27, 2019) (AD 2019-12-13). AD 2019-12-13 applied to all The
Boeing Company Model 757 airplanes. The NPRM was published in the
Federal Register on February 12, 2025 (90 FR 9403). The NPRM was
prompted by the determination that a modification must be done to
address the unsafe condition. In the NPRM, the FAA proposed to continue
to require the actions in AD 2019-12-13. The NPRM also proposed to
require for certain airplanes a change to the lateral control box
support assembly and installation of an aileron trim actuator bracket,
and for certain other airplanes replacement of the existing actuator
lateral control fitting with an aileron trim actuator bracket, which
terminates the repetitive checks and inspections. The FAA is issuing
this AD to address failure of the aileron trim actuator attachment lug
and subsequent loss of feel force, wheel centering, and lateral trim.
The unsafe condition, if not corrected, could cause over-control of the
airplane and subsequent lateral pilot-induced oscillations that could
adversely affect continued safe flight and landing.
Discussion of Final Airworthiness Directive
Comments
The FAA received comments from Air Line Pilots Association,
International (ALPA), Aviation Partners Boeing, Boeing, United
Airlines, and one individual who supported the NPRM without change.
The FAA received additional comments from two commenters, including
Delta Air Lines (Delta) and two individuals. One of the comments was
outside the scope of this AD. The following presents the relevant
comments received on the NPRM and the FAA's response to each comment.
Effect of Winglets on Accomplishment of the Proposed Actions
Aviation Partners Boeing stated that the installation of winglets
per Supplemental Type Certificate (STC) ST01518SE does not affect
compliance with the proposed AD.
The FAA agrees with the commenter that STC ST01518SE does not
affect the accomplishment of the manufacturer's service instructions.
Therefore, the installation of STC ST01518SE does not affect the
ability to accomplish the actions required by this AD. The FAA has not
changed this AD in this regard.
[[Page 47547]]
Request To Change Compliance Time
An individual requested that the FAA change the compliance time for
the modification to a phased approach, such as a 24- to 36-month
compliance window, to allow operators to accomplish fleet modifications
efficiently without disrupting flight operations. The commenter stated
that, given the scale of this modification across the Boeing Model 757
fleet, implementing the modifications during scheduled heavy
maintenance checks would minimize airplane downtime and supply chain
constraints. The commenter also stated that rushing to implement the
modifications could lead to parts shortages, maintenance upholds, and
operational disruptions. The commenter concluded that a risk-based
prioritization approach could ensure higher-risk airplanes are
addressed first while maintaining operational stability, and that a
flexible timeline will help achieve the intended safety improvements
effectively.
The FAA disagrees with changing the compliance time. In developing
an appropriate compliance time for this AD, the FAA considered the
recommendations of the manufacturer, the urgency associated with the
subject unsafe condition, the availability of required parts, and the
practical aspect of accomplishing the required modification within a
period of time that corresponds to the normal scheduled maintenance for
most affected operators. In consideration of these items, the FAA has
determined that compliance time of within 10,000 flight hours or 30
months from the effective date of the AD, whichever occurs first, will
ensure an acceptable level of safety. However, under the provisions of
paragraph (k) of this AD, the FAA will consider requests for approval
of an extension of the compliance time if sufficient data are submitted
to substantiate that the new compliance time would provide an
acceptable level of safety. The FAA also clarifies that operators are
allowed to implement the modification at any time within the compliance
period during their normal scheduled maintenance. The FAA has not
changed the AD in this regard.
Request To Add Note to Paragraph (i) of Proposed AD
Delta requested that the FAA add a note to paragraph (i) of the
proposed AD that refers operators to Boeing Alert Requirements Bulletin
757-27A0160 RB, dated April 1, 2024, as a global acceptable method of
compliance (AMOC) to the requirement in paragraph (h) of the proposed
AD. Paragraph (h) proposed to require doing the repair using a method
approved in accordance with the procedures specified in the AMOC
paragraph of the proposed AD instead of contacting Boeing for repair
instructions, as specified in Boeing Alert Requirements Bulletin 757-
27A0159 RB, dated March 29, 2019, and Revision 1, dated April 29, 2020.
The commenter stated that every operator that has not requested Boeing
Alert Requirements Bulletin 757-27A0160 RB as an AMOC to paragraph (h)
of the proposed AD would each have to submit an AMOC request to use
that service bulletin in lieu of repair instructions. Delta stated that
identifying Boeing Alert Requirements Bulletin 757-27A0160 RB as an
AMOC in the proposed AD would reduce strain on operators and the FAA in
processing AMOC requests.
The FAA disagrees with the request. An AMOC to the inspections
required by paragraph (g) of this AD, along with the exception in
paragraph (h) of this AD, is not necessary if the operator performs the
modification in paragraph (i) of this AD. As stated in paragraph (i) of
this AD, doing the modification required by this paragraph terminates
the inspections required by paragraph (g) of this AD. The FAA has not
changed the AD in this regard.
Request To Fix Typographical Errors in Service Information
Delta requested that the FAA address typographical errors in Boeing
Service Bulletin 757-27A0160, dated April 1, 2024. Delta stated that
under step 2 of ``Part 2: Feel and Trim Mechanism Assembly and Aileron
Trim Actuator Installation,'' the second substep should be renumbered
from ``a.'' to ``b.'' and the text of that substep should be changed
from ``Install kept the . . .'' to ``Install the kept . . . .'' Delta
also stated that substep 3.a. of ``Part 3: Restoration,'' should be
changed from ``Restore electrical power from the airplane,'' to
``Restore electrical power to the airplane.'' Delta recognized that
these errors are in steps that are not required for compliance but
asserted that the information is relevant to completing the
modification and the errors do not properly convey the intent of the
sentence.
The FAA agrees with the corrections that Delta has identified but
no change to this AD is necessary. The FAA reviewed the service
information and confirmed the typographical errors occur in steps that
are not required for compliance.
Conclusion
The FAA reviewed the relevant data, considered any comments
received, and determined that air safety requires adopting this AD as
proposed. Accordingly, the FAA is issuing this AD to address the unsafe
condition on these products. Except for minor editorial changes, this
AD is adopted as proposed in the NPRM. None of the changes will
increase the economic burden on any operator.
Material Incorporated by Reference Under 1 CFR Part 51
The FAA reviewed Boeing Alert Requirements Bulletin 757-27A0159 RB,
Revision 1, dated April 29, 2020. This material specifies procedures
for repetitive checks of the aileron trim actuator bearing for free
rotation, repetitive detailed inspections of the aileron trim actuator
attachment lug for damage or cracking, and applicable on-condition
actions. On-condition actions include high frequency eddy current
(HFEC) inspections of the aileron trim actuator attachment lug for
cracking, repair, and replacement. This revision only adds references
to AD 2019-12-13 and does not add any new actions.
The FAA also reviewed Boeing Alert Requirements Bulletin 757-
27A0160 RB, dated April 1, 2024. This material specifies procedures for
modifying the affected airplanes, which includes for certain airplanes
changing the lateral control box support assembly (which includes doing
a portable method C penetrant inspection of the machined surface of the
lug for any crack and repair as applicable) and installing an aileron
trim actuator bracket, and for certain other airplanes replacing the
existing actuator lateral control fitting with an aileron trim actuator
bracket. Accomplishment of the modification terminates the repetitive
checks and inspections specified in Boeing Alert Requirements Bulletin
757-27A0159 RB.
This AD also requires Boeing Alert Requirements Bulletin 757-
27A0159 RB, dated March 29, 2019, which the Director of the Federal
Register approved for incorporation by reference as of July 12, 2019
(84 FR 30577, June 27, 2019).
This material is reasonably available because the interested
parties have access to it through their normal course of business or by
the means identified in the ADDRESSES section.
Costs of Compliance
The FAA estimates that this AD affects 460 airplanes of U.S.
registry. The FAA estimates the following costs to comply with this AD:
[[Page 47548]]
Estimated Costs
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Cost on U.S.
Action Labor cost Parts cost Cost per product operators
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Repetitive inspections (retained 3 work-hours x $85 $0 $255 per inspection $117,300 per
actions from AD per hour = $255 per cycle. inspection cycle.
2019[dash]12[dash]13). inspection cycle.
Install aileron trim actuator 6 work-hours x $85 3,820 $4,330.............. $1,991,800.
bracket (new required action). per hour = $510.
Change the lateral control box 2 work-hours x $85 0 $170................ $69,020.*
assembly for Groups 1, 4, and 5 per hour = $170.
(new required action).
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* The number of airplanes in Groups 1, 4, and 5, as identified in Boeing Alert Requirements Bulletin 757-27A0160
RB, dated April 1, 2024, is estimated to be 406.
The FAA estimates the following costs to do any necessary on-
condition actions that would be required based on the results of the
inspection. The agency has no way of determining the number of aircraft
that might need these on-condition actions:
On-Condition Costs
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Cost per
Action Labor cost Parts cost product
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Replacement (retained actions 4 work-hours x $17,693 $18,033
from AD $85 per hour =
2019[dash]12[dash]13). $340.
HFEC inspection (retained 1 work-hour x 0 85
actions from AD $85 per hour =
2019[dash]12[dash]13). $85.
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The FAA has received no definitive data on which to base the cost
estimates for the on-condition repair specified in this 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.
The FAA is 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
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 this AD:
(1) Is not a ``significant regulatory action'' under Executive
Order 12866,
(2) Will not affect intrastate aviation in Alaska, 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.
List of Subjects in 14 CFR Part 39
Air transportation, Aircraft, Aviation safety, Incorporation by
reference, Safety.
The Amendment
Accordingly, under the authority delegated to me by the
Administrator, the FAA amends 14 CFR part 39 as follows:
PART 39--AIRWORTHINESS DIRECTIVES
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:
0
a. Removing Airworthiness Directive (AD) 2019-12-13, Amendment 39-19668
(84 FR 30577, June 27, 2019); and
0
b. Adding the following new AD:
2025-20-04 The Boeing Company: Amendment 39-23157; Docket No. FAA-
2025-0196; Project Identifier AD-2024-00250-T.
(a) Effective Date
This airworthiness directive (AD) is effective November 6, 2025.
(b) Affected ADs
This AD replaces AD 2019-12-13, Amendment 39-19668 (84 FR 30577,
June 27, 2019) (AD 2019-12-13).
(c) Applicability
This AD applies to all The Boeing Company Model 757-200, -200CB,
-200PF, and -300 series airplanes, certificated in any category.
(d) Subject
Air Transport Association (ATA) of America Code 27, Flight
controls.
(e) Unsafe Condition
This AD was prompted by a report of the failure of the aileron
trim actuator attachment lug. The FAA is issuing this AD to address
failure of the aileron trim actuator attachment lug and subsequent
loss of feel force, wheel centering, and lateral trim. The unsafe
condition, if not corrected, could cause over-control of the
airplane and subsequent lateral pilot-induced oscillations, which
could adversely affect continued safe flight and landing.
(f) Compliance
Comply with this AD within the compliance times specified,
unless already done.
(g) Retained Required Actions, With Revised Service Information
This paragraph restates the requirements of paragraph (g) of AD
2019-12-13, with revised service information. Except as specified by
paragraph (h) of this AD: At the applicable times specified in the
``Compliance'' paragraph of Boeing Alert Requirements Bulletin 757-
27A0159 RB,
[[Page 47549]]
Revision 1, dated April 29, 2020, do all applicable actions
identified in, and in accordance with, the Accomplishment
Instructions of Boeing Alert Requirements Bulletin 757-27A0159 RB,
dated March 29, 2019, or Boeing Alert Requirements Bulletin 757-
27A0159 RB, Revision 1, dated April 29, 2020. As of the effective
date of this AD, only use Boeing Alert Requirements Bulletin 757-
27A0159 RB, Revision 1, dated April 29, 2020, for the actions
required by this paragraph.
Note 1 to paragraph (g): Guidance for accomplishing the actions
required by this AD can be found in Boeing Alert Service Bulletin
757-27A0159, dated March 29, 2019, which is referred to in Boeing
Alert Requirements Bulletin 757-27A0159 RB, dated March 29, 2019.
Note 2 to paragraph (g): Guidance for accomplishing the actions
required by this AD can also be found in Boeing Alert Service
Bulletin 757-27A0159, Revision 1, dated April 29, 2020, which is
referred to in Boeing Alert Requirements Bulletin 757-27A0159 RB,
Revision 1, dated April 29, 2020.
(h) Retained Exception, With Revised Service Information
This paragraph restates the requirements of paragraph (h)(2) of
AD 2019-12-13, with revised service information. Where Boeing Alert
Requirements Bulletin 757-27A0159 RB, dated March 29, 2019, and
Boeing Alert Requirements Bulletin 757-27A0159 RB, Revision 1, dated
April 29, 2020, specify contacting Boeing for repair instructions:
This AD requires doing the repair using a method approved in
accordance with the procedures specified in paragraph (k) of this
AD.
(i) New Required Actions
Except as specified by paragraph (j) of this AD: At the
applicable times specified in the ``Compliance'' paragraph of Boeing
Alert Requirements Bulletin 757-27A0160 RB, dated April 1, 2024, do
all applicable actions identified in, and in accordance with, the
Accomplishment Instructions of Boeing Alert Requirements Bulletin
757-27A0160 RB, dated April 1, 2024. Doing the modification required
in this paragraph terminates the inspections required by paragraph
(g) of this AD.
Note 3 to paragraph (i): Guidance for accomplishing the actions
required by this AD can be found in Boeing Alert Service Bulletin
757-27A0160, dated April 1, 2024, which is referred to in Boeing
Alert Requirements Bulletin 757-27A0160 RB, dated April 1, 2024.
(j) Exceptions to Requirements Bulletin Specifications
(1) Where the Compliance Time columns of the tables in the
``Compliance'' paragraph of Boeing Alert Requirements Bulletin 757-
27A0160 RB, dated April 1, 2024, refer to the original issue date of
Requirements Bulletin 757-27A0160 RB, this AD requires using the
effective date of this AD.
(2) Where Boeing Alert Requirements Bulletin 757-27A0160 RB,
dated April 1, 2024, specifies contacting Boeing for repair
instructions: This AD requires doing the repair using a method
approved in accordance with the procedures specified in paragraph
(k) of this AD.
(k) Alternative Methods of Compliance (AMOCs)
(1) The Manager, AIR-520, Continued Operational Safety Branch,
FAA, has the authority to approve AMOCs for this AD, if requested
using the procedures found in 14 CFR 39.19. In accordance with 14
CFR 39.19, send your request to your principal inspector or
responsible Flight Standards Office, as appropriate. If sending
information directly to the manager of the certification office,
send it to the attention of the person identified in paragraph
(l)(1) of this AD. Information may be emailed to: [email protected].
Before using any approved AMOC, notify your appropriate principal
inspector, or lacking a principal inspector, the manager of the
responsible Flight Standards Office.
(2) An AMOC that provides an acceptable level of safety may be
used for any repair, modification, or alteration required by this AD
if it is approved by The Boeing Company Organization Designation
Authorization (ODA) that has been authorized by the Manager, AIR-
520, Continued Operational Safety Branch, FAA, to make those
findings. To be approved, the repair method, modification deviation,
or alteration deviation must meet the certification basis of the
airplane, and the approval must specifically refer to this AD.
(3) AMOCs approved for AD 2019-12-13 are approved as AMOCs for
the corresponding provisions of paragraph (g) of this AD.
(l) Related Information
(1) For more information about this AD, contact Katherine
Venegas, Aviation Safety Engineer, FAA, 2200 South 216th St., Des
Moines, WA 98198; phone: 562-627-5353; email:
[email protected].
(2) Material identified in this AD that is not incorporated by
reference is available at the address specified in paragraph (m)(5)
of this AD.
(m) Material Incorporated by Reference
(1) The Director of the Federal Register approved the
incorporation by reference (IBR) of the material listed in this
paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
(2) You must use this material as applicable to do the actions
required by this AD, unless this AD specifies otherwise.
(3) The following material was approved for IBR on November 6,
2025.
(i) Boeing Alert Requirements Bulletin 757-27A0159 RB, Revision
1, dated April 29, 2020.
(ii) Boeing Alert Requirements Bulletin 757-27A0160 RB, dated
April 1, 2024.
(4) The following material was approved for IBR on July 12, 2019
(84 FR 30577, June 27, 2019).
(i) Boeing Alert Requirements Bulletin 757-27A0159 RB, dated
March 29, 2019.
(ii) [Reserved]
(5) For the Boeing material identified in this AD, contact
Boeing Commercial Airplanes, Attention: Contractual & Data Services
(C&DS), 2600 Westminster Blvd., MC 110-SK57, Seal Beach, CA 90740-
5600; telephone 562-797-1717; website myboeingfleet.com.
(6) You may view this material at the FAA, Airworthiness
Products Section, Operational Safety Branch, 2200 South 216th St.,
Des Moines, WA. For information on the availability of this material
at the FAA, call 206-231-3195.
(7) You may view this material at the National Archives and
Records Administration (NARA). For information on the availability
of this material at NARA, visit www.archives.gov/federal-register/cfr/ibr-locations or email [email protected].
Issued on September 26, 2025.
Peter A. White,
Deputy Director, Integrated Certificate Management Division, Aircraft
Certification Service.
[FR Doc. 2025-19394 Filed 10-1-25; 8:45 am]
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