Airworthiness Directives; Textron Lycoming IO-540, LTIO-540 and TIO-540 Series Reciprocating Engines

[Federal Register Volume 67, Number 183 (Friday, September 20, 2002)]
[Rules and Regulations]
[Pages 59139-59156]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 02-24030]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2002-NE-03-AD; Amendment 39-12883; AD 2002-19-03]
RIN 2120-AA64


Airworthiness Directives; Textron Lycoming IO-540, LTIO-540 and 
TIO-540 Series Reciprocating Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule, request for comments.

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SUMMARY: This amendment supersedes emergency airworthiness directive 
(AD) 2002-17-53 that was sent previously to all known U.S. owners and 
operators of Textron Lycoming LTIO-540 and TIO-540 series engines, 
rated at 300 horsepower (HP) or higher. That action requires, before 
further flight, replacing certain serial-numbered crankshafts that were 
hammer forged with crankshafts that were press forged. That AD was 
prompted by reports of crankshaft failures in LTIO-540 and TIO-540 
engines, rated at 300 HP or higher. This amendment expands the suspect 
population of engines to include engines with crankshafts that were 
manufactured between March 1997 and the present and all IO-540 engines 
with crankshafts that were manufactured between March 1997 and the 
present that have been modified by supplemental type certificate (STC) 
by installing a turbocharger system. The actions specified by this AD 
are intended to prevent failure of the crankshaft, which could result 
in total engine power loss, in-flight engine failure and possible 
forced landing.

DATES: Effective September 20, 2002.
    The incorporation by reference of certain publications listed in 
the rule is approved by the Director of the Federal Register as of 
September 20, 2002.
    Comments for inclusion in the Rules Docket must be received on or 
before November 19, 2002.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), New England Region, Office of the Regional 
Counsel, Attention: Rules Docket No. 2002-NE-

[[Page 59140]]

03-AD, 12 New England Executive Park, Burlington, MA 01803-5299. 
Comments may be inspected at this location, by appointment, between 8 
a.m. and 4:30 p.m., Monday through Friday, except Federal holidays. 
Comments may also be sent via the Internet using the following address: 
``[email protected]''. Comments sent via the Internet must 
contain the docket number in the subject line.

FOR FURTHER INFORMATION CONTACT: Rocco Viselli or Norm Perenson, 
Aerospace Engineer, New York Aircraft Certification Office, FAA, Engine 
and Propeller Directorate, 10 Fifth Street, Third Floor, Valley Stream, 
NY 11581-1200; telephone (516) 256-7531 or (516) 256-7537; fax (516) 
568-2716.

SUPPLEMENTARY INFORMATION: On August 16, 2002, the FAA issued emergency 
AD 2002-17-53, applicable to Textron Lycoming LTIO-540 and TIO-540 
series engines, rated at 300 HP or higher, to supersede emergency AD 
2002-04-51 issued on February 11, 2002. AD 2002-17-53 requires 
replacing certain crankshafts that were manufactured using a hammer-
forged process with crankshafts that were manufactured using a press-
forged process. That action was prompted by reports of 17 crankshaft 
failures in LTIO-540 and TIO-540 engines, rated at 300 HP or higher, 
which were assembled with certain crankshafts that were manufactured 
using a hammer-forged process. The FAA is continuing the investigation 
into the cause of the crankshaft failures, and further regulatory 
action may follow. This action is prompted by an additional crankshaft 
failure that was outside the population of crankshafts covered by AD 
2002-17-53. This AD requires the same replacement of certain 
crankshafts before further flight, and includes material testing of 
certain crankshafts manufactured between March 1997 and the present. 
This AD also expands the applicability to include all IO-540 engines 
with crankshafts that were manufactured between March 1997 and the 
present that have been modified by STC by installing a turbocharger 
system. This condition, if not corrected, could result in crankshaft 
failure, which could result in total engine power loss, in-flight 
engine failure and possible forced landing.

Manufacturer's Service Information

    The FAA has reviewed the technical contents of Lycoming Mandatory 
Service Bulletin (MSB) No. 552, dated August 16, 2002, that provide 
tables of the affected engine and crankshaft serial numbers (SN's).

FAA's Determination of an Unsafe Condition and Required Actions

    Since an unsafe condition has been identified that is likely to 
exist or develop on other Textron Lycoming LTIO-540 and TIO-540 
engines, rated at 300 HP or higher, and on IO-540 engines that have 
been modified by STC by installing a turbocharger system with certain 
crankshafts installed, this AD requires removal of certain crankshafts 
before further flight and material testing of certain other 
crankshafts.

Immediate Adoption of This AD

    Since it was found that immediate corrective action was required, 
notice and opportunity for prior public comment thereon were 
impracticable and contrary to the public interest, and good cause 
existed to make the AD effective immediately on August 16, 2002, to all 
known U.S. owners and operators of Textron Lycoming LTIO-540 and TIO-
540 engines, rated at 300 HP or higher. These conditions still exist, 
and the AD is hereby published in the Federal Register as an amendment 
to Section 39.13 of part 39 of the Federal Aviation Regulations (14 CFR 
part 39) to make it effective to all persons.

Comments Invited

    Although this action is in the form of a final rule that involves 
requirements affecting flight safety and, thus, was not preceded by 
notice and an opportunity for public comment, comments are invited on 
this rule. Interested persons are invited to comment on this rule by 
submitting such written data, views, or arguments as they may desire. 
Communications should identify the Rules Docket number and be submitted 
in triplicate to the address specified under the caption ADDRESSES. All 
communications received on or before the closing date for comments will 
be considered, and this rule may be amended in light of the comments 
received. Factual information that supports the commenter's ideas and 
suggestions is extremely helpful in evaluating the effectiveness of the 
AD action and determining whether additional rulemaking action would be 
needed.
    Comments are specifically invited on the overall regulatory, 
economic, environmental, and energy aspects of the rule that might 
suggest a need to modify the rule. All comments submitted will be 
available, both before and after the closing date for comments, in the 
Rules Docket for examination by interested persons. A report that 
summarizes each FAA-public contact concerned with the substance of this 
AD will be filed in the Rules Docket.
    Commenters wishing the FAA to acknowledge receipt of their comments 
submitted in response to this notice must submit a self-addressed, 
stamped postcard on which the following statement is made: ``Comments 
to Docket No. 2002-NE-03-AD.'' The postcard will be date stamped and 
returned to the commenter.

Regulatory Analysis

    This final rule does not have federalism implications, as defined 
in Executive Order 13132, because it 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. Accordingly, 
the FAA has not consulted with state authorities prior to publication 
of this final rule.
    The FAA has determined that this regulation is an emergency 
regulation that must be issued immediately to correct an unsafe 
condition in aircraft, and is not a ``significant regulatory action'' 
under Executive Order 12866. It has been determined further that this 
action involves an emergency regulation under DOT Regulatory Policies 
and Procedures (44 FR 11034, February 26, 1979). If it is determined 
that this emergency regulation otherwise would be significant under DOT 
Regulatory Policies and Procedures, a final regulatory evaluation will 
be prepared and placed in the Rules Docket. A copy of it, if filed, may 
be obtained from the Rules Docket at the location provided under the 
caption ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration amends part 39 of 
the Federal Aviation Regulations (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. Section 39.13 is amended by adding the following new 
airworthiness directive:


[[Page 59141]]


2002-19-03 Textron Lycoming: Amendment 39-12883. Docket No. 2002-NE-
03-AD. Supersedes Emergency AD 2002-17-53.

Applicability

    This AD is applicable to all Textron Lycoming LTIO-540 and TIO-
540 engines, rated at 300 horsepower (HP) or greater and all IO-540 
engines, rated at any HP, that have been modified by supplemental 
type certificate (STC) listed in Table 1 of this AD, by installing a 
turbocharger system. These engines are used on, but not limited to 
Piper Navajo (PA 31, PA 31-350, and PA 31-325), Piper Saratoga (PA 
32-301T, PA 32R-301T), Piper Aerostar (PA 60-700P), Piper Malibu 
Mirage (PA 46-350P), Piper Mojave (PA 31P-350) Appalachian Aircraft 
Corporation Gavilan (EL-1), and Cessna T-206 airplanes.Table 1 
follows:

                      Table 1.--List of STC Numbers
------------------------------------------------------------------------
 
------------------------------------------------------------------------
SA000214DE         SA00356DE          SA01925AT         SA09650SC
SA469NE            SA2062WE           SA2118NM          SE2122WE
SA2123NM           SA257CE            SA2657WE          SA2082WE
SA305SO            SA3513WE           SA3719SW          SA385WE
SA4942NM           SA529WE            SA530WE           SA539WE
SA5699NM           SA811WE            SA840WE           SA909WE
SA978WE            SE00357DE          SE01949AT         SE1657NM
SE978NM            SE17WE             SE21WE            SE22WE
SE4157NM           SE5869SW           SE40WE            SE60WE
SE6WE              SE7734SW           SE81WE            SA01925AT
SA1648NM           SA4156NM           SA1747CE          SE4941NM
SA2656WE           SA000214DE         ................  ................
------------------------------------------------------------------------


    Note 1: This AD applies to each engine identified in the 
preceding applicability provision, regardless of whether it has been 
modified, altered, or repaired in the area subject to the 
requirements of this AD. For engines that have been modified, 
altered, or repaired so that the performance of the requirements of 
this AD is affected, the owner/operator must request approval for an 
alternative method of compliance in accordance with paragraph (g) of 
this AD. The request should include an assessment of the effect of 
the modification, alteration, or repair on the unsafe condition 
addressed by this AD; and, if the unsafe condition has not been 
eliminated, the request should include specific proposed actions to 
address it.

Compliance

    Compliance with this AD is required as indicated unless already 
done.
    To prevent crankshaft failure, which could result in total 
engine power loss, in-flight engine failure and possible forced 
landing, do the following:

LTIO-540 Engines, TIO-540 Engines, Rated at 300 HP or Greater

    (a) If your engine SN is listed in Table 1 of Lycoming Mandatory 
Service Bulletin (MSB) No. 552, dated August 16, 2002, remove the 
crankshaft before further flight.
    (b) If your engine SN is listed in Table 2 of this AD, do the 
following; Table 2 follows:

[[Page 59142]]

[GRAPHIC] [TIFF OMITTED] TR20SE02.044

    (1) Contact Lycoming, 652 Oliver Street, Williamsport, PA 17701, 
U.S.A.; telephone (570) 323-6181, within 10 hours time-in-service (TIS) 
to arrange for a crankshaft material test.
    (2) Operation of the engine beyond 10 hours TIS after the effective 
date of this AD or while the material is being tested is not permitted.
    (3) If your crankshaft fails the material testing, remove the 
crankshaft before further flight.
    (4) If your crankshaft passes the material testing, the crankshaft 
may be returned to service.
    (c) If your engine SN is listed in Table 3 of this AD, do the 
following; Table 3 follows:

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[GRAPHIC] [TIFF OMITTED] TR20SE02.051

    (1) Contact Lycoming, 652 Oliver Street, Williamsport, PA 17701, 
U.S.A.; telephone (570) 323-6181, contact Lycoming, 652 Oliver Street, 
Williamsport, PA 17701, U.S.A.; telephone (570) 323-6181 within 50 
hours time-in-service (TIS) or 6 months after the effective date of 
this AD, whichever occurs earlier, to arrange for a crankshaft material 
test.
    (2) Operation of the engine beyond 50 hours TIS or 6 months after 
the effective date of this AD, whichever occurs earlier, or while the 
material is being tested is not permitted.
    (3) If your crankshaft fails the material testing, remove the 
crankshaft before further flight.
    (4) If your crankshaft passes the material testing, the crankshaft 
may be returned to service.

IO-540 Engines Modified by STC by Installing a Turbocharger System and 
All Engines That Have Been Overhauled

    (d) If your engine was manufactured, overhauled or had the 
crankshaft replaced after March 1, 1997, and your engine SN is not 
covered in paragraphs (a), (b), or (c) of this AD, do the following:

[[Page 59150]]

    (1) Determine the SN of your crankshaft.
    (2) If your crankshaft SN is listed in Table 2 of Lycoming MSB 552, 
dated August 16, 2002, remove the crankshaft before further flight.
    (3) If your crankshaft SN is listed in Table 4 of this AD, do the 
following; Table 4 follows:
[GRAPHIC] [TIFF OMITTED] TR20SE02.052

    (i) Contact Lycoming, 652 Oliver Street, Williamsport, PA 17701, 
U.S.A.; telephone (570) 323-6181, within 10 hours time-in-service (TIS) 
to arrange for a crankshaft material test.
    (ii) Operation of the engine beyond 10 hours TIS after the 
effective date of this AD or while the material is being tested is not 
permitted.
    (iii) If your crankshaft fails the material testing, remove the 
crankshaft before further flight.
    (iv) If your crankshaft passes the material testing, the crankshaft 
may be returned to service.
    (4) If your crankshaft SN is listed in Table 5 of this AD, do the 
following; Table 5 follows:

[[Page 59151]]

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[GRAPHIC] [TIFF OMITTED] TR20SE02.058

BILLING CODE 4910-13-C
    (i) Contact Lycoming, 652 Oliver Street, Williamsport, PA 17701, 
U.S.A.; telephone (570) 323-6181, contact Lycoming, 652 Oliver Street, 
Williamsport, PA 17701, U.S.A.; telephone (570) 323-6181 within 50 
hours time-in-service (TIS) or 6 months after the effective date of 
this AD, whichever occurs earlier, to arrange for a crankshaft material 
test.
    (ii) Operation of the engine beyond 50 hours TIS or 6 months after 
the effective date of this AD, whichever occurs earlier, or while the 
material is being tested is not permitted.
    (iii) If your crankshaft fails the material testing, remove the 
crankshaft before further flight.
    (iv) If your crankshaft passes the material testing, the crankshaft 
may be returned to service.

Disposition of Crankshafts That Have Passed the Material Test

    (e) A crankshaft that has passed the Lycoming material testing may 
be returned to service.

Disposition of Crankshafts That Have Failed the Material Test

    (f) After the effective date of this AD, do not install in any 
engine, any crankshaft that has failed the material test.

Denial of Alternative Methods of Compliance

    (g) An alternative method of compliance to perform material testing 
on crankshafts listed by SN in Table 2 of Lycoming MSB 552, dated 
August 16, 2002, will not be approved.

Special Flight Permits

    (h) Special flight permits may be issued in accordance with 
Sec. Sec.  21.197 and 21.199 of the Federal Aviation Regulations (14 
CFR 21.197 and 21.199) to operate the airplane to a location where the 
requirements of this AD can be done.

Documents That Have Been Incorporated By Reference

    (i) The actions must be done in accordance with the following 
Lycoming Mandatory Service Bulletin No. 552, dated August 16, 2002. 
This incorporation by reference was approved by the Director of the 
Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. 
Copies may be obtained from Lycoming, 652 Oliver Street, Williamsport, 
PA 17701, U.S.A. Copies may be inspected at the FAA, New England 
Region, Office of the Regional Counsel, 12 New England Executive Park, 
Burlington, MA; or at the Office of the Federal Register, 800 North 
Capitol Street NW., suite 700, Washington, DC.

Effective Date

    (j) This amendment becomes effective September 20, 2002.

    Issued in Burlington, Massachusetts, on September 16, 2002.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 02-24030 Filed 9-19-02; 8:45 am]
BILLING CODE 4910-13-P

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