Airworthiness Directives; Boeing Model 777-200 and -300 Series Airplanes

[Federal Register Volume 67, Number 75 (Thursday, April 18, 2002)]
[Rules and Regulations]
[Pages 19104-19107]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 02-9390]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2002-NM-38-AD; Amendment 39-12714; AD 2002-08-06]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 777-200 and -300 Series 
Airplanes

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

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SUMMARY: This amendment adopts a new airworthiness directive (AD) that 
is applicable to certain Boeing Model 777-200 and -300 series 
airplanes. This action requires a one-time torque check (inspection) of 
the bolts that attach the pivot fittings to the horizontal stabilizer 
through the upper and lower titanium straps, to determine if the bolts 
are adequately torqued, and follow-on actions. This action is necessary 
to prevent failure of the pivot fittings, which could result in loss of 
control of the horizontal stabilizer and consequent loss of control of 
the airplane. This action is intended to address the identified unsafe 
condition.

DATES: Effective May 3, 2002.
    The incorporation by reference of certain publications listed in 
the regulations is approved by the Director of the Federal Register as 
of May 3, 2002.
    Comments for inclusion in the Rules Docket must be received on or 
before June 17, 2002.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), Transport Airplane Directorate, ANM-114, 
Attention: Rules Docket No. 2002-NM-38-AD, 1601 Lind Avenue, SW., 
Renton, Washington 98055-4056. Comments may be inspected at this 
location between 9:00 a.m. and 3:00 p.m., Monday through Friday, except 
Federal holidays. Comments may be submitted via fax to (425) 227-1232. 
Comments may also be sent via the Internet using the following address: 
[email protected]. Comments sent via fax or the Internet must 
contain ``Docket No. 2002-NM-38-AD'' in the subject line and need not 
be submitted in triplicate. Comments sent via the Internet as attached 
electronic files must be formatted in Microsoft Word 97 for Windows or 
ASCII text.
    The service information referenced in this AD may be obtained from 
Boeing

[[Page 19105]]

Commercial Airplane Group, P.O. Box 3707, Seattle, Washington 98124-
2207. This information may be examined at the FAA, Transport Airplane 
Directorate, 1601 Lind Avenue, SW., Renton, Washington; or at the 
Office of the Federal Register, 800 North Capitol Street, NW., suite 
700, Washington, DC.

FOR FURTHER INFORMATION CONTACT: John Craycraft, Aerospace Engineer, 
Airframe Branch, ANM-120S, FAA, Seattle Aircraft Certification Office, 
1601 Lind Avenue, SW., Renton, Washington 98055-4056; telephone (425) 
227-2782; fax (425) 227-1181.

SUPPLEMENTARY INFORMATION: The FAA has received a report of improperly 
torqued bolts that attach the pivot fittings to the horizontal 
stabilizer on certain Boeing Model 777-200 and -300 series airplanes. 
The improper torqueing occurred during production. Two pivot fittings 
attach the aft part of the horizontal stabilizer to the body structure. 
Two titanium straps attach the upper and lower surface of each pivot 
fitting to the upper and lower surface of the horizontal stabilizer. 
The straps are attached to the pivot fitting with eight bolts at each 
location. Insufficient bolt torque in multiple locations will cause the 
bolts to loosen and may cause failure of the pivot fittings. Such 
failure could result in loss of control of the horizontal stabilizer 
and consequent loss of control of the airplane.

Explanation of Relevant Service Information

    The FAA has reviewed and approved Boeing Alert Service Bulletin 
777-55A0013, Revision 1, dated January 31, 2002, which describes 
procedures for a torque check (inspection) of the two aft rows of bolts 
which attach the pivot fittings to the horizontal stabilizer through 
the upper and lower titanium straps, to determine if the bolts are 
adequately torqued, and follow-on actions.
    For Group 1 airplanes, the follow-on actions include removing the 
nut and measuring run-on torque if the torque value is between 300 
inch-pounds and 1,550 inch-pounds measured on the nut side (1,705 inch-
pounds measured on the head side). Replace any nut that does not meet 
the run-on torque requirements; if the torque values on one to three 
bolts in a joint are less than 300 inch-pounds, remove the bolts with 
those values. Do a visual inspection for indications of galling, 
fretting, and wear, and replace the bolt if discrepancies are found, 
then do an open-hole high frequency eddy current (HFEC) inspection for 
cracks; oversize the holes if cracks are found or the hole is not 
round; and install new oversize bolts. If the torque values of four or 
more bolts in a joint are less than 300 inch-pounds, remove all the 
bolts in the joint (maximum of four bolts at one time); and repeat the 
visual and HFEC inspections specified above.
    For Group 2 airplanes, the follow-on actions include removing the 
nut and measuring run-on torque if the torque value on any bolt is 
between 400 inch-pounds and 2,100 inch-pounds measured on the nut side 
(2,310 inch-pounds measured on the head side). Replace any nut that 
does not meet the run-on torque requirements; if the torque values on 
one to three bolts in a joint are less than 400 inch-pounds, remove the 
bolts with those values. Do a visual inspection for indications of 
galling, fretting, and wear, and replace the bolt if any discrepancies 
are found, then do an open-hole HFEC inspection for cracks; oversize 
the holes if cracks are found or the hole is not round; and install new 
oversize bolts. If the torque values of four or more bolts in a joint 
are less than 400 inch-pounds, remove all the bolts in the joint 
(maximum of four bolts at one time); and repeat the visual and HFEC 
inspections specified above.
    Accomplishment of the actions specified in the service bulletin is 
intended to adequately address the identified unsafe condition.

Explanation of the Requirements of the Rule

    Since an unsafe condition has been identified that is likely to 
exist or develop on other airplanes of the same type design, this AD 
requires accomplishment of the actions specified in the service 
bulletin described previously, except as discussed below.

Differences Between This AD and Alert Service Bulletin

    This AD differs from the referenced service bulletin in the 
following ways:
    <bullet> The service bulletin recommends doing the torque check 
(inspection) ``within 90 days after the revision date of service 
bulletin,'' but this AD requires the inspection be done within 90 days 
after the effective date of the AD.
    <bullet> The service bulletin specifies that the manufacturer may 
be contacted for disposition of certain repair conditions. This AD 
requires the repair of those conditions to be accomplished per a method 
approved by the FAA, or per data meeting the type certification basis 
of the airplane approved by a Boeing Company Designated Engineering 
Representative who has been authorized by the Manager, Seattle Aircraft 
Certification Office, to make such findings.
    <bullet> In Steps 4. and 5. of the Work Instructions of the service 
bulletin, the procedure to verify that there is no less than the 
chamfer of the bolt and no more than three threads protruding through 
the nut (as specified in Steps 6.e. and 7.e. of the Work Instructions) 
was inadvertently omitted. Replacement of the bolts if more than three 
threads are protruding also was omitted from those steps in the service 
bulletin. This AD requires that check and replacement, if necessary, be 
done per Step 6.e. or 7.e. of the Work Instructions of the service 
bulletin.
    <bullet> The service bulletin identifies the inspection described 
only as a ``visual inspection.'' For clarity, this AD refers to that 
inspection as a ``detailed inspection.'' Note 2 of this AD defines such 
an inspection.

Determination of Rule's Effective Date

    Since a situation exists that requires the immediate adoption of 
this regulation, it is found that notice and opportunity for prior 
public comment hereon are impracticable, and that good cause exists for 
making this amendment effective in less than 30 days.

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 shall 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.
    Submit comments using the following format:
    <bullet> Organize comments issue-by-issue. For example, discuss a 
request to change the compliance time and a request to change the 
service bulletin reference as two separate issues.
    <bullet> For each issue, state what specific change to the AD is 
being requested.
    <bullet> Include justification (e.g., reasons or data) for each 
request.

[[Page 19106]]

    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 rule must submit a self-addressed, 
stamped postcard on which the following statement is made: ``Comments 
to Docket Number 2002-NM-38-AD.'' The postcard will be date stamped and 
returned to the commenter.

Regulatory Impact

    The regulations adopted herein 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. Therefore, it 
is determined that this final rule does not have federalism 
implications under Executive Order 13132.
    The FAA has determined that this regulation is an emergency 
regulation that must be issued immediately to correct an unsafe 
condition in aircraft, and that it 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:

2002-08-06  Boeing: Amendment 39-12714. Docket 2002-NM-38-AD.

    Applicability: Model 777-200 and -300 series airplanes as listed 
in Boeing Alert Service Bulletin 777-55A0013, Revision 1, dated 
January 31, 2002; certificated in any category.

    Note 1: This AD applies to each airplane 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 airplanes 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 (e) 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: Required as indicated, unless accomplished 
previously.
    To prevent failure of the pivot fittings of the horizontal 
stabilizer, which could result in loss of control of the horizontal 
stabilizer and consequent loss of control of the airplane, 
accomplish the following:

Torque Check (Inspection)

    (a) Within 90 days after the effective date of this AD, do the 
following inspections of the aft bolts of the pivot fittings 
attached to the horizontal stabilizer per the Accomplishment 
Instructions of Boeing Alert Service Bulletin 777-55A0013, Revision 
1, dated January 31, 2002:
    (1) Do a torque check (inspection) to determine if the bolts are 
adequately torqued per the service bulletin.
    (2) Do a detailed inspection of the bolt thread protrusion 
through the nut. Replace any bolt that has less than the chamfer of 
the bolt or more than three threads protruding through the nut per 
Steps 6.d. and 6.e. or Steps 7.d. and 7.e. of the Work Instructions 
of the service bulletin for Group 1 or Group 2 airplanes, as 
applicable.

    Note 2: For the purposes of this AD, a detailed inspection is 
defined as: ``An intensive visual examination of a specific 
structural area, system, installation, or assembly to detect damage, 
failure, or irregularity. Available lighting is normally 
supplemented with a direct source of good lighting at intensity 
deemed appropriate by the inspector. Inspection aids such as mirror, 
magnifying lenses, etc., may be used. Surface cleaning and elaborate 
access procedures may be required.''


    Note 3: For Group 1 airplanes and Group 2 airplanes with WBnnn 
variable numbers (where nnn is any three digits); inspections and 
follow-on actions done before the effective date of this AD per 
Boeing Service Bulletin 777-55A0013, dated December 19, 2001, are 
considered acceptable for compliance with the corresponding actions 
specified in paragraph (a)(1) of this AD.

Follow-On Actions

    (3) Do Steps 8. and 9. of the Work Instructions in Part B of the 
service bulletin if the torque value of all attachment bolts is 
found to be within the specified limits, then no further action is 
required by this AD.
    (b) During the inspection required by paragraph (a)(1) of this 
AD, if the torque value of any attachment bolt is found to be less 
than or equal to the value specified in Step 4. of the Work 
Instructions of Boeing Alert Service Bulletin 777-55A0013, Revision 
1, dated January 31, 2002: Before further flight, do all actions 
(includes removing the nut and measuring run-on torque; replacing 
any nut that does not meet the run-on torque requirements; a visual 
inspection for indications of galling, fretting, and wear; replacing 
the bolt if any discrepancies are found; and an open-hole high 
frequency eddy current (HFEC) inspection for cracks), as specified 
in and per Steps 5., 6., and 7., as applicable, of the Work 
Instructions of Boeing Alert Service Bulletin 777-55A0013, Revision 
1, dated January 31, 2002, for Group 1 or Group 2 airplanes, as 
applicable.
    (c) If any cracking is found during the HFEC inspection and the 
service bulletin specifies contacting Boeing for repair 
instructions: Before further flight, repair per a method approved by 
the Manager, Seattle Aircraft Certification Office (ACO), FAA; or 
per data meeting the type certification basis of the airplane 
approved by a Boeing Company Designated Engineering Representative 
who has been authorized by the Manager, Seattle ACO, to make such 
findings. For a repair method to be approved by the Manager, Seattle 
ACO, as required by this paragraph, the Manager's approval letter 
must specifically reference this AD.

Reporting Requirement

    (d) Within 10 days after doing the inspections required by 
paragraph (a) of this AD: Submit a report of the bolt torque values 
and run-on torque values of the nut, and/or any damaged areas found, 
to the FAA Certification Management Office--Boeing, ANM-108B, 1601 
Lind Avenue, SW., Renton, Washington 98055-4056; at the applicable 
time specified in paragraph (b)(1) or (b)(2) of this AD. Information 
collection requirements contained in this AD 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.

Alternative Methods of Compliance

    (e) An alternative method of compliance or adjustment of the 
compliance time that provides an acceptable level of safety may be 
used if approved by the Manager, Seattle

[[Page 19107]]

ACO. Operators shall submit their requests through an appropriate 
FAA Principal Maintenance Inspector, who may add comments and then 
send it to the Manager, Seattle ACO.

    Note 4: Information concerning the existence of approved 
alternative methods of compliance with this AD, if any, may be 
obtained from the Seattle ACO.

Special Flight Permits

    (f) Special flight permits may be issued in accordance with 
sections 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 accomplished.

Incorporation by Reference

    (g) Except as provided by paragraph (c) of this AD, the actions 
shall be done in accordance with Boeing Alert Service Bulletin 777-
55A0013, Revision 1, dated January 31, 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 Boeing Commercial Airplane Group, P.O. Box 3707, 
Seattle, Washington 98124-2207. Copies may be inspected at the FAA, 
Transport Airplane Directorate, 1601 Lind Avenue, SW., Renton, 
Washington; or at the Office of the Federal Register, 800 North 
Capitol Street, NW., suite 700, Washington, DC.

Effective Date

    (h) This amendment becomes effective on May 3, 2002.

    Issued in Renton, Washington, on April 11, 2002.
Vi L. Lipski,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 02-9390 Filed 4-17-02; 8:45 am]
BILLING CODE 4910-13-U

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