Airworthiness Directives; Lycoming Engines (Formerly Textron Lycoming) AEIO-540, IO-540, LTIO-540, O-540, and TIO-540 Series Reciprocating Engines

[Federal Register Volume 69, Number 50 (Monday, March 15, 2004)]
[Rules and Regulations]
[Pages 12057-12060]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 04-5262]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2002-NE-31-AD; Amendment 39-13519; AD 2004-05-24]
RIN 2120-AA64


Airworthiness Directives; Lycoming Engines (Formerly Textron 
Lycoming) AEIO-540, IO-540, LTIO-540, O-540, and TIO-540 Series 
Reciprocating Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

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SUMMARY: The FAA is superseding an existing airworthiness directive 
(AD) for Lycoming Engines (Formerly Textron Lycoming) AEIO-540, IO-540, 
LTIO-540, O-540, and TIO-540 series reciprocating engines. That action 
requires replacing certain zinc-plated crankshaft gear retaining bolts. 
This action retains that requirement, but expands the population of 
affected engines. In addition, this AD adds five additional kits for 
replacing the crankshaft gear retaining bolts. This AD results from 
notification from the Manufacturer of 161 engines not identified in the 
previous AD. This AD also results from approval of the five additional 
kits as alternative methods of compliance with AD 2002-23-06. We are 
issuing this AD to prevent loss of all engine power and possible forced 
landing.

DATES: Effective March 30, 2004. The Director of the Federal Register 
approved the incorporation by reference of Lycoming Service Bulletin 
554, dated September 30, 2002, on November 19, 2002 (67 FR 68932, 
November 14, 2002). The Director of the Federal Register approved the 
incorporation by reference of Lycoming Mandatory Service Bulletin No. 
554, Supplement 5, dated August 15, 2003, as of March 30, 2004.
    We must receive any comments on this AD by May 14, 2004.

ADDRESSES: Use one of the following addresses to submit comments on 
this AD:
    <bullet<ls-thn-eq> By mail: Federal Aviation Administration (FAA), 
New England Region, Office of the Regional Counsel, Attention: Rules 
Docket No. 2002-NE-31-AD, 12 New England Executive Park, Burlington, MA 
01803-5299.
    <bullet<ls-thn-eq> By fax: (781) 238-7055.
    <bullet<ls-thn-eq> By e-mail: [email protected]
    You can get the service information referenced in this AD from 
Lycoming, a Textron Company, 652 Oliver Street, Williamsport, PA 17701; 
telephone (570) 323-6181. You can also access this service information 
electronically on http://www.lycoming.textron.com.
    You may examine the AD docket, by appointment, at the FAA, New 
England Region, Office of the Regional Counsel, 12 New England 
Executive Park, Burlington, MA. You may examine the service 
information, by appointment, 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.

FOR FURTHER INFORMATION CONTACT: Norm Perenson, Aerospace Engineer, New 
York Aircraft Certification Office, FAA, Engine and Propeller 
Directorate, 1600 Stewart Avenue, Suite 410, Westbury, NY 11590; 
telephone (516) 228 7337; fax (516) 794 5531.

SUPPLEMENTARY INFORMATION: On November 8, 2002, we issued AD 2002-23-
06, Amendment 39-12950 (67 FR 68932, November 14, 2002). That AD 
requires replacing the crankshaft gear retaining bolt:
    <bullet<ls-thn-eq> Before further flight on engines that have been 
overhauled or have had the gear retaining bolt replaced between 
November 27, 1996 and November 10, 1998, and that have not complied 
with emergency AD 2002-20-51 by using a bolt from the gear bolt 
replacement kit, 05K19987 and
    <bullet<ls-thn-eq> Within 10 hours time-in-service (TIS) or 7 days 
after the effective date of that AD, on engines that have complied with 
AD 2002-20-51, but did not install a bolt from gear bolt replacement 
kit, 05K19987, and
    <bullet<ls-thn-eq> Within 10 hours TIS or 7 days after the 
effective date of that AD, on engines that have been overhauled in the 
field, or that have had the gear retaining bolt replaced in the field 
between November 10, 1998, and the effective date of AD 2002-23-06 
(November 19, 2002).
    That AD was prompted by two failures of zinc-plated crankshaft gear 
retaining bolts, and a reassessment of the extent to which the suspect 
bolts may still be present in the field. That condition, if not 
corrected, could result in loss of all engine power and possible forced 
landing.

Actions Since AD 2002-23-06 Was Issued

    Since that AD was issued, Lycoming identified 161 additional 
engines by serial number (SN) that they might have assembled with a 
zinc-plated crankshaft gear retaining bolt, part number (P/N) STD-2209, 
during the initial assembly or during a subsequent rebuild or overhaul 
of the engine. Lycoming also developed five additional kits for other 
maintenance purposes that also contain replacement gear retaining 
bolts. We approved those kits as alternate methods of compliance with 
AD 2002-23-06, and incorporated those kits in this new AD. In addition, 
any bolt, STD-2209, installed by Lycoming after November 10, 1998, is 
cadmium plated and is not affected by AD 2002-23-06. This includes STD-
2209 bolts installed using Service Bulletin (SB) 554 in production, 
overhaul, or for any other reason. Lycoming has replaced bolt, STD-
2209, with bolt, STD-2247. This new bolt, STD-2247, is not affected by 
this AD.

Relevant Service Information

    We have reviewed and approved the technical contents of Lycoming SB 
No. 554, dated September 30, 2002, that describes procedures for 
replacing the existing crankshaft gear retaining bolt. We have also 
reviewed Lycoming Mandatory SB (MSB) No. 554, Supplement 5, dated 
August 15, 2003. That MSB provides lists of engine SNs, by engine 
model, of engines that were assembled with zinc-plated crankshaft gear 
retaining bolt, P/N STD-2209, during the initial assembly or during a

[[Page 12058]]

subsequent rebuild or overhaul of the engine by Lycoming.

FAA's Determination and Requirements of This AD

    The unsafe condition described previously is likely to exist or 
develop on other T/L AEIO-540, IO-540, O-540, LTIO-540, and TIO-540 
series reciprocating engines of the same type design. We are issuing 
this AD to prevent the loss of all engine power and possible forced 
landing. This AD requires replacing the crankshaft gear retaining bolt:
    <bullet<ls-thn-eq> Before further flight on engines that have been 
overhauled or have had the gear retaining bolt replaced between 
November 27, 1996 and November 10, 1998, by Lycoming, that have an 
engine serial number listed in Lycoming SB 554, and that have not 
complied with AD 2002-23-06.
    <bullet<ls-thn-eq> Before further flight on engines that have 
complied with AD 2002-23-06, but did not install a bolt from gear bolt 
replacement kits: 05K19987, 05K23325, 05K23326, 05K23327, 05K23335, or 
05K233367, or with a bolt that has a P/N other than P/N STD-2209.
    <bullet<ls-thn-eq> Before further flight on engines that have been 
overhauled in the field, between November 27, 1996 and the affective 
date of AD 2002-23-06 (November 19, 2002) that have not had the gear 
retaining bolt replaced with a bolt from kits: 05K19987, 05K23325, 
05K23326, 05K23327, 05K23335 or 05K23336, or with a bolt that has a P/N 
other than P/N STD-2209.
    <bullet<ls-thn-eq> Within 10 hours TIS or 7 days after the 
effective date of this AD, whichever occurs earlier, on engines listed 
by SN in Lycoming MSB No. 554, Supplement 5, dated August 15, 2003.
    You must use the service information described previously to 
perform the actions required by this AD.

FAA's Determination of the Effective Date

    Since an unsafe condition exists that requires the immediate 
adoption of this AD, we have found that notice and opportunity for 
public comment before issuing this AD are impracticable, and that good 
cause exists for making this amendment effective in less than 30 days.

Changes to 14 CFR Part 39--Effect on the AD

    On July 10, 2002, we issued a new version of 14 CFR part 39 (67 FR 
47997, July 22, 2002), which governs our AD system. This regulation now 
includes material that relates to special flight permits, alternative 
methods of compliance, and altered products. This material previously 
was included in each individual AD. Since this material is included in 
14 CFR part 39, we will not include it in future AD actions.

Comments Invited

    This AD is a final rule that involves requirements affecting flight 
safety and was not preceded by notice and an opportunity for public 
comment; however, we invite you to submit any written relevant data, 
views, or arguments regarding this AD. Send your comments to an address 
listed under ADDRESSES. Include ``AD Docket No. 2002-NE-31-AD'' in the 
subject line of your comments. If you want us to acknowledge receipt of 
your mailed comments, send us a self-addressed, stamped postcard with 
the docket number written on it; we will date-stamp your postcard and 
mail it back to you. We specifically invite comments on the overall 
regulatory, economic, environmental, and energy aspects of the rule 
that might suggest a need to modify it. If a person contacts us 
verbally, and that contact relates to a substantive part of this AD, we 
will summarize the contact and place the summary in the docket. We will 
consider all comments received by the closing date and may amend the AD 
in light of those comments.
    We are reviewing the writing style we currently use in regulatory 
documents. We are interested in your comments on whether the style of 
this document is clear, and your suggestions to improve the clarity of 
our communications with you. You may get more information about plain 
language at http://www.faa.gov/language and http://www.plainlanguage.gov.

Examining the AD Docket

    You may examine the AD Docket (including any comments and service 
information), by appointment, between 8 a.m. and 4:30 p.m., Monday 
through Friday, except Federal holidays. See ADDRESSES for the 
location.

Regulatory Findings

    We have determined that 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 the 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 summary of the costs to comply with this AD and 
placed it in the AD Docket. You may get a copy of this summary by 
sending a request to us at the address listed under ADDRESSES. Include 
``AD Docket No. 2002-NE-31-AD'' in your request.

List of Subjects in 14 CFR Part 39

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

Adoption of the Amendment

0
Accordingly, under 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

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 removing Amendment 39-12950 (67 FR 
68932, November 14, 2002) and by adding a new airworthiness directive, 
Amendment 39-13519, to read as follows:

2004-05-24 Lycoming Engines (Formerly Textron Lycoming): Amendment 
39-13519. Docket No. 2002-NE-31-AD. Supersedes AD 2002-23-06, 
Amendment 39-12950.

Effective Date

    (a) This airworthiness directive (AD) becomes effective March 
30, 2004.

Affected ADs

    (b) This AD supersedes AD 2002-23-06, Amendment 39-12950.

Applicability

    (c) This AD applies to all Lycoming Engines (Formerly Textron 
Lycoming) AEIO-540, IO-540, LTIO-540, O-540, and TIO-540 series 
reciprocating engines with crankshaft gear retaining bolts, part 
number (P/N) STD-2209 installed, except:
    (1) O-540-F series engines to which AD 99-03-05 applies and on 
which the bolt has not been subsequently replaced, and
    (2) Engines on which the bolt was installed during original 
assembly or was replaced by Lycoming as specified in Service 
Bulletin (SB) 554 after November 10, 1998, and
    (3) Engines with a bolt P/N STD-2209 supplied as part of a bolt 
replacement kit

[[Page 12059]]

05K19987, 05K23325, 05K23326, 05K23327, 05K23335, or 05K23336, and
    (4) Engines with single-drive dual magnetos.
    (5) These engines are installed on, but not limited to the 
following aircraft:

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Aero Commander. (500), (500-B), (500-E), (500-U)
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Aero Mercantil. Gavilan.
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Aerofab. Renegade 250.
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Bellanca Aircraft. Aries T-250
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Britten-Norman. (BN-2).
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Cessna Aircraft. Skylane C-182, Stationair C-206, Turbo Skylane T182T,
 Turbo Stationair T-206
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Christen. Pitts (S-2S), (S-2B).
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Commander Aircraft. 114TC, 114B
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DeHavilland. (DH-114-2X)
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Dornier. (DO-28-B1)
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Evangel-Air.
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Extra-Flugzeugbau. Extra 300.
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Found Bros. (FBA-2C), Centennial (100)
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Gippsland. GA-200.
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Helio. Military (H-250).
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King Engineering. Angel.
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Maule. MT-7-260, M-7-260, MX-7-235, MT-7-235, M7-235, Star
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Rocket (MX-7-235), Super Rocket (M-6-235), Super Std. Rocket (M-7-235).
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Mooney Aircraft. ``TLS'' M20M.
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Moravan. Zlin-50L
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Pilatus Britten-Norman. Islander (BN-2A-26), Islander (BN-2A-27),
 Islander II (BN-2B-26), Islander (BN-2A-21), Trislander (BN-2A-Mark III-
 2), Islander (BN-2B).
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Piper Aircraft. 700P Aerostar, Aerostar 600A, Aerostar 601B, Aerostar
 601P, Apache (PA-23 ``235''), Aztec (PA-23 ``250''), Aztec (PA-23
 ``250''), Comanche (PA-24 ``250''), Comanche (PA-24 ``260''), Aztec F,
 Aztec C (PA-23 ``250'', Cherokee (PA-24 ``250''), Cherokee (PA-28
 ``235''), Cherokee Six (PA-32 ``260'', Cherokee Six (PA-32-300).
 ``LANCE'', Comanche (PA-24 ``150''), Comanche (PA-24 ``250''), Comanche
 (PA-24), Comanche (PA-24 ``260''), Comanche 260, Mirage (PA-46-350P,
 Navajo (PA-31), Navajo (PA-31-300), Navy Aztec (PA-23 ``250''), Pawnee
 (PA-24 ``235''), Pawnee (PA-25 ``260''), Saratoga (PA-32-300), Brave
 300, Sequoia 602P, T-1020, T35, Turbo Aztec (PA-23-250), Turbo Saratoga
 TC (PA-32-301T)
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S.O.C.A.T.A. Rallye 235CA., Rallye 235GT, Rallye 235C, TB-20
------------------------------------------------------------------------

Unsafe Condition

    (d) This AD results from an expanded population of affected 
engines, and approval of five kits for replacing the crankshaft gear 
retaining bolts. We are issuing this AD to prevent the loss of all 
engine power and possible forced 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.

Engines That Have Complied With Emergency AD 2002-20-51 or AD 2002-23-
06

    (f) No further action is required for AEIO-540, LTIO-540, IO-
540, O-540, and TIO-540 series engines that have:
    (1) A bolt, P/N STD-2209 that was included in bolt replacement 
kit: 05K19987, 05K23325, 05K23326, 05K23327, 05K23335, 05K23336; or
    (2) A bolt P/N STD-2209 that was installed by Lycoming as 
specified in SB 554 after November 10, 1998; or
    (3) A bolt with a P/N other than P/N STD-2209.
    (g) For AEIO-540, LTIO-540, IO-540, O-540, and TIO-540 series 
engines that have complied with emergency AD 2002-20-51, replace the 
crankshaft gear retaining bolt with a new bolt that does not have P/
N STD-2209, unless the bolt that was installed was:
    (1) Included in bolt replacement kit: 05K19987, 05K23325, 
05K23326, 05K23327, 05K23335, 05K23336; or
    (2) A bolt installed by Lycoming as specified in SB 554 after 
November 10, 1998; or
    (3) A bolt with a P/N other than STD-2209.
    (4) You can find information on replacing the retaining bolt in 
Lycoming SB No. 554, dated September 30, 2002.

Engines Listed by Serial Number (SN) in Lycoming SB 554, Dated 
September 30, 2002

    (h) No further action is required for AEIO-540, LTIO-540, IO-
540, O-540, and TIO-540 engines with:
    (1) A single-drive dual magneto, and all O-540-F engines to 
which AD 99-03-05 applies and on which the bolt has not been 
subsequently replaced with a bolt other than one included in gear 
bolt replacement kit: 05K19987, 05K23325, 05K23326, 05K23327, 
05K23335, 05K23336; or

[[Page 12060]]

    (2) A bolt replaced by Lycoming as specified in SB 554 after 
November 10, 1998; or
    (3) A bolt, other than P/N STD-2209, including any O-540-F 
engines listed by SN in Table 1 of Lycoming SB No. 554, dated 
September 30, 2002.
    (i) Before further flight, for all other engines that have an 
engine SN listed in Table 1 of Lycoming SB No. 554, dated September 
30, 2002, replace the crankshaft gear retaining bolt with:
    (1) A new bolt included in gear bolt replacement kit: 05K19987, 
05K23325, 05K23326, 05K23327, 05K23335, 05K23336; or
    (2) A bolt with a P/N other than STD-2209.
    (3) You can find information on replacing the retaining bolt in 
Lycoming SB No. 554, dated September 30, 2002.

Bolts That Have Been Replaced During Field Maintenance or Field 
Overhaul

    (j) Before further flight, replace the crankshaft gear retaining 
bolt with a new bolt supplied as part of gear bolt replacement kit: 
05K19987, 05K23325, 05K23326, 05K23327, 05K23335, 05K23336, or a 
bolt with a P/N other than P/N STD-2209, if:
    (1) The bolt on an O-540-F series engine was replaced after 
compliance with AD 99-03-05 with a bolt that was not included in 
bolt replacement kit: 05K19987, 05K23325, 05K23326, 05K23327, 
05K23335, 05K23336; or
    (2) The bolt on an AEIO, LTIO, IO, O, or TIO-540 series engine 
was replaced during field maintenance or field overhaul between 
November 27, 1996, and the effective date of this AD with a bolt 
that was not included in bolt replacement kit: 05K19987, 05K23325, 
05K23326, 05K23327, 05K23335, or 05K23336.
    (3) You can find information on replacing the bolt in Lycoming 
SB No. 554, dated September 30, 2002.

Engines Listed by Serial Number (SN) in Lycoming Mandatory Service 
Bulletin (MSB) 554, Supplement 5, Dated August 15, 2003

    (k) If an engine model and SN is listed in Lycoming MSB 554, 
Supplement 5, dated August 15, 2003, replace the crankshaft gear 
retaining bolt within 10 hours TIS, or 7 days after the effective 
date of this AD, whichever is earlier, with:
    (1) A new bolt included in gear bolt replacement kit: 05K19987, 
05K23325, 05K23326, 05K23327, 05K23335, 05K23336; or
    (2) Bolt STD-2247, or
    (3) A bolt with a P/N other than P/N STD-2209.
    (4) You can find information on replacing the retaining bolt in 
Lycoming SB No. 554, dated September 30, 2002.

Recording Gear Bolt Replacement Kit Number

    (l) After the effective date of this AD, record the part number 
of the gear bolt or the number of the gear bolt replacement kit: 
05K19987, 05K23325, 05K23326, 05K23327, 05K23335, or 05K23336, in 
the engine records when recording compliance with this AD.

Prohibition Against Installing Gear Retaining Bolts P/N STD-2209

    (m) After the effective date of this AD, do not install any 
crankshaft gear retaining bolt, P/N STD-2209, except one that is 
included in a Lycoming gear bolt replacement kit: 05K19987, 
05K23325, 05K23326, 05K23327, 05K23335, or 05K23336, onto any engine 
listed in this AD.

Alternative Methods of Compliance

    (n) 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.

Material Incorporated by Reference

    (o) Engine serial numbers are listed in Lycoming Mandatory 
Service Bulletin No. 554, Supplement 5, dated August 15, 2003; and 
in Table 1 of Lycoming Service Bulletin No. 554, dated September 30, 
2002. The incorporation by reference of Lycoming Service Bulletin 
No. 554, dated September 30, 2002, was previously approved by the 
Director of the Federal Register on November 19, 2002 (67 FR 68932, 
November 14, 2002). The incorporation by reference of Lycoming 
Mandatory Service Bulletin No. 554, Supplement 5, dated August 15, 
2003, was approved by the Director of the Federal Register in 
accordance with 5 U.S.C. 552(a) and 1 CFR part 51. You can get a 
copy from Lycoming, a Textron Company, 652 Oliver Street, 
Williamsport, PA 17701; telephone (570) 323-6181. You can also get 
this information ``www.lycoming.textron.com''. You may review copies 
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.

    Issued in Burlington, Massachusetts, on March 3, 2004.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 04-5262 Filed 3-12-04; 8:45 am]
BILLING CODE 4910-13-P

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