Airworthiness Directives; Lycoming Engines (Formerly Textron Lycoming) AEIO-360, IO-360, O-360, LIO-360, LO-360, AEIO-540, IO-540, O-540, and TIO-540 Series Reciprocating Engines

[Federal Register Volume 70, Number 179 (Friday, September 16, 2005)]
[Rules and Regulations]
[Pages 54618-54622]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-18323]


-----------------------------------------------------------------------

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-21864; Directorate Identifier 2005-NE-29-AD; 
Amendment 39-14276; AD 2005-19-11]
RIN 2120-AA64


Airworthiness Directives; Lycoming Engines (Formerly Textron 
Lycoming) AEIO-360, IO-360, O-360, LIO-360, LO-360, AEIO-540, IO-540, 
O-540, and TIO-540 Series Reciprocating Engines

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Final rule.

-----------------------------------------------------------------------

SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
certain Lycoming Engines (formerly Textron Lycoming) AEIO-360, IO-360, 
O-360, LIO-360, LO-360, AEIO-540, IO-540, O-540, and TIO-540 series 
reciprocating engines rated at 300 horsepower (HP) or lower. This AD 
requires replacing certain crankshafts. This AD results from reports of 
12 crankshaft failures in Lycoming 360 and 540 series engines rated at 
300 HP or lower. We are issuing this AD to prevent failure of the 
crankshaft, which could result in total engine power loss, in-flight 
engine failure, and possible loss of the aircraft.

DATES: This AD becomes effective October 21, 2005. The Director of the 
Federal Register approved the incorporation by reference of certain

[[Page 54619]]

publications listed in the regulations as of October 21, 2005.

ADDRESSES: You can get the service information identified in this 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 AD docket on the Internet at http://dms.dot.gov 
or in Room PL-401 on the plaza level of the Nassif Building, 400 
Seventh Street, SW., Washington, DC.

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: The FAA proposed to amend 14 CFR part 39 
with a proposed airworthiness directive (AD). The proposed AD applies 
to Lycoming Engines (formerly Textron Lycoming) AEIO-360, IO-360, O-
360, LIO-360, LO-360, AEIO-540, IO-540, O-540, and TIO-540 series 
reciprocating engines rated at 300 horsepower (HP) or lower. We 
published the proposed AD in the Federal Register on July 22, 2005 (70 
FR 42282). That action proposed to require replacing certain 
crankshafts within 50 hours time-in-service or 6 months after the 
effective date of the proposed AD, whichever is earlier.

Examining the AD Docket

    You may examine the docket that contains the AD, any comments 
received, and any final disposition in person at the Docket Management 
Facility Docket Offices 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 Building at the street address stated in 
ADDRESSES. Comments will be available in the AD docket shortly after 
the DMS receives them.

Comments

    We provided the public the opportunity to participate in the 
development of this AD. We have considered the comments received.

Will Additional Engines and Crankshafts Be Affected in the Future

    One commenter asks if additional serial numbered engines and 
crankshafts will be affected in the future.
    At this time we do not anticipate that the affected population will 
increase, but Lycoming and the FAA are monitoring crankshaft 
performance.

Affected Engines and Crankshafts

    The same commenter asks why these engines and crankshafts are the 
only ones affected by the SB and AD.
    Both the previous AD (2002-19-03) and this AD advise that the 
affected population of engines and crankshafts were manufactured in a 
specific time period. We are addressing that time period.

Suspect Crankshafts Should Be Either Tested or Replaced

    One commenter states that suspect crankshafts should be either 
tested or replaced before further flight, because the problem with 
these crankshafts is similar to the problem that caused the crankshaft 
failures on the 540 engines.
    We disagree. The compliance interval in this AD is based on an 
assessment of operating stresses, service experience, and duty cycle of 
the affected engine population. The compliance interval differs from 
that imposed in AD 2002-19-03 due to differences in these parameters.

Request To Include Lycoming TIO-540-AE2A and Other Unspecified Engine 
Models

    One commenter requests that we include the Lycoming TIO-540-AE2A 
and other unspecified engine models in this AD. The commenter states 
that many of the TIO-540-AE2A engines have never been recalled or 
replaced yet should be, because recent litigation has shown that 
Lycoming's crankshaft end core sample test is insufficient.
    We disagree. We have seen no evidence that refutes the validity of 
the test. Further, AD 2002-19-03 (the previous AD) effective on 
September 20, 2002, described two groups of crankshafts. We required 
one crankshaft group to be removed before further flight, and we 
required the other crankshaft group to have a sample of the crankshaft 
material tested. The crankshafts in each group were selected based on 
our evaluation of the risk both groups presented. Crankshafts from 
either group may be installed in the TIO-540-AE2A engine model. No 
failures of crankshafts listed in either group have occurred since.

Conclusion

    We have carefully reviewed the available data, including the 
comments received, and determined that air safety and the public 
interest require adopting the AD as proposed.

Costs of Compliance

    We estimate that this AD will affect 1,128 engines installed on 
aircraft of U.S. registry. We estimate that it will take the following 
work hours to perform the inspection:

------------------------------------------------------------------------
                                                              Number of
             Type of  application               Work-hours     engines
                                                per engine     affected
------------------------------------------------------------------------
Helicopter...................................          12            200
Constant-Speed Propeller.....................           3            557
Fixed-Pitch Propeller........................           1.5          371
------------------------------------------------------------------------

    We also estimate that it will take about 33 work hours to replace 
the crankshaft. We estimate the average labor rate is $65 per work hour 
and that required parts for each engine will cost about $16,218. Based 
on these figures, we estimate the total cost of the AD to U.S. 
operators to be $18,594,724. Lycoming Engines informed us that they 
intend to supply the new parts at no charge, which may substantially 
reduce the estimated cost of 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.
    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 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;

[[Page 54620]]

    (2) Is not a ``significant rule'' under 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 at the 
address listed under ADDRESSES.

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 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 adding the following new airworthiness 
directive:

2005-19-11 Lycoming Engines: Amendment 39-14276. Docket No. FAA-
2005-21864; Directorate Identifier 2005-NE-29-AD.

Effective Date

    (a) This airworthiness directive (AD) becomes effective October 
21, 2005.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Lycoming Engines (Formerly Textron 
Lycoming) AEIO-360, IO-360, O-360, LIO-360, LO-360, AEIO-540, IO-
540, O-540, and TIO-540 series reciprocating engines, rated at 300 
horsepower (HP) or lower, manufactured new, rebuilt, overhauled 
after March 1, 1999, or that had a crankshaft installed after March 
1, 1999. These engines are installed on, but not limited to, the 
following aircraft:

------------------------------------------------------------------------
          Engine model               Manufacturer       Aircraft model
------------------------------------------------------------------------
IO-540-V4A5.....................  A.M.F.............  17-D Mushshak
                                  Aero Commander....  500 B, S, U/Merlyn
                                                       Products Conv.
IO-540-E1A5.....................  Aero Commander....  500-E
                                  Aerofab...........  LA 250 Renegade
                                  Aeronautica.......  Agricola Mexicana
                                                       Quail
IO-540-K1F5.....................  Aerostar..........  600
                                  Aircraft            Mushshak
                                   Manufacturing
                                   Factory.
O-540-E4A5......................  Aviamilano........  F-250 Flamingo
IO-540-C4B5.....................  Avions............  Pierre Robin HR-
                                                       100/250
LO-360-A1G6D....................  Beech.............  76 Duchess
O-360-A1G6D.....................  ..................  76 Duchess
                                                      C-24R Sierra or
                                                       200 Sierra
                                  Bellanca..........  Aircraft Aries T-
                                                       250
O-540-E4B5......................  Britten Norman....  BN-2 Islander
O-540-E4C5......................  ..................  BN-2A & BN-2B
                                                       Islander
IO-540-K1B5.....................  ..................  BN-2A Islander
                                  Celair............  Eagle
O-360-A1F6......................  Cessna............  177 Cardinal
O-360-A1F6D.....................  ..................  177 Cardinal
O-540-J3C5D.....................  ..................  182-RG Skylane
IO-540-AB1A5....................  ..................  182-S
O-360-F1A6......................  ..................  C-172RG Cutlass RG
IO-540-AC1A5....................  ..................  C-206 Stationair
                                                      R-G Cardinal
IO-360-A1B6D....................  ..................  R-G Cardinal
TIO-540-AK1A....................  ..................  T182T Skylane
O-540-L3C5D.....................  ..................  TR-182 Turbo
                                                       Skylane
AEIO-540-D4A5...................  Christen Pitts....  S-2S, S-2B
IO-540-T4B5D....................  Commander.........  114
IO-540-T4B5.....................  ..................  114B
TIO-540-AG1A....................  ..................  114TC
                                  Dornier...........  DO-28
IO-540-K1J5D....................  Embraer...........  EMB-201 Ipanema
O-540-B4B5......................  ..................  EMB-710 Corioca
                                                      EMB-720 Minuano
                                                      EMB-720 Minuano &
                                                       EMB-721 Sertanejo
                                                      EMB-721 Sertanejo
AEIO-540-L1B5...................  Extra-Flugzeugbau.  Extra 300
                                  F.F.A.............  FFA-2000
                                                       Eurotrainer
                                  H.A.L.............  HPT-32
O-540-A1A5......................  Helio Military....  H-250
AEIO-360-A1E6...................  Integrated Systems  Omega
IO-540-M1C5.....................  King Engineering..  Angel
                                  Korean Air........  Chang Gong-91
                                  Lake..............  LA-4-200 Buccaneer
O-540-J3A5......................  Maule.............
                                                      MT-7-260 & M-7-260
                                                      MX-7-235 Star
                                                       Rocket
IO-540-W1A5.....................  ..................  MX-7-235, MT-7-235
                                                       & M7-235
                                  Mod Works.........  Trophy 212
                                                       Conversion
IO-360-A3B6.....................  Mooney............  201
                                                      M-201

[[Page 54621]]

 
IO-360-A1B6.....................  ..................  M-20-J
IO-360-A3B6D....................  ..................  M20J-201
TIO-540-AF1B....................  ..................  M20M TLS Bravo
                                  Moravan...........  Z143L Zlin
                                                      Z242L Zlin
                                  Partenavia........  P-68 Series
                                                       Observer
IO-540-K1J5.....................  Piper.............  600-A Aerostar
IO-540-S1A5.....................  ..................  601-A, 601B & 601P
                                                       Aerostar
IO-540-AA1A5....................  ..................  602P Sequoia
O-540-A1B5......................  ..................  PA-23-235 Aztec &
                                                       PA-24-250
                                                       Comanche
                                                      PA-23-250 Aztec
IO-540-J4A5.....................  ..................  PA-23-250 Aztec
IO-540-C1B5.....................  ..................  PA-23-250 Aztec &
                                                       PA-24-250
                                                       Comanche
TIO-540-C1A.....................  ..................  PA-23-250T Turbo
                                                       Aztec
                                                      PA-24-150 Comanche
O-540-A1C5......................  ..................  PA-24-250 Comanche
O-540-A1D5......................  ..................  PA-24-250 Comanche
IO-540-D4A5.....................  ..................  PA-24-260 Comanche
                                                      PA-24-260 Comanche
O-540-B2C5......................  ..................  PA-25-235 Pawnee
O-540-B2B5......................  ..................  PA-28-235 Cherokee
                                                      PA-28-235 Cherokee
IO-360-C1C6.....................  ..................  PA-28R-201 Arrow
IO-540-M1A5.....................  ..................  PA-31-300 Navajo
                                                      PA-32-260 Cherokee
                                                       6
IO-540-K1G5.....................  ..................  PA-32-300 & PA-32-
                                                       301 Saratoga
IO-540-K1A5.....................  ..................  PA-32-300 Cherokee
                                                       6
IO-540-K1A5D....................  ..................  PA-32-300 Cherokee
                                                       6
IO-540-K1G5D....................  ..................  PA-32-300R Lance
                                                      PA-32-301R
                                                       Saratoga
IO-360-C1E6.....................  ..................  PA-34-200 Seneca I
IO-540-K1G5.....................  ..................  PA-36-300 Brave
O-360-A1H6......................  ..................  PA-44-180
LO-360-A1H6.....................  ..................  PA-44-180 Seminole
IO-540-K1K5.....................  ..................  T-35 Pillan
                                  Robin.............  R-3000/235
O-540-F1B5......................  Robinson..........  R-44
                                  Rockwell..........  114
                                  Ruschmeyer........  MF-85
                                  Saab..............  MFI-15 Safari or
                                                       MFI-17 Supporter
                                  Scottish Avia.....  Bulldog
                                  Siai Marchetti....  S-205
                                  Siai Marchetti....  S-208 & SF-260
                                  Siai Marchetti....  SF-260
                                  Siai Marchetti....  SF-260
                                  Slingsby..........  Firefly T3A
                                  Socata............  R-235 Rallye
                                                       Cuerrier
                                                      Rallye 235CA
IO-540-C4D5D....................  ..................  TB-20 Trinidad
                                                      TB-200
TIO-540-AB1AD...................  ..................  TB-21 & TB-21-TC
                                                       Trinidad TC
IO-540-AB1A5....................  Stoddard Hamilton.  Glasair
IO-540-K1H5.....................  Stoddard Hamilton.  Glasair III
IO-540-L1C5.....................  Swearingen          SX-300
                                   Aircraft.
                                  Transava..........  T-300 Skyfarmer
AEIO-360-A1B6...................  Valmet............  L-70 Vinka
                                  Wassmer...........  WA4-21
                                  Yoeman............  Aviation YA-1
------------------------------------------------------------------------

Unsafe Condition

    (d) This AD results from 12 crankshaft failures in Lycoming 
model 360 and 540 series engines rated at 300 HP or lower. We are 
issuing this AD to prevent failure of the crankshaft, which could 
result in total engine power loss, in-flight engine failure, and 
possible loss of the airplane.

Compliance

    (e) You are responsible for having the actions required by this 
AD performed within 50 hours time-in-service or 6 months after the 
effective date of this AD, whichever is earlier, unless the actions 
have already been done.

Engines Manufactured Before March 1, 1999

    (f) If Lycoming Engines manufactured new, rebuilt, or overhauled 
your engine before March 1, 1999, and you haven't had the crankshaft 
replaced, no further action is required.

AEIO-540, IO-540, O-540, and TIO-540 Series Engines Manufactured New or 
Rebuilt, Overhauled, or That Had a Crankshaft Installed After March 1, 
1999

    (g) For AEIO-540, IO-540, O-540, and TIO-540 series engines 
manufactured new or rebuilt, overhauled, or that had a crankshaft 
installed after March 1, 1999, do the following:
    (1) If Table 1 or Table 2 of Lycoming Mandatory Service Bulletin 
(MSB) No. 566, dated July 11, 2005, lists your engine serial

[[Page 54622]]

number (SN), use Table 4 to verify the crankshaft SN.
    (2) If Table 4 of Lycoming MSB No. 566, dated July 11, 2005, 
lists your crankshaft SN, replace the crankshaft with a crankshaft 
that is not listed in Table 4 of Lycoming MSB No. 566, dated July 
11, 2005.

AEIO-360, IO-360, O-360, LIO-360, and LO-360 Series Engines 
Manufactured New or Rebuilt, Overhauled, or That Had a Crankshaft 
Installed After March 1, 1999

    (h) For AEIO-360, IO-360, O-360, LIO-360, and LO-360 series 
engines manufactured new or rebuilt, overhauled, or that had a 
crankshaft installed after March 1, 1999, do the following:
    (1) If Table 3 of Lycoming MSB No. 566, dated July 11, 2005, 
lists your engine SN, use Table 4 to verify the crankshaft SN.
    (2) If Table 4 of Lycoming MSB No. 566, dated July 11, 2005, 
lists your crankshaft SN, replace the crankshaft with a crankshaft 
that is not listed in Table 4 of Lycoming MSB No. 566, dated July 
11, 2005.

Prohibition Against Installing Certain Crankshafts

    (i) After the effective date of this AD, do not install any 
crankshaft that has a SN listed in Table 4 of Lycoming MSB No. 566, 
dated July 11, 2005, into any engine.

Alternative Methods of Compliance (AMOCs)

    (j) The Manager, New York Aircraft Certification Office, has the 
authority to approve AMOCs for this AD if requested using the 
procedures found in 14 CFR 39.19.

Related Information

    (k) None.

Material Incorporated by Reference

    (l) You must use Lycoming Mandatory Service Bulletin No. 566, 
dated July 11, 2005, to perform the actions required by this AD. The 
Director of the Federal Register approved the incorporation by 
reference of this service bulletin in accordance with 5 U.S.C. 
552(a) and 1 CFR part 51. Contact 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 for a 
copy of this service information. You may review copies at the 
Docket Management Facility; U.S. Department of Transportation, 400 
Seventh Street, SW., Nassif Building, Room PL-401, Washington, DC 
20590-0001, on the Internet at http://dms.dot.gov, or at the 
National Archives and Records Administration (NARA). For information 
on the availability of this material at NARA, call 202-741-6030, or 
go to: http://www.archives.gov/federal-register/cfr/ibr-locations.html.

    Issued in Burlington, Massachusetts, on September 9, 2005.
Jay J. Pardee,
Manager, Engine and Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 05-18323 Filed 9-15-05; 8:45 am]
BILLING CODE 4910-13-P

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