Airworthiness Directives; The Boeing Company Airplanes

[Federal Register Volume 87, Number 172 (Wednesday, September 7, 2022)]
[Rules and Regulations]
[Pages 54609-54613]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2022-19221]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2022-0148; Project Identifier AD-2021-00922-T; 
Amendment 39-22110; AD 2022-14-05]
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) 2015-12-
03, which applied to certain The Boeing Company Model 777-200, -200LR, 
-300, and -300ER series airplanes. AD 2015-12-03 required repetitive 
freeplay inspections and lubrication of the right and left elevators, 
rudder, and rudder tab, and related investigative and corrective 
actions if necessary. This AD was prompted by engineering testing which 
revealed that the force being applied to the elevator to detect 
excessive freeplay was insufficient. This AD continues to require 
certain actions in AD 2015-12-03 for certain airplanes, and requires 
revising the existing maintenance or inspection program, as applicable, 
for certain other airplanes, to incorporate a revised or new elevator 
freeplay maintenance procedure, as applicable. This AD also adds 
airplanes to the applicability. The FAA is issuing this AD to address 
the unsafe condition on these products.

DATES: This AD is effective October 12, 2022.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of October 12, 
2022.
    The Director of the Federal Register approved the incorporation by 
reference of a certain other publication listed in this AD as of July 
21, 2015 (80 FR 34252, June 16, 2015).

ADDRESSES: For service information identified in this final rule, 
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; internet https://www.myboeingfleet.com. You may view this service information 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 
https://www.regulations.gov by searching for and locating Docket No. 
FAA-2022-0148.

Examining the AD Docket

    You may examine the AD docket at https://www.regulations.gov by 
searching for and locating Docket No. FAA-2022-0148; 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.

FOR FURTHER INFORMATION CONTACT: Luis Cortez-Muniz, Aerospace Engineer, 
Airframe Section, FAA, Seattle ACO Branch, 2200 South 216th St., Des 
Moines, WA 98198; phone and fax: (206) 231-3958; email: [email protected].

SUPPLEMENTARY INFORMATION:

Background

    The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 
CFR part 39 to supersede AD 2015-12-03, Amendment 39-18176 (80 FR 
34252, June 16, 2015) (AD 2015-12-03). AD 2015-12-03 applied to certain 
The Boeing Company Model 777-200, -200LR, -300, and -300ER series 
airplanes. The NPRM published in the Federal Register on March 24, 2022 
(87 FR 16654). The NPRM was prompted by the manufacturer's 
determination that the procedure for the rudder freeplay inspection 
available at the time did not properly detect excessive freeplay in the 
rudder control load loop. The NPRM was also prompted by engineering 
testing which revealed that the force being applied to the elevator to 
detect excessive freeplay was insufficient. In the NPRM, the FAA 
proposed to continue to require certain actions in AD 2015-12-03 for 
certain airplanes, and to require revising the existing maintenance or 
inspection program, as applicable, for certain other airplanes, to 
incorporate a revised or new elevator

[[Page 54610]]

freeplay maintenance procedure, as applicable. The NPRM also proposed 
to add airplanes to the applicability. The FAA is issuing this AD to 
address excessive wear in the load loop components of the control 
surfaces, which could lead to excessive freeplay of the control 
surfaces, flutter, and consequent loss of control of the airplane.

Discussion of Final Airworthiness Directive

Comments

    The FAA received comments from The Air Line Pilots Association, 
International (ALPA) and Boeing, who supported the NPRM without change.
    The FAA received additional comments from United Airlines. The 
following presents the comments received on the NPRM and the FAA's 
response.

Request for Exception To Correct Service Information Typographical 
Error

    United Airlines (UAL) asked that the FAA consider including an 
exception in paragraph (i) of the proposed AD due to a typographical 
error in Boeing Special Attention Service Bulletin 777-27-0062, 
Revision 4, dated July 15, 2021. UAL stated that it identified a 
typographical error in Appendix A, paragraph 1.f., ``Freeplay 
Inspection,'' in the CAUTION note just before step (6). UAL added that 
the note shows the conversion of 84 square inches as 5,420 square 
centimeters; however, 84 square inches calculates to 542 square 
centimeters.
    The FAA agrees that Appendix A of the referenced service 
information contains a typographical error, as described by the 
commenter. Therefore, that FAA has added an exception to paragraph 
(i)(5) of this AD which states that where Appendix A, paragraph 1.f., 
``Freeplay Inspection,'' of Boeing Special Attention Service Bulletin 
777-27-0062, Revision 4, dated July 15, 2021, specifies to use a pad 
that distributes the force over an area of 84 square inches (5,420 
square centimeters) or more, this AD requires using a pad that 
distributes the force over an area of 84 square inches (542 square 
centimeters) or more. The FAA also revised the introductory text to 
paragraph (i)(5) to specify that a new exception has been added.

Conclusion

    The FAA reviewed the relevant data, considered any comments 
received, and determined that air safety requires adopting this AD as 
proposed. Except for minor editorial changes, and any other change 
described previously, this AD is adopted as proposed in the NPRM. None 
of the changes will increase the economic burden on any operator.

Related Service Information Under 1 CFR Part 51

    The FAA reviewed Boeing Special Attention Service Bulletin 777-27-
0062, Revision 4, dated July 15, 2021. This service information 
specifies procedures for changing the elevator freeplay instructions by 
adding changes to the input force, elevator freeplay limit, and power 
control unit (PCU) bypass test setup.
    This AD also requires Boeing Special Attention Service Bulletin 
777-27-0062, Revision 2, dated January 27, 2014, which the Director of 
the Federal Register approved for incorporation by reference as of July 
21, 2015 (80 FR 34252, June 16, 2015).
    This service information is reasonably available because the 
interested parties have access to it through their normal course of 
business or by the means identified in ADDRESSES.

Costs of Compliance

    The FAA estimates that this AD affects 281 airplanes of U.S. 
registry. The FAA estimates the following costs to comply with this AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                 Cost on U.S.
         Required actions               Labor cost        Parts cost      Cost per product     operators (218)
----------------------------------------------------------------------------------------------------------------
Measurement (inspection),          4 work-hours x $85               $0  $340 per             $74,120 per
 elevator.                          per hour = $340                      measurement          measurement
                                    per measurement                      (inspection) cycle.  (inspection)
                                    (inspection) cycle.                                       cycle.
Lubrication, elevator............  17 work-hours x $85               0  $1,445 per           $315,010 per
                                    per hour = $1,445                    lubrication cycle.   lubrication cycle.
                                    per lubrication
                                    cycle.
Measurement (inspection), rudder.  4 work-hours x $85                0  $340 per             $74,230 per
                                    per hour = $340                      measurement          measurement
                                    per measurement                      (inspection) cycle.  (inspection)
                                    (inspection) cycle.                                       cycle.
Lubrication, rudder..............  7 work-hours x $85                0  $595 per             $129,710 per
                                    per hour = $595                      lubrication cycle.   lubrication cycle.
                                    per lubrication
                                    cycle.
Measurement (inspection), rudder   3 work-hours x $85                0  $255 per             $55,590 per
 tab.                               per hour = $255                      measurement          measurement
                                    per measurement                      (inspection) cycle.  (inspection)
                                    (inspection) cycle.                                       cycle.
Lubrication, rudder tab..........  5 work-hours x $85                0  $425 per             $92,650 per
                                    per hour = $425                      lubrication cycle.   lubrication cycle
                                    per lubrication
                                    cycle.
----------------------------------------------------------------------------------------------------------------

    The FAA has received no definitive data that would enable the 
agency to provide cost estimates for the on-condition corrective 
actions specified in this AD.
    The FAA has determined that revising the existing maintenance or 
inspection program takes an average of 90 work-hours per operator, 
although the agency recognizes that this number may vary from operator 
to operator. Since operators incorporate maintenance or inspection 
program changes for their affected fleet(s), the FAA has determined 
that a per-operator estimate is more accurate than a per-airplane 
estimate. Therefore, the FAA estimates the average total cost per Model 
777F operator to be $7,650 (90 work-hours x $85 per work-hour).

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

[[Page 54611]]

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) 2015-12-03, Amendment 39-18176 
(80 FR 34252, June 16, 2015); and
0
b. Adding the following new AD:

2022-14-05 The Boeing Company: Amendment 39-22110; Docket No. FAA-
2022-0148; Project Identifier AD-2021-00922-T.

(a) Effective Date

    This airworthiness directive (AD) is effective October 12, 2022.

(b) Affected ADs

    This AD replaces AD 2015-12-03, Amendment 39-18176 (80 FR 34252, 
June 16, 2015) (AD 2015-12-03).

(c) Applicability

    This AD applies to The Boeing Company airplanes, certificated in 
any category, identified in paragraphs (c)(1) and (2) of this AD.
    (1) All Model 777-200, -200LR, -300, and -300ER series 
airplanes.
    (2) Model 777F airplanes with an original airworthiness 
certificate or original export certificate of airworthiness issued 
on or before the effective date of this AD.

(d) Subject

    Air Transport Association (ATA) of America Code 27, Flight 
Controls.

(e) Unsafe Condition

    This AD was prompted by the manufacturer's determination that 
the procedure for the rudder freeplay inspection available at the 
time did not properly detect excessive freeplay in the rudder 
control load loop. This AD was also prompted by engineering testing 
that revealed that the force being applied to the elevator to detect 
excessive freeplay was insufficient. The FAA is issuing this AD to 
address excessive wear in the load loop components of the control 
surfaces, which could lead to excessive freeplay of the control 
surfaces, flutter, and consequent loss of control of the airplane.

(f) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.

(g) Retained Repetitive Inspections of Elevators, Rudder, and Rudder 
Tab, With Revised Service Information

    This paragraph restates the requirements of paragraph (g) of AD 
2015-12-03, with revised service information. For Model 777-200, -
200LR, -300, and -300ER series airplanes: At the applicable times 
specified in tables 1, 2, and 3 of paragraph 1.E., ``Compliance,'' 
of Boeing Special Attention Service Bulletin 777-27-0062, Revision 
2, dated January 27, 2014, or Revision 4, dated July 15, 2021, 
except as provided by paragraph (i)(1) of this AD: Inspect the 
freeplay of the right and left elevators, rudder, and rudder tab by 
accomplishing all of the actions specified in Parts 1, 3, and 5 of 
the Accomplishment Instructions of Boeing Special Attention Service 
Bulletin 777-27-0062, Revision 2, dated January 27, 2014, or 
Revision 4, dated July 15, 2021, except as provided by paragraphs 
(i)(2) through (5) of this AD. Repeat the inspections thereafter at 
the intervals specified in tables 1, 2, and 3 of paragraph 1.E., 
``Compliance,'' of Boeing Special Attention Service Bulletin 777-27-
0062, Revision 2, dated January 27, 2014, or Revision 4, dated July 
15, 2021. If, during any inspection required by this paragraph, the 
freeplay exceeds any applicable measurement specified in Part 1, 3, 
and 5, as applicable, of the Accomplishment Instructions of Boeing 
Special Attention Service Bulletin 777-27-0062, Revision 2, dated 
January 27, 2014, or Revision 4, dated July 15, 2021, before further 
flight, do the applicable corrective actions in accordance with Part 
1, 3, and 5 of the Accomplishment Instructions of Boeing Special 
Attention Service Bulletin 777-27-0062, Revision 2, dated January 
27, 2014, or Revision 4, dated July 15, 2021. After the effective 
date of this AD use only Boeing Special Attention Service Bulletin 
777-27-0062, Revision 4, dated July 15, 2021.

(h) Retained Repetitive Lubrication, With Revised Service Information

    This paragraph restates the requirements of paragraph (h) of AD 
2015-12-03, with revised service information. For Model 777-200, -
200LR, -300, and -300ER series airplanes: At the applicable times 
specified in tables 1, 2, and 3 of paragraph 1.E., ``Compliance,'' 
of Boeing Special Attention Service Bulletin 777-27-0062, Revision 
2, dated January 27, 2014, or Revision 4, dated July 15, 2021, 
except as provided by paragraph (i)(1) of this AD: Lubricate the 
elevator components, rudder components, and rudder tab components, 
by accomplishing all of the actions specified in Parts 2, 4, and 6 
of the Accomplishment Instructions of Boeing Special Attention 
Service Bulletin 777-27-0062, Revision 2, dated January 27, 2014, or 
Revision 4, dated July 15, 2021. Repeat the lubrication thereafter 
at the interval specified in tables 1, 2, and 3 of paragraph 1.E., 
``Compliance,'' of Boeing Special Attention Service Bulletin 777-27-
0062, Revision 2, dated January 27, 2014, or Revision 4, dated July 
15, 2021. After the effective date of this AD use only Boeing 
Special Attention Service Bulletin 777-27-0062, Revision 4, dated 
July 15, 2021.

(i) Exceptions to Service Information Specifications, With Revised 
Service Information and a New Exception

    This paragraph restates the requirements of paragraph (i) of AD 
2015-12-03, with revised service information and a new exception, 
for Model 777-200, -200LR, -300, and -300ER series airplanes.
    (1) Where Boeing Special Attention Service Bulletin 777-27-0062, 
Revision 2, dated January 27, 2014, and Revision 4, dated July 15, 
2021, specify a compliance time ``after the original issue date on 
this service bulletin,'' this AD requires compliance within the 
specified compliance time after July 25, 2007 (the effective date of 
AD 2007-13-05, Amendment 39-15109 (72 FR 33856, June 20, 2007)). 
After the effective date of this AD, only Boeing Special Attention 
Service Bulletin 777-27-0062, Revision 4, dated July 15, 2021, may 
be used.
    (2) Where Appendix B, paragraph 1.f., ``Freeplay Inspection,'' 
step (8), of Boeing Special Attention Service Bulletin 777-27-0062, 
Revision 2, dated January 27, 2014, specifies that the center of the 
pad must be within 1.0 inch (13 millimeters) of the center line of 
the rib rivets in the rudder tab, this AD requires that the center 
of the tab must be within 1.0 inch (25 millimeters) of the center 
line of the rib rivets in the rudder tab.
    (3) Where Appendix C, paragraph 1.e., ``Rudder Tab Surface 
Freeplay--Inspection,''

[[Page 54612]]

step (2) and step (6), of Boeing Special Attention Service Bulletin 
777-27-0062, Revision 2, dated January 27, 2014, specify that the 
placement of the force gage and pad should be within one inch of the 
centerline line of the middle rudder power control unit (PCU) rib 
and at 12 +/- 1 inch (305 +/- 72 millimeters) forward of the rudder 
tab trailing edge, this AD requires placement of the force gage and 
pad within one inch of the centerline line of the middle rudder PCU 
rib and at 12 +/- 1 inch (305 +/- 25 millimeters) forward of the 
rudder tab trailing edge.
    (4) Where Appendix C, paragraph 1.e., ``Rudder Tab Surface 
Freeplay--Inspection,'' step (3), of Boeing Special Attention 
Service Bulletin 777-27-0062, Revision 2, dated January 27, 2014, 
specifies to apply a 30 +/- pound (133 +/- 14 newton) force, this AD 
requires applying a 30 +/- 3 pound force (133 +/- 14 newton) force.
    (5) Where the CAUTION note just before step (6) of Appendix A, 
paragraph 1.f., ``Freeplay Inspection,'' of Boeing Special Attention 
Service Bulletin 777-27-0062, Revision 4, dated July 15, 2021, 
specifies using a pad that distributes the force over an area of 84 
square inches (5,420 square centimeters) or more, this AD requires 
using a pad that distributes the force over an area of 84 square 
inches (542 square centimeters) or more.

(j) New Maintenance or Inspection Program Revision

    For Model 777F airplanes: Within 30 days after the effective 
date of this AD, revise the 777F elevator freeplay maintenance 
procedure in the existing maintenance or inspection program, as 
applicable, by doing the actions specified in paragraphs (j)(1) 
through (3) of this AD.
    (1) Remove the existing hydraulic depressurization PCU test 
setup procedure step and replace it by incorporating the information 
specified in figure 1 to paragraph (j) of this AD.
    (2) Revise the jack test force used to push the elevator up to 
225 +/- 10 lb (102.1 +/- 4.5 kg).
    (3) Revise the elevator freeplay dial indicator limit to 0.34 
in. (152 mm) or less.
[GRAPHIC] [TIFF OMITTED] TR07SE22.017

    Note 1 to paragraph (j): Refer to AMM task 27-31-09-200-801, 
dated September 5, 2021, for additional guidance.

(k) No Alternative Actions or Intervals

    After the existing maintenance or inspection program has been 
revised as required by paragraph (j) of this AD, no alternative 
actions (e.g., inspections) or intervals may be used unless the 
actions or intervals are approved as an alternative method of 
compliance (AMOC) in accordance with the procedures specified in 
paragraph (m) of this AD.

(l) Credit for Previous Actions

    This paragraph provides credit for the actions specified in 
paragraphs (g) and (h) of this AD, if those actions were performed 
before the effective date of this AD using Boeing Special Attention 
Service Bulletin 777-27-0062, Revision 3, dated October 9, 2015.

(m) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Seattle ACO 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

[[Page 54613]]

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 (n)(1) of this AD. Information 
may be emailed to: [email protected].
    (2) Before using any approved AMOC, notify your appropriate 
principal inspector, or lacking a principal inspector, the manager 
of the responsible Flight Standards Office.
    (3) 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, Seattle 
ACO 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.
    (4) AMOCs approved previously for the freeplay measurements of 
the right and left rudder tab required by AD 2015-12-03, are 
approved as AMOCs for the corresponding provisions of this AD.
    (5) AMOCs approved previously for the freeplay measurements of 
the rudder required by AD 2015-12-03, are approved as AMOCs for the 
corresponding provisions of this AD.
    (6) AMOCs approved previously for the repetitive lubrications 
required by AD 2015-12-03, are approved as AMOCs for the 
corresponding provisions of this AD.

(n) Related Information

    (1) For more information about this AD, contact Luis Cortez-
Muniz, Aerospace Engineer, Airframe Section, FAA, Seattle ACO 
Branch, 2200 South 216th St., Des Moines, WA 98198; phone and fax: 
(206) 231-3958; email: [email protected].
    (2) Service information identified in this AD that is not 
incorporated by reference is available at the addresses specified in 
paragraphs (o)(5) and (6) of this AD.

(o) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference (IBR) of the service information listed 
in this paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this service information as applicable to do 
the actions required by this AD, unless this AD specifies otherwise.
    (3) The following service information was approved for IBR on 
October 12, 2022.
    (i) Boeing Special Attention Service Bulletin 777-27-0062, 
Revision 4, dated July 15, 2021.
    (ii) [Reserved]
    (4) The following service information was approved for IBR on 
July 21, 2015 (80 FR 34252, June 16, 2015).
    (i) Boeing Special Attention Service Bulletin 777-27-0062, 
Revision 2, dated January 27, 2014.
    (ii) [Reserved]
    (5) For service information 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; internet https://www.myboeingfleet.com.
    (6) You may view this service information 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 service information that is incorporated 
by reference at the National Archives and Records Administration 
(NARA). For information on the availability of this material at 
NARA, email [email protected], or go to: https://www.archives.gov/federal-register/cfr/ibr-locations.html.

    Issued on June 27, 2022.
Christina Underwood,
Acting Director, Compliance & Airworthiness Division, Aircraft 
Certification Service.
[FR Doc. 2022-19221 Filed 9-6-22; 8:45 am]
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