Airworthiness Directives; CFM International, S.A. Engines

[Federal Register Volume 90, Number 117 (Friday, June 20, 2025)]
[Rules and Regulations]
[Pages 26195-26198]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2025-11340]


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

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2024-2668; Project Identifier AD-2024-00561-E; 
Amendment 39-23061; AD 2025-12-03]
RIN 2120-AA64


Airworthiness Directives; CFM International, S.A. Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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

SUMMARY: The FAA is superseding Airworthiness Directive (AD) 2023-09-
06, which applied to all CFM International, S.A. Model (CFM) LEAP-1A23, 
LEAP-1A24, LEAP-1A24E1, LEAP-1A26, LEAP-1A26CJ, LEAP-1A26E1, LEAP-1A29, 
LEAP-1A29CJ, LEAP-1A30, LEAP-1A32, LEAP-1A33, LEAP-1A33B2, and LEAP-
1A35A (LEAP-1A) engines. AD 2023-09-06 required replacement of certain 
high-pressure turbine (HPT) rotor stage 1 disks (HPT stage 1 disks), 
forward outer seals, and compressor rotor stages 6-10 spools. AD 2023-
09-06 also prohibited installation of an HPT stage 1 disk, forward 
outer seal, or compressor rotor stages 6-10 spool that has a part 
number and serial number identified in the service information onto any 
engine. Since the FAA issued AD 2023-09-06, the manufacturer identified 
additional affected parts that were manufactured from material 
suspected to have reduced material properties due to iron inclusion, 
which prompted this AD. This AD retains the requirements to replace 
certain HPT stage 1 disks, forward outer seals, and compressor rotor 
stages 6-10 spools and expands the applicability to include additional 
affected parts manufactured from the same material suspected to have 
reduced material properties due to iron inclusion. The FAA is issuing 
this AD to address the unsafe condition on these products.

DATES: This AD is effective July 25, 2025.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of July 25, 
2025.
    The Director of the Federal Register approved the incorporation by 
reference of certain other publications listed in this AD as of June 
23, 2023 (88 FR 32092, May 19, 2023).

ADDRESSES: 
    AD Docket: You may examine the AD docket at regulations.gov under 
Docket

[[Page 26196]]

No. FAA-2024-2668; 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.
    Material Incorporated by Reference:
    <bullet> For CFM material identified in AD, contact CFM, GE 
Aviation Fleet Support, 1 Neumann Way, M/D Room 285, Cincinnati, OH 
45215; phone: (877) 432-3272; email: [email protected].
    <bullet> You may view this material at the FAA, Airworthiness 
Products Section, Operational Safety Branch, 1200 District Avenue, 
Burlington, MA 01803. For information on the availability of this 
material at the FAA, call (817) 222-5110. It is also available at 
regulations.gov under Docket No. FAA-2024-2668.

FOR FURTHER INFORMATION CONTACT: Mehdi Lamnyi, Aviation Safety 
Engineer, FAA, 2200 South 216th Street, Des Moines, WA 98198; phone: 
(781) 238-7743; email: [email protected].

SUPPLEMENTARY INFORMATION: 

Background

    The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 
CFR part 39 to supersede AD 2023-09-06, Amendment 39-22429 (88 FR 
32092, May 19, 2023), (AD 2023-09-06). AD 2023-09-06 applied to all CFM 
Model LEAP-1A engines. The NPRM was published in the Federal Register 
on December 23, 2024 (89 FR 104462). The NPRM was prompted by further 
analysis by the manufacturer which identified additional affected parts 
that were manufactured from material suspected to have reduced material 
properties due to iron inclusion. In the NPRM, the FAA proposed to 
require replacement of certain HPT stage 1 disks, forward outer seals, 
and compressor rotor stages 6-10 spools. In the NPRM, the FAA also 
proposed to prohibit installation of an HPT stage 1 disk, forward outer 
seal, or compressor rotor stages 6-10 spool that has a part number and 
serial number identified in the material incorporated by reference onto 
any engine. The FAA is issuing this AD to address the unsafe condition 
on these products.

Discussion of Final Airworthiness Directive

Comments

    The FAA received comments from three commenters. Commenters 
included the Air Line Pilots Association, International (ALPA), CFM 
international, and StandardAero. ALPA supported the NPRM without 
change. The following presents the comments received on the NPRM and 
the FAA's response to each comment.

Request To Update Service Material to Latest Revision

    CFM requested that the FAA update the proposed AD to refer to the 
latest revision of CFM Service Bulletin (SB) LEAP-1A-72-00-0507-01A-
930A-D. CFM noted that CFM SB LEAP-1A-72-00-0507-01A-930A-D, Issue 001, 
dated January 24, 2024 (CFM SB LEAP-1A-72-00-0507-01A-930A-D, Issue 
001) is being updated to include additional affected HPT stage 1 disk 
serial numbers in Tables 1 through 2.
    The FAA agrees and has updated paragraph (g)(4) of this AD to 
reference CFM SB LEAP-1A-72-00-0507-01A-930A-D, Issue 002, dated April 
24, 2025 (CFM SB LEAP-1A-72-00-0507-01A-930A-D, Issue 002). The FAA has 
also updated the language in paragraph (g)(4) of this AD to refer to 
``Tables 1 through 3'' of CFM SB LEAP-1A-72-00-0507-01A-930A-D, Issue 
002 because Issue 002 includes an additional table with affected parts. 
The FAA also added a Credit for Previous Actions paragraph to this AD, 
allowing operators to take credit for required actions if accomplished 
prior to the effective date of this AD using CFM SB LEAP-1A-72-00-0507-
01A-930A-D, Issue 001. None of the HPT stage 1 disk serial numbers 
referenced in CFM SB LEAP-1A-72-00-0507-01A-930A-D, Issue 002 are 
included in any engine installed on airplanes of U.S. Registry. 
Therefore, this change imposes no additional burden on operators who 
are required to comply with this AD.

Request To Include Thrust Ratings

    StandardAero requested that the FAA revise the proposed AD to 
include XLR thrust ratings and reference CFM SB LEAP-1A-72-00-0529-01A-
930A-D. StandardAero noted that CFM recently released CFM SB LEAP-1A-
72-00-0529-01A-930A-D, which prohibits the installation of affected 
parts into any XLR rated LEAP-1A engine. StandardAero also mentioned 
that it may be beneficial to expand the scope of the NPRM to ensure 
affected parts are not installed into these engines at future shop 
visits.
    The FAA disagrees with the request because the airworthiness 
limitations section of the engine shop manual does not allow for any of 
the affected part serial numbers listed in CFM SB LEAP-1A-72-00-0529-
01A-93 0A-D to be installed onto an XLR engine. The FAA did not change 
this AD as a result of this comment.

Conclusion

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

Material Incorporated by Reference Under 1 CFR Part 51

    The FAA reviewed CFM SB LEAP-1A-72-00-0507-01A-930A-D, Issue 002, 
dated April 24, 2025, which identifies the part numbers and serial 
numbers of HPT stage 1 disks, forward outer seals, and compressor rotor 
stages 6-10 spools with potentially reduced material properties and 
specifies procedures for replacement of these parts.
    This AD also requires the following material, which the Director of 
the Federal Register approved for incorporation by reference as of June 
23, 2023 (88 FR 32092, May 19, 2023):
    <bullet> CFM Service Bulletin LEAP-1A-72-00-0470-01A-930A-D, Issue 
003, dated March 3, 2023.
    <bullet> CFM Service Bulletin LEAP-1A-72-00-0493-01A-930A-D, Issue 
002, dated November 17, 2022.
    <bullet> CFM Service Bulletin LEAP-1A-72-00-0496-01A-930A-D, Issue 
001, dated March 7, 2023.
    This material is reasonably available because the interested 
parties have access to it through their normal course of business or by 
the means identified in the ADDRESSES section.

Costs of Compliance

    The FAA estimates that this AD affects 42 engines installed on 
airplanes of U.S. registry.
    The FAA estimates the following costs to comply with this AD:

[[Page 26197]]



                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                          Cost per  Cost on U.S.
             Action                   Labor cost                  Parts cost              product     operators
----------------------------------------------------------------------------------------------------------------
Replace HPT stage 1 disk (42      8 work-hours x $85  $215,635 (pro-rated).............   $216,315    $9,085,230
 affected parts).                  per hour = $680.
Replace forward outer seal (24    8 work-hours x $85  $47,500 (pro-rated)..............     48,180     1,156,320
 affected parts).                  per hour = $680.
Replace compressor rotor stages   8 work-hours x $85  $37,660 (pro-rated)..............     38,340       575,100
 6-10 spool (15 affected parts).   per hour = $680.
----------------------------------------------------------------------------------------------------------------

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 
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 2023-09-06, Amendment 39-22429 
(88 FR 32092, May 19, 2023); and
0
b. Adding the following new airworthiness directive:

2025-12-03 CFM International, S.A.: Amendment 39-23061; Docket No. 
FAA-2024-2668; Project Identifier AD-2024-00561-E.

(a) Effective Date

    This airworthiness directive (AD) is effective July 25, 2025.

(b) Affected ADs

    This AD replaces AD 2023-09-06, Amendment 39-22429 (88 FR 32092, 
May 19, 2023) (AD 2023-09-06).

(c) Applicability

    This AD applies to CFM International, S.A. Model (CFM) LEAP-
1A23, LEAP-1A24, LEAP-1A24E1, LEAP-1A26, LEAP-1A26CJ, LEAP-1A26E1, 
LEAP-1A29, LEAP-1A29CJ, LEAP-1A30, LEAP-1A32, LEAP-1A33, LEAP-
1A33B2, and LEAP-1A35A engines.

(d) Subject

    Joint Aircraft System Component (JASC) Code 7230, Turbine Engine 
Compressor Section; 7250, Turbine Section.

(e) Unsafe Condition

    This AD was prompted by a manufacturer investigation that 
revealed that certain high-pressure turbine (HPT) rotor stage 1 
disks (HPT stage 1 disks), forward outer seals, and compressor rotor 
stages 6-10 spools were manufactured from material suspected to have 
reduced material properties due to iron inclusion. The FAA is 
issuing this AD to prevent fracture and consequent uncontained 
failure of certain HPT stage 1 disks, forward outer seals, and 
compressor rotor stages 6-10 spools. The unsafe condition, if not 
addressed, could result in uncontained debris release, damage to the 
engine, and damage to the airplane.

(f) Compliance

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

(g) Required Actions

    (1) For engines with an installed HPT stage 1 disk, forward 
outer seal, or compressor rotor stages 6-10 spool having a part 
number (P/N) and serial number (S/N) identified in Compliance, 
paragraph 3.E., Tables 1 through 9, of CFM Service Bulletin (SB) 
LEAP-1A-72-00-0496-01A-930A-D, Issue 001, dated March 7, 2023 (CFM 
SB LEAP-1A-72-00-0496-01A-930A-D, Issue 001): At the next piece-part 
exposure of the HPT stage 1 disk, forward outer seal, or compressor 
rotor stages 6-10 spool, as applicable, or before exceeding the 
applicable cycles since new (CSN) threshold identified in 
Compliance, paragraph 3.E., Tables 1 through 9, of CFM SB LEAP-1A-
72-00-0496-01A-930A-D, Issue 1, whichever occurs first after June 
23, 2023 (the effective date of AD 2023-09-06); or if the applicable 
CSN threshold has been exceeded as of June 23, 2023 (the effective 
date of AD 2023-09-06), within 50 flight cycles (FCs) from June 23, 
2023 (the effective date of AD 2023-09-06); remove the HPT stage 1 
disk, forward outer seal, or compressor rotor stages 6-10 spool, as 
applicable, from service and replace with a part eligible for 
installation.
    (2) For engines with an installed forward outer seal having a P/
N and S/N identified in Compliance, paragraph 3.E., Tables 1 through 
2, of CFM SB LEAP-1A-72-00-0470-01A-930A-D, Issue 003, dated March 
3, 2023 (CFM SB LEAP-1A-72-00-0470-01A-930A-D, Issue 003): At the 
next piece-part exposure of the forward outer seal, or before 
exceeding the applicable CSN threshold identified in Compliance, 
paragraph 3.E., Tables 1 through 2, of CFM SB LEAP-1A-72-00-0470-
01A-930A-D, Issue 003, whichever occurs first after June 23, 2023 
(the effective date of AD 2023-09-06); or if the applicable CSN 
threshold has been exceeded as of June 23, 2023 (the effective date 
of AD 2023-09-06), within 50 FCs from June 23, 2023 (the effective 
date of AD 2023-09-06); remove the forward outer seal from service 
and replace with a part eligible for installation.
    (3) For engines with an installed HPT stage 1 disk having a P/N 
and S/N identified in Compliance, paragraph 3.E., Tables 1 through 
2, of CFM SB LEAP-1A-72-00-0493-01A-930A-D, Issue 002, dated 
November 17, 2022 (CFM SB LEAP-1A-72-00-0493-01A-930A-D, Issue 002): 
At the next piece-part exposure of the HPT stage 1 disk, or before 
exceeding the applicable CSN threshold identified in Compliance, 
paragraph 3.E., Tables 1 through 2, of CFM SB LEAP-1A-72-00-0493-
01A-930A-D, Issue 002, whichever occurs first after June 23, 2023 
(the effective date of AD 2023-09-06); or if the applicable CSN 
threshold has been exceeded as of June 23,

[[Page 26198]]

2023 (the effective date of AD 2023-09-06), within 50 FCs from June 
23, 2023 (the effective date of AD 2023-09-06), remove the HPT stage 
1 disk from service and replace with a part eligible for 
installation.
    (4) For engines with an installed HPT stage 1 disk having a P/N 
and S/N identified in Compliance, paragraph 3.E., Tables 1 through 
3, of CFM SB LEAP-1A-72-00-0507-01A-930A-D, Issue 002, dated April 
24, 2025 (CFM SB LEAP-1A-72-00-0507-01A-930A-D, Issue 002): At the 
next piece-part exposure of the HPT stage 1 disk, or before 
exceeding the applicable CSN threshold identified in Compliance, 
paragraph 3.E., Tables 1 through 3, of CFM SB LEAP-1A-72-00-0507-
01A-930A-D, Issue 002, whichever occurs first after the effective 
date of this AD; or if the applicable CSN threshold has been 
exceeded as of the effective date of this AD, within 50 FCs from the 
effective date of this AD; remove the HPT stage 1 disk from service 
and replace with a part eligible for installation.

(h) Definition

    For the purpose of this AD, a ``part eligible for installation'' 
is an HPT stage 1 disk, forward outer seal, or compressor rotor 
stages 6-10 spool that does not have a P/N and S/N identified in the 
service information listed in paragraphs (g)(1) through (4) of this 
AD.

(i) Installation Prohibition

    After the effective date of this AD, do not install an HPT stage 
1 disk, forward outer seal, or compressor rotor stages 6-10 spool 
that has a P/N and S/N identified in the service information listed 
in paragraphs (g)(1) through (4) of this AD on any engine.

(j) Credit for Previous Actions

    You may take credit for the actions required by paragraph (g)(4) 
of this AD if you performed those actions before the effective date 
of this AD using CFM SB LEAP-1A-72-00-0507-01A-930A-D, Issue 001, 
dated January 24, 2024.

(k) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, AIR-520 Continued Operational Safety 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 local 
Flight Standards District Office, as appropriate. If sending 
information directly to the manager of AIR-520 Continued Operational 
Safety Branch, send it to the attention of the person identified in 
paragraph (l)(1) of this AD and email to: [email protected].
    (2) Before using any approved AMOC, notify your appropriate 
principal inspector, or lacking a principal inspector, the manager 
of the local flight standards district office/certificate holding 
district office.

(l) Additional Information

    (1) For more information about this AD, contact Mehdi Lamnyi, 
Aviation Safety Engineer, FAA, 2200 South 216th Street, Des Moines, 
WA 98198; phone: (781) 238-7743; email: [email protected].
    (2) CFM material that is not incorporated by reference is 
available at the address specified in paragraph (m)(5) of this AD.

(m) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference (IBR) of the material listed in this 
paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this material as applicable to do the actions 
required by this AD, unless the AD specifies otherwise.
    (3) The following material was approved for IBR on July 25, 
2025.
    (i) CFM Service Bulletin LEAP-1A-72-00-0507-01A-930A-D, Issue 
002, dated April 24, 2025.
    (ii) [Reserved]
    (4) The following material was approved for IBR on June 23, 2023 
(88 FR 32092, May 19, 2023).
    (i) CFM Service Bulletin LEAP-1A-72-00-0470-01A-930A-D, Issue 
003, dated March 3, 2023.
    (ii) CFM Service Bulletin LEAP-1A-72-00-0493-01A-930A-D, Issue 
002, dated November 17, 2022.
    (iii) CFM Service Bulletin LEAP-1A-72-00-0496-01A-930A-D, Issue 
001, dated March 7, 2023.
    (5) For CFM material identified in this AD, contact CFM 
International, S.A., GE Aviation Fleet Support, 1 Neumann Way, M/D 
Room 285, Cincinnati, OH 45215; phone: (877) 432-3272; email: 
[email protected].
    (6) You may view this material at the FAA, Airworthiness 
Products Section, Operational Safety Branch, 1200 District Avenue, 
Burlington, MA 01803. For information on the availability of this 
material at the FAA, call (817) 222-5110.
    (7) You may view this material at the National Archives and 
Records Administration (NARA). For information on the availability 
of this material at NARA, visit www.archives.gov/federal-register/cfr/ibr-locations or email [email protected].

    Issued on June 10, 2025.
Peter A. White,
Deputy Director, Integrated Certificate Management Division, Aircraft 
Certification Service.
[FR Doc. 2025-11340 Filed 6-18-25; 8:45 am]
BILLING CODE 4910-13-P

The complete text was extracted from the official GovInfo HTML edition for this publication. Acquired 2026-10-09T01:23:41.450474+00:00. Text extraction preserves the recorded source wording; it does not determine current requirements.

Open the captured official edition

Source SHA-256

d33c0d688aed31a1a71eae4c2203ba28b6c64d6a5f60491724f8bd9904464a67

Text SHA-256

08e9c7639ff30790a9bc9c5788fd2f9f033e16ca41b2a60ce69c70fbe7fa8d17