Airworthiness Directives; The Boeing Company Airplanes

[Federal Register Volume 90, Number 189 (Thursday, October 2, 2025)]
[Rules and Regulations]
[Pages 47546-47549]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2025-19394]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2025-0196; Project Identifier AD-2024-00250-T; 
Amendment 39-23157; AD 2025-20-04]
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) 2019-12-
13, which applied to all The Boeing Company Model 757 airplanes. AD 
2019-12-13 required repetitive checks of the aileron trim actuator 
bearing for free rotation, repetitive detailed inspections of the 
aileron trim actuator attachment lug for damage and cracking, and 
applicable on-condition actions. This AD was prompted by the 
determination that a modification must be done to address the unsafe 
condition. This AD retains the actions in AD 2019-12-13. This AD also 
requires for certain airplanes changing the lateral control box support 
assembly and installing an aileron trim actuator bracket, and for 
certain other airplanes replacing the existing actuator lateral control 
fitting with an aileron trim actuator bracket, which terminates the 
repetitive checks and inspections. The FAA is issuing this AD to 
address the unsafe condition on these products.

DATES: This AD is effective November 6, 2025.
    The Director of the Federal Register approved the incorporation by 
reference of certain publications listed in this AD as of November 6, 
2025.
    The Director of the Federal Register approved the incorporation by 
reference of a certain other publication listed in this AD as of July 
12, 2019 (84 FR 30577, June 27, 2019).

ADDRESSES: 
    AD Docket: You may examine the AD docket at regulations.gov under 
Docket No. FAA-2025-0196; 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 the Boeing material 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; website myboeingfleet.com.
    <bullet> You may view this material 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 regulations.gov under 
Docket No. FAA-2025-0196.

FOR FURTHER INFORMATION CONTACT: Katherine Venegas, Aviation Safety 
Engineer, FAA, 2200 South 216th St., Des Moines, WA 98198; phone: 562-
627-5353; email: [email protected].

SUPPLEMENTARY INFORMATION:

Background

    The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 
CFR part 39 to supersede AD 2019-12-13, Amendment 39-19668 (84 FR 
30577, June 27, 2019) (AD 2019-12-13). AD 2019-12-13 applied to all The 
Boeing Company Model 757 airplanes. The NPRM was published in the 
Federal Register on February 12, 2025 (90 FR 9403). The NPRM was 
prompted by the determination that a modification must be done to 
address the unsafe condition. In the NPRM, the FAA proposed to continue 
to require the actions in AD 2019-12-13. The NPRM also proposed to 
require for certain airplanes a change to the lateral control box 
support assembly and installation of an aileron trim actuator bracket, 
and for certain other airplanes replacement of the existing actuator 
lateral control fitting with an aileron trim actuator bracket, which 
terminates the repetitive checks and inspections. The FAA is issuing 
this AD to address failure of the aileron trim actuator attachment lug 
and subsequent loss of feel force, wheel centering, and lateral trim. 
The unsafe condition, if not corrected, could cause over-control of the 
airplane and subsequent lateral pilot-induced oscillations that could 
adversely affect continued safe flight and landing.

Discussion of Final Airworthiness Directive

Comments

    The FAA received comments from Air Line Pilots Association, 
International (ALPA), Aviation Partners Boeing, Boeing, United 
Airlines, and one individual who supported the NPRM without change.
    The FAA received additional comments from two commenters, including 
Delta Air Lines (Delta) and two individuals. One of the comments was 
outside the scope of this AD. The following presents the relevant 
comments received on the NPRM and the FAA's response to each comment.

Effect of Winglets on Accomplishment of the Proposed Actions

    Aviation Partners Boeing stated that the installation of winglets 
per Supplemental Type Certificate (STC) ST01518SE does not affect 
compliance with the proposed AD.
    The FAA agrees with the commenter that STC ST01518SE does not 
affect the accomplishment of the manufacturer's service instructions. 
Therefore, the installation of STC ST01518SE does not affect the 
ability to accomplish the actions required by this AD. The FAA has not 
changed this AD in this regard.

[[Page 47547]]

Request To Change Compliance Time

    An individual requested that the FAA change the compliance time for 
the modification to a phased approach, such as a 24- to 36-month 
compliance window, to allow operators to accomplish fleet modifications 
efficiently without disrupting flight operations. The commenter stated 
that, given the scale of this modification across the Boeing Model 757 
fleet, implementing the modifications during scheduled heavy 
maintenance checks would minimize airplane downtime and supply chain 
constraints. The commenter also stated that rushing to implement the 
modifications could lead to parts shortages, maintenance upholds, and 
operational disruptions. The commenter concluded that a risk-based 
prioritization approach could ensure higher-risk airplanes are 
addressed first while maintaining operational stability, and that a 
flexible timeline will help achieve the intended safety improvements 
effectively.
    The FAA disagrees with changing the compliance time. In developing 
an appropriate compliance time for this AD, the FAA considered the 
recommendations of the manufacturer, the urgency associated with the 
subject unsafe condition, the availability of required parts, and the 
practical aspect of accomplishing the required modification within a 
period of time that corresponds to the normal scheduled maintenance for 
most affected operators. In consideration of these items, the FAA has 
determined that compliance time of within 10,000 flight hours or 30 
months from the effective date of the AD, whichever occurs first, will 
ensure an acceptable level of safety. However, under the provisions of 
paragraph (k) of this AD, the FAA will consider requests for approval 
of an extension of the compliance time if sufficient data are submitted 
to substantiate that the new compliance time would provide an 
acceptable level of safety. The FAA also clarifies that operators are 
allowed to implement the modification at any time within the compliance 
period during their normal scheduled maintenance. The FAA has not 
changed the AD in this regard.

Request To Add Note to Paragraph (i) of Proposed AD

    Delta requested that the FAA add a note to paragraph (i) of the 
proposed AD that refers operators to Boeing Alert Requirements Bulletin 
757-27A0160 RB, dated April 1, 2024, as a global acceptable method of 
compliance (AMOC) to the requirement in paragraph (h) of the proposed 
AD. Paragraph (h) proposed to require doing the repair using a method 
approved in accordance with the procedures specified in the AMOC 
paragraph of the proposed AD instead of contacting Boeing for repair 
instructions, as specified in Boeing Alert Requirements Bulletin 757-
27A0159 RB, dated March 29, 2019, and Revision 1, dated April 29, 2020. 
The commenter stated that every operator that has not requested Boeing 
Alert Requirements Bulletin 757-27A0160 RB as an AMOC to paragraph (h) 
of the proposed AD would each have to submit an AMOC request to use 
that service bulletin in lieu of repair instructions. Delta stated that 
identifying Boeing Alert Requirements Bulletin 757-27A0160 RB as an 
AMOC in the proposed AD would reduce strain on operators and the FAA in 
processing AMOC requests.
    The FAA disagrees with the request. An AMOC to the inspections 
required by paragraph (g) of this AD, along with the exception in 
paragraph (h) of this AD, is not necessary if the operator performs the 
modification in paragraph (i) of this AD. As stated in paragraph (i) of 
this AD, doing the modification required by this paragraph terminates 
the inspections required by paragraph (g) of this AD. The FAA has not 
changed the AD in this regard.

Request To Fix Typographical Errors in Service Information

    Delta requested that the FAA address typographical errors in Boeing 
Service Bulletin 757-27A0160, dated April 1, 2024. Delta stated that 
under step 2 of ``Part 2: Feel and Trim Mechanism Assembly and Aileron 
Trim Actuator Installation,'' the second substep should be renumbered 
from ``a.'' to ``b.'' and the text of that substep should be changed 
from ``Install kept the . . .'' to ``Install the kept . . . .'' Delta 
also stated that substep 3.a. of ``Part 3: Restoration,'' should be 
changed from ``Restore electrical power from the airplane,'' to 
``Restore electrical power to the airplane.'' Delta recognized that 
these errors are in steps that are not required for compliance but 
asserted that the information is relevant to completing the 
modification and the errors do not properly convey the intent of the 
sentence.
    The FAA agrees with the corrections that Delta has identified but 
no change to this AD is necessary. The FAA reviewed the service 
information and confirmed the typographical errors occur in steps that 
are not required for compliance.

Conclusion

    The FAA reviewed the relevant data, considered any comments 
received, and determined that air safety requires adopting this AD as 
proposed. Accordingly, the FAA is issuing this AD to address the unsafe 
condition on these products. Except for minor editorial changes, 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 Boeing Alert Requirements Bulletin 757-27A0159 RB, 
Revision 1, dated April 29, 2020. This material specifies procedures 
for repetitive checks of the aileron trim actuator bearing for free 
rotation, repetitive detailed inspections of the aileron trim actuator 
attachment lug for damage or cracking, and applicable on-condition 
actions. On-condition actions include high frequency eddy current 
(HFEC) inspections of the aileron trim actuator attachment lug for 
cracking, repair, and replacement. This revision only adds references 
to AD 2019-12-13 and does not add any new actions.
    The FAA also reviewed Boeing Alert Requirements Bulletin 757-
27A0160 RB, dated April 1, 2024. This material specifies procedures for 
modifying the affected airplanes, which includes for certain airplanes 
changing the lateral control box support assembly (which includes doing 
a portable method C penetrant inspection of the machined surface of the 
lug for any crack and repair as applicable) and installing an aileron 
trim actuator bracket, and for certain other airplanes replacing the 
existing actuator lateral control fitting with an aileron trim actuator 
bracket. Accomplishment of the modification terminates the repetitive 
checks and inspections specified in Boeing Alert Requirements Bulletin 
757-27A0159 RB.
    This AD also requires Boeing Alert Requirements Bulletin 757-
27A0159 RB, dated March 29, 2019, which the Director of the Federal 
Register approved for incorporation by reference as of July 12, 2019 
(84 FR 30577, June 27, 2019).
    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 460 airplanes of U.S. 
registry. The FAA estimates the following costs to comply with this AD:

[[Page 47548]]



                                                 Estimated Costs
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                                                                                                Cost on U.S.
              Action                    Labor cost        Parts cost    Cost per product          operators
----------------------------------------------------------------------------------------------------------------
Repetitive inspections (retained   3 work-hours x $85             $0  $255 per inspection   $117,300 per
 actions from AD                    per hour = $255 per                cycle.                inspection cycle.
 2019[dash]12[dash]13).             inspection cycle.
Install aileron trim actuator      6 work-hours x $85          3,820  $4,330..............  $1,991,800.
 bracket (new required action).     per hour = $510.
Change the lateral control box     2 work-hours x $85              0  $170................  $69,020.*
 assembly for Groups 1, 4, and 5    per hour = $170.
 (new required action).
----------------------------------------------------------------------------------------------------------------
* The number of airplanes in Groups 1, 4, and 5, as identified in Boeing Alert Requirements Bulletin 757-27A0160
  RB, dated April 1, 2024, is estimated to be 406.

    The FAA estimates the following costs to do any necessary on-
condition actions that would be required based on the results of the 
inspection. The agency has no way of determining the number of aircraft 
that might need these on-condition actions:

                           On-Condition Costs
------------------------------------------------------------------------
                                                               Cost per
            Action                Labor cost     Parts cost    product
------------------------------------------------------------------------
Replacement (retained actions  4 work-hours x       $17,693      $18,033
 from AD                        $85 per hour =
 2019[dash]12[dash]13).         $340.
HFEC inspection (retained      1 work-hour x              0           85
 actions from AD                $85 per hour =
 2019[dash]12[dash]13).         $85.
------------------------------------------------------------------------

    The FAA has received no definitive data on which to base the cost 
estimates for the on-condition repair specified in 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.
    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) 2019-12-13, Amendment 39-19668 
(84 FR 30577, June 27, 2019); and
0
b. Adding the following new AD:

2025-20-04 The Boeing Company: Amendment 39-23157; Docket No. FAA-
2025-0196; Project Identifier AD-2024-00250-T.

(a) Effective Date

    This airworthiness directive (AD) is effective November 6, 2025.

(b) Affected ADs

    This AD replaces AD 2019-12-13, Amendment 39-19668 (84 FR 30577, 
June 27, 2019) (AD 2019-12-13).

(c) Applicability

    This AD applies to all The Boeing Company Model 757-200, -200CB, 
-200PF, and -300 series airplanes, certificated in any category.

(d) Subject

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

(e) Unsafe Condition

    This AD was prompted by a report of the failure of the aileron 
trim actuator attachment lug. The FAA is issuing this AD to address 
failure of the aileron trim actuator attachment lug and subsequent 
loss of feel force, wheel centering, and lateral trim. The unsafe 
condition, if not corrected, could cause over-control of the 
airplane and subsequent lateral pilot-induced oscillations, which 
could adversely affect continued safe flight and landing.

(f) Compliance

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

(g) Retained Required Actions, With Revised Service Information

    This paragraph restates the requirements of paragraph (g) of AD 
2019-12-13, with revised service information. Except as specified by 
paragraph (h) of this AD: At the applicable times specified in the 
``Compliance'' paragraph of Boeing Alert Requirements Bulletin 757-
27A0159 RB,

[[Page 47549]]

Revision 1, dated April 29, 2020, do all applicable actions 
identified in, and in accordance with, the Accomplishment 
Instructions of Boeing Alert Requirements Bulletin 757-27A0159 RB, 
dated March 29, 2019, or Boeing Alert Requirements Bulletin 757-
27A0159 RB, Revision 1, dated April 29, 2020. As of the effective 
date of this AD, only use Boeing Alert Requirements Bulletin 757-
27A0159 RB, Revision 1, dated April 29, 2020, for the actions 
required by this paragraph.
    Note 1 to paragraph (g): Guidance for accomplishing the actions 
required by this AD can be found in Boeing Alert Service Bulletin 
757-27A0159, dated March 29, 2019, which is referred to in Boeing 
Alert Requirements Bulletin 757-27A0159 RB, dated March 29, 2019.
    Note 2 to paragraph (g): Guidance for accomplishing the actions 
required by this AD can also be found in Boeing Alert Service 
Bulletin 757-27A0159, Revision 1, dated April 29, 2020, which is 
referred to in Boeing Alert Requirements Bulletin 757-27A0159 RB, 
Revision 1, dated April 29, 2020.

(h) Retained Exception, With Revised Service Information

    This paragraph restates the requirements of paragraph (h)(2) of 
AD 2019-12-13, with revised service information. Where Boeing Alert 
Requirements Bulletin 757-27A0159 RB, dated March 29, 2019, and 
Boeing Alert Requirements Bulletin 757-27A0159 RB, Revision 1, dated 
April 29, 2020, specify contacting Boeing for repair instructions: 
This AD requires doing the repair using a method approved in 
accordance with the procedures specified in paragraph (k) of this 
AD.

(i) New Required Actions

    Except as specified by paragraph (j) of this AD: At the 
applicable times specified in the ``Compliance'' paragraph of Boeing 
Alert Requirements Bulletin 757-27A0160 RB, dated April 1, 2024, do 
all applicable actions identified in, and in accordance with, the 
Accomplishment Instructions of Boeing Alert Requirements Bulletin 
757-27A0160 RB, dated April 1, 2024. Doing the modification required 
in this paragraph terminates the inspections required by paragraph 
(g) of this AD.
    Note 3 to paragraph (i): Guidance for accomplishing the actions 
required by this AD can be found in Boeing Alert Service Bulletin 
757-27A0160, dated April 1, 2024, which is referred to in Boeing 
Alert Requirements Bulletin 757-27A0160 RB, dated April 1, 2024.

(j) Exceptions to Requirements Bulletin Specifications

    (1) Where the Compliance Time columns of the tables in the 
``Compliance'' paragraph of Boeing Alert Requirements Bulletin 757-
27A0160 RB, dated April 1, 2024, refer to the original issue date of 
Requirements Bulletin 757-27A0160 RB, this AD requires using the 
effective date of this AD.
    (2) Where Boeing Alert Requirements Bulletin 757-27A0160 RB, 
dated April 1, 2024, specifies contacting Boeing for repair 
instructions: This AD requires doing the repair using a method 
approved in accordance with the procedures specified in paragraph 
(k) of this AD.

(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 
responsible Flight 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 
(l)(1) of this AD. Information may be emailed to: [email protected]. 
Before using any approved AMOC, notify your appropriate principal 
inspector, or lacking a principal inspector, the manager of the 
responsible Flight Standards Office.
    (2) 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, AIR-
520, Continued Operational Safety 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.
    (3) AMOCs approved for AD 2019-12-13 are approved as AMOCs for 
the corresponding provisions of paragraph (g) of this AD.

(l) Related Information

    (1) For more information about this AD, contact Katherine 
Venegas, Aviation Safety Engineer, FAA, 2200 South 216th St., Des 
Moines, WA 98198; phone: 562-627-5353; email: 
[email protected].
    (2) Material identified in this AD 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 this AD specifies otherwise.
    (3) The following material was approved for IBR on November 6, 
2025.
    (i) Boeing Alert Requirements Bulletin 757-27A0159 RB, Revision 
1, dated April 29, 2020.
    (ii) Boeing Alert Requirements Bulletin 757-27A0160 RB, dated 
April 1, 2024.
    (4) The following material was approved for IBR on July 12, 2019 
(84 FR 30577, June 27, 2019).
    (i) Boeing Alert Requirements Bulletin 757-27A0159 RB, dated 
March 29, 2019.
    (ii) [Reserved]
    (5) For the Boeing material 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; website myboeingfleet.com.
    (6) You may view this material 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 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 September 26, 2025.
Peter A. White,
Deputy Director, Integrated Certificate Management Division, Aircraft 
Certification Service.
[FR Doc. 2025-19394 Filed 10-1-25; 8:45 am]
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