AD 2005-12-05 Airworthiness Directives; Boeing Model 737-200, 737-300, 737-400, 737-500, 737-600, 737-700, 737-800, 737-900, 757-200, and 757-300 Series Airplanes; and McDonnell Douglas Model DC-10-10, DC-10-10F, DC-10-30, DC-10-30F, DC-10-40, MD-10-10F, MD-10-30F, MD-11, and MD-11F Airplanes

(c) This AD applies to the airplanes listed in Table 1 of this AD, certificated in any category. Table 1.—Affected Airplane Models Airplane manufacturer Airplane model Modified by Supplemental Type Certificate (STC) Boeing 737-200, -300, -400, -500, -600, -700, -800, and -900 series ST01335LA Boeing 757-200 and -300 series ST01334LA McDonnell Douglas DC-10-10, DC-10-10F, DC-10-30, DC-10-30F, DC-10-40, MD-10-10F, MD-10-30F, MD-11, and MD-11F ST01391LA Unsafe Condition (d) This AD was prompted by reports of discrepancies with the reinforced flight deck door. We are issuing this AD to prevent inadvertent release of the decompression latch and consequent opening of the decompression panel in the flight deck door, or penetration of the flight deck door by smoke or shrapnel, any of which could result in injury to the airplane flightcrew. We are also issuing this AD to find and fix wire chafing, which could result in arcing, fire, and/or reduced controllability of the airplane.

(e) You are responsible for having the actions required by this AD performed within the compliance times specified, unless the actions have already been done. Requirements of AD 2003-14-04 Note 1: Where there are differences between this AD and the referenced service bulletins, this AD prevails. Modification (f) For airplanes listed in Table 2 of this AD: Within 90 days after July 25, 2003 (the effective date of AD 2003-14-04, amendment 39-13223), modify the reinforced flight deck door according to paragraph (f)(1), (f)(2), or (f)(3) of this AD, as applicable. Table 2.—Airplane Models Subject to Requirements of AD 2003-14-04 Airplane manufacturer Airplane model As listed in C&D Aerospace Service Bulletin— Boeing 737-200, -300, -400, -500, -600, -700, -800, and -900 series B221001-52-03, Revision 3, dated March 25, 2003 Boeing 757-200 and -300 series B231001-52-02, Revision 4, dated March 19, 2003. McDonnell Douglas DC-10-10F, DC-10-30, DC-10-30F, DC-10-40, MD-10-30F, MD-11, and MD-11F B211200-52-02, Revision 1, dated June 3, 2003. (1) For Boeing Model 737-200, -300, -400, -500, -600, -700, -800, and -900 series airplanes: Modify the upper and lower pressure relief latch assemblies on the flight deck door by doing all actions specified in and according to paragraphs 3.A., 3.B., and 3.C. of the Accomplishment Instructions of C&D Aerospace Service Bulletin B221001-52-03, Revision 3, dated March 25, 2003. One latch strap should be installed at the bottom of the upper pressure relief assembly, and a second latch strap should be installed at the top of the lower pressure relief assembly. When properly installed, the strap should cover a portion of the latch hook. (2) For Boeing Model 757-200 and -300 series airplanes: Modify the upper and lower pressure relief latch assemblies on the flight deck door by doing all actions specified in and according to paragraphs 3.A., 3.B., and 3.C. of the Accomplishment Instructions of C&D Aerospace Service Bulletin B231001-52-02, Revision 4, dated March 19, 2003. One latch strap should be installed at the bottom of the upper pressure relief assembly, and a second latch strap should be installed at the top of the lower pressure relief assembly. When properly installed, the strap should cover a portion of the latch hook. (3) For McDonnell Douglas DC-10-10F, DC-10-30, DC-10-30F, DC-10-40, MD-10-30F, MD-11, and MD-11F airplanes: Install spacers in the upper and lower pressure relief latch assemblies of the flight deck door, by doing all actions specified in and according to paragraphs 3.A., 3.C., and 3.D. of C&D Aerospace Service Bulletin B211200-52-02, Revision 1, dated June 3, 2003; or Revision 2, dated September 29, 2003. Modifications Accomplished Per Previous Issues of Service Bulletin (g) For airplanes listed in Table 2 of this AD: Modifications accomplished before July 25, 2003, in accordance with a service bulletin listed in paragraph (g)(1), (g)(2), or (g)(3) of this AD; as applicable; are considered acceptable for compliance with the corresponding action specified in paragraph (f) of this AD. (1) For Boeing Model 737-200, -300, -400, -500, -600, -700, -800, and -900 series airplanes: C&D Aerospace Service Bulletin B221001-52-03, dated December 6, 2002; Revision 1, dated January 2, 2003; or Revision 2, dated February 20, 2003. (2) For Boeing Model 757-200 and -300 series airplanes: C&D Aerospace Service Bulletin B231001-52-02, dated December 6, 2002; Revision 1, dated January 2, 2003; Revision 2, dated February 20, 2003; or Revision 3, dated March 7, 2003. (3) For McDonnell Douglas DC-10-10F, DC-10-30, DC-10-30F, DC-10-40, MD-10-30F, MD-11, and MD-11F airplanes: C&D Aerospace Service Bulletin B211200-52-02, dated April 30, 2003. Parts Installation (h) As of July 25, 2003, no person may install, on any airplane, a reinforced flight deck door having any part number listed in the paragraph 1.A. of C&D Aerospace Service Bulletin B221001-52-03, Revision 3, dated March 25, 2003; B231001-52-02, Revision 4, dated March 19, 2003; or B211200-52-02, Revision 1, dated June 3, 2003; as applicable; unless the door has been modified as required by paragraph (f) of this AD. New Requirements of This AD: Model 737 and 757 Series Airplanes: Revise Maintenance Program (i) For Model 737-200, -300, -400, -500, -600, -700, -800, and -900 series airplanes; and Model 757-200 and -300 series airplanes: Within 6 months after the effective date of this AD, revise the FAA-approved maintenance inspection program to include the information specified in C&D Aerospace Report CDRB22-69, Revision E, dated November 8, 2002. Modifications to Flight Deck Door (j) Modify the reinforced flight deck door by doing all applicable actions specified in the applicable service bulletin listed in Table 3 of this AD at the applicable compliance time specified in that table. Where the applicable service bulletin includes an instruction to install a placard to show that the service bulletin has been accomplished, this AD does not require that action. Table 3.—New Modifications to the Flight Deck Door For these models— Equipped with a flight deck door assembly having this P/N— Within this compliance time after the effective date of this AD— (months) Do all actions in the accomplishment instructions of— McDonnell Douglas DC-10-10, DC-10-10F, DC-10-30, DC-10-30F, DC-10-40, MD-10-10F, MD-10-30F, MD-11, and MD-11F airplanes B211200 6 C&D Aerospace Service Bulletin B211200-52-01, Revision 3, dated September 18, 2003. McDonnell Douglas Model MD-11 and MD-11F airplanes B251200 6 C&D Aerospace Service Bulletin B251200-52-01, dated April 30, 2003. Boeing Model 737-200, -300, -400, -500, -600, -700, -800, and -900 series airplanes; and Model 757-200 and -300 B221200 18 C&D Aerospace Service Bulletin B221200-52-01, Revision 1, dated June 27, 2003 Boeing Model 737-200, -300, -400, -500, -600, -700, -800, and -900 series airplanes B221001 18 C&D Aerospace Service Bulletin B221001-52-03, Revision 3, dated March 25, 2003; except as provided by paragraph (k) of this AD. Boeing Model 757-200 and-300 series airplanes B231001 18 C&D Aerospace Service Bulletin B231001-52-02, Revision 4, dated March 19, 2003; except as provided by paragraph (k) of this AD. McDonnell Douglas DC-10-10, DC-10-10F, DC-10-30, DC-10-30F, DC-10-40, MD-10-10F, MD-10-30F, MD-11, and MD-11F airplanes B211200 18 C&D Aerospace Service Bulletin B211200-52-02, Revision 1, dated June 3, 2003; or Revision 2, dated September 29, 2003, except as provided by paragraph (k) of this AD. (k) For airplanes subject to paragraph (f) of this AD: Actions required by paragraph (f) of this AD that were done within the compliance time specified in paragraph (f) of this AD do not need to be repeated in accordance with paragraph (j) of this AD. Modifications Accomplished Per Previous Issues of Service Bulletin (l) Modifications accomplished before the effective date of this AD in accordance with an applicable service bulletin listed in Table 4 of this AD are considered acceptable for compliance with the corresponding action specified in paragraph (j) of this AD. Table 4.—Acceptable Service Information for Previous Modifications Service bulletin Revision level Date C&D Aerospace Service Bulletin B211200-52-01 Original February 27, 2003. C&D Aerospace Service Bulletin B211200-52-01 1 March 7, 2003. C&D Aerospace Service Bulletin B211200-52-01 2 June 3, 2003. C&D Aerospace Service Bulletin B211200-52-02 Original April 30, 2003. C&D Aerospace Service Bulletin B221001-52-03 Original December 6, 2002. C&D Aerospace Service Bulletin B221001-52-03 1 January 2, 2003. C&D Aerospace Service Bulletin B221001-52-03 2 February 20, 2003. C&D Aerospace Service Bulletin B221200-52-01 Original April 30, 2003. C&D Aerospace Service Bulletin B231001-52-02 Original December 6, 2002. C&D Aerospace Service Bulletin B231001-52-02 1 January 2, 2003. C&D Aerospace Service Bulletin B231001-52-02 2 February 20, 2003. C&D Aerospace Service Bulletin B231001-52-02 3 March 7, 2003. Model 737-200 Series Airplanes: Wiring Modification/Inspection (m) For Model 737-200 series airplanes equipped with flight deck door assembly P/N B221001: Within 18 months after the effective date of this AD, do paragraphs (m)(1) and (m)(2) of this AD. (1) Rework the wiring for the flight deck door to relocate a power wire for the flight deck door, in accordance with the Accomplishment Instructions of C&D Aerospace Alert Service Bulletin B221001-52A05, Revision 3, dated October 3, 2003. Actions accomplished before the effective date of this AD in accordance with C&D Aerospace Alert Service Bulletin B221001-52A05, dated April 17, 2003; Revision 1, dated May 14, 2003; and Revision 2, dated June 19, 2003; are acceptable for compliance with the corresponding action required by this paragraph. (2) Perform a general visual inspection for chafing of wire bundles in the area of the flight deck door and applicable corrective actions by doing all of the actions in the Accomplishment Instructions of C&D Aerospace Alert Service Bulletin B221001-52A02, dated November 5, 2002. Any applicable corrective actions must be done before further flight. Note 2: For the purposes of this AD, a general visual inspection is “a visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to ensure visual access to all surfaces in the inspection area. This level of inspection is made under normal available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked.” Parts Installation (n) As of the effective date of this AD, no person may install a reinforced flight deck door under any STC listed in Table 1 of this AD, on any airplane, unless all applicable requirements of this AD have been done on the door. Alternative Methods of Compliance (AMOCs) (o)(1) The Manager, Los Angeles Aircraft Certification Office (ACO), FAA, has the authority to approve AMOCs for this AD, if requested in accordance with the procedures found in 14 CFR 39.19. (2) Alternative methods of compliance, approved previously in accordance with AD 2003-14-04, amendment 39-13223, are approved as alternative methods of compliance with this AD. Material Incorporated by Reference (p) You must use the service information that is specified in Table 5 of this AD to perform the actions that are required by this AD, unless the AD specifies otherwise. Table 5.—Material Incorporated by Reference Service bulletin Revision level Date C&D Aerospace Alert Service Bulletin B221001-52A02 Original November 5, 2002. C&D Aerospace Alert Service Bulletin B221001-52A05 3 October 3, 2003. C&D Aerospace Service Bulletin B211200-52-01 3 September 18, 2003. C&D Aerospace Service Bulletin B211200-52-02 1 June 3, 2003. C&D Aerospace Service Bulletin B211200-52-02 2 September 29, 2003. C&D Aerospace Service Bulletin B221001-52-03 3 March 25, 2003. C&D Aerospace Service Bulletin B221200-52-01 1 June 27, 2003. C&D Aerospace Service Bulletin B231001-52-02 4 March 19, 2003. C&D Aerospace Service Bulletin B251200-52-01 Original April 30, 2003. C&D Aerospace Report CDRB22-69 E November 8, 2002 (1) The Director of the Federal Register approves the incorporation by reference of the service information specified in Table 6 of this AD in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Table 6.—New Material Incorporated by Reference Service bulletin Revision level Date C&D Aerospace Alert Service Bulletin B221001-52A02 Original November 5, 2002. C&D Aerospace Alert Service Bulletin B221001-52A05 3 October 3, 2003. C&D Aerospace Service Bulletin B211200-52-01 3 September 18, 2003. C&D Aerospace Service Bulletin B211200-52-02 2 September 29, 2003. C&D Aerospace Service Bulletin B221200-52-01 1 June 27, 2003. C&D Aerospace Service Bulletin B2105200-52-01 Original April 30, 2003. C&D Aerospace Report CDRB22-69 E November 8, 2002. (2) The Director of the Federal Register previously approved the incorporation by reference of the service information specified in Table 7 of this AD as of July 25, 2003 (68 FR 41063, July 10, 2003). Table 7.—Material Previously Incorporated by Reference Service bulletin Revision level Date C&D Aerospace Service Bulletin B211200-52-02 1 June 3, 2003. C&D Aerospace Service Bulletin B221001-52-03 3 March 25, 2003. C&D Aerospace Service Bulletin B231001-52-02 4 March 19, 2003. (3) To get copies of the service information, go to Boeing Commercial Airplanes, P.O. Box 3707, Seattle, Washington 98124-2207; or C&D Aerospace, 5701 Bolsa Avenue, Huntington Beach, California 92647-2063. To view the AD docket, go to the Docket Management Facility, U.S. Department of Transportation, 400 Seventh Street SW., room PL-401, Nassif Building, Washington, DC. To review copies of the service information, go to the National Archives and Records Administration (NARA). For information on the availability of this material at the NARA, call (202) 741-6030, or go to http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html. Issued in Renton, Washington, on May 26, 2005. Ali Bahrami, Manager, Transport Airplane Directorate, Aircraft Certification Service. [FR Doc. 05-11514 Filed 6-13-05; 8:45 am] BILLING CODE 4910-13-P