AD 2005-19-23 Airworthiness Directives; Boeing Model 767-200, -300, and -300F Series Airplanes Powered by General Electric or Pratt & Whitney Engines

Models named: 767-200, -300, -300F series. Read the applicability below — it usually turns on serial or part numbers too.

This AD applies to Boeing Model 767-200, -300, and -300F series airplanes, certificated in any category, as identified in Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005.

You are responsible for having the actions required by this AD performed within the compliance times specified, unless the actions have already been done. Restatement of Requirements of AD 2004-09-14 Repetitive Inspections (f) Except as provided by paragraph (g) of this AD, before the accumulation of 10,000 total flight cycles, or within 600 flight cycles after May 15, 2001 (the effective date of AD 2001-07-05, amendment 39-12170), whichever occurs later: Accomplish the inspections required by paragraph (f)(1) or (f)(2) of this AD, as applicable. (1) Perform a detailed inspection of the four aft-most fastener holes in the horizontal tangs of the midspar fitting of the strut to detect cracking, in accordance with Part 1, “Detailed Inspection,” of the Accomplishment Instructions of Boeing Service Bulletin 767-54A0101, Revision 1, dated February 3, 2000. If no cracking is detected, repeat the inspection thereafter at the applicable intervals specified in Table 1, “Reinspection Intervals for Part 1—Detailed Inspection” included in Figure 1 of the service bulletin. Note 1: For the purposes of this AD, a detailed inspection is: “An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirror, magnifying lenses, etc., may be necessary. Surface cleaning and elaborate procedures may be required.” (2) Perform a high frequency eddy current (HFEC) inspection of the four aft-most fastener holes in the horizontal tangs of the midspar fitting of the strut to detect discrepancies (cracking, incorrect fastener hole diameter), in accordance with Part 2, “High Frequency Eddy Current (HFEC) Inspection,” of the Accomplishment Instructions of the service bulletin. Accomplish the requirements specified in paragraph (f)(2)(i) or (f)(2)(ii) of this AD, as applicable; and repeat the inspection thereafter at the applicable intervals specified in Table 2, “Reinspection Intervals for Part 2—HFEC Inspection” included in Figure 1 of the service bulletin. (i) If no cracking is detected and the fastener hole diameter is less than or equal to 0.5322 inch, before further flight, rework the hole in accordance with Part 3 of the Accomplishment Instructions of the service bulletin. (ii) If no cracking is detected and the fastener hole diameter is greater than 0.5322 inch, before further flight, accomplish the requirements specified in either paragraph (h)(1) or (h)(2) of this AD. (g) For airplanes on which the two aft-most fasteners have been inspected in accordance with Boeing Service Bulletin 767-54A0101, Revision 1, dated February 3, 2000, prior to May 15, 2001: Perform the initial inspection of the four aft-most fasteners in accordance with paragraph (f) of this AD before the accumulation of 10,000 total flight cycles, or within 1,500 flight cycles after May 15, 2001, whichever occurs later. Corrective Actions (h) If any cracking is detected after accomplishment of any inspection required by paragraph (f) of this AD, before further flight, accomplish the requirements specified in either paragraph (h)(1) or (h)(2) of this AD. (1) Accomplish the terminating action specified in Part 4 of the Accomplishment Instructions of Boeing Service Bulletin 767-54A0101, Revision 1, dated February 3, 2000; Boeing Service Bulletin 767-54A0101, Revision 3, dated September 5, 2002; or Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005. Accomplishment of this paragraph terminates the requirements of this AD. After the effective date of this AD, only Boeing Alert Service Bulletin 767-54A0101, Revision 4, may be used. (2) Replace the midspar fitting of the strut with a serviceable part, or repair in accordance with a method approved by the Manager, Seattle Aircraft Certification Office (ACO), FAA. Repeat the applicable inspection thereafter at the applicable time specified in paragraph (f)(1) or (f)(2) of this AD. (i) If any discrepancies (cracking, incorrect fastener hole diameter) are detected during any inspection required by paragraph (f) or (p) of this AD, for which the service bulletin specifies that the manufacturer may be contacted for disposition of those repair conditions: Before further flight, accomplish the applicable related investigative and corrective actions (including fastener hole rework and/or midspar fitting replacement) using a method approved in accordance with the procedures specified in paragraph (q) of this AD. Additional Inspections (j) Prior to the accumulation of 10,000 total flight cycles, or within 600 flight cycles after June 9, 2004 (the effective date of AD 2004-09-14), whichever occurs later: Perform the inspections specified in paragraph (f)(1) or (f)(2) of this AD, as applicable, on all eight aft-most fastener holes or the four forward fastener holes in the group of eight aft-most fastener holes not inspected per paragraph (f)(1), (f)(2), or (g) of this AD. The inspection must be done per the Accomplishment Instructions in Boeing Service Bulletin 767-54A0101, Revision 3, dated September 5, 2002; or Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005. Accomplishment of the applicable inspection on all eight aft-most fastener holes constitutes terminating action for the repetitive inspection requirements of paragraphs (f)(1), (f)(2), and (g) of this AD. (k) If no cracking or discrepancy is detected during any detailed inspection required by paragraph (j) of this AD, repeat the inspections of all eight aft-most fastener holes thereafter at the applicable intervals specified in Table 1 of this AD. (l) If no cracking or discrepancy is detected during any HFEC inspection required by paragraph (j) of this AD or by this paragraph of this AD: Perform the follow-on actions specified in paragraph (f)(2)(i) or (f)(2)(ii) of this AD, as applicable, per the Accomplishment Instructions in Boeing Service Bulletin 767-54A0101, Revision 3, dated September 5, 2002; or Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005; and repeat the inspections of all eight aft-most fastener holes thereafter at the applicable intervals specified in Table 1 of this AD. Table 1.—Repetitive Inspection Intervals for All Eight Aft-Most Fastener Holes If— Repetitive intervals— (1) All eight aft-most fastener holes were inspected per paragraph (j) of this AD: At the applicable intervals specified in Table 1, “Reinspection Intervals for Part 1,” or Table 2, “Reinspection Intervals for Part 2,” as applicable. Both tables are included in Figure 1 of the applicable service bulletin.   Within 1,500 flight cycles after the effective date of this AD, only the repetitive intervals in Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005, may be used. (2) Only the four forward fastener holes in the group of eight aft-most fastener holes were inspected per paragraph (j) of this AD: At the next scheduled repetitive inspection required by paragraph (f)(1) of (f)(2) of this AD, as applicable. Thereafter at the applicable intervals specified in Table 1, “Reinspection Intervals for Part 1,” or Table 2, “Reinspection Intervals for Part 2,” as applicable. Both tables are included in Figure 1 of the applicable service bulletin.   Within 1,500 flight cycles after the effective date of this AD, only the repetitive intervals in Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005, may be used. Corrective Actions for Discrepancies (m) If any cracking or discrepancy is detected during any inspection required by paragraphs (j), (k), or (l) of this AD, before further flight: Accomplish the corrective actions described in paragraph (h) of this AD, except as provided in paragraph (i) of this AD. Service Bulletin Revisions (n) Accomplishing the terminating action in paragraph (h)(1) of this AD before June 9, 2004, in accordance with the service bulletin revisions in Table 2 of this AD, is acceptable for compliance with the requirements of this AD. After the effective date of this AD, only Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005, may be used for accomplishing the terminating action in paragraph (h)(1) of this AD. Table 2.—Service Bulletins for Terminating Action Service bulletin Revision Date Boeing Alert Service Bulletin 767-54A0101 Original September 23, 1999. Boeing Service Bulletin 767-54A0101 2 January 10, 2002. Inspections Accomplished per Previous Issues of Service Bulletin (o) Inspections required by paragraphs (f) and (g) of this AD that are accomplished before June 9, 2004, in accordance with the service bulletin revisions in Table 3 of this AD are considered acceptable for compliance with the corresponding action specified in this AD. Table 3.—Service Bulletins for Previously Accomplished Inspections Boeing service bulletin Revision Date Boeing Service Bulletin 767-54A0101 2 January 10, 2002. Boeing Service Bulletin 767-54A0101 3 September 5, 2002. Boeing Alert Service Bulletin 767-54A0101 4 February 10, 2005. New Requirements of This AD Inspections of Closeout Angle and Corrective Action (p) For airplanes for which the “Reinspection Intervals for Part 1,” referenced in Table 1 of paragraph (l) of this AD apply: At the next applicable inspection, do an HFEC inspection for cracks of the closeout angle that covers the two aft-most fasteners in the lower tang of the midspar fitting and any related investigative and corrective actions, by doing all the applicable actions specified in the Accomplishment Instructions of Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005. Repeat the inspection at the applicable interval in Table 1, “Reinspection Intervals for Part 1,” in Figure 1 of the alert service bulletin. Note 2: Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005, refers to the Boeing service bulletins in the Table 4 of this AD as additional sources of service information for doing the terminating action in paragraph (h)(1) of this AD. Table 4.—Additional Sources of Service Information Boeing service bulletin Revision level Date Title 767-54-0052 Original June 11, 1992 Nacelles/Pylons—Strut—Aft Lower Spar—Fastener Corrosion—Inspection and Replacement. 767-54-0061 2 November 23, 1999 Nacelles/Pylons—Wing-to-Strut Attach Fittings—Lower Spar Bushing Inspection and Replacement. 767-54-0069 2 August 31, 2000 Nacelles/Pylons—Midspar Fitting—Underwing Sideload Fitting—Fuse Pin Replacement and Wing Rework. 767-54-0072 Original March 13, 1997 Nacelles/Pylons—Strut Attach Upper Link—Upper Link Inspection, Rework or Replacement. 767-54-0074 Original March 27, 1997 Nacelles/Pylons—Strut Attach Fuse Pins—Upper link Fuse Pin Inspection/Replacement. Where this service bulletin refers to a cotter pin with part number (P/N) MS25665-374, the P/N should be MS24665-374. Where this service bulletin says, “If no crack indication is found, reinstall the fuse pin,” the correct statement is “If no crack indication is found, continue to Step F.” 767-54-0080 1 May 9, 2002 Nacelles/Pylons—Pratt and Whitney Powered Airplanes—Nacelle Strut and Wing Structure Modification. 767-54-0081 1 February 7, 2002 Nacelles/Pylons—General Electric Powered Airplanes—Nacelle Strut and Wing Structure Modification. 767-54A0062 5 November 11, 2002 Nacelles/Pylons—Strut Attach Fuse Pins—Midspar Fuse Pin Inspection and Replacement. 767-54A0094 2 February 7, 2002 Nacelles/Pylons—Strut-to-Wing Attachment—Diagonal Brace Inspection/Rework/Replacement. 767-57-0063 1 November 30, 2000 Wings—Side Load Underwing Fitting—Inspection/Rework. Note 3: Certain service bulletins referenced in Table 4 of this AD are related to the ADs listed in Table 5 of this AD. Table 5.—Other Relevant Rulemaking AD Applicability Related Boeing service bulletin AD requirement AD 94-11-02, amendment 39-8918, (59 FR 27229, May 26, 1994) All Boeing Model 767 series airplanes 767-54A0062 Repetitive detailed visual and eddy current inspections to detect cracks of certain midspar fuse pins, and replacement of any cracked midspar fuse pin with a new fuse pin. AD 99-07-06, amendment 39-11091 (64 FR 14578, March 26, 1999) Certain Boeing Model 767 series airplanes 767-54A0094 Repetitive inspections to detect cracking or damage of the forward and aft lugs of the diagonal brace of the nacelle strut; follow-on actions, if necessary; and an optional terminating action for the repetitive inspections. Superseded by AD 2000-07-05. AD 2000-07-05, amendment 39-11659 (65 FR 18883, April 10, 2000) Certain Boeing Model 767 series airplanes 767-54A0094 Requires the previously optional terminating action of AD 99-07-06. AD 2000-10-51, amendment 39-11770 (65 FR 37011, June 13, 2000) Certain Boeing Model 767 series airplances 767-54-0074 One-time inspection to determine whether certain bolts are installed in the side load underwing fittings on both struts, and various follow-on actions, if necessary. AD 2001-02-07, amendment 39-12091 (66 FR 8085, January 29, 2001) Certain Boeing Model 767 series airplanes powered by Pratt & Whitney engines 767-54-0069, 767-54-0080, and 767-54-0094 Modification of the nacelle strut and wing structure. Terminates certain requirements of AD 94-11-02. AD 2001-06-12, amendment 39-12159 (66 FR 17492, April 2, 2001) Certain Boeing Model 767 series airplanes powered by General Electric engines 767-54-0069, 767-54-0081, and 767-54-0094 Modification of the nacelle strut and wing structure. Terminates certain requirements of AD 94-11-02. AD 2003-03-02, amendment 39-13026 (68 FR 4374, January 29, 2003) All Boeing Model 767 series airplanes 767-54A0062 Supersedes AD 94-11-02; Retains all requirements but reduces certain compliance times for certain inspections, expands the detailed and eddy current inspections, and limits the applicability. Alternative Methods of Compliance (AMOCs) (q)(1) The Manager, Seattle 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) AMOCs approved previously according to AD 2004-09-14, amendment 39-13603, are approved as AMOCs for the corresponding requirements of this AD. (3) An AMOC that provides an acceptable level of safety may be used for any repair required by this AD, if it is approved by an Authorized Representative for the Boeing Commercial Airplanes Delegation Option Authorization Organization who has been authorized by the Manager, Seattle ACO, to make those findings. For a repair method to be approved, the repair must meet the certification basis of the airplane, and the approval must specifically refer to this AD. (4) Before using any AMOC approved in accordance with § 39.19 on any airplane to which the AMOC applies, notify the appropriate principal inspector in the FAA Flight Standards Certificate Holding District Office. Material Incorporated by Reference (r) You must use the service information identified in Table 6 of this AD to perform the actions that are required by this AD, unless the AD specifies otherwise. Table 6.—Material Incorporated by Reference Service bulletin Revision level Date Boeing Service Bulletin 767-54A0101 1 February 3, 2000. Boeing Service Bulletin 767-54A0101 3 September 5, 2002. Boeing Alert Service Bulletin 767-54A0101 4 February 10, 2005. (1) The Director of the Federal Register approved the incorporation by reference of Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005, in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. (2) On June 9, 2004 (69 FR 24947, May 5, 2004), the Director of the Federal Register approved the incorporation by of Boeing Service Bulletin 767-54A0101, Revision 3, dated September 5, 2002. (3) On May 15, 2001 (66 FR 18523, April 10, 2001), the Director of the Federal Register approved the incorporation by reference of Boeing Service Bulletin 767-54A0101, Revision 1, dated February 3, 2000. (4) Contact Boeing Commercial Airplanes, P.O. Box 3707, Seattle, Washington 98124-2207, 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., room PL-401, Nassif Building, Washington, DC; 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 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 September 13, 2005. Kalene C. Yanamura, Acting Manager, Transport Airplane Directorate, Aircraft Certification Service. [FR Doc. 05-18785 Filed 9-21-05; 8:45 am] BILLING CODE 4910-13-P

This AD was prompted by a report of a crack in a closeout angle that covers the two aft-most fasteners in the lower tang of the midspar fitting; and the discovery of a crack in the lower tang of the midspar fitting under the cracked closeout angle. We are issuing this AD to prevent fatigue cracking in the primary strut structure and reduced structural integrity of the strut, which could result in separation of the strut and engine.