AD 2005-25-24 Airworthiness Directives; Boeing Model 777-200 and -300 Series Airplanes

Models named: 777-200, -300 series. Read the applicability below — it usually turns on serial or part numbers too.

This AD applies to Boeing Model 777-200 and -300 series airplanes, certificated in any category, as identified in Boeing Service Bulletin 777-27A0056, Revision 1, dated July 8, 2004.

You are responsible for having the actions required by this AD performed within the compliance times specified, unless the actions have already been done. Detailed Inspections (f) At the applicable compliance time(s) specified in Table 1 of this AD, do detailed inspections of the parts specified in paragraphs (f)(1) through (f)(5) of the left inboard, left outboard, right inboard, and right outboard flaperon PCUs; and do any other specified and corrective actions as applicable; by doing all of the actions specified in the Accomplishment Instructions of Boeing Service Bulletin 777-27A0056, Revision 1, dated July 8, 2004. Do the other specified action and applicable corrective actions before further flight. (1) Forward lugs of the PCU for nicks, gouges, and fretting damage. (2) Aft lugs of the yoke assembly for fretting damage. (3) Aft lugs of the yoke assembly for signs of wear on the anti-rotation lugs, unless paragraph (g) or (h) of this AD, as applicable, has been accomplished. (4) Aft lugs of the yoke assembly bearings for signs of migration or rotation, unless paragraph (g) or (h) of this AD, as applicable, has been accomplished. (5) Attachment hardware for the PCU to yoke assembly for damage. Table 1.—Compliance Times Applicable airplanes Initial inspection Repetitive inspections Group 1 airplanes: Model 777-200 and -300 airplanes powered by General Electric or Pratt & Whitney engines, line numbers (L/Ns) 1 through 297 inclusive Before the accumulation of 5,000 total flight cycles since the date of issuance of the original standard airworthiness and certificate or the date of issuance of the original export certificate of airworthiness; or within 12 months after the effective date of this AD; whichever is later None. Group 2 airplanes: Model 777-200 and -300 airplanes powered by Rolls-Royce engines, L/Ns 1 through 297 inclusive Before the accumulation of 1,000 total flight cycles since the date of issuance of the original standard airworthiness certificate or the date of issuance of the original export certificate of airworthiness; or within 180 days after the effective date of this AD; whichever is later At intervals not to exceed 5,000 flight hours or 750 days, whichever is later. Group 3 airplanes: Model 777-200 and -300 airplanes powered by Rolls-Royce engines, L/Ns 298 and subsequent Before the accumulation of 5,000 total flight hours since the date of issuance of the original standard airworthiness certificate or the date of issuance of the original export certificate of airworthiness; or within 750 days after the effective date of this AD; whichever is later At intervals not to exceed 5,000 flight hours or 750 days, whichever is later. Concurrent Actions for Certain Airplanes (g) For Model 777-200 series airplanes identified in Boeing Service Bulletin 777-27-0009, Revision 1, dated May 8, 2003: Before or concurrently with accomplishing paragraph (f) of this AD, replace the yoke assemblies and pins of the left inboard, left outboard, right inboard, and right outboard flaperon PCUs with new, improved yoke assemblies and pins by doing all of the actions specified in the Accomplishment Instructions of Boeing Service Bulletin 777-27-0009, Revision 1, dated May 8, 2003; except where the service bulletin specifies installing yoke assembly having part number (P/N) 251W1130-1, install yoke assembly having P/N 251W1130-3. Optional Terminating Action for Certain Repetitive Inspections (h) For Model 777-200 and -300 series airplanes identified in Boeing Service Bulletin 777-27-0049, dated August 30, 2001: Replacing the yoke assemblies of the left inboard, left outboard, right inboard, and right outboard flaperon PCUs with new, improved yoke assemblies having improved bearing retention, and doing any other specified and corrective actions, by doing all of the actions specified in the Accomplishment Instructions of Boeing Service Bulletin 777-27-0049, dated August 30, 2001, terminates the detailed inspections required by paragraphs (f)(3) and (f)(4) of this AD. Credit for Pin Replacements of the Outboard Flaperon PCUs (i) Accomplishment of the actions specified in paragraph (b) or (d) of AD 99-13-05, amendment 39-11198, before the effective date of this AD is acceptable for compliance with the pin replacements of the left and right outboard flaperon PCUs required by paragraph (g) of this AD. Parts Installation (j) As of the effective date of this AD, no person may install on any airplane the following parts: Yoke assembly having P/N S251W115-3 or P/N 251W1130-1; and pin having P/N S251W115-2. Alternative Methods of Compliance (AMOCs) (k)(1) The Manager, Seattle 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) Before using any AMOC approved in accordance with 14 CFR 39.19 on any airplane to which the AMOC applies, notify the appropriate principal inspector in the FAA Flight Standards Certificate Holding District Office. (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. Material Incorporated by Reference (l) You must use Boeing Service Bulletin 777-27A0056, Revision 1, dated July 8, 2004; and Boeing Service Bulletin 777-27-0009, Revision 1, dated May 8, 2003, as applicable, to perform the actions that are required by this AD, unless the AD specifies otherwise. The optional terminating action provided by paragraph (h) of this AD, if accomplished, must be done in accordance with Boeing Service Bulletin 777-27-0049, dated August 30, 2001. The Director of the Federal Register approved the incorporation by reference of these documents in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. 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, December 6, 2005. Kevin M. Mullin, Acting Manager, Transport Airplane Directorate, Aircraft Certification Service. [FR Doc. 05-24050 Filed 12-15-05; 8:45 am] BILLING CODE 4910-13-P

This AD results from reports indicating that operators have found worn, fretted, and fractured bolts that attach the yoke assembly to the flaperon power control unit (PCU). We are issuing this AD to prevent damage and eventual fracture of the yoke assembly, pin assembly, and attachment bolts that connect the inboard and outboard PCUs to a flaperon, which could lead to the flaperon becoming unrestrained and consequently departing from the airplane. Loss of a flaperon could result in asymmetric lift and reduced roll control of an airplane. A departing flaperon could also cause damage to the horizontal and vertical stabilizers, which could result in loss of control of the airplane if damage is significant.