AD 2006-07-10 Airworthiness Directives; Boeing Model 727 Airplanes

Models named: 727, 727C, 727-100, 727-100C, 727-200, 727-200F. Read the applicability below — it usually turns on serial or part numbers too.

This AD applies to Boeing Model 727, 727C, 727-100, 727-100C, 727-200, and 727-200F airplanes, certificated in any category; as identified in Boeing Alert Service Bulletin 727-53A0153, Revision 7, dated August 14, 2003.

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 Certain Requirements of AD 91-09-07 (f) For airplanes listed in Boeing Service Bulletin 727-53-0153, Revision 5, dated December 14, 1989: Visually inspect the forward entry doorway frame for cracks in accordance with Boeing Service Bulletin 727-53-0153, dated February 1, 1980, or Revisions 1 through 5, at the earlier of the times indicated in subparagraphs (f)(1) or (f)(2) of this AD. Repeat the inspection at intervals not to exceed 3,700 landings until accomplishment of the one-time high frequency eddy current (HFEC) inspection for cracking and the one-time dimensional inspection for anomalies required by paragraph (i) of this AD, or the one-time dimensional inspection for anomalies and the initial HFEC inspection for cracking of the forward frame of the forward entry doorway at BS 303.9 specified in paragraph (h) of this AD, as applicable. (1) Within the next 1,850 landings after March 11, 1983 (the effective date of AD 83-03-01, amendment 39-4561), or prior to accumulating a total of 25,000 landings, whichever occurs later; or (2) Within the next 1,850 landings after May 16, 1986 (the effective date of AD 83-03-01 R1, amendment 39-5283), or prior to accumulating a total of 15,000 landings, whichever occurs later. (g) For airplanes modified in accordance with Boeing Service Bulletin 727-53-0153, dated February 1, 1980; through Revision 4, dated November 8, 1985; conduct the inspections described in paragraph (f) of this AD prior to the accumulation of 10,000 landings after the modification or within the next 3,700 landings after May 28, 1991 (the effective date of AD 91-09-07), whichever occurs later. Repeat the inspection at intervals not to exceed 3,700 landings until accomplishment of the one-time HFEC inspection for cracking and the one-time dimensional inspection for anomalies required by paragraph (i) of this AD, or the one-time dimensional inspection for anomalies and the initial HFEC inspection for cracking of the forward frame of the forward entry doorway at BS 303.9 specified in paragraph (h) of this AD, as applicable. New Requirements of This AD Repetitive Inspections for Certain Airplanes (h) For Group 1 airplanes as defined by Boeing Alert Service Bulletin (ASB) 727-53A0153, Revision 7, dated August 14, 2003, with the exception of certain Group 1 airplanes specified in paragraph (i) of this AD: Perform a one-time dimensional inspection for anomalies (e.g., minimum dimension requirements, jagged edges, chafing, nicks, or gouges) of the web cutouts at stringers S-15 and S-16, and HFEC inspections for cracking of the forward frame of the forward entry doorway at BS 303.9; in accordance with Figure 1 of the Accomplishment Instructions of Revision 7 of the ASB at the times specified in paragraph (h)(1) or (h)(2) of this AD, as applicable. With the exception of the one-time dimensional inspection (Step 1 of Figure 1) of the web cutouts at S-15L and S-16L, repeat the HFEC inspections for cracking of the forward frame of the forward entry doorway at BS 303.9 at intervals not to exceed 3,700 flight cycles until the requirements of paragraph (l) of this AD have been accomplished. (1) For Group 1 airplanes that have not been modified or repaired in accordance with any issue of the service bulletin through Revision 7 inclusive specified in Table 1 of this AD: Perform the inspection before the accumulation of 15,000 total flight cycles, or within 1,800 flight cycles after the effective date of this AD, whichever occurs later. Table 1.—Service bulletin Revisions Service bulletin Revision level Date Boeing Service Bulletin 727-53-153 Original February 1, 1980. Boeing Service Bulletin 727-53-153 Revision 1 June 19, 1981. Boeing Service Bulletin 727-53-153 Revision 2 December 3, 1982. Boeing Service Bulletin 727-53-153 Revision 3 June 17, 1983. Boeing Service Bulletin 727-53-153 Revision 4 November 8, 1985. Boeing Service Bulletin 727-53-0153 Revision 5 December 14, 1989. Boeing Service Bulletin 727-53-0153 Revision 6 August 27, 1992. Boeing Alert Service Bulletin 727-53A153 Revision 7 August 14, 2003. (2) For Group 1 airplanes that have been modified as specified in Boeing Repair Kit 65C20303-1 in accordance with any issue of the service bulletin through Revision 4 inclusive as specified in Table 1 of this AD: Perform the inspection before the accumulation of 10,000 flight cycles after the modification, or within 1,800 flight cycles after the effective date of this AD, whichever occurs later. One-Time Inspections and Terminating Actions for Certain Other Airplanes (i) For Group 1 airplanes, as defined by Boeing ASB 727-53A0153, Revision 7, dated August 14, 2003, that have been modified in accordance with Revision 5 or 6 of Boeing Service Bulletin 727-53-0153 as specified in Table 1 of this AD, or that have been repaired in accordance with Boeing Repair Kit 65C20303-8 or -25 as specified in Revision 2 through Revision 6 inclusive of the service bulletin as specified in Table 1 of this AD: Within 4,500 flight cycles after the effective date of this AD, do a one-time HFEC for cracking and a dimensional inspection for any anomaly (e.g., minimum dimension requirements, jagged edges, chafing, nicks or gouges) of the web cutouts at stringers S-15L and S-16L of the forward frame of the forward entry doorway at BS 303.9, in accordance with Step 1 and Step 2 of Figure 1 of the Accomplishment Instructions of Boeing ASB 727-53A0153, Revision 7, dated August 14, 2003. For these airplanes, accomplishment of the HFEC, dimensional inspections, and any applicable corrective actions, constitutes terminating action for all the repetitive inspection requirements of this AD. Inspections for Group 2 Airplanes (j) For Group 2 airplanes, as defined by Boeing ASB 727-53A0153, Revision 7, dated August 14, 2003, that have not been modified or repaired in accordance with Revision 7 of the ASB: Before the accumulation of 17,000 total flight cycles, or within 4,500 flight cycles after the effective date of this AD, whichever occurs later, perform a one-time dimensional inspection for anomalies ( e.g. , minimum dimension requirements, jagged edges, chafing, nicks, or gouges) of the web cutouts at stringers S-15 and S-16, and HFEC inspections for cracking of the forward frame of the forward entry doorway at BS 303.9; in accordance with Figure 2 of the Accomplishment Instructions of Revision 7 of the ASB. With the exception of the one-time dimensional inspection (Step 1 of Figure 2) of the web cutouts at S-15L and S-16L, repeat the HFEC inspections for cracking of the forward frame of the forward entry doorway at BS 303.9 at intervals not to exceed 3,700 flight cycles until the requirements of paragraph (l) of this AD have been accomplished. Corrective Actions (k) If any cracking is detected during any inspection, or any anomaly is detected during any dimensional inspection required by this AD: Before further flight, accomplish the actions in paragraph (k)(1) or (k)(2) of this AD, as applicable. (1) For any cracking that is within the limits specified in the Accomplishment Instructions of Boeing ASB 727-53A0153, Revision 7, dated August 14, 2003: Repair the cracking in accordance with Revision 7 of the ASB. (2) For any cracking that is outside the limits specified in the Accomplishment Instructions of Boeing ASB 727-53A0153, Revision 7, dated August 14, 2003, or for any anomaly that is detected during any dimensional inspection required by this AD: Repair in accordance with a method approved by the Manager, Seattle Aircraft Certification (ACO), FAA; or in accordance with the procedures specified in paragraph (n) of this AD. Terminating Actions for Certain Airplanes (l) For airplanes specified in paragraph (l)(1) or (l)(2) of this AD: At the time specified in paragraph (m) of this AD, perform the inspections specified in Figure 1 or Figure 2, as applicable, of Revision 7 of Boeing ASB 727-53A0153, dated August 14, 2003, and as specified by paragraph (h) or (j) of this AD, as applicable. Before further flight, following the inspections, modify the forward frame in accordance with the Accomplishment Instructions of Revision 7 of the ASB. Concurrent accomplishment of the inspections and modification constitutes terminating action for the repetitive inspections required by this AD. (1) Group 1 airplanes that have not been modified or repaired in accordance with Boeing Repair Kit 65C20303-8 or -25, as specified in Boeing Service Bulletin 727-53-153, Revision 2, dated December 3, 1982; Revision 3, dated June 17, 1983; or Revision 4, dated November 8, 1985; Boeing Service Bulletin 727-53-0153, Revision 5, dated December 14, 1989; or Revision 6, dated August 27, 1992; or Boeing ASB 727-53A0153, Revision 7, dated August 14, 2003. (2) Group 2 airplanes that have not been repaired or modified in accordance with Revision 7 of Boeing ASB 727-53A0153, dated August 14, 2003. Note 1: Accomplishment of the terminating actions specified in paragraph (i) or (l) of this AD does not relieve the operator of responsibility to comply with the inspection requirements of the operator's standard structural maintenance program. Compliance Times for the Requirements of Paragraph (l) of This AD (m) Accomplish the actions required in paragraph (l) of this AD at the later of the times specified in paragraph (m)(1) or (m)(2) of this AD. (1) Prior to the accumulation of 60,000 total flight cycles. (2) Within 48 months or 7,200 flight cycles after the effective date of this AD, whichever occurs first. Alternative Methods of Compliance (AMOCs) (n)(1) The Manager, Seattle ACO, 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 § 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. (4) AMOCs approved previously in accordance with AD 91-09-07, amendment 39-6982, are approved as AMOCs with the corresponding requirements and provisions of this AD. (5) Accomplishment of the actions specified in paragraph (l) of this AD constitutes an AMOC with paragraph A. of AD 90-06-09, amendment 39-6488, only for the structural modification requirements of Boeing Service Bulletin 727-53-153, as specified in Boeing Document D6-54860, Revision C, dated December 11, 1989, which is the appropriate source of service information specified by AD 90-06-09. Material Incorporated by Reference (o) You must use the applicable service bulletins or alert service bulletin specified in Table 2 of this AD to perform the actions that are required by this AD, unless the AD specifies otherwise. Boeing Service Bulletin 727-53-153, Revision 1, including Addendum, dated June 19, 1981, contains the following effective pages:   Page No. Revision level shown on page Date shown on page 1-25 1 June 19, 1981. 26 Original February 1, 1980. Addendum 1-6 1 June 19, 1981. Boeing Service Bulletin 727-53-153, Revision 4, including Addendum, dated November 8, 1985, contains the following effective pages:   Page number Revision level shown on page Date shown on page 1-11, 13-19, 21 4 November 8, 1985. 12, 20, 22 3 June 17, 1983. Addendum 1, 4 3 June 17, 1983. 2, 3, 5, 6 4 November 8, 1985. 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. Table 2.—Material Incorporated by Reference Service bulletin Revision level Date 1. Boeing Service Bulletin 727-53-153 Original February 1, 1980. 2. Boeing Service Bulletin 727-53-153, including Addendum Revision 1 June 19, 1981. 3. Boeing Service Bulletin 727-53-153, including Addendum Revision 2 December 3, 1982. 4. Boeing Service Bulletin 727-53-153, including Addendum Revision 3 June 17, 1983. 5. Boeing Service Bulletin 727-53-153, including Addendum Revision 4 November 8, 1985. 6. Boeing Service Bulletin 727-53-0153, including Addendum Revision 5 December 14, 1989. 7. Boeing Alert Service Bulletin 727-53A0153 Revision 7 August 14, 2003. Issued in Renton, Washington, on March 17, 2006. Ali Bahrami, Manager, Transport Airplane Directorate, Aircraft Certification Service. [FR Doc. 06-3065 Filed 3-31-06; 8:45 am] BILLING CODE 4910-13-P

This AD was prompted by reports of cracking of the forward frame of the forward entry doorway of airplanes previously modified. We are issuing this AD to prevent the loss of the structural integrity of the forward entry doorway due to cracking at Body Station (BS) 303.9, and consequent cracking of the fuselage skin and rapid decompression of the airplane.