AD 2006-17-07 Airworthiness Directives; Pratt & Whitney JT8D-1, -1A, -1B, -7, -7A, -7B, -9, -9A, -11, -15, -15A, -17, -17A, -17R, -17AR, -209, -217, -217A, -217C, and -219 Turbofan Engines

This AD applies to the following Pratt & Whitney (PW) JT8D-1, -1A, -1B, -7, -7A, -7B, -9, -9A, -11, -15, -15A, -17, -17A, -17R, -17AR, -209, -217, -217A, -217C, and -219 turbofan engines, with 8th stage high pressure compressor (HPC) front hubs: Table 1.—AD Applicability If the HPC front hub is coated with: And if the stage 8-9 spacer is coated with: And the HPC front hub: Then this AD is: (1) PWA 110-21 at any time Any Operated in a JT8D-15, 15A, -17, -17R, or -17AR engine Applicable. See paragraph (f) and Table 2 of this AD. (2) PWA 110-21 at any time Any Operated in a JT8D-209, -217, -217A, -217C, or -219 engine Applicable. See paragraph (h) and Table 4 of this AD. (3) Nickel-Cadmium PWA 110-21 at any time Operated in a JT8D-209, -217, -217A, -217C, or -219 engine Applicable. See paragraph (i) and Table 5 of this AD. (4) Nickel-Cadmium PWA 110-21 at any time Operated in a JT8D-1, -1A, -1B, -7, -7A, -7B, -9, -9A, -11, -15, -15A, -17, -17R, or -17AR engine Not applicable. (5) PWA 110-21 at any time Any Operated in a JT8D-1, -1A, -1B, -7, -7A, -7B, -9, -9A, or -11, but never operated in a JT8D-15, -15A, -17, -17A, -17R, -17AR, -209, -217, -217A, -217C, or -219 engine Not applicable. (6) Nickel-Cadmium Any type but PWA 110-21 Not applicable. These engines are installed on, but not limited to, Boeing DC-9, MD-80 series, 727 series, and 737 series airplanes.

You must accomplish the actions required by this AD within the compliance times specified, unless the actions have already been done. Any engine with an HPC front hub that has been inspected using AD 2002-23-14, AD 2003-12-07, or AD 2003-16-05, is considered in compliance with this AD. JT8D-1, -1A, -1B, -7, -7A, -7B, -9, -9A, -11, -15, -15A, -17, -17A, -17R, and -17AR Turbofan Engines—Inspect or Replace HPC Front Hubs, HPC Disks, and Stage 8-9 Spacers (f) For applicable JT8D-1, -1A, -1B, -7, -7A, -7B, -9, -9A, -11, -15, -15A, -17, -17A, -17R, and -17AR turbofan engines specified in Table 1 of this AD, do the following: (1) Using the inspection schedule in Table 2 of this AD, strip the protective coating, visually inspect for fretting wear, fluorescent magnetic particle inspect (FMPI) for cracks, reidentify, replate HPC front hubs and stage 8-9 spacers, and replace if necessary. (2) Use paragraphs 1. through 3.B.(7)(b) under “For Rear Compressor Front Hubs that Have Operated With PWA 110-21 coating AT ANY TIME During Their Service Life in JT8D-15, -15A, -17, -17A, -17R, -17AR Engine Models.” of PW Alert Service Bulletin (ASB) JT8D A6468, dated December 23, 2004. Table 2.—HPC Front Hub Inspection Schedule HPC front hub cycles-Since-New (CSN) on the effective date of this AD Inspect before additional cycles-in-service (CIS) or CSN, whichever occurs first Also inspect 7th stage HPC disks and 9th stage-through-12th stage HPC disks using: (i) 19,000 or more 500 CIS or 20,000 CSN Paragraph (f)(3) of this AD. (ii) 15,500 or more, but fewer than 19,000 1,000 CIS or 19,500 CSN Paragraph (f)(3) of this AD. (iii) 5,000 or more, but fewer than 15,500 16,500 CSN Paragraph (f)(3) of this AD. (iv) Fewer than 5,000 that are accessible If the parts have been inspected and are acceptable, parts may be reinstalled. Inspect again using the criteria in (iii) of this Table Paragraph (f)(3) of this AD. (3) When the HPC front hub is inspected, visually inspect for fretting wear and FMPI for cracks on 7th stage HPC disks and 9th stage-through-12th stage HPC disks. Inspection information can be found in the applicable sections of JT8D Engine Manual Part Number (P/N) 481672, listed in the following Table 3: Table 3.—Seventh Stage HPC Disks and 9th Stage-Through-12th Stage HPC Disks Inspection Information Stage Chapter/section Visual inspection Fretting inspection FMPI 7 72-36-41 Inspection-01 Inspection-04 Inspection-03. 9 72-36-43 Inspection-01 Inspection-04 Inspection-03. 10 72-36-44 Inspection-01 Inspection-04 Inspection-03. 11 72-36-45 Inspection-01 Inspection-04 Inspection-03. 12 72-36-46 Inspection-01 Inspection-04 Inspection-03. JT8D-15, -15A, -17, -17A, -17R, and -17AR Turbofan Engines—Cycle Adjustment for HPC Front Hubs That Entered Service With Nickel-Cadmium Plating and PWA 110-21 Coating (g) For JT8D-15, -15A, -17, -17A, -17R, and -17AR turbofan engines with front hubs that entered service with Nickel-Cadmium plating and PWA 110-21 coating, but have also operated during the life of the hub with PWA 110-21 coating: (1) You are allowed to make a cycle adjustment if the hub was never operated with a PWA 110-21-coated stage 8-9 spacer. (2) Use the information under “Compliance” of PW ASB JT8D A6468, dated December 23, 2004, to determine the adjustment. JT8D-209, -217, -217A, -217C, and -219 Turbofan Engines—Inspect or Replace HPC Front Hubs and Stage 8-9 Spacers (h) For applicable JT8D-209, -217, -217A, -217C, and -219 turbofan engines specified in Table 1, Row (1) of this AD, do the following: (1) Using the inspection schedule in Table 4 of this AD, strip the protective coating, visually inspect for fretting wear, FMPI for cracking, reidentify, replate HPC front hubs and the stage 8-9 spacers, and replace if necessary. (2) Use paragraphs 1. through 1.A. and paragraphs 2. through 2.C.(2)(g)2 of Accomplishment Instructions of PW ASB JT8D A6430, Revision 2, dated December 23, 2004. Table 4.—HPC Front Hub Inspection Schedule—Hubs Coated With PWA 110-21 HPC front hub CSN on the effective date of this AD Inspect before additional CIS or CSN, whichever occurs first Also inspect 7th stage HPC disks and 9th stage-through-12th stage HPC disks using: (i) 19,000 or more 500 CIS or 20,000 CSN Paragraph (h)(3) of this AD. (ii) 15,500 or more, but fewer than 19,000 1,000 CIS or 19,500 CSN Paragraph (h)(3) of this AD. (iii) 5,000 or more, but fewer than 15,500 16,500 CSN Paragraph (h)(3) of this AD. (iv) Fewer than 5,000 that are accessible If the parts have been inspected and are acceptable, parts may be reinstalled. Inspect again using the criteria in (iii) of this Table Paragraph (h)(3) of this AD. (i) For applicable JT8D-209, -217, -217A, -217C, and -219 turbofan engines specified in Table 1, Row (2) of this AD, do the following: (1) Using the inspection schedule in Table 5 of this AD, strip the protective coating, visually inspect for fretting wear, FMPI for cracking, reidentify, replate HPC front hubs and the stage 8-9 spacers, and replace if necessary. (2) Use paragraphs 1., 1.C, and 4. through 4.C.(2)(g)2 of Accomplishment Instructions of PW ASB JT8D A6430, Revision 2, dated December 23, 2004, for all applicable hubs with any type of coating. Table 5.—HPC Front Hub Inspection Schedule—Hubs Coated With Nickel-Cadmium HPC front hub CSN on the effective date of this AD Inspect before additional CIS or CSN, whichever occurs first Also inspect 7th stage HPC disks and 9th stage-through-12th stage HPC disks using: (i) 19,000 or more 500 CIS or 20,000 CSN Paragraph (h)(3) of this AD. (ii) 17,000 or more, but fewer than 19,000 1,000 CIS or 19,500 CSN Paragraph (h)(3) of this AD. (iii) 9,000 or more, but fewer than 17,000, that have not been inspected 18,000 CSN Paragraph (h)(3) of this AD. (iv) 9,000 or more, but fewer than 17,000, that were inspected before accumulating 9,000 CSN 15,500 CSN Paragraph (h)(3) of this AD. (j) When the HPC front hub is inspected, visually inspect for fretting wear and FMPI for cracks on 7th stage HPC disks and 9th stage-through-12th stage HPC disks. Inspection information can be found in the applicable sections of JT8D-200 Engine Manual P/N 773128, listed in Table 3 of this AD. JT8D-209, -217, -217A, -217C, and -219 Turbofan Engines—Cycle Adjustment for HPC Front Hubs That Entered Service With Nickel-Cadmium Plating and PWA 110-21 Coating (k) For JT8D-209, -217, -217A, -217C, and -219 turbofan engines with HPC front hubs that entered service with Nickel-Cadmium plating, but have also operated during the life of the hub with PWA 110-21 coating: (1) You are allowed to make a cycle adjustment. (2) Use the information under “CONDITION A” of PW ASB JT8D A6430, Revision 2, dated December 23, 2004, to determine the adjustment. Replacement of HPC Front Hubs and Stage 8-9 Spacers That Have Operated With PWA 110-21 Coating, As Optional Action—All Engines (l) For all applicable engines, as an optional action for the visual inspections in this AD, replace HPC front hubs and stage 8-9 spacers that have operated with PWA 110-21 coating in the interface between the hub and the stage 8-9 spacer and HPC disks currently coated with PWA 110-21, as follows: (1) Install a Nickel-Cadmium plated HPC front hub that has never operated with PWA 110-21 coating in the interface between the HPC front hub and the stage 8-9 spacer. (2) Install a Nickel-Cadmium plated or Electroless Nickel-plated stage 8-9 spacer. (3) Install HPC disks that have never operated with PWA 110-21 coating. Prohibition Against Recoating the HPC Front Hub, Stage 7 HPC Disk, and Stage 8-9 Spacer With PWA 110-21—All Engines (m) Do not recoat the HPC front hub with PWA 110-21 (Repair-23 of Chapter/Section 72-36-42 of JT8D-200 Engine Manual, P/N 773128, and Repair-27 and Repair-28 of Chapter/Section 72-36-42 of JT8D Engine Manual, P/N 481672). (n) Do not recoat the 7th stage disk with PWA 110-21 (Repair-15 of Chapter/Section 72-36-41 of JT8D-200 Engine Manual, P/N 773128, and Repair-15 of Chapter/Section 72-36-41 of JT8D Engine Manual, P/N 481672). (o) Do not recoat the stage 8-9 spacer with PWA 110-21 (Repair-03, Task 72-36-12-30-003-002, of Chapter/Section 72-36-12 of JT8D-200 Engine Manual, P/N 773128, and Repair-01, Task 72-36-12-30-001-002, of Chapter/Section 72-36-12 of JT8D Engine Manual, P/N 481672). Prohibition Against Reinstalling HPC Front Hubs and Stage 8-9 Spacers Coated With PWA 110-21 (p) After the effective date of this AD, do not reinstall HPC front hubs and stage 8-9 spacers coated with PWA 110-21. Definition (q) For the purpose of this AD, “accessible” is defined as when the HPC front hub is removed from the engine and the hub is debladed. Alternative Methods of

This AD results from an investigation by PW which concluded that any HPC front hub or HPC disk coated with PWA 110-21 that ever operated on JT8D-15, -15A, -17, -17A, -17R, -17AR, -209, -217, -217A, -217C, and -219 turbofan engines, could crack before reaching their published life limit. We are issuing this AD to prevent a rupture of an HPC front hub or an HPC disk that could result in an uncontained engine failure and damage to the airplane.