AD 2007-03-07 Airworthiness Directives; Boeing Model 737 Airplanes

Models named: 737-100, -200, -200C, -300, -400, -500, -600, -700, -700C, -800. Read the applicability below — it usually turns on serial or part numbers too.

This AD applies to all Boeing Model 737-100, -200, -200C, -300, -400, -500, -600, -700, -700C, -800 and -900 series airplanes, certificated in any category.

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 2002-20-07 R1 Installation (f) Except as provided by paragraphs (h) and (i) of this AD: Within 6 years after November 12, 2002 (the effective date of AD 2002-20-07), do the actions required by paragraphs (f)(1) and (f)(2) of this AD, in accordance with a method approved by the Manager, Seattle Aircraft Certification Office (ACO), FAA. (1) Install a new rudder control system that includes new components such as an aft torque tube, hydraulic actuators, and associated input control rods, and additional wiring throughout the airplane to support failure annunciation of the rudder control system in the flight deck. The system also must incorporate two separate inputs, each with an override mechanism, to two separate servo valves on the main rudder PCU; and an input to the standby PCU that also will include an override mechanism. (2) Make applicable changes to the adjacent systems to accommodate the new rudder control system. New Requirements of This AD For Certain Airplanes: Tests, Suspension of Certain Master Minimum Equipment List Item, Replacements, Inspection, and Corrective Actions (g) For airplanes on which the actions required by paragraph (f) of this AD have been done before the effective date of this AD: Do the actions in paragraphs (g)(1) through (g)(4) of this AD, as applicable. (1) At the applicable times listed in paragraph 1.E., “Compliance,” of the applicable service bulletin specified in Table 2 of this AD; except, where the service bulletin specifies a compliance time from the date on the service bulletin, this AD requires compliance within the specified compliance time after the effective date of this AD: Do the tests specified in Table 2 of this AD, until all applicable actions required by paragraph (g)(4) of this AD have been done in accordance with the applicable service bulletin specified in Table 4 of this AD. Do all applicable corrective actions specified in Table 2 of this AD before further flight. Table 2.—Repetitive Tests for Certain Airplanes For model— Do— In accordance with the accomplishment instructions of— (i) 737-100, -200, and -200C series airplanes identified as Group 1, Configuration 1, in the service bulletin The “Rudder Main Power Control Unit Force Fight Test,” the “Standby Rudder Actuator Shutoff Valve Test,” and any applicable corrective action Boeing Alert Service Bulletin 737-27A1281, dated June 14, 2006. (ii) 737-300, -400, and -500 series airplanes identified as Group 2, Configuration 1, in the service bulletin The “Rudder Main Power Control Unit Force Fight Test,” the “Standby Rudder Actuator Shutoff Valve Test,” and any applicable corrective action Boeing Alert Service Bulletin 737-27A1281, dated June 14, 2006. (iii) 737-600, -700, -700C, -800, and -900 series airplanes identified as Group 1, Configuration 1, in the service bulletin The “Rudder Main Power Control Unit Force Fight Monitor Test,” the “Operational Test of the Standby Hydraulic Actuation System,” and any applicable corrective action Boeing Alert Service Bulletin 737-27A1280, dated May 25, 2006. (iv) 737-600, -700, -700C, -800, and -900 series airplanes identified as Group 2 in the service bulletin The “Rudder Main Power Control Unit Force Fight Monitor Test,” and any applicable corrective action Boeing Alert Service Bulletin 737-27A1280, dated May 25, 2006. (2) At the applicable times listed in Table 3 of this AD, do the “Operational Test of the Standby Hydraulic Actuation System,” and any applicable corrective action, until all applicable actions required by paragraph (g)(4) of this AD have been done in accordance with the applicable service bulletin specified in Table 4 of this AD. The actions must be done in accordance with the Accomplishment Instructions of Boeing Alert Service Bulletin 737-27A1280, dated May 25, 2006. Do all applicable corrective actions before further flight. Table 3.—Repetitive Operational Tests for Certain Airplanes For model— On which the input control rod of the standby rudder PCU— Do the “Operational Test of the Standby Hydraulic Actuation System”— And repeat the test at intervals not to exceed— (i) 737-600, -700, -700C, -800, and -900 series airplanes identified as Group 2 in the service bulletin Has not been replaced as required by paragraph (g)(4)(v) of this AD Within 110 flight hours or 7 days after the effective date of this AD, whichever occurs later 110 flight hours or 7 days, whichever occurs later. (ii) 737-600, -700, -700C, -800, and -900 series airplanes identified as Group 2 in the service bulletin Has been replaced as required by paragraph (g)(4)(v) of this AD Within 60 days after the effective date of this AD 500 flight hours. (3) As of the effective date of this AD, do not use the Master Minimum Equipment List Item 27-21, “STBY RUD ON light,” until all applicable actions required by paragraph (g)(4) of this AD are done. (4) At the applicable time specified in Table 4 of this AD, do the replacement(s) and inspection, as applicable, specified in that table. Do all applicable corrective actions specified in Table 4 of this AD before further flight. Doing all applicable actions ends the requirements of paragraphs (g)(1) through (g)(3) of this AD. Table 4.—Replacement of Input Control Rods, Inspection, and Corrective Action, as Applicable For model— Do the following action(s)— In accordance with— And do the replacement(s) and inspection, as applicable— (i) 737-100, -200, and -200C series airplanes identified as Groups 1 through 9, Configuration 3, in the service bulletin Replace both input control rods of the main rudder PCU with new input control rods Part 2 of the Accomplishment Instructions of Boeing Service Bulletin 737-27-1252, Revision 3, dated May 12, 2006 Within 24 months after the effective date of this AD. (ii) 737-300, -400, and -500 series airplanes identified as Groups 1 through 19, Configuration 3, in the service bulletin Replace both input control rods of the main rudder PCU with new input control rods Part 2 of the Accomplishment Instructions of Boeing Service Bulletin 737-27-1255, Revision 3, dated May 10, 2006 Within 24 months after the effective date of this AD. (iii) 737-600, -700, -700C, -800, and -900 series airplanes identified as Groups 1 through 20, Configuration 3, in the service bulletin Replace both input control rods of the main rudder PCU with new input control rods, inspect the input control rod of the standby rudder PCU to determine if part number (P/N) 251A3495-1 is installed, and do any corrective action Part 2 of the Accomplishment Instructions of Boeing Service Bulletin 737-27-1253, Revision 3, dated May 12, 2006 Within 24 months after the effective date of this AD. (iv) 737-600, -700, -700C, -800, and -900 series airplanes identified as Group 1 in the service bulletin Replace both input control rods of the main rudder PCU with new input control rods The Accomplishment Instructions of Boeing Alert Service Bulletin 737-27A1279, dated June 20, 2006 Within 24 months after the effective date of this AD. (v) 737-600, -700, -700C, -800, and -900 series airplanes identified as Group 1 in the service bulletin Replace the input control rod of the standby rudder PCU with a new input control rod The Accomplishment Instructions of Boeing Alert Service Bulletin 737-27A1279, dated June 20, 2006 Within 90 days after the effective date of this AD. For Certain Other Airplanes: Install New Rudder Control System Per Service Information (h) For airplanes on which the actions required by paragraph (f) of this AD have not been done before the effective date of this AD: As of the effective date of this AD, use the applicable service bulletin specified in Table 5 of this AD to do the actions required by paragraph (f) of this AD at the time specified in that paragraph. Table 5.—Service Bulletins for Installation of New Rudder Control System For model— Identified as— Do the actions required by paragraph (f) of this AD in accordance with— (1) 737-100, -200, and -200C series airplanes Groups 1 through 9, Configurations 1 and 2, in the service bulletin Part 1 of the Accomplishment Instructions of Boeing Service Bulletin 737-27-1252, Revision 3, dated May 12, 2006. (2) 737-300, -400, and -500 series airplanes Groups 1 through 19, Configurations 1 and 2, in the service bulletin Part 1 of the Accomplishment Instructions of Boeing Service Bulletin 737-27-1255, Revision 3, dated May 10, 2006. (3) 737-600, -700, -700C, -800, and -900 series airplanes Groups 1 through 20, Configurations 1 and 2, in the service bulletin Part 1 of the Accomplishment Instructions of Boeing Service Bulletin 737-27-1253, Revision 3, dated May 12, 2006. (i) Before or concurrently with the requirements of paragraph (h) of this AD, do the actions specified in Table 6 of this AD. Table 6.—Before/Concurrent Requirements Before or concurrently with the actions specified in— Do these actions— In accordance with the accomplishment instructions of— (1) Paragraph (h)(1) of this AD (i) Remove the rudder position sensor of the automatic flight control system Boeing Service Bulletin 737-22-1042, Revision 1, dated April 5, 1985.   (ii) Replace the rudder feel and centering assembly with a new all-mechanical unit Boeing 737 Service Bulletin 27-1026, dated January 15, 1971.   (iii) Install the rudder pressure reducer and yaw damper coupler Boeing Service Bulletin 737-27A1206, Revision 3, dated December 14, 2000.   (iv) Install provisional wires for rudder system enhancement Boeing Service Bulletin 737-27-1246, Revision 1, including Appendix A, dated February 21, 2002.   (v) Replace the P5-3 panel with a new panel Boeing Service Bulletin 737-27-1263, Revision 1, dated September 25, 2003.   (vi) Replace the input lever for the auxiliary rudder power control package with a new input lever Smiths Aerospace Actuation Systems Service Bulletin 1150-27-05A, dated August 28, 2003. (2) Paragraph (h)(2) of this AD (i) Install provisional wires for rudder system enhancement Boeing Service Bulletin 737-27-1246, Revision 1, including Appendix A, dated February 21, 2002.   (ii) Replace the P5-3 panel with a new panel Boeing Service Bulletin 737-27-1264, Revision 1, dated April 3, 2003.   (iii) Install a new yaw damper coupler Boeing Service Bulletin 737-27A1206, Revision 3, dated December 14, 2000.   (iv) Inspect the trailing edge beam on the vertical fin and rework if necessary Boeing Service Bulletin 737-55-1052, Revision 1, dated August 5, 2004.   (v) Replace the input lever for the auxiliary rudder power control package with a new input lever Smiths Aerospace Actuation Systems Service Bulletin 1150-27-05A, dated August 28, 2003. (3) Paragraph (h)(3) of this AD (i) Install provisional wires for rudder system enhancement Boeing Service Bulletin 737-27-1247, Revision 1, dated July 25, 2002.   (ii) Replace the P5-3 panel with a new panel Boeing Service Bulletin 737-27-1262, dated December 19, 2002.   (iii) Relocate the wire bundle routing in the vertical stabilizer Boeing Alert Service Bulletin 737-27A1239, dated January 11, 2001. Parts Installation (j) As of the effective date of this AD, no person may install an input control rod, P/N 251A3495-1, on any airplane. Alternative Methods of Compliance (AMOCs) (k)(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) 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) Except as provided by paragraph (j) of this AD: AMOCs approved previously in accordance with AD 2002-20-07 R1 are approved as AMOCs for the corresponding provisions of paragraphs (f) and (h) of this AD. Material Incorporated by Reference (l) You must use the applicable service bulletin specified in Table 7 of this AD to perform the actions that are required by this AD, unless the AD specifies otherwise. Boeing Service Bulletin 737-22-1042, Revision 1, dated April 5, 1985, contains the following effective pages:   Page Nos. Revision level shown on page Date shown on page 1-7, 9 1 April 5, 1985. 8 Original July 1, 1983. 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 FAA, Transport Airplane Directorate, 1601 Lind Avenue, SW., Renton, Washington; or at the National Archives and Records Administration (NARA). For information on the availability of this material at NARA, call 202-741-6030, or go to: http://www.archives.gov/federal-register/cfr/ibr-locations.html. Table 7.—Material Incorporated by Reference Boeing Service Bulletin Revision level Date Boeing Alert Service Bulletin 737-27A1239 Original January 11, 2001. Boeing Alert Service Bulletin 737-27A1279 Original June 20, 2006. Boeing Alert Service Bulletin 737-27A1280 Original May 25, 2006. Boeing Alert Service Bulletin 737-27A1281 Original June 14, 2006. Boeing Alert Service Bulletin 737-22-1042 1 April 5, 1985. Boeing Alert Service Bulletin 737-27A1206 3 December 14, 2000. Boeing Alert Service Bulletin 737-27-1246, including Appendix A 1 February 21, 2002. Boeing Alert Service Bulletin 737-27-1247 1 July 25, 2002. Boeing Alert Service Bulletin 737-27-1252 3 May 12, 2006. Boeing Alert Service Bulletin 737-27-1253 3 May 12, 2006. Boeing Alert Service Bulletin 737-27-1255 3 May 10, 2006. Boeing Alert Service Bulletin 737-27-1262 Original December 19, 2002. Boeing Alert Service Bulletin 737-27-1263 1 September 25, 2003. Boeing Alert Service Bulletin 737-27-1264 1 April 3, 2003. Boeing Alert Service Bulletin 737-55-1052 1 August 5, 2004. Boeing 737 Alert Service Bulletin 27-1026 Original January 15, 1971. Smiths Aerospace Actuation Systems Service Bulletin 1150-27-05A Original August 28, 2003. Issued in Renton, Washington, on January 25, 2007. Ali Bahrami, Manager, Transport Airplane Directorate, Aircraft Certification Service. [FR Doc. E7-1496 Filed 1-31-07; 8:45 am] BILLING CODE 4910-13-P

This AD results from a report of a fractured rod end of an input control rod of the main rudder power control unit (PCU) and a subsequent report of a fractured rod end of the input control rod of the standby rudder PCU. We are issuing this AD to prevent failure of one of the two input control rods of the main rudder PCU, which, under certain conditions, could result in reduced controllability of the airplane; and to prevent failure of any combination of two input control rods of the main rudder PCU and/or standby rudder PCU, which could cause an uncommanded rudder hardover event and result in loss of control of the airplane.