AD 2021-20-19 Airworthiness Directives; The Boeing Company Airplanes

Models named: 767-200, -300, -300F, -400ER series. Read the applicability below — it usually turns on serial or part numbers too.

This AD applies to The Boeing Company Model 767-200, -300, -300F, and -400ER series airplanes, certificated in any category, having line numbers (L/N) 1 through 1200 inclusive.

Comply with this AD within the compliance times specified, unless already done.

Within 60 days after the effective date of this AD, revise the existing maintenance or inspection program, as applicable, to incorporate the applicable information in Section A, including Subsections A.1, A.2, A.3, A.4, and A.5, of Boeing 767-200/300/300F/400ER Special Compliance Items/Airworthiness Limitations, D622T001-9-04, dated January 2020; except as provided by paragraph (h) of this AD. The initial compliance times for the airworthiness limitation instructions (ALI) tasks are within the applicable compliance times specified in paragraphs (g)(1) through (14) of this AD: (1) For airplanes identified in the applicability for AWL No. 28-AWL-01, “External Wires Over Auxiliary (Center) Fuel Tank”: At the applicable time specified in paragraph (g)(1)(i) or (ii) of this AD. (i) For airplanes that did not have any version of AWL No. 28-AWL-01 in their maintenance or inspection program before the effective date of this AD: Within 144 months since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within 12 months after the effective date of this AD, whichever occurs later. (ii) For airplanes not identified in paragraph (g)(1)(i) of this AD: Within 144 months since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within 144 months after the most recent inspection, if any, was performed as specified in AWL No. 28-AWL-01; whichever occurs later. (2) For airplanes identified in the applicability for AWL No. 28-AWL-05, “Lightning Protection—Hydraulic Line Fuel Tank Penetration Bonding Path”: At the applicable time specified in paragraph (g)(2)(i) or (ii) of this AD. (i) For airplanes that did not have any version of AWL No. 28-AWL-05 in their maintenance or inspection program before the effective date of this AD: At the later of the times specified in paragraphs (g)(2)(i)(A) and (B) of this AD. (A) Within 25,000 flight hours or 72 months, whichever occurs first since issuance of the original airworthiness certificate or original export certificate of airworthiness. (B) Within 60 days after the effective date of this AD. (ii) For airplanes not identified in paragraph (g)(2)(i) of this AD: At the later of the times specified in paragraphs (g)(2)(ii)(A) and (B) of this AD. (A) Within 25,000 flight hours or 72 months, whichever occurs first since issuance of the original airworthiness certificate or original export certificate of airworthiness. (B) Within 25,000 flight hours or 72 months, whichever occurs first after the most recent inspection, if any, was performed as specified in AWL No. 28-AWL-05. (3) For airplanes identified in the applicability for AWL No. 28-AWL-18, “Fuel Quantity Indicating System (FQIS)—Out of Tank Wiring Lightning Shield to Ground Termination”: At the applicable time specified in paragraph (g)(3)(i) or (ii) of this AD. (i) For airplanes that did not have any version of AWL No. 28-AWL-18 in their maintenance or inspection program before the effective date of this AD: Within 144 months since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within 12 months after the effective date of this AD, whichever occurs later. (ii) For airplanes not identified in paragraph (g)(3)(i) of this AD: Within 144 months since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within 144 months after the most recent inspection, if any, was performed as specified in AWL No. 28-AWL-18; whichever occurs later. (4) For airplanes identified in the applicability for AWL No. 28-AWL-20, “Auxiliary (Center) Tank Override Fuel Pumps Auto Shutoff Circuit”: At the applicable time specified in paragraph (g)(4)(i) or (ii) of this AD. (i) For airplanes that did not have any version of AWL No. 28-AWL-20 in their maintenance or inspection program before the effective date of this AD: Within 12 months since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within 60 days after the effective date of this AD, whichever occurs later. (ii) For airplanes not identified in paragraph (g)(4)(i) of this AD: At the latest of the times specified in paragraphs (g)(4)(ii)(A) through (C) of this AD. (A) Within 12 months since issuance of the original airworthiness certificate or original export certificate of airworthiness. (B) Within 12 months after the most recent inspection, if any, was performed as specified in AWL No. 28-AWL-20. (C) Within 12 months after accomplishment of the actions specified in Boeing Service Bulletin 767-28A0083 or Boeing Service Bulletin 767-28A0084, as applicable. (5) For airplanes identified in the applicability for AWL No. 28-AWL-21, “AC and DC Fuel Pump Fault Current Bonding Jumper Installation”: At the applicable time specified in paragraph (g)(5)(i) or (ii) of this AD. (i) For airplanes that did not have any version of AWL No. 28-AWL-21 in their maintenance or inspection program before the effective date of this AD: Within 72 months since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within 6 months after the effective date of this AD, whichever occurs later. (ii) For airplanes not identified in paragraph (g)(5)(i) of this AD: Within 72 months since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within 72 months after the most recent inspection, if any, was performed as specified in AWL No. 28-AWL-21; whichever occurs later. (6) For airplanes identified in the applicability for AWL No. 28-AWL-27, “Over-Current and Arcing Protection Electrical Design Features Operation—AC Fuel Pump Ground Fault Interrupter (GFI)”: At the applicable time specified in paragraph (g)(6)(i) or (ii) of this AD. (i) For airplanes that did not have any version of AWL No. 28-AWL-27 in their maintenance or inspection program before the effective date of this AD: Within 12 months since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within 60 days after the effective date of this AD, whichever occurs later. (ii) For airplanes not identified in paragraph (g)(6)(i) of this AD: At the latest of the times specified in paragraphs (g)(6)(ii)(A) through (C) of this AD. (A) Within 12 months since issuance of the original airworthiness certificate or original export certificate of airworthiness. (B) Within 12 months after the most recent inspection, if any, was performed as specified in AWL No. 28-AWL-27. (C) Within 12 months after accomplishment of the actions specified in Boeing Service Bulletin 767-28A0085. (7) For airplanes identified in the applicability for AWL No. 28-AWL-28, “Auxiliary (Center) Tank Override/Jettison Fuel Pump Failed On Protection System”: At the applicable time specified in paragraph (g)(7)(i) or (ii) of this AD. (i) For airplanes that did not have any version of AWL No. 28-AWL-28 in their maintenance or inspection program before the effective date of this AD: Within 12 months since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within 60 days after the effective date of this AD, whichever occurs later. (ii) For airplanes not identified in paragraph (g)(7)(i) of this AD: At the latest of the times specified in paragraphs (g)(7)(ii)(A) through (C) of this AD. (A) Within 12 months since issuance of the original airworthiness certificate or original export certificate of airworthiness. (B) Within 12 months after the most recent inspection, if any, was performed as specified in AWL No. 28-AWL-28. (C) Within 12 months after accomplishment of the actions specified in Boeing Service Bulletin 767-28A0085. (8) For airplanes identified in the applicability for AWL No. 28-AWL-35, “Cushion Clamps and Teflon Sleeving Installed on Out-of-Tank Wire Bundles Installed on Brackets that are Mounted Directly on the Fuel Tanks”: At the applicable time specified in paragraph (g)(8)(i) or (ii) of this AD. (i) For airplanes that did not have any version of AWL No. 28-AWL-35 in their maintenance or inspection program before the effective date of this AD: Within 144 months since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within 12 months after the effective date of this AD, whichever occurs later. (ii) For airplanes not identified in paragraph (g)(8)(i) of this AD: At the latest of the times specified in paragraphs (g)(8)(ii)(A) through (C) of this AD. (A) Within 144 months since issuance of the original airworthiness certificate or original export certificate of airworthiness. (B) Within 144 months after the most recent inspection, if any, was performed as specified in AWL No. 28-AWL-35. (C) Within 144 months after accomplishment of the actions specified in Boeing Service Bulletin 767-57A0102. (9) For airplanes identified in the applicability for AWL No. 28-AWL-37, “FQIS BITE Test (Auxiliary (Center) Tank Circuit Test)”: At the applicable time specified in paragraph (g)(9)(i) or (ii) of this AD. (i) For airplanes that did not have any version of AWL No. 28-AWL-37 in their maintenance or inspection program before the effective date of this AD: Within 750 flight hours since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within 60 days after the effective date of this AD, whichever occurs later. (ii) For airplanes not identified in paragraph (g)(9)(i) of this AD: Within 750 flight hours since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within 750 flight hours after the most recent inspection, if any, was performed as specified in AWL No. 28-AWL-37; whichever occurs later. (10) For airplanes identified in the applicability for AWL No. 28-AWL-38, “Fuel Level Sensing System (FLSS) Dry Capacitance Test”: At the applicable time specified in paragraph (g)(10)(i) or (ii) of this AD. (i) For airplanes that did not have any version of AWL No. 28-AWL-38 in their maintenance or inspection program before the effective date of this AD: Within 750 flight hours since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within 60 days after the effective date of this AD, whichever occurs later. (ii) For airplanes not identified in paragraph (g)(10)(i) of this AD: Within 750 flight hours since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within 750 flight hours after the most recent inspection, if any, was performed as specified in AWL No. 28-AWL-38; whichever occurs later. (11) For airplanes identified in the applicability for AWL No. 28-AWL-101, “Engine Fuel Suction Feed Operational Test”: At the applicable time specified in paragraph (g)(11)(i) or (ii) of this AD. (i) For airplanes that did not have any version of AWL No. 28-AWL-101 in their maintenance or inspection program before the effective date of this AD: At the later of the times specified in paragraphs (g)(11)(i)(A) and (B) of this AD. (A) Within 7,500 flight hours or 36 months, whichever occurs first since issuance of the original airworthiness certificate or original export certificate of airworthiness. (B) Within 60 days after the effective date of this AD. (ii) For airplanes not identified in paragraph (g)(11)(i) of this AD: At the later of the times specified in paragraphs (g)(11)(ii)(A) and (B) of this AD. (A) Within 7,500 flight hours or 36 months, whichever occurs first since issuance of the original airworthiness certificate or original export certificate of airworthiness. (B) Within 7,500 flight hours or 36 months, whichever occurs first after the most recent inspection, if any, was performed as specified in AWL No. 28-AWL-101. (12) For airplanes identified in the applicability for AWL No. 28-AWL-102, “Fuel Quantity Indicating System (FQIS)— Low Fuel and Fuel Config Indication Test”: At the applicable time specified in paragraph (g)(12)(i) or (ii) of this AD. (i) For airplanes that did not have any version of AWL No. 28-AWL-102 in their maintenance or inspection program before the effective date of this AD: Within 750 flight hours since issuance of the original airworthiness certificate or original export certificate of airworthiness; or within 60 days after the effective date of this AD, whichever occurs later. (ii) For airplanes not identified in paragraph (g)(12)(i) of this AD: At the latest of the times specified in paragraphs (g)(12)(ii)(A) through (C) of this AD. (A) Within 750 flight hours since issuance of the original airworthiness certificate or original export certificate of airworthiness. (B) Within 750 flight hours after the most recent inspection, if any, was performed as specified in AWL No. 28-AWL-102. (C) Within 750 flight hours after accomplishment of the actions specified in Boeing Service Bulletin 767-31-0295 or Boeing Service Bulletin 767-31-0302, as applicable. (13) For airplanes identified in the applicability for AWL No. 47-AWL-04, “Nitrogen Generation System (NGS)—Nitrogen-Enriched Air (NEA) Distribution Ducting”: At the applicable time specified in paragraph (g)(13)(i) or (ii) of this AD. (i) For airplanes that did not have any version of AWL No. 47-AWL-04 in their maintenance or inspection program before the effective date of this AD: Within the applicable interval specified in AWL No. 47-AWL-04 since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within 4 months after the effective date of this AD, whichever occurs later. (ii) For airplanes not identified in paragraph (g)(13)(i) of this AD: Within the applicable interval specified in AWL No. 47-AWL-04 since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within that applicable interval since the most recent inspection, if any, was performed as specified in AWL No. 47-AWL-04; whichever occurs later. (14) For airplanes identified in the applicability for AWL No. 47-AWL-05, “Nitrogen Generation System (NGS)—Cross Vent Check Valve”: At the applicable time specified in paragraph (g)(14)(i) or (ii) of this AD. (i) For airplanes that did not have any version of AWL No. 47-AWL-05 in their maintenance or inspection program before the effective date of this AD: Within the applicable interval specified in AWL No. 47-AWL-05 since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within 4 months after the effective date of this AD, whichever occurs later. (ii) For airplanes not identified in paragraph (g)(14)(i) of this AD: Within the applicable interval specified in AWL No. 47-AWL-05 since issuance of the original airworthiness certificate or original export certificate of airworthiness, or within that applicable interval since the most recent inspection, if any, was performed as specified in AWL No. 47-AWL-05; whichever occurs later.

This AD was prompted by significant changes made to the airworthiness limitations (AWLs) related to fuel tank ignition prevention and the nitrogen generation system. The FAA is issuing this AD to address the potential for ignition sources inside fuel tanks caused by latent failures, alterations, repairs, or maintenance actions, which, in combination with flammable fuel vapors, could result in a fuel tank explosion and consequent loss of the airplane.

This AD affects the ADs specified in paragraphs (b)(1) through (7) of this AD. (1) AD 2008-11-01 R1, Amendment 39-16145 (74 FR 68515, December 28, 2009) (AD 2008-11-01 R1). (2) AD 2010-06-10, Amendment 39-16234 (75 FR 15322, March 29, 2010) (AD 2010-06-10). (3) AD 2011-25-05, Amendment 39-16881 (77 FR 2442, January 18, 2012) (AD 2011-25-05). (4) AD 2013-25-02, Amendment 39-17698 (79 FR 24541, May 1, 2014) (AD 2013-25-02). (5) AD 2014-08-09, Amendment 39-17833 (79 FR 24546, May 1, 2014) (AD 2014-08-09). (6) AD 2014-20-02, Amendment 39-17975 (79 FR 59102, October 1, 2014) (AD 2014-20-02). (7) AD 2018-20-13, Amendment 39-19447 (83 FR 52305, October 17, 2018) (AD 2018-20-13).