AD 97-12-03 Airworthiness Directives; Boeing Model 747 Series Airplanes

Models named: 747 series. Read the applicability below — it usually turns on serial or part numbers too.

Model 747 series airplanes as listed in Boeing Alert Service Bulletin 747-54A2179, Revision 1, dated November 27, 1996; certificated in any category, except for airplanes on which the strut/wing modification has been accomplished in accordance with the following Boeing alert service bulletins: 1. Boeing Alert Service Bulletin 747-54A2157, dated January 12, 1995; Revision 1, dated August 3, 1995; or Revision 2, dated November 14, 1996; 2. Boeing Alert Service Bulletin 747-54A2158, dated November 30, 1994; Revision 1, dated August 17, 1995; or Revision 2, dated August 15, 1996; or 3. Boeing Alert Service Bulletin 747-54A2159, dated November 3, 1994; Revision 1, dated June 1, 1995; or Revision 2, dated March 14, 1996. Note 1: This AD applies to each airplane identified in the preceding applicability provision, regardless of whether it has been otherwise modified, altered, or repaired in the area subject to the requirements of this AD. For airplanes that have been modified, altered, or repaired so that the performance of the requirements of this AD is affected, the owner/operator must request approval for an alternative method of compliance in accordance with paragraph (n) of this AD. The request should include an assessment of the effect of the modification, alteration, or repair on the unsafe condition addressed by this AD; and, if the unsafe condition has not been eliminated, the request should include specific proposed actions to address it.

Required as indicated, unless accomplished previously. To prevent drooping of the strut at the strut-to-wing interface, and consequent separation of the engine and strut from the airplane due to cracking or fracturing of the midspar fitting clevis, accomplish the following: Restatement of Requirements of AD 96-25-01 (a) For all airplanes: Except as provided by paragraph (d) of this AD, perform a detailed visual borescope inspection to detect cracking, corrosion, and/or fracturing of the lower horizontal clevis of both midspar fittings of the inboard struts, in accordance with Boeing Alert Service Bulletin 747-54A2179, dated June 27, 1996, or Revision 1, dated November 27, 1996, at the time specified in paragraph (a)(1), (a)(2), (a)(3), or (a)(4) of this AD, as applicable. (1) For airplanes identified as Group 1 or Group 6 in the alert service bulletin: Perform the initial inspection at the time specified in paragraph (a)(1)(i) or (a)(1)(ii), as applicable. Thereafter, repeat this inspection at intervals not to exceed every 150 flight cycles, or every 3 months, whichever occurs first. (i) Within 150 flight cycles or 60 days after January 2, 1997 (the effective date of AD 96-25-01, amendment 39-9842), whichever occurs first. Or (ii) For airplanes on which terminating action has been accomplished within 500 flight cycles prior to January 2, 1997, in accordance with Boeing Service Bulletin 747-54-2118, Revision 1, dated May 21, 1987; Revision 2, dated April 21, 1988; Revision 3, dated September 29, 1988; or Revision 4, dated May 11, 1989: Perform the initial inspection within 500 flight cycles or 12 months after January 2, 1997, whichever occurs first. (2) For airplanes identified as Group 2 or Group 4 in the alert service bulletin: Perform the initial inspection at the time specified in paragraph (a)(2)(i) or (a)(2)(ii) of this AD, as applicable. Thereafter, repeat this inspection at intervals not to exceed every 300 flight cycles or 6 months, whichever occurs first. (i) Within 150 flight cycles or 60 days after January 2, 1997, whichever occurs first. Or (ii) For airplanes on which terminating action has been accomplished within 1,000 flight cycles prior to January 2, 1997, in accordance with Boeing Service Bulletin 747-54-2118, Revision 1, dated May 21, 1987; Revision 2, dated April 21, 1988; Revision 3, dated September 29, 1988; or Revision 4, dated May 11, 1989: Perform the initial inspection within 1,000 flight cycles or 12 months after January 2, 1997, whichever occurs first. (3) For airplanes identified as Group 3 in the alert service bulletin: Perform the initial inspection at the time specified in paragraph (a)(3)(i) or (a)(3)(ii) of this AD, as applicable. Thereafter, repeat this inspection at intervals not to exceed every 350 flight cycles or 6 months, whichever occurs first. (i) Within 150 flight cycles or 60 days after January 2, 1997, whichever occurs first. Or (ii) For airplanes on which terminating action has been accomplished within 1,000 flight cycles prior to January 2, 1997, in accordance with Boeing Service Bulletin 747-54-2118, Revision 1, dated May 21, 1987; Revision 2, dated April 21, 1988; Revision 3, dated September 29, 1988; or Revision 4, dated May 11, 1989: Perform the initial inspection within 1,000 flight cycles or 12 months after January 2, 1997, whichever occurs first. (4) For airplanes identified as Group 5 in the alert service bulletin: Perform the initial inspection at the time specified in paragraph (a)(4)(i) or (a)(4)(ii) of this AD, as applicable. Thereafter, repeat the inspection at intervals not to exceed every 300 flight cycles or 6 months, whichever occurs first. (i) Within 150 flight cycles or 60 days after January 2, 1997, whichever occurs first. (ii) For airplanes on which terminating action has been accomplished within 800 flight cycles prior to January 2, 1997, in accordance with Boeing Service Bulletin 747-54-2118, Revision 1, dated May 21, 1987; Revision 2, dated April 21, 1988; Revision 3, dated September 29, 1988; or Revision 4, dated May 11, 1989: Perform the initial inspection within 800 flight cycles or 12 months after January 2, 1997, whichever occurs first. (b) For airplanes identified as Group 1 in Boeing Alert Service Bulletin 747-54A2179, dated June 27, 1996, or Revision 1, dated November 27, 1996: Except as provided by paragraph (e) of this AD, perform a detailed visual borescope inspection to detect cracking, corrosion, and/or fracturing of the lower horizontal clevis of both midspar fittings of the outboard struts, in accordance with Boeing Alert Service Bulletin 747-54A2179, dated June 27, 1996, or Revision 1, dated November 27, 1996, at the time specified in paragraph (b)(1) or (b)(2) of this [[Page 31335]] AD, as applicable. Thereafter, repeat the inspection at intervals not to exceed every 300 flight cycles or 6 months, whichever occurs first. (1) Within 200 flight cycles or 60 days after January 2, 1997, whichever occurs first. Or (2) For airplanes on which the terminating action has been accomplished within the last 1,000 flight cycles prior to January 2, 1997, in accordance with Boeing Service Bulletin 747-54-2118, Revision 1, dated May 21, 1987; Revision 2, dated April 21, 1988; Revision 3, dated September 29, 1988; or Revision 4, dated May 11, 1989: Perform the inspection within 1,000 flight cycles or 12 months after January 2, 1997, whichever occurs first. New Requirements of this AD (c) For all airplanes: After the effective date of this AD, prior to the accomplishment of each inspection required by paragraph (a), (b), (d), or (e), of this AD, remove the sealant common to the lower leg of the horizontal clevis of the inboard (for all airplanes) midspar fittings, and the outboard (for Groups 1 and 6 airplanes) and clean the midspar fittings, in accordance with Boeing Alert Service Bulletin 747-54A2179, Revision 1, dated November 27, 1996. Prior to further flight following accomplishment of these actions, apply corrosion inhibitive compound BMS 3-23 to any area where the original sealant was removed or disturbed, in accordance with Boeing Standard Operational Procedures (BSOP) 20-41-05 for Model 747 series airplanes. (d) Accomplishment of the actions specified in this paragraph is an alternative to compliance with paragraph (a) of this AD. Perform an ultrasonic/detailed visual inspection to detect cracking, corrosion, and/or fracturing of the lower horizontal clevis of both midspar fittings of the inboard struts, in accordance with Boeing Alert Service Bulletin 747-54A2179, Revision 1, dated November 27, 1996, at the time specified in paragraph (d)(1), (d)(2), (d)(3), or (d)(4) as applicable. (1) For airplanes identified as Group 1 or 6 in the alert service bulletin: Perform the inspections at the time specified in paragraph (d)(1)(i) or (d)(1)(ii) of this AD. Thereafter, repeat the inspections at intervals not to exceed every 1,000 flight cycles or 18 months, whichever occurs first. (i) Within 150 flight cycles or 3 months after accomplishing the last inspection required by paragraph (b) of AD 96-25-01 or paragraph (a) of this AD. (ii) For airplanes on which terminating action has been accomplished within 500 flight cycles after January 2, 1997, in accordance with Boeing Service Bulletin 747-54-2118, Revision 1, dated May 21, 1987; Revision 2, dated April 21, 1988; Revision 3, dated September 29, 1988; or Revision 4, dated May 11, 1989: Perform the initial inspection within 500 flight cycles or 12 months after January 2, 1997, whichever occurs first. (2) For airplanes identified as Group 2 or 4 in the alert service bulletin: Perform the inspection at the time specified in paragraph (d)(2)(i) or (d)(2)(ii) of this AD, as applicable. Thereafter, repeat this inspection at intervals not to exceed every 1,500 flight cycles or 18 months, whichever occurs first. (i) Within 300 flight cycles or 6 months after accomplishing the last inspection required by paragraph (b) of AD 96-25-01 or paragraph (a) of this AD. Or (ii) For airplanes on which terminating action has been accomplished within 1,000 flight cycles after January 2, 1997, in accordance with Boeing Service Bulletin 747-54-2118, Revision 1, dated May 21, 1987; Revision 2, dated April 21, 1988; Revision 3, dated September 29, 1988; or Revision 4, dated May 11, 1989: Perform the initial inspection within 1,000 flight cycles or 12 months after January 2, 1997, whichever occurs first. (3) For airplanes identified as Group 3 in the alert service bulletin: Perform the inspection at the time specified in paragraph (d)(3)(i) or (d)(3)(ii) of this AD, as applicable. Thereafter, repeat the inspection at intervals not to exceed every 2,500 flight cycles or 18 months, whichever occurs first. (i) Within 350 flight cycles or 6 months after accomplishing the last inspection required by paragraph (b) of AD 96-25-01 or paragraph (a) of this AD. Or (ii) For airplanes on which terminating action has been accomplished within 1,000 flight cycles after January 2, 1997, in accordance with Boeing Service Bulletin 747-54-2118, Revision 1, dated May 21, 1987; Revision 2, dated April 21, 1988; Revision 3, dated September 29, 1988; or Revision 4, dated May 11, 1989: Perform the initial inspection within 1,000 flight cycles or 12 months after January 2, 1997, whichever occurs first. (4) For airplanes identified as Group 5 in the alert service bulletin: Perform the inspection at the time specified in paragraph (d)(4)(i) or (d)(4)(ii) of this AD, as applicable. Thereafter, repeat the inspection at intervals not to exceed every 1,500 flight cycles or 18 months, whichever occurs first. (i) Within 300 flight cycles or 6 months after accomplishing the last inspection required by paragraph (b) of AD 96-25-01 or paragraph (a) of this AD. Or (ii) For airplanes on which terminating action has been accomplished within 800 flight cycles after January 2, 1997, in accordance with Boeing Service Bulletin 747-54-2118, Revision 1, dated May 21, 1987; Revision 2, dated April 21, 1988; Revision 3, dated September 29, 1988; or Revision 4, dated May 11, 1989: Perform the initial inspection within 800 flight cycles or 12 months after January 2, 1997, whichever occurs first. (e) For airplanes identified as Group 1 in Boeing Alert Service Bulletin 747-54A2179, Revision 1, dated November 27, 1996: Accomplishment of the actions specified in this paragraph is an alternative to compliance with paragraph (b) of this AD. Perform an ultrasonic/detailed visual inspection to detect cracking, corrosion, and/or fracturing of the lower horizontal clevis of both midspar fittings of the outboard struts, in accordance with Boeing Alert Service Bulletin 747-54A2179, Revision 1, dated November 27, 1996, at the time specified in paragraph (e)(1) or (e)(2) of this AD, as applicable. Thereafter, repeat the inspection at intervals not to exceed every 2,000 flight cycles or 18 months, whichever occurs first. (1) Within 300 flight cycles or 6 months after accomplishing the last inspection required by paragraph (c) of AD 96-25-01 or paragraph (b) of this AD. Or (2) For airplanes on which terminating action has been accomplished within 1,000 flight cycles after January 2, 1997, in accordance with Boeing Service Bulletin 747-54-2118, Revision 1, dated May 21, 1987; Revision 2, dated April 21, 1988; evision 3, dated September 29, 1988; or Revision 4, dated May 11, 1989: Perform the inspection within 1,000 flight cycles or 12 months after January 2, 1997, whichever occurs first. (f) For all airplanes: After the effective date of this AD, prior to the accomplishment of each inspection required by paragraphs (g), (h), or (i), of this AD, remove the sealant of the upper horizontal leg surface and clean the midspar fittings in accordance with Boeing Alert Service Bulletin 747-54A2179, Revision 1, dated November 27, 1996. Prior to further flight following accomplishment of these actions: Restore the sealant of the upper horizontal leg surface in accordance with the alert service bulletin. (g) For all airplanes: Within 90 days after the effective date of this AD, perform an ultrasonic/detailed visual inspection to detect cracking, corrosion, and/or fracturing of the upper horizontal clevis of both midspar fittings of the inboard struts, in accordance with Boeing Alert Service Bulletin 747-54A2179, Revision 1, dated November 27, 1996. Repeat the ultrasonic/detailed visual inspection thereafter at the time specified in paragraph (g)(1), (g)(2), or (g)(3), as applicable. (1) For airplanes identified as Group 1 or 6 in the alert service bulletin: Repeat at intervals not to exceed every 1,000 flight cycles or 18 months, whichever occurs first. (2) For airplanes identified as Group 2, 4, or 5 in the alert service bulletin: Repeat at intervals not to exceed every 1,500 flight cycles or 18 months, whichever occurs first. (3) For airplanes identified as Group 3 in the alert service bulletin: Repeat at intervals not to exceed every 2,500 flight cycles or 18 months, whichever occurs first. (h) For airplanes identified as Group 1 in Boeing Alert Service Bulletin 747-54A2179, Revision 1, dated November 27, 1996: Within 90 days after the effective date of this AD, perform an ultrasonic/ detailed visual inspection of the upper horizontal clevis of both midspar fittings of the outboard strut to detect cracking, corrosion, and/or fracturing, in accordance with the alert service bulletin. Repeat the inspection thereafter at intervals not to exceed every 2,000 flight cycles or 18 months, whichever occurs first. (i) For airplanes specified in paragraph (i)(1) or (i)(2) of this AD: Perform the actions specified in paragraph (a), (b), (d), (e), (f), (g), or (h) of this AD, as applicable, at the time specified in paragraph (i)(1) or (i)(2) of this AD, as applicable. Thereafter, perform the repetitive inspections at the time specified in paragraph (a), (b), (d), (e), (f), (g), or (h) of this AD, as applicable. (1) For airplanes on which rework of all the fastener holes has been accomplished in [[Page 31336]] accordance with Boeing Alert Service Bulletin 747-54A2179, dated June 27, 1996, Revision 1, dated November 27, 1996, or Boeing Service Bulletin 747-54-2118, dated July 25, 1986: Perform the initial inspection at the later of the times specified in paragraphs (i)(1)(i) and (i)(1)(ii) of this AD. (i) Prior to the accumulation of 3,000 total landings, or within 3 years after accomplishment of the rework, whichever occurs first. Or (ii) Within 90 days after the effective date of this AD. (2) For airplanes on which the midspar fittings have been replaced in accordance with Boeing Alert Service Bulletin 747- 54A2179, Revision 1, dated November 27, 1996, or Boeing Service Bulletin 747-54-2118, dated July 25, 1986; Revision 1, dated May 21, 1987; Revision 2, dated April 21, 1988; Revision 3, dated September 29, 1988; or Revision 4, dated May 11, 1989: Perform the initial inspection at the later of the times specified in paragraphs (i)(2)(i) and (i)(2)(ii) of this AD. (i) Prior to the accumulation of 5,000 landings, or within 5 years after the fitting has been replaced, whichever occurs first. Or (ii) Within 90 days after the effective date of this AD. (j) For all airplanes: If any cracking, corrosion, or fracturing is detected during any inspection required by this AD that is outside the limits specified in Boeing Alert Service Bulletin 757- 54A2179, Revision 1, dated November 27, 1996, and the damaged area is within the area limits specified in the alert service bulletin, prior to further flight, accomplish the requirements of paragraph (j)(1) or (j)(2) of this AD. (1) Accomplish the strut/wing modification specified in paragraph (j)(1)(i), (j)(1)(ii), or (j)(1)(iii) of this AD, as applicable. Following accomplishment of that action, no further action is required by this AD. (i) For airplanes equipped with Rolls Royce Model RB211 series engines: Accomplish the strut/wing modification in accordance with Boeing Alert Service Bulletin 747-54A2157, Revision 2, dated November 14, 1996. Accomplishment of this paragraph terminates the requirements of AD 95-13-05, amendment 39-9285. (ii) For airplanes equipped with General Electric Model CF6-45 or -50 series engines, or Pratt & Whitney Model JT9D-70 series engines: Accomplish the strut/wing modification in accordance with Boeing Alert Service Bulletin 747-54A2158, Revision 2, dated August 15, 1996. Accomplishment of this paragraph terminates the requirements of AD 95-13-07, amendment 39-9287. (iii) For airplanes equipped with Pratt & Whitney Model JT9D series engines (excluding Model JT9D-70 engines): Accomplish the strut/wing modification in accordance with Boeing Alert Service Bulletin 747-54A2159, Revision 2, dated March 14, 1996. Accomplishment of this paragraph terminates the requirements of AD 95-10-16, amendment 39-9233. (2) Replace the midspar fittings of the strut with new fittings in accordance with Boeing Alert Service Bulletin 747-54A2179, Revision 1, dated November 27, 1996. Repeat the inspections thereafter at the intervals specified in paragraph (i)(2) of this AD. (k) If any cracking, corrosion, or fracturing is detected during any inspection required by this AD that is outside the limits specified in Boeing Alert Service Bulletin 747-54A2179, Revision 1, dated November 27, 1996, and the damaged area is outside the area limits specified in the alert service bulletin, prior to further flight, accomplish the requirements of either paragraph (j)(1) or (j)(2) of this AD, or repair in accordance with a method approved by the Manager, Seattle ACO. (l) For all airplanes: If any cracking, corrosion, or fracturing is detected during any inspection required by this AD and it is within the limits specified in Boeing Alert Service Bulletin 757- 54A2179, Revision 1, dated November 27, 1996: Prior to further flight, accomplish the requirements of paragraph (l)(1), (l)(2), (l)(3), or (l)(4) of this AD. (1) Rework any discrepant area in accordance with the alert service bulletin. Following the rework, repeat the actions required by paragraph (a), (b), (d), (e), (f), (g), or (h) of this AD, as applicable, at the intervals specified in those paragraphs. (2) Rework all the fastener holes in accordance with the alert service bulletin. Within 3,000 flight cycles or 3 years after reworking all the fastener holes, whichever occurs first: Repeat the actions required by paragraph (i)(1) of this AD, and accomplish the repetitive inspections required by paragraph (i) of this AD. (3) Replace the midspar fittings in accordance with the alert service bulletin. Within 5,000 flight cycles or 5 years after replacing the midspar fittings, whichever occurs first: Repeat the actions required by paragraph (i)(2) of this AD, and accomplish the repetitive inspections required by paragraph (i) of this AD. (4) Accomplish the strut/wing modification specified in paragraph (j)(1)(i), (j)(1)(ii), or (j)(1)(iii) of this AD, as applicable. Following accomplishment of that action, no further action is required by this AD. (m) Accomplishment of the strut/wing modification specified in paragraph (j)(1)(i), (j)(1)(ii), or (j)(1)(iii) of this AD constitutes terminating action for the requirements of this AD. (n) An alternative method of compliance or adjustment of the compliance time that provides an acceptable level of safety may be used if approved by the Manager, Seattle ACO. Operators shall submit their requests through an appropriate FAA Principal Maintenance Inspector, who may add comments and then send it to the Manager, Seattle ACO. Note 2: Information concerning the existence of approved alternative methods of compliance with this AD, if any, may be obtained from the Seattle ACO. (o) Special flight permits may be issued in accordance with sections 21.197 and 21.199 of the Federal Aviation Regulations (14 CFR 21.197 and 21.199) to operate the airplane to a location where the requirements of this AD can be accomplished. (p) Certain actions shall be done in accordance with the Boeing Alert Service Bulletins listed in the following table. The incorporation by reference of those documents was approved previously by the Director of the Federal Register, in accordance with 5 U.S.C. 552(a) and 1 CFR part 51, as of the dates specified in the table below: ------------------------------------------------------------------------ Approval Date and Federal Referenced Service Bulletin and Date Register Citation ------------------------------------------------------------------------ 747-54A2157, January 12, 1995............. July 28, 1995 (60 FR 33333, June 28, 1995). 747-54A2158, November 30, 1994............ July 28, 1995 (60 FR 33336, July 28, 1995). 747-54A2159, November 3, 1994............. June 21, 1995 (60 FR 27008, May 22, 1995). ------------------------------------------------------------------------ Certain other actions shall be done in accordance with the Boeing Alert Service Bulletins listed in the following table. The incorporation by reference of those documents was approved previously by the Director of the Federal Register on January 22, 1997 (61 FR 66201, December 12, 1996), in accordance with 5 U.S.C. 552(a) and 1 CFR part 51: ------------------------------------------------------------------------ Revision Referenced Service Bulletin Level Date ------------------------------------------------------------------------ 747-54A2179......................... Original June 27, 1996. 747-54A2157......................... 1 Aug. 3, 1995. 747-54A2157......................... 2 Nov. 14, 1996. 747-54A2158......................... 1 Aug. 17, 1995. 747-54A2158......................... 2 Aug. 15, 1996. 747-54A2159......................... 1 June 1, 1995. 747-54A2159......................... 2 Mar. 14, 1996. ------------------------------------------------------------------------ Certain other actions shall be done in accordance with Boeing Alert Service Bulletin 747-54A2179, Revision 1, dated November 27, 1996. This incorporation by reference was approved by the Director of the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Copies may be obtained from Boeing Commercial Airplane Group, P.O. Box 3707, Seattle, Washington 98124-2207. Copies may be inspected at the FAA, Transport Airplane Directorate, 1601 Lind Avenue, SW., Renton, Washington; or at the Office of the Federal Register, 800 North Capitol Street, NW., suite 700, Washington, DC. (q) This amendment becomes effective on June 24, 1997. Issued in Renton, Washington, on May 30, 1997. Darrell M. Pederson, Acting Manager, Transport Airplane Directorate, Aircraft Certification Service. [FR Doc. 97-14769 Filed 6-6-97; 8:45 am] BILLING CODE 4910-13-U