Airworthiness Directive · Amendment 39-14121 · Boeing Model 737-200, 737-300, 737-400, 737-500, 737-600, 737-700, 737-800, 737-900, 757-200, and 757-300 Series Airplanes; and McDonnell Douglas Model DC-10-10, DC-10-10F, DC-10-30, DC-10-30F, DC-10-40, MD-10-10F, MD-10-30F, MD-11, and MD-11F Airplanes
Boeing Model 737-200, 737-300, 737-400, 737-500, 737-600, 737-700, 737-800, 737-900, 757-200, and 757-300 Series Airplanes; and McDonnell Douglas Model DC-10-10, DC-10-10F, DC-10-30, DC-10-30F, DC-10-40, MD-10-10F, MD-10-30F, MD-11, and MD-11F Airplanes
Superseded. A later AD replaced this one: AD 2007-10-12. Comply with the one in force.
(c) This AD applies to the airplanes listed in Table 1 of this AD, certificated in any category.
| Airplane manufacturer | Airplane model | Modified by Supplemental Type Certificate (STC) |
|---|---|---|
| Boeing | 737-200, -300, -400, -500, -600, -700, -800, and -900 series | ST01335LA |
| Boeing | 757-200 and -300 series | ST01334LA |
| McDonnell Douglas | DC-10-10, DC-10-10F, DC-10-30, DC-10-30F, DC-10-40, MD-10-10F, MD-10-30F, MD-11, and MD-11F | ST01391LA |
(d) This AD was prompted by reports of discrepancies with the reinforced flight deck door. We are issuing this AD to prevent inadvertent release of the decompression latch and consequent opening of the decompression panel in the flight deck door, or penetration of the flight deck door by smoke or shrapnel, any of which could result in injury to the airplane flightcrew. We are also issuing this AD to find and fix wire chafing, which could result in arcing, fire, and/or reduced controllability of the airplane.
The FAA is superseding an existing airworthiness directive (AD), which applies to certain transport category airplanes. That AD currently requires modification of the reinforced flight deck door. This new AD expands the applicability of the existing AD and requires other actions related to the reinforced flight deck door. These other actions include modifying the door, inspecting and modifying wiring in the area, and revising the maintenance program to require more frequent testing of the decompression panels of the flight deck door. This AD is prompted by reports of discrepancies with the reinforced flight deck door. We are issuing this AD to prevent inadvertent release of the decompression latch and consequent opening of the decompression panel in the flight deck door, or penetration of the flight deck door by smoke or shrapnel, any of which could result in injury to the airplane flightcrew. This AD also requires finding and fixing wire chafing, which could result in arcing, fire, and/or reduced controllability of the airplane.
Note 1: Where there are differences between this AD and the referenced service bulletins, this AD prevails.
(f) For airplanes listed in Table 2 of this AD: Within 90 days after July 25, 2003 (the effective date of AD 2003-14-04, amendment 39-13223), modify the reinforced flight deck door according to paragraph (f)(1), (f)(2), or (f)(3) of this AD, as applicable.
| Airplane manufacturer | Airplane model | As listed in C&D Aerospace Service Bulletin— |
|---|---|---|
| Boeing | 737-200, -300, -400, -500, -600, -700, -800, and -900 series | B221001-52-03, Revision 3, dated March 25, 2003 |
| Boeing | 757-200 and -300 series | B231001-52-02, Revision 4, dated March 19, 2003. |
| McDonnell Douglas | DC-10-10F, DC-10-30, DC-10-30F, DC-10-40, MD-10-30F, MD-11, and MD-11F | B211200-52-02, Revision 1, dated June 3, 2003. |
(1) For Boeing Model 737-200, -300, -400, -500, -600, -700, -800, and -900 series airplanes: Modify the upper and lower pressure relief latch assemblies on the flight deck door by doing all actions specified in and according to paragraphs 3.A., 3.B., and 3.C. of the Accomplishment Instructions of C&D Aerospace Service Bulletin B221001-52-03, Revision 3, dated March 25, 2003. One latch strap should be installed at the bottom of the upper pressure relief assembly, and a second latch strap should be installed at the top of the lower pressure relief assembly. When properly installed, the strap should cover a portion of the latch hook.
(2) For Boeing Model 757-200 and -300 series airplanes: Modify the upper and lower pressure relief latch assemblies on the flight deck door by doing all actions specified in and according to paragraphs 3.A., 3.B., and 3.C. of the Accomplishment Instructions of C&D Aerospace Service Bulletin B231001-52-02, Revision 4, dated March 19, 2003. One latch strap should be installed at the bottom of the upper pressure relief assembly, and a second latch strap should be installed at the top of the lower pressure relief assembly. When properly installed, the strap should cover a portion of the latch hook.
(3) For McDonnell Douglas DC-10-10F, DC-10-30, DC-10-30F, DC-10-40, MD-10-30F, MD-11, and MD-11F airplanes: Install spacers in the upper and lower pressure relief latch assemblies of the flight deck door, by doing all actions specified in and according to paragraphs 3.A., 3.C., and 3.D. of C&D Aerospace Service Bulletin B211200-52-02, Revision 1, dated June 3, 2003; or Revision 2, dated September 29, 2003.
(g) For airplanes listed in Table 2 of this AD: Modifications accomplished before July 25, 2003, in accordance with a service bulletin listed in paragraph (g)(1), (g)(2), or (g)(3) of this AD; as applicable; are considered acceptable for compliance with the corresponding action specified in paragraph (f) of this AD.
(1) For Boeing Model 737-200, -300, -400, -500, -600, -700, -800, and -900 series airplanes: C&D Aerospace Service Bulletin B221001-52-03, dated December 6, 2002; Revision 1, dated January 2, 2003; or Revision 2, dated February 20, 2003.
(2) For Boeing Model 757-200 and -300 series airplanes: C&D Aerospace Service Bulletin B231001-52-02, dated December 6, 2002; Revision 1, dated January 2, 2003; Revision 2, dated February 20, 2003; or Revision 3, dated March 7, 2003.
(3) For McDonnell Douglas DC-10-10F, DC-10-30, DC-10-30F, DC-10-40, MD-10-30F, MD-11, and MD-11F airplanes: C&D Aerospace Service Bulletin B211200-52-02, dated April 30, 2003.
(h) As of July 25, 2003, no person may install, on any airplane, a reinforced flight deck door having any part number listed in the paragraph 1.A. of C&D Aerospace Service Bulletin B221001-52-03, Revision 3, dated March 25, 2003; B231001-52-02, Revision 4, dated March 19, 2003; or B211200-52-02, Revision 1, dated June 3, 2003; as applicable; unless the door has been modified as required by paragraph (f) of this AD.
New Requirements of This AD:
(i) For Model 737-200, -300, -400, -500, -600, -700, -800, and -900 series airplanes; and Model 757-200 and -300 series airplanes: Within 6 months after the effective date of this AD, revise the FAA-approved maintenance inspection program to include the information specified in C&D Aerospace Report CDRB22-69, Revision E, dated November 8, 2002.
(j) Modify the reinforced flight deck door by doing all applicable actions specified in the applicable service bulletin listed in Table 3 of this AD at the applicable compliance time specified in that table. Where the applicable service bulletin includes an instruction to install a placard to show that the service bulletin has been accomplished, this AD does not require that action.
| For these models— | Equipped with a flight deck door assembly having this P/N— | Within this compliance time after the effective date of this AD— (months) | Do all actions in the accomplishment instructions of— |
|---|---|---|---|
| McDonnell Douglas DC-10-10, DC-10-10F, DC-10-30, DC-10-30F, DC-10-40, MD-10-10F, MD-10-30F, MD-11, and MD-11F airplanes | B211200 | 6 | C&D Aerospace Service Bulletin B211200-52-01, Revision 3, dated September 18, 2003. |
| McDonnell Douglas Model MD-11 and MD-11F airplanes | B251200 | 6 | C&D Aerospace Service Bulletin B251200-52-01, dated April 30, 2003. |
| Boeing Model 737-200, -300, -400, -500, -600, -700, -800, and -900 series airplanes; and Model 757-200 and -300 | B221200 | 18 | C&D Aerospace Service Bulletin B221200-52-01, Revision 1, dated June 27, 2003 |
| Boeing Model 737-200, -300, -400, -500, -600, -700, -800, and -900 series airplanes | B221001 | 18 | C&D Aerospace Service Bulletin B221001-52-03, Revision 3, dated March 25, 2003; except as provided by paragraph (k) of this AD. |
| Boeing Model 757-200 and-300 series airplanes | B231001 | 18 | C&D Aerospace Service Bulletin B231001-52-02, Revision 4, dated March 19, 2003; except as provided by paragraph (k) of this AD. |
| McDonnell Douglas DC-10-10, DC-10-10F, DC-10-30, DC-10-30F, DC-10-40, MD-10-10F, MD-10-30F, MD-11, and MD-11F airplanes | B211200 | 18 | C&D Aerospace Service Bulletin B211200-52-02, Revision 1, dated June 3, 2003; or Revision 2, dated September 29, 2003, except as provided by paragraph (k) of this AD. |
(k) For airplanes subject to paragraph (f) of this AD: Actions required by paragraph (f) of this AD that were done within the compliance time specified in paragraph (f) of this AD do not need to be repeated in accordance with paragraph (j) of this AD.
(l) Modifications accomplished before the effective date of this AD in accordance with an applicable service bulletin listed in Table 4 of this AD are considered acceptable for compliance with the corresponding action specified in paragraph (j) of this AD.
| Service bulletin | Revision level | Date |
|---|---|---|
| C&D Aerospace Service Bulletin B211200-52-01 | Original | February 27, 2003. |
| C&D Aerospace Service Bulletin B211200-52-01 | 1 | March 7, 2003. |
| C&D Aerospace Service Bulletin B211200-52-01 | 2 | June 3, 2003. |
| C&D Aerospace Service Bulletin B211200-52-02 | Original | April 30, 2003. |
| C&D Aerospace Service Bulletin B221001-52-03 | Original | December 6, 2002. |
| C&D Aerospace Service Bulletin B221001-52-03 | 1 | January 2, 2003. |
| C&D Aerospace Service Bulletin B221001-52-03 | 2 | February 20, 2003. |
| C&D Aerospace Service Bulletin B221200-52-01 | Original | April 30, 2003. |
| C&D Aerospace Service Bulletin B231001-52-02 | Original | December 6, 2002. |
| C&D Aerospace Service Bulletin B231001-52-02 | 1 | January 2, 2003. |
| C&D Aerospace Service Bulletin B231001-52-02 | 2 | February 20, 2003. |
| C&D Aerospace Service Bulletin B231001-52-02 | 3 | March 7, 2003. |
(m) For Model 737-200 series airplanes equipped with flight deck door assembly P/N B221001: Within 18 months after the effective date of this AD, do paragraphs (m)(1) and (m)(2) of this AD.
(1) Rework the wiring for the flight deck door to relocate a power wire for the flight deck door, in accordance with the Accomplishment Instructions of C&D Aerospace Alert Service Bulletin B221001-52A05, Revision 3, dated October 3, 2003. Actions accomplished before the effective date of this AD in accordance with C&D Aerospace Alert Service Bulletin B221001-52A05, dated April 17, 2003; Revision 1, dated May 14, 2003; and Revision 2, dated June 19, 2003; are acceptable for compliance with the corresponding action required by this paragraph.
(2) Perform a general visual inspection for chafing of wire bundles in the area of the flight deck door and applicable corrective actions by doing all of the actions in the Accomplishment Instructions of C&D Aerospace Alert Service Bulletin B221001-52A02, dated November 5, 2002. Any applicable corrective actions must be done before further flight.
Note 2: For the purposes of this AD, a general visual inspection is “a visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to ensure visual access to all surfaces in the inspection area. This level of inspection is made under normal available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked.”
(n) As of the effective date of this AD, no person may install a reinforced flight deck door under any STC listed in Table 1 of this AD, on any airplane, unless all applicable requirements of this AD have been done on the door.
(o)(1) The Manager, Los Angeles Aircraft Certification Office (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) Alternative methods of compliance, approved previously in accordance with AD 2003-14-04, amendment 39-13223, are approved as alternative methods of compliance with this AD.
(p) You must use the service information that is specified in Table 5 of this AD to perform the actions that are required by this AD, unless the AD specifies otherwise.
| Service bulletin | Revision level | Date |
|---|---|---|
| C&D Aerospace Alert Service Bulletin B221001-52A02 | Original | November 5, 2002. |
| C&D Aerospace Alert Service Bulletin B221001-52A05 | 3 | October 3, 2003. |
| C&D Aerospace Service Bulletin B211200-52-01 | 3 | September 18, 2003. |
| C&D Aerospace Service Bulletin B211200-52-02 | 1 | June 3, 2003. |
| C&D Aerospace Service Bulletin B211200-52-02 | 2 | September 29, 2003. |
| C&D Aerospace Service Bulletin B221001-52-03 | 3 | March 25, 2003. |
| C&D Aerospace Service Bulletin B221200-52-01 | 1 | June 27, 2003. |
| C&D Aerospace Service Bulletin B231001-52-02 | 4 | March 19, 2003. |
| C&D Aerospace Service Bulletin B251200-52-01 | Original | April 30, 2003. |
| C&D Aerospace Report CDRB22-69 | E | November 8, 2002 |
(1) The Director of the Federal Register approves the incorporation by reference of the service information specified in Table 6 of this AD in accordance with 5 U.S.C. 552(a) and 1 CFR part 51.
| Service bulletin | Revision level | Date |
|---|---|---|
| C&D Aerospace Alert Service Bulletin B221001-52A02 | Original | November 5, 2002. |
| C&D Aerospace Alert Service Bulletin B221001-52A05 | 3 | October 3, 2003. |
| C&D Aerospace Service Bulletin B211200-52-01 | 3 | September 18, 2003. |
| C&D Aerospace Service Bulletin B211200-52-02 | 2 | September 29, 2003. |
| C&D Aerospace Service Bulletin B221200-52-01 | 1 | June 27, 2003. |
| C&D Aerospace Service Bulletin B2105200-52-01 | Original | April 30, 2003. |
| C&D Aerospace Report CDRB22-69 | E | November 8, 2002. |
(2) The Director of the Federal Register previously approved the incorporation by reference of the service information specified in Table 7 of this AD as of July 25, 2003 (68 FR 41063, July 10, 2003).
| Service bulletin | Revision level | Date |
|---|---|---|
| C&D Aerospace Service Bulletin B211200-52-02 | 1 | June 3, 2003. |
| C&D Aerospace Service Bulletin B221001-52-03 | 3 | March 25, 2003. |
| C&D Aerospace Service Bulletin B231001-52-02 | 4 | March 19, 2003. |
(3) To get copies of the service information, go to Boeing Commercial Airplanes, P.O. Box 3707, Seattle, Washington 98124-2207; or C&D Aerospace, 5701 Bolsa Avenue, Huntington Beach, California 92647-2063. To view the AD docket, go to the Docket Management Facility, U.S. Department of Transportation, 400 Seventh Street SW., room PL-401, Nassif Building, Washington, DC. To review copies of the service information, go to 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.
The aircraft, engines and makers this AD names, by the model designations in its text. A model listed here may still be outside the AD's serial ranges.
