Airworthiness Directive · Amendment 39-14918 · Boeing Model 737 Airplanes
Boeing Model 737 Airplanes
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.
The FAA is superseding an existing airworthiness directive (AD) that applies to all Boeing Model 737 airplanes. The existing AD currently requires installation of a new rudder control system and changes to the adjacent systems to accommodate that new rudder control system. For certain airplanes, this new AD adds, among other actions, repetitive tests of the force fight monitor of the main rudder power control unit (PCU), repetitive tests of the standby hydraulic actuation system, and corrective action; as applicable. For those airplanes, this new AD also adds, among other actions, replacement of both input control rods of the main rudder PCU and the input control rod of the standby rudder PCU with new input control rods, as applicable, which ends the repetitive tests. For certain other airplanes, this new AD adds installation of an enhanced rudder control system in accordance with new service information. This AD results from a report of a fractured rod end of an input control rod of the main rudder 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.
You are responsible for having the actions required by this AD performed within the compliance times specified, unless the actions have already been done.
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.
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.
| 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.
| 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.
| 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 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.
| 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.
| 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. |
As of the effective date of this AD, no person may install an input control rod, P/N 251A3495-1, on any airplane.
