Airworthiness Directive · Amendment 39-16363 · Nacelles/pylons
The Boeing Company Model 767-200, -300, and -300F Series Airplanes Powered by General Electric or Pratt & Whitney Engines
This AD applies to The Boeing Company Model 767-200, -300, and -300F series airplanes, certificated in any category; as identified in Boeing Alert Service Bulletin 767-54A0101, Revision 5, dated June 29, 2010.
The FAA is superseding an existing airworthiness directive (AD) that applies to certain Model 767-200, -300, and -300F series airplanes. The existing AD currently requires repetitive inspections to detect discrepancies of the 8 aft-most fastener holes in the horizontal tangs of the midspar fitting of the strut, and corrective actions if necessary. The existing AD also requires repetitive inspections for cracks of the closeout angle that covers the 2 aft-most fasteners in the lower tang of the midspar fitting, and related investigative and corrective actions if necessary. The existing AD also provides an optional terminating action for the repetitive inspections. This new AD reduces the compliance times for doing the inspections. This AD results from reports of cracks in the midspar fitting tangs. We are issuing this AD to detect and correct fatigue cracking in the primary strut structure and reduced structural integrity of the strut, which could result in separation of the strut and engine.
You are responsible for having the actions required by this AD performed within the compliance times specified, unless the actions have already been done.
Note 1: Notwithstanding any inspection done in accordance with AD 2005-19-23, inspect within the compliance times specified in this AD.
At the applicable time specified in paragraph (h) of this AD: Do the actions specified in either paragraph (g)(1) or (g)(2) of this AD.
(1) Do a detailed inspection for cracking of the 8 aft-most fastener holes in the horizontal tangs of the midspar fitting of the strut, and a surface high frequency eddy current (HFEC) inspection for cracking of the closeout angle that covers the 2 aft-most fasteners in the lower tang of the midspar fitting, in accordance with Part 1, “Detailed Inspection of Midspar Fitting and Surface High Frequency Eddy Current (HFEC) Inspection of Closeout Angle,” of the Work Instructions of Boeing Alert Service Bulletin 767-54A0101, Revision 5, dated June 29, 2010.
(2) Do an open-hole HFEC inspection for cracking of each fastener hole, inspect to determine the size of each fastener hole, and do all applicable related investigative and corrective actions, in accordance with Part 2, “Open Hole HFEC Inspection,” of the Work Instructions of Boeing Alert Service Bulletin 767-54A0101, Revision 5, dated June 29, 2010, except as required by paragraphs (m) and (n) of this AD, and except as provided by paragraph (p) of this AD. Do all applicable related investigative and corrective actions before further flight.
(h) At the applicable time specified in paragraph (h)(1) or (h)(2) of this AD, do the actions specified in paragraph (g) of this AD.
(1) For airplanes on which an inspection (any Part 1 or Part 2 inspection) has not been done in accordance with any service bulletin listed in Table 1 of this AD as of the effective date of this AD: Prior to the accumulation of 8,000 total flight cycles, or within 90 days after the effective date of this AD, whichever occurs later, do the actions specified in paragraph (g) of this AD.
| Service Bulletin | Revision | Date |
|---|---|---|
| Boeing Alert Service Bulletin 767-54A0101 | 4 | February 10, 2005. |
| Boeing Alert Service Bulletin 767-54A0101 | 5 | June 29, 2010. |
| Boeing Service Bulletin 767-54A0101 | 2 | January 10, 2002. |
| Boeing Service Bulletin 767-54A0101 | 3 | September 5, 2002. |
(2) For airplanes on which any inspection (any Part 1 or Part 2 inspection) has been done in accordance with any service bulletin listed in Table 1 of this AD as of the effective date of this AD: Within 400 flight cycles after doing the most recent inspection or within 90 days after the effective date of this AD, whichever occurs later, do the actions specified in paragraph (g) of this AD.
(i) If, during any detailed and surface HFEC inspection specified by paragraph (g)(1) of this AD, no cracking is found, do the actions specified in either paragraph (i)(1) or (i)(2) of this AD.
(1) Repeat the inspections specified in paragraph (g)(1) of this AD thereafter at intervals not to exceed 400 flight cycles.
(2) Within 400 flight cycles after doing the most recent inspections specified in paragraph (g)(1) of this AD, do the actions specified in paragraph (g)(2) of this AD and repeat thereafter at intervals not to exceed 6,000 flight cycles.
(j) If, during the actions specified by paragraph (g)(2) of this AD, the terminating action specified in Part 4 of the Work Instructions of Boeing Alert Service Bulletin 767-54A0101, Revision 5, dated June 29, 2010, is not done, do the actions specified in either paragraph (j)(1) or (j)(2) of this AD.
(1) Within 6,000 flight cycles after doing the actions specified in paragraph (g)(2) of this AD, do the inspections specified in paragraph (g)(1) of this AD and repeat the inspections thereafter at intervals not to exceed 400 flight cycles.
(2) Repeat the actions specified in paragraph (g)(2) of this AD thereafter at intervals not to exceed 6,000 flight cycles.
If, during any inspection specified by paragraph (g)(1) of this AD, any crack is found in the midspar fitting tangs, before further flight, do the actions specified in paragraph (k)(1) or (k)(2) of this AD.
(1) Do the terminating action specified in Part 4 of the Work Instructions of Boeing Alert Service Bulletin 767-54A0101, Revision 5, dated June 29, 2010, except as required by paragraph (m) of this AD. Accomplishment of this paragraph terminates the requirements of this AD.
(2) Replace the midspar fitting of the strut with a new part, or repair in accordance with a method approved by the Manager, Seattle Aircraft Certification Office (ACO), FAA. Within 8,000 flight cycles after doing the replacement, do the actions specified in either paragraph (k)(2)(i) or (k)(2)(ii) of this AD.
(i) Do the inspections specified in paragraph (g)(1) of this AD and repeat the inspections thereafter at intervals not to exceed 400 flight cycles.
(ii) Do the actions specified in paragraph (g)(2) of this AD and repeat the actions thereafter at intervals not to exceed 6,000 flight cycles.
(l) If, during any surface HFEC inspection specified by paragraph (g)(1) of this AD, any crack is found in the closeout angle, before further flight, do the open-hole HFEC inspection for cracking and all applicable related investigative and corrective actions, in accordance with Part 2, “Open Hole HFEC Inspection,” and step 4.b.(2) of Part 1, “Detailed Inspection of Midspar Fitting and Surface High Frequency Eddy Current (HFEC) Inspection of Closeout Angle,” of the Work Instructions of Boeing Alert Service Bulletin 767-54A0101, Revision 5, dated June 29, 2010, except as required by paragraphs (m) and (n) of this AD, and except as provided by paragraph (p) of this AD. If the terminating action specified in Part 4 of the Work Instructions of Boeing Alert Service Bulletin 767-54A0101, Revision 5, dated June 29, 2010, is not done, do the actions specified in either paragraph (l)(1) or (l)(2) of this AD.
(1) Within 6,000 flight cycles after doing the actions specified in paragraph (l) of this AD, do the inspections specified in paragraph (g)(1) of this AD and repeat the inspections thereafter at intervals not to exceed 400 flight cycles.
(2) Within 6,000 flight cycles after doing the actions specified in paragraph (l) of this AD, do the actions specified in paragraph (g)(2) of this AD, and repeat the actions thereafter at intervals not to exceed 6,000 flight cycles.
Where Boeing Alert Service Bulletin 767-54A0101, Revision 5, dated June 29, 2010, specifies that the manufacturer may be contacted for disposition of repair conditions: Before further flight, accomplish the repair using a method approved in accordance with the procedures specified in paragraph (r) of this AD.
(n) If, during any open-hole HFEC inspection required by paragraph (g)(2) or (l) of this AD, any crack is found in the midspar fitting and the hole size is 0.5322 inch, before further flight, do the terminating action specified in paragraph (k)(1) of this AD.
Doing the terminating action specified in Part 4 of the Work Instructions of Boeing Alert Service Bulletin 767-54A0101, Revision 5, dated June 29, 2010, terminates the requirements of this AD.
Note 2: Boeing Alert Service Bulletin 767-54A0101, Revision 5, dated June 29, 2010, refers to the Boeing service bulletins in Table 2 of this AD as additional sources of guidance for doing the terminating action in paragraphs (k) and (o) of this AD.
| Boeing Service Bulletin | Revision level | Date | Title |
|---|---|---|---|
| 767-54-0052 | Original | June 11, 1992 | Nacelles/Pylons—Strut—Aft Lower Spar—Fastener Corrosion—Inspection and Replacement. |
| 767-54-0061 | 2 | November 23, 1999 | Nacelles/Pylons—Wing-to-Strut Attach Fittings—Lower Spar Bushing Inspection and Replacement. |
| 767-54-0069 | 2 | August 31, 2000 | Nacelles/Pylons—Midspar Fitting—Underwing Sideload Fitting—Fuse Pin Replacement and Wing Rework. |
| 767-54-0072 | Original | March 13, 1997 | Nacelles/Pylons—Strut Attach Upper Link—Upper Link Inspection, Rework or Replacement. |
| 767-54-0080 | 1 | May 9, 2002 | Nacelles/Pylons—Pratt and Whitney Powered Airplanes—Nacelle Strut and Wing Structure Modification. |
| 767-54-0081 | 1 | February 7, 2002 | Nacelles/Pylons—General Electric Powered Airplanes—Nacelle Strut and Wing Structure Modification. |
| 767-54A0062 | 6 | November 5, 2009 | Nacelles/Pylons—Strut Attach Fuse Pins—Midspar Fuse Pin Inspection and Replacement. |
| 767-54A0074 | 1 | April 24, 2008 | Nacelles/Pylons—Strut Attach Fuse Pins—Upper link Fuse Pin Inspection/Replacement. |
| 767-54A0094 | 2 | February 7, 2002 | Nacelles/Pylons—Strut—to—Wing Attachment—Diagonal Brace Inspection/Rework/Replacement. |
| 767-57-0063 | 1 | November 30, 2000 | Wings—Side Load Underwing Fitting —Inspection/Rework. |
Note 3: Certain service bulletins referenced in Table 2 of this AD are related to the ADs listed in Table 3 of this AD.
| AD | Applicability | Related Boeing Service Bulletin | AD requirement |
|---|---|---|---|
| AD 2000-07-05, amendment 39-11659 | Certain Boeing Model 767 series airplanes | 767-54A0094 | Repetitive inspections to detect cracking or damage of the forward and aft lugs of the diagonal brace of the nacelle strut; follow-on actions, if necessary; and terminating action for the repetitive inspections. |
| AD 2004-16-12, amendment 39-13768 | Certain Boeing Model 767-200, -300, and -300F series airplanes powered by Pratt & Whitney engines or General Electric engines | 767-54-0069, 767-54-0080, 767-54-0081, and 767-54A0094 | Modification of the nacelle strut and wing structure. |
| AD 2009-20-09, amendment 39-16032 | Certain Boeing Model 767-200, -300, and -300F series airplanes | 767-54A0074 | Repetitive inspections for fatigue cracking and corrosion of the upper link fuse pin of the nacelle struts, and related investigative and corrective actions if necessary. |
| AD 2010-03-08, amendment 39-16192 | Certain Boeing Model 767-200, -300, and -300F series airplanes | 767-54A0062, 767-54-0069 | Repetitive detailed and eddy current inspections to detect cracks of certain midspar fuse pins, and corrective action if necessary. |
In lieu of doing the related investigative and corrective actions required by paragraph (g)(2) or (l) of this AD, before further flight, replace the midspar fitting of the strut with a new part, or repair in accordance with a method approved by the Manager, Seattle Aircraft Certification Office (ACO), FAA. Within 8,000 flight cycles after doing any replacement, do the actions specified in either paragraph (p)(1) or (p)(2) of this AD.
(1) Do the inspections specified in paragraph (g)(1) of this AD and repeat the inspections thereafter at intervals not to exceed 400 flight cycles.
(2) Do the actions specified in paragraph (g)(2) of this AD and repeat the actions thereafter at intervals not to exceed 6,000 flight cycles.
Doing the terminating action specified in Part 4 of the Work Instructions of any service bulletin listed in Table 4 of this AD before the effective date of this AD is acceptable for compliance with the requirements of this AD.
| Service Bulletin | Revision | Date |
|---|---|---|
| Boeing Alert Service Bulletin 767-54A0101 | Original | September 23, 1999. |
| Boeing Alert Service Bulletin 767-54A0101 | 4 | February 10, 2005. |
| Boeing Service Bulletin 767-54A0101 | 1 | February 3, 2000. |
| Boeing Service Bulletin 767-54A0101 | 2 | January 10, 2002. |
| Boeing Service Bulletin 767-54A0101 | 3 | September 5, 2002. |
