Airworthiness Directive · Amendment 39-17786 · Nacelles/pylons
The Boeing Company Airplanes
(1) This AD applies to The Boeing Company Model 757-200, -200PF, and -200CB series airplanes, certificated in any category, line numbers 1 through 735 inclusive, equipped with Rolls-Royce RB211 engines.
(2) Installation of Supplemental Type Certificate (STC) ST01518SE (http://rgl.faa.gov/Regulatory_and_Guidance_Library/rgstc.nsf/0/48e13cdfbbc32cf4862576a4005d308b/Body/0.48A!OpenElement&FieldElemFormat=gif) does not affect the ability to accomplish the actions required by this AD. Therefore, for airplanes on which STC ST01518SE is installed, a “change in product” alternative method of compliance (AMOC) approval request is not necessary to comply with the requirements of 14 CFR 39.17.
We are superseding Airworthiness Directive (AD) 2004-12-07 for certain The Boeing Company Model 757 series airplanes equipped with Rolls-Royce RB211 engines. AD 2004-12-07 required modification of the nacelle strut and wing structure; and for certain airplanes, repetitive detailed inspections of certain aft bulkhead fasteners for loose or missing fasteners, and corrective action if necessary. For certain other airplanes, AD 2004-12-07 required a one-time detailed inspection of the middle gusset of the inboard side load fitting for proper alignment, and realignment if necessary; a one-time eddy current inspection of certain fastener holes for cracking, and repair if necessary; and a detailed inspection of certain fasteners for loose or missing fasteners, and replacement with new fasteners if necessary. This new AD specifies a maximum compliance time limit. This AD was prompted by reports indicating that the actual operational loads applied to the nacelle are higher than the analytical loads that were used during the initial design. We are issuing this AD to prevent fatigue cracking in primary strut structure and consequent reduced structural integrity of the strut.
This paragraph restates the requirements of paragraph (a) of AD 2004-12-07, Amendment 39-13666 (69 FR 33561, June 16, 2004), with new service information: Modify the nacelle strut and wing structure according to Boeing Service Bulletin 757-54-0035, dated July 17, 1997; Revision 1, dated April 15, 1999; Revision 2, dated June 13, 2002; or Revision 6, dated December 2, 2011; except as specified in paragraph (l) of this AD; at the later of the times specified in paragraph (g)(1) or (g)(2) of this AD, except as required by paragraph (i) of this AD. All of the terminating actions described in paragraph I.C., Table I, “Strut Improvement Bulletins,” on page 6 of Boeing Service Bulletin 757-54-0035, dated July 17, 1997; page 7 of Boeing Service Bulletin 757-54-0035, Revision 1, dated April 15, 1999; and on page 7 of Boeing Service Bulletin 757-54-0035, Revision 2, dated June 13, 2002; as applicable; must be accomplished prior to, or concurrently with, the accomplishment of the modification of the nacelle strut and wing structure required by this paragraph. After July 21, 2004 (the effective date of AD 2004-12-07), use only Boeing Service Bulletin 757-54-0035, Revision 2, dated June 13, 2002; or Boeing Service Bulletin 757-54-0035, Revision 6, dated December 2, 2011. After the effective date of this AD, use only Boeing Service Bulletin 757-54-0035, Revision 6, dated December 2, 2011. Accomplishment of the actions required by paragraph (i) of this AD terminates the requirements of this paragraph.
(1) Prior to the accumulation of 37,500 total flight cycles, or prior to 20 years since the date of manufacture of the airplane, whichever occurs first.
(2) Within 3,000 flight cycles after January 3, 2000 (the effective date of AD 99-24-07, Amendment 39-11431 (64 FR 66370, November 26, 1999)).
This paragraph restates the requirements of paragraph (c) of AD 2004-12-07, Amendment 39-13666 (69 FR 33561, June 16, 2004), with new service information. For airplanes on which the modification required by paragraph (g) of this AD has been done according to Boeing Service Bulletin 757-54-0035, dated July 17, 1997: Within 15,000 flight cycles after doing the modification required by paragraph (g) of this AD, or within 3 years after July 21, 2004 (the effective date of AD 2004-12-07), whichever is later; do a one-time detailed inspection of the middle gusset of the inboard side load fitting for proper alignment, according to Part II of the Accomplishment Instructions of Boeing Service Bulletin 757-54-0035, Revision 1, dated April 15, 1999; or Revision 2, dated June 13, 2002, excluding Evaluation Form; or Boeing Service Bulletin 757-54-0035, Revision 6, dated December 2, 2011; except as specified by paragraph (l) of this AD. If the gusset is not aligned properly: Before further flight, machine the gusset to the specified angle according to the Accomplishment Instructions of Boeing Service Bulletin 757-54-0035, Revision 1, dated April 15, 1999; or Revision 2, dated June 13, 2002, excluding Evaluation Form; or Boeing Service Bulletin 757-54-0035, Revision 6, dated December 2, 2011. As of the effective date of this AD, use only Boeing Service Bulletin 757-54-0035, Revision 6, dated December 2, 2011, for accomplishing the actions required by this paragraph.
For airplanes on which the modification of the nacelle strut and wing structure required by paragraph (g) of this AD has not been done as of the effective date of this AD: Do the modification required by paragraph (g) of this AD at the later of the times specified in paragraphs (i)(1) and (i)(2) of this AD.
(1) At the time specified in paragraph 1.E., “Compliance,” of Boeing Service Bulletin 757-54-0035, Revision 6, dated December 2, 2011, except that where this service bulletin specifies a compliance time “from the date on Revision 4 of this service bulletin,” this AD requires compliance within the specified compliance time after the effective date of this AD.
(2) Within 3,000 flight cycles after January 3, 2000 (the effective date of AD 99-24-07, Amendment 39-11431 (64 FR 66370, November 26, 1999)).
Concurrently with or prior to the accomplishment of the actions required by paragraph (i) of this AD, do the actions specified in paragraphs (j)(1) and (j)(2) of this AD.
(1) For airplanes identified in Boeing Service Bulletin 757-54-0003, Revision 1, dated August 30, 1985: Modify the nacelle strut upper spar, in accordance with the Accomplishment Instructions of Boeing Service Bulletin 757-54-0003, Revision 1, dated August 30, 1985.
(2) For airplanes identified in Boeing Service Bulletin 757-54-0028, Revision 1, dated August 25, 1994: Do a detailed inspection and non-destructive test inspection for cracking of the lower chord, mid-chord, and holes (for cracking, galling, corrosion, or damage due to fastener removal), in accordance with the Accomplishment Instructions of Boeing Service Bulletin 757-54-0028, Revision 1, dated August 25, 1994.
Note 1 to paragraph (j) of this AD: Paragraph D. of Boeing Service Bulletin 757-54-0035, Revision 6, dated December 2, 2011, incorrectly states that the actions described in Boeing Service Bulletin 757-54-0003, Revision 1, dated August 30, 1985; and Boeing Service Bulletin 757-54-0028, Revision 1, dated August 25, 1994; no longer need to be accomplished.
(1) If any cracking is found during any inspection required by paragraph (j)(2) of this AD: Before further flight, repair the cracking using a method approved in accordance with the procedures specified in paragraph (n) of this AD.
(2) If any holes with galling, corrosion, or damage due to fastener removal are found during any inspection required by paragraph (j)(2) of this AD: Before further flight, repair the holes, in accordance with the Accomplishment Instructions of Boeing Service Bulletin 757-54-0028, Revision 1, dated August 25, 1994.
Although Boeing Service Bulletin 757-54-0035, Revision 6, dated December 2, 2011, specifies to work the wing modification before the strut modification, this AD allows for the wing and strut modifications to occur simultaneously. This AD also allows for both struts to be modified simultaneously.
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.
Aircraft
