Airworthiness Directive · Amendment 39-22541 · Wings
The Boeing Company Airplanes
This AD applies to all The Boeing Company Model 777-200, -200LR, -300, -300ER, and 777F series airplanes, certificated in any category, excluding the airplanes identified in paragraphs (c)(1) and (2) of this AD.
(1) Boeing Model 777-200 series airplanes having a maximum taxi weight equal to or less than 547,000 pounds.
(2) Boeing Model 777F series airplanes with manufacturer line numbers of 1743 and subsequent.
The FAA is superseding Airworthiness Directive (AD) 2022-18- 11, which applied to all The Boeing Company Model 777 airplanes. AD 2022-18-11 required repetitive inspections for cracking of the left- and right-side ring chords, repair angles, front spar lower chords, and front spar webs (depending on configuration) common to a certain underwing longeron; modification of the front spar lower chord for some airplanes; repetitive post-modification inspections; and applicable on- condition actions. This AD was prompted by a report of a crack found in a front spar lower chord, and the determination that errors in the service information mandated by AD 2022-18-11 introduced a new unsafe condition related to the application of certain fastener cap seals. This AD retains the actions required by AD 2022-18-11, and requires a maintenance records review of previously modified airplanes for the procedures used during that modification, and applicable corrective actions. The FAA is issuing this AD to address the unsafe condition on these products.
This paragraph restates the requirements of paragraph (g) of AD 2022-18-11, with no changes. Except as specified by paragraph (h) of this AD: At the applicable times specified in the “Compliance” paragraph of Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, do all applicable actions identified in, and in accordance with, the Accomplishment Instructions of Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021. Actions identified as terminating action in Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, terminate the applicable required actions of this AD, provided the terminating action is done in accordance with the Accomplishment Instructions of Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021.
Note 1 to paragraph (g): Guidance for accomplishing the actions required by this AD can be found in Boeing Alert Service Bulletin 777-57A0122, dated October 8, 2021, which is referred to in Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021.
(1) Where the Compliance Time columns of the tables in the “Compliance” paragraph of Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, use the phrase “the original issue date of Requirements Bulletin 777-57A0122 RB,” this AD requires replacing those words with “October 31, 2022, the effective date of AD 2022-18-11.”
(2) Where Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, specifies contacting Boeing for repair instructions: This AD requires repair using a method approved in accordance with the procedures specified in paragraph (j) of this AD.
(3) Where the “Compliance” paragraph of Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, uses the phrase “Tables 1 through 50,” this AD requires replacing those words with “Tables 1 through 54.”
(4) During application of any cap seal to a fastener, fastener head, and fastener threads and collars, as required by this AD, the cap seal must be applied with a thickness equal to or greater than the dimensions specified in figure 1 to paragraph (h)(4) of this AD.
Figure 1 to paragraph (h)(4) — Cap seal minimum thickness (all dimensions in inches)
(5) Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, does not require the application of cap seals to underwing longeron fasteners, fastener heads, and fastener threads and collars for the airplane groups and configurations identified in paragraphs (h)(5)(i) through (iv) of this AD. For those airplane groups and configurations, however, this AD requires application of a cap seal to the underwing longeron fasteners at the locations identified in Figures 81 and 144 of Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, during installation of the underwing longeron.
(i) Groups 7 and 8, Configurations 5 through 8, on the left side.
(ii) Group 9, Configurations 1 and 2, on the left side.
(iii) Groups 7 and 8, Configurations 2, 6, 10, and 14, on the right side.
(iv) Group 9, Configurations 1 and 3, on the right side.
(6) Where Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, requires inspections that may require the removal of fastener cap seals, this AD requires that if the cap seal is removed, a cap seal of BMS 5-45 sealant be reapplied with a thickness equal to or greater than the dimensions specified in figure 1 to paragraph (h)(4) of this AD before further flight after completion of the inspection.
(7) The Effectivity of Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, does not include Boeing Model 777F series airplanes having line numbers 1713, 1717, 1720, and 1724 through 1742 inclusive. However, for those airplanes, this AD requires accomplishment of the applicable actions specified in the Boeing Alert Requirements Bulletin for Group 6.
For airplanes on which the applicable actions of Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, have been accomplished before the effective date of this AD: Within 30 days after the effective date of this AD, review the maintenance records to determine the procedures used to apply cap seals during accomplishment of the actions in Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021.
(1) If all of the conditions specified in paragraphs (i)(1)(i) through (iii) of this AD are met, no further work is required by paragraph (i) of this AD.
(i) If the underwing longeron was removed for any reason during accomplishment of the actions in Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, a cap seal was applied to the underwing longeron fasteners, fastener threads, and fastener collars at the locations identified in Figures 81 and 144 of Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, during installation.
(ii) All cap seals were applied using procedures with thickness dimensions greater than or equal to those given in figure 1 to paragraph (h)(4) of this AD.
(iii) All cap seals that were removed to accomplish any inspection in accordance with Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, were replaced with cap seals of BMS 5-45 sealant of thickness dimensions greater than or equal to those given in figure 1 to paragraph (h)(4) of this AD.
(2) If any cap seal was applied using procedures with thickness dimensions less than those given in figure 1 to paragraph (h)(4) of this AD, or if the maintenance records do not definitively specify the procedures used: At the applicable time specified in paragraph (i)(2)(i) or (ii) of this AD, replace the cap seal in accordance with the Accomplishment Instructions of Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, using a cap sealing procedure with thickness greater than or equal to the dimensions given in figure 1 to paragraph (h)(4) of this AD.
(i) For airplanes equipped with a flammability reduction means approved by the FAA as compliant with the fuel tank flammability reduction (FTFR) requirements of 14 CFR 25.981(b) or 26.33(c)(1), or an ignition mitigation means approved by the FAA as compliant with the FTFR requirements of 14 CFR 25.981(c) or 26.33(c)(2): Within 180 days after the effective date of this AD,
(ii) For airplanes not described in paragraph (i)(2)(i) of this AD: Within 90 days after the effective date of this AD.
(3) For any cap seal that was not applied, or for any cap seal that was removed for inspections and not replaced, or if the maintenance records do not definitively specify the procedures used: At the applicable time specified in paragraph (i)(3)(i) or (ii) of this AD, apply a cap seal of BMS 5-45 sealant using an accepted method with thickness greater than or equal to the dimensions given in figure 1 to paragraph (h)(4) of this AD.
Note 2 to paragraph (i)(3): Guidance for applying a cap seal can be found in the Boeing Model 777 Aircraft Maintenance Manual section 28-11-00.
(i) For airplanes equipped with a flammability reduction means approved by the FAA as compliant with the fuel tank flammability reduction (FTFR) requirements of 14 CFR 25.981(b) or 26.33(c)(1), or an ignition mitigation means approved by the FAA as compliant with the FTFR requirements of 14 CFR 25.981(c) or 26.33(c)(2): Within 180 days after the effective date of this AD.
(ii) For airplanes not described in paragraph (i)(3)(i) of this AD: Within 90 days after the effective date of this AD.
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
