ALL OPERATORS TELEX - ALL OPERATORS TELEX

SUBJECT: A318/A319/A320/A321 - ATA 55-40 - INSPECTION OF RUDDER SIDE SHELLS FOR POTENTIAL SKIN TO HONEYCOMB DISBOND
OUR REF: AOT A320-55A1038 dated 22 April 09

1. AIRCRAFT AFFECTED All A318/A319/A320/A321 aircraft equipped with rudders having the Serial Numbers (SN) listed in Technical Disposition ref. TD/K4/S2/27086/2009 issue C Table 1, and having a honeycomb core density of 24 kg/m3 (rudders ticked "x" in column "24kg core"). Or All A318/A319/A320/A321 aircraft equipped with rudders having the Serial Numbers (SN) listed in Technical Disposition ref. TD/K4/S2/27086/2009 issue C Table 1, and having accumulated 20000 FC or more at receipt date of this AOT. Note: Affected rudders having accumulated less than 20000 FC at receipt date of this AOT will be inspected through a forthcoming dedicated Inspection Service Bulletin planned to be issued by end of May 2009. The following rudders that have been inspected through the sampling campaign, do not need to be inspected as per this AOT: SN TS-2359 MSN 998 AFR SN TS-1096 MSN 94 DLH SN TS-1149 MSN 147 DLH The following rudder that has been inspected through the sampling campaign, is only to be inspected at trailing edge location, in accordance with this AOT. SN TS-1536 MSN 533 CCM For this rudder, the ELCh inspection described in paragraph 4.2.2.2 must be performed within 4500 FC from accomplishment of the sampling inspection, and repeated one time at an interval not exceeding 4500 FC. In case a rudder originally fitted on one aircraft (refer to Aircraft Inspection Report delivery document) has been removed and installed on another aircraft, it is the responsibility of the operator to apply the required instructions contained in this AOT to the new aircraft. If the cross-reference Rudder SN/ Aircraft MSN given in TD/K4/S2/27086/2009 issue C Table 1 does not reflect the current status, contact Airbus.

2. REFERENCED DOCUMENTATION REF.1: OIT 999.0092/08: ATA55 – Rudder side shell skin disbonding REF.2: A318/A319/A320/A321 SRM 55-41-13 Fig. 1 item 1 and item 5 REF.3: Technical Disposition ref. TD/K4/S2/27086/2009 issue C REF.4. NTM TASK 51-10-26-220-801 – Temporary Revision TR 51-003 (ELCh inspection) REF 5: NTM TASK 51-10-28-220-801 – Temporary Revision TR 51-002 (Vacuum Loss inspection) REF 6: NTM TASK 51-10-25-290-801 or TASK 51-10-25-290-802 (Thermography inspection)REF 7: NTM TASK 51-10-19-280-801 (Tap test inspection)

3. REASON 3.1 BACKGROUND A deformation was visually detected on the rudder side shell of an A319 and an A321 in-service aircraft. Both rudders were sent to Airbus facilities for further analysis. A review of production records revealed that the deformations reported on both rudders corresponded to areas that had been reworked in production. The conclusion of the investigation is that the disbonding most likely occurred as a consequence of excessive temperature applied, during a hot curing rework of the inner skin in production. This rework occurred outside the autoclave. Operators were informed thru OIT REF.1 dispatched in November 2008 and revised in March 2009.
3.2 AIM For rudders that have been reworked in production with similar hot curing process, this AOT calls for:

- a one-time Vacuum Loss inspection at rudder shell reinforced areas

- a three(3)-times repetitive ELCh inspection at rudder shell trailing edge area

- a repetitive ELCh inspection in other rudder shell areas; until a Vacuum Loss inspection is performed (considered as the terminating action)

4. SHORT TERM ACTION 4.1 PLANNING AND MANPOWER This AOT is subject to an Airbus Monitored Retrofit Campaign. For logistic purposes please provide in advance the inspection planning. Your focal point for the planning and the logistics is: Wera DIETZ, SEOT2, Customer Services Phone: +33 (0)5 67 19 14 22 Fax: +33 (0)5 61 93 27 45 Mailto: wera.dietz@airbus.com 4.1.1 ACCOMPLISHMENT TIMESCALE Accomplishment timescale depends on the locations of the areas to be inspected, which are fully described in Technical Disposition ref. TD/K4/S2/27086/2009 issue C. 4.1.1.1 FOR REINFORCED AREAS The one-time Vacuum Loss inspection described in paragraph 4.2.2.1 must be performed within 200 days from the receipt date of this AOT. 4.1.1.2 FOR TRAILING EDGE AREA The ELCh inspection described in paragraph 4.2.2.2 must be performed within 20 months from the receipt date of this AOT, and repeated two times at intervals not exceeding 4500 FC. Further to the third inspection without findings, no further actionis required as per this AOT. 4.1.1.3 FOR OTHER AREAS (SPLICE/LOWER RIB/UPPER EDGE/LEADING EDGE/OTHER LOCATIONS) The repetitive ELCh inspection described in paragraph 4.2.2.3.A. must be performed:

- within 200 days from the receipt date of this AOT

- then, repeated at intervals not exceeding 1500 FC / 200 days (whichever occurs first)

- up to accomplishment of the terminating one-time Vacuum Loss inspection mentioned in paragraph 4.2.2.3.B., that must be performed within 20 months from the receipt date of this AOT. Accomplishment of this terminating one-time inspection cancels the repetitive ELCh inspection requirements described in paragraph 4.2.2.3.A. 4.1.2 MANPOWER The manpower estimates given below are based on the direct labour to do the work. These estimates assume that the work will be done by experienced personnel. They might need to be revised upwards to suit operators' circumstances. These estimates do not include the manpower required for repairs in case of findings. A) Vacuum Loss inspection:

- Inspection: 1 man-hour per linear meter

- Hole restoration and resin curing time: 12 hours maximum elapsed time B) ELCh inspection: Note: Refer to Technical Disposition ref. TD/K4/S2/27086/2009 issue C for identification of inspection area:

- Location B: 4 man-hours

- Location C: 2 man-hours

- Location D: 1 man-hour

- Location E : 0.5 man-hours

- Location F : 2 man-hours Figures are given for one side shell to be inspected.

4.2 DESCRIPTION 4.2.1 JOB PREPARATION AND ACCESS Refer to Technical Disposition ref. TD/K4/S2/27086/2009 issue C paragraph "Job preparation". 4.2.2 INSPECTION INSTRUCTIONS Rudder shells must be inspected only in areas mentioned in Technical Disposition ref. TD/K4/S2/27086/2009 issue C Table 1. Example: Rudder SN TS-2205 (end of table 1) This rudder must be inspected on L/H side shell, at trailing edge location as per Technical Disposition location B. Other areas are not to be inspected. It must be also inspected on R/H side shell, at lower rib location as per Technical Disposition location D. Other areas are not to be inspected. 4.2.2.1 FOR REINFORCED AREA Perform a one-time Vacuum Loss inspection according to Technical Disposition ref. TD/K4/S2/27086/2009 issue C location A.Specific inspection instructions are to be requested by mail to: Nicolas SEYNAEVE, SEES1 Customer Services Phone: +33 (0)5 61 93 34 38 Fax: +33 (0)5 61 93 36 14 Mailto: nicolas.seynaeve@airbus.com 4.2.2.2 FOR TRAILING EDGE AREA Perform three(3)-times repetitive ELCh inspection according to Technical Disposition ref. TD/K4/S2/27086/2009 issue C location B. 4.2.2.3 FOR OTHER AREAS (SPLICE/LOWER RIB/UPPER EDGE/LEADING EDGE/OTHER LOCATIONS) A.) Perform a repetitive ELCh inspection according to Technical Disposition ref. TD/K4/S2/27086/2009 issue C locations C, D, E, F, G and H. B.) Perform a one-time Vacuum Loss inspection according to specific Technical Dispositions. In order to obtain these instructions, please send a request to: Nicolas SEYNAEVE, SEES1 Customer Services Phone: +33 (0)5 61 93 34 38 Fax: +33 (0)5 61 93 36 14 Mailto: nicolas.seynaeve@airbus.com They will be provided in a time-frame compatible with the inspection planning (refer to paragraph 4.1). 4.2.3 JOB CLOSE UP Refer to Technical Disposition TD ref. TD/K4/S2/27086/2009 issue C paragraph "Job close up)". 4.2.4 ACTIONS IN CASE OF FINDINGS In case of findings, document accurately the relevant inspection report sheet, and contact Airbus at the following address before next flight to get further instructions: SEER1/SEER2/SEER3 Customer Services Fax: +33 (0)5 61 93 28 73 Mailto: region1.StructureRepairSupport@airbus.com region2.StructureRepairSupport@airbus.com region3.StructureRepairSupport@airbus.com Or for AOG request: AIRTAC (Airbus Technical AOG Center) Customer Services Phone: +33 (0)5 61 93 34 00 Fax: +33 (0)5 61 93 35 00 Mailto: airtac@airbus.com 4.2.5 REPORTING If there are no findings, report to Airbus within 10 days from the inspection date of each affected rudder, at the following address: Nicolas SEYNAEVE, SEES1Customer Services Phone: +33 (0)5 61 93 34 38 Fax: +33 (0)5 61 93 36 14 Mailto: nicolas.seynaeve@airbus.com 4.2.6 MATERIAL, TOOLING

- Adjustable access platform or Cherry Picker

- Inspection equipment for ELCh as per REF.4

- Inspection equipment for Vacuum Loss inspection as per REF. 5

- Inspection equipment for Thermography as per REF. 6

- Inspection equipment for Tap test as per REF. 7 Note 1: In order for Airbus to provide adequate support to all affected operators, it is recommended to place a Purchase Order for ELCh tool two weeks ahead of the first scheduled inspection. Note 2: A CD-Rom including ELCh familiarization has been shipped to all affected operators via Airbus Field Service stations. Note 3: Instructions for restoration of Vacuum Loss inspection holes are detailed in the specific Technical Dispositions, and can be performed in 2 steps:

- Temporary restoration: Hole closing with self-adhesive patches, allowed for 4500 FC

- Permanent restoration: Hole filling with resin and restoration of surface protection. Local thermography inspection is required before resin injection, to ensure sandwich structure is free of liquid. Note 4: For thermography inspection, as a limited number of equipment is available for loan from Airbus, necessary Infrared camera could also be purchased at the following address:
FLIR SYSTEMS Internet address: <http://www.flir.com/>

5. AOT APPROVAL The technical content of this AOT has been approved under the authority of EASA Design Organization Approval number EASA 21J.031. It is anticipated that this AOT will be rendered mandatory.

6. REPORTING/ACKNOWLEDGMENT Operators are requested to acknowledge receipt of this AOT within 48 hours after receipt to: MR. R. LASCOURS, SEE, SITA CODE TLSBT7X, FAX: +33 / (0) 5 61 30 00 79 This acknowledgement can be made through the Airbus RCSM when available.
Best regards,
A. VIEILLARD VICE PRESIDENT A318/A319/A320/A321 PROGRAMME CUSTOMER SERVICES DIRECTORATE If you receive this message via e-mail/internet, we draw your attention to the fact that it may be monitored and/or intercepted. Further, whilst Airbus has taken reasonable measures to ensure theintegrity of this message and its contents, no warranty, whether express or implied, is given that the contents hereof conform to the original. In case of any doubt, please retrieve this document from your SITA address or AirbusWorld or request that it be retransmitted by fax or telex.