Subject: MAINTENANCE OF EMERGENCY 

EVACUATION SYSTEMS FOR 

AIRCRAFT OPERATING UNDER 

PART 121 

Date: 4/4/03 

Initiated by: AFS-300 

AC No: 43-208 

Change: 

1. What is the purpose of this advisory circular (AC)? 

This AC provides information and guidance for the maintenance of emergency evacuation 

systems (EES) used on aircraft operating under the provisions of Title 14 of the Code of Federal 

Regulations (14 CFR) part 121. Additionally, this AC discusses the responsibilities and means 

of compliance for the air carrier and persons performing maintenance. 

2. What systems are included in the EES? 

The EES includes components of all aircraft slide-equipped exits affecting the emergency egress 

function (e.g., slides, slide/rafts, doors, door mechanisms, door opening assist mechanisms, tail 

cone release mechanisms, arm/disarm mechanisms, slide activation mechanisms, electronic slide 

monitoring systems, and slide-to-airframe attachments). 

3. Who does this AC apply to?

This AC applies to 14 CFR part 121 air carriers. 

BACKGROUND 

4. Why was the Emergency Evacuation Task Force created?

a. The National Transportation Safety Board (NTSB) made safety recommendations 

A-99-99 through -103, relating to accidents/incidents where the failure of an EES component 

was a factor. Past efforts aimed at improving EES reliability did not result in significant 

improvements. Therefore, a comprehensive strategic plan was designed to improve aircraft EES 

reliability. The overall strategy is to increase awareness of the EES maintenance processes, for

equipment installed on and taken off of the aircraft, and to develop new air carrier operations 

specifications for EES maintenance programs. 
AC 43-208 4/4/03 

b. In 1985, the Public Technical Conference was held to solicit and review information on 

topics relating to the emergency evacuation of transport category airplanes. Participants included 

experts in aircraft design, manufacture, operations and maintenance, passenger safety, and 

aircraft emergency evacuation. During the conference, it became clear that an extended effort 

would be necessary to properly consider the issues raised by the participants. As a result, in 

September 1985, the Federal Aviation Administration (FAA) Administrator established the 

Emergency Evacuation Task Force, which consisted of FAA personnel, 14 CFR part 121 air 

carriers, 14 CFR part 145 repair stations, and manufacturers, to accomplish the following: 

(1) Pursue issues raised during the Public Technical Conference;

(2) Reassess existing regulations on emergency evacuation of transport category

airplanes; and 

(3) Prepare a public report of the findings and recommendations of the task force. 

5. What issues did the Emergency Evacuation Task Force identify? 

a. The Emergency Evacuation Task Force consisted of three technical working groups that 

were formed to consider the issues raised at the Public Technical Conference. The technical

working groups were organized into the following disciplines: Design and Certification, 

Training and Operations, and Maintenance and Reliability. A complete record of the Emergency

Evacuation Task Force proceedings is available in the U.S. Department of Transportation (DOT) 

FAA Report Number DOT/FAA/VS-86/1, Volumes I and II.

b. The Maintenance and Reliability group identified the following issues on the reliability of 

emergency evacuation slides and recommended the development of an AC to address them:

(1) Improper maintenance; 

(2) Training and qualifications; 

(3) Mandatory reporting of malfunctions, defects, and failures of evacuation systems; 

(4) Required Inspection Items (RII); 

(5) Functional testing of evacuation systems on the aircraft; and 

(6) Inspection intervals.

c. A study and evaluation of slide maintenance facilities by the Emergency Evaluation Task 

Force revealed various deficiencies in current maintenance practices. These deficiencies can 

compromise the safe and reliable operation of EES and contribute to slide malfunctions and 

failures during emergency evacuations, emergency evacuation demonstrations, and functional 

testing. An analysis of Service Difficulty Reports (SDR) and accident/incident data involving

aircraft evacuations disclosed the following problem areas: 

(1) Improper packing defects, which include: 

(a) Slides not folded in accordance with packing instructions;

(b) Slides twisted in containers; 

(c) Improper cover configuration; 

(d) Nylon webbing installed around the slide after folding;

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4/4/03 AC 43-208 

(e) Improper routing of the inflation hose; 

(f) Cross threading of the jet pump line;

(g) Improper routing of the firing lanyard; 

(h) Improper packboard installation; and 

(i) Incorrect frangible link installation. 

(2) Improper installation defects, which include: 

(a) Improperly routed firing inflation cable; 

(b) Unattached girt bar release cable;

(c) Uninstalled slide cover retainer cable; and 

(d) Improperly positioned slides. 

(3) Component failures/defects, which include: 

(a) Separated seams; 

(b) Low pressure in inflation bottle; 

(c) Bent slide fork fitting;

(d) Inflation tube failure; 

(e) Worn girt bar latch; 

(f) Torn fabric at girt bar attachment area;

(g) Broken pull handle cable assembly; 

(h) Broken lanyard; 

(i) Squib failure; 

(j) Flapper valve failure; and 

(k) Jammed girt bar. 

MAINTENANCE REQUIREMENTS 

6. What elements are essential for maintenance programs to reduce EES malfunctions and 

failures? 

An air carrier’s FAA-approved inspection program and FAA-approved continuous airworthiness 

maintenance program (CAMP) should contain the maintenance requirements for EES. The 

following program areas are identified as essential to an adequate maintenance program to reduce

EES malfunctions and failures. 

a. Maintenance Organization. The air carrier’s maintenance organization is responsible to 

see that maintenance on the EES is performed in accordance with its manual. The organization 

will also ensure that competent personnel, adequate facilities, and equipment training is provided 

for EES maintenance. Air carriers using the maintenance services of a contractor will also 

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AC 43-208 4/4/03 

provide the contractor with a copy of current, complete, and accurate instructions from its

maintenance manual.

b. Maintenance Manuals and Documents. 

(1) Each service and maintenance facility will maintain current applicable maintenance

manuals for the specific equipment being maintained. A maintenance manual control system

will be used to see that all manuals are current, and include applicable manufacturers’ service

letters and bulletins. 

(2) Minimum performance standards for emergency evacuation slides are provided in

Technical Standard Order TSO-C69, Emergency Evacuation Slides, Ramps, and Slide/Rafts, as 

revised. 

c. Training and Qualification. Because of the complexity and safety-critical nature of EES 

maintenance, the air carrier should see that each person performing maintenance or inspections 

on EES is properly trained and qualified and understands the current maintenance instructions. 

Inspection personnel training and documentation of EES maintenance should be part of the 

training program. In addition, the air carrier should consider including recurrent training as part 

of its training program and should determine the competency and currency of any contracted 

maintenance provider. The air carrier should also promote safety-critical awareness to any

person who works with or in the vicinity of EES. 

d. Records and Reports. 

(1) The mechanic or repairman should accomplish maintenance recordkeeping and 

reporting requirements in accordance with applicable regulations and the air carrier’s 

requirements. 

(2) The air carrier is required to have airworthiness release procedures for any EES 

maintenance, in accordance with 14 CFR 121.709. 

(3) The air carrier is required to have procedures for reporting the occurrence or detection 

of each failure, malfunction, or defect of any component of the EES, in accordance with 

14 CFR 121.703. This includes any failure, defect, or malfunction identified during an actual 

emergency or during training, testing, maintenance, demonstrations, or inadvertent deployments. 

e. Required Inspection Items (RII). The manufacturer should identify in its overhaul 

manual the critical tasks involved in packing, installing, and maintaining EES components. 

These tasks should be incorporated into the air carrier’s manual as RII items. 

f. Functional Testing.

(1) Functional testing of the evacuation slide while it is installed on the aircraft tests the

complete EES. This includes the operation of door systems with the evacuation system engaged, 

as well as slide inflation and deployment. Air carriers may perform functional testing of the

slides in conjunction with hands-on flight attendant training. 

(2) Documentation of functional testing is necessary to determine that any malfunction or

failure is adequately defined. This can identify potential maintenance and design changes to 

increase the reliability for the aircraft EES. Video recording is an effective method to use in 

documenting functional tests. 

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4/4/03 AC 43-208 

(3) All functional testing of the EES should be performed in accordance with the 

manufacturer’s instructions and as approved in the air carrier’s manual. 

g. Maintenance Facility. Maintenance and testing facilities should be kept clean, 

environmentally regulated (e.g., temperature/humidity control), and equipped with appropriate air 

handling and vacuum systems. To prevent foreign object damage to the slide assembly, 

slide-servicing areas should be segregated from all other types of work areas. 

7. What EES maintenance tasks should be conducted during scheduled maintenance? 

a. Maintenance tasks should be performed in accordance with the air carrier’s FAAapproved maintenance program, which is usually approved based on the manufacturer’s 

instructions for continued airworthiness. For EES’ continued airworthiness, manufacturers and 

air carriers should determine appropriate life limits of safety critical components. 

b. The following are examples of EES maintenance tasks incorporated into a typical

maintenance program: 

(1) Check the evacuation slide assembly for proper inflation bottle pressure. 

(2) Clean, inspect, and lubricate the girt bar and attachment latches. 

(3) Check the slide assembly operation by deploying the slide from the aircraft. 

Accomplish this check on a sampling inspection basis, so that continued maintenance

requirements remain valid and include, as part of the sampling inspection, accidental slide 

deployment data. Accidental deployment data may be used to support revised inspection or 

overhaul times. 

(4) Remove the slide from the aircraft and inspect the surrounding areas to determine that 

nothing could interfere with or prevent deployment. 

(5) Visually check the slide packboard release and deployment mechanism. 

(6) Perform an off-aircraft operational test of the slide to determine proper inflation and 

air retention, using facilities equipped for this type of testing.

(7) If a slide inadvertently falls from an aircraft, inspect it in accordance with the 

manufacturer’s instructions and procedures before reinstallation. Internal damage, which may

not be detectable by external inspections, may be present. 

8. Why are maintenance time limitations needed? 

a. Inspection periods for EES will determine the continued serviceability and immediate 

readiness of EES equipment for its intended emergency purpose. Major inspection periods are 

established to determine that all components of the equipment are complete and serviceable and 

may be expected to remain in this condition until either the next major inspection or actual use

under emergency conditions. 

b. Two types of inspection tasks are used in aircraft maintenance: failure-finding tasks, 

which identify functional failures, and failure prevention tasks, which identify potential failures. 

Therefore, an air carrier’s maintenance time limitations should contain a list of EES tasks, 

consisting of on-aircraft inspections, measurements, or tests, from which a determination is made

of the item’s capability to immediately perform its intended emergency purpose. Deployment or

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AC 43-208 4/4/03 

functional testing should be included and used on a sampling basis to validate the serviceability

of each item of the EES. In the continuing analysis and surveillance system (CASS) process (see 

paragraph 8) for EES, an increase of failures during deployments or functional testing will 

initiate a corresponding increase in the sampling rate. 

c. Scheduled deployments on the aircraft or during a combination of on-aircraft functional 

tests, inspections, and test-fixture usage may be used, provided the test-fixture replicates the 

aircraft installation. The number of scheduled deployment checks should be included for 

statistical validity. Inadvertent deployments, while a source of useful information, should not be 

considered or used as the sole source of reliability information. 

d. The inspection and overhaul time limits for EES may be revised after an air carrier has 

gained service experience and has substantiating data to justify a revision. The inspection 

periods for EES will determine the continued service readiness for emergency use. Revisions to 

inspection and overhaul times should be accomplished in accordance with the manufacturer’s 

recommendations and the air carrier’s approved maintenance program, where appropriate. 

9. What is the Continuing Analysis and Surveillance System (CASS)? 

CASS is an air carrier quality assurance system. The FAA has introduced regulatory

requirements that require air carriers to establish and use a system for the continued analysis and 

surveillance of the performance and effectiveness of inspection and maintenance programs. 

10. What related documents are available? 

a. 14 CFR. Title 14 CFR, sections 121.309, 121.310, and 121.373. 

b. FAA Document. Copies of U.S. Department of Transportation (DOT) FAA Report 

Number DOT/FAA/VS-86/1 (Volumes I and II), Task Force Report on Emergency Evacuation of 

Transport Airplanes (July 1986), may be obtained from the U.S. Department of Commerce, 

National Technical Information Service, 5285 Port Royal Road, Springfield, VA 22161 by

calling 1-800-553-6847. 

c. Advisory Circulars. Copies of the following ACs may be obtained from the U.S. 

Department of Transportation, Subsequent Distribution Office, SVC-121.23, Ardmore East 

Business Center, 3341 Q 75th, Landover, MD 20785, or at http://www1.airweb.faa.gov/ 

Regulatory_and_Guidance_Library/rgAdvisoryCircular.nsf/MainFrame?OpenFrameSet. 

(1) AC 00-46, Aviation Safety Reporting Program, as revised. 

(2) AC 20-41, Substitute Technical Standard Order (TSO) Aircraft Equipment, as 

revised. 

(3) AC 20-62, Eligibility, Quality, and Identification of Aeronautical Replacement Parts, 

as revised. 

(4) AC 20-77, Use of Manufacturers’ Maintenance Manuals. 

(5) AC 20-114, Manufacturers’ Service Documents. 

(6) AC 120-16, Continuous Airworthiness Maintenance Programs, as revised. 

(7) AC 120-17, Maintenance Control by Reliability Methods, as revised. 

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AC 43-208 4/4/03 

(8) AC 121-1, Standard Operations Specifications Aircraft Maintenance Handbook, as 

revised. 

(9) AC 121-22, Maintenance Review Board (MRB), as revised. 

d. Other Documents. Technical Standard Order TSO-C69, Emergency Evacuation Slides, 

Ramps, and Slide/Rafts, as revised. Copies may be obtained from FAA, Office of Airworthiness, 

Aircraft Certification Service, Aircraft Technical Programs Branch (AIR-120), 800 Independence 

Ave., S.W., Washington, D.C. 20591. 

11. How can one get copies of this and other FAA publications? 

a. You can purchase the CFRs and those ACs from the Superintendent of Documents, U.S. 

Government Printing Office, Washington, D.C. 20402. A list of all ACs is available at 

http://www1.airweb.faa.gov/Regulatory_and_Guidance_Library/

rgAdvisoryCircular.nsf/MainFrame?OpenFrameSet. You can also obtain a copy of current 

regulations from the CFR online at http://www.access.gpo.gov/ecfr/. 

b. You can request free ACs from the U.S. Department of Transportation, Subsequent 

Distribution Office, Ardmore East Business Center, 3341 Q 75th Avenue, Landover, MD 20785. 

c. You can be placed on FAA’s mailing list for free ACs by contacting the U.S. Department 

of Transportation, SVC-121.21, Distribution Requirements Section, Washington, D.C. 20590. 

/s/ Louis Cusimano for

James J. Ballough 

Director, Flight Standards Service 

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