ALL OPERATORS TELEX - ALL OPERATORS TELEX

SUBJECT: A319/A320/A321 - ATA 55-40 – INSPECTION OF RUDDER SIDE SHELLS FOR POTENTIAL SKIN TO HONEYCOMB DISBOND (INSPECTION PROGRAM DIFFERENT FROM AOT A320-55A1038) OUR REF: A320-55A1039 dated 4 November 09

1. AIRCRAFT AFFECTED All A319/A320/A321 aircraft equipped with rudders referenced below: In case a rudder originally fitted on one aircraft (refer to AIR: 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 does not reflect the current status or if the identification plate is missing, contact Airbus. Configuration 1: Rudder SN MSN A/L TS-2081 0711 ACA TS-3004 1623 ACA TS-2511 1137 AUA TS-3288 1901 GFA TS-2768 1379 IBE TS-2160 0792 LVG TS-1278 0275 MXA TS-2999 1618 MXA TS-2129 0763 TAP TS-2125 0759 UAL TS-2201 0836 UAL TS-3051 1664 UAL TS-2328 0953 USA TS-2425 1050 USA Rudders listed in configuration 1 correspond to rudders that have to be inspected in bounded shell area only. Configuration 2: Rudder SN MSN A/L TS-2124 0760 ABQ TS-2123 0757 ACA TS-1092 0090 IAC TS-3694 2322 JST TS-3061 1673 MXA TS-1032 0032 NWA TS-2424 1058 NWA TS-2109 0745 PAL TS-1314 0311 ART TS-1520 0520 SWR TS-2037 0673 SWR TS-3709 2340 TGW TS-1428 0424 TCX TS-2559 1181 TAP TS-1445 0442 UAL TS-4148 2785 VLG Rudders listed in configuration 2 correspond to rudders that have to be removed from the aircraft within the compliance time given in paragraph 4.1.1.2.2. REFERENCED DOCUMENTATION REF.1: OIT 999.0092/08: ATA55 – Rudder side shell skin disbonding REF 2: AOT A320-55A1038 Rev.02 dated 28 September 2009 REF.3: A319/A320/A321 SRM 55-41-13 Fig. 1 item 1 and item 5 REF.4. NTM TASK 51-10-26-220-801 – (ELCh inspection) REF 5: NTM TASK 51-10-28-220-801 – (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 51-10-10-260-801 – (X-Ray inspection) REF 8: NTM TASK 51-10-24-270-801 – Temporary Revision from NTM August 09 – TR 51-004 (Ultrasonic 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. For rudders that have been reworked in production with similar hot curing process, an inspection program is being build-up, which calls for vacuum loss inspection and/or Elasticity Laminate Checker (ELCh) inspection depending on the affected rudder shell areas:

- Inspection of rudders having accumulated more than 20000 FC is covered by AOT REF.2, except for those listed in this AOT.

- Inspection of other rudders will be covered by forthcoming Service Bulletins, except for those listed in this AOT.
3.2 AIM Rudders listed in the effectivity of this AOT have also been reworked with similar hot curing process. However they require a different inspection program ( due to rework location not fully recorded) than those inspected through AOT REF.2. Therefore this AOT calls for a specific process depending on the rudder configuration.

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 22Fax: +33 (0)5 61 93 27 45 Mailto: wera.dietz@airbus.com

4.1.1 ACCOMPLISHMENT TIMESCALE For the purpose of this AOT a Reference Date is defined as the receipt date of this AOT, or the date when the rudder will accumulate 20000 FC from it first installation on aircraft, whichever occurs later. 4.1.1.1 RUDDERS CONFIGURATION 1 For each rudder referenced paragraph 1 configuration 1, the inspection process will have to be carried out in two phases:

- Phase 1 – Inspections including X-Ray: The inspections described in paragraph 4.2.2.1.1 must be performed within 20 months from the receipt date of this AOT, or within 200 days from the Reference Date of this AOT, whichever occurs first. These inspections include: ? For areas with complete documentation ? A one-time ELCh inspection at rudder trailing edge area (not terminative) ? A terminating one-time vacuum loss inspection at rudder reinforced areas and other areas ? For areas with not complete documentation ? An ELCh, X-Ray and thermography (when necessary) inspection Then, Airbus will provide a second Technical Disposition to: ? For areas with complete documentation ? Provide repetitive ELCh inspection instructions for trailing edge area. ? For areas with not complete documentation (based on X-Ray films) ? Provide repetitive ELCh inspection instructions for trailing edge area. ? Provide terminating one-time vacuum loss inspection instructions in other areas

- Phase 2 – Remaining inspection actions: The inspections described in paragraph 4.2.2.1.2 must be performed within 200 days/1500 FC (whichever occurs first) from the inspection phase 1 date. For this phase 2 inspection: o For the trailing edge area: The ELCh inspection will have to be repeated two times, at intervals not exceeding 4500 FC, but not less than 4000 FC from the last inspection. Following the third inspection without finding, no further action is required. o For the other areas, the one-time vaccum loss inspection will be a terminating action.
4.1.1.2 RUDDERS CONFIGURATION 2 For rudders SN TS-1032 and SN TS-1092 (which have an honeycomb core density of 24 kg/m3), the action described in paragraph 4.2.2.2 must be performed within 200 days from the receipt date of this AOT. For the other rudders in configuration 2, the action described in paragraph 4.2.2.2 must be performed within 20 months from the receipt date of this AOT, or 200 days from the Referenced Date of this AOT, whichever occurs first.
4.1.2 MANPOWERThe 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: 1.5 man-hours per square meter. C) X-Ray inspection 12 hours maximum elapsed time
4.2 DESCRIPTION 4.2.1 JOB PREPARATION AND ACCESS Refer to the Technical Dispositions paragraph "Job preparation".
4.2.2 INSPECTION INSTRUCTIONS 4.2.2.1 RUDDERS CONFIGURATION 1 4.2.2.1.1 INSPECTION PHASE 1 Perform vacuum loss inspection (terminating action) or ELCh inspection according to specific Technical Dispositions referenced below. For special indicated areas perform ELCh, X-Ray and thermography inspections.Airbus will propose an X-ray supervisor to support this activity onsite, and to ensure X-Ray films are accurate enough to map the production rework. Please contact SEOT2 (c.f parag. 4.1) for inspection planning. Rudder SN Technical Disposition TS-1278 TD/K4/S2/28732/2009 issue A TS-2081 TD/K4/S2/28735/2009 issue A TS-2125 TD/K4/S2/28736/2009 issue A TS-2129 TD/K4/S2/29269/2009 issue A TS-2160 TD/K4/S2/28737/2009 issue A TS-2201 TD/K4/S2/28729/2009 issue A TS-2328 TD/K4/S2/28730/2009 issue A TS-2425 TD/K4/S2/28731/2009 issue A TS-2511 TD/K4/S2/28733/2009 issue A TS-2768 TD/K4/S2/28734/2009 issue A TS-2999 TD/K4/S2/28738/2009 issue A TS-3004 TD/K4/S2/28739/2009 issue A TS-3051 TD/K4/S2/28740/2009 issue A TS-3288 TD/K4/S2/28741/2009 issue A These Technical Dispositions 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
4.2.2.1.2 INSPECTION PHASE 2 Perform the vacuum loss and/or ELCh inspections according to thespecific Technical Dispositions which will be issued by Airbus, based on the X-Ray inspection pictures. Remaining repetitive ELCh inspections for Trailing Edge area will be also addressed by these phase 2 Technical Dispositions. A 10 days lead-time is estimated to produce the Technical Disposition after receipt of the X-Ray films (refer to paragraph 4.2.5). References are given below: Rudder SN Technical Disposition TS-1278 TD/K4/S2/28790/2009 issue A TS-2081 TD/K4/S2/28793/2009 issue A TS-2125 TD/K4/S2/28794/2009 issue A TS-2129 TD/K4/S2/29270/2009 issue A TS-2160 TD/K4/S2/28795/2009 issue A TS-2201 TD/K4/S2/28787/2009 issue A TS-2328 TD/K4/S2/28788/2009 issue A TS-2425 TD/K4/S2/28789/2009 issue A TS-2511 TD/K4/S2/28791/2009 issue A TS-2768 TD/K4/S2/28792/2009 issue A TS-2999 TD/K4/S2/28796/2009 issue A TS-3004 TD/K4/S2/28797/2009 issue A TS-3051 TD/K4/S2/28798/2009 issue A TS-3288 TD/K4/S2/28799/2009 issue A
4.2.2.2 RUDDERS CONFIGURATION 2 The rudder must be removed from the aircraft and replaced. Airbus must be contacted in order to get instructions for further use of this rudder.
4.2.3 JOB CLOSE UP Refer to the Technical Dispositions 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, SEES1 Customer Services Phone: +33 (0)5 61 93 34 38Fax: +33 (0)5 61 93 36 14 Mailto: nicolas.seynaeve@airbus.com For rudders in configuration 1: Hardware (developed X-Ray films and the film layout arrangement) has to be sent within 10 days from the inspection date to: Wolfgang Bisle Department EDSWNG AIRBUS Deutschland GmbH Airbus-Allee 1 28199 Bremen Germany 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 X-Ray as per REF.7

- Inspection equipment for Ultrasonic as per REF.8 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 (option I): Hole closing with selfadhesive patches, allowed for 4500 FC. Correct cover application has to be ensured by frequent detailed visual inspections until permanent restoration is performed, at intervals not exceeding 750 FC/100 days (whichever occurs first), or

- Temporary restoration (option II): Hole filling with resin. Ultrasonic inspection in reinforced areas only and local thermography inspection in other areas are required before resin injection. Final restoration has to be performed not later than 4500 FC.

- Permanent restoration: Hole filling with resin and restoration of surface protection. Ultrasonic inspection in reinforced areas only and local thermography inspection in other areas are required before resin injection. 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 48hours 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 the integrity 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 the Airbus AOLS system or request that it be retransmitted by fax or telex.