CESSNA AIRCRAFT COMPANY 

P. O. BOX 7704 

WICHITA, KANSAS 67277-7704 

STRUCTURES 

MODEL NO: 150 (and others) 

REPORT NO: S-150-ATA25/01RD 

REPAIR DEFINITION 

STEEL SEAT FOOT / ROLLER HOUSING REPAIR 

REPORT DATE: July 28, 2011 

PREPARED BY: John Baldessari 

John Baldessari 

PREPARED BY: Gale Meek 

Gale Meek 

APPROVED BY: Tony Massucci 

Tony Massucci 

Cessna Aircraft Company Page 1.1

P. O. Box 7704 Report S-150-ATA25/01RD

Wichita, KS 67277 Aircraft: multiple serial nos.

1.0 AIRCRAFT DATA

This repair is valid for the following aircraft models and serials numbers: 

Model Serial Range 

150 15059019 15079405 

F150 F150-0001 F15001428 

A150 A1500001 A1500734 

FA150 FA1500001 FA1500120 

FRA150 FRA1500121 FRA1500336 

152 15279406 15286033 

F152 F15201429 F15201980 

A152 A1520735 A1521049 

FA152 FA1520337 FA1520425 

FA152 FA1520348 FA1520425 

SPECIAL NOTES

• This Repair Definition covers only the damage defined in this document 

and it is the responsibility of the repair facility to assure that the defined 

damage agrees with the actual damage, i.e. no cracks, no twisting, or 

other damage. 

• All nondestructive inspections (NDI) specified in the Repair Definition must 

be performed by a qualified facility. 

The repair described in the report satisfies applicable strength and fatigue, fail 

safe, and/or damage tolerance requirements. Approved data for structural 

substantiation and back-up data for this repair are contained in Engineering’s 

Repair Definition Archive. 

The structural repairs designed herein for these aircraft do not affect the original 

structural inspection criteria (procedures or timing) as published in the 

appropriate Cessna Maintenance Manuals. 

The repair definition contained within this document has been found to comply 

with the following regulations: 

Part 3 of the Civil Air Regulations dated May 25, 1956, as amended by 3-4, 

Paragraphs 3.171, 3.172, 3.173, 3.174, 3.292, 3.293, 3.294, 3.295, 3.296, 

and 3.386.

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Cessna Aircraft Company Page 2.1

P. O. Box 7704 Report S-150-ATA25/01RD

Wichita, KS 67277 Aircraft: multiple serial nos.

2.0 DAMAGE DESCRIPTION

FAA Airworthiness Directive (AD) 2011-10-09 became effective June 17, 2011, 

and requires Cessna Aircraft owners to inspect seat rails and seat foot (“roller 

housing”) structure for cracks, wear, or other deformations. 

Among other requirements, the AD specifies that the geometry for the tangs of 

the seat roller housings must fall within certain limits -- reference. AD 2011-10-

09 paragraphs (g)(6), (g)(6)(i), and Figure 4 (reproduced in Fig. 2.0-1 below). 

FIGURE 2.0-1 ROLLER HOUSING TANG GEOMETRY REQUIREMENTS PER 

AD 2011-10-09

(6) Due to wear or deformation of the tangs, inspect the tang length from the inner edge of 

the tang to the outer edge (the bend area) of the roller housing (see figure 4). 

(i) The minimum measurement allowed for the remaining tang length is 0.230 inches 

remaining on either of the tangs, from the inner edge of the tang to the outer edge (the bend 

area) of the roller housing. If the measurement is less than 0.230 inches on either of the tangs, 

before further flight, replace the roller housing. 

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Cessna Aircraft Company Page 2.2

P. O. Box 7704 Report S-150-ATA25/01RD

Wichita, KS 67277 Aircraft: multiple serial nos.

In the case of seats which use steel roller housings (e.g. as defined by Cessna 

drawings 0311310 “Roller, Pilot Seat”, and 0514016 “Housing Assy – Seat 

Roller”), the tangs may not meet the dimensional requirements set forth in the AD 

due to primarily to deformation or bending of the seat feet, rather than being 

caused by actual wear / loss of material. Ref. Figures 2.0-2 and 2.0-3 for 

examples of this type of deformation / bending of roller housing geometry. 

FIGURE 2.0-2 DETAIL OF BENDING / DEFORMATION OF SEAT ROLLER 

HOUSING SIDE WALL

steel seat foot / roller housing 

m/f 0.080” thick 4130 sheet, 

90 ksi (typ.) 

roller housing side 

wall bent out from 

vertical / parallel to 

opposite side wall 
Cessna Aircraft Company Page 2.3

P. O. Box 7704 Report S-150-ATA25/01RD

Wichita, KS 67277 Aircraft: multiple serial nos.

FIGURE 2.0-3 DETAIL OF DEFORMED / BENT SEAT ROLLER HOUSING 

TANGS

steel seat foot / roller housing 

m/f 0.080” thick 4130 sheet, 

90 ksi (typ.) 

roller housing tang bent 

out from nominal position 

of approx. 10.33° from 

horizontal 
Cessna Aircraft Company Page 3.1

P. O. Box 7704 Report S-150-ATA25/01RD

Wichita, KS 67277 Aircraft: multiple serial nos

3.0 REPAIR DEFINITION

Read the entire service document prior to beginning the repair; contact Cessna 

Customer Service if the repair cannot be performed as described below. Steel 

seat roller housings may be gently formed (or “bent”) back to a configuration 

conforming to specifications as shown in Figure3.2-1 below and AD 2011-10-09, 

followed by an NDI inspection (as identified in paragraph 3.2.4) for any cracking. 

Note that this is a cold forming operation. No heating is to be done for this 

operation. 

This repair procedure is only applicable to seats which are listed in Section 1.0 

which have not been modified with non-production roller housings. Production 

seat roller housings are made of 4130 steel and in normalized (90 ksi) condition. 

3.1 MATERIALS REQUIRED FOR REPAIR

No special materials are required to perform this repair. 

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Cessna Aircraft Company Page 3.2

P. O. Box 7704 Report S-150-ATA25/01RD

Wichita, KS 67277 Aircraft: multiple serial nos

3.2 REPAIR PROCEDURE

1. Using suitable tools, form (or “bend”) the roller housing side walls and 

tangs to match the geometry specifications shown in Figure 3.2-1 below 

(or as close as possible, while still preventing interference with the seat 

rail and allowing free movement). Suitable tools include a hardwood block 

that will fit inside the roller housing, a non-marring hammer, pliers or vice 

grips with smooth jaws, or similar tools suitable for forming or bending 

without damage to the roller housing. 

FIGURE 3.2-1 ROLLER HOUSING GEOMETRY SPECIFICATIONS

0311312 -4, -5 Roller Housing 

0514016 -2, -4 Housing 

0.080” thick 4130 sheet 

normalized (90 ksi) 

0.41” 

(ref.) 90° ± 5° 

2 pl. 

10.33° ± 5° 

2 pl. 

0.11” R 

min., 2 pl. 

0.77” 

(ref.) 

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Cessna Aircraft Company Page 3.3

P. O. Box 7704 Report S-150-ATA25/01RD

Wichita, KS 67277 Aircraft: multiple serial nos

2. Polish to a surface finish of 125 RMS (surface smoothness, ref. ASME 

B46.1-2009) or better following all forming operations. Take care not to 

nick, gouge, or wrinkle any of the roller housing surfaces during forming 

operations. 

3. Following forming operations, check roller housing geometry against the 

requirements set forth in AD 2011-10-09. If the geometry still does not 

meet the requirements of AD 2011-10-09, the roller housing must be 

replaced. 

4. Following forming operations, check all surfaces of the roller housing for 

cracks using dye penetrant and/or eddy current inspection methods. If 

any cracks are found, the roller housing must be replaced. 

5. Repair surface finish / paint where required in accordance with the 

appropriate Cessna Maintenance Manual for the model of aircraft being 

repaired. 

6. Make a logbook entry stating compliance with this repair definition. 

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Cessna Aircraft Company Page 3.4

P. O. Box 7704 Report S-150-ATA25/01RD

Wichita, KS 67277 Aircraft: multiple serial nos

3.3 GENERAL

• This repair is authorized for the stated Serial Numbered airplanes only. 

• This repair is for an unmodified airplane. Any non-Cessna modification that 

affects the aircraft gross weight, original design, or performance may 

invalidate published Continued Airworthiness requirements (i.e., inspection 

techniques and/or interval). Contact the STC Holder or originator of the 

modification for revised inspection criteria.