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[Federal Register Volume 90, Number 26 (Monday, February 10, 2025)]
[Rules and Regulations]
[Pages 9203-9207]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2025-02395]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2023-1488; Project Identifier AD-2023-00182-T; 
Amendment 39-22946; AD 2025-02-13]
RIN 2120-AA64

Airworthiness Directives; The Boeing Company Airplanes

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
certain The Boeing Company Model 757-200, -200CB, and -200PF series 
airplanes. This AD was prompted by a report indicating an operator has 
found cracks on three Model 757-200PF airplanes at the main deck cargo 
door cutout forward and aft hinge attachment holes. This AD requires a 
maintenance record check for repairs at the forward and aft hinge areas 
of the main deck cargo door cutout; repetitive open-hole high frequency 
eddy current (HFEC) inspections for cracks in the unrepaired areas of 
the bear strap, skin, doubler, and upper sill chord at the main deck 
cargo door forward and aft hinge attachment holes; and applicable 
corrective actions. The FAA is issuing this AD to address the unsafe 
condition on these products.

DATES: This AD is effective March 17, 2025.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of March 17, 
2025.

ADDRESSES: 
    AD Docket: You may examine the AD docket at regulations.gov under 
Docket No. FAA-2023-1488; or in person at Docket Operations between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays. The AD 
docket contains this final rule, any comments received, and other 
information. The address for Docket Operations is U.S. Department of 
Transportation, Docket Operations, M-30, West Building Ground Floor, 
Room W12-140, 1200 New Jersey Avenue SE, Washington, DC 20590.

[[Page 9204]]

    Material Incorporated by Reference:
     For Boeing material identified in this AD, contact Boeing 
Commercial Airplanes, Attention: Contractual & Data Services (C&DS), 
2600 Westminster Blvd., MC 110-SK57, Seal Beach, CA 90740-5600; 
telephone 562-797-1717; website myboeingfleet.com.
     You may view this material at the FAA, Airworthiness 
Products Section, Operational Safety Branch, 2200 South 216th St., Des 
Moines, WA. For information on the availability of this material at the 
FAA, call 206-231-3195. It is also available at regulations.gov under 
Docket No. FAA-2023-1488.

FOR FURTHER INFORMATION CONTACT: Wayne Ha, Aviation Safety Engineer, 
FAA, 2200 South 216th Street, Des Moines, WA 98198; phone: 562-627-
5238; email: [email protected].

SUPPLEMENTARY INFORMATION: 

Background

    The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 
CFR part 39 by adding an AD that would apply to certain The Boeing 
Company Model 757-200, -200CB, and -200PF series airplanes. The NPRM 
published in the Federal Register on August 4, 2023 (88 FR 51745). The 
NPRM was prompted by a report of cracks found at the main deck cargo 
door forward and aft hinge attachment holes. In the NPRM, the FAA 
proposed to require a maintenance records check for repairs at the 
forward and aft hinge areas of the main deck cargo door cutout; 
repetitive open-hole high frequency eddy current (HFEC) inspections for 
cracks in the unrepaired areas of the bear strap, skin, doubler, and 
upper sill chord at the main deck cargo door forward and aft hinge 
attachment holes; and corrective actions. The FAA is issuing this AD to 
detect and correct cracks in the main deck cargo door hinge area, which 
could result in reduced structural integrity of the airplane.
    The FAA issued a supplemental notice of proposed rulemaking (SNPRM) 
to amend 14 CFR part 39 by adding an AD that would apply to certain The 
Boeing Company Model 757-200, -200CB, and -200PF series airplanes. The 
SNPRM published in the Federal Register on April 29, 2024 (89 FR 
33294). The SNPRM was prompted by a determination that airplanes that 
have been modified from a passenger to a freighter configuration using 
VT Mobile Aerospace Engineering (VT MAE) Supplemental Type Certificate 
(STC) ST03562AT, ST03952AT, or ST04242AT were inadvertently omitted in 
the NPRM. The SNPRM proposed to add airplanes to the applicability. The 
FAA is issuing this AD to address the unsafe condition on these 
products.

Discussion of Final Airworthiness Directive

Comments

    The FAA received a comment from Boeing who supported the SNPRM 
without change.
    The FAA received additional comments from FedEx Express (FedEx) and 
VT Mobile Aerospace Engineering (VT MAE). The following presents the 
comments received on the SNPRM and the FAA's response to each comment.

Requests To Extend Compliance Time for Certain Airplanes

    FedEx stated that the FAA is placing an unrealistic timeline and 
burden, without any data, on operators with airplanes modified by VT 
MAE STC ST03562AT. Within paragraph (g)(1) of the proposed AD and 
paragraph 3, Compliance, of Boeing Alert Requirements Bulletin 757-
53A0106 RB, dated January 3, 2023, the FAA is granting airplanes 
identified in paragraph (c)(1)(i) of the proposed AD and paragraph 1, 
Effectivity, of Boeing Alert RB 757-53A0106 RB, dated January 3, 2023, 
a minimum of 2,800 flight cycles, but the modified VT MAE STC ST03562AT 
airplanes only get 30 days. FedEx stated that there is no way FedEx can 
comply with a 30-day maintenance record check on 118 airplanes. This 
unsubstantiated 30-day compliance time will end up grounding a majority 
of the FedEx 757-200 fleet. If the FAA keeps this proposed 30-day 
maintenance record check compliance, FedEx will immediately request 
approval to extend the compliance time via an alternative method of 
compliance (AMOC). However, AMOC processing by the FAA could take 30 
days to approve and still result in a FedEx 757-200 fleet grounding, 
even if the FAA agrees to the extension.
    Similarly, VT MAE stated that it is impossible for their operators 
to comply with the requirements within 30 days after the effective date 
of the AD. This is particularly true for FedEx, which operates 118 
Boeing Model 757-200 special freighter airplanes converted per VT MAE 
STC ST03562AT (14 pallet configuration). VT MAE added that for the 
airplanes converted per VT MAE STC ST03562AT (14 Pallet Configuration), 
VT MAE STC ST03952AT (14 pallet configuration), and VT MAE STC 
ST04242AT (15 pallet configuration), the installation of the main deck 
cargo door hinge is identical to the Boeing 757-200 Special Freighter 
(SF) airplanes converted per Boeing STC ST00916WI-D. The installation 
of the main deck cargo door hinge in Drawing 657N3270 that is 
applicable to both Boeing Model 757-200SF series airplanes and modified 
VT MAE STC airplanes per VT MAE STC ST03562AT (14 pallet 
configuration), VT MAE STC ST03952AT (14 pallet configuration), and VT 
MAE STC ST04242AT (15 pallet configuration).
    The FAA agrees with the requests. The FAA did not intend to require 
a maintenance record check for any repair at the forward and aft hinge 
areas of the main deck cargo door cutout in paragraph (g)(2) of the 
proposed AD. The FAA has changed paragraph (g)(2) of this AD to require 
obtaining inspection instructions and applicable repair instructions 
using a method approved by the FAA. The FAA agrees that the Boeing 
Model 757 airplanes that have been modified by VT MAE STC ST03562AT (14 
pallet configuration), ST03952AT (14 pallet configuration), and 
ST04242AT (15 pallet configuration) are affected by this AD, because 
these airplane configurations have the main deck cargo door cutouts.

Request To Use Work Instructions for Group 2 in Boeing Alert 
Requirements Bulletin 757-53A0106 RB for Modified VT MAE STC Airplanes

    FedEx referred to paragraph (g)(2) of the proposed AD, which would 
require obtaining inspection instructions and applicable repair 
instructions using a method approved by the FAA. Boeing STC ST00916WI-D 
and VT MAE STC ST03562AT are identical. The VT MAE STC ST03562AT main 
deck cargo door hinge installation is done in accordance with Boeing 
Drawing 657N3270, which is applicable to Model Boeing 757-200SF 
airplanes. According to Boeing Letter FED-SU-1901571 and VT MAE 
Document No. 337/STR-100, both Boeing and VT MAE own the technical data 
for VT MAE STC ST03562AT. For repairs, service bulletins, ADs, etc., on 
Boeing Model 757-200 airplanes, Boeing and VT MAE provide direction and 
approval to FedEx. As stated in the initial comment period by FedEx and 
VTMAE, FedEx will be utilizing the Group 2 instructions in Boeing Alert 
Requirements Bulletin 757-53A0106 RB, dated January 3, 2023, to address 
the unsafe condition identified in the SNPRM. If this is not acceptable 
to the FAA, FedEx requested that the FAA provide a method of compliance 
(MOC) for VT MAE STC ST03562AT airplanes to comply with the SNPRM. 
According to FedEx and VT MAE (design approval holder), utilizing the 
Group 2 instructions in Boeing Alert Requirements Bulletin 757-53A0106

[[Page 9205]]

RB, dated January 3, 2023, will address the unsafe condition identified 
in the SNPRM.
    Therefore, FedEx requested a change to the requirements for 
airplanes converted to a freighter configuration using VT MAE STC 
ST03562AT, ST03952AT, or ST04242AT. Specifically, FedEx requested that 
those airplanes be required to use instructions for Group 2 in Boeing 
Alert Requirements Bulletin 757-53A0106 RB, dated January 3, 2023.
    Similarly, VT MAE proposed to utilize the inspections, methods, and 
intervals \1\ in Group 2 of Boeing Alert Requirements Bulletin 757-
53A0106 RB, dated January 3, 2023, for the modified airplanes per VT 
MAE STC ST03562AT (14 pallet configuration), VT MAE STC ST03952AT (14 
pallet configuration), and VT MAE STC ST04242AT (15 pallet 
configuration).
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    \1\ Initial compliance time of 27,500 flight cycles from the 
freighter conversion date or 2,800 flight cycles after the effective 
date of the AD, with repetitive inspections at intervals not to 
exceed 7,000 flight cycles.
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    The FAA does not agree with the requests. At this time, whether the 
VT MAE and Boeing STCs are identical in the areas affected by this 
proposed AD or using the compliance methods and times for Group 2 
airplanes adequately address the identified unsafe condition has not 
been determined. FedEx and VT MAE are to request that the FAA provide a 
method of compliance (MOC) for airplanes with VT MAE STC ST03562AT (14 
pallet configuration), VT MAE STC ST03952AT (14 pallet configuration), 
and VT MAE STC ST04242AT (15 pallet configuration) to comply with the 
SNPRM. The FAA has not changed this AD in response to this request.
    The FAA does not agree to change paragraph (g)(2) as FedEx 
specifically requested but has changed paragraph (g)(2) of this AD from 
a requirement to perform a maintenance record check for repairs to a 
requirement to obtain inspection instructions and applicable repair 
instructions.

Request To Base Compliance Time on AD Type

    FedEx stated that a 30-day compliance time is designated for 
emergency ADs. The commenter stated that as paragraph (g)(2) of the 
proposed AD is written, the FAA is forcing an emergency AD on VT MAE 
STC ST03562AT airplanes in paragraph (c)(1)(ii) of the proposed AD with 
no substantiating data, while airplanes identified in paragraph 
(c)(1)(i) of the proposed AD, Group 2 (Boeing STC ST00916WI-D 
airplanes) are allowed to maintain the original compliance time (27,500 
flight cycles after conversion or 2,800 flight cycles after the AD's 
effective date, whichever occurs later). FedEx pointed out that the FAA 
is applying inconsistent compliance times for airplanes modified per 
Boeing STC ST00916WI-D and airplanes modified by VT MAE STC ST03562AT 
airplanes--and, as stated in a previous comment, these are identical 
STCs.
    The FAA does not agree with this request. There is no merit to 
FedEx's statement that a 30-day compliance time is designated for 
emergency ADs. The compliance time does not determine the type of AD, 
and the AD type is not limited to a compliance time range. This is not 
an emergency AD. The 30-day compliance time is to allow for FedEx and 
VT MAE to request the FAA to provide a method of compliance (MOC) for 
airplanes modified with VT MAE STCs to comply with the AD. Boeing and 
VT MAE own the technical data, which can be provided for justification 
prior to the compliance time ending. The FAA has not changed this AD in 
response to this request.

Conclusion

    The FAA reviewed the relevant data, considered any comments 
received, and determined that air safety requires adopting this AD as 
proposed. Accordingly, the FAA is issuing this AD to address the unsafe 
condition on these products. Except for minor editorial changes, and 
any other changes described previously, this AD is adopted as proposed 
in the SNPRM. None of the changes will increase the economic burden on 
any operator.

Material Incorporated by Reference Under 1 CFR Part 51

    The FAA reviewed Boeing Alert Requirements Bulletin 757-53A0106 RB, 
dated January 3, 2023. This material specifies procedures for a 
maintenance record check for repairs at the forward and aft hinge areas 
of the main deck cargo door cutout; repetitive open-hole HFEC 
inspections for cracks in the unrepaired areas of the bear strap, skin, 
doubler, and upper sill chord at the main deck cargo door forward and 
aft hinge attachment holes; and corrective actions including obtaining 
and following procedures for alternative inspections and crack repairs.
    This material is reasonably available because the interested 
parties have access to it through their normal course of business or by 
the means identified in the ADDRESSES section.

Costs of Compliance

    The FAA estimates that this AD affects 564 airplanes of U.S. 
registry. The FAA estimates the following costs to comply with this AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                Cost on U.S.
              Action                    Labor cost        Parts cost    Cost per product          operators
----------------------------------------------------------------------------------------------------------------
Maintenance record check.........  1 work-hour * x $85            $0  $85.................  $47,940.
                                    per hour = $85.
HFEC inspections.................  26 work-hours x $85             0  $2,210 per            $1,246,440 per
                                    per hour = $2,210,                 inspection cycle.     inspection cycle.
                                    per inspection
                                    cycle.
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* The time to do the maintenance record check will vary by operator but would likely take no more than 1 work-
  hour per airplane.

    The FAA has received no definitive data on which to base the cost 
estimates for the on-condition actions specified in this AD.

Authority for This Rulemaking

    Title 49 of the United States Code specifies the FAA's authority to 
issue rules on aviation safety. Subtitle I, section 106, describes the 
authority of the FAA Administrator. Subtitle VII: Aviation Programs, 
describes in more detail the scope of the Agency's authority.
    The FAA is issuing this rulemaking under the authority described in 
Subtitle VII, Part A, Subpart III, Section 44701: General requirements. 
Under that section, Congress charges the FAA with promoting safe flight 
of civil aircraft in air commerce by prescribing regulations for 
practices, methods, and procedures the Administrator finds necessary 
for safety in air commerce. This regulation is within the scope of that 
authority because it addresses an unsafe condition that is likely to 
exist or

[[Page 9206]]

develop on products identified in this rulemaking action.

Regulatory Findings

    This AD will not have federalism implications under Executive Order 
13132. This AD will not have a substantial direct effect on the States, 
on the relationship between the national government and the States, or 
on the distribution of power and responsibilities among the various 
levels of government.
    For the reasons discussed above, I certify that this AD:
    (1) Is not a ``significant regulatory action'' under Executive 
Order 12866,
    (2) Will not affect intrastate aviation in Alaska, and
    (3) Will not have a significant economic impact, positive or 
negative, on a substantial number of small entities under the criteria 
of the Regulatory Flexibility Act.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

The Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA amends 14 CFR part 39 as follows:

PART 39--AIRWORTHINESS DIRECTIVES

0
1. The authority citation for part 39 continues to read as follows:

    Authority: 49 U.S.C. 106(g), 40113, 44701.

Sec.  39.13  [Amended]

0
2. The FAA amends Sec.  39.13 by adding the following new airworthiness 
directive:

2025-02-13 The Boeing Company: Amendment 39-22946; Docket No. FAA-
2023-1488; Project Identifier AD-2023-00182-T.

(a) Effective Date

    This airworthiness directive (AD) is effective March 17, 2025.

(b) Affected ADs

    None.

(c) Applicability

    (1) This AD applies to The Boeing Company Model 757-200, -200CB, 
and -200PF series airplanes specified in paragraph (c)(1)(i) or (ii) 
of this AD, certificated in any category.
    (i) Airplanes identified in Boeing Alert Requirements Bulletin 
757-53A0106 RB, dated January 3, 2023.
    (ii) Airplanes converted to a freighter configuration using VT 
MAE Supplemental Type Certificate (STC) ST03562AT, ST03952AT, or 
ST04242AT.
    (2) Installation of STC ST01518SE does not affect the ability to 
accomplish the actions required by this AD. Therefore, for airplanes 
on which STC ST01518SE is installed, a ``change in product'' 
alternative method of compliance (AMOC) approval request is not 
necessary to comply with the requirements of 14 CFR 39.17.

(d) Subject

    Air Transport Association (ATA) of America Code 53, Fuselage.

(e) Unsafe Condition

    This AD was prompted by a report indicating an operator has 
found cracks on three Model 757-200PF airplanes at the main deck 
cargo door cutout forward and aft hinge attachment holes. The FAA is 
issuing this AD to detect and correct cracks in the main deck cargo 
door hinge area. Undetected cracks in the main deck cargo door hinge 
area could result in reduced structural integrity of the airplane.

(f) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.

(g) Required Actions

    (1) For the airplanes identified in paragraph (c)(1)(i) of this 
AD: Except as specified by paragraph (h) of this AD, at the 
applicable times specified in the ``Compliance'' paragraph of Boeing 
Alert Requirements Bulletin 757-53A0106 RB, dated January 3, 2023, 
do all applicable actions identified in, and in accordance with, the 
Accomplishment Instructions of Boeing Alert Requirements Bulletin 
757-53A0106 RB, dated January 3, 2023.

    Note 1 to paragraph (g)(1): Guidance for accomplishing the 
actions required by this AD can be found in Boeing Alert Service 
Bulletin 757-53A0106, dated January 3, 2023, which is referred to in 
Boeing Alert Requirements Bulletin 757-53A0106 RB, dated January 3, 
2023.

    (2) For the airplanes identified in paragraph (c)(1)(ii) of this 
AD: Within 30 days after the effective date of this AD, obtain 
inspection instructions and applicable repair instructions using a 
method approved by the Manager, AIR-520, Continued Operational 
Safety Branch, FAA. Comply with all applicable instructions at the 
time specified in the instructions.

(h) Exceptions to Service Information Specifications

    (1) Where the Compliance Time columns of the tables in the 
``Compliance'' paragraph of Boeing Alert Requirements Bulletin 757-
53A0106 RB, dated January 3, 2023, use the phrase the original issue 
date of Requirements Bulletin 757-53A0106 RB, this AD requires using 
the effective date of this AD.
    (2) Where Boeing Alert Requirements Bulletin 757-53A0106 RB, 
dated January 3, 2023, specifies contacting Boeing for repair 
instructions or for alternative inspections, this AD requires doing 
the repair, or doing the alternative inspections and applicable on-
condition actions using a method approved in accordance with the 
procedures specified in paragraph (i) of this AD.

(i) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, AIR-520, Continued Operational Safety Branch, 
FAA, has the authority to approve AMOCs for this AD, if requested 
using the procedures found in 14 CFR 39.19. In accordance with 14 
CFR 39.19, send your request to your principal inspector or 
responsible Flight Standards Office, as appropriate. If sending 
information directly to the manager of the certification office, 
send it to the attention of the person identified in paragraph 
(j)(1) of this AD. Information may be emailed to: [email protected].
    (2) Before using any approved AMOC, notify your appropriate 
principal inspector, or lacking a principal inspector, the manager 
of the responsible Flight Standards Office.
    (3) An AMOC that provides an acceptable level of safety may be 
used for any repair, modification, or alteration required by this AD 
if it is approved by The Boeing Company Organization Designation 
Authorization (ODA) that has been authorized by the Manager, AIR-
520, Continued Operational Safety Branch, to make those findings. To 
be approved, the repair method, modification deviation, or 
alteration deviation must meet the certification basis of the 
airplane, and the approval must specifically refer to this AD.

(j) Related Information

    (1) For more information about this AD, contact Wayne Ha, 
Aviation Safety Engineer, FAA, 2200 South 216th Street, Des Moines, 
WA 98198; phone: 562-627-5238; email: [email protected].
    (2) Material identified in this AD that is not incorporated by 
reference is available at the address specified in paragraph (k)(3) 
of this AD.

(k) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference (IBR) of the material listed in this 
paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this material as applicable to do the actions 
required by this AD, unless the AD specifies otherwise.
    (i) Boeing Alert Requirements Bulletin 757-53A0106 RB, dated 
January 3, 2023.
    (ii) [Reserved]
    (3) For Boeing material identified in this AD, contact Boeing 
Commercial Airplanes, Attention: Contractual & Data Services (C&DS), 
2600 Westminster Blvd., MC 110-SK57, Seal Beach, CA 90740-5600; 
telephone 562-797-1717; website myboeingfleet.com.
    (4) You may view this material at the FAA, Airworthiness 
Products Section, Operational Safety Branch, 2200 South 216th St., 
Des Moines, WA. For information on the availability of this material 
at the FAA, call 206-231-3195.
    (5) You may view this material at the National Archives and 
Records Administration (NARA). For information on the availability 
of this material at NARA, visit www.archives.gov/federal-register/cfr/ibr-locations, or email [email protected].

[[Page 9207]]

    Issued on January 21, 2025.
Suzanne Masterson,
Deputy Director, Integrated Certificate Management Division, Aircraft 
Certification Service.
[FR Doc. 2025-02395 Filed 2-7-25; 8:45 am]
BILLING CODE 4910-13-P
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