[Federal Register Volume 70, Number 192 (Wednesday, October 5, 2005)]
[Proposed Rules]
[Pages 58103-58107]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-19940]


-----------------------------------------------------------------------

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-21331; Directorate Identifier 2005-NE-07-AD]
RIN 2120-AA64


Airworthiness Directives; Engine Components Incorporated (ECi) 
Reciprocating Engine Connecting Rods

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Notice of proposed rulemaking (NPRM).

-----------------------------------------------------------------------

SUMMARY: The FAA proposes to adopt a new airworthiness directive (AD) 
for certain Lycoming Engines (formerly Textron Lycoming) 360 and 540 
series reciprocating engines with ECi connecting rods, part number (P/
N) AEL 11750, installed. This proposed AD would require replacing 
certain serial-numbered connecting rods, P/N AEL 11750. This proposed 
AD would also prohibit installing certain ECi connecting rods, P/N AEL 
11750 into any Lycoming 360 or 540 series reciprocating engines. This 
proposed AD results from reports of connecting rods with excessive 
variation in circularity of the journal bores. We are proposing this AD 
to prevent fatigue failure of the connecting rod and uncommanded 
shutdown of the engine.

DATES: We must receive any comments on this proposed AD by December 5, 
2005.

ADDRESSES: Use one of the following addresses to comment on this 
proposed AD.
    <bullet> DOT Docket Web site: Go to http://dms.dot.gov and follow 
the instructions for sending your comments electronically.
    <bullet> Government-wide rulemaking Web site: Go to http://www.regulations.gov and follow the instructions for sending your 
comments electronically.
    <bullet> Mail: Docket Management Facility; U.S. Department of 
Transportation, 400 Seventh Street, SW., Nassif Building, Room PL-401, 
Washington, DC 20590-0001.
    <bullet> Fax: (202) 493-2251.
    <bullet> Hand Delivery: Room PL-401 on the plaza level of the 
Nassif Building, 400 Seventh Street, SW., Washington, DC, between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
    You may examine the comments on this proposed AD in the AD docket 
on the Internet at http://dms.dot.gov.

FOR FURTHER INFORMATION CONTACT: Peter Hakala, Aerospace Engineer, 
Special Certification Office, FAA, Rotorcraft Directorate, 2601 Meacham 
Blvd., Fort Worth, TX 76193; telephone (817) 222-5145; fax (817) 222-
5785.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send us any written relevant data, views, or 
arguments regarding this proposal. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2005-21331; 
Directorate Identifier 2005-NE-07-AD'' in the subject line of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of the proposed AD. We will 
consider all comments received by the closing date and may amend the 
proposed AD in light of those comments.
    We will post all comments we receive, without change, to http://dms.dot.gov, including any personal information you provide. We will 
also post a report summarizing each substantive verbal contact with FAA 
personnel concerning this proposed AD. Using the search function of the 
DOT docket Web site, anyone can find and read the comments in any of 
our dockets, including the name of the individual who sent the comment 
(or

[[Page 58104]]

signed the comment on behalf of an association, business, labor union, 
etc.). You may review the DOT's complete Privacy Act Statement in the 
Federal Register published on April 11, 2000 (65 FR 19477-78) or you 
may visit http://dms.dot.gov.

Examining the AD Docket

    You may examine the docket that contains the proposal, any comments 
received and, any final disposition in person at the Docket Management 
Facility Docket Offices between 9 a.m. and 5 p.m., Monday through 
Friday, except Federal holidays. The Docket Office (telephone (800) 
647-5227) is located on the plaza level of the Department of 
Transportation Nassif Building at the street address stated in 
ADDRESSES. Comments will be available in the AD docket shortly after 
the Docket Management Facility receives them.

Discussion

    On October 16, 2003, ECi informed the FAA that an engine 
experienced an in-flight engine failure and uncommanded shutdown. The 
failure occurred after 50 hours time-in-service (TIS) after an engine 
overhaul. The engine overhaul included replacing the engine crankshaft, 
the connecting rods, and the connecting rod bearings. We conducted a 
post-accident investigation that included an engine teardown. The 
engine teardown showed that one connecting rod and one connecting rod 
bearing were destroyed. The three remaining connecting rod bearings had 
an unusual ``tank tread'' pattern around the surface that mates with 
the crankshaft journal. A visual examination of the three remaining 
connecting rods revealed the journal bores had the same ``tank tread'' 
pattern found on the mating surface of the bearings.

Results of the FAA's Investigation of New Connecting Rods

    We approved reciprocating engine connecting rods, P/N AEL 11750, 
for use on Lycoming 360 and 540 series reciprocating engines under a 
Parts Manufacturer Approval (PMA). The Airmotive Engineering Corp, 
Division of Engine Components Incorporated, holds the PMA. ECi markets 
the parts as ECi parts. We determined the ECi engineering drawings for 
the connecting rods contain inadequate criteria to control circularity 
of the bearing bore. Because of that, the manufacturing process used to 
machine the bore resulted in excessive scalloping. The scalloping 
resulted in excessive variation in the circularity necessary for the 
proper functioning of the connecting rods. We also determined the 
inspection methods that ECi used to inspect the newly manufactured 
connecting rods were not sufficiently accurate to identify the 
manufacturing defects in circularity.
    We obtained four new ECi connecting rods from the field and two new 
ECi connecting rods directly from ECi. A U.S. Government test facility 
measured the connecting rods using high-precision test measuring 
equipment. The test facility found the journal bores in all of the 
connecting rods had excessive scalloping. Our analysis of measurements 
from the test facility show that the scalloping prevents proper fitting 
between the connecting rod and it's associated rod bearing. The poor 
fit between these critical engine components results in a significant 
reduction in performance and fatigue strength. Journal bores with 
excessive surface scalloping or machine chattering can result in two 
adverse conditions:
    (1) Poor contact between the journal bore and it's bearing 
substantially reduces heat transfer from the bearing. The resulting 
increase in bearing temperature substantially reduces the fatigue 
strength of the bearing.
    (2) The scalloping or machine chattering prevents adequate 
development of the hydrodynamic oil film needed to lubricate and cool 
the bearing. This allows metal-to-metal contact between the bearing and 
the connecting rod journal
    On December 22, 2003, ECi made a design drawing revision to better 
define dimensions and improve the quality control for the manufacture 
of the connecting rod, P/N AEL 11750. We have not received any reports 
of service difficulties for connecting rods, P/N AEL 11750, produced 
after January 2004 with the improved design.
    This condition, if not corrected, could result in fatigue failure 
of the connecting rod and uncommanded shutdown of the engine.

FAA's Determination and Requirements of the Proposed AD

    We have evaluated all pertinent information and identified an 
unsafe condition that is likely to exist or develop on other products 
of this same type design. We are proposing this AD, which would 
require:
    <bullet> Replacing certain serial-numbered ECi connecting rods, P/N 
AEL 11750, with 1,500 or more hours TIS on the connecting rod, within 
50 hours TIS after the effective date of the AD.
    <bullet> Replacing certain serial-numbered ECi connecting rods, P/N 
AEL 11750, with fewer than 1,500 hours TIS on the connecting rod, 
before accumulating 1,500 hours TIS on the connecting rod.
    This proposed AD would also prohibit installing any ECi connecting 
rod, P/N AEL 11750, with a serial number 54/6 or lower, into any engine 
after the effective date of the AD.

Costs of Compliance

    We estimate that this proposed AD would affect about 2,800 Lycoming 
Engines 360 and 540 series reciprocating engines installed on aircraft 
of U.S. registry. We also estimate that it would take about 4 work 
hours per engine to perform the proposed actions, and that the average 
labor rate is $65 per work hour. Required parts would cost about $450 
per connecting rod. Based on these figures, we estimate the total cost 
of the proposed AD to U.S. operators to be $1,988,000. ECi has 
indicated that they might provide operators and repair stations credit 
for returned connecting rods.

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.
    We are 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 develop on products identified in this 
rulemaking action.

Regulatory Findings

    We have determined that this proposed AD would not have federalism 
implications under Executive Order 13132. This proposed AD would 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 the proposed 
regulation:
    1. Is not a ``significant regulatory action'' under Executive Order 
12866;
    2. Is not a ``significant rule'' under the DOT Regulatory Policies 
and Procedures (44 FR 11034, February 26, 1979); and

[[Page 58105]]

    3. Would not have a significant economic impact, positive or 
negative, on a substantial number of small entities under the criteria 
of the Regulatory Flexibility Act.
    We prepared a regulatory evaluation of the estimated costs to 
comply with this proposed AD. See the ADDRESSES section for a location 
to examine the regulatory evaluation.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Safety.

The Proposed Amendment

    Under the authority delegated to me by the Administrator, the 
Federal Aviation Administration proposes to amend 14 CFR part 39 as 
follows:

PART 39--AIRWORTHINESS DIRECTIVES

    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]

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

Engine Components Incorporated (ECi): Docket No. FAA-2005-21331; 
Directorate Identifier 2005-NE-07-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by December 5, 
2005.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Lycoming Engines (formerly Textron 
Lycoming) 360 and 540 series reciprocating engines specified in 
Table 1 of this AD with Engine Components Incorporated (ECi) 
connecting rods, part number (P/N) AEL 11750 installed.

                         Table 1.--Engine Models
------------------------------------------------------------------------
 
-------------------------------------------------------------------------
                              Engine Model
0-360- A1A, A1AD, A1C, A1D, A1F, A1F6, A1F6D, A1G, A1G6, A1G6D, A1H,
 A1H6, A1LD, A1P, A2A, A2D, A2E, A2F, A2G, A2H, A3A, A3AD, A3D, A4A,
 A4AD, A4D, A4G, A4J, A4K, A4M, A4N, A4P, A5AD, B1A, B1B, B2A, B2B, C1A,
 C1C, C1E, C1F, C1G, C2A, C2B, C2C, C2D, C2E, C4F, C4P, D1A, D2A, D2B,
 F1A6, G1A6, J2A;
HO-360- A1A, B1A, B1B, C1A;
IO-360- B1A, B1B, B1C, B1D, B1E, B1F, B1F6, B1G6, B2E, B2F, B2F6, B4A,
 E1A, F1A, L2A;
LO-360- A1G6D, A1H6;
HIO-360- A1A, A1B, B1A, B1B;
AEIO-360- B1B, B1D, B1F, B1F6, B1G6, B2F, B2F6, B4A, H1A, H1B;
O-540- A1A, A1A5, A1B5, A1C5, A1D, A1D5, A2B, A3D5, A4A5, A4B5, A4C5,
 A4D5, B1A5, B1B5, B1D5, B2A5, B2B5, B2C5, B4A5, B4B5, D1A5, E4A5, E4B5,
 E4C5, F1A5, F1B5, G1A5, G2A5, H1A5, H1A5D, H1B5D, H2A5, H2A5D, H2B5D;
AEIO-540- D4A5, D4B5, D4C5, D4D5;
IO-540- A1A5, B1A5, B1B5, B1C5, C1B5, C1C5, C2C, C4B5, C4C5, C4D5,
 C4D5D, D4A5, D4B5, D4C5, E1A5, E1B5, E1C5, G1A5, G1B5, G1C5, G1D5,
 G1E5, G1F5, J4A5, N1A5, P1A5, R1A5, T4A5D, T4B5, T4B5D, T4C5D, V4A5,
 V4A5D;
LTIO-540- K1AD;
TIO-540- C1A, E1A, G1A, H1A, K1AD, AA1AD, AB1AD, AB1BD, AF1A, AF1B,
 AG1A.
------------------------------------------------------------------------

    These engines are installed on, but not limited to, the aircraft 
listed in Table 2 of this AD.

                        Table 2.--Aircraft Models
------------------------------------------------------------------------
         Aircraft manufacturer                    Aircraft model
------------------------------------------------------------------------
Aero Boero.............................  AB-180, AB-260.
Aero Commander.........................  Lark (100), Aero Commander
                                          (500, 500-B, 500-E, 500-U).
Aero Engine Service Ltd................  Victa (R-2).
Aerofab Inc............................  Renegade 250, Turbo Renegade
                                          (270).
Aviamilano.............................  Flamingo (F-250).
Aviat..................................  Husky.
Avions Pierre Robin....................  (HR100/250).
Beagle.................................  Airedale (A-109), Husky (D5-180
                                          01-U).
Beech Aircraft.........................  Travel-Air (95, B-95, B-95A, B-
                                          95B), Duchess 76, Sport,
                                          Musketeer Custom III,
                                          Sundowner 180.
Bellanca Aircraft......................  Scout (8GCBC-CS, 8GCBC FP),
                                          Super Decathlon (8KCAB-180),
                                          Aries T-250.
Bolkow.................................  207, Klemm (K1-107C).
Britten-Norman.........................  BN-2.
Brooklanda.............................  Scoutmaster.
C.A.A.R.P..............................  S A.N. (M-23III), C.A.P. (10).
C. Itoh and Co.........................  Fuji FA-200.
Center Est Aeronautique................  Regente (DR-253).
Cerva..................................  (CE-43 Guepard).
Cessna Aircraft........................  Cardinal, Cardinal 172, Teal
                                          III. TSC (1A3), Skyhawk,
                                          Cutlass RG.
Christen...............................  Husky (A-1), Christen. Pitts (S-
                                          2S), (S-2B).
DeHavilland............................  Drover (DHA-3MK3), Heron
                                          Conversion.
Dinfia.................................  Ranquel (lA-51), Querandi (1A-
                                          45).
Dornier................................  (DO-28 , DO-28-B1, DO-8-B1).
Doyn Aircraft..........................  Doyn-Cessna (170B, 172, 172A,
                                          172B).
Doyn Aircraft..........................  Doyn-Beech (Beech 95).
Doyn Aircraft..........................  Doyn-Piper (PA-23 ``160'', PA-
                                          23 ``200'', PA-24 ``250'', PA-
                                          23 ``250'').
Earl Horton............................  Pawnee (Piper PA-25).
Embraer................................  Corioca (EMB-710), Impanema
                                          ``AG.''
F.F.A..................................  Bravo (200).
Found Bros.............................  (FBA-2C), Centennial (100).
Fuji...................................  (FA-200).
General Aviation.......................  Model 114.
Gippsland..............................  GA-200.
Great Lakes............................  Trainer.
Grob...................................  G115/Sport-Acro.
Grumman American.......................  Tiger.

[[Page 58106]]

 
H.A.L..................................  HPT-32.
Hughes Tool Co.........................  (269A, 269-A-1, YHO-2HU, 300).
Intermountain Mfg. Co..................  Call Air (A-6, A-9, IAR821, IAR-
                                          822, IAR-826, IAR-823).
Kingsford-Smith........................  Bushmaster (O-6).
Lake Aircraft..........................  Colonial (C-2, LA-4, 4A or 4P),
                                          Seawolf.
Malmo..................................  Vipan (MF-10B, MF1-10).
Maule..................................  Star Rocket MX-7-180, MX-7-
                                          180A, Star Rocket (MX-7-235),
                                          Super Rocket (M-6-235), Super
                                          Std. Rocket (M-7-235).
Mid-States Mfg. Co.....................  Twin Courier (H-500), (U-5).
Mooney Aircraft........................  Master ``21'' (M-20D, M-20E),
                                          Mark ``20B'', ``20D'',(M20B,
                                          M20C), Statesman (M-20G), Mark
                                          ``21'' (M-20E), .''TLS'' M20M.
Moravan................................  Zlin-50L.
Mundry.................................  CAP-10.
Nash Aircraft Ltd......................  Petrel.
Neiva..................................  lPD-590V.
Norman Aeroplace Co....................  NAC-1 Freelance.
Omega Aircraft.........................  BS-12D1.
Partenavia.............................  Oscar (P-66).
Penn Yan...............................  Super Cub Conversion.
Pilatus Britten-Norman.................  Islander (BN-2A-26), Islander
                                          (BN-2A-27, IslanderII (BN-2B-
                                          26), Islander (BN-2A-21),
                                          Trislander (BN-2A-Mark III-2).
Piper Aircraft.........................  Comanche (PA-24), Seminole (PA-
                                          44), Cherokee ``C''(PA-28
                                          ``180''), Cherokee ``D'' (PA-
                                          28 ``180''), Archer II(PA-28
                                          ``18''), Arrow (PA-28
                                          ``180R''), Seminole (PA-44),
                                          Comanche (PA-24 ``150''),
                                          Aztec (PA-23 ``250''),Cherokee
                                          (PA-24 ``250''), Pawnee (PA-24
                                          ``235''),Cherokee (PA-28
                                          ``235''), Aztec (PA-23
                                          ``235''),Cherokee (PA-28
                                          ``235''), Comanche (PA-24
                                          ``260''),Cherokee Six (PA-32
                                          ``260''), Pawnee (PA-25
                                          ``260''),Aztec B (PA-23
                                          ``250''), Comanche (PA-24
                                          ``250''),Aztec C (PA-23
                                          ``250''), Aztec F, Comanche
                                          (PA-24),Turbo Aztec (PA-23-
                                          250).
Pitts..................................  S-1S.
Poeschel...............................  P-300.
Procaer................................  Picchio (F-15-A).
Rawdon Brow............................  Radon (T-1).
Regente................................  N-591.
Rhein-Flugzeughau......................  RF-V
Riley Aircraft.........................  Rocket-Cessna (310), Turbo-
                                          Rocket, Turbo-Aztec.
Robin..................................  Regent (DR400/180), Remorqueur
                                          (DR400/180R), R-3170, Aiglon
                                          (R-1180T).
Robinson...............................  R-44.
Rockwell...............................  Commander (114, 114B, 114TC).
S A.A.B................................  Safir (91-D).
Schweizer Aircraft Corporation.........  269A.
S.O.C.A.T.A............................  Tobago (TB-10), Rallye
                                          Commodore (MS-893), Rallye
                                          180GI, Sportana Sportsman (RS-
                                          180), Rallye 235CA,Rallye
                                          235GT, Rallye 235C, TB-20,
                                          Trinidad TB-20,Trinidad TC TB-
                                          21.
Shrike.................................  (500-S).
Societe Aeronautique Normande..........  D-140, Jodel (D-140C).
Mousquetaire...........................
Siai-Marchetti.........................  (S-205, SF-260, SF-208).
Silvercraft............................
Std. Helicopter........................
Sud....................................  Gardan (GY-180).
T. R. Smith Aircraft...................  Aerostar, (600).
United Consultants.....................  See-Bee.
Utva...................................  75.
Valmet.................................  PIK-23.
Varga..................................  Kachina.
Wassmer................................  Super 4 (WA-50A), Sancy (WA-
                                          40), Baladou (WA-40), Pariou
                                          (WA-40), (WA-50), Europa WA-
                                          52, WA-421, WA4-2V.
Yoeman Aviation........................  YA-1.
------------------------------------------------------------------------

Unsafe Condition

    (d) This AD results from reports of connecting rods with 
excessive variation in circularity of the journal bores. We are 
issuing this AD to prevent fatigue failure of the connecting rod and 
uncommanded shutdown of the engine.

Compliance

    (e) You are responsible for having the actions required by this 
AD performed within the compliance times specified unless the 
actions have already been done.

Engines Not Repaired or Overhauled Since New

    (f) If your engine has not been overhauled or had any repair 
since new, no further action is required.

[[Page 58107]]

Engines Overhauled or Repaired Since New

    (g) If your engine was overhauled or repaired since new, do the 
following:
    (1) Before further flight inspect the maintenance records and 
engine logbook to determine if the overhaul or repair facility used 
ECi connecting rods, P/N AEL 11750.
    (2) If the connecting rods are not ECi, P/N AEL 11750, no 
further action is required.
    (3) If the connecting rods are ECi, P/N AEL 11750, and if the 
serial number is 54/7 or higher, no further action is required.
    (4) If the connecting rods are ECi, P/N AEL 11750, and if the 
serial number is 54/6 or lower, do the following:
    (i) If the connecting rod has 1,500 or more hours time-in-
service (TIS), replace the connecting rod with a connecting rod that 
has a SN 54/7 or higher, or that has a P/N not specified in this AD 
within 50 hours TIS after the effective date of this AD.
    (ii) If the connecting rod has fewer than 1,500 hours TIS, 
replace the connecting rod with a connecting rod that has a SN 54/7 
or higher, or that has a P/N not specified in this AD before 
accumulating 1,500 hours TIS on the connecting rod.
    (h) After the effective date of this AD, do not install any ECi 
connecting rod, P/N AEL 11750, that has SN 54/6 or lower into any 
engine.

Alternative Methods of Compliance (AMOCs)

    (i) The Manager, Special Certification Office, has the authority 
to approve alternative methods of compliance for this AD if 
requested using the procedures found in 14 CFR 39.19.

Related Information

    (j) None.

    Issued in Burlington, Massachusetts, on September 28, 2005.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 05-19940 Filed 10-4-05; 8:45 am]
BILLING CODE 4910-13-P