Document ID: FAA-2013-0369-0001
Agency: faa
Document Type: Proposed Rule
Title: Airworthiness Directives: The Boeing Company Airplanes
Posted Date: 2013-05-10T04:00Z

[Federal Register Volume 78, Number 91 (Friday, May 10, 2013)]
[Proposed Rules]
[Pages 27315-27318]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2013-11168]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2013-0369; Directorate Identifier 2012-NM-128-AD]
RIN 2120-AA64

Airworthiness Directives; The Boeing Company Airplanes

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: We propose to adopt a new airworthiness directive (AD) for all 
The Boeing Company Model 757 airplanes. This proposed AD was prompted 
by reports of fractured rudder pedal pushrod connecting bolts in a 
rudder pedal assembly. This proposed AD would require repetitive 
replacements of the rudder pedal pushrod connecting bolts and 
repetitive inspections of the rudder pedal assembly bolt holes in each 
of the captain and the first officer rudder pedal assemblies, and if 
necessary, repair or replacement of worn rudder pedal assemblies. We 
are proposing this AD to prevent fracture of the rudder pedal pushrod 
connecting bolts during pedal use, which could result in a large 
involuntary input to the rudder, nose-wheel steering, and braking 
systems, leading to a runway excursion.

DATES: We must receive comments on this proposed AD by June 24, 2013.

ADDRESSES: You may send comments, using the procedures found in 14 CFR 
11.43 and 11.45, by any of the following methods:
     Federal eRulemaking Portal: Go to http://www.regulations.gov. Follow the instructions for submitting comments.

[[Page 27316]]

     Fax: 202-493-2251.
     Mail: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue SE., Washington, DC 20590.
     Hand Delivery: Deliver to Mail address above between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
    For service information identified in this proposed AD, contact 
Boeing Commercial Airplanes, Attention: Data & Services Management, 
P.O. Box 3707, MC 2H-65, Seattle, WA 98124-2207; telephone 206-544-
5000, extension 1; fax 206-766-5680; Internet https://www.myboeingfleet.com. You may review copies of the referenced service 
information at the FAA, Transport Airplane Directorate, 1601 Lind 
Avenue SW., Renton, Washington 98057-3356. For information on the 
availability of this material at the FAA, call 425-227-1221.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov; or in person at the Docket Management Facility 
between 9 a.m. and 5 p.m., Monday through Friday, except Federal 
holidays. The AD docket contains this proposed AD, the regulatory 
evaluation, any comments received, and other information. The street 
address for the Docket Office (phone: 800-647-5527) is in the ADDRESSES 
section. Comments will be available in the AD docket shortly after 
receipt.

FOR FURTHER INFORMATION CONTACT: Marie Hogestad, Aerospace Engineer, 
Systems and Equipment Branch, FAA, ANM-130S, Seattle Aircraft 
Certification Office, 1601 Lind Avenue SW., Renton, Washington 98057-
3356; phone: 425-917-6418; fax: 425-917-6590; email: 
marie.hogestad@faa.gov.

SUPPLEMENTARY INFORMATION: 

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments about this proposal. Send your comments to an address listed 
under the ADDRESSES section. Include ``Docket No. FAA-2013-0369; 
Directorate Identifier 2012-NM-128-AD'' at the beginning of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of this proposed AD. We 
will consider all comments received by the closing date and may amend 
this proposed AD because of those comments.
    We will post all comments we receive, without change, to http://www.regulations.gov, including any personal information you provide. We 
will also post a report summarizing each substantive verbal contact we 
receive about this proposed AD.

Discussion

    We received reports of fractured rudder pedal pushrod connecting 
bolts on Boeing Model 757 airplanes. One operator discovered a bolt was 
fractured during an inspection, following a report that the captain's 
right pedal was loose. Another operator reported a fractured bolt 
during the airplane pushback. When the captain applied the brakes, the 
right hand rudder pedal collapsed and both pedals fell forward. An 
inspection revealed that a rudder pedal pushrod bolt was fractured, 
resulting in a full left rudder input. Also, in a separate incident, 
during routine maintenance, while the brakes were released, a loud 
crack was heard and the right hand rudder pedal went all the way 
forward. During investigation, it was determined that the captain's 
right hand rudder pedal pushrod bolt had fractured. The rudder pedal 
pushrod connecting bolt secures the rudder pedal arm to the rudder 
pushrod. The bolt is cantilevered in a single shear arrangement that is 
not capable of carrying its design load if there is looseness in the 
installation (bolt bending is introduced). The bolts can also rotate, 
due to lack of bolt clamp-up, causing additional wear. This condition, 
if not corrected, could result in a fracture of the rudder pedal 
pushrod connecting bolts during pedal use, which could result in large 
involuntary input to the rudder, nose-wheel steering, and braking 
systems, leading to a runway excursion.

Related Rulemaking

    We issued AD 2001-22-13, Amendment 39-12492 (66 FR 55075, November 
1, 2001), for certain Model 737, 747, 757, 767, and 777 series 
airplanes. That AD requires replacing the rudder pedal pushrod 
fasteners (bolts) for the captain's and first officer's pedal 
assemblies with titanium fasteners (bolts).
    We have determined that titanium bolts are under-strength on Model 
757 airplanes and must be replaced with Inconel bolts. Titanum bolts 
do, however, meet the static and fatigue requirements for the other 
airplane models affected by AD 2001-22-13, Amendment 39-12492 (66 FR 
55075, November 1, 2001).

Relevant Service Information

    We reviewed Boeing Alert Service Bulletin 757-27A0153, dated May 9, 
2012, as revised by Boeing Alert Service Bulletin 757-27A0153, Revision 
1, dated October 29, 2012. For information on the procedures and 
compliance times, see this service information at http://www.regulations.gov by searching for Docket No. FAA-2013-0369.

FAA's Determination

    We are proposing this AD because we evaluated all the relevant 
information and determined the unsafe condition described previously is 
likely to exist or develop in other products of the same type design.

Proposed AD Requirements

    This proposed AD would require accomplishing the actions specified 
in the service information described previously. Replacements of the 
rudder pedal pushrod connecting bolts are done after each inspection 
specified in paragraph (g) of this AD, regardless of the inspection 
results. Some actions would terminate the requirements of AD 2001-22-
13, Amendment 39-12492 (66 FR 55075, November 1, 2001), for Model 757 
airplanes.

Costs of Compliance

    We estimate that this proposed AD affects 685 airplanes of U.S. 
registry.
    We estimate the following costs to comply with this proposed AD:

[[Page 27317]]

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                 Cost on U.S.
             Action                    Labor cost         Parts cost      Cost per product        operators
----------------------------------------------------------------------------------------------------------------
Inspect/replace bolts (Condition  5 work-hours x $85             $217   $642 per inspection  $439,770 per
 1 in the Accomplishment           per hour = $425                       cycle.               inspection cycle.
 Instructions of Boeing Alert      per inspection
 Service Bulletin 757-27A0153,     cycle.
 dated May 9, 2012, as revised
 by Boeing Alert Service
 Bulletin 757-27A0153, Revision
 1, dated October 29, 2012).
----------------------------------------------------------------------------------------------------------------

    We estimate the following costs to do any necessary repairs/
replacements that would be required based on the results of the 
proposed inspection. We have no way of determining the number of 
aircraft that might need these repairs/replacements:

                                               On-Condition Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                     Cost per
                     Action                            Labor cost               Parts cost            product
----------------------------------------------------------------------------------------------------------------
Replace rudder pedal assembly (Condition 2 in    2 work-hours x $85 per  Unknown................            $170
 the Accomplishment Instructions of Boeing        hour = $170.
 Alert Service Bulletin 757-27A0153, dated May
 9, 2012, as revised by Boeing Alert Service
 Bulletin 757-27A0153, Revision 1, dated
 October 29, 2012).
Repair rudder pedal assembly (Condition 3 in     3 work-hours x $85 per  Unknown................             255
 the Accomplishment Instructions of Boeing        hour = $255.
 Alert Service Bulletin 757-27A0153, dated May
 9, 2012, as revised by Boeing Alert Service
 Bulletin 757-27A0153, Revision 1, dated
 October 29, 2012).
Repair rudder pedal assembly (Condition 4 in     4 work-hours x $85 per  Unknown................             340
 the Accomplishment Instructions of Boeing        hour = $340.
 Alert Service Bulletin 757-27A0153, dated May
 9, 2012, as revised by Boeing Alert Service
 Bulletin 757-27A0153, Revision 1, dated
 October 29, 2012).
----------------------------------------------------------------------------------------------------------------

    The on-condition costs in the table above are per rudder pedal 
assembly. Depending on the diamater of the holes found during the 
inspection, it may be necessary to replace or repair the rudder pedal 
assemblies. The parts cost to replace or repair the rudder pedal 
assemblies are not included in the estimate. It is considered ``Parts & 
Materials Supplied by the Operator'', which is referenced in Boeing 
Alert Service Bulletin 757-27A0153, dated May 9, 2012, as revised by 
Boeing Alert Service Bulletin 757-27A0153, Revision 1, dated October 
29, 2012.
    According to the manufacturer, some of the costs of this proposed 
AD may be covered under warranty, thereby reducing the cost impact on 
affected individuals. We do not control warranty coverage for affected 
individuals. As a result, we have included all costs in our cost 
estimate.

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 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 this 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),
    (3) Will not affect intrastate aviation in Alaska, and
    (4) 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 Proposed Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA proposes to amend 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 (AD):

The Boeing Company: Docket No. FAA-2013-0369; Directorate Identifier 
2012-NM-128-AD.

(a) Comments Due Date

    We must receive comments by June 24, 2013.

(b) Affected ADs

    Certain requirements of this AD terminate the requirements of AD 
2001-22-13, Amendment 39-12492 (66 FR 55075, November 1, 2001), for 
Model 757 airplanes.

[[Page 27318]]

(c) Applicability

    This AD applies to all The Boeing Company Model 757-200, -200PF, 
-200CB, and -300 series airplanes, certificated in any category.

(d) Subject

    Joint Aircraft System Component (JASC)/Air Transport Association 
(ATA) of America Code 27, Flight Controls.

(e) Unsafe Condition

    This AD was prompted by reports of fractured rudder pedal 
pushrod connecting bolts in the rudder pedal assembly. We are 
issuing this AD to prevent fracture of the rudder pedal pushrod 
connecting bolts during pedal use, which could result in a large 
involuntary input to the rudder, nose-wheel steering, and braking 
systems, leading to a runway excursion.

(f) Compliance

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

(g) Inspection

    Within 60 months after the effective date of this AD, do a 
detailed inspection of the rudder pedal assembly bolt holes to 
determine the diameter, in each of the captain and the first officer 
rudder pedal assemblies, in accordance with the Accomplishment 
Instructions of Boeing Alert Service Bulletin 757-27A0153, dated May 
9, 2012, as revised by Boeing Alert Service Bulletin 757-27A0153, 
Revision 1, dated October 29, 2012. Repeat this inspection 
thereafter at intervals not to exceed 15,000 flight cycles.

(h) Installation

    Do the applicable actions specified in paragraph (h)(1), (h)(2), 
or (h)(3) of this AD for each of the captain and first officer 
rudder pedal assemblies, based on the results of any inspection 
required by paragraph (g) of this AD. Accomplishment of paragraph 
(h)(1), (h)(2), or (h)(3) of this AD terminates the requirements of 
AD 2001-22-13, Amendment 39-12492 (66 FR 55075, November 1, 2001), 
for that Model 757 airplane only.
    (1) If the diameters of both holes are within 0.3120 and 0.3140 
inch on the assembly, before further flight, install new rudder 
pedal pushrod connect bolt, washer, nut, and cotter pin, in 
accordance with the Accomplishment Instructions of Boeing Alert 
Service Bulletin 757-27A0153, dated May 9, 2012, as revised by 
Boeing Alert Service Bulletin 757-27A0153, Revision 1, dated October 
29, 2012.
    (2) If the diameter of only one hole is greater than 0.3140 inch 
on the assembly, before further flight, do the actions specified in 
paragraphs (h)(2)(i) and (h)(2)(ii) of this AD.
    (i) Install a new rudder pedal assembly, or install a bushing in 
the worn hole, in accordance with the Accomplishment Instructions of 
Boeing Alert Service Bulletin 757-27A0153, dated May 9, 2012, as 
revised by Boeing Alert Service Bulletin 757-27A0153, Revision 1, 
dated October 29, 2012.
    (ii) Install new rudder pedal pushrod connecting bolt, washer, 
nut, and cotter pin, in accordance with the Accomplishment 
Instructions of Boeing Alert Service Bulletin 757-27A0153, dated May 
9, 2012, as revised by Boeing Alert Service Bulletin 757-27A0153, 
Revision 1, dated October 29, 2012.
    (3) If the diameters of both holes are greater than 0.3140 inch 
on the assembly, before further flight, do the actions specified in 
paragraphs (h)(3)(i) and (h)(3)(ii) of this AD.
    (i) Install a new rudder pedal assembly, or install two bushings 
in the two worn holes, in accordance with the Accomplishment 
Instructions of Boeing Alert Service Bulletin 757-27A0153, dated May 
9, 2012, as revised by Boeing Alert Service Bulletin 757-27A0153, 
Revision 1, dated October 29, 2012.
    (ii) Install new rudder pedal pushrod connecting bolt, washer, 
nut, and cotter pin, in accordance with the Accomplishment 
Instructions of Boeing Alert Service Bulletin 757-27A0153, dated May 
9, 2012, as revised by Boeing Alert Service Bulletin 757-27A0153, 
Revision 1, dated October 29, 2012.

(i) Parts Installation

    As of the effective date of this AD, no person may install, in a 
rudder pedal assembly of any Boeing 757 airplane, a bolt having part 
number (P/N) BACB30NM5DK47.

(j) Credit for Previous Actions

    This paragraph provides credit for the actions required by 
paragraphs (g) and (h) of this AD, if operators installed washers 
having part number NAS1149D0516J, NAS1149D0532J, and NAS1149D0563J, 
and if those actions were performed before the effective date of 
this AD using Boeing Alert Service Bulletin 757-27A0153, dated May 
9, 2012, which is not incorporated by reference in this AD, as 
unmodified by Boeing Alert Service Bulletin 757-27A0153, Revision 1, 
dated October 29, 2012.

(k) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Seattle Aircraft Certification Office (ACO), 
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 local 
Flight Standards District Office, as appropriate. If sending 
information directly to the manager of the ACO, send it to the 
attention of the person identified in the Related Information 
section of this AD. Information may be emailed to: 9-ANM-Seattle-ACO-AMOC-Requests@faa.gov.
    (2) Before using any approved AMOC, notify your appropriate 
principal inspector, or lacking a principal inspector, the manager 
of the local flight standards district office/certificate holding 
district office.
    (3) An AMOC that provides an acceptable level of safety may be 
used for any repair required by this AD if it is approved by the 
Boeing Commercial Airplanes Organization Designation Authorization 
(ODA) that has been authorized by the Manager, Seattle ACO, to make 
those findings. For a repair method to be approved, the repair must 
meet the certification basis of the airplane, and the approval must 
specifically refer to this AD.

(l) Related Information

    (1) For more information about this AD, contact Marie Hogestad, 
Aerospace Engineer, Systems and Equipment Branch, FAA, ANM-130S, 
Seattle Aircraft Certification Office, 1601 Lind Avenue SW., Renton, 
Washington 98057-3356; phone: 425-917-6418; fax: 425-917-6590; 
email: marie.hogestad@faa.gov.
    (2) For service information identified in this AD, contact 
Boeing Commercial Airplanes, Attention: Data & Services Management, 
P. O. Box 3707, MC 2H-65, Seattle, WA 98124-2207; telephone 206-544-
5000, extension 1; fax 206-766-5680; Internet https://www.myboeingfleet.com. You may review copies of the referenced 
service information at the FAA, Transport Airplane Directorate, 1601 
Lind Avenue SW., Renton, Washington 98057-3356. For information on 
the availability of this material at the FAA, call 425-227-1221.

    Issued in Renton, Washington, on May 2, 2013.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.

[FR Doc. 2013-11168 Filed 5-9-13; 8:45 am]
BILLING CODE 4910-13-P