Document ID: FAA-2009-0018-0001
Agency: faa
Document Type: Rule
Title: Airworthiness Directives: General Electric Company CF6-80C2 Series Turbofan Engines
Posted Date: 2009-03-16T04:00Z

[Federal Register: March 16, 2009 (Volume 74, Number 49)]
[Proposed Rules]               
[Page 11043-11045]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr16mr09-18]                         

========================================================================
Proposed Rules
                                                Federal Register
________________________________________________________________________

This section of the FEDERAL REGISTER contains notices to the public of 
the proposed issuance of rules and regulations. The purpose of these 
notices is to give interested persons an opportunity to participate in 
the rule making prior to the adoption of the final rules.

========================================================================

[[Page 11043]]

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2009-0018; Directorate Identifier 2009-NE-01-AD]
RIN 2120-AA64

 
Airworthiness Directives; General Electric Company CF6-80C2 
Series Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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

SUMMARY: The FAA proposes to adopt a new airworthiness directive (AD) 
for General Electric Company (GE) CF6-80C2 series turbofan engines with 
certain thrust reverser ballscrew gearbox assembly adjustable-length 
end actuators installed. This proposed AD would require initial visual 
inspections and repetitive replacements of the \3/8\-inch rod-ends 
installed on the thrust reverser ballscrew gearbox assembly adjustable-
length end actuators, along with optional terminating action to those 
repetitive replacements. This proposed AD would also require initial 
visual inspections and replacements, if necessary, of the other 
hardware connecting the thrust reverser transcowls to the engine. This 
proposed AD results from reports of four failures of rod-ends on 
certain thrust reverser ballscrew gearbox assembly adjustable-length 
end actuators, leading to partial or complete separation of the 
transcowl from the engine and airplane during thrust reversal. We are 
proposing this AD to prevent loss of thrust control, asymmetric thrust, 
increased stopping distance, and possibly hazardous debris on the 
runway, which could result in unsafe landings.

DATES: We must receive any comments on this proposed AD by May 15, 
2009.

ADDRESSES: Use one of the following addresses to comment on this 
proposed AD.
     Federal eRulemaking Portal: Go to http://
www.regulations.gov and follow the instructions for sending your 
comments electronically.
     Mail: Docket Management Facility, U.S. Department of 
Transportation, 1200 New Jersey Avenue, SE., West Building Ground 
Floor, Room W12-140, Washington, DC 20590-0001.
     Hand Delivery: Deliver to Mail address above between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
     Fax: (202) 493-2251.

FOR FURTHER INFORMATION CONTACT: Christopher J. Richards, Aerospace 
Engineer, Engine Certification Office, FAA, Engine & Propeller 
Directorate, 12 New England Executive Park, Burlington, MA 01803; e-
mail: christopher.j.richards@faa.gov; telephone (781) 238-7133; fax 
(781) 238-7199.

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-2009-0018; Directorate 
Identifier 2009-NE-01-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://
www.regulations.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 Web site, anyone can find and read the comments in any 
of our dockets, including, if provided, the name of the individual who 
sent the comment (or 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).

Examining the AD Docket

    You may examine the AD docket on the Internet at http://
www.regulations.gov; or in person at the Docket Operations office 
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 Operations office (telephone (800) 647-5527) is 
the same as the Mail address provided in the ADDRESSES section. 
Comments will be available in the AD docket shortly after receipt.

Discussion

    Since January 2007, we received reports of four GE CF6-80C2 series 
turbofan engine thrust reverser transcowls separating from the engine 
and airplane during thrust reverser deployment while landing. 
Investigation has revealed that the \3/8\-inch adjustable rod-ends on 
the adjustable-length end actuators can fail in fatigue. When a rod-end 
fails, additional load is put on the thrust reverser system center 
drive unit (CDU). This additional load can cause the CDU clevis bracket 
fasteners to fail or the CDU clevis pin to lose its retaining 
capability, both causing separation of the transcowl from the engine 
and airplane. This condition, if not corrected, could result in loss of 
thrust control, asymmetric thrust, increased stopping distance, and 
possibly hazardous debris on the runway, which could result in unsafe 
landings.

Relevant Service Information

    We have reviewed and approved the technical contents of Middle 
River Aircraft Systems Alert Service Bulletin (ASB) No. CF6-80C2 S/B 
78A1162, Revision 1, dated February 13, 2009. That ASB describes 
procedures for inspecting ballscrew gearbox assembly adjustable-length 
end actuator \3/8\-inch rod-ends and torsion arms, clevis fasteners, 
clevis pins, and clevis pin retaining clips. That ASB also describes 
procedures for replacing broken rod-ends, worn, damaged, or deformed 
torsion arms, loose clevis fasteners, clevis pins that do not meet wear 
limits, and loose clip retainer nuts and bolts.

[[Page 11044]]

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 
initial and repetitive replacements of the \3/8\-inch rod-ends 
installed on the thrust reverser ballscrew gearbox assembly adjustable-
length end actuators, along with optional terminating action to those 
repetitive replacements. The proposed AD would also require an initial 
visual inspection and replacement if necessary, of the other hardware 
that connects the thrust reverser transcowl to the engine. The proposed 
AD would require you to use the service information described 
previously to perform these actions.

Costs of Compliance

    We estimate that this proposed AD would affect 750 GE CF6-80C2 
series turbofan engines installed on airplanes of U.S. registry. We 
also estimate that it would take about 1.5 work-hours per engine to 
perform the proposed inspection, 0.8 work-hour per engine to perform 
the proposed rod-end replacement, and 24 work-hours per engine to 
perform the proposed clevis bracket replacement. The average labor rate 
is $80 per work-hour. Required rod-ends would cost about $168 per 
engine. We estimate that 75 engines would require clevis bracket 
replacement. Required replacement clevis brackets and associated labor 
would cost about $826,500. Based on these figures, we estimate the 
total cost of the proposed AD to U.S. operators to be $1,090,500.

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 AD:
    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
    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. You may get a copy of this summary at the 
address listed under ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, 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:

General Electric Company: Docket No. FAA-2009-0018; Directorate 
Identifier 2009-NE-01-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by May 15, 
2009.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to General Electric Company (GE) CF6-80C2 
series turbofan engines with thrust reverser ballscrew gearbox 
assembly adjustable-length end actuators having \3/8\-inch rod-end, 
part number (P/N) KBE6-59, MS21242S06, M81935/1-6, B15946-13, or 
15946000-13, installed. These engines are installed on, but not 
limited to, Airbus A300-600/R/F and A310-200/300, and Boeing 747-
200B/300/400/400D/400F, 767-200/300/300F/400ER, and MD-11 airplanes.

Exemption

    (d) GE CF6-80C2 series turbofan engines that have completed the 
initial compliance actions in Middle River Aircraft Systems (MRAS) 
Alert Service Bulletin (ASB) No. CF6-80C2 S/B 78A1162, dated 
December 30, 2008, or ASB No. CF6-80C2 S/B 78A1162, Revision 1, 
dated February 13, 2009:
    (1) Are allowed to take credit for accomplishing paragraphs (g) 
and (h) of this AD; however
    (2) All \3/8\-inch rod-ends, including those on engines which 
satisfy paragraph (d) of this AD, are subject to the replacement 
requirements in paragraph (i) of this AD.

Unsafe Condition

    (e) This AD results from reports of four failures of rod-ends on 
certain thrust reverser ballscrew gearbox assembly adjustable-length 
end actuators, leading to partial or complete separation of the 
transcowl from the engine and airplane during thrust reversal. We 
are issuing this AD to prevent loss of thrust control, asymmetric 
thrust, increased stopping distance, and possibly hazardous debris 
on the runway, which could result in unsafe landings.

Compliance

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

Visual Inspection and Fastening Hardware Replacements

    (g) Within 500 flight cycles after the effective date of this 
AD, do the following:
    (1) Inspect all translating cowl clevis pin retaining clips and 
associated fastening hardware, including those on the center drive 
unit (CDU), to ensure they are properly assembled and securely 
fastened in place. If a retaining clip is not completely covering 
the clevis pin and firmly attached to the clevis, remove and replace 
the fastening hardware. Use paragraphs 3.B.(2)(b) and 3.B.(2)(c) of 
MRAS ASB No. CF6-80C2 S/B 78A1162, Revision 1, dated February 13, 
2009, to do the inspections.
    (2) Remove and inspect all clevis pins for physical damage or 
significant corrosion. Use paragraphs 3.C.(1) through 3.C.(3) of 
MRAS ASB No. CF6-80C2 S/B 78A1162, Revision 1, dated February 13, 
2009, to do the removals, inspections, and part disposition as 
necessary.
    (3) Inspect the clevis brackets and four clevis fasteners at 
each of the clevis brackets (upper, center, and lower) for 
structural integrity. Use paragraphs 3.F.(1)(a) and 3.F.(1)(b) of 
MRAS ASB No. CF6-80C2 S/B 78A1162, Revision 1, dated February 13, 
2009, to do the inspections.
    (4) If loose or missing clevis fasteners are found, remove and 
replace the clevis

[[Page 11045]]

fasteners. Use paragraphs 3.F.(2)(a) through 3.F(2)(c) of MRAS ASB 
No. CF6-80C2 S/B 78A1162, Revision 1, dated February 13, 2009, to do 
the replacements.

Initial Rod-End Replacements

    (h) For all \3/8\-inch translating cowl adjustable-length 
actuator rod-ends, P/N KBE6-59, MS21242S06, B15946-13, 15946000-13, 
or M81935/1-6 having more than 600 flight cycles-since-new on the 
effective date of this AD, replace them with P/N M81935/1-6, zero 
time rod-ends within 500 flight cycles after the effective date of 
this AD. Use paragraphs 3.E.(2) through 3.E.(7) of MRAS ASB No. CF6-
80C2 S/B 78A1162, Revision 1, dated February 13, 2009, to do the 
replacements.

Repetitive \3/8\-inch Rod-End Replacements

    (i) Repetitively replace \3/8\-inch translating cowl adjustable-
length actuator rod-ends, P/N M81935/1-6, that were installed as 
specified in paragraph (h) of this AD, before they accumulate 11,000 
flight cycles, with a zero time \3/8\-inch adjustable-length rod-
end, P/N M81935/1-6. Use paragraphs 3.E.(2) through 3.E.(7) of MRAS 
ASB No. CF6-80C2 S/B 78A1162, Revision 1, dated February 13, 2009, 
to do the replacements.

Optional Terminating Action

    (j) As an optional terminating action to the repetitive \3/8\-
inch rod-end replacements required by this AD, replace the \3/8\-
inch adjustable rod-ends with either a fixed length rod-end, P/N 
3238726-1, -2, or MS9560-08, or a 7/16-inch adjustable rod-end, P/N 
3238729-1. Use paragraph 3.E.(1) of MRAS ASB No. CF6-80C2 S/B 
78A1162, Revision 1, dated February 13, 2009, to do the 
replacements.

Installation Prohibition

    (k) Rod-ends removed to comply with this AD are not eligible for 
installation on any aircraft.

Previous Credit

    (l) Inspections and replacements and optional terminating action 
performed before the effective date of this AD using MRAS ASB No. 
CF6-80C2 S/B 78A1162, dated December 30, 2008, satisfy the required 
initial actions and optional terminating action of this AD.

Alternative Methods of Compliance

    (m) The Manager, Engine 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

    (n) Contact Christopher J. Richards, Aerospace Engineer, Engine 
Certification Office, FAA, Engine & Propeller Directorate, 12 New 
England Executive Park, Burlington, MA 01803; e-mail: 
christopher.j.richards@faa.gov; telephone (781) 238-7133; fax (781) 
238-7199, for more information about this AD.
    (o) Contact Middle River Aircraft Systems, Mail Point 46, 103 
Chesapeake Park Plaza, Baltimore, MD 21220, attn: Warranty Support; 
telephone (410) 682-0094; fax (410) 682-0100, for a copy of the 
service information identified in this AD.

    Issued in Burlington, Massachusetts, on March 9, 2009.
Francis A. Favara,
Manager, Engine and Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. E9-5575 Filed 3-13-09; 8:45 am]

BILLING CODE 4910-13-P