AD 94-03-08

This amendment supersedes an existing airworthiness directive (AD), applicable to McDonnell Douglas Model DC-10 series airplanes and Model KC-10A (military) airplanes, that currently requires certain structural modifications and inspections. This amendment requires additional structural modifications and inspections. This amendment is prompted by an evaluation by the Model DC-10 Task Group, which identified additional modifications for mandatory action. The actions specified by this AD are intended to prevent degradation in the structural capabilities of the affected airplanes. This action also reflects the FAA's decision that long-term continued operational safety should be assured by actual modification of the airframe, where feasible, rather than only repetitive inspections for known service problems.

Final rule.

94-03-08 MCDONNELL DOUGLAS: Amendment 39-8815. Docket 93-NM-112-AD. Supersedes AD 90-16-04, Amendment 39-6613. \n\n\tApplicability: Model DC-10-10, -10F, -15, -30, -30F, -40, and -40F series airplanes and Model KC-10A (military) airplanes, certificated in any category. \n\n\tCompliance: Required as indicated, unless accomplished previously. \n\n\tNOTE 1: Paragraphs (a) and (c) of this AD restate the requirements for an initial inspection and the repetitive inspections contained in paragraphs A. and C. of AD 90-16-04. Therefore, for operators who have previously accomplished at least the initial inspection in accordance with AD 90-16-04, paragraphs (a) and (c) of this AD require that the next scheduled inspection be performed within the specified repetitive inspection interval after the last inspection performed in accordance with paragraphs A. and C. of AD 90-16-04. \n\n\tNOTE 2: Paragraphs (b) and (d) of this AD restate the modification requirements of paragraphs B. and D. of AD90-16-04. As allowed by the phrase, "unless accomplished previously," if the requirements of paragraphs B. and D. of AD 90-16-04 have been accomplished previously, paragraphs (b) and (d) of this AD do not require that they be repeated. \n\n\tTo prevent structural failure, accomplish the following: \n\n\t(a)\tFor service bulletins other than those identified in paragraph (c) of this AD, within the threshold for inspections specified in the service bulletins listed in Table 2.1 of McDonnell Douglas Report No. MDC-K1571, "DC-10/KC-10 Aging Aircraft Service Action Requirements Document," Revision A, dated February 28, 1990 (hereafter referred to as the "SARD, Revision A"), or Revision B, dated March 24, 1993 (hereafter referred to as the "SARD, Revision B"), or within one repetitive inspection period specified in those service bulletins after September 10, 1990 (the effective date of AD 90-16-04, Amendment 39-6613), whichever occurs later, inspect for cracks in accordance with those servicebulletins. Repeat these inspections thereafter at the intervals specified in the service bulletins listed in Table 2.1 of the SARD, Revision A or Revision B. \n\n\t\t(1)\tIf any crack is found as a result of any inspection, prior to further flight, either accomplish the terminating modification in accordance with the applicable service bulletin, or repair in accordance with a method approved by the Manager, Los Angeles Aircraft Certification Office (ACO), FAA, Transport Airplane Directorate. \n\n\tNOTE 3: Detection of any discrepancies other than cracking necessitates appropriate corrective action in accordance with the provisions of Part 43 of the Federal Aviation Regulations (FAR). \n\n\t\t(2)\tModification in accordance with paragraph (b) of this AD terminates the individual inspection requirements of the applicable service bulletin. \n\n\t(b)\tFor service bulletins other than those identified in paragraph (c) of this AD, prior to reaching the incorporation thresholds listed in the SARD, Revision A or Revision B, or prior to four years after September 10, 1990, whichever occurs later, accomplish the structural modifications specified in the service bulletins listed under "S/B No. Rev." in Table 2.1 of the SARD, Revision A or Revision B. \n\n\tNOTE 4: The service bulletin revision levels listed under "Recommended Modification" in Table 2.1 of the SARD, Revision B, are acceptable revisions for modifications accomplished prior to September 10, 1990. \n\n\tNOTE 5: The modifications required by this paragraph do not terminate the inspection requirements of any other AD unless that AD specifies that any such modification constitutes terminating action for the inspection requirements. \n\n\t(c)\tFor McDonnell Douglas Service Bulletins A30-37, 30-38, 53-16, 53-19, 53-25, 54-11, 54-27, 54-33, 55-2, and 57-7, listed in Table 2.1 of the SARD, Revision A; and for McDonnell Douglas Service Bulletins A30-37, 30-38, 53-16, 53-19, 53-25, 54-11, 54-27, 55-2, and 57-7, listed in Table 2.1of the SARD, Revision B: Within the threshold for inspections listed under "S/B Change Required" in Table 2.1 of the SARD, Revision A or Revision B, or within one repetitive inspection period specified under "S/B Change Required" in Table 2.1 of the SARD, Revision A or Revision B, after September 10, 1990, whichever occurs later, inspect for cracks in accordance with a method approved by the Manager, Los Angeles Aircraft Certification Office (ACO), FAA, Transport Airplane Directorate. Repeat these inspections thereafter at the intervals specified under "S/B Change Required" in Table 2.1 of the SARD, Revision A or Revision B. \n\n\t\t(1)\tIf any crack is found during any inspection, prior to further flight, either accomplish the terminating modification in accordance with the applicable service bulletin, or repair in accordance with a method approved by the Manager, Los Angeles ACO, FAA, Transport Airplane Directorate. \n\n\t\t(2)\tModification in accordance with paragraph (d) of this AD terminates the individual inspection requirements of the applicable service bulletin. \n\n\t(d)\tPrior to four years after September 10, 1990, accomplish the structural modifications stipulated in the service bulletins specified in paragraph (c) of this AD. \n\n\t(e)\tWithin the threshold for inspections specified in the service bulletins listed in Table 2.2 of the SARD, Revision B, or within one repetitive inspection period specified in those service bulletins after the effective date of this AD, whichever occurs later, inspect for cracks in accordance with those service bulletins. Repeat these inspections thereafter at the intervals specified in the service bulletins listed in Table 2.2 of the SARD, Revision B. \n\n\t\t(1)\tIf any crack is found during any inspection, prior to further flight, either accomplish the terminating modification in accordance with the applicable service bulletin, or repair in accordance with a method approved by the Manager, Los Angeles ACO, FAA, Transport AirplaneDirectorate. \n\n\t\t(2)\tModification in accordance with paragraph (f) of this AD terminates the individual inspection requirements of the applicable service bulletin. \n\n\t(f)\tPrior to reaching the incorporation thresholds listed in the SARD, Revision B, or within four years after the effective date of this AD, whichever occurs later, accomplish the structural modifications specified in the service bulletins listed in Table 2.2 of the SARD, Revision B. \n\n\tNOTE 6: The service bulletin revision levels listed under "Recommended Modification" in Table 2.2 of the SARD, Revision B, are acceptable revisions for modifications accomplished prior to the effective date of this AD. \n\n\tNOTE 7: The modifications required by this paragraph do not terminate the inspection requirements of any other AD unless that AD specifies that any such modification constitutes terminating action for the inspection requirements. \n\n\t(g)\tAn alternative method of compliance or adjustment of the compliance timethat provides an acceptable level of safety may be used if approved by the Manager, Los Angeles ACO, FAA, Transport Airplane Directorate. Operators shall submit their requests through an appropriate FAA Principal Maintenance Inspector, who may add comments and then send it to the Manager, Los Angeles ACO. \n\n\tNOTE 8: Information concerning the existence of approved alternative methods of compliance with this AD, if any, may be obtained from the Los Angeles ACO. \n\n\t(h)\tSpecial flight permits may be issued in accordance with FAR 21.197 and 21.199 to operate the airplane to a location where the requirements of this AD can be accomplished. \n\n\t(i)\tThe inspections, and modification shall be done in accordance with McDonnell Douglas Report No. MDC-K1571, "DC-10/KC-10 Aging Aircraft Service Action Requirements Document," Revision A, dated February 28, 1990; or McDonnell Douglas Report No. MDC K1571, "DC-10/KC-10 Aging Aircraft Service Action Requirements Document", Revision B, dated March 24, 1993, which contains the following list of effective pages: \n\n\n\nPage Number\nRevision Sym\nShown on Page\n Date \t\t\nShown on Page \n\n\n\nPages xiii and xiv\n(Not shown on these pages)\nMarch 24, 1993 \n \t\nThe incorporation by reference of McDonnell Douglas Report No. MDC K1571, "DC-10/KC-10 Aging Aircraft Service Action Requirements Document", Revision B, dated March 24, 1993, is approved by the Director of the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR Part 51. The incorporation by reference of McDonnell Douglas Report No. MDC-K1571, "DC-10/KC-10 Aging Aircraft Service Action Requirements Document," Revision A, dated February 28, 1990, was approved previously by the Director of the Federal Register in accordance 5 U.S.C. 552(a) and 1 CFR Part 51 as of September 10, 1990 (55 FR 31816, August 6, 1990). Copies may be obtained from McDonnell Douglas Corporation, P.O. Box 1771, Long Beach, California 90801-1771, Attention: Business Unit Manager, Technical Publications - Technical Administrative Support, C1-L5B. Copies may be inspected at the FAA, Transport Airplane Directorate, 1601 Lind Avenue, SW., Renton, Washington; or at the FAA, Transport Airplane Directorate, Los Angeles Aircraft Certification Office, 3229 East Spring Street, Long Beach, California; or at the Office of the Federal Register, 800 North Capitol Street, NW., suite 700, Washington, DC; or at the Office of the Federal Register, 800 North Capitol Street, NW., suite 700, Washington, DC. \n\n\t(j)\tThis amendment becomes effective on March 21, 1994.

A proposal to amend part 39 of the Federal Aviation Regulations by superseding AD 90-16-04, Amendment 39-6613 (55 FR 31816, August 6, 1990), which is applicable to McDonnell Douglas Model DC-10 series airplanes and Model KC-10A (military) airplanes, was published in the Federal Register on October 12, 1993 (58 FR 52717). The action proposed to supersede AD 90-16-04 to require additional structural modifications and inspections.\n\n\tInterested persons have been afforded an opportunity to participate in the making of this amendment. Due consideration has been given to the two comments received.\n\n\tThe commenters support the proposed rule.\n\n\tAfter careful review of the available data, including the comments noted above, the FAA has determined that air safety and the public interest require the adoption of the rule as proposed.\n\n\tThere are approximately 426 Model DC-10 series airplanes and Model KC-10A (military) airplanes of the affected design in the worldwide fleet.\n\n\tThe FAA estimates that 194 airplanes of U.S. registry were originally affected by AD 90-16-04. The requirements of that AD were estimated to take approximately 360 work hours at a current average labor rate of $55 per work hour. The cost for required modification kits was estimated to be $9,600 per airplane. Based on these figures, the FAA estimated that the total cost impact of AD 90-16-04 on U.S. operators would be $5,703,600, or $29,400 per airplane, over the initial 4-year time period. (These figures do not include the cost of downtime, planning, set-up, familiarization, or tool acquisition.)\n\n\tThe FAA estimates that a total of 269 airplanes of U.S. registry will be affected by the new requirements specified in this AD. This increase in the number of affected airplanes is due to various reasons, including transfer of ownership and the fact that additional airplanes have accumulated time-in-service since the issuance of AD 90-16-04 and have now reached thethreshold for modification/inspection. The new additional requirements contained in this AD action will take approximately 796 additional work hours per airplane to accomplish, at an average labor rate of $55 per work hour. Required parts will cost an additional $101,900 per airplane. Based on these figures, the total additional cost impact of this AD on U.S. operators is estimated to be $39,187,920, or $145,680 per airplane, over a 4-year time period. (These figures do not include the cost of downtime, planning, set-up, familiarization, and tool acquisition.)\n\n\tThe figures discussed above are based on the assumption that no operator has yet accomplished the currently required or the newly required requirements of this AD action. However, the FAA has been advised that various modifications that are required by this AD have previously been accomplished on many of the affected airplanes. Therefore, the future total cost impact of this AD is less than the figure shown.\n\n\tAdditional airplanes will be affected as they accumulate time-in-service and reach the threshold for modification/inspection.\n\n\tThe regulations adopted herein will not have substantial direct effects 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. Therefore, in accordance with Executive Order 12612, it is determined that this final rule does not have sufficient federalism implications to warrant the preparation of a Federalism Assessment.\n\n\tFor the reasons discussed above, I certify that this action (1) is not a "significant regulatory action" under Executive Order 12866; (2) is not a "significant rule" under DOT Regulatory Policies and Procedures (44 FR 11034, February 26, 1979); 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. A final evaluation has been prepared for this action and it is contained in the Rules Docket. A copy of it may be obtained from the Rules Docket at the location provided under the caption "ADDRESSES."\n\nList of Subjects in 14 CFR Part 39\n\n\tAir transportation, Aircraft, Aviation safety, Incorporation by reference, Safety.\n\nAdoption of the Amendment \n\n\tAccordingly, pursuant to the authority delegated to me by the Administrator, the Federal Aviation Administration amends 14 CFR part 39 of the Federal Aviation Regulations as follows:\n\nPART 39 - AIRWORTHINESS DIRECTIVES\n\n\t1.\tThe authority citation for part 39 continues to read as follows:\n\nAuthority: 49 U.S.C. App. 1354(a), 1421 and 1423; 49 U.S.C. 106(g); and 14 CFR 11.89.\n\n§ 39.13 - (Amended)\n\n\t2.\tSection 39.13 is amended by removing amendment 39-6613 (55 FR 31816, August 6, 1990), and by adding a new airworthiness directive (AD), amendment 39-8815, to read as follows: