AD 2005-26-10

The FAA is adopting a new airworthiness directive (AD) for Lycoming Engines (formerly Textron Lycoming) models 320, 360, and 540 series, "Parallel Valve" reciprocating engines, with certain Engine Components Inc. (ECi) cylinder assemblies, part number (P/N) AEL65102 series "Classic Cast", installed. This AD requires replacing these ECi cylinder assemblies. This AD results from reports of about 30 failures of the subject cylinder assemblies marketed by ECi. We are issuing this AD to prevent loss of engine power due to cracks in the cylinder assemblies and possible engine failure caused by separation of a cylinder head.

Final rule.

2005-26-10 Engine Components Incorporated (ECi): Amendment 39-14431. Docket No. FAA-2005-22358; Directorate Identifier. 2005-NE-20-AD.

Effective Date

(a) This airworthiness directive (AD) becomes effective January 31, 2006.

Affected ADs

(b) None.

Applicability

(c) This AD applies to Lycoming Engines (formerly Textron Lycoming) models 320, 360, and 540 series, parallel valve, reciprocating engines specified in Table 1 of this AD, with Engine Components Inc. (ECi) cylinder assemblies, part number (P/N) AEL65102 series "Classic Cast", with casting P/N AEL65099 and serial numbers (SNs) 1 through 9879, installed.

Table 1.--Engine Models

Cylinder head part number:

Installed on engine models

AEL65102 NST04
O 320 A1B, A2B, A2C, A2D, A3A, A3B, B2B, B2C, B3B, B3C, C2B, C2C, C3B, C3C, D1A, D1AD, D1B, D1C, D1D, D1F, D2A, D2B, D2C, D2F, D2G, D2H, D2J, D3G, E1A, E1B, E1C, F1F, E1J, E2A, E2B, E2C, E2D, E2E, E2F, E2G, E2H, E3D,E3H
IO 320 A1A, A2A, B1A, B1B, B1C, B1D, B1E, B2A, C1B, D1A, D1AD, D1B, D1C, E1A, E1B, E2A, E2B
AEIO 320 D1B, D2A, D2B, E1A, E1B, E2B
AIO 320 A1A, A1B, A2A, A2B, B1B, C1B
LIO 320 B1A
AEL65102 NST05
O 320 C1A, C1F, F1
A LIO 320 C1A
AEL65102 NST06
O 320 A1A, A2A, A2B, A2C, A3A, A3B, A3C, E1A, E1B, E2A, E2C
AEL65102 NST07
O 320 A2A, B1A, B1B
AEL65102 NST08
O 320 C1A, C1B, C2A, C2B, C3A, C2B, C3C

AEL65102 NST10
O 360 A1A, A1C, A1D, A2A, A2E, A3A, A3D, A4A, C1A, C1C, C1G, C2A, C2B, C2C, C2D, B1A, B1B, B2A, B2B, D1A, D2A, D2B
IO 360 B1A, B1B, B1C
HO 360 A1A, B1A, B1B
HIO 360 B1A, B1B
AEIO 360 B1B
AEIO 540 A1A, A1A5, A1B5, A1C5, A1D, A1D5, A2B, A3D5, A4A5, A4B5, A4C5, A4D5, B1A5, B1B5, B1C5, B2C5D, B4A5, B4A5D, D1A5, E1A, E4A5, E4B5, E4C5, F1A5, F1B5, G1A5, G2A5
IO 540 C1B5, C1C5, C2C, C4B5, C4B5D, C4C5, D4A5, D4B5, N1A5, N1A5D

AEL65102 NST12
O 360 A1A, A1AD, A1C, A1D, A1F,A1F6, A1F6D, A1G, A1G6, A1G6D, A1H, A1H6, A1J, A1LD, A2A, A2D, A2F, A2G, A2H, A3A, A3AD, A3D, A4A, A4AD, A4D, A4G, A4J, A4JD, A4K, A4M, A4N, A5AD, B1A, C1A, C1E, C1F, C1G, C2A, C2B, C2C, C2D, C2E, D2A, F1A6, G1A6
TIO 360 A1A6D
LTO 360 A1A6D
IO 360 A1G6D, A1H6, B1B, B1BD, B1D, B1E, B1F, B1F6, B2E, B2F, B2F6, B4A, E1A, E4A, F1A
IHO 360 B1A, B1B
AEIO 360 B1B, B1D, B1F, B1F6, B1G6, B2F, B2F6, B4A, H1A
O 540 A4D5, B2B5, B2C5, B2C5D, B4B5, B4B5D, E4A5, E4B5, E4B5D, E4C5, G1A5, G1A5D, G2A5, H1A5, H1A5D, H1B5, H1B5D, H2A5, H2A5D, H2B5D
IO 540 C4A5, C4B5, C4B5D, C4D5D, D4A5, D4B5, D4C5, N1A5, T4A5, T4A5D, T4B5D, T4C5D, V4A5D
AEIO 540 D4A5, D4B5, D4C5

AEL65102 NST26
IO 540 J4A5, R1A5
TIO 540 C1A, E1A, G1A, H1A

AEL65102 NST38
(T)IO 360 F1A
TIO 360 AA1AD, AB1AD, C1A, C1AD, AF1A, K1AD
LTIO 540 K1AD

AEL65102 NST43
O 540 J1A5D, J1B5D, J1C5D, J1D5D, J2A5D, J2B5D, J2C5D, J3A5, J3A5D, J3C5D
IO 540 L3C5D, W1A5D, W3A5D
AEL65102 NST44
O 540 L3C5DFor information, the subject engines are installed on, but not limited to, the aircraft listed in the following Table 2:

Table 2.--Engines Installed on, But Not Limited to

O 320 A1A
Piper Aircraft: Tri-Pacer (PA 22 "150", PA 22S "150"), Apache (PA 23), Pawnee (PA 25) Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
Mooney Aircraft: Mark (20A)
Dinfia: Ranquel (1A 46)
Simmering-Graz Pauker: Flamingo (SGP M 222)
Aviamilano: Scricciolo (P 19)
Vos Helicopter Co.: Spring Bok
O 320 A1B
Piper Aircraft: Tri-Pacer (PA 22 "150", PA 22S "150"), Apache (PA 23)
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
S.O.C.A.T.A.: Horizon (Gardan)

O 320 A2A
Piper Aircraft: Tri-Pacer (PA 22 "150", PA 22S "150"), Agriculture (PA 18A "150") Super Cub (PA 18 "150"), Caribbean (PA 22 "150"), Pawnee (PA 25)
Intermountain Mfg. Co.: Call Air Texas (A 5, A 5T)
Lake Aircraft: Colonial (C 1)
Rawdon Bros.: Rawdon (T 1, T 15, T 15D)
Shinn Engineering: Shinn (2150 A)
Dinfia: Ranquel (1A) 46)
Neiva: (1PD 5802)
Sud: Gardan-Horizon (GY 80)
LaVerda: Falco (F8L Series II, America)
Malmo: Vipan (MF1 10)
Kingsford Smith: Autocrat (SCRM 153)
Aero Commander: 100

O 320 A2B
Piper Aircraft: Tri-Pacer (PA 22 "150", PA 22S "150"), Cherokee (PA 28 "150"), Super Cub (PA 18 "150")
Champion Aircraft: Challenger (7GCA, 7GCB, 7KC), Citabria (7GCAA, 7GCRC), Agriculture (7GCBA)
Beagle: Pup (150)
Artic: Interstate S1B2
Robinson: R 22Varga: Kachina 2150A

O 320 A2C
Robinson: R 22
Cicare: Cicare AG
Bellanca Aircraft: Citabria 150 (7GCAA), Citabria 150S (7GCBC)
O 320 A2D
Piper Aircraft: Apache (PA 23)

O 320 A3A
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
Corben-Fettes: Globe Special (Globe GC 1B)

O 320 A3B
Piper Aircraft: Apache (PA 23)
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
Teal II: TSC (1A2)
O 320 B1A
Piper Aircraft: Apache (PA 23 "160")
DoynAircraft: Doyn-Cessna (170, 170A, 170B)
Malmo: Vipan (MF1 10)
O 320 B1B
Piper Aircraft: Apache (PA 23 "160")
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
O 320 B2A
Piper Aircraft: Tri-Pacer (PA 22 "160", PA 22S "160")

O 320 B2B
Piper Aircraft: Tri-Pacer (PA 22 "160", PA 22S "160")
Beagle: Airedale (D5 160)
Fuji-Heavy Industries: Fuji (F 200)
Uirapuru: Aerotec 122
O 320 B2C
Robinson: R 22
O 320 B2D
Maule: MX 7 160
O 320 B2E
Lycon
O 320 B3A
Piper Aircraft: Apache (PA 23 "160")
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
O 320 B3B
Piper Aircraft: Apache (PA 23 "160")
Doyn Aircraft: Doyn-Cessna (170, 170A, 170B)
Sud: Gardan (GY80 160)
O 320 C1A
Piper Aircraft: Apache (PA 23 "160")
Riley Aircraft: Rayjay (Apache)
O 320 C1B
Piper Aircraft: Apache (PA 23 "160")
O 320 C3A
Piper Aircraft: Apache (PA 23 "160")
O 320 C3B
Piper Aircraft: Apache (PA 23 "160")

O 320 D1A
Sud: Gardan (GY 80)
Gyroflug: Speed Cancard
Grob: G115O 320 D1F
Slingsby: T67 Firefly

O 320 D2A
Piper Aircraft: Cherokee (PA 28S "160")
Robin: Major (DR400 140B), Chevalier (DR 360), (R 3140)
S.O.C.A.T.A.: Tampico TB9
Slingsby: T67C Firefly
Daetwyler: MD 3 160
Nash Aircraft Ltd.: Petrel
Aviolight: P66D Delta
General Avia: Pinguino

O 320 D2B
Beech Aircraft: Musketeer (M 23)
Piper Aircraft: Cherokee (PA 28 "160")
O 320 D2J
Cessna Aircraft: Skyhawk 172
O 320 D3G
Piper Aircraft: Warrior II, Cadet (PA 28 161)
O 320 E1A
Grob: G115
O 320 E1C
M.B.B. (Messerschmitt-Boelkow-Blohm): Monsun (BO 209 B)
O 320 E1F
M.B.B.: Monsun (BO 209 B)

O 320 E2A
Piper Aircraft: Cherokee (PA 28 "140", PA 28 "150")
Robin: Major (DR 340), Sitar, Bagheera (GY 100 135)
S.O.C.A.T.A.: Super Rallye (MS 886), Rallye Commodore (MS 892)
Siai-Marchetti: (S 202)
F.F.A.: Bravo (AS 202/15)
Partenavia: Oscar (P66B), Bucker (131 APM)
Aeromot: Paulistina P 56
Pezetel: Koliber 150

O 320 E2C
Beech Aircraft: Musketeer III (M 23III)
M.B.B.: Monsun (BO 209 B)
O 320 E2D
Cessna Aircraft: Cardinal (172 I, 177)
O 320 E2F
M.B.B.: Monsun (BO 209 B),
Wassmer Pacific (WA 51)
O 320 E2G
American Aviation Corp.: Traveler

O 320 E3D
Piper Aircraft: Cherokee (140)
Beech Aircraft: Sport

O 320 H2AD
Cessna Aircraft: Skyhawk 172
Partenavia: P 66C
IO 320 B2A
Piper Aircraft: Twin Comanche (PA 30)
IO 320 B1C
Hi. Shear: Wing
IO 320 B1D
Ted Smith Aircraft: Aerostar
IO 320 C1A
Piper Aircraft: Twin Comanche (PA 30 Turbo)
IO 320 D1A
M.B.B.: Monsun (BO 209 C)
IO 320 D1B
M.B.B.: Monsun (BO 209 C)
IO 320 E1A
M.B.B.: Monsun (BO 209 C)
IO 320 E1B
Bellanca Aircraft
IO 320 E2A
Champion Aircraft: Citabria
IO 320 E2B
Bellanca Aircraft
IO 320 F1A
CAAR Engineering: Carr Midget
LIO 320 B1A
Piper Aircraft: Twin Comanche (PA 39)
LIO 320 C1A
Piper Aircraft: Twin Comanche (PA 39)
AIO 320 B1B
M.B.B.: Monsun (BO 209 C)
AEIO 320 D1B
Slingsby: T67M Firefly
AEIO 320 D2B
Hundustan Aeronautics Ltd.: HT 2

AEIO 320 E1A
Bellanca Aircraft
Champion Aircraft

AEIO 320 E1B
Bellanca Aircraft
Champion Aircraft: Decathalon (8KCAB CS)

AEIO 320 E2B
Bellanca Aircraft
Champion Aircraft: Decathalon (8KCAB)
O 320 A1A
Riley Aircraft: Riley Twin

O 360 A1A
Beech Aircraft: Travel Air (95, B 95)
Piper Aircraft: Comanche (PA 24)
Intermountain Mfg. Co.: Call Air (A 6)
Lake Aircraft: Colonial (C 2, LA 4, 4A or 4P)
Doyn Aircraft: Doyn-Cessna (170B, 172, 172A, 172B)
Mooney Aircraft: Mark "20B"(M 20B)
Earl Horton: Pawnee (Piper PA 25)
Dinfia: Ranquel (1A 51)
Neiva: (1PD 5901)
Regente: (N 591)
Wassmer: Super 4 (WA 50A), Sancy (WA 40), Baladou (WA 40), Pariou (WA 40)
Sud: Gardan (GY 180)
Bolkow: (207)
Partenavia: Oscar (P 66)
Siai-Marchetti: (S 205) Procaer: Picchio (F 15 A)
S.A.A.B.: Safir (91 D)
Malmo: Vipan (MF 10B)
Aero Boero: AB 180
Beagle: Airedale (A 109)
DeHavilland: Drover (DHA 3MK3)
Kingsford-Smith: Bushmaster (J5 6)
Aero Engine Service Ltd.: Victa (R 2)
O 360 A1AD
S.O.C.A.T.A.: Tabago TB 10

O 360 A1D
Piper Aircraft: Comanche (PA 24)
Lake Aircraft: Colonial (LA 4, 4A or 4P)
Doyn Aircraft: Doyn-Beech (Beech 95)
Mooney Aircraft: Master "21"(M 20E), Mark "20B", "20D", (M20B, M20C), Mooney Statesman (M 20G)
Dinfia: Querandi (1A 45)
Wassmer: (WA 50)
Malmo: Vipan (MF1 10)
Cessna Aircraft: Skyhawk
Doyn Aircraft: Doyn-Piper (PA 23 "160")
O 360 A1F6
Cessna Aircraft: Cardinal

O 360 A1F6D
Cessna Aircraft: Cardinal 177
Teal III: TSC (1A3)
O 360 A1G6
Aero Commander
O 360 A1G6D
Beech Aircraft: Duchess 76
O 360 A1H6
Piper Aircraft: Seminole (PA 44)
O 360 A1LD
Wassmer: Europa WA 52
O 360 A1P
Aviat: Husky

O 360 A2A
Center Est Aeronautique: Regente (DR 253)
S.O.C.A.T.A.:Rallye Commodore (MS 893)
Societe Aeronautique Normande: Mousquetaire (D 140)
Bolkow: Klemm (K1 107C)
Partenavia: Oscar (P 66)
Beagle: Husky (D5 180) (J1 U)

O 360 A2D
Piper Aircraft: Comanche (PA 24), Cherokee "C"(PA 28 "180")
Mooney Aircraft: Master "21"(M 20D), Mark "21"(M 20E)
O 360 A2E
Std. Helicopter

O 360 A2F
Aero Commander: Lark (100)
Cessna Aircraft: Cardinal
O 360 A2G
Beech Aircraft: Sport

O 360 A3A
C.A.A.R.P.S.A.N.: (M 23III)
Societe Aeronautique Normande: Jodel (D 140C)
Robin: Regent (DR400/180), Remorqueur (DR400/180R). R 3170
S.O.C.A.T.A.: Rallye 180GT, Sportavia Sportsman (RS 180)
Norman Aeroplace Co.: NAC 1 Freelance
Nash Aircraft Ltd.: Petrel

O 360 A3AD
S.O.C.A.T.A.: TB 10
Robin: Aiglon (R 1180T)
O 360 A4A
Piper Aircraft: Cherokee "D"(PA 28 "180")
O 360 A4D
Varga: Kachina
O 360 A4G
Beech Aircraft: Musketeer Custom III

O 360 A4K
Grumman American: Tiger
Beech Aircraft: Sundowner180
O 360 A4M
Piper Aircraft: Archer II (PA 28 "18")
Valmet: PIK 23
O 360 A4N
Cessna Aircraft: 172 (Optional)
O 360 A4P
Penn Yan: Super Cub Conversion
O 360 A5AD
C. Itoh and Co.: Fuji FA 200
O 360 B2C
Seabird Aviation: SB7L
O 360 C1A
Intermountain Mfg. Co.: Call Air (A 6)
O 360 C1E
Bellanca Aircraft: Scout (8GCBC CS)
O 360 C1F
Maule: Star Rocket MX 7 180
O 360 C1G
Christen: Husky (A 1)
O 360 C2B
Hughes Tool Co.: (269A)
O 360 C2D
Hughes Tool Co.: (269A)
O 360 C2E
Hughes Tool Co.: (YHO 2HU) Military
Bellanca Aircraft: Scout (8GCBC FP)
O 360 C4F
Maule: MX 7 180A
O 360 C4P
Penn Yan: Super Cub Conversion
O 360 E1A6D
Piper Aircraft: Seminole (PA 44 "180")
O 360 F1A6
Cessna Aircraft: Cutlass RG
O 360 J2A
Robinson: R22
IO 360 B1A
Beech Aircraft: Travel-Air (B 95A)
Doyn Aircraft: Doyn-Piper (PA 23 "200")
IO 360 B1B
Beech Aircraft: Travel-Air (B 95B)
Doyn Aircraft: Doyn-Piper (PA 23 "200")
Fuji: (FA 200)
IO 360 B1D
United Consultants: See-Bee
IO 360 B1E
Piper Aircraft: Arrow (PA 28 "180R")
IO 360 B1F
Utva: 75
IO 360 B2E
C.A.A.R.P. C.A.P. (10)
IO 360 B1F6
Great Lakes: Trainer
IO 360 B1G6
American Blimp: Spector 42
IO 360 B2F6
Great Lakes: Trainer
LO 360 A1G6D
Beech Aircraft: Duchess
LO 360 A1H6
Piper Aircraft: Seminole (PA 44)
IO 360 E1A
T.R. Smith Aircraft: Aerostar
IO 360 L2A
Cessna Aircraft: Skyhawk C 172
IO 360 M1A
Diamond Aircraft: DA 40

IO 360 M1B
Vans Aircraft: RV6, RV7, RV8
Lancair: 360
AIO 360 B1B
Moravan: Zlin (Z 526 L)
AEIO 360 B1F
F.F.A.: Bravo (200)
Grob: G115/Sport-Acro
AEIO 360 B1G6
Great Lakes
AEIO 360 B2F
Mundry: CAP 10
AEIO 360 B4A
Pitts: S 1S
AEIO 360 H1A
Bellanca Aircraft: Super Decathalon (8KCAB 180)
AEIO 360 H1B
American Champion: Super Decathalon

TO 360 C1A6D
Avions Pierre Robin
Partenavia
Rockwell: 112TC
TO 360 F1A6D
Maule: Star Rocket (M 5 210TC)
TIO 360 C1A6D
Partenavia:P68C TC
VO 360 A1A
Brantly Hynes Helicopter: (B 2)
VO 360 A1B
Brantly Hynes Helicopter: (B 2, B2 A). Military (YHO 3BR)
VO 360 B1A
Brantly Hynes Helicopter: (B 2, B2 A)
IVO 360 A1A
Brantly Hynes Helicopter: (B2 B)
HO 360 B1A
Hughes Tool Co.: (269A)
HO 360 B1B
Hughes Tool Co.: (269A)
HO 360 C1A
Schweizer: (300C)
HIO 360 B1A
Hughes Tool Co.: Military (269 A 1). (TH 55A)
HIO 360 B1B
Hughes Tool Co.: (269A)
HIO 360 G1A
Schweizer: (CB)
O 540 A1A
Rhein-Flugzeugbau: (RF 1)
O 540 A1A5
Piper Aircraft: Comanche (PA 24 "150")
Helio: Military (H 250)
Yoeman Aviation: (YA 1)
O 540 A1B5
Piper Aircraft: Aztec (PA 23 "250"), Comanche (PA 24 "250")
O 540 A1C5
Piper Aircraft: Comanche (PA 24 "250")
O 540 A1D
Found Bros.: (FBA 2C)
Dornier: (DO 28 B1)
O 540 A1D5
Piper Aircraft: Aztec (PA 23 "250"), Comanche (PA 24 "250"), Military Aztec (U 11A) Dornier: (DO 28)
O 540 A2B
Aero Commander: (500)
Mid-States Mfg. Co.: Twin Courier (H 500), (U 5)

O 540 A3D5
Piper Aircraft: Navy Aztec (PA 23 "250")
O 540 B1A5
Piper Aircraft: Apache (PA 23 "235")
O 540 B1B5
Piper Aircraft: Cherokee (PA 24 "250")
Doyn Aircraft: Doyn-Piper (PA 24 "250")
O 540 B1D5
Wassmer: (WA 421)
O 540 B2B5
Piper Aircraft: Pawnee (PA 24 "235"), Cherokee (PA 28 "235"), Aztec (PA 23 "235") Intermountain Mfg. Co.: Call Air (A 9)
Rawdon Bros.: Rawdon (T 1)
S.O.C.A.T.A.: Rallye 235CA
O 540 B2C5
Piper Aircraft: Pawnee (PA 24 "235")
O 540 B4B5
Piper Aircraft: Cherokee (PA 28 "235")
Embraer: Corioca (EMB 710)
S.O.C.A.T.A.: Rallye 235GT, Rallye 235C
Maule: Star Rocket (MX 7 235), Super Rocket (M 6 235),
Super Std. Rocket (M 7 235)
O 540 E4A5
Piper Aircraft: Comanche (PA 24 "260")
Aviamilano: Flamingo (F 250)
Siai-Marchetti: (SF 260), (SF 208)
O 540 E4B5
Britten-Norman: (BN 2)
Piper Aircraft: Cherokee Six (PA 32 "260")

O 540 E4C5
Pilatus Britten-Norman: Islander (BN 2A 26), Islander (BN 2A 27), Islander II (BN 2B 26), Islander (BN 2A 21), Trislander (BN 2A Mark III 2)
O 540 F1B5
Omega Aircraft: (BS 12D1)
Robinson: (R 44)
O 540 G1A5
Piper Aircraft: Pawnee (PA 25 "260")
O 540 H1B5D
Aero Boero: 260
O 540 H2A5
Embraer: Impanema "AG"
Gippsland: GA 200
O 540 H2B5D
Aero Boero: 260
O 540 J1A5D
Maule: Star Rocket (MX 7 235), Super Rocket (M 6 235), Super Std. Rocket (M 7 235)
O 540 J3A5
Robin: R 3000/235
O 540 J3A5D
Piper Aircraft: Dakota (PA 28 236)
O 540 J3C5D
Cessna Aircraft: Skylane RG
O 540 L3C5D
Cessna Aircraft: TR 182, Turbo Skylane RG
IO 540 C1B5
Piper Aircraft: Aztec B (PA 23 "250"), Comanche (PA 24 "250")
IO 540 C1C5
Riley Aircraft: Turbo-Rocket

IO 540 C4B5
Piper Aircraft: Aztec C (PA 23 "250"), Aztec F
Wassmer: (WA4 21)
Avions Pierre Robin: (HR100/250)
Bellanca Aircraft: Aries T 250
Aerofab: Renegade 250
IO 540 C4D5
S.O.C.A.T.A.: TB 20
IO 540 C4D5D
S.O.C.A.T.A.: Trinidad TB 20
IO 540 D4A5
Piper Aircraft: Comanche (PA 24 "260")
Siai-Marchetti: (SF 260)
IO 540 D4B5
Cerva: (CE 43 Guepard)
IO 540 J4A5
Piper Aircraft: Aztec (PA 23 "250")
IO 540 R1A5
Piper Aircraft: Comanche (PA 24)
IO 540 T4A5D
General Aviation: Model 114
IO 540 T4B5
Commander: 114B
IO 540 T4B5D
Rockwell: 114
IO 540 T4C5D
Lake Aircraft: Seawolf

IO 540 V4A5
Maule: MT 7 260, M 7 260
Aircraft Manufacturing Factory
IO 540 V4A5D
Brooklands: Scoutmaster
IO 540 W1A5
Maule: MX 7 235, MT 7 235, M7 235
IO 540 W1A5D
Maule: Star Rocket (MX 7 235), Super Rocket (M 6 235), Super Std. Rocket (M 7 235)
IO 540 W3A5D
Schweizer: Power Glider

AEIO 540 D4A5
Christen: Pitts (S 2S), S 2B)
Siai-Marchetti: SF 260
H.A.L.: HPT 32
Slingsby: Firefly T3A

AEIO 540 D4B5
Moravan: Zlin-50L
H.A.L.: HPT 32
AEIO 540 D4D5
Burkhart Grob: Grob G, 115T Aero
TIO 540 C1A
Piper Aircraft: Turbo Aztec (PA 23 250)
TIO 540 K1AD
Piper Aircraft
TIO 540 AA1AD
Aerofab Inc.:Turbo Renegade (270)
TIO 540 AB1AD
S.O.C.A.T.A.: Trinidad TC TB 21
TIO 540 AB1BD
Schweizer
TIO 540 AF1A
Mooney Aircraft: "TLS"M20M
TIO 540 AF1B
Mooney Aircraft: "TLS"M20M
TIO 540 AG1A
Commander Aircraft: 114TC
TIO 540 AK1A
Cessna Aircraft: Turbo Skylane T182T
LTIO 540 K1AD
Piper Aircraft

Unsafe Condition

(d) This AD results from reports of about 30 failures of the subject cylinder assemblies marketed by ECi. We are issuing this AD to prevent loss of engine power due to cracks in the cylinder assemblies and possible engine failure caused by separation of a cylinder head.

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 major repair since new, no further action is required.

Engines Overhauled or Repaired Since New

(g) If your engine was overhauled or repaired since new, do the following:

(1) Determine if ECi cylinder assemblies, P/N AEL65102 series "Classic Cast", with casting P/N AEL65099 and SNs 1 through 9879 are installed on your engine, as follows:

(i) Inspect the engine log books and maintenance records for reference to the subject ECi cylinder assemblies.

(ii) If the engine log books and maintenance records did not record the P/N and SN of the cylinder assemblies, visually inspect the cylinder assemblies and verify the P/N and SN of the cylinder assemblies.

(2) If the cylinder assemblies are not ECi, P/N AEL65102 series "Classic Cast", with casting P/N AEL65099, no further action is required.

(3) If any cylinder assembly is an ECi P/N AEL65102 series "Classic Cast", with casting P/N AEL65099 and a SN 1 through 9879, do the following:

(i) If the cylinder assembly has fewer than 800 operating hours- in-service (HIS) on the effective date of this AD, replace the cylinder assembly at no later than 800 operating HIS. No action is required until the operating HIS reaches 800 hours.

(ii) If the cylinder assembly has 800 operating HIS or more on the effective date of this AD, replace the cylinder assembly within 60 operating HIS after the effective date of this AD.

Definition of a Replacement Cylinder Assembly

(h) For the purpose of this AD, a replacement cylinder assembly is defined as follows:

(1) A serviceable cylinder assembly made by Lycoming Engines.

(2) A serviceable FAA-approved, Parts Manufacturer Approval cylinder assembly from another manufacturer.

(3) A serviceable ECi cylinder assembly, P/N AEL65102 series, "Titan", with casting P/N AEL85009.

(4) A serviceable ECi cylinder assembly, P/N AEL65102 series, with casting P/N AEL65099, that has a SN 9880 or higher.

Prohibition of Cylinder Assemblies, P/N AEL65102 Series "Classic Cast", With Casting P/N AEL65099 and SNs 1 Through 9879

(i) After the effective date of this AD, do not install any ECi cylinder assembly, P/N AEL65102, with casting P/N AEL65099 that has a SN 1 through 9879, onto any engine.

Alternative Methods of Compliance

(j) 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

(k) ECi Service Bulletin No. 05-08, dated September 1, 2005, pertains to the subject of this AD.

The FAA proposed to amend 14 CFR part 39 with a proposed AD. The proposed AD applies to certain ECi cylinder assemblies, P/N AEL65102 series, with casting P/N AEL65099, installed on Lycoming Engines models 320, 360, and 540 series, parallel valve reciprocating engines. Parallel valve Lycoming reciprocating engines are identified by the intake and exhaust valves in a parallel configuration. We published the proposed AD in the Federal Register on September 9, 2005 (70 FR 53586). That action proposed to require replacing these ECi cylinder assemblies.

Examining the AD Docket

You may examine the docket that contains the AD, any comments received, and any final disposition in person at the Docket Management Facility Docket Office 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 DMS receives them.

Comments

We provided the public the opportunity to participate in the development of this AD. We have considered the comments received.

Request To Extend the Proposed AD Comment Period

One commenter, a law office representing ECi, requests we extend the proposed AD comment period an additional 90 days. We do not agree. We have worked with ECi for the past four years regarding the safety and airworthiness issues with the affected ECi cylinder assemblies. ECi is very familiar with the problems with these cylinder assemblies. ECi published Service Bulletin No. 05-08, dated September 1, 2005, for the identification and warranty of the affected cylinder assemblies. Evidence of ECi's awareness of the problem is confirmed by the extensive correspondence with the FAA regarding the service difficulties with P/N AEL65102 "Classic Cast" cylinder assemblies. For these reasons, and because of the minimal amount of comments received (two) on the proposed AD, we find it unnecessary to extend the proposed AD comment period.

Request To Allow Cylinder Assembly Removal at Normal Operating Time- Between-Overhaul

One commenter, ECi, requests that we allow affected cylinder assemblies to be removed at the normal engine operating time-between- overhaul. We do not agree. We have carefully reviewed ECi's request. Both ECi and the FAA participated in the Alloytek Metallurgical Services, Inc. examination and analysis. The examination and analysis showed that the failure mode of the ECi cylinder assemblies, P/N AEL65102, is most likely due to metal fatigue. The proposed AD required replacing affected cylinder assemblies at no later than 800 operating hours-in-service. The failure data records show that a longer operating time for the affected cylinder assemblies would jeopardize aircraft safety. We have not changed the AD.

Conclusion

We have carefully reviewed the available data, including the comments received, and determined that air safety and the public interest require adopting the AD as proposed.

Costs of Compliance

There were 9,879 ECi cylinder assemblies produced of the affected design available to the worldwide fleet. ECi reported that about fifteen percent of their cylinder assemblies go to foreign countries. We estimate ten percent of the remaining cylinders were never installed or are already removed from service, leaving 7,557 cylinder assemblies in service in the United States. We estimate that 1,574 Lycoming engines are in the United States with the subject cylinder assemblies installed. We estimate that it will take about two work hours per engine to perform the aircraft inspections of the cylinder assemblies for applicability, and that the average labor rate is $65 per work hour. From the Lycoming Engines "Removal and Installation Labor Allowance Guidebook", dated May 2000, the complete cylinder replacement for a fourcylinder engine takes 12 hours, while the complete cylinder replacement for a six cylinder engine takes 16 hours. Required parts will cost about $1,000 per cylinder assembly. Based on these figures, we estimate that the total cost of the AD to U.S. operators to be $9,152,140. ECi indicated that they might give operators and repair stations credit for returned cylinder assemblies toward the purchase of new ECi cylinder assemblies.

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 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) 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.

We prepared a summary of the costs to comply with this AD and placed it in the AD Docket. 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, Safety.

Adoption of the Amendment

Accordingly, under the authority delegated to me by the Administrator, the Federal Aviation Administration amends 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: