2005-19-23 Boeing: Amendment 39-14288. Docket No. FAA-2005-21355; Directorate Identifier 2005-NM-037-AD. \n\nEffective Date \n\n\t(a) This AD becomes effective October 27, 2005. \n\nAffected ADs \n\n\t(b) This AD supersedes AD 2004-09-14. \n\nApplicability \n\n\t(c) This AD applies to Boeing Model 767-200, -300, and -300F series airplanes, certificated in any category, as identified in Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005. \n\nUnsafe Condition \n\n\t(d) This AD was prompted by a report of a crack in a closeout angle that covers the two aft-most fasteners in the lower tang of the midspar fitting; and the discovery of a crack in the lower tang of the midspar fitting under the cracked closeout angle. We are issuing this AD to prevent fatigue cracking in the primary strut structure and reduced structural integrity of the strut, which could result in separation of the strut and engine. \n\nCompliance \n\n\t(e) You are responsible for having the actionsrequired by this AD performed within the compliance times specified, unless the actions have already been done. \n\nRestatement of Requirements of AD 2004-09-14 \n\nRepetitive Inspections \n\n\t(f) Except as provided by paragraph (g) of this AD, before the accumulation of 10,000 total flight cycles, or within 600 flight cycles after May 15, 2001 (the effective date of AD 2001-07-05, amendment 39-12170), whichever occurs later: Accomplish the inspections required by paragraph (f)(1) or (f)(2) of this AD, as applicable. \n\n\t(1) Perform a detailed inspection of the four aft-most fastener holes in the horizontal tangs of the midspar fitting of the strut to detect cracking, in accordance with Part 1, "Detailed Inspection," of the Accomplishment Instructions of Boeing Service Bulletin 767- 54A0101, Revision 1, dated February 3, 2000. If no cracking is detected, repeat the inspection thereafter at the applicable intervals specified in Table 1, "Reinspection Intervals for Part 1--Detailed Inspection" included in Figure 1 of the service bulletin. \n\n\tNote 1: For the purposes of this AD, a detailed inspection is: "An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirror, magnifying lenses, etc., may be necessary. Surface cleaning and elaborate procedures may be required." \n\n\t(2) Perform a high frequency eddy current (HFEC) inspection of the four aft-most fastener holes in the horizontal tangs of the midspar fitting of the strut to detect discrepancies (cracking, incorrect fastener hole diameter), in accordance with Part 2, "High Frequency Eddy Current (HFEC) Inspection," of the Accomplishment Instructions of the service bulletin. Accomplish the requirements specified in paragraph (f)(2)(i) or (f)(2)(ii) of this AD, as applicable; and repeat the inspection thereafter atthe applicable intervals specified in Table 2, "Reinspection Intervals for Part 2--HFEC Inspection" included in Figure 1 of the service bulletin. \n\n\t(i) If no cracking is detected and the fastener hole diameter is less than or equal to 0.5322 inch, before further flight, rework the hole in accordance with Part 3 of the Accomplishment Instructions of the service bulletin. \n\n\t(ii) If no cracking is detected and the fastener hole diameter is greater than 0.5322 inch, before further flight, accomplish the requirements specified in either paragraph (h)(1) or (h)(2) of this AD. \n\n\t(g) For airplanes on which the two aft-most fasteners have been inspected in accordance with Boeing Service Bulletin 767-54A0101, Revision 1, dated February 3, 2000, prior to May 15, 2001: Perform the initial inspection of the four aft-most fasteners in accordance with paragraph (f) of this AD before the accumulation of 10,000 total flight cycles, or within 1,500 flight cycles after May 15, 2001, whichever occurs later. \n\nCorrective Actions \n\n\t(h) If any cracking is detected after accomplishment of any inspection required by paragraph (f) of this AD, before further flight, accomplish the requirements specified in either paragraph (h)(1) or (h)(2) of this AD. \n\n\t(1) Accomplish the terminating action specified in Part 4 of the Accomplishment Instructions of Boeing Service Bulletin 767-54A0101, Revision 1, dated February 3, 2000; Boeing Service Bulletin 767- 54A0101, Revision 3, dated September 5, 2002; or Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005. Accomplishment of this paragraph terminates the requirements of this AD. After the effective date of this AD, only Boeing Alert Service Bulletin 767-54A0101, Revision 4, may be used. \n\n\t(2) Replace the midspar fitting of the strut with a serviceable part, or repair in accordance with a method approved by the Manager, Seattle Aircraft Certification Office (ACO), FAA. Repeat the applicable inspection thereafter at the applicable time specified in paragraph (f)(1) or (f)(2) of this AD. \n\n\t(i) If any discrepancies (cracking, incorrect fastener hole diameter) are detected during any inspection required by paragraph (f) or (p) of this AD, for which the service bulletin specifies that the manufacturer may be contacted for disposition of those repair conditions: Before further flight, accomplish the applicable related investigative and corrective actions (including fastener hole rework and/or midspar fitting replacement) using a method approved in accordance with the procedures specified in paragraph (q) of this AD. \n\nAdditional Inspections \n\n\t(j) Prior to the accumulation of 10,000 total flight cycles, or within 600 flight cycles after June 9, 2004 (the effective date of AD 2004-09-14), whichever occurs later: Perform the inspections specified in paragraph (f)(1) or (f)(2) of this AD, as applicable, on all eight aft-most fastener holes or the four forward fastener holes in the group of eight aft-most fastener holes not inspected per paragraph (f)(1), (f)(2), or (g) of this AD. The inspection must be done per the Accomplishment Instructions in Boeing Service Bulletin 767-54A0101, Revision 3, dated September 5, 2002; or Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005. Accomplishment of the applicable inspection on all eight aft- most fastener holes constitutes terminating action for the repetitive inspection requirements of paragraphs (f)(1), (f)(2), and (g) of this AD. \n\n\t(k) If no cracking or discrepancy is detected during any detailed inspection required by paragraph (j) of this AD, repeat the inspections of all eight aft-most fastener holes thereafter at the applicable intervals specified in Table 1 of this AD. \n\n\t(l) If no cracking or discrepancy is detected during any HFEC inspection required by paragraph (j) of this AD or by this paragraph of this AD: Perform the follow-on actions specified in paragraph (f)(2)(i) or (f)(2)(ii) of this AD, as applicable, per the Accomplishment Instructions in Boeing Service Bulletin 767-54A0101, Revision 3, dated September 5, 2002; or Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005; and repeat the inspections of all eight aft-most fastener holes thereafter at the applicable intervals specified in Table 1 of this AD. \n\n\tTable 1.--Repetitive Inspection Intervals for All Eight Aft-Most \n\n\nIf-\nRepetitive intervals- \n\n\n\n\n\n\n\n\n(1) All eight aft-most fastener holes were inspected per paragraph (j) of this AD:. \nAt the applicable intervals specified in Table 1, "Reinspection Intervals for Part 1,"or Table 2, \n"Reinspection Intervals for Part 2,"as applicable. Both tables are included in Figure 1 of the applicable service bulletin. \nWithin 1,500 flight cycles after the effective date of this AD, only the repetitive intervals in Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005, may be used.(2) Only the four forward fastener holes in the group of eight aft-most fastener holes were inspected per paragraph (j) of this AD:. \nAt the next scheduled repetitive inspection required by paragraph (f)(1) of (f)(2) of this AD, as applicable. Thereafter at the applicable intervals specified in Table 1, "Reinspection Intervals for Part 1,"or Table 2, "Reinspection Intervals for Part 2,"as applicable. Both tables are included in Figure 1 of the applicable service bulletin. \nWithin 1,500 flight cycles after the effective date of this AD, only the repetitive intervals in Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005, may be used. \n\n\t\nCorrective Actions for Discrepancies \n\n\t(m) If any cracking or discrepancy is detected during any inspection required by paragraphs (j), (k), or (l) of this AD, before further flight: Accomplish the corrective actions described in paragraph (h) of this AD, except as provided in paragraph (i) of this AD. \n\nService Bulletin Revisions \n\n\t(n) Accomplishing the terminating action in paragraph (h)(1) of this AD before June 9, 2004, in accordance with the service bulletin revisions in Table 2 of this AD, is acceptable for compliance with the requirements of this AD. After the effective date of this AD, only Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005, may be used for accomplishing the terminating action in paragraph (h)(1) of this AD. \n\n\tTable 2.--Service Bulletins for Terminating Action \n\n\nService bulletin \nRevision \nDate \nBoeing Alert Service Bulletin 767-54A0101 \nOriginal \nSeptember 23, 1999. \nBoeing Service Bulletin 767-54A0101 \n2\nJanuary 10, 2002. \n\nInspections Accomplished per Previous Issues of Service Bulletin \n\n\t(o) Inspections required by paragraphs (f) and (g) of this AD that are accomplished before June 9, 2004, in accordance with the service bulletin revisions in Table 3 of this AD are considered acceptable for compliance with thecorresponding action specified in this AD. \n\n\tTable 3.--Service Bulletins for Previously Accomplished Inspections \n\n\nBoeing service bulletin \nRevision \nDate \nBoeing Service Bulletin 767-54A0101 \n2 \nJanuary 10, 2002. \nBoeing Service Bulletin 767-54A0101 \n3 \nSeptember 5, 2002. \nBoeing Alert Service Bulletin 767-54A0101 \n4 \nFebruary 10, 2005. \n\nNew Requirements of This AD \n\nInspections of Closeout Angle and Corrective Action \n\n\t(p) For airplanes for which the "Reinspection Intervals for Part 1," referenced in Table 1 of paragraph (l) of this AD apply: At the next applicable inspection, do an HFEC inspection for cracks of the closeout angle that covers the two aft-most fasteners in the lower tang of the midspar fitting and any related investigative and corrective actions, by doing all the applicable actions specified in the Accomplishment Instructions of Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005. Repeat the inspection at the applicable interval in Table 1, "Reinspection Intervals for Part 1," in Figure 1 of the alert service bulletin. \n\n\tNote 2: Boeing Alert Service Bulletin 767-54A0101, Revision 4, dated February 10, 2005, refers to the Boeing service bulletins in the Table 4 of this AD as additional sources of service information for doing the terminating action in paragraph (h)(1) of this AD. \n\n\tTable 4.--Additional Sources of Service Information \n\n\nBoeing service bulletin \nRevision level \nDate \nTitle \n\n\n\n\n767-54-0052\nOriginal\nJune 11, 1992\nNacelles/Pylons-Strut-Aft Lower Spar-Fastener Corrosion-In-spection and Replacement. \n\n\n\n\n767-54-0061 \n2\nNovember 23, 1999 \nNacelles/Pylons-Wing-to-Strut Attach Fittings-Lower Spar Bushing Inspection and Replacement. \n\n\n\n\n767-54-0069 \n2 \nAugust 31, 2000 \nNacelles/Pylons-Midspar Fitting-Underwing Sideload Fitting-Fuse Pin Replacement and Wing Rework. \n\n\n\n\n767-54-0072\nOriginal\nMarch 13, 1997 \nNacelles/Pylons-Strut Attach Upper Link-Upper Link Inspection, Rework or Replacement. \n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n767-54-0074\nOriginal \nMarch 27, 1997\nNacelles/Pylons-Strut Attach Fuse Pins-Upper link Fuse Pin Inspection/Replacement. Where this service bulletin refers to a cotter pin with part number (P/N) MS25665-374, the P/N should be MS24665-374. Where this service bulletin says, "If no crack indication is found, reinstall the fuse pin,"the correct statement is \n"If no crack indication is found, continue to Step F." \n\n\n\n\n767-54-0080 \n1 \nMay 9, 2002 \nNacelles/Pylons-Pratt and Whitney Powered Airplanes-Nacelle Strut and Wing Structure Modification. \n\n\n\n\n767-54-0081\n1\nFebruary 7, 2002 \nNacelles/Pylons-General Electric Powered Airplanes-Nacelle Strut and Wing Structure Modification. \n\n\n\n\n767-54A0062 \n5\nNovember 11, 2002 \nNacelles/Pylons-Strut Attach Fuse Pins-Midspar Fuse Pin Inspection and Replacement. \n\n\n\n\n767-54A0094\n2 \nFebruary 7, 2002 \nNacelles/Pylons-trut-to-Wing Attachment-Diagonal Brace Inspection/Rework/Replacement. \n767-57-0063\n1\nNovember 30, 2000 \nWings-Side Load Underwing Fitting-Inspection/Rework. \n\n\n\tNote 3: Certain service bulletins referenced in Table 4 of this AD are related to the ADs listed in Table 5 of this AD. \n\n\tTable 5.--Other Relevant Rulemaking \n\n\n\nAD \nApplicability \nRelated Boeing service bulletin \nAD requirement \n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\nAD 94-11-02, amendment 39- 8918, (59 FR 27229, May \n26, 1994). \nAll Boeing Model 767 series \nairplanes. \n767-54A0062 ......................... \nRepetitive detailed visual and eddy current \ninspections to detect cracks of certain midspar fuse pins, and replacement of any \ncracked midspar fuse pin with a new fuse pin. \n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\nAD 99-07-06, amendment 39- 11091 (64 FR 14578, March \n26, 1999). \nCertain Boeing Model 767 se-\nries airplanes. \n767-54A0094 ......................... \nRepetitive inspections to detect cracking or damage of the forward and aft lugs of the \ndiagonal brace of the nacelle strut; follow-on actions, if necessary; and an optional \nterminating action for the repetitive inspections. Superseded by AD 2000-07-05. \nAD 2000-07-05, amendment 39-11659 (65 FR 18883, April 10, 2000).\n\nCertain Boeing Model 767 series airplanes. \n767-54A0094 ......................... \nRequires the previously optional terminating action of AD 99-07-06. \n\n\n\n\n\n\n\n\n\n\n\n\nAD 2000-10-51, amendment \n39-11770 (65 FR 37011, \nJune 13, 2000). \n\nCertain Boeing Model 767 \nseries airplances. \n767-54-0074 .......................... \nOne-time inspection to determine whether certain bolts are installed in the side load underwing fittings on both struts, and various follow-on actions, if necessary. \n\n\n\n\n\n\n\n\nAD 2001-02-07, amendment \n39-12091 (66 FR 8085, \nJanuary 29, 2001). \nCertain Boeing Model 767 se-\nries airplanes powered by \nPratt & Whitney engines. \n767-54-0069, 767-54-0080, \nand 767-54-0094. \nModification of the nacelle strut and wing structure. Terminates certain requirements of AD 94-11-02. \n\n\n\n\n\n\n\n\nAD 2001-06-12, amendment \n39-12159 (66 FR 17492, \nApril 2, 2001). \nCertain Boeing Model 767 se-\nries airplanes powered by \nGeneral Electric engines. \n767-54-0069, 767-54-0081, \nand 767-54-0094. \nModification of the nacelle strut and wing structure. Terminates certain requirements of AD 94-11-02. \n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\nAD 2003-03-02, amendment \n39-13026 (68 FR 4374, January 29, 2003). \nAll Boeing Model 767 series \nairplanes. \n767-54A0062 ......................... \nSupersedes AD 94-11-02; Retains all requirements but reduces certain compliance \ntimes for certain inspections, expands the detailed and eddy current inspections, and limits the applicability. \n\nAlternative Methods of Compliance (AMOCs) \n\n\t(q)(1) The Manager, Seattle ACO, FAA, has the authority to approve AMOCs for this AD, if requested in accordance with the procedures found in 14CFR 39.19. \n\n\t(2) AMOCs approved previously according to AD 2004-09-14, amendment 39-13603, are approved as AMOCs for the corresponding requirements of this AD. \n\n\t(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 an Authorized Representative for the Boeing Commercial Airplanes Delegation Option Authorization Organization who 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. \n\n\t(4) Before using any AMOC approved in accordance with Sec. 39.19 on any airplane to which the AMOC applies, notify the appropriate principal inspector in the FAA Flight Standards Certificate Holding District Office. \n\nMaterial Incorporated by Reference \n\n\t(r) You must use the service information identified in Table 6 of this AD to perform the actions that are required by this AD, unless the AD specifies otherwise. \n\n\tTable 6.--Material Incorporated by Reference \n\n\nService bulletin \nRevision level \nDate \nBoeing Service Bulletin 767-54A0101 \n1 \nFebruary 3, 2000. \nBoeing Service Bulletin 767-54A0101 \n3 \nSeptember 5, 2002. \nBoeing Alert Service Bulletin 767-54A0101 \n4 \nFebruary 10, 2005. \n\n\n\t(1) The Director of the Federal Register approved the incorporation by reference of Boeing Alert Service Bulletin 767- 54A0101, Revision 4, dated February 10, 2005, in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. \n\n\t(2) On June 9, 2004 (69 FR 24947, May 5, 2004), the Director of the Federal Register approved the incorporation by of Boeing Service Bulletin 767-54A0101, Revision 3, dated September 5, 2002. \n\n\t(3) On May 15, 2001 (66 FR 18523, April 10, 2001), the Director of the Federal Register approved the incorporation by reference of Boeing Service Bulletin 767-54A0101, Revision 1, dated February 3, 2000. \n\n\t(4) Contact Boeing Commercial Airplanes, P.O. Box 3707, Seattle, Washington 98124-2207, for a copy of this service information. You may review copies at the Docket Management Facility, U.S. Department of Transportation, 400 Seventh Street, SW., room PL-401, Nassif Building, Washington, DC; on the Internet at http://dms.dot.gov; or \nat the National Archives and Records Administration (NARA). For information on the availability of this material at the NARA, call (202) 741-6030, or go to http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html .