AD 2005-19-11

The FAA is adopting a new airworthiness directive (AD) for certain Lycoming Engines (formerly Textron Lycoming) AEIO-360, IO-360, O-360, LIO-360, LO-360, AEIO-540, IO-540, O-540, and TIO-540 series reciprocating engines rated at 300 horsepower (HP) or lower. This AD requires replacing certain crankshafts. This AD results from reports of 12 crankshaft failures in Lycoming 360 and 540 series engines rated at 300 HP or lower. We are issuing this AD to prevent failure of the crankshaft, which could result in total engine power loss, in-flight engine failure, and possible loss of the aircraft.

Final rule.

2005-19-11 Lycoming Engines: Amendment 39-14276. Docket No. FAA- 2005-21864; Directorate Identifier 2005-NE-29-AD.

Effective Date

(a) This airworthiness directive (AD) becomes effective October 21, 2005.

Affected ADs

(b) None.

Applicability

(c) This AD applies to Lycoming Engines (Formerly Textron Lycoming) AEIO-360, IO-360, O-360, LIO-360, LO-360, AEIO-540, IO- 540, O-540, and TIO-540 series reciprocating engines, rated at 300 horsepower (HP) or lower, manufactured new, rebuilt, overhauled after March 1, 1999, or that had a crankshaft installed after March 1, 1999. These engines are installed on, but not limited to, the following aircraft:

Engine model
Manufacturer
Aircraft model

A.M.F
17 D Mushshak
IO 540 V4A5
Aero Commander
500 B, S, U/Merlyn Products Conv.

Aero Commander
500 E

Aerofab
LA 250 Renegade
IO 540 E1A5
Aeronautica
Agricola Mexicana Quail

Aerostar
600
IO 540 K1F5
Aircraft Manufacturing Factory
Mushshak
O 540 E4A5
Aviamilano
F 250 Flamingo
IO 540 C4B5
Avions
Pierre Robin HR 100/250
LO 360 A1G6D
Beech
76 Duchess

76 Duchess

Beech
C 24R Sierra or 200 Sierra
O 360 A1G6D
Bellanca
Aircraft Aries T 250
O 540 E4B5
Britten Norman
BN 2 Islander
O 540 E4C5
Britten Norman
BN 2A & BN 2B Islander

Britten Norman
BN 2A Islander
IO 540 K1B5
Celair
Eagle
O 360 A1F6
Cessna
177 Cardinal
O 360 A1F6D
Cessna
177 Cardinal
O 540 J3C5D
Cessna
182 RG Skylane
IO 540 AB1A5
Cessna
182 S
O 360 F1A6
Cessna
C 172RG Cutlass RG

C 206 Stationair
IO 540 AC1A5
Cessna
R G Cardinal
IO 360 A1B6D
Cessna
R G Cardinal
TIO 540 AK1A
Cessna
T182T Skylane
O 540 L3C5D
Cessna
TR 182 Turbo Skylane
AEIO 540 D4A5
Christen Pitts
S 2S, S 2B
IO 540 T4B5D
Commander
114
IO 540 T4B5
Commander
114B

Commander
114TC
TIO 540 AG1A
Dornier
DO 28
IO 540 K1J5D
Embraer
EMB 201 IpanemaEMB 710 Corioca

EMB 720 Minuano
O 540 B4B5
Embraer
EMB 720 Minuano & EMB 721 Sertanejo EMB 721 Sertanejo

Extra-Flugzeugbau
Extra 300

F.F.A
FFA 2000 Eurotrainer
AEIO 540 L1B5
H.A.L
HPT 32
O 540 A1A5
Helio Military
H 250
AEIO 360 A1E6
Integrated Systems
Omega

King Engineering
Angel

Korean Air
Chang Gong 91
IO 540 M1C5
Lake
LA 4 200 Buccaneer

MT 7 260 & M 7 260
O 540 J3A5
Maule.
MX 7 235 Star Rocket

Maule
MX 7 235, MT 7 235 & M7 235
IO 540 W1A5
Mod Works
Trophy 212 Conversion
IO 360 A3B6
Mooney
201
M 201

IO 360 A1B6
Mooney
M 20 J
IO 360 A3B6D
Mooney
M20J 201

Mooney
M20M TLS Bravo

Z143L Zlin

Moravan
Z242L Zlin
TIO 540 AF1B
Partenavia
P 68 Series Observer
IO 540 K1J5
Piper
600 A Aerostar
IO 540 S1A5
Piper
601 A, 601B & 601P Aerostar
IO 540 AA1A5
Piper
602P Sequoia

PA 23 235 Aztec & PA 24 250 Comanche
O 540 A1B5
Piper
PA 23 250 Aztec
IO 540 J4A5
Piper
PA 23 250 Aztec
IO 540 C1B5
Piper
PA 23 250 Aztec & PA 24 250 Comanche

PA 23 250T Turbo Aztec
TIO 540 C1A
Piper
PA 24 150 Comanche
O 540 A1C5
Piper
PA 24 250 Comanche
O 540 A1D5
Piper
PA 24 250 Comanche

PA 24 260 Comanche
IO 540 D4A5
Piper
PA 24 260 Comanche
O 540 B2C5
Piper
PA 25 235 Pawnee

PA 28 235 Cherokee
O 540 B2B5
Piper
PA 28 235 Cherokee
IO 360 C1C6
Piper
PA 28R 201 Arrow
IO 540 M1A5
Piper
PA 31 300 Navajo PA 32 260 Cherokee 6
IO 540 K1G5
Piper
PA 32 300 & PA 32 301 Saratoga
IO 540 K1A5
Piper
PA 32 300 Cherokee 6
IO 540 K1A5D
Piper
PA 32 300 Cherokee 6

PA 32 300R Lance
IO 540 K1G5D
Piper
PA 32 301R Saratoga
IO 360 C1E6
Piper
PA 34 200 Seneca I
IO 540 K1G5
Piper
PA 36 300 Brave
O 360 A1H6
Piper
PA 44 180
LO 360 A1H6
Piper
PA 44 180 Seminole

Piper
T 35 Pillan
IO 540 K1K5
Robin.
R 3000/235

Robinson
R 44

Rockwell
114

Ruschmeyer
MF 85

Saab
MFI 15 Safari or MFI 17 Supporter

Scottish Avia
Bulldog

Siai Marchetti
S 205

Siai Marchetti
S 208 & SF 260

Siai Marchetti
SF 260

Siai Marchetti
SF 260

Slingsby
Firefly T3A
O 540 F1B5
Socata
R 235 Rallye Cuerrier Rallye 235CA

TB 20 Trinidad
IO 540 C4D5D
Socata
TB 200
TIO 540 AB1AD
Socata
TB 21 & TB 21 TC Trinidad TC
IO 540 AB1A5
Stoddard Hamilton
Glasair
IO 540 K1H5
Stoddard Hamilton
Glasair III

Swearingen Aircraft
SX 300
IO 540 L1C5
Transava
T 300 Skyfarmer

Valmet
L 70 Vinka

Wassmer
WA4 21
AEIO 360 A1B6
Yoeman
Aviation YA 1

Unsafe Condition

(d) This AD results from 12 crankshaft failures in Lycoming model 360 and 540 series engines rated at 300 HP or lower. We are issuing this AD to prevent failure of the crankshaft, which could result in total engine power loss, in-flight engine failure, and possible loss of the airplane.Compliance

(e) You are responsible for having the actions required by this AD performed within 50 hours time-in-service or 6 months after the effective date of this AD, whichever is earlier, unless the actions have already been done.

Engines Manufactured Before March 1, 1999

(f) If Lycoming Engines manufactured new, rebuilt, or overhauled your engine before March 1, 1999, and you haven't had the crankshaft replaced, no further action is required.

AEIO-540, IO-540, O-540, and TIO-540 Series Engines Manufactured New or Rebuilt, Overhauled, or That Had a Crankshaft Installed After March 1, 1999

(g) For AEIO-540, IO-540, O-540, and TIO-540 series engines manufactured new or rebuilt, overhauled, or that had a crankshaft installed after March 1, 1999, do the following:

(1) If Table 1 or Table 2 of Lycoming Mandatory Service Bulletin (MSB) No. 566, dated July 11, 2005, lists your engine serial number (SN), use Table 4 to verify the crankshaft SN.

(2) If Table 4 of Lycoming MSB No. 566, dated July 11, 2005, lists your crankshaft SN, replace the crankshaft with a crankshaft that is not listed in Table 4 of Lycoming MSB No. 566, dated July 11, 2005.

AEIO-360, IO-360, O-360, LIO-360, and LO-360 Series Engines Manufactured New or Rebuilt, Overhauled, or That Had a Crankshaft Installed After March 1, 1999

(h) For AEIO-360, IO-360, O-360, LIO-360, and LO-360 series engines manufactured new or rebuilt, overhauled, or that had a crankshaft installed after March 1, 1999, do the following:

(1) If Table 3 of Lycoming MSB No. 566, dated July 11, 2005, lists your engine SN, use Table 4 to verify the crankshaft SN.

(2) If Table 4 of Lycoming MSB No. 566, dated July 11, 2005, lists your crankshaft SN, replace the crankshaft with a crankshaft that is not listed in Table 4 of Lycoming MSB No. 566, dated July 11, 2005.

Prohibition Against Installing Certain Crankshafts

(i) After the effective date of this AD, do not install anycrankshaft that has a SN listed in Table 4 of Lycoming MSB No. 566, dated July 11, 2005, into any engine.

Alternative Methods of Compliance (AMOCs)

(j) The Manager, New York Aircraft Certification Office, has the authority to approve AMOCs for this AD if requested using the procedures found in 14 CFR 39.19.

Related Information

(k) None.

Material Incorporated by Reference

(l) You must use Lycoming Mandatory Service Bulletin No. 566, dated July 11, 2005, to perform the actions required by this AD. The Director of the Federal Register approved the incorporation by reference of this service bulletin in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Contact Lycoming, 652 Oliver Street, Williamsport, PA 17701; telephone (570) 323-6181; fax (570) 327- 7101, or on the Internet at http://www.Lycoming.Textron.com 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., Nassif Building, Room PL-401, Washington, DC 20590-0001, on the Internet at http://dms.dot.gov, or at the National Archives and Records Administration (NARA). For information on the availability of this material at NARA, call 202-741-6030, or go to: http://www.archives.gov/federal-register/cfr/ibr-locations.html .

The FAA proposed to amend 14 CFR part 39 with a proposed airworthiness directive (AD). The proposed AD applies to Lycoming Engines (formerly Textron Lycoming) AEIO-360, IO-360, O- 360, LIO-360, LO-360, AEIO-540, IO-540, O-540, and TIO-540 series reciprocating engines rated at 300 horsepower (HP) or lower. We published the proposed AD in the Federal Register on July 22, 2005 (70 FR 42282). That action proposed to require replacing certain crankshafts within 50 hours time-in-service or 6 months after the effective date of the proposed AD, whichever is earlier.

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 Offices 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.

Will Additional Engines and Crankshafts Be Affected in the Future

One commenter asks if additional serial numbered engines and crankshafts will be affected in the future.

At this time we do not anticipate that the affected population will increase, but Lycoming and the FAA are monitoring crankshaft performance.

Affected Engines and Crankshafts

The same commenter asks why these engines and crankshafts are the only ones affected by the SB and AD.

Both the previous AD (2002-19-03) and this AD advise that the affected population of engines and crankshafts were manufactured in a specific time period. We are addressing that time period.

Suspect Crankshafts Should Be Either Tested or Replaced

One commenter states that suspect crankshafts should be either tested or replaced before further flight, because the problem with these crankshafts is similar to the problem that caused the crankshaft failures on the 540 engines.

We disagree. The compliance interval in this AD is based on an assessment of operating stresses, service experience, and duty cycle of the affected engine population. The compliance interval differs from that imposed in AD 2002-19-03 due to differences in these parameters.

Request To Include Lycoming TIO-540-AE2A and Other Unspecified Engine Models

One commenter requests that we include the Lycoming TIO-540-AE2A and other unspecified engine models in this AD. The commenter states that many of the TIO-540-AE2A engines have never been recalled or replaced yet should be, because recent litigation has shown that Lycoming's crankshaft end core sample test is insufficient.

We disagree. We have seen no evidence that refutes the validity of the test. Further, AD 2002-19-03 (the previous AD) effective on September 20, 2002, described two groups of crankshafts. We required one crankshaft group to be removed before further flight, and we required the other crankshaft group to have a sample of the crankshaft material tested. The crankshafts in each group were selected based on our evaluation of the risk both groups presented. Crankshafts from either group may be installed in the TIO-540-AE2A engine model. No failures of crankshafts listed in either group have occurred since.

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

We estimate that this AD will affect 1,128 engines installed on aircraft of U.S. registry. We estimate that it will take the following work hours to perform the inspection:

Type of application
Work-hours per engine
Number of engines affected
Helicopter
12
200

Constant-Speed Propeller
3
557

Fixed-Pitch Propeller
1 .5
371

We also estimate that it will take about 33 work hours to replace the crankshaft. We estimate the average labor rate is $65 per work hour and that required parts for each engine will cost about $16,218. Based on these figures, we estimate the total cost of the AD to U.S. operators to be $18,594,724. Lycoming Engines informed us that they intend to supply the new parts at no charge, which may substantially reduce the estimated cost of this AD.

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, Incorporation by reference, 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: