2004-17-01 Cessna Aircraft Company: Amendment 39-13772; Docket No. 2002-CE-23-AD; Supersedes AD 2002-22-17, amendment 39-12944; and AD 2003-21-04, amendment 39-13339.
When Does This AD Become Effective?
(a) This AD becomes effective on September 26, 2004.
What Other ADs Are Affected by This Action?
(b) This AD supersedes AD 2002-22-17, amendment 39-12944; and AD 2003-21-04, amendment 39-13339.
What Airplanes Are Affected by This AD?
(c) This AD affects the following airplane models and serial numbers that are certificated in any category:
(1) Group 1 (retains the actions from AD 2003-21-04, and adds all flap bellcranks to the applicability):
Model
Serial Nos.
208
208B
20800001 through 20800369
208B0001 through 208B1014, 208B1017, 208B1018, 208B1020 through 208B1024, 208B1026, and 208B1029 through 208B1033.
(2) Group 2 (retains the requirement of AD 2002-22-17 that you repetitively inspect the inboard forward flap bellcranks for cracks, eventually replace these bellcranks, and provides the option of installing the new design flap bellcrank to increase the life limits and terminate the repetitive inspections): Models 208 and 208B airplanes, all serial numbers.
What Is the Unsafe Condition Presented in This AD?
(d) This AD is the result of (since FAA issued AD 2002-22-17) Cessna's design of a new flap bell crank with a life limit of 40,000 landings (instead of 7,000 landings), and (since FAA issued AD 2003- 21-04) further analysis and examination of cracks and missing/ incomplete welds in all of the bell cranks. The actions specified in this AD are intended to prevent failure of any bellcrank due to cracks, deformation, or missing/incomplete welds. This failure could lead to damage to the flap system and surrounding structure and result in reduced or loss of control of the airplane.
What Must I Do To Address This Problem for Group 1 Airplanes?
(e) To address this problem for Group 1 airplanes, youmust do the following:
Actions
Compliance
Procedures
(1) Inspect the right inboard forward flap bellcrank assembly for cracks, deformation, and missing/incomplete welds. The affected flap bellcrank incorporates one of the following part numbers (P/N):
(i) P/N 2622083-18;
(ii) P/N 2622281-2;
(iii) P/N 2692001-2; or
(iv) P/N 2622281-12.
Within the next 25 landings after October 21, 2003 (the effective date of AD 2003-21-04). If landings are unknown, then you may multiply hours time-in-service (TIS) by 1.25. For the purposes of this AD, you may substitute 20 hours TIS for 25 landings.
Use a flashlight and a mirror as necessary to see if welds (1), (4), (5), and (6) exist and are at least 0.06-inch thick around the full circumference of the shaft. These welds and the inspection procedures are referenced in Figure 1, details A, B, and C; and Views A-A and B-B of Cessna Caravan Service Bulletin No.: CAB03-11, Revision 1, dated September 24, 2003.
(2) Inspect the left inboard forward bellcrank for
cracks, deformation, and missing/incomplete welds. The affected flap bellcrank incorporates one of the following part P/Ns:
(i) P/N 262283-15; or
(ii) P/N 2622281-1.
Within the next 25 landings after September 26, 2004, the effective date of this AD. If landings are unknown, then you may multiply hours TIS by 1.25. For the purposes of this AD, you may substitute 20 hours TIS for 25 landings.
Use a flashlight and a mirror as necessary to see if welds (1) through (4) exist and are at least 0.06-inch thick around the full circumference of the shaft. These welds and the inspection procedures are referenced in Figure 2, details A, B, and C; and Views A-A and B-B of Cessna Caravan Service Bulletin No.: CAB03-11, Revision 1, dated
September 24, 2003.
(3) Inspect the inboard aft bellcrank for cracks, deformation, and missing/incomplete welds.
The affected flap bellcrank incorporates one
of the following P/Ns:
(i) P/N 2622267-1; or
(ii) P/N2622267-2;
(iii) P/N 2622267-7;
(iv) P/N 2622267-8;
(v) P/N 2622083-1; or
(vi) P/N 2622083-2.
Within the next 25 landings after September 26, 2004, the effective date of this AD. If landings are unknown, then you may multiply hours TIS by 1.25. For the purposes of this AD, you may substitute 20 hours TIS for 25 landings.
Use a flashlight and a mirror as necessary to see if welds (1), (2), (4), and (5) exist and are at least 0.05-inch thick around the full circumference of the shaft. These welds and the inspection procedures are referenced in Figure 3, details A, B, and C; and Views A-A and B-B of Cessna Caravan Service Bulletin No.: CAB03-11, Revision 1, dated September 24, 2003.
(4) Inspect the outboard bellcrank for cracks, deformation, and missing/incomplete welds.
The affected flap bellcrank incorporates one of the following P/Ns:
(i) P/N 2622091-1; or
(ii) P/N 2622091-2;
(iii) P/N 2622091-9;
(iv) P/N 2622091-10;
(v) P/N 2622091-17; or
(vi) P/N 2622091-18.
Within the next 25 landings after September 26, 2004, the effective date of this AD. If lands are unknown, then you may multiply hours TIS by 1.25. For the purposes of this AD, you may substitute 20 hours TIS for 25 landings.
Use a flashlight and a mirror as necessary to see if welds (1) through (4) exist and are at least 0.05-inch thick around the full circumference of the shaft. These welds and the inspection procedures are referenced in Figure 4, details A, B, and C; and Views A-A and B-B of Cessna Caravan Service Bulletin No.: CAB03-11, Revision 1, dated September 24, 2003.
(5) If you find cracks, deformation, or missing/incomplete welds during the inspection required by paragraphs (e)(1) through (e)(4) of this AD, then do one of the following:
(i) Replace the bellcrank with a new bellcrank; or
(ii) Prohibit the use of flaps through the actions of paragraph (g) of this AD.
Replace or do the flap prohibition actions before further flight after the inspection requiredin paragraphs (e)(1) through (e)(4) of this AD. If you choose the flap prohibition, you must have the replacement done within 200 hours TIS after the inspection required by paragraphs (e)(1) through (e)(4) of this AD. After the new flap bellcrank is installed, the Temporary Revision 208PHTR02, dated September 23, 2003, should be removed.
Replacement: Use the Accomplishment Instructions of Cessna Caravan Service bulletin No.: CAB02-12, Revision 1, dated January 27, 2003, and the Accomplishment Instructions of Cessna Caravan Service Kit No.: SK208-148A, dated January 27, 2003, or refer to the Maintenance Manual, Chapter 27, Flap System-Maintenance Practices, for bellcrank removal and installation
procedures.
Flap Prohibition: Use the information in the Temporary Revision 208PHTR02, dated September 23, 2003. The action is referenced in Cessna Caravan Service Bulletin No.: CAB03-11, Revision 1, dated September 24, 2003.
What Must I Do To Address This Problem for Group 2 Airplanes?
(f) To address this problem for Group 2 airplanes, you must do the following:
Actions
Compliance
Procedures
(1) Repetitive Inspections: Inspect, using eddy current method, any inboard forward flap bellcrank (P/N 2622281-2, 2622281-12, 2692001-2, or FAA-approved equivalent P/N) for cracks.
Initially inspect upon the accumulation of 4,000 landings on the bellcrank or within the next 250 landings after December 31, 2002 (the effective date of AD 2002-22- 17), whichever occurs later.
Repetitively inspect thereafter at every 500 landings until 7,000 landings are accumulated at which time you must replace as required in paragraphs (f)(2) and (f)(3) of this AD. No repetitive inspections are required when a P/N 2622311-7 (or FAA-approved equivalent P/N) inboard forward flap
bellcrank is installed.
Follow the Inspection Instructions of Cessna Caravan Service Bulletin No.: CAB02-1, dated February 11, 2002, and the applicable maintenance manual.
(2) Initial Replacement: Replace any inboard
forward flap bellcrank (P/N 2622281-2,
2622281-12, 2692001-2, or FAA-approved
equivalent P/N) with either:
(i) a new flap bellcrank with the same P/N
2622281-2, 262228-12, 269001-2, or FAA-approved or equivalent P/N; or
(ii) a new flap bellcrank (P/N 2622311-7 or FAA-approved equivalent P/N).
If cracks are found, replace or do the flap prohibition actions before further flight after the inspection required in paragraphs (f)(1) of this AD. If you choose the flap prohibition, you must have the replacement done within 200 hours TIS after the inspection required by paragraphs (f)(1) of this AD. After the
new flap bellcrank is installed, the
Temporary Revision 208PHTR02, dated September 23, 2003, should be removed. If cracks are not found, initially replace at whichever occurs later: upon the accumulation of 7,000 landings on the bellcrank or within the next 75 landings after December 31, 2002 (the effective date of AD 2002-22--17).
Replacement:For flap bellcrank (P/N 2622281-2, 2622281-12, 2692001-2, or FAA-approved equivalent P/N): Follow the Instructions of Cessna Caravan Service Bulletin No.: CAB02-1, dated February 11, 2002, and the applicable maintenance manual. For new flap bellcrank (P/N 2622311-7 or FAA-approved equivalent P/N): Follow the Accomplishment Instructions of Cessna Caravan Service Bulletin No.: CAB02-12, Revision 1, dated January 27, 2003, and the Accomplishment Instructions of Cessna Caravan Service Kit No.: SK208-148A, dated January 27, 2003. Flap Prohibitions: Use the information in the Temporary Revision 208PHTR02, dated September 23,
2003.
(3) Life Limits (Repetitive Replacements):
(i) The life limit for the inboard forward flap bellcranks (P/N 2622281-2, 2622281-12, 2692001-2, or FAA-approved equivalent P/
N) is 7,000 landings. Repetitive inspections every 500 landings begin at 4,000 landings (see paragraph (f)(1) of this AD.)
(ii) The life limit for the inboard forward flap bellcranks (P/N2622311-7 or FAA-approved equivalent P/N) is 40,000 landings. No repetitive inspections are required on these
bellcranks.
Replace at the applicable referenced life limits
Use the service information referenced in paragraph (f)(2) of this AD.
Note 1: Inboard forward flap bellcranks (P/N 2622281-2, 2622281- 12, or 2692001-2) with 7,000 landings or more do not have to be replaced until 75 landings after December 31, 2002 (the effective date of AD 2002-22-17), unless found cracked.
Note 2: The compliance times of this AD are presented in landings instead of hours TIS. If the number of landings is unknown, hours TIS may be used by multiplying the number of hours TIS by 1.25.
What Are the Actions I Must Do if I Choose the Flap Prohibition Option?
(g) Insert Temporary Revision, 208PHTR02, dated September 23, 2003, into the applicable pilot's operating handbook and FAA- approved airplane flight manual. The owner/operator holding at least a private pilot certificateas authorized by section 43.7 of the Federal Aviation Regulations (14 CFR 43.7) may incorporate this information into the AFM. Make an entry into the aircraft records showing compliance with this portion of the AD in accordance with section 43.9 of the Federal Aviation Regulations (14 CFR 43.9).
(1) This procedure applies to Cessna Models 208 and 208B landplanes. For other FAA-approved aircraft configurations (for example, amphibian, floatplanes, and so forth), you must operate with flaps up per the appropriate airplane flight manual supplement.
(2) This procedure allows for applicable deviation from the Master Minimum Equipment List (MMEL) for these airplanes until the flap bell crank is replaced. The applicable MMEL requirements go back into effect at the time of flap bell crank replacement.
May I Request an Alternative Method of Compliance?
(h) You may request a different method of compliance or a different compliance time for this AD by following the procedures in 14 CFR 39.19. Unless FAA authorizes otherwise, send your request to your principal inspector. The principal inspector may add comments and will send your request to the Manager, Wichita Aircraft Certification Office (ACO), FAA.
(1) For information on any already approved alternative methods of compliance, contact Paul Nguyen, Aerospace Engineer, FAA, Wichita ACO, 1801 Airport Road, Room 100, Wichita, Kansas 67209; telephone: 316-946-4125; facsimile: 816-946-4107.
(2) Alternative methods of compliance approved under AD 2002-22- 17 and AD 2003-21-04 are not approved for this AD.
Does This AD Incorporate Any Material by Reference?
(i) You must do the actions required by this AD following the instructions in the service information presented in paragraphs (i)(1) and (i)(2) of this AD.
(1) On December 31, 2002 (67 FR 68508, November 12, 2002) and in accordance with 5 U.S.C. 552(a) and 1 CFR part 51, the Director of the Federal Register approved the incorporation ofCessna Service Bulletin No.: CAB02-1, dated February 11, 2002.
(2) On October 21, 2003 (68 FR 59707, October 17, 2003), and in accordance with 5 U.S.C. 552(a) and 1 CFR part 51, the Director of the Federal Register approved the incorporation of Cessna Caravan Service Bulletin No.: CAB03-11, Revision 1, dated September 24, 2003; Cessna Caravan Service Bulletin No. CAB02-12, revision 1, dated January 27, 2003; and Cessna Caravan Service Kit No.: SK208- 148A, dated January 27, 2003 (original issue: October 21, 2002).
(3) You may get a copy from Cessna Aircraft Company, Product Support, P.O. Box 7706, Wichita, Kansas 67277; telephone: (316) 517- 5800; facsimile: (316) 942-9006. You may review copies at FAA, Central Region, Office of the Regional Counsel, 901 Locust, Room 506, Kansas City, Missouri 64106; 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/code_of_federal_regulations/ibr_locations.html.