AD 2000-05-09

[Federal Register Volume 65, Number 45 (Tuesday, March 7, 2000)]
[Rules and Regulations]
[Pages 11861-11866]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 00-5459]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2000-NM-67-AD; Amendment 39-11618; AD 2000-05-09]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 757-200, -200PF, and -
200CB Series Airplanes Powered by Rolls-Royce RB211-535C/E4/E4B 
Turbofan Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

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SUMMARY: This amendment supersedes an existing airworthiness directive 
(AD), applicable to certain Boeing Model 757-200, -200PF, and -200CB 
series airplanes, that currently requires repetitive inspections of the 
engine thrust control cable system to detect discrepancies of the wire 
rope, fittings, and pulleys; and replacement, if necessary. That AD 
also requires a one-time inspection to determine the part number of 
certain pulleys, and replacement of existing pulleys with new pulleys, 
if necessary; and modification of the engine thrust control

[[Page 11862]]

cable installation. This new action corrects a certain part number. 
This AD is prompted by reports of failure of certain engine thrust 
control cables. The actions specified by this AD are intended to 
prevent failure of certain engine thrust control cables, which could 
result in a severe asymmetric thrust condition during landing, and 
consequent reduced controllability of the airplane.

DATES: Effective March 22, 2000.
    The incorporation by reference of certain publications, as listed 
in the regulations, was approved previously by the Director of the 
Federal Register as of February 7, 2000 (65 FR 1, January 3, 2000).
    Comments for inclusion in the Rules Docket must be received on or 
before May 8, 2000.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), Transport Airplane Directorate, ANM-114, 
Attention: Rules Docket No. 2000-NM-67-AD, 1601 Lind Avenue, SW., 
Renton, Washington 98055-4056.
    The service information referenced in this AD may be obtained from 
Boeing Commercial Airplane Group, P.O. Box 3707, Seattle, Washington 
98124-2207. This information may be examined at the FAA, Transport 
Airplane Directorate, 1601 Lind Avenue, SW., Renton, Washington; or at 
the Office of the Federal Register, 800 North Capitol Street, NW., 
suite 700, Washington, DC.

FOR FURTHER INFORMATION CONTACT: Kathrine Rask, Aerospace Engineer, 
Propulsion Branch, ANM-140S, FAA, Transport Airplane Directorate, 
Seattle Aircraft Certification Office, 1601 Lind Avenue, SW., Renton, 
Washington 98055-4056; telephone (425) 227-1547; fax (425) 227-1181.

SUPPLEMENTARY INFORMATION: On December 22, 1999, the FAA issued AD 99-
27-06, amendment 39-11487 (65 FR 1, January 3, 2000), applicable to 
certain Boeing Model 757-200, -200PF, and -200CB series airplanes, to 
require repetitive inspections of the engine thrust control cable 
system to detect discrepancies of the wire rope, fittings, and pulleys; 
and replacement, if necessary. That AD also requires a one-time 
inspection to determine the part number of certain pulleys and 
replacement of existing pulleys with new pulleys, if necessary; and 
modification of the engine thrust control cable installation. That 
action was prompted by reports of failure of certain engine thrust 
control cables. The actions required by that AD are intended to prevent 
failure of certain engine thrust control cables, which could result in 
a severe asymmetric thrust condition during landing, and consequent 
reduced controllability of the airplane.

Actions Since Issuance of Previous Rule

    Since the issuance of that AD, the FAA has determined that a 
typographical error in paragraph (b) of AD 99-27-06 identified part 
number (P/N) BAC30M4 as a part number for the thrust control cable 
pulleys. However, as referenced in the preamble of the final rule, 
BACP30M4 is the correct P/N for the pulleys, as P/N BAC30M4 does not 
exist. In all other respects, the original document is correct.

Explanation of Requirements of Rule

    Since an unsafe condition has been identified that is likely to 
exist or develop on other airplanes of this same type design, this AD 
supersedes AD 99-27-06 to continue to require repetitive inspections of 
the engine thrust control cable system to detect discrepancies of the 
wire rope, fittings, and pulleys; and replacement, if necessary. This 
AD also continues to require a one-time inspection to determine the 
part number of certain pulleys, and replacement of existing pulleys 
with new pulleys, if necessary; and modification of the engine thrust 
control cable installation.

Determination of Rule's Effective Date

    Since a situation exists that requires the immediate adoption of 
this regulation, it is found that notice and opportunity for prior 
public comment hereon are impracticable, and that good cause exists for 
making this amendment effective in less than 30 days.

Comments Invited

    Although this action is in the form of a final rule that involves 
requirements affecting flight safety and, thus, was not preceded by 
notice and an opportunity for public comment, comments are invited on 
this rule. Interested persons are invited to comment on this rule by 
submitting such written data, views, or arguments as they may desire. 
Communications shall identify the Rules Docket number and be submitted 
in triplicate to the address specified under the caption ADDRESSES. All 
communications received on or before the closing date for comments will 
be considered, and this rule may be amended in light of the comments 
received. Factual information that supports the commenter's ideas and 
suggestions is extremely helpful in evaluating the effectiveness of the 
AD action and determining whether additional rulemaking action would be 
needed.
    Comments are specifically invited on the overall regulatory, 
economic, environmental, and energy aspects of the rule that might 
suggest a need to modify the rule. All comments submitted will be 
available, both before and after the closing date for comments, in the 
Rules Docket for examination by interested persons. A report that 
summarizes each FAA-public contact concerned with the substance of this 
AD will be filed in the Rules Docket.
    Commenters wishing the FAA to acknowledge receipt of their comments 
submitted in response to this rule must submit a self-addressed, 
stamped postcard on which the following statement is made: ``Comments 
to Docket Number 2000-NM-67-AD.'' The postcard will be date stamped and 
returned to the commenter.

Regulatory Impact

    The regulations adopted herein 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. Therefore, it 
is determined that this final rule does not have federalism 
implications under Executive Order 13132.
    The FAA has determined that this regulation is an emergency 
regulation that must be issued immediately to correct an unsafe 
condition in aircraft, and that it is not a ``significant regulatory 
action'' under Executive Order 12866. It has been determined further 
that this action involves an emergency regulation under DOT Regulatory 
Policies and Procedures (44 FR 11034, February 26, 1979). If it is 
determined that this emergency regulation otherwise would be 
significant under DOT Regulatory Policies and Procedures, a final 
regulatory evaluation will be prepared and placed in the Rules Docket. 
A copy of it, if filed, may be obtained from the Rules Docket at the 
location provided under the caption ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration amends part 39 of 
the Federal Aviation Regulations (14 CFR part 39) as follows:

[[Page 11863]]

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. Section 39.13 is amended by removing amendment 39-11487 (65 FR 
1, January 3, 2000) and by adding a new airworthiness directive (AD), 
amendment 39-11618, to read as follows:

2000-05-09  Boeing: Amendment 39-11618. Docket 2000-NM-67-AD. 
Supersedes AD 99-27-06, Amendment 39-11487.

    Applicability: Model 757-200, -200PF, and -200CB series 
airplanes powered by Rolls-Royce RB211-535C/E4/E4B turbofan engines, 
certificated in any category.

    Note 1: This AD applies to each airplane identified in the 
preceding applicability provision, regardless of whether it has been 
modified, altered, or repaired in the area subject to the 
requirements of this AD. For airplanes that have been modified, 
altered, or repaired so that the performance of the requirements of 
this AD is affected, the owner/operator must request approval for an 
alternative method of compliance in accordance with paragraph (f) of 
this AD. The request should include an assessment of the effect of 
the modification, alteration, or repair on the unsafe condition 
addressed by this AD; and, if the unsafe condition has not been 
eliminated, the request should include specific proposed actions to 
address it.

    Compliance: Required as indicated, unless accomplished 
previously.
    To prevent engine thrust control cable failure, which could 
result in a severe asymmetric thrust condition during landing, and 
consequent reduced controllability of the airplane, accomplish the 
following:

Inspections and Corrective Actions

    (a) Within 24 months or 6,000 flight hours after February 7, 
2000 (the effective date of AD 99-27-06, amendment 39-11487), 
whichever occurs first: Accomplish the ``Thrust Control Cable 
Inspection Procedure'' specified in Appendix 1. (including Figure 1) 
of this AD to verify the integrity of the thrust control cables. 
Prior to further flight, repair any discrepancy found in accordance 
with the procedures described in the Boeing 757 Maintenance Manual. 
Repeat the inspection thereafter at intervals not to exceed 24 
months or 6,000 flight hours, whichever occurs first.
    (b) For airplanes having line numbers 1 through 636 inclusive: 
Within 24 months or 6,000 flight hours after February 7, 2000, 
whichever occurs first, perform a one-time inspection of the 8 
engine thrust control cable pulleys in the struts (4 in each strut) 
to determine the part number (P/N) of each pulley. If any pulley 
having P/N 65B80977-1 or BACP30M4 is installed, prior to further 
flight, replace it with a pulley having P/N 255T1232-7, in 
accordance with the procedures described in the Boeing 757 Airplane 
Maintenance Manual.

    Note 2: The location of the pulleys to be inspected in 
accordance with paragraph (b) of this AD is specified in Chapters 
53-11-53-04, 76-11-52-01, and 76-11-52-02 of the Boeing 757 
Illustrated Parts Catalog.

Modifications

    (c) For airplanes identified in Boeing Service Bulletin 757-76-
1, dated May 18, 1984: Within 24 months or 6,000 flight hours after 
February 7, 2000, whichever occurs first, remove the guide bracket 
of the engine thrust control cable located on the front spar of the 
right wing, in accordance with the service bulletin.
    (d) For airplanes identified in Boeing Service Bulletin 757-76-
0005, dated May 5, 1988: Within 24 months or 6,000 flight hours 
after February 7, 2000, whichever occurs first, remove the engine 
thrust control cable breakaway stop assemblies, and replace sections 
of the engine thrust control cables with smaller diameter cables in 
accordance with the service bulletin.
    (e) For airplanes identified in Boeing Service Bulletin 757-
30A0018, Revision 2, dated September 9, 1999: Within 60 days after 
February 7, 2000, install a support bracket assembly between the 
window heat wire bundle and the engine thrust control cable; and 
adjust the wire bundle clearance, as necessary, to parallel the 
minimum clearance specified in Boeing Alert Service Bulletin 757-
30A0018, Revision 1, dated September 17, 1998; or Boeing Service 
Bulletin 757-30A0018, Revision 2, dated September 9, 1999.

Alternative Method of Compliance

    (f) An alternative method of compliance or adjustment of the 
compliance time that provides an acceptable level of safety may be 
used if approved by the Manager, Seattle Aircraft Certification 
Office (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, Seattle ACO.

    Note 3: Information concerning the existence of approved 
alternative methods of compliance with this AD, if any, may be 
obtained from the Seattle ACO.

Special Flight Permits

    (g) Special flight permits may be issued in accordance with 
sections 21.197 and 21.199 of the Federal Aviation Regulations (14 
CFR 21.197 and 21.199) to operate the airplane to a location where 
the requirements of this AD can be accomplished.

Incorporation by Reference

    (h) Except as provided by paragraphs (a) and (b) of this AD, the 
modifications shall be done in accordance with Boeing Service 
Bulletin 757-76-1, dated May 18, 1984; Boeing Service Bulletin 757-
76-0005, dated May 5, 1988; Boeing Alert Service Bulletin 757-
30A0018, Revision 1, dated September 17, 1998; and Boeing Service 
Bulletin 757-30A0018, Revision 2, dated September 9, 1999. This 
incorporation by reference was approved previously by the Director 
of the Federal Register as of February 7, 2000 (65 FR 1, January 3, 
2000). Copies may be obtained from Boeing Commercial Airplane Group, 
P.O. Box 3707, Seattle, Washington 98124-2207. Copies may be 
inspected at the FAA, Transport Airplane Directorate, 1601 Lind 
Avenue, SW., Renton, Washington; or at the Office of the Federal 
Register, 800 North Capitol Street, NW., suite 700, Washington, DC.
    (i) This amendment becomes effective on March 22, 2000.

Appendix 1.

Thrust Control Cable Inspection Procedure

1. General

    A. Clean the cables, if necessary, for the inspection, in 
accordance with Boeing 757 Maintenance Manual 12-21-31.
    B. Use these procedures to verify the integrity of the thrust 
control cable system. The procedures must be performed along the 
entire cable run for each engine. To ensure verification of the 
portions of the cables which are in contact with pulleys and 
quadrants, the thrust control must be moved by operation of the 
thrust and/or the reverse thrust levers to expose those portions of 
the cables.
    C. The first task is an inspection of the control cable wire 
rope. The second task is an inspection of the control cable 
fittings. The third task is an inspection of the pulleys.

    Note: These three tasks may be performed concurrently at one 
location of the cable system on the airplane, if desired, for 
convenience.

2. Inspection of the Control Cable Wire Rope

    A. Perform a detailed visual inspection to ensure that the cable 
does not contact parts other than pulleys, quadrants, cable seals, 
or grommets installed to control the cable routing. Look for 
evidence of contact with other parts. Correct the condition if 
evidence of contact is found.

    Note: For the purposes of this procedure, a detailed visual 
inspection is defined as: ``An intensive visual examination of a 
specific structural area, system, installation, or assembly to 
detect damage, failure, or irregularity. Available lighting is 
normally supplemented with a direct source of good lighting at 
intensity deemed appropriate by the inspector. Inspection aids such 
as mirror, magnifying lenses, etc., may be used. Surface cleaning 
and elaborate access procedures may be required.''

    B. Perform a detailed visual inspection of the cable runs to 
detect incorrect routing, kinks in the wire rope, or other damage. 
Replace the cable assembly if:
    (1) One cable strand had worn wires where one wire cross section 
is decreased by more than 40 percent (see Figure 1),
    (2) A kink is found, or
    (3) Corrosion is found.
    C. Perform a detailed visual inspection of the cable: To check 
for broken wires, rub a cloth along the length of the cable. The 
cloth catches on broken wires.
    (1) Replace the 7x7 cable assembly if there are two or more 
broken wires in 12 continuous inches of cable or there are three or 
more broken wires anywhere in the total cable assembly.

[[Page 11864]]

    (2) Replace the 7x19 cable assembly if there are four or more 
broken wires in 12 continuous inches of cable or there are six or 
more broken wires anywhere in the total cable assembly.

3. Inspection of the Control Cable Fittings

    A. Perform a detailed visual inspection to ensure that the means 
of locking the joints are intact (wire locking, cotter pins, 
turnbuckle clips, etc.). Install any missing parts.
    B. Perform a detailed visual inspection of the swaged portions 
of swaged end fittings to detect surface cracks or corrosion. 
Replace the cable assembly if cracks or corrosion are found.
    C. Perform a detailed visual inspection of the unswaged portion 
of the end fitting. Replace the cable assembly if a crack is 
visible, if corrosion is present, or if the end fitting is bent more 
than 2 degrees.
    D. Perform a detailed visual inspection of the turnbuckle. 
Replace the turnbuckle if a crack is visible or if corrosion is 
present.

4. Inspection of Pulleys

    A. Perform a detailed visual inspection to ensure that pulleys 
are free to rotate. Replace pulleys which are not free to rotate.
BILLING CODE 4910-13-U

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[GRAPHIC] [TIFF OMITTED] TR07MR00.001



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    Issued in Renton, Washington, on March 1, 2000.
Donald L. Riggin,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 00-5459 Filed 3-6-00; 8:45 am]
BILLING CODE 4910-13-C