AD 2005-24-05

[Federal Register Volume 70, Number 225 (Wednesday, November 23, 2005)]
[Rules and Regulations]
[Pages 70718-70720]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 05-23156]


-----------------------------------------------------------------------

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-23085; Directorate Identifier 2005-SW-25-AD; 
Amendment 39-14385; AD 2005-24-05]
RIN 2120-AA64


Airworthiness Directives; Boeing Vertol Model 107-II Helicopters

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

-----------------------------------------------------------------------

SUMMARY: This amendment adopts a new airworthiness directive (AD) for 
Boeing Vertol (Boeing) Model 107-II helicopters. This action requires a 
visual and magnetic particle inspection of the quill shaft. This 
amendment is prompted by the discovery of cracks in a quill shaft 
during a routine inspection. The actions specified in this AD are 
intended to detect a fatigue crack in a quill shaft and prevent 
separation of the quill shaft between the aft transmission and the mix 
box assembly, loss of rotor synchronization, and subsequent loss of 
control of the helicopter.

DATES: Effective December 8, 2005.
    Comments for inclusion in the Rules Docket must be received on or 
before January 23, 2006.

ADDRESSES: Use one of the following addresses to submit comments on 
this AD:
    <bullet> DOT Docket Web site: Go to <a href="http://dms.dot.gov">http://dms.dot.gov</a> and follow 
the instructions for sending your comments electronically;
    <bullet> Government-wide rulemaking Web site: Go to <a href="http://www.regulations.gov">http://www.regulations.gov</a> and follow the instructions for sending your 
comments electronically;
    <bullet> Mail: Docket Management Facility; U.S. Department of 
Transportation, 400 Seventh Street, SW., Nassif Building, Room PL-401, 
Washington, DC 20590;
    <bullet> Fax: (202) 493-2251; or
    <bullet> Hand Delivery: Room PL-401 on the plaza level of the 
Nassif Building, 400 Seventh Street, SW., Washington, DC, between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
    You may get the service information identified in this AD from The 
Boeing Company, c/o Service Engineering, MC P01-10, P.O. Box 16858, 
Philadelphia, PA 19142-3227.

Examining the Docket

    You may examine the docket that contains the AD, any comments, and 
other information on the Internet at <a href="http://dms.dot.gov">http://dms.dot.gov</a>, or in person 
at the Docket Management System (DMS) 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 the ADDRESSES section. Comments will be available in the AD 
docket shortly after the DMS receives them.

FOR FURTHER INFORMATION CONTACT: George Duckett, Aviation Safety 
Engineer, FAA, New York Aircraft

[[Page 70719]]

Certification Office, Airframe and Propulsion Branch, 1600 Stewart 
Ave., suite 410, Westbury, New York 11590, telephone (516) 228-7325, 
fax (516) 794-5531.

SUPPLEMENTARY INFORMATION: This amendment adopts a new AD for Boeing 
Model 107-II helicopters. This action requires a visual and magnetic 
particle inspection of the quill shaft. This amendment is prompted by 
the discovery of cracks in a quill shaft during a routine 700-hour TIS 
clutch replacement in which a magnetic particle inspection of the quill 
shaft was done. Investigation shows that cracking on the ends of the 
spline teeth of the quill shaft, around the pinhole, occurs due to a 
wear step in the mating pinion gear splines. These cracked spline teeth 
can provide stress concentrations that may lead to fatigue cracks. This 
condition, if not corrected, could result in separation of the quill 
shaft between the aft transmission and the mix box assembly, loss of 
rotor synchronization, and subsequent loss of control of the 
helicopter.
    We have reviewed Boeing Service Bulletin No. 107-63-1005, Revision 
1, dated April 27, 2005, which describes procedures for inspections of 
quill shafts, part number (P/N) 107D2067, all dash numbers. The service 
bulletin also specifies rejecting any quill shaft with chipped or 
cracked teeth or any quill shaft with a crack and, although not 
required by this AD, specifies measuring and recording wear in the 
spline of the mating pinion gear, P/N 107D2215. Also, Boeing recommends 
replacing unairworthy quill shafts with airworthy quill shafts, P/N 
107D2067-5. These part-numbered quill shafts have been improved with a 
shot-peen process. However, in this AD, we are only requiring that you 
replace any unairworthy quill shaft with an airworthy quill shaft with 
any approved P/N.
    This AD is an interim action which covers initial inspections of 
the quill shaft. We plan to follow this AD with a superseding Notice of 
Proposed Rulemaking (NPRM) containing longer term requirements. The 
NPRM will propose adding the pinion gear wear measurements specified in 
the service bulletin and will propose adding recurring inspections of 
the quill shaft. Also, because we still have not determined the cause 
of the wear steps in the mating pinion gear splines, we may consider 
further rulemaking when the cause is ultimately determined.
    This unsafe condition is likely to exist or develop on other 
helicopters of the same type design. Therefore, this AD is being issued 
to detect a fatigue crack in a quill shaft and prevent separation of 
the quill shaft between the aft transmission and the mix box assembly, 
loss of rotor synchronization, and subsequent loss of control of the 
helicopter. This AD requires the following for a helicopter with a 
quill shaft, P/N 107D2067, and a pinion gear, P/N 107D2215, installed:
    <bullet> Remove the aft transmission assembly, separate the mix box 
assembly from the aft transmission, and remove the quill shaft from the 
pinion gear assembly;
    <bullet> Visually inspect the external spline of the quill shaft 
for a chipped or cracked tooth around the pinhole; and
    <bullet> Magnetic particle inspect the quill shaft for a crack.
    <bullet> Replace any quill shaft that has a crack or a chipped or 
cracked tooth with an airworthy quill shaft before further flight.

If the pinion gear has 700 or more hours TIS, comply within 50 hours 
TIS, unless accomplished within the previous 350 hours TIS. If the 
pinion gear has less than 700 hours TIS, comply on or before reaching 
750 hours TIS.
    The short compliance time involved is required because these high-
usage helicopters can quickly develop pinion gear wear that could lead 
to cracks in the quill shaft and adversely affect the structural 
integrity and controllability of the helicopter. Therefore, the actions 
described previously are required within 50 hours TIS, a short time 
period of about 2 weeks based on the high usage rate of these model 
helicopters, and this AD must be issued immediately.
    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.
    We estimate that this AD will affect 7 helicopters. We estimate 
that each helicopter inspection will take about 17 work hours at an 
average labor rate of $65 per work hour. Required parts will cost 
$2,500 for each quill shaft. Based on these figures, we estimate the 
total cost impact of the AD on U.S. operators to be $10,235, assuming 
one quill shaft is replaced on the fleet.

Comments Invited

    This AD is a final rule that involves requirements that affect 
flight safety and was not preceded by notice and an opportunity for 
public comment; however, we invite you to submit any written data, 
views, or arguments regarding this AD. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2005-23085; 
Directorate Identifier 2005-SW-25-AD'' at the beginning of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of the AD. We will consider 
all comments received by the closing date and may amend the AD in light 
of those comments.
    We will post all comments we receive, without change, to <a href="http://dms.dot.gov">http://dms.dot.gov</a>, including any personal information you provide. We will 
also post a report summarizing each substantive verbal contact with FAA 
personnel concerning this AD. Using the search function of our docket 
web site, you can find and read the comments to any of our dockets, 
including the name of the individual who sent the comment. You may 
review the DOT's complete Privacy Act Statement in the Federal Register 
published on April 11, 2000 (65 FR 19477-78), or you may visit <a href="http://dms.dot.gov">http://dms.dot.gov</a>.

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 the regulation:
    1. Is not a ``significant regulatory action'' under Executive Order 
12866;
    2. Is not a ``significant rule'' under the 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 an economic evaluation of the estimated costs to comply 
with this AD. See the DMS to examine the economic evaluation.

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

[[Page 70720]]

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.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Safety.

Adoption of the Amendment

0
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:

PART 39--AIRWORTHINESS DIRECTIVES

0
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]

0
2. Section 39.13 is amended by adding a new airworthiness directive to 
read as follows:

2005-24-05 Boeing Vertol (Boeing): Amendment 39-14385. Docket No. 
FAA-2005-23085; Directorate Identifier 2005-SW-25-AD.

    Applicability: Model 107-II helicopters, all serial numbers, 
with a quill shaft, part number (P/N) 107D2067, all dash numbers, 
and a spiral bevel pinion gear (pinion gear), P/N 107D2215, 
installed, certificated in any category.
    Compliance: Required as indicated.
    To detect a fatigue crack in a quill shaft to prevent separation 
of the quill shaft between the aft transmission and the mix box 
assembly, loss of rotor synchronization, and subsequent loss of 
control of the helicopter, accomplish the following:
    (a) For a helicopter with a pinion gear installed with the 
following hours time-in-service (TIS):

------------------------------------------------------------------------
         Pinion gear hours TIS                   Compliance time
------------------------------------------------------------------------
700 or more hours TIS..................  Within 50 hours TIS, unless
                                          accomplished within the
                                          previous 350 hours TIS.
Less than 700 hours TIS................  On or before reaching 750 hours
                                          TIS.
------------------------------------------------------------------------

    (1) Remove the aft transmission assembly, separate the mix box 
assembly from the aft transmission, and remove the quill shaft from 
the pinion gear assembly;
    (2) Visually inspect the external spline of the quill shaft for 
a chipped or cracked tooth around the pinhole; and
    (3) Magnetic particle inspect the quill shaft for a crack.
    (b) Before further flight, replace any quill shaft that has a 
crack or a chipped or cracked tooth with an airworthy quill shaft.

    Note 1: Boeing Service Bulletin No. 107-63-1005, Revision 1, 
dated April 27, 2005, pertains to the subject of this AD.


    Note 2: Replacement quill shafts manufactured by Kawasaki Heavy 
Industries (KHI) for use on their Model KV107-II helicopters must be 
approved by the geographic Aircraft Certification Office (ACO) on a 
case-by-case basis for installation on a Boeing Model 107-II 
helicopter.

    (c) To request a different method of compliance or a different 
compliance time for this AD, follow the procedures in 14 CFR 39.19. 
Contact the Manager, New York ACO, Engine and Propeller Directorate, 
FAA, for information about previously approved alternative methods 
of compliance.
    (d) Special flight permits will not be issued.
    (e) This amendment becomes effective on December 8, 2005.

    Issued in Fort Worth, Texas, on November 16, 2005.
Scott A. Horn,
Acting Manager, Rotorcraft Directorate, Aircraft Certification Service.
[FR Doc. 05-23156 Filed 11-22-05; 8:45 am]
BILLING CODE 4910-13-P