AD 2024-21-02

[Federal Register Volume 89, Number 211 (Thursday, October 31, 2024)]
[Rules and Regulations]
[Pages 86721-86723]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 2024-25365]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2024-1695; Project Identifier AD-2023-00783-E; 
Amendment 39-22869; AD 2024-21-02]
RIN 2120-AA64


Airworthiness Directives; Lycoming Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
Lycoming Engines (Lycoming) model engines that have a certain 
connecting rod assemblies installed. This AD was prompted by several 
reports of connecting rod failures, which resulted in uncontained 
engine failure and in-flight shutdowns (IFSDs). This AD requires 
repetitive oil inspections for bronze metal particulates and, if found, 
additional inspections of the connecting rod bushings for damage, 
proper fit, movement, and wear, and replacement if necessary. As 
terminating action to the connecting rod bushing inspections, this AD 
requires replacement of the connecting rod bushings with parts eligible 
for installation. The FAA is issuing this AD to address the unsafe 
condition on these products.

DATES: This AD is effective December 5, 2024.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of December 5, 
2024.

ADDRESSES: 
    AD Docket: You may examine the AD docket at <a href="http://regulations.gov">regulations.gov</a> under 
Docket No. FAA-2024-1695; or in person at Docket Operations between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays. The AD 
docket contains this final rule, any comments received, and other 
information. The address for Docket Operations is U.S. Department of 
Transportation, Docket Operations, M-30, West Building Ground Floor, 
Room W12-140, 1200 New Jersey Avenue SE, Washington, DC 20590.
    Material Incorporated by Reference:
    <bullet> For Lycoming material identified in this AD, contact 
Lycoming Engines, 652 Oliver Street, Williamsport, PA 17701; phone: 
(800) 258-3279; website: <a href="http://lycoming.com/contact/knowledge-base/publications">lycoming.com/contact/knowledge-base/publications</a>.
    <bullet> You may view this material at the FAA, Airworthiness 
Products Section, Operational Safety Branch, 1200 District Avenue, 
Burlington, MA 01803. For information on the availability of this 
material at the FAA, call (817) 222-5110. It is also available at 
<a href="http://regulations.gov">regulations.gov</a> under Docket No. FAA-2024-1695.

FOR FURTHER INFORMATION CONTACT: James Delisio, Aviation Safety 
Engineer, FAA, 1701 Columbia Avenue, College Park, GA 30337; phone: 
(516) 228-7321; email: <a href="/cdn-cgi/l/email-protection#aec4cfc3cbdd80cacbc2c7ddc7c1eec8cfcf80c9c1d8"><span class="__cf_email__" data-cfemail="b8d2d9d5ddcb96dcddd4d1cbd1d7f8ded9d996dfd7ce">[email&#160;protected]</span></a>.

SUPPLEMENTARY INFORMATION:

Background

    The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 
CFR part 39 by adding an AD that would apply to Lycoming model engines 
that have certain connecting rod assemblies installed. The NPRM 
published in the Federal Register on June 28, 2024 (89 FR 53911). The 
NPRM was prompted by several reports of connecting rod failures, which 
resulted in uncontained engine failure and IFSDs, and a manufacturer 
investigation where it was determined that affected connecting rod 
small end bushings may be installed on additional populations of 
Lycoming engines. The manufacturer also determined that degradation of 
the connecting rod small end bushings is detectable during oil change 
inspections. In the NPRM, the FAA proposed to require repetitive oil 
inspections for bronze metal particulates and, if found, additional 
inspections of the connecting rod bushings for damage (e.g. 
deterioration, missing metal), proper fit, movement, and wear, and 
replacement if necessary. As terminating action to the connecting rod 
bushing inspections, the NPRM also proposed to require replacement of 
the connecting rod bushings with parts eligible for installation. The 
FAA is issuing this AD to address the unsafe condition on these 
products.

Discussion of Final Airworthiness Directive

Comments

    The FAA received one comment from Aeroclub de Columbia. The 
following presents the comment received on the NPRM and the FAA's 
response to the comment.

Request To Clarify Scheduling of Inspections

    Aeroclub de Columbia requested that the FAA confirm whether the 
recurrent inspections required by paragraph (g) of the proposed AD 
should also be scheduled monthly for aircraft in 14 CFR part 91 (non-
commercial) operations. Aeroclub de Columbia noted

[[Page 86722]]

that Lycoming Service Bulletin 480F suggests changing the oil every 50 
hours or every 4 months, but several aircraft maintenance manuals 
specify oil replacement every 50 hours without a calendar time 
restriction.
    To clarify, this AD does not define or mandate the frequency of oil 
changes after the initial oil change. Subsequent oil changes are part 
of the engine's regular maintenance program, therefore the recurring 
frequency is outside the scope of this AD. Although repetitive 
inspections are required during this regular maintenance interval, they 
are tied to the operator's oil change frequency and that frequency is 
not being defined by this AD. The FAA did not change this AD as a 
result of this comment.

Conclusion

    The FAA reviewed the relevant data, considered any comments 
received, and determined that air safety requires adopting this AD as 
proposed. Accordingly, the FAA is issuing this AD to address the unsafe 
condition on these products. Except for minor editorial changes, and 
any other changes described previously, this AD is adopted as proposed 
in the NPRM. None of the changes will increase the economic burden on 
any operator.

Material Incorporated by Reference Under 1 CFR Part 51

    The FAA reviewed Lycoming Mandatory Service Bulletin No. 630A, 
dated June 13, 2017, which specifies procedures for inspection of the 
connecting rod bushings for damage, proper fit, movement, and wear. 
This material is reasonably available because the interested parties 
have access to it through their normal course of business or by the 
means identified in the ADDRESSES section.

Costs of Compliance

    The FAA estimates that this AD affects 16,000 engines installed on 
airplanes of U.S. registry.
    The FAA estimates the following costs to comply with this AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                       Cost per    Cost on U.S.
                  Action                            Labor cost           Parts cost    product       operators
----------------------------------------------------------------------------------------------------------------
Inspect oil..............................  2 work-hours x $85 per hour          $65         $235      $3,760,000
                                            = $170.
Inspect connecting rod bushings..........  1 work-hour x $85 per hour             0           85       1,360,000
                                            = $85.
Replace connecting rod bushings (per       4.5 work-hours x $85 per             380          762      12,192,000
 bushing).                                  hour = $382.
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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.
    The FAA is 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

    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) Will not affect intrastate aviation in Alaska, 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.

List of Subjects in 14 CFR Part 39

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

The Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA amends 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. The FAA amends Sec.  39.13 by adding the following new airworthiness 
directive:

2024-21-02 Lycoming Engines: Amendment 39-22869; Docket No. FAA-
2024-1695; Project Identifier AD-2023-00783-E.

(a) Effective Date

    This airworthiness directive (AD) is effective December 5, 2024.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to Lycoming Engines (Lycoming) model engines 
that have an affected part and part number (P/N) installed and are 
assembled within the ship date range, as specified in Table 1 to 
paragraph (c) of this AD.

                                     Table 1 to Paragraph (c)--Affected P/Ns
----------------------------------------------------------------------------------------------------------------
                     P/N                                   Affected part                   Ship date range
----------------------------------------------------------------------------------------------------------------
LW-13923.....................................  Connecting Rod Bushing..............        01/30/2009-11/17/2015
LW-11750.....................................  Connecting Rod Assembly.............        01/30/2009-11/19/2015
78030........................................  Connecting Rod Assembly.............        01/30/2009-03/31/2016
LW-19332.....................................  Connecting Rod Assembly.............        01/30/2009-01/03/2016
LW-13865.....................................  Connecting Rod Assembly.............        01/30/2009-02/14/2017

[[Page 86723]]

 
77450........................................  Connecting Rod Assembly.............        01/30/2009-02/14/2017
LW-13422.....................................  Connecting Rod Assembly.............        01/30/2009-02/14/2017
LW-13937.....................................  Connecting Rod Assembly.............        01/30/2009-02/14/2017
LW-15288.....................................  Connecting Rod Assembly.............        01/30/2009-02/14/2017
----------------------------------------------------------------------------------------------------------------

    Note 1 to paragraph (c): The affected parts are known to be 
installed on Lycoming Model AEIO-320 series, AEIO-360 series, AEIO-
390 series, AEIO-540 series, AEIO-580-B1A, AIO-320 series, AIO-360 
series, HIO-360 series, HIO-390-A1A, HIO-540-A1A, HO-360 series, IO-
320 series, IO-360 series, IO-390 series, IO-540 series, IVO-360-
A1A, IVO-540-A1A, LHIO-360 series, LIO-320 series, LIO-360 series, 
LO-360 series, LTIO-540 series, LTO-360 series, O-233-A1, O-235 
series, O-320 series, O-340 series, O-360 series, O-435 series, O-
540 series, SO-580 series, TEO-540 series, TIGO-541 series, TIO-360 
series, TIO-540 series, TIO-541 series, TIVO-540-A2A, TO-360 series, 
TVO-435 series, TVO-540-A1A, VO-360 series, VO-435 series, VO-540 
series, and VSO-580-A1A engines.

(d) Subject

    Joint Aircraft System Component (JASC) Code 8500, Engine 
(Reciprocating).

(e) Unsafe Condition

    This AD was prompted by several reports of connecting rod 
failures resulting in uncontained engine failure and in-flight 
shutdowns (IFSDs). The FAA is issuing this AD to prevent connecting 
rod failure. The unsafe condition, if not addressed, could result in 
engine failure, an IFSD, and loss of control of the aircraft.

(f) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.

(g) Required Actions

    (1) At the next oil change or within 4 months after the 
effective date of this AD, whichever occurs first, and thereafter at 
every oil change until the bushing replacement required by either 
paragraph (g)(3) or (4) of this AD is done, perform a visual 
inspection of the engine oil filter, oil pressure screen, and oil 
suction screen (depending on the engine configuration) for bronze 
metal particulates. The actions required by this paragraph may be 
performed by the owner/operator (pilot) holding at least a private 
pilot certificate and must be entered into the aircraft records 
showing compliance with this AD in accordance with 14 CFR 43.9(a) 
and 91.417(a)(2)(v). The record must be maintained as required by 14 
CFR 91.417, 121.380, or 135.439.
    Note 2 to paragraph (g)(1): Guidance for engine oil filter, oil 
pressure screen, and oil suction screen inspection instructions and 
identification of metallic solids may be found in Lycoming Mandatory 
Service Bulletin No. (MSB) 480F, dated May 25, 2017 (Lycoming MSB 
480F).
    (2) If, during any inspection required by paragraph (g)(1) of 
this AD, any bronze metal particulates are found and the source is 
identified as the connecting rod bushings, before further flight, 
inspect all affected connecting rod bushings for damage (e.g. 
deterioration, missing metal), proper fit, movement, and wear in 
accordance with ``Connecting Rod Bushing Inspection,'' of Lycoming 
MSB 630A, dated June 13, 2017.
    Note 3 to paragraph (g)(2): Guidance for identifying the source 
of metallic contamination may be found in Table 3 of Lycoming MSB 
480F.
    (3) If the connecting rod bushings fail any inspection required 
by paragraph (g)(2) of this AD, before further flight, replace the 
connecting rod bushings with parts eligible for installation. This 
terminates the repetitive inspection required by paragraph (g)(1) of 
this AD.
    (4) At the next engine overhaul, replace the connecting rod 
bushings with parts eligible for installation. This terminates the 
repetitive inspection required by paragraph (g)(1) of this AD.

(h) Definition

    For the purpose of this AD, a ``part eligible for installation'' 
is any connecting rod bushing having P/N 01K28983.

(i) Credit for Previous Actions

    You may take credit for the actions required by paragraph (g)(1) 
of this AD if you performed those actions before the effective date 
of this AD using Lycoming MSB 480F.

(j) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, East Certification Branch, FAA, has the 
authority to approve AMOCs for this AD, if requested using the 
procedures found in 14 CFR 39.19. In accordance with 14 CFR 39.19, 
send your request to your principal inspector or local Flight 
Standards District Office, as appropriate. If sending information 
directly to the manager of the branch office, send it to the 
attention of the person identified in paragraph (k)(1) of this AD 
and email to: <a href="/cdn-cgi/l/email-protection#457c68243336682b3c24262a68262a36052324246b222a33"><span class="__cf_email__" data-cfemail="95acb8f4e3e6b8fbecf4f6fab8f6fae6d5f3f4f4bbf2fae3">[email&#160;protected]</span></a>.
    (2) Before using any approved AMOC, notify your appropriate 
principal inspector, or lacking a principal inspector, the manager 
of the local flight standards district office/certificate holding 
district office.

(k) Additional Information

    (1) For more information about this AD, contact James Delisio, 
Aviation Safety Engineer, FAA, 1701 Columbia Avenue, College Park, 
GA 30337; phone: (516) 228-7321; email: <a href="/cdn-cgi/l/email-protection#1f757e727a6c317b7a73766c76705f797e7e31787069"><span class="__cf_email__" data-cfemail="0f656e626a7c216b6a63667c66604f696e6e21686079">[email&#160;protected]</span></a>.
    (2) Service information identified in this AD that is not 
incorporated by reference is available at the address specified in 
paragraph (l)(3) of this AD.

(l) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference (IBR) of the material listed in this 
paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this material as applicable to do the actions 
required by this AD, unless the AD specifies otherwise.
    (i) Lycoming Engines Mandatory Service Bulletin No. 630A, dated 
June 13, 2017.
    (ii) [Reserved]
    (3) For Lycoming Engines material identified in this AD, contact 
Lycoming Engines, 652 Oliver Street, Williamsport, PA 17701; phone: 
(800) 258-3279; website: <a href="http://lycoming.com/contact/knowledge-base/publications">lycoming.com/contact/knowledge-base/publications</a>.
    (4) You may view this material at the FAA, Airworthiness 
Products Section, Operational Safety Branch, 1200 District Avenue, 
Burlington, MA 01803. For information on the availability of this 
material at the FAA, call (817) 222-5110.
    (5) You may view this material at the National Archives and 
Records Administration (NARA). For information on the availability 
of this material at NARA, visit <a href="http://www.archives.gov/federal-register/cfr/ibr-locations">www.archives.gov/federal-register/cfr/ibr-locations</a> or email <a href="/cdn-cgi/l/email-protection#80e6f2aee9eef3f0e5e3f4e9efeec0eee1f2e1aee7eff6"><span class="__cf_email__" data-cfemail="b1d7c39fd8dfc2c1d4d2c5d8dedff1dfd0c3d09fd6dec7">[email&#160;protected]</span></a>.

    Issued on October 28, 2024.
Victor Wicklund,
Deputy Director, Compliance & Airworthiness Division, Aircraft 
Certification Service.
[FR Doc. 2024-25365 Filed 10-30-24; 8:45 am]
BILLING CODE 4910-13-P