Airworthiness Directives; 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

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-21864; Directorate Identifier 2005-NE-29-AD; Amendment 39-14276; AD 2005-19-11]

RIN 2120-AA64

Airworthiness Directives; 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

AGENCY:

Federal Aviation Administration (FAA), Department of Transportation (DOT).

ACTION:

Final rule.

SUMMARY:

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.

DATES:

This AD becomes effective October 21, 2005. The Director of the Federal Register approved the incorporation by reference of certain

publications listed in the regulations as of October 21, 2005.

ADDRESSES:

You can get the service information identified in this AD from 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.

You may examine the AD docket on the Internet at

http://dms.dot.gov

or in Room PL-401 on the plaza level of the Nassif Building, 400 Seventh Street, SW., Washington, DC.

FOR FURTHER INFORMATION CONTACT:

Norm Perenson, Aerospace Engineer, New York Aircraft Certification Office, FAA, Engine & Propeller Directorate, 1600 Stewart Avenue, Suite 410, Westbury, NY 11590; telephone (516) 228-7337; fax (516) 794-5531.

SUPPLEMENTARY INFORMATION:

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.

§ 39.13

[Amended]

2. The FAA amends § 39.13 by adding the following new airworthiness directive:

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

IO-540-V4A5

A.M.F

17-D Mushshak

Aero Commander

500 B, S, U/Merlyn Products Conv.

IO-540-E1A5

Aero Commander

500-E

Aerofab

LA 250 Renegade

Aeronautica

Agricola Mexicana Quail

IO-540-K1F5

Aerostar

600

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

O-360-A1G6D

76 Duchess

C-24R Sierra or 200 Sierra

Bellanca

Aircraft Aries T-250

O-540-E4B5

Britten Norman

BN-2 Islander

O-540-E4C5

BN-2A & BN-2B Islander

IO-540-K1B5

BN-2A Islander

Celair

Eagle

O-360-A1F6

Cessna

177 Cardinal

O-360-A1F6D

177 Cardinal

O-540-J3C5D

182-RG Skylane

IO-540-AB1A5

182-S

O-360-F1A6

C-172RG Cutlass RG

IO-540-AC1A5

C-206 Stationair

R-G Cardinal

IO-360-A1B6D

R-G Cardinal

TIO-540-AK1A

T182T Skylane

O-540-L3C5D

TR-182 Turbo Skylane

AEIO-540-D4A5

Christen Pitts

S-2S, S-2B

IO-540-T4B5D

Commander

114

IO-540-T4B5

114B

TIO-540-AG1A

114TC

Dornier

DO-28

IO-540-K1J5D

Embraer

EMB-201 Ipanema

O-540-B4B5

EMB-710 Corioca

EMB-720 Minuano

EMB-720 Minuano & EMB-721 Sertanejo

EMB-721 Sertanejo

AEIO-540-L1B5

Extra-Flugzeugbau

Extra 300

F.F.A

FFA-2000 Eurotrainer

H.A.L

HPT-32

O-540-A1A5

Helio Military

H-250

AEIO-360-A1E6

Integrated Systems

Omega

IO-540-M1C5

King Engineering

Angel

Korean Air

Chang Gong-91

Lake

LA-4-200 Buccaneer

O-540-J3A5

Maule

MT-7-260 & M-7-260

MX-7-235 Star Rocket

IO-540-W1A5

MX-7-235, MT-7-235 & M7-235

Mod Works

Trophy 212 Conversion

IO-360-A3B6

Mooney

201

M-201

IO-360-A1B6

M-20-J

IO-360-A3B6D

M20J-201

TIO-540-AF1B

M20M TLS Bravo

Moravan

Z143L Zlin

Z242L Zlin

Partenavia

P-68 Series Observer

IO-540-K1J5

Piper

600-A Aerostar

IO-540-S1A5

601-A, 601B & 601P Aerostar

IO-540-AA1A5

602P Sequoia

O-540-A1B5

PA-23-235 Aztec & PA-24-250 Comanche

PA-23-250 Aztec

IO-540-J4A5

PA-23-250 Aztec

IO-540-C1B5

PA-23-250 Aztec & PA-24-250 Comanche

TIO-540-C1A

PA-23-250T Turbo Aztec

PA-24-150 Comanche

O-540-A1C5

PA-24-250 Comanche

O-540-A1D5

PA-24-250 Comanche

IO-540-D4A5

PA-24-260 Comanche

PA-24-260 Comanche

O-540-B2C5

PA-25-235 Pawnee

O-540-B2B5

PA-28-235 Cherokee

PA-28-235 Cherokee

IO-360-C1C6

PA-28R-201 Arrow

IO-540-M1A5

PA-31-300 Navajo

PA-32-260 Cherokee 6

IO-540-K1G5

PA-32-300 & PA-32-301 Saratoga

IO-540-K1A5

PA-32-300 Cherokee 6

IO-540-K1A5D

PA-32-300 Cherokee 6

IO-540-K1G5D

PA-32-300R Lance

PA-32-301R Saratoga

IO-360-C1E6

PA-34-200 Seneca I

IO-540-K1G5

PA-36-300 Brave

O-360-A1H6

PA-44-180

LO-360-A1H6

PA-44-180 Seminole

IO-540-K1K5

T-35 Pillan

Robin

R-3000/235

O-540-F1B5

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

Socata

R-235 Rallye Cuerrier

Rallye 235CA

IO-540-C4D5D

TB-20 Trinidad

TB-200

TIO-540-AB1AD

TB-21 & TB-21-TC Trinidad TC

IO-540-AB1A5

Stoddard Hamilton

Glasair

IO-540-K1H5

Stoddard Hamilton

Glasair III

IO-540-L1C5

Swearingen Aircraft

SX-300

Transava

T-300 Skyfarmer

AEIO-360-A1B6

Valmet

L-70 Vinka

Wassmer

WA4-21

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 any crankshaft 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.

Issued in Burlington, Massachusetts, on September 9, 2005.

Jay J. Pardee,

Manager, Engine and Propeller Directorate, Aircraft Certification Service.

[FR Doc. 05-18323 Filed 9-15-05; 8:45 am]

BILLING CODE 4910-13-P