[Federal Register: September 16, 2005 (Volume 70, Number 179)]

[Rules and Regulations]

[Page 54618-54622]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr16se05-4]
–––––––––––––––––––––––––––––––––––

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 TextronLycoming) 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.

1
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.

2
 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
 (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:

4
AIRWORTHINESS DIRECTIVE

Aircraft Certification Service U.S. Department

Washington, DC of Transportation
Federal Aviation
Administration
We post ADs on the internet at www.faa.gov/aircraft/safety/alerts/
The following Airworthiness Directive issued by the Federal Aviation Administration in accordance with the provisions of Title 14 of the Code of Federal Regulations (14 CFR) part 39,
applies to an aircraft model of which our records indicate you may be the registered owner. Airworthiness Directives affect aviation safety and are regulations which require immediate
attention. You are cautioned that no person may operate an aircraft to which an Airworthiness Directive applies, except in accordance with the requirements of the Airworthiness
Directive (reference 14 CFR part 39, subpart 39.3).

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 Beech 76 Duchess
C–24R Sierra or 200 Sierra
Bellanca Aircraft Aries T–250
O–540–E4B5 Britten Norman BN–2 Islander
O–540–E4C5 Britten Norman BN–2A & BN–2B Islander

5
 Engine model Manufacturer Aircraft model
IO–540–K1B5 Britten Norman BN–2A Islander
Celair Eagle
O–360–A1F6 Cessna 177 Cardinal
O–360–A1F6D Cessna 177 Cardinal
O–540–J3C5D Cessna 182–RG Skylane
IO–540–AB1A5 Cessna 182–S
O–360–F1A6 Cessna C–172RG Cutlass RG
IO–540–AC1A5 Cessna C–206 Stationair
R–G Cardinal
IO–360–A1B6D Cessna R–G Cardinal
TIO–540–AK1A Cessna T182T Skylane
O–540–L3C5D Cessna TR–182 Turbo Skylane
AEIO–540–D4A5 Christen Pitts S–2S, S–2B
IO–540–T4B5D Commander 114
IO–540–T4B5 Commander 114B
TIO–540–AG1A Commander 114TC
Dornier DO–28
IO–540–K1J5D Embraer EMB–201 Ipanema
O–540–B4B5 Embraer 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 Maule. MX–7–235, MT–7–235 & M7–235
Mod Works Trophy 212 Conversion
IO–360–A3B6 Mooney 201
M–201
IO–360–A1B6 Mooney M–20–J
IO–360–A3B6D Mooney M20J–201
TIO–540–AF1B Mooney M20M TLS Bravo
Moravan Z143L Zlin
Z242L Zlin
Partenavia P–68 Series Observer
IO–540–K1J5 Piper 600–A Aerostar
IO–540–S1A5 Piper 601–A, 601B & 601P Aerostar
IO–540–AA1A5 Piper 602P Sequoia
O–540–A1B5 Piper PA–23–235 Aztec & PA–24–250 Comanche
PA–23–250 Aztec

6
 Engine model Manufacturer Aircraft model
IO–540–J4A5 Piper PA–23–250 Aztec
IO–540–C1B5 Piper PA–23–250 Aztec & PA–24–250 Comanche
TIO–540–C1A Piper PA–23–250T Turbo Aztec
PA–24–150 Comanche
O–540–A1C5 Piper PA–24–250 Comanche
O–540–A1D5 Piper PA–24–250 Comanche
IO–540–D4A5 Piper PA–24–260 Comanche
PA–24–260 Comanche
O–540–B2C5 Piper PA–25–235 Pawnee
O–540–B2B5 Piper PA–28–235 Cherokee
PA–28–235 Cherokee
IO–360–C1C6 Piper PA–28R–201 Arrow
IO–540–M1A5 Piper PA–31–300 Navajo
PA–32–260 Cherokee 6
IO–540–K1G5 Piper PA–32–300 & PA–32–301 Saratoga
IO–540–K1A5 Piper PA–32–300 Cherokee 6
IO–540–K1A5D Piper PA–32–300 Cherokee 6
IO–540–K1G5D Piper PA–32–300R Lance
PA–32–301R Saratoga
IO–360–C1E6 Piper PA–34–200 Seneca I
IO–540–K1G5 Piper PA–36–300 Brave
O–360–A1H6 Piper PA–44–180
LO–360–A1H6 Piper PA–44–180 Seminole
IO–540–K1K5 Piper 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 Socata TB–20 Trinidad
TB–200
TIO–540–AB1AD Socata 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

7
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.

8
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