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2004-10-01: 6th Stage Low Pressure Turbine (LPT) Air Seals

FAA order 2004-10-01 is an airworthiness directive in force since June 15, 2004. The FAA's subject line: 6th Stage Low Pressure Turbine (LPT) Air Seals. It names the Pratt & Whitney JT9D-3A, Pratt & Whitney JT9D-7, Pratt & Whitney JT9D series engines: about 18 aircraft on the U.S. register today across them, though an order usually covers particular versions or serial numbers rather than every one. System: engine.

What it applies to as the FAA lists it

Kind of product
Engine
Makes
Pratt & Whitney Division
Models
JT9D-20, JT9D-20J, JT9D-3A, JT9D-7, JT9D-7A, JT9D-7AH, JT9D-7F, JT9D-7H, JT9D-7J
Engine series
Pratt & Whitney JT9D-3A 4 aircraft
Pratt & Whitney JT9D-7 1 aircraft
Pratt & Whitney JT9D series 13 aircraft

Dates and paperwork

In force since
June 15, 2004
Published
May 11, 2004 (signed April 30, 2004)
Docket
2003-NE-34-AD
Status
Current
The FAA's document
Read the order on the FAA's site

The FAA's summary their words, unchanged

The FAA is adopting a new airworthiness directive (AD) for Pratt & Whitney (PW) JT9D-3A, -7, -7A, -7AH, -7H, -7F, -7J, -20, and -20J turbofan engines. This AD clarifies a life limit for certain part numbers of 6th stage low pressure turbine (LPT) air seals, and requires their removal from service before accumulating 15,000 cycles-since-new (CSN). This AD results from reports of certain 6th stage LPT air seals possibly not being life tracked due to confusion from updates to the engine manuals. We are issuing this AD to prevent failure of the 6th stage LPT air seal, which could cause LPT damage resulting in an uncontained engine failure.

The order itself the regulatory text, as published

Show the full text (4,022 characters)
2004-10-01 Pratt & Whitney: Amendment 39-13631. Docket No. 2003-NE-34-AD. Effective Date (a) This AD becomes effective June 15, 2004. Affected ADs (b) None. Applicability (c) This AD applies to Pratt & Whitney (PW) JT9D-3A, -7, -7A, -7AH, -7H, -7F, -7J, -20, and -20J turbofan engines. These engines are installed on, but not limited to, Boeing 747-100, 747-200, 747SR, 747SP, and DC10-40 series airplanes. Unsafe Condition (d) This AD results from reports of certain 6th stage low pressure turbine (LPT) air seals possibly not being life tracked due to confusion from updates to the engine manuals. Chapter 5 of Engine Manuals, part numbers (P/Ns) 646028, 770407, and 770408 will be revised to show a life limit of 15,000 cycles-since-new (CSN) for 6th stage LPT air seals P/Ns 808846, 809171, 811260 and 811261. We are issuing this AD to prevent failure of the 6th stage LPT air seal which could cause LPT damage, resulting in an uncontained engine failure.Compliance (e) You are responsible for having the actions required by this AD performed within the compliance times specified unless the actions have already been done. Determine Service Life (f) For 6th stage LPT air seals, P/Ns 808846, 809171, 811260, and 811261, with an unknown number of cycles since installed, calculate the service life within 60 days after the effective date of this AD. (1) Use Method 1 of the Accomplishment Instructions of PW Service Bulletin (SB) No. JT9D 6448, dated June 10, 2003, for when all service records are available for the specific air seal, to calculate the service life. (2) Use Method 2 of the Accomplishment Instructions of PW SB No. JT9D 6448, dated June 10, 2003, for when any or all service records are not available for a specific air seal, to calculate the service life. If the worst-case daily utilization rate is unknown, use the fleet worst-case daily utilization rate of 2.9 cycles/day. Removal From Service (g) Remove 6th stage LPT air seals, P/Ns 808846, 809171, 811260, and 811261, from service at or before accumulating the CSN in the following Table 1. Table 1.-Part Number and Engine Applicability Part number Engine applicability Life limit CSN 808846 (old) JT9D-3A, -7, -7A, -7AH, -7H, -7F, -7J, -20, -20J 15,000 811260 (new) JT9D-3A, -7, -7A, -7AH, -7H, -7F, -7J, -20, -20J 15,000 809171 (old) JT9D-3A, -7, -7A, -7AH, -7H, -7F, -20 15,000 811261 (new) JT9D-3A, -7, -7A, -7AH, -7H, -7F, -20 15,000 (h) If the service life cannot be determined as specified in paragraph (f) of this AD, remove the 6th stage LPT air seal before accumulating 2,500 cycles-in-service after the effective date of this AD. (i) After the effective date of this AD, do not install any 6th stage LPT air seal, P/N 808846, 809171, 811260, or 811261, that exceeds 15,000 CSN, or that was removed to comply with paragraph (h) of this AD because its service life could not be determined. AlternativeMethods of Compliance (j) The Manager, Engine Certification Office, has the authority to approve alternative methods of compliance for this AD if requested using the procedures found in 14 CFR 39.19. Material Incorporated by Reference (k) You must use Pratt & Whitney Service Bulletin No. JT9D 6448, dated June 10, 2003, to perform the service life calculations 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. You can get a copy from Pratt & Whitney, 400 Main St., East Hartford, CT 06108; telephone (860) 565-8770; fax (860) 565-4503. You can review copies at the FAA, New England Region, Office of the Regional Counsel, 12 New England Executive Park, Burlington, MA; 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/code_of_federal_regulations/ibr_locations.html . Related Information (l) None.

Source: FAA Dynamic Regulatory System, airworthiness directives. The FAA's document is the authority; the register counts are this site's, from the FAA register of October 7, 2026. Connections as data: /graph/directive/2004-10-01.json · aircraft systems.