2006-20-08: Rod ends of aileron power control actuator, superseding AD 99-05-04

2006-20-08 Empresa Brasileira de Aeronautica S.A. (EMBRAER): Amendment 39-14777. Docket No. FAA-2005-23145; Directorate Identifier 2000-NM-215-AD. Effective Date (a) This AD becomes effective November 8, 2006. Affected ADs (b) This AD supersedes AD 99-05-04. Applicability (c) This AD applies to all EMBRAER Model EMB-145, -145ER, - 145MR, -145LR, -145XR, -145MP, and -145EP airplanes, certificated in any category. Unsafe Condition (d) This AD results from the issuance of mandatory continuing airworthiness information by the Brazilian airworthiness authority. We are issuing this AD to detect and correct cracking or breaking of the rod ends and connecting fittings of the aileron power control actuator (PCA), which could result in reduced controllability of the airplane. 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. Restatement of Certain Requirements of AD 99-05-04 Initial and Repetitive Inspections (f) Within 24 hours (1 day) after March 29, 1999 (the effective date of AD 99-05-04), perform a detailed inspection to detect cracking or failure of the rod ends of the PCA at the aileron and wing connection points, in accordance with EMBRAER Alert Service Bulletin 145-27-A054, Change 01, dated February 17, 1999; or EMBRAER Service Bulletin 145-27-0054, Change 03, dated March 30, 2000, or Change 04, dated February 14, 2005. Repeat the inspection in accordance with the service bulletin thereafter at intervals not to exceed 3 days or 25 flight hours, whichever occurs later, until the initial inspection required by paragraph (h) of this AD is done. Note 1: For the purposes of this AD, a detailed inspection is: "An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirror, magnifying lenses, etc., may be necessary. Surface cleaning and elaborate procedures may be required." Corrective Actions (g) If any cracked or failed rod end is detected during any inspection performed in accordance with paragraph (f) of this AD, prior to further flight, replace the aileron PCA with a new or serviceable part having the same part number, in accordance with EMBRAER Alert Service Bulletin 145-27-A054, Change 01, dated February 17, 1999; or EMBRAER Service Bulletin 145-27-0062, Revision 03, dated December 11, 2002, or Revision 04, dated March 8, 2004. After the effective date of this AD, replace the aileron PCA only with a new or serviceable part that is listed in the "New P/N" column in section 2. "Material--Cost and Availability" of EMBRAER Service Bulletin 145-27-0062, Revision 03, dated December 11, 2002, or Revision 04, dated March 8, 2004. Do the replacement in accordance with the Accomplishment Instructions of the service bulletin. Where the service bulletin specifies to send parts to the parts manufacturer, that action is not required by this AD. New Requirements of This AD Repetitive Inspections (h) At the applicable "Initial Inspection" compliance time in Table 1 of this AD: Do a general visual inspection to detect cracking or failure of the rod ends and connecting fittings in the left- and right-hand PCAs at the aileron and wing structure connection points, in accordance with Part I of the Accomplishment Instructions of EMBRAER Service Bulletin 145-27-0054, Change 03, dated March 30, 2000, or Change 04, dated February 14, 2005. Repeat the inspection at the applicable "Repeat" interval in Table 1 of this AD. Doing the initial inspection in accordance with paragraph (h) of this AD terminates the repetitive inspections in paragraph (f) of this AD. Table 1 Initial and Repetitive Inspection Intervals For airplanes that have PCAs with partnumber (P/N) Do the initial inspection Repeat the inspection 394900-1003 or 394900-1005 Within 3 days after the effective date of this AD. At intervals not to exceed 25 flight hours or 3 days, whichever occurs later. 394900-1007 Within 14 days after the effective date of this AD. At intervals not to exceed 100 flight hours or 14 days, whichever occurs later. 418800-1001, 418800-1003, 418800-9003, 418800-1005, 418800-9005, 418800-1007, or 418800-9007; and that have new reinforced PCA fittings installed in accordance with paragraph (k) or (l) of this AD Within 500 flight hours after the effective date of this AD. At intervals not to exceed 500 flight hours. Note 2: For the purposes of this AD, a general visual inspection is "A visual examination of an interior or exterior area, installation, or assembly to detect obvious damage, failure, or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to ensure visual access to all surfaces in the inspection area. This level of inspection is made under normally available lighting conditions such as daylight, hangar lighting, flashlight, or droplight and may require removal or opening of access panels or doors. Stands, ladders, or platforms may be required to gain proximity to the area being checked." No Cracked or Failed PCA Rod Ends or Connecting Fittings (i) If no cracked or failed PCA rod end or connecting fitting is found during any inspection required by paragraph (h) of this AD: Repeat the inspection required by paragraph (h) of this AD at the applicable time specified in Table 1 of this AD. Corrective Actions for Cracked or Failed Rod Ends (j) If any cracked or failed rod end is found during any inspection required by paragraph (h) of this AD: Before further flight, replace the aileron PCA with a new or serviceable part as listed in the "New P/N" column in section 2. "Material--Cost and Availability" of EMBRAER Service Bulletin 145-27-0062, Change 02, dated September 12, 2000; Revision 03, dated December 11, 2002; or Revision 04, dated March 8, 2004. Do the replacement in accordance with the Accomplishment Instructions of the service bulletin. Where the service bulletin specifies to send parts to the parts manufacturer, that action is not required by this AD. Corrective Actions for Cracked or Failed PCA Connecting Fittings (k) If any cracked or failed PCA connecting fitting at the wing or aileron side is found during any inspection required by paragraph (h) of this AD: Before further flight, replace the PCA connecting fitting with a new, reinforced fitting, in accordance with Part I of the Accomplishment Instructions of EMBRAER Service Bulletin 145-57-0019, Change 01, dated March 30, 2000, Change 02, dated May 3, 2001, or Change 03, dated February 11, 2004; and EMBRAER Service Bulletin 145-27-0061, dated October 19, 1999, Change 01, dated October 29, 1999, Change 02, dated September 12, 2000, Change 03, dated March 14, 2001, or Revision 04, dated August 11, 2004. PCA Connecting Fitting Replacement (l) For airplanes with aileron PCAs with P/N 394900-1003, 394900-1005, 394900-1007, 418800-1001, 418800-1003, 418800-9003, 418800-1005, 418800-9005, 418800-1007, or 418800-9007: Except as required by paragraph (k) of this AD, at the applicable time in paragraphs (l)(1) and (l)(2) of this AD, replace the aileron PCA connecting fittings with new, reinforced fittings, in accordance with Part I of the Accomplishment Instructions of EMBRAER Service Bulletin 145-57-0019, Change 01, dated March 30, 2000, Change 02, dated May 3, 2001, or Change 03, dated February 11, 2004; and Part I of the Accomplishment Instructions of EMBRAER Service Bulletin 145- 27-0061, Change 02, dated September 12, 2000, Change 03, dated March 14, 2001, or Revision 04, dated August 11, 2004. (1) For airplanes with PCAs with P/N 394900-1003, 394900-1005, or 394900-1007: At the later of the times in paragraphs (l)(1)(i) and (l)(1)(ii) of this AD. (i) Before the airplane accumulates 6,000 total flight hours. (ii) Within 3 days or 25 flight hours after the effective date of this AD, whichever occurs later. (2) For airplanes with PCAs with P/N 418800-1001, 418800-1003, 418800-9003, 418800-1005, 418800-9005, 418800-1007, or 418800-9007: Before the airplane accumulates 6,000 total flight hours, or within 600 flight hours after the effective date of this AD, whichever occurs later. (m) For airplanes with PCAs with P/N 418800-1001, 418800-1003, 418800-9003, 418800-1005, 418800-9005, 418800-1007, or 418800-9007: At the applicable time specified in Table 1 of this AD following the replacement specified in paragraph (l) of this AD, do a general visual inspection of the replaced part using a method approved by either the Manager, International Branch, ANM-116, Transport Airplane Directorate, FAA; or the Departmento de Aviacao Civil (or its delegated agent). Doing the inspections in accordance with EMBRAER EMB-145 Aircraft Maintenance Manual Task 27-12-01-212-002- A00, "Inspect (Visual Inspection) Aileron PCA Rod Ends/Fitting Lugs for Integrity and General Condition," is one approved method. Thereafter, repeat the inspection at the applicable time specified in Table 1 of this AD. Optional Terminating Action (n) Airplanes that meet all conditions in paragraphs (n)(1), (n)(2), (n)(3), and (n)(4) of this AD are not subject to the requirements of paragraphs (f), (h), (i), (j), (k), (l), and (m) of this AD. (1) The airplane is equipped with new aileron PCAs with P/N 418800-1001, 418800-1003, 418800-9003, 418800-1005, 418800-9005, 418800-1007, or 418800-9007. (2) The airplane is equipped with new, reinforced PCA fittings installed in production or in accordance with the Accomplishment Instructions of EMBRAER Service Bulletin 145-57-0019, Change 01, dated March 30, 2000, Change 02, dated May 3, 2001, or Change 03, dated February 11, 2004; and EMBRAER Service Bulletin 145-27-0061, dated October 19, 1999, Change 01, dated October 29, 1999, Change 02, dated September 12, 2000, Change 03, dated March 14, 2001, or Revision 04, dated August 11, 2004; as applicable. (3) The airplane is equipped with an aileron damper with P/N 41012130-103 or 41012130-104 that was installed in production or in accordance with the Accomplishment Instructions of any service bulletin listed in Table 2 of this AD. Table 2 Aileron Damper Installation Service Bulletins EMBRAER Service Bulletin Revision Level Date 145-27-0063 Original March 30, 2000 145-27-0063 Change 01 October 2, 2000 145-27-0063 Change 02 March 22, 2002 145-27-0063 Change 03 May 27, 2004 145-27-0063 Revision 04 October 13, 2004 145-27-0063 Revision 05 March 16, 2005 (4) The general visual inspections for structural integrity of the aileron PCA and the aileron damper terminals and fittings at the wing and aileron sides at intervals not exceeding 1,000 flight hours, established in the EMBRAER Model EMB-145 Maintenance Review Board document, are implemented. Alternative Methods of Compliance (AMOCs) (o)(1) The Manager, International Branch, ANM-116, Transport Airplane Directorate, FAA, has the authority to approve AMOCs for this AD, if requested in accordance with the procedures found in 14 CFR 39.19. (2) Before using any AMOC approved in accordance with Sec. 39.19 on any airplane to which the AMOC applies, notify the appropriate principal inspector in the FAA Flight Standards Certificate Holding District Office. (3) Alternative methods of compliance approved previously in accordance with AD 99-05-04 are approved as alternative methods of compliance with this AD. Related Information (p) Brazilian airworthiness directive 1999-02-01R6, dated June 21, 2004, also addresses the subject of this AD. Incorporation by Reference (q) You must use the EMBRAER service bulletins identified in Table 3 ofthis AD, as applicable, to perform the actions that are required by this AD, unless the AD specifies otherwise. If accomplished, you must use the EMBRAER service bulletins identified in Table 4 of this AD, to perform the aileron damper installation provided in paragraph (n)(3) of this AD, unless the AD specifies otherwise. Table 3 Required Service Bulletins Incorporated by Reference Service Bulletin Revision/Change Level Date EMBRAER Alert Service Bulletin 145-27-A054 Change 01 February 17, 1999 EMBRAER Service Bulletin 145-27-0054 Change 03 March 30, 2000 EMBRAER Service Bulletin 145-27-0054 Change 04 February 14, 2005 EMBRAER Service Bulletin 145-27-0061 Original October 19, 1999 EMBRAER Service Bulletin 145-27-0061 Change 01 October 29, 1999 EMBRAER Service Bulletin 145-27-0061 Change 02 September 12, 2000 EMBRAER Service Bulletin 145-27-0061 Change 03 March 14, 2001 EMBRAER Service Bulletin 145-27-0061 Revision 04 August 11, 2004 EMBRAER ServiceBulletin 145-27-0062 Change 02 September 12, 2000 EMBRAER Service Bulletin 145-27-0062 Revision 03 December 11, 2002 EMBRAER Service Bulletin 145-27-0062 Revision 04 March 8, 2004 EMBRAER Service Bulletin 145-57-0019 Change 01 March 30, 2000 EMBRAER Service Bulletin 145-57-0019 Change 02 May 3, 2001 EMBRAER Service Bulletin 145-57-0019 Change 03 February 11, 2004 Table 4 Aileron Damper Installation Service Bulletins Incorporated By Reference EMBRAER Service Bulletin Revision Level Date 145-27-0063 Original March 30, 2000 145-27-0063 Change 01 October 2, 2000 145-27-0063 Change 02 March 22, 2002 145-27-0063 Change 03 May 27, 2004 145-27-0063 Revision 04 October 13, 2004 145-27-0063 Revision 05 March 16, 2005 EMBRAER Service Bulletin 145-57-0019, Change 03, dated February 11, 2004, contains the following effective pages: Page Number Change Level Shown on Page Date Shown on Page 1-4 03 February 11, 2004 5-71 02 May 3,2001 (1) The Director of the Federal Register approved the incorporation by reference of the documents identified in Table 5 of this AD in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Table 5 New Material Incorporated by Reference EMBRAER Service Bulletin Revision/Change Level Date 145-27-0054 Change 03 March 30, 2000 145-27-0054 Change 04 February 14, 2005 145-27-0061 Original October 19, 1999 145-27-0061 Change 01 October 29, 1999 145-27-0061 Change 02 September 12, 2000 145-27-0061 Change 03 March 14, 2001 145-27-0061 Revision 04 August 11, 2004 145-27-0062 Change 02 September 12, 2000 145-27-0062 Revision 03 December 11, 2002 145-27-0062 Revision 04 March 8, 2004 145-27-0063 Original March 30, 2000 145-27-0063 Change 01 October 2, 2000 145-27-0063 Change 02 March 22, 2002 145-27-0063 Change 03 May 27, 2004 145-27-0063 Revision 04 October 13, 2004 145-27-0063 Revision 05 March 16, 2005 145-57-0019 Change 01March 30, 2000 145-57-0019 Change 02 May 3, 2001 145-57-0019 Change 03 February 11, 2004 (2) The Director of the Federal Register approved the incorporation by reference of EMBRAER Alert Service Bulletin 145-27- A054, Change 01, dated February 17, 1999, on March 29, 1999 (64 FR 13892, March 23, 1999). (3) Contact Empresa Brasileira de Aeronautica S.A. (EMBRAER), P.O. Box 343--CEP 12.225, Sao Jose dos Campos--SP, Brazil, 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., Room PL-401, Nassif Building, Washington, DC; 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 the NARA, call (202) 741-6030, or go to http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html .