2009-21-07: Thrust and thrust control

2009-21-07 General Electric Company: Amendment 39-16044. Docket No. FAA-2009-0018; Directorate Identifier 2009-NE-01-AD. Effective Date (a) This airworthiness directive (AD) becomes effective December 1, 2009. Affected ADs (b) None. Applicability (c) This AD applies to General Electric Company (GE) CF6-80C2 series turbofan engines with thrust reverser ballscrew gearbox assembly adjustable-length end actuators having 3/8-inch rod-ends installed. These engines are installed on, but not limited to, Airbus A300-600/R/F and A310-200/300, and Boeing 747-200B/300/400/ 400D/400F, 767-200/300/300F/400ER, and MD-11 airplanes. Unsafe Condition (d) This AD results from reports of four failures of rod-ends on certain thrust reverser ballscrew gearbox assembly adjustable-length end actuators, leading to partial or complete separation of the transcowl from the engine and airplane during thrust reversal. We are issuing this AD to prevent asymmetric thrust and lossof thrust control. 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. Visual Inspection and Fastening Hardware Replacements (f) Within 500 flight cycles after the effective date of this AD, do the following: (1) Inspect all translating cowl clevis pin retaining clips and associated fastening hardware, including those on the center drive unit (CDU), to ensure they are properly assembled and securely fastened in place. If a retaining clip is not completely covering the clevis pin and firmly attached to the clevis, remove and replace the fastening hardware. Use paragraphs 3.B.(1) and 3.B.(2), excluding 3.B.(2)(a), of Middle River Aircraft Systems (MRAS) Alert Service Bulletin (ASB) No. CF6-80C2 S/B 78A1162, Revision 3, dated September 10, 2009, to do the inspections. (2) Remove and inspect all clevis pins for physical damage or significant corrosion. Use paragraphs 3.C.(1) through 3.C.(3), excluding the recording requirement in paragraph 3.C.(3)(b) of MRAS ASB No. CF6-80C2 S/B 78A1162, Revision 3, dated September 10, 2009, to do the removals, inspections, and part disposition as necessary. (3) Inspect the clevis assemblies and four clevis fasteners at each of the clevis assemblies (upper, center, and lower) for structural integrity. Use paragraphs 3.F.(1), excluding 3.F.(1)(c) of MRAS ASB No. CF6-80C2 S/B 78A1162, Revision 3, dated September 10, 2009, to do the inspections. (4) If loose or missing clevis fasteners are found, remove and replace the clevis fasteners, or defer the repair and deactivate the thrust reverser. Use paragraph 3.F.(2) of MRAS ASB No. CF6-80C2 S/B 78A1162, Revision 3, dated September 10, 2009, to do the replacements. Initial Rod-End Replacements (g) For all 3/8-inch translating cowl adjustable-length actuator rod-ends having more than 600 flight cycles-since-new on the effective date of this AD, replace them with P/N M81935/1-6, or other approved part number, zero time rod-ends within 500 flight cycles after the effective date of this AD. Use paragraph 3.E., excluding both 3.E.(8) and the recording requirement in paragraph 3.E.(5) of MRAS ASB No. CF6-80C2 S/B 78A1162, Revision 3, dated September 10, 2009, to do the replacements. Repetitive 3/8-Inch Rod-End Replacements (h) Repetitively replace the 3/8-inch translating cowl adjustable-length actuator rod-ends that were installed as specified in paragraph (g) of this AD, before they accumulate 11,000 flight cycles, with a zero time 3/8-inch adjustable-length rod-end, P/N M81935/1-6 or other approved part number. Since the rod-ends are not serialized, track their life by using the associated actuator assembly's life. Use paragraphs 3.E., excluding both paragraph 3.E.(8) and the recording requirement in paragraph 3.E.(5), of MRAS ASB No. CF6-80C2 S/B 78A1162, Revision 3, dated September 10, 2009, to do the replacements. Optional Terminating Action (i) As an optional terminating action to the repetitive 3/8- inch rod-end replacements required by this AD, replace the 3/8- inch adjustable rod-ends with a 7/16-inch adjustable rod-end and nut or you may replace the adjustable end actuator with a fixed end actuator. Use paragraph 3.E.(1) of MRAS ASB No. CF6-80C2 S/B 78A1162, Revision 3, dated September 10, 2009, to do the replacements. Installation Prohibition (j) After the effective date of this AD, do not install rod-ends P/Ns KBE6-59, MS21242S06, B15946-13 or 15946000-13, on any engine subject to this AD. Rod-ends removed to comply with this AD are not eligible for installation on any aircraft. Previous Credit (k) Inspections and replacements and optional terminating action performed before the effective date of this AD using MRAS ASB No. CF6-80C2 S/B 78A1162, dated December 30, 2008; Revision 1, dated February 13, 2009; or Revision 2, dated June 22, 2009, satisfythe required initial actions and optional terminating action of this AD. Alternative Methods of Compliance (l) 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. Related Information (m) Contact Christopher J. Richards, Aerospace Engineer, Engine Certification Office, FAA, Engine & Propeller Directorate, 12 New England Executive Park, Burlington, MA 01803; e-mail: christopher.j.richards@faa.gov; telephone (781) 238-7133; fax (781) 238-7199, for more information about this AD. Material Incorporated by Reference (n) You must use Middle River Aircraft Systems Alert Service Bulletin No. CF6-80C2 S/B 78A1162, Revision 3, dated September 10, 2009, 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 Middle River Aircraft Systems, 103 Chesapeake Park Plaza, MF 46, Baltimore, MD 21220; telephone (410) 682-0080; fax (410) 682-0100; or e-mail: bulletins@mras-usa.com, for a copy of this service information. You may review copies at the FAA, New England Region, 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/cfr/ ibr-locations.html.