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2010-04-05 MCCAULEY PROPELLER SYSTEMS:
Amendment 39-16198. Docket No. FAA-2010-0093; Directorate Identifier 97-ANE-06-AD.

EFFECTIVE DATE

(a) This airworthiness directive (AD) becomes effective March 10, 2010.

AFFECTED ADS

(b) This AD supersedes AD 2003-12-05, Amendment 39-13190.

APPLICABILITY

(c) This  AD  applies  to  McCauley  Propeller  Systems  1A103/TCM  series
    propellers, all serial numbers. These propellers are installed on, but
    not limited to  Cessna 152, Cessna  A152, Reims F152,  and Reims FA152
    series   airplanes,   and  on   airplanes   with  Lycoming   0-235-L2C
    reciprocating  engines  modified  by  Supplemental  Type  Certificates
    SA1763SO, SA5695NM, SA1000NW, and SA432NE.

UNSAFE CONDITION

(d) This AD  results from  16 reports  received  of  propeller hubs  found
    cracked since  AD 2003-12-05  was issued.  We are  issuing this  AD to
    prevent propeller separation  due to hub  fatigue cracking, which  can
    result in loss of control 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.

INITIAL INSPECTION OF PROPELLERS NOT PREVIOUSLY INSPECTED

(f) For  propellers  not  previously  inspected   using  McCauley  Service
    Bulletin (Alert) No. 221C, dated September 7, 1999, or McCauley  Alert
    Service Bulletin  (ASB) No.  ASB221D,  dated  January 28, 2008, do the
    following:

(1) For propellers  with more  than  1,500 operating hours  time-since-new
    (TSN) or unknown operating hours TSN on the effective date of this AD,
    within  the  next 50  operating  hours time-in-service  (TIS),  do the
    actions specified in paragraphs (h) through (m) of this AD.

(2) For  propellers  with  1,500 or  fewer  operating  hours  TSN  on  the
    effective date of this AD, upon reaching 1,500 operating hours TSN  or
    within the  next 50  operating hours  TIS, whichever  is later, do the
    actions specified in paragraphs (h) through (m) of this AD.

INITIAL INSPECTION OF PROPELLERS PREVIOUSLY INSPECTED

(g) For  propellers previously  inspected using  McCauley Service Bulletin
    (Alert)  No.  221C,  dated  September 7,  1999,  or  McCauley  ASB No.
    ASB221D, dated January 28, 2008, do the following:

(1) For  propellers  with  more  than 1,500  operating  hours TSN  on  the
    effective date of this AD,  and with 750 or more operating hours  time
    -since-last-inspection (TSLI), within the next 50 operating hours TIS,
    do the actions specified in paragraphs (h) through (m) of this AD.

(2) For  propellers  with  more  than 1,500  operating  hours TSN  on  the
    effective date  of this  AD, and  with fewer  than 750 operating hours
    TSLI, before reaching 750 operating  hours TSLI or within the  next 50
    operating hours TIS, whichever occurs later, do the actions  specified
    in paragraphs (h) through (m) of this AD.

(h) Visual- and dye-penetrant-inspect for cracks in the propeller hub.

(i) Inspect the bolt holes and ream the holes if necessary.

(j) Inspect the steel reinforcement plates and gaskets.

(k) Remove propellers that are not within the bolt hole inspection  limits
    or have cracks that are not within the rework limits.

(l) Rework propellers that have cracks that meet acceptable rework limits.

(m) Use the Accomplishment Instructions of McCauley ASB No. ASB221E, dated
    January 28, 2010,  to  do the  inspections, rework,  and removals from
    service.

REPETITIVE PROPELLER INSPECTIONS

(n) Thereafter, for all propellers, within every additional 750  operating
    hours TIS, perform the actions  in paragraphs (h) through (m)  of this
    AD.

ALTERNATIVE METHODS OF COMPLIANCE

(o) The Manager, Wichita Aircraft 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.

SPECIAL FLIGHT PERMITS

(p) Under  39.23, we  are  limiting the  availability  of  special  flight
    permits for this AD. Special flight permits are available only if:

(1) The operator has not observed abnormal propeller vibration or abnormal
    engine vibration.

(2) The  operator has  not  made earlier  reports  of  abnormal  propeller
    vibration,  abnormal  engine vibration,  or  other abnormal  propeller
    operations that have not been addressed.

RELATED INFORMATION

(q) Contact  Thomas   Teplik,   Aerospace   Engineer,   Wichita   Aircraft
    Certification Office,  FAA, Small  Airplane Directorate,  1801 Airport
    Road,  Room  100, Wichita,  KS  67209; e-mail:  thomas.teplik@faa.gov;
    telephone: (316) 946-4196; fax:  (316) 946-4107, for more  information
    about this AD.

MATERIAL INCORPORATED BY REFERENCE

(r) You  must use  McCauley Propeller  Systems Alert  Service Bulletin No.
    ASB221E, dated January 28,  2010, to perform the  inspections, rework,
    and removals  from service  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 McCauley Propeller Systems, 5800 E. Pawnee, Wichita, KS 67218,
    telephone: (800)621-7767; e-mail: productsupport@mccauley.textron.com;
    Web:  http://www.mccauley.textron.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.

Issued in Burlington, Massachusetts, on February 8, 2010. Peter A.  White,
Assistant   Manager,   Engine   and   Propeller   Directorate,    Aircraft
Certification Service.

FOR  FURTHER  INFORMATION  CONTACT:  Thomas  Teplik,  Aerospace  Engineer,
Wichita Aircraft  Certification Office,  FAA, Small  Airplane Directorate,
1801   Airport    Road,   Room    100,   Wichita,    KS   67209;   e-mail:
thomas.teplik@faa.gov; telephone: (316) 946-4196; fax: (316) 946-4107.
PREAMBLE 

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

SUMMARY: The FAA is superseding an existing airworthiness directive (AD) for McCauley Propeller Systems 1A103/TCM series propellers. That AD requires, for certain serial numbers (S/Ns) of McCauley Propeller Systems 1A103/TCM series propellers, initial and repetitive visual and dye penetrant inspections for cracks in the propeller hub, replacement of propellers with cracks that do not meet acceptable limits, and rework of propellers with cracks that meet acceptable limits. This AD requires, for all McCauley Propeller Systems 1A103/TCM series propellers, the same actions but at reduced compliance times. This AD also requires inspections of the bolt holes, reaming holes if necessary, and inspections of steel reinforcement plates and gaskets. This AD results from 16 reports received of propeller hubs found cracked since AD 2003-12-05 was issued. We are issuing this AD to prevent propeller separation due to hub fatigue cracking, which can result in loss of control of the airplane.

DATES: Effective March 10, 2010. The Director of the Federal Register approved the incorporation by reference of certain publications listed in the regulations as of March 10, 2010.

We must receive any comments on this AD by April 26, 2010.

ADDRESSES: Use one of the following addresses to comment on this AD.

Federal eRulemaking Portal: Go to http:// www.regulations.gov and follow the instructions for sending your comments electronically.
Mail: Docket Management Facility, U.S. Department of Transportation, 1200 New Jersey Avenue, SE., West Building Ground Floor, Room W12-140, Washington, DC 20590-0001.
Hand Delivery: Deliver to Mail address above between 9 a.m. and 5 p.m., Monday through Friday, except Federal holidays.
Fax: (202) 493-2251.

FOR FURTHER INFORMATION CONTACT: Thomas Teplik, Aerospace Engineer, Wichita Aircraft Certification Office, FAA, Small Airplane Directorate, 1801 Airport Road, Room 100, Wichita, KS 67209; e-mail: thomas.teplik@faa.gov; telephone: (316) 946-4196; fax: (316) 946-4107.

SUPPLEMENTARY INFORMATION: The FAA amends 14 CFR part 39 by superseding AD 2003-12-05, Amendment 39-13190 (68 FR 35155, June 12, 2003). That AD requires, for certain S/Ns of McCauley Propeller Systems 1A103/TCM series propellers, initial and repetitive visual and dye penetrant inspections for cracks in the propeller hub, replacement of propellers with cracks that do not meet acceptable limits, and rework of propellers with cracks that meet acceptable limits. That AD was the result of reports of hub cracking on the camber (forward) side of the propeller hub near the attachment bolt holes on certain propellers. That condition, if not corrected, could result in propeller separation due to hub fatigue cracking, which can result in loss of control of the airplane.

Actions Since AD 2003-12-05 Was Issued

Since AD 2003-12-05 was issued, we received 16 reports of propeller hubs found cracked. Two of the cracks were on propellers outside the propeller range of serial numbers affected by AD 2003-12-05. These cracks began at a bolt hole and extended through to the hub outer surface. These propellers had fewer than 3,000 operating hours time-in-service (TIS). AD 2003-12-05 required inspections starting at 3,000 operating hours TIS. We have not yet been able to determine the cause of the propeller hub cracking.

Relevant Service Information

We have reviewed and approved the technical contents of McCauley Propeller Systems Alert Service Bulletin (ASB) No. ASB221E, dated January 28, 2010. That ASB describes, for all McCauley Propeller Systems 1A103/TCM series propellers, procedures for initial and repetitive visual and dye penetrant inspections for cracks in the propeller hub, removal from service of propellers with cracks that do not meet acceptable limits, and rework of propellers with cracks that meet acceptable limits.

FAA's Determination and Requirements of This AD

The unsafe condition described previously is likely to exist or develop on other McCauley Propeller Systems 1A103/TCM series propellers of the same type design. We are issuing this AD to prevent propeller separation due to hub fatigue cracking, which can result in loss of control of the airplane. This AD requires, for all McCauley Propeller Systems 1A103/TCM series propellers, initial and repetitive visual and dye penetrant inspections for cracks in the propeller hub, including bolt holes, reaming holes if necessary, inspections of steel reinforcement plates and gaskets, removal from service of propellers with cracks that do not meet acceptable limits, and rework of propellers with cracks that meet acceptable limits. You must use the service information described previously to perform the actions required by this AD.

FAA's Determination of the Effective Date

Since an unsafe condition exists that requires the immediate adoption of this AD, we have found that notice and opportunity for public comment before issuing this AD are impracticable, and that good cause exists for making this amendment effective in less than 30 days.

Interim Action

These actions are interim actions and we may take further rulemaking actions in the future.

Comments Invited

This AD is a final rule that involves requirements affecting flight safety and was not preceded by notice and an opportunity for public comment; however, we invite you to send us any written relevant data, views, or arguments regarding this AD. Send your comments to an address listed under ADDRESSES. Include "Docket No. FAA-2010-0093; Directorate Identifier 97- ANE-06-AD'' in the subject line of your comments. We specifically invite comments on the overall regulatory, economic, environmental, and energy aspects of the rule that might suggest a need to modify it.

We will post all comments we receive, without change, to http:// www.regulations.gov, including any personal information you provide. We will also post a report summarizing each substantive verbal contact with FAA personnel concerning this AD. Using the search function of the Web site, anyone can find and read the comments in any of our dockets, including, if provided, the name of the individual who sent the comment (or signed the comment on behalf of an association, business, labor union, etc.). You may review the DOT's complete Privacy Act Statement in the Federal Register published on April 11, 2000 (65 FR 19477-78).

Examining the AD Docket

You may examine the AD docket on the Internet at http:// www.regulations.gov; or in person at the Docket Operations office between 9 a.m. and 5 p.m., Monday through Friday, except Federal holidays. The AD docket contains this AD, the regulatory evaluation, any comments received, and other information. The street address for the Docket Operations office (telephone (800) 647-5527) is the same as the Mail address provided in the ADDRESSES section. Comments will be available in the AD docket shortly after receipt.

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 the 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

Under the authority delegated to me by the Administrator, the Federal Aviation Administration amends part 39 of the Federal Aviation Regulations (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.

Sec. 39.13 [Amended]

2. The FAA amends Sec. 39.13 by removing Amendment 39-13190 (68 FR 35155, June 12, 2003), and by adding a new airworthiness directive, Amendment 39-16198, to read as follows: