Tdata AD

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2024-21-02	LYCOMING ENGINES: Amendment 39-22869; Docket No. FAA-2024-1695; Project Identifier AD-2023-00783-E.

(a) EFFECTIVE DATE

    This airworthiness directive (AD) is effective December 5, 2024.

(b) AFFECTED ADS

    None.

(c) APPLICABILITY

    This AD applies to Lycoming Engines (Lycoming) model engines that have
    an affected  part and  part number  (P/N) installed  and are assembled
    within the ship date range, as  specified in Table 1 to paragraph  (c)
    of this AD.

                   TABLE 1 TO PARAGRAPH (C)--AFFECTED P/NS

    ______________________________________________________________________
      P/N               AFFECTED PART                  SHIP DATE RANGE    
    ______________________________________________________________________
    LW-13923        Connecting Rod Bushing          01/30/2009-11/17/2015
    LW-11750        Connecting Rod Assembly         01/30/2009-11/19/2015
    78030           Connecting Rod Assembly         01/30/2009-03/31/2016
    LW-19332        Connecting Rod Assembly         01/30/2009-01/03/2016
    LW-13865        Connecting Rod Assembly         01/30/2009-02/14/2017
    77450           Connecting Rod Assembly         01/30/2009-02/14/2017
    LW-13422        Connecting Rod Assembly         01/30/2009-02/14/2017
    LW-13937        Connecting Rod Assembly         01/30/2009-02/14/2017
    LW-15288        Connecting Rod Assembly         01/30/2009-02/14/2017
    ______________________________________________________________________

NOTE 1 TO PARAGRAPH (c): The  affected parts are known to be  installed on
Lycoming Model AEIO-320 series, AEIO-360 series, AEIO-390 series, AEIO-540
series, AEIO-580-B1A, AIO-320 series, AIO-360 series, HIO-360 series,  HIO
-390-A1A, HIO-540-A1A, HO-360 series, IO-320 series, IO-360 series, IO-390
series, IO-540 series, IVO-360-A1A, IVO-540-A1A, LHIO-360 series,  LIO-320
series, LIO-360 series, LO-360 series, LTIO-540 series, LTO-360 series, O-
233-A1, O-235  series, O-320  series,  O-340  series, O-360  series, O-435
series, O-540 series, SO-580 series, TEO-540 series, TIGO-541 series,  TIO
-360 series, TIO-540 series, TIO-541 series, TIVO-540-A2A, TO-360  series,
TVO-435 series, TVO-540-A1A, VO-360 series, VO-435 series, VO-540  series,
and VSO-580-A1A engines.

(d) SUBJECT

    Joint   Aircraft   System   Component   (JASC)   Code   8500,   Engine
    (Reciprocating).

(e) UNSAFE CONDITION

    This AD  was prompted  by several  reports of  connecting rod failures
    resulting  in  uncontained  engine  failure  and  in-flight  shutdowns
    (IFSDs). The FAA is issuing this AD to prevent connecting rod failure.
    The  unsafe  condition,  if  not  addressed,  could  result  in engine
    failure, an IFSD, and loss of control of the aircraft.

(f) COMPLIANCE

    Comply  with this  AD within  the compliance  times specified,  unless
    already done.

(g) REQUIRED ACTIONS

(1) At the next oil change or within 4 months after the effective date  of
    this AD, whichever  occurs first, and  thereafter at every  oil change
    until the bushing replacement  required by either paragraph  (g)(3) or
    (4) of this AD is done, perform a visual inspection of the engine  oil
    filter, oil pressure screen, and oil suction screen (depending on  the
    engine  configuration)  for  bronze  metal  particulates.  The actions
    required  by this  paragraph may  be performed  by the  owner/operator
    (pilot)  holding at  least a  private pilot  certificate and  must  be
    entered into the aircraft records  showing compliance with this AD  in
    accordance with 14 CFR 43.9(a) and 91.417(a)(2)(v). The record must be
    maintained as required by 14 CFR 91.417, 121.380, or 135.439.

NOTE 2 TO PARAGRAPH (g)(1):  Guidance for engine oil filter,  oil pressure
screen, and oil suction screen inspection instructions and  identification
of metallic solids may be found in Lycoming Mandatory Service Bulletin No.
(MSB) 480F, dated May 25, 2017 (Lycoming MSB 480F).

(2) If, during any inspection required by paragraph (g)(1) of this AD, any
    bronze metal particulates  are found and  the source is  identified as
    the  connecting  rod  bushings,  before  further  flight,  inspect all
    affected  connecting  rod  bushings  for  damage  (e.g. deterioration,
    missing  metal), proper  fit, movement,  and wear  in accordance  with
    "Connecting Rod Bushing Inspection," of Lycoming MSB 630A, dated  June
    13, 2017.

NOTE  3  TO  PARAGRAPH  (g)(2): Guidance  for  identifying  the  source of
metallic contamination may be found in Table 3 of Lycoming MSB 480F.

(3) If the connecting rod bushings fail any  inspection  required by para-
    graph (g)(2) of this AD, before further flight, replace the connecting
    rod bushings with parts eligible for installation. This terminates the
    repetitive inspection required by paragraph (g)(1) of this AD.

(4) At the next engine overhaul, replace the connecting rod bushings  with
    parts  eligible  for  installation.  This  terminates  the  repetitive
    inspection required by paragraph (g)(1) of this AD.

(h) DEFINITION

    For the purpose  of this AD,  a "part eligible  for installation" is
    any connecting rod bushing having P/N 01K28983.

(i) CREDIT FOR PREVIOUS ACTIONS

    You may take  credit for the  actions required by  paragraph (g)(1) of
    this AD if  you performed those  actions before the  effective date of
    this AD using Lycoming MSB 480F.

(j) ALTERNATIVE METHODS OF COMPLIANCE (AMOCS)

(1) The  Manager, East  Certification Branch,  FAA, has  the authority  to
    approve AMOCs for this AD, if requested using the procedures found  in
    14 CFR 39.19. In  accordance with 14 CFR  39.19, send your request  to
    your principal inspector or local Flight Standards District Office, as
    appropriate. If  sending information  directly to  the manager  of the
    branch office, send  it to the  attention of the  person identified in
    paragraph (k)(1) of this AD and email to: 9-avs-nyaco-cos@faa.gov.

(2) Before  using  any approved  AMOC, notify  your appropriate  principal
    inspector, or lacking a principal inspector, the manager of the  local
    flight standards district office/certificate holding  district office.

(k) ADDITIONAL INFORMATION

(1) For more  information about this  AD, contact James  Delisio, Aviation
    Safety Engineer, FAA,  1701 Columbia Avenue,  College Park, GA  30337;
    phone: (516) 228-7321; email: james.delisio@faa.gov.

(2) Service information identified in this AD that is not incorporated  by
    reference is available at the address specified in paragraph (l)(3) of
    this AD.

(l) MATERIAL INCORPORATED BY REFERENCE

(1) The  Director of  the Federal  Register approved  the incorporation by
    reference  (IBR) of  the material  listed in  this  paragraph  under 5
    U.S.C. 552(a) and 1 CFR part 51.

(2) You must use this material as applicable to do the actions required by
    this AD, unless the AD specifies otherwise.

(i) Lycoming Engines Mandatory Service  Bulletin No. 630A, dated June  13,
    2017.

(ii) [Reserved]

(3) For Lycoming Engines material identified in this AD, contact  Lycoming
    Engines, 652 Oliver Street,  Williamsport, PA 17701; phone:  (800) 258
    -3279; website: lycoming.com/contact/knowledge-base/publications.

(4) You may view this material at the FAA, Airworthiness Products Section,
    Operational Safety Branch, 1200 District Avenue, Burlington, MA 01803.
    For information on the availability of this material at the FAA,  call
    (817) 222-5110.

(5) You may view this material at the National Archives and Records Admin-
    istration (NARA). For information on the availability of this material
    at NARA, visit www.archives.gov/federal-register/cfr/ibr-locations  or
    email fr.inspection@nara.gov.

Issued on October 28, 2024. Victor Wicklund, Deputy Director, Compliance &
Airworthiness Division, Aircraft Certification Service.

FOR FURTHER INFORMATION CONTACT: James Delisio, Aviation Safety  Engineer,
FAA, 1701 Columbia Avenue, College Park, GA 30337; phone: (516)  228-7321;
email: james.delisio@faa.gov.

PREAMBLE

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2024-1695; Project Identifier AD-2023-00783-E;
Amendment 39-22869; AD 2024-21-02]
RIN 2120-AA64

Airworthiness Directives; Lycoming Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

-----------------------------------------------------------------------

SUMMARY: The FAA is adopting a new airworthiness directive (AD) for
Lycoming Engines (Lycoming) model engines that have a certain
connecting rod assemblies installed. This AD was prompted by several
reports of connecting rod failures, which resulted in uncontained
engine failure and in-flight shutdowns (IFSDs). This AD requires
repetitive oil inspections for bronze metal particulates and, if found,
additional inspections of the connecting rod bushings for damage,
proper fit, movement, and wear, and replacement if necessary. As
terminating action to the connecting rod bushing inspections, this AD
requires replacement of the connecting rod bushings with parts eligible
for installation. The FAA is issuing this AD to address the unsafe
condition on these products.

DATES: This AD is effective December 5, 2024.

The Director of the Federal Register approved the incorporation by
reference of a certain publication listed in this AD as of December 5, 2024.

ADDRESSES:
AD Docket: You may examine the AD docket at regulations.gov under
Docket No. FAA-2024-1695; or in person at Docket Operations between 9
a.m. and 5 p.m., Monday through Friday, except Federal holidays. The AD
docket contains this final rule, any comments received, and other
information. The address for Docket Operations is U.S. Department of
Transportation, Docket Operations, M-30, West Building Ground Floor,
Room W12-140, 1200 New Jersey Avenue SE, Washington, DC 20590.

Material Incorporated by Reference:

For Lycoming material identified in this AD, contact
Lycoming Engines, 652 Oliver Street, Williamsport, PA 17701; phone:
(800) 258-3279; website: lycoming.com/contact/knowledge-base/publications.

You may view this material at the FAA, Airworthiness
Products Section, Operational Safety Branch, 1200 District Avenue,
Burlington, MA 01803. For information on the availability of this
material at the FAA, call (817) 222-5110. It is also available at
regulations.gov under Docket No. FAA-2024-1695.

FOR FURTHER INFORMATION CONTACT: James Delisio, Aviation Safety
Engineer, FAA, 1701 Columbia Avenue, College Park, GA 30337; phone:
(516) 228-7321; email: james.delisio@faa.gov.

SUPPLEMENTARY INFORMATION:

Background

The FAA issued a notice of proposed rulemaking (NPRM) to amend 14
CFR part 39 by adding an AD that would apply to Lycoming model engines
that have certain connecting rod assemblies installed. The NPRM
published in the Federal Register on June 28, 2024 (89 FR 53911). The
NPRM was prompted by several reports of connecting rod failures, which
resulted in uncontained engine failure and IFSDs, and a manufacturer
investigation where it was determined that affected connecting rod
small end bushings may be installed on additional populations of
Lycoming engines. The manufacturer also determined that degradation of
the connecting rod small end bushings is detectable during oil change
inspections. In the NPRM, the FAA proposed to require repetitive oil
inspections for bronze metal particulates and, if found, additional
inspections of the connecting rod bushings for damage (e.g.
deterioration, missing metal), proper fit, movement, and wear, and
replacement if necessary. As terminating action to the connecting rod
bushing inspections, the NPRM also proposed to require replacement of
the connecting rod bushings with parts eligible for installation. The
FAA is issuing this AD to address the unsafe condition on these
products.

Discussion of Final Airworthiness Directive

Comments

The FAA received one comment from Aeroclub de Columbia. The
following presents the comment received on the NPRM and the FAA's
response to the comment.

Request To Clarify Scheduling of Inspections

Aeroclub de Columbia requested that the FAA confirm whether the
recurrent inspections required by paragraph (g) of the proposed AD
should also be scheduled monthly for aircraft in 14 CFR part 91 (non-
commercial) operations. Aeroclub de Columbia noted
that Lycoming Service Bulletin 480F suggests changing the oil every 50
hours or every 4 months, but several aircraft maintenance manuals
specify oil replacement every 50 hours without a calendar time
restriction.

To clarify, this AD does not define or mandate the frequency of oil
changes after the initial oil change. Subsequent oil changes are part
of the engine's regular maintenance program, therefore the recurring
frequency is outside the scope of this AD. Although repetitive
inspections are required during this regular maintenance interval, they
are tied to the operator's oil change frequency and that frequency is
not being defined by this AD. The FAA did not change this AD as a
result of this comment.

Conclusion

The FAA reviewed the relevant data, considered any comments
received, and determined that air safety requires adopting this AD as
proposed. Accordingly, the FAA is issuing this AD to address the unsafe
condition on these products. Except for minor editorial changes, and
any other changes described previously, this AD is adopted as proposed
in the NPRM. None of the changes will increase the economic burden on
any operator.

Material Incorporated by Reference Under 1 CFR Part 51

The FAA reviewed Lycoming Mandatory Service Bulletin No. 630A,
dated June 13, 2017, which specifies procedures for inspection of the
connecting rod bushings for damage, proper fit, movement, and wear.
This material is reasonably available because the interested parties
have access to it through their normal course of business or by the
means identified in the ADDRESSES section.

Costs of Compliance

The FAA estimates that this AD affects 16,000 engines installed on
airplanes of U.S. registry.
The FAA estimates the following costs to comply with this AD:

Estimated Costs

ACTION	LABOR COST	PARTS COST	COST PER PRODUCT	COST ON U.S. OPERATORS
Inspect oil	2 work-hours x $85 per hour = $170.	$65	$235	$3,760,000
Inspect connecting rod bushings	1 work-hour x $85 per hour = $85.	0	85	1,360,000
Replace connecting rod bushings (per bushing).	4.5 work-hours x $85 per hour = $382.	380	762	12,192,000

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.

The FAA is 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

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) Will not affect intrastate aviation in Alaska, 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.

List of Subjects in 14 CFR Part 39

Air transportation, Aircraft, Aviation safety, Incorporation by
reference, Safety.

The Amendment

Accordingly, under the authority delegated to me by the
Administrator, the FAA 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.

Sec. 39.13 [Amended]

2. The FAA amends Sec. 39.13 by adding the following new airworthiness
directive: