AD/Con/84 Amdt 3 Starter Adapter Assembly (Cth)

AIRWORTHINESS DIRECTIVE

On the effective date specified below, and for the reasons set out in the background section, the CASA delegate whose signature appears below revokes Airworthiness Directive (AD) AD/CON/84 Amdt 2 and issues the following AD under subregulation 39.001(1) of CASR 1998.  The AD requires that the action set out in the requirement section (being action that the delegate considers necessary to correct the unsafe condition) be taken in relation to the aircraft or aeronautical product mentioned in the applicability section: (a) in the circumstances mentioned in the requirement section; and (b) in accordance with the instructions set out in the requirement section; and (c) at the time mentioned in the compliance section.

Teledyne Continental Motors Piston Engines

AD/CON/84 Amdt 3 Starter Adapter Assembly 5/2007

Applicability:

Teledyne Continental Motors (TCM) GTSIO-520 series reciprocating engines.

Note 1:  These engines are installed on, but not limited to, Twin Commander (formerly Aero Commander) model 685, Cessna model 404, 411 series, and 421 series, British Aerospace, Aircraft Group, Scottish Division model B.206 series 2 and Aeronautica Macchi model AM-3 airplanes.

Requirement:

1.    For any engine that experiences rough running conditions regardless of time-in-service (TIS), perform the inspection procedures specified in Part 1 and Part 3 of Teledyne Continental Motors (TCM) Mandatory Service Bulletin (MSB) No. MSB94-4G dated 31 October 2005 or later FAA approved revisions, and replace components as necessary.

An engine is considered rough-running if there is a sudden increase in the perceived vibration levels that cannot be cleared by adjustment of the engine controls; particularly the fuel mixture setting.  Information on rough running engines can be found in the aircraft manufacturer's Airplane Flight Manual, Pilot's Operating Handbook, or Aircraft Owners Manual.

Special flight permits are prohibited for rough-running engines described in this AD.

2.    Perform the inspection procedures specified in Part 2 of MSB94-4G or later FAA approved revisions, and replace components as necessary.

3.    Perform the inspection procedures specified in Part 3 of MSB94-4G or later FAA approved revisions, and replace components as necessary.

4.    Install TCM service kit, P/N EQ6642 (new) or EQ6642R (rebuilt), using the service kit installation procedures specified in Part 5 of MSB94-4G dated
31 October 2005 or later FAA approved revisions.

Note 2:  Installation of the service kit does not constitute terminating action for the inspection and component replacements detailed in other requirements of this AD.

5.    If, during an inspection in accordance with Requirement 1, 2 or 3 of this AD, you find needle bearing P/N 537721, installed in the crankcase, replace it with a serviceable bushing P/N 654472 or equivalent approved bearing.  Use the bushing installation procedure specified in Part 4 of TCM MSB94-4G or later FAA approved revisions.

Note 3:  FAA Airworthiness Directive AD 2007-05-15 Amendment 39-14976 dated
12 March 2007 refers.

Compliance:

1.    Before further flight.

2.    For any engine that has been inspected earlier in accordance with the instructions of this AD at any revision status:

Continue the inspections at the next 100-hours time-in-service (TIS) inspection or annual inspection, whichever occurs first after the effective date of this AD. Thereafter, repeat the inspections at each 100-hours TIS inspection, (plus or minus 10 hours) or annual inspection, whichever occurs first.

For any engine that has NOT been inspected earlier:

Within 25 hours TIS or annual inspection, which ever occurs first, after the effective date of this AD. Thereafter, repeat the inspections at each 100-hours TIS inspection (plus or minus 10 hours) or annual inspection, whichever occurs first.

3.    For any starter adapter with 400 hours or more TIS or unknown TIS on the effective date of this AD:

Unless previously accomplished, carry out within 25 hours TIS after the effective date of this AD and repeatedly thereafter, at intervals not to exceed 400-hours TIS (plus or minus 10 hours).

For any starter adapter with less than 400 hours TIS on the effective date of this AD:

Upon accumulation of 400 hours TIS (plus or minus 10 hours), and repeatedly thereafter, at intervals not to exceed 400-hours TIS (plus or minus 10 hours).

4.    Unless previously accomplished, carry out at the next engine overhaul or starter adapter replacement after the effective date of this AD, whichever occurs first.

5.    Before reassembling components.

This Amendment becomes effective on 10 May 2007.

Background:

This AD results from six service difficulty reports and one fatal accident report received related to the failed starter adapter assemblies.  The actions detailed in this AD are intended to prevent failure of the starter adapter assembly and / or crankshaft gear, resulting in failure of the engine and possible forced landing.

The current amendment makes reference to the latest revision of TCM service documents and the latest FAA AD 2007-05-15.

The Amendment 2 of this AD became effective on 22 December 2005.

The Amendment 1 of this AD became effective on 2 November 2005.

Charles Lenarcic
Delegate of the Civil Aviation Safety Authority

27 March 2007