AD/DA40/4 Amdt 1 Fuel Valve Universal Joints (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/DA40/4 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.

Diamond DA40 Series Aeroplanes

AD/DA40/4 Amdt 1 Fuel Valve Universal Joints 6/2006

Applicability:

Diamond Aircraft Industries DA40 aircraft serial numbers 40.006 though 40.079 inclusive, 40.081 through 40.083 inclusive, 40.201 through 40.417 inclusive, with fuel shaft Part No. D41-2823-20-00 pre Rev “a” installed.

Note 1:  The inspection requirements of this AD only apply to pre Revision “a” fuel shafts.

Requirement:

1.    Carry out an inspection of the universal joints of the fuel selector/fuel valve assembly in accordance with Diamond Aircraft Industries GmbH Mandatory Service Bulletin No. MSB 40-030/3 or later approved revisions.

2.    If defects are found during the inspection detailed in Requirement 1 of this Directive replace the complete drive assembly with new joint Part No.
D41-2823-20-00 Rev “a” or higher in accordance with Diamond Aircraft Industries GmbH Mandatory Service Bulletin No. MSB 40-030/3 or later approved revisions.

Replacement of the shaft with a Rev “a” or later joint provides terminating action for the requirements of this AD.

Note 2:  EASA AD 2006-0067 which supersedes Austrian Airworthiness Directive
No. A-2004-003 refers.

Compliance:

For aeroplanes with a time-since-new (TSN) of more than 200 flight hrs:

For Requirement 1: Initial inspection within 15 hours after the effective date of this AD, unless previously accomplished; thereafter at intervals not to exceed 50 hours time in service (TIS).

For Requirement 2: Prior to further flight.

For aeroplanes with a TSN of 200 flight hours or less:

For Requirement 1: At the next scheduled inspection but not to exceed 50 hours TIS after the effective date of this AD; thereafter at intervals not to exceed 50 hours TIS.

For Requirement 2: Prior to further flight.

This Amendment becomes effective on 8 June 2006.
Background:	Abnormal manufacturing variations of the universal joints in combination with mechanical wear can lead to universal joint failures and subsequent disconnection between the fuel selector and the fuel valve.  This condition might remain unrecognized by the pilot and can result in fuel starvation during flight and/or the unavailability of the emergency fuel shut-off function.

James Coyne
Delegate of the Civil Aviation Safety Authority

28 April 2006