Ad/DHC-8/103 - Cockpit Door Hinge Attachment (Cth)

AIRWORTHINESS DIRECTIVE

For the reasons set out in the background section, the CASA delegate whose signature appears below issues the following Airworthiness Directive (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.

Bombardier (Boeing Canada/De Havilland) DHC-8 Series Aeroplanes

AD/DHC-8/103 Cockpit Door Hinge Attachment 11/2005

Applicability:

DHC-8 aircraft, Models 102, 103, 106, 201, 202, 301, 311, 314, and 315, with serial numbers 003 through 557; equipped with cockpit door installation, part numbers 82510074-( ), 82510294-( ), 82510310-001, 8Z4597-001, H85250010-( ),
82510700-( ), or 82510704-( ), except 82510704-502 and 82510704-503.

Note: -( ) denotes all dash numbers.

Requirement:

1.    Applicable to aircraft serial numbers 003 through 451, 453 through 463, 465 through 489, 491 through 505, and 507.

Modify the cockpit door single-point hinge attachment to a two-point hinge attachment by incorporating Modsum 8Q100859 in accordance with Bombardier Service Bulletin 8-52-54 initial issue, dated 12 May 2004, or Revision A, dated
5 November 2004, or a later Transport Canada approved revision.

Note 1:  Installation of Modifications 8/2337 and 8/3339 are required for aircraft serial numbers 003 through 407, 409 through 412, and 414 through 433, before installation of Modsum 8Q100859.

2.    Applicable to aircraft serial numbers 452, 464, 490, 506, and 508 through 557.

Modify the cockpit door single point attachment to a two-point hinge attachment by incorporating Modsum 8Q900267 in accordance with Bombardier Service Bulletin 8-52-58 dated 12 May 2004, or a later Transport Canada approved revision.

Note 2:  Installation of Modsums 8Q200015, 8Q420101, and 8Q420143 are required before installation of Modsum 8Q900267.

Compliance:

Within 24 months after 27 October 2005.

This Airworthiness Directive becomes effective on 27 October 2005.

Background: During testing of the cockpit door, it was observed that the door lower hinge block rotated which resulted in disengagement of the mating hinge pin and excessive door deflection.  The lower hinge block rotated because it was attached to its support structure with only one attachment bolt, which prevented it from reacting to any moment force.  This condition, if not corrected, could result in breakage and uncontrolled release of the cockpit door under certain decompression situations.

David Villiers
Delegate of the Civil Aviation Safety Authority

15 September 2005