AD/B767/161 - Engine Strut Wire Bundles

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Legislation au F2006B03338 In force Legislative Instrument

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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 39.1 (1) of CAR 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.

 

Boeing 767 Series Aeroplanes

 

AD/B767/161 Engine Strut Wire Bundles 2/2002

 

Applicability: Model 767 series aeroplanes, line numbers 1 through 821 inclusive, equipped with Pratt & Whitney PW4000 series engines.

 

Requirement: 1. Perform a one-time detailed visual inspection of the wire bundles located in the aft section of the strut forward fairing panel of both engine struts to detect chafing damage, per Boeing Service Bulletin (SB) 767-73A0049, Revision 3, dated 20 December 2000, or Revision 4, dated 5April 2001.

 

Inspections accomplished prior to the effective date of this Directive per SB 767- 73A0049, Revision 2, dated 27 April 2000, or per Boeing Standard Wiring Practices Manual D6-73A0049, Subject 20-10-13 or 20-30-12, are acceptable for compliance with the applicable action specified in this Directive.

 

Note 1: For the purposes of this Directive, a detailed visual inspection is defined as: "An intensive visual examination of a specific structural area, system, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at intensity deemed appropriate by the inspector. Inspection aids such as mirror, magnifying lenses, etc., may be used. Surface cleaning and elaborate access procedures may be required.''

 

2.        If chafing damage of any wire bundle is detected during the Requirement 1 inspection, repair the bundle in accordance with SB 767-73A0049, Revision 3 or Revision 4.

 

3.        Replace all wires that were repaired by splicing, in accordance with Requirement 2, with new wires per SB 767-73A0049, Revision 3 or Revision 4.

 

Note 2: Any of the Type 2 tapes listed in Boeing Standard Wiring Practices Manual D6-54446, Subject 20-00-11, dated 1 May 2000, are acceptable alternatives to the TFE-2X Teflon wrap specified in Figure 1 of Boeing SB 767-73A0049, Revision 3 or Revision 4.

 

4.        Carry out the following actions in accordance with the Accomplishment Instructions of Boeing SB 767-73-0051, dated 20 December 2000.

 

  1. Visually inspect the wire bundles to detect chafing damage; if any damaged wires are found, replace the wires that require a splice repair with new wires.

 

b.        Replace the existing support bracket of the wire bundle with a new bridge bracket, support bracket, and wire bundle clamps.

 

Boeing 767 Series Aeroplanes

 

AD/B767/161 (continued)

 

5.        Report inspection results, as described in SB 767-73A0049, Revision 3 or Revision 4, to Boeing Commercial Airplane Group, P.O. Box 3707, Seattle, Washington 98124-2207 USA.

 

6.        Support brackets located in the aft section of the strut forward fairing panel of either engine strut, as identified in the "Existing Part Number'' column of Paragraph 2.E. of Boeing SB 767-73-0051, may not be installed on any aeroplane.

 

Note 3: FAA AD 2001-24-01 Amdt 39-12517 refers.

 

Compliance:  For Requirement 1 - Prior to the accumulation of 10,000 hours time-in-service (TIS) or within 180 days after the effective date of this Directive, whichever occurs later.

 

For Requirement 2 - Before further flight, immediately following the Requirement 1 inspection.

 

For Requirement 3 - Concurrent with Requirement 4.

 

For Requirement 4 - Within 6,000 hours TIS or 18 months after the effective date of this Directive, whichever occurs later.

 

For Requirement 5 - Within 10 days after accomplishing the actions required by Requirements 1 or 4.

 

For Requirement 6 - As of the effective date of this Directive.

 

This Airworthiness Directive becomes effective on 21 February 2002.

 

Background:  This Directive requires a one-time detailed visual inspection of certain wire bundles located in the aft section of the strut forward fairing panel of both engine struts to detect chafing damage and, if necessary, repair or replacement of wiring. The Directive also requires replacement of wires repaired by splicing and damaged wires that require splicing, and replacement of the support brackets of the existing wire bundles with new brackets and clamps.

 

Boeing 767 Series Aeroplanes

 

AD/B767/161 (continued)

 

These actions are intended to prevent the potential for dual wire faults from grounded, separated, or shorted wires, which could result in inadvertent takeoff thrust overboost, in-flight loss of thrust, or engine shutdown.


 

Eugene Paul Holzapfel

Delegate of the Civil Aviation Safety Authority 14 January 2002

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 


The above AD is notified in the Commonwealth of Australia Gazette on 30 January 2002.

Overview

The Airworthiness Directive AD/B767/161 was issued by the Civil Aviation Safety Authority (CASA) in 2002 to address safety concerns regarding the Boeing 767 Series Aeroplanes, specifically those equipped with Pratt & Whitney PW4000 series engines. This directive was enacted under subregulation 39.1 (1) of the Civil Aviation Regulations 1998 (CAR 1998) to ensure the airworthiness of the affected aircraft by mandating specific inspections and repairs to prevent potential in-flight safety hazards. The policy objective of the directive is to mitigate the risks associated with chafing damage to wire bundles, which could lead to critical failures such as inadvertent thrust overboost, loss of thrust, or engine shutdown. The directive applies to all Model 767 series aeroplanes, line numbers 1 through 821 inclusive, and requires a one-time detailed visual inspection of the wire bundles in the aft section of the strut forward fairing panel of both engine struts, followed by necessary repairs or replacements to ensure the integrity of the wiring systems.

Scope and Application

The Airworthiness Directive (AD) applies specifically to Boeing 767 series aeroplanes, line numbers 1 through 821 inclusive, which are equipped with Pratt & Whitney PW4000 series engines. The AD mandates a series of actions to address an identified unsafe condition related to the engine strut wire bundles. These actions include a one-time detailed visual inspection to detect chafing damage, repair of any detected damage, replacement of wires that have been repaired by splicing, and certain modifications to the wire bundle support brackets. The directive mandates reporting of inspection results to Boeing Commercial Airplane Group and prohibits the installation of certain existing support brackets in the specified area. Compliance with the AD must be achieved within specified timeframes, with some actions required before further flight and others within a set number of hours in service or a set number of months following the AD's effective date. The AD extends its application nationally across the Commonwealth of Australia, ensuring that all operators of the specified aircraft models adhere to these safety requirements.

Key Provisions

The main operative sections of this Airworthiness Directive (AD) set out the requirements for certain actions to be taken on Boeing 767 Series Aeroplanes, specifically those equipped with Pratt & Whitney PW4000 series engines. According to section 2 of the AD, a detailed visual inspection of the wire bundles located in the aft section of the strut forward fairing panel of both engine struts is required to detect chafing damage. If such damage is found during the inspection, the wire bundles must be repaired in accordance with Boeing Service Bulletin (SB) 767-73A0049, Revision 3 or 4. Moreover, all wires that were repaired by splicing must be replaced with new wires as per the same Boeing Service Bulletin. In addition, the existing support brackets of the wire bundles must be replaced with new bridge brackets, support brackets, and wire bundle clamps, as outlined in the Accomplishment Instructions of Boeing SB 767-73-0051. The inspection results must be reported to Boeing Commercial Airplane Group within 10 days after the inspection or the required actions are completed. Finally, the support brackets identified in Paragraph 2.E of Boeing SB 767-73-0051 must not be installed on any aeroplane. The AD imposes several obligations and requirements on the parties governed by it. The primary requirement is the performance of a one-time detailed visual inspection of the specified wire bundles, as defined in the AD. This inspection must be conducted in accordance with the instructions provided in Boeing SB 767-73A0049, Revision 3 or 4, or the Boeing Standard Wiring Practices Manual. If chafing damage is detected during the inspection, the damaged wire bundles must be repaired and any wires that were repaired by splicing must be replaced with new wires. The existing support brackets of the wire bundles must also be replaced with new brackets and clamps as per Boeing SB 767-73-0051. Finally, the inspection results must be reported to Boeing Commercial Airplane Group within the specified timeframe. The AD does not explicitly outline any specific offences, penalties, or civil/criminal consequences for breach. However, non-compliance with the requirements set out in the AD may result in the aircraft being deemed unairworthy. This could potentially lead to the aircraft being grounded, which could have severe consequences for the operator, including financial losses and reputational damage. Additionally, failure to comply with the AD may result in regulatory action being taken against the operator, such as fines or other penalties imposed by the Civil Aviation Safety Authority (CASA). The AD may also have implications for insurance coverage, as non-compliance with regulatory requirements may result in a denial of claims or increased insurance premiums.

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Sourced from the Federal Register of Legislation at 26 August 2026. For the latest information on Australian Government law please go to https://www.legislation.gov.au.