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737 Classic Trailing Edge Flap Carriage Solution

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737 Classic Trailing Edge Flap Carriage Solution. 737C Carriage Installation. 737 Classic Fleet Concern TE Flap Carriage Spindle Fractures. - PowerPoint PPT Presentation

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Page 1: 737 Classic Trailing Edge  Flap Carriage Solution

737 Classic Trailing Edge Flap Carriage Solution

Page 2: 737 Classic Trailing Edge  Flap Carriage Solution

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737C Carriage Installation

Page 3: 737 Classic Trailing Edge  Flap Carriage Solution

Fracture of both inboard and outboard flap carriage spindles in the critical “A” location or through the “B” location to the cross bolt on an outboard flap may preclude continued safe flight and landing of the airplane.

Southwest Airlines experienced the first reported “dual fracture” during approach for landing in November 2003.

A

B Fractures in this area are caused primarily by corrosion on the carriage spindles.

737 Classic Fleet ConcernTE Flap Carriage Spindle Fractures

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Page 4: 737 Classic Trailing Edge  Flap Carriage Solution

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AD 2003-24-08 states that the FAA considered the requirements given “interim action” and that they were considering further rulemaking. The FAA has now determined that further rulemaking is necessary.

Effectivity: 737-100/-200/-200C/-300/-400/-500 Series Aircraft

Actions:

Would supersede AD 2003-24-08.

Comply with Gap Check and NDT inspections described in SB 57A1277.

Comply with spindle diameter limits specified in SB 57A1218.

Overhaul carriage spindles > 12,000 cycles or 8 years of service.

Life limit of 48,000 cycles mandatory.

FAA Notice of Proposed Rule Making2009-NM-076-AD

Page 5: 737 Classic Trailing Edge  Flap Carriage Solution

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AD 2009-23-10 states that the FAA considered the requirements given “interim action” and that they were considering further rulemaking. The FAA has now determined that further rulemaking is necessary.

Effectivity: 737-100/-200/-200C/-300/-400/-500 Series Aircraft

Actions:

Would supersede AD 2009-23-10.

Same requirements of AD 2009-23-10 with one exception.

Optional Terminating action to replace or rework suspect HVOF bases would be made mandatory IAW SB 737-57A1304 (Within 4 years after Aug 11th 2009).

FAA Notice of Proposed Rule Making2009-NM-210-AD

Page 6: 737 Classic Trailing Edge  Flap Carriage Solution

Issued to provide instructions for the inspection of the HVOF coated carriage spindles for corrosion and thermal spray flaking.

Effectivity: 737-300, -400, -500 Series Aircraft (carriages installed during overhaul or replacement after February 2006)

Inspections:

Review of records to determine if applicable carriage has been installed

Detailed or borescope inspection of applicable carriage spindle

Gap check or NDT (ultrasonic) inspection of applicable carriage spindle

Applicable carriages require rework or replacement. Contact Boeing for part disposition.

SB 737-57A1304 is made mandatory by FAA AD 2009-23-10 (Supersedes AD 2008-15-05).

CMM 57-53-36 includes instructions for rework and/or replacement of all suspect carriages.

Boeing / FAA ActionSB 737-57A1304 Rev 1, 8/11/09

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Inspection IntervalsCondition Action Compliance Time Repeat Interval

(Not to Exceed)

All Airplanes Records inspection to find suspect HVOF carriage spindles (refer to applicable S/N’s)

Within 30 days after Aug 5th, 2008.

Not Applicable

Airplanes with applicable HVOF carriage spindles (refer to applicable S/N’s)

Detailed inspection or borescope inspection of carriage spindle

Within 30 days after Nov 24th 2009 or 90 days from installation of a HVOF carriage spindle, whichever occurs later;

90 Day

If No Corrosion is Found Gap check or NDT (ultrasonic) inspection per SB 57A1277

Before Further Flight 15 days or 150 flight cycles, whichever occurs later

If Potential Indications are Found

Detailed inspection of entire spindle surface

Before Further Flight Not Applicable

If Corrosion is Found Replace Carriage Before Further Flight Not Applicable

If Severed Spindle is Indicated Replace Carriage Before Further Flight Not Applicable

Airplanes with applicable HVOF carriage spindles (refer to applicable S/N’s)

Replace or refurbish the carriage. Refurbished carriages have “R” added to S/N

Within 4 years after 11-Aug-2009

Replacement or refurbishment terminates inspections.

Boeing / FAA ActionAD 2009-23-10 Effective: 11/24/09

Optional Terminating

Action*

* FAA NPRM 2009-NM-210-AD would make the optional terminating action mandatory if adopted.

Page 8: 737 Classic Trailing Edge  Flap Carriage Solution

Issued to provide instructions for removal, inspection, and overhaul of outboard carriage spindles. Revision 4 of this SB (6/19/07) recommends a finite life limit for carriage sub-assemblies. Prior to Revision 4, carriages were not life limited.

Effectivity: 737-100/-200/-200C/-300/-400/-500 Series Aircraft

Actions:

Records inspection for carriage spindle life limit

Detailed inspection of carriage spindle for corrosion

Overhaul carriage spindles > 12,000 cycles or 8 years of service.

Fractured or severed spindles require replacement, corroded spindles may be overhauled per CMM 57-53-35 (-200 series) or 57-53-36 (-300 series)

FAA Notice of Proposed Rule Making: 2009-NM-076-AD. The proposed AD would supersede AD 2003-24-08 and require both repetitive inspections and compliance with

the Life Limit recommended by SB 757A1218.

Boeing / FAA ActionSB 737-57A1218 Rev 5, 2/9/09

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Life Limit Compliance

Condition Action Compliance Time

737-100/-200/-200C 737-300/-400/-500

Airplanes with an undocumented carriage or a documented carriage > 48,000 total cycles

Replace carriage with a new or documented carriage

Within 3 years from 19-Jun-2007 or within 7,500 flight cycles from 19-Jun-2007, whichever occurs first

Within 6 years from 19-Jun-2007 or within 15,000 flight cycles from 19-Jun-2007, whichever occurs first.

Airplanes with a documented carriage having < 48,000 total cycles

Replace carriage with new or documented carriage

Prior to carriage accumulating 48,000 cycles or as defined by one of the compliance criteria above, whichever is later.New (zero time) carriages shall not go over 48,000 cycles.

Prior to carriage accumulating 48,000 cycles or as defined by one of the compliance criteria above, whichever is later.New (zero time) carriages shall not go over 48,000 cycles.

Boeing / FAA ActionSB 737-57A1218 Rev 5, 2/9/09

Page 10: 737 Classic Trailing Edge  Flap Carriage Solution

Issued to provide instructions for the inspection of the outboard midflap carriage spindles to detect fractured, severed, or corroded carriage spindles.

Effectivity: 737-100, -200, -200C, -300, -400, -500 Series Aircraft

Inspections:

NDT Inspection (Ultrasonic Inspection)

Gap Check

Fractured or severed spindles require replacement, corroded spindles require overhaul per CMM 57-53-35 (-200 series) or 57-53-36 (-300 series) and SB 737-57A1218 Rev 5 (or later).

SB 737-57A1277 is made mandatory by FAA AD 2003-24-08.

Boeing / FAA ActionSB 737-57A1277 Rev 1, 11/25/03

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Page 11: 737 Classic Trailing Edge  Flap Carriage Solution

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Inspection Intervals

New Carriages (Never Been Overhauled)

737-100 thru -500

Days Cycles

> 20,000 Cycles or 8 years in service, whichever is less

Gap Check 3 30

Ultrasonic NDT 60 600

12,000 to 20,000 Cycles Gap Check 15 150

Ultrasonic NDT 180 1500

< 12,000 Cycles Gap Check N/A N/A

Ultrasonic NDT N/A N/A

Boeing / FAA ActionSB 737-57A1277 Rev 1, 11/25/03

Page 12: 737 Classic Trailing Edge  Flap Carriage Solution

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Inspection Intervals

Previously Overhauled Carriages

737-100/-200 737-300/-400/-500

Days Cycles Days Cycles

> 20,000 Cycles Gap Check 1 20 3 30

Ultrasonic NDT

6 60 15 150

12,000 to 20,000 Cycles or 8 years in service since last OH, whichever is less

Gap Check 3 30 3 30

Ultrasonic NDT

15 150 15 150

3,000 to 11,999 Cycles

Gap Check 7 70 14 140

Ultrasonic NDT

60 500 180 1500

< 3,000 Cycles Gap Check N/A N/A N/A N/A

Ultrasonic NDT

180 1500 N/A N/A

Boeing / FAA ActionSB 737-57A1277 Rev 1, 11/25/03

Page 13: 737 Classic Trailing Edge  Flap Carriage Solution

Issued to provide instructions to rework applicable carriages by replacing roller bearings with new, self-lubricated bearings.

Effectivity: 300/-400/-500 Series Aircraft, Line Positions 1001-3132

Actions:

Remove existing roller bearings and replace with new self-lubricated bearings

No Compliance Time is Given

Other Boeing Action…SB 737-57-1227 Rev 2, 5/16/06

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Page 14: 737 Classic Trailing Edge  Flap Carriage Solution

Issued to provide instructions to rework applicable carriages by machining clearance chamfers on the carriage detents and side roller assemblies.

Effectivity: 300/-400 Series Aircraft, Line Positions 1001-1698

Actions:

Chamfer detent lugs and side roller fittings

No Compliance Time is Given

Other Boeing Action…SB 737-57-1181 Rev 6, 6/22/95

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Page 15: 737 Classic Trailing Edge  Flap Carriage Solution

Base Carriage Replacement and Identification

Many 737C TE Flap Carriage Bases are being removed from service due to undersize spindle ODs. Boeing no longer allows any repair to spindles that are out of CMM limits.

Ongoing Industry Issue

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Position Old Carriage Sub AssyNew Carriage Sub

Assy

Outboard Flap,OutboardCarriage WBL 355

65C27409-565C27409-965C27409-1365C27409-1765C27409-25 65C27409-29

Outboard Flap,Inboard CarriageWBL 254

65C27409-665C27409-1065C27409-1865C27409-2165C27409-2365C27409-27 65C27409-31

Note: Interchangeabilities listed above based on PN 65C27409-29 and -31 APL.

Base Carriage Interchangeability

Page 17: 737 Classic Trailing Edge  Flap Carriage Solution

New Carriage Sub Assy

New Carriage PNs (Bearings that need Lubrication)

New Carriage PNs (Bearings that are Self-Lubricated)

65C27409-2965-46481-145XXX (L/H)65-46481-146XXX (R/H)

65-46481-149XXX (L/H)65-46481-150XXX (R/H)

65C27409-3165-46481-143XXX (L/H)65-46481-144XXX (R/H)

65-46481-147XXX (L/H)65-46481-148XXX (R/H)

Note: (L/H) or (R/H) designates position of carriage on the aircraft. Do not mark (L/H) or (R/H) on reworked carriages.**XXX is customer assigned suffix showing that a new base carriage has been used.

*Exa

mpl

e O

nly*

New Carriage Sub Assy New Carriage PNs

65C27409-2965C34483-7XXX (L/H)65C34483-8XXX (R/H)

65C27409-3165C34483-5XXX (L/H)65C34483-6XXX (R/H)

Note: (L/H) or (R/H) designates position of carriage on the aircraft. Do not mark on reworked carriages.**XXX is customer assigned suffix showing that a new base carriage has been used.

Typical Re-Part Marking of Carriages Used by Some Airlines

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Page 18: 737 Classic Trailing Edge  Flap Carriage Solution

The Outboard Flap Carriage Assy. supports the Flap on the Flap Track and moves the Flap during

extension or retraction.

Curtiss-Wright Repair Station Capability Complete spindle overhaul capability Turn Around Time

Multiple scenarios, but normally 17 calendar days or less

Flat-Rate overhaul pricing available: Greased bearing configurations Greaseless bearing configurations

Exchange Units Available

FAA Directives 2009-NM-076-AD – SB 737-57A1218/1277 AD 2009-23-10 – SB 737-57A1304 AD 2003-24-08 – SB 737-57A1277

Major Service Bulletins 737-57A1304 – HVOF Spindle

Inspection 737-57A1218 – Spindle OH / Life

Limit 737-57A1277 – Spindle Inspection 737-57-1227 – Self-lubricated

Bearings 737-57-1181 – Toggle Interference

737-300/-400/-500 (CMM 57-53-36)

65C34483-5 thru -8

65-46481-87 thru -94, -97 thru -136, -144 thru -150

Part Numbers – 737-100/-200 (CMM 57-53-35) 65-79949-1 thru -8

65-46481-1 thru -86, -95, -96

737C Flap Carriage Summary

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