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/LYC/117 Amdt 1 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.
Lycoming Piston Engines
AD/LYC/117 Amdt 2
Lycoming Crankshaft Replacement
11/2012
 
Applicability:
Lycoming Engines (L)O-360, (L)IO-360, AEIO-360, O-540, IO-540, AEIO-540, (L)TIO-540, IO-580, and IO-720 series reciprocating engines listed by engine model number and serial number in Table 1, Table 2, Table 3, or Table 4 of Lycoming Mandatory Service Bulletin (MSB) 569A dated 11 April 2006, and those engines with crankshafts listed by crankshaft serial number (S/N) in Table 5 of MSB 569A.
This AD is NOT applicable if the engine meets any of the following conditions, and the crankshaft has not been replaced since meeting the condition:
A.   Engines that are in compliance with:
i)     CASA AD/LYC/107 or Lycoming MSB No. 552 or MSB No. 553; or
ii)    CASA AD/LYC/112 or Lycoming MSB No. 566 or AD/LYC/115 or Lycoming MSB 566 Supplement 1; or
iii)   Lycoming MSB No. 569, or MSB No. 569A; or
B.   Lycoming Engines manufactured new, rebuilt, overhauled, or repaired the engine, or replaced the crankshaft in the engine before 1 January 1997, and the crankshaft has not been replaced since then; or
C.   Table 1, Table 2, Table 3, or Table 4 of Lycoming MSB No. 569A lists the engine S/N, and Table 5 of MSB No. 569A does not list the crankshaft S/N; or
D.   Lycoming engine model TIO-540-U2A with serial number (S/N) L-4641-61A.
Note 1:  If it was previously determined that the engine and/or crankshaft was not affected only by using the start date of March 1, 1997, then the engine and/or crankshaft may be affected.  Verify that the engine and/or crankshaft S/N is not published in Service Bulletin No. 569A.  If the engine and/or crankshaft S/N is not published in Service Bulletin No. 569A, then no further action is required.  If the engine and/or crankshaft S/N is published in Service Bulletin No. 569A, follow the instructions for compliance.

Requirement:
1.    If Table 5 of Lycoming MSB No. 569A dated 11 April 2006 lists the crankshaft S/N, replace the affected crankshaft with a crankshaft that is not listed in Table 5 of MSB No. 569A.
2.    Do not install any crankshaft that has a S/N listed in Table 5 of Lycoming MSB No. 569A into any engine.
Note 2:  FAA AD 2006-20-09 Amendment 39-14778 dated 29 September 2006 refers.

Compliance:
1.    At the earliest of the following, after the original effective date of this AD:
i)     The time of the next engine overhaul as specified in Lycoming Engines Service Instruction No. 1009AU dated 18 November, 2009; or subsequent revision approved by FAA (DER).; or
ii)    The next separation of the crankcase; or
iii)   No later than 12 years from the time the crankshaft first entered service or was last overhauled, whichever is later.
2.    After the original effective date of this AD.

 
This Amendment becomes effective on 4 June 2012.

Background:
This AD results from reports of 23 confirmed failures of similar crankshafts in Lycoming Engines 360 and 540 series reciprocating engines.  CASA is issuing this AD to prevent failure of the crankshaft, which will result in total engine power loss, in-flight engine failure, and possible loss of the aircraft.
This amendment corrects an error in the date published in the applicability section of this AD.  This amendment requires further assessment of those engines/crankshafts that were previously assessed using the start date of March 1, 1997.  If this date was used the engine/crankshaft may still be affected.  The date has been amended in response to the manufacturer issuing supplement No. 1 to the referenced MSB 569A.
Amendment 2 of this AD changes the compliance statement 1.i) to reference Lycoming Engines Service Instruction No. 1009AU dated 18 November, 2009; or subsequent revision approved by FAA (DER), thus ensuring correct referencing of future revisions of this bulletin.
Amendment 1 of this AD became effective on 24 September 2009.
The original issue of this AD became effective 23 November 2006.

Mike Higgins
Delegate of the Civil Aviation Safety Authority
30 May 2012