{"id":"F2008L02854","name":"AD/DA40/8 - Flight Controls - Aileron Bellcrank and Rod Ends","slug":"ad-da40-8-flight-controls-aileron-bellcrank-and-rod-ends","collection":"legislative_instrument","jurisdiction":"commonwealth","status":"in_force","isInForce":true,"actNumber":null,"makingDate":null,"administeringDepartment":null,"currentVersion":{"id":74729,"registerId":"commonwealth-F2008L02854-current","compilationNumber":null,"startDate":"2026-04-02","status":"InForce","reasons":null,"registeredAt":null},"sections":[{"sectionNumber":"Diamond DA40 Series Aeroplanes","sectionType":"division","heading":"Diamond DA40 Series Aeroplanes","content":"### Diamond DA40 Series Aeroplanes\n\n| AD/DA40/8 | Flight Controls - Aileron Bellcrankand Rod Ends | 9/2008 |\n| --------- | ----------------------------------------------- | ------ |\n\n| Applicability: | Diamond Aircraft Industries GmbH - Austria, and Shandong Bin Ao Aircraft Industries Co., Limited - People’s Republic of China DA 40 D aircraft with Part Number (P/N) DA4-2717-50-00 aileron bellcranks or P/N DA4-2757-30-00 flap bellcranks installed.Note 1: The following DA 40 D aircraft are known to have been delivered with P/N DA4-2717-50-00 aileron bellcranks, P/N DA4-2757-30-00 flap bellcranks and bent P/N DAI-9027-00-01 rod ends installed: Serial numbers 40.080, 40.084, D4.001 through D4.188, D4.190 through D4.261, D4.263 through D4.317, D4.326 through D4.329 and 40.DS001 through 40.DS004.             |\n| -------------- | ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- |\n| Requirement:   | 1. Replace the P/N DA4-2717-50-00 aileron bellcrank with the improved design P/N DA4-2717-50-00-01 aileron bellcrank; replace each P/N DA4-2757-30-00 flap bellcrank with the improved design P/N D60-2757-30-00 flap bellcrank and replace any bent rod ends with straight parts, in accordance with Diamond Aircraft Industries GmbH MSB-D4-059 dated 14 February 2008 orMSB-D4-059/1 dated 31 March 2008 or later NAA approved revision.2. Do not install a P/N DA4-2717-50-00 aileron bellcrank or P/N DA4-2757-30-00 flap bellcrank or any bent rod ends on that aircraft.Note 2: EASA AD 2008-0114 dated 12 June 2008 refers. |\n| Compliance:    | For Requirement 1: Within the next 200 flight hours after the effective date of this AD, unless previously accomplished.For Requirement 2: From the effective date of this AD.                                                                                                                                                                                                                                                                                                                                                                                                                                                      |\n|                | This Airworthiness Directive becomes effective on 28 August 2008.                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                   |\n\n| Background: | The original designed bellcranks for the aileron and flap control system in the wing needed to be installed with slightly bent rod ends during production of the aircraft to avoid friction and possible chafing. In addition to being a non-preferable production practice, this creates the risk of replacement parts being installed during subsequent in-service maintenance without being bent or not being bent correctly. This condition, if not detected and corrected, could lead to chafing damage of the aileron or flap control system and consequent loss of control of the aircraft. Diamond Aircraft Industries has now developed new bellcranks that allow for additional angular movement of the push rod, thereby eliminating the chafing risk without using bent rod ends. This AD requires the replacement of the aileron- and flap bellcranks with improved parts and the replacement of any bent rod ends. In addition, this AD prohibits reinstallation of P/N DA4-2717-50-00 aileron bellcranks, P/NDA4-2757-30-00 flap bellcranks and bent rod ends P/N DAI-9027-00-01 as replacement parts. |\n| ----------- | --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- |\n\n![](image.001.png)  \nJames Coyne  \nDelegate of the Civil Aviation Safety Authority\n\n16 July 2008","sortOrder":0},{"sectionNumber":"AD/DA40/8","sectionType":"part","heading":"AD/DA40/8","content":"## AD/DA40/8","sortOrder":1},{"sectionNumber":"Flight Controls - Aileron Bellcrankand R","sectionType":"part","heading":"Flight Controls - Aileron Bellcrankand Rod Ends","content":"## Flight Controls - Aileron Bellcrank  \nand Rod Ends","sortOrder":2},{"sectionNumber":"9/2008","sectionType":"part","heading":"9/2008","content":"## 9/2008","sortOrder":3}],"analysis":{"flash_summary_failed":{"failed":true,"reason":"A positive credit balance is required for all requests, including BYOK, so fallback providers remain available. Add credits at https://vercel.com/d?to=%2F%5Bteam%5D%2F%7E%2Fai%3Fmodal%3Dtop-up to continue.","source":"analysis-cron"},"flash_summary":{"complexity_score":3,"scope_assessment":{"changed":false,"description":"The AD’s scope aligns with the safety issue described in the Background: eliminate chafing by replacing specified bellcranks and bent rod ends and prohibiting their reinstallation. It targets explicitly identified part numbers and serial ranges and imposes a clear compliance deadline (Requirement 1–2; Compliance). It does not broaden to unrelated components or aircraft types beyond those listed."},"complexity_factors":["Narrow, part-numbered applicability (specific P/Ns and listed serial numbers) increases precision but requires accurate record checks (Applicability).","Mandatory replacement with specific improved P/Ns and removal of bent rod ends creates straightforward technical work but imposes parts and labour costs on owners/operators (Requirement 1).","Immediate ban on reinstalling legacy parts requires continuous compliance at every maintenance action (Requirement 2; Compliance).","Fixed compliance window of \"within the next 200 flight hours\" creates scheduling constraints for operators (Compliance).","Dependence on manufacturer service bulletins MSB-D4-059 / MSB-D4-059/1 or later NAA-approved revisions links execution to those documents and any updates (Requirement 1).","Reference to an EASA AD and NAA approval introduces multi-jurisdictional regulatory alignment considerations (Requirement note).","Inspection to identify ‘bent’ rod ends and correct parts may require hands-on maintenance checks rather than simple paperwork verification (Background)."],"plain_english_summary":"This Airworthiness Directive requires owners/operators of specified Diamond DA40 D aeroplanes fitted with particular aileron and flap bellcranks or bent rod ends to replace those parts with redesigned components and to stop reinstalling the old parts. It sets a 200-flight-hour deadline to complete replacements and takes effect immediately for the prohibition. The change aims to remove a chafing risk in the control system that could lead to loss of control."},"kimi_summary":{"content_quality":"ok","complexity_score":3,"scope_assessment":{"changed":false,"description":"This is a targeted safety directive addressing a specific manufacturing defect in a specific aircraft type. The scope remains precisely limited to the aileron and flap bellcrank issue described in the background. No scope creep is evident."},"complexity_factors":["Short, single-purpose directive with only 2 requirements","Limited applicability — specific aircraft model (DA40 D) and specific serial numbers listed exhaustively","Only 3 part numbers to track (2 bellcrank types plus rod ends)","Simple compliance structure: replacement deadline plus immediate prohibition","Single cross-reference to European aviation safety document (EASA AD 2008-0114)","No nested definitions, no conditional logic beyond the applicability criteria","Background section explains the engineering rationale in plain language"],"plain_english_summary":"This AD mandates replacement of faulty wing control components on specified Diamond DA40 D aeroplanes (listed by serial number) to remove factory‑installed bent rod ends and upgraded bellcranks. It affects owners/operators of those aircraft and prohibits reinstalling the old parts.\n\nIt matters because the bent components can lead to chafing, flight‑control failure and loss of control; compliance is required within 200 flight hours from 28 Aug 2008."}},"importantCases":[],"_links":{"self":"/api/acts/ad-da40-8-flight-controls-aileron-bellcrank-and-rod-ends","history":"/api/acts/ad-da40-8-flight-controls-aileron-bellcrank-and-rod-ends/history","analysis":"/api/acts/ad-da40-8-flight-controls-aileron-bellcrank-and-rod-ends/analysis","conflicts":"/api/acts/ad-da40-8-flight-controls-aileron-bellcrank-and-rod-ends/conflicts","importantCases":"/api/acts/ad-da40-8-flight-controls-aileron-bellcrank-and-rod-ends/important-cases","documents":"/api/acts/ad-da40-8-flight-controls-aileron-bellcrank-and-rod-ends/documents"}}