{"id":"F2005L03921","name":"AD/PHZL/85 - Propeller Blade Thrust Bearing","slug":"ad-phzl-85-propeller-blade-thrust-bearing","collection":"legislative_instrument","jurisdiction":"commonwealth","status":"in_force","isInForce":true,"actNumber":null,"makingDate":null,"administeringDepartment":null,"currentVersion":{"id":39736,"registerId":"commonwealth-F2005L03921-current","compilationNumber":null,"startDate":"2026-04-01","status":"InForce","reasons":null,"registeredAt":null},"sections":[{"sectionNumber":"Propellers - Variable Pitch - Hartzell","sectionType":"division","heading":"Propellers - Variable Pitch - Hartzell","content":"### Propellers - Variable Pitch - Hartzell\n\n| AD/PHZL/85 | Propeller Blade Thrust Bearing | 1/2006 |\n| ---------- | ------------------------------ | ------ |\n\n| Applicability: | Hartzell Propeller Inc. model HD-E6C-3( ) propellers.Note 1: These propellers are installed on, but not limited to Fairchild Dornier GmbH 328-100 series aeroplanes.Note 2: The parentheses indicate the presence or absence of an additional letter(s) which vary the basic propeller blade model designation. This AD still applies regardless of whether these letters are present or absent on the propeller blade model designation.                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                               |\n| -------------- | --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- |\n| Requirement:   | 1. Unless previously accomplished in accordance with Hartzell ASBHD-ASB-61-026, dated 6 August 2001, or Hartzell Service LetterHD-SL-61-034, dated 7 May 2001, replace all propeller blade thrust bearings, part numbers (P/N's) C-2882-1, C-2882-2, and C-7075, with thrust bearings P/N C- 7438, in accordance with paragraph 3 of the Accomplishment Instructions of Hartzell Alert Service Bulletin (ASB) HD-SB-61-026 or later FAA approved revisions.Propellers that have had blade thrust bearings replaced using Hartzell ASBHD-ASB-61-026, dated 6 August 2001, or Hartzell Service LetterHD-SL-61-034, dated 7 May 2001, are considered to be in compliance with Requirement 1 of this AD.2. Unless previously accomplished perform a visual inspection of the propeller hub for cracks, in accordance with paragraph 3 of the Accomplishment Instructions of Hartzell Alert Service Bulletin ASB HD-ASB-61-023, Revision 1, dated 23 May 2001 or later FAA approved revisions.3. Unless previously accomplished perform an eddy current inspection (ECI) of the propeller hub for cracks, in accordance with paragraph 3 of the Accomplishment Instructions of Hartzell ASB HD-ASB-61-023, Revision 1, dated 23 May 2001 or later FAA approved revisions.4. Remove from service cracked propeller hubs and replace with a serviceable hub.5. Do not install propeller blade thrust bearings P/N's C-2882-1, C-2882-2, orC-7075 into any HD-E6C-3( ) Hartzell propeller models.Note 3: FAA AD 2002-22-08 Amdt 39-12933refers. |\n| Compliance:    | For Requirement 1, 2 and 3:Within 50 hours time-in-service (TIS) after the effective date of this AD, or nine months after the effective date of this AD, or when the propeller is next disassembled after the effective date of this AD, whichever occurs first.4. Before further flight after the effective date of this AD.5. After the effective date of this AD.                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                   |\n|                | This Airworthiness Directive becomes effective on 19 January 2006.                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      |\n| Background:    | The FAA and Hartzell Propeller Inc. have been reviewing and investigating reports of current design propeller blade thrust bearings, P/N's C-2882-1, C-2882-2, andC-7075, found fractured during disassembly, one or more blades becoming jammed in position during operation, pitch change fork fractures causing loss of blade pitch control, and excessive vibration. The current design thrust bearings have demonstrated a tendency to have brittle fracture and reduced strength characteristics, for which the cause has yet to be determined. This action requires replacement of the current design propeller blade thrust bearings, P/N's C-2882-1, C-2882-2, andC-7075, with a new design propeller blade thrust bearing, P/N C-7438, and a 10X magnification-assisted visual inspection and ECI of propeller hubs for cracks. This condition, if not corrected, could result in loss of aircraft control due to loss of blade pitch control, inability to fully feather the propeller, hub fracture, and blade release.                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     |\n\n![](image.001.png)  \nJames Coyne  \nDelegate of the Civil Aviation Safety Authority\n\n30 November 2005","sortOrder":0},{"sectionNumber":"AD/PHZL/85","sectionType":"part","heading":"AD/PHZL/85","content":"## AD/PHZL/85","sortOrder":1},{"sectionNumber":"Propeller Blade Thrust Bearing","sectionType":"part","heading":"Propeller Blade Thrust Bearing","content":"## Propeller Blade Thrust Bearing","sortOrder":2},{"sectionNumber":"1/2006","sectionType":"part","heading":"1/2006","content":"## 1/2006","sortOrder":3}],"analysis":{"kimi_summary":{"content_quality":"ok","complexity_score":3,"scope_assessment":{"changed":false,"description":"This AD maintains its original narrow scope — addressing a specific safety defect in a specific propeller model series. The document does not show evidence of scope creep; it remains tightly focused on the bearing replacement and hub inspection requirements arising from the identified failure mode."},"complexity_factors":["Single, specific technical subject matter (one propeller model series)","Five distinct but clearly numbered requirements","Straightforward compliance timeline with three alternative triggers (hours/time/disassembly)","Minimal cross-referencing — only references to specific Hartzell Service Bulletins and one FAA AD","No nested exceptions or conditional logic beyond 'unless previously accomplished' clauses","Clear applicability section with simple parenthetical notation explained","Approximately 8 defined part numbers and model references, all explicitly listed"],"plain_english_summary":"This is an **Airworthiness Directive (AD)** — a mandatory safety order issued by Australia's Civil Aviation Safety Authority (CASA). Think of it as a recall notice for aircraft parts, but with legal force.\n\n**What it does:**\nThis directive orders owners and operators of specific Hartzell propellers (model HD-E6C-3) to replace faulty blade thrust bearings and inspect the propeller hubs for cracks. The bearings in question (part numbers C-2882-1, C-2882-2, and C-7075) have been failing — cracking, jamming blades, or causing vibrations that could make the aircraft uncontrollable.\n\n**Who it affects:**\n- Anyone operating aircraft with Hartzell HD-E6C-3 propellers (commonly found on Fairchild Dornier 328-100 planes)\n- Maintenance organisations servicing these propellers\n- Essentially: if you own, operate, or maintain one of these propellers in Australia, you must comply\n\n**What must be done:**\n1. **Replace the bearings** — Swap out the faulty bearings for a new, improved design (part number C-7438)\n2. **Inspect the hub visually** — Check for cracks using 10x magnification\n3. **Eddy current inspection** — A specialised non-destructive test using electromagnetic fields to detect hidden cracks in the hub\n4. **Remove cracked hubs** — Any cracked hubs must be taken out of service immediately\n5. **Ban on reinstallation** — The old bearing models can never be installed in these propellers again\n\n**Why it matters:**\nThe faulty bearings can fracture without warning, causing blades to jam, pitch control to fail, or even blades to detach entirely. This could lead to catastrophic loss of aircraft control. The directive gives operators a window (50 flight hours, 9 months, or next disassembly — whichever comes first) to get the work done, with immediate action required if cracks are found."},"flash_summary":{"complexity_score":4,"scope_assessment":{"changed":false,"description":"The instrument is a targeted airworthiness directive addressing a specific hardware failure mode (brittle fracture of certain thrust bearing P/Ns) and prescribing a replacement and inspections. It does not expand beyond that original corrective safety purpose. The AD clarifies applicability (including model suffix variants), accepts prior compliance under specified Hartzell documents, and harmonises with FAA material, but these are within the original remedial scope rather than a significant scope expansion."},"complexity_factors":["Multiple discrete mandatory actions (replace bearings, visual inspection with 10× magnification, eddy‑current inspection, remove cracked hubs, installation prohibition)","Cross‑references to multiple Hartzell service documents (ASB HD‑ASB‑61‑026, HD‑ASB‑61‑023 Rev 1, and Service Letter HD‑SL‑61‑034) and allowance for later FAA‑approved revisions","Conditional compliance timing with three alternative triggers (50 TIS hours, nine months, or next disassembly)","List of specific part numbers to be removed (C‑2882‑1, C‑2882‑2, C‑7075) and the replacement P/N (C‑7438)","Applicability wording covering model suffix variations (HD‑E6C‑3( ) with or without additional letters) and a non‑exhaustive list of installed aircraft (note re Dornier 328‑100)","Interaction with prior compliance (previously completed work per certain ASBs/service letter is accepted) creating an exception pathway","Reference to an external FAA AD (FAA AD 2002‑22‑08) for related regulatory context"],"plain_english_summary":"**What this instrument does (mechanically)\n\n- Requires operators and maintainers to replace certain older-design propeller blade thrust bearings with a new-design bearing on Hartzell HD‑E6C‑3( ) variable‑pitch propellers. Specifically, bearings with part numbers (P/N) C-2882-1, C-2882-2, and C-7075 must be replaced by P/N C-7438 (Requirement 1).\n- Requires a visual inspection (with 10× magnification) and an eddy‑current inspection (ECI) of the propeller hub for cracks, and mandates removal and replacement of any cracked hubs (Requirements 2–4).\n- Prohibits installing the old bearing part numbers (C-2882-1, C-2882-2, C-7075) into any HD‑E6C‑3( ) propeller after the effective date (Requirement 5).\n- Cross‑references Hartzell Alert Service Bulletins (ASBs) for the exact inspection and replacement procedures and allows compliance when those ASBs (or later FAA‑approved revisions) have been followed.\n- Sets deadlines for compliance: replace bearings and perform inspections within 50 flight hours, or within nine months, or at the next propeller disassembly (whichever comes first). If a cracked hub is found, it must be removed before further flight (Compliance).\n\n**Who this affects\n\n- Aircraft operators and owners that use Hartzell HD‑E6C‑3( ) propellers. The AD specifically notes these propellers are installed on (but not limited to) Fairchild Dornier 328‑100 series aircraft (Applicability).\n- Licensed maintenance organisations and mechanics who perform propeller maintenance and inspections under Hartzell ASBs. They must perform the specified replacement and inspection work and document compliance.\n- Parts suppliers and inventory managers, because affected bearings must be removed from stock and new‑design bearings supplied instead.\n\n**Why it matters (stated purpose and practical effect)\n\n- Stated purpose: reports showed brittle fractures and failures in the older thrust bearing design (P/Ns C-2882‑1, C-2882‑2, C-7075) during disassembly and operation; those failures can lead to blades jamming, pitch‑change fork fractures, loss of blade pitch control, inability to feather, hub fracture, or blade release (Background).\n- Practical effect: the required replacements and inspections reduce the risk of in‑flight propeller control failures by substituting a new bearing design (P/N C‑7438) and checking hubs for crack damage.\n\n**Who pays, who decides, and what behaviour changes\n\n- Who pays: aircraft operators and owners pay for parts (new bearings), labour for replacement, inspections (including ECI equipment or contracted service), and any hub replacement. There is also indirect cost from aircraft downtime while work is done.\n- Who decides: the regulator requires compliance; actual work and method are implemented by operators and their authorised maintenance organisations following Hartzell ASBs (Requirement text and cross‑references).\n- Behaviour changes: operators must remove and stop using specified old bearings, introduce a new part into maintenance cycles, add routine inspections (visual 10× and ECI as specified), and replace any cracked hubs before flight.\n\n**Trade‑offs, costs and implementation considerations (testing the purpose claims)\n\n- Costs and burden: concentrated on the affected operators and their maintenance providers (parts, labour, ECI capability, and downtime). If new bearings are in short supply, operators could face scheduling delays. Any hub replacements increase cost and downtime further (Requirements 1–4).\n- Compliance complexity and discretion: the AD relies on Hartzell ASBs and 'later FAA‑approved revisions' for procedural detail, so maintainers must follow those documents and any FAA approvals. That creates dependency on manufacturer documentation and on FAA approval history (Requirements and Compliance).\n- Safety benefit vs opportunity cost: the safety benefit is concrete (replacing a bearing design that has fractured); the opportunity cost is the maintenance resources and aircraft out of service during compliance windows.\n- Effects on competition and independent providers: independent MROs can perform the work provided they follow the ASB procedures and hold required approvals; the AD does not prescribe a single supplier for parts but effectively requires the new P/N bearing (C‑7438), which concentrates demand on suppliers of that part.\n- Risk of substitution or workaround: the AD explicitly prohibits reinstalling the old P/Ns after the effective date (Requirement 5), so operators cannot defer by substituting older parts; they must install the new design or remove the hub/propeller from service.\n- Cross‑jurisdictional coordination: the AD notes a related FAA AD (FAA AD 2002‑22‑08) (Note 3), indicating harmonisation with FAA requirements and that operators on internationally registered aircraft should track both regulators' directives.\n\n**Implementation steps an operator must take (practical checklist)\n\n- Identify all HD‑E6C‑3( ) propellers in the fleet and check blade P/Ns (Applicability, Note 2).\n- Determine whether bearings were already replaced per Hartzell ASB HD‑ASB‑61‑026 or Service Letter HD‑SL‑61‑034 (if so, Requirement 1 is satisfied).\n- If not already done, schedule replacement of P/Ns C‑2882‑1/C‑2882‑2/C‑7075 with P/N C‑7438 within the compliance window (50 TIS hours, or nine months, or next disassembly) (Compliance, Requirement 1).\n- Perform the visual (10×) inspection and ECI of hubs per Hartzell ASB HD‑ASB‑61‑023 Rev 1 (or later FAA‑approved revisions) within the compliance window (Requirements 2–3).\n- Replace any cracked hubs before further flight (Requirement 4).\n- Cease installing the older bearing P/Ns after the effective date (Requirement 5).\n\n**Source sections cited:** Requirements 1–5; Compliance; Background; Applicability (including Notes)."},"flash_summary_failed":{"failed":true,"reason":"Unauthenticated. Configure AI_GATEWAY_API_KEY or use a provider module. Learn more: https://ai-sdk.dev/unauthenticated-ai-gateway","source":"analysis-cron"}},"importantCases":[],"_links":{"self":"/api/acts/ad-phzl-85-propeller-blade-thrust-bearing","history":"/api/acts/ad-phzl-85-propeller-blade-thrust-bearing/history","analysis":"/api/acts/ad-phzl-85-propeller-blade-thrust-bearing/analysis","conflicts":"/api/acts/ad-phzl-85-propeller-blade-thrust-bearing/conflicts","importantCases":"/api/acts/ad-phzl-85-propeller-blade-thrust-bearing/important-cases","documents":"/api/acts/ad-phzl-85-propeller-blade-thrust-bearing/documents"}}