The AD prescribes narrowly tailored compliance steps anchored to specified documents and timing. The following practical checklist follows the AD language and sequence; it cites the relevant requirement or compliance clause where available in the text.
Step 1 , Confirm applicability. Verify the engine model is within the AD scope: TCM IO‑360, LTSIO‑360, TSIO‑360, IO‑520, LIO‑520, LTSIO‑520, TSIO‑520 series, or Rolls‑Royce IO‑360 and TSIO‑360 series. The AD applies only to those engines listed in the "Applicability" block.
Step 2 , Identification per CSB96‑8 (Requirement 1). When a crankshaft is next removed from the engine after the effective date (Amendment 1 effective 12 May 2005), determine whether the crankshaft was manufactured by the "Airmelt" or "VAR" process by following the identification procedure in TCM Critical Service Bulletin CSB96‑8 dated 25 June 1996 (or a later revision only if that revision is "approved by FAA").
- If the identification procedure confirms VAR manufacture, proceed to Step 3.
- If the procedure shows "Airmelt" or if the manufacturing process is unknown, do not return that crankshaft to service. Instead, proceed to Step 4.
Step 3 , Inspections for VAR crankshafts (Requirement 2 and Requirement 3). For VAR crankshafts, carry out both inspection streams as the AD requires.
- Ultrasonic inspection: Conduct the ultrasonic inspection "in accordance with the procedures specified in TCM Mandatory SB No. MSB96‑10 dated 15 August 1996 or later revision approved by FAA" (Requirement 2). The AD explicitly states the ultrasonic inspection is in addition to the MPI or other inspections in the overhaul manuals, so do not treat one as substituting for the other except where the AD allows MPI as a time‑limited alternate.
- MPI: Carry out Magnetic Particle Inspection per the procedures specified in TCM or Rolls‑Royce overhaul manuals as applicable (Requirement 3). Amendment 1 clarifies the source of approved data for MPI.
Step 4 , Replacement for Airmelt or unknown crankshafts (Requirement 1). If the crankshaft is Airmelt or manufacture is unknown, remove it and replace it with a "serviceable crankshaft manufactured using the VAR process." The AD states "Do not fit removed non‑VAR crankshaft into any engine." Ensure the replacement VAR crankshaft meets any manufacturer serviceability criteria in the applicable overhaul manual or service bulletins.
Step 5 , Observe timing rules (Compliance). The AD instructs that identification and removal/replacement be done "whenever the crankshaft is next removed from the engine, after the effective date of this directive" (Compliance 1). Inspections are required "Repetitively, at the next and subsequent installation of the VAR crankshaft in the engine" (Compliance 2). MPI is permitted as an alternate to ultrasonic inspection "up to 31 December 2006" (Compliance 3 and Background). Incorporate these timing rules into maintenance scheduling.
Step 6 , Use only specified or FAA‑approved revised documents. When following the identification and ultrasonic inspection procedures, use CSB96‑8 and MSB96‑10 as dated in the AD or use later revisions only if those are "approved by FAA." For MPI procedures use the TCM or Rolls‑Royce overhaul manuals "as applicable" and ensure the source of MPI data aligns with the clarification in Amendment 1.
Step 7 , Avoid re‑installation of removed non‑VAR parts. Treat removed non‑VAR crankshafts as unfit for reinstallation. The AD’s language is categorical: "Do not fit removed non‑VAR crankshaft into any engine."
Step 8 , Plan for capability transition. The AD’s Background acknowledges a capability gap in ultrasonic inspection capability and allows MPI as interim alternate up to a stated date. Operators should plan to have ultrasonic inspection capability (equipment, trained personnel, or contracted service providers) in place before the MPI allowance expires on 31 December 2006.
Step 9 , Coordinate with parts suppliers and overhaul providers. Because replacement with VAR crankshafts is required where a crankshaft is Airmelt or unknown, operators should ensure availability of serviceable VAR crankshafts and confirm their serviceability per manufacturer criteria in overhaul manuals or the service bulletins noted in the AD.
Step 10 , Document actions and ensure traceability. While the AD text does not state recordkeeping requirements, compliance will be demonstrable only if identification, replacement and inspection actions are recorded and traceable to the effective date and to the manufacturer's procedures used. Record the identification method (CSB96‑8 or FAA‑approved revision), the inspection procedures used (MSB96‑10 or FAA‑approved revision, overhaul manual MPI procedures), the part numbers and manufacturing process determinations, and the dates of removal and installation in order to demonstrate adherence to the AD’s timing and procedural requirements.
Step 11 , Monitor for FAA‑approved revisions. The AD permits use of "later revision approved by FAA" for CSB96‑8 and MSB96‑10. Maintain awareness of any such FAA approvals to ensure the version of the SB you rely on is acceptable under the AD.
Adhering to the AD requires stepwise execution: identify process at next removal, replace non‑VAR or unknown crankshafts with VAR, perform both ultrasonic and MPI inspections where applicable (subject to the time‑limited MPI alternate), and do these inspections at each VAR crankshaft reinstallation. The AD’s procedural dependencies on CSB96‑8, MSB96‑10 and manufacturer overhaul manuals must be respected, and any later revisions must carry FAA approval to be acceptable.