Proposed Rule2025-17179
Airworthiness Directives; The Boeing Company Airplanes
Primary source
Metadata and text below are from the Federal Register, a public-domain U.S. government work. Always verify the official published version before relying on it for any legal matter.
Published
September 8, 2025
Issuing agencies
Transportation DepartmentFederal Aviation Administration
Abstract
The FAA proposes to adopt a new airworthiness directive (AD) for certain The Boeing Company Model 757-200 and -300 series airplanes. This proposed AD was prompted by a determination that new or more restrictive airworthiness limitations are necessary. This proposed AD would require revising the existing maintenance or inspection program, as applicable, to incorporate new or more restrictive airworthiness limitations. The FAA is proposing this AD to address the unsafe condition on these products.
Full Text
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<title>Federal Register, Volume 90 Issue 171 (Monday, September 8, 2025)</title>
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[Federal Register Volume 90, Number 171 (Monday, September 8, 2025)]
[Proposed Rules]
[Pages 43159-43162]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 2025-17179]
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Proposed Rules
Federal Register
________________________________________________________________________
This section of the FEDERAL REGISTER contains notices to the public of
the proposed issuance of rules and regulations. The purpose of these
notices is to give interested persons an opportunity to participate in
the rule making prior to the adoption of the final rules.
========================================================================
Federal Register / Vol. 90, No. 171 / Monday, September 8, 2025 /
Proposed Rules
[[Page 43159]]
DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. FAA-2025-2275; Project Identifier AD-2025-00796-T]
RIN 2120-AA64
Airworthiness Directives; The Boeing Company Airplanes
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Notice of proposed rulemaking (NPRM).
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SUMMARY: The FAA proposes to adopt a new airworthiness directive (AD)
for certain The Boeing Company Model 757-200 and -300 series airplanes.
This proposed AD was prompted by a determination that new or more
restrictive airworthiness limitations are necessary. This proposed AD
would require revising the existing maintenance or inspection program,
as applicable, to incorporate new or more restrictive airworthiness
limitations. The FAA is proposing this AD to address the unsafe
condition on these products.
DATES: The FAA must receive comments on this proposed AD by October 23,
2025.
ADDRESSES: You may send comments, using the procedures found in 14 CFR
11.43 and 11.45, by any of the following methods:
<bullet> Federal eRulemaking Portal: Go to <a href="http://regulations.gov">regulations.gov</a>. Follow
the instructions for submitting comments.
<bullet> Fax: 202-493-2251.
<bullet> Mail: U.S. Department of Transportation, Docket
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New
Jersey Avenue SE, Washington, DC 20590.
<bullet> Hand Delivery: Deliver to Mail address above between 9
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
AD Docket: You may examine the AD docket at <a href="http://regulations.gov">regulations.gov</a> under
Docket No. FAA-2025-2275; or in person at Docket Operations between 9
a.m. and 5 p.m., Monday through Friday, except Federal holidays. The AD
docket contains this NPRM, any comments received, and other
information. The street address for Docket Operations is listed above.
Material Incorporated by Reference:
<bullet> For Aviation Partners Boeing material identified in this
proposed AD, contact Aviation Partners Boeing, 555 Andover Park West,
Suite 200, Tukwila, WA 98188; telephone 206-830-7699; fax 206-767-0535;
email <a href="/cdn-cgi/l/email-protection#264a4348416647504f47524f494856475452484354550845494b"><span class="__cf_email__" data-cfemail="7a161f141d3a1b0c131b0e1315140a1b080e141f080954191517">[email protected]</span></a>; website <a href="http://aviationpartnersboeing.com">aviationpartnersboeing.com</a>.
<bullet> You may view this material at the FAA, Airworthiness
Products Section, Operational Safety Branch, 2200 South 216th St., Des
Moines, WA.
FOR FURTHER INFORMATION CONTACT: Sarah Illg, Aviation Safety Engineer,
FAA, 3960 Paramount Boulevard, Lakewood, CA 90712; phone: 206-231-3517;
email: <a href="/cdn-cgi/l/email-protection#0e5d6f7c6f66204f20476262694e686f6f20696178"><span class="__cf_email__" data-cfemail="adfeccdfccc583ec83e4c1c1caedcbcccc83cac2db">[email protected]</span></a>.
SUPPLEMENTARY INFORMATION:
Comments Invited
The FAA invites you to send any written relevant data, views, or
arguments about this proposal. Send your comments using a method listed
under the ADDRESSES section. Include ``Docket No. FAA-2025-2275;
Project Identifier AD-2025-00796-T'' at the beginning of your comments.
The most helpful comments reference a specific portion of the proposal,
explain the reason for any recommended change, and include supporting
data. The FAA will consider all comments received by the closing date
and may amend this proposal because of those comments.
Except for Confidential Business Information (CBI) as described in
the following paragraph, and other information as described in 14 CFR
11.35, the FAA will post all comments received, without change, to
<a href="http://regulations.gov">regulations.gov</a>, including any personal information you provide. The
agency will also post a report summarizing each substantive verbal
contact received about this NPRM.
Confidential Business Information
CBI is commercial or financial information that is both customarily
and actually treated as private by its owner. Under the Freedom of
Information Act (FOIA) (5 U.S.C. 552), CBI is exempt from public
disclosure. If your comments responsive to this NPRM contain commercial
or financial information that is customarily treated as private, that
you actually treat as private, and that is relevant or responsive to
this NPRM, it is important that you clearly designate the submitted
comments as CBI. Please mark each page of your submission containing
CBI as ``PROPIN.'' The FAA will treat such marked submissions as
confidential under the FOIA, and they will not be placed in the public
docket of this NPRM. Submissions containing CBI should be sent to Sarah
Illg, Aviation Safety Engineer, FAA, 3960 Paramount Boulevard,
Lakewood, CA 90712; phone: 206-231-3517; email: <a href="/cdn-cgi/l/email-protection#491a283b28216708670025252e092f2828672e263f"><span class="__cf_email__" data-cfemail="0a596b786b62244b244366666d4a6c6b6b246d657c">[email protected]</span></a>.
Any commentary that the FAA receives that is not specifically
designated as CBI will be placed in the public docket for this
rulemaking.
Background
The FAA issued AD 2020-01-18, Amendment 39-19824 (85 FR 5304,
January 30, 2020); corrected February 26, 2020 (85 FR 10969) (AD 2020-
01-18), for all the Boeing Company Model 757 airplanes. AD 2020-01-18
requires revising the existing maintenance or inspection program, as
applicable, to incorporate new or more restrictive airworthiness
limitations. AD 2020-01-18 includes a requirement to revise the
existing maintenance or inspection program to incorporate a
supplemental program to address the effect of Supplemental Type
Certificate (STC) ST01518SE. The FAA issued AD 2020-01-18 to address
fatigue cracking of the principal structural elements, which could
adversely affect the structural integrity of the airplane.
Since the FAA issued AD 2020-01-18, the FAA has received an
operator report indicating that during a maintenance H-check
inspection, a crack was found at the splice fitting between the
original wing and the Aviation Partners Boeing (APB) modified lower
wing skin panel, which is spliced at wing station (WS) 711 on a Boeing
Company Model 757-200 airplane with the APB blended winglets installed
in accordance with STC ST01518SE. APB reviewed the crack finding and
determined the existing airworthiness limitations (AWL) structural
significant items (SSI) 57-20-
[[Page 43160]]
32B does not provide adequate probability of detection for foreseeable
fatigue cracking of SSIs at station WS 711. If cracks grow undetected,
it may result in the inability of a principal structural element to
sustain limit loads. The FAA has determined that it is necessary to
revise the existing maintenance or inspection program, as applicable,
to incorporate new or more restrictive airworthiness limitations for
The Boeing Company Model 757-200 and -300 airplanes that have been
modified in accordance with STC ST01518SE, with or without blended or
scimitar blended winglets installed. Incorporating the revision
required by this proposed AD would terminate the requirements of
paragraphs (g) and (h)(2) of AD 2020-01-18.
The FAA is proposing this AD to address the potential for fatigue
cracking on the wing and winglet. This condition, if not addressed,
could result in the inability of a principal structural element to
sustain limit loads, which could adversely affect the structural
integrity of the airplane.
FAA's Determination
The FAA is issuing this NPRM after determining that the unsafe
condition described previously is likely to exist or develop on other
products of the same type design.
Material Incorporated by Reference Under 1 CFR Part 51
The FAA reviewed Aviation Partners Boeing AP57.2-0604.2 Supplement
to D622N001-9 (September 2020) 757 Maintenance Planning Data (MPD)
document, Section 9, Airworthiness Limitations (AWLs) and Certification
Requirements (CMRs) Boeing 757-200 with Winglets FAA STC NUMBER
ST01518SE AND EASA STC NUMBER 10015659, Revision February 2022; and
AP57.3-0604.2 Supplement to D622N001-9 (September 2020) 757 MPD
document, Section 9, AWLs and CMRs 757-300 with Blended Winglets FAA
STC NUMBER ST01518SE AND EASA STC NUMBER 10015659, Revision August
2022. This material specifies airworthiness limitations for structural
inspections, structural safe life parts, systems, and certification
maintenance requirements.
The FAA also reviewed Aviation Partners Boeing AP57.2-0604.2-DTR
Supplement to D622N001-DTR (October 2018) 757 Damage Tolerance Rating
(DTR) Check Form Document for Boeing 757-200 with Winglets FAA STC
NUMBER ST01518SE AND EASA STC NUMBER 10015659, Revision August 2023;
and Aviation Partners Boeing AP57.3-0604.2-DTR Supplement to D622N001-
DTR (October 2018) 757 DTR Check Form Document for Boeing 757-300 with
Blended Winglets FAA STC NUMBER ST01518SE AND EASA STC NUMBER 10015659,
Revision August 2023. This material provides the DTR check forms and
the procedure for their use.
This material is reasonably available because the interested
parties have access to it through their normal course of business or by
the means identified in the ADDRESSES section.
Proposed AD Requirements in This NPRM
This proposed AD would require revising the existing maintenance or
inspection program, as applicable, to incorporate new or more
restrictive airworthiness limitations. This proposed AD would also
require sending inspection results to Aviation Partners Boeing.
This proposed AD would require revisions to certain operator
maintenance documents to include new actions (e.g., inspections).
Compliance with these actions is required by 14 CFR 91.403(c). For
airplanes that have been previously modified, altered, or repaired in
the areas addressed by this proposed AD, the operator may not be able
to accomplish the actions described in the revisions. In this
situation, to comply with 14 CFR 91.403(c), the operator must request
approval for an alternative method of compliance according to paragraph
(j) of this proposed AD.
Differences Between This Proposed AD and the Service Information
This proposed AD would require that the reports specified in the
service information identified in paragraph (g) of this proposed AD be
submitted within 10 days after the airplane is returned to service,
instead of 10 days after each individual finding as specified in the
documents. The FAA has included this grace period in paragraph (g)(3)
of this proposed AD.
Costs of Compliance
The FAA estimates that this AD, if adopted as proposed, would
affect 156 airplanes of U.S. registry. The FAA estimates the following
costs to comply with this proposed AD:
The FAA has determined that revising the existing maintenance or
inspection program takes an average of 90 work-hours per operator,
although the agency recognizes that this number may vary from operator
to operator. Since operators incorporate maintenance or inspection
program changes for their affected fleet(s), the FAA has determined
that a per-operator estimate is more accurate than a per-airplane
estimate. Therefore, the FAA estimates the average total cost per
operator to be $7,650 (90 work-hours x $85 per work-hour).
On-Condition Costs
----------------------------------------------------------------------------------------------------------------
Action Labor cost Parts cost Cost per product
----------------------------------------------------------------------------------------------------------------
Reporting..................................... 1 work-hour x $85 per hour = $85 $0 $85
----------------------------------------------------------------------------------------------------------------
Paperwork Reduction Act
A federal agency may not conduct or sponsor, and a person is not
required to respond to, nor shall a person be subject to a penalty for
failure to comply with a collection of information subject to the
requirements of the Paperwork Reduction Act unless that collection of
information displays a currently valid OMB Control Number. The OMB
Control Number for this information collection is 2120-0056. Public
reporting for this collection of information is estimated to take
approximately 1 hour per response, including the time for reviewing
instructions, searching existing data sources, gathering and
maintaining the data needed, and completing and reviewing the
collection of information. All responses to this collection of
information are mandatory. Send comments regarding this burden estimate
or any other aspect of this collection of information, including
suggestions for reducing this burden, to: Information Collection
Clearance Officer, Federal Aviation Administration, 10101 Hillwood
Parkway, Fort Worth, TX 76177-1524.
Authority for This Rulemaking
Title 49 of the United States Code specifies the FAA's authority to
issue rules on aviation safety. Subtitle I, section 106, describes the
authority of the FAA Administrator. Subtitle VII: Aviation Programs,
describes in more
[[Page 43161]]
detail the scope of the Agency's authority.
The FAA is issuing this rulemaking under the authority described in
Subtitle VII, Part A, Subpart III, Section 44701: General requirements.
Under that section, Congress charges the FAA with promoting safe flight
of civil aircraft in air commerce by prescribing regulations for
practices, methods, and procedures the Administrator finds necessary
for safety in air commerce. This regulation is within the scope of that
authority because it addresses an unsafe condition that is likely to
exist or develop on products identified in this rulemaking action.
Regulatory Findings
The FAA determined that this proposed AD would not have federalism
implications under Executive Order 13132. This proposed AD would not
have a substantial direct effect on the States, on the relationship
between the national government and the States, or on the distribution
of power and responsibilities among the various levels of government.
For the reasons discussed above, I certify this proposed
regulation:
(1) Is not a ``significant regulatory action'' under Executive
Order 12866,
(2) Would not affect intrastate aviation in Alaska, and
(3) Would not have a significant economic impact, positive or
negative, on a substantial number of small entities under the criteria
of the Regulatory Flexibility Act.
List of Subjects in 14 CFR Part 39
Air transportation, Aircraft, Aviation safety, Incorporation by
reference, Safety.
The Proposed Amendment
Accordingly, under the authority delegated to me by the
Administrator, the FAA proposes to amend 14 CFR part 39 as follows:
PART 39--AIRWORTHINESS DIRECTIVES
0
1. The authority citation for part 39 continues to read as follows:
Authority: 49 U.S.C. 106(g), 40113, 44701.
Sec. 39.13 [Amended]
0
2. The FAA amends Sec. 39.13 by adding the following new airworthiness
directive:
The Boeing Company: Docket No. FAA-2025-2275; Project Identifier AD-
2025-00796-T.
(a) Comments Due Date
The FAA must receive comments on this airworthiness directive
(AD) by October 23, 2025.
(b) Affected ADs
This AD affects AD 2020-01-18, Amendment 39-19824 (85 FR 5304,
January 30, 2020); corrected February 26, 2020 (85 FR 10969) (AD
2020-01-18).
(c) Applicability
This AD applies to The Boeing Company Model 757-200 and -300
series airplanes, certificated in any category, that have been
modified in accordance with supplemental type certificate (STC)
ST01518SE, with or without blended or scimitar blended winglets
installed.
(d) Subject
Air Transport Association (ATA) of America Code 05, Time Limits/
Maintenance Checks; 57, Wings.
(e) Unsafe Condition
This AD was prompted by a determination that new or more
restrictive airworthiness limitations are necessary. The FAA is
issuing this AD to address fatigue cracking on the wing and winglet.
This condition, if not addressed, could result in the inability of a
principal structural element to sustain limit loads, which could
adversely affect the structural integrity of the airplane.
(f) Compliance
Comply with this AD within the compliance times specified,
unless already done.
(g) Maintenance or Inspection Program Revision
(1) For Model 757-200 series airplanes: Within 30 days after the
effective date of this AD, revise the existing maintenance or
inspection program, as applicable, to incorporate the service
information specified in paragraphs (g)(1)(i) and (ii) of this AD.
The initial compliance time for doing the tasks is at the time
specified in the service information identified in paragraphs
(g)(1)(i) and (ii) of this AD, or within 6 months or 500 flight
cycles after the effective date of this AD, whichever occurs later.
(i) Aviation Partners Boeing AP57.2-0604.2 Supplement to
D622N001-9 (September 2020) 757 Maintenance Planning Document (MPD)
document, Section 9, Airworthiness Limitations (AWLs) and
Certification Maintenance Requirements (CMRs) Boeing 757-200 with
Winglets FAA STC NUMBER ST01518SE AND EASA STC NUMBER 10015659,
Revision February 2022.
(ii) Aviation Partners Boeing AP57.2-0604.2-DTR Supplement to
D622N001-DTR (October 2018) 757 Damage Tolerance Rating (DTR) Check
Form Document for Boeing 757-200 with Blended Winglets FAA STC
NUMBER ST01518SE AND EASA STC NUMBER 10015659, Revision August 2023.
(2) For Model 757-300 series airplanes: Within 30 days after the
effective date of this AD, revise the existing maintenance or
inspection program, as applicable, to incorporate the service
information specified in paragraphs (g)(2)(i) and (ii) of this AD.
The initial compliance time for doing the tasks is at the time
specified in the service information identified in paragraphs
(g)(2)(i) and (ii) of this AD, or within 6 months or 500 flight
cycles after the effective date of this AD, whichever occurs later.
(i) Aviation Partners Boeing AP57.3-0604.2 Supplement to
D622N001-9 (September 2020) 757 MPD document, Section 9, AWLs and
CMRs 757-300 with Blended Winglets FAA STC ST01518SE and EASA STC
Number 10015659, Revision August 2022.
(ii) Aviation Partners Boeing AP57.3-0604.2-DTRSupplement to
D622N001-DTR (October 2018) 757 Damage Tolerance Rating (DTR) Check
Form Document for Boeing 757-300 with Blended Winglets FAA STC
NUMBER ST01518SE AND EASA STC NUMBER 10015659, Revision August 2023.
(3) The reports specified in the service information identified
in paragraphs (g)(1)(i) and (ii) of this AD and (g)(2)(i) and (ii)
of this AD must be submitted within 10 days after the airplane is
returned to service, instead of 10 days after each individual
finding as specified in the service information identified in
paragraphs (g)(1)(i) and (ii) of this AD and (g)(2)(i) and (ii) of
this AD.
(h) No Alternative Actions or Intervals
After the existing maintenance or inspection program has been
revised as required by paragraph (g) of this AD, no alternative
actions (e.g., inspections) or intervals, may be used unless the
actions and intervals are approved as an alternative method of
compliance (AMOC) in accordance with the procedures specified in
paragraph (j) of this AD.
(i) Terminating Action for Paragraphs (g) and (h)(2) of AD 2020-01-18
Accomplishing the actions required by paragraph (g) this AD
terminates the requirements specified in paragraphs (g) and (h)(2)
of AD 2020-01-18 for The Boeing Company Model 757-200 and -300
series airplanes that have been modified in accordance with STC
ST01518SE, with or without blended or scimitar blended winglets
installed.
(j) Alternative Methods of Compliance (AMOCs)
(1) The Manager, AIR-770, West Certification Branch, FAA, has
the authority to approve AMOCs for this AD, if requested using the
procedures found in 14 CFR 39.19. In accordance with 14 CFR 39.19,
send your request to your principal inspector or responsible Flight
Standards Office, as appropriate. If sending information directly to
the manager of the West Certification Branch, send it to the
attention of the person identified in paragraph (k) of this AD.
Information may be emailed to: <a href="/cdn-cgi/l/email-protection#de9f93919d9eb8bfbff0b9b1a8"><span class="__cf_email__" data-cfemail="f1b0bcbeb2b1979090df969e87">[email protected]</span></a>. Before using any
approved AMOC, notify your appropriate principal inspector, or
lacking a principal inspector, the manager of the responsible Flight
Standards Office.
(2) An AMOC that provides an acceptable level of safety may be
used for any repair, modification, or alteration required by this AD
if it is approved by The Boeing Company Organization Designation
Authorization (ODA) that has been authorized by the Manager, AIR-
770, West Certification
[[Page 43162]]
Branch, FAA, to make those findings. To be approved, the repair
method, modification deviation, or alteration deviation must meet
the certification basis of the airplane, and the approval must
specifically refer to this AD.
(3) AMOCs approved previously for AD 2020-01-18, Amendment 39-
19824 (85 FR 5304, January 30, 2020); corrected February 26, 2020
(85 FR 10969); AD 2006-11-11 Amendment 39-14615 (71 FR 30278, May
26, 2006); and AD 2001-20-12, Amendment 39-12460 (66 FR 52492,
October 16, 2001); are approved as AMOCs for the corresponding
provisions of this AD, except for AMOCs that included revised
compliance times.
(k) Related Information
For more information about this AD, contact Sarah Illg, Aviation
Safety Engineer, FAA, 3960 Paramount Boulevard, Lakewood, CA 90712;
phone: 206-231-3517; email: <a href="/cdn-cgi/l/email-protection#52013320333a7c137c1b3e3e35123433337c353d24"><span class="__cf_email__" data-cfemail="580b392a39307619761134343f183e3939763f372e">[email protected]</span></a>.
(l) Material Incorporated by Reference
(1) The Director of the Federal Register approved the
incorporation by reference of the material listed in this paragraph
under 5 U.S.C. 552(a) and 1 CFR part 51.
(2) You must use this material as applicable to do the actions
required by this AD, unless the AD specifies otherwise.
(i) Aviation Partners Boeing AP57.2-0604.2 Supplement to
D622N001-9 (September 2020) 757 Maintenance Planning Document (MPD)
document, Section 9, Airworthiness Limitations (AWLs) and
Certification Maintenance Requirements (CMRs) Boeing 757-200 with
Winglets FAA STC NUMBER ST01518SE AND EASA STC NUMBER 10015659,
Revision February 2022.
(ii) Aviation Partners Boeing AP57.2-0604.2-DTR Supplement to
D622N001-DTR (October 2018) 757 Damage Tolerance Rating (DTR) Check
Form Document for Boeing 757-200 with Winglets FAA STC NUMBER
ST01518SE AND EASA STC NUMBER 10015659, Revision August 2023.
(iii) Aviation Partners Boeing AP57.3-0604.2 Supplement to
D622N001-9 (September 2020) 757 Maintenance Planning Document (MPD)
document, Section 9, Airworthiness Limitations (AWLs) and
Certification Maintenance Requirements (CMRs) 757-300 with Blended
Winglets FAA STC ST01518SE and EASA STC Number 10015659, Revision
August 2022.
(iv) Aviation Partners Boeing AP57.3-0604.2-DTR Supplement to
D622N001-DTR (October 2018) 757 Damage Tolerance Rating (DTR) Check
Form Document for Boeing 757-300 with Blended Winglets FAA STC
Number ST01518SE AND EASA STC NUMBER 10015659, Revision August 2023.
(3) For Aviation Partners Boeing material identified in this AD,
contact Aviation Partners Boeing, 555 Andover Park West, Suite 200,
Tukwila, WA 98188; telephone 206-830-7699; fax 206-767-0535; email
<a href="/cdn-cgi/l/email-protection#69050c070e29081f00081d00060719081b1d070c1b1a470a0604"><span class="__cf_email__" data-cfemail="fd9198939abd9c8b949c899492938d9c8f8993988f8ed39e9290">[email protected]</span></a>; website <a href="http://aviationpartnersboeing.com">aviationpartnersboeing.com</a>.
(4) You may view this material at the FAA, Airworthiness
Products Section, Operational Safety Branch, 2200 South 216th St.,
Des Moines, WA. For information on the availability of this material
at the FAA, call 206-231-3195.
(5) You may view this material at the National Archives and
Records Administration (NARA). For information on the availability
of this material at NARA, visit <a href="http://www.archives.gov/federal-register/cfr/ibr-locations">www.archives.gov/federal-register/cfr/ibr-locations</a> or email <a href="/cdn-cgi/l/email-protection#0365712d6a6d70736660776a6c6d436d6271622d646c75"><span class="__cf_email__" data-cfemail="3452461a5d5a47445157405d5b5a745a5546551a535b42">[email protected]</span></a>.
Issued on September 3, 2025.
Paul R. Bernado,
Acting Director, Compliance & Airworthiness Division, Aircraft
Certification Service.
[FR Doc. 2025-17179 Filed 9-5-25; 8:45 am]
BILLING CODE 4910-13-P
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