FAA to Diamond Pilots: Secure Those Doors Before They Fly Away!
Published Date: 5/13/2026
Proposed Rule
Summary
The FAA wants all Diamond Aircraft DA 40 series planes to update their flight manuals and check their passenger doors because some doors have come loose during flights. Pilots and owners will need to inspect, fix, or replace door parts to keep everyone safe. Comments on this plan are open until June 29, 2026, and these fixes might cost some time and money but will stop scary door problems in the sky!
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Analyzed Economic Effects
5 provisions identified: 3 benefits, 2 costs, 0 mixed.
Mandatory AFM Changes and Door Inspections
If you operate a Diamond Aircraft Model DA 40, DA 40 F, or DA 40 NG, the FAA proposes you must revise the airplane flight manual (AFM) and perform inspections and modifications of the passenger door latching and safety hook areas. The rule requires the AFM revision and initial inspections within 100 hours time-in-service (TIS) or 100 days after the AD's effective date and adds repetitive inspections and corrective actions per the Diamond Aircraft work instruction.
Estimated Compliance Costs and Affected Fleet
The FAA estimates this AD would affect 987 U.S.-registered airplanes. The FAA's cost estimates include $85 per airplane for the AFM revision, $331 per airplane for the initial inspection, and $85 per inspection for repetitive inspections; the FAA also lists on-condition replacement costs for parts.
Handle-Force Measurements and Gas Spring Rules
The AD requires measuring the passenger door handle actuation force and sets specific thresholds: 1.8 kg (18 N), 2 kg (20 N), and 6 kg (60 N). If the measured force is less than 1.8 kg and a prior measurement was 2–6 kg, you must repeat inspections every 100 hours TIS until you replace the gas spring within 12 months; if the measured force is less than 1.8 kg and the prior measurement was greater than 6 kg or less than 2 kg, you must replace the gas spring before further flight.
Pilot Exception to Revise AFM
The proposed AD lets the owner/operator who holds at least a private pilot certificate revise the AFM and record compliance in the maintenance records. That AFM revision action may be done by the pilot rather than requiring a certified mechanic.
No Manufacturer Reporting Required by AD
Although the Diamond Aircraft work instruction and service bulletin ask operators to submit execution reports to the manufacturer, this proposed AD explicitly does not require submitting those reports. Operators are not required by this AD to report inspection findings to the manufacturer.
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