FAA Mandates Jet Engine Seal Replacements After In-Flight Failure
Published Date: 2/4/2025
Rule
Summary
The FAA is making a new rule for certain CFM LEAP-1A and LEAP-1C jet engines because a key seal part failed during a flight. Owners must remove and replace this seal on LEAP-1A engines and can’t install the affected parts on either engine model anymore. This rule starts March 11, 2025, to keep flights safe without causing big costs or delays.
Analyzed Economic Effects
3 provisions identified: 0 benefits, 3 costs, 0 mixed.
Mandatory seal removal and replacement
If you operate airplanes with CFM LEAP-1A engines that have the affected HPT rotor interstage seal P/N and S/N listed in the CFM service bulletin, you must remove that seal and replace it at the next engine shop visit or before the engine exceeds the listed cyclic threshold (for most LEAP-1A models 11,100 cycles since new; for LEAP-1A26CJ and LEAP-1A29CJ 9,700 cycles since new). This requirement takes effect March 11, 2025.
FAA estimated compliance cost to U.S. operators
The FAA estimates this AD affects 56 engines on U.S. airplanes. The FAA estimates per-engine compliance cost at $196,020 (12 work-hours at $85/hour = $1,020 labor plus $195,000 parts), for a total estimated cost to U.S. operators of $10,977,120.
Ban on installing affected seals
Starting March 11, 2025, you may not install any HPT rotor interstage seal having the P/N and S/N listed in the identified CFM service bulletins into any LEAP-1A or LEAP-1C engine. The prohibition uses the specific P/N/S/N tables in CFM SB LEAP-1A-72-00-0525-01A-930A-D (Issue 002-00) and CFM SB LEAP-1C-72-00-0124-01A-930A-D (Issue 001-00).
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