Boeing 757: More checks, fewer headaches, FAA says
Published Date: 2/12/2025
Proposed Rule
Summary
If you own or work with Boeing 757 airplanes, the FAA wants you to keep doing safety checks on the aileron trim parts but also add some new fixes to stop problems for good. These changes mean some parts will be swapped out to avoid repeated inspections, keeping flights safer and smoother. Comments on this plan are open until March 31, 2025, so now’s the time to speak up!
Analyzed Economic Effects
4 provisions identified: 0 benefits, 4 costs, 0 mixed.
Mandatory bracket installation to stop repeated inspections
For certain Boeing 757 airplanes, the proposed rule would require installing an aileron trim actuator bracket (or replacing the actuator lateral control fitting with that bracket). The FAA estimates this installation is 6 work-hours at $85/hour plus $3,820 in parts = $4,330 per airplane, and applying that estimate across the 460 U.S.-registered airplanes yields a total estimated cost of $1,991,800.
Potential on-condition repairs and inspections costs
If inspections find damage, the rule requires on-condition actions. The FAA estimates an aileron-trim actuator replacement would involve 4 work-hours at $85/hour plus parts for a total of $18,033 per replacement, and a high-frequency eddy current (HFEC) inspection is estimated at 1 work-hour = $85 per inspection. The FAA did not estimate how many airplanes will need these on-condition actions.
Repetitive aileron-trim inspections remain required
If you operate a Boeing 757 (-200, -200CB, -200PF, or -300), you must continue the repetitive checks and detailed inspections of the aileron trim actuator and its attachment lug required by AD 2019-12-13. The FAA estimates the inspection labor is 3 work-hours at $85/hour = $255 per inspection cycle, and the rule would affect 460 U.S.-registered airplanes (fleet cost of $117,300 per inspection cycle).
Change lateral control box assembly for many 757s
For airplanes identified as Groups 1, 4, and 5, the proposed AD would require changing the lateral control box support assembly (which includes a portable method C penetrant inspection and any applicable repair) and installing the aileron trim actuator bracket where needed. The FAA estimates 406 airplanes are in Groups 1, 4, and 5, and estimates this change at 2 work-hours at $85/hour = $170 per airplane (fleet total $69,020).
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