Jet Engines Flawed: FAA Orders Disk Swaps Now!
Published Date: 3/4/2025
Rule
Summary
If you fly planes with CFM LEAP-1A, 1B, or 1C engines, listen up! The FAA found some turbine disks with a manufacturing flaw and now requires those parts to be swapped out to keep flights safe. This rule kicks in April 8, 2025, so airlines will need to act fast, but it’s all about making sure your flight stays smooth and secure.
Analyzed Economic Effects
4 provisions identified: 1 benefits, 3 costs, 0 mixed.
Required replacement of faulty LPT disks
The FAA requires removal and replacement of certain low-pressure turbine (LPT) stage 4 and stage 5 disks on CFM LEAP-1A, LEAP-1B, and LEAP-1C engines to prevent fracture and uncontained failures. The rule explicitly targets disks with part numbers and serial numbers listed in the CFM service bulletins dated September 18, 2024.
FAA cost estimate to U.S. operators
The FAA estimates this AD affects 13 engines on U.S. airplanes: 2 LEAP-1A stage 5 replacements, 8 LEAP-1B stage 5 replacements, and 3 LEAP-1B stage 4 replacements. Estimated cost per engine is $238,250 for the LEAP-1A stage 5 disk, $217,850 for the LEAP-1B stage 5 disk, and $455,550 for the LEAP-1B stage 4 disk, with total U.S. operator costs of $476,500, $1,742,800, and $1,366,650 respectively.
When replacements must happen
The AD is effective April 8, 2025, and requires affected disks to be removed at the next piece-part exposure or before exceeding the cycles-since-new thresholds listed in the CFM service bulletins. The NPRM and AD reference replacement thresholds that can be as low as 2,400 cycles since new and as high as 19,000 cycles since new, depending on the part and table in the service bulletin.
Installation ban for listed disks
After April 8, 2025, operators may not install any LPT stage 4 or stage 5 disk that has a part number and serial number identified in the referenced CFM service bulletins into LEAP-1A, LEAP-1B, or LEAP-1C engines. The AD explicitly prohibits installation of the listed P/N and S/N parts in the applicable engines.
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