Pratt Engines Face Bolt Checks: FAA Cracks Down Early
Published Date: 3/19/2025
Rule
Summary
If you fly planes with Pratt & Whitney Canada PW535E or PW535E1 engines, listen up! The FAA found some bolts in these engines can crack too soon, so they’re requiring regular inspections and replacements if needed starting April 23, 2025. This keeps flights safe and might cost some time and money for checks, but it’s worth it to avoid bigger problems.
Analyzed Economic Effects
3 provisions identified: 1 benefits, 2 costs, 0 mixed.
Estimated inspection and replacement costs
The FAA estimates 521 affected engines on U.S. registry. A borescope inspection is estimated at $170 per engine (2 work-hours at $85/hour), totaling $88,570 across U.S. operators; if replacement is required, the FAA estimates labor $340 (4 work-hours at $85/hour) plus parts $337,701, for a total estimated on-condition cost of $338,041 per engine.
Reduced risk of uncontained engine debris
The AD is intended to prevent cracking, fracture, missing, or loosening of the gas generator case to turbine support case retaining bolts that could lead to flange separation, uncontained engine debris, and damage to the engine and airplane. The AD requires inspections and replacements to address this unsafe condition, effective April 23, 2025.
Mandatory bolt inspections and fixes
If you operate aircraft with Pratt & Whitney Canada PW535E or PW535E1 engines, you must perform borescope inspections (BSI) of the gas generator case to turbine support case retaining bolts (P/N MS9696-08 and P/N MS9489-06). Inspect within 400 engine cycles from April 23, 2025, repeat thereafter at intervals not to exceed 400 engine cycles, and replace any bolt found cracked, fractured, missing, or loose before further flight.
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