FAA Orders Honda Jet Flap Replacements for Safety
Published Date: 12/23/2025
Proposed Rule
Summary
The FAA is updating safety rules for certain Honda HA-420 airplanes to fix a flap control part that could cause trouble by bumping into other parts. Owners will need to replace this part with a new, improved version to keep flying safe. Comments on this update are open until February 6, 2026, and the fix might cost some time and money but keeps everyone safer in the sky!
Analyzed Economic Effects
4 provisions identified: 1 benefits, 3 costs, 0 mixed.
Mandatory Pushrod Replacement Within 2 Years
If you own or operate an affected Honda HA-420 airplane, you must replace the flap control pushrod assemblies with redesigned assemblies within 2 years after the AD's effective date. The FAA estimates the replacement parts cost $5,168 plus 22 work-hours (22 x $85/hr = $1,870) for a total of $7,038 per airplane, affecting 107 U.S.-registered airplanes and a total estimated cost of $753,066.
Continued Repetitive Corrosion Maintenance
For Group 1 HA-420 airplanes, you must keep removing, cleaning, and applying corrosion inhibiting compound (CIC) to flap control pushrod assemblies within 90 days after November 19, 2021 or 18 months after first standard airworthiness certificate (whichever is later), and reapply CIC every 90 days or 300 hours time-in-service, whichever occurs first. The FAA estimates the recurring reapplication cost at $155 each time and lists costs on U.S. operators for these retained actions (e.g., $85,360 for 44 airplanes for the initial retained action, and $6,820 for repeated applications across 44 airplanes).
Prohibition on Installing Certain Pushrod Parts
As of the AD's effective date, you may not install any inboard or outboard flap control pushrod assembly part number identified in the Effectivity section of Honda Alert Service Bulletin SB-420-27-009 Revision B (dated August 5, 2025). This limits parts you can install during maintenance or repairs.
Manufacturer May Cover Some Costs Under Warranty
The FAA notes that, according to the manufacturer, some or all of the costs of this proposed AD may be covered under warranty, which could reduce the cost impact on affected operators.
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