FAA Orders Ultrasonic Checks on Pratt Whitney Engines
Published Date: 5/22/2026
Rule
Summary
If you own or operate certain Pratt & Whitney RTX engines, get ready for new safety checks starting June 26, 2026. The FAA wants regular ultrasonic scans to catch cracks early and replace parts if needed, all to keep flights safe after a serious engine event. These inspections might cost some time and money but are crucial to avoid bigger problems down the runway.
Analyzed Economic Effects
5 provisions identified: 2 benefits, 3 costs, 0 mixed.
Required removal of certain air seals
If an HPT 1st-stage air seal has one of these serial numbers—CKLBME2702, CKLBME2703, CKLBME2704, CKLBME2705, CKLBME2711, or CKLBMS8019 (P/N 50L663 or 50L959)—you must remove that air seal from service at the next piece part opportunity after June 26, 2026 and replace it with a part eligible for installation. The AD lists those serial numbers and part numbers in table 1 to paragraph (g)(1).
Estimated inspection and replacement costs
The FAA estimates this AD affects 124 engines on U.S. aircraft. The agency estimates per-inspection labor costs of $340 for the HPC 15th-stage disk and $425 for each of the front turbine hub, HPT 2nd-stage hub, and HPT 1st-stage air seal; and estimates 6 engines will need replacement of HPT 1st-stage air seals at a parts cost of $763,000 each (cost per product $763,085; total $4,578,510). On-condition replacement parts are estimated in the hundreds of thousands of dollars (for example, $312,850 to replace an HPC 15th-stage disk).
Mandatory ultrasonic inspections
If you own or operate aircraft with Pratt & Whitney RTX Model PW4074, PW4074D, PW4077, PW4077D, PW4084D, PW4090, or PW4090-3 engines, you must perform angle ultrasonic scan inspections (AUSIs) of the HPC 15th-stage disk, front turbine hub, HPT 1st-stage air seal, and HPT 2nd-stage hub at the next "piece part opportunity" after June 26, 2026 and at every subsequent piece part opportunity. The inspections must follow the Pratt & Whitney service bulletins dated June 20, 2024 listed in the AD.
Optional ALS update ends inspections
You may avoid the repetitive AD inspections by updating the Airworthiness Limitations Section (ALS) of the engine manual and your approved maintenance or inspection program to incorporate the ALS additional inspections in figure 1 to paragraph (i) of the AD. Revising the ALS as specified constitutes terminating action for the AD requirements in paragraphs (g)(1) through (g)(3).
New-part installation eligibility rule
A new, zero-time HPC 15th-stage disk, front turbine hub, HPT 1st-stage air seal, or HPT 2nd-stage hub is considered "part eligible for installation" if it has an FAA Form 8130-3 from the original equipment manufacturer dated July 1, 2025 or later. This replaces a prior requirement that zero-time parts must have passed an AUSI at production to be eligible.
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