CFM56 Inlet Gearbox Hardware No 3 Bearing Reliability CFM56-7B Aft Air/Oil Seal

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CFMI Proprietary information CFM56 Inlet Gearbox Hardware No 3 Bearing Reliability CFM56-7B Aft Air/Oil Seal October, 2004 2 CFMI Proprietary information CFM56-7B Inlet Gearbox Assembly No 3 Ball Bearing Spring Housing No 3 Roller Bearing Horizontal Bevel Gear No 3 Forward Air/Oil Seal No 3 Aft Air/Oil Seal No 3 Bearing Lock Nut Inlet Gearbox Housing 24 Nuts that hold 3B/3R/Spring Housing to IGB Housing This gearbox is used in the CFM56-5A, CFM56-5B, CFM56-5C, and CFM56-7B engine applications 3 CFMI Proprietary information CFM56 No. 3 Ball Bearing Reliability October 2003 thru September 2004 UER's IFSD Hours UER Rate IFSD Rate CFM56-3 1 1 9.898 0.101 0.101 CFM56-7 2 0 9.250 0.216 0.000 Total 3 1 19.148 0.157 0.052 Note: Rates are per Million Engine Flight Hours • CFM56-3/-7B Models- Hard Particle Contamination 每 CFM56-3 S/B 72-923 recommends 50-75 Hour inspection interval on engines delivered between April, 1997 and ESN 860-226 until they reach 10,000 Hours 每 Extensive IGB Cleanliness Improvements incorporated across all CFM56 Production • CFM56-7B Programs - Ball Skidding 每 Engineering investigation 每 Bearing offset has impact on skidding 每 Engine Testing Complete 每 Able to reproduce skidding with minimum offset housing 每 Design change in place to increase min offset 每 Field action to inspect Spring Housing at exposure, re-identify or modify to achieve offset • CFM56-3/-7B Models - Winsted Non-Tumbled Ball Population (Fleet Highlites Aug 2002) 每 Root Cause Identified 每 No Field Actions recommended 每 Corrective Actions implemented at all bearing suppliers • Residual Stress Specification Implemented 12/00 • Heat Treat and Improved Tumbling Process are now VSE controlled at all vendors • CFM56-3/-7B Models - MRC Ball Cracking 每 Root Cause Identified 每 Corrective Actions Implemented 每 No Field Actions recommended 4 CFMI Proprietary information CFM56-7B No 3 Bearing Reliability How does the No 3 bearing reliability compare with total fleet? CFM56-Total Fleet vs. CFM56-7B No 3 Ball Bearing Reliability 12 Month Rolling Average 0.000 0.200 0.400 0.600 0.800 1.000 1.200 Jan-99 Mar-99 May-99 Jul-99 Sep-99 Nov-99 Jan-00 Mar-00 May-00 Jul-00 Sep-00 Nov-00 Jan-01 Mar-01 May-01 Jul-01 Sep-01 Nov-01 Jan-02 Mar-02 May-02 Jul-02 Sep-02 Nov-02 Jan-03 Mar-03 May-03 Jul-03 Sep-03 Nov-03 Jan-04 Mar-04 May-04 Jul-04 Sep-04 Date Quantity of Events Per Million EFH CFM56-7B UER Rate CFM56-7B IFSD Rate CFM56-Total IFSD Rate CFM56-Total UER Rate CFM56-7B Reliability is similar to total CFM56 fleet Cleanliness and ball process improvements having impact on total reliability 5 CFMI Proprietary information CFM56-7 No 3 Bearing Reliability No 3 Bearing Events since Entry into Service • 15 Total UER＊s / 5 IFSD＊s in 32.44 Million Engine Flight Hours 每 Cumulative UER/IFSD Rates 每 0.462/0.154 events per MEFH • Investigation Findings 每 Hard Particle Contamination 每 6 events 每 Ball Skidding 每 2 Events 每 Winsted Ball Residual Stress 每 1 Event 每 MRC Ball Cracking 每 1 Event 每 No Root Cause Established 每 3 Events 每 Under Investigation 每 2 Event Event Date Eng Mod Prod or O/H ESN IFSD UER Brg TSN Brg CSN Bearing P/N Brg S/N Engine Delivery Date Last MCDI Oil Type Winsted Population MRC Population Investigation Findings 9-May-00 7B Prod 874-618 X 3913 1729 1460M52P03 FCAB2990 Mar-99 Normal MCD Insp Mobil Jet 2 Yes No Hard Particle Contamination 27-Aug-01 7B Prod 875-386 X X 7044 3136 1460M52P03 FCAB3906 Nov-98 DMS System- Did not register chip2s3a8t f0ailure. Yes No No Root Cause Established 17-Dec-01 7B Prod 877-205 X X 3262 4984 1665M98P02 MDAHH822 Jan-00 424H/377C 2380 No No Ball Skidding 1-May-02 7B Prod 889-331 X 3136 3098 1460M50P03 FBGE5245 May-01 Normal MCD Insp Aeroshell 560 No No Ball Skidding 28-May-02 7B Prod 877-419 X 5527 3895 1665M98P02 MDAHN045 Jun-00 Normal MCD Insp Mobil Jet 254 No Yes Ball Cracking - MRC 15-Sep-02 7B Prod 876-663 X X 5249 2262 1460M52P03 FCAC1025 Nov-00 280 Hrs/137 Cyc 2380 No No No Root Cause Established 20-Dec-02 7B Prod 888-278 X 4571 2099 1665M98P02 MDAJC188 Apr-01 Normal MCD Insp No No Hard Particle Contamination 12-Mar-03 7B Prod 888-972 X 2688 1927 1665M98P02 MDAKG935 May-02 Normal MCD Insp MJ254 No Yes Under Investigation - BSD 11-Apr-03 7B Prod 888-639 X 3353 1030 1460M52P03 FCAC9834 Oct-01 Normal MCD Insp MJ2 No No Hard Particle Contamination 28-May-03 7B Prod 874-440 X 17154 7200 1460M52P03 FCAB3897 Nov-98 Normal MCD Insp Yes No Residual Stress 4-Jun-03 7B Prod 889-274 X X 7760 2083 1665M98P02 MDAHY887 Mar-01 Chips generated prior to IFSD MJ2 No No Hard Particle Contamination 29-Jul-03 7B Prod 888-301 X 8549 4824 1665M98P02 MDAJC203 Apr-01 500 hours No No Hard Particle Contamination 10-Sep-03 7B Prod 888-321 X X 8621 2476 1665M98P02 MDAJC232 Apr-01 Not reported No No No Root Cause Established 17-Jun-04 7B Prod 876-635 X 10480 3690 1665M98P02 MDAHN623 Oct-00 500 Hours No No Hard Particle Contamination 22-Aug-04 7B Prod 890-691 X 1354 736 1460M52P03 FCAF6023 Jan-04 294 Hours MJ2 No No Under Investigation 6 CFMI Proprietary information CFM56-7B No 3 Aft Air/Oil Seal Teflon Problem/Background: • Epoxy adhesive used to bond the Teflon seal onto the Air-Oil seal has suffered cohesive failures on two high time CFM56-7B engines • Review of parts at shop visit does not indicate this is a wide spread issue • Analysis indicates that this epoxy adhesive may not have adequate long term temperature capability • CFM has a program to qualify a new higher temperature adhesive for Teflon 每 Expect new adhesive availability 4Q04 • Recommendation 每 replace Teflon at next shop visit using current adhesive until new adhesive is available 每 CFM requests customers to report any findings of loose teflon 7 CFMI Proprietary information Actions / Plan • Two new adhesives currently in evaluation 每 Back-back comparison to current adhesive • Room temp and elevated temperatures • Humidity conditioning • Fluid resistance 每 Test completion in Nov-04 • Go Forward Plan 每 Document experience at overhaul shops for all CFM models 每 Complete testing of new adhesives 每 Complete root cause assessment 每 Go fwd decision - target 4Q04 8 CFMI Proprietary information Actions / Plan • New Adhesive 每 Two new 400 F adhesives currently being tested • EA9673 (Loctite) and FM2550 (Cytec) being compared to baseline adhesive • Adhesives have been assessed at room temperature and 350 F in pristine condition with equal or better performance versus baseline epoxy • Humidity conditioning (60 days) of other shear test samples in-process. Will be ready for testing in late October, 04 • Fluid resistance of new adhesives to be assessed based on supplier data 每 All testing will be complete in mid November, 04 每 GE EMPIS spec drafted to define new adhesive • Go Forward Plan 每 Document experience at overhaul shops for all CFM models 每 Complete testing of new adhesive 每 4Q04 每 Obtain CFMI Tech Review approval • Target intro by CID 每 4Q04 每 Intro new adhesive to ESM repairs 每 4Q04

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CFM56 Inlet Gearbox Hardware No 3 Bearing Reliability CFM56-7B Aft Air/Oil Seal

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CFM56 Inlet Gearbox Hardware No 3 Bearing Reliability CFM56-7B Aft Air/Oil Seal

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