NE-08-17R3 9992M60G06

A suspected unapproved parts (SUP) investigation regarding engine parts overhauled by Propulsion Technology LLC, repair station certificate number XZ4R084M, has revealed that repairs on CFM56 life-limited parts hardware did not meet the requirements of the CFM56 engine overhaul manual. Seal tooth plasma coating was inspected and determined to be, in some areas, thicker than the engine overhaul manual limits. The investigation also found seal tooth plasma coating overspray between the seal teeth, which was not permitted by the engine overhaul manual and potential missed cracks during the fluorescent-penetrant inspection. After processing by Propulsion Technology LLC, the parts listed below may not conform to type design. We are developing inspections with CFM International to determine if the parts conform to type design, as well as developing repair procedures to restore nonconforming parts to type design. Propulsion Technology LLC returned many of these parts to third-party suppliers and repair stations for subsequent installation. The potential non-airworthy condition of these parts was unknown to the third-party suppliers, repair stations, owners, and operators who, in some cases, returned these parts to service. We received the attached list that identifies by P/N and S/N, the suspect parts considered in the SUP investigation for the CFM56 engine models listed above.
The SUP investigation was completed and closed by the FAA in May 2008. A letter of correction was issued and this SAIB was initially released.