AD NUMBER: 2011-10-13

MANUFACTURER: Diamond Aircraft Industries GmbH Models DA 42, DA 42 NG, and DA 42 M-NG Airplanes
SUBJECT: Airworthiness Directive 2011-10-13

SUMMARY: The FAA is adopting a new airworthiness directive (AD) for the products listed above. This AD results from mandatory continuing airworthiness information (MCAI) issued by an aviation authority of another country to identify and correct an unsafe condition on an aviation product. The MCAI describes the unsafe condition as:

Since 2004, more than 30 reports have been received of in-flight loss of a rear passenger door on Diamond airplanes, the majority of which were DA 40s. In addition at least 18 doors have been replaced because of damage found on the hinge. Diamond Aircraft Industries conducted analyses and structural tests to determine the root cause of the door opening in flight. The conclusions were that the primary locking mechanism provided adequate strength to react to the loads in flight. It was also determined that the root cause was the crew not properly securing the rear passenger door by the main locking mechanism, prior to flight. Damage to the hinges has been caused primarily by external loads (wind gust conditions) while the airplane was parked.

All DA 40 and DA 42 airplanes have a system installed that provides a warning if the main door latch is not fully closed and a secondary safety latch (with retaining bracket) design feature. The initial intended design function of the latch was to hold the rear passenger door in the "near closed" position while on the ground, protecting the door from wind gusts. However, the original retaining bracket Part Number (P/N) DA4-5200-00-69 might not hold the door in this "near closed" position while in flight.

This condition, if not corrected, could result in the rear passenger door opening and departing the airplane in flight.

This AD to requires actions to correct the unsafe condition on these products.

FMI: http://rgl.faa.gov/Regulatory_and_Guidance_Library/rgAD.nsf/0/AE2B382617F32C518625788F004B61DB?OpenDocument