EASA AD US-2025-16-09: Pacific Scientific Company: Rotary Buckle Assemblies - Inspection / Reidentification / Replacement

What to do

Affected operators must inspect the Pacific Scientific rotary buckle assemblies by September 22, 2025, and depending on inspection results, replace screws with hex head screws or replace the entire buckle. Operators may temporarily prohibit use of the seat by removing the male side of the lap belt and placarding the seat inoperative until repairs are completed. Documentation and reidentification of the buckle after maintenance are required to demonstrate compliance.

Summary

The Pacific Scientific Company: Rotary Buckle Assemblies - Inspection / Reidentification / Replacement is a final rule airworthiness directive (AD 2025-16-09) issued by the Federal Aviation Administration (FAA) affecting all airplanes equipped with Pacific Scientific Company rotary buckle assemblies part numbers 1111475 (all dash numbers) and 1111548-01 manufactured between January 2012 and April 2013 or with unknown manufacture dates. This AD addresses a manufacturing defect in the screws inside the buckles that could lead to buckle failure under load. The directive mandates inspection, possible screw replacement, buckle reidentification, or buckle replacement to ensure occupant restraint system integrity.

What changed

This new AD introduces mandatory inspections of the affected rotary buckle assemblies for missing or loose screw heads and requires replacing any defective screws or the entire buckle as necessary. It expands the applicability period from January 2012 through April 2013, adding more affected units compared to the initial proposal. The AD also prohibits installation of certain buckles and allows optional placarding of seats as inoperative until corrective actions are completed.

Why it matters

This AD is critical for aviation professionals because it addresses a safety risk that could lead to occupant restraint failure during flight, posing a serious hazard. Operators and maintenance organizations must ensure compliance to avoid unsafe conditions and potential regulatory penalties. The directive affects a large number of buckles worldwide, so timely action is necessary to maintain airworthiness and passenger safety.