How do you determine whether a component should be repaired or replaced?

• A. Repair should be performed only if the part is new and unused.
• B. Replacement is always chosen for any minor damage.
• C. Repair must be used even if limits are exceeded.
• D. Repair within limits, replace if damage exceeds limits or compromises safety.

Answer: (D)

Decisions about repairing versus replacing hinge on whether the damage stays within the approved repair limits and whether a repair would restore the part to a safe, airworthy condition. If the damage is within those limits and the repair can be performed using the manufacturer’s approved procedures without compromising strength or safety, a repair is permitted. If the damage exceeds the defined limits or a repair would still leave the part unsafe or unable to meet required performance, replacement is required. This approach prevents unnecessary replacements when a proper repair can bring the part back to service, and it ensures safety by not accepting a repair that leaves the component below acceptable standards. For example, a small, non-load-bearing surface imperfection on a noncritical part might be repairable within limits, while a deep crack or distortion on a structural or safety-critical component would necessitate replacement.