# AD 90-07-05: Flap Track Inspection - Type: Airworthiness directive - Status: Current - Products: Boeing 727-100 Series, 727-100C Series, 727-200 Series, 727-200F Series, 727 Series and 727C Series - Effective: April 27, 1990 - Superseded by: Nothing supersedes this AD - Product type: Aircraft, Large airplane - Amendment: 39-6548 - Docket: 89-NM-83-AD - Registered aircraft: 25 may be affected, by airframe or engine model (OpenAirDocs) - FAA DRS: https://drs.faa.gov/browse/excelExternalWindow/651EA2705E7F53518625695E007211BE.0001 - DRS record last changed: May 30, 2024 - Page: https://openairdocs.org/ad/90-07-05 ## The airworthiness directive 90-07-05 BOEING: Amendment 39-6548. Docket No. 89-NM-83-AD. Applicability: All Model 727 series airplanes, certificated in any category. Compliance: Required as indicated, unless previously accomplished. To prevent separation of an inboard trailing edge flap due to corrosion or cracking of the inboard track, accomplish the following: A. For airplanes with flap tracks that have neither the repair nor the preventative modification installed, as specified in Boeing Service Bulletin 727-57-117, Revision 5, dated January 30, 1981, or earlier revisions, accomplish the following: 1. INSPECTION a. Accomplish the initial inspections required by paragraphs A.1.b., A.1.c, and A.1.d, below, prior to (1) or (2), below, whichever occurs later: (1) prior to the accumulation of 7,000 flight cycles or 5 years since manufacture, whichever occurs first; or (2) within the next 1,000 flight cycles or 6 months after the effective date of this AD, whichever occurs first. b. Accomplish either of the following inspections: (1) Perform a close visual inspection for cracks and corrosion of the inboard trailing edge flaps inboard track in accordance with the Accomplishment Instructions of Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989. Repeat this inspection at intervals not to exceed 3,000 flight cycles or 18 months, whichever occurs first. (2) Remove the flap track from the airplane, and perform a visual and magnetic particle inspection for cracks and corrosion in the flap track, in accordance with Figure 1 of Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989. Repeat these inspections at intervals not to exceed 9,000 flight cycles or 6 years, whichever occurs first. c. Inspect the inboard trailing edge flaps inboard track for loose mounting bolts. Repeat this inspection at intervals not to exceed 3,000 flight cycles or 18 months, whichever occurs first.d. If the track has a laminated shim installed in accordance with Boeing Service Bulletin 727-57-0178, Revision New, dated May 5, 1988, visually inspect the laminated shim for correct location in accordance with Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989. Repeat this inspection at intervals not to exceed 3,000 flight cycles or 18 months, whichever occurs first. 2. REPAIR a. If cracks with or without corrosion are detected as a result of the inspections required by paragraph A.1.b, above, and do not exceed the limits specified in Figures 1 or 3 of Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989, prior to further flight, repair in accordance with the service bulletin. If the crack extends into the flap track web, inspect the crack using a borescope at intervals not to exceed 3,000 flight cycles or 18 months, whichever occurs first. If crack growth occurs, repair in accordance with this paragraph or A.2.b., below. Ifonly corrosion is detected and it does not exceed the limits specified in Figure 3 of the service bulletin, repair in accordance with the service bulletin within 12 months. If the crack does not extend into the flap track web, repairs made in accordance with this paragraph terminate the repetitive inspections required by paragraph A.1.b., above. b. If cracks or corrosion are detected which exceed the limits specified in Figures 1 or 3 of Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989, prior to further flight, replace the flap track. c. If loose mounting bolts are detected as a result of the inspections required by paragraph A.1.c., above, retorque the bolts in accordance with Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989, prior to further flight. Modification in accordance with Figure 2 of the service bulletin, terminates the repetitive inspections for loose mounting bolts required in paragraph A.1.c., above. d. If the track is repaired with a splice plate in accordance with Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989, or earlier revisions, within 12,000 flight cycles since repair or 1,000 flight cycles after the effective date of this AD, whichever occurs later, perform a close visual inspection for cracks of the inboard trailing edge flaps inboard track at the aft splice plate fasteners, in accordance with the Accomplishment Instructions of the service bulletin. Repeat this inspection at intervals not to exceed 3,000 flight cycles or 18 months, whichever occurs first. If cracks are detected, replace the flap track prior to further flight. e. If a mislocated laminated shim is detected as a result of the inspections required by paragraph A.1.d., above, and the mislocation exceeds the limits specified in the Accomplishment Instructions of Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989, prior to further flight, reinstall the shimor replace the shim in accordance with the service bulletin. Replacement of the shim terminates the repetitive inspections required by paragraph A.1.d., above. B. For airplanes with flap tracks which have the preventative modification installed in accordance with Boeing Service Bulletin 727-57-117, Revision 5, dated January 30, 1981, or earlier revisions, accomplish the following: 1. INSPECTION a. Accomplish the initial inspections required by paragraphs B.1.b. and B.1.c., below, prior to (1) or (2), below, whichever occurs later: (1) within 9,000 flight cycles since modification or 6 years since modification, whichever occurs first; or (2) within the next 1,000 flight cycles or 6 months after the effective date of this AD, whichever occurs first. b. Accomplish either of the following inspections: (1) Perform a close visual inspection for cracks and corrosion of the inboard trailing edge flaps inboard track in accordance with the Accomplishment Instructions of Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989. Repeat this inspection at intervals not to exceed 3,000 flight cycles or 18 months, whichever occurs first. (2) Remove the flap track from the airplane, and perform a visual and magnetic particle inspection for cracks and corrosion in the flap track, in accordance with Figure 1 of Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989. Repeat these inspections at intervals not to exceed 9,000 flight cycles or 6 years, whichever occurs first. c. Inspect the inboard trailing edge flaps inboard track for loose mounting bolts. Repeat this inspection at intervals not to exceed 3,000 flight cycles or 18 months, whichever occurs first. 2. REPAIR a. If cracks with or without corrosion are detected as a result of the inspections required by paragraphs B.1.b., above, and do not exceed the limits specified in Figures 1 or 3 of Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989, prior to further flight, repair in accordance with the service bulletin. If the crack extends into the flap track web, inspect the crack using a borescope, at intervals not to exceed 3,000 flight cycles or 18 months, whichever occurs first. If crack growth occurs, repair in accordance with this paragraph or B.2.b., below. If only corrosion is detected, and it does not exceed the limits specified in Figure 3 of the service bulletin, repair in accordance with the service bulletin within 12 months. If the crack does not extend into the flap track web, repairs made in accordance with this paragraph terminate the repetitive inspections required by paragraph B.1.b., above. b. If cracks or corrosion are detected which exceed the limits specified in Figures 1 or 3 of Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989, prior to further flight, replace the flap track. c. If loose mounting bolts are detected as a result of the inspections required by paragraph B.1.c., above, prior to further flight, retorque the bolt in accordance with Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989. Modification in accordance with Figure 2 of the service bulletin, terminates the repetitive inspections for loose mounting bolts required by paragraph B.1.c., above. d. If the track is repaired with a splice plate in accordance with Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989, within 12,000 flight cycles since repair or 1,000 flight cycles after the effective date of this AD, whichever occurs later, perform a close visual inspection for cracks of the inboard trailing edge flaps inboard track at the aft splice plate fasteners, in accordance with the service bulletin. Repeat this inspection at intervals not to exceed 3,000 flight cycles or 18 months, whichever occurs first. If cracks are detected, replace the flap track prior to further flight.C. For airplanes with flap tracks that have been repaired with the splice plate in accordance with Boeing Service Bulletin 727-57-117, Revision 5, dated January 30, 1981, or earlier revisions, accomplish the following: 1. INSPECTION a. Accomplish the initial inspections required by paragraphs C.1.b., C.1.c., and C.1.d., below, prior to (1) or (2), below, whichever occurs later: (1) within 12,000 flight cycles since repair or 8 years since repair, whichever occurs first; or (2) within the next 1,000 flight cycles or 6 months after the effective date of this AD, whichever occurs first. b. Remove the flap track from the airplane, and perform a visual and magnetic particle inspection for cracks and corrosion in the flap track, in accordance with Figure 1 of Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989. Repeat these inspections at intervals not to exceed 9,000 flight cycles or 6 years, whichever occurs first. c. Inspectthe inboard trailing edge flaps inboard track for loose mounting bolts. Repeat this inspection at intervals not to exceed 3,000 flight cycles or 18 months, whichever occurs first. d. Perform a close visual inspection for cracks of the inboard trailing edge flaps inboard track at the aft splice plate fasteners, in accordance with the service bulletin. Repeat this inspection at intervals not to exceed 3,000 flight cycles or 18 months, whichever occurs first. If cracks are detected, replace the flap track prior to further flight. 2. REPAIR a. If new cracks, crack growth, or corrosion are detected as a result of the inspections required by paragraph C.1.b., above, and do not exceed the limits specified in paragraph C.2.b., below, prior to further flight, repair in accordance with Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989. If the crack extends into the flap track web, inspect the crack using a borescope at intervals not to exceed 3,000flight cycles or 18 months, whichever occurs first. If crack growth occurs, repair in accordance with this paragraph or C.2.b., below. If the crack does not extend into the flap track web, repairs made in accordance with this paragraph terminate the repetitive inspections required by paragraph C.1.b., above. b. Replace the flap track prior to further flight if any of the following occur: (1) The crack length is within the short limits specified in Figure 1 of Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989, and the crack runs toward the flap track integral rib. (2) The crack length exceeds the short limits specified in Figure 1 of Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989. (3) The corrosion exceeds the limits specified in Figure 3 of Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989. c. If loose mounting bolts are detected as a result of the inspections required by paragraph C.1.c., above, prior to further flight, retorque the bolts in accordance with the service bulletin. Repair in accordance with Figures 3 or 4 of the service bulletin terminates the repetitive inspections for loose mounting bolts required by paragraph C.1.c., above. d. If the track is repaired with a splice plate in accordance with Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989, perform a close visual inspection for cracks of the inboard trailing edge flaps inboard track at the aft splice plate fasteners, in accordance with the service bulletin. Repeat this inspection at intervals not to exceed 3,000 flight cycles or 18 months, whichever occurs first. If cracks are detected, replace the flap track prior to further flight. D. The following constitutes terminating action for the inspection requirements of this AD: 1. Modification in accordance with Figure 2 of Boeing Service Bulletin 727-57-0178, Revision 3, dated December 21, 1989; or2. Repair in accordance with Figure 3 of the service bulletin, if no splice plate is required. E. An alternate means of compliance or adjustment of the compliance time, which provides an acceptable level of safety, may be used when approved by the Manager, Seattle Aircraft Certification Office, FAA, Northwest Mountain Region. NOTE: The request should be forwarded through an FAA Principal Maintenance Inspector (PMI), who will either concur or comment, and then send it to the Manager, Seattle Aircraft Certification Office. F. Special flight permits may be issued in accordance with FAR 21.197 and 21.199 to operate airplanes to a base in order to comply with the requirements of this AD. All persons affected by this directive who have not already received the appropriate service documents from the manufacturer may obtain copies upon request to Boeing Commercial Airplanes, P.O. Box 3707, Seattle, Washington 98124. These documents may be examined at the FAA, Northwest Mountain Region, Transport Airplane Directorate, 17900 Pacific Highway South, Seattle, Washington, or Seattle Aircraft Certification Office, 9010 East Marginal Way South, Seattle, Washington. This amendment (39-6548, AD 90-07-05) becomes effective on April 27, 1990. ## Affected data sheets (1) (OpenAirDocs) The type certificate data sheets whose models the AD names. - [TCDS A3WE](https://openairdocs.org/tcds/A3WE): The Boeing Company; names 6 of 6 models: 727-100 Series, 727 Series, 727-200 Series, 727-100C Series, 727-200F Series, 727C Series ## Registered aircraft it may apply to (OpenAirDocs) Matched by airframe and engine model; the AD's applicability may narrow it by serial number, part number or equipment. - Aircraft: 25 (25 by airframe model, 0 by engine model) - Makers: Boeing 25 Models with the most aircraft: - [Boeing 727-223](https://openairdocs.org/model/boeing-727-223): 9 aircraft (airframe model) - [Boeing 727-227](https://openairdocs.org/model/boeing-727-227): 4 aircraft (airframe model) - [Boeing 727-225](https://openairdocs.org/model/boeing-727-225): 2 aircraft (airframe model) - [Boeing 727-200F](https://openairdocs.org/model/boeing-727-200f): 1 aircraft (airframe model) - [Boeing 727-200](https://openairdocs.org/model/boeing-727-200): 1 aircraft (airframe model) - [Boeing 727-212](https://openairdocs.org/model/boeing-727-212): 1 aircraft (airframe model) - [Boeing 727-230](https://openairdocs.org/model/boeing-727-230): 1 aircraft (airframe model) - [Boeing 727-232](https://openairdocs.org/model/boeing-727-232): 1 aircraft (airframe model) - [Boeing 727-243](https://openairdocs.org/model/boeing-727-243): 1 aircraft (airframe model) - [Boeing 727-247](https://openairdocs.org/model/boeing-727-247): 1 aircraft (airframe model) - [Boeing 727-264](https://openairdocs.org/model/boeing-727-264): 1 aircraft (airframe model) - [Boeing 727-281](https://openairdocs.org/model/boeing-727-281): 1 aircraft (airframe model) - [Boeing 727-277](https://openairdocs.org/model/boeing-727-277): 1 aircraft (airframe model) All 13 models: https://openairdocs.org/ad/90-07-05/models.md Every aircraft: https://openairdocs.org/ad/90-07-05/aircraft.md Its text cites no advisory circulars or STCs. --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain.