# Boeing Alert Service Bulletin 747-53A2367: Revision 5

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- Document: [Boeing Alert Service Bulletin 747-53A2367](https://openairdocs.org/service-documents/boeing/747-53a2367.md)
- Title as filed: U.S. DOT/FAA - SB-747-53A2367-05
- Pages: 171
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## Text

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### Page 1

Commercial 
Airplanes
747
Service Bulletin
ALERT
Number: 747-53A2367
Original Issue: December 18, 1991
Revision 5: July 08, 2014
ATA System: 5331
SUBJECT: FUSELAGE - Skin - Body Skin Lap Joint Inspections Based On Fatigue Test Results
Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15
CFR 300-774). An export license may be required before it is used for development, production or use by foreign
persons from specific countries. The controller of this data has the individual responsibility to abide by all export
laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET
Copyright © 1991 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document
are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The
Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner,
BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and
Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in
connection with this document unless provided in writing by Boeing.
Original Issue: December 18, 1991
747-53A2367Revision 5: July 08, 2014
1 of 171
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Table of Contents
Revision Transmittal Sheet ............................................ 5
Summary ...................................................... 9
1. PLANNING INFORMATION ........................................ 1 3
A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 1 9
B. Concurrent Requirements ...................................... 1 9
C. Reason ................................................ 1 9
D. Description .............................................. 2 0
E. Compliance .............................................. 2 5
F. Approval ............................................... 3 2
G. Manpower .............................................. 3 6
H. Weight and Balance Changes .................................... 4 0
I. Electrical Load Data ......................................... 4 0
J. References .............................................. 4 0
1. Existing Data: ......................................... 4 0
2. Data Supplied with this Service Bulletin: ........................... 4 1
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 4 2
K. Publications Affected ........................................ 4 3
L. Interchangeability and Intermixability of Parts ........................... 4 3
M. Software Accomplishment Summary ................................ 4 3
2. MATERIAL INFORMATION ........................................ 4 5
A. Material - Price and Availability ................................... 4 5
B. Industry Support Information .................................... 4 6
C. Parts Necessary for Each Airplane ................................. 4 6
1. Kits/Parts: ........................................... 4 6
2. Parts and Materials Supplied by the Operator: ........................ 6 2
3. Parts Modified and Reidentified: ............................... 6 2
4. Parts Removed and Not Replaced: .............................. 6 2
D. Parts Necessary to Change Spares ................................. 6 2
E. Special Tooling - Price and Availability ............................... 6 2
F. Special Tooling Necessary to do this Service Bulletin ....................... 6 2
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 6 3
A. GENERAL INFORMATION ..................................... 6 3
B. WORK INSTRUCTIONS ....................................... 6 7
FIGURE 1: THIS FIGURE IS DELETED .................................. 7 6
FIGURE 2: THIS FIGURE IS DELETED .................................. 7 7
FIGURE 3: THIS FIGURE IS DELETED .................................. 7 8
FIGURE 4: THIS FIGURE IS DELETED .................................. 7 9
FIGURE 5: THIS FIGURE IS DELETED .................................. 8 0
FIGURE 6: THIS FIGURE IS DELETED .................................. 8 1
FIGURE 7: THIS FIGURE IS DELETED .................................. 8 2
FIGURE 8: THIS FIGURE IS DELETED .................................. 8 3
FIGURE 9: SECTION 41 - LAP JOINT INSPECTION [Group 1, 3, 7] .................. 8 4
FIGURE 10: SECTION 41 - LAP JOINT INSPECTION [Group 2, 4, 8-9] ................. 8 8
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FIGURE 11: SECTION 41 - LAP JOINT INSPECTION [Group 5-6, 10-13] ................ 9 2
FIGURE 12: SECTION 42 - LAP JOINT INSPECTION [Group 1-2, 4-5, 7-9, 11-13] ........... 9 6
FIGURE 13: SECTION 42 - LAP JOINT INSPECTION [Group 10] .................... 1 0 0
FIGURE 14: SECTION 46 - LAP JOINT INSPECTION [Group 1-2, 4-5, 12] ............... 1 0 4
FIGURE 15: SECTION 41, STRINGER 6 - LAP JOINT MODIFICATION ................ 1 0 7
FIGURE 16: SECTION 41, STRINGER 23 - LAP JOINT MODIFICATION ................ 1 0 9
FIGURE 17: SECTION 42 - LAP JOINT INSPECTION [Group 3, 6] ................... 1 1 2
FIGURE 18: SECTION 41, STRINGER 44 - LAP JOINT MODIFICATION ................ 1 1 7
FIGURE 19: SECTION 42, STRINGER 44 - LAP JOINT MODIFICATION ................ 1 1 9
FIGURE 20: SECTION 46 - LAP JOINT INSPECTION [Group 7-9, 11, 13] ............... 1 2 1
FIGURE 21: SECTION 46 - LAP JOINT INSPECTION [Group 10] .................... 1 2 7
FIGURE 22: SECTION 46 - LAP JOINT INSPECTION [Group 3, 6] ................... 1 3 0
FIGURE 23: SECTION 44 - LAP JOINT INSPECTION [Group 3, 6] ................... 1 3 3
FIGURE 24: SECTION 41, STRINGER 6 - LAP JOINT POST-MODIFICATION INSPECTION ..... 1 3 6
FIGURE 25: SECTION 41, STRINGER 23 - LAP JOINT POST-MODIFICATION INSPECTION .... 1 4 2
FIGURE 26: SECTION 41, STRINGER 44 - LAP JOINT POST-MODIFICATION INSPECTION .... 1 4 6
FIGURE 27: SECTION 42, STRINGER 44 - LAP JOINT POST-MODIFICATION INSPECTION .... 1 4 9
FIGURE 28: SECTION 41, STRINGER 6, STA 340 TO STA 400 - LAP JOINT POST-MODIFICATION
INSPECTION - LEFT SIDE - AIRPLANES WITH EXTERNAL DOUBLERS INSTALLED AS
GIVEN IN SB 747-53-2272 BETWEEN STA 340 AND STA 400 [Group 4-6, 9-11] .... 1 5 2
FIGURE 29: SECTION 41, STRINGER 6, STA 340 TO STA 400 - LAP JOINT POST-MODIFICATION
INSPECTION - RIGHT SIDE - AIRPLANES WITH EXTERNAL DOUBLERS INSTALLED AS
GIVEN IN SB 747-53-2272 BETWEEN STA 340 AND STA 400 [Group 4-6, 9-11] .... 1 5 8
Appendix A: REDUCED EDGE MARGIN PROCEDURES ........................ 1 6 4
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Commercial 
Airplanes
747
Service Bulletin
ALERT
Revision Transmittal SheetNumber: 747-53A2367Original Issue: December 18, 1991
Revision 5: July 08, 2014
ATA System: 5331
SUBJECT: FUSELAGE - Skin - Body Skin Lap Joint Inspections Based On Fatigue Test Results
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION
More work is necessary on airplanes that have had lap joint modifications accomplished as given in previous
revisions of this service bulletin before 20,000 total flight cycles. Post-modification inspections will be required
within 15,000 flight cycles after modification in order to allow continued operation to the Limit of Validity (LOV)
of 35,000 total flight cycles.
In addition, more work is necessary on airplane line numbers 604 - 685 that had external doublers installed as
given in Service Bulletin 747-53-2272 at Stringer 6 from Station 340 to Station 400. Post-modification inspection
at Stringer 6 from Station 340 to Station 400 is now required.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-10-05 is related to this service bulletin.
REASON FOR REVISION
This revision is sent to add post-modification inspections for all airplanes, and to give instructions for modification
of 747SP airplanes rather than requiring operators to contact Boeing for modification instructions. Other changes
have also been made.
These sections were changed:
1. In the Summary: Added Widespread Fatigue Damage (WFD) statement. Added new SRP and FTD
references. Added planning data table. Updated the Action section, related Airworthiness Directives,
and summary illustration.
2. In paragraph 1.A., Effectivity: Revised some group descriptions in the Group/Configuration table. Added
Group 12 for 747-200B and -300 airplanes, line numbers 688 through 750, that do not have a side
cargo door (these airplanes were previously in Group 5). Added Group 13 for 747-200B and -300
airplanes, line numbers 686 through 810, that do have a side cargo door (these airplanes were previously
in Group 11). Group 12 and 13 airplanes have unique inspection requirements due to a thicker skin at
the Stringer 6 lap joint from Station 340 to 400.
3. In Paragraph 1.C., Reason: Added reason for Revision 5, added WFD statement, and added new SRP
and FTD references.
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4. In Paragraph 1.D., Description: Added description of post-modification inspection requirements, and
added "More work" statements for Revision 5. Added reference to 747 SRM 53-30-03, Figure 19.
5. In Paragraph 1.E., Compliance: Updated related AD information. Added information for post-repair
inspection requirements. Updated compliance Tables 1 and 2 so that existing compliance times are
based from the effective dates of related Airworthiness Directives where applicable. In compliance
Table 1, revised footnote "(f)" (previously footnote "(g)") to be applicable to new Group 13 and added
footnote "(h)" which was previously a general information note in the Accomplishment Instructions.
Removed post-modification actions from Compliance Table 2. Added new Compliance Tables 3, 4, 5,
and 6 for post-modification inspection requirements.
6. In Paragraph 1.F., Approval: Updated Alternative Method of Compliance (AMOC) statements to reflect
new compliance tables. Added new AMOC statements for AD 2012-10-03 and AD 2013-16-24.
7. In Paragraph 1.G., Manpower: Added manpower information for post-modification inspections.
8. In Paragraph 3.A., General Information: Updated some existing notes and added new notes 27 through
33. Added reference to 747 SRM 53-30-03, Figure 19.
9. In Paragraph 3.B., Work Instructions: Added information for post-repair inspection requirements. Revised
PART 3 to make modification instructions applicable for Group 3 and 6 airplanes, and removed the
instruction for operators to contact Boeing for modification of Group 3 and 6 airplanes (no vertical
revision lines shown for deleted steps). Added PART 4, PART 5, and PART 6 for post-modification
inspection requirements.
10. In Figure 11: Revised footnote (c) to also reference Service Bulletin 747-53-2253.
11. In Figure 15: Revised notes related to previous modifications at Stringer 6.
12. Figures 24, 25, 26, and 27: These new figures have been added for post-modification inspections of
areas where modification doublers have been installed as given in this service bulletin.
13. Figures 28 and 29: These new figures have been added for post-modification inspections at Stringer
6 from Station 340 to Station 400 on applicable line numbers 604 - 685 with external doublers installed
as given in Service Bulletin 747-53-2272 or as given in Service Bulletin 747-53-2253.
14. Revised "cracks found" and "no cracks found" conditions to "any crack found" and "no crack found",
respectively, throughout the service bulletin.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes,
to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY
December 18, 1991Original Issue:
January 27, 1994Revision 1:
October 30, 2008Revision 2:
January 15, 2009Revision 3:
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January 13, 2011Revision 4:
July 08, 2014Revision 5:
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Commercial 
Airplanes
747
Service Bulletin
ALERT
SummaryNumber: 747-53A2367Original Issue: December 18, 1991
Revision 5: July 08, 2014
ATA System: 5331
SUBJECT: FUSELAGE - Skin - Body Skin Lap Joint Inspections Based On Fatigue Test Results
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
CONCURRENT REQUIREMENTS
None.
BACKGROUND
Based on a structural review of the 747 airplane, incorporation of the inspection shown in this service bulletin
is recommended on the 747 airplanes shown in this service bulletin. This service bulletin gives data for the
inspection and repair of certain 747 airplane body skin longitudinal lap joints. These inspections and repairs are
necessary for safe operation of 747 airplanes past the design goal for economic usage.
Boeing has completed extended pressure fatigue tests on two 747 fuselage test articles. These tests have
identified areas of the body lap joints where fatigue cracks can occur. Inspection and repair of these areas is
necessary for safe operation of 747 airplanes past the design goal for economic usage.
The inspections in this service bulletin will make sure that fatigue cracks in the body lap joints shown are found
and repaired before they become critical. Skin cracks not detected prior to reaching critical crack length may
result in in-flight depressurization of the airplane and the inability to withstand current regulatory fail-safe loads.
Revision 2: Subsequent to the release of Revision 1 of this service bulletin, a review of all lap joints was
accomplished for the affected airplanes. It was determined that all lap joints with upper skin thickness of 0.090
inches or less should be inspected at the times given in Paragraph 1.E., Compliance. In addition, a review of
all bulletins which recommend repeat inspections was performed to determine if the inspections were appropriate
on aging airplanes. This review indicated that certain lap joints where the skin thickness is less than or equal to
0.071 inches should be modified at the times given in Paragraph 1.E., Compliance on airplane line numbers
201 through 810.
The skin lap joints affected by this service bulletin have been determined to be structure that is susceptible to
Widespread Fatigue Damage (WFD). For more information about WFD, refer to 747-SL-53-088.
Boeing Service Related Problem (SRP) 747-SRP-53-0278 and 747-SRP-53-0437 are related to this service
bulletin.
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Boeing Fleet Team Digest (FTD) article 747 FTD 53-13003 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more
information.
ReferenceAffectedPlanning Data
Paragraph 1.A.2., Spares AffectedNoSpares Affected
Paragraph 1.E., Compliance and Paragraph
1.F., Approval
YesAD Related
Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change
Paragraph 1.I., Electrical Load DataNoElectrical Load Changed
Paragraph 1.K., Publications AffectedNoPublications Affected
Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew
Operations Manual and/or FAA Approved Air-
plane Flight Manual)
Paragraph 2.C.1., Kits/PartsYesKits/Parts Required
Paragraph 2.C.2., Parts and Materials Supplied
by the Operator
YesOperator Supplied Parts/Material
Paragraph 2.F., Special Tooling Necessary to
do this Service Bulletin
NoSpecial Tooling Required
ACTION (PRR 85901-88RS)
Lap joint inspection:
– Do external eddy current inspections of certain lap joints for cracks. These lap joints are in Section 41,
Section 42, Section 44 and Section 46. If no crack is found, do the inspection again at the time shown in
this service bulletin. If any crack is found, remove the fastener in the cracked hole and sufficient adjacent
fasteners and do open hole HFEC inspections to find the crack length. Repair as shown in the structural
repair manual before any more flights.
Lap joint modification:
– Do eddy current inspections of the lap joints in sections 41 and 42 that will be modified. If any crack is found,
repair the crack and contact Boeing for lap joint modification instructions. For areas where no crack is
found,do the lap joint modifications.
Lap joint post-modification inspection:
– Do detailed and eddy current inspections for cracks in the skin and/or doubler structure at certain lap joint
areas where external modification doublers were installed. If any crack is found, contact Boeing for repair
instructions and do the repair.
EFFECTIVITY
747-100, 747-100B, 747-100B SUD, 747-200B, 747-300, 747SP, and 747SR airplanes. Refer to Paragraph
1.A., Effectivity for the list of affected airplanes.
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COMPLIANCE
Refer to Service Bulletin Paragraph 1.E., Compliance for Compliance information.
Federal Aviation Administration (FAA) Airworthiness Directives AD 90-06-06, AD 2004-07-22 R1, AD 2005-08-01,
AD 2006-20-02, AD 2006-22-09, AD 2006-24-02, AD 2006-24-05, AD 2007-15-07, AD 2008-16-14, AD
2009-04-16, AD 2010-10-05, AD 2012-10-03 , and AD 2013-16-24 are related to this service bulletin.
INDUSTRY SUPPORT INFORMATION
This service bulletin was first released before October of 1994. Thus industry support for affected airplanes
depends upon whether you ever filed a warranty claim with Boeing on this service bulletin.
MANPOWER
Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION
Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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BOEING SERVICE BULLETIN 747-53A2367
ALERT  ALERT
S-39
FORWARD WING-TO-BODY FAIRING
S-45
LAP JOINT
(TYPICAL)
RIGHT SIDE SHOWN
LEFT SIDE SIMILAR
AFT
S-40  WING-TO-BODY
FAIRING
S-46  STA  SECTION 46
2360
SECTION 44
-12
DO EDDY CURRENT INSPECTIONS OF  STA  1480
SKIN LAP JOINTS FOR CRACKS IN  LAP  JOINT
UPPER FASTENER ROWS.  (TYPICAL)
DO A STRUCTURAL MODIFICATION ON
SPECIFIED LAP JOINTS AT STRINGERS
6, 23 AND 44  S-19
DO POST MODIFICATION INSPECTIONS
FOR CRACKS.
STA
1000
CRACK  UPPER SKIN  PROTRUDING  S-19
HEAD FASTENER
• (TYPICAL)  STA  520  S-23
FLUSH HEAD  STA
UPPER -.  ROW  FASTENER  (TYPICAL)  SECTIONS 41 AND 42  140
NOTE: INSPECTION AREAS VARY
DEPENDING ON CONFIGURATION.
SECTION 42,
SECTION 41  44 AND 46  1479023
STRINGER  STRINGER
(TYPICAL)  (TYPICAL)
Original Issue: December 18, 1991
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### Page 13

Commercial 
Airplanes
747
Service Bulletin
ALERT
Number: 747-53A2367
Original Issue: December 18, 1991
Revision 5: July 08, 2014
ATA System: 5331
SUBJECT: FUSELAGE - Skin - Body Skin Lap Joint Inspections Based On Fatigue Test Results
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
1.    PLANNING INFORMATION
A. Effectivity
1. Airplanes
Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line
Number, and Serial Number data.
This service bulletin is for the airplanes shown below. An equivalent change is on subsequent
production airplanes. Refer to PRR85901-88RS for data about this change.
DESCRIPTIONCONFIGURATIONGROUP
747-100, -100B, -200B, -300, and SR airplanes, line numbers 201
through 603, except nose cargo door airplanes, airplanes changed
to Stretched Upper Deck (SUD) configuration, and airplanes that
have had a Boeing side cargo door modification.
-1
747-200B airplanes, line numbers 201 through 603, that have been
changed to SUD configuration and have not had a Boeing side cargo
door modification.
-2
747SP airplanes, line numbers 201 through 603.-3
747-200B and -300 airplanes, line numbers 604 through 628, except
nose cargo door airplanes and airplanes that have had a Boeing side
cargo door modification.
-4
747-200B and 747-300 airplanes without a side cargo door, line
numbers 629 through 683, except line number 679.
-5
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DESCRIPTIONCONFIGURATIONGROUP
747SP airplane line number 676.-6
747-200B and -300 airplanes, line numbers 201 through 603, that
have had a Boeing side cargo door modification, but do not have a
nose cargo door and have not been changed to SUD configuration.
-7
747-200B airplanes, line numbers 201 through 603, that have been
changed to SUD configuration and have had a Boeing side cargo
door modification.
-8
747-200B airplanes, line numbers 604 through 628, that have had a
Boeing side cargo door modification, but do not have a nose cargo
door.
-9
747-200B airplane line numbers 679 and 685.-10
747-200B and -300 airplanes, line numbers 629 through 675, that
were delivered from Boeing with a side cargo door, or have had a
Boeing side cargo door modification.
-11
747-200B and -300 airplanes, line numbers 688 through 750, that
do not have a side cargo door.
-12
747-200B and -300 airplanes, line numbers 686 through 810, that
were delivered from Boeing with a side cargo door, or have had a
Boeing side cargo door modification.
-13
Airplane Models:
747-100, 747-100B, 747-100B SUD, 747-200B, 747-300, 747SP, 747SR
GroupVariable Number
1RA260 - RA266
1RA313 - RA318
1RA415 - RA418
1RA528
1RA541 - RA548
1RA725 - RA731
1RA744 - RA745
7RA749 - RA750
1RA783 - RA784
1RB006 - RB016
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GroupVariable Number
11RB411 - RB412
13RB413
13RB421
1RB601 - RB607
1RB681 - RB697
1RB711
1RB721 - RB723
1RB741 - RB748
1RD003 - RD004
1RD021 - RD022
1RD041 - RD054
7RD055
1RD056 - RD059
1RD071 - RD072
1RD081
7RD082
1RD083
1RD091 - RD092
1RD101 - RD104
1RD121 - RD127
1RD131 - RD141
7RD142
1RD143
7RD144
10RD166 - RD167
1RD171 - RD172
1RD181 - RD183
7RD201 - RD204
1RD221 - RD224
7RD225
1RD226
11RD227
5RD231 - RD232
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GroupVariable Number
11RD233
5RD234
12RD235
1RD241 - RD243
1RD251 - RD259
5RD260 - RD262
1RD271 - RD272
5RD291 - RD292
11RD301 - RD302
5RD311
1RD351 - RD357
7RD358
7RD361 - RD366
2RD381 - RD383
7RD411 - RD412
1RD413 - RD414
1RD421 - RD426
1RD431 - RD435
7RD441 - RD442
1RD451 - RD455
4RD456
7RD461
1RD471 - RD475
1RD513 - RD519
7RD531 - RD533
7RD551
7RD561
7RD571
7RD581 - RD583
7RD591 - RD593
8RD601 - RD607
7RD621 - RD623
7RD641 - RD649
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GroupVariable Number
7RD651 - RD658
11RD659
7RD661
7RD671
7RD681 - RD682
7RD691 - RD692
7RD701 - RD702
8RD721 - RD722
7RD741 - RD742
7RD751 - RD753
9RD754
11RD755
7RD761
7RD771
9RD772 - RD773
11RD774 - RD775
7RD781
9RD782
11RD783
11RD791
13RD792
1RE001
3RG001 - RG009
3RG091
3RG095
3RG101 - RG104
3RG121 - RG126
3RG141 - RG142
3RG161 - RG164
3RG171 - RG174
3RG191 - RG193
3RG211 - RG213
3RG221 - RG222
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GroupVariable Number
3RH101
6RH102
3RH111 - RH112
3RH121 - RH122
5RS001 - RS002
1RS201
1RS211 - RS212
1RS221 - RS222
1RS231 - RS237
4RS238 - RS241
1RS251 - RS253
4RS254
5RS255 - RS258
12RS259
12RS263
12RS265 - RS268
1RS271
4RS272 - RS273
5RS274 - RS276
4RS291 - RS292
4RS301
5RS302 - RS304
12RS305 - RS306
4RS311 - RS315
5RS316 - RS320
12RS331 - RS333
5RS341
12RS342
1RS699
7RS701 - RS702
13RS703
7RS711 - RS712
11RS713
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GroupVariable Number
9RS721
11RS722
13RS731 - RS732
11RS741 - RS743
11RS751 - RS752
11RS761
13RS762
11RS771
13RS781 - RS782
13RS786
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
As a result of the FAA-sponsored Aging Fleet Conference, a 747 Structures Working Group with Airline
and Boeing members and FAA observers was formed to review structural service bulletin modifications
and inspections and recommend selected service bulletins for incorporation on aging airplanes. The
747 Structures Working Group has determined that the inspections shown in this service bulletin should
be accomplished on the airplanes shown in this service bulletin at or before the accumulation of 22,000
flight cycles. This service bulletin gives data for the inspection and repair of certain 747 airplane body
skin longitudinal lap joints. These inspections and repairs are necessary for safe operation of 747
airplanes past the design goal for economic usage.
Boeing has completed extended pressure fatigue tests on two 747 fuselage test articles. These tests
have identified areas of the body lap joints where fatigue cracks can occur. Inspection and repair of
these areas is necessary for safe operation of 747 airplanes past the design goal for economic usage.
The inspections in this service bulletin will make sure that fatigue cracks in the body lap joints shown
are found and repaired before they become critical. Skin cracks not detected prior to reaching critical
crack length may result in in-flight depressurization of the airplane and the inability to withstand current
regulatory fail-safe loads.
Revision 1 was sent to recommend that the inspections shown in this service bulletin be accomplished
on the 747 airplanes shown in this service bulletin at or before the accumulation of 22,000 flight cycles.
As a result of the FAA-sponsored Aging Fleet Conference, a 747 Structures Working Group with Airline
and Boeing members and FAA observers was formed to review structural service bulletin modifications
and inspections and recommend selected service bulletins for incorporation on aging airplanes. The
747 Structures Working Group has determined that the inspections shown in this service bulletin should
be accomplished on the airplanes shown in this service bulletin at or before the accumulation of 22,000
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flight cycles. Revision 1 was also sent to add references to FAA Notice of Proposed Rule Making, FAA
Docket Number 93-NM-182-AD. The data given in Notice of Status Change 747-53-2367 NSC 1 and
NSC 2 is included in Revision 1. NSC 1 was sent to give operators data about when to do inspections
at Stringer 6 after Service Bulletin 747-53-2272 has been installed. NSC 2 was sent to tell operators
that airplanes with a nose cargo door should not be listed in Paragraph 1.A., Effectivity.
Revision 2: Subsequent to the release of Revision 1 of this service bulletin, a review of all lap joints
was accomplished for the affected airplanes. It was determined that all lap joints with upper skin
thickness of 0.090 inches or less should be inspected at the times given in Paragraph 1.E., Compliance.
In addition, a review of all bulletins which recommend repeat inspections was performed to determine
if the inspections were appropriate on aging airplanes. This review indicated that certain lap joints
where the skin thickness is less than or equal to 0.071 inches should be modified at the times given in
Paragraph 1.E., Compliance on airplane line numbers 201 through 810.
Revision 2 was sent to expand the lap joint inspection area shown in this service bulletin and add a
lap joint modification for specific areas. A detailed list of changes is given in the Revision Transmittal
Sheet section of Revision 2.
Revision 3 was sent to include the following changes in Paragraph 1.E., Compliance:
— In the top row of Table 1, the third column has been changed to include "(Whichever Occurs Later)".
— In Table 1, footnote (c), has been changed to refer to SSI F-25I instead of SSI F-25J.
The data given in Information Notice 747-53A2367 IN 03 was included in Revision 3. IN 03 included
the data noted above.
Revision 4 is sent to revise the modification drawings that are specified for Stringer 6 lap joint
modification. A detailed list of changes is given in the Revision Transmittal Sheet section of Revision
4.
Revision 5 is sent to add post-modification inspections for all airplanes, and to give instructions for
modification of 747SP airplanes rather than requiring operators to contact Boeing for modification
instructions. Other changes have also been made. A detailed list of changes is given in the Revision
Transmittal Sheet section of Revision 5.
The skin lap joints affected by this service bulletin have been determined to be structure that is
susceptible to Widespread Fatigue Damage (WFD). For more information about WFD, refer to
747-SL-53-088.
Boeing Service Related Problem (SRP) 747-SRP-53-0278 and 747-SRP-53-0437 are related to this
service bulletin.
Boeing Fleet Team Digest (FTD) article 747 FTD 53-13003 is related to this service bulletin.
D. Description
Based on a structural review of the 747 airplane, it is recommended that the inspections shown in this
service bulletin be accomplished on the 747 airplanes shown in this service bulletin at or before the
accumulation of 22,000 flight cycles.
Lap joint inspection:
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– Do external eddy current inspections of certain lap joints for cracks. These lap joints are in Section
41, Section 42, Section 44 and Section 46. If any crack is found, do the inspection again at the
time shown in this service bulletin. If no crack is found, remove the fastener in the cracked hole
and sufficient adjacent fasteners and do open hole HFEC inspections to find the crack length.
Repair as shown in the structural repair manual before any more flights.
Lap joint modification:
– Do eddy current inspections of the lap joints in sections 41 and 42 that will be modified. If any
crack is found, repair the crack and contact Boeing for lap joint modification instructions. For areas
where no crack is found, do the lap joint modifications.
Lap joint post-modification inspection:
– Do detailed and eddy current inspections for cracks in the skin and/or doubler structure at certain
lap joint areas where external modification doublers were installed. If any crack is found, contact
Boeing for repair instructions and do the repair.
On 747 airplane line numbers 1 through 603, the Stringer 6 lap joint from Station 340 to 400 requires
inspection, modification, and post-modification inspection as given in Service Bulletins 747-53-2253
and/or 747-53-2272. Therefore, baseline inspections of Stringer 6 from Station 340 to 400 as given in
this service bulletin are not required. However, if the external doublers as given in Service Bulletin
747-53-2272 or Service Bulletin 747-53-2253 are not installed, do the modification of Stringer 6 from
Station 340 to 400 as given in this service bulletin, or Service Bulletin 747-53-2272, or Service Bulletin
747-53-2253 at or before 20,000 total flight cycles (AD 90-06-06, AD 2013-16-24). Do post-modification
inspections as given in Service Bulletin 747-53-2253 or as given in this service bulletin, as applicable.
On 747 airplane line numbers 1 through 628, the Stringer 6 lap joint from Station 400 to 520 requires
inspection, modification, and post-modification inspection as given in Service Bulletin 747-53A2303.
Therefore, the baseline inspections of Stringer 6 from Station 400 to 520 as given in this service bulletin
are not required. However, if the external doublers as given in Service Bulletin 747-53A2303 are not
installed, do the modification of Stringer 6 from Station 400 to 520 as given in this service bulletin or
Service Bulletin 747-53A2303 at or before 23,000 total flight cycles (AD 90-06-06). Do post-modification
inspections as given in Service Bulletin 747-53A2303 or as given in this service bulletin, as applicable.
On 747 airplane line numbers 604 through 685, the Stringer 6 lap joint from Station 340 to 400 requires
modification as given in Service Bulletin 747-53-2272 at or before 20,000 total flight cycles. Therefore,
the baseline inspections and modification of Stringer 6 from Station 340 to 400 as given in this service
bulletin are not required. However, if the external doublers as given in Service Bulletin 747-53-2272
are not installed, then the modification of Stringer 6 from Station 340 to 400 can be accomplished as
given in Service Bulletin 747-53-2272 or this service bulletin. For these line numbers, post-modification
inspections should be done as given in this service bulletin regardless of the method of external doubler
installation.
This service bulletin is listed in Boeing Document D6-35999, "Aging Airplane Service Bulletin Structural
Modification and Inspection Program, Model 747."
Revision 1 - No more work is necessary on airplanes inspected by the initial release of this service
bulletin as a result of Revision 1. Continue to do inspections as shown in this service bulletin.
Revision 2 - More work is necessary on airplanes changed as given in the initial release or revision 1
of this service bulletin. Lap joint inspections are necessary over an expanded inspection area. Lap joint
modification is necessary in specific areas at the time given in Paragraph 1.E., Compliance.
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Revision 3 - No more work is necessary on airplanes changed as given in Revision 2. However, as
specified in Revision 2, more work is necessary on airplanes inspected as given in the initial release
or Revision 1 of this service bulletin. Lap joint inspections are necessary over an expanded inspection
area. Lap joint modification is necessary in specific areas at the time given in Paragraph 1.E.,
Compliance.
Revision 4 - No more work is necessary on airplanes changed as shown in Revision 3 of this service
bulletin. However, the requirement for repeat AREA 1 inspections may have been unclear in previous
revisions of this service bulletin. For any airplane that did not have the AREA 1 inspected during the
previous repeat inspection, Boeing recommends accomplishment of the combined AREA 1 and AREA
2 inspections during the next planned inspection as given in this service bulletin.
Revision 5 - More work is necessary on airplanes that have had lap joint modifications accomplished
as given in previous revisions of this service bulletin before 20,000 total flight cycles. Post-modification
inspections will be required within 15,000 flight cycles after modification in order to allow continued
operation to the Limit of Validity (LOV) of 35,000 total flight cycles.
Revision 5 - In addition, more work is necessary on airplane line numbers 604 - 685 that had external
doublers installed as given in Service Bulletin 747-53-2272 at Stringer 6 from Station 340 to Station
400. Post-modification inspection at Stringer 6 from Station 340 to Station 400 is now required.
NOTE: Inspection and maintenance alternatives are shown in a diagram in Section 3.,
ACCOMPLISHMENT INSTRUCTIONS.
1.
2. If an external doubler has been installed along the affected lap joint:
— If the external doubler was installed by Service Bulletin 747-53A2305 at Stringer
44, then no additional inspection or modification is required by this Service
Bulletin in the area of the external doubler.
— If the external doubler was installed by 747 SRM 53-30-03, Figures 11, 13, 14,
16, 17, 19, 20, 22, 23, 25, 26, 28, 29, 31, 32, 34, 48, and the external doubler
is 40 inches or less, then no additional inspections are required by this Service
Bulletin.
— If the external doubler installed by 747 SRM 53-30-03, Figures 11, 13, 14, 16,
17, 19, 20, 22, 23, 25, 26, 28, 29, 31, 32, 34, 48, is longer than 40 inches, inspect
as given in paragraph 1.E. Compliance, Table 1.
— If an external doubler was installed as given in Service Bulletin 747-53-2386,
then additional inspections are required by this Service Bulletin in the area of
the doubler. The inspection requirements are given in the applicable figures of
this service bulletin and the perimeter row inspection requirements are given in
Boeing 747 RAG document D6-36181, "Repair Assessment Guidelines - Model
747".
— For all external repair or modification doublers not listed above, contact Boeing
with details of the external doubler so that the modification and its inspection
can be determined.
3. This note is deleted (Revision 5).
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4. If the damaged area is more than the limits specified in the structural repair manual,
write to Boeing for repair instructions. To help Boeing send a reply, give the limits
and location of the damage. When possible, send sketches and photographs. If the
damage includes corrosion, send data on the length, width and largest depth of clean
up. SEND TO: BOEING COMMERCIAL AIRPLANE GROUP ATTENTION:
MANAGER, AIRLINE SUPPORT
5. At all lap joint areas not covered by the lap joint modification given in this service
bulletin, a lap joint modification must be installed in additional locations at 35,000
total flight cycles. Boeing is not planning to provide engineering drawings for the
modification.
6. Because of the extent of the work required to accomplish the modification in this
Service Bulletin, jacking and support of the airplane will be necessary. Boeing can
provide a jacking plan for incorporation of the bulletin. To have Boeing assist in
developing jacking/support recommendations the following is required:
— A list of structures related Service Bulletins to be incorporated.
— The exact airplane configuration including weight and center of gravity.
— Whether the following will be installed or removed: landing gear, flaps, engines,
pylons and interiors.
— The airplane identification (line number or variable number).
— List the lap joints to be modified and lap the joints that require repair (if possible).
— Provide the planned incorporation date for the bulletin modification. Provide
adequate time for Boeing to develop the necessary data and for any required
contacts or agreements to be developed.
NOTE: Boeing recommends that Service Bulletin 747-53A2563, "Fuselage - Skin - Inspections of the
Fuselage Skin and Butt Joint Splice Straps for Scribe Lines" be done prior to installation of
any modification doublers as given in this service bulletin. If the scribe line inspections are
not done prior to installation of modification doublers, it may be necessary to remove the
doublers at a later time to do scribe line inspections.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones
ZoneModel
112, 113, 114, 115, 116, 117, 118, 121, 122,
123, 124, 125, 126, 127, 128, 141, 142, 143,
144, 145, 146, 147, 148, 151, 152, 211, 212,
221, 222, 223, 224, 225, 226, 231, 232, 241,
242, 243, 244, 251, 252, 253, 254, 261, 262,
263, 264, 271, 272, 273, 274
747-300
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Group 1:
Affected Maintenance Zones
ZoneModel
112, 113, 114, 115, 116, 117, 118, 121, 122,
123, 124, 125, 126, 127, 128, 141, 142, 143,
144, 145, 146, 147, 148, 151, 152, 211, 212,
221, 222, 223, 224, 225, 226, 231, 232, 233,
234, 241, 242, 243, 244, 251, 252, 253, 254,
261, 262, 263, 264, 271, 272, 273, 274
747-100, 747-100B, 747-200B,
747SR
Group 2, 8, 10:
Affected Maintenance Zones
ZoneModel
112, 113, 114, 115, 116, 117, 118, 121, 122,
123, 124, 125, 126, 127, 128, 141, 142, 143,
144, 145, 146, 147, 148, 151, 152, 211, 212,
221, 222, 223, 224, 225, 226, 231, 232, 233,
234, 241, 242, 243, 244, 251, 252, 253, 254,
261, 262, 263, 264, 271, 272, 273, 274
747-200B
Group 3, 6:
Affected Maintenance Zones
ZoneModel
112, 113, 114, 115, 116, 117, 118, 121, 122,
125, 126, 127, 128, 141, 142, 143, 144, 145,
146, 147, 148, 151, 152, 211, 212, 221, 222,
223, 224, 225, 226, 231, 232, 241, 242, 243,
244, 251, 252, 253, 254, 261, 262, 263, 264
747SP
Group 4-5, 7, 9, 11-13:
Affected Maintenance Zones
ZoneModel
112, 113, 114, 115, 116, 117, 118, 121, 122,
123, 124, 125, 126, 127, 128, 141, 142, 143,
144, 145, 146, 147, 148, 151, 152, 211, 212,
221, 222, 223, 224, 225, 226, 231, 232, 241,
242, 243, 244, 251, 252, 253, 254, 261, 262,
263, 264, 271, 272, 273, 274
747-200B, 747-300
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Group 5:
Affected Maintenance Zones
ZoneModel
222, 223, 224, 225, 226, 231, 232, 233, 234,
241, 242, 243, 244, 251, 252, 253, 254, 261,
262, 263, 264, 271, 272, 273, 274
747-100B SUD
E. Compliance
Federal Aviation Administration (FAA) Airworthiness Directives AD 90-06-06, AD 2004-07-22 R1, AD
2005-08-01, AD 2006-20-02, AD 2006-22-09, AD 2006-24-02, AD 2006-24-05, AD 2007-15-07, AD
2008-16-14, AD 2009-04-16, AD 2010-10-05, AD 2012-10-03 and AD 2013-16-24  are related to this
service bulletin.
The effective date of AD 94-12-04 is July 13, 1994.
The effective date of AD 2010-10-05 is June 21, 2010.
To comply with the service bulletin recommendations, existing AD requirements, and possible future
FAA AD requirements, operators must complete the actions included in Tables 1, 2, 3, 4, 5, and 6, as
applicable.
Group 1-3, 7-8:
For airplanes that have Stringer 6, Station 340 - 400, external doublers installed as given in Service
Bulletin 747-53-2272 or Service Bulletin 747-53-2253: No action is required by this service bulletin at
Stringer 6, Station 340 - 400. Do post-modification inspections as given in Service Bulletin 747-53-2253.
Group 1-4, 7-9:
For airplanes that have Stringer 6, Station 400 - 520, external doublers installed as given in Service
Bulletin 747-53A2303: No action is required by this service bulletin at Stringer 6, Station 400 - 520. Do
post-modification inspections as given in Service Bulletin 747-53A2303.
Group 4-6, 9-11:
For airplanes that have Stringer 6, Station 340 - 400, external doublers installed as given in Service
Bulletin 747-53-2272: Modification is not required by this service bulletin at Stringer 6, Station 340 -
400. Do post-modification inspections as given in this service bulletin.
For areas where a lap joint SRM repair was installed and the repair doubler(s) is greater than or equal
to 40 inches long, refer to Table 1.
For areas where a lap joint SRM repair was installed and the repair doubler(s) is less than 40 inches
long, refer to the applicable SRM or Boeing 747 RAG (Document D6-36181, "Repair Assessment
Guidelines - Model 747") for inspection requirements (including inspection method and compliance
time).
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Table 1 - Lap Joint Inspection.
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
-Within 1,000
flight cycles
after the effec-
tive date of
AD 94-12-04.
Within 3,000
flight cycles af-
ter the last
HFEC inspec-
tion of the area
as given in the
SSID.
Before
22,000 total
flight cycles.
(h)
Do the Area 1 eddy
current inspections
for cracks in the skin
as given in Para-
graph 3.B., Work In-
structions, PART 1.
All Airplanes
(c)
-Within 1,000
flight cycles
after the effec-
tive date of
AD 2010-10-
05.
Within 3,000
flight cycles af-
ter the last
HFEC inspec-
tion of the area
as given in the
SSID.
Before
22,000 total
flight cycles.
(h)
Do the Area 2 eddy
current inspections
for cracks in the skin
as given in Para-
graph 3.B., Work In-
structions, PART 2.
All Airplanes
(c)
-Before further flight.Repair the lap joint
as given in Para-
graph 3.B., Work In-
structions, PART 1
or PART 2.
Any crack found.
2,400 flight cycles
or 1,500 flight cy-
cles for airplanes
with more than
30,000 total flight
cycles.
Within 1,000
flight cycles
after the Revi-
sion 5 date of
this service
bulletin
Within 2,400 flight cycles after
the last inspection, or within
1,500 flight cycles after the
last inspection for airplanes
with more than 30,000 total
flight cycles.
Repeat the external
LFEC inspection for
cracks as given in
Paragraph 3.B.,
Work Instructions,
PART 1 and PART
2.
No crack is found in
the area covered by
external doublers in-
stalled in accordance
with Boeing Service
Bulletin 747-53-2386
(a) (b) (g)
3,000 flight cycles
or 1,500 flight cy-
cles for airplanes
with more than
30,000 total flight
cycles.
Within 3,000 flight cycles after the last inspec-
tion, or within 1,500 flight cycles after the last
inspection for airplanes with more than
30,000 total flight cycles.
Repeat the inspec-
tion for cracks as
given in Paragraph
3.B., Work Instruc-
tions, PART 1 and
PART 2.
Any area where no
crack is found except
in the area covered by
external doublers in-
stalled in accordance
with Boeing Service
Bulletin 747-53-2386 (a) (b) (f)
3,000 flight cycles
or 1,500 flight cy-
cles for airplanes
with more than
30,000 total flight
cycles.
Within 15,000 flight cycles after the repair
was installed.
Accomplish internal
HFEC inspections
for cracks as given
in Boeing 747 RAG
Document D6-
36181, "Repair As-
sessment Guide-
lines - Model 747."
Areas where a lap joint
SRM repair was in-
stalled as given in
Paragraph 3.B., Work
Instructions, PART 1
or PART 2, and the re-
pair doubler(s) is
greater than or equal
to 40 inches long.
(a) (b) (e)
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Table 1 - Lap Joint Inspection.
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
(a) For laps joints specified in Paragraph 3.B., Work Instructions, PART 3: On airplanes with more than 30,000
total flight cycles, reduce the inspection interval to 1,500 flight cycles until the lap joint modification given
in Paragraph 3.B., Work Instructions, PART 3 is accomplished.
(b) Accomplishment of a lap joint modification as given in Paragraph 3.B., Work Instructions, PART 3 terminates
the repeat inspections as given in Paragraph 3.B., Work Instructions, PART 1 and PART 2 for the length
of the lap joint that is modified.
(c) The Supplemental Structural Inspection Document (SSID) D6-35022, Revision G for SSI's F-25G, F-25H,
and F-25I provides inspection options for the subject lap joints. Only the HFEC inspection will allow this
compliance time.
(d) This information is deleted.
(e) At tear straps and frame shear ties, where skin is not inspectable for less than 4 inches, HFEC inspection
is not required.
(f) For Group 7, 8, 9, 11, and 13 airplanes, inspections of the lap joints in Section 46 at Stringer 4 left, between
Station (STA) 1720 and STA 1740, and between STA 1960 and STA 1980 must be repeated at intervals
not to exceed 1,500 flight cycles. This inspection is for cracks in the upper skin under an external doubler.
(g) Inspections of the skin at the perimeter row of fasteners of the repair or modification doublers are given
in Boeing 747 RAG document D6-36181, "Repair Assessment Guidelines - Model 747".
(h) If the external skin panel of an affected lap joint has been replaced, do the inspection before 22,000 flight
cycles since skin replacement.
Table 2 - Lap Joint Modification.
Compliance Time (Whichever Occurs Later)ActionCondition
Within 3,000 flight cycles
after the effective date of
AD 2010-10-05.
Before 30,000 total flight
cycles.
(e)
Do the lap joint modification as
given in Paragraph 3.B., Work
Instructions, PART 3.
All airplanes.
(a) (b) (c) (d)
(a) Accomplishment of a lap joint modification as given in Paragraph 3.B., Work Instructions, PART 3 terminates
the repeat inspections required by Compliance Table 1 for the length of the lap joint that is modified.
(b) For lap joints specified in Paragraph 3.B., Work Instructions, PART 3: On airplanes with more than 30,000
total flight cycles, the repeat inspection intervals in Compliance Table 1 must be reduced to 1,500 flight
cycles until the lap joint modification is accomplished.
(c) It is not necessary to accomplish this modification between STA 340 and STA 400 at the Stringer 6 lap
joints if an external doubler modification has already been installed as given in Service Bulletin 747-53-
2272 or Service Bulletin 747-53-2253. For airplane line numbers 201 through 685, the requirement to install
external doublers at the Stringer 6 lap joints between STA 340 and STA 400 at or before 20,000 total flight
cycles, as given in Service Bulletin 747-53-2272 or Service Bulletin 747-53-2253, remains applicable.
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Table 2 - Lap Joint Modification.
Compliance Time (Whichever Occurs Later)ActionCondition
(d) It is not necessary to accomplish this modification between STA 400 and STA 520 at the Stringer 6 lap
joints if an external doubler modification has already been installed as given in Service Bulletin 747-
53A2303. For airplane line numbers 201 through 628, the requirement to install external doublers at the
Stringer 6 lap joints between STA 400 and STA 520 at or before 23,000 total flight cycles, as given in
Service Bulletin 747-53A2303 (AD 90-06-06), remains applicable.
(e) Any Airworthiness Directive having an earlier compliance time for modification should be complied with
instead of the compliance time stated in this table.
Group 1-3, 7-8:
Table 3 - Lap Joint Post-Modification Inspection - Areas with External Doublers installed as given in this
service bulletin (Stringers 6, 23, and 44).
Repeat Inter-
val (Not to Ex-
ceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 1,000
flight cycles after
the Revision 5
date of this ser-
vice bulletin.
Within 10,000
flight cycles after
accomplishing
the modification
as given in Para-
graph 3.B., Work
Instructions,
PART 3.
Do internal detailed and surface
HFEC inspections for cracks in the
skin and internal doubler along the
edge fastener rows of the modifica-
tion at Stringer 6, between STA
340 and STA 400 as given in
Paragraph 3.B., Work Instructions,
PART 4.
All airplanes.
(a) (c)
AND
-Within 1,000
flight cycles after
the Revision 5
date of this ser-
vice bulletin.
Within 15,000
flight cycles after
accomplishing
the modification
as given in Para-
graph 3.B., Work
Instructions,
PART 3.
Do internal detailed and surface
HFEC inspections for cracks in the
skin or internal doubler along the
edge fastener rows of the modifica-
tion at Stringer 6, between STA
400 and STA 520; at Stringer 23;
and at Stringer 44, as given in
Paragraph 3.B., Work Instructions,
PART 4.
(b) (c)
-Before further flight.Contact Boeing for repair instruc-
tions and do the repair.
Any crack found.
3,000 flight cy-
cles.
--In unrepaired areas: Repeat the
internal detailed and surface HFEC
inspections for cracks in the skin
or internal doubler along the edge
fastener rows of the modification
as given in Paragraph 3.B., Work
Instructions, PART 4.
No crack found.
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Group 1-3, 7-8:
Table 3 - Lap Joint Post-Modification Inspection - Areas with External Doublers installed as given in this
service bulletin (Stringers 6, 23, and 44).
Repeat Inter-
val (Not to Ex-
ceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
(a) This action is only required if external doublers were installed as given in this service bulletin at Stringer
6, between STA 340 and STA 400, as an alternative method of compliance to AD 90-06-06 or AD 2013-
16-24. If external doublers were already installed as given in Service Bulletin 747-53-2272 or Service
Bulletin 747-53-2253, then do the post-modification inspections as given in Service Bulletin 747-53-2253.
(b) This action is only required at Stringer 6, between STA 400 and STA 520, if doublers were installed as
given in this service bulletin as an alternative method of compliance to AD 90-06-06. If external doublers
were already installed as given in Service Bulletin 747-53A2303, then do the post-modification inspections
as given in Service Bulletin 747-53A2303.
(c) If lap joints were modified at different times, each modified area must be inspected within the specified
number of flight since that area was modified.
Group 4-6, 9-11:
Table 4 - Lap Joint Post-Modification Inspection - Areas with External Doublers installed as given in
Service Bulletin 747-53-2272 at Stringer 6, from STA 340 to STA 400.
Repeat Inter-
val (Not to Ex-
ceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 1,000
flight cycles after
the Revision 5
date of this ser-
vice bulletin.
Within 10,000
flight cycles after
installation of
Stringer 6 exter-
nal doublers as
given in Service
Bulletin 747-53-
2272.
Do external detailed, low frequen-
cy eddy current (LFEC), and HFEC
inspections for cracks in the skin
and external doubler as given in
Paragraph 3.B., Work Instructions,
PART 5.
(a) (b) (c)
Airplanes with exter-
nal doublers installed
as given in Service
Bulletin 747-53-2272
at Stringer 6, between
STA 340 and STA
400.
-Before further flight.Contact Boeing for repair instruc-
tions and do the repair.
Any crack found.
1,000 flight cy-
cles.
--In unrepaired areas: Repeat the
external detailed and LFEC inspec-
tions for cracks in the skin as given
in Paragraph 3.B., Work Instruc-
tions, PART 5.
No crack found and
the airplane will have
less than 15,000 flight
cycles since Stringer
6 external doublers
were installed as giv-
en in Service Bulletin
747-53-2272.
AND
3,000 flight cy-
cles.
--In unrepaired areas: Repeat the
external detailed and HFEC inspec-
tions for cracks in the external
doubler as given in Paragraph
3.B., Work Instructions, PART 5.
(d)
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Group 4-6, 9-11:
Table 4 - Lap Joint Post-Modification Inspection - Areas with External Doublers installed as given in
Service Bulletin 747-53-2272 at Stringer 6, from STA 340 to STA 400.
Repeat Inter-
val (Not to Ex-
ceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
1,000 flight cy-
cles.
--In unrepaired areas: Do/Repeat
the external detailed and LFEC in-
spections for cracks in the skin as
given in Paragraph 3.B., Work In-
structions, PART 6.
No crack found and
the airplane will have
15,000 or more flight
cycles since Stringer
6 external doublers
were installed as giv-
en in Service Bulletin
747-53-2272.
AND
3,000 flight cy-
cles.
--In unrepaired areas: Do/Repeat
the internal and external detailed
and HFEC inspections for cracks
in the skin and external doubler as
given in Paragraph 3.B., Work In-
structions, PART 6.
(d)
(a) If lap joints were modified at different times, each modified area must be inspected within the specified
number of flights since that area was modified.
(b) If external doublers were installed as given in this service bulletin at Stringer 6, between STA 340 and
STA 400, then the inspections of Stringer 6, between STA 340 and STA 400 must be done as given in
compliance Table 5 instead of the inspections given in this compliance table.
(c) Also do inspections of Stringer 6 from STA 400 to STA 520, Stringer 23, and Stringer 44 as given in
compliance Table 5.
(d) To determine which repeat inspection is required (PART 5 or PART 6), calculate the number flight cycles
at the time of the next scheduled inspection.
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Group 4-6, 9-11:
Table 5 - Lap Joint Post-Modification Inspection - Areas with External Doublers installed as given in this
service bulletin.
Repeat Inter-
val (Not to Ex-
ceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 1,000
flight cycles after
the Revision 5
date of this ser-
vice bulletin.
Within 10,000
flight cycles after
accomplishing
the modification
as given in Para-
graph 3.B., Work
Instructions,
PART 3.
Do internal detailed and surface
HFEC inspections for cracks in the
skin and internal doubler along the
edge fastener rows of the modifica-
tion at Stringer 6, between STA
340 and STA 400 as given in
Paragraph 3.B., Work Instructions,
PART 4.
All airplanes.
(a) (c)
AND
-Within 1,000
flight cycles after
the Revision 5
date of this ser-
vice bulletin.
Within 15,000
flight cycles after
accomplishing
the modification
as given in Para-
graph 3.B., Work
Instructions,
PART 3.
Do internal detailed and surface
HFEC inspections for cracks in the
skin or internal doubler along the
edge fastener rows of the modifica-
tion at Stringer 6, between STA
400 and STA 520; at Stringer 23;
and at Stringer 44, as given in
Paragraph 3.B., Work Instructions,
PART 4.
(b) (c)
-Before further flight.Contact Boeing for repair instruc-
tions and do the repair.
Any crack found.
3,000 flight cy-
cles.
--In unrepaired areas: Repeat the
internal detailed and surface HFEC
inspections for cracks in the skin
or internal doubler along the edge
fastener rows of the modification
as given in Paragraph 3.B., Work
Instructions, PART 4.
No crack found.
(a) This action is only required if external doublers were installed as given in this service bulletin at Stringer
6, between STA 340 and STA 400. If external doublers were already installed as given in Service Bulletin
747-53-2272, then do the post-modification inspections of Stringer 6, between STA 340 and STA 400 as
given in compliance Table 4.
(b) For Group 4 and 9 airplanes (line numbers 604 - 628), this action is only required at Stringer 6, between
STA 400 and STA 520, if doublers were installed as given in this service bulletin as an alternative method
of compliance to AD 90-06-06. If external doublers were already installed as given in Service Bulletin 747-
53A2303, then do the post-modification inspections as given in Service Bulletin 747-53A2303.
(c) If lap joints were modified at different times, each modified area must be inspected within the specified
number of flights since that area was modified.
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Group 12-13:
Table 6 - Lap Joint Post-Modification Inspection.
Repeat Inter-
val (Not to Ex-
ceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 1,000
flight cycles after
the Revision 5
date of this ser-
vice bulletin.
Within 15,000
flight cycles after
accomplishing
the modification
as given in Para-
graph 3.B., Work
Instructions,
PART 3.
Do internal detailed and surface
HFEC inspections for cracks in the
skin or internal doubler along the
edge fastener rows of the modifica-
tion as given in Paragraph 3.B.,
Work Instructions, PART 4.
(a)
All airplanes.
-Before further flight.Contact Boeing for repair instruc-
tions and do the repair.
Any crack found.
3,000 flight cy-
cles.
--In unrepaired areas: Repeat inter-
nal detailed and surface HFEC in-
spections for cracks in the skin or
internal doubler along the edge
fastener rows of the modification
as given in Paragraph 3.B., Work
Instructions, PART 4.
No crack found.
(a) If lap joints were modified at different times, each modified area must be inspected within the specified
number of flight since that area was modified.
F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified
in this service bulletin comply with the applicable regulations and are FAA approved, as well as European
Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved
airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on
the airplane in its original Boeing delivery configuration or as modified by other approved Boeing
changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected
by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval
before incorporating this service bulletin.
This service bulletin has been approved by the FAA. In addition, the manager of the FAA Seattle ACO
approves the accomplishment of the inspection, repair, modification and post-modification inspection
procedures with the corresponding compliance times specified in Tables 1, 2, 3, 4, 5, and 6 under
paragraph 1.E., "Compliance," of Service Bulletin 747-53A2367 Revision 5, as an alternative method
of compliance (AMOC) to the accomplishment of the corresponding inspection and repair requirements
of paragraphs (h) and (i) of FAA AD 2004-07-22 R1, for the inspection of Structural Significant Items
(SSI) F-25G, F-25H, and F-25I of Supplemental Structural Inspection Document (SSID) D6-35022
Revision G, dated December 2000. This AMOC only applies to the areas inspected as given in this
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### Page 33

service bulletin. When this service bulletin specifies contacting Boeing for repair instructions, the repair
instructions must be approved by the FAA in accordance with paragraph (l) of the AD. All provisions
of AD 2004-07-22 R1 that are not specifically referenced in this paragraph, including the initial inspection
threshold and repeat intervals per paragraph (h) and (i) of AD 2004-07-22 R1, remain fully applicable
and must be complied with accordingly until the inspections per this service bulletin begin.
In addition, the manager of the FAA Seattle ACO also approves the accomplishment of the modification
and post-modification inspection procedures specified in Table 2, 3, 4, 5, and 6 under paragraph 1 .E.,
"Compliance," of Service Bulletin 747-53A2367 Revision 5, as an AMOC to the accomplishment of the
corresponding inspection and repair requirements of paragraphs (h) and (i) of FAA AD 2004-07-22 R1,
for the inspection of SSI F-25K of SSID D6-35022 Revision G, dated December 2000. This AMOC only
applies to the areas modified as given in this service bulletin. When this service bulletin specifies
contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in
accordance with paragraph (I) of the AD. All provisions of AD 2004-07-22 R1 that are not specifically
referenced in this paragraph,including the initial inspection threshold and repeat intervals per paragraph
(h) and (i) of AD 2004-07-22 R1 , remain fully applicable and must be complied with accordingly until
the inspections per this service bulletin begin.
In addition, the manager of the FAA Seattle ACO also approves the accomplishment of the inspection
and repair procedures with the corresponding compliance times specified in Table 1, under paragraph
1.E., "Compliance" of Service Bulletin 747-53A2367 Revision 5, as an AMOC to the accomplishment
of the inspection and repair procedures with the corresponding compliance times specified in Table 1
under paragraph 1.E., "Compliance" of Service Bulletin 747-53A2367 Revision 3, dated October 30,
2008, required by paragraphs (g), (h), and (i) of AD 2010-10-05. When this service bulletin specifies
contacting Boeing for repair instructions, the repair instructions must be in accordance with paragraph
(m) of AD 2010-10-05. All provisions of AD 2010-10-05 that are not specifically referenced in this
paragraph remain fully applicable and must be complied with accordingly.
In addition, the manager of the FAA Seattle ACO also approves the accomplishment of the modification
and post-modification inspection procedures with the corresponding compliance times specified in
Table 2, 3, 4, 5, and 6 under paragraph 1.E., "Compliance" of Service Bulletin 747-53A2367 Revision
5, as an AMOC to the accomplishment of the inspection, repair and modification procedures with the
corresponding compliance times specified in Table 1 and Table 2 under paragraph 1.E., "Compliance"
of Service Bulletin 747-53A2367 Revision 3, dated October 30, 2008, required by paragraphs (g), (h),
(i) and (j) of AD 2010-10-05. This AMOC is valid only for areas where the external doublers are installed
in accordance with Service Bulletin 747-53A2367 Revision 5. When this service bulletin specifies
contacting Boeing for repair instructions, the repair instructions must be in accordance with paragraph
(m) of AD 2010-10-05. All provisions of AD 2010-10-05 that are not specifically referenced in this
paragraph remain fully applicable and must be complied with accordingly.
In addition, the manager of the FAA Seattle ACO also approves the accomplishment of the inspection
procedures with the corresponding compliance times specified in Table 1, under paragraph 1.E.,
"Compliance," of Service Bulletin 747-53A2367 Revision 5, as an AMOC to the accomplishment of the
post-modification inspection requirements with corresponding compliance times required by paragraph
(p) of AD 2008-16-14. This AMOC is only for areas where inspections are done in accordance with this
service bulletin. When this service bulletin specifies contacting Boeing for repair instructions, the repair
instructions must be approved in accordance with paragraph (v) of the AD. All provisions of AD
2008-16-14 that are not specifically referenced in this paragraph remain fully applicable and must be
complied with accordingly.
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In addition, the manager of the FAA Seattle ACO also approves the accomplishment of the modification
and post-modification inspection procedures with corresponding compliance times specified in Table
2, 3, 4, 5, and 6 under paragraph 1.E., "Compliance," of Service Bulletin 747-53A2367 Revision 5, as
an AMOC to the accomplishment of the inspection requirements with corresponding compliance times
required by paragraph (g) of AD 2006-22-09. This AMOC is only for areas where the modification
doublers have been installed in accordance with this service bulletin. When this service bulletin specifies
contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in
accordance with paragraph (j) of the AD. All provisions of AD 2006-22-09 that are not specifically
referenced in this paragraph remain fully applicable and must be complied with accordingly.
In addition, the manager of the FAA Seattle ACO also approves the accomplishment of the modification
and post-modification inspection procedures with corresponding compliance times specified in Table
2, 3, 4, 5, and 6 under paragraph 1.E., "Compliance," of Service Bulletin 747-53A2367 Revision 5, as
an AMOC to the accomplishment of the modification and post-modification inspections required by
paragraphs (m), and (n) of AD 2013-16-24. This AMOC is only for areas where Stringer 6 external
doublers are installed in accordance with this service bulletin. This AMOC is not valid for the modification
threshold. The modification threshold given in AD 2013-16-24, paragraph (m) remains in effect. When
this service bulletin specifies contacting Boeing for repair instructions, the repair instructions must be
approved by the FAA in accordance with paragraph (q) of the AD. All provisions of AD 2013-16-24 that
are not specifically referenced in this paragraph remain fully applicable and must be complied with
accordingly.
In addition, the manager of the FAA Seattle ACO also approves the accomplishment of the modification
and post-modification inspection procedures specified in Table 2, 3, 4, 5, and 6 under paragraph 1.E.,
"Compliance," of Service Bulletin 747-53A2367 Revision 5, as an AMOC to the accomplishment of the
inspection and modification required by paragraphs (g), (i), (j), and (o) of AD 2012-10-03. This AMOC
is valid only for areas where the external doublers are installed in accordance with Service Bulletin
747-53A2367 Revision 5. When this service bulletin specifies contacting Boeing for repair instructions,
the repair instructions must be approved by the FAA in accordance with paragraph (q) of the AD. All
provisions of AD 2012-10-03 that are not specifically referenced in this paragraph, including the
compliance time for modification, remain fully applicable and must be complied with accordingly.
In addition, the manager of the FAA Seattle ACO also approves the accomplishment of the modification
and post-modification inspection procedures specified in Table 2, 3, 4, 5, and 6 under paragraph 1.E.,
"Compliance," of Service Bulletin 747-53A2367 Revision 5, as an AMOC to the accomplishment of the
inspection and modification required by paragraphs (g), (i), and (j) of AD 2009-04-16. This AMOC is
valid only for areas where the external doublers are installed in accordance with Service Bulletin
747-53A2367 Revision 5. When this service bulletin specifies contacting Boeing for repair instructions,
the repair instructions must be approved by the FAA in accordance with paragraph (k) of the AD. All
provisions of AD 2009-04-16 that are not specifically referenced in this paragraph, including the
compliance time for modification, remain fully applicable and must be complied with accordingly.
In addition, the manager of the FAA Seattle ACO also approves the accomplishment of the modification
and post-modification inspection procedures with corresponding compliance times specified in Table
2, 3, 4, 5, and 6 under paragraph 1.E., "Compliance," of Service Bulletin 747-53A2367 Revision 5, as
an AMOC to the accomplishment of the inspection procedures with corresponding compliance times
specified in Table 1, under paragraph 1.E., "Compliance," of Service Bulletin 747-53A2675, dated
October 12, 2006, required by paragraph (f) of AD 2006-24-05. This AMOC is only for areas where
Stringer 6 modification doublers have been installed in accordance with this service bulletin. When this
service bulletin specifies contacting Boeing for repair instructions, the repair instructions must be
approved by the FAA in accordance with paragraph (j) of the AD. All provisions of AD 2006-24-05 that
are not specifically referenced in this paragraph remain fully applicable and must be complied with
accordingly.
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In addition, the manager of the FAA Seattle ACO also approves the accomplishment of the modification
and post-modification inspection procedures with corresponding compliance times specified in Table
2, 3, 4, 5, and 6 under paragraph 1.E., "Compliance," of Service Bulletin 747-53A2367 Revision 5, as
an AMOC to the accomplishment of the inspection requirements with the corresponding compliance
times required by paragraph (f) and (k) of AD 2006-24-02. This AMOC is only for areas where Stringer
6 modification doublers have been installed in accordance with this service bulletin. When this service
bulletin specifies contacting Boeing for repair instructions, the repair instructions must be approved by
the FAA in accordance with paragraph (n) of the AD. All provisions of AD 2006-24-02 that are not
specifically referenced in this paragraph remain fully applicable and must be complied with accordingly.
In addition, the manager of the FAA Seattle ACO also approves the accomplishment of the modification
and post-modification inspection procedures specified in Table 2, 3, 4, 5, and 6 under paragraph 1.E.,
"Compliance," of Service Bulletin 747-53A2367 Revision 5, as an AMOC to the accomplishment of the
Zone 1 external doubler modification requirement aft of body Station 340, at Stringer 6, with the
corresponding compliance time for Service Bulletin 747-53-2272, Service Bulletin 747-53-2253, and
Service Bulletin 747-53A2303, specified in Section 3 of the Aging Airplane Service Bulletin Structural
Modification and Inspection Program Document D6-35999, dated March 31, 1989, required by paragraph
A. of AD 90-06-06. This AMOC is valid only for areas where the external doublers are installed in
accordance with Service Bulletin 747-53A2367 Revision 5. When this service bulletin specifies contacting
Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with
paragraph C. of the AD. All provisions of AD 90-06-06 that are not specifically referenced in this
paragraph, including the compliance time for modification, remain fully applicable and must be complied
with accordingly.
In addition, the manager of the FAA Seattle ACO also approves the accomplishment of the modification
and post-modification inspection procedures specified in Table 2, 3, 4, 5, and 6 under paragraph 1.E.,
"Compliance," of Service Bulletin 747-53A2367 Revision 5, as an AMOC to the accomplishment of the
modification required by paragraph (s) of AD 2005-08-01. This AMOC is only for areas where Stringer
6 modification doublers have been installed aft of body Station 340 in accordance with this service
bulletin. When this service bulletin specifies contacting Boeing for repair instructions, the repair
instructions must be approved by the FAA in accordance with paragraph (t) of the AD. All provisions
of AD 2005-08-01 that are not specifically referenced in this paragraph, including the compliance time
for modification, remain fully applicable and must be complied with accordingly.
In addition, the manager of the FAA Seattle ACO also approves the accomplishment of the modification
and post-modification inspection procedures specified in Table 2, 3, 4, 5, and 6 under paragraph 1 .E.,
"Compliance," of Service Bulletin 747-53A2367 Revision 5, as an AMOC to the accomplishment of the
inspection and modification requirements specified in Tables 1 and 2, under paragraph 1.E.,
"Compliance," of Service Bulletin 747-53A2542, dated February 16, 2006, required by paragraphs (f)
and (h) of AD 2007-15-07. This AMOC is valid only for areas where the external doublers are installed
in accordance with Service Bulletin 747-53A2367 Revision 5. When this service bulletin specifies
contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in
accordance with paragraph (i) of the AD. All provisions of AD 2007-15-07 that are not specifically
referenced in this paragraph, including the compliance time for modification, remain fully applicable
and must be complied with accordingly.
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In addition, the manager of the FAA Seattle ACO also approves the accomplishment of the modification
and post-modification inspection procedures specified in Table 2, 3, 4, 5, and 6 under paragraph 1.E.,
"Compliance," of Service Bulletin 747-53A2367 Revision 5, as an AMOC to the accomplishment of the
inspection required by paragraphs (f) and (h) of AD 2006-20-02. This AMOC is only for areas where
the modification doublers have been installed in accordance with this service bulletin. When this service
bulletin specifies contacting Boeing for repair instructions, the repair instructions must be approved by
the FAA in accordance with paragraph (k) of the AD. All provisions of AD 2006-20-02 that are not
specifically referenced in this paragraph remain fully applicable and must be complied with accordingly.
G. Manpower
The data below shows an estimate of the man-hours necessary to do this inspection for each airplane.
This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator
man-hour data if necessary. The estimate does not include lost time. These are some examples of lost
time:
— Time to adjust to the workplace
— Time to schedule the work
— Time to examine the work
— Time to cure the materials
— Time to make the parts
— Time to find the tools.
Group 1, 7:
Lap Joint Inspections - Area 1
Elapsed Time
(Hours)
Man-HoursNumber of Per-
sons
Task
32.5652Inspect Section 41 Lap Joints
38381Inspect Section 42 Lap Joints
35351Inspect Section 46 Lap Joints
105 (a)138TOTAL
(a) Elapsed time will be less if Sections 41, 42 and 46 are inspected at the same time.
Group 2, 4, 8-9:
Lap Joint Inspections - Area 1
Elapsed Time
(Hours)
Man-HoursNumber of Per-
sons
Task
35.5712Inspect Section 41 Lap Joints
38381Inspect Section 42 Lap Joints
35351Inspect Section 46 Lap Joints
108 (a)144TOTAL
(a) Elapsed time will be less if Sections 41, 42 and 46 are inspected at the same time.
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### Page 37

Group 3:
Lap Joint Inspections - Area 1
Elapsed Time
(Hours)
Man-HoursNumber of Per-
sons
Task
32.5652Inspect Section 41 Lap Joints
22221Inspect Section 42 Lap Joints
38381Inspect Section 46 Lap Joints
92.5 (a)125TOTAL
(a) Elapsed time will be less if Sections 41, 42 and 46 are inspected at the same time.
Group 5, 10-13:
Lap Joint Inspections - Area 1
Elapsed Time
(Hours)
Man-HoursNumber of Per-
sons
Task
38762Inspect Section 41 Lap Joints
38381Inspect Section 42 Lap Joints
35351Inspect Section 46 Lap Joints
111 (a)149TOTAL
(a) Elapsed time will be less if Sections 41, 42 and 46 are inspected at the same time.
Group 6:
Lap Joint Inspections - Area 1
Elapsed Time
(Hours)
Man-HoursNumber of Per-
sons
Task
38762Inspect Section 41 Lap Joints
22221Inspect Section 42 Lap Joints
38381Inspect Section 46 Lap Joints
98 (a)136TOTAL
(a) Elapsed time will be less if Sections 41, 42 and 46 are inspected at the same time.
Group 1-2, 4-5, 7-9, 11-13:
Lap Joint Inspections - Expanded Area 2
Elapsed Time
(Hours)
Man-HoursNumber of Per-
sons
Task
28.51144Inspect Section 41 Lap Joints
47.51904Inspect Section 42 Lap Joints
39.51584Inspect Section 46 Lap Joints
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Group 1-2, 4-5, 7-9, 11-13:
Lap Joint Inspections - Expanded Area 2
Elapsed Time
(Hours)
Man-HoursNumber of Per-
sons
Task
115.5 (a)462TOTAL
(a) Elapsed time will be less if Sections 41, 42, and 46 are inspected at the same time.
Group 3, 6:
Lap Joint Inspections - Expanded Area 2
Elapsed Time
(Hours)
Man-HoursNumber of Per-
sons
Task
28.51144Inspect Section 41 Lap Joints
80.53224Inspect Section 42, 44, and 46 Lap
Joints
109 (a)436TOTAL
(a) Elapsed time will be less if Sections 41, 42, 44 and 46 are inspected at the same time.
Group 10:
Lap Joint Inspections - Expanded Area 2
Elapsed Time
(Hours)
Man-HoursNumber of Per-
sons
Task
28.51144Inspect Section 41 Lap Joints
40.01604Inspect Section 42 Lap Joints
36.71474Inspect Section 46 Lap Joints
105.2 (a)421TOTAL
(a) Elapsed time will be less if Sections 41, 42, and 46 are inspected at the same time.
Lap Joint Modification
Elapsed Time
(Hours)
Man-HoursNumber of Per-
sons
Task
287.75460416Section 41 Modification
303.7512154Section 42 Modification
591.5 (a)5819TOTAL
(a) Elapsed time will be less if Sections 41 and 42 are modified at the same time.
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### Page 39

Group 1-3, 7-8, 12-13:
Lap Joint - Post-Modification Inspection
Elapsed HoursTask HoursNumber of PersonsTask
2.505.002Open Access
7.7531.004FIGURE 24
(a) (b)
5.7523.004FIGURE 25
3.2513.004FIGURE 26
7.0028.004FIGURE 27
2.505.002Close Access
28.75105.00TOTAL FOR EACH AIRPLANE
(a) Inspection of Stringer 6, STA 340 to 400, are only required for Groups 1-3, 7-8 if external
doublers are installed as given in this service bulletin as an alternative method of compli-
ance.
(b) Inspection of Stringer 6, STA 400 to 520, are only required for Groups 1-3, 7-8 if external
doublers are installed as given in this service bulletin as an alternative method of compli-
ance.
Group 4-6, 9-11:
Lap Joint - Post-Modification Inspection
Elapsed HoursTask HoursNumber of PersonsTask
2.259.004Open Access
5.7523.004FIGURE 25
3.2513.004FIGURE 26
7.0028.004FIGURE 27
6.25 (a)12.50 (a)2FIGURE 28 (Table 1 - external
inspections)
12.50 (a)25.00 (a)2FIGURE 28 (Table 2 - internal
and external inspections)
6.25 (a)12.50 (a)2FIGURE 29 (Table 1 - external
inspections)
12.50 (a)25.00 (a)2FIGURE 29 (Table 2 - internal
and external inspections)
2.259.004Close Access
37.25124.00TOTAL FOR EACH AIRPLANE
(a)(a)
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### Page 40

Group 4-6, 9-11:
Lap Joint - Post-Modification Inspection
Elapsed HoursTask HoursNumber of PersonsTask
(a) Total only includes hours for FIGURE 28, Table 1 and FIGURE 29, Table 1 inspections
for airplanes with less than 15,000 flight cycles since Stringer 6 external doubler was in-
stalled as given in Service Bulletin 747-53-2272. If Table 2 inspections are done for air-
planes with 15,000 or more flight cycles since Stringer 6 external doubler was installed
as given in Service Bulletin 747-53-2272, then the FIGURE 28 and FIGURE 29 inspection
time will increase to the amount shown for Table 2 inspections.
H. Weight and Balance Changes
Due to the large number of possible repairs/modifications that may be required, and due to the variability
of the repairs/modifications when installed, weight and balance calculations are not given for this service
bulletin. Boeing recommends that operators weigh each airplane to determine weight and moment
changes before the airplane is returned to service.
I. Electrical Load Data
Not changed.
J. References
1. Existing Data:
a. Engineering Change Memo PRR 85901-88RS
b. Boeing Service Bulletin 747-53-2253, 747-53-2272, 747-53-2386, 747-53A2303, 747-53A2305,
747-53A2542, 747-53A2563, 747-53A2675
c. Boeing Service Letter 747-SL-51-048, 747-SL-53-088
d. Boeing Service Related Problem (SRP) 747-SRP-53-0278, 747-SRP-53-0437
e. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2004-07-22 R1, 2005-08-01,
2006-20-02, 2006-22-09, 2006-24-02, 2006-24-05, 2007-15-07, 2008-16-14, 2009-04-16,
2010-10-05, 2012-10-03, 2013-16-24, 90-06-06, 94-12-04
f. Standard Overhaul Practices Manual (SOPM) 20-41-01, 20-50-01, 20-50-11
g. 747 Fleet Team Digest (FTD) 53-13003
h. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00, Part 6, 53-30-00, Part 6, 53-30-02
or 53-30-03 or 53-30-06
i. 747 Repair Assessment Guidelines (RAG)
j. 747-100/200/300 Structural Repair Manual (SRM) 51-10-06, 51-30-08, 51-70-00, 51-70-03,
53-10-04, 53-30-03
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### Page 41

k. 747-SP Structural Repair Manual (SRM) 51-10-06, 51-30-08, 51-70-00, 51-70-03, 53-39-01
2. Data Supplied with this Service Bulletin:
a. Drawings:
ADCNDCN/REVSheetTitleDrawing No
-A1Kit - Lap Splice Modification, S-6, Sta 340
Sta 520
141U0008
--10
--11
--12
-A13
-A14
-A15
--2
--3
--4
--5
--6
--7
--8
-A9
-APSDLKit - Lap Splice Modification, S-6, Sta 340
Sta 520
141U0008#DL
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### Page 42

ADCNDCN/REVSheetTitleDrawing No
-A1Kit - Lap Splice Modification, S-6, STA 340
- STA 520
141U0059
-A10
-A11
-A12
-A13
-A14
-A15
-A16
-A17
-A18
-A19
-A2
-A3
-A4
-A5
-A6
-A7
-A8
-A9
--PSDLKit - Lap Splice Modification, S-6, STA 340
- STA 520
141U0059#DL
-A1747 Section 41, S-23 Skin Reinforcement -
STA 220 - 400.
691U1050
-CPSDL747 Section 41, S-23 Skin Reinforcement -
STA 220 - 400.
691U1050#DL
-A1Lap Splice Reinforcement , Stringer 44 ,
STA 420 - STA 520
691U1051
-CPSDLLap Splice Reinforcement , Stringer 44 ,
STA 420 - STA 520
691U1051#DL
-A1Lap Splice Reinforcement, Stringer 44, STA
520 - STA 741
691U1052
-CPSDLLap Splice Reinforcement, Stringer 44, STA
520 - STA 741
691U1052#DL
3. Installation Drawings Used in the Preparation of this Service Bulletin:
None.
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### Page 43

K. Publications Affected
1. Publications:
None.
2. Damage Tolerance Based Structural Inspections:
Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue
Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the
Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected
are contained in Paragraph 1.E., Compliance of this service bulletin or in existing documents.
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
M. Software Accomplishment Summary
Not affected.
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BLANK PAGE

### Page 45

2.    MATERIAL INFORMATION
A. Material - Price and Availability
Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane, as shown
below. Alternatively, operators can supply/fabricate their own parts. If there is a limit to the quantity
(QTY) of available kits, a supply sequence is given by Spares. More kits become available as shown
in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order.
Unit Price thru
Jan 31/11
ROLT
(Weeks)
QTYDateNameKit Number
$5001.00431Jan 21/10Kit - Lap Splice Modifica-
tion
141U0059-1
$4887.00433Dec 08/09Kit - Lap Splice Modifica-
tion
141U0059-2
$5004.00432Jan 21/10Kit - Lap Splice Modifica-
tion
141U0059-3
$4333.00433Dec 08/09Kit - Lap Splice Modifica-
tion
141U0059-4
$6787.00431Jan 21/10Kit - Lap Splice Modifica-
tion
141U0059-5
$6880.00433Dec 08/09Kit - Lap Splice Modifica-
tion
141U0059-6
$6708.00432Jan 21/10Kit - Lap Splice Modifica-
tion
141U0059-7
$6645.00434Jan 21/10Kit - Lap Splice Modifica-
tion
141U0059-8
$5898.00431Jan 21/10Kit - Lap Splice Modifica-
tion
141U0059-9
$5465.00432Dec 08/09Kit - Lap Splice Modifica-
tion
141U0059-10
$7586.00431Jan 21/10Kit - Lap Splice Modifica-
tion
141U0059-11
$6961.00432Dec 08/09Kit - Lap Splice Modifica-
tion
141U0059-12
Unit Price thru
Jan 31/11
ROLT
(Weeks)
QTYDateNameKit Number
$3135.00(a)(a)(a)Kit - Lap Splice Modifica-
tion
141U0008-1
$3121.00(a)(a)(a)Kit - Lap Splice Modifica-
tion
141U0008-2
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### Page 46

Unit Price thru
Jan 31/11
ROLT
(Weeks)
QTYDateNameKit Number
$3135.00(a)(a)(a)Kit - Lap Splice Modifica-
tion
141U0008-3
$3122.00(a)(a)(a)Kit - Lap Splice Modifica-
tion
141U0008-4
$2990.00(a)(a)(a)Kit - Lap Splice Modifica-
tion
141U0008-5
$2990.00(a)(a)(a)Kit - Lap Splice Modifica-
tion
141U0008-6
$3096.00(a)(a)(a)Kit - Lap Splice Modifica-
tion
141U0008-7
$2948.00(a)(a)(a)Kit - Lap Splice Modifica-
tion
141U0008-8
(a) These kits were not available at the time of release of Revision 2 of this service bulletin. Boeing
recommends that operators submit a purchase order 18 months in advance of performing the
modification.
B. Industry Support Information
This service bulletin was first released before October of 1994. Thus industry support for affected
airplanes depends upon whether you ever filed a warranty claim with Boeing on this service bulletin.
C. Parts Necessary for Each Airplane
1. Kits/Parts:
NOTE: The kits shown below are for lap splice modification at Stringer 6. See Drawing 141U0008,
Sheet 1 and Drawing 141U0059, Sheet 1 for kit applicability. The kits below can be
ordered from Boeing, or the equivalent parts can be supplied by the operator.
To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
Kit 141U0008
NotesExisting
Part
Number
NameQTYNew Part Number
-1-2-3-4-5-6
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 340 -
STA 520
-.....141U0008-1
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 340 -
STA 520
.-....141U0008-2
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 340 -
STA 520
..-...141U0008-3
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### Page 47

Kit 141U0008
NotesExisting
Part
Number
NameQTYNew Part Number
-1-2-3-4-5-6
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 340 -
STA 520
...-..141U0008-4
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 340 -
STA 520
....-.141U0008-5
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 340 -
STA 520
.....-141U0008-6
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 520
1.....141U0008-11
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 520
.1....141U0008-12
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 520
..1...141U0008-13
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 520
...1..141U0008-14
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 520
....11141U0008-15
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 520
1.....141U0008-41
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 520
.1....141U0008-42
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 520
..1...141U0008-43
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 520
...1..141U0008-44
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 520
....1.141U0008-45
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### Page 48

Kit 141U0008
NotesExisting
Part
Number
NameQTYNew Part Number
-1-2-3-4-5-6
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 520
.....1141U0008-46
Kit 141U0008
NotesExisting
Part
Number
NameQTYNew Part Number
-7-8-11-12-13-14
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 340 -
STA 520
-.....141U0008-7
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 340 -
STA 520
.-....141U0008-8
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 520
..-...141U0008-11
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 520
...-..141U0008-12
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 520
....-.141U0008-13
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 520
.....-141U0008-14
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 520
11....141U0008-17
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 520
1.....141U0008-47
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 520
.1....141U0008-48
(a)BOLT, 100 DEG HEX DR..21212121BACB30NW6K5X
(a)BOLT, 100 DEG HEX DR..4444BACB30NW6K8X
COLLAR..25252525BACC30M6
(a)RIVET, 100 DEG....48BACR15GF6D10
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### Page 49

Kit 141U0008
NotesExisting
Part
Number
NameQTYNew Part Number
-7-8-11-12-13-14
(a)RIVET, 100 DEG..578571..BACR15GF6D4
(a)RIVET..421385947947BACR15GF6D5
(a)RIVET, 100 DEG..688583675546BACR15GF6D6
(a)RIVET, 100 DEG..473405492422BACR15GF6D7
(a)RIVET, 100 DEG..159162221200BACR15GF6D8
(a)RIVET, 100 DEG..15192522BACR15GF6D9
(a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer
than indicated. Also, if any fasteners part numbers listed are not available or have been superseded,
substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65B88700.
Kit 141U0008
NotesExisting
Part
Number
NameQTYNew Part Number
-15-17-41-42-43-44
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 520
-.....141U0008-15
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 520
.-....141U0008-17
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 520
..-...141U0008-41
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 520
...-..141U0008-42
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 520
....-.141U0008-43
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 520
.....-141U0008-44
EXTERNAL DOUBLER..1...141U0035-1
EXTERNAL DOUBLER...1..141U0035-2
EXTERNAL DOUBLER..1...141U0035-3
EXTERNAL DOUBLER...1..141U0035-4
EXTERNAL DOUBLER....1.141U0035-5
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### Page 50

Kit 141U0008
NotesExisting
Part
Number
NameQTYNew Part Number
-15-17-41-42-43-44
EXTERNAL DOUBLER.....1141U0035-6
STRUCTURAL FILLER....1.141U0035-7
STRUCTURAL FILLER.....1141U0035-8
(a)BOLT, 100 DEG HEX DR2.....BACB30NW6K3X
(a)BOLT, 100 DEG HEX DR62....BACB30NW6K4X
(a)BOLT, 100 DEG HEX DR.6....BACB30NW6K5X
(a)BOLT, 100 DEG HEX DR4.....BACB30YP6K4
(a)BOLT, 100 DEG HEX DR24....BACB30YP6K5
(a)BOLT, 100 DEG HEX DR.2....BACB30YP6K6
COLLAR66....BACC30BL6
COLLAR88....BACC30M6
(a)RIVET, UNIVERSAL HD195130....BACR15BB6D4C
(a)RIVET, UNIVERSAL HD1017....BACR15BB6D6C
(a)RIVET, UNIVERSAL HD69....BACR15BB6D7C
(a)RIVET, 100 DEG579.....BACR15GF6D4
(a)RIVET959646....BACR15GF6D5
(a)RIVET, 100 DEG22987....BACR15GF6D6
(a)RIVET, 100 DEG300367....BACR15GF6D7
(a)RIVET, 100 DEG9228....BACR15GF6D8
(a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer
than indicated. Also, if any fasteners part numbers listed are not available or have been superseded,
substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65B88700.
Kit 141U0008
NotesExisting
Part
Number
NameQTYNew Part Number
-45-46-47-48
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 520
-...141U0008-45
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 520
.-..141U0008-46
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### Page 51

Kit 141U0008
NotesExisting
Part
Number
NameQTYNew Part Number
-45-46-47-48
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 520
..-.141U0008-47
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 520
...-141U0008-48
EXTERNAL DOUBLER1...141U0035-9
EXTERNAL DOUBLER.1..141U0035-10
STRUCTURAL FILLER1...141U0035-11
STRUCTURAL FILLER.1..141U0035-12
EXTERNAL DOUBLER..1.141U0035-13
EXTERNAL DOUBLER...1141U0035-14
STRUCTURAL FILLER..1.141U0035-15
STRUCTURAL FILLER...1141U0035-16
Kit 141U0059
NotesExisting
Part
Number
NameQTYNew Part Number
-1-2-3-4-5-6
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 340 -
STA 400
-.....141U0059-1
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 340 -
STA 400
.-....141U0059-2
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 340 -
STA 400
..-...141U0059-3
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 340 -
STA 400
...-..141U0059-4
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 400 -
STA 520
....-.141U0059-5
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 400 -
STA 520
.....-141U0059-6
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 18, 1991
747-53A2367Revision 5: July 08, 2014
51 of 171
BOEING SERVICE BULLETIN 747-53A2367
ALERTALERT

### Page 52

Kit 141U0059
NotesExisting
Part
Number
NameQTYNew Part Number
-1-2-3-4-5-6
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 400
1.....141U0059-21
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 400
.1....141U0059-22
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
400 - STA 520
....1.141U0059-23
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
400 - STA 520
.....1141U0059-24
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 400
.1....141U0059-31
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 400
...1..141U0059-32
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 400 - STA 520
....11141U0059-33
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 400
1.....141U0059-37
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 400
..1...141U0059-38
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 400
..1...141U0059-41
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 400
...1..141U0059-42
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 18, 1991
747-53A2367Revision 5: July 08, 2014
52 of 171
BOEING SERVICE BULLETIN 747-53A2367
ALERTALERT

### Page 53

Kit 141U0059
NotesExisting
Part
Number
NameQTYNew Part Number
-7-8-9-10-11-12
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 400 -
STA 520
-.....141U0059-7
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 400 -
STA 520
.-....141U0059-8
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 340 -
STA 400
..-...141U0059-9
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 340 -
STA 400
...-..141U0059-10
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 400 -
STA 520
....-.141U0059-11
KIT - LAP SPLICE MODIFI-
CATION, S-6, STA 400 -
STA 520
.....-141U0059-12
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 400
..1...141U0059-25
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 400
...1..141U0059-26
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
400 - STA 520
....1.141U0059-27
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
400 - STA 520
.....1141U0059-28
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 400 - STA 520
11....141U0059-34
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 400
...1..141U0059-35
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 400 - STA 520
....11141U0059-36
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 18, 1991
747-53A2367Revision 5: July 08, 2014
53 of 171
BOEING SERVICE BULLETIN 747-53A2367
ALERTALERT

### Page 54

Kit 141U0059
NotesExisting
Part
Number
NameQTYNew Part Number
-7-8-9-10-11-12
KIT - FASTENERS, LAP
SPLICE MODIFICATION, S-
6, STA 340 - STA 400
..1...141U0059-39
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
400 - STA 520
1.....141U0059-43
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
400 - STA 520
.1....141U0059-44
Kit 141U0059
NotesExisting
Part
Number
NameQTYNew Part Number
-21-22-23-24-25-26
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 400
-.....141U0059-21
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 400
.-....141U0059-22
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
400 - STA 520
..-...141U0059-23
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
400 - STA 520
...-..141U0059-24
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 400
....-.141U0059-25
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 400
.....-141U0059-26
STRINGER FILLER11..11141U0060-2
TEAR STRAP DOUBLER11..11141U0060-4
TEAR STRAP FILLER11..11141U0060-6
FLAT FILLER11..11141U0060-8
TAPERED FILLER1...1.141U0060-9
TAPERED FILLER.1...1141U0060-10
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 18, 1991
747-53A2367Revision 5: July 08, 2014
54 of 171
BOEING SERVICE BULLETIN 747-53A2367
ALERTALERT

### Page 55

Kit 141U0059
NotesExisting
Part
Number
NameQTYNew Part Number
-21-22-23-24-25-26
STRINGER FILLER..11..141U0060-12
TEAR STRAP DOUBLER..11..141U0060-14
TEAR STRAP FILLER..11..141U0060-16
FLAT FILLER..11..141U0060-18
TAPERED FILLER..1...141U0060-19
TAPERED FILLER...1..141U0060-20
STRINGER FILLER..11..141U0060-22
TEAR STRAP DOUBLER..22..141U0060-24
TEAR STRAP FILLER..33..141U0060-28
EXTERNAL DOUBLER1...1.141U0060-37
EXTERNAL DOUBLER.1...1141U0060-38
SKIN EXTENSION..1...141U0060-39
SKIN EXTENSION...1..141U0060-40
EXTERNAL DOUBLER1.....141U0060-41
EXTERNAL DOUBLER.1....141U0060-42
EXTERNAL DOUBLER..1...141U0060-43
EXTERNAL DOUBLER...1..141U0060-44
EXTERNAL DOUBLER....1.141U0060-45
EXTERNAL DOUBLER.....1141U0060-46
FILLER11..11141U0060-52
STRINGER FILLER11..11141U0060-56
FILLER11..11141U0060-60
FILLER..11..BACF3F008J032NN
FILLER11..11BACF3F010L035NN
SHIM, LAMINATED..33..BACF3F011J015NN
FILLER, FLAT..11..BACF3F011J017NN
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 18, 1991
747-53A2367Revision 5: July 08, 2014
55 of 171
BOEING SERVICE BULLETIN 747-53A2367
ALERTALERT

### Page 56

Kit 141U0059
NotesExisting
Part
Number
NameQTYNew Part Number
-27-28-31-32-33-34
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
400 - STA 520
-.....141U0059-27
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
400 - STA 520
.-....141U0059-28
KIT - FASTENERS, LAP
SPLICE MODIFICATION,
S-6, STA 340 - STA 400
..-...141U0059-31
KIT - FASTENERS, LAP
SPLICE MODIFICATION,
S-6, STA 340 - STA 400
...-..141U0059-32
KIT - FASTENERS, LAP
SPLICE MODIFICATION,
S-6, STA 400 - STA 520
....-.141U0059-33
KIT - FASTENERS, LAP
SPLICE MODIFICATION,
S-6, STA 400 - STA 520
.....-141U0059-34
STRINGER FILLER11....141U0060-12
TEAR STRAP DOUBLER11....141U0060-14
TEAR STRAP FILLER11....141U0060-16
FLAT FILLER11....141U0060-18
TAPERED FILLER1.....141U0060-19
TAPERED FILLER.1....141U0060-20
STRINGER FILLER11....141U0060-22
TEAR STRAP DOUBLER22....141U0060-24
TEAR STRAP FILLER33....141U0060-28
SKIN EXTENSION1.....141U0060-39
SKIN EXTENSION.1....141U0060-40
EXTERNAL DOUBLER1.....141U0060-47
EXTERNAL DOUBLER.1....141U0060-48
(a)HI-LOK.....2BACB30MY8K4
(a)BOLT.....2BACB30MY8K5
(a)BOLT, HEX DRIVE.....12BACB30MY8K6
(a)BOLT, PROTRUDING HD.....4BACB30MY8K6Y
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 18, 1991
747-53A2367Revision 5: July 08, 2014
56 of 171
BOEING SERVICE BULLETIN 747-53A2367
ALERTALERT

### Page 57

Kit 141U0059
NotesExisting
Part
Number
NameQTYNew Part Number
-27-28-31-32-33-34
(a)BOLT.....40BACB30MY8K7
(a)BOLT, PROTRUDING HD.....2BACB30MY8K7Y
(a)HI-LOK PROT HEAD.....5BACB30MY8K8
(a)BOLT, 100 DEG HEX DR...22.BACB30NW6K4X
(a)BOLT, 100 DEG HEX DR..942118BACB30NW6K5X
(a)BOLT, 100 DEG HEX DR...3..BACB30NW6K5Y
(a)HI-LOK....4.BACB30NW6K6
(a)BOLT, 100 DEG HEX DR..22414.BACB30NW6K6X
(a)BOLT, 100 DEG HEX DR...18..BACB30NW6K6Y
(a)BOLT....2.BACB30NW6K7
(a)BOLT, 100 DEG HEX DR..5245464BACB30NW6K7X
(a)BOLT, 100 DEG HEX DR..9.84BACB30NW6K8X
(a)BOLT, 100 DEG HEX DR...4..BACB30NW6K8Y
(a)BOLT, PROTRUDING HD..22..BACB30NX6K4X
(a)BOLT, PROTRUDING HD.....2BACB30NX6K5X
(a)BOLT, PROTRUDING HD....22BACB30NX6K6X
COLLAR..2224BACC30BH6
COLLAR..92559726BACC30M6
COLLAR.....50BACC30M8
COLLAR...25..BACC30R6
COLLAR.....6BACC30R8
FILLER11....BACF3F008J032NN
SHIM, LAMINATED33....BACF3F011J015NN
FILLER, FLAT11....BACF3F011J017NN
(a)RIVET, UNIVERSAL HD..99..BACR15BB6D4C
(a)RIVET, UNIVERSAL HD..2.3940BACR15BB6D5C
(a)RIVET, UNIVERSAL HD..3543BACR15BB6D6C
(a)RIVET, UNIVERSAL HD..2246BACR15BB6D7C
(a)RIVET, UNIVERSAL HD....32BACR15BB6D8C
(a)RIVET, UNIVERSAL HD...24.61BACR15BB7D10C
(a)RIVET, UNIVERSAL HD.....6BACR15BB7D11C
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 18, 1991
747-53A2367Revision 5: July 08, 2014
57 of 171
BOEING SERVICE BULLETIN 747-53A2367
ALERTALERT

### Page 58

Kit 141U0059
NotesExisting
Part
Number
NameQTYNew Part Number
-27-28-31-32-33-34
(a)RIVET, UNIVERSAL HD...8..BACR15BB7D6C
(a)RIVET, UNIVERSAL HD...132.6BACR15BB7D7C
(a)RIVET, UNIVERSAL HD...264.80BACR15BB7D8C
(a)RIVET, UNIVERSAL HD...73.110BACR15BB7D9C
(a)RIVET, UNIVERSAL HD.....20BACR15BB8D10C
(a)RIVET, UNIVERSAL HD...1.2BACR15BB8D11C
(a)RIVET, UNIVERSAL HD...33..BACR15BB8D6C
(a)RIVET, UNIVERSAL HD...9..BACR15BB8D7C
(a)RIVET, UNIVERSAL HD...2.5BACR15BB8D8C
(a)RIVET, UNIVERSAL HD.....44BACR15BB8D9C
(a)RIVET, 100 DEG..32147911BACR15GF6D10
(a)RIVET, 100 DEG..653682..BACR15GF6D4
(a)RIVET..506535864779BACR15GF6D5
(a)RIVET, 100 DEG..330228180215BACR15GF6D6
(a)RIVET, 100 DEG..472322859735BACR15GF6D7
(a)RIVET, 100 DEG..297144241253BACR15GF6D8
(a)RIVET, 100 DEG..1289225970BACR15GF6D9
(a)RIVET, 100 DEG.....83BACR15GF7D6
(a)RIVET, 100 DEG.....90BACR15GF7D7
(a)RIVET, 100 DEG.....6BACR15GF7D8
(a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer
than indicated. Also, if any fasteners part numbers listed are not available or have been superseded,
substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65B88700.
Kit 141U0059
NotesExisting
Part
Number
NameQTYNew Part Number
-35-36-37-38-39-41
KIT - FASTENERS, LAP
SPLICE MODIFICATION,
S-6, STA 340 - STA 400
-.....141U0059-35
KIT - FASTENERS, LAP
SPLICE MODIFICATION,
S-6, STA 400 - STA 520
.-....141U0059-36
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 18, 1991
747-53A2367Revision 5: July 08, 2014
58 of 171
BOEING SERVICE BULLETIN 747-53A2367
ALERTALERT

### Page 59

Kit 141U0059
NotesExisting
Part
Number
NameQTYNew Part Number
-35-36-37-38-39-41
KIT - FASTENERS, LAP
SPLICE MODIFICATION,
S-6, STA 340 - STA 400
..-...141U0059-37
KIT - FASTENERS, LAP
SPLICE MODIFICATION,
S-6, STA 340 - STA 400
...-..141U0059-38
KIT - FASTENERS, LAP
SPLICE MODIFICATION,
S-6, STA 340 - STA 400
....-.141U0059-39
KIT - PARTS, LAP SPLICE
MODIFICATION, S-6, STA
340 - STA 400
.....-141U0059-41
STRINGER FILLER.....1141U0060-2
TEAR STRAP FILLER.....1141U0060-6
FLAT FILLER.....1141U0060-8
TAPERED FILLER.....1141U0060-25
TEAR STRAP DOUBLER.....1141U0060-30
EXTERNAL DOUBLER.....1141U0060-37
EXTERNAL DOUBLER.....1141U0060-41
FILLER.....1141U0060-52
STRINGER FILLER.....1141U0060-56
FILLER.....1141U0060-60
(a)BOLT, 100 DEG HEX DR.2.2..BACB30NW6K4X
(a)BOLT, 100 DEG HEX DR921949.BACB30NW6K5X
(a)BOLT, 100 DEG HEX DR...3..BACB30NW6K5Y
(a)HI-LOK.4....BACB30NW6K6
(a)BOLT, 100 DEG HEX DR221422422.BACB30NW6K6X
(a)BOLT, 100 DEG HEX DR...18..BACB30NW6K6Y
(a)BOLT.2....BACB30NW6K7
(a)BOLT, 100 DEG HEX DR5248524552.BACB30NW6K7X
(a)BOLT, 100 DEG HEX DR989.9.BACB30NW6K8X
(a)BOLT, 100 DEG HEX DR...4..BACB30NW6K8Y
(a)BOLT, PROTRUDING HD2.222.BACB30NX6K4X
(a)BOLT, PROTRUDING HD.2....BACB30NX6K5X
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 18, 1991
747-53A2367Revision 5: July 08, 2014
59 of 171
BOEING SERVICE BULLETIN 747-53A2367
ALERTALERT

### Page 60

Kit 141U0059
NotesExisting
Part
Number
NameQTYNew Part Number
-35-36-37-38-39-41
(a)BOLT, PROTRUDING HD.2....BACB30NX6K6X
COLLAR24222.BACC30BH6
COLLAR9299925592.BACC30M6
COLLAR...25..BACC30R6
FILLER.....1BACF3F010L035NN
(a)RIVET, UNIVERSAL HD9.999.BACR15BB6D4C
(a)RIVET, UNIVERSAL HD2382.2.BACR15BB6D5C
(a)RIVET, UNIVERSAL HD34353.BACR15BB6D6C
(a)RIVET, UNIVERSAL HD23222.BACR15BB6D7C
(a)RIVET, UNIVERSAL HD.2....BACR15BB6D8C
(a)RIVET, UNIVERSAL HD.2....BACR15BB6D9C
(a)RIVET, UNIVERSAL HD...24..BACR15BB7D10C
(a)RIVET, UNIVERSAL HD...34..BACR15BB7D6C
(a)RIVET, UNIVERSAL HD...152..BACR15BB7D7C
(a)RIVET, UNIVERSAL HD...356..BACR15BB7D8C
(a)RIVET, UNIVERSAL HD...83..BACR15BB7D9C
RIVET, UNIVERSAL HD...1..BACR15BB8D11C
(a)RIVET, UNIVERSAL HD...24..BACR15BB8D6C
(a)RIVET, UNIVERSAL HD...18..BACR15BB8D7C
(a)RIVET, UNIVERSAL HD...2..BACR15BB8D8C
(a)RIVET, 100 DEG3279321432.BACR15GF6D10
(a)RIVET, 100 DEG..399442..BACR15GF6D4
(a)RIVET1159410575565975.BACR15GF6D5
(a)RIVET, 100 DEG219587502319427.BACR15GF6D6
(a)RIVET, 100 DEG564790578485559.BACR15GF6D7
(a)RIVET, 100 DEG296633319151397.BACR15GF6D8
(a)RIVET, 100 DEG14729912892143.BACR15GF6D9
(a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer
than indicated. Also, if any fasteners part numbers listed are not available or have been superseded,
substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65B88700.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 18, 1991
747-53A2367Revision 5: July 08, 2014
60 of 171
BOEING SERVICE BULLETIN 747-53A2367
ALERTALERT

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