# Boeing Alert Service Bulletin 747-53A2463: Revision 2 - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2014-1052; AD 2015-15-01 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 747-53A2463](https://openairdocs.org/service-documents/boeing/747-53a2463.md) - Title as filed: U.S. DOT/FAA - Service Bulletin 747-53A2463 Revision 02 - Pages: 112 - PDF: https://openairdocs.org/files/sha256/ee/de/eede3e7c5f31446a2d9c7817de5e519d20f703ffe073df2b783e0e9c268b887b - Page: https://openairdocs.org/service-documents/boeing/747-53a2463/file/eede3e7c5f31 ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2463 Original Issue: March 07, 2002 Revision 2: June 16, 2014 ATA System: 5310 5331 SUBJECT: FUSELAGE - Skin - Longitudinal Lap Joints Inspection and Repair 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 © 2002 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 Unpublished Work.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: March 07, 2002 747-53A2463Revision 2: June 16, 2014 1 of 112 4.0 ### Page 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 2 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT BLANK PAGE ### Page 3 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 7 B. Concurrent Requirements ...................................... 1 7 C. Reason ................................................ 1 7 D. Description .............................................. 1 8 E. Compliance .............................................. 1 9 F. Approval ............................................... 2 4 G. Manpower .............................................. 2 6 H. Weight and Balance Changes .................................... 2 8 I. Electrical Load Data ......................................... 2 8 J. References .............................................. 2 8 1. Existing Data: ......................................... 2 8 2. Data Supplied with this Service Bulletin: ........................... 2 9 3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 9 K. Publications Affected ........................................ 3 0 L. Interchangeability and Intermixability of Parts ........................... 3 0 M. Software Accomplishment Summary ................................ 3 0 2. MATERIAL INFORMATION ........................................ 3 1 A. Material - Price and Availability ................................... 3 1 B. Industry Support Information .................................... 3 1 C. Parts Necessary for Each Airplane ................................. 3 1 1. Kits/Parts: ........................................... 3 1 2. Parts and Materials Supplied by the Operator: ........................ 3 1 3. Parts Modified and Reidentified: ............................... 3 1 4. Parts Removed and Not Replaced: .............................. 3 1 D. Parts Necessary to Change Spares ................................. 3 1 E. Special Tooling - Price and Availability ............................... 3 1 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 1 3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 3 A. GENERAL INFORMATION ..................................... 3 3 B. WORK INSTRUCTIONS ....................................... 3 5 FIGURE 1: DELETED ............................................ 4 2 FIGURE 2: EXTERIOR ACCESS ...................................... 4 3 FIGURE 3: INTERNAL ACCESS ...................................... 4 6 FIGURE 4: LOCATION OF LAP JOINTS 0.090 INCHES OR LESS, GROUP 1 [Group 1] ....... 5 7 FIGURE 5: LOCATION OF LAP JOINTS 0.090 INCHES OR LESS, GROUPS 2 - 14 [Group 2-14] . . 58 FIGURE 6: EXTERNAL LFEC UPPER ROW SKIN INSPECTION - GROUP 1 [Group 1] ........ 6 5 FIGURE 7: EXTERNAL LFEC UPPER ROW SKIN INSPECTION - GROUPS 2 - 14 [Group 2-14] . . . 66 FIGURE 8: INTERNAL MFEC LOWER ROW SKIN INSPECTION .................... 7 7 FIGURE 9: LOCATION OF LAP JOINTS 0.071 INCHES OR LESS ................... 7 8 FIGURE 10: POST-MODIFICATION INSPECTION - INTERNAL HFEC INSPECTION ......... 8 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 3 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 4 FIGURE 11: POST-MODIFICATION INSPECTION - OPEN-HOLE HFEC INSPECTION ........ 9 7 Appendix A: SKIN / STRINGER DIAGRAMS - GROUP 1 [Group 1] .................... 9 9 Appendix B: SKIN / STRINGER DIAGRAMS - GROUPS 2 - 14 [Group 2-14] .............. 1 0 0 Appendix C: STRINGER 6 AND 14 INSPECTION IN SECTION 41 ................... 1 1 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 4 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 5 Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2463Original Issue: March 07, 2002 Revision 2: June 16, 2014 ATA System: 5310 5331 SUBJECT: FUSELAGE - Skin - Longitudinal Lap Joints Inspection and Repair This revision includes all pages of the service bulletin. COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directives AD 86-09-07 R1, AD 2004-07-22 R1, AD 2004-13-02, AD 2006-22-09, AD 2010-14-10, and AD 2010-21-04 are related to this service bulletin. The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. More work is necessary on airplanes changed or inspected in accordance with the original issue and Revision 1 of this service bulletin. The (more) work is necessary at lap joints where the thickness of the upper (overlapping) skin at the upper row of fasteners in the lap joint is 0.090 inches or less. At these lap joints, a structural modification is to be accomplished by the time given in Paragraph 1.E., Compliance. No airplanes have been added to the service bulletin effectivity. REASON FOR REVISION This revision is sent to give instructions to do structural modification and post-modification inspections. A structural modification is necessary at lap joints where the thickness of the upper (overlapping) skin at the upper row of fasteners is 0.090 inches or less. Revision 1 of this service bulletin gave instructions to do a structural modification at lap joints where the skin thickness at the upper fastener row is 0.071 inches or less. Subsequent to Revision 1 release of this service bulletin, additional analysis was done, which showed that lap joints where the thickness of the upper (overlapping) skin is 0.090 inches or less should be modified by the time given in Paragraph 1.E., Compliance. At the time of Revision 2 release of this service bulletin, Boeing records show that no operators have contacted Boeing for a structural modification instructions in accordance with Revision 1 of this service bulletin. In addition to the modification instructions, minor clarifications are added to show skin thicknesses in the lap joints. Also, information related to Group 1 airplane has been deleted. Boeing record shows that Group 1, which includes RR201 airplane only, has been permanently withdrawn from service and scrapped. These sections were changed: 1. In Summary, Background, updated to show that the modification given in this service bulletin applies to lap joints where skin thickness is 0.090 inches or less. Added the latest SRP number, description of structure affected by widespread fatigue damage (WFD) description, and summary evaluation table. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 5 of 112 ### Page 6 2. In Summary, Action, updated to show that the modification given in this service bulletin applies to lap joints where skin thickness is 0.090 inches or less. Also, deleted the notes since the detailed information in the notes are already given in Paragraph 3., Accomplishment Instructions. 3. In Summary, Compliance, updated FAA AD references with the effective date of the FAA AD. Added FAA AD 2010-14-10, which supersedes FAA AD 94-17-01, and FAA AD 2010-21-04, which supersedes AD 90-15-06 and AD 94-12-09. 4. In Summary, updated the summary figure to change the skin thickness from 0.071 to 0.090 for the structural modification. 5. In Paragraph 1.C., Reason, updated to show that the modification given in this service bulletin applies to lap joints where skin thickness is 0.090 inches or less. Added the latest SRP number and a reason for this revision. Deleted the list of changed sections for Revision 1. 6. In Paragraph 1.D., Description, added information about the structural modification requirement, "more work" statement, and affected maintenance zones tables. Deleted the notes since the detailed information in the notes are already given in Paragraph 3., Accomplishment Instructions. 7. In Paragraph 1.E., Compliance: – Updated FAA AD references with the effective date of the FAA AD. – Added FAA AD 2010-14-10, which supersedes FAA AD 94-17-01, and FAA AD 2010-21-04, which supersedes AD 90-15-06 and AD 94-12-09. – Moved post-repair inspection requirements to a new table. – Added a general reference to Paragraph 3., Accomplishment Instructions, for the required actions. – Added applicable "Part" of Paragraph 3., Accomplishment Instructions, for the required actions. – Added tables to give compliance information for structural modification and post-modification inspection instructions. – Added clarifications to the existing conditions and compliance times. 8. In Paragraph 1.F., Approval, updated alternative method of compliance (AMOC) approval paragraphs for the affected FAA ADs. 9. In Paragraph 1.G., Manpower, added manpower table for the post-modification inspection. 10. In Paragraph 1.H., Weight and Balance Changes, updated the skin thickness to 0.090 inch or less. 11. In Paragraph 1.J.1., Existing Data, updated the reference list. 12. In Paragraph 1.J.2., Data Supplied with this Service Bulletin, added drawings to be sent with this service bulletin. 13. In Paragraph 1.J.3., Installation Drawings Used in the Preparation of this Service Bulletin, added a drawing reference. 14. In Paragraph 1.K., Publications Affected, added a description of the effects on the fatigue critical structure and damage tolerance inspection due to the change given in this service bulletin. 15. Added Paragraph 1.M., Software Accomplishment Summary. 16. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, updated the information. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 6 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 7 17. In Paragraph 3.A., General Information, updated existing notes and added new notes. 18. In Paragraph 3.B., Work Instructions: – Added "Part" labels for each major sections. – Deleted work instructions related to Group 1 airplane. – Added clarification regarding the structural modification. – Added references to Paragraph 1.E., Compliance, when referring to compliance information. – Added clarification regarding external doubler repairs and post-repair inspection instructions. – Added references to the SRM for allowable damage limits and general damage removal instructions. – Added clarification regarding SRM repairs in the area where the skin thickness is 0.090 inches or less and 0.071 inches or less. – Added structural modification instructions. – Added post-modification inspection instructions. 19. In FIGURE 4, information was deleted. 20. In FIGURE 5, added clarification for Str-44 between Sta. 400 - 520. Also added clarification for Str-4 between Sta. 1627 - 1741 and Sta. 1961 - 2002 on airplanes with main deck side cargo door. Updated footnotes to clarify inspection and modification requirements. 21. In FIGURE 6, information was deleted. 22. In FIGURE 7, updated the NDT reference and changed the skin thickness information at stringer 23 in Section 46. 23. In FIGURE 9, changed the skin thickness information at stringer 4 in Section 46. 24. In FIGURE 10 and FIGURE 11, added post-modification inspection instructions. 25. In APPENDIX A, information was deleted. 26. In APPENDIX B, changed the skin thickness information at stringer 23 in Section 46. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes. Pages with no vertical lines have no important changes. REVISION HISTORY March 07, 2002Original Issue: April 16, 2009Revision 1: June 16, 2014Revision 2: Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 7 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 8 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT BLANK PAGE ### Page 9 Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2463Original Issue: March 07, 2002 Revision 2: June 16, 2014 ATA System: 5310 5331 SUBJECT: FUSELAGE - Skin - Longitudinal Lap Joints Inspection and Repair 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 Accomplishment of the inspections in this service bulletin will help ensure that cracks and corrosion in the skin at lap joints in the fuselage are found and repaired. Small undetected cracks can propagate and join to form a large crack which could cause rapid in-flight decompression. The skin segments on affected airplanes are joined by longitudinal lap joints which are cold bonded and are fastened by 3 rows of fasteners. The lap joints on affected 747 airplanes are manufactured using similar processes as the lap joints on 737 airplanes. A 737 airplane experienced a rapid decompression while beginning descent. After the airplane landed safely it was inspected, and the skin above the forward entry door was found to be separated at the S-4R lap joint with a tear running along the lap joint for approximately 28 inches. The skin was bent back at the upper edge of the stringer at S-5R and formed a roughly rectangular opening in the airplane, hinged at S-5R. The opening went from approximately Body Station (BS) 328 to BS 300. The airplane had 78,198 flight-cycles and 77,115 flight hours. The crack was in the (lower) overlapped skin at the lower row of fasteners of the lap joint. Upon further investigation of the damage, the (lower) overlapped skin panel of the damaged S-4R lap joint was found to have numerous scratches running horizontally on the faying surface. Metallurgical evaluation of the damage revealed that the scratches contributed to the initiation of the fatigue cracks. Subsequent inspections on other 737 airplanes showed that there were cracks and corrosion in other lap joints at various locations. The cracks were in the (upper) overlapping skin panel at the upper row of fasteners. Affected 747 airplanes have lap joints similar to 737 airplanes, and therefore the same fatigue cracking could occur on 747 airplanes where the thickness of the upper (overlapping) skin in a lap joint is 0.090 inches or less. No reports of this type of cracking have been received on 747 airplanes. On affected 747 airplanes severe corrosion of the skin has occurred at the lap joint. On airplanes after line number 200 the lap joints are assembled using sealant and improved assembly processes. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 9 of 112 ### Page 10 Subsequent to Revision 1 release of this service bulletin, a review of all service bulletins that recommend repeat inspections was performed to determine if the inspections were appropriate for aging airplanes. This review indicated that lap joints where the thickness of the upper (overlapping) skin is 0.090 inches or less should be modified by the time given in Paragraph 1.E., Compliance, on aging 747 airplanes, line numbers 2 through 200. Boeing Service Related Problem (SRP) 747-SRP-53-0135, 747OP-SRP-53-0292, and 747-SRP-53-0436 are related to this service bulletin. The longitudinal lap joints have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). 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 ChangesNoWeight 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/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator NoOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Inspections are to be done at all lap joints where the thickness of the upper (overlapping) skin at the upper fastener row is 0.090 inches or less. External low frequency eddy current (LFEC) inspections (for corrosion) are to be done at the upper row of fasteners of the lap joint and internal medium frequency eddy current (MFEC) inspections (for cracks) are to be done at the lower row of fasteners of the lap joint. These inspections are to be done by the times given in Paragraph 1.E., Compliance. Skin cracks and corrosion are to be repaired in accordance with Paragraph 3.B., Work Instructions, and Paragraph 1.E., Compliance. At lap joints where the thickness of the upper (overlapping) skin at the upper row of fasteners is 0.090 inches or less, a structural modification is to be accomplished by the time given Paragraph 1.E., Compliance. EFFECTIVITY 747-100, 747-200B, 747-200F Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 10 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 11 COMPLIANCE Refer to Paragraph 1.E., Compliance. Federal Aviation Administration (FAA) Airworthiness Directives AD 86-09-07 R1, AD 2004-07-22 R1, AD 2004-13-02, AD 2006-22-09, AD 2010-14-10 , and AD 2010-21-04 are related to this service bulletin. The effective date of AD 2004-13-02 is July 29, 2004. The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin. MANPOWER Refer to Paragraph 1.G., Manpower. MATERIAL INFORMATION None. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 11 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 12 (OCR) BOEING SERVICE BULLETIN 747-53A2463 ALERT ALERT S-34 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 S-12 STA 1480 LAP JOINT (TYPICAL) S-12 S-19 CRACK UPPER SKIN PROTRUDING 1000 HEAD FASTENER S-19 (TYPICAL) STA FLUSH HEAD 520 S-23 UPPER - FASTENER ROW (TYPICAL) STA SECTIONS 41 AND 42 140 LOWER - ROW LFEC AND MFEC INSPECT SKIN LAP CORROSION JOINTS FOR CRACKS AND CORROSION IN UPPER AND LOWER FASTENER ROWS CRACKS IN LOWER SKIN LOWER SKIN ACCOMPLISH A STRUCTURAL SECTION 41 SECTION MODIFICATION ON ALL LAP JOINTS STRINGER (TYPICAL) 42 AND 46 STRINGER (TYPICAL) WHERE THE SKIN THICKNESS IS 0.090 INCHES OR LESS V43416 Original Issue: March 07, 2002 Revision 2: June 16, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2463 Work - See page 1 for details. 12 of 112 ### Page 13 Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2463 Original Issue: March 07, 2002 Revision 2: June 16, 2014 ATA System: 5310 5331 SUBJECT: FUSELAGE - Skin - Longitudinal Lap Joints Inspection and Repair 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. DESCRIPTIONCONFIGURATIONGROUP 747-200F series airplane, line number 168.-1 747-100 and -200B series airplanes, line numbers 88 through 200 with different skin thickness than airplanes in groups 3 through 8 and groups 10 through 14. -2 747-100 series airplane, line number 3 with different skin thickness than airplanes in group 2, groups 4 through 9 and groups 11 through 14. -3 747-100 series airplanes, line numbers 81, 83 and 84 with different skin thickness than airplanes in groups 2 through 3, groups 5 through 10 and groups 12 through 14. -4 747-100 series airplanes, line numbers 4 through 76 with different skin thickness than airplanes in groups 2 through 4, groups 6 through 11 and groups 13 through 14. -5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 13 of 112 ### Page 14 DESCRIPTIONCONFIGURATIONGROUP 747-100 series airplanes, line numbers 59 through 79 with different skin thickness than airplanes in groups 2 through 5, groups 7 through 12 and group 14. -6 747-100 series airplanes, line numbers 86 and 87 with different skin thickness than airplanes in groups 2 through 6 and groups 8 through 14. -7 747-100 series airplanes, line numbers 89 through 193 with different skin thickness than airplanes in groups 2 through 7 and groups 9 through 13. -8 747-100 series airplanes, line numbers 94 through 161 with different skin thickness than airplanes in groups 3 through 8 and groups 10 through 14. -9 747-100 series airplane, line number 2 with different skin thickness than airplanes in group 2, groups 4 through 9 and groups 11 through 14. -10 747-100 series airplanes, line numbers 80, 82 and 85 with different skin thickness than airplanes in groups 2 through 3, groups 5 through 10 and groups 12 through 14. -11 747-100 series airplanes, line numbers 5 through 78 with different skin thickness than airplanes in groups 2 through 4, groups 6 through 11 and groups 13 through 14. -12 747-100 series airplanes, line numbers 46 through 67 with different skin thickness than airplanes in groups 2 through 5, groups 7 through 12 and group 14. -13 747-100 series airplanes, line numbers 90 through 143 with different skin thickness than airplanes in groups 2 through 7 and groups 9 through 13. -14 Airplane Models: 747-100, 747-200B, 747-200F GroupVariable Number 10RA002 3RA003 5RA004 - RA005 12RA006 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 14 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 15 GroupVariable Number 5RA007 - RA010 12RA011 5RA012 - RA014 12RA015 5RA016 - RA025 12RA026 2RA027 9RA028 - RA030 2RA031 - RA032 9RA033 2RA034 12RA101 - RA103 5RA104 - RA110 12RA111 - RA112 2RA113 - RA115 11RA161 - RA162 9RA163 2RA164 5RA201 - RA203 2RA216 - RA217 2RA245 - RA246 5RA251 - RA254 2RA255 - RA259 5RA301 - RA303 2RA304 - RA312 5RA351 - RA358 4RA359 2RA360 2RA369 - RA373 13RA401 - RA405 8RA406 - RA414 4RA501 2RA502 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 15 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 16 GroupVariable Number 5RA521 - RA523 9RA524 2RA525 - RA527 2RA532 - RA540 5RA551 - RA552 2RA559 - RA561 5RA581 2RA582 2RA585 5RA601 4RA602 12RA631 11RA632 9RA633 - RA635 2RA651 - RA652 2RA671 - RA677 2RA701 - RA702 2RA721 - RA724 2RA741 - RA743 2RA761 - RA762 2RA781 - RA782 13RA901 - RA902 6RA903 - RA907 7RA908 - RA909 14RA910 - RA916 2RB001 - RB005 12RB041 5RB042 12RB043 2RB044 2RB071 - RB075 2RB101 - RB102 2RD001 - RD002 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 16 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 17 GroupVariable Number 1RR201 2. Spares Affected None. B. Concurrent Requirements None. C. Reason Accomplishment of the inspections in this service bulletin will help ensure that cracks and corrosion in the skin at lap joints in the fuselage are found and repaired. Small undetected cracks can propagate and join to form a large crack which could cause rapid in-flight decompression. The skin segments on affected airplanes are joined by longitudinal lap joints which are cold bonded and are fastened by 3 rows of fasteners. The lap joints on affected 747 airplanes are manufactured using similar processes as the lap joints on 737 airplanes. A 737 airplane experienced a rapid decompression while beginning descent. After the airplane landed safely it was inspected, and the skin above the forward entry door was found to be separated at the S-4R lap joint with a tear running along the lap joint for approximately 28 inches. The skin was bent back at the upper edge of the stringer at S-5R and formed a roughly rectangular opening in the airplane, hinged at S-5R. The opening went from approximately Body Station (BS) 328 to BS 300. The airplane had 78,198 flight-cycles and 77,115 flight hours. The crack was in the (lower) overlapped skin at the lower row of fasteners of the lap joint. Upon further investigation of the damage, the (lower) overlapped skin panel of the damaged S-4R lap joint was found to have numerous scratches running horizontally on the faying surface. Metallurgical evaluation of the damage revealed that the scratches contributed to the initiation of the fatigue cracks. Subsequent inspections on other 737 airplanes showed that there were cracks and corrosion in other lap joints at various locations. The cracks were in the (upper) overlapping skin panel at the upper row of fasteners. Affected 747 airplanes have lap joints similar to 737 airplanes, and therefore the same fatigue cracking could occur on 747 airplanes where the thickness of the upper (overlapping) skin in a lap joint is 0.090 inches or less. No reports of this type of cracking have been received on 747 airplanes. On affected 747 airplanes severe corrosion of the skin has occurred at the lap joint. On airplanes after line number 200 the lap joints are assembled using sealant and improved assembly processes. Subsequent to Revision 1 release of this service bulletin, a review of all service bulletins that recommend repeat inspections was performed to determine if the inspections were appropriate for aging airplanes. This review indicated that lap joints where the thickness of the upper (overlapping) skin is less than or equal to 0.090 inches should be modified by the time given in Paragraph 1.E., Compliance, on aging 747 airplanes, line numbers 2 through 200. Boeing Service Related Problem (SRP) 747-SRP-53-0135, 747OP-SRP-53-0292, and 747-SRP-53-0436 are related to this service bulletin. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 17 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 18 Revision 1 is sent to add instruction to do a structural modification which is to be accomplished at lap joints where the thickness of the upper (overlapping) skin at the upper row of fasteners is 0.071 inches or less. Also, revision 1 is sent to clarify the inspection requirements in locations where external repair doublers have been installed. Revision 2 is sent to give instructions to do structural modification and post-modification inspections. A structural modification is necessary at lap joints where the thickness of the upper (overlapping) skin at the upper row of fasteners is 0.090 inches or less. Revision 1 of this service bulletin gave instructions to do a structural modification at lap joints where the skin thickness at the upper fastener row is 0.071 inches or less. Subsequent to Revision 1 release of this service bulletin, additional analysis was done, which showed that lap joints where the thickness of the upper (overlapping) skin is 0.090 inches or less should be modified by the time given in Paragraph 1.E., Compliance. At the time of Revision 2 release of this service bulletin, Boeing records show that no operators have contacted Boeing for a structural modification instructions in accordance with Revision 1 of this service bulletin. In addition to the modification instructions, minor clarifications are added to show skin thicknesses in the lap joints. Also, information related to Group 1 airplane has been deleted. Boeing record shows that Group 1, which includes RR201 airplane only, has been permanently withdrawn from service and scrapped. D. Description Inspections are to be done at all lap joints where the thickness of the upper (overlapping) skin at the upper fastener row is 0.090 in. or less. External low frequency eddy current (LFEC) inspections (for corrosion) are to be done at the upper row of fasteners of the lap joint and internal medium frequency eddy current (MFEC) inspections (for cracks) are to be done at the lower row of fasteners of the lap joint. These inspections are to be done by the times given in Paragraph 1.E., Compliance. Skin cracks and corrosion are to be repaired in accordance with Paragraph 3.B., Work Instructions, and Paragraph 1.E., Compliance. At lap joints where the thickness of the upper (overlapping) skin at the upper row of fasteners is 0.090 inches or less, a structural modification is to be accomplished by the time given Paragraph 1.E., Compliance. Revision 1: More work is necessary on airplanes changed as shown in the initial release of this service bulletin. The (more) work is necessary at lap joints where the thickness of the upper (overlapping) skin at the upper fastener row is 0.071 inches or less. At these lap joints, a structural modification is to be accomplished by the time given Paragraph 1.E., Compliance. The instruction for the structural modification will be based on the condition of the lap splices on the individual airplane to be modified. It is likely that analysis and unique instruction/drawings will be needed to define the structural modification for each airplane. Operators will need to make a contract with Boeing to get instruction for the structural modification. Revision 2: More work is necessary on airplanes changed or inspected in accordance with the original issue and Revision 1 of this service bulletin. The (more) work is necessary at lap joints where the thickness of the upper (overlapping) skin at the upper row of fasteners in the lap joint is 0.090 inch or less. At these lap joints, a structural modification is to be accomplished by the time given in Paragraph 1.E., Compliance. The work in this service bulletin is done in the maintenance zone(s) given below. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 18 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 19 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, 274 747-200F Group 2: 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, 747-200B Group 3-14: 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 E. Compliance Boeing recommends that operators do the inspections and modification given in this service bulletin at the times given in the tables below. Federal Aviation Administration (FAA) Airworthiness Directives AD 86-09-07 R1, AD 2004-07-22 R1, AD 2004-13-02, AD 2006-22-09, AD 2010-14-10 , and AD 2010-21-04 are related to this service bulletin. The effective date of AD 2004-13-02 is July 29, 2004. The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. For SRM and non-SRM external doubler repairs accomplished at lap joints and the repair doubler(s) is greater than or equal to 40 inches long, refer to Table 4. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 19 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 20 For SRM and non-SRM external doubler repairs accomplished at lap joints 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). Do the required actions in accordance with Paragraph 3. Accomplishment Instructions. Table 1: Longitudinal Lap Joints - Inspection for Corrosion Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 24 months after the effective date of AD 2004- 13-02. Do an external LFEC in- spections for corrosion at the upper row of fasten- ers in the lap joint in ac- cordance with PART 3. (a) (b) (c) Lap joint has upper (over- lapping) skin thickness 0.090 inches or less at the upper fastener row and has not been modified in accor- dance with Paragraph 3.B., Work Instructions. --Refer to Table 4 and PART 7. New or existing external doubler repairs accom- plished in accordance with 747-100/200/300 SRM 53- 30-03, Figure 13,19, or 25. -Before further flight. Repair lap joint in accor- dance with PART 3. Corrosion found. 72 Months.Within 72 months after the initial in- spection. Repeat the inspection for corrosion in accordance with PART 3. (c) No corrosion found. 72 Months.Within 72 months after the repair. Repeat the inspection for corrosion in accordance with PART 3. (c) Lap joint blend-out corro- sion repair(s). (a) This inspection is not applicable in areas of a lap joint where an external doubler repair has been accomplished in accordance with 747-100/200/300 SRM 53-30-03, Figure 13, 19, or 25. Refer to Table 4 and PART 7 for additional post-repair inspections of these re- pairs. (b) For external doubler repairs other than those given in 747-100/200/300 SRM 53-30-03, Figure 13, 19, or 25, the LFEC inspections given in this service bulletin are applicable/nec- essary. Also, refer to Table 4 and PART 7 for additional post-repair inspections of these repairs. (c) Accomplishment of structural modification in accordance with PART 5, terminates the in- spection requirements, only in the area of the modification, given in this service bulletin. After the modification, do a post-modification inspection given in this service bulletin. Continue to do repeat inspections in the area that was not modified. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 20 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 21 Table 2: Longitudinal Lap Joints - Inspection for Cracks Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before 30,000 total flight-cycles or within 12 months after the effective date of AD 2004- 13-02. Do an internal MFEC in- spection for skin cracks at the lower row of fasten- ers in the lap joint in ac- cordance with PART 4. (a) (b) (c) Lap joint has upper (over- lapping) skin thickness 0.090 inches or less at the upper fastener row and has not been modified in accor- dance with Paragraph 3.B., Work Instructions. --Refer to Table 4 and PART 7. New or existing external doubler repairs accom- plished in accordance with 747-100/200/300 SRM 53- 30-03, Figure 13,19, or 25. -Before further flight. Repair the lap joint in ac- cordance with PART 4. Cracks found. 2,000 flight-cycles.Within 2,000 flight- cycles after the ini- tial inspection. Repeat the inspection for cracks in accordance with PART 4. (c) No cracks found. (a) This inspection is not applicable in areas of a lap joint where an external doubler repair has been accomplished in accordance with 747-100/200/300 SRM 53-30-03, Figure 13, 19, or 25. Refer to Table 4 and PART 7 for additional post-repair inspections of these re- pairs. (b) For external doubler repairs other than those given in 747-100/200/300 SRM 53-30-03, Figure 13, 19, or 25, the MFEC inspections for cracks given in this service bulletin are applicable/necessary. Also, refer to Table 4 and PART 7 for additional post-repair inspec- tions of these repairs. (c) Accomplishment of structural modification in accordance with PART 5, terminates the in- spection requirements, only in the area of the modification, given in this service bulletin. After the modification, do a post-modification inspection given in this service bulletin. Continue to do repeat inspections in the area that was not modified. Table 3: Structural Modification Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 14,000 flight-cycles after the modification or 3,000 flight-cycles after the Revision 2 date of this ser- vice bulletin, whichever occurs later. (e) Accomplish the structural modification in accor- dance with PART 5. (a) Lap joint has upper (over- lapping) skin thickness 0.090 inches or less at the upper fastener row and a modification given in SB 747-53A2267 and SB 747- 53-2307 have been accom- plished. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 21 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 22 Table 3: Structural Modification Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before 26,000 total flight-cycles, or within 1,500 flight- cycles after the Revision 2 date of this service bul- letin, whichever occurs later. Accomplish the structural modification in accor- dance with PART 5. (a) (d) Lap joint has upper (over- lapping) skin thickness 0.090 inches or less at the upper fastener row and a modification given in SB 747-53A2267 and SB 747- 53-2307 have not been ac- complished. (c) (b)(b)Refer to Table 5. (b)Structural modification ac- complished in accordance with Paragraph 3.B., Work Instructions. (a) Modification instructions are given in PART 5. If the modification cannot be done, contact Boeing for modification instructions and do the modification. Any alternative modification must be approved by the FAA. (b) This information is deleted. (c) Based on the airplane delivery dates, all airplanes affected by this service bulletin should have the modification given in service bulletin 747-53A2267. If an airplane does not have the modification given in service bulletin 747-53A2267, contact Boeing for special instruc- tion. (d) For airplanes that have deep countersink areas (as defined in service bulletin 747-53- 2307) that have not been modified in accordance with service bulletin 747-53-2307, modification of the deep countersink areas can be included in the structural modification given in PART 5. Note that the modification compliance times given in service bulletin 747-53-2307 remain applicable for airplanes that have deep countersink areas that have not been modified in accordance with that service bulletin. (e) If the modifications given in SB 747-53A2267 and SB 747-53-2307 were both accomplished and at different times, the compliance time for the structural modification given in PART 5, should be based on the earlier previous modification. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 22 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 23 Table 4: Post-Repair Inspection - External Lap Joint Repairs Greater Than or Equal to 40 Inches Long Repeat Interval (Not to Exceed) Compliance TimeActionCondition 3,000 flight-cycles.Within 15,000 flight cycles after the re- pair was installed or 1,200 flight cy- cles after the Revi- sion 2 date of this service bulletin, whichever occurs later. Do an internal HFEC in- spection of the repairs in accordance with 747 SRM and Paragraph 3.B., Work Instructions, PART 7. (a) (b) (c) New or existing external doubler repairs accom- plished at lap joints in ac- cordance with 747- 100/200/300 SRM 53-30- 03, Figure 13, 19, or 25 and the repair doubler(s) is greater than or equal to 40 inches long and initial (existing) fastener holes common to the repair have been zero-timed in accordance with SRM. 3,000 flight-cycles.Before 15,000 total flight cycles or within 1,200 flight cycles after the Revision 2 date of this service bul- letin. Do an internal HFEC in- spection of the repairs in accordance with 747 SRM and Paragraph 3.B., Work Instructions, PART 7. (a) (b) (c) (d) All other SRM external doubler repairs accom- plished at lap joints and the repair doubler(s) is greater than or equal to 40 inches long. 3,000 flight-cycles.Before 15,000 total flight cycles or within 1,200 flight cycles after the Revision 2 date of this service bul- letin, whichever occurs later. Do an assessment and internal HFEC inspection of the repairs in accor- dance with the 747 RAG and Paragraph 3.B., Work Instructions, PART 7. (a) (b) (c) (d) Non-SRM external doubler repairs accomplished at lap joints and the repair dou- bler(s) is greater than or equal to 40 inches long. -Before further flight. Contact Boeing for repair instructions and do the repair. Crack or corrosion found. (a) Blind rivet repairs also require inspections in accordance with the 747 SRM. (b) Post-repair HFEC inspection is not necessary at tear-straps and frame shear ties provided the length over which the skin is not inspected is 4 inches or less. If the length in which the skin is not inspected is greater than 4 inches, contact Boeing for an alternative inspec- tion instructions and do the inspection. (c) Accomplishment of structural modification in accordance with PART 5 terminates the in- spection requirements, only in the area of the modification, given in this service bulletin. After the modification, do a post-modification inspection given in this service bulletin. Continue to do repeat inspections in the area that was not modified. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 23 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 24 Table 4: Post-Repair Inspection - External Lap Joint Repairs Greater Than or Equal to 40 Inches Long Repeat Interval (Not to Exceed) Compliance TimeActionCondition (d) Until the structural modification in accordance with PART 5 is installed, any inspection or replacement requirements for blind fastener repairs in accordance with applicable 747 SRM must be accomplished. Table 5: Post-Modification Inspection Repeat Interval (Not to Exceed) Compliance TimeActionCondition 3,000 flight cycles.Within 15,000 flight cycles after the modification. Do an internal HFEC in- spection for skin or exist- ing internal doubler cracks in accordance with PART 6. Structural modification ac- complished in accordance with Paragraph 3.B., Work Instructions. and 6,000 flight cycles.Before 20,000 total flight cycles or within 6,000 flight cycles after the modification, whichever occurs later. Do an open-hole HFEC inspection for splice strap cracks in accordance with PART 6. (a) -Before further flight. Contact Boeing for repair instructions and do the repair. Crack found. (a) The post-modification open-hole HFEC inspection given in this service bulletin meets the requirements of Boeing document D6-35022, 747 Supplemental Structural Inspection Document, item number F-26A and F-26C only for the areas modified in accordance with PART 5. 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 24 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 25 The Manager of the FAA Seattle ACO approves the accomplishment of the structural modification (and associated post-modification inspection) procedures specified in Tables 3 and 5 of paragraph 1.E., Compliance of this service bulletin as an AMOC to the requirements of paragraphs A., B., C., and D. of AD 86-09-07 R1. This AMOC only applies to the areas modified as given in this service bulletin. When this service bulletin specifies contacting Boeing for inspection, repair, or modification instructions, the instructions must be approved by the FAA in accordance with paragraph F. of the AD. All provisions of AD 86-09-07 R1 that are not specifically referenced in this paragraph remain fully applicable and must be complied with accordingly. The Manager of the FAA Seattle ACO also approves the accomplishment of the applicable structural modification (and associated post-modification inspection) procedures specified in Tables 3 and 5 of Paragraph 1.E., Compliance of this service bulletin as an AMOC to the corresponding requirements of paragraphs (h) and (i) of AD 2004-07-22 R1 for the areas inspected by Boeing document D6-35022, 747 Supplemental Structural Inspection Document, item numbers F-25G, F-25H, F-25I, and F-25K. This AMOC only applies to the areas modified by this service bulletin. This AMOC does not apply to the compliance times of the initial inspection given in AD 2004-07-22 R1. When this service bulletin specifies contacting Boeing for inspection, repair, or modification instructions, the 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 remain fully applicable and must be complied with accordingly. The Manager of the FAA Seattle ACO also approves the accomplishment of the applicable structural modification (and associated post-modification inspection) procedures specified in Tables 3 and 5 of Paragraph 1.E., Compliance of this service bulletin as an AMOC to the corresponding requirements of paragraphs (h) and (i) of AD 2004-07-22 R1 for the areas inspected by Boeing document D6-35022, 747 Supplemental Structural Inspection Document, item numbers F-26A and F-26C. This AMOC only applies to the areas inspected using open-hole HFEC during the post-modification inspection in accordance with Figure 11 of this service bulletin. This AMOC does not apply to the compliance times of the initial inspection given in AD 2004-07-22 R1. When this service bulletin specifies contacting Boeing for inspection, repair, or modification instructions, the 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 remain fully applicable and must be complied with accordingly. The manager of the FAA Seattle ACO also approves the accomplishment of the applicable inspection, repair, and structural modification (and associated post-modification inspection) procedures specified in Tables 1 through 5 of Paragraph 1.E., Compliance of this service bulletin as an AMOC to the corresponding requirements of paragraphs (a) and (d) of AD 2004-13-02. This AMOC only applies to the areas inspected or modified as given in this service bulletin. When this service bulletin specifies contacting Boeing for inspection, repair, or modification instructions, the instructions must be approved by the FAA in accordance with paragraph (e) of the AD. All provisions of AD 2004-13-02 that are not specifically referenced in this paragraph remain fully applicable and must be complied with accordingly. The Manager of the FAA Seattle ACO also approves the accomplishment of the inspection, repair, and structural modification (and associated post-modification inspection) procedures specified in Tables 3 and 5 of Paragraph 1.E., Compliance of this service bulletin as an AMOC to the corresponding requirements of paragraphs (f) and (h) of AD 2006-22-09. This AMOC only applies to the areas inspected or modified by this service bulletin. This AMOC does not apply to the compliance times of the initial inspection given in AD 2006-22-09. When this service bulletin specifies contacting Boeing for inspection, repair, or modification instructions, the 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 25 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 26 The Manager of the FAA Seattle ACO also approves the accomplishment of the structural modification (and associated post-modification inspection) procedures specified in Tables 3 and 5 of Paragraph 1.E., Compliance of this service bulletin, as an AMOC to the requirements of paragraphs (g), (h) and (i) of AD 2010-14-10. This AMOC only applies to the areas modified as given in this service bulletin. When this service bulletin specifies contacting Boeing for inspection, repair, or modification instructions, the instructions must be approved by the FAA in accordance with paragraph (k) of the AD. All provisions of AD 2010-14-10 that are not specifically referenced in this paragraph remain fully applicable and must be complied with accordingly. The Manager of the FAA Seattle ACO also approves the accomplishment of the structural modification (and associated post-modification inspection) procedures specified in Tables 3 and 5 of Paragraph 1.E., Compliance of this service bulletin, as an AMOC to the requirements of paragraphs (g), (h), (i), (k), (l), (m), (n), (o), and (p) of AD 2010-21-04. This AMOC only applies to the areas modified as given in this service bulletin. When this service bulletin specifies contacting Boeing for inspection and modification instructions, the instructions must be approved by the FAA in accordance with paragraph (q) of the AD. All provisions of AD 2010-21-04 that are not specifically referenced in this paragraph remain fully applicable and must be complied with accordingly. G. Manpower The table below shows an estimate of the man-hours necessary to do this service bulletin 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. External Inspection - Body Section 41 and 42 (a) Elapsed HoursTask HoursNumber of Per- sons Task 4164Open Access 60.52414Inspect 5204Close Access 69.5277.0TOTAL FOR EACH AIRPLANE (a) Additional time will be required to repair any cracks or corrosion damage. External Inspection - Body Section 46 (a) Elapsed HoursTask HoursNumber of Per- sons Task 4164Open Access 73.52944Inspect Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 26 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 27 External Inspection - Body Section 46 (a) Elapsed HoursTask HoursNumber of Per- sons Task 5204Close Access 82.5330TOTAL FOR EACH AIRPLANE (a) Additional time will be required to repair any cracks or damage found. Internal Inspection - Body Section 41 and 42 (a) Elapsed HoursTask HoursNumber of Per- sons Task 1038258Open Access 37.51504Remove Sealant (b) 79.03154Inspect 151.512108Close Access 3712500TOTAL FOR EACH AIRPLANE (a) Additional time will be required to repair any cracks or corrosion damage. (b) Remove Sealant from fastener in bottom row of lap joint before the first internal inspection only. Remove sufficient sealant to inspect forward and aft edge of fastener from inside the airplane. Internal Inspection - Body Section 46 (a) Elapsed HoursTask HoursNumber of Per- sons Task 84.56758Open Access 45.01804Remove Sealant (b) 95.53824Inspect 1249908Close Access 3492227TOTAL FOR EACH AIRPLANE (a) Additional time will be required to repair any cracks or corrosion damage. (b) Remove Sealant from fastener in bottom row of lap joint before the first internal inspection only. Remove sufficient sealant to inspect forward and aft edge of fastener from inside the airplane. Structural Modification Elapsed HoursTask HoursNumber of Per- sons Task 191.501532.008Open Access (a) (b)(b)(b)Modification Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 27 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 28 Structural Modification Elapsed HoursTask HoursNumber of Per- sons Task 279.002232.008Close Access (a) (b)(b)TOTAL FOR EACH AIRPLANE (a) The manpower estimate is based on the total number of lap joints where the modification is applicable (approximately 18250 inches of lap joint to be mod- ified). (b) The instruction for the structural modification will be based on the condition of the lap splices on the individual airplane to be modified. Post-Modification Inspection Elapsed HoursTask HoursNumber of Per- sons Task 191.501532.008Open Access (a) (b)(b)(b)Inspection 279.002232.008Close Access (a) (b)(b)TOTAL FOR EACH AIRPLANE (a) The manpower estimate is based on the total number of lap joints where the modification is applicable (approximately 18250 inches of lap joint to be mod- ified). (b) A manpower estimate cannot be given until the modification is defined. H. Weight and Balance Changes Installation of lap joint repairs and modifications where the upper (overlapping) skin thickness at the upper row of fasteners is less than or equal to 0.090 inches will affect the weight and balance of the airplane. Determination of these changes is necessary, once the configuration of the lap joint repairs and modifications are defined. I. Electrical Load Data Not applicable J. References 1. Existing Data: a. Boeing Service Bulletin 747-53-2253, 747-53-2272, 747-53-2307, 747-53A2267, 747-53A2303, 747-53A2321, 747-53A2563 b. Boeing Service Letter 747-SL-51-048 c. Boeing Service Related Problem (SRP) 747-SRP-53-0135, 747-SRP-53-0436, 747OP-SRP-53-0292 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 28 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 29 d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2004-07-22 R1, 2004-13-02, 2006-22-09, 2010-14-10, 2010-21-04, 86-09-07 R1, 90-15-06, 94-12-09, 94-17-01 e. Standard Overhaul Practices Manual (SOPM) 20-41-05, 20-43-03, 20-44-04, 20-50-19, 20-50-20 f. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00, Procedure 1, 11, or 16, Part 6, 51-00-00, Procedure 4 or 23, Part 6, 51-00-00, Procedure 5 or 12, Part 6, 53-30-14 g. 747 Repair Assessment Guidelines (RAG) h. 747 Supplemental Structural Inspection Document (SSID) F-25G, F-25H, F-25I, F-25K, F-26A, and F-26C i. 747-100/200/300 Aircraft Maintenance Manual (AMM) 12-09-02, 12-09-04, 25-11-01, 25-11-02, 25-11-03, 25-11-05, 25-14-01, 25-21-01, 25-21-02, 25-21-04, 25-21-12, 25-22-01, 25-22-03, 25-22-06, 25-23-01, 25-23-04, 25-23-05, 25-24-00, 25-24-05, 25-24-11, 25-24-12, 25-24-19, 25-25-01, 25-25-03, 25-25-04, 25-26-02, 25-26-03, 25-26-06, 25-27-00, 25-28-01, 25-28-15, 25-28-23, 25-31-04, 25-40-01, 25-40-03, 25-52-01, 25-52-03, 25-52-04, 25-53-15, 25-55-01, 25-55-02, 25-55-03, 25-59-01, 25-68-02, 31-00-00, 34-11-00, 35-00-00, 35-21-00, 51-21-00, 52-11-01, 52-13-01, 52-51-01, 53-21-01, 53-21-02 j. 747-100/200/300 Structural Repair Manual (SRM) 51-10-01, 51-30-02, 51-30-05, 53-30-01, 53-30-03 2. Data Supplied with this Service Bulletin: a. Drawings: ADCNDCN/REVSheetTitleDrawing No --1LAP SPLICE MODIFICATION624U0114 --2 --3 --4 --5 --6 --7 --8 --9 3. Installation Drawings Used in the Preparation of this Service Bulletin: TitleDrawing Number Skin Panel Installation - Sta 741.10 to Sta 1000, Str 12 to Str 1965B04113 Panel Instl - Passenger Window, Sta 741.10 to Sta 1000, S-19 to S-2365B04114 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 29 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 30 TitleDrawing Number Skin Panel Instl - Sta 741.10 to Sta 1000, S-23 to S-3465B04115 Skin Panel Instl - Sta 741.10 to Front Spar Bhd, S-34 to S-3965B04116 Skin Panel Instl - Sta 741.10 to Front Spar Bhd, S-39 to S-4465B04117 Skin Panel Instl - Sta 1480 to 1741.10 S-4L to S-4R65B04127 Skin Panel Instl - Sta 1480 to 1741.10 S-4 to S-1265B04128 Skin Panel Instl - Sta 1480 to 1741.10 S-12 to S-1965B04129 Panel Instl - Pass Window, Sta 1480 to Sta 1741.1, S-19 to S-2365B04130 Skin Panel Instl - Sta 1480 to Sta 1741.1, S-23 to S-3465B04131 Skin Panel Instl - Sta 1480 to Sta 1741.10 S-34 to S-4065B04132 Skin Panel Instl - Sta 1480 - Sta 1741.1 S-40 to S-4665B04133 Panel Instl - Passenger Window, Sta 1741.10 to Sta 1961.10, S-19 to S-2365B04138 Skin Panel Instl - Lwr, S-34 to S-44, Sta 400-52065B07659 The table above lists applicable drawings used to prepare this service bulletin. The drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. The drawings may not be applicable to all airplane configurations or operators. 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 None M. Software Accomplishment Summary Not affected. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 30 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 31 2. MATERIAL INFORMATION A. Material - Price and Availability None. B. Industry Support Information Boeing warranty remedies are not available for the configuration changes, inspection, and/or repair procedures given in this service bulletin. C. Parts Necessary for Each Airplane 1. Kits/Parts: None. 2. Parts and Materials Supplied by the Operator: Refer to Drawing 624U0114, Sheets 1 - 9. 3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. D. Parts Necessary to Change Spares None. E. Special Tooling - Price and Availability None. F. Special Tooling Necessary to do this Service Bulletin No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 31 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 32 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 32 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT BLANK PAGE ### Page 33 3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. NOTE: 1. Unless shown differently, these dimensions and tolerances are used: — Linear dimensions are in inches — Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch. — Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch — Angular tolerance is plus or minus 2 degrees — Hole dimensions for standard solid rivets and fasteners are given in 747 Structural Repair Manual (SRM), Chapter 51 — Torque Values: – Values for structural fasteners are given in 747 Structural Repair Manual, Chapter 51. – Values for airframe maintenance tasks are included in Chapter 20 of 747 Airplane Maintenance Manual (AMM). – Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM). – Values for engine maintenance tasks are included in Chapter 70 of 747 Airplane Maintenance Manual (AMM). – Non-standard torque values for maintenance tasks are included in the applicable installation step. 2. Use the approved fastener and process material substitutions in accordance with SRM Chapter 51. 3. Obey all of the warnings and cautions given in the specified manual sections. 4. As an alternative to the Boeing specified Airplane Maintenance Manuals (AMM's), operator's equivalent procedure can be used. 5. The lap joint repairs given in 747-100/200/300 SRM 53-30-03, Figures 12, 18, and 27 are not to be used to repair damage found with the inspections given in this service bulletin. 6. For lap joints with upper (overlapping) skin thickness of 0.090 inches or less, a blend-out repair can be made to remove damage within the allowable limits (up to 10% of the original thickness) in accordance with 747-100/200/300 SRM 53-30-01, Figure 1. General procedure for various damage removal is given in 747-100/200/300 SRM 51-10-01. If the damage is more the allowable limits given in the SRM (more than 10% of the original thickness), do the following: – Do a repair in accordance with 747-100/200/300 SRM 53-30-03, Figure 13, 19 or 25. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 33 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 34 – For lap joints with upper (overlapping) skin thickness of 0.090 inches or less (but greater than 0.071 inches), the lap joint is to be repaired to the nearest frame where the thickness of the upper skin at the upper row of fasteners is more than 0.090 inches. FIGURE 4 and FIGURE 5 show the location of all the lap joints where the thickness of the upper (overlapping) skin at the upper row of fasteners is 0.090 inches or less. – For lap joints with upper (overlapping) skin thickness of 0.071 inches or less, the lap joint is to be repaired to the nearest frame where the thickness of the upper skin at the upper row of fasteners is more than 0.071 inches. FIGURE 9 shows the location of all the lap joints where the thickness of the upper (overlapping) skin at the upper row fasteners is 0.071 inches or less. 7. This information is deleted. 8. Refer to Paragraph 1.E., Compliance, for thresholds and repeat inspection intervals. 9. For Group 1, FIGURE 4 shows which lap joints are to be inspected. For Group 2-14, FIGURE 5 shows which lap joints are to be inspected. 10. To inspect the upper (overlapping) skin at the upper row of fasteners shown in FIGURE 6 and FIGURE 7, the skin thickness must be known to perform the NDT procedure specified. FIGURE 6 and FIGURE 7 include tables that give the skin thickness of the overlapping skin at the upper fastener row of the lap joint. APPENDIX A and APPENDIX B illustrate the skin thickness for the required inspection. 11. For the inspection of the lower (overlapped) skin as shown in FIGURE 8, the skin thickness is given in the specified NDT procedure. 12. The intent of the internal inspection access data in FIGURE 3 is to show general internal access. The figure may not show all possible AMM procedures for all the airplanes being inspected. Operators should use the necessary AMM procedures for the airplane being inspected. 13. The inspections shown in this service bulletin do not replace the inspections shown in previous service bulletins. 14. Airplanes are to be inspected in accordance with this service bulletin regardless of whether or not the full modification or the optional modification given in service bulletin 747-53A2267 or service bulletin 747-53-2307 has been accomplished. 15. For this service bulletin it is assumed that the appropriate doublers have been installed at stringer 6, from station 340 to 400 as shown in Service Bulletin 747-53-2253 or 747-53-2272. Therefore, work at stringer 6 between BS 340 and 400 is excluded from this service bulletin. 16. Service Bulletin 747-53A2321 shows a modification of the skin panel between station 340 and 520 and between stringer 6 and 14. Service Bulletin 747-53A2321 skin panel modification requires that the doublers at stringer 6 from station 400 to 520 shown in Service Bulletin 747-53A2303 be installed. The inspection in this service bulletin assumes that the external doublers at stringer 6 from station 400 to 520 shown in Service Bulletin 747-53A2303 have been installed, when the skin panel Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 34 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 35 modification in Service Bulletin 747-53A2321 has been done. Contact Boeing if the skin panel modification shown in Service Bulletin 747-53A2321 has been done and Service Bulletin 747-53A2303 stringer 6 doublers from station 400 to 520 have not been installed. See Appendix C for possible configuration difference of lap splices at stringer 6 and 14, in section 41 relating to the modifications shown in Service Bulletins 747-53A2321 and 747-53A2303. 17. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 18. This information is deleted. 19. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. 20. Boeing Service Letter 747-SL-51-048, Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided. 21. The instructions in Paragraph 3.B., Work Instructions and the figures can include operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing Index contain data on versions of the tools or test equipment that you can use. It is permitted to use replaced tools. It is not permitted to use superseded tools. 22. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 23. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. 24. It is recommended that the scribe line inspections (in the area of the lap splices) given in Service Bulletin 747-53A2563, "FUSELAGE - Skin - Inspections of the Fuselage Skin and Butt Joint Splice Straps for Scribe Lines" be done in the affected areas prior to the modification. If the scribe line inspections are not done prior to the modification, it may be necessary to remove the modification doublers to accomplish the scribe line inspection. The modifications given in this service bulletin may not be applicable in locations where there is a scribe line. B. WORK INSTRUCTIONS Group 1: PART 1 - INSPECTION / REPAIR FOR CORROSION - GROUP 1 AIRPLANES 1. This information is deleted. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 35 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 36 Group 1: PART 2 - INSPECTION / REPAIR FOR CRACKS - GROUP 1 AIRPLANES 1. This information is deleted. Group 2-14: PART 3 - INSPECTION / REPAIR FOR CORROSION - GROUP 2 - 14 AIRPLANES 1. Get Access. Refer to FIGURE 2. 2. Do an external LFEC inspection for corrosion in accordance with FIGURE 7. Do this inspection at lap joints where the thickness of the upper (overlapping) skin at the upper fastener row is 0.090 inch or less. NOTE: 1. This inspection is not necessary where a lap joint has been modified in accordance with this service bulletin, Paragraph 1.E., Compliance, Table 3. Accomplishment of structural modification in accordance with Paragraph 3.B., Work Instructions, terminates the inspection requirements, only in the area of the modification, given in this service bulletin. After the modification, do a post-modification inspection by the time given in Paragraph 1.E., Compliance, Table 5. Continue to do repeat inspections in the area that was not modified by the time given in Paragraph 1.E., Compliance, Tables 1 and 4. 2. This inspection is not applicable in areas of a lap joint where an external doubler repair has been accomplished in accordance with 747-100/200/300 SRM 53-30-03, Figure 13, 19, or 25. For other external doubler repairs, LFEC inspections are to be accomplished in accordance with this service bulletin by the time given in Paragraph 1.E., Compliance, Table 1. If the LFEC inspection cannot be accomplished at these doubler repairs, contact Boeing for a special LFEC inspection procedure and do the inspection. In addition, applicable post-repair, assessment and inspections of the repairs are to be done in accordance with SRM, 747 RAG (Document D6-36181, "Repair Assessment Guidelines - Model 747"), or Paragraph 1.E., Compliance, Table 4 and PART 7. 3. FIGURE 5 shows the location of all the lap joints where the thickness of the upper (overlapping) skin at the upper fasteners row is 0.090 inch or less. FIGURE 9 shows the location of all the lap joints where the thickness of the upper (overlapping) skin at the upper fasteners row is 0.071 inch or less. 3. If corrosion is found and the depth of the corrosion is less than 10% of the original thickness of the skin, remove the corrosion with a blend out repair in accordance with 747-100/200/300 SRM 51-10-01 . If the depth of the corrosion is more than 10% of the original thickness of the skin, repair the skin in accordance with 747-100/200/300 SRM 53-30-03, Figure 13, 19, or 25. If the thickness of the upper (overlapping) skin at the upper row of fasteners in the lap splice is 0.090 inches or less but greater than 0.071, extend the SRM repair to the nearest frame where the thickness of the upper (overlapping) skin at the upper row of fasteners in the lap splice is more than 0.090 inches. If the Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 36 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 37 thickness of the upper (overlapping) skin is 0.071 inches or less, extend the SRM repair to the nearest frame where the thickness of the upper (overlapping) skin at the upper row of fasteners in the lap splice is more than 0.071 inches. If the SRM repair is made at the intersection of a lap joint and the wing-to-body fairing, install shims adjacent to protruding head fasteners to give a satisfactory fairing/body interface in accordance with figure 5 of service bulletin 747-53A2267. 4. Close Access. Refer to FIGURE 2. 5. Do repeat inspections for corrosion by the times given in Paragraph 1.E., Compliance, Table 1. 6. Do post-repair inspections of external lap joint repairs in accordance with PART 7. Group 2-14: PART 4 - INSPECTION / REPAIR FOR CRACKS - GROUP 2 - 14 AIRPLANES 1. Get Access. Refer to FIGURE 3. 2. Do an internal MFEC inspection for skin cracks in accordance with FIGURE 8. Do this inspection at lap joints where the thickness of the upper (overlapping) skin at the upper fastener row is 0.090 inch or less. NOTE: 1. This inspection is not necessary where a lap joint has been modified in accordance with this service bulletin, Paragraph 1.E., Compliance, Table 3. Accomplishment of structural modification in accordance with Paragraph 3.B., Work Instructions, terminates the inspection requirements, only in the area of the modification, given in this service bulletin. After the modification, do a post-modification inspection by the time given in Paragraph 1.E., Compliance, Table 5. Continue to do repeat inspections in the area that was not modified by the time given in Paragraph 1.E., Compliance, Tables 2 and 4. 2. This inspection is not applicable in areas of a lap joint where an external doubler repair has been accomplished in accordance with 747-100/200/300 SRM 53-30-03, Figure 13, 19, or 25. For other external doubler repairs, MFEC inspections are to be accomplished in accordance with this service bulletin by the time given in Paragraph 1.E., Compliance, Table 2. If the MFEC inspection cannot be accomplished at these doubler repairs, contact Boeing for a special MFEC inspection procedure and do the inspection. In addition, applicable post-repair, assessment and inspections of the repairs are to be done in accordance with SRM, 747 RAG, or Paragraph 1.E., Compliance, Table 4 and PART 7. 3. FIGURE 5 shows the location of all the lap joints where the thickness of the upper (overlapping) skin at the upper fasteners row is 0.090 inch or less. FIGURE 9 shows the location of all the lap joints where the thickness of the upper (overlapping) skin at the upper fasteners row is 0.071 inch or less. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 37 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 38 3. If any crack is found, repair the skin in accordance with 747-100/200/300 SRM 53-30-03, Figure 13, 19, or 25. If the thickness of the upper (overlapping) skin is 0.090 inches or less but greater than 0.071, extend the SRM repair to the nearest frame where the thickness of the upper (overlapping) skin at the upper row of fasteners in the lap splice is more than 0.090 inches. If the thickness of the upper (overlapping) skin is 0.071 inches or less, extend the SRM repair to the nearest frame where the thickness of the upper (overlapping) skin at the upper row of fasteners in the lap splice is more than 0.071 inches. If the SRM repair is made at the intersection of a lap joint and the wing-to-body fairing, install shims adjacent to protruding head fasteners to give a satisfactory fairing/body interface in accordance with Figure 5 of service bulletin 747-53A2267. 4. Close Access. Refer to FIGURE 3. 5. Do repeat inspections for cracks by the times given in Paragraph 1.E., Compliance, Table 2. 6. Do post-repair inspections of external lap joint repairs in accordance with PART 7. PART 5 - STRUCTURAL MODIFICATION - GROUP 1 - 14 AIRPLANES 1. At lap joints where the thickness of the upper (overlapping) skin at the upper fastener row is 0.090 inch or less, do a structural modification by the time given in Paragraph 1.E., Compliance, Table 3. Do the modification in accordance with the drawings in the following table: NOTE: The modification instructions given in this service bulletin cover typical structural configurations found on the airplane. The modifications given in this service bulletin can be connected to existing lap splice modifications given in other service bulletins. If any corrosion is found or is remaining after the cutout of the lap splice for the modification, contact Boeing for repair instructions and do the repair. 1. 2. If the modification cannot be done, contact Boeing for modification instructions and do the modification. Any alternative modification must be approved by the FAA. 3. Unless specified otherwise in the modification drawings, end modification doubler 3 - 4 inches away from any existing external or internal doubler at door cutout corners. 4. Due to the size of the structural modification, there will be an increase in the aerodynamic drag on the airplane after the modification is accomplished. Determination of the drag will be necessary once the configuration of the structural modification is defined and airplane performance penalties associated with the increased drag will need to be documented in an Appendix to the Airplane Flight Manual. In addition, changes in the airplane weight and balance will need to be determined once the configuration of the structural modification is defined. 5. FIGURE 4 and FIGURE 5 show the location of lap joints where the thickness of the upper (overlapping) skin at the upper fasteners row is 0.090 inch or less. 6. For access data, refer to FIGURE 2 and FIGURE 3. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 38 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 39 Drawing NumberLap Splice Modification Description 624U0114, Sheet 1Typical lap splice without blended skin 624U0114, Sheet 2Typical lap splice with blended skin above or below the lap joint 624U0114, Sheet 3Typical modification doubler splice 624U0114, Sheet 4Typical lap splices adjacent to windows 624U0114, Sheet 5Typical lap splices adjacent to windows, modifi- cation doubler splice 624U0114, Sheet 6Typical lap splice adjacent to fuselage skin cutouts and edges 624U0114, Sheet 7Typical lap splice at Sta. 420 - 520, S-44 624U0114, Sheet 8Typical lap splice at circumferential joints 624U0114, Sheet 9Typical lap splice at locations where an SRM repair is installed 2. Refer to the following general instructions when doing the modification: a. Get access. Refer to FIGURE 2 and FIGURE 3. b. Remove the fasteners in the longitudinal lap splice. c. Tape a stainless steel sheet or other protective material to the fuselage skin common to the modification area to protect fuselage skin. NOTE: To help separate the bonded skins, cold soak the joint with dry ice (solid carbon dioxide) for approximately 30 minutes. d. Carefully separate the skins with nylon or hardwood wedges. Use a sufficient number of wedges to slowly and continuously move apart the skins to prevent buckling. CAUTION: DO NOT GOUGE, SCRATCH OR BUCKLE THE SKIN ADJACENT TO THE MODIFICATION. e. Carefully cut the overlapped and overlapping skin. Use a metal guard between the skins to prevent damage to the overlapped skin. Maintain a minimum internal radius of 0.50 inch and external radius of 0.38 inch of the cutout. f. Make sure the surrounding structure has no corrosion and cracks in accordance with 747-100/200/300 SRM 51-10-01. If there are existing SRM repairs installed, remove the repair and zero-time the holes in accordance 747-100/200/300 SRM 51-10-01 as shown in the modification drawing to make sure there are no cracks. Ensure 2.0D minimum edge margin at existing shear ties, tear straps, etc., unless otherwise specified. If any remaining cracks are found, contact Boeing for repair instructions and do the repair. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 39 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 40 – If corrosion is found and the depth of the corrosion is less than 10% of the original thickness of the skin, remove the corrosion with a blend out repair in accordance with 747-100/200/300 SRM 51-10-01. – If any remaining cracks are found, contact Boeing for repair instructions and do the repair. g. Remove any adhesive remaining on the surfaces of the skin panels that have been moved apart. h. Make the modification parts in accordance with the drawing, 624U0114. Add local fillers/tapered shims to limit maximum pull-up to 0.010 inch. Make fillers and tapered shims from 2024-T3. Refer to SOPM 20-50-20 as an accepted procedure. For all fillers with upper edges that meet against the lower edge of the overlapping skin, a minimum edge of 1.5D is acceptable on existing fasteners at the upper edge of these fillers due to close proximity of the lower edge of the overlapping skin. i. Assemble the modification parts and drill the fastener holes. Make sure that the new fastener holes do not occur at sudden changes in the material thickness on the machined skins. j. Disassemble the modification parts. k. Remove all nicks, scratches, gouges, burrs, and sharp edges from the modification parts and the skin panels. l. Apply chemical conversion coating to the modification parts and the bare aluminum surfaces of the skin panels. Refer to SOPM 20-43-03 as an accepted procedure. m. Apply one coat of BMS 10-79, Type II or Type III primer to the modification parts and the bare aluminum surfaces of the skins panels. Refer to SOPM 20-44-04 as an accepted procedure. n. Install the modification parts with BMS 5-95 sealant between the faying surfaces. – Install all fasteners and their related collars/nuts in accordance with 747-100/200/300 SRM 51-30-02. Replace existing fasteners with the same type and size fasteners. The existing fasteners may be oversized 1/64 to 1/32 inch diameter to meet hole size requirements in accordance with 747-100/200/300 SRM 51-30-05. Install BACC30M( ) collars on all standard and first oversize BACB30NW( )K( )/BACB30NW()K()X and BACB30MY( )K( )/BACB30MY( )K( )X hi-loks. Install BACC30R( ) collars on all second oversize BACB30NW( )K( )Y and BACB30MY( )K( )Y hi-loks. Install BACC30X( ) collars on all standard and first oversize BACB30NX( )K( )/BACB30NX( )K( )X hi-loks and BACC30AC( ) collars on all second oversize BACB30NX( )K( )Y hi-loks. – Install all hi-loks in aluminum structure in transition fit holes and in steel or a stack-up combination of aluminum and steel in a close ream hole in accordance with 747-100/200/300 SRM 51-30-02 and 747-100/200/300 SRM 51-30-05. – Install fasteners wet with BMS 5-95 sealant. Refer to SOPM 20-50-19 as an accepted procedure. o. Remove protective material from the fuselage skin. p. Apply a fillet seal to the edge of the modification parts and the cutout in the skin. Refer to SOPM 20-50-19 as an accepted procedure. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 40 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 41 q. Apply the finish to the modification area. Refer to 747-100/200/300 AMM 51-21-00 as an accepted procedure. Refer to 747-100/200/300 AMM 51-21-00 as an accepted procedure. r. Apply corrosion inhibiting compound, BMS 3-23, to the interior surface of the lap splice area. Refer to SOPM 20-41-05 as an accepted procedure. s. Close access. Refer to FIGURE 2 and FIGURE 3. 3. Put the airplane back to a serviceable condition. PART 6 - POST-MODIFICATION INSPECTION - GROUP 1 - 14 AIRPLANES 1. Do an internal HFEC inspection for skin or existing internal doubler cracks in accordance with FIGURE 10 by the time given in Paragraph 1.E., Compliance, Table 5. 2. Do an open-hole HFEC inspection for splice strap cracks in accordance with FIGURE 11 by the time given in Paragraph 1.E., Compliance, Table 5. 3. If any crack is found, contact Boeing for repair instructions and do the repair. 4. If no crack is found, put the airplane back to a serviceable condition. 5. Do repeat inspections for cracks by the time given in Paragraph 1.E., Compliance, Table 5. PART 7 - POST-REPAIR INSPECTION - EXTERNAL LAP JOINT REPAIRS 1. For external lap joint repairs with repair doubler(s) less than 40 inches long, refer to the applicable SRM or Boeing 747 RAG (Document D6-36181, "Repair Assessment Guidelines - Model 747") for requirements (including inspection method and compliance time). 2. For external lap joint repairs with repair doubler(s) greater than or equal to 40 inches long, do the following by the time given in Paragraph 1.E., Compliance, Table 4: a. At any new or existing external doubler repairs accomplished at lap joints in accordance with any SRM, do an internal HFEC inspection of the repairs in accordance with the 747 SRM. b. At any non-SRM external doubler repairs accomplished at lap joints, do an assessment and internal HFEC inspection of the repairs in accordance with the 747 RAG. c. If any crack or corrosion is found, contact Boeing for repair instructions and do the repair. d. Do repeat inspections by the time given in Paragraph 1.E., Compliance, Table 4. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 41 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 42 (OCR) BOEING SERVICE BULLETIN 747-53A2463 ALERT ALERT THIS FIGURE IS DELETED. 1553909 The data in this figure was moved to Paragraph 1.E., Compliance, with Revision 1. FIGURE 1: DELETED (SHEET 1 OF 1) Она 2 м: 16. 207, 2002 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 747-53A2463 Work - See page 1 for details. 42 of 112 ### Page 43 (OCR) BOEING SERVICE BULLETIN 747-53A2463 ALERT ALERT • SEE → SEE (C SEE ® 191W 191R 191P 191AA 191CC 191EE 191Q 191U 191S 191X 191 FF DOOR 191T DOOR 191V 191DD 191Y 191BB 191Z FWD C FORWARD FAIRING LEFT SIDE VIEW V43258 FIGURE 2: EXTERIOR ACCESS (SHEET 1 OF 3) Original Issue: March 01, 2002 Revision 2 June 16, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2463 Work - See page 1 for details. 43 of 112 ### Page 44 (OCR) BOEING SERVICE BULLETIN 747-53A2463 ALERT ALERT 192W 192R 192P 192AA 192CC 192EE 192U 192Q 192FF 192V DOOR FWD FORWARD FAIRING RIGHT SIDE VIEW 293D 294D 293C 294C 293E 294E 293F 294F 193G 194G 193B 194B 193C 194C 193D 194D 193F 194F FWD A LEFT SIDE SHOWN RIGHT SIDE OPPOSITE V43259 FIGURE 2: EXTERIOR ACCESS (SHEET 2 OF 3) Original Issue: March 07, 2002 Revision 2 June 16, 2014 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright @ Unpublished 747-53A2463 Work - See page 1 for details. 44 of 112 ### Page 45 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. Lower Body NOTESQTYREFERENCESNAMETASKSTEP --747-100/200/300 AMM 12-09-02 Wing-to-Body FairingRemove / Keep 1 747-100/200/300 AMM 12-09-04 FIGURE 2: EXTERIOR ACCESS (SHEET 3 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2 June 16, 2014 45 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 46 (OCR) BOEING SERVICE BULLETIN 747-53A2463 ALERT ALERT SEE DO SEE DO SEE F 3) PRESSURIZED TAIL AREA 2) BULK CARGO AREA 1) CONTAINERIZED CARGO BAY PRESSURIZED (3 NOSE AREA CONTAINERIZED 1 CARGO BAY AFT PRESSURE BULKHEAD AFT CARGO DOOR AFT WING-TO-BODY FAIRING FORWARD WING-TO-BODY FAIRING FORWARD CARGO DOOR V43306 FIGURE 3: INTERNAL ACCESS (SHEET 1 OF 11) Original Issue: March 07, 2002 Revision 2 June 16, 2014 Export Controlled ECCN: 9E991 - BOEING 747-53A2463 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 112 ### Page 47 (OCR) BOEING SERVICE BULLETIN 747-53A2463 ALERT ALERT OVERHEAD PANELS P5, PT, P12, (AND P126) STA 332 STA FLIGHT 394 ENGINEER'S STATION STA LAVATORY 260 AREA PILOTS' STATION OBSERVERS' UPPER DECK STATION STA STOWAGE 340 AREA UP FWD< STA 520 TYPICAL FLIGHT DECK INSTALLATION ALL AFFECTED CONFIGURATIONS SIMILAR V43318 FIGURE 3: INTERNAL ACCESS (SHEET 2 OF 11) Original Issue: March 07, 2002 Revision 2 June 16, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2463 Work - See page 1 for details. 47 of 112 ### Page 48 FIGURE 3: INTERNAL ACCESS (SHEET 3 OF 11) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2 June 16, 2014 48 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 49 (OCR) BOEING SERVICE BULLETIN 747-53A2463 ALERT ALERT STA STA 300 TUP 330 → FWD V43320 FIGURE 3: INTERNAL ACCESS (SHEET 4 OF 11) Original Issue: March 07, 2002 Revision 2 June 16, 2014 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 747-53A2463 Work - See page 1 for details. 49 of 112 ### Page 50 (OCR) BOEING SERVICE BULLETIN 747-53A2463 ALERT ALERT FLIGHT COMPARTMENT AFT PARTITION FLIGHT COMPARTMENT DOOR E11 RACK ENCLOSURE PARTITION RIGHT CREW DOOR LEFT CREW DOOR (IF INSTALLED) FLOOR MOUNTED ESCAPE SLIDE FORWARD LEFT (TYPICAL) PARTITION TYPICAL UPPER DECK CONFIGURATION WITH LEFT AND RIGHT CREW DOOR (OTHER UPPER DECK CONFIGURATIONS SIMILAR) CENTER LIGHTED REVEAL UPPER CLOSURE PANEL LOWER CLOSURE PANEL STOWAGE BIN PSU PANEL WINDOW REVEAL V43321 FIGURE 3: INTERNAL ACCESS (SHEET 5 OF 11) Original Issue: March 07, 2002 Revision 2 June 16, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2463 Work - See page 1 for details. 50 of 112 ### Page 51 (OCR) BOEING SERVICE BULLETIN 747-53A2463 ALERT ALERT ATTENDANT SERVICE PANEL PASSENGER SERVICE UNIT CEILING PANEL OVERHEAD STOWAGE BIN ATTENDANT PANEL MAIN ENTRY DOOR ONE SIDEWALL LINING PANEL TYPICAL MAIN DECK CONFIGURATION (OTHER MAIN DECK CONFIGURATIONS SIMILAR) V43322 FIGURE 3: INTERNAL ACCESS (SHEET 6 OF 11) Original Issue: March 07, 2002 Revision 2 June 16, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2463 Work - See page 1 for details. 51 of 112 ### Page 52 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The intent of this internal inspection access figure is to shows a general internal access. The figure may not show all possible AMM procedures for all the airplanes being inspected. Operators should use the necessary AMM procedures for the airplane being inspected. Lower Body NOTESQTYREFERENCESNAMETASKSTEP Containerized Cargo Bay FIGURE 3: INTERNAL ACCESS (SHEET 7 OF 11) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2 June 16, 2014 52 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 53 Lower Body NOTESQTYREFERENCESNAMETASKSTEP not shown-747-100/200/300 AMM 25-52-01 Sidewall liningRemove / Keep 1 not shown-747-100/200/300 AMM 25-52-03 Performed Lining Panels Remove / Keep not shown-747-100/200/300 AMM 25-53-15 Ball Transfer PanelRemove / Keep not shown-747-100/200/300 AMM 25-52-04 InsulationRemove / Keep Bulk Cargo Area not shown-747-100/200/300 AMM 25-55-01 Cargo Nets and Di- viders Remove / Keep 2 not shown-747-100/200/300 AMM 25-55-02 Sidewall Linings and Floors Remove / Keep not shown-747-100/200/300 AMM 25-55-03 InsulationRemove / Keep Pressurized Nose and Tail Area not shown-747-100/200/300 AMM 25-21-04 InsulationRemove / Keep 3 Upper Body Flight Deck NOTESQTYREFERENCESNAMETASKSTEP --747-100/200/300 AMM 25-11-02 Flight Engineer SeatRemove / Keep 4 --747-100/200/300 AMM 25-11-03 Observer SeatRemove / Keep --747-100/200/300 AMM 25-11-05 Crew SeatRemove / Keep --747-100/200/300 AMM 25-11-01 Pilot SeatRemove / Keep 5 (a)-747-100/200/300 AMM 31-00-00 P5, P7, P12, and (P126 if installed) Remove / Keep 6 --747-100/200/300 AMM 25-14-01 Sidewall liningRemove / Keep 7 not shown-747-100/200/300 AMM 34-11-00 Pitot Static TubingRemove / Keep 8 FIGURE 3: INTERNAL ACCESS (SHEET 8 OF 11) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2 June 16, 2014 53 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 54 Upper Body Flight Deck NOTESQTYREFERENCESNAMETASKSTEP not shown-747-100/200/300 AMM 35-00-00 Oxygen TubingRemove / Keep 9 --747-100/200/300 AMM 53-21-01 Crew Escape HatchRemove / Keep 10 (a) Remove and keep disconnect panels behind P5, circuit breaker. Upper Deck NOTESQTYREFERENCESNAMETASKSTEP --(b)Equipment and Fur- nishing Remove / Keep 11 Maintenance Manual Subject (AMM) Equipment Name 747-100/200/300 AMM 25-21-02Window Reveal 747-100/200/300 AMM 25-21-04Sidewall and Ceiling Insulation 747-100/200/300 AMM 25-22-03Ceiling Panels 747-100/200/300 AMM 25-23-01Passenger Service Units 747-100/200/300 AMM 25-24-00Forward Closets 747-100/200/300 AMM 25-24-11Forward Right Partition 747-100/200/300 AMM 25-24-12Forward Left Partition 747-100/200/300 AMM 25-24-19Crew Rest Area 747-100/200/300 AMM 25-25-01Passenger Seats 747-100/200/300 AMM 25-25-04Wall Mounted Attendant Seat 747-100/200/300 AMM 25-26-02Stairway Forward Right Partition 747-100/200/300 AMM 25-26-03Stair Aft Right Partition 747-100/200/300 AMM 25-26-06Stairway Forward Left Partition 747-100/200/300 AMM 25-28-15Sidewall Stowage Units 747-100/200/300 AMM 25-28-23Overhead Stowage Bins 747-100/200/300 AMM 25-40-03Lavatories 747-100/200/300 AMM 25-68-02Floor Mounted Escape Slide 747-100/200/300 AMM 52-13-01Crew Entry Door 747-100/200/300 AMM 52-51-01Flight Compartment Door FIGURE 3: INTERNAL ACCESS (SHEET 9 OF 11) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2 June 16, 2014 54 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 55 Upper Deck NOTESQTYREFERENCESNAMETASKSTEP (b) Remove and keep equipment and furnishings as required to gain access to STA 420 through STA 520 lap joints. Refer to the maintenance manual AMM subjects. Main Deck NOTESQTYREFERENCESNAMETASKSTEP --(c)Equipment and Fur- nishing Remove / Keep 12 Maintenance Manual Subject (AMM) Equipment Name 747-100/200/300 AMM 25-21-01Sidewall Lining Panels 747-100/200/300 AMM 25-21-02 747-100/200/300 AMM 25-21-04Sidewall and Ceiling Insulation 747-100/200/300 AMM 25-21-12Sidewall Dado Panels 747-100/200/300 AMM 25-22-01Ceiling Panels 747-100/200/300 AMM 25-22-03 747-100/200/300 AMM 25-22-06Entryway Ceiling Panels 747-100/200/300 AMM 25-23-01Passenger Service Units 747-100/200/300 AMM 25-23-04Attendant Service Unit 747-100/200/300 AMM 25-24-00Forward Closets 747-100/200/300 AMM 25-24-05Partitions 747-100/200/300 AMM 25-25-01Passenger Seats 747-100/200/300 AMM 25-25-03Track Mounted Attendant Seats 747-100/200/300 AMM 25-25-04Wall Mounted Attendant Seats 747-100/200/300 AMM 25-27-00Floor Covering 747-100/200/300 AMM 25-28-01Insulation Blankets 747-100/200/300 AMM 25-28-23Overhead Stowage Bins 747-100/200/300 AMM 25-31-04Sidewall Galleys 747-100/200/300 AMM 25-40-01Sidewall Lavatories 747-100/200/300 AMM 25-59-01Cargo Lining Panels 747-100/200/300 AMM 25-23-05Attendant Panel 747-100/200/300 AMM 35-21-00Oxygen Tubing FIGURE 3: INTERNAL ACCESS (SHEET 10 OF 11) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2 June 16, 2014 55 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 56 Main Deck NOTESQTYREFERENCESNAMETASKSTEP 747-100/200/300 AMM 52-11-01Main Entry Door No. 1 747-100/200/300 AMM 53-21-02Floor Panels (c) Remove and keep equipment and furnishings as required to gain access to Station 140 through Station 2360 lap joints. Refer to the maintenance manual AMM subjects. NOTESQTYREFERENCESNAMETASKSTEP (d)SealantRemove13 after inspectionCorrosion Inhibiting Compound Install14 (d) Remove sealant sufficient to inspect forward and aft of the fastener. FIGURE 3: INTERNAL ACCESS (SHEET 11 OF 11) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 07, 2002 747-53A2463Revision 2 June 16, 2014 56 of 112 BOEING SERVICE BULLETIN 747-53A2463 ALERTALERT ### Page 57 (OCR) BOEING SERVICE BULLETIN 747-53A2463 ALERT ALERT This Figure applies only to: Group 1. THIS FIGURE IS DELETED. D38438 FIGURE 4: LOCATION OF LAP JOINTS 0.090 INCHES OR LESS, GROUP 1 (SHEET 1 OF 1) Original Issue: March 07, 2002 Revision 2 June 16, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2463 Work - See page 1 for details. • 57 of 112 ### Page 58 (OCR) BOEING SERVICE BULLETIN 747-53A2463 ALERT ALERT This Figure applies only to: Group 2-14. SEE C SEE A • RS STA STA STA STA STA STA 134 520 1000 1480 1961.1 2360 SEE SEE SEE (A STA STA STA STA STA STA 134 520 1000 0871 1961.1 2360 SEE SE ORS (MAIN DECK SIDE CARGO DOOR MODIFICATION) V43276 FIGURE 5: LOCATION OF LAP JOINTS 0.090 INCHES OR LESS, GROUPS 2 - 14 (SHEET 1 OF 7) Original Issue: March 07, 2002 Revision 2 June 16, 2014 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 747-53A2463 Work - See page 1 for details. 58 of 112 ### Page 59 (OCR) BOEING SERVICE BULLETIN 747-53A2463 ALERT ALERT STA 1000 DEEP COUNTERSINK STA 941 STAS-O FASTENER AREA 941 STA _ S-6 STA 520 767 _S-12 STA STA 400 . S-19 STA 340 287 _S-23 - S-14 STA 134.4 LEFT SIDE SHOWN RIGHT SIDE OPPOSITE STA 000000000 774 AREA OF INSPECTION 0000 400 STA (GROUP 3,10) STA 928 (GROUP 2, 4,3,0,1,0,, S-45 11,12,13,14 STA 929 S-39 STA 1000 • CANTED BULKHEAD STA 5-34 440 ' S-44 STA 965 STA V43335 918 FIGURE 5: LOCATION OF LAP JOINTS 0.090 INCHES OR LESS, GROUPS 2 - 14 (SHEET 2 OF 7) Original Issue: March 07, 2002 Revision 2 June 16, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2463 Work - See page 1 for details. 59 of 112 ### Page 60 (OCR) BOEING SERVICE BULLETIN 747-53A2463 ALERT ALERT STA 2360 STA S-4 STA 1961 1741 _ S-12 STA 1627 _ S-19 _S-23 STA 1480 STA 1626 LEFT SIDE SHOWN AREA OF INSPECTION (GROUP 2, (GROUP 3,4, 8,9,14) 5,6,7,10,11, STA 12,13) 1586 STA STA 1488 1540 STA 1741 STA 1726 (GROUP 3,5, S-40 6,10,12,13) STA 1961 STA 2360 STA 1480 STA 1689 7,8,9,11,14) (GROUP 2,4, S-46 S-34 V43338 FIGURE 5: LOCATION OF LAP JOINTS 0.090 INCHES OR LESS, GROUPS 2 - 14 (SHEET 3 OF 7) Original Issue: March 07, 2002 Revision 2 June 16, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2463 Work - See page 1 for details. 60 of 112 The text continues at https://openairdocs.org/service-documents/boeing/747-53a2463/file/eede3e7c5f31.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). 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