# Boeing Alert Service Bulletin 747-53A2499: U.S. DOT/FAA - Boeing Service Bulletin - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2010-0232; AD 2010-26-10 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 747-53A2499](https://openairdocs.org/service-documents/boeing/747-53a2499.md) - Title as filed: U.S. DOT/FAA - Boeing Service Bulletin - Pages: 297 - PDF: https://openairdocs.org/files/sha256/d0/9c/d09cbe49e9922e00f1e43ec692bc5a62abe2f6a8fdcb0f975e20b8b09ea576bc - Page: https://openairdocs.org/service-documents/boeing/747-53a2499/file/d09cbe49e992 ## 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 Number: 747-53A2499 Original Issue: August 11, 2005 Revision 2: August 12, 2010 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Section 41, 42, and 46 Body Skin Lap Joint Inspections and Modifications Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). 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all export laws. 9E991ECCN: BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2005 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. 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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 1 of 297 5.0 ### Page 2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 2 of 297 BOEING SERVICE BULLETIN 747-53A2499 BLANK PAGE ### Page 3 Table of Contents Revision Transmittal Sheet ............................................ 5 Summary ...................................................... 7 1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1 1. Airplanes ............................................ 1 1 2. Spares Affected ........................................ 1 8 B. Concurrent Requirements ...................................... 1 8 C. Reason ................................................ 1 8 D. Description .............................................. 1 9 E. Compliance .............................................. 2 3 F. Approval ............................................... 2 6 G. Manpower .............................................. 2 9 H. Weight and Balance Changes .................................... 3 0 I. Electrical Load Data ......................................... 3 0 J. References .............................................. 3 1 1. Existing Data: ......................................... 3 1 2. Data supplied with this Service Bulletin: ........................... 3 1 3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 4 K. Publications Affected ........................................ 3 4 L. Interchangeability and Intermixability of Parts ........................... 3 4 2. MATERIAL INFORMATION ........................................ 3 5 A. Material - Price and Availability ................................... 3 5 B. Industry Support Information .................................... 3 6 C. Parts Necessary For Each Airplane ................................. 3 6 1. Kits/Parts: ........................................... 3 6 2. Parts and Materials Supplied by the Operator: ........................ 5 2 3. Parts Modified and Reidentified: ............................... 5 2 4. Parts Removed and Not Replaced: .............................. 5 2 D. Parts Necessary to Change Spares ................................. 5 2 E. Special Tooling - Price and Availability ............................... 5 2 F. Special Tooling Necessary to do this Service Bulletin ....................... 5 2 3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 3 A. GENERAL INFORMATION ..................................... 5 3 B. WORK INSTRUCTIONS ....................................... 5 6 FIGURE 1: LOGIC DIAGRAM ....................................... 6 1 FIGURE 2: LAP JOINT INSPECTION [Group 1, 16] ........................... 6 2 FIGURE 3: LAP JOINT INSPECTION [Group 2] .............................. 7 3 FIGURE 4: LAP JOINT INSPECTION [Group 3] .............................. 8 9 FIGURE 5: LAP JOINT INSPECTION [Group 4] ............................. 1 0 3 FIGURE 6: LAP JOINT INSPECTION [Group 5] ............................. 1 1 9 FIGURE 7: LAP JOINT INSPECTION [Group 6] ............................. 1 3 3 FIGURE 8: LAP JOINT INSPECTION [Group 7] ............................. 1 4 9 FIGURE 9: LAP JOINT INSPECTION [Group 8] ............................. 1 6 5 FIGURE 10: LAP JOINT INSPECTION [Group 9] ............................. 1 7 9 FIGURE 11: LAP JOINT INSPECTION [Group 10] ............................ 1 9 1 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 3 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 4 FIGURE 12: LAP JOINT INSPECTION [Group 11] ............................ 2 0 5 FIGURE 13: LAP JOINT INSPECTION [Group 12] ............................ 2 1 9 FIGURE 14: LAP JOINT INSPECTION [Group 13] ............................ 2 3 3 FIGURE 15: LAP JOINT INSPECTION [Group 14] ............................ 2 4 8 FIGURE 16: SECTION 41, STRINGER 6 - LAP JOINT MODIFICATION [Group 1-15] ......... 2 6 1 FIGURE 17: SECTION 41, STRINGER 23 - LAP JOINT MODIFICATION [Group 1, 14-15] ...... 2 6 5 FIGURE 18: SECTION 41, STRINGER 23 - LAP JOINT MODIFICATION [Group 2-12] ........ 2 6 7 FIGURE 19: SECTION 41, STRINGER 23 - LAP JOINT MODIFICATION [Group 13] ......... 2 6 9 FIGURE 20: SECTION 41, STRINGER 44 - LAP JOINT MODIFICATION [Group 1-15] ........ 2 7 1 FIGURE 21: SECTION 42, STRINGER 44 - LAP JOINT MODIFICATION [Group 1, 13-15] ...... 2 7 4 FIGURE 22: SECTION 42, STRINGER 44 - LAP JOINT MODIFICATION [Group 2-12] ........ 2 7 6 FIGURE 23: LAP JOINT INSPECTION [Group 15] ............................ 2 7 8 Appendix A: REDUCED EDGE MARGIN PROCEDURES ........................ 2 9 0 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 4 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 5 Commercial Airplanes 747 Service Bulletin Revision Transmittal SheetNumber: 747-53A2499Original Issue: August 11, 2005 Revision 2: August 12, 2010 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Section 41, 42, and 46 Body Skin Lap Joint Inspections and Modifications This Revision includes all pages of the service bulletin. COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2006-05-09 is related to this service bulletin. No more work is necessary on airplanes changed as shown in the original issue or Revision 1 of this service bulletin. No airplanes have been added to the service bulletin effectivity as a result of this revision; however, some airplanes from Group 1 were added to Group 15 and Group 16. REASON FOR REVISION This revision is sent to include the following changes: — In Summary: Updated related Airworthiness Directives. Added reference to paragraph 2.A., Material - Price and Availability due to addition of Boeing supplied kits. — In paragraph 1.A., Effectivity: Added new Group 15 for 747-400 passenger airplanes (without a main deck side cargo door) that have been modified by Boeing to Boeing Converted Freighter (BCF). Also, added new Group 16 for airplanes modified to Large Cargo Freighter. Group 15 and 16 airplanes were previously in Groups 1. — In paragraph 1.C., Reason: Added reason for sending Revision 2. — In paragraph 1.D., Description: Added "No more work" statement and recommendation to accomplish Service Bulletin 747-53A2563 prior to accomplishing modification as given in this service bulletin. A note was clarified and updated table of other lap joint service bulletins. Added Affected Maintenance Zones tables. — In paragraph 1.E., Compliance: Updated related Airworthiness Directives. Updated paragraph callouts, updated Supplemental Structural Inspection (SSI) callout, and added/updated footnotes in Table 1. In Table 2, revised the grace period for modification to specify after the Revision 1 date of this service bulletin instead of original release date and added footnotes. Also, added post-modification requirements and requirements for airplanes that have exceeded 35,000 total flight cycles. Also, added Tables 3 and 4 for Group 16 airplanes. — In paragraph 1.F., Approval: Updated existing Alternative Method of Compliance (AMOC) statements for Airworthiness Directives (AD) 94-15-17, 2004-07-22 R1, 2006-05-09, and 2008-16-14. Added AMOC statements for several additional ADs that could be affected if the inspections and/or modifications are done as given in this service bulletin. — In paragraph 1.G., Manpower: Revised Group number due to added groups. Also, revised estimates for Section 42 modification. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 5 of 297 ### Page 6 — In paragraph 1.J., References: Updated existing data references and updated/added drawing data supplied with the service bulletin. — In paragraph 1.K., Publications Affected: Added information for damage tolerance based inspections. — In paragraph 2.A., Material Price and Availability: Added price and availability information for stringer 6 modification kits. — In paragraph 2.C., Parts Necessary for Each Airplane: Added parts kit lists for stringer 6 modification kits. — In paragraph 3.A., General Information: Updated/Added general information notes. — In paragraph 3.B, Work Instructions: Added reference to new Figure 23 for Group 15 airplanes, and added instructions and applicability for Group 16. Updated SRM references for repair. Added recommendation to accomplish Service Bulletin 747-53A2563 prior to accomplishing modification as given in this service bulletin. Updated airplane group applicability in the instructions. — In Figure 2, added applicability for Group 16. — In Figures 3, 5, 7-9, 11-15, and 23: Clarified note (a). — In Figure 15: Corrected note identifier. Note (e) was incorrectly sequenced as note (f). — In Figure 16: Revised illustration and step table to reflect new drawings for stringer 6 modification. — In Figures 17 through 22, updated airplane group applicability. — Figure 23: This new figure has been added to specify unique inspection requirements for airplanes that have been modified to BCF. — Appendix A: This new appendix has been added to specify procedures when reduced edge margin exists at fastener locations common to shear ties. The data given in Information Notice 747-53A2499 IN01 is included in this revision. Some of the data given in Information Notice 747-53A2499 IN02 is included in this revision. The data from IN02 that is not included has either been superseded, or is no longer applicable. Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes. 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 August 11, 2005Original Issue: October 30, 2008Revision 1: August 12, 2010Revision 2: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 6 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 7 Commercial Airplanes 747 Service Bulletin SummaryNumber: 747-53A2499Original Issue: August 11, 2005 Revision 2: August 12, 2010 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Section 41, 42, and 46 Body Skin Lap Joint Inspections and Modifications CONCURRENT REQUIREMENTS None. BACKGROUND This service bulletin gives data for the inspection and repair of certain fuselage skin longitudinal lap joints. These inspections and repairs are necessary for safe operation of airplanes past the design goal for economic usage. Boeing has completed extended pressure fatigue tests on a 747-100SR and a 747-400 fuselage test article. Analysis of these test results have identified areas of the fuselage lap joints where fatigue cracks can occur. Boeing has also used updated analysis methods on the 747 skin longitudinal lap joints. Inspection and repair of these areas is necessary for safe operation of airplanes past the design goal for economic usage. The inspections in this service bulletin will make sure that fatigue cracks in the overlapping skin at the upper row of fasteners in certain fuselage lap joints are found and repaired before they become critical. Skin cracks not detected prior to reaching critical crack length may result in the inability to withstand current regulatory fail-safe loads, in-flight depressurization of the airplane or loss of structural integrity. Revision 1: Subsequent to the release of the original issue of this service bulletin, a review of all lap joints was accomplished for the affected airplanes. It was determined that all lap joints with an upper skin thickness of 0.090 inches or less should be inspected at the times given in Paragraph 1.E., Compliance. In addition, a review of all service bulletins which recommend repeat inspections was accomplished to determine if the inspections were appropriate on aging airplanes. This review indicated that certain lap joints where the skin thickness is less than or equal to 0.071 inches should be modified at the times given in Paragraph 1.E., Compliance. Boeing Service Related Problem (SRP) 747-SRP-53-0211 and 747OP-SRP-53-0279 are related to this service bulletin. ACTION (PRR 85901-91RS) Lap joint inspection BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 7 of 297 ### Page 8 Do external High Frequency Eddy Current (HFEC) inspections of certain lap joints for cracks. These lap joints are in Section 41, Section 42, and Section 46. In addition, do internal and external Low Frequency Eddy Current (LFEC) inspections at certain doublers common to these lap joints. If no cracks are found, do the inspection again at the time shown in this service bulletin. If cracks are found, remove the fastener in the cracked hole and sufficient adjacent fasteners and do open hole HFEC inspections to find the crack length. Repair before any more flights. Repair as shown in the structural repair manual or ask Boeing for repair data. As part of the repair, do open-hole HFEC inspections of the skin at all existing fastener locations common to the repair. Lap joint modification Do eddy current inspections of the lap joints in sections 41 and 42 that will be modified. If cracks are found, repair the cracks and contact Boeing for lap joint modification instructions. For areas where no cracks are found, do the lap joint modifications. EFFECTIVITY 747-200C, 747-200F, 747-400, 747-400D, and 747-400F airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. COMPLIANCE Refer to Service Bulletin Paragraph 1.E., for Compliance information. Federal Aviation Administration (FAA) Airworthiness Directives 90-06-06, 90-21-17, 90-23-14, 94-15-17, 2004-07-22 R1, 2005-08-01, 2006-05-09, 2006-20-02, 2006-22-09, 2006-24-02, 2006-24-05, 2007-15-07, 2008-16-14, and 2009-04-16 are related to this service bulletin. The Federal Aviation Administration (FAA) will possibly release another 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, repair, or modification procedures given in this service bulletin. MANPOWER Refer to Paragraph 1.G., Manpower. MATERIAL INFORMATION Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 8 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 9 (OCR) BOEING SERVICE BULLETIN 747-53A2499 an alaus DO EXTERNAL SURFACE HFEC INSPECTIONS OF THE SKIN AROUND THE UPPER ROW OF FASTENERS IN CERTAIN LAP JOINTS IN SECTION 41, 42 AND 46. IF CRACKS ARE FOUND, REPAIR BEFORE ANY MORE FLIGHTS AS SHOWN IN THE SRM. DO STRUCTURAL MODIFICATIONS ON SPECIFIED LAP JOINTS AT STRINGERS 6 AND 23 IN SECTION 41 AND AT STRINGER 44 IN W49253 SECTIONS 41 AND 42. Original Issue: August 11, 2005 Revision 2: August 12, 2010 747-53A2499 Copyright © Unpublished Work - See page 1 for details. BOEING PROPRIETARY - 9 of 297 ### Page 10 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 10 of 297 BOEING SERVICE BULLETIN 747-53A2499 BLANK PAGE ### Page 11 Commercial Airplanes 747 Service Bulletin Number: 747-53A2499 Original Issue: August 11, 2005 Revision 2: August 12, 2010 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Section 41, 42, and 46 Body Skin Lap Joint Inspections and Modifications 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. Refer to PRR85901-44RS and PRR85901-91RS for data about this change. DESCRIPTIONCONFIGURATIONGROUP 747-400 airplanes without a main deck side cargo door, except airplanes modified by Boeing to Boeing Converted Freighter (BCF) configuration as of 2/19/2010. -1 All 747-200F airplanes, line numbers 201 through 347, with a main deck side cargo door. -2 747-200F airplanes, line numbers 201 through 347, without a main deck side cargo door. -3 747-200F airplanes, line numbers 348 through 628, with a main deck side cargo door. -4 All 747-200F airplanes, line numbers 348 through 628, without a main deck side cargo door. -5 747-200F airplanes, line numbers 629 through 685.-6 747-200F airplanes, line numbers 686 and on.-7 747-200C airplanes, line numbers 201 through 327, with a main deck side cargo door. -8 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 11 of 297 ### Page 12 DESCRIPTIONCONFIGURATIONGROUP 747-200C airplanes, line numbers 201 through 327, without a main deck side cargo door. -9 747-200C airplanes, line numbers 328 through 628.-10 747-200C airplanes, line numbers 629 through 685.-11 747-200C airplanes, line numbers 686 and on.-12 All 747-400F airplanes.-13 All 747-400 airplanes with a main deck side cargo door, except 747-400F airplanes. This group includes 747-400 airplanes with a main deck side cargo door that have been modified by Boeing to BCF configuration. -14 747-400 passenger airplanes (previously in Group 1) that have been modified by Boeing to BCF configuration as of 2/19/2010. -15 747-400 airplanes that have been modified to Large Cargo Freighter.-16 Airplane Models: 747-200C, 747-200F, 747-400, 747-400D, 747-400F GroupVariable Number 1RF001 - RF006 9RJ131 - RJ133 9RJ151 - RJ152 8RJ301 - RJ302 10RJ303 11RJ321 12RJ322 10RJ331 - RJ333 13RL401 - RL403 13RL411 - RL436 13RL451 - RL456 13RL461 - RL462 13RL471 - RL481 13RL491 - RL492 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 12 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 13 GroupVariable Number 13RL501 - RL502 13RL511 - RL516 13RL521 - RL522 13RL531 - RL534 13RL551 13RL561 - RL568 13RL571 - RL572 13RL576 - RL577 13RL579 13RL581 - RL586 13RL651 - RL655 13RL671 - RL675 13RL681 - RL684 13RL751 - RL752 1RM001 - RM007 1RM010 - RM013 1RM021 - RM024 1RM026 - RM030 1RM036 - RM045 1RM051 - RM053 1RM071 1RM081 - RM084 1RM091 1RM096 - RM097 1RM116 - RM117 1RM126 - RM127 15RM128 1RM129 - RM132 1RM136 - RM147 1RM156 - RM158 1RM166 - RM177 1RM191 - RM192 1RM231 - RM233 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 13 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 14 GroupVariable Number 1RM241 - RM246 1RM261 - RM264 1RM316 - RM318 1RM331 - RM333 1RM341 1RM351 - RM355 1RM366 - RM367 1RM401 - RM403 1RM426 1RM431 1RM441 - RM443 1RM445 14RM801 - RM803 14RM811 - RM813 13RM851 - RM859 13RM861 - RM863 13RM871 - RM899 13RM901 - RM906 13RM911 3RR001 - RR004 4RR005 4RR021 - RR023 7RR024 - RR025 4RR031 2RR202 4RR203 - RR204 6RR205 7RR206 2RR221 - RR222 4RR223 - RR226 2RR261 5RR262 4RR263 - RR265 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 14 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 15 GroupVariable Number 6RR266 - RR267 2RR301 - RR303 4RR304 - RR306 7RR307 - RR310 2RR331 4RR332 4RR336 2RR341 - RR344 4RR345 4RR361 - RR362 4RR421 - RR422 6RR431 - RR432 7RR441 - RR442 7RR451 4RR501 - RR504 4RR521 7RR522 7RR526 4RR531 4RR551 - RR553 7RR554 - RR556 4RR561 7RR566 13RR701 13RR721 - RR724 13RR746 - RR748 13RR851 - RR856 13RR861 - RR862 13RR951 - RR952 14RT001 - RT014 14RT021 - RT022 14RT031 - RT035 14RT041 - RT047 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 15 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 16 GroupVariable Number 14RT061 14RT071 - RT075 14RT101 - RT103 14RT121 14RT131 - RT137 14RT151 - RT152 14RT161 - RT168 1RT401 - RT412 1RT431 - RT447 1RT451 - RT455 15RT456 1RT457 - RT460 15RT461 1RT462 - RT469 1RT471 - RT499 15RT501 1RT502 - RT505 15RT506 - RT510 1RT511 - RT512 15RT513 1RT514 - RT515 15RT516 1RT517 15RT518 - RT520 1RT521 - RT523 15RT524 1RT525 - RT527 15RT528 1RT529 - RT535 1RT551 - RT568 1RT571 15RT572 - RT577 1RT578 - RT591 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 16 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 17 GroupVariable Number 1RT601 - RT630 16RT631 - RT632 1RT633 - RT641 15RT642 1RT643 - RT654 15RT655 - RT657 1RT671 - RT673 1RT681 - RT682 1RT691 - RT699 1RT701 - RT704 1RT711 - RT717 1RT741 - RT742 16RT743 1RT744 - RT750 15RT751 - RT752 1RT753 - RT757 1RT776 - RT777 15RT781 - RT782 1RT783 - RT784 1RT801 - RT803 1RT811 - RT814 1RT831 - RT836 15RT837 1RT861 - RT864 16RT876 1RT877 - RT880 1RT931 - RT932 1RT945 - RT949 1RT951 - RT952 14RT953 - RT954 1RT955 1RT966 15RT967 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 17 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 18 GroupVariable Number 1RU001 - RU006 1RU016 - RU017 1RU031 - RU032 1RU051 - RU052 1RU059 - RU062 1RU081 - RU083 1RU101 - RU102 1RU121 - RU132 1RU801 - RU809 1RU831 - RU841 2. Spares Affected None. B. Concurrent Requirements None. C. Reason This service bulletin gives data for the inspection and repair of certain fuselage skin longitudinal lap joints. These inspections and repairs are necessary for safe operation of airplanes past the design goal for economic usage. Boeing has completed extended pressure fatigue tests on a 747-100SR and a 747-400 fuselage test article. Analysis of these test results have identified areas of the fuselage lap joints where fatigue cracks can occur. Boeing has also used updated analysis methods on the 747 skin longitudinal lap joints. Inspection and repair of these areas is necessary for safe operation of airplanes past the design goal for economic usage. The inspections in this service bulletin will make sure that fatigue cracks in the overlapping skin at the upper row of fasteners in certain fuselage lap joints are found and repaired before they become critical. Skin cracks not detected prior to reaching critical crack length may result in the inability to withstand current regulatory fail-safe loads, in-flight depressurization of the airplane or loss of structural integrity. Boeing Service Related Problem (SRP) 747-SRP-53-0211 and 747OP-SRP-53-0279 are related to this service bulletin. Revision 1: Subsequent to the release of the original issue of this service bulletin, a review of all lap joints was accomplished for the affected airplanes. It was determined that all lap joints with an upper skin thickness of 0.090 inches or less should be inspected at the times given in Paragraph 1.E., Compliance. In addition, a review of all service bulletins which recommend repeat inspections was accomplished to determine if the inspections were appropriate on aging airplanes. This review indicated that certain lap joints where the skin thickness is less than or equal to 0.071 inches should be modified at the times given in Paragraph 1.E., Compliance. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 18 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 19 Revision 1 is sent to expand the eddy current inspection areas and to add lap joint modifications for specific lap joints. A detailed list of changes is given in the Revision Transmittal Sheet section of Revision 1. Revision 2 is sent to revise the modification drawings that are specified for stringer 6 lap joint modification. New Groups 15 and 16 have also been created for airplanes modified by Boeing to Boeing Converted Freighter (BCF), and airplanes modified to Large Cargo Freighter (LCF). BCF airplanes have unique inspection requirements. A detailed list of changes is given in the Revision Transmittal Sheet section of Revision 2. D. Description Lap joint inspection Do external High Frequency Eddy Current (HFEC) of certain lap joints for cracks. These lap joints are in Section 41, Section 42, and Section 46. In addition, do internal and external Low Frequency Eddy Current (LFEC) inspections at certain doublers common to these lap joints. If no cracks are found, do the inspection again at the time shown in this service bulletin. If cracks are found, remove the fastener in the cracked hole and sufficient adjacent fasteners and do open hole HFEC inspections to find the crack length. Repair before any more flights. Repair as shown in the structural repair manual or ask Boeing for repair data. As part of the repair, do open-hole HFEC inspections of the skin at all existing fastener locations common to the repair. Lap joint modification Do eddy current inspections of the lap joints in sections 41 and 42 that will be modified. If cracks are found, repair the cracks and contact Boeing for lap joint modification instructions. For areas where no cracks are found, do the lap joint modifications. Effectivity is divided into 16 groups due to configuration differences. Revision 1 - More work is necessary on airplanes changed as given in the initial release of this service bulletin. The eddy current inspection areas have been expanded and lap joint modifications are necessary in specific areas at the time given in Paragraph 1.E., Compliance. Revision 2 - No more work is necessary on airplanes changed as shown in the original issue or Revision 1 of this service bulletin. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 19 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 20 NOTE: The related service bulletin for 747-100, 747-200B, 747-300, 747SP, and 747SR airplanes is 747-53A2367. 1. 2. If the external skin panel of an affected lap joint has been replaced, start to do the inspections of that lap joint 22,000 full pressure flight-cycles after the skin panel was replaced. 3. At all lap joints not covered by the lap joint modification given in this service bulletin, additional inspections and/or a lap joint modification must be accomplished at 35,000 total flight cycles. Boeing is not planning to provide inspection methods and engineering drawings for the modification. 4. Because of the extent of the work required to accomplish the modification in this Service Bulletin, jacking and support of the airplane will be necessary. Boeing can provide a jacking plan for the incorporation of the bulletin. To have Boeing assist in developing jacking/support recommendations the following is required: — A list of structures related Service Bulletins to be incorporated. — The exact airplane configuration including weight and center of gravity. — Whether the following will be installed or removed: landing gear, flaps, engines, pylons and interiors. — The airplane identification (line number or variable number). — List the lap joints to be modified and lap the joints that require repair (if possible). — Provide the planned incorporation date for the bulletin modification. Provide adequate time for Boeing to develop the necessary data and for any required contacts or agreements to be developed. 5. Some of the lap joints shown in this service bulletin are also affected by other Boeing Service Bulletins as shown in the tables that follow. The information in these tables is for reference only, and no prior or concurrent work is required for this service bulletin. Lap Joints Affect- ed EffectivityADSubjectService Bul- letin Number S-34, S-39, and S- 44 from STA 741 to STA 841 and from STA 1641 to STA 1741 (Lower lobe lap splices at the wing to body fair- ings.) All 747s line number 201 - 814 2008-16-14Fuselage - Skin - Lap Splice Upper Counter- sunk Fastener Row In- spection Repair and Modification at Wing-To Body Fairing 747-53A2312 S-12, from STA 520 to STA 740 All 747s line number 201 - 230 94-15-17Fuselage - Skin - Body Skin Lap Joint Inspection and Fastener Replace- ment at Stringer 12 From Body Station 520 to 741.1 747-53-2366 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 20 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 21 Lap Joints Affect- ed EffectivityADSubjectService Bul- letin Number S-6, from STA 340 to STA 520 All 747s2006-22-09Fuselage - Skin - Inspec- tion for Cracks at Multiple Sites in Fuselage Skin Lap Joints 747-53A2501 S-6, from STA 340 to 400 747 air- planes, line numbers 1 - 603 90-23-14Fuselage - Nose Section - Station 340 to 400 Stringer 6 Inspection and Modification 747-53-2253 S-6, from STA 400 to 520 747 air- planes, line numbers 1 - 628 90-21-17Fuselage - Nose Section - Station 400 to 520 Stringer Lap Splice In- spection, Repair and Modification 747-53A2303 S-6, from STA 340 to 400 747 air- planes, line numbers 1 - 603 2009-04-16Fuselage - Skin - Fuse- lage Skin at Stringer 6, from STA 340 to STA 400 - Inspection, Repair, and Modification 747-53A2748 The service bulletin that follows includes a repair and a modification that affects the lap joint at S-44L from STA 560 to STA 580. Boeing Service Bulletin 747-53A2499 provides the appropriate inspection instructions for affected airplanes that have been repaired or modified as shown in Service Bulletin 747-53-2386. Lap Joints Affect- ed EffectivityADSubjectService Bul- letin Number S-44L, from STA 560 to STA 580 All 747s line number 1 - 886, except 747-400s -Fuselage - Skin - Skin Inspec- tion, Repair, and Modification at the Body Station 570 Equipment Cooling Outlet 747-53-2386 NOTE: Boeing recommends that Service Bulletin 747-53A2563, "Fuselage - Skin - Inspections of the Fuselage Skin and Butt Joint Splice Straps for Scribe Lines" be done prior to installation of any modification doublers in accordance with this service bulletin. If the scribe line inspections are not done prior to installation of modification doublers, it may be necessary to remove the doublers at a later time to do scribe line inspections. The work in this service bulletin is done in the maintenance zone(s) given below. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 21 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 22 Group 1: Affected Maintenance Zones ZoneModel 112, 113, 114, 115, 116, 117, 118, 121, 122, 123, 124, 125, 126, 127, 128, 141, 142, 143, 144, 145, 146, 147, 148, 151, 152, 211, 212, 221, 222, 223, 224, 225, 226, 231, 232, 241, 242, 243, 244, 251, 252, 253, 254, 261, 262, 263, 264, 271, 272, 273, 274 747-400, 747-400D Group 2-7: 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 8-12: 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, 274 747-200C Group 13: Affected Maintenance Zones ZoneModel 112, 113, 114, 115, 116, 117, 118, 121, 122, 123, 124, 125, 126, 127, 128, 141, 142, 143, 144, 145, 146, 147, 148, 151, 152, 211, 212, 221, 222, 223, 224, 225, 226, 231, 232, 233, 234, 241, 242, 243, 244, 251, 252, 253, 254, 261, 262, 263, 264, 271, 272, 273, 274 747-400F BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 22 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 23 Group 14-15: Affected Maintenance Zones ZoneModel 112, 113, 114, 115, 116, 117, 118, 121, 122, 123, 124, 125, 126, 127, 128, 141, 142, 143, 144, 145, 146, 147, 148, 151, 152, 211, 212, 221, 222, 223, 224, 225, 226, 231, 232, 241, 242, 243, 244, 251, 252, 253, 254, 261, 262, 263, 264, 271, 272, 273, 274 747-400 Group 16: Affected Maintenance Zones ZoneModel 112, 113, 114, 115, 116, 117, 118, 211, 212, 221, 222, 223, 224, 225, 121A, 122A, 125A, 126A 747-400 E. Compliance Federal Aviation Administration (FAA) Airworthiness Directives 90-06-06, 90-21-17, 90-23-14, 94-15-17, 2004-07-22 R1, 2005-08-01, 2006-05-09, 2006-20-02, 2006-22-09, 2006-24-02, 2006-24-05, 2007-15-07, 2008-16-14, and 2009-04-16 are related to this service bulletin. The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Group 1-15: Table 1 - Lap Joint Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later)ActionCondition -Within 1,000 flight cycles af- ter the original issue date on this service bul- letin. Within 3,000 flight cycles af- ter the last HFEC inspec- tion of the area as given in the SSID. (c) Before 22,000 total flight cycles. Do the Area 1 eddy current inspections for cracks in the skin as given in work instructions Paragraph 3.B.1., Part 1. All airplanes -Within 1,000 flight cycles af- ter the Revision 1 date on this service bulletin. Within 3,000 flight cycles af- ter the last HFEC inspec- tion of the area as given in the SSID. (c) Before 22,000 total flight cycles. Do the Area 2 eddy current inspections for cracks in the skin as given in work instructions Paragraph 3.B.2., Part 2. All airplanes BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 23 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 24 Group 1-15: Table 1 - Lap Joint Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later)ActionCondition -Before further flight.Repair the lap joint as given in work in- structions Para- graph 3.B.1.q. or 3.B.2.p. (d) (g) Any crack found. 3,000 flight-cy- cles, or 1,500 flight cycles for airplanes with more than 30,000 total flight cycles. (a) (b) (f) Within 3,000 flight-cycles after the last inspec- tion, or within 1,500 flight-cycles after the last inspection for airplanes with more than 30,000 total flight-cycles. Repeat the inspec- tion for cracks as given in work in- structions Para- graph 3.B.1., Part 1 and 3.B.2., Part 2. Areas where no crack is found. 3,000 flight-cy- cles, or 1,500 flight cycles for airplanes with more than 30,000 total flight cycles. (a) (b) (e) (f) Within 15,000 flight-cycles after the repair was installed. Accomplish internal HFEC inspections for cracks as given in the applicable 747 SRM or D6- 36181, "Repair As- sessment Guide- lines - Model 747." Areas where a lap joint repair was in- stalled as given in the Paragraph 3.B. Work Instructions of this service bulletin, and repair doubler(s) is greater than or equal to 40 inches long. (d) (g) (a) For laps joints specified in work instructions Paragraph 3.B.3., Part 3 on airplanes with more than 30,000 total flight cycles, reduce the inspection interval to 1,500 flight cycles until the lap joint modification given in Paragraph 3.B.3., Part 3 is accomplished. (b) Accomplishment of a lap joint modification as given in work instructions Paragraph 3.B.3, Part 3 terminates the repeat inspections as given in work instructions Paragraphs 3.B.1., Part 1 and 3.B.2., Part 2 for the length of the lap joint that is modified. (c) The Supplemental Structural Inspection Document (SSID) D6-35022, Revision G for SSI's F-25G, F-25H, and F-25I provides inspection options for the subject lap joints. Only the HFEC inspection will allow this compliance time. (d) Refer to the applicable 747 SRM or D6-36181, "Repair Assessment Guidelines - Model 747" for inspection requirements (including inspection method and compliance time) of areas where a lap joint repair was installed as given in work instruction Paragraph 3.B.1.q or 3.B.2.p, and the repair doubler(s) is less than 40 inches long. The inspections given in this table are no longer necessary for those areas. (e) At tearstraps and frame shear ties, where skin is not inspectable for less than 4 inches, HFEC inspection is not required. (f) In the area covered by external doublers installed as given in Boeing Service Bulletin 747-53-2386, this inspection must be repeated at intervals not to exceed 2,400 flight-cycles. This inspection is for cracks in the upper skin under the doublers. Furthermore, at Stringer 4 left, between STA 1720 and STA 1740, and BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 24 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 25 Group 1-15: Table 1 - Lap Joint Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later)ActionCondition between STA 1960 and STA 1980; this inspection must be repeated at intervals not to exceed 1,500 flight- cycles. This inspection is for cracks in the upper skin under an external doubler. (g) Until the structural modification as given in work instructions Paragraph 3.B.3., Part 3 is installed, any in- spection or replacement requirements as given in the applicable 747 SRM must be accomplished. Group 1-15: Table 2 - Lap Joint Modification Compliance Time (Whichever Occurs Later)ActionCondition Within 3,000 flight-cycles after the Revision 1 date of this service bulletin. (b) Before 30,000 total flight cy- cles. Do the lap joint modification as given in Work Instructions Paragraph 3.B.3., Part 3. (a) (d) All airplanes. Within 15,000 flight-cycles after modification was done.Additional lap joint modifica- tions and/or inspections are required. Contact Boeing for instructions. (c) Areas where lap joint modification was done as given in work instructions Paragraph 3.B.3., Part 3 before the air- plane accumulated 20,000 total flight cy- cles. (d) Before 35,000 total flight cycles.Additional lap joint modifica- tions and/or inspections are required. Contact Boeing for instructions and perform those actions provided by Boeing's instructions. (c) All airplanes. (a) Accomplishment of a lap joint modification as given in Paragraph 3.B.3, Part 3 terminates the repeat in- spections as given in work instructions Paragraph 3.B.1., Part 1 and 3.B.2., Part 2 for the length of the lap joint that is modified. (b) For lap joints specified in Paragraph 3.B.3., Work Instructions, Part 3 on airplanes with more than 30,000 total flight cycles, the inspection intervals in Table 1 and Table 2 must be reduced to 1,500 flight cycles until the lap joint modification is accomplished as given in Paragraph 3.B.3., Work Instructions, Part 3. (c) It is suggested that operators contact Boeing for instructions at least one year before the inspection/mod- ification data will be needed. (d) The external modification doubler installation as given in Service Bulletin 747-53A2499 Revision 1 meets the requirements of the modification as given in this service bulletin revision. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 25 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 26 Group 16: Table 3 - Lap Joint Inspection Compliance TimeActionCondition As given in Service Bulletin 747-53A2817.Do the inspections of lap joints as given in work instruc- tions Paragraph 3.B.1., Part 1. (a) All airplanes. (a) These inspections of lap joints are related to Service Bulletin 747-53A2817. Group 16: Table 4 - Lap Joint Modification Compliance TimeActionCondition As given in Service Bulletin 747-53A2817.Do the modification provided by Boeing. (a) All airplanes. (a) Contact Boeing for modification instructions a minimum of two years prior to reaching the compliance time. NOTE: 1. On airplanes modified or repaired as shown in Boeing Service Bulletin 747-53-2386, do repeated external Low Frequency Eddy Current (LFEC) inspections of the area at S-44L from STA 560 to STA 580 every 2,400 flight-cycles, as shown in this service bulletin. 2. On airplanes with a Main Deck Side Cargo Door, do repeated internal LFEC inspections of the area at S-4L from STA 1720 to STA 1740 and from STA 1960 to STA 1980 every 1,500 flight-cycles, as shown in this service bulletin. F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office (ACO) approves the inspection, repair, and modification procedures with the corresponding compliance times specified in Tables 1 and 2 under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2499, Revision 2, as an AMOC to the inspections and repairs required by paragraphs (h), (i), and (j) of AD 2004-07-22 R1, for the inspection of Structural Significant Items (SSI) F-25G, F-25H, and F-25I of Supplemental Structural Inspection Document (SSID) D6-35022, Revision BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 26 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 27 G. This AMOC only applies to the areas inspected by this service bulletin. When this service bulletin specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (l) of the AD. All provisions of AD 2004-07-22 R1 that are not specifically referenced in this paragraph, including the initial inspection threshold per paragraph (i) of AD 2004-07-22 R1, remain fully applicable and must be complied with. In addition, the Manager of the FAA Seattle ACO approves the modification procedures with the corresponding compliance times specified in Table 2 under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2499, Revision 2, as an AMOC to the inspections and repairs required by paragraphs (h), (i), and (j) of AD 2004-07-22 R1, for the inspection of SSI F-25K of SSID D6-35022, Revision G. This AMOC only applies to the areas modified by this service bulletin. When this service bulletin specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (l) of the AD. All provisions of AD 2004-07-22 R1 that are not specifically referenced in this paragraph, including the initial inspection threshold per paragraph (i) of AD 2004-07-22 R1, remain fully applicable and must be complied with. In addition, the Manager of the FAA Seattle ACO approves the inspection procedures with the corresponding compliance times specified in Table 1, under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2499, Revision 2, as an AMOC to the post-modification inspection requirements with the corresponding compliance times required by paragraph (p) of AD 2008-16-14. This AMOC is only for areas where inspections are done in accordance with this service bulletin. When this service bulletin specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (v) of the AD. All provisions of AD 2008-16-14 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. In addition, the Manager of the FAA Seattle ACO approves the inspection, repair, and modification procedures with the corresponding compliance times specified in Tables 1 and 2, under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2499, Revision 2, as an AMOC to the inspection and repair requirements with the corresponding compliance times required by paragraphs (f) and (g) of AD 2006-05-09. When this service bulletin specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (i) of the AD. All provisions of AD 2006-05-09 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. In addition, the Manager of the FAA Seattle ACO approves the inspection and repair procedures with the corresponding compliance times specified in Table 1, under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2499, Revision 2, as an AMOC to the post-modification inspection and repair requirements with the corresponding compliance times required by paragraph (c) of AD 94-15-17. This AMOC is only for areas where inspections are done in accordance with this service bulletin. When this service bulletin specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (d) of the AD. All provisions of AD 94-15-17 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. In addition, the Manager of the FAA Seattle ACO approves the modification procedures with the corresponding compliance times specified in Table 2, under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2499, Revision 2, as an AMOC to the inspection requirements with the corresponding compliance times required by paragraph (g) of AD 2006-22-09. This AMOC is only for areas where modification doublers have been installed in accordance with this service bulletin. When this SB specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (j) of the AD. All provisions of AD 2006-22-09 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 27 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 28 In addition, the Manager of the FAA Seattle ACO approves the modification procedures with the corresponding compliance times specified in Table 2, under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2499, Revision 2, as an AMOC to the inspection requirements with the corresponding compliance times required by paragraph A. of AD 90-23-14. When this SB specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph E. of the AD. All provisions of AD 90-23-14 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. In addition, the Manager of the FAA Seattle ACO approves the modification procedures with the corresponding compliance times specified in Table 2, under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2499, Revision 2, as an AMOC to the inspection and modification requirements with the corresponding compliance times required by paragraphs A., C., and D. of AD 90-21-17. When this SB specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph G. of the AD. All provisions of AD 90-21-17 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. In addition, the Manager of the FAA Seattle ACO approves the modification procedures with the corresponding compliance times specified in Table 2, under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2499, Revision 2, as an AMOC to the inspection and modification requirements with the corresponding compliance times required by paragraphs (g), (i), and (j) of AD 2009-04-16. When this SB specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (k) of the AD. All provisions of AD 2009-04-16 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. In addition, the Manager of the FAA Seattle ACO approves the modification procedures with the corresponding compliance times specified in Table 2, under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2499, Revision 2, as an AMOC to the inspection procedures with the corresponding compliance times specified in Table 1, under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2675, dated October 12, 2006, required by paragraph (f) of AD 2006-24-05. This AMOC is only for areas where stringer 6 modification doublers have been installed in accordance with this service bulletin. When this SB specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (j) of the AD. All provisions of AD 2006-24-05 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. In addition, the Manager of the FAA Seattle ACO approves the modification procedures with the corresponding compliance times specified in Table 2, under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2499, Revision 2, as an AMOC to the inspection requirements with the corresponding compliance times required by paragraph (f) and (k) of AD 2006-24-02. This AMOC is only for areas where stringer 6 modification doublers have been installed in accordance with this service bulletin. When this SB specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (n) of the AD. All provisions of AD 2006-24-02 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. In addition, the Manager of the FAA Seattle ACO approves the modification procedures with the corresponding compliance times specified in Table 2, under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2499, Revision 2, as an AMOC to the Zone 1 external doubler modification requirement aft of body station (Sta) 340, at Stringer 6, with the corresponding compliance time for Service Bulletin 747-53-2272, Revision 12, Service Bulletin 747-53-2253 initial release, and Service Bulletin 747-53A2303, initial release, specified in Section 3 of the Aging Airplane Service Bulletin Structural Modification and Inspection Program Document D6-35999, dated March 31, 1989 required by paragraph BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 28 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 29 A. of AD 90-06-06. This AMOC is only for areas where the external doublers are installed in accordance with Service Bulletin 747-53A2499, Revision 2. When this SB specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph C. of the AD. All provisions of AD 90-06-06 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. In addition, the Manager of the FAA Seattle ACO approves the modification procedures with the corresponding compliance times specified in Table 2, under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2499, Revision 2, as an AMOC to the modification requirements with the corresponding compliance times required by paragraph (s) of AD 2005-08-01. This AMOC is only for areas on the skin where stringer 6 modification doublers have been installed aft of BS 340 in accordance with this service bulletin. When this SB specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (t) of the AD. All provisions of AD 2005-08-01 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. In addition, the Manager of the FAA Seattle ACO approves the modification procedures with the corresponding compliance times specified in Table 2, under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2499, Revision 2, as an AMOC to the inspection and modification requirements with the corresponding compliance times specified in Tables 1 and 2, under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2542, dated February 16, 2006 required by paragraphs (f) and (h) of AD 2007-15-07. When this SB specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (i) of the AD. All provisions of AD 2007-15-07 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. In addition, the Manager of the FAA Seattle ACO approves the modification procedures with the corresponding compliance times specified in Table 2, under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2499, Revision 2, as an AMOC to the inspection requirements with the corresponding compliance times required by paragraphs (f) and (h) of AD 2006-20-02. This AMOC is only for areas where modification doublers have been installed in accordance with this service bulletin. When this SB specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (k) of the AD. All provisions of AD 2006-20-02 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. G. Manpower The table below shows an estimate of the task-hours necessary to do this inspection for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task-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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 29 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 30 Groups 1 through 16 - Lap Joint Inspections - Area 1 Elapsed HoursTask-HoursNumber of Per- sons Task 2.5010.004Prepare 21.0084.004Examine Section 41 40.00160.004Examine Section 42 74.25297.004Examine Section 46 137.50551.00 (a)TOTAL FOR EACH AIRPLANE (a) More time will be necessary for repairs if cracks are found. Groups 1 through 16 - Lap Joint Inspections - Area 1 and Area 2 Elapsed HoursTask-HoursNumber of Per- sons Task 2.5010.004Prepare 21.0084.004Examine Section 41 47.50190.004Examine Section 42 97.75391.004Examine Section 46 168.75675.00 (a)TOTAL FOR EACH AIRPLANE (a) More time will be necessary for repairs if cracks are found. Groups 1 through 16 - Lap Joint Modifications Elapsed HoursTask-HoursNumber of Per- sons Task 287.754604.0016Modify Section 41 303.751215.004Modify Section 42 591.55819.00TOTAL FOR EACH AIRPLANE H. Weight and Balance Changes Installation of lap joint repairs and modifications given in this service bulletin 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 changed. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 30 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 31 J. References 1. Existing Data: a. Engineering Change Memo PRR85901-44RS and PRR85901-91RS. b. Service Related Problem (SRP) 747-SRP-53-0211 and 747OP-SRP-53-0279. c. 747-100/-200/-300 Structural Repair Manual (SRM) Subject 51-10-04, 51-10-06, 51-30-08, 51-70-00, 51-70-03, 53-30-03. d. 747-400 Structural Repair Manual (SRM) Subject 51-10-01, 51-10-03, 51-20-05, 51-40-08, 53-00-01. e. 747-400F Structural Repair Manual (SRM) Subject 51-10-01, 51-10-03, 51-20-05, 51-40-08, 53-00-01. f. 747-400LCF Structural Repair Manual (SRM) Subject 51-10-01, 51-10-03, 51-20-05, 51-40-08, 53-00-01. g. 747 Nondestructive Test (NDT) Manual D6-7170, Part 6, Subject 51-00-00, 53-30-00, 53-30-02, 53-30-06. h. 747 Supplemental Structural Inspection Document (SSID) Boeing Document D6-35022. i. Boeing Service Bulletins 747-53-2253, 747-53-2272, 747-53A2303, 747-53-2305, 747-53A2312, 747-53-2366, 747-53A2367, 747-53-2386, 747-53A2501, 747-53A2563, 747-53A2748. j. FAA Airworthiness Directives 90-06-06, 90-21-17, 90-23-14, 94-15-17, 2004-07-22 R1, 2005-08-01, 2006-05-09, 2006-20-02, 2006-22-09, 2006-24-02, 2006-24-05, 2007-15-07, 2008-16-14, and 2009-04-16. k. Boeing Parts Standards Document D-590. l. Boeing Drawing 012W6100. m. Boeing Standard Overhaul Practices Manual (SOPM) 20-41-01 and 20-50-11. 2. Data supplied with this Service Bulletin: a. Drawings: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 31 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 32 ADCNDCN/REVSheetTitleDrawing No --1Kit - Lap Splice Modification, S-6, Sta 340 - Sta 520 141U0008 --10 --11 --12 -A13 -A14 -A15 --2 --3 --4 --5 --6 --7 --8 -A9 -APSDLKit - Lap Splice Modification, S-6, Sta 340 - Sta 520 141U0008#DL BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 32 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 33 ADCNDCN/REVSheetTitleDrawing No --1Kit - Lap Splice Modification, S-6, Sta 340 - 520 141U0059 -A10 -A11 -A12 -A13 -A14 -A15 -A16 -A17 -A18 -A19 -A2 -A3 -A4 -A5 -A6 -A7 -A8 -A9 --PSDLKit - Lap Splice Modification, S-6, Sta 340 - 520 141U0059#DL -B2Lap Splice Reinforcement, Stringer 23, Sta 220 - Sta 400 691U1050 --3 --4 --5 -CPSDLLap Splice Reinforcement, Stringer 23, Sta 220 - Sta 400 691U1050#DL -A1Lap Splice Reinforcement, Stringer 44, Sta 420 - Sta 520 691U1051 -CPSDLLap Splice Reinforcement, Stringer 44, Sta 420 - Sta 520 691U1051#DL -A1Lap Splice Reinforcement, Stringer 44, Sta 520 - Sta 471 691U1052 --2 -A3 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 33 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 34 ADCNDCN/REVSheetTitleDrawing No -CPSDLLap Splice Reinforcement, Stringer 44, Sta 520 - Sta 471 691U1052#DL 3. Installation Drawings Used in the Preparation of this Service Bulletin: None. 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. L. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 34 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 35 2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane, as shown below. Alternatively, operators can fabricate their own parts. If there is a limit to the quantity (QTY) of available kits, a supply sequence is given by Spares. More kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order. Unit Price thru Jan 31/11 ROLT (Weeks) QTYDateNameKit Number $5001.00431Jan 21/10Kit - Lap Splice Modifica- tion 141U0059-1 $4887.00433Dec 08/09Kit - Lap Splice Modifica- tion 141U0059-2 $5004.00432Jan 21/10Kit - Lap Splice Modifica- tion 141U0059-3 $4333.00433Dec 08/09Kit - Lap Splice Modifica- tion 141U0059-4 $6787.00431Jan 21/10Kit - Lap Splice Modifica- tion 141U0059-5 $6880.00433Dec 08/09Kit - Lap Splice Modifica- tion 141U0059-6 $6708.00432Jan 21/10Kit - Lap Splice Modifica- tion 141U0059-7 $6645.00434Jan 21/10Kit - Lap Splice Modifica- tion 141U0059-8 $5898.00431Jan 21/10Kit - Lap Splice Modifica- tion 141U0059-9 $5465.00432Dec 08/09Kit - Lap Splice Modifica- tion 141U0059-10 $7586.00431Jan 21/10Kit - Lap Splice Modifica- tion 141U0059-11 $6961.00432Dec 08/09Kit - Lap Splice Modifica- tion 141U0059-12 Unit Price thru Jan 31/11 ROLT (Weeks) QTYDateNameKit Number $3135.00(a)(a)(a)Kit - Lap Splice Modifica- tion 141U0008-1 $3121.00(a)(a)(a)Kit - Lap Splice Modifica- tion 141U0008-2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 35 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 36 Unit Price thru Jan 31/11 ROLT (Weeks) QTYDateNameKit Number $3135.00(a)(a)(a)Kit - Lap Splice Modifica- tion 141U0008-3 $3122.00(a)(a)(a)Kit - Lap Splice Modifica- tion 141U0008-4 $2990.00(a)(a)(a)Kit - Lap Splice Modifica- tion 141U0008-5 $2990.00(a)(a)(a)Kit - Lap Splice Modifica- tion 141U0008-6 $3096.00(a)(a)(a)Kit - Lap Splice Modifica- tion 141U0008-7 $2948.00(a)(a)(a)Kit - Lap Splice Modifica- tion 141U0008-8 (a) These kits are were not available at the time of release of Revision 2 of this service bulletin. Boeing recommends that operators submit a purchase order 18 months in advance of performing the modification. B. Industry Support Information Boeing warranty remedies are not available for the inspection, repair, or modification procedures given in this service bulletin. C. Parts Necessary For Each Airplane 1. Kits/Parts: NOTE: The kits shown below are for lap splice modification at stringer 6. See Drawing 141U0008, Sheet 1 and Drawing 141U0059, Sheet 1 for kit applicability. The kits below can be ordered from Boeing, or the equivalent parts can be supplied by the operator. To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. Kit 141U0008 NotesExisting Part Number NameQTYNew Part Number -1-2-3-4-5-6 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 340 - STA 520 -.....141U0008-1 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 340 - STA 520 .-....141U0008-2 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 340 - STA 520 ..-...141U0008-3 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 36 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 37 Kit 141U0008 NotesExisting Part Number NameQTYNew Part Number -1-2-3-4-5-6 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 340 - STA 520 ...-..141U0008-4 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 340 - STA 520 ....-.141U0008-5 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 340 - STA 520 .....-141U0008-6 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 520 1.....141U0008-11 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 520 .1....141U0008-12 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 520 ..1...141U0008-13 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 520 ...1..141U0008-14 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 520 ....11141U0008-15 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 520 1.....141U0008-41 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 520 .1....141U0008-42 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 520 ..1...141U0008-43 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 520 ...1..141U0008-44 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 520 ....1.141U0008-45 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 37 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 38 Kit 141U0008 NotesExisting Part Number NameQTYNew Part Number -1-2-3-4-5-6 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 520 .....1141U0008-46 Kit 141U0008 NotesExisting Part Number NameQTYNew Part Number -7-8-11-12-13-14 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 340 - STA 520 -.....141U0008-7 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 340 - STA 520 .-....141U0008-8 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 520 ..-...141U0008-11 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 520 ...-..141U0008-12 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 520 ....-.141U0008-13 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 520 .....-141U0008-14 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 520 11....141U0008-17 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 520 1.....141U0008-47 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 520 .1....141U0008-48 (a)BOLT, 100 DEG HEX DR..21212121BACB30NW6K5X (a)BOLT, 100 DEG HEX DR..4444BACB30NW6K8X COLLAR..25252525BACC30M6 (a)RIVET, 100 DEG....48BACR15GF6D10 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 38 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 39 Kit 141U0008 NotesExisting Part Number NameQTYNew Part Number -7-8-11-12-13-14 (a)RIVET, 100 DEG..578571..BACR15GF6D4 (a)RIVET..421385947947BACR15GF6D5 (a)RIVET, 100 DEG..688583675546BACR15GF6D6 (a)RIVET, 100 DEG..473405492422BACR15GF6D7 (a)RIVET, 100 DEG..159162221200BACR15GF6D8 (a)RIVET, 100 DEG..15192522BACR15GF6D9 (a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65B88700 are used to determine the part numbers used as substitutes. Kit 141U0008 NotesExisting Part Number NameQTYNew Part Number -15-17-41-42-43-44 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 520 -.....141U0008-15 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 520 .-....141U0008-17 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 520 ..-...141U0008-41 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 520 ...-..141U0008-42 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 520 ....-.141U0008-43 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 520 .....-141U0008-44 EXTERNAL DOUBLER..1...141U0035-1 EXTERNAL DOUBLER...1..141U0035-2 EXTERNAL DOUBLER..1...141U0035-3 EXTERNAL DOUBLER...1..141U0035-4 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 39 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 40 Kit 141U0008 NotesExisting Part Number NameQTYNew Part Number -15-17-41-42-43-44 EXTERNAL DOUBLER....1.141U0035-5 EXTERNAL DOUBLER.....1141U0035-6 STRUCTURAL FILLER....1.141U0035-7 STRUCTURAL FILLER.....1141U0035-8 (a)BOLT, 100 DEG HEX DR2.....BACB30NW6K3X (a)BOLT, 100 DEG HEX DR62....BACB30NW6K4X (a)BOLT, 100 DEG HEX DR.6....BACB30NW6K5X (a)BOLT, 100 DEG HEX DR4.....BACB30YP6K4 (a)BOLT, 100 DEG HEX DR24....BACB30YP6K5 (a)BOLT, 100 DEG HEX DR.2....BACB30YP6K6 COLLAR66....BACC30BL6 COLLAR88....BACC30M6 (a)RIVET, UNIVERSAL HD195130....BACR15BB6D4C (a)RIVET, UNIVERSAL HD1017....BACR15BB6D6C (a)RIVET, UNIVERSAL HD69....BACR15BB6D7C (a)RIVET, 100 DEG579.....BACR15GF6D4 (a)RIVET959646....BACR15GF6D5 (a)RIVET, 100 DEG22987....BACR15GF6D6 (a)RIVET, 100 DEG300367....BACR15GF6D7 (a)RIVET, 100 DEG9228....BACR15GF6D8 (a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65B88700 are used to determine the part numbers used as substitutes. Kit 141U0008 NotesExisting Part Number NameQTYNew Part Number -45-46-47-48 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 520 -...141U0008-45 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 40 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 41 Kit 141U0008 NotesExisting Part Number NameQTYNew Part Number -45-46-47-48 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 520 .-..141U0008-46 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 520 ..-.141U0008-47 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 520 ...-141U0008-48 EXTERNAL DOUBLER1...141U0035-9 EXTERNAL DOUBLER.1..141U0035-10 STRUCTURAL FILLER1...141U0035-11 STRUCTURAL FILLER.1..141U0035-12 EXTERNAL DOUBLER..1.141U0035-13 EXTERNAL DOUBLER...1141U0035-14 STRUCTURAL FILLER..1.141U0035-15 STRUCTURAL FILLER...1141U0035-16 Kit 141U0059 NotesExisting Part Number NameQTYNew Part Number -1-2-3-4-5-6 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 340 - STA 400 -.....141U0059-1 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 340 - STA 400 .-....141U0059-2 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 340 - STA 400 ..-...141U0059-3 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 340 - STA 400 ...-..141U0059-4 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 400 - STA 520 ....-.141U0059-5 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 41 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 42 Kit 141U0059 NotesExisting Part Number NameQTYNew Part Number -1-2-3-4-5-6 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 400 - STA 520 .....-141U0059-6 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 1.....141U0059-21 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 .1....141U0059-22 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 400 - STA 520 ....1.141U0059-23 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 400 - STA 520 .....1141U0059-24 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 400 .1....141U0059-31 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 400 ...1..141U0059-32 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 400 - STA 520 ....11141U0059-33 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 400 1.....141U0059-37 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 400 ..1...141U0059-38 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 ..1...141U0059-41 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 ...1..141U0059-42 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 42 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 43 Kit 141U0059 NotesExisting Part Number NameQTYNew Part Number -7-8-9-10-11-12 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 400 - STA 520 -.....141U0059-7 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 400 - STA 520 .-....141U0059-8 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 340 - STA 400 ..-...141U0059-9 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 340 - STA 400 ...-..141U0059-10 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 400 - STA 520 ....-.141U0059-11 KIT - LAP SPLICE MODIFICA- TION, S-6, STA 400 - STA 520 .....-141U0059-12 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 ..1...141U0059-25 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 ...1..141U0059-26 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 400 - STA 520 ....1.141U0059-27 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 400 - STA 520 .....1141U0059-28 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 400 - STA 520 11....141U0059-34 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 400 ...1..141U0059-35 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 400 - STA 520 ....11141U0059-36 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 43 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 44 Kit 141U0059 NotesExisting Part Number NameQTYNew Part Number -7-8-9-10-11-12 KIT - FASTENERS, LAP SPLICE MODIFICATION, S- 6, STA 340 - STA 400 ..1...141U0059-39 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 400 - STA 520 1.....141U0059-43 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 400 - STA 520 .1....141U0059-44 Kit 141U0059 NotesExisting Part Number NameQTYNew Part Number -21-22-23-24-25-26 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 -.....141U0059-21 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 .-....141U0059-22 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 400 - STA 520 ..-...141U0059-23 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 400 - STA 520 ...-..141U0059-24 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 ....-.141U0059-25 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 .....-141U0059-26 STRINGER FILLER11..11141U0060-2 TEAR STRAP DOUBLER11..11141U0060-4 TEAR STRAP FILLER11..11141U0060-6 FLAT FILLER11..11141U0060-8 TAPERED FILLER1...1.141U0060-9 TAPERED FILLER.1...1141U0060-10 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 44 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 45 Kit 141U0059 NotesExisting Part Number NameQTYNew Part Number -21-22-23-24-25-26 STRINGER FILLER..11..141U0060-12 TEAR STRAP DOUBLER..11..141U0060-14 TEAR STRAP FILLER..11..141U0060-16 FLAT FILLER..11..141U0060-18 TAPERED FILLER..1...141U0060-19 TAPERED FILLER...1..141U0060-20 STRINGER FILLER..11..141U0060-22 TEAR STRAP DOUBLER..22..141U0060-24 TEAR STRAP FILLER..33..141U0060-28 EXTERNAL DOUBLER1...1.141U0060-37 EXTERNAL DOUBLER.1...1141U0060-38 SKIN EXTENSION..1...141U0060-39 SKIN EXTENSION...1..141U0060-40 EXTERNAL DOUBLER1.....141U0060-41 EXTERNAL DOUBLER.1....141U0060-42 EXTERNAL DOUBLER..1...141U0060-43 EXTERNAL DOUBLER...1..141U0060-44 EXTERNAL DOUBLER....1.141U0060-45 EXTERNAL DOUBLER.....1141U0060-46 FILLER11..11141U0060-52 STRINGER FILLER11..11141U0060-56 FILLER11..11141U0060-60 FILLER..11..BACF3F008J032NN FILLER11..11BACF3F010L035NN SHIM, LAMINATED..33..BACF3F011J015NN FILLER, FLAT..11..BACF3F011J017NN BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 45 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 46 Kit 141U0059 NotesExisting Part Number NameQTYNew Part Number -27-28-31-32-33-34 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 400 - STA 520 -.....141U0059-27 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 400 - STA 520 .-....141U0059-28 KIT - FASTENERS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 ..-...141U0059-31 KIT - FASTENERS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 ...-..141U0059-32 KIT - FASTENERS, LAP SPLICE MODIFICATION, S-6, STA 400 - STA 520 ....-.141U0059-33 KIT - FASTENERS, LAP SPLICE MODIFICATION, S-6, STA 400 - STA 520 .....-141U0059-34 STRINGER FILLER11....141U0060-12 TEAR STRAP DOUBLER11....141U0060-14 TEAR STRAP FILLER11....141U0060-16 FLAT FILLER11....141U0060-18 TAPERED FILLER1.....141U0060-19 TAPERED FILLER.1....141U0060-20 STRINGER FILLER11....141U0060-22 TEAR STRAP DOUBLER22....141U0060-24 TEAR STRAP FILLER33....141U0060-28 SKIN EXTENSION1.....141U0060-39 SKIN EXTENSION.1....141U0060-40 EXTERNAL DOUBLER1.....141U0060-47 EXTERNAL DOUBLER.1....141U0060-48 (a)HI-LOK.....2BACB30MY8K4 (a)BOLT.....2BACB30MY8K5 (a)BOLT, HEX DRIVE.....12BACB30MY8K6 (a)BOLT, PROTRUDING HD.....4BACB30MY8K6Y BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 46 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 47 Kit 141U0059 NotesExisting Part Number NameQTYNew Part Number -27-28-31-32-33-34 (a)BOLT.....40BACB30MY8K7 (a)BOLT, PROTRUDING HD.....2BACB30MY8K7Y (a)HI-LOK PROT HEAD.....5BACB30MY8K8 (a)BOLT, 100 DEG HEX DR...22.BACB30NW6K4X (a)BOLT, 100 DEG HEX DR..942118BACB30NW6K5X (a)BOLT, 100 DEG HEX DR...3..BACB30NW6K5Y (a)HI-LOK....4.BACB30NW6K6 (a)BOLT, 100 DEG HEX DR..22414.BACB30NW6K6X (a)BOLT, 100 DEG HEX DR...18..BACB30NW6K6Y (a)BOLT....2.BACB30NW6K7 (a)BOLT, 100 DEG HEX DR..5245464BACB30NW6K7X (a)BOLT, 100 DEG HEX DR..9.84BACB30NW6K8X (a)BOLT, 100 DEG HEX DR...4..BACB30NW6K8Y (a)BOLT, PROTRUDING HD..22..BACB30NX6K4X (a)BOLT, PROTRUDING HD.....2BACB30NX6K5X (a)BOLT, PROTRUDING HD....22BACB30NX6K6X COLLAR..2224BACC30BH6 COLLAR..92559726BACC30M6 COLLAR.....50BACC30M8 COLLAR...25..BACC30R6 COLLAR.....6BACC30R8 FILLER11....BACF3F008J032NN SHIM, LAMINATED33....BACF3F011J015NN FILLER, FLAT11....BACF3F011J017NN (a)RIVET, UNIVERSAL HD..99..BACR15BB6D4C (a)RIVET, UNIVERSAL HD..2.3940BACR15BB6D5C (a)RIVET, UNIVERSAL HD..3543BACR15BB6D6C (a)RIVET, UNIVERSAL HD..2246BACR15BB6D7C (a)RIVET, UNIVERSAL HD....32BACR15BB6D8C (a)RIVET, UNIVERSAL HD...24.61BACR15BB7D10C (a)RIVET, UNIVERSAL HD.....6BACR15BB7D11C BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 47 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 48 Kit 141U0059 NotesExisting Part Number NameQTYNew Part Number -27-28-31-32-33-34 (a)RIVET, UNIVERSAL HD...8..BACR15BB7D6C (a)RIVET, UNIVERSAL HD...132.6BACR15BB7D7C (a)RIVET, UNIVERSAL HD...264.80BACR15BB7D8C (a)RIVET, UNIVERSAL HD...73.110BACR15BB7D9C (a)RIVET, UNIVERSAL HD.....20BACR15BB8D10C (a)RIVET, UNIVERSAL HD...1.2BACR15BB8D11C (a)RIVET, UNIVERSAL HD...33..BACR15BB8D6C (a)RIVET, UNIVERSAL HD...9..BACR15BB8D7C (a)RIVET, UNIVERSAL HD...2.5BACR15BB8D8C (a)RIVET, UNIVERSAL HD.....44BACR15BB8D9C (a)RIVET, 100 DEG..32147911BACR15GF6D10 (a)RIVET, 100 DEG..653682..BACR15GF6D4 (a)RIVET..506535864779BACR15GF6D5 (a)RIVET, 100 DEG..330228180215BACR15GF6D6 (a)RIVET, 100 DEG..472322859735BACR15GF6D7 (a)RIVET, 100 DEG..297144241253BACR15GF6D8 (a)RIVET, 100 DEG..1289225970BACR15GF6D9 (a)RIVET, 100 DEG.....83BACR15GF7D6 (a)RIVET, 100 DEG.....90BACR15GF7D7 (a)RIVET, 100 DEG.....6BACR15GF7D8 (a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65B88700 are used to determine the part numbers used as substitutes. Kit 141U0059 NotesExisting Part Number NameQTYNew Part Number -35-36-37-38-39-41 KIT - FASTENERS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 -.....141U0059-35 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 48 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 49 Kit 141U0059 NotesExisting Part Number NameQTYNew Part Number -35-36-37-38-39-41 KIT - FASTENERS, LAP SPLICE MODIFICATION, S-6, STA 400 - STA 520 .-....141U0059-36 KIT - FASTENERS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 ..-...141U0059-37 KIT - FASTENERS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 ...-..141U0059-38 KIT - FASTENERS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 ....-.141U0059-39 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 .....-141U0059-41 STRINGER FILLER.....1141U0060-2 TEAR STRAP FILLER.....1141U0060-6 FLAT FILLER.....1141U0060-8 TAPERED FILLER.....1141U0060-25 TEAR STRAP DOUBLER.....1141U0060-30 EXTERNAL DOUBLER.....1141U0060-37 EXTERNAL DOUBLER.....1141U0060-41 FILLER.....1141U0060-52 STRINGER FILLER.....1141U0060-56 FILLER.....1141U0060-60 (a)BOLT, 100 DEG HEX DR.2.2..BACB30NW6K4X (a)BOLT, 100 DEG HEX DR921949.BACB30NW6K5X (a)BOLT, 100 DEG HEX DR...3..BACB30NW6K5Y (a)HI-LOK.4....BACB30NW6K6 (a)BOLT, 100 DEG HEX DR221422422.BACB30NW6K6X (a)BOLT, 100 DEG HEX DR...18..BACB30NW6K6Y (a)BOLT.2....BACB30NW6K7 (a)BOLT, 100 DEG HEX DR5248524552.BACB30NW6K7X (a)BOLT, 100 DEG HEX DR989.9.BACB30NW6K8X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 49 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 50 Kit 141U0059 NotesExisting Part Number NameQTYNew Part Number -35-36-37-38-39-41 (a)BOLT, 100 DEG HEX DR...4..BACB30NW6K8Y (a)BOLT, PROTRUDING HD2.222.BACB30NX6K4X (a)BOLT, PROTRUDING HD.2....BACB30NX6K5X (a)BOLT, PROTRUDING HD.2....BACB30NX6K6X COLLAR24222.BACC30BH6 COLLAR9299925592.BACC30M6 COLLAR...25..BACC30R6 FILLER.....1BACF3F010L035NN (a)RIVET, UNIVERSAL HD9.999.BACR15BB6D4C (a)RIVET, UNIVERSAL HD2382.2.BACR15BB6D5C (a)RIVET, UNIVERSAL HD34353.BACR15BB6D6C (a)RIVET, UNIVERSAL HD23222.BACR15BB6D7C (a)RIVET, UNIVERSAL HD.2....BACR15BB6D8C (a)RIVET, UNIVERSAL HD.2....BACR15BB6D9C (a)RIVET, UNIVERSAL HD...24..BACR15BB7D10C (a)RIVET, UNIVERSAL HD...34..BACR15BB7D6C (a)RIVET, UNIVERSAL HD...152..BACR15BB7D7C (a)RIVET, UNIVERSAL HD...356..BACR15BB7D8C (a)RIVET, UNIVERSAL HD...83..BACR15BB7D9C (a)RIVET, UNIVERSAL HD...1..BACR15BB8D11C (a)RIVET, UNIVERSAL HD...24..BACR15BB8D6C (a)RIVET, UNIVERSAL HD...18..BACR15BB8D7C (a)RIVET, UNIVERSAL HD...2..BACR15BB8D8C (a)RIVET, 100 DEG3279321432.BACR15GF6D10 (a)RIVET, 100 DEG..399442..BACR15GF6D4 (a)RIVET1159410575565975.BACR15GF6D5 (a)RIVET, 100 DEG219587502319427.BACR15GF6D6 (a)RIVET, 100 DEG564790578485559.BACR15GF6D7 (a)RIVET, 100 DEG296633319151397.BACR15GF6D8 (a)RIVET, 100 DEG14729912892143.BACR15GF6D9 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 50 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 51 Kit 141U0059 NotesExisting Part Number NameQTYNew Part Number -35-36-37-38-39-41 (a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65B88700 are used to determine the part numbers used as substitutes. Kit 141U0059 NotesExisting Part NumberNameQTYNew Part Number -42-43-44 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 340 - STA 400 -..141U0059-42 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 400 - STA 520 .-.141U0059-43 KIT - PARTS, LAP SPLICE MODIFICATION, S-6, STA 400 - STA 520 ..-141U0059-44 STRINGER FILLER1..141U0060-2 TEAR STRAP FILLER1..141U0060-6 FLAT FILLER1..141U0060-8 STRINGER FILLER.11141U0060-12 TEAR STRAP FILLER.11141U0060-16 STRINGER FILLER.11141U0060-22 TEAR STRAP DOUBLER.22141U0060-24 TAPERED FILLER1..141U0060-26 TEAR STRAP FILLER.33141U0060-28 TEAR STRAP DOUBLER1..141U0060-30 EXTERNAL DOUBLER1..141U0060-38 SKIN EXTENSION.1.141U0060-39 SKIN EXTENSION..1141U0060-40 EXTERNAL DOUBLER1..141U0060-42 EXTERNAL DOUBLER.1.141U0060-43 EXTERNAL DOUBLER..1141U0060-44 TEAR STRAP DOUBLER.11141U0060-50 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 51 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 52 Kit 141U0059 NotesExisting Part NumberNameQTYNew Part Number -42-43-44 FILLER1..141U0060-52 FLAT FILLER.11141U0060-54 STRINGER FILLER1..141U0060-56 TAPERED FILLER.1.141U0060-57 TAPERED FILLER..1141U0060-58 FILLER1..141U0060-60 FILLER.11BACF3F008J032NN FILLER1..BACF3F010L035NN SHIM, LAMINATED.33BACF3F011J015NN FILLER, FLAT.11BACF3F011J017NN 2. Parts and Materials Supplied by the Operator: Materials and fasteners are required to do the lap splice modifications. Operators should refer to modification drawings and the SRM for specific raw material and fastener requirements. The drawing numbers and SRM references are in the accomplishment instructions and figures. 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 52 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 53 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. The sequence of steps given in Figures 2-15, and 23 can be changed. Inspections can be done concurrently. 2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 3. Obey all of the warnings and cautions given in the specified manual sections. 4. These work instructions refer to procedures included on 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 "as given in" are included in the instruction, the procedure in the Boeing document must be used. 5. 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 are given in 747 Structural Repair Manual, Chapter 51 — Torque limits to tighten nuts and bolts are given in 747 Structural Repair Manual, Chapter 51. 6. For approved fastener and process material substitutions, refer to 747-400 Structural Repair Manual, Chapter 51. Alternate fasteners are given in 747-400 Structural Repair Manual Chapter 51 and Boeing Drawing 012W6100. 7. If the length of any fastener specified in this service bulletin does not meet the installation standards in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards in SRM Chapter 51 may be used. 8. If an external doubler has been installed per another service bulletin along an affected lap joint: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 53 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 54 — If the external doubler was installed as given in Service Bulletin 747 53-2253, Service Bulletin 747-53A2303, or Service Bulletin 747-53-2272 at stringer 6, then no additional inspection is required by this service bulletin in the area of the external doubler. — If the external doubler was installed as given in Service Bulletin 747-53-2305 at stringer 44, then no additional inspection is required by this service bulletin in the area of the external doubler. 9. A heavy continuous line or a hatched line is used to indicate the lap joint areas that should be inspected as shown in Figures 2-15, and 23, and lap joint areas that should be modified as shown in Figures 16 to 22. 10. If a skin panel is replaced, the inspection threshold for the affected lap joint can be calculated from the time when the skin was replaced. 11. The inspections in this service bulletin can be done on either Anodized or Alodine rivets. 12. For the lap joint at BL 0, the inspection shown in this service bulletin applies to the left most row of fasteners in the lap joint. 13. Remove wing-to-body fairing panels from Section 42 and Section 46 as necessary to do the inspections defined in the figures. 14. Refer to Paragraph 1.E., Compliance for thresholds and repeat inspection intervals. 15. Because of the extent of the work required to accomplish the modification in this Service Bulletin, jacking and support of the airplane will be necessary. Boeing can provide a jacking plan for the incorporation of the bulletin. To have Boeing assist in developing jacking/support recommendations the following is required: — A list of structures related Service Bulletins to be incorporated. — The exact airplane configuration including weight and center of gravity. — Whether the following will be installed or removed: landing gear, flaps, engines, pylons and interiors. — The airplane identification (line number or variable number). — List the lap joints to be modified and the lap joints that require repair (if possible). — Provide the planned incorporation date for the bulletin modification. Provide adequate time for Boeing to develop the necessary data and for any required contacts or agreements to be developed. 16. The instructions identified in Paragraph 3.B. Work Instructions and the Figures(s) give the recommended sequence of steps. The sequence of steps to do this service bulletin can be changed. 17. General refinish instructions for aluminum parts: Unless otherwise specified, touch up finish on aluminum parts with Alodine (F-17.10) + Primer (F-19.47). 18. Unless otherwise specified, use the following instructions for locating new fastener holes: Maintain 2D minimum edge margin on all parts. 1.7D edge margin is acceptable if limited by adjacent structure. Maintain 3D minimum fastener spacing. Equally space fasteners where appropriate. For heads and tails of new fasteners, maintain 0.25 inch minimum clearance with adjacent structure. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 54 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 55 19. When accomplishing PART 3 - LAP JOINT MODIFICATION at stringer 6: If modification kits are purchased from Boeing, some new parts are provided with excess material. Trim edges of new parts as required to eliminate interference with adjacent parts or fasteners. Maintain 2D edge margin on all new parts. 1.7D edge margin is acceptable, if necessary, unless otherwise specified. 20. When accomplishing PART 3 - LAP JOINT MODIFICATION: Deburr and break sharp edges on all trimmed parts. Maintain surface finish of 125 Microinches Ra or better. 21. When accomplishing PART 3 - LAP JOINT MODIFICATION: Ensure sufficient edge margin at existing fastener hole locations. Fastener edge margin requirements are defined in Appendix A. 22. Refer to SOPM 20-41-01 for explanations of Boeing finish codes. 23. During surface HFEC inspection of the upper row of fasteners at stringers 40L and 40R, and just AFT of STA 1480 (STA 1483), existing angles may be installed over the lap joint making the skin inaccessible for surface HFEC at two fastener locations (one fastener on each side of the airplane). HFEC inspection at these locations is not required if the fasteners are not accessible. 24. During surface HFEC inspection of the upper row of fasteners at stringers 34L and 34R, and just AFT of STA 1480 (STA 1481 to STA 1483.5), existing angles and fittings may be installed over the lap joint making the skin inaccessible for surface HFEC at six fastener locations (three fasteners on each side of the airplane). HFEC inspection at these locations is not required if the fasteners are not accessible. 25. For stringer 6 lap joint modification, 691U1049 modification drawings identified in Revision 1 of this service bulletin have been replaced by 141U0059 drawings (for locations with a crew service door) and 141U0008 drawings (for locations without a crew service door). 26. For airplanes that do not have existing doublers installed forward of STA 340 at stringer 6: If modification is done at stringer 6 from STA 340 to STA 400, it is not necessary to chamfer the forward edges of the new doublers at STA 340. Instead, Boeing recommends that operators fillet seal the new doublers as given in 747-100/-200/-300 SRM 51-10-06 or 747-400 SRM 51-20-05 or 747-400F SRM 51-20-05, or 747-400LCF SRM 51-20-05, including the forward facing edges. 27. For doublers installed at stringer 44L/44R, Boeing recommends that operators apply fillet seal as given in 747-100/-200/-300 SRM 51-10-06 or 747-400 SRM 51-20-05 or 747-400F SRM 51-20-05, or 747-400LCF SRM 51-20-05. 28. For doublers installed at stringer 23L/23R, Boeing recommends that operators apply fillet seal as given in 747-100/-200/-300 SRM 51-10-06 or 747-400 SRM 51-20-05 or 747-400F SRM 51-20-05, or 747-400LCF SRM 51-20-05, and aerodynamically seal the forward facing edges as given in 747-100/-200/-300 SRM 51-70-00 or 747-400 SRM 51-10-01 or 747-400F SRM 51-10-01, or 747-400LCF SRM 51-10-01, and SOPM 20-50-11. 29. For airplanes that operate with Reduced Vertical Separation Minimum (RVSM), skin waviness measurements as given in 747-400 SRM 51-10-03 are not required after doublers are installed as given in Figure 17 of the service bulletin. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 55 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 56 30. For airplanes that operate with Reduced Vertical Separation Minimum (RVSM), skin waviness measurements as given in 747-100/-200/-300 SRM 51-70-03 are not required after doublers are installed as given in Figure 18 of the service bulletin. 31. For airplanes that operate with Reduced Vertical Separation Minimum (RVSM), skin waviness measurements as given in 747-400F SRM 51-10-03 are not required after doublers are installed as given in Figure 19 of the service bulletin. 32. For airplanes that operate with Reduced Vertical Separation Minimum (RVSM), skin waviness measurements as given in 747-400LCF SRM 51-10-03 are not required after doublers are installed. 33. Although 747-400 SRM 51-40-08, 747-400F SRM 51-40-08, 747-400LCF SRM 51-40-08, and 747-100/-200/-300 SRM 51-30-08 give instructions for installation of countersink repair washers, it is not required to install repair washers in existing countersinks under the modification doublers that are installed as given in this service bulletin. Instead of repair washers, fill existing countersinks with BMS 5-95 sealant prior to doubler installation. 34. Remove sound dampening (acoustical) tape from the skin, as necessary, in areas where lap joint inspection or modification is being done. After inspection or modification, it is optional to install new sound dampening tape. Refer to standard industry practices and/or refer to BAC5801 to install new tape to match tape on surrounding skin. B. WORK INSTRUCTIONS 1. PART 1 - LAP JOINT INSPECTION - AREA 1 a. Group 1: Do inspections of the lap joints as given in Figure 2, Inspection Area 1. b. Group 2: Do inspections of the lap joints as given in Figure 3, Inspection Area 1. c. Group 3: Do inspections of the lap joints as given in Figure 4, Inspection Area 1. d. Group 4: Do inspections of the lap joints as given in Figure 5, Inspection Area 1. e. Group 5: Do inspections of the lap joints as given in of Figure 6, Inspection Area 1. f. Group 6: Do inspections of the lap joints as given in Figure 7, Inspection Area 1. g. Group 7: Do inspections of the lap joints as given in Figure 8, Inspection Area 1. h. Group 8: Do inspections of the lap joints as given in Figure 9, Inspection Area 1. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 56 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 57 i. Group 9: Do inspections of the lap joints as given in Figure 10, Inspection Area 1. j. Group 10: Do inspections of the lap joints as given in Figure 11, Inspection Area 1. k. Group 11: Do inspections of the lap joints as given in Figure 12, Inspection Area 1. l. Group 12: Do inspections of the lap joints as given in Figure 13, Inspection Area 1. m. Group 13: Do inspections of the lap joints as given in Figure 14, Inspection Area 1. n. Group 14: Do inspections of the lap joints as given in Figure 15, Inspection Area 1. o. Group 15: Do inspections of the lap joints as given in Figure 23, Inspection Area 1. p. Group 16: Do inspections of the lap joints in the areas specified as given in Service Bulletin 747-53A2817 using the inspection methods as given in Figure 2. The areas that are not specifically referenced in Service bulletin 747-53A2817 are not necessary to inspect. NOTE: Service bulletin 747-53A2817 refers to previous releases of this service bulletin. The inspection information in Service Bulletin 747-53A2817 is also applicable to this service bulletin revision. q. If cracks are found, repair the cracks before any more flights. Do the steps that follow: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 57 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 58 (1) Remove the fastener from the hole that indicates a crack. (2) Remove all fasteners in the upper fastener row of the lap joint within 10 inches forward and aft of the crack location, and do open-hole High Frequency Eddy Current (HFEC) inspection of the fastener holes to find cracks. Use 747 NDT Manual, Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16. If cracking is found, continue performing open-hole HFEC inspection of the fastener holes within 10 inches forward and aft of the crack location for cracks. (3) Repair the crack as given in 747-100/200/300 SRM 53-30-03, Figures 11, 13, 14, 16, 17, 19, 20, 22, 23, 25, 26, 28, 29, 31, 32, 34, and 48, or 747-400 SRM 53-00-01, Repair 10, 12, and 16, or 747-400F SRM 53-00-01, Repair 10, 12, and 16, or 747-400SF SRM 53-00-01. If cracks are larger than the limits shown in the structural repair manual, ask Boeing for repair data. As part of the repair, do open-hole HFEC inspections of the skin at all existing fastener locations common to the repair. Until the structural modification as given in work instructions Paragraph 3.B.3., Part 3 is installed, any inspection or replacement requirements as given in the applicable 747 SRM must be accomplished. r. Put the airplane back to a serviceable condition. Do the inspections again at the time given in Paragraph 1.E., Compliance. 2. PART 2 - LAP JOINT INSPECTION - AREA 2 a. Group 1: Do inspections of the lap joints as given in Figure 2, Inspection Area 2. b. Group 2: Do inspections of the lap joints as given in Figure 3, Inspection Area 2. c. Group 3: Do inspections of the lap joints as given in Figure 4, Inspection Area 2. d. Group 4: Do inspections of the lap joints as given in Figure 5, Inspection Area 2. e. Group 5: Do inspections of the lap joints as given in Figure 6, Inspection Area 2. f. Group 6: Do inspections of the lap joints as given in Figure 7, Inspection Area 2. g. Group 7: Do inspections of the lap joints as given in Figure 8, Inspection Area 2. h. Group 8: Do inspections of the lap joints as given in Figure 9, Inspection Area 2. i. Group 9: Do inspections of the lap joints as given in Figure 10, Inspection Area 2. j. Group 10: Do inspections of the lap joints as given in Figure 11, Inspection Area 2. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 58 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 59 k. Group 11: Do inspections of the lap joints as given in Figure 12, Inspection Area 2. l. Group 12: Do inspections of the lap joints as given in Figure 13, Inspection Area 2. m. Group 13: Do inspections of the lap joints as given in Figure 14, Inspection Area 2. n. Group 14: Do inspections of the lap joints as given in Figure 15, Inspection Area 2. o. Group 15: Do inspections of the lap joints as given in Figure 23, Inspection Area 2. p. If cracks are found, repair the cracks before any more flights. Do the steps that follow: (1) Remove the fastener from the hole that indicates a crack. (2) Remove all fasteners in the upper fastener row of the lap joint within 10 inches forward and aft of the crack location, and do open-hole High Frequency Eddy Current (HFEC) inspection of the fastener holes to find cracks. Use 747 NDT Manual, Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16. If cracking is found, continue performing open-hole HFEC inspection of the fastener holes within 10 inches forward and aft of the crack location for cracks. (3) Repair the crack as given in 747-100/200/300 SRM 53-30-03, Figures 11, 13, 14, 16, 17, 19, 20, 22, 23, 25, 26, 28, 29, 31, 32, 34, and 48, or 747-400 SRM 53-00-01, Repair 10, 12, and 16, or 747-400F SRM 53-00-01, Repair 10, 12, and 16, or 747-400SF SRM 53-00-01. If cracks are larger than the limits shown in the structural repair manual, ask Boeing for repair data. As part of the repair, do open-hole HFEC inspections of the skin at all existing fastener locations common to the repair. Until the structural modification as given in work instructions Paragraph 3.B.3., Part 3 is installed, any inspection or replacement requirements as given in the applicable 747 SRM must be accomplished. q. Put the airplane back to a serviceable condition. Do the inspections again at the time given in Paragraph 1.E., Compliance. 3. PART 3 - LAP JOINT MODIFICATION NOTE: Boeing recommends that Service Bulletin 747-53A2563, "Fuselage - Skin - Inspections of the Fuselage Skin and Butt Joint Splice Straps for Scribe Lines" be done prior to installation of any modification doublers as given in this service bulletin. If the scribe line inspections are not done prior to installation of modification doublers, it may be necessary to remove the doublers at a later time to do scribe line inspections. a. Group 1-15: Do the Section 41, stringer 6L and 6R lap joint modification between Station (STA) 340 and STA 520 as given in Figure 16. If cracks are found, contact Boeing. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 59 of 297 BOEING SERVICE BULLETIN 747-53A2499 ### Page 60 NOTE: 1. If stringer 6 between STA 340 and STA 400 has been modified by Service Bulletin 747-53-2272 then there is no modification required by this Service Bulletin. 2. If a repair doubler exists in the area to be modified, contact Boeing for further instructions. b. Do the Section 41, stringer 23L and 23R lap joint modification between STA 220 and STA 400 as given in: (1) Group 1, 14-15: Figure 17 (2) Group 2-12: Figure 18 (3) Group 13: Figure 19 If cracks are found, contact Boeing. NOTE: If a repair doubler exists in the area to be modified, contact Boeing for further instructions. c. Group 1-15: Do the Section 41, stringer 44L and 44R lap joint modification between STA 420 and STA 520 as given in Figure 20. If cracks are found, contact Boeing. NOTE: If a repair doubler exists in the area to be modified, contact Boeing for further instructions. d. Do the Section 42, stringer 44L and 44R lap joint modification between STA 520 and STA 741.1 as given in Figure: (1) Group 1, 13-15: Figure 21 (2) Group 2-12: Figure 22 If cracks are found, contact Boeing. NOTE: If a repair doubler exists in the area to be modified, contact Boeing for further instructions. e. Group 16: Contact Boeing for modification instructions as given in with Paragraph 1.E., Compliance. f. Put the airplane back to a serviceable condition. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: August 11, 2005 747-53A2499Revision 2: August 12, 2010 60 of 297 BOEING SERVICE BULLETIN 747-53A2499 The text continues at https://openairdocs.org/service-documents/boeing/747-53a2499/file/d09cbe49e992.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.