# Boeing Alert Service Bulletin 747-53A2559: Revision 1

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- Title as filed: Service Bulletin
- Pages: 957
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### Page 1

Commercial 
Airplanes
747
Service Bulletin
Number: 747-53A2559
Original Issue: January 08, 2009
Revision 1: August 04, 2011
ATA System: 5312
SUBJECT: FUSELAGE - Main Frame - Center Section - Tension Tie and Frame - Modification -
Stretched Upper Deck Airplanes
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 © 2009 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Unpublished Work - All Rights Reserved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.
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Table of Contents
Revision Transmittal Sheet ............................................ 7
Summary ...................................................... 9
1. PLANNING INFORMATION ........................................ 1 3
A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 1 8
B. Concurrent Requirements ...................................... 1 8
C. Reason ................................................ 1 8
D. Description .............................................. 1 9
E. Compliance .............................................. 2 0
F. Approval ............................................... 2 2
G. Manpower .............................................. 2 2
H. Weight and Balance Changes .................................... 3 0
I. Electrical Load Data ......................................... 3 1
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 3
K. Publications Affected ........................................ 3 3
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 7
C. Parts Necessary For Each Airplane ................................. 3 7
1. Kits/Parts: ........................................... 3 7
2. Parts and Materials Supplied by the Operator: ....................... 1 5 8
3. Parts Modified and Reidentified: ............................... 1 5 9
4. Parts Removed and Not Replaced: ............................. 1 5 9
D. Parts Necessary to Change Spares ................................ 1 5 9
E. Special Tooling - Price and Availability .............................. 1 5 9
F. Special Tooling Necessary to do this Service Bulletin ...................... 1 5 9
3. ACCOMPLISHMENT INSTRUCTIONS ................................. 1 6 1
A. GENERAL INFORMATION .................................... 1 6 1
B. WORK INSTRUCTIONS ...................................... 1 6 3
FIGURE 1: REMOVE SHEAR PANEL - LEFT SIDE [Group 1-2] .................... 1 7 0
FIGURE 2: REMOVE SHEAR PANEL - RIGHT SIDE [Group 1-2] ................... 1 7 6
FIGURE 3: STA 1120 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - LEFT SIDE [Group
1-2] ............................................... 1 8 2
FIGURE 4: STA 1120 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - RIGHT SIDE
[Group 1-2] .......................................... 1 9 1
FIGURE 5: STA 1120 - INSTALLATION - NEW FRAME SECTION - LEFT SIDE [Group 1-2] .... 2 0 0
FIGURE 6: STA 1120 - INSTALLATION - NEW FRAME SECTION - RIGHT SIDE [Group 1-2] .... 2 1 4
FIGURE 7: STA 1120 - INSTALLATION - NEW TENSION TIE SECTION - LEFT SIDE [Group 1-2] . 228
FIGURE 8: STA 1120 - INSTALLATION - NEW TENSION TIE SECTION - RIGHT SIDE [Group 1-2] . 235
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FIGURE 9: STA 1140 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - LEFT SIDE [Group
2 ,  4 ]  .............................................. 2 4 2
FIGURE 10: STA 1140 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - RIGHT SIDE
[Group 2, 4] .......................................... 2 5 2
FIGURE 11: STA 1140 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - LEFT SIDE [Group
1 ,  3 ,  5 ]  ............................................. 2 6 2
FIGURE 12: STA 1140 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - RIGHT SIDE
[Group 1, 3, 5] ......................................... 2 7 2
FIGURE 13: STA 1140 - INSTALLATION - NEW FRAME SECTION - LEFT SIDE [Group 1-2] .... 2 8 2
FIGURE 14: STA 1140 - INSTALLATION - NEW FRAME SECTION - RIGHT SIDE [Group 1-2] .... 2 9 7
FIGURE 15: STA 1140 - INSTALLATION - NEW TENSION TIE SECTION - LEFT SIDE [Group 2] . . 312
FIGURE 16: STA 1140 - INSTALLATION - NEW TENSION TIE SECTION - RIGHT SIDE [Group 2] . 320
FIGURE 17: STA 1140 - INSTALLATION - NEW TENSION TIE SECTION - LEFT SIDE [Group 1] . . 328
FIGURE 18: STA 1140 - INSTALLATION - NEW TENSION TIE SECTION - RIGHT SIDE [Group 1] . 335
FIGURE 19: STA 1160 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - LEFT SIDE [Group
1-2] ............................................... 3 4 2
FIGURE 20: STA 1160 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - RIGHT SIDE
[Group 1-2] .......................................... 3 5 0
FIGURE 21: STA 1160 - INSTALLATION - NEW FRAME SECTION - LEFT SIDE [Group 1-2] .... 3 5 8
FIGURE 22: STA 1160 - INSTALLATION - NEW FRAME SECTION - RIGHT SIDE [Group 1-2] .... 3 7 2
FIGURE 23: STA 1160 - INSTALLATION - NEW TENSION TIE SECTION - LEFT SIDE [Group 1-2] . 386
FIGURE 24: STA 1160 - INSTALLATION - NEW TENSION TIE SECTION - RIGHT SIDE [Group 1-2] . 393
FIGURE 25: STA 1180 - THIS FIGURE IS DELETED (REVISION 1) .................. 4 0 0
FIGURE 26: STA 1180 - THIS FIGURE IS DELETED (REVISION 1) .................. 4 0 1
FIGURE 27: STA 1180 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - LEFT SIDE . 402
FIGURE 28: STA 1180 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - RIGHT SIDE
................................................. 4 1 0
FIGURE 29: STA 1180 - INSTALLATION - NEW FRAME SECTION - LEFT SIDE [Group 1-5] .... 4 1 8
FIGURE 30: STA 1180 - INSTALLATION - NEW FRAME SECTION - RIGHT SIDE [Group 1-5] .... 4 2 8
FIGURE 31: STA 1180 - THIS FIGURE IS DELETED (REVISION 1) .................. 4 3 8
FIGURE 32: STA 1180 - THIS FIGURE IS DELETED (REVISION 1) .................. 4 3 9
FIGURE 33: STA 1180 - INSTALLATION - NEW TENSION TIE SECTION - LEFT SIDE ........ 4 4 0
FIGURE 34: STA 1180 - INSTALLATION - NEW TENSION TIE SECTION - RIGHT SIDE ....... 4 4 8
FIGURE 35: STA 1200 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - LEFT SIDE [Group
1-2] ............................................... 4 5 5
FIGURE 36: STA 1200 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - RIGHT SIDE
[Group 1-2] .......................................... 4 6 2
FIGURE 37: STA 1200 - INSTALLATION - NEW FRAME SECTION - LEFT SIDE [Group 1-2] .... 4 6 9
FIGURE 38: STA 1200 - INSTALLATION - NEW FRAME SECTION - RIGHT SIDE [Group 1-2] .... 4 8 1
FIGURE 39: STA 1200 - INSTALLATION - NEW TENSION TIE SECTION - LEFT SIDE [Group 1-2] . 493
FIGURE 40: STA 1200 - INSTALLATION - NEW TENSION TIE SECTION - RIGHT SIDE [Group 1-2] . 500
FIGURE 41: STA 1220 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - LEFT SIDE [Group
1-2] ............................................... 5 0 7
FIGURE 42: STA 1220 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - RIGHT SIDE
[Group 1-2] .......................................... 5 1 8
FIGURE 43: STA 1220 - INSTALLATION - NEW FRAME SECTION - LEFT SIDE [Group 1-2] .... 5 2 9
FIGURE 44: STA 1220 - INSTALLATION - NEW FRAME SECTION - RIGHT SIDE [Group 1-2] .... 5 4 5
FIGURE 45: STA 1220 - INSTALLATION - NEW TENSION TIE SECTION - LEFT SIDE [Group 1-2] . 560
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FIGURE 46: STA 1220 - INSTALLATION - NEW TENSION TIE SECTION - RIGHT SIDE [Group 1-2] . 568
FIGURE 47: SHEAR PANEL INSTALLATION - LEFT SIDE [Group 1-2] ................. 5 7 6
FIGURE 48: SHEAR PANEL INSTALLATION - RIGHT SIDE [Group 1-2] ................ 5 8 5
FIGURE 49: STA 1120 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - LEFT SIDE [Group
3-5] ............................................... 5 9 4
FIGURE 50: STA 1120 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - RIGHT SIDE
[Group 3-5] .......................................... 6 0 2
FIGURE 51: STA 1120 - INSTALLATION - NEW FRAME SECTION - LEFT SIDE [Group 3-5] .... 6 1 0
FIGURE 52: STA 1120 - INSTALLATION - NEW FRAME SECTION - RIGHT SIDE [Group 3-5] .... 6 2 4
FIGURE 53: STA 1120 - INSTALLATION - NEW TENSION TIE SECTION - LEFT SIDE [Group 3-5] . 638
FIGURE 54: STA 1120 - INSTALLATION - NEW TENSION TIE SECTION - RIGHT SIDE [Group 3-5] . 646
FIGURE 55: STA 1140 - INSTALLATION - NEW FRAME SECTION - LEFT SIDE [Group 3-5] .... 6 5 4
FIGURE 56: STA 1140 - INSTALLATION - NEW FRAME SECTION - RIGHT SIDE [Group 3-5] .... 6 6 7
FIGURE 57: STA 1140 - INSTALLATION - NEW TENSION TIE SECTION - LEFT SIDE [Group 3, 5] . 680
FIGURE 58: STA 1140 - INSTALLATION - NEW TENSION TIE SECTION - RIGHT SIDE [Group 3, 5] . 687
FIGURE 59: STA 1160 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - LEFT SIDE [Group
3-5] ............................................... 6 9 4
FIGURE 60: STA 1160 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - RIGHT SIDE
[Group 3-5] .......................................... 7 0 2
FIGURE 61: STA 1160 - INSTALLATION - NEW FRAME SECTION - LEFT SIDE [Group 3-5] .... 7 1 0
FIGURE 62: STA 1160 - INSTALLATION - NEW FRAME SECTION - RIGHT SIDE [Group 3-5] .... 7 2 4
FIGURE 63: STA 1160 - INSTALLATION - NEW TENSION TIE SECTION - LEFT SIDE [Group 3-5] . 738
FIGURE 64: STA 1160 - INSTALLATION - NEW TENSION TIE SECTION - RIGHT SIDE [Group 3-5] . 745
FIGURE 65: STA 1200 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - LEFT SIDE [Group
3-5] ............................................... 7 5 2
FIGURE 66: STA 1200 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - RIGHT SIDE
[Group 3-5] .......................................... 7 5 9
FIGURE 67: STA 1200 - INSTALLATION - NEW FRAME SECTION - LEFT SIDE [Group 3-5] .... 7 6 6
FIGURE 68: STA 1200 - INSTALLATION - NEW FRAME SECTION - RIGHT SIDE [Group 3-5] .... 7 7 8
FIGURE 69: STA 1200 - INSTALLATION - NEW TENSION TIE SECTION - LEFT SIDE [Group 3-5] . 790
FIGURE 70: STA 1200 - INSTALLATION - NEW TENSION TIE SECTION - RIGHT SIDE [Group 3-5] . 798
FIGURE 71: STA 1220 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - LEFT SIDE [Group
3-4] ............................................... 8 0 6
FIGURE 72: STA 1220 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - RIGHT SIDE
[Group 3-4] .......................................... 8 1 7
FIGURE 73: STA 1220 - INSTALLATION - NEW FRAME SECTION - LEFT SIDE [Group 3-5] .... 8 2 8
FIGURE 74: STA 1220 - INSTALLATION - NEW FRAME SECTION - RIGHT SIDE [Group 3-5] .... 8 4 3
FIGURE 75: STA 1220 - INSTALLATION - NEW TENSION TIE SECTION - LEFT SIDE [Group 3-4] . 858
FIGURE 76: STA 1220 - INSTALLATION - NEW TENSION TIE SECTION - RIGHT SIDE [Group 3-4] . 866
FIGURE 77: STA 1220 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - LEFT SIDE [Group
5 ]  ................................................ 8 7 4
FIGURE 78: STA 1220 - REMOVE EXISTING TENSION TIE AND FRAME STRUCTURE - RIGHT SIDE
[Group 5] ............................................ 8 8 5
FIGURE 79: STA 1220 - INSTALLATION - NEW TENSION TIE SECTION - LEFT SIDE [Group 5] . . 896
FIGURE 80: STA 1220 - INSTALLATION - NEW TENSION TIE SECTION - RIGHT SIDE [Group 5] . 904
FIGURE 81: POST MODIFICATION INSPECTION - LEFT SIDE [Group 1-2] .............. 9 1 2
FIGURE 82: POST MODIFICATION INSPECTION - RIGHT SIDE [Group 1-2] ............. 9 1 9
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FIGURE 83: POST MODIFICATION INSPECTION - LEFT SIDE [Group 3-5] .............. 9 2 6
FIGURE 84: POST MODIFICATION INSPECTION - RIGHT SIDE [Group 3-5] ............. 9 3 3
FIGURE 85: STA 1140 - INSTALLATION - NEW TENSION TIE SECTION - LEFT SIDE [Group 4] . . 940
FIGURE 86: STA 1140 - INSTALLATION - NEW TENSION TIE SECTION - RIGHT SIDE [Group 4] . 948
Appendix A: METHOD TO DISCONNECT TENSION TIES ........................ 9 5 6
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Commercial 
Airplanes
747
Service Bulletin
Revision Transmittal SheetNumber: 747-53A2559Original Issue: January 08, 2009
Revision 1: August 04, 2011
ATA System: 5312
SUBJECT: FUSELAGE - Main Frame - Center Section - Tension Tie and Frame - Modification -
Stretched Upper Deck Airplanes
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION
Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-024-AD is related to
this service bulletin.
Federal Aviation Administration (FAA) Airworthiness Directives 2004-07-22 R1, 2007-16-19, and 2007-23-18
are related to this service bulletin.
No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin.
REASON FOR REVISION
This revision is sent to correct the service bulletin figure that is called out for Group 1-2 modification at STA
1140, change the washers that are required at BACB30US bolt locations, correct refinish instructions for aluminum
and steel parts, and revise the top kit for Group 4 airplanes. Several other changes have also been made.
The following sections were changed:
1. Throughout the service bulletin: Appearance, location, and format of some text and information has changed
as a result of new service bulletin standards and requirements. These changes do not affect the technical
content of the service bulletin and are considered minor. Therefore, these changes are not identified with
a vertical line on the left edge of the page.
2. In Summary, Compliance, added a reference to the FAA NPRM.
3. In paragraph 1.A., Effectivity: Moved twenty-one (21) airplanes from Group 2 to Group 4 because they have
been modified to Boeing Converted Freighter.
4. In paragraph 1.D., Description: Added maintenance zone data.
5. In paragraph 1.E., Compliance: Added a reference to the FAA NPRM and note (a) to clarify that the Part 2
inspections are required after the modification has been accomplished.
6. In paragraph 1.J.1., Existing Data, updated the reference list to add the FAA NPRM.
7. In paragraph 1.J.2., Data supplied with this Service Bulletin: Updated revision level of 624U0065, sheets
2, 6, 12, 16, 40, 44, 48, and 54.
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8. In paragraph 2.A., Material Price and Availability: Updated price and availability information for top kits.
Also, revised the top kit number for Group 4 airplanes. The -43 top kit has been replaced by the -53.
9. In paragraph 2.C.2., Parts and Materials Supplied by the Operator: Deleted BACS40R008C037F and
associated note (d). Shim BACS40R008C037F is supplied in the Boeing Top Kit. Added BACW10BP4DP,
BACW10BP32DP, BACR15GF7D( ), and note (f). Also, added supplemental parts that may be needed for
Group 4 airplanes if 015U1803-43 top kit was previously purchased.
10. In paragraph 3.A., General Information: Corrected general refinish instructions for steel parts and aluminum
parts.
11. In paragraph 3.B., Work Instructions - Access and Restoration: Revised the AMM reference for
removal/installation of insulation.
12. In paragraph 3.B., Work Instructions - Part 1, Step 9: Corrected figure callout for Group 1-2 right side frame
structure installation at STA 1140 (Figure 14 was Figure 16). Also, corrected figure callouts for Group 1, 3,
and 5 left and right side tension tie structure installation at STA 1180 (Figures 27, 28, 33, and 34 were
Figures 25, 26, 31, and 32, respectively).
13. In Figure 1 and 2: Corrected hole diameter for rivet installation.
14. In Figure 7, 8, 15, 16, 17, 18, 23, 24, 33, 34, 39, 40, 45, 46, 53, 54, 57, 58, 63, 64, 69, 70, 75, 76, 79, 80,
85, and 86: Changed BACW10BP4NDP and BACW10BP32NDP washers to BACW10BP4DP and
BACW10BP32DP, respectively. Boeing recommends installation of "DP" washers under the nuts common
to BACB30US bolts in order to ensure proper clamp-up. However, previous installations with "NDP" washers
are satisfactory.
15. In Figure 25, 26, 31, and 32: These Figures are deleted. Figures 27, 28, 33, and 34 are now identified as
the correct figures for Group 1, 3, and 5 tension tie removal and installation at STA 1180.
16. In Figure 51 and 52: Added unused fastener code letter "E" to comply with new service bulletin format
requirements.
17. In Figure 53 and 54: Corrected quantity of BACB30US4K15.
18. In Figure 73 and 74: Corrected bolt part number (BACB30NW6K6X was BACB30NW6K5X).
19. In Appendix A: Added description for Method 1 for disconnecting tension ties. Deleted Method 2 for
disconnecting tension ties. Method 1 ensures that the shape of the fuselage contour is maintained.
The data given in Information Notice 747-53A2559 IN 01 is included in this revision.
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
January 08, 2009Original Issue:
August 04, 2011Revision 1:
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Commercial 
Airplanes
747
Service Bulletin
SummaryNumber: 747-53A2559Original Issue: January 08, 2009
Revision 1: August 04, 2011
ATA System: 5312
SUBJECT: FUSELAGE - Main Frame - Center Section - Tension Tie and Frame - Modification -
Stretched Upper Deck Airplanes
CONCURRENT REQUIREMENTS
None.
BACKGROUND
This service bulletin gives instructions for modification of upper deck tension ties and adjacent frame structure
on stretched upper deck (SUD) airplanes. The tension ties have been determined to be structure that is susceptible
to Widespread Fatigue Damage (WFD). WFD can cause tension ties to become severed or disconnected from
the frames. Severed or disconnected Tension Ties and/or Frames at multiple locations could result in rapid
in-flight decompression.
For more information about WFD, refer to Boeing Service Letter 747-SL-53-088A.
Service Bulletin 747-53A2507 recommends initial and repeat inspection of SUD airplane tension ties from body
station (STA) 1120 to STA 1220. Service Bulletin 747-53A2507 was issued to address multiple reports of cracks
found in tension ties and adjacent frame structure. Accomplishment of the modification in this service bulletin
terminates the repeat inspection requirement of Service Bulletin 747-53A2507.
Federal Aviation Administration (FAA) Airworthiness Directive 2007-23-18 is related to Service Bulletin
747-53A2507.
Additionally, for airplanes that have not already terminated the repeat inspection requirement of Service Bulletin
747-53A2610 "FUSELAGE - Main Frame - Center Section - Tension Tie Inspection, Repair, and Modification -
Stretched Upper Deck (SUD) Special Freighters", accomplishment of the modification given in this service
bulletin terminates the repeat inspection requirement of Service Bulletin 747-53A2610 for the modified areas.
Federal Aviation Administration (FAA) Airworthiness Directive 2007-16-19 is related to Service Bulletin
747-53A2610.
Boeing Service Related Problem (SRP) 747-SRP-53-0215 is related to this service bulletin.
ACTION (PRR 85901-53RS)
Get access to the Frame to Tension Tie joints at STA 1120 through STA 1220. At each station, disconnect and
remove a section of the tension tie between the frame and approximate Buttock Line (BL) 36. For each frame,
remove a specified section of the frame above and below the tension tie attach point. After the existing frame
and tension tie structure has been removed and discarded, install new frame and tension tie structure. Do the
modification on both sides of the airplane.
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### Page 10

After modification, do initial and repeat detailed inspections of the modified tension ties and the modified frame
structure at the compliance times specified in paragraph 1.E., Compliance.
EFFECTIVITY
747-100B SUD, 747-200B, 747-300, 747-400, and 747-400D airplanes. Refer to paragraph 1.A.1, Effectivity.
NOTE: For 747-200B airplanes, only airplanes that have been modified to Stretched Upper Deck are affected.
COMPLIANCE
Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-024-AD is 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.
Federal Aviation Administration (FAA) Airworthiness Directives 2004-07-22 R1, 2007-16-19, and 2007-23-18
are related to this service bulletin.
Refer to paragraph 1.E, Compliance.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the inspections and modifications given in this service bulletin.
MANPOWER
Modification
Elapsed HoursTotal Task HoursAirplanes
149.0298.0Group 1
149.5299.0Group 2
136.5273.0Group 3
138.5277.0Group 4
139.0278.0Group 5
MATERIAL INFORMATION
Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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BOEING SERVICE BULLETIN 747-53A2559

### Page 11 (OCR)

BOEING SERVICE BULLETIN 747-53A2559
STA
1120
AT THE ENDS OF EACH TENSION TIE, REMOVE AND REPLACE THE TENSION TIE
STRUCTURE OUTBOARD OF APPROXIMATE BUTTOCK LINE 36.0. DO
POST-MODIFICATION INSPECTIONS OF THE REPLACED TENSION TIE STRUCTURE AT
THE COMPLIANCE TIMES SPECIFIED IN PARAGRAPH 1.E., COMPLIANCE
STA
1120
NOD2008000
FWD
STA
1220
REMOVE AND REPLACE THE
SHEAR PANEL STRUCTURE
AT EACH TENSION TIE ATTACH JOINT, REMOVE AND REPLACE A
SECTION OF THE FRAME STRUCTURE. DO POST MODIFICATION  INSPECTIONS OF REPLACED FRAME STRUCTURE AT THE COMPLIANCE  1443791
TIMES SPECIFIED IN PARAGRAPH 1.E., COMPLIANCE
Original Issue: January 08, 2009
Revision 1: August 04, 2011  747-53A2559
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BLANK PAGE

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Commercial 
Airplanes
747
Service Bulletin
Number: 747-53A2559
Original Issue: January 08, 2009
Revision 1: August 04, 2011
ATA System: 5312
SUBJECT: FUSELAGE - Main Frame - Center Section - Tension Tie and Frame - Modification -
Stretched Upper Deck Airplanes
1.    PLANNING INFORMATION
A. Effectivity
1. Airplanes
This service bulletin is for the airplanes shown below. Refer to PRR 85901-53RS for data about
this change.
Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line
Number, and Serial Number data.
NOTE: Some airplanes were delivered with Extended Upper Deck Modifications that installed
floor beams aft of STA 740. These airplanes are not the same as airplanes delivered with
a Stretched Upper Deck (SUD), which includes 747-300, 747-400 passenger airplanes,
and some 747-100 and 747-200 SUD modified airplanes.
DESCRIPTIONCONFIGURATIONGROUP
747-100B SUD/-200B/-300 Stretched Upper Deck passenger
airplanes that have not been modified by Boeing to Special Freighter
(SF) configuration. These airplanes have stow bin support fittings
installed on the STA 1140 and STA 1180 tension ties.
-1
747-400/-400D airplanes that have not been modified by Boeing to
Boeing Converted Freighter (BCF) configuration. These airplanes
have stow bin support fittings installed on the STA 1180 tension tie.
-2
747-300 airplanes that have been modified by Boeing to SF
configuration. These airplanes have stow bin support fittings installed
on the STA 1140 and STA 1180 tension ties.
-3
747-400 airplanes that have been modified by Boeing to BCF
configuration as of 4/15/2011. These airplanes have stow bin support
fittings installed on the STA 1180 tension tie.
-4
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DESCRIPTIONCONFIGURATIONGROUP
747-200B airplanes that were modified by Boeing to Stretched Upper
Deck configuration, then subsequently modified by Boeing to SF
configuration. These airplanes have stow bin support fittings installed
on the STA 1140 and STA 1180 tension ties.
-5
Airplane Models:
747-100B SUD, 747-200B, 747-300, 747-400, 747-400D
GroupVariable Number
1RD381 - RD383
5RD601 - RD602
1RD603 - RD607
1RD721 - RD722
2RF001 - RF006
2RM001 - RM007
2RM010 - RM013
2RM021 - RM024
2RM026 - RM030
2RM036 - RM045
2RM051 - RM053
2RM071
2RM081 - RM084
2RM091
2RM096 - RM097
2RM116 - RM117
2RM126 - RM127
4RM128
2RM129 - RM132
2RM136 - RM147
2RM156 - RM158
2RM166 - RM177
2RM191 - RM192
2RM231 - RM233
2RM241 - RM246
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GroupVariable Number
2RM261 - RM264
2RM316 - RM318
2RM331 - RM333
2RM341
2RM351 - RM355
2RM366 - RM367
2RM401 - RM403
2RM426
2RM431
2RM441 - RM443
2RM445
2RM801 - RM803
2RM811 - RM813
1RS001 - RS002
1RS201
1RS211 - RS212
1RS221 - RS222
1RS231 - RS241
1RS251 - RS259
1RS263
1RS265 - RS268
1RS271 - RS276
1RS291 - RS292
1RS301 - RS306
1RS311 - RS320
1RS331 - RS333
1RS341 - RS342
1RS699
1RS701 - RS703
1RS711 - RS713
3RS721 - RS722
1RS731 - RS732
3RS741
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GroupVariable Number
1RS742
3RS743
1RS751 - RS752
1RS761
3RS762
3RS771
1RS781 - RS782
3RS786
2RT001 - RT014
4RT021 - RT022
4RT031 - RT033
2RT034 - RT035
2RT041 - RT047
2RT061
4RT071 - RT072
2RT073 - RT074
4RT075
2RT101 - RT103
2RT121
2RT131 - RT137
2RT151 - RT152
4RT161
2RT162 - RT163
4RT164
2RT165 - RT168
2RT401 - RT412
2RT431 - RT447
2RT451 - RT455
4RT456
2RT457 - RT460
4RT461
2RT462 - RT469
2RT471 - RT499
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GroupVariable Number
4RT501
2RT502 - RT505
4RT506 - RT510
2RT511 - RT512
4RT513
2RT514 - RT515
4RT516
2RT517
4RT518 - RT520
2RT521 - RT523
4RT524
2RT525 - RT527
4RT528
2RT529 - RT535
2RT551 - RT568
2RT571
4RT572 - RT579
2RT580 - RT591
2RT601 - RT630
2RT633 - RT641
4RT642
2RT643 - RT654
4RT655 - RT657
2RT671 - RT673
2RT681 - RT682
2RT691 - RT699
2RT701 - RT704
2RT711 - RT717
2RT741 - RT750
4RT751 - RT752
2RT753 - RT757
2RT776 - RT777
4RT781 - RT782
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GroupVariable Number
2RT783 - RT784
2RT801 - RT803
2RT811 - RT814
2RT831 - RT836
4RT837
2RT861 - RT864
2RT877 - RT880
2RT931 - RT932
2RT945 - RT949
2RT951 - RT955
2RT966
4RT967
2RU001 - RU006
2RU016 - RU017
2RU031 - RU032
2RU051 - RU052
2RU059 - RU062
2RU081 - RU083
2RU101 - RU102
2RU121 - RU132
2RU801 - RU809
2RU831 - RU841
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
This service bulletin gives instructions for modification of upper deck tension ties and adjacent frame
structure on stretched upper deck (SUD) airplanes. The tension ties have been determined to be
structure that is susceptible to Widespread Fatigue Damage (WFD). WFD can cause tension ties to
become severed or disconnected from the frames. Severed or disconnected Tension Ties and/or
Frames at multiple locations could result in rapid in-flight decompression.
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For more information about WFD, refer to Boeing Service Letter 747-SL-53-088A.
Service Bulletin 747-53A2507 recommends initial and repeat inspection of SUD airplane tension ties
from body station (STA) 1120 to STA 1220. Service Bulletin 747-53A2507 was issued to address
multiple reports of cracks found in tension ties and adjacent frame structure. Accomplishment of the
modification in this service bulletin terminates the repeat inspection requirement of Service Bulletin
747-53A2507.
Federal Aviation Administration (FAA) Airworthiness Directive 2007-23-18 is related to Service Bulletin
747-53A2507.
Additionally, for airplanes that have not already terminated the repeat inspection requirement of Service
Bulletin 747-53A2610 "FUSELAGE - Main Frame - Center Section - Tension Tie Inspection, Repair,
and Modification - Stretched Upper Deck (SUD) Special Freighters", accomplishment of the modification
given in this service bulletin terminates the repeat inspection requirement of Service Bulletin
747-53A2610 for the modified areas.
Federal Aviation Administration (FAA) Airworthiness Directive 2007-16-19 is related to Service Bulletin
747-53A2610.
Boeing Service Related Problem (SRP) 747-SRP-53-0215 is related to this service bulletin.
Revision 1 - No more work is necessary on airplanes changed in accordance with the original issue of
this service bulletin.
D. Description
Get access to the Frame to Tension Tie joints at STA 1120 through STA 1220. At each station,
disconnect and remove a section of the tension tie between the frame and approximate Buttock Line
(BL) 36. For each frame, remove a specified section of the frame above and below the tension tie
attach point. After the existing frame and tension tie structure has been removed and discarded, install
new frame and tension tie structure. Do the modification on both sides of the airplane.
After modification, do initial and repeat detailed inspections of the modified tension ties and the modified
frame structure at the compliance times specified in paragraph 1.E., Compliance.
Revision 1 is sent to correct the service bulletin figure that is called out for Group 1-2 modification at
STA 1140, change the washers that are required at BACB30US bolt locations, correct refinish instructions
for aluminum and steel parts, and revise the top kit for Group 4 airplanes. Several other changes have
also been made. A detailed list of changes is given in the Revision Transmittal Sheet section of Revision
1.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones
ZoneModel
243, 244747-100B SUD, 747-200B, 747-
300
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Group 2:
Affected Maintenance Zones
ZoneModel
243, 244747-400, 747-400D
Group 3:
Affected Maintenance Zones
ZoneModel
243, 244747-300
Group 4:
Affected Maintenance Zones
ZoneModel
243, 244747-400
Group 5:
Affected Maintenance Zones
ZoneModel
243, 244747-200B
E. Compliance
Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2009-NM-024-AD is
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.
Federal Aviation Administration (FAA) Airworthiness Directives 2004-07-22 R1, 2007-16-19, and
2007-23-18 are related to this service bulletin.
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Table 1: Tension Tie and Frame - Modification and Post-Modification Inspections
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 3,000
flight cycles af-
ter the original
issue date of
this service bul-
letin
Before 17,000 to-
tal flight cycles
Do the tension tie and frame
structure modification from STA
1120 to STA 1220 as given in the
Accomplishment Instructions,
paragraph 3.B., Part 1
All airplanes
-Within 1,000
flight cycles af-
ter the original
issue date of
this service bul-
letin
Before 8,000
flight cycles after
modification as
given in the Ac-
complishment In-
structions, para-
graph 3.B., Part
1
Do a detailed inspection of the
entire tension tie and the modified
frame structure from STA 1120 to
STA 1220 for cracks as given in
the Accomplishment Instructions,
paragraph 3.B., Part 2
(a)
3,000 flight cycles--Repeat the detailed inspection of
the tension tie and frame struc-
ture from STA 1120 to STA 1220
for cracks as given in the Accom-
plishment Instructions, paragraph
3.B., Part 2
No crack found
(a)
-Before further flightContact Boeing for repair instruc-
tions, and do the repair
Any crack found
3,000 flight cycles--Repeat the detailed inspection of
the tension tie and frame struc-
ture from STA 1120 to STA 1220
for cracks as given in the Accom-
plishment Instructions, paragraph
3.B., Part 2
(a)
-Within 1,000
flight cycles af-
ter the original
issue date of
this service bul-
letin
Before 14,000
flight cycles after
modification as
given in the Ac-
complishment In-
structions, para-
graph 3.B., Part
1
Contact Boeing for additional
modification requirements
All airplanes
(a) These inspections are required only after the modification has been accomplished. Inspections before
modification should be done in accordance with Service Bulletin 747-53A2507.
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F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified
in this service bulletin comply with the applicable regulations and are FAA approved, as well as European
Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved
airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on
the airplane in its original Boeing delivery configuration or as modified by other approved Boeing
changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected
by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval
before incorporating this service bulletin.
This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle ACO
approves the accomplishment of the modification procedures with corresponding compliance times
specified in Table 1 under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2559, Revision
1, as an alternative method of compliance (AMOC) to the corresponding inspection and repair
requirements of paragraphs (h), (i), and (j) of FAA AD 2004-07-22 R1, for the inspection of Structural
Significant Item (SSI) F-19A of Supplemental Structural Inspection Document (SSID) D6-35022, Revision
G, dated December 2000. This AMOC only applies to the areas modified as given in this service bulletin.
When this service bulletin specifies contacting Boeing for repair instructions, the repair instructions
must be approved by the FAA in accordance with paragraph (l) of the AD. All provisions of AD
2004-07-22 R1 that are not specifically referenced in this paragraph remain fully applicable and must
be complied with.
The Manager of the FAA Seattle ACO also approves the modification procedures with the corresponding
compliance times specified in Table 1 under paragraph 1.E., "Compliance", of Service Bulletin
747-53A2559, Revision 1, as an AMOC to the inspection and corrective action requirements with
corresponding compliance times required by paragraphs (f), (g), (h), and (i) of AD 2007-23-18. This
AMOC only applies to the areas modified as given in this service bulletin. When this service bulletin
specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA
in accordance with paragraph (l) of the AD. All provisions of AD 2007-23-18 that are not specifically
referenced in this paragraph remain fully applicable and must be complied with.
The Manager of the FAA Seattle ACO also approves the modification procedures with the corresponding
compliance times specified in Table 1 under paragraph 1.E., "Compliance", of Service Bulletin
747-53A2559, Revision 1, as an AMOC to the inspection and corrective action requirements with the
corresponding compliance times specified in paragraph 1.E., "Compliance", of Service Bulletin
747-53A2610, dated May 10, 2007, required by paragraph (f) of AD 2007-16-19. This AMOC only
applies to the areas modified in accordance with this service bulletin. When this service bulletin specifies
contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in
accordance with paragraph (j) of the AD. All provisions of AD 2007-16-19 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 the modification and
post-modification 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:
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— Time to adjust to the workplace
— Time to schedule the work
— Time to inspect the work
— Time to cure the materials
— Time to make the parts
— Time to find the tools.
Elapsed HoursTask HoursNumber of Per-
sons
Task
3.256.502Access
4.759.502Restoration
8.0016.00TOTAL FOR EACH AIRPLANE
Group 1-2:
Shear Panel Removal/Installation
Elapsed HoursTask HoursNumber of Per-
sons
Task
---Remove Shear Panels
2.505.002Figure 1
2.505.002Figure 2
---Install Shear Panels
2.505.002Figure 47
2.505.002Figure 48
10.0020.00TOTAL FOR EACH AIRPLANE
Group 1-2:
STA 1120 Modification
Elapsed HoursTask HoursNumber of Per-
sons
Task
---STA 1120 Modification - Left Side
3.006.002Figure 3
6.0012.002Figure 5
2.505.002Figure 7
---STA 1120 Modification - Right Side
3.006.002Figure 4
6.0012.002Figure 6
2.505.002Figure 8
23.0046.00TOTAL FOR EACH AIRPLANE
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Group 3-5:
STA 1120 Modification
Elapsed HoursTask HoursNumber of Per-
sons
Task
---STA 1120 Modification - Left Side
3.006.002Figure 49
6.0012.002Figure 51
2.254.502Figure 53
---STA 1120 Modification - Right Side
3.006.002Figure 50
6.0012.002Figure 52
2.254.502Figure 54
22.5045.00TOTAL FOR EACH AIRPLANE
Group 1:
STA 1140 Modification
Elapsed HoursTask HoursNumber of Per-
sons
Task
---STA 1140 Modification - Left Side
3.757.502Figure 11
6.0012.002Figure 13
3.006.002Figure 17
---STA 1140 Modification - Right Side
3.757.502Figure 12
6.0012.002Figure 14
3.006.002Figure 18
25.5051.00TOTAL FOR EACH AIRPLANE
Group 2:
STA 1140 Modification
Elapsed HoursTask HoursNumber of Per-
sons
Task
---STA 1140 Modification - Left Side
3.507.002Figure 9
6.0012.002Figure 13
2.505.002Figure 15
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Group 2:
STA 1140 Modification
Elapsed HoursTask HoursNumber of Per-
sons
Task
---STA 1140 Modification - Right Side
3.507.002Figure 10
6.0012.002Figure 14
2.505.002Figure 16
24.0048.00TOTAL FOR EACH AIRPLANE
Group 3, 5:
STA 1140 Modification
Elapsed HoursTask HoursNumber of Per-
sons
Task
---STA 1140 Modification - Left Side
3.757.502Figure 11
6.0012.002Figure 55
2.505.002Figure 57
---STA 1140 Modification - Right Side
3.757.502Figure 12
6.0012.002Figure 56
2.505.002Figure 58
24.5049.00TOTAL FOR EACH AIRPLANE
Group 4:
STA 1140 Modification
Elapsed HoursTask HoursNumber of Per-
sons
Task
---STA 1140 Modification - Left Side
3.507.002Figure 9
6.0012.002Figure 55
2.505.002Figure 85
---STA 1140 Modification - Right Side
3.507.002Figure 10
6.0012.002Figure 56
2.505.002Figure 86
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Group 4:
STA 1140 Modification
Elapsed HoursTask HoursNumber of Per-
sons
Task
24.5049.00TOTAL FOR EACH AIRPLANE
Group 1-2:
STA 1160 Modification
Elapsed HoursTask HoursNumber of Per-
sons
Task
---STA 1160 Modification - Left Side
3.006.002Figure 19
6.0012.002Figure 21
2.254.502Figure 23
---STA 1160 Modification - Right Side
3.006.002Figure 20
6.0012.002Figure 22
2.254.502Figure 24
22.5045.00TOTAL FOR EACH AIRPLANE
Group 3-5:
STA 1160 Modification
Elapsed HoursTask HoursNumber of Per-
sons
Task
---STA 1160 Modification - Left Side
3.006.002Figure 59
6.0012.002Figure 61
2.254.502Figure 63
---STA 1160 Modification - Right Side
3.006.002Figure 60
6.0012.002Figure 62
2.254.502Figure 64
22.5045.00TOTAL FOR EACH AIRPLANE
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STA 1180 Modification
Elapsed HoursTask HoursNumber of Per-
sons
Task
---STA 1180 Modification - Left Side
3.006.002Figure 27
4.509.002Figure 29
3.006.002Figure 33
---STA 1180 Modification - Right Side
3.006.002Figure 28
4.509.002Figure 30
3.006.002Figure 34
21.0042.00TOTAL FOR EACH AIRPLANE
Group 1-2:
STA 1200 Modification
Elapsed HoursTask HoursNumber of Per-
sons
Task
---STA 1200 Modification - Left Side
2.505.002Figure 35
4.759.502Figure 37
2.254.502Figure 39
---STA 1200 Modification - Right Side
2.505.002Figure 36
4.759.502Figure 38
2.254.502Figure 40
19.0038.00TOTAL FOR EACH AIRPLANE
Group 3-5:
STA 1200 Modification
Elapsed HoursTask HoursNumber of Per-
sons
Task
---STA 1200 Modification - Left Side
2.505.002Figure 65
4.759.502Figure 67
2.254.502Figure 69
---STA 1200 Modification - Right Side
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Group 3-5:
STA 1200 Modification
Elapsed HoursTask HoursNumber of Per-
sons
Task
2.505.002Figure 66
4.759.502Figure 68
2.254.502Figure 70
19.0038.00TOTAL FOR EACH AIRPLANE
Group 1-2:
STA 1220 Modification
Elapsed HoursTask HoursNumber of Per-
sons
Task
---STA 1220 Modification - Left Side
4.258.502Figure 41
4.509.002Figure 43
2.254.502Figure 45
---STA 1220 Modification - Right Side
4.258.502Figure 42
4.509.002Figure 44
2.254.502Figure 46
22.0044.00TOTAL FOR EACH AIRPLANE
Group 3-4:
STA 1220 Modification
Elapsed HoursTask HoursNumber of Per-
sons
Task
---STA 1220 Modification - Left Side
3.757.502Figure 71
4.509.002Figure 73
2.254.502Figure 75
---STA 1220 Modification - Right Side
3.757.502Figure 72
4.509.002Figure 74
2.254.502Figure 76
21.0042.00TOTAL FOR EACH AIRPLANE
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Group 5:
STA 1220 Modification
Elapsed HoursTask HoursNumber of Per-
sons
Task
---STA 1220 Modification - Left Side
4.258.502Figure 77
4.509.002Figure 73
3.006.002Figure 79
---STA 1220 Modification - Right Side
4.258.502Figure 78
4.509.002Figure 74
3.006.002Figure 80
23.5047.00TOTAL FOR EACH AIRPLANE
Group 1-2:
Post-Modification Inspection
Elapsed HoursTask HoursNumber of Per-
sons
Task
---Inspection - Left Side
1.503.002Figure 81
---Inspection - Right Side
1.503.002Figure 82
3.006.00TOTAL FOR EACH AIRPLANE
Group 3-5:
Post-Modification Inspection
Elapsed HoursTask HoursNumber of Per-
sons
Task
---Inspection - Left Side
1.503.002Figure 83
---Inspection - Right Side
1.503.002Figure 84
3.006.00TOTAL FOR EACH AIRPLANE
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H. Weight and Balance Changes
Group 1-2:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+28515.2+25.46STA 1120 modification
+26824.2+23.53STA 1140 modification
+22121.2+19.07STA 1160 modification
+22054.2+18.69STA 1180 modification
+23580.0+19.65STA 1200 modification
+20935.2+17.16STA 1220 modification
+144030.0+123.56TOTAL FOR EACH AIRPLANE
Group 3-4:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+30755.2+27.46STA 1120 modification
+26345.4+23.11STA 1140 modification
+31818.8+27.43STA 1160 modification
+22054.2+18.69STA 1180 modification
+30900.0+25.75STA 1200 modification
+34623.6+28.38STA 1220 modification
+176497.2+123.56TOTAL FOR EACH AIRPLANE
Group 5:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+28515.2+25.46STA 1120 modification
+26824.2+23.53STA 1140 modification
+22121.2+19.07STA 1160 modification
+22054.2+18.69STA 1180 modification
+23580.0+19.65STA 1200 modification
+39759.8+32.59STA 1220 modification
+181633.4+155.03TOTAL FOR EACH AIRPLANE
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I. Electrical Load Data
Not changed.
J. References
1. Existing Data:
a. 747-100/200/300 Aircraft Maintenance Manual (AMM) 24-22-00, 25-14-02, 25-22-04, 25-25-01
b. 747-100/200/300 Structural Repair Manual (SRM) 51-10-01
c. 747-400 Aircraft Maintenance Manual (AMM) 24-22-00, 25-14-02, 25-22-04, 25-25-01
d. 747-400 Structural Repair Manual (SRM) 51-10-02
e. 747 Non-Destructive Testing (NDT) Manual, Part 6, Chapter 51-00-00, Figure 1, 11, or 16
f. Boeing Service Related Problem (SRP) 747-SRP-53-0215
g. Boeing Service Bulletin 747-53A2507 "FUSELAGE - Stretched Upper Deck Frame and Tension
Tie - Inspection and Repair"
h. Boeing Service Bulletin 747-53A2610 "FUSELAGE - Main Frame - Center Section - Tension
Tie Inspection, Repair, and Modification - Stretched Upper Deck (SUD) Special Freighters"
i. Boeing Service Letter 747-SL-53-088A
j. FAA Airworthiness Directives 2004-07-22 R1, 2007-16-19, and 2007-23-18
k. Standard Overhaul Practices Manual (SOPM) 20-41-01, 20-41-02, 20-41-05, 20-43-03
l. Federal Aviation Administration (FAA) Notice of Proposed Rule Making (NPRM)
2009-NM-024-AD
2. Data supplied with this Service Bulletin:
a. Drawings:
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### Page 32

ADCNDCN/REVSheetTitleDrawing No
--1FUSELAGE - STRETCHED UPPER DECK
TENSION TIE MODIFICATION
624U0065
-A10
--11
-A12
--13
--14
--15
-A16
--19
-A2
--20
--21
--22
--23
--24
--25
--26
--27
--28
--29
--3
--30
--31
--32
--33
--34
--35
--36
--37
--38
--39
--4
-A40
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### Page 33

ADCNDCN/REVSheetTitleDrawing No
41 - -
--42
--43
-A44
--45
--46
--47
-A48
--49
--5
--50
--51
--52
--53
-A54
-A6
--7
--8
--9
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
Fuselage - Stretched Upper Deck Tension Tie Modification144U0061
These drawings were used to prepare this service bulletin. These drawings are not necessary to
make the specified changes, and are not supplied with this service bulletin. These drawings may
not be applicable to all airplane configurations or operators.
K. Publications Affected
1. Publications:
None.
2. Damage Tolerance Based Structural Inspections:
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### Page 34

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.
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### 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. Operators
are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin.
The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.
Prices are in United States Dollars. Terms: Net 30 days.
Reference this service bulletin and submit your purchase order by one of these methods:
1. Order on-line via ATA Spec 2000 or The Boeing PART Page
2. Fax to (206) 662-7145
REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST
RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE
INFORMATION.
Group 1:
Unit Price as of
the Revision 1
date of this Ser-
vice Bulletin (US
Dollars)
ROLT as of the
Revision 1 date of
this Service Bul-
letin (Calendar
Days)
QTYDateNameKit Number
$576,584.006694Nov 27/07TOPKIT - TENSION
TIE MODIFICATION -
STRETCHED UPPER
DECK - (Passenger)
015U1803-2
Group 2:
Unit Price as of
the Revision 1
date of this Ser-
vice Bulletin (US
Dollars)
ROLT as of the
Revision 1 date of
this Service Bul-
letin (Calendar
Days)
QTYDateNameKit Number
$576,584.006694Nov 27/07TOPKIT - TENSION
TIE MODIFICATION -
STRETCHED UPPER
DECK - (Passenger)
015U1803-3
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### Page 36

Group 3:
Unit Price as of
the Revision 1
date of this Ser-
vice Bulletin (US
Dollars)
ROLT as of the
Revision 1 date of
this Service Bul-
letin (Calendar
Days)
QTYDateNameKit Number
$534,693.00669--TOPKIT - TENSION
TIE MODIFICATION -
STRETCHED UPPER
DECK - (-300 Special
Freighter)
015U1803-42
Group 4:
Unit Price as of
the Revision 1
date of this Ser-
vice Bulletin (US
Dollars)
ROLT as of the
Revision 1 date of
this Service Bul-
letin (Calendar
Days)
QTYDateNameKit Number
(a)(a)(a)(a)TOPKIT - TENSION
TIE MODIFICATION -
STRETCHED UPPER
DECK - (-400 Boeing
Converted Freighter)
015U1803-43
$534,693.00669--TOPKIT - TENSION
TIE MODIFICATION -
STRETCHED UPPER
DECK - (-400 Boeing
Converted Freighter)
015U1803-53
(a) 015U1803-43 topkit is no longer available. If 015U1803-43 topkit has been purchased, then the supple-
mental parts identified in paragraph 2.C.2., "Parts and Materials Supplied by the Operator" are necessary.
Group 5:
Unit Price as of
the Revision 1
date of this Ser-
vice Bulletin (US
Dollars)
ROLT as of the
Revision 1 date of
this Service Bul-
letin (Calendar
Days)
QTYDateNameKit Number
$537,244.00669--TOPKIT - TENSION
TIE MODIFICATION -
STRETCHED UPPER
DECK - (-200B Special
Freighter)
015U1803-55
NOTE: Due to the limited number of kits available and the long ROLT, Boeing recommends that
operators submit purchase orders 18 months in advance of performing the modification.
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### Page 37

B. Industry Support Information
Boeing warranty remedies are not available for the inspection or modification procedures given in this
service bulletin.
C. Parts Necessary For Each Airplane
1. Kits/Parts:
NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by
the Operator, are necessary for each airplane. The Top Kit is divided into Figure kits for
each installation figure shown in the table below.
To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
Figure Kit
876521Top Kit
111111015U1803-2
111111015U1803-3
------015U1803-42
------015U1803-53
------015U1803-55
Figure Kit
181716151413Top Kit
11--11015U1803-2
--1111015U1803-3
------015U1803-42
------015U1803-53
------015U1803-55
Figure Kit
302924232221Top Kit
111111015U1803-2
111111015U1803-3
11----015U1803-42
11----015U1803-53
11----015U1803-55
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### Page 38

Figure Kit
403938373433Top Kit
111111015U1803-2
111111015U1803-3
----11015U1803-42
----11015U1803-53
----11015U1803-55
Figure Kit
484746454443Top Kit
111111015U1803-2
111111015U1803-3
------015U1803-42
------015U1803-53
------015U1803-55
Figure Kit
565554535251Top Kit
------015U1803-2
------015U1803-3
111111015U1803-42
111111015U1803-53
111111015U1803-55
Figure Kit
646362615857Top Kit
------015U1803-2
------015U1803-3
111111015U1803-42
1111--015U1803-53
111111015U1803-55
Figure Kit
747370696867Top Kit
------015U1803-2
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### Page 39

Figure Kit
747370696867Top Kit
------015U1803-3
111111015U1803-42
111111015U1803-53
111111015U1803-55
Figure Kit
868580797675Top Kit
------015U1803-2
------015U1803-3
----11015U1803-42
11--11015U1803-53
--11--015U1803-55
Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
876521
QTY
FLAT DOUBLER11144U0062-11
FLAT TRIPLER11144U0062-12
ALUMINUM
STRAP
1144U0062-13
ALUMINUM
STRAP
1144U0062-14
STEEL STRAP11144U0062-15
STEEL STRAP11144U0062-16
STEEL STRAP11144U0062-17
FILLER11144U0062-18
FILLER11144U0062-7
STRAP11144U0062-8
REPLACEMENT
FRAME SECTION
1144U0063-1
LOWER SPLICE
ANGLE
1144U0063-10
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### Page 40

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
876521
QTY
STIFFENER11144U0063-11
FWD SHEAR TIE,
S-10 TO S-10A
11144U0063-12
AFT SHEAR TIE,
S-10 TO S-10A
11144U0063-13
FWD SHEAR TIE,
S-10A TO S-11
11144U0063-14
AFT SHEAR TIE,
S-10A TO S-11
11144U0063-15
FAILSAFE CHORD
SPLICE
11144U0063-16
REPLACEMENT
CHORD
1144U0063-19
REPLACEMENT
FRAME SECTION
1144U0063-2
REPLACEMENT
CHORD
1144U0063-20
STIFFENER11144U0063-21
STIFFENER11144U0063-22
ANGLED DOU-
BLER #1
1144U0063-3
ANGLED DOU-
BLER #1
1144U0063-4
ANGLED DOU-
BLER #2
1144U0063-5
ANGLED DOU-
BLER #2
1144U0063-6
TENSION TIE
SPLICE
22144U0063-69
LOWER SPLICE
ANGLE
1144U0063-9
SHEAR TIE TEE,
S-7 TO S-8
11144U0064-1
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### Page 41

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
876521
QTY
SHEAR TIE TEE,
S-8 TO S-9
11144U0064-2
SHEAR TIE TEE,
S-9 TO S-10
11144U0064-4
REPLACEMENT
SPLICE TEE, S-11
TO S-12
11144U0064-5
STRINGER CLIP
TEE
22144U0064-6
TENSION TIE
STOCK SEGMENT
22144U0064-66
STRINGER CLIP
TEE
22144U0064-7
STRINGER CLIP
TEE
33144U0064-8
STRINGER CLIP
TEE
33144U0064-9
BOLT, 100 DEG
HEX DR
1313BACB30NW6K5X
BOLT-CSK. HEAD11BACB30NW6K9
HEX DRIVE BOLT1155BACB30NX6K10
BOLT44BACB30NX6K11
BOLT, PROTRUD-
ING HD
11BACB30NX6K12
BOLT, PROTRUD-
ING HD
2424BACB30NX6K3
BOLT, PROTRUD-
ING HD
33BACB30NX6K3X
BOLT, PROTRUD-
ING HD
2423BACB30NX6K4
BOLT, PROTRUD-
ING HD
1717BACB30NX6K4X
BOLT, PROTRUD-
ING HD
22BACB30NX6K4Y
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### Page 42

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
876521
QTY
BOLT5555BACB30NX6K5
BOLT, PROTRUD-
ING HD
1011BACB30NX6K5X
BOLT667474BACB30NX6K6
BOLT, PROTRUD-
ING HD
44BACB30NX6K6X
BOLT, PROTRUD-
ING HD
1111BACB30NX6K6Y
HI-LOK113737BACB30NX6K7
BOLT, PROTRUD-
ING HD
1010BACB30NX6K7X
BOLT, PROTRUD-
ING HD
2323BACB30NX6K8
BOLT, PROTRUD-
ING HD
34BACB30NX6K8Y
BOLT77BACB30NX6K9
BOLT, PROTRUD-
ING HD
11BACB30NX6K9X
HI-LOK5151BACB30NX8K3
HI-LOK3737BACB30NX8K4
HI LOK2626BACB30NX8K5
BOLT55BACB30NX8K6
BOLT, HEX DRIVE1414BACB30NX8K7
BOLT55BACB30US3K13Y
BOLT11BACB30US3K14Y
BOLT11BACB30US3K16Y
BOLT11BACB30US3K17Y
BOLT, 12 PT
HEAD
66BACB30US4K14
BOLT, 12 PT
HEAD
33BACB30US4K15
BOLT3031BACB30VT6K5
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### Page 43

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
876521
QTY
BOLT1516BACB30VT6K6
COLLAR1515BACC30AC6
COLLAR99289289BACC30BH6
COLLAR133133BACC30BH8
COLLAR4444BACC30BL6
COLLAR1414BACC30M6
FILLER11BACF3F009E020NN
FILLER11BACF3F010L036NN
FILLER, FLAT11BACF3F010T019NN
FILLER, RECTAN-
GULAR
11BACF3H09JH051HN
TAPERED FILLER44BACF3T01A10-40
SELF-LOCKING
NUT
44BACN10HR3CD
NUT66BACN10HR4CD
RIVET, UNIVER-
SAL HD
1111BACR15BB6AD4C
RIVET, UNIVER-
SAL HD
2121BACR15FT5D4C
RIVET, UNIVER-
SAL HD
2121BACR15FT5D5C
RIVET, UNIVER-
SAL HD
1313BACR15FT6D4C
RIVET1313BACR15FT6D5C
RIVET1111BACR15GF6D5
RIVET, 100 DEG4242BACR15GF6D9
RIVET, 100 DEG1313BACR15GF8D9
SHIM, LAMINAT-
ED
22BACS40R008A036F
SHIM, LAMINAT-
ED
44BACS40R008B051F
WASHER, PLAIN44BACW10BP32CD
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### Page 44

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
876521
QTY
WASHER, PLAIN66BACW10BP32DP
WASHER44BACW10BP32NDP
WASHER66BACW10BP4CD
WASHER99BACW10BP4DP
WASHER66BACW10BP4NDP
Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
222118171413
QTY
DOUBLER11144U0062-21
DOUBLER11144U0062-22
STRUCTURAL
STRAP
11144U0062-23
FILLER11144U0062-24
STRAP1144U0062-25
STRAP1144U0062-26
STRAP11144U0062-27
STRAP11144U0062-28
STRAP11144U0062-29
REINFORCING
STRAP
11144U0062-30
REINFORCING
STRAP
11144U0062-31
RADIUS STRAP11144U0062-32
SPACER11144U0062-33
REPLACEMENT
DOUBLER SEC-
TION
11144U0062-34
FILLER11144U0062-47
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### Page 45

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
222118171413
QTY
STRAP11144U0062-48
FILLER11144U0062-50
FLAT DOUBLER11144U0062-51
FLAT TRIPLER11144U0062-52
STRAP11144U0062-70
FAILSAFE CHORD
SPLICE
11144U0063-16
STIFFENER22144U0063-21
STIFFENER22144U0063-22
FWD SHEAR TIE,
S-10 TO S-10A
11144U0063-25
AFT SHEAR TIE,
S-10 TO S-10A
11144U0063-26
FWD SHEAR TIE,
S-10A TO S-11
11144U0063-27
AFT SHEAR TIE,
S-10A TO S-11
11144U0063-28
DOUBLER1144U0063-29
DOUBLER1144U0063-30
REPLACEMENT
FAILSAFE CHORD
11144U0063-31
TENSION TIE
SPLICE
22144U0063-32
STIFFENER22144U0063-33
REINFORCING
ANGLE
1144U0063-35
REINFORCING
ANGLE
1144U0063-36
REPLACEMENT
FRAME SECTION
1144U0063-37
REPLACEMENT
FRAME SECTION
1144U0063-38
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### Page 46

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
222118171413
QTY
REPLACEMENT
FRAME SECTION
1144U0063-41
REPLACEMENT
FRAME SECTION
1144U0063-42
ANGLED DOU-
BLER #1
1144U0063-43
ANGLED DOU-
BLER #1
1144U0063-44
ANGLED DOU-
BLER #2
1144U0063-45
ANGLED DOU-
BLER #2
1144U0063-46
AFT SHEAR TIE,
S-10A TO S-11
11144U0063-51
AFT SHEAR TIE,
S-10 TO S-10A
11144U0063-52
FWD SHEAR TIE,
S-10A TO S-11
11144U0063-53
FWD SHEAR TIE,
S-10 TO S-10A
11144U0063-54
REPLACEMENT
CHORD
1144U0063-55
REPLACEMENT
CHORD
1144U0063-56
LOWER SPLICE
ANGLE
1144U0063-57
LOWER SPLICE
ANGLE
1144U0063-58
TENSION TIE
SEGMENT STOCK
22144U0064-23
STRINGER CLIP
TEE
55144U0064-25
STRINGER CLIP
TEE
55144U0064-26
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### Page 47

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
222118171413
QTY
SHEAR TIE TEE,
S-8 TO S-9
11144U0064-27
SHEAR TIE TEE,
S-9 TO S-10
11144U0064-28
SHEAR TIE TEE,
S-7 TO S-8
11144U0064-41
SHEAR TIE TEE,
S-8 TO S-9
11144U0064-42
SHEAR TIE TEE,
S-9 TO S-10
11144U0064-43
REPLACEMENT
SPLICE TEE, S-11
TO S-12
1144U0064-45
REPLACEMENT
SPLICE TEE, S-11
TO S-12
1144U0064-46
STRINGER CLIP
TEE
44144U0064-6
STRINGER CLIP
TEE
44144U0064-7
STRINGER CLIP
TEE
22144U0064-8
STRINGER CLIP
TEE
22144U0064-9
BOLT, 100 DEG
HEX DR
1313BACB30NW6K7X
HEX DRIVE BOLT441919BACB30NX6K10
BOLT, PROTRUD-
ING HD
1111BACB30NX6K10X
BOLT, PROTRUD-
ING HD
11BACB30NX6K10Y
BOLT3344BACB30NX6K11
BOLT, PROTRUD-
ING HD
11BACB30NX6K11X
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### Page 48

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
222118171413
QTY
BOLT, PROTRUD-
ING HD
33BACB30NX6K11Y
BOLT, PROTRUD-
ING HD
1144BACB30NX6K12
BOLT, PROTRUD-
ING HD
33BACB30NX6K12Y
BOLT, PROTRUD-
ING HD
33BACB30NX6K2X
BOLT, PROTRUD-
ING HD
23231818BACB30NX6K3
BOLT, PROTRUD-
ING HD
4433BACB30NX6K3X
BOLT, PROTRUD-
ING HD
30301515BACB30NX6K4
BOLT, PROTRUD-
ING HD
19194141BACB30NX6K4X
BOLT, PROTRUD-
ING HD
2222BACB30NX6K4Y
BOLT383811BACB30NX6K5
BOLT, PROTRUD-
ING HD
121345BACB30NX6K5X
BOLT, PROTRUD-
ING HD
33BACB30NX6K5Y
BOLT93945151BACB30NX6K6
BOLT, PROTRUD-
ING HD
3411BACB30NX6K6X
BOLT, PROTRUD-
ING HD
141422BACB30NX6K6Y
HI-LOK32327676BACB30NX6K7
BOLT, PROTRUD-
ING HD
8833BACB30NX6K7X
BOLT, PROTRUD-
ING HD
1133BACB30NX6K7Y
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48 of 957
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### Page 49

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
222118171413
QTY
BOLT, PROTRUD-
ING HD
18181616BACB30NX6K8
BOLT, PROTRUD-
ING HD
22BACB30NX6K8Y
BOLT1415BACB30NX6K9
BOLT, PROTRUD-
ING HD
1111BACB30NX6K9X
BOLT, PROTRUD-
ING HD
3322BACB30NX6K9Y
BOLT, PROTRUD-
ING HD
5860BACB30NX8K2
HI-LOK1616BACB30NX8K3
HI-LOK3030BACB30NX8K4
BOLT, PROTRUD-
ING HD
11BACB30NX8K4X
HI LOK1212BACB30NX8K5
BOLT, PROTRUD-
ING HD
1188BACB30NX8K5X
BOLT45BACB30NX8K6
BOLT, HEX DRIVE1414BACB30NX8K7
BOLT, PROTRUD-
ING HD
11BACB30NX8K7X
BOLT1212BACB30NX8K8
BOLT33BACB30US3K14Y
BOLT11BACB30US3K15Y
BOLT, 12 PT
HEAD
22BACB30US4K10
BOLT, 12 PT
HEAD
55BACB30US4K11
BOLT, 12 PT
HEAD
23BACB30US4K12
BOLT, 12 PT
HEAD
12BACB30US4K13
BOEING PROPRIETARY -
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Original Issue: January 08, 2009
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49 of 957
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### Page 50

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
222118171413
QTY
BOLT, 12 PT
HEAD
33BACB30US4K14
BOLT1717BACB30VT6K5
BOLT2828BACB30VT6K6
HI-LOK2929BACB30VT6K7
COLLAR20201919BACC30AC6
COLLAR299299250250BACC30BH6
COLLAR111441461010BACC30BH8
COLLAR44443131BACC30BL6
COLLAR1313BACC30M6
FILLER11BACF3F010L036NN
FILLER, FLAT11BACF3F010M040NN
FILLER, RA-
DIUSED EDGE
1111BACF3H07RH010HN
FILLER, RECTAN-
GULAR
11BACF3H09JH053HN
TAPERED FILLER44BACF3T01A10-40
SELF-LOCKING
NUT
33BACN10HR3CD
NUT99BACN10HR4CD
RIVET, UNIVER-
SAL HD
13131111BACR15BB6AD4C
RIVET13131111BACR15GF6D5
RIVET, 100 DEG49493333BACR15GF6D8
RIVET, 100 DEG991313BACR15GF8D9
SHIM, LAMINAT-
ED
44BACS40R007B050F
SHIM, LAMINAT-
ED
22BACS40R008A036F
WASHER, PLAIN33BACW10BP32CD
WASHER, PLAIN55BACW10BP32DP
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Original Issue: January 08, 2009
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### Page 51

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
222118171413
QTY
WASHER33BACW10BP32NDP
WASHER99BACW10BP4CD
WASHER1212BACW10BP4DP
WASHER99BACW10BP4NDP
WASHER, PLAIN1111BACW10P168L
Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
343330292423
QTY
ALUMINUM
STRAP
1144U0062-53
ALUMINUM
STRAP
1144U0062-54
STEEL STRAP11144U0062-55
STEEL STRAP11144U0062-56
STEEL STRAP11144U0062-57
FILLER11144U0062-58
FLAT DOUBLER11144U0062-61
FILLER11144U0062-62
STEEL STRAP11144U0062-63
STEEL STRAP11144U0062-64
STEEL STRAP11144U0062-65
FILLER11144U0062-68
STRAP11144U0062-69
STRAP11144U0062-70
ALUMINUM
STRAP
1144U0062-71
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51 of 957
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### Page 52

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
343330292423
QTY
ALUMINUM
STRAP
1144U0062-72
FAILSAFE CHORD
SPLICE
22144U0063-16
TENSION TIE
SPLICE
22144U0063-32
REPLACEMENT
FRAME SECTION
1144U0063-61
REPLACEMENT
FRAME SECTION
1144U0063-62
ANGLED DOU-
BLER #1
1144U0063-63
ANGLED DOU-
BLER #1
1144U0063-64
ANGLED DOU-
BLER #2
1144U0063-65
ANGLED DOU-
BLER #2
1144U0063-66
REPLACEMENT
FAILSAFE CHORD
1144U0063-67
REPLACEMENT
FAILSAFE CHORD
1144U0063-68
TENSION TIE
SPLICE
22144U0063-69
TENSION TIE
SEGMENT STOCK
22144U0064-23
STRINGER CLIP
TEE
44144U0064-6
SHEAR TIE TEE,
S-8 TO S-9
11144U0064-61
SHEAR TIE TEE,
S-9 TO S-10
11144U0064-62
SHEAR TIE TEE,
S-10 TO S-11
11144U0064-63
BOEING PROPRIETARY -
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Original Issue: January 08, 2009
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52 of 957
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### Page 53

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
343330292423
QTY
REPLACEMENT
SPLICE TEE, S-11
TO S-12
11144U0064-65
TENSION TIE
STOCK SEGMENT
22144U0064-66
STRINGER CLIP
TEE
44144U0064-7
BOLT, 100 DEG
HEX DR
1313BACB30NW6K5X
BOLT, 100 DEG
HEX DR
11BACB30NW8K6X
BOLT, PROTRUD-
ING HD
2424BACB30NX6K3
BOLT, PROTRUD-
ING HD
1818BACB30NX6K4
BOLT, PROTRUD-
ING HD
1414BACB30NX6K4X
BOLT, PROTRUD-
ING HD
22BACB30NX6K4Y
BOLT9090BACB30NX6K5
BOLT, PROTRUD-
ING HD
1011BACB30NX6K5X
BOLT4242BACB30NX6K6
BOLT, PROTRUD-
ING HD
34BACB30NX6K6X
BOLT, PROTRUD-
ING HD
77BACB30NX6K6Y
BOLT, PROTRUD-
ING HD
88BACB30NX6K7X
BOLT, PROTRUD-
ING HD
2020BACB30NX6K8
BOLT, PROTRUD-
ING HD
33BACB30NX6K8X
BOLT, PROTRUD-
ING HD
66BACB30NX6K8Y
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 08, 2009
747-53A2559Revision 1: August 04, 2011
53 of 957
BOEING SERVICE BULLETIN 747-53A2559

### Page 54

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
343330292423
QTY
BOLT33BACB30NX6K9
BOLT, PROTRUD-
ING HD
22BACB30NX6K9X
BOLT, PROTRUD-
ING HD
16183738BACB30NX8K2
HI-LOK61613535BACB30NX8K3
HI-LOK26262626BACB30NX8K4
HI LOK26261010BACB30NX8K5
BOLT4545BACB30NX8K6
BOLT, HEX DRIVE14141414BACB30NX8K7
BOLT1212BACB30NX8K8
BOLT3423BACB30US3K11Y
BOLT22BACB30US3K14Y
BOLT12BACB30US3K15Y
BOLT11BACB30US3K16Y
BOLT, 12 PT
HEAD
5623BACB30US4K12
BOLT, 12 PT
HEAD
3466BACB30US4K13
BOLT4343BACB30VT6K5
COLLAR1414BACC30AC6
COLLAR237237BACC30BH6
COLLAR160162126126BACC30BH8
COLLAR4343BACC30BL6
COLLAR1313BACC30M6
COLLAR11BACC30M8
FILLER, RA-
DIUSED EDGE
1111BACF3H07RH010HN
SELF-LOCKING
NUT
3344BACN10HR3CD
NUT8888BACN10HR4CD
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 08, 2009
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54 of 957
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### Page 55

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
343330292423
QTY
RIVET, UNIVER-
SAL HD
99BACR15BB6AD4C
RIVET99BACR15GF6D5
RIVET, 100 DEG4848BACR15GF6D8
SHIM, LAMINAT-
ED
22BACS40R008B051F
SHIM,LAMINATED4522BACS40R008B052F
WASHER, PLAIN3344BACW10BP32CD
WASHER, PLAIN4466BACW10BP32DP
WASHER3344BACW10BP32NDP
WASHER8888BACW10BP4CD
WASHER12121010BACW10BP4DP
WASHER8888BACW10BP4NDP
WASHER, PLAIN1111BACW10P168L
Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
444340393837
QTY
FILLER11144U0062-107
FILLER11144U0062-108
FLAT DOUBLER11144U0062-110
STRAP11144U0062-111
FLAT DOUBLER11144U0062-81
FILLER11144U0062-89
STRAP11144U0062-90
ALUMINUM
STRAP
1144U0062-91
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 08, 2009
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55 of 957
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### Page 56

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
444340393837
QTY
ALUMINUM
STRAP
1144U0062-92
STEEL STRAP11144U0062-93
STEEL STRAP11144U0062-94
STEEL STRAP11144U0062-95
FILLER11144U0062-96
REPLACEMENT
FRAME SECTION
1144U0063-101
REPLACEMENT
FRAME SECTION
1144U0063-102
ANGLED DOU-
BLER #1
1144U0063-103
ANGLED DOU-
BLER #1
1144U0063-104
ANGLED DOU-
BLER #2
1144U0063-105
ANGLED DOU-
BLER #2
1144U0063-106
SPLICE PLATE11144U0063-111
REPLACEMENT
CHORD
1144U0063-117
REPLACEMENT
CHORD
1144U0063-118
LOWER SPLICE
ANGLE
1144U0063-119
LOWER SPLICE
ANGLE
1144U0063-120
CLIP1144U0063-125
CLIP1144U0063-126
CLIP1144U0063-127
CLIP1144U0063-128
FAILSAFE CHORD
SPLICE
1111144U0063-16
BOEING PROPRIETARY -
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Original Issue: January 08, 2009
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56 of 957
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### Page 57

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
444340393837
QTY
TENSION TIE
SPLICE
11144U0063-69
TENSION TIE
SPLICE
11144U0063-75
REPLACEMENT
FRAME SECTION
1144U0063-81
REPLACEMENT
FRAME SECTION
1144U0063-82
ANGLED DOU-
BLER #1
1144U0063-83
ANGLED DOU-
BLER #1
1144U0063-84
ANGLED DOU-
BLER #2
1144U0063-85
ANGLED DOU-
BLER #2
1144U0063-86
REPLACEMENT
CHORD
1144U0063-91
REPLACEMENT
CHORD
1144U0063-92
LOWER SPLICE
ANGLE
1144U0063-93
LOWER SPLICE
ANGLE
1144U0063-94
SHEAR TIE TEE,
S-6 TO S-7
1144U0064-101
SHEAR TIE TEE,
S-6 TO S-7
1144U0064-102
SHEAR TIE TEE,
S-7 TO S-8
11144U0064-103
SHEAR TIE TEE,
S-8 TO S-9
11144U0064-104
SHEAR TIE TEE,
S-9 TO S-10
11144U0064-105
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 08, 2009
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### Page 58

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
444340393837
QTY
SHEAR TIE TEE,
S-10 TO S-11
11144U0064-107
REPLACEMENT
SPLICE TEE, S-11
TO S-12
1144U0064-109
REPLACEMENT
SPLICE TEE, S-11
TO S-12
1144U0064-110
STRINGER CLIP33144U0064-112
STRINGER CLIP
TEE
4444144U0064-6
TENSION TIE
STOCK SEGMENT
22144U0064-66
STRINGER CLIP
TEE
4444144U0064-7
REPLACEMENT
SPLICE TEE, S-11
TO S-12
11144U0064-82
SHEAR TIE TEE,
S-7 TO S-8
11144U0064-83
SHEAR TIE TEE,
S-8 TO S-9
11144U0064-84
SHEAR TIE TEE,
S-9 TO S-10
11144U0064-85
SHEAR TIE TEE,
S-10 TO S-11
11144U0064-86
STRINGER CLIP1111144U0064-91
BOLT, 100 DEG
HEX DR
1313BACB30NW6K5X
HI-LOK22BACB30NW6K6
BOLT, 100 DEG
HEX DR
1313BACB30NW6K6X
HI-LOK11BACB30NW6K8
BOLT-CSK. HEAD11BACB30NW6K9
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 08, 2009
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58 of 957
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### Page 59

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
444340393837
QTY
BOLT, PROTRUD-
ING HD
8822BACB30NX6K16X
BOLT, PROTRUD-
ING HD
75752424BACB30NX6K3
BOLT, PROTRUD-
ING HD
4444BACB30NX6K3X
BOLT, PROTRUD-
ING HD
28281616BACB30NX6K4
BOLT, PROTRUD-
ING HD
18181414BACB30NX6K4X
BOLT, PROTRUD-
ING HD
171722BACB30NX6K4Y
BOLT13713788125125BACB30NX6K5
BOLT, PROTRUD-
ING HD
10101011BACB30NX6K5X
BOLT, PROTRUD-
ING HD
1616BACB30NX6K5Y
BOLT9090336363BACB30NX6K6
BOLT, PROTRUD-
ING HD
7744BACB30NX6K6X
BOLT, PROTRUD-
ING HD
121255BACB30NX6K6Y
HI-LOK12121212BACB30NX6K7
BOLT, PROTRUD-
ING HD
8877BACB30NX6K7X
BOLT, PROTRUD-
ING HD
66BACB30NX6K7Y
BOLT, PROTRUD-
ING HD
99111516BACB30NX6K8
BOLT, PROTRUD-
ING HD
5533BACB30NX6K8X
BOLT, PROTRUD-
ING HD
3333BACB30NX6K8Y
BOLT1011910BACB30NX6K9
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 08, 2009
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59 of 957
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### Page 60

Group 1:
KIT 015U1803-2
NOTES
Existing Part
NumberName
Figure
New Part Number
444340393837
QTY
BOLT, PROTRUD-
ING HD
1111BACB30NX6K9X
HI-LOK5757BACB30NX8K3
HI-LOK2222BACB30NX8K4
HI LOK2122BACB30NX8K5
BOLT, PROTRUD-
ING HD
11BACB30NX8K5X
BOLT45BACB30NX8K6
BOLT, HEX DRIVE1414BACB30NX8K7
BOLT34BACB30US3K11Y
BOLT, 12 PT
HEAD
34BACB30US4K12
BOLT, 12 PT
HEAD
66BACB30US4K13
BOLT69695656BACB30VT6K5
COLLAR53531010BACC30AC6
COLLAR4254251212279279BACC30BH6
COLLAR11911911BACC30BH8
COLLAR69695656BACC30BL6
COLLAR16171313BACC30M6
FILLER,FLAT11BACF3F009J037NN
FILLER-FLAT11BACF3F009J044NN
FILLER, FLAT11BACF3F010L034NN
FILLER11BACF3F010L035NN
FILLER1111BACF3F010T025NN
FILLER, RECTAN-
GULAR
11BACF3H09JH042HN
FILLER, RECTAN-
GULAR
11BACF3H09JH046HN
SELF-LOCKING
NUT
33BACN10HR3CD
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 08, 2009
747-53A2559Revision 1: August 04, 2011
60 of 957
BOEING SERVICE BULLETIN 747-53A2559

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