# Boeing Alert Service Bulletin 747-53A2866: No revision named

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- Title as filed: U.S. DOT/FAA - SB-747-53A2866-00
- Pages: 46
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### Page 1

Commercial 
Airplanes
747
Service Bulletin
ALERT
Number: 747-53A2866
Original Issue: December 04, 2013
ATA System: 5312
SUBJECT: FUSELAGE - Main Frame - Center Section - Tension Ties - Inspection, Repair, and
Replacement
Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15
CFR 300-774). An export license may be required before it is used for development, production or use by foreign
persons from specific countries. The controller of this data has the individual responsibility to abide by all export
laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET
Copyright © 2013 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document
are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The
Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner,
BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and
Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in
connection with this document unless provided in writing by Boeing.
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747-53A2866
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3.0

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### Page 3

Table of Contents
Summary ...................................................... 5
1. PLANNING INFORMATION ........................................ 9
A. Effectivity ................................................ 9
1. Airplanes ............................................. 9
2. Spares Affected ........................................ 1 4
B. Concurrent Requirements ...................................... 1 4
C. Reason ................................................ 1 4
D. Description .............................................. 1 5
E. Compliance .............................................. 1 6
F. Approval ............................................... 1 9
G. Manpower .............................................. 2 0
H. Weight and Balance Changes .................................... 2 1
I. Electrical Load Data ......................................... 2 1
J. References .............................................. 2 1
1. Existing Data: ......................................... 2 1
2. Data Supplied with this Service Bulletin: ........................... 2 1
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 4
K. Publications Affected ........................................ 2 4
L. Interchangeability and Intermixability of Parts ........................... 2 4
M. Software Accomplishment Summary ................................ 2 4
2. MATERIAL INFORMATION ........................................ 2 5
A. Material - Price and Availability ................................... 2 5
B. Industry Support Information .................................... 2 5
C. Parts Necessary for Each Airplane ................................. 2 5
1. Kits/Parts: ........................................... 2 5
2. Parts and Materials Supplied by the Operator: ........................ 2 5
3. Parts Modified and Reidentified: ............................... 2 5
4. Parts Removed and Not Replaced: .............................. 2 5
D. Parts Necessary to Change Spares ................................. 2 5
E. Special Tooling - Price and Availability ............................... 2 6
F. Special Tooling Necessary to do this Service Bulletin ....................... 2 6
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 7
A. GENERAL INFORMATION ..................................... 2 7
B. WORK INSTRUCTIONS ....................................... 2 9
FIGURE 1: TENSION TIE DETAILED INSPECTION (STA 880 - STA 1100) [Group 1, Configuration 2; Group
2 ]  ................................................ 3 5
FIGURE 2: TENSION TIE DETAILED AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION
(STA 880 - STA 1100) [Group 1, Configuration 2; Group 2] ................. 3 8
FIGURE 3: FRAME DETAILED INSPECTION (TYPICAL FOR STA 880 - STA 1100) [Group 1, Configuration
2; Group 2] ........................................... 4 1
APPENDIX A: LOGIC DIAGRAM 1 - TENSION TIE INSPECTION, REPAIR, AND REPLACEMENT [Group 1,
Configuration 2; Group 2] ................................... 4 4
APPENDIX B: LOGIC DIAGRAM 2 - POST-REPLACEMENT TENSION TIE INSPECTION AND REPAIR [Group
1, Configuration 2; Group 2] .................................. 4 6
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Commercial 
Airplanes
747
Service Bulletin
ALERT
SummaryNumber: 747-53A2866Original Issue: December 04, 2013
ATA System: 5312
SUBJECT: FUSELAGE - Main Frame - Center Section - Tension Ties - Inspection, Repair, and
Replacement
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
CONCURRENT REQUIREMENTS
None.
BACKGROUND
This service bulletin gives instructions for inspection, repair, and replacement of the upper deck tension ties on
stretched upper deck (SUD) airplanes that have been converted to Boeing Special Freighter (SF) or Boeing
Converted Freighter (BCF). Severed or disconnected tension ties at multiple locations could result in rapid
decompression and loss of structural integrity.
This service bulletin is for station locations from 880 to 1100 where floor beams were replaced with tension ties
during conversion to SF or BCF. Tension ties have been determined to be structure that is susceptible to
Widespread Fatigue Damage (WFD). WFD could cause multiple adjacent tension ties to become severed or
disconnected from the frames. For more information about WFD, refer to Boeing Service Letter 747-SL-53-088.
Accomplishment of the inspection and replacement actions in this service bulletin will ensure that tension tie
cracks are detected, and that cracked tension ties are repaired or replaced before they become severed.
Service Bulletin 747-53A2507 and 747-53A2559 are for inspection, repair, and modification of tension tie and
frame structure at station locations from 1120 to 1220 where tension ties were installed in production on the
same airplanes.
Boeing Service Related Problem (SRP) 747-SRP-53-0435 is related to this service bulletin.
Fleet Team Digest article 747 FTD 53-13006 is related to this service bulletin.
The following table is provided to operators for planning purposes only. Refer to the applicable sections for more
information.
ReferenceAffectedPlanning Data
Paragraph 1.A.2., Spares AffectedNoSpares Affected
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ReferenceAffectedPlanning Data
Paragraph 1.E., ComplianceYesAD Related
Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change
Paragraph 1.I., Electrical Load DataNoElectrical Load Changed
Paragraph 1.K., Publications AffectedNoPublications Affected
Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew
Operations Manual and/or FAA Approved Air-
plane Flight Manual)
Paragraph 2.C.1., Kits/PartsNoKits/Parts Required
Paragraph 2.C.2., Parts and Materials Supplied
by the Operator
YesOperator Supplied Parts/Materials
Paragraph 2.F., Special Tooling Necessary to
do this Service Bulletin
NoSpecial Tooling Required
ACTION
No action is required for airplanes that have not been converted by Boeing to SF or BCF configuration.
For airplanes that have been converted by Boeing to SF or BCF configuration, do the following actions:
INSPECTIONS:
– Get access to the tension tie structure from station 880 to station 1100. Do initial and repetitive detailed
inspections for cracks in the tension tie structure at each station location. For a longer repeat inspection
interval, also do HFEC inspection for cracks in the forward and aft tension tie channels around the fasteners.
If any cracks are found, get access to the frame structure at stations where tension ties were found cracked
and do a detailed inspection of the frame structure between stringer 3 and stringer 12 on both sides of the
airplane. Repair or replace any cracked structure.
REPLACEMENT:
– At each station from 880 to 1100, remove and discard the existing tension tie channels. Also, remove and
discard the existing straps and fillers at the outboard ends of the tension tie where the tension tie attaches
to the frame. Do HFEC inspection of all open holes in the frame structure where the tension tie was removed.
If a crack is found in a frame, contact Boeing for repair instructions and do the repair. Install new tension
tie channels, straps, and fillers. Before installation of permanent fasteners at the outboard ends of the
tension ties, cold work the fastener holes common to the frames and straps.
POST-REPLACEMENT INSPECTIONS:
– After replacement, restart initial and repetitive detailed (or detailed and HFEC) inspections beginning at the
post-replacement inspection threshold in accordance with this service bulletin.
EFFECTIVITY
747-100B SUD, 747-200B, 747-300, 747-400, and 747-400D airplanes. Refer to Paragraph 1.A., Effectivity, for
the list of affected airplanes.
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COMPLIANCE
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the inspections, repairs, or replacement procedures given in this
service bulletin.
MANPOWER
Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION
Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
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### Page 8 (OCR)

BOEING SERVICE BULLETIN 747-53A2866
ALERT  ALERT
STA
1220
STA
880
D  ~
STA
1220
SIA
1100
STA  DO DETAILED (OR DETAILED AND HFEC)
880  INSPECTIONS FOR CRACKS IN THE TENSION
TIES FROM STATION 880 TO STATION 1100. DO
A DETAILED INSPECTION OF THE FRAME AT
ANY STATION WHERE A CRACK IS FOUND IN
THE TENSION TIE. REPAIR OR REPLACE ANY
CRACKED TENSION TIE OR FRAME
STRUCTURE. REPLACE THE TENSION TIES
FROM STATION 880 TO STATION 1100 BEFORE
THE THRESHOLD FOR REPLACEMENT
SPECIFIED IN THIS SERVICE BULLETIN.
Original Issue: December 04, 2013
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### Page 9

Commercial 
Airplanes
747
Service Bulletin
ALERT
Number: 747-53A2866
Original Issue: December 04, 2013
ATA System: 5312
SUBJECT: FUSELAGE - Main Frame - Center Section - Tension Ties - Inspection, Repair, and
Replacement
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
1.    PLANNING INFORMATION
A. Effectivity
1. Airplanes
Refer to Service Bulletin Index D6-30300 Part 3 for Airplane Variable Number, Line Number, and
Serial Number data.
This service bulletin is for the airplane(s) shown below.
DESCRIPTIONCONFIGURATIONGROUP
747-100B, 747-200B, 747-300, 747-400, and 747-400D airplanes,
built in a Stretched Upper Deck (SUD) configuration, or modified to
SUD by Boeing, except airplanes modified by Boeing to Special
Freighter (SF) or Boeing Converted Freighter (BCF) configuration
before release of the Original Issue of this service bulletin.
-1
Airplanes that have not been modified by Boeing to SF or BCF.1
Airplanes that are modified by Boeing to SF or BCF configuration
after release of the Original Issue of this service bulletin.
2
747-200B, 747-300, and 747-400 airplanes that have been modified
by Boeing to SF or BCF configuration before release of the Original
Issue of this service bulletin.
-2
Airplane Models:
747-100B SUD, 747-200B, 747-300, 747-400, 747-400D
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GroupVariable Number
1RD381 - RD383
2RD601 - RD602
1RD603 - RD607
1RD721 - RD722
1RF001 - RF006
1RM001 - RM007
1RM010 - RM013
1RM021 - RM022
1RM024
1RM026 - RM030
1RM036 - RM045
1RM051 - RM053
1RM071
1RM081 - RM084
1RM091
1RM096 - RM097
1RM116 - RM117
1RM126 - RM127
2RM128
1RM129 - RM132
1RM136 - RM147
1RM156 - RM158
1RM166 - RM177
1RM191 - RM192
1RM231 - RM233
1RM241 - RM246
1RM261 - RM264
1RM316 - RM318
1RM331 - RM333
1RM341
1RM351 - RM355
1RM366 - RM367
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GroupVariable Number
1RM401 - RM403
1RM426
1RM431
1RM441 - RM443
1RM445
1RM801 - RM803
1RM811 - 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
2RS721 - RS722
1RS731 - RS732
2RS741
1RS742
2RS743
1RS751 - RS752
1RS761
2RS762
2RS771
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GroupVariable Number
1RS781 - RS782
2RS786
1RT001 - RT014
2RT021 - RT022
2RT031 - RT033
1RT034 - RT035
1RT041 - RT047
2RT061
2RT071 - RT072
1RT073 - RT074
2RT075
1RT101 - RT103
1RT121
1RT131 - RT137
1RT151 - RT152
2RT161
1RT162 - RT163
2RT164
1RT165 - RT168
1RT401 - RT412
1RT431 - RT447
1RT451 - RT455
2RT456
1RT457 - RT460
2RT461
1RT462 - RT469
1RT471 - RT499
2RT501
1RT502 - RT505
2RT506 - RT510
1RT511 - RT512
2RT513
1RT514 - RT515
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GroupVariable Number
2RT516
1RT517
2RT518 - RT520
1RT521 - RT523
2RT524
1RT525
2RT526
1RT527
2RT528
1RT529
2RT530
1RT531 - RT535
1RT551 - RT568
1RT571
2RT572 - RT579
1RT580 - RT591
1RT601 - RT630
1RT633 - RT641
2RT642
1RT643 - RT653
2RT654 - RT657
1RT671 - RT673
1RT681 - RT682
2RT691 - RT692
1RT693 - RT699
1RT701 - RT704
1RT711 - RT717
1RT741 - RT742
1RT744 - RT750
2RT751 - RT752
1RT753 - RT757
1RT776 - RT777
2RT781 - RT782
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GroupVariable Number
1RT783 - RT784
1RT801 - RT803
1RT811 - RT814
1RT831 - RT836
2RT837
1RT861 - RT864
1RT877 - RT880
1RT931 - RT932
1RT945 - RT949
1RT951 - RT955
1RT966
2RT967
1RU001 - RU006
1RU016 - RU017
1RU031 - RU032
1RU051 - RU052
1RU060 - 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 instructions for inspection, repair, and replacement of the upper deck tension
ties on stretched upper deck (SUD) airplanes that have been converted to Boeing Special Freighter
(SF) or Boeing Converted Freighter (BCF). Severed or disconnected tension ties at multiple locations
could result in rapid decompression and loss of structural integrity.
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This service bulletin is for station locations from 880 to 1100 where floor beams were replaced with
tension ties during conversion to SF or BCF. Tension ties have been determined to be structure that
is susceptible to Widespread Fatigue Damage (WFD). WFD could cause multiple adjacent tension ties
to become severed or disconnected from the frames. For more information about WFD, refer to Boeing
Service Letter 747-SL-53-088.
Accomplishment of the inspection and replacement actions in this service bulletin will ensure that
tension tie cracks are detected, and that cracked tension ties are repaired or replaced before they
become severed.
Service Bulletin 747-53A2507 and 747-53A2559 are for inspection, repair, and modification of tension
tie and frame structure at station locations from 1120 to 1220 where tension ties were installed in
production on the same airplanes.
Boeing Service Related Problem (SRP) 747-SRP-53-0435 is related to this service bulletin.
Fleet Team Digest article 747 FTD 53-13006 is related to this service bulletin.
D. Description
No action is required for airplanes that have not been converted by Boeing to SF or BCF configuration.
For airplanes that have been converted by Boeing to SF or BCF configuration, do the following actions:
INSPECTIONS:
– Get access to the tension tie structure from station 880 to station 1100. Do initial and repetitive
detailed inspections for cracks in the tension tie structure at each station location. For a longer
repeat inspection interval, also do HFEC inspection for cracks in the forward and aft tension tie
channels around the fasteners. If any cracks are found, get access to the frame structure at stations
where tension ties were found cracked and do a detailed inspection of the frame structure between
stringer 3 and stringer 12 on both sides of the airplane. Repair or replace any cracked structure.
REPLACEMENT:
– At each station from 880 to 1100, remove and discard the existing tension tie channels. Also,
remove and discard the existing straps and fillers at the outboard ends of the tension tie where
the tension tie attaches to the frame. Do HFEC inspection of all open holes in the frame structure
where the tension tie was removed. If a crack is found in a frame, contact Boeing for repair
instructions and do the repair. Install new tension tie channels, straps, and fillers. Before installation
of permanent fasteners at the outboard ends of the tension ties, cold work the fastener holes
common to the frames and straps.
POST-REPLACEMENT INSPECTIONS:
– After replacement, restart initial and repetitive detailed (or detailed and HFEC) inspections beginning
at the post-replacement inspection threshold in accordance with this service bulletin.
The work in this service bulletin is done in the maintenance zone(s) given below.
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Group 1:
Affected Maintenance Zones
ZoneModel
225, 226747-100B SUD, 747-200B, 747-
300, 747-400, 747-400D
Group 2:
Affected Maintenance Zones
ZoneModel
225, 226747-200B, 747-300, 747-400
E. Compliance
Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.
When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When
more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION
numbers for that CONDITION number or OPTION number.
Logic diagrams corresponding to each compliance table are included in APPENDIX A. The logic
diagrams only show the conditions and actions, and are for reference only.
Group 1, Configuration 1:
No action is required. If a Group 1, Configuration 1 airplane is converted to BCF in the future, then it
becomes a Configuration 2 airplane and the actions in the following tables will apply.
Group 1, Configuration 2; Group 2:
Table 1: Tension Tie Inspection, Repair, and Replacement
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 2,000
flight cycles af-
ter the Original
Issue date of
this service bul-
letin.
Within 10,000
flight cycles af-
ter conversion
to SF or BCF
configuration.
Do PART 1: TENSION TIE DE-
TAILED INSPECTION for cracks.
-OR-
Do PART 2: TENSION TIE DE-
TAILED and HIGH FREQUENCY
EDDY CURRENT INSPECTION
for cracks.
All airplanes.
(a)
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### Page 17

Group 1, Configuration 2; Group 2:
Table 1: Tension Tie Inspection, Repair, and Replacement
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
2,000 flight cycles
if PART 1 inspec-
tion was previously
done.
--OPTION 1: Do/Repeat PART 1:
TENSION TIE DETAILED IN-
SPECTION for cracks.
CONDITION 1:
NO TENSION TIE
CRACK FOUND.
OPTION 2: Do/Repeat PART 2:
TENSION TIE DETAILED and
HIGH FREQUENCY EDDY
CURRENT INSPECTION for
cracks.
-OR-
5,000 flight cycles
if PART 2 inspec-
tion was previously
done.
OPTION 3: Do PART 5: TEN-
SION TIE REPLACEMENT.
(a)
-Before further flight.Do PART 3: FRAME DETAILED
INSPECTION for cracks.
CONDITION 2:
TENSION TIE
CRACK FOUND.
-Before further flight.ACTION 1: Contact Boeing for
repair instructions and do the re-
pair.
CONDITION 3:
FRAME CRACK
FOUND.
-Before further flight.ACTION 2: Do PART 4: TEN-
SION TIE REPAIR.
-Before further flight.Do PART 4: TENSION TIE RE-
PAIR.
CONDITION 4:
NO FRAME
CRACK FOUND.
2,000 flight cycles
if PART 1 inspec-
tion was previously
done.
--OPTION 1: Do/Repeat PART 1:
TENSION TIE DETAILED IN-
SPECTION for cracks.
CONDITION 5:
TENSION TIE
CRACK HAS
BEEN REPAIRED. OPTION 2: Do/Repeat PART 2:
TENSION TIE DETAILED and
HIGH FREQUENCY EDDY
CURRENT INSPECTION for
cracks.
-OR-
5,000 flight cycles
if PART 2 inspec-
tion was previously
done.
OPTION 3: Do PART 5: TEN-
SION TIE REPLACEMENT.
(a)
-Within 2,000
flight cycles af-
ter the Original
Issue date of
this service bul-
letin.
Within 22,000
flight cycles af-
ter conversion
to SF or BCF
configuration.
Do PART 5: TENSION TIE RE-
PLACEMENT.
(a) (b)
All airplanes.
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### Page 18

Group 1, Configuration 2; Group 2:
Table 1: Tension Tie Inspection, Repair, and Replacement
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Before further flight.Contact Boeing for repair instruc-
tions and do the repair.
Frame crack is
found during ac-
complishment of
PART 5: TEN-
SION TIE RE-
PLACEMENT.
-See Compliance Table 2.Do Post-Replacement Tension
Tie Inspection and Repair actions
in accordance with Compliance
Table 2.
Tension Tie re-
placement has
been done in ac-
cordance with
Paragraph 3.B.,
Work Instructions,
PART 5 of this
service bulletin.
(a) Accomplishment of PART 5: TENSION TIE REPLACEMENT is terminating action for the initial and
repetitive inspections specified in this table. However, post-replacement inspections are required as
specified in "Table 2: Post-Replacement Tension Tie Inspection and Repair".
(b) Due to the after-modification requirements, and the possibility that it will be necessary to replace the
tension ties again, Boeing does not recommend tension tie replacement prior to 13,000 total flight-cycles.
Group 1, Configuration 2; Group 2:
Table 2: Post-Replacement Tension Tie Inspection and Repair
Repeat Interval (Not to
Exceed)
Compliance TimeActionCondition
-Within 10,000 flight
cycles after the
tension ties were
replaced in accor-
dance with Para-
graph 3.B., Work
Instructions,
PART5 of this ser-
vice bulletin.
Do PART 1: TENSION TIE DE-
TAILED INSPECTION for cracks.
-OR-
Do PART 2: TENSION TIE DE-
TAILED and HIGH FREQUENCY
EDDY CURRENT INSPECTION
for cracks.
Tension Tie replacement
has been done in accor-
dance with Paragraph 3.B.,
Work Instructions, PART 5
of this service bulletin.
2,000 flight cycles if PART
1 inspection was previous-
ly done.
-OPTION 1: Do/Repeat PART 1:
TENSION TIE DETAILED IN-
SPECTION for cracks.
CONDITION 1: NO TEN-
SION TIE CRACK FOUND.
-OR-
5,000 flight cycles if PART
2 inspection was previous-
ly done.
OPTION 2: Do/Repeat PART 2:
TENSION TIE DETAILED and
HIGH FREQUENCY EDDY CUR-
RENT INSPECTION for cracks.
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Group 1, Configuration 2; Group 2:
Table 2: Post-Replacement Tension Tie Inspection and Repair
Repeat Interval (Not to
Exceed)
Compliance TimeActionCondition
-Before further
flight.
Do PART 3: FRAME DETAILED
INSPECTION for cracks.
CONDITION 2: TENSION
TIE CRACK FOUND.
-Before further
flight.
ACTION 1: Contact Boeing for re-
pair instructions and do the repair.
CONDITION 3: FRAME
CRACK FOUND.
-Before further
flight.
ACTION 2: Do PART 4: TENSION
TIE REPAIR.
-Before further
flight.
Do PART 4: TENSION TIE RE-
PAIR.
CONDITION 4: NO
FRAME CRACK FOUND.
2,000 flight cycles if PART
1 inspection was previous-
ly done.
-OPTION 1: Do/Repeat PART 1:
TENSION TIE DETAILED IN-
SPECTION for cracks.
CONDITION 5: TENSION
TIE CRACK HAS BEEN
REPAIRED.
-OR-
5,000 flight cycles if PART
2 inspection was previous-
ly done.
OPTION 2: Do/Repeat PART 2:
TENSION TIE DETAILED and
HIGH FREQUENCY EDDY CUR-
RENT INSPECTION for cracks.
F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified
in this service bulletin comply with the applicable regulations and are FAA approved, as well as European
Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved
airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on
the airplane in its original Boeing delivery configuration or as modified by other approved Boeing
changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected
by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval
before incorporating this service bulletin.
This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle ACO
approves the accomplishment of the inspection, repair, and replacement procedures with corresponding
compliance times specified in Tables 1 and 2 under Paragraph 1.E., "Compliance" of Service Bulletin
747-53A2866, Original Issue, as an AMOC to the inspection requirements of paragraphs (h) and (i) of
AD 2004-07-22 R1, for the inspection of Structural Significant Item (SSI) F-19A, F-19B, F-19D, F-20A,
F-20C, and F-20E of the Supplemental Structural Inspection Document (SSID) D6-35022, Revision G,
dated December 2000, and Revision TR-08-001, dated June 2006. This AMOC only applies to the
areas where tension ties were inspected or replaced 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 (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 accordingly.
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G. Manpower
The table below shows an estimate of the task hours necessary to do the inspection and replacement
actions 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 inspect the work
 Time to cure the materials
 Time to make the parts
 Time to find the tools.
INSPECTION and POST-REPLACEMENT INSPECTION
Elapsed HoursTask HoursNumber of PersonsTask
3.7515.004Open Access
4.0016.004FIGURE 1: Tension Tie De-
tailed Inspection (a)
33.50134.004FIGURE 2: Tension Tie De-
tailed and High Frequency
Eddy Current Inspection (a)
3.006.002FIGURE 3: Frame Detailed
Inspection (b)
3.7515.004Restoration
11.5046.00TOTAL FOR EACH AIRPLANE
(a) The Total for Each Airplane is based on FIGURE 1 inspection. FIGURE 2 inspection
is optional to FIGURE 1 inspection. FIGURE 2 estimates are not included in the total.
(b) If required. Not included in total. Estimate is for inspection of one frame. Multiply the
estimate by the number of frames that need to be inspected.
REPLACEMENT
Elapsed HoursTask HoursNumber of PersonsTask
3.7515.004Open Access
84.00336.004PART 5 - TENSION TIE RE-
PLACEMENT (a)
3.7515.004Restoration
91.50366.00TOTAL FOR EACH AIRPLANE
(a) Does not include time for repairs if frames are found cracked during tension tie replace-
ment. If frames are found cracked, more time will be necessary.
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H. Weight and Balance Changes
None.
I. Electrical Load Data
Not changed.
J. References
1. Existing Data:
a. Boeing Service Bulletin 747-53A2507, 747-53A2559
b. Boeing Service Letter 747-SL-51-048, 747-SL-53-088
c. Boeing Service Related Problem (SRP) 747-SRP-53-0435
d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2004-07-22 R1
e. Service Bulletin Index D6-30300
f. Standard Overhaul Practices Manual (SOPM) 20-41-05, 20-43-03, 20-50-01
g. 747 Fleet Team Digest (FTD) 53-13006
h. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00
i. 747-100/200/300 Aircraft Maintenance Manual (AMM) 24-22-00, 25-59-01, 25-59-05
j. 747-100/200/300 Structural Repair Manual (SRM) 51-30-09, 51-50-01
k. 747-400 Aircraft Maintenance Manual (AMM) 24-22-00, 25-59-01, 25-59-05
l. 747-400SF Structural Repair Manual (SRM) 51-40-09, 51-50-02, 53-20-30, 53-40-30
2. Data Supplied with this Service Bulletin:
a. Drawings:
ADCNDCN/REVSheetTitleDrawing No
-B1TENSION TIE INSTL - STA 880 - STA
1220, MOD
657U7304
-D2
-D3
-C4
-C5
-C6
-KPL
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ADCNDCN/REVSheetTitleDrawing No
-APSDLTENSION TIE INSTL - STA 880 - STA
1220, MOD
657U7304#DL
-C1TENSION TIE DETAILS, STA 880 -STA
1220, MOD
657U7314
-C2
-C3
-C4
-C5
-B6
--7
--8
--9
-GPL
--PSDLTENSION TIE DETAILS, STA 880 -STA
1220, MOD
657U7314#DL
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ADCNDCN/REVSheetTitleDrawing No
--11TENSION TIE REWORK INSTL STA 880
THRU STA 1220 MOD
814B9001
-A12
-A13
-A14
--15
--16
--17
--18
--19
--20
-A21
--22
--23
-B24
-A25
-B26
--27
--28
--29
--30
--31
-B32
--33
--34
--35
--36
-B37
--38
--39
--40
-A41
--42
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ADCNDCN/REVSheetTitleDrawing No
-FPSDLTENSION TIE REWORK INSTL STA 880
THRU STA 1220 MOD
814B9001#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.
M. Software Accomplishment Summary
Not affected.
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2.    MATERIAL INFORMATION
A. Material - Price and Availability
The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary for Each
Airplane. As an alternative, operators can purchase the parts from Boeing Spares. This service bulletin
does not show the Boeing price and supply data.
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:
None.
2. Parts and Materials Supplied by the Operator:
NotesNameQTYPart Number / Speci-
fication
(a) (b) (c)Chemical Conversion Coatingas requiredAlodine
(b) (c)Primeras requiredBMS 10-11, Type I
(b) (c)Corrosion Inhibiting Compoundas requiredBMS 3-23, Type II
(b) (c)Sealantas requiredBMS 5-95
(a) Refer to SOPM 20-43-03 for material alternatives.
(b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for sup-
plier data.
(c) This material could be necessary for tension tie repairs. More parts will be necessary if tension
tie replacement is required. If necessary, contact Boeing for the engineering drawing information
to determine the required parts if tension tie replacement will be accomplished.
3. Parts Modified and Reidentified:
None.
4. Parts Removed and Not Replaced:
None.
D. Parts Necessary to Change Spares
None.
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E. Special Tooling - Price and Availability
The 747 Structural Repair Manual Subject 747-100/200/300 SRM 51-30-09 or 747-400SF SRM 51-40-09
gives data about cold working tools and sleeves necessary to do the work given in this service bulletin.
These tools are available from industry sources.
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.
NOTE: Special tools are not necessary to do the change in this service bulletin. However, standard
cold working tools are necessary for cold working of the holes at the ends of the tension ties
if the tension ties are replaced in accordance with this service bulletin.
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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. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
2. Obey all of the warnings and cautions given in the specified manual sections.
3. Unless shown differently, these dimensions and tolerances are used:
– Linear dimensions are in inches
– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus
or minus 0.03 inch
– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch
– Angular tolerance is plus or minus 2 degrees
– Hole dimensions for standard solid rivets and fasteners are in Structural Repair
Manual (SRM) Chapter 51
– Torque Values:
— Values for structural fasteners are given in 747 Structural Repair Manual,
Chapter 51.
— Values for airframe maintenance tasks are included in Chapter 20 of 747
Airplane Maintenance Manual (AMM).
— Non-standard torque values for maintenance tasks are included in the
applicable installation step.
4. Use the approved fastener and process material substitutions in accordance with
SRM Chapter 51.
5. If the length of any fastener specified in this service bulletin does not meet installation
standards given in SRM Chapter 51, then a fastener of the same specification, or
an approved substitute, with a length which meets the installation standards given
in SRM Chapter 51 may be used. In addition, washers may be installed for fastener
grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate
full threaded fasteners (screws) needed for installation in this service bulletin.
6. A Detailed Inspection is defined as: An intensive examination of a specific item,
installation, or assembly to detect damage, failure, or irregularity. Available lighting
is normally supplemented with a direct source of good lighting at an intensity deemed
appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be
necessary. Surface cleaning and elaborate procedures may be required.
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7. These work instructions refer to procedures included in other Boeing documents.
When the words "refer to" are used and the operator has an accepted alternative
procedure, the accepted alternative procedure can be used. When the words "in
accordance with" are included in the instruction, the procedure in the Boeing document
must be used.
8. Boeing Service Letter 747-SL-51-048, Damage Reporting and Repair Plan/Design
Guidelines, is an acceptable procedure to request information from Boeing for
additional structural repair instructions. The Service Letter describes what information
must be provided to Boeing before a structural repair can be provided.
9. The instructions in Paragraph 3.B., Work Instructions and the figures can include
operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated
Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing
Index contain data on versions of the tools or test equipment that you can use. It is
permitted to use replaced tools. It is not permitted to use superseded tools.
10. If it is necessary to remove more parts for access, you can remove those parts. If
you can get access without removing identified parts, it is not necessary to remove
all of the identified parts. Jacking and shoring limitations must be observed.
11. Where the work instructions include installation of a kept part, a new or serviceable
part with the same part number can be installed as an alternative to the kept part.
12. If shading is used, shaded areas in Figures are to separate the non-critical and
non-authoritative information from the critical and authoritative information.
13. When more than one OPTION is given for a CONDITION, do only one of the OPTION
numbers. When more than one ACTION is given for a CONDITION number or an
OPTION number, do all of the ACTION numbers for that CONDITION number or
OPTION number.
14. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS
are in Paragraph 1.E., Compliance.
15. Some steps in the Work Instructions are identified as Required for Compliance (RC).
If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps
identified as RC must be done to comply with the AD. Alternative procedures for
steps not identified with RC can be used if the RC steps can still be done as specified,
and the airplane can be put back in a serviceable condition. An Alternative Method
of Compliance (AMOC) is not necessary for deviations to steps that are not identified
as RC.
16. For 747-100/200/300 airplanes that have been modified by Boeing to Special Freighter
(SF) configuration, the 747-100/200/300 SRM does not include repairs for tension
ties from STA 880 to STA 1100 that were installed during conversion. It is acceptable
to use 747-400SF SRM 53-20-30 or 747-400SF SRM 53-40-30, as applicable, for
repair of STA 880 - STA 1100 tension ties on 747-100/200/300 airplanes.
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17. Refer to APPENDIX A for Logic Diagram 1 related to the tension tie initial inspection,
repair, and replacement requirements. Refer to APPENDIX B for Logic Diagram 2
related to the post-replacement inspection and repair requirements. Logic diagrams
are provided as an aid only. Information contained in Paragraph 1.E., Compliance
is the primary source for compliance times. Information in Paragraph 3.B., Work
Instructions is the primary source for tasks required for compliance.
18. Replacement of tension tie channels with original SF or BCF modification parts in
accordance with Paragraph 3.B., Work Instructions, PART 5 on airplanes RS762
and RT456 would cancel the effect of the modification performed by Service Bulletin
747-53A2610. Therefore, PART 5 instructions include a requirement to concurrently
incorporate Service Bulletin 747-53A2610 modification on any aft tension tie channels
being installed as replacements.
B. WORK INSTRUCTIONS
Group 1, Configuration 1:
No action is required for airplanes that have not been converted by Boeing to Special Freighter (SF)
or Boeing Converted Freighter (BCF) configuration.
Group 1, Configuration 2; Group 2:
Tension Tie Inspection, Repair, and Replacement
1. Do PART 1: TENSION TIE DETAILED INSPECTION for cracks, or Do PART 2: TENSION TIE
DETAILED and HIGH FREQUENCY EDDY CURRENT INSPECTION for cracks.
CONDITION 1: NO TENSION TIE CRACK FOUND
a. Do one of the following:
(1) OPTION 1: Do/Repeat PART 1: TENSION TIE DETAILED INSPECTION for cracks.
(2) OPTION 2: Do/Repeat PART 2: TENSION TIE DETAILED and HIGH FREQUENCY
EDDY CURRENT INSPECTION for cracks.
(3) OPTION 3: Do PART 5: TENSION TIE REPLACEMENT.
CONDITION 2: TENSION TIE CRACK FOUND
a. Do PART 3: FRAME DETAILED INSPECTION for cracks.
CONDITION 3: FRAME CRACK FOUND
(1) ACTION 1: Contact Boeing for repair instructions and do the repair.
(2) ACTION 2: Do PART 4: TENSION TIE REPAIR.
CONDITION 4: NO FRAME CRACK FOUND
(1) Do PART 4: TENSION TIE REPAIR.
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CONDITION 5: TENSION TIE CRACK HAS BEEN REPAIRED
a. Do one of the following:
(1) OPTION 1: Do/Repeat PART 1: TENSION TIE DETAILED INSPECTION for cracks.
(2) OPTION 2: Do/Repeat PART 2: TENSION TIE DETAILED and HIGH FREQUENCY
EDDY CURRENT INSPECTION for cracks.
(3) OPTION 3: Do PART 5: TENSION TIE REPLACEMENT.
2. Do PART 5: TENSION TIE REPLACEMENT.
Group 1, Configuration 2; Group 2:
Post-Replacement Tension Tie Inspection and Repair
1. Do PART 1: TENSION TIE DETAILED INSPECTION for cracks, or Do PART 2: TENSION TIE
DETAILED and HIGH FREQUENCY EDDY CURRENT INSPECTION for cracks.
CONDITION 1: NO TENSION TIE CRACK FOUND
a. Do one of the following:
(1) OPTION 1: Do/Repeat PART 1: TENSION TIE DETAILED INSPECTION for cracks.
(2) OPTION 2: Do/Repeat PART 2: TENSION TIE DETAILED and HIGH FREQUENCY
EDDY CURRENT INSPECTION for cracks.
CONDITION 2: TENSION TIE CRACK FOUND
a. Do PART 3: FRAME DETAILED INSPECTION for cracks.
CONDITION 3: FRAME CRACK FOUND
(1) ACTION 1: Contact Boeing for repair instructions and do the repair.
(2) ACTION 2: Do PART 4: TENSION TIE REPAIR.
CONDITION 4: NO FRAME CRACK FOUND
(1) Do PART 4: TENSION TIE REPAIR.
CONDITION 5: TENSION TIE CRACK HAS BEEN REPAIRED
a. Do one of the following:
(1) OPTION 1: Do/Repeat PART 1: TENSION TIE DETAILED INSPECTION for cracks.
(2) OPTION 2: Do/Repeat PART 2: TENSION TIE DETAILED and HIGH FREQUENCY
EDDY CURRENT INSPECTION for cracks.
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Group 1, Configuration 2; Group 2:
PART 1: TENSION TIE DETAILED INSPECTION
1. Remove electrical power and ground the airplane. Refer to 747-100/200/300 AMM 24-22-00 or
747-400 AMM 24-22-00 as accepted procedures.
2. At stations 880 to 1100, remove the main deck cargo compartment lining panels and insulation
as necessary to get access to the tension tie structure. Refer to 747-100/200/300 AMM 25-59-01
or 747-400 AMM 25-59-01 as an accepted procedure for lining panels. Refer to 747-100/200/300
AMM 25-59-05 or 747-400 AMM 25-59-05 as an accepted procedure for insulation.
3. RC - At each tension tie station from 880 to 1100, do a detailed inspection for cracks in the tension
tie structure in accordance with FIGURE 1.
4. Re-install any insulation that was removed for access. Refer to 747-100/200/300 AMM 25-59-05
or 747-400 AMM 25-59-05 as an accepted procedure.
5. Re-install any lining panels that were removed for access. Refer to 747-100/200/300 AMM 25-59-01
or 747-400 AMM 25-59-01 as an accepted procedure.
6. Supply electrical power to the airplane. Refer to 747-100/200/300 AMM 24-22-00 or 747-400 AMM
24-22-00 as an accepted procedure.
7. Return the airplane to a serviceable condition.
Group 1, Configuration 2; Group 2:
PART 2: TENSION TIE DETAILED and HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION
1. Remove electrical power and ground the airplane. Refer to 747-100/200/300 AMM 24-22-00 or
747-400 AMM 24-22-00 as accepted procedures.
2. At stations 880 to 1100, remove the main deck cargo compartment lining panels and insulation
as necessary to get access to the tension tie structure. Refer to 747-100/200/300 AMM 25-59-01
or 747-400 AMM 25-59-01 as an accepted procedure for lining panels. Refer to 747-100/200/300
AMM 25-59-05 or 747-400 AMM 25-59-05 as an accepted procedure for insulation.
3. RC - At each tension tie station from 880 to 1100, do detailed and HFEC inspections for cracks in
the tension tie structure in accordance with FIGURE 2.
4. Re-install any insulation that was removed for access. Refer to 747-100/200/300 AMM 25-59-05
or 747-400 AMM 25-59-05 as an accepted procedure.
5. Re-install any lining panels that were removed for access. Refer to 747-100/200/300 AMM 25-59-01
or 747-400 AMM 25-59-01 as an accepted procedure.
6. Supply electrical power to the airplane. Refer to 747-100/200/300 AMM 24-22-00 or 747-400 AMM
24-22-00 as an accepted procedure.
7. Return the airplane to a serviceable condition.
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Group 1, Configuration 2; Group 2:
PART 3: FRAME DETAILED INSPECTION
1. At any station where a crack was found in a tension tie, remove the main deck cargo compartment
lining panels and insulation as necessary to get access to the frame structure between stringer 3
to stringer 12 on both sides of the airplane. Refer to 747-100/200/300 AMM 25-59-01 or 747-400
AMM 25-59-01 as an accepted procedure for lining panels. Refer to 747-100/200/300 AMM 25-59-05
or 747-400 AMM 25-59-05 as an accepted procedure for insulation.
2. RC - At any station where a crack was found in a tension tie, do a detailed inspection of the frame
structure between stringer 3 and stringer 12 in accordance with FIGURE 3
Group 1, Configuration 2; Group 2:
PART 4: TENSION TIE REPAIR
CAUTION: MAKE SURE THAT THE AIRPLANE IS SUPPORTED IN THE JIGGED POSITION
BEFORE YOU DISASSEMBLE TWO ADJACENT FRAMES OR TENSION TIES. IF YOU
DO NOT, YOU WILL CAUSE DAMAGE TO THE STRUCTURE.
1. Put the airplane in a jigged position. Refer to 747-100/200/300 SRM 51-50-01 or 747-400SF SRM
51-50-02 as an accepted procedure. It is not necessary to put the airplane into a jigged position
if the airplane has the following conditions:
a. Only one tension tie or frame is disassembled.
b. There is a minimum of one tension tie and frame attached between those that are
disassembled.
2. RC - Repair any cracked tension tie in accordance with 747-400SF SRM 53-20-30 or 747-400SF
SRM 53-40-30 as applicable.
3. Re-install any insulation that was removed for access. Refer to 747-100/200/300 AMM 25-59-05
or 747-400 AMM 25-59-05 as an accepted procedure.
4. Re-install any lining panels that were removed for access. Refer to 747-100/200/300 AMM 25-59-01
or 747-400 AMM 25-59-01 as an accepted procedure.
5. Supply electrical power to the airplane. Refer to 747-100/200/300 AMM 24-22-00 or 747-400 AMM
24-22-00 as an accepted procedure.
6. Return the airplane to a serviceable condition.
Group 1, Configuration 2; Group 2:
PART 5: TENSION TIE REPLACEMENT
1. Remove electrical power and ground the airplane. Refer to 747-100/200/300 AMM 24-22-00 or
747-400 AMM 24-22-00 as accepted procedures.
2. At stations 880 to 1100, remove the main deck cargo compartment lining panels and insulation
as necessary to get access to the tension tie structure. Refer to 747-100/200/300 AMM 25-59-01
or 747-400 AMM 25-59-01 as an accepted procedure for lining panels. Refer to 747-100/200/300
AMM 25-59-05 or 747-400 AMM 25-59-05 as an accepted procedure for insulation.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
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747-53A2866
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BOEING SERVICE BULLETIN 747-53A2866
ALERTALERT

### Page 33

CAUTION: MAKE SURE THAT THE AIRPLANE IS SUPPORTED IN THE JIGGED POSITION
BEFORE YOU DISASSEMBLE TWO ADJACENT FRAMES OR TENSION TIES. IF YOU
DO NOT, YOU WILL CAUSE DAMAGE TO THE STRUCTURE.
3. Put the airplane in a jigged position. Refer to 747-100/200/300 SRM 51-50-01 or 747-400SF SRM
51-50-02 as an accepted procedure. It is not necessary to put the airplane into a jigged position
if the airplane has the following conditions:
a. Only one tension tie or frame is disassembled.
b. There is a minimum of one tension tie and frame attached between those that are
disassembled.
4. RC - At each station location from STA 880 to STA 1100, remove and discard the existing tension
tie channels. Also, remove and discard the existing steel plates, straps and fillers at the outboard
ends of the tension ties where the tension ties attach to the frames.
5. RC - After each tension tie is removed, do open hole HFEC inspection for cracks at all hole locations
where fasteners where removed from adjacent frame structure to remove the tension tie. Do the
inspection in accordance with 747 NDT Manual Part 6, 51-00-00, Procedure 1, 11, or 16. If any
crack is found, contact Boeing for repair instructions and do the repair.
6. RC - At each station location from STA 880 to STA 1100, temporarily install new tension tie
channels, steel plates, straps, and fillers which are the same as the original SF or BCF modification
parts that were removed. Install the new parts in accordance with the applicable SF or BCF
modification drawings specified in Paragraph 1.J.2., Data Supplied with this Service Bulletin, except
oversize any existing open fastener holes 1/32 inch. Maintain 2D minimum edge margin. Continue
with the following steps to install new tension ties.
7. RC - For airplanes that are included in the effectivity of Service Bulletin 747-53A2610, incorporate
the Service Bulletin 747-53A2610 modification on the new tension ties, concurrently with installation
of the new tension ties.
8. RC - At each station location from STA 880 to STA 1100, cold work the entire stack-up at all
fastener holes where the tension tie attaches to the frame. Also, cold work the entire stack-up at
all fastener holes that are common to the steel plates/straps, plus three fastener pairs inboard of
the ends of the steel plates. Do the cold working at both ends of the tension tie (both sides of the
airplane). Use the "high interference" cold work process in accordance with 747-100/200/300 SRM
51-30-09 or 747-400SF SRM 51-40-09, as applicable.
9. RC - After cold working, at each station location from STA 880 to STA 1100, permanently install
new tension tie channels, steel plates, straps, and fillers which are the same as the original SF or
BCF modification parts that were removed. Install the new structure in accordance with the
applicable SF or BCF modification drawings specified in Paragraph 1.J.2., Data Supplied with this
Service Bulletin, except install oversize fasteners at existing open fastener holes.
10. RC - Apply BMS 3-23, Type II, or equivalent, Corrosion Inhibiting Compound to the modified areas.
Refer to SOPM 20-41-05 as an accepted procedure.
11. Re-install any insulation that was removed for access. Refer to 747-100/200/300 AMM 25-59-05
or 747-400 AMM 25-59-05 as an accepted procedure.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
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ALERTALERT

### Page 34

12. Re-install any lining panels that were removed for access. Refer to 747-100/200/300 AMM 25-59-01
or 747-400 AMM 25-59-01 as an accepted procedure.
13. Supply electrical power to the airplane. Refer to 747-100/200/300 AMM 24-22-00 or 747-400 AMM
24-22-00 as an accepted procedure.
14. Return the airplane to a serviceable condition.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 04, 2013
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BOEING SERVICE BULLETIN 747-53A2866
ALERTALERT

### Page 35 (OCR)

BOEING SERVICE BULLETIN 747-53A2866
ALERT  ALERT
This Figure applies only to: Group 1, Configuration 2; Group 2.
STA
880
2268711
FIGURE 1: TENSION TIE DETAILED INSPECTION (STA 880 - STA 1100)
(SHEET 1 OF 3)
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### Page 36 (OCR)

BOEING SERVICE BULLETIN 747-53A2866
ALERT  ALERT
TENSION  TIE  TYPICAL VIEW FOR TENSION TIE DETAILED INSPECTION  (STA 880-STA 1100)  A-A
FRAME
2268714
FIGURE 1: TENSION TIE DETAILED INSPECTION (STA 880 - STA 1100)
(SHEET 2 OF 3)
Original Issue: December 04, 2013
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PROPRIETARY - Copyright © Unpublished
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### Page 37

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
More DataQtyIdentificationNameTaskStep
(a)-657U7314-( )Forward and Aft Ten-
sion Tie Channels
Inspect1
(a) Do a detailed inspection for cracks in the forward and aft tension tie channels in the inspection area shown.
Station 880 is shown. Other stations are similar. Do the inspection at all stations from Station 880 to
Station 1100. Inspect Qty 2 tension tie channels (one forward and one aft) at each station location. Total
quantity of tension tie channels to be inspected = 24.
FIGURE 1: TENSION TIE DETAILED INSPECTION (STA 880 - STA 1100)
(SHEET 3 OF 3)
Export Controlled ECCN: 9E991 - BOEING
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BOEING SERVICE BULLETIN 747-53A2866
ALERTALERT

### Page 38 (OCR)

BOEING SERVICE BULLETIN 747-53A2866
ALERT  ALERT
This Figure applies only to: Group 1, Configuration 2; Group 2.
STA
880
2268851
FIGURE 2: TENSION TIE DETAILED AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION (STA
880 - STA 1100)
(SHEET 1 OF 3)
Original Issue: December 04, 2013
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Work - See page 1 for details.  38 of 46

### Page 39 (OCR)

BOEING SERVICE BULLETIN 747-53A2866
ALERT  ALERT
TENSION  TIE  TYPICAL VIEW FOR TENSION TIE DETAILED AND HFEC INSPECTION  (STA 880-STA 1100)  A-A
FRAME
2268850
FIGURE 2: TENSION TIE DETAILED AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION (STA
880 - STA 1100)
(SHEET 2 OF 3)
Original Issue: December 04, 2013
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PROPRIETARY - Copyright © Unpublished
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### Page 40

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
More DataQtyIdentificationNameTaskStep
(a) (c)-657U7314-( )Forward and Aft Ten-
sion Tie Channels
Inspect1
(b) (c)-657U7314-( )Forward and Aft Ten-
sion Tie Channels
Inspect2
(a) Do a detailed inspection for cracks in the forward and aft tension tie channels in the inspection area shown.
(b) Do surface HFEC inspection for cracks around fasteners in the tension tie channels. Inspect from both
sides of the tension tie in order to inspect both the forward and aft channels. It is not necessary to do the
inspection where the tension tie channels are covered by straps, fittings, or other structure. Do the inspec-
tion in accordance with 747 NDT Manual Part 6, 51-00-00, Procedure 4 or 23.
(c) Station 880 is shown. Other stations are similar. Do the inspection at all stations from Station 880 to
Station 1100. Inspect Qty 2 tension tie channels (one forward and one aft) at each station location. Total
quantity of tension tie channels to be inspected = 24.
FIGURE 2: TENSION TIE DETAILED AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION (STA
880 - STA 1100)
(SHEET 3 OF 3)
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PROPRIETARY - Copyright © Unpublished
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BOEING SERVICE BULLETIN 747-53A2866
ALERTALERT

### Page 41 (OCR)

BOEING SERVICE BULLETIN 747-53A2866
ALERT  ALERT
This Figure applies only to: Group 1, Configuration 2; Group 2.
STA
880
2268853
FIGURE 3: FRAME DETAILED INSPECTION (TYPICAL FOR STA 880 - STA 1100)
(SHEET 1 OF 3)
Original Issue: December 04, 2013
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### Page 42 (OCR)

BOEING SERVICE BULLETIN 747-53A2866
ALERT  ALERT
S-8R  S-9R  S-10R  \S-10AR÷  S-11R
S-7R
S-6R
S-5R
S-4R
S-3AR
S-3  TYPICAL VIEW FOR FRAME DETAILED INSPECTION
FRAME  TENSION  TIE  (STA 880-STA 1100)  A-A
S-3AL
2268882
FIGURE 3: FRAME DETAILED INSPECTION (TYPICAL FOR STA 880 - STA 1100)
(SHEET 2 OF 3)
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### Page 43

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
More DataQtyIdentificationNameTaskStep
(a) (c)--Frame - Left SideInspect1
(b) (c)--Frame - Right SideInspect2
(a) Do a detailed inspection for cracks in the left side of the frame between stringer 3L and stringer 12L as
shown. Inspect the frame at each station location from STA 880 to STA 1100. Total quantity of frames to
be inspected = 12.
(b) Do a detailed inspection for cracks in the right side of the frame between stringer 3R and stringer 12R as
shown. Inspect the frame at each station location from STA 880 to STA 1100. Total quantity of frames to
be inspected = 12.
(c) Station 880 is shown. Other stations are similar. Do the inspection at all stations where a crack was found
in a tension tie.
FIGURE 3: FRAME DETAILED INSPECTION (TYPICAL FOR STA 880 - STA 1100)
(SHEET 3 OF 3)
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ALERTALERT

### Page 44 (OCR)

BOEING SERVICE BULLETIN 747-53A2866
ALERT  ALERT
This Appendix applies only to: Group 1, Configuration 2; Group 2.
DO PART 1: TENSION TIE DETAILED INSPECTION FOR CRACKS.
DO PART 2: TENSION TIE DETAILED AND HIGH FREQUENCY EDDY
CURRENT INSPECTION FOR CRACKS.
CONDITION 1:  CONDITION 2:
NO TENSION TIE  TENSION TIE
CRACK FOUND.  CRACK FOUND.
OPTION 1:  OPTION 2:  OPTION3:
DO/REPEAT PART 1:  TENSION TIE DETAILED AND  DO/REPEAT PART 2:  DO PART 5
TENSION TIE DETAILED  HIGH FREQUENCY EDDY  TENSION TIE
INSPECTION FOR  CRACKS.  INSPECTION FOR CRACKS  CURRENT  REPLACEMENT.
APPENDIX B  SEE  INSPECTIOM FOR CRACKS  FRAME DETAILED  DO PART 3:
CONDITION 3:  CONDITION 4
FRAME CRACK FOUND  NO FRAME CRACK FOUND.
ACTION 1:
CONTACT BOEING
FOR REPAIR INSTRUCTIONS
AND DO THE REPAIR.
DO PART 4:
ACTION 2:  TENSION TIE REPAIR.
DO PART 4:
TENSION TIE REPAIR.
CONDITION 5:
TENSION TIE CRACK
HAS BEEN REPAIRED
OPTION 1:  OPTION 2:  OPTION 3:
INSPECTION FOR CRACKS  TENSION TIE DETAILED  DO/REPEAT PART 1:  HIGH FREQUENCY EDDY CURRENT  TENSION TIE DETAILED AND  DO/REPEAT PART 2:  TENSION TIE REPLACEMENT.  DO PART 5:
INSPECTION FOR CRACKS.  SEE APPENDIX B  2282367
APPENDIX A: LOGIC DIAGRAM 1 - TENSION TIE INSPECTION, REPAIR, AND REPLACEMENT
(SHEET 1 OF 2)
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### Page 45

Do PART 5 - TENSION TIE REPLACEMENT before the compliance time for replacement
specified in Paragraph 1.E., Compliance, Table 1. After replacement, do inspections as
specified in Paragraph 1.E., Compliance, Table 2, and refer to LOGIC DIAGRAM 2.
FLAG NOTE 1:
APPENDIX A:  LOGIC DIAGRAM 1 - TENSION TIE INSPECTION, REPAIR, AND REPLACEMENT
(SHEET 2 OF 2)
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ALERTALERT

### Page 46 (OCR)

BOEING SERVICE BULLETIN 747-53A2866
ALERT  ALERT
This Appendix applies only to: Group 1, Configuration 2; Group 2.
DO PART 1: TENSION TIE DETAILED INSPECTION FOR CRACKS.
DO PART 2: TENSION TIE DETAILED AND HIGH FREQUENCY EDDY
CURRENT INSPECTION FOR CRACKS.
CONDITION 1:  CONDITION 2
NO TENSION TIE  TENSION TIE
CRACK FOUND.  CRACK FOUND.
OPTION 1:  OPTION 2:
TENSION TIE DETAILED  DO/REPEAT PART 1:  INSPECTION FOR  CRACKS.  TENSION TIE DETAILED AND  INSPECTION FOR CRACKS.  HIGH FREQUENCY EDDY  DO/REPEAT PART 2:  CURRENT
DO PART 3:
FRAME DETAILED
INSPECTIOM FOR CRACKS
CONDITION 3:  CONDITION 4
FRAME CRACK FOUND  NO FRAME CRACK FOUND.
ACTION 1:
CONTACT BOEING
FOR REPAIR INSTRUCTIONS
AND DO THE REPAIR.
DO PART 4:
ACTION 2:  TENSION TIE REPAIR.
DO PART 4:
TENSION TIE REPAIR.
CONDITION 5:
TENSION TIE CRACK
HAS BEEN REPAIRED
OPTION 1:  OPTION 2:  7
DO/REPEAT PART 1:  DO/REPEAT PART 2:
TENSION TIE DETAILED  TENSION TIE DETAILED AND
INSPECTION FOR CRACKS.  HIGH FREQUENCY EDDY CURRENT  INSPECTION FOR CRACKS
…J  2282668
APPENDIX B: LOGIC DIAGRAM 2 - POST-REPLACEMENT TENSION TIE INSPECTION AND REPAIR
(SHEET 1 OF 1)
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