# Boeing Alert Service Bulletin 757-53A0102: No revision named

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- Document: [Boeing Alert Service Bulletin 757-53A0102](https://openairdocs.org/service-documents/boeing/757-53a0102.md)
- Title as filed: U.S. DOT/FAA - SB-757-53A0102-00
- Pages: 33
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## Text

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### Page 1

Commercial 
Airplanes
757
Service Bulletin
ALERT
Number: 757-53A0102
Original Issue: October 08, 2015
ATA System: 5330
SUBJECT: FUSELAGE - Skin - Section 43 - Lap Splice Inspection, Inner Skin Lower Fastener
Row, at S-14R, STA 440-540
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 © 2015 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document
are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The
Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner,
BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and
Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in
connection with this document unless provided in writing by Boeing.
Original Issue: October 08, 2015
757-53A0102
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 18
K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 19
3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 19
3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
FIGURE 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA
440-540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FIGURE 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT
S-14R, STA 440-540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: EXTERNAL DFEC
INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 (OPTION
1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 2: INTERNAL HFEC
SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540
(OPTION 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
APPENDIX C: OPEN AND CLOSE ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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Commercial 
Airplanes
757
Service Bulletin
ALERT
SummaryNumber: 757-53A0102Original Issue: October 08, 2015
ATA System: 5330
SUBJECT: FUSELAGE - Skin - Section 43 - Lap Splice Inspection, Inner Skin Lower Fastener
Row, at S-14R, STA 440-540
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
The inner skin of lap splices at Stringer S-14R, lower fastener row for 757-200, and 757-200CB models have
been determined to be susceptible to Widespread Fatigue Damage (WFD). Cracking was found on the fatigue
test article, and WFD analysis has identified the need for inspections. Currently, there have been no reports of
cracking on airplanes in service. Inspections will mitigate a safety issue, allowing continued operation to the
Limit of Validity (LOV). This action is necessary to find any fatigue crack in the skin panel. Accomplishment of
the inspections in this service bulletin will make sure that any fuselage skin crack at Stringer S-14R, between
STA 440 and STA 540 is found. Continued operation with any undetected skin crack could adversely affect the
structural integrity of the airplane.
The fuselage lap splice inner skin at the locations affected by this service bulletin have been determined to be
structure that is susceptible to Widespread Fatigue Damage (WFD).
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### Page 6

This table is provided to operators for planning purposes only. Refer to the applicable sections for more
information.
ReferenceAffectedPlanning Data
Paragraph 1.A.2., Spares AffectedNoSpares Affected
Paragraph 1.E., Compliance and Paragraph
1.F., Approval
YesAD Related
Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change
Paragraph 1.I., Electrical Load DataNoElectrical Load Changed
Paragraph 1.K., Publications AffectedNoPublications Affected
Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew
Operations Manual and/or FAA Approved Air-
plane Flight Manual)
Paragraph 2.C.1., Kits/PartsNoKits/Parts Required
Paragraph 2.C.2., Parts and Materials Supplied
by the Operator
NoOperator Supplied Parts/Material
Paragraph 2.F., Special Tooling Necessary to
do this Service Bulletin
NoSpecial Tooling Required
ACTION
This service bulletin gives instructions to do either Dual Frequency Eddy Current (DFEC) or High Frequency
Eddy Current (HFEC) inspections of the fuselage lap splice, inner skin lower fastener row, at S-14R, STA 440-540
for any crack.
If any crack is found, contact The Boeing Company for repair instructions and do the repair.
If no crack is found, repeat the inspections at the interval specified in Paragraph 1.E., Compliance.
EFFECTIVITY
All 757-200/-200CB Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE
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.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the inspections given in this service bulletin.
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MANPOWER
Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION
None.
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### Page 8 (OCR)

BOEING SERVICE BULLETIN 757-53A0102
ALERT  ALERT
STA
440
STA
540
OUTER SKIN
OR
INNER SKIN
OPTION 1:  S-14R
EXTERNAL DFEC INSPECTION OF
INNER SKIN LOWER FASTENER ROW,
AT S-14R, STA 440-540
STA
440
OPTION 2:
INTERNAL HFEC SURFACE
INSPECTION OF INNER SKIN
LOWER FASTENER ROW, AT S-14R,
S-14R  STA 440-540
2403897
Original Issue: October 08, 2015
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### Page 9

Commercial 
Airplanes
757
Service Bulletin
ALERT
Number: 757-53A0102
Original Issue: October 08, 2015
ATA System: 5330
SUBJECT: FUSELAGE - Skin - Section 43 - Lap Splice Inspection, Inner Skin Lower Fastener
Row, at S-14R, STA 440-540
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 D624N001 PART 2 for Airplane Variable Number, Line Number,
and Serial Number data.
This service bulletin is for the airplanes shown below.
This service bulletin is applicable to all 757-200/-200CB Airplanes. The Variable Numbers and
Group Information for the applicable airplanes is given below.
DESCRIPTIONCONFIGURATIONGROUP
757-200/-200CB Airplanes-1
Airplane Models:
757-200, 757-200CB
GroupVariable Number
1NA001 - NA002
1NA005
1NA008
1NA021 - NA028
1NA195
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GroupVariable Number
1NA197 - NA199
1NA201 - NA213
1NA215 - NA239
1NA301 - NA305
1NA342 - NA344
1NA346 - NA352
1NA392 - NA399
1NA401 - NA408
1NA441 - NA447
1NA502 - NA505
1NA509 - NA510
1NA512
1NA514 - NA535
1NA537 - NA538
1NA541 - NA546
1NA548 - NA586
1NB001 - NB004
1NB021 - NB023
1NB036 - NB041
1NB052 - NB053
1NB061 - NB068
1NB070 - NB073
1NB079
1NB131 - NB148
1NB161 - NB162
1NB167 - NB168
1NB201 - NB202
1NB221 - NB228
1NB230
1NB236
1NB239
1NB261 - NB267
1NB291 - NB299
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GroupVariable Number
1NB301 - NB302
1NB311 - NB312
1NB321 - NB331
1NB421 - NB424
1NB426 - NB438
1NB446
1NB451 - NB454
1NB501 - NB523
1NB561
1NB571
1NB581 - NB583
1NC001 - NC003
1NC005
1NC008
1NC012 - NC013
1NC017 - NC018
1NC020 - NC022
1NC024
1NC026
1NC029 - NC033
1NC042
1NC051 - NC052
1NC056 - NC062
1NC066 - NC084
1NC091 - NC094
1NC151
1NC161
1ND002
1ND004
1ND011 - ND027
1ND029 - ND044
1ND046 - ND059
1ND111 - ND113
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GroupVariable Number
1ND161 - ND166
1ND168 - ND199
1ND201 - ND203
1ND221 - ND225
1ND241 - ND248
1ND301 - ND322
1ND401
1ND891
1ND895
1NE001 - NE004
1NE006 - NE008
1NE011 - NE030
1NE032 - NE081
1NE083 - NE088
1NE092 - NE094
1NE141 - NE150
1NE161 - NE177
1NE201 - NE204
1NE301
1NE311 - NE325
1NJ001 - NJ004
1NJ031 - NJ032
1NJ551 - NJ555
1NN001 - NN002
1NN051 - NN052
1NP901 - NP904
1NT201 - NT202
1NT231 - NT234
1NT237 - NT240
1NT242
1NT245 - NT248
1NT281 - NT289
1NT341 - NT347
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GroupVariable Number
1NT351 - NT360
1NT371 - NT373
1NT375 - NT379
1NT381 - NT386
1NT401 - NT409
1NT411 - NT412
1NT426 - NT427
1NT431 - NT432
1NT436 - NT438
1NT441 - NT442
1NT446
1NT701 - NT769
1NT791 - NT796
1NT861 - NT862
1NT881 - NT885
1NT901 - NT903
1NT905 - NT916
1NT971 - NT985
1NU031 - NU038
2. Spares Affected
None.
B. Concurrent Requirements
None.
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C. Reason
The inner skin of lap splices at Stringer S-14R, lower fastener row for 757-200, and 757-200CB models
have been determined to be susceptible to Widespread Fatigue Damage (WFD). Cracking was found
on the fatigue test article, and WFD analysis has identified the need for inspections. Currently, there
have been no reports of cracking on airplanes in service. Inspections will mitigate a safety issue,
allowing continued operation to the Limit of Validity (LOV). This action is necessary to find any fatigue
crack in the skin panel. Accomplishment of the inspections in this service bulletin will make sure that
any fuselage skin crack at Stringer S-14R, between STA 440 and STA 540 is found. Continued operation
with any undetected skin crack could adversely affect the structural integrity of the airplane.
The fuselage lap splice inner skin at the locations affected by this service bulletin have been determined
to be structure that is susceptible to Widespread Fatigue Damage (WFD).
D. Description
This service bulletin gives instructions to do either Dual Frequency Eddy Current (DFEC) or High
Frequency Eddy Current (HFEC) inspections of the fuselage lap splice, inner skin lower fastener row,
at S-14R, STA 440-540 for any crack.
If any crack is found, contact The Boeing Company for repair instructions and do the repair.
If no crack is found, repeat the inspections at the interval specified in Paragraph 1.E., Compliance.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones
ZoneModel
232757-200, 757-200CB
E. Compliance
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.
Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.
Two options are given for the inspection and the corresponding corrective action for any crack. Operators
must do OPTION 1 or OPTION 2.
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A logic diagram showing compliance tasks and compliance times is included as an aid in APPENDIX
A and APPENDIX B.
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.
Table 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-
540 (OPTION 1)
Repeat Inter-
val (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 40,000
total flight cycles.
Do PART 1: EXTERNAL DFEC INSPEC-
TION OF INNER SKIN LOWER FASTEN-
ER ROW, AT S-14R, STA 440-540, for
any crack. (a)
All Airplanes
--Before further
flight.
ACTION 1:
Contact The Boeing Company for repair
instructions and do the repair.
CONDITION 1:
ANY CRACK
FOUND
12,000 flight
cycles. (a) (b)
--ACTION 2:
Repeat PART 1: EXTERNAL DFEC IN-
SPECTION OF INNER SKIN LOWER
FASTENER ROW, AT S-14R, STA 440-
540, for any crack at the unrepaired ar-
eas.
12,000 flight
cycles. (a) (b)
--Repeat PART 1: EXTERNAL DFEC IN-
SPECTION OF INNER SKIN LOWER
FASTENER ROW, AT S-14R, STA 440-
540, for any crack.
CONDITION 2:
NO CRACK
FOUND
(a) It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs,
approved by the Boeing ODA via FAA 8100-9 form, cover the affected inspection areas, provided the
repairs extend a minimum of three rows of fasteners common to the outermost repair doubler above and
below the original group of lap splice fasteners. Damage Tolerance Inspection instructions specified in
approval for existing repairs must continue. Inspections outside of the repaired region must continue in
accordance with this service bulletin.
(b) It is acceptable, at operator discretion, to use PART 2: INTERNAL HFEC SURFACE INSPECTION OF
INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 during repeat inspections.
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### Page 16

Table 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R,
STA 440-540 (OPTION 2)
Repeat Inter-
val (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 40,000
total flight cycles.
Do PART 2: INTERNAL HFEC SUR-
FACE INSPECTION OF INNER SKIN
LOWER FASTENER ROW, AT S-14R,
STA 440-540, for any crack. (a)
All Airplanes
--Before further
flight.
ACTION 1:
Contact The Boeing Company for repair
instructions and do the repair.
CONDITION 1:
ANY CRACK
FOUND
12,000 flight
cycles. (a) (b)
--ACTION 2:
Repeat PART 2: INTERNAL HFEC
SURFACE INSPECTION OF INNER
SKIN LOWER FASTENER ROW, AT S-
14R, STA 440-540, for any crack at the
unrepaired areas.
12,000 flight
cycles. (a) (b)
--Repeat PART 2: INTERNAL HFEC
SURFACE INSPECTION OF INNER
SKIN LOWER FASTENER ROW, AT S-
14R, STA 440-540, for any crack.
CONDITION 3:
NO CRACK
FOUND
(a) It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs,
approved by the Boeing ODA via FAA 8100-9 form, cover the affected inspection areas, provided the
repairs extend a minimum of three rows of fasteners common to the outermost repair doubler above and
below the original group of lap splice fasteners. Damage Tolerance Inspection instructions specified in
approval for existing repairs must continue. Inspections outside of the repaired region must continue in
accordance with this service bulletin.
(b) It is acceptable, at operator discretion, to use PART 1: EXTERNAL DFEC INSPECTION OF INNER
SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 during repeat inspections.
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.
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G. Manpower
The table below shows an estimate of the task hours necessary to do this inspection for each airplane.
This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator
task hour data if necessary. The estimate does not include lost time. These are some examples of lost
time:
• Time to adjust to the workplace
• Time to schedule the work
• Time to inspect the work
• Time to cure the materials
• Time to make the parts
• Time to find the tools
OPTION 1
1. EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA
440-540
Elapsed HoursTask HoursNumber of PersonsTask
3.503.501FIGURE 1
3.503.50TOTAL FOR EACH AIRPLANE
(a) Hours for repairs are not included and are dependent on inspection findings.
OPTION 2
1. INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT
S-14R, STA 440-540
Elapsed HoursTask HoursNumber of PersonsTask
1.603.202OPEN ACCESS
3.503.501FIGURE 2
1.603.202CLOSE ACCESS
6.709.90TOTAL FOR EACH AIRPLANE
(a) Hours for repairs are not included and are dependent on inspection findings.
H. Weight and Balance Changes
None.
I. Electrical Load Data
Not changed.
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J. References
1. Existing Data:
a. Boeing Service Letter 757-SL-51-022
b. Service Bulletin Index D624N001
c. Standard Overhaul Practices Manual (SOPM) 20-50-01
d. 757 Aircraft Maintenance Manual (AMM) 25-21-02, 25-21-05, 25-25-01
e. 757 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01, Part 6, 51-00-19, Part 6, 53-00-11
2. Data Supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
SKIN PANEL INSTL - STA 439 TO 661 STGR 14R TO 26L143N3400
SKIN PANEL INSTL - STA 439 THRU 661 AND 781 THRU 900,
STGR 10 TO 14
143N3200
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 but no new DTIs are necessary.
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
None.
B. Industry Support Information
Boeing warranty remedies are not available for the inspections given in this service bulletin.
C. Parts Necessary for Each Airplane
1. Kits/Parts
None.
2. Parts and Materials Supplied by the Operator
None.
3. Parts Modified and Reidentified
None.
4. Parts Removed and Not Replaced
None.
D. Parts Necessary to Change Spares
None.
E. Special Tooling - Price and Availability
None.
F. Special Tooling Necessary to do this Service Bulletin
No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance
and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator tool supply to make sure all necessary tools are available.
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### Page 21

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 757 Structural Repair Manual,
Chapter 51.
— Values for airframe maintenance tasks are included in Chapter 20 of 757
Aircraft Maintenance Manual (AMM).
— Values for electrical maintenance tasks are included in Chapter 20 of
Standard Wiring Practices Manual (SWPM).
— Values for engine maintenance tasks are included in Chapter 70 of 757
Aircraft Maintenance Manual (AMM).
— Non-standard torque values for maintenance tasks are included in the
applicable installation step.
4. Use the approved fastener, process and 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. 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.
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7. Boeing Service Letter 757-SL-51-022, 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.
8. Refer to APPENDIX A, and APPENDIX B for logic diagram(s). 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.
9. 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.
10. 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.
11. Use of colors in Figures is based on guidance from the ATA e-Business Program
(ATA) iSpec 2200.
12. 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.
13. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS
are in Paragraph 1.E., Compliance.
14. Some steps in the Work Instructions are labeled as Required for Compliance (RC).
If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps
labeled as RC, including sub-steps under an RC step and any figures identified in
an RC step, must be done to comply with the AD. An Alternative Method of
Compliance (AMOC) is required for any deviations to RC steps, including sub-steps
and identified figures. Steps not labeled as RC may be deviated from using accepted
methods in accordance with the operator's maintenance or inspection program without
obtaining approval of an AMOC. This is provided that the RC steps, including
sub-steps and identified figures, can still be done as specified, and the airplane can
be put back in an airworthy condition.
B. WORK INSTRUCTIONS
1. RC - Two options are given for the inspection and the corresponding corrective action for any
crack. Operators must do OPTION 1 or OPTION 2.
NOTE: It is not necessary to do inspections in accordance with this service bulletin in areas where
existing repairs, approved by the Boeing ODA via FAA 8100-9 form, cover the affected
inspection areas, provided the repairs extend a minimum of three rows of fasteners
common to the outermost repair doubler above and below the original group of lap splice
fasteners. Damage Tolerance Inspection instructions specified in approval for existing
repairs must continue. Inspections outside of the repaired region must continue in
accordance with this service bulletin.
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a. OPTION 1: External Dual Frequency Eddy Current (DFEC) Inspection:
(1) Do PART 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER
ROW, AT S-14R, STA 440-540, for any crack.
(a) CONDITION 1: ANY CRACK FOUND
1) ACTION 1: Contact The Boeing Company for repair instructions and do the
repair.
2) ACTION 2: Repeat PART 1: EXTERNAL DFEC INSPECTION OF INNER SKIN
LOWER FASTENER ROW, AT S-14R, STA 440-540, for any crack at the
unrepaired areas.
NOTE: It is acceptable, at operator discretion, to use PART 2: INTERNAL
HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER
ROW, AT S-14R, STA 440-540 during repeat inspections.
(b) CONDITION 2: NO CRACK FOUND
1) Repeat PART 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER
FASTENER ROW, AT S-14R, STA 440-540, for any crack, at the repeat interval
in accordance with Paragraph 1.E., Compliance.
NOTE: It is acceptable, at operator discretion, to use PART 2: INTERNAL
HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER
ROW, AT S-14R, STA 440-540 during repeat inspections.
b. OPTION 2: Internal High Frequency Eddy Current (HFEC) Surface Inspection:
(1) Do PART 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER
FASTENER ROW, AT S-14R, STA 440-540, for any crack.
(a) CONDITION 1: ANY CRACK FOUND
1) ACTION 1: Contact The Boeing Company for repair instructions and do the
repair.
2) ACTION 2: Repeat PART 2: INTERNAL HFEC SURFACE INSPECTION OF
INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540, for any crack
at the unrepaired areas.
NOTE: It is acceptable, at operator discretion, to use PART 1: EXTERNAL
DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT
S-14R, STA 440-540 during repeat inspections.
(b) CONDITION 3: NO CRACK FOUND
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1) Repeat PART 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN
LOWER FASTENER ROW, AT S-14R, STA 440-540, for any crack, at the repeat
interval in accordance with Paragraph 1.E., Compliance.
NOTE: It is acceptable, at operator discretion, to use PART 1: EXTERNAL
DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT
S-14R, STA 440-540 during repeat inspections.
2. Put the airplane back to a serviceable condition.
PART 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R,
STA 440-540
1. Do an external DFEC inspection of the inner skin lower fastener row, for any crack, in accordance
with FIGURE 1.
PART 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW,
AT S-14R, STA 440-540
1. Do an internal HFEC surface inspection of the inner skin lower fastener row, for any crack, in
accordance with FIGURE 2.
NOTE: To open and close access, refer to APPENDIX C.
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BOEING SERVICE BULLETIN 757-53A0102
ALERT  ALERT
STA
440
STA
540
— S-14R
0000000000000  STA
440
STA
540
S-14R -
S-14R LAP SPLICE  INSPECTION AREA  2405067
FIGURE 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA
440-540
(SHEET 1 OF 2)
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### Page 26

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
More DataLocationNameTaskStep
(a)S-14R, STA 440 to
STA 540
Inner SkinInspect1
(a) Do an external DFEC inspection of the inner skin for any crack along the lower fastener row, at Stringer
S-14R from STA 440 to STA 540, in accordance with 757 NDT Manual Part 6, 53-00-11.
FIGURE 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA
440-540
(SHEET 2 OF 2)
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### Page 27 (OCR)

BOEING SERVICE BULLETIN 757-53A0102
ALERT  ALERT
STA
440
STA
540
— S-14R
0000000000000  STA
540
0o0
STA
440
S-14R
S-14R LAP SPLICE  INSPECTION AREA  2406130
FIGURE 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT
S-14R, STA 440-540
(SHEET 1 OF 2)
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### Page 28

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
More DataLocationNameTaskStep
(a)S-14R, STA 440 to
STA 540
Inner SkinInspect1
(a) Do an internal HFEC surface inspection of the inner skin for any crack along the lower fastener row, at
Stringer S-14R from STA 440 to STA 540, in accordance with 757 NDT Manual Part 6, 51-00-01, or 757
NDT Manual Part 6, 51-00-19.
FIGURE 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT
S-14R, STA 440-540
(SHEET 2 OF 2)
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### Page 29

Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary
source for compliance times. Information contained in Paragraph 3.B., Work Instructions is the prim ary source
for tasks required for compliance.
1. The table below gives the description for the parts and conditions called out in the following logic
diagram.
DescriptionTitle
EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R,
STA 440-540
PART 1
ANY CRACK FOUNDCONDITION 1
NO CRACK FOUNDCONDITION 2
2. The table below gives the description for the flag notes called out in the following logic diagram.
DescriptionFlag Note Letter
It is not necessary to do inspections in accordance with this service bulletin in areas where
existing repairs, approved by the Boeing ODA via FAA 8100-9 form, cover the affected
inspection areas, provided the repairs extend a minimum of three rows of fasteners
common to the outermost repair doubler above and below the original group of lap splice
fasteners. Damage Tolerance Inspection instructions specified in approval for existing
repairs must continue. Inspections outside of the repaired region must continue in accor-
dance with this service bulletin.
(a)
It is acceptable, at operator discretion, to use PART 2: INTERNAL HFEC SURFACE IN-
SPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 during
repeat inspections.
(b)
APPENDIX A:  LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: EXTERNAL DFEC
INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 (OPTION 1)
(SHEET 1 OF 2)
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### Page 30 (OCR)

BOEING SERVICE BULLETIN 757-53A0102
ALERT  ALERT
WHICHEVER OCCURS LATER
WITHIN 3,000 FLIGHT
CYCLES AFTER THE
BEFORE 40,000 TOTAL  FLIGHT CYCLES  ORIGINAL ISSUE DATE  OF THIS SERVICE
BULLETIN
OPTION 1
DO PART 1 [(a)
CONDITION 1  CONDITION 2
BEFORE FURTHER  NOT TO EXCEED
FLIGHT  12,000 FLIGHT CYCLES
ACTION 1: CONTACT THE
BOEING COMPANY FOR  REPEAT PART 1 [a
REPAIR INSTRUCTIONS  (D)
AND DO THE REPAIR
NOT TO EXCEED
12,000 FLIGHT CYCLES
ACTION 2:
REPEAT PART 1
2421571
APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: EXTERNAL DFEC
INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 (OPTION 1)
(SHEET 2 OF 2)
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### Page 31

Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary
source for compliance times. Information contained in Paragraph 3.B., Work Instructions is the primary source
for tasks required for compliance.
1. The table below gives the description for the parts and conditions called out in the following logic
diagram.
DescriptionTitle
INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW,
AT S-14R, STA 440-540
PART 2
ANY CRACK FOUNDCONDITION 1
NO CRACK FOUNDCONDITION 3
2. The table below gives the description for the flag notes called out in the following logic diagram.
DescriptionFlag Note Letter
It is not necessary to do inspections in accordance with this service bulletin in areas where
existing repairs, approved by the Boeing ODA via FAA 8100-9 form, cover the affected
inspection areas, provided the repairs extend a minimum of three rows of fasteners
common to the outermost repair doubler above and below the original group of lap splice
fasteners. Damage Tolerance Inspection instructions specified in approval for existing
repairs must continue. Inspections outside of the repaired region must continue in accor-
dance with this service bulletin.
(a)
It is acceptable, at operator discretion, to use PART 1: EXTERNAL DFEC INSPECTION
OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 during repeat in-
spections.
(b)
APPENDIX B:  LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 2: INTERNAL HFEC
SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 (OPTION 2)
(SHEET 1 OF 2)
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### Page 32 (OCR)

BOEING SERVICE BULLETIN 757-53A0102
ALERT  ALERT
WHICHEVER OCCURS LATER
WITHIN 3,000 FLIGHT
BEFORE 40,000 TOTAL  FLIGHT CYCLES  CYCLES AFTER THE  ORIGINAL ISSUE DATE  OF THIS SERVICE
BULLETIN
V
OPTION 2
DO PART 2 (a)
CONDITION 1  CONDITION 3
BEFORE FURTHER  NOT TO EXCEED
FLIGHT  12,000 FLIGHT CYCLES
ACTION 1: CONTACT THE
REPAIR INSTRUCTIONS  BOEING COMPANY FOR  REPEAT PART 2 (a)
AND DO THE REPAIR
NOT TO EXCEED
12,000 FLIGHT CYCLES
ACTION 2:
REPEAT PART 2
2426647
APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 2: INTERNAL HFEC
SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 (OPTION 2)
(SHEET 2 OF 2)
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### Page 33

OPEN ACCESS
1. To open access, do as follows:
a. Remove and keep the Passenger Seats. Refer to 757 AMM 25-25-01 as an accepted procedure.
b. Remove and keep the Sidewall Panels. Refer to 757 AMM 25-21-02 as an accepted procedure.
c. Remove and keep the Sidewall Insulation. Refer to 757 AMM 25-21-05 as an accepted procedure.
CLOSE ACCESS
1. To close access, do as follows:
a. Install the kept Sidewall Insulation. Refer to 757 AMM 25-21-05 as an accepted procedure.
b. Install the kept Sidewall Panels. Refer to 757 AMM 25-21-02 as an accepted procedure.
c. Install the kept Passenger Seats. Refer to 757 AMM 25-25-01 as an accepted procedure.
APPENDIX C:  OPEN AND CLOSE ACCESS
(SHEET 1 OF 1)
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---
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