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Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-53A0109 RB Original Issue:
September 25, 2025 ATA System: 5300 SUBJECT: FUSELAGE - Fuselage - Section 43 and Section 46 - Stringer S-14 Lower Panels Removal and Replacement
THIS DOCUMENT IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.
THIS IS AN ENHANCED REQUIRED FOR COMPLIANCE DOCUMENT. THE BOEING PROCESSES USED
TO CREATE THE SERVICE BULLETIN (SB) AND THE REQUIREMENTS BULLETIN (RB) ENSURE THAT THE INFORMATION BETWEEN "RC START" AND "RC END" IN THE SB ARE IDENTICAL TO THE INFORMATION IN THE SAME SECTIONS (COMPLIANCE, WORK INSTRUCTIONS…) OF THE RB WHICH THE SB REFERS TO AS THE RELATED DOCUMENT.
1.
Effectivity A. Airplanes This bulletin is applicable to 757-200, 757-200CB Airplane(s), line number(s) 1-138, 140, 142, 144-146, 148, 150-175, 177-180, 182-183, 185, 187-188, 190, 192, 194, 196, 198, 200-236, 238-257, 259-299, 301-313, 315-317, 319-321, 323-325, 327-329, 331-333, 335-339, 341-394, 396-398, 400-402, 404-406, 408-410, 412-476, 478-480, 482-484, 486-488, 490-492, 494-568, 570-572, 574-576, 578, 580, 582-624, 626-627, 629-630, 632-633, 635, 637, 639, 641, 643, 645, 647-648, 650, 652-653, 655, 657-658, 660-674, 676-678, 680-682, 684-686, 688-690, 692-727, 731-732, 735-754, 756-758, 760-762, 764, 766, 768, 770, 772-773, 775, 777, 779-803, 805-809, 811-812, 814, 816-817, 819-822, 824-838, 840-845, 847-848, 850-854, 856-878, 880-881, 883-905, 907-908, 910-911, 913-914, 916-917, 919-922, 924-925, 927-928, 930-959, 961-962, 964-971, 973-975, 977, 979, 981-984, 986-989, 991-994, 996, 998, 1000, 1002, 1005-1006, 1009-1013, 1015-1016, 1026, 1028-1029, 1041, 1044-1050 in 7 Group(s). Where the effectivity is presented with hyphens between line numbers, the airplane applicability means "through" and "inclusive",
e.g. line numbers 1-9 means line numbers 1 through 9 inclusive.
The Variable Numbers and Group Information for the applicable airplanes is given below.
DESCRIPTIONCONFIGURATIONGROUP 757-200 Passenger airplanes with 2 lower cargo doors with no aft potable water service panel at stringer S-27L, STA 1650.
- 1 757-200 Passenger airplanes with 4 passenger doors and no overwing exit doors, 2 lower cargo doors and aft potable water service panel at stringer S-27L, STA 1650.
- 2 Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 25, 2025 757-53A0109 RB 5 of 105
DESCRIPTIONCONFIGURATIONGROUP 757-200 Passenger airplanes with overwing exit doors, 2 lower cargo doors and aft potable water service panel at stringer S-27L, STA 1650.
- 3 757-200 Passenger airplanes with overwing exit doors, 2 lower cargo doors, aft potable water service panel at stringer S-27L, STA 1650 and Door 4 lavatory service panel, 166AR.
- 4 757-200 Passenger airplanes with 3 lower cargo doors that have not been converted into Special Freighters (SF) in accordance with Boeing Supplemental Type Certificate (STC) ST00916WI-D.
- 5 757-200CB Combi airplane.- 6 190-Passenger Configuration.1 Passenger-Cargo Configuration.2 191-Passenger Configuration.3 757-200 airplanes that have been converted into Special Freighters (SF) in accordance with Boeing STC ST00916WI-D.
- 7 Airplane Models:
757-200, 757-200CB GroupVariable Number 1NA001 - NA028 1NA191 - NA199 7NA201 - NA204 5NA205 7NA206 - NA213 5NA214 7NA215 - NA236 1NA237 - NA239 1NA301 - NA305 5NA341 - NA352 5NA391 - NA399 1NA401 - NA408 GroupVariable Number 1NA441 - NA447 4NA501 - NA586 4NB001 - NB004 1NB021 - NB023 1NB036 - NB041 1NB051 - NB053 1NB061 - NB073 1NB079 1NB131 - NB148 1NB161 - NB162 1NB166 - NB168 1NB201 - NB204 GroupVariable Number 1NB221 - NB228 1NB230 1NB236 1NB239 1NB261 - NB267 1NB291 - NB299 1NB301 - NB302 1NB311 - NB312 1NB321 - NB331 1NB421 - NB438 1NB446 1NB451 - NB454 Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 25, 2025 757-53A0109 RB 6 of 105 REQUIREMENTS BULLETIN 757-53A0109
ALERTALERT
GroupVariable Number 1NB501 - NB523 1NB561 1NB571 1NB581 - NB583 1NC001 - NC033 1NC041 - NC042 1NC051 - NC052 1NC056 - NC062 1NC066 - NC084 1NC091 - NC094 1NC151 1NC161 4ND001 - ND007 4ND011 - ND059 4ND111 - ND113 4ND161 - ND199 4ND201 - ND203 4ND221 - ND225 4ND241 - ND248 4ND301 - ND322 4ND401 GroupVariable Number 4ND891 6ND895 4NE001 - NE008 4NE011 - NE088 4NE091 - NE094 4NE141 - NE150 4NE161 - NE177 4NE201 - NE204 4NE301 - NE302 4NE311 - NE325 2NJ001 - NJ004 2NJ031 - NJ032 2NJ551 - NJ555 3NN001 - NN002 3NN051 - NN052 1NP901 - NP904 1NT201 - NT202 1NT231 - NT234 1NT237 - NT240 1NT242 1NT245 - NT248 GroupVariable Number 1NT281 - NT289 1NT341 - NT347 1NT351 - NT360 1NT371 - NT373 1NT375 - NT379 1NT381 - NT386 1NT401 - NT409 1NT411 - NT412 1NT426 - NT427 1NT431 - NT432 1NT436 - NT438 1NT441 - NT442 1NT446 4NT701 - NT769 4NT791 - NT796 4NT861 - NT862 4NT881 - NT885 4NT901 - NT916 4NT971 - NT985 4NU031 - NU038 -- B.
Spares Affected None.
2. CONCURRENT REQUIREMENTS None.
3. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Requirements Bulletin 757-53A0109 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin 757-53A0109 RB mandatory.
Federal Aviation Administration (FAA) Airworthiness Directives AD 2016-15-04, AD 2018-18-07, AD 2019-07-04, and AD 2020-01-18 are related to Requirements Bulletin 757-53A0109 RB.
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 25, 2025 757-53A0109 RB 7 of 105 REQUIREMENTS BULLETIN 757-53A0109
ALERTALERT
Accomplish the required action(s), based on the applicable condition(s) in Table(s) 1 through 6, in accordance with 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 or an OPTION, do all of the ACTION numbers for that CONDITION or OPTION.
Group 1:
Table 1: Section 43 and Section 46 - Fuselage Skin Panel/Bond Assembly Replacement Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Do a General Visual Inspection (GVI) or a Maintenance Records Check for any existing repair of the fuselage skin panels between stringers S-14 and S-19 on the left and right sides, from STA 439 to STA 661; and between stringers S-14L and S-20L, from STA 1180 to STA 1621; and between stringers S-14R and S- 20R, from STA 1459 to STA 1621.
All Airplanes.
-Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Contact The Boeing Company for alternative modification instructions to the Requirements Bulletin 757-53A0109 RB and do the modification and applicable oncondition action(s).
CONDITION 1:
ANY EXISTING REPAIR FOUND.
-Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Replace the fuselage skin panels or bond assemblies between stringers S-14 and S-19 on the left and right sides, from STA 439 to STA 661; and between stringers S-14L and S-20L, from STA 1180 to STA 1621; and between stringers S-14R and S- 20R, from STA 1459 to STA 1621 with new fuselage skin panels or bond assemblies.
CONDITION 2:
NO EXISTING REPAIR FOUND.
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 25, 2025 757-53A0109 RB 8 of 105 REQUIREMENTS BULLETIN 757-53A0109
ALERTALERT
Group 2:
Table 2: Section 43 and Section 46 - Fuselage Skin Panel/Bond Assembly Replacement Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Do a General Visual Inspection (GVI) or a Maintenance Records Check for any existing repair of the fuselage skin panels between stringers S-14 and S-19 on the left and right sides, from STA 439 to STA 661; and between stringers S-14 and S-20 on the left and right sides, from STA 1180 to STA 1621.
All Airplanes.
-Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Contact The Boeing Company for alternative modification instructions to the Requirements Bulletin 757-53A0109 RB and do the modification and applicable oncondition action(s).
CONDITION 3:
ANY EXISTING REPAIR FOUND.
-Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Replace the fuselage skin panels or bond assemblies between stringers S-14 and S-19 on the left and right sides, from STA 439 to STA 661; and between stringers S-14 and S-20 on the left and right sides, from STA 1180 to STA 1621 with new fuselage skin panels or bond assemblies.
CONDITION 4:
NO EXISTING REPAIR FOUND.
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 25, 2025 757-53A0109 RB 9 of 105 REQUIREMENTS BULLETIN 757-53A0109
ALERTALERT
Group 3-4:
Table 3: Section 43 and Section 46 - Fuselage Skin Panel/Bond Assembly Replacement Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Do a General Visual Inspection (GVI) or a Maintenance Records Check for any existing repair of the fuselage skin panels between stringers S-14 and S-19 on the left and right sides, from STA 439 to STA 661; and between stringers S-14 and S-20 on the left and right sides, from STA 1180 to STA 1621.
All Airplanes.
-Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Contact The Boeing Company for alternative modification instructions to the Requirements Bulletin 757-53A0109 RB and do the modification and applicable oncondition action(s).
CONDITION 5:
ANY EXISTING REPAIR FOUND.
-Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Replace the fuselage skin panels or bond assemblies between stringers S-14 and S-19 on the left and right sides, from STA 439 to STA 661; and between stringers S-14 and S-20 on the left and right sides, from STA 1180 to STA 1621 with new fuselage skin panels or bond assemblies.
CONDITION 6:
NO EXISTING REPAIR FOUND.
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 25, 2025 757-53A0109 RB 10 of 105 REQUIREMENTS BULLETIN 757-53A0109
ALERTALERT
Group 5:
Table 4: Section 43 and Section 46 - Fuselage Skin Panel/Bond Assembly Replacement Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Do a General Visual Inspection (GVI) or a Maintenance Records Check for any existing repair of the fuselage skin panels between stringers S-14 and S-19 on the left and right sides, from STA 439 to STA 661; and between stringers S-14 and S-20 on the left and right sides, from STA 1180 to STA 1621.
All Airplanes.
-Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Contact The Boeing Company for alternative modification instructions to the Requirements Bulletin 757-53A0109 RB and do the modification and applicable oncondition action(s).
CONDITION 7:
ANY EXISTING REPAIR FOUND.
-Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Replace the fuselage skin panels or bond assemblies between stringers S-14 and S-19 on the left and right sides, from STA 439 to STA 661; and between stringers S-14 and S-20 on the left and right sides, from STA 1180 to STA 1621 with new fuselage skin panels or bond assemblies.
CONDITION 8:
NO EXISTING REPAIR FOUND.
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 25, 2025 757-53A0109 RB 11 of 105 REQUIREMENTS BULLETIN 757-53A0109
ALERTALERT
Group 6:
Table 5: Section 43 and Section 46 - Fuselage Skin Panel/Bond Assembly Replacement Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Do a General Visual Inspection (GVI) or a Maintenance Records Check for any existing repair of the fuselage skin panels between stringers S-14R and S-19R, from STA 439 to STA 661; and between stringers S-14 and S-20 on the left and right sides, from STA 1180 to STA 1621.
All Airplanes.
-Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Contact The Boeing Company for alternative modification instructions to the Requirements Bulletin 757-53A0109 RB and do the modification and applicable oncondition action(s).
CONDITION 9:
ANY EXISTING REPAIR FOUND.
-Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Replace the fuselage skin panels or bond assemblies between stringers S-14R and S-19R, from STA 439 to STA 661; and between stringers S-14 and S-20 on the left and right sides, from STA 1180 to STA 1621 with new fuselage skin panels or bond assemblies.
CONDITION 10:
NO EXISTING REPAIR FOUND.
Group 7:
Table 6: Section 43 and Section 46 - Fuselage Skin Panel/Bond Assembly Replacement Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Do a General Visual Inspection (GVI) or a Maintenance Records Check for any existing repair of the fuselage skin panels between stringers S-14R and S-19R, from STA 439 to STA 661; and between stringers S-14 and S-20 on the left and right sides, from STA 1180 to STA 1621.
All Airplanes.
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 25, 2025 757-53A0109 RB 12 of 105 REQUIREMENTS BULLETIN 757-53A0109
ALERTALERT
Group 7:
Table 6: Section 43 and Section 46 - Fuselage Skin Panel/Bond Assembly Replacement Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Contact The Boeing Company for alternative modification instructions to the Requirements Bulletin 757-53A0109 RB and do the modification and applicable oncondition action(s).
CONDITION 11:
ANY EXISTING REPAIR FOUND.
-Within 2,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0109 RB but not earlier than 51,000 total flight cycles.
Before 60,000 total flight cycles but not earlier than 51,000 total flight cycles.
Replace the fuselage skin panels or bond assemblies between stringers S-14R and S-19R, from STA 439 to STA 661; and between stringers S-14 and S-20 on the left and right sides, from STA 1180 to STA 1621 with new fuselage skin panels or bond assemblies.
CONDITION 12:
NO EXISTING REPAIR FOUND.
4.
APPROVAL This Requirements Bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this document comply with the applicable regulations and are FAA approved, as well as European Union Aviation Safety Agency (EASA) approved for all EASA approved airplanes listed in this Requirements Bulletin effectivity. This document and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other Boeing changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this Requirements Bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this Requirements Bulletin.
In addition, the Manager of the FAA Continued Operational Safety Branch approves accomplishment of the modification defined in this requirements bulletin as an alternative method of compliance (AMOC) to the requirements of paragraph (g) of AD 2019-07-04 for the inspections of the inner skin at the S-14L and S-14R fuselage skin lap splices along the lower fastener row at areas common to a skin panel replacement accomplished in accordance with this bulletin. All provisions of AD 2019-07-04 that are not specifically referenced above remain fully applicable and must be complied with accordingly.
In addition, the Manager of the FAA Continued Operational Safety Branch approves accomplishment of the modification defined in this requirements bulletin as an alternative method of compliance (AMOC) to the requirements of paragraph (g) of AD 2016-15-04 for the inspections of the inner skin at the S-14R fuselage skin lap splices along the lower fastener row at areas common to a skin panel replacement accomplished in accordance with this bulletin. All provisions of AD 2016-15-04 that are not specifically referenced above remain fully applicable and must be complied with accordingly.
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 25, 2025 757-53A0109 RB 13 of 105 REQUIREMENTS BULLETIN 757-53A0109
ALERTALERT
In addition, the Manager of the FAA Continued Operational Safety Branch approves accomplishment of the modification defined in this requirements bulletin as an alternative method of compliance (AMOC) to the requirements of paragraph (g) of AD 2018-18-07 for the inspections of the inner skin at the S-14L and S-14R fuselage skin lap splices along the lower fastener row at areas common to a skin panel replacement accomplished in accordance with this bulletin, and for the inspections of the outer skin at the S-19L, S-19R, S-20L and S-20R fuselage skin lap splices along the upper fastener row at areas common to a skin panel replacement accomplished in accordance with this bulletin. All provisions of AD 2018-18-07 that are not specifically referenced above remain fully applicable and must be complied with accordingly.
In addition, the Manager of the FAA Continued Operational Safety Branch approves accomplishment of the modification defined in this requirements bulletin as an alternative method of compliance (AMOC) to the requirements of paragraphs (g) and (h)(1) of AD 2020-01-18 for the SSI 53-30-07 and SSI 53-60-07 inspections of the inner skin at the S-14L and S-14R fuselage skin lap splices along the lower fastener row as listed in Section 9 of Maintenance Planning Document (MPD), D622N001-9, at areas common to a skin panel replacement accomplished in accordance with this bulletin, and for the inspections of the outer skin at the S-19L, S-19R, S-20L and S-20R fuselage skin lap splices along the upper fastener row as listed in Section 9 of Maintenance Planning Document (MPD), D622N001-9, at areas common to a skin panel replacement accomplished in accordance with this bulletin. All provisions of AD 2020-01-18 that are not specifically referenced above remain fully applicable and must be complied with accordingly.
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 25, 2025 757-53A0109 RB 14 of 105 REQUIREMENTS BULLETIN 757-53A0109
ALERTALERT
5. ACCOMPLISHMENT INSTRUCTIONS A.
GENERAL INFORMATION NOTE: 1. This is an Enhanced Required for Compliance document. There will be a separate Service Bulletin (SB) and a separate Requirements Bulletin (RB). If an RB is mandated by an Airworthiness Directive (AD), then all applicable requirements specified in the RB must be done. In the RB, the "Refer to the listed procedures..." column of the table(s) in the Work Instructions is for reference only. The procedures in that column are not required by the AD and are for guidance only. For the related SB, some locations are marked RC Start and RC End to identify the requirements that are restated from the RB. For the related SB, the areas between RC Start and RC End, including sub-steps and any figures identified between RC Start and RC End, must be done to comply with the AD. Therefore, an Alternative Method of Compliance (AMOC) is required for any deviations to steps between RC Start and RC End, including substeps and identified figures. For the related SB, the steps not between RC Start and RC End 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 steps between RC Start and RC End, including sub-steps and identified figures, can still be done as specified, and the airplane can be put back in an airworthy condition. Figures not required for compliance are omitted from the RB.
2.
This is an Enhanced Required for Compliance document. The Boeing processes used to create the Service Bulletin (SB) and the Requirements Bulletin (RB) ensure that the information between "RC Start" and "RC End" in the SB are identical to the information in the same sections (Compliance, Work Instructions...) of the RB which the SB refers to as the related document.
3. The compliance times for the actions in WORK INSTRUCTIONS are in Compliance.
4. 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.
5. Unless shown differently, these dimensions and tolerances are used:
– Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets 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).
— Non-standard torque values for maintenance tasks are included in the applicable installation step.
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 25, 2025 757-53A0109 RB 15 of 105 REQUIREMENTS BULLETIN 757-53A0109
ALERTALERT
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.
7. 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.
8.
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.
9. Use the approved fastener, process and material substitutions in accordance with SRM Chapter 51.
10. A Detailed Inspection (DET) is defined as: An intensive examination of a specific item, installation or assembly to detect damage, failure or irregularity. This could include tactile assessment in which a component or assembly can be checked for tightness/security. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors and magnifying lenses may be necessary. Surface cleaning and elaborate access procedures may be required.
11. A General Visual Inspection (GVI) is defined as: A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance, unless otherwise specified. A mirror may be necessary to enhance visual access to all exposed surfaces in the inspection area. This level of inspection is made under normally available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked.
Basic cleaning may be required to ensure appropriate visibility.
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 or an OPTION, do all of the ACTION numbers for that CONDITION or OPTION.
13. Use of colors in Figures is based on guidance from the ATA e-Business Program (ATA) iSpec 2200.
14. Refer to APPENDIX G through APPENDIX L for skin panel, bond assembly, panel assembly, and panel installation part number applicability.
15. A maintenance records check for repairs on a skin panel to be replaced can be done provided an existing repair can be conclusively determined from that check.
16. Some Boeing skin panel spare parts are supplied in a temporary configuration. Those parts are identified with a 'U' or 'Y' in the place of the '-' (dash) in the part number. It is permitted to install parts identified with a 'U' or 'Y' as an alternative to the '-' (dash) part number. Boeing Drawing 005W0900 contains more data.
Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 25, 2025 757-53A0109 RB 16 of 105 REQUIREMENTS BULLETIN 757-53A0109