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Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-53A0115 RB Original Issue: January 25, 2022 ATA System: 5333 5363 SUBJECT: FUSELAGE - Sections 43 and 46 - S-13 to S-14 Fuselage Frame Splice Inspection EXPORT CONTROLLED - This technology or software is subject to the U.S. Export Administration Regulations (EAR), (15 C.F.R. Parts 730-774). No authorization from the U.S. Department of Commerce is required for export, re-export, in-country transfer, or access EXCEPT to country group E:1 or E:2 countries/persons per Supp.1 to Part 740 of the EAR.

9E991ECCN:

Copyright © 2022 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Unpublished Work.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: January 25, 2022 757-53A0115 RB 1 of 290

2.0

Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 25, 2022 757-53A0115 RB 2 of 290 REQUIREMENTS BULLETIN 757-53A0115

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Table of Contents

1. EFFECTIVITY5

A. Airplanes5

B. Spares Affected7

2. CONCURRENT REQUIREMENTS7

3. COMPLIANCE7

4. APPROVAL57

5. ACCOMPLISHMENT INSTRUCTIONS59

A. General Information59

B. Work Instructions60

FIGURE 1: GENERAL VISUAL INSPECTION - FUSELAGE FRAME SPLICES BETWEEN S-13 AND S-14

IN SECTIONS 43 AND 46 - LEFT SIDE [Group 1-2]116

FIGURE 2: GENERAL VISUAL INSPECTION - FUSELAGE FRAME SPLICES BETWEEN S-13 AND S-14

IN SECTIONS 43 AND 46 - RIGHT SIDE [Group 1-2]122

FIGURE 3: GENERAL VISUAL INSPECTION - FUSELAGE FRAME SPLICES BETWEEN S-13 AND S-14

IN SECTIONS 43 AND 46 - LEFT SIDE [Group 3]128

FIGURE 4: GENERAL VISUAL INSPECTION - FUSELAGE FRAME SPLICES BETWEEN S-13 AND S-14

IN SECTIONS 43 AND 46 - RIGHT SIDE [Group 3]135

FIGURE 5: GENERAL VISUAL INSPECTION - FUSELAGE FRAME SPLICES BETWEEN S-13 AND S-14

IN SECTIONS 43 AND 46 - LEFT SIDE [Group 4]142

FIGURE 6: GENERAL VISUAL INSPECTION - FUSELAGE FRAME SPLICES BETWEEN S-13 AND S-14

IN SECTIONS 43 AND 46 - RIGHT SIDE [Group 4]149

FIGURE 7: GENERAL VISUAL INSPECTION - FUSELAGE FRAME SPLICES BETWEEN S-13 AND S-14

IN SECTIONS 43 AND 46 - LEFT SIDE [Group 5]156

FIGURE 8: GENERAL VISUAL INSPECTION - FUSELAGE FRAME SPLICES BETWEEN S-13 AND S-14

IN SECTIONS 43 AND 46 - RIGHT SIDE [Group 5]163

FIGURE 9: GENERAL VISUAL INSPECTION - FUSELAGE FRAME SPLICES BETWEEN S-13 AND S-14

IN SECTIONS 43 AND 46 - LEFT SIDE [Group 6]170

FIGURE 10: GENERAL VISUAL INSPECTION - FUSELAGE FRAME SPLICES BETWEEN S-13 AND S-14

IN SECTIONS 43 AND 46 - RIGHT SIDE [Group 6]176

FIGURE 11: HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION - UPPER FRAMES AT FUSELAGE FRAME SPLICES BETWEEN S-13 AND S-14 IN SECTION 43 - LEFT SIDE [Group 1-3] . 182 FIGURE 12: HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTIONS - UPPER FRAMES AT FUSELAGE FRAME SPLICES BETWEEN S-13

AND S-14 IN SECTION 46 - LEFT SIDE [Group 1-2, 6]186

FIGURE 13: HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION - UPPER FRAMES AT FUSELAGE FRAME SPLICES BETWEEN S-13 AND S-14 IN SECTION 43 - RIGHT SIDE [Group 1-3, 5-6]

.194

FIGURE 14: HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTIONS - UPPER FRAMES AT FUSELAGE FRAME SPLICES BETWEEN S-13

AND S-14 IN SECTION 46 - RIGHT SIDE [Group 1]200

FIGURE 15: HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTIONS - UPPER FRAMES AT FUSELAGE FRAME SPLICES BETWEEN S-13

AND S-14 IN SECTION 46 - RIGHT SIDE [Group 2, 6]210

FIGURE 16: HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION - UPPER FRAMES AT FUSELAGE FRAME SPLICES BETWEEN S-13 AND S-14 IN SECTION 46 - LEFT SIDE [Group 3, 5] .220 FIGURE 17: HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION - UPPER FRAMES AT FUSELAGE FRAME SPLICES BETWEEN S-13 AND S-14 IN SECTION 46 - RIGHT SIDE [Group 3, 5] .225 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.

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FIGURE 18: HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTIONS - UPPER FRAMES AND SPLICE DOUBLER AT FUSELAGE FRAME

SPLICES BETWEEN S-13 AND S-14 IN SECTION 43 - LEFT SIDE [Group 4]232

FIGURE 19: HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTIONS - UPPER FRAMES AT FUSELAGE FRAME SPLICES BETWEEN S-13

AND S-14 IN SECTION 46 - LEFT SIDE [Group 4]241

FIGURE 20: HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION- UPPER FRAMES AT FUSELAGE FRAME SPLICES BETWEEN S-13 AND S-14 IN SECTION 43 - RIGHT SIDE [Group 4] . 253 FIGURE 21: HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTIONS - UPPER FRAMES AT FUSELAGE FRAME SPLICES BETWEEN S-13

AND S-14 IN SECTION 46 - RIGHT SIDE [Group 4]259

FIGURE 22: HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTIONS - UPPER FRAMES AND SPLICE DOUBLER AT FUSELAGE FRAME

SPLICES BETWEEN S-13 AND S-14 IN SECTION 43 - LEFT SIDE [Group 5]273

FIGURE 23: HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTIONS - UPPER FRAMES AND SPLICE DOUBLER AT FUSELAGE FRAME

SPLICES BETWEEN S-13 AND S-14 IN SECTION 43 - LEFT SIDE [Group 6]282

Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 25, 2022 757-53A0115 RB 4 of 290 REQUIREMENTS BULLETIN 757-53A0115

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Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-53A0115 RB Original Issue: January 25, 2022 ATA System: 5333 5363 SUBJECT: FUSELAGE - Sections 43 and 46 - S-13 to S-14 Fuselage Frame Splice Inspection

THIS DOCUMENT 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 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, 757-200PF Airplane(s), line number(s) 1-803, 805-809, 811-817, 819-838, 840-845, 847-848, 850-854, 856-905, 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 6 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 Airplanes, with 4 doors and 2 lower cargo doors.- 1 757-200 Airplanes, with 4 doors and 3 lower cargo doors.- 2 757-200 Airplanes, with overwing emergency exits.- 3 757-200PF Airplanes.- 4 757-200CB Airplane.- 5 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 25, 2022 757-53A0115 RB 5 of 290

DESCRIPTIONCONFIGURATIONGROUP 757-200 Airplanes that have incorporated STC ST00916WI-D (Special Freighter Conversion).

- 6 Airplane Models:

757-200, 757-200CB, 757-200PF GroupVariable Number 1NA001 - NA028 1NA191 - NA199 6NA201 - NA204 2NA205 6NA206 - NA213 2NA214 6NA215 - NA236 1NA237 - NA239 1NA301 - NA305 2NA341 - NA352 2NA391 - NA399 1NA401 - NA408 1NA441 - NA447 3NA501 - NA586 3NB001 - NB004 1NB021 - NB023 1NB036 - NB041 1NB051 - NB053 1NB061 - NB073 1NB079 1NB131 - NB148 1NB161 - NB162 1NB166 - NB168 1NB201 - NB204 1NB221 - NB228 1NB230 GroupVariable Number 1NB236 1NB239 1NB261 - NB267 1NB291 - NB299 1NB301 - NB302 1NB311 - NB312 1NB321 - NB331 1NB421 - NB438 1NB446 1NB451 - NB454 1NB501 - NB523 1NB561 1NB571 1NB581 - NB583 1NC001 - NC033 1NC041 - NC042 1NC051 - NC052 1NC056 - NC062 1NC066 - NC084 1NC091 - NC094 1NC151 1NC161 4NC901 - NC951 4NC971 - NC974 3ND001 - ND007 3ND011 - ND059 GroupVariable Number 3ND111 - ND113 3ND161 - ND199 3ND201 - ND203 3ND221 - ND225 3ND241 - ND248 3ND301 - ND322 3ND401 3ND891 5ND895 3NE001 - NE008 3NE011 - NE088 3NE091 - NE094 3NE141 - NE150 3NE161 - NE177 3NE201 - NE204 3NE301 - NE302 3NE311 - NE325 1NJ001 - NJ004 1NJ031 - NJ032 1NJ551 - NJ555 3NN001 - NN002 3NN051 - NN052 1NP901 - NP904 4NS601 - NS616 4NT001 - NT009 1NT201 - NT202 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 25, 2022 757-53A0115 RB 6 of 290 REQUIREMENTS BULLETIN 757-53A0115

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GroupVariable Number 1NT231 - NT234 1NT237 - NT240 1NT242 1NT245 - NT248 1NT281 - NT289 1NT341 - NT347 1NT351 - NT360 1NT371 - NT373 GroupVariable Number 1NT375 - NT379 1NT381 - NT386 1NT401 - NT409 1NT411 - NT412 1NT426 - NT427 1NT431 - NT432 1NT436 - NT438 1NT441 - NT442 GroupVariable Number 1NT446 3NT701 - NT769 3NT791 - NT796 3NT861 - NT862 3NT881 - NT885 3NT901 - NT916 3NT971 - NT985 3NU031 - 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 757-53A0115 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin 757-53A0115 RB mandatory.

Accomplish the required actions, based on the applicable conditions in Tables 1 through 10, 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 1-2:

Table 1: Inspections of the Upper Frames at Fuselage Frame Splices between S-13 and S-14 in Sections 43 and 46, Left Side Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,500 flight cycles after the original issue date of Requirements Bulletin 757- 53A0115 RB.

Before 50,000 total flight cycles.

Do General Visual Inspections or a maintenance records check of the upper frames at the frame splices between S-13L and S- 14L in Sections 43 and 46 for any repair.

All airplanes Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 25, 2022 757-53A0115 RB 7 of 290 REQUIREMENTS BULLETIN 757-53A0115

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Group 1-2:

Table 1: Inspections of the Upper Frames at Fuselage Frame Splices between S-13 and S-14 in Sections 43 and 46, Left Side Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,500 flight cycles after the original issue date of Requirements Bulletin 757- 53A0115 RB.

Before 50,000 total flight cycles.

CONDITION 1 (ACTION 1):

Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspections and applicable corrective actions.

CONDITION 1:

ANY REPAIR

FOUND IN SEC- TION 43 -Within 2,500 flight cycles after the original issue date of Requirements Bulletin 757- 53A0115 RB.

Before 50,000 total flight cycles.

CONDITION 1 (ACTION 2):

Do surface High Frequency Eddy Current (HFEC) inspections of the upper frames at the frame splices between S-13L and S- 14L in Section 43 for any crack in the unrepaired frames.

-Before further flight.CONDITION 1.1 (ACTION 1):CONDITION 1.1:

Contact The Boeing Company for repair instructions and do the repair.

ANY CRACK

FOUND IN SEC- TION 43 6,000 flight cycles.-CONDITION 1.1 (ACTION 2):

Repeat the surface HFEC inspections of the upper frames at the frame splices between S- 13L and S-14L in Section 43 for any crack. (a) 6,000 flight cycles.-Repeat the surface HFEC inspections of the upper frames at the frame splices between S- 13L and S-14L in Section 43 for any crack. (a) CONDITION 1.2:

NO CRACK FOUND IN SECTION 43 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 25, 2022 757-53A0115 RB 8 of 290 REQUIREMENTS BULLETIN 757-53A0115

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Group 1-2:

Table 1: Inspections of the Upper Frames at Fuselage Frame Splices between S-13 and S-14 in Sections 43 and 46, Left Side Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,500 flight cycles after the original issue date of Requirements Bulletin 757- 53A0115 RB.

Before 50,000 total flight cycles.

CONDITION 2 (ACTION 1):

Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspections and applicable corrective actions.

CONDITION 2:

ANY REPAIR

FOUND IN SEC- TION 46 -Within 2,500 flight cycles after the original issue date of Requirements Bulletin 757- 53A0115 RB.

Before 50,000 total flight cycles.

CONDITION 2 (ACTION 2):

Do surface HFEC inspections of the upper frames at the frame splices between S-13L and S- 14L in Section 46 for any crack in the unrepaired frames.

-Within 2,500 flight cycles after the original issue date of Requirements Bulletin 757- 53A0115 RB.

Before 50,000 total flight cycles.

CONDITION 2 (ACTION 3):

Do a sub-surface Low Frequency Eddy Current (LFEC) inspection of the upper frame at the frame splice between S-13L and S-14L in Section 46 for any crack in the unrepaired frame.

-Before further flight.CONDITION 2.1 (ACTION 1):CONDITION 2.1:

Contact The Boeing Company for repair instructions and do the repair.

ANY CRACK

FOUND IN SEC- TION 46 3,000 flight cycles.-CONDITION 2.1 (ACTION 2):

Repeat the surface HFEC inspections of the upper frames at the frame splices between S- 13L and S-14L in Section 46 for any crack. (a) 3,000 flight cycles.-CONDITION 2.1 (ACTION 3):

Repeat the sub-surface LFEC inspection of the upper frame at the frame splice between S-13L and S-14L in Section 46 for any crack. (b) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 25, 2022 757-53A0115 RB 9 of 290 REQUIREMENTS BULLETIN 757-53A0115

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Group 1-2:

Table 1: Inspections of the Upper Frames at Fuselage Frame Splices between S-13 and S-14 in Sections 43 and 46, Left Side Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition 3,000 flight cycles.-CONDITION 2.2 (ACTION 1):CONDITION 2.2:

Repeat the surface HFEC inspections of the upper frames at the frame splices between S- 13L and S-14L in Section 46 for any crack. (a)

NO CRACK FOUND IN SECTION 46 3,000 flight cycles.-CONDITION 2.2 (ACTION 2):

Repeat the sub-surface LFEC inspection of the upper frame at the frame splice between S-13L and S-14L in Section 46 for any crack. (b) -Within 2,500 flight cycles after the original issue date of Requirements Bulletin 757- 53A0115 RB.

Before 50,000 total flight cycles.

Do surface HFEC inspections of the upper frames at the frame splices between S-13L and S- 14L in Section 43 for any crack.

CONDITION 3:

NO REPAIR

FOUND IN SEC- TION 43 -Before further flight.CONDITION 3.1 (ACTION 1):CONDITION 3.1:

Contact The Boeing Company for repair instructions and do the repair.

ANY CRACK

FOUND IN SEC- TION 43 6,000 flight cycles.-CONDITION 3.1 (ACTION 2):

Repeat the surface HFEC inspections of the upper frames at the frame splices between S- 13L and S-14L in Section 43 for any crack. (a) 6,000 flight cycles.-Repeat the surface HFEC inspections of the upper frames at the frame splices between S- 13L and S-14L in Section 43 for any crack. (a) CONDITION 3.2:

NO CRACK FOUND IN SECTION 43 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 25, 2022 757-53A0115 RB 10 of 290 REQUIREMENTS BULLETIN 757-53A0115

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Group 1-2:

Table 1: Inspections of the Upper Frames at Fuselage Frame Splices between S-13 and S-14 in Sections 43 and 46, Left Side Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,500 flight cycles after the original issue date of Requirements Bulletin 757- 53A0115 RB.

Before 50,000 total flight cycles.

CONDITION 4 (ACTION 1):

Do surface HFEC inspections of the upper frames at the frame splices between S-13L and S- 14L in Section 46 for any crack.

CONDITION 4:

NO REPAIR

FOUND IN SEC- TION 46 -Within 2,500 flight cycles after the original issue date of Requirements Bulletin 757- 53A0115 RB.

Before 50,000 total flight cycles.

CONDITION 4 (ACTION 2):

Do a sub-surface LFEC inspection of the upper frame at the frame splice between S-13L and S-14L in Section 46 for any crack.

-Before further flight.CONDITION 4.1 (ACTION 1):CONDITION 4.1:

Contact The Boeing Company for repair instructions and do the repair.

ANY CRACK

FOUND IN SEC- TION 46 3,000 flight cycles.-CONDITION 4.1 (ACTION 2):

Repeat the surface HFEC inspections of the upper frames at the frame splices between S- 13L and S-14L in Section 46 for any crack. (a) 3,000 flight cycles.-CONDITION 4.1 (ACTION 3):

Repeat the sub-surface LFEC inspection of the upper frame at the frame splice between S-13L and S-14L in Section 46 for any crack. (b) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 25, 2022 757-53A0115 RB 11 of 290 REQUIREMENTS BULLETIN 757-53A0115

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Group 1-2:

Table 1: Inspections of the Upper Frames at Fuselage Frame Splices between S-13 and S-14 in Sections 43 and 46, Left Side Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition 3,000 flight cycles.-CONDITION 4.2 (ACTION 1):CONDITION 4.2:

Repeat the surface HFEC inspections of the upper frames at the frame splices between S- 13L and S-14L in Section 46 for any crack. (a)

NO CRACK FOUND IN SECTION 46 3,000 flight cycles.-CONDITION 4.2 (ACTION 2):

Repeat the sub-surface LFEC inspection of the upper frame at the frame splice between S-13L and S-14L in Section 46 for any crack. (b)

(a) It is not required to do the surface HFEC inspection in areas where an approved repair covers the affected inspection zone, if the repair meets the conditions that follow:

1. The repair is the corrective action to the crack condition identified in Requirements Bulletin 757- 53A0115 RB and installed after the original issue date of Requirements Bulletin 757-53A0115

RB, AND

2. The installed repair was approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9.

(b) It is not required to do the sub-surface LFEC inspection in areas where an approved repair covers the affected inspection zone, if the repair meets the conditions that follow:

1. The repair is the corrective action to the crack condition identified in Requirements Bulletin 757- 53A0115 RB and installed after the original issue date of Requirements Bulletin 757-53A0115

RB, AND

2. The installed repair was approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9.

Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.

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