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Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-53A0118 RB Original Issue: October 22, 2021 ATA System: 5363 SUBJECT: FUSELAGE - SECTION 46 - Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection 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: Copyright © 2021 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 Unpublished Work.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 Original Issue: October 22, 2021 757-53A0118 RB 1 of 68 4.0 ### Page 2 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 2 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT BLANK PAGE ### Page 3 Table of Contents 1. EFFECTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 A. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 B. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2. CONCURRENT REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3. COMPLIANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4. APPROVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 5. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. Work Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 FIGURE 1: STA 1380 FRAME - BETWEEN S-22R TO THE LOWER SILL THRESHOLD - GENERAL VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 FIGURE 3: STA 1380 FRAME INNER CHORD - HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 FIGURE 4: STA 1380 FRAME INNER CHORD - LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 FIGURE 5: STA 1380 FRAME WEB - HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION . 60 FIGURE 6: STA 1380 FRAME - GUIDE TRACK FITTING INSTALLATION . . . . . . . . . . . . . . . 63 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 3 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 4 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 4 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT BLANK PAGE ### Page 5 Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-53A0118 RB Original Issue: October 22, 2021 ATA System: 5363 SUBJECT: FUSELAGE - SECTION 46 - Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web 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, 757-300 Airplane(s), line number(s) 1-1050 in 2 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, line number 1 to 57.-1 757-200/-200CB/-200PF/-300 Airplanes, line number 58 to 1050.-2 Airplane Models: 757-200, 757-200CB, 757-200PF, 757-300 GroupVariable Number 1NA001 - NA021 2NA022 - NA028 1NA191 - NA192 GroupVariable Number 2NA193 - NA199 1NA201 - NA217 2NA218 - NA239 GroupVariable Number 2NA301 - NA305 2NA341 - NA352 1NA391 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 5 of 68 ### Page 6 GroupVariable Number 2NA392 - NA399 1NA401 - NA404 2NA405 - NA408 2NA441 - NA447 1NA501 - NA506 2NA507 - NA586 1NB001 - NB004 2NB021 - NB023 2NB036 - NB041 2NB051 - NB053 2NB061 - NB073 2NB079 2NB131 - NB148 2NB161 - NB162 2NB166 - NB168 2NB201 - NB204 2NB221 - NB228 2NB230 2NB236 2NB239 2NB261 - NB267 2NB291 - NB299 2NB301 - NB302 2NB311 - NB312 2NB321 - NB331 2NB421 - NB438 2NB446 2NB451 - NB454 2NB501 - NB523 2NB561 2NB571 2NB581 - NB583 1NC001 - NC002 GroupVariable Number 2NC003 - NC033 2NC041 - NC042 2NC051 - NC052 2NC056 - NC062 2NC066 - NC084 2NC091 - NC094 2NC151 2NC161 2NC901 - NC951 2NC971 - NC974 2ND001 - ND007 2ND011 - ND059 2ND111 - ND113 2ND161 - ND199 2ND201 - ND203 2ND221 - ND225 2ND241 - ND248 2ND301 - ND322 2ND401 2ND891 2ND895 2NE001 - NE008 2NE011 - NE088 2NE091 - NE094 2NE141 - NE150 2NE161 - NE177 2NE201 - NE204 2NE301 - NE302 2NE311 - NE325 2NJ001 - NJ004 2NJ031 - NJ032 2NJ551 - NJ555 2NL001 - NL002 GroupVariable Number 2NL006 - NL017 2NL101 - NL109 2NL141 2NL601 - NL616 2NN001 - NN002 2NN051 - NN052 2NP901 - NP904 2NS601 - NS616 2NT001 - NT009 2NT201 - NT202 2NT231 - NT234 2NT237 - NT240 2NT242 2NT245 - NT248 2NT281 - NT289 2NT341 - NT347 2NT351 - NT360 2NT371 - NT373 2NT375 - NT379 2NT381 - NT386 2NT401 - NT409 2NT411 - NT412 2NT426 - NT427 2NT431 - NT432 2NT436 - NT438 2NT441 - NT442 2NT446 2NT701 - NT769 2NT791 - NT796 2NT861 - NT862 2NT881 - NT885 2NT901 - NT916 2NT971 - NT985 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 6 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 7 GroupVariable Number 2NU031 - NU038 2NU701 - NU705 GroupVariable Number 2NU721 - NU728 2NU731 - NU732 GroupVariable Number -- -- B. Spares Affected None. 2. CONCURRENT REQUIREMENTS None. 3. COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2002-24-02 is related to Requirements Bulletin 757-53A0118 RB. The effective date of AD 2002-24-02 is January 7, 2003. Federal Aviation Administration (FAA) Airworthiness Directive AD 2017-24-10 is related to Requirements Bulletin 757-53A0118 RB. The effective date of AD 2017-24-10 is January 9, 2018. Federal Aviation Administration (FAA) Airworthiness Directive AD 2020-01-18 is related to Requirements Bulletin 757-53A0118 RB. The effective date of AD 2020-01-18 is March 5, 2020. The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to Requirements Bulletin 757-53A0118 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin 757-53A0118 RB mandatory. Group 1: Accomplish the required action(s), based on the applicable condition(s) in Table 1, in accordance with Accomplishment Instructions. Group 2: Accomplish the required action(s), based on the applicable condition(s) in Table 2, 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. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 7 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 8 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,000 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 13,000 to- tal flight cycles. Do a General Visual Inspection or a maintenance records check of the STA 1380 frame for any repair. All Airplanes -Within 3,000 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles or within 13,000 flight cycles after the re- pair was installed, whichever occurs first. CONDITION 1 (ACTION 1): Do a surface High Frequency Eddy Current (HFEC) inspection of the STA 1380 frame inner chord for any crack. CONDITION 1: ANY APPROVED REPAIR FOUND (a)(b) -Within 3,000 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles or within 13,000 flight cycles after the re- pair was installed, whichever occurs first. CONDITION 1 (ACTION 2): Do a sub-surface Low Frequen- cy Eddy Current (LFEC) inspec- tion of the STA 1380 frame in- ner chord for any crack. -Within 3,000 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles or within 13,000 flight cycles after the re- pair was installed, whichever occurs first. CONDITION 1 (ACTION 3): Do a surface HFEC inspection of the STA 1380 frame web for any crack. -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 THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC IN- SPECTION 3,000 flight cycles.-CONDITION 1.1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 8 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 9 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition 3,000 flight cycles.-Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) CONDITION 1.2: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC INSPECTION -Before further flight.CONDITION 1.3 (ACTION 1):CONDITION 1.3: Contact The Boeing Company for repair instructions and do the repair. ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC IN- SPECTION 3,000 flight cycles.-CONDITION 1.3 (ACTION 2): Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) 3,000 flight cycles.-Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) CONDITION 1.4: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 9 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 10 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 1.5 OPTION 1 (ACTION 1): CONDITION 1.5: ANY CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RE- SULT OF THE WEB HFEC INSPECTION Do a STA 1380 frame web re- pair in accordance with the 757 Structural Repair Manual (SRM). 3,000 flight cycles.-CONDITION 1.5 OPTION 1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) -Before further flight.CONDITION 1.5 OPTION 2 (ACTION 1): Contact The Boeing Company for alternative repair instructions and do the repair. 3,000 flight cycles.-CONDITION 1.5 OPTION 2 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) 3,000 flight cycles.-Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) CONDITION 1.6: NO CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 10 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 11 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,000 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 13,000 to- tal flight cycles. CONDITION 2 (ACTION 1): Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspec- tions and applicable corrective actions. CONDITION 2: ANY REPAIR FOUND THAT DOES NOT MEET APPROVED RE- PAIR CRITERIA -Within 3,000 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles. CONDITION 2 (ACTION 2): Do a surface HFEC inspection of the STA 1380 frame inner chord for any crack in the unre- paired areas. -Within 3,000 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles. CONDITION 2 (ACTION 3): Do a sub-surface LFEC inspec- tion of the STA 1380 frame in- ner chord for any crack in the unrepaired areas. -Within 3,000 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles. CONDITION 2 (ACTION 4): Do a surface HFEC inspection of the STA 1380 frame web for any crack in the unrepaired ar- eas. -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 THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC IN- SPECTION 3,000 flight cycles.-CONDITION 2.1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 11 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 12 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition 3,000 flight cycles.-Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) CONDITION 2.2: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC INSPECTION -Before further flight.CONDITION 2.3 (ACTION 1):CONDITION 2.3: Contact The Boeing Company for repair instructions and do the repair. ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC IN- SPECTION 3,000 flight cycles.-CONDITION 2.3 (ACTION 2): Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) 3,000 flight cycles.-Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) CONDITION 2.4: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 12 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 13 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 2.5 OPTION 1 (ACTION 1): CONDITION 2.5: ANY CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RE- SULT OF THE WEB HFEC INSPECTION Do a STA 1380 frame web re- pair in accordance with the 757 Structural Repair Manual (SRM). 3,000 flight cycles.-CONDITION 2.5 OPTION 1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) -Before further flight.CONDITION 2.5 OPTION 2 (ACTION 1): Contact The Boeing Company for alternative repair instructions and do the repair. 3,000 flight cycles.-CONDITION 2.5 OPTION 2 (ACTION 2): Repeat the surface HFEC inspection of the STA 1380 frame web for any crack. (c)(e) 3,000 flight cycles.-Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) CONDITION 2.6: NO CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 13 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 14 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,000 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles. CONDITION 3 (ACTION 1): Do a surface HFEC inspection of the STA 1380 frame inner chord for any crack. CONDITION 3: NO REPAIR FOUND -Within 3,000 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles. CONDITION 3 (ACTION 2): Do a sub-surface LFEC inspec- tion of the STA 1380 frame in- ner chord for any crack. -Within 3,000 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles. CONDITION 3 (ACTION 3): Do a surface HFEC inspection of the STA 1380 frame web for any crack. -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 THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC IN- SPECTION 3,000 flight cycles.-CONDITION 3.1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) 3,000 flight cycles.-Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) CONDITION 3.2: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 14 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 15 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 3.3 (ACTION 1):CONDITION 3.3: Contact The Boeing Company for repair instructions and do the repair. ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC IN- SPECTION 3,000 flight cycles.-CONDITION 3.3 (ACTION 2): Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) 3,000 flight cycles.-Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) CONDITION 3.4: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC INSPECTION -Before further flight.CONDITION 3.5 OPTION 1 (ACTION 1): CONDITION 3.5: ANY CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RE- SULT OF THE WEB HFEC INSPECTION Do a STA 1380 frame web re- pair in accordance with the 757 Structural Repair Manual (SRM). 3,000 flight cycles.-CONDITION 3.5 OPTION 1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) -Before further flight.CONDITION 3.5 OPTION 2 (ACTION 1): Contact The Boeing Company for alternative repair instructions and do the repair. 3,000 flight cycles.-CONDITION 3.5 OPTION 2 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 15 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 16 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition 3,000 flight cycles.-Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) CONDITION 3.6: NO CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION (a) An approved inner chord repair is any inner chord repair with an inner chord segment replacement approved by The Boeing Company Organization Designation Authorization (ODA) via an FAA 8100-9 form. (b) An approved web repair is any web repair accomplished in accordance with 757-200 SRM 53-00-07 Repair 2 or 757-200 SRM 53-00-07 Repair 4 (For 757-200 Special Freighter STC ST00916WI-D only). (c) It is not required to do the surface HFEC inspection in areas where a repair covers or is in 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- 53A0118 RB and installed after the original issue date of Requirements Bulletin 757-53A0118 RB, AND 2. The installed repair was approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. (d) It is not required to do the sub-surface LFEC inspection in areas where a repair covers or is in 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- 53A0118 RB and installed after the original issue date of Requirements Bulletin 757-53A0118 RB, AND 2. The installed repair was approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. (e) Continue to inspect the STA 1380 frame web at the repeat intervals given in Requirements Bulletin 757- 53A0118 RB if a section of the web is replaced in accordance with the SRM. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 16 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 17 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,300 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 13,000 to- tal flight cycles. Do a General Visual Inspection or a maintenance records check of the STA 1380 frame for any repair. All Airplanes -Within 3,300 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles or within 13,000 flight cycles after the re- pair was installed, whichever occurs first. CONDITION 4 (ACTION 1): Do a surface High Frequency Eddy Current (HFEC) inspection of the STA 1380 frame inner chord for any crack. CONDITION 4: ANY APPROVED REPAIR FOUND (a)(b) -Within 3,300 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles or within 13,000 flight cycles after the re- pair was installed, whichever occurs first. CONDITION 4 (ACTION 2): Do a sub-surface Low Frequen- cy Eddy Current (LFEC) inspec- tion of the STA 1380 frame in- ner chord for any crack. -Within 3,300 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles or within 13,000 flight cycles after the re- pair was installed, whichever occurs first. CONDITION 4 (ACTION 3): Do a surface HFEC inspection of the STA 1380 frame web 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 THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC IN- SPECTION 6,000 flight cycles.-CONDITION 4.1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 17 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 18 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition 6,000 flight cycles.-Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) CONDITION 4.2: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC INSPECTION -Before further flight.CONDITION 4.3 (ACTION 1):CONDITION 4.3: Contact The Boeing Company for repair instructions and do the repair. ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC IN- SPECTION 6,000 flight cycles.-CONDITION 4.3 (ACTION 2): Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) 6,000 flight cycles.-Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) CONDITION 4.4: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 18 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 19 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 4.5 OPTION 1 (ACTION 1): CONDITION 4.5: ANY CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RE- SULT OF THE WEB HFEC INSPECTION Do a STA 1380 frame web re- pair in accordance with the 757 Structural Repair Manual (SRM). 6,000 flight cycles.-CONDITION 4.5 OPTION 1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) -Before further flight.CONDITION 4.5 OPTION 2 (ACTION 1): Contact The Boeing Company for alternative repair instructions and do the repair. 6,000 flight cycles.-CONDITION 4.5 OPTION 2 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) 6,000 flight cycles.-Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) CONDITION 4.6: NO CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 19 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 20 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,300 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 13,000 to- tal flight cycles. CONDITION 5 (ACTION 1): Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspec- tions and applicable corrective actions. CONDITION 5: ANY REPAIR FOUND THAT DOES NOT MEET APPROVED RE- PAIR CRITERIA -Within 3,300 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles. CONDITION 5 (ACTION 2): Do a surface HFEC inspection of the STA 1380 frame inner chord for any crack in the unre- paired areas. -Within 3,300 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles. CONDITION 5 (ACTION 3): Do a sub-surface LFEC inspec- tion of the STA 1380 frame in- ner chord for any crack in the unrepaired areas. -Within 3,300 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles. CONDITION 5 (ACTION 4): Do a surface HFEC inspection of the STA 1380 frame web for any crack in the unrepaired ar- eas. -Before further flight.CONDITION 5.1 (ACTION 1):CONDITION 5.1: ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC IN- SPECTION Contact The Boeing Company for repair instructions and do the repair. 6,000 flight cycles.-CONDITION 5.1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 20 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 21 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition 6,000 flight cycles.-Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) CONDITION 5.2: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC INSPECTION -Before further flight.CONDITION 5.3 (ACTION 1):CONDITION 5.3: ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC IN- SPECTION Contact The Boeing Company for repair instructions and do the repair. 6,000 flight cycles.-CONDITION 5.3 (ACTION 2): Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) 6,000 flight cycles.-Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) CONDITION 5.4: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 21 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 22 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 5.5 OPTION 1 (ACTION 1): CONDITION 5.5: ANY CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RE- SULT OF THE WEB HFEC INSPECTION Do a STA 1380 frame web re- pair in accordance with the 757 Structural Repair Manual (SRM). 6,000 flight cycles.-CONDITION 5.5 OPTION 1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) -Before further flight.CONDITION 5.5 OPTION 2 (ACTION 1): Contact The Boeing Company for alternative repair instructions and do the repair. 6,000 flight cycles.-CONDITION 5.5 OPTION 2 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) 6,000 flight cycles.-Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) CONDITION 5.6: NO CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 22 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 23 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,300 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles. CONDITION 6 (ACTION 1): Do a surface HFEC inspection of the STA 1380 frame inner chord for any crack. CONDITION 6: NO REPAIR FOUND -Within 3,300 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles. CONDITION 6 (ACTION 2): Do a sub-surface LFEC inspec- tion of the STA 1380 frame in- ner chord for any crack. -Within 3,300 flight cycles af- ter the original issue date of the Require- ments Bulletin 757-53A0118 RB. Before 20,000 to- tal flight cycles. CONDITION 6 (ACTION 3): Do a surface HFEC inspection of the STA 1380 frame web for any crack. -Before further flight.CONDITION 6.1 (ACTION 1):CONDITION 6.1: Contact The Boeing Company for repair instructions and do the repair. ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC IN- SPECTION 6,000 flight cycles.-CONDITION 6.1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) 6,000 flight cycles.-Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) CONDITION 6.2: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 23 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 24 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 6.3 (ACTION 1):CONDITION 6.3: Contact The Boeing Company for repair instructions and do the repair. ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC IN- SPECTION 6,000 flight cycles.-CONDITION 6.3 (ACTION 2): Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) 6,000 flight cycles.-Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) CONDITION 6.4: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC INSPECTION -Before further flight.CONDITION 6.5 OPTION 1 (ACTION 1): CONDITION 6.5: ANY CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RE- SULT OF THE WEB HFEC INSPECTION Do a STA 1380 frame web re- pair in accordance with the 757 Structural Repair Manual (SRM). 6,000 flight cycles.-CONDITION 6.5 OPTION 1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) -Before further flight.CONDITION 6.5 OPTION 2 (ACTION 1): Contact The Boeing Company for alternative repair instructions and do the repair. 6,000 flight cycles.-CONDITION 6.5 OPTION 2 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 24 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 25 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition 6,000 flight cycles.-Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) CONDITION 6.6: NO CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION (a) An approved inner chord repair is any inner chord repair with an inner chord segment replacement approved by The Boeing Company Organization Designation Authorization (ODA) via an FAA 8100-9 form. (b) An approved web repair is any web repair accomplished in accordance with 757-200 SRM 53-00-07 Repair 2 or 757-200CB SRM 53-00-07 Repair 2 or 757-200PF SRM 53-00-07 Repair 2 or 757-300 SRM 53-00-07 Repair 2 or 757-200 SRM 53-00-07 Repair 4 (For 757-200 Special Freighter STC ST00916WI- D only). (c) It is not required to do the surface HFEC inspection in areas where a repair covers or is in 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- 53A0118 RB and installed after the original issue date of Requirements Bulletin 757-53A0118 RB, AND 2. The installed repair was approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. (d) It is not required to do the sub-surface LFEC inspection in areas where a repair covers or is in 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- 53A0118 RB and installed after the original issue date of Requirements Bulletin 757-53A0118 RB, AND 2. The installed repair was approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. (e) Continue to inspect the STA 1380 frame web at the repeat intervals given in Requirements Bulletin 757- 53A0118 RB if a section of the web is replaced in accordance with the SRM. 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)/Joint Aviation Authorities (JAA) approved for all EASA/JAA 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. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 25 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 26 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 Los Angeles ACO Branch approves accomplishment of the inspections and actions 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 supplemental structural inspections of SSI 53-60-11 [No. 2 Cargo Door Cutout BS 1380 Edge Frame Inner Chord S-23 to Lower Sill (L/N 1-57 & L/N 58 and on)] listed in 757 MPD Document D622N001-9. This AMOC only applies to the common structural inspection areas on the Inner Chord. All provisions of AD 2020-01-18 that are not specifically referenced above remain fully applicable and must be complied with accordingly. In addition, the Manager of the FAA Los Angeles ACO Branch approves accomplishment of the inspections and actions defined in this requirements bulletin as an alternative method of compliance (AMOC) to the requirements of paragraphs (g) and (h) of AD 2017-24-10. This AMOC only applies to the common structural inspection areas on the Inner Chord. All provisions of AD 2017-24-10 that are not specifically referenced above remain fully applicable and must be complied with accordingly. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 26 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 27 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. 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). — 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). Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 27 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 28 — Non-standard torque values for maintenance tasks are included in the applicable installation step. 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 General Visual Inspection 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. 11. 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. 12. 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. 13. A review of the airplane maintenance records can be used if you can conclusively determine STA 1380 frame repair installation. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 28 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 29 B. WORK INSTRUCTIONS Actions Required For Compliance 1. Requirements Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition PART 1: OPEN AC- CESS -Do a General Visual Inspection or a maintenance records check of the STA 1380 frame for any repair. All Airplanes -FIGURE 1 PART 2: CLOSE ACCESS (This step is required if GVI and ON CONDI- TION ACTIONS are not done at same time.) - PART 1: OPEN AC- CESS (This step is required if GVI and ON CONDITION ACTIONS are not done at same time.) -CONDITION 1 (ACTION 1): Do a surface High Frequency Eddy Current (HFEC) inspection of the STA 1380 frame inner chord for any crack. CONDITION 1: ANY APPROVED RE- PAIR FOUND (a)(b) FIGURE 2- -FIGURE 3 -FIGURE 4CONDITION 1 (ACTION 2): Do a sub-surface Low Frequen- cy Eddy Current (LFEC) inspec- tion of the STA 1380 frame in- ner chord for any crack. -FIGURE 5CONDITION 1 (ACTION 3): Do a surface HFEC inspection of the STA 1380 frame web for any crack. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 29 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 30 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition --CONDITION 1.1 (ACTION 1):CONDITION 1.1: Contact The Boeing Company for repair instructions and do the repair. ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RE- SULT OF THE INNER CHORD HFEC INSPEC- TION PART 1: OPEN AC- CESS -CONDITION 1.1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) FIGURE 2- -FIGURE 3 PART 1: OPEN AC- CESS -Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) CONDITION 1.2: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC INSPECTION FIGURE 2- -FIGURE 3 --CONDITION 1.3 (ACTION 1):CONDITION 1.3: Contact The Boeing Company for repair instructions and do the repair. ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RE- SULT OF THE INNER CHORD LFEC INSPEC- TION -FIGURE 4CONDITION 1.3 (ACTION 2): Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) -FIGURE 4Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) CONDITION 1.4: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 30 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 31 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition -757-200 SRM 53-00-07 Repair 2 or 757-200 SRM 53-00-07 Repair 4 (For 757-200 Special Freighter STC ST00916WI-D only) CONDITION 1.5 OPTION 1 (ACTION 1): Do a STA 1380 frame web re- pair in accordance with the 757 Structural Repair Manual (SRM). CONDITION 1.5: ANY CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION -FIGURE 6 PART 2: CLOSE ACCESS - -FIGURE 5CONDITION 1.5 OPTION 1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) --CONDITION 1.5 OPTION 2 (ACTION 1): -FIGURE 6Contact The Boeing Company for alternative repair instructions and do the repair. PART 2: CLOSE ACCESS - -FIGURE 5CONDITION 1.5 OPTION 2 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) -FIGURE 6-CONDITION 1.6: NO CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION PART 2: CLOSE ACCESS - -FIGURE 5Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 31 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 32 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition --CONDITION 2 (ACTION 1):CONDITION 2: Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspec- tions and applicable corrective actions. ANY REPAIR FOUND THAT DOES NOT MEET APPROVED REPAIR CRITERIA PART 1: OPEN AC- CESS (This step is required if GVI and ON CONDITION ACTIONS are not done at same time.) -CONDITION 2 (ACTION 2): Do a surface HFEC inspection of the STA 1380 frame inner chord for any crack in the unre- paired areas. FIGURE 2- -FIGURE 3 -FIGURE 4CONDITION 2 (ACTION 3): Do a sub-surface LFEC inspec- tion of the STA 1380 frame in- ner chord for any crack in the unrepaired areas. -FIGURE 5CONDITION 2 (ACTION 4): Do a surface HFEC inspection of the STA 1380 frame web for any crack in the unrepaired ar- eas. --CONDITION 2.1 (ACTION 1):CONDITION 2.1: ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC INSPECTION Contact The Boeing Company for repair instructions and do the repair. PART 1: OPEN AC- CESS -CONDITION 2.1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) FIGURE 2- -FIGURE 3 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 32 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 33 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition PART 1: OPEN AC- CESS -Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) CONDITION 2.2: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC INSPECTION FIGURE 2- -FIGURE 3 --CONDITION 2.3 (ACTION 1): Contact The Boeing Company for repair instructions and do the repair. CONDITION 2.3: ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC INSPECTION -FIGURE 4CONDITION 2.3 (ACTION 2): Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) -FIGURE 4Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) CONDITION 2.4: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 33 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 34 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition -757-200 SRM 53-00-07 Repair 2 or 757-200 SRM 53-00-07 Repair 4 (For 757-200 Special Freighter STC ST00916WI-D only) CONDITION 2.5 OPTION 1 (ACTION 1): Do a STA 1380 frame web repair in accordance with the 757 Structural Repair Manual (SRM). CONDITION 2.5: ANY CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION -FIGURE 6 PART 2: CLOSE ACCESS - -FIGURE 5CONDITION 2.5 OPTION 1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) --CONDITION 2.5 OPTION 2 (ACTION 1): -FIGURE 6Contact The Boeing Company for alternative repair instructions and do the repair. PART 2: CLOSE ACCESS - -FIGURE 5CONDITION 2.5 OPTION 2 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) -FIGURE 6-CONDITION 2.6: NO CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION PART 2: CLOSE ACCESS - -FIGURE 5Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 34 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 35 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition PART 1: OPEN AC- CESS (This step is required if GVI and ON CONDITION ACTIONS are not done at same time.) -CONDITION 3 (ACTION 1): Do a surface HFEC inspection of the STA 1380 frame inner chord for any crack. CONDITION 3: NO REPAIR FOUND FIGURE 2- -FIGURE 3 -FIGURE 4CONDITION 3 (ACTION 2): Do a sub-surface LFEC inspec- tion of the STA 1380 frame in- ner chord for any crack. -FIGURE 5CONDITION 3 (ACTION 3): Do a surface HFEC inspection of the STA 1380 frame web for any crack. --CONDITION 3.1 (ACTION 1):CONDITION 3.1: Contact The Boeing Company for repair instructions and do the repair. ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RE- SULT OF THE INNER CHORD HFEC INSPEC- TION PART 1: OPEN AC- CESS -CONDITION 3.1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) FIGURE 2- -FIGURE 3 PART 1: OPEN AC- CESS -Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) CONDITION 3.2: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC INSPECTION FIGURE 2- -FIGURE 3 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 35 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 36 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition --CONDITION 3.3 (ACTION 1):CONDITION 3.3: Contact The Boeing Company for repair instructions and do the repair. ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RE- SULT OF THE INNER CHORD LFEC INSPEC- TION -FIGURE 4CONDITION 3.3 (ACTION 2): Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) -FIGURE 4Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) CONDITION 3.4: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 36 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 37 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition -757-200 SRM 53-00-07 Repair 2 or 757-200 SRM 53-00-07 Repair 4 (For 757-200 Special Freighter STC ST00916WI-D only) CONDITION 3.5 OPTION 1 (ACTION 1): Do a STA 1380 frame web re- pair in accordance with the 757 Structural Repair Manual (SRM). CONDITION 3.5: ANY CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION -FIGURE 6 PART 2: CLOSE ACCESS - -FIGURE 5CONDITION 3.5 OPTION 1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) --CONDITION 3.5 OPTION 2 (ACTION 1): -FIGURE 6Contact The Boeing Company for alternative repair instructions and do the repair. PART 2: CLOSE ACCESS - -FIGURE 5CONDITION 3.5 OPTION 2 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) -FIGURE 6-CONDITION 3.6: NO CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION PART 2: CLOSE ACCESS - -FIGURE 5Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) (a) An approved inner chord repair is any inner chord repair with an inner chord segment replacement approved by The Boeing Company Organization Designation Authorization (ODA) via an FAA 8100-9 form. (b) An approved web repair is any web repair accomplished in accordance with 757-200 SRM 53-00-07 Repair 2 or 757-200 SRM 53-00-07 Repair 4 (For 757-200 Special Freighter STC ST00916WI-D only). Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 37 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 38 Group 1: Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition (c) It is not required to do the surface HFEC inspection in areas where a repair covers or is in 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- 53A0118 RB and installed after the original issue date of Requirements Bulletin 757-53A0118 RB, AND 2. The installed repair was approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. (d) It is not required to do the sub-surface LFEC inspection in areas where a repair covers or is in 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- 53A0118 RB and installed after the original issue date of Requirements Bulletin 757-53A0118 RB, AND 2. The installed repair was approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. (e) Continue to inspect the STA 1380 frame web at the repeat intervals given in Requirements Bulletin 757- 53A0118 RB if a section of the web is replaced in accordance with the SRM. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 38 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 39 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition PART 1: OPEN AC- CESS -Do a General Visual Inspection or a maintenance records check of the STA 1380 frame for any repair. All Airplanes -FIGURE 1 PART 2: CLOSE ACCESS (This step is required if GVI and ON CONDI- TION ACTIONS are not done at same time.) - PART 1: OPEN AC- CESS (This step is required if GVI and ON CONDITION ACTIONS are not done at same time.) -CONDITION 4 (ACTION 1): Do a surface High Frequency Eddy Current (HFEC) inspection of the STA 1380 frame inner chord for any crack. CONDITION 4: ANY APPROVED RE- PAIR FOUND (a)(b) FIGURE 2- -FIGURE 3 -FIGURE 4CONDITION 4 (ACTION 2): Do a sub-surface Low Frequen- cy Eddy Current (LFEC) inspec- tion of the STA 1380 frame in- ner chord for any crack. -FIGURE 5CONDITION 4 (ACTION 3): Do a surface HFEC inspection of the STA 1380 frame web for any crack. --CONDITION 4.1 (ACTION 1):CONDITION 4.1: Contact The Boeing Company for repair instructions and do the repair. ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RE- SULT OF THE INNER CHORD HFEC INSPEC- TION PART 1: OPEN AC- CESS -CONDITION 4.1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) FIGURE 2- -FIGURE 3 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 39 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 40 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition PART 1: OPEN AC- CESS -Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) CONDITION 4.2: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC INSPECTION FIGURE 2- -FIGURE 3 --CONDITION 4.3 (ACTION 1):CONDITION 4.3: Contact The Boeing Company for repair instructions and do the repair. ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RE- SULT OF THE INNER CHORD LFEC INSPEC- TION -FIGURE 4CONDITION 4.3 (ACTION 2): Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) -FIGURE 4Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) CONDITION 4.4: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 40 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 41 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition -757-200 SRM 53-00-07 Repair 2 or 757-200CB SRM 53-00- 07 Repair 2 or 757-200PF SRM 53-00-07 Repair 2 or 757-300 SRM 53-00-07 Repair 2 or 757-200 SRM 53-00-07 Repair 4 (For 757-200 Special Freighter STC ST00916WI-D only) CONDITION 4.5 OPTION 1 (ACTION 1): Do a STA 1380 frame web re- pair in accordance with the 757 Structural Repair Manual (SRM). CONDITION 4.5: ANY CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION -FIGURE 6 PART 2: CLOSE ACCESS - -FIGURE 5CONDITION 4.5 OPTION 1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) --CONDITION 4.5 OPTION 2 (ACTION 1): -FIGURE 6Contact The Boeing Company for alternative repair instructions and do the repair. PART 2: CLOSE ACCESS - -FIGURE 5CONDITION 4.5 OPTION 2 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) -FIGURE 6-CONDITION 4.6: NO CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION PART 2: CLOSE ACCESS - -FIGURE 5Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 41 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 42 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition --CONDITION 5 (ACTION 1):CONDITION 5: Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspec- tions and applicable corrective actions. ANY REPAIR FOUND THAT DOES NOT MEET APPROVED REPAIR CRITERIA PART 1: OPEN AC- CESS (This step is required if GVI and ON CONDITION ACTIONS are not done at same time.) -CONDITION 5 (ACTION 2): Do a surface HFEC inspection of the STA 1380 frame inner chord for any crack in the unre- paired areas. FIGURE 2- -FIGURE 3 -FIGURE 4CONDITION 5 (ACTION 3): Do a sub-surface LFEC inspec- tion of the STA 1380 frame in- ner chord for any crack in the unrepaired areas. -FIGURE 5CONDITION 5 (ACTION 4): Do a surface HFEC inspection of the STA 1380 frame web for any crack in the unrepaired ar- eas. --CONDITION 5.1 (ACTION 1):CONDITION 5.1: ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC INSPECTION Contact The Boeing Company for repair instructions and do the repair. PART 1: OPEN AC- CESS -CONDITION 5.1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) FIGURE 2- -FIGURE 3 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 42 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 43 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition PART 1: OPEN AC- CESS -Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) CONDITION 5.2: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC INSPECTION FIGURE 2- -FIGURE 3 --CONDITION 5.3 (ACTION 1): Contact The Boeing Company for repair instructions and do the repair. CONDITION 5.3: ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC INSPECTION -FIGURE 4CONDITION 5.3 (ACTION 2): Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) -FIGURE 4Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) CONDITION 5.4: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 43 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 44 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition -757-200 SRM 53-00-07 Repair 2 or 757-200CB SRM 53-00- 07 Repair 2 or 757-200PF SRM 53-00-07 Repair 2 or 757-300 SRM 53-00-07 Repair 2 or 757-200 SRM 53-00-07 Repair 4 (For 757-200 Special Freighter STC ST00916WI-D only) CONDITION 5.5 OPTION 1 (ACTION 1): Do a STA 1380 frame web re- pair in accordance with the 757 Structural Repair Manual (SRM). CONDITION 5.5: ANY CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION -FIGURE 6 PART 2: CLOSE ACCESS - -FIGURE 5CONDITION 5.5 OPTION 1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) --CONDITION 5.5 OPTION 2 (ACTION 1): -FIGURE 6Contact The Boeing Company for alternative repair instructions and do the repair. PART 2: CLOSE ACCESS - -FIGURE 5CONDITION 5.5 OPTION 2 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) -FIGURE 6-CONDITION 5.6: NO CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION PART 2: CLOSE ACCESS - -FIGURE 5Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 44 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 45 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition PART 1: OPEN AC- CESS (This step is required if GVI and ON CONDITION ACTIONS are not done at same time.) -CONDITION 6 (ACTION 1): Do a surface HFEC inspection of the STA 1380 frame inner chord for any crack. CONDITION 6: NO REPAIR FOUND FIGURE 2- -FIGURE 3 -FIGURE 4CONDITION 6 (ACTION 2): Do a sub-surface LFEC inspec- tion of the STA 1380 frame in- ner chord for any crack. -FIGURE 5CONDITION 6 (ACTION 3): Do a surface HFEC inspection of the STA 1380 frame web for any crack. --CONDITION 6.1 (ACTION 1):CONDITION 6.1: Contact The Boeing Company for repair instructions and do the repair. ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RE- SULT OF THE INNER CHORD HFEC INSPEC- TION PART 1: OPEN AC- CESS -CONDITION 6.1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) FIGURE 2- -FIGURE 3 PART 1: OPEN AC- CESS -Repeat the surface HFEC in- spection of the STA 1380 frame inner chord for any crack. (c) CONDITION 6.2: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD HFEC INSPECTION FIGURE 2- -FIGURE 3 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 45 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 46 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition --CONDITION 6.3 (ACTION 1):CONDITION 6.3: Contact The Boeing Company for repair instructions and do the repair. ANY CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RE- SULT OF THE INNER CHORD LFEC INSPEC- TION -FIGURE 4CONDITION 6.3 (ACTION 2): Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) -FIGURE 4Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack. (d) CONDITION 6.4: NO CRACK FOUND IN THE STA 1380 FRAME INNER CHORD AS THE RESULT OF THE INNER CHORD LFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 46 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 47 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition -757-200 SRM 53-00-07 Repair 2 or 757-200CB SRM 53-00- 07 Repair 2 or 757-200PF SRM 53-00-07 Repair 2 or 757-300 SRM 53-00-07 Repair 2 or 757-200 SRM 53-00-07 Repair 4 (For 757-200 Special Freighter STC ST00916WI-D only) CONDITION 6.5 OPTION 1 (ACTION 1): Do a STA 1380 frame web re- pair in accordance with the 757 Structural Repair Manual (SRM). CONDITION 6.5: ANY CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION -FIGURE 6 PART 2: CLOSE ACCESS - -FIGURE 5CONDITION 6.5 OPTION 1 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) --CONDITION 6.5 OPTION 2 (ACTION 1): -FIGURE 6Contact The Boeing Company for alternative repair instructions and do the repair. PART 2: CLOSE ACCESS - -FIGURE 5CONDITION 6.5 OPTION 2 (ACTION 2): Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) -FIGURE 6-CONDITION 6.6: NO CRACK FOUND IN THE STA 1380 FRAME WEB AS THE RESULT OF THE WEB HFEC INSPECTION PART 2: CLOSE ACCESS - -FIGURE 5Repeat the surface HFEC in- spection of the STA 1380 frame web for any crack. (c)(e) (a) An approved inner chord repair is any inner chord repair with an inner chord segment replacement approved by The Boeing Company Organization Designation Authorization (ODA) via an FAA 8100-9 form. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 47 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 48 Group 2: Table 2: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Refer to the listed procedures in SB 757-53A0118 Origi- nal Issue or later approved revi- sions as an accept- ed procedure. Method of ComplianceActionCondition (b) An approved web repair is any web repair accomplished in accordance with 757-200 SRM 53-00-07 Repair 2 or 757-200CB SRM 53-00-07 Repair 2 or 757-200PF SRM 53-00-07 Repair 2 or 757-300 SRM 53-00-07 Repair 2 or 757-200 SRM 53-00-07 Repair 4 (For 757-200 Special Freighter STC ST00916WI- D only). (c) It is not required to do the surface HFEC inspection in areas where a repair covers or is in 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- 53A0118 RB and installed after the original issue date of Requirements Bulletin 757-53A0118 RB, AND 2. The installed repair was approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. (d) It is not required to do the sub-surface LFEC inspection in areas where a repair covers or is in 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- 53A0118 RB and installed after the original issue date of Requirements Bulletin 757-53A0118 RB, AND 2. The installed repair was approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. (e) Continue to inspect the STA 1380 frame web at the repeat intervals given in Requirements Bulletin 757- 53A0118 RB if a section of the web is replaced in accordance with the SRM. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 48 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 49 (OCR) REQUIREMENTS BULLETIN 757-53A0118 ALERT ALERT STA 1380 STAO S-23R LOWER SILL THRESHOLD NUMBER 2 CARGO DOOR CUTOUT 2968184 FIGURE 1: STA 1380 FRAME - BETWEEN S-22R TO THE LOWER SILL THRESHOLD - GENERAL VISUAL INSPECTION (SHEET 1 OF 2) Original Issue: October 22, 2021 Export Controlled ECCN: 9E991 757-53A0118 RB Copyright © Unpublished Work - See page 1 for details. 49 of 68 ### Page 50 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for this figure. More DataQtyIdentificationNameTaskStep (a)--FRAMEInspect1 (a) Do a General Visual Inspection or a maintenance records check for any repair on the forward and aft side of the STA 1380 frame from S-22R to the lower door sill. FIGURE 1: STA 1380 FRAME - BETWEEN S-22R TO THE LOWER SILL THRESHOLD - GENERAL VISUAL INSPECTION (SHEET 2 OF 2) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 50 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 51 (OCR) REQUIREMENTS BULLETIN 757-53A0118 ALERT ALERT STA 1380 STAO S-23R LOWER SILL THRESHOLD NUMBER 2 CARGO DOOR CUTOUT 2968191 FIGURE 3: STA 1380 FRAME INNER CHORD - HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION (SHEET 1 OF 6) Original Issue: October 22, 2021 Export Controlled ECCN: 9E991 757-53A0118 RB Copyright © Unpublished Work - See page 1 for details. 51 of 68 ### Page 52 (OCR) REQUIREMENTS BULLETIN 757-53A0118 ALERT ALERT WEB INNER CHORD 1 → 5-22R *→5.23R OUTER CHORD LOWER SILL THRESHOLD S-25R INBD S-26R A-A \ SURFACE HFEC 2968187 INSPECTION AREA FIGURE 3: STA 1380 FRAME INNER CHORD - HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION (SHEET 2 OF 6) Original Issue: October 22, 2021 Export Controlled ECCN: 9E991 757-53A0118 RB Copyright © Unpublished Work - See page 1 for details. 52 of 68 ### Page 53 (OCR) REQUIREMENTS BULLETIN 757-53A0118 ALERT ALERT 1 INNER CHORD REVEAL STRIP WEB OUTER CHORD -WD B-B TILLA INSPECTFON AREA 2980137 FIGURE 3: STA 1380 FRAME INNER CHORD - HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION (SHEET 3 OF 6) Original Issue: October 22, 2021 Export Controlled ECCN: 9E991 Copyright © Unpublished 757-53A0118 RB Work - See page 1 for details. 53 of 68 ### Page 54 (OCR) REQUIREMENTS BULLETIN 757-53A0118 ALERT ALERT FOOTPRINT OF REMOVED GUIDE TRACK FITTING BACKUP FITTING <1 INCH MIN 2) INNER CHORD FILLET RADIUS D. 1 INCH MIN WEB S-22R S-23R OUTER CHORD S-24R S-25R S-26R S-27R INBD SURFACE HFEC INSPECTION AREA C-C 2968189 FIGURE 3: STA 1380 FRAME INNER CHORD - HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION (SHEET 4 OF 6) Original Issue: October 22, 2021 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. 54 of 68 ### Page 55 (OCR) REQUIREMENTS BULLETIN 757-53A0118 ALERT ALERT REVEAL STRIP, INNER CHORD BACKUP FITTING FWD D-D INNER CHORD FILLET RADIUS SURFACE HFEC 2968192 INSPECTION AREA FIGURE 3: STA 1380 FRAME INNER CHORD - HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION (SHEET 5 OF 6) Original Issue: October 22, 2021 Export Controlled ECCN: 9E991 Copyright © Unpublished 757-53A0118 RB Work - See page 1 for details. 55 of 68 ### Page 56 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for this figure. More DataQtyIdentificationNameTaskStep (a)-146N8511-2 OR 146N1027-8 INNER CHORDInspect1 (b)-146N8511-2 OR 146N1027-8 INNER CHORDInspect2 (a) Do a surface HFEC inspection for any crack in the STA 1380 frame inner chord, between stringer S-23R and the lower sill threshold, from the aft side of the frame installation, in accordance with 757 NDT Man- ual Part 6, 51-00-01 or 757 NDT Manual Part 6, 51-00-19. (b) Do a surface HFEC inspection for any crack in the STA 1380 frame inner chord fillet radius, above the back up fitting and guide track fitting nut plates, from the forward side of the frame installation, in accordance with 757 NDT Manual Part 6, 51-00-01 or 757 NDT Manual Part 6, 51-00-19. FIGURE 3: STA 1380 FRAME INNER CHORD - HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION (SHEET 6 OF 6) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 56 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 57 (OCR) REQUIREMENTS BULLETIN 757-53A0118 ALERT ALERT STA 1440 STA 1380 STA 1380 SIA 1440 S-24R S-25R S-26R - THRESHOLD NUMBER 2 CARGO DOOR CUTOUT 2968196 FIGURE 4: STA 1380 FRAME INNER CHORD - LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION (SHEET 1 OF 3) Original Issue: October 22, 2021 Export Controlled ECCN: 9E991 757-53A0118 RB Copyright © Unpublished Work - See page 1 for details. 57 of 68 ### Page 58 (OCR) REQUIREMENTS BULLETIN 757-53A0118 ALERT ALERT STA * 1380 5 LOCATIONS ‚FRAME WEB REVEAL STRIP TYPICAL CRACK LOCATION FRAME S-24R INNER CHORD DOOR STOP FRAME OUTER FITTING #5 CHORD FOOTPRINT OF REMOVED GUIDE TRACK FITTING S-25R SKIN SEAL RETAINER BEAR STRAP DOOR STOP LOCATION TYPICAL CRACK FITTING #6 S-26R SUB-SURFACE LFEC INSPECTION AREA 2968197 FIGURE 4: STA 1380 FRAME INNER CHORD - LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION (SHEET 2 OF 3) Original Issue: October 22, 2021 Export Controlled ECCN: 9E991 757-53A0118 RB Copyright © Unpublished Work - See page 1 for details. 58 of 68 ### Page 59 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for this figure. More DataQtyIdentificationNameTaskStep (a)(b)--INNER CHORDInspect1 (a) Do a sub-surface Low Frequency Eddy Current (LFEC) inspection around each fastener or hole for any crack in the inner chord, through the web in accordance with 757 NDT Manual Part 6, 51-00-23. At the fastener locations with nutplates, the rivets that attach the nutplate may cause an edge effect signal which is not a crack indication. AF-4087 is an optional smaller LFEC probe that can be used for fasteners with a short edge distance to the inner chord. (b) The angle of the nutplates and the position of the nutplate rivets may differ from what is shown in this figure. FIGURE 4: STA 1380 FRAME INNER CHORD - LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION (SHEET 3 OF 3) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: October 22, 2021 757-53A0118 RB 59 of 68 REQUIREMENTS BULLETIN 757-53A0118 ALERTALERT ### Page 60 (OCR) REQUIREMENTS BULLETIN 757-53A0118 ALERT ALERT STA 1440 STA 1380 STA 1380 STAO S-24R S-25R S-26R LOWER SILL THRESHOLD NUMBER 2 CARGO DOOR CUTOUT 2972249 FIGURE 5: STA 1380 FRAME WEB - HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION (SHEET 1 OF 3) Original Issue: October 22, 2021 Export Controlled ECCN: 9E991 Copyright © Unpublished 757-53A0118 RB Work - See page 1 for details. 60 of 68 The text continues at https://openairdocs.org/service-documents/boeing/757-53a0118-rb/file/8edc46f889f3.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.