# Boeing Alert Requirements Bulletin 757-53A0121 RB: No revision named - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2023-1046; AD 2024-05-09 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Requirements Bulletin 757-53A0121 RB](https://openairdocs.org/service-documents/boeing/757-53a0121-rb.md) - Title as filed: 757-53A0121 RB - Pages: 56 - PDF: https://openairdocs.org/files/sha256/71/0a/710a7becf3c40a4eb52efb441345bce4374b3df3c4022284d5f4d8e9d21f2fb5 - Page: https://openairdocs.org/service-documents/boeing/757-53a0121-rb/file/710a7becf3c4 ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. 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: 757-53A0121 RB Original Issue: September 28, 2022 ATA System: 5360 SUBJECT: FUSELAGE - Structural Inspections - STA 1640 Frame Web common to the Lower Hinge Intercostal Tee Clip - 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 Unpublished Work.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 Original Issue: September 28, 2022 757-53A0121 RB 1 of 56 3.0 ### Page 2 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 2 of 56 REQUIREMENTS BULLETIN 757-53A0121 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 A. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 B. Work Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 FIGURE 1: LEFT SIDE - STA 1640 FRAME WEB AT THE LOWER HINGE INTERCOSTAL TEE CLIP ULTRASONIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 FIGURE 2: RIGHT SIDE - STA 1640 FRAME WEB AT THE LOWER HINGE INTERCOSTAL TEE CLIP ULTRASONIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 APPENDIX I: LEFT SIDE - STA 1640 FRAME AT THE LOWER HINGE INTERCOSTAL TEE CLIP MAINTENANCE RECORDS CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 APPENDIX J: RIGHT SIDE - STA 1640 FRAME AT THE LOWER HINGE INTERCOSTAL TEE CLIP MAINTENANCE RECORDS CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 3 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 4 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 4 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT BLANK PAGE ### Page 5 Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-53A0121 RB Original Issue: September 28, 2022 ATA System: 5360 SUBJECT: FUSELAGE - Structural Inspections - STA 1640 Frame Web common to the Lower Hinge Intercostal Tee Clip - 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, 757-300 Airplane(s), line number(s) 1-49, 51, 53, 55-57, 59-62, 64-76, 79-80, 82-88, 91-92, 94-97, 99-122, 124-138, 140, 142, 144, 146, 148, 150-159, 161-165, 167, 169-174, 177-178, 180, 182-183, 185, 187-188, 190, 192, 194, 196, 198, 200-209, 212-213, 215-236, 238-257, 259-299, 301-313, 315-317, 319-321, 323-325, 327-329, 331-333, 335-339, 341-394, 396-398, 400-402, 404-406, 408-410, 412-476, 478-480, 482-484, 486-488, 490-492, 494-568, 570-572, 574-576, 578, 580, 582-624, 626-627, 629-630, 632-633, 635, 637, 639, 641, 643, 645, 647-648, 650, 652-653, 655, 657-658, 660-674, 676-678, 680-682, 684-686, 688-690, 692-727, 731-732, 735-754, 756-758, 760-762, 764, 766, 768, 770, 772-773, 775, 777, 779-812, 814, 816-822, 824-878, 880-881, 883-1050 in 4 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 and the -200CB airplanes with production line numbers 45 and on that have a long inner chord strap at the Body Station (STA) 1640 fuselage frame. -1 757-300 airplanes.-2 757-200 airplanes within production line numbers 1-44 that have a short inner chord strap at the STA 1640 fuselage frame. -3 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 5 of 56 ### Page 6 DESCRIPTIONCONFIGURATIONGROUP 757-200 Boeing special freighter airplanes (STC ST00916WI-D) within production line numbers 1-44 that have a short inner chord strap at the STA 1640 fuselage frame. -4 Airplane Models: 757-200, 757-200CB, 757-300 GroupVariable Number 3NA001 - NA021 1NA022 - NA028 3NA191 1NA192 - NA199 4NA201 - NA204 3NA205 4NA206 - NA213 3NA214 1NA237 - NA239 1NA301 - NA305 1NA341 - NA352 1NA391 - NA399 3NA401 - NA403 1NA404 - NA408 1NA441 - NA447 3NA501 - NA504 1NA505 - NA586 3NB001 1NB002 - NB004 1NB021 - NB023 1NB036 - NB041 1NB051 - NB053 1NB061 - NB073 1NB079 1NB131 - NB148 GroupVariable Number 1NB161 - NB162 1NB166 - NB168 1NB201 - NB204 1NB221 - NB228 1NB230 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 GroupVariable Number 1NC151 1NC161 1ND001 - ND007 1ND011 - ND059 1ND111 - ND113 1ND161 - ND199 1ND201 - ND203 1ND221 - ND225 1ND241 - ND248 1ND301 - ND322 1ND401 1ND891 1ND895 1NE001 - NE008 1NE011 - NE088 1NE091 - NE094 1NE141 - NE150 1NE161 - NE177 1NE201 - NE204 1NE301 - NE302 1NE311 - NE325 1NJ001 - NJ004 1NJ031 - NJ032 1NJ551 - NJ555 2NL001 - NL002 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 6 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 7 GroupVariable Number 2NL006 - NL017 2NL101 - NL109 2NL141 2NL601 - NL616 1NN001 - NN002 1NN051 - NN052 1NP901 - NP904 1NT201 - NT202 1NT231 - NT234 1NT237 - NT240 1NT242 1NT245 - NT248 GroupVariable Number 1NT281 - NT289 1NT341 - NT347 1NT351 - NT360 1NT371 - NT373 1NT375 - NT379 1NT381 - NT386 1NT401 - NT409 1NT411 - NT412 1NT426 - NT427 1NT431 - NT432 1NT436 - NT438 1NT441 - NT442 GroupVariable Number 1NT446 1NT701 - NT769 1NT791 - NT796 1NT861 - NT862 1NT881 - NT885 1NT901 - NT916 1NT971 - NT985 1NU031 - NU038 2NU701 - NU705 2NU721 - NU728 2NU731 - NU732 -- 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 757-53A0121 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin 757-53A0121 RB mandatory. Accomplish the required action(s), based on the applicable condition(s) in Tables 1 through 8, 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: September 28, 2022 757-53A0121 RB 7 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 8 Group 1: Table 1: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compli- ance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles af- ter the original issue date of Requirements Bulletin 757- 53A0121 RB. Before 20,000 total flight cy- cles. Do a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any ex- isting repair. All Airplanes. -Within 2,000 flight cycles af- ter the original issue date of Requirements Bulletin 757- 53A0121 RB. Within 15,000 flight cycles af- ter the frame segment re- placement. Do the Ultrasonic (UT) inspection of the frame web for any crack. CONDITION 1: THE EXISTING REPAIR FOUND IS A FRAME SEGMENT REPLACE- MENT THAT IS BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -Before further flight.CONDITION 1.1 (AC- TION 1): CONDITION 1.1: ANY CRACK FOUND. Contact The Boeing Company for repair in- structions and do the re- pair. 6,000 flight cycles.-CONDITION 1.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) 6,000 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) CONDITION 1.2: NO CRACK FOUND. -Within 2,000 flight cycles af- ter the original issue date of Requirements Bulletin 757- 53A0121 RB. Before 20,000 total flight cy- cles. Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspec- tions and applicable cor- rective actions. CONDITION 2: THE EXISTING REPAIR FOUND IS NOT A FRAME SEGMENT REPLACE- MENT OR IS A FRAME SEGMENT REPLACE- MENT THAT IS NOT BOEING ODA APPROVED WITH AN FAA FORM 8100-9. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 8 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 9 Group 1: Table 1: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compli- ance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles af- ter the original issue date of Requirements Bulletin 757- 53A0121 RB. Before 20,000 total flight cy- cles. Do the Ultrasonic (UT) inspection of the frame web for any crack. CONDITION 3: NO EXISTING REPAIR IS FOUND. -Before further flight.CONDITION 3.1 (AC- TION 1): CONDITION 3.1: ANY CRACK FOUND. Contact The Boeing Company for repair in- structions and do the re- pair. 6,000 flight cycles-CONDITION 3.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) 6,000 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) CONDITION 3.2: NO CRACK FOUND. (a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 RB in the repair affected area if the repair meets all of the conditions that follow: 1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0121 RB. 2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. 3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0121 RB. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 9 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 10 Group 1: Table 2: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles af- ter the original issue date of Requirements Bulletin 757- 53A0121 RB. Before 20,000 total flight cy- cles. Do a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any ex- isting repair. All Airplanes. -Within 2,000 flight cycles af- ter the original issue date of Requirements Bulletin 757- 53A0121 RB. Within 15,000 flight cycles af- ter the frame segment re- placement. Do the Ultrasonic (UT) inspection of the frame web for any crack. CONDITION 4: THE EXISTING REPAIR FOUND IS A FRAME SEGMENT REPLACE- MENT THAT IS BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -Before further flight.CONDITION 4.1 (AC- TION 1): CONDITION 4.1: ANY CRACK FOUND. Contact The Boeing Company for repair in- structions and do the re- pair. 6,000 flight cycles.-CONDITION 4.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) 6,000 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) CONDITION 4.2: NO CRACK FOUND. -Within 2,000 flight cycles af- ter the original issue date of Requirements Bulletin 757- 53A0121 RB. Before 20,000 total flight cy- cles. Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspec- tions and applicable cor- rective actions. CONDITION 5: THE EXISTING REPAIR FOUND IS NOT A FRAME SEGMENT REPLACE- MENT OR IS A FRAME SEGMENT REPLACE- MENT THAT IS NOT BOEING ODA APPROVED WITH AN FAA FORM 8100-9. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 10 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 11 Group 1: Table 2: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles af- ter the original issue date of Requirements Bulletin 757- 53A0121 RB. Before 20,000 total flight cy- cles. Do the Ultrasonic (UT) inspection of the frame web for any crack. CONDITION 6: NO EXISTING REPAIR FOUND. -Before further flight.CONDITION 6.1 (AC- TION 1): CONDITION 6.1: ANY CRACK FOUND. Contact The Boeing Company for repair in- structions and do the re- pair. 6,000 flight cycles.-CONDITION 6.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) 6,000 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) CONDITION 6.2: NO CRACK FOUND. (a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 RB in the repair affected area if the repair meets all of the conditions that follow: 1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0121 RB. 2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. 3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0121 RB. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 11 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 12 Group 2: Table 3: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Do a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any ex- isting repair. All Airplanes. -Within 2,000 flight cycles af- ter the original issue date of Requirements Bulletin 757- 53A0121 RB. Within 5,600 flight cycles af- ter the frame segment re- placement. Do the Ultrasonic (UT) inspection of the frame web for any crack. CONDITION 7: THE EXISTING REPAIR FOUND IS A FRAME SEGMENT REPLACE- MENT THAT IS BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -Before further flight.CONDITION 7.1 (AC- TION 1): CONDITION 7.1: ANY CRACK FOUND. Contact The Boeing Company for repair in- structions and do the re- pair. 3,200 flight cycles.-CONDITION 7.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) 3,200 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) CONDITION 7.2: NO CRACK FOUND. -Within 2,000 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspec- tions and applicable cor- rective actions. CONDITION 8: THE EXISTING REPAIR FOUND IS NOT A FRAME SEGMENT REPLACE- MENT OR IS A FRAME SEGMENT REPLACE- MENT THAT IS NOT BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -Within 2,000 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Do the Ultrasonic (UT) inspection of the frame web for any crack. CONDITION 9: NO EXISTING REPAIR FOUND. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 12 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 13 Group 2: Table 3: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 9.1 (AC- TION 1): CONDITION 9.1: ANY CRACK FOUND. Contact The Boeing Company for repair in- structions and do the re- pair. 3,200 flight cycles.-CONDITION 9.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) 3,200 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) CONDITION 9.2: NO CRACK FOUND. (a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 RB in the repair affected area if the repair meets all of the conditions that follow: 1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0121 RB. 2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. 3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0121 RB. Group 2: Table 4: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Do a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any ex- isting repair. All Airplanes. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 13 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 14 Group 2: Table 4: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles af- ter the original issue date of Requirements Bulletin 757- 53A0121 RB. Within 5,600 flight cycles af- ter the frame segment re- placement. Do the Ultrasonic (UT) inspection of the frame web for any crack. CONDITION 10: THE EXISTING REPAIR FOUND IS A FRAME SEGMENT REPLACE- MENT THAT IS BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -Before further flight.CONDITION 10.1 (AC- TION 1): CONDITION 10.1: ANY CRACK FOUND. Contact The Boeing Company for repair in- structions and do the re- pair. 3,200 flight cycles.-CONDITION 10.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) 3,200 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) CONDITION 10.2: NO CRACK FOUND. -Within 2,000 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspec- tions and applicable cor- rective actions. CONDITION 11: THE EXISTING REPAIR FOUND IS NOT A FRAME SEGMENT REPLACE- MENT OR IS A FRAME SEGMENT REPLACE- MENT THAT IS NOT BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -Within 2,000 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Do the Ultrasonic (UT) inspection of the frame web for any crack. CONDITION 12: NO EXISTING REPAIR FOUND. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 14 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 15 Group 2: Table 4: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 12.1 (AC- TION 1): CONDITION 12.1: ANY CRACK FOUND. Contact The Boeing Company for repair in- structions and do the re- pair. 3,200 flight cycles.-CONDITION 12.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) 3,200 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) CONDITION 12.2: NO CRACK FOUND. (a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 RB in the repair affected area if the repair meets all of the conditions that follow: 1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0121 RB. 2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. 3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0121 RB. Group 3: Table 5: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Do a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any ex- isting repair. All Airplanes. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 15 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 16 Group 3: Table 5: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles af- ter the original issue date of Requirements Bulletin 757- 53A0121 RB. Within 11,000 flight cycles af- ter the frame segment re- placement. Do the Ultrasonic (UT) inspection of the frame web for any crack. CONDITION 13: THE EXISTING REPAIR FOUND IS A FRAME SEGMENT REPLACE- MENT THAT IS BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -Before further flight.CONDITION 13.1 (AC- TION 1): CONDITION 13.1: ANY CRACK FOUND. Contact The Boeing Company for repair in- structions and do the re- pair. 4,300 flight cycles.-CONDITION 13.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) 4,300 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) CONDITION 13.2: NO CRACK FOUND. -Within 2,000 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspec- tions and applicable cor- rective actions. CONDITION 14: THE EXISTING REPAIR FOUND IS NOT A FRAME SEGMENT REPLACE- MENT OR IS A FRAME SEGMENT REPLACE- MENT THAT IS NOT BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -Within 2,000 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Do the Ultrasonic (UT) inspection of the frame web for any crack. CONDITION 15: NO EXISTING REPAIR FOUND. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 16 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 17 Group 3: Table 5: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 15.1 (AC- TION 1): CONDITION 15.1: ANY CRACK FOUND. Contact The Boeing Company for repair in- structions and do the re- pair. 4,300 flight cycles.-CONDITION 15.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) 4,300 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) CONDITION 15.2: NO CRACK FOUND. (a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 RB in the repair affected area if the repair meets all of the conditions that follow: 1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0121 RB. 2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. 3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0121 RB. Group 3: Table 6: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Do a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any ex- isting repair. All Airplanes. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 17 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 18 Group 3: Table 6: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,000 flight cycles af- ter the original issue date of Requirements Bulletin 757- 53A0121 RB. Within 11,000 flight cycles af- ter the frame segment re- placement. Do the Ultrasonic (UT) inspection of the frame web for any crack. CONDITION 16: THE EXISTING REPAIR FOUND IS A FRAME SEGMENT REPLACE- MENT THAT IS BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -Before further flight.CONDITION 16.1 (AC- TION 1): CONDITION 16.1: ANY CRACK FOUND. Contact The Boeing Company for repair in- structions and do the re- pair. 4,300 flight cycles.-CONDITION 16.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) 4,300 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) CONDITION 16.2: NO CRACK FOUND. -Within 2,000 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspec- tions and applicable cor- rective actions. CONDITION 17: THE EXISTING REPAIR FOUND IS NOT A FRAME SEGMENT REPLACE- MENT OR IS A FRAME SEGMENT REPLACE- MENT THAT IS NOT BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -Within 2,000 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Do the Ultrasonic (UT) inspection of the frame web for any crack. CONDITION 18: NO EXISTING REPAIR FOUND. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 18 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 19 Group 3: Table 6: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 18.1 (AC- TION 1): CONDITION 18.1: ANY CRACK FOUND. Contact The Boeing Company for repair in- structions and do the re- pair. 4,300 flight cycles.-CONDITION 18.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) 4,300 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) CONDITION 18.2: NO CRACK FOUND. (a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 RB in the repair affected area if the repair meets all of the conditions that follow: 1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0121 RB. 2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. 3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0121 RB. Group 4: Table 7: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 1,800 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Do a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any ex- isting repair. All Airplanes. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 19 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 20 Group 4: Table 7: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 1,800 flight cycles af- ter the original issue date of Requirements Bulletin 757- 53A0121 RB. Within 3,000 flight cycles af- ter the frame segment re- placement. Do the Ultrasonic (UT) inspection of the frame web for any crack. CONDITION 19: THE EXISTING REPAIR FOUND IS A FRAME SEGMENT REPLACE- MENT THAT IS BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -Before further flight.CONDITION 19.1 (AC- TION 1): CONDITION 19.1: ANY CRACK FOUND. Contact The Boeing Company for repair in- structions and do the re- pair. 1,800 flight cycles.-CONDITION 19.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) 1,800 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) CONDITION 19.2: NO CRACK FOUND. -Within 1,800 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspec- tions and applicable cor- rective actions. CONDITION 20: THE EXISTING REPAIR FOUND IS NOT A FRAME SEGMENT REPLACE- MENT OR IS A FRAME SEGMENT REPLACE- MENT THAT IS NOT BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -Within 1,800 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Do the Ultrasonic (UT) inspection of the frame web for any crack. CONDITION 21: NO EXISTING REPAIR IS FOUND. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 20 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 21 Group 4: Table 7: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 21.1 (AC- TION 1): CONDITION 21.1: ANY CRACK FOUND. Contact The Boeing Company for repair in- structions and do the re- pair. 1,800 flight cycles.-CONDITION 21.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) 1,800 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) CONDITION 21.2: NO CRACK FOUND. (a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 RB in the repair affected area if the repair meets all of the conditions that follow: 1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0121 RB. 2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. 3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0121 RB. Group 4: Table 8: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 1,800 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Do a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any ex- isting repair. All Airplanes. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 21 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 22 Group 4: Table 8: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 1,800 flight cycles af- ter the original issue date of Requirements Bulletin 757- 53A0121 RB. Within 3,000 flight cycles af- ter the frame segment re- placement. Do the Ultrasonic (UT) inspection of the frame web for any crack. CONDITION 22: THE EXISTING REPAIR FOUND IS A FRAME SEGMENT REPLACE- MENT THAT IS BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -Before further flight.CONDITION 22.1 (AC- TION 1): CONDITION 22.1: ANY CRACK FOUND. Contact The Boeing Company for repair in- structions and do the re- pair. 1,800 flight cycles.-CONDITION 22.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) 1,800 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) CONDITION 22.2: NO CRACK FOUND. -Within 1,800 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspec- tions and applicable cor- rective actions. CONDITION 23: THE EXISTING REPAIR FOUND IS NOT A FRAME SEGMENT REPLACE- MENT OR IS A FRAME SEGMENT REPLACE- MENT THAT IS NOT BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -Within 1,800 flight cycles after the original issue date of Require- ments Bulletin 757-53A0121 RB. Do the Ultrasonic (UT) inspection of the frame web for any crack. CONDITION 24: NO EXISTING REPAIR FOUND. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 22 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 23 Group 4: Table 8: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 24.1 (AC- TION 1): CONDITION 24.1: ANY CRACK FOUND. Contact The Boeing Company for repair in- structions and do the re- pair. 1,800 flight cycles.-CONDITION 24.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) 1,800 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) CONDITION 24.2: NO CRACK FOUND. (a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 RB in the repair affected area if the repair meets all of the conditions that follow: 1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0121 RB. 2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. 3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0121 RB. 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 approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this Requirements Bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this Requirements Bulletin. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 23 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 24 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 24 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT BLANK PAGE ### Page 25 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 engine maintenance tasks are included in Chapter 70 of 757 Aircraft Maintenance Manual (AMM). — Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM). Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 25 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 26 — 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. 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. 8. 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. 9. Use the approved fastener, process and material substitutions in accordance with SRM Chapter 51. 10. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. 11. Documentation should exist for all repairs in the designated areas in this service bulletin and therefore a maintenance records check is needed to conclusively determine if a repair is installed or not. B. WORK INSTRUCTIONS Actions Required For Compliance 1. Requirements Group 1: Table 1: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Refer to the listed proce- dures in SB 757-53A0121 Original Issue or later approved revisions as an accepted procedure. Method of ComplianceActionCondition -APPENDIX IDo a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any existing repair. All Airplanes Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 26 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 27 Group 1: Table 1: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Refer to the listed proce- dures in SB 757-53A0121 Original Issue or later approved revisions as an accepted procedure. Method of ComplianceActionCondition DO PART 1: OPEN AC- CESS. -Do the Ultrasonic (UT) in- spection of the frame web for any crack. CONDITION 1: THE EXISTING REPAIR FOUND IS A FRAME SEGMENT REPLACE- MENT THAT IS BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -FIGURE 1 DO PART 2: CLOSE AC- CESS. -CONDITION 1.1 (ACTION 1): CONDITION 1.1: ANY CRACK FOUND Contact The Boeing Com- pany for repair instructions and do the repair. DO PART 1: OPEN AC- CESS. -CONDITION 1.1 (ACTION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 1 DO PART 2: CLOSE AC- CESS. --CONDITION 1.2: NO CRACK FOUND DO PART 1: OPEN AC- CESS. -Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 1 DO PART 1: OPEN AC- CESS. -Contact The Boeing Com- pany for alternative inspec- tion and corrective action instructions and do the al- ternative inspections and applicable corrective ac- tions. CONDITION 2: THE EXISTING REPAIR FOUND IS NOT A FRAME SEGMENT REPLACE- MENT OR IS A FRAME SEGMENT REPLACE- MENT THAT IS NOT BOEING ODA AP- PROVED WITH AN FAA FORM 8100-9. DO PART 2: CLOSE AC- CESS. - DO PART 1: OPEN AC- CESS. -Do the Ultrasonic (UT) in- spection of the frame web for any crack. CONDITION 3: NO EXISTING REPAIR FOUND -FIGURE 1 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 27 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 28 Group 1: Table 1: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Refer to the listed proce- dures in SB 757-53A0121 Original Issue or later approved revisions as an accepted procedure. Method of ComplianceActionCondition DO PART 2: CLOSE AC- CESS. -CONDITION 3.1 (ACTION 1): CONDITION 3.1: ANY CRACK FOUND Contact The Boeing Com- pany for repair instructions and do the repair. DO PART 1: OPEN AC- CESS. -CONDITION 3.1 (ACTION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 1 DO PART 2: CLOSE AC- CESS. --CONDITION 3.2: NO CRACK FOUND DO PART 1: OPEN AC- CESS. -Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 1 (a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 RB in the repair affected area if the repair meets all of the conditions that follow: 1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0121 RB. 2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. 3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0121 RB. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 28 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 29 Group 1: Table 2: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Refer to the listed proce- dures in SB 757-53A0121 Original Issue or later approved revisions as an accepted procedure. Method of ComplianceActionCondition -APPENDIX JDo a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any existing repair. All Airplanes DO PART 1: OPEN AC- CESS. -Do the Ultrasonic (UT) in- spection of the frame web for any crack. CONDITION 4: THE EXISTING REPAIR FOUND IS A FRAME SEGMENT REPLACE- MENT THAT IS BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -FIGURE 2 DO PART 2: CLOSE AC- CESS. -CONDITION 4.1 (ACTION 1): CONDITION 4.1: ANY CRACK FOUND Contact The Boeing Com- pany for repair instructions and do the repair. DO PART 1: OPEN AC- CESS. -CONDITION 4.1 (ACTION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 2 DO PART 2: CLOSE AC- CESS. --CONDITION 4.2: NO CRACK FOUND DO PART 1: OPEN AC- CESS. -Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 2 DO PART 1: OPEN AC- CESS. -Contact The Boeing Com- pany for alternative inspec- tion and corrective action instructions and do the al- ternative inspections and applicable corrective ac- tions. CONDITION 5: THE EXISTING REPAIR FOUND IS NOT A FRAME SEGMENT REPLACE- MENT OR IS A FRAME SEGMENT REPLACE- MENT THAT IS NOT BOEING ODA AP- PROVED WITH AN FAA FORM 8100-9. DO PART 2: CLOSE AC- CESS. - Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 29 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 30 Group 1: Table 2: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Refer to the listed proce- dures in SB 757-53A0121 Original Issue or later approved revisions as an accepted procedure. Method of ComplianceActionCondition DO PART 1: OPEN AC- CESS. -Do the Ultrasonic (UT) in- spection of the frame web for any crack. CONDITION 6: NO EXISTING REPAIR FOUND -FIGURE 2 DO PART 2: CLOSE AC- CESS. -CONDITION 6.1 (ACTION 1): CONDITION 6.1: ANY CRACK FOUND Contact The Boeing Com- pany for repair instructions and do the repair. DO PART 1: OPEN AC- CESS. -CONDITION 6.1 (ACTION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 2 DO PART 2: CLOSE AC- CESS. --CONDITION 6.2: NO CRACK FOUND DO PART 1: OPEN AC- CESS. -Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 2 (a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 RB in the repair affected area if the repair meets all of the conditions that follow: 1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0121 RB. 2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. 3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0121 RB. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 30 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 31 Group 2: Table 3: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Refer to the listed proce- dures in SB 757-53A0121 Original Issue or later approved revisions as an accepted procedure. Method of ComplianceActionCondition -APPENDIX IDo a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any existing repair. All Airplanes DO PART 1: OPEN AC- CESS. -Do the Ultrasonic (UT) in- spection of the frame web for any crack. CONDITION 7: THE EXISTING REPAIR FOUND IS A FRAME SEGMENT REPLACE- MENT THAT IS BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -FIGURE 1 DO PART 2: CLOSE AC- CESS. -CONDITION 7.1 (ACTION 1): CONDITION 7.1: ANY CRACK FOUND Contact The Boeing Com- pany for repair instructions and do the repair. DO PART 1: OPEN AC- CESS. -CONDITION 7.1 (ACTION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 1 DO PART 2: CLOSE AC- CESS. --CONDITION 7.2: NO CRACK FOUND DO PART 1: OPEN AC- CESS. -Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 1 DO PART 1: OPEN AC- CESS. -Contact The Boeing Com- pany for alternative inspec- tion and corrective action instructions and do the al- ternative inspections and applicable corrective ac- tions. CONDITION 8: THE EXISTING REPAIR FOUND IS NOT A FRAME SEGMENT REPLACE- MENT OR IS A FRAME SEGMENT REPLACE- MENT THAT IS NOT BOEING ODA AP- PROVED WITH AN FAA FORM 8100-9. DO PART 2: CLOSE AC- CESS. - Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 31 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 32 Group 2: Table 3: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Refer to the listed proce- dures in SB 757-53A0121 Original Issue or later approved revisions as an accepted procedure. Method of ComplianceActionCondition DO PART 1: OPEN AC- CESS. -Do the Ultrasonic (UT) in- spection of the frame web for any crack. CONDITION 9: NO EXISTING REPAIR FOUND -FIGURE 1 DO PART 2: CLOSE AC- CESS. -CONDITION 9.1 (ACTION 1): CONDITION 9.1: ANY CRACK FOUND Contact The Boeing Com- pany for repair instructions and do the repair. DO PART 1: OPEN AC- CESS. -CONDITION 9.1 (ACTION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 1 DO PART 2: CLOSE AC- CESS. --CONDITION 9.2: NO CRACK FOUND DO PART 1: OPEN AC- CESS. -Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 1 (a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 RB in the repair affected area if the repair meets all of the conditions that follow: 1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0121 RB. 2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. 3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0121 RB. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 32 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 33 Group 2: Table 4: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Refer to the listed proce- dures in SB 757-53A0121 Original Issue or later approved revisions as an accepted procedure. Method of ComplianceActionCondition -APPENDIX JDo a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any existing repair. All Airplanes DO PART 1: OPEN AC- CESS. -Do the Ultrasonic (UT) in- spection of the frame web for any crack. CONDITION 10: THE EXISTING REPAIR FOUND IS A FRAME SEGMENT REPLACE- MENT THAT IS BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -FIGURE 2 DO PART 2: CLOSE AC- CESS. -CONDITION 10.1 (AC- TION 1): CONDITION 10.1: ANY CRACK FOUND Contact The Boeing Com- pany for repair instructions and do the repair. DO PART 1: OPEN AC- CESS. -CONDITION 10.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 2 DO PART 2: CLOSE AC- CESS. --CONDITION 10.2: NO CRACK FOUND DO PART 1: OPEN AC- CESS. -Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 2 DO PART 1: OPEN AC- CESS. -Contact The Boeing Com- pany for alternative inspec- tion and corrective action instructions and do the al- ternative inspections and applicable corrective ac- tions. CONDITION 11: THE EXISTING REPAIR FOUND IS NOT A FRAME SEGMENT REPLACE- MENT OR IS A FRAME SEGMENT REPLACE- MENT THAT IS NOT BOEING ODA AP- PROVED WITH AN FAA FORM 8100-9. DO PART 2: CLOSE AC- CESS. - Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 33 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 34 Group 2: Table 4: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Refer to the listed proce- dures in SB 757-53A0121 Original Issue or later approved revisions as an accepted procedure. Method of ComplianceActionCondition DO PART 1: OPEN AC- CESS. -Do the Ultrasonic (UT) in- spection of the frame web for any crack. CONDITION 12: NO EXISTING REPAIR FOUND -FIGURE 2 DO PART 2: CLOSE AC- CESS. -CONDITION 12.1 (AC- TION 1): CONDITION 12.1: ANY CRACK FOUND Contact The Boeing Com- pany for repair instructions and do the repair. DO PART 1: OPEN AC- CESS. -CONDITION 12.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 2 DO PART 2: CLOSE AC- CESS. --CONDITION 12.2: NO CRACK FOUND DO PART 1: OPEN AC- CESS. -Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 2 (a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 RB in the repair affected area if the repair meets all of the conditions that follow: 1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0121 RB. 2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. 3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0121 RB. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 34 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 35 Group 3: Table 5: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Refer to the listed proce- dures in SB 757-53A0121 Original Issue or later approved revisions as an accepted procedure. Method of ComplianceActionCondition -APPENDIX IDo a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any existing repair. All Airplanes DO PART 1: OPEN AC- CESS. -Do the Ultrasonic (UT) in- spection of the frame web for any crack. CONDITION 13: THE EXISTING REPAIR FOUND IS A FRAME SEGMENT REPLACE- MENT THAT IS BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -FIGURE 1 DO PART 2: CLOSE AC- CESS. -CONDITION 13.1 (AC- TION 1): CONDITION 13.1: ANY CRACK FOUND Contact The Boeing Com- pany for repair instructions and do the repair. DO PART 1: OPEN AC- CESS. -CONDITION 13.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 1 DO PART 2: CLOSE AC- CESS. --CONDITION 13.2: NO CRACK FOUND DO PART 1: OPEN AC- CESS. -Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 1 DO PART 1: OPEN AC- CESS. -Contact The Boeing Com- pany for alternative inspec- tion and corrective action instructions and do the al- ternative inspections and applicable corrective ac- tions. CONDITION 14: THE EXISTING REPAIR FOUND IS NOT A FRAME SEGMENT REPLACE- MENT OR IS A FRAME SEGMENT REPLACE- MENT THAT IS NOT BOEING ODA AP- PROVED WITH AN FAA FORM 8100-9. DO PART 2: CLOSE AC- CESS. - Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 35 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 36 Group 3: Table 5: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Refer to the listed proce- dures in SB 757-53A0121 Original Issue or later approved revisions as an accepted procedure. Method of ComplianceActionCondition DO PART 1: OPEN AC- CESS. -Do the Ultrasonic (UT) in- spection of the frame web for any crack. CONDITION 15: NO EXISTING REPAIR FOUND -FIGURE 1 DO PART 2: CLOSE AC- CESS. -CONDITION 15.1 (AC- TION 1): CONDITION 15.1: ANY CRACK FOUND Contact The Boeing Com- pany for repair instructions and do the repair. DO PART 1: OPEN AC- CESS. -CONDITION 15.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 1 DO PART 2: CLOSE AC- CESS. --CONDITION 15.2: NO CRACK FOUND DO PART 1: OPEN AC- CESS. -Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 1 (a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 RB in the repair affected area if the repair meets all of the conditions that follow: 1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0121 RB. 2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. 3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0121 RB. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 36 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 37 Group 3: Table 6: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Refer to the listed proce- dures in SB 757-53A0121 Original Issue or later approved revisions as an accepted procedure. Method of ComplianceActionCondition -APPENDIX JDo a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any existing repair. All Airplanes DO PART 1: OPEN AC- CESS. -Do the Ultrasonic (UT) in- spection of the frame web for any crack. CONDITION 16: THE EXISTING REPAIR FOUND IS A FRAME SEGMENT REPLACE- MENT THAT IS BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -FIGURE 2 DO PART 2: CLOSE AC- CESS. -CONDITION 16.1 (AC- TION 1): CONDITION 16.1: ANY CRACK FOUND Contact The Boeing Com- pany for repair instructions and do the repair. DO PART 1: OPEN AC- CESS. -CONDITION 16.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 2 DO PART 2: CLOSE AC- CESS. --CONDITION 16.2: NO CRACK FOUND DO PART 1: OPEN AC- CESS. -Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 2 DO PART 1: OPEN AC- CESS. -Contact The Boeing Com- pany for alternative inspec- tion and corrective action instructions and do the al- ternative inspections and applicable corrective ac- tions. CONDITION 17: THE EXISTING REPAIR FOUND IS NOT A FRAME SEGMENT REPLACE- MENT OR IS A FRAME SEGMENT REPLACE- MENT THAT IS NOT BOEING ODA AP- PROVED WITH AN FAA FORM 8100-9. DO PART 2: CLOSE AC- CESS. - Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 37 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 38 Group 3: Table 6: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Refer to the listed proce- dures in SB 757-53A0121 Original Issue or later approved revisions as an accepted procedure. Method of ComplianceActionCondition DO PART 1: OPEN AC- CESS. -Do the Ultrasonic (UT) in- spection of the frame web for any crack. CONDITION 18: NO EXISTING REPAIR FOUND -FIGURE 2 DO PART 2: CLOSE AC- CESS. -CONDITION 18.1 (AC- TION 1): CONDITION 18.1: ANY CRACK FOUND Contact The Boeing Com- pany for repair instructions and do the repair. DO PART 1: OPEN AC- CESS. -CONDITION 18.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 2 DO PART 2: CLOSE AC- CESS. --CONDITION 18.2: NO CRACK FOUND DO PART 1: OPEN AC- CESS. -Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 2 (a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 RB in the repair affected area if the repair meets all of the conditions that follow: 1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0121 RB. 2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. 3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0121 RB. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 38 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 39 Group 4: Table 7: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Refer to the listed proce- dures in SB 757-53A0121 Original Issue or later approved revisions as an accepted procedure. Method of ComplianceActionCondition -APPENDIX IDo a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any existing repair. All Airplanes DO PART 1: OPEN AC- CESS. -Do the Ultrasonic (UT) in- spection of the frame web for any crack. CONDITION 19: THE EXISTING REPAIR FOUND IS A FRAME SEGMENT REPLACE- MENT THAT IS BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -FIGURE 1 DO PART 2: CLOSE AC- CESS. -CONDITION 19.1 (AC- TION 1): CONDITION 19.1: ANY CRACK FOUND Contact The Boeing Com- pany for repair instructions and do the repair. DO PART 1: OPEN AC- CESS. -CONDITION 19.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 1 DO PART 2: CLOSE AC- CESS. --CONDITION 19.2: NO CRACK FOUND DO PART 1: OPEN AC- CESS. -Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 1 DO PART 1: OPEN AC- CESS. -Contact The Boeing Com- pany for alternative inspec- tion and corrective action instructions and do the al- ternative inspections and applicable corrective ac- tions. CONDITION 20: THE EXISTING REPAIR FOUND IS NOT A FRAME SEGMENT REPLACE- MENT OR IS A FRAME SEGMENT REPLACE- MENT THAT IS NOT BOEING ODA AP- PROVED WITH AN FAA FORM 8100-9. DO PART 2: CLOSE AC- CESS. - Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 39 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 40 Group 4: Table 7: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Refer to the listed proce- dures in SB 757-53A0121 Original Issue or later approved revisions as an accepted procedure. Method of ComplianceActionCondition DO PART 1: OPEN AC- CESS. -Do the Ultrasonic (UT) in- spection of the frame web for any crack. CONDITION 21: NO EXISTING REPAIR FOUND -FIGURE 1 DO PART 2: CLOSE AC- CESS. -CONDITION 21.1 (AC- TION 1): CONDITION 21.1: ANY CRACK FOUND Contact The Boeing Com- pany for repair instructions and do the repair. DO PART 1: OPEN AC- CESS. -CONDITION 21.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 1 DO PART 2: CLOSE AC- CESS. --CONDITION 21.2: NO CRACK FOUND DO PART 1: OPEN AC- CESS. -Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 1 (a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 RB in the repair affected area if the repair meets all of the conditions that follow: 1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0121 RB. 2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. 3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0121 RB. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 40 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 41 Group 4: Table 8: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Refer to the listed proce- dures in SB 757-53A0121 Original Issue or later approved revisions as an accepted procedure. Method of ComplianceActionCondition -APPENDIX JDo a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any existing repair. All Airplanes DO PART 1: OPEN AC- CESS. -Do the Ultrasonic (UT) in- spection of the frame web for any crack. CONDITION 22: THE EXISTING REPAIR FOUND IS A FRAME SEGMENT REPLACE- MENT THAT IS BOEING ODA APPROVED WITH AN FAA FORM 8100-9. -FIGURE 2 DO PART 2: CLOSE AC- CESS. -CONDITION 22.1 (AC- TION 1): CONDITION 22.1: ANY CRACK FOUND Contact The Boeing Com- pany for repair instructions and do the repair. DO PART 1: OPEN AC- CESS. -CONDITION 22.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 2 DO PART 2: CLOSE AC- CESS. --CONDITION 22.2: NO CRACK FOUND DO PART 1: OPEN AC- CESS. -Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 2 DO PART 1: OPEN AC- CESS. -Contact The Boeing Com- pany for alternative inspec- tion and corrective action instructions and do the al- ternative inspections and applicable corrective ac- tions. CONDITION 23: THE EXISTING REPAIR FOUND IS NOT A FRAME SEGMENT REPLACE- MENT OR IS A FRAME SEGMENT REPLACE- MENT THAT IS NOT BOEING ODA AP- PROVED WITH AN FAA FORM 8100-9. DO PART 2: CLOSE AC- CESS. - Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 41 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 42 Group 4: Table 8: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip Refer to the listed proce- dures in SB 757-53A0121 Original Issue or later approved revisions as an accepted procedure. Method of ComplianceActionCondition DO PART 1: OPEN AC- CESS. -Do the Ultrasonic (UT) in- spection of the frame web for any crack. CONDITION 24: NO EXISTING REPAIR FOUND -FIGURE 2 DO PART 2: CLOSE AC- CESS. -CONDITION 24.1 (AC- TION 1): CONDITION 24.1: ANY CRACK FOUND Contact The Boeing Com- pany for repair instructions and do the repair. DO PART 1: OPEN AC- CESS. -CONDITION 24.1 (AC- TION 2): Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 2 DO PART 2: CLOSE AC- CESS. --CONDITION 24.2: NO CRACK FOUND DO PART 1: OPEN AC- CESS. -Repeat the Ultrasonic (UT) inspection of the frame web for any crack. (a) -FIGURE 2 (a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 RB in the repair affected area if the repair meets all of the conditions that follow: 1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0121 RB. 2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9. 3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0121 RB. Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 42 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 43 (OCR) REQUIREMENTS BULLETIN 757-53A0121 ALERT ALERT STA 1640 STA 1640 - S-13L LOWER HINGE INTERCOSTAL - S-14L - S-15L 0000 0000000 oooooooooo - S-16L FWD VIEW LOOKING OUTBOARD 3002110 FIGURE 1: LEFT SIDE - STA 1640 FRAME WEB AT THE LOWER HINGE INTERCOSTAL TEE CLIP ULTRASONIC INSPECTION (SHEET 1 OF 4) Original Issue: September 28, 2022 Export Controlled ECCN: 9E991 757-53A0121 RB Copyright © Unpublished Work - See page 1 for details. 43 of 56 ### Page 44 (OCR) REQUIREMENTS BULLETIN 757-53A0121 ALERT ALERT SUPPORT FITTING • OUTER CHORD TYPICAL CRACKS IN FRAME WEB FRAME WEB LOWER HINGE FITTING TEE CLIP LOWER HINGE INTERCOSTAL INBD A TRANSDUCER POSITION ULTRASONIC INSPECTION VIEW LOOKING AFT 3002111 FIGURE 1: LEFT SIDE - STA 1640 FRAME WEB AT THE LOWER HINGE INTERCOSTAL TEE CLIP ULTRASONIC INSPECTION (SHEET 2 OF 4) Original Issue: September 28, 2022 757-53A0121 RB Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. 44 of 56 ### Page 45 (OCR) REQUIREMENTS BULLETIN 757-53A0121 ALERT ALERT STA 1640 FRAME WEB TEE CLIP LOWER HINGE FITTING ULTRASONIC INSPECTION AREA FWD (VIEW LOOKING DOWN ROTATED 90° CLOCKWISE A-A 3004078 FIGURE 1: LEFT SIDE - STA 1640 FRAME WEB AT THE LOWER HINGE INTERCOSTAL TEE CLIP ULTRASONIC INSPECTION (SHEET 3 OF 4) Original Issue: September 28, 2022 Export Controlled ECCN: 9E991 757-53A0121 RB Copyright © Unpublished Work - See page 1 for details. 45 of 56 ### Page 46 More DataQtyIdentificationNameTaskStep (a)--STA 1640 Frame WebInspect1 (a) Do an Ultrasonic (UT) inspection of the STA 1640 frame web at the two fastener locations common to the lower hinge intercostal tee clip upper fastener row for any crack in accordance with 757 NDT Manual Part 4, 53-60-01. FIGURE 1: LEFT SIDE - STA 1640 FRAME WEB AT THE LOWER HINGE INTERCOSTAL TEE CLIP ULTRASONIC INSPECTION (SHEET 4 OF 4) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 46 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 47 (OCR) REQUIREMENTS BULLETIN 757-53A0121 ALERT ALERT / STA 1640 STA 1640 S-13R- 000 LOWER • HINGE INTERCOSTAL S-14R .o..... S-15R - o000o0000000 .... ITS S-16R - .... FWD VIEW LOOKING OUTBOARD 3002112 FIGURE 2: RIGHT SIDE - STA 1640 FRAME WEB AT THE LOWER HINGE INTERCOSTAL TEE CLIP ULTRASONIC INSPECTION (SHEET 1 OF 4) Original Issue: September 28, 2022 757-53A0121 RB Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. 47 of 56 ### Page 48 (OCR) REQUIREMENTS BULLETIN 757-53A0121 ALERT ALERT SUPPORT FITTING OUTER CHORD TYPICAL CRACKS IN FRAME WEB FRAME WEB LOWER HINGE FITTING TEE CLIP LOWER HINGE INTERCOSTAL INBD ULTRASONIC INSPECTION TRANSDUCER POSITION VIEW LOOKING AFT 3002114 FIGURE 2: RIGHT SIDE - STA 1640 FRAME WEB AT THE LOWER HINGE INTERCOSTAL TEE CLIP ULTRASONIC INSPECTION (SHEET 2 OF 4) Original Issue: September 28, 2022 757-53A0121 RB Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. 48 of 56 ### Page 49 (OCR) REQUIREMENTS BULLETIN 757-53A0121 ALERT ALERT STA 1640 FRAME WEB LOWER HINGE TEEP FITTING ULTRASONIC INSPECTION FWD AREA (VIEW LOOKING DOWN) (ROTATED 90° COUNTER-CLOCKWISE) A-A 3004079 FIGURE 2: RIGHT SIDE - STA 1640 FRAME WEB AT THE LOWER HINGE INTERCOSTAL TEE CLIP ULTRASONIC INSPECTION (SHEET 3 OF 4) Original Issue: September 28, 2022 Export Controlled ECCN: 9E991 757-53A0121 RB Copyright © Unpublished Work - See page 1 for details. 49 of 56 ### Page 50 More DataQtyIdentificationNameTaskStep (a)--STA 1640 Frame WebInspect1 (a) Do an Ultrasonic (UT) inspection of the STA 1640 frame web at the two fastener locations common to the lower hinge intercostal tee clip upper fastener row for any crack in accordance with 757 NDT Manual Part 4, 53-60-01. FIGURE 2: RIGHT SIDE - STA 1640 FRAME WEB AT THE LOWER HINGE INTERCOSTAL TEE CLIP ULTRASONIC INSPECTION (SHEET 4 OF 4) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 50 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 51 (OCR) REQUIREMENTS BULLETIN 757-53A0121 ALERT ALERT STA 1720 STA STA 1640 1701 STA 1681.8 STA 1661 STA 1640 SIA 1620 STA 1600 • S-6L ~ S-7L - S-8L S-19L S-9L S-20L →S-10L ~S-11L B •S-13L S-14L S-15L MAINTENANCE RECORDS CHECK S-16L FOR REPAIRS IN THESE AREAS 3002491 APPENDIX I: LEFT SIDE - STA 1640 FRAME AT THE LOWER HINGE INTERCOSTAL TEE CLIP MAINTENANCE RECORDS CHECK (SHEET 1 OF 3) Original Issue: September 28, 2022 757-53A0121 RB Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. 51 of 56 ### Page 52 (OCR) REQUIREMENTS BULLETIN 757-53A0121 ALERT ALERT STA 1640 000 0000 .o.o. 00 S-13L - LOWER HINGE INTERCOSTAL - S-14L • S-15L FWD ............ - S-16L + + S-13L INTERCOSTAL INTERCOSTAL VIEW LOOKING OUTBOARD STRAP TEE CLIP LOWER HINGE • INTERCOSTAL TEE CLIP INTERCOSTAL STRAP LOWER HINGE FITTING - S-14L +i+ INTERCOSTAL ~ INTERCOSTAL STRAP TEE CLIP + - OUTER CHORD MAINTENANCE RECORDS CHECK INBD VIEW LOOKING AFT A-A 3013241 FOR REPAIRS IN THESE AREAS APPENDIX I: LEFT SIDE - STA 1640 FRAME AT THE LOWER HINGE INTERCOSTAL TEE CLIP MAINTENANCE RECORDS CHECK (SHEET 2 OF 3) Original Issue: September 28, 2022 Export Controlled ECCN: 9E991 757-53A0121 RB Copyright © Unpublished Work - See page 1 for details. 52 of 56 ### Page 53 More DataQtyIdentificationNameTaskStep (a)--STA 1640 FrameMaintenance Record Check 1 (b)--STA 1640 FrameMaintenance Record Check 2 (a) Do a maintenance records check of the STA 1640 frame to find any frame segment replacement between S-9L and S-20L that is common to the Lower Hinge Intercostal (LHI). (b) Do a maintenance records check of the STA 1640 frame at the lower hinge intercostal to look for evidence of repair parts, blending, non-production or oversized fasteners, and freeze plug repairs which cannot be visually detected in the frame web common to the Ultrasonic (UT) inspection area. APPENDIX I: LEFT SIDE - STA 1640 FRAME AT THE LOWER HINGE INTERCOSTAL TEE CLIP MAINTENANCE RECORDS CHECK (SHEET 3 OF 3) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 53 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT ### Page 54 (OCR) REQUIREMENTS BULLETIN 757-53A0121 ALERT ALERT STA 1720 /STA STA 1640 1701 STA 1681.8 STA 1661 STA 1640 STA 1620 STA 1600 S-6R S-7R' S-8R- S-17R S-9R' • S- 18R S-19R • S-20R S-10R' S-11R S-13R S-14R' S-15R S-16R MAINTENANCE RECORDS CHECK FOR REPAIRS IN THESE AREAS 3002492 APPENDIX J: RIGHT SIDE - STA 1640 FRAME AT THE LOWER HINGE INTERCOSTAL TEE CLIP MAINTENANCE RECORDS CHECK (SHEET 1 OF 3) Original Issue: September 28, 2022 Export Controlled ECCN: 9E991 757-53A0121 RB Copyright © Unpublished Work - See page 1 for details. 54 of 56 ### Page 55 (OCR) REQUIREMENTS BULLETIN 757-53A0121 ALERT ALERT STA 1640 S-13R LOWER - HINGE INTERCOSTAL S-14R- S-15R S-13R + + S-16R- • ... • • . • .... INTERCOSTAL TEE CLIP INTERCOSTAL STRAP VIEW LOOKING OUTBOARD INTERCOSTAL TEE CLIP LOWER HINGE INTERCOSTAL STRAP LOWER HINGE FITTING S-14R INTERCOSTAL INTERCOSTAL STRAP TEE CLIP OUTER CHORD VIEW LOOKING AFT A-A INBD MAINTENANCE RECORDS 3013240 CHECK FOR REPAIRS IN THESE AREAS APPENDIX J: RIGHT SIDE - STA 1640 FRAME AT THE LOWER HINGE INTERCOSTAL TEE CLIP MAINTENANCE RECORDS CHECK (SHEET 2 OF 3) Original Issue: September 28, 2022 757-53A0121 RB Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. 55 of 56 ### Page 56 More DataQtyIdentificationNameTaskStep (a)--STA 1640 FrameMaintenance Record Check 1 (b)--STA 1640 FrameMaintenance Record Check 2 (a) Do a maintenance records check of the STA 1640 frame to find any frame segment replacement between S-9R and S-20R that is common to the Lower Hinge Intercostal (LHI). (b) Do a maintenance records check of the STA 1640 frame at the lower hinge intercostal to look for evidence of repair parts, blending, non-production or oversized fasteners, and freeze plug repairs which cannot be visually detected in the frame web common to the Ultrasonic (UT) inspection area. APPENDIX J: RIGHT SIDE - STA 1640 FRAME AT THE LOWER HINGE INTERCOSTAL TEE CLIP MAINTENANCE RECORDS CHECK (SHEET 3 OF 3) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details. Original Issue: September 28, 2022 757-53A0121 RB 56 of 56 REQUIREMENTS BULLETIN 757-53A0121 ALERTALERT --- 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.