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Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-53A0122 RB Original Issue:

September 26, 2025 ATA System: 5365 SUBJECT: FUSELAGE - Section 46 - Between Stringers S-13 and S-14, from STA 1380 to STA 1620, Fuselage Frame Splice Inspection EXPORT CONTROLLED - This technology or software is subject to the U.S. Export Administration Regulations (EAR), (15 C.F.R. Parts 730-774). No authorization from the U.S. Department of Commerce is required for export, re-export, in-country transfer, or access EXCEPT to country group E:1 or E:2 countries/persons per Supp.1 to Part 740 of the EAR.

9E991ECCN:

Copyright © 2025 The Boeing Company 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 26, 2025 757-53A0122 RB 1 of 30

2.0

Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 26, 2025 757-53A0122 RB 2 of 30 REQUIREMENTS BULLETIN 757-53A0122

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Table of Contents

1. EFFECTIVITY .

.5

A. Airplanes5

B. Spares Affected5

2. CONCURRENT REQUIREMENTS6

3. COMPLIANCE6

4. APPROVAL10

5. ACCOMPLISHMENT INSTRUCTIONS11

A. General Information11

B. Work Instructions13

FIGURE 1: LEFT SIDE - FUSELAGE FRAME SPLICES BETWEEN STRINGERS S-13L AND S-14L FROM

STA 1380 TO STA 1620 - GENERAL VISUAL INSPECTION19

FIGURE 2: RIGHT SIDE - FUSELAGE FRAME SPLICES BETWEEN STRINGERS S-13R AND S-14R

FROM STA 1380 TO STA 1620 - GENERAL VISUAL INSPECTION22

FIGURE 3: LEFT SIDE - UPPER FRAMES AT THE FUSELAGE FRAME SPLICES BETWEEN STRINGERS

S-13L AND S-14L FROM STA 1380 TO STA 1620 - DETAILED INSPECTION25

FIGURE 4: RIGHT SIDE - UPPER FRAMES AT THE FUSELAGE FRAME SPLICES BETWEEN STRINGERS

S-13R AND S-14R FROM STA 1380 TO STA 1620 - DETAILED INSPECTION28

Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 26, 2025 757-53A0122 RB 3 of 30 REQUIREMENTS BULLETIN 757-53A0122

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Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 26, 2025 757-53A0122 RB 4 of 30 REQUIREMENTS BULLETIN 757-53A0122

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Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-53A0122 RB Original Issue:

September 26, 2025 ATA System: 5365 SUBJECT: FUSELAGE - Section 46 - Between Stringers S-13 and S-14, from STA 1380 to STA 1620, Fuselage Frame Splice Inspection

THIS DOCUMENT IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.

THIS IS AN ENHANCED REQUIRED FOR COMPLIANCE DOCUMENT. THE BOEING PROCESSES USED

TO CREATE THE SERVICE BULLETIN (SB) AND THE REQUIREMENTS BULLETIN (RB) ENSURE THAT THE INFORMATION BETWEEN "RC START" AND "RC END" IN THE SB ARE IDENTICAL TO THE INFORMATION IN THE SAME SECTIONS (COMPLIANCE, WORK INSTRUCTIONS…) OF THE RB WHICH THE SB REFERS TO AS THE RELATED DOCUMENT.

1.

Effectivity A. Airplanes This bulletin is applicable to 757-300 Airplane(s), line number(s) 804, 810, 818, 839, 846, 849, 855, 906, 909, 912, 915, 918, 923, 926, 929, 960, 963, 972, 976, 978, 980, 985, 990, 995, 997, 999, 1001, 1003-1004, 1007-1008, 1014, 1017-1025, 1027, 1030-1040, 1042-1043 in 1 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 All 757-300 Airplanes.- 1 Airplane Models:

757-300 GroupVariable Number 1NL001 - NL002 1NL006 - NL017 1NL101 - NL109 GroupVariable Number 1NL141 1NL601 - NL616 1NU701 - NU705 GroupVariable Number 1NU721 - NU728 1NU731 - NU732 -- B.

Spares Affected Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 26, 2025 757-53A0122 RB 5 of 30

None.

2.

CONCURRENT REQUIREMENTS None.

3. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Requirements Bulletin 757-53A0122 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin 757-53A0122 RB mandatory.

Accomplish the required action(s), based on the applicable condition(s) in Table 1 and 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.

Table 1: Inspections of the Upper Frames at Fuselage Frame Splices between Stringers S-13 and S-14 from STA 1380 to STA 1620, Left Side Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0122 RB.

Before 40,000 total flight cycles.

Do a General Visual Inspection (GVI) or a maintenance records check of the forward and aft sides of the upper frames at the frame splices between S-13L and S-14L, from STA 1380 to STA 1620, for any repair.

All Airplanes.

-Within 3,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0122 RB.

Before 40,000 total flight cycles.

CONDITION 1 (ACTION 1):

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

CONDITION 1:

ANY REPAIR FOUND.

-Within 3,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0122 RB.

Before 40,000 total flight cycles.

CONDITION 1 (ACTION 2):

Do a Detailed Inspection (DET) of the upper frames around the uppermost fastener common to the fail-safe chord at the frame splices between S-13L and S- 14L, from STA 1380 to STA 1620, for any crack in the unrepaired areas.

Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 26, 2025 757-53A0122 RB 6 of 30 REQUIREMENTS BULLETIN 757-53A0122

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Table 1: Inspections of the Upper Frames at Fuselage Frame Splices between Stringers S-13 and S-14 from STA 1380 to STA 1620, Left Side Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -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.

12,000 flight cycles.-CONDITION 1.1 (ACTION 2):

Repeat the DET of the upper frames around the uppermost fastener common to the fail-safe chord at the frame splices between S-13L and S-14L, from STA 1380 to STA 1620, for any crack. (a) 12,000 flight cycles.-Repeat the DET of the upper frames around the uppermost fastener common to the fail-safe chord at the frame splices between S-13L and S-14L, from STA 1380 to STA 1620, for any crack. (a) CONDITION 1.2:

NO CRACK FOUND.

-Within 3,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0122 RB.

Before 40,000 total flight cycles.

Do a DET of the upper frames around the uppermost fastener common to the fail-safe chord at the frame splices between S- 13L and S-14L, from STA 1380 to STA 1620, for any crack.

CONDITION 2:

NO REPAIR FOUND.

-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.

12,000 flight cycles.-CONDITION 2.1 (ACTION 2):

Repeat the DET of the upper frames around the uppermost fastener common to the fail-safe chord at the frame splices between S-13L and S-14L, from STA 1380 to STA 1620, for any crack. (a) Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 26, 2025 757-53A0122 RB 7 of 30 REQUIREMENTS BULLETIN 757-53A0122

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Table 1: Inspections of the Upper Frames at Fuselage Frame Splices between Stringers S-13 and S-14 from STA 1380 to STA 1620, Left Side Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition 12,000 flight cycles.-Repeat the DET of the upper frames around the uppermost fastener common to the fail-safe chord at the frame splices between S-13L and S-14L, from STA 1380 to STA 1620, for any crack. (a) CONDITION 2.2:

NO CRACK FOUND.

(a) It is not required to do the DET inspections in accordance with Requirements Bulletin 757-53A0122 RB in the repair affected area(s) if the repair(s) meet all of the conditions that follow:

1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0122 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(s), states the post repair inspection plan for the repair affected area(s), and approves the inspection plan as an alternative inspection method to the inspection(s) in Requirements Bulletin 757-53A0122 RB.

Table 2: Inspections of the Upper Frames at Fuselage Frame Splices between Stringers S-13 and S-14 from STA 1380 to STA 1620, Right Side Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0122 RB.

Before 40,000 total flight cycles.

Do a General Visual Inspection (GVI) or a maintenance records check of the forward and aft sides of the upper frames at the frame splices between S-13L and S-14L, from STA 1380 to STA 1620, for any repair.

All Airplanes.

Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 26, 2025 757-53A0122 RB 8 of 30 REQUIREMENTS BULLETIN 757-53A0122

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Table 2: Inspections of the Upper Frames at Fuselage Frame Splices between Stringers S-13 and S-14 from STA 1380 to STA 1620, Right Side Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0122 RB.

Before 40,000 total flight cycles.

CONDITION 3 (ACTION 1):

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

CONDITION 3:

ANY REPAIR FOUND.

-Within 3,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0122 RB.

Before 40,000 total flight cycles.

CONDITION 3 (ACTION 2):

Do a Detailed Inspection (DET) of the upper frames around the uppermost fastener common to the fail-safe chord at the frame splices between S-13R and S- 14R, from STA 1380 to STA 1620, for any crack in the unrepaired areas.

-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.

12,000 flight cycles.-CONDITION 3.1 (ACTION 2):

Repeat the DET of the upper frames around the uppermost fastener common to the fail-safe chord at the frame splices between S-13R and S-14R, from STA 1380 to STA 1620, for any crack. (a) 12,000 flight cycles.-Repeat the DET of the upper frames around the uppermost fastener common to the fail-safe chord at the frame splices between S-13R and S-14R, from STA 1380 to STA 1620, for any crack. (a) CONDITION 3.2:

NO CRACK FOUND.

-Within 3,000 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0122 RB.

Before 40,000 total flight cycles.

Do a DET of the upper frames around the uppermost fastener common to the fail-safe chord at the frame splices between S- 13R and S-14R, from STA 1380 to STA 1620, for any crack.

CONDITION 4:

NO REPAIR FOUND.

Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 26, 2025 757-53A0122 RB 9 of 30 REQUIREMENTS BULLETIN 757-53A0122

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Table 2: Inspections of the Upper Frames at Fuselage Frame Splices between Stringers S-13 and S-14 from STA 1380 to STA 1620, Right Side Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -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.

12,000 flight cycles.-CONDITION 4.1 (ACTION 2):

Repeat the DET of the upper frames around the uppermost fastener common to the fail-safe chord at the frame splices between S-13R and S-14R, from STA 1380 to STA 1620, for any crack. (a) 12,000 flight cycles.-Repeat the DET of the upper frames around the uppermost fastener common to the fail-safe chord at the frame splices between S-13R and S-14R, from STA 1380 to STA 1620, for any crack. (a) CONDITION 4.2:

NO CRACK FOUND.

(a) It is not required to do the DET inspections in accordance with Requirements Bulletin 757-53A0122 RB in the repair affected area(s) if the repair(s) meet all of the conditions that follow:

1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0122 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(s), states the post repair inspection plan for the repair affected area(s), and approves the inspection plan as an alternative inspection method to the inspection(s) in Requirements Bulletin 757-53A0122 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) approved for all EASA approved airplanes listed in this Requirements Bulletin effectivity. This document and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other Boeing changes.

If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this Requirements Bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this Requirements Bulletin.

Export Controlled ECCN: 9E991 See page 1 for details Original Issue: September 26, 2025 757-53A0122 RB 10 of 30 REQUIREMENTS BULLETIN 757-53A0122

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5. ACCOMPLISHMENT INSTRUCTIONS A.

GENERAL INFORMATION NOTE: 1. This is an Enhanced Required for Compliance document. There will be a separate Service Bulletin (SB) and a separate Requirements Bulletin (RB). If an RB is mandated by an Airworthiness Directive (AD), then all applicable requirements specified in the RB must be done. In the RB, the "Refer to the listed procedures..." column of the table(s) in the Work Instructions is for reference only. The procedures in that column are not required by the AD and are for guidance only. For the related SB, some locations are marked RC Start and RC End to identify the requirements that are restated from the RB. For the related SB, the areas between RC Start and RC End, including sub-steps and any figures identified between RC Start and RC End, must be done to comply with the AD. Therefore, an Alternative Method of Compliance (AMOC) is required for any deviations to steps between RC Start and RC End, including substeps and identified figures. For the related SB, the steps not between RC Start and RC End may be deviated from using accepted methods in accordance with the operator's maintenance or inspection program without obtaining approval of an AMOC; this is provided that the steps between RC Start and RC End, including sub-steps and identified figures, can still be done as specified, and the airplane can be put back in an airworthy condition. Figures not required for compliance are omitted from the RB.

2.

This is an Enhanced Required for Compliance document. The Boeing processes used to create the Service Bulletin (SB) and the Requirements Bulletin (RB) ensure that the information between "RC Start" and "RC End" in the SB are identical to the information in the same sections (Compliance, Work Instructions...) of the RB which the SB refers to as the related document.

3. The compliance times for the actions in WORK INSTRUCTIONS are in Compliance.

4. Boeing Service Letter 757-SL-51-022, Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided.

5. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque Values:

— Values for structural fasteners are given in 757 Structural Repair Manual, Chapter 51.

— Values for airframe maintenance tasks are included in Chapter 20 of 757 Aircraft Maintenance Manual (AMM).

— Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM).

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— 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 Detailed Inspection (DET) is defined as: An intensive examination of a specific item, installation or assembly to detect damage, failure or irregularity. This could include tactile assessment in which a component or assembly can be checked for tightness/security. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors and magnifying lenses may be necessary. Surface cleaning and elaborate access procedures may be required.

11. A General Visual Inspection (GVI) is defined as: A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance, unless otherwise specified. A mirror may be necessary to enhance visual access to all exposed surfaces in the inspection area. This level of inspection is made under normally available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked.

Basic cleaning may be required to ensure appropriate visibility.

12. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION or an OPTION, do all of the ACTION numbers for that CONDITION or OPTION.

13. A maintenance records check for any existing repair at the frame splices can be done provided an existing repair at the frame splices can be conclusively determined from that check. If the maintenance records check cannot conclusively determine an existing repair at the frame splices, the General Visual Inspection (GVI) must be done.

14. Use of colors in Figures is based on guidance from the ATA e-Business Program (ATA) iSpec 2200.

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